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ENGINE GENERAL INFORMATION

0A TABLE OF CONTENTS
CLEANNESS ............................................. 2 ENGINE ASSEMBLY ................................. 7
LH side view .............................................................. 7 RH side view ............................................................. 7 Front view ................................................................. 8 Fan belt ..................................................................... 8

COOLING SYSTEM ................................. 16 FUEL SYSTEM ........................................ 17
Fuel supply system ................................................ 18

MAINTENANCE AND REPAIR ................ 19
Maintenance and lubrication ................................... 19 Guidelines for service work safety ........................... 20

ENGINE CONTROLS ................................ 9
ECU related components .......................................... 9 Engine control system ............................................ 10 Electrical components and pre heating system ...... 12

OWNER INSPECTIONS AND SERVICES 25
While operating the vehicle ..................................... 25 At each fuel fill ........................................................ 25 At least twice a month ............................................ 25 At least monthly ..................................................... 25 At least twice a year ............................................... 26 Each time the oil is changed .................................. 26 At least annually ..................................................... 26

INTAKE SYSTEM .................................... 13 EXHAUST SYSTEM ................................ 14 LUBRICATION SYSTEM ......................... 15

STANDARD BOLTS SPECIFICATIONS . 27

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CLEANNESS
Cleanness of DI Engine Fuel System and Service Procedures
The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pressure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100 µm of preciseness. The pressure regulation and injector operation are done by electric source from engine ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine. You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right side figure shows the clearance between internal operating elements.

Valve actuator lift: 0.028 mm Hair

Diameter: 0.40 mm Operating clearance: 0.002 mm Diameter: 2.0 mm

Nozzle hole

The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of system problems and claims may arise.

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GENERAL

Job Procedures
1. Always keep the workshop and lift clean (especially, from dust). 2. Always keep the tools clean (from oil or foreign materials). 3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system. Wash your hands and do not wear working gloves. 4. Follow the below procedures before starting service works for fuel system.

Carefully listen the symptoms and problems from customer.

Visually check the leaks and vehicle appearance on the wiring harnesses and connectors in engine compartment.

Locate the fault. If the cause is from fuel system (from priming pump to injector, including return line), follow the step 1 through step 3 above.

NOTICE
• Clean the engine compartment before starting service works.

Tool kit for high pressure line

Took kit for low pressure line

Removal tool box and cap kits

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ENGINE GENERAL INFORMATION
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SENSOR

5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing caps to perform the diagnosis for DI engine fuel system in “DIAGNOSIS” section in this manual. At this point, thoroughly clean the related area in engine compartment.

CONTROL

FUEL

COOLING

Perform the diagnosis proceee with SCAN-100 (refer to “DI10 DIAGNOSIS” section in this manual).

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6. Follow the job procedures. If you find a defective component, replace it with new one.

Disconnect the negative battery cable.

For safety reasons: check pressure is low before opening the HP systems (pipes)

Use special tools and torque wrench to perform the correct works. Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail and each injector should be replaced with new ones. The pipes should be tightened to specified tightening torques during installation. Over or under torques out of specified range may cause damages and leaks at connections. Once installed, the pipes have been deformed according to the force during installtion, therefore they are not reusable. The copper washer on injector should be replaced with new one. The injector holder bolt should be tightened to specified tightening torque as well. If not, the injection point may be deviated from correct position, and it may cause engine disorder.

Plug the disconnected parts with sealing caps, and remove the caps immediately before replacing the components.

Fuel Pressure Sensor High pressure pump Common Rail

IMV valve Low and high pressure pump Fuel temperature sensor

High Pressure Pipe

Water separator Water detection sensor

Priming pump

Label (C2I)

Fuel Filter

Injector

Sensors
HFM sensor Cam position sensor

Fuel tank Components:
- High pressure fuel pump - Fuel injectors - Fuel rail - Electroc control unit (ECU)

ECU

Crank position sensor Knock sensor etc.

- Fuel pressure sensor - Various sensors and actuators

Supply line Return line ECU communication line

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GENERAL

7. Plug the removed components with clean and undamaged sealing caps and store it into the box to keep the conditions when it was installed. 8. Clear the high pressure offset value by SCAN100 after replacing the high pressure pump.

9. To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard. NOTICE
• Do not crank engine before having filled pump. Priming pump

11. With SCAN-100, check if there are current faults and erase the history faults. NOTE
• For details, refer to “Diagnosis table”.

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SENSOR

CONTROL

10. Check the installed components again and connect the negative battery cable. Start the engine and check the operating status.

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DI Engine and Its Expected Problems and Remedies Can be Caused by Water in Fuel
SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION.
In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and season. However, above phenomenon can be happened if stations have poor facilities or sell improper fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector. Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns through fuel filter to have an effect of built-in heater (see fuel system).

SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL
As mentioned above, some gas stations supply fuel with excessive than specified water. In the conventional IDI engine, excessive water in the fuel only causes dropping engine power or engine hunting. However, fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication of pump caused by poor coating film during high speed pumping and bacterization (under long period parking). To prevent problems can be caused by excessive water in fuel, water separator is installed inside of fuel filter. When fuel is passing filter, water that has relatively bigger specific gravity is accumulated on the bottom of the filter.

If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain level. Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)

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GENERAL

ENGINE ASSEMBLY
LH SIDE VIEW

RH SIDE VIEW

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FRONT VIEW

FAN BELT

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ENGINE CONTROLS

ECU RELATED COMPONENTS

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Brake fluid reservoir EGR valve Vacuum pump ABS/ESP modulator

Engine oil dipstick FFH Oil separator (PCV valve ) Vacuum modulator

Coolant reservoir

Air cleaner assembly Engine oil filler cap

Fuse box

Battery

HFM sensor

VGT turbo charger

Washer fluid reservoir Fuel filter & priming pump Engine PWM electric fan & fan shroud Power steering oil reservoir

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ENGINE GENERAL INFORMATION
SENSOR CONTROL

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ENGINE CONTROL SYSTEM
The figures below show the components in the D20DT engine.

Engine Control System
Major Sensors and Components

Injector

Glow Plug

Common Rail

Camshaft Position Sensor

Booster Pressure Sensor

Fuel Pressure Sensor (Common Rail)

Crankshaft Position Sensor

Common Rail

Knock Sensor (1 EA) & Water Temperature Sensor Water temp. sensor Knock sensor

Vacuum Modulator

HP Pump

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IP Interior Fuse Box (Passenger Side) Accelerator Pedal Module Installed

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Engine Accessories Related to ECU

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Engine ECU

Mounting Location

Engine ECU main relay

VGT & EGR vacuum modulators, HFM

HP pumpIMV

Hazard warning lamp

Integrated with 2 PPSs

Fuel Filter Sensor

HFM Sensor Priming Pump Service Interval (Fuel Filter)
EU Only General Replace every 30,000 km (Draining water from fuel filter: whenever replacing the engine oil) Replace every 25,000 km (Draining water from fuel filter: whenever replacing the engine oil)

Fuel Filter

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ENGINE GENERAL INFORMATION
SENSOR CONTROL

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Glow Plug

Preheat Warning Lamp (Cluster)

Preheat Control Unit

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No G5 for 4 cylinders (Without D20DT)

IG1 power terminal

Glow plug control signal(ECU113)

Ground terminal Battery main wire K-Line Glow plug terminal (#1 ~ #4) (ECU 34)

Battery

Preheat completion transmit terminal : No use for vehicle without remote engine start

ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM

Alternator

Starter motor

Engine compartment fuse box

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PTC / FFH: 12V - 115A

12V - 2.2kw

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INTAKE SYSTEM

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Supplying Compressed Air with Turbocharger’s Operation Coolant port To corresponding cylinders

Intake Manifold

Air cleaner

Turbocharger

Intercooler From intercooler

Recirculation of Exhaust Gas when EGR Valve Operates Intake outlet hose Air cleaner Intake compressed air EGR valve

Front air duct Exhaust gas

HFM Sensor
Pretension graph

Plug-in sensor

Turbocharger Intercooler Terbocharger intercooler

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Air cleaner

Turbocharger

Temperature Sensor

Uncompressed air

Compressed air

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SENSOR CONTROL

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PCV Oil Separator DOC (Diesel Catalytic Converter) Exhaust Manifold To turbocharger To EGR pipe

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Cylinder head cover (oil + gas)

ENGINE GENERAL INFORMATION

Inlet port

Blow-by gas (air duct hose) From cylinders

EXHAUST SYSTEM

Oil (oil gauge pipe)

EGR Valve Intake compressed air

The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover. Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/ closes due to pressure differences between the intake side and crankcase.

Exhaust gas

Turbocharger Vacuum Modulator

VGT Turbocharger

Vacuum modulator
Turbocharger actuator Vacuum pump

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To exhaust pipe (DOC)

Engine ECU (No. 95)

EEGR Pipe Passage for recirculation of exhaust gas

Exhaust manifold

IP interior fuse box (RH) No.63(7.5A)

PCV Oil Separator

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LUBRICATION SYSTEM

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Cylinder head cover (oil + gas) Cylinder Head Cover
Blow-by gas (air duct hose)

Oil Pressure Warning Lamp (Cluster)

Inlet port
Oil (oil gauge pipe)

The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover. Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/ closes due to pressure differences between the intake side and crankcase.

Cluster

Oil dipstick gauge

Oil Filter & Oil Cooler Oil Strainer

Oil Pan and Baffle Plate (Integrated Type)

Oil cooler

Oil filter

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ENGINE GENERAL INFORMATION
SENSOR CONTROL FUEL COOLING LUB

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Coolant inlet hose

Coolant Port

Coolant reservoir

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Return hose Coolant outlet port

COOLING SYSTEM

Coolant outlet hose PWM electric fan Engine Oil Filter & Cooler Oil cooler Oil filter cap

Radiator Oil pressure switch Radiator Assembly Cooling Fan and Fan Clutch

Water Pump & Pipe

Cylinder block

Thermostat (inside)

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Oil cooler Radiator

Oil filter

Reservoir (Coolant inlet hose)

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FUEL SYSTEM

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Injector

Fuel Filter & Priming Pump

Fuel filter

Priming pump

Connector

HP Pump

Cylinder Head

Fuel return hose Fuel pipe

Fuel return port

Fuel return port

Fuel temperature sensor

Fuel rail pressure sensor IMV valve Low pres- Venturi sure fuel IMV supply port connector Common rail High pressure fuel supply port

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High pressure fuel pipe

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SENSOR CONTROL

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FUEL SUPPLY SYSTEM
Fuel Pressure Sensor
High pressure pump

Common Rail

IMV valve Low and high pressure pump Fuel temperature sensor

High Pressure Pipe

Water separator Priming pump

Label (C2I)

Fuel Filter

Injector

Sensors
HFM sensor Cam position sensor Crank position sensor Knock sensor etc.

Fuel tank Components:
- High pressure fuel pump - Fuel injectors - Fuel rail

ECU

- Fuel pressure sensor - Various sensors and actuators

- Electroc control unit (ECU)

Supply line Return line ECU communication line

According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various operations and variables.

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GENERAL

MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
Normal Vehicle Use
The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: 1. To carry passengers and cargo within the limitation of the tire inflation prassure. Refer to “Wheels and Tire” in section 4H. 2. To be driven on reasonable road surfaces and within legal operating limits.

Fuel Filter Replacement
Replace the engine fuel filter every. 1. Gasoline Engine: 60,000 km (36,000 miles) 2. Diesel Engine: 30,000 km (18,000 miles)

Replace spark plugs with same type. 1. Type: BOSCH: F8DC4 BERU: 14F-8DU4 Champion: C11YCC 2. Gap: 0.8 ± 0.1 mm

Explanation of Scheduled Maintenance Services
The services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.

Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the Distributor and at the spark plugs. Replace the wires as needed.
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Brake System Service
Check the disc brake pads or the drum brake linings. Check the pad and the lining thickness carefully.

Engine Oil and Oil Filter Change
Always use above the API SH grade or recommended engine oil.

Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Tire Rotation (Left-hand Drive Type)

Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage.

Cooling System Service
Drain, flush and refill the system with new coolant. Refer to “Recommended Fluids And Lubricants” in this section.

Air Cleaner Element Replacement
Clean the air cleaner element every. 1. Gasoline Engine: 15,000 km (10,000 miles) 2. Diesel Engine: 10,000 km (6,000 miles) Replace the air cleaner element every. 1. Gasoline Engine: 60,000 km (36,000 miles) 2. Diesel Engine: 30,000 km (18,000 miles) Replace the air cleaner more often under dusty conditions.
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ENGINE GENERAL INFORMATION

CONTROL

Engine Oil Viscosity

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Spark Plug Replacement

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GUIDELINES FOR SERVICE WORK SAFETY
General Cautions on Inspection/Service
NOTICE
During service works, be sure to observe below general items for your safety. • For service works, be sure to disconnect battery negative (-) terminal if not starting and inspection. • While inspecting vehicle and replacing various consumable parts, be sure to take caution not to damage vehicle and injure people. • Engine and transmission may be hot enough to burn you. So inspect related locations when they cooled down enough. • If engine is running, keep your clothing, tools, hair and hands away from moving parts.

To maintain and operate the vehicle under optimum state by performing safe service works, the service works should be done by following correct methods and procedures. Accordingly, the purpose of this manual is to prevent differences that can be caused by personal working method, skill, ways and service procedures and to allow prompt/correct service works.

• Even when the ignition key is turned off and positioned to LOCK, electrical fan can be operated while working on near around electrical fan or radiator grille if air conditioner or coolant temperature rises. • Every oil can cause skin trouble. Immediately wash out with soap if contacted. • Painted surface of the body can be damaged if spilled over with oil or anti-freeze. • Never go under vehicle if supported only with jack. • Never near the battery and fuel related system to flames that can cause fire like cigarette. • Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on. • While connecting the battery terminals, be cautious of polarities (+, –) not to be confused. • There are high voltage and currency on the battery and vehicle wires. So there can be fire if short-circuited. • Do not park while running the engine in an enclosed area like garage. There can be toxication with CO, so make sufficient ventilation. • The electrical fan works electrically. So the fan can be operated unexpectedly during working causing injuries if the ignition key is not in LOCK position. Be sure to check whether ignition key is in LOCK position before work. • Be careful not to touch hot components like catalytic converter, muffler and exhaust pipe when the engine is running or just stopped. They may burn you badly.

Note, Notice
While using this manual, there are a lot of Note or Notice having below meaning. NOTE
• Note means detailed description of supplementary information on work procedure or skill.

NOTICE
• Notice means precautions on tool/device or part damages or personal injuries that can occur during service works.

However, above references and cautions cannot be inclusive measures, so should have habits of taking concerns and cautions based on common senses.

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GENERAL

Guidelines on Engine Service
To prevent personal injuries and vehicle damages that can be caused by mistakes during engine and unit inspection/repair and to secure optimum engine performance and safety after service works, basic cautions and service work guidelines that can be easily forgotten during engine service works are described in.

Fuel and lubrication system
Painted surface of the body can be damaged or rubber products (hoes) can be corroded if engine oil and fuel are spilled over. If spilled over engine, foreign materials in air can be accumulated on the engine damaging fuel system. 1. If work on the fluid system such as fuel and oil, working area should be well ventilated and mechanic should not smoke. 2. Gasket or seal on the fuel/lubrication system should be replaced with new and bolts and nuts should be tightened as specified. 3. After removal/installation works, be sure to check whether there is leak on the connecting section.

Cautions before service works
1. Before work on engine and each electrical equipment, be sure to disconnect battery negative (-) terminal. 2. Before service works, be sure to prepare the works by cleaning and aligning work areas. 3. Always position the ignition switch to OFF if not required. If not, there can be electrical equipment damages or personal injuries due to short-circuit or ground by mistake. 4. There should be no leak from fuel injection system (HP pump, fuel hose, high pressure pipe) of the D20DT & D27DT engine. So they should be protected from foreign materials. 5. While removing the engine, do not position the jack and others under the oil pan or engine. To secure the safety, use only safety hook on the engine.

Engine and accessories
Engine has a lot of precise portions so tightening torque should be correct during disassembly/assembly and removal/installation and service work should be done in clean ways during disassembly/assembly. Maintaining working area clean and cautious service administration is essential element of service works while working on the engine and each section of the vehicle. So the mechanics should well aware of it. 1. While removing the engine, related parts (bolts, gaskets, etc.) should be aligned as a group. 2. While disassembling/assembling internal components of the engine, well aware of disassembly/assembly section in this manual and clean each component with engine oil and then coat with oil before installation. 3. While removing engine, drain engine oil, coolant and fuel in fuel system to prevent leakage. 4. During service work of removal/installation, be sure to check each connected portions to engine not to make interference.

Electrical equipment
Electrical equipment should be handled more carefully. Currently, the engine is equipped with a lot of electrical equipments so there can be engine performance drops, incomplete combustion and other abnormals due to short and poor contact. Mechanics should well aware of vehicle’s electrical equipment. 1. If have to work on the electrical equipment, be sure to disconnect battery negative (-) terminal and position the ignition switch to off if not required. 2. When replacing electrical equipment, use the same genuine part and be sure to check whether ground or connecting portions are correctly connected during installation. If ground or connecting portion is loosened, there can be vehicle fire or personal injury.

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ENGINE GENERAL INFORMATION
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CONTROL

FUEL

COOLING

If fine dust or foreign material enters into DI engine’s fuel system, there can be serious damages between HP pump and injectors. So, be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt. (Refer to cleanness in this manual while working on DI engine fuel system)

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During Service Work - Inspection
1. Before lifting up the vehicle with lift, correctly support the lifting points and lift up. 2. When using a jack, park the vehicle on the level ground and block front and rear wheels. Position the jack under the frame and lift up the vehicle and then support with chassis stand before service work. 3. Before service work, be sure to disconnect battery negative (-) terminal to prevent damages by bad wire and short.

4. If service from interior of the vehicle, use protection cover to prevent damage and contamination of seat and floor. 5. Brake fluid and anti-freeze can damage painted surface of body. So carefully handle them during service work.

6. Use recommended and specified tools to increase efficiency of service work. 7. Use only genuine spare parts.

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If reused, normal functions cannot be maintained. 9. Align the disassembled parts in clean according to disassembling order and group for easy assembling. 10. According to installing positions, the bolts and nuts have different hardness and design. So be careful not to mix removed bolts and nuts each other and align them according installing positions. 11. To inspect and assemble, clean the parts. 12. Securely clean the parts that related with oil not to be affected by viscosity of oil. 13. Coat oil or grease on the driving and sliding surfaces before installing parts. 14. Use sealer or gasket to prevent leakage if necessary. 15. Damaged or not, never reuse removed gasket. Replace with new and cautious on installing directions. 16. Tighten every bolt and nut with specified torque. 17. When service work is completed, check finally whether the work is performed properly or the problem is solved. 18. If work on the fuel line between priming pump and injector (including return line), be sure to cover the removed parts with cap and be careful not to expose the connecting passage and removed parts to external foreign materials or dust. (Refer to cleanness.) 19. If remove high pressure fuel supply pipe between HP pump and fuel rail and high pressure fuel pipe between fuel rail and each injector, be sure to replace them with new.

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8. Never reuse cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them with new.

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During Service Work for Electric Devices
NOTICE
• Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or serious damage.

1. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery negative (-) terminal, turn off ignition key. 2. Replace with specified capacity of fuse if there is bad, blown or short circuited fuse. If use electrical wire or steel wire other than fuse, there can be damages on the various electrical systems. If replaced with over-capacity fuse, there can be damages on the related electrical device and fire. 3. Every wire on the vehicle should be fastened securely not to be loosened with fixing clip. 4. If wires go through edges, protect them with tape or other materials not to be damaged. 5. Carefully install the wires not to be damaged during installation/removal of parts due to interference. 6. Be careful not to throw or drop each sensor or relay. 7. Securely connect each connector until hear a “click” sound.

Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move during working. NOTICE
During lifting, be sure to check whether vehicle is empty. • Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating under the front door. • Install lift connecting device on the edge of front and rear of board-on lift.

WARNING
• Be sure to use attachment during lifting to prevent the lift from contacting with body floor. • While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear. When fixing the lift floor, be careful not to contact with brake tube and fuel lines.

2. Safety jack and safety stand
If lift up the vehicle with safety jack and stand, should be more careful during works. WARNING
• Never be under the vehicle if supported with only jack. If have to be under the vehicle, be sure to use safety block. • Use wheel block in front and rear of every wheel.

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OWNER INSPECTIONS AND SERVICES
WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check all the button locations. 4. Pull out the oil level indicator and look at the oil level on it. 5. Add oil, if needed, to keep the oil level above the lower mark. Avoid overfilling the engine, since this may cause engine damage. 6. Push the indicator all the way back down into the engine after taking the reading. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading.

Brake System Operation
Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system.

Exhaust System Operation
Be alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system inspected and repaired immediately.

Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.

Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheel needs to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment.

Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if necessary.
COOLING SENSOR CONTROL FUEL

AT LEAST TWICE A MONTH
Tire And Wheel Inspection and Pressure Check
Check the tire for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold (check the spare also, unless it is a stowaway). Maintain the recommended pressures. Refer to “Wheels and Tire” is in section 4H.

Steering System Operation
Be alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or has too much free play, or is unusual sounds are noticed when turning or parking.

Headlamp Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.

AT LEAST MONTHLY
Lamp Operation
Check the operation of the license plate lamp, the headlamps (including the high beams), the parking lamps, the fog lamps, the taillamp, the brake lamps, the turn signals, the backup lamps and the hazard warning flasher.

AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately.

Engine Oil Level
Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm. 1. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan. 2. Pull out the oil level indicator (dip stick). 3. Wipe it clean, and push the oil level indicator back down all the way.
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Fluid Leak Check
Periodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.

ENGINE GENERAL INFORMATION
ACTYON SM - 2006.03

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26

0A Hood Latch Operation
When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly.

AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 4G, Power Steering System.

Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open passage.

AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.

Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints must stay in the desired position.

EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Inspect other brake parts, the parking brake, etc., at the same time. Inspect the brakes more often if habit or conditions result in frequent braking.

Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must be securely stowed at all times. Oil the jack ratchet or the screw mechanism after each use.

Key Lock Service
Lubricate the key lock cylinder.

Steering, Suspension and Front Drive Axle Boot And Seal Inspection
Inspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace the seals if necessary.

Body Lubrication Service
Lubricate all the body door hinges including the hood, the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and any folding seat hardware.

Underbody Flushing
Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control. At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then flush the underbody with plain water.

Exhaust System Inspection
Inspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaust system. Look for broken, damaged, missing, or out-ofposition parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment.

Engine Cooling System
Inspect the coolant and freeze protection fluid. If the fluid is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the proper mixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation.
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Drain the Water from Fuel Filter
When the water level inside water separator in fuel filter exceeds a certain level, water separator warning light comes on and buzzer sounds. Also, the driving force of the vehicle decreases. If these conditions occur, immediately drain the water from fuel filter & water separator.
ENGINE GENERAL INFORMATION
ACTYON SM - 2006.03

0A

27
GENERAL

STANDARD BOLTS SPECIFICATIONS
Torque (Nm / Ib-in) Bolt* M3 × 0.5 M4 × 0.7 M5 × 0.8 M6 × 1.0 M8 × 1.25 M10 × 1.25 M10 × 1.5 M12 × 1.25 M12 × 1.75 M14 × 1.5 M16 × 1.5 M18 × 1.5 M20 × 1.5 M22 × 0.5 M24 × 1.5 M24 × 2.0 4T 0.5 Nm (4.5 lb-in) 1.2 Nm (11 lb-in) 2.4 Nm (22 lb-in) 4.0 Nm (36 lb-in) 8.6 Nm (77 lb-in) 18.6 Nm (14 lb-in) 18.6 Nm (14 lb-in) 34.3 Nm (25 lb-in) 32.3 Nm (24 lb-in) 54.0 Nm (40 lb-in) 81.3 Nm (60 lb-in) 117.6 Nm (87 lb-in) 166.6Nm (123 lb-in) 225.4Nm (167 lb-in) 284.2 Nm (210 lb-in) 274.4 Nm (203 lb-in) *Diameter X pitch in millimeters Standard 7T 0.9 Nm (8 lb-in) 2.0 Nm (18 lb-in) 4.0 Nm (36 lb-in) 6.7 Nm (60 lb-in) 15.7 Nm (12 lb-in) 32.3 Nm (24 lb-in) 30.4 Nm (22 lb-in) 56.8 Nm (42 lb-in) 53.9 Nm (40 lb-in) 89.2 Nm (66 lb-in) 107.8 Nm (80 lb-in) 196.0 Nm (145 lb-in) 274.4 Nm (203 lb-in) 372.4 Nm (276 lb-in) 480.2 Nm (355 lb-in) 460.6 Nm (341 lb-in) 9T 1.3 Nm (12 lb-in) 3.0 Nm (27 lb-in) 5.6 Nm (50 lb-in) 9.7 Nm (87 lb-in) 22.5 Nm (17 lb-in) 46.0 Nm (34 lb-in) 44.1 Nm (33 lb-in) 82.3 Nm (61 lb-in) 77.4 Nm (57 lb-in) 127.4 Nm (94 lb-in) 196.0 Nm (145 lb-in) 284.2 Nm (210 lb-in) 392.0 Nm (290 lb-in) 529.2 Nm (392 lb-in) 686.0 Nm (508 lb-in) 666.4 Nm (493 lb-in) 4T 0.7 Nm (6.3 lb-in) 1.6 Nm (14 lb-in) 3.1 Nm (28 lb-in) 5.4 Nm (49 lb-in) 12.7 Nm (9 lb-in) 25.5 Nm (19 lb-in) 24.5 Nm (18 lb-in) 45.0 Nm (33 lb-in) 43.1 Nm (32 lb-in) 71.6 Nm (53 lb-in) 107.8 Nm (80 lb-in) 156.8 Nm (116 lb-in) 215.6 Nm (160 lb-in) 294.0 Nm (218 lb-in) 382.2 Nm (283 lb-in) 372.4 Nm (276 lb-in) Limit 7T 1.2 Nm (11 lb-in) 2.6 Nm (23 lb-in) 5.2 Nm (47 lb-in) 9.0 Nm (81 lb-in) 20.6 Nm (15.2 lb-in) 42.1 Nm (31 lb-in) 41.2 Nm (30 lb-in) 75.5 Nm (56 lb-in) 71.5 Nm (53 lb-in) 117.6 Nm (87 lb-in) 186.2 Nm (138 lb-in) 264.6 Nm (196 lb-in) 362.6 Nm (268 lb-in) 490.0 Nm (362 lb-in) 637.0 Nm (471 lb-in) 617.4 Nm (457 lb-in) 9T 17 Nm (15 lb-in) 4.0 Nm (36 lb-in) 7.6 Nm (68 lb-in) 12.7 Nm (114 lb-in) 30.4 Nm (22 lb-in) 60.8 Nm (31 lb-in) 58.8 Nm (44 lb-in) 107.8 Nm (80 lb-in) 98.0 Nm (73 lb-in) 166.6 Nm (123 lb-in) 264.6 Nm (196 lb-in) 372.4 Nm (276 lb-in) 519.4 Nm (384 lb-in) 705.6 Nm (522 lb-in) 921.2 Nm (682 lb-in) 891.8 Nm (660 lb-in)

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ENGINE GENERAL INFORMATION
ACTYON SM - 2006.03

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0A

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.

3. Determine extra proper tightening torque if tightens with washer or packing. 4. If tightens bolts on the below materials, be sure to determine the proper torque. 1) Aluminum alloy: Tighten to 80 % of above torque table. 2) Plastics: Tighten to 20 % of above torque table.

ENGINE GENERAL INFORMATION
ACTYON SM - 2006.03

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ENGINE ASSEMBLY
01 TABLE OF CONTENTS
STRUCTURE AND FUNCTION DESCRIPTIONS .. 2
Major components in engine and engine compartment .............. 2 Engine structure ........................................................................ 3 Specifications and performance curve ........................................ 5

DIAGNOSTIC INFORMATION AND PROCEDURE ... 8
Oil leak diagnosis ...................................................................... 8 Compression pressure test ........................................................ 9 Cylinder pressure leakage test ................................................ 11 Tightening torque ..................................................................... 12

REMOVAL AND INSTALLATION OF ENGINE ...... 15
Removal and installation of engine assembly ........................... 15 Engine accessories ................................................................. 20

DISASSEMBLY AND REASSEMBLY ................... 24
Components and special tools ................................................. 24 Inspection before disassembly and reassembly ....................... 26 Engine accessories ................................................................. 27 Engine overhaul ....................................................................... 42

2

01

STRUCTURE AND FUNCTION DESCRIPTIONS
MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
The electronically controlled advanced D20DT engine that has high pressure fuel system has been introduced to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.

ABS/ESP modulator

Fuse box

Brake fluid reservoir

Battery

Washer fluid reservoir Fuel filter & priming pump HFM sensor VGT Turbo charger
CHANGED BY EFFECTIVE DATE AFFECTED VIN

EGR valve

Vacuum pump

Oil separator (PCV valve )

Engine oil filler cap

Engine oil dipstick

FFH

ENGINE ASSEMBLY
ACTYON SM - 2006.03

Air cleaner assembly

Coolant reservoir

Engine

PWM electric fan & fan shroud

Power steering oil reservoir

Vacuum modulator

01

3
GENERAL

ENGINE STRUCTURE
Front View
Cam position sensor Tightening torque: 12 ± 1.7 Nm Oil dipstick gauge Oil separator (with PCV) Viscos clutch pulley

Idle pulley
EGR valve

VGT Turbo charger EGR pipe Power steering pump Water pump pulley Power steering pump pulley Auto tensioner pulley Alternator Air conditioner compressor Crankshaft pulley

Oil pan

Auto tensioner

Top View

Oil separator

VGT Turbo charger

Injector (10 ± 1.0 Nm → 180 + 20°) Oil pipe (40 ± 4.0 Nm) Fuel pressure sensor Water outlet port

Cylinder head cover Glow plug (15 ± 3 Nm) Vacuum pump (10 ± 1.0 Nm) Common rail (25 ± 2.5 Nm)

Booster pressure sensor
Tightening torque: (10 ± 1.0 Nm)

EGR valve

Oil filler

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01

Right Side View

EGR valve Intake manifold

Knock sensor 20 ± 2.6 Nm

Booster pressure sensor Vacuum pump

Power steering pump oil reservoir

Oil filter & oil cooler Vacuum modulator for EGR valve Crank position sensor Tightening torque: 0.8 ± 0.4 Nm Gap: 0.7 ~ 1.5 mm Flywheel

Power steering pump HP pump assembly

Air conditioner compressor

Vacuum modulator for VGT turbocharger actuator Engine mounting bracket

Left Side View

Oil separator (with PCV) Oil dipstick gauge

Cylinder head jack valve screw EGR pipe VGT Turbo charger assembly Water pump

Cylinder block assembly Alternator

Oil pan

Engine mounting bracket
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5
GENERAL

SPECIFICATIONS AND PERFORMANCE CURVE
Specifications
Description
Engine Cylinder Type/Number of cylinders Inner diameter (mm) Stroke (mm) Displacement (cc) Compression ratio Maximum output (ps/rpm) Maximum torque (Nm/rpm) Idle speed For Manual Transmission For Automatic Transmission Valve Intake Opens (BTDC) Closes (ABDC) Exhaust Opens (BBDC) Closes (ATDC) Camshaft Fuel system Type Fuel type Fuel pump type Fuel supply pressure

D20DT
D20DT/4-cylinder 86.2 85.6 1998 17.5:1 141/4,000 310/1,800 ~ 2,750 780 ± 50 rpm 780 ± 50 rpm 9° 26° 38° 16° DOHC Low sulfur diesel Vane pump in HP pump HP pump inlet port: max. 400 mbar HP pump outlet port (with IMV fully open): over 1,050 bar at every 10,000 km 75 SAE 10W40, 5W40 (MB Sheet 229.1, 229.3 approved oil) Forced delivery Full flow, filter element type 7.5 Water cooling type Belt operated type 85 WAX pellet type 11.5

Water separation in fuel filter Fuel tank capacity ( ) Lubrication system Oil specification Lubrication type Oil filter type Oil capacity ( ) Cooling system Cooling type Cooling fan operation type Thermostat (Fully Open: 100°C) Opening temperature (°C) Type Coolant capacity ( )

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ACTYON SM - 2006.03

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6

01

Engine Performance Curve
Output and Torque

ENGINE ASSEMBLY
ACTYON SM - 2006.03

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01

7
GENERAL

Oil Temperature/Pressure and Boost Pressure

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01

DIAGNOSTIC INFORMATION AND PROCEDURE
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.

Black Light and Dye Method
A dye and light kit is available for finding leaks, Refer to the manufacturer’s directions when using the kit. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

Finding the Leak
1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, power steering fluid, etc. 2. Identify where the fluid is leaking from. 1) After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2) Wait a few minutes. 3) You should be able to find the approximate location of the leak by the drippings on the paper. 3. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach. 4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent. 1) Clean the area well. 2) Dry the area. 3) Operate the vehicle for several miles at normal operating temperature and varying speeds. 4) After operating the vehicle, visually check the suspected component. 5) If you still cannot locate the leak, try using the powder or black light and dye method.

Repairing the Leak
Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.

Gaskets
1. The fluid level/pressure is too high. 2. The crankcase ventilation system is malfunctioning. 3. The fasteners are tightened improperly or the threads are dirty or damaged. 4. The flanges or the sealing surface is warped. 5. There are scratches, burrs or other damage to the sealing surface. 6. The gasket is damaged or worn. 7. There is cracking or porosity of the component. 8. An improper seal was used (where applicable).

Seals
1. The fluid level/pressure is too high. 2. The crankcase ventilation system is malfunctioning. 3. The seal bore is damaged (scratched, burred or nicked). 4. The seal is damaged or worn. 5. Improper installation is evident. 6. There are cracks in the components. 7. The shaft surface is scratched, nicked or damaged. 8. A loose or worn bearing is causing excess seal wear.

Powder Method
1. Clean the suspected area. 2. Apply an aerosol-type powder (such as foot powder) to the suspected area. 3. Operate the vehicle under normal operating conditoins. 4. Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.
ENGINE ASSEMBLY
ACTYON SM - 2006.03

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9
GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY

COMPRESSION PRESSURE TEST
The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating status. NOTICE
• Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving components of engine (e.g., belt and cooling fan). • Park the vehicle on the level ground and apply the parking brake. • Do not allow anybody to be in front of the vehicle.

Specifications
Compression ratio Test temperature Compression pressure Normal value Minimum value Permissible pressure difference between individual cylinders 18 : 1 at normal operating temperature (80°C) 32 bar 18 bar Max. 3 bar

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ACTYON SM - 2006.03

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01

Measuring Procedure
NOTICE
• Disconnect the fuel rail pressure sensor connector to cut off the fuel injection. • Discharge the combustion residues in the cylinders before testing the compression pressure. • Apply the parking brake before cranking the engine.

1. Warm the engine up to normal operating temperature (80°C). 2. Disconnect the fuel rail pressure sensor connector to cut off the fuel injection. 3. Place the diagram sheet to compression pressure tester.

4. Remove the glow plugs and install the compression pressure tester into the plug hole.
Tightening torque (Tester) 15 Nm

5. Crank the engine for approx. 10 seconds by using the start motor. 6. Record the test result and measure the compression pressure of other cylinders with same manner. 7. If the measured value is not within the specifications, perform the cylinder pressure leakage test.

ENGINE ASSEMBLY
ACTYON SM - 2006.03

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11
GENERAL

CYLINDER PRESSURE LEAKAGE TEST
If the measured value of the compression pressure test is not within the specifications, perform the cylinder pressure leakage test.

Permissible Pressure Leakage
Test temperature At whole engine At valve and cylinder head gasket At piston ring at normal operating temperature (80°C) Max. 25 % Max. 10 % Max. 20 %

NOTICE
• Perform the pressure leakage test in order (1 - 2 - 3 - 4) • Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the combustion chamber)

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01

TIGHTENING TORQUE
NO.
1

Name
Main bearing cap

Size
M11 x 67

Quantity
10

Tightening Torque (Nm)
55 ± 5 120° ± 10° 40 ± 5 90° ± 10° 10 ± 1 25 ± 2.5 10 ± 1 10 ± 1 10 ± 1 45 ± 5 90° ± 10° 200 180° ± 10° 10 ± 1 10 ± 1 10 ± 1 25 ± 2.5 25 ± 2.5 65 ± 5 25 ± 2.5 85 ± 5 270° + 10° 25 ± 2.5 90° ± 10° 65 ± 5 82 ± 6 32 ± 3 10 ± 1 10 ± 1 10 ± 1 25 ± 2.5 25 ± 2.5 25 ± 2.5 46 ± 4.6 46 ± 4.6

2 3 4

Connecting rod cap Rear cover Oil pump

M9 x 51 M6 x 20 M8 x 35SOC M6 x 40

8 6 3 6 3 2 8

5

T.G.C.C

M6 x 60 M6 x 70

6

Flywheel

M10 x 22

7

Crankshaft hub

M20 x 85 M6 x 20

1 20 3 3 4 3 1 2 2 1 9 1 1 1 1 7 4 2 1 2 2 1 1

8

Oil pan

M6 x 35 M6 x 85 M8 x 40

9 10

High pressure pump mounting bolt High pressure pump main nut (intershaft)

M8 x 55 M14 x 1.5 M8 x 25

11

Cylinder head

M8 x 50 M10 x 158 M10 x 177

12 13 14 15 16 17 18

Camshaft sprocket (Intake) Camshaft sprocket (Exhaust) Chain tensioner Auto tensioner Water pump assembly Water pump pulley Hot water inlet pipe assembly

M11 x 40 M24 M12 x 90 (UP) M8 x 45 (LOWER) M6 x 50 M6 x 10 M6 x 12 M8 x 80

19

Alternator bracket

M8 x 34 M8 x 30

20

Alternator

M10 x 90 M10 x 116

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ACTYON SM - 2006.03

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NO.
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13
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Name
Air conditioner compressor bracket assembly Air conditioner compressor sub bracket assembly Intake manifold

Size
M8 x 25 M8 x 60 M6 x 16 M8 x 20 M8 x 50 M8 x 133 M6 x 16 M8 x 105 M8 x 28 M8 x 14 M6 x 20 M8 x 46 M8 x 35 M8 M8 M10 x 1.0 M16 (Cylinder block side) M8 M8 x 20 M6 x 16 (T/C side) M6 x 16 (Cylinder block side) M6 x 25 M8 M6 x 16 M6 x 16 M8 x 25 M8 x 30 M5 M6 x 20 M6 x 25 M6 x 55 M6 x 85 M6 x 35 M6 x 16 M6 x 16 M8 x 35

Quantity
1 3 1 1 5 5 2 1 1 1 2 8 2 8 3 1 1 1 1 2 2 4 2 2 4 2 2 5 3 5 1 3 18 4 1 1 2 1

Tightening Torque (Nm)
25 ± 2.5 25 ± 2.5 10 ± 1.0 25 ± 2.5 25 ± 2.5 25 ± 2.5 25 ± 2.5 25 ± 2.5 20 ± 2.6 12 ± 1.7 10 ± 1.0 15 ± 1.5 15 ± 1.5 40 ± 4.0 25 ± 2.5 18 ± 1.8 25 ± 2.5 23 ± 2.3 25 ± 2.5 10 ± 1.0 10 ± 1.0 10 ± 1.0 35 ± 3.5 10 ± 1.0 10 ± 1.0 25 ± 2.5 25 ± 2.5 15 ± 3.0 10 ± 1.0 10 ± 1.0 10 ± 1.0 10 ± 1.0 10 ± 1.0 10 ± 1.0 10 ± 1.0 25 ± 2.5 25 ± 2.5 25 ± 2.5

22

23

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Acoustic cover bracket Knock sensor Camshaft position sensor Booster pressure sensor Exhaust manifold stud bolt Exhauster manifold nut Turbo charger assembly Turbocharger hollow bolt Turbocharger oil feed pipe Turbocharger support bar (nut) Turbocharger support bar (bolt) Turbocharger return pipe EGR valve assembly EGR-LH pipe nut EGR-RH pipe nut EGR center bolt EGR center pipe Glow plug Vacuum pump

43 44 45 46

Cooling fan bracket assembly Cylinder head cover Vacuum modulator Oil dipstick tube

47

Oil filter assembly

M8 x 55 M8 x 125

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ACTYON SM - 2006.03

14
NO.
48 49 50 51 52 53 54 55 56 57 58 59

01
Name
Fuel rail assembly Injector Fuel pipe clip (H-C) Fuel pipe clip (C-I) Crankshaft position sensor Power steering pump Head screw plug Cam shaft cap bolt Piston topping Connecting rod end play Cam shaft end play Crank shaft end play

Size
M8 x 35 M6 x 60 M14 M14 M6 x 14 GAP M8 x 100 M8 x 60 -

Quantity
2 4 2 8 1 2 1 20 -

Tightening Torque (Nm)
25 ± 2.5 10 ± 1.0 180° + 20° 40 ± 4.0 40 ± 4.0 0.8 ± 0.4 0.7 ± 1.5 mm 25 ± 2.5 25 ± 2.5 25 ± 2.5 0.765 ~ 1.055 mm 0.500 ~ 1.500 mm 0.100 ~ 0.350 mm 0.100 ~ 0.254 mm

ENGINE ASSEMBLY
ACTYON SM - 2006.03

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15
GENERAL

REMOVAL AND INSTALLATION OF ENGINE
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
Removal
Preceding Work

2. Drain the engine coolant.

Summary of Engine Removal

Remove the engine accessories, front bumper and radiator. Unscrew the engine mounting bolts (17 mm) at both sides and remove the engine assembly.

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ENGINE ASSEMBLY
ACTYON SM - 2006.03

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1. Disconnect the negative battery cable.

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ASSY

2 Nm 2. Remove the transmission and transfer case assembly. Store it in a safe place and observe the regulation when disposing. Be careful not to spill the oil from the oil lines when disconnecting them in the vehicle with automatic transmission. Drain the engine coolant.16 01 Removal and Installation Preceding Work 1. Installation Notice Tightening torque 12 ± 1. 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Disconnect the negative battery cable and remove the skid plate under the engine compartment. NOTICE • Use only the designated container to collect the coolant. • Use only Ssangyong genuine engine coolant when refilling.2006. ENGINE ASSEMBLY ACTYON SM .

2006. A. Remove the coolant reservoir (A).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN SENSOR CONTROL Unscrew the mounting bolts (10 mm). Air Cleaner Front Duct Radiator upper hose Release the clamps on the reservoir and radiator and remove the return hose and pipe. Coolant Reservoir Clamp Mounting bolts Supply hoses B. and remove the air cleaner front duct.01 4. disconnect the return/supply hoses. and remove the coolant reservoir. Remove the engine hood assembly (refer to “Body” section). coolant return hose (B) and air cleaner front air duct (C). Return Hose and Pipe Return hose and pipe C. release the hose clamps. ENGINE ASSEMBLY ACTYON SM . Unscrew the mounting bolts (10 mm). 17 GENERAL 5. FUEL COOLING LUB Mounting bolts EXHAUST I N T A K E HOUSING ASSY .

2006. Hose (LH) Intercooler hose Radiator lower hose Hose (RH) Intercooler hose Radiator upper hose ENGINE ASSEMBLY ACTYON SM . Remove the air cleaner intake hose and HFM sensor. Remove the left intercooler hose and the lower hose of the radiator.18 01 6. Remove the right intercooler hose and the upper hose of the radiator.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . HFM sensor 7.

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................................................................................. ...............................................................................................................................................................................................................................................01 19 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY MEMO ............... ......................................................... ..................................................................................... ............... ................................................................................................................................................................................................................................................................... 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CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. ..................................................................................................................................................................... ................. ...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................2006........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ ............. ........................................................................................................................................................................................................................................................................................................................................................

2006.20 01 ENGINE ACCESSORIES Remove/disconnect the accessories as below (no specific sequence): Engine Main Wiring Connector Booster Vacuum Hose Heater Hose and Pipe Main wiring Alternator Wiring Harness Battery Cable and Battery Assembly Ground ENGINE ASSEMBLY ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

03 SENSOR CONTROL FUEL COOLING LUB A/C Compressor Connector and Inlet/Outlet Pipes EXHAUST I N T A K E HOUSING ASSY .01 21 GENERAL Fuel Filter Hose Preheat Control Unit Connector Vacuum hose Preheat relay Fuel pump Tightening torque: 16 ~ 23 Nm Power steering pump Negative Cable to Engine Power Steering Pump Pipes and Hose CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .22 01 Remove two engine mounting bolts (LH/RH) and remove the engine assembly using the engine jack.2006. Rear bracket for engine removal Front bracket for engine removal Engine mounting Engine mounting LH mounting (lower side of VGT) RH mounting (lower side of HP pump) ENGINE ASSEMBLY ACTYON SM .

2006.01 Mounting Location in Underbody 23 GENERAL CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

24 01 DISASSEMBLY AND REASSEMBLY COMPONENTS AND SPECIAL TOOLS Injector Puller Y99220072B Glow Plug Wrench Y99220132B Sealing Caps 665 995 5844 Fuel Pipe Wrench Injector Copper Washer Puller Y99220022B Valve Remover/Installer Y99220082B Pulley Lock/Wrench Y99220052B Engine Lock 602 589 00 40 00 ENGINE ASSEMBLY ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 25 GENERAL Glow Plug Socket Removal/Installation Device for HP Pump Removal/Installation Socket for High Pressure Pipe Head Bolt Wrench CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .2006.

Remove the cylinder block drain plug and seal and completely drain the residual coolant from the cylinder block. 4. When the fan belt is installed. gently pump the belt shock absorber mounting bolt (M19) 3 times. Installation Notice Tightening torque 25 ± 2. 2.5 Nm ENGINE ASSEMBLY ACTYON SM .2006. Installation Notice Tightening torque 30 Nm Replace the seal with new one once removed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Take off the fan belt while pushing the mounting bolt (M19). 3.26 01 INSPECTION BEFORE DISASSEMBLY AND REASSEMBLY Preparations and Preceding Works 1. Loosen the oil drain plug and completely drain the engine oil.

2006.03 COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 27 GENERAL ENGINE ACCESSORIES PCV valve and oil separator Turbo charger EGR pipe (LH. Center. RH) Cooling fan clutch Auto tensioner Alternator Fuel return hose EGR valve Cable and connector CONTROL SENSOR FUEL Oil filter assembly Power steering pump Air conditioner compressor Start motor Mounting bracket CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .

5 Nm 18 ± 1. 2. Be careful with the intereference The vacuum hose for the EGR valve should be routed over the engine main wiring.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .0 Nm 10 ± 1.8 Nm Support bar Nut Bolt 23 ± 2.28 01 Cautions When Installing the Engine 1.3 Nm 25 ± 2.5 Nm Turbocharger actuator Oil supply tube Hollow bolt 25 ± 2.0 Nm ENGINE ASSEMBLY ACTYON SM . Tightening torque of oil pipes on VGT Turbocharger assembly 25 ± 2.5 Nm Lower Oil return tube Upper 10 ± 1. Connection of vacuum hose The vacuum hose from the vacuum modulator for turbocharger actuator control should be routed under the fuel return hose and the engine main wiring.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 29 GENERAL 3. Vacuum modulator Tightening torque: 10 ± 1.2006.0 Nm VGT turbocharger vacuum modulator connector Gray VGT vacuum outlet hose EGR valve vacuum modulator connector Black EGR vacuum outlet hose CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .

2006. Precautions: . Sealant specification: .Part number: 661 989 56 A0 .DB 2210 (Drei Bond) .30 01 Sealant for Engine Applied Locations Timing Gear Case Cover Vacuum Pump Oil Pan Idle Pulley Bracket 1. .Never use Loctite 5900 on DI engine. ENGINE ASSEMBLY ACTYON SM .Characteristic: It is hardened twice faster than Loctite 5900.Be careful not to clog the oil hole with sealant when installing the vacuum pump. 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

remove the components from top to bottom. be careful not to splash the lubricants to engine and body when disassembly. 31 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Removal and Installation Order of Major Accessories 1. Oil Filter Assembly 4-1. avoid getting into other components.03 . Especially.2006. Vacuum Modulator 1) Camshaft Position Sensor 2) Crankshaft Position Sensor 3) Injector Fuel Line Connector 4) Glow Plug Connector 2. Turbo Charger CHANGED BY EFFECTIVE DATE AFFECTED VIN Alternator Assembly ENGINE ASSEMBLY ACTYON SM . Power Steering Pump Assembly 6. However. Air Conditioner Compressor Assembly 7. In general. Belt Tensioning Assembly 5. PCV Valve Assembly + Oil Dipstick Tube 8. Engine Cables and Connectors 5) Fuel Return Hose 6) High/Low Pressure Hoses in HP Pump 7) Ground Cables 8) Fuel Pressure Sensor Connector 3. Fuel Hoses 9) Booster Pressure Sensor Connector 10) Knock Sensor Connector 11) Coolant Temperature Sensor Connector 12) HP Pump: Fuel Temperature Sensor (Green) 3-1. EGR Valve Assembly IMV (Brown) 4.01 The engine accessories can be removed without any specific order.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2) Remove the high fuel pressure pipe mounting bolts with a special tool. • High fuel pressure supply pipe at common rail side Installation Notice Tightening torque 40 ± 4 Nm ENGINE ASSEMBLY ACTYON SM . NOTICE • Replace the pipes with new ones.0 Nm NOTICE • Plug the openings of injector nozzle and common rail with sealing caps after removed the fuel pipes.32 01 1. Be careful not to be mixed the fuel pipes because the pipe appearance of D27DT (#1 and #3 cylinders and #2 and #4) are same each other.2006. Installation Notice Tightening torque 40 ± 4. Remove the fuel pipes. 1) Remove the fuel supply pipes between each cylinder and common rail with a special tool.

5 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . Lower: 10M x 2) Installation Notice Upper bolt Lower bolt 25 ± 2.0 Nm 33 GENERAL 4) Unscrew the bracket mounting bolts and remove the high fuel pressure supply pipes. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 3) High fuel pressure supply pipe at HP pump side Installation Notice Tightening torque 40 ± 4. Disconnect the vacuum hoses and module cables from the vacuum modulator. (Upper: 10 M x 2.5 Nm 25 ± 2.03 SENSOR From vacuum pump CONTROL FUEL 2. NOTE • Special tool: Fuel pipe remover and installer Turbo charger booster vacuum modulator NOTICE • Put the installation marks on the modulator hoses and connectors.2006. To turbo charger booster EGR booster vacuum modulator 1) Remove the vacuum modulator bracket.

Fuel Return Hose Injector Fuel Line Connector Glow Plug Connector Camshaft Position Sensor Crankshaft Position Sensor HP Pump Connector Fuel temperature Sensor Oil Pressure Switch IMV Knock Sensor Connector Coolant Temperature Sensor Connector Fuel Pressure Sensor Connector Booster Pressure Sensor Connector ENGINE ASSEMBLY ACTYON SM . Disconnect the wiring harnesses and connectors from the engine.34 01 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

1) Disconnect the vacuum hose from the EGR valve. Disconnect the high and low fuel pressure hoses from the HP pump. COOLING • Be careful not to damage the hose connections. 2) Unscrew the EGR valve bolts and EGR #1 pipe connecting bolts and remove the EGR valve and steel gasket. EXHAUST I N T A K E HOUSING ASSY .01 1) Remove the cable assembly from the engine. and then remove the engine cable assembly. Remove the EGR valve and EGR valve pipe. remove the cables after removing the fuel pipes. NOTICE • Plug the openings in HP pump immediately after disconnecting the hoses. NOTICE • Be careful not to damage the HP pump connecting pipe (venturi) while removing the fuel hose from the HP pump.0 Nm.0 Nm.03 SENSOR CONTROL FUEL LUB 4. 5. 35 GENERAL IMPORTANT • Remove the cable screws and ground cable. Installation Notice EGR valve bolt EGR valve and center pipe bolt D20DT 10 ± 1.2006. M6 10 ± 1. M6 CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . IMPORTANT • If possible. It makes the operation easier and protect the cables and connectors.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 Nm Bolt 10 ± 1. ENGINE ASSEMBLY ACTYON SM . If flown out.0 Nm 2 • The EGR #3 pipe should be replaced with new one.5 Nm • The EGR #2 pipe should be replaced with new one. • Make sure that the convex surface of new steel gasket is facing to the bolts. 4) Unscrew the EGR valve #3 pipe (2) mounting bolts and remove the pipe from the exhaust manifold. 1) Remove the oil cooler hose. 6. Installation Notice Center pipe mounting bolt Center pipe and #1 pipe bolt and nut 25 ± 2. NOTICE • Be careful not to flow out the residual oil from the engine.2006. immediately wipe it out.36 01 3) Remove the EGR valve #1 pipe. Remove the oil filter assembly. Installation Notice Tightening torque Nut 35 ± 3.5 Nm 35 ± 3. 2) Remove the oil filter assembly mounting bolts.

• Be careful not to damage the rubber parts of the shock absorber when removing. when installing.01 3) Remove the oil filter assembly from the cylinder block.2006. remove the bolts from bottom to top section. store the removed shock absorber assembly with standing up.5 Nm 37 GENERAL 7. On the contrary. • For air bleeding. Remove the belt tensioning device. tighten the bolts from top to bottom section.03 SENSOR CONTROL FUEL 2) Remove the shock absorber upper mounting bolt. pump the shock absorber around 3 times after installation. Installation Notice • Replace the oil filter gasket with new one. NOTICE • To prevent the oil leaks. Installation Notice Tightening torque 32 ± 3 Nm Installation Notice Tightening torque 82 ± 6 Nm 3) Remove the belt tensioning device. • To prevent the oil leaks. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 1) Remove the shock absorber lower mounting bolt. Tightening torque 25 ± 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .

Installation Notice Tightening torque 25 ± 2. 2) Remove the power steering pump assembly from the engine. 1) Unscrew the bolts and remove the air conditioner compressor assembly. store the removed power steering pump assembly with standing up.38 01 8. 9.5 Nm • Be careful not to flow out the oil. Remove the air conditioner compressor assembly. NOTICE • To prevent the oil leaks.5 Nm ENGINE ASSEMBLY ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1) Remove the power steering pump mounting bolts. Installation Notice Front bolt Side bolt 25 ± 2.5 Nm 2) Unscrew the bolts and remove the air conditioner mounting bracket. Installation Notice Tightening torque 25 ± 2. Remove the power steering pump assembly.5 Nm 25 ± 2.

39 GENERAL 2) Remove the PCV valve hose connected to the engine oil hose. Unscrew the bracket bolts and remove the dipstick tube with O-ring. Remove the oil dipstick tube assembly. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • Insert new O-ring into the oil dipstick tube before installation. Installation Notice Tightening torque 10 ± 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .03 SENSOR FUEL 3) Unscrew the PCV valve mounting bolts and remove the PCV valve assembly.2006.0 Nm CONTROL 11. 1) Remove the PCV valve hose. Remove the PCV valve assembly.01 10.

Tightening torque 10 ± 1.0 Nm 12. Remove the turbo charger assembly. 1) Unscrew the bolts and remove the oil supply pipe.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Upper bolt (M19) Lower bolt (M17) 25 ± 2. Installation Notice Tightening torque 25 ± 2.2006. Installation Notice • Make sure to install the gasket with correct direction.0 Nm 3) Unscrew the turbo charger mounting bracket bolts.0 Nm 2) Unscrew the bolts and remove the oil return pipe.5 Nm ENGINE ASSEMBLY ACTYON SM .40 01 Installation Notice Tightening torque 10 ± 1.5 Nm 20 ± 2.

Installation Notice Tightening torque 25 ± 2. 1) Unscrew the bolts and remove the alternator.5 Nm 25 ± 2. NOTICE • Alternator Capacity: 140 A Tightening torque 46 ± 4.2006. Remove the alternator assembly. Installation Notice M13 bolt Torx 6 bolt 25 ± 2.03 SENSOR Installation Notice CONTROL FUEL 13. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 4) Unscrew the turbo charger mounting bolts to exhaust manifold.5 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .5 Nm 41 GENERAL NOTICE • Use only 12 1/2 wrench. 5) Remove the turbo charger assembly.6 Nm 2) Remove the alternator mounting bracket.

• Replace the copper washers with new ones when installing. Remove the glow plugs with a special tool. NOTICE • Be careful not to take off the sealing caps on the injectors and fuel system.42 01 ENGINE OVERHAUL 1. Unscrew the injector nozzle holder bolts (12-sided) and remove the injector bracket. 3. Installation Notice Tightening torque 9 ± 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .0 Nm. remove it with a special tool as shown in the figure. 4.2006. If the copper washer is in injector hole. Remove the injectors with a injector extractor (special tool). 190° + 10° 2. Installation Notice Tightening torque 15 ~ 18 Nm ENGINE ASSEMBLY ACTYON SM .

HOUSING 6. Unscrew the bolt and remove the camshaft position sensor. Remove the booster sensor from the engine. Installation Notice Tightening torque 10 ± 1. 8. COOLING LUB EXHAUST I N T A K E ASSY .0 Nm Installation Notice Tightening torque 12 ± 2 Nm CONTROL Apply Loctite on the thread before installation.0 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . Unscrew the Torx bolts and remove the common rail from the engine.5 Nm 43 GENERAL NOTICE • Plug the openings with sealing cap. Installation Notice Tightening torque 25 ± 2. Unscrew the bolts and remove the cooling fan pulley while holding it with a special tool.2006.03 SENSOR FUEL 7. Installation Notice Tightening torque 10 ± 1.01 5.

Installation Notice Tightening torque M6 x 20: 24 EA M6 x 35: 3 EA M6 x 85: 3 EA M8 x 40: 4 EA Nm 10 ± 1.5 ENGINE ASSEMBLY ACTYON SM .2006.0 Nm 10. Unscrew the bolts and remove the cooling fan bracket assembly (timing chain cover).0 Nm 11.0 Nm 12. Remove the cooling fan belt idle pulley while holding it with a special tool. Installation Notice Tightening torque 10 ± 1. Installation Notice Tightening torque 10 ± 1. Turn over the engine and remove the oil pan.0 10 ± 1. Unscrew the bolts and remove the cylinder head cover.0 25 ± 2.44 01 9.0 10 ± 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque 10 ± 1.

01 45 GENERAL NOTICE • Remove the oil seal residues from the oil pan and apply the liquid gasket on the parting surface. Installation Notice Tightening torque 40 ± 4. Otherwise. Unscrew the bolts and remove the water pump. Unscrew the bolts and remove the thermostat. Installation Notice Tightening torque 10 ± 1. Mark the installation direction to prevent wrong installation. 15.2006. COOLING EXHAUST I N T A K E HOUSING ASSY . it may cause a sealing trouble. 13. LUB Installation Notice Tightening torque 10 ± 1.0 Nm • Be careful not to flow out the residual coolant.03 SENSOR CONTROL FUEL 14.0 Nm NOTICE • The exhaust manifold gasket is removed along with the exhaust manifold.0 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . Unscrew the nuts and remove the exhaust manifold.

0 Nm ENGINE ASSEMBLY ACTYON SM . Unscrew the bolts and remove the coolant inlet port from the intake manifold.2006.46 01 16.5 Nm NOTICE • Replace the gasket with new one once removed. Installation Notice Tightening torque 10 ± 1. Unscrew the bolts and remove the intake manifold assembly. Unscrew the bolts and remove the water pump housing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 17. 18. Installation Notice Tightening torque 10 ± 1. Installation Notice Tightening torque 25 ± 2. Installation Notice Tightening torque 25 ± 2. Remove the vacuum pump from the cylinder head.5 Nm • Be careful not to get the coolant into the intake manifold and engine. 19.0 Nm • Be careful not to flow out the residual coolant.

Pull out the lock pin and remove the upper chain guide bracket.5 Nm. Installation Notice Tightening torque 25 ± 2.03 SENSOR CONTROL FUEL 22. 47 GENERAL 21. Unscrew the bolt and remove the intake camshaft sprocket. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Install the engine lock (special tool) onto the flywheel ring gear so that the engine will not rotate.2006. Remove the chain tensioner.0 Nm 23. 90° ± 10° CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . Preceding Works: removal of EGR pipe and oil dipstick tube Installation Notice Tightening torque 65 ± 5.01 20.

#4 Do not remove the bolts at a time completely. ENGINE ASSEMBLY ACTYON SM .2006.5 Nm. Unscrew the bolt and remove the exhaust camshaft sprocket. Remove the camshaft bearing cap bolts so that the tightening force can be relieved evenly. #3. #9 • Exhaust: #2. #8. 90° ± 10° 25.48 01 24. Remove the intake and exhaust camshafts from the cylinder head.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque 25 ± 2. Installation Notice Tightening torque 25 ± 2. Remove them step by step evenly or camshaft can be seriously damaged. Exhaust Intake • Intake: #7. #5 However. #10 • Exhaust: #1. there is no specific removal sequence. • Intake: #6.5 Nm 26.

• To prevent the oil leaks.5 25 ± 2. 49 GENERAL 28.5 85 ± 5 Nm. • Be careful not to be contaminated by foreign materials. Measure the length of cylinder head bolts. it indicates the oil inside of HLA has been flown out. NOTICE • Avoid contact with hot metal parts when removing the HLA device immediately after stopping the engine. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .01 27. replace the cylinder head bolt. Remove the cylinder head bolts according to the numerical sequence. • If the HLA can be easily pressed in by hand. Remove the finger follower and the HLA device. Length when new 177 mm 158 mm Maximum Limit 179 mm 160 mm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM .2006. If the maximum length is exceeded by 2 mm. replace it with new one.03 SENSOR FUEL 29. In this case. Installation Notice Tightening torque M8 x 25: 2 EA M8 x 50: 2 EA M12 x 177: 11 EA M12 x 158: 1 EA (Vacuum pump side) Nm 25 ± 2. Pull out the pin and remove the timing chain guide from the engine. store the removed finger follower and HLA device with standing up. 3 x 90° + 10° CONTROL 30.

Measure the piston protrusion from the parting surface. • Always insert new washer first. Make sure to place the “TOP” mark upward. Put the steel gasket on the cylinder block and position the cylinder head. • Store the removed injectors and glow plugs so that they will not be damaged. ENGINE ASSEMBLY ACTYON SM . 1.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 32.055 mm 33. Remove the cylinder head. Tighten the cylinder head bolts to specified torque and torque angle.0 Nm Tightening torque Step 2 85 ± 5. Step 1 20 ± 2.50 01 31.765 ~ 1. Specified Value: 0. Remove the cylinder head gasket. NOTICE • Inspect the cylinder head surface. • The bolts (12) at vacuum pump side are shorter than others.0 Nm Step 3 90 ± (3 times) + 10° • Apply the oil on the bolt thread when installing. Installation Notice • Replace the cylinder head gasket with new one. 2.

Installation Notice Tightening torque 25 ± 2. Unscrew the bolts and remove the oil strainer assembly. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .5 Nm 1) Unscrew the bearing cap bolts. Turn over the engine and remove the baffle plate.0 Nm 90° + 10° NOTICE • Align the oil grooves in bearing cap and connecting rod. Installation Notice Step 1 Step 2 55 ± 5.01 34.0 Nm 51 GENERAL 35.2006. Remove the piston assembly from the cylinder block. CONTROL FUEL 36.03 SENSOR Tighten the bolts from #1 cap. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . 2) Remove the bearing caps and lower bearing shells. Installation Notice Tightening torque 10 ± 1.

180° + 10° 38. Installation Notice Tightening torque 10 ± 1. NOTICE • Replace the piston ring.2006. NOTICE • Do not mix up upper and lower crankshaft bearing shells. Installation Notice Tightening torque 200 ± 20 Nm. 4) Remove the snap ring piston pin from the piston. 37. Lock the flywheel and remove the center bolt and crankshaft pulley. 5) Disassemble the piston and connecting rod. 6) Remove the piston rings from the piston.52 01 3) Remove the piston assembly through the cylinder.0 Nm ENGINE ASSEMBLY ACTYON SM . 1) Remove the cover bolts.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . bearing and snap ring with new ones. Remove the timing chain cover assembly.

CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE ASSEMBLY ACTYON SM . Remove the HP pump bolts and the HP pump bracket bolts. NOTICE • Apply the sealant on the parting surface. 1) Remove the HP pump assembly. Remove the timing chain guide rail and timing chain. 53 GENERAL 39.2006. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .03 SENSOR CONTROL FUEL 40.01 2) Hold the timing chain and remove the timing chain cover by tapping it with a rubber hammer and a screwdriver.

0 Nm. Unscrew the bolts and remove the crankshaft bearing caps. 90° + 10° NOTICE • Remove the bearing cap bolts from inside to outside with a pair. 90° + 10° 43.54 01 41. 42. • Do not mix up the crankshaft bearing caps and shells. Remove the crankshaft sprocket with a special tool. Installation Notice Tightening torque 45 ± 5.2006.0 Nm. • Replace the gaskets and bearings with new ones. NOTE • Install in the reverse order of removal. Installation Notice Tightening torque 55 ± 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Make sure to install the gaskets in correct direction. • Tighten the fasteners with the specified tightening torques. ENGINE ASSEMBLY ACTYON SM . Remove the flywheel and the crankshaft strainer.

....... 40 PISTON AND CONNECTING ROD ........ 44 Disassembly and reassembly .......................................................................ENGINE HOUSING 02 TABLE OF CONTENTS CYLINDER HEAD/CYLINDER BLOCK ......................................... 2 Camshaft assembly ........................... 42 Piston ring ........... 27 CRANKSHAFT .................................. 49 Disassembly and reassembly ............................................................... 43 Cylinder inner diameter and piston size ............. 45 HIGH PRESSURE PUMP (HPP) .......... 23 Cylinder block ............................................................................................... 52 ....................... 36 Disassembly and reassembly ......................................................................... 30 Arrangement of thrust washers and bearings ......................... 37 FLYWHEEL ................................................................. manual transmission equipped vehicle) .................. 49 Components locator ................................................................................................ 31 Torsional vibration damper ......... 14 Timing chain assembly ......................... 40 Dual mass flywheel (DMF............................................................................................................................................................................................. 2 Cylinder head .....................................................

Swirl and tangential port 3.2006. 4-bolt type cylinder head bolt 4. Integrated chain housing and cylinder head 6.2 02 CYLINDER HEAD/CYLINDER BLOCK CYLINDER HEAD Cylinder head bolt Oil Return Check Valve System Characteristics 1. Oil gallery: drilled and sealing with cap and screw plug Intake manifold Exhaust manifold ENGINE HOUSING ACTYON SM . Water jacket integrated casting 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 4-valve DOHC valve mechanism 2.

Removal of intake and exhaust manifold 3.15 ~ 0. CONTROL Cylinder Head Mating Surface Check Specifications Height “A” (cylinder head parting surface . Tightening torque 60 Nm NOTICE • Examine the cylinder head for air bubbling. 2. Immerse the cylinder head with the pressure plate into warm water (approx. Removal of valves 1.075 mm 0. Install the cylinder head on the pressure plate.86 mm -0.2006. 60°C) and pressurize with compressed air to 2 bar. COOLING LUB EXHAUST I N T A K E HOUSING Test Procedures ASSY .9 mm 0.1 mm 0.1 mm 140. replace the cylinder head.15 mm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .004 mm 0.9 ~ 141.075 mm within 0. Place the pressure plate on a flat-bed work bench.03 SENSOR FUEL 3.74 ~ 0.02 3 GENERAL Cylinder Head Pressure Leakage Test Preceding Works: 1. If the air bubbles are seen. Removal of cylinders 2.cylinder head cover parting surface) Minimum height after machining Flatness In longitudinal direction In transverse direction Permissible variation of parallelism of top parting surface to bottom in longitudinal direction Peak-to-valley height Valve recess “a” Intake valve Exhaust valve 140.

Measure the cylinder head height “A”. ENGINE HOUSING ACTYON SM . Valve recess “a” Intake Valve 0. 2.9 mm NOTICE • If the height is less than the limit.86 Exhaust Valve -0. Limit Over 140. Insert the valves into the valve guides and measure the recesses.15 ~ 0.2006.15 NOTICE • If the measured value is out of the specified range.74 ~ 0. machine the valve seat as much as necessary until the specified value is achieved. the cylinder head must be replaced.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .4 02 Measurement 1.

Remove the cylinder head cover.03 SENSOR CONTROL FUEL 2. Rotate the crankshaft pulley to align the OT marks. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .1 OT) CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .6 (intake).02 5 GENERAL Cylinder Head Disassembly Preceding Works: 1. Disconnect the injector fuel lines. (align the cylinder No. 1) Align the mark (notch) on sprocket for cylinder No. (transmission “N” position) 1. 3. 2. Apply the parking brake and place the chocks under the tires. Disconnect the negative battery cable.1 (exhaust) and for cylinder No. connector and preglow plug connector. CAUTION • Cover the openings of fuel line with the protective caps.2006. Remove the EGR pipe.

Mark on the timing chain. Remove the high pressure pump and mark on the high pressure pump sprocket. 6. ENGINE HOUSING ACTYON SM . Remove the camshaft position sensor.6 02 4. intake camshaft sprocket and exhaust camshaft sprocket for timing setting during installation.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 7. 5.2006. Remove the chain tensioner after removing the EGR pipe and oil dipstick.

Remove the upper guide rail with a sliding hammer.03 SENSOR CONTROL FUEL 10. Hold the camshafts and remove the intake camshaft sprocket and exhaust camshaft sprocket. Remove the oil cooler and the intake manifold. Remove the cylinder head bolts according to the numerical sequence. 7 GENERAL 9. 11. 1) M8 x 25: 2EA 2) M8 x 50: 2EA 3) M12 x 177: 9EA 4) M12 x 158: 1EA (vacuum pump side) CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006.02 8.

765 ~ 1.055 mm ENGINE HOUSING ACTYON SM . Measure the piston protrusion from the mating surface. Standard 0. • If there is a sign of oil leakage on the cylinder head gasket. Remove the cylinder head.2006.8 02 12. replace it with new one. 13. • Store the removed injectors and glow plugs so that they will not be damaged.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . CAUTION • Inspect the cylinder head mating surface.

Measure the length of cylinder head bolts.03 SENSOR FUEL 3.02 9 GENERAL Reassembly 1. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • Make sure that the convex surface of upper guide rail faces to front side • Be careful not to alter the timing point of high pressure pump. 2. Step 1: 20 ± 2. replace the cylinder head bolt. NOTICE • Make sure to place the “TOP” mark upward.2006. Install the cylinder head with the steel gasket. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . • The bolts at vacuum pump side are shorter than others. 1) If the maximum length is exceeded by 2 mm. • Always insert new washer first.0 Nm Step 3: 360° (120° x 3) + 10° CONTROL NOTICE • Apply the oil on the bolt thread when installing.0 Nm Tightening torque Step 2: 85 ± 5. Tighten the cylinder head bolts to specified torque and torque angle. 4. Pull the timing chain over the cylinder head and install the upper guide rail.

Tightening torque 25 Nm + 90° NOTICE • If the sprocket bolt is stretched over 0. NOTICE • Make sure that the markings on camshaft sprocket and timing chain are aligned. Install the intake and exhaust camshaft sprockets and the timing chain.2006.10 02 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Install the chain tensioner. • Always install the intake camshaft sprocket first. Tightening torque 65 ± 5. 6. 1) Make sure that the upper guide rail is installed with proper direction.9 mm. ENGINE HOUSING ACTYON SM .0 Nm NOTICE • Make sure that the EGR steel gasket is properly installed. 2) Make sure that the timing chain is securely seated on the guide rails. replace it with new one.

• The fuel pipes are not reusable to keep the cleanness and parts damage. Remove the protective caps from the injector and install the new fuel supply pipes. 11 GENERAL 8. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • If the markings are not aligned.02 7. reinstall the cylinder head.2006.03 SENSOR CONTROL NOTICE FUEL 9. NOTICE • Apply the sealant on the bolt threads when installing the high pressure pump. Rotate the crankshaft pulley two revolutions and ensure that the OT mark on the crankshaft pulley and the OT mark on the camshaft pulley are aligned. Install the cylinder head cover and the high pressure pump housing. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the cylinder head assembly. Install the removed cylinder head on the assembly board (special tool) and set the supporting bar and lever (special tool) on the cylinder head. Remove the valves from the cylinder head. valve seat and valve spring.2006. 4. Push the valve spring seat down with the lever and remove the valve cotter. ENGINE HOUSING ACTYON SM . 3. 2.12 02 Intake/Exhaust-Removal/Installation 1.

03 SENSOR CONTROL FUEL Y99220162B COOLING LUB EXHAUST I N T A K E HOUSING ASSY .02 13 GENERAL Special Tools and Equipment Name and Part Number Y99220092B Compression pressure measuring adapter and gauge Application Y99220082B Supporting bar and lever Guide pin extractor Y99220112B Intake manifold guide pin CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.14 02 CAMSHAFT ASSEMBLY Preceding Work: Removal of cylinder head cover Finger Follower and HLA Intake Camshaft and Exhaust Camshaft Camshaft Sprockets Cylinder Head Camshaft Position Sensor Chain Tensioner ENGINE HOUSING ACTYON SM .

ECU learns every cylinder of the engine with crankshaft position sensor signals so can run the engine even though the camshaft position sensor is defective during engine running. when engine is started. The signal voltage will be 0V if protrusion and camshaft position sensor are near and 5 V if apart.03 SENSOR CONTROL The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor end is attached on the camshaft and then rotates with it. Accordingly.02 15 GENERAL Camshaft Position Sensor Gap Hall voltage <Location of Camshaft Position Sensor> <Operation Principle of Hall Sensor> Pulse generation Sensor air gap Tightening torque Operating temperature Cam angle ± 6° 0. can recognize specific cylinder’s status. The rotating speed of camshaft is half of the crankshaft and controls engine’s intake and exhaust valves.45 ~ 1.2006. camshaft position sensor is necessary to identify the cylinders correctly during initial starting. magnetic field changes direction of electron on the semi-conductor wafer to the current flow direction that passes through wafer from the right angle. Especially when started first. it is difficult to calculate the stroke of a specific cylinder with only crankshaft position sensor. by using camshaft position when the piston is moving toward TDC (OT). By installing sensor on the camshaft. FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . If sensor protrusion passes camshaft position sensor’s semi-conductor wafer. However. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).80 mm 10 ~ 14 Nm . camshaft hall sensor generates signal voltage. When operation power is supplied from camshaft position sensor.40 ~ 130°C Ground Camshaft sensor <Circuit Diagram of Camshaft Position Sensor> CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . compression stroke or exhaust stroke. ECU can recognize that the No.

2006. Rotate the crankshaft pulley to align the OT marks. connector and preglow plug connector. 2.6 (intake). 3. (align the cylinder No. (transmission “N” position) 1. Remove the EGR pipe. Apply the parking brake and place the chocks under the tires. Disconnect the negative battery cable.1 (exhaust) and for cylinder No.16 02 Disassembly Preceding Works: 1. Remove the cylinder head cover. 1) Align the mark (notch) on sprocket for cylinder No.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2. CAUTION • Cover the openings of fuel line with the protective caps. Disconnect the injector fuel lines.1 OT) ENGINE HOUSING ACTYON SM .

Remove the high pressure pump and mark on the high pressure pump sprocket. 7. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Mark on the timing chain. intake camshaft sprocket and exhaust camshaft sprocket for timing setting during installation.2006. Remove the camshaft position sensor. Remove the chain tensioner after removing the EGR pipe and oil dipstick. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .02 4.03 SENSOR CONTROL FUEL 6. 17 GENERAL 5.

there is no specific removal sequence. 3) Do not remove the bolts at a time completely. #3. Remove the finger follower and the HLA device. Remove the camshaft bearing cap bolts so that the tightening force can be relieved evenly. 4) Remove the exhaust camshafts and then remove the intake camshaft. #9 10. Remove them step by step evenly or camshaft can be seriously damaged. Finger Follower HLA ENGINE HOUSING ACTYON SM .18 02 8. #4 Intake: #7. 1) Exhaust: #1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . #8.2006. #5 2) Intake: #6. 9. • • Exhaust: #2. #10 However. Hold the camshafts and remove the intake camshaft sprocket and exhaust camshaft sprocket.

Tighten the camshaft bearing cap bolts. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . NOTICE • Perform the air bleeding process if it has been stored for a extended period of time. Place the bearing cap with the OT marks on both camshafts facing upward. #10 4) Exhaust: #1. Finger Follower HLA 2. Install the HLA device and finger follower. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . #5 Tightening torque 25 Nm NOTICE • Check the finger follower positions and align if needed. NOTICE • Apply the sealant on the cap (#12) for the vacuum pump when installing. 1) Intake: #7. #3.03 SENSOR CONTROL FUEL 3.2006. #8. Check the HLA device with the diagnosis procedures before installation. Part number: 661 989 56 A0 (DB2210) • Apply the oil on the bearing journals before installation. #9 2) Exhaust: #2.02 19 GENERAL Reassembly 1. • Make sure that it is properly installed on the locating pin. #4 3) Intake: #6.

9 mm. NOTICE • Make sure that the markings on camshaft sprocket and timing chain are aligned.20 02 4. Install the intake and exhaust camshaft sprockets and the timing chain. ENGINE HOUSING ACTYON SM . • Always install the intake camshaft sprocket first. Tightening torque 25 Nm + 90° NOTICE • If the sprocket bolt is stretched over 0.0 Nm NOTICE • Make sure that the EGR steel gasket is properly installed. Install the chain tensioner. replace it with new one. 2) Make sure that the timing chain is securely seated on the guide rails.2006. 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Tightening torque 65 ± 5. 1) Make sure that the upper guide rail is installed with proper direction.

Remove the protective caps from the injector and install the new fuel supply pipes.03 SENSOR CONTROL NOTICE FUEL 8. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . reinstall the cylinder head.2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . NOTICE • If the markings are not aligned. 21 GENERAL 7. • The fuel pipes are not reusable to keep the cleanness and parts damage.02 6. Install the cylinder head cover and the high pressure pump housing. Rotate the crankshaft pulley two revolutions and ensure that the OT mark on the crankshaft pulley and the OT mark on the camshaft pulley are aligned. NOTICE • Apply the sealant on the bolt threads when installing the high pressure pump.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .22 02 Special Tools and Equipment Name and Part Number Y99220152B HLA remover Application Y99220142B Stem seal installer ENGINE HOUSING ACTYON SM .2006.

Tensioner guide rail 12.02 23 GENERAL TIMING CHAIN ASSEMBLY Chain Drive System System Layout Oil injecting direction 2. Lower guide rail 8.03 SENSOR 1. Crankshaft sprocket 10. Chain tensioner CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Oil pump sprocket 9.2006. HP pump sprocket 6. Upper guide rail 3. Intake camshaft sprocket 4. Exhaust camshaft sprocket 7. Oil pump tensioner CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Oil nozzle 11. Clamping guide rail 5.

can reduce wears of each guide rail and sprocket.5 % from overall length (Replace if extended by over 7. By doing so. No. Guide rail can prevent chain slap when chain is extended and reduce chain wears.000 N 4. Replace when the chain is extended by 0.7 mm 6. Location of guide rail 1) Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket 2) Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket 3) Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket 4) Lower guide rail: Between HP pump sprocket and crankshaft sprocket ENGINE HOUSING ACTYON SM .0485 mm) Chain Tensioner Check valve * Check valve opening pressure: 0. while engine running. Load limits: 19. The material is plastic. Chain type: Double Bush 2. Tightening torque 65 ± 5.24 Chain 02 1.525 mm 3.5 bar The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil pressure in the tensioner. not loose.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Overall length: 1409.2 ~ 0.0 Nm (Installed on the cylinder head) Guide Rail Guide rail is used to optimize the movement of chain drive system like tensioner. 1. Pitch: 9.2006. The tensioner performs function of adjusting chain tension to be always tight. of links: 148 EA 5. Guide rail is needed especially when the distance between the sprockets are too long.

Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( 3.2006.02 Timing Setting 25 GENERAL 1. Check marking links on the chain (Gold marking) 2. Align another marking link to HP pump sprocket marking ( ) ) ) CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .03 SENSOR CONTROL FUEL COOLING Sprocket marking: 4 points (Gold marking) LUB EXHAUST I N T A K E HOUSING ASSY . Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( 4.

6. 7. Remove the oil pump drive chain. Remove the lower guide rail. 8. Remove the cylinder head assembly. 2. 11. 9. Remove the upper guide rail while pushing the retaining spring with a screwdriver. 4. 3. Remove the chain guide rail with a sliding hammer. 10. NOTICE • Thoroughly clean the removed components before installing. Remove the chain cover.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 5. Remove the oil pan. Install in the reverse order of removal. Remove the oil pump drive chain. ENGINE HOUSING ACTYON SM .26 02 Removal and Installation 1.2006. Remove the timing chain. Remove the tensioner guide rail.

2006.02 27 GENERAL CYLINDER BLOCK Water jacket design to increase the cooling efficiency Cambering type skirt to reduce the noise CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING Deep head bolt thread to prevent the deformation at cylinder bore surfaces ASSY .

If happens knocking. And also controls pilot injection very precisely during MAP learning. 1 MΩ 25 kHz .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Water jacket design to increase the cooling efficiency of cylinder bore bridge 4. Knock sensor is used to detect those knockings caused by abnormal combustions. vibration and harshness (NVH) 1) Minimize the vibration by adding external ribs 2) Adding the ribs around oil pan mating surface Knock Sensor Two knock sensors are located on the cylinder block (intake manifold side). When knock sensor is defective. To detect engine vibration under abnormal combustion.40 ~ 150°C 26 ± 8 mV/g (at 5 kHz) Output voltage 22 ~ 37 mV/g (3 ~ 10 kHz) 22 ~ 57 mV/g (10 ~ 20 kHz) Tightening torque 20 ± 5 Nm ENGINE HOUSING ACTYON SM . Rib design by considering strength against engine vibrations and weight 2. knock sensor has piezoelectric element fixed on the vibration plate and this vibration plate is fixed on the base. Reinforcement of strength 1) Main bearing housing / Main bearing cap 2) Extended main bearing cap bolt 6. pistons or connecting rods vibrate and occurs heavy sounds that hit metal. Reducing the noise.2006.28 02 System Characteristics 1. be sure to check the tightening torque of the sensor and connector connecting conditions. Insulating resistance Resonance frequency Operating temperature Min. Before checking the knock sensor unit. intake air volume and coolant temperature. engine ECU corrects injection timing based on MAP values like engine speed. It controls idling stabilities and turns on the engine warning light when detects injector damages. Deep head bolt thread to prevent the deformation at cylinder bore surfaces 5. Cambering type skirt design on case housing wall to reduce the engine noise 3.

Nut 3. CONTROL SENSOR Ground Knock sensor Signal Signal Knock sensor (Except D20DT) Ground <Circuit Diagram of Knock Sensor> CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Body 10. Upper contact plate 7. 4.2006. Insulation disc 6.03 FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Disc spring 4. Weight 5. Piezo element 8. Lower contact plate 9.7 kW. Terminal NOTICE • The knock sensor should be tightened with the specified tightening torque. The internal resistance of the sensor is approx. Otherwise. the engine output may be decreased and the “ENGINE CHECK” warning lamp may come on.02 29 GENERAL <Location of Knock Sensor> 1. Sensor housing 2.

30 02 CRANKSHAFT Preceding Works: Removal of end cover Removal of pistons Removal of crankshaft sprocket 1. Crankshaft thrust bearing cap 8. Crankshaft main bearing shells..2006. Upper thrust bearing 3.0 Nm. 55 ± 5. Crankshaft 4.. lower 5.... Crankshaft main bearing shells.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 12-sided stretch bolt . 90° + 10° ENGINE HOUSING ACTYON SM . upper 2.. Crankshaft main bearing cap 7. Lower thrust bearing 6.

Refer to the table on next page to select bearings when installing. Upper thrust bearing 4. lower 5. Crankshaft 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Crankshaft main bearing shells.02 31 GENERAL ARRANGEMENT OF THRUST WASHERS AND BEARINGS 2 3 1 4 5 1. upper 3. Crankshaft main bearing shells.2006. Lower thrust bearing • The clearance between bearing shell and bore and between bearing shell and journal are various.03 SENSOR CONTROL NOTICE FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

733 26.255 2.333 26.100 ~ 0.260 2.270 2. Matching the Crankshaft Bearing Shells to Basic Bearing Bore in Crankcase Marking of Basic Bearing Bore in Lower Mating Surface Relevant Crankshaft Bearing Shell With Color Coding 1 punch mark or blue 2 punch marks or yellow 3 punch marks or red blue or white .945 ~ 61.265 ~ 2.260 ~ 2.945 61.35 2.20 2.15 2.260 ~ 2.270 ~ 2.940 Upper Main Bearing 2.800 ~ 26.2006.yellow red or white .955 61.950 ~ 61.027 ~ 0.265 ~ 2.254 Max. 0.265 2.068 Max.280 ~ 2.260 2.950 61.255 2.300 Thrust Bearing 0.433 26.955 ~ 61.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .300 ~ 26.25 2.265 - Lower Main Bearing 2.blue yellow or white .965 ~ 61.500 ~ 26.070 0.051 Max.700 ~ 26.32 02 Dimensions of Crankshaft Main Bearing Color Blue Yellow Red White Violet Crankshaft Journal 61.080 - Axial clearance Matching the Fit Bearing Journal Width to Thrust Washers Fit bearing Journal Width 26.270 ~ 2.40 NOTICE • Measure the crankshaft axial clearance and correct if necessary with appropriate thrust washers.275 Bearing Clearance Description Radial clearance When new Wear limit When new Wear limit (mm) Crankshaft Bearing 0.533 26.red ENGINE HOUSING ACTYON SM .833 (mm) Thrust Washer Thickness 2.275 ~ 2. 0.960 ~ 61.960 61. • Thrust washers of the same thickness must be installed on both sides of the fit bearing. 0.400 ~ 26.026 ~ 0.

blue yellow or white .yellow red or white .red Selection of Upper Main Bearing Shell Punch Mark Color Blue Yellow Red • • • • • • Selection of Lower Main Bearing Shell Mark B Y R W V Color Blue Yellow Red White Violet CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .02 33 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Matching Crankshaft Bearing Shells to Basic Bearing Journal of Crankshaft Marking of Bearing Journals on Crank Webs blue or white .blue red or white .blue Relevant Crankshaft Bearing Shell With Color Coding blue or white .blue yellow or white .2006.03 .

Rear edge c. Distance between ‘+’ max. voltage and ‘-’ max. can recognize No. The AC voltage increases as the engine speed increases.2006. The piston position that coupled with crankshaft is main factor in calculating injection timing. piston position and engine speed. When the crankshaft rotates. 1 cylinder and calculate the crankshaft speed. By analyzing the reference position and camshaft position sensor. voltage a. ECU converts the alternative signals into digital signals to recognize crankshaft position. no signal occurs from the 2-missing-tooth on the increment type driven plate.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ‘+’ signal will be generated from near the front edge and ‘-’ signal will be generated from near the rear edge among teeth on the driven plate near to crankshaft position. By using these teeth. 1 and 5 cylinders.34 02 Crankshaft Position Sensor Permanent magnet Iron Standard position Ring gear coil <Location of Crankshaft Position Sensor> <Structure of Crankshaft Position Sensor> The crankshaft position sensor is located near to flywheel on the rear of cylinder block. Front edge b. <Drive Plate> A. ECU recognizes TDC of No. It generates AC voltage between increment type driven plate that fixed on flywheel inside. 2-missing-tooth ENGINE HOUSING ACTYON SM . The sensor consists of soft iron core that winded copper wire on permanent magnet and generates sign wave AC voltage when magnetism on the sensor wheel passes the sensor. however.

02 35 GENERAL Drive plate Crankshaft position sensor Signal <Circuit Diagram of Crankshaft Position Sensor> Output voltage ( 1 ~ 150 V) Sensor unit coil resistance (Ω) Sensor air gap Operating temperature Tightening torque Min. voltage: 1.3 mm) Max voltage: 150 V (7000 rpm. air gap: 1.2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING Ground ASSY .7 ~ 1. air gap: 0.3 mm) 1.5 mm .40 ~ 150°C 6 ~ 8 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .090 ± 15 % 0.0 V (40 rpm.

using silicone oil.36 02 TORSIONAL VIBRATION DAMPER Laser welding Pin Cover Hub Bearing Bushing Inertia ring Pin Silicone oil System Description 1. cover.2006. ENGINE HOUSING ACTYON SM . inertia ring. but this crankshaft pulley (viscous damper). bushing. silicone oil 2. Functions: The crankshaft pulley optimizes the drive system by reducing the amount of torsional vibration in crankshaft. bearing. takes advantage of less changing viscosity according to the temperature.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Conventional rubber damper is limited in changing materials (rubbers) to absorb vibration. Components: Hub.

Remove the bearing caps and lower thrust bearing. • Do not mix up the bearing shells. NOTICE • The crankshaft bearing caps are marked with stamped numbers. 8. Unscrew the bolts and remove the connecting rod journal bearing and bearing caps. NOTICE • Do not mix up the bearing shells. Remove the bearing caps. NOTICE • Position the #1 piston at TDC and remove the piston connecting rod journal bearing caps. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Start to remove from the crankshaft pulley side.2006. Remove the upper bearing shells from the crankcase. Separate the lower bearing shells from the bearing caps. 3. 7. 2. Remove the upper thrust washers.02 37 GENERAL DISASSEMBLY AND REASSEMBLY 1. Remove the crankshaft.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 4. 6. Remove the bearing cap bolts. 5.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Coat the upper thrust washers with oil and insert into the crankcase so that the oil grooves are facing the crank webs (arrow). Replace if necessary. Coat the lower thrust washers with oil and insert into the crankcase so that the oil grooves are facing the crank webs (arrow). Install the crankshaft bearing caps according to the markings and tighten the bolts. NOTICE • The retaining lugs should be positioned in the grooves (arrow). 5. the 12-sided stretch bolts should be replaced. 4. NOTICE • If the maximum permissible length of L= 63.Reassembly 1.8 mm is exceeded. ENGINE HOUSING ACTYON SM . Thoroughly clean the oil galleries and check the journal section and bearings. Installation Notice Tightening torque 55 ± 5 Nm + 90° + 10° • Install from #1 cap.2006. 2.38 02 Crankshaft . Coat the new crankshaft with engine oil and place it on the crankcase. 3.

39 GENERAL CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . 1) When new: 0. Position the #1 piston at TDC and install the crankshaft. Install the piston connecting rod journal to the crankshaft journal and tighten the bolts.100 ~ 0.02 6.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .300 mm 9. Measure the crankshaft bearing axial clearance. 8. 7.2006.266 mm 2) When used: 0. Rotate the crankshaft by hand and check whether it rotates smoothly.

When starting the engine.2006. DMF measure the crankshaft speed. this drive the crank train mechanism initially by using the power from the start motor. and controls the ignition timing. sends the signals to ECU.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Also. MANUAL TRANSMISSION EQUIPPED VEHICLE) Primary wheel Ring gear Trigger ring Primary wheel Secondary wheel Plastic bushing System Description This flywheel is installed to the rear end of crankshaft and transfers the output from the engine to the power train mechanism. Conventional flywheel DMF ENGINE HOUSING ACTYON SM .40 02 FLYWHEEL DUAL MASS FLYWHEEL (DMF.

2. Enhanced vehicle silence and riding comforts: reduced engine torque fluctuation 3. Stable revolution of the primary and secondary wheel by using planetary gear: Works as auxiliary damper against spring changes 3. medium. 2.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Increased durability by using plastic bushing (extends the lifetime of grease) Characteristics of DMF 1.2006. When the output changes from the engine is low during compression stroke ( ): The damper increases the torque changes to clutch. Reduced shifting shocks 4. and high speed) by applying respective spring constant at each range.02 41 GENERAL Structure Function and characteristics 1. Filters irregularities of engine: The secondary flywheel operates almost evenly so does not cause gear noises 2. Improved torque response by using 3-stage type spring: Strengthens the torque response in all ranges (low. Reduced vibration noise from the powertrain by blocking the torsional vibrations 2. Less heat generation due to no direct friction against spring surface: Plastic material is covered on the spring outer surface 4. The mass of the primary flywheel is less than conventional flywheel so the engine irregularity increases more (less pulsation absorbing effect) 3. Smooth acceleration and deceleration CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . When the output changes from the engine is high during power stroke ( ): The damper absorbs the shocks to reduce the changes to transmission. <Example of DMF operation> <Torque change curve of engine and drive shaft> Angular acceleration amplitude [1/s2] Conventional system DMF Engine Engine Transmission Transmission Speed [rpm] Speed [rpm] System Characteristics Function 1. Transmission protection function: Reduces the torsional vibration to powertrain (transmission) by reducing the irregularity of engine Advantages of DMF 1.

809 mm 1. No.812 ~ 1.2 mm Steel / Gas nitride 40 ± 5.1 compression ring 2. 90° + 10° 4g 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.133 (±0. No.2 compression ring 3.0 Nm.009) mm 74 Applied 0.018) mm φ 86.815 mm ENGINE HOUSING ACTYON SM . Oil ring Description Cylinder bore diameter Piston outer diameter (D1) Clearance between bore and piston Piston cooling gallery Pin offset Compression ratio Length of piston pin Material of top ring / coating Tightening torque of connecting rod bolt Permissible weight difference of connecting rod Thickness of connecting rod bearing (Red) Thickness of connecting rod bearing (Yellow) Thickness of connecting rod bearing (Blue) ENG φ 86.15 mm (Thrust) 17.42 02 PISTON AND CONNECTING ROD 1.812 mm 1.2 (0~0.809 ~ 1.806 ~ 1.5 : 1 71.

070 3.03 SENSOR CONTROL FUEL Replacement of Piston Ring COOLING LUB EXHAUST I N T A K E HOUSING ASSY .1 compression ring 2.02 43 GENERAL PISTON RING 1. Arrange the piston ring ends to be 120° apart.2 compression ring 3. Oil ring 5.075 ~ 0.35 3rd groove: 0.20 ~ 0.050 ~ 0. Install the piston so that “Y” marking on piston head is facing in the direction of travel.35 2nd groove: 0. No. 1) Piston ring end gap (mm) 1st groove: 0. Hook spring 1. Coil spring and oil control ring 6.2006. Adjust the hook spring joint in the oil ring 180° away from the ring end.090 3rd oil ring: 0. Measure piston ring end gap.030 ~ 0. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .119 2nd compression ring: 0.20 ~ 0.20 ~ 0. No. 4.40 2) Clearance between piston ring and piston (mm) 1st compression ring: 0.

212 ~ 86.130 86.218 86. B or X B or X +5 + 10 Cylinder Diameter 86.217 ~ 86.300 ~ 86.142 86.2006.136 ~ 86.231 ENGINE HOUSING ACTYON SM .137 86.167 ~ 86.250 ~ 86.200 ~ 86.212 86.129 ~ 86.44 02 CYLINDER INNER DIAMETER AND PISTON SIZE (Unit : mm) Code A X B +5 + 10 Used piston A or X A.206 ~ 86.260 86.124 ~ 86.181 86.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .310 Piston Diameter 86.206 86.

050 ~ 0.1 compression ring 2nd compression ring 3rd oil ring 0.35 mm 0. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . • Make sure that the piston ring end is not aligned to axial direction and lateral direction. Arrange the piston ring ends to be 120° apart. Install the compression ring and oil ring on the piston with a special tool.1 piston ring is thicker than No.20 ~ 0. • Arrange the oil ring end to opposite position of current ring end.20 ~ 0.35 mm 0. • Oil ring is not directional. NOTICE • Install the No.40 mm CONTROL 1st groove: 11. Check the clearance of piston rings with a thickness gauge and adjust if necessary.2 piston ring.2 pistons so that “Y” marking on piston head is facing upward.20 ~ 0.1 and No.040 ~ 0. No. 1st groove 2nd groove 3rd groove 0.080 mm CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .0 mm 2nd groove: 10.03 SENSOR Piston ring end play (mm) FUEL 2.02 45 GENERAL DISASSEMBLY AND REASSEMBLY 1.075 ~ 0.090 mm 0. Check the clearance of piston oil ring and compression ring with a thickness gauge and adjust if necessary.119 mm 0. • No.0 mm 3.5 mm 3rd groove: 7.2006.

Lubricate the cylinder bore.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . connecting rod bearing journals. 6. Fit the piston onto connecting rod so that the marking on piston crown and locking slot are facing to straight ahead direction. Push piston into the cylinder with a wooden stick. NOTICE • Do not heat up the piston. Therefore. 8. 7. • Install bearing rod bearing cap so that the retaining lugs are on the same side of the connecting rod bearing. NOTICE • Install the piston so that the piston recess (marking) or the stamped surface of connecting rod is facing to straight ahead direction. Place new snap rings into the grooves. Insert connecting rod bearing shells. NOTICE • The upper and lower connecting rod bearings have same appearance. connecting rod bearing shells and pistons. 5.2006. NOTICE • The snap rings should be replaced with new one. Lubricate piston pin and push in by hand. make sure to check the part number before replacing them.46 02 4. 9. ENGINE HOUSING ACTYON SM .

Installation Notice Tightening torque 40 ± 5.2006.02 10.0 Nm. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .1 mm 47 GENERAL 11. Position piston to TDC and measure the distance between piston and mating surface of crankcase. Limit “C” 7.5 ~ 1. 90° + 10° • End play of connecting rod cap Specified value 0.765 ~ 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .055 mm FUEL 12.03 SENSOR CONTROL Permissible piston protrusion 0. Lubricate the new connecting rod bolts and tighten.5 mm • Measure at both ends of axial direction. Measure stretch shaft diameter of the connecting rod bolts.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .48 02 Special Tools and Equipment Name and Part Number Y99220122B Piston protrusion measuring jig Application Y99220172B Piston insertion jig ENGINE HOUSING ACTYON SM .2006.

Plunger 4. Drive shaft and cam ring 5.03 SENSOR CONTROL FUEL IMV connector COOLING Fuel temperature sensor LUB High pressure line Venturi return line Low pressure line EXHAUST I N T A K E HOUSING ASSY . Fuel temperature sensor 9. Inlet Metering Valve (IMV) 2. Venting 10.2006. Pressure regulator CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Hydraulic pressure head 3.02 49 GENERAL HIGH PRESSURE PUMP (HPP) COMPONENTS LOCATOR Inlet Metering Valve (IMV) High pressure supply line 1. Housing 6. Low pressure pump 8. High fuel pressure supply line 11. Roller and shoe 7.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .50 02 High Pressure Pump and Fuel System Injector pipe Protective cap Injector pipe Return tube Fuel rail (common rail) Injector High pressure pipe Upper bracket for high pressure pipe Injector clamp Injector washer HP pump Bearing housing Sprocket HP pump bracket Gasket ENGINE HOUSING ACTYON SM .2006.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .02 51 GENERAL Installation of High Pressure Pump Vehicle with Engine HP pump Gasket Sprocket Nut Bracket Bearing housing Bolt CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .2006.

52 02 DISASSEMBLY AND REASSEMBLY Preceding Works: 1. Removal of oil dipstic gauge NOTICE • To prevent oil leaks. • Be careful not to damage the rubber bellows.2006. Removal of fan belt (including cooling fan and fan clutch) and fan shroud 2. • Plug the oil ports for HP pump with sealing caps.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Removal of water pump pulley 4. Removal of intake manifold assembly 3. ENGINE HOUSING ACTYON SM . Removal of EGR pipe 6. Removal of auto tensioner 5. store the removed auto tensioner it upright position.

Remove the engine belt pulleys. 2.without SST Disassembly Preceding Works: 1. store the removed auto tensioner in upright position. Turn the auto tensioner counterclockwise and remove the fan belt. Disconnect the negative battery cable. Unscrew lower bolt (13 mm) and upper bolt (24 mm) and remove the auto tensioner. 1) Cooling fan pulley 2) Coolant pump pulley 3. HOUSING ASSY .02 53 GENERAL HP Pump . NOTICE • To prevent oil leaks. • Pump the auto tensioner several times before installing it. 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . Apply the parking brake and place the chocks under the tires.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E 1.2006. (transmission “N” position) NOTICE • Slacken the pulley bolt.

Align the OT mark by rotating the crankshaft. 2) Disconnect the fuel lines to high pressure pump. ENGINE HOUSING ACTYON SM . Unscrew the bolts and remove the vacuum modulator bracket.2 EGR pipe. 7. 1) Disconnect the high pressure pump and vacuum modulator connector.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Rotate the crankshaft clockwise so that the HP pump sprocket holes are aligned to the bolt holes. Remove the high pressure pump housing. 1) Open the oil filler cap and check if the OT mark on crankshaft is aligned to the notch on the camshaft. 3) Plug the openings of pipes and ports with protective caps to keep the cleanness of the fuel system.54 02 4. 4) Remove the high pressure fuel pipe between HP pump and common rail. 6. 5. Preceding Work: Remove the No.2006.

11.02 8. • Make sure that the center bolt is securely tightened. NOTICE • Tap the center bolt with a hammer after tightening. Hold the HP pump sprocket and slacken the center bolt. Slacken three HP pump mounting bolts until they rest on the sprocket. 55 GENERAL 9. Loosen the HP pump center nut by tapping it with a hammer.2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 10. Remove the remaining bolts with the same manner and remove the high pressure pump.

NOTICE • Replace the fuel lines to HP pump with new ones (cannot be reused). • Tighten the center nut with the specified tightening torque. Tightening torque 65 Nm NOTICE • The center nut should be replaced once removed (cannot be reused).56 02 Reassembly 1. Tighten the HP pump bolts. Hold the HP pump sprocket and tighten the center nut.2006. Install the vacuum modulator bracket. Tightening torque 25 Nm 3. Replace the HP pump gasket with new one (cannot be reused).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Make sure that the connectors are installed to the correct locations. 4. (RR: white tape) ENGINE HOUSING ACTYON SM . 2.

02 5. Apply the sealant to the HP pump housing and tighten the bolts. NOTICE • Open the oil filler cap and check if the OT mark on crankshaft is aligned to the notch on the camshaft.2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • Sealant (DB2210): 661 989 56 A0 57 GENERAL 6. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .0 Nm 32 Nm Tightening torque 7. 82 ± 6. Install the auto tensioner and belt pulleys. Rotate the crankshaft pulley two revolutions and ensure that the OT mark on the crankshaft pulley and the OT mark on the camshaft pulley are aligned.

58 02 HP Pump .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.with SST Special Service Tool SST Installation HP Pump Installation HP pump mounting hole on engine ENGINE HOUSING ACTYON SM .

02 59 GENERAL Preceding Works: 1. Remove the auto tensioner from the engine. Disconnect the negative battery cable.) 2. Removal 1. Take off the fan belt while turning the auto tensioner counterclockwise. Remove the PWM electric fan. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . put the removed auto tensioner in up-light position.2006. ¼±Çà ÀÛ¾÷ NOTICE • To prevent from the oil leaking. • Plug all fuel supply ports with seal caps (including removed ones). remove the battery. 2. put the removed auto tensioner in up-light position. * To prevent from the oil leaking. 3. (If necessary.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Remove the front air duct assembly. • Be careful not to damage the rubber bellows when removing the auto tensioner.

Open Caps Unscrew Mounting Bolts Idle pulleys caps 5. Remove the idle bracket.60 02 3. B).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . B) and unscrew the mounting bolts to remove the idle pulleys (A. 4.2006. Open the caps (A. Unscrew Mounting Bolt Remove Idle Bracket ENGINE HOUSING ACTYON SM . Unscrew four bolts and remove the water pump pulley.

Center Nut Mounting Bolts CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM . (To keep cleanness. Disconnect the fuel line to high pressure pump. 7.02 61 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY 6.) A.2006. Remove the oil separator and EGR cooler pipe. Remove the chain tensioner and rotate the crankshaft so that the upper holes on HP pump sprocket are horizontally aligned. A.03 . plug the opening with a sealing cap. Remove the center nut on high pressure pump and loosen three hexagon bolts. (At this moment. Disconnect the vacuum modulator connector and fuel line. Connector B. Connector 8. Fuel line A. B. the holes on sprocket are aligned to mounting bolts for HP pump. Chain tensioner * Three HP pump mounting bolts are visible. Remove the vacuum modulator bracket.) Remove Chain Tensioner HP Pump Sprocket Rotate the sprocket so that the upper holes on HP pump sprocket are horizontally aligned.

ENGINE HOUSING ACTYON SM . 10. 11.62 02 9.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Install the special service tool on the high pressure pump sprocket.2006. Separate the sprocket from the high pressure pump by turning the center bolt on special service tool. Remove the special service tool and unscrew three mounting bolts to remove the high pressure pump.

03 . 2. The gasket for high pressure pump cannot be reused.02 NOTE 1.2006. It should be replaced with new one if removed. Place an alignment mark on the high pressure pump shaft and key. 63 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Key groove Alignment mark CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE HOUSING ACTYON SM .

mounting bolts and center nut in order. ENGINE HOUSING ACTYON SM . 3. NOTICE • The vacuum modulator connector and vacuum hose should be connected to correct positions. 4. temporarily tighten three mounting bolts first. (However. Install in the reverse order of removal. The wiring with white tape should face to the rear-end of engine.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 Nm 65 ± 5 Nm 2. Apply the specified sealant (DB2210: 661 989 56 A0) and tighten the bolts to the specified tightening torque. Install the accessories.64 02 Installation 1. Install the vacuum modulator bracket. then fully tighten the center bolt. Tightening torque Hexagon mounting bolt Center nut 25 ± 2.2006.

.............................. 4 Components .............................................INTAKE SYSTEM 03 TABLE OF CONTENTS AIR FLOWS ......................................................................................................7 Precautions when installing intake system ...... 17 Intake manifold assembly .............................. 3 INTAKE SYSTEM LAYOUT .... 20 .................................................................. 13 Intercooler ... 9 Air flow sensor (hot film air mass sensor) ............................................................................................................................. 4 Work flow of intake system ......................

03 3 GENERAL AIR FLOWS Intake valve (in combustion chamber) Intake manifold Air cleaner Turbo charger Engine HFM sensor Intake air outlet hose Intercooler Intake air inlet hose CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006.

It controls the pressure control valve for the turbocharger booster.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Housing 7. Cylinder housing 3. Hybrid 8. It measures the air volume supplied to the combustion chamber and the air temperature. O-ring 11.4 03 INTAKE SYSTEM LAYOUT WORK FLOW OF INTAKE SYSTEM VGT Turbocharger Combustion Chamber in Engine Air Cleaner HFM Sensor Intercooler Intake Manifold VGT Turbocharger Turbocharger actuator Exhaust pipe (diesel catalytic converter) Intake (air cleaner) Exhaust gas Compressed air (intercooler) Air Cleaner HFM Sensor The HFM sensor is installed in the air intake passage between the air cleaner and the intake manifold. Hybrid cover Plug-in sensor 5. Measuring duct cover 6. Temperature sensor INTAKE SYSTEM ACTYON SM . Sensor Temperature sensor Protection grid 9. Protection grid 4. Plug-in sensor 2. Major Functions Front Air Duct • • It controls the EGR feedback. 1. Mounting plate 10.

The intercooler is the device which cools the supercharged air.2006.) 5 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Intake manifold Intake air Intake air Intake manifold Exhaust gas Intake Manifold Exhaust gas Vacuum modulator for turbocharger actuator EGR vacuum modulator Vacuum Modulator EGR valve Vacuum pump IP interior fuse (RH) No.03 EGR Valve and Its Location (* For details.03 . refer to “EGR” section. CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . 96 Turbocharger Intercooler The charging efficiency may be lowered or the knocking may happen as the intake air is heated and the density of air is lowered.63-7.5A Engine ECU No.

5 Nm Tightening torque (M8X50/133-10 EA) : 25 ± 2.5 Nm Tightening torque (M6X16-2 EA) : 10 ± 1.0 Nm INTAKE SYSTEM ACTYON SM .2006.0 Nm EGR pipe assembly EGR pipe gasket EGR-LH pipe assembly Tightening torque (M6X16-2 EA) : 10 ± 1.5 Nm EGR-RH pipe assembly EGR valve assembly Tightening torque (M6X25-4 EA) : 10 ± 1.0 Nm EGR valve gasket EGR pipe gasket Tightening torque (M6X16-2 EA) : 10 ± 1.0 Nm Tightening torque (M8X25/30-4 EA) : 25 ± 2.6 03 Layout Intake manifold Tightening torque (M8-nut) : 35 ± 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

The intake port is composed of the dual port (tangential and helical port) which increases the swirl ratio in mid/low operating range.03 SENSOR Intake air (intercooler) CONTROL FUEL Coolant emission port COOLING LUB EXHAUST I N T A K E HOUSING ASSY .5 Nm).03 7 GENERAL COMPONENTS Intake Manifold Assembly The intake manifold assembly is built for the optimized mixture of the EGR gas in the intake chamber when the compressed air in the turbocharger is sent to the intake port. Intake Manifold EGR pipe (RH) Coolant emission port Vacuum modulator to the EGR valve Exhaust gas EGR pipe (LH) Incoming of intake air (No operation of EGR valve) EGR pipe (center) Incoming of intake air and exhaust gas (Operation of EGR valve) Intake air Coolant emission port Intake air Exhaust gas CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . NOTICE • The inlet port and coolant outlet port is integrated together. Also. Therefore. be careful not to let the residual coolant in the manifold enter the inlet port when removing the intake manifold. The SUS + Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the sealing effect. replace the gasket with a new one and tighten it to the specified torque (25 ± 2.2006. However. improves acceleration/fuel consumption and decreases particle materials. there are some differences in the form of the EGR valve and 4-cylinder engine.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Intercooler Removal and Installation For removal and installation procedures. However. Thus.2006. more air is entered the cylinder than the engine only with the turbocharger to give more power. refer to the “Cooling system” section in DI engine service manual. the intake air is heated during the compression process in the turbocharger compressor and the density is lowered. The intercooler is the device which cools (50 ~ 60°C) the air entering the engine from high temperature (100 ~ 110°C) to maintain the turbocharging efficiency.8 03 Turbocharger Intercooler Assembly The turbocharger is designed to improve the engine power by introducing more air (oxygen) into the engine. INTAKE SYSTEM ACTYON SM .

Connections of EGR pipe Tightening torque 10 ± 1.2006. 1. Hose between air cleaner and turbocharger Tightening torque 6 ~ 7 Nm 2.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .03 9 GENERAL PRECAUTIONS WHEN INSTALLING INTAKE SYSTEM Intake (Inlet/Outlet) Hose and EGR Pipe The clamps of hoses and EGR pipe should be tightened to the specified tightening torque when installing the engine assembly or servicing on the air cleaner duct. Hose between turbocharger and intercooler Tightening torque 6 ~ 7 Nm 3. the turbocharger and the intercooler.0 Nm 4. Fixing clamps on inlet hose (intake manifold and intercooler) Tightening torque 6 ~ 7 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM .

. Correction .Do not use a screwdriver.2006. . the turbocharger and the intercooler.10 03 Precautions When Installing : The clamps on the hoses should be tightened to the specified tightening torque when installing the engine assembly or servicing on the air cleaner duct. 3.Check if the clamp is out of place or the intercooler is leaking. Always use a torque wrench when tightening the clamps.Always observe the tightening torque when installing the related parts. 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1. Symptoms : Insufficient engine power. smoke or noise when accelerating (whistle noise). Cause : Clamp is out of place due to the turbocharging pressure or inproper tightening torque. Tightening torque of intake hose clamp 6 ~ 7 Nm INTAKE SYSTEM ACTYON SM .

2. Clean or replace the element as required.2006. Loosen the locking clamp and remove the intake duct. Disconnect the HFM sensor connector. Remove the air cleaner element.03 SENSOR CONTROL FUEL 4. CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . Unscrew the screws and remove the air cleaner cover. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .Replacement Preceding Work: Disconnection of negative battery cable 1.03 11 GENERAL Air Cleaner Element . 3.

If the inside of housing is contaminated. be careful not to contaminate during the replacement. 3.Removal and Installation Preceding Work: Removal of air cleaner cover 1. 5.12 03 Air Cleaner Housing .Check 1. Check the air cleaner body. Check the air duct for damage. 2. INTAKE SYSTEM ACTYON SM . If the element is partially clogged. contamination and damage.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . replace it with new one. Otherwise. corrosion and damage. contaminants can get into the engine. Set aside the return hose and remove the coolant reservoir bolts. 2. Install in the reverse order of removal. cover and packing for deformation. 4. If the contamination is severe.2006. Check the air cleaner housing for clogging. remove the contaminants. NOTICE • When cleaning the air cleaner with compressed air. direct the air from inside (engine) to outside (ambient air). Air Cleaner Housing/Element . remove the dust or foreign materials with the compressed air. contamination and damage. Check the air cleaner element for clogging. 3. Also. Remove the air cleaner housing bolts.

Housing 8. the air cleaner housing. The HFM6 installation is effected in the air intake system between the air filter and the throttle device. or as pre-assembled plug-in sensor module including cylinder housing. which is controlled to an excess temperature using a heating resistor and a temperature sensor. various cylinder housing sizes are provided.2006. O-ring Application The micro-mechanical HFM6 hot-film air mass sensor with flow direction detection by pulsating mass air flow has been conceived for load recording with internal combusion engines with petrol and diesel fuel injection. The heating area is located in the centre of the diaphragm. A thin diaphragm is generated on the silicon-based sensor element by means of etching. The HFM6 is installed either as a plug-in sensor in an existing part of the airducting. Plug-in sensor 7. e. Through a metering channel on the plug-in sensor housing a portion of the air flow from the cylinder housing is routed past a sensor element. Design and Function The hot-film air mass sensor is a thermal flowmeter. The HFM6 may only be operated with a suitable control unit. Depending on the required air flow rate of the combustion engine.g. The sensor element with its temperature sensors and the heating area is exposed to the air mass flow. Sensor 9.03 13 GENERAL AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR) Air outlet Air inlet 2. in the case of supercharged engines between the air cleaner and the supercharger. Mounting plate 11.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN SENSOR CONTROL General FUEL COOLING LUB 1. Cylinder housing 3. Protection grid 4. The HFM6 also records. Hybrid EXHAUST I N T A K E HOUSING ASSY . The degree of this excess INTAKE SYSTEM ACTYON SM . in addition to the air mass taken in by the engine. Measuring duct cover 6. such as. A heating resistor and various temperature sensors are laid out on this diaphragm. the temperature of the air taken in. Hybrid cover 5. Temperature sensor 10.

(Ω) Ω 39. Digital signal processing takes place after digitising the resistor bridge voltage and the intake air temperature sensor signal. (°C) -40 -20 0 20 40 60 80 100 120 130 R min. while high temperature causes a low resistance as the following table. The downstream temperature sensor approximately retains its temperature. Low temperature produces a high resistance.120 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .850 5. When there is no incoming flow. a resistor which changes value based on the temperature of the air entering the engine.096 565 312 184 114 91 R nom.760 15.14 03 temperature depends on the temperature of the air flowing in.119 2. Intake Air Temperature The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor.140 12.660 5.829 2. Temperature sensors are located symmetrically in relation to the heating area upstream and downstream of the heating area.290 1. Without incoming air flow. The temperature sensors indicate a temperature difference which is dependent upon amount and direction of the incoming flow. The IAT sensor is also used to control spark timing when the manifold air is cold. The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to determine the IAT.260 13.420 1. Temp.238 654 370 222 141 114 Voltage NTC output voltage (1K Ohm Pull-Up) A/D Count Signal(Voltage) Temperature INTAKE SYSTEM ACTYON SM . (Ω) Ω 43. The plug-in sensor housing contains the electronic module with the evaluation circuit for the sensor.166 609 340 202 127 102 R max.2006. With incoming flow.499 2.(Ω) Ω 35. The ECM knows the intake IAT by measuring the voltage. The difference signal of the temperature sensor is evaluated as a resistance bridge. The voltage will be high when the manifold air is cold and low when the air is hot. due to the air heated up in the heating area. the part of the diaphragm upstream of the heating area is cooled down due to heat transfer in the boundary layer.551 1. the temperature at the diaphragm edges declines in an approximately linear fashion. This enables temperature compensation on the basis of the chip temperature and a standardization of the output characteristic curve. these sensors indicate the same temperature.

2006. signal <Circuit Diagram of HFM Sensor> COOLING CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM .03 15 GENERAL Power supply Intake air flow sensor Air mass signal Ground Air Temp.03 SENSOR CONTROL FUEL LUB Intake air temperature sensor HFM sensor EXHAUST I N T A K E HOUSING ASSY .

3. Unscrew the bolts and remove the HFM sensor assembly.Removal and Installation HFM Sensor Preceding Work: Disconnection of negative battery cable 1.16 03 HFM Sensor . Installation Notice Tightening torque 4 ~ 5 Nm 4. Install the reverse order of removal. Loosen the clamps on the air cleaner and the turbo charger and remove the duct.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. 2. Disconnect the HFM sensor connector. INTAKE SYSTEM ACTYON SM .

Intercooler CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . Thus cooler air gives more power and better fuel economy.03 17 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY INTERCOOLER The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine.03 . 1. However. Cold air has more oxygen molecules than warm air. the intake air is heated (100 ~ 110°C) during the compression process in turbo charger compressor and the density is lowered. The intercooler is the device which cools (50 ~ 60°C) the air entering the engine.2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Disconnect all wiring harnesses and related connectors from the front side of radiator assembly. INTAKE SYSTEM ACTYON SM .Removal and Installation 1. Ambient AQS sensor temperature Connector switch Receiver drier Ambient temperature sensor 2.18 03 Intercooler .2006. Remove the front end center member.

Remove the intercooler inlet hose and outlet hose.2006. Unscrew the bolts and remove the intercooler assembly. 19 GENERAL 4. 6.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .03 3. Tightening torque 6 ~ 7 Nm 5. Remove the hood latch cable and remove the radiator support upper member. CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . Install in the reverse order of removal.

Shape that delivers the required capacity of compressed air from turbo charger to inlet port 2. Integrated inlet port and coolant outlet port INTAKE SYSTEM ACTYON SM . Optimized EGR gas mixture in inlet chamber 3.2006. Maximized intake efficiency with helical and tangential inlet port 1) Improving the swirl ratio in low and mid operating range 2) Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range 4.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .20 03 INTAKE MANIFOLD ASSEMBLY System Characteristics 1.

2006.03 21 GENERAL Special Tools and Equipment Name and Part Number Y99220112B Intake manifold guide pin Installation of intake manifold CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Application .

Open the coolant reservoir cap and loosen the drain cock to drain the coolant. • Make sure that the convex surface of gasket is facing to the pressurized direction. Remove the EGR valve mounting bolts and gasket. 4.Removal/Installation Preceding Work: Disconnection of negative battery cable 1. Remove the EGR exhaust pipe (primary) mounting bolts and gasket. 7.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . INTAKE SYSTEM ACTYON SM . 3. Lift up the vehicle and remove the skid plate. NOTICE • Replace the pipes (2. Loosen the clamp and remove the coolant inlet hose (2). Remove the coolant inlet port housing. 3) at both sides of EGR cooler (1) and gaskets with new ones. 6.22 03 Intake Manifold . 5.2006. Remove the vacuum hose from EGR valve. Remove the air inlet hose (1) from intake manifold. 2.

1) Vacuum hose bracket in turbo charger 2) Booster pressure sensor 3) Main wiring bracket 4) Ground cable bracket 5) Fuel pressure sensor connector 9. Unscrew the bolts and remove the vacuum modulator bracket. CONTROL CHANGED BY EFFECTIVE DATE AFFECTED VIN INTAKE SYSTEM ACTYON SM . • Plug the fuel return port of the HP pump with a sealing cap.2006. Remove the injector return line at HP pump. NOTICE • Replace the pipes with new one once removed. 11. Remove the HP pump fuel return line at fuel filter. Installation Notice Tightening torque 9.03 SENSOR FUEL COOLING • Plug the openings of pipes and ports with sealing caps to keep the cleanness of the fuel system. LUB EXHAUST I N T A K E HOUSING ASSY .0 Nm 23 GENERAL 10.03 8. 13. Remove the HP pump fuel supply line bolts. 12. Remove the HP pump fuel supply line mounting bracket. NOTICE • Be careful not to damage the pipes to HP pump. Remove the brackets and connectors from top section of the engine.

• Make sure that the residual coolant in intake manifold gets into the inside of inlet port. M8 x 45: 6EA M8 x 130: 6EA 15. • If replaced only gasket without any other service operation.2006. Unscrew the bolt in oil filter and remove the intake manifold and gasket. Installation Notice Tightening torque 25 ± 2.5 Nm Check the length of the bolts before installation. Remove the intake manifold mounting bolts. 17.24 03 14. NOTICE • Replace the gasket with new one. Lift up the vehicle and remove the propeller shaft joint bolts. completely remove the coolant and other contaminants from the engine before installation. 16.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Replace the gasket with new one. Install in the reverse order of removal. INTAKE SYSTEM ACTYON SM .

..................... 24 EGR VALVE AND VACUUM MODULATOR ......................................................................................... 48 Electrical circuit related to vacuum modulator .................5 VGT (Variable Geometry Turbocharger) ......................................................................................................... 42 Removal and Installation of EGR Valve ..................................... 50 EXHAUST SYSTEM AND MUFFLER ....................................3 Turbo charger assembly .....................................................................................2 Exhaust gas flows ............................. 42 Composition ......................... 55 .. 54 System overview ................................................. 38 EGR valve and turbo charger actuator control vacuum circuit .. 38 EGR system ....................... 2 Components locator ............................... 54 Muffler ...........................EXHAUST SYSTEM 04 TABLE OF CONTENTS EXHAUST SYSTEM LAYOUT ............................................. 39 VACUUM MODULATOR ............................................................................. 43 Removal and Installation of vacuum modulator assembly ....................

03 EXHAUST SYSTEM Diesel catalytic converter To turbocharger Exhaust manifold EGR valve COMPONENTS LOCATOR EXHAUST SYSTEM LAYOUT To EGR valve Intake manifold EGR center pipe EGR Valve and Installation Location Intake manifold Intake air (intercooler) Intake manifold Intake manifold Exhaust manifold CHANGED BY EFFECTIVE DATE AFFECTED VIN EGR pipe (RH) EGR pipe EGR pipe (LH) Diesel catalytic converter → Muffler .2 Exhaust Manifold 04 ACTYON SM .2006.

2006.03 SENSOR CONTROL EGR booster vacuum modulator To turbo charger booster Turbo charger booster vacuum modulator FUEL COOLING Turbo charger (turbine side) LUB EXHAUST I N T A K E HOUSING A ASSY .04 3 GENERAL EXHAUST GAS FLOWS Catalytic converter Exhaust pipe Muffler Atmosphere A Exhaust gas Turbo charger booster Exhaust manifold Blow-by gas EGR valve EGR pipe Engine -Combustion Chamber- Exhaust Manifold Turbo Charger Exhaust Muffler Atmosphere EGR Valve Intake Manifold CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .

3. Install in the reverse order of removal. Otherwise.0 Nm • Replace the gasket with new one.2006. it may cause the leakage of exhaust gas.4 04 Exhaust Manifold . 2. Installation Notice Tightening torque 35 ± 3. Installation Notice Tightening torque 40 ± 4. Remove the #3 pipe of EGR valve from the exhaust manifold. Replace the gasket and pipe with new ones. Remove the two intake hoses from the turbo charger. Unscrew the nuts and remove the exhaust manifold and gasket. EXHAUST SYSTEM ACTYON SM . 5. Remove the turbo charger assembly (refer to Turbo Charger section). 4.Removal and Installation 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 Nm • The #3 pipe of EGR valve is exposed to the high temperature and pressure of exhaust gas.

The regular turbo charger operates by utilizing the pressure from the exhaust gas and the other.04 5 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY TURBO CHARGER ASSEMBLY The turbo charger is an air pump installed on the intake manifold. Therefore. Diffuser: With the meaning of spreading out it is a device that transforms fluid’s speed energy into the pressure energy by enlarging the fluid’s passage to slow down the flow. by installing the turbo charger on the intake manifold. operates by utilizing power from the engine. which has been introduced to the diffuser having a passage with big surface. as the engine’s power enhances.03 . As the turbine. weight of the engine increases by 10 to 15 % whereas the output power increases by 35 to 45 %. being circumferentially accelerated by the centrifugal force. subsequently. is rotated by exhaust gas pressure the impeller. When the turbo charger is installed. into the diffuser. Also. CHANGED BY EFFECTIVE DATE AFFECTED VIN Impeller Turbine Intercooler Intake Intercooler coolant Exhaust EXHAUST SYSTEM ACTYON SM . It enhances power and increases torque power of engine to increase the fuel consumption rate. at intake end. transforms its speed energy into the pressure energy while being supplied to the cylinder improving the volume efficiency. Operating Principle of Turbo Charger The turbo charger has one shaft where at each ends are installed with two turbines having different angles to connect one end of housing to the intake manifold and the other end to the exhaust manifold. enhances output power. called Super Charger.2006. it increases the torque power and improves the fuel consumption rate. at exhaust end. The engine without turbo charger cannot get as much power output as it inducts air by the means of vacuum being generated from descending strokes of the piston. The turbo charger is often referred to as the exhaust turbine turbo charger. Also. gets rotated to send air around center of the impeller. The air. it supplies great amounts of air to the cylinder increasing the volume efficiency and. the exhaust efficiency improves as the exhaust turbine rotates.

back plate and compressor housing. It is comprised with the shaft supporting center housing (supporting the compressor with two float journal bearings). The turbine rotates turbine wheel by receiving exhaust gas energy from the engine. Center housing 6. Turbine wheel 3. 2. 1. Compressor housing 4. Oil return line EXHAUST SYSTEM ACTYON SM . the turbine side parts of turbine wheel. Air inlet (from atmosphere) B. Turbine housing 2.2006. Air flow C. shroud and turbine housing. Bypass flap A. Exhaust gas inlet (from cylinder) D. Exhaust gas bypass passage H. Control link 8. Compressor wheel 5. Oil supply opening J.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . and the compressor side parts of compressor wheel. Turbo charger booster pressure control valve 7.6 04 Construction of Turbo Charger The turbine wheel in turbo charger and compressor wheel are installed at each side of the shaft. The compressor receives torque energy from the turbine and the compressor wheel inducts air to force it inside of the cylinder. 1. Exhaust gas outlet (to atmosphere) E.

during operation of the engine. is being widely used as it is simple. Therefore.03 . NOTICE • Stopping the engine immediately after driving at high speed stops oil from being supplied to the bearing and may cause it to get burnt. It could be rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from the engine. Therefore. the engine must be stopped after cooling the turbo system by sufficiently idling the engine. As surface of the passage increases. During operation of the engine. Therefore. the turbine receives temperature of exhaust gas and it rotates in high speed.2006.000 to 15. Impeller Turbine shaft Turbine Thrust collar Floating bearing The radial type has the impeller plate arranged in straight line at the center of shaft and. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .000 rpm.04 7 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Impeller The impeller is wings (wheel) installed on the intake end and performs the role of pressurizing air into the cylinder. which supports the turbine shaft that rotates at about 10. it rotates. The radial type is used as the turbine’s wings. As the impeller rotates in the housing with the diffuser installed in it. it rotates the compressor and performs the role of transforming heat energy of exhaust gas into torque energy. compared to the backward type. Turbine Impeller Exhaust gas Diffuser Oil passage Turbine The turbine is wings installed at the exhaust end where. it requires to have sufficient rigidity and heat resisting property. Floating Bearing Floating Bearing is a bearing. At the same time. the air receives centrifugal force to be accelerated in the direction of housing’s outer circumference and flows into the diffuser. as the impeller is on the same shaft. exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate by coming in contact with the turbine’s wings from the outer circumference within housing of the turbine and is exhausted through the exhaust manifold. easy to manufacture and appropriate for high speed rotation. by the pressure of exhaust gas. the efficiency of compressor is determined by the impeller and diffuser. air flown into the diffuser transforms its speed energy into pressure energy and flows into the intake manifold where the pressurized air is supplied to cylinder each time the intake valve of cylinder opens up.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The difference of the booster pressure control between the existing IDI engine and DI engine is that in IDI engine. In order to control these.2006. the booster pressure control valve is installed on the turbo charger. The maximum turbo charging pressure must be controlled as excessive increase in the pressure and power output can cause critical damages to the engine. booster pressure of the intake manifold operates the booster pressure control valve connected directly to the turbo charger whereas in DI engine. Refer to the EGR section in following pages for the function of turbo charger and HFM sensor in exhaust system. Booster pressure control valve unit and vacuum modulator Turbo charger booster Turbo charger booster vacuum modulator EXHAUST SYSTEM ACTYON SM . the control is achieved by utilizing vacuum modulator (vacuum from a vacuum pump) designed to control the booster pressure control valve.8 04 Booster Pressure Control Valve Unit (Turbo Charger Actuator) In order to reduce discharging of hazardous exhaust gas and to avoid the engine’s overrun the turbo charger must be appropriately controlled. It operates booster pressure control valve by supplying electrical power to the vacuum modulator having the amount of air being flown into the HFM sensor from the engine’s ECU as the base signal.

CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . NOTICE • Idling for long period of time can cause oil leakage to the turbine side due to low pressure of exhaust gas and the rotation speed of turbine wheel. 2) Oil Leakage: Followings are the reasons for oil leakage condition. Must inspect after overhauling the turbo charger. 2. Therefore. If the engine is running radically after replacing the engine oil or oil filter brings poor oil supply condition.04 9 GENERAL Diagnosis and Maintenance for Turbo Charger System Cautions During Driving The following lists cautions to take during test drive and on the turbo charger vehicle. Inspection of Turbo Charger When problem occurs with the turbo charger.2006. Please note this is not a turbo charger problem. In such condition. it’s necessary to start off after idling the engine for about 1 minute allowing oil to circulate to the turbo charger after the replacement. the engine should be stopped possibly in the idle condition. To avoid this. excessive discharge of exhaust gas.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . before being started. When the engine is stopped abruptly after driving at high speed. it could cause engine power decline. • Problems in engine: In case where the oil is smeared on inner wall section of the exhaust gas opening. NOTICE • After string for long period of time during winter season or in the low temperature condition where the fluidity of engine oil declines. an oil film between the journal bearing and the housing shaft journal section gets broken and this causes abrasion of the journal bearing due to the contact of metal parts. 1) Interference: In case where the oil leak sign exists. outbreak of abnormal noise and excessive consumption of oil. It’s important not to drastically increase the engine rpm starting the engine. that abrasion has occurred on the journal bearing. The repeat of such condition significantly reduces life of the turbo charger. It could make rotation at excessive speed even before the journal bearing is lubricated and when the turbo charger rotates in poor oil supply condition. the turbo charger continues to rotate in condition where the oil pressure is at ‘0’. the existence of interference of housing and wheel. most of times. which must be considered during the operation. 1. should be cranked to circulate oil and must drive after checking the oil pressure is in normal condition by idling the engine for few minutes. 3. • Problems in turbo charger: In case where the oil is smeared on only at the exhaust gas outlet section. oil leakage and contamination (at blade edge) of foreign materials. with a lamp. Inspection of turbine in turbo charger Remove the exhaust pipe at the opening of the turbine and check. it could cause damage of bearing seizure within few seconds. even the small traces of interferences on the turbine wheel mean. 1. Inspection when installed 1) Check the bolts and nuts for looseness or missing 2) Check the intake and exhaust manifold for looseness or damage 3) Check the oil supply pipe and drain pipe for damages 4) Check the housing for crack and deterioration 2. the engine.

10 04 3) Oil Drain Pipe Defect In case where oil flow from the turbo charger sensor housing to the crank case is not smooth would become the reason for leakage as oil builds up within the center housing. Also. Must inspect after the overhaul. clogging and damage of the oil drain pipe and the pressure of blow-by gas within the crank case must be inspected. EXHAUST SYSTEM ACTYON SM . amount of air in the compressor inlet increases but the turbo charge pressure is not high. Therefore. it could induce inner damage as rotating balance of the turbo charger gets out of alignment. which makes negative pressure at the compressor section causing the oil leakage within the center housing. it’s necessary to check whether the foreign materials have contaminated intake/exhaust manifold or inside of engine. 3.2006. At this time. NOTICE • No problem will occur with the turbo charger if above conditions are found in early stage but oil leaked over long period of time will solidify at each section causing to breakout secondary defects. NOTICE • Must absolutely not operate the turbo charger with the compressor outlet and inlet opened as it could damage the turbo charger or be hazardous during inspection. clogged by substances such as dust. Damages by foreign materials: In case where the compressor wheel is damaged by foreign materials requires having an overhaul. 1. 2) Overuse of engine break (especially in low gear) in down hill makes significantly low exhaust gas energy compared to the time where great amount of air is required during idling conditions of the engine. Interference: In case where is trace of interference or smallest damage on the compressor wheel means. In such case. Oil Leakage: The reason for oil leakage at the compressor section is the air cleaner. 1) Rotating in high speed at no-load for extended period of time can cause oil leakage to the compressor section as oil pressure within the center housing gets higher than pressure within the compressor housing. oil thickens (sludge) at high temperature and becomes the indirect reason of wheel hub section. Inspection of Turbine Thoroughly check the followings. most of times. 4) Damages from Foreign Materials When the foreign materials get into the system.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . that abrasion has occurred on the journal bearing. causes the compressor inlet negative pressure. 2.

2006.04 11 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Path of Turbo Charger Defect The following tries to understand the defects that can occur with vehicle installed with the turbo charger and to manage the reasons of such defects. In case where oil pan/oil pipe has been contaminated. Contamination of Oil Journal Bearing Damage or Wear Clogging of Oil Passage Metal Contact Poor Oil Supply Shaft Journal Bearing Wear Rotor Wear Seal Wear at Exhaust System Seal Wear at Intake System Interference of Turbine and Compressor Components Oil Leakage Abnormal Noise Lack of Power/Poor Acceleration (Lack of Turbo Charged Pressure) Check Booster Pressure Control Valve CHANGED BY EFFECTIVE DATE AFFECTED VIN Check Exhaust Gas Pipes EXHAUST SYSTEM ACTYON SM .03 . 1. oil filter is defected and where adhesive of gaskets has been contaminated into the oil line.

Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of oil line.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Poor Oil Supply Metal Contact of Shaft /Journal Bearing/ Center Housing Inner Part Journal Bearing/Center Housing Inner Part Wear/Seizure Melt down of Bearing to Turbine Wheel Journal Rotor Rotational Movement Seal Wear at Exhaust System Seal Wear at Intake System Interference of Turbine and Compressor Components Oil Leakage Abnormal Noise Lack of Power/Poor Acceleration (Lack of Turbo Charged Pressure) EXHAUST SYSTEM ACTYON SM .2006.12 04 2.

03 SENSOR CONTROL COOLING Rotor Bearing Wear EXHAUST I N T A K E HOUSING ASSY . Turbine Side: Inflow of foreign materials from engine Compressor Side: such as air filter. muffler and nut Inflow of Foreign Materials 13 GENERAL Inflow of Foreign Materials into Turbine Inflow of Foreign Materials into Compressor Shaft Wheel Blade Break Compressor Wheel Blade Break Unbalancing Rotor Rotation LUB Rotor Turning Movement FUEL Seal Wear at Exhaust System Seal Wear at Intake System Interference of Turbine and Compressor Components Oil Leakage Abnormal Noise Lack of Power/Poor Acceleration (Lack of Turbo Charged Pressure) CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .2006.04 3.

Defects caused by reasons other than that of the turbo charger. Clogging of Oil Drain Pipe Oil Leakage at Seal Misunderstanding of Oil Leakage Carbonization Caused By High Temperature No Problems in Turbo Charger System Vacuum Modulator Power Control Error for Controlling Actuator in Engine ECU Seal Wear Oil Leakage Oil Leakage at Compressor Inflow of Dust Increase of Negative Pressure Increase at Inlet Side Oil Leak Sign at Compressor Inlet and Outlet Excessive Inflow of Blow-By Gas. Idling at Low Speed.14 04 4. Oil Leakage at Turbine <In case where the scanner displays as electrical malfunction> Excessive Engine Wear Dampness or Poor Connection of Turbo Charger Actuator Connecting Vacuum Circuit Oil Leakage at Turbine Housing Entrance Detection of DTC Code Caused By HFM Sensor or EGR Valve Malfunction <Mechanical Malfunction> Excessive Inflow of Blow-By Gas. No-Load High Speed Rotation Misunderstanding of Oil Leakage No Problems in Turbo Charger System EXHAUST SYSTEM ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

abnormal vibration and noise can be checked. The leakage condition in the engine block and turbine housing opening can be determined by the occurrence of abnormal noise of exhaust. During idling of the engine. 8. Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign materials. In case where the noise of engine is louder than usual. 15 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Cautions When Examining the Defects: 1. check whether the bolts on pipe connecting section are loose as well as the connecting condition of vacuum port and modulator. Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in connecting area of the duct. 3. after the turbo charger) by applying soap water. When the engine rotates or in case where there is change in noise level. 2. Inspect both side of the turbo charger wheel after removing inlet and outlet pipe of the turbo charger. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . NOTICE • It’s important not to drive the engine when the intake manifold hose has been removed. After stopping the engine. which must be fully aware of. check for leakage in the connecting section of pipe (hoses and pipes. 1) Is the rotation smooth when the rotor is rotated by hand? 2) Is the movement of bearing normal? 3) Inspect whether there has been any signs of interference between two wheels.04 How to Diagnose The followings are cautions to take in handling defects of turbo charger. 9. 5.2006. 6. And it could affect the smooth supply of engine oil and discharge. 4.03 . check for clogging of air cleaner or air cleaner duct or if there is any significant amount of dust in the compressor housing. 7. Immediately stop the engine when abnormal vibration and noise is detected and make thorough inspection whether the turbo charger shaft wheel has any damages as well as checking the condition of connections between pipes. By running the engine at idle speed. During the inspection of center housing. inspect inside of the housing by removing the oil drain pipe to check for sludge generation and its attachment condition at shaft area or turbine side. there is possibility of dampness in the areas related with air cleaner and engine or engine block and turbo charger. duct connections. which is connected to the actuator.

16 04 Diagnosis and Measure Poor Engine Power or Smoke Discharge Air Cleaner Contamination and Clogging of Oil Pass Type Air Cleaner YES Replace Air Cleaner Element or Oil Pass Type Air Filter NO Slack between Compressor Entrance and Exhaust Manifold Connection YES NO Leaks at Intake Manifold YES Reconnect Connections Inspect and Repair Intake Manifold NO Poor Rotation or Interference of Turbo Charger Components YES Leaks at Exhaust Manifold YES NO Leaks at Turbo Charger Connecting Flange NO Inspect and Repair Intake Manifold Refer to Diagnosis Table NO Clogging Between Compressor Exit and Intake Manifold YES Clogging Between Air Cleaner and Compressor YES NO NO Clogging of Engine Muffler YES Clean or Replace Affected Components NO Clean or Replace Affected Components Clean or Replace Affected Components Clogging of Engine Intake/ Exhaust Manifold YES Inspect and Repair Related Components NO Weakness of Engine Function.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Timing Defects of Each Valve YES Inspect and Repair Related Components EXHAUST SYSTEM ACTYON SM . Intake/Exhaust Valve Damage.

04 17 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Before Diagnosis The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in related system as the first priority. This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air. HUBER EGR System for IDI Engine (Including the EGR Valve Potentiometer) CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . signal of required value can not be received from the EGR potentiometer causing to display as malfunction of related parts. comparatively.03 . At this time. in accordance with various input element. As a reference. Most problems with the occurrence of system malfunction are from conditions of vacuum line and connector connections and the causes from the malfunction of mechanical mechanism is actually very few. due to the driving condition or. It is necessary to manually check on the connections if there are any slacks or loose circuits even if the visual inspection shows vacuum hose as being connected. could create customer’s complaint and by connecting the scanning device could display as the malfunction of the EGR valve’s potentiometer. according to the circumstances. For example. making detail inspections of vacuum circuits of each system before connecting the scan tool or vacuum tester. This vehicle. When abnormal condition occurs with the EGR system. due to the leakage of vacuum. the controller sent correct output value to the EGR vacuum modulator but. when there are no problems with basic components. the controller has to receive feedback whether the EGR valve operates correctly according to the value sent to the EGR modulator and this role is performed by the EGR potentiometer located at top section of the EGR valve. this car has a separate controller to control the HUBER EGR and.2006. as described in prior sentence. the basic approach is. let’s assume that there is a vehicle having vacuum leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. If there are not any problems then the next inspection area is the connections of the system connectors. the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control. In other word. will be reduced. smog or other conditions. As previously explained. The DI engine ECU receives feedback signal of change in amount of air being passed through the HFM sensor according to the opening amount of the EGR valve. the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has different shape than the HUBER EGR valve because the EGR valve’s operation signal in the DI engine is performed by the HFM sensor instead of the EGR potentiometer.

When DI engine. to reduce the amount of the fuel injection in no-load rapid acceleration mode. the IDI engine’s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection. EXHAUST SYSTEM ACTYON SM . one is same as being the modulator for EGR valve whereas the HUBER EGR system’s the other modulator controls ALDA of injection pump and the DI engine’s the other modulator controls waist gate of the turbo charger.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . recognizes that current mode is the no-load rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the injector. disregarding the modulator for the EGR valve in DI engine. This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical injection system and DI engine is capable of making electronically controlled fuel injection.18 04 The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator. basing input signal from the related sensors such as acceleration pedal sensor and engine RPM. one must keep in mind that the other modulator is used to control the booster pressure valve in turbo charger. In other word. Therefore.2006.

Valve) YES Repair (overhaul) Engine Refer to Diagnosis Table Excessive Consumption of Engine Oil YES Replace Air Cleaner Element YES YES Refer to Diagnosis Table Replace with Specified Oil NO Poor Oil Seal at Turbo Turbine Side (trace of leakage in housing and wheel) YES Oil Leakage at Engine Exhaust Manifold (damages to ring. Piston.03 SENSOR Improper Inspection of Air Cleaner Contamination NO Improper Viscosity of Engine Oil Being Used NO Poor Oil Seal at Turbo Compressor Side (Oil leak sign at housing and wheel) CONTROL FUEL COOLING LUB EXHAUST I N T A K E Reconnection Inspect PVC Line Replace Oil Filter HOUSING ASSY . piston and valve) YES NO Refer to Diagnosis Table Inspect or Repair Manifold CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .2006.04 When Engine Exhaust Gas shows White Smog or Blue Smog 19 GENERAL Poor Connection between Compressor Outlet and Intake Manifold YES NO Oil Leak Sign Around Intake Manifold YES NO Clogging of Engine Oil Element YES NO Clogging or Damage between Air Cleaner and Turbo YES Clean or Replace Affected Components Oil Leakage at Seal between Turbo Charger and Compressor YES NO NO Engine Malfunction (Ring.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .20 04 Abnormal Noise from Turbo Charger System Contamination or Clogging of Air Cleaner YES NO Leaks at Pipe and Hose Duct Parts between Manifolds of Turbo Charger YES NO Inflow of Foreign Material to Compressor Entrance or Housing YES Inspect and Repair Air Cleaner Element and Turbo Charger after Removing Foreign Materials Clean or Replace If required Inspect or Replace Connections NO Poor Rotation of Rotating Turbo Charger Components and Interference YES Repair Housing and Turbo Charger and Inspect Normal Operation for Engine Inflow of Foreign Materials to Intake Manifold YES Inspect and Repair Air Cleaner Element and Turbo Charger after Removing Foreign Materials NO Inflow of Foreign Materials to Muffler YES NO Repair Muffler and Turbo Charger After Removing Foreign Materials NO Check the Interference between Rotating Turbo Charger Components and Housing YES Refer to Diagnosis Table EXHAUST SYSTEM ACTYON SM .

2006.03 SENSOR Excessive Filling of Oil When Installing NO Clogging of Oil Drain Pipes in Turbo Charger NO Gel Type Oil in Center Housing or Excessively Contaminated Oil CONTROL FUEL COOLING LUB Clogging of Compressor by Dust NO Excessive Deposit of Carbon or Combustion Residues Inside of Turbine Wheel by Oil Contamination NO Gel Type Oil in Center Housing EXHAUST I N T A K E Repair or Replace Air Cleaner Element and Turbo Charger Repair or Replace Exhaust Manifold HOUSING ASSY .04 21 GENERAL Poor Rotation of the Turbo Charger Compressor Wheel Damages By Inflow of Foreign Material YES NO Turbine Wheel Damages By Inflow of Foreign Material YES NO Interference of Compressor Wheel with Housing YES Fatigue and Wear in Bearing or Shaft Journal (Refer to Diagnosis Table) NO YES Repair or Replace Air Cleaner Element and Turbo Charger YES Repair or Replace Turbo Charger YES Repair or Replace Engine Oil Filter and Turbo Charger Oil Leakage at Turbine in Turbo Charger YES Oil Disappears After Combustion YES Clean or Replace Drain Line YES Repair or Replace Engine Oil Filter and Turbo Charger NO Deterioration of Turbo Charger Journal YES NO Poor Engine Function (Too High Blow-by gas pressure in crankcase) YES Refer to Diagnosis Table Inspect PVC Line CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Repair or Replace Air Cleaner Element and Turbo Charger NO NO Clogging of Engine Muffler YES Refer to Diagnosis Table Inspect PCV Line EXHAUST SYSTEM ACTYON SM .22 04 Oil Leakage at Compressor in Turbo Charger Contamination of Air Cleaner Element YES NO Too High Oil Viscosity YES NO Clogging or Damage of Pipe between Air Cleaner and Turbo Charger YES Replace Damaged Components after Cleaning clogged Area NO Clean or Replace Air Cleaner Element Replace With Specified Oil Looseness in Connection between Compressor Outlet and Intake Manifold YES Reconnect After Inspection NO Oil Leakage at Intake Manifold YES Inspect and Repair Intake Manifold NO Clogging of Oil Drain Pipe in Turbo Charger System YES Clean Clogged Area After Inspection NO Clogging Between Compressor Outlet and Intake Manifold YES Deterioration or Damage to Compressor Wheel YES Clean.

refer to Diagnosis section.03 SENSOR CONTROL Poor Function of Engine Oil Pump FUEL NO COOLING LUB EXHAUST I N T A K E Reinstall While Using Specified Oil Add Oil During Idling HOUSING ASSY .2006.04 Wear in Turbo Charger Inner Diameter and Shaft Journal 23 GENERAL Poor Oil Filling When Installing or Replacing Turbo Charger YES NO Contamination of Oil Filter or Use of Low Grade Oil YES Clean or Replace Air Cleaner Element / Replace With Specified Oil NO Lack of Oil in Turbo Charger YES NO Poor Oil Supply by Clogging of Oil Supply Pipe in Turbo Charger YES Clean and Repair Damaged Components Wear in Journal Section By Clogging in Center Housing YES Repair or Replace Turbo Charger NO Clogging of Engine Oil Filter YES NO Replace Oil Filter YES Inspect and Replace If Required For other diagnosis. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .

drive-off performance and pass-ahead acceleration.1% increase 15. 2.2006. (60 -> 100 kph) EXHAUST SYSTEM ACTYON SM .1% decrease Highest speed (kph x 10) Drive-off sec. Enhanced highest speed: 4. The following chart shows the comparison values between a normal turbocharger and VGT regarding highest speed.1% compared to normal turbocharger. Enhanced drive-off performance: The time taken to reach from 0 kph to 100 kph decreases 15.1% of the highest speed increases compared to normal turbocharger. The shorter it is the better performance. (0 -> 100 kph) Pass-ahead sec.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN Normal turbocharger VGT VGT VGT . Enhance pass-ahead performance: This is evaluated by measuring the time taken to reach from 60 kph to 100 kph. 1.1% decrease Normal turbocharger Normal turbocharger 15. 4. 3.24 04 VGT (VARIABLE GEOMETRY TURBOCHARGER) Overview VGT is a certain type of turbocharger system that increases the intake air volume by using the exhaust air flow.

8 Nm 18 ± 1.03 SENSOR CONTROL FUEL COOLING Instrument panel (passenger side) No.5 Nm Turbine housing Turbocharger actuator Adaptor pipe Tightening torque 25 ± 2.2006.04 25 GENERAL Structure Turbocharger actuator EGR vacuum modulator Vacuum Turbopump charger actuator EGR pipe Support bar Oil return tube Tightening Torque Turbocharger assembly Tightening torque 25 ± 2.0 Nm 10 ± 1.95 LUB EXHAUST I N T A K E Oil supply tube HOUSING Vacuum modulator Turbocharger vacuum modulator ASSY .0 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .8 Nm Compressor housing Oil return tube Support bar Upper connection Lower connection 32 ± 3.5A ECU No.63-7.2 Nm Upper connection Lower connection 10 ± 1.2 Nm 32 ± 3.5 Nm Oil supply tube Upper connection Lower connection 18 ± 1.

26 04 Components of VGT Hollow bolt Turbocharger assembly Seal ring Seal ring Oil supply tube Adaptor Turbocharger actuator Gasket Oil return tube Gasket EXHAUST SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

run the engine at idle speed until the turbocharger cools down. Turbine wheel: This is rotated by exhaust gas and connected to the compressor wheel through turbocharger shaft. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . the bearing may be stuck because the oil cannot be supplied. Turbine housing: This is located on the exhaust manifold and encloses the turbine wheel.000 ~ 150. If the engine stops when the turbocharger is still hot. Compressor housing: This induces the fresh air to the compressor wheel and supplies the compressed air to the intercooler through the hose. seal. This is lubricated by engine oil.04 27 GENERAL Components Bearing housing and center housing: This encloses the bearing.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . oil recirculation path and turbocharger shaft.000 rpm). floating bearing is used for this system. and compresses and draws the fresh air. Turbocharger shaft: This is located within center housing and connects the turbine wheel to the compressor wheel. Unison ring Compressor wheel (Impeller): This is rotated by turbine wheel connected through turbocharger shaft. To prevent the turbocharger from being damaged. VGT actuator: This prevent the turbocharged pressure from increasing over the specified value. Floating bearing: Turbocharger rotates at very high speed (100. After high speed driving.2006.

2006. 11 vanes are used as a passage for the exhaust gas led to the turbine inlet. Variable turbine inlet vane The variable turbine inlet vane is connected through the unison ring and vane arm. And on the turbine shaft. the flow passage area of exhaust gas varies. At high speed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . According to their rotation. the flow passage is widened and the much exhaust gas is generated.28 04 Components In VGT system. and the vane control actuator is installed to activate the unison ring towards the turbine housing. EXHAUST SYSTEM ACTYON SM . the turbine and compressor are installed on a same shaft. resulting in considerably increasing the delivery energy of turbine. 11 vanes are rotated when the actuator is activated. Therefore. the flow passage is narrowed and the flow speed of the exhaust gas increases. 11 variable inlet vanes are installed to change the flow of exhaust gas. At low speed. Vane control actuator The vane control actuator is connected to the VGT solenoid valve duty-controlled by the engine computer (ECU) via the vacuum hose. resulting in increasing the delivery energy of turbine. The turbine housing and compressor housing are installed to cover the turbine and compressor. Also. Duty control Unison ring Vane control actuator VGT Solenoid valve Engine ECU Turbine housing Alternator vacuum pump Compressor housing Compressor Unison ring Vane control actuator Low speed Turbine Variable turbine inlet vane Vane Vane arm Unison ring The unison ring is designed to be capable to rotate either clockwise or counterclockwise and to connect to the vane control actuator. the duty rate of the solenoid valve is changed by ECU according to the operating conditions and accordingly the movement of the actuator is controlled. the round unison ring is mounted behind vanes to activate all vanes concurrently.

For example. resulting in increasing the flow speed of exhaust gas and running the turbine quickly and powerfully. when air flows through the venturi tube.03 SENSOR CONTROL Vane control actuator FUEL Alternator vacuum pump COOLING LUB EXHAUST I N T A K E Booster pressure Accelerator pedal signal Vehicle speed signal Clutch signal HOUSING ASSY .2006. if the inner diameter of venturi is more narrowed. Flow tube V1 x A1 = V2 x A2 = Constant Venturi tube Venturi tube Venturi tube CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . EGR valve Intercooler VGT Intake air Coolant temperature Target booster pressure Intake air temperature VGT modulator Vane actuator Duty control Vacuum pump ECU Engine rpm Feedback VGT (Air mass) VGT Solenoid valve Duty control Engine ECU High speed Low speed Unison ring Vane Vane arm Low speed Basic principle at low speed At low speed. as VGT can inhale more air than normal turbocharger. the flow speed is so much faster (refer to the equation).04 29 GENERAL Principles How it works at low speed Normal turbocharger can’t get the turbo effect because the amount of exhaust gas is not much and the flow speed is slow in a low speed zone. it utilizes the principle of venturi. it can give the benefit of the increased output even in a low speed zone. but VGT allows the flow passage of exhaust gas to narrow. In this case. the flow speed is faster and the pressure is lower at the point “A”. Therefore.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The output will increase in submission to the increase of intake air volume. if the inner diameter of venturi is more widened. the amount of exhaust gas increases and it is accompanied with a great force.30 04 How it works at low speed In a high speed zone. Therefore. EGR valve Intercooler Booster pressure Accelerator pedal signal Vehicle speed signal Clutch signal VGT Intake air Coolant temperature Target booster pressure Intake air temperature VGT modulator Vane actuator Duty control Vacuum pump ECU Engine rpm Feedback VGT (Air mass) VGT Solenoid valve Duty control Engine ECU Alternator vacuum pump Vane control actuator Unison ring High speed High speed Vane Vane arm Low speed EXHAUST SYSTEM ACTYON SM . the turbine in the turbocharger by the releasing force of abundant exhaust gas can deliver a more increased energy to the compressor.

If the engine speed is less than 700 rpm 2.04 Controlling VGT system 31 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY The VGT control system checks the engine revolution. intake air temperature. If the accelerator pedal sensor is defective If any of above conditions is met. by controlling the solenoid valve to 300 Hz of frequency and the duty value. If the mass flow sensor is defective 7. water temperature. If the booster pressure sensor is defective 6. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Take a note that the booster pressure sensor is adopted. The ECU drives the vane control actuator to control the booster pressure. accelerator pedal value. vehicle speed and clutch switch signal to determine the driving conditions of a vehicle.2006. If the throttle flap is defective 8. If any part related to the EGR is defective 4. If the coolant temperature is below approx. ECU will not control the VGT system. This helps to maintain the engine at its optimum condition.03 . which is designed to perform the feedback control for matching the booster pressure targeted by ECU by measuring the booster pressure actually. 0? 3. booster pressure. atmospheric pressure. The booster pressure map that is targeted on according to the engine revolution and fuel injection volume is determined inside of ECU. If the VGT actuator is defective 5. The feedback control allows more accurate controlling. 8 Conditions for inhibiting VGT operation 1.

which may lead to a malfunction of the variable mechanism. Renew them if you found looseness of the screw or actuator axle. the engine oil may be provided to variable mechanism assembled towards the turbine housing. The turbocharger should be kept horizontally. When exposed to excessive impact or vibration. 2. 4. 3. because they are shipped after precisely adjusting from the factory. The actuator axle may be deformed.32 04 Notes and Check for VGT Notes When Handling VGT 1. Never re-adjust the adjusting screw marked with yellow paint or the axial end of actuator. EXHAUST SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . If there is much engine oil in the turbocharger and it is kept vertically with the turbine housing downward. the inside mechanism may be damaged even though the outside is intact. Do not move or assemble the actuator axle by grasping it in hands. The turbocharger is sensitive to excessive vibration coming from external impact. which affects the precisely adjusted value.2006.

It is sufficient to simply maintain or service the engine thoroughly. 1) Do not raise the engine rpm rapidly after starting the engine.04 5. 4) whether there is damages or influences by hot temperature. not the turbocharger. check conditions of the engine because the fault may be due to the engine. noisy engine operation 3. reduced engine output 2. 2. it is not necessary to additionally check the turbocharger according to mileage or operation hours. Firstly. The engine oil may be provided to the compressor housing if you rapidly operate the turbocharger with excessive revolutions immediately after installing to the engine.2006. not the turbocharger. 3. 2. check conditions of the turbocharger as follows: 1) whether the compressor is damaged by metal debris or foreign materials. LUB SENSOR CONTROL FUEL COOLING Check Procedures 1. Do not let any metal debris enter when installing to the engine. 2) Do not raise the engine rpm rapidly after renewing the engine oil and filter element. Damage on the turbocharger bearing: Noise can be heard during the turbocharger is operating (The whole turbocharger may be damaged when the bearing is damaged). 6. excessive exhaust gas emitting The symptoms may be due to a fault of the engine. you can check the cause of the fault visually before removing the turbocharger from the engine. In most cases. Leaking of the turbocharger housing: More engine oil is consumed when leaking. Operation conditions of actuator’s diaphragm: It is impossible to control the turbocharger when the operation is poor. Therefore. Then. The following symptoms occur if there is a fault in the turbocharger: 1.03 EXHAUST I N T A K E HOUSING ASSY . 7. 3) Do not stop the turbocharger rapidly after operating at high engine speed. 3) whether there is no contact between the wheel and the housing (check the bearing for damage). excessive engine oil consumption 4. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . 33 GENERAL Check and Service The turbocharger is rarely out of order or damaged unless the engine is operated in abnormal conditions. 2) whether the turbine is damaged by metal debris or foreign materials. Diagnosis and Servicing 1. replenish a small amount of clean engine oil to the inlet before connecting the oil inlet pipe of the turbocharger. After installing to the engine.

use only soft brush or solvent other than sand paper or metallic tools. 4. 6. Replace the gasket and sealing with new ones once removed. 2. EXHAUST SYSTEM ACTYON SM . If suspected. Use only the turbocharger with same specifications. 5. When eliminating the carbon deposit from the turbine wheel during the service procedure. Tighten the fasteners with specified tightening torque.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . the turbocharger should be serviced at Ssangyong Authorized Service Center. Adaptor pipe Oil supply tube Turbocharger pressure regulator Vacuum hose Bolt Support bar Oil return pipe Cautions When Removing/Installing 1.2006. check the oil supply pressure. Change the engine oil before starting the engine.34 04 Removal and Installation Basically. 3. Check if the turbine nozzle actuator operates properly.

03 SENSOR CONTROL FUEL COOLING EXHAUST I N T A K E HOUSING ASSY . Remove the intake hose assembly by removing the clamp on the inlet hose of of the air cleaner. 2.Connecting section of the intercooler side. 1.HFM sensor connector LUB 2. Drain the engine oil by removing the drain plug of the oil pan.Turbocharger connection B.2006. A.04 35 GENERAL Removal and Installation of Turbocharger Preceding Work: 1. Tightening torque 6 ~ 7 Nm A. Remove the intercooler hose of turbocharger. Hose to oil separator B. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Remove the negative battery cable.

4. Remove two mounting nuts on the exhaust pipe of the turbocharger.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.5 Nm Vacuum hose Lower Exhaust pipe Tightening torque 25 ± 2. Separate the hook for engine ground cable and remove the lower mounting bolts from the oil return pipe. Upper Tightening torque 25 ± 2.5 Nm 5.36 04 3. Tightening torque 23 ± 2.0 Nm EXHAUST SYSTEM ACTYON SM . Disconnect the vacuum hose from the turbocharger. Remove the support bar mounting bolt and nut from the turbocharger to remove the support bar.3 Nm Nut 6. Hook Bolt Tightening torque 10 ± 1.

Remove the hollow bolt from the oil supply pipe of the turbocharger and remove the pipe.3 Nm 8.04 7.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .5 Nm Tightening torque 25 ± 2.2006. Tightening torque 25 ± 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Remove the turbocharger assembly. Upper Side Lower Side 37 GENERAL Tightening torque 15 ± 1. Remove three mounting nuts from the exhaust manifold of turbocharger.5 Nm Tightening torque 23 ± 2.5 Nm 9.

EGR valve 2. Vacuum modulator 3. Vacuum pump 4. EGR center pipe (EGR cooler) 5. Intake manifold EXHAUST SYSTEM ACTYON SM . Also.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Various sensor Signals Vacuum modulator Air filter Vacuum pump EGR valve HFM sensor 1.2006. the engine ECU receives the feedback signals of the amount of air flowing through the HFM sensor.38 04 EGR VALVE AND VACUUM MODULATOR EGR SYSTEM General Information EGR system controls the opening value of EGR valve by transmitting electrical signal (PWM control) from the engine ECU to vacuum modulator.

04 39 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM CIRCUIT Vacuum Modulator The biggest difference between the vacuum circuit and layout of the HUBER EGR system after K2004 has been introduced is the location of the vacuum modulator for EGR valve control and the function of the other modulator. it controls the turbo charger actuator. In case of EGR equipped vehicle (IDI Engine). in DI engine. DI engine vacuum modulator 1. EGR valve vacuum modulator To EGR valve From vacuum pump To Turbo Charger Actuator (Gray) To EGR Valve (Black) To turbo charger actuator Vacuum pump CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .03 . it performs the role of controlling the PLA of injection pump whereas.2006. Turbo charger booster vacuum modulator 2.

2006.40 04 Vacuum Modulator and Vacuum Hose Below figures illustrate vacuum hoses and related parts of EGR or turbo where wrong or poor connection of vacuum hose would display condition of engine irregularity and defect diagnostic codes on the scan tool.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Related with EGR valve From vacuum pump EGR valve Vacuum modulator for EGR valve control Related with turbo charger actuator Turbo charger pressure valve Vacuum modulator for turbo charger booster control From vacuum pump EXHAUST SYSTEM ACTYON SM .

the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated by vacuum pump with PWM type controls.2006. Main relay Engine ECU Vacuum modulator for VGT turbocharger actuator Vacuum modulator for EGR valve Engine extension wiring CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .04 41 GENERAL EGR System Diagram Intercooler EGR valve Regulated vacuum pressure Modulator Vacuum pump Duty control Feedback EGR (Air Mass) ECU Improved target EGR Pedal RPM signal signal Air intake signal (for EGR feedback control) Turbo charger : Intake air : Exhaust gas COOLING EGR valve EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU signals. 1.03 SENSOR CONTROL FUEL LUB EXHAUST I N T A K E HOUSING Exhaust manifold Intake manifold ASSY . EGR valve opening point : -220~250 mmHg EGR modulator According to ECU signals.

2006.42 04 VACUUM MODULATOR COMPOSITION Layout EGR valve Turbocharger actuator Vacuum pump hose Vacuum pump Turbocharger vacuum modulator EGR vacuum modulator Vacuum Modulator for VGT Turbocharger Actuator Control Vacuum Modulator for EGR Valve IP internal fuse (RH) No. 96 EXHAUST SYSTEM ACTYON SM .63-7.5A Engine ECU No.63-7.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5A Engine ECU No. 95 IP internal fuse (RH) No.

2006.5 Nm Tightening torque (nut) 35 ± 3. Inlet hose to Intake Manifold Vacuum Hose to EGR Valve Tightening torque 6 ~ 7 Nm 2. Remove the inlet hose to the intake manifold and disconnect the vacuum hose of the EGR valve.0 Nm Tightening torque (hexagon bolt) 10 ± 1.04 43 GENERAL REMOVAL AND INSTALLATION OF EGR VALVE EGR Valve and Pipe 1. Remove the mounting bolt/nut to remove the left pipe of the EGR valve and unscrew four hexagon bolts to remove the EGR valve assembly.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .0 Nm EGR Valve Assembly Tightening torque (bolt) 10 ± 1.5 Nm Tightening torque (M8 X 25) 25 ± 2.0 Nm 3. EGR Valve Pipe (RH) Tightening torque (bolt) 10 ± 1. EGR Valve Pipe (LH) Tightening torque (bolt) 10 ± 1. Remove the right pipe of the EGR valve and remove the center pipe.5 Nm EXHAUST SYSTEM ACTYON SM .0 Nm EGR Valve Pipe (Center) Tightening torque (M8 X 30) 25 ± 2.

0 Nm) EXHAUST SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . EGR RH Pipe and Gasket Center pipe bolt (2 EA) (M6 X 16: 10 ± 1.5 Nm) * M8 mounting nut should be replaced with new one.5 Nm) EGR Valve EGr valve mounting bolt (4 EA) (M6 X 25: 10 ± 1.2006.44 04 4. NOTICE 1.0 Nm) Center pipe lower bolt (2 EA) (M8 X 25: 25 ± 2. 2.0 Nm) Exhaust manifold nut (2 EA) (M8: 35 ± 3. Observe the tightening torque of the bolts and nuts when installing pipes. Replace the gaskets of the pipes with new ones. The protruding side should face to pressurized section.0 Nm) EGR LH Pipe and Gasket Intake pipe bolt (4 EA) (M6 X 16: 10 ± 1.5 Nm) LH pipe mounting bolt (2 EA) (M6 X 16: 10 ± 1. Install in the reverse order of removal. EGR valve Center Pipe Center pipe upper bolt (2 EA) (M8 X 25: 25 ± 2.

CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . troubleshoot the system according to the following procedures. Therefore. check the power supply and ground condition by performing the following electrical check for EGR valve vacuum modulator. Make sure that the vacuum system source functions properly by checking the engine vacuum pump for leakage. EGR related DTC check using SCAN-100 Connect the SCAN-100 to the CAN module and check if there is any DTC related to EGR. Inspection for EGR vacuum system Check the EGR vacuum system (engine vacuum pump . DTC Related to EGR System P0400 P1405 P1406 Faulty EGR valve control Short circuit to EGR vacuum modulator (GND) Short circuit to EGR vacuum modulator (B+) All DTCs are related to EGR valve vacuum modulator.03 . check the EGR system again. EGR valve Main vacuum when idling: 690 mmHg Vacuum modulator for turbocharger actuator Brake booster IWE locking hub Vacuum modulator for EGR valve 2. check the vacuum hose. If DTC is appeared. kinked hose and leaks due to interference with surrounding components. the engine power may be decreased or the exhaust gas may be increased. 1. Also check the EGR vacuum modulator's wiring connector. Specifically. Therefore. it may be due to the vacuum system.04 45 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Inspection for EGR System If the EGR system is malfunctioning.EGR valve) for malfunction. If these happen.vacuum modulator for controlling EGR valve .2006. connections.

The following is the procedure for checking the power supplied to the vacuum modulator.2006. 1 Installtion of multimeter IP interior fuse (RH) No.5 A) in the interior fuse box which is located in the instrument panel (RH). Electrical check for EGR valve vacuum modulator The EGR valve vacuum modulator is supplied with power from the main relay and fuse No. HFM Vacuum Modulator Vacuum modulator for VGT turbocharger actuator Vacuum modulator for EGR valve HP pumpIMV Hazard warning lamp Connector Connector Terminal No. Therefore. 96 EXHAUST SYSTEM ACTYON SM . those relays and fuses should be checked first. Both are supplied with the same power and controlled (duty cycle) by engine ECU.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .46 04 3. 63 (7.5A Engine ECU No.63-7. IP Interior Fuse Box (Passenger Side) Engine ECU main relay VGT & EGR vacuum modulators. The vacuum modulator for the VGT turbocharger actuator is installed on the top of the vacuum modulator for EGR valve.

3.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Check the unit according to the following procedures. Remove the intake inlet hose. check the EGR valve as a unit.04 47 GENERAL 4. 4. EGR valve check If there is no problem found so far. Check if EGR valve starts to open when the vacuum gauge indicates approx. If the valve is severely contaminated. It may not operate due to the contamination by the carbon or other foreign materials. Be careful not to damage it. The EGR valve is working as a passage for exhaust gas. Connect the vacuum tester to EGR valve. 220 ~ 250 mmHg. completely wipe it out with soft cloth. Check the conditions of EGR valve. 2.2006.

3. EGR valve vacuum hose Vacuum pump hose Vacuum hose for turbocharger actuator Brake booster IWE locking hub 2. Disconnect the vacuum modulator connectors to turbocharger (A) and EGR valve (B).2006. Separate the vacuum hose to EGR valve (1). Unscrew the mounting bolts and remove the vacuum modulators. the vacuum hose to turbocharger (2) and the vacuum hose to vacuum pump (3) in turn.48 04 REMOVAL AND INSTALLATION OF VACUUM MODULATOR ASSEMBLY Removal and Installation 1. Tightening torque 10 ± 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .0 Nm EXHAUST SYSTEM ACTYON SM .

63-7.63-7.5A Port to EGR valve Vacuum modulator for EGR valve IP internal fuse (RH) Engine ECU No.03 .2006. 96 No. 95 No. Components Bracket Vacuum modulator for VGT turbocharger actuator Port to VGT turbocharger actuator Port to vacuum pump IP internal fuse (RH) Engine ECU No. Unscrew the mounting bolts and remove the vacuum modulator bracket.5A CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Vacuum modulator 5.04 49 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY 4. Install in the reverse order of removal.

63 Engine main relay Fuse No.50 04 ELECTRICAL CIRCUIT RELATED TO VACUUM MODULATOR Main relay Engine ECU Vacuum modulator Vacuum for VGT turbomodulator for charger actuator EGR valve Engine extension wiring IP Fuse Box (Passenger Side) Engine Main Relay & Fuse No.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5A) EXHAUST SYSTEM ACTYON SM . 63 (7. 63 (7.5A) Fuse No.

04 51 GENERAL Operation Principle of Vacuum Modulator Vacuum pump Output vacuum ATM Connector Vacuum control Diaphragm Seat assembly Spring Plunger Atmospheric pressure Air flow During duty increase (B) During duty reduction (C) Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover and magnetic force (II) in plunger. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . According to ECU signals. the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900 ± 20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E Plunger HOUSING ASSY .

Duty down state (Fig. Flowing volume Output characteristics Output vacuum (-mmHg) Up Down EXHAUST SYSTEM ACTYON SM . A): Original vacuum and seat section. Duty up state (Fig. ON/OFF periods are most unstable and vacuum consumption is most high.2006. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate the pressure. Floating plunger Stroke (mm) Max. Distance 1mm DUTY 50% Output C/V Operating principles when duty is applied from 0 to 50 % Vacuum consumption: Compared to 50 % of duty. 3 stoppers keep sealing 2. B): Original vacuum pressure is connected to inside of diaphragm chamber 3.52 04 Operating principle: Balance between original vacuum pressure and magnetic forcs (see aboe figure) 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Normal state (Fig.

Shut-off conditions 1. (EGR OFF under high RPM range) 3. Engine is running 2. Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings. (EGR OFF under high torque range) 4. Main map: EGR volume is controlled based on intake air volume 2. Engine rpm: over 2. Idle period: over 50 seconds CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM . Vehicle speed is within a specified range. Coolant temperature is within a specified range. EGR OFF under extended period of idling.04 Operating conditions 1. Engine torque is within a specified range. Auxiliary map 1) Coolant temperature (Coolant temperature sensor) 2) Engine rpm (Crankshaft position sensor) 3) Engine load (TPS): Detection of sharp acceleration 4) Intake air temperature (HFM): Decreases when over 60°C 5) Atmospheric pressure (Barometric sensor): Compensation of altitude 3.2006. (EGR OFF under high or low temperature) 7.950 rpm 2. Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure) 6. (EGR OFF under high speed range) 53 GENERAL 5. Coolant temperature: over 100°C or below 10°C 4. Vehicle speed: over 105 km/h 3. Control logic 1. Engine RPM is within a specified range.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

EXHAUST SYSTEM ACTYON SM .54 04 EXHAUST SYSTEM AND MUFFLER Tail pipe Muffler #1 Pipe DOC (Diesel Oxidation Catalyst) MUFFLER The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by eliminating the flowing resistance from the exhaust gas. construction and location.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The important elements of the muffler are volume.

missing or mispositioned parts. DOC (Diesel Oxidation Catalyst) DOC (Diesel Oxidation Catalyst) is the purification device to reduce the toxic emissions from the exhaust gas from the engine. By using the chemical reaction. the amount of toxic gas such as NOx can be reduced.04 55 GENERAL SYSTEM OVERVIEW Exhaust System Check the complete exhaust system and the nearby body areas and trunk lid for broken. or other deterioration which could permit exhaust fumes to seep into the trunk may be an indication of a problem in one of these areas. holes. Muffler Aside from the exhaust manifold connection. the exhaust system uses a flange and seal joint design rather than a slip joint coupling design with clamp and U-bolts. If the ganger is not properly installed. install the hanger to the correct location so that the exhaust system cannot contact to the underbody and other components. open seams. the heat shield to block the heat from DOC is installed to the underbody.2006. damaged. Heat Shield The heat shield protects the vehicle and components from the high heat generated from the exhaust system. it may cause the vibration that is very difficult to diagnose. If hole. Hanger The hanger is to support the components. Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops. make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials. open seams. The same procedure is applicable to the rear muffler assembly. never contact the lift pad when lifting up the vehicle.03 SENSOR CONTROL FUEL COOLING In this vehicle. LUB EXHAUST I N T A K E HOUSING ASSY . the complete assembly should be replaced. and the heat shield to block the heat from the rear muffler is installed to the underbody between the fuel tank and the rear muffler. Any defects should be corrected immediately. NOTICE • To prevent damage of DOC. Therefore. NOTICE • When you are inspecting or replacing exhaust system components. loose connections. or any deterioration is discovered upon inspection of the front muffler and pipe assembly. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .

and nowadays gamma Alumina is used usually. If a lead compound or phosphorus adheres to the surface and the temperature rises.56 04 DOC (Diesel Oxidation Catalyst) System and principle Oxidation catalytic technology for diesel engine is basically the same with it of gasoline engine used before development of 3 primary catalyst (2 primary catalyst). this technology is being used mainly. Catalytic converter structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite. and in the future it is being expected to keep it below 0. delta. And it should keep over 80% of PM reducing rate. Monolith type is lighter than other types. Washer coat operates first. And also it reduces diesel odor and black smoke. (10 times of a football field) Generally Alumina (AL2O3) is used as a raw material and its 7 phases of gamma. but because its portion in total PM is low. easy to manufacture and quickly approaches to proper temperature. if temperature of exhaust gas becomes over 300°C. DOC (Diesel Oxidation Catalyst) reduces HO and CO contained exhaust gas over 80 %.000 ~ 500. and its effect and performance were already proved. and this produced gas is very harmful to human body. Because of low reducing rate for PM of DOC. it reduces approx. On the other hand.000 ft3. in order to guarantee safety rate of PM regulation. platinum or palladium are being used as a catalyst. Ph) operates to washer coat next. it is a problem that it makes the reaction of oxidation. Pd.2006. and at present it plays a role as a transition stage. which SO2 produce SO3 and H2 SO4 by reacting to oxygen in exhaust gas. theta have big areas and high stability for the temperature. To prevent is.05 %. The total area of general monolith converter is about 45. and catalytic metal elements (Pt. The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith. Washer coat is used to make a contact surface with exhaust gas bigger by adhering closely to small holes of inner layer. previously it is requested that the sulfur content rate of fuel should be below 0. Cover Insulation Mat Upper part of converter Plate Lower part of converter Monolith catalyst Inlet gas Outlet gas EXHAUST SYSTEM ACTYON SM . and removes SOF (Soluble Organic Fraction) over 50 ~ 80 %.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 20 ~ 40 % of TPM (Total Particulate Material). its surface is decreased.01 %.

SOF (HC) + O2 ..... 57 GENERAL Purification of catalytic converter 1. 4CO2 + 6H2O Aldehide Aromatic HC 6........... it should keep the temperature range of 400 to 500°C for normal condition.. and NOx does so near the temperature of 400 to 500°C.04 Catalytic converter and temperature Catalytic converter has the normal function of purification at a range of the temperature... 2CO2 3....03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY ... 2CO + O2 .. Purification of soluble organic fraction (SOF) over 180°C Chemical reaction formula 1.2006. HC purification rate becomes better according to the increase of temperature in the normal range of temperature.. Adhesion of soluble organic fraction (SOF) below 180°C 2... 2C2H6 + 7O2 .... Because it has a weak point of decreasing of the purification rate in the condition of continuous high temperature.. Oxygen adheres to catalytic material : below 180°C Catalytic Material Catalytic Material CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .. CO purification rate becomes the best near the temperature of 450°C. O2 +H2O 2........

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Catalytic material conversion process by DOC PAH (Aromatic HC) Catalyzer Method for reduction of NOx NOx is generated a great deal in case that combustion temperature and excess air factor are high.2006. EXHAUST SYSTEM ACTYON SM . EGR valve can decrease NOx (30 to 35% decrease) by making temperature of combustion chamber fall by means of exhaust gas re-circulation. Catalytic material supplies each CO and HC with O2 for their oxidation : above 180°C Catalytic Material Catalytic Material 6.58 04 5.

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03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Diesel catalytic converter (Rear) A. Remove the upper bolts at turbo charger. Unscrew two mounting bolts/nuts from the upper side (turbocharger). 2.Removal and Installation 1. No. Diesel catalytic converter EXHAUST SYSTEM ACTYON SM .2006. Turbocharger 3.60 04 Exhaust Pipe . NOTICE • Use the universal type wrench. Remove the pipe mounting rubber using a screwdriver.1 Exhaust Pipe A.

03 SENSOR CONTROL FUEL COOLING • Remove two mounting bolts/nuts from the muffler side and remove the pipe mounting rubber using a screwdriver. No. LUB 4.2 Exhaust Pipe and Muffler EXHAUST I N T A K E HOUSING ASSY .2006. Remove two lower mounting bolts/nuts and the gasket. CHANGED BY EFFECTIVE DATE AFFECTED VIN EXHAUST SYSTEM ACTYON SM .04 61 GENERAL B. 5. No.3 Exhaust Pipe and Muffler • Remove the pipe mounting rubber using a screwdriver.

......................................................................3 Lubrication diagram ................. 15 TROUBLE DIAGNOSIS ............. 4 Specifications ....5 Engine oil change .... 13 Oil pan assembly ..................................2 Lubrication system layout .. 19 .........................................................................LUBRICATION SYSTEM 05 TABLE OF CONTENTS LUBRICATION SYSTEM ............................................................................................. 14 Removal and installation of oil pan and oil pump ............................................................................. 2 Layout and overview .............................................................................................................................................................................9 Oil spray nozzle ........................

2 PCV Oil Separator Cylinder Head Cover Oil pressure Warning Lamp (Cluster) 05 ACTYON SM . Then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/closes due to pressure differences between the intake side and crankcase.03 LUBRICATION SYSTEM Cylinder head cover (oil + gas) Blow-by gas (air duct hose) Lubrication System Inlet port Oil (oil gauge pipe) Cluster LAYOUT AND OVERVIEW LUBRICATION SYSTEM The first separation will happen when blowby gas passes through baffle plates in cylinder head cover. Oil dipstick gauge Oil Filter & Oil Cooler Oil Strainer Oil Pan and Baffle Plate (Integrated Type) CHANGED BY EFFECTIVE DATE AFFECTED VIN Oil cooler Oil filter .2006.

05 3 GENERAL LUBRICATION SYSTEM LAYOUT Main oil gallery: φ 16 Hole to cylinder head: φ 9 Main bearing hole: φ 7 Chain and injection pump: φ 7 Return hole: φ 14 Chain nozzle: φ 1 HP pump bearing: φ 6 Cylinder Block CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING Cylinder Head ASSY .2006.

LUBRICATION SYSTEM ACTYON SM . the return check valve is installed in oil supply line of cylinder head. Opening pressure of by-pass valve in oil filter: 3 ± 0.4 05 LUBRICATION DIAGRAM Chain lubrication HLA device Camshaft bearing Vacuum pump Chain tensioner check valve Return check valve to cylinder head Oil injection nozzle Thrust bearing Turbo charger Connecting rod bearing Main bearing Filter by-pass valve Oil filter Contaminated oil gallery By-pass throttle Clean oil gallery Relief valve Oil cooler Oil pump and strainer Oil filter Oil pan 1.2006. To prevent instant oil shortage after stopping the engine.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .4 bar 2.

8 ± 0.3 liter Initial change: 5. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when most trips are less than 16 km) 3. every 5.1 6. And.55 bar 3. When doing frequent trailer towing 1. When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic. Operating temperature: -40 ~ 140°C 2. In hilly or moutainous terrain 5.03 SENSOR CONTROL FUEL COOLING Oil Pressure Switch LUB EXHAUST I N T A K E HOUSING ASSY .000 km or 6 months under severe conditions) Same interval with engine oil 5.3 Viscosity: See MB Sheet 224.3 bar Engine oil filter Oil relief valve opening pressure Severe Condition: 1.8 ~ 8.1 or 229. 2. Permissible pressure: 10 bar CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM . When operating in dusty.3 ~ 0.000 km or 12 months (Frequently check the oil level and add if needed.2006. Operating pressure: 0.05 5 GENERAL SPECIFICATIONS Engine oil Specification Capacity Service interval Approved by MB Sheet 229. Change every 10. sandy and salty areas 4.000 km.

2006.3 bar 1. Enlarged pump capacity: Width of tooth (pump gear): 33 mm 2. Replace two oil cooler gaskets with new ones when the oil cooler has been removed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .8 ± 0.1/3 SAE 10W 40. Increased number of teeth (sprocket): 26 Oil Cooler 1. 5W 40 Relief Valve Opening Pressure 5.6 05 Oil Pump Oil MB SHEET 229. Oil cooler mounting bolt: M6 x 16: 4 Installation Notice Tightening torque 10 Nm 2. LUBRICATION SYSTEM ACTYON SM .

and controls the blow-by gas speed to send only gas to separator.2006.05 7 GENERAL Blow-by Gas Reduction Device Oil dipstick tube to air duct hose Cylinder Head Cover Blow-by gas inlet port Baffle plate FUEL ACTYON SM . CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM SENSOR CONTROL COOLING LUB EXHAUST I N T A K E PCV valve + oil separator HOUSING ASSY .03 U-type oil drain pipe Baffle plate assembly: The baffle plates in cylinder head cover separates oil and gas from blow-by gas.

1. Tightening torque 120 ~ 160 kg/cm2 LUBRICATION SYSTEM ACTYON SM . Start the engine and let it run until the coolant temperature reaches at normal operating temperature (80 ~ 90°C). Drain the engine oil.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 3. Disconnect the oil pressure switch connector and remove the switch. 2. Separated oil returns to oil pan via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV valve that opens/closes due to pressure differences between the intake side and crankcase. Install the oil pressure gauge into the switch hole. Raise the engine speed by 2000 rpm and measure the engine oil pressure.5 ~ 3. Specified oil pressure 2.0 kg/cm2 (2000 rpm) 5.2006.8 05 Oil Separator Inlet port (oil + gas) (connected to cylinder head cover through blow-by hose) Outlet port (gas only) (connected to air duct hose) Oil drain (oil only) (connected to oil pan through oil dipstick tube) The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover. NOTICE • Apply the Loctite onto the thread of the switch and check for oil leaks. then oil and gas will be separated due to cyclone effect after entering the oil separator inlet port. 4. Install the switch and engage the connector. Engine Oil Pressure Check Check the oil level and quality before checking the oil pressure.

• Replace the drain plug washer with new one. In hilly or moutainous terrain 5. fouling of the spark plugs and excessive formation of carbon residue. 2. 2. Change every 10. sandy and salty areas 4. 5. Remove the oil filler cap. Fill the engine oil through the oil filler opening. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when most trips are less than 16 km) 3. When operating in dusty.2006. When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic. Shorten the change interval under severe conditions. When doing frequent trailer towing NOTICE • Water separation from the fuel filter should be performed when changing the engine oil. Oil drain plug 25 ± 2. to increased oil consumption. oil filter and oil drain plug to drain the oil. Wait until the oil is cooled down. Park the vehicle on the level ground and warm up the engine until it reaches normal operating temperature. NOTICE • The oil should not go above the upper mark on the dipstick.03 SENSOR CONTROL 3. for example. NOTICE • After driving. CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM . Engine Oil Changing Procedures 1.5 Nm NOTICE • Over-tightening may cause oil leaks.000 km or 12 months Frequently check and add if needed.05 9 GENERAL ENGINE OIL CHANGE Change interval: Initial change 5. the engine oil temperature may be high enough to burn you. Add the engine oil if needed and check for the oil leaks. Severe condition: 1. FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Install new oil filter and tighten the drain plug with specified tighten torque. Stop the engine again and check the oil level. This would lead. Stop the engine and wait around 5 minutes. Close the oil filler cap and start the engine.000 km. 4. 6.

1) Lubricate the engine oil gasket with engine oil before installation. refer to the “Lubrication System” section in this manual. For changing procedures.5 Nm Oil Filter and Cooler . Oil filter 25 ± 2. 2) Tighten it with the specified tightening torque.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Disconnect the ground cable from the oil pressure switch. 2.10 05 Engine oil filter change 1.2006. Remove the oil cooler hoses (supply and return lines). Draining of engine oil 2. LUBRICATION SYSTEM ACTYON SM .Removal and Installation Preceding Works: 1. Removal of EGR vacuum modulator bracket 1.

2006. 4. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Installation Notice Tightening torque 23 ± 2. Remove the oil cooler and filter mounting bolt.03 SENSOR CONTROL FUEL 5. Remove the oil cooler and filter assembly from the cylinder block.05 3. CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM .3 Nm 11 GENERAL • Pay attention to the length of bolts. NOTICE • The oil cooler and filter assembly cannot be replaced separately. Install in the reverse order of removal.

12 05 Oil Dipstick Guide Tube . NOTICE • After installation.5 Nm • Replace the pipe with new one.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque 35 ± 3. Pull out the engine oil dipstick.2006. 3. check for oil leaks. Install in the reverse order of removal. LUBRICATION SYSTEM ACTYON SM .Removal and Installation 1. 4. Installation Notice Tightening torque 10 Nm • Replace the O-ring with new one. Unscrew the bolt and remove the oil dipstick guide tube.3). Remove the EGR valve pipe (No. 2.

Unscrew the bolts and remove the nozzle. Oil spray nozzle 3................ Remove the oil pan or crankshaft........05 13 GENERAL OIL SPRAY NOZZLE a 2 3 1........ CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM ...03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E 1 HOUSING ASSY ....2006. Combination bolt ... 10 Nm a.. Fitting sleeve 2....... Oil duct Disassembly 1... 2.

Oil pump relief valve plug 13. Washer 15. Drain plug .. Bolt 23... Oil pump chain tensioner 19... Oil pump cover 3. 10 Nm 14. Oil pump driven shaft 9....... Spring 11. Cylindrical pin 24. Bolt 4. Oil pump sprocket assy 25..5 Nm (replace the washer) 6......... Oil pump roller chain 17.. Oil pump chain spring 20...... Oil pump relief valve pin 12.. Bolt . Spring pin 7... Oil pump chain lock link 18... Bolt 16....03 CHANGED BY EFFECTIVE DATE AFFECTED VIN ........... Basket LUBRICATION SYSTEM ACTYON SM ..... Oil pump drive shaft 8.. 25 ± 2... Bush 21...2006.....14 05 OIL PAN ASSEMBLY 1.... Oil pump sprocket 22.. Oil pump relief valve piston 10... Oil pump screen assy 26. Drain plug washer 5... Oil pump 2..

Remove the front axle assembly. (For details.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .) 3. (Store the drained engine oil in the specified container.2006. 2.) Oil Pan Assembly 1.0 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN M12 mounting bolt Tightening torque 55 ± 10 Nm LUBRICATION SYSTEM ACTYON SM . Remove the negative battery cable.5 Nm) M6 mounting bolt Tightening torque 10 ± 1. Drain the engine oil from the drain plug of the oil pan. 10 mm mounting bolt Tightening torque (10 ± 1 Nm) Mounting location (RH) Mounting Location (RH) M8 bolt M8 mounting bolt Tightening torque (25 ± 2. refer to “Chassis” section. Unscrew the mounting bolt from the oil pan and separate the oil pan using a rubber hammer.05 15 GENERAL REMOVAL AND INSTALLATION OF OIL PAN AND OIL PUMP Preceding Work: 1.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Wash out the oil pan to remove any foreign material. Remove the oil pan by lowering it to the front side (front bumper side). Apply the specified sealant to the oil pan evenly (DB 2210: 661 989 56 A0). Oil Pan Assembly Oil pan baffle plate (integrated type) When Installing 1. 3. NOTICE • Be careful of the residual oil in the oil pan. Tighten the mounting bolt on the oil pan to the specified torque. 2.16 05 2. LUBRICATION SYSTEM ACTYON SM .

Hexagon Mounting Bolt (6 mm) Removal FUEL Tightening torque 25 ± 2.5 Nm NOTICE • Add the engine oil through the top of the oil pump when reinstalling the oil pump and the oil strainer.03 SENSOR CONTROL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM . 1.2006. Unscrew three mounting hexagon bolts to remove the oil pump assembly.05 17 GENERAL Oil Pump and Oil Strainer Preceding Work: Remove the oil pan assembly.

18 05 Oil Pump Components Plunger Oil pump Compression spring Guide pin Screw plug: 50 Nm Oil strainer Mounting Bolt of Oil Pan and Tightening Torque M6 x 85 bolt (3 EA) 10 ± 1.0 Nm M8 x 40 bolt (4 EA) 25 ± 2.2006.0 Nm M6 x 35 bolt (3 EA) 10 ± 1.0 Nm 17 mm (TM side) mounting bolt 55 ± 10 Nm M6 x 20 bolt (20 EA) 10 ± 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 Nm LUBRICATION SYSTEM ACTYON SM .

2006.05 19 GENERAL TROUBLE DIAGNOSIS Symptom • Loosened oil pan bolts • Poor sealing at oil seal • Loosened oil filter • Loosened oil pressure switch • Poor sealing at camshaft front oil seal • Poor sealing at crankshaft front oil seal • Poor sealing at crankshaft rear oil seal Excessive oil consumption • Poor sealing at cylinder head cover gasket • Damaged cylinder head cover gasket • Oil intrusion into combustion chamber • Stuck piston ring • Worn piston or cylinder • Worn piston ring or ring groove • Improper position of ring cut-outs • Worn or damaged valve mechanism • Oil leaks • Defective turbo charger Defective lubrication system • Improper viscosity • Loosened oil pressure switch Low engine oil pressure • Low engine oil level • Poor oil pump • Worn or damaged oil pump relief valve • Clogged oil filter or oil strainer • Oil leaks • Replace with specified oil • Retighten • Add • Replace • Replace • Replace or clean • Repair Cause • Loosened oil drain plug • Retighten • Retighten • Replace • Retighten • Retighten • Replace • Replace • Replace • Replace • Replace • Clean Action ASSY • Boring or replace • Replace piston and piston ring • Adjust • Replace • Repair • Check CHANGED BY EFFECTIVE DATE AFFECTED VIN LUBRICATION SYSTEM ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB • Remove carbon or replace ring EXHAUST I N T A K E HOUSING .

.................................................................................................................. 34 Overview ....... 3 Specifications .......... 12 INSPECTION AND REPAIR .............................. 15 PREHEATING SYSTEM ......................................................................................................COOLING SYSTEM 06 TABLE OF CONTENTS COOLING SYSTEM .................................................................... 2 ENGINE COOLING SYSTEM .................................................................................................................. 35 Preheating relay ............. 40 ......................................... 35 Preheating system diagram ..... 13 Inspection .................. 13 REMOVAL AND INSTALLATION ................................ 36 Preglow plug .............................................................

2 06 COOLING SYSTEM Coolant Reservoir FFH Water Pump Radiator Assembly Cooling Fan and Fan Clutch Coolant Temperature Sensor COOLING SYSTEM ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

03 SENSOR CONTROL FUEL Coolant reservoir COOLING LUB Oil cooler EXHAUST I N T A K E HOUSING ASSY .06 3 GENERAL ENGINE COOLING SYSTEM Coolant reservoir Engine Cylinder head Thermostat Heater Radiator Water pump Cylinder block (Heater line) <PTC Engine Coolant Flows> Engine Cylinder head Thermostat Heater Radiator Water pump Cylinder block Oil cooler <FFH Engine Coolant Flows> • Cylinder block side Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump • Cylinder head side Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .2006.

2006. : It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5. coolant inflows through the heater line rear section (cylinder #4 and #5) of cylinder head. However. In OM 600 engine.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . the cooling fan is installed with water pump. in D27DT engine. 3. coolant inflows from cylinder block through oil cooler (refer to coolant flows layout in previous page). (in front of cylinder #1) : Improved shape and gasket material to prevent coolant from leaking From cylinder head From reservoir 4 6 5 From heater 1 2 3 2. Cylinder head coolant outlet port is integrated into intake manifold.4 06 Function Description Cylinder head Intake manifold Coolant outlet port 1. COOLING SYSTEM ACTYON SM . in case of D27DT engine. In OM 600 engine. it is connected to water pump with an additional pulley. however.

and a belt pulley.2006. The coolant reservoir is connected to the radiator by a hose and to the engine cooling system by another hose. which could cause serious injury. When the engine stops. This keeps the radiator filled with the coolant to the desired level at all times and increases the cooling efficiency. CONTROL The coolant reservoir is a transparent plastic reservoir. NOTICE • Scalding hot coolant and steam could be blown out under pressure.03 SENSOR FUEL Coolant reservoir COOLING LUB EXHAUST I N T A K E HOUSING ASSY . a drive shaft. Maintain the coolant level between the MIN and MAX marks on the coolant reservoir when the system is cold. The portion of the engine coolant displaced by this expansion flows from the radiator and the engine into the coolant reservoir. cannot be disassembled. Be careful not to damage the radiator core when servicing. The displaced engine coolant is then drawn back into the radiator and the engine. similar to the windshield washer reservoir. The air trapped in the radiator and the engine is degassed into the coolant reservoir. the engine coolant cools and contracts. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and.06 Radiator This vehicle has a lightweight tube-and-fin aluminum radiator. CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Never remove the coolant reservoir cap when the engine and radiator are hot. 5 GENERAL Water pump The belt-driven centrifugal water pump consists of an impeller. therefore. As the vehicle is driven. the engine coolant heats and expands.

the thermostat opens. As the engine warms. As the wax pellet cools.1 mm 8 mm COOLING SYSTEM ACTYON SM . Thermostat Begins to open Fully open Operating Temperature (°C) 85°C 100°C Opening Value (mm) 0. The thermostat stops the flow of the engine coolant from the engine to the radiator to provide faster warm-up. As the vehicle is driven and the engine warms. the engine coolant is allowed to circulate only throughout the heater core to warm it quickly and evenly. The thermostat is mounted in the water pump housing. The thermostat closes at 85°C. The thermostat remains closed while the engine coolant is cold. This allows the engine coolant to flow through the radiator where the heat is dissipated. This allows the engine coolant to flow through the engine cooling system and cool the engine. and to regulate the coolant temperature. The wax pellet in the thermostat is hermetically sealed in a metal case. This opening and closing of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits. forcing the valve open. the wax pellet element in the thermostat expands and exerts pressure against the metal case. When the engine coolant reaches a specified temperature.6 06 Thermostat A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. the engine coolant temperature increases. preventing circulation of the engine coolant through the radiator. The thermostat begins to open at 85°C and is fully open at 100°C. At this point. The wax element of the thermostat expands when it is heated and contracts when it is cooled.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. the contraction allows a spring to close the valve.

from radiator 7 GENERAL When partially opened (85°C ~ 100°C) CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .2006.03 SENSOR CONTROL If the cooling system is fully filled with. FUEL When fully opened (above 100°C) COOLING LUB EXHAUST I N T A K E HOUSING ASSY .06 When closed (up to 85°C) X. the coolant is automatically bled through ball valve (arrow) in thermostat. to crankcase Z. from cylinder head Y.

8 06 Viscous fan clutch The cooling speed increases approx. 1. and clothing away from the engine cooling fans to help prevent personal injury.500 rpm and the coolant temperature is 90 to 95°C. no attempt should be made to repair or reuse the damaged part. NOTICE • If a fan blade is bent or damaged in any way. Clutch housing 2. Cooling fan 7. Bracket cover 12. NOTICE • Keep hands. Oil chamber 16. tools. Flange 4. Separator disc 13. The electric cooling fans increase the flow of air across the radiator fins and across the condenser on air conditioner.000 to 4. A/C On 1) The ECU will turn the cooling fan on at high speed when the A/C system is on. Needle bearing 6. Lever valve 15.2006. Spring 9. A/C Off or Non-AC Model 1) The cooling fan operates at low speed when the coolant temperature reaches 95°C and at high speed when the coolant temperature reaches 100°C. Operating chamber The cooling fans are mounted behind the radiator in the engine compartment. Oil scraper 8. Bi-metal 11. Supply port 14.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2) The cooling fan is turned from high speed to low speed at 97°C and turns off at 90°C. This fan is electric and can turn on even when the engine is not running. COOLING SYSTEM ACTYON SM . An electric motor attached to the radiator support drives the fan. Seal ring 5. Drive disc 3. 1. 2.000 rpm with wind noise when the engine speed is 4. A bent or damaged fan assembly should always be replaced with a new one to prevent possible injury. The fan is 320 mm in diameter with five blades to aid the airflow through the radiator and the condenser. 1. Pin 10.

which could cause serious injury. 9 GENERAL Coolant Level Check NOTICE • Scalding hot coolant and steam could be blown out under pressure. rinse affected areas immediately with plenty of water.2006. Never remove the coolant reservoir cap when the engine and radiator are hot. Change the coolant if necessary. • Take precautions to prevent antifreeze coming in contact with the skin.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 2. If contact happens. Add if needed. 1.06 Engine coolant temperature sensor The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal voltage to the Engine Control Unit (ECU). eyes or vehicle body. Place the vehicle on a level ground and check the coolant level through the coolant reservoir. CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .

the fuel injected as foggy state forms big compounds causing incomplete combustion. NTC resister has characteristics that if the engine temperature rises. So the sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU to increase the fuel volume during cold start for better starting. And detects engine overheating for fuel volume reduction to protect the engine. If the fuel injected into the engine through injector has more turbulence. controls electrical fan and A/C compressor to protect the engine 3. controls fuel volume to correct idle speed 2.062 1. Sends information for emission control Temperature 20 50 80 120 NTC 1 Resistance ( Ω ) 2. then combusts very well. When engine is overheated. However. ECU functions as below with coolant temperature sensor signals. 1. if engine temperature is too low.800 638 200 Signal Auto amp Ground <Coolant Temperature Sensor Circuit> COOLING SYSTEM ACTYON SM . the resistance lowers so the ECU detects lowering signal voltages.2006. When engine is cold.10 06 Coolant Temperature Sensor Temp.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .550 826 321 123 NTC 2 Resistance ( Ω ) 6. Resistance <Coolant Temperature Sensor> <Output Characteristics of Coolant Temperature Sensor> Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.

06 11 GENERAL Trouble Diagnosis Symptom Low coolant level • Leaks in radiator • Leaks in coolant reservoir • Leaks in heater core • Leaks in hose connection • Damaged coolant hose • Leaks in water pump gasket • Leaks in water pump internal seal • Leaks in coolant inlet cap • Leaks in thermostat housing • Improper tightening torque of cylinder head • Damaged cylinder head gasket Excessively high coolant temperature • Coolant leaks (too low coolant level) • Improper coolant mixture ratio • Kinked coolant hose • Defective thermostat • Defective water pump • Defective radiator • Defective coolant reservoir and cap • Cracks on cylinder head or cylinder block • Clogged coolant passages in cylinder head or cylinder block • Clogged radiator core • Improper operation of cooling fan • Faulty temperature sensor or defective harness Excessively low coolant temperature • Stuck thermostat (with open) • Improper operation of cooling fan • Faulty temperature sensor or defective harness Cause • Replace radiator Action • Replace coolant reservoir • Replace heater • Reconnect hose or replace clamp • Replace hose • Replace gasket • Replace water pump • Replace water inlet cap gasket • Replace thermostat sealing • Retighten • Replace cylinder head gasket • Add coolant • Check coolant concentration • Repair or replace hose • Replace thermostat • Replace water pump • Replace coolant reservoir or cap • Replace cylinder head or cylinder block • Clean coolant passages • Clean radiator core • Replace cooling fan or repair related circuit • Replace sensor or repair related circuit • Replace thermostat • Replace cooling fan or repair related circuit • Replace sensor or repair related circuit • Replace radiator CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .1 Centrifugal 72.5 0.3 Wax pellet type 85 100 83 min.12 06 SPECIFICATIONS Description Cooling system Coolant Thermostat Type Capacity Type Initial opening temperature Fully opening temperature Fully closing temperature Stroke Cooling fan Blades Diameter Low speed ON temp Low speed OFF temp High speed ON temp High speed OFF temp High speed ON temp.33 ~ 3.78 0.2 ~ 1. (By A/C pressure) Coolant reservoir Pressure valve opening pressure Vacuum valve opening pressure Water pump Type Impeller diameter Impeller blades Radiator Type Core width Core height Core thickness Minimum radiation capability Coolant temperature sensor Anti-freeze agent Resistance (at 20°C) Resistance (at 80°C) Type Mixture ratio (water and anti-freeze) mm mm mm Kcal/h KΩ KΩ − − mm °C °C °C °C psi Kg/cm2 Kg/cm2 mm °C °C °C mm Unit - Specification Water cooling forced circulation 11.3 10 Down-flow 701 372 18 45. 8 5 320 (2) 91 88 95 92 270 1.35 ALUTEC-P78 50 : 50 COOLING SYSTEM ACTYON SM .32 ~ 0.000 3.

NOTICE • Scalding hot coolant and steam could be blown out under pressure. Heat the water and check the valve opening temperature.06 13 GENERAL INSPECTION AND REPAIR INSPECTION Cooling System 1. EXHAUST I N T A K E HOUSING ASSY . Valve opening temperature DI Engine: 85 ± 2°C Temperature gauge CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Replace or retighten as required. Add the coolant up to upper mark (arrow) on the reservoir. LUB 2. which could cause serious injury. and then remove the cap. Never remove the coolant reservoir cap when the before the temperature goes down below 90°C.4 bar. Release the pressure from coolant reservoir by loosening one notch of coolant reservoir cap. Install the tester to the coolant reservoir and apply the pressure of 1. Check the coolant hoses.2006.03 SENSOR Thermostat CONTROL FUEL COOLING 3. Immerse the thermostat into the water. 4. pipes and connections for leaks after the pointer of the tester drops.

COOLING SYSTEM ACTYON SM . Heat the water and check the resistance.25 Ω / 20°C Terminal B Thermostat 1. Stir the oil during heating it. 2. and terminal B and gauge unit housing. If the measured resistance is out of specified value.8 Ω / -20°C 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Coolant temperature at point A Coolant temperature at point B 113 ± 3°C 116°C NOTICE • Use only engine oil for this inspection.14 06 Coolant Temperature Gauge Unit 1. 3.8 Ω / 115°C 24. Never heat the oil over required temperature.2006. replace the gauge unit. Measure the resistance between terminal A and gauge unit housing.) Terminal B (for glow plug) 0. Terminal A Terminal A (for coolant temp. Immerse the senor unit into the water. Heat the oil until it reaches the specified temperature and check if the coolant temperature switch is turned “OFF”.4 Ω / 79°C 23. Immerse the thermostat into the oil.

2006.03 SENSOR CONTROL 4. Disconnect the HFM sensor connector. Loosen the clamp and remove the coolant inlet hose (radiator to thermostat housing). CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .06 15 GENERAL REMOVAL AND INSTALLATION Coolant Hose (Inlet/Outlet) Preceding Work: Draining of coolant 1. 3. 2. Remove the air intake duct from the air cleaner. FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Loosen the clamp and remove the coolant outlet hose (engine to radiator).

Lift up the vehicle and remove the skid plate. 6. Release the clamps and remove the intake hose.2006. Remove the air cleaner duct.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Removal of coolant inlet and outlet hose 1. Unscrew the fan shroud mounting bolts. Shroud and Cooling Fan/Clutch Preceding Work: 1. Draining of coolant 2. COOLING SYSTEM ACTYON SM . Loosen the clamp and remove the lower inlet hose. 3. 2.16 06 5.

06 5.2006. Installation Notice Tightening torque 45 ± 4. CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Install in the reverse order of removal.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .5 Nm 17 GENERAL 6. Remove the shroud. Unscrew the center bolt and remove the cooling fan clutch while holding the pulley with counter holder (special tool). 7.

....................... Belt pulley 5..................... Thermostat housing 2........ Bolt ........03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .... Replace 3............. Removal of V-belt 3....... Water pump bearing housing COOLING SYSTEM ACTYON SM ... 10 Nm 4... Gasket .... Removal of cooling fan 1..... Removal of shroud 4.......................................................... Draining of coolant 2.. 10 Nm 6............ Bolt .2006......18 06 Water Pump .............Assembly Preceding Works: 1.......

06 1. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Installation Notice Tightening torque 23 ± 2.03 SENSOR FUEL 3. 19 GENERAL 2.3 Nm Installation Notice Tightening torque 10 Nm CONTROL CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Unscrew the bolts and remove the EGR pipe and bracket. Remove the V-belt while pressing down the auto tensioner adjusting bolt.2006. Unscrew the bolts and remove the belt pulley while holding the belt pulley with a special tool.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . COOLING SYSTEM ACTYON SM .2006. Install in the reverse order of removal. 6. • Plug the oil dipstick hole with a cap not to get the foreign materials into the engine. Unscrew the bolts and remove the water pump assembly.20 06 NOTICE • Replace the O-ring in oil dipstick with new one. Installation Notice Tightening torque 10 Nm NOTICE • Remove the gasket residues from the sealing surface and replace the gasket with new one. 5.

............ Coolant hose CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .2006............ Replace 4................. Thermostat CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Bolt ...06 21 GENERAL Thermostat Preceding Works: 1... Draining of coolant 2.................... Removal of V-belt 3.....03 SENSOR 1............. Removal of intake duct (air cleaner to turbo charger) 2......... 10 Nm 5.............. Gasket .. Removal of cooling fan 4.... Water pump housing 3...... Seal 6.......

3.0 Nm 2.2006. Remove the thermostat. COOLING SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .22 06 1. Installation Notice Tightening torque 10 ± 1. Install in the reverse order of removal. Unscrew the bolts and remove the thermostat housing.

0 Nm NOTICE • Be careful not to damage the O-ring in coolant outlet pipe (cylinder head side).5 Nm 4.03 SENSOR CONTROL FUEL 3. Remove the heater hose.2006. 2. Unscrew the bolts and remove the alternator bracket. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Removal of thermostat assembly 1. Unscrew the bolts and remove the alternator.06 23 GENERAL Water Pump Housing Preceding Works: 1. • Remove the gasket residues from the sealing surface and replace the gasket with new one. CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .6 Nm Installation Notice Tightening torque 25 ± 2. Installation Notice Tightening torque 46 ± 4. Removal of water pump assembly 2. 5. Install in the reverse order of removal. Installation Notice Tightening torque 10 ± 1. Unscrew the bolts and remove the water pump housing.

Draining of engine coolant Removal Procedure Intercooler Electric Fans Radiator Condenser COOLING SYSTEM ACTYON SM . Electric Fans.2006. Radiator Preceding Works: 1. Condenser.24 06 Radiator Components of Radiator Module Related Components (Assembly): Intercooler. Removal of front bumper assembly 3. Disconnection of negative battery cable 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Discharge of refrigerant 4.

Disconnect the intercooler hoses. Removal and Installation 1. 2.03 SENSOR CONTROL 2. LH Tightening torque: 6 ~ 7 Nm RH Tightening torque: 6 ~ 7 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • Store the refrigerant and engine coolant in a safe place. Remove the lower cover. Remove the air cleaner duct. 3.2006.06 25 GENERAL Radiator and Intercooler Preceding Works: 1. Drain the engine coolant into the designated container. Collect the refrigerant from A/C system.

COOLING SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . High Pressure Pipe: compressor side Low Pressure Pipe: receiver drier side Tightening torque: 16 ~ 23 Nm NOTICE • Plug the openings of the pipes with sealing caps. Unscrew the bolts and remove the radiator brackets. Inlet Hose Return Hose Outlet Hose 4. 5. Remove the inlet.2006. Remove A/C hose and condenser pipe.26 06 3. outlet and return hoses.

Remove the transmission oil cooler pipes. Tightening torque 6 ~ 7 Nm Release the clamp Tightening torque: 6 ~ 7 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Installation Notice Tightening torque 25 ~ 35 Nm 27 GENERAL 7. 8.06 6. Remove the outlet pipe from the intercooler. Pull out the fixing clips and remove the radiator.2006.03 SENSOR Remove two bolts (10 mm) CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .28 06 9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator. Intercooler Assembly COOLING SYSTEM ACTYON SM .

29 GENERAL Radiator CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . COOLING LUB EXHAUST I N T A K E HOUSING ASSY .03 SENSOR CONTROL Condenser FUEL 11. Remove the T/M oil cooler pipes from the radiator.06 10.2006. Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

COOLING SYSTEM ACTYON SM .2006.30 06 Replacement of Fan Belt Preceding Work: Disconnect the negative battery cable. Turn the fan belt adjusting bolt (19 mm) counterclockwise.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Remove the fan belt.2006.06 2. 31 GENERAL Fan Belt Arrangement CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .

Unscrew the bolts and remove the coolant reservoir.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .32 06 Coolant Reservoir 1. Installation Notice Tightening torque 7 Nm 4. 2. COOLING SYSTEM ACTYON SM . Drain the coolant. 3. Remove the hoses. Install in the reverse order of removal.2006.

CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . NOTICE • Keep the coolant mixture ratio of 50:50 (water : antifreezer).06 33 GENERAL Draining and Adding of Coolant 1.2006. 2. 7. Remove the drain plug and seal in the cylinder block and drain the coolant. Add the coolant through the coolant reservoir. 6. Add if necessary. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . NOTICE • Collect the drained coolant with a proper container. Installation Notice Tightening torque 30 Nm 5. Warm up the engine until the thermostat begins to open and check if the coolant level is at “FULL” mark on the reservoir. Install the drain plug in bottom of radiator. Loosen the drain plug in bottom of radiator and drain the coolant. and then remove the cap. Never remove the coolant reservoir cap when the before the temperature goes down below 90°C. • Add the coolant until the water flows out through the overflow hose. FUEL 3. NOTICE • Scalding hot coolant and steam could be blown out under pressure. which could cause serious injury.03 SENSOR CONTROL 4. Release the pressure from coolant reservoir by loosening one notch of coolant reservoir cap. Replace the seal with new one and install the drain plug.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.34 06 PREHEATING SYSTEM ECU Glow Indicator (Meter Cluster) Glow plug Preheat relay Battery Tightening torque when installing 15 ± 3 Nm No G5 for 4 cylinders (Without D20DT) IG1 power supply terminal Glow plug control signal (ECU113) Ground terminal Battery main wire Glow plug terminal (#1 ~ #4) K-line (ECU 34) Preheat completion transmit terminal : No use for vehicle without remote engine start COOLING SYSTEM ACTYON SM .

K-LINE for information exchanges between preheating unit and ECU 1) Transmits preheating unit self-diagnosis results to ECU 2) Transmits glow plug diagnosis results and operating status to ECU PREHEATING RELAY Structure K-LINE #1 (ECU 34) IG1 Power terminal Glow plug control signal (ECU 113) Ground terminal B+main wire (12V) Glow plug terminal CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM .2006. ECU receives coolant temperature and engine speed to control. Preheating relay activation by ECU controls 1) Senses engine temperature and controls the preheating/after heating time 2) Glow indicator 3. Engine preheating/post heating functions 2. after monitoring the engine preheating/post heating and glow plug diagnosis function. 1. the fault contents will be delivered to ECU.06 35 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY OVERVIEW Glow plug is installed on the cylinder head (combustion chamber) in the D20DT preheating control unit system. Cold starting performance has improved and exhaust gas during cold starting has reduced.03 .

3 Ω Below 150 mV at each glow plug (at 16A of current) MAX 1 mA Specification COOLING SYSTEM ACTYON SM .2006.36 06 PREHEATING SYSTEM DIAGRAM Coolant temperature sensor 113 Specifications Description Rated voltage Operating voltage range Operating range Relay operating voltage Relay releasing voltage Relay coil resistance Voltage drop Parasitic current DC 12 V DC 8 ~ 15 V .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 V 11.40 ~ + 100°C Over 6.5 V Over 1.

Pre-Heating 1. Post-heating 1. Under the following conditions. pollutants and noises. Glow plug makes communication only as response to demand. 3. Check glow plug for short to ground Forceful relay shut-down 1. 3 glow plug Defective No. 2. When glow plug is shorted to ground K-Line communication 1. 5 glow plug open (N/A for D20DT engine) No. 4. Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU. 5. The surface of glow plug will be heated up to 850°C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke. 2 glow plug open CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Checking glow plugs 1.06 37 GENERAL Function Preheating system controls and checks following functions and operating conditions. 4 glow plug Defective No. Preheating time is controlled by ECU. 1 glow plug Defective No. 1 glow plug open No. 1) When there is no response from glow plug module within 2 seconds 2) When an error is detected in checksum 3) Less byte is received DTC P1678 P1679 P1680 P1676 P1677 P0671 P0672 P0673 P0674 P0675 Defective Glow plug open Glow plug short Glow plug . 2. 2. 2 glow plug Detailed description Preheat control driver open Preheat control driver short Preheat control driver is short to ground Communication fault between ECU and preheat controller Communication fault between ECU and preheat controller No. The idle rpm will be increased to reduce toxic smoke. When power is supplied. ECU starts self-diagnosis within 2 seconds.short to ground Glow plug communication fault Defective glow plug controller Defective No. ECU sends the results to preheating time control relay through K-Line to start communication. The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from the battery and there are normal communications with ECU within 2 seconds. 4 glow plug open No.2006. Check each glow plug for open in circuit due to overvoltage 3. communication error occurs. When the engine is started. post-heating starts by ECU controls.03 SENSOR DTC CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 3 glow plug open No. 5 glow plug Defective No. Post-heating time is controlled by ECU. Check each glow plug for short in circuit 2.

-30 °C 115 sec • B+ : below 15. • After engine starting • After operating time elapsed Release • Torque : 190/170 Nm Conditions • Speed: 2100/2050 rpm -20 °C 10 sec -10 °C 5 sec 0 °C 2 sec 10 °C 0 sec 20 °C 0 sec -30 °C 18 sec • IG: “ON” -25 °C 16 sec Glow Operating Time Indicator Operating Conditions Release • When engine cranking Conditions COOLING SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . -35 °C -25 °C 22 sec -20 °C 19 sec -10 °C 17 sec 0 °C 14 sec 10 °C 0 sec 20 °C 0 sec Pre31 sec Operating Time heating • IG: “ON” Operating Conditions Coolant Temp.38 06 Operating time Coolant Temp.2V -20 °C 80 sec -10 °C 30 sec • After operating time elapsed Release Conditions • IG: “OFF” • When engine cranking 0 °C 19 sec 10 °C 11 sec 20 °C 11 sec 35 °C 0 sec Postheating Operating Time Operating Conditions Coolant Temp.2006.

Disconnect the glow plug connectors and loosen the glow plugs.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 3. Remove the glow plugs from the cylinder head with a special tool. Plug the openings of the glow plugs with sealing caps. 2. Set aside the harnesses on the cylinder head.2006.06 39 GENERAL Removal and Installation 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Installation Notice Tightening torque 4. Turn the ignition switch to “OFF” position and disconnect the negative battery cable.

Clean and Blow Out Air gun Check the Color Mark Check the color mark COOLING SYSTEM ACTYON SM .2006.5 Resistance: 1400 ± 300 mΩ at 20 ± 2ºC Green Yellow The color mark on insulator surface may be invisible due to the carbon contamination. Always use only the designated version with correct color mark on insulator surface. To check the color easily. Specifications BERU version Color mark on insulator surface: Green Tip diameter: φ 4 Resistance: 680 ± 110 mΩ at 20 ± 2ºC NGK version Color mark on insulator surface: Yellow Tip diameter: φ 3. disconnect the harness connector and clean the preglow plug mounting area with carbon cleaner.40 06 PREGLOW PLUG Two versions of preglow plugs are used in this vehicle. Wait for a while and blow out the area with a compressed air.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

Engine oil.03 . Long nose pliers Removal and Installation of Preglow Plug Preceding Work: Disconnect the negative battery cable. Disconnect the wiring harness with long nose pliers and clean the preglow mounting area with the compressed air (using air gun).2006.. Carbon cleaner (Product name: IPO CHOKE & CARBURATOR CLEANER. 1. Air gun 2. NOTICE • At this moment. Spray the carbon cleaner into the gap between preglow plug and cylinder head and wait for 10 minutes. Air gun (small). Preglow plug wrench (special service tool). check the color mark on insulator surface and bring the same version of preglow plug for replacement. Model name: PRO NO 5007. NGK: Yellow) CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . (BERU: Green. Remove the dirt and foreign materials completely with the compressed air (using air gun).06 41 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Preparations for Replacing Preglow Plug Torque wrench. Manufacturer: Sunbo).

4. 5.2006. (tightening torque: 15 ± 3 Nm) NOTICE • To prevent the preglow plug from breaking. carefully turn the wrench with the torque below 20 Nm. If needed. COOLING SYSTEM ACTYON SM . apply the engine oil into the gap between preglow plug and cylinder head and wait for 5 minutes.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the preglow plug with torque wrench. Thoroughly remove the foreign materials from the preglow plug hole. • Never use the air impact tool or other tools.42 06 3. use the carbon cleaner or air gun. To avoid damage.

25 Nm) Preglow plug wrench .Special Service Tool (10 mm) Part number: Y99220132B 1) Check the preglow plug trouble code with SCAN-100. NGK: Yellow Tip diameter BERU: 4 mm NGK: 3. 2) SCAN-100 can display only one trouble code. Preglow plug circuit check COOLING LUB EXHAUST I N T A K E HOUSING ASSY .03 SENSOR Color mark on insulator surface BERU: Green CONTROL FUEL 2.06 43 GENERAL Remarks 1. Check whether each preglow plug circuit is open with multitester.5 mm CHANGED BY EFFECTIVE DATE AFFECTED VIN COOLING SYSTEM ACTYON SM . Required tools Carbon Cleaner Torque Wrench (max.2006.

.............FUEL SYSTEM 07 TABLE OF CONTENTS CAUTIONS FOR DI ENGINE .............................................................. 5 Fuel injection system ............................................ 11 Inlet Metering Valve (IMV) ................................................................................................ 16 Injector ............ 2 FUEL SYSTEM ............................. 13 High fuel pressure line .............................................................................................. 5 Fuel transfer line .............................................................................. 38 ..

the driving force of the vehicle decreases (torque reduction). If these conditions occur. For the draining procedures. this warning light comes on and buzzer sounds. FUEL SYSTEM ACTYON SM . causes and actions. 39 cc). please refer to “How to drain the water from fuel filter” section. DI engine controls the fuel injection and timing electrically.2006. Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level (approx.2 07 CAUTIONS FOR DI ENGINE This chapter describes the cautions for DI engine equipped vehicle. System Safety Mode When a severe failure has been occurred in a vehicle. symptoms when engine malfunctioning. Also. immediately drain the water from fuel filter. It reduces the driving force. delivers high power and reduces less emission. DI Engine Comparatively conventional diesel engines. Refer to “Diagnosis” section in this manual. warning lights. the system safety mode is activated to protect the system. This includes the water separation from engine.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . restricts the engine speed (rpm) and stops engine operation.

When the vehicle is under the conditions as below. press the priming pump until it becomes rigid before starting the engine. press the priming pump until it becomes rigid before starting the engine. After replacing the fuel filter Fuel Filter and Water Separator 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .000 km) 3. Water drain plug (water separating operation: every 10. After draining the water from fuel separator 3.2006. • The water drain from fuel filter should be performed whenever changing the engine oil. Priming pump NOTICE • When replaced the fuel filter or drained the water from fuel filter. After run out of fuel 2.07 3 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Priming Pump The priming pump installed in fuel pump is the device to fill the fuel into the fuel filter. Fuel filter 2.03 . Conditions for Using Priming Pump 1.

2. 5. NOTICE • Be careful not to be injured by surrounding equipment during the working procedures. 4.2006. Make sure to perform the job in step 4. Wait until a certain amount of fuel gets out from the port. Press the priming pump until it becomes rigid. It may cause starting problem or fuel system problem. FUEL SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Place the water container under the fuel filter. Turn the drain plug (2) to “A” direction to drain the water. Start the engine and check the conditions.4 07 Draining the Water From Fuel Filter 1. air may get into the fuel line. 3. WARNING • If the priming pump is not properly operated. then turn the drain plug to “B” direction to tighten it.

Furthermore.07 5 GENERAL FUEL SYSTEM FUEL INJECTION SYSTEM Electronic Control of Fuel System Fuel Pressure Sensor High pressure pump Common Rail IMV valve Low and high pressure pump Fuel temperature sensor High Pressure Pipe Water separator Water detection sensor Label (C2I) HFM sensor Cam position sensor Crank position sensor Knock sensor etc. the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those signals. pilot injection set values. Especially.2006.High pressure fuel pump . engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time.Various sensors and actuators . CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .03 SENSOR Sensors CONTROL Injector FUEL Fuel Filter COOLING Priming pump LUB EXHAUST I N T A K E HOUSING ASSY .Fuel pressure sensor . various operations and variables. ECU uses signals from coolant temperature sensor and air temperature sensor.Fuel rail ECU . Fuel tank Components: .Fuel injectors . Air flow (hot film) sensor detects intake air volume and sends the signals to ECU. booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection starting.Electroc control unit (ECU) Supply line Return line ECU communication line According to input signals from various sensors. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by variable resistance changes in accelerator pedal sensor.

The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure. high pressure section that transfers fuel in high pressure and ECU control section. fuel system is completely different from injection pump type fuel supply system on the conventional Diesel engine. Common rail High pressure pipe Fuel pressure sensor Injector D20DT: 4 EA D27DT: 5 EA Priming pump Fuel pump (High pressure pump. and they are controlled electronically by engine ECU.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Accordingly.2006. transfer pump) <Fuel Line System> Fuel filter Fuel route Transfer Pump Fuel Tank Priming Pump Fuel Filter Transfer Pressure Line Injector Common Rail High Pressure Pump Fuel Pressure Regulation Valve High Pressure Line FUEL SYSTEM ACTYON SM .6 07 Composition of Fuel System Components in fuel system are designed to generate and distribute high pressure.

3 bar Common rail Venturi over 1050 bar * IMV valve fully open Injector Priming pump Fuel filter Except D20DT High pressure supply line Transfer pressure supply line Return line Fuel tank CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .2006.07 7 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Hydranlic Cycle in Fuel Line (Tramsfer and High Pressure Line) Transfer pressure regulation Pressure limiter (High pressure) Transfer pump High pressure pump Return valve Inlet valve below 2 bar below -0.03 .

fuel system including pump components. to supply fuel smoothly. it has structure to prevent fuel from leaking in shocks.8 07 Components of Low Pressure Transfer Line Low pressure stage is to supply sufficient fuel to high pressure section and components are as below.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 0. slopes and corners and. Therefore. Also. delivery valve and injector nozzles may be damaged. the hand priming pump is installed to bleed air from transfer line. 1. 1. Fuel filter It requires more purified fuel supply than conventional diesel engine. When the vehicle is under the conditions as below. Fuel filter 4. Hand priming pump 3. Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump.3 bar). After replacing the fuel filter Press the priming pump until it becomes rigid before starting the engine. FUEL SYSTEM ACTYON SM . it separates water from fuel to prevent water from getting into FIE system (high pressure line). Other low pressure fuel hoses Fuel tank Fuel tank is made of anti-corrosion material and its allowable pressure is 2 times of operating pressure (more than min. If there are foreign materials in the fuel. it may cause poor engine starting or damage to each component. It has protective cap and safety valve to prevent excessive pressure building. Priming pump If fuel runs out during driving or air gets into fuel line after fuel filter replacement. After run out of fuel 2. After draining the water from fuel separator 3. Fuel tank (including strainer) 2. Transfer pump 5. press the priming pump until it becomes rigid before starting the engine. And more.

CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . Inlet Metering Valve) included in high pressure pump housing keeps pressure to a desired level. 1. the fuel pressure in the rail is maintained to a specific value. High pressure pump 2.2006. Even though the injectors inject fuel from the rail. Injector 7. And the fuel pressure regulating valve (IMV. and driven by crankshaft with timing chain. Rail pressure sensor 3. Fuel pressure is measured by rail pressure sensor. The components are as below: 1.03 . It is because the effect of accumulator is increased by unique elasticity of fuel. Common rail 5. Fuel pressure regulating valve (IMV) High pressure pump This is plunger pump that generates high pressure.07 9 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Components of High Pressure Transfer Line In the high pressure section. High pressure pipe 6. Common rail It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel.600 bar and this compressed fuel is transferred to high pressure accumulator (common rail) in tube through high pressure line. The high pressure pump increases system pressure of fuel to approx. Pressure limit valve 4. sufficient fuel pressure that injectors requires will be generated and stored.

Injection lines between rail and injectors are all in the same length.2006. The injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine.10 07 High pressure pipe (fuel pipe) Fuel line transfers high pressure fuel. remaining fuel after injection returns to fuel tank through return line. Water separation interval: every 10. the pump transfers fuel from the fuel tank to high pressure pump. To deliver the continuously required fuel volume. Transfer pump The transfer pump is included in the housing of the high pressure pump. Accordingly.000 km (same with engine oil change interval) 3. Fuel filter replacement 1. Never reuse the removed fuel filter FUEL SYSTEM ACTYON SM . it means the lengths between the rail and each injector are the same and the differences in length are compensated by each bending. it is made of steel to endure intermittent high frequency pressure changes that occur under maximum system pressure and injection stops.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . When injector nozzle is open.000 km 2. The transfer pump is the volumetric blade type pump. Pressure limit valve. needle and nozzle and controlled by engine ECU. Injectors The fuel injection device is composed of electrical solenoid valve. fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line. Fuel filter change interval: every 30.

The transfer pump is included in the housing of the HP pump. Four blades set at 90°. Each blade is held against the liner by a coil spring. An eccentric liner fixed to the housing of the HP pump by 6 Torx bolts.2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . The connection is provided by splines. therefore. 3. A rotor turned by the shaft of the HP pump. The inlet and outlet orifice.07 11 GENERAL FUEL TRANSFER LINE Transfer Pump Description The transfer pump is the device to provide sufficient fuel to high fuel pressure line and is mechanical type feed pump that is driven by timing chain linked to crankshaft. The transfer pump is the volumetric blade type pump and consists of the following components: 1. 4. a hand priming pump is installed to bleed air from fuel transfer line. 2. The liner is positioned by two off-set pins in order to prevent any assembly errors. This mechanical type feed pump is subject to air inflow. Transfer pump HP pump <Sectional Diagram of Fuel Pump> <Sectional Diagram of Transfer Pump> CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .

The previous chamber is now in position 2. The volume contained in the chamber quickly rises. It is now in position 3. The fuel is expelled under pressure. The changes in volume according to the angle of rotation of the rotor are small. the liner and the blades decreases quickly. A regulating valve allows the transfer pressure to be maintained at a practically constant level (about 6 bar) throughout the whole range of engine operations by returning some of the fuel to the pump inlet. 4. The depression caused by the transfer pump’s rotation is sufficient to draw in diesel fuel through the filter. The changes in volume according to the angle of rotation of the rotor are small. Fuel is drawn into the chamber. Fuel pressure (bar) Fuel pump speed (rpm) Characteristics of the transfer pump Regulating pressure Volume controlled Flow 6 bar 5. It is finally in position 4. The pressure inside the chamber rises sharply. the liner and two successive blades (refer to above figure). The pressure inside the chamber drops sharply. The rotor continues to rotate.500 rpm pump Intake capacity FUEL SYSTEM ACTYON SM .6 cm3/revolution 90 /h at 300 rpm pump 650 /h at 2. 2. The rotor continues to rotate. the volume of the chamber is minimal. the liner and the two blades is at the maximum. The rotor makes a quarter turn clockwise. The volume area controlled by the rotor. The inlet and outlet orifices are now sealed off.2006. The outlet orifice is uncovered.03 65 mbar at 100 rpm pump CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1.12 07 Principle of operation Housing Rotor Blade Chamber Consider the chamber between the rotor. When the chamber is in position 1. The inlet orifice is uncovered. The transfer pump is driven by the shaft of the HP pump. The volume area controlled by the rotor. transfer pressure thus rises with engine speed. 3.

To reduce the back leak flow. Firstly. it allows the efficiency of the injection system to be improved. Secondary. it allows the temperature to be reduced in the fuel tank. since the HP pump only compresses the amount of fuel necessary to maintain in the rail the level of pressure required by the system as a function of the engine’s operating conditions.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006. Fuel temperature at system backleak Fuel Temp. also called the inlet metering valve. by reducing the back leak flow. the pressure reduction in the fluid (from rail pressure down to atmospheric pressure) gives off a large amount of heat.07 13 GENERAL INLET METERING VALVE (IMV) Overview The LP actuator. it is necessary to limit the amount of heat generated by the fuel pressure reduction. is used to control the rail pressure by regulating the amount of fuel which is sent to the pumping element of the HP pump.(°C) without IMV with IMV Torque (Nm) CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . it is sufficient to adapt the flow of the HP pump to the engine’s requirements throughout its operating range. When the excess fuel is discharged into the back leak circuit. This actuator has two purposes: 1. This leads to a temperature rise in the fuel entering the tank. IMV effect without IMV with IMV Torque (Nm) Rail pressure = 80 bar 2. In order to prevent too high a temperature being reached.

Two O-rings ensuring pressure tightness between the hydraulic head and the body of the IMV. A piston filter located at inlet. It is fed with fuel by the transfer pump via two radial holes.14 07 Composition of IMV The IMV is located on the hydraulic head of the pump. The IMV consists of the following components: 1.2006. A piston held in the fully open position by a spring. Coil Transfer pump Fuel Filter Spring Solenoid High pressure Piston Outlet hole O-ring Fuel Transfer pump FUEL SYSTEM ACTYON SM . but also all the components of the injection system located downstream of the IMV. A body provided with two radial inlet holes and an axial outlet hole. 3. A cylindrical filter is fitted over the feed orifices of the IMV.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 4. 2. This makes it possible to protect not only the LP actuator. 5.

it is necessary to have: • Flow introduced into the HP pump = Injected flow + Injector backleak flow + injector control flow The IMV is normally open when it is not being supplied with fuel.4 Ω (at 25°C) Battery voltage (It is prohibited to supply the IMV directly at the battery voltage during the diagnostic test) 1A 260 g 40°C < T < 125°C 40°C < T < 90°C Normally open without power (The flow decreases as the current rises). At each point of operation. current Weight Operating temperature Fluid temperature Control logic 1. The IMV is controlled by current. The flow/current law is represented below.4 mm 5. It cannot therefore be used as a safety device to shut down the engine if required.4 mm 3.2006.07 15 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Principle of Operation The LP actuator is used to proportion the amount of fuel sent to the pumping element of the HP pump in such a way that the pressure measured by the HP sensor is equal to the pressure demand sent out by the ECU.03 . • ECU determines the value of the current to be sent to the IMV according to: • Engine speed • Flow demand • Rail pressure demand • Measured rail pressure E C U • Inlet Metering Valve (IMV) CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . Flow / Current Law Flow (I/hr) Current (mA) Specifications Piston stroke Diameter of holes Coil resistance Power supply Max.

any problems of dynamic pressure tightness are eliminated because the high pressure is generated in the fixed part of the pump. 1600 bar and sends this high pressurized fuel to high pressure accumulator (common rail) via high pressure line.2006. Housing 6. Operating pressure limit: 2100 bar 3. Gear ratio (engine: pump): 0. Drive shaft and cam ring 5. but the cam which turns around the hydraulic head. IMV (Inlet Metering Valve) 2.16 07 HIGH FUEL PRESSURE LINE High Pressure Pump Description This pump generates high fuel pressure and is driven by timing chain (radial plunger principle). High fuel pressure . Pressure regulator Fuel supply Specifications 1. Hydraulic Head 3.Inside lubrication (rear bearing): Fuel . Maximum sealing pressure: when using a plug instead of PRV. Transfer pump 8. Driving torque: 15 Nm / 1600 bar 9.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Fuel temperature sensor Fuel discharge 9.OUT 11. Plunger 4. vibration and noise since the pump no longer determines the injection period. no leaks around pump outlet port (when applying 2500 bar of constant pressure) 4. Vent 10. 1. 048 bar (to end of filter’s lifetime) 8. Pump inlet pressure: Relative pressure Max. The differences from conventional rotary pumps lies in the fact that it is no longer the hydraulic head rotor which turns inside the cam. Thus. Operating temperature: Continuously operating within temperature range of -30°C ~ 120°C in engine compartment 6. Maximum operating pressure: 1600 ± 150 bar 2.625 10. Fuel pressure at inlet (pressure regulating valve): 6 bar 5. Lubrication: . Inflowing fuel temperature: The maximum inflowing fuel temperature is 85°C (continuously able to operate) 7. This pump pressurizes the fuel to approx. It is possible to extend the pumping phase in order to considerably reduce drive torque. Roller and shoe 7.Outside lubrication (front bearing): Engine oil FUEL SYSTEM ACTYON SM .

4. The transfer pressure is sufficient to open the inlet valve and to move the pumping plungers apart. thus. the ball is unbalanced and it opens. The required power to drive pump is determined by set pressure for rail and pump speed (delivery flow). Thus. During the input phase. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . transfer pressure pushes back the inlet valve. the inlet valve closes. When the diametrically opposite rollers simultaneously encounter the leading edge of the cam. Consequently. Roller Plunger <Fuel Input> <Pressurize> This high pressure pump generates the driving torque with low peak torque to maintain the stress to driving components. During the filling phase.2006. Fuel is then pumped into the rail at high pressure. ensuring the pressure tightness of the body of the pumping element. the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner face. The valve closes as soon as the pressure in the pumping element becomes higher than the transfer pressure. Thus the ball rests on its seat. When the pressure becomes higher than the pressure inside the rail. During the input phase.03 . the delivery valve opens. When the pressure in the element becomes higher than the pressure in the rail.07 Principle of operation 17 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY 1. This torque is smaller than that of conventional injection pump. Note that the fuel leakage or defective pressure control valve may affect the engine output. the plungers are pushed towards each other. 5. the rollers are kept in contact with the cam by means of coil springs mounted on either side of each shoe. 2. only a small load will be applied to pump. the fuel is pumped under pressure into the rail. the dead volume between the two plungers fills with fuel. As soon as the pressure becomes higher than the transfer pressure. Fuel enters the body of the pumping element. 3.

the plungers are forced together and pressure quickly rises in the body of the pumping element. Phasing of the HP pump Conventional fuel injection pumps ensure pressurizing and distribution of the fuel to the different injectors. FUEL SYSTEM ACTYON SM . Thus the ball rests on its seat. It allows pressure control to be improved by synchronizing peak pressures produced by the pump with pressuredrops caused by each injection. the setting or phasing of the pump offers two advantages: 1. the ball is unbalanced and it opens.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . it is therefore not necessary to set the pump in relation to the engine. When the rollers simultaneously encounter the leading edge of the cam. When the pressure in the element becomes higher than the pressure in the rail. When the two diametrically opposite rollers encounter the leading edges of the cam.18 07 Inlet valve and delivery valve During the input phase. The HP pump of the common rail system is no longer used for the fuel distribution. Nevertheless. Fuel enters the body of the pumping element.2006. Of the pumping element. It allows the torque variations of the camshaft and the pump to be synchronized in order to reduce the stresses on the timing belt. 2. It is essential to set the pump in such a way that the injection occurs at the required place during the cycle. the two plungers are forced apart. Fuel is then pumped into the rail at high pressure. Under the effect of the transfer pressure. transfer pressure pushes back the inlet valve. The minimum flow required to ensure adequate operation of the pump is 50 /h. This phasing allows pressure stability to be improved. <Inlet Valve> <Delivery Valve> Lubrication and cooling of the HP pump Lubrication and cooling of the pump are provided by the fuel circulation. ensuring the pressure tightness of the body of the pumping element. the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner face. The spring calibration is negligible compared with the pressure forces. pressure suddenly rises in the body. During the input phase. The valve closes as soon as the pressure in the pumping element becomes higher than the transfer pressure. which helps to reduce the difference in flow between the cylinders.

The below figure describes the pump operations when acceleration and deceleration. this fuel gets into the IMV that controls only the fuel to the high pressure pump. When need high fuel pressure (acceleration) IMV open Venturi to common rail Fuel supply to fuel tank Backleak Transfer pump High pressure pump CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .07 19 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY HP Pump Fuel Route The fuel passed through the fuel filter is sent to the transfer pump via the HP inlet pump.2006. this fuel passes through the transfer pump by the transferring pressure and maintains the predefined value by the regulating valve in HP pump. Also.03 .

Performance curve of HP pump The time required to obtain a sufficient pressure in the rail to enable the engine to start depends on the volume of the system (definition of the rail.2006. The IMV installed in the high pressure side (hydraulic head) of HP pump precisely controls the fuel amount and delivers the rail pressure feedback same as required amount. The IMV is controlled by ECU.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . goes into the common rail through the high pressure pipe.). etc. The aim is to reach a pressure of 200 bars in 1. • Maximum operating pressure: 1600 ± 150 bar Rail pressure (bar) Engine speed (rpm) <Pressure Curve of HP Pump> FUEL SYSTEM ACTYON SM .20 07 When do not need high fuel pressure (deceleration) IMV close Venturi to common rail Fuel supply to fuel tank Backleak Transfer pump High pressure pump The fuel is sent to the high pressure side (hydraulic head) and compressed by the plunger. length of the pipes. And.5 revolutions (3rd compression).

07 21 GENERAL Sectional View of HP Pump <Transfer Pump> IMV valve High pressure pump <IMV Valve and High Pressure Pump (Drive Shaft)> CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Shoe and Roller.22 07 Inlet valve Temperature sensor Shoe and roller Supply valve <Inlet Valve. Temperature Sensor> <Hydraulic Head> FUEL SYSTEM ACTYON SM . Outlet Valve.

NOTICE • Slacken the pulley bolt. 1) Cooling fan pulley 2) Coolant pump pulley 3) Idle pulley 3. Apply the parking brake and place the chocks under the tires. store the removed auto tensioner in upright position. Remove the engine belt pulleys. 2.03 SENSOR CONTROL FUEL 2. (transmission "N" position) 1. Unscrew lower bolt (13 mm) and upper bolt (24 mm) and remove the auto tensioner. COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . NOTICE • To prevent oil leaks. Disconnect the negative battery cable. • Pump the suto tensioner several times before installing it. Turn the auto tensioner counterclockwise and remove the fan belt.07 23 GENERAL Removal and Installation Removal Preceding Works: 1.

8. 1) Disconnect the high pressure pump and vacuum modulator connector.2 EGR pipe. FUEL SYSTEM ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .24 07 6. 7. Remove the high pressure pump housing. 3) Plug the openings of pipes and ports with protective caps to keep the cleanness of the fuel system. Preceding Work: Remove the No. 2) Disconnect the fuel lines to high pressure pump. 4) Remove the high pressure fuel pipe between HP pump and common rail. 1) Open the oil filler cap and check if the OT mark on crankshaft is aligned to the notch on the camshaft. Align the OT mark by rotating the crankshaft. 9. Rotate the crankshaft clockwise so that the HP pump sprocket holes are aligned to the bolt holes. Unscrew the bolts and remove the vacuum modulator bracket.

NOTICE • Tap the center bolt with a hammer after tightening. • Make sure that the center bolt is securely tightened.2006. Hold the HP pump sprocket and slacken the center bolt.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 10.07 8. Remove the remaining bolts with the same manner and remove the high pressure pump. 25 GENERAL 9. Loose the HP pump center nut by tapping it with a hammer. 11. Slacken three HP pump mounting bolts until they rest on the sprocket. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .

Tightening torque 25 Nm 3. • Tighten the center nut with the specified tightening torque.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Replace the fuel lines to HP pump with new ones (cannot be reused). 4. Replace the HP pump gasket with new one (cannot be reused). Tighten the HP pump bolts. • Make sure that the connectors are installed to the correct locations.2006. Hold the HP pump sprocket and tighten the center nut. 2. (The wiring end with white tape FUEL SYSTEM ACTYON SM .26 07 Installation 1. Install the vacuum modulator bracket. Tightening torque 65 Nm NOTICE • The center nut should be replaced once removed (cannot be reused).

NOTICE • Open the oil filler cap and check if the OT mark on crankshaft is aligned to the notch on the camshaft. NOTICE • Sealant (DB2210): 661 989 56 A0 27 GENERAL 6. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .07 5.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Rotate the crankshaft pulley two revolutions and ensure that the OT mark on the crankshaft pulley and the OT mark on the camshaft pulley are aligned. Apply the sealant to the HP pump housing and tighten the bolts.2006. 7. Install the auto tensioner and belt pulleys.

Therefore.28 07 Fuel Filter Function Foreign materials in fuel can damage the pump components. And. from HP pump to HP pump from fuel tank to fuel tank Water Sensor Effective water storing rolame: 120cc Warning light ON level: 39 cc Fuel filter Fuel level in filter: 500 ± 25 cm3 Filtering effective • Particles larger than 3µm > 98 % • Particles larger than 5µm > 99.8 % • Particles larger than 15µm > 100 % Drain plug FUEL SYSTEM ACTYON SM . the operation performance will drop dramatically. the high pressure direct injection engine must use fuel filter. diesel fuel may contain water due to condensation by temperature changes and this condensation water can damage the system by corroding the injection system. the common rail engine should have function that can drain water periodically. Otherwise. Thus.2006. transfer valve and injectors.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

000 km It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 75 cc) in the filter to let the driver drain the water. When those symptoms happen. and results in protection of FIE system. Water reserve capacity: 124 cc 3. Fuel De-Waxing – Improving starting performance in cold weather Due to characteristics of diesel fuel. Water drain interval: When changing engine oil or every 20. Water warning light turning on level: 39 cc 4. engine may stall.07 Change Interval: 30. some of the fuel (temperature rises due to high compression) in the HP pump in D27DT engine return to the filter to warm up fuel when temperature is below 50°C by improving cold start performance during cold winter.000 km Water separation and storage function 29 GENERAL 2.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E Water sensor HOUSING ASSY 1. (manual drain) . however. Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system. some of fuel components solidify during cold winter under below a specific temperature (-15°C).2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .

30 07 Removal and Installation 1.2006. Disconnect the fuel supply and return hoses. Remove the fuel filter. Press the priming pump until it becomes rigid to deliver the fuel to the transfer line of HP pump. 4. 5. FUEL SYSTEM ACTYON SM . • Ensure that the hoses are connected to correct positions. 3. NOTICE • Plug the openings of hoses and fuel filter with sealing caps. Loosen the bracket bolts and disconnect the hose from the drain plug. Install in the reverse order of removal.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2.

the fuel in the fuel tank should be transferred to the filter by using priming pump. the fuel is also used for pump lubrication. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . diesel fuel has lubrication effects due to its viscosity.2006. The pressure on this line affects the lifetime of fuel filter. After draining the water from fuel separator 3. Relations Between Pressure and Temperature in Fuel Transfer Line Pump inlet pressure COOLING Pump Fuel transfer line Injector Ventury Pump outlet pressure Injector No. After replacing the fuel filter from fuel tank to fuel filter NOTICE • When the fuel filter is replaced. it may cause poor engine starting or damage to each component. press the priming pump until it becomes rigid before starting the engine. 2. 100% of fuel is returned to fuel tank to cool down the temperature and then increase the lubrication effects of fuel and prevent heat damage on each section of high fuel pressure line. After run out of fuel 2. this lubrication performance drops as the temperature rises.5 return pressure 1.03 SENSOR CONTROL High pressure common rail FUEL LUB EXHAUST I N T A K E HOUSING ASSY . When the vehicle is under the conditions as below.1 return pressure Injector No.07 31 GENERAL Priming Pump If fuel runs out during driving or air gets into fuel line after fuel filter replacement. However. Therefore. Temperature of fuel transfer line 1) Pump inlet temperature is less than 80°C. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine. 2) Above figure shows the temperature changes in each section caused by temperature changes in pump inlet section. Thus. Conditions for using Priming Pump 1. when the fuel temperature is over 50°C. The fuel transfer line is the line between fuel tank and HP pump inlet port. Accordingly. the hand priming pump is installed to bleed air from transfer line. the temperature of fuel pump inlet is up to 80°C. And.

Even when a large amount of fuel leaks. 345. Relieve the pressure pulsation 2. This high pressure accumulator is commonly used in all cylinders. the common rail maintains its internal pressure. Dimension: • Volume: 19.055 ± 0.2006.11 mm • Outer diameter: 27 mm 3.04 V ≅ 0 bar 4. This ensures that the injection pressure can be maintained from when the injector opens. Simultaneously.1V 2) Sensor output signal voltage: • 4. temperature after engine stops: 140°C (acceptable against total 15 hours) 6. Ambient temperature: 1) available within -40°C ~ 125°C 2) Spontaneous max. the pressure changes due to the delivery from HP pump and the fuel injection is diminished by rail volume. Material: Forged Steel 2. Removal and installation: 10 times without any damage FUEL SYSTEM ACTYON SM .32 07 High Pressure Accumulator (Common Rail) Description The high pressure accumulator reserves the high pressure fuel. Function 1. Fuel pressure sensor Integrated type 1) Sensor input voltage: 5 ± 0.125 V ≅ 1600 ± 15 bar • 0. Provide pressure information to ECU (fuel pressure sensor) Specifications 1.5 ± 0. Fluid temperature: -40 ~ 100°C under normal operating conditions 7.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Operating pressure range 1) Normal condition: 0 ~ 1800 bar 2) Exceptional condition: available within 1800 ~ 2100 bar 3) Bursting pressure: over 2500 bar 5.5 ± 1cc • Length: Max.

5 33 GENERAL HP pipe Injector HP pipe Fuel pressure sensor HP pump High Fuel Pressure Pipe 1. the high pressure pipe assembly should be used only once.07 D20DT No. 3 No. total period: 20 hours) 3) Bursting pressure: over 2500 bar 5. 4 No. NOTICE • Make sure to replace the removed high fuel pressure pipes.03 SENSOR CONTROL FUEL <High Pressure Accumulator> COOLING LUB EXHAUST I N T A K E High fuel pressure pipe HOUSING ASSY . 2 No. 4 4. Material: Steel (Zn Plated) 3. To keep cleanness and tightness. 2 No. Internal pressure 1) Internal operating pressure: 0 ~ 1600 bar during its lifetime 2) Spontaneous max. rail and injector with high pressure 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . 4 No. 3 No.2006. pressure when restoring: 2100 bar (max. 3. 1 D27DT No. Function: Resistant to pressure changes. tightness against surroundings. supplying fuel through pump. 2. • Tighten the fasteners with the specified tightening torque. 1 No. Common: Cylinder 1.

0 Nm NOTICE • Replace the fuel pipes with new ones. NOTICE • Replace the fuel pipes with new ones. • Plug the openings of hole in the common rail with sealing caps. 5. • Plug the openings of hole in the common rail with sealing caps. Installation Notice Tightening torque 40 ± 1.34 07 Removal and Installation Preceding Work: Removal of engine cover 1. Unscrew the high fuel pressure line nuts and remove the fuel pipes. 4. Installation Notice Tightening torque 25 ± 2. FUEL SYSTEM ACTYON SM . • Plug the openings of hole in the common rail with sealing caps. Install in the reverse order of removal.2006. Installation Notice Tightening torque 40 ± 1. Unscrew the bolts and remove the common rail asssembly. Disconnect the fuel pressure sensor connector. • Plug the openings of hole in the common rail with sealing caps. Unscrew the nuts and remove the fuel supply main pipe from the fuel line.0 Nm NOTICE • Replace the fuel pipes with new ones.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .5 Nm NOTICE • Replace the fuel pipes with new ones. 3. 2.

when the shape of diaphragm changes. ECU uses them to control fuel volume and injection time.1 V 2.2006. The fuel in the rail reaches to sensor diaphragm via blind hole in the pressure sensor and the pressure signal converts to electrical signal. When received these signals.07 35 GENERAL Fuel Pressure Sensor Fuel pressure sensor on the center of common rail detects instant fuel pressure changes and then sends to ECU.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Sensor input voltage: 5 ± 0.5 ~ 5 V. Accordingly.055 ± 0. electrical resistance in the layers on the diaphragm changes then can measure 0. The signal measured by sensor will be amplified to input to ECU. This piezo element type sensor changes pressure into electrical signal. Output signal voltage of sensor 1) 4.04 V: 0 bar CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .5 ± 0. 1.125 V: 1600 ± 15 bar 2) 0.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.36 07 Sensing area Pressure Physical changes Converts to electric signal Amplifier Electrically amplyfying signal <Operation Principle of Fuel Pressure Sensor> Upper area Output voltage Lower area Pressure (P) <Sensor Voltage> Piezo resistance Ground SIG REF 5V Pressure sensor <Circuit Diagram of Fuel Pressuer Sensor> FUEL SYSTEM ACTYON SM .

Fuel temperature sensor is installed on the fuel return line to correct pressure after measuring fuel temperature. 5V is supplied to the sensor and voltage drop by temperature is delivered to ECU to measure the fuel temperature through analog-digital converter (ADC).07 37 GENERAL Fuel Temperature Sensor Temperature Resistance <Fuel Temperature Sensor> <Output Characteristics of Fuel Temperature Sensor> Fuel temperature sensor is a NTC resistor that sends fuel temperature to ECU.03 SENSOR CONTROL Fuel Temp Sensor FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . In case of NTC resistor. Signal Ground <Circuit Diagram of Fuel Temperature Sensor> HFM Sensor Refer to “Intake System” Crankshaft Position Sensor Refer to “Engine Assembly” Knock Sensor Refer to “Engine Assembly” Camshaft Position Sensor Refer to “Engine Assembly” CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . the resistance lowers if engine temperature rises so the ECU detects lowering signal voltages.2006.

2006.35 mm · Injector nozzle 22. Tighten the injector holder bolts with the specified tightening torque. 890 mm3/min Control: PWM type (solenoid injector) Tightening: By clamping fork Edge filter Leak off nipple C2I label Fuel return: Nipple Nozzle holder body Bobbin C2I value Cap nut Control valve Adaptor plate Nozzle body Washer Nozzle needle FUEL SYSTEM ACTYON SM . 3.155 mm Nozzle basic: 5 Holes. Specifications Length: · Injector body 181. 150° Cone Angle. Be careful not to drop the injector. Special cautions: 1. 4.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . These C21 values should be input to ECU by using Scan-i when replacing the ECU or injectors.38 07 INJECTOR The C21 labels including injector characteristics are attached in each injector. Replace the copper washer in injector with new one. Plug the openings of hoses and pipes with the sealing caps. 2.

The effort needed to move the valve must be minimal. These orifices are: 1. The injector supply orifice (Nozzle Path Orifice: NPO) 2. When the needle has to close (at the end of injection): the valve closes again so that pressure is re-established in the control chamber. 2. The control chamber filling orifice (Inlet Orifice: INO) NOP nozzle path orifice Spacer INO inlet irifice SPO spill orifice Control chamber CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . unless very high currents are used.03 . 2. 3. Spring pressure ensures contact between the valve and its seat. it is impossible to directly control the injector by using an electromagnetic actuator.07 39 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY The maximum injection pressures are approximately 1. The forces to be overcome in order to lift the needle of the injector are therefore very large. The injector is therefore indirectly controlled by means of a valve controlling the pressurizing or discharging of the control chamber located above the needle: 1.2006.600 bar. Vo l u m e under high pressure Valve Spill orifice Valve Contact making seal Depressurization grooves Vo l u m e under vacuum Spacer The spacer is situated underneath the valve support. Valve In order to guarantee response time and minimum energy consumption: 1. which means that the valve must be in hydraulic equilibrium in the closed position. It integrates the control chamber and the three calibrated orifice which allow operation of the injector. The valve stroke must be as short as possible. To lift the valve. The valve must be as light as possible. When the needle is required to lift (at the start of injection): the valve is opened in order to discharge the control chamber into the back leak circuit. The control chamber discharge orifice (Spill Orifice: SPO) 3. which would be incompatible with the reaction times required for the multiple injections. Because of this. it is therefore required to overcome the force being applied by this spring.

The pressure force applied by the fuel onto the needle is: Ff = S * Prail The needle is closed and hence there is no fluid circulation through the NPO orifice. the valve opens.40 07 Principle of Operation S Ff = pressure * space Ff = (Ff == rail * S) (Ff P Pr Fo = pressure * space Fo P (Fo == rail * S) (Fo = A) A Valve closed Needle closed No injection Valve opens Needle closed No injection Valve closes Needle open End of injection Valve closed Needle closed No injection Injector at rest The valve is closed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN * S: The area of the flat upper surface of the injector’s needle * A: The area of the needle surface situated above the section of contact between the needle and its seat * Ff: The force applied by the fuel onto section “S” * Fo: The force applied by the fuel onto section “A” . Solenoid valve control When the solenoid valve is energized. The cone of the needle is therefore subject to the rail pressure. The control chamber is subject to the rail pressure. As soon as Ff > Fo. The fuel contained in the control chamber is expelled through the discharge orifice known as the Spill Orifice (SPO). There is no injection. The force applied by the fuel to the needle is: Fo = A * Prail Since Ff > Fo. FUEL SYSTEM ACTYON SM . While static. the needle is held in the closed position. the needle remains held against its seat and there is no injection. the nozzle produces no pressure drop.2006.

this pressure drop is zero.2006. End of injection As soon as the solenoid valve is de-energized. When the pressure in the control chamber becomes higher than the pressure applied to the needle’s cone. the injector’s needle remains lifted.07 41 GENERAL Start of injection As soon as Ff < Fo. The pressure applied to the cone of the needle (the injection pressure) is therefore lower than the rail pressure. When the rail pressure is at its highest (1600 bar). this pressure drop exceeds 100 bar. The pressure in the control chamber cannot exceed the rail pressure. the injection stops. or in other words: Pcontrol < Prail * A/S The needle lifts and injection begins. fuel circulation is established to feed the injector. the thrust section areas situated on either side of the needle is therefore to apply different pressures to each of these faces.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Since the needle is open. Prail * S (Prail P) * S When static. As long as the valve is open. CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . the valve closes and the control chamber is filled. This pressure limitation is achieved by the NPO orifice which produces a pressure drop when fuel is passing through it. so it is therefore necessary to limit the pressure applied to the needle’s cone. The passage of the fuel through the inlet orifice of the injector (similar to a nozzle) leads to a pressure drop which depends on the rail pressure. When injection begins.

600 bar (max. Operating pressure limit: 2.100 bar Maximum fuel volume at each injector cycle 1. Main Injection 5 mm3 85 mm3 (within 200 ~ 1.600 bar) Main injection Pilot injection Small injection separation 3. 200 (duration between the end of pilot injection and start of main injection) 4. Pilot Injection 2. Minimum operating pressure: start injection over 100 bar 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Small injection separation: min.2006. Opening Delay : Delayed time from applying operating voltage to start of injection 5.42 07 Fuel Pressure Fuel pressure 1. Maximum operating pressure: 1. operating pressure in normal conditions) 3. Adjustment of feedback injection volume: C2I 10% signal amplitude Opening Delay Definition Injection rate Injector drive pulse 10% signal amplitude Time ( ) FUEL SYSTEM ACTYON SM .

5 A HOUSING ASSY .0 A Through hold current = 7. The air gap between the valve and the coil is reduced and the electromagnetic force to be applied to the valve can thus be reduced.0 A Through pull current = 7. The call current is higher than the hold current because during the hold phase. The low current allows the Joule effect losses in the ECU and injector to be reduced.24 I 2RT CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .5 A Time Pull-in period Hold period 1.03 SENSOR CONTROL FUEL COOLING The control current of the coil takes the following form: LUB EXHAUST I N T A K E Peak hold current = 22. 2.2006. NOTE • Joule Effect: Heat capacity (H) = 0. It is no longer necessary to overcome the valve inertia.07 43 GENERAL Injector Control Current Peak pull current = 22.

This injection is for reducing the engine noise and vibration. the fuel injection volume and injection timing is calibrated according to fuel pressure and fuel temperature.2006. In other words. Basic values for pilot injection are adjusted according to the coolant temperature and intake air pressure. a small amount of fuel is injected to help proper combustion. Pilot injection Before starting main injection. Main Injection In above two step injection. Cylinder pressure (p) Needle lift (k) Cylinder pressure (p) Angle of crankshaft <Characteristic Curve of Discharge without Pilot Injection> Angle of crankshaft <Characteristic Curve of Discharge with Pilot Injection> FUEL SYSTEM ACTYON SM .44 07 Fuel Injection Other than conventional diesel engine. it makes the pressure increase in combustion chamber during combustion smooth to reduce the engine noise and vibration (suppressing the surging). common diesel engine use two steps injection as follows: 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN Needle lift (k) . Pilot Injection 2.

03 . then calculates the injection volume. engine rpm. coolant temperature. 45 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY The main injection determines the pilot injection has been occurred. Ignition pressure without pilot injection Angle of crankshaft <Characteristic Curve of Combustion Chamber Pressure During Pilot Injection> CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM . Pressure 1. intake air temperature and atmospheric pressure are basic date to calculate the fuel injection volume in main injection.2006. Ignition pressure with pilot injection 2a.07 Main injection Actual output from engine is achieved by main injection. Main injection 1a. Accelerator pedal sensor. Pilot injection 2.

NOTICE • Plug the openings of the injectors with sealing caps. • Pull the dropped washer out from the engine with a special tool. Installation Notice 9 ± 1. Installation Notice Tightening torque 40 ± 4 Nm NOTICE • Replace the fuel pipes with new ones. 3. Disconnect the injector holder. Remove the injectors with a special tool. Remove the relevant connector for the injector. Unscrew the injector holder bolts.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 7. holder bolts and fuel supply pipes with new ones. Unscrew the bolts and remove the fuel pipes. 5. Install in the reverse order of removal.0 Nm Tightening torque 190° + 10° Replace the bolts with new ones. Disconnect the injector return hose.46 07 Removal and Installation Preceding Work: Removal of engine cover 1. • Plug the openings of the common rail with sealing caps. FUEL SYSTEM ACTYON SM . NOTICE • Replace the copper washer.2006. 2. 6. 4. NOTICE • Plug the openings with sealing caps.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006.07 47 GENERAL Circuit Diagram CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .

48 07 FUEL SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .2006.07 49 GENERAL CHANGED BY EFFECTIVE DATE AFFECTED VIN FUEL SYSTEM ACTYON SM .

............................ 2 Engineecu and other components .......................................................5 Fuel pressure control ........ 20 ............................................................ 4 ENGINE CONTROL SYSTEM .. 12 Fuel flow control ..............................................................3 Side view ............................................................................ENGINE CONTROL SYSTEM 08 TABLE OF CONTENTS SENSORS FOR DIAGNOSIS ...............................................2 Top view ............................................................ 13 Individual Injector calibration (C2I) ............................................................................................................................................................................... 5 ECU .................. 11 Fuel injection control ..... 18 Minimum drive pulse (MDP) learning ...........................................................

2 08 ACTYON SM .2006.03 Coolant inlet hose Coolant Port Coolant reservoir ENGINE CONTROL SYSTEM Return hose Coolant outlet port Coolant outlet hose Engine Oil Filter and Cooler Oil cooler Oil Filter cap SENSORS FOR DIAGNOSIS ENGINE ECU AND OTHER COMPONENTS Radiator Oil pressure switch Water Pump and Pipe Cylinder block Thermostat (inside) CHANGED BY EFFECTIVE DATE AFFECTED VIN Oil cooler Radiator Oil filter Reservior (coolant inlet hose) .

2006.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Fuel Pressure Sensor Booster Pressure Sensor .08 3 GENERAL TOP VIEW Injectors (4 EA) Glow Plugs (4 EA) CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM .

4 08 SIDE VIEW Coolant Temperature Sensor Knock Sensors (1 EA) Fuel Temperature Sensor Fuel Pressure Regulating Valve Crankshaft Position Sensor ENGINE CONTROL SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

engine ECU calculates driver’s demand (position of the accelerator pedal) and then controls overall operating performance of engine and vehicle on that time. the ECU uses signals from coolant temperature and air temperature sensor.08 5 GENERAL ENGINE CONTROL SYSTEM ECU According to input signals from various sensors. booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection start and pilot injection set values and to various operations and variables.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . Especially. the engine ECU controls the air-fuel ratio by recognizing instant air volume changes through air flow sensor to pursue low emission gases (EGR valve control). Furthermore.2006. ECU receives signals from sensors through data line and then performs effective engine air-fuel ratio controls based on those signals. Air flow (hot film) sensor detects intake air volume and then transmits to ECU. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that generated by variable resistance changes in accelerator pedal sensor.

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Description Fuel filter water detection sensor RPM signal output Knock sensor signal (#2) Knock sensor signal (#1) Knock sensor ground (#1) Auto cruise result signal ACC 1 sensor ground CAN. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 K-LINE #1 K-LINE #2 Vehicle speed sensor signal input IG 1 Clutch pedal switch Auto cruise acceleration signal ACC 2 sensor signal Engine ground Rail pressure sensor signal Rail pressure sensor ground Auto cruise OFF Auto cruise safety switch A/C pressure signal Fuel filter water detection warning lamp Remote starter output Glow plug control Glow plug warning lamp ACC 2 sensor ground ABD signal ECU power hold relay Description Engine ground Engine ground Main power (IG 1) Main power (IG 1) Main power (IG 1) Rail pressure sensor power supply Pin No.2006.6 08 Pin No.H1 ACC 2 sensor power supply Brake lamp switch Vehicle speed indication lamp Preheater #1 Preheater #2 Knock sensor ground (#2) HFM sensor (air temperature sensor) Engine ground Auto cruise deceleration signal ACC 1 sensor signal ACC 1 sensor power supply CAN -LO A/C cycling pressure switch Brake pedal switch Trip computer CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM .03 .

79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Booster pressure sensor signal Booster pressure sensor ground Waste gate actuator EGR valve Crankshaft position sensor (+) HFM sensor (power supply) IMV (fuel pressure regulating valve) Engine ground A/C relay Cooling fan LOW Cooling fan HIGH Crankshaft position sensor (-) HFM sensor (air mass sensor) HFM sensor (ground) 7 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Description Pin No. 4) Injector ground (#2.2006. 5) CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . 3.08 Pin No. 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 Injector #5 Injector #2 Blower switch Description Coolant temperature signal Coolant temperature sensor ground Camshaft position sensor signal Camshaft position sensor ground Engine check warning lamp Booster pressure sensor power supply Fuel temperature sensor signal Fuel temperature sensor ground Camshaft position sensor power supply Immobilizer Engine check warning lamp Injector #1 Injector #4 Injector #3 Injector ground (#1.03 .

A/C signal. For example. engine warning light) Preheater (auxiliary heater) K . Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure and activates injector solenoid valve to control the fuel injection period and injection timing. Operating temperature range of ECU is normally -40 ~ +85°C and protected from factors like oil. Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-current-phase and then the injectors should work very correctly under every working condition. improve fuel economy and enhance safety. there are EGR.8 08 ECU Inputs·Outputs Inputs Control Output Booster pressure sensor Atmospheric pressure sensor (Built-in ECU) Air flow sensor (HFM) Coolant temperature sensor Fuel temperature sensor Fuel pressure sensor Fuel filter water sensor Knock sensor crankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal (IG. To control the fuel volume precisely under repeated injections. booster pressure control.line CAN communication Self-diagnosis Structure and Function of ECU Function of ECU 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. high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages. A/C compressor) Injector EGR system Fuel pressure regulating valve (IMV) E C U Electrical fan control (Low/High-speed) A/C compressor relay Glow plug relay Immobilizer Warning lights (Water warning light. autocruise (export only) and immobilizer and adopted CAN communication to exchange data among electrical systems (automatic T/M and brake system) in the vehicle fluently. Auxiliary function of ECU has adopted to reduce emission gas. glow plug indicator light. so controls various actuators in response to engine changes. water and electromagnetism and there should be no mechanical shocks. brake. comforts and conveniences.2006. ENGINE CONTROL SYSTEM ACTYON SM . clutch.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . And Scanner can be used to diagnose vehicle status and defectives.

Controls by operating stages : To make optimum combustion under every operating stage. 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. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . 2. Starting injection volume control : During initial starting.03 . injecting fuel volume will be calculated by function of temperature and engine cranking speed. ECU should calculate proper injection volume in each stage by considering various factors. 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. 3.08 9 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Control Function of ECU 1.2006.

5. Remove the ECU bracket nuts.10 08 ECU . 2. Flip up the front passenger’s seat and remove the ECU cover nuts.Removal and Installation 1. For immobilizer equipped vehicle. 4. Backup the below data with Scan-i when replacing the ECU. Unscrew the ECU connect bolt and remove the ECU assembly. 1) Current ECU data 2) Vehicle Identification Number (VIN) 3) Variant coding data 4) Then. 3. additional coding operation is necessary.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . input the data into new ECU. Install in the reverse order of removal.2006. ENGINE CONTROL SYSTEM ACTYON SM .

2. Rail pressure is controlled by closed loop regulation of IMV. 1.03 SENSOR CONTROL FUEL COOLING Fuel Pressure Control LUB EXHAUST I N T A K E HOUSING ASSY . the nozzle’s penetration will be excessive and part of the fuel will be sprayed directly onto the sides of the cylinder. current is reduced so that the fuel sent to the high pressure pump is increased. A special pressure demand is necessary in order to obtain the additional flow required during starts. This demand is determined according to injected fuel and coolant temperature. 2. Controls IMV to make the rail pressure to reach to the required value. Fuel pressure is corrected according to air temperature. So there occurs smoke and damages engine durability. A mapping system – open loop – determines the current which needs to be sent to the actuator in order to obtain the flow demanded by the ECU. coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving. If the pressure is lower than the demand. causing incomplete combustion. 2. The closed loop will correct the current value depending on the difference between the pressure demand and the pressure measured. Flow demand IMV current Open Engine speed IMV Rail pressure demand Error PIG governor Current Correction Measured rail pressure CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . When engine speed and load are high : The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize combustion. If the pressure is higher than the demand. 1. Determines rail pressure according to engine operating conditions.08 11 GENERAL FUEL PRESSURE CONTROL Fuel Pressure Control Elements Pressure control consists of 2 principle modules. 1. The aim is to adapt the injection pressure to the engine’s requirements.2006. Pressure in the fuel rail is determined according to engine speed and load on the engine. If injection pressure is too high. When engine speed and load are low : The degree of turbulence is low. current is increased so that the fuel sent to the high pressure pump is reduced.

2006. 4. When the EGR rate increases. 1. This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the pressure demand. During the starting phase. the timing advance must be sufficient to allow the combustion to begin correctly. When the engine is warm. To do this. The elements are.12 08 FUEL INJECTION CONTROL Fuel Injection Control Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors. 3. A first correction is made according to the air and coolant temperatures. 5. Injection volume 3. This correction makes it possible to adapt the timing to the operating temperature of the engine. This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation. Pilot injection timing control The pilot injection timing is determined as a function of the engine speed and of the total flow. 2. A third correction is made according to the coolant temperature and the time which has passed since starting. This correction allows the pilot injection timing to be adapted to the operating temperature of the engine. This correction allows the injection timing advance to be increased while the engine is warming up (initial 30 seconds). the injection timing advance must in fact be increased in order to compensate for the fall in termperature in the cylinder. ENGINE CONTROL SYSTEM ACTYON SM . A fourth correction is made according to the pressure error. the pilot injection timing is determined as a function of the engine speed and of the coolant temperature.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude. special mapping is used to determine the injection timing advance as a function of the engine speed and of the water temperature. The elements are. 1) a reference tooth (CTP) 2) the delay between this tooth and the start of the pulse (Toff) 3) the pulse time (Ton) Main injection timing control The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow. When the engine is cold. During starting. Injection control consists as below. Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver. 1. This correction is used to adapt the timing advance as a function of the atmospheric pressure and therefore the altitude. This requirement only concerns the starting phase. The purpose of this correction is to reduce the misfiring and instabilities which are liable to occur after a cold start. A first correction is made according to the air and coolant temperatures. 1. Injection timing 2. A second correction is made according to the atmospheric pressure. the injection timing must be retarded in order to position the start of combustion close to the TDC. A fifth correction is made according to the rate of EGR. the timing can be retarded to reduce the combustion temperature and polluting emissions (NOx). since once the engine has started the system must re-use the mapping and the corrections described previously. A second correction is made according to the atmospheric pressure. 2.

the antagonistic torque (engine brake) transmitted to the drive wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels locking. Once the engine changes to normal operation. the vehicle’s speed falls below the value required by the driver. the system uses the total fuel. As soon as the injected fuel becomes lower than the flow limit determined by the ASR trajectory control system. The main fuel is obtained by subtracting the pilot injection fuel from the total fuel. 2. : The driver’s demand is compared with the value of the minimum flow determined by the idle speed controller.2006. The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . The system therefore chooses the smaller of the two values in order to avoid any loss of control of the vehicle during accelerations. This value is then compared with the lower flow limit determined by the ASR trajectory control system. This strategy allows the flow to be limited as a function of the operating conditions of the engine. This strategy leads to a fuel correction which is added to the total fuel of each cylinder. the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand. The correction is determined before each injection as a function of the instantaneous engine speed. As soon as the injected fuel becomes higher than the fuel limit determined by the ASR trajectory control system. the system uses the supercharged fuel. 2. As soon as the main fuel falls below this value. It is therefore the greater of these 2 values which is retained by the system. A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the engine. the engine torque transmitted to the wheels exceeds the adhesion capacity of the vehicle and there is a risk of the drive wheels skidding. A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. When the driver release the pedal. The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed during transient conditions. the idle speed controller takes over to determine the minimum fuel which must be injected into the cylinder to prevent the enigne from stalling. This value is then compared with the fuel limit determined by the ASR trajectory control system. When the driver depress the pedal. 1. This value is then compared with the flow limit determined by the cruise control. The pilot flow represents the amount of fuel injected during the pilot injection. it is his demand which is taken into account by the system in order to determine the fuel injected. The system therefore chooses the greater of these 2 values in order to maintain the speed at the required level. This valve is then compared with the flow limit determined by the flow limitation strategy.08 13 GENERAL FUEL FLOW CONTROL Main Flow Control The main flow represents the amount of fuel injected into the cylinder during the main injection. The system thus chooses the greater of these 2 values (main flow & pilot flow) in order to prevent any loss of control of the vehicle during a sharp deceleration. Until the stating phase has finished. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . As soon as the injected fuel becomes lower than the flow limit determined by the cruise control. 1. The system therefore chooses the smaller of these 2 values in order to protect the engine.

It is calculated as a function of the pedal position and of the engine speed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. ENGINE CONTROL SYSTEM ACTYON SM . A mapping determines the maximum fuel which can be injected as a function of the driver demand and the rail pressure. it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle. The driver demand is then corrected according to the coolant temperature. The system compares the driver demand with this limit and chooses the smaller of the 2 values. This correction is added to the driver demand.14 08 Driver’s request Idle speed controller ASR traction control Cruise control Flow limit Speed limiter ASR traction control Engine status Anti-oscillation strategy Overflow Programmed engine stop Main flow < controllable min.flow Pilot injection flow Main flow request 0 Driver Demand The driver demand is the translation of the pedal position into the fuel demand. Since the flow is proportional to the injection time and to the square root of the injection pressure. The driver demand is filtered in order to limit the hesitations caused by rapid changes of the pedal position.

000 rpm. 2) Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to 3. 4. The first module determines the required idle speed according to: 1) The operating conditions of the engine (coolant temperature. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool. The system chooses the lowest of all these values. The flow limitation depending on the filling of the engine with air is determined according to the engine speed and the air flow. The flow limitation depending on the atmospheric pressure is determined according to the engine speed and the atmospheric pressure. 5) It is possible to increase or to reduce the required idle speed with the aid of the diagnostic tool. It allows the maximum torque delivered by the engine to be limited.08 15 GENERAL Idle Speed Controller The idle speed controller consists of 2 principal modules: 1. 3. others) 3) The battery voltage 4) The presence of any faults liable to interface with the rail pressure control or the injection control. This limitation allows smoke emissions to be reduced during stabilized running. A correction depending on the coolant temperature is added to the flow limitation. and depending on the gravity of the fault.000 rpm. the engine speed and the time which has passed since starting. 2. A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system. In this case. 3) Reduce fuel logic 3: Limits the engine speed to 2. In this case. The full load flow curve is determined according to the gear engaged and the engine speed. Superchager Flow Demand The supercharge flow is calculated according to the engine speed and the coolant temperature. The second module is responsible for providing closed loop control of the engine’s idle speed by adapting the minimum fuel according to the difference between the required idle speed and the engine speed. This correction makes it possible to reduce the mechanical stresses while the engine is warming up. Flow Limitation The flow limitation strategy is based on the following strategies: 1. It allows smoke emissions to be reduced when driving at altitude. The correction is determined according to the coolant temperature. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . the accelerated idle speed is activated to prevent the engine from stalling when operating in degraded mode.2006. A correction depending on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during cold starts. air conditioning. 2. the system activates: 1) Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . gear engaged) 2) Any activation of the electrical consumers (power steering.

Its position is such that only the combustion noises produced by the pilot injection are measured . The principle of use of the accelerometer is based on the detection of the combustion noises. Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. the pilot flow is determined on the basis of the engine speed and the coolant temperature. The difference between these two instantaneous speeds is then calculated. Detection of an injector which has stuck closed The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The pilot injection resetting principle therefore consists of determining the MDP. Accelerometer Strategy Resetting the pilot injection The accelerometer is used to reset the pilot injection flow in closed loop for each injector. The sensor is positioned in such a way as to receive the maximum signal for all the cylinders. This method allows the correction of any injector deviations over a period of time. However. 2. 1. 1. This amount is determined according to the engine speed and the total flow. It is therefore placed just before the main injection. 3. A first correction is made according to the air and water temperature. known as the ratio. This correction is used to adapt the pilot flow according to the atmospheric pressure and therefore the altitude. it is possible to efficiently correct the pilot flows. the ignition time decreases because the end-of-compression temperature is higher. This correction allows the pilot flow to be adapted to the operating temperature of the engine. the time to be added to the main injection pulse for the different injectors is determined. The pilot flow can therefore be reduced because there is obviously less combustion noise when the engine is warm.16 08 Pilot Flow Control The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This variable. The raw signals from the accelerometer are processed to obtain a variable which quantifies the intensity of the combustion. For each injector. When the engine is warm. The second window is used to measure the intensity of the pilot combustion. in other words the pulse corresponding to the start of the increase in value of the ratio (increase of vibration due to fuel combustion). this time is calculated according to the initial offset of the injector and the instantaneous speed difference. The accelerometer does not allow any evaluation of the quantity injected. On the basis of this information. 2. a fault is signaled by the system. In this case. the pulse value will be measured when the injector starts injection and this pulse value is called the MDP (Minimum Drive Pulse). consists of the ratio between the intensity of the background noise and the combustion noise. 1. 2. ENGINE CONTROL SYSTEM ACTYON SM . A second correction is made according to the atmospheric pressure. The difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold. A first window is used to establish the background noise level of the accelerometer signal for each cylinder. Finally. This window must therefore be positioned at a moment when there cannot be any combustion. During starting. The instantaneous speeds on two successive injections are first calculated.

An increase in the ratio can be the consequence of various causes: 1. Fuel leak in the cylinder If the ratio becomes too high. When the engine is idling. The first MDP value is provided by the C2I. Pilot injection too strong 2. a fault is signaled and the engine is shut down. but otherwise a fault is signaled to indicate a sensor failure.08 Cylinder pressure Needle lift 17 GENERAL Major pilot injection Ratio Minor pilot injection No pilot injection No injection Detection of leaks in the cylinders The accelerometer is also used to detect any injector which may have stuck open. If the ratio remains high despite these interventions. the detection window is set too low for the combustion caused by the main injection. this shows that a real leak is present. The ratio therefore increases considerably in the detection window. It is this increase which allows the leaks to be detected. high load and small leak). Each resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector. If there is a leak in the cylinder. This combustion is set off at about 20 degrees before TDC and before main injection. the etection must be extremely robust. the new minimum pulse value replaces the value obtained during the previous resetting. The detection principle is based on monitoring the ratio. the strategy initially restricts the pilot injection flow and retards the main injection.03 SENSOR CONTROL FUEL COOLING This is done periodically under certain operating conditions. It is based on detection of the combustion. LUB EXHAUST I N T A K E HOUSING ASSY . the accumulated fuel self-ignites as soon as the temperature and pressure conditions are favorable (high engine speed. Detection of an accelerometer fault This strategy permits the detection of a fault in the sensor or in the wiring loom connecting the sensor to the ECU. Because of the severity of the recovery process (engine shut-down). The recovery modes associated with this fault consist of inhibition of the pilot injection and discharge through the injectors. this shows that the accelerometer is working properly.2006. Main combustion offset 3. The threshold beyond which a fault is signaled is a percentage of the maximum possible value of the ratio. When the resetting is finished. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . If the ratio increases.

Delivery (mm3/st) Drive pulse (µsec) Common rail injectors are very accurate components. the friction between moving parts and electromagnetic field level are different from one injector to the other. It is impossible to control efficiently the engine with such a dispersion between the different injectors. The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial hydraulic map of the injector. It is necessary to add a correction that allows injecting the demanded fuel delivery whatever the initial hydraulic characteristics of the injector is. So. This high level of accuracy requires very low machining tolerances (few ).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. So. ENGINE CONTROL SYSTEM ACTYON SM . the pulse should be corrected according to characteristics of each injector. It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having the following shape.18 08 INDIVIDUAL INJECTOR CALIBRATION (C2I) Injected fuel is proportional to square root of injection time and rail pressure.5 to 100 mg/str under pressure varying from 150 to 1600 bar. due to the machining dispersion. Nevertheless. the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg/str from one injector to the other. They are able to inject fuel delivery between 0. the loss of charge through the functional orifices.

1. to make the most optimal fuel injection. If C2I is not input. When replacing the injector. characteristics of each injector. 19 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY C2I consists of 16-digit. cannot accelerate the vehicle even when the accelerator pedal is depressed. When ECU is replaced. 2.03 . C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector’s C2I value. If not. composed of numbers from 1 to 9 and alphabets from A to F. engine power drops and occurs irregular combustion.08 C2I is composed of models on these characteristics of injectors.2006. C2I Number (16 digits) C2I value For coding of C2I. refer to “Diagnosis” section CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . ECU remembers C2I. C2I code of every injector should be input.

1 Fault MDP learning on injector No. 5 Diagnosis • Check each injector ENGINE CONTROL SYSTEM ACTYON SM . 1 ~ 2 mm/str.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . so precise control of the injector can be difficult if it gets old.500 rpm 10 V < MDP < 16 V 0 < fuel temperature < 80 °C 5 seconds Trouble Codes Trouble code P1171 P1172 P1173 P1174 P1175 Description Fault MDP learning on injector No. 4 Fault MDP learning on injector No. can correct pilot injections effectively.7 bar > 2.2006. So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors. Through MDP controls.20 08 MINIMUM DRIVE PULSE (MDP) LEARNING When the pulse value that the injector starts injection is measured. it is called mininum drive pulse (MDP). Pilot injection volume is very small. 3 Fault MDP learning on injector No. 2 Fault MDP learning on injector No. Learning Conditions Coolant temperature Vehicle speed Intake manifold pressure Engine speed Battery voltage Fuel temperature Initial MDP learning on each injector > 75°C > 50 Km/h (over 5 seconds) > 0.

At this time. 1 and 2 sensors are defective.1 (ACC 1) sensor signal determines fuel injection volume and injection timing during driving. • For detailed information. LUB EXHAUST I N T A K E HOUSING ASSY . the trouble code of “P-1124 Accelerator pedal sensor stuck” is stored into ECU. 2 (ACC 2) sensor signal compares whether the No.03 SENSOR CONTROL FUEL COOLING Accelerator pedal sensor changes accelerator pedal position into electrical signal and then sends to ECU to let know the driver’s demand. 1 sensor signal value is correct.2006. There are 2 sensors in the accelerator pedal sensor.08 21 GENERAL Accelerator Pedal Sensor <Location of Accelerator Pedal Sensor> <When Depressing the Accelerator Pedal and Brake Pedal Simultaneously> If accelerator pedal No. and acceleration responses are getting bad and engine rpm hardly increases. Accelerator pedal No. it will be resumed to normal condition. NOTICE • When depressing the accelerator pedal and brake pedal simultaneously while driving. refer to “Diagnosis” section in this manual. If depressing the accelerator pedal over 3 times. and accelerator pedal No. the acceleration response will be diminished abruptly and cannot drive with over 70 km/h even though depressing the accelerator pedal to its end. ECU remembers defect code. 2 4 Signal 1 3 A/PEDAL SENSOR Ground 1 6 Signal 2 5 Ground CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM .

Temperature (°C) 20 50 80 120 NTC 1 Resistance (Ω) Ω 2. then combusts very well. controls electrical fan and A/C compressor to protect the engine. 3. 2.22 08 Coolant Temperature Sensor Temp.2006. Resistance <Coolant Temperature Sensor> <Output Characteristics of Coolant Temperature Sensor> Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU. 1. And detects engine overheating for fuel volume reduction to protect the engine. controls fuel volume to correct idle speed. if engine temperature is too low. However. So the sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU to increase the fuel volume during cold start for better starting.062 1. the fuel injected as foggy state forms big compounds causing incomplete combustion. If the fuel injected into the engine through injector has more turbulence. NTC resister has characteristics that if the engine temperature rises.449 826 321 123 NTC 2 Resistance (Ω) Ω 6. When engine is overheated.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Sends information for emission control.800 638 200 Signal Auto amp Ground <Circuit Diagram of Coolant Temperature Sensor> ENGINE CONTROL SYSTEM ACTYON SM . When engine is cold. ECU functions as below with coolant temperature sensor signals. the resistance lowers so the ECU detects lowering signal voltages.

The other function is determining EGR operation stops.03 SENSOR CONTROL VO VO VS P = VS x ( P x 0. Output voltage calculation Voltage (V) Pressure (bar) <Output Characteristics of Sensor> CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM .08 23 GENERAL Boost Pressure Sensor <Location of Boost Pressure Sensor> Not using terminals <Boost Pressure Sensor> Boost pressure sensor uses piezo element and uses only 3 terminals out of 6. 1.2006.04) : Output voltage : Supply voltage : Applying voltage FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY . It sets fuel injection timing and corrects fuel injection volume according to atmospheric pressure.0.004 .

35 V) TR 7ms 10 Nm Ground REF 5V SIG <Circuit Diagram of Booster Pressure Sensor> ENGINE CONTROL SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . consuming current Responsibility Tightening torque 20 ~ 250 KPa .35 V 10 mA (supply voltage at 5.2006.40 ~ 125°C 4.24 08 Performance proofing pressure range Performance proofing temperature range Storage proofing temperature range Performance proofing supply voltage Max.40 ~ 110°C .85 ~ 5.

speed 4.03 . Controls cooling fan 3. ECU uses these signals to calculate the vehicle speed and meter cluster shows signals as vehicle speed. Function 1. Limits idle control correction duty range 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN ENGINE CONTROL SYSTEM ACTYON SM . Used for exhaust gas control mode CAN communication ABS or ESP control unit <Circuit Diagram of Vehicle Speed Sensor> Barometric Sensor It is built-in the ECU and detects absolute pressure of atmosphere to correct fuel injection timing and injection volume according to altitude.2006. Cuts fuel injection if exceeds max.08 25 GENERAL SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY Vehicle Speed Sensor The ABS or ESP control unit sends the vehicle speed signals to ECU. Controls vehicle shifting feeling 5.

equipped for export). These switch signals are related with accelerator pedal sensor operations and used to control the fuel volume during braking. engine ECU recognizes as normal brake signals.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Another different function is canceling auto cruise function if equipped (auto cruise control . Clutch pedal switch (NO) Engine ground 2 1 <Clutch Pedal Switch Circuit> ENGINE CONTROL SYSTEM ACTYON SM .2006. Brake pedal switch (NC) IGN 1 Brake lamp switch (NO) <Brake Switch Circuit> Clutch pedal switch Clutch pedal switch is installed on the upper of the clutch and sends clutch pedal operations to engine ECU. It means there are no problems in operating accelerator pedal when the brake pedal is operated but the fuel volume reduces if operates brake pedal while the accelerator pedal is depressed. It has dual structure with 2 combined switches and there are brake switch 1 and 2. When these 2 signals are input.26 08 Other switches Brake switch Brake switch detects brake pedal operations and then sends to engine ECU. It means it corrects fluctuation happens during gear shifting. Contact type switch allows engine ECU to recognize the shifting points to correct the fuel volume.

................... 2 Sensors in engine compartment ........... 5 Circuit diagram of starting and alternator ...........................................................3 Specifications ..............................4 Circuit diagram of preheating system ............................... 7 General .......................................................................... 7 Alternator ................................................................................................. 6 TROUBLE DIAGNOSIS ..................................... 9 Starter ................................................................................................... 10 .........................................................2 Electric devices in engine compartment .................................ELECTRIC DEVICES AND SENSORS 09 TABLE OF CONTENTS ELECTRIC DEVICES AND SENSORS........

2006.2 09 ELECTRIC DEVICES AND SENSORS SENSORS IN ENGINE COMPARTMENT Booster Pressure Sensor Fuel Pressure Sensor Camshaft Position Sensor Oil Pressure Switch Coolant Temperature Sensor Crankshaft Position Sensor Fuel Temperature Sensor Knock Sensor (1 EA) ELECTRIC DEVICES AND SENSORS ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

2006.09 3 GENERAL ELECTRIC DEVICES IN ENGINE COMPARTMENT Alternator Capacity PTC equipped vehicle : 12V .115A Glow Plug Air Conditioner Compressor Starter CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC DEVICES AND SENSORS ACTYON SM .140A FFH equipped vehicle : 12V .03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .

2 160 4500 1700/430 18 55 0.2006.90AH 160 Seized type 11.5 2 7 MF 12V .5 Parallel Max.6 12.1 21.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .4 09 SPECIFICATIONS Description Starter Type Output power No load test ≅ 12 volts Drive pinion speed at no load Drive pinion speed at load Brush length Armature diameter Armature run-out Segment groove depth Alternator Type Output voltage / current Unit Kw A rpm rpm/A mm mm mm mm V/A Specification WP220 2. 60 (at -35°C) Regulator type Regulating voltage Brush Length Quantity Wear limit Battery Type Capacity Glow plug Reserved capatity Type Rated voltage Circuit connection Preheating time V mm mm AH RC sec ELECTRIC DEVICES AND SENSORS ACTYON SM .7 CS128D PTC equipped vehicle: 12V-140A FFH equipped vehicle: 12V-115A ← 14.

03 SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY .09 5 GENERAL CIRCUIT DIAGRAM OF PREHEATING SYSTEM PREHEATING CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC DEVICES AND SENSORS ACTYON SM .2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .6 09 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR STARTING & CHARGING ELECTRIC DEVICES AND SENSORS ACTYON SM .2006.

• Repair or replace the battery cable. • Battery run down. • Replace the ignition switch. • Open ground circuit. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . • Battery. • Replace the ignition switch. • Faulty wiring harness. Starter motor does not stop • Faulty starter motor. Battery discharge • Loosen the generator drive belt. • Replace the ignition switch. but too slow • Low battery voltage. • Repair the ground short. • Repair or replace the battery cable. corroded.09 7 GENERAL TROUBLE DIAGNOSIS GENERAL Condition No crank Probable Cause • Low battery voltage. or damaged. Charging indicator lamp does not put out lights after starting the engine • Battery cable is corroded or damaged. • Repair or replace the battery cable. Battery over charging • Generator voltage regulator faulty • Voltage detecfing wiring faulty CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC DEVICES AND SENSORS ACTYON SM . • Repair the open or a short circuit. Starter motor running. • Faulty starter motor. corroded. • Ground short. • Battery cable is loose. • Battery cables are loose. Correction • Charging the battery or replace the battery. • Connected circuit is open. • Replace the flywheel. • Faulty ignition switch. or damaged. but not cranking • Broken the flywheel ring gear. • Generator ground circuit is open or a short. • Replace generator • Repair wiring Crank ok. • Replace the battery.2006. • Faulty starter motor or starter motor circuit is open. • Repair the open ground circuit. • Repair or replace the starter motor/starter motor circuit. • Charging the battery or replace the battery. • Adjust the belt tension or replace the belt. • Repair the wiring harness. • Adjust the belt tension or replace the belt. • The circuit is open or a short. • Repair or replace the starter motor. • Loosen the generator drive belt. • Faulty ignition switch. • Repair or replace the charging indicator lamp/fuse. • Replace the starter motor. • Repair the open circuit. • Repair or replace the starter motor.03 SENSOR CONTROL FUEL • Broken the clutch pinion gear or faulty starter motor. • Faulty ignition switch. • Repair the circuit. Charging indicator lamp does not work when the ignition switch on (engine does not work) • Charging indicator lamp is blown or fuse is blown.

8 09 Symptom Cause • Ignition coil faulty • Distributor (including optical sensor) faulty • Spark plug malfuntion • Ignition timing faulty (spark plug light is normal) Action • Replace ignition coil • Replace distribator (or sensor) • Replace spark plug or adjust clearance • Resetting valve timing • Replace spark plug or adjust clearance • Replace ignition coil • Resetting valve timing • Resetting valve timing Hard engine starting Unstable engine idling • Spark plug malfunction • Ignition coil faulty • Ignition timing faulty Enging acceralation malfunction • Ignition timing faulty ELECTRIC DEVICES AND SENSORS ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.

... Disconnect the negative battery cable............ 2..... Install in the reverse order of removal......... Remove the plug connection. Cooling fan 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC DEVICES AND SENSORS ACTYON SM . Bolt ...... Installation Notice Tightening torque 45 Nm 4......... Plug connection COOLING Removal and Installation 1....09 9 GENERAL ALTERNATOR 1... 45 Nm 3.. Unscrew the bolts and remove the alternator.....03 SENSOR CONTROL FUEL LUB EXHAUST I N T A K E HOUSING ASSY . 3.. Alternator 4...2006.........

. Starter 2.....................2006.................. 48 Nm ELECTRIC DEVICES AND SENSORS ACTYON SM ...................... Bolt ...........10 09 STARTER 1.............. 15 Nm 4.. Nut ........................................ Washer 3......03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .......

Disconnect the negative battery cable.2006. 2. Remove the upper and lower mounting bolts. Disconnect the starter terminal.09 11 GENERAL Removal and Installation 1. Install in the reverse order of removal. 5. CHANGED BY EFFECTIVE DATE AFFECTED VIN ELECTRIC DEVICES AND SENSORS ACTYON SM .03 SENSOR CONTROL FUEL 4. Lift up the vehicle and remove the front propeller shaft mounting bolts. COOLING LUB EXHAUST I N T A K E HOUSING ASSY . 3.

............................ 28 FUNCTION SELECTION ........................... 4 REPROGRAM ...............................SCAN-100 TABLE OF CONTENTS SCAN-100 GENERAL .......................................................................... 30 ................................................................................................................. 3 D-CARD DOWNLOAD ............................................ 3 SCAN LOAD ..................................... 8 ENTERING DIAGNOSIS PROCEDURES ...............................................

windows 98 also should be installed.03 ECU . Copy a given program.SCAN-100 3 SCAN SCAN-100 GENERAL SCAN LOAD 1. Screen Flow Description Make a directory ”SCANLOAD” in hard disk. In addition. the previous requirements should be satisfied in your computer. and execute a “setup.2006. Click the button the target directory. after finishing installing setup program. If the windows configuration is not set up. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . 2. Installation In order to install SCANLOAD. . and then follow the procedure of the below.exe”. Introduction This SCANLOAD program is designed to write an operating program to your program card of SCAN-100. Complete installing the windows. to install the program in Execute the program.

Inserting Program Card into SCAN-100 1. program card and data memory card. “PCMCIA” cards and memory capacities. Program card: Data memory card: Capacities of program card: This card contains the operation program of SCAN-100. Card Eject Button 5. ) side up and to the direction of arrow. Capacities of data memory card: It is able to extend its memory capacity up to 10MByte. RS-232 communication cable 4. DC Power Jack 3. Push this card all the way to the end. PC Terminal 2. Notches 1. And if the card is inserted in a wrong way. SCAN-100 has two kinds of PCMCIA card. Program Card 6. the card may not be set in the slot. Memory Card Slot 3. Program Card Slot 2. AC/DC Power Supply 2. Inserting program card : Insert the card with label(SCAN-100 program card ver. 2. PCMCIA card is consist of FLASH memory. etc. It is able to extend its memory capacity up to 16MByte. and its basic memory is 2MByte.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Hinged Body 4. a wave data.4 SCAN-100 D-CARD DOWNLOAD 1. DIAGNOSIS ACTYON SM . This is used for recording a traveling data. Connecting SCAN-100 to PC 1.

2006.SCAN-100 5 SCAN 3. Press “PWR” key after pushing a hotkey (“YES” + “NO” + “2”). CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Selecting Download Mode of SCAN-100 1. Connect communication port of PC to left input port of SCAN-100 by using a download communication cable. 2.03 ECU . Perform a SCANLOAD program. 3.

2006. Select the communication port connected to SCAN100. Basic screen of download mode. and click the button .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Click the button . DIAGNOSIS ACTYON SM .6 SCAN-100 4. in an initial screen. Perform Scanload Screen Flow Description Click the button . Select a file which you wish to write.

03 ECU . If the download is completed. if not. If the ID of a selecting file is same to the SCAN-100’s ID.2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Then you get a message.SCAN-100 7 SCAN Screen Flow Description Click the button . then it shows message. Write a selecting file to program card of SCAN-100. then is indicated.

. Refer to “SCANLOAD USER’S GUIDE” in supplied CD-ROM inside SCAN-100 kit box....... 2 2. R-CARD DATA VIEW (SCAN-100) . 6 STEP IV Reprogramming the ECU (SCAN-100 to ECU) 1. 7 DIAGNOSIS ACTYON SM .8 SCAN-100 REPROGRAM 1.. 6 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN ........ ECU REPROGRAM (SCAN-100 to ECU) .. R-CARD DOWNLOAD (PC to SCAN-100) ... Download the reprogramming data to the R-CARD (PC to R-CARD) STEP III 1.. (R-CARD reprogramming data) STEP II Update the D-CARD program..2006...... R-CARD DATA ERASE (SCAN-100) . Reprogramming Flow Chart STEP I Reprogramming data file provided from SYMC..... if necessary (PC to D-CARD) 1...

SCAN-100 9 SCAN 2. Connecting the SCAN-100 to PC 1. Check and see if the D-Card exist in the upper slot (Slot “A”) of SCAN-100.03 ECU . SCAN-100 AC/DC Power Supply 2. RS-232 Communication Cable 4. 3. DC Power Jack 3. PC Terminal CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . R-Card Download (PC to SCAN-100) 1.2006. Check and see if the R-Card exist in the lower slot (Slot “B”) of SCAN-100. 2.

1-1) If your SCAN-100 display above screen (fig. DIAGNOSIS ACTYON SM . Press the POWER ON the SCAN-100 and process the steps as below. please go to the next step.2006.1-1).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .10 SCAN-100 4. #1 #2 Select “1” #4 #3 #5 (Fig.

11 SCAN #7 6.EXE” file.2006. Select the file to be matched with your vehicle model and drag it onto the “KWPSEND.SCAN-100 5. Key-in the number of the COM PORT connected with SCAN-100 in the key board #8 CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .03 ECU .

SYN DI1742T$.2 WESTERN EUROPE (EURO III REGULATION) DS3742S$.3 NAG (A/T) CHAIRMAN 2.2 GENERAL AREA DS1742P$.12 SCAN-100 7. Repeat the Step 4 through Step 7 for downloading the reprogramming data of the other vehicle model.SYN DH1742P$.2006.2 WESTERN EUROPE (EURO III REGULATION) FILE NAME DT1742G$.SYN DZ1742G$. 1-2) while successful downloading #1 #2 Select “2” (Fig. The SACN 100 shows below figure (Fig.2 REXTON 2. 1 2 3 4 5 6 7 VEHICLE MODEL CHAIRMAN 2.SYN DH37427$. No.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2 GENERAL AREA REXTON 3.SYN S3 10 KYRON D20DT ECU HCC6AM01.SYN DG1742V$.SYN DF1742O$.SYN S1 9 MUSSO/KORANDO 3.3 BTRA (A/T) CHAIRMAN 2.8 CHAIRMAN 3.SYN DIAGNOSIS ACTYON SM . 1-2) 8.8 REXTON 3.SYN VEHICLE STATUS T1 Z1 F1 G1 I1 H1 H3 8 MUSSO/KORANDO 3.

SCAN-100 13 SCAN 3. ” key.2006. R-Card Data View (SCAN-100) This mode is to confirm data which is saved in R-CARD of SCAN-100. It is possible data scroll using the “ . ” key. It is possible data scroll using the “ . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . 4. R-Card Data Erase (SCAN-100) This mode is to erase the data saved in R-CARD of SCAN-100 Input the number you want to erase directly or move the cursor to which you want to erase and press "ENTER" key.03 ECU .

ECU Reprogram (SCAN-100 to ECU) . Check the ECU S/W Number Next page DIAGNOSIS ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .14 SCAN-100 5. Check the vehicle to be reprogrammed. Connect the SCAN-100 to the diagnostic connector of the vehicle.DSL 1. 2. #1 #2 Select “1” #4 #3 after 1sec.2006.

Select “6” #6 Exit the ECU REPRORGRAMMING PROCEDURE after 1sec. Next page CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Not necessary.03 ECU .2006.SCAN-100 Preceding page S/W Number: HCC6A S/W Number: HCC63. HCC67 or HCC69 15 SCAN #5 If the S/W Number is HCC6A. already updated after 1sec.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.16 SCAN-100 Preceding page Select “1” #7 #8 ENTER “Yes” # 10 #9 ENTER Input the reprogramming date # 11 # 12 After Finish Next page DIAGNOSIS ACTYON SM .

SCAN-100 Preceding page 17 SCAN CAUTION • Take care that do not power off and disconnect the scan tool when the boot block is reprogrammed. you have to select No. you have to select No. 3 (Euro Ver. 1(Euro Ver. ECU can be damaged.) If the target vehicle has the manual transmission. If the target vehicle has the automatic transmission.2006.03 ECU # 13 .) Next page CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .) or No.4 (Non Euro Ver.2 (Non Euro Ver.) or No.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .18 SCAN-100 Preceding page A/T Vehicle M/T Vehicle # 14 A/T Vehicle M/T Vehicle # 15 # 16 Press “ESC” DIAGNOSIS ACTYON SM .

SCAN-100 Preceding page 19 SCAN With Immobilizer system => Press “ENTER” Without Immobilizer ECU System => Press “ESC” # 17 “Yes” # 18 “Yes” # 19 Next page CHANGED BY EFFECTIVE DATE AFFECTED VIN Next page DIAGNOSIS ACTYON SM .03 .2006.

2006.20 SCAN-100 Preceding page Preceding page # 20 “No” # 22 # 21 “ENTER” DIAGNOSIS ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

#1 #2 Select “1” after 1sec.GSL 1. ECU Reprogram (SCAN-100 to ECU) . Connect the SCAN-100 to the diagnostic connector of the vehicle.2006. #3 Check the “Vehicle Status” is H1 or h1 Next page Next page CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . 2. Check the vehicle to be reprogrammed.SCAN-100 21 SCAN 6.03 ECU .

DO NOT REPROGRAM !!! #5 Exit the ECU REPRORGRAMMING PROCEDURE Next page DIAGNOSIS ACTYON SM . start reprogram If the vehicle status is h1 (Small Alphabet).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.22 SCAN-100 Preceding page Preceding page #4 If vehicle status is H1 (Large Alphabet).

8 .2 ECU(RATIO) #9 #8 “ENTER” Confirm the P/N of ECU and Reprogramming Date ECU P/N .2 : 162 545 6232 Select “Yes” Start to Reprogram Select “No” Select the correct ECU version Next page CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .MUSSO/KORNAND 3.REXTON 3.2 : 162 545 7532 : 162 545 7332 : 162 545 7932 : 162 545 5532 Input the reprogramming date .REXTON 2.2006. ” key.CHAIRMAN 2.CHAIRMAN 3.8 . Select “Yes” 05] MUSSO / KORANDO 3.2 .SCAN-100 Preceding page 23 SCAN #6 #7 Select Vehicle It is possible data scroll using the “ .03 ECU .

24 SCAN-100 Preceding page # 10 # 11 After Finish (BOOT BLOCK REPROGRAM) CAUTION • Take care that do not power off and disconnect the scan tool when the boot block is reprogrammed. Error on boot block lead to replacement the ECU (S/W BLOCK REPROGRAM) Reprogram OK # 13 # 12 Press Any Key DIAGNOSIS ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . 25 SCAN CASE 2: Error when “The S/W Block” is reprogrammed.2006.03 ECU .SCAN-100 In Case of Unsuccessful (Not Good) CASE 1: Error when “The Boot Block” is reprogrammed.

DIAGNOSIS ACTYON SM . “YES” CASE 2: When Part Number(ECU S/W Type) is not same of ECU and selected data. “YES” When press “ESC” key. Return to main menu.26 SCAN-100 In Case of Reprogram not Allowed.2006. CASE 1: When ECU is already reprogrammed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

2 .03 ECU .8 .MUSSO/KORNAND 3.CHAIRMAN 2.SCAN-100 Read ECU Identification 27 SCAN Select “2” VEHICLE STATUS .2006.REXTON 2.CHAIRMAN 3.8 .2 : S1 Write VIN Select “3” Select “Yes” CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .REXTON 3.2 : F1 : G1 : I1 : H1 .

DIAGNOSIS ACTYON SM . Select “7] KYRON” and press “ SELECTION” screen.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .28 SCAN-100 ENTERING DIAGNOSIS PROCEDURES 1. Select “1] DSL D20DT" in [MODEL SELECTION] screen and press “ ”.2006. Select “1] DIAGNOSIS” and press “ MENU” screen. ” in “MAIN 2. ” in “CONTROL UNIT 4. ” in “VEHICLE 3. Select “1] ECU” and press “ SELECTION” screen.

The “FUNCTION SELECTION” screen is displayed.SCAN-100 5. 29 SCAN CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .03 ECU .2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . “NO TROUBLE DETECTED” message appears. 3.2006.30 SCAN-100 FUNCTION SELECTION Check the Trouble Code Preceding Work: Perform the “Entering Diagnosis Procedures” 1. if you press “ DIAGNOSIS ACTYON SM . then if you press “ ”: Displays the sensor data for the detected trouble (Freeze Frame Mode). The “DIAGNOSTIC TROUBLE CODEs” screen is displayed and it shows the trouble. ”: Displays the help tips for the detected trouble. 2. NOTE • If there is not any fault. When selecting a trouble code. Select “1] TROUBLE CODE” and press “ENTER” in “FUNCTION SELECTION” screen.

NOTE • You can freeze up to 5 items (*: selected items).03 ECU . 57 sensor data. Select the items you want to see and press “ key to freeze them. Select “2] DATA LIST” and press “ SELECTION” screen. ” in “FUNCTION 2. The screen shows approx.SCAN-100 31 SCAN Sensor Data Check Preceding Work: Perform the “Entering Diagnosis Procedures” 1.2006. 3. ” CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .

Select the item you want to see and press “ ”. the screen as shown in figure is displayed.2006.32 SCAN-100 Actuator Check Preceding Work: Perform the “Entering Diagnosis Procedures” 1. The screen shows 19 items. DIAGNOSIS ACTYON SM . if you select “02] GLOW PLUG” item and press “ ”.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Select “3] ACTUATOR” and press “ SELECTION” screen. For example. 3. ” in “FUNCTION 2.

6. The “ACTIVATING” message appears and the relay operation alarm sounds. ” key in CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . If you want to operate the glow plug relay.03 ECU . 33 SCAN 5. Scan-100 displays “GOOD”.SCAN-100 4. If you want to stop the operation press “ keyboard. If the system operates normally.2006. press “ ” key.

Fix the trouble and go back to “1] TROUBLE CODE” screen and check if the trouble has been changed to “H (History trouble code)” code. Select “1] TROUBLE CODE” and press “ “FUNCTION SELECTION” screen. DIAGNOSIS ACTYON SM . H = History trouble 3. The “DIAGNOSTIC TROUBLE CODEs” screen is displayed and it shows the trouble.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. NOTE • C = Current trouble. ” in 2.34 SCAN-100 Trouble Code Clear Preceding Work: Perform the “Entering Diagnosis Procedures” 1.

only the history trouble codes will be cleared. press “ ” key to go back to “FUNCTION SELECTION” screen. If you press “ ”.2006. The “TROUBLE CODE CLEAR” screen is displayed.03 ECU . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . • Check the trouble codes after clearing the trouble codes. NOTE • Current trouble codes will not be cleared. In this screen. 35 SCAN 5.SCAN-100 4. select “4] TROUBLE CODE CLEAR” and press “ ”. If the trouble has been change to “H (History trouble code)” code.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The “ECU IDENTIFICATION” screen that shows the VIN. 3. ” 2. ” to input the DIAGNOSIS ACTYON SM . Select “5] ECU IDENTIFICATION” and press “ in “FUNCTION SELECTION” screen. ECU software version and programming date is displayed.2006. press “ vehicle identification number. If you replaced the ECU. ECU software number.36 SCAN-100 ECU Identification Preceding Work: Perform the “Entering Diagnosis Procedures” 1.

3. The “INJECTOR (C2I) CORRECTIONS” screen that shows current C2I coding values of #1 to #4 injector is displayed.03 ECU . 1.2006. enter the C2I value of the relevant injector. 2. If you replaced the ECU. go to C2I Coding item and check the injector and coded injector C2I value. Select “6] INJECTOR (C2I) CORRECTIONS” and press “ ” in “FUNCTION SELECTION” screen.SCAN-100 37 SCAN Injector (C2I) Corrections Preceding Work: Perform the “Entering Diagnosis Procedures” NOTICE • If the injector/ECU has been replaced or the injector system defective is suspected. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • C2I coding number: 16 digits (ex. the message as shown in figure appears with alarm sound.38 SCAN-100 NOTE • The C2I value of replacing injector is recorded in the label. press “ ” key. 2) If you enter the valid C2I value of the relevant injector. the message as shown in figure appears with alarm sound. You can see the previous C2I value. NOTE • If you want to go back to previous screen. B1 B9 D4 1B 43 C6 0E 4F) 1) If you enter the invalid C2I value of the relevant injector.2006. DIAGNOSIS ACTYON SM .

SCAN-100 39 SCAN Leak Detection Preceding Work: Perform the “Entering Diagnosis Procedures” NOTE • This item is for checking the high fuel pressure after the IMV supply line of HP pump in DI engine fuel system.2006. If you still suspect that the fuel pressure system is defective even after no trouble is detected.03 ECU . 1. ” in 2. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . The “LEAK DETECTION” screen that shows the checking conditions as shown in figure is displayed. perform the fuel pressure test again by using a fuel pressure tool kit. Select “1] LEAK DETECTION” and press “ “FUNCTION SELECTION” screen.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .40 SCAN-100 Preceding page DIAGNOSIS ACTYON SM .

” in 2.2006.03 ECU . ”.SCAN-100 41 SCAN Variant Coding Preceding Work: Perform the “Entering Diagnosis Procedures” 1. Select “8] VARIANT CODING” and press “ “FUNCTION SELECTION” screen. select “1] READ VARIANT VALUE” and press “ 3. When the “VARIANT CODING” screen is displayed. Select “1] ENGINE VARIANT CODING” and press “ ” in “FUNCTION SELECTION” screen. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .

42 SCAN-100 4. The “VARIANT CODING” screen that shows currently equipped devices is displayed.2006. ENGINE CHASSIS DIAGNOSIS ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

Select “ Select “ ” only for the vehicle with ABS or ESP system. Select “ ” only for the vehicle with PTC type supplementary heater (in DI engine). must select “ ” to confirm that this vehicle doesn’t have remote starter. Select “ACTYON” . Select “SEDAN” . DIAGNOSIS ACTYON SM .Automatic coding. (W/O Aircon : NO) Select “ ” only for the vehicle with M/T neutral switch.Automatic coding Select “ ” only for the vehicle with TPMS system. Select “Yes” only for the vehicle with EPB system.2006. Select the appropriate system. Select the coding status. Select the appropriate system.SCAN-100 43 SCAN Engine Related Coding Item Variant Coding Item ECU coding completed Supplementary heater (PTC) Auto cruise Immobilizer Remote starter Selection NO/YES NO/YES “ Description ECU ” is automatically selected. W/ Telematics: Yes W/O Telematics: No Select the appropriate system.Automatic coding. (For DI engine equipped vehicle. select “ION (BTRA)”) Select the appropriate system. Select the region. . NO/YES NO/YES NO/YES No remote starter system is applied to this model. Neutral signal input (M/T “N” signal) NO/YES(WIRE)/CAN Chassis Related Coding Item Variant Coding Item Engine model DOM/EXP Telematics Selector lever Transmission ABS/EBS SSPS Transfer case (4WD) Sedan/Limousine Vehicle type Coding EAS EPB TPMS CHANGED BY EFFECTIVE DATE AFFECTED VIN Selection D20DT/G23D DOM/GENERAL/EU Yes/No MT/DC5AT/BTRA AT ION(BTRA)/DC LEVER/DURA LEVER NA/ABS/TCS/ESP NO/YES NA/TOD/PT 4WD/ AWD/PT 4WD (W/O 4L) SEDAN/LIMOUSINE ACTYON CODING COMPLETED NA/ECS/EAS(2)/EAS(4) NO/YES NO/YES Description Select the appropriate engine. CAN Select. Select “ ” only for the vehicle with ECPS system. ” only for the vehicle with immobilizer system. ” only for the vehicle with part time TC system. Vehicle speed signal ABS or ESP TOD/Part time TC (4WD) Air conditioner CAN/WIRE NO/YES NO/YES NO/YES Select “ ” only for the vehicle with A/C system. Select “ Select “ ” only for the vehicle with auto cruise system. Select the appropriate selector lever. However.03 .

7. If you need to change the variant coding. If you press “ ”.2006. select “2] WRITE VARIANT CODING” and press “ ”. And. change the item by using arrow keys. In the screen. When the “WRITE VARIANT CODING VALUE” screen is displayed. 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Follow the instructions on the display of Scan-100. DIAGNOSIS ACTYON SM .44 SCAN-100 4. then “VARIANT CODING” screen is displayed. the message as shown in figure appears. press “ ” key to go back to “VARIANT CODING” screen. 6.

03 ECU .SCAN-100 45 SCAN 8.2006. * Chassis variant coding should be done in the same procedures as for Engine variant coding. Select “READ VARIANT VALUE” to see the coding coded value. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .

4.2006. NOTICE • Do not turn off the Scan-100 at this time. Select “9] MISCELLANEOUS” and press “ “FUNCTION SELECTION” screen.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ” in 3. Select “3] ECU REPLACE” and press “ “FUNCTION SELECTION” screen. ” in 2. • Record the below data: 1) Vehicle identification number 2) Variant coding value 3) C2I coding value 4) Multi calibration DIAGNOSIS ACTYON SM .46 SCAN-100 ECU Replace Preceding Work: Perform the “Entering Diagnosis Procedures” 1. Before starting ECU replace. When the “ECU REPLACE (STEP 2)” screen is displayed followed by “ECU REPLACE (STEP 1) screen. check the ECU S/W version of old ECU and new ECU. turn the ignition “OFF” and remove the currently installed ECU.

the message as shown in figure 1 (system 6. Install the new ECU. figure 1 figure 2 7. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .2006. 47 SCAN ”. select the relevent model.03 ECU .SCAN-100 5. In “MULTI CALIBRATION” screen. and then “MULTI CALIBRATION” screen (figure 2) is displayed. If you turn the ignition switch to “ON” position and press “ initialization) appears.

the immobilizer coding should be done after completed the multi calibration. Backup data: 1) Multi calibration value 2) VIN value 3) Variant code value 4) Injector (C2I) value 10. In immobilizer equipped vehicle. If the multi calibration is completed successfully.48 SCAN-100 8.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . When you press “ ”.2006. the processing message as shown in figure appears. DIAGNOSIS ACTYON SM . 9. “ECU REPLACE (STEP 5) screen is displayed.

Identification of VIN number . Follow the instructions on the display of Scan-100. 49 SCAN 12.SCAN-100 11. Press “ ” for the vehicle equipped with immobilizer system.Immobilizer coding #1 #2 #4 #3 #5 #6 CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . .2006.03 ECU .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .50 #7 SCAN-100 #8 # 10 #9 # 11 # 12 DIAGNOSIS ACTYON SM .2006.

2006. 51 SCAN CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .03 ECU .SCAN-100 13. Press “ ” to return to “MAIN MENU” screen.

2006. 4. If the versions of ECUs are not matched. 2. Press “ ” to run the multi calibration. replace the ECU as follows. VIN/Variant Data/C21 Data is not read from ECU. 1. Replace the ECU with new one. Select “3] ECU REPLACE” and press “ “FUNCTION SELECTION” screen.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . program the new ECU after replacement. ” in 3. DIAGNOSIS ACTYON SM .52 SCAN-100 ECU Replace (Scan-100 Communication is not available) If the Scan-100 communication is not available due to ECU failure.

and press “ 10. select “5] ECU IDENTIFICATION” ”.2006. the message screen shown in the figure is displayed. To enter the VIN. To enter the data. 7. 9. The VIN/Variant Data/C21 Data should be input manually. 1) Vehicle with A/T: 2] Dom/Gen A/T 2) Vehicle with M/T: 4] Dom/Gen M/T 53 SCAN 6.SCAN-100 5.03 ECU . press “ESC” on the screen in Step 5 and go back to main screen. Press “ ” and enter the VIN again. If the multi calibration is completed successfully. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . 8. Select the appropriate model in “MULTI CALIBRATION SELECTION” screen.

Enter the VIN into the number plate on the screen. 13. When the “WRITE VARIANT CODING” screen is displayed. If any of digits is wrong.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . select “2] WRITE VARIANT CODING” and press “PRESS”. 12. Make sure that the VIN code is correct. The nearest injector from the radiator is number 1 and the number goes higher as it moves away. Remove the engine acoustic cover and enter the 16 digits code on each injector label for all of five injectors. Select “8] VARIANT CODING” and press “PRESS” in “FUNCTION SELECTION” screen. DIAGNOSIS ACTYON SM . To change the number to the character.2006. change the item by using arrow keys. Select “6] INJECTOR (C2I) CORRECTIONS” and press “ ” in “FUNCTION SELECTION” screen.54 SCAN-100 11. When the “VARIANT CODING” screen is displayed. you should enter full code again. use the arrow keys.

The fuel supply pressure varies according to the offset value and the engine output could be decreased due to this variation. measure the fuel pressure with a tester. If the setting value is not 0. check whether all rail pressure offset values is set to 0 in the Rail Pressure Reset screen in SCAN-100. When the engine output decreases. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Select “2] RAIL PRESSURE RESET” in “FUNCTION SELECTION” screen. repair the affected components and reset the rail pressure offset value to 0. 1. However. defective fuel system.SCAN-100 55 SCAN Rail Pressure Reset Rail Pressure Reset Procedures The engine ECU needs a specific amount of fuel according to the fuel supply lines and vehicle driving conditions. If any defective is found. The rail pressure reset procedures should be done after replacing any high pressure pump and fuel system related components. 2. ECU designates the offset value to the high pressure pump to compensate it.03 ECU . Select the vehicle model. if the fuel supply (pressure) is not achieved due to. for instance.2006.

check the fuel pressure and other DTC generations before starting the rail pressure reset operation. Enter the current rail pressure value and press [ENTER] to reset the offset value.56 SCAN-100 3. DIAGNOSIS ACTYON SM . 4.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • If the offset value is not set to 0. The screen returns back to step 3 after displaying the [RAIL PRESSURE RESET IS SUCCESSFUL] message.

..........................................ECU 3 SCAN ECU TROUBLE DIAGNOSIS TABLE INDEX OF DTC .......................................03 ....... 4 Trouble diagnosis table ...........2006........ 7 CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM ..............

.. 24 P0266 Injector #2 Balancing Fault ............. 11 P0106 High Booster Pressure Sensor Signal .......................................................... 15 P1286 Low Resistance for Injector #1 wiring harness .Short .................. 18 P1115 Coolant Temperature Sensor Malfunction ........................ 27 DIAGNOSIS ACTYON SM ..... 25 P1204 Injector #4 Circuit Short ....Short to Ground ...................2006...........Short to ground ............................................. 25 P1202 Injector #2 Circuit Short .................................... 20 P0115 Supply Voltage Fault to Coolant Temperature Sensor ........................... 21 P1482 Condenser Fan #1 Circuit Malfunction ................................. 9 P1105 Barometric Sensor Circuit Short (Vref) ........................... 21 P0325 Accelerometer #1 (Knock Sensor) Malfunction .................... 18 P1291 High Resistance for Injector #3 wiring harness . 23 P1619 Injector Bank #2 Malfunction .........Open ................................ 16 P1289 High Resistance for Injector #2 wiring harness .. 22 P0330 Accelerometer #2 (Knock Sensor) Malfunction (only D27DT) .4 ECU INDEX OF DTC P0102 Low HFM Sensor Signal (Circuit Open) ...... 26 P0182 Fuel temperature sensor ................... 18 P1290 Low Resistance for Injector #3 wiring harness ......................... 26 P0180 Fuel temperature sensor ......................................................... 14 P1572 Brake Lamp Signal Fault ...................................... 15 P1287 High Resistance for Injector #1 wiring harness ............ 14 P0571 Brake Pedal Switch Fault ............. 21 P1481 Condenser Fan #1 Circuit Malfunction ................... 23 P1618 Injector Bank #2 Malfunction .......... 13 P1106 Booster Pressure Sensor Malfunction ..................Low Voltage ..................Short .................. 10 P0560 Battery Voltage Malfunction ............... 10 P0109 Low Booster Pressure Sensor Signal ...............................................Short to +Batt .......... 15 P1571 Brake Lamp Signal Fault ......................... 24 P0275 Injector #5 Balancing Fault (only D27DT) .......................................... 26 P0183 Fuel temperature sensor .... 24 P0272 Injector #4 Balancing Fault ....................................... 25 P0205 Injector #5 Circuit Open (only D27DT) ........... 7 P0100 Air Mass Flow (HFM) Malfunction (Vref) ........ 17 P1294 Low Resistance for Injector #5 wiring harness (only D27DT) ..... 24 P0269 Injector #3 Balancing Fault ......................................................... 12 P0108 Booster Pressure Sensor Short .............. 9 P0562 Low Battery Voltage ........................Low Voltage ..................................................... 12 P0105 Supply Voltage Fault to Booster Pressure Sensor ...Vref .......................................... 27 P1678 Glow Plug Drive Malfunction ................................................................... 24 P0201 Injector #1 Circuit Open ..........Short ....... 17 P1295 High Resistance for Injector #5 wiring harness (only D27DT) .............................................. 24 P0202 Injector #2 Circuit Open .................................. 16 P1292 Low Resistance for Injector #4 wiring harness ................................................ 25 P1205 Injector #5 Circuit Short (only D27DT) ......... 24 P0204 Injector #4 Circuit Open .............................High Voltage ............................................................... 23 P0263 Injector #1 Balancing Fault ......Open ......03 CHANGED BY EFFECTIVE DATE AFFECTED VIN ....... 19 P0117 Coolant Temperature Sensor Malfunction ......................... 8 P0341 Cam Position Sensor Malfunction (Poor Synchronization) .............................Short to Ground ..................................................... 9 P0372 Crank Angle Sensor Malfunction .... 25 P1201 Injector #1 Circuit Short .. 20 P1480 Condenser Fan #1 Circuit Malfunction ............................ 13 P1109 Booster Pressure Sensor Initial Check Fault ............ 19 P0118 Coolant Temperature Sensor Malfunction .. 8 P0336 Too Large Clearance of Crank Angle Sensor ......... 20 P1406 EGR Solenoid Valve Malfunction ......................................................................................... 7 P0103 High HFM Sensor Signal (Circuit Short) ......... 21 P1526 Condenser Fan #2 Circuit Malfunction ......Open ................ 25 P0203 Injector #3 Circuit Open ..................... 10 P0563 High Battery Voltage ...... 21 P1528 Condenser Fan #2 Circuit Malfunction ......................Short to Ground ..............................................Open .......................... 20 P1405 EGR Solenoid Valve Malfunction .......Short to B+ ..................... 11 P0107 Booster Pressure Sensor Open/GND Short . 22 P1612 Injector Bank #1 Malfunction ........ 25 P1203 Injector #3 Circuit Short .................... 16 P1288 Low Resistance for Injector #2 wiring harness .................................... 8 P0344 Cam Position Sensor Malfunction (Cam Signal Missing) ............ 22 P1611 Injector Bank #1 Malfunction ................................. 21 P1527 Condenser Fan #2 Circuit Malfunction ........................................................................................................ 18 P0704 Clutch switch malfunction ............... 20 P0685 Main Relay Malfunction ....High Voltage ................. 17 P1293 High Resistance for Injector #4 wiring harness ... 8 P0219 Too Small Clearance of Crank Angle Sensor ........................ 9 P1108 Barometric Sensor (High) .............. 9 P1107 Barometric Sensor (Low) .

.................. 38 P0220 Accelerator Pedal Sensor #2 Malfunction ...........5 V) ...........Short to Ground ...................................... 45 P0335 No Crank Signals ................. 44 P1614 ECU C2I/MDP Fault ...................................................................Supply Voltage Fault ..Stuck .......... 28 P1254 Maximum Rail Pressure Control Malfunction (IMV Fault) .............................................................Open ............................. 37 P1124 Accelerator Pedal Sensor Malfunction .. 35 P1172 #2 Injector MDP Malfunction ...........................Short to Ground ............................... 29 P1253 Minimum Rail Pressure Control Malfunction (IMV Fault) ..... 40 P1190 Fuel Rail Pressure Sensor Initial Signal Fault ................. 41 P0643 ECU Supply Voltage 1 Fault ........ 39 P0193 Fuel Rail Pressure Sensor Malfunction ......... 36 P1121 Accelerator Pedal Sensor #2 Malfunction ......... 40 P1192 Fuel Rail Pressure Sensor Initial Signal Fault ...................Low (2.............................................................................................................................................................Short ............................... 43 P0246 Turbo Charger Actuator Circuit Fault ................. 44 P1622 ECU Fault ............Low (5 V) ..5 V) ................................................................................ 43 P0697 ECU Supply Voltage Fault (2... 41 P1500 Vehicle Speed Fault ........................................... 44 P1621 ECU Fault .High ................... 31 P1259 Too Large High Pressure Fuel in Rail Pressure System ...........................Short to B+ ..................................................Open ......Short to B+ ......... 32 P0255 IMV Driver Circuit Malfunction ......................................................Open ........... 28 P1532 #1 Heater operating circuit .. 31 P1191 Pressure Build Up ............ 37 P1123 Accelerator Pedal Sensor Malfunction (Reducde Torque Mode) ........ 27 P1680 Glow Plug Drive Malfunction ..... 43 P1600 ECU Shut Down Fault .......Low (5 V) ........................ 43 P1607 ECU Injector Cut Fault ..... 46 P1677 Glow Plug Controller Fault ..... 27 P1531 #1 Heater operating circuit ............................. 45 P1676 Glow Plug Communication Fault ...........................Too Slow ............... 44 P1615 ECU Fault .. 44 P1616 ECU Fault ...... 42 P0641 ECU Supply Voltage 1 Fault (5 V) ...........................................High ........................................................... 27 P1530 #1 Heater operating circuit . 30 P1257 Too Large Transfer Pressure Fuel in Rail Pressure System ............................... 45 P0400 EGR Control Valve Fault ....... 38 P0192 Fuel Rail Pressure Sensor Malfunction ......................2006................. 42 P0652 ECU Supply Voltage 2 Fault ...........................Short ....... 42 P0698 ECU Supply Voltage Fault .......Short ...... 44 P1602 ECU Fault ...............................................High (5 V) ............Stuck .. 45 P1235 VGT Operation Fault ...... 38 5 SCAN ECU P0223 Accelerator Pedal Sensor #2 Malfunction .. 32 P0253 IMV Driver Circuit Malfunction ...Open ................. 32 P0251 IMV Driver Circuit Malfunction ................................Open ....... 43 P0245 Turbo Charger Actuator Circuit Fault .......................................... 44 P1148 Accelerometer (Knock Sensor) Learning Fault .............. 37 P1122 Accelerator Pedal Sensor Malfunction (Limp Home Mode) ................................... 34 P0110 Intake Air Temperature Circuit Malfunction ...........................Open .................Short to Ground ........Short to Ground ............... 28 P1534 #2 Heater operating circuit ......... 28 P1535 #2 Heater operating circuit .....03 .....................Short ..........Source Power Problem ............. 37 P0123 Accelerator Pedal Sensor #1 Malfunction ................. 43 P0606 ECU Watchdog Fault ........................... 28 P1536 #2 Heater operating circuit ............ 39 P0190 Supply Voltage Fault to Fuel Rail Pressure Sensor .......................................................................... 46 CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM ............................. 32 P0112 Intake Air Temperature Circuit Malfunction ... 36 P1175 #5 Injector MDP Malfunction (only D27DT) ............................................................. 35 P1171 #1 Injector MDP Malfunction ..................................................... 30 P1258 Too Small High Pressure Fuel in Rail Pressure System .......... 37 P0122 Accelerator Pedal Sensor #1 Malfunction ...................................................5 V) ......................................... 42 P0653 ECU Supply Voltage 2 Fault ...............Low .....Supply Voltage Fault ........................................High (2.................................................High (5 V) ........................... 43 P0699 ECU Supply Voltage Fault ......... 36 P1120 Accelerator Pedal Sensor #1 Malfunction .............. 37 P0120 Accelerator Pedal Sensor #1 Malfunction ......................................................... 39 P0191 Fuel Rail Pressure Sensor Signal Fault .............................................. 40 P1193 Fuel Rail Pressure Sensor Initial Signal Fault .............................. 44 P1601 ECU Fault ......................................................... 38 P0222 Accelerator Pedal Sensor #2 Malfunction ........ 45 P1608 ECU Fault ........ 29 P1256 Too Small Transfer Pressure Fuel in Rail Pressure System ............Short to B+ ............................................ 35 P1174 #4 Injector MDP Malfunction ........................................ 36 P1252 Too High IMV Pressure ........ 36 P1173 #3 Injector MDP Malfunction ......... 41 P0642 ECU Supply Voltage 1 Fault ..............................................................ECU P1679 Glow Plug Drive Malfunction ....... 41 P0215 Main Relay Fault ...........Short ..................................................Open ................................................................................Short ...... 42 P0651 ECU Supply Voltage 2 Fault (5 V) ........... 44 P1606 ECU Fault ........................... 45 P1170 Torque Trim Fault ................... 44 P1620 ECU Fault .................

... 46 P0673 #5 Glow Plug Fault ......................................................................................................Open (only D27DT) ................. 50 P0644 CAN cluster failure .................. 48 P1149 Too High Water Level in Fuel Filter ...03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .............................................. 46 P0674 #1 Glow Plug Fault . 47 P1672 #4 Glow Plug Fault .... 47 P1671 #3 Glow Plug Fault ...........................Short (B+) ....2006..... 48 P1540 Air Conditioner Operating Circuit Fault ..........................Open ..... 51 P1566 Auto cruise switch failure (OFF) .................................. 49 P1632 Immobilizer Fault (refer to immobilizer section) ......................................... 48 P1634 Immobilizer Fault (refer to immobilizer section) ...... 51 P3040 ECU internal failure ..................................... 50 P0608 ABS/ESP coding failure ..................Short (B+) ............................... 51 P1657 Engine mount control failure (Open) ......... 50 P1501 Variant coding failure (vehicle speed) ..Short (B+) (only D27DT) ......................... 51 P1567 Auto cruise switch failure ......... 48 P0700 TCU Signal Fault ....................................................................... 51 P0671 #3 Glow Plug Fault .... 50 P1103 Low HFM Sensor Signal .............................................................................................................. 49 P1636 Immobilizer Fault (refer to immobilizer section) ........Short .... 47 P1675 #2 Glow Plug Fault ...... 50 P1565 Auto cruise switch failure (Acceleration) ......Open ................ 47 P0675 #2 Glow Plug Fault ....................................... 49 P1631 Immobilizer Fault (refer to immobilizer section) .. 48 P1630 Wrong response from Immobilizer (refer to immobilizer section) .......................... 51 P1568 Auto cruise switch failure (Deceleration) ............................................................6 ECU P1633 Immobilizer Fault (refer to immobilizer section) ....................................................... 51 P1569 Auto cruise switch failure (Safety) ..... 48 P1542 Air Conditioner Operating Circuit Fault ....................................... 51 P1659 Engine mount control failure (Short to ground) .Short (B+) .. 51 P1658 Engine mount control failure (Short to B+) .......................Open ........................ 50 P0602 Vehicle speed sensor coding failure ...Open .. 50 P1503 Vehicle speed sensor input failure .. 50 P0600 CAN BUS failure ......... 48 P1541 Air Conditioner Operating Circuit Fault ........................ 47 P1673 #5 Glow Plug Fault ... 51 P3041 ECU internal failure (only D27DT) ............................... 48 P1635 No response from Immobilizer (refer to immobilizer section) ............Short to Ground ................................ 49 DIAGNOSIS ACTYON SM ................................................................................ 49 P0633 Immobilizer Fault (refer to immobilizer section) ............................... 46 P0672 #4 Glow Plug Fault ........Short (B+) .... 51 P0805 Abnormal neutral signal ........ 50 P1102 High HFM Sensor Signal ............ 50 P0613 TCU coding failure ........................................... 47 P1674 #1 Glow Plug Fault ...............................................................Open .......

99 V • 10 Kg/h: 1.5667 ~ 4.2226 ~ 1.4388 ~ 3.3778 V • 30 Kg/h: 1.2398 V • 15 Kg/h: 1.4388 ~ 3.7146 V • 60 Kg/h: 2.7762 V • 250 Kg/h: 3.HFM sensing values are lower than minimum sensing values.Actual air mass flow vs.20%) Stop Stop Mode CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .3778 V • 30 Kg/h: 1. Output voltages.2683 V • 640 Kg/h: 4. .2398 V • 15 Kg/h: 1.1619 ~ 2.7762 V • 250 Kg/h: 3. P0103 High HFM Sensor Signal (Circuit Short) .1619 ~ 2. Output voltages.Replace the ECU if required.03 . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.ECU 7 SCAN ECU TROUBLE DIAGNOSIS TABLE DTC P0102 Trouble Low HFM Sensor Signal (Circuit Open) Help .Actual air mass flow vs.1945 ~ 4.2006.7215 ~ 2. .6469 V .2226 ~ 1.7146 V • 60 Kg/h: 2.9511 V • 480 Kg/h: 4.50%) (max.99 V • 10 Kg/h: 1. • -20 Kg/h: 0.Replace the ECU if required. • Check the ECU pin #83 and #84 for open circuit.2683 V • 640 Kg/h: 4.Check the resistance in HFM sensor.3552 ~ 1.9511 V • 480 Kg/h: 4.6783 ~ 1.2057 V • 120 Kg/h: 2.47 V • 0 Kg/h: 0.5667 ~ 4.Check the ECU wiring harness (open and poor contact).7215 ~ 2.5037 V • 370 Kg/h: 3.Check the ECU wiring harness (open and poor contact).2057 V • 120 Kg/h: 2.1945 ~ 4. • Check the ECU pin #83 and #84 for open circuit.6783 ~ 1.HFM sensing values are higher than maximum sensing values.8796 ~ 3. • -20 Kg/h: 0. .Check the resistance in HFM sensor.6469 V . .8796 ~ 3.5037 V • 370 Kg/h: 3. .47 V • 0 Kg/h: 0.3552 ~ 1. .

Check the source voltage of cam position sensor (specified value: 4.Measure the air gap: 0. .Check the source voltage of cam position sensor (ECU pin #111) (specified value: 4.7762 V • 250 Kg/h: 3.50%) (max. . . O P0219 Too Small Clearance of Crank Angle Sensor .8 mm . .47 V • 0 Kg/h: 0.1619 ~ 2. .2057 V • 120 Kg/h: 2.Actual air mass flow vs. • -20 Kg/h: 0. .Replace the ECU if required. poor contact).Measure the air gap: 0.Replace the ECU if required.3 mm of air gap: outputs 1.8796 ~ 3.2 ~ 1.20%) Stop Stop Mode DTC P0100 Trouble Air Mass Flow (HFM) Malfunction (Vref) Help . P0344 Cam Position Sensor Malfunction (Cam Signal Missing) .Measure the air gap: 0.1945 ~ 4. short.3778 V • 30 Kg/h: 1. • Drive plate (A/T).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Replace the ECU if required.7146 V • 60 Kg/h: 2.2226 ~ 1.3 mm of air gap: outputs 150 V at 7000 rpm . . O DIAGNOSIS ACTYON SM .3552 ~ 1.9511 V • 480 Kg/h: 4. DMF (M/T) .3 ~ 1. short.Check the sensor wiring harness for ECU pin #103 and #104 (open.Check the cam position sensor. Output voltages.Check the sensor wiring harness for ECU pin #90 and #82 (open.Crank angle signal faults or clearance too close.No cam recognition signal (missing events).2683 V • 640 Kg/h: 4.7215 ~ 2.2398 V • 15 Kg/h: 1.Replace the ECU if required. poor contact).5 ~ 12 V).8 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.3 mm • 1. .5037 V • 370 Kg/h: 3.4388 ~ 3.Check the teeth condition. O P0341 Cam Position Sensor Malfunction (Poor Synchronization) . short.2 ~ 1.The external power supply is faulty. poor contact).2006. . • Check the external power supply. . • Check the sensor wiring harness (open.5667 ~ 4. .Check the resistance of crank angle sensor: 1090 Ω ± 15 %.0 V at 40 rpm • 0. poor contact).Check the sensor wiring harness for ECU pin #103 and #104 (open. .8 mm .99 V • 10 Kg/h: 1.Check the cam position sensor.6783 ~ 1.Not synchronized with Crank angle signal.5 ~ 12 V).6469 V . short.

5 V CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Even though cam position recognition is normal. 35 Kpa: 1. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. poor contact).Out of range about barometric sensor (short to ground). • 15 Kpa: 0 V • 55 Kpa: 2.2006. .3 mm of air gap: outputs 1.0 V 80 Kpa: 3.Check the sensor wiring harness for ECU pin #90 and #82 (open.3 mm of air gap: outputs 1. poor contact).Replace the ECU.03 .0 V 110 Kpa: 4.0 V at 40 rpm • 0.0 V . .20%) Stop Stop Mode O P0372 Crank Angle Sensor Malfunction . .0 V 110 Kpa: 4. .Actual barometric pressure vs. • Drive plate (A/T). .3 mm • 1.Check the resistance of crank angle sensor: 1090 Ω ± 15 %.3 mm of air gap: outputs 150 V at 7000 rpm .Check the resistance of crank angle sensor: 1090 Ω ± 15 %.3 ~ 1.Replace the ECU if required.Check the teeth condition.0 V .Air gap of crank angle sensor is abnormal. • 15 Kpa: 0 V • 55 Kpa: 2. Output voltages.0 V 35 Kpa: 1. .Actual barometric pressure vs.5 V P1108 Barometric Sensor (High) . DMF (M/T) . short.Measure the air gap: 0.0 V • 100 Kpa: 4.ECU 9 SCAN ECU DTC P0336 Trouble Too Large Clearance of Crank Angle Sensor Help .Check the sensor wiring harness for ECU pin #90 and #82 (open.0 V • 100 Kpa: 4. O P1107 Barometric Sensor (Low) . .Replace the ECU if required. Output voltages.Replace the ECU. no crank angle signal recognition (missing tooth).0 V 80 Kpa: 3. • 15 Kpa: 0 V • 55 Kpa: 2.Check the teeth condition. • Drive plate (A/T). .3 mm • 1.Measure the air gap: 0. . 35 Kpa: 1. short.0 V 110 Kpa: 4.0 V .3 mm of air gap: outputs 150 V at 7000 rpm .0 V 80 Kpa: 3.3 ~ 1. DMF (M/T) .0 V at 40 rpm • 0.Out of range about barometric sensor (over voltage). P1105 Barometric Sensor Circuit Short (Vref) .50%) (max. Output voltages.Out of range about barometric sensor (short to B+).Actual barometric pressure vs.Replace the ECU.5 V • 100 Kpa: 4.

Check the battery wiring harness for ECU pin #3.Replace the ECU if required. poor contact). . .Check the battery wiring harness for ECU pin #3. P0563 High Battery Voltage . .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .Measure the resistance between body ground and ECU ground. #4 and #5 (open.Malfunction in recognition of system source voltage (Higher than threshold).Check the body ground. • More than minimum 16 Volts in 2000 rpm below . O DIAGNOSIS ACTYON SM .Replace the ECU if required.Check the battery wiring harness for ECU pin #3.20%) Stop Stop Mode O DTC P0562 Trouble Low Battery Voltage Help .Malfunction in recognition of system source voltage (A/D converter faults).Replace the ECU if required. • Repair the ECU ground if the resistance is high.10 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . • Repair the ECU ground if the resistance is high.Measure the resistance between body ground and ECU ground. • Less than minimum 8 Volts in 2000 rpm below • Less than 10 Volts in 2000 rpm above. • Less than minimum 8 Volts in 2000 rpm below • Less than 10 Volts in 2000 rpm above.Check the alternator. .Malfunction in recognition of system source voltage (Lower than threshold). #4 and #5 (open.50%) (max. short. • Repair the ECU ground if the resistance is high. . poor contact). . . short.Check the battery main relay and fuse. . . short. #4 and #5 (open.Check the battery main relay and fuse. . O P0560 Battery Voltage Malfunction .2006.Measure the resistance between body ground and ECU ground.Check the body ground. . . poor contact).Check the body ground.

. • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.4 bar: 0.20%) Stop Stop Mode P0106 High Booster Pressure Sensor Signal .If there is turbo boost control fault. . poor contact).50%) (max.2006.Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously. .Check the sensor wiring harness for ECU pin #99 and #100 (open.545 ~ 2.Actual boost pressure vs.Replace the ECU if required. Output voltages. .Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously.545 ~ 2. .Check the sensor wiring harness for ECU pin #99 and #100 (open.4 bar: 4.6520 V • 2.Actual boost pressure vs. . • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Higher than specified values). Should be checked followings also.6520 V • 2.Visually check sensor and replace if required.490 bar • 0.4 bar: 2.03 .ECU 11 SCAN ECU DTC P0109 Trouble Low Booster Pressure Sensor Signal Help .6920 V .If there is turbo boost control fault.4 bar: 4. . poor contact).Visually check sensor and replace if required.4 bar: 2.6120 V • 1.6920 V . . .Check the supply voltage to sensor.Replace the ECU if required.4 bar: 0. Should be checked followings also. . • Raw Signal Range: 0.490 bar • 0.Check the supply voltage to sensor.6120 V • 1. . Output voltages. • Raw Signal Range: 0.Out of signal range about boost pressure sensor at Ignition key-On and Engine Stop (Lower than specified values). .

6520 V • 2. .Check the sensor wiring harness for ECU pin #99 and #100 (open.50%) (max. Output voltages • Raw Signal Range: 0.6120 V • 1.Replace the ECU if required.Check the supply voltage to sensor. Should be checked followings also.Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously.4 bar: 2. • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction DIAGNOSIS ACTYON SM .If there is turbo boost control fault.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Should be checked followings also. .Actual boost pressure vs. . • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction P0108 Booster Pressure Sensor Short .6920 V . Output voltages • Raw Signal Range: 0.Visually check sensor and replace if required. .Visually check sensor and replace if required. .20%) Stop Stop Mode DTC P0107 Trouble Booster Pressure Sensor Open/GND Short Help . .490 bar • 0. . .If there is turbo boost control fault. .Check the sensor wiring harness for ECU pin #99 and #100 (open. .Actual boost pressure vs.6920 V .Replace the ECU if required.545 ~ 2.Out of signal range about boost pressure sensor at Engine running condition (Lower than specified values).6520 V • 2.4 bar: 4.4 bar: 4. .6120 V • 1.Check the supply voltage to sensor.4 bar: 0. poor contact). .490 bar • 0.Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously.12 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Out of signal range about boost pressure sensor at Engine running condition (Higher than specified values).4 bar: 2.2006. poor contact).545~2.4 bar: 0.

Replace the ECU if required.Check the supply voltage to sensor.4 bar: 2.2006.6920 V .50%) (max.4 bar: 4.Replace the ECU if required.20%) Stop Stop Mode P1106 Booster Pressure Sensor Malfunction . . . . poor contact). .Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously.Check the supply voltage to sensor.4 bar: 0. . Output voltages • Raw Signal Range: 0.490 bar • 0.03 . Should be checked followings also.6520 V • 2. poor contact).Visually check sensor and replace if required.6920 V . • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . .4 bar: 0.545 ~ 2. . . • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .545 ~ 2. Output voltages.Actual boost pressure vs.4 bar: 4.6120 V • 1.Visually check sensor and replace if required.6520 V • 2.4 bar: 2. Should be checked followings also.Check the sensor wiring harness for ECU pin #100 and #108 (open.If there is turbo boost control fault.Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously.6120 V • 1.Out of range of supply voltages about boost pressure sensor at Ignition keyOn and Engine Stop (Higher than specified values).490 bar • 0.Out of range of supply voltages about boost pressure sensor at Ignition keyOn and Engine Stop (Higher than specified values). .If there is turbo boost control fault.Check the sensor wiring harness for ECU pin #99 and #100 (open. • Raw Signal Range: 0.ECU 13 SCAN ECU DTC P0105 Trouble Supply Voltage Fault to Booster Pressure Sensor Help . . .Actual boost pressure vs.

. .If there is turbo boost control fault.6520 V • 2. .Check the supply voltage to brake and light switch (12 V). .Check the supply voltage to sensor. .Actual boost pressure vs.Check the brake and light switch wiring harness.14 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check the brake and light switch for contact. . DIAGNOSIS ACTYON SM .Check whether existing or not about turbo boosting control malfunction (P1235) simultaneously. poor contact). Should be checked followings also.50%) (max. . Output voltages • Raw Signal Range: 0. • Leakage before turbo system • Vacuum pump malfunction • Waste gate’ solenoid valve • Turbo charger system defect or malfunction itself • Air inlet restriction • Exhaust system restriction P0571 Brake Pedal Switch Fault .2006. .Replace the ECU if required. .Visually check sensor and replace if required. .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .4 bar: 4. poor contact).Check the sensor wiring harness for ECU pin #99 and #100 (open.490 bar • 0.Check the ECU wiring harness for ECU pin #77 and #58 (short.Implausible signal values or range about boost pressure sensor at Engine running condition (Higher than specified values).545 ~ 2.20%) Stop Stop Mode DTC P1109 Trouble Booster Pressure Sensor Initial Check Fault Help . one signal (NO) is sent to auto cruise and the other (NC) is sent to brake lamp.Replace the ECU if required.4 bar: 0. .6920 V .6120 V • 1.4 bar: 2.The brake pedal switch or light switch is faulty. • Brake pedal switch: Normal Close (NC) • Light switch: Normal Open (NO) • When operating the brake switch.

03 . one signal (NO) is sent to auto cruise and the other (NC) is sent to brake lamp. short.50%) (max.Check the supply voltage to brake pedal switch (12 V). • Brake pedal switch: Normal Close (NC) • Light switch: Normal Open (NO) • When operating the brake pedal switch. .Replace the ECU if required. P1286 Low Resistance for Injector #1 wiring harness .The brake pedal switch is faulty. replace injector #1 and perform C2I coding. .115 Ω (injector circuit open) . .Check the injector #1 wiring harness for open circuit. .Check the brake pedal switch wiring harness. . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . check the ECU wiring harness.Check the brake pedal and light switch for contact. • If the pin in injector #1 is defective.20%) Stop Stop Mode P1571 Brake Lamp Signal Fault .Check the brake pedal switch for contact.The brake pedal switch or light switch is faulty. • Brake pedal switch: Normal Close (NC) • Light switch: Normal Open (NO) • When operating the brake pedal switch.Check the supply voltage to brake pedal and light switch (12 V).Replace the ECU if required. then check again.Check the injector #1 wiring harness and electric isolation.ECU 15 SCAN ECU DTC P1572 Trouble Brake Lamp Signal Fault Help . one signal (NO) is sent to auto cruise and the other (NC) is sent to brake lamp. . • If the pin in injector #1 is not defective. poor contact). poor contact). .Check the brake pedal and light switch wiring harness. . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . .Out of range about wiring harness resistance for Injector #1. . • Low: Less than 0. short.Check the ECU wiring harness for ECU pin #77 (open.2006.Check the ECU wiring harness for ECU pin #58 (open. .Replace the ECU if required.

then check again.20%) Stop Stop Mode DTC P1287 Trouble High Resistance for Injector #1 wiring harness Help .Check the injector #1 wiring harness and electric isolation. • Low: Less than 0. check the wiring harness between ECU and injector. . . .Check the injector #2 wiring harness for open circuit.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • If the trouble still exists after removing the injector connector.Check the injector #2 wiring harness and electric isolation. check the wiring harness between ECU and injector. .50%) (max. then check again.728 Ω (injector circuit short) .115 Ω (injector circuit open) . then check again. check the ECU wiring harness. replace injector #2 and perform C2I coding.Replace the ECU if required. .Out of range about wiring harness resistance for Injector #1.2006. • If the trouble still exists after removing the injector connector. replace injector #2 and perform C2I coding.Replace the ECU if required.Out of range about wiring harness resistance for Injector #2. DIAGNOSIS ACTYON SM .Out of range about wiring harness resistance for Injector #2. • High: More than 0.16 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. • High: More than 0. . • If the pin in injector #2 is defective. P1289 High Resistance for Injector #2 wiring harness .728 Ω (injector circuit short) .Replace the ECU if required. P1288 Low Resistance for Injector #2 wiring harness .Check the injector #2 wiring harness for short circuit. replace injector #1 and perform C2I coding. • If the pin in injector #2 is not defective. • If the trouble is fixed after removing the injector connector.Check the injector #1 wiring harness for short circuit. • If the trouble is fixed after removing the injector connector.Check the injector #2 wiring harness and electric isolation.

Check the injector #4 wiring harness and electric isolation. • Low: Less than 0. • If the pin in injector #4 is not defective. then check again. .Replace the ECU if required.Replace the ECU if required.ECU 17 SCAN ECU DTC P1292 Trouble Low Resistance for Injector #4 wiring harness Help . check the ECU wiring harness.Out of range about wiring harness resistance for Injector #4. . check the wiring harness between ECU and injector. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. • If the trouble is fixed after removing the injector connector.03 .115 Ω (injector circuit open) .Replace the ECU if required. • If the pin in injector #5 is defective. • If the trouble still exists after removing the injector connector.Check the injector #5 wiring harness for open circuit. • If the pin in injector #5 is not defective. replace injector #5 and perform C2I coding. then check again. then check again. • Low: Less than 0. replace injector #4 and perform C2I coding.Check the injector #5 wiring harness and electric isolation.20%) Stop Stop Mode P1293 High Resistance for Injector #4 wiring harness .Out of range about wiring harness resistance for Injector #4.Check the injector #4 wiring harness and electric isolation. .115 Ω (injector circuit open) .Check the injector #4 wiring harness for short circuit.50%) (max. • High: More than 0.2006. check the ECU wiring harness. . replace injector #4 and perform C2I coding.728 Ω (injector circuit short) . . • If the pin in injector #4 is defective.Out of range about wiring harness resistance for Injector #5. .Check the injector #4 wiring harness for open circuit. P1294 Low Resistance for Injector #5 wiring harness (only D27DT) .

Out of range about wiring harness resistance for Injector #3. . .18 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check the switch wiring harness.Out of range about wiring harness resistance for Injector #3.Check the injector #5 wiring harness and electric isolation. P1290 Low Resistance for Injector #3 wiring harness . . P0704 Clutch switch malfunction . • If the trouble still exists after removing the injector connector. • If the trouble is fixed after removing the injector connector. then check again. check the wiring harness between ECU and injector. replace injector #3 and perform C2I coding.Check the injector #5 wiring harness for short circuit. . DIAGNOSIS ACTYON SM . • If the trouble still exists after removing the injector connector. • Check the ECU pin #38 for open.20%) Stop Stop Mode DTC P1295 Trouble High Resistance for Injector #5 wiring harness (only D27DT) Help .115 Ω (injector circuit open) . . • If the trouble is fixed after removing the injector connector.The clutch switch is faulty (Manual Transmission Only). • Low: Less than 0. then check again.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Replace the ECU if required.Replace the ECU if required.Replace the ECU if required.Out of range about wiring harness resistance for Injector #5. • High: More than 0. then check again. .Check the injector #3 wiring harness and electric isolation. • If the pin in injector #3 is not defective.728 Ω (injector circuit short) . check the ECU wiring harness. • High: More than 0. . P1291 High Resistance for Injector #3 wiring harness . replace injector #5 and perform C2I coding. .Check the switch supply voltage and operations. • If the pin in injector #3 is defective.2006.Check the injector #3 wiring harness for short circuit.728 Ω (injector circuit short) . replace injector #3 and perform C2I coding.Check the injector #3 wiring harness and electric isolation. short and poor contact.Replace the ECU if required. .50%) (max. check the wiring harness between ECU and injector.Check the injector #3 wiring harness for open circuit.

short and poor contact).Check the wiring harness (open. .9 Ω .Check the supply voltage to sensor.If Fuel temperature is invalid. • ECU pin #101 and #102 . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.3 Ω • 80°C: 321.Actual coolant temp.ECU 19 SCAN ECU DTC P1115 Trouble Coolant Temperature Sensor Malfunction Help .03 .Visually check the sensor and replace if required.50%) (max.Visually check the sensor and replace if required. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . .20%) Stop Stop Mode P0118 Coolant Temperature Sensor Malfunction .Implausible values of coolant temperature (If the temperature is below the limits values after warm up).Actual coolant temp. the previous coolant temperature is retained.3 Ω • 80°C: 321.Check the supply voltage to sensor.4 Ω • 100°C: 112. water pump radiator related coolant route (thermostat stuck).Malfunction in recognition of coolant temperature • More than maximum values (Circuit Short) • External power supply malfunction .Replace the ECU if required.4 Ω • 100°C: 112. the previous coolant temperature is retained. vs. .If Fuel temperature is invalid.Check the thermostat.9 Ω . . . .2006. .Short . Resistance • 20°C: 2449 Ω • 50°C: 826.Replace the ECU if required. • ECU pin #101 and #102 . vs. Resistance • 20°C: 2449 Ω • 50°C: 826. .Check the wiring harness (short and poor contact).

Check the EGR actuator wiring harness.Check the supply voltage to EGR solenoid valve.Check the EGR valve for stick. • ECU pin #101 and #102 .Open Help .9 Ω . . . • EGR controller circuit: Open or short to ground .20 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. P0115 Supply Voltage Fault to Coolant Temperature Sensor Main Relay Malfunction .If the forced operation is not available. .4 Ω.4 Ω • 100°C: 112.Out of range about EGR gas: Low.Check the relay wiring harness (open.Check the EGR valve for stick. 12 V is applied.Check if the supply voltage of approx. . short and poor contact). .4 Ω . . .Check the resistance of EGR actuator: 15.Check the supply voltage to sensor.Check the EGR solenoid valve.Check the EGR solenoid valve.Out of range about EGR gas: High.2006. . P0685 P1405 EGR Solenoid Valve Malfunction . .Check the wiring harness (open and poor contact).Check the ECU wiring harness for open and short.Short to ground .Short to +Batt . • ECU pin #96 DIAGNOSIS ACTYON SM .Check the resistance of EGR actuator: 15.Check the ECU wiring harness for open and short. .The the main relay is unexpectedly high/low state (ECU is supplied after 3 seconds). . . vs.Actual coolant temp.20%) Stop Stop Mode DTC P0117 Trouble Coolant Temperature Sensor Malfunction .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Check for open and short: ECU pin #9.Check the supply voltage to EGR solenoid valve.Malfunction in recognition of coolant temperature • Less than minimum values (Circuit Open) • External power supply malfunction . .3 Ω • 80°C: 321. Resistance • 20°C: 2449 Ω • 50°C: 826. the previous coolant temperature is retained.If Fuel temperature is invalid. .50%) (max.Replace the ECU if required.Visually check the sensor and replace if required. • EGR controller circuit: Short to battery . replace the ECU. . • ECU pin #96 P1406 EGR Solenoid Valve Malfunction .Relay resistance: 92 ± 9 Ω (at 20°C) .Check the EGR actuator wiring harness.

Open Help .If the forced operation is not available after replacing the relay.Check the relay and relay wiring harness. replace the ECU.Check the ECU wiring harness for open and short. • ECU pin #81 .Short to Ground . .ECU 21 SCAN ECU DTC P1480 Trouble Condenser Fan #1 Circuit Malfunction .Condenser fan #2: Open .Open . • ECU pin #80 . replace the ECU. P1526 Condenser Fan #2 Circuit Malfunction . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. replace the ECU.Check the relay and relay wiring harness.Check the ECU wiring harness for open and short. replace the ECU.Condenser fan #2: Short . P1482 Condenser Fan #1 Circuit Malfunction .Condenser fan #1: Open . .03 . P1527 Condenser Fan #2 Circuit Malfunction . • ECU pin #81 . .If the forced operation is not available after replacing the relay. . .If the forced operation is not available after replacing the relay.Check the relay and relay wiring harness.Condenser fan #2: Short to ground .50%) (max. replace the ECU.Short .If the forced operation is not available after replacing the relay.If the forced operation is not available after replacing the relay.20%) Stop Stop Mode P1481 Condenser Fan #1 Circuit Malfunction . . replace the ECU. P1528 Condenser Fan #2 Circuit Malfunction .Short to Ground .If the forced operation is not available after replacing the relay.Check the ECU wiring harness for open and short.Check the relay and relay wiring harness.Short . • ECU pin #80 . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Check the ECU wiring harness for open and short.Check the relay and relay wiring harness.2006.Check the relay and relay wiring harness. • ECU pin #80 .Condenser fan #1: Short .Check the ECU wiring harness for open and short.Check the ECU wiring harness for open and short. • ECU pin #81 .Condenser fan #1: Short to ground. .

50%) (max.20%) Stop Stop Mode DTC P0325 Trouble Accelerometer #1 (Knock Sensor) Malfunction Help . P1611 Injector Bank #1 Malfunction .22 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. #3) circuit (Low): Short to Ground or to Battery.If the trouble still exists even after replacing the accelerometer.Check the ECU wiring harness for open and short.The signal / noise ratio is too low about accelerometer # 1. DIAGNOSIS ACTYON SM . #4.Check the accelerometer wiring harness and tightening torque. . . • ECU pin #45 and #46 .Check the ECU wiring harness.Replace the ECU if required.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . replace the ECU.The signal / noise ratio is too low about accelerometer # 2.Low Voltage .2006.Operating voltage: 6 ~ 18 V . • Check the other injectors with same manner.Malfunction of injector (#1. . . replace the injector (perform C2I coding after replacement). replace the ECU. . . • If recurred. • ECU pin #44 and #63 .Check the ECU wiring harness for open and short.Check if the trouble recurs while installing the injectors one by one with the ignition key “ON”. P0330 Accelerometer #2 (Knock Sensor) Malfunction (only D27DT) . • Tightening torque: 20 ± 5 Nm . • If recurred.Check if the trouble recurs with the injectors removed and the ignition key “OFF”.If the trouble still exists even after replacing the accelerometer.Check the accelerometer wiring harness and tightening torque. • Tightening torque: 20 ± 5 Nm .Check the injector bank #1: Open and poor contact . check the injector and ECU wiring harness.

Check the ECU wiring harness. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Malfunction of injector (#1. . • Check the other injectors with same manner.2006.Malfunction of injector (#2. . P1619 Injector Bank #2 Malfunction . • If recurred.Replace the ECU if required.Check if the trouble recurs with the injectors removed and the ignition key “OFF”.Low Voltage . #5) circuit (Low): Short to Ground or to Battery. #3) circuit (High): Short to Ground or to Battery. • If recurred.ECU 23 SCAN ECU DTC P1612 Trouble Injector Bank #1 Malfunction .50%) (max. replace the injector (perform C2I coding after replacement). . replace the injector (perform C2I coding after replacement). . . . . • If recurred.High Voltage Help . . check the injector and ECU wiring harness. check the injector and ECU wiring harness.Check the injector bank #2: Short and poor contact .Replace the ECU if required. • If recurred.Operating voltage: 6 ~ 18 V .Check if the trouble recurs while installing the injectors one by one with the ignition key “ON”. O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . • Check the other injectors with same manner. • If recurred. .Replace the ECU if required. .High Voltage . • If recurred.Operating voltage: 6 ~ 18 V . #5) circuit (High): Short to Ground or to Battery.Check the injector bank #1: Short and poor contact . check the injector and ECU wiring harness.Check the ECU wiring harness.Check if the trouble recurs with the injectors removed and the ignition key “OFF”.Check the ECU wiring harness. replace the injector (perform C2I coding after replacement).Check if the trouble recurs with the injectors removed and the ignition key “OFF”. .Check if the trouble recurs while installing the injectors one by one with the ignition key “ON”.03 . • Check the other injectors with same manner. #4.Operating voltage: 6 ~ 18 V .Check if the trouble recurs while installing the injectors one by one with the ignition key “ON”.Malfunction of injector (#2.20%) Stop Stop Mode O P1618 Injector Bank #2 Malfunction . .Check the injector bank #2: Open and poor contact .

2006. .Check the inlet tube for clogging. .Replace the ECU if required (perform C2I coding after replacement). P0201 Injector #1 Circuit Open . O P0202 Injector #2 Circuit Open . perform C2I coding and check again. . . . O DIAGNOSIS ACTYON SM . .Check the inlet tube for clogging.Check the glow plug.Injector #4 cylinder balancing faults (Injector stuck closed). .Check the injector circuit for open. • If the injector pin is normal. .Injector #5 cylinder balancing faults (Injector stuck closed).Check the injector circuit for open. . . P0266 Injector #2 Balancing Fault . . . P0275 Injector #5 Balancing Fault (only D27DT) .Check the EGR.Injector #3 cylinder balancing faults (Injector stuck closed).Check the glow plug.Check the injector circuit for open.Check the glow plug. .Injector #1 cylinder balancing faults (Injector stuck closed). P0269 Injector #3 Balancing Fault . . .Replace the ECU if required. .Check the EGR. #121).Check the EGR. P0272 Injector #4 Balancing Fault .Replace the ECU if required (perform C2I coding after replacement).Injector #1 circuit malfunction: Open. . .Injector #2 circuit malfunction: Open.Replace the ECU if required (perform C2I coding after replacement).Check the injector circuit for open.Check the inlet tube for clogging. .20%) Stop Stop Mode DTC P0263 Trouble Injector #1 Balancing Fault Help . • If the injector pin is defective. .Check the EGR. check the ECU wiring harness (ECU pin: #118.Check the inlet tube for clogging. • If the injector pin is defective.Check the glow plug. • If the injector pin is normal.Replace the ECU if required (perform C2I coding after replacement).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .50%) (max. #114).24 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check the glow plug. . perform C2I coding and check again.Replace the ECU if required.Replace the ECU if required (perform C2I coding after replacement).Check the inlet tube for clogging. . . . . check the ECU wiring harness (ECU pin: #117.Injector #2 cylinder balancing faults (Injector stuck closed).Check the EGR. .Check the injector circuit for open.

perform C2I coding and check again. O P1201 Injector #1 Circuit Short . • If the trouble recurs with the injector removed.Replace the ECU if required. Perform C2I coding and check again. . perform C2I coding and check again. check the wiring harness between the injector and ECU (ECU pin: #117.Replace the ECU if required. . check the wiring harness between the injector and ECU (ECU pin: #117. • If the injector pin is defective. #115). Perform C2I coding and check again.Injector #5 circuit malfunction: Open. P1205 Injector #5 Circuit Short (only D27DT) .50%) (max.Injector #4 circuit malfunction: Open. • If the trouble recurs with the injector removed. #116). • If the injector pin is defective.2006. . check the wiring harness between the injector and ECU (ECU pin: #118. check the ECU wiring harness (ECU pin: #117. #120). • If the trouble recurs with the injector removed.Replace the ECU if required.03 . . #114). .Injector #4 circuit malfunction: Short. . • If the injector pin is normal. check the ECU wiring harness (ECU pin: #117. • If the trouble recurs with the injector removed.Injector #2 circuit malfunction: Short. • If the trouble does not recur. check the wiring harness between the injector and ECU (ECU pin: #118. • If the trouble does not recur.Replace the ECU if required. replace the injector. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . perform C2I coding and check again. Perform C2I coding and check again. check the ECU wiring harness (ECU pin: #118. Perform C2I coding and check again. O P0203 Injector #3 Circuit Open . #120).20%) Stop Stop Mode O P0205 Injector #5 Circuit Open (only D27DT) .Injector #1 circuit malfunction: Short.ECU 25 SCAN ECU DTC P0204 Trouble Injector #4 Circuit Open Help . replace the injector. replace the injector.Injector #5 circuit malfunction: Short.Replace the ECU if required. • If the injector pin is normal. replace the injector.Replace the ECU if required.Injector #3 circuit malfunction: Open. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. • If the trouble does not recur. • If the injector pin is defective. #115). #121). • If the injector pin is normal.Replace the ECU if required. P1204 Injector #4 Circuit Short . . P1202 Injector #2 Circuit Short . • If the trouble does not recur.

The sensing values are higher than specified values for fuel temperature sensor. .394 Ω • 120°C: 0. • If the trouble does not recur.814 Ω 50°C: 0.Short to B+ . -20°C: 21.20%) Stop Stop Mode DTC P1203 Trouble Injector #3 Circuit Short Help .481 Ω • 25°C: 2. (More than maximum sensing values 140°C .Replace the ECU if required. #110 . short and poor contact.Check the supply voltage to sensor.481 Ω • 25°C: 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .199 Ω • 70°C: 0.Actual fuel temp.780 Ω • -10°C: 12.2006.Circuit Short) .Circuit Open) . replace the injector.873 Ω 0°C: 7.252 Ω • 40°C: 1. Resistance • -40°C: 75.Check the ECU wiring and replace the ECU if required. check the wiring harness between the injector and ECU (ECU pin: #117.462 Ω • 10°C: 4.Recovery values when fuel temperature sensor failure: 95°C .811 Ω 90°C: 0.50%) (max.Check the ECU wiring and replace the ECU if required. #116). Resistance • -40°C: 75.Check the supply voltage to sensor. • If the trouble recurs with the injector removed.873 Ω 0°C: 7.812 Ω 30°C: 1. Perform C2I coding and check again. #110 .The sensing values are lower than specified values for fuel temperature sensor. • ECU pin: #109.252 Ω • 40°C: 1. .812 Ω 30°C: 1.355 Ω 20°C: 2.Injector #3 circuit malfunction: Short.206 Ω DIAGNOSIS ACTYON SM . vs. (Less than maximum sensing values .Actual fuel temp.780 Ω • -10°C: 12.087 Ω . short and poor contact.40°C . P0182 Fuel temperature sensor . -20°C: 21.26 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.814 Ω 50°C: 0.206 Ω P0183 Fuel temperature sensor .199 Ω • 70°C: 0.Check the wiring harness for open.811 Ω 90°C: 0. .355 Ω 20°C: 2.Recovery values when fuel temperature sensor failure: 95°C .462 Ω • 10°C: 4.Short to Ground . vs.087 Ω . • ECU pin: #109.394 Ω • 120°C: 0.Check the wiring harness for open.

The power source circuit is faulty for fuel temperature sensor.087 Ω .Check the ECU wiring and replace the ECU if required.Glow plug circuit malfunction: Short to ground.Check the wiring harness for open.355 Ω Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . . (Fuel temperature sensor is mounted in high pressure pump) .ECU 27 SCAN ECU DTC P0180 Trouble Fuel temperature sensor .Check the supply voltage to sensor.Open . .Check the ECU wiring and replace the ECU if required.Check the glow plug power supply.Check the glow plug power supply. . . . • ECU pin #113 .814 Ω 50°C: 0.812 Ω 30°C: 1. short and poor contact.Glow plug circuit malfunction: Short.2006. • ECU pin #113 . • ECU pin: #109.Check the ECU wiring and replace the ECU if required.Check the glow plug wiring harness for open. P1530 #1 Heater operating circuit .481 Ω • 25°C: 2.Check the glow plug relay operations.Check the ECU wiring and replace the ECU if required.#1 heater circuit malfunction: Open.Vref Help .Short to Ground .Check the heater relay operations. • ECU pin #113 .Short . .Check the glow plug power supply.Check the ECU wiring and replace the ECU if required.252 Ω • 40°C: 1. #110 . . . -20°C: 21. .394 Ω • 120°C: 0.Actual fuel temp.Check the wiring harness for open.50%) (max. . . • ECU pin #61 .Check the glow plug wiring harness for open.Glow plug circuit malfunction: Open.Check the glow plug relay operations.20%) Stop Stop Mode P1678 Glow Plug Drive Malfunction .462 Ω 0°C: 7.780 Ω • 10°C: 4. P1679 Glow Plug Drive Malfunction .If the forced operation is not available.Check the glow plug wiring harness for open. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . replace the ECU. vs.206 Ω • -10°C: 12.811 Ω 90°C: 0.Check the glow plug relay operations.873 Ω 20°C: 2.03 .Open . Resistance • -40°C: 75.199 Ω • 70°C: 0. .Recovery values when fuel temperature sensor failure: 95°C . P1680 Glow Plug Drive Malfunction .

• ECU pin #62 .Check the wiring harness for short.Short to Ground .Check the heater relay operations.Check the ECU wiring and replace the ECU if required.Check the heater relay operations.Check the heater relay operations. P1534 #2 Heater operating circuit .#2 heater circuit malfunction: Short to ground. • ECU pin #61 . . replace the ECU. . .If the forced operation is not available.20%) Stop Stop Mode DTC P1531 Trouble #1 Heater operating circuit .Check the ECU wiring and replace the ECU if required.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • ECU pin #62 . .Check the ECU wiring and replace the ECU if required.#1 heater circuit malfunction: Short to ground.If the forced operation is not available.Open . replace the ECU.If the forced operation is not available. . replace the ECU.Check the wiring harness for open.Short to B+ . replace the ECU. • ECU pin #62 . DIAGNOSIS ACTYON SM . . P1535 #2 Heater operating circuit .Check the heater relay operations. P1536 #2 Heater operating circuit .28 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . . .#2 heater circuit malfunction: Open. .Check the wiring harness for short. .Short to B+ Help .If the forced operation is not available.2006.Short to Ground .#2 heater circuit malfunction: Short.Check the wiring harness for short. • ECU pin #61 . P1532 #1 Heater operating circuit .Check the heater relay operations.Check the ECU wiring and replace the ECU if required.Check the ECU wiring and replace the ECU if required. replace the ECU.50%) (max.If the forced operation is not available. . . .Check the wiring harness for short.#1 heater circuit malfunction: Short. .

055 ± 0.5 ± 0.44 Ω • When out of specified value: replace high pressure pump and IMV .1 V • Output voltage at 1600 bar: 4. • Check the fuel level in fuel tank.Check the ECU wiring harness. . . Check the fuel system for air influx. • Check the fuel filter specification.5 ± 0. Check the fuel system for air influx.125 V • Output voltage at atmospheric pressure: 0.Check the IMV wiring harness.Check the ECU wiring harness. • Check the fuel level in fuel tank. • Supply voltage: 5 ± 0.03 .04 V . • Supply voltage: 5 ± 0.Check the rail pressure sensor. .Check the IMV wiring harness. fuel rails and high pressure pipes for leaks. . fuel rails and high pressure pipes for leaks.055 ± 0.2006.50%) (max. .Replace the ECU if required. . • Check the ECU pin #87 for open and short.Replace the ECU if required.Rail pressure faults: Too high .1 V • Output voltage at 1600 bar: 4.44 Ω • When out of specified value: replace high pressure pump and IMV . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. .Rail pressure faults: Too low . • Check the ECU pin #87 for open and short.ECU 29 SCAN ECU DTC P1254 Trouble Maximum Rail Pressure Control Malfunction (IMV Fault) Help .Check the transfer pressure fuel pressure lines.20%) Stop Stop Mode P1253 Minimum Rail Pressure Control Malfunction (IMV Fault) .Check the high pressure fuel lines.Check the transfer pressure fuel pressure lines.Check the high pressure fuel lines.125 V • Output voltage at atmospheric pressure: 0. • Check the fuel filter specification. O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . .04 V .Check the IMV resistance: 5.Check the rail pressure sensor.Check the IMV resistance: 5.

P1257 Too Large Transfer Pressure Fuel in Rail Pressure System . • Check the fuel rails and high pressure pipes for leaks.5 ± 0.04 V . • Check the fuel filter specification. Check the fuel system for air influx.Check the ECU wiring harness.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .Check the ECU wiring harness.Check the transfer pressure fuel pressure lines. .Check the rail pressure sensor. • Supply voltage: 5 ± 0.055 ± 0.Rail pressure fault: IMV current trim too high.Rail pressure fault: IMV current trim too high.Check the IMV resistance: 5.1 V • Output voltage at 1600 bar: 4. .Check the high pressure fuel system. • Check the ECU pin #87 for open and short. . Check the fuel system for air influx.Replace the ECU if required. O DIAGNOSIS ACTYON SM . .2006. • Check the fuel rails and high pressure pipes for leaks.30 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.1 V • Output voltage at 1600 bar: 4.5 ± 0.44 Ω • When out of specified value: replace high pressure pump and IMV . drift.04 V .125 V • Output voltage at atmospheric pressure: 0. • Supply voltage: 5 ± 0. .Check the IMV resistance: 5.Replace the ECU if required.125 V • Output voltage at atmospheric pressure: 0.Check the high pressure fuel system.44 Ω • When out of specified value: replace high pressure pump and IMV . .Check the transfer pressure fuel pressure lines. • Check the fuel filter specification.055 ± 0.50%) (max. . • Check the fuel level in fuel tank.Check the rail pressure sensor. drift.Check the IMV wiring harness.Check the IMV wiring harness. .20%) Stop Stop Mode DTC P1256 Trouble Too Small Transfer Pressure Fuel in Rail Pressure System Help . . • Check the ECU pin #87 for open and short. • Check the fuel level in fuel tank.

. • Check the fuel rails and high pressure pipes for leaks. • Check the fuel level in fuel tank. . . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Replace the ECU if required. . • Supply voltage: 5 ± 0. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.ECU 31 SCAN ECU DTC P1258 Trouble Too Small High Pressure Fuel in Rail Pressure System Help .Check the ECU wiring harness.04 V .Check the rail pressure sensor.055 ± 0. drift. drift. Check the fuel system for air influx.50%) (max. .Check the high pressure fuel system.Check the IMV wiring harness.Check the transfer pressure fuel lines.5 ± 0.1 V • Output voltage at 1600 bar: 4.20%) Stop Stop Mode P1259 Too Large High Pressure Fuel in Rail Pressure System . • Check the fuel filter specification. . . Check the fuel system for air influx.44 Ω • When out of specified value: replace high pressure pump and IMV . • Check the ECU pin #87 for open and short.44 Ω • When out of specified value: replace high pressure pump and IMV .2006.Rail pressure fault: IMV current trim too high. • Check the fuel rails and high pressure pipes for leaks.5 ± 0.055 ± 0. • Check the fuel level in fuel tank.Rail pressure fault: IMV current trim too high.Replace the ECU if required.Check the ECU wiring harness. • Supply voltage: 5 ± 0.Check the IMV resistance: 5.1 V • Output voltage at 1600 bar: 4.03 . .04 V .Check the IMV wiring harness.Check the high pressure fuel system. . .Check the IMV resistance: 5.125V • Output voltage at atmospheric pressure: 0. • Check the fuel filter specification.125 V • Output voltage at atmospheric pressure: 0.Check the rail pressure sensor.Check the transfer pressure fuel lines. • Check the ECU pin #87 for open and short.

Check the rail pressure sensor. Check the fuel system for air influx.IMV driver circuit malfunction: Short . • When out of specified value: replace high pressure pump and IMV . . O O P0251 IMV Driver Circuit Malfunction .Replace the ECU if required.32 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.20%) Stop Stop Mode O DTC P1191 Trouble Pressure Build Up .Short to Ground .04 V .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • When out of specified value: replace high pressure pump and IMV .Replace the ECU if required.Check the IMV resistance.Check the ECU wiring harness.Replace the ECU if required. O O O DIAGNOSIS ACTYON SM .50%) (max.Check the IMV wiring harness. • Check the ECU pin #87 for open and short.Check the IMV resistance. P0255 IMV Driver Circuit Malfunction . .Check the IMV wiring harness.055 ± 0.Check the IMV wiring harness.Short . • Check the fuel rails and high pressure pipes for leaks.Check the transfer pressure fuel lines. . .The pressure build up during cranking is too slow.125 V • Output voltage at atmospheric pressure: 0.IMV driver circuit malfunction: Short to ground . . .IMV driver circuit malfunction: Open . . • Check the fuel filter specification.Check the ECU wiring harness. O O P0253 IMV Driver Circuit Malfunction .Open . .44 Ω • When out of specified value: replace high pressure pump and IMV .Check the IMV resistance.Check the high pressure fuel system.5 ± 0. • Check the ECU pin #87 for short.Too Slow Help .1 V • Output voltage at 1600 bar: 4. • Check the ECU pin #87 for short to ground.Check the IMV wiring harness. • Supply voltage: 5 ± 0.Check the IMV resistance: 5.2006. • Check the fuel level in fuel tank.Check the ECU wiring harness.Replace the ECU if required. .Check the ECU wiring harness. • Check the ECU pin #87 for open. • When out of specified value: replace high pressure pump and IMV . . .

• Actual air temperature vs.Replace the ECU if required.340 Ω • 100°C: 0.Check the ECU wiring harness. • Actual air temperature vs.ECU 33 SCAN ECU DTC Trouble Help .03 . .18 Ω • 50°C: 1.Check the supply voltage to sensor.420 Ω • 40°C: 1.40 Ω • Recovery values when intake air temperature sensor failure: 50°C . Resistance • -40°C: 39.50%) (max.20%) Stop Stop Mode CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . Voltages • 20°C: 2.Check the sensor wiring harness. • Check the ECU pin #64 and #84 for open. • Check the source power circuit for short to ground.2006.65 Ω • 30°C: 2.Check the sensor resistance.609 Ω • 80°C: 0.The intake air temperature sensing value is lower than maximum value of 150°C: Open .850 Ω • 0°C: 5. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.202 Ω • 120°C: 0.499 Ω • 20°C: 2.127 Ω • Recovery values when intake air temperature sensor failure: 50°C .260 Ω • -20°C: 13.166 Ω • 60°C: 0. .

.499 Ω • 20°C: 2.18 Ω • 50°C: 1. Voltages • 20°C: 2.40 Ω • Recovery values when intake air temperature sensor failure: 50°C . • Check the ECU pin #64 and #84 for open.Check the ECU wiring harness.65 Ω • 30°C: 2.Replace the ECU if required.260 Ω • -20°C: 13.20%) Stop Stop Mode DTC P0112 Trouble Intake Air Temperature Circuit Malfunction .609 Ω • 80°C: 0.420 Ω • 40°C: 1.340 Ω • 100°C: 0.Check the sensor wiring harness.34 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. • Actual air temperature vs.50%) (max.850 Ω • 0°C: 5.166 Ω • 60°C: 0. DIAGNOSIS ACTYON SM .Check the supply voltage to sensor.Check the sensor resistance.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Check the source power circuit for short to ground.Open Help . . • Actual air temperature vs.The intake air temperature sensing value is lower than maximum value of 150°C: Open .2006.202 Ω • 120°C: 0.127 Ω • Recovery values when intake air temperature sensor failure: 50°C . Resistance • -40°C: 39.

340 Ω • 100°C: 0.Check fault code .The intake air temperature sensing value is lower than minimum value or higher than maximum value.Replace the injector and perform C2I coding again.Check the sensor resistance.Check the supply voltage to sensor.202 Ω • 120°C: 0. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . • Actual air temperature vs.40 Ω • Recovery values when intake air temperature sensor failure: 50°C .03 . 75°C above condition try again .Check the sensor wiring harness.65 Ω • 30°C: 2.50%) (max.ECU 35 SCAN ECU DTC P0110 Trouble Intake Air Temperature Circuit Malfunction .420 Ω • 40°C: 1. .18 Ω • 50°C: 1. .Coolant temp.260 Ω • -20°C: 13.127 Ω • Recovery values when intake air temperature sensor failure: 50°C . 75°C above condition try again .499 Ω • 20°C: 2.No fault condition.20%) Stop Stop Mode P1171 #1 Injector MDP Malfunction . • Check the ECU pin #64 and #84 for open and short. P1172 #2 Injector MDP Malfunction . .166 Ω • 60°C: 0. Resistance • -40°C: 39.Coolant temp. • Actual air temperature vs. or the external power to HFM sensor is faulty.The #2 injector MDP is faulty.Replace the injector and perform C2I coding again.C2I coding check . • Check the source power circuit for short to ground. . vehicle speed 70 KPH . Voltages • 20°C: 2.Replace the ECU if required.C2I coding check .No fault condition.609 Ω • 80°C: 0.850 Ω • 0°C: 5.Source Power Problem Help .The #1 injector MDP is faulty. .Check the ECU wiring harness.2006. vehicle speed 70 KPH . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check fault code .

Check the IMV resistance: 5. .5 ± 0. vehicle speed 70 KPH . • Check the fuel rails and high pressure pipes for leaks.Check the wiring harness.Check fault code .Coolant temp.Coolant temp.The rail pressure is excessively high. . 75°C above condition try again .Check the supply voltage to sensor.44 Ω • When out of specified value: replace high pressure pump and IMV . • Check the fuel level in fuel tank.Check the high pressure fuel system.Check the IMV wiring harness.The #4 injector MDP is faulty.Check fault code .Replace the ECU if required.36 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. P1173 #3 Injector MDP Malfunction . . .Coolant temp. • Supply voltage: 5 ± 0.Check the transfer pressure fuel lines.The potentiometer 1 is not plausible with potentiometer 2. .No fault condition.Replace the injector and perform C2I coding again. P1175 #5 Injector MDP Malfunction (only D27DT) . 75°C above condition try again . O DIAGNOSIS ACTYON SM .Check the ECU wiring harness.1 V • Output voltage at 1600 bar: 4.04 V .C2I coding check .No fault condition. . 53 and #32.125 V • Output voltage at atmospheric pressure: 0. Check the fuel system for air influx. • Check the fuel filter specification. . 75°C above condition try again . . vehicle speed 70 KPH .Replace the ECU if required.The #3 injector MDP is faulty.50%) (max. .No fault condition.Replace the injector and perform C2I coding again. 14 for open and short.The #5 injector MDP is faulty.20%) Stop Stop Mode DTC P1174 Trouble #4 Injector MDP Malfunction Help . . • Check the ECU pin #87 for open and short. P1120 Accelerator Pedal Sensor #1 Malfunction . .Check the ECU wiring harness.055 ± 0.Check fault code .Check the rail pressure sensor.2006.C2I coding check .Check the accelerator pedal module. .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . P1252 Too High IMV Pressure .Replace the injector and perform C2I coding again. • Check the ECU pin #71.C2I coding check . . vehicle speed 70 KPH .

O O P0123 Accelerator Pedal Sensor #1 Malfunction .Replace the ECU if required. 53 and #32. 32. .Check the supply voltage to sensor.Check the supply voltage to sensor.Check the wiring harness.ECU 37 SCAN ECU DTC P1121 Trouble Accelerator Pedal Sensor #2 Malfunction Help .Check the ECU wiring harness. . 14 for open and short. . #53 for open and poor contact. 53 and #57. .Check the wiring harness.Check the ECU wiring harness.Check the accelerator pedal module. . .2006.50%) (max.Check the wiring harness. .Short .Check the ECU wiring harness. . . 53 and #57. • Check the ECU pin #72.03 . .Stuck .Replace the ECU if required. .Check the ECU wiring harness. • Check the ECU pin #71.Check the brake switch wiring harness and operations.When triggering limp home mode. .Replace the ECU if required O O P1124 Accelerator Pedal Sensor Malfunction .The accelerator pedal sensor is stuck. . • Check the ECU pin #71. • Check the circuit for open and short.Check the supply voltage to sensor.Out of range about potentiometer 1 of pedal sensor: lower than specified values .Check the accelerator pedal module. 71. 71. O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Check the accelerator pedal operations. . • Check the ECU pin #71.The potentiometer 2 is not plausible with potentiometer 1. O O P1123 Accelerator Pedal Sensor Malfunction (Reducde Torque Mode) . 14 for open and short.Check the accelerator pedal. 32. • Check the circuit for open and short. . #53 for short and poor contact. . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . O P0122 Accelerator Pedal Sensor #1 Malfunction . . .Out of range about potentiometer 1 of pedal sensor: higher than specified values . .Check the ECU wiring harness. .Check the wiring harness. • Check the ECU pin #72. . .Open .Check the ECU wiring harness.Replace the ECU if required.Replace the ECU if required.Check the accelerator pedal module.Check the wiring harness. . .Check the supply voltage to sensor. .Check the supply voltage to sensor. .Check the accelerator pedal module.20%) Stop Stop Mode O O P1122 Accelerator Pedal Sensor Malfunction (Limp Home Mode) .Replace the ECU if required.Check the accelerator pedal. 14 for open and short. .When triggering reduced torque mode.

Replace the ECU if required.Replace the ECU if required.The 2.Supply Voltage Fault Help . • Check the ECU pin #57. .Check the wiring harness.20%) Stop Stop Mode O DTC P0120 Trouble Accelerator Pedal Sensor #1 Malfunction .Short . • Check the ECU pin #32.2006. #14 for short and poor contact. . .Check the supply voltage to sensor.Check the ECU wiring harness.Check the accelerator pedal.Check the wiring harness. . O P0220 Accelerator Pedal Sensor #2 Malfunction .The 5 V supply voltage is faulty.Check the wiring harness.Replace the ECU if required.38 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check the ECU wiring harness. O O P0223 Accelerator Pedal Sensor #2 Malfunction . .Check the ECU wiring harness. #14 for open and poor contact. P0222 Accelerator Pedal Sensor #2 Malfunction . . • Check the ECU pin #72. .Check the wiring harness.Check the accelerator pedal. . • Check the circuit for open and short. • Check the circuit for open and short.Check the ECU wiring harness. .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . #14 for open and short.Check the accelerator pedal.Open .Replace the ECU if required.50%) (max.Out of range about potentiometer 2 of pedal sensor: higher than specified values . . .Check the supply voltage to sensor.Check the accelerator pedal.5 V supply voltage is faulty. • Check the ECU pin #32. • Check the circuit for open and short. . . .Out of range about potentiometer 2 of pedal sensor: lower than specified values . #53 for open and short. . O DIAGNOSIS ACTYON SM . . • Check the circuit for open and short. .Check the supply voltage to sensor.Check the supply voltage to sensor.Supply Voltage Fault . .

Check the fuel rail pressure sensor. • Maximum sensing values: 1. .Check the supply voltage to sensor.Check the supply voltage to sensor. #26 for open and poor contact. O P0190 Supply Voltage Fault to Fuel Rail Pressure Sensor .Check the fuel rail pressure sensor.600 bar (Short) .ECU 39 SCAN ECU DTC P0192 Trouble Fuel Rail Pressure Sensor Malfunction .112 bar (Open) .04V .5 ± 0.The supply voltage to fuel rail pressure sensor is faulty. #26 for open and short.5±0.Check the fuel rail pressure sensor.125 V • Output voltage at atmospheric pressure: 0. . • Check the ECU pin #25.5±0. #26 for short and poor contact.50%) (max.125V • Output voltage at atmospheric pressure: 0.Replace the ECU if required.04 V .2006. • Check the ECU pin #25. . • Check the ECU pin #6.Replace the ECU if required.Check the sensor and ECU wiring harness.Short . • Output voltage at 1600 bar: 4.Check the sensor and ECU wiring harness.The fuel rail pressure sensing values are lower than specified values.055± 0. • Check the fuel rails and high pressure pipes for leaks.055± 0.Open Help .125V • Output voltage at atmospheric pressure: 0. . .The fuel rail pressure sensing values are higher than specified values.Check the supply voltage to sensor. • Check the fuel rails and high pressure pipes for leaks. • Minimum sensing values: . • Output voltage at 1600 bar: 4. . . O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Check the sensor and ECU wiring harness.Replace the ECU if required.04V . • Check the fuel rails and high pressure pipes for leaks.20%) Stop Stop Mode O P0193 Fuel Rail Pressure Sensor Malfunction .055 ± 0. • Output voltage at 1600 bar: 4.03 . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.

Check the supply voltage to sensor. • Check the ECU pin #6. • Maximum sensing values: 90 bar (Short) .04 V . • Check the fuel rails and high pressure pipes for leaks.Check the sensor and ECU wiring harness.Replace the ECU if required. P1192 Fuel Rail Pressure Sensor Initial Signal Fault .Replace the ECU if required. • Check the ECU pin #25. #26 for open and short.Check the fuel rail pressure sensor.Check the supply voltage to sensor. . . . • Check the ECU pin #25.The rail pressure sensor initial values are higher than specified values with the ignition “ON”. • Check the fuel rails and high pressure pipes for leaks. • Output voltage at 1600 bar: 4.Check the sensor and ECU wiring harness.The rail pressure drop is too high.Check the supply voltage to sensor.Check the fuel rail pressure sensor. .Replace the ECU if required.04 V .5 ± 0. • Minimum sensing values: bar (Open) 9 0 O . P1193 Fuel Rail Pressure Sensor Initial Signal Fault .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .125 V • Output voltage at atmospheric pressure: 0. .055 ± 0.20%) Stop Stop Mode O O DTC P0191 Trouble Fuel Rail Pressure Sensor Signal Fault Help .High .5 ± 0. O DIAGNOSIS ACTYON SM . . .50%) (max.Check the sensor and ECU wiring harness.055 ± 0.2006.40 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.04 V .Low .055 ± 0. • Output voltage at 1600 bar: 4. #26 for short and poor contact. • Output voltage at 1600 bar: 4.125 V • Output voltage at atmospheric pressure: 0.The rail pressure sensor initial values are lower than specified values with the ignition “ON”.125 V • Output voltage at atmospheric pressure: 0. #26 for open and poor contact.Check the fuel rail pressure sensor.5 ± 0. • Check the fuel rails and high pressure pipes for leaks.

. 4. . . . .The main relay is stuck . . .5 ± 0.Replace the ECU if required.Check the ECU wiring harness.ECU 41 SCAN ECU DTC P1190 Trouble Fuel Rail Pressure Sensor Initial Signal Fault Help .Replace the ECU if required.2006.04 V .The vehicle speed signal through CAN communication is faulty.Check the sensor and ECU wiring harness.If the forced operation is not available. .50%) (max. . • Output voltage at 1600 bar: 4.03 .Resistance of main relay: 92 Ω ± 9 Ω (at 20°C) .Replace the ECU if required. .Check the ECU wiring harness.20%) Stop Stop Mode O O . P0642 ECU Supply Voltage 1 Fault . Shut down.055 ± 0.Check the CAN communication line for open and short.Check the main relay wiring harness. • Check the fuel rails and high pressure pipes for leaks. • Maximum sensing values: 90 bar (Short) • Minimum sensing values: bar (Open) 90 Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. #26 for open and short.Check the wiring harnesses. replace the ECU.125 V • Output voltage at atmospheric pressure: 0.Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1 .Low (5 V) .Check the supply voltage to sensor. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Stuck . • Check the ECU pin #25.The rail pressure sensor initial values are higher or lower than specified values with the ignition “ON”. P0215 Main Relay Fault .Check the fuel rail pressure sensor. • Check the ECU pin #3.Check the ABS/ESP and TCU communication lines. 5 for open and short. .Check the fuse for main relay P1500 Vehicle Speed Fault .Malfunction reference supply voltage from ECU • Supply voltage: 5 V .

.Check the wiring harnesses.High (5 V) .Check the wiring harnesses.Malfunction reference supply voltage from ECU • Supply voltage: 5 V . O O DIAGNOSIS ACTYON SM .Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1 . rail pressure sensor.20%) Stop Stop Mode DTC P0643 Trouble ECU Supply Voltage 1 Fault .Replace the ECU if required.Replace the ECU if required. . cam sensor .Replace the ECU if required.Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1. rail pressure sensor.Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1 .Replace the ECU if required.Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1. rail pressure sensor.Check the wiring harnesses. booster pressure sensor.Malfunction reference supply voltage from ECU • Supply voltage: 5 V .2006.Check the supply voltage to each sensor • Supply voltage (5 V): accelerator pedal sensor 1.Check the wiring harnesses. . . cam sensor .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . P0641 ECU Supply Voltage 1 Fault (5 V) . HFM sensor.Low (5 V) . HFM sensor.Malfunction reference supply voltage from ECU • Supply voltage: 5 V .Replace the ECU if required.High (5 V) Help . . P0652 ECU Supply Voltage 2 Fault .Check the wiring harnesses. O O O P0653 ECU Supply Voltage 2 Fault . HFM sensor. cam sensor . booster pressure sensor.Malfunction reference supply voltage from ECU • Supply voltage: 5 V . O O P0651 ECU Supply Voltage 2 Fault (5 V) .Malfunction reference supply voltage from ECU • Supply voltage: 5 V . booster pressure sensor.42 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.50%) (max.

5 V .5 V) . O P0246 Turbo Charger Actuator Circuit Fault . .Check the supply voltage to each sensor • Supply voltage (2.Replace the ECU if required.Malfunction reference supply voltage from ECU • Supply voltage: 2. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.50%) (max.Check the chassis ground wiring harness.Check the solenoid valve. .High (2. .The ECU is defective. . • Check the ECU pin #95 for open and short. .Short to B+ .ECU 43 SCAN ECU DTC P0698 Trouble ECU Supply Voltage Fault .Replace the ECU if required.Check the ECU wiring harness for short and poor contact.The waste gate driver circuit is short to ground or open . . .Check the ECU.5 V): accelerator pedal sensor 2 . .Check the wiring harnesses. P0697 ECU Supply Voltage Fault (2. .Replace the ECU if required.Low (2.Short .5 V .5 V) Help . P0245 Turbo Charger Actuator Circuit Fault . .Check the ECU. . .Replace the ECU if required.Malfunction reference supply voltage from ECU • Supply voltage: 2. . O P1607 ECU Injector Cut Fault .5 V .20%) Stop Stop Mode P0699 ECU Supply Voltage Fault .Check the wiring harnesses.Replace the ECU if required. .Check the actuator wiring harness.55 V): accelerator pedal sensor 2 .03 .The turbo charger actuator power source circuit is short.Check the solenoid valve.Malfunction reference supply voltage from ECU • Supply voltage: 2. O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM . O O P0606 ECU Watchdog Fault .Check the supply voltage to each sensor • Supply voltage (2.Replace the ECU if required.Check the wiring harnesses.Replace the ECU if required. .The ECU is defective.55 V): accelerator pedal sensor 2 .Check the actuator wiring harness.Check the ECU wiring harness.Check the chassis ground wiring harness.5 V) .2006.Check the supply voltage to each sensor • Supply voltage (2. .

The ECU is defective. . .Replace the ECU if required. . .The ECU is defective. . P1601 ECU Fault .The ECU is defective.Check the chassis ground wiring harness.Check the chassis ground wiring harness. .Check the ECU. .Check the ECU. . .Check the chassis ground wiring harness.The ECU is defective.Replace the ECU if required. .The ECU is defective.Replace the ECU if required.Replace the ECU if required.Replace the ECU if required. . .Check the ECU. .The ECU is defective.The ECU is defective.The ECU is defective.Check the ECU. . . O O P1621 ECU Fault .Check the ECU. O O P1615 ECU Fault .Check the chassis ground wiring harness.Check C2I code .The ECU is defective.Check the ECU.Check the chassis ground wiring harness. .2006. . O O P1622 ECU Fault .Replace the ECU if required.Check the chassis ground wiring harness.The ECU is defective.Check the ECU. . .44 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. .Replace the ECU if required.Check the chassis ground wiring harness.Replace the ECU if required. .Check the chassis ground wiring harness.20%) Stop Stop Mode O DTC P1600 Trouble ECU Shut Down Fault Help .Check the ECU. O O DIAGNOSIS ACTYON SM . .Replace the ECU if required.Check the ECU. O P1602 ECU Fault .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .50%) (max. . .Check the chassis ground wiring harness. O O P1620 ECU Fault .Check the chassis ground wiring harness. .Check the ECU. . . . O O P1616 ECU Fault .Replace the ECU if required. O O P1606 ECU Fault . . O P1614 ECU C2I/MDP Fault . .

Check the EGR actuator wiring harness. . .Replace the ECU if required.20%) Stop Stop Mode O P0400 EGR Control Valve Fault P1235 VGT Operation Fault . .Check if the MDP is successful. • The EGR controller circuit is open or short to ground.Refer to P0372. O P0335 P1170 No Crank Signals Torque Trim Fault .When the EGR emission is more than specified value.Replace the ECU if required. O P1608 ECU Fault .03 .4 Ω. • The EGR controller is short to battery.High . .Refer to P0372. .Check the supply voltage to sensor.Check the supply voltage to EGR solenoid valve.The boost pressure control is faulty.Replace the ECU if required. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. .2006.ECU 45 SCAN ECU DTC P1148 Trouble Accelerometer (Knock Sensor) Learning Fault Help .Check the wiring harness and the ECU wiring harness.The ECU is defective.50%) (max. . . .Check the ECU. . .Check the ECU wiring harness. . .Check the chassis ground wiring harness.Check the resistance of EGR valve: 15. . . O CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Check the accelerometer (knock sensor) sensor and wiring harness.Check if the EGR valve is stuck.Check the air intake system. • Check the ECU pin #96 for open and short. .

Check the resistance of each glow plug: below 1 Ω. . . .46 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .Open .The glow plug circuit is open. . • Check the ECU pin #34 for short to ground.Check each glow plug wiring harness. .Check each glow plug wiring harness. .Check the resistance of each glow plug: below 1 Ω.2006. .Check the glow plug wiring harness.Check the glow plug wiring harness. .Check or replace glow controller. . .Replace the ECU if required.Check the resistance of glow plug: below 1 Ω.Check the communication line between ECU and each glow plug.The glow plug circuit is open.Check the communication line between ECU and each glow plug. P0673 #5 Glow Plug Fault .Check the resistance of glow plug: below 1Ω.Check the glow plug relay.Check the ECU wiring harness. . . .glow controller is faulty. DIAGNOSIS ACTYON SM .Check the communication line between ECU and each glow plug.Open . . .The glow plug circuit is open.Replace the ECU if required.Check the communication line between ECU and glow controller.Check the ECU wiring harness.Check the ECU wiring harness. . .50%) (max. • Check the ECU pin #34 for short to ground. . .Check or replace glow controller. .Check or replace glow controller. .Check the ECU wiring harness.Replace the ECU if required. . .Check the glow controller.Check each glow plug wiring harness.Open . P0671 #3 Glow Plug Fault .Replace the ECU if required.Replace the ECU if required. .Check the communication line between ECU and glow controller. P0672 #4 Glow Plug Fault .20%) Stop Stop Mode DTC P1676 Trouble Glow Plug Communication Fault Help . . . . .The communication between ECU and glow controller is faulty. .Check the resistance of each glow plug: below 1 Ω.Check the ECU wiring harness. P1677 Glow Plug Controller Fault .

Replace the ECU if required.Check the resistance of each glow plug: below 1 Ω. . . . CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Short (B+) .Check the ECU wiring harness.Check or replace glow controller. .Check the communication line between ECU and each glow plug. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Open Help .Short (B+) .Open .Check the resistance of each glow plug: below 1 Ω.Check or replace glow controller. .Replace the ECU if required.Check the ECU wiring harness. .Check each glow plug wiring harness.The glow plug circuit is short.The glow plug circuit is open. .Check the communication line between ECU and each glow plug. .Check or replace glow controller. . . . P1672 #4 Glow Plug Fault . . P1671 #3 Glow Plug Fault .Check the communication line between ECU and each glow plug.Check each glow plug wiring harness.Check the communication line between ECU and each glow plug. .The glow plug circuit is short.Replace the ECU if required.ECU 47 SCAN ECU DTC P0674 Trouble #1 Glow Plug Fault . .Check the communication line between ECU and each glow plug. .Short (B+) . .Check or replace glow controller.50%) (max.Replace the ECU if required. . .Replace the ECU if required. . . . P1674 #1 Glow Plug Fault .03 . . .Check each glow plug wiring harness.Check the ECU wiring harness.Check the resistance of each glow plug: below 1 Ω . . .Check the ECU wiring harness. .Short (B+) . .Check the ECU wiring harness.Check the resistance of each glow plug: below 1 Ω . P1673 #5 Glow Plug Fault .Check or replace glow controller.2006. .The glow plug circuit is open. .The glow plug circuit is short. .20%) Stop Stop Mode P0675 #2 Glow Plug Fault . . .The glow plug circuit is short.Check the ECU wiring harness.Check the communication line between ECU and each glow plug.Check each glow plug wiring harness.Check the resistance of each glow plug: below 1Ω.Check each glow plug wiring harness.Replace the ECU if required.Check or replace glow controller. .Check each glow plug wiring harness.Check the resistance of each glow plug: below 1 Ω .

2006. O P1149 P1634 Too High Water Level in Fuel Filter Immobilizer Fault (refer to immobilizer section) P1635 No response from Immobilizer (refer to immobilizer section) . .Short to Ground . . .Perform the immobilizer coding again.Check the resistance of each glow plug: below 1Ω .Replace the ECU or TCU if required. .50%) (max.Check each glow plug wiring harness.Check the ECU if required. P0700 TCU Signal Fault .Check the air conditioner sensors and wiring harnesses. . . . .48 ECU Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Check the ECU if required.The communication between ECU and TCU is faulty.Perform the immobilizer coding again.Check the ECU wiring harness. .Check the immobilizer unit for open and short or check the supply voltage. . P1540 Air Conditioner Operating Circuit Fault . .Short (B+) Help .Check the ECU wiring harness. .The glow plug circuit is short. . .Check the immobilizer antenna. .Check or replace glow controller. .No response from immobilizer. .Short . .Replace the ECU or immobilizer if required.Check the ECU if required. .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .Check the air conditioner sensors and wiring harnesses.Check the immobilizer unit for open and short or check the supply voltage.No response from immobilizer.Check the ECU pin #54.Replace the ECU if required.Check the air conditioner sensors and wiring harnesses.Drain the water from fuel filter.Check the ECU wiring harness. . P1541 Air Conditioner Operating Circuit Fault .20%) Stop Stop Mode DTC P1675 Trouble #2 Glow Plug Fault .Check the communication line between ECU and TCU. • Check the ECU pin #34 for open and short.Replace the ECU if required.Open . DIAGNOSIS ACTYON SM . .Check the communication line between ECU and each glow plug. • Check the ECU pin #34 for open and short.Check the ECU wiring harness. . .Check the ECU wiring harness.Check the ECU wiring harness. 73 for open and short.Check the immobilizer antenna. . P1542 Air Conditioner Operating Circuit Fault . .

ECU 49 SCAN ECU DTC P1630 Trouble Wrong response from Immobilizer (refer to immobilizer section) Help .Check the ECU wiring harness. .03 .Check the immobilizer unit for open and short or check the supply voltage.Check the immobilizer antenna and transponder for damage.Check the ECU wiring harness. . . . • Check the ECU pin #34 for open and short.The invalid key is inserted or no communication between transponder and immobilizer (no response from transponder). . . . . .Perform the immobilizer coding again. . . . . .Perform the immobilizer coding again. P1632 Immobilizer Fault (refer to immobilizer section) . .2006.Replace the ECU if required.Perform the immobilizer coding again. Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. . • Check the ECU pin #34 for open and short.Check the ECU wiring harness. • Check the ECU pin #34 for open and short.Check the ECU wiring harness.No response from immobilizer.No key coding. .Key memory is (permissible .Check the immobilizer antenna and transponder for damage.Replace the ECU if required.Check the immobilizer antenna and transponder for damage. . .Check the immobilizer antenna and transponder for damage. .Perform the immobilizer coding again. CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Check the ECU wiring harness. P0633 Immobilizer Fault (refer to immobilizer section) .Check the immobilizer unit for open and short or check the supply voltage. • Check the ECU pin #34 for open and short.5). .50%) (max.The immobilizer is not operating. • Check the ECU pin #34 for open and short.Check the immobilizer unit for open and short or check the supply voltage.Perform the immobilizer coding again.Replace the ECU if required.Replace the ECU if required.Replace the ECU if required. . .20%) Stop Stop Mode P1631 Immobilizer Fault (refer to immobilizer section) .Check the immobilizer unit for open and short or check the supply voltage. .Check the immobilizer unit for open and short or check the supply voltage.Check the immobilizer antenna and transponder for damage. P1633 Immobilizer Fault (refer to immobilizer section) . not available .

Severe trouble is not defined. ABS/ESP vehicle). P0602 Vehicle speed sensor coding failure .Check the ECU wiring harness.HFM sensing values are lower than specified sensing values (not circuit failure but sensor failure). the vehicle speed sensor failure appears.Perform the immobilizer coding again. . Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max.Even though the ESP or TCCU is not installed in the vehicle.ABS/ESP variant coding is failure. • Check the ECU pin #34 for open and short.CAN communication is failure. . .Check the “Vehicle speed sensor” coding.CAN cluster is failure. the trouble code does not appear.20%) Stop Stop Mode P1102 High HFM Sensor Signal .50%) (max.Specified pulse: 52 pulses/1 revolution . . . the vehicle speed signal is sent through CAN communication. . .Check the immobilizer unit for open and short or check the supply voltage.50 ECU DTC P1636 Trouble Immobilizer Fault (refer to immobilizer section) Help . P1103 Low HFM Sensor Signal P1501 Variant coding failure (vehicle speed) P1503 Vehicle speed sensor input failure . . .HFM sensing values are higher than specified sensing values (not circuit failure but sensor failure).2006.Replace the ECU if required.CAN related device in ECU is defective. P0600 CAN BUS failure .CAN communication between units is failure. .If the vehicle speed is below 15 km/h (even over 1. .CAN communication between units is failure.600 rpm of engine speed) when the “Vehicle speed sensor” coding is “YES” (Non-ABS vehicle).If the “Vehicle speed sensor” coding is “NO” (CAN. the vehicle speed input failure appears. .If the pulse from speed pulse ring is more than specified value during the specified interval when the “Vehicle speed sensor” coding is “YES” (NonABS vehicle). DIAGNOSIS ACTYON SM .TCU variant coding is failure. .Check the “Vehicle speed sensor” coding.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . P0608 P0613 ABS/ESP coding failure TCU coding failure P0644 CAN cluster failure .CAN communication between units is failure.Check the immobilizer antenna and transponder for damage. . . .

Torque Torque Delayed Immediately Limp Reduction Reduction Engine Engine Home MIL (max. .Auto cruise deceleration switch or related wiring harness is defective.Check the neutral switch wiring harness.Engine mount level control circuit is failure. CAN cluster sends this signal to ECU via CAN communication line.ECU internal failure . . . . Then. . .The “Neutral” signal from manual transmission is sent to CAN cluster.50%) (max.ECU 51 SCAN ECU DTC P1565 P1566 P1567 P1568 P1569 P3040 P3041 P1657 P1658 P1659 P0805 Trouble Auto cruise switch failure (Acceleration) Auto cruise switch failure (OFF) Auto cruise switch failure Auto cruise switch failure (Deceleration) Auto cruise switch failure (Safety) ECU internal failure ECU internal failure (only D27DT) Engine mount control failure (Open) Engine mount control failure (Short to B+) Engine mount control failure (Short to ground) Abnormal neutral signal Help .Auto cruise safety switch or related wiring harness is defective.Auto cruise acceleration switch or related wiring harness is defective. .20%) Stop Stop Mode CHANGED BY EFFECTIVE DATE AFFECTED VIN DIAGNOSIS ACTYON SM .Engine mount level control circuit is short to B+.ECU cannot determine where the signal problem is.2006. in neutral switch.ECU internal failure . . wiring or CAN communication line.Auto cruise OFF switch or related wiring harness is defective. . .Auto cruise switch or related wiring harness is defective.Engine mount level control circuit is short to ground.03 .

...................... 2 Ion (BTRA) automatic transmission .... 14 Power train system ............................................ 45 Faulty shift pattern ........................................... 43 Electrical / garage shift test ......................... 46 Shift quality faults ........................ 25 Manual 1 ................. 101 Clearing trouble codes ........................... 4 Shift pattern diagram ....... 111 Connector end view ............................................................. 42 Fluid leak diagnosis and repair ........................... 2 Specifications .................... 23 Reverse .......................... 41 Functional check procedure .................................................. 48 After teardown faults ....................................................................................................................................... 45 Drive faults ............................................................ 13 Hydraulic control circuit ..................................ION (BTRA) AUTO TRANSMISSION TABLE OF CONTENTS DESCRIPTION AND OPERATION ................. 113 ............................................ 6 Control systems ................................ 13 Accelerator pedal sensor ......................................................................... 22 Park and neutral ........................... 52 Ion automatic transmission assembly .... 33 Drive 3 lock up and manual 3 lock up ....................................... 44 Electronic adjustments .................................. 101 Circuit diagram of TCU .......................................... 52 ON-VEHICLE SERVICE ................. 98 Removal and installation of TCU ................ 67 Front and rear band adjustment ....... 31 Drive 3 and manual 3 . 101 Diagnostic trouble codes ................................................... 100 TROUBLE CODE DIAGNOSIS .............................................................................................................................................................. 56 Rebuild warnings ........................................ 44 Road test procedure ................ 99 Fastener tightening specifications ................... 54 UNIT REPAIR ................................................ 95 Gear shift control lever ...................................... 52 Valve body ......................................... 35 Drive 4 (overdrive) ...... 44 SPECIAL TOOLS AND EQUIPMENT ............. 41 DIAGNOSIS ................................................. 101 TCU diagnostic system overview ....................................................................................................................................................................................................... 39 SYMPTOM DIAGNOSIS ................................... 37 Drive 4 lock up .................. 5 Operators interfaces .......... 27 Drive 1 ............... 50 REPAIR INSTRUCTIONS ....................................... 7 Electronic control system .................................................................................................................................................................................................... 41 Basic knowledge required ................... 7 Hydraulic control system .................................................................... 41 Transmission fluid level service procedure ......................... 29 Drive 2 and manual 2 ...... 112 DIAGNOSTIC INFORMATION AND PROCEDURES .......... 57 Assembly procedure .......... 56 Disassembly procedure ........................................... 18 Power flows ...

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. rate of throttle opening. These features benefit the customer through improved fuel economy and noise reduction. Power (kW) Configuration 260 mm Torque Converter-Wide 320 160 Ratio Gear Set Splined Output for Transfer Case The TCM utilizes throttle position. Y220_3A2010 ION (BTRA) AUTO TRANSMISSION ACTYON SM . The output pressure of this solenoid is controlled as a function of transmission fluid temperature to maintain consistent shift feel throughout the operating range. WINTER schedule is used to facilitate starting in second gear. and a POWER schedule is used to maximize performance. Of primary significance is the Transmission Control Module (TCM) which is a microprocessor based control system. engine speed. Typically the NORMAL schedule is used to maximize fuel economy and driveability. vehicle speed. gear selector position and mode selector inputs.2 DESCRIPTION AND OPERATION ION (BTRA) AUTOMATIC TRANSMISSION The ION (BTR) Four Speed Automatic Transmission is an electronically controlled overdrive four speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and eliminates unnecessary slippage. The TCM drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects. and several independent schedules are programmed depending on the vehicle. transmission fluid temperature. Shift scheduling is highly flexible. Max. and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects.

3 Appearance 4WD Automatic Transmission M / T Servo Adapter housing Inhibiter switch CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.03 A / CON A / BAG 2WD Automatic Transmission BRAKE ST’NG SP AXLE CLUTCH Oil cooler outlet T/C Torque converter Oil cooler return A/T .

278 ~ 2.2 kΩ (1.0 V) 10.6 ~ 19.0 V) 1.638 ~ 17.000 0.5 V) 6.5 ~ 4.0 V) 4.4 kΩ (2.177 ~ 6.5 13.0 V) Remark ION (BTRA) AUTO TRANSMISSION ACTYON SM .0 ~ 3.742 1.8 ~ 2.616 Ω 2.428 4.9 kΩ (2.5 V) 18.5 V) 3.8 ~ 7.2006.708 2.8 ~ 11. 9.4 kΩ (1.55 260 (mm) 3 EA 1 EA 2 EA 1 EA 3 EA 4 EA 2 EA 76 kg CASTROL TQ 95 Approx.4 SPECIFICATIONS Description Gear ratios 1st 2nd 3rd 4th Reverse Final gear ratio Torque converter Diamerter Number of element Number of Step Number of Phase Transmission component Planetary gear set One-way clutch Multi disc clutch Band brake Weight Oil Including oil Fluid specification Fluid capacity Resistance of oil temperature sensor -20°C 0°C 20°C 100°C 135°C Resistance of gear position sensor 1 gear position 2 gear position 3 gear position D gear position N gear position R gear position P gear position Specifications 2.0 ~ 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2 kΩ (3.287 Ω 5.0 kΩ (4.508 1.723 Ω 177 ~ 196 Ω 75 ~ 85 Ω 1.2 kΩ (3.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T SHIFT PATTERN DIAGRAM . Power Mode CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .5 Normal Mode * WINTER mode has same shift pattern with NORMAL mod3e except 2nd gear drive-off.2006.

When NORMAL mode is selected upshifts will occur to maximize fuel economy. fourth to second (4 → 2).Overdrive range is used for all normal driving conditions. The inhibitor switch allows the engine to be started. Engine braking is applied with reduced throttle. • D . • P . the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF.Manual 2 provides two gear ratios (first and second). • 3 . When WINTER mode is selected. ION (BTRA) AUTO TRANSMISSION ACTYON SM . The driving modes available to be selected vary with vehicle types.Manual 1 is used to provide the maximum engine braking when driving down the severe gradients. When POWER mode is selected. But the final drive is not locked by the parking pawl.6 OPERATORS INTERFACES There are three operator interfaces as the following. Do not select the Park position until the vehicle comes to a complete stop because it mechanically locks the output shaft. POWER and WINTER modes. starting in second gear is facilitated. first to third (1 → 3).Neutral allows the engine to be started and operated while driving the vehicle. Typically the driver should have the option to select among NORMAL. Driving Mode Selector Switch Gear Shift Control Lever Staggered Gate Gear Selection Indicator Window Y220_3A2020 Driving Mode Selector The driving mode selector consists of a driving mode selector switch and indicator light. third to first (3 → 1) and second to first (2 → 1) shifts are all available as a function of vehicle speed. • N . upshifts will occur to give maximum performance and the POWER mode indicator light is switched ON. • 1 . Gear Shift Control Lever The transmission uses a conventional shift control lever. • Gear Shift Control Lever • Driving Mode Selector • Indicator Light • 2 . The inhibitor switch enables reverse lamp operation.Reverse allows the vehicle to be operated in a rearward direction. The gear shift control lever can be moved from one position to another within the staggered configuration of the shift control lever gate to positively indicate the gear selection.Manual 3 provides three gear ratios (first through third) and prevents the transmission from operating in 4th gear. fourth to third (4 → 3).Park position prevents the vehicle from rolling either forward or backward by locking the transmission output shaft. so thewheels are free to rotate. First to second (1 → 2). Downshifts are available by depressing the accelerator. 3rd gear is used when driving on long hill roads or in heavy city traffic. The driving mode selector is located on the center console and allows the driver to select the driving mode. Lockup clutch may be enabled in 3rd and 4th gears depending on vehicle type. Downshifts are available for safe passing by depressing the accelerator. third to second (3 → 2). • Auto shift indicator light comes ON when the ignition switch ON and shows the gear shift control lever posi-tion. 4th gear (overdrive gear) reduces the fuel consumption and the engine noise. the parking should be used in addition to the park position.2006. For safety reasons. • R . second to fourth (2 → 4). • POWER mode indicator light comes ON when the POWER mode is selected and when the kickdown switch is depressed. second to third (2 → 3). It is used to provide more power when climbing hills or engine braking when driving down a steep hill or starting off on slippery roads. throttle position and the time change rate of the throttle position. The inhibitor switch allows the engine to be started.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Indicator Light The indicator light is located on the instrument panel. • WINTER mode indicator light comes ON when the WINTER mode is selected. There is no power transferred through the transmission in Neutral. third to fourth (3 → 4).

adjusts the variable pressure solenoid ramp pressure then executes the shift. ELECTRONIC CONTROL SYSTEM The electronic control system comprises of sensors. For further details of limp modes and memory retention refer to the Diagnostic Trouble Code Diagnosis Section.40 and 185°F). a diagnostics output and the driving mode indicator light. • Output circuits which control external devices such as the Variable Pressure Solenoid (VPS) driver. for example when arc welding or jump starting. One is the electronic control system that monitors vehicle parameters and adjusts the transmission performance. The TCM contains: • Processing logic circuits which include a central microprocessor controller and a back-up memory system. • Input circuits. and to turn ON and OFF the two regulator valves that control the shift feel. Once the TCM has determined the type of gearshift required the TCM accesses the shift logic.40 and 85°C (. The seventh solenoid is the proportional or Variable Pressure Solenoid (VPS) which works with the two regulator valves to control shift feel. result in full limp mode giving only third or fourth gear and reverse. It is also protected against electrical noise and voltage spikes. When a failure or abnormal operation is detected the TCM records the condition code in the diagnostics memory and implements a Limp Home Mode (LHM). Throttle input calibration constants and the diagnostics information are stored in Electrically Erasable Programmable Read Only Memory (EEPROM) that retains the memory even when power to the TCM is disconnected. The TCM is designed to operate at ambient temperatures between . Another is the hydraulic control system that implements the commands of the electronic control system commands. This control is via the hydraulic valve body. via the shift schedule. Six of the seven solenoids are used to control the line pressure.7 BTRA M74 4WD automatic transmission consists of two control systems. . whenever the input conditions change such that the required gear state is different to the current gear state. In general input failures are handled by providing a default value. however all the usual precautions should be observed. operate the shift valves and the torque converter lock-up clutch. The TCM reads the inputs and activates the outputs according to values stored in Read Only Memory (ROM). CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . On/ Off solenoid drivers. Output failures. the TCM initiates a gear shift to bring the two states back into line.2006. It is mounted under the driver’s side front seat in the vehicle cabin. Transmission Control Module (TCM) The TCM is an in-vehicle micro-processor based transmission management system. The TCM continuously monitors every input and output circuit for short or open circuits and operating range. The actual limp home mode used depends upon the failure detected with the object to maintain maximum driveability without damaging the transmission. TCM continuously monitors the input values and uses these. which contains seven electromagnetic solenoids.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T CONTROL SYSTEMS Processing logic Shift schedule and calibration information is stored in an Erasable Programmable Read Only Memory (EPROM). At the same time it monitors. the current gear state. estimates the engine torque output. which are capable of damaging the transmission. The TCM controls the hydraulic control system. to determine the required gear state. via the solenoid outputs. a TCM and seven solenoids.

a TCM and seven solenoids. Once the TCM has determined the type of gearshift required the TCM accesses the shift logic. The seventh solenoid is the proportional or Variable Pressure Solenoid (VPS) which works with the two regulator valves to control shift feel. Transmission Control Module (TCM) The TCM is an in-vehicle micro-processor based transmission management system. and to turn ON and OFF the two regulator valves that control the shift feel. Six of the seven solenoids are used to control the line pressure. result in full limp mode giving only third or fourth gear and reverse. On/ Off solenoid drivers. adjusts the variable pressure solenoid ramp pressure then executes the shift. Output failures. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . The TCM contains: • Processing logic circuits which include a central microprocessor controller and a back-up memory system. .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T CONTROL SYSTEMS Processing logic Shift schedule and calibration information is stored in an Erasable Programmable Read Only Memory (EPROM). ELECTRONIC CONTROL SYSTEM The electronic control system comprises of sensors. The TCM is designed to operate at ambient temperatures between . the TCM initiates a gear shift to bring the two states back into line. a diagnostics output and the driving mode indicator light. • Output circuits which control external devices such as the Variable Pressure Solenoid (VPS) driver. It is mounted under the driver’s side front seat in the vehicle cabin. In general input failures are handled by providing a default value. Another is the hydraulic control system that implements the commands of the electronic control system commands.2006.7 BTRA M74 4WD automatic transmission consists of two control systems. This control is via the hydraulic valve body. • Input circuits. estimates the engine torque output. via the shift schedule. One is the electronic control system that monitors vehicle parameters and adjusts the transmission performance. TCM continuously monitors the input values and uses these. The TCM controls the hydraulic control system. to determine the required gear state. which are capable of damaging the transmission. It is also protected against electrical noise and voltage spikes. Throttle input calibration constants and the diagnostics information are stored in Electrically Erasable Programmable Read Only Memory (EEPROM) that retains the memory even when power to the TCM is disconnected. however all the usual precautions should be observed.40 and 185°F). the current gear state. For further details of limp modes and memory retention refer to the Diagnostic Trouble Code Diagnosis Section. for example when arc welding or jump starting. whenever the input conditions change such that the required gear state is different to the current gear state. via the solenoid outputs. The TCM continuously monitors every input and output circuit for short or open circuits and operating range. When a failure or abnormal operation is detected the TCM records the condition code in the diagnostics memory and implements a Limp Home Mode (LHM). operate the shift valves and the torque converter lock-up clutch. The actual limp home mode used depends upon the failure detected with the object to maintain maximum driveability without damaging the transmission. At the same time it monitors.40 and 85°C (. which contains seven electromagnetic solenoids. The TCM reads the inputs and activates the outputs according to values stored in Read Only Memory (ROM).

transmission fluid temperature. • Engine Speed The engine speed signal is derived from the Controller Area Network (CAN) via Engine Control Module (ECM). This results in maximum oil flow through the external oil cooler and eliminates slippage in the torque converter. sends the output shaft speed signal to the Engine Control Module (ECM). ION (BTRA) AUTO TRANSMISSION ACTYON SM . If the transmission fluid temperature exceeds 135°C (275°F). throttle position.2006.177 2. vehicle speed. the TCM will impose converter lock-up at lower vehicle speeds and in some vehicles flashes the mode indicator light. the TCM requires engine speed. 723 196 85 Y220_3A2040 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Vehicle Speed The vehicle speed sensor.8 Y220_3A2030 TCM inputs To function correctly. This ensures the correct gear selection and shift feel for all driving conditions.638 5. gear position and Kickdown Switch inputs to determine the variable pressure solenoid current ramp and on/off solenoid states.278 117 75 Maximum 17. which is located in the transfer case. • Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission.616 2.287 6. Both these actions combine to reduce the oil temperature in the transmission.03 Temperature (°C) -20 0 20 100 135 (Overheat Mode Threshold) Resistance (Ohms) Minimum 13. The information is then transferred to the TCM via the CAN. The inputs required by the TCM are as follows. This sensor is a typical Negative Temperature Coefficient (NTC) resistor with low temperatures producing a high resistance and high temperatures producing a low resistance.

8 ~ 2. Y220_3A2050 Gear position sensor The gear position sensor is incorporated in the inhibitor switch mounted on the side of the transmission case. Connection to the diagnostic input of the TCM is via a connector included in the vehicle’s wiring harness or computer interface. If the battery voltage is greater than 16. This signal is taken from the main supply to the TCM.6 ~ 19 4.2 3 3 ~ 3.4 21.4 6.9 Pin No. This input may also be used to clear the stored fault history data from the TCM’s retentive memory.5 V. Readings for Resistance / Shift Lever Positions Shift Lever Position Manual 1 Manual 2 Manual 3 Drive Neutral Reverse Park Ω Resistance (kΩ) 1 ~ 1. the TCM will resume normal operation after a 30 seconds delay period. 1 2 3 4 5 6 7 8 9 10 Wire Color Red Blue Yellow Orange Green Violet Brown Green White White Connects to Solenoid 1 Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 6 Solenoid 7 Solenoid 5 Temperature Sensor Temperature Sensor • Indicate to the TCM which lever position has been selected by way of a varying resistance. If the battery voltage at the TCM falls below 11. This condition normally occurs only when the battery is in poor condition. • Solenoids • Mode Indicator Light Y220_3A2060 • Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.5 ~ 4.2 10. All other shifts are allowed but may not occur because of the reduced voltage. Codes and colors in Solenoid Loom Pin No.3 V. TCM outputs The outputs from the TCM are supplied to the components described below.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T • Illuminate the reverse lamps when Reverse is selected . the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited. The gear position sensor is a multi-function switch providing three functions. the transmission will adopt limp home mode and all solenoids are turned OFF.9 Diagnostic inputs The diagnostic control input or K-line is used to initiate the outputting of diagnostic data from the TCM to a diagnostic test instrument.8 ~ 7. Battery voltage monitoring input The battery voltage monitoring input is connected to the positive side of the battery.8 ~ 11. When system voltage recovers.2 18.

This solenoid provides the signal pressure to the clutch and band regulator. Solenoid ON activates the clutch. • Solenoid 5: S5 is a variable pressure solenoid that ramps the pressure during gear changes. • Solenoid 1 and 2: S1 and S2 are normally open ON/ OFF solenoids that set the selected gear. thereby controlling the shift pressures. Solenoid Logic for Static Gear States Gear 1st 2nd 3rd 4th Reverse Neutral Park S1 ON OFF OFF ON OFF OFF OFF S2 ON ON OFF OFF OFF OFF OFF ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Solenoid 3 and 4: S3 and S4 are normally open ON/ OFF solenoids that combine to control shift quality and sequencing. S4 switches the front band regulator valve OFF or ON. Solenoids 1 to 6 (S1 to S6) are mounted in the valve body. S5 also provides the signal pressure for the converter clutch regulator valve. These solenoids determine static gear position by operating the shift valves. S3 switches the clutch regulator valve OFF or ON. Solenoid OFF gives high pressure. • Solenoid 7: S7 is a normally open ON/OFF solenoid that controls the application of the converter clutch. Note that S1 and S2 solenoids also send signal pressure to allow or prohibit rear band engagement.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Solenoid 6: S6 is a normally open ON/OFF solenoid that sets the high/low level of line pressure. S5 also provides the signal pressure for the converter clutch regulator valve. while Solenoid 7 (S7) is mounted in the pump cover.10 Solenoids The TCM controls seven solenoids.2006.

550 mA to 400 mA @ 60 kph.2006.03 S4 OFF S3 OFF S4 OFF 2-3 S2 OFF S3 ON S4 ON 3-4 4-3 4-2 S1 ON S4 ON S4 ON S3 ON 750 mA to 600 mA 750 mA to 900 mA S4 OFF S1 OFF S4 OFF S1 OFF 750 mA to 950 mA 4-1 S3 ON S4 ON 3-2 S2 ON S4 ON 600 mA to 450 mA @ 20 kph. 3-1 S3 ON S4 ON 2-1 S4 ON Conv. 800 mA to 650 mA @ 100 kph.11 Solenoid Operation during Gearshifts Shift 1-2 1-3 To Initiate Shift S1 OFF S4 ON S1 OFF S2 OFF S3 ON S4 ON Typical S5 Current Ramp 750 mA to 600 mA To Complete Shift S4 OFF S3 OFF 850 mA to 750 mA S4 OFF T/C 1-4 S2 OFF S3 ON S4 ON 850 mA to 750 mA 700 mA to 500 mA S3 OFF CLUTCH ACTYON SM . Clutch ON OFF S7 ON 700 mA to 400 mA 600 mA to 100 mA 700 mA to 950 mA 800 mA to 950 mA 600 mA to 1000 mA S2 ON S3 OFF S2 ON S3 OFF S4 OFF S4 OFF S1 ON S2 ON S3 OFF S4 OFF S1 ON S4 OFF S7 OFF CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION A / CON A / BAG BRAKE ST’NG SP AXLE M / T A/T .

gear state and engine speed.2006. Line 500 pressure. from ECM via CAN without any additional sensors. that is no gearshift is taking place. A variable pressure solenoid produces a hydraulic pressure inversely proportional to the current applied. Line pressure is completely independent of shift pressure and is a function of throttle position. the mode indicator light may be used to indicate the mode that has been selected or if an overheat condition exists. The stored trouble codes can also be cleared by scan tool. stored faults. the VPS current is set to 200 mA giving maximum output pressure. The particular code is sent to the microprocessor via the K-line and this results in the software selecting the correct shift and VPS ramp parameters. is the reference pressure for the VPS. K-Line The K-line is typically used for obtaining diagnostic information from the TCM. TCM obtains the actual engine speed and throttle position. The output port is open to exhaust at the solenoid valve. At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by pushing the plunger away from the valve. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . This allows for one TCM design to be used over different vehicle mod-els. Y220_3A2070 Variable pressure solenoid multiplexing system Friction element shifting pressures are controlled by the Variable Pressure Solenoid (VPS). runtime parameters are then available. The friction elements are then fed oil pressure equal to Line 500 multiplied by the amplification ratio. VPS pressure is multiplexed to the clutch regulator valve.03 . When the VPS is at standby. Mode indicator light Depending on the application. This applies full Line 500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure it squeezes the S5 oil out between the regulator valve and the plunger. Normally open (NO) solenoid POWER ON: Line 500 port is closed. Decreasing current increases output (S5) pressure. Under steady state conditions the band and clutch regulator valve solenoids are switched OFF. When a shift is initiated the required ON/OFF solenoid is switched ON cutting the supply of Line 500 to the plunger. This results in a reduction of sensors and wiring. The K-line can be used for vehicle coding at the manufacturer’s plant or in the workshop. Current applied will vary between a minimum oaf 200 mA and a maximum of 1000 mA.12 Solenoid valve symbols (ON/OFF solenoids) The solenoid symbol shown adjacent to each solenoid on the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power ON or OFF. Communication systems CAN The Controller Area Network (CAN) connects various control modules by using a twisted pair of wires. S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures. vehicle speed and accelerator position etc. The VPS then carries out the required pressure ramp and the timed shift is completed by switching OFF the ON/ OFF solenoid and returning the VPS to the standby pressure. and the VPS output pressure is always below line 500 pressure. Increasing current decreases output (S5) pressure. The mode indicator light is usually located on the instrument cluster. The output port is open to line 500. (approximately 440 to 560 kPa). During a gearshift the TCM applies a progressively increasing or decreasing (ramped) current to the solenoid. to share common information. A scan tool with a special interface is connected to the TCM via Data Link Connector (DLC) and all current faults. This system enables either the band or clutch or both to be electrically controlled for each gearshift. POWER OFF: The exhaust port is closed. the band regulator valve and the converter clutch regulator valve during automatic gearshifts.

Torque converter lock-up is initiated by toggling the converter clutch control valve with an ON/OFF solenoid. • Converter clutch control valve • Clutch apply feed regulator valve Connector M / T The transferred values from accelerator pedal sensors to ECU is sent to TCU via the CAN communication lines. The solenoid supply pressure regulator valve provides reference pressure for all the solenoids. 2 sensor (ACC 2) determines if the signals from No. pump body and main case. The signals from No. • B1R exhaust valve All upshifts are accomplished by simultaneously switching on a shift valve(s). It consists of two sensors.1 sensor (ACC 1) is the element to determine the amount of the fuel injection and injection timing while the signals from No. Low pressure can be obtained by activating an ON/OFF solenoid with high line pressure being the default mode. 1 sensor is correct by comparing them with its own signal values. The valve body contains the following. BRAKE ST’NG SP AXLE CLUTCH T/C A/T HYDRAULIC CONTROL SYSTEM ACCELERATOR PEDAL SENSOR .2006. All downshifts are accomplished by switching VPS pressure to the band and/or clutch regulator valve and sending a ramped current to the VPS. and high and low for reverse. The actual apply and release of the clutch is regulated by the VPS via the converter clutch regulator valve. • Primary regulator valve for line pressure • Converter clutch regulator valve • Solenoid S7 The main case contains the following.13 The hydraulic controls are located in the valve body. This pressure has no effect on shift quality and merely provides static clutch capacity during steady state operation. and then sending the VPS a ramped current. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . The primary regulator valve is located in the pump cover and supplies four line pressures.03 A / CON A / BAG The accelerator pedal sensor changes the position of the accelerator pedal into the electric signal and sends the conditions that a driver requires to the engine ECU. switching VPS pressure to the band and/or clutch regulator valve. The TCU changes the gear by determining the shift timing according to these values. high and low for forward gears. The shift is completed by switching the regulators OFF and at the same time causing the VPS to reach maximum pressure. • Manual valve • Three shift valves • Sequence valve • Solenoid supply pressure regulator valve • Line pressure control valve • Band apply feed regulator valve • Solenoid S1 to S6 • Reverse lockout valve The pump cover contains the following. The shift is completed by simultaneously switching the regulators OFF. switching the shift valves and at the same time causing the VPS to return to stand-by pressure.

switching VPS pressure to the band and/or clutch regulator valve. and high and low for reverse. The valve body contains the following. high and low for forward gears.13 The hydraulic controls are located in the valve body. The primary regulator valve is located in the pump cover and supplies four line pressures. pump body and main case. Low pressure can be obtained by activating an ON/OFF solenoid with high line pressure being the default mode. The signals from No. It consists of two sensors. and then sending the VPS a ramped current. 2 sensor (ACC 2) determines if the signals from No. 1 sensor is correct by comparing them with its own signal values. The shift is completed by simultaneously switching the regulators OFF. • Manual valve • Three shift valves • Sequence valve • Solenoid supply pressure regulator valve • Line pressure control valve • Band apply feed regulator valve • Solenoid S1 to S6 • Reverse lockout valve The pump cover contains the following. The TCU changes the gear by determining the shift timing according to these values. • Primary regulator valve for line pressure • Converter clutch regulator valve • Solenoid S7 The main case contains the following. The shift is completed by switching the regulators OFF and at the same time causing the VPS to reach maximum pressure.2006. The solenoid supply pressure regulator valve provides reference pressure for all the solenoids. Torque converter lock-up is initiated by toggling the converter clutch control valve with an ON/OFF solenoid. All downshifts are accomplished by switching VPS pressure to the band and/or clutch regulator valve and sending a ramped current to the VPS. The actual apply and release of the clutch is regulated by the VPS via the converter clutch regulator valve.1 sensor (ACC 1) is the element to determine the amount of the fuel injection and injection timing while the signals from No. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • B1R exhaust valve All upshifts are accomplished by simultaneously switching on a shift valve(s). This pressure has no effect on shift quality and merely provides static clutch capacity during steady state operation.03 A / CON A / BAG The accelerator pedal sensor changes the position of the accelerator pedal into the electric signal and sends the conditions that a driver requires to the engine ECU. • Converter clutch control valve • Clutch apply feed regulator valve Connector M / T The transferred values from accelerator pedal sensors to ECU is sent to TCU via the CAN communication lines. BRAKE ST’NG SP AXLE CLUTCH T/C A/T HYDRAULIC CONTROL SYSTEM ACCELERATOR PEDAL SENSOR . switching the shift valves and at the same time causing the VPS to return to stand-by pressure.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.14 HYDRAULIC CONTROL CIRCUIT Y220_3A208A ION (BTRA) AUTO TRANSMISSION ACTYON SM .

During a 2-1 gearshift the band apply feed oil is allowed to exhaust via the 1-2 shift valve. ION (BTRA) AUTO TRANSMISSION ACTYON SM . the C4 clutch is engaged and the front band (B1) is released. It is used on all 2-3 and 3-2 gearshifts. The 1-2 shift valve works in conjunction with the 3-4 shift valve to disengage the C4 clutch in first gear.2006. and engage C4 in second gear.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH Y220_3A2110 T/C M / T A/T Valve Body . The switching of this valve is achieved by S2 which is located at the end of the valve spool. 2 position. These actions are sequenced by the 4-3 sequence valve. The switching of this valve is achieved by S1 which is located at the end of the valve spool. 4 position. CHANGED BY EFFECTIVE DATE AFFECTED VIN 3-4 shift valve The 3-4 shift valve is a two position valve. • Connects the inner apply area of the front servo (B1AI) to the Band Apply Feed (BAF) circuit thus allowing greater apply forces to the front band.15 Y220_3A2090 Manual valve The manual valve is connected to the vehicle selector mechanism and controls the flow of oil to the forward and reverse circuits. During a 4-3 gearshift. 2-3 shift valve The 2-3 shift valve is a two position valve. The manual valve directs the line pressure into the PRND fluid circuits. It is used for all 3-4 and 4-3 gearshifts. The switching of this valve is achieved by using S1 and/ or S2. When the valve is moved to the 3. During a 1-2 gearshift drive oil from the manual valve passes through to the second gear circuit. When Manual 1 is selected the C4 clutch and rear band (B2) are engaged. During a 3-4 gearshift the 3-4 shift valve: • Exhausts the front band release (B1R) circuit thereby allowing the application of the front band (B1). It is used for all 1-2 and 2-1 gearshifts. oil from the second gear circuit is routed to the third gear circuit and the transmission is changed to third gear. • Exhausts the Overrun Clutch (OC) circuit which allows the C4 clutch to disengage. Y220_3A2120 Y220_3A2100 1-2 shift valve The 1-2 shift valve is a two position valve that must be switched to the 2. In the 1. second gear oil from the 1-2 shift valve is prevented from entering the third gear circuit. 3 and 4 position in order to get any forward gear other than first gear. The manual valve function is identical in all forward gear positions except that in the Manual 1 position an additional supply of oil is directed to the 12 shift valve for application of the rear band and the C4 overrun clutch.

ION (BTRA) AUTO TRANSMISSION ACTYON SM . It switches during 3-4 and 4-3 gearshifts although it performs no function during the 3-4 shift.16 The 3-4 shift valve also switches during 1-2 and 2-1 gearshifts where its function is to apply the overrun clutch (C4) in second gear but to release it in first gear. It provides a regulated pressure to the front servo. Third gear oil supplied to the valve is regulated to provide an output pressure. Heavy throttle application causes the normally open S6 to open (switch Off) thus closing line 500 and opening S6 to exhaust.03 Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio (1.4: 1) valve. and controls the change rate of the front band (B1) state to give the desired shift quality. Line pressure control valve Line pressure is controlled by S6. This valve provides a regulated pressure to the C1 clutch and controls the change rate of the clutch state to give the desired shift quality. Line pressure is used as the feeding oil to this regulator and the output is termed line 500. Clutch Apply Feed (CAF) pressure.25 times the line 500 pressure. Clutch apply feed regulator valve The clutch apply feed regulator valve is a fixed ratio (2. the output pressure is 2. Y220_3A2140 Y220_3A2160 Solenoid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids (S1 to S7).25 times the S5 signal pressure when S3 is ON. 25:1) valve. of 2.4 times the S5 signal pressure when S4 is ON. which acts as the line pressure control valve.4 times the line 500 pressure. it is opposed by spring force and causes LOW line pressure for light throttle application and cruising. Y220_3A2150 Y220_3A2130 4-3 sequence valve The 4-3 sequence valve is a two position spring loaded valve. Removal of S6 pressure from the PRV results in HIGH line pressure. Refer to “1-2 Shift Valve” in this section. CHANGED BY EFFECTIVE DATE AFFECTED VIN . When S4 is OFF the output pressure is 1. When S6 pressure is applied to the end of the Primary Regulator Valve (PRV). When S3 is OFF. During the 4-3 shift the 4-3 sequence valve delays the connection of the Clutch Apply Feed (CAF) circuit to the B1R circuit until the B1R circuit has been fully pressurized by using the third gear circuit. Band Apply Feed (BAF) pressure.2006. Second gear oil supplied to the valve is regulated to provide an output pressure. of 1. Note that the C4 clutch is applied in Manual 1 by virtue of the manual valve and the 1-2 shift valve. This prevents objectionable engine flare on completion of the 4-3 gearshift.

CLUTCH T/C M / T A/T . In this position. Y220_3A2190 Y220_3A2180 When the manual valve is in P. R or N positions. R and N. The PRV also regulates the supply of oil to the converter via the converter feed port.17 S1. The cascade effect of the PRV ensures the first priority of the valve is to maintain line pressure at very low engine speeds. to connect the line pressure to the B2 feed. 2 or 1 positions. This feature protects the transmission from abuse by preventing the undesirable application of B2 at high speed. CHANGED BY EFFECTIVE DATE AFFECTED VIN Primary regulator valve The Primary Regulator Valve (PRV) regulates the transmission line pressure (or pump output pressure). If any of the above conditions are not satisfied. When S6 is switched ON. engagement of B2 is prohibited.2006. and the output of S5. This prevents the application of B2 in any of the forward driving gears except M1.S2 pressure is exhausted and the valve is held in the lockout position by the spring. This valve uses S1-S2 pressure as a signal pressure and controls the application of the rear band (B2). ION (BTRA) AUTO TRANSMISSION ACTYON SM . Oil is fed to both the inner and outer apply areas of the rear servo piston.03 A / CON A / BAG BRAKE ST’NG SP AXLE Reverse lockout valve The reverse lockout valve is a two position valve contained in the upper valve body. Note that if the transmission is in failure mode. overriding any signal pressures and holding the valve in the lockout position. and by providing a reverse lockout function. Pump cover Y220_3A2170 While the manual valve is in D. If there is an excess of oil for the transmission’s needs then the PRV moves further to allow oil to return to the suction port. When the engine speed increases and the pump supplies an excess of oil the PRV moves to uncover the converter feed port thereby pressurizing the converter. Under these conditions. Throttle position = 12 %. This valve gives either high or low line pressure depending on whether S6 is switched OFF or ON. Low line pressure is used during light throttle applications and cruising. In R. B2 is applied in P. 3. R. The reverse lockout valve toggles under the influence of the S1-S2 pressure. When reverse gear is selected. the TCM switches solenoids S1 and S2 to OFF. Heavy throttle will cause S6 to switch OFF and thereby cause high line pressure. This stepped line pressure control has no detrimental effect on shift feel because all shifting pressures are controlled by separate band and clutch regulator valves. drive oil is applied to the spring end of the valve. vehicle speed = 10 km/h. vehicle speed = 3 km/h. S6 pressure is applied to the PRV moving it against spring pressure and opening the line pressure circuit to the pump suction port resulting in reduced line pressure. Engine speed = 1600 rpm. This is achieved by applying reverse oil line pressure to the PRV to assist the spring load. both the low and high line pressure values are boosted to guard against slippage. the rear band will be applied at all times in P. The other end of the valve contains ports for line pressure feedback and S6 pressure. the TCM switches solenoids S1 and S2 to ON. • • • • In P or N. and N if the following conditions are satisfied. drive oil is exhausted and the reverse lockout valve may be toggled by S1-S2 pressure. applying B2.

The cross-sectional arrangement is very modular in nature. When the valve is in the OFF or released position. regulated oil from the converter clutch regulator valve is directed to the apply side of the converter clutch. When the valve is in the ON or applied position. These subassemblies are. Converter clutch apply and release application is smoothed by electronically varying the S5 circuit pressure. To provide oil flow to the cooler the converter clutch control valve directs converter feed oil from the PRV directly to the cooler circuit. Four main sub-assemblies are installed within the case to complete the build. converter feed oil from the PRV is directed to the release side of the converter clutch.2006. This oil remains within the converter because the converter clutch piston is sealed against the flat friction surface of the converter cover. B1R exhaust valve The B1R exhaust valve is a two position spring loaded valve located in the transmission case directly adjacent to the front servo.18 Y220_3A2200 Y220_3A2220 Converter clutch regulator valve The converter clutch regulator valve regulates the pressure of the oil which applies the converter clutch. oil returns to the converter clutch control valve and is then directed to the oil cooler. The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa.03 Y220_3A2240 POWER TRAIN SYSTEM The Power Train System consists of. It permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band (B1). ION (BTRA) AUTO TRANSMISSION ACTYON SM . with the output pressure being variable according to the signal pressure from the S5 circuit. Y220_3A2210 Converter clutch control valve The converter clutch control valve is a two position valve which applies or releases the converter clutch. • • • • • • A torque converter with single face lock-up clutch Four multi-plate clutch assemblies Two brake bands Two one-way clutches Planetary gear set Parking mechanism A conventional six pinion Ravigneaux compound planetary gear set is used with overdrive (fourth gear) being obtained by driving the carrier. This prevents the need to force the oil back from the front servo through the valve body and through the 3-4 shift valve. CHANGED BY EFFECTIVE DATE AFFECTED VIN . The switching of this valve is governed by the signal pressure from S7. After flowing through the converter. Input oil from the line 500 circuit is regulated within the valve.

The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 kPa. When the valve is in the OFF or released position. These subassemblies are. The cross-sectional arrangement is very modular in nature. Converter clutch apply and release application is smoothed by electronically varying the S5 circuit pressure.03 Y220_3A2240 POWER TRAIN SYSTEM The Power Train System consists of. This oil remains within the converter because the converter clutch piston is sealed against the flat friction surface of the converter cover. To provide oil flow to the cooler the converter clutch control valve directs converter feed oil from the PRV directly to the cooler circuit. The switching of this valve is governed by the signal pressure from S7. This prevents the need to force the oil back from the front servo through the valve body and through the 3-4 shift valve. ION (BTRA) AUTO TRANSMISSION ACTYON SM . regulated oil from the converter clutch regulator valve is directed to the apply side of the converter clutch. Input oil from the line 500 circuit is regulated within the valve. with the output pressure being variable according to the signal pressure from the S5 circuit. oil returns to the converter clutch control valve and is then directed to the oil cooler. • • • • • • A torque converter with single face lock-up clutch Four multi-plate clutch assemblies Two brake bands Two one-way clutches Planetary gear set Parking mechanism A conventional six pinion Ravigneaux compound planetary gear set is used with overdrive (fourth gear) being obtained by driving the carrier. It permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band (B1). After flowing through the converter. Four main sub-assemblies are installed within the case to complete the build. Y220_3A2210 Converter clutch control valve The converter clutch control valve is a two position valve which applies or releases the converter clutch.18 Y220_3A2200 Y220_3A2220 Converter clutch regulator valve The converter clutch regulator valve regulates the pressure of the oil which applies the converter clutch.2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN . B1R exhaust valve The B1R exhaust valve is a two position spring loaded valve located in the transmission case directly adjacent to the front servo. converter feed oil from the PRV is directed to the release side of the converter clutch. When the valve is in the ON or applied position.

ELEMENTS ENGAGED Gear First Second Third Fourth Reverse Manual 1 Gear Ratio 2.03 A / CON A / BAG BRAKE X ST’NG SP AXLE CLUTCH T/C M / T A/T . In addition. The 2-3 shift is accomplished by applying the C1 clutch and releasing the B1 band.000 0.428 2. The 1-2 shift is accomplished by applying the B1 band and overrunning the 1-2 OWC. This arrangement allows for extensive subassembly testing and simplistic final assembly during production.2006. First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). Reverse gear is engaged by applying the C3 clutch and the B2 band.741 C1 C2 X X C3 C4 B1 B2 1-2 OWC X 3-4 OWC X X X LU CLUTCH X X X X X X X X X X X X X X Y220_3A2250 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . The C4 clutch is applied in the Manual 1.708 2. A general description of the operation of the Power Train System is detailed below. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the 3-4 OWC.508 1.741 1. the C4 clutch is also applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting.19 • Gear set-sprag-centre support • C1 -C2 -C3 -C4 clutch sub-assembly • Pump assembly • Valve body assembly One. 2 and 3 ranges to provide engine braking. or a combination of selective washers are used between the input shaft flange and the number 4 bearing to control the transmission end float. Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used throughout. The B2 band is also applied in the Manual 1 range to accomplish the low-overrun shift.

Torsional damper springs are provided in the damper and piston assembly to absorb any engine torque fluctuations during lock-up. This only occurs in reverse gear. 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting. this clutch pack allows the input shaft to drive the planet carrier. Lock-up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions. locking-up the converter and eliminating unwanted slippage. Y220_3A2270 Y220_3A2260 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Whenever lock-up occurs. Lock-up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover. C3 CLUTCH: When applied this clutch pack allows the input shaft to drive the reverse sun gear. This occurs in third and fourth gears. the impeller is attached to the converter cover. C1 CLUTCH: When applied. C4 CLUTCH: When applied this clutch provides engine braking on overrun.20 Torque converter The torque converter consists of a turbine. stator pump. Clutch packs There are four clutch packs. This occurs in all forward gears. The addition of the damper and piston assembly en-ables the torque converter to lock-up under favorable conditions.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . C2 CLUTCH: When applied this clutch pack allows the input shaft to drive the forward sun gear via the 3-4 OWC.2006. As in conventional torque converters. improved fuel consumption is achieved. This occurs in Manual 1. All clutch packs are composed of multiple steel and friction plates. the turbine is splined to the input shaft and the stator is mounted on the pump housing via a one way clutch (sprag). impeller and a lock-up damper and piston assembly.

Y220_3A2280 This 3-4 OWC is located between the C4 and the C2 clutch assemblies.) Parking mechanism When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl. B2 is activated in Park. both areas are utilized for greater clamping force. ST’NG SP AXLE CLUTCH T/C M / T A/T . The one way clutch is engaged only in Drive 1. In fourth gear both areas are utilized for greater clamping force. The B1 band is a flexible band which is engaged by the front servo piston. This allows the carrier to rotate around the center support in one direction only.03 A / CON A / BAG The 1-2 OWC is located between the planetary carrier assembly and the center support.21 Bands The transmission utilizes two bands. When activated B1 prevents the reverse sun gear from rotating by holding the C3 clutch assembly stationary. The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case. the 1-2 OWC and the 3-4 OWC. also known as a sprag. Neutral and Manual 1. the B1 band (sometimes known as the 2-4 band). In Park. The B2 band is a solid band which is engaged by the rear servo piston. BRAKE One way clutches The transmission uses two OWCs. In Manual 1 only the inner area of the apply piston is utilized. and the B2 band (sometimes known as the low-reverse band). When activated B2 prevents the planet carrier assembly from rotating. second and third gears but unlocks in fourth gear and during overrun.2006. preventing accidental engagement of Park. When Park is not selected a return spring holds the parking pawl clear of the output shaft. In second gear only the outer area of the apply piston is utilized. (Note that a third OWC is located in the torque converter. Y220_3A2290 Planetary gear set The planetary gear set used in the transmission is a conventional six pinion Ravigneaux compound gear set. This allows the C2 clutch to drive the forward sun gear in first. Y220_3A2300 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Reverse. B1 is activated in second and fourth gear. Reverse and Neutral.

C1 X X C2 X X X X X C3 X - C4 X X X - B1 X - B2 X X X - 1-2 OWC X - 3-4 OWC X X X X X LU CLUTCH - ION (BTRA) AUTO TRANSMISSION ACTYON SM .Drive 1 • Power Flow . • Power Flow .Drive 3 Lock Up • Power Flow .Manual 1 • Power Flow .Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections.2006.Reverse • Power Flow .22 POWER FLOWS The power flows for the various transmission selections are listed below.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Neutral and Park • Power Flow .Drive 2 ELEMENTS ENGAGED Gear State Park and Neutral Reverse Manual 1 Drive 1 Drive 2 and Manual 2 Drive 3 and Manual 3 Drive 3 Lock Up and Manual 3 Lock Up Drive 4 Overdrive Drive 4 Lock Up X X X X X X X • Power Flow .Drive 3 • Power Flow .Drive 4 (Overdrive) • Power Flow .

23 Y220_3A231A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T PARK AND NEUTRAL .

• The S5 circuit is charged by the variable pressure solenoid (S5).Park and neutral In Park and Neutral.2006. In Park the transmission is mechanically locked by engaging a case mounted pawl with teeth on the output shaft ring gear. • Line pressure is prevented from entering the drive circuit by the manual valve. and lubrication circuits are charged from the primary regulator valve. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows: • Solenoids S1 and S2 are switched OFF. ELEMENTS ENGAGED Gear State Park and Neutral C1 - C2 - C3 - C4 - B1 - B2 X 1-2 OWC - 3-4 OWC - LU CLUTCH - Y220_3A2320 ION (BTRA) AUTO TRANSMISSION ACTYON SM . and to improve the low range engagement for 4WD applications. • The line 500 circuit is charged by the solenoid supply pressure regulator valve. • The converter. oil cooler. The rear band is applied to eliminate ‘clunk’ on engagement of the reverse gear.24 Power flow . • The B1 circuit and all clutch circuits are open to exhaust.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . there is no drive to the planetary gear set. • Line (pump) pressure is applied to the Primary Regulator Valve (PRV) and to the solenoid supply pressure regulator valve. No other clutches or bands are applied.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T REVERSE .25 Y220_3A233A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.

• Line pressure feeds the reverse oil circuit via the manual valve.26 Power flow . The elements of the transmission function as follows.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Reverse In Reverse. • Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear servo piston for B2 band application. • Solenoids S1 and S2 are switched OFF. • All other clutch and band apply circuits are open to exhaust. • Reverse oil is routed from the manual valve to the C3 clutch. transmission drive is via the input shaft and the forward clutch cylinder to the hub of the C3 clutch. • The C3 clutch is engaged and drives the reverse sun gear in a clock-wise direction. • The internal ring being splined to the output shaft drives it in an anti-clockwise or reverse direction. • The long pinion drives the internal ring gear in the same direction. ELEMENTS ENGAGED Gear State Reverse C1 - C2 - C3 X C4 - B1 - B2 X 1-2 OWC - 3-4 OWC - LU CLUTCH - Y220_3A2340 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Control To maintain this arrangement in the steady state solenoids and valves are activated as follows.2006. • Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost the line pressure value. • The B2 band is engaged and holds the planetary gear carrier stationary causing the long pinion to rotate anti-clockwise about its axis on the pinion shaft.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T MANUAL 1 .27 Y220_3A235A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.

• The C4 clutch provides engine braking through the 3-4 OWC on overrun. ELEMENTS ENGAGED Gear State Manual 1 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows. C1 - C2 X C3 - C4 X B1 - B2 X 1-2 OWC - 3-4 OWC X LU CLUTCH - Y220_3A2360 ION (BTRA) AUTO TRANSMISSION ACTYON SM . • The short pinion drives the long pinion clockwise. • The 1-2. • The long pinion rotating about its axis drives the internal ring gear and the output shaft in a clockwise or forward direction. via the 3-4 OWC. 2-3. transmission drive is via the input shaft to the forward clutch cylinder. and 3-4 shift valves are held in their first gear positions by line 500 pressure. • Drive (line pressure) oil from the manual valve engages the C2 clutch. • Lo-1st (line pressure) oil is routed through the 1-2 shift valve to the C4 clutch. • The forward sun gear drives the short pinion anticlockwise.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The elements of the transmission function as follows. • The B2 band is engaged to hold the planetary gear carrier stationary. • The C2 clutch is engaged to drive the forward sun gear. • Solenoids S1 and S2 are switched ON. and to the inner apply area of the rear servo piston for B2 band application.Manual 1 In Manual 1.2006.28 Power flow .

2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 1 .29 Y220_3A237A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

Drive 1 In Drive 1. • The short pinion drives the long pinion clockwise. • The 1-2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction.30 Power flow . 2-3. The elements of the transmission function as follows: • The C2 clutch is engaged to drive the forward sun gear via the 3-4 OWC. • There is no engine braking on overrun. ELEMENTS ENGAGED Gear State Drive 1 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows: • Solenoids S1 and S2 are switched ON. • Drive (line pressure) oil from the manual valve engages the C2 clutch. • The 1-2. and 3-4 shift valves are held in their first gear positions by line 500 pressure. C1 - C2 X C3 - C4 - B1 - B2 - 1-2 OWC X 3-4 OWC X LU CLUTCH - Y220_3A2380 ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006. transmission drive is via the input shaft to the forward clutch cylinder.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • The forward sun gear drives the short pinion anticlockwise.

31 Y220_3A239A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 2 AND MANUAL 2 .

• The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun. transmission drive is via the input shaft and forward clutch cylinder.The outer apply area of the front servo . • Solenoid S1 is switched OFF. • The C2 clutch is applied to drive the forward sun gear.The 3-4 shift valve for use when the transmission is shifted into fourth gear • Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch. • 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve. • When S1 switches OFF.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Drive 2 and manual 2 In Drive 2 and Manual 2. moves the 3-4 shift valve to the left. • Drive (line pressure) oil from the manual valve engages the C2 clutch. • Band apply feed oil is directed to. • The forward sun gear drives the short pinion anticlockwise. S2 is switched ON.32 Power flow . • The B1 band is applied holding the reverse sun gear stationary therefore the long pinion walks around the reverse sun gear taking the internal ring gear and output shaft with it in a clockwise or forward direction. C1 - C2 X C3 - C4 X B1 X B2 - 1-2 OWC - 3-4 OWC X LU CLUTCH - Y220_3A2400 ION (BTRA) AUTO TRANSMISSION ACTYON SM .The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear . At the same time S1 oil is directed to the 1-2 shift valve which moves the valve to the second gear position.2006. • The short pinion drives the long pinion clockwise. which is derived from line 500 pressure. The elements of the transmission function as follows. S1 oil pressure. and to the 2-3 shift valve. ELEMENTS ENGAGED Gear State Drive 2 and Manual 2 Control To maintain this arrangement in the steady state solenoids and valves are activated as follows. • The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the Band Apply Feed (BAF) circuit. .

2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 3 AND MANUAL 3 .33 Y220_3A241A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

Drive 3 and manual 3 In Drive 2 and Manual 2. • 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply feed regulator valve and to the 2-3 shift valve. . The CAF oil is directed to. and is directed through the 3-4 shift valve to the spring end of the 4-3 sequence valve. • The forward sun gear and the planet carrier are driven clockwise at the same speed therefore there is no relative motion between the sun gear and the pinions. • Band apply feed oil is directed to. transmission drive is via the input shaft and forward clutch cylinder. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows: • Solenoid S1 is switched OFF. and to the 4-3 sequence valve. . ELEMENTS ENGAGED C1 X C2 X C3 - C4 X B1 - B2 - 1-2 OWC - 3-4 OWC X LU CLUTCH - Y220_3A2420 ION (BTRA) AUTO TRANSMISSION ACTYON SM . • The C2 clutch is engaged to drive the forward sun gear. • 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve. Gear State Drive 3 and Manual 3 • The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ra-tio) to the Band Apply Feed (BAF) circuit.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the Clutch Apply Feed (CAF) circuit.34 Power flow . • The C1 clutch is engaged to drive the planet carrier. • The 1-2 shift valve is held in the third gear position by S1-S2 oil pressure. the 2-3 and 3-4 shift valves are held in the third gear position by line 500 pressure.The outer apply area of the front servo .The C1clutch .The 3-4 shift valve for use when the transmission is shifted into fourth gear • 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.2006.The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear .The 4-3 sequence valve • At the 4-3 sequence valve the CAF oil becomes Band 1 Release Feed (B1R-F) oil. • Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch. S2 is switched OFF. • The short pinion drives the long pinion clockwise. The elements of the transmission function as follows. • With S1 and S2 switched OFF. • The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun. • The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed. and to the release side of the front servo piston to hold band 1 OFF.

35 Y220_3A243A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP .2006.

is directed by the converter clutch control valve to the engage side of the converter clutch.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ELEMENTS ENGAGED Gear State Drive 3 Lock Up and Manual 3 Lock Up C1 X C2 X C3 - C4 X B1 - B2 - 1-2 OWC - 3-4 OWC X LU CLUTCH X Y220_3A2440 ION (BTRA) AUTO TRANSMISSION ACTYON SM . transmission drive is the same as for Drive 3 but with the application of the converter lock up clutch to provide positive no-slip converter drive.Drive 3 lock up and manual 3 lock up In Drive 3 Lock Up and Manual 3 Lock Up.36 Power flow . drive oil at the converter clutch regulator valve. • Regulated apply feed oil. • When S7 is switched ON.2006. S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid. Control Control for Drive 3 Lock Up and Manual 3 Lock Up is the same as for Drive 3 with the addition of the converter clutch circuit activated by solenoid S7. • Converter clutch release oil is exhausted at the converter clutch control valve. • Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit. This allows the valve to move to the clutch engage position.

37 Y220_3A245A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 4 (OVERDRIVE) .2006.

in overdrive ratio. the long pinion walks around the stationary reverse sun gear and rotates around its axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i.38 Power flow . . • As the planet carrier tuns. • With S1 switched ON. • The C1 clutch is applied to drive the planet carrier clockwise. the 3-4 shift valve is held in the fourth gear position by line 500 pressure on the small end of the valve. • With S2 switched OFF.the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear • 2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.Drive 4 (Overdrive) In Drive 4 (Overdrive). • Solenoid S1 is switched ON. ELEMENTS ENGAGED C1 X C2 X C3 - C4 - B1 X B2 - 1-2 OWC - 3-4 OWC - LU CLUTCH - Y220_3A2460 ION (BTRA) AUTO TRANSMISSION ACTYON SM . • 2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply feed regulator valve. • The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ra-tio) to the Band Apply Feed (BAF) circuit. S2 is switched OFF. • The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC. the 2-3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve. The elements of the transmission function as follows. and to the 2-3 shift valve. • Band apply feed oil is directed to.the C1 clutch .the 4-3 sequence valve • Drive oil (line pressure) from the manual valve engages the C2 clutch. • The B1 band is applied to hold the reverse sun gear stationary. • The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC.the outer apply area of the front servo . . • The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the Clutch Apply Feed (CAF) circuit.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Gear State Drive 4 Overdrive • The 1-2 shift valve is held in the fourth gear position by S2 oil pressure. • The CAF oil is directed to.2006. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows. and to the 4-3 sequence valve. • 3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve.the inner apply area of the front servo piston via the 3-4 shift valve . transmission drive is via the input shaft to the forward clutch cylinder.e.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DRIVE 4 LOCK UP .2006.39 Y220_3A247A CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Regulated apply feed oil. Control To maintain this arrangement in the steady state solenoids and valves are activated as follows. This allows the valve to move to the clutch engage position. ELEMENTS ENGAGED Gear State Drive 4 Lock Up C1 X C2 X C3 - C4 - B1 X B2 - 1-2 OWC - 3-4 OWC - LU CLUTCH X Y220_3A2480 ION (BTRA) AUTO TRANSMISSION ACTYON SM .40 Power flow . S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid.Drive 4 lock up In Drive 4 Lock Up. drived from drive oil at the converter clutch regulator valve. • When S7 is switched ON. • Converter clutch release oil is exhausted at the converter clutch control valve. • Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication circuit. transmission drive is the same as for Drive 4 but with the application of the converter lock up clutch to provide positive no-slip converter drive. is directed by the converter clutch control valve to the engage side of the converter clutch.

• Check the fluid level according to the Fluid Level Service Procedure. Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. • Check if the transmission fluid is not burnt by smell. The following functional check procedure will indicate the proper path of diagnosing the transmission by describing the basic checks and then referencing the locations of the specific checks. • Ensure that the transmission is not in Limp Home Mode (LHM). They will help you to follow diagnostic procedures. After repairing the vehicle. a circuit tester. • Check that the cooler flow is not restricted. • Use on-board diagnostic tool or a scan tool to see if any transmission trouble codes have been set. Refer to the appropriate “Diagnostic Trouble Code (DTC)” information and repair the vehicle as directed. Do not. and they permanently seal the wire from corrosion. NOTICE • The specific fluid used in this transmission turns brown during normal operation. jumper wires or leads and a line pressure gauge set. • Check the transmission fluid leak. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Inspect the oil and check for metal or other contaminants in the oil pan. SP NOTICE AXLE CLUTCH T/C M / T A/T DIAGNOSTIC INFORMATION AND PROCEDURES . • Perform the Road Test Procedure in this section. This will eliminate the unnecessary removal of transmission components. under any circum-stances. • Perform the Electrical/Garage Shift Tests. • Check the battery terminals and the earth connections for corrosion or looseness. attempt to diagnose a transmission problem without this basic knowledge.2006. • Check all electrical plug connections for tightness. These probe devices are inexpensive and easy to install.41 DIAGNOSIS BASIC KNOWLEDGE REQUIRED You must be familliar with some basic electronics to use this section of the Service Manual. The functional check procedure is designed to verify the correct operation of electronic components in the transmission.03 A / CON A / BAG BRAKE ST’NG • If a wire is probed with a sharp instrument and not properly sealed afterward. NOTICE • Lack of the basic knowledge of this transmis-sion when performing diagnostic procedures could result in incorrect diagnostic performance or damage to transmission components. Brown fluid does not indicate a transmission fault. FUNCTIONAL CHECK PROCEDURE Begin with the Functional Check Procedure which provides a general outline of how to diagnose automatic transmission. the wire will corrode and an open circuit will result. perform the road test and verify that the code has not set again. Special Tools You should be able to use a Digital Volt Meter (DVM).

Do not. SP NOTICE AXLE CLUTCH T/C M / T A/T DIAGNOSTIC INFORMATION AND PROCEDURES . FUNCTIONAL CHECK PROCEDURE Begin with the Functional Check Procedure which provides a general outline of how to diagnose automatic transmission. • Perform the Road Test Procedure in this section. NOTICE • Lack of the basic knowledge of this transmis-sion when performing diagnostic procedures could result in incorrect diagnostic performance or damage to transmission components. • Check all electrical plug connections for tightness. Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . NOTICE • The specific fluid used in this transmission turns brown during normal operation. • Use on-board diagnostic tool or a scan tool to see if any transmission trouble codes have been set. under any circum-stances.41 DIAGNOSIS BASIC KNOWLEDGE REQUIRED You must be familliar with some basic electronics to use this section of the Service Manual. • Inspect the oil and check for metal or other contaminants in the oil pan. They will help you to follow diagnostic procedures. • Check that the cooler flow is not restricted. a circuit tester. attempt to diagnose a transmission problem without this basic knowledge. These probe devices are inexpensive and easy to install. • Check if the transmission fluid is not burnt by smell. and they permanently seal the wire from corrosion.03 A / CON A / BAG BRAKE ST’NG • If a wire is probed with a sharp instrument and not properly sealed afterward. Special Tools You should be able to use a Digital Volt Meter (DVM). Refer to the appropriate “Diagnostic Trouble Code (DTC)” information and repair the vehicle as directed. This will eliminate the unnecessary removal of transmission components. jumper wires or leads and a line pressure gauge set. • Ensure that the transmission is not in Limp Home Mode (LHM). • Check the fluid level according to the Fluid Level Service Procedure. After repairing the vehicle. The following functional check procedure will indicate the proper path of diagnosing the transmission by describing the basic checks and then referencing the locations of the specific checks. The functional check procedure is designed to verify the correct operation of electronic components in the transmission. perform the road test and verify that the code has not set again. the wire will corrode and an open circuit will result. Brown fluid does not indicate a transmission fault. • Perform the Electrical/Garage Shift Tests. • Check the transmission fluid leak.2006. • Check the battery terminals and the earth connections for corrosion or looseness.

Clean the filler plug and check that there is no damage to the ‘O’ ring. When the three minutes passed after the engine stopped. 6. Clean all dirt from around the fluid filler plug. 5. Install the filler pump into the filler hole. Transmission fluid level should be checked at temperature 50 . Remove the fluid filler plug. This will allow the transmission to be within the correct temperature range. If the oil level is low. When adding or changing transmission fluid use only Castrol TQ 95 automatic transmission fluid. or loss of drive. Turn the engine OFF. Clean the filler plug and check that there is no damage to the ‘O’ ring. pausing a few seconds in each range. Depending on the service procedure performed. The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse.140°F). A low fluid level will result in slipping and loss of drive/ reverse or delay on engagement of drive/ reverse when the vehicle is cold. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). ION (BTRA) AUTO TRANSMISSION ACTYON SM . Start the vehicle in P (Park) with the parking brake and the brake applied. but no greater than four hours.5 liters 4. the transmission should be inspected for fluid leaks and any leaks should be fixed before setting the transmission fluid level. The vehicle is first checked for transmission diagnostic messages on the scan tool.5 liters 2. Also when the transmission fluid level is low. Install the fluid filler plug and tighten it to 33 Nm (24 lb-ft). start the engine and allow the engine to idle for approximately 5 minutes or. 4. Remove the fluid filler plug.5 liters. The use of incorrect fluid will cause the performance and durability of the transmission to be severely degraded. Clean all dirt from around the fluid filler plug. 3. Return the gear shift lever to P (Park). Fluid Level Diagnosis procedure 1. 3. If there is no loss of drive when the vehicle is driven warm and a vehicle speed signal fault is registered. Park the vehicle on a hoist. • If fluid does not drain through the filler hole although adding a total of 1. If the vehicle is at operating temperature allow the vehicle to cool down for two hours. move the gear shift control lever through the gear ranges. Return the gear shift control lever to P (Park). pausing a few seconds in each range and adding the fluid until gear application is felt. add the following amounts of fluid through the filler plug hole prior to adjusting the fluid level: Converter empty Converter full 9. control lever through the gear ranges.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Fluid Level Set After Service 1. 2. Check if the fluid level is aligned with the bottom of the filler hole. it is possible to register a vehicle speed signal fault. • If fluid drains through the filler hole the transmission may have been overfilled. wipe any fluid around the filler plug with a rag or shop towel. then fluid should be added to the transmission. CAUTION • Removal of the fluid filler plug when the transmission fluid is hot may cause injury if fluid drains from the filler hole. With the brake pedal pressed. move the gear shift. inspection pit or similar raised level surface.2006. • If fluid does not drain through the filler hole. remove the filler pump. if possible.42 TRANSMISSION FLUID LEVEL SERVICE PROCEDURE This procedure is to be used when checking a concern with the fluid level in a vehicle. Turn the engine OFF and raise the vehicle. a loss of drive may occur when the transmission fluid temperature is low. Place a fluid container below the fluid filler plug. the transmission fluid level may be low. With the engine idling. The vehicle must be control level to obtain a correct fluid level measurement. When the fluid level checking procedure is completed. add a small quantity of fluid to the correct level. Lower the vehicle with the filler pump still connected and partially fill the fluid through the filler hole. drive the vehicle for a few kilometers. Follow steps 1 through 4 of the Fluid Level Diagnosis Procedure.60°C (82 . When the fluid stops draining the fluid level is correct. If not. Or if the vehicle is at cool status. One symptom of low fluid level is a momentary loss of drive when driving the vehicle around a corner.

Make the necessary repairs. move the shift lever through the gear ranges. 190°F). Repairing the fluid leak Once the leak point is found the source of the leak must be determined. if applicable. Check if the fluid level is aligned with the bottom of the filler hole. If not. add a small quantity of fluid to the correct level. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88°C. With the engine idling. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88°C. Methods for Locating Leaks General method 1. 4. Make the necessary repairs to correct the leak. • Water or coolant in fluid. • Damaged. This should result in the transmission temperature being in the range 50 . pausing a few seconds in each range and adding the fluid until gear application is felt. • Case or component porosity. Park the vehicle over clean paper or cardboard. Wipe any fluid around the filler plug with a rag or shop towel.2006. 2. Thoroughly clean the suspected leak area. remove the filler plug. Then add an additional 0. M / T A / CON A / BAG BRAKE ST’NG SP ACTYON SM . CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION AXLE CLUTCH T/C A/T Powder method 1. 2. 2. Turn the en-gine OFF and raise the vehicle on the hoist. FLUID LEAK DIAGNOSIS AND REPAIR The cause of most external leaks can generally be located and repaired with the transmission in the vehicle. 190°F). Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak. Verify that the leak is transmission fluid.5 litres of fluid. 3.03 Dye and black light method 1. Make the necessary repairs. 6. 4. 3.60°C (82 . move the gear shift control lever through the gear ranges.140°F). damaged or worn. The following list describes the potential causes for the leak: • Fasteners are not torqued to specification. • Fluid level is too high. • Plugged vent or damaged vent tube. 5. Turn the engine OFF and raise the vehicle.5 to 4. Turn the engine OFF and look for fluid spots on the paper.5 kilometers with light throttle so that the engine does not exceed 2500 rpm. 5. With the brake applied. Thoroughly clean the suspected leak area. Drive the vehicle at 3. pausing a few seconds in each range at the engine idling.43 4. Add dye to the transmission through the transmission fluid filler plug. 7. Install the fluid filler plug and tighten it to 33 N•m (24 lb-ft). 5. • Fastener threads and fastener holes are dirty or corroded. Use the black light to find the fluid leak. 3. Follow the manufacturer’s recommendation for the amount of dye to be used. Lower the vehicle with the filler pump still connected and start the vehicle in P (Park) with the parking brake and the brake applied. • Loose or worn bearing causing excess seal or sleeve wear. 6. 6. When the three minutes passed after the engine stopped. • Fluid drain back holes plugged. Return the gear shift lever to P (Park). Return the gear shift lever to P (Park). Turn the engine OFF. • Gaskets. warped or scratched seal bore or gasket surface. Install the fluid filler plug and tighten it to 33 N•m (24 lb-ft). Apply an aerosol type powder (foot powder) to the suspected leak area. ensuring the vehicle is level. . seals or sleeves are misaligned.

pausing a few seconds in each range and adding the fluid until gear application is felt. warped or scratched seal bore or gasket surface. 3.5 litres of fluid.03 Dye and black light method 1.43 4. 3. Follow the manufacturer’s recommendation for the amount of dye to be used. move the shift lever through the gear ranges. Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak. • Fluid level is too high. • Fastener threads and fastener holes are dirty or corroded. Return the gear shift lever to P (Park). CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION AXLE CLUTCH T/C A/T Powder method 1. Use the black light to find the fluid leak. With the engine idling. 4. ensuring the vehicle is level. M / T A / CON A / BAG BRAKE ST’NG SP ACTYON SM . damaged or worn. Return the gear shift lever to P (Park). 5. • Loose or worn bearing causing excess seal or sleeve wear. • Fluid drain back holes plugged. 6.60°C (82 . 7. move the gear shift control lever through the gear ranges. 5. Repairing the fluid leak Once the leak point is found the source of the leak must be determined. seals or sleeves are misaligned. Add dye to the transmission through the transmission fluid filler plug. Install the fluid filler plug and tighten it to 33 N•m (24 lb-ft). Methods for Locating Leaks General method 1. 2. Park the vehicle over clean paper or cardboard. Apply an aerosol type powder (foot powder) to the suspected leak area. Lower the vehicle with the filler pump still connected and start the vehicle in P (Park) with the parking brake and the brake applied. Verify that the leak is transmission fluid. The following list describes the potential causes for the leak: • Fasteners are not torqued to specification. Make the necessary repairs. When the three minutes passed after the engine stopped. With the brake applied. 6. Turn the engine OFF and raise the vehicle. Thoroughly clean the suspected leak area. Thoroughly clean the suspected leak area. 3. 190°F). Turn the engine OFF. pausing a few seconds in each range at the engine idling. Make the necessary repairs to correct the leak. • Damaged. 5. Turn the engine OFF and look for fluid spots on the paper. Wipe any fluid around the filler plug with a rag or shop towel. Make the necessary repairs. Turn the en-gine OFF and raise the vehicle on the hoist. FLUID LEAK DIAGNOSIS AND REPAIR The cause of most external leaks can generally be located and repaired with the transmission in the vehicle. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88°C. add a small quantity of fluid to the correct level. if applicable. 2.5 to 4. 6. Drive the vehicle at 3. Check if the fluid level is aligned with the bottom of the filler hole. This should result in the transmission temperature being in the range 50 . • Water or coolant in fluid.140°F).5 kilometers with light throttle so that the engine does not exceed 2500 rpm. 2. Then add an additional 0. Drive the vehicle for approximately 25 km (15 miles) or until the transmission reaches normal operating temperature (88°C. • Plugged vent or damaged vent tube. 190°F). 4. Install the fluid filler plug and tighten it to 33 N•m (24 lb-ft). . • Case or component porosity.2006. • Gaskets. remove the filler plug. If not.

Monitor the A/C COMPRESSOR STATUS signal while pushing the A/C switch. A scan tool provides valuable information and must be used on the automatic transmission for accurate diagnosis. Connect scan tool to Data Link Connector (DLC) terminal. If the inputs are not checked before operating the transmission. Vehicle coding The vehicle coding is integrated as part of the diagnostic software. • This test should be performed when traffic and road conditions permit. PEDAL POSITION LEARNT OPEN ACCEL. and turn OFF when the A/C switch is repushed. PEDAL POSITION LEARNT A/C COMPRESSOR STATUS KICKDOWN SWITCH STATUS 4WD STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. Start engine. a simple electrical condition could be misdiagnosed as a major transmission condition. • Observe all traffic regulations.44 ELECTRICAL / GARAGE SHIFT TEST This preliminary test should be performed before a hoist or road test to make sure electronic control inputs are connected and operating. FLUID TEMPERATURE VOLTAGE A/C SWITCH KICKDOWN SWITCH VOLTAGE 4WD LAMP LOW VOLTAGE 4WD LAMP HIGH VOLTAGE MODE SWITCH VOLTAGE BATTERY VOLTAGE 6. ROAD TEST PROCEDURE • Perform the road test using a scan tool. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal. 8. PEDAL POSITION TRANSMISSION GEAR STATE GEAR SHIFT LEVER POSITION TRANSMISSION FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CLOSED ACCEL. Verify that the appropriate signals are present. 7. • Gear selections should be immediate and not harsh. ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the ranges. • The A/C COMPRESSOR STATUS should come ON when the A/C switch is pressed. 1. Move gear shift control lever to P (Park) and set the parking brake. These signals may include: • • • • • • • • • • • • • • • • • • • • • • • • ENGINE SPEED VEHICLE SPEED THROTTLE POSITION ACCEL. • THROTTLE POSITION should increase with engine speed. 2. 4. 5. Turn the scan tool ON. A scan tool has the function to code the vehicle through the K-line.2006. • Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console. ELECTRONIC ADJUSTMENTS Idle speed adjustments Carry out the adjustments to the idle speed as detailed in the workshop manual. 3.

These signals may include: • • • • • • • • • • • • • • • • • • • • • • • • ENGINE SPEED VEHICLE SPEED THROTTLE POSITION ACCEL. 8. Move gear shift control lever to P (Park) and set the parking brake. Verify that the appropriate signals are present. 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ROAD TEST PROCEDURE • Perform the road test using a scan tool. Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the ranges. 1. Monitor the A/C COMPRESSOR STATUS signal while pushing the A/C switch. a simple electrical condition could be misdiagnosed as a major transmission condition. PEDAL POSITION LEARNT A/C COMPRESSOR STATUS KICKDOWN SWITCH STATUS 4WD STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. Connect scan tool to Data Link Connector (DLC) terminal. PEDAL POSITION TRANSMISSION GEAR STATE GEAR SHIFT LEVER POSITION TRANSMISSION FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CLOSED ACCEL. • The A/C COMPRESSOR STATUS should come ON when the A/C switch is pressed. • This test should be performed when traffic and road conditions permit. FLUID TEMPERATURE VOLTAGE A/C SWITCH KICKDOWN SWITCH VOLTAGE 4WD LAMP LOW VOLTAGE 4WD LAMP HIGH VOLTAGE MODE SWITCH VOLTAGE BATTERY VOLTAGE 6. ELECTRONIC ADJUSTMENTS Idle speed adjustments Carry out the adjustments to the idle speed as detailed in the workshop manual. • Observe all traffic regulations. Start engine. 3. 4. PEDAL POSITION LEARNT OPEN ACCEL. Vehicle coding The vehicle coding is integrated as part of the diagnostic software. and turn OFF when the A/C switch is repushed. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal. A scan tool has the function to code the vehicle through the K-line. Turn the scan tool ON. 7. If the inputs are not checked before operating the transmission. 2.2006.44 ELECTRICAL / GARAGE SHIFT TEST This preliminary test should be performed before a hoist or road test to make sure electronic control inputs are connected and operating. A scan tool provides valuable information and must be used on the automatic transmission for accurate diagnosis. • THROTTLE POSITION should increase with engine speed. ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Gear selections should be immediate and not harsh. • Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console.

Turn the scan tool ON. If the inputs are not checked before operating the transmission. • THROTTLE POSITION should increase with engine speed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Move gear shift control lever to P (Park) and set the parking brake. 4. ION (BTRA) AUTO TRANSMISSION ACTYON SM . 8. Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the ranges.2006. PEDAL POSITION TRANSMISSION GEAR STATE GEAR SHIFT LEVER POSITION TRANSMISSION FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT CLOSED ACCEL. PEDAL POSITION LEARNT OPEN ACCEL. PEDAL POSITION LEARNT A/C COMPRESSOR STATUS KICKDOWN SWITCH STATUS 4WD STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. Start engine. Monitor the A/C COMPRESSOR STATUS signal while pushing the A/C switch. 1. Vehicle coding The vehicle coding is integrated as part of the diagnostic software. Verify that the appropriate signals are present. • This test should be performed when traffic and road conditions permit. • The A/C COMPRESSOR STATUS should come ON when the A/C switch is pressed. • Gear selections should be immediate and not harsh. A scan tool has the function to code the vehicle through the K-line. and turn OFF when the A/C switch is repushed. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal. FLUID TEMPERATURE VOLTAGE A/C SWITCH KICKDOWN SWITCH VOLTAGE 4WD LAMP LOW VOLTAGE 4WD LAMP HIGH VOLTAGE MODE SWITCH VOLTAGE BATTERY VOLTAGE 6.44 ELECTRICAL / GARAGE SHIFT TEST This preliminary test should be performed before a hoist or road test to make sure electronic control inputs are connected and operating. 3. Connect scan tool to Data Link Connector (DLC) terminal. A scan tool provides valuable information and must be used on the automatic transmission for accurate diagnosis. These signals may include: • • • • • • • • • • • • • • • • • • • • • • • • ENGINE SPEED VEHICLE SPEED THROTTLE POSITION ACCEL. ELECTRONIC ADJUSTMENTS Idle speed adjustments Carry out the adjustments to the idle speed as detailed in the workshop manual. 7. a simple electrical condition could be misdiagnosed as a major transmission condition. • Observe all traffic regulations. ROAD TEST PROCEDURE • Perform the road test using a scan tool. • Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console. 5. 2.

Repair as necessary. • Inspect and clean PRV. Top up as necessary. • “Z” link displaced. • 3-4 or 1-2 One Way Clutch (OWC) installed backwards or failed. • Damaged input shaft sealing rings. • Inspect and replace as necessary. • Check servo adjustment or replace rear band as necessary. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Inspect and repair as necessary. • Blocked feed in C1/C2 cylinder. • C2 piston broken or cracked. • Failure in C3.45 DRIVE FAULTS Condition No Drive in D Possible Causes • Insufficient auto transmission fluid. • Dislodged output shaft snap ring. No drive in Drive and Reverse • Damaged/broken pump gears. C3 hub or C1/C2 cylinder. • Inspect and replace as necessary. clean and re-install the PRV. C3 hub or C1/C2 cylinder. • Inspect and replace pump gears as necessary. • Check for failure in C3. • Inspect and clean C1/C2 feed. • Inspect and replace as necessary. • Overdrive shaft or input shaft seal rings failed. • Reinstall/renew the ‘z’ link. No Drive in Reverse No engine braking in Manual 1 Engine braking in Manual 1 is OK • Rear band or servo faulty. • Remove. ST’NG SP AXLE CLUTCH T/C M / T A/T SYMPTOM DIAGNOSIS . Action • Check the fluid level.2006. • Inspect and replace as necessary.03 A / CON A / BAG BRAKE • Jammed Primary Regulator Valve (PRV). • Primary Regulator Valve (PRV) jammed open.

(Gives 1st in 3rd and 2nd in 4th.2006. • Inspect and repair as necessary. 1-2-Neutral (1st over run) • S2 always ON. Repair or replace as necessary. Repair or replace as necessary. • Rear servo inner “O” ring missing. Refit or replace as necessary. 1-4 shift only1-3-4 (Delayed 12 shift) • S1 always ON. Repair or replace as necessary. • Inspect and repair as necessary.3rd. • Inspect S1. Repair or replace as necessary. and 3rd (tied up in 3rd) • 1-2 shift valve jammed. • Rear band slipping when hot. • Inspect and replace or refit as necessary • Inspect “O” ring. Repair or replace as necessary. 1-2-3 only. • Check for open circuit or wiring fault. • 3-4 shift valve jammed. Refit or replace as necessary. • Loose band adjustment. • Inhibitor switch fault.) • Over-run Clutch (OC) /low ball misplaced. • Front servo piston or seal failed. • Inspect the 1-2 shift valve.46 FAULTY SHIFT PATTERN Condition 2-3 shift only (no 4th or 1st) Possible Causes • S1 always OFF. • Inspect C1 clutch. • Inspect S2. • 2-3 shift valve jammed. • Inspect inhibitor switch. 1-3 shift only • B1 failed. Refit or replace as necessary. 3rd and 4th only 1st. Repair or replace as necessary. • Inspect rear band adjustment. 1-2-1 only • C1 clutch failed or slipping in 3rd and 4th. Action • Inspect S1. • Inspect and adjust as necessary. 4-3 shift only • S2 always OFF. No manual 4-3. • Inspect the 2-3 shift valve. • 2-3 shift valve jammed. • Inspect ball. Adjust as necessary. ION (BTRA) AUTO TRANSMISSION ACTYON SM . Repair or replace as necessary. • Reverse/Low-1st ball misplaced.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Inspect the 2-3 shift valve. 2nd and 4th only or 1st. • Inspect S2. and 4th only 1st and 2nd only or 1st. • Check for 12 Volts applied to S1 at all times or for wiring fault. • Inspect “O” ring. Repair or replace as necessary. 2nd. • Inspect ball. • Inspect the 3-4 shift valve. • Check for open circuit or wiring fault. • S1/S2 ball misplaced. • Check for 12 Volts applied to S1 at all times or for wiring fault. Refit or replace as necessary. Repair or replace as necessary. Repair or replace as necessary. 1-3-4 only • Smaller “O” ring on front servo piston failed or missing. 3-2 or 2-1 No manual 1st 1st gear only or 2nd.

Action • Inspect the release valve. • Inspect the regulator valve. • Damaged or dislodged C1 piston bleedball. Refit or replace as necessary. • Damaged C1 piston “O” rings. • Inspect the release valve. • Faulty S3 or S2 solenoid.47 Condition Harsh 2-3 shift Possible Causes • Jammed band 1 release valve. Refit or replace as necessary. • Inspect the ball. • Faulty clutch apply regulator valve. Repair or replace as necessary. • Inspect the “O” rings.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Refit or replace as necessary. • Damaged input shaft sealing rings. • Inspect the “O” rings. • Inspect the regulator valve. • Inspect S5. Refit or replace as necessary. Repair or replace as necessary. • Incorrect front band adjustment. • Faulty or damaged variable pressure solenoid (S5). • Inspect S1 or S4. • Faulty band apply regulator valve. Repair or replace as necessary. • Faulty S1 or S4 solenoid. Repair or replace as necessary. • Inspect the sealing rings. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Missing or damaged clutch apply feed ball. Harsh 3-4 shift • Jammed band 1 release valve. • Inspect S3 or S2. Repair or replace as necessary. Refit or replace as necessary. Adjust as necessary. Repair or replace as necessary. • Damaged front servo piston “O” rings.2006. • Inspect the bleed ball. Repair or replace as necessary. • Inspect the band.

Tied up on 2-3 • Incorrect band adjustment • Front servo plastic plug missing • B1R spring broken. • Low-1st check ball misplaced. • Replace the plug. • Inspect and replace the sealing rings and/or shaft as necessary. • Refit the ball. Refit or replace as necessary • Inspect the ball. Realign as necessary. • Inspect and re-fit the ball.2006. ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Inspect and replace the ball. or replace S5. Repair the clutch as necessary.48 SHIFT QUALITY FAULTS Condition All Shifts Firm Possible Causes • Incorrect auto transmission fluid (ATF). • Damaged C4 clutch. • C1 piston check ball jammed. Manual 4-3-2-1 is soft delayed or missing • Over-run Clutch (OC) /Low-1st ball misplaced. • Replace the ball. Refit or replace as necessary. • Cracked C2 piston (leaking into C4). • Check the clearance and adjust as necessary. • 4-3 sequence valve in backwards. • Restriction in C1 feed. • Inspect S5 and replace as necessary. • C4 clutch worn or burnt. • Inspect and adjust or replace rear band. • Inspect and replace the sealing rings and/or shaft as necessary. • Inspect the clutch. • Check that S5 is fitted correctly. Repair or replace as necessary. Flare on 2-3 • B1R spring/plug left out. • Inspect C4 clutch. • C4 wave plate not lined up with the holes in the piston. Action • Drain and fill with specified ATF. Firm 1-2 Hot 4th Tied up • S5 worn. • Band apply and clutch apply regulator springs misplaced. • S5 faulty won. • Overdrive or input shaft sealing rings damaged. • Replace the spring. • Inspect and repair the C1 clutch as necessary.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • C1/B1R ball misplaced. • Overdrive or input shaft sealing rings damaged. • Inspect piston. • C1 clutch damaged. Flare on 3-2 Firm Manual low shift-high line press. • Incorrect C4 pack clearance. • Inspect band apply and clutch apply regulator springs. Slips in reverse. Replace or repair as necessary. no manual 1st • Rear band incorrectly adjusted or damage • Low-1st check ball misplaced. • Check the alignment. • Replace the spring/plug. Slips in 4th • C1/B1R ball misplaced. • Refit the valve. • Inspect and adjust band as necessary. • C1 clutch damaged. or incorrectly fitted. • Replace the piston. • Inspect C4. Flare on 4-3. Repair or replace as necessary. • Inspect and clean C1 feed.

repair or replace as necessary. Action • Check the resistance. • Faulty S1 or S4 solenoid. repair or replace S5 as necessary. • Incorrect front band adjustment. • Faulty Band Apply Regulator (BAR) valve.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .49 Condition Harsh 1-2 shift Possible Causes • Faulty inhibitor switch. • Faulty solenoid 7. • Faulty or damaged variable pressure solenoid (S5). • Faulty throttle position sensor. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Inspect. • Inspect and repair as necessary. • Inspect and clean CCCV. • Inspect and replace the sensor as necessary. repair or replace the BAR as necessary. Replace the inhibitor switch as necessary. • Inspect and adjust the band as necessary. • Damaged front servo piston “O” rings. • Inspect and replace the “O” rings as necessary.2006. repair or replace S1 or S4 as necessary. Stalls when Drive or Reverse Selected Shudder on Rolldown • Jammed Converter Clutch Control Valve (CCCV). • Inspect. • Misassembled front servo return spring. • Inspect. • Inspect.

• Overdrive or input shaft sealing rings damaged. • Inspect and adjust the C4 pack clearance as necessary. repair C2 and adjust the linkage as necessary. • Overdrive or output shaft sealing rings damaged. • C2 piston cracked. B1 burnt • B1R spring broken. • Repair C1. replace the sealing rings and/or shaft as necessary. • Ball capsule jammed. Inspect and replace the C1 piston as necessary. • Inspect and refit the ball as necessary. • C1/B1R ball misplaced. • C4 wave plate not lined up properly. • Inspect and repair C1 and replace the spring. • Repair C4. • Repair B1. • Repair C1. C1 burnt • B1R spring left out. Action • Inspect. • Repair C2. • Overdrive/output shaft sealing rings damaged. Refit the ball as necessary.no manual 1st ) • Rear band incorrectly adjusted or damaged. • Inspect and adjust the band as necessary. • Replace sealing ring. • Repair C4. • Reverse-low/first ball misplaced. Inspect and refit the capsule as necessary. • Repair C1.03 . • Repair C4. repair or replace the C2 piston as necessary. • Repair C1.50 AFTER TEARDOWN FAULTS Condition C2 burnt Possible Causes • Gear shift lever linkage out of adjustment. Inspect and refit the valve as necessary. • C1 piston cracked. repair or replace S6 as necessary. • Inspect C4 and repair as necessary. • Repair C1. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . • 4-3 sequence valve in backwards.2006. Inspect and refit the ball as necessary.stuck low. • C2 piston cracked. • Repair C2. Inspect. • Input shaft sealing ring cut. B2 burnt (Slips in reverse . Inspect. Inspect and replace the ball as necessary. • S6 foiled . Inspect and replace the sealing tongs and/or shaft as necessary. Inspect and realign the sealing rings and/or shaft as necessary. • Inspect and repair B1 and replace the spring as necessary. Inspect and realign the wave plate as necessary. • Clutch Apply Feed (CAF) /B1R ball left out. • Repair C4. Inspect and replace the C2 piston as necessary. C4 burnt • Incorrect C4 pack clearance. • Over-run Clutch (OC) /low-1st ball misplaced. Inspect. • Repair C2.

CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . No lock up at light throttle • C1 bias valve in backwards.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C • Input shaft “O” ring missing or damaged. M / T A/T . • Inspect and replace the “O” ring as necessary. Action • Inspect and replace the “O” ring as necessary. • Inspect and refit the valve as necessary. • Converter clutch regulator valve in backwards. • Inspect and refit the valve as necessary.51 Condition Firm converter lock or unlock Possible Causes • Input shaft “O” ring missing or damaged.2006.

4.52 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE ION AUTOMATIC TRANSMISSION ASSEMBLY Removal and Installation 1. Remove the locking pin from the shift lever onnecting rod. For removal and installation of the transfer case. Remove the caps from the torque converter mounting bolt hole and then remove six mounting bolts (13M) from the torque converter. refer to the “Transfer Case” section. 3. Torque converter mounting bolt hole Turn the crankshaft so that each mounting bolt is placed at bolt hole. Disconnect the transmission connector. and remove one by one. ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Remove the transfer in case of 4-wheel drive vehicle. 2.

Unscrew the mounting bolts and remove the automatic transmission housing.2006. Remove two union bolts from the oil cooler pipe. Remove mounting bolts from the oil cooler pipes (LH/RH). 7.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T . Tightening torque 55 ~ 65 Nm (41 ~ 48 lb-ft) CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .53 5. M / T Tightening torque 25 ~ 35 Nm (18 ~ 26 lb-ft) 6.

Tightening torque 25 ~ 35 Nm (18 ~ 26 lb-ft) 3. Remove the drain plug and drain the oil completely.2006. 2. Remove the oil filter. 5. ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Tightening torque 4 ~ 6 Nm NOTICE • Remove the oil pan slowly while keeping its level not to spill oil from it. 4. Unscrew nine mounting bolts and remove the oil pan. Remove the mounting clamp from the oil filter.54 VALVE BODY Removal and Installation 1. Remove the negative battery cable.

Remove the bolt from the valve body ground. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Unscrew the mounting bolts and remove the valve body from the transmission. Tightening torque 8 ~ 13 Nm 8. Install in the reverse order of removal.55 6.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T .2006. 9. A/T 7. Disconnect the solenoid valve connectors.

• Ensure that. Y220_3A2710 ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Be wary of any situation where water enters the transmission.2006. the following warnings are to be noted. measure the flow over 15 seconds with the vehicle idling in park. • Follow the throttle position calibration procedure in this manual if the engine control module/ transmission control module (ECM/TCM) is swapped. • The cooler flow should be checked after the transmission has been fitted. This may result in fluid foaming and leaking through the breather. • The flow rate should exceed 1 liter in 15 seconds.56 UNIT REPAIR REBUILD WARNINGS Prior to rebuilding a transmission system.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Ensure that both earth straps (one at the battery terminal and one on the vehicle body) are connected in the vehicle before connecting the positive side of the battery. This can be done by applying compressed air to the rear cooler line forcing oil and any contaminants out of the front cooler line. before replacing a transmission the cooler lines are flushed out to remove any debris. With the front cooler line connected and the rear line run into a suitable container.

Y220_3A2500 4. 10mm and 12 mm double hex socket. • The transmission is dismantled in a modular fashion. and an 8mm. in particular numbers 30. 3.57 Transmission Tools Required 0555-336256 Transmission Bench Cradle 0555-336257 Pump Puller NOTICE • Remove the inhibitor switch before washing the transmission in solvent or hot wash. Refer to Special Tools Table in this chapter for details of all special tools required when performing disassembly procedures. 5. Mount the transmission on the transmission bench cradle 0555-336256. Remove the converter and the converter housing.2006. Remove the oil pan and the oil pan seal. and the details of disassembly for each module are given under the appropriate subject. Remove the valve body securing screws and remove the valve body from the case. • It is assumed that the transmission fluid has been drained when the transmission was removed from the vehicle and that the “special tools” quoted are available. 2. Y220_3A2510 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T DISASSEMBLY PROCEDURE . • Technicians overhauling these transmissions will also require a selection of good quality Torx bit sockets. 40 and 50. 1. Remove each end of the filter retaining clip from the valve body and remove the filter. Disconnect the wires from each solenoid valve and ground and lay the wiring to one side. 6.

13. Y220_3A2550 ION (BTRA) AUTO TRANSMISSION ACTYON SM . 9. Remove the front band.2006. Remove the adaptor housing bolts and adaptor housing. Y220_3A2530 12.58 7. 8. Y220_3A2540 14. forward clutch cylinder. Remove the front band struts. Remove the front servo cover. Remove the pump to case bolts using a multi-hex 8 mm spanner. Remove the input shaft. Using the pump puller 0555-336257. Y220_3A2520 10. Remove the front servo cover circlip. piston and spring. remove the pump and pump cover. and the overdrive shaft as an assembly. NOTICE • The plastic servo block is retained by the piston return spring only.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . withdrawing them through the front of the case. 11. Remove the C3 clutch cylinder and sun gears.

NOTICE • Do not hammer the output shaft to remove the centre support as this will cause permanent damage to the thrust bearing surfaces. 4. Pull the shaft to release the drive pin from the selector quadrant.03 A / CON A / BAG BRAKE ST’NG SP 20. Y220_3A2580 Y220_3A2590 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . NOTICE • Vise the both end of rear band using the plier and lean forward about 15 degrees Y220_3A2560 Y220_3A2570 Transmission Case Tools Required 0555-336258 Cross Shaft Pin Remover/Installer (Detent Lever) 0555-336261 Cross Shaft Seal Remover 0555-336265 Cross Shaft Pin Remover/Installer (Inhibitor Switch) 1. Remove the centre support. and planetary gear set as an assembly. Remove the two centre support retaining bolts using a T50 Torx bit. Remove the circlip from the cross shaft. 19. AXLE CLUTCH T/C M / T A/T .59 15. Remove the parking rod cam plate using a T40 Torx bit. Remove the rear band struts and remove the band. Remove the inhibitor switch bolts and inhibitor switch from the case. 18. 17. 1-2 one way clutch. Remove the pin from the side of cross shaft inhibitor switch using cross shaft pin remover/installer (inhibitor switch) 0555-336265. 2. 16. Remove the centre support retaining circlip.2006. Remove the cross shaft seals with cross shaft seal remover 0555-336261. Remove the output shaft assembly. 3.

Depress the tangs and withdraw the 10 pin connector into the case.7 solenoid valve wire from the front of the case.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the B1R circlip. 13. 15. Remove the cross shaft pin and spring. 10. 7. Remove both band adjustment shims.2006. Inspect cooler line fittings and replace as necessary. 11. 6. Y220_3A2600 8. Y220_3A2620 12. Y220_3A2630 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Using cross shaft pin remover/installer (detent lever) 0555-336258. press the pin from the cross shaft and withdraw the shaft from the case. Remove the parking pawl pivot pin and the pawl and spring from the case. Inspect the case for damage. Y220_3A2610 9. 17. 14. Remove the wiring loom assembly. Remove the rear servo cover and piston assembly. valve and spring. Inspect the output shaft bushing in the case and replace if necessary. 16.60 5. Detach the No. Remove the shaft and the rear servo lever. Remove the manual valve lever and the park rod.

5. Remove the No.61 18. 5 needle bearing from the C4 hub. Remove the overdrive shaft and the C1 clutch hub assembly from the clutch cylinder. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . 6. drive the pin out from the inside of the case and remove the lever and spring. Place the assembly in a horizontal position. Remove the C2/C4 clutch hub assembly and remove the No. Removethe C2 clutch plates.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T A/T . 4. 7. Remove the C1 clutch plates from the cylinder. then using a wide shallow tapered drift as a wedge. 2.2006. 4 needle bearing (2) and adjustment shims (1) from the input shaft. Remove the circlip from the front of the clutch cylinder and remove the input shaft. 3. To remove the park rod lever: Remove the circlip from the inner end of the pivot shaft and tap the outer end of the shaft until it moves free from the case. Remove the circlip retaining the C3 clutch hub in the rear of the clutch cylinder and remove the hub. 8. Forward Clutch Cylinder Tools Required 0555-336259 Clutch Spring Compressor 1. NOTICE T/C Y220_3A2640 Y220_3A2650 Y220_3A2660 Y220_3A2670 • Do not remove the park rod lever unless absolutely necessary.

03 . Remove the thrust plate (4). 13. Notice Make sure that the spring keeper is not caught in the circlip groove. CHANGED BY EFFECTIVE DATE AFFECTED VIN Y220_3A2720 ION (BTRA) AUTO TRANSMISSION ACTYON SM . No. 12.2006. Invert the clutch cylinder on the compressor tool and removethe C1 clutch piston return spring in asimilar manner. Y220_3A2680 11. Remove the thrust block from the C4 clutch cylinder hub. No. Invert the clutch cylinder and remove the C4 clutch sleeve.62 9. and that all the spring pressure is released. clutch plates and the two wave washers. keeper and spring. The 3-4 one way clutch is located between the C2 and C4 clutch hubs.7 needle bearing (2) thrust washer (1) and lipped thrust washer (3) from the C3 clutch cylinder. 2. Remove the clutch plate retaining circlip and re-move the clutch plates. 3. apply air pressure to the apply ports in the bore of the cylinder. Remove the spring retaining circlip. Remove the forward sun gear. Y220_3A2690 Y220_3A2700 C3 Clutch Cylinder Tools Required 0555-336259 Clutch Spring Compressor 1. thrust plate (6) and nylon thrust plate (7) from the clutch cylinder hub. 10. To remove the clutch pistons from the clutch cylinder. and the hubs may be separated by rotating one hub clockwise and withdrawing it from the other. before removing the tool.6 needle bearing (5). Mount the clutch cylinder on clutch spring compressor 0555-336259 with the C2/C4 end uppermost and compress the piston return spring. Release the tool and remove the circlip.

7. Remove the reverse sun gear and C3 washer from the cylinder. Remove the sealing rings from the C3 clutch cylinder. Planet Carrier Assembly and Centre Support 1. 2. Separate the centre support from the planet carrier by rotating it anti-clockwise.2006. Remove the circlip and release the spring. 9 (2) needle bearing and washer (1) from the output shaft and the planet carrier. Remove the one way clutch retainer (4) from the planet carrier. Remove the No. apply air pressure to the port between the iron sealing rings on the bearing journals of the cylinder. Remove the tool. 4. To remove the clutch piston from the clutch cylinder. 9. Lift the one way clutch (1) from the planet carrier (5). 5. 3.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T . and that all spring pressure has been released. 5.63 4. before removing the tool. Remove the circlip (2) retaining the one way clutch outer race (3) in the planet carrier and remove the race. keeper and spring. M / T Y220_3A2730 Y220_3A2740 Y220_3A2750 Y220_3A2760 6. circlip. 8. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . NOTICE • Make sure that the spring keeper has not been caught in the circlip groove. Mount the clutch assembly on clutch spring compressor 0555-336259 and compress the piston return spring.

Remove the five Torx head screws from the cover plate with T30 Torx bit.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Do not strike the converter support tube to loosen the pump body. 5. Y220_3A2770 4. Remove the cover plate.2006. Remove the ball check valve and one spring from the pump cover. gasket and seal from the cover. 2. Separate the pump body from the pump cover. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket. Y220_3A2790 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Remove the wiring loom retainer plate and remove solenoid valve 7 with a T30 Torx bit.64 Pump NOTICE The following valves are housed in the pump cover: • Solenoid valve 7 • Converter clutch control valve • Converter clutch regulator valve • Primary regulator valve 1. Y220_3A2780 6. 3. Note that the long screw holds the pump body to the pump body cover.

Remove the lip seal from the front of the pump body. Remove the four valves. NOTICE • Be aware that the manual valve will fall out of the valve body. Slide the manual valve out of the lower valve body. 6.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T . 4. Valve Body 1. M / T Y220_3A2800 Y220_3A2810 Y220_3A2820 Y220_3A2830 8. 4. 30 Torx bit. Separate the upper and lower valve bodies by lifting the upper body and the separator plate together. Turn the upper body over and place it on the bench with the separator plate uppermost. NOTICE • Take care that the bracket is not separated from the solenoid valve. 6 and valve assemblies. Remove the pump gears from the pump body. 3. Remove the 24 clamping screws with a No. 9. Place the valve body assembly on the bench with the upper body uppermost. 5. Depress the plug inward and remove the retaining pin for each of the three valves. NOTICE • Some of the valves and plugs are preloaded by springs and may unexpectedly fall out of the cover when the pins are removed.2006. plugs and springs.65 7. Remove the manual valve detent spring and retainer plate using a T40 Torx bit. 10. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . 2. Take note of the angular relationship of the solenoid valve terminals to the valve body and remove the solenoid valves 1. 3. 5. 2.

Remove the retaining plate. 3-4. NOTICE • The plug is preloaded by the spring and may unexpectedly fall out of the valve body. Drive out the retaining pin and remove the spring and ball check valve adjacent to the BAR valve. Y220_3A2870 ION (BTRA) AUTO TRANSMISSION ACTYON SM . spring and valve. 9. remove the retaining pin. Remove the retaining plates and pins from the 1-2. Remove the 1-2. BAR and CAR valves. Depress the line pressure release valve. disc (if fitted). Depress the solenoid valve 5 valve. 2-3 and 3-4 shift valves. Y220_3A2840 10. NOTICE • Once the pins are removed. 12. Remove the filter (1) and the large nylon check ball (2) from the lower valve body. spring and valve Y220_3A2860 15. Lift the separator plate and gaskets from the upper valve body. 11. Remove the plug. 16. The pins can be removed with a magnet. 8. plug.66 7. damper guide and spring. 14. spring and re-verse lockout valve. Y220_3A285A 13. Depress the 4-3 sequence valve plug and remove the retaining plate. the plates are loose in the valve body and will drop out when the valve body is turned over. 2-3. Remove the retaining in and remove the valve.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the five nylon check balls exposed in the valve body. NOTICE • The valve is preloaded by the spring and may unexpectedly fall out of the valve body. 17.2006.

plugs and the breather. 40 and 50.2006. Y220_3A2500 3. 1. the valve will peen its way into and through the separator plate) • Ensure that the ’E’clip is fitted to the cross shaft. (If this is not fitted.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T ASSEMBLY PROCEDURE . 2. 10 mm and 12 mm double hex socket. Turn the transmission case upside down on the bench and mount it to the transmission bench cradle 0555336256. and secure with the circlip. • Technicians overhauling these transmissions will also require a selection of good quality Torx bit sockets. • Ensure that all aspects of the parking mechanism are working. and an 8 mm. Ensurethatthebreatheris clear. Y220_3A2880 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . applying a sealant where applicable.67 Transmission Tools Required 0555-336256 Transmission Bench Cradle 0555-336258 Cross Shaft Pin Remover/Installer (Detent Lever) 0555-336263 0555-336265 Cross Shaft bullet Cross Shaft Pin Remover/Installer (Inhibitor Switch) 0555-336262 Cross Shaft Seal Installer NOTICE • The transmission is assembled in modular fashion and details of assembly for each module are given under the appropriate subject. Assemble the B1R valve and spring. in particular numbers 30. Tighten the fittings to specifications. • Ensure that the B1R circlip is fitted to the case. Ensure that the circlip is completely seated in its groove. Install all fittings. andcheckthat the lube fitting in the rear of the case is fittedand clear of obstruction.

Insert the cross shaft into the case. then install the antirattle spring on the shaft. Y220_3A2890 5. Install the parking pawl pivot pin and spring. NOTICE • The pawl must pivot freely on its pin. Install the rear servo lever and pivot pin. complete with the return spring and pivot pin. Assemble the park rod lever. Connect the park rod to the manual valve detent lever.2006. NOTICE • Care must be taken when applying sealant to ensure that it is not applied between the pin and the lever. Ensure the spring and cam collar is firmly installed on the rod.68 4. NOTICE • The lever must pivot freely on its pin. applying a small amount of sealant to the outer end of the pivot pin. NOTICE Y220_3A2640 • The lever must pivot freely on its pin and the spring must return the park rod lever to its correct location.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 9. 10. Secure the pivot pin with the circlip. Y220_3A2900 8. 6. from the side opposite to the inhibitor switch. Check that the cam collar slides freely on the rod. 7. Y220_3A2910 ION (BTRA) AUTO TRANSMISSION ACTYON SM .

Y220_3A2600 16. 12. Thoroughly check the terminal wiring loom for condition and continuity. Install the detent lever drive pin in the shaft using cross shaft pin remover/installer (detent lever) 0555336258 with the adaptor over the pin. Y220_3A2580 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Remove the tool and fit the spring retaining circlip to the shaft.69 11.03 A / CON A / BAG BRAKE ST’NG SP AXLE 13. Press the pin into the shaft until the tool bottoms. Y220_3A2920 14. Torque the bolts as per specifications. 15. Push the shaft through the detent lever until it starts in the detent lever side of the case.2006. Install the new cross shaft seals using cross shaft seal installer 0555-336262 (1) and cross shaft bullet 0555-336263 (2). Poition the manual valve detent lever. Install the inhibitor switch on the case. Press the pin into the shaft until the tool bottoms using cross shaft pin installer/remover (inhibitor switch) 0555-336265. Installation Notice Tightening torque 4 ~ 6 Nm (35 ~ 53 lb-in) 18. Y220_3A2930 17. aligning it with the cross-shaft bore in the case. CLUTCH T/C M / T A/T .

Check for damage to parking pawl teeth on the ring gear. assemble the ring gear to the output shaft and secure with circlip. Y220_3A2610 Output Shaft and Gear Assembly 1. Y220_3A2980 ION (BTRA) AUTO TRANSMISSION ACTYON SM . 7. Check that the sealing ring grooves have not been damaged. Carefully install the output shaft assembly in the case to prevent damage to the sealing rings. 10 needle bearing assembly onto the output shaft using petroleum jelly. Install the 10 pin connector in the case engaging the tangs on the connector in the notches in case. 6. Replace if necessary. 2. Lubricate the sealing rings with automatic transmission fluid. Position the wiring loom and locate the solenoid valve 7 contact and terminal in the pump mounting flange at the front of the case. Check that the output shaft bush is not worn or damaged. Install the No. Replace if necessary. Assemble the sealing rings to the output shaft with the scarf cut uppermost. 4. The solenoid valve 7 wire is routed under the park rod and cross shaft in the case. Y220_3A2970 5.2006. Ensure that the circlip is firmly seated in its groove. If previously dismantled. Y220_3A2940 20. 3.70 19. 8.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

NOTICE • Do not use petroleum jelly on the gasket. soak the new band in automatic transmission fluid for a minimum of five minutes prior to assembly.71 1. Install the bolts and tighten to specification. Check the rear band for any cracks or damage along the lining and metal backing. Y220_3A2630 6. 3. Assemble the gasket to the cover and fit the assembly to the case. Install the reaction anchor strut into the main case. 5. Installation Notice Tightening torque 16 ~ 22 Nm (12 ~ 16 lb-ft) Y220_3A2960 Rear Servo Assembly 1. Install the cam plate and tighten the screws to specification. Apply additional Loctite 202 or equivalent as required to the rear servo to case bolts. 3. Check the servo piston “O” rings and gasket for any damage.2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE 4. Installation Notice Tightening torque CHANGED BY EFFECTIVE DATE AFFECTED VIN 30 ~ 35 Nm (22 ~ 26 lb-ft) Y220_3A2990 ION (BTRA) AUTO TRANSMISSION ACTYON SM . and fit the “O” rings to the piston grooves. Y220_3A2950 5. 2. NOTICE • If fitting a new band. CLUTCH T/C M / T A/T Rear Band Assembly . 2. Position the apply strut on the rear band then engage the apply strut in the servo lever. ensuring that “O” ring compression is adequate but not excessive. without shims. Lubricate the servo piston “O” rings with automatic transmission fluid. Assemble the piston to the cover. 4. Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case. then position the rear servo rod into the spigot. Align the spring on the piston spigot.

4. Install the bolts and torque to specifications. 3. Install the circlip retainer ensuring that the circlip is completely seated in the groove of the case. Lubricate the No. 10 mm ~ 0. 10. 8. Replace if necessary.2006. Check that the plugs are fitted to the centre support. Press the race to the bottom of the drum and install the retaining circlip (2). Y220_3A2760 5. Install the centre support bolts finger tight. 9 needle bearing and washer with petroleum jelly and fit them to the rear face of the planet carrier. Install the planet assembly and the centre support into the case. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and that the pinion end float is within 0. and align the centre support mounting bolt holes.03 .50 mm. Install the One Way Clutch (OWC) retainer (1) to the planet carrier with the inner edge pointing downwards. then assemble the centre support into the OWC. Remove the centre support bolts and apply Loctite 222 or equivalent to the threads. 6. Install the outer (3) race in the drum.72 Planet Carrier Assembly and Centre Support 1. Ensure the circlip is firmly seated in its groove. ensuring that the support will rotate in an anti-clockwise direction only. Inspect the OWC race and the sprag assemblies for wear or damage. 9. Y220_3A20A0 2. Install the OWC (1) into the outer race with the lip edge uppermost. Lubricate the sprags with automatic transmission fluid. Y220_3A2750 7. Installation Notice Y220_3A2560 Tightening torque 20 ~ 27 Nm (15 ~ 20 lb-ft) CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

Install the front servo assembly into the case. Assemble the piston.2006. Install the adaptor housing and torque the bolts to specification. NOTICE • Do not use petroleum jelly to hold the gasket in position. 3. Y220_3A2520 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Fit the piston push rod assembly into the front servo cover. Lubricate the cover “O” ring with automatic transmission fluid and fit to the cover. 6. spring. T/C A/T Adaptor Housing Assembly .73 1.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH 3. seat and retaining ring. 2. Install the front servo block and spring into the case. Lubricatethepiston “O” rings with automatic transmission fluid and fit to the piston. 4. Apply additional Loctite 202 or equivalent as required to the adapter housing bolts. M / T Y220_3A20B0 Installation Notice Tightening torque 30 ~ 35 Nm (22 ~ 26 lb-ft) Front Servo Assembly 1. 2. Position a new gasket onto the adaptor housing. Install a new seal to the adaptor housing. push rod. belleville washer. Y220_3A20C0 5.

Compress the servo cover and fit the servo cover retaining circlip.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 3. Y220_3A20E0 4. NOTICE • If fitting a new band. 5. aligning the gap with the pan rail. Position the apply strut in its retaining clip and engage it with the band and the servo piston rod.2006. Install the reaction anchor strut to the case. 6. Position the strut retainers on the band. Check the band for all cracks or damage along its lining and metal backing. Position the reaction strut in its retaining clip and engage it with the band and anchor strut. Y220_3A2550 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Install the front band into the transmission case. and ensuring that it is completely seated in its groove. Y220_3A20D0 Front Band Assembly 1. ensuring that it is properly seated in place. 2. soak the band in automatic transmission fluid for a minimum of 5 minutes prior to assembly.74 7.

3. 10. Check the C4 piston bleed orifices are clear of obstructions. Check the feed orifices in the cylinder bore are clear of obstructions. Check the C2 piston bleed orifices are clear of obstructions. Fit the C4 piston into the C2 piston with the bleed orifices in alignment. M / T A/T C2/C4 Clutch Assembly .75 Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit NOTICE • Do not mix the clutch piston return springs. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . 9.03 A / CON A / BAG BRAKE ST’NG SP AXLE T/C • Check pistons for cracks. NOTICE • “O” rings must not be twisted in the grooves. 5. 2. Lubricate the “O” rings with Automatic Transmission Fluid (ATF) 4. 6. CLUTCH Y220_3A20F0 Y220_3A20G0 1. • Ensure that the snap rings are fitted correctly.2006. 8. 7. Fit the small “O” rings onto the inner groove and the large “O” rings onto the outer groove of the piston. Lubricate the “O” rings with ATF. with the piston bleed orifices aligned with the holes on the outside of the cylinder. until the outer diameter of the C2 piston enters the inner diameter of the cylinder. Install the C2/C4 piston assembly into the cylinder. Fit the small “O” ring onto the inner groove. and the large “O” ring onto the outer groove of the piston. Position the clutch cylinder with the C2/C4 cavity facing upwards.

and fit the spring retainer over the spring. Position the cylinder with the C1 cavity upwards. Using 0555-336259 clutch spring compressor. and that the cylinder feed orifices are clear of obstructions. Using 0555-336259 clutch spring compressor. 16. Install the C2 wave washer into the cylinder with the crest of one wave covering one of the bleed orifices inthe C2 piston. Measure and record the thickness of the flange of the C2 sleeve. Assemble the piston return spring to the piston. compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove. NOTICE • The wire diameter of this spring is 5.76 11. then remove the tool. in the following sequence: • • • • • • • • Steel plate (selective) Friction disc Steel plate Friction disc Steel plate Friction disc Steel plate Wave washer Y220_3A20I0 ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 12. 19. 20.26 mm. 14. Y220_3A20H0 18. Install the piston into the cylinder until the outer diameter of the piston enters the inner diameter of the cylinder. then remove the tool. Install the C4 clutch plates and wave washer into the C2 actuating sleeve. NOTICE • The wire diameter of this spring is 4. 15. 17. NOTICE • “O” rings must not be twisted in the grooves.2006.3 mm. with the rounded edge of the steel plates down. Y220_3A2690 13. compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove. Lubricate the “O” rings with ATF and fit them to their respective grooves. Install the spring and spring retainer onto the piston. Check the C1 piston check valves are not damaged and are free to move.

and the clutch Pack supporting a 2 kg weight. A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 23.4 ~ 1. `016. Holding the cylinder horizontal. If new friction plates are being fitted.8 mm. NOTICE • The clutch pack clearance must be taken before the elements are soaked in ATF.2006.4 ~ 1. `022). If the clutch is to be gauged from the top of the pressure plate.77 21. or Friction disc (0574-000012 & `017) • Steel plate (selective) • Friction disc • Steel plate (selective) • Friction disc Y220_3A20L0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . until the sleeve contacts the C2 wave washer. the dimension from the underside of the C2 pressure plate to the selective steel is to be between 1. 22. `015. Reassemble the sleeve and clutch pack into the cylinder. `019. install the sleeve and clutch plate assembly into the cylinder. Observe the alignment of the wave washer to the hole in the cylinder. Use selective plates to achieve the correct specification. `014. Install the C2 clutch plates in the cylinder in the following sequence: • Friction disc • Steel plate • Friction disc • Steel plate • Steel plate (0574-000013. Y220_3A20J0 NOTICE • With the C2 wave spring compressed. then the dimension is to be the actual thickness of the pressure plate plus 1. remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly.03 A / CON 24. with the crest of one wave of the washer in line with one of the holes in the outside of the cylinder.8 mm. Check the C4 clutch pack clearance using 0555336260 clutch pack clearance kit. Y220_3A20K0 25.

28.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 34. Use selective plates to achieve the correct specification. Check the clutch pack clearance using only the weight from 0555-336260 clutch pack clearance kit. 30. If new friction plates are being fitted. 37. Engage the C2/C4 clutch hub assembly in the C4 clutch plates. ensuring that the circlip is firmly seated in its groove. 36. Install the C2 clutch plates.2006. Fit the thrust plate over the cylinder inner hub. 35. 29. Align the tangs and fit the nylon thrust washer onto the C4 hub. Remove the C2 clutch plates from the clutch cylinder. Check the rotation of the C2 hub. Align and fit the C4 hub to the C2 clutch and the OWC assembly. NOTICE • With the clutch pack supporting a 2 kgweight. 33.78 26. remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly. 27. Y220_3A20N0 32.05 mm. While holding the C4 hub. 31. Y220_3A20M0 NOTICE • The clutch pack clearance must be taken before the elements are soaked in ATF. Apply petroleum jelly to the No. Y220_3A20O0 ION (BTRA) AUTO TRANSMISSION ACTYON SM . the dimension from the C3 clutch hub locating step to the friction plate is to be between 0. 5 needle bearing and fit it to the C4 hub. the C2 hub should rotate in the clockwise direction and lockup in the anti-clockwise direction when viewed from the C2 hub. Lubricate and fit the 3-4 OWC and end caps to the C2 hub. Install the C3 hub and secure it with the circlip.80 ~ 1.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Check the orifices in the cylinder are clear of obstructions. Using 0555-336259 clutch spring compressor compress the spring sufficiently to enable the installation of the retaining circlip. 10. 3. Coat the C3 piston “O” rings with automatic trans-mission fluid and fit the small “O” ring onto the inner ring and the large “O” ring onto the outer ring of the C3 piston. NOTICE • Take care not to cut the “O” ring. 2. Check that the bleed orifices of the piston are clean and clear of obstructions. Fit the C3 wave plate to the C3 piston face. Install the C3 piston in the cylinder until the outside diameter of the piston enters the inside diameter of the cylinder.2006. 7. Install the reverse sun gear in the C3 cylinder. Lubricate the C3 washer with petroleum jelly and fit to the inner face of the reverse sun gear. 4. and remove the tool. ensuring that the “O” ring compression is adequate but not excessive. 5. NOTICE • “O” rings must not be twisted in the grooves. Y220_3A20P0 6. Coat the sealing rings with automatic transmission fluid and fit into the C3 cylinder grooves. grooves and thrust face for condition. 8. ensuring that the circlip is firmly seated in the groove. Coat the “O” ring with automatic transmission fluid and fit it to the groove of the reverse sun gear. ensuring that one crest of the wave plate of the C3 piston face is aligned over one of the piston orifices.79 C3 Clutch and Reverse Sun Gear Assembly Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit 1. Y220_3A2730 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Assemble the spring and spring retainer on the piston. Check the C3 cylinder bush outside diameter and the centre support inside diameter are in good condition and not damaged. Y220_3A20Q0 9. Check the reverse sun gear splines.

Place the weight on the pressure plate and measure the distance from the end of the cylinder to the top of the pressure plate. `019.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • With the clutch pack supporting a weight of 2kg. Assemble the clutch plates and discs into the cylinder in the following sequence : • Steel plate • Friction disc • Steel plate • Steel plate (0574-000013. `014. Check the C3 clutch clearance using 0555-336260 clutch pack clearance kit in the following manner (weight only). 14. `017) • Steel plate (selective) • Friction disc • Steel plate (selective) Y220_3A20R0 • Friction disc 12. f. a. Install the circlip. If new friction plates are being fitted. Y220_3A20S0 e. `016. Lift the pressure plate up against the circlip and measure the distance from the end of the cylinder to the top of the pressure plate. the clearance between the snap ring and the top of the pressure plate is to be between 1. Record this figure. NOTICE Y220_3A20TA • The clutch pack clearance must be taken before the elements are soaked in automatic transmission fluid. `022). `015. or Friction disc (0574-000012. b.80 11.07 ~ 1. c. remove the clutch pack and soak the friction elements in automatic transmission fluid for a minimum of five minutes prior to reassembly. 15. Align and fit the pressure plate with the counterbore facing away from the clutch plates. Remove the weight. Subtract the second reading from the first reading to obtain the clutch pack clearance.45 mm. ION (BTRA) AUTO TRANSMISSION ACTYON SM . d. 13. Record this figure.

7. Align and fit the C3 clutch assembly over the forward sun gear. Align and fit the plastic thrust washer to the thrust plate with petroleum jelly. 2.7 needle bearing assembly over the forward sun gear. Y220_3A20W0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . ensuring that the thrust washer is between the bearing and the sun gear. Lubricate the No. Y220_3A20V0 4. Y220_3A20U0 3. Place the assembly to one side. 6. Ensure the lugs on the outside diameter of the bearing fit in the thrust plate counterbore. 6 needle bearing. Install the assembly over the forward sun gear shaft against the No.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .81 Forward Sun Gear and C3 Clutch Pack Assembly 1. Lubricate the lipped thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear.6 needle bearing with petroleum jelly and fit it to the thrust plate. Fit the No. 5.2006.

Y220_3A20X0 3. Assemble the clutch plate and disc into the cylinder in the following sequence: • • • • • • • • • • Steel plate Friction disc Steel plate Friction disc Steel plate Steel plate ( 0574-000013. Coat the sealing rings. `014.82 C1 Clutch Overdrive Shaft and Input Shaft Assembly Tools Required 0555-336260 Clutch Pack Clearance Kit NOTICE • Ensure that the snap rings are fitted correctly. `015. `016. 6 bearing doesn’t drop out of the bearing retainer. or friction disc (0574-000012 & `017) Steel plate (selective) Friction disc Steel plate (selective) Friction disc Y220_3A20Y0 ION (BTRA) AUTO TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . make sure the No. large and small. with petroleum jelly and fit them to the overdrive shaft. The sealing rings may be held in place with a small amount of petroleum jelly. especially the C1 piston. `019. • Do not mix clutch piston return springs.2006. • Check pistons for cracks. Check the overdrive shaft grooves for any defect. 1. `022). • If the C1/C2 clutch packs separate from the C3 clutch pack. 2.

2006. the dimension from the input shaft locating stop to the friction disc must be 0. Check the fit of the C1 clutch hub on the overdrive shaft. If it is loose.90 mm. Carefully fit the overdrive shaft into the C1 cylinder so as not to damage the sealing ring. the hub and shaft assembly must be replaced. AXLE Y220_3A2660 Y220_3A21A0 7. Use selective plates to achieve the correct specifi-cation. remove the clutch pack and soak the friction elements in automatic transmission fluid for a minimum of five minutes prior to assembly. 9. Coat the small nylon thrust spacer with petroleum jelly and install it over the overdrive shaft. 12. Check the clutch pack clearance using 0555-336260 clutch pack clearance kit. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Check the input shaft for any defect. NOTICE • With the clutch pack supporting a 2 kg weight.70 ~ 0. Y220_3A20Z0 NOTICE • The clutch pack clearance must be taken before elements are soaked in automatic transmission fluid.83 4. T/C M / T A/T . Coat the sealing rings with petroleum jelly and fit onto the input shaft. Fit the input shaft into the cylinder and secure it with the circlip. 5. 11. Fit the small bronze C1 hub thrust washer in place with petroleum jelly. ensuring that the circlip is completely seated in the groove. If new friction plates are being fitted. 8. 10.03 A / CON A / BAG BRAKE ST’NG SP CLUTCH 6.

Lubricate the pump bush. 1. Install the pump driven gear and the pump drive gear into the pump body. Y220_3A2810 ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Check the transmission end float. Put the pump body to one side. This will help to detect any missing parts or incorrect assembly.04 ~ 0. and the drive and driven gears. • Ensure that the correct “O” ring is fitted for the application. Install this assembly in the transmission case. Avoid any axial impact loads during assembly. Check the pump body for any damage. 5. Lubricate the pump body “O” ring with automatic transmission fluid and fit it to the pump body. with automatic transmission fluid. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. Y220_3A21B0 Pump Cover and Converter NOTICE • Do not wash the nose of solenoid valves in solvent.84 13.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 14. 2. Using a straight edge and thickness gauge. Install the seal flush with the front face of the pump body. 3. chips or irregularity.018 mm. Y220_3A21C0 4. 6. • Be careful not to damage the needle bearings on the assembly. check that the clearance between pump face and gears is 0. Check that the bush is firmly staked in the drive gear.

Install the converter clutch regulator valve. ensuring that the regulator valve slides freely. Lubricate all loose parts with automatic transmission fluid prior to assembly. Y220_3A21F0 12. Ensure that the pump cover cavities.03 A / CON A / BAG BRAKE ST’NG SP AXLE 9.2006. ports and holes are clean and free of any obstruction. spring and “O” ring. spring and plunger to the pump cover. Install the retaining pin. Y220_3A21D0 10. Assemble the primary regulator valve. Y220_3A21E0 11. plug. CLUTCH T/C M / T A/T . then fit the regulator valve plug and “O” ring. Install the retaining pin. 8.85 7. KAA5A1GO Y220_3A21G0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

Install the cover plate. and “O” ring. 16. Y220_3A21H0 15. Tighten the solenoid valve 7 screw. ensuring that the periphery of the cover plate is flush with the periphery of the pump cover.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ION (BTRA) AUTO TRANSMISSION ACTYON SM . in order that at assembly neither the wiring and the connector contacts or rubs on the input shaft or the C1/C2 clutch cylinder. Install the converter release check ball and spring. spring.86 13. 18. (1-5) Installation Notice Tightening torque 13 ~ 16 Nm (10 ~ 12 lb-ft) 19. solenoid valve 7 with the retainer and the solenoid valve wiring retainer to the pump cover. Y220_3A21K0 Installation Notice Tightening torque 13 ~ 16 Nm (10 ~ 12 lb-ft) • Check that neither the wiring nor the connector protrudes excessively.2006. 14. Tighten the screws to specification in the order. plug. Y220_3A21J0 17. Install the retaining pin. Install the converter clutch control valve. Install the gasket on the pump cover.

(A-F) Installation Notice Tightening torque Bolt (A-E): 24 ~ 27 Nm (18 ~ 20 lb-ft) T/C Y220_3A21L0 Y220_3A21M0 Y220_3A21N0 Screw (F): 13 ~ 16 Nm (10 ~ 12 lb-ft) 22. e. Attach a dial indicator to the front of the transmission case with the stylus resting on the end of the input shaft. 24. 4 bearing and the input shaft bearing surface. adjust the front and rear bands to specifications. Tighten the bolts and the screw to specification in the order. shims are to be placed between the No. d. Refer to “Front and Rear Band Adjustment” in this section. Fit the “O” ring to the pump cover outer diameter. 21. On completion of this procedure. If the end float clearance is less than 0. 27. Perform the following steps to check the end float : a. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .65 mm.50 ~ 0. Assemble the pump to the pump cover. Apply additional Loctite 202 or equivalent as required to the pump cover to case bolts. ensuring that the pump is flush against the pump cover.2006. 23. Tighten all bolts and the crescent screw finger tight. Installation Notice Tightening torque 24 ~ 34 Nm (18 ~ 25 lb-ft) 25. c. Install the pump and cover assembly over the input shaft being careful not to damage the sealing rings.5 mm then the transmission has been assembled incorrectly or the parts are out of specification.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T A/T . Apply a force of approximately 250 N or 25 kg to the input shaft. Install and tighten bolts to specification. Zero the dial indicator. Install the pump to transmission case gasket onto the case. 26. Place a small lever behind the forward clutch cylinder and lever the cylinder forward. The measurement recorded on the dial indicator is the transmission end float or clearance between the No. b.4 bearing and the converter support tube.87 20. If the unshimmed end float clearance is greater than specification. Check that the transmission end float is 0.

• Check the line pressure relief valve for swarf. they can be swapped. Y220_3A21O0 3. springs. • Locate the detent spring central to the detent lever. • Check the 4-3 sequence valve and spring orientation. Install the line pressure relief valve. • Check that all valves slide freely in their location. ports and holes for damage or obstructions. • When servicing the transmission. • Be aware of ball positions in the upper valve body. Y220_3A21P0 ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006. and be aware of replacing the shims. • Thoroughly wash all loose components. • The orifices in the valve body are for stability and safeguard. ensure that the solenoid valve 5 damper spring is not broken. • Check that the 12 mm ball is in the lower body. Do not drill them larger. • Be aware of 1-2 and 3-4 shift valve positions. spring and disc. tapered end first. 1. Secure with the retaining pin.88 Valve Body NOTICE • Do not wash the nose of solenoid valves in solvent. plunger and retaining pin. • Check the valve body cavities.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . • Wash the upper and lower valve bodies thoroughly with cleansing solvent and blow dry. Install the detent lever locating pin 2. Install the Band Apply Regulator (BAR) valve.

spring. Install the 2-3 shift valve and retaining pin. Install the 1-2 shift valve.2006.89 4. Y220_3A2860 6. Y220_3A21Q0 7. Y220_3A2870 5. Y220_3A21R0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . plug and retaining plate. Install the solenoid valve 5 damper guide and spring. Install the 4-3 sequence valve. plug and retaining pin.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . piston and retaining pin.

Y220_3A2850 ION (BTRA) AUTO TRANSMISSION ACTYON SM .90 8. Y220_3A21U0 12. 15. Y220_3A21T0 10. Check the upper and lower valve body gaskets for damage. Y220_3A21S0 9.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Install the Clutch Apply Regulator (CAR) valve. Install the 3-4 shift valve and retaining pin. plunger and retaining pin. springs. 13. Repair or replace the separator plate as necessary. Replace the gaskets as necessary. Install the lower valve body gasket on the lower valve body.2006. spring and retaining pin. Install the solenoid valve supply valve. 11. Check the separator plate for burrs and damage. spring and retaining plate. 14. Position the third feed ball (large nylon) in the valve body and install the solenoid valve 6 filter. NOTICE • This aluminum valve is easily damaged. Install solenoid valve 6 plunger.

Ensure that the valve is correctly oriented. Holding the separator plate to the upper valve body to prevent the check balls from falling out. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Install solenoid valves 1. Y220_3A2840 Installation Notice Tightening torque 11 ~ 16 Nm (8 ~ 12 lb-ft) 20. Install the separator plate over the upper valve body.91 16. Ensure the solenoid valve is firmly secured by the retainer and that the screw is tightened to specification. BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 4 and 6. Install the reverse lockout valve. install the upper valve body on the lower valve body. Installation Notice Tightening torque 8 ~ 12 Nm (71 ~ 106 lb-in) Y220_3A2830 • The wiring loom ground wire eyelet terminal is secured beneath the solenoid valve 1 retainer. 3. spring. Position the five nylon ball checks in the upper valve body. plug and retaining plate.03 A / CON A / BAG 19. Y220_3A21V0 17. 2.2006. Install all screws finger tight then tighten the screws to specification in the prescribed sequence. Fit the upper valve body gasket. 18.

Installation Notice Tightening torque 8 ~ 12 Nm (71 ~ 106 lb-in) Y220_3A21W0 22.2006. Align the valve body assembly on the transmission case and install the manual valve lever to manual valve link.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Ensure that the solenoid valve is pushed firmly into the valve body by the retainer and that the screw is tightened to specification. ensuring that the screw is tight-ened to specification. Installation Notice Tightening torque 20 ~ 22 Nm (15 ~ 16 lb-ft) Y220_3A21X0 23. Fit the long end of the link to the manual valve first. Install the manual shift valve. Install solenoid valve 5. Check the spring for wear or damage.92 21. support plate and screw). Install the securing bolts and tighten to specification in the specified sequence. Installation Notice Tightening torque 8 ~ 13 Nm (71 ~ 115 lb-in) Y220_3A21Z0 ION (BTRA) AUTO TRANSMISSION ACTYON SM . Install the detent spring assembly (spring. NOTICE • Be aware that the manual valve will fall out of the valve body. Y220_3A21Y0 24.

5. This ensures that the gasket remains on the pan ridge. Assemble the gasket on the pan lip. A / BAG 1. 26. Y220_3A2510 3. Do not over torque pan bolts as this may distort the pan and cause leaks. Y220_3A22B0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .93 25. Secure the oil filter assembly with the retainer.violet NOTICE Y220_3A22A0 Oil Filter and Pan Assembly NOTICE • Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has occurred. • Ensure that the internal line pressure plus in the valve body is fitted. BRAKE ST’NG SP AXLE CLUTCH • All hardware must be correctly installed and torqued to specification.03 A / CON 2. • To aid the assembly of the pan gasket. Connect the solenoid valve wiring as detailed below: Solenoid valve 1 . T/C M / T A/T . The gasket must be free of any distortion when installed.green Solenoid valve 6 . Lubricate the oil filter sealing ring with automatic transmission fluid. The spigot must not lean on one side while being fitted.bIue Solenoid valve 3 .orange Solenoid valve 5 .yellow Solenoid valve 4 . Carefully assemble the oil filter to the valve body.red Solenoid valve 2 . Check the alignment of the detent roller and the manual lever quadrant. 4.2006. use a small amount of Vaseline at the pan/gasket interface. Check that the magnet is located in the dimple in the corner of the oil pan.

Fit the converter ensuring that the tangs are engaged in the pump gear. Installation Notice Tightening torque 4 ~ 6 Nm (35 ~ 53 lb-in) Y220_3A22C0 Torque Converter and Housing Assembly 1.2006. Locate the torque converter housing on the transmission main case.94 6. 2. Clear the threads on the output shaft and apply Loctite 243 or equivalent as required to threads. 3. 2. Installation Notice Y220_3A22D0 Tightening torque 54 ~ 68 Nm (40 ~ 50 lb-ft) • All the hardware must be correctly installed and torqued to specification. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence Do not over torque.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Ensure that the tangs do not contact the pump seal. 3. “O” ring and torque the nut to specification. Output Flange Assembly (2WD 1. Apply additional Loctite 202 or equivalent as required to the converter housing to case bolts. Installation Notice Y220_3A2040 KAC5A040 Tightening torque 35 Nm (26 lb-ft) ION (BTRA) AUTO TRANSMISSION ACTYON SM . Install the flange. Install and tighten bolts to specification. Position the transmission detent lever into the park position and lock the output shaft.

Measure the travel of the push rod and subtract 3 mm to find the shim size required.2006. 2.95 Front Band Setting Procedure Y220_3A22E0 1. c. Re-check that the push rod travel. wear or corrosion. Replace as necessary. b. c. Apply air at 650/700 kPa to the front servo apply area (B1 outer) b. The click indicates that the shim is clipped home correctly.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T FRONT AND REAR BAND ADJUSTMENT . The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced. (3mm ± 0. 3. Shim(s) are to be pressed on by hand until an audible click is heard. NOTICE • A minimum of one shim is required at all times minimum shim size is 1 mm. a. The shim(s) are to be installed between the case abutment face and the anchor strut flange. Measure the projection of the front servo push rod from the transmission case dimension ’A’. Inspect the shim(s) for damage. Release the air. d. The thickness of available shims are listed in the table below.25mm) CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Fit the selected shim(s) to the shank of the anchor strut as follows: a.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . c. 75 mm and divide the remainder by 2. Inspect the shim(s) for damage. 3. Apply air at 650/700 kPa to the rear servo apply area (B2 outer) b. wear or corrosion and replace as necessary. a. 2. Re-check that the piston travel. (3. subtract 3. The thickness of available shims are listed in the table below. The shim(s) are to be pressed on by hand until an audible click is heard.75 mm ± 0. Measure the travel of the piston.96 Rear Band Setting Procedure Y220_3A22F0 1.625 mm) ION (BTRA) AUTO TRANSMISSION ACTYON SM . Measure distance “A” from the rear servo piston to the inner face of the transmission case using vernier calipers. NOTICE • A minimum of one shim is required at all times minimum shim size is 1 mm. Fit the selected shim(s) to the shank of the anchor strut as follows. The click indicates that the shim is clipped home correctly. a. Release the air. The shim(s) are to be installed between the case abutment face and the anchor strut flange. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced c.2006. b.5 to find shim size.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .97 Y220_3A22G0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.

5. Installation should follow the removal procedure in the reverse order.2006. Disconnect the P position lamp by turning it from the middle housing. Remove the gear shift control lever knob. 12. 3. Y220_3A25R0 ION (BTRA) AUTO TRANSMISSION ACTYON SM . 4. Refer to Section Interior Trim. Separate the P position switches assembly with the P position lamp wiring harness from the gear shift control lever assembly. Separate the upper and middle housing from the gear shift control lever assembly by unlocking the lock. Remove the gear shift control lever assembly. 13. 2. 8. Remove the P position switches assembly bolts. Remove the gear shift control lever by pushing the pin. 9.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Adjust the brake transmission shift interlock ease the operation well. Remover the spring and bushes from the pin of the gear shift control lever. 7.98 GEAR SHIFT CONTROL LEVER Disassembly and Assembly Procedure 1. 11. Remove the upper housing. Y220_3A25P0 6. Disconnect the negative battery cable. Remove the clips supporting the springs and bushes from the pin of the pin of the gear shift control lever. Y220_3A25Q0 10. Remove the middle housing with the mode selector switch wiring harness from the gear shift control lever assembly.

Tightening torque 10 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . Disconnect the connector and remove TCU. LH/RH).99 REMOVAL AND INSTALLATION OF TCU 1. BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 2.2006. Remove the TCU mounting bolts (10 mm. 3. Disconnect the negative battery cable.03 A / CON A / BAG 4. Move the driver's seat forward and unfold the cut section of the carpet.

100 FASTENER TIGHTENING SPECIFICATIONS Application Adaptor Housing to Case Bolts Cam Plate to Case (Parking Pawl) Screws Centre Support to Case Bolts Detent Spring Screw Extension Housing to Case Bolts Front Propeller Shaft Bolts Inhibitor Switch to Case Bolts Oil Cooler Pipes Oil Pan to Case Bolts On/Off Solenoid valve Retainer Screws Output Flange Nuts Pump Cover Plate to Crescent Screw Pump Cover Plate to Pump Cover Screws Pump Cover to Case Bolts Pump to Pump Cover Bolts Rear Propeller Shaft Bolts Rear Servo Cover to Case Bolts TCM Mounting Bolt Torque Converter Housing to Case Bolts Torque Converter Mounting Bolts Transfer Case to Transmission Housing Bolts Transmission Filler Plug Upper Valve Body to Lower Valve Body Screws Valve Body To Case Bolts Variable Pressure Solenoid valve (S5) Retainer Screw Nm 30 ~ 35 16 ~ 22 20 ~ 27 20 ~ 22 54 ~ 68 70 ~ 80 4~6 40 ~ 45 4~6 8 ~ 12 35 13 ~ 16 13 ~ 16 24 ~ 34 24 ~ 27 70 ~ 80 30 ~ 35 10 54 ~ 68 42 35 ~ 60 30 ~ 35 11 ~ 16 8 ~ 13 8 ~ 12 Lb-Ft 22 ~ 26 12 ~ 16 15 ~ 20 15 ~ 16 40 ~ 50 52 ~ 59 29 ~ 33 26 10 ~ 12 10 ~ 12 18 ~ 25 18 ~ 20 52 ~ 59 22 ~ 26 40 ~ 50 31 26 ~ 44 22 ~ 26 8 ~ 12 - Lb-Ft 35 ~ 53 35 ~ 53 71 ~ 106 89 71 ~ 115 71 ~ 106 ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

03 A / CON A / BAG BRAKE DIAGNOSTIC TROUBLE CODES ST’NG SP AXLE CLUTCH When the TCU detects a system fault. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . T/C A/T TROUBLE CODE DIAGNOSIS .Returns to the normal operation if the failure does not occur within 30 seconds. which will help to find the cause of the problem more quickly.87 V Symptom: .Cannot shift to 1st.Check inhibitor switch and TCU connector for proper connection. This code is present while the fault conditions are met and is stored as a ‘History DTC’ until cleared. checks and fault clearing.Cannot shift to 1st.101 TCU DIAGNOSTIC SYSTEM OVERVIEW NOTICE • To prevent Transmission Control Module (TCM) damage. M / T In the case where the vehicle type is certified for Eure On-Board Diagnostic (EOBD) compliance.12 V Symptom: . . etc.Check gear position sensor for short to B+. Action: . .2006. 3rd and 4th gear.Check gear position sensor for short to ground. a Diagnostic Trouble Code (DTC) is set in the TCU. the response to the fault may include action by the ECM.Gear position sensor signal of the inhibitor switch is higher than the normal value (defective inhibitor switch) . TCM fuse. TCM pigtail connector. Condition for setting and clearing each TCU DTC are provided in the relevant sections. .Specified value of inhibitor switch: 4.this information may be helpful in the diagnostic process. . Always note the DTCs present before clearing . the Engine Control Module (ECM) provides the communication link to the EOBD scan tool to pass on any EOBD relevant codes from the TCU.Check inhibitor switch and TCU connector for proper connection. jumper cables. The ignition key must be OFF when disconnection or reconnection the power to the TCM (for example bttery cable.Replace TCU if necessary. including the illumination of the Malfunction lndicator Lamp (MIL). P0708 High gear position sensor input Cause: .Replace TCU if necessary. Action: . . for details on EOBD system function.Gear position sensor signal of the inhibitor switch is lower than the normal value (defective gear position sensor) . 3rd and 4th gear position.Specified value of gear position sensor signal: 0. . . Where a type B DTC has been set in an EOBD vehicle.Torque converter clucth stops from its operation.Torque converter clucth stops from its operation. . The table below contains a list of all supported DTCs and the classification of each for EOBD purposes. Refer to Engine Control.Returns to the normal operation if the failure does not occur within 30 seconds. DTC Code P0707 Defective Low gear position sensor input Cause: Cause and Action . Some diagnostic tables will tell you to clear the codes before using the chart. CLEARING TROUBLE CODES TCU DTCs should be cleared after repairs have been completed.).

Specified value of inhibitor switch: 4.12 V Symptom: . Always note the DTCs present before clearing .Check gear position sensor for short to ground. .Gear position sensor signal of the inhibitor switch is lower than the normal value (defective gear position sensor) . DTC Code P0707 Defective Low gear position sensor input Cause: Cause and Action .Torque converter clucth stops from its operation. .Replace TCU if necessary.Cannot shift to 1st. the response to the fault may include action by the ECM.this information may be helpful in the diagnostic process. Refer to Engine Control.Check inhibitor switch and TCU connector for proper connection. . the Engine Control Module (ECM) provides the communication link to the EOBD scan tool to pass on any EOBD relevant codes from the TCU. 3rd and 4th gear. T/C A/T TROUBLE CODE DIAGNOSIS .Torque converter clucth stops from its operation. The ignition key must be OFF when disconnection or reconnection the power to the TCM (for example bttery cable.).Returns to the normal operation if the failure does not occur within 30 seconds.Replace TCU if necessary. for details on EOBD system function. including the illumination of the Malfunction lndicator Lamp (MIL). .03 A / CON A / BAG BRAKE DIAGNOSTIC TROUBLE CODES ST’NG SP AXLE CLUTCH When the TCU detects a system fault. . Action: .Specified value of gear position sensor signal: 0. TCM pigtail connector. TCM fuse.Gear position sensor signal of the inhibitor switch is higher than the normal value (defective inhibitor switch) . 3rd and 4th gear position. .Check inhibitor switch and TCU connector for proper connection. . This code is present while the fault conditions are met and is stored as a ‘History DTC’ until cleared. Action: .87 V Symptom: .Check gear position sensor for short to B+. which will help to find the cause of the problem more quickly.Cannot shift to 1st. Condition for setting and clearing each TCU DTC are provided in the relevant sections. CLEARING TROUBLE CODES TCU DTCs should be cleared after repairs have been completed. P0708 High gear position sensor input Cause: .101 TCU DIAGNOSTIC SYSTEM OVERVIEW NOTICE • To prevent Transmission Control Module (TCM) damage. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006. a Diagnostic Trouble Code (DTC) is set in the TCU. etc. checks and fault clearing. . Some diagnostic tables will tell you to clear the codes before using the chart. Where a type B DTC has been set in an EOBD vehicle.Returns to the normal operation if the failure does not occur within 30 seconds. M / T In the case where the vehicle type is certified for Eure On-Board Diagnostic (EOBD) compliance. jumper cables. The table below contains a list of all supported DTCs and the classification of each for EOBD purposes.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .The W/N/P mode switch's connection is intermittently disconnected (the input of the mode switch changes rapidly). .The switch is fixed to normal mode.Replace solenoicd valve (S7) if necessary.The rpm of engine and output shaft is not consistent with the characteristic under the condition with torque converter not engaged.Oil temperature is fixed to 120°C . Action: .Torque converter clutch is locked.Oil temperature of T/M exceeds the specified value. Action: . .Returns to the normal operation if the failure does not occur within 30 seconds. . .Returns to the normal operation if the failure does not occur within 3 seconds.2006.Returns to the normal operation if the failure does not occur within 30 seconds.Check W/N/P mode switch input circuit for short or open circuit. . . . • Allowable slip rpm of torque converter < 50 rpm Symptom: . • Allowable slip rpm of torque converter:100 rpm Symptom: .Check T/M oil temperature sensor for short or open circuit. .Replace TCU if necessary.Check T/M connector TCU connector for their proper connection. • Oil temperature sensor voltage > 4.Returns to the normal operation if the failure does not occur within 3 seconds. . .Torque conver clutch is engaged when solenoid valve (S7) is not operated.Check T/M connector and TCU connector for proper connection.Replace TCU if necessary. P0790 Defective W/N/P mode switch Cause: . . .Torque converter clutch cannot be locked Action: .Check T/M connector TCU connector for their proper connection.The rpm of engine and output shaft is not consistent with the selected shift's gear ratio. .Replace W/N/P mode switch if necessary. .88 V • Oil temperature sensor voltage < 0.Check solenoid valve (S7) wiring for short to ground or open circuit. Action: ION (BTRA) AUTO TRANSMISSION ACTYON SM .Torque conver clutch cannot be engaged even when solenoid valve (S7) is operated. .Shifting impression is poor. . Symptom: .Check W/N/P mode switch wiring.Replace solenoicd valve (S7) if necessary. P0742 Torque converter clutch engaged Cause: .21 V Symptom: .Check solenoid valve (S7) wiring for short to B+.102 DTC Code P0741 Defective Torque converter clutch cannot be engaged Cause: Cause and Action .Replace TCU if necessary. P0710 Defective T/M oil temperature sensor Cause: .

Action: . .Replace TCU if necessary. Symptom: .The engine rpm signal (CAN) is out of specified value or there is no engine rpm signal.The TCU supply voltage is low or there is no measured voltage value. Action: . .Enters into the emergency mode. . • TCU supply voltage > 16. • Output shaft rpm < 0 rpm • Output shaft rpm > 9000 rpm .Check ECU and TCU connectors for poor contact.The TCU supply voltage is high.5 V Symptom: . Action: .Replace TCU if necessary.All solenoid valves stop from their operation when high battery voltage is detected.103 DTC Code P1703 Abnormal engine rpm (CAN) Cause: .Replace TCU if necessary.The engine rpm corresponding to the max.No.Cannot shift down by limiting the engine rpm to prevent the engine from overrunning.Returns to the normal operation if the failure does not occur within 3 seconds. . . Action: . . .The actual vehicle speed is 0 while other signals indicate that vehicle is moving. • Engine rpm < 0 rpm • Engine rpm > 7000 rpm Symptom: .Check TCU terminal for short to B+ or short to ground.Returns to the normal operation if the failure does not occur within 30 seconds.Replace TCU if necessary. 6 solenoid valve (S6) stops from its operation. engine torque is applyed to the shifting condition. Symptom: .The output shaft signal (CAN) is out of specified value or there is no output shaft signal.Returns to the normal operation if the failure does not occur within 3 seconds and the rpm is over 0.Check ECU and TCU connectors for poor contact. .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T Defective Cause and Action . P1708 Low TCU supply voltage Cause: . P1704 Abnormal output shaft rpm (CAN) Cause: . bending or deformation.Check TCU terminal for poor contact. P1709 High TCU supply voltage Cause: .Returns to the normal operation if the failure does not occur within 30 seconds. .Cannot shift to 1st gear position. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM . . .Cannot shift to other gear positions due to the low supply voltage.2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Returns to the normal operation if the failure does not occur within 30 seconds.VPS (Variable pressure solenoid valve) is used for controlling clutch and band pressure while shifting.DTC disappears after turning ignition from OFF to ON. .Replace TCU if necessary. .Shifting impression is poor. . . . . (self-test when IGN ON) .Enters into the emergency mode.Shifting impression is poor. .Cannot shift to 4th gear position.The program memory is defective (self-test when IGN ON).Determines the vehicle coding value via CAN communication or selects 0 for the coding value. ION (BTRA) AUTO TRANSMISSION ACTYON SM . • Accelerator pedal signal < 0 % • Accelerator pedal signal > 100 % Symptom: . . .104 DTC Code P1713 Defective Defective accelerator pedal signal (CAN) Cause: Cause and Action .Replace TCU if necessary.The VPS offset stored in EEPROM is incorrect (self-test when IGN ON). Action: P1718 Defective ROM Cause: .DTC disappears after turning ignition from OFF to ON.The calculated checksum value is not consistent with the stored checksum value.No output signal. . • VPS offset > 120 mA Symptom: . . Action: P1717 Defective RAM Cause: .Enters into the emergency mode. Symptom: .The vehicle coding stored in EEPROM is defective (self-test when IGN ON). N B2. .Replace TCU if necessary. Action: .The accelerator pedal signal is not used for P.DTC disappears after turning ignition from OFF to ON. . P1714 Defective vehicle coding Cause: . .Replace TCU if necessary.RAM operates abnormally.The interior default value is applied for shift determination (if the accelerator pedal signal is defective. . Action: . R.The accelerator pedal signal (CAN) is out of the specified value. Symptom: . .DTC disappears after turning ignition from OFF to ON. Symptom: .2006.Torque converter clucth stops from its operation. Action: P1715 Abnormal VPS offset Cause: . ECU selects the default value and sends it and error message to TCU via CAN line).Replace TCU if necessary.No output signal.Check ECU and TCU connectors for poor contact and their terminals for bend or deformation.

. 1 solenoid valve is OFF. 1 solenoid valve operates with the No. Action: . .Determines the vehicle coding value via CAN communication or selects 0 for the coding value. . T/C A / CON ACTYON SM .Enters into the emergency mode.Check TCU connector and terminals for poor contact. .Check No. . Action: . .EEPROM memory is defective. . . .The No.Replace TCU if necessary. 2 solenoid valve to control the oil flow for the 1-2 shift valve.Check TCU connector for proper connection and its terminal for bend or deformation.Shifting impression is poor.Check ECU and TCU connectors wiring for poor contact. .The calculated checksum value is not consistent with the stored checksum value or the error occurs in EEPROM communication.Replace No. Symptom: .Replace TCU if necessary. .DTC disappears after turning ignition from OFF to ON.The solenoid valve connection is short to B+.Cannot use information necessary for TCU via CAN communication. 1 solenoid valve open Cause: . CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T A/T Defective Cause and Action . .1 solenoid valve if necessary.105 DTC Code P1719 Abnormal CAN communication Cause: .Selects 0 for the coding value. Symptom: .Replace TCU if necessary. (self-test when IGN ON) Symptom: .DTC disappears after turning ignition from OFF to ON. . .The default value is used for all CAN signals.Enters into the emergency mode. Action: P1733 No.2006.DTC disappears after turning ignition from OFF to ON. .03 P1720 Defective EEPROM Cause: . 1 solenoid valve wiring and connector (especially its ground condition).Returns to the normal operation if the failure does not occur within 30 seconds.The No. P1722 Action: Incorrect vehicle model Cause: . .Check ECU and TCU connectors' terminals for bend or deformation. . Symptom: .Cannot detect the vehicle coding through EEPROM or CAN communication. .Specified resistance value: 22 ~ 30Ω .1 solenoid valve internal circuit or solenoid valve wiring is open.Enters into the emergency mode.The No.

Symptom: . .The No.The No.Check No. .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .The solenoid valve connection is short to B+.Check TCU connector for proper connection and its terminal for bend or deformation.Replace No.Check No. 3 solenoid valve wiring and connector (especially. 2 solenoid valve open Cause: Cause and Action .DTC disappears after turning ignition from OFF to ON.Replace TCU if necessary.The No.The No.Enters into the emergency mode.The No. . . 4 solenoid valve to shift smoothly and control the shifting order. . . . Symptom: . 3 solenoid valve open Cause: .The solenoid valve connection is short to B+. 1 solenoid valve to control the oil flow for the 2-3 shift valve. 2 solenoid valve circuit is open. 2 solenoid valve operates with the No. 3 solenoid valve turns the clutch regulator valve ON and OFF. . 2 solenoid valve wiring and connector (especially. .Shifting impression is poor.Check TCU connector for proper connection and its terminal for bend or deformation.Specified resistance value: 22 ~ 30Ω . .The No. its ground condition). 3 solenoid valve is OFF. 3 solenoid valve circuit is open. .DTC disappears after turning ignition from OFF to ON.The No. .Replace No.Specified resistance value: 22 ~ 30Ω .106 DTC Code P1734 Defective No. P1735 No. 2 solenoid valve is OFF.2006. . Action: . . . ION (BTRA) AUTO TRANSMISSION ACTYON SM . 3 solenoid valve operates with the No.Replace TCU if necessary.3 solenoid valve if necessary.2 solenoid valve if necessary. its ground condition). Action: .

5 solenoid valve is a variable solenoid valve to change the pressure for shifting.The No. 4 solenoid valve operates with the No.Specified resistance value: 22 ~ 30Ω . 5 solenoid valve wiring and connector (especially. . . 4 solenoid valve is OFF or ON.Check TCU connector for proper connection and its terminal for bend or deformation.The solenoid valve connection is short to B+. .03 No. . Symptom: . .Cannot to shift to 1st gear position.The No. . . 4 solenoid valve open Cause: . . P1738 No. Symptom: .The No.Replace No.6 ~ 5. its ground condition). P1737 SP A / CON A / BAG BRAKE ST’NG ACTYON SM .The No. CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION AXLE CLUTCH T/C M / T A/T Defective Cause and Action .2006.The No.Replace TCU if necessary. 5 solenoid valve circuit is open.DTC disappears after turning ignition from OFF to ON. Action: . Action: . (No.5Ω .4 solenoid valve if necessary.The No. .Specified resistance value: 3. .Shifting impression is poor. 6 solenoid valve is used to set the hydraulic line pressure to HIGH/LOW level.Replace No. 4 solenoid valve circuit is open. .Check TCU connector for proper connection and its terminal for bend or deformation. Action: .Check No.The solenoid valve connection is short to B+.Check No. 6 solenoid valve circuit is open. Symptom: .DTC disappears after turning ignition from OFF to ON.107 DTC Code P1736 No. . . 4 solenoid valve turns the clutch regulator valve ON and OFF.Replace TCU if necessary. 4 solenoid valve is always OFF. .Replace No.The hydraulic line pressure is high.DTC disappears after turning ignition from OFF to ON. 6 solenoid valve wiring and connector (especially. .5 solenoid valve if necessary.Replace TCU if necessary. .Check No. 3 solenoid valve to shift smoothly and control the shifting order.The solenoid valve connection is short to B+. . 6 solenoid valve if necessary.The No. . . .Shifting impression is poor.Check TCU connector for proper connection and its terminal for bend or deformation. 6 solenoid valve stops its operation) . 4 solenoid valve wiring and connector (especially. 5 solenoid valve open Cause: .Specified resistance value: 22 ~ 30Ω . its ground condition). 6 solenoid valve open Cause: .The No.The No. its ground condition). .

Replace No.DTC disappears after turning ignition from OFF to ON. 7 solenoid valve circuit is open. .2006. . . . 1 solenoid valve operates with the No. 2 solenoid valve operates with the No.The torque converter clutch cannot be locked. .The No.The No. Action: .The No. 1 solenoid valve wiring and connector (especially its ground condition). Symptom: .Check TCU connector for proper connection and its terminal for bend or deformation.Replace TCU if necessary. . P1742 No.Check No. . . 2 solenoid valve wiring and connector (especially its ground condition). .Enters into the emergency mode.Check No. 7 solenoid valve if necessary. 7 solenoid valve open Cause: Cause and Action .Check TCU connector for proper connection and its terminal for bend or deformation.The No. 2 solenoid valve short Cause: .The No. ION (BTRA) AUTO TRANSMISSION ACTYON SM .The No. its ground condition). Action: . P1741 No. .Enters into the emergency mode.The No. 1 solenoid valve short Cause: .Check No. 2 solenoid valve circuit is short to ground.Check TCU connector for proper connection and its terminal for bend or deformation. 1 solenoid valve to control the oil flow for the 2-3 shift valve. .108 DTC Code P1739 Defective No.The solenoid valve connection is short to B+. Action: . 7 solenoid valve stops its operation (OFF).Specified resistance value: 22 ~ 30Ω . Symptom: . . .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Specified resistance value: 22 ~ 30Ω . 7 solenoid valve wiring and connector (especially.Replace No. 2 solenoid valve to control the oil flow for the 1-2 shift valve. 1 solenoid valve circuit is short to ground.The No.Replace TCU if necessary. Symptom: . . .Replace No.1 solenoid valve if necessary. . 2 solenoid valve is OFF.Replace TCU if necessary.Specified resistance value: 22 ~ 30Ω .DTC disappears after turning ignition from OFF to ON. . 7 solenoid valve controls the operation of the torque converter clutch. . 1 solenoid valve is OFF. . 2 solenoid valve if necessary.The No.DTC disappears after turning ignition from OFF to ON.

Action: .Check TCU connector for proper connection and its terminal for bend or deformation.109 DTC Code P1743 No. BRAKE A / CON A / BAG ST’NG ACTYON SM . .The No. . 5 solenoid valve wiring and connector (especially.Replace TCU if necessary.Check No. its ground condition).Specified resistance value: 3. 4 solenoid valve short Cause: .DTC disappears after turning ignition from OFF to ON. Action: . .The No. . . 5 solenoid valve circuit is short to ground. .Check TCU connector for proper connection and its terminal for bend or deformation. Symptom: . 4 solenoid valve if necessary. .Specified resistance value: 22 ~ 30Ω . 4 solenoid valve is always OFF. 4 solenoid valve to shift smoothly and control the shifting order. Symptom: . 3 solenoid valve to shift smoothly and control the shifting order. 4 solenoid valve operates with the No.03 . 4 solenoid valve circuit is short to ground.DTC disappears after turning ignition from OFF to ON.Replace No.5Ω . . Action: . 3 solenoid valve turns the clutch regulator valve ON and OFF.2006.Check TCU connector for proper connection and its terminal for bend or deformation. . 3 solenoid valve wiring and connector (especially its ground condition). 3 solenoid valve if necessary. .The No.The No. Symptom: .Replace TCU if necessary.Shifting impression is poor.Replace TCU if necessary. P1745 No. 3 solenoid valve operates with the No. 3 solenoid valve short Cause: .The No. 3 solenoid valve circuit is short to ground.5 solenoid valve if necessary.The No.The No. .The No. 4 solenoid valve turns the clutch regulator valve ON and OFF. 4 solenoid valve wiring and connector (especially its ground condition). . . CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION SP AXLE CLUTCH T/C . . . .Shifting impression is poor. 4 solenoid valve is OFF.6 ~ 5.Shifting impression is poor. 5 solenoid valve short Cause: .The No. .The No.Check No.Replace No. P1744 No. .Specified resistance value: 22 ~ 30Ω .Replace No. 3 solenoid valve is OFF. M / T A/T Defective Cause and Action .DTC disappears after turning ignition from OFF to ON. 5 solenoid valve is a variable solenoid valve to change the pressure for shifting.Check No.The No.

110 DTC Code P1746 Defective No. .Specified resistance value : 22 ~ 30Ω .Cannot to shift to 1st gear position.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . .The No. Cause: .The torque converter clutch cannot be locked.The hydraulic line pressure is high. Action: . 7 solenoid valve stops its operation (OFF). 6 solenoid valve is used to set the hydraulic line pressure to HIGH/LOW level.2006. . its ground condition).Check TCU connector for proper connection and its terminal for bend or deformation. Symptom: . (No.The No.Replace No. 6 solenoid valve short Cause: Cause and Action . . 7 solenoid valve wiring and connector (especially.Replace TCU if necessary.Check No.The No.Check TCU connector for proper connection and its terminal for bend or deformation. P1747 No. 7 solenoid valve controls the operation of the torque converter clutch. . 6 solenoid valve if necessary. . 7 solenoid valve short ION (BTRA) AUTO TRANSMISSION ACTYON SM .Check No.Replace No. its ground condition). . 7 solenoid valve circuit is short to ground. .The No. 6 solenoid valve circuit is short to ground.DTC disappears after turning ignition from OFF to ON.The No. Symptom: . .DTC disappears after turning ignition from OFF to ON.Specified resistance value: 22 ~ 30Ω . Action: . 7 solenoid valve if necessary. . .Replace TCU if necessary. 6 solenoid valve stops its operation) . 6 solenoid valve wiring and connector (especially.

03 A / CON A / BAG BRAKE ST’NG SP AXLE (DSL) TCU CLUTCH T/C M / T A/T CIRCUIT DIAGRAM OF TCU .2006.111 10Pin PLUG (A/T) CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .112 CONNECTOR END VIEW Y220_3A25O0 ION (BTRA) AUTO TRANSMISSION ACTYON SM .2006.

336263 Cross Shaft Bullet Y220_3A22V0 CHANGED BY EFFECTIVE DATE AFFECTED VIN ION (BTRA) AUTO TRANSMISSION ACTYON SM .113 Name and Part Number 0555 .336256 Transmission Bench Cradle 0555 .336257 Pump Puller M / T Y220_3A22Q0 Y220_3A22S0 Y220_3A22U0 Y220_3A22W0 Y220_3A22P0 ss Shaft Pin Remover / Installer (Detent Lever) 0555 .336262 Cross Shaft Seal Installer 0555 .336259 Clutch Spring Compressor Y220_3A22R0 0555 .336261 Cross Shaft Seal Remover Y220_3A22T0 0555 .2006.336260 Clutch Pack Clearance Kit 0555 .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T SPECIAL TOOLS AND EQUIPMENT .

336270 End Float Measuring Shaft Y220_3A23B0 Y220_3A23C0 0555 .336267 Pump Alignment Tool 0555 .336269 End Float Measuring Adaptor 0555 .336268 Pump Seal Installer Y220_3A22Z0 Y220_3A23A0 0555 .336266 Adaptor Housing Seal Installer Y220_3A22X0 Y220_3A22Y0 0555 .2006.336302 Output Shaft Bullet Y220_3A23D0 ION (BTRA) AUTO TRANSMISSION ACTYON SM .336265 Cross Shaft Pin Remover / Installer (Inhibitor Switch) 0555 .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .114 Name and Part Number 0555 .

............................................................. 28 Disassembly and reassembly ................... 6.... Manual transmision system ............... Overview and characteristics of manual transmission ... Location ...... 24 Removal and installation (4WD) ........MANUAL TRANSMISSION 3170 TABLE OF CONTENTS GENERAL INFORMATION .................................................. 3............................ 4... 33 Inspection/maintenance .. 8 System components ............................................... 64 Special tools and equipment ..........9 Shifting mechanism ................... 67 .. 3 1....... 17 Diagnostic information and procedures ........................ 8 1....... 7..........................................5 MANUAL TRANSMISSION .......... 2.................................3 2............................................................................................ 8... 5...............................

To improve the shifting performance. The semi-remote control type gear shift mechanism is used to prevent incorrect shifting. 5.3170 3 1. The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model. To prevent the double engagement. 3-piece double cone is used for 1/2 shift. MANUAL TRANSMISSION ACTYON SM .2006. 5/R gears. 3/4. the independent interlock devices are installed.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T GENERAL INFORMATION . NOTE • TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement. The synchronizing devices are installed in 1/2. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION System Components Inside M / T Front View Features 1. 3. All gears are the helical type and high strength materials. 4. NOTE • The helical type gear prevents the axial gear missing and provides less noise. 2.

Concentric slave cylinder adapter bolt Tightening Torque 40 ~ 50 Nm 30 ~ 40 Nm 42 ~ 57 Nm 70 ~ 100 Nm 30 ~ 40 Nm 17 ~ 26 Nm 10 ~ 16 Nm MANUAL TRANSMISSION ACTYON SM .919 ATF DEXRON II 3.536 1.6 Inspect at every 10. Neutral switch 6.2006.not including transmission fluid Gear ratio/Gear teeth (input gear: main gear) 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse gear Transmission fluid Specification Capacity ( ) 2WD 4WD Change interval Specifications (D20DT.000 km (add or replace if necessary) Tightening Torque Description 1. Shift top cover bolt (12 mm) 7.475 1. Extension housing spring plug (27 mm) 5. Extension housing bolt (14 mm) 4. Oil drain plug & filler plug 2.807 3. Backup lamp switch (24 mm) 3.4 3170 Specifications Description Length (mm) Distance between shafts (mm) Input torque (kg-m) Transmission control type Weight (kg) .4 3.7 kg-m (340 Nm) Semi-remote 44 kgm 4.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .000 km. D27DT) 628.3 mm 81 mm 34.000 0. replace at every 60.315 2.

03 A / CON A / BAG BRAKE AXLE CLUTCH T/C M / T A/T 2.3170 5 Neutral Switch 0.2006. MANUAL TRANSMISSION SYSTEM .5 mm N (Neutral) Switch 0.5 mm SP Outside View of N Switch Inside View of N Switch ST’NG CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .

the N switch signal is transmitted to the instrument panel. While depressing the clutch (Clutch switch detection). The RPM increases in accordance with the temperature of the engine coolant (Engine coolant temperature sensor detection). e. the system determines the shifting timing by using the clutch switch and the N switch and raises the engine RPM (100 ~ 200 rpm). When the vehicle is trying to start from the stopped state (vehicle speed below 3 km/h). Aids a smooth start of the vehicle by raising the RPM during the gear shifting when the engine is cold. The gear lever is at any position other than neutral (N switch detection).15 Actyon 12 E C U Instrument Panel E C CAN communication U Terminal Return spring Spring Body Ball MANUAL TRANSMISSION ACTYON SM .09. Operation conditions are as follows. d. Vehicle Made After 04. • -20°C ~ 20°C: approx. 100 ~ 170 rpm increase • Approx. When the gear has been smoothly shifted and the vehicle speed exceeds 3km/h. c. it returns to the previous operation interval of the engine RPM. 80°C (normal temperature of the engine coolant): approx. 200 rpm increase f. a. The vehicle speed is at the stopped state (Vehicle speed below 3km/h detection). In case of Actyon. 100 rpm increase • 20°C ~ 60°C: approx.2006. b. Start the vehicle while depressing the clutch pedal (Clutch switch detection). and then the instrument panel transmits it to the engine ECU through the CAN communication.6 3170 Function of N Switch 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

if you set the variant coding in the engine ECU. The HDC function operates only if the M/T shift lever is in forward or reverse position. T/C Variant Coding Related to N Switch A/T .15 BODY IN: after 154600 SP MANUAL TRANSMISSION ACTYON SM . you must do it differently. and you must set the variant coding differently according to the vehicle category and specification as below. Detects the position of the shifting lever for the HDC operation among ABS/ESP functions. Thus.3170 7 2.2006. Please refer to the ABS/ESP section for the specific information related to the HDC.09.03 A / BAG Automatic transmission & Rodius model with automatic transmission before 2006 BRAKE ST’NG CLUTCH The N switch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires. M / T A / CON CHANGED BY EFFECTIVE DATE AFFECTED VIN Variant Coding Options AXLE Neutral Signal Input None / Wire / CAN Actyon & Kyron models with manual transmission New Rexton model with manual transmission Manufactured after 04.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .11) M/T assembly M/T Assembly Backup lamp switch Adapter Spring plug on extension housing Oil filler plug Oil drain plug N Switch MANUAL TRANSMISSION ACTYON SM .2006. LOCATION Transfer case Oil filler plug Center cross member & transmission insulater mounting Oil drain plug Trasmission housing bolt (14 mm .8 3170 MANUAL TRANSMISSION 1.

03 A / CON Transmission adapter Interlock plate A / BAG Shift Fork and Rail Combinations BRAKE Reverse gear Counter shaft 3rd gear 4th gear SP AXLE CLUTCH T/C A/T .2006. SYSTEM COMPONENTS Gear Combinations 5/R shift fork 1/2 shift fork 3/4 shift fork M / T 1st gear 2nd gear 5th gear Output shaft Input shaft ST’NG R Idle 3/4 rail 5/R rail 1/2 rail Reverse Fork plate CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .3170 9 2.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .10 3170 Sectional View MANUAL TRANSMISSION ACTYON SM .2006.

Taper roller bearing (counter) 14. Inner race (reverse) 16. Taper roller bearing 12. Reverse counter gear 50. 1st gear 19. Synchro key 25. 5th counter gear 52. 2nd gear 28. 5th clutch gear 55. Double synchro sleeve 27. Pin spring 72. Synchro hub (5th & R) 51. Reverse idler spacer 40. Transmission adapter 44. Reverse idler gear 39.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .05 mm) 46. Pin 8. Reverse gear 48. Semi-remote lever assembly 71. Needle bearing (Reverse idler) 38. Synchro inner ring 23. Thrust washer 56. 1st clutch gear 20. Oil drain plug (40 ~ 50 Nm) 6. Counter lock nut 62. Input shaft spacer (Bearing end play: 0 ~ 0. Shift lever 70. Counter shaft 13.05 mm) 45. Shift shaft 69. 5th outside retainer ring 58. Synchro . Taper roller bearing (main) 11. Output shaft oil seal 64. Retainer ring (3 & 4th) 34. Input shaft oil seal 3. Reverse idler shaft 36. Adapter dowel pin 35. Transmission housing 2.2006. Needle bearing 18. Synchro ring (4/5/R) 32. 3rd gear 29. Pin spring CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Reverse needle bearing 47. Offset plate 65.middle cone 22. Counter roller bearing assembly 61. Shift ball 57. Reverse clutch gear 49. Hexagon flange bolt (17 ~ 26 Nm) 5. Sealing 7. Inner race (1st gear) 17. Synchro outer ring (for 1st gear) 21. Counter screw (4~6 Nm) 66. 4th clutch gear 10. Front cover (DWF) 4. Synchro hub (3 & 4th gears) 31. 5th needle bearing 53. Output shaft 15. Input shaft 9. Retainer ring (Reverse idler) 42. 3rd clutch gear 30. Top cover 67. Counter shaft bushing 60. Counter oil seal 68. 5th gear 54. Extension housing 63.3170 11 1. 5th retainer ring 59. Single synchro sleeve (5th & R) 33. Reverse idler bracket (Bolt: 30 ~ 40 Nm) 41. Synchro hub (1st & 2nd gears) 26. Counter spacer (Bearing end play: 0 ~ 0. Synchro spring 24. Dowel pin 37. Reverse lock nut (150 ~ 195 Nm) 43.

Shift lever 10. Counter shaft 16. Backup lamp switch (tightening torque: 30 ~ 40 Nm) 7. Spring pin (6 x 25) 18.2006. Input shaft 15. Concentric slave cylinder adapter (tightening torque: 10 ~ 16 Nm) MANUAL TRANSMISSION ACTYON SM . Shift rail (3 & 4th) 8. Spring pin (6 x 25) 19. Shift lug (5 & reverse) 5. Shift rail (1 & 2th) 12.12 3170 Cross Sectional Diagram of Major Components Front View (Section A-A) Tightening Torque: 40~50 Nm Sealant: Bond-592 LOCTITE Tightening Torque: 30~40 Nm Sealant: Bond-592 LOCTITE Rear View (Section B-B) 1. Reverse idler assembly 17. Backup lamp switch 20. Interlock plate 11. Shift rail (5 & reverse) 6. Spring pin (6 x 25) 4. Shift fork (3 & 4th) 14. Reverse idler bracket (tightening torque: 30 ~ 40 Nm) 2. Interlock bolt (tightening torque: 40 ~ 50 Nm) 9. Spring pin (6 x 25) 13.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Shift lug (3 & 4th) 3.

03 A / CON A / BAG Tightening Torque: 70~100 Nm Sealant: Bond-592 LOCTITE BRAKE ST’NG AXLE CLUTCH T/C A/T . Spring pin 14. Rolling plunger 20. TGS pin 15. Sliding bushing 6.3170 13 Shift Rail and 5/R Gear (Section C-C) 1/2 shift rail M / T 5/R shift rail 3/4 shift rail Offset Lever (Section D-D) Tightening Torque: 30~40 Nm Sealant: Bond-592 LOCTITE Tightening Torque: 17 ~ 26 Nm SP Tightening Torque: 40~50 Nm Grease: CASTROL SPHEEROL EPL2 1. Dowel pin 11. Sealing 9. Neutral switch 8. Spring plug CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Lock bolt 17. Reverse lock plate 3. TGS mounting bushing 16.2006. Offset lever 18. Air vent 10. Offset lever bushing 19. TGS bushing 13. Reverse lock bolt 4. Return spring 21. Stopper plate 5. Backup lamp switch 7. Washer lock 12. Reverse lock spring 2.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Power Flow 1st gear Counter shaft 4th gear 3rd 2nd gear gear 1st Reverse gear gear 5th gear 2nd gear 4th gear 3rd 2nd gear gear 1st Reverse gear gear 5th gear MANUAL TRANSMISSION ACTYON SM .14 3170 Power Flows 1st & 2nd Gear .

3170 15 3rd & 4th Gear .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .Power Flow 3rd gear 4th gear 3rd gear 2nd gear 1st gear Reverse gear 5th gear 4th gear 4th gear 3rd gear 2nd gear 1st Reverse gear gear 5th gear CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .

16 3170 Power Flows (Cont’d) 5th & Reverse Gear .2006.Power Flow 5th gear 4th gear 3rd gear 2nd gear 1st Reverse gear gear 5th gear Reverse gear Reverse gear 4th gear 3rd gear 2nd gear 1st gear Reverse idler gear 5th gear MANUAL TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

3170 17 Interlock System Interlock system prevents the gears from meshing over two sets.2006.03 A / CON A / BAG BRAKE ST’NG Select 1/2 (3/4 & 5/R lock) Select 3/4 (1/2 & 5/R lock) Select 5/R (1/2 & 3/4 lock) SP AXLE CLUTCH T/C M / T A/T 3. Interlock bolt Interlock plate Inner shift lever Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward. SHIFTING MECHANISM . Neutral 5/R select 5/R shift 5th gear disengaged CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .

Offset lever 2. Also. Shift check device It determines the shift fork position (N or each gear) and gives a detent movement to notice a shift lever seating when operating the shift lever. the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected. Hub spline Sleeve spline Clutch gear spline MANUAL TRANSMISSION ACTYON SM .18 3170 Offset Lever and Rolling Plunger To make the next shift easier.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Detent pin Top cover Shift shaft Set 2. Rolling plunger (rolling plunger return spring and ball) 1. 1. Shift lever 3. Shift lever 4. it prevent the selected gear from getting out of its meshed position. Gear jump out locking device It prevents the shift lever is beyond the correct shift position while shifting.2006.

Its circuit is formed when the reverse gear is selected.03 A / CON A / BAG BRAKE ST’NG SP AXLE Backup Lamp Switch T/C M / T A/T .2006.3170 3. NOTICE Installation Notice • Sealant: Bond-592-Loctite • Tightening torque: 30 Nm ~ 40 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . 19 Offset lever Offset plate CLUTCH It is normal open type switch. Guiding a control direction and preventing an over stroke.

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. sleeve. Synchronizer key 5. MANUAL TRANSMISSION ACTYON SM . 5/R. • The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery). 3/4 and 5/R shift: Single cone type 2. Synchronizer ring 4. 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . key and spring (1/2. Synchronizer inner cone 7. 1/2 shift: Double cone type .20 3170 Synchronizer Composition It consists of synchronizer hub. Synchronizer sleeve 2. Synchronizer key locking ring 6. ring. Synchronizer middle cone NOTICE • Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve.2006. Synchronizer hub 3. and 3/4 synchronizer are different from each other).

[1st step] Sleeve Synchronizer ring Gear spline area Projected area Synchronizer key Spline area of sleeve Spline area of synchronizer ring [2nd step] Sleeve Synchronizer ring Gear spline area Synchronizer key A / BAG A / CON ACTYON SM .3170 21 Acone 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. Even though the clutch gear continues to spin until friction slows it down or stops it.03 Spline area of sleeve Spline area of synchronizer ring [3rd step] Sleeve Synchronizer ring Gear spline area Synchronizer key Spline area of sleeve Spline area of synchronizer ring CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION BRAKE ST’NG SP AXLE CLUTCH T/C M / T Synchronizer Element During Shift A/T . the possibility of broken or damaged teeth is reduced and shifting effort is lowered. when the driver shifts into another gear he/she is trying to mesh gears that may be moving at different speeds.2006. Thus. Whenever a vehicle is rolling. By using synchronizers. the transmission main shaft is truning and the clutch gear is spinning.

45 mm (10 spacers with increment of 50 MANUAL TRANSMISSION ACTYON SM . Taper roller bearing for input shaft 2.75 ~ 1.05 mm NOTICE Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft. End play B: 0 ~ 0. End play A: 0 ~ 0.45 mm (15 spacers with increment of 50 m) • For output shaft: 0. Taper roller bearing for counter shaft A.03 m) CHANGED BY EFFECTIVE DATE AFFECTED VIN .22 3170 Bearing The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in transmission housing. (Specified range of end play: 0 ~ 0.5 mm) • For input shaft: 0.4 ~ 1. Taper Roller Bearing Needle Bearings End Play of Taper Roller Bearing 1.2006.05 mm B.

For initial installation for taper roller bearing and needle roller bearing. lubrication for shift rail: MoS2 Grease. Oil level Oil drain screw NOTICE • Sealant on oil drain screw during installation: Bond-592 Loctite • Tightening torque: 40 ~ 50 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . each shaft and gear assembly receive the axial force and this force acts as a resistance to rotating gears.03 A / CON A / BAG BRAKE SP AXLE Lock nut CLUTCH M / T A/T Thrust Ring (Washer) . Input shaft Thrust ring 1 Thrust 5/R washer synchronizer 3/4 synchronizer 1/2 synchronizer Output shaft T/C Counter gear assembly Head set gear 3rd gear 2nd gear 1st gear Reverse gear 5th gear ST’NG Lubrication Transmission oil: ATF DEXRON II.2006.3170 23 When the driving force from engine is transmitted to the output shaft of transmission.

Worn or damaged flywheel pilot bushing. Pilot bearing between input shaft and output shaft binding. adapter or case cover. Check or replace synchronizer parts. Replace pilot bushing. Replace damaged parts. Check or replace synchronizer parts. Check or replace loose parts on shaft or rail.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Worn or damaged forks. shift fork. Gears crash when shifting Engine idle speed too high. Remove extension. Binding of sliding synchronizers or gears. Synchronizer damaged or excessively worn. Check worn or damaged synchronizer parts and replace if necessary. Damaged offset lever. Tighten bolts to specified value. Damaged synchronizer. Replace pilot bushing. Replace worn or damaged parts. Worn or damaged fork due to loosened shaft. Blocking ring damaged.Check or replace damaged parts. Worn or damaged synchronizer.Check synchronizers and gears and replace damaged parts. Worn or damaged flywheel pilot bushing. improper alignment. adapter or case cover. Damaged or faulty clutch. Shift or shift rail binding. Damaged gear(s). Transmission locked in one gear Fork or offset lever loose on shaft or rail. Worn or damaged gears. Replace extension. Check worn or damaged parts. Check or replace backup switch. worn index slots or friction surfaces worn or damaged. Realign if necessary. Check or replace gear(s). Check or replace blocking ring. Improper or low transmission oil. adapter or case cover. Adjust shim thickness using roller bearings if necessary. Check for wear or damaged. Check or replace damaged parts. shaft or rail. selector plate or selector arm. Remove extension. adapter and case cover. Hard shift or control lever will not move into gear When reversing. adapter and case cover. Remove extension. Adjust idle speed to specified speed. faulty backup switch. Transmission jumps out Loosened transmission or flywheel housing bolts. Adjust or replace clutch. Action Replace control lever and housing assembly. MANUAL TRANSMISSION ACTYON SM . Bell housing misaligned. Check worn or damaged gears and replace if necessary. Excessive countershaft end play. Replace roll pin(s). Adjust or replace clutch. Remove extension. Add or replace with specified oil. rail or shifting fork.24 3170 4.2006. Check for wear or damaged. Replace or check roller bearings. Clutch not releasing. offset lever. Align bell housing and bore. DIAGNOSTIC INFORMATION AND PROCEDURES Trouble Diagnosis Symptom Can not shift (control lever moves) Cause Control lever assembly broken or damaged.

T/C Realign correctly. Replace oil seal. Tighten as specified.03 A / CON A / BAG BRAKE SP Tighten as specified. Replace if necessary. Noisy gears. CLUTCH Check bearings. Clean leaking surfaces. Improper flywheel housing to engine crankshaft alignment. Check for worn or damaged gears (including speedometer gear). Replace if necessary. Clean or replace vent or breather. Improperly applied sealant. M / T Cause Action A/T . then check for leaks. Worn or damaged oil seal. Check oil level.3170 25 Trouble Diagnosis (Cont’d) Symptom Transmission noise Improper or low transmission oil. Loose bolts or other attaching parts. Vent or breather clogged. Reapply sealant. Add or drain and replace with proper oil. Noisy transmission bearing.2006. AXLE Transmission leakage Leakage from transmission. Clean all exposed surfaces. bearing rollers and parts for wear or damage. Loose bolts at sealing faces. Too much oil. ST’NG CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .26 3170 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 MANUAL TRANSMISSION ACTYON SM .

NOTICE • Do not check or change the oil Immediately after driving off. NOTICE • The oil in manual transmission is major element for mechanical durability of transmission. add the oil through the oil level plug (1).03 A / CON A / BAG 1. it is OK. Check the oil level with a specific interval and replace if needed. If the oil level is up to the bottom line (5 ~ 7 mm) of plug hole. Fully tighten the plug and check the oil leaks. Place the vehicle on the flat and even ground and stop the engine.3170 27 Place the vehicle on the flat and even ground and stop the engine. check the oil level. After 5 minutes. apply sealant (Bond-592 Loctite) on the thread and tighten it to the specified torque.2006. 2. NOTICE • When installing the oil drain plug. Oil drain plug BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T OIL CHECK/CHANGE . check the oil level. Remove the oil level plug (1) and check the oil level. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . After 5 minutes. 1. Oil level plug 2. It may cause serious hurt. 3. If needed. 4. • The oil replacement should be done at the qualified and authorized service station.

MANUAL TRANSMISSION ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Removal and Installation Preceding Work: Disconnect the battery negative cable and remove the center console.Center Mounting insulator Oil drain plug Transmission housing mounting bolt (14 mm . the removal procedure of the transfer case is not included.28 3170 5.11EA) M/T assembly • When removing the manual transmission from 2WD vehicle. REMOVAL AND INSTALLATION (4WD) Transfer case Oil filler plug Cross member .

Installation Notice Tightening torque 12 ~ 23 Nm 2 CLUTCH T/C Installation Notice Tightening torque 40 ~ 50 Nm SP Tightening torque: 81 ~ 89 Nm Tightening torque: 81 ~ 89 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . BRAKE ST’NG AXLE 3. And. Installation Notice Tightening torque 12 ~ 23 Nm 1 29 Change lever M / T 2. If the oil should be changed. Set aside the removed shafts not to disturb the operation. Unscrew two bolts (1) and remove the change lever from shift lever.2006. Unscrew two bolts (12 mm) (2) from semi-remote controller. Unscrew four bolts (17 mm) and separate the rear and front propeller shafts connected to transfer case output shaft. remove the oil drain plug (A) in transmission housing and fully drain the oil.3170 1.03 A / CON A / BAG 4. A/T . retighten the plug (A).

neutral switch connector. Support the underbody of transmission with a hydraulic jack not to deflect it and unscrew the bolts (14 mm . Disconnect the air bleeder hose. Tightening torque: 28 ~ 47 Nm Tightening torque: 85 ~ 95 Nm Tightening torque: 85 ~ 95 Nm 7.2EA) and remove the cross member.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 6.2 EA) at both sides and remove the mounting insulator bracket. Mounting Insulator Tightening torque: 28 ~ 47 Nm Bracket Tightening torque: 28 ~ 47 Nm MANUAL TRANSMISSION ACTYON SM .4EA) and cross nuts (14 mm . Unscrew the mounting bolts (14 mm .30 3170 5. back up lamp switch connector and transfer case connectors. Unscrew two bolts (14 mm) at both sides and remove the transmission mounting insulator.

Separate the clutch oil hose from adapter. (Clamp the hose with a locking pliers after separating the clutch oil hose to prevent the oil from leaking. Unscrew eleven bolts (14 mm) and remove the transfer case with a hydraulic jack. make sure to install it to the correct direction.) Adapter CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . 31 Tightening torque: 38 ~ 52 Nm NOTICE • When installing the transfer case. From transfer case side (lower: 3) 9. • From transmission side (upper: 8).03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .2006.3170 8.

MANUAL TRANSMISSION ACTYON SM . Check the components for wear or damage before installation. Tightening torque: 50 ~ 60 Nm Tightening torque: 50 ~ 60 Nm 11. 1.32 3170 10. 2.2006. Carefully lower the hydraulic jack to remove the transmission assembly. Support the transmission housing with a hydraulic jack and unscrew eleven transmission bolts (17 mm). Check the concentric slave cylinder for abnormal wear and replace if necessary. Inspection before Installation Install in the reverse order of removal. Check the pressure plate spring for wear.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . ST’NG SP AXLE CLUTCH T/C M / T A/T 6.03 A / CON A / BAG BRAKE 3. Pull out the lock washer (1) and remove the TGS pin (2). 2.2006. DISASSEMBLY AND REASSEMBLY . 4. Remove the transmission oil drain screw (hexagon. Tilt the offset lever and pull out the spring pin (6 x 25) to remove the offset lever. 14 mm) and completely drain the oil.3170 33 MANUAL TRANSMISSION ASSEMBLY Disassembly 1. 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. Place the removed transmission on the workbench.

Remove the bolts from the extension housing with a wrench (14 mm). Be careful not to drop them. NOTICE • Remove the offset lever and rolling plunger with the extension housing. Remove the rear ball bearing with a puller and remove the speedometer driven gear.34 3170 5. 6. Remove the extension housing with a special tool. 8. 7.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Remove the 5/R shift fork spring pin (6 x 28). MANUAL TRANSMISSION ACTYON SM .

9. 10. 35 NOTICE • Be careful that the retainer ring does not pop out. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Pull the counter gear (5th gear) retainer ring out from the ring groove with a ring pliers. Remove the counter reverse spacer. Spread the retainer ring and remove the 5th counter gear with a puller.3170 8-1.

Remove the thrust washer from the shaft. NOTICE • Be careful not to lose or mix the spring pins. Remove the 5th gear retainer ring with a ring pliers. Remove the 5th gear and pull out the spring pin. 14.2006. 13. Remove two 5th gear needle bearings. NOTICE • Be careful not to lose or mix the needle bearings.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 12.36 3170 11. MANUAL TRANSMISSION ACTYON SM .

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . NOTICE • Store at a safe place not to be mixed with other synchronizer rings. 17. Remove the counter reverse gear. the reverse gear and the shift fork at a time. Remove 5/R gear retainer ring from the shaft with a ring pliers.3170 15. Remove the 5th gear synchronizer ring. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . 37 16. 18. Remove the 5/R synchronizer hub assembly.2006. NOTICE • Store the ring with the relevant gear to prevent incorrect installation.

20. 21.38 3170 19.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . It may damage the level grooves resulting in incorrect installation. Remove the counter reverse gear needle bearing. Remove the interlock bolt (17 mm). NOTICE • Be careful not to damage the adapter mating surface. Remove the gear assembly from the housing.2006. MANUAL TRANSMISSION ACTYON SM . Carefully remove the gear assembly. 22. NOTICE • Do not forcefully remove the gear assembly. Remove the transmission adapter from the transmission housing.

Place the output shaft and counter gear on the special tool.3170 23.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Remove the shift rail and shift fork. b. a. Remove the main and counter gear assembly. Pull out the pins from 5/R and 1/2 shift rails and remove the shift rails through the rear section of adapter. NOTICE • To prevent the bearing damage. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Remove the 3/4 gear retainer ring.2006. 25. Pull out the locking pins from shift forks. Place the output shaft assembly with the 1st gear facing down and remove the intermediate taper roller bearing with a special tool. • Do not use general bearing puller. 26. NOTICE • Be careful not to lose or mix the retainer ring. 39 24. securely seat the special tool before removing the intermediate taper roller bearing that is pressed in.

Remove the main taper roller bearing. 28. Remove the reverse gear inner race. Remove the 3/4 gear synchronizer hub and single synchronizer sleeve and 3rd gear with a special tool. 30. Pull out the needle bearing. Loosen the 1/2 gear and hub and double synchronizer sleeve with a press.40 3170 27. MANUAL TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 29.2006.

NOTICE 41 32. intermediate cone and outer ring in 2nd gear side.03 A / CON A / BAG BRAKE ST’NG Synchronizer inner ring Synchronizer intermediate cone Synchronizer outer ring SP AXLE CLUTCH T/C M / T • Store the disassembled gears by relevant components. Remove the 1/2 gear synchronizer hub along with double synchronizer sleeve. 1st gear and needle bearing from the shaft. Remove the synchronizer inner ring. A/T . 33. 34.2006. Synchronizer outer ring Synchronizer intermediate cone Synchronizer inner ring CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Remove the inner race.3170 31. Remove the synchronizer inner intermediate cone and outer ring in 1st gear side.

2006.42 3170 35. Remove the oil seal from the extension housing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the 2nd gear and needle bearing. 36. MANUAL TRANSMISSION ACTYON SM .

a.2006. shift lever b. 1/2 and 3/4 shift fork d. 5. Check the following components for wear: a. Main shaft and gears c. Each shift lever shift fork CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Clean all the disassembled components with solvent and dry them with compressed air. Input shaft b. Check the surface conditions on: a. 3. Detent/guide plate and offset lever f. Check the bearing and shaft supporting area for wear and replace if needed. extension housing. Input bearing retainer 2.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Shift shaft e. wear and damage. Selector arm b. Case. Do not grind the precisely machined components. Check the components for crack. Interlock plate c.3170 Inspection Before Assembly 1. Reverse idler shaft and gears. Counter shaft and 5th drive gear c. NOTICE • Replace the excessively worn components. Counter shaft rear bearing retainer 43 4.

pads. pads. Clutch release bearing c. MANUAL TRANSMISSION ACTYON SM . 8. Reverse fork and reverse idler gear sleeve 6. 1/2 shift fork. Check the following components for excessive wear: a. crack and break and replace if needed. Hub and sleeve h. Main shaft rear bearing g. pads. synchronizer sleeve j. Check the gear sets for excessive wear. Counter shaft front and rear bearing 7. Check the gear sets for wear in teeth surface. synchronizer sleeve i. Main shaft thrust bearing mating surface e.44 3170 g. Main shaft speed gear roller bearing f. 3/4 shift fork. Crankshaft pilot bushing in front of input shaft b.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . synchronizer sleeve k. Main shaft pilot bearing roller d. 5th gear shift rail/fork.

Wear on cone clutch surface in synchronizer ring (brass) engaging the gears 45 10.3170 9. Measure the clearance between synchronizer ring and speed gear.4 mm b.5 mm NOTICE • If the clearance is excessive. a. Engagement of hub and sleeve b.87 ~ 1.2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Check the engagement of synchronizer sleeve and speed gear clutch. replace it with new one. New 3/4 gear synchronizer ring: 0. a. Check the conditions of each synchronizer sleeve and hub. it may cause the missing or breakage of the gears. New 1/2 gear synchronizer ring: 0. Check the speed gear clutch and synchronizer sleeve for damage in teeth surface.88 ~ 1. 12. Otherwise. 11.

Insert three keys into 1/2 synchronizer hub and double synchronizer sleeve. intermediate cone and inner ring in turn. NOTICE • 1/2 gear double synchronizer sleeve doesn’t have a step at edge. Install the synchronizer spring in offset so that it should not be missed out. Install the 2nd gear. 2. NOTICE • The 1st/2nd/3rd gear needle bearings have one bearing row and the sizes of them are same. 3/4 and 5/R gears have it. The 5th needle bearing is smaller than others and consists of two bearings.46 3170 Assembly 1. 3. Groove No step MANUAL TRANSMISSION ACTYON SM .2006. However. The reverse needle bearing has two bearing rows. Install the 2nd gear needle bearing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . synchronizer outer ring.

Install the synchronizer outer ring. Align the synchronizer key and the synchronizer ring groove in 2nd gear. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . NOTICE • Make sure that the hub groove faces to 2nd gear. Install the 1st gear. Install the 1st gear needle bearing. 47 5.3170 4.2006. Install the 1/2 synchronizer hub and double synchronizer sleeve into the output shaft by using a press.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 7. 6. intermediate cone and inner ring into the 1/2 synchronizer hub in turn.

Install the main taper roller bearing by using a press. NOTICE • The 1st inner race doesn’t have a step at edge. Install the reverse gear inner race by using a press. Install the 1st gear inner race by using a press.48 3170 8. NOTICE • The reverse gear inner race has a step at edge.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . MANUAL TRANSMISSION ACTYON SM . 9. 10. Place the output shaft assembly with the 1st gear facing downward and install the 3rd gear needle bearing. 11.2006.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Insert three keys into 3/4 synchronizer hub and synchronizer sleeve. Install the 3rd gear. Place the groove in hub to face the 3rd gear and align the synchronizer key and the synchronizer ring groove in 3rd gear. NOTICE • 3/4 gear synchronizer sleeve have a step at edge.2006. 49 13. 14. Install the synchronizer ring on the 3rd gear. Install the synchronizer spring in offset so that it should not be missed out. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .3170 12.

0 to 0.2006. Install the 3/4 gear retainer ring. 16. MANUAL TRANSMISSION ACTYON SM . NOTICE • Apply the force on the inner race other than other points. Install the intermediate taper roller bearing by using a press. Place the input shaft to face downward on the work bench.5 mm by using a feeler gauge. 17. Install the input shaft along with the 4th synchronizer ring.50 3170 15.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Adjust the end play between retainer ring and hub to a range of 0.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 21. Place the counter gear with input/output shaft on the workbench. 51 19. 20. NOTICE • The reverse gear needle bearing has two bearing rows and the others consist of two bearings. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Install the reverse gear needle bearing. insert a special tool.3170 18.2006. Install the transmission adapter on the input shaft and the counter gear. To relieve the load and to provide a clearance to the shaft bearing.

NOTICE • Adjust the end play between retainer ring and hub to a range of 0. Install the reverse gear in the shaft.52 3170 22. Install the 5/R gear retainer ring. 23.5 mm by using a feeler gauge. 24. Install the synchronizer ring on the reverse gear.2006. Install the synchronizer spring in offset so that it should not be missed out.0 to 0. MANUAL TRANSMISSION ACTYON SM . Insert three keys into 5/R synchronizer hub and synchronizer sleeve. NOTICE • Place the groove in hub to face the 5th gear and align the synchronizer key and the synchronizer ring groove in reverse gear. 25.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

29. Install the counter reverse gear using a press.2006. NOTICE • Place the counter reverse gear with a longer protrusion facing to the adapter. 53 27. Install the 5th synchronizer ring.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .3170 26. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Install the counter reverse spacer. Install two 5th gear needle bearings in line. 28.

Install the counter 5th gear retainer ring.54 3170 30. 31.2006. 33. MANUAL TRANSMISSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • The retainer ring is loosened when it is removed. Install the locking ball. Install the 5th counter gear using a press. so retract it before installing it. At this time. Install the 5th gear. 32. place it with a longer protrusion area facing to the adapter.

2006.22 mm using a feeler gauge.3170 34. Place the gear assembly on a workbench in parallel.08 to 0. 36. Install the inner race of counter roller bearing using a press. Install the thrust washer (t= 5. 37.0) while aligning the key grooves. NOTICE • Adjust the end play between retainer ring and hub to a range of 0.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . NOTICE • Place it with a protrusion area facing to the 5th gear. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Install the retainer ring. 55 35.

but 1/ 2 and 5/R aren’t. NOTICE • The 1/2 and 5/R shift fork are compatible. 39. 40. Install the inner shift lever and interlock plate in the 3/ 4 gear shift rail.56 3170 Interlock plate Inner shift lever 38. NOTICE • The spring pin for locking the inner shift lever is small (6 × 22) and its slot should face to the shaft. MANUAL TRANSMISSION ACTYON SM . Install the 3/4 gear shift rail in the transmission adapter.2006. Install the 3/4 shift fork and shift rail while aligning the grooves. Also. NOTICE • The longer section of the shift rail should face to the input shaft. Install the 3/4 gear shift fork. the 3/4 shift fork is chamfered.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . but 3/4 shift fork isn’t. 41.

57 43. 44.3170 42. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Partially engage the 1/2 shift fork to the shift rail. 45. Install the shift lug on the 1/2 shift rail. Install the reverse lock spring.2006. reverse lock plate and reverse lock bolts.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Partially engage the 5/R gear shift fork to the groove on shift rail. NOTICE • Align the 1/2 gear shift lug and interlock plate mating surface. Install the 1/2 gear shift rail in the transmission adapter.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Install the spring pin into the 1/2 shift lug. Install the spring pin into the 1/2 shift fork. NOTICE • Place the spring pin with the pin slot facing to the shaft. NOTICE • Align the 5/R shift lug and the interlock plate surface. Install the 5/R shift lug and 5/R shift fork on the shift rail.58 3170 46. 47. MANUAL TRANSMISSION ACTYON SM . Install the spring pin into the 5/R shift lug. NOTICE • Place the spring pin with the pin slot facing to the shaft. 49. NOTICE • Place the spring pin with the pin slot facing to the shaft. 48.2006.

NOTICE • Place the spring pin with the pin slot facing to the shaft. NOTICE • Place the spring pin with the pin slot facing to the shaft. 52. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .3170 50.2006. 59 51.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Install the stopper plate on the 3/4 shift rail and insert the spring pin (intermediate size: t= 6 x 25). Install the spring pin into the 5/R shift fork. Install the reverse lock plate and reverse lock spring on the 1/2 shift rail.

Apply the sealant to the extension housing. Press down the extension housing against the adapter. Install the gear assembly and the adapter to the transmission housing.2006. Install the speedometer driven gear on the output shaft and install the ball bearing using a press.60 3170 53.bulk #732 54. Apply the sealant to the transmission housing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Sealant: Silicon sealant -bulk #732 MANUAL TRANSMISSION ACTYON SM . NOTICE • Sealant: Silicon sealant . 55. 56.

Insert the offset lever into the 3/4 rail and install the spring pin. Installation Notice Sealant Tightening torque Bond 592 loctite 40 ~ 50 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . Installation Notice Tightening torque 42 ~ 57 Nm 61 58. 60.3170 57. NOTICE • Make sure that the gear is in neutral position.2006. Apply the sealant to the interlock bolt (17 mm) and insert it into the interlock plate hole.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 59. Apply the grease into the offset lever bushing. Tighten the extension housing bolts (14 mm-10EA). the interlock bolt cannot be inserted into the interlock plate hole. If not.

Installation Notice Sealant Tightening torque Silicon sealant -bulk #732 17 ~ 26 Nm MANUAL TRANSMISSION ACTYON SM . Apply the sealant to the top cover and install four bolts (12 mm).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . NOTICE • Make sure that the gear is in the neutral position.62 3170 61.2006.

Pull out the dowel pin and remove the reverse idler shaft. Unscrew the reverse lock nut and idler bracket bolts and remove the bracket and spacer. Remove the components as follows and install in the reverse order of removal. CLUTCH T/C M / T A/T Transmission Adapter . Apply the sealant when installing. a. b.03 A / CON A / BAG BRAKE ST’NG SP AXLE 2. Remove the reverse idler gear and the needle bearing. Remove the reverse idler retainer ring. NOTICE Tightening torque Sealant Tightening torque Bond-592 LOCTITE 30 ~ 40 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .3170 63 Disassembly and Assembly 1. NOTICE Tightening torque Reverse idler bracket bolt Reverse lock nut 17 ~ 26 Nm 70 ~ 100 Nm Backup Lamp Switch Remove the backup lamp switch with 24 mm wrench. c.2006.

Remove the input spacer. 2.2006. counter gear. MANUAL TRANSMISSION ACTYON SM . Separate the front fork cover from the housing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Unscrew nine bolts (14 mm) and remove the front fork cover. 3. NOTICE • The shim adjustment is necessary when replacing the housings.64 3170 7. input shaft and output shaft. INSPECTION/MAINTENANCE Shim Adjustment 1.

Tighten the adjusting bolt on the special tool to hold the bearings. 65 5. Prepare the special tools and dial gauge.03 A / CON A / BAG 6. 7.2006.3170 4. Place the transmission vertically with the output shaft facing downward and set the special tool on the counter gear and input shaft. CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM . BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Apply a proper force to the counter gear and input shaft so that the end plays for bearings are maximized. Remove the counter spacer.

Installation Notice Starting torque Sealant Tightening torque 20 ~ 25 Nm Silicon sealant -bulk#732 17 ~ 26 Nm MANUAL TRANSMISSION ACTYON SM .05 mm 11. End play 0 ~ 0. Apply the sealant to the front fork cover and tighten the bolts (14 mm). If the measured value is out of the specified range.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . adjust it by using spacers.2006. Put the probe end of the gauge on the main taper roller bearing race and measure the end play. If the measured value is out of the specified range. Set up the dial gauge on the transmission housing surface and put the gauge needle to “0” point. adjust it by using spacers. a. Put the probe end of the gauge on the taper roller bearing outer race in counter gear and measure the end play. End play 0 ~ 0. 9. Measure the starting torque after installation.05 mm 10.66 3170 8. a.

SPECIAL TOOLS AND EQUIPMENT .3170 67 Name and Part Number 661 589 04 62 00 (W 99 31 007 0B) Transmission fixture Application M / T Removal/installation of transmission Bearing puller Pressure pipe W 99 31 003 1B Insert key Providing a space to input shaft bearing CHANGED BY EFFECTIVE DATE AFFECTED VIN MANUAL TRANSMISSION ACTYON SM .03 A / CON A / BAG BRAKE W 99 31 002 1B Pressing of the bearing and gear ST’NG SP AXLE W 99 31 001 1B Removal of pressed in intermediate taper roller bearing CLUTCH T/C A/T 8.2006.

68

3170
Name and Part Number Application
Assembly of gears and bearings on the shafts

W 99 31 004 1B Die

W 99 31 005 2B Holder

Measurement of taper roller bearing end play

W 99 31 006 1B Dial gauge holder

Measurement of bearing end play by installing it on the counter and main taper roller bearing outer race in manual transmission

W 99 31 007 1B Drift

Removal of 5/R synchronizer hub assembly, reverse gear and shift fork at one time

MANUAL TRANSMISSION
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & IWE LOCKING HUB SYSTEM
3240 / 3410 TABLE OF CONTENTS
GENERAL ................................................. 2
1. Overview ............................................................ 2

IWE LOCKING HUB SYSTEM ............... 35
1. 2. 3. 4. 5. Locking hub system ....................................... 35 Vacuum system .............................................. 36 Components of IWE (Integrated wheel end) .. 37 Vacuum locking hub check ............................ 41 Removal and installation of IWE (Integrated wheel end) .................................... 44

PART TIME TRANSFER CASE ............... 3
1. 2. 3. 4. 5. 6. 7. Structure ........................................................... 3 System Layout ................................................. 4 Power Flow ....................................................... 5 Composition ...................................................... 8 Oil level check and change ............................ 14 General diagnosis ........................................... 15 Removal and installation ................................. 16

TCCU (TRANSFER CASE CONTROL UNIT) ....................................................... 21
1. 2. 3. 4. 5. 6. 7. 8. 9. Major changes in TCCU ................................. 21 Transfer case block diagram .......................... 22 Transfer case circuit diagram ......................... 23 Shift Motor Connector and Magnetic Clutch Power Supply Connector ................................ 25 System operation ........................................... 27 Trouble diagnosis test .................................... 30 Self-diagnosis test .......................................... 31 Diagnostic trouble code .................................. 32 Removal and installation of TCCU .................. 34

2

3240

GENERAL
1. OVERVIEW
The part time transfer case achieves direct connection from the power of the rear wheels to the power of the front wheels by the lock up hub when selecting 4WD "HIGH" and the power is supplied by the sealant chain in the transfer case. The simple operation of switches on instrument panel allows to shift between “2H” and “4H” easily while driving. The warning lamp warns the driver when the system is defective. The 4WD system installed on ACTYON does not have big difference in comparison to the conventional part time transfer case, but the changes in comparison to the conventional transfer case are as follows:

1. Delete 4L (LOW 4WD) - Delete the planetary gear, reduction hub and shift fork. - Add the coupling according to the deletion of the planetary gear. 2. No additional coding is required when replacing TCCU. 3. 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. 4. Delete the pin related to the speed sensor in the TCCU pins. 5. Change the wiring connector of the transfer case from 4-pin to 1-pin (supply voltage and ground related to the speed sensor). Instrument panel(Note 1) : 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
Total length Mating surface of front flange Weight Oil capacity Oil specification Location Major elements Housing Tightening bolt Input shaft

Part Time T/C
343 mm 40 mm 32.4 Kg (with oil) 1.4 L ATF DEXRON III Transfer case Part time 11EA, M8 x 1.25 A/T: External spline M/T: Internal spline

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

3

1. STRUCTURE
M / T

Front axle

Power steering assembly Front propeller shaft ION 4th gear automatic transmission
SP A / CON A / BAG BRAKE
ACTYON SM - 2006.03

Part time transfer case

TCCU

Rear propeller shaft

Rear axle

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

ST’NG

AXLE

Front locking hub system (IWE)

CLUTCH

T/C

A/T

PART TIME TRANSFER CASE

4

3240

2. SYSTEM LAYOUT
4WD switch
Shifting to 4H mode (to 4H direction) Shifting to 2H mode (to 2H direction)

I/P (4WD indicator)
Shifting to 4H mode (4WD HIGH comes on) Shifting to 2H mode (4WD HIGH goes off) System defective (4WD CHECK comes on)

TCCU

Solenoid valve

Magnetic clutch

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

5

Part time transfer case
M / T

Front wheel side

Front wheel side 2WD Engine

Front (4WD) Transfer case Rear (2WD) 4WD

Rear wheel side

Rear wheel side
BRAKE

Switching 2H

4H

TCCU

Locking hub solenoid

Transfer case

Locking hub operation (Released internal vacuum)

Rear propeller shaft

Front propeller shaft

Rear axle

Front axle

Rear wheel

Front wheel

Electric Power Vacuum

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

Flow Layout

A / BAG

ST’NG

SP

AXLE

CLUTCH

T/C

A/T

3. POWER FLOW

6

3240

2H Mode (Rear Wheel Drive)

To transmission

Rear axle (rear wheel)

Layout

Transmission output shaft

Transfer case Input shaft ↓ Rear output shaft Front output shaft

Rear propeller shaft

Rear wheel

Rear axle

Rear wheel

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

7

4H Mode (4 Wheel Drive - High speed)
A/T

Layout
Front wheel Front axle Front wheel

Transmission output shaft

Front propeller shaft

Transfer case Input shaft ↓ Rear output shaft Front output shaft

Rear propeller shaft

Rear wheel

Rear axle

Rear wheel

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

Front axle (front wheel)

AXLE

CLUTCH

T/C

To transmission

Rear axle (rear wheel)

M / T

8

3240

4. COMPOSITION
Location

Magnetic clutch power supply connector (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)

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

9

Internal Structure

Coupling

Oil pump
T/C

Magnetic clutch Output shaft to rear wheel

2H-4H shift fork (Lock-up fork)

Motor connector Magnetic coil clutch connector

Difference From The Conventional Part time T/C
• Deletion of 4L (LOW 4WD), planetary gear, reduction hub and 4H-4L shift fork • Deletion of parts related to the speed signal: speed sensor, tone wheel and wiring • Addition of the coupling which connects the input shaft with the output shaft

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

Output shaft to front wheel

A / BAG

Shift motor

BRAKE

ST’NG

SP

AXLE

CLUTCH

Input shaft

M / T

A/T

10

3240

Exploded View of New Transfer Case

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

11

1. Snap ring 2. Snap ring 3. Bearing 4. Hub 5. Input shaft assembly 5a. Input shaft 5b. Bearing 6. Collar 7. Main shaft assembly 7a. Main shaft 7b. Oil pump 8. Clamp 9. Hose 10. Filter 11. Electric coil assembly 12. Cam/Coil housing assembly 13. Snap ring 14. Armature 15. Lockup hub 16. Sleeve return spring 17. Lockup collar 18. Driving sprocket 19. Return spring 20. Shift rail 21. Shift fork 22. Electric shift cam 23. Torsion spring 24. Spacer 25. Shift shaft 26. Transfer case assembly 26a. Transfer case 26b. Cover dowel 26c. Oil seal 26d. Ball bearing 26e. Input seal

27. Breather 28. Sticker 29. Output shaft 30. Dust deflector 31. Magnet 32. Snap ring 33. Lower sprocket 34. Spacer 35. Chain 36. Ring 37. Bearing 38. Bearing 39. Cover 40. Bendible clip 41. Bolt 42. Oil seal 43. Washer 44. Nut 45. Companion flange 46. Oil seal 47. Spacer 48. Nut 49. Clip 50. Bolt 51. Relay mounting bracket 52. Locking clip 53. Connector 54. Bolt 55. Electric motor assembly 56. Oil seal 57. Plug

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

A/T

12

3240

Exploded View for Conventional Transfer Case

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

13

1. Snap ring 2. Snap ring 3. Snap ring 4. Bearing 5. Hub 6. Input shaft assembly 7. Thrust plate 8. Sun gear 9. Snap ring 10. Carrier assembly 11. Reduction hub 12. Main shaft 13. Clamp 14. Hose 15. Filter assembly 16. Driving sprocket 17. Lockup collar 18. Spring 19. Lockup hub 20. Armature 21. Snap ring 22. Cam/coil housing assembly 23. Electric coil assembly 24. Return spring 25. Shift rail 26. Shift fork 27. Shift fork assembly 28. Electric shift cam 29. Spring 30. Spacer 31. Shift shaft 32. Retaining ring 33. Transfer case assembly

34. Breather 35. Name plate 36. Output shaft 37. Dust deflector 38. Magnet 39. Snap ring 40. Lower sprocket 41. Spacer 42. Chain 43. Retaining ring 44. Bearing 45. Bearing 46. Cover 47. Clip 48. Bolt 49. Clip 50. Washer 51. Nut 52. Companion flange 53. Oil seal 54. Spacer 55. Tone wheel 56. Nut 57. Clip 58. Screw 59. Clip 60. Connector lock 61. Connector 62. Bolt 63. Cap screw 64. Transfer case control motor assembly 65. Oil seal 66. Plug

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

A/T

14

3240

5. OIL CHECK AND CHANGE
Oil Level Check
1. Clean the oil level plug (filler plug) and surroundings. 2. Remove the oil level plug an check whether oil is spilled out. 3. Add oil if necessary. Tighten the oil level plug. Installation Notice
Tightening torque 19 ~ 30 Nm
Drain plug Oil level plug

Oil Change
1. Clean the oil level plug (filler 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 (filler plug). 4. Drain the oil and tighten the drain plug. 5. Fill the oil through the oil level plug until oil begins to drip out. Installation Notice
Tightening torque 19 ~ 30 Nm

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 (filler plug) or drain plug since this will damage the threads in the plug.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

15

Symptoms
Electric shift problems

Check
• Faulty or damaged TCCU, motor, clutch or internal wirings • Damaged or worn shift cam, hub, fork and rail shift • Binding shift fork, hub collar or gear

Action
M / T A / CON A / BAG BRAKE ST’NG
ACTYON SM - 2006.03

• Overhaul and check, replace if necessary • Overhaul and check for wear and damage and replace if necessary. • Check sliding parts, replace if necessary. • Check internal parts and replace drive chain. • Drain and replace with specified oil. • Retighten as specified. • Disassemble bearings and parts and check for wear or damage. Replace if necessary. • Check for wear and damage including speedometer gear. Replace if necessary. • Disassemble and check for wear and damage. Replace if necessary. • Adjust tire pressure. • Replace the case. • Clean case and parts and check for leakage. • Remove breather hose and clean. Replace if necessary. • Use specified oil and adjust oil level. • Retighten. • Use specified sealant and retighten. • Replace oil seal.

Noise in 4WD operation • Improper or low oil • Loosened bolts or mounted parts • Noisy T/C bearing • Gear’s abnormal noise Noise in 4H • Worn or damaged sprockets or drive chain • Incorrect tire pressure Transfer case oil leakage • Cracked transfer case • Leakage from other parts • Breather clogging • Improper or too much oil • Loosened sealing bolts • Improperly applied sealant • Worn or damaged 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.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

SP

AXLE

CLUTCH

Cannot drive front wheel • Broken drive chain when shifting to 4H

T/C

A/T

6. GENERAL DIAGNOSIS

16

3240

7. REMOVAL AND INSTALLATION
Transfer Case
1. Disconnect the motor connector from the transfer case.

2. Remove the front and rear propeller shafts by separating the front propeller shaft from transfer case and remove the rear propeller shaft completely.
Front Rear

Installation Notice
Tightening torque 81 ~ 89 Nm (T/C)

Installation Notice
Tightening torque 81 ~ 89 Nm (T/C) 70 ~ 80 Nm (Axle)

3. Disconnect the air hose from the transfer case.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240

17

Tightening torque: (28 ~ 47 Nm)

Tightening torque: (85 ~ 95 Nm)
ST’NG

Tightening torque
Mounting insulator Bracket bolt 28 ~ 47 Nm 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)

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

5. Unscrew two bolts (14 mm) and remove the transfer case mounting insulator and insulator bracket by removing two bolts.

SP

AXLE

CLUTCH

T/C

Tightening torque: (85 ~ 95 Nm)

M / T

A/T

4. Place the safety jack under the transfer case and automatic transmission. Unscrew two transmission cross member bolts (14 mm) and the center bolt (14 mm), and remove the transmission cross member.

18

3240

7. When installing, keep the tightening torque and install in reverse order of removal.
Side View Front View

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3240 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.

19

Magnetic coil clutch connector

NOTICE
• Remove two nuts to separate the bracket and motor.

Bracket mounting nut

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

3. Unscrew three transfer case motor bolts (10 mm) and a bracket bolt to remove the motor.

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

Motor connector

M / T

A/T

20

3240

3. Pull the shift motor assembly out by pulling it rearward while keeping the level. Clean the mating surface of the transfer case and shift motor. NOTICE
• Do not disassemble the shift motor since it is replaced as an assembled unit.

4. Apply sealant on the mating surface when installing new shift motor assembly. 5. Install in the reverse order of removal. Make sure that the mode switch selection is matched with the motor’s driving position before installation. NOTICE
• To do that, install new shift motor on the same location that the used shift motor was on.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

21

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:
T/C M / T
ACTYON SM - 2006.03

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. 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. 5. The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU.
CLUTCH A / CON A / BAG BRAKE ST’NG SP AXLE

Location

TCU

TCCU

Pin Arrangement

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

A/T

TCCU (Transfer Case Control Unit)

22

3410

2. TRANSFER CASE BLOCK DIAGRAM

Battery voltage

13 26

2 15

Shift motor output (Motor LOW-HIGH)

Ignition switch ON/OFF

23

1 14

Shift motor output (Motor HIGH-LOW)

Position 1 Position 2 Position 3 Position 4

18 5 19 17

P A R T T I M E T C C U

11

Electronic magnetic clutch coil

20

Position encoder ground (Return position)

2WD/4WD switch

4

HIGH/LOW switch

16

CAN HIGH

8

21

K-Line (Self diagnosis)

CAN LOW

9 24
Hub solenoid

12 25

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

23

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

A/T

3. CIRCUIT DIAGRAM OF TRANSFER CASE

Transfer case shitf motor Power supply to magnetic coil

24

3410

TCCU Pin Numbers and Description

T/C: Transfer Case Pin No.
1 2 3 4 5 6 7 8 9 10 11

Function
Motor HI - LO Motor LO - HI 4WD switch Position 2 CAN H

Input/Output
Output Output Input Input -

Description
This is a terminal that outputs the input signal to the T/C motor during the 4WD switch operation. When switching the 2WD mode to 4WD mode, the battery power is supplied to “Motor Hi-Lo” and the opposite side is earthed, and vice versa. Switch position converting (2H-4H) recognition Detecting shift motor position 2 position. These lines are sharing the information among the related units through the CAN communication. The differences from the conventional part time T/C models are that the speed sensing type tone wheel in T/C has been eliminated and the speed signal comes from the ABS/ESP HECU or the instrument panel. Supplying the voltage to clutch coil for all shifting operations • When supplying power: Battery voltage • When no power supplied: Ground power Provide the ground to TCCU Battery voltage supplying terminal to operate the system Same as No.1, 2 pin Recognition converting switch between 4H and 4L Detecting shift motor position 4 position. Detecting shift motor position 1 position. Detecting shift motor position 3 position. Providing the ground related to shift motor sensor plate. Connected to trouble diagnosis connector Power supply terminal when ignition switch is ON Locking hub system applied to KYRON makes difference in related to the conventional part time system and the vacuum supply in operating process.

Both CAN L EMC (Electronic magnetic clutch) Ground Battery Motor High-Low Motor Low-High High-Low switch Position 4 Position 1 Position 3 Position return K-Line Ignition power Solenoid power supply Ground Battery Output

12 13 14 15 16 17 18 19 20 21 22 23 24

Input Input Output Output Input Input Input Input Both Input Output

25 26

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

25

4. CONNECTORS OF SHIFT MOTOR AND MAGNETIC CLUTCH POWER SUPPLY
Shift Motor Connector

Unit
T/C

Shift Motor Connector Pin Arrangement
When selecting a position in the 4WD switch (2H, 4H), TOD control unit exactly changes the motor position to 2H and 4H by detecting the electric signals from position encoder that monitors motor position. Pin
1 2 3 4 5 6 7

Function
Position A Position B Position C Position D Position ground Control (4H -2H) Control (2H - 4H)
1 (Violet) 3 (Brown/ White) 2 (White) 6 (Yellow) 4 (Orange/ White) 5 (Yellow/ White) 7 (Orange)

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

M / T

A/T

26

3410

Magnetic Clutch Power Supply Connector

The transfer case integrated in KYRON doesn’t have an internal speed sensor. Therefore, there are not extra terminals for speed sensor power supply and ground. Pin
A

Function
Magnetic clutch coil power supply

Transfer case side

Supply side

Note (Old Version)

The rear speed sensor utilizes the hall effect. It generates 0V and 5V of square type digital wave according 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 available, electric current flows into the clutch coil. The coil magnetized by this electric current pull in the lockup hub to engage into output spline. Accordingly, the power is transferred to front wheels.

A (Brown) B (Green) C (Blue) D (Gray/Red)

Pin
A B C D

Function
Clutch coil Sensor power (5V) Sensor signal Sensor ground

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

27

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 during driving.
TCCU TCU

1. 2H → 4H a. Change the 4WD switch in instrument panel from 2H to 4H. b. This shift is available during driving. c. The “4WD HIGH” indicator in meter cluster comes on.
When the System is Defective • The “4WD CHECK” warning lamp comes on

2. 4H → 2H a. Change the 4WD switch in instrument panel from 4H to 2H. b. This shift is available during driving. c. The “4WD HIGH” indicator in meter cluster goes out.
2H - 4H

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

A/T

5. SYSTEM OPERATION

28

3410

Position Encoder
The position encoder is the code that TCCU can determine the shift motor position. Position Code
1 0 1 0 0 0 0 2 0 0 0 1 0 0 3 0 1 1 1 1 1 4 0 0 0 0 0 1

Motor Position
Left Stop 2H Zone 1 Zone 2 Zone 3 4H

Remark

Input voltage
1: above 4.5V (HIGH) 0: below 0.5V (LOW)

Operation 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. 2. TCCU starts diagnosis by operating clutch coil 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.

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.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

29

Motor Controls
1. 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 occurs due to timeout. This failure appears when the shifting time between 2H and 4H 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). 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. 2. The shift motor moves in 4H mode. 3. The locking 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 LOWHIGH direction for 5 seconds so that the motor is not left in unidentified position.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

A/T

30

3410

6. TROUBLE DIAGNOSIS TEST
Shift Motor Test
1. Check short and open circuit before and during shifting. 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. 4. The trouble code for the shift motor can be erased by using scanner.

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. 2. When the timeout occurs, TCCU cuts off the voltage to shift motor and operates the compensation mode.

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 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. a. General encoder fault: Invalid position code input b. Short to ground of position encoder circuit: Ground for encoder circuit

Clutch Coil Test
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.

Compensation
1. The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOWHIGH direction for 5 seconds so that the motor is not left in unrecognized position.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

31

Connect Scan-I to the diagnostic connector located under the steering wheel.

2. The transfer case system is malfunctioning when: a. The “4WD CHECK” indicator remains on after 0.6 second after turning the ignition switch ON. b. 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 and open circuit.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

M / T

1. TCCU detects the transfer case systems malfunctions and indicates malfunctioning part(s) through flickering of the “4WD CHECK” indicator.

A/T

7. SELF-DIAGNOSIS TEST

32

3410

8. DIAGNOSTIC TROUBLE CODE
Code
P1806 P1821

Description
Defective CAN commuication Open or short to magnetic clutch (EMC) circuit

Action
- Check communication line. - Replace TCCU if necessary. - When power is not supplied to magnetic clutch coil properly - When the circuit is open or short to ground for 0.8 seconds (Warning lamp comes on) - The magnetic clutch operates correctly if the correct signal is supplied for 0.8 seconds even though it is open. (Warning lamp goes off and it is stored as history fault in memory) - Voltage at TCCU pin No. 11: 11~15 V - EMC resistance: 2.5 Ù - Check the relevant connectors for contact. - Replace TCCU if necessary.

P1822

Defective locking hub solenoid

- When the locking hub solenoid operates, there is no malfunction in magnetic clutch and TCCU to the hub solenoid output is open or short to ground for 0.8 seconds - Warning lamp comes on. - Check the relevant harnesses for contact. - Replace locking hub solenoid if necessary.

P1841

Open to ground in shift motor circuit

- When TCCU detects motor’s malfunction for 1 second (Action: IGN OFF → ON) - Check the relevant harnesses for contact. - Replace TCCU if necessary.

P1842

Short to ground in shift motor output circuit

- When TCCU detects motor’s malfunction for 1 second (Action: IGN OFF → ON) - Check the relevant harnesses for contact. - Replace TCCU if necessary.

P1843

Defective position sensor in motor

- When no operation is detected in position sensor - When no operation is detected for 1.5 seconds while 2H-4H operation - Check the relevant harnesses for contact. - Replace TCCU if necessary.

P1850

Defective position encoder

- When TCCU detects a fault in position encoder for 1 second while during 4WD shifting (Position encoder: Detects the angle when shift motor rotates) - IGN OFF → ON: The current state is cancelled and it is stored as history malfunction in memory. - The warning lamp comes on. - Check the relevant harnesses. - Check the relevant connectors for contact. - Check the shift motor.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3410

33

Code
P1851

Description
Shoft to ground for position encoder 1

Action
M / T A / CON
ACTYON SM - 2006.03

- No 4WD shift possible if it occurs before shifting into 4WD mode. - 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

Shoft to ground for position encoder 2

- No 4WD shift possible if it occurs before shifting into 4WD mode. - 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

Shoft to ground for position encoder 3

- No 4WD shift possible if it occurs before shifting into 4WD mode. - Check the relevant harnesses for short. TCCU pin No. 19 - Check the relevant connectors for contact. - Check the shift motor. - Short to ground for position encoder 3 in shift motor

P1854

Shoft to ground for position encoder 4

- No 4WD shift possible if it occurs before shifting into 4WD mode. - 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.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

T/C

A/T

34

3410

9. REMOVAL AND INSTALLATION OF TCCU
1. Slide the drive’s seat as far as it goes and fold up the carpet.
TCCU

2. Unscrew two bolts (10 mm) on the TCCU. Installation Notice
Tightening torque 10 Nm

3. Disconnect the TCCU connector and remove the TCCU. NOTICE
• Be careful not to apply any impact to TCCU body.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

4116

35

1. LOCKING HUB SYSTEM
The transfer case and the TCCU differ from previous models only in the speed sensor related parts. However, the operaing process of 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 Booster Vacuum pump TCCU Atmosphere Vacuum modulator (for engine) Vacuum solenoid valve for IWE
ST’NG M / T A / CON A / BAG
ACTYON SM - 2006.03

Electrical signal

Atmosphere

Locking hub actuator

Locking hub actuator

Vacuum generation process in front hub actuator:
Vacuum pump 4WD switch

Air filter

Solenoid valve

TCCU

Hub actuator (FR) Atmosphere
CHANGED BY EFFECTIVE DATE AFFECTED VIN

Hub actuator (FL) Atmosphere
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

BRAKE

SP

AXLE

CLUTCH

T/C

A/T

IWE LOCKING HUB SYSTEM

36

4116

2. VACUUM SYSTEM RELATED TO 4WD
In 4WD mode, the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve.

Vacuum operation during 2WD mode During 2WD mode, the vacuum pressure from vacuum pump is continuously 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 gear.

Air filter

Hub actuator (RH)

Hub actuator (LH)

4WD (releasing vacuum pressure from hub actuator) 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.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

4116

37

Front Hub Assembly

Rubber O-ring Replace it with a new one when removing. Function: preventing moisture and foreign matter from entering into gears.
CLUTCH A / CON A / BAG BRAKE
ACTYON SM - 2006.03

Steel O-ring Preventing the actuator hub from pressing against the wheel end hub

Gear

NOTICE
• Rubber O-ring: Replace it with a new one when removing/installing 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

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

ST’NG

SP

Apply the grease to the steel O-ring before installation.

AXLE

T/C

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.

M / T

A/T

3. COMPONENTS OF IWE (INTEGRATED WHEEL END)

38

4116

Solenoid Valve

The vacuum solenoid valve is installed at bottom of the battery tray and 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. During the 4WD mode, the TCCU applies 12V to the vacuum solenoid to block the vacuum pressure.

Hub Actuator

TCCU

Vacuum pump

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 operates only within the actuator.
Supplying vacuum pressure Atmosphere

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

4116 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

39

Front wheel end

Drive shaft

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)

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

Front hub end gear is visible (4WD mode released)

SP

AXLE

CLUTCH

T/C

M / T

A/T

40

4116

Front Wheel End in Vehicle with 4WD

Front Wheel End in Vehicle without 4WD

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

4116

41

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.
T/C

Vacuum gauge

Solenoid valve

Connect vacuum gauge to vacuum line of front hub actuator.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

A / CON

A / BAG

BRAKE

ST’NG

SP

AXLE

CLUTCH

M / T

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, it may be engaged with the front drive shaft and the front locking hub and also it may cause leakage in the vacuum system supplied to the brake booster. Make sure that the vacuum lines are not leaking.

A/T

4. VACUUM LOCKING HUB CHECK

42

4116

3. Check vacuum pressure with vacuum pressure gauge.
2WD: Vacuum Pressure Applied

Vacuum applied

During 2WD mode, the vacuum pressure is applied to the locking hub actuator and the drive shaft is separated from the front wheel hub end gear. Thus, when applying the vacuum pressure with a vacuum pressure gauge, only the wheel must rotate.

4WD: Vacuum Pressure Released

Vacuum applied

During 4WD mode, the vacuum pressure 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.

PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
ACTYON SM - 2006.03

CHANGED BY EFFECTIVE DATE AFFECTED VIN

the actuator hub component condition is OK.03 A / CON Normal Leakage A / BAG Disconnect the vacuum hose from the hub actuator and install the vacuum pressure gauge to the hub actuator. If the vacuum pressure is not maintained. replace the actuator with a new one. CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM .4116 43 Hub Actuator Check If the vacuum pressure is maintained. BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Apply vacuum pressure to make sure the hub actuator maintains vacuum pressure.2006.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Note: Wheel Speed Sensor Location Front side (2WD) Rear side (5-link type) 1. Unscrew the two screws and remove the brake disc. Tightening torque: (85 ~ 105 Nm) 2.2006.44 4116 5. Unscrew the two bolts (19 mm) and set the removed brake caliper on the frame. REMOVAL AND INSTALLATION OF IWE (INTEGRATED WHEEL END) Wheel Speed Sensor Preceding Work: Disconnect the negative battery cable and remove the tires. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM .

10 mm). Unscrew the three wheel end hub mounting bolts (hexagon. Unscrew the mounting bolt (5 mm) and remove the wheel speed sensor. Remove the hub cap and unscrew the lock nut. Slightly pull the wheel end hub until the wheel speed sensor is visible.4116 45 3.2006. Tightening torque: (6 ~ 8 Nm) CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM . SP AXLE CLUTCH T/C M / T NOTICE A/T . • Replace the hub cap with a new one when installing.03 A / CON A / BAG BRAKE ST’NG 4. Tightening torque: (28 ~ 30 Nm) Installation Notice Tightening torque 100 ~ 130 Nm 5.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Disconnect the wheel speed sensor connector and the cable. Disconnect Connector Wheel Speed Sensor PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM .2006.46 4116 6.

Unscrew the two bolts (10 mm) and remove the brake dust cover. 1. Pull out the steering gear linkage lock pin from the knuckle.4116 Locking Hub Actuator Assembly Preceding Work: 1. Remove the tire and the brake disc. Pull out the upper arm lock pin and unscrew the mounting nut (19 mm). Installation Notice Tightening torque 4 ~ 8 Nm 47 2.2006. 2.03 A / CON A / BAG BRAKE ST’NG AXLE CLUTCH T/C M / T A/T . do not fully remove the nut. Unscrew the mounting nut (19 mm) and remove the tie rod end. At this time. SP Tightening torque: (140 ~ 160 Nm) 3. Lock pin Tightening torque: (110 ~ 130 Nm) CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM . Remove the wheel speed sensor.

2006. Tightening torque: (140 ~ 160 Nm) 5. Unscrew the lower arm mounting nut (22 mm). Remove the knuckle between upper arm and lower arm with special tool.48 4116 4.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM .

4116 Hub Actuator 49 1. Unscrew the three bolts (10 mm) on the disassembled locking hub actuator assembly and remove the hub actuator.03 A / CON A / BAG BRAKE AXLE CLUTCH T/C M / T A/T . Tightening torque: (8 ~ 12 Nm) Structure of Hub Actuator Vacuum tube Vent tube ST’NG SP Detail 1 Clutch ring 2 Shift fork 7 Shift seal 6 Housing Piston Diaphragm Spring CHANGED BY EFFECTIVE DATE AFFECTED VIN PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM .2006.

50 4116 Inspection 1. Be careful not to damage the internal seal ring of the hub actuator.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Check the internal seal ring of hub actuator for damage. Replace the O-ring of the locking hub end with a new one. PART TIME TRANSFER CASE & LOCKING HUB SYSTEM ACTYON SM . 2.2006. Installation Notice * Completely clean the parts and apply the grease them before installing in the correct order.

.... 8 CLUTCH ASSEMBLY ............................................................................................................................. Removal and installation . 2 1........ 6 Trouble diagnosis ...............................................CLUTCH 3010 TABLE OF CONTENTS GENERAL .. 3.. 10 1........ 4.............................................................. 2 Specifications ............................................... Function and overview ................ 7 Maintenance ................................. 10 ................................... 2............................

Function SAT is new clutch system which adjusts the clutch free play according to the wear of clutch disc. 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. and its durability is superior.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2. 3. • Clutch master cylinder (mounted on clutch pedal) • Concentric slave cylinder (mounted inside of transmission) CLUTCH ACTYON SM . This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly. FUNCTION AND OVERVIEW SAT (Self Adjusting Technology) Clutch System 1. Operating Elements The clutch release system consists of the clutch pedal and clutch release cylinder. This system provides higher efficiency than conventional clutch system. 3) → Pressure plate (4) Overview 1. The clutch pressure plate is fitted into a clutch steel cover. Internal Components of Clutch Cover 2. Driving Elements The driving elements consist of two flat surfaces machined to a smooth finish. The driving and driven elements are held in contact by spring pressure. Operation Description • Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so. 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. One of these is the rear face of the engine flywheel and the other is the clutch pressure plate.2 3010 GENERAL 1. • Disc wear (Free play) → Diaphragm spring (1) → Adjusting equipment (2. pressure plate is pushed to clutch disc side at the amount of wear.

Adapter/Pipe Assembly B. Transmission housing 2.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T Functions . Clutch Assembly C. Washer 6.2006. Concentric Slave Cylinder Cross Sectional View of Clutch Assembly 1. Clutch disc cover assembly 4. Bolt CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Clutch disc assembly 3.3010 3 Components of Clutch Assembly A. Bolt 5.

The piston in cylinder returns to its original position. Cap Chamber assembly Pipe CLUTCH ACTYON SM . the push rod pushes the piston and the piston cup. piston. It consists of oil tank. cylinder.4 3010 Clutch Master Cylinder and Reservoir The clutch master cylinder generates the hydraulic pressure by moving the piston within the cylinder. an hydraulic pressure is produced within the master cylinder and transmitted to the concentric slave cylinder which then pushes the diaphragm to separate the pressure plate from the clutch disc. Clutch / Brake fluid reservoir Nipple Clutch reservoir hose Brake master cylinder Clamp Clutch master cylinder Clutch Release Chamber The clutch release chamber keeps the hydraulic pressure in the clutch hose and pipe stable and also helps the hydraulic pressure to transfer quickly and generates the remaining pressure in the hose and pipe when the clutch is operated. When releasing the clutch pedal.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . and the clutch operation stops. it returns to its original position through the elasticity of diaphragm. During this operation. which sends the oil in the oil reservoir tank to the concentric slave cylinder through the hose and pipe. piston cup spring and push rod. and the clutch fluid is supplied from the brake fluid reservoir tank.2006. Operation: When depressing the clutch pedal.

The spline part is installed in the . The transmission input shaft can be inserted into the spline part. engine power disconnection is difficult and the gear damage with abnormal noise will occur. where the engine power can be interrupted. its structure is simple. Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet). center of the disc and transmits the engine s electric power to the transmission. pressure plate) and clutch disc. A / BAG Clutch Disc BRAKE ST’NG SP AXLE Clutch Assembly CLUTCH T/C M / T A/T .03 A / CON The clutch disc is installed between the engine flywheel and the pressure plate. 5 Clutch assembly is composed of clutch cover (diaphragm spring. The clutch pedal has some free play that prohibits its operation prior to generating the resistance by depressing 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. the concentric slave cylinder pushes the pressure plate diaphragm and separates the pressure plate. and the cushion spring is installed to prevent friction materials (facing) from unevenly wearing out. CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Clutch Cover When depressing the clutch pedal.2006.3010 Clutch Pedal 1. and the pedal effort is small. The clutch disc has friction materials on its edges. If this free play is too wide. The advantages of using the diaphragm spring: the pressure varies only a little even when the clutch disc facing is considerably worn out. 2.

6 3010 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .0 ± 0.46 mm 7.3 mm Clutch cover assembly setting force Clutch master cylinder Stroke Inner diameter Concentric slave cylinder Stroke Sectional area Clutch fluid Min.0 mm 263 cm2 / 2 Free: 9. 720 kg 30 mm φ 17.4 ~ 10 mm When loaded: 9. SPECIFICATIONS Specifications Description Operating type Clutch pedal Type Maximum pedal stroke Pedal free play Clutch disc Type Dimension of facing Facing size/quantity Thickness of disc Specification Hydraulic Suspended 140 mm 5 ~ 15 mm Single dry diaphragm 240 × 155 × 4.0 mm 706 mm2 DOT3 or DOT4 Tightening Torque Description Clutch housing bolt (8 locations) Clutch cover (pressure plate assembly) bolt Concentric slave cylinder bolt (3 locations) Concentric slave cylinder flare nut Adapter flare nut Clutch oil pipe flange nut Master cylinder bolt Fulcrum (clutch pedal bushing) bolt/nut Clutch pedal bracket mounting bolt Stopper bolt Tightening Torque 49 ~ 59 Nm 21 ~ 27 Nm 10 ~ 16 Nm 20 ~ 25 Nm 20 ~ 25 Nm 15 ~ 18 Nm 8 ~ 18 Nm 16 ~ 32 Nm 8 ~ 18 Nm 16 ~ 22 Nm CLUTCH ACTYON SM .2006.

2006. excessive run-out. damaged lining Dirty or damaged splines on input shaft or clutch disc Damaged clutch pressure plate Clutch chatters when starting Oily facing Hard or faulty facing Burnt cushion spring Faulty pressure plate Bent clutch diaphragm spring Hard or bent flywheel surface Engine mounts loose or burnt lever Difficult pedal operation Poor bleeding in hydraulic system Poor lubrication on pedal shaft Poor lubrication on clutch pedal Not using the clutch Insufficient clutch pedal free play Excessive wear of clutch disc facing After disengagement Clutch noisy Worn or damaged concentric slave cylinder Repair release cylinder Repair or replace Repair as necessary Replace Repair or replace Replace Replace Replace Replace Adjust or replace Tighten or replace Bleed or replace Lubricate or replace Repair Adjust Replace Replace When disengaging Faulty installation of clutch assembly or bearing Repair Clutch pedal is partially depressed and vehicle speed is reduced Damaged pilot bushing Replace CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . TROUBLE DIAGNOSIS .3010 7 Check Clutch slips • Too low vehicle speed • Insufficient power on hills Possible Cause Excessive wear of facing Hard or oily facing Damaged diaphragm or flywheel Damaged or burnt diaphragm spring Insufficient clutch pedal free play Faulty operation of clutch pedal Worn or damaged clutch disc Replace Action M / T Adjust or replace Replace Replace Adjust Repair or replace Replace Replace Repair or replace Adjust or replace Replace Adjust Poor disengagement Vibration or excessive run-out of disc Rust or wear of clutch disc spline Oily facing Burnt diaphragm spring Excessive clutch pedal free play Faulty clutch release cylinder Worn disc.03 A / CON A / BAG BRAKE ST’NG SP Hard to shift or does not shift Excessive clutch pedal free play Adjust pedal freeplay AXLE CLUTCH T/C A/T 3.

undo the air bleed bolt and bleed the air and fluid from the fluid line. 5. NOTE • This work has to be done by two service persons. • Use only the Ssangyong genuine clutch fluid. Repeat step 3 through 4 until no more air bubbles are in the escaping fluid.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Connect a plastic hose to the bleed bolt. MAINTENANCE Air Bleeding Air bleed Adapter Plastic hose Plastic hose NOTICE • Keep the fluid level over MAX in reservoir during bleeding operation. • Do not let the fluid contact a painted surface.2006.8 3010 4. 1. Slowly depress the clutch pedal several times. check the clutch system for operation and noise. Remove the air bleed bolt cap from the adapter. Clutch fluid DOT 3. • After bleeding. and check the clutch fluid level in reservoir after service. 3. 2. 4. 4 CLUTCH ACTYON SM . With clutch pedal fully depressed. Put the other side of the hose into a empty container.

the clearance between the clutch disc and pressure plate may be changed. * P/No: D9930 . 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).03 A / CON A / BAG BRAKE SP AXLE CLUTCH T/C M / T A/T . How to Use Special Tool ST’NG How to identify SAT clutch specification Identify the SAT clutch with compensation device (arrow) on clutch cover.0010C CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . checking the clutch assy) NOTICE • When reinstall the clutch assembly without the special zig. Service Instruction 1. disc can be slipped and worn easily. (Example: engine removal and reinstallation. Replacement of clutch disc → Replace the clutch cover assembly together. always use the designated tools and special tools for maintenance.3010 9 Clutch Replacement To prevent early wear and slip in clutch disc. Reinstallation of clutch disc and cover → Apply the jig set (SST) on the clutch cover set before removing the clutch disc and cover. for the SAT clutch. 2.2006. flywheel related job. Also.

Clutch housing 8. Concentric slave cylinder 10. Clutch hydraulic pipe 4. Concentric slave pipe 9. Clutch disc A-A : Connection CLUTCH ACTYON SM . Clutch cover 11. Clutch fluid chamber 5. Adapter 7.10 3010 CLUTCH ASSEMBLY 1. Clutch master cylinder 3.2006. REMOVAL AND INSTALLATION Components 1. Clutch pedal 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Clutch hydraulic hose 6.

2006. Special tool NOTICE • Do not remove the bolts at a time. Loosen the clutch cover bolts 1/2 turns in cross sequence until the spring tension is released. Adapter 2. Insert the centering pin (special tool) into center spline. Installation Notice Tightening torque 24 ± 3 Nm NOTICE • Loosen the mounting bolt while the special tool is installed. Remove the transmission assembly (Refer to “M/T” section). CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . or clutch cover may be damaged or deformed. A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T Removal and Installation of Components .3010 11 Clutch Assembly 1. Disconnect the clutch fluid hose from the adapter.03 A / CON 3. Use the locking pliers to prevent the fluid leakage.

Unscrew the bolts and remove the clutch cover. NOTICE • Be careful not to drop the pressure plate and clutch disc. pressure plate and clutch disc.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .12 3010 4. T/M installation mark Clutch disc Pressure plate CLUTCH ACTYON SM .2006.

Tightening torque: 10 ~ 16 Nm 4. • Do not re-use the used clutch fluid and brake fluid. Unscrew the oil pipe adapter mounting bolt from the clutch housing and remove the adapter and oil pipe.3010 Concentric Slave and Adapter 1. • Replace parts if necessary. * Keep the specified tightening torque. clean all the components. NOTICE • Before installation.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .2006. 3. Installation Notice Tightening torque 20 ~ 25 Nm 13 2. Unscrew the oil pipe nut in the clutch housing and remove the oil pipe. Install in the reverse order of removal. CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Unscrew three bolts and remove the concentric slave cylinder assembly on the input shaft of cylinder.

CLUTCH ACTYON SM . Disconnect the clutch master cylinder push rod from the clutch pedal and remove the clutch master cylinder (refer to “Removal of Clutch Pedal” section). Disconnect the clutch fluid feed pipe (to chamber) and unscrew two clutch master cylinder mounting nuts (10 mm).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 5.14 3010 Clutch Master Cylinder 1. Drain the clutch fluid. 6. Brake and clutch fluid reservoir Nipple Clutch reservoir hose Brake master cylinder Clamp Clutch master cylinder 3. 2. Install in the reverse order of removal and check “air bleeding and clutch pedal operation” after installation.2006. Tightening torque: 15 ~ 18 Nm Tightening torque: 8 ~ 18 Nm 4. Fill brake and clutch fluid rese rvoir. Disconnect the clutch fluid feed hose from the brake reservoir.

Push rod on clutch master cylinder side Pin ST’NG SP NOTICE Clutch pedal • Securely install the snap pin as shown in figure. Unscrew the clutch master cylinder mounting bolts. Installation Notice Tightening torque 8 ~ 18 Nm Stud bolt (1EA) Push rod on master cylinder Hexagon flange nut Clutch pedal mounting hole Pedal box assembly CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Installation Notice Tightening torque 8 ~ 18 Nm Dash panel 15 Stud bolt on clutch pedal side Hexagon flange nut T/C M / T Stud bolt on clutch pedal side CLUTCH Cylinder module assembly 2. Remove the snap pin from master cylinder push rod side. Unscrew the mounting nut (12 mm) and remove the pedal box assembly.2006. 3.3010 Clutch Pedal 1.03 A / CON A / BAG Snap pin BRAKE AXLE A/T .

Check the fulcrum bolt and the bushing for wear. • Keep the tightening torque.2006. • Replace the bushings with new ones. Adjust pedal stroke after installation. loosen the lock nut (C) of the stopper bolt (D) and turn the stopper bolt until the stroke is correct. • Remove foreign materials. tighten the lock nut. Inspection and Adjustment 1. the pedal for bending and the spring for damage. Pedal Stroke (A) Maximum pedal stroke 140 mm 2. NOTICE • Apply long-life grease (T/M DBL 6611.00) to the connections. CLUTCH ACTYON SM . 3. After adjustment.16 3010 Installation Notice Install in the reverse order of removal. 4. Pedal Height (B) Height (from carpet) 181 ± 5 mm NOTICE • To adjust the pedal height. loosen the lock nut (F) of the master cylinder and turn the push rod until the free play is correct.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Pedal Free Play (E) Free play 5 ~ 15 mm NOTICE • To adjust the pedal free play.

CLUTCH T/C M / T A/T . Chamber and Pipe Master cylinder Oil chamber Primary oil pipe Secondary clutch fluid pipe Concentric slave cylinder adapter CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Unscrew the pipe bolt and remove the secondary clutch fluid pipe from concentric slave cylinder adapter. Unscrew the bolt and remove the supply pipe from clutch master cylinder. Be careful not to mix the pipes.2006. However.03 A / CON A / BAG BRAKE ST’NG • Make sure to bleed the air from the system after installation. NOTE Tightening torque: 15 ~ 18 Nm • Check each pipe bolt for oil leaks. 2. Installation Notice Tightening torque 15 ~ 18 Nm 17 4.3010 Clutch Chamber Removal/Installation 1. Drain the fluid. • Clutch pipes are reusable. 5. Install the pipes. SP AXLE 3. Unscrew the supply pipe bolt and remove primary oil pipe from clutch fluid chamber. you must check the pipes for damages and cracks.

Clutch Disc a.3 mm 3. replace the disc.7 mm CLUTCH ACTYON SM . Check the strap plate rivet for looseness and replace the clutch cover if necessary. crack and discoloration. Run-out limit Within 0. oil and grease. c. Check the facing for rivet looseness. If it is out of limit. Clutch Disc Run-Out a. Check the diaphragm spring tip for wear and height unevenness.8 mm b. Unevenness limit 0. Clutch Cover Assembly a. 2. Measure the rivet head depth. Wear limit 0.18 3010 Inspection and Maintenance 1. b. replace the disc. Check the pressure plate surface for wear.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . uneven contact. Measure the clutch disc run-out and if it is out of limit. sticks.2006.

Check any heat damage. Check the pressure plate spring for wear. Pressure Plate a. 5. CHANGED BY EFFECTIVE DATE AFFECTED VIN CLUTCH ACTYON SM . Concentric Slave Cylinder a.2006. NOTICE • The excessively worn components should be replaced. abnormal noise.03 A / CON A / BAG Concentric Slave Cylinder Assembly BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . poor rotation and wear of the concentric slave cylinder bearing.3010 19 4.

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......... 20 ................................................8 5-LINK TYPE REAR AXLE ..................................... Location ..................................... Removal and installation .. 5 2.................................................................................. Front axle assembly ...........................................AXLE 4120 / 4210 TABLE OF CONTENTS GENERAL ..............................6 3...... 15 2............. Location ......... 15 1................................................ 3 FRONT AXLE .................................................................. Removal and installation ............. 5 1..............................

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T GENERAL .2006.4120 3 Front Axle M / T Rear Axle CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .55R → ← M/T 4.4 L 448.55R ← ← φ 182.4 mm Offset ← 38.GL5 1.4 L ← ← ← ← ← ← ← ← AXLE ACTYON SM .8 mm 28.9 mm 45 kg ← 1.27R Hypoid Front axle A/T 4.GL5 1.27R ← Rear axle A/T 4. For details.7 mm 90 kg - Housing ← ← Oil Specification Capacity Length Width Weight SAE 80W/90 .4 4120 The specification below is for front and rear axles equipped in Actyon. aluminum cover) SAE 80W/90 .0 mm 1717.9 L 469. including gear ratio and specific specifications.1 mm Steel casting (steel. Location Specification Torque Gear ratio Type Gear Size M/T 4.0 mm 681. refer to each section.58 mm (DYMOS) 35 mm Steel φ 218.

4120 5 1.03 A / CON From vacuum pump A / BAG Tire wheel BRAKE ST’NG SP AXLE CLUTCH T/C A/T FRONT AXLE .2006. LOCATION M / T Sectional Diagram Knuckle To atmosphere Cap & lock nut Tightening torque: 28 ~ 32 Nm Tire lock bolt Tightening torque: 120 ~ 140 Nm Brake disc Axle shaft CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .

2006. 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 ACTYON SM .6 4120 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

2006.4120 7 Front Axle Housing Assembly Front axle housing Axle mounting bolt Front axle Axle mounting bolt Nut Axle mounting lower bushing Axle mounting upper bushing Axle mounting lower bushing Axle mounting bracket Axle mounting bolt Axle mounting lower bushing Axle mounting bracket CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .03 A / CON A / BAG Air bleed hose BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .

Unscrew five wheel nuts (21 mm) in diagonal direction by 2 to 3 steps and remove tires.2006.8 4120 3. 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 AND INSTALLATION Preceding work: Perform the following steps before removing and installing the front axle assembly (axle housing/axle shaft). Installation Notice Tightening torque 120 ~ 140 Nm Wheel cap AXLE ACTYON SM . Removal of the front tire Remove the front tire wheel caps.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Caution 1.

4120 9 2. Brake hose Vacuum hose 3. Wheel speed sensor connector and vacuum hose (At Both Sides) Disconnect the wheel speed sensor cable and connector.03 A / BAG BRAKE ST’NG AXLE CLUTCH T/C M / T A/T . Connector Be careful not to damage the vacuum hose.2006. and disconnect the vacuum hose from the locking hub actuator. Brake disc caliper Unscrew two mounting bolts (19 mm) and remove the brake disc caliper. Hang the removed caliper to the upper arm using the holder. Installation Notice Tightening torque 85 ~ 105 Nm SP A / CON CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .

Remove the hub bearing cap and unscrew the lock nut (14 mm) on the brake disc. Unscrew the upper arm lock nut. Hub bearing cap Tightening torque: 28 ~ 32 Nm NOTICE • The hub bearing cap and the lock nut are not reusable. Loosen the upper arm (1) and the tie rod end (2) and remove the assembly by lifting it.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . and then remove the front disc and the wheel end assembly. Always replace them with new ones after removal.2006. the tie rod end lock nut and the lower arm lock nut from knuckle. 2. AXLE ACTYON SM . Upper arm (1) Tightening torque: 140 ~ 160 Nm Tie rod end (2) Tightening torque: 110 ~ 130 Nm Lower arm (3) Tightening torque: 150 ~ 170 Nm 3.10 4120 Removal of Axle Shaft Removal and Installation 1.

M / T Components Boot band Drive shaft Shaft Boot band Boot band Seal Boot (in-board) Ball joint Boot (out-board) Boot band Housing (in-board) CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM . Remove the axle shaft from the axle housing using a special tool.2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T .4120 11 4.

Unscrew the four bolts (17 mm) on the axle housing and remove the axle mounting bracket.12 4120 Removal of Axle Housing 1. Installation Notice Tightening torque 95 ~ 142 Nm 3.2006. Installation Notice Tightening torque 80 ~ 100 Nm AXLE ACTYON SM . Remove the axle shaft from the axle housing. Removal of mounting bolt Unscrew the mounting nut (22 mm) at right side of the axle housing and remove the axle mounting bolt.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2. Remove the propeller shaft and secure it to frame.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T 4. 5. Otherwise. A/T . Place a safety jack under the axle housing and remove one axle mounting bolt (22 mm).4120 13 Tightening Torque T/C Mounting nut (22 mm) Bracket bolt (17 mm) 95 ~ 142 Nm 80 ~ 100 Nm NOTE • Remove the power steering hose mounting bracket before removing the left pin bolt. Installation Notice Tightening torque 95 ~ 142 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .2006. Unscrew one mounting nut (22 mm) at left side of the axle housing and four bolts on mounting bracket (17 mm) to remove the mounting bracket. it cannot be removed due to interruption.

Remove the fixing clip on the air bleed hose above the axle housing and carefully lower the safety jack.2006. Air bleed hose Front axle housing Axle mounting bolt Front axle Axle mounting bolt Axle mounting bolt Nut Axle mounting lower bushing Axle mounting lower bushing Axle mounting upper bushing Axle mounting lower bushing Axle mounting bracket Axle mounting bracket AXLE ACTYON SM . Axle Housing Assembly NOTICE • Be careful not to damage the left and right seals in axle housing when removing the axle mounting bracket or axle assembly.14 4120 6.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T 5-LINK TYPE REAR AXLE .2006.4210 15 1. LOCATION M / T CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.16 4210 Components Axle Shaft Disc Type Axle Housing Axle Yoke Rear Axle Axle Housing Axle Shaft Drum Type AXLE ACTYON SM .

4210 17 Front View Rear View SP Specifications Description Axle shaft type Axle housing type Differential Type Gear type Final gear ratio DI engine + M/T DI engine + A/T Oil Capacity Specification Specification Semi-floating type Build-up type Conventional Hypoid 4.2006.9 L SAE 80W/90 GL-5 CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .55 1.03 A / CON A / BAG BRAKE ST’NG AXLE CLUTCH T/C M / T A/T Specifications .27 4.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .18 4210 Trouble Diagnosis Symptom Noise (during driving straight ahead) Lack of oil Low oil viscosity Low oil quality Excessive backlash of ring gear Worn or damaged tooth of ring and pinion gear Worn or damaged drive pinion gear Worn bearing and side gear spline Distortion of axle housing Distortion of differential case Worn pinion shaft Incorrect drive pinion preload Incorrect contact of ring gear and pinion Oil leakage Excessive oil Improper sealing of carrier mating surface Cracked axle housing Worn or damaged oil seal Noise (during turning) Worn or damaged tooth of pinion or side gear Worn pinion shaft Excessive backlash of pinion gear and side gear Excessive end-play of axle shaft Incorrect contact of side gear and differential case Cracked axle housing Distortion or poor installation of drive pinion oil seal Damaged or torn drive pinion oil seal Loosened bearing collar Worn or damaged universal joint Worn or damaged axle shaft bearing Heated Lack of oil Insufficient backlash of gears Excessive preload of bearing Cause Action Replenish Replace Replace Replace Replace Replace Replace Replace Replace Replace Adjust Reassembly Adjust to proper level Correct Replace Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replenish Adjust Adjust AXLE ACTYON SM .

Apply gear-marking compound (Prussian blue/red lead) on the ring gear teeth.03 A / BAG BRAKE ST’NG (toward toe) AXLE CLUTCH T/C M / T A/T . Flank contact Insufficient backlash • Gear contacts on the low flank • Gear can be damaged or worn • Noise can be occured Adjust backlash • Move the ring gear toward the drive pinion (toward the ring gear center line) CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .4210 Inspection of Ring Gear Tooth Contact Pattern 1. Abnormal contact Tooth Contact Pattern 1. Toe contact Insufficient backlash • Tooth can be damaged or broken under heavy load Adjust backlash • Select proper shim to move the drive pinion against the ring gear (toward heel) 3. 19 2. Face contact Excessive backlash • Drive pinion shaft is apart from the ring gear • Noise can be occured Adjust backlash • Move the drive pinion toward the ring gear (toward the center of ring gear) A / CON 4. Heel contact Possible Cause Excessive backlash • Noise can be occured Adjust backlash Remedy • Select proper shim to SP move the drive pinion toward the ring gear 2.2006. Rotate the ring gear and check the tooth contact pattern.

Disconnect and secure the wheel speed sensor cable.20 4210 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque 6 ~ 8 Nm AXLE ACTYON SM . Unscrew the mounting bolt (10 mm) . Unscrew the two mounting bolts (19 mm) and remove the rear brake disc caliper.2006. Caliper mounting bolt 85 ~ 105 Nm 2. REMOVAL AND INSTALLATION Rear Axle Shaft (Disc Brake Type) Preceding Works: Remove the tire. 1. Secure the removed caliper on the vehicle frame.

4210 21 3. Remove the lock pin and disconnect the parking brake cable. Parking brake cable Lock pin 5. Remove the brake disc. CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM . Adjusting nut 4. Unscrew the adjusting nut of the parking brake cable equalizer to loosen the parking brake cable.2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 7.2006.22 4210 6. Installation Notice Tightening torque 50 ~ 64 Nm AXLE ACTYON SM . Remove the plastic plug from the axle shaft flange. Unscrew the four flange lock bolts (17 mm) on the axle housing flange and remove the axle shaft.

Air Breather (Lock Bolt 10 mm . Remove the wheel speed sensor (A). 1. Parking Brake Cable .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T Rear Axle Housing .LH/RH Tightening torque: 85 ~ 105 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .2006.1 EA) Tightening torque: 6 ~ 8 Nm C. Disc Brake Caliper . the parking brake cable (C) and the disc brake caliper (D) from the rear axle.1EA) .LH/RH D. A.LH/RH Tightening torque: 6 ~ 8 Nm B. the air breather lock nut (B). Wheel Speed Sensor (10 mm .4210 23 Preceding Works: Remove the tire.

Lateral rod D.2 EA: LH/RH) rear axle housing.03 40 ~ 60 Nm Tightening torque 70 ~ 80 Nm Tightening torque 150 ~ 180 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the propeller shaft to the F. Propeller shaft B. A. Upper arm bolt/nut (22 mm) bar (14 mm . lateral rod mounting nut (22 mm) B. Mounting bracket bolts of stabilizer E. 10 mm: bolt) Tightening torque 150 ~ 180 Nm Tightening torque 150 ~ 180 Nm Tightening torque 80 ~ 100 Nm F. Place a safety jack under the axle housing and unscrew the connections. Upper arm A. Shock absorber bolt/nut (17 mm: nut. Lower arm C.2006. Stabilizer mounting bracket E. Lower arm bolt/nut (22 mm) C. Shock absorber D.24 4210 2. Assembly mark Tightening torque AXLE ACTYON SM .

Rear View 25 CHANGED BY EFFECTIVE DATE AFFECTED VIN AXLE ACTYON SM .2006.03 A / CON A / BAG BRAKE Front View ST’NG SP AXLE CLUTCH T/C M / T A/T .4210 3. Carefully lower the safety jack to remove the rear axle assembly from the vehicle frame.

......... 2 System layout . 2..... 4.................... 6.................................... 6 Removal and installation ................................................................................ 2 1.............. 12 Lower arm .............. Overview ....SUSPENSION 4410 / 4510 TABLE OF CONTENTS FRONT SUSPENSION ...................... 5..... 19 1........................................................................................................ 2........................................ System overview .......... 14 REAR SUSPENSION (5-LINK TYPE) ........ 10 Stabilizer bar .......................................... 19 System layout ....... 25 ................................................... 24 Removal and installation ................................................ 20 Trouble diagnosis .............. 3........................... 8 Coil spring & shock absorber assembly ............................. 3.............................................. 4........................................................

Lower Arm Assembly The lower arm is mounted to the knuckle. the shock absorber and the lower arm assembly. which enhances the comforts. 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. upper arm assembly. lower arm assembly. driving force. It relieves the load delivered from the tire to the knuckle. It absorbs the vibrations and impacts from road surface. Components Knuckle. 1. Suspension type: Double Wishbone 2. This enables to absorb the various impacts according to the load shapes and to ensure the drivability.2 4410 FRONT SUSPENSION 1.2006. coil spring. SYSTEM OVERVIEW Overview The suspension is the device to connect the axle and vehicle frame. SUSPENSION ACTYON SM . braking force and drivability. This enables to absorb the various impacts according to the load shapes and to ensure the drivability.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

03 A / CON A / BAG BRAKE ST’NG A transverse mounted spring steel bar controls and minimizes body lean or tipping on corners.4410 3 Stabilizer Bar T/C Stabilizer bar mounting bracket Bushing Stabilizer bar Link Coil Spring Coil Spring Shock absorber A section of spring steed rod is wound in a spiral pattern or shape coil provides a cushion to absorb road imperfections and returns the vehicle to a predetermined right height. SP AXLE CLUTCH M / T A/T . It is a major contributor to a vehicle's handling balance and ride quality. This is a round bar which connects the left wheel suspension assembly with the right side.2006. The main function is to keep both wheels rolling at the same rate when meeting bumps. Higher spring rates and shorter overall lengths are commonly used to lower the vehicle's ride height for enhanced appearance and improved handling. but it also affects handling. Yoke CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .

and a cylinder tube.2006. Coil spring Shock absorber Yoke 2.4 4410 Shock Absorber Assembly 1. This double tube type shock absorber restrains the vibrations by using oil resistance. This provides better drivability even though the structure is complicated. enhances drivability. The piston has an orifice and valve and the cylinder is filled with oil. This relieves the vertical vibrations of vehicle to provide ride comforts.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . This vehicle uses the gas shock absorber with cylindrical double tube. This shock absorber is connected to the piston rod in the strut. This vehicle uses the strut type shock absorber. The shock absorber consists of a tube with piston and rod. prevents the spring break. Amplitude Time without shock absorber with shock absorber SUSPENSION ACTYON SM . and extends the life span of steering components.

Yoke 9. Bumper stopper 11. Spacer 16. Spring 8. Piston 6. Upper spring seat 13. Washer 17. Rubber 15. Bolt CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T Sectional Drawing of Shock Absorber . Rebound stopper 4.2006. Yoke bracket 3. Spring seat rubber 12. Boot 10. Nut 18. Rubber 14. Cylinder 5. Shock absorber assembly 7. Lower spring seat 2.4410 5 1.

6 4410 2.5°) 4.5°) 86.2006.4° ± 0. SYSTEM LAYOUT Specifications Description Suspension type Spring type Shock absorber type Stabilizer type Toe-in Wheel alignment Camber Caster Height “H” (When tightening upper arm/ lower arm/shock absorber yoke nut) Specification Double wishbone Coil spring Cylindrical double tube (gas type) Torsion bar 2 ± 2 mm [0 ~ 4 mm] -0.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .19° ± 0.5 ± 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 ACTYON SM .3° (the difference between both ends is should be below 0.5° (the difference between both ends is should be below 0.

4410 7 Upper arm (on frame) bolt / nut Tightening torque: 110 ~ 130 Nm T/C Stabilizer bar link lower nut Tightening torque: 110 ~ 130 Nm Stabilizer bar mounting clamp bolt Tightening torque: 30 ~ 45 Nm 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 EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T Stabilizer bar link upper nut Tightening torque: 30 ~ 50 Nm Coil spring mounting nut Tightening torque: 60 ~ 80 Nm A/T .2006.

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. Upper arm nut (19 mm.8 4410 3. Wheel speed sensor cable : Remove the wheel speed sensor cable and the connector from the upper arm. Installation Notice Tightening torque 120 ~ 140 Nm 1. Remove the tires. Preceding Works 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . knuckle side) : Remove the cotter pin first and then remove the castle nut. 2. SUSPENSION ACTYON SM . Remove the wheel cap and loosen the wheel nuts in several steps.2006. Tightening torque: 140 ~ 160 Nm NOTICE • Replace the cotter pin with new one when installing.

4410 9 3. 12 mm nut Tightening torque: 110 ~ 130 Nm 4. Upper arm : Separate the upper arm from the frame first. Upper Arm Assembly Upper arm Bolt / nut Cotter pin Castle nut CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .2006. and then separate it from the knuckle with a special tool.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Upper arm bolt/nut (frame side) 12 mm bolt : Remove the upper arm mounting bolts and nuts (LH/RH) from the frame.

10 4410 4. 2.1 EA) Shock absorber yoke Stabilizer link 14 mm : Unscrew the lower nut of coil spring/shock absorber yoke from the lower arm. The upper mounting nuts of the coil spring/shock absorber assembly (14 mm . unscrew the two upper mounting nuts in engine compartment. COIL SPRING & SHOCK ABSORBER ASSEMBLY Preceding Work Remove the tire and the upper arm. 1.3 EA) : At first. Engine Compartment Tightening torque: 60 ~ 80 Nm Wheel House Tightening torque: 60 ~ 80 Nm : Unscrew the upper mounting nut (14 mm) of the coil spring shock absorber in wheel house cover.2006. Do not completely remove the nut. 12 mm Tightening torque: 150 ~ 170 Nm SUSPENSION ACTYON SM . The lower nut of the coil spring/shock absorber yoke (24 mm .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

Remove the coil spring/shock absorber. Lock bolt Tightening torque: 100 ~ 120 Nm Yoke CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM . make sure that slot B and protrusion A are aligned.03 A / CON A / BAG BRAKE ST’NG AXLE CLUTCH T/C A/T .4410 11 3. : Unscrew all the mounting nuts on the coil spring/shock absorber and separate the coil spring/shock absorber.2006. M / T Coil Spring Assembly SP Coil spring Shock absorber When installing the yoke to the coil spring/shock absorber.

2006. Mounting bracket Stabilizer bar Bushing Tightening torque: 30 ~ 45 Nm SUSPENSION ACTYON SM . Unscrew two bracket mounting bolts (14 mm) and remove the stabilizer bar assembly. STABILIZER BAR Preceding Work Remove the tires. Remove the stabilizer bar link. Tightening torque: 30 ~ 50 Nm Tightening torque: 110 ~ 130 Nm : Unscrew the lower mounting nut (12 mm) and upper mounting nut (10 mm) to remove the stabilizer bar link assembly.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 2. 1.12 4410 5.

Be cautious of the direction of the bushing and washer when installing.2006.4410 13 Components Bushing M / T Link Washer Nut Tightening torque: 30 ~ 50 Nm 7 ~ 10 mm Washer Bushing NOTICE 1. LH: yellow mark RH: white mark Stabilizer Bar Assembly Bracket Bracket Stabilizer bar Bushing Bushing Link Nut Link Nut CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM . 2. Be cautious of the marks on the front stabilizer bar (LH/RH) when installing.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T .

14 4410 6. 2.5° (the difference between both ends is should be below 0. LOWER ARM Preceding Works: 1. Make an alignment mark on the camber adjusting bolt of lower arm (frame side).3° (the difference between both ends is should be below 0.4° ± 0.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. Wheel Alignment Description Toe-in Camber Caster Specification 2 ± 2 mm [0 ~ 4] -0.5°) 4. Remove the tires.19° ± 0.5°) Front Rear SUSPENSION ACTYON SM .

Loosen the steering gear box by unscrewing the steering gear box mounting bolts (arrows) and remove the camber adjusting bolts.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .4410 15 3. Interference between camber bolt and steering gear box Interference between camber bolt and steering gear box CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .2006.

The lower arm mounting bolts/nuts on the frame (LH/RH) Tightening torque: 180 ~ 190 Nm : Before removing nuts and bolts of lower arm assembly. LH/ RH).2006. NOTE • Always perform the wheel alignment procedures after removing and reinstalling the lower arm assembly. make the alignment marks on the mounting nuts (14 mm. Lower link nut (12 mm) Lower yoke nut (24 mm) Tightening torque 1. LH/RH) and the camber adjusting bolts (14 mm. Lower link nut (110 ~ 130 Nm) 2.16 4410 Removal and Installation 1. 2. Lower shock absorber yoke nut (150 ~ 170 Nm) SUSPENSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Unscrew the lower nut of stabilizer bar link and the lower nut of coil spring/shock absorber yoke.

A/T . 5. Unscrew the lower mounting nut (14 mm) and remove the lower arm from knuckle end bolt with special tool.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T 3. Components CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM . Place a safety jack under the lower arm and unscrew the lower shock absorber yoke bolt. Remove the yoke while raising the lower arm with the safey jack.4410 17 Tightening torque: 50 ~ 70 Nm Knuckle lower mounting nut (14 mm) Tightening torque: 140 ~ 160 Nm 4. Remove the lower arm assembly from the body.2006.

2. 4.03 A/T REAR SUSPENSION (5-LINK TYPE) . It relieves the vibrations and impacts delivered from wheels to vehicle body. Coil Spring: It is installed between the rear axle and body frame. and minimizes the vehicle’s slope when the wheels are moving up and down separately to maintain the vehicle’s stability. Lateral Rod: It compensates the transverse load to the vehicle. 3. 5. lateral rod and stabilizer bar. shock absorber. upper and lower arm.2006. OVERVIEW The rear suspension is to keep the ride comforts and drivability as the front suspension and this vehicle uses 5-link suspension system. It enhances the ride comforts and prevents the fatigue break of the spring. CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .4510 19 1. M / T A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C 1. Shock Absorber: It absorbs the vertical vibration of the vehicle body. Upper/Lower Arm: It compensates the longitudinal load to the vehicle. Stabilizer Bar: It maintains the balance of the vehicle when turning. It consists of coil springs on both sides.

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . SYSTEM LAYOUT Lower Arm (Link) Stabilizer Bar Link Stabilizer Bar Upper Arm (Link) Shock Absorber Lateral Rod Coil Spring Seat (Upper) Axle Housing SUSPENSION ACTYON SM .20 4510 2.

17 mm + 12 mm): 38 Nm A/T .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE Upper arm (22 mm) 165 Nm Stabilizer bar link (upper.17 mm + 12 mm): 38 Nm T/C M / T Stabilizer bar link (lower.17 mm + 14 mm): 38 Nm CLUTCH Stabilizer bar link (lower.4510 21 Lower arm (22 mm) 165 Nm Lateral rod (22 mm) 165 Nm Shock absorber (lower: 7 mm + 10 mm) 90 Nm Shock absorber (upper: 2 mm) 30 ~ 45 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .

2006.22 4510 Location Shock Absorber Assembly Coil Spring Assembly Lateral Rod Assembly SUSPENSION ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

2006.4510 23 Stabilizer Assembly Stabilizer Bar Link Upper/Lower Arm Assembly CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .

2006.24 4510 3.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . TROUBLE DIAGNOSIS Symptom Vehicle rolling Cause Broken stabilizer bar Faulty shock absorber Action Replace Replace Re-tighten Replace Replace Replace Adjust pressure Replace Tighten to specified torque Replace Replace Replace Replace Replace Replace Replace Replace Adjust Re-tighten or replace Replace Abnormal noise Loosened mountings Damaged or worn wheel bearing Damaged shock absorber Damaged tire Poor riding comfort Over inflated tire Faulty shock absorber Loosened wheel nut Bent or broken coil spring Damaged tire Worn bushing Vehicle pulls to right or left Deformed arm assembly Worn bushing Bent or broken coil spring Hard steering Excessive resistance of lower arm ball joint Insufficient tire pressure Faulty power steering Steering instability Vehicle bottoming Worn or loosened lower arm bushing Worn or broken coil spring SUSPENSION ACTYON SM .

4510 25 System Layout Rear suspension assembly Stabilizer bar link A / BAG Coil spring Upper arm CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .2006. REMOVAL AND INSTALLATION .03 A / CON Lateral rod BRAKE ST’NG SP AXLE CLUTCH Stabilizer bar Lower arm T/C Shock absorber M / T A/T 4.

Remove the coil spring using a special tool (Be careful of the installation direction).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1) Unscrew the lateral rod mounting nut (22 mm) on axle. 1. 2. Installation Notice Tightening torque 150 ~ 180 Nm SUSPENSION ACTYON SM .26 4510 Removal of Components Remove the rear suspension components in order. Installation Notice Tightening torque 150 ~200 Nm 2) Unscrew the lateral rod mounting bolt/nut (22 mm) on frame.2006. Remove the lateral rod.

Disconnect the link and the bracket from the stabilizer bar to remove the stabilizer bar.2006. 1) Unscrew the stabilizer bar link mounting nuts (upper/lower) and remove the link. Installation Notice Tightening torque Protrusion of upper bolt 38 Nm 7 ~ 12 mm 27 2) Remove the mounting cap bracket and bushing from the stabilizer bar (LH/RH). Installation Notice Tightening torque 30 ~ 45 Nm CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .4510 3.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .

2006. Installation Notice Tightening torque 80 ~ 100 Nm SUSPENSION ACTYON SM . Remove the shock absorber between the frame and the axle. 1) Remove the upper mounting nut (17 mm) and the shock absorber bolt (6 mm) as shown in the figure.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque Protrusion of upper bolt 30 ~ 45 Nm 6 ~ 9 mm 2) Remove the lower bolt/nut (17 mm).28 4510 4.

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). Unscrew upper arm mounting bolt/nut (22 mm) on axle.4510 5. CHANGED BY EFFECTIVE DATE AFFECTED VIN SUSPENSION ACTYON SM .2006.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . 29 A. Remove the upper arm from frame and axle. B. Unscrew upper arm mounting bolt/nut (22 mm) on frame.

Remove the lower arm from the frame and the axle.2006. 1) Remove the wheel speed sensor cable (1) and the parking cable (2) mounting bolt (12 mm) when removing the lower arm. Installation Notice Tightening torque 150 ~ 180 Nm 3) Unscrew lower arm mounting bolt/nut (22 mm) on axle. Mounting bolt 2) Unscrew lower arm mounting bolt/nut (22 mm) on frame.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .30 4510 6. Installation Notice Tightening torque 150 ~ 180 Nm SUSPENSION ACTYON SM .

.............................................................. 8 Removal and Installation ............ 3................................. 3 System layout ... Overview ......................................... 12 ............... 3 1....4 Inspection and Service ......................... 4..................................POWER STEERING SYSTEM 4610 TABLE OF CONTENTS GENERAL INFORMATION ....................................................... 2.....

7 ATF Dexron II 1.2006.1 CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T GENERAL INFORMATION .3 124 4° 8° 5.2 ~ 95.03 Specifications Description Steering wheel Type Outer diameter Steering gear box Type Gear ratio Steering angle Inner Outer Oil pump Type Maximum pressure Displacement Pulley size Tilt column adjusting angle Up Down Minimum turning radius Oil Specification Capacity ( ) (m) (kgf/cm2) (cm3/rev) (mm) (mm) Specification 4-spoke type 390 Rack and pinion ∞ 36. The operating force of the rack moves the wheels through the tie rod. rack and gear box. Even though the hydraulic pressure cannot be generated. and the movement of the pinion moves the rack through the pinion gear combined to the rack gear. The power steering pump is a vane type and delivers hydraulic pressure to operate the power steering system. the front wheels are steered and the vehicle moves to the desired direction. The pressure relief valve in the pump controls the discharging pressure. However. OVERVIEW When a driver turns the steering wheel. oil reservoir.2° 32. In this case. The integrated rack piston converts the hydraulic pressure to linear movement. The power steering system consists of pump. M / T A / CON ACTYON SM . a driver can steer the vehicle without power assist but it needs very high steering force. there is a certain limitation to increase the steering efficiency only with the mechanical methods.4° Vane type 88.3 11.4610 3 1. The rotary control valve in the rack and pinion gear directs the oil from the power steering pump to one side of the rack piston. A steering system using hydraulic pressure has been introduced to decrease the driver’s steering effort while using the normal gear ratio. the tie rod end and the steering knuckle. the operating force of the steering wheel is conveyed to the pinion.

SYSTEM LAYOUT Steering gear box mounting bracket bolts (14 mm .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.4 4610 2.2EA): 100 ~ 130 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 POWER STEERING SYSTEM ACTYON SM .

03 A / CON A / BAG BRAKE ST’NG SP AXLE T/C M / T A/T .2006.4610 5 Pipe bracket bolt (10 mm) Tightening torque: 9 ~ 14 Nm Pipe bracket bolt (10 mm) Tightening torque: 9 ~ 14 Nm CLUTCH Pipe mounting nut Tightening torque: 20 ~ 26 Nm Gear box mounting bolt CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM .

2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .6 4610 Components Steering wheel Column shaft Tightening torque: 20 ~ 25 Nm Tightening torque: 40 ~ 60 Nm Tightening torque: 20 ~ 25 Nm Tightening torque: 7 ~ 11 Nm Lower shaft Tightening torque: 18 ~ 25 Nm Tightening torque: 35 ~ 45 Nm Tightening torque: 20 ~ 26 Nm Tightening torque: 100 ~ 130 Nm Tightening torque: 100 ~ 130 Nm Steering gear box Tie rod end POWER STEERING SYSTEM ACTYON SM .

2006.4610 7 Steering wheel M / T Column shaft BRAKE Steering gear box CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM .03 A / CON A / BAG ST’NG SP Lower shaft AXLE CLUTCH T/C A/T .

8 4610 3. TROUBLE DIAGNOSIS Symptom Hard steering Cause Lack of lubrication. Abnormal wear or binding of steering ball joint due to intrusion of foreign material Damaged or faulty steering gear Improper preload of steering pinion Faulty steering shaft joint Steering fluid leaks Lack of fluid or air-in system Faulty steering oil pump Damaged or loosened pump drive belt Clogging oil line Damaged wheel or tire Faulty suspension system Action Lubricate or replace Replace gear assembly Adjust Replace Repair or replace Replenish or bleed Replace Adjust or replace Repair or replace Repair or replace Repair or replace Replace Repair or replace Repair or replace Repair or replace Replace gear assembly Replace Retighten Replace Replace gear assembly Repair or replace Repair or replace Replace Retighten Replace Replace Repair or replace Repair or replace Retighten Replace gear assembly Repair Retighten Adjust or replace Retighten Retighten Bleed Replace Steering pulls to one side Damaged steering linkage Damaged wheel or tire Faulty brake system Faulty suspension system Excessive wheel play Worn steering gear Worn or damaged steering ball joint Loosened steering gearbox mounting bolts Poor return of steering wheel Damaged or binding steering ball joint Improper preload of steering pinion Damaged wheel or tire Faulty suspension system Steering wheel shimmy Damaged steering linkage Loosened steering gearbox mounting bolt Damaged or binding steering ball joint Worn or damaged front wheel bearing Damaged wheel or tire Faulty suspension system Abnormal noise from steering system Loosened steering gearbox mounting bolt Faulty steering gear Steering column interference Loosened steering linkage Damaged or loosened oil pump drive belt Loosened oil pump bracket Loosened oil pump mounting bolt Air-in system Faulty oil pump POWER STEERING SYSTEM ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

Steering Effort Check 1.0 kg NOTICE • The difference between both sides should be within 0. Park the vehicle on a paved and flat ground and place the front wheels at straight ahead direction. 2. 2. Steering effort below 3. Steering Angle Check 1. Inner Outer 36° 20' 32° 40' Specified value NOTICE • If the free play is out of the specified value. Specified value 30 mm 9 • If the free play is out of the specified value.000 rpm.6 kg. Install the spring scale on the circumference of the steering wheel and measure the steering effort in both directions. Turn the steering wheel until the tires starts to move and measure the distance on the circumference (free play) of the steering wheel. CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM . Place the front wheel on a turning radius measuring tool. Replace or repair if necessary. check the free play in steering column shaft connection and steering linkage. check and adjust the toe-in. Start the engine and let it run around 1.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH NOTICE T/C M / T A/T . 3. Turn the steering wheel to the its both ends and measure the maximum steering angle.2006.4610 Power Steering Wheel Free Play Check 1. 2. Start the engine and place the wheels at straight ahead direction.

one is checked at normal operating temperature. 7. Turn the steering wheel several times so that the oil temperature reaches to normal operating level (oil temperature: 50 ~ 80°C). 3. 3. 1. the pump is normal. Place the vehicle on a flat ground and start the engine and let it run at idle speed. 10. Apply the parking brake. If the difference between two measurements is below 5 mm and the level is between MAX and MIN level. If not. bleed air from the system. it’s normal. 2.2006. 5. 4. and the other one is checked when it is cooled. 5. Pump relief valve pressure Pump pressure at no load 89 ~ 97 kg/cm2 3 ~ 5 kg/cm2 Oil Level Check The power steering oil level have to be checked by two conditions. replace the power steering pump. Place the steering wheel at straight ahead direction. If the pump pressure is in specified range.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Fully close the valve in pressure gauge and measure the oil pressure (pump relief valve pressure). Measure the oil pressure with the gauge valve fully open (with no load). 2. Connect to reservoir’s supply side Connect to power steering pipe 9. Unscrew the pressure line fitting in power steering pump. If it is over 5 mm. 6. Adjust the oil level between MAX and MIN. Turn the steering wheel several times so that the oil temperature reaches to normal operating level (oil temperature: 50 ~ 80°C). Place the shift lever to neutral position. NOTICE • To prevent internal damage. Fully open the valve in pressure gauge. Install the pressure gauge between the power steering pump and the power steering oil pressure line. 8. POWER STEERING SYSTEM ACTYON SM . Start the engine and let it run at idle speed. Measure the oil level in the power steering oil reservoir. Displacement of oil level Engine off Engine on Checking 1.10 4610 Oil Pump Pressure and Oil Level Check Oil Pump Pressure Check the oil pump pressure to locate any defect in oil pump. do not close the gauge valve over 10 seconds. 4.

4610 Air Bleeding From Power Steering System 11 Checking If Bubble is Found SP Air Bleeding 1. 5. 4. 3. Start the engine and repeat step 2 and step 3 after bleeding. * Checking * 1. 2. Turn the steering wheel to its both ends for 2 to 3 times. NOTICE • Position the gear shift lever to “N (M/T)” or “P (A/T)”. add the specified oil into the reservoir to the specified level. CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM . Lift up the vehicle with the steering wheel in straight ahead direction (No-load to tires). and apply the parking brake before starting the engine.2006. Add the specified oil into reservoir up to the max level. 2.03 A / CON A / BAG BRAKE ST’NG AXLE CLUTCH T/C M / T A/T . If any bubble is not found. Repeat step 3 until any bubble cannot be seen in the reservoir. This process should be performed to check if air still exists in the power steering system.

Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module assembly). 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.2006. • Disconnect the remote control connectors for each component (airbag and horn). Removal and Installation 1. REMOVAL AND INSTALLATION Steering Column Shaft Preceding Work: Disconnect the negative battery cable and place the tires to straight ahead direction.12 4610 4. Alignment mark Tightening torque: 40 ~ 60 Nm POWER STEERING SYSTEM ACTYON SM . 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Disconnect the airbag module connector.

2006.03 A / CON A / BAG BRAKE SP AXLE CLUTCH T/C M / T 3. A/T . Remove the protective panel and lower undercover from the lower panel. Protective cover and lower undercover Column cover ST’NG CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM .4610 13 4. Unscrew three column cover mounting bolts from the steering column shaft and remove the upper/lower column covers. Remove the instrument panel side cover and unscrew the side lock bolt and screws to remove the instrument lower panel (refer to “Body” section).

Disconnect the contact coil and connector from the column shaft and unscrew four contact coil mounting screws to remove the contact coil assembly.14 4610 5. Contact coil mounting screw Connectors Alignment marks POWER STEERING SYSTEM ACTYON SM .2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .

4610 6. 15 Mounting screws Connectors Combination Switch CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Disconnect the connector and unscrew the mounting screws to remove the combination switch.2006.

2006. Mounting Bolts (3 EA) Mounting Bolts (2 EA) Tightening torque: 20 ~ 25 Nm Tightening torque: 20 ~ 25 Nm Lower Shaft Mounting Bolt (1 EA) Tightening torque: 18 ~ 25 Nm POWER STEERING SYSTEM ACTYON SM .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Unscrew the bolts and nuts and remove the steering column shaft assembly while pulling it down.16 4610 7.

2006. Remove the lower shaft mounting nuts on the floor at driver’s side. Remove the lower shaft by pulling it up. • Be cautious of the alignment marks.03 A / CON A / BAG BRAKE ST’NG SP AXLE Tightening torque: 18 ~ 25 Nm Tightening torque: 18 ~ 25 Nm CLUTCH T/C M / T A/T Lower Shaft . Remove the upper and lower lock bolts of lower shaft inside of the vehicle.4610 17 1. Installation Notice Tightening torque 7 ~ 11 Nm 3. NOTICE • Install the lower shaft so that the lock bolt can be inserted into the point without spline. Lower Shaft CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM ACTYON SM . 2.

Unscrew the joint bolts of the lower shaft and remove the lower shaft and gear box. Remove the tie rod from steering knuckle. W 99 44 002 0A (661 589 13 33 00) Ball Joint Puller 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Remove the cotter pin and lock nut to remove the tie rod using a special tool.2006. 2. POWER STEERING SYSTEM ACTYON SM . Remove the tire. Disconnect the negative battery cable. 1.18 4610 Steering Gear Box Preceding Works: 1.

and then tighten the left mounting bolt with the specified tightening torque.4610 3. T/C M / T A / CON ACTYON SM . • Be careful not to spill the oil on the floor and vehicle body. CHANGED BY EFFECTIVE DATE AFFECTED VIN POWER STEERING SYSTEM A / BAG Gear box Cross Member Nut BRAKE SP CLUTCH A/T .03 Tightening torque: 20 ~ 26 Nm AXLE Supply and Return Pipes ST’NG Gear Box Mounting/Gear box Cross Member Gear box Mounting Clamping Bolt Tightening torque: 100 ~ 130 Nm Tightening torque: 100 ~ 130 Nm Tightening torque: 100 ~ 130 Nm NOTICE • Tighten the center bolt/nut first. • Be careful of O-ring from being off the position. Supply and Return Pipes 19 NOTICE • Plug the pipe openings with caps. Disconnect the power steering pipes and remove the steering gearbox mounting bolts.2006.

Disconnect the power steering return hose and remove the high pressure pipe nut. Installation Notice Tightening torque 20 ~ 23 Nm POWER STEERING SYSTEM ACTYON SM .2006. High pressure pipe Return hose 3. Remove the drive belt. 2.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Installation Notice Tightening torque 40 ~ 50 Nm NOTICE • Plug the openings so that power steering fluid doesn't leak out. Unscrew the bracket mounting nuts and remove the power steering gear pump assembly.20 4610 Steering Gear Pump 1.

................................ABS/ESP SYSTEM 4890 / 4891 TABLE OF CONTENTS GENERAL INFORMATION ............ Sensor calibration and forced operation of actuator and sensor value ............ 4... 65 ABS circuit in each operation range ... 5..... 3.......... 13 BAS (brake assist system) ................... 8............................. 10............. 2............................................ 7 General information ...................................... 6............ 18 Components and locations .......... 4. 5 3.................. 28 Hydraulic circuit diagram ........ 3................ 50 16...................................... 62 1........... 29 Hydraulic pressure for each ESP operating range ......................................................... 67 Components description ....... 6 ABS SYSTEM ............................ 30 12..... 17 HDC (hill descent control) .... 48 15... Brake operation and noise ....... 2. Hydraulic circuit of bas (brake assist system) ............. 27 ESP system related precautions ........... 11....................................................................................................................................................... 9................... 25 Input and output diagram ................ 6........... 8 Principle of ESP ...................................................................... ABS/ESP trouble diagnosis ........ 66 Components and location ......... ESP system air bleeding ................ Specifications ............ 7........... 16 ARP (active roll-over protection) .. Components description . 64 Hydraulic circuit of ABS ........ 55 1. 32 13. 2 1.................... 33 14.. 5.................................... 7 Components of ESP . General information .............................. ................... 2 2.... 69 ESP (ELECTRONIC STABILITY PROGRAM) SYSTEM ...... Input and output diagram ................................ 68 Removal and installation .....

ABS/ESP SYSTEM ACTYON SM . Description Without ABS With ABS or ESP Brake type Drum brake Solid disc Rear Disc Solid disc type Rear Disc and Caliper (1 Internal Cylinder) For the parking brake system. Two cylinders are installed in each caliper. GENERAL INFORMATION For the front brake system. the hand operated type parking brake is installed regardless of the models.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.2 4890 GENERAL INFORMATION 1. the ventilated disc type is applied regardless of the ABS/ESP system installation.4 mm) is installed on ABS/ESP equipped vehicle. 10. it differ between ABS/ESP system equipped vehicle and non-ABS/ESP equipped vehicle. The drum type brake is installed on non-ABS equipped vehicle while the solid disc (thickness: approx. Description Without ABS or ESP With ABS or ESP Caliper diameter 43mm 45mm Front Disc Piston Ventilated disc type Front Ventilated Disc and Caliper (2 internal Cylinders) For the rear brake system.

4890 3 Front Disc Brake Rear Disc Brake One internal cylinder CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C Two internal cylinders M / T A/T Sectional Drawing .2006.

There is no separate unit to process the wheel speed sensor signal. This sensor is to signal the vehicle speed to the engine ECU.4 4890 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. The wheel speed sensor is connected to the engine ECU (terminal 36).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 36 Wheel speed sensor Engine ECU CAN HI 54 73 CAN LO Battery (B+) Instrument panel TCU 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 ABS/ESP SYSTEM ACTYON SM . and is connected to other related systems through CAN communication.2006. TCCU. transmission and instrument panel. where its signal is processed.

rear wheels operated Hand Operated φ 254 mm 0.81 mm ST’NG φ 254 mm SP 24 mm AXLE CLUTCH Brake booster T/C Brake master cylinder Type Tandem type (with level sensor) M / T A/T 2./O. of drum Mechanical type.9 mm 10 mm 2 mm 10.0 : 1 150 mm 1 ~ 4 mm ABS/ESP I. SPECIFICATIONS .D.8 DOT4 φ 190 mm Brake fluid Capacity Specification CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . of cylinder Type Booster pressure ratio Type I.D. of caliper cylinder Brake pad thickness Brake pad wear limit Disc plate thickness Disc plate wear limit I.7 ~ 0.4 mm 8./O. of drum WxLxT I.4 mm Vacuum assisted type 9:1 Ventilated disc type 2 x φ 45 mm 10.D.D.D. of caliper cylinder Brake pad thickness Brake pad wear limit Disc plate thickness Disc plate wear limit I.5 mm Parking brake Type Operation type I.D.2006.D. of wheel cylinder I.D. operating stroke Free play NON-ABS 4.4890 5 Description Brake pedal Item Pedal ratio Max. of disc plate 55 x 243 x 5 - φ 42.5 mm 2 mm 26 mm Front brake φ 294 / φ 184 mm Drum type Solid disc type - Rear brake Type I.D. of disc plate 2 x φ 43 mm φ 25.D.03 A / CON φ 299 / φ 220 mm A / BAG BRAKE φ 23.

in both the automatic and manual transmission.6 4890 3. noise is smaller when deeply depressing the brake pedal. “screeching” sound always occurs and. Phenomenon 2. When operating the brake several times. the disc temperature goes up and the micro-rusts come off and the noise goes away. Phenomenon 3. If depressing the brake pedal when the engine is cold. “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. Depending on the driving conditions. when. Due to this moisture. Distinguish between the information given below and the actual problems and then. adhesion and slip repeatedly take place between the brake disk and the friction material. When operating the brake system at low speed and low pressure. the brake system poorly operates or noise (abnormal sound) occurs due to the partial contact. after driving for a while. or slightly depressing the brake pedal. noise gets louder when slightly depressing the brake pedal and oppositely. noise may sound due to the friction of micro-rusts. through the following process. When starting the engine under this condition. called “morning effect” in professional terms.2006. for some time after the brake disk/pad replacement. This is simply a physical phenomenon. ABS/ESP SYSTEM ACTYON SM . The bed-in is a state that the brake system normally works and gives no noise out. after about 300 km city driving. Therefore. the dew condensation phenomenon sets moisture on the brake disc as the window frost forms. It is also a physical phenomenon and has no relation with the brake performance. This usually occurs in the morning. the iron within the brake disc and pad oxidizes. This usually occurs when the bed-in is not made between the disc and the pad’s friction material. inspect the vehicle and take appropriate measures. the sound disappears. BRAKE OPERATION AND NOISE This section describes the noise phenomena occured possibly in the brake system operation. Noise Phenomena and Causes Phenomenon 1. slightly releasing the brake pedal in the neutral gear at downhill roads. forming undetectable micro-rusts on the disc surface. Slip or screech after the brake pad replacement. and this makes the braking power inconstant. It frequently occurs at the low braking power and low speed. This is the noise “Creep groan” that occurs when. the contact area of the pad friction material is enlarged and the disk is in complete contact with the pad’s friction material. and gives out the brake noise. and does not imply any problems with the brake system.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . instantly increasing or decreasing. When the temperature goes down.

ARP (Active Rollover Protection) 8. EBD (Electronic Brake-Force Distribution) 3. HBA (Hydraulic Brake Assist System) 7. HDC (Hill Descent Control) CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . ABS (Anti-Lock Brake System) 2. AYC (Active Yaw Control. ABD (Automatic Braking Differential) 4.4892 7 1. The HDC (Hill Descent Control) is newly introduced function that helps drivers maintain their speed automatically by switch operation when driving slowly on steep hills (over 10°).2006. the vehicle position control depending on the driving conditions and the road conditions.03 A/T ESP (Electronic Stability Program) SYSTEM . and 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. ASR (Acceleration Slip Regulation) 5. the HBA (Hydraulic Brake Assist System) that improves the braking power in an emergency. 1. GENERAL INFORMATION The ESP system consists of basic ABS functions. ESP HECU HDC Switch / Indicator M / T A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C Functions applied on ESP system are as follows. Understeer Oversteer control) 6.

Detects lateral acceleration. longitudinal acceleration and yaw rate. ABS/ESP SYSTEM ACTYON SM . COMPONENTS OF ESP ESP OFF Switch HDC Switch ESP is deactivated by pressing the switch (ESP warning lamp comes on) ESP is activated by pressing the switch again (ESP warning lamp goes off) HDC is activated by pressing the switch (Green HDC indicator comes on) HDC is deactivated by pressing the switch again (Green HDC indicator goes off) Steering Angle Sensor (Steering Wheel) Sensor cluster Detects the angle of the steering wheel and sends it to HECU.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.8 4892 2.

2006.4892 9 HECU Receives the signals from wheel speed sensor. sensor cluster and pressure sensor and perform the vehicle stability control function.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . Rear Wheel Speed Sensor (LH/RH) Wheel Speed Sensor For 4WD CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . steering wheel angle sensor.

10 4892 Cautions When Removing the Front Wheel Speed Sensor The locking hub system (Part time 4WD) utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator. the front wheel end system (including disc) should be removed before removing the front wheel speed sensor.2006. Thus.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . It is installed inside the backing plate to be protected from heat and foreign materials. Therefore. Front Wheel Speed Sensor Rear Wheel Speed Sensor Wheel speed sensor Wheel Speed Sensor Wheel speed sensor The wheel end should be removed before removing the wheel speed sensor. ABS/ESP SYSTEM ACTYON SM . the wheel speed sensor is installed on the front wheel end area.

03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH M / T A/T The rubber O-ring in IWE (Integrated Wheel End) should be replaced with new one when the front wheel end has been removed. If the rubber seal ring or the round spring is damaged. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .4892 11 The hub actuator of the IWE system should be installed with the same angle with the drive shaft so that the inner rubber seal ring cannot be stuck. . The rubber O-ring prevents moisture and foreign materials from entering the IWE system. the actuator assembly should be replaced. Rubber O-ring T/C Rubber seal ring (Internal steel spring included) Please refer to the part time transfer case section for more specific information. the round steel spring is installed on the rubber seal ring.2006. Also.

Sensor cluster (integrated yaw rate sensor and lateral sensor) and longitudinal sensor installed in IP. longitudinal and lateral sensors. some devices will be added to the ABS system including the HECU (Hydraulic & Electronic Control Unit) and wheel speed sensor. used for sensing G value for HDC (Hill Descent Control).425 ~ 1.425 mm 4WD: 0.7 mm Rear airgap: 0.175mm Steering Wheel Angle Sensor Sensor Cluster N/A Maximum angular velocity: 1500°/sec Working voltage: 9 ~ 16 V Integrated yaw rate sensor. Two pressure sensors installed on the master cylinder 2.2006.425 ~ 1. The devices are as follows: 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 3. SWAS (Steering Wheel Angle Sensor) installed in the steering column. Analog Output In steering wheel N/A Under the center A/C panel of the instrument panel Pressure Sensor N/A Under master cylinder ABS/ESP SYSTEM ACTYON SM .1 ~ 0. Also. Comparison with ABS System Name HECU (Hydraulic & Electronic Control Unit) Wheel Speed Sensor Specifications ABS CPU: PEC 1 (32bit) Memory: 512 KB EEP ROM: 1KB Active Type ESP CPU: PEC 1 (32bit) Memory: 512 KB EEP ROM: 1KB Active Type Location Side of brake booster Mounted in each wheel (×4EA) Front airgap 2WD: 0.12 4892 When the ESP system is added to the ABS system.

vehicles are designed to have under steering. PRINCIPLE OF ESP . When compared with under steering vehicles.03 A / CON A / BAG Braking force BRAKE Braked wheel ST’NG SP AXLE CLUTCH T/C M / T A/T 3. and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the brake. The yaw rate sensor. lateral sensor and longitudinal sensor in the sensor cluster and the steering angle sensor under the steering column detect the spin present at any wheels during over-steering. under-steering or cornering. Under Steering Desired course Desired course With ESP Without ESP Over Steering With ESP Braked wheel Compensating yaw moment Without ESP Compensating yaw moment Braking force Understeering Understeering is when the steering wheel is steered to a certain angle during driving and the front tires slip toward the reverse direction of the desired direction.2006. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .4892 13 Understeer & Oversteer Control ESP (Electronic Stability Program) recognizes critical driving conditions. 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). Oversteering Oversteering is when the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction. The vehicle can return back to inside of cornering line when the steering wheel is steered toward the inside even when the vehicle front is slipped outward. such as panic reactions in dangerous situations. 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 controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed 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. Generally. As the centrifugal force increases.

ESP intervention never takes place during backup. Then the ESP system applies the brake at the front outer wheel to compensate the yaw moment value. In order to compensate to this problem. When various systems operate simultaneously under a certain situation. The order may be changed depending on the vehicle driving situations and driving conditions. the ESP system sets the priority among systems.14 4892 ESP Controls During Under Steering The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeering with the yaw rate sensor and the lateral sensor. The system operates in the order of TCS (ASR or ABD). ESP and ABS.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions. the vehicle does not lose its driving direction and the driver can steer the vehicle as driver intends. the ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. In this way. The following figure shows the operating range according to driving conditions. Operating range Turning Turning ABS/ESP SYSTEM ACTYON SM . the vehicle does not lose its driving direction and the driver can steer the vehicle as he or she intends. And when yaw rate sensor detects the rate exceeding 4 degree/seconds. ESP Control As the single-track vehicle model used for the calculations is only valid for a vehicle moving forward. when the brakes are applied during cornering at the speed of 100 km/h. In this way. Then the ESP system applies the brake at the rear inner wheel to compensate the yaw moment value.2006. ESP Controls During Oversteering The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs towards the vehicle cornering direction during oversteering with the yaw rate sensor and the lateral sensor. the ABS system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. For example. there may be vehicle control problems due to internal malfunction of a system or simultaneous operations.

2006. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating.4892 15 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.03 A / CON A / BAG BRAKE SP AXLE CLUTCH e Engin l o contr T/C M / T A/T Vehicle Control During Cornering . Operations Understeering Control Oversteering Control ESP auto brake Only ESP operating No braking by driver ESP auto brake Non-ESP auto brake ESP + Conventional brake ESP auto brake Driver foot brake operation ST’NG e Engin l ontro c (ABS not operating) ESP + ABS brake The slip occurs under ESP operation ABS operation + TCS (Engine control) The slip occurs under ESP operation TCS operation En c o gin nt e ro l ESP CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .

The BAS System increases the braking force under urgent situations to enhance the inputted braking force from the driver. Pressure: over 20 bar 2. When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver. which leads to dangerously long braking distance. If the drive depresses the brake pedal slowly.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006. In this case. the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels. Pressure sensor HECU Hydraulic line Operating conditions: 1. Pressure changes: over 1500 bar/sec 3. elderly or physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required under emergency. There are 2 pressure sensors under the master cylinder. An inexperienced. When the ESP ECU system determines that emergency braking is present. the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals. Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary. the pressure change is not high.16 4892 4. ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster. the pump operates. only the conventional brake system with booster is activated. 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. Experienced drivers Deceleration -m/s 2 Inexperienced drivers Elderly and physically weak drivers Time (s) The brake pressure value and the changed value of the pressure sensor are the conditions in which the BAS system operates. but not with sufficient pressure. BAS (BRAKE ASSIST SYSTEM) BAS (Brake Assist System) system helps in an emergency braking situation when the driver applies the brake fast. Vehicle speed: over 7 Km/h ABS/ESP SYSTEM ACTYON SM .

vehicle safety (rollover prevention) takes the first priority and thus.4892 17 One must note that the ARP system. 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. steering angle sensor and lateral sensor.03 A / CON BRAKE Steering wheel angle sensor Input data signal processing Yaw rate torque value calculation Comparative data processing Actuator operation ST’NG The vehicle driving condition is controlled by the internally programmed logic according to the input signals from wheel speed sensor. ARP (ACTIVE ROLL-OVER PROTECTION) . by controlling brakes and the engine. A/T 5. the ARP function is also deactivated when the ESP function is not operatable due to system malfunction). SP Vehicle speed Radius AXLE CLUTCH Lateral sensor (inside sensor cluster) T/C M / T The ARP (Active Roll-over Protection) system is a safety assistant device that minimizes. stronger engine control is in effect. is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power. the physical tendency of the vehicle rollover during sharp lane changes or U-turns. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . Consequently. the vehicle speed decreases rapidly. • The ARP function is activated when the vehicle is subject to turning over due to sharp cornering even when the ESP function is turned off (however. Brake force Lateral sensor ESP AREA Driving conditions A / BAG Longitudinal sensor Wheel speed sensor Yaw rate value Other reference values ARP AREA Yaw rate value Input data signal processing Assess whether vehicle condition meets ARP operation condition Adjust with ARP function NOTICE • During the ARP operation. For the system.2006. just as general assistant devices including the ABS. so the driver must take caution for the vehicle may drift away from the lane. software is added to the existing ESP system and no additional device or switch is needed.

it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10%. However. HDC Switch HDC Indicator (Instrument Panel) Sensor Cluster (G Sensor) When you press the HDC switch.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . HDC (HILL DESCENT CONTROL) System Overview The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about 7 km/h by 0. HDC Red letters HDC Green letters ABS/ESP SYSTEM ACTYON SM . if the G sensor detects a downhill steepness exceeding 10%.5 second of interval. the HDC automatically terminates the operation. When the vehicle speed reaches below 7 km/h (refer to the information below). the ESP’s HDC function operates. When this occurs. it transmits the HDC operation signal to the ESP HECU. When the HDC switch is in operation. and the HDC may operate. and when the HDC operates.1G. When the G sensor within the sensor cluster detects a slope level exceeding 10%.2006. When you see a steep downhill ahead. the green HDC indictor flashes at 0. the green HDC indicator flashes along with a loud operation sound. press the HDC switch and the green HDC indicator comes on. on steep roads (slope level exceeding 10%) through a separately installed switch operation. The G Sensor within the sensor cluster detects the steepness of driving roads.18 4892 6. NOTICE • The G sensor in sensor cluster measures the actual road steepness. the green HDC indicator comes on.

that is because the engine may turn off during the HDC operation process. Gearshift lever position (Forward/Reverse) and and Automatic transmission: operates in any position except for P (parking) or N (neutral) positions. When HDC switch is turned ON 2.) Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission). and cannot solely detect the 1st gear position.. termination slope level: when it reaches 8%) 2H/4H mode: vehicle speed below 50 km/h (operation slope level: 8%. 4. When not depressing the accelerator pedal or brake pedal. NOTICE • The vehicles with manual transmission do not have a separate device or switch that detects the 1st gear. but is converted to the stand-by mode. though the HDC also operates in 2nd gear position. It only detects the forward/reverse driving direction of the vehicle through backup lamp switch and neutral switch. and and ST’NG • The vehicle speed given in step (4) varies according to the vehicle driving mode. You may face a very dangerous situation if the engine turns off at a steep hill. 1) Speed available in HDC mode (slope) Forward driving Reverse driving 2H/4H mode: vehicle speed below 50 km/h (operation slope level: 10%.5 km/h (manual transmission) CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .2006. 3. etc. 8.4892 19 HDC (Hill Descent Control) System Operating Conditions 1.03 A / CON A / BAG BRAKE NOTE SP AXLE CLUTCH T/C Manual transmission: operates in the 1st gear or reverse gear position (does not operate in neutral position). The reason why. For manual transmission equipped vehicle. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode). and the speed ranges by the vehicle driving mode and condition are as follows. M / T A/T . When the vehicle speed increases again as a result of the increase of the road steepness. HDC system should operated only in 1st gear. termination slope level: when it reaches 5%) 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. • The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. the HDC goes into operation.

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. the HDC operates until the vehicle reaches the speed value given in step (4). drivers can control the vehicle speed to a desired level by depressing and releasing the pedal. When releasing the pedal. When the slope level exceeds 10%. 10% of slope level indicates that the heigh is 1 m when the transverse length is 10 m. l 1G = 9. In this case. NOTE ex) tan X 100 = 1 100 X 100 = 10 (%) For example.8 m/s2: Acceleration ABS/ESP SYSTEM ACTYON SM . When the slope level exceeds 20% during the HDC operation When depressing the accelerator pedal. HDC continues its operation and the braking power is increased.2006. Therefore. but this is a normal condition due to HDC operation. HDC starts its operation again. HDC system is changed to stand-by mode. HDC system is changed to stand-by mode. When the slope level is between 10% and 20% during the HDC operation When depressing the accelerator pedal or brake pedal. HDC operation is overridden. When depressing the brake pedal. Slope level exceeds 10%.20 4892 5.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . HECU sounds an abnormal noise and brake pedal may be very rigid. 6. If the ESP function is in operation.

HDC operation is overridden.g. If the ESP function is in operation. 5. When the vehicle speed is out of the specified values (under 7 km/h). When the internal temperature of HDC system goes over 450°C due to long downhill driving on a steep hill with HDC operated.4892 21 1. SP AXLE CLUTCH M / T A/T HDC (Hill Descent Control) System Non-Operation Conditions . the HDC warning lamp stays on. When the slope level is below 10% CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . vehicle position control. or or The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. 6. The HDC can be operated in this range even where the HDC warning lamp blinks. Gearshift lever has passed neutral (N) position. or • The red HDC warning lamp blinks when the internal temperature goes over 350°C. BAS. When the ESP related functions. or or NOTICE • Vehicle with manual transmission: Sensing at the neutral switch • Vehicle with automatic transmission: Sensing at the selector lever unit T/C 3. ARP is activated during HDC operation. 4. When it reaches 450°C. but a programmed logic inside the HECU predicts the temperature based on the operating times and conditions of HDC. When HDC switch is turned OFF 2.2006. e.03 A / CON A / BAG BRAKE NOTICE ST’NG There is no specific temperature sensor in the system.

RPM 2. 2. Engine torque 3. (HDC CONTROLLER) HDC indicator and warning lamp (instrument panel) Sensor cluster Longitudinal acceleration sensor HDC stand-by.22 4892 Input/Output Signals for HDC Operation The HDC controller operates its function in the HECU inside the ESP unit and receives the following signals to perform the hill descent control function. If the slope level exceeds 20%. ABS/ESP SYSTEM ACTYON SM . When depressing brake pedal during HDC operation. HDC switch Modulator pump Gear position sensing Manual transmission: Neutral position → Neutral switch (N) Reverse position → Backup lamp switch Automatic transmission: Selector lever E S P LDF Valve and MCI valve HECU (Valve modulator) Engine condition monitoring 1. HDC function is still activated and the brake pressure is added. Gas pedal module (monitoring gas pedal depression) When depressing accelerator pedal during HDC operation. HDC is deactivated. H E C U Stop lamp Brake pedal switch When the HDC operates. If the slope level is between 10% and 20.2006. operation and other warnings are sent from HECU to the instrument panel through the CAN communication line and the green or red indicator flickers or comes on on the instrument panel. it is deactivated (regardless of the slope level). HECU turns on the stop lamp by supplying 12V power (separate relay).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 1.

HDC is operating with operating sound. the HDC warning lamp comes on when: • Initial ignition ON • HDC system error occurs • Brake system overheat CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . The HDC switch is a push & self return type switch – when you press it once. this signifies operation mode after the engine starts.4892 23 This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/ OFF) and operation conditions.5 seconds of interval) OFF The HDC switch is turned ON. Even when HDC switch is ON. but a programmed logic inside the HECU predicts the temperature based on the operating numbers and conditions of HDC (HDC cannot be operated). it stops the operation. As given in the table above.8 seconds) CLUTCH HDC HDC T/C M / T A/T Operation of HDC Indicator Controller . System overheat High brake system temperature (over 350°C) HDC stand-by mode HDC is operating OFF Blinking Alternate blinking of green and red lamp (0. Blinking (0. green (function lamp) and red (warning lamp). NOTICE Basically. and the operating requirements are met.) OFF ON (goes off after 1. HDC Indicator HDC Operation Mode Green HDC Warning Lamp Red Not available HDC switch OFF HDC system error OFF OFF ON OFF ON OFF Stand-by HDC switch ON In operation HDC system is operating. HDC operation stops automatically. The HDC indicator on the instrument panel has two modes.03 A / CON Too high brake system temperature (over 450°C) A / BAG BRAKE ST’NG The HDC switch is turned ON.5 seconds of interval) OFF ON There is no specific temperature sensor in the system. if the ignition is OFF. but HDC system is in stand-by mode because the operating requirements are not met.2006. SP AXLE Initial ignition ON (From hence. it starts to operate and when you press it again. the brake system’s basic functions can work even when there are problems with the HDC system.

when a driver make sharp turns or drive on rough roads. because. but this is a normal condition during the HDC operation. • Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems. the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle. The noise during the HDC operation is very different from that during the ABS/ESP operation. because they may feel unfamiliar with its function and operation process.2006.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .24 4892 Cautions When Using HDC System Customers must first acquaint themselves with the HDC operation related information. e. do not use it on public road. This noise may be irritating and accompany some vibration. Below is the summary of precautions to remember in HDC operation. As mentioned previously. the HDC may suddenly operate for these sudden shocks influencing the G sensor values.g. it attempts to control the physical properties of the vehicle weight with the braking power. • During the HDC operation. Thus. NOTICE • The HDC system is intended for use only on off-roads with a slope level exceeding 10%. When such occurs. a loud noise and the vehicle vibration may occur from the HECU and the brake system. on steep hills. ABS/ESP SYSTEM ACTYON SM . • Driver must turn the HDC switch to OFF position when driving on public and level roads. operation conditions and non-operation conditions.

the HDC switch and the HDC indicator has been added to the system as the HDC system has been applied.4892 25 There are no major changes in the ESP system of ACTYON comparing to the conventional ESP system.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T 7. COMPONENTS AND LOCATIONS . However.2006. Master cylinder pressure sensor Active Wheel Speed Sensor Valve body Motor pump CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .

03 .26 4892 Comparison with ABS System No 1 2 3 4 5 HECU Pressure sensor Wheel speed sensor Sensor cluster Steering wheel angle sensor Name ESP Component 0 0 0 0 0 ABS Components 0 N/A 0 N/A N/A Remark ESP system contains ESP OFF switch and HDC switch.2006. ESP OFF Switch HDC Indicator ABS / ESP Indicator Steering Wheel Angle Sensor HDC Switch Sensor Cluster (Yaw Rate + Lateral Sensor + Longitudinal Sensor) CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .

2006. ECU) Battery+ (voltage to pump) 32 15 CAN LO M / T ACTYON SM .4892 27 Input/Output of ESP System Battery+ (voltage to hydraulic valve. 8 This line is used to send the error code to diagnostic connector when an ABS related component is defective. INPUT AND OUTPUT DIAGRAM . 22 23 21 IG1 ST1 SWAS (Steering wheel angle sensor) ST2 STN Ground 7 28 30 3 5 ABS/ESP SYSTEM 47 Ground (Pump) 16 Ground (Valve) CHANGED BY EFFECTIVE DATE AFFECTED VIN A/T 8. T/C A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH IG1 4 Brake switch 41 41 Stop lamp power supply Supplying power to brake lamp when operating HDC.03 1 11 CAN HI Sending and receiving the information such as speed signal of ABS HECU from/to ECUs through CAN communication. ESP switch 40 Wheel speed sensor (FL) Signal Ground 45 46 34 33 HDC relay power supply Signal Wheel speed sensor (FR) Ground Signal Wheel speed sensor (RL) Ground E S P H E C U 9 HDC switch HDC operation switch Power source CAN-H CAN-L Ground Sensor cluster 36 37 6 29 25 31 Signal Wheel speed sensor (RR) Ground 43 42 Power source Pressure sensor 1 Signal Ground Power source Pressure sensor 2 Signal Ground 18 20 19 2 Diagnostic connector pin No.

The ESP system is only a supplementary device for comfortable driving. 5. the feeling can be different depending on vehicle driving conditions. Feeling when ESP is working When the ESP system activates.28 4892 9. Noise and vibration that driver feels when ESP system is operating The ESP system may transfer noise and vibration to the driver due to the pressure changes caused by the motor and valve operations in a very short period of time.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . And. so the driver must take caution for the vehicle may drift away from the lane. the vehicle speed decreases rapidly. a loud noise and the vehicle vibration may occur from the HECU and the brake system. Driver must turn the HDC switch to OFF position when driving on public and level roads. the ESP warning lamp on the instrument panel flashes and beep comes on every 0. stronger engine control is in effect.1 seconds. 4. Thus. but this is a normal condition during the HDC operation. 2. The HDC system is intended for use only on off-roads with a slope level exceeding 10%. ARP Operation During the ARP operation. the HDC may suddenly operate for these sudden shocks influencing the G sensor values. 3. when a driver make sharp turns or drive on rough roads. During the HDC operation. The warning lamp flashes and warning beep sounds when the ESP is operating When the ESP operates during vehicle movement. keep in mind that the output and vehicle speed could be decreased without rpm increase due to the ASR function that controls the engine power. 8. do not use it on public road. Consequently. you will feel differently when the ESP system is activated during the ABS is operating with the brakes applied and when the brakes are not applied on a curve. Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems. 7. ESP SYSTEM RELATED PRECAUTIONS 1. When the vehicle exceeds its physical limits. the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle. vehicle safety (rollover prevention) takes the first priority and thus. it cannot be controlled. If the ESP system operates when the brake is applied. Keep on the safe driving. the brake pressure will be increased on the corresponding wheel which already has braking pressure for the ESP controls. 6. When such occurs. For example. ABS/ESP SYSTEM ACTYON SM .2006. Do not rely on the system. As mentioned previously.

if the vehicle is equipped with ESP. For details. whereas the normally-closed shuttle valve and the outlet valve are closed. refer to “Hydraulic Pressure for each ESP Operating Range”. When the ESP system is operating. the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit. decrease or unchanged conditions.) When compared to the vehicle equipped with ABS only.2006. the normally-open separation valve will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve. Also. it will be operated with 3-channel method.03 A / CON A / BAG FR outlet valve (NC) FL outlet valve (NC) RR outlet valve (NC) RL outlet valve (NC) BRAKE ST’NG FR inlet valve (NO) FL inlet valve (NO) RR inlet valve (NO) RL inlet valve (NO) SP AXLE CLUTCH T/C M / T A/T 10.4892 29 Pressure sensor Damper (primary circuit) Separation valve (NO) Damping chamber Shuttle valve Low pressure accumulator Pump Shuttle valve Damper (secondary circuit) Separation valve (NO) Wheel (FR) Wheel (FL) Wheel (RR) Wheel (RL) If the vehicle is equipped with ABS. HYDRAULIC CIRCUIT DIAGRAM . the normally-open separation valve and the inlet valve are open. Then. the inlet and outlet valves will be closed or open depending on the braking pressure increase. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . (When controlling ABS system only. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes. 4 wheels will be controlled independently with 4-channel method. the braking force at each wheel will be controlled with 3-channel 4-sensor method.

30 4892 11. the brake fluid will be sent to each wheel via the separation valve and inlet valve. The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied. ESP Hydraulic unit (decreased pressure) 2 Low pressure chamber Shuttle valve Separation valve Pump Inlet valve Outlet valve The pressure decreases just before the wheel speed drops and the wheels are locked. HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE ESP Hydraulic unit in idling and normal braking position 1 Low pressure chamber Shuttle valve Separation valve Pump Inlet valve Outlet valve In this position. The shuttle valve and the separation valve do not operate while decompression. ABS/ESP SYSTEM ACTYON SM . the electrically operated shuttle valve and the outlet valve are closed.2006. Then the pump operates to allow fast oil drainage. the separation valve and the inlet valve are open (normal open).03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . When the brake is applied under these conditions.

During ESP operation.03 A / CON Low pressure chamber Shuttle valve A / BAG BRAKE ST’NG The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. the pressure will be increased continuously until just before the corresponding wheel gets locked. SP AXLE Inlet valve Outlet valve CLUTCH Separation valve T/C Low pressure chamber Shuttle valve M / T A/T . the pump is operated. the hydraulic pressure at the wheels will not be lost or supplied any more.2006.4892 31 ESP unit circuit (when the pressure is maintained) 3 Pump ESP unit circuit (when the pressure is increased) 4 Separation valve Pump Inlet valve Outlet valve The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then. When ESP operates while the ABS is operating. By closing the valves. the separation valve closes and only the shuttle valve at the pump opens. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . the pressure in the pump increases until just before the corresponding wheel gets locked. HYDRAULIC CIRCUIT OF BAS (BRAKE ASSIST SYSTEM) Low pressure chamber Shuttle valve Separation valve Pump Inlet valve Outlet valve Inlet valve Outlet valve Rear wheel Front wheel The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. Then. The motor still keeps rotating and the outlet valve and the separation valve will stay closed. When HECU recognizes that it is an emergency and it is required for hard braking. ABS/ESP SYSTEM ACTYON SM . depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing.2006.32 4892 12. When the wheel starts to lock. it operates the pump immediately to apply the brake pressure at the wheels. the BAS function cancels and switches to ABS operation.

Other components b: plunger. Rear RH (only applicable to ESP) Front wheel RH Front wheel LH Rear RH and LH (Rear LH when ESP is applied) Secondary cylinder ESP ECU Primary cylinder ECU connector has 47 pins and the number of valves in valve body is 12 (with ESP) or 6 (only with ABS). solenoid valve and ECU including solenoid valve. c: cam bushing HECU internal valve Pump Motor Valve Body ABS/ESP SYSTEM ACTYON SM . COMPONENTS DESCRIPTION .2006. HECU installed in a vehicle HECU consists of motor pump. Comparison of ESP HECU and ABS/EBD HECU ABS HECU ESP HECU 3.4892 33 HECU (Hydraulic & Electronic Control Unit) 1.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T 13. 2.

Disconnect the negative battery terminal. 3. Disconnect the front and rear wheel brake pipes. 5. Remove any foreign material on the openings of hydraulic pipe and seal it with tape. Tightening torque HECU mounting nut 4 ~ 8 Nm NOTICE • Do not disassemble the removed HECU. ABS/ESP SYSTEM ACTYON SM . Unscrew two mounting nuts and remove the HECU. 2.2006. Disconnect the primary and secondary pipes between HECU and master cylinder. Tightening torque Master cylinder to HECU 13 ~ 20 Nm 4.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .34 4892 Removal and Installation 1. Tightening torque HECU to each hydraulic line 13 ~ 20 Nm NOTICE • Be careful not to damage the HECU pipes and nut threads when reinstalling. Disconnect the ESP unit connector.

refer to "Sensor calibration". When installing HECU to another vehicle for test or any other reason. 7.4892 35 6. Install in the reverse order of removal. NOTICE • Perform the variant coding and sensor cluster calibration if HECU or sensor cluster is replaced. Perform the sensor cluster calibration using "SCAN-100". ST’NG CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . Refer to "Bleeding Using SCAN-100" section. Removal and Installation of Wheel Speed Sensor Refer to "Wheel Speed Sensor in ABS system". For the calibration procedure. NOTICE • No coding is required when installing new HECU to the vehicle since it has automatic coding function. it is automatically coded with the vehicle's data. 9. T/C M / T A/T .2006.03 A / CON A / BAG BRAKE SP AXLE CLUTCH 8. Replenish with brake fluid and bleed air after installation. Perform the variant coding.

Primary pressure sensor 3.75 V (brake applied)) 0 ~ 170 bar ABS/ESP SYSTEM ACTYON SM .75 ~ 5. Second pressure sensor 4.75 V (This is linearly changed from 0.2006. Master cylinder 2. Inside of pressure sensor 7.25 ~ 4.25 V 0.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Connector Specifications Supplying voltage Output voltage Operating pressure range 4. Hydraulic pipe in primary circuit 5.36 4892 Pressure Sensor Location 2 1 3 1. Hydraulic pipe in secondary circuit 6.5 V (brake not applied) to 4.

03 BRAKE ST’NG SP The voltage value is approx. CLUTCH T/C A/T .5 ~ 4.5 V (brake not applied) to 4. AXLE Two sensors installed in the lower side of the master cylinder consist of two ceramic discs. Vehicle speed: over 7 km/h Ground Power 2 1 3 Signal output 18 < Primary pressure sensor > Ground Power 2 1 3 Signal output 21 23 22 < Secondary pressure sensor > < ESP unit > CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . The voltage value is linearly changed from 0.75 V (brake applied). BAS operating conditions: 1. When brake pressure is applied from the master cylinder.2006. Pressure changes: over 1500 bar/sec 3. the ceramic disk moves towards the fixed ceramic disk and the electric charge volume changes accordingly. 1 is its ground and pin no. Pressure: 20 bar 2.5 V when the brake is not operated. Pressure Sensor Circuit The ESP unit supplies around 5V power to two pressure sensors installed on the ESP system when the ignition switch is ON. 3 outputs the sensor output voltage to the ESP unit.75V.5V and.4892 37 Description Master cylinder Master cylinder M / T A / CON A / BAG 19 20 Brake not applied Brake pressure The pressure value of the brake and the change value of the pressure sensor are operating conditions for BAS operation. Due to this change the capacitance changes and it is measured in the voltage value. The distance (S) between the two ceramic discs with different polarity changes as the pressure changes of the brake. this voltage is about 0. during the brake operation it increases linearly to about 0. 0. one disc is stationary and the other is moved according to the brake pressure. Each sensor’s pin no. When the brake is not in operation.

Install in the reverse order of removal. 4.38 4892 Removal and Installation 1. Remove the primary and secondary pressure sensors. Remove the fuel filter bracket. Remove the connector of the pressure sensor.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Bleed the brake system after installation. ABS/ESP SYSTEM ACTYON SM . 5. Place an empty container under the pressure sensors to collect the oil. 7.2006. 2. When installing Tightening torque 33 ~ 37 Nm 6. Disconnect the battery negative terminal. Remove the fuel filter bracket to remove the pressure sensor. 3.

7 ~ +1. using the electronic signal. the longitudinal acceleration sensor detects the slope level of the driving road and provides important information for the HDC operation. During the vehicle cornering. Sensor cluster Supplying voltage Output voltage during stopping Yaw rate sensor operating range Lateral acceleration sensor operating range Longitudinal acceleration sensor operating range Approx. There is an additional electronic circuit to send and receive the internal data to/from the CAN communication.7m/s2 ) Sensor Cluster Operation and Principles The lateral sensor.7m/s2 ) -1.4892 39 Location M / T 1. Especially.25V) Approx.5V (Ignition switch “ON”) -75°/S ~ +75°/S -1.7g (16. 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.7g (16. 2. longitudinal sensor and the yaw rate sensor are integrated into the sensor cluster. Center fascia panel 2.7 ~ +1. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . 5V (4.03 A / CON Specification (Sensor cluster: Yaw rate sensor + Lateral acceleration sensor + Longitudinal acceleration sensor) A / BAG BRAKE ST’NG SP AXLE Installed sensor cluster CLUTCH T/C A/T Sensor Cluster .75 ~ 5.2006.

0. Therefore.8 V. The ESP control operates when a divergence occurs between the vehicle yawing and the steering angle (i. the sensor cluster produces an output signal of 0 V (fail safe function in the yaw rate sensor). 5 V with ignition key “ON” and the output range through CAN line is approx.2 ~ 4. A/D converter Power supply circuit Micro controller CAN module Yaw rate sensor Lateral sensor Longitudinal sensor < Internal electric circuit of sensor cluster > ABS/ESP SYSTEM ACTYON SM . vibration occurs at the top and bottom as shown in the figure. Pressure Sensor Circuit 1 Power 4 2 5 3 6 CAN -L 25 CAN -H Ground Power 29 31 6 <Sensor Cluster> <ESP Unit> The ESP sensor cluster can be considered as one module. The supplied voltage from ESP unit is approx. it detects the yawing of the vehicle.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . 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.2006. This vibration is transmitted through the CAN communication line by the form of voltage value. When a sensor is faulty. In other words.e. The measured value by lateral/longitudinal and yaw rate sensors is transmitted to ESP unit via two CAN lines. the ESP operates when the driver’s intended position differs from the vehicle position). the occurrence of vehicle yawing does not imply the ESP operation.40 4892 The Microscopic tuning forks in the yaw rate sensor measures the acceleration on the vertical axis of the vehicle.

Unscrew two A/C controller mounting screws and remove the A/C controller. 41 2. 1. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . Remove the mounting screw and disconnect the connectors to remove the AV head unit assembly.03 A / CON A / BAG BRAKE ST’NG AXLE CLUTCH T/C M / T A/T . Separate the center fascia panel and disconnect the connector to remove the center fascia panel.4892 Removal and Installation of Sensor Cluster Preceding Work: Disconnect the negative battery cable. NOTE • AV head unit may have different connectors according to the specifications.2006. SP Remove two screws 3.

6. Therefore. For the calibration. Unscrew the cluster mounting bolts at both sides and disconnect the connector.42 4892 4. Install in the reverse order of removal. be careful not to impact on them when removing and installing.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . When installing Tightening torque 10 Nm 5. NOTICE • The installing direction and location are very important when installing the sensor cluster. refer to "Sensor Calibration (Initialization)". • Sensors are integrated into the sensor cluster.2006. ABS/ESP SYSTEM ACTYON SM . Make sure to perform the sensor cluster calibration after replacing the sensor cluster. Make sure that there are not any foreign material and interference with floor carpet on the mounting surface.

Multifunction switch assembly NOTICE • For removal and installation.0 V) CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . angular velocity Working temperature Supplying voltage Output voltage (HI) Output voltage (LO) 9 ~ 16 V 10 mA 1500°/S . Specifications Working voltage Max. output current Detected max. 3. SWAS (Steering Wheel Angle Sensor) 2.1 V) Approx. 1.3 ~ 2.30 ~ 75°C 9 ~ 16 V (battery voltage) Approx.50 V (3. refer to "Removal and Installation of Multifunction Switch" section. 1.2006.03 A/T SWAS: Steering Wheel Angle Sensor .0 ~ 4.4892 43 Location of Steering Wheel Angle Sensor M / T A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C SWAS is installed at the bottom of air bag clock spring in steering wheel and sends the steering angle signal to ESP HECU.50 V (1.

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 Wheel Angle Sensor (SWAS) ESP STN ST2 ST1 Ground H E C U Supplying voltage Number of pulse per revolution Duty High .V Low .V ST1 and ST2 STN ABS/ESP SYSTEM ACTYON SM .03 9 ~ 16 V VHigh 45 Pulses /1 rev ST1 VLow Approx.3 ~ 2. 50 % ST2 3. The detected voltage will be transmitted to the HECU as a pulse from the 3 terminals. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned. Then.1 V 1.44 4892 Steering wheel angle sensor connector LED Phototransistor 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. the voltage occurs through the holes.0 V Detects steering wheel angle and angular velocity as an average value Detects the center value of steering wheel VHigh VLow VHigh 2° STN VLow Center line of steering wheel CHANGED BY EFFECTIVE DATE AFFECTED VIN .0 ~ 4.2006.

the ESP warning lamp blinks minimum of 4 times every 175 milliseconds. ESP function is a supplementary device to adjust the vehicle position when it is unstable. Even when the ESP is operated for a very short period of time. 4 times CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . ON ESP operation (including TCS) OFF 175ms ON ESP warning lamp OFF 175ms Min.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C A/T ESP OFF Switch . lower the speed and pay attention to the safe driving. when ESP warning lamp blinks and a beep sounds.2006.4892 45 Location M / T ESP OFF Switch ESP Warning Lamp Blinking in Control ESP warning lamp blinks and a beep sounds when ESP control is activated. The ESP warning lamp goes off when ESP function is deactivated. Therefore.

When you turn the ESP system off by pressing the ESP switch for over 150 ms. (However. the ESP system will be resumed when ignition switch is turned on again. the ESP OFF mode and the ESP warning lamp will not be changed. PUSH RELEASE 350 ms PUSH RELEASE HI ESP operation LO Disabled range 150 ms 150 ms ESP function (including TCS) ON OFF 150 ms 150 ms ON ESP warning lamp OFF NOTICE • If turning the ignition switch off while the ESP system is activated or deactivating the ESP system. we can see that the ESP system will be cancelled after a certain period (approx. The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms. The detailed operation procedures are as follows.2006. the ESP warning lamp and ESP system will not be turned on. 3. the ESP OFF switch does not operate. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms. ABS/ESP SYSTEM ACTYON SM . The ESP system will be cancelled after approximately 150 ms. The switch returns to normal position when the OFF switch is released. the ARP function still operates. When it is pushed for less than 150 ms. • When the ESP OFF switch is pushed within 350 ms of being turned off.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . Based on the above procedures. The switch returns to normal position when the OFF switch is released. Then. And the ABS system is still operated. 150 ms. • The ESP OFF switch operates when it is pushed for over 150 ms. 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 and the ESP warning lamp is on. • When the vehicle is controlled by ESP system during driving. 1. The ESP system will be resumed after approx. 2. • The ARP function still operates after turning off the ESP system.) The detailed operation procedures are as follows: 1. the TCS system (including ABD function) is turned off. the ESP warning lamp on the instrument panel comes on. 150 ms) from releasing period of the switch to the original position. the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. 2. The ESP system does not get cancelled immediately when the ESP warning lamp is turned on by pressing the ESP OFF switch.46 4892 ESP System Cancellation Using the ESP OFF Switch When the ESP OFF switch is pushed (for over approximately 150 ms). 3.

03 A / CON A / BAG BRAKE SP Cancellation of ESP OFF mode AXLE CLUTCH T/C M / T A/T . 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. mode ON OFF OFF ON ON ON ON OFF OFF ON Controls ABS NO OK OK NO NO NO NO OK OK NO ESP W/L ON BLINKS WHEN ESP OPERATION ON ON ON ON ON ON ON ON ASR NO OK NO NO NO NO NO NO NO NO ABD NO OK NO NO NO NO NO NO NO NO Vehicle yaw control NO OK NO NO NO NO NO NO OK 1) NO NOTICE • When the driver depresses the brake pedal during the ESP OFF mode. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .5 seconds. the ESP unit determines it as a ESP OFF switch malfunction. Warning Lamp ABS W/L Initial start (for 1. ESP-OFF mode Entering diag. the ESP system is resumed after 10 seconds.4892 ESP OFF Switch Monitoring 47 When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds.2006. the yaw control is performed to compensate the vehicle stability (posture) during ESP operation. the ESP unit resets the ESP OFF switch for approx. When the ESP OFF switch is pushed. When the ESP OFF switch returns to normal position. 3. Push Release HI ESP operation 10 sec 3.5 sec Return to switch signal ON OFF Reset to normal condition LO Detect failure ESP function (including TCS) Turning the ESP warning lamp off ST’NG ESP warning lamp ON OFF 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) is working. However.8 sec) Normal mode ESP fault ABS fault System fault Low battery voltage High battery voltage High brake pad temp.

3. After removal and installation of the brake master cylinder. Air Bleeding Should be Done When 1. After removal and installation of the brake oil pipes and hoses.03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ESP SYSTEM AIR BLEEDING The vehicle equipped only with ABS can use the conventional air bleeding procedure. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw. 7. The oil supply device should be filled with sufficient oil. This procedure needs at least 3 persons for doing below jobs: a. however. run the oil supply device to supply oil and depress the brake pedal repeatedly. After removal and installation of the ABS HECU. Check the conditions of oil supply device. 6. Air Bleeding Procedures 1. After replacing the brake fluid. Depress the brake pedal repeatedly. b. the vehicle equipped with ESP should use the oil supply device using a compressor inorder to bleed the air. 4. 2. Bleed the air in each wheel by using diagnostic device’s air bleeding menu.48 4892 14.2006. Apply the parking brake and start the engine when the shift lever is at "P" position. At this time. Perform the same procedures at each wheel. 2. 3. 4. Connect the oil supply device (air bleeding device) with air compressor to brake fluid reservoir. 5. c. ABS/ESP SYSTEM ACTYON SM . the modulator motor runs for 180 seconds. The air bleeding procedure should be started from the rear right wheel. Loosen the air bleed screw in caliper and place an empty container under the screw. Simultaneously. Collect the bleeding oil from the air bleed screw into the container.

(PUMP MOTOR & VALVE ACTIVATING) 3. 2. OPEN THR BLEED SCREW. CLOSE BLEEDER SCREW.2006. TOTAL ACTIVE TIME : 180 [Sec] AIR BLEEDING(TEVES ABS/ESP) >>>> REAR/RIGHT AIR BLEEDING <<<< AIR BLEEDING(TEVES ABS/ESP) >>>> REAR/RIGHT AIR BLEEDING <<<< FINISHED BLEEDING. CONTINUALLY PUMPING BRAKE PEDAL. AIR BLEEDING(TEVES ABS/ESP) >>>> REAR/RIGHT AIR BLEEDING <<<< ACTIVATING PUMP MOTOR & VALVE THE WHEEL MUST BE BLEED UNTILE THERE IS FOAMLESS AND BUBBLE FREE BRAKE FLUID SEEN AT THE BLEED SCREW.03 A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T .4892 49 Air Bleeding by Using Scan-100 AIR BLEEDING(TEVES ABS/ESP) 1] REAR/RIGHT CHANNEL 2] REAR/LEFT CHANNEL 3] FRONT/LEFT CHANNEL 4] FRONT/RIGHT CHANNEL Select one of the above items DO YOU START AIR BLEEDING ? (Yes / No) 1. TIME : xxx [Sec] BUBBLE FREE(FOAMLESS) ? (Yes / No) CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . PRESS “ENTER”.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN . ABOVE 1. LATERAL SENSOR (Only ESP) 3. .2006. PRESSURE SENSOR (Only ESP) 4. ABS/ESP SYSTEM ACTYON SM .50 4892 15. SENSOR CALIBRATION AND FORCED OPERATION OF ACTUATOR AND SENSOR VALUE Sensor Calibration (Initialzation) SENSOR INITIALIZE (ABS/ESP) ACTUATOR TEST 1. IF YOU START "INITIALZE SENSOR" ADAPT TO AUTOMATIC.VEHICLE STATUS IS FLAT. LONGITUDINAL SENSOR (Only ABS & ESP) 2.2.DO NOT PUT THE BRAKE PEDAL. . Initialize both the primary and secondary pressure sensors when initializing a pressure sensor. Select one of the above items Steering wheel angle sensor 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).3 ALL SENSOR (Only ABS & ESP) 5.ENGINE IS NOT RUNNING. PROCEDURE : MUST BE FOLLOW THE ABOVE CONDITION. STEERING WHEEL ANGLE SENSOR (Only ESP) SENSOR INITIALIZE LONGITUDINAL ACCEL SENSOR (4WD only) DO YOU START INITIALIZE ? (Yes/No) CONDITION : .

10 Sec CONDITION : IG. REAR(ESP: REAR/LEFT) OUTLET VALVE 7. REAR(ESP: REAR/LEFT) INLET VALVE 6. FRONT/LEFT INLET VALVE 2. PUMP MOTOR Select one of the above items ---------------------------------------------------ON(ACTIVE): “YES” KEY OFF(STOP): “NO” KEY OTHER ITEM : “ . FRONT/RIGHT OUTLET VALVE 5. 1st TCS VALVE(Only ESP) 10. FRONT/LEFT OUTLET VALVE 3.4892 51 Actuator ACTUATOR TEST ACTUATOR TEST 1.03 A / CON FRONT/LEFT INLET VALVE A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C M / T A/T . REAR/RIGHT(Only ESP) INLET VALVE 8.2006. ” ---------------------------------------------------ACTIVE TIME : Max. FRONT/RIGHT INLET VALVE 4. 2nd TCS VALVE(Only ESP) 11. 1st ESV VALVE(Only ESP) 12. REAR/RIGHT(Only ESP) OUTLET VALVE 9. ON or IDLE CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . 2nd ESV VALVE(Only ESP) 13.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .52 4892 Clearing Code CLEAR VARIANT CODE VEHICLE CODING CLEAR -------------------------------------------------DO YOU START TO CLEAR? ( YES / NO ) ABS/ESP SYSTEM ACTYON SM .2006.

4892 53 No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Content Wheel Speed FR Wheel Speed FL Wheel Speed RR Wheel Speed RL Battery Voltage Longitudinal Acceleration Sensor Lateral Aceleration Sensor Yaw Rate Sensor Steering Wheel Angle sensor Pressure Sensor (Primary) Pressure Sensor (Secondary) EBD Control BTCS Control Engine TCS Control ESP Control ESP/TCS OFF Switch ABS Control Stop Lamp Switch Unit 0.1 km/h 0.01 g +: Left Turn 0.2006.03 A/T ABS/ESP Sensor Value .1 V 0.1 km/h 0. X: N/A) A / CON ST’NG A / BAG BRAKE SP T/C AXLE CLUTCH M / T CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .1 km/h 0.5 deg/s +: Left Turn 5 deg +: Left Turn 1 bar 1 bar Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation ON / OFF Operation / Non-operation ON / OFF ESP O O O O O O O O O O O O O O O O O O ABS O O O O O O X (Fixed Value: 0) X (Fixed Value: 0) X (Fixed Value: 0) X (Fixed Value: 0) X (Fixed Value: 0) O X (Fixed Value: 0) X (Fixed Value: 0) X (Fixed Value: 0) X (Fixed Value: 0) O O (O: Applied.01 g-: Straight ahead 0.1 km/h 0.

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .2006.54 4892 ABS / ESP Forced Operation No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name FL Inlet Valve FL Outlet Valve FR Inlet Valve FR Outlet Valve Rear (or RL) Inlet Valve (*1) Rear (or RL) Outlet Valve (*1) RR Inlet Valve (*2) RR Outlet Valve (*2) TCS Valve Primary (*3) TCS Valve Secondary (*3) ESV Valve Primary (*3) ESV Valve Secondary (*3) Motor Pump Operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation Operation / Non-operation ABS/ESP SYSTEM ACTYON SM .

Short or poor contact wire to sensor Action . 0.Too large air gap between wheel speed sensor and tooth wheel .Different number of teeth in tooth wheel Action .Defective front RH wheel speed sensor .425 mm (2WD).Check the connection of the wheel speed sensor connector . 0. ABS/ESP TROUBLE DIAGNOSIS .475 ~1.Check the wheel speed sensor connector .Check the connection of the wheel speed sensor connector .Check the harness connection .03 A / CON A / BAG Front RH Wheel speed sensor C1021 Wheel speed sensor front right-electrical BRAKE Sensor Monitoring .475 ~ 1.Defective front LH wheel speed sensor 2.Check air gap between wheel speed sensor and tooth wheel and tooth wheel mounting (Specified air gap: 0.C1022 Cause .4892 55 o: Applied x: N/A Function Defective Components Trouble Code Descriptions Wheel speed sensor front left-electrical Wheel speed sensor front left-other System M / T Front LH Wheel speed sensor C1011 C1012 ABS ESP T/C 1. C1011 Cause .Too large air gap between wheel speed sensor and tooth wheel .425 mm (2WD).Short or poor contact wire to sensor Action .Check the harness connection 2.Check the number of teeth (48) in tooth wheel C1022 Wheel speed sensor front right-other ABS ESP 1.C1021 Cause .Check the connection of HECU connector . C1012 Cause .No signals from wheel speed sensor and tooth wheel .Different number of teeth in tooth wheel Action .1 ~ 0.Check the number of teeth (48) in tooth wheel CHANGED BY EFFECTIVE DATE AFFECTED VIN O O ABS/ESP SYSTEM ACTYON SM .Check air gap between wheel speed sensor and tooth wheel and tooth wheel mounting (Specified air gap: 0.1 ~ 0.2006.7 mm (4WD)) ST’NG AXLE CLUTCH A/T 16.Defective front LH wheel speed sensor .Check the wheel speed sensor connector and HECU connector .No signals from wheel speed sensor and tooth wheel .Defective front RH wheel speed sensor .Check the connection of HECU connector .Check the connection of HECU connector O O SP .7 mm (4WD)) .

Check the harness connection 2. C1031 Cause .Check the connection of the HECU connector . C1042 Cause .Check the connection of the HECU connector . C1041 Cause .Different number of teeth in tooth wheel Action . C1032 Cause .56 4892 Function Defective Components Trouble Code Descriptions Wheel speed sensor rear left-electrical Wheel speed sensor rear left-other System Rear RH Wheel speed sensor C1031 C1032 ABS ESP 1.Check the harness connection 2.425 ~ 1.Defective rear RH wheel speed sensor .Check air gap between wheel speed sensor and tooth wheel and tooth wheel mounting (Specified air gap: 0.Short or poor contact wire to sensor Action .Defective rear LH wheel speed sensor .Check the connection of the wheel speed sensor connector .Defective rear LH wheel speed sensor .No signals from wheel speed sensor and tooth wheel .Check the connection of the wheel speed sensor connector .Check the wheel speed sensor connector .Different number of teeth in tooth wheel Action .Too large air gap between wheel speed sensor and tooth wheel .425 ~ 1.Defective rear RH wheel speed sensor .Check air gap between wheel speed sensor and tooth wheel and tooth wheel mounting (Specified air gap: 0.2006.Check the number of teeth (48) in tooth wheel Rear LH Wheel speed sensor C1041 C1042 Wheel speed sensor rear left-electrical Wheel speed sensor rear left-other ABS ESP 1.No signals from wheel speed sensor and tooth wheel .Check the number of teeth (48) in tooth wheel ABS/ESP SYSTEM ACTYON SM .Short or poor contact wire to sensor Action .Check the connection of the HECU connector O O Sensor Monitoring .Too large air gap between wheel speed sensor and tooth wheel .175 mm) .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN O O .175 mm) .Check the wheel speed sensor connector and HECU connector .

Poor installation of steering wheel angle sensor and abnormal signal Action .1V) Longitudinal acceleration sensor C1071 C1072 Longitudinal acceleration sensor-electrical Longitudinal acceleration sensor-other ABS ESP 1.1V) • ST2 voltage check: between ESP unit terminal No.Abnormal signal voltage from steering wheel angle sensor .Check the supplying voltage: (Specified voltage: 9 ~ 16 V) .1V) • STN voltage check: between ESP unit terminal No.Check the connection of the pressure sensor connector X O Steering wheel angle sensor Cause C1061 Defective steering wheel angle sensor ABS ESP . C1072 Cause .Abnormal signals from steering wheel angle sensor .Check the output voltage: Check voltage between ESP unit terminals with ignition ON • ST1 voltage check: between ESP unit terminal No.Ground to signal and power supply line or short to power supply line .3 ~ 4. C1071 2.3 ~ 4.Abnormal signal from steering wheel angle sensor .Check the output voltage: Check voltage between ESP unit terminals with ignition ON X O CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .2006.Check the supplying voltage: (Specified voltage: 9 ~ 16 V) X O Sensor Monitoring .4892 57 Function Defective Components Pressure sensor Cause Trouble Code C1051 Descriptions Defective input sensor System ABS ESP M / T A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C .Ground to signal and power supply line or short to power supply line .Internally defective steering wheel angle sensor .Abnormal signal voltage from steering wheel angle sensor .03 A/T . 5 and ground (Specified voltage: 1.Abnormal signals from pressure sensor .Defective pressure sensor or harness Action .3 ~ 4.Poor installation of steering wheel angle sensor and abnormal signal Action .Internally defective steering wheel angle sensor .12 and ground (Specified voltage: 1. 2 and ground (Specified voltage: 1.

C1074 Cause .Abnormal internal A/D converter voltage: Over 5.0 V / Lo: 6.5 ± 0.Over voltage out of specified range (18.Replace the sensor cluster Sensor Monitoring 2.Poor installation of sensor .960 V) to sensor cluster → Short circuit between supplying voltage output of sensor cluster and ground .Abnormal signals from lateral acceleration sensor .0 ± 1.0 V) Action .Overheated brake disc due to excessive operation of HDC Action .Poor contact or installation of harness Action .Low voltage out of specified range (9.Defective sensor cluster .0 ~ 0.3 V) Action .Overheated brake disc due to braking force: over 500°C .5 V ) .5 V) → Short to ground on sensor cluster .Poor ground of sensor cluster (0. C1102 Cause .Abnormal signals from yawing sensor .Check the supplying voltage O Brake disc C1111 Disk temperature is high ABS ESP Brake Monitoring Cause .58 4892 Function Defective Components Sensor cluster 1.7 ± 0.Abnormal supplying voltage (4.Replace the sensor X O Battery 1.0 ± 1.Defective or short circuit of CAN communication line Action .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Operating voltage exceeds specified range (Hi: 18. C1101 Cause C1101 C1102 Battery under voltage Battery over voltage ABS ESP Battery Voltage Monitoring .580 ~ 4.Check the supplying voltage O 2.0 ± 3 % .2006.Stop driving for a period of time after turning off the ESP X O ABS/ESP SYSTEM ACTYON SM . C1073 Cause Trouble Code C1073 C1074 Descriptions Sensor cluster -electrical Sensor cluster-other System ABS ESP .Check the connection of the sensor cluster connector .Internally defective HECU .

and controller .Internally defective HECU Action . valve relay in HECU ABS ESP Valve Monitoring .Check the connection of the HECU connector .Check the supplying voltage . C1202 (5202) Cause .Defective sensor and short to supplying voltage line .Replace the HECU .Check the harness and connector X 2.Defective ESP OFF switch harness (short to ground) Action .Internally defective HECU .0 V) or no supplying voltage to pump motor Pump Monitoring .Replace the HECU O O HECU C1401 HECU-internal ABS ESP HECU and Sensor Monitoring Cause .Defective brake switch harness Brake Monitoring Action .Replace the HECU O O CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .Abnormal supplying voltage to valve solenoid . C1201 (5201) Cause Trouble Code C1201 C1202 Descriptions Defective brake lamp switch Defective ESP OFF switch System ABS ESP M / T A / CON A / BAG BRAKE ST’NG SP AXLE CLUTCH T/C .Defective A/D converter.Too low (below 6.Check the connection of the harness and connector for ESP OFF switch O Valve.03 A/T .Poor ground Action .Check the HECU connector O O Pump motor Cause C1311 Defective pump motor ABS ESP .2006.4892 59 Function Defective Components Brake lamp switch ESP OFF switch 1. internal voltage regulator.Mechanical defective in brake switch .Mechanical defective in ESP OFF switch .Over 0.Poor contact in pump motor connector . valve relay Cause C1301 Defective valve.93 V of voltage from pump motor voltage .Abnormal temperature sensor signal Action .Check the battery voltage .

Short circuit to CAN communication line .Initialize the sensors X O Vehicle coding Cause C1170 Vehicle coding error or misinstallation of HECU ABS ESP .Check engine ECU coding .Short or open to CAN communication line .Replace the exact HECU CAN communication Cause C1601 CAN communication error ABS ESP .Check the HECU coding and vehicle coding .Abnormal signals from sensors .03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .Perform vehicle coding .Overload to CAN communication Action .Check the engine ECU .Check the CAN communication line .Check the connection of the engine ECU connector X O ABS/ESP SYSTEM ACTYON SM .Discrepancy between HECU coding and vehicle coding . C1602 Cause .Abnormal sensor data Action .Check the sensors .2006.60 4892 Function Defective Components Sensor initialization Cause Trouble Code C1501 Descriptions Abnormal sensor initialization System ABS ESP .Poor connection of CAN communication line Action .Defective CAN communication Action CAN Communication Monitoring O O .Misinstallation of HECU .Check the CAN communication line O O CAN communication C1602 Communication error between CAN communication line and engine ECU ABS ESP 1.

Short to CAN communication line .Replace the cluster (meter) CAN communication Cause .Check the A/T TCU .Check the CAN communication line ST’NG .Check the connection of the engine ECU connector CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM .Check the CAN communication line .Check the connection of the TCU connector 2.Short to CAN communication line (communication with the cluster (meter)) Action .Data error from engine ECU Action .Check the CAN communication line .Short to CAN communication line .2006.Overload to CAN communication X O SP AXLE CLUTCH A/T .03 A / CON A / BAG BRAKE CAN Communication Monitoring Action .Check engine ECU . C1605 Cause .4892 61 Function Defective Components Trouble Code Descriptions Communication error between TCU and CAN Communication error between TCCU and CAN Communication error between cluster (Meter) and CAN System M / T C1603 CAN communication C1604 C1605 ABS ESP T/C 1. C1604 Cause .Check the connection of the TCCU connector 3.Check the connection of the cluster (meter) and connector .Overload to CAN communication Action . C1603 Cause .Check the CAN communication line C1612 Signal from engine ECU is abnormal ABS ESP O O .Check the TCCU .

03 CHANGED BY EFFECTIVE DATE AFFECTED VIN .62 4890 ABS SYSTEM The following figure shows the basic system components of the ABS. Front Wheel Speed Sensor (for 4WD) Rear Wheel Speed Sensor HECU (Valve Body and ECU Integrated Type) Rear wheel speed sensor (RR) Front wheel speed sensor (FR) Valve body Rear wheel speed sensor (RL) ABS HECU B: Plunger Motor pump C: Cam bushing Front wheel speed sensor (FL) ABS warning lamp ABS/ESP SYSTEM ACTYON SM . front wheel speed sensor and rear wheel speed sensor.2006. This system consists of HECU (valve body and ECU integrated type).

2006. the front wheel end system (including disc) should be removed before removing the front wheel speed sensor. Thus. It is installed inside the backing plate to be protected from heat and foreign materials. CHANGED BY EFFECTIVE DATE AFFECTED VIN ABS/ESP SYSTEM ACTYON SM . Therefore.4890 Cautions When Removing the Front Wheel Speed Sensor 63 The locking hub system of the ACTYON part time 4WD utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator. the wheel speed sensor is installed on the front wheel end area.03 A / CON A / BAG BRAKE SP AXLE CLUTCH T/C M / T A/T . Front Wheel Speed Sensor Rear Wheel Speed Sensor Backing Plate Wheel speed sensor ST’NG Wheel Speed Sensor Wheel Speed Sensor The wheel end should be remove before removing the wheel speed sensor.

1 NOTICE IG1 4 • No specific terminal exists to display vehicle speed or ABS warning lamp. ABS/ESP SYSTEM ACTYON SM . Signal Wheel speed sensor (FR) 34 33 36 37 43 42 16 Ground Signal Wheel speed sensor (RL) Ground 47 Ground (pump) Signal Wheel speed sensor (RR) Currently applied wheel speed sensors are active type and have the PCB with resistance.03 Ground Ground (valve and ECU) CHANGED BY EFFECTIVE DATE AFFECTED VIN .64 4890 1. Signal 15 11 Wheel speed sensor (FL) Ground 45 46 U 2 Diagnosis connector pin no. INPUT AND OUTPUT DIAGRAM Input/Output of ABS Battery + (hydraulic valve and ECU power supply) 32 Battery + (pump supply power) ABS HECU supplies battery power to operate hydraulic pump and