Ssangyong+Kyron Manual

GENERAL INFORMATION
00 TABLE OF CONTENTS
DIMENSIONS ........................................................... 3 SPECIFICATIONS .................................................... 4 VEHICLE IDENTIFICATION ...................................... 6 MAINTENANCE SCHEDULE ................................... 9 RECOMMENDED FLUIDS AND LUBRICANTS ...... 11
00
3
GENERAL
DIMENSIONS
Unit: mm
Top View
Side View
Front View
Rear View
* ( ) : Optional
CHANGED BY EFFECTIVE DATE AFFECTED VIN
GENERAL INFORMATION
KYRON SM - 2005.09
00
SPECIFICATIONS
Descriptions General Overall length (mm) Overall width (mm) Overall height (mm) Gross vehicle weight (kg) A/T M/T Curb vehicle weight (kg) A/T M/T Fuel Fuel tank capacity ( Engine Engine name Numbers of cylinders/Compression ratio Total displacement (cc) Camshaft arrangementMax. power Max. power A/T M/T Max. torque A/T M/T Idle speed Cooling system Coolant capacity ( Lubrication type Max. oil capacity ( ) ) ) D20DT 4,660 1,880 1,740 (1,755: with roof rack) 2,530 2,530 2WD: 1,920 / 4WD: 2,028 2WD: 1,893 / 4WD: 2,001 Diesel 75 D20DT 4 / 17.5:1 1,998 DOHC 141 ps / 4,000 rpm 141 ps / 4,000 rpm 310 Nm / 1,800 ~ 2,750 rpm 310 Nm / 1,800 ~ 2,750 rpm 750 20 rpm D27DT 4,660 1,880 1,740 (1,755: with roof rack) 2,530 2,530 4WD: 2,071 4WD: 2,030 Diesel 75 D27DT 5 / 18:1 2,696 DOHC 165 ps / 4,000 rpm 165 ps / 4,000 rpm 340 Nm / 1,800 ~ 3,250 rpm 340 Nm / 1,800 ~ 3,250 rpm 750 20 rpm
Water- cooled / forced circulation Water- cooled / forced circulation 11.5 11.5
Gear pump, forced circulation Gear pump, forced circulation 8.2 Turbocharger, air-cooled Semi- Remote control, floor change type 1st 2nd 3rd 4th 5th Reverse 4.315 2.475 1.536 1.000 0.807 3.919 Electronic, 5-speed Floor change type 9.2 Turbocharger, air-cooled Semi- Remote control, floor change type 4.315 2.475 1.536 1.000 0.807 3.919 Electronic, 5-speed Floor change type
Turbocharger and cooling type Manual Transmission Operating type Gear ratio
Automatic Transmission * ( ) Optional
Model Operating type
GENERAL INFORMATION
KYRON SM - 2005.09
00
5
GENERAL
Descriptions Automatic Transmission Gear ratio 1st 2nd 3rd 4th 5th Reverse 1st Reverse 2nd Transfer Case Model Type Gear ratio High (4H) Low (4L) Clutch (M/T) Operating type Disc type Power Steering Type Steering angle Inner Outer Front Axle Drive shaft type Axle housing type Gear ratio M/T A/T Rear Axle Drive shaft type 5-Link type Independent type Axle housing type Gear ratio M/T A/T Brake Master cylinder type Booster type Brake type Front wheels Rear wheels Parking brake Suspension Front suspension Rear suspension Air Conditioner Electrical Solid axle suspension
D20DT 3.951 2.423 1.486 1.000 0.833 3.147 1.930 Part-time Planetary gear type 1.000 : 1 2.483 : 1 Hydraulic type Dry single diaphragm type Rack and pinion 36.2 32.4 Ball joint type Build-up type 4.27 3.54 Semi-floating type Independent type Build-up type 4.27 3.54 Tandem type
D27DT 3.595 2.186 1.405 1.000 0.831 3.167 1.926 Part-time Planetary gear type 1.000 : 1 2.483 : 1 Hydraulic type Dry single diaphragm type Rack and pinion 36.2 32.4 Ball joint type Build-up type 3.91 3.31 Semi-floating type Independent type Build-up type 3.91 3.31 Tandem type
Vacuum assisted booster type Vacuum assisted booster type Disc type Drum (disc) Disc type Drum (disc)
Cable type (internal expansion) Cable type (internal expansion) Wishbone + coil spring 5-link + coil spring R-134a (650 30g) MF / 12 - 90 12 - 2.2 With PTC: 12 - 140 (With FFH: 12 - 115) Wishbone + coil spring 5-link + coil spring R-134a (650 30g) MF / 12 - 90 12 - 2.2 With PTC: 12 - 140 (With FFH: 12 - 115)
Refrigerant (capacity) Battery type / Capacity (V-AH) Starter capacity (V-kW) Alternator capacity (V-A)
GENERAL INFORMATION
KYRON SM - 2005.09
00
VEHICLE IDENTIFICATION
Chassis Number Certification Label
The chassis number is stamped on the frame behind the front right tire.
The certification label is located on the drivers door sill.
Engine Number (D20DT)
Engine Number (D27DT)
The engine number is stamped on the lower area of cylinder block in the intake manifold side.
GENERAL INFORMATION
KYRON SM - 2005.09 CHANGED BY EFFECTIVE DATE AFFECTED VIN
00
7
GENERAL
1. Vehicle Identification Number

Vehicle identification number (VIN) is is on the right front axle upper frame.
[KPTS0A1KS5P 122357]
K .. Nation T .. Vehicle Type S .. Line Models 0 .. Body Type A .. Trim Level 1 .. Restraint System K .. Engine Type (K: Korea) (T: Passenger car - 4WD) (S: Kyron) (0: 5-door) (A: Standard, B: Deluxe, C: Super deluxe) (0: No seatbelts, 1: 3-point seatbelts, 2: 2-point seatbelt) (9: 3199cc, In-line 6 cylinders, Gasoline E32) (K: 1998cc - common rail direct injection (D20DT), F: 2696cc - common rail direct injection (D27DT)) (S: All area except North America) (3: 2003, 4: 2004, 5: 2005) (P: Pyungtaek plant) (Production serial number) P .. Maker Identification (P: Ssangyong Motor Company)
S .. Check Digit 5 .. Model Year P .. Plant Code 122357
2. Certification Label
The certification label is affixed on the bottom of drivers side B-pillar.
GENERAL INFORMATION
KYRON SM - 2005.09
00
3. Engine Serial Number

The engine serial number is stamped on the lower area of cylinder block in intake manifold side.
D20DT D27DT
4. Manual Transmission Number

The transmission label is affixed on the upper area of clutch housing.
5. Automatic Transmission Number

The transmisson label is affixed on the right area of transmission housing.
6. Transfer Case Number

The transfer case label is affixed on the transfer case housing.
GENERAL INFORMATION
KYRON SM - 2005.09
00
9
GENERAL
MAINTENANCE SCHEDULE
General
Descriptions
Engine Oil and Oil Filter Coolant Additional Water Separator: A.W.S. Brake / Clutch Fluid Brake Pipes and Hoses Brake Pad, Shoe, and Disc Air Cleaner Element Fuel Filter Automatic Transmission Fluid Manual Transmission Fluid Transfer Case Fluid Axle Oil Front Rear Air Conditioner Filter
Daily Check Weekly Check
* Use only approved Ssangyong genuine parts.
Service Interval
Initial change: 5,000 km, change every 10,000 km or 12 months (But, shorten the service interval under severe conditions) Change every 60,000 km or 3 years. And, inspect and replenish as necessary. Inspect 10,000 km, change every 150,000 km or 5 years Change every 2 years (Inspect frequently) Initial check: 1,000 km, periodic check: every 20,000 km or 1 year, replace as necessary. Periodic check: every 10,000 km, adjust or replace as necessary. Initial clean: 5,000 km, clean every 10,000 km, replace every 30,000 km (But, shorten the service interval under severe conditions)
Replace every 25,000 km (Draining water from fuel filter: every 10,000 km) Inspect every 10,000 km or 6 months (But change every 60,000 km under severe conditions) Inspect 10,000 km, change every 60,000 km (Frequent check of oil leak) Inspect 10,000 km, change every 60,000 km (Frequent check of oil leak) Inspect frequently, change every 30,000 km Inspect frequently, change every 30,000 km Change every 10,000 km (But, shorten the service interval under severe conditions)
Severe Conditions in Automatic Transmission and Axle 1. Towing a trailer or off-road driving 2. Taxi, patrol service or delivery service (extended idling and excessive driving with low speed) Severe Conditions in Air Conditioner Filter 1. Pollutant area or off-road driving, extended air conditioner or heater operation Sever Conditions in Air Cleaner Element 1. Pollutant area or off-road driving
Severe Conditions in Engine 1. Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below 16 km when the outside temperature remains below freezing 2. Driving in hilly or mountainous terrain, sandy or dusty area 3. High load driving such as trailer towing
GENERAL INFORMATION
KYRON SM - 2005.09
10
00
EU ONLY
Descriptions
Engine Oil and Oil Filter Coolant Brake / Clutch Fluid Brake Pipes and Hoses Brake Pad, Shoe, and Disc Air Cleaner Element Fuel Filter Automatic Transmission Fluid Manual Transmission Fluid Transfer Case Fluid Axle Oil Front Rear Air Conditioner Filter
Daily Check Weekly Check
* Use only approved Ssangyong genuine parts.
Service Interval
Change every 15,000 km or 12 months (But, shorten the service interval under severe conditions) Change every 60,000 km or 3 years. And, inspect and replenish as necessary. Change every 2 years (Inspect frequently) Periodic check: every 15,000 km or 1 year, replace as necessary. Periodic check: every 15,000 km, adjust or replace as necessary. Clean every 15,000 km, replace every 30,000 km (But, shorten the service interval under severe conditions) Replace every 30,000 km (Draining water from fuel filter: every 10,000 km) Inspect every 15,000 km or 12 months (But change every 60,000 km under severe conditions) Inspect 15,000 km, change every 60,000 km (Frequent check of oil leak) Inspect 15,000 km, change every 60,000 km (Frequent check of oil leak) Inspect frequently, change every 30,000 km Inspect frequently, change every 30,000 km Change every 10,000 km (But, shorten the service interval under severe conditions)
Severe Conditions in Air Conditioner Filter 1. Pollutant area or off-road driving, extended air conditioner or heater operation Sever Conditions in Air Cleaner Element 1. Pollutant area or off-road driving * EU Countries
Severe Conditions in Engine 1. Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below 16 km when the outside temperature remains below freezing 2. Driving in a hilly or mountainous terrain, sandy, or dusty area 3. High load driving such as trailer towing Severe Conditions in Automatic Transmission and Axle 1. Towing a trailer or off-road driving 2. Taxi, patrol service or delivery service (extended idling and excessive driving with low speed)
1. Only countries that belong to EU. (It does not apply to all countries in EU.)
GENERAL INFORMATION
KYRON SM - 2005.09
00
11
GENERAL
RECOMMENDED FLUIDS AND LUBRICANTS

Capacity Descriptions Engine Oil D20DT 7.5 11.5 8.0 4WD: 2WD: Transfer Case Fluid Axle Oil 3.6 3.4 1.3 1.3 Ssangyong genuine oil (ATF DEXRON III) 4WD: D27DT 8.5 11.5 8.0 3.6 Specifications Ssangyong genuine engine oil (Approved by MB Sheet 229.1 or 229.3) Ssangyong genuine coolant Shell AFT 3353 or Fuchs AFT 3353 Ssangyong genuine oil (ATF DEXRON II)
Engine Coolant Automatic Transmission Fluid Manual Transmission Fluid
Front
Automatic Transmission Manual Transmission
1.4 1.4 1.9

As required 1.0
1.4 ~ 1.5 1.4 2.2

As required 1.0
Ssangyong genuine oil (API GL-5 or SAE 80W/90)
Rear
Brake/Clutch Fluid
Solid Axle Suspension
Ssangyong genuine oil (API GL-5 or SAE 80W/90) Ssangyong genuine oil (DOT4)
Ssangyong genuine oil (ATF DEXRON III)
Power Steering Fluid
NOTICE
Use only Ssangyong recommended fluids and lubricants. Do not mix any different types or brands of oils or fluids. This may cause damages. Keep the specified levels when adding or replacing the fluids.
GENERAL INFORMATION
KYRON SM - 2005.09
MEMO
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AUTOMATIC TRANSMISSION (DC 5-SPEED)

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

1. Appearance ......................................................... 4 2. Structure and specifications ............................... 5 3. Power flow ......................................................... 11
HYDRAULIC CIRCUIT ........................... 80

1. 2. 3. 4. Hydraulic circuit diagram .................................. 80 Hydraulic circuit ................................................ 85 Adapter plug ..................................................... 91 Valve body ......................................................... 93
FUNCTION AND DESCRIPTION........... 19

1. 2. 3. 4. 5. 6. Selector lever .................................................... 19 Torque converter ................................................ 24 Planetary gear set ............................................ 27 Multiple-disc clutch .......................................... 28 Freewheel ......................................................... 29 Others ............................................................... 30
TCU (Transmission Control Unit) ........ 99 TROUBLE CODE AND DIAGNOSIS ... 104
1. Trouble diagnosis with SCAN-100 .................. 104 2. DTC (Diagnosis Trouble Code) of DC5AT ....... 105 3. Removal and installation of TCU .................... 112
REMOVAL AND INSTALLATION ........... 33

Selector lever and link ...................................... 33 Front and rear propeller shaft ........................... 36 Transmission assembly .................................... 38 Replacing the o-ring on parking pawl guide sleeve ................................................................ 42 5. Disassembly and reassembly (DC 5-SPEED A/T) ............................................ 46 6. Valve body ......................................................... 65 1. 2. 3. 4.
3650
GENERAL INFORMATION
1. OVERVIEW
DC 5-speed Automatic Transmission Assembly
T-Tronic DC 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the torque converter. The ratios for the gears are realized by three planetary gear sets. The 5th gear is designed with a step-up ratio of 0.83 as an overdrive. The selector lever is controlled by electronically and mechanically. The gears are shifted by the corresponding combination of three hydraulically actuated multiple-disc brakes, three hydraulically actuated multiple-disc clutches and two mechanical one-way clutches. This electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting in relation to engine power. This function improves shifting quality significantly. And, the driver can select S (Standard) mode or W (Winter) mode according to the driving conditions.
Instrument Panel
TCU Assembly
TCCU TCU
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Releasing Lock-up Solenoid Valve
Standard Mode / Winter Mode
Selector Lever
Downshift (Manual Mode) 1 2 3 4 D The shiftable gear is down by one step as the lever is moved to left (-) direction.
Upshift (Manual Mode) 1 2 3 4 D The shiftable gear is up by one step as the lever is moved to right (+) direction.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
* When the gear selector lever cannot be moved from P position to other positions, manually release the lock-up function as shown in figure.
S mode is used in normal driving. When W mode is selected, the vehicle starts from 2nd gear (forward and reverse) to achieve smooth starting on the slippery road.
AXLE
CLUTCH
T/C
M / T
A/T
3650
AUTOMATIC TRANSMISSION (DC 5-SPEED)

1. APPEARANCE
Left Side
With Torque Converter Without Torque Converter
Rear View
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Structure
This sectional drawing is based on DC 5-speed A/T 2WD model. 4WD model has also same structure.
1. Torque converter 2. Oil pump 3. Input shaft 4. Disc brake B1 5. Disc clutch C1 6. Disc clutch C2
7. Disc brake B3 8. Disc clutch C3 9. Disc brake B2 10. Output shaft 11. Parking lock gear 12. Intermediate shaft
13. Freewheel F2 14. Center planetary gear set 15. Electric control unit (valve body) 16. Freewheel F1 (Front planetary gear set) 17. Stator shaft 18. Converter lockup clutch
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
2. STRUCTURE AND SPECIFICATIONS
3650
Specifications
Item
Input torque Weight (including ATF) Diameter (torque converter) Lockup function Gear ratios 1st 2nd 3rd 4th 5th Rev. 1st: S / Rev. 2nd: W Driving type Fluid specification Fluid capacity Selector lever position P.R.N.D D+/DParking lock system 3.951 2.423 1.486 1.000 0.833 3.147/1.93 2WD/4WD Fuchs ATF 3353 or Shell ATF 3353 Approx. 8 Mechanical Electrical Brake switch (signal) TGS lever Selected lever indication P.R.N.D 4, 3, 2, 1 Oil temperature sensor TCU Shift solenoid valve (25C) Resistance Operating distance Operating current M/P, S/P solenoid valve (23C) Resistance Operating distance Operating current Lockup solenoid valve (25C) Resistance Operating distance Operating current Operating range Speed sensor Type Operating voltage Start lockout switch Switch contact Switch contact Resistance: R, D Lever position CAN 0.5 ~ 2.5 k EGS 52 3.8 0.2 0.2 mm 1.5 ~ 2 A 5.0 0.2 0.6 mm 0 ~ 1.2 A 2.5 0.2 0.2 mm 1.5 ~ 2.0 A 3rd to 5th gears HALL type 6V ON (D, R position) OFF (P, N position)
5-Speed Automatic Transmission D20DT D27DT
2WD (580 Nm), 4WD (400 Nm) 76 kg (2WD), 78 kg (4WD) 270 mm Yes 3.595 2.186 1.405 1.000 0.831 3.167/1.926
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Item
Mode switch
5-Speed Automatic Transmission

W (Winter)
One-way clutch Planetary gear set Disc clutch Number of planetary gear set pinion (Front, Center, Rear) C1 C2 C3 Disc brake B1 B2 B3
F1, F2 4, 4, 4 Single side friction plate Double side friction plate Single side friction plate Single side friction plate Double side friction plate Double side friction plate
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
S (Standard)
A/T
3650
Characteristics of Automatic Transmission

Performance Curve D20DT
Standard Mode WINTER Mode (2WD)
Upshift: Downshift: Lockup (slipping): Unlock (open): FAST OFF: Dynamic shift zone:
Lockup Mode (Open/Slipping)
FAST OFF: When abruptly releasing the accelerator pedal, the transmission remains at 4th gear other than 4 shift (when slowly releasing the accelerator pedal, 5 the transmission is shifted to 5th gear). Dynamic shift zone: When operating the accelerator pedal ( ), the 4 3 shift is completed by kick-down signal after completion of 4 3 shift (100% of pedal position). When promptly operating the accelerator pedal ( ), the 4 3 shift is done in shaded area (93% of pedal position). 4th gear: 1.000 5th gear: 0.833 Rev. 1st gear: 3.147 Rev. 2nd gear: 1.93
Low Mode (4WD)
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Standard Mode
FAST OFF 4-5
FAST OFF 3-4
FAST OFF: When abruptly releasing the accelerator pedal, the transmission remains at 4th gear other than 4 5 shift (when slowly releasing the accelerator pedal, the transmission is shifted to 5th gear).
C
5-4
FAST OFF 2-5 4-5
Dynamic shift zone:

4-3
3-4
3-2 2-3 FAST OFF 1-2 1-2
2-1
4th gear: 1.000 5th gear: 0.831 Rev. 1st gear: 3.167 Rev. 2nd gear: 1.926
WINTER Mode
20
PEDAL VALUE (%)
40
60
80
100
5rd GEAR OPEN
5-4 4-5
5rd GEAR SLIPPING 4rd GEAR OPEN

3-4 2-3 3-2 4-3
4rd GEAR SLIPPING 3rd GEAR OPEN
3rd GEAR SLIPPING
20
PEDAL VALUE (%)
40
60
80
100
20
PEDAL VALUE (%)
40
60
80
100
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
When operating the accelerator pedal ( ), the 4 3 shift is completed by kick-down signal after completion of 4 3 shift (100% of pedal position). When promptly operating the accelerator pedal ( ), the 4 3 shift is done in shaded area (93% of pedal position).
STNG
SP
AXLE
CLUTCH
Upshift: Downshift: Lockup (slipping): Unlock (open): FAST OFF: Dynamic shift zone:
T/C
M / T
D27DT
A/T
10
3650
General Characteristics
Characteristic
Slope recognition (down hill, up hill) Engine torque reduction Engine rpm limitation ESP Operation
Function and Effect

Slope is recognized based on engine RPM and accelerator pedal position. Delays up shift Ignition timing is delayed to reduce torque at all shifting moments. Improves shift quality Engine rpm is limited until the gears are fully engaged when shifting from N to D. Prevents shift shock When the ESP is controlling the engine torque, shifting is not available and vehicle starts off with 2nd gear. Cannot use kick-down function and shift at maximum rpm Brake control is not affected. It is not shifted up when accelerator pedal is abruptly released. To get engine brake effect during cornering As altitude increases (atmospheric pressure reduces), engine torque decreases. To compensate this torque reduction, shift up occurs when depressing the accelerator pedal more than usual operation (adjusting shift diagram). Improves driving performance and increases torque If transmission fluid temperature is too low, the shifting point gets delayed in full throttle and kick down. Improves driving performance When starting the engine with cycling the ignition switch (OFF and ON) due to transmission trouble, the selector lever should be placed in P position. If starting the engine with selector lever N position, the lever should be moved into P position. The selector valve changes the path of hydraulic pressure in selector lever P position. The hydraulic pressure flows to direct operation mode via R and D valve to operate reverse 2nd and forward 2nd gear. Function to optimize the shifting quality. Compensates the shifting quality according to play and wear
ABS Operation Fast-off function Altitude recognition
Oil temperature
Hydraulic pressure is produced in emergency driving mode
Adaptation
Torque converter lockup clutch
Flywheel
Engine torque
Torque converter
Automatic transmission
Final drive gear
Output torque
Multiple disc clutch
Multiple disc brake
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
11
Sectional View
Brake B1 (disk) assembly Brake B3 (disk) assembly Brake B2 (disk) assembly
Shifting Elements
Gear 1 2 3 4 5 P/N 1) P/N 2) R 1) R 2) 1) Selector program switch: S mode
C1
C2
C3
3) 3)
B1
3)
B2
B3
F1
F2
3)
3)
2) Selector program switch: W mode
3) Overrun
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
C1 (Disk clutch) assembly
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
3. POWER FLOW
12
3650
1st Gear (D20DT: 3.951, D27DT: 3.595)
Input
Output
16. Torque converter lockup clutch A. Engine speed B. Transmission, input shaft C. 1st gear ratio D. 2nd gear ratio
E. 3rd gear ratio F. Locking elements H. Rear planetary gear set L. Stator
M. Center planetary gear set P. Impeller T. Turbine wheel V. Front planetary gear set
1. Input shaft: Clockwise rotation 2. Front sun gear: Locked by F1 and B1, Planetary gear carrier: Rotation with reduced speed 3. Rear ring gear: Counterclockwise rotation 4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed 5. Center ring gear: Clockwise rotation 6. Center sun gear: Locked by B2, Rotation with reduced speed 7. Output shaft: Clockwise rotation
Gear 1 3) Overrun C1 C2 C3
3)
B1
3)
B2
B3
F1
F2
Lockup clutch
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
13
Output
16. Torque converter lockup clutch A. Engine speed B. Transmission, input shaft C. 1st gear ratio
D. 2nd gear ratio E. Locking elements H. Rear planetary gear set L. Stator
1. Input shaft: Clockwise rotation 2. Sun gear and planetary gear carrier: Clockwise rotation by C1 activation 3. Rear ring gear: Clockwise rotation 4. Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed 5. Center ring gear: Clockwise rotation 6. Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed 7. Output shaft: Clockwise rotation
Gear 2
3) Overrun
C1
C2
C3
3)
B1
B2
B3
F1
F2
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
2nd Gear (D20DT: 2.423, D27DT: 2.186)
14
3650
3rd Gear (D20DT: 1.486, D27DT: 1.405)
Input
Output
D. Locking elements H. Rear planetary gear set L. Stator M. Center planetary gear set
P. Impeller T. Turbine wheel V. Front planetary gear set
1. Input shaft: Clockwise rotation 2. Front ring gear: Clockwise rotation 3. Center ring gear: Clockwise rotation by clutch 2 activation (direct connection) 4. Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed 5. Output shaft: Clockwise rotation
Gear 3 C1 C2 C3 B1 B2 B3 F1 F2
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
15
Output
16. Torque converter lockup clutch A. Engine speed B. Planetary gear set
L. Stator M. Center planetary gear set P. Impeller
T. Turbine wheel V. Front planetary gear set
1. Input shaft: Clockwise rotation 2. Front ring gear: Clockwise rotation 3. Center ring gear and rear planetary gear carrier: Clockwise rotation 4. Front sun gear and planetary gear carrier: Clockwise rotation (direct connection) 5. Rear ring gear: Clockwise rotation 6. Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection) 7. Center sun gear: Clockwise rotation by C3 activation 8. Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection) 9. Output shaft: Clockwise rotation
Gear 4 C1 C2 C3 B1 B2 F1 F2
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
4th Gear (1.000)
16
3650
5th Gear (D20DT: 0.833, D27DT: 0.831)
Output
E. 3rd gear ratio F. Locking elements H. Rear planetary gear set L. Stator
1. Input shaft: Clockwise rotation 2. Front sun gear: Locked by B1, Planetary gear carrier: Rotation with reduced speed 3. Rear planetary gear ring gear: Clockwise rotation with reduced speed 4. Center ring gear and rear planetary gear carrier: Clockwise rotation by clutch C2 activation 5. Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increased speed) 6. Center sun gear: Clockwise rotation with increased speed by clutch C3 activation 7. Center planetary gear carrier: Clockwise rotation (increased speed) 8. Output shaft: Clockwise rotation (increased speed)
Gear 5
3) Overrun
AUTO TRANSMISSION
C1
C2
C3
B1
3)
B2
B3
F1
F2
3650
17
Input
Output
E. Locking elements F. Locking elements H. Rear planetary gear set L. Stator
1. Input shaft: Clockwise rotation 2. Front ring gear: Clockwise rotation 3. Front sun gear: Locked by one-way clutch F1 4. Front planetary gear carrier: Clockwise rotation (reduced speed) 5. Rear planetary gear ring gear: Clockwise rotation 6. Rear planetary gear carrier: Locked by B3 7. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) 8. Center ring gear: Locked by B3 9. Center planetary gear carrier: Counterclockwise rotation (reduced speed) 10. Output shaft: Counterclockwise rotation
Gear R (S)
3) Overrun
C1
C2
C3
B1
3)
B2
B3
F1
F2
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Reverse 1st Gear (D20DT: 3.147, D27DT: 3.167) - Standard (S) Mode
18
3650
Reverse 2nd Gear (D20DT: 1.93, D27DT: 1.926) - Winter (W) Mode Mode
Input
Output
D. 2nd gear ratio E. Locking elements H. Rear planetary gear set L. Stator
1. Input shaft: Clockwise rotation 2. Front ring gear: Clockwise rotation 3. Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection) 4. Rear ring gear: Clockwise rotation 5. Rear planetary gear carrier and center ring gear: Locked by brake B3 6. Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) 7. Center planetary gear carrier: Counterclockwise rotation (reduced speed) 8. Output shaft: Counterclockwise rotation
Gear R (W) C1 C2 C3 B1 B2 B3 F1 F2
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
19
1. SELECTOR LEVER
Function
Selector lever control unit functions as follows: 1. Informing the selector levers position to other units via CAN. 2. Turning on the selector lever indicator while tail lamp is turning on. 4. Operating the parking/reverse lock system.
CLUTCH T/C M / T
3. Turning on the back-up lamp during reverse driving.
Terminals
Pin No.
1 2 3 4 5 6 7 8 9
Use For
Back-up lamp power supply Ignition power Selector lever unit power CAN LO CAN HI Brake switch signal Ground Self diagnosis connector Tail lamp relay
Remark
Connected to ABS/ESP HECU, engine ECU, TCU, instrument panel etc.
Selector lever position indicator comes on when tail lamp is turned ON

AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
A/T
FUNCTION AND DESCRIPTION
20
3650
Circuit Diagram
Ignition switch
Ignition switch/ TCU terminal A2 (29) Tail lamp relay Self diagnostic 10
Brake switch 9 3 8 6
5 1 Selector lever control unit Backup lamp 7 Instrument panel, HECU, ECU 4
B1 (41) B2 (40)
AUTO TRANSMISSION
KYRON SM - 2005.09
3650 Shifting Mode
21
P (Parking and engine starting position)

: This position is used to park the vehicle, start the engine and let the vehicle be stationaly. To shift into any other positions, must depress the brake pedal (parking lock system).
R (Reverse driving) N (Neutral, starting and towing position)

: The engine can be started in this position. And, this position is used in temporary stop. (Depress the brake pedal for safty.)
T/C
: This position is used to reverse the vehicle.
Selector lever moves only when the brake pedal is depressed.
Downshift (Manual mode) 1 2 3 4 D The shiftable gear is down by one step as the lever is moved to left (-) direction.
Upshift (Manual mode) 1 2 3 4 D The shiftable gear is up by one step as the lever is moved to right (+) direction. Selector lever can be moved without depressing the brake pedal.
WARNING
Turn the ignition key to OFF position before doing this operation.
Shift Lever Lock Release
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Selector lever can be moved without depressing the brake pedal, however for safety reasons, the brake pedal should be depressed.
STNG
SP
AXLE
CLUTCH
M / T
A/T
22
3650
Mode Switch W (Winter Mode)

: When W mode is selected, the Winter mode indicator in meter cluster comes on, and the vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road. (forward and reverse driving)
S (Standard Mode)
: S mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit) provides pleasant driving by changing the shifting pattern according to the driving habits.
In winter mode, the up shift becomes faster and the down shift becomes slower for improving fuel consumption. The W mode is automatically changed to S mode in full throttle or kick-down operation. The vehicle can starts off with 2nd reverse gear (gear ratio: 1.92 ~ 1.93) when the W mode is selected. It is very useful on icy and slippery road. However, in this case, the W switch should be selected before placing the selector lever to R position. Even though W mode is selected, the vehicle starts off with 1st gear in following: 1. When the selector lever is in 1 position. 2. When fully (85% or more) depressing the accelerator pedal. When the system recognizes the mode switch operation, the selector lever control unit sends the control signal TCU via CAN communication.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650 Connection Between Selector Lever and A/T
23
Tightening torque: 4 ~ 8 Nm
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Tighten the bolts to the specified tightening torques as shown in the figure so that the selector lever position should be input correctly. The transmission range lever and gear selector lever (P R N D) should be positioned in N position.
A/T
24
3650
2. TORQUE CONVERTER
Function (4WD)
Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and stator. The pump impeller is welded at converter housing and the converter housing is bolted at the drive plate. The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to transmission input shaft converts this hydraulic energy to mechanical energy again. The stator between pump and turbine increases the output torque from turbine by converting the flowing direction. The stator has a torque converter area that changes the flowing direction and a fluid coupling area where the stator rotates. And, the lockup clutch integrated in torque converter prevents the power from losing and reduces fuel consumption.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
25

M / T
5rd GEAR OPEN 5rd GEAR SLIPPING 4rd GEAR OPEN 4rd GEAR SLIPPING 3rd GEAR OPEN 3rd GEAR SLIPPING
D20DT
D27DT
20
PEDAL VALUE (%)
40
60
80
100
3. Stator 4. Stator shaft
7. Converter cover 8. One-way clutch
11. Piston
Lockup clutch consists of multiple disc clutches as shown in the figure and is activated in 3rd, 4th and 5th gears. The aim of using torque converter lockup clutch is to reduce the fuel consumption and exhaust gas emissions of the vehicle by reducing torque converter slip. This stands in contradiction to the ride comfort demands made on the drive train with regard to its vibration behaviors. The task of the electronic transmission control is therefore to close the clutch in all driving situations relevant to fuel consumption, if possible, and ensure that the engine vibrations are isolated from the drive train. The characteristic curves shown in the diagram illustrate the different operating states of the torque converter lockup clutch in relation to the accelerator pedal position and the transmission output speed, plotted for one transmission gear.
Variables influencing the states of the torque converter lockup clutch: 1. Accelerator pedal movement 2. Uphill and downhill gradients 3. Transmission shift functions 4. Transmission oil temperature 5. Load conditions 6. Engine control influences 7. If the fluid temperature is over 130C, the lock up clutch is operated at 1st and 2nd gears. (to reduce the fluid temperature)
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
1. Pump 2. Turbine
5. Outer multiple disc 6. Inner multiple disc
9. Input shaft 10. Disk
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
Lock Up Clutch
26
3650
Lock-up Clutch Control Valve
Lock-up clutch
Converter outlet
Converter inlet
Lubrication
Oil cooler
Release Operating pressure
Drain
Lubrication pressure Shift valve pressure
Drain
Lockup clutch regulating valve controls the lockup clutch in torque converter and distributes the lubricating oil to the friction parts. TCU generates the lockup clutch control pressure by duty controlling the lockup solenoid valve, and this pressure is applied to the lockup clutch regulating valve to engage, disengage and slip the lockup clutch. When the lockup clutch control pressure is increased, the lockup clutch regulating valve moves up and the working pressure is applied to lockup clutch. In its regulating position (slipping, torque converter lockup clutch pressurized), a reduced volume of lubricating oil flows through the annular passage bypassing the torque converter and passing direct through the oil cooler into the transmission. The rest of the lubricating oil is directed via the throttle a into the torque converter in order to cool the torque converter lockup clutch.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
27
Pinion gear Sun gear
Planetary gear carrier
Locked
Output
Output
Ring gear locked Sun gear driving (clockwise) Planet gears driven (rotating counterclockwise) Planet carrier driven (revolving clockwise) Relatively low step-down ratio Sun gear locked Ring gear driving (clockwise) Planet gears driven (rotating clockwise) Planet carrier driven (revolving clockwise) Direction reversal and step-down ratio Planet carrier locked Sun gear driving (clockwise) Planet gears driven (counterclockwise) Ring gear driven (counterclockwise) Gear ratio: teeth of sun gear / teeth of ring gear
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
Relatively high step-down ratio
BRAKE
Relatively high step-down ratio
Relatively low step-down ratio
Direction reversal and step-down ratio
STNG
SP
AXLE
Output
Input
Locked
Input
CLUTCH
T/C
M / T
Ring gear
A/T
3. PLANETARY GEAR SET
28
3650
4. MULTIPLE-DISC CLUTCH
1. Input shaft 9. Externally toothed disc 10. Internally toothed disc H1. Rear sun gear C1a. Piston C1 C1b. Externally toothed disc carrier C1
C1c. Internally toothed disc carrier C1 C2a. Piston C2 C2b. Externally toothed disc carrier C2 C3a. Piston C3 C3b. Externally toothed disc carrier C3 C3c. Internally toothed disc carrier C3
M1. Middle sun gear M3. Middle planet carrier M4. Middle ring gear V1. Front sun gear V3. Front planet carrier V4. Front ring gear
Location
Three multiple-disc clutches, the front, middle and rear multiple-disc clutches K1, K2 and K3, are located in the planetary gear sets in the transmission housing.
Function and description

A multiple-disc clutch consists of a number of internally toothed discs (10) on an internally toothed disc carrier and externally toothed discs (9) on an externally toothed disc carrier. If the piston (C1a) on multiple-disc clutch C1 is subjected to oil pressure, it presses the internal and external discs of the disc set together. The sun gear (V1) is locked with the planet carrier (V3) via the externally toothed disc carrier (C1b) and the internally toothed disc carrier (C1c). The front planetary gear set is thus locked and turns as a closed unit. If the multiple-disc clutch C2 is actuated via the piston (C2a), the piston compresses the disc set. The ring gear (V4) of the front planetary gear set is locked with the ring gear (M4) of the middle planetary gear set via the externally toothed disc carrier (C2b) and the middle planet carrier (M3) on which the internally toothed discs are seated. Ring gear (V4) and ring gear (M4) turn at the same speed as the input shaft (1). If the multiple-disc clutch C3 is actuated via the piston (C3a), the piston compresses the disc set. The sun gear (M1) of the middle planetary gear set is locked with the sun gear (H1) of the rear planetary gear set via the externally toothed disc carrier (C3b) and the internally toothed disc carrier (C3c).Sun gear (M1) and sun gear (H1) turn at the same speed.
AUTO TRANSMISSION
3650
29
Rotating direction
T/C
Locking element
Locking element (3)
Inner race (2)
Outer race (1)

SP
Locking element cage (4)
Location
Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear planetary gear set between the sun gear and the intermediate shaft.
A / BAG A / CON
Function and description

The freewheel consists of an outer race (1), an inner race (2), a number of locking elements (3) and a cage (4) for these locking elements. If the inner race (2) of the freewheel is locked and the outer race (1) turns in direction A, the locking elements (3) adopt a diagonal position on account of their special contours, allowing the freewheel function. The outer race (1) slides over the locking elements (3) with negligible friction. If the rotation of the outer race (1) changes to direction B, the locking elements (3) stand up and lock the outer and inner races (1, 2) together.
AUTO TRANSMISSION
KYRON SM - 2005.09
BRAKE
STNG
V1/H1 Front or rear sun gear
AXLE
CLUTCH
M / T
A/T
5. FREEWHEEL
30
3650
6. OTHERS
Parking Lock Mechanism
Location and function
The parking lock gear (6) is located on the output shaft in the rear section of the transmission housing. In selector lever position P, the cone (3) slides between the parking lock pawl(4) and the guide sleeve (5). The parking lock pawl (4) is therefore pushed against the parking lock gear (6). If the tooth of the parking lock pawl (4) does not engage in a tooth space when the vehicle is stationary, but rather touches a tooth of the parking lock gear (6), the cone (3) is pre-tensioned by the spring (2) and positioned ready for operation. If the parking lock gear (6) continues to turn, the parking lock pawl (4) engages in the next tooth space. To prevent damage due to misuse, the widths of the tooth spaces are designed such that the parking lock pawl (4) can only engage when the vehicle is stationary or moving very slowly. If the vehicle rolls faster, the shape of the teeth prevents the parking lock pawl (4) from engaging.
1. Detent plate 2. Spring 3. Cone
4. Parking lock pawl 5. Guide sleeve 6. Parking lock gear
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
31
OIL LEVEL CONTROL

Function
Opening
STNG
Planetary gear set chamber
Float
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set does not splash in oil if the oil level rises. The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil level rises, the oil forces the float (1) against the housing. The float separates the oil chamber from the gear set chamber. The lubricating oil which escapes further from the gear sets is thrown against the housing wall by the rotating parts and flows now through the upper opening (arrow) back into the oil chamber. Reduction of power losses and prevention of fluid loss from the transmission at high fluid level.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
Oil chamber
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
32
3650
Oil Check and Specification
Lock pin
Cap
Tube O-ring
* Install cap (2) on tube (1) and insert lock pin (3) into the cap.
Tips for checking and adding

1. Place the vehicle on level ground. Pull out the lock pin and remove the cap (add 4 to 5 liter if oil has been completely drained out). 2. Place the selector lever to P position. Start the engine and leave it idling. 3. Warm the engine up while moving the selector lever to all positions. Check if the oil temperature is approx. 80C with a scanner (apply the parking brake). : Selector lever position - R or D 4. Check the oil level with oil dipstick while engine is running in P position. 5. Check several times with attention, and add or drain the oil as required. 6. After checking and adding oil, install the cap in the reverse order of removal.
Automatic transmission fluid capacity and specification

Fluid capacity Specification Approx. 8 (initial filling)
Fuchs ATF 3353 or Shell ATF 3353
NOTICE
The oil temperature should be checked at D or R position.
AUTO TRANSMISSION
3650
33
1. SELECTOR LEVER AND LINK

1. Place the gear selector lever at D position. Release the lock and remove the knob from the selector lever.
M / T A / CON A / BAG BRAKE STNG SP AXLE CLUTCH T/C
2. Remove the center console upper cover and disconnect the cigarette lighter. Remove the selector lever cover
3. Separate the selector lever pin with a flat blade screwdriver.
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
REMOVAL AND INSTALLATION
34
3650
4. Unscrew the bolt and remove the link from the shift lever. Installation Notice
Shift rod mounting nut 15 ~ 23 Nm
5. Disconnect the selector lever connector, unscrew the mounting bolts (three hexagon bolts), and remove the selector lever assembly.
Disconnect Connector
Remove Bolts (3)
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
35
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
6. Install in the reverse order of removal. Make sure the selector lever and the shift lever are at the same position.
36
3650
2. FRONT AND REAR PROPELLER SHAFT

1. Before removing the front and rear propeller shaft, make installation marks on the yoke and flange.
Preceding Work
Front Propeller Shaft (Transfer Case Side)
1. Drain the automatic transmission fluid. 2. Disconnect the negative cable from battery.
Front Propeller Shaft (Axle Side)
Front Propeller Shaft
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
37
Rear Propeller Shaft (Transfer Case Side) Tightening torque: 81 ~ 89 Nm
Rear Propeller Shaft (Axle Side)
Rear Propeller Shaft Mounting Bracket
Rear Propeller Shaft
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
38
3650
3. TRANSMISSION ASSEMBLY
1. Remove the under cover from the vehicle.
2. Unscrew the crankshaft pulley mounting bolt (27 mm) with a wrench.
3. Remove the protective cover from the service hole for torque converter mounting bolts. Remove six torque converter mounting bolts while aligning them with service hole by rotating the crankshaft bolt.
Torque converter mounting bolt
Service hall protective cover
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
39
4. Unscrew the transmission mounting bolts and carefully remove the transmission with a transmission jack.
NOTICE
Be careful not to drop the torque converter when removing the automatic transmission assembly.
5. Remove the torque converter with a special service tool from the transmission.
6. Install in the reverse order of removal. NOTICE

Apply a small amount of transmission oil on the drive flange of torque converter before installation.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
40
3650
Others
NOTICE
Be careful not to damage the O-ring when removing the dipstick gauge.
Oil Cooling Pipe (Outlet)
Oil Cooling Pipe (inlet) Tightening torque: 25 ~ 35 Nm
Oil Dipstick Gauge
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
41
Shift Lever Link

T/C
Transmission Mounting Insulator and Bracket Tightening torque: 28 ~ 47 Nm

STNG
Transfer Case Assembly Cross Member Assembly Tightening torque: 28 ~ 47 Nm
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
M / T
A/T
42
3650
4. REPLACING THE O-RING ON PARKING PAWL GUIDE SLEEVE

Preceding Works: Removing valve body
When the oil is leaking due to wear or hardening of O-ring on the parking pawl guide sleeve, the O-ring should be replaced with new one.
Parking Pawl Guide Sleeve

NOTICE
Once the O-rings have been removed on the parking pawl guide sleeve and the guide bushing, replace them with new ones.
Spring
Connected to parking lock gear
Guide bushing
Rubber O-ring Parking pawl guide Sleeve
Rubber O-ring
Snap ring
Snap ring
Parking lock lever
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
1. Remove the rear housing cover from the automatic transmission.
43
Installation Notice
Tightening torque 200 Nm
3. Remove the snap ring on the parking pawl guide sleeve in the transmission housing.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
* Bend the collar nut to lock it during installation.
A / BAG
BRAKE
STNG
SP
AXLE
2. Stretch out the bent point (arrow) of 12-sided collar nut on output shaft. Remove the color nut on output shaft with special tool and then separate the flange from the output shaft.
CLUTCH
T/C
M / T
A/T
44
3650
4. Remove the snap ring on the parking pawl guide bushing.
5. Push out the parking pawl guide bushing from inside with a proper tool.
6. Pull up the parking lock lever and remove the parking guide sleeve, parking lock lever and spring.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
45
Pull up this lever to remove the parking pawl guide sleeve.

STNG
7. Replace the O-rings of the parking pawl guide sleeve and bushing.
Guide bushing
NOTICE
Keep clean when installing the O-ring. Open the package of new O-ring just prior to installation. Especially, do not work with cotton gloves wearing.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
46
3650
5. DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T)

Valve Body Assembly
5. Components of Valve Body
1. Adapter plug 2. Drain plug 3. Fixing bolts 4. Oil filter 5. Valve body 5-1. Valve body assembly 5-2. Body assembly
5-3. Pin 5-4. Leaf spring 5-5. Bolts 5-6. Electric kit 5-7. Solenoid valve 5-8. Lifting solenoid valve 5-9. Solenoid valve
5-10. Plate spring 5-11. Screw 5-12. Screw 5-13. Bolts 6. Oil pan 7. Magnet
AUTO TRANSMISSION
KYRON SM - 2005.09
3650 Disassembly and Reassembly

NOTE
47
Installation Notice
Installation Notice
3. Remove the oil filter.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
2. Unscrew the oil pan (6) fixing bolts and remove the oil pan.
STNG
SP
AXLE
CLUTCH
1. Unscrew the hexagon bolts (7 mm) of the adapter plug and remove the guide bush from transmission housing.
T/C
The automatic transmission is very precise equipment. Keep the transmission clean and tighten the bolts with specified tightening torque.
M / T
To eliminate unnecessary working time and process, prepare general tools, special tools, and gaskets before starting the work.
A/T
48
3650
4. Unscrew the bolts and remove the valve body from transmission housing. Installation Notice
5. Disassemble and reassemble the valve body assembly. NOTE

Refer to Valve Body (page 72) section.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
49
Transmission housing
CLUTCH
Converter housing assembly
1. Install the transmission assembly on the workbench.
2. Remove the rear extension housing from transmission housing. Installation Notice
Tightening torque 30 ~ 35 Nm
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Disassembly and Reassembly
STNG
SP
AXLE
T/C
M / T
A/T
Converter Housing and Transmission Housing
50
3650
3. Stretch out the bent point (arrow) in 12-sided collar nut on output shaft.
4. Unscrew the collar nut with special tool and remove the output shaft flange. Installation Notice
* Bend the collar nut to lock it during installation.
5. Remove the rear oil seal ring.
6. Remove the circlip with a circlip pliers and remove the washer.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
7. Remove the ball bearing from transmission housing. 1) Install the flare clamping pliers. 2) Install the puller onto inner bearing race. 3) Rotate the clamping pliers counterclockwise (arrow direction) to tighten. Puller 001 589 50 33 00 (P99420041B) Collet chuck 140 589 06 34 00 (P99360031C) 3) Remove the ball bearing from transmission housing.
51
8. Unscrew the socket bolts separate the transmission housing from converter housing. Installation Notice
NOTE
Gently rock the transmission housing to make the removal process easier.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
52
3650
Converter Housing Assembly

Clutch C3
Clutch C2
Clutch C1
Brake B1
Oil Pump
AUTO TRANSMISSION
KYRON SM - 2005.09

1. Remove the clutch C3 from converter housing assembly.
53
4. Remove the brake B1. 1) Remove the bolts on brake B1. Installation Notice
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
54
3650
2) Remove the bolts in converter housing. Installation Notice
Installation Notice 8 Nm
3) Remove the brake B1 from converter housing.
4) Separate the plate from valve body. NOTICE

Install two bolts on the opposite side of disc brake B1 and tap the surface of disc brake B1 with plastic hammer to remove it from converter housing. Align the dowel pin (arrow) on disc brake B1 and groove in converter housing when installing. Apply the sealant on the socket bolts and tighten them.
5. Unscrew the bolts and remove the oil pump. Installation Notice
NOTICE
Install two bolts on the opposite side of oil pump housing and tap the surface of oil pump with plastic hammer to remove it from converter housing.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
1) Remove the pump gears (1, 2) from pump housing.
55
2) Check the radial seal ring (3), and replace if necessary. 3) Replace the O-ring (4) with new one. NOTICE
Lubricate the pump gears (1, 2) before installation. Place the pump gear (2) into pump housing and install the pump gear (1) onto the pump housing chamber.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
56
3650
Transmission Housing Assembly
Parking Lock Gear
Brake B2
Brake B3
Snap Ring
Components of Selector Lever
AUTO TRANSMISSION
KYRON SM - 2005.09

1. Install the transmission housing assembly on workbench.
57
2. Remove the snap ring from transmission housing.
3. Remove the spring washer and disc pack B3 from transmission housing. NOTICE
To make the removal of snap ring (133a) easier, remove the disc pack B3 while compressing it. Check each disc for wear and burnt out.
4. Remove the fixing bolts for brake B2 from transmission housing. Installation Notice
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
58
3650
5. Remove the disc brake B2 from transmission housing.
6. Remove the parking lock gear.
7. Remove the fixing bolts for range selector lever. Installation Notice
NOTICE
Check the sealing ring for damage.
8. Remove the range selector lever, rod and detent plate.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
9. Remove the snap rings from parking lock pawl.
59
10. Remove the pin from transmission housing.
11. Remove the parking lock pawl from transmission housing.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
60
3650
Components of Each Assembly

Clutch C1
5a
1b
Clutch C2
Clutch C3
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
61
Clutch C1 1. Outer multiple-disc carrier/clutch C1 1b. Sealing ring 2. Piston 3. Sealing ring in piston 4. Disc spring 5. Spring plate 5a. Sealing ring 6. Snap ring 7. Multiple-disc pack 8. Snap ring 9. Snap ring 10. Front freewheel A. Oil pressure bore
Clutch C2 11. Inner multiple-disc carrier/clutch C1 with integrated foot gear set 12. Hollow gear 13. Snap ring 14. Axial needle bearing 15. Clutch C2 and input shaft 16. Piston 17. Inner sealing ring in piston 18. Outer sealing in piston 19. Disc spring 20. Spring retainer 21. Snap ring 22. Multiple-disc set 23. Snap ring Clutch C3 24. Outer multiple-disc carrier 25. Sealing ring 26. Piston 27. Spring plate 28. Disc spring 29. Snap rig 30. Multiple-disc pack
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
62
3650
Multi-disc brake B1
Multi-disc brake B2
Multi-disc brake B1 1. Externally toothed disc carrier/multiple-disc brake B1 2. Piston 3. Spring washer, back pressure/piston 4. Snap ring 5. Spring washer/multiple-disc pack 6. Multiple-disc pack 7. Snap ring
Multi-disc brake B2 8. Disc carrier B2 9. Sealing ring 10. Sealing ring 11. Piston in B2 12. Sealing ring in piston guide ring 13. Sealing ring in piston guide ring 14. Piston disc spring 15. Spring plate 16. Snap ring 17. Piston guides in B2 and B3 18. O-ring 19. Multiple-disc pack 20. Snap ring 21. Disc spring
AUTO TRANSMISSION
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63
Rear gear set and center output shaft
Rear freewheel and rear hollow shaft
Rear gear set and center output shaft 1. Output shaft in center gear set 2. Needle bearing 3. Teflon ring 4. Thrust washer 5. Thrust needle bearing 6. Shim 7. Circlip 8. Rear gear set 9. Thrust washer 10. Clutch C3 11. Rear hollow shaft C. Oil outlet port in clutch C3 D. Oil inlet port in clutch C3
Rear freewheel and rear hollow shaft 12. Hollow shaft 13. O-ring 14. Snap ring 15. Freewheel 16. Inner disc carrier and rear sun gear/clutch C3 17. Thrust needle bearing 18. Shim 19. Circlip
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
64
3650
When Installing the Transmission

1. Measure the clearance between the ball bearing and the parking lock gear. 1) Place the measuring bridge on the top of transmission housing and measure the distance from the parking lock gear (a) to the measuring bridge. 2) Measure the distance from measuring bridge to the ball bearing groove on mating surface with gauge (b). 3) Adjust the axial play E with adjusting shim. ex): Distance a Distance b Difference Axial play E Shim size
Axial play
49.90 mm 49.00 mm 0.90 mm 0.40 mm 0.50 mm

0.3 ~ 0.5 mm
NOTICE
Select a proper thickness of shim: 0.2, 0.3, 0.4, 0.5 mm
2. Install a shim. Measuring bridge 126 589 04 31 00
3. Insert the ball bearing into rear part of transmission housing. NOTICE
Measure the clearance between ball bearing (2) and circlip. Install the appropriate size of circlip (2.0, 2.1, 2.2 mm).
4. Install the radial sealing with a special tool.
AUTO TRANSMISSION
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65
Structure of Electro-hydraulic Control Module (Shift Plate)
D. Clutch lockup control valve, shift valve B2
Rear Section
Filter
Plastic valve Valve ball (steel)
Filter
Dowel pin Valve ball (plastic)
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
A. Adjusting valve/operating pressure, adjusting valve/ Lubricating pressure, adjusting valve/2-3 group overlap
B. 1-2/4-5 shift group, adjusting valve/shift pressure, adjusting valve/control valve pressure, adjusting valve/shift valve pressure C. 3-4 shift group
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
6. VALVE BODY
66
3650
Left Section
1. Shift housing 2. 1-2/4-5 command valve 3. 1-2/4-5 holding pressure shift valve 4. 1-2/4-5 shift pressure shift valve 5. 1-2/4-5 overlap control valve 6. Shift pressure control valve 7. Regulating pressure control valve
8. Shift valve pressure control valve 9. Torque converter lockup clutch control valve 10. 2-3 shift pressure shift valve 11. 2-3 command valve 12. 2-3 holding pressure shift valve 13. Shift valve B2
Right Section
1. Valve housing 2. Selector valve 3. 2-3 overlap control valve 4. Lubricating pressure control valve 5. Operating pressure control valve
6. 3-4 holding pressure shift valve 7. 3-4 command valve 8. 3-4 shift pressure shift valve 9. 3-4 overlap control valve
AUTO TRANSMISSION
KYRON SM - 2005.09

1. Remove the leaf spring (5) 2. Remove the bolt (1).
Bolts (29)
67
Installation Notice
3. Remove the shift housing (4) from valve housing (2).

Valve housing
NOTICE
Before installation, make sure to insert the dowel pin into correct position. Sealing plate
4. Remove the sealing plate (3). NOTICE

Do not forget that there are 4 plastic balls and 8 steel balls in shift housing.
Shift housing Bolt
Installation Notice
NOTICE
Check the valves for damage and replace them, if necessary.
6. Install in the reverse order of removal.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
5. Unscrew the bolts from shift housing and valve housing and remove the side cover.
STNG
Leaf spring
SP
AXLE
CLUTCH
T/C
M / T
A/T
68
3650
SPECIAL TOOLS AND EQUIPMENT

Name and Part Number
126 589 01 62 00 (W99360220B) Handle
Application
Removal/installation of torque converter
116 589 06 59 00 (W99360180B) Fixing plate
Fixing automatic transmission
140 589 12 15 00 (P99360041C) Drift punch
Installation of sealing ring
001 589 50 33 00 (P99420041B) Puller
Removal and installation of transmission housing ball bearing
AUTO TRANSMISSION
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69
140 589 34 63 00 (A99360030B) Mounting plate
Fixing automatic transmission
140 589 06 34 00 (P99360031C) Collet chuck
Removal and installation of transmission housing ball bearing
140 589 13 43 00 (P99360021C) Piston puller
Removal and installation of B1, B2 and B3 pistons
126 589 02 09 00 Socket
Removal and installation of collar nut for output shaft
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Application
A/T
70
3650

128 589 04 31 00 (W99360242C) Measuring bridge Measuring the clearance between ball bearing and parking lock gear
Application
Compressor
Compressing clutch and disc brake
AUTO TRANSMISSION
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71
* Tool for ATF checking only Name and Part Number

126 589 12 63 00 (W99360282A) Funnel

210 589 00 71 00 (P99360012C) Hand pipe
T/C M / T
140 589 15 21 00 Dipstick gauge
140 589 49 63 00 Filling pipe
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
A/T
72
3650
VALVE BODY
Shift Pressure Control Solenoid Valve
8 7 9 7
10
7 E F
1. Leaf spring 2. Contact spring 3. Conductor track 4. O-ring 5. O-ring 6. Shift plate
7. Leaf spring and socket bolt 8. Solenoid valve A. 1-2, 4-5 shift solenoid valve B. 3-4 shift solenoid valve
9. Solenoid valve C. Shift pressure control solenoid valve D. Modulating pressure control solenoid valve 10. Solenoid valve E. Lockup PWM solenoid valve F. 2-3 shift solenoid valve
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Function
The plastic Electric Hydraulic Control Unit (EHU) is installed on the top of valve body. Speed sensor, start lock-out switch and oil temperature sensors are integrated in EHU. The 13-pin connector is connected to automatic transmission via PCB. The solenoid valves are sealed with two O-rings against the valve body. The solenoid valves are pressed against the valve body by the leaf springs.
T/C A / CON A / BAG BRAKE STNG SP AXLE CLUTCH M / T
Three up/downshift solenoid valves are installed on the top of hydraulic control unit.
Characteristics of up/downshift solenoid valve

The solenoid valve remains energized and therefore open until the shift process is completed according to the engine and transmission conditions. If a solenoid valve is energized, it opens and transmits the shift valve pressure to the corresponding command valve.
Working current Operating distance Resistance 1.5 ~ 2.0 A 0.2 mm 3.91 0.12 (25C)
60ms T (Time) 1.5A I (Current)
2.5A
1 cycle time: approx 20 ms
Circuit Diagram
B3 (38)
3-4 shift S/V
2-3 shift S/V
1-2, 4-5 shift S/V
B12 (14) B10 (16) B11 (15)
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
74
3650
Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve
Solenoid valve
1. Leaf spring 2. Shift plate 3. Strainer
4. MP control solenoid valve 5. SP control solenoid valve
Function
These valves control the modulating pressure and the shift pressure by applying appropriate current to solenoid valves according to driving condition of engine and transmission. When the current value from TCU is high or low, accordingly the regulated pressure decreases or increases.
Working current Operating distance Resistance 0 ~ 1.2 A 0.6 mm 5.0 0.3 (23C)
Line pressure Regulated pressure Regulated pressure Drain line
Drain line
Line pressure
AUTO TRANSMISSION
KYRON SM - 2005.09
3650 Circuit Diagram
75
B3 (38)
B4 (37) B5 (36)
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
76
3650
Lockup Solenoid Valve
1. Leaf spring 2. O-ring
3. Shift plate
Function
This valve activates and releases the lockup clutch by adjusting the current to solenoid valve according to engine throttle opening value and output shaft speed. The lockup clutch operates in 3rd, 4th and 5th gear step by step in order to reduce shift shocks.
Working current Operating distance Resistance Operating range 1.5 ~ 2.0 A 0.2 mm 2.5 0.2 (25C) 3, 4, 5
Circuit Diagram
B3 (38)
Lockup S/V 11
B9 (17)
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77
Speed sensor (n3)
Speed sensor (n2)
1. Leaf spring 2. Valve body
3. Pulse ring
Function
The speed sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests against the valve body, presses the speed sensors against the transmission housing. This ensures a precise distance between speed sensors and impulse rings. The speed sensor (n3) detects the speed of the front sun gear and the speed sensor (n2) detects the speed of the front planetary carrier. If the speed sensor is defective, the transmission is operated in emergency driving mode. Below diagram shows the detection of speed sensor.
Gear 1 2 3 4 5 R (S mode) R (W mode) N2 N3
Circuit Diagram
B6 (35) B13 (13)
Speed sensor n3
Speed sensor n2
B14 (12)
B8 (33)
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Speed Sensor
78
3650
Oil Temperature Sensor
Oil temperature sensor
Function
The oil temperature sensor is installed in the hydraulic control unit and is connected in series with the starter lock-out contact. This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed. The oil temperature has a considerable effect on the shifting time and therefore the shift quality. By measuring the oil temperature, shift operations can be optimized in all temperature ranges.
Circuit Diagram
Start lock out switch
B7 (34)
AD converter
B8 (33)
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1. Plunger 2. Permanent magnet
3. Reed contact
Function
The starter lock-out switch is installed beside the oil temperature sensor and is actuated by a cam rail, which is located on the latching plate. In the selector lever positions P and N, the permanent magnet is moved away from the reed contact. This opens the reed contact and the transmission control module receives an electrical signal. The transmission control module activates the starter lock-out relay module. This closes the electrical circuit to the starter in selector lever positions P and N via the starter lock-out relay module. In other words, when the selector lever is in driving positions, the switch contact is closed and the starter cannot be operated.
Circuit Diagram
B+ ST Start lock out switch

B7 (34) B8 (33) 30 86
AD converter
Start Relay
87 85

A12 (7)
Start motor
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Starter Lock-out Switch
80
3650
HYDRAULIC CIRCUIT
1. HYDRAULIC CIRCUIT DIAGRAM
AUTO TRANSMISSION
KYRON SM - 2005.09
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81
A. Valve Housing 1. Selector valve 2. 2-3 overlap control valve 3. Lubricating pressure control valve 4. Operating pressure control valve 5. Holding pressure shift valve 6. Command valve 7. 3-4 shift valve 8. 3-4 overlap control valve 9. One-way throttle valve
B. Shift Housing 10. Ball change over valve 11. Ball change over valve 12. Filter screen 13. Ball change over valve 14. 1-2/4-5 command valve 15. 1-2/4-5 holding pressure shift valve 16. 1-2/4-5 shift valve 18. 1-2/4-5 overlap control valve 19. Shift pressure control valve 20. Regulating pressure control valve 21. Shift valve pressure control valve 22. Lock-up clutch control valve 24. 2-3 shift valve 25. 2-3 command valve 26. 2-3 holding pressure shift valve 27. B 2 shift valve 50. Oil pump 51. Oil cooler 52. Oil pan 53. Oil filter 54. Oil sump
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
82
3650
Oil Pressure
Modulating pressure control solenoid valve
Shift pressure control solenoid valve
1. Lubricating pressure control valve 2. Operating pressure control valve 3. One-way throttle valve 4. Shift pressure control valve 5. Control valve - control valve pressure
6. Shift pressure control valve 7. Oil pump 8. Drain p-A. Operating pressure
Operating Pressure (P-A)

The inscribed gear type oil pump is installed into the torque converter housing and is driven via the drive flange of the torque converter. The operating pressure produced from oil pump supplies oil pressure to main line in hydraulic system to operate the actuator. The operating pressure is the highest pressure in the hydraulic system. All other pressures are derived from it. The operating pressure is regulated at the operating pressure control valve depending on load (modulating pressure) and driving range (C1, C2 pressure). The spring in the operating pressure control valve adjusts a minimum pressure level (base pressure).
Lubricating Pressure (P-sm)

This pressure limits the pressure in torque converter and lubricates and cools down the mechanical transmission parts. At the operating pressure control valve, excess fluid is diverted to the lubricating pressure control valve (1) and, from there, regulated for transmission lubrication use (including torque converter).
AUTO TRANSMISSION
3650
83
Control Valve Pressure (P-rv)

The control valve pressure is set at the control pressure regulating valve (5) in relation to the operating pressure up to 8 bar. This pressure supplies oil to modulating pressure (MP) solenoid valve, shift pressure (SP) solenoid valve and shift valve pressure control valve (6).
Modulating Pressure (P-m)

The modulating pressure is adjusted at the modulating pressure control solenoid valve. The height of modulating pressure is dependent on engine load by TCU. It acts on the operating pressure control valve and the pressure overlap control valve. It increases the operating pressure (line pressure) when the load is heavy.
Shift Pressure (P-s)

The shift pressure is adjusted at the shift pressure control solenoid valve and shift pressure control valve (4). Additional pressure from clutch C2 acts on the shift pressure control valve. As a result, the shift pressure in 2nd gear is reduced.
Shift Valve Pressure (P-sv)

The shift valve pressure converts the control valve pressure (p-RV) to shift valve pressure. Then it supplies oil to command valve, lockup solenoid valve, and shift pressure control solenoid valves.
STNG A / CON
AUTO TRANSMISSION
KYRON SM - 2005.09
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
84
3650
Shift Groups
The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during and after a gear change, is called a shift group. The hydraulic system consists of 3 shift groups. A shift group can be in two phases. 1. Shift phase 2. Stationary phase In the shift phase, a change takes place in one shift group of the engaged clutch/brake. The other two shift groups are then in the stationary phase. Shift group C1/B1 (gear change 1-2/4-5) is responsible for the up/down shifts 1-2/2-1 and 4-5/5-4. It includes: 1. Clutch C1 2. Brake B1 3. Command valve 4. Holding pressure shift valve 5. 1-2/4-5 shift solenoid valve 6. Pressure overlap control valve 7. 1-2/4-5 shift solenoid valve Shift group C2/C3 (gear change 2-3) is responsible for the up/down shifts 2-3/3-2. It includes: 1. Clutch C2 2. Clutch C3 3. Command valve 4. Holding pressure shift valve 5. 2-3 shift solenoid valve 6. Pressure overlap control valve 7. 2-3 shift solenoid valve Shift group C3/B2 (gear change 3-4) is responsible for the up/down shifts 3-4/4-3 and the engagement process. It includes: 1. Clutch C3, 3-4 pressure overlap control valve 2. Brake B2, 3-4 shift solenoid valve 3. Brake B3 4. Command valve 5. Holding pressure shift valve 6. 3-4 shift solenoid valve
AUTO TRANSMISSION
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85
Selector Lever N
3-4 shift solenoid valve
1. Selector valve 5. 3-4 holding pressure shift valve 6. 3-4 command valve 7. 3-4 shift pressure shift valve 8. 3-4 overlap control valve 10. Ball valve 13. Ball valve 14. 1-2/4-5 command valve 19. Shift pressure control valve 27. B2 shift valve
B2a : B2 piston B2b : Opposite face of B2 piston m : Annular surface p-A : Operating pressure p-Mod : Modulating pressure p-RV : Control valve pressure p-S : Shift pressure p-S/RMV : Shift pressure/control solenoid valve p-SV : Shift valve pressure
The operating pressure (p-A) is formed and travels via the 2-3 holding pressure shift valve, the 2-3 command valve and ball valve (13) to clutch C3 and via the 3-4 command valve (6) to the end face of the 3-4 shift pressure shift valve (7). At the same time, the 3-4 solenoid valve is energized. This allows shift valve pressure (p-SV) to enter the spring chamber of the shift valve B2 (27) and to reach the end face of the 3-4 command valve (6). The shift valve B2 (27) is held in the upper position and the 3-4 command valve (6) moves towards the right. At the end face of the 3-4 shift pressure shift valve (7), the operating pressure (p-A) is replaced by shift valve pressure (p-SV).
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
2. HYDRAULIC CIRCUIT
86
3650
Hydraulic Circuit when Selector Lever is in D Position (Shift Phase)
1. Selector valve 5. 3-4 holding pressure shift valve 6. 3-4 command valve 7. 3-4 shift valve 8. 3-4 overlap control valve 10. Ball valve 13. Ball valve 14. 1-2/4-5 command valve 19. Shift pressure control valve 27. B2 shift valve
B2a : B2 piston B2b : Opposite face of B2 piston m : Annular surface p-A : Operating pressure p-Mod : Modulating pressure p-RV : Control valve pressure p-S : Shift pressure p-S/RMV : Shift pressure/control solenoid valve p-SV : Shift valve pressure
The selector valve (1) opens the shift pressure (p-S) feed connection from the ball valve (10) with the shift valve B2 (27). With the shift valve B2 (27) in the upper position, shift pressure (p-S) travels behind the piston B2 (B2a) and simultaneously to the opposite face of the piston B2 (B2b). The brake B2 begins to activate.
AUTO TRANSMISSION
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6. 3-4 command valve 7. 3-4 shift valve 8. 3-4 overlap control valve 10. Ball valve 13. Ball valve 14. 1-2/4-5 command valve 19. Shift pressure control valve 27. B2 shift valve 32. Pressure holding valve
m : Annular surface p-A : Operating pressure p-Mod : Modulating pressure p-RV : Control valve pressure p-S : Shift pressureShift pressure p-S/RMV : Shift pressure/control solenoid valve p-SV : Shift valve pressure
The pressure on the opposite face of the piston B2 (B2b) ensures a soft activation of the brake B2. The TCU monitors the activation sequence via the speed of input shaft, which slows down as the frictional connection in the brake increases. When the speed drops to the specified level, TCU shuts off the power to the 3-4 shift solenoid valve. The spring chamber of the shift valve B2 (27) is depressurized and moves downwards. This connects the line to the opposite face of the piston B2 (B2b) with the pressure holding valve (32). The pressure on the opposite face of the piston B2 (B2b) drops to a residual pressure. The 3-4 command valve (6) moves to the left. The operating pressure (p-A) travels via the holding pressure shift valve (5) and the 3-4 command valve (6) to the piston of brake B2 (B2a).
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
1. Selector valve 5. 3-4 holding pressure shift valve
B2a : B2 piston B2b : Opposite face of B2 piston
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Hydraulic Circuit when Selector Lever is in D Position (1st Gear)
88
3650
Hydraulic Circuit after Shifted to 1st Gear
1-2/4-5 shift solenoid valve
14. 1-2/4-5 command valve 15. 1-2/4-5 holding pressure shift valve 16. 1-2 /4-5 shift valve 18. 1-2/4-5 overlap control valve
0 : Return flow to oil sump p-A : Operating pressure p-MOD : Modulating pressure p-S : Shift pressure p-SV : Shift valve pressure
The end face of 1-2/4-5 command valve (14) is kept unpressurized via the 1-2/4-5 solenoid valve. The operating pressure is applied to the brake B1 via the holding pressure shift valve (15). The clutch C1 is unpressurized. The operating pressure from brake B1 acts against the holding pressure shift valve (15) and the end face of 1-2/4-5 shift pressure shift valve (16).
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16. 1-2/4-5 shift valve 18. 1-2/4-5 overlap control valve
p-MOD : Modulating pressure p-S : Shift pressure p-SV : Shift valve pressure
The shift valve pressure (p-SV) is directed onto the end face of the 1-2/4-5 command valve (14) via the 1-2/4-5 shift solenoid valve. The command valve (14) moves up and the shift pressure (p-S) coming from the 1-2/4-5 shift pressure shift valve (16) is routed via the command valve (14) to clutch C1. Overlap pressure is simultaneously applied to brake (B1) from the pressure overlap control valve (18). The B1 pressure acting on the end face of shift pressure shift valve (16) is replaced by operating pressure (p-A). The increasing shift pressure (p-S) on clutch C1 acts on the annular surface of the pressure overlap control valve (18) and reduces the overlap pressure controlled by the pressure overlap control valve (18). It will shift at a corresponding pressure on the holding pressure shift valve (15).
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
14. 1-2/4-5 command valve 15. 1-2/4-5 holding pressure shift valve
o : Return flow to oil sump p-A : Operating pressure
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Hydraulic Circuit During Shift Phase (2nd Gear)
90
3650
Hydraulic Circuit after Completed Gear Change (2nd Gear)
14. 1-2/4-5 command valve 15. 1-2/4-5 holding pressure shift valve 16. 1-2/4-5 shift valve 18. 1-2/4-5 overlap control valve
o : Return flow to oil sump p-A : Operating pressure p-MOD : Modulating pressure p-S : Shift pressure p-SV : Shift valve pressure
The 1-2/4-5 shift solenoid valve interrupts the pressure on the end face of the command valve (14) and it returns to its base position. The operating pressure (p-A) is now applied to clutch C1 via the holding pressure shift valve (15) and the command valve (14). The brake B1 is disengaged (unpressurized). The spring of the shift pressure shift valve (16) moves it into base position.
AUTO TRANSMISSION
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91
The adapter plug is an input and output terminal assembly for TCU to control the valve body. It is installed to the valve body with 7 mm bolts. To prevent oil leakage, two O-rings are installed on the plug. 1. Remove the heat shield for adapter plug wire next to exhaust tube.
2. Turn the adapter plug lock counterclockwise and disconnect the plug connector.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
3. ADAPTER PLUG
92
3650
3. Unscrew the bolts (7 mm) and carefully remove the adapter plug. NOTICE
Keep the specified tightening torque (4 Nm 0.5 Nm). Otherwise, it may result in unnecessary replacement of electric kit in assembly due to oil leakage. Do not apply an excessive force to remove the adapter plug. It may cause an internal damage to electrci kit.
4. Place an empty container under the adapter plug and remove the adapter plug.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
93
Valve body can be replaced from onboard and from removed transmission. Valve Body Assembly
Valve body
Electric kit
Lock-up PWM solenoid valve
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Shift pressure solenoid valve
STNG
Modulating pressure solenoid valve
1-2/4-5 Shift pressure solenoid valve
SP
AXLE
CLUTCH
T/C
M / T
A/T
4. VALVE BODY
94
3650
Valve Body Replacement (Onboard)

1. Remove the oil pan drain plug and drain the oil completely.
2. Unscrew the six oil pan bolts (T30) and carefully lower the oil pan (6).
3. Carefully remove the oil filter.
AUTO TRANSMISSION
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95
4. Unscrew the fixing bolts (T30).
5. Carefully remove the valve body from transmission housing.

SP
Valve Body Assembly
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
96
3650
Valve Body Replacement (From Removed T/M)

Preceding Works: Install the transmission on the workbench. NOTE
To eliminate unnecessary working time and process, prepare general tools, special tools, and gaskets before starting the work. The automatic transmission is very precise equipment. Keep the transmission clean and tighten the bolts with specified tightening torque.
1. Unscrew the hexagon bolt (7 mm) and remove the guide bush from transmission housing. Installation Notice
2. Unscrew the oil pan bolts and remove the oil pan. Installation Notice
3. Remove the oil filter.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
4. Unscrew the bolts and remove the valve body from transmission housing. Installation Notice
97
5. Disassemble the valve body assembly.
5-1. Unscrew the socket bolts on the solenoid valve and remove the leaf springs. Installation Notice
The length of socket bolts vary. Be careful not to mix up.
5-2. Remove the solenoid valves from the valve body.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
NOTICE
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Tightening torque
8 Nm
A/T
98
3650
NOTICE
Make sure to install the solenoid valves in place Check the O-rings, and replace if necessary.
5-3. Remove the electronic control module from the shift plate. NOTICE
Correctly align the electronic control module onto the shift plate by using two central pins when installing.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
99
Function
TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit.
TCU
1. Shifting Method Basic shift operation includes up-shift and down-shift for all gear groups. The shift control unit determines driving resistance, accelerator pedal position, vehicle speed and some parameters (road surface condition, up hill and down hill gradients, trailer driving conditions, catalytic converter conditions, driving habits and automatic transmission oil temperature) to select a shift gear. 2. Down Shift When engine speed increases excessively, the down shift does not occur. To get an engine brake effect during downhill driving, the current gear is maintained in speed control mode. 3. Engine RPM Adjustment During shifting, the engine torque is reduced to optimize the shift operation by delaying the ignition time. 4. Lock-Up Clutch Control The lockup clutch in torque converter is activated in 3rd, 4th and 5th gear and operates in sequence via PWM solenoid valve. 5. Others The transmission is automatically controlled to compensate durability and wear. The shift control values such as shifting point, shifting time, pressure during shifting, and lockup clutch control are permanently saved and the diagnosis is partially available.
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
TCU (Transmission Control Unit)
100
3650
TCU Block Diagram
Engine torque Max. Engine torque Engine power loss Engine rpm
M/P S/V S/P S/V
Power supply (valves) 1-2/4-5 gears S/V 3-4 gears S/V
Engine control
ACC pedal position Shift pattern changes Engine control status Engine torque reduction
Sol. valve
D I T C G I T A A C L
2-3 gears S/V Lockup clutch S/V
Wheel speed FR, FL
Sensor power supply Sensor ground
ABS/ ESP HECU
Wheel speed RR, RL Shift pattern changes Driving force control
Sensor
Start signal
Starter relay
Trouble diagnosis connector
Pos. ID signal
Selector lever W/S mode signal Position unit
N2 speed
T/M
N
Back-up lamp
N3 speed
U
Diagnosis
Diag. Conn.
TCU(EGS) power W/S mode signal Selector lever indication P/N starting recognition
IGN1
I/P
Mileage TCU(EGS) ground
Power ground
* Refer to the circuit diagram for the detailed wiring connection and related pin number.
AUTO TRANSMISSION
3650
101
Emergency driving mode can largely be divided in electrical defective and hydraulic pressure/mechanical defective.
T/C
Electrical defect
1. If an electrical defective occurs in transmission during driving, current shift gear position is held. 1) Shut off of various solenoid valves 2) Internal pressure in transmission increases (shift shock gets bigger when changing selector lever due to maximized MP and SP) 3) Lockup clutch is released 2. If the shift operation cannot be activated, the driver must reset the system as follows: 2) Wait for 10 seconds after stopping the engine (release hydraulic pressure) 3) Start the engine. 4) Place the selector lever to D or R position.
1. Characteristics that appears in the vehicle are as below: 1) Holds at 3rd gear (It can be held at proper gear if the fault occurs at 3rd gear) 2) Electrical devices operate normally and the shift shock is acceptable during shift operation. 2. If the shift operation cannot be activated, the driver must reset the system as follows: 1) Stop the vehicle. 2) Stop the engine. 3) In most cases, it is reset when the engine is started and the vehicle operate normally.
AUTO TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Mechanical/hydraulic pressure defect
STNG
SP
1) Stop the vehicle and place the selector lever to P position.
AXLE
CLUTCH
M / T
The emergency driving mode is to minimize the vehicles operation, which is a mode for maintaining minimum driving condition if the automatic transmission is defective. In emergency driving mode, excessively long driving and unreasonable driving should be avoided to prevent a critical fault occurence in advance.
A/T
Characteristics of TCU and Automatic Transmission (LHM: Limp-Home Mode)
102
3650
CAN (Controller Area Network)

Function
CAN Input Signal

Accelerator pedal position Wheel speed (all wheels) Engine rpm, Engine torque Coolant temperature Downshift Speed control (constant) 2nd gear start up control Gear status in transfer case Selector lever position Odometer (I/P) Kick-down status
CAN Output Signal
Selected gear Shifted status Lock-up clutch status
Driving position
TCU
Engine torque control Dangerous status (changes to emergency mode when overloading, dangerous conditions, and internal fault exists) ATF Temperature
Circuit Diagram
Self diagnostic 11
A18 (1) B1 (41)
B2 (40)
Instrument panel
Selector lever unit
AUTO TRANSMISSION
KYRON SM - 2005.09
3650 Connector Arrangement and Pin Functions

Connector
103
10
12
17
M / T
23
30
33
38
L H
TCU (Connector connection)
A18
A9
B14
B9
AXLE
A8
A1 Connector A
B8
B1 Connector B
STNG
DC No. EWD No.

1 7 12 13 14 15 16 17 29 30 33 34 35 36 37 38 L H
Description
Diagnostic Initiating the starter relay Speed sensor N2 Speed sensor voltage supply 1-2, 4-5 solenoid valve 3-4 solenoid valve 2-3 solenoid valve Lockup clutch solenoid valve TCU voltage supply Ground Speed sensor ground ATF temperature, Starter lock-out contact Speed sensor N3 Modulating pressure solenoid valve Shift pressure solenoid valve Each solenoid valve voltage CAN LOW CAN HIGH
Connected to
Diagnostic connector pin No.11 Starter relay 13-pin plug No.3 13-pin plug No.7 13-pin plug No.13 13-pin plug No.9 13-pin plug No.8 13-pin plug No.11 13-pin plug No.12 13-pin plug No.4 13-pin plug No.1 13-pin plug No.2 13-pin plug No.10 13-pin plug No.6 ECM, HECU, selector lever unit, instrument panel ECM, HECU, selector lever unit, instrument panel
AUTO TRANSMISSION
KYRON SM - 2005.09
A18 A12 B14 B13 B12 B11 B10 B9 A2 A1 B8 B7 B6 B5 B4 B3 B2 B1
A / CON
A / BAG
BRAKE
Pin No.
SP
CLUTCH
T/C
Connector A
Connector B
A/T
104
3650
TROUBLE CODE AND DIAGNOSIS

1. TROUBLE DIAGNOSIS WITH SCAN-100
Diagnostic Connector
Scan-100 Diagnosis Procedure

1. Connect the Scan-100 harness connector to the diagnostic socket. 2. Turn the ignition switch to ON position. 3. Select [TROUBLE CODE] in [FUNCTION SELECTION] screen and press [ENTER]. 4. Select [KYRON] in [VEHICLE SELECTION] screen and press and press [ENTER]. 5. Select [TCU] in [CONTROL UNIT SELECTION] screen and press [ENTER]. 6. Select DC 5-speed transmission. 7. Select [SELF-DIAGNOSTICS] in [SELECT TEST ITEM] screen. 8. Determine the DTC and locate the trouble cause.
NOTE
Choose data list item to check sensors and other informative data.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
105
Trouble Code
P2000
Defectives
Faulty TCU internal watchdog test
Action
- Self-diagnosis with IGN ON. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists.
P2001
Faulty TCU internal watchdog function
- Self-diagnosis. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists. - Self-diagnosis with IGN ON. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists.
P2002
Faulty TCU external watchdog test
P2003
Faulty TCU external watchdog function Faulty TCU Clock
- Self-diagnosis. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists. - Self-diagnosis. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists.
P2004
P2005
Faulty TCU RAM
P2006
Faulty TCU RAM CAN-Controller 1
P2007
Faulty TCU RAM CAN-Controller 2
P2008
Faulty TCU ROM
- Self-diagnosis with IGN ON. - When the TCU internal checksum is different from scanner checksum. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists.
P200A
Faulty TCU EEPROM
P200B P200C P2010
Faulty TCU CPU (internal) Faulty TCU program control No TCU variant coding
- Self-diagnosis. - Check harness contact. - Self-diagnosis. - Check harness contact. - Self-diagnosis with IGN ON. - When the TCU coding is not exist. - Check again after TCU coding.
P2011
Faulty TCU variant coding
- Self-diagnosis with IGN ON. - When the TCU coding is faulty. - Check again after TCU coding.
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
2. DTC (DIAGNOSIS TROUBLE CODE) OF DC5AT
106
3650
Trouble Code
P2012
Defectives
Faulty TCU checksum
Action
P2013
Faulty TCU (internally)
P2100
Defective 1-2, 4-5 shift solenoid valve
- When 1-2 or 4-5 shift solenoid valve is defective. - Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN OFF, then and disconnect TCU connector). TCU connector terminals: B12 (14), B3 (38) Specified value : 3.8 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
P2101
1-2, 4-5 shift solenoid valve - short
- When 1-2 or 4-5 shift solenoid valve is defective. - Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B12 (14), B3 (38) Specified value : 3.8 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
P2102
Defective 2-3 shift solenoid valve
- When 2-3 shift solenoid valve is defective. - Measure the resistance of 2-3 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B12 (14), B3 (38) Specified value : 3.8 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
P2103
2-3 shift solenoid valve - short
- When 2-3 shift solenoid valve is defective. - Measure the resistance of 2-3 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B12 (14), B3 (38) Specified value : 3.8 0.2 - Triggered mechanical emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Trouble Code
P2104
107
Defective 3-4 shift solenoid valve
- When 3-4 shift solenoid valve is defective.

- Measure the resistance of 3-4 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B11 (15), B3 (38) Specified value : 3.8 0.2 - Triggered mechanical emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact. P2105 3-4 shift solenoid valve - short - When 3-4 shift solenoid valve is defective. - Measure the resistance of 3-4 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B11 (15), B3 (38) Specified value : 3.8 0.2 - Triggered mechanical emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact. P2106 Defective lockup clutch solenoid valve - Measure the resistance of lockup clutch solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B9 (17), B3 (38) Specified value : 2.5 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact. P2107 Defective modulator pressure solenoid valve - Measure the resistance of modulator pressure solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B5 (36), B3 (38) Specified value : 5.0 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact. P2108 Defective shift pressure solenoid valve - Measure the resistance of shift pressure solenoid valve (turn the IGN OFF, then disconnect TCU connector). TCU connector terminals: B4 (37), B3 (38) Specified value : 5.0 0.2 - Triggered emergency mode when the defective is detected. Electrical error : Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
Defectives
Action
108
3650
Trouble Code
P2200
Defectives
Faulty speed sensor N2 signal
Action
- When the speed sensor N2 detects 0 rpm of front sun gear speed. - Check the related harness for open, short and contact. TCU connector terminal B14: rectangular wave signal B8: signal ground B13: 6V
P2203
Faulty speed sensor N3 signal
- When the speed sensor N3 detects 0 rpm of planetary gear carrier speed. - Check the related harness for open, short and contact. TCU TCU connector terminal B6: rectangular wave signal B8: signal ground B13: 6V
P220A
Abnormal speed sensor output signal (N2, N3) T/M Oil temperature sensor - short
- When the rpm difference between speed sensor N2 and N3 is over 150 rpm. - Check the related harness for open, short and contact. - Turn the IGN OFF, then disconnect TCU connector. - Selector lever position: R or D - T/M Measure the resistance of oil temperature sensor. TCU connector terminals B7, B8 - Check the related harness for open, short and contact.
P2220
P2221
Abnormal T/M oil temperature sensor signal
- Turn the IGN OFF, then disconnect TCU connector. - Selector lever position: R or D - Measure the resistance of T/M oil temperature sensor. TCU connector terminals: B7, B8 - Check the related harness for open, short and contact.
P2222
Abnormal T/M oil temperature sensor signal
- Turn the IGN OFF, then disconnect TCU connector. - Selector lever position : R or D - Measure the resistance of T/M oil temperature sensor. TCU connector terminals: B7, B8 - Check the related harness for open, short and contact.
P2300
Faulty CAN communication
- Turn the IGN OFF, then disconnect TCU connector. - Check the communication line for open, short and contact. - Measure the resistance of CAN line: B1, B2 Specified value : approx. 120 - Turn the IGN OFF, then disconnect TCU connector.
P2301
Faulty CAN communication
- Check the communication line for open, short and contact. - Measure the resistance of CAN line: B1, B2 Specified value : approx. 120
P2310
CAN: Faulty brake system communication
- Check CAN communication line H and L. - Check ABS/ESP unit. - Check the related harness for open, short and contact.
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Trouble Code
P2311
109
CAN: Faulty ECU communication
- Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact.
P2312
CAN: Faulty ECU communication
P2313
CAN: Faulty selector lever control communication
- Check CAN communication line H and L. - Check selector lever. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check instrument cluster. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check TCCU/TOD unit. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check ABS/ESP unit. - Check the related harness for open, short and contact.
P2315
CAN: Faulty instrument panel communication
P2317
CAN: Faulty communication between TCCU/TOD and CAN (For 4WD only) CAN: Faulty brake system signal
P2330
P2331
CAN: Faulty ECU message
P2332
CAN: Faulty ECU message
P2333
CAN: Faulty selector lever signal
- Check CAN communication line H and L. - Check selector lever. Check selector lever. - Check the related harness for open, short and contact.
P2335
CAN: Faulty instrument cluster signal
- Check CAN communication line H and L. - Check instrument cluster. - Check the related harness for open, short and contact.
P2337
CAN: Faulty TCCU/TOD (For 4WD only)
- Check CAN communication line H and L. - Check TCCU/TOD unit. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check ABS/ESP unit. Check wheel speed sensor connector. Check the air gap between tooth wheel and wheel speed sensor. (Air gap: 0.309 ~ 0.958 mm) Check the numbers of tooth wheel: 48 - Check the related harness for open, short and contact.
P2400
CAN: Faulty rear RH wheel speed sensor signal
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
Defectives
Action
110
3650
Trouble Code
P2401
Defectives
CAN: Faulty rear LH wheel speed sensor signal
Action
- Check CAN communication line H and L. - Check ABS/ESP unit. Check wheel speed sensor connector. Check the air gap between tooth wheel and wheel speed sensor. (Air gap: 0.309 ~ 0.958 mm) Check the numbers of tooth wheel: 48 - Check the related harness for open, short and contact.
P2402
CAN: Faulty front RH wheel speed sensor signal
- Check CAN communication line H and L. - Check ABS/ESP unit. Check wheel speed sensor connector. Check the air gap between tooth wheel and wheel speed sensor. (Air gap: 0.335 ~ 0.945 mm) Check the numbers of tooth wheel: 48
P2403
CAN: Faulty front LH wheel speed sensor signal
- Check CAN communication line H and L. - Check ABS/ESP unit. Check wheel speed sensor connector. Check the air gap between tooth wheel and wheel speed sensor. (Air gap: 0.335 ~ 0.945 mm) Check the numbers of tooth wheel: 48
P2404
CAN: No brake signal
- Check CAN communication line H and L. - Check ABS/ESP unit. - Check the related harness for open, short and contact.
P2405
CAN: No accelerator pedal signal
P2406
CAN: No engine torque signal
P2407
CAN: No ESP signal
P2408
CAN: No minimum engine torque signal
- Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact.
P2409
CAN: No maximum engine torque signal
P240A
CAN: No engine rpm signal
AUTO TRANSMISSION
KYRON SM - 2005.09
3650
Trouble Code
P240B
111
CAN: No engine coolant temperature signal
- Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact. - Check CAN communication line H and L. - Check selector lever. - Check the related harness for open, short and contact.
P240C
CAN: No selector lever position signal
P240D
CAN: No transfer case position signal (For 4WD only)
- Check CAN communication line H and L. - Check TCCU/TOD unit. - Check the related harness for open, short and contact. - Cycle the IGN switch from OFF to ON. Check A/T system again after a certain period of driving. - If the trouble still exists, replace A/T assembly. - To protect transmission, any shift is not available.
P2500
Invalid transmission gear ratio
P2501
Excessive engine rpm
P2503 P220B P2510
Faulty recognition of currently selected gear Excessive N2, N3 rpm Torque converter lockup clutch stuck
- Check selector lever. - Check the related harness for open, short and contact. - Check speed sensor N2 and N3. - Check the hydraulic lines for leaks (valve No.22 in valve body). - Check the resistance of lockup clutch solenoid valve (Turn the IGN OFF, then disconnect TCU connector). TCU connector terminals B9 (17), B3 (18) Specified value : 2.5 0.2 - Triggered emergency mode when the defective is detected. Fixed at 2nd gear in D range. - Check the related harness for open, short and contact.
P2511 P2520 P2502 P2600 P2601 P2602 P2603
Faulty torque converter lockup heat control Faulty recognition of torque reduction Poor gear mesh, transmission slip Too low TCU supply voltage Too high TCU supply voltage Abnormal solenoid valve supply voltage Abnormal speed sensor supply voltage
- Check the hydraulic lines for leaks. - Check ECU. - Check the hydraulic lines for leaks. - Check oil filter. - Check TCU supply voltage. - Check TCU supply voltage. - Check solenoid supply voltage. - Check speed sensor supply voltage. TCU connector terminals B13 (13) : 6V
AUTO TRANSMISSION
KYRON SM - 2005.09
A/T
Defectives
Action
112
3650
3. REMOVAL AND INSTALLATION OF TCU

1. Disconnect the negative battery cable. 2. Slide the drives seat and fold up the carpet.
3. Unscrew the two bolts (10 mm) on TCU. Installation Notice

4. Disconnect the TCU connect and remove the TCU.
AUTO TRANSMISSION
KYRON SM - 2005.09
MANUAL TRANSMISSION
GENERAL INFORMATION ...................................... 3
1. Overview and characteristics of manual transmission ........... 3 2. Manual transmission system ................................................5
MANUAL TRANSMISSION ................................... 10

1. 2. 3. 4. 5. 6. 7. 8. Location .............................................................................. 10 System components ........................................................... 11 Shifting mechanism ............................................................ 19 Diagnostic information and procedures ............................... 26 Removal and installation ..................................................... 30 Disassembly and reassembly ............................................. 36 Inspection/maintenance ...................................................... 67 Special tools and equipment ............................................... 70
3170
1. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION

SYSTEM COMPONENTS
Inside
M / T
Front View
Features
1. All gears use the helical type and high strength materials. NOTE
The helical type gear prevents the axial gear missing and provides less noise.
4. The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock devices are installed. NOTE
TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement.
2. The semi-remote control type gear shift mechanism is used to prevent incorrect shifting. 3. To improve the shifting performance, 3-piece double cone is used for 1/2 shift.
5. The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
GENERAL INFORMATION
3170
Specifications
Description
Length (mm) Distance between shafts (mm) Input torque (kg-m) Transmission control type Weight (kg) - 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 ( )
Specifications (D20DT, D27DT)

628.3 mm 81 mm 34.7 kg-m (340 Nm) Semi-remote 44 kgm 4.315 2.475 1.536 1.000 0.807 3.919 ATF DEXRON II 3.6 / 3.4 (4WD / 2WD)
Change interval
Inspect at every 10,000 km, replace at every 60,000 km (add or replace if necessary)
Tightening Torque
Description
1. Oil drain plug & filler plug 2. Backup lamp switch (24 mm) 3. Extension housing bolt (14 mm) 4. Extension housing spring plug (27 mm) 5. Neutral switch 6. Shift top cover bolt (12 mm) 7. 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
KYRON SM - 2005.09
3170
Neutral Switch
0.5 mm
N (Neutral) Switch
0.5 mm
Outside N Switch
Inside N Switch
STNG
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
2. MANUAL TRANSMISSION SYSTEM
3170
Function of N Switch
1. Aids a smooth start of the vehicle by raising the RPM during the gear shifting when the engine is cold. When the vehicle is trying to start from the stopped state (vehicle speed below 3 km/h), the N switch determines the shifting timing by using the clutch switch and the N switch. It raises the engine RPM (100 ~ 200 rpm). Operation conditions are as follows. 1) The vehicle speed is at the stopped state (Vehicle speed below 3km/h detection). 2) While depressing the clutch (Clutch switch detection). 3) The gear lever is at a position other than neutral (N switch detection). 4) Start the vehicle while depressing the clutch pedal (Clutch switch detection). 5) The RPM increases in accordance with the temperature of the engine coolant (Engine coolant temperature sensor detection). : appx. 100 rpm increase : appx. 100 ~ 170 rpm increase : appx. 80C (normal temperature of the engine coolant): around 200 rpm increase 6) When the gear has been smoothly shifted and the vehicle speed exceeds 3km/h, it returns to the previous operation interval of the engine RPM. In case of Kyron, the N switch signal is transmitted to the instrument panel, and then the instrument panel transmits it to the engine ECU through the CAN communication.
Vehicle Made After 04.09.15
Kyron
12
E C U
Instrument Panel
E C
CAN communication
Terminal Return spring Spring Body Ball
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
2. Detects the position of the shifting lever for the HDC operation among ABS/ESP functions. It is used for the second item of the 6 operation conditions of the ABS/ESPs HDC function. Please refer to the ABS/ ESP section for the specific information related to the HDC. 1) HDC Operation switch ON 2) Forward/Reverse Shifting lever location
and and
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in the neutral position). Automatic transmission: possibly operates except in the P (parking) or N (neutral) position.
NOTICE
The vehicle with the manual transmission does not have a separate device or switch that detects the 1st gear. It only detects the forward/reverse direction of the vehicle through the back-up light switch and the neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, though the HDC also operates in the 2nd gear position, is because the engine may turn off during the HDC operation process. You may face a very dangerous situation if the engine turns off at a steep hill. The HDC aids the slowdown of the vehicle when driving down a steep hill and cannot sufficiently decelerate only with the engine brake. Thus, a driver must operate the HDC only in the 1st gear when driving a vehicle with the manual transmission.
3) When not depressing the accelerator pedal or brake pedal. 4) The vehicle speed is above 7 km/h (based on the automatic transmission/4H drive mode). 5) The ESPs vehicle position control function and HBA function are not in operation.
and and and
The HDC is added to aid drivers when driving down the hill, but when any basic function of the ESP is in operation prior to the HDC system operation, the ESP takes priority over the HDC. 6) The inclination of the driving road exceeds 10%. When the inclination of the driving road exceeds 10%, the HDC operates until the vehicle reaches the speed condition given in step 4).
When the Inclination is 10% ~ 20% During the HDC Operation When depressing the accelerator pedal or brake pedal, it converts to the stand-by mode, and when depressing the accelerator pedal again, the HDC operates again. Therefore, driver may maintain a desired speed by repeating this depressing and releasing process of the accelerator pedal.
When the Inclination Exceeds 20% During the HDC Operation When depressing the accelerator pedal, it converts to the HDC operation stand-by mode. When depressing the brake pedal, the HDC operation state is maintained and the braking power is enhanced. In this case, the HECU emits an abnormal noise and the brake pedal may feel very rigid, but this is a normal occurrence resulted from the HDC operation.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A/T
3170
Note: Overview of HDC Operation HDC (Hill Descent Control) System The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about 7 km/h with increment of 0.1G, on steep roads (inclination exceeding 10%) through a separately installed switch operation. When the vehicle speed reaches below 7 km/h (refer to the information below), the HDC automatically terminates the operation.
The HDC does not have a separate sensor for the input signal and detects the inclination of hills by using the G sensor (acceleration sensor) in the sensor cluster. When you see a steep downhill ahead, press the HDC switch and the green HDC indicator comes on. When the G sensor within the sensor cluster detects a inclination exceeding 10%, the ESPs HDC function operates. When this occurs, the green HDC indicator goes off along with a loud operation noise. HDC Switch
Sensor Cluster
HDC Indicator (Instrument panel)
The G Sensor within the sensor cluster detects the inclination of driving roads. When the HDC switch is in operation, if the G sensor detects a downhill inclination exceeding 10%, it transmits the HDC operation signal to the ESP HECU.
When pressing the HDC switch, the green HDC indicator on the instrument panel comes on, and when the HDC operates, the green HDC indictor blinks with 0.5 seconds of interval.
HDC
NOTICE
The G sensor within the sensor cluster measures the actual road inclination. However, it may recognize a sharp turn or rough road as a downhill with a inclination exceeding 10%, and the HDC may operate. Red Letters
HDC
Green Letters
* For the specific information, please refer to the ABS/ ESP section.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170 Variant Coding Related to N Switch
Variant Coding Options

T/C
Neutral Signal Input
None / Wire / CAN

No Yes
Kyron model with manual transmission

AXLE
New Rexton model with manual transmission Manufactured after 04.09.15 BODY IN: after 154600
SP
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Automatic transmission
CLUTCH
M / T
Kyrons N Switch transmits information to the ECU through the CAN communication while New Rexton is connected to the ECU through wires. Thus, if you set the variant coding in the engine ECU, you must do it differently, and you must set the variant coding differently according to the vehicle category and specification as below.
A/T
10
3170
MANUAL TRANSMISSION
1. LOCATION
Transfer case
Oil filler plug
Center cross member & transmission insulater mounting Oil drain plug
Trasmission housing bolt (14 mm - 11)
T/M assembly
T/M Assembly
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
11
2. SYSTEM COMPONENTS
Gear Combinations
1st gear
2nd gear
5th gear
Output shaft
Input shaft
STNG
R Idle
Reverse gear
Counter shaft
3rd gear
4th gear
3/4 rail
5/R rail
1/2 rail Reverse Fork plate
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
Transmission adapter
Interlock plate
A / BAG
Shift Fork and Rail Combinations
BRAKE
SP
AXLE
CLUTCH
T/C
5/R shift fork
1/2 shift fork
3/4 shift fork
M / T
A/T
12
3170
Sectional View
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
13
1. Transmission front housing 2. Input shaft oil seal 3. Front cover (DWF) 4. Hexagon flange bolt (17 ~ 26 Nm) 5. Oil drain plug (40 ~ 50 Nm) 6. Sealing 7. Pin 8. Input shaft 9. 4th clutch gear 10. Taper roller bearing (main) 11. Taper roller bearing 12. Counter shaft 13. Taper roller bearing (counter) 14. Output shaft 15. Inner race (reverse) 16. Inner race (1st) 17. Needle bearing 18. 1st gear 19. 1st clutch gear 20. Synchro outer ring (for 1st gear) 21. Synchro - middle cone 22. Synchro inner ring 23. Synchro spring 24. Synchro key 25. Synchro hub (1st & 2nd) 26. Double synchro sleeve 27. 2nd gear 28. 3rd gear 29. 3rd clutch gear 30. Synchro hub (3 & 4th) 31. Synchro ring (4/5/R) 32. Single synchro sleeve (5th & R) 33. Retainer ring (3 & 4th) 34. Adapter dowel pin 35. Reverse idler shaft 36. Dowel pin
37. Needle bearing (Reverse idler) 38. Reverse idler gear 39. Reverse idler spacer 40. Reverse idler bracket (Bolt: 30 ~ 40 Nm) 41. Retainer ring (Reverse idler) 42. Reverse lock nut (150 ~ 195 Nm) 43. Transmission adapter 44. Input shaft spacer (Bearing end play: 0 ~ 0.05 mm) 45. Counter spacer (Bearing end play: 0 ~ 0.05 mm) 46. Reverse needle bearing 47. Reverse gear 48. Reverse clutch gear 49. Reverse counter gear 50. Synchro hub (5th & R) 51. 5th counter gear 52. 5th needle bearing 53. 5th gear 54. 5th clutch gear 55. Thrust washer 56. Shift ball 57. 5th outside retainer ring 58. 5th retainer ring 59. Counter shaft bushing 60. Counter roller bearing assembly 61. Counter lock nut 62. Extension housing 63. Output shaft oil seal 64. Offset plate 65. Counter screw (4~6 Nm) 66. Top cover 67. Counter oil seal 68. Shift shaft 69. Shift lever 70. Semi-remote lever assembly 71. Pin spring 72. Pin spring
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
14
3170
Front View and Rear View

Front View
Rear View
1. Reverse idler bracket (tightening torque: 30 ~ 40 Nm) 2. Shift lug (3 & 4th) 3. Spring pin (6 x 25) 4. Shift lug (5 & reverse) 5. Shift rail (5 & reverse) 6. Backup lamp switch (tightening torque: 30 ~ 40 Nm) 7. Shift rail (3 & 4th) 8. Interlock bolt (tightening torque: 40 ~ 50 Nm) 9. Shift lever 10. Interlock plate 11. Shift rail (1 & 2nd) 12. Spring pin (6 x 25)
13. Shift fork (3 & 4th) 14. Input shaft 15. Counter shaft 16. Reverse idler assembly 17. Spring pin (6 x 25) 18. Spring pin (6 x 25) 19. Concentric slave cylinder adapter (tightening torque: 10 ~ 16 Nm) (8) Bond-592 loctite (6) Bond-592 loctite
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
15
Shift Rail and 5/R Gear 1/2 shift rail

M / T
5/R shift rail 3/4 shift rail
Offset Lever
SP
1. Reverse lock spring 2. Reverse lock plate 3. Reverse lock bolt (tightening torque: 8 ~ 12 Nm) 4. Stopper plate 5. Air vent (tightening torque: 20 ~ 35 Nm) 6. Lock washer 7. TGS bushing 8. Outer spring pin
9. TGS pin 10. Lock bolt (tightening torque: 17 ~ 26 Nm) 11. Offset lever 12. Offset lever bushing 13. Rolling plunger 14. Return spring 15. Spring plug (tightening torque: 70 ~ 100 Nm)
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
A/T
Cross Sectional Diagram of Major Components
16
3170
Power Flows
1st gear Counter shaft
4th gear
3rd 2nd gear gear
1st Reverse gear gear
5th gear
2nd
4th gear
3rd 2nd gear gear
5th gear
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
17
3rd
M / T
4th
4th gear
3rd gear
2nd gear
5th gear
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
4th gear
3rd gear
2nd gear
1st gear
Reverse gear
5th gear
SP
AXLE
CLUTCH
T/C
A/T
Power Flows (Contd)
18
3170
Power Flows (Contd)
5th
4th gear
3rd gear
2nd gear
5th gear
Reverse gear
Reverse gear
4th gear 3rd gear
2nd gear
1st gear Reverse idler gear
5th gear
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
19
Interlock System
Interlock system prevents the gears from meshing over two sets.
Interlock bolt
Interlock plate
Inner shift lever
Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward.
Neutral
5/R select
5/R shift
5th gear disengaged
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Reverse Interlock System
STNG
1/2 (3/4 & 5/R lock)
3/4 (1/2 & 5/R lock)
5/R (1/2 & 3/4 lock)
SP
AXLE
CLUTCH
T/C
M / T
A/T
3. SHIFTING MECHANISM
20
3170
Offset Lever and Rolling Plunger

To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected.
1. Offset lever 2. Shift lever
3. Shift lever 4. Rolling plunger (rolling plunger return spring and ball)
1. Shift check device It determines the shift fork position (N or each gear) and gives a detent movement to notice a shift lever seating when operating the shift lever. Also, it prevent the selected gear from getting out of its meshed position.
Detent pin Top cover
Shift shaft
Set ball
2. Gear jump out locking device It prevents the shift lever is beyond the correct shift position while shifting.
Hub spline
Sleeve spline
Clutch gear spline
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
21
3. Guiding a control direction and preventing an over stroke.
Offset lever
Offset plate
Backup Lamp Switch

It is normal open type switch. Its circuit is formed when the reverse gear is selected. NOTICE
Sealant: Bond-592-Loctite Tightening torque: 30 Nm ~ 40 Nm
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Installation Notice
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
22
3170
Synchronizer
Composition
It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each other). 1. 3/4 and 5/R shift: Single cone type 2. 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner cone and middle cone)
Single Cone Type Double Cone Type
1/2 shift
3/4 shift
5/R shift
1/2 shift
3/4 shift
5/R shift
1. Synchronizer sleeve 2. Synchronizer hub 3. Synchronizer ring 4. Synchronizer key
5. Synchronizer key locking ring 6. Synchronizer inner cone 7. 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. The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery).
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
23
Synchronizer element
A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning and the clutch gear is spinning. Even though the clutch is disengaged, the clutch gear continues to spin until friction slows it down or stops it. Thus when the driver shifts into another gear, he/she is trying to mesh gears that may be moving at different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is lowered.
Sleeve
Synchronizer ring Gear spline area
Projected area Synchronizer key Spline area of sleeve

SP A / CON
KYRON SM - 2005.09
Spline area of synchronizer ring
[2nd step] Sleeve Synchronizer ring Gear spline area

STNG A / BAG BRAKE
Synchronizer key
Spline area of sleeve
[3rd step]
Sleeve
Synchronizer ring Gear spline area
Synchronizer key Spline area of sleeve
MANUAL TRANSMISSION
AXLE
CLUTCH
[1st step]
T/C
M / T
A/T
24
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.
Taper Roller Bearing Needle Bearings
1. Taper roller bearing (input shaft, counter shaft and output shaft) 2. Needle bearings for 1/2 and 3/4 shift
3. Needle bearing for reverse gear (with cut out area) 4. Needle bearing for 5th gear
End Play of Taper Roller Bearing
1. Taper roller bearing for input shaft 2. Taper roller bearing for counter shaft
A. End play A: 0 ~ 0.05 mm B. End play B: 0 ~ 0.05 mm
NOTICE
Use the following spacers to adjust the end play (A or B) between input shaft and counter shaft. (Specified range of end play: 0 ~ 0.5 mm) For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 m) For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 m)
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
25
When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly receives the axial force and this force acts as a resistance to rotating gears.
Input shaft Thrust ring 1 Thrust 5/R washer synchronizer
3/4 synchronizer
1/2 synchronizer
Output shaft
Lock nut Counter gear assembly

AXLE
Head set gear
3rd gear
2nd gear
Reverse gear
1st gear
5th gear
STNG
Transmission oil: ATF DEXRON III Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease
Oil level
Oil drain screw
NOTICE
Sealant on oil drain screw during installation: Bond-592 Loctite Tightening torque: 40 ~ 50 Nm
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Lubrication
SP
CLUTCH
T/C
M / T
A/T
Thrust Ring (Washer)
26
3170
4. DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis
Symptom
Can not shift (control lever moves)
Cause
Control lever assembly broken or damaged. Damaged offset lever, shift fork, selector place or selector arm. Clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears.
Action
Replace control lever and housing assembly. Remove extension, adapter or case cover. Check or replace damaged parts. Adjust or replace clutch. Add or replace with specified oil. Remove extension, adapter or case cover. Check or replace damaged parts. Remove extension, adapter or case cover. Check synchronizers and gears and replace damaged parts. Check or replace backup switch. Replace pilot bushing. Adjust idle speed to specified speed. Adjust or replace clutch. Replace or check roller bearings. Check or replace synchronizer parts. Align bell housing and bore. Check or replace gear(s). Replace pilot bushing. Tighten bolts to specified value. Realign if necessary. Check or replace synchronizer parts. Check or replace blocking ring. Check worn or damaged parts. Adjust shim thickness using roller bearings if necessary. Check for wear or damaged. Replace worn or damaged parts. Replace extension, adapter or case cover. Check or replace loose parts on shaft or rail. Replace roll pin(s). Remove extension, adapter or case cover. Check for wear or damaged. Replace damaged parts. Check worn or damaged synchronizer parts and replace if necessary. Check worn or damaged gears and replace if necessary.
Hard shift or control lever will not move into gear
If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Gears crash when shifting Engine idle speed too high. Damaged or faulty clutch. Pilot bearing between input shaft and output shaft binding. Damaged synchronizer. Bell housing misaligned. Damaged gear(s). Worn or damaged flywheel pilot bushing. Transmission jumps out Loosened transmission or flywheel housing bolts, improper alignment. Synchronizer damaged or excessively worn. Blocking ring damaged, worn index slots or friction surfaces worn or damaged. Excessive countershaft end play. Worn or damaged fork due to loosened shaft, rail or shifting fork. Transmission locked in one gear Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft or rail. Worn or damaged synchronizer. Worn or damaged gears.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
27
Trouble Diagnosis (Contd)

Symptom
Transmission noise
Improper or low transmission oil. Loose bolts or other attaching parts. Improper flywheel housing to engine crankshaft alignment. Noisy transmission bearing. Noisy gears.
Add or drain and replace with proper oil. Tighten as specified.
Check for worn or damaged gears (including speedometer gear). Replace if necessary. Clean all exposed surfaces, then check for leaks. Clean or replace vent or breather. Check oil level.
Vent or breather clogged. Too much oil. Loose bolts at sealing faces. Improperly applied sealant. Worn or damaged oil seal.
Clean leaking surfaces. Reapply sealant. Replace oil seal.

STNG
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
Tighten as specified.
AXLE
Transmission leakage
Leakage from transmission.
CLUTCH
Check bearings, bearing rollers and parts for wear or damage. Replace if necessary.
T/C
Realign correctly.
M / T
Cause
Action
A/T
28
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
3170
29
Place the vehicle on the flat and even ground and stop the engine. After 5 minutes, check the oil level.
NOTICE
Do not check or change the oil Immediately after driving off. It may cause serious hurt.
2. If needed, add the oil through the oil level plug hole (1). 3. Fully tighten the plug and check the oil leaks. 4. If the oil level is up to the bottom line (5 ~ 7 mm) of plug hole, it is OK.
Place the vehicle on the flat and even ground and stop the engine. After 5 minutes, check the oil level. 1. Remove the oil level plug (1) and check the oil level. NOTICE
If the oil level is up to the bottom line (5 ~ 7 mm) of plug hole, it is OK.
NOTICE
The oil in manual transmission is major element for mechanical durability of transmission. Check the oil level with a specific interval and replace if needed. The oil replacement should be done at the qualified and authorized service station.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
1. Oil level check plug
2. Oil drain plug
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
OIL CHECK/CHANGE
30
3170
5. REMOVAL AND INSTALLATION

Transfer case
Oil filler plug
Cross member - Center Mounting insulator
Oil drain plug
Transmission housing mounting bolt (14 mm - 11EA)
T/M assembly
Removal and Installation

Preceding Work: Disconnect the battery negative cable and remove the center console.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
31
1. Unscrew two bolts (12 mm) and remove the change lever from shift lever. Installation Notice
1
2. Unscrew two bolts (12 mm) from semi-remote controller. Installation Notice
2
3. If the oil should be changed, remove the oil drain plug (A) in transmission housing and fully drain the oil. And, retighten the plug (A). Installation Notice
4. Unscrew four bolts (17 mm) and separate the rear and front propeller shafts connected to transfer case output shaft. Compress the propeller shaft and bind to torsion bar not to disturb the operation.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Change lever
A/T
32
3170
5. Disconnect the air bleeder hose, neutral switch connector, back up lamp switch connector and transfer case connectors.
6. Support the underbody of transmission with a hydraulic jack not to deflect it and unscrew the bolts (14 mm - 4EA) and cross nuts (14 mm - 2EA) and remove the cross member.
7. Unscrew two bolts (14 mm) at both sides and remove the transmission mounting insulator. Unscrew the mounting bolts (14 mm, 2) at both sides and remove the mounting insulator bracket.
Mounting Insulator Tightening torque: 28 ~ 47 Nm Bracket
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
8. Unscrew eleven bolts (14 mm) and remove the transfer case with a hydraulic jack.
33
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)
9. Disconnect the clutch oil hose from adapter.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
34
3170
10. Support the transmission housing with a hydraulic jack and unscrew eleven transmission bolts (17 mm). (Tightening torque: 50 ~ 60 Nm)
11. Carefully lower the hydraulic jack with transmission assembly.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170 Inspection before Installation

Install in the reverse order of removal. Check the components for wear or damage before installation. 1. Check the concentric slave cylinder for abnormal wear and replace if necessary. 2. Check the pressure spring plate for wear. NOTICE
The excessively worn components should be replaced.
35
3. Check the alignment conditions of clutch housing as follows: 1) Install the magnetic holder on pressure spring. 2) Alignment check for housing bore Install a dial gauge in the housing bore. Note the measurement while rotating the crankshaft for one revolution.
3) Alignment check for clutch housing surface Install a dial gauge on the clutch housing surface. Note the measurement while rotating the crankshaft for one revolution. NOTICE
If the pointer indicates beyond 0.010 inch, align the clutch housing by inserting shims between housing and clutch.
4. Check the following parts, if necessary 1) Pressure plate spring assembly 2) Disc 3) Flywheel NOTICE
The excessively worn components should be replaced. SAT clutch cover can not be re-installed if disassembled. SST is needed for re-vse. Refer to the P.11 at the of this book clutch section.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
36
3170
6. DISASSEMBLY AND REASSEMBLY

MANUAL TRANSMISSION ASSEMBLY
Disassembly
1. Remove the transmission oil drain plug (hexagon, 14 mm) and completely drain the oil. Place the removed transmission on the workbench.
2. Pull out the lock washer (1) and remove the TGS pin (2).
3. Push the semi remote lever rearward and unscrew the mounting bolts (4) with a wrench (12 mm) to remove the top cover. NOTE
Be careful not to lose the disassembled components.
4. Pull out the spring pin (6 x 25) and remove the offset lever.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
5. Remove the bolts from the extension housing with a wrench (14 mm).
37
6. Remove the extension housing with a special tool. NOTICE

Remove the offset lever and rolling plunger with the extension housing. Be careful not to drop them.
7. Remove the rear ball bearing with a puller and remove the speedometer driven gear.
8. Remove the 5/R shift fork spring pin (6 x 28).
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
38
3170
1) Pull the counter gear (5th gear) retainer ring out from the ring groove with a ring pliers.
NOTICE
Be careful not to stiffen the retainer ring.
9. Spread the retainer ring and remove the 5th counter gear with a puller.
10. Remove the counter reverse spacer.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
11. Remove the 5th gear retainer ring with a ring pliers.
39
12. Remove the thrust washer from the shaft.
13. Remove the 5th gear and pull out the spring pin. NOTICE
Be careful not to lose or mix the spring pins.
14. Remove the 5th gear needle bearings (2). NOTICE

Be careful not to lose or mix the needle bearings.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
40
3170
15. Remove the 5th gear synchronizer ring. NOTICE

Store at a safe place not to be mixed with other synchronizer rings.
16. Remove 5/R gear retainer ring from the shaft with a ring pliers. NOTICE
Store the ring with the relevant gear to prevent incorrect installation.
17. Remove the 5/R synchronizer hub assembly, the reverse gear and the shift fork at a time.
18. Remove the counter reverse gear.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
19. Remove the counter reverse gear needle bearing. NOTICE
Store the needle bearing with the relevant gear.
41
20. Remove the interlock bolt (17 mm).
21. Remove the transmission adapter from the surface. NOTICE

Be careful not to damage the adapter mating surface.
22. Remove the gear assembly from the housing. NOTICE

Do not forcefully remove the gear assembly. It may damage the level grooves resulting in incorrect installation. Carefully remove the gear assembly.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
42
3170
23. Remove the main and counter gear assembly. 1) Pull out the pins from 5/R and 1/2 shift rails and remove the shift rails 2) Pull out the locking pins from shift forks.
24. Remove the shift rail and shift fork. Place the output shaft and counter gear on the special tool.
25. Place the output shaft assembly with the 1st gear facing down and remove the intermediate taper roller bearing with a special tool. NOTICE
To prevent the bearing damage, securely seat the special tool before removing the intermediate taper roller bearing that is pressed in. Do not use general bearing puller.
26. Remove the 3/4 gear retainer ring. NOTICE

Be careful not to lose or mix the retainer ring.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
27. Remove the 3/4 gear synchronizer hub and single synchronizer sleeve and 3rd gear with a special tool. Pull out the needle bearing.
43
28. Loose the 1/2 gear and hub and double synchronizer sleeve with a press.
29. Remove the reverse gear inner race.
30. Remove the main taper roller bearing.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
44
3170
31. Remove the inner race from 1st gear and 1st gear from 1st gear, and remove the needle bearing from the shaft. NOTICE
Store the disassembled gears by relevant components.
32. Remove the synchronizer inner intermediate cone and outer ring in 1st gear side.
Synchronizer inner ring
Synchronizer intermediate cone
Synchronizer outer ring
33. Remove the 1/2 gear synchronizer hub along with double synchronizer sleeve.
34. Remove the synchronizer inner intermediate cone and outer ring in 2nd gear side.
Synchronizer outer ring
Synchronizer intermediate cone
Synchronizer inner ring
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
35. Remove the 2nd gear and needle bearing.
45
36. Remove the oil seal from the extension housing.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
46
3170
Inspection Before Reassembly

1. Clean all the disassembled components with solvent and dry them with compressed air. Check the components for crack, wear and damage. 1) Case, extension housing, shift lever 2) Input bearing retainer 3) Counter shaft rear bearing retainer 2. Check the bearing and shaft supporting area for wear and replace if needed. 3. Check the surface conditions on: 1) Input shaft 2) Main shaft and gears 3) Counter shaft and 5th drive gear
4. Reverse idler shaft and gears NOTICE

Replace the excessively worn components. Do not grind the precisely machined components.
5. Check the following components for wear: 1) Selector arm 2) Interlock plate 3) 1/2 and 3/4 shift fork 4) Shift shaft 5) Detent/guide plate and offset lever 6) Each shift lever shift fork
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
7) Hub and sleeve 8) 1/2 shift fork, pads, synchronizer sleeve
47
9) 3/4 shift fork, pads, synchronizer sleeve 10) 5th gear shift rail/fork, pads, synchronizer sleeve 11) Reverse fork and reverse idler gear sleeve
6. Check the following components for excessive wear: 1) Crankshaft pilot bushing in front of input shaft 2) Clutch release bearing 3) Main shaft pilot bearing roller 4) Main shaft thrust bearing mating surface 5) Main shaft speed gear roller bearing 6) Main shaft rear bearing 7) Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface. 8. Check the gear sets for excessive wear, crack and break and replace if needed.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
48
3170
9. Check the conditions of each synchronizer sleeve and hub. 1) Engagement of hub and sleeve 2) Wear on cone clutch surface in synchronizer ring (brass) engaging the gears
10. Measure the clearance between blocking ring and speed gear. 1) New 1/2 gear synchronizer ring: 0.87 ~ 1.4 mm 2) New 3/4 gear synchronizer ring: 0.88 ~ 1.5 mm NOTICE
If the clearance is excessive, replace it with new one. Otherwise, it may cause the missing or breakage of the gears.
11. Check the speed gear clutch and synchronizer sleeve for damage in teeth surface. 12. Check the engagement of synchronizer sleeve and speed gear clutch.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170 Reassembly
1. Install the 2nd gear needle bearing. NOTICE
The 1st/2nd/3rd gear needle bearings have one bearing row and the sizes of them are same. The reverse needle bearing has two bearing rows. The 5th needle bearing is smaller than others and consists of two bearings.
49
2. Install the 2nd gear and synchronizer outer ring, intermediate cone and inner ring in turns.
3. Insert three keys into 1/2 synchronizer hub and double synchronizer sleeve. Install the synchronizer spring in offset so that it should not be missed out. NOTICE
1/2 gear double synchronizer sleeve doesnt have a step at edge, however, 3/4 and 5/R gears have it. Groove
No step
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
50
3170
4. Install the 1/2 synchronizer hub and double synchronizer sleeve into the output shaft by using a press.
NOTICE
Make sure that the hub groove faces to 2nd gear. Align the synchronizer key and the synchronizer ring groove in 2nd gear.
5. Install the synchronizer outer ring, intermediate cone and inner ring in turns.
6. Install the 1st gear.
7. Install the 1st gear needle bearing.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
8. Install the 1st gear inner race by using a press. NOTICE
The 1st inner race doesnt have a step at edge.
51
9. Install the main taper roller bearing by using a press.
10. Install the reverse gear inner race by using a press. NOTICE
The reverse gear inner race has a step at edge.
11. Place the output shaft assembly with the 1st gear facing downward and install the 3rd gear needle bearing.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
52
3170
12. Install the 3rd gear.
13. Install the synchronizer ring on the 3rd gear.
14. Insert three keys into 3/4 synchronizer hub and synchronizer sleeve. Install the synchronizer spring in offset so that it should not be missed out. NOTICE
3/4 gear synchronizer sleeve have a step at edge. Place the groove in hub to face the 3rd gear and align the synchronizer key and the synchronizer ring groove in 3rd gear.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
15. Install the 3/4 gear retainer ring. NOTICE
Adjust the end play between retainer ring and hub to a range of 0.0 to 0.5 mm by using a feeler gauge.
53
NOTICE
Apply the force on the inner race other than other points.
17. Install the input shaft along with the 4th synchronizer ring. Place the input shaft to face downward on the work bench.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
16. Install the intermediate taper roller bearing by using a press. Install the intermediate taper roller bearing by using a press.
CLUTCH
T/C
M / T
A/T
54
3170
18. To relieve the load and to provide a clearance to the shaft bearing, insert a special tool.
19. Place the counter gear with input/output shaft on the workbench.
20. Install the transmission adapter on the input shaft and the counter gear.
21. Install the reverse gear needle bearing. NOTICE

The reverse gear needle bearing has two bearing rows and the others consist of two bearings.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
22. Install the reverse gear in the shaft.
55
23. Install the synchronizer ring on the reverse gear.
24. Insert three keys into 5/R synchronizer hub and synchronizer sleeve. Install the synchronizer spring in offset so that it should not be missed out. NOTICE
Place the groove in hub to face the 5th gear and align the synchronizer key and the synchronizer ring groove in reverse gear.
25. Install the 5/R gear retainer ring. NOTICE

MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
56
3170
26. Install the counter reverse gear by using a press. NOTICE

Place the counter reverse gear with a longer protrusion facing to the adapter.
27. Install the counter reverse spacer.
28. Install the 5th synchronizer ring.
29. Install two 5th gear needle bearings in line.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
30. Install the 5th gear.
57
32. Install the counter 5th gear retainer ring.
33. Install the locking ball.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
31. Install the 5th counter gear by using a press. At this time, place it with a longer protrusion area facing to the adapter.
CLUTCH
T/C
M / T
A/T
58
3170
34. Install the thrust washer (t= 5.0) while aligning the key grooves.
35. Install the retainer ring. NOTICE

36. Install the inner race of counter roller bearing by using a press. NOTICE
Place it with a protrusion area facing to the 5th gear.
37. Place the gear assembly on a workbench in parallel.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
38. Install the inner shift lever and interlock plate in the 3/ 4 gear shift rail. NOTICE
Interlock plate Inner shift lever
59
39. Install the 3/4 gear shift rail in the transmission adapter. NOTICE
The part which is longer the distance between the left hold of shift rail and the end of shift rail should face to the input shaft.
40. Install the 3/4 gear shift fork. NOTICE

The 1/2 and 5/R shift fork are compatible, but 3/4 shift fork isnt. Also, the 3/4 shift fork is chamfered, but 1/ 2 and 5/R arent.
41. Install the 3/4 shift fork and shift rail while aligning the grooves.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
The spring pin for locking the inner shift lever is small (6 22) and its slot should face to the shaft.
A/T
60
3170
42. Install the 1/2 gear shift rail in the transmission adapter.
43. Partially engage the 1/2 shift fork to the shift rail.
44. Install the shift lug on the 1/2 shift rail. Install the reverse lock spring, reverse lock plate and reverse lock bolts. NOTICE
Align the 1/2 gear shift lug and interlock plate mating surface.
45. Partially engage the 5/R gear shift fork to the shift rail.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
46. Install the 5/R shift lug and 5/R shift fork on the shift rail. NOTICE
61
47. Install the spring pin into the 1/2 shift lug. NOTICE
Place the spring pin with the pin slot facing to the shaft.
48. Install the spring pin into the 5/R shift lug. NOTICE
49. Install the spring pin into the 1/2 shift fork. NOTICE
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Align the 5/R shift lug and the interlock plate surface.
A/T
62
3170
50. Install the spring pin into the 5/R shift fork. NOTICE
51. Install the reverse lock plate and reverse lock spring on the 1/2 shift rail. 52. Install the stopper plate on the 3/4 shift rail and insert the spring pin. (intermediate size: t= 6 x 25) NOTICE
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
53. Apply the sealant to the transmission housing. NOTICE
Sealant: Silicon sealant - bulk #732
63
54. Install the gear assembly and the adapter to the transmission housing. 55. Install the speedometer driven gear on the output shaft and install the ball bearing by using a press.
56. Apply the sealant to the extension housing. Press down the extension housing against the adapter. NOTICE
Sealant: Silicon sealant -bulk #732
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
64
3170
57. Tighten the extension housing bolts (14 mm-10EA). Installation Notice
58. Insert the offset lever into the 3/4 rail and install the spring pin. 59. Apply the grease into the offset lever bushing.
60. Apply the grease to the interlock bolt (17 mm) and insert it into the interlock plate hole and bolt hole. NOTICE
Make sure that the gear is at neutral position. If not, the interlock bolt cannot be inserted into the interlock plate hole.
Installation Notice
Sealant Tightening torque Bond 592 loctite 40 ~ 50 Nm
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
61. Apply the grease to the top cover and install four bolts (12 mm). NOTICE
65
Installation Notice
Sealant Tightening torque Silicon sealant -bulk #732 17 ~ 26 Nm
T/C
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
M / T
Make sure that the gear is at neutral position.
A/T
66
3170
TRANSMISSION ADAPTER
Disassembly and Assembly
1. Remove the reverse idler retainer ring.
2. Remove the components as follows and install in the reverse order of removal. 1) Unscrew the reverse lock nut and idler bracket bolts and remove the bracket and spacer. 2) Remove the reverse idler gear and the needle bearing. 3) Pull out the dowel pin and remove the reverse idler shaft. NOTICE
Tightening torque
Reverse idler bracket bolt Reverse lock nut
17 ~ 26 Nm 70 ~ 100 Nm
BACKUP LAMP SWITCH

Remove the backup lamp switch with 24 mm wrench. Apply the sealant when installing. NOTICE
Tightening torque
Sealant Tightening torque
Bond-592 LOCTITE 30 ~ 40 Nm
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
67
SHIM ADJUSTMENT
1. Unscrew nine bolts (14 mm) and remove the front fork cover. NOTICE
The shim adjustment is necessary when replacing the housings, counter gear, input shaft and output shaft.
2. Separate the front fork cover from the housing.
3. Remove the input spacer.
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
7. INSPECTION/MAINTENANCE
68
3170
4. Remove the counter spacer.
5. Prepare the special tools and dial gauge.
6. Prepare the special tools and dial gauge. Place the transmission with the output shaft facing downward and set the special tool on the counter gear and input shaft. Apply a proper force to the counter gear and input shaft so that the end plays for bearings are maximized.
7. Tighten the adjusting bolt on the special tool to hold the bearings.
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
8. Set up the dial gauge on the transmission housing surface and put the gauge needle to 0 point. 9. Put the probe end of the gauge on the taper roller bearing outer race in counter gear and measure the end play. 1) If the measured value is out of the specified range, adjust it by using spacers.
End play 0 ~ 0.05 mm
69
10. Put the probe end of the gauge on the main taper roller bearing outer race and measure the end play. 1) If the measured value is out of the specified range, adjust it by using spacers.
End play 0 ~ 0.05 mm
11. Apply the sealant to the front fork cover and tighten the bolts (14 mm). Measure the starting torque after installation. Installation Notice
Starting torque Sealant Tightening torque 20 ~ 25 Nm Silicon sealant -bulk#732 17 ~ 26 Nm
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
70
3170
8. SPECIAL TOOLS AND EQUIPMENT

661 589 04 62 00 (W 99 31 007 0B) Transmission fixture
Application
Removal/installation of transmission
W 99 31 001 1B Bearing puller
Removal of pressed in intermediate taper roller bearing
W 99 31 002 1B Pressure pipe
Pressing of the bearing and gear
W 99 31 003 1B Insert key
Providing a space to input shaft bearing
MANUAL TRANSMISSION
KYRON SM - 2005.09
3170
71

W 99 31 004 1B Die Assembly of gears and bearings on the shafts
Application
M / T
Holder
Dial gauge holder
W 99 31 007 1B Drift
Removal of 5/R synchronizer hub assembly, reverse gear and shift fork at one time
MANUAL TRANSMISSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
W 99 31 006 1B
Measurement of taper roller bearing end play
STNG
SP
AXLE
W 99 31 005 2B
Measurement of taper roller bearing end play
CLUTCH
T/C
A/T
MEMO
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PART TIME TRANSFER CASE & LOCKING HUB SYSTEM

3240 / 3410 TABLE OF CONTENTS
GENERAL ................................................. 2
1. Overview .............................................................. 2
REMOVAL AND INSTALLATION ........... 26

1. Components location ........................................ 26 2. Removal and installation of IWE (Integrated Wheel End) ....................................................... 34
PART TIME TRANSFER CASE ............... 3

1. 2. 3. 4. Structure ............................................................. 3 System layout and functions .............................. 5 Locking hub system ........................................... 6 Transfer case .................................................... 15
SPECIAL TOOLS AND EQUIPMENT .... 41 TCCU (TRANSFER CASE CONTROL UNIT) ....................................................... 42
1. Major changes in TCCU .................................... 42
POWER FLOW ....................................... 20

1. 2. 3. 4. Power flow ......................................................... 20 2H mode (2WD) ................................................ 21 4H mode (4WD - high speed) ........................... 22 4L mode (4WD - low speed) ............................. 23
SYSTEM OPERATION ........................... 44

1. 2. 3. 4. TCCU (Transfer Case Control Unit) .................. 44 Trouble diagnosis test ...................................... 47 Self-diagnosis test ............................................ 48 Diagnostic trouble code .................................... 49
TROUBLE SHOOTING .......................... 24

1. General diagnosis ............................................. 24
MAINTENANCE AND REPAIR .............. 25

1. Oil level check and change .............................. 25
3240
GENERAL
1. OVERVIEW
By using the planetary gear sets, two-gears shift type part time transfer case achieves direct connection when selecting 4WD HIGH and 2.48 of reduction gear ratio when selecting 4WD LOW. The silent chain in transfer case transfers the output power to front wheels. The simple operation of switches on instrument panel allows to shift between 2H and 4H easily while driving (for 4L: stop vehicle first). The warning lamp warns the driver when the system is defective. The 4WD system integrated in KYRON does not have big difference in comparison to the conventional part time transfer case, but the changes in comparison to the conventional transfer case are as follows: 1. No additional coding is required when replacing TCCU. 2. Delete the devices (tone wheel speed sensor, wiring etc.) related to the speed sensor in the transfer case. This system receives the speed signals from ABS/ESP HECU or instrument panel (for non-ABS vehicle(Note 1)) through the CAN communication. 3. The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU. Note : In non-ABS vehicle, the vehicle speed sensor is installed on the rear drive axle. The engine ECU sends the speed signal to the instrument panel, and then the instrument panel provides the information to TCCU and other devices.
Specifications
Description
Total length Mating surface of front flange Weight Oil capacity Location Major elements Housing Tightening bolt Input shaft
Part Time T/C

343 mm 40 mm 33.9 Kg (without oil) 1.4 L Transfer case Part time 11EA, M8 x 1.25 A/T: External spline M/T: Internal spline
Ring gear Sun gear
Inserted into housing groove Separated input shaft and sun gear

KYRON SM - 2005.09
3240
1. STRUCTURE
M / T
Front axle
Front locking hub system (IWE)
Front propeller shaft

SP
KYRON SM - 2005.09
Transmission
Part time transfer case
Rear propeller shaft
Rear axle (IRS type)
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
A/T
PART TIME TRANSFER CASE
3240
Components Location
Magnet clutch power supply connector (for 1 pin) Transfer case main connector
Shift motor connector
Transfer case assembly T/C motor Rear propeller shaft
Oil drain plug (Tightening torque: 19 ~ 30 Nm) Damper
Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm)

KYRON SM - 2005.09
3240
System Layout
Indicators (T/C control indicator lamp)
HECU (Wheel speed signal)
T/C control switch
TCCU
CAN Communication Output

SP
KYRON SM - 2005.09
Vacuum line Solenoid valve Atmosphere Atmosphere
Transfer case FL Locking hub FR Locking hub
Magnetic clutch
Motor
Front output shaft
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
2. SYSTEM LAYOUT AND FUNCTIONS
3240
3. LOCKING HUB SYSTEM

The transfer case and the TCCU differ from previous models only in the speed sensor related parts. However, the vacuum locking hub operation system works oppositely from previous models and its components also have changed. The vacuum locking hub that is applied to Kyron uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator. It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear.
Operating Process Vacuum pump
Booster Atmosphere Electrical signal Vacuum modulator (for engine)
TCCU Atmosphere
Vacuum solenoid valve for IWE
Locking hub actuator
Locking hub actuator
Vacuum generation process in front hub actuator:

TCCU T/C control switch
Vacuum pump
Solenoid valve
Air filter (Vacuum hose)
Hub actuator (FR)
Hub actuator (FL)
Atmosphere
Atmosphere

KYRON SM - 2005.09
3240
Vacuum System
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
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.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
3240
Components of IWE (Integrated Wheel End)

Front Hub Assembly
The front hub assembly is connected to the tire and it drives the wheel by receiving the rotation force from the drive shaft during 4WD mode. When the hub actuator is moved to the gear (vacuum pressure released), the 4WD mode is engaged. When the hub actuator is out of the gear (vacuum pressure applied), the 4WD mode is concelled.
Rubber O-ring Replace it with a new one when removing. Function: preventing moisture and foreign matter from entering into gears.
Steel O-ring Preventing the actuator hub from pressing against the wheel end hub
Apply the grease to the steel O-ring before installation.
Gear
NOTICE
Rubber O-ring: Replace it with a new one when removing/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

KYRON SM - 2005.09
3240
Solenoid Valve
The vacuum solenoid valve is installed at bottom of the battery tray (theft warning horn side) 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.
Vacuum pump
TCCU
AXLE
Actuator
Locking Hub Actuator
Atmosphere

KYRON SM - 2005.09
A / CON
A / BAG
Supplying vacuum pressure
BRAKE
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.
STNG
SP
CLUTCH
T/C
M / T
A/T
10 2WD:
3240
The locking hub actuator is out of the front wheel hub end gear when applying the vacuum pressure.
Locking hub actuator: pulled in when applying vacuum pressure
Front wheel end
Drive shaft
Front hub end gear is not visible (4WD mode released)
4WD:
The locking hub actuator is engaged with the front wheel hub end gear when releasing the vacuum pressure.
Locking hub actuator: pulled out when releasing vacuum pressure
Front wheel end
Drive shaft
Front hub end gear is not invisible (4WD mode engaged)

3240 Front Wheel End in Vehicle with 4WD
11
Front Wheel End in Vehicle without 4WD

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
12
3240
Vacuum Locking Hub Check

Compared to conventional locking hub systems, when the vehicle is in 2WD mode, the vacuum pressure from vacuum pump is continuously applied to the locking hub actuator. If any vacuum line is leaking, the 4WD system may not operate. Make sure that the vacuum lines are not leaking. How to check the vacuum locking hub system: 1. Disconnect hub actuator vacuum line from vacuum solenoid valve. 2. Connect vacuum gauge to vacuum line of hub actuator.
Vacuum gauge
Solenoid valve
Connect vacuum gauge to vacuum line of front hub actuator.

KYRON SM - 2005.09
3240
13
3. Check vacuum pressure with vacuum pressure gauge.

2WD: vacuum pressure 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
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.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
14
3240
Hub Actuator Check
Disconnect the vacuum hose from the hub actuator and install the vacuum pressure gauge to the hub actuator. Apply vacuum pressure to make sure the hub actuator maintains vacuum condition.
Normal
Leakage
If the vacuum pressure is maintained, the actuator hub component condition is OK.
If the vacuum pressure is not maintained, replace the actuator with a new one.

KYRON SM - 2005.09
3240
15
Appearance
Connect to transmission output shaft
Air bleeder Transfer case assembly
Rear flange
Shift motor connector Shift motor Connect to front propeller shaft
Front flange 1 pin connector (For magnetic clutch power supply) * Delete power supply terminal and ground for conventional speed sensor.
KYRON SM - 2005.09
A / CON
A / BAG
Connect to rear propeller shaft
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
4. TRANSFER CASE
16
3240
Sectional Drawing
Planetary gear set
Oil pump Magnetic clutch
Input shaft
Connect to rear propeller shaft
4H-4L Shift fork (Reduction shift fork)
2H-4H Shift fork (Lockup fork)
Shift motor
Connect to front propeller shaft

KYRON SM - 2005.09
3240
17
When selecting a position in the 4WD switch (2H, 4H, 4L), TOD control unit exactly changes the motor position to 2H, 4H and 4L by detecting the electric signals from position encoder that monitors motor position. Pin
1 2 3 4 5 6 7
Position A Position B Position C Position D Position ground Control (4L - 4H -2H) Control (2H - 4H - 4L)
1 (Violet) 3 (Brown/ White) 2 (White) 6 (Yellow) 4 (Orange/ White) 5 (Yellow/ White) 7 (Orange)
Rear view of connector
Connector Shape and Function

Magnetic Clutch Coil Power Supply Connector
The transfer case integrated in KYRON doesnt have an internal speed sensor and receives the speed signal from ABS/ESP HECU or the instrument panel (Non-ABS vehicle) via CAN communication. Therefore, there are not extra terminals for speed sensor power supply and ground. 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

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Function
A/T
Shift Motor Connector
18
3240
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
HIGH/LOW switch
16
CAN HIGH
21
K-Line (Self diagnosis)
CAN LOW
9 24
Hub solenoid
12 25

KYRON SM - 2005.09
3240 Transfer Case Circuit Diagram
19

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
20
3240
POWER FLOW
1. POWER FLOW
Switch Transfer 2H, 4H 4L
TCCU
Locking Hub Solenoid
Locking Hub Operation (Internal vacuum released)
Transfer
Front Propeller Shaft
Front Axle
Rear Axle
Front Wheel
Rear Wheel

KYRON SM - 2005.09
3240
21
2. 2H MODE (2WD)
M / T
Transmission
Power Flow
Transmission Output Shaft
Rear Wheel
Transfer Case Input Shaft Output Shaft Rear Propeller Shaft Rear Axle
Rear Wheel

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Front Axle (Front Wheel)
SP
AXLE
CLUTCH
Rear Axle (Rear Wheel)
T/C
A/T
22
3240
3. 4H MODE (4WD - HIGH SPEED)
Transmission
Power Flow
TCCU
Motor
Transmission Input Shaft
Shift Cam, Rail, Fork
4WD-HI
Locking Hub Solenoid Operation
Magnetic Clutch
T/C Output Shaft
Engagement of Front Drive Shaft and Locking Hub
Front Wheel Drive

KYRON SM - 2005.09
3240
23
Shift Cam, Rail, Fork
4WD-LO
Locking Hub Solenoid Operation
Magnetic clutch
Output Shaft
Engagement of Front Drive Shaft and Locking Hub
Front Wheel Drive

KYRON SM - 2005.09
A / CON
Planetary Gear
A / BAG
TCCU
Motor
Transmission Input Shaft
BRAKE
Power Flow
STNG
SP
AXLE
CLUTCH
T/C
Transmission
M / T
A/T
4. 4L MODE (4WD - LOW SPEED)
24
3240
TROUBLE SHOOTING
1. GENERAL DIAGNOSIS
Symptoms
Electric shift problems
Check
Faulty or damaged TCCU, speed sensor, motor, clutch or internal wirings Damaged or worn shift cam, hub, fork and rail shift Binding shift fork, hub collar or gear
Action
Overhaul and check, replace if necessary Overhaul and check for wear and damage. 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.
Cannot drive front wheel Broken drive chain when shifting to 4H, 4L Noise in 4WD operation Improper or low oil Loosened bolts or mounted parts Noisy T/C bearing Gear abnormal noise Noise in 4H or 4L 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.

KYRON SM - 2005.09
3240
25
1. OIL LEVEL 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
Oil level plug
Drain plug
Oil Change
1. Clean the oil level plug, drain plug and surroundings. 2. Place a proper container under the transfer case. 3. Remove the drain plug and then remove the oil level plug (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
Oil level plug Drain plug
Cautions for Oil Level Check and Plugs

1. Be careful of hot oil when draining. 2. Do not use an impact wrench to remove or tighten the oil level plug or drain plug since this will damage the threads in the plug.

KYRON SM - 2005.09
A/T
MAINTENANCE AND REPAIR
26
3240

1. COMPONENTS LOCATION
Magnetic clutch power supply connector (for No.1 pin) Transfer case main connector
Shift motor connector
Transfer case assembly
T/C motor
Rear propeller shaft Drain plug (Tightening torque: 19 ~ 30 Nm) Damper Front propeller shaft
Filler plug (Tightening torque: 19 ~ 30 Nm)

KYRON SM - 2005.09
3240
27

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Exploded View
28
3240
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 shield 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. Hexagon bolt 63. Hexagon cap screw 64. Electric motor assembly 65. Oil seal 66. Pipe plug

KYRON SM - 2005.09
3240 Transfer Case

1. Disconnect the motor connector from the transfer case.
29
2. Remove the rear propeller shaft. And separate the front propeller shaft from transfer case.
SP
Front
Rear
Tightening torque
81 ~ 89 Nm (T/C)
Tightening torque
81 ~ 89 Nm (T/C ) 70 ~ 80 Nm (Axle)
3. Disconnect the air hose from the transfer case.

KYRON SM - 2005.09
A / CON
Installation Notice
Installation Notice
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
30
3240
4. Place the safety jack under the transfer case and automatic transmission. Unscrew the transmission cross member bolts (14 mm) and the center bolt (14 mm), and remove the transmission cross member.
Tightening torque: (85 ~ 95 Nm) Tightening torque: (28 ~ 47 Nm)
Tightening torque: (85 ~ 95 Nm)
5. Unscrew the bolts (14 mm) and remove the transfer case mounting insulator and insulator bracket. Tightening torque
Mounting insulator Bracket bolt 28 ~ 47 Nm 28 ~ 47 Nm
6. Unscrew eleven bolts (12 mm) and carefully remove the transfer case. Installation Notice
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)

KYRON SM - 2005.09
3240
7. When installing, keep the tightening torque and install in reverse order of removal.
Side View Front View
31

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
32
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.
Motor connector
Magnetic coil clutch connector
NOTICE
Remove two nuts to separate the bracket and motor.
Bracket mounting nut

KYRON SM - 2005.09
3240
33
NOTICE
T/C
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 motors driving position before installation. NOTICE
To do that, install a new shift motor on the same location that the used shift motor was on.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
M / T
3. Pull the shift motor assembly out while keeping the level. Clean the mating surface of the transfer case and shift motor.
A/T
34
3240
2. REMOVAL AND INSTALLATION OF IWE (INTEGRATED WHEEL END)

Wheel Speed Sensor
Preceding Work: Disconnect the negative battery cable and remove the tires.
Note: Wheel speed sensor location
Front side (2WD)
Rear side (5-link type)
Rear side (IRS type)
1. Unscrew the two bolts (19 mm) and set the removed brake caliper on the frame.
2. Unscrew the two screws and remove the brake disc.

KYRON SM - 2005.09
3240
35
3. Remove the hub cap and unscrew the lock nut.
Replace the hub cap with a new one when installing.
4. Unscrew the three wheel end hub mounting bolts (10 mm). Installation Notice
BRAKE STNG
5. Slightly pull the wheel end hub until the wheel speed sensor is visible. Unscrew the mounting bolt (5 mm) and remove the wheel speed sensor.

KYRON SM - 2005.09
A / CON
A / BAG
SP
AXLE
CLUTCH
T/C
M / T
NOTICE
A/T
36
3240
6. Disconnect the wheel speed sensor and the cable.
Disconnect connector
Wheel speed sensor

KYRON SM - 2005.09
3240
37
Preceding Work: 1. Remove the tire and the brake disc. 2. Remove the wheel speed sensor. 1. Unscrew the two bolts (10 mm) and remove the brake dust cover. Installation Notice
2. Pull out the upper arm lock pin and unscrew the mounting nut (19 mm). At this time, do not fully remove the nut.
SP
3. Pull out the steering gear linkage lock pin from the knuckle. Unscrew the mounting nut (19 mm) and remove the tie rod end.
Lock pin

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
Locking Hub Actuator Assembly
38
3240
4. Unscrew the lower arm mounting nut (22 mm).
5. Remove the knuckle between upper arm and lower arm with special tool.

KYRON SM - 2005.09
3240 Hub Actuator
39
1. Unscrew the three bolts (10 mm) on the disassembled locking hub actuator assembly and remove the hub actuator.
Vacuum tube Vent tube

STNG
Detail
1 Clutch ring 2 Shift fork
Shift seal 7
Housing 6 Piston
Diaphragm
Spring
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
Structure of Hub Actuator
AXLE
CLUTCH
T/C
M / T
A/T
40
3240
Inspection
1. Check the internal seal ring of hub actuator for damage.
2. Replace the O-ring of the locking hub end with a new one.
Installation Notice
* Completely clean the parts and apply the grease them before installation. Be careful not to damage the internal seal ring of the hub actuator.

KYRON SM - 2005.09
3240
41

661 589 01 37 00 (W 99 31 001 1B) Pliers Removal/installation of carrier assembly in transfer case
Application
M / T
KYRON SM - 2005.09
DW 220 - 080 (W 99 31 005 0B) Oil seal installer
Installation of oil seal to transmission case
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
SPECIAL TOOLS AND EQUIPMENT
42
3240
TCCU (Transfer Case Control Unit)

1. MAJOR CHANGES IN TCCU
TCCU controls the 4WD system and is located under the drivers seat. The new TCCU makes some difference compared with TCCU for the conventional part time transfer case and the differences are as follows: 1. No additional coding is required when replacing TCCU. 2. Delete the devices (tone wheel, wiring etc.) related to the speed sensor in the transfer case. This system receives the speed signals from ABS/ESP HECU or instrument panel (for nonABS vehicle(Note 1)) through the CAN communication. 3. Delete the pin related to the speed sensor from TCCU pins. 4. Change the transfer case wiring connector from No.4 pin to No.1 pin (Power and ground related to the speed sensor). 5. The new TCCU is available to install on the vehicle with the conventional DI engine part time TCCU.
Location
TCU
TCCU
Pin Arrangement

KYRON SM - 2005.09
3240
43
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.
AXLE A / CON A / BAG BRAKE STNG SP
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

KYRON SM - 2005.09
CLUTCH
T/C
M / T
A/T
TCCU Pin Numbers and Description
44
3240
SYSTEM OPERATION
1. TCCU (TRANSFER CASE CONTROL UNIT)
4WD Operation
TCCU is located under the drivers seat and permits the vehicle to shift from the two-wheel drive to the four-wheel drive (and back shift) according to drivers switch operation during driving (for the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
TCCU TCU
1. 2H 4H 1) Change the 4WD switch in instrument panel from 2H to 4H. 2) This shift is available during driving. 3) The 4WD HIGH indicator in meter cluster comes on.
When the System is Defective The 4WD CHECK warning lamp comes on
2. 4H 2H 1) Change the 4WD switch in instrument panel from 4H to 2H. 2) This shift is available during driving. 3) The 4WD HIGH indicator in meter cluster goes out. 3. 4H 4L 1) This function is only available when the speed signal from speed sensor is about to stop (below 2 km/h). 2) This function is only available when the clutch pedal is depressed (manual transmission) or the selector lever is selected to the N position (automatic transmission). (TCCU must recognize the clutch pedal signal or N signal.) 3) Change the 4WD switch in instrument panel from 4H to 4L. 4) The 4WD LOW warning lamp in meter cluster flickers during this process, then goes out when the shift is completed. 5) The 4WD CHECK warning lamp comes on when the system is defective.
2H - 4H - 4L
3240
45
Reading 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 0 1 1 1 0 1 2 0 0 0 1 0 0 0 0 0 1 0 1 3 0 1 1 1 1 1 0 0 0 0 0 1 4 0 0 0 0 0 1 1 1 0 0 0 1
M / T
Motor Position
Left Stop 2H Zone 1 Zone 2 Zone 3 4H Zone 4 Zone 5
Remark
T/C
Input voltage 1: above 4.5V (HIGH) 0: below 0.5V (LOW)
4L
STNG
Shift completed
Right stop Encoder Off State
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 and hub solenoid for 1.5 seconds. 3. The shift operation is controlled to move only toward selector switch position if the selector switch position is not met with shift motor position code when the ignition switch is turned to ON.
Function of indicating lamp during shifting

1. As the operation of shift motor starts, the indicator flickers in the interval of 0.3 seconds and stops after the shifting operation is completed or cancelled. 1) Operation diagram of 4H indicator when changing the switch to 4H from 4L 2) Operation diagram of 4H indicator when changing the switch to 4L from 2H/4H
0.3 seconds
0.3 seconds

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
Zone 6
AXLE
CLUTCH
A/T
46
3240
Drive Mode Change

The shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2 seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis. Once the motor starts, the shift conditions are no longer checked. Shift conditions are as follows: 1. Normal battery voltage and shift motor for all gears 2. 2H and 4H shifts has nothing to do with the vehicle speed, the N position in the automatic transmission or the clutch signal. 3. The shift operation between 4H and 4L is only available when the vehicle speed is below 11 rpm or 2 kph.
Motor Controls
1. The shift steps have the sequence of 2H 4H 4L and 4L 4H 2H. TCCU operates the shift motor until it reads the required position code. If it detects the faulty code, the system is operated with the compensation mode. 2. Once the shift operation is started, it is completed regardless of the ignition power. If there are not operating signals from the position sensor, the shifting failure due to timeout occurs. This failure appears when the shifting time between 2H and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift. Once the shifting time exceeds the specified time, TCCU cannot properly supply the voltage to shift motor and is operated in compensation mode. 3. Even though the system recognizes a fault before motor starts, it is considered as a fault. 4. Motor stops operation when it reaches target range.
Synchronization
Synchronization occurs during shifting from 2WD (2H) to 4WD (4H or 4L). The synchronizer clutch and the hub solenoid are controlled during the synchronization as follows: 1. The clutch coil operates when the selector changes from 2H to 4H/4L. 2. The shift motor moves in 4H mode. 3. The hub solenoid starts its operation 4 seconds after shifted to 4H. 4. The clutch coil stops its operation 5 seconds after the hub solenoid is activated.
Compensation
The motor stops when the encoder related to troubles are detected during shift operation. It moves toward LOWHIGH direction for 5 seconds so that the motor is not left in unidentified position.

KYRON SM - 2005.09
3240
47
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 and 3 seconds after completion of 4H-4L shift. 2. When the timeout occurs, TCCU cuts off the voltage to shift motor and operates the compensation mode.
Position Encoder Test

STNG A / CON A / BAG BRAKE
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. 1) General encoder fault: Invalid position code input 2) 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.

KYRON SM - 2005.09
SP
AXLE
CLUTCH
T/C
M / T
A/T
2. TROUBLE DIAGNOSIS TEST
48
3240
3. SELF-DIAGNOSIS TEST
1. TCCU detects the transfer case systems malfunctions and indicates malfunctioning part(s) through flickering of the 4WD CHECK indicator. Connect Scan-I to the diagnostic connector located under the steering wheel.
2. The transfer case system is malfunctioning when: 1) The 4WD CHECK indicator remains on after 0.6 second when turning the ignition switch ON. 2) The 4WD CHECK indicator continuously comes on during driving.
3. Connect Scan-I to the diagnostic connector and read the defective code with the ignition switch ON (refer to Diagnosis Table). 4. After repairing, erase the defective code stored in TCCU.
NOTICE
Before replacing the malfunction parts with defective code, check the wires and connectors for looseness.

KYRON SM - 2005.09
3240
49
Code
P1806
Description
Defective CAN commuication
Action
M / T
KYRON SM - 2005.09
- Check communication line. - Replace TCCU if necessary.
P1805
Defective mode switch
- When the mode switch is defective - Check TCCU pin No.4 and 16. - Mode change 4H (No contact: Open) 4L (Pin No.16: Ground)
CLUTCH A / CON A / BAG BRAKE STNG SP AXLE T/C
2H (Pin No. 4: Ground)
P1821
Open or short to ground in magnetic clutch coil circuit
- Voltage at TCCU pin No.11: 11 ~ 15 V - EMC resistance: 2.5 - Check the relevant connectors for contact. - Replace TCCU if necessary.
P1822
Open or short to ground in hub control circuit
- When the hub control circuit is open or short to ground over 0.2 second - Replace TCCU if necessary.
P1841
Open to ground in shift motor circuit
- When TCCU detects the motor failure for 1 second - Check the relevant harnesses for contact. - Replace TCCU if necessary.
P1842
Short to ground in shift motor output circuit
- When TCCU detects the motor failure for 1 second - Check the relevant harnesses for contact. - Replace TCCU if necessary.
P1843
Defective position sensor in motor
- 2H-4H: after 1.5 seconds - 4H-4L: after 3 seconds - Check the relevant harnesses for contact. - Replace TCCU if necessary.
P1844
Stuck in 4L mode
- When no shifting operation from 4L to 4H, even though the shift conditions are satisfied and no error. - Replace TCCU if necessary.
A/T
4. DIAGNOSTIC TROUBLE CODE
50
3240
Code
P1850
Description
Defective position encoder
Action
- When the position encoder is defective - Check the relevant harnesses. - Check the relevant connectors for contact. - Check the shift motor.
P1851
Short to ground for position encoder 1
- Short to ground for position encoder 1 in shift motor - Check the relevant harnesses for short. TCCU pin No.18 - Check the relevant connectors for contact. - Check the shift motor.
P1852
P1853
P1854
P1815
Abnormal CAN neutral signal
- No neutral signal from automatic transmission over 1 second through CAN. - Check CAN communication line. - Check TCU.

KYRON SM - 2005.09
3240 Removal and Installation of TCCU

1. Slide the drives seat and fold up the carpet.
TCCU
51
2. Unscrew two nuts on the TCU. Installation Notice

NOTICE
Be careful not to apply any impact to TCCU body.

KYRON SM - 2005.09
A / CON
3. Disconnect the TCCU connect and remove the TCCU.
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
MEMO
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CLUTCH
GENERAL................................................................ 3
1. 2. 3. 4. Function and overview ........................................................... 3 Specifications ....................................................................... 8 Trouble diagnosis .................................................................. 9 Maintenance ....................................................................... 10
CLUTCH ASSEMBLY ............................................ 12

1. Removal and installation ..................................................... 12 2. Special tools ane epuipment ............................................... 22
3010
1. FUNCTION AND OVERVIEW

SAT (Self Adjusting Technology) Clutch System
1. Function
SAT is new clutch system which adjusts the clutch free play according to the wear of clutch disc.
Internal Components of Clutch Cover
T/C M / T
2. Operation description
1) Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch disc side at the amount of wear. 2) Disc wear (Free play) Diaphragm spring (1) Adjusting equipment (2, 3) Pressure plate (4)
STNG
1. Driving Elements
The driving elements consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel and the other is the clutch pressure plate. The clutch pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel.
2. Driven Elements
The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft. The driving and driven elements are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly.
3. Operating Elements
The clutch release system consists of the clutch pedal and clutch release cylinder. This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by using release lever and release fork. This system provides higher efficiency than conventional clutch system, and its durability is superior. 1) Clutch master cylinder (mounted on clutch pedal) 2) Concentric slave cylinder pipe (mounted inside of transmission)
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
Overview
BRAKE
SP
AXLE
CLUTCH
A/T
GENERAL
3010
Functions
Components of Clutch Assembly A. Adapter/Pipe Assembly
B. Clutch Assembly
C. Concentric Slave Cylinder
Cross Sectional View of Clutch Assembly
1. Transmission housing 2. Clutch disc assembly
3. Clutch disc cover assembly 4. Bolt
5. Washer 6. Bolt
CLUTCH
KYRON SM - 2005.09
3010 Clutch Master Cylinder and Reservoir
Operation: When depressing the clutch pedal, the push rod pushes the piston and the piston cup, which sends the oil in the oil reservoir tank to the concentric slave cylinder through the hose and pipe. During this operation, an oil pressure is produced within the master cylinder and transmitted as follows: concentric slave cylinder clutch cover clutch disc. When releasing the clutch pedal, it returns to its original position through the motion of the clutch cover and the spring within the cylinder, and the clutch operation stops. The piston in cylinder returns to its original position.
Clutch / Brake fluid reservoir Nipple

AXLE
Clutch reservoir hose
Clutch Release Chamber

The clutch release chamber keeps the oil pressure in the clutch hose and pipe stable and also helps the oil pressure to transfer quickly and generates the remaining pressure in the hose and pipe when the clutch is operated.
Cap
Chamber assembly
Pipe
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Brake master cylinder
Clamp
Clutch master cylinder
STNG
SP
CLUTCH
T/C
M / T
The clutch master cylinder generates the hydraulic pressure by moving the piston within the cylinder. It consists of oil tank, cylinder, piston, piston cup spring and push rod, and the clutch fluid is supplied from the brake fluid reservoir tank.
A/T
3010
Clutch Pedal
1. Pendant type clutch pedal (leverage effect is applied to reduce the effort to the feet). 2. The clutch pedal has some free play that prohibits its operation prior to generating the resistance by 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. If this free play is too wide, engine power disconnection is difficult and the gear damage with abnormal noise will occur.
Clutch Assembly
Clutch assembly is composed of clutch cover (diaphragm spring, pressure plate) and clutch disc.
Clutch Disc
The clutch disc is installed between the engine flywheel and the pressure plate. The spline part is installed in the , center of the disc and transmits the engine s electric power to the transmission. The transmission input shaft can be inserted into the spline part. The clutch disc has friction materials on its edges, where the engine power can be interrupted, and the cushion spring is installed to prevent friction materials (facing) from unevenly wearing out.
Clutch Cover Assembly

When depressing the clutch pedal, the concentric slave cylinder pushes the pressure plate diaphragm and separates the pressure plate. The advantages of using the diaphragm spring: the pressure varies only a little even when the clutch disc facing is considerably worn out, its structure is simple, and the pedal effort is small.
CLUTCH
KYRON SM - 2005.09
3010 Mounting on Dash Panel

Models without ABS/ESP Models with ABS/ESP
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Oil chamber
Tube (Master cylinder-oil chamber)
Oil chamber
Tube (Master cylinder-oil chamber)
SP
Clutch pipe mounting clip
Clutch pipe mounting clip
AXLE
CLUTCH
T/C
M / T
A/T
3010
2. 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 Diesel engine equipped vehicle: 140 mm 5 ~ 10 mm Single dry diaphragm 240 155 4.0 mm 263 cm2 / 2 Free: 9.4 ~ 10 mm When loaded: 9.0 0.3 mm
Clutch cover assembly setting force Clutch master cylinder Stroke Inner diameter Concentric slave cylinder Stroke Sectional area Clutch fluid
Min. 720 kg 28.4 mm
17.04 mm
7.0 mm 706 mm2 DOT3 or DOT4
Tightening Torque
Description
Clutch housing bolt (8 locations) Clutch cover (pressure plate) 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 ~ 22 Nm 8 ~ 18 Nm 16 ~ 22 Nm
CLUTCH
KYRON SM - 2005.09
3010
Check
Clutch slips
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, excessive run-out, damaged lining Dirty or burred 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 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
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
Hard to shift or will not shift
Excessive clutch pedal free play
Adjust pedal freeplay
AXLE
CLUTCH
T/C
A/T
3. TROUBLE DIAGNOSIS
10
3010
4. MAINTENANCE
Air Bleeding
Air bleed Clutch
Plastic tube
NOTICE
Keep the fluid level over MAX in reservoir during bleeding operation. Do not let the fluid contact a painted surface.
1. Remove the air bleed bolt cap on the release cylinder. Connect a plastic tube to the bolt. 2. Put the other side of the tube into a empty container. 3. Slowly pump the clutch pedal several times. 4. With clutch pedal fully depressed, undo the air bleed bolt and bleed the air and fluid from the fluid line. 5. Repeat step 3 through 4 until no more air bubbles are in the escaping fluid. NOTE
This work has to be done by two service persons. After bleeding, check the clutch system for operation and noise. Use only the Ssangyong genuine clutch fluid, and check the clutch fluid level in reservoir.
Clutch fluid
DOT 3, 4
CLUTCH
KYRON SM - 2005.09
3010
11
To prevent early wear and slip in clutch disc, always use the designated tools and special tools for maintenance.
M / T
Service Instruction
1. Replacement of clutch disc Replace the clutch cover assembly together. 2. Reinstallation of clutch disc & cover Apply the zig set (SST) on the clutch cover set. (Example: engine removal and reinstallation, flywheel related job, checking the clutch assy)
T/C
NOTICE
When reinstall the clutch assembly without the special zig, disc can be slipped and worn easily.
AXLE
How to Use Special Tool

How to identify SAT clutch specification Identify the SAT clutch with compensation device (arrow) on clutch cover.
Installation of Special Zig

Remove the transmission and place the zig set (4 pieces) between the clutch cover and diaphram spring around (refer to the picture).
* P/No: D9930 - 0010C
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
CLUTCH
A/T
Clutch Replacement
12
3010
CLUTCH ASSEMBLY
Components
1. Clutch pedal 2. Clutch master cylinder 3. Clutch hydraulic pipe 4. Clutch fluid chamber 5. Clutch hydraulic hose 6. Adapter
7. Clutch housing 8. Concentric slave pipe 9. Concentric slave cylinder 10. Clutch cover 11. Clutch disc A-A : Connection
CLUTCH
KYRON SM - 2005.09
3010
13
Clutch Assembly
1. Disconnect the clutch fluid hose from the adapter.
Hose connection (clip mounted)
3. Insert the centering pin (special tool) into center spline. Loosen the clutch cover bolts 1/2 turns in cross sequence until the spring tension is released. NOTICE
Do not remove the bolts at a time, or clutch cover may be damaged or deformed.
Installation Notice
Tightening torque 24 3 Nm
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
2. Remove the transmission assembly.
AXLE
CLUTCH
T/C
M / T
A/T
Removal and Installation of Components
14
3010
4. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc. NOTICE
Be careful not to drop the pressure plate and clutch disc.
T/M installation mark
Clutch disc
CLUTCH
KYRON SM - 2005.09
Pressure plate
3010 Concentric Slave Cylinder

1. Unscrew the nut and remove the oil pipe from the clutch housing. Installation Notice
15
2. Unscrew the oil pipe adapter mounting bolt from the clutch housing and remove the adapter and oil pipe.
3. Unscrew three bolts and remove the concentric slave cylinder assembly on the input shaft of cylinder.
4. Install in the reverse order of removal. NOTICE

Before installation, clean all the components. Do not re-use the used clutch fluid. Apply a small amount of clutch fluid on the internal components such as piston. Replace parts if necessary.
Keep the specified tightening torque.

CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
16
3010
Clutch Master Cylinder

1. Drain the clutch fluid. 2. Disconnect the clutch fluid feed hose from the brake reservoir.
Brake and clutch fluid reservoir Nipple
Clutch reservoir hose
Clamp
3. Disconnect the clutch fluid feed pipe (to chamber) and unscrew two clutch master cylinder mounting nuts (10 mm).
4. Disconnect the clutch master cylinder push rod from the clutch pedal and remove the clutch master cylinder. 5. Install in the reverse order of removal and check air bleeding and clutch pedal operation after installation.
CLUTCH
KYRON SM - 2005.09
3010 Clutch Pedal

1. Unscrew the clutch master cylinder mounting bolts. Installation Notice
Dash panel
17
Stud bolt on clutch pedal side Hexagon flange nut

Stud bolt on clutch pedal side
Cylinder module assembly
2. Remove the snap pin from master cylinder push rod.

Push rod on clutch master cylinder side Pin
Snap pin
INSTALLATION NOTICE
Clutch pedal Securely install the snap pin as shown in figure.
3. Unscrew the mounting nut (12 mm) and remove the pedal box assembly. Installation Notice
Stud bolt (1EA)
Push rod on master cylinder
Hexagon flange nut
Clutch pedal mounting hole
Pedal box assembly
CLUTCH
KYRON SM - 2005.09
A/T
18
3010
Installation Notice Install in the reverse order of removal. Adjust pedal stroke after installation. NOTICE
Apply long-life grease (T/M DBL 6611.00) to the connections. Remove foreign materials. Keep the tightening torque. Replace the bushings with new ones.
Inspection and Adjustment 1. Pedal Stroke (A)

Maximum pedal stroke 140 mm
2. Pedal Height (B)

Height (from carpet) 181 5 mm
NOTICE
To adjust the pedal stroke, loosen the lock nut (C) of the stopper bolt (D) and turn the stopper bolt until the stroke is correct. After adjustment, tighten the lock nut.
3. Pedal Free Play (E)

Free play 5 ~ 15 mm
NOTICE
To adjust the pedal free play, loosen the lock nut (F) of the master cylinder and turn the push rod until the free play is correct.
4. Check the fulcrum bolt and the bushing for wear, the pedal for bending and the spring for damage.
CLUTCH
KYRON SM - 2005.09
3010 Clutch Chamber

Removal/Installation 1. Drain the fluid. 2. Unscrew the bolt and remove the supply pipe from clutch master cylinder. Installation Notice
19
4. Unscrew the pipe bolt and remove the secondary clutch fluid pipe from concentric slave cylinder adapter. 5. Install the pipes. Be careful not to mix the pipes. NOTE
Check each pipe bolt for oil leaks. Clutch pipes are reusable. However, you must check the pipes for damages and cracks.
Chamber and Pipe Master cylinder
Oil chamber
Primary oil pipe
Secondary clutch fluid pipe
Concentric slave cylinder adapter
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Make sure to bleed the air from the system after installation.
SP
AXLE
3. Unscrew the supply pipe bolt and remove primary oil pipe from clutch fluid chamber.
CLUTCH
T/C
M / T
A/T
20
3010
Inspection and Maintenance

1. Clutch Cover Assembly 1) Check the diaphragm spring tip for wear and height unevenness.
Unevenness limit 0.8 mm
2) Check the pressure plate surface for wear, crack and discoloration. 3) Check the strap plate rivet for looseness and replace the clutch cover if necessary.
2. Clutch Disc 1) Check the facing for rivet looseness, sticks, oil and grease. 2) Measure the rivet head depth. If it is out of limit, replace the disc.
Wear limit 0.3 mm
3. Clutch Disc Run-Out 1) Measure the clutch disc run-out and if it is out of limit, replace the disc.
Run-out limit Within 0.7 mm
CLUTCH
KYRON SM - 2005.09
3010
21
4. Pressure Plate 1) Check the pressure spring for wear. NOTICE

The excessively worn components should be replaced.
5. Concentric Slave Cylinder 1) Check any heat damage, abnormal noise, poor rotation and wear of the concentric slave cylinder bearing.
CLUTCH
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
22
3010
2. SPECIAL TOOLS AND EQUIPMENT

D9930 - 0010C Zig set - diaphram spring
Application
Support diaphram spring when disassembled
CLUTCH
KYRON SM - 2005.09
AXLE
GENERAL ................................................................ 3
1. Overview ................................................................................ 3
FRONT AXLE .......................................................... 5 FRONT AXLE ASSEMBLY ...................................... 6 REMOVAL AND INSTALLATION ............................ 8 5-LINK TYPE REAR AXLE .................................... 15
1. Location .............................................................................. 15 2. Removal and installation ..................................................... 18
INDEPENDENT SUSPENSION TYPE REAR AXLE ... 24

1. 2. 3. 4. 5. Overview .............................................................................. 24 Exploded view ..................................................................... 26 IRDA (Independent Rear Drive Axle) .................................... 28 Removal and installation ..................................................... 30 Trouble diagnosis ................................................................ 32
4120
1. OVERVIEW
Compared to previous models, in addition to existing 5-link suspension, the IRDA (Independent Rear Drive Axle) is adopted for the independent type suspension in this vehicle. The below figures for rear axle show the rear axle with the independent type suspension (4WD, A/T).
Front Axle
CLUTCH M / T A / CON A / BAG BRAKE STNG SP AXLE T/C
Rear Axle IRDA (Independent Rear Drive Axle)
AXLE
KYRON SM - 2005.09
A/T
GENERAL
4120
Location
Specification Torque D20DT Gear ratio 4.27 Type Gear Size Offset M/T -
Front axle
A/T D27DT 3.91 D20DT 3.54 D27DT 3.31 Hypoid
Rear axle
Independent suspension 5,164 Nm 5-link -
198.1 mm
30 mm Steel casting (steel, aluminum cover)
218 mm (diameter) Less than 30 mm Aluminum die casting SAE 75W/90 (Synthetic) 1.5 L 412 mm 292 mm 30 kg
243.8 mm
Steel casting (steel, aluminum cover)
Housing
Specification Oil Capacity Length Width Weight
SAE 80W/90
SAE 80W/90
1.4 L 448.0 mm 681.9 mm 45 kg
1.4 L
1.9 L 469.0 mm 1717.7 mm 100 kg
AXLE
KYRON SM - 2005.09
4120
Location
M / T
Sectional Diagram
Knuckle
To air
Cap & lock nut Tightening torque: 28 ~ 32 Nm Tire fixing bolt Tightening torque: 120 ~ 140 Nm Brake disc
Axle shaft
AXLE
KYRON SM - 2005.09
A / CON
From vacuum pump
A / BAG
Tire wheel
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
FRONT AXLE
4120
FRONT AXLE ASSEMBLY
Front Disc & Wheel end Assembly Wheel speedo cable
Locking hub actuator Brake disc
Knuckle
Front wheel speed sensor cable Brake disc
Disc dust cover
Axle Shaft Assembly Front disc assembly
Wheel speed sensor & cable
Axle shaft assembly Locking hub actuator
AXLE
KYRON SM - 2005.09
4120
Front Axle Housing Assembly
Air bleed hose 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
AXLE
KYRON SM - 2005.09
AIRCON
AIR BAG
BRAKE
STEERING SUSPENSION
AXLE
CLUTCH
T/C
M / T
A/T
4120

Caution
1. Be careful not to damage the seal ring in the locking hub actuator when installing the front disc and the hub end assembly.
Seal ring
1. Removal of the front tire

Remove the front tire wheel caps. Unscrew five wheel nuts (21 mm) in diagonal direction and remove tires. Installation Notice
Wheel cap
AXLE
KYRON SM - 2005.09
4120
2. Wheel speed sensor connector and vacuum hose

Disconnect the wheel speed sensor cable and connector, and disconnect the vacuum hose from the locking hub actuator.
LH
T/C M / T A / CON A / BAG BRAKE STNG SP AXLE CLUTCH
Connector
Be careful not to damage the vacuum hose.
Brake hose Vacuum hose
RH
3. Brake disc caliper

Unscrew two mounting bolts (19 mm) and remove the brake disc caliper. Set the removed caliper on the vehicle frame. Installation Notice
AXLE
KYRON SM - 2005.09
A/T
10
4120
Axle Shaft
1. Remove the hub bearing cap and unscrew the lock nut (14 mm) on the brake disc.
Hub bearing cap
NOTICE
The hub bearing cap and the lock nut are not reusable. Always replace them with new ones after removal.
2. Unscrew the upper arm lock nut, the tie rod end lock nut and the lower arm lock nut from knuckle, and then remove the front disc and the wheel end assembly.
Upper arm (1) Tightening torque: 140 ~ 160 Nm
Tie rod end (2) Tightening torque: 110 ~ 130 Nm
Lower arm (3) Tightening torque: 150 ~ 170 Nm
3. Loosen the upper arm (1) and the tie rod end (2) and remove the assembly.
AXLE
KYRON SM - 2005.09
4120
11
4. Remove the axle shaft.

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)
AXLE
KYRON SM - 2005.09
AIRCON
AIR BAG
BRAKE
STEERING SUSPENSION
AXLE
CLUTCH
T/C
A/T
12
4120
Axle Housing
1. Remove the axle shaft from the axle housing. Remove the propeller shaft and secure it to frame.
2. Removal of mounting bolt Unscrew the mounting nut (22 mm) at right side and remove the axle mounting bolt. Installation Notice
3. Unscrew the four bolts (17 mm) on the axle housing and remove the axle mounting bracket. Installation Notice
AXLE
KYRON SM - 2005.09
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. Otherwise, it cannot be removed due to interruption.
Installation Notice
AXLE
KYRON SM - 2005.09
AIRCON
AIR BAG
BRAKE
STEERING SUSPENSION
5. Place a safety jack under the axle housing and remove the axle mounting bolts (22 mm).
AXLE
CLUTCH
M / T
4. 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.
A/T
14
4120
6. Remove the fixing clip on the air bleed hose above the axle housing and carefully lower the safety jack.
Axle Housing Assembly
NOTICE
Be careful not to damage the left and right seals in axle housing when removing the axle mounting bracket and axle assembly.
Air bleed hose Front axle housing
Axle mounting bolt
Front axle Axle mounting bolt Axle 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
KYRON SM - 2005.09
4120
15
1. LOCATION
M / T
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
5-LINK TYPE REAR AXLE
16
4120
Components
Axle Shaft
Disc type
Axle Housing
Axle Yoke
Rear Axle
Axle Housing
Axle Shaft Drum Type
AXLE
KYRON SM - 2005.09
4120
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 (D20DT / D27DT) DI engine + A/T (D20DT / D27DT) Oil Capacity Specification
Specification
Semi-floating type Build-up type Conventional Hypoid 4.27 / 3.91 3.54 / 3.31 1.9 L SAE 80W/90 or API GL-5
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
Specifications
18
4120

Rear Axle Shaft (Disc Brake Type)
Preceding Works: Remove the tire. 1. Unscrew the two mounting bolts (19 mm) and remove the brake disc caliper. Set the removed caliper on the vehicle frame.
Caliper mounting bolt 85 ~ 105 Nm
2. Unscrew the mounting bolt (10 mm) and disconnect the wheel speed sensor cable. Installation Notice
AXLE
KYRON SM - 2005.09
4120
19
3. Unscrew the adjusting nut of the parking brake cable equalizer to loosen the parking brake cable.
Adjusting nut
4. Remove the lock pin and disconnect the parking brake cable.
Parking brake cable Lock pin
5. Remove the brake disc.
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
20
4120
6. Remove the plastic plug from the axle shaft flange.
7. Unscrew the four flange lock bolts (17 mm) on the axle housing flange and remove the axle shaft. Installation Notice
AXLE
KYRON SM - 2005.09
4120
21
Preceding Works: Remove the tire. 1. Remove the wheel speed sensor (A), the air breather lock nut (B), the parking brake cable (C) and the disc brake caliper (D) from the rear axle.
A. Wheel Speed Sensor (10 mm - 1EA) - LH/RH Tightening torque: 6 ~ 8 Nm B. Air Breather (Lock Bolt 10 mm - 1 EA)
C. Parking Brake Cable - LH/RH
D. Disc Brake Caliper - LH/RH Tightening torque: 85 ~ 105 Nm
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Rear Axle Housing
22
4120
2. Place a safety jack under the axle housing and unscrew the connections. A. lateral rod mounting nut (22 mm) B. Lower arm bolt/nut (22 mm) C. Shock absorber bolt/nut (17 mm: nut, 10 mm: bolt)
Tightening torque
150 ~ 180 Nm
Tightening torque
150 ~ 180 Nm
Tightening torque
80 ~ 100 Nm
F. Upper arm
A. Lateral rod
D. Stabilizer mounting bracket
E. Propeller shaft
B. Lower arm
C. Shock absorber
D. Mounting bracket bolts of stabi- E. Propeller shaft lizer bar (14 mm - 2 EA: LH/RH)
F. Upper arm bolt/nut (22 mm)
Assembly mark
Tightening torque
AXLE
KYRON SM - 2005.09
40 ~ 60 Nm
Tightening torque
70 ~ 80 Nm
Tightening torque
150 ~ 180 Nm
4120
3. Carefully lower the safety axle to remove the rear axle assembly from the vehicle frame.
Front View
23
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Rear View
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
24
4120
INDEPENDENT SUSPENSION TYPE REAR AXLE

1. OVERVIEW
Introduction
Compared to previous models, in addition to existing 5-link suspension, the IRDA (Independent Rear Drive Axle) is adopted for the independent type suspension in this vehicle.
AXLE
KYRON SM - 2005.09
4120
25
Specifications
Description
Type Torque M/T Gear ratio A/T Type Gear Size Offset 3.54 / 3.31 (D20DT / D27DT) Hypoid 218 mm (diameter) Less than 30 mm Independent suspension 5,164 Nm 4.27 / 3.91 (D20DT / D27DT)
Rear axle
5-link CLUTCH T/C
Steel casting (steel, aluminum cover)

STNG
Housing
Aluminum die casting
Oil
Specification
SAE 75W/90 (Synthetic) 1.5 L 412 mm 292 mm 30 kg
SAE 80W/90
Capacity Length Width Weight
1.9 L 469.0 mm 1717.7 mm 100 kg
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
243.8 mm
AXLE
M / T
A/T
26
4120
2. EXPLODED VIEW
6 1 2 3 5 4 11 12 18 19 13 14 15 16 17 20 7 8 9 10
45 44 43 42 41 39 37 35 36 34 33 32 31 30 29 28 27 26 38 21 40 22 23 24 25
1. Differential case side bearing assembly 2. Ring gear 3. Differential pinion thrust washer 4. Differential pinion gear 5. Cross shaft snap ring 6. Differential side gear thrust washer 7. Differential side gear 8. Differential case cross shaft 9. Differential gear 10. Differential thrust washer 11. Differential side gear 12. Differential side gear thrust washer 13. Differential case 14. Differential case side bearing assembly
15. Ring gear bolt 16. Cover fan gasket 17. Dowel pin 18. Cover fan 19. Vent connector 20. Cover fan bolt 21. Dowel pin 22. Pinion spacer 23. Pinion head bearing assembly 24. Pinion shim 25. Pinion gear 26. Output shaft 27. Output shaft snap ring 28. Shaft seal assembly 29. Differential case side bearing snap ring 30. Differential bearing race
31. Drain plug 32. Drain plug washer 33. Fill plug 34. Fill plug washer 35. Pinion flange nut 36. Pinion flange washer 37. Pinion flange assembly 38. Pinion seal assembly 39. Pinion tail bearing assembly 40. Carrier housing 41. Differential bearing assembly 42. Differential case side bearing snap ring 43. Shaft seal assembly 44. Output shaft snap ring 45. Output shaft
AXLE
KYRON SM - 2005.09
4120
27
Rear axle assembly Ball joint
Boot
STNG
Rear axle shaft
Boot Ball joint
Brake disc
Back plate Hub bearing Parking brake
Wheel / Tire
Lock nut

AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
Sectional Drawing
28
4120
3. IRDA (INDEPENDENT REAR DRIVE AXLE)

IRDA Axle Mounting Bolt (30 mm - 1 EA) Tightening torque: 95 ~ 142 Nm
Brake Disc Lock Nut (30 mm - 1 EA)
* Caulk the nut after tightening
Axle Shaft Assembly
Axle shaft
Rear axle shaft
Hub plane washer Mounting bolt (axle side) Tightening torque: 70 ~ 80 Nm
Lock nut Tightening torque: 250 ~ 350 Nm
AXLE
KYRON SM - 2005.09
4120
29
Axle Housing Bracket Mounting Bolt

M / T
Rear axle bracket
T/C
Axle Housing Mounting Bracket Bolt
Axle Housing Mounting Bolt
Rear axle bracket
Rear axle
AXLE
KYRON SM - 2005.09
AIRCON
AIR BAG
BRAKE
STEERING SUSPENSION
AXLE
CLUTCH
A/T
30
4120

1. Loosen the locked positions and remove the lock nut (24 mm).
2. Make an alignment mark on the flanges of the axle shaft and the axle housing. Unscrew the six bolts (Torx 10 mm) and remove the axle shaft while lowering the axle shaft flange.
Alignment mark
Lower the axle shaft. Remove the axle shaft.
AXLE
KYRON SM - 2005.09
4120
3. Unscrew the two axle housing mounting bolts (22 mm).
31
4. Unscrew the mounting bolt (30 mm) and carefully lower the safety jack with axle housing assembly.
Backlash Check
Measure the backlash between the drive pinion and ring gear.
Specified value 0.15 ~ 0.20 mm
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
32
4120
Symptom
Noise (during driving straight ahead) Lack of oil Low viscosity of oil Inferior oil Excessive backlash of ring gears Worn or damaged tooth of ring and pinion gear Worn or damaged drive pinion bearing Wear of side bearing and side gear spline Bending of axle housing Distortion of differential case Wear of pinion shaft Incorrect drive pinion preload Incorrect contact of ring gear and pinion Excessive oil Oil leakage Fault seal of carrier contact surface Axle housing crack Worn or damaged oil seal Worn or damaged tooth of pinion or side gear Noise (during turning) Wear of pinion shaft Excessive backlash of pinion gear and side gear Excessive end-play of axle shaft Incorrect contact of side gear and differential case Axle housing crack 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 Lack of oil Heating Insufficient backlash of gears Excessive preload of bearing
Cause
Action
Replenish Replace Replace Adjust Replace Replace Replace Replace Replace Replace Adjust Reassembly Adjust Correct Replace Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replenish Adjust Adjust
AXLE
KYRON SM - 2005.09
4120
33
Inspection of Ring Gear Tooth Contact Pattern

1. Normal contact Apply gear-marking compound (Prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern.
2. Abnormal contact Tooth Contact Pattern

1. Heel contact
Possible Cause
Excessive backlash Noise can be occurred
Remedy
Adjust backlash (Decrease backlash) Select proper shin to move the drive pinion toward the ring gear (toward toe)
2. Toe contact
Insufficient backlash Tooth can be damaged or broken under heavy load
Adjust backlash (Increase backlash) Select proper shim to move the drive pinion against the ring gear (toward heel)
3. Face contact
Excessive backlash Drive pinion shaft is apart from the ring gear Noise can be occurred
Adjust backlash (Increase pinion shim) Move the drive pinion toward the ring gear (toward the center of ring gear)
4. Flank contact
Insufficient backlash Gear contacts on the low flank Gear can be damaged or worn Noise can be occurred
Adjust backlash (Decrease pinion shim) Move the ring gear toward the drive pinion (toward the ring gear center line)
AXLE
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
MEMO
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SUSPENSION
FRONT SUSPENSION ............................. 2
1. 2. 3. 4. 5. 6. System overview ................................................. 2 System layout ..................................................... 6 Removal and installation ..................................... 8 Coil spring & shock absorber assembly .......... 10 Stabilizer bar ..................................................... 12 Lower arm ......................................................... 14
IRS TYPE REAR SUSPENSION ........... 32

1. 2. 3. 4. Overview ............................................................ 32 Specifications ................................................... 34 Trouble diagnosis .............................................. 34 Removal and installation ................................... 36
5-LINK (RIGID TYPE) REAR SUSPENSION ........................................................ 19

1. 2. 3. 4. Overview ............................................................ 19 System layout ................................................... 20 Trouble diagnosis .............................................. 25 Removal and installation ................................... 26
4411
FRONT SUSPENSION
1. SYSTEM OVERVIEW
Overview
The suspension is the device to connect the axle and vehicle frame. It absorbs the vibrations and impacts from road surface, which enhances the comforts, driving force, braking force and drivability. 1. Suspension type: Double Wishbone 2. Component Knuckle, upper arm assembly, lower arm assembly, coil spring, shock absorber assembly and stabilizer
Upper Arm Assembly
The upper arm is mounted to the frame and the knuckle and it relieves the load delivered from the tire to the knuckle. This enables to absorb the various impacts according to the load shapes and to ensure the drivability.
Lower Arm Assembly
The lower arm is mounted to the knuckle and the shock absorber. It relieves the load delivered from the tire to the knuckle. This enables to absorb the various impacts according to the load shapes and to ensure the drivability.
SUSPENSION
KYRON SM - 2005.09
4411
Stabilizer Bar
T/C
Stabilizer bar mounting bracket
Bushing Stabilizer bar
Link
Coil Spring
A section of spring steel rod is wound in a spiral pattern or shape coil provides a cushion to absorb road imperfections and returns the vehicle to a predetermined ride height. It is amajor contributor to a vehicles handling balance and ride quality. Higher spring rates and shorter overall lengths are commonly used to lower the vehicles ride height for enhanced appearance and improved handling.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
A transverse mounted spring steel bar controls and minimizes body lean or tipping on corners. This is a round bar which connects the left wheel suspension assembly with the right side. The main function is to keep both wheels rolling at the same rate when meeting bumps, but it also affects handling.
SP
AXLE
CLUTCH
M / T
A/T
4411
Shock Absorber Assembly

1. This vehicle uses the strut type shock absorber. This shock absorber is connected to the piston rod in the strut. This relieves the vertical vibrations of vehicle to provide ride comforts, prevents the spring break, enhances drivability, and extends the life span of steering components.
Coil spring
Shock absorber
Yoke
2. The telescopic shock absorber consists of a tube with piston and rod, and a cylinder tube. The piston has an orifice and valve and the cylinder is filled with oil. This double tube type shock absorber restrains the vibrations by using oil resistance. This provides better drivability even though the structure is complicated. This vehicle uses the gas shock absorber with cylindrical double tube.
Amplitude
Time without shock absorber with shock absorber
SUSPENSION
KYRON SM - 2005.09
4411
1. Lower spring seat 2. Yoke bracket 3. Rebound stopper 4. Cylinder 5. Piston 6. Shock absorber assembly 7. Spring 8. Yoke 9. Boot
10. Bumper stopper 11. Spring seat rubber 12. Upper spring seat 13. Rubber 14. Rubber 15. Spacer 16. Washer 17. Nut 18. Bolt
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Sectional Drawing of Shock Absorber
4411
2. SYSTEM LAYOUT
Specifications
Description
Suspension type Spring type Shock absorber type Stabilizer type Toe-in Wheel alignment Camber Caster Height H
Specification
Double wishbone Coil spring Cylindrical double tube (gas type) Torsion bar 2 2 mm -0.19 0.3 (the difference between both ends is should be below 30' ) 4.4 0.5 (the difference between both ends is should be below 30' ) 96.5 5 mm
Upper arm (on knuckle) nut Tightening torque: 140 ~ 160 Nm
Upper Arm Assembly
Coil Spring
Shock Absorber
Front axle shaft assembly
Stabilizer Bar Assembly
Steering gear box assembly Lower Arm Assembly Shock Absorber Yoke Lower arm (on knuckle) nut Tightening torque: 140 ~ 160 Nm Knuckle Assembly
SUSPENSION
KYRON SM - 2005.09
4411
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
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
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
4411

Upper Arm
: Remove the upper arm assembly according to the sequences shown below and keep the specified tightening torque when reinstalling it.
Preceding Works
1. Remove the tires. Remove the wheel cap and loosen the wheel nuts in several steps. Installation Notice
1. Wheel speed sensor cable
: Remove the wheel speed sensor cable and the connector from the upper arm.
2. Upper arm nut (19 mm, knuckle side)
: Remove the split pin first and then remove the mounting nut.
NOTICE
Replace the split pin with a new one when installing.
SUSPENSION
KYRON SM - 2005.09
4411
3. Upper arm bolt/nut (frame side) 12 mm bolt
: Remove the upper arm mounting bolts and nuts (LH/RH).
12 mm nut Tightening torque: 110 ~ 130 Nm
4. Upper arm
: Separate the upper arm from the frame first, and then separate it from the knuckle with a special tool.
Upper Arm Assembly Upper arm Bolt / nut
Split pin Castle nut
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
10
4411
4. COIL SPRING & SHOCK ABSORBER ASSEMBLY

Preceding Work
Remove the tire and the upper arm. 1. The upper mounting nuts of the coil spring/shock absorber assembly (14 mm - 3 EA) : At first, unscrew the two upper mounting nuts in engine compartment.
Engine Compartment
Wheel House
: Unscrew the upper mounting nut (14 mm) under the wheel house. 2. The lower nut of the coil spring/shock absorber yoke (24 mm - 1 EA)
Shock absorber yoke (24 mm)
Stabilizer link (12 mm)
: Unscrew the lower nut of coil spring/shock absorber yoke from the lower arm. Do not completely remove the nut.
SUSPENSION
KYRON SM - 2005.09
4411
11
3. Remove the coil spring/shock absorber.

M / T
Coil Spring Assembly

SP
Coil spring
Shock absorber
When installing the yoke to the coil spring/shock absorber, make sure that slot B and protrusion A are aligned.
Lock bolt Tightening torque: 100 ~ 120 Nm
Yoke
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
A/T
12
4411
5. STABILIZER BAR
Preceding Work
Remove the tires.
1. Remove the stabilizer bar link.

: Unscrew the lower mounting nut (12 mm) and upper mounting nut (10 mm) to remove the stabilizer bar link assembly.
2. Unscrew the two bracket mounting bolts (14 mm) and remove the stabilizer bar assembly.
Mounting bracket Stabilizer bar
Bushing
SUSPENSION
KYRON SM - 2005.09
4411
13
Components Bushing
M / T
Link Washer 7 ~ 10 mm
Nut
Washer
Bushing
NOTICE
1. Be cautious of the direction of the bushing and washer when installing. 2. Be cautious of the marks on the front stabilizer bar (LH/RH) when installing. LH: yellow mark RH: white mark
Stabilizer Bar Assembly Bracket Bracket
Stabilizer bar Bushing Bushing
Link Nut
Link Nut
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
14
4411
6. LOWER ARM
Preceding Works: 1. Remove the tires. 2. Make an alignment mark on the camber adjusting bolt of lower arm (frame side).
Wheel Alignment
Description
Toe-in Camber Caster
Specification
2 2 mm -0.19 0.3 (the difference between both ends is should be below 30' ) 4.4 0.5 (the difference between both ends is should be below 30' )
Front
Rear
SUSPENSION
KYRON SM - 2005.09
4411
15
3. Disconnect the SSPS solenoid valve connector.
4. Loosen the steering gear box by unscrewing the steering gear box mounting bolts (arrows) and remove the camber adjusting bolts.
Interference between camber bolt and steering gear box
Interference between camber bolt and steering gear box
NOTICE
Be careful not to damage the SSPS solenoid valve connector.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
16
4411 Removal and Installation

1. The lower arm mounting bolts/nuts on the frame (LH/RH)
: Before removing lower arm assembly, make the alignment marks on the mounting nut (14 mm) on the frame and camber adjusting bolt (14 mm). NOTE
Always perform the wheel alignment procedures after removing and reinstalling the lower arm assembly.
2. Unscrew the lower nut of stabilizer bar link and the lower nut of coil spring/shock absorber yoke.
Lower link nut (12 mm)
Lower yoke nut (24 mm)
Tightening torque 1. Lower link nut (110 ~ 130 Nm) 2. Lower shock absorber yoke nut (150 ~ 170 Nm)
SUSPENSION
KYRON SM - 2005.09
4411
17
Knuckle lower mounting nut (14 mm) Tightening torque: 140 ~ 160 Nm
4. Place a safety jack under the lower arm and unscrew the lower shock absorber yoke bolt. Remove the yoke while raising the safety jack with lower arm.
5. Remove the lower arm assembly from the vehicle.

Components
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
3. Unscrew the lower mounting nut (14 mm) and remove the lower arm from knuckle end bolt with special tool.
A/T
18
4510
MEMO
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SUSPENSION
KYRON SM - 2005.09
4510
19
1. OVERVIEW
The rear suspension is also to keep the ride comforts and drivability and this vehicle uses 5-link suspension system. It consists of coil springs on both sides, shock absorber, upper and lower arm, lateral rod and stabilizer bar.
1. Stabilizer Bar: It maintains the balance of the vehicle when turning, and minimizes the vehicles slope when the wheels are moving up and down separately.
2. Lateral Rod: It controls the transverse load to the vehicle.
3. Upper/Lower Arm: It controls the longitudinal load to the vehicle.
4. Shock Absorber: It absorbs the vertical vibration of the vehicle body. It enhances the ride comforts and prevents the fatigue break of the spring.
5. Coil Spring: It is installed between the rear axle and body frame. It relieves the vibrations and impacts delivered from wheels to vehicle body.
SUSPENSION
KYRON SM - 2005.09
A/T
5-LINK (RIGID TYPE) REAR SUSPENSION
20
4510
2. SYSTEM LAYOUT
Lower Arm (Link)
Stabilizer Bar Link
Stabilizer Bar Upper Arm (link)
Shock Absorber
Lateral Rod
Coil Spring Seat (Upper)
Axle Housing
SUSPENSION
KYRON SM - 2005.09
4510
21
Lower arm (22 mm) 150 ~ 180 Nm
Lateral rod (22 mm) 165 Nm
Shock absorber (lower: 7 mm + 10 mm) 80 ~ 100 Nm
Shock absorber (upper: 2 mm) 30 ~ 45 Nm
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
Upper arm (22 mm) 150 ~ 180 Nm
Stabilizer bar link (upper- 17 mm + 14 mm): 30 ~ 45 Nm
CLUTCH
Stabilizer bar link (lower- 17 mm + 12 mm): 40 ~ 60 Nm
T/C
M / T
Stabilizer bar link (lower- 17 mm + 12 mm): 60 ~ 80 Nm
A/T
22
4510
Location
Shock Absorber Assembly Coil Spring Assembly
Lateral Rod Assembly
SUSPENSION
KYRON SM - 2005.09
4510
23
Stabilizer Assembly
Stabilizer Bar Link
Upper/Lower Arm Assembly
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
24
4510
Installation Drawing
Front View
Rear View
SUSPENSION
KYRON SM - 2005.09
4510
25
Symptom
Vehicle rolling
Cause
Broken stabilizer bar Faulty shock absorber
Action
Replace Replace Re-tighten Replace Replace Replace Pressure adjust Replace Tighten as specified torque Replace Replace Replace
SP CLUTCH A / CON A / BAG BRAKE STNG AXLE T/C M / T
Abnormal noises
Loosening mountings Damaged or worn wheel bearing Damaged shock absorber Damaged tire
Poor riding
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
Replace Replace Replace Replace Replace Adjust Re-tighten or replace Replace
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
KYRON SM - 2005.09
A/T
26
4510

System Layout
Shock absorber Stabilizer bar
Upper arm
Rear suspension assembly
Stabilizer bar link
Lateral rod
Coil spring
Lower arm
SUSPENSION
KYRON SM - 2005.09
4510 Removal of Components

Remove the rear suspension components in order. 1. Remove the coil spring using a special tool.
27
1) Unscrew the lateral rod mounting nut (22 mm) on axle. Installation Notice
BRAKE
2) Unscrew the lateral rod mounting bolt/nut (22 mm) on frame. Installation Notice
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
STNG
2. Remove the lateral rod.
SP
AXLE
CLUTCH
T/C
M / T
A/T
28
4510
3. Disconnect the link and the bracket from the stabilizer bar to remove the stabilizer bar. 1) Unscrew the stabilizer bar link mounting nuts (upper/lower) and remove the link. Installation Notice
Tightening torque Protrusion of upper bolt 30 ~ 45 Nm 7 ~ 12 mm
2) Remove the mounting cap bracket and bushing from the stabilizer bar (LH/RH). Installation Notice
SUSPENSION
KYRON SM - 2005.09
4510
4. Remove the shock absorber between the frame and the axle.
29
1) Remove the upper mounting nut (17 mm) and the shock absorber bolt (6 mm) as shown in the figure. Installation Notice
Protrusion of upper bolt
27 mm
STNG
Installation Notice
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
2) Remove the lower bolt/nut (17 mm).
BRAKE
SP
Tightening torque
30 ~ 45 Nm
AXLE
CLUTCH
T/C
M / T
A/T
30
4510
5. Remove the upper arm between frame and the axle.
A. Unscrew upper arm mounting bolt/nut (22 mm) on axle.
B. Unscrew upper arm mounting bolt/nut (22 mm) on frame.
Tightening torque
150 ~ 180 Nm
Tightening torque
150 ~ 180 Nm
NOTICE
The fuel tank should be removed before removing the rear left bolts (upper arm and lower arm).
SUSPENSION
KYRON SM - 2005.09
4510
6. Remove the lower arm from the frame and the axle. 1) Remove the wheel speed sensor cable (1) and the parking cable (2) mounting bolt (12 mm) when removing the lower arm.
31
2) Unscrew lower arm mounting bolt/nut (22 mm) on frame. Installation Notice
BRAKE STNG
3) Unscrew lower arm mounting bolt/nut (22 mm) on axle. Installation Notice
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
SP
AXLE
CLUTCH
Mounting bolt
T/C
M / T
A/T
32
4520
IRS TYPE REAR SUSPENSION

1. OVERVIEW
Overview
The rear suspension is also to keep the ride comforts and drivability and this vehicle uses IRS (Independent Rear Suspension) and RIGID type. It consists of coil spring, shock absorber, upper arm, track rod, thrust link and stabilizer bar.
69 5 mm
Coil Spring This is installed between the rear axle and body frame. It relieves the vibrations and impacts delivered from wheels to vehicle body. The spring should be installed as the red mark is over the yellow mark. Red Yellow
SUSPENSION
KYRON SM - 2005.09
4520
33
Stabilizer Bar A transverse mounted spring steel bar controls and minimizes body lean or tipping on corners. This is a round bar which connects the left wheel suspension assembly with the right side. The main function is to keep both wheels rolling at the same rate when meeting bumps; but it also affects handling.
Shock Absorber This relieves the vertical vibrations of vehicle to provide ride comforts, prevents the spring break, enhances drivability, and extends the life span of steering components.
STNG
Upper Arm/Coil Spring Link Upper Arm: This is connected to the knuckle and body frame and controls the longitudinal load to the vehicle. Coil Spring Link: This is connected to the knuckle and body frame and reduces the weight to coil spring and shock absorber. It means that this controls the vertical load to the vehicle.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
34
4520
2. SPECIFICATIONS
Description
Suspension type Spring type Stabilizer bar type Shock absorber Type Max. length Min. length
Coil spring
Specification
IRS type Coil spring Torsion bar Cylindrical double tube 463 mm 310 mm 14.9 mm
Coil thickness Inner diameter of coil (A) Free length (B) Length at load (C) Spring rate
70.1 mm
344.9 mm 252.1 mm 8.68 5 %
Trouble Diagnosis
Symptom
Vehicle rolling Broken stabilizer bar Faulty shock absorber Abnormal noises Loosening mountings Damaged or worn wheel bearing Damaged shock absorber Damaged tire Poor riding 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
Cause
Action
Replace Replace Re-tighten Replace Replace Replace Pressure adjust Replace Tighten as specified torque Replace Replace Replace Replace Replace Replace Replace Replace Adjust Re-tighten or replace Replace
SUSPENSION
KYRON SM - 2005.09
4520
35
Inspection
Wheel Bearing End Play
1. Release the parking brake. 2. Raise the rear wheel. 3. Check if the wheel bearing end play exists while rocking the wheel. 4. If the end play is excessive, retighten the castle nut. 5. If the end play still exists, replace the wheel bearing.
Wheel Bearing Preload

1. Release the parking brake. 2. Raise the rear wheel and rotate it several times. 3. Remove the tire. 4. Hook a spring gauge on a hub bolt and pull it. Read the scale on the gauge at the point when the drum starts to move. It is preload. 5. Check if the preload is within the specified range.
Specified value 1.4 ~ 4.3 kg.cm
BRAKE
6. If the measured preload is out of the specified range, retighten the castle nut to the specified torque. 7. If the trouble still exists, replace the wheel bearing with a new one.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
36
4520

Components and Tightening Torque
Upper Arm Stabilizer bar link: 40 ~ 60 Nm Body: 110 ~ 130 Nm Coil Spring
Body: 110 ~ 130 Nm Knuckle: 140 ~ 160 Nm
Red Yellow * The spring should be installed so that the red mark is over the yellow mark.
Track Rod
Body: 150 ~ 170 Nm
Knuckle: 11 ~ 13 Nm
Stabilizer Bar
Stabilizer bar link: 40 ~ 60 Nm
Stabilizer bar mounting bracket bolt: 40 ~ 60 Nm
Stabilizer bar link: 40 ~ 60 Nm
SUSPENSION
KYRON SM - 2005.09
4520
37
Thrust Link
Wheel Speed Sensor
Body: 150 ~ 170 Nm
Knuckle: 110 ~ 130 Nm
Knuckle: 120 ~ 150 Nm
Shock Absorber Body: 30 ~ 45 Nm
Coil spring link: 60 ~ 80 Nm
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Body: 110 ~ 130 Nm
STNG
Coil Spring Link
SP
AXLE
CLUTCH
T/C
Mounting bolt: 6 ~ 8 Nm
M / T
A/T
38
4520
Rear Suspension Module

1. Remove the tire (21 mm - 5 wheel nuts). Installation Notice
Remove and tighten the wheel nuts in several steps in a crisscross sequence.
2. Remove the brake disc caliper and set the removed caliper on the frame (17 mm - 2 bolts).
3. Unscrew the two stabilizer bar mounting bracket bolts (14 mm) from body (frame) and remove the stabilizer bar.
Mounting bracket
SUSPENSION
KYRON SM - 2005.09
4520
39
4. Install the special tool to the coil spring and compress the coil spring with the tool. Unscrew the upper nut (17 mm) on the shock absorber.
T/C
6. Unscrew the bolt (10 mm) and remove the parking brake cable and wheel speed sensor.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
5. Tighten the special tool to compress the coil spring. Remove the coil spring and spring seat while pulling down the coil spring link.
AXLE
CLUTCH
M / T
A/T
40
4520
7. Place the safety jack under the rear sub frame and unscrew the sub frame mounting bolts (body side : 22 mm 4 EA) and the axle housing hexagon nut (22 mm - 1 EA). Unscrew the thrust link mounting bolt/nut (14 mm) on body.
A. Axle housing mounting nut (22 mm) Tightening torque: 95 ~ 142 Nm B. Thrust link bolt/nut on body Tightening torque: 150 ~ 170 Nm
C. Sub frame coil bolt (front - 14 mm) Tightening torque: 95 ~ 142 Nm
D. Sub frame bolt (rear - 14 mm) Tightening torque: 95 ~ 142 Nm
SUSPENSION
KYRON SM - 2005.09
4520
8. Lower the safety jack and remove the sub frame from the vehicle.
41
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
42
4520
Shock Absorber Assembly

Preceding Work: Remove the tire. 1. Compress the coil spring with special tool and unscrew the shock absorber upper nut on body (frame) (17 mm - 1EA).
2. Unscrew the shock absorber lower bolt/nut (bolt: 14 mm / nut: 17 mm) on coil spring link.
3. Remove the shock absorber from the rear suspension.
SUSPENSION
KYRON SM - 2005.09
4520 Coil Spring Assembly

Preceding Works: 1. Remove the tires. 2. Unscrew the bolt and lower the stabilizer bar. 1. Compress the coil spring with special tool.
43
2. Release the compression force of coil spring by loosening the lower shock absorber bolt/nut and remove the coil spring and upper spring seat.
STNG
Upper spring seat
Coil spring
Red Yellow
NOTICE
The spring should be installed so that the red mark is over the yellow mark.
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
44
4520
Stabilizer Bar Assembly

Preceding Work: Remove the tires. 1. Unscrew the two bolts (14 mm) and remove the stabilizer bar bracket.
Tightening torque: 40 ~ 60 Nm Bracket Bushing Bolt
Stabilizer bar
2. Unscrew the bolt/nut (14 mm) on the link and stabilizer bar and remove the stabilizer bar. Also, unscrew the bolt (12 mm) on the knuckle and remove the link.
Link mounting nut Tightening torque: 40 ~ 60 Nm
Stabilizer bar mounting nut Tightening torque: 40 ~ 60 Nm
SUSPENSION
KYRON SM - 2005.09
4520
45
3. Install the stabilizer link. Be cautious of the installing direction.
LH/RH Link
T/C
Link
Link
Stabilizer bar
Bracket and bushing
Bracket and bushing
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Link mounting nut
Link mounting nut
SP
AXLE
CLUTCH
M / T
A/T
46
4520
Suspension Assembly
Preceding Work: Install a special tool to the coil spring.
Upper Arm
: Unscrew the bolt/nut and remove the upper arm.
Upper Arm
19 mm - 1EA: nut (Tightening torque: 110 ~ 130 Nm)
Stabilizer Bar Link (upper)
Upper Arm (Knuckle Side)
19 mm - 1EA: bolt/nut (Tightening torque: 140 ~ 160 Nm)
Upper Arm
SUSPENSION
KYRON SM - 2005.09
4520
47
: Unscrew the nut and remove the track rod.

Track Rod on Sub Frame Upper Arm
Make an alignment mark on toe-in adjusting nut.
Track Rod on Knuckle

STNG
Thrust Link
: Unscrew the bolt/nut and remove the thrust link.
Thrust Link on Body Thrust Link on Knuckle
SUSPENSION
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
Track Rod
A/T
48
4520
Coil Spring Link Assembly

Preceding Works: 1. Remove the tires. 2. Unscrew the bracket bolts and lower the stabilizer bar. 3. Remove the coil spring.
Unscrew the lower shock absorber bolt on coil spring link and the bolt/nut on sub frame of the coil spring link and knuckle to remove the coil spring link assembly.
Camber Adjustment Make an alignment mark on camber adjusting nut/bolt before removing them.
Bolt/Nut on Lower Shock Absorber (Knuckle Side)
Rear Suspension (Module Side)
1. Bolt and nut (lower shock absorber) 2. Bolt and nut (knuckle, 22 mm)
Bolt and nut (sub frame, 22 mm)
SUSPENSION
KYRON SM - 2005.09
POWER STEERING SYSTEM

GENERAL INFORMATION ...................................... 3
1. Overview ................................................................................ 3 2. System layout ......................................................................4
SSPS (SPEED SENSING POWER STEERING) .... 8

1. General information ...............................................................8 2. Trouble diagnosis ................................................................ 15 3. Removal and installation ..................................................... 24
4610
1. OVERVIEW
The power steering has been designed to make the wheel move more easily than in a manual steering system. The hydraulic power assists the process utilizing hydraulic fluid. The fluid increases pressure in the power steering pump and aids the movement of the steering mechanism. The power steering system consists of pump, oil reservoir, rack and gear box. The power steering pump is a vane type and delivers hydraulic pressure to operate the power steering system. The pressure relief valve in the pump controls the discharging pressure. The rotary valve in the rack and the pinion gear directs the oil from the power steering pump to one side of the rack piston. The integrated rack piston converts the hydraulic pressure to linear movement. The operating force of the rack moves the wheels through the tie rod, the tie rod end and the steering knuckle. Even though the hydraulic pressure cannot be generated, a driver can steer the vehicle without power assist but it needs very high steering force. In this case, the operating force of the steering wheel is conveyed to the pinion, and the movement of the pinion moves the rack through the pinion gear combined to the rack gear.
M / T A / CON
KYRON SM - 2005.09
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) ( /min) (mm) (mm)
Specification
4-spoke type 390 Rack and pinion 36 20' 32 40' Vane type 85 ~ 92 10.5 124 4 8 5.7 ATF Dexron III 1.0
STNG A / BAG BRAKE
SP
AXLE
CLUTCH
T/C
A/T
GENERAL INFORMATION
4610
2. SYSTEM LAYOUT
Steering gear box mounting bracket bolts (14 mm - 2EA): 30 ~ 40 Nm
Power steering gear box assembly Power steering pump assembly Power steering gear box pipe
Feed pipe nut Tightening torque: 40 ~ 50 Nm
Power steering high pressure hose and pipe
Tie rod end
Power steering return pipe With SSPS Gear box pipe Power steering gear box Power steering high pressure hose and pipe
SSPS Solenoid Valve
* cannot be replaced Return hose and pipe

KYRON SM - 2005.09
4610
Pipe bracket bolt (10 mm) Tightening torque: 9 ~ 14 Nm
Gear box mounting bolt
Installation Drawing of SSPS

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Pipe mounting nut Tightening torque: 20 ~ 26 Nm
STNG
SP
AXLE
CLUTCH
T/C
M / T
Pipe bracket bolt (10 mm) Tightening torque: 9 ~ 14 Nm
A/T
4610
Components
Steering wheel Column shaft
Lower shaft Tightening torque: 18 ~ 25 Nm
Tightening torque: 65 ~ 80 Nm Tightening torque: 45 ~ 50 Nm
Steering gear box
Tie rod end

KYRON SM - 2005.09
4610
Steering wheel
M / T
Column shaft
BRAKE
Steering gear box

KYRON SM - 2005.09
A / CON
A / BAG
STNG
SP
Lower shaft
AXLE
CLUTCH
T/C
A/T
4610
SSPS (Speed Sensing Power Steering)

1. GENERAL INFORMATION
Overview
In the conventional constant power assist steering system, the steerability gets lighter as vehicle speed rises, and this may cause a dangerous situation. Where as having heavy steerability in high speed driving makes it difficult to manipulate the steering wheel when vehicle is in stop. This steering system solves this problem as the steerability is changed according to the vehicle speed, which is called Speed Sensitive Power Steering (SSPS). SSPS, by providing appropriate steerability to a driver according to the changes of vehicle speed, gives steering stability. The power steering control unit adjusts the hydraulic pressure to reaction plunger by controlling the pressure solenoid valve located in the gear box to optimize the steerability. In other words, the steering wheel gets lighter by adjusting steerability in stop or low speed and provides steering stability by adjusting steering wheel to become heavier in high speed.
SSPS (Speed Sensitive Power Steering)
NOTICE
If the SSPS solenoid valve is defective, the power steering assembly should be replaced.

KYRON SM - 2005.09
4610
Input/Output of SSPS Control Unit
IG Power Solenoid Valve Ground (SSPS warning lamp)

CLUTCH T/C
SSPS CONTROL UNIT CAN HIGH
Meter Cluster
CAN LOW
Trouble Diagnosis
SSPS Configuration
STNG
PCV Spring Spool Pressure
Pinion valve Valve body
Filter
Balance line
Right cylinder
Connector Left cylinder
Solenoid valve Reaction device

line Reaction
Plunger
Steering gear box
PCV (Pressure Control Valve)

This valve controls the hydraulic pressure supplied to reaction device by moving the spool valve according to the changes of solenoid valve.
Reaction device
This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV.
Solenoid valve
This valve determines the valve spool position in PCV with the electric current supplied from SSPS control unit.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
M / T
A/T
Function
10
4610
Solenoid Valve Location
Cannot be replaced
The SSPS control unit controls the amount of electric current to the solenoid valve according to the vehicle speed. In other words, the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve spool position that is linked with solenoid valve according to the amount of electric current. The changes of hydraulic pressure applied to input shaft according to the pressure changes applied to the reaction plunger provide proper steerability based on the amount of electric current.
Specifications
Description
Voltage Rating Current Rating Resistance
Specification
DC 12 V 1.0 A 6.7 1

KYRON SM - 2005.09
4610
11
Operation
1. During parking and low speed driving
Solenoid valve
Hydraulic pressure (cut off) Return port Inlet port
1) The SSPS control unit outputs nearly maximum electrical current. 3) The hydraulic pressure coming from pump is not supplied to the reaction device as the spool orifice is cut off. 4) The hydraulic pressure is cut off and the manipulation of steering wheel becomes lighter.
2) The solenoid rod pushes the PCV spool to the right side.
2. In medium and high speed driving
Solenoid valve
Hydraulic pressure (cut off) Return port Inlet port
1) The shaft operating force of solenoid rod is reduced due to the reduction of output current from the SSPS control unit. 2) The coil spring pulls the PCV spool toward solenoid valve to open it. 3) The hydraulic pressure from pump flows to pinion reaction area through orifice and applies reaction force to reaction plunger. 4) At this time, the reaction plunger transmits the reaction force to V-groove in input shaft to provide heavy steerability.

KYRON SM - 2005.09
SP
AXLE
CLUTCH
T/C
M / T
A/T
12
4610
SSPS Control Unit

1. To provide proper steerability to a driver, the SSPS control unit controls the solenoid valve by receiving the vehicle speed and the throttle position data via CAN communication. 2. The SSPS control unit controls the working current for the solenoid valve with PWM type duty ratio of 333 Hz frequency and sets the target current to 1A during 1 second after the ignition is ON. 3. When a trouble occurs in the system, the SSPS control unit generates a trouble code using fail safe function.
4 8
3 2 7 6
1 5
Pin No.
1 2 3 4 5 6 7 8
Function
Ignition Power Supply CAN HIGH Solenoid Solenoid Ground Warning Lamp (SSPS) CAN LOW Self Diagnosis
Location SSPS unit

KYRON SM - 2005.09
4610 System Control

The SSPS system, according to the vehicle speed, enables to achieve proper steering characteristics by controlling hydraulic pressure to reaction plunger located in input shaft of power steering gear box. In other words, the SSPS control unit enhances the parking conveniences by controlling duty type current control. It provides heavy steerability with low current as the vehicle speed increases. Also, it provides light steerability with high current as the vehicle speed decreases.
Vehicle speed [km/h] Current [A]
13
1. During parking and low speed driving During parking and driving in low speed, the control unit supplies approx. 1 A of electric current to solenoid valve. Then, the spool located in PCV compresses the upper spring and elevates upward, and the working pressure from oil pump (A port) is not able to flow to the reaction plunger (C port). As a result, the pressing force from the reaction plunger disappears and the steerability enhances.
PCV Balance line Spring Spool Pressure Filter
Pinion valve Valve body Right cylinder
Connector Left cylinder
Solenoid valve Plunger Reaction device Steering gear box Reaction line

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
14
4610
2. During high speed driving During high speed driving, the control unit supplies weak electric current to solenoid valve. Then, the spool located PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C port) through B port. As a result, the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier.
PCV Balance line Spring Spool Pressure B Port Connector Filter
Pinion valve Valve body Right cylinder
Left cylinder
Solenoid valve Reaction device Reaction line Plunger Steering gear box

KYRON SM - 2005.09
4610
15
Electric Current Check

1. Disconnect the solenoid valve connector (waterproof connector) and install the ammeter between the solenoid valve connector and the wiring harness. NOTICE
Do not ground the solenoid terminal.
SSPS solenoid valve
2. When the vehicle speed is at 0 km/h, check whether the electric current for solenoid is in specified range and check that the current is reduced as the vehicle speed increases.
Current 0.9 ~ 1.1 A (vehicle speed at 0 km/h)
Current [mA]

KYRON SM - 2005.09
A / CON
A / BAG
Vehicle speed [km/h]
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
16
4610
Flow Chart for Trouble Diagnosis

NOTE
Use a Scan-I to check. Refer to the circuit diagram for the SSPS ECU.
Any problem with ECU power supply fuse? Yes Check ignition switch with ECU disconnected and ignition switch ON.
No
Open wiring (damaged harness)
Repair harness/replace fuse.
Reconnect or repair harness. If normal, replace ECU.
Is the voltage between ground terminal and ECU harness connector No.4 measured by 12 V? Yes
No
Damaged or disconnected harness between fuse and ECU No.5 terminal
Repair harness.
Disconnect battery (-) terminal and check.
Check the continuity between No.1 and No.2 connector in ECU harness. Yes
No
Disconnect the SSPS solenoid valve connector in engine compartment and check.
Check the continuity between 2 connectors in steering gear box solenoid. Yes Damaged or disconnected wiring between ECU and SSPS solenoid valve connector
No
Damaged or disconnected wiring in SSPS solenoid valve coil
Replace power steering assembly or repair connection area.
Is the resistance No between terminal No.1 and No.2 measured by 5.7 ~ 7.7 W (at 20C) during integrity check? Yes
Poor contact in SSPS solenoid valve connector
Repair solenoid valve connector.
Poor contact in SSPS solenoid valve connector or defective ECU
Check solenoid valve connector or replace ECU.

KYRON SM - 2005.09
4610 Fail Safe Function

No.
1 2 3
17
Trouble
Trouble Condition
Detecting Trouble Time Code

1 sec 1 sec 60 sec C1104 C1105 *C1212
Action
Solenoid current: 0 A Solenoid current: 0 A Vehicle speed: 80 Km/h Solenoid current: 0 A Solenoid current: 0 A
Description
10 V < VIG < 16 V 10 V < VIG < 16 V Input signal of vehicle speed of 5 km/h for over 1 second IGN ON/OFF Power On Reset
M / T A / CON A / BAG BRAKE STNG SP AXLE
KYRON SM - 2005.09
Over voltage VIG > 17 V Low voltage VIG < 8 V Vehicle speed sensor ECU error Detected current PW > 30 %, vehicle speed 0 km/h Faulty EEPROM Read/Write, PWM management error Detected current > 1.28 A When solenoid is disconnected Target current - detected current > 0.2 A and VIG > 13 V
4 5
1 sec 1 sec 1 sec 2 sec 30 sec
C1604 C2203
CAN error
No CAN messages
C1623
Vehicle speed: 80 Km/h
Received messages more than once
C1212 Help C1212 Trouble Code: displayed when the vehicle speed sensor is faulty. 1. If the vehicle is 0 km/h for 60 seconds while depressing the accelerator pedal, it is determined by 80 km/h. 2. Release condition: goes back to normal status when the vehicle speed is over 5 km/h for 1 second. 3. Check for CAN communication line (pin No. 3 and 6). 4. Check the connectors for poor contact.
NOTICE
When the Fail Safe function is activated, the steering wheel operation needs much more force due to no currents to SSPS solenoid.
CLUTCH
T/C
A/T
18
4610
Circuit Diagram
YR
SSPS Control Unit
LG
BrB
BG
GB
LgY
GB
LgY
LG
BrB
BG
SSPS Solenoid
Diagnosis "12"
Cluster "B11"

KYRON SM - 2005.09
4610
19
Symptom
Hard steering
Cause
Lack of lubrication, Abnormal wear or binding of steering ball joint 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 tire Faulty suspension system
Action
Lubricate or replace Replace gear assembly Adjust
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
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
Replace gear assembly Replace
Poor return of steering wheel
Damaged or binding steering ball joint Improper preload of steering pinion Damaged wheel or tire Faulty suspension system
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
KYRON SM - 2005.09
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
A / CON
A / BAG
BRAKE
Retighten
STNG
Repair or replace
SP
AXLE
CLUTCH
T/C
Replace
M / T
A/T
Trouble Diagnosis
20
4610
General Inspection
Power Steering Wheel Free Play Check
1. Start the engine and place the wheels at straight ahead direction. 2. Turn the steering wheel until the tires starts to move and measure the distance on the circumference of the steering wheel.
Specified value 30 mm
NOTICE
If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary.
Steering Effort Check

1. Park the vehicle on a paved and flat ground and place the front wheels at straight ahead direction. 2. Start the engine and let it run around 1,000 rpm. 3. Install the spring scale on the circumference of the steering wheel and measure the steering effort in both directions.
Steering effort below 3.0 kg
NOTICE
The difference between both sides should be within 0.6 kg.
Steering Angle Check

1. Place the front wheel on a turning radius measuring tool. 2. Turn the steering wheel to the its both ends and measure the maximum steering angle.
Inner Outer 36 20' 32 40'
Specified value
NOTICE
If the free play is out of the specified value, check and adjust the toe-in.

KYRON SM - 2005.09
4610
21
Oil Pump Pressure and Oil Level Check Oil Pump Pressure
Check the oil pump pressure to locate any defect in oil pump. 1. Unscrew the pressure line fitting in power steering pump. 2. Install the pressure gauge between the power steering pump and the power steering oil pressure line. 3. Place the shift lever to neutral position. 4. Apply the parking brake. 5. Open the valve in pressure gauge. 6. Start the engine and let it run at idle speed. 7. Turn the steering wheel several times so that the oil temperature reaches to normal operating level (oil temperature: 50 ~ 80C). 8. Fully close the valve in pressure gauge and measure the oil pressure. 9. Measure the oil pressure with the gauge valve fully open. 10. If the pump pressure is in specified range, the pump is normal. If not, replace the power steering pump. NOTICE
To prevent internal damage, do not close the gauge valve over 10 seconds.
Pump relief valve pressure Pump pressure at no load
89 ~ 97 kg/cm2 3 ~ 5 kg/cm2

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
22
4610
Oil Level Check

The power steering oil level have to be checked by two conditions; one is checked at normal operating temperature, and the other one is checked when it is cooled. If the difference between two measurements is below 5 mm and the level is between MAX and MIN level, its normal. If it is over 5 mm, bleed air from the system. Checking 1. Place the vehicle on a flat ground and start the engine and let it run at idle speed. 2. Turn the steering wheel several times so that the oil temperature reaches to normal operating level (oil temperature: 50 ~ 80C). 3. Place the steering wheel at straight ahead direction. 4. Measure the oil level in the power steering oil reservoir. 5. Adjust the oil level between MAX and MIN.
Engine off Engine on Displacement of oil level

KYRON SM - 2005.09
4610 AIR BLEEDING
23
Checking Bubble is Found

SP
Air Bleeding
1. Lift up the vehicle in straight ahead direction of the steering wheel (No-load to tires). 2. Add the specified oil into reservoir up to the max level. 3. Turn the steering wheel to its both ends repeatedly until any bubble cannot be seen in the reservoir. 4. If any bubble is not found anymore, add the specified oil into the reservoir to the specified level. * Checking * 1. Start the engine and repeat the second and third step above. 2. This process should be performed to check if air still exists in the power steering system.
NOTICE
Position the gear shift lever to N (M/T) or P (A/T), and apply the parking brake before starting the engine.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
24
4610

The SSPS unit is installed on the bottom of engine ECU located in the passenger foot wall. NOTICE
If the SSPS solenoid valve is defective, the power steering assembly should be replaced.
SSPS Control Unit

Preceding Work: Disconnect the negative battery cable. 1. Remove the engine ECU under the floor carpet.
2. Disconnect the SSPS control unit connector and separate the SSPS control unit from engine ECU.

KYRON SM - 2005.09
4610
25
SSPS Control Unit

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
26
4610
Steering Column Shaft

Preceding Work: Disconnect the negative battery cable and place the tires to straight ahead direction.

1. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the airbag module connector.
2. Unscrew the steering wheel lock nut and remove the wheel with special tool. NOTICE
Make an alignment marks on the column shaft and steering wheel for correct installation.
3. Remove the instrument panel side cover and unscrew the side lock bolt and screws to remove the instrument lower panel.

KYRON SM - 2005.09
4610
27
4. Remove the protective panel and undercover from the lower panel and remove the upper/lower column covers.
5. Disconnect the contact coil and connector from the column shaft and remove the contact coil assembly.
SP
Contact coil mounting screw
Inlet portDisconnect the connector
Align the alignment marks when installing

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
A/T
28
4610
6. Disconnect connectors and remove the combination switch from the steering column.
Unscrew the mounting screws
Disconnect the connectors
Combination Switch Assembly

KYRON SM - 2005.09
4610
7. Unscrew the bolts and nuts and remove the steering column shaft assembly while pulling down it.
29
Mounting Bolts (3 EA)
Mounting Bolts (2 EA)

M / T
Lower Shaft Mounting Bolt (1 EA)

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
30
4610
Lower Shaft
1. Remove the upper lock bolt inside the vehicle and the lower lock bolt in underbody.
2. Remove the lower shaft mounting nuts on floor. Installation Notice

3. Remove the lower shaft. NOTICE

Install the lower shaft so that the lock bolt can be inserted into the point without spline. Be cautious of the alignment marks.
Lower Shaft Assembly

KYRON SM - 2005.09
4610
31
Preceding Works: 1. Disconnect the negative battery cable. 2. Remove the tire. 1. Remove the cotter pin and lock nut. Remove the tie rod from steering knuckle by using a special tool. 661 589 13 33 00 (W 99 44 002 0A) Ball Joint Puller
SP
2. Remove the SSPS connector.

STNG
3. Unscrew the lower bolts and remove the lower shaft and gear box.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
AXLE
CLUTCH
T/C
M / T
A/T
Steering Gear Box
32
4610
4. Disconnect the power steering pipes and remove the steering gearbox mounting bolts.
Supply and Return Pipes
NOTICE
Plug the pipe openings with caps. Be careful not to spill the oil on the floor and vehicle body.
Gear Box Mounting/Gear box Cross Member
Gear box Mounting Clamping Bolt
NOTICE
Tighten the center bolt/nut first, and then tighten the left mounting bolt with the specified tightening torque.

KYRON SM - 2005.09
4610
33
1. Remove the drive belt.
2. Disconnect the power steering return hose and remove the high pressure pipe nut. Installation Notice
NOTICE
Plug the openings so that power steering fluid doesn't leak out.
High pressure pipe
Return hose
3. Unscrew the nuts and remove the pump assembly with bracket. Installation Notice

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Steering Gear Pump
MEMO
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ABS/ESP SYSTEM
GENERAL INFORMATION ...................... 2
1. General information .......................................... 2 2. Specifications ................................................... 5 3. Brake operation and noise ............................... 6
ABS SYSTEM ......................................... 60

1. 2. 3. 4. 5. 6. 7. 8. General information ........................................ 60 Configuration of ABS system ......................... 63 Input and output diagram ................................ 64 Hydraulic circuit of ABS ................................. 65 ABS circuit in each operation range .............. 66 Components and location ............................... 67 Components description ................................. 68 Removal and installation ................................. 69
ESP SYSTEM ........................................... 7

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. General information .......................................... 7 General information of ESP system ................. 8 Principle of ESP ............................................. 12 HBA (Hydraulic Brake Assist system) ........... 15 ARP (Active Roll-over Protection) .................. 16 HDC (Hill Descent Control) ............................. 17 Components and locations ............................. 24 Input and output diagram ................................ 26 ESP system related precautions ................... 27 Hydraulic circuit diagram ................................ 28 Hydraulic pressure for each ESP operating range ............................................................... 29 Hydraulic circuit of HBA (Hydraulic Brake Assist) ................................. 31 Components description ................................. 32 Bleeding ESP system .................................... 46 ABS/ESP trouble diagnosis ........................... 48
4890
GENERAL INFORMATION
For the front brake system, the ventilated disc type is applied regardless of the ABS/ESP system installation. Two 43 mm diameter calipers (non-ABS/ESP equipped vehicles) and two 45 mm diameter calipers (ABS/ESP equipped vehicles) are installed. Front Disc
Front Ventilated Disc and Caliper (2 internal Cylinders)
For the rear brake system, specifications differ between ABS/ESP system equipped vehicles and non-ABS/ESP system equipped vehicles. The drum type brake is installed on non-ABS equipped vehicles. When ABS/ESP is installed on the 5-link type suspension, the solid disc (disc thickness: approx. 10.4 mm) is installed. When ABS/ESP is installed on the independent suspension, the ventilated disc (disc thickness: approx. 20 mm) is installed.
Rear Disc
ABS/ESP + 5Link Suspension: solid type disc ABS/ESP + Independent suspension: ventilated disc Rear Disc and Caliper (1 Internal Cylinder)
Parking brake system: The hand operated type parking brake is installed on vehicles with the manual transmission and the foot operated type parking brake is installed on vehicles with the automatic transmission.
Hand Operated Type (Vehicle with Manual Transmission)

ABS/ESP SYSTEM
KYRON SM - 2005.09
Foot Operated Type (Vehicle with Automatic Transmission)

4890
Front Disc Brake
Rear Disc Brake
One internal cylinder
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
Two internal cylinders
M / T
A/T
Sectional Drawing
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. This sensor is to signal the vehicle speed to the engine ECU, TCCU, transmission, and instrument panel. There is no separate unit to process the wheel speed sensor signal. The wheel speed sensor is connected to the engine ECU (terminal 36), where its signal is processed, and is connected to other related systems through CAN communication.
36
Battery (B+) Wheel speed sensor CAN HI
KYRON D27DT E C U
73 54
Instrument panel CAN LO TCU TCCU
Location of the wheel speed sensor (rear right wheel)

Location of the Sensor Connector
Connector Appearance In vehicle without ABS In vehicle with ABS/ESP
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
Description
Brake pedal Pedal ratio Max. operating stroke Free play Brake master cylinder Brake booster Front brake Type I.D. of cylinder Type Booster pressure ratio Type I.D. of caliper cylinder Pad thickness Brake pad wear limit Disc plate thickness Disc plate wear limit I.D./O.D. of disc plate Rear brake Type I.D. of drum WxLxT I.D. of wheel cylinder I.D. of caliper cylinder Brake pad thickness Wear limit of brake pad Disc plate thickness Wear limit of disc plate I.D./O.D. of disc plate Parking brake Type Operation type I.D. of drum Brake fluid Capacity Specification
NON-ABS (5-link suspension)
ABS/ESP 5-link suspension

4.0 : 1 150 mm 1 ~ 4 mm Tandem type (with level sensor)
T/C
Independent suspension (IRS)

M / T
25.4 mm
Vacuum assisted type 9:1 Ventilated disc type 2 x 43 mm 10.5 mm 2 mm 26 mm 24 mm 2 x 45 mm 10.5 mm 2 mm
SP CLUTCH
28 mm 25.4 mm
294 / 184 mm
Drum type
294 / 184 mm
Solid disc type Ventilated disc type STNG A / CON A / BAG BRAKE
254 mm
55 x 243 x 5
23.81 mm
-
42.9 mm
10 mm 2 mm 10.4 mm 8.5 mm
42.9 mm
10 mm 2 mm 20 mm 18.4 mm
299/ 220 mm
307/ 214 mm
Mechanical type, rear wheels operated Manual type - Foot
Mechanical type, rear wheels operated Manual type - Hand (MT)/Foot (AT)
254 mm
190 mm
0.7 ~ 0.8 DOT4
190 mm
ABS/ESP SYSTEM
KYRON SM - 2005.09
AXLE
A/T
2. SPECIFICATIONS
4890
3. BRAKE OPERATION AND NOISE

This section describes the noise phenomena possibly occurring in the brake system operation. Distinguish between the information given below and the actual problems and then, inspect the vehicle and take appropriate measures.
Noise Phenomena and Causes

Phenomenon 1. If depressing the brake when the engine is cold, screeching sound always occurs and, after driving for a while, it disappears. This usually occurs in the morning. When the temperature goes down, the dew condensation phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the iron within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc surface. When starting the engine under this condition, noise may sound due to the friction of micro-rusts. When operating the brake several times, the disc temperature goes up and the micro-rusts come off and the noise goes away. Depending on the driving conditions, noise gets louder when slightly depressing the brake pedal and oppositely, noise is smaller when deeply depressing the brake pedal. This is simply a physical phenomenon, called morning effect in professional terms, and does not imply any problems with the brake system. Phenomenon 2. Slip or screech after the brake pad replacement. This usually occurs when the bed-in is not made between the disk and the pads friction material. The bed-in is a state that the brake system normally works and gives no noise out, when, after about 300 km city driving, the contact area of the pad friction material is enlarged and the disk is in complete contact with the pads friction material. Therefore, for some time after the brake disk/pad replacement, the brake system poorly operates or noise (abnormal sound) occurs due to the partial contact. Phenomenon 3. Groaning sound occurs in the automatic transmission vehicle when slightly taking the foot off the brake pedal to slowly start after waiting for the signal, or slightly depressing the brake pedal. This is the noise Creep groan that occurs when, in both the automatic and manual transmission, slightly releasing the brake pedal in the neutral gear at downhill roads. It frequently occurs at the low braking power and low speed, through the following process. When operating the brake system at low speed and low pressure, adhesion and slip repeatedly take place between the brake disk and the friction material, and this makes the braking power inconstant, instantly increasing or decreasing, and gives out the brake noise. It is also a physical phenomenon and has no relation with the brake performance.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
The ESP system consists of basic ABS functions, the vehicle position control depending on the driving conditions and the road conditions, the HBA (Hydraulic Brake Assist System) that improves the braking power in an emergency, the ARP (Active Rollover Protection) that obstructs the physical tendency to rollover during sharp turns and prevents the vehicle rollover by quickly and firmly controlling the engine output and the brake. 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%: about 5.71 (degree)).
ESP HECU HDC Switch / Indicator
Functions applied on ESP system are as follows. 1. ABS (Anti-Lock Brake System) 2. EBD (Electronic Brake-Force Distribution) 3. ABD (Automatic Braking Differential) 4. ASR (Acceleration Slip Regulation) 5. AYC (Active Yaw Control, Understeer Oversteer control) 6. HBA (Hydraulic Brake Assist System) 7. ARP (Active Rollover Protection) 8. HDC (Hill Descent Control)
ABS/ESP SYSTEM
KYRON SM - 2005.09
A/T
ESP SYSTEM
4890
2. GENERAL INFORMATION OF ESP SYSTEM

Differences compared to other models: Appearance of wheel speed sensor, Location, Layout of relevant components
ESP HECU
Active Wheel Speed Sensor
HDC Switch
The transfer case (T/C) installed on this vehicle doesnt have the internal speed sensing device and receives the speed signal for T/C control from ESP HECU via CAN bus.
[Conventional T/C]
[New T/C]
With speed sensor
Without speed sensor
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
Cautions When Removing the Front Wheel Speed Sensor
The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the conventional approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator. Thus, the wheel speed sensor is installed on the front wheel end area. It is installed inside the backing plate to be protected from heat and foreign materials. Therefore, the front wheel end system (including disc) should be removed before removing the front wheel speed sensor.
Front Wheel Speed Sensor (4WD) Backing plate
Rear Wheel Speed Sensor (IRS Type)
Wheel speed sensor
Wheel Speed Sensor
Backing plate Wheel speed sensor
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
10
4890
The rubber O-ring in IWE (Integrated Wheel End) should be replaced with new one when the front wheel end has been removed. The rubber O-ring prevents moisture and foreign materials from entering the IWE system. In addition, when installing the hub actuator of the IWE system, you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed.
Rubber O-ring
Rubber seal ring (Internal steel spring included)
Please refer to the part time transfer case section for more specific information.
ABS/ESP SYSTEM
4890
11
When the ESP system is added to the ABS system, some devices will be added to the HECU (Hydraulic & Electronic Control Unit) and wheel speed sensor used in the ABS system. The devices are as follows: 1. 2 pressure sensors installed on the master cylinder 2. Sensor cluster (integrated yaw rate sensor and lateral sensor) and longitudinal sensor installed in IP. 3. SWAS (Steering Wheel Angle Sensor) installed in the steering column.
Name
HECU (Hydraulic & Electronic Control Unit)
Specifications ABS
CPU: PEC 1 (32 bit) Memory: 512 KB EEP ROM: 1 KB Active Type
ESP
CPU: PEC 1 (32 bit) Memory: 512 KB EEP ROM: 1 KB New software version: KM 20 Active Type
Location
beside of brake booster
Clock Frequency: 28 MHz Clock Frequency: 33 MHz
Rear airgap: 0.309 ~ 0.958 mm Steering Wheel Angle Sensor Sensor Cluster N/A Maximum angular velocity: 1500/sec Working voltage: 9 ~ 16 V N/A Integrated yaw rate sensor and lateral sensor. Also, used for sensing G value for HDC (Hill Descent Control). Analog Output Behind the center audio in instrument panel In steering wheel
Pressure Sensor
N/A
Under master cylinder
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Wheel Speed Sensor
Mounted in each wheel ( 4EA) Front airgap: 0.335 ~ 0.945 mm
SP
AXLE
CLUTCH
Comparison with ABS System
T/C
M / T
A/T
12
4890
3. PRINCIPLE OF ESP
Understeer & Oversteer Control
ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to under-steering or over-steering during cornering. The yaw rate sensor, lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the spin present at any wheels during over-steering, under-steering or cornering. The ESP ECU controls against over-steering or under-steering during cornering by controlling the vehicle stability using the input values from the sensors and applying the brakes independently to the corresponding wheels. The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output (coupled with the ASR system).
Under Steering Desired course Desired course With ESP Over Steering
Without ESP
With ESP Braked wheel

Compensating yaw moment
Braked wheel Without ESP
Braking force
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. Generally, vehicles are designed to have under steering. 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. As the centrifugal force increases, the tires can easily lose the traction and the vehicle tends to slip outward when the curve angle gets bigger and the speed increases.
Oversteering Oversteering is when the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction. When compared with under steering vehicles, 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.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
13
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. Then the ESP system applies the brake at the rear inner wheel to compensate the yaw moment value. In this way, the vehicle does not lose its driving direction and the driver can steer the vehicle as driver intends.
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. Then the ESP system applies the brake at the front outer wheel to compensate the yaw moment value. In this way, the vehicle does not lose its driving direction and the driver can steer the vehicle as he or she intends.
ESP Control
As the single-track vehicle model used for the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup. The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel. And when yaw rate sensor detects the rate exceeding 4 degree/seconds, the ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function. When various systems operate simultaneously under a certain situation, there may be vehicle control problems due to internal malfunction of a system or simultaneous operations. In order to compensate to this problem, the ESP system sets the priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and ABS. The order may be changed depending on the vehicle driving situations and driving conditions.
Operating range
Turning
Turning
ABS/ESP SYSTEM
KYRON SM - 2005.09
A/T
14
4890
Vehicle Control During Cornering

The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operating during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating. Operations Understeering Control Oversteering Control
ESP auto brake
Only ESP operating No braking by driver

ESP auto brake
e Engin l o contr
ESP + Conventional brake (ABS not operating)

ESP auto brake Driver foot brake operation
ESP + ABS brake

The slip occurs under ESP operation ABS operation
+ TCS (Engine Control)

The slip occurs under ESP operation TCS operation
e Engin l ontro c
ABS/ESP SYSTEM
KYRON SM - 2005.09
En c o gin nt e ro l
ESP
4890
15
Deceleration -m/s
An inexperienced, elderly or physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required under emergency. The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver. Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary, 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. When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels.
10 8
Experienced drivers
Inexperienced drivers 4 Elderly and physically weak drivers 2
0.2
0.4
0.6
0.8
1.0 Time (s)

SP
Pressure sensor
HECU
Hydraulic line
Operating conditions: 1. Pressure: over 20 bar 2. Pressure changes: over 1500 bar/sec 3. Vehicle speed: over 7 Km/h
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
The brake pressure value and the changed value of the pressure sensor are the conditions in which the HBA System operates. There are 2 pressure sensors under the master cylinder. When the ESP ECU system determines that emergency braking is present, the pump operates, the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves. If the drive depresses the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake system with booster is activated.
STNG
AXLE
CLUTCH
T/C
M / T
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking distance. ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster.
A/T
4. HBA (HYDRAULIC BRAKE ASSIST SYSTEM)
16
4890
5. ARP (ACTIVE ROLL-OVER PROTECTION)

The ARP (Active Roll-over Protection) system is a safety assistant device that minimizes, by controlling brakes and the engine, the physical tendency of the vehicle rollover during sharp lane changes or U-turns. For the system, software is added to the existing ESP system and no additional device or switch is needed. One must note that the ARP system, just as general assistant devices including the ABS, is only a safety assistant device using the ESP system and its function is useless when the situation overcomes the physical power. Following picture shows how the ARP compensates the vehicle position by varying each wheels braking power to overcome the physical tendency of the vehicle rollover during sharp turns.
Lateral) ( sensor
Brake force
Vehicle speed
Radius
The vehicle driving condition is controlled by the internally programmed logic according to the input signals from wheel speed sensor, steering angle sensor and lateral sensor.
Steering wheel angle sensor
Input data signal processing
Yaw rate torque value calculation
Comparative data processing
Actuator operation
Lateral sensor ESP AREA Wheel speed sensor Yaw rate value Yaw rate sensor Other reference values Driving conditions
ARP AREA
Input data signal processing
Assess whether vehicle condition meets ARP operation condition
Adjust with ARP function
NOTICE
During the ARP operation, vehicle safety (rollover prevention) takes the first priority and thus, stronger engine control is in effect. Consequently, the vehicle speed decreases rapidly, so the driver must take caution for the vehicle may drift away from the lane.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
17
System Overview
The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about 7 km/h by 0.1G, on steep roads (slope level exceeding 10%) through a separately installed switch operation. When the vehicle speed reaches below 7 km/h (refer to the information below), the HDC automatically terminates the operation.
HDC Switch
When you see a steep downhill ahead, press the HDC switch and the green HDC indicator comes on. When the G sensor within the sensor cluster detects a slope level exceeding 10%, the ESPs HDC function operates. When this occurs, the green HDC indicator flashes along with a loud operation sound.
Sensor Cluster (G Sensor)
HDC Indicator (Instrument Panel)
The G Sensor within the sensor cluster detects the steepness of driving roads. When the HDC switch is in operation, if the G sensor detects a downhill steepness exceeding 10%, it transmits the HDC operation signal to the ESP HECU.
When you press the HDC switch, the green HDC indicator comes on, and when the HDC operates, the green HDC indictor flashes at 0.5 second of interval.
HDC
NOTICE
The G sensor in sensor cluster measures the actual road steepness. However, it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10%, and the HDC may operate. Red letters
HDC
Green letters
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
6. HDC (HILL DESCENT CONTROL)
18
4890
HDC (Hill Descent Control) System Operating Conditions

1. When HDC switch is turned ON 2. Gearshift lever position (Forward/Reverse) and and
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in neutral position). Automatic transmission: operates in any position except for P (parking) or N (neutral) positions.
NOTICE
The vehicles with manual transmission do not have a separate device or switch that detects the 1st gear. It only detects the forward/reverse driving direction of the vehicle through backup lamp switch and neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, though the HDC also operates in 2nd gear position, is because the engine may turn off during the HDC operation process. You may face a very dangerous situation if the engine turns off at a steep hill. The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. For manual transmission equipped vehicle, HDC system should operated only in 1st gear.
3. When not depressing the accelerator pedal or brake pedal. 4. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode).
and and
NOTE
The vehicle speed given in step (3) varies according to the vehicle driving mode, and the speed ranges by the vehicle driving mode and condition are as follows.
1) Speed available in HDC mode (slope) 2H/4H mode: vehicle speed below 50 km/h (operation slope level: 10%, termination Forward slope level: when it reaches 8%)
driving
4L mode: vehicle speed below 25 km/h (operation slope level: 10%, termination slope level: when it reaches 5%)
2H/4H mode: vehicle speed below 50 km/h (operation slope level: 8%, termination slope Reverse level: when it reaches 5%)
driving
4L mode: vehicle speed below 25 km/h (operation slope level: 8%, termination slope level: when it reaches 4%)
2) HDC target speed in 2H/4H mode (The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches 7 km/h, but is converted to the stand-by mode. When the vehicle speed increases again as a result of the increase of the road steepness, etc., the HDC goes into operation.) Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission) 3) HDC target speed in 4L mode Forward and reverse driving: 3 km/h
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
19
5. Vehicle position control function in ESP and HBA function are not in operation:
and
When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed value given in step (4).
When the slope level is between 10% and 20% during the HDC operation
When the slope level exceeds 20% during the HDC operation
In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation.
STNG
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the brake pedal, HDC continues its operation and the braking power is increased.
AXLE
When depressing the accelerator pedal or brake pedal, HDC system is changed to stand-by mode. When depressing the accelerator pedal again, HDC starts its operation again. Therefore, drivers can control the vehicle speed to a desired level by operating the accelerator pedal.
CLUTCH
T/C
6. Slope level exceeds 10%.
M / T
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP function is in operation, HDC operation is overridden.
A/T
20
4890
HDC (Hill Descent Control) System Non-Operation Conditions

1. When HDC switch is turned OFF 2. Gearshift lever has passed neutral (N) position. or or
NOTICE
Vehicle with manual transmission: Sensing at the neutral switch Vehicle with automatic transmission: Sensing at the selector lever unit
3. When the vehicle speed is out of the specified values. 4. When the ESP related functions, e.g. vehicle position control, HBA, ARP is activated during HDC operation.
or or
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP function is in operation, HDC operation is overridden. 5. When the internal temperature of HDC system goes over 450C due to long downhill driving on a steep hill with HDC operated. or
There is no specific temperature sensor in the system, but a programmed logic inside the HECU predicts the temperature based on the operating numbers and conditions of HDC.
NOTICE
The red HDC warning lamp blinks when the internal temperature goes over 350C. When it reaches 450C, the HDC warning lamp comes on. The HDC can be operated in the range even where the HDC warning lamp blinks.
6. When the slope level is below 10% When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed condition given in step (4).
When depressing the accelerator pedal, HDC system is changed to stand-by mode. When depressing the brake pedal, HDC continues its operation and the braking power is increased. In this case, HECU sounds an abnormal noise and brake pedal may be very rigid, but this is a normal condition due to HDC operation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
21
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
2. Engine torque 3. Gas pedal module (monitoring gas pedal depression) When depressing accelerator pedal during HDC operation, it is deactivated (regardless of the slope level).
E C U
Stop lamp
Brake pedal switch
When the HDC operates, HECU turns on the stop lamp by supplying 12V power (separate relay).
When depressing brake pedal during HDC operation, 1. If the slope level is between 10% and 20: HDC is deactivated. 2. If the slope level exceeds 20%, HDC function is still activated and the brake pressure is added.
(HDC CONTROLLER)
HDC indicator and warning lamp (instrument panel)
Sensor cluster
Longitudinal acceleration sensor
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
1. RPM
SP
AXLE
CLUTCH
T/C
M / T
A/T
Input/Output Signals for HDC Operation
22
4890
Operation of HDC Indicator Controller

This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC switch is a push & self return type switch when you press it once, it starts to operate and when you press it again, it stops the operation. HDC Indicator HDC Operation Mode Green HDC Warning Lamp Red
HDC
Initial ignition ON (From hence, this signifies operation mode after the engine starts. Even when HDC switch is ON, if the ignition is OFF, HDC operation stops automatically.) Not available HDC switch OFF HDC system error Stand-by HDC switch ON OFF
HDC
ON (goes off after 1.8 seconds) OFF ON OFF
OFF OFF ON
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating requirements are not met. In operation HDC system is operating. Blinking (0.5 seconds of interval) OFF
The HDC switch is turned ON, and the operating requirements are met. HDC is operating with operating sound. System overheat High brake system temperature (over 350C) HDC stand-by mode HDC is operating OFF Blinking
Alternate blinking of green and red lamp (0.5 seconds of interval) OFF ON
Too high brake system temperature (over 450C)
There is no specific temperature sensor in the system, but a programmed logic inside the HECU predicts the temperature based on the operating numbers and conditions of HDC (HDC cannot be operated).
NOTICE
Basically, the brake systems basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: Initial ignition ON HDC system error occurs Brake system overheat
ABS/ESP SYSTEM
KYRON SM - 2005.09
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23
Customers must first acquaint themselves with the HDC operation related information, e.g. operation conditions and non-operation conditions, because they may feel unfamiliar with its function and operation process. The noise during the HDC operation is very different from that during the ABS/ESP operation. This noise may be irritating and accompany some vibration, because, on steep hills, it attempts to control the physical properties of the vehicle weight with the braking power. Below is the summary of precautions to remember in HDC operation.
NOTICE
CLUTCH A / CON
The HDC system is intended for use only on off-roads with a slope level exceeding 10%. Thus, do not use it on public road. Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems. Driver must turn the HDC switch to OFF position when driving on public and level roads. As mentioned previously, when a driver make sharp turns or drive on rough roads, the HDC may suddenly operate for these sudden shocks influence the G sensor values. When such occurs, the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle. During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and the brake system, but this is a normal condition during the HDC operation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
STNG
SP
AXLE
T/C
M / T
A/T
Cautions When Using HDC System
24
4890
7. COMPONENTS AND LOCATIONS
Master cylinder pressure sensor
Sensor cluster: (Yaw rate + lateral sensor + longitudinal sensor)
HECU (Valve body and ECU integrated type)
Valve body
Motor pump
ABS/ESP SYSTEM
KYRON SM - 2005.09
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25
No
1 2 3 4 5 HECU Pressure sensor
Name
ESP Component
0 0 0 0 0 0
Remark
Wheel speed sensor Sensor cluster Steering wheel angle sensor
0 N/A N/A
ESP OFF Switch

A / CON
ABS / ESP Indicator
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
STNG
SP
Active Wheel Speed Sensor
HDC Switch
HDC Indicator
AXLE
CLUTCH
T/C
M / T
N/A
ESP system contains ESP OFF switch and HDC switch.
A/T
Comparison with ABS System
26
4890
8. INPUT AND OUTPUT DIAGRAM

Input/Output of ESP System
Battery+ (voltage to hydraulic v/v, ECU) 32 15 CAN LO
Battery+ (voltage to pump)
11
CAN HI Sending and receiving the information such as speed signal of ABS HECU from/to ECUs through CAN communication.
IG1
Brake switch
41 41 Stop lamp power supply Supplying power to brake lamp when operating HDC.
ESP switch
40
Wheel speed sensor (FL)
Signal Ground
45 46 34 33
Signal Wheel speed sensor (FR) Ground
E S P H E C U
HDC relay power supply
HDC switch HDC operation switch
Signal Wheel speed sensor (RL) Ground
36 37
6 29 25 31
Power source CAN-H CAN-L Ground Sensor cluster
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
Diagnostic connector pin No. 8 This line is used to send the error code to diagnostic connector when an ABS related component is defective.
22 23 21 In ESP equipped vehicle, the signals from SWAS are sent to ECS ECU. 47 Ground (Pump)
IG1 ST1 SWAS (Steering wheel angle sensor) ST2 STN Ground
7 28 30 3 5 16
Ground (Valve)
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
27
2. Too frequent use of HDC system may weaken the durability of the ESP HECU and related systems. 3. Driver must turn the HDC switch to OFF position when driving on public and level roads. As mentioned previously, when a driver make sharp turns or drive on rough roads, the HDC may suddenly operate for these sudden shocks influence the G sensor values. When such occurs, the driver may panic because the vehicle speed drops sharply and the driver will experience difficulty in controlling the vehicle. 4. During the HDC operation, a loud noise and the vehicle vibration may occur from the HECU and the brake system, but this is a normal condition during the HDC operation. 5. The warning lamp flashes and warning beep sounds when the ESP is operating When the ESP operates during vehicle movement, the ESP warning lamp on the instrument panel flashes and beep comes on every 0.1 seconds.
SP A / CON
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
1. The HDC system is intended for use only on off-roads with a slope level exceeding 10%. Thus, do not use it on public road.
A/T
9. ESP SYSTEM RELATED PRECAUTIONS
28
4890
10. HYDRAULIC CIRCUIT DIAGRAM
Pressure sensor
Damper (primary circuit) Separation valve (NO)
Damper (secondary circuit)
Separation valve (NO) Damping chamber
Shuttle valve Low pressure accumulator
Pump
Shuttle valve
FR inlet valve (NO)
FL inlet valve (NO)
RR inlet valve (NO)
RL inlet valve (NO)
FR outlet valve (NC)
FL outlet valve (NC)
RR outlet valve (NC)
RL outlet valve (NC)
Wheel (FR)
Wheel (FL)
Wheel (RR)
Wheel (RL)
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
29
For details, refer to Hydraulic Pressure for each ESP Operating Range.
11. HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE

1 2
STNG SP
Low pressure chamber
Shuttle valve
Low pressure chamber Shuttle valve
Separation valve Pump Pump
Separation valve
ESP Hydraulic unit in idling and normal braking position In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel via the separation valve and inlet valve.
ESP Hydraulic unit (decreased pressure) The pressure decreases just before the wheel speed drops and the wheels. 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. Then the pump operates to allow fast oil drainage.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
Inlet valve
Outlet valve
Inlet valve
Outlet valve
A / BAG
BRAKE
AXLE
CLUTCH
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit. When the vehicle brakes are not applied during engine running or when applying the non-ABS operating brakes, the normally-open separation valve and the inlet valve are open, whereas the normally-closed shuttle valve and the outlet valve are closed. When the ESP system is operating, the normally-open separation valve will be closed by the solenoid valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet and outlet valves will be closed or open depending on the braking pressure increase, decrease or unchanged conditions.
T/C
M / T
A/T
30
4890
ESP unit circuit (when the pressure is maintained)

3
Separation valve Pump
Inlet valve
Outlet valve
The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the separation valve closes and only the shuttle valve at the pump opens.
ESP unit circuit (when the pressure is increased)

4
Inlet valve
Outlet valve
The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is operated. When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the corresponding wheel gets locked.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
31
Shuttle valve
Inlet valve
Front wheel
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immediately to apply the brake pressure at the wheels. Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA function cancels and switches to ABS operation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Outlet valve
Rear wheel
STNG
SP
Inlet valve
Outlet valve
AXLE
CLUTCH
T/C
M / T
A/T
12. HYDRAULIC CIRCUIT OF HBA (HYDRAULIC BRAKE ASSIST)
32
4890
13. COMPONENTS DESCRIPTION

HECU (Hydraulic & Electronic Control Unit)
1. HECU installed in a vehicle HECU consists of motor pump, solenoid valve and ECU.
Rear RH (only applicable to ESP) Front RH
ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ESP (6 valve for ABS), and they cannot be disassembled.
Front LH Rear RH and LH (Rear LH when ESP is applied) Secondary Primary
ESP ECU
2. Comparison ESP HECU and ABS/EBD HECU

ABS HECU ESP HECU
3. Other components
HECU
ABS/ESP SYSTEM
KYRON SM - 2005.09
Pump Motor
Valve Body
4890
33

1. Disconnect the control unit connector.
M / T
2. Disconnect the primary and secondary master cylinder pipes from HECU. Tightening torque
Master cylinder to HECU 13 ~ 20 Nm
STNG SP
3. Disconnect the front and rear wheel brake pipes. Tightening torque
HECU to each hydraulic line 13 ~ 20 Nm
NOTICE
Be careful not to damage the HECU pipes and nut threads when reinstalling.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
AXLE
CLUTCH
T/C
A/T
34
4890
Pressure Sensor
Location
1 3
1. Master cylinder 2. Primary pressure sensor 3. Second pressure sensor 4. Hydraulic pipe in primary circuit
5. Hydraulic pipe in secondary circuit 6. Inside of pressure sensor 7. Connector
Specifications
Supplying voltage Output voltage Output range 4.75 ~ 5.25 V 0.25 ~ 4.75 V (This is linearly changed from 0.5 V (brake not applied) to 4.75 V (brake applied)) 0 ~ 170 bar
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
35
Description
Master cylinder Master cylinder
Brake not applied
Brake applied
The distance (S) between the disks and, thus, the capacitance changes when pressure is applied to the movable disk by a braking intervention. The voltage value is approx. 0.5 V when the brake is not operated.
The voltage value is linearly changed from 0.5 V (brake not applied) to 4. 75 V (brake applied).
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. Each sensors pin no. 1 is its ground and pin no. 3 outputs the sensor output voltage to the ESP unit. When the brake is not in operation, this voltage is about 0.5V and, during the brake operation it increases linearly to about 0.5 ~ 4.75V.
Ground Power
1 3
Signal output
19 20 18
< Primary pressure sensor >
Ground Power
1 3
Signal output
21 23 22
HBA operating conditions: 1. Pressure: 20 bar 2. Pressure changes: over 1500 bar/sec 3. Vehicle speed: over 7 km/h
< Secondary pressure sensor >
< ESP unit >
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
The sensor consists of two ceramic disks, one of which is stationary and the other movable. The distance between these disks changes when pressure is applied.
The pressure sensors operate on the principle of changing capacitance (a).
When brake pressure is applied from the master cylinder, the ceramic disk moves towards the fixed ceramic disk and the electric charge volume changes accordingly.
CLUTCH
T/C
M / T
A/T
36
4890

1. Disconnect the battery negative terminal.
2. Remove the connector of the pressure sensor.
3. Remove the fuel filter bracket to remove the pressure sensor.
4. Place an empty container under the pressure sensors to collect the oil. 5. Remove the primary and secondary pressure sensors. When installing
7. Bleed the brake system after installation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
37
Location
1. Center fascia panel (left/right) 2. Sensor cluster
3. Installed sensor cluster 4. Inside of sensor cluster
Specification (sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor)
Supplying voltage Output voltage during stopping Yaw rate sensor operating range Lateral acceleration sensor operating range Longitudinal acceleration sensor operating range Approx. 5V (4.75 ~ 5.25V) Approx. 2.5V (Ignition switch ON) -75/S ~ +75/S -1.7 ~ +1.7g (16.7m/s2 ) -1.7 ~ +1.7g (16.7m/s2 )
Sensor Cluster Operation and Principles

The lateral sensor, longitudinal sensor and the yaw rate sensor are integrated into the sensor cluster. There is an additional electronic circuit to communicate with CAN. During the vehicle cornering, the microscopic tuning forks installed in the yaw rate sensor detects the yaw rate (acceleration around the vertical axis of the vehicle) and transmits it through the CAN communication line to the ESP unit, using the electronic signal. Especially, the longitudinal acceleration sensor detects the slope level of the driving road and provides important information for the HDC operation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Sensor Cluster
38
4890
The Microscopic tuning forks in the yaw rate sensor measures the acceleration on the vertical axis of the vehicle. When the angular acceleration occurs on the vertical axis of the vehicle (Z axis) and this acceleration occurs more than 4 (4 degree) per second, vibration occurs at the top and bottom as shown in the figure. This vibration is transmitted through the CAN communication line by the form of voltage value. In other words, it detects the yawing of the vehicle.
The ESP control operates when a divergence occurs between the vehicle yawing and the steering angle (i.e. the ESP operates when the drivers intent differs from the vehicle position). Therefore, the occurrence of vehicle yawing does not imply the ESP operation.
Sensor Cluster Circuit
1
Power
CAN -L
25
4 2 5 3 6
CAN -H Ground Power 29 31 6
<Sensor Cluster>
<ESP Unit>
The ESP sensor cluster can be considered as one module. The measured value by lateral/longitudinal and yaw rate sensors is transmitted to ESP unit via two CAN lines. The supplied voltage from ESP unit is approx. 5 V with ignition key ON and the output range through CAN line is approx. 0.2 ~ 4.8 V. When a sensor is faulty, the sensor cluster produces an output signal of 0 V (fail safe function).
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
KYRON SM - 2005.09

Preceding Work: Disconnect the battery negative cable. 1. Remove the center fascia panels (left/right).
39
Remove three screws before removal
2. Remove the AV head unit assembly.
Remove four screws

A / CON
NOTE
AV head unit may have different connectors according to the specifications.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
40
4890
3. Disconnect the sensor cluster connector and unscrew the cluster mounting bolts. When installing
Tightening torque 7 ~ 9Nm
NOTICE
The installing direction and location are very important when installing the sensor cluster. Make sure that there are not any foreign material and interference with floor carpet on the mounting surface.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
41
Location
SWAS is installed at the bottom of air bag clock spring in steering handle and sends the steering angle signal to ESP HECU.
Specifications
Working voltage Max. output current Detected max. angular velocity Working temperature Supplying voltage Output voltage (HI) Output voltage (LO) 9 ~ 16V 10 mA 1500/S - 30 ~ 75C 9 ~ 16V (battery voltage) Approx. 3.50V (3.0 ~ 4.1V) Approx. 1.50V (1.3 ~ 2.0V)
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
1. SWAS (Steering Wheel Angle Sensor) 2. Combination switch assembly
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
SWAS: Steering Wheel Angle Sensor
42
4890
Steering wheel angle sensor connector
LED
Phototransistor
Steering column
Slotted plate
The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage occurs through the holes. The detected voltage will be transmitted to the ECS unit as a pulse from the 3 terminals. Then, the two voltage pulses are used to get the average value for detecting the steering wheel position and its angle speed. And the other pulse is used for checking the alignment of the steering wheel.
IGN1
Steering Wheel Angle Sensor (SWAS)
ESP
STN ST2 ST1 Ground
H E C U
Working voltage Number of pulse per revolution Duty High - V Low - V ST1 and ST2 STN
ABS/ESP SYSTEM
KYRON SM - 2005.09
9 ~ 16 V
VHigh
45 Pulses /1 rev
ST1
VLow
Approx. 50 %
ST2
3.0 ~ 4.1 V 1.3 ~ 2.0 V Detects steering wheel angle and angular velocity as an average value Detects the center value of steering wheel
VHigh VLow VHigh
STN
VLow Center line of steering wheel
4890
43
Location
ESP OFF Switch
ESP Warning Lamp Blinking in Control

ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds.
ON ESP operation (including TCS) OFF
175ms
ON ESP warning lamp OFF

175ms
Min. 4 times
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
ESP OFF Switch
44
4890
ESP System Cancellation Using the ESP OFF Switch

When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP warning lamp on the instrument panel comes on. The detailed operation procedures are as follows: 1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be cancelled after approximately 150 ms. Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system (including ABD function) is turned off. And the ABS system is still operated.
Resuming the ESP System by Using the ESP OFF Switch

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch is pushed (for over approximately 150 ms) while the ESP system is not operating. The detailed operation procedures are as follows. 1. The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be resumed after approx. 150 ms.
PUSH RELEASE 350 ms PUSH
RELEASE
HI ESP operation LO
Disabled range
150 ms
150 ms
ESP function (including TCS)
ON OFF
150 ms 150 ms
NOTICE
When turning the ignition switch off while the ESP system is activated, the ESP system will be resumed when ignition switch is turned on again. When the vehicle is controlled by ESP system during driving, the ESP OFF switch does not operate. The ESP OFF switch operates when it is pushed for over 150 ms. When it is pushed for less than 150 ms, the ESP OFF mode and the ESP warning lamp will not be changed. When the ESP OFF switch is pushed within 350 ms of being turned off, the ESP warning lamp and ESP system will not be turned on.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890 ESP OFF Switch Monitoring
45
When the ESP unit recognizes that the ESP OFF switch is pushed for over 10 seconds, the ESP unit determines it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 10 seconds. However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and then goes out when the ESP system is resumed. When the ESP OFF switch returns to normal position, the ESP unit resets the ESP OFF switch for approx. 3.5 seconds.
Push Release HI ESP operation LO 10 sec 3.5 sec Return to switch signal ON OFF Reset to normal condition
Turning the ESP warning lamp off

STNG
ESP warning lamp
ON OFF
The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is working. Warning Lamp ABS W/L
Initial start (for 1.8 sec) Normal mode ESP fault ABS fault System fault Low batt. voltage High battery voltage High brake pad temp. ESP-OFF mode Entering diag. mode ON OFF OFF ON ON ON ON OFF OFF ON ON ON ON ON ON ON ON
ESP W/L
ON BLINKS WHEN ESP OPERATION
ABS
NO OK OK NO NO NO NO OK OK NO
ASR
NO OK NO NO NO NO NO NO NO NO
ABD
Vehicle yaw control

NO OK NO NO NO NO NO NO OK 1) NO
NOTICE
When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate the vehicle stability (posture) during ESP operation.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
Controls
BRAKE
ESP Warning Lamp Operation Depending on System Conditions
SP
Cancellation of ESP OFF mode
AXLE
CLUTCH
T/C
Detect failure
M / T
A/T
46
4890
14. ESP SYSTEM AIR BLEEDING

The vehicle equipped only with ABS can use the conventional air bleeding procedure, however, the vehicle equipped with ESP should use the oil supply device using a compressor inorder to bleed the air.
Air Bleeding Should Be Done When

1. After removal and installation of the brake master cylinder. 2. After removal and installation of the ABS HECU. 3. After removal and installation of the brake oil pipes and hoses. 4. After replacing the brake fluid.
Air Bleeding Procedures

1. Apply the parking brake and start the engine when the shift lever is at "P" position. 2. Connect the oil supply device (air bleeding device) with air compressor to brake reservoir. The oil supply device should be filled with sufficient oil. 3. Loosen the air bleed screw in caliper and place an empty container under the screw. 4. Bleed the air in each wheel by using diagnostic device. At this time, the modulator motor runs for 180 seconds. 5. Simultaneously, run the oil supply device to supply oil and depress the brake pedal repeatedly. This procedure needs at least 3 persons for doing below jobs: 1) Collect the bleeding oil into the container. 2) Depress the brake pedal repeatedly. 3) Check the conditions of oil supply device. The air bleeding procedure should be started from the rear right wheel. 6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw. 7. Perform the same procedures at each wheel.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
47
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. OPEN THR BLEED SCREW. 2. CONTINUALLY PUMPING BRAKE PEDAL. (PUMP MOTOR & VALVE ACTIVATING) 3. 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. CLOSE BLEEDER SCREW. PRESS ENTER.
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. TIME : xxx [Sec] BUBBLE FREE(FOAMLESS) ? (Yes / No)
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
48
4890
15. ABS/ESP TROUBLE DIAGNOSIS

o: Applied x: N/A
Function
Defective Components
Trouble Code
Descriptions
Wheel speed sensor front left-electrical Wheel speed sensor front left-other
System
Front LH Wheel speed sensor
C1011 (5011) C1012 (5012)
ABS
ESP
1. C1011 (5011)
Cause - Defective front LH wheel speed sensor - Short or poor contact wire to sensor Action - Check the wheel speed sensor connector - Check HECU connector - Check the harness connection
2. C1012 (5012)
Cause - Defective front LH wheel speed sensor - No signals from wheel speed sensor and tooth wheel - Too large air gap between wheel speed sensor and tooth wheel - Different number of teeth in tooth wheel
Sensor Monitoring
Action - Check the wheel speed sensor connector - Check HECU connector - Check air gap and tooth wheel mounting (Specified air gap: 0.335 ~ 0.945 mm) - Check the number of teeth (48) in tooth wheel
Front RH Wheel speed sensor
C1021 (5021) C1022 (5022)
Wheel speed sensor front right-electrical Wheel speed sensor front right-other
1.C1021 (5021)
Cause - Defective front RH wheel speed sensor - Short or poor contact wire to sensor Action - Check the wheel speed sensor connector - Check HECU connector - Check the harness connection
2.C1022 (5022)
Cause - Defective front RH wheel speed sensor - No signals from wheel speed sensor and tooth wheel - Too large air gap between wheel speed sensor and tooth wheel - Different number of teeth in tooth wheel Action - Check the wheel speed sensor connector and HECU connector - Check air gap and tooth wheel mounting (Specified air gap: 0.335 ~ 0.945 mm) - Check the number of teeth (48) in tooth wheel
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
49
Function
Trouble Code
Descriptions
Wheel speed sensor rear left-electrical Wheel speed sensor rear left-other
System
M / T
Rear RH Wheel speed sensor
C1031 (5031) C1032 (5032)
ABS
ESP
T/C
1. C1031 (5031)
Cause - Short or poor contact wire to sensor Action - Check the wheel speed sensor connector - Check the HECU connector - Check the harness connection - Defective rear RH wheel speed sensor
2. C1032 (5032)
Cause - Defective rear RH wheel speed sensor - No signals from wheel speed sensor and tooth wheel - Too large air gap between wheel speed sensor and tooth wheel - Different number of teeth in tooth wheel
O
SP
Sensor Monitoring
Action - Check the wheel speed sensor connector - Check the HECU connector - Check the number of teeth (48) in tooth wheel - Check air gap and tooth wheel mounting (Specified air gap: 0.309 ~ 0.958 mm)
C1042 (5042)
Wheel speed sensor rear left-other
Cause - Defective rear LH wheel speed sensor - Short or poor contact wire to sensor Action - Check the wheel speed sensor connector - Check the HECU connector - Check the harness connection
2. C1042 (5042)
Cause - Defective rear LH wheel speed sensor - No signals from wheel speed sensor and tooth wheel - Too large air gap between wheel speed sensor and tooth wheel - Different number of teeth in tooth wheel Action - Check the wheel speed sensor connector and HECU connector - Check air gap and tooth wheel mounting (Specified air gap: 0.309 ~ 0.958 mm) - Check the number of teeth (48) in tooth wheel
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
1. C1041 (5041)
A / BAG
Rear LH Wheel speed sensor
C1041 (5041)
Wheel speed sensor rear left-electrical
BRAKE
STNG
AXLE
CLUTCH
A/T
50
4890
Function
Defective Components Pressure sensor

Cause
Trouble Code
C1051 (5051)
Descriptions
Defective input sensor
System ABS ESP
- Abnormal signals from pressure sensor - Defective pressure sensor or harness Action - Check the pressure sensor connector

Cause
C1061 (5061)
Defective steering wheel angle sensor
- Internally defective steering wheel angle sensor - Abnormal signals from steering wheel angle sensor - Short circuit between supplying voltage output and ground - Abnormal signal voltage from steering wheel angle sensor - Poor installation of steering wheel angle sensor and abnormal signal Action - Check the supplying voltage: (Specified voltage: 9 ~ 16 V)
Sensor Monitoring
- Check the output voltage: Check voltage between ESP unit terminals with ignition ON ST1 voltage check: between ESP unit terminal No. 5 and ground (Specified voltage: 1.3 ~ 4.1V) ST2 voltage check: between ESP unit terminal No. 2 and ground (Specified voltage: 1.3 ~ 4.1V) STN voltage check: between ESP unit terminal No.12 and ground (Specified voltage: 1.3 ~ 4.1V)
Sensor cluster
1. C1073 (5073)
Cause
C1073 (5073) C1074 (5074)
Sensor cluster -electrical Sensor cluster-internal
- Operating voltage exceeds specified range (Hi: 18.0 1.0 V / Lo: 6.5 0.5 V ) - Poor contact or installation of harness Action - Check the sensor cluster connector - Replace the sensor cluster
2. C1074 (5074)
Cause - Internally defective HECU - Abnormal A/D converter voltage: 5.0 3 % - Abnormal supplying voltage (4.580 ~ 4.960 V) to sensor cluster Short circuit between supplying voltage output of sensor cluster and ground - Poor ground of sensor cluster (0.0 ~ 0.5 V) Short to ground on sensor cluster - Abnormal signals from lateral acceleration sensor - Abnormal signals from yawing sensor - Poor installation of sensor - Defective sensor cluster - Defective or short circuit of CAN communication line Action - Replace the sensor ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
51
Battery
1. C1101 (5101)
Cause
C1101 (5101) C1102 (5102)
Battery under voltage Battery over voltage
ABS
ESP
M / T
Battery Voltage Monitoring
- Low voltage out of specified range (9.7 0.3 V) - Check the supplying voltage
T/C
Action
O
CLUTCH
2. C1102 (5102)
Cause - Over voltage out of specified range (18.0 1.0 V) Action - Check the supplying voltage
AXLE
Brake disc
Cause
C1111 (5111)
Disk temperature is high
- Overheated brake disk due to braking force: over 500C Action - Stop driving for a period of time after turning off the ESP
1. C1201 (5201)
Cause - Mechanical defective in brake switch - Defective brake switch harness Action - Check the harness and connector
2. C1202 (5202)
Cause - Mechanical defective in ESP OFF switch - Defective ESP OFF switch harness (short to ground) Action - Check the harness and connector for ESP OFF switch
A / CON
Valve, valve relay

Cause
C1301 (5301)
Defective valve, valve relay in HECU
Valve Monitoring
- Abnormal supplying voltage to valve solenoid - Internally defective HECU Action - Replace the HECU - Check the battery voltage - Check the HECU connector
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
Brake Monitoring
Brake lamp switch ESP OFF switch
C1201 (5201) C1202 (5202)
Defective brake lamp switch Defective ESP OFF switch
STNG
SP
A/T
Function
Trouble Code
Descriptions
System
52
4890
Function
Defective Components Motor pump

Cause
Trouble Code
C1302 (5302)
Descriptions
Defective motor pump
System ABS ESP
- Too low (below 6.0 V) or no supplying voltage to pump motor
Pump Monitoring
- Over 0.93 V from pump motor voltage - Poor contact in pump motor connector - Poor ground Action - Check the supplying voltage - Check the HECU connector - Replace the HECU
HECU
Cause - Internally defective HECU
C1401 (5401)
HECU hardware
- Defective A/D converter, internal voltage regulator, and controller - Defective sensor and short to supplying voltage line - Abnormal temperature sensor signal Action - Replace the HECU
HECU and Sensor Monitoring
Sensor initialization
Cause
C1501 (5501)
Abnormal sensor initialization
- Abnormal signals from sensors - Abnormal sensor data Action - Check the sensors - Initialize the sensors
Vehicle coding
Cause
C1170 (5170)
Variant coding error, or misinstallation HECU
- Discrepancy between HECU coding and vehicle coding - Defective CAN communication line - Misinstallation HECU Action - Check the HECU coding and vehicle coding - Perform vehicle coding - Replace the exact HECU - Check engine ECU variant coding
(O)
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
53
CAN communication
Cause
C1601 (5601)
CAN communication error
ABS
ESP
M / T
- Short or open to CAN communication line - Poor connection of CAN communication line Action - Check the CAN communication line - Check the HECU connector
(O)
O
T/C
C1602 (5602)
CAN communication
C1603 (5603) C1604 (5604) C1605 (5605)
Communication error between TCU and HECU Communication error between TCCU (4WD) and HECU Communication error between cluster (Meter) and HECU
Cause
- Short to CAN communication line Action - Check the engine ECU - Check the CAN communication line - Check the engine ECU connector
STNG
- Overload to CAN communication Action
2. C1603 (5603)
Cause - Short to CAN communication line - Overload to CAN communication Action Action - Check the TCU - Check the CAN communication line - Check the TCU connector
3. C1604 (5604)
Cause - Short to CAN communication line - Overload to CAN communication Action Action - Check the TCCU - Check the CAN communication line - Check the TCCU connector
4. C1605 (5605)
Cause - Short to CAN communication line - Overload to CAN communication Action Action - Check the cluster (meter) - Check the CAN communication line - Check the cluster (meter) connector
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
1. C1602 (5602)
AXLE
CLUTCH
Communication error between engine ECU and HECU
A/T
Function
Trouble Code
Descriptions
System
54
4890
Function
Defective Components CAN signal error EMS
Trouble Code
C1612 (5612)
Descriptions
Signal from engine ECU is abnormal
System ABS ESP
CAN Communication Monitoring
Cause - Engine ECU is defective - Signal from engine ECU error Action - Check engine ECU - Check ECU S/W version
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
55
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
1 km/h 1 km/h 1 km/h 1 km/h 0.1V 0.01 g-: Straight ahead 0.01 g +: Left Turn 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 X X X O O
(O: Applied, X: N/A)
A / CON STNG A / BAG BRAKE SP T/C AXLE CLUTCH M / T
ABS/ESP SYSTEM
KYRON SM - 2005.09
A/T
ABS/ESP Sensor Value
56
4890
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
KYRON SM - 2005.09
4890
57
SENSOR INITIALIZE (Only ESP) 1] LONGITUDINAL SENSOR (4WD only) 2] LATERAL SENSOR 3] PRESSURE SENSOR 4] ABOVE 1,2,3 ALL SENSOR
SENSOR INITIALIZE LONGITUDINAL ACCEL SENSOR(4WD only) DO YOU START INITIALIZE ? (Yes/No) CONDITION : - ENGINE IS NOT RUNNING. - VEHICLE STATUS IS FLAT. - DO NOT PUT THE BRAKE PEDAL.
CLUTCH A / CON A / BAG BRAKE STNG SP AXLE T/C M / T
Select one of the above items
PROCEDURE : MUST BE FOLLOW THE ABOVE CONDITION. IF YOU START "INITIALZE SENSOR" ADAPT TO AUTOMATIC. Initialize both the primary and secondary pressure sensors when initializing a pressure sensor.
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).
ABS/ESP SYSTEM
KYRON SM - 2005.09
A/T
Sensor Initialzation (ABS & ESP)
58
4890
Actuator
ACTUATOR TEST
ACTUATOR TEST 1. FRONT/LEFT INLET VALVE 2. FRONT/LEFT OUTLET VALVE 3. FRONT/RIGHT INLET VALVE 4. FRONT/RIGHT OUTLET VALVE 5. REAR(ESP: REAR/LEFT) INLET VALVE 6. REAR(ESP: REAR/LEFT) OUTLET VALVE 7. REAR/RIGHT(Only ESP) INLET VALVE 8. REAR/RIGHT(Only ESP) OUTLET VALVE 9. 1st TCS VALVE(Only ESP) 10. 2nd TCS VALVE(Only ESP) 11. 1st ESV VALVE(Only ESP) 12. 2nd ESV VALVE(Only ESP) 13. PUMP MOTOR Select one of the above items
FRONT/LEFT INLET VALVE ---------------------------------------------------ON(ACTIVE): YES KEY OFF(STOP): NO KEY OTHER ITEM : ,
---------------------------------------------------ACTIVE TIME : Max. 10 Sec CONDITION : IG. ON or IDLE
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
59
CLEAR VARIANT CODE

M / T
VEHICLE CODING CLEAR -------------------------------------------------DO YOU START TO CLEAR? ( YES / NO )
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
Clearing Code
60
4890
ABS SYSTEM
Differences compared to other models: Appearance of wheel speed sensor, Location, Layout of relevant components
ABS HECU
Active Wheel Speed Sensor (for 4WD)
The transfer case (T/C) installed on this vehicle doesnt have the internal speed sensing device and receives the speed signal for T/C control from ABS HECU.
Conventional Transfer Case
New Transfer Case
With Speed Sensor
Without Speed Sensor
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
Cautions When Removing the Front Wheel Speed Sensor
61
The locking hub system of the KYRON part time 4WD utilizes a different hub actuator from the conventional approach. It utilizes IWE (Integrated Wheel End) system that locks the 4WD depending on the vacuum condition within the actuator. Thus, the wheel speed sensor is installed on the front wheel end area. It is installed inside the backing plate to be protected from heat and foreign materials. Therefore, the front wheel end system (including disc) should be removed before removing the front wheel speed sensor.
Backing Plate
AXLE
Backing Plate Wheel Speed Sensor
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
Wheel Speed Sensor
BRAKE
STNG
SP
CLUTCH
Front Wheel Speed Sensor
Rear Wheel Speed Sensor
T/C
M / T
A/T
62
4890
The rubber O-ring in IWE (Integrated Wheel End) should be replaced with new one when the front wheel end has been removed. The rubber O-ring prevents moisture and foreign materials from entering the IWE system. In addition, when installing the hub actuator of the IWE system, you must install it from the same angle as the drive shaft to prevent the rubber seal ring inside the actuator from being squeezed.
Rubber O-ring
Rubber seal ring (Internal steel spring included)
Please refer to the part time transfer case section for more specific information.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
63
The following figure shows the basic system components of the ABS. This system consists of HECU (valve body and ECU integrated type), front wheel speed sensor, and rear wheel speed sensor.
Front Wheel Speed Sensor (for 4WD)
HECU (Valve body and ECU integrated type)
Valve body Front wheel speed sensor (FR) ABS HECU Rear wheel speed sensor (RL)
Front wheel speed sensor (FL) B: Plunger C: Can bushing ABS warning lamp Motor pump
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Rear wheel speed sensor (RR)
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
2. CONFIGURATION OF ABS SYSTEM
64
4890
3. INPUT AND OUTPUT DIAGRAM

Input/Output of ABS (without TPMS)
Battery + (hydraulic valve and ECU power supply)
32
Battery + (pump supply power) ABS HECU supplies battery power to operate hydraulic pump and hydraulic valve even when the ignition switch is OFF.
NOTICE IG1
4 No specific terminal exists to display vehicle speed or ABS warning lamp. Data is transmitted through CAN communication.
Brake switch
41
H E C
CAN LO CAN HI Sending and receiving the information such as speed signal of ABS HECU from/ to ECUs through CAN communication.
Signal
15 11
Wheel speed sensor (FL)
Ground
45 46
Diagnosis connector pin no.8 This line is used to send the error code to diagnostic connector when an ABS related component is defective.
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. It measures wheel speed by using current value changing when wheel rotates.
ABS/ESP SYSTEM
KYRON SM - 2005.09
Ground
Ground (valve and ECU)
4890
65
Master cylinder
T/C
Damping chamber Pump
Inlet valve (FR)
Inlet valve (FL)
Inlet valve (all rear wheel)
Wheel (FR)
Wheel (FL)
Wheel (RR)
Wheel (RL)
The vehicle equipped only with the ABS controls the wheels braking force using or channel 4-sensor method. The front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves. The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one from the previous model.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
Outlet valve (FR)
Outlet valve (FL)
Outlet valve (all rear wheel)
A / BAG
BRAKE
STNG
Low pressure accumulator
Low pressure accumulator
SP
AXLE
CLUTCH
Primary circuit
Secondary circuit
M / T
A/T
4. HYDRAULIC CIRCUIT OF ABS
66
4890
5. ABS CIRCUIT IN EACH OPERATION RANGE

1
2
Inlet valve Pump Pump Inlet valve
Outlet valve
Outlet valve
Hydraulic Pressure Circuit when ABS is Not Operating The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve. At this moment, the normally-closed outlet valve is closed. The speed of the wheel that hydraulic pressure is delivered reduces gradually.
No Hydraulic Pressure Circuit when ABS is Operating As hydraulic pressure on each wheel increases, the wheel tends to lock. In order to prevent the wheel from locking, the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases. At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic pressure.
3
Pump
Pump
Inlet valve
Inlet valve Outlet valve
Outlet valve
Pressure Decreases in the Circuit when ABS is Operating Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases. This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels. In order to prevent from hydraulic pressure increases, the inlet valve is closed and the outlet valve is opened. Also, the oil is sent to the low pressure chamber and the wheel speed increases again. The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder. This may make the driver to feel the brake pedal vibration and some noises.
Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases, the inlet valve opens and the wheels pressure increases due to the master cylinder pressure. The oil in the low pressure chamber circulates to the wheel by the pump and the wheel speed decreases as the hydraulic pressure at wheel increases. This operation continues repetitively until there are no signs that the ABS ECU is locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at the brake pedal.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
67
Front LH wheel
Front RH wheel Secondary master cylinder

AXLE
Wheel Speed Sensor - Front (for 4WD)
Wheel Speed Sensor - Rear
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
Rear RH/LH wheel
CLUTCH
T/C
Primary master cylinder
M / T
A/T
6. COMPONENTS AND LOCATION
68
4890
7. COMPONENTS DESCRIPTION
1) HECU (Hydraulic & Electronic Control Unit)
This section is provided only for the understanding of HECU. Note that this component cannot be disassembled for repair and maintenance. HECU consists of motor pump, valve body, solenoid valve and ECU. ECU connector has 47 pins and the number of valves in valve body is 6 when equipped with only ABS and 12 when equipped with ESP system.
1. Motor pump
2. Valve body
<Pumping>
The motor is operated when ABS is activated. The cam-shaped output shaft of the motor (a) enables the brake system to receive and supply the brake fluid during the motor operation.
The cam bushing (c) is installed between plungers (b) and it draws and discharges the brake fluid.
When the cam pushes the left plunger during motor operation, the system pressure is generated in the left cylinder. At this time, the right plunger is expanded by spring force and the expanded volume of the right cylinder draws the brake fluid.
3. ECU (Including Solenoid Valves)

HECU controls the hydraulic valves by supplying or cutting off the voltage to solenoid valves depending on the wheel speed and other information from wheel speed sensors. The ABS ECU has 6 solenoid valves. It has three channels; 2 channels for front wheels and 1 channel for rear wheels Each channel has one inlet and one outlet valve, therefore, there are six solenoid valves. Main functions are 1) Overall control of ABS functions 2) Monitoring of ABS electric components 3) Diagnosis function support
<ECU lower cover>
The electrical components are weak to moisture. To protect ECU, Gore Tex-based plate is used at ECU lower cover. The vent hall (arrow) allows air to ventilate but does not allow moisture to penetrate.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
69
HECU Assembly
1. Disconnect the battery negative cable. 2. Disconnect the ABS hydraulic unit connector.
Tightening torque
STNG
Master cylinder - HECU
20 ~ 24 Nm
Tightening torque
HECU - Each hydraulic line 15 ~ 19 Nm
NOTICE
Be careful not to damage the HECU pipe and nut thread when reinstall.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
4. Disconnect the front and rear wheel brake pipes.
A / BAG
BRAKE
SP
3. Disconnect the primary and secondary master cylinder pipes from HECU.
AXLE
CLUTCH
T/C
M / T
A/T
70
4890
5. Unscrew two mounting nuts and carefully remove HECU. Tightening torque
HECU mounting nut 4 ~ 8 Nm
NOTICE
Do not attempt to disassemble the HECU assembly. Wrap the opening of pipes and HECU to prevent contamination.
6. Install in the reverse order of removal. 7. After reinstallation, add some oil and perform the brake air bleeding. NOTICE
When you install a new HECU to the vehicle, coding is executed automatically. Thus, no additional coding is necessary.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
71
<Front wheel speed sensor>
<Rear wheel speed sensor>

T/C
This sensor contains: 1. Four resistance 2. Supply voltage from HECU (12 V) 3. Internal printed circuit board The system uses the wheatstone bridge that detects and compares the changes in each resistance value. Before passing through the comparison measuring device, the sine wave current is obtained. But, after passing through it, a square wave, that is recognized by ECU, will be generated.
A / CON
Specification
Air gap between sensor and rotor Front: 2WD: 0.475 ~ 1.453 mm (Tightening torque: 6 ~ 8 Nm) 4WD: 0.1 ~ 0.7 mm (Tightening torque: 15 ~ 20 Nm) Rear: 0.037 ~1.175 mm (5-link suspension) 0.489 ~1.039 mm (Independent suspension) Wheel speed sensor current (vehicle speed: at approx. 2.75 Km/h) Wheel speed sensor voltage (one rotation per a second at -40 ~ +60)
IHIGH : Approx. 14 mA ILOW : Approx. 7 mA 7.5 ~ 20 V
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / BAG
BRAKE
STNG
<Active wheel speed sensor>
<Wheatstone bridge type>
SP
AXLE
CLUTCH
M / T
The speed sensor used in traditional ABS is made of permanent magnet and transmits the output voltage that changes as the wheel rotor rotates to the HECU system. New wheel speed sensor detects the wheel speed through the current value that depends on the resistance that changes according to the magnetic field by using four resisters and supplying the 12 V power supply to the sensor.
A/T
AWSS: Active Wheel Speed Sensor
72
4890
Front Wheel Speed Sensor

1. Disconnect the front wheel speed sensor connector.
2. Remove the front brake disc. Loosen the hub end bolts (do not remove) and disconnect the wheel speed sensor.
ABS/ESP SYSTEM
KYRON SM - 2005.09
4890
73
3. Remove one of self-locking hexagon bolt.
When Installing
Keep the specified tightening torque and air gap. Tightening torque
Front wheel speed sensor Airgap 2WD 6 ~ 8 Nm 15 ~ 20 Nm 4WD 0.475 ~ 1.453 mm 0.1 ~ 0.7 mm
NOTICE
Tighten the bolts with the specified tightening torque. Otherwise, the air gap between the wheel speed sensor and wheel rotor may be out of specified value, and this may cause an incorrect input value to HECU.
ABS/ESP SYSTEM
KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
74
4890

1. Disconnect the speed sensor connector. Set aside the wheel speed sensor cable.
2. Remove one of self-locking bolt (10 mm). Remove rear wheel speed sensor.
When Installing
Keep the specified tightening torque and air gap. Tightening torque
Wheel speed sensor Airgap (mm) 6 ~ 8 Nm 0.037 ~ 1.175 (5-link) 0.489 ~ 1.039 (IRS)
NOTICE
Tighten the bolts with the specified tightening torque. Otherwise, the air gap between the wheel speed sensor and wheel rotor may be out of specified value, and this may cause an incorrect input value to HECU.
ABS/ESP SYSTEM
KYRON SM - 2005.09
AIR BAG SYSTEM

AIR BAG SYSTEMS (INCLUDING CURTAIN AIR BAGS) .............................................................. 3
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Overview ............................................................................. 3 Locations and related components ................................... 4 Air bag system operation process ....................................6 Air bag module and other components ............................. 8 Electrical wiring diagram ................................................. 16 Air bag system deploy (firing loop) ................................. 17 Air bag deployment signal output (crash out) ................. 18 Air bag warning lamp operational conditions .................. 19 Reminder for air bag related component replacement .... 20 Servicing the air bag system ........................................... 21 Diagnosis ......................................................................... 31
8810
1. OVERVIEW
The air bag systems for this vehicle are not much different from the previous air bag system installed in REXTON. The curtain air bags are installed at the bottom of the roof trim and they enhance the passengers safety. The drivers and passengers curtain air bags individually deploy. When the front air bags deploy, the seat belt pretensioners retract the seat belts too. Collision sensors, a kind of impact G (acceleration) sensor, detect the front and longitudinal collisions and determine whether or not the air bags are deployed. The roles of each collision sensor are as below:
M / T A / CON A / BAG BRAKE STNG SP
KYRON SM - 2005.09
Front G sensors (inside the air bag unit) 1. Send signals to the front air bags and the drivers and front passengers seat belt pretensioners. 2. By the signal from this sensor, front air bags (drivers and passengers air bags) deploy and the seat belt pretensioners of the drivers and passengers seat belts retract seat belts. Curtain air bag G sensors 1. These are located inside the left and right B-pillar panel bottoms. When a collision occurs, the air bag at the side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the air bag at the side of collision deploys, not both. Once an air bag deploys, its repair parts vary according to the deployment situation and damage to the vehicle from collision. Needed repairs also slightly vary between the front air bags and the curtain air bags. The following are the differences: Replacement parts when the front air bags deploy: the air bag units and their connection wires (connectors included), the seat belt pretensioners and their connection wires (connectors included), the entire front air bags, and the instrument panel (IP). Replacement parts when a curtain air bag deploys: the new curtain air bag for the deployed side, the air bag unit and its connection wires (connectors included), the collision G sensor assembly for the curtain air bag, and the trims and roof headlining for the broken parts.
NOTICE
When an air bag deploys (curtain air bags and seat belt pretensioners included), the air bag unit must be replaced. Please do not attempt to delete the failure code with SCAN-100 because some data about the deployment situation are stored in the unit. The air bag related components, especially the air bag unit, must be stored in a sealed case to prevent any damage. Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance. The detonator may explode due to a sudden extra power supplied by the tester. Before removing or installing any air bag related components, disconnect the negative battery cable.
AIR BAG SYSTEM
AXLE
CLUTCH
T/C
A/T
AIR BAG SYSTEMS (INCLUDING CURTAIN AIR BAGS)
8810
2. LOCATIONS AND RELATED COMPONENTS

LH
When the curtain air bag (LH) deploys
Curtain air bag collision G sensor
RH
BPT: Belt Pretensioner
When the curtain air bag (RH) deploys
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
DAB: Driver Air Bag
Air Bag Unit (SDM) The collision G sensor is installed inside this. And it sends out signals to deploy the front air bags (drivers and passengers air bags) and (or) the drivers and passengers seat belt pretensioners or the drivers and passengers curtain air bag. When the front collision G sensor sends out only the air bag deployment signal, the signal deploys the two front air bags and activates their seat belt pretensioners.
PAB: Passenger Air Bag

AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STICS 40 ms after receiving the air bag deployment signal at the vehicle speed 3 or higher km/h, it sends out the door UNLOCK signal for 5 seconds.
STNG
SP
AXLE
Air bag warning lamp
CLUTCH
T/C
M / T
A/T
8810
3. AIR BAG SYSTEM OPERATION PROCESS

The overall air bag operation process and its functions and roles are broadly explained in this block diagram. This diagram summarizes and highlights the functions adopted by Ssangyoung Motors.
Air Bag System Block Diagram (Functions and Roles Included)

Battery
Load Dump Protection DC/DC Converter Converts the battery voltage into the air bag operation voltage (5V) and the energy reservoir voltage (about 30V) that is transmitted at the moment of the air bag deployment. Security Circuit
Longitudinal/Lateral Direction Collision (G) Sensor Sends out signals to operate the front air bags and the seat belt pretensioners. This sensor detects any longitudinal/lateral deceleration occurring when vehicle collides. Then, the sensor supplies the data to the micro controller.
Micro Controller (MI-COM)
When the initial ignition ON: blinks 6 times at 1Hz. When the system error: after coming on for 6 seconds, goes off for 1 second and then stays on. When outside system error: after coming on for 6 seconds, goes off.
Warning Lamp Output
Diagnosis Output
The Air Bag Waning Lamp on the Instrument Panel
Diagnose with the K-line and use the 9th diagnosis connector
Diagnosis Connector
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
Watch Dog
Check
Drivers air bag module
Check
Passengers air bag module
Micro Controller (MI-COM)

Check Passengers pretensioner
Check
Check
Curtain air bag module (RH)
Communicating With the Curtain Air Bag Sensor
Communicating With the Curtain Air Bag Sensor
Each curtain air bag independently operates from the front air bags. Depending upon the severity of impact, only the left or right air bag may deploy.
The Collision G Sensor for the Curtain Air Bag (LH)

The Collision G Sensor for the Curtain Air Bag (RH)
The collision G sensors for the curtain air bags are installed at the bottom of left and right B-pillars. Each measures deceleration rate at time of collision and supplies information about the collision to the air bag unit. Each sensor measures the G value from its side and transmits the decesion to its air bag unit.
AIR BAG SYSTEM
KYRON SM - 2005.09
A / CON
Curtain air bag module (LH)
A / BAG
BRAKE
STNG
Check
Drivers pretensioner
SP
AXLE
CLUTCH
T/C
M / T
The watchdog monitors the micro controller, the air bags, and the seat belt pretensioners. When any error occurs, it turns on the air bag warning lamp.
When the front air bags deploy, the drivers air bag and the front passengers air bag deploy simultaneously and their seat belt pretensioners also simultaneously retract their seat belts. The air bag unit monitors conditions of the air bags and the seat belt pretensioners. When any error occurs, it stores the failure diagnostic code or turns on the air bag warning lamp on the instrument panel.
A/T
8810
4. AIR BAG MODULE AND OTHER COMPONENTS

This section describes the air bag module installed in Kyron. The module consists of the inflator, the cushion, and the mounting cover.
DAB: Driver Air Bag

The drivers air bag is installed inside the steering wheel. If the acceleration sensor (inside the air bag unit) is activated by the deceleration from vehicle collision, the detonation is fired by the electrical signal of the air bag unit. Then, the detonation sets off explosives and nitrogen gas is generated. At this point, the air bag very quickly deploys and the gas is emitted from the relieving hole to absorb impact upon the driver.
Front View
Rear View
Components
1. Air bag cover

6
2. Air bag housing 3. Air bag cushion (approx. 50 liters) 4. Inflator* (approx. 190 Kpa) 5. Retainer ring 6. Horn switch
Inflator * The inflator is composed of the detonator, explosives, and the gas generator. It inflates air bag when vehicle collides.
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
PAB: Passenger Air Bag

The passengers air bag is installed inside the instrument panel above the glove box. Its operation process is the same as the drivers one. The drivers air bag, the passengers air bag, and the seat belt pretensioners on both seats are made to operate together. When the collision G sensor inside the air bag unit sends a collision signal, the air bag unit instantaneously applies a high current to the drivers and passengers air bags and the seat belt pretensioners on both seats, fires the detonator in the inflator, and inflates the air bag cushions (curtain air bags independently operate in case of the side collisions).
Front View
Components
1. Passengers air bag module housing 2. Inflator 3. Air bag cushion 4. Retainer 5. Nut
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Rear View
SP
AXLE
CLUTCH
T/C
M / T
A/T
10
8810
Curtain Air Bag (CAB)

The curtain air bags are installed on both sides of the roof side rails and inside the headlinings. Each curtain air bag is also composed of the air bag cushion and the inflator that has the detonator, explosives, and the gas generator. A collision situation is detected by the curtain air bag collision G sensor installed at the lower side of the B-pillar. The signal is transmitted to the air bag unit. The air bag unit instantly inflates the necessary air bag necessary by sending a high current.
When the Curtain Air Bag is Installed
Terms of the Curtain Air Bag

tin oun oi g p nt
air tain Cur
bag
Inf
or lat
mo
nt
po ing
int
Nut and bolt Wrapper cover Air bag cushion Gas guide
Inflator When the Curtain Air Bag Deploys
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
11
Components
T/C
STNG
a-a
b-b
Sectimal view a-a
Sectimal view b-b
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
CLUTCH
M / T
A/T
12
8810
Driver and Passenger BPT (Belt Pre-Tensioner)

The belt pretensioner retracts the seat belt to tighten or take up slack in the wearer's belt. When a collision occurs or when brakes are applied, a seat belt with a pretensioner detects the stopping action and tightens the belt before the wearer is propelled forward. This holds the occupant more securely in the seat.
Belt Pretensioner (Driver Side)
Belt Pretensioner (Passenger Side)
Curtain air bag G sensor Belt pretensioner (LH)
Belt pretensioner (RH)
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
13
Components
20
18
10 17 19
16
14 4 9
2. Reel bracket 3. Ring upper stay 4. D-ring 5. Bending tongue 6. Tongue stopper 7. Mini anchor 8. D-bolt 9. Washer
10. Fiber washer 11. Rivet

12
12. ID label 13. Plastic washer 14. Steel washer 15. D-bolt
1 10 2 9
11 8
16. Label 17. D-bolt 18. Spacer 19. Bush 20. Mini anchor cover
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
15
13
1. Pretensioner reel assembly
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
Belt Pretensioner
A/T
14
8810
Air Bag Unit

Air bag unit is installed under the AV head unit in center fascia panel.
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
15
Drivers Side
Passengers Side
T/C
Tightening torque: 9 Nm 1 Nm
Signal terminal
Ground
Connector
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
M / T
The curtain air bag sensor is installed inside each B-pillar of the drivers and passengers seats (that is, around the pretensioner reel). The body panel has guiding holes to ensure its correct installation. But incorrect tightening torque may break the sensor or make it insecure. As a result, the sensor may have inaccurate judgment and have the air bag deployed inaccurately.
A/T
Curtain Air Bag Sensor
16
8810
5. ELECTRICAL WIRING DIAGRAM
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
17
According to the collision deceleration rate that each collision G sensor reads, the air bag unit sends out about 2~4 or higher Amp current. This current generates some heat, which fires the detonator in the inflator. This table shows the basic inner resistance of the air bag related module and the basic instant current necessary for a firing.
Air bag module Resistance (at -30 ~ 85C) Firing current for 2msec (at -35C) Driver/passenger air bag (DAB / PAB) 2 0.3 1.2 Amp Belt pretensioner (BPT) 2.15 0.35 0.8 Amp Curtain air bag (CAB) 2 0.3 1.0 Amp
NOTICE
Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance. The detonator may explode due to a sudden extra power supplied by the tester.
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
Before removing or installing any air bag related components, disconnect the negative battery cable.
AXLE
CLUTCH
T/C
M / T
A/T
6. AIR BAG SYSTEM DEPLOY (FIRING LOOP)
18
8810
7. AIR BAG DEPLOYMENT SIGNAL OUTPUT (CRASH OUT)

When any air bag deploys, another signal is sent to the sticks to do two basic security operations. One operation is the automatic door unlock function that cancels the automatic door lock mode.
200 ms Deployment signal output (Crash out)
Automatic Door Unlock (Crash unlock: unlock when colliding)

1. When the ignition key is the ON position, the air bag signal is not accepted for the first 7 seconds. 2. When the ignition key is the ON position and the vehicle speed is 3 km/h or higher, 40 ms after receiving the air bag deployment signal, the sticks sends out the door UNLOCK signal for 5 seconds. 3. Even though the ignition switch is turned off in the middle of the unlock signal being sent out, the unlock signal continues for the remaining time. 4. This function cancels when the ignition key is withdrawn.
ON ING KEY SW (*1) OFF T1 AIR BAG DEPLOYMENT SIGNAL ON OFF T2 DOOR UNLOCK RELAY ON OFF T1 : 200 ms T2 : 40 ms T3 T3 : 5 sec
NOTICE
Reminder for door lock/unlock control The unlock function by the air bag signal takes priority over any other lock/unlock operations. While or after the automatic unlock is made by the air bag system, any lock or unlock request by other functions is ignored unless the ignition key switch is turned off. When another lock or unlock output is requested while the door is being either locked or unlock, the new request will be ignored. But, if an unlock request is made by the air bag signal or the remote control key, the request will be accepted. When the lock and unlock functions are simultaneously requested, the lock will be performed and the unlock will be ignored.
AIR BAG SYSTEM
8810
19
The air bag warning lamp on the instrument panel has a few operational conditions. The following are the conditions:
Ignition
OFF
OFF
When Turning the Ignition Switch to the ON Position

When the air bag unit detects any malfunctions in its unit When it is recorded as a system failure in the air bag unit, the air bag warning lamp on the instrument panel comes on for about 6 seconds and goes off for 1 second. Then the waning lamp stays on.
ON Ignition OFF Air bag warning lamp ON OFF 6 seconds
When the Air Bag Unit Receives Any Malfunction Signals from the Other Systems
When, due to an error from outside the system, the intermittent failure signal is received 5 times or less, the air bag warning lamp comes on for about 6 seconds and then, goes off.
ON Ignition OFF Air bag warning lamp ON OFF 6 seconds
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
Air bag warning lamp
ON
CLUTCH
ON
T/C
The air bag unit performs a turn-on test when the ignition is turned on. The air bag unit flashes the air bag warning lamp six times by supplying an intermittent ground to the warning lamp circuit. After flashing six times, the air bag warning lamp will turn off if no more malfunctions have been detected.
M / T
When Turning the Ignition Switch to ON Position
A/T
8. AIR BAG WARNING LAMP OPERATIONAL CONDITIONS
20
8810
9. REMINDER FOR AIR BAG RELATED COMPONENT REPLACEMENT

NOTICE
When an air bag deploys (curtain air bags and seat belt pretensioners included), the air bag unit must be replaced. Please do not attempt to delete the failure code with scan-100 because some data about the deployment situation are stored in the unit. The air bag related components, especially the air bag unit, must be stored in a sealed case to prevent any damage. Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance. The detonator may explode due to a sudden extra power supplied by the tester. Before removing or installing any air bag related components, disconnect the negative battery cable.
Collision sensors, a kind of impact G (acceleration) sensor, detect the front and longitudinal collisions and determine whether or not the air bags are deployed. The roles of each collision sensor are as below: Front G sensors (inside the air bag unit) 1. Send signals to the front air bags and the drivers and front passengers seat belt pretensioners. 2. By the signal from this sensor, front air bags (drivers and passengers air bags) deploy and the seat belt pretensioners of the drivers and passengers seat belts retract seat belts. Curtain air bag G sensors 1. These are located inside the left and right B-pillar panel bottoms. When collision occurs, the air bag at the side of collision deploys accordingly. Please pay attention to that, in the case of the curtain air bag, only the air bag at the side of collision deploys, not both.
Once an air bag deploys, its repair parts vary according to the deployment situation and damage to the vehicle from collision. Needed repairs also slightly vary between the front air bags and the curtain air bags. The following are the differences: Replacement parts when the front air bags deploy: the air bag units and their connection wires (connectors included), the seat belt pretensioners and their connection wires (connectors included), the entire front air bags, and the instrument panel (IP). Replacement parts when a curtain air bag deploys: the new curtain air bag for the deployed side, the air bag unit and its connection wires (connectors included), the collision G sensor assembly for the curtain air bag, and the trims and roof headlining for the broken parts.
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
21
DAB: Driver Air Bag

Preceding Work: Disconnect the negative battery cable. 1. Remove the air bag module assembly from steering wheel.
2. Disconnect all connectors and remove the air bag assembly.

STNG
Components Front View Rear View
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
Release the hook before disconnecting the connector.
A / BAG
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
10. SERVICING THE AIR BAG SYSTEM
22
8810
Contact Coil
Preceding Work: Disconnect the negative battery cable and remove the steering wheel. 1. Disconnect the connector of the contact coil.
2. Unscrew four screws and remove the contact coil. Place the contact coil at the center position when installing.
Align the arrows when installing.
Components
NOTICE
If the contact coil is not properly aligned, the steering wheel may not be able to rotate completely during a turning. Restricted turning ability may cause the vehicle to crash. Improper alignment of the contact coil also may make the SIR system inoperative, preventing the air bags from deploying during a crash. Turn the contact coil clockwise until it stops and turn it counterclockwise approx. 2.9 0.2 marks. turns to align the
AIR BAG SYSTEM

KYRON SM - 2005.09
8810 PAB: Passenger Air Bag
23
Preceding Work: Disconnect the battery nagative cable and remove the instrument panel assembly. (For details, refer to Body section.) 1. Remove the lower air duct from the removed instrument panel assembly.
2. Unscrew five nuts on the air bag module (10 mm).
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
24
8810
3. Remove the air bag module assembly from the instrument panel.
WARNING
The air bag module cannot be removed. Below picture is only for reference.
Components
Retainer
Air bag cushion
Inflator
Air bag module housing
AIR BAG SYSTEM

KYRON SM - 2005.09
8810 CAB: Curtain Air Bag
25
Preceding Work: Disconnect the battery negative cable and remove the instrument panel assembly. (For details, refer to Body section.)
1. Disconnect the connector of the curtain air bag while releasing the hook.
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
26
8810
2. Remove the handle bracket and then remove the curtain air bag assembly.
Components
AIR BAG SYSTEM

KYRON SM - 2005.09
8810 Air Bag Unit (SDM)

Preceding Work: Disconnect the negative battery cable. 1. Remove the center fascia, drivers lower panel, passengers lower panel and center console. (For details, refer to Body section.)
27
1. Center fecia (LH/RH) 2. Drivers lower panel
3. Passengers lower panel 4. Center console
2. Remove the AV head unit assembly. (For details, refer to AV System section.)
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
28
8810
3. Unscrew the screws on the instrument panel and remove the relevant components (power socket/shift lever cover).
Mounting Screw (Same at Both Sides)
Power Socket Cover Mounting Screw
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
4. Unscrew two screws and remove the lower center air duct.
29
Components
NOTICE
When an air bag deploys (curtain air bags and seat belt pretensioners included), the air bag unit must be replaced. Please do not attempt to delete the failure code with scan - I because some data about the deployment situation are stored in the unit. The air bag related components, especially the air bag unit, must be stored in a sealed case to prevent any damage. Please do not connect a tester to any air bag connector or single item to measure the supplied power or resistance. The detonator may explode due to a sudden extra power supplied by the tester. Before removing or installing any air bag related components, disconnect the negative battery cable.
A / CON
AIR BAG SYSTEM

KYRON SM - 2005.09
A / BAG
BRAKE
STNG
SP
AXLE
5. Disconnect the connector and remove the air bag unit.
CLUTCH
T/C
M / T
A/T
30
8810
Curtain Air Bag G Sensor

Preceding Work: Disconnect the negative battery cable. 1. Remove the B-pillar panel at both sides. Disconnect the connector and remove the G sensor. Installation Notice
Tightening torque 9 Nm 1 Nm
Passengers Side
NOTICE
The body panel has guiding holes to ensure its correction installation. But incorrect tightening torque may break the sensor or make it insecure. As a result, the sensor may have inaccurate judgment and have the air bag deployed inaccurately. Because the gap between the installation bolt and the sensor is small, grind the bolt-locking socket to around 1.5 mm before mounting the curtain air bag sensor fixation bolt.
Components
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
31
Trouble Code
1101
Defections
High battery voltage
Action
Check alternator output voltage. Check battery condition (over 21.4 V for 16 seconds). Check air bag unit terminals for damage. Check alternator output voltage. Check battery condition (below 7.2 V for 16 seconds, resumes when the voltage is normal level for 9.6 seconds) Check air bag unit terminals for damage. Check curtain air bag sensor connector. Check curtain air bag sensor wiring. Check air bag unit terminals for damage. Check if curtain air bag sensor is short to battery voltage or ground. Check if curtain air bag sensor is defective. Check battery condition (below 10.6 V for 16 seconds, resumes when the voltage is normal level for 9.6 seconds). Check driver air bag connector. Check driver air bag wiring (including clock spring). Check air bag unit terminals for damage. Resistance of squib: over 6.1 Check driver air bag connector. Check driver air bag connector (including clock spring). Check air bag unit terminals for damage. Resistance of squib: below 1.1 Check driver air bag connector. Check driver air bag wiring (including clock spring). Check air bag unit terminals for damage. Resistance of Firing Loop: below 2 k Check driver air bag connector. Check driver air bag wiring (including clock spring). Check the air bag unit terminals for damage. Resistance of Firing Loop: below 2 k Check passenger air bag connector. Check passenger air bag wiring. Check the air bag unit terminals for damage. Resistance of squib: below 0.8 Check passenger air bag connector. Check passenger air bag wiring. Check air bag unit terminals for damage. Resistance of squib: over 4.0 Check passenger air bag connector. Check passenger air bag wiring. Check the air bag unit terminals for damage. Resistance of Firing Loop: below 2 k
1102
Low battery voltage
1103
Low communication voltage for curtain air bag sensor
1346
Drivers air bag circuit resistance is too high
1347
Drivers air bag circuit resistance is too low
1348
Drivers air bag circuit is short to ground
1349
Drivers air bag circuit is short to battery voltage
1352
Passengers air bag circuit resistance is too low
1353
Passengers air bag circuit resistance is too high
1354
Passengers air bag circuit is short to ground
AIR BAG SYSTEM

KYRON SM - 2005.09
A/T
11. DIAGNOSIS
32
8810
Trouble Code
1355
Defections
Passengers air bag circuit is short to battery voltage
Action
Check passenger air bag connector. Check passenger air bag wiring. Check air bag unit terminals for damage. Resistance of squib: below 2 k Check driver pretensioner connector. Check driver pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: over 4.2 Check driver pretensioner connector. Check driver pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 0.8 Check driver pretensioner connector. Check driver pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 2 k Check driver pretensioner connector. Check driver pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 2 k Check passenger pretensioner connector. Check passenger pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: over 4.2 W Check passenger pretensioner connector. Check passenger pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 0.8 Check passenger pretensioner connector. Check passenger pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 2 k Check passenger pretensioner connector. Check passenger pretensioner wiring. Check air bag unit terminals for damage. Resistance of squib: below 2 k Check driver curtain air bag connector. Check driver curtain air bag wiring. Check the air bag unit terminals for damage. Resistance of squib: over 4.3 Check driver curtain air bag connector. Check driver curtain air bag wiring. Check the air bag unit terminals for damage. Resistance of squib: below 0.6
1361
Drivers pretensioner circuit resistance is too high
1362
Drivers pretensioner circuit resistance is too low
1363
Drivers pretensioner circuit is short to ground
1364
Drivers pretensioner circuit is short to battery voltage
1367
Passengers pretensioner circuit resistance is too high
1368
Passengers pretensioner circuit resistance is too low
1369
Passengers pretensioner circuit is short to ground
1370
Passengers pretensioner circuit is short to battery voltage
1378
Drivers curtain air bag circuit resistance is too high
1379
Drivers curtain air bag circuit resistance is too low
AIR BAG SYSTEM

KYRON SM - 2005.09
8810
Trouble Code
1380
33
Drivers curtain air bag is short to ground
1381
Drivers curtain air bag is short to battery voltage
1385
Passengers curtain air bag is short to battery voltage
1395
Air bag connector problem
1400
Drivers curtain air bag sensor problem Drivers curtain air bag sensor circuit is short to ground
1401
1402
Drivers curtain air bag sensor circuit is short to battery voltage Communication error in drivers curtain air bag
1409
AIR BAG SYSTEM

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
1384
Passengers curtain air bag is short to ground
AXLE
1383
Passengers curtain air bag circuit resistance is too low
CLUTCH
1382
Passengers curtain air bag circuit resistance is too high
Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 2 k Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 2 k Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance of squib: over 4.3 Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance of squib: below 0.6 Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 2 k Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 2 k Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. Check driver curtain air bag connector. Check driver curtain air bag wiring. Check the air bag unit terminals for damage. Resistance: below 250 Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 25 Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. If the voltage drops below 10.6 V during normal system operation, the trouble code is generated. This trouble code is linked with B1 400, B1 401, B1 402, B1 414.
T/C
M / T
A/T
Defections
Action
34
8810
Trouble Code
1414
Defections
Wrong drivers curtain air bag sensor Passengers curtain air bag sensor Passengers curtain air bag sensor circuit is short to ground
Action
Check driver curtain air bag connector. Check driver curtain air bag wiring. Check air bag unit terminals for damage. Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 250 Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Resistance: below 25 Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check the air bag unit terminals for damage. If the voltage drops below 10.6 V during normal system operation, the trouble code is generated. This trouble code is linked with B1 403, B1 404, B1 405, B1 415. Check passenger curtain air bag connector. Check passenger curtain air bag wiring. Check air bag unit terminals for damage. Replace SDM. Replace SDM. Replace SDM.
1403
1404
1405
Passengers curtain air bag sensor circuit is short to battery voltage Communication error in passengers curtain air bag
1410
1415
Wrong drivers curtain air bag sensor SDM internal fault Frontal impact record Drivers curtain air bag impact record Passengers curtain air bag impact record Belt pretensioner operation record Warning lamp error
1620 1650 1651 1652 1657 2500
Replace SDM. Replace SDM. Check wiring to warning lamp. Check warning lamp bulb. Check SDM unit terminal.
AIR BAG SYSTEM

KYRON SM - 2005.09
AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM ................. 2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. System layout and components ...................... 2 Ventilation system ............................................ 4 Air conditioner module wiring and layout ......... 5 Air conditioner controller (unit) ......................... 9 Self diagnosis (only for FATC air conditioner) 18 System diagram .............................................. 23 Sensors and actuators ................................... 24 Air quality system (AQS) ............................... 26 Air conditioner module sensors and actuators30 Removal and installation ................................. 40
FFH (FUEL FIRED HEATER) SYSTEM 61

1. 2. 3. 4. 5. 6. 7. Overview .......................................................... 61 FFH layout ...................................................... 62 Specifications ................................................. 64 FFH operating process ................................... 65 Components and functions ............................. 70 Removal and installation ................................. 75 Trouble diagnosis ............................................ 82
PTC (Positive Temperature Coefficient) SYSTEM .................................................. 86

1. 2. 3. 4. Overview .......................................................... 86 Components .................................................... 87 PTC operating process ................................... 88 Removal and installation ................................. 90
6810

1. SYSTEM LAYOUT AND COMPONENTS
Type Air Conditioner Controller
FATC
Manual air conditioner
Sun Sensor - Instrument Panel Upper Left
It changes sun load coming through front windshield into current to input to FATC controller.
AQS Switch
Compressor
AQS Sensor and Ambient Temperature Sensor AQS sensor
Ambient temperature sensor
A function that turns on/off the air source selection and air quality system.
KYRON SM - 2005.09
This sensor is installed at the front bottom of engine compartment. This changes the air source mode by detecting the air pollution.
6810
Front Air Conditioner Module Assembly - Inside of Instrument Panel

Heater Unit Side Coolant temperature sensor Air mix door actuator Air source door actuator
Air conditioner filter

CLUTCH
Power transistor Thermo AMP Air conditioner controller wire
Main wire
Bloor Unit Side

STNG
KYRON SM - 2005.09
Condenser
Installed in front of vehicle and condenses vapor refrigerant into low temperature and high pressure liquid refrigerant. Coolant Temperature Sensor (On Engine)
Receiver Drier (LH)
Engine ECU (Passenger Footstep)
* Absorbs moisture in the refrigerant and reserves refrigerant to supply smoothly.
* Detects A/C switch position, coolant temperature, engine condition and driving condition to control the air conditioner.
* A sensor that detects coolant temperature and transmits to engine ECU.
A / CON
A / BAG
BRAKE
SP
AXLE
Mode door actuator
T/C
M / T
A/T
6810
2. VENTILATION SYSTEM
Locations of Vents
Air Duct

KYRON SM - 2005.09
6810 Air Duct Layout
Front Air Conditioner Module Wiring Layout Coolant temperature detection sensor Mode door actuator Air source door actuator Power transistor
Main wire connector
Air mix door actuator
Intake sensor
Blower motor
Active incar sensor (interior temperature sensor) and humidity sensor Air conditioner controller unit

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
3. AIR CONDITIONER MODULE WIRING AND LAYOUT
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
6810
Air Conditioner Module And Sensors

Locations
Air Source Door Actuator Coolant Temperature Sensor Air Conditioner Filter
Mode Door Actuator
Intake Sensor
A/C Controller Unit
Interior Temperature Sensor (Interior Humidity Sensor) Power Transistor/Blower Motor
Power transistor
Interior temperature and humidity sensor

KYRON SM - 2005.09
Blower motor
6810
Components A/C filter Air source door case Blower unit case (upper)
Interior/Ambient door actuator Blower unit case (lower)
Blower motor assembly
Evaporator
Coolant temperature detection sensor
Power transistor Intake sensor A/C cable assembly
Heater unit case (right)

A / BAG
Air mix door actuator
Lower duct Heater core
Mode door
Heater unitcase (left)
Mode door link assembly
Mode door actuator

KYRON SM - 2005.09
A / CON
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
6810
PTC Heater and FFH Heater Layout

PTC Heater Assembly Layout
PTC
FFH Heater Assembly Layout

KYRON SM - 2005.09
6810
Functions of Full Automatic Air Conditioner Controller ( )

1 2 11 6 4
10
9
STNG
1. TEMP switch 2. AUTO switch 3. OFF switch
4. AMB switch 5. Mode switch 6. Blower switch
7. AQS switch 8. FRE switch 9. Defroster switch
10. A/C switch

BRAKE A / CON A / BAG
11. VFD (Display)

KYRON SM - 2005.09
SP
AXLE
CLUTCH
T/C
M / T
A/T
4. AIR CONDITIONER CONTROLLER (UNIT)
10
6810
Functions of Full Automatic Air Conditioner Controller (ll)

Temperature Control Switch and AUTO Button
When pressing the air conditioner AUTO mode and temperature control dial switch, the system operates in AUTO mode and can set the desired temperature (18 ~ 32C) by rotating. To get the desired temperature, the air conditioner controls compressor, door mode, air source door, air mix door and blower motor automatically.
Active Incar/Humidity Sensor (AIH Sensor)
The AIH sensor is installed on the air conditioner controller unit. It is a sensor that detects interior temperature and humidity.
Display Window (VFD)

Each switch mode appears as a symbol on the fluorescent display and malfunction of each sensor in air conditioner control system is also displayed.
AQS mode Defroster A/C operation Air flow direction
Auto mode Temperature (ambient air temperature, interior set temperature)
Fan speed
Indicates the ambient temperature is displayed

KYRON SM - 2005.09
Air recirculation Fresh air

6810 Fan Speed Control Switch and AMP Switch
11
When pressing this switch, the outside temperature measured by ambient temperature sensor comes on for 5 seconds and then returns back to preset temperature.
Mode Switch
By depressing this switch, the airflow mode is changed.
A/C Switch:
When pressing this switch, the air conditioner operates in manual mode and A/C ON indicator comes on.
The air flows towards face. (Vent mode) The air flows towards face and floor. (Bi-level mode) The air flows towards floor. (Foot mode) The air flows towards front windshield and floor. (Defrost and foot mode)
SP A / CON A / BAG
KYRON SM - 2005.09
A/C [OFF] Switch AQS System

Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected through AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears (refer to AQS and ambient temperature sensor).
Air Source Selection Switch

When pressing this switch, the air recirculates in the vehicle inside and indicator comes on. When pressing it again, the indicator goes off and the fresh air comes in. (However, under defroster mode or defroster/foot mode, it stays in the fresh air mode.)
Defroster Switch
When pressing this switch, the airflow direction will be changed to windshield and door glasses, the air conditioner operates automatically and outside air comes in. At this moment, the defroster indicator, air conditioner indicator and fresh air mode indicator come on. When pressing the switch again, the air conditioner returns back to normal operations.
When pressing the AUTO switch, the defroster mode appears on the VFD until the coolant temperature reaches at a certain level.
BRAKE
STNG
AXLE
CLUTCH
T/C
M / T
When controlling the fan speed by rotating this switch in AUTO mode, the mode is changed from AUTO to manual and the fan speed can be changed in 8 stages.
A/T
12
6810
Full Automatic Air Conditioner Controller
Interior temperature and humidity sensor

KYRON SM - 2005.09
6810
13
17
5 18 14 13 12 11 10 9 8 7
M / T
19
20
15 16
10
11
12
13 14
15 16
17
18
19
20
REC FRE FR/DEF FAN speed 0 FAN speed 1 FAN speed 2 FAN speed 3 FAN speed 4 FAN speed 5 FAN speed 6 FAN speed 7 FAN speed 8 MODE VENT MODE B/L MODE FOOT MODE D/F AUTO (AUTO A/C) A/C AQS AMB OFF (IGN ON) OFF (IGN OFF) TEMPDIAL

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
If the TEMP DIAL is set under 18.0C, this shows Lo. If it is set over 32.0C, this shows Hi.
A/T
Full Automatic Air Conditioner Controller Operation Table
14
6810
Full Automatic Air Conditioner Operations

This section describes the main operations of full automatic air conditioner.
Blower Motor Control

In AUTO mode, the blower motor automatically controls the fan in 33 levels according to the sensing conditions (e. g., ambient temperature and room temperature). In MANUAL mode, the blower motor controls the fan in 8 levels by the fan switch operation. Fan control in AUTO mode (33 levels) Control voltage
0V 4V 4.25 V 4.5 V 4.75 V 5V 5.25 V 5.5 V 5.75 V
Level
OFF 1 2 3 4 5 6 7 8
Level
9 10 11 12 13 14 15 16 17
Control voltage
6V 6.25 V 6.5 V 6.75 V 7V 7.25 V 7.5 V 7.75 V 8V
Level
18 19 20 21 22 23 24 25 26
Control voltage
8.25 V 8.5 V 8.75 V 9V 9.25 V 9.5 V 9.75 V 10 V 10.25 V
Level
27 28 29 30 31 32 33
Control voltage
10.5 V 10.75 V 11 V 11.25 V 11.5 V 11.75 V VACC
Fan control in MANUAL mode (8 levels)

8th level
1st level
Level Control voltage
1 4~ 4.75 V
2 5~ 5.75 V
3 6~ 6.75 V
4 7~ 7.75 V
5 8~ 8.75 V
6 9~ 9.75 V
7 10 ~ 10.75 V
8 11 ~ Battery voltage
Heating Start Control

In winter, when the engine coolant temperature is low or the hot wind has not been sufficiently generated, the airflow from the vent is not hot and so, not helpful to heating. The heating control is to restrain this airflow from releasing. Thus, before the coolant temperature reaches at 55C, the blower motor is set to first stage in Auto mode and the blower operating voltage increases by 0.075V/sec, following the increase of duct temperature. The air flow direction is in DEF mode (below 20C), D/F mode (20C~55C) and AUTO mode (55C). When the coolant temperature sensor is defective, the heating control function is cancelled after 500 seconds.
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15
Cooling Start Airflow Control

When the intake temperature sensor indicates over 35C, the voltage value increases by 1 V/sec with delay from 3 seconds after the compressor starts its operation. In the initial operation stage, the hot air is discharged to the windshield (DEF mode) for a specific period of time (approx. 5 seconds). This prevents the hot air from suddenly discharging to the front passengers.
Ambient Air Temperature Display

When the AMB button is pressed, the ambient temperature is displayed for 5 seconds. When the vehicle stops while driving, the ambient temperature before stop is displayed.
Amount of Sunload Compensation Control

The air flow is directed to VENT according to the amount of sunload. In VENT and B/L modes, the blower voltage increases within 2.5 V.
Recirculation Control
A. AUTO control: Fresh air, 20% of fresh air, Recirculated air B. MANUAL control: Fresh air, Recirculated air C. COMP OFF control: Fresh air (AUTO mode) D. PTC linked control: When PTC is activated, the recirculation door is fixed at 30% of fresh air position. When PTC is deactivated, it returns to previous mode. E. AQS control: In initial stage, the recirculation mode is activated for 35 seconds. After then AQS sensor converts the mode between recirculation and fresh air.
DEF Mode Compensation Control

In DEF mode, the voltage increases 2 V compared to that in AUTO mode. The voltage after compensation should not exceed 7 V.
Maximum Cooling/Heating Control

17.5C (Max.)
Mode Inside air/Ambient air Air mix Air conditioner Blower motor Foot Ambient air 100% OFF Hi
High Intake Air Temperature Delay Control

When the intake temperature sensor indicates over 35C, the voltage value increases by 1 V/sec with delay from 3 seconds after the compressor starts its operation.
32.5C (Min.)
VENT Inside air 0% ON Hi
COMP Control
- Intake air temperature control: COMP OFF when the thermo AMP temperature is below 2C, COMP ON when it is over 4C.

KYRON SM - 2005.09
A/T
16
6810
Manual Air Conditioner Controller

Manual air conditioner controller controls the fan speed, air distribution direction, air source selection and temperature control with motor actuators according to soft button and dial switch operations.
Fan Speed Control Switch

The fan speed can be adjusted in 4 stages.
A/C Switch
When the A/C switch is pressed, the indicator comes on and the air conditioner starts to operate. When the switch is pressed again, the air conditioner stops its operation and indicator goes out.
A/C operation indicator
Bi-level Mode
The air flows towards front windshield and floor and the indicator comes on.
Vent Mode
The air flows towards face and the indicator comes on.
Foot Mode
The air flows towards floor and the indicator comes on.

KYRON SM - 2005.09
6810
17
Temperature Control Switch

The temperature can be adjusted by rotating the switch. Counterclockwise direction (blue): Lower temperature Clockwise direction (red): Higher temperature
Lower temperature
Higher temperature
Air Source Selection Switch

When pressing this switch, the air recirculates in the vehicle inside and indicator comes on. When pressing it again, the indicator goes off and the fresh air comes in.
Recirculation indicator
Defroster Switch
When pressing this switch, the airflow direction will be changed to windshield and door glasses, the air conditioner operates automatically and outside air comes in. At this moment, the indicator comes on. When the defrosting is completed, press the switch to return to normal operations.
Defroster & Foot Mode

The air flows towards face and floor and the indicator comes on.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
18
6810
5. SELF DIAGNOSIS (ONLY FOR FATC AIR CONDITIONER)

Self Diagnosis
1. Starting Self Diagnosis
Turn the ignition switch to OFF position and press OFF switch for more than 5 seconds within 10 seconds.
1.
2) Check LED segments on the vacuum fluorescent display (VFD).
1) Press OFF switch more than 5 seconds.

KYRON SM - 2005.09
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19
2. Set in Trouble Diagnosis Step 2

In this step, check the air mix door and sensors for defect. Once the system starts diagnosis step 2, the digit 2 is displayed, implying step 2, on the display window and the trouble diagnosis for sensors is executed. If no failure exists, 20 is displayed. If any failure exists, the appropriate trouble code is displayed as below. 1) Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 2
2) Indication of Step 2. Starting self diagnosis
3) Sensor failure code blinking
NOTICE
The symbol "-" in front of step number "2" means a short circuit of the blinking sensor.
Short-circuit in the ambient air temperature sensor
First sensor failure code blinks twice
Second sensor failure code blinks twice
Trouble Code Code

0 1 2 3 4
Malfunction
VDF segments are OK Defective ambient temperature sensor Defective interior temperature sensor Defective duct temperature sensor Defective intake sensor
Remark
Code
5 6 7 8 9
Malfunction
Defective sun sensor Check Air mix door Defective humidity sensor -
Remark

KYRON SM - 2005.09
A / CON
-21
A / BAG
21
25
BRAKE
When two sensors are defective
STNG
SP
AXLE
10 ~ 20 seconds
21
CLUTCH
T/C
M / T
A/T
20
6810

In this step, check the position and conditions of recirculation air door and mode door. Slightly turn the TEMP switch until 3 is displayed on the display window. If no failure exists, "30" is displayed. If any failure exists, the appropriate trouble code is displayed.
1) Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 3
21
3
2) Indication of Step 2. Starting self diagnosis
30
3) Sensor failure code blinking (30: no failure)
Trouble Code Code

1 2 3 4 5
Malfunction
Defective VENT Defective B/L FOOT D/F
Remark
Code
6 7 8 9 0
Malfunction
DEF FRE 20% FRE REC All door OK
Remark

KYRON SM - 2005.09
6810 4. Set in Trouble Diagnosis Step 4

In this step, check the position of actuator door, check the fan speed, and check the compressor operation.
21
1) Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4
2)
Press
Press
41 30
Function Check Displayed Number
Mode door Interior/Ambient door Air mix door Blower Compressor
Press
42
Press
43
Press Press
41
VENT REC F/COOL 4.5 V ON
42
B/L REC F/COOL 10.5 V ON
43
B/L 20%FRE F/HOT 8.5 V OFF
44
FOOT FRE F/HOT 8.5 V OFF
45
D/F FRE F/HOT 8.5 V ON
46
STNG
DEF FRE F/HOT MAX ON
In this step, check the conditions of temperature related sensors. Slightly turn the TEMP switch in step 4 until 51 is displayed on the display window. When pressing DEF switch displayed temperature changes as shown below in turns.
1) Slightly turn to right to set in trouble diagnosis step 5. 2) Press Press Press
51
20 oC
Ambient air temperature
18.5 oC
Interior air temperature
18 oC 43
Intake air temperature

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
AXLE
46
45
44
CLUTCH
T/C
M / T
Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window. When pressing DEF switch ,mode changes as shown below in turns to check each function.
A/T
22
6810

In this step, the temperature can be compensated within the range of -3C to 3C in the control process according to the temperature to air conditioner controller. The step 6 initiates when slightly rotating the fan speed switch (other than TEMP switch) in step 5.
2) C o m p e n s a t e s the temperature by turning TEMP dial.
61
1) Starts the trouble diagnosis step 6 by turning fan speed dial.
61
Step 6
-3 oC
Min. temperature compensation value
Max. temperature compensation value
43
3 oC
7. Canceling the Trouble Diagnosis

Turn the AUTO switch ON or turn the ignition key OFF.

KYRON SM - 2005.09
6810
23
This figures shows the input and output system between A/C components and A/C controller.
User Control
Setting temperature
Power transistor
Fan speed control (Blower motor control)
Water temp. sensor Incar temperature Sun loads Air mix motor Air conditioner controller Temperature control
Environments
Mode motor Interior /Ambient motor
Air flow control Interior/Ambient control

SP A / CON A / BAG BRAKE STNG
AQS sensor Intake temp. sensor
Vehicle information
Vehicle speed
Engine ECM
Compressor control
Air Conditioner Compressor Control by Engine ECU

In case of current vehicle models, the system turns ON/OFF the compressor switch according to refrigerant pressure, ambient temperature and condenser temperature to protect air conditioner circuits. However, for the vehicle equipped with DI engine, the engine ECU turns off air conditioner compressor as below in addition to above conditions. 1. Coolant temperature: below -20C 2. Coolant temperature: over 115C 3. For approx. 4 seconds after starting the engine 4. When engine speed is below 650 rpm 5. When engine speed is over 4,500 rpm 6. During abrupt acceleration for the vehicle equipped with manual transmission

KYRON SM - 2005.09
AXLE
CLUTCH
Ambient temperature
T/C
M / T
A/T
6. SYSTEM DIAGRAM
24
6810
7. SENSORS AND ACTUATORS

Sun Sensor
It is installed on the upper left end of instrument panel. It is using characteristics that the amount of current changes according to amount of light on the photosensitive surface. Photo diode, converts the changes in light intensity into electrical changes, detects the amount of light coming through windshield and changes it into current and then sends the signal to FATC controller.
Inspection
1. Remove the sun sensor and measure the current between terminals under sunlight. 2. Measure the current again under shade. It is in normal conditions if the measured value is less than the measured value under sunlight. 3. Turn the ignition switch to ON position. 4. Measure the voltage to the sun sensor from FATC connector. (approx. 2.5 V under sunlight and 4.8 V under shade.) 5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller.

KYRON SM - 2005.09
6810
25
Active Incar/Humidity Sensor: AIH Sensor

The AIH sensor is installed at the driver side instrument panel undercover. It is a sensor that detects interior temperature and humidity.
Active incar sensor (interior temperature sensor)
Functions
Incar temperature sensor This sensor is a negative temperature coefficient (NTC) thermistor and detects the interior temperature with air coming from senor hole and then sends the voltage value according to the changed resistance to FATC controller. Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Humidity sensor
STNG
SP
AXLE
CLUTCH
T/C
Location
M / T
A/T
26
6810
8. AIR QUALITY SYSTEM (AQS)

Components of AQS
AQS sensor and ambient temperature sensor AQS sensor
Ambient temperature sensor Connector
AQS Operation
1. Air Quality System (AQS) changes the air source selection to recirculation mode when polluted air is detected through AQS sensor. The air source selection returns back to fresh air intake mode after a specified period or the polluted air disappears.
Press the AUTO switch

KYRON SM - 2005.09
6810
27
2. When pressing the AQS switch, the AQS indicator on display window comes on, and the air source selection is automatically changed to recirculation mode (REC). At this moment, the self diagnosis and preheating mode of AQS is performed for 35 seconds.
AQS indicator comes on Changed to recirculation mode from fresh air mode
AQS switch
SP
NOTICE
When pressing DEF switch during in this process, the AQS indicator goes out and the air source selection is changed to fresh air mode from recirculation mode. When pressing the AQS switch again, the self diagnosis and preheating mode of AQS operates only for the remaining time.
3. After the self diagnosis and preheating mode of AQS is completed, the AQS system operates according to the air pollution. If the air pollution is not serious, the AQS system changes the air source selection to fresh air mode. 4. Although turning off the air conditioner while the AQS is in operation, the AQS stays ON (indicator on). However, if the air conditioner is turned on by turning the ignition switch ON from OFF, the AQS stops its operation and the indicator goes out and the display window shows the initial screen.
NOTE
If the AQS switch is pressed in, the AQS function works regardless of air conditioner controller operation.
KYRON SM - 2005.09
AXLE
CLUTCH
T/C
M / T
A/T
28
6810
5. The modes available AQS function: 1) AUTO mode 2) Fan speed control dial operation mode 3) A/C switch operation. At this mode, the AQS system operates according to the AQS switch operation.
NOTICE
If the ignition switch is turned off with AQS ON, the AQS is turned on when turning the ignition switch on again.
AUTO A/C ON (TEMP switch ON) Adjusting fan speed control dial Mode change (MODE switch)
Pressing AQS AUTO A/C ON (TEMP switch ON) switch AQS ON
Adjusting fan speed control dial

Pressing AQS switch Mode change (MODE switch) AQS OFF
Memory return
(when system OFF)
6. The AQS is turned off, 1) When pressing the defroster switch 2) When pressing the recirculation mode switch

KYRON SM - 2005.09

1. Disconnect the negative battery cable and remove headlamps.
29
AQS sensor
Connector

KYRON SM - 2005.09
A / CON
A / BAG
2. Disconnect the AQS sensor connector, unscrew two bolts (10 mm) and remove the AQS sensor assembly. (Install in the reverse order of removal.)
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
30
6810
9. AIR CONDITIONER MODULE SENSORS AND ACTUATORS

Water Temperature Sensor
Water temperature Sensor
Inspection
If the water temperature sensor defect code (DTC 3) is set, check as below. 1. Remove the water temperature sensor and measure the resistance between terminals on the sensor connector. (standard: approx. 25C, 2.2 k) In addition, if the resistance is extremely high or low, replace the sensor. 2. If the measured value is out of the specified range, replace the water temperature sensor. If the measured value is within the specified range, check as below. 3. Turn the ignition switch to ON position and measure the voltage to water temperature sensor from the FATC controller connector. (standard: approx. 2 V at 25C) 4. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller.

KYRON SM - 2005.09
6810
31

Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.
The water temperature sensor should be removed after removing the air conditioner module assembly. 1. Disconnect the connector from the removed A/C module assembly and then remove the bracket screw on heater pipe.
T/C A / CON
KYRON SM - 2005.09
2. Remove the heater pipe bracket and separate the water temperature sensor from bracket.
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
M / T
A/T
32
6810
Power Transistor
The power transistor controls the fan speed. It controls the blower motor operating speed without stages by changing the current value to the base of power transistor when receiving the fan control signal from FATC.
Air conditioner power transistor
Inspection
If the power transistor defect code (DTC 6) appears, check as below. 1. Turn the ignition switch to ON position. 2. Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6. 3. The specified voltage value in each stage: Stage Blower (V) Stage 1
4.5
Stage 2
6.0
Stage 3
7.5
Stage 4
9.0
Stage 5
11
Stage 6
Max HI
4. If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the power transistor.
6810
33

Preceding Work: Disconnect the negative battery cable.

KYRON SM - 2005.09
A / CON
A / BAG
2. Unscrew the mounting screws and remove the power transistor.
BRAKE
STNG
SP
AXLE
CLUTCH
1. Remove the lower instrument panel in front of passenger seat and disconnect the power transistor connector.
T/C
The power transistor should be removed after removing the lower instrument panel in front of passenger seat. (For removal and installation of the lower instrument panel, refer to the "Body" section.)
M / T
A/T
34
6810
Mode Door Actuator

The mode door actuator is an actuator that closes, opens and adjusts the mode door for VENT, FOOT and DEF mode to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed.
The air flows towards face. (Vent mode)
The air flows towards face and foot. (Bi-level mode)
The air flows The air flows towards towards foot. front windshield and foot. (Foot mode) (Defroster and foot mode)
Mode door actuator

KYRON SM - 2005.09
6810
35

Preceding Work: Disconnect the negative battery cable. First remove the driver side instrument lower panel in order to remove and install mode door actuator. For removal and installation of the panel, refer to BODY section. 1. Remove the lower instrument panel in front of driver seat. Disconnect the mode door actuator connector and remove two mounting screws.
Bi-level
Windshield mode door lever

Vent
Defroster and foot
Foot
Foot mode door lever
NOTE
Make sure that the mode door link mounted on the air conditioner module assembly. When installing, if the location of the mode door link is not correct, may not operate properly.

KYRON SM - 2005.09
A / CON
Face mode door lever
A / BAG
BRAKE
2. Separate the mode door actuator and remove the mode door link assembly.
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
36
6810
IN/EX - Air Door Actuator

The air source door actuator sets the intake door mode according to the control signal from FATC.
In/ex air actuator component
In/ex air door actuator location

Preceding Work: Disconnect the negative battery cable and then remove the instrument panel assembly. Remove the drivers instrument lower panel and then disconnect the connection connector of the mode door actuator and the mounting screws (2EA). Remove the in/ex air door actuator.

KYRON SM - 2005.09
6810
37
The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according to the control signals from FATC.
Air mix door actuator component

CLUTCH
Air mix door actuator location
Preceding Work: Disconnect the battery negative cable and remove the instrument panel assembly. With the instrument panel assembly removed as shown in the above figure, disconnect the air mix door actuator and unscrew two mounting screws to remove the air mix door actuator.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
T/C
M / T
A/T
Air Mix Door Actuator
38
6810
Intake Temperature Sensor

The Intake Sensor outputs the compressor ON or OFF signal to ECU to prevent evaporator from freezing. The sensing part of the thermistor is the evaporator fin contact type.
Intake Sensor location
Intake Sensor
If the air conditioner does not turn on, check as below. 1. Remove the Intake Sensor and measure the voltage between terminal No. 1 and 2 on the connector. 2. Check whether the output voltages (ON: approx. 12 V, off: 0 V). 3. If the voltage value is out of the specified value, replace the Intake Sensor. If the circuit is in normal condition, check as below. 4. Turn the ignition switch to ON position and turn on the air conditioner by pressing the A/C button. And measure the voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V) 5. If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller.

KYRON SM - 2005.09
6810
39

Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly. 1. Unscrew three mounting bolts (10 mm) on air conditioner module assembly and remove the sensor wire of air conditioner module. Separate the blower unit from the heater unit.
Heater unit side
Mounting Bolt at Bottom of A/C Module

SP
2. Separate the upper case and lower case of blower unit and remove the Intake Sensor from the evaporator.
Intake Sensor
Evaporator

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
AXLE
CLUTCH
Blower unit
T/C
M / T
A/T
40
6810

Air Conditioner Module Assembly
Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly. 1. Collect the air conditioner refrigerant before removing the air conditioner module. (dispose the wasted refrigerant to designated place) 2. Drain radiator coolant. 1. Disconnect the heater hose (A) from the engine compartment and remove the A/C high/low pressure pipe mounting nuts.
A. Inner/outer heater hose and clamp
* Remove the mounting nut and loosen the coolant reservoir.
B. A/C joint pipe mounting nut

KYRON SM - 2005.09
6810
41
2. Unscrew four mounting screws on A/C module assembly (in engine compartment).
Behind vaccum pump: 1
3. Carefully remove the A/C module assembly.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Behind FFH pump: 3
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
42
6810
A/C Module Mounting Location
Mounting locations inside of vehicle
Mounting locations on backide of A/C module
Front View

KYRON SM - 2005.09
6810
43
Preceding Work: Disconnect the negative battery cable and remove the center fascia panel assembly.
1. With the center fascia panel removed, unscrew two mounting screws from the A/C controller switch assembly.
3. Remove the A/C controller switch assembly.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
2. Disconnect the connectors from the A/C controller switch assembly.
SP
AXLE
CLUTCH
T/C
M / T
Air Controller Switch Assembly
A/T
Air Controller Switch And Active Incar/Humidity Sensor
44
6810
Active In-Car/humidity Sensor

Disconnect the sensor connector, unscrew two mounting screws, and remove the sensor from the air conditioner controller switch.
Disconnect Connector
Active in-car sensor/ humidity sensor
Remove Mounting Screw

KYRON SM - 2005.09
6810
45
Air Duct (On Instrument Panel)

Preceding Work: Disconnect the negative battery cable and remove the instrument panel assembly.

KYRON SM - 2005.09
A / CON
1. Unscrew the mounting screws (one at each side and four in center area) and remove the front air duct.
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Air Duct Assembly
46
6810
2. Unscrew the mounting screws (one at each side) and remove the left and right air ducts.
3. Unscrew the mounting screws (one at each side) and remove the upper air duct.

KYRON SM - 2005.09
6810
47
Preceding Work: 1. Disconnect the negative battery cable and remove the center fascia panel and center lower panel. 2. Remove the center console assembly.
Floor Air Duct

T/C
1. Unscrew two center mounting screws in floor air duct. 2. Unscrew the mounting bolts and remove the air duct.
Vehicle with Foot Parking Brake
Mounting Screws
Lower Air Duct Assembly

STNG
Vehicle with Hand Parking Brake

A / CON

KYRON SM - 2005.09
A / BAG
BRAKE
SP
AXLE
CLUTCH
M / T
A/T
Floor Air Duct
48
6810
Front Floor Air Duct

1. Driver side lower air duct is installed behind the lower instrument panel. Remove it according to the procedures for removal of lower panel.
Air conditioner module assembly
Floor air duct (LH)
Floor air duct (RH)
Floor air duct
2. Passenger side floor air duct is located under the air conditioner module.
Mounting screw

KYRON SM - 2005.09
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49
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KYRON SM - 2005.09
A / CON
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
A / BAG
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
BRAKE
STNG
SP
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
AXLE
CLUTCH
T/C
M / T
A/T
MEMO
50
6810
Vent Grille Assembly

Preceding Work: Disconnect the negative battery cable. The vent center grille and the vent side grille should be removed after removing the relevant panel.
Side Vent Grille

The driver side vent grille is located on the outside mirror switch bezel assembly.
Removal/Installation
Unscrew four mounting screws and remove the vent grille assembly.
Left side vent grille
Front Vent Grille

Front vent grille is mounted on the instrumetn panel with one screw. Unscrew the mounting screw and pull the vent grille out of the instrument panel.

KYRON SM - 2005.09
6810
51
Center vent grille is mounted on the center facia panel with four screws (two at each side).
Center vent grille
1. Unscrew the mounting screws with the front air duct removed.
STNG
Right side vent grille
Right side vent grille
2. Pull the vent grille out of instrument panel.

KYRON SM - 2005.09
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SP
Side Vent Grille
AXLE
CLUTCH
T/C
M / T
A/T
Center Vent Grille
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6810
Condenser Assembly
Preceding Work: 1. Collect the A/C refrigerant. 2. Remove the front bumper assembly. 3. Drain the coolant (Store the collected A/C refrigerant and coolant into the designated container.)

1. Remove the air cleaner duct. (Unscrew two mounting screws, release the cleaner hose clamp and remove the duct.)
2. Remove the pipes from the radiator oil cooler for automatic transmission. Installation Notice

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53
3. Remove the right and left hoses from the inter cooler.
LH RH
4. Remove the inlet/outlet hoses and return hose from the radiator.
Radiator Inlet Hose Return Hose
5. Remove the air conditioner hose and pipe at condenser side.

High-pressure Pipe: Compressor Side Low-pressure Pipe: Receiver Dryer Side
Plug the pipe openings with a seal caps after disconnecting the high/ low pressure pipes.

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SP
AXLE
CLUTCH
T/C
M / T
A/T
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6810
6. Disconnect the ambient temperature switch connector and the AQS sensor connector and remove the ambient temperature switch.
7. Unscrew three mounting bolts (10 mm) and remove the hood latch mounted on the front end panel and support panel.
8. Unscrew the mounting bolt (10 mm) and remove the front support panel.

KYRON SM - 2005.09
6810
9. Unscrew four bolts and remove the radiator mounting bracket.
55
11. Remove the mounting clips and remove the radiator assembly.
BRAKE

KYRON SM - 2005.09
A / CON
A / BAG
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
10. Unscrew three mounting bolts (10 mm) and then remove the front end panel.
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6810
12. Remove the outlet pipe from the inter cooler.

Remove Two Mounting Bolts (10 mm).
13. Unscrew the upper and lower mounting bolts (10 mm) and remove the inter cooler from the radiator.
Inter Cooler Assembly

KYRON SM - 2005.09
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14. Remove the oil cooler pipes for automatic transmission from the radiator assembly.
57
15. Unscrew five mounting bolts (10 mm) and remove the air conditioner condenser assembly.

KYRON SM - 2005.09
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STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
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6810
Receiver Dryer Assembly

Preceding Work: 1. Disconnect the negative battery cable. 2. Collect the air conditioner refrigerant. 1. Disconnect the connector from the receiver dryer.
2. Unscrew the mounting nuts on the receiver dryer and remove the high/low pressure pipes.
The oil rings on the pressure pipes should be replaced with new ones once removed.
3. Unscrew the mounting bolt and remove the receiver dryer.

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59
Preceding Work: Disconnect the negative battery cable and collect the air conditioner refrigerant. 1. Remove the cooling fan belt from the engine.
2. Disconnect the connector from the compressor.

KYRON SM - 2005.09
A / CON
3. Unscrew the flange nuts of pressure pipes and compressor mounting bolts and remove the compressor assembly.
Tightening torque: 16 ~ 23 Nm Tightening torque: 16 ~ 23 Nm
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Compressor Assembly
60
6810
Piping Layout of Air Conditioner and Heater

Joint pipe assembly Liquid pipe Heater inlet hose
Heater outlet hose Receiver drier Compressor Liquid hose
Suction hose
Discharging hose
A/C condenser assembly
Joint pipe assembly
Liquid pipe Suction hose
Receiver drier
Liquid hose

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61
1. OVERVIEW
The system is to increase the coolant temperature quickly by firing diesel fuel in the burner that is installed in engine cooling system when in winter time the ambient temperature and engine coolant temperature is low. (Option) The DI engine equipped vehicle has the Positive Temperature Coefficient (PTC) system as a basic equipment. FFH is operated by the coolant temperature and ambient temperature while PTC is operated by the coolant temperature intake air temperature. FFH system consists of independent fuel lines and fuel pump, coolant circuit and coolant circulation pump, electrical glow plug and exhaust system. It also provides the diagnostic function. FFH system cannot be operated or stopped by drivers intention. The FFH system is automatically operated by the coolant temperature and the ambient temperature. The FFH system operates up to more 2 minutes to burn the residual fuel inside the system when stopping the engine during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction.
Components Locator
Diagnostic connector
Ambient temperature switch
FFH Fuel pump
FFH

KYRON SM - 2005.09
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FFH (FUEL FIRED HEATER) SYSTEM
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6910
2. FFH LAYOUT
Components
1. FFH assembly 2. Water pump and bracket assembly 3. FFH bracket assembly 4. FFH water pump bracket 5. FFH NO.3 inlet hose 6. FFH NO.2 inlet hose
7. FFH pipe assembly & silencer 8. Ambient temperature switch 9. FFH fuel pump 10. Fuel pump bracket 11. Fuel pipe NO.1 12. Fuel pipe NO.2
13. Fuel pipe NO.3 14. Tube clip mounting 15. Tube clip mounting 16. Intake hose 17. Clamp 18. FFH NO.1 inlet hose

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1. Jacket 2. Jacket cover 3. Combustion air fan 4. Combustion chamber 5. Combustion chamber with flame tube 6. Heat exchanger 7. Controller 8. Seal (between combustion chamber and combustion air fan) 9. O-ring 10. Glow plug with cable 11. Seal (between combustion chamber and heat exchanger) 12. Upper bush for fuel pipe 13. Lower bush for fuel pipe 14. Flame sensor 15. Bush for flame sensor (graphite) 16. Control and overheating sensor with cable 17. O-ring
18. Surface sensor with cable 19. Controller connector - 14-pin connector (waterproof) 20. Pressure spring for surface sensor 21. Pressure spring for control and overheating sensor 22. O-ring 23. Coolant hose (inlet) 24. Coolant hose (outlet) 25. Tooth ring (2x) 26. Cable harness cover 27. Rubber seal 28. O-ring 29. Screw (M4 x 55 TORX / 2x) 30. Screw (M4 x 16 TORX / 2x) 31. Screw (M4 x 12 TORX / 2x) 32. Screw (M4 x 16 TORX / 4x) 33. Screw (M4 x 44 TORX / 4x) 34. Controller cable harness 35. Insulation washer

KYRON SM - 2005.09
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SP
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CLUTCH
T/C
M / T
A/T
Exploded View
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6910
3. SPECIFICATIONS
Heater
Heating medium Control of the heat flow Heat flow Fuel consumption per hour Mean electric power consumption In operation At start After-running Rated voltage * Lower voltage limit: An undervoltage protection device in the controller switches the heaters off at approx. 10 volt. * Upper voltage limit: An overvoltage protection device in the controller switches the heaters off at approx. 15 volt. Tolerable operating pressure Minimum water flow through the heater Fuel Tolerable ambient temperature Operation Storage Weight (without coolant and water pump & bracket) Large (full load) 5,000 W approx. 0.63 Liter 35 W 100 W 12 W 12 V 10 V 15 V up to 2.5 bar overpressure 300 L/H In the main fuel tank (fuel) - 40C ~ 80C -40C ~ 125C approx. 2.3 kg
D5S-H
Coolant Small 2,300 W approx. 0.28 Liter 11 W

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Operating Condition
FFH is operated according to the ambient temperature and coolant tempreature.
Initial Operating Conditions of FFH

Initial Operating Conditions of FFH: Ambient temperature: below 5C Coolant temperature: below 75C Repeated Operating Conditions of FFH: Coolant temperature: below 75C When the difference between the ambient temperature at initial operation and current ambient temperature is over 3C (to reduce the hysteresis with the temperature difference when operating FFH), FFH is operated again. For example, if the initial operating temperature was 4C, the ambient temperature at repeat operation should be below 1C and the coolant temperature should be below 75C.
CLUTCH A / CON A / BAG BRAKE STNG SP AXLE T/C
FFH Operations According To the Changes of Coolant Temperature
75
Water temp. outlet
Above graph shows the FFH control process while the FFH is operating. The control element is coolant temperature as shown in the graph. The FFH is operated in HI mode (high output: approx. 5,000 W) until the coolant temperature reaches at 80C and starts to be operated in LO mode (low output: approx. 2,300 W) from 81C. When the coolant temperature reaches at approx. 85C, FFH stops its operation until the operating conditions will be met again.

KYRON SM - 2005.09
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A/T
4. FFH OPERATING PROCESS
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6910
Coolant Circulating Route
Water pump Fan Engine
Front
Heater Blower fan Heater module Heating system
Connecting the Coolant Circuit

The heater is connected to the coolant circuit in the coolant feed pipe from the vehicle engine to the heat exchanger. NOTICE
Parts conveying coolant must be routed and fastened in such a way that they pose no temperature risk to person or material sensitive to temperature from radiation and direct contact. Before working on the coolant circuit, disconnect the negative battery cable and wait until all components have cooled down completely. When installing the heater and the water pump, note the direction of flow of the coolant circuit. Fill the heater and water hoses with coolant before connecting to the coolant circuit. When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts. Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures. Secure all hose connections with hose clamps.

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The FFH has various sensors in FFH unit, and the FFH unit is connected to the water pump, the fuel circulation pump and the ambient temperature sensor (switch) that provides important signals for the initial and repeat operations.

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STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Circuit Diagram
68
6910
Control and Safety Mode

Heater Operations and Safety Mode
1. If the fuel pump fails to ignite within 90 seconds after fuel pumping starts, the start procedure is repeated as described. If after a further 90 seconds fuel pumping the fuel pump still fails to ignite, the heater is switched off in fault mode. The controller is locked after a certain number of failed starts. 2. If the flame does out by itself during operation, firstly a new start is activated. If the fuel pump fails to ignite within 90 seconds after fuel pumping has started again, the heater is switched off. 3. If the heater is overheated (lack of water, poorly vented cooling circuit), the overheating sensor triggers, the fuel supply is interrupted and the heater is switched off. 4. The heater is switched off if the lower or upper voltage limit is reached. 5. The fuel pump does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted. 6. The fan motor speed is monitored continuously. If the fan motor does not start up, is blocked or if the speed falls below 40% of the nominal speed, the heater is switched off in fault mode after 120 seconds. 7. It is possible to diagnose the system by connecting the diagnostic device to controller. For details, refer to the Diagnosis Procedures section. [EMERGENCY SHUTDOWN]
If an emergency shutdown -EMERGENCY OFF- is necessary during operation, proceed as follows; Pull the fuse (Ef6: 20A) out. Disconnect the heater from the battery.
Specification - Water Pump

Rated voltage Operating voltage Power consumption Pumping capacity (0.1 bar) Operating temperature Weight 12 V 9 V ~ 15 V 16 W 800 l/h - 40C ~ 135C 0.28 kg
Characteristic Curve of Water Pump (12 V)

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KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
Switching Diagram According to Temperature Changes
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
Function Diagram
70
6910
5. COMPONENTS AND FUNCTIONS

NOTICE
There is no need to disassemble the FFH unit for repair. This section is to show the internal components of the FFH unit.
Jacket cover
1. The O-rings are installed between jacket cover and two coolant hoses. 2. The coolant hoses should be connected to right side. 1) Jacket 2) Jacket cover 3) Cable harness cover
Control and overheating sensor

1. The Control and overheating sensor and cable harness make up one component. 1) Control and overheating sensor 2) Mounting spring
Check controller and overheating sensor

Check the control and overheating sensor with a digital multimeter. If the resistance according to the changes of flame. sensor temperature is out of specified values, the flame sensor is defective.
Resistance []
Temperature [C]
Specified value
Temperature [C] Resistance [W] 0 10 20 30 8.06 40 5.33 50 3.60 60 2.48 70 1.75 80 1.25 90 0.91 100 0.67 110 0.50 120 0.38
32.54 19.87 12.48

KYRON SM - 2005.09
6910 Surface Sensor

1. The surface sensor and cable harness make up one component. 1) Surface sensor 2) Mounting spring
71
Check Surface Sensor

Check the surface sensor with a digital multimeter. If the resistance of flame sensor is out of specified values, the flame sensor is defective.
Resistance []
Temperature [C]
Specified value
Temperature [C] Resistance [W] 0 10 20 30 8.90 40 6.20 50 4.41 60 3.19 70 2.34 80 1.75 90 1.32 100 1.02 120 0.62
Controller
The surface heater and cable harness make up one component. 1) Controller 2) Jacket 3) Combustion chamber housing 4) Mounting screw

KYRON SM - 2005.09
A / CON
30.00 19.53 13.03
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
72
6910
Glow Plug
1) Glow plug 2) Combustion chamber with flame pipe
Combustion Chamber Housing

1) Jacket 2) Combustion chamber housing 3) Insulation washer 4) Seal - combustion chamber / combustion air fan 5) Seal - combustion chamber / heat exchanger
Flame Sensor
1) Flame sensor 2) Graphite bush 3) Bush

KYRON SM - 2005.09
6910 Check Flame Sensor

Resistance []
73
1. Jacket 2. Combustion chamber 3. Combustion chamber housing 4. Insulation washer 5. Seal - combustion chamber / combustion air fan 6. Seal - combustion chamber / heat exchanger
Temperature [C]
-50
10
20
30
50
80
90
100
130
150
200
250
300
350
400
Resistance [W] 803 1000 1022 1062 1097 1194 1309 1347 1385 1498 1573 1758 1941 2120 2297 2470
SP
1) Combustion chamber 2) O-ring 3) Rubber seal 4) Combustion air fan 5) Screw
Combustion air fan

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
Combustion Air Fan
AXLE
Specified value
CLUTCH
Temperature [C]
T/C
M / T
Check the surface sensor with a digital multimeter. If the resistance of flame sensor is out of specified values, the flame sensor is defective.
A/T
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6910
Combustion Chamber
1) Combustion chamber 2) Heat exchanger 3) Jacket 4) O-ring 5) Seal - combustion chamber / heat exchanger
Heat Exchanger
1) Jacket 2) Combustion chamber with flame tube 3) Heat exchanger 4) Seal - combustion chamber / heat exchanger 5) O-ring (for heat exchanger)
Heat Exchanger
1) Heat exchanger 2) Jacket 3) Stopper 4) Groove (bottom of heat exchanger)

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Preceding Work: Disconnect the negative battery cable. NOTICE

The FFH is an auxiliary device that automatically operates or stops according to the coolant temperature and the ambient air temperature. In initial operating stage, the fuel pump generates the operating sound and the FFH heater produces white smoke. These are normal states to fill the fuel into the FFH fuel line. After replacing the FFH related components, fill up the system with fuel.
Fuel Pump
3. From Fuel Tank

STNG
4. FFH Fuel Pump
2. Wiring
Fuel tank
FFH

KYRON SM - 2005.09
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A / BAG
1. To FFH
BRAKE
SP
AXLE
CLUTCH
T/C
M / T
A/T
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6910
1. Disconnect the fuel pump connector with the vehicle lifted.
2. Disconnect the fuel hose from fuel pump.
3. Unscrew the bracket mounting bolt (10 mm) and remove the fuel pump assembly.
NOTICE
Plug the hose opening with a seal cap to prevent oil leakage

KYRON SM - 2005.09
6910 Ambient Temperature Switch

Preceding Work: Disconnect the negative battery cable and remove the right headlamp.
77
1. Remove the ambient temperature sensor from holder. 2. Disconnect sensor connector while pushing the connector pin.

KYRON SM - 2005.09
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A / BAG
BRAKE
* The ambient temperature switch should be removed after removing the headlamp.
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
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6910
FFH Assembly
FFH Assembly
FFH Coolant Circulation Pump Assembly

KYRON SM - 2005.09
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1. Disconnect the FFH coolant circulation pump (A) connector and FFH connector (B).
79
NOTICE
STNG
Plug the hose openings with seal caps to prevent oil leakage.
3. Unscrew the hose clamps on the FFH coolant circulation pump and remove the inlet and outlet hoses.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
SP
2. Remove the hose and pipe from the fuel pump.
AXLE
CLUTCH
T/C
M / T
A/T
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6910
4. Unscrew five bracket nuts (10 mm) and remove the FFH coolant circulation pump assembly. 1) Unscrew three mounting nuts at bottom of coolant reservoir. FFH Assembly
2) Unscrew the mounting nuts from the FFH coolant circulation pump.
Front Mounting Nut FFH Exhaust Pipe Side

KYRON SM - 2005.09
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5. Fuel feeding operation should be performed after replacing FFH assembly or fuel lines.
Fuel Feeding Operation
81
Otherwise, FFH system could make white smoke with abnormal noise.
1. Connect the ambient temperature switch connector as shown in picture (A). 2. Check if the fuel comes out after engine started as the FFH fuel supply hose is disconnected. (Picture B)
3. If the fuel is sprayed out, connect the fuel pipe to FFH assembly and keep the engine running for 1 minute. 4. Connect the ambient temperature switch connector.
Picture A

KYRON SM - 2005.09
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AXLE
CLUTCH
T/C
M / T
NOTICE
Picture B
A/T
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6910
FFH Heater Trouble Diagnosis Precedure
Connect Scan-100 to the diagnostic connector located at the lower instrument panel.
1. Select [KYRON] in [VEHICLE SELECTION].
2. Select FFH (FUEL FIRED HEATER) in [CONTROL UNIT SELECTION]. 3. Select the trouble code out of check items.

KYRON SM - 2005.09
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Trouble Code
0 10 11 12 14
83
No faults Shutdown for overvoltage Shutdown for undervoltage Overheating (abnormal reference value) Overheating (difference evaluation-1)
M / T A / CON
KYRON SM - 2005.09
Measure battery voltage (must be < 15.9V). Check alternator and overvoltage. Measure battery voltage (must be > 10.2V under load). Check alternator, wiring and undervoltage. Temperature at overheating sensor > 125C: check cooling system. Check temperature sensor and overheating sensor, replace if necessary. Difference in temperature values between surface sensor and control overheating sensor is too large. (Prerequisite for this trouble code display is that the heater is in operation and the water temperature at the overheating sensor has reached min. 80C): check cooling system. Check temperature sensor and overheating sensor, replace if necessary Heater does not operate (The controller is locked.) Delete trouble code to release controller lock: check cooling system. Check temperature sensor and overheating sensor, replace if necessary If the surface sensor has a far higher temperature value than the control overheating sensor, then the system proceeds with a fault shutdown. Temperature at control overheating sensor > 130C: check cooling system Check temperature sensor and overheating sensor, replace if necessary. Check plug cable for damage, replace if necessary Check plug cable for damage, replace if necessary Check plug cable for damage, replace if necessary Check the communication line. Defective fan wheel or combustion air fan motor (frozen, contaminated, stiff, damaged cable) Check cable harness for damage, replace if necessary. Defective fan wheel or combustion air fan motor (contaminated, stiff) Check cable harness for damage, replace if necessary. Check the ground and short of combustion air fan motor circuit, replace if necessary. Check connector. Check connector. -
15
Overheating (abnormal heater operation)
16
Overheating (difference evaluation-2)
17
Overheating (defective hardware-2)
20 21 22 23 24 25 30 31 32
Open glow plug circuit Overload or short circuit of glow plug Short circuit of glow plug Short circuit of communication line Abnormal speed of combustion fan motor Defective combustion fan motor Overload or short circuit of combustion fan motor0 Abnormal output of combustion fan motor Abnormal water pump operation Overload or short circuit of water pump Abnormal output of water pump
34 36 38 39 41 42 43
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
Trouble Description
Remedies
84
6910
Trouble Code
47 48 49 50 51
Trouble Description
Overload or short circuit of fuel pump Abnormal fuel pump operation Short circuit of fuel pump (B+) Improper operation Delayed heating time
Remedies
Check cable harness for damage, replace if necessary. Check cable harness for damage, replace if necessary. Check plug-in connection, replace if necessary. Check cable harness for open to battery voltage, replace if necessary. The controller is locked due to excessive starting problem. During start (no flame formed yet), the flame sensor reports temperature value too high for too long, check exhaust gas, combustion air and flame sensor. Check exhaust gas and combustion air. Check fuel quantity and fuel supply. Clean or replace filter in fuel pump. Fault (no more starting attempt allowed ). Check exhaust gas and combustion air system. Check fuel quantity and fuel supply. Check flame sensor - see trouble code 64 and 65. Fault (no more starting attempt allowed ). Check exhaust gas and combustion air system. Check fuel quantity and fuel supply. Check flame sensor - see trouble code 64 and 65. Check cable harness for damage, check plug-in connection, replace if necessary. Check sensor resistance value, replace if necessary. Check cable harness, replace if necessary. Check sensor resistance value, replace if necessary. Check cable harness for damage, check plug-in connection, replace if necessary. Check sensor resistance value, replace if necessary. Check cable harness, replace if necessary. Check sensor resistance value, replace if necessary. Check cable harness for damage, check plug-in connection, replace if necessary. Check sensor resistance value, replace if necessary. Check cable harness, replace if necessary. Check sensor resistance value, replace if necessary. Replace controller. If too many resets occurs, replace controller Replace controller. Replace controller. Replace controller.
52
Time exceeded for cold blowing
53
Flame aborted from large stage
54
Flame aborted from small stage
60
Abnormal overheating sensor operation Short circuit or ground of overheating sensor Abnormal flame sensor operation
61 64
65 71
Short circuit of flame sensor Defective surface sensor
72 74 87 88 89 90 91 92 93 94
Short circuit of surface sensor Defective overheating prevention device Watchdog reset Abnormal reset function ROM error RAM error Defective transistor

KYRON SM - 2005.09
6910
Trouble Code
95
85
Software error
Check cable harness for open to battery voltage, replace if necessary. Replace controller. Replace controller. Replace controller.
T/C M / T
Replace controller. 96 97 98 99 Abnormal process operation Wrong processor cycle Defective main relay EEPROM error
Replace controller.
Trouble Diagnosis
Causes
Low coolant level Leakage in radiator Leakage in coolant auxiliary tank Leakage in heater core Leakage in joint junction of coolant hose Leakage in defective coolant hose Leakage in water pump gasket Leakage in water pump sealing Leakage in water inlet cap Leakage in thermostat housing Insufficient tightening torque of cylinder head bolt Damaged cylinder head gasket Abnormally high coolant temperature The coolant leakage (Check the coolant level) Excessive anti-freezer Poor coolant hose condition Defective thermostat Defective water pump Defective radiator Defective coolant auxiliary tank or tank cap Crack in cylinder head or in cylinder block Clogged water flow in cylinder head or block Clogged water flow in radiator core Defective cooling fan Defective temp. sensor, wiring, and lamp cluster Abnormally low coolant temperature Defective thermostat Defective cooling fan Defective temp. sensor, wiring, and lamp cluster
Change radiator. Change coolant auxiliary tank Change heater core. Check hose or replace clamp. Change hose. Change water pump. Change water inlet cap gasket. Change thermostat sealing. Tighten bolt to specified torque. Change cylinder head gasket. Add coolant Check density of coolant (Anti-freezer). Check bent of hose, replace if necessary. Change thermostat Change water pump. Change radiator. Change coolant auxiliary tank or tank cap. Change cylinder head or cylinder block. Clean coolant flow line. Clean radiator core. Change or check cooling fan. Change sensor or check relevant wiring. Change thermostat. Change or check cooling fan. Change sensor or check relevant wiring. Change gasket.

KYRON SM - 2005.09
A / CON
A / BAG
BRAKE
STNG
SP
AXLE
Remedies
CLUTCH
A/T
Trouble Description
Remedies
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6810
PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM

1. OVERVIEW
The supplementary electrical heater is installed in DI engine equipped vehicle as a basic equipment. The PTC system is operated according to two temperature values measured at the coolant temperature sensor and HFM sensor. This device is mounted in the heater air outlet and increase the temperature of air to the passenger compartment. Because PTC system is heated by electrical power, high capacity alternator is required. (Alternator of 12V 75A/ 90A has changed to 12V 140A) Non-operational Condition - During engine cranking - When too low battery voltage (Below 11V) - During preheating process of glow plugs
PTC Assembly Engine ECU
PTC Ground
* The ground ring terminal should be secured as shown in below figure. Mounting bolt PTC earthling Earth plate terminal
Tightening torque: 6 ~ 10 Nm PTC Relay and Fuse
PTC (Relay 1)
PTC Heater 2 (40A)
PTC Heater 1 (40A) PTC (Relay 2)
PTC Heater 3 (40A)

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2. COMPONENTS
M / T
Radiator Element
Frame
Connector
Spring clip
PTC-Ceramic
Characteristics of PTC
P.T.C Heater
Heating type Element Advantages Air heating type Ceramic PTC (BaTio3) 1. Stable output regardless of voltage changes 2. Block the overcurrent with switch effect of PTC element 3. High heating capacity in a moment 4. Excellent durability of heating element against high current

KYRON SM - 2005.09
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A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
A/T
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6810
3. PTC OPERATING PROCESS

PTC Operating (ON) Condition
The operating condition of PTC is controlled by two step. Generally, ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor.
1st step (Initial PTC operating condition)

1. When coolant temperature < 15C, PTC is operating (ON). 2. When coolant temperature 15C, tow conditions described below must be satisfied.
2nd step (Coolant temperature: 15C)

1. When coolant temperature 65C 3. When coolant temperature and ambient temperature -10C PTC operates (ON) 0C ~ 5C, PTC operates (ON)
2. When coolant temperature 65 ~ 60C and ambient temperature -10C ~ 0C PTC operates (ON) 60C and ambient temperature
PTC OFF Condition

1. Air conditioner blower switch OFF 2. Ambient temperature sensor error (wiring short or open) 3. When engine cranking 4. Battery voltage is lower than 11V 5. When preheating the engine (Glow indicator ON)

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Electrical Wiring

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A / CON
A / BAG
BRAKE
STNG
SP
AXLE
CLUTCH
T/C
M / T
A/T
90
6810

Preceding Work: Disconnect the negative battery cable and the instrument panel. 1. Disconnect the PTC connector while pulling out it (A).
2. Unscrew two mounting bolts and remove the PTC assembly from the A/C module assembly.

KYRON SM - 2005.09

RKSTICS (REKES+STICS) / STICS ....................... 3
1. 2. 3. 4. 5. 6. Overview ................................................................................ 3 Specifications ....................................................................... 4 Functions and specifications ................................................8 Trouble shooting ................................................................. 18 Diagnosis trouble code and help tips .................................. 47 Electrical wiring diagrams ................................................... 49
8710
The RKSTICS (REKES + STICS (Super Time & Integrated Control System)) communicates with the transmitter (remote controller) and other electronic systems to transmit and receive the data. The STICS also includes a diagnosis function that can inspect the error for related devices.
Door Lock Relay
PAS Buzzer
Door Lock Relay
RKSTICS (REKES + STICS) / STICS

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
RK STICS
CLUSTER
SPWM
IMMO
STICS
1. OVERVIEW
EL
RKSTICS (REKES+STICS) / STICS
8710
2. SPECIFICATIONS
Electrical Performance
Electrical Performance
Item
Rated voltage Operating voltage Operating temperature Reserved temperature Max. operating humidity Resistible voltage Insulating resistance Parasitic current Voltage drop
Requirement
DC 12.0 V DC 9.0 V ~ 16.0 V -30C ~ +80C -40C ~ +85C 95% 24 V No heat and fire due to the current leaks. below 7.0 mA below 1.5 V
Remark
Should operate normally within this range. (9.5 V ~ 16.0 V only for auto hazard lamp function) Should operate normally within this range.
Confined with PCB, waterproof and coating that requires the insulation. When initiating the sleep mode after removing ignition key and locking the doors Pin no. 72 and 2, 4, 7, 8, 9, 10, 11, 12, 19, 24, 27, 28, 29, 30, 31, 32, 33, 36, 56, 57, 58, 59, 60, 61, 70, 71
below 1.8 V
Pin no. 72 and 5, 6, 16, 17, 18, 20, 21, 23, 35, 37, 39, 41, 42, 43, 44, 45, 62, 64, 65, 66, 67, 68, 69
Characteristics of Radio Wave

1. Transmitting frequency: 447.800 0.0125 MHz 2. Channel width: below 12.5 KHz 3. Frequency bandwidth: below 8.5 KHz 4. Modulation method: FSK (Frequency Shift Keying) 5 Receiving distance: Approx. 10 ~ 15 m (In case there are not obstacles around the system)

KYRON SM - 2005.09
8710
Rated Load
NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Description
Chime bell / Buzzer Front Room lamp Rear Room lamp Key hole illumination Seatbelt warning lamp Parking brake warning lamp Door ajar warning lamp Door lock relay Door unlock relay Horn relay Tail lamp relay Hazard warning relay Power window relay Rear defogger relay Wiper LOW relay Wiper HIGH relay Front washer motor Rear washer motor relay Headlamp relay Front defogger relay
Rated Load
DC 12 V 350 mA (Inducted load) DC 12 V 16 W (Lamp load) DC 12 V 8 W (Lamp load) DC 12 V 1.2 W (Lamp load) DC 12 V 1.2 W (Lamp load) DC 12 V 1.2 W (Lamp load) DC 12 V 1.2 W (Lamp load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 200 mA (Inducted load) DC 12 V 250 mA (Inducted load) DC 12 V 250 mA (Inducted load) DC 12 V 1.5 A DC 12 V 500 mA (Inducted load) DC 12 V 750 mA (Inducted load) DC 12 V 200 mA (Inducted load)
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8710
Input Signals
NO.
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 IGN1 IGN2 ALT_D Key reminder (door ajar warning switch) Drivers door switch Passengers door switch Rear door switch Tailgate switch Hood switch Drivers door lock/unlock switch Passengers door lock/unlock switch Rear door lock/unlock switch Tailgate lock/unlock switch Rear defogger switch Seatbelt switch Hazard warning flasher selection switch Parking brake switch Air bag collision sensor Wiper motor (parking) switch Washer switch Intermittent auto switch Auto washer switch Intermittent resistance Speed sensor IDR (Coding) Front defogger switch Central door lock switch Rear washer switch Multifunction auto light switch Indicator lamp switch Seat adjustment and switch memory unit Rain sensor Diagnosis (SCAN-100) Immobilizer
Input Signal Name
Logic Status
ON = BAT (IGN ON or START) ON = BAT (IGN ON) ON = BAT equivalent (engine running) IGN = BAT (Key in) OPEN = GND, CLOSE = OPEN OPEN = GND, CLOSE = OPEN OPEN (one of rear seat) = GND CLOSE (all rear seats) = OPEN OPEN = GND, CLOSE = OPEN OPEN = GND, CLOSE = OPEN LOCK = OPEN, UNLOCK = GND LOCK = OPEN, UNLOCK = GND UNLOCK (one of rear seat) = GND LOCK (all rear seats) = OPEN LOCK = OPEN, UNLOCK = GND ON = GND, OFF = OPEN Unfastened = GND, Fastened = OPEN ON = GND, OFF = OPEN ON = GND, OFF = OPEN ON = 200 ms output (LOW), OFF = OPEN STOP = BAT VOLTAGE, ROTATING = GND ON = BAT, OFF = OPEN ON = BAT, OFF = OPEN ON = BAT, OFF = OPEN 0W ~ 51 KW (for intermittent wiper) ON = GND (PWM), OFF = OPEN ON = BAT, OFF = OPEN ON = GND, OFF = OPEN ON = GND, OFF = OPEN ON = BAT, OFF = OPEN ON = GND, OFF = OPEN ON = BAT/GND, OFF = OPEN (Approx. 5.1 V ~ 9.2 V) ON = GND (PWM), OFF = OPEN ON = GND (DATA), OFF = BAT ON = GND (DATA), OFF = BAT (KWP2000) ON = GND (DATA), OFF = BAT (KWP2000)

KYRON SM - 2005.09
8710 Chattering of Input Signals

1. Vehicle speed input:
2. 20 ms target input: Wiper motor A/S (parking) terminal 3. 100 ms target input switch All switches except wiper motor A/S (parking) terminal
Time Tolerance
1. If not indicated, time tolerance will be 10%. However, if less than 500 ms, time tolerance will be 100 ms. 2. The time indicated in each function does not include chattering processing time from switch input changing point.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
The vehicle speed is the average value of 4 pulses among 6 pulse inputs regardless of the input for 1.0 second after IGI 1 ON. The time indicated in each function does not include the vehicle speed calculating time.
EL
8710
3. FUNCTIONS AND SPECIFICATIONS

Wiper and Washer Operations
Front wiper operation MIST When pulling up the lever, the wiper operates once and the wiper lever returns to the OFF position. OFF Stop the operation.
Front Automatic Wiping Speed Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in the AUTO position. Fast: Fast interval Slow: Slow interval
AUTO
Operates automatically according to the vehicle speed or the amount of rain.
LO
Continuous wipe, slow operation.
HI
Continuous wipe, fast operation Front Auto Washer and Wiper Switch When pressing the auto washer switch with the wiper switch OFF, the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times, after then the washer fluid is sprayed and the wiper sweeps off 3 times again.
Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch. When releasing the switch, it returns to the rear wiper operate position.
Rear Wiper Operation
Rear Wiper Stops
Wiper and Washer Coupled Operation Pull the lever briefly (below 0.6 seconds): One wiping cycle Pull and hold the lever for more than 0.6 seconds: Three wiping cycles with washer spray
Rear Washer and Wiper The rear washer and the wiper operate only while holding the switch. When releasing the switch, it returns to OFF position.
8710
Wiper MIST and Front Washer Coupled Wiper

1. The wiper relay is turned on 0.3 seconds after turning ON the washer switch for 0.1 ~ 0.59 seconds with the ignition key ON, and it is turned off when the parking terminal is turned off.
STICS A / CRUISE
KYRON SM - 2005.09
KEY IN & IGN2 SW
ON OFF T2 ON
WASHER SW OFF ON OFF ON OFF T1

CLUSTER
WIPER MOTOR PARKING
WIPER LOW RELAY
T1: 0.3
T2: 0.1 ~ 0.59 sec

WIPER
2. The wiper relay is turned on 0.3 seconds after turning ON the washer switch over 0.6 seconds with the ignition key ON, and it is turned on three times immediately after turning off the washer switch.
KEY IN & IGN2 SW
ON OFF
ON WASHER SW OFF T3 WIPER MOTOR PARKING ON OFF ON OFF T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle T1
WIPER LOW RELAY
S E AT
S / ROOF
LAMP
T2
PAS
R / SENSOR
AV
S/W
SPWM
IMMO
EL
10
8710
3. When the washer switch is ON for more than 0.6 seconds during the wiper operation by the INT switch, the operation in step (2) is performed. When it is ON for a certain period of time (0.1 to 0.59 seconds), the operation in step (1) is performed.
KEY IN & IGN2 SW
ON OFF ON
INT SW OFF T2 WASHER SW ON OFF T4 WIPER MOTOR PARKING ON OFF ON OFF T1 T5 T3: over 0.6 sec T1 T5 T4: 3 cycles T5: pause T3
WIPER LOW RELAY
T1: within 0.3 sec
T2: 0.1 ~ 0.59 sec
Rear Washer Motor Control

1. When the rear washer switch is turn on with the ignition switch ON, the rear washer motor relay output is activated from the time when the rear washer switch is turned on, and it is deactivated when the rear washer switch is turned off. 2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation.
KEY IN & IGN2 SW
ON OFF ON OFF
REAR WASHER SW
REAR WASHER MOTOR RELAY
ON OFF

KYRON SM - 2005.09
8710 Auto Washer and Wiper Switch (AFW)
11
KEY IN & IGN2 SW
ON OFF AUTO
INT SW AUTO AUTO WASHER SWITH ON
OFF ON OFF
T1
CLUSTER
T6 WASHER MOTOR OPERATING ON OFF

AV
T2
T2
OFF T4 T5 ON OFF T3
T1: over 100 ms
T2: 1.0 0.1 sec
T3: within 0.3 sec
T4: 4 cycles T5: 3 cycles
T6: 0.5 0.1 sec

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER LOW RELAY
WIPER
WASHER MOTOR PARKING
ON
S/W
SPWM
IMMO
STICS
1. When the auto washer switch is turned on with the ignition switch ON and the INT switch OFF, the washer motor output is activated for 1 second. If the system recognizes this output, the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second. Then, the wiper relay output is deactivated after 3 cycles.
EL
12
8710
2. The auto washer switch output is overridden during the washer coupled wiper operation. 3. The auto washer switch input is overridden during the auto washer coupled wiper operation. 4. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation. 5. When the auto INT switch input is received during the auto washer operation, the auto washer operation stops and the auto INT operation is activated.
KEY IN & IGN2 SW INT AUTO WITCH
ON OFF ON OFF ON T1 OFF ON T2 OFF
FRONT WASHER SW
AUTO WASHER SW
WASHER MOTOR OUTPUT WIPER MOTOR PARKING
ON OFF ON OFF ON OFF T1: over 0.6 sec T2: over 100 ms T3: within 0.3 sec T4: 3 cycles T3 T3 T4
WIPER LOW RELAY

KYRON SM - 2005.09
8710 Rain Sensor Coupled Wiper and Auto Light Control

If equipped with RKSTICS rain sensor, it has following operation system.
13
System layout
Multi-function (wiper) Switch
Auto washer SW Washer SW Volume (Resistance) LIN (Local Interconnect Network) communication
IGN 1 (15)
4 1
RKSTICS
N.C. (Numerical Control) Wiper parking 2
Wiper LO
Wiper HI

KYRON SM - 2005.09
A / CRUISE
S E AT
Wiper Motor
S / ROOF
LAMP
PAS
R / SENSOR
Auto Light Sensor
WIPER
Rain Sensor &
AV
S/W
INT Auto SW
CLUSTER
SPWM
IMMO
STICS
EL
14
8710
INT Switch Auto Position Reminder (Power-Up Reminder Wiper)

1. When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of communication with rain sensor. 2. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions (while the ignition key is in the ON position). When the wiper switch is turned to the ON position again from other positions, the system drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal.
ON OFF ON OFF Rain Detected OFF T1 WIPER LOW RELAY ON OFF T1: 1 cycle T1 T1
KEY IN & IGN2 SW
INT AUTO SW
RAIN SENSOR to RKSTICS
Rain sensing unit (auto light integrated type)
Multifunction wiper switch: AUTO and sensitivity control
A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section (rain sensor mounting section on the windshield) with photodiode (auto light sensor integrated type)
KYRON SM - 2005.09
AUTO: Wiper operates automatically by rain sensor FAST SLOW: Auto delay/Auto speed control. A position that can control sensitivity against rains in the windshield and transmits wiping demand signal accordingly
8710 Washer Coupled Wiper in Rain Sensing Mode
15
2. The operation data is sent to the rain sensor even during the washer coupled wipers operation.
ON OFF AUTO OFF ON WASHER SW OFF ON WIPER P-POS OFF WIPER LOW RELAY RAIN SENSOR ON OFF Override Rain Sensing
KEY IN & IGN2 INT AUTO SW
Rain Sensing Sensitivity Control

1. The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (while the ignition key is in the ON position, the wiper switch is in the ON position, and the wiper motor is in Parked position). However, the wiper motor can be operated only when the rain sensor detects the Rain Detected signal. * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
T1 ON WIPER LOW RELAY OFF
T1
T1
T1: 1 cycle

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Rain Detected RAIN SENSOR to RKSTICS OFF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. The washer coupled wiper is operated when receiving the washer switch input with the ignition switch ON and the auto INT switch ON in the rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during the continuous operation.
EL
16
8710
Wiper Operation When the Wiper Parking Terminal Is Grounded

1. The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is grounded (while the ignition key is in ON position and the wiper switch is in ON position). * The wiper motor runs only when the rain sensor requires.
WIPER PARKING
IGN (Operation) GND (Stop)
SENSITIVITY
SEN. 2
RKSTICS to RAIN SENSOR
2. When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity for 2 seconds, then continuously outputs the parking signal of current sensitivity. * The wiper motor runs only when the rain sensor requires.
IGN (Operation) WIPER PARKING GND (Stop)
SENSITIVITY
SEN. 2

KYRON SM - 2005.09
8710 Defective Rain Sensor
17
SENSITIVITY
Malfunction signal: No T1 ON WIPER LOW RELAY OFF T1: 1 cycle
S_COMMFAULT RAIN SENSOR to RKSTICS OFF
T1 ON WIPER LOW RELAY OFF T1: 1 cycle

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
SENSITIVITY
R / SENSOR
2. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in ON position and the wiper switch is in ON position).
WIPER
AV
S/W
CLUSTER
Malfunction signal: Yes
SPWM
IMMO
STICS
1. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor (while the ignition key is in ON position and the wiper switch is in ON position).
EL
18
8710
4. TROUBLE SHOOTING
Symptom 1. The wiper does not operate one cycle when turning the multifunction wiper switch to the AUTO from the OFF position or starting the engine while the wiper switch is in the AUTO position.
1. When starting the engine with the multifunction wiper switch in the AUTO position, the wiper operates one cycle to remind a driver that the wiper switch is in the AUTO position. 2. When the wiper switch is turned to AUTO from OFF, the wiper operates one cycle. It always operates one cycle for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF. However, the wiper operates up to 5 minutes after rain stops. If this function does not occur, check No. 8 pin. If the pin is normal, check the wiper relay related terminals in the ICM box.
Symptom 2.
It rains but the system does not work in the AUTO position.
1. Check whether the multifunction wiper switch is in the AUTO position. 2. Check the power to the sensor. Check the conditions of the pin 3 (Ground) and the pin 4 (IGN). 3. Check the wiper relay for defective.
Symptom 3.
The wiper operates 3 or 4 times at high speed abruptly.
Check whether the variable resistance knob on the multifunction wiper switch is set in FAST. The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity.
Symptom 4.
The wiper operates continuously even on the dry glass.
1. Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could be occurred. In this case, replace the wiper blade with a new one. 2. Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity.
Symptom 5.
The wiper does not operate at high speed even in heavy rain.
Check if the wiper operates at high speed when grounding pin 1 and pin 2.
Symptom 6.
The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in FAST" or "SLOW. Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage.

KYRON SM - 2005.09
8710
19
Auto Light Control

1. The tail lamps and headlamps can be controlled with the communication with the rain sensor only when the auto light switch is in the AUTO position with the ignition switch ON.
STICS A / CRUISE
IGN KEY IGN2
ON OFF AUTO OFF Headlight Taillamp ON OFF ON OFF
AUTO LIGHT SW RAIN SENSOR DATA
TAILLAMP RELAY HEADLAMP RELAY
Auto light sensor

KYRON SM - 2005.09
S E AT
Auto light sensor
S / ROOF
LAMP
PAS
Emitter lense
R / SENSOR
3. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.)
WIPER
2. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically.
AV
S/W
CLUSTER
SPWM
IMMO
EL
20
8710
Speed Sensitive INT (Intermittent) Wiper

For RKSTICS without the rain sensor, perform the following operation: 1. Controls the wiper intermittent operation by the values from the vehicle speed and the volume. 1) Calculates and converts the Intermittent interval automatically by using the INT VOLUME when the ignition switch is in the ON position and the INT switch is in the ON position. 2) The wipers are operated in vehicle speed sensitive mode when turning the INT switch to the ON position with the engine running or starting the engine with the INT switch positioned to ON. 3) Intermittent interval (at 0 km/h): 3 0.5 ~ 19 2 seconds 2. Vehicle speed calculation [Input the vehicle speed] It is calculated by the numbers of input pulses for one second.
1 [PULSE/SEC] =
60 [km/h] X 60 [sec] 637 X 4 PULSE
1.41 [km/h]
3. VOLUME calculation The pause time of the vehicle speed sensitive INT wiper is calculated by the INT volume (input voltage). Each level has the hysteresis. 4. Pause time calculation 1) Pause time: the duration that wipers are stopped at parking position 2) Elapsed time: the duration after the wiper motor started to operate from parking position 3) The pause time is calculated by the vehicle speed and the VOLUME. If the pause time is below 1.0 second, the wipers operate without pause. If the pause time is over 1.5 seconds, the wipers operate intermittently.

KYRON SM - 2005.09
8710
21
Pause time of vehicle speed sensitive INT wiper

Vehicle Speed
Resistance
Vehicle speed (km/h)
Speed sensitive INT (intermittent) wiper 1) The wiper relay continues to output for remaining ON time even when the INT switch is turned off. 2) IGN 2 switch ON, INT switch OFF: Resume the intermittent time when turning ON 3) IGN 2 switch OFF, INT switch ON: Resume the intermittent time when turning ON Controls when the wiper motor parking is defective 1) The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is ON (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch) (The output stops immediately after turning OFF the switch.)

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
CAUTION
LAMP
PAS
R / SENSOR
WIPER
Pause time (sec.)
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
22
8710
(The ignition key reminder warning has priority over the TAILLAMP ON WARNING.)
Ignition Key Reminder Warning
1. The chime buzzer output in the ICM box continues when opening the drivers door while the ignition key is inserted the into ignition switch. 2. When removing the ignition key or closing the drivers door during chime buzzer output, the output turns off. 3. This function is not available when the ignition switch is ON.
ON IGN1 OFF
IN IGN KEY SW OUT OPEN Dr DOOR CLOSE
ON CHIME BUZZER OFF
Chime buzzer
Ignition Key Reminder

1. The system outputs UNLOCK for 5 seconds after the drivers door is opened and the door lock switch is changed to LOCK (while the ignition key is in ignition switch). 2. The system outputs UNLOCK for 5 seconds (T2) when the door lock switch is changed to LOCK from UNLOCK and the drivers door is closed within 0.5 seconds (while the ignition key is in the ignition switch). 3. If the UNLOCK conditions are met, the UNLOCK output should be unconditionally activated. However, if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK, the UNLOCK output is not activated.
8710
23
IGN KEY REMINDER
ON IN OUT LOCK UNLOCK OPEN T1
DOOR LOCK SW(*1)
DOOR SW (*2) CLOSE ON UNLOCK RELAY OFF T1: within 0.5 sec T2 T3 T2: 5.0 sec T3 T3 T2
T3: OFF during T2 output
(*1): Drivers door is opened and drivers door lock switch is turned to LOCK, (*2): Drivers door is opened and passengers door lock switch is turned to LOCK
IGN KEY
KEY ON IN OUT LOCK UNLOCK OPEN
ALL Door LOCK SW (*1)
Door SW (*2) CLOSE ON Door UNLOCK OFF T1: 5 sec 0.5 sec T1 T1
(*1) DR & PS & RR DOOR LOCK SW & T/GATE LOCK SW, (*2) DR or PS or RR DOOR SW
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
1. All doors, except the tailgate and hood, output UNLOCK for 5 seconds when the LOCK signal is inputted (while the ignition key is removed and one of doors is opened). 2. When the door is closed during the unlock output for 5 seconds, the unlock output stops. 3. When the ignition key is inserted during the output, the output continues for approx. 5 seconds. 4. If the ignition switch is in the ON position or the ignition switch is removed, the above steps are performed. If the key is in the key cylinder, the ignition key reminder function is activated. 5. This function does not work if the vehicle speed is over 10 km/h.
WIPER
AV
All Door Lock Prevention Function when a Door is Opened
S/W
CLUSTER
SPWM
IMMO
STICS
EL
24
8710
Mark Lamp Left on Warning

1. The chime buzzer in the ICM box sounds with the interval of 0.8 second when opening the drivers door while the tail lamp is turned on and the ignition key is removed. 2. The chime/buzzer output stops when turning off the tail lamp and closing the drivers door. 3. The system outputs UNLOCK for 5 seconds when the drivers and passengers door lock switch is locked (while the tail lamp is turned on and the drivers door is open). 4. This function is not available when the ignition key is in the ON position.
ON IGN1 OFF
ON TAIL LAMP RELAY OFF OPEN Dr DOOR CLOSE
Dr DOR LOCK SW
UNLOCK LOCK T2 ON T2
UNLOCK RELAY OFF T1 ON C/BUZZER OFF T1: 0.8 sec 0.1 sec T2: 5 sec 0.5 sec T1

KYRON SM - 2005.09
8710 Door Ajar Warning
25
1. The warning light in indicator display comes on when opening any of the drivers door, the passengers door, the rear doors or the tailgate while the vehicle speed is below 10 km/h. 2. The warning light goes off when closing the door under step 1. 3. The warning light blinks when the vehicle speed is over 10 km/h while the warning light is turned on. 4. The warning light blinks when a door is open while the vehicle speed is over 10 km/h. 5. The warning light goes off when closing the door under step 3. 6. The warning light comes on when the vehicle speed is below 10 km/h under step 3.
IMMO
KYRON SM - 2005.09
ON IGN1 OFF OPEN DOOR SW (*1) CLOSE OVER V1 VEHICLE SPEED
T2 DOOR AJAR WARN LAMP

WIPER
ON OFF T3 T2: 0.6 sec T3: 0.3 sec V1 = 10 Km/h
(*1) DOOR OPEN: Dr or Ps or Rr or T/GATE = OPEN CLOSE: Dr & Ps &r Rr & T/GATE = CLOSE
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
BELOW V1
S/W
CLUSTER
SPWM
STICS
EL
26
8710
Seat Belt Warning

1. The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the ignition key to ON from OFF. If the seat belt is fastened before turning the ignition key to the the ON position, the warning light in the indicator display blinks, however, the chime buzzer does not sound. 2. The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to the OFF position. 3. The chime buzzer stops and the seat belt warning light stays on for the specified duration when fastening the seat belt during the warning operation. 4. The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is the ON position.
ON IGN1 SW OFF FASTEN S/BELT SW UNFASTEN T3 ON S/BELT WARN LAMP OFF T1 T2 ON C/BUZZER OFF T1: 0.6 sec T2: 6.0 sec T3: 0.3 sec T2
Seat Belt Warning Lamp
Chime Buzzer
Chime buzzer
The seat belt warning light comes on and the chime buzzer in the ICM box sounds for 6 seconds when turning the ignition key to ON from OFF. After fastening the seat belt, the chime buzzer stops.
8710 Parking Brake Warning
27
ON IGN1 SW OFF
ON OFF
S/W
P/BRAKE
Over V1 Below V1 T4 ON P/BREAK WARN LAMP OFF T3 T1 T4

WIPER
KYRON SM - 2005.09
T2
ON C/BUZZER OFF T5 T6
T1: 2.0 sec 0.5 sec T2: 0.6 sec T3: 0.3 sec T4: 4.0 sec V1: 10 Km/h T5: 2.5 sec 0.1 sec T6: 1.5s 0.1 sec
Hand Operated Type (Manual Transmission Equipped Vehicle)

Foot Operated Type (Automatic Transmission Equipped Vehicle)

A / CRUISE
S E AT
S / ROOF
Parking Brake: Hand operated type (manual transmission equipped vehicle), Foot operated type (automatic transmission equipped vehicle)
LAMP
PAS
R / SENSOR
AV
VEHICLE SPEED
CLUSTER
SPWM
1. The parking brake warning light comes on for approx. 4 seconds when turning the ignition key from the OFF to the ON position regardless of the vehicle speed and the parking brake switch position. After this 4 seconds, the warning lamp comes on, goes off or blinks according to the vehicle speed and the parking brake switch position. 2. The warning light comes on when the parking brake switch is turned on while the vehicle speed is below 10 km/h. 3. The warning light goes off when turning off the parking brake switch under step 2. 4. The warning light blinks and the chime buzzer in the ICM box sounds for 2.85 seconds and stops for 1.5 seconds when the vehicle speed is over 10 km/h for more than 2 seconds while the parking brake switch is turned on. 5. The warning light goes off and the chime buzzer stops when turning off the parking brake switch under step 4. 6. The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 10 km/h under step 4. 7. This function is not available when the ignition key is turned to the OFF position.
IMMO
STICS
EL
28
8710
Center/Luggage Room Lamp Control

The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the center/luggage room lamp switch is at the coupled operating position and the key reminder switch is OFF. 1. When the door (Drivers/Passengers/Rear) is opened, the front and center room lamps come on and automatically go off after 30 seconds. 2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the drivers door, passengers door or rear doors. 3. The decaying operation must have greater than 32 steps per one second. 4. The room lamp output should stop immediately after turning on the ignition key during the decaying operation. 5. The front room lamp and the center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed. 6. The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output. (The lamp stays on when unlocked by the remote control key.) 7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2. 8. The room lamp output stops immediately after receiving the lock signal from drivers door, passengers door and rear doors lock switch while the drivers door, passenger's door and rear doors are closed. 9. The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch is pressed.
OPEN Dr or Ps DOOR SW CLOSE
ON IGN KEY REMINDER SW OFF
REMOTE CONTROL UNLOCK
RECEIVE NO SIGNAL
ON UNLOCK OUTPUT OFF
FRONT ROOM LAMP
ON OFF T2 T3
T1
T4
T1: 30 sec
T2: 2 sec
T3: 3 sec
T4 : 30 sec

KYRON SM - 2005.09
8710
29
Front Room Lamp
Center and Luggage Room Lamp

STICS A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV S/W CLUSTER SPWM
KYRON SM - 2005.09
Tailgate
Drivers seat
Center Room Lamp (Lamp : ON) Luggage Room Lamp (Tailgate coupled type)
Center Room Lamp (Door coupled type) Luggage Room Lamp (Lamp : OFF)
12V / 10W - 2EA
12V / 10W - 1EA
Front room lamp (drivers or passengers) is turned on and off when pressing in this switch (1 or 2). However, it comes on when the door is open and goes off when the door is closed. The front and center room lamps come on when pressing the room lamp main switch (3).
Center Room Lamp
Luggage Room Lamp
The center room lamp comes on while the switch is at the door coupled position when the door is open. The lamp always comes on while the switch is at the other position.
The luggage room lamp comes only when the tailgate is open while the switch is at the tailgate coupled position.
IMMO
EL
30
8710
Ignition Key Hole Illumination

1. The ignition key hole illumination comes on when opening the drivers door or passenger's door while the ignition key is removed. 2. The ignition key hole illumination stays on for 10 seconds when closing the door after step 1. 3. The output stops when the ignition key is turned to the ON position. 4. The output stops when receiving the lock signal from the remote control key (under armed mode).
ON IGN KEY (*1) OFF OPEN DOOR SW (*2) CLOSE ON KEY ILLUMI LAMP OFF T1 T1 T1
T1 : 10 sec (*1) ON : IGN KEY = ON OFF : IGN KEY = OFF (*2) OPEN : Dr or Ps DOOR = OPEN CLOSE : Dr & Ps DOOR = CLOSE
Key cylinder with key hole illumination
For diesel and gasoline engine equipped vehicle
For diesel engine equipped vehicle
Without immobilizer With key hole illumination
With immobilizer With key hole illumination

KYRON SM - 2005.09
8710 Battery Saver (Tail Lamp Auto Cut)
31
IN IGN KEY OUT
AUTO CUT
AUTO CUT
TAIL LAMP OFF OPEN CLOSE ON OFF
Front Defogger Timer

1. The front defogger output is ON when turning ON the front defogger switch while the ignition switch is ON (with engine running). 2. The output stops when turning on the defogger switch again during its operation. 3. The output is ON only for 6 minutes when turning ON the front defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. 4. The output is OFF when the ignition switch is OFF.
OFF ALT HIGH LOW ON OFF ON OFF T1 ALT LOW = 9V 1V T1: 12 minutes T1 T1 T2 T3 T3: 6 minutes T1 ON: IGN2 & ALT = ON OFF: IGN2 OR ALT = OFF
FR DEFOGGER SW FR DEFOGGER RELAY
T2: within 10 minutes

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
IGN2
ON
PAS
R / SENSOR
WIPER
AV
TAIL LAMP RELAY
S/W
Dr DOOR
CLUSTER
ON
SPWM
IMMO
1. The tail lamp is turned on or off according to the operations of the tail lamp switch. 2. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door after removing the ignition key without turning off the tail lamp. 3. The tail lamp relay is turned on when inserting the ignition key into the ignition switch. 4. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door while the ignition key is removed and the tail lamp is turned on.
STICS
EL
32
8710
Rear Defogger Timer

1. The rear defogger output is ON when turning ON the rear defogger switch while the IGN 2 switch is ON (with engine running). 2. The output is OFF when turning ON the rear defogger switch again during output. 3. The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes. This can be done only once. 4. The output is OFF when the IGN 2 switch is OFF.
ON IGN2 OFF HIGH ALT LOW ON OFF ON OFF
RR DEFOGGER SW
RR DEFOGGER RELAY
T1
T1
T1
T2
T3
T1
ALT LOW = 9V 1V
T1: 12 minutes
T2: within 10 minutes
T3: 6 minutes
ON: IGN 2 & ALT = ON OFF: IGN 2 or ALT = OFF
Tailgate and outside rearview mirror heated glass switch Press this switch to turn on the tailgate and the outside rearview mirror heated glass. It will operate for about 12 minutes.
Windshield heated glass switch Press this switch to turn on the windshield heated glass. It will operate for about 12 minutes.

KYRON SM - 2005.09
8710 Headlamp Control
33
2. The output is OFF when receiving the LOCK signal from the remote control key while outputting the headlamp relay. However, other signals other than LOCK are overridden. 3. The output is OFF when inserting the ignition key and turning it to the ON position while outputting the headlamp relay.
ON REMOTE CONTROL NO SIGNAL
THEFT DETERRENT OPERATION
OTHERS
AV
HEADLAMP RELAY PWR
ON OFF ON OFF T1 T1 : 20 sec
HEADLAMP RELAY OUTPUT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
ARMED MODE
CLUSTER
SPWM
IMMO
STICS
1. When the system receives the remote control key after receiving the LOCK signal (theft deterrent mode) with the ignition switch OFF, it supplies the power to the headlamp relay to turn on the headlamp (turned off after 20 seconds).
EL
34
8710
Door Lock/Unlock Control by Door Lock Switch

1. The door lock system outputs LOCK for 0.5 seconds when positioning the driver's or passengers door lock switch to the lock position. 2. The door lock system outputs UNLOCK for 0.5 seconds when positioning the driver's or passenger's door lock switch to the unlock position. 3. LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other functions. 4. All door lock signals are UNLOCK for 0.5 seconds just for once when receiving the LOCK signal within 0.5 seconds after closing the drivers or passenger's door while the ignition key is removed.
LOCK UNLOCK LOCK UNLOCK OPEN CLOSE ON OFF ON OFF T1: 0.5 sec T2: 0.5 sec T3: within 0.5 sec T4: 0.5 sec
DR DOOR LOCK SW PS DOOR LOCK SW DR/PS DOOR SW
T1
T3
DOOR LOCK RELAY
T2
T4
DOOR UNLOCK RELAY
Door Lock/Unlock by Central Door Lock Switch

1. The door lock system outputs LOCK/UNLOCK for 0.5 seconds when operating the central door lock switch. (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) 2. The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored.
CENTRAL LOCK SW MONITORING ON OFF LOCK UNLOCK T1 DOOR LOCK RELAY ON OFF T2 DOOR UNLOCK RELAY ON OFF T1: 0.5 sec
KYRON SM - 2005.09
T2: 0.5 sec
8710 Door LOCK/UNLOCK by Remote Control Key

1. The door lock relay output is ON for 0.5 seconds when receiving the remote control lock signal. 2. The door unlock relay output is ON for 0.5 seconds when receiving the remote control unlock signal.
35
LOCK TX SIGNAL NO SIGNAL
T2 DOOR LOCK RELAY ON OFF

CLUSTER SPWM
DOOR UNLOCK RELAY
ON OFF
ON HORN RELAY OFF
T4
AV
T6 ON HAZARD RELAY OFF T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec T5 T5 T5
Door button
Panic button

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
IMMO
STICS
EL
36
8710
Auto Door Lock

1. The door lock system outputs LOCK when the vehicle speed maintains over 50 km/h. However, it doesn't output LOCK when all doors are locked or failed. 2. If any of doors is unlocked after outputting LOCK in step 1, outputs LOCK up to 5 times (except step 1) at the interval of one second. 3. If any of doors is unlocked after 5 times of "LOCK" outputs, the door is regarded as FAIL. 4. If the door that was regarded as fail changes (UNLOCK to LOCK) to unlock, only one LOCK output will be done. 5. If any door is regarded as FAIL, the auto door lock function does not work (if it is occurred when the vehicle speed is over 50 km/h, the auto door lock output does not occur even if the vehicle speed falls below 50 km/h and accelerates again to over 50 km/h.). Nonetheless, the central door lock function works properly. 6. When the system receives UNLOCK signal from a door switch, it outputs LOCK signals 5 times. If additional LOCK signal from another door switch is detected during the period, the system outputs five LOCK signals 5 times for the door. 7. The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this function or the key is cycled (IGN1=OFF) (even when there is no LOCK output while the vehicle speed maintains over 50 km/h under lock condition). (If the LOCK condition is established with the ignition switch ON, the system outputs UNLOCK signal unconditionally when turning the ignition switch to OFF position.) However, when the ignition key is turned to OFF position, the lock output conditions will be cancelled. 8. The FAIL condition of the door will be erased when the ignition key is turned to OFF position.
IGN1 SW
ON OFF OVER 50 km/h BELOW 50 km/h UNLOCK LOCK T1
VEHICLE SPEED
DOOR LOCK SW (*1)
DOOR LOCK OUTPUT
ON OFF
T2
5 times T2 T2 T2 T2
T2: 0.5 sec (*1) LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK

KYRON SM - 2005.09
8710 Auto Door Unlock (Crash Unlock)
37
1. The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to ON position. 2. After this period, the door lock system outputs UNLOCK for all doors for 5 seconds from 0.4 seconds after receiving the air bag collision signal. 3. Even though the key is turned to OFF position during the output of UNLOCK, the output continues on for remaining period. 4. The function is erased when turning off the IGN switch.
STICS A / CRUISE
ON IGN SW OFF T1 AIR BAG SIG ON OFF T2 ON OFF T3
UNLOCK RELAY
T1: 200 ms
T2: 40 ms
T3: 5 sec
CAUTION
The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions. The LOCK/UNLOCK request by other functions will be ignored after/during the output of UNLOCK by the air bag. However, the door lock is controlled by other functions when the ignition switch is OFF. LOCK (or UNLOCK) output is ignored if LOCK (or UNLOCK) output is required while performing the output of LOCK (or UNLOCK). If the door lock system outputs LOCK and UNLOCK simultaneously, only the LOCK output can be activated.

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
38
8710
Time Lag Power Window Control

1. The power window relay output is ON when turning on the ignition switch. 2. The power window relay output is ON for 30 seconds when turning off the ignition switch. The power window relay output is OFF when opening the drivers door or the passengers door. 3. The power window relay is turned OFF when receiving the remote control key lock signal (armed mode) during its extended operation period of 30 seconds.
ON IGN1 OFF Dr, Ps DOOR SWITCH OPEN CLOSE T1 P/WINDOW SWITCH ON OFF T1: 30 sec T2: OFF during T1 output T2
PANIC Warning (With ignition key in)

1. The PANIC warning output is ON (theft deterrent horn) when receiving the PANIC signal from the remote control key (pressing PANIC button). 2. The PANIC warning output is OFF when receiving any signal from the remote control key during PANIC warning. 3. Followings are theft deterrent warnings: 1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft deterrent. 2) The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning (PANIC output is OFF). 3) The PANIC warning output is ON when receiving the PANIC signal from the remote control key in Armed Ready / Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode). 4. This function operates only in armed mode.
Tx SIGNAL (REMOTE CONTROL SIGNAL) ON OFF
THEFT DETERRENT MODE
WARNING OFF T1 T2 ON T1
HORN OFF T3 T1: 27 sec T2: 0.5 sec T3: 1.0 sec

KYRON SM - 2005.09
8710 Description of Burglar Alarm Function

1. Definitions of Door Open and Close Door OPEN: Any of door switches (engine hood, front doors, rear doors, tailgate) output OPEN signal. Door CLOSE: All door switches (engine hood, front doors, rear doors, tailgate) output CLOSE signal. 2) Door LOCK: Any of door lock switches (front doors, rear doors, tailgate) output LOCK signal. Door UNLOCK: All lock switches (front doors, rear doors, tailgate) output UNLOCK signal.
39
2. Armed mode activation requirements 1) The LOCK output is ON when receiving the LOCK signal from transmitter while the ignition key is removed and all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output: once, hazard relay output: twice). 2) The theft deterrent horn and hazard relay outputs are ON when receiving the LOCK signal from the remote control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice). 3) When receiving LOCK signal from the remote control key while any of doors is not closed, only the LOCK output can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning flasher). At this moment, if the ignition key is in the ignition switch, the door unlock switch is turned ON or the door lock switch is unlocked, it cancels the armed mode and activates the normal mode. 4) When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving UNLOCK signal, it outputs LOCK and then activates armed mode (RELOCK operation). Also, at this moment, the system outputs hazard warning flasher twice. 5) The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Engine hood open warning lamp The warning lamp comes on when the engine hood is open.
S/W
CLUSTER
SPWM
IMMO
STICS
1) Definitions in theft deterrent mode
EL
40
8710
LOCK Tx SIGNAL NO SIGNAL UNLOCK ENTRANCE DOOR SW ENTRANCE DOOR LOCK SW OPEN CLOSE LOCK UNLOCK ON OFF ON OFF ON HAZARD RELAY OFF ON OFF T3 OPERATION ARMED MODE OTHERS T1: 0.5 sec T2: 1.0 sec T3: 50 ms T4: 1.0 sec T5: 30 sec T1 T2 T4 T5
DOOR LOCK RELAY
(Dr) DOOR UNLOCK RELAY
HORN

KYRON SM - 2005.09
8710
3. Armed mode cancellation requirements
41
4. Warning operation requirements 2) When unlocking the door lock switch in armed mode by other than the remote control key 3) When closing and then opening the door after completion of warning (27 seconds) 5. Warning operation 1) The theft deterrent horn and hazard warning flasher output is ON for 27 seconds with the interval of 1 second. 6. Warning cancellation requirements 1) Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, PANIC) during warning operation. 2) Cancels warning after 27 seconds (remaining period) while the ignition key is turned to ON position. 3) If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is canceled immediately and the warning buzzer stops after 27 seconds (remaining time). 7. Operation when warning is cancelled 1) The theft deterrent horn and hazard warning flasher outputs are OFF.
S/W STICS
KYRON SM - 2005.09
1) When opening the door in armed mode
WARNING REQUIREMENTS WARNING CANCELLATION
ESTABLISHED NO ESTABLISHED ESTABLISHED
NORMAL
T2
ON
OFF
HORN
OFF
WARNING
OPERATION STATUS
OTHERS
T1: 0.5 sec
T2: 1.0 sec
T3: 27 sec
A / CRUISE
S E AT
S / ROOF
T3
T3
LAMP
ON
T1
PAS
HAZARD RELAY
R / SENSOR
THEFT DETERRENT STATE
NO ESTABLISHED WARNING ARMED
WIPER
AV
CLUSTER
SPWM
IMMO
EL
1) Unlocking by remote control key or engine starting.
42
8710
8. Operations when removing and installing the battery Installed Removed

Normal Armed Armed Ready Armed Warning Warning Completion RELOCK Ready
Normal
Armed
Warning
Remark
If the system is in armed mode while installing a battery, the horn sounds and the emergency warning lamp blinks (Same operations with warning in armed mode). RELOCK Operation It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key, the system outputs LOCK signal and activates the armed mode.

KYRON SM - 2005.09
8710 Specifications of Remote Control Key
43
When any of switches on remote control key is pressed, the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle. Switch Functions on Remote Control Key Function
Door lock Function Door unlock PANIC
STICS
Switch Operation
Briefly press the switch briefly Press and hold the door switch Briefly press the panic button
SPWM IMMO
KYRON SM - 2005.09
Panic button 1. Panic function 1) The theft deterrent horn sounds approx. 27 seconds when pressing this button for 0.1 ~ 0.5 seconds. 2) It stops when pressing any of the buttons on the remote control key.
Door button 1. Door lock (short press) 1) The door is locked and it goes into the armed mode when pressing this button for 0.1 ~ 0.5 seconds. 2. Door unlock (long press) 1) The door is unlocked and it gets out of the armed mode when pressing this button for 0.5 ~ 1.0 seconds. 2) The front room lamp comes on for 30 seconds when receiving door unlock signal by the remote control key while the front room lamp coupled switch is pressed.
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
EL
44
8710
Receiver
1. Operating requirements IGN Key = OUT (removed) 2. Code registration requirement Codes can be registered only through SCAN-100. 3. Transmitter Code Registration 1) Up to two transmitter codes can be registered. 2) The received code cannot be output during the registration. 3) Both single REKES and dual REKES must be encoded through the SCAN-100.
Remote Door Lock

1. All doors are locked when briefly pressing the door LOCK switch on remote control key (less than 0.5 seconds). 2. The system outputs LOCK signal immediately after receiving the door lock message from the remote control key. The system activates the theft deterrent mode when all doors are locked while they are fully closed (the hazard warning lamps blink twice.).
REMOTE CONTROL KEY PRESS THE DOOR LOCK BUTTON
Door Lock
0.5 0.1 seconds DOOR LOCK OUTPUT OFF ON DOOR LOCK SWITCH UNLOCK LOCK ON SENSING OFF ON HAZARD LAMP OFF ON HORN OFF 50 ms 0.5 0.1 seconds 0.5 0.1 seconds 0.5 0.1 seconds Door Close, Hood Close, Door Lock, T/Gate Close Chattering time

KYRON SM - 2005.09
8710 Door Unlock
45
1. The door unlock operates when pressing the door switch on the remote control key for longer than 0.5 seconds.
STICS A / CRUISE
KYRON SM - 2005.09
2. The door unlock relay is ON for 0.5 seconds when receiving the door unlock message from the remote control key. 3. The hazard warning lamps blink once only when all the doors unlocked.
RECEIVING MESSAGE OFF ON Chattering time DOOR UNLOCK
DOOR UNLOCK OUTPUT DOOR LOCK SWITCH
LOCK ON
SENSING OFF ON HAZARD LAMP OFF

AV S/W
0.1 seconds 0.1
PANIC
1. This function operates when pressing the PANIC switch on the remote control key for less than 0.5 seconds. 2. The horn sounds for 27 seconds when receiving the PANIC message from the remote control key.
Pressing PANIC button UNLOCK LOCK 0.5 sec ON HORN OFF 0.1 sec
DOOR LOCK SWITCH
T1
27 sec
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
CLUSTER
UNLOCK
DOOR UNLOCK
SPWM
IMMO
EL
46
8710
Auto Door Lock

1. It the door is not opened within 30 seconds after unlocking the door with remote control key, the system outputs LOCK signal and activates the armed mode (Relock function).
DOOR UNLOCK SIGNAL
OFF ON 0.5 seconds 0.1 second
Max 30 seconds 0.3 seconds
DOOR LOCK SWITCH
UNLOCK LOCK
Door Unlock
Auto Door Unlock

KYRON SM - 2005.09
8710
47
5. DIAGNOSIS TROUBLE CODE AND HELP TIPS

Fault Code
01 02 03 04 05 06 07 08 09 10
Malfunction
Dr Door Lock Knob Ps Door Lock Knob Rr Door Lock Knob T/Gate Lock Knob Door Lock Output Door Unlock Output C/DR Lock Output DR Lock Output PS Lock Output Auto Door Lock Output
Descriptions
STICS A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV S/W CLUSTER SPWM IMMO
Drivers door lock knob is not operated when locking/unlocking doors. Passengers door lock knob is not operated when locking/unlocking doors. Rear door lock knob is not operated when locking/unlocking doors. Tailgate lock knob is not operated when locking/unlocking doors. All door lock knob are not moved to lock position even when the door lock relay is activated. All door lock knob are not moved to unlock position even when the door unlock relay is activated. Doors are locked by central door lock switch while the engine is running. Doors are locked by drivers door lock switch while the engine is running. Doors are locked by passengers door lock switch while the engine is running. Door lock knob is not moved to lock position when the system outputs auto door lock signal while the ignition switch is in ON position and the vehicle speed is over 50 km/h. Door lock knob is not moved to unlock position after receiving the output from collision sensor. The WIPER P-POS signal is not detected when the wiper relay is activated. The vehicle speed over 3 km/h is detected at the speed signal area while the ignition switch is in ON position and the alternator signal is D LOW. The circuit is open (over 4.5 V) when changing the INT volume in the speed sensitive INT wiper (saved as history error). The vehicle speed over 200 km/h is detected (saved as history error). A signal is sent to the collision sensor input area while the ignition switch is in OFF position (saved as history error unconditionally). The RKSTICS outputs UNLOCK signal after receiving collision sensor input while the ignition switch is in ON position (saved as history error). The STICS outputs the Door Unlock signal due to the collision sensor and the feedback value is in proper range (saved as history error). The door warning indicator blinks when the vehicle speed is over 10 km/h (saved as history error). The parking brake indicator blinks when the vehicle speed is over 10 km/h (saved as history error). The auto washer output is not sent to the front washer (saved as history error). The front washer switch receives the input signal for more than 10 seconds (saved as history error).
11 12 13
Auto Door Unlock Output Wiper Output SPEED SIGNAL
14 15 16 17
INT WIPER Volume SPEED SENSOR A/BAG COLLISION SENSOR INPUT A/BAG COLLISION SENSOR OUTPUT A/BAG COLLISION MONITOR Door Ajar Warning IND PARKING BRAKE IND Auto Washer Out WASHER RELAY
18 19 20 21 22

KYRON SM - 2005.09
EL
48
8710
Fault Code
23 24
Malfunction
REMOCON VOLTAGE CHECK SBR S/BELT SW (Only EU) SBR SENSOR (Only EU) SBR CONNECTION (Only EU)
Descriptions
The voltage from remote control key is saved as history error. When the seat belt switch circuit is OPEN (HIGH) in KEY OUT & ARMED MODE, the system recognizes it as FAIL and saves it as History error (Normal Close (GND)). When the sensor value is recognized in KEY OUT & ARMED MODE, the system saves it as History error. When the seat belt switch circuit maintains OPEN (HIGH) in KEY OUT & ARMED MODE while the vehicle speed is over 50 km/h, the system saves it as History error.
25 26

KYRON SM - 2005.09
8710
49
6. ELECTRIC WIRING DIAGRAMS

Power/Ground, Chime Bell, Buzzer, Warning Lamp (Brake, Seat Belt, DR Open)
EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
50
8710
Central Door Lock Circuit

KYRON SM - 2005.09
8710
51
Tail Lamp, Hazard, Power Window

EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
52
8710
Windshield Heated Glass (Defogger)

KYRON SM - 2005.09
8710
53
Panic, Auto Light & Rain Sensing, Room Lamp

EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
54
8710
FRT Wiper/Washer & RR Washer

KYRON SM - 2005.09

Preceding Works: 1. Disconnect the negative battery cable. 2. Remove the lower panel in front of drivers seat. (For details, refer to BODY section.)
55
1. Disconnect the connectors from STICS unit and remove the RKSTICS antenna.
AV
2. STICS antenna 3. Chime/buzzer connector
5. Door lock/unlock relay connector

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
1. STICS connector
4. PAS buzzer connector
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
56
8710
2. Unscrew two mounting bolts (10 mm - 2EA) and remove the STICS unit.
RK-STICS antenna
Chime bell
Door lock relay
PAS buzzer RK-STICS
3. Separate the STICS unit.

STICS Unit

KYRON SM - 2005.09
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM .......................................... 2
1. 2. 3. 4. 5. 6. 7. Overview ...............................................................................2 Basic functions of immobilizer key (REKES function) .......3 Other functions in system ...................................................4 Replacement of electronic head part (excluding key plate) ...6 REKES operation logic ........................................................ 7 Dual REKES coding .......................................................... 10 Immobilizer coding and removal of immobilizer unit ......... 12
7010
IMMOBILIZER SYSTEM
1. OVERVIEW
The immobilizer unit communicates with the engine control unit to enable the engine starting.
Immobilizer
What is the immobilizer system?

The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU. Refer to the information that follows for specific functions and their descriptions.
Transponder Battery
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
2. BASIC FUNCTIONS OF IMMOBILIZER KEY (REKES FUNCTION)

1. Door and tailgate lock (briefly press) All doors and tailgate are locked and the vehicle the theft deterrent mode is activated. 2. Door and tailgate unlock (press and hold) All doors and tailgate are unlocked and the theft deterrent mode is deactivated. The front room lamp and the center room lamp come on for 30 seconds. The lamps go off immediately when the LOCK signal is sent from the remote control key (room lamp coupled function).
STICS A / CRUISE
Door button
PANIC function (with ignition key in) Theft deterrent horn sounds approx. 27 seconds.
The doors cannot be locked by remote control if they are not closed. The PANIC function operates only in theft deterrent mode.
The PANIC function operates only in theft deterrent mode.
Specification Quantity
CR 2032
LAMP
one
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
S E AT
S / ROOF
PAS
R / SENSOR
NOTICE
WIPER
AV
PANIC button
S/W
Key plate 1. Engine start 2. Door lock/unlock
CLUSTER
SPWM
IMMO
EL
7010
3. OTHER FUNCTIONS IN SYSTEM

Immobilizer Function
The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
2
Transponder The immobilizer unit transmits the encrypted code to the transponder. Immobilizer Unit
The transponder sends an encrypted signal to the unit as a response.
The transmitted code is changed to an encrypted signal in the unit.
The system compares the signal from transponder and the encrypted signal in immobilizer unit.
NOTICE
In the following cases, a driver may be unable to start the vehicle with the immobilizer. When two or more immobilizer keys come into contact with (each) other(s). When the key is close to any device sending or receiving electromagnetic fields or waves. When the key is close to any electronic or electric devices such as lightening equipment, security keys or security cards. When the key is close to a magnetic or metal object or a battery.
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
5
ELECTRIC
Immobilizer and Warning Lamp
Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: immobilizer unit is not coded
SPWM
When turning the ignition key to ON position, the ECU transmits the challenge message to the immobilizer unit. (to verify whether the key is valid)
Only when the two signals are identical, it recognizes the key as the authorized one and transmits the positive message to the ECU.
NOTICE
Do not drop or shock to the transponder in the key as it may be damaged. When you erase the code or register an extra key, let the owner attend on the site. With a damaged transponder, the engine cannot be started.
NOTICE
In any case, the immobilizer system can not be removed from the vehicle. If you attempt to remove it and damage the system, starting will be impossible, so never attempt to remove, damage or modify it. The remote engine starter cannot be installed on the vehicle equipped with the immobilizer system.
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
AUTO CRUISE
S E AT
SUNROOF
LAMP
PAS
RAINSENSOR
WIPER
Engine Control Unit (ECU)
The ECU starts the engine.
AV
SWITCH
CLUSTER
IMMO
This indicator comes on when the ignition key is communicating with the engine control unit (during engine starting) and goes out after starting the engine.
STICS
7010
4. REPLACEMENT OF ELECTRONIC HEAD PART (EXCLUDING KEY PLATE)

Replace the Electronic Head Part of the Immobilizer When:
1. The transponder (immobilizer key) is broken or damaged. 2. The immobilizer system is not properly functioning.
Rubber cover
Key plate
Screws (2EA)
Key electronic head assembly
Remove the rubber cover on the back of the key assembly. Remove two screws to uncover the key plate. Install the new electronic head assembly on the key plate.
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
5. REKES OPERATION LOGIC

Remote Door Lock
STICS A / CRUISE
1. When briefly pressing the door lock switch on the remote control key for less than 0.5 seconds, all doors are locked. 2. The system outputs the LOCK signal immediately after receiving the door lock message from the remote control key. If the vehicle is locked while all doors including tailgate and engine hood are closed, the theft deterrent mode is activated (hazard warning lamps are blinking twice).
PRESS DOOR LOCK
Door Lock 0.5 sec 0.1 OFF ON UNLOCK Chattering time
DOOR LOCK OUTPUT DOOR LOCK SWITCH
SENSOR LOCK
HAZARD LAMP 0.5 sec 0.1 ON HORN OFF 0.5 sec 0.1 0.5 sec 0.1
Door Close, Hood Close, Door Lock, T/Gate Close
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
7010
Door Unlock
1. When pressing and holding the door unlock switch on the remote control key for more than 0.5 seconds, all doors are unlocked. 2. When receiving the DOOR UNLOCK message from the remote control key, the door unlock relay is turned on for 0.5 seconds. 3. The hazard warning lamps blink once only when the doors are successfully unlocked.
PRESS DOOR UNLOCK SWITCH OFF ON Door Unlock UNLOCK DOOR LOCK SWITCH LOCK ON SENSING OFF ON HAZARD LAMP OFF
DOOR UNLOCK OUTPUT
Chattering time
0.1 sec 0.1
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
Remote PANIC (With ignition key in)

1. When briefly pressing the PANIC switch on the remote control key for less than 0.5 seconds, the PANIC function is activated. 2. When receiving the PANIC message from the remote control key, the horn sounds for 27 seconds.
EL A / CRUISE
0.5 sec ON HORN OFF 0.1 sec
T1 T1: 27 sec
27 sec
AV
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
DOOR LOCK SIWTCH
UNLOCK LOCK
IMMO
PRESS PANIC SWITCH
STICS
10
7010
6. DUAL REKES CODING

The new coding is required by using the scanner when lost the transmitter. Vehicles with REKES function only have one REKES remote control key and vehicles with immobilizer system have two keys with remote control function. Therefore, there is a need to code two immobilizer keys. 1. After connecting the scanner and selecting KYRON, then select DUAL REKES. 2. To start to code, press YES in the below screen. This results in clearing the key codings of the old REKES. REKES REMOCON CODING KYRON DUAL REKES
DO YOU START REKES CODING? [Yes / No]
4. The below screen is displayed when the first key coding is completed. To start the second coding, press YES. REKES REMOCON CODING KYRON DUAL REKES >>>> FIRST KEY CODING OK. <<<< REMOCON ID. CODE : 0X AX FX XX KEY CODE NUMBER : 01
3. Press one button of a remote control key once for 0.5 - 1.5 sec. You can hear a beep sound.
REKES REMOCON CODING KYRON DUAL REKES
PROCESSING THE CODING. Press the remocon button.
DO YOU START 2nd KEY CODING? [ Yes / No ]
(About 0.5-1.5 second)
Continued
IMMOBILIZER SYSTEM
7010
11
To exit REKES key coding, press ENTER. REKES REMOCON CODING KYRON DUAL REKES
REKES REMOCON CODING KYRON DUAL REKES
PROCESSING THE CODING. Press the remocon button. (About 0.5-1.5 second)
REMOCON ID. CODE : 0X AX FX XX KEY CODE NUMBER : 01
[ENTER] : EXIT
8. After exiting the SCAN-100 and disconnecting it from the diagnostic connector, perform the function tests for the remote control keys. If they do not work, repeat the above dual REKES key coding procedures.
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
7. Back to return the main screen when you have finished coding.
WIPER
AV
S/W
CLUSTER
>>>> SECOND KEY CODING OK. <<<<
SPWM
IMMO
5. Press one button of a second remote control key once for 0.5 - 1.5 sec. You can hear a beep sound.
6. The below screen is displayed when the second key coding is completed.
STICS
EL
12
7010
7. IMMOBILIZER CODING AND REMOVAL OF IMMOBILIZER UNIT

When Replacing the ECU
After replacing the ECU with new one, perform the variant coding. Then, insert the ignition key and perform the immobilizer coding.
When Replacing the Immobilizer Unit or Key Head Part

When inserting an ignition key after replacing the immobilizer unit, the ECU transmits the challenge message and waits for the response message. The immobilizer unit indicator blinks with 0.5 Hz of interval to inform that the immobilizer unit is not programmed (i.e. newly replaced). In this case, the immobilizer coding should be performed.
Removal of Immobilizer Unit

Preceding Works: Remove the battery negative cable. 1. Remove the lower panel from the drivers seat. (For details, refer to BODY section.) 2. Remove the steering column shaft assembly. (For details, refer to STEERING section.)
3. Remove the connector from the key switch and disconnect the immobilizer unit.
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
13
Immobilizer Coding
CONTROL UNIT SELECTION KYRON IMMOBILIZER 1] ECU 2] TCU 3] ABS / ESP 4] AIR-BAG 5] TCCU 6] IMMOBILIZER
CLUSTER
FUNCTION SELECTION KYRON IMMOBILIZER 1] READ FINGERPRINT 6 2] IDENTIFICATION 3] CODING
KYRON IMMOBILIZER
KYRON IMMOBILIZER
WIPER
KYRON SM - 2005.09
ENTER TESTER PASSWORD YES 1 1 4 3 4
>>>> WARNING <<<<
If you start immobilizer coding procedure, value of coded key is cleared.
11434
Continued
IMMOBILIZER SYSTEM
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
Are you sure? [Yes/No]
R / SENSOR
AV
TEST PASSWORD
IMMOBILIZER CODING
S/W
SPWM
IMMO
STICS
EL
14
7010
11434
INPUT USER ID. KYRON IMMOBILIZER ENTER USER ID. 114 1 1 4
IMMOBILIZER CODING KYRON IMMOBILIZER ENTER TESTER PASSWORD
Turn OFF ignition key. Press ENTER
Range : 0 ~ 255
FAIL OK
IMMOBILIZER CODING KYRON IMMOBILIZER
CODING FAIL. Turn OFF ignition key. After Check the IMMO. System, Retry Coding Procedure. Turn ON ignition key
Wait for 30 Seconds. and then Turn ON ignition key. Rest time: 27 seconds Press ENTER
Press ENTER
ENTER
Continued
IMMOBILIZER SYSTEM
KYRON SM - 2005.09
7010
15
ENTER
STICS
IMMOBILIZER CODING KYRON IMMOBILIZER 1st Key Coding OK

IMMO
Remove key and insert 2nd key, and then Turn ON ignition key. Press ENTER
Please wait.
CLUSTER
KYRON SM - 2005.09
05 Seconds
All Key Coding OK ESC

AV

WIPER
Are you sure exit ? [ Yes / No ]
CODING END. Turn OFF ignition key, and then Turn ON ignition key. Press ENTER
IMMOBILIZER SYSTEM
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
S/W
SPWM
Turn OFF ignition key.
Input code to first key.
EL
MEMO
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SEAT POSITION WITH MEMORY

SPWM (Seat Position With Memory) UNIT ............ 3
1. 2. 3. 4. 5. 6. Overview ...............................................................................3 Components .........................................................................4 Operations ...........................................................................5 Input/output of SPWM unit .................................................. 8 Control and operating conditions ......................................... 9 Removal and installation of seat ....................................... 15
7410
Location (Bottom of divers seat)
SPWM
Functions of SPWM
Seat Position With Memory Power seat control
Drivers seat and outside mirror position memory
1. Adjusting the power seats position with the seat adjusting switch 2. Adjusting the angle of the outside rearview mirrors (OSRVM) 3. Seat memory positions: for 3 persons 4. Folding/Unfolding the outside rearview mirrors

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Outside rearview mirror control
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
The memory setting of seat position is available availabe for up to 3 different drivers. Each driver can set his/her own drivers seat and outside rearview mirrors positions and they will be stored in the computer. Even if someone have moved your seat and outside rearview mirrors, the memory positions will be recalled automatically by pressing the position button.
STICS
1. OVERVIEW
EL
SPWM (Seat Position With Memory) UNIT
7410
2. COMPONENTS
SPWM Unit
LH outside rearview mirror
RH outside rearview mirror
Front cushion motor/ sensor Reclining motor/ sensor Rear cushion motor/ sensor Sliding motor/ sensor
Seat memory switch
Outside rearview mirror folding switch
Seat adjusting switch

KYRON SM - 2005.09
7410
3. OPERATIONS
Outside Rearview Mirror Control
Outside Rearview Mirror Folding Switch To fold the outside rearview mirrors, press the switch. To unfold the mirrors, press again. Mirror Selection Switch L: Driver side mirror R: Passenger side mirror
STICS EL
Aiming Switch Select the driver side mirror (L) or passenger side mirror (R) with the mirror selection switch. And then adjust the selected mirror up, down, left, or right by pressing the corresponding edges of the switch to get the direct rearview.
Seat Position Control
Seat Slide Adjustment
Seat Height Adjustment
Seat Tilt Adjustment

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
Seatback Reclining Adjustment
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
7410
Drivers Seat Position Memory Function

The position memory is available for up to three drivers. Each driver can set his/her own driver's seat outside rearview mirrors and interior rearview mirror positions and they will be separately stored in the integrated computer. If somebody has moved the seat, the memory positions can be recalled automatically by pressing the position button.
STOP button
Position buttons (1, 2, 3)
SET button
Storing Memory Settings

1. Position the transmission shift lever to P with the ignition switch ON (for your safety, do not start the engine). Apply the parking brake if the vehicle is equipped with M/T. 2. Adjust the drivers seat and outside rearview mirrors to the desired positions. 3. Press the SET button. The indicator on the button will come on. 4. Within 5 seconds, press the buttons ( blinks 3 times. ), ( ) or ( ) you want to set. The indicator on the set button

KYRON SM - 2005.09
7410
Operating Memory Settings

1. Press and hold the desired buttons ( , or ) for more than 1.5 seconds.
STICS A / CRUISE
2. Drivers seat and outside rearview mirrors start to move. The position memory recall is canceled if moving the vehicle during its operation. 3. Wait until they stop moving. 4. When the position memory recall is completed, the buzzer sounds twice. (If failed, the buzzer sounds three times.) CAUTION
The position memory recall is canceled if operating the seat or the outside rearview mirrors during its operation. In the vehicle equipped with automatic transmission, the position memory recall is not available if the parking brake is released and the gear shift lever is not in P position. In the vehicle equipped with manual transmission, the position memory recall is not available if the parking brake is released. If the position memory recall is successfully completed the buzzer sounds twice. If it failed, the buzzer sounds three times.

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
7410
4. INPUT/OUTPUT OF SPWM UNIT

Seat memory power Sliding motor Cushion front motor
Seat sliding, rear lift power
Seat reclining, front lift power
Cushion rear motor
Instrument panel: gear shift lever at P position In the vehicle equipped with automatic transmission, the position memory recall is not available if the gear shift lever is not in P position.
RH outside rearview mirror folding/unfolding motor
LH outside rearview mirror folding/unfolding motor Parking brake operation In the vehicle equipped with manual transmission, the position memory recall is not available if the parking brake is released. Vehicle speed signal If vehicle speed is over 3 km/h, the position memory recall is not available.
SPWM UNIT
RH outside mirror Up/ Down adjustment motor
RH outside mirror Left/ Right adjustment motor
LH outside mirror Up/ Down adjustment motor Outside rearview mirror folding switch LH outside mirror Left/ Right adjustment motor Outside rearview mirror adjusting switch Power seat control switch The changes of each motor are always monitored by the sensor in the motor.
Seat memory switch

KYRON SM - 2005.09
7410
5. CONTROL AND OPERATING CONDITIONS

Seat Position Memory
Seat Position Memory Operation
1. To store the seat position and the outside rearview mirror position, press the SET button and, within 5 seconds, press one of position switches. The memory setting is available for up to 3 different drivers. 2. The memory set mode is only available within 5 seconds after pressing the SET button.
STICS A / CRUISE
MEMORY SW
ON OFF Memory set mode over 100 ms Cannot memorize
POSITION SW
ON OFF 5 sec 5 sec
3. If any of the following conditions is met, the memory set mode is canceled. 2) When adjusting the seat or outside rearview mirror positions during the memory recall operation. 3) When turning off the ignition switch. 4) When pressing the STOP button 5) When the memory setting is completed. 4. The memory recall is not available when the vehicle speed is over 3 km/h or the gear shift lever is not in P position with the parking brake released. 5. The memory set can be unlimitedly renewed. 6. The stored positions are erased when disconnecting the battery cables. 8. The buzzer sounds twice if the memory setting/recalling is completed. 9. The buzzer sounds three times if an error is found in the sensor during the memory recall operation.
LAMP S E AT S / ROOF WIPER PAS R / SENSOR
1) No switch inputs within 5 seconds after pressing SET button.
7. The buzzer sounds once if the memory set mode is activated.

KYRON SM - 2005.09
AV
S/W
CLUSTER
SPWM
over 100 ms
IMMO
EL
10
7410
Seat Memory Recall Operation

1. When pressing the position switch with the ignition switch ON, the seat and outside rearview mirrors move to the memorized positions. 2. When pressing another position switch during previously activated memory recall operation, the newly pressed position switch takes priority and recalls its stored position. 3. The buzzer sounds once if a position switch is pressed. 4. If any of the following conditions is met, the memory recall function is deactivated. 1) When turning off the ignition switch. 2) When the gear shift lever is not in P position with the parking brake released. 3) When the parking brake is released (only for the vehicle equipped with manual transmission) 4) When the vehicle speed is over 3 km/h. 5) When pressing the STOP button during the memory recall operation. 6) When adjusting the seat or outside rearview mirrors during the memory recall operation. 5. The seat will not move unless a position switch has a memory setting. 6. Timing Chart
ON IGN SW OFF 1.5 0.2 sec ON POSITION SWITCH OFF Once ON BUZZER OFF ON OFF Twice
MANUAL OPERATION SWITCH (SEAT, OUTSIDE REARVIEW MIRROR ADJUSTING SWITCH) VEHICLE SPEED
Over 3 km/h Below 3 km/h ON
STOP BUTTON
OFF
ON RECALL OPERATION OFF

KYRON SM - 2005.09
7410
11
POWER SEAT
Seat Position Control
1. The position sensor senses the changes of motor in the seat. 2. The seat position is stored by the memory order of position switch. 3. The stored seat position is recalled by the recall order of position switch. 4. The manual adjustment of seat positions takes priority over the memory and recall orders.
STICS EL
Motor Drive Control

1. In the case of the automatic control, each motor drive is delayed for 100 msec to prevent the irruptive current from being overlapped. The priorities are as follows. Seat sliding Seatback reclining Seat cushion height adjusting (front) Seat cushion height adjusting (rear)
Seat sliding relay
ON OFF Min 100 ms
OFF Min 100 ms
Seat cushion (front) adjusting relay
ON OFF Min 100 ms
Seat cushion (rear) adjusting relay
OFF
LAMP
Seat sliding: 16 seconds, Seatback reclining: 50 seconds, Cushion height adjusting: 6 seconds 3. Reverse control When reversing the control motor, the motor starts to rotate in the opposite direction 100 msec after the forward driving is completed. 4. The motor doesnt operate if the difference between the stored position and the current position is out of the specified range. 1) Sliding: 12 edges (6 pulses) 2) Cushion height: 6 edges (3 pulses) 3) Reclining: 100 mV

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
2. Continuous motor driving time
PAS
R / SENSOR
WIPER
Seatback reclining relay
ON
AV
S/W
CLUSTER
SPWM
IMMO
12
7410
Error Detection
After the motor starts to drive, if the position sensor value doesnt change for about 3 seconds during the seat sliding or seatback reclining adjustment and for 1.6 seconds during the seat cushion height adjustment, it is determined that the harness circuit is open or the sensor failure occurred. If an error is detected, The memory recall operation stops. However, the seat can be adjusted by manual switches. The memory recall operation can be activated after the failure is corrected. This is determined when the system detects the value changes from the position sensor. This is called the Release of automatic control stop
Relay Protection
Once the relay is turned on, it will not be turned off within 60 ms.
Specifications
1. Rated voltage: DC 12 V 2. Operating voltage: DC 9 ~ 16 V 3. Current consumption: Max. 500 mA (not including the load) 4. Operating temperature range: -30C ~ 75C 5. Reserve temperature range: -40C ~ 85C 6. Parasitic current: Max. 2 mA

KYRON SM - 2005.09
7410
13
Outside Rearview Mirror (OSRVM)

Mirror Position Control
1. The position sensor senses the changes of motors in the mirrors. 2. The mirror position is stored by the memory order of position switch. 3. The mirror position is recalled by the recall order of position switch. 4. The manual adjustment of mirror positions takes priority over the memory and recall orders.
STICS EL
1. Driving sequence Horizontal Vertical 2. Control during memory recall Specifications of the field of vision 1) Horizontal direction: 1.5 ~ 3.7 V 2) Vertical direction: 1.5 ~ 3.7 V 3. LOCK detection Timer monitors the motor driving time to detect LOCK condition. 1) Monitoring the memory recall time If the memory recall operation cannot be finished within 40 seconds after activating it, the system stop the motor output and terminate the control. Field of vision: The control range of mirror that is not limited mechanically. The control range of that doesnt affect the sensor characteristics
Even though the motor runs, if the drive input change (for 5 seconds) from the position sensor doesnt change, it is determined that the harness circuit is open or the motor/sensor failure occurred. When an error is detected, any memory set or recall operations are prohibited, but the manual operation is possible. When the sensor input changes by a manual operation, this error is cleared.
Specification
1. Rated voltage: DC 12 V 2. Operating voltage: DC 9 ~ 16 V 3. Current consumption: Max. 300 mA (not including the load) 4. Operating temperature range: -30C ~ 75C 5. Reserve temperature range: -40C ~ 85C

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
Error Detection
WIPER
AV
S/W
CLUSTER
SPWM
Motor Drive Control
IMMO
14
7410
Folding/Unfolding of Outside Rearview Mirror

Operation Logic
1. When pressing the outside rearview mirror folding switch, the outside rearview mirrors are folded. 2. Normal operation mode Mode changes between Folding and Unfolding 3. The outside rearview mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignition switch. 4. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is extended 13 seconds when pressing the switch again.
Timing Chart
IGN
ON OFF
POWER RELAY
ON OFF T3 T3
T2
SIDE REARVIEW MIRROR FOLDING SWITCH
ON OFF T1
FOLD/UNFOLD
T T1 T : T < T1 , T1 : 13 3 sec , T2 : 30 6 sec , T3 : 1 sec 0.1 sec

KYRON SM - 2005.09
7410
15
6. REMOVAL AND INSTALLATION OF SEAT

Drivers Seat (Power Seat)
1. Slide the seat all the way to the rear and remove the seal rail mounting bolts (LH/RH: 14 mm - 1EA). Installation Notice
IMMO STICS EL
2. Slide the seat to the front stop and remove the seat rear mounting bolts (LH/RH: 14 mm - 1EA). Installation Notice
3. Pull up the seat and disconnect the harness connector. Remove the seat assembly.
Release the hook to disconnect the connector.

S / ROOF
Connector on seat
Main connector
KYRON SM - 2005.09
A / CRUISE
S E AT
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
16
7410
4. Unscrew the screws (arrows) and remove the protective cover.
5. Disconnect the harness connector and remove the SPWM unit.
SPWM unit

KYRON SM - 2005.09
CLUSTER
INSTRUMENT CLUSTER ....................................... 2
1. 2. 3. 4. Descriptions of indicator display ...........................................2 Warning & indicator panel ................................................... 10 Removal and installation of meter cluster ............................ 18 Electrical wiring diagrams ................................................... 21
8010
INSTRUMENT CLUSTER
The instrument cluster sends and receives the data through CAN communication. The HDC warning light and the engine hood open warning light are newly introduced.
1. DESCRIPTIONS OF INDICATOR DISPLAY
1. Tachometer 2. Speedometer 3. Left turn signal indicator 4. Right turn signal indicator 5. Engine coolant temperature gauge 6. Fuel gauge 7. Engine overheat warning light 8. Fog lamp indicator 9. High beam indicator 10. Door ajar warning light 11. Sea belt reminder (passengers seat)
12. Brake warning light 13. Low fuel level warning light 14. Winter mode indicator 15. ESP warning light 16. 4WD HIGH indicator 17. Battery charge warning light 18. Air bag warning light 19. HDC indicator 20. Immobilizer indicator 21. Water separator warning light 22. Seat belt reminder (drivers seat)
23. 4WD LOW indicator 24. 4WD CHECK warning light 25. Auto shift indicator (for automatic transmission) 26. ODOmeter/ Trip odometer 27. ABS warning light 28. EBD warning light 29. Engine hood open warning light 30. Glow indicator 31. Engine check warning light 32. Engine oil pressure warning light 33. Auto cruise indicator
CLUSTER
KYRON SM - 2005.09
8010
Configuration
Front View
Rear View
AV
Main Connector No.1 No.10
Sub Connector No.1 No.10
No.11
No.20
No.11
No.20
CLUSTER
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8010
Connector Pin Arrangement
Main Connector - 20 pins
Sub Connector - 20 pins
1. A/T N (Neutral) output 2. Hood open 3. Seat belt (passenger) 4. SSPS 5. 6. Front fog lamp 7. Hazard warning flasher 8. 9. Charge 10. IGN (alternator) 11. A/T P (Parking) output 12. Air bag 13. Seat blet (driver) 14. High beam (-) 15. RH indicator lamp (+) 16. High beam (+) 17. LH indicator lamp (+) 18. Oil pressure 19. Parking brake signal input (STICS) 20. -
1. 2. 3. 4P output 4. Buzzer output 5. Light (+) 6. PGND (signal -) 7. Engine check 8. Door open 9. 10. Battery 11. Troubleshooting 12. Fuel input signal 13. RESET / MODE switch 14. M/T N (Neutral) input 15. M/T P (Parking) input 16. CAN Low 17. CAN High 18. AGND (Fuel -) 19. MGND (Micom -) 20. IGN
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KYRON SM - 2005.09
8010
Warning Lights and Indicators

Engine Tachometer
Danger range (red zone)
STICS EL
The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the current number of engine revolutions. Under the normal engine operating temperature, the proper idling speed is 700 ~ 800 rpm. The red zone (danger rpm range) starts from 4,500 rpm. 1. Connect the tachometer for tune-up test and start the engine. 2. Eliminate the hysteresis by tapping the tachometer. 3. Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive.
Engine speed (rpm) Tolerance (rpm)
750 -
1000 +100 -100
2000 +100 -100
3000 +100 -100
4000 +100 -100
5000 +100 -100
6000 -
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KYRON SM - 2005.09
A / CRUISE
S E AT
If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner and then compare the value on tachometer with the reading from scanner.
S / ROOF
Checking
LAMP
PAS
Description
Specification (VIN=13 0.1V, Temperature: 25C)
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
8010
Speedometer
The speedometer indicates the vehicle speed by calculating the signals from the rear (right 8 LEFT) wheel speed sensor through ABS or ESP unit. In this model, the wheel speed sensor is installed at the rear tire area even though the ABS/ESP is not equipped. Its signal is used as a standard vehicle speed that is transmitted to instrument panel, TCU, TCCU, and engine ECU via CAN communication. 1. ABS/ESP (equipped): ABS/ESP ECU (208h), RR RH wheel speed sensor 2. ABS/ESP (not equipped): ENG ECU (320h), RR RH wheel speed sensor If the speedometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in speedometer. However, these symptoms also could be appeared when the tire has uneven wear, different tire inflation pressures or different tire specifications. Perform the speedometer test regarding the tolerance as described. However, it is not similar simple work in field due to lack of measuring conditions such as test equipment and preciseness. 1. Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester. 2. Check if the speedometer pointer is shaking and the abnormal noise sounds. 3. Eliminate the hysteresis by tapping the speedometer. Description
Standard speed (Km/h) Tolerance (Km/h) 20 +4 0 40 +4 0
(VIN = 13 0.1V, Temperature: 25C)

(60) +7 +2.5 80 +9 +3.5 100 +10.5 +4 120 +12.5 +6 140 +14.5 +7.5 (160) +16 +8.5 (180) +18 +10
NOTICE
The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
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KYRON SM - 2005.09
8010 Fuel Level Gauge
The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer. Note that this vehicle doesn't have a service hole for checking the fuel sender connector in the fuel tank. The fuel sender and its connector can be checked and replaced only when the fuel tank is removed. The power supply and resistance value should be measured at the connector in front of the fuel sender (refer to wiring diagram). When the power supply and output resistance are normal, the float operation by fuel level may be defective; if so, replace the fuel sender.
AV A / CRUISE
Tolerance and resistance value by indicating angle

Tolerance and resistance value by indicating angle (VIN = 13.5 0.1 V, temperature: 25C)
Scale Indicating angle () Tolerance () Resistance () Full 38 Full (Gauge) 105 +4, 0 43 (3/4) 78.75 67 1/2 52.5 5 99.5 (1/4) 26.25 150 Empty (Gauge) 0 0, -4 276.3 Empty 283
This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.
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KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8010
Coolant Temperature Gauge
The coolant temperature gauge displays the coolant temperature with a pointer. The angle of pointer that changes by coolant temperature is as shown below. Tolerance and resistance value by indicating angle
Indicating angle () Tolerance 0 +0C -4C Coolant temperature Less than 40C 52.5 +0C -4C 70 ~ 110C 120C 102 105 +4C +0C Over 125C
Measurement of coolant temperature sensor resistance

Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range. Resistance value by coolant temperature: 20C - 2449W 5 % 50C - 826W 5 % 80C - 321W 5 % 100C - 12W 5%
When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection.
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KYRON SM - 2005.09
8010 TRIP ODOmeter (TRIP A, TRIP B) and ODOmeter
Odometer/Trip Odometer
When pressing the TRIP/RESET switch on the center panel, the odometer/trip odometer is converted and the meter resets to 0.0 km in Trip A and Trip B.
Displaying range: 0.0 ~ 999.9 km
TRIP A
TRIP B
Displaying range: 0.0 ~ 999.9 km
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KYRON SM - 2005.09
A / CRUISE
S E AT
ODO
Displaying range: 0 ~ 999999 km
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
10
8010
2. WARNING & INDICATOR PANEL

ESP Warning Light This warning light comes on when pressing the ESP OFF switch or the ESP system is defective. If the ESP function operates while driving, this warning light flickers and the alarm sounds. HDC Warning Light Green light on: HDC is ready for use (by pressing the HDC switch). Green light blinking: HDC is being applied. Red light on: the HDC system is overheated or malfunctioning. When HDC is applied, the green HDC indicator blinks. When the red HDC indicator is on, the HDC system is overheated or malfunctioning. When the red HDC indicator is on, the HDC function does not work. Battery Charge Warning Light This warning light comes on when the ignition switch is turned on and go off when the engine is started. If this light doesnt go off after engine starting or comes on while driving, it means there is a malfunction in the system. Air Bag Warning Light When the ignition is switched on, this warning light illuminates and then should go out, to confirm that the air bag is operational. If it does not come on, or if it does not go out, or if it flashes or illuminates continuously while driving, it means that there is malfunction in the system.
Immobilizer Indicator This indicator comes on when the ignition key is communicating with the engine control unit (during engine starting) for approx. 0.5 seconds.
Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level, this 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 and water separator. Seat Belt Reminder 4WD LOW Indicator When shifting the driving mode between 4WD LOW and 4WD HIGH, this indicator blinks until the shifting operation is completed. After completion of mode change, the indicator goes out. 4WD CHECK Warning Light If 4WD CHECK warning light stays on continuously, it may indicate that there is something wrong in the transfer case system. The seat belt warning light comes on and the seat belt warning chime sound for 6 seconds when the ignition switch is turned to ON position unless the drivers seat belt is securely fastened. This reminding operation stops when the driver fastens the seat belt even during its operation period.
4WD Indicator 4WD HIGH indicator When shifting the driving mode from "4L" to "4H", this indicator blinks until the shifting operation is completed. After completion of the mode change to 4H, the indicator comes on.
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KYRON SM - 2005.09
8010
11
This warning light comes on when the SSPS system is defective. When this warning light comes one, the steerability becomes heavy. Door Open Warning Light This light comes on when a door or tailgate is either opened or not closed completely. Brake Warning Light This warning light comes on and warning buzzer sounds when the parking brake is applied and/or the brake fluid level is lower than specified level.
High Beam Indicator This indicator illuminates when the headlight high beam is switched on.
Low Fuel Level Warning Light This warning light indicates that the fuel will soon be exhausted. The time it takes to turn on, however, varies according to the vehicle operating conditions or gradient of the road. Winter Mode Indicator The indicator comes on when the Winter mode (W) switch near the gear selector lever is pressed. Use this mode to drive off smoothly under icy and slippery road.
Glow Indicator This indicator comes on when the ignition switch is turned on and stays on for a short time or may go off right away. When the glow plugs are sufficiently heated ABS Warning Light for cold starting, the light will go out. In the vehicle equipped with direct injection type engine, this indicaThis warning light comes on when the ignition switch is tor may come on very shortly or may not come on. turned to ON and should go out if the system is normal. The vehicle equipped with ABS performs self-diagnosis Engine Hood Open Warning Light on the system when the engine is started and drives off. During the diagnosis, brake pedal vibration and noise When the engine hood is open, this light comes on to may be apparent when the driving motors discharges inform the driver. the hydraulic pressure from the internal hydraulic device. This means the ABS is properly functioning. EBD Warning Light This warning light comes on when the ignition switch is turned to ON and should go out if the system is normal. If the If the light stays on or comes on while driving, some of EBD system is abnormal, EBD warning light comes on. engine control components including sensors and devices are defective. Engine Oil Pressure Warning Light When this warning light comes on, the vehicle operates in safety mode to maintain minimum driving con- This warning light comes on when the ignition is switched ditions and to prevent the system from being damaged. on and should go out when the engine is started. If the In this mode, the engine driving force may be decreased light comes on while driving, it indicates that the oil pressure is dangerously low. or the engine may stall. Engine Check Warning Light
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KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
When the tail or head lights are on, the fog lights come on if the fog light switch is turned to the ON position. Then, the fog light indicator comes on the instrument panel.
IMMO
Fog Lamp Indicator
STICS
When the engine coolant temperate is abnormally hot (over 120C), the engine overheat warning light blinks and a warning buzzer sounds. (check the coolant system)
SSPS Warning Light
EL
Over Temp. Warning Light
12
8010

This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC switch is a push & self return type switch when you press it once, it starts to operate and when you press it again, it stops the operation. HDC indicator HDC Operation Mode Green HDC warning lamp Red
HDC
HDC
ON OFF ON OFF
OFF OFF ON
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating requirements are not met. In operation HDC system is operating. Blinking (0.5 seconds of interval) OFF
Alternate blinking of green and red lamp (0.5 seconds of interval) OFF ON
NOTICE
Basically, the brake systems basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: Initial ignition ON HDC system error occurs Brake system overheat
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KYRON SM - 2005.09
8010
13
ESP Warning Lamp

SPWM STICS A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV S/W CLUSTER IMMO EL
500 ms ON ESP warning lamp OFF 500 ms Min. 4 times
1. When receiving CAN data LAMP: (200h, 1.5) ESP - INFO - BL: when receiving data, 500 ms on/off BUZZER: (200h, 1.4) ESP - INFO - BUZZ: when receiving data, 100 ms on/off
ESP System Cancellation Using the ESP OFF Switch

When the ESP switch is pressed (for over approximately 150 ms), the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP warning lamp on the instrument panel comes on. The detailed operation procedures are as follows: 1. The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be cancelled after approximately 150 ms. Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system is turned off. And the basic ABS system will operate.

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating. The detailed operation procedures are as follows. 1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be resumed after approx. 150 ms.
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KYRON SM - 2005.09
14
8010
PUSH
RELEASE 350 ms
PUSH
RELEASE
HI ESP operation LO
Disabled range 150 ms 150 ms
ON ESP operation (including TCS) OFF 150 ms 150 ms ON ESP warning lamp OFF
NOTICE
ESP OFF Switch Monitoring

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KYRON SM - 2005.09
8010
15
Push HI ESP operation LO 10 sec 3.5 sec Return to switch signal ESP function (including TCS) ON OFF Error detection
Release
Reset to normal condition
Cancellation of ESP OFF mode Turning the ESP warning lamp off ON ESP warning lamp OFF

Initial start (for 1.8 sec) Normal mode ESP fault ABS fault System fault Low batt. voltage High battery voltage High brake pad temp. ESP-OFF mode Entering diag. mode ON
Controls ABS
NO
ESP W/L
ON BLINKS WHEN ESP OPERATION ON ON ON ON ON ON ON ON
ASR
NO
ABD
NO
Vehicle yaw control

NO
OFF OFF ON ON ON ON OFF OFF ON
OK OK NO NO NO NO OK OK NO
OK NO NO NO NO NO NO NO NO
OK NO NO NO NO NO NO NO NO
OK NO
NO NO NO NO OK Note 1) NO
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KYRON SM - 2005.09
A / CRUISE
NOTICE
S E AT
S / ROOF
LAMP
NO
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
16
8010
Reasons why N Switch Signal is Transmitted to Instrument Panel *(1)

1. HDC operation signal The HDC function operates when the HDC switch is turned on with gear shift lever is in forward/reverse driving positions. Vehicles with the automatic transmission receive the signal from the gear shift lever unit and vehicles with manual transmission receive the neutral signal from the N (neutral) switch. 1) Manual transmission: operates in the 1st gear or reverse gear position (does not operate in the neutral position). 2) Automatic transmission: operates in all hear positions except P (parking) and N (neutral) position.
The vehicle with the manual transmission doesnt have a independent device or switch that detects the 1st gear position. It detects only the forward/reverse direction through the rear light switch and the neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, although the HDC also operates at over the 2nd gear, is because the engine may be turned off during the HDC operation. The HDC operates on the very steep road. Thus, it should be used only when the transmission is in the 1st gear position.
2. Raising the RPM in vehicles with the manual transmission. This switch detects whether the gear is in N position or in other positions. The instrument cluster sends the signal to the engine ECU. The engine ECU receives the N switch signal, the vehicle speed, the clutch operating conditions, and the engine coolant temperature and raises the engine speed by 100-200 rpm. This helps the vehicle start smoothly during gear shifting.
N Switch
Outside
Inside
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KYRON SM - 2005.09
8010 Vehicle Speed Input to Non-ABS Equipped Vehicle

The wheel speed sensor is installed on the rear right wheel regardless of the ABS/ESP installation.
17
36 Wheel speed sensor DSL Engine ECU
Battery(+)
SPWM
CAN HI 54 CAN LO 73 Cluster

CLUSTER
CLUSTER
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
IMMO
STICS
This sensor is to signal the vehicle speed to the engine ECU, TCCU, transmission, and instrument panel. There is no separate unit to process the wheel speed sensor signal. The wheel speed sensor is connected to the engine ECU (terminal 36), where its signal is processed, and is connected to other related systems through CAN communication.
EL
18
8010
3. REMOVAL AND INSTALLATION OF METER CLUSTER

Preceding Works: Disconnect the negative battery cable.
Location
Cluster
Center Fascia Panel Assembly (LH/RH)
Cluster
Outside Mirror Switch Bezel Assembly
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KYRON SM - 2005.09

1. Remove the left center fascia panel and unscrew three mounting screws on the hazard switch bezel assembly. NOTE
19
For details, refer to Removal and Installation of Instrument Panel.
2. Remove four instrument panel mounting screws.
3. Disconnect the outside mirror switch bezel connector and remove the meter cluster panel assembly.
NOTICE
Be careful not to damage the another components during removal procedures.
CLUSTER
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
Remove the bottom of the center fascia panel first.
EL
20
8010
4. Unscrew four cluster mounting screws.
5. Disconnect the connectors from the back of meter cluster and remove the cluster from the instrument panel.
CLUSTER
KYRON SM - 2005.09
8010
21
4. ELECTRICAL WIRING DIAGRAMS

Gauge (speed, RPM, fuel, temp), Warning Lamp (fuel, fuel filter, ABS/ ESP, brake, HDC, 4WD)
EL
CLUSTER
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
22
8010
Warning Lamp (batt charge, oil, hood, door, eng check, air bag, ssps, seat belt), Turn Signal, Fog Lamp, Hazard
CLUSTER
KYRON SM - 2005.09
SWITCHES / ELECTRIC DEVICES

8510 / 7770 / 8610 / 7632 / 7610 TABLE OF CONTENTS
SWITCH ARRANGEMENT ........................ 2 CENTER FASCIA & BEZEL SWITCH ASSEMBLY ............................................... 4
1. 2. 3. 4. 5. 6. Location ............................................................... 4 Switch arrangement ............................................. 5 Functions ............................................................. 6 Switches in hazard & bezel switch assembly ...... 8 Center fascia switch bezel assembly ................. 19 Removal and installation of hazard & bezel switch assembly ...................................... 21
SEAT POSITION MEMORY SWITCH ...... 72

1. 2. 3. 4. 5. 6. Location and functions ....................................... 72 Switch arrangement ........................................... 73 Exploded view .................................................... 74 Output voltage in each switch position ............... 74 Functions and operations ................................... 75 Removal and installation of seat position memory switch .................................................. 77 7. Electrical diagram of power seat & outside rearview mirror .................................................... 79
OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY ................................. 27

1. Location ............................................................. 27 2. Switch arrangement ........................................... 28 3. Switches in outside rearview mirror switch bezel assembly ................................................. 29 4. Removal and installation .................................... 36
AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL .......................... 81

1. 2. 3. 4. Locations and functions ..................................... 81 Components ...................................................... 82 Circuit diagram ................................................... 83 Removal and installation .................................... 84
MULTIFUNCTION SWITCH .................... 86

1. 2. 3. 4. 5. Overview ............................................................. 86 Functions and operations ................................... 87 Operating range ................................................. 90 Connector pin arrangement ................................ 91 Removal and installation .................................... 92
OVERHEAD CONSOLE SWITCH ........... 41

1. Location ............................................................. 41 2. Components ...................................................... 42 3. Switches in overhead console switch assembly ........................................................... 43 4. Removal and installation of overhead console switch ................................................................ 50
DIGITAL CLOCK ..................................... 96 CIGARETTE LIGHTER ............................ 98
SWITCH ASSEMBLY ON DRIVERS DOOR ARMREST .................................... 53

1. 2. 3. 4. 5. 6. Locations and functions ..................................... 53 Switch arrangement and appearance ................. 54 Power window operations ................................... 55 Circuit diagram of power window ........................ 56 Central door lock/unlock switch ......................... 58 Removal and installation of power window switch ................................................................ 64
POWER OUTLET .................................. 100 HORN (INCLUDING THEFT WARNING HORN) ................................................... 103
1. 2. 3. 4. Location ........................................................... 103 Electrical wiring diagram of horn ...................... 104 STICS control for theft deterrent mode ............. 105 Removal and installation .................................. 110
8510
SWITCH ARRANGEMENT
Outside Rearview Mirror Folding Switch To fold the outside rearview mirrors, press the switch. To unfold the mirrors, press it again. HDC Switch When this button is pressed once, HDC is ready for use. The green HDC indicator comes on the instrument panel. When the button is pressed again, HDC is deactivated and the indicator goes off. (Refer to ABS/ESP section.)
Tailgate Glass and Out side Rearview Mirror Heated Glass Switch Press this switch to turn on the tailgate and outside rearview mirror defogger. It will operate for about 12 minutes. ESP OFF Switch If you press the ESP OFF switch, the ESP function stops and the indicator lamp in instrument panel comes on. Press this switch again to resume the ESP function. At this time, the indicator lamp goes out. TRIP Switch To choose a desired driving distance display mode, press the switch: Changing sequence: ODO - TRIP A - TRIP B - ODO Windshield Heated Glass Switch Press this switch to turn on the windshield heated glass. It will operate for about 12 minutes.
Seat Position Memory Switch
The position memory is available for up to three drivers. Each driver can set his/ her own drivers seat and outside rearview mirrors positions and it will be separately stored in the integrated computer. If somebody has moved the seat, the memory positions can be recalled automatically by pressing the position button.
Drivers Power Window Switch
Driver can controls all door windows (Open/Close/Lock/ Unlock) and doors (Lock/ Unlock) with this switch unit.
8510
Additional Functions of Multifunction Switch Washer fluid will be sprayed onto the rear window glass once during rear wiper operation. Rear wiper operation Front wiper operation range (move the wiper lever up/down)
Auto light position
T/C Control Switch Audio Remote Control Switch Drivers Seat Warmer Switch
POWER MODE MUTE
Passengers Seat Warmer Switch
SEEK SEEK
VOL VOL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
Room lamp operating switch
Room lamp operating switch
AV
Main room lamp switch
S/W
Sun roof switch
CLUSTER
Washer fluid will be sprayed onto the rear window glass and the wiper will also operate once.
Front Wiper and Washer Coupled Operation Pull the lever briefly (below 0.6 seconds): One wiping cycle Pull and hold the lever for more than 0.6 seconds: Three wiping cycles with washer spray
SPWM
IMMO
Auto Washer Switch When the front wiper switch is off and this switch is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times. Then, the fluid will be sprayed again and the wiper will automatically operate 3 times.
STICS
EL
8510
CENTER FASCIA & BEZEL SWITCH ASSEMBLY

1. LOCATION
The center fascia switch consists of hazard switch bezel assembly, T/C control switch and seat warmer switch.
Center Fascia Assembly [Front View] [Rear View]

KYRON SM - 2005.09
8510
2. SWITCH ARRANGEMENT
Tailgate glass and outside rearview mirror heated glass switch HDC switch
STICS EL
Windshield heated glass switch
TRIP switch
Hazard switch
AV
T/C Control Switch

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
Drivers Seat Warmer Switch
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
8510
3. FUNCTIONS
HDC Switch
When you press the HDC switch, the green HDC indicator comes on, and when the HDC operates, the green HDC indictor blinks with 0.5 second of interval. NOTICE The HDC system is an automatic descent control device that allows the vehicle to automatically decelerate to about 7 km/h by 0.1G, on steep roads (slope level exceeding 10%) through a separately installed switch operation. When the vehicle speed reaches below 7 km/h (refer to the information below), the HDC automatically terminates the operation.
The G sensor in sensor cluster measures the actual road steepness. However, it may recognize a sharp turn or rough road as a downhill road with a slope level exceeding 10%, and the HDC may operate.
Tailgate Glass & Outside Rearview Mirror Heated Glass Switch
1. Press this switch to turn on the tailgate and outside rearview mirror heated glass. It will operate for about 12 minutes. 2. Press the switch again to stop the operation.
Hazard Switch
3. This switch is designed to defrost and defog on tailgate glass and outside rearview mirrors. 4. The heated glass will operate for about 6 minutes when the switch is pressed again within 10 minutes after completion of its first operation cycle. 5. The indicators in the switch come on when in use.
TRIP Switch
To choose a desired driving distance display mode, press the switch: Changing sequence: ODO - TRIP A - TRIP B - ODO TRIP A/B display will be initialized to 0 km when the distance of an individual trip exceeds 999.9 km. If you press and hold the reset button for more than one second in TRIP A or TRIP B mode, the trip ODO meter resets to zero.
TRIP A
Unit: 0.0 ~ 999.9 km
Windshield Heated Glass Switch
This switch is designed to defrost and defog on windshield. 1. Press this switch to turn on the windshield heated glass. It will operate for about 12 minutes. 2. Press the switch again to stop the operation. 3. The indicators in the switch come on when in use.
TRIP B
Unit: 0.0 ~ 999.9 km
ODO
Unit: 0 ~ 999999 km

KYRON SM - 2005.09
8510
T/C Control Switch
Choose a proper mode according to the road conditions. 4WD HIGH

This indicator blinks during mode changes to 4 H mode, then goes off after completion of mode change. Drivers Seat Warmer Switch
4WD LOW
This indicator blinks during mode changes to 4 L mode, then goes off after completion of mode change.
4WD CHECK
This warning light comes on when the 4WD system is defective.
Headlight Leveling Switch

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8510
4. SWITCHES IN HAZARD & BEZEL SWITCH ASSEMBLY

HDC Switch
Overview
HDC switch is a Push & Self Return type switch and connected to ABS/ESP HECU terminal. This switch has an illumination lamp connected to the tail lamp circuit.
ABS/ESP HECU
9 4 1
HDC Switch
ON 1(B) 2(GND) 3(IND) 4(ILL+) 5(ILL-)
OFF

KYRON SM - 2005.09
8510

This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/ OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC switch is a push & self return type switch when you press it once, it starts to operate and when you press it again, it stops the operation. HDC Indicator HDC Operation Mode Green HDC Warning Lamp Red
HDC
HDC
ON (goes off after 1.8 seconds) OFF ON OFF
OFF OFF ON
The HDC switch is turned ON, but HDC system is in stand-by mode because the operating requirements are not met. In operation HDC system is operating. Blinking (0.5 second of interval) OFF
Alternate blinking of green and red lamp (0.5 second of interval) OFF ON
NOTICE
Basically, the brake systems basic functions can work even when there are problems with the HDC system. As given in the table above, the HDC warning lamp comes on when: 1) Initial ignition ON 2) HDC system error occurs 3) Brake system overheat

KYRON SM - 2005.09
EL
10
8510
HDC (Hill Descent Control) System Operating Conditions

1. When HDC switch is turned ON 2. Gearshift lever position (Forward/Reverse) and and
Manual transmission: operates in the 1st gear or reverse gear position (does not operate in neutral position). Automatic transmission: operates in any position except P (parking) or N (neutral) positions.
NOTICE
The vehicles with manual transmission do not have a separate device or switch that detects the 1st gear. It only detects the forward/reverse driving direction of the vehicle through backup lamp switch and neutral switch, and cannot solely detect the 1st gear position. The reason for noting the 1st gear above, though the HDC also operates in 2nd gear position, is because the engine may turn off during the HDC operation process. You may face a very dangerous situation if the engine turns off at a steep hill. The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. For manual transmission equipped vehicle, HDC system should operated only in 1st gear.
3. When not depressing the accelerator pedal or brake pedal. 4. The vehicle speed is above 7 km/h (in Automatic transmission/4H mode).
and and
NOTE
The vehicle speed given in step (3) varies according to the vehicle driving mode, and the speed ranges by the vehicle driving mode and condition are as follows.
1) Speed available in HDC mode (slope) 2H/4H mode: vehicle speed below 50 km/h (operation slope level: 10%, termination slope
Forward level: when it reaches 8%) driving 4L mode: vehicle speed below 25 km/h (operation slope level: 10%, termination slope
level: when it reaches 5%) 2H/4H mode: vehicle speed below 50 km/h (operation slope level: 8%, termination slope
Reverse level: when it reaches 5%) driving 4L mode: vehicle speed below 25 km/h (operation slope level: 8%, termination slope level:
when it reaches 4%) 2) HDC target speed in 2H/4H mode (The HDC target speed is the speed that the HDC is not terminated even after the vehicle speed reaches 7 km/h, but is converted to the stand-by mode. When the vehicle speed increases again as a result of the increase of the road steepness, etc., the HDC goes into operation.) Forward driving: 7 km/h Reverse driving: 7 km/h (automatic transmission), 8.5 km/h (manual transmission) 3) HDC target speed in 4L mode Forward and reverse driving: 3 km/h

KYRON SM - 2005.09
8510
11
5. Vehicle position control function in ESP and HBA function are not in operation:
and
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP function is in operation, HDC operation is overridden.
6. Slope level exceeds 10%. When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed value given in step (4).

KYRON SM - 2005.09
EL
12
8510
HDC (Hill Descent Control) System Non-Operation Conditions

1. When HDC switch is turned OFF 2. Gearshift lever has passed neutral (N) position. or or
NOTICE
Vehicle with the manual transmission: Sensing at the neutral switch Vehicle with the automatic transmission: Sensing at the selector lever unit
3. When the vehicle speed is out of the specified values. 4. When the ESP related functions, e.g. vehicle position control, HBA, ARP is activated during HDC operation.
or or
The HDC is the device to improve the engine brake effect during downhill driving on a steep hill. If the ESP function is in operation, HDC operation is overridden. 5. When the internal temperature of HDC system goes over 350C due to long downhill driving on a steep hill with HDC operated. or
There is no specific temperature sensor in the system, but a programmed logic inside the HECU predicts the temperature based on the operating numbers and conditions of HDC.
NOTICE
The red HDC warning lamp blinks when the internal temperature goes over 350C. When it reaches 450C, the HDC warning lamp comes on. The HDC can be operated in the range even where the HDC warning lamp blinks.
6. When the slope level is below 10% When the slope level exceeds 10%, the HDC operates until the vehicle reaches the speed condition given in step (4).

KYRON SM - 2005.09
8510
13
Tailgate/Outside Rearview Mirror Heated Glass Switch

Overview
Tailgate/Outside rearview mirror heated glass switch is a Push & Self Return type switch. 1. The outside rearview mirror & tailgate glass defogger operates for approx. 12 minutes when pressing this switch while the ignition switch is turned on. 2. It stops when pressing the switch again during its operation. 3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6 minutes. 4. It stops when the ignition switch is turned to OFF.
STICS A / CRUISE
T/LP REPLAY STICS
RR DEFOGGER SW U GND
IND
ILL+
ILL-
1(U) 2(GND) 3(IND) 4(ILL+) 5(ILL-)

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
ON
OFF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
14
8510
Timing Chart
IGN2 SW
ON OFF HIGH
ALT L LOW Tailgate glass/ Outside rearview mirror heated glass switch Defogger relay OFF T1 T1 T1 T2 T3 T1 ON OFF ON
ALT L = 9 V 1 V (Key ON) & ALT = ON
T1: 12 min.
T2: within 10 min
T3: 6 min
ON: IGN2
OFF: IGN2 (Key ON) or ALT = OFF

KYRON SM - 2005.09
8510
15
Windshield Heated Glass Switch

Overview
Windshield heated glass switch is a Push & Self Return type switch. 1. The windshield defogger operates for approx. 12 minutes when pressing this switch while the ignition switch is turned on. 2. It stops when pressing the switch again during its operation. 3. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6 minutes. 4. It stops when the ignition switch is turned to OFF.
STICS A / CRUISE
KYRON SM - 2005.09
STICS IND
GND
ON 1(U) 2(GND) 3(IND) 4(ILL+) 5(ILL-)
OFF
S E AT
S / ROOF
LAMP
PAS
ILL+
ILL-
R / SENSOR
T/LP REPLAY
RR DEFOGGER SW
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
16
8510
Timing Chart
ON IGN2 SW OFF HIGH ALT L LOW Windshield defogger SW ON OFF ON Defogger Relay OFF T1 T1 T1 T2 T3 T1
ALT L = 9 V 1 V (Key ON) & ALT = ON
T1: 12 min.
T2: within 10 min.
T3: 6 min.
ON: IGN2
OFF: IGN2 (Key ON) or ALT = OFF

KYRON SM - 2005.09
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17
TRIP Switch
Overview
Trip switch is a Push & Self Return type switch. To choose a desired driving distance display mode, press the switch: Changing sequence: ODO - TRIP A - TRIP B - ODO TRIP A/B display will be initialized to 0 km when the distance of an individual trip exceeds 999.9 km. If you press and hold the reset button for more than one second in TRIP A or TRIP B mode, the trip ODO meter resets to zero.
TRIP A
Unit: 0.0 ~ 999.9 km
STICS
KYRON SM - 2005.09
TRIP B
Unit: 0.0 ~ 999.9 km
ODO
Unit: 0 ~ 999999 km
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
18
8510
Hazard Switch
Overview
Hazard switch is connected to the turn signal lamp circuit.

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19
5. CENTER FASCIA SWITCH BEZEL ASSEMBLY

T/C Control Switch
Overview
T/C control switch is the rotary type switch with steps and the switch operation is recognized by TCCU. This switch has an illumination lamp connected to the tail lamp circuit.
STICS A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV S/W CLUSTER SPWM IMMO EL
TCCU
TAIL LAMP
GND
CAUTIONS
There could be mechanical noises and shocks during To shift from 4L into another mode or vice versa, stop mode changes. However, these are normal conditions the vehicle and depress the brake pedal before any due to mode changing operations. shift. Use only the 2H mode on a normal paved surface. Do If the 4WD CHECK warning light stays on, have the not drive your vehicle in the 4H or 4L position on 4WD system checked. paved road surfaces. Doing so will result in damages When cornering a curved road in 4WD LOW or 4WD to the drive train. HIGH drive mode, there could be some mechanical Driving in a 4 wheel mode on a normal paved surface shocks and resistances in vehicles drive train. These will cause unwanted noises, premature wear of tires, are normal conditions due to internal resistance in drive or increased fuel consumption. train when the 4WD LOW is properly working. To avoid damages to the drive train, do not drive your vehicle with excessively high speed in sharply curved road.

KYRON SM - 2005.09
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8510
Seat Warmer Switch

Overview
Seat warmer switch is Push lock type switch. When the seat warmer switch is operated, the seat cushion and seatback gets warm. If the temperature of seat surface gets 40 5C, the thermistor cuts or connects the power to heated wire to maintain the temperature to the specified level. The is no control switch and unit to control the temperature of the seat surface temperature.
NOTE
The temperature of seat surface should be increased over 20C within 3 minutes after turning on the switch while a person (height: 175 5 cm, weight: 75 5 kg) occupies the seat.
CAUTIONS
Do not place anything sharp on the seat. When cleaning the seats, do not use organic solvents such as benzene or thinner. Do not use this function when the engine is not running. The battery could be discharged.

KYRON SM - 2005.09
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21
6. REMOVAL AND INSTALLATION OF HAZARD & BEZEL SWITCH ASSEMBLY

Location
Tailgate glass & outside rearview mirror heated glass switch
HDC switch Hazard warning switch Windshield heated glass switch TRIP switch
Drivers seat warmer switch
Passengers seat warmer switch

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
T/C control switch
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
22
8510

1. Remove the RH panel from the center fascia panel and unscrew three screws from the center fascia panel.
2. Disconnect the switch connectors and remove the center fascia panel assembly.

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23
Remove Three Mounting Screws
Remove Four Mounting Screws

LAMP

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
Front View
Rear View
EL
3. Remove the hazard switch bezel assembly and miscellaneous switch assembly from the removed center fascia panel.
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8510
4. Remove each switch from the hazard switch bezel assembly.
Front View
Side View
Rear View
1) Remove the round cover and switches.
2) Remove the hazard switch mounting bracket and remove the hazard switch.

KYRON SM - 2005.09
8510
5. Remove each switch from the miscellaneous switch assembly.
25
Front View
Rear View
Side View
STICS

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Drivers Seat Warmer Switch
T/C Control Switch
S/W
CLUSTER
SPWM
IMMO
EL
26
8510
Center Fascia Panel
Digital clock
HDC switch
Tailgate glass & outside rearview mirror heated glass switch
TRIP switch
Windshield heated glass switch Hazard warning switch
T/C control switch
Drivers seat warmer switch Passengers seat warmer switch Headlight leveling switch

KYRON SM - 2005.09
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27
Outside rearview mirror switch bezel assembly consists of outside rearview mirror folding switch, ESP OFF switch and rear fog lamp switch (regional option).
Front View of Outside Rearview Mirror Bezel Panel

AV
Rear View of Outside Rearview Mirror Bezel Panel

LAMP

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
Rear fog lamp switch
IMMO
STICS
1. LOCATION
EL
OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
28
8510
Outside Rearview Mirror Folding Switch
ESP OFF Switch
Outside Rearview Mirror Angle Adjusting Switch

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29
3. SWITCHES IN OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY

Outside Rearview Mirror Folding and Adjusting Switch
Overview
Outside rearview mirror folding switch is Self return type switch and outside rearview mirror control switch is Seesaw & Self return type switch. The outside rearview mirrors folding/unfolding function is not available when the vehicle speed is over 3 km/h. You can fold and unfold the mirros for 30 seconds after ignition OFF. Do not fold or unfold the outside rearview mirrors manually. It may cause a malfunction of the mirror folding system.
To fold the outside rearview mirrors, press the switch. To unfold the mirrors, press it again.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
30
8510
The outside rearview mirrors can be folded and unfolded within 30 6 seconds even after turning off the ignition switch. To prevent the outside rearview mirrors from stopping during its operation, the mirror operating time is extended 13 seconds when pressing the switch again.
Timing Chart
IGN SW
ON OFF
P/W TIME RELAY
ON OFF T3 T3
T2
FOLDING SW
ON OFF T1
FOLDING UNFOLDING
T T1
T: T < T1, T1: 13 3 sec, T2: 30 6 sec, T3: 1 Sec 0.1 sec

KYRON SM - 2005.09
8510 Electrical Wiring Diagrams
31

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
32
8510
ESP OFF switch

Overview
ESP OFF switch is Self return type switch.
ESP OFF Switch

KYRON SM - 2005.09
8510 ESP System Cancellation Using the ESP OFF Switch
33

The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch is pushed (for over approximately 150 ms) while the ESP system is not operating. The detailed operation procedures are as follows. 1. The ESP warning lamp goes off when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be resumed after approx. 150 ms.
PUSH RELEASE 350 ms PUSH
RELEASE
WIPER
HI ESP operation LO
Disabled range
150 ms
150 ms
OFF
150 ms 150 ms
NOTICE

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
ON
R / SENSOR
AV
S/W
CLUSTER
SPWM
When the ESP switch at the center switch panel is pushed (for over approximately 150 ms), the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors. Then, the ESP warning lamp on the instrument panel comes on. The detailed operation procedures are as follows: 1. The ESP warning lamp comes on when the ESP OFF switch is pushed for over 150 ms. 2. The switch returns to normal position when the OFF switch is released. 3. The ESP system will be cancelled after approximately 150 ms. Based on the above procedures, we can see that the ESP system will be cancelled after a certain period (approx. 150 ms) from releasing the switch to the original position. The ESP system does not get canceled immediately when the ESP warning lamp is turned on by pressing the ESP OFF switch. When you turn the ESP system off by pressing the ESP switch for over 150 ms, the TCS system (including ABD function) is turned off. And the ABS system is still operated.
IMMO
STICS
EL
34
8510

175 ms ON ESP warning lamp OFF 175 ms Min. 4 times
ESP OFF Switch Monitoring

Push Release HI ESP operation LO 10 sec 3.5 sec Return to switch signal ON OFF Cancellation of ESP OFF mode Turning the ESP warning lamp off ESP warning lamp ON OFF Reset to normal condition Detect failure

KYRON SM - 2005.09
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35

Initial start (for 1.8 sec) Normal mode ESP fault ABS fault System fault Low batt. voltage High battery voltage High brake pad temp. ESP-OFF mode Entering diag. mode ON OFF OFF ON ON ON ON OFF OFF ON
STICS A / CRUISE
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
ABD
Vehicle yaw control

NO OK NO NO NO NO NO NO OK
NOTICE
WIPER S E AT S / ROOF LAMP PAS R / SENSOR

KYRON SM - 2005.09
AV
NO
S/W
CLUSTER
SPWM
IMMO
EL
36
8510

Location
Outside rearview mirror angle adjusting switch
ESP OFF switch
Rear fog lamp switch

KYRON SM - 2005.09
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37

1. Remove the center fascia panel and unscrew four screws on the meter cluster fascia panel.
EL
KYRON SM - 2005.09
To make the operation easier, move down the steering wheel.
A / CRUISE
S E AT
NOTE
S / ROOF
LAMP
PAS
R / SENSOR
2. Disconnect the connector from the outside rearview mirror switch bezel assembly and remove the meter cluster fascia panel.
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
38
8510
3. Remove the switch assembly from the removed meter cluster fascia panel.
Front View
Rear View
4. Remove the round cover on the switch assembly.
Round cover

KYRON SM - 2005.09
8510
5. Remove each switch from the outside rearview mirror switch bezel assembly.
39
Switch Assembly
Remove the switch bracket.
ESP OFF Switch
Outside Rearview Mirror Adjusting Switch

AV
Outside Rearview Mirror Folding Switch

LAMP

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
40
8510
Meter Cluster Fascia Panel
Round cover
Outside rearview mirror adjusting switch bracket
ESP switch
Fog lamp switch
Outside rearview mirror adjusting switch

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41
Sunroof switch
SPWM
Passengers spot switch The passengers room lamp comes on if you depress the spot switch (B).
Luggage Room Lamp
Center Room Lamp

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
Drivers spot switch The drivers room lamp comes on if you depress the spot switch (A).
IMMO
STICS
1. LOCATION
Main room lamp switch Front/center room lamps are turned on when pressing in this switch. They are turned off when pressing in this switch again.
EL
OVERHEAD CONSOLE SWITCH
42
8510
2. COMPONENTS
Front Room Lamp (Overhead Console Lamp)
Sun roof switch Overhead console case
Main room lamp switch
Interior light switch
Center Room Lamp and Luggage Room Lamp

Center Room Lamp Luggage Room Lamp

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3. SWITCHES IN OVERHEAD CONSOLE SWITCH ASSEMBLY

Overview
Front room lamp switches in overhead console: Push ON/OFF type Sunroof switch: Rotary, self return type
Main room lamp switch (Push ON-OFF type)
STICS EL
Passengers spot lamp switch (Push ON-OFF type)
Drivers spot lamp switch (Push ON-OFF type)

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
Sunroof switch connector
Front room lamp connector
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
44
8510
Sunroof Switch

KYRON SM - 2005.09
8510 Front Room Lamp
45

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
Passengers spot lamp switch (Push ON-OFF type)
Drivers spot lamp switch (Push ON-OFF type)
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
Main room lamp switch (Push ON-OFF type)
STICS
EL
46
8510
Room Lamp Control

The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the center/luggage room lamp switch is at coupled operating position and the key reminder switch is OFF. 1. The front room lamp comes on when opening the door (drivers/passengers/rear) and goes off automatically in 30 seconds. 2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the door within 30 seconds. 3. The decaying operation must have greater than 32 steps per one second. 4. The room lamp output should stop immediately after turning on the ignition key during decaying operation. 5. The front room lamp comes on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed. 6. The front/rear room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output. 7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2. 8. The room lamp output stops immediately after receiving the lock signal from drivers door, passenger's door and rear doors lock switch while the driver's door, passenger's door and rear doors are closed.
DRS OR PSS DOOR SW
OPEN CLOSE
IGN KEY REMINDER SW
ON OFF
Tx UNLOCK
RECEIVE NO SIGNAL
UNLOCK OUTPUT
ON OFF
Fr ROOM LAMP
ON OFF T2 T3
T1
T4
T1: 30 sec.
T2: 2 sec.
T3: 3 sec.
T4: 30 sec.

KYRON SM - 2005.09
8510 Electrical Wiring Diagram of Room Lamp
47

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
48
8510
Sunroof Switch
Close
Open
Sunroof Sliding Operation Open

To fully open the sunroof, briefly rotate the sunroof switch clockwise (OPEN direction) with the sunroof closed. To partially open the sunroof, rotate and hold the sunroof switch until it reaches at the desired position.
Sunroof Tilting Operation Tilt-up

To tilt-up the sunroof, rotate the sunroof switch counterclockwise (CLOSE direction) with the sunroof fully closed.
Tilt-down Close
To fully close the sunroof, briefly rotate the sunroof switch counterclockwise (CLOSE direction) with the sunroof open. To partially close the sunroof, rotate and hold the sunroof switch until it reaches at the desired position. To tilt-down the sunroof, rotate the sunroof switch clockwise (OPEN direction) with the sunroof tilted-up.
Circuit Diagram of Sunroof Switch
Sunroof switch connector
The sunroof switch is a Self return type switch and connected to the power supply terminal and sunroof circuit. For details, refer to Sunroof section.

KYRON SM - 2005.09
8510 Circuit Diagram of Sunroof
49

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
50
8510
4. REMOVAL AND INSTALLATION OF OVERHEAD CONSOLE SWITCH

1. Open the sunglasses box and unscrew the mounting screws (2 EA). Mounting screw Mounting screw
NOTE
For details, refer to the LAMP section.
2. Remove the overhead console switch assembly and disconnect the connector.

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8510
51
3. Remove the front room lamp switch from the removed overhead console switch assembly.
4. Unscrew three mounting screws and remove the sunroof switch.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
52
8510
Components
Sunroof switch
Room lamp main switch
Lamp
Lamp

KYRON SM - 2005.09
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53
Driver can control all door windows (Open/Close/Lock/Unlock) and doors (Lock/Unlock) power this switch unit. Driver's door window switch has Auto down/Auto up function. The window can be controlled within 30 seconds even after turning off the ignition switch. However, if any of front doors is opened or the Lock switch on the remote control key is pressed (theft deterrent mode is activated) during the delaying period, the delaying time is immediately canceled (power window relay is deactivated).
Drivers door window switch
Passengers Door Window Switch

LAMP

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Rear RH Door Window Switch
PAS
R / SENSOR
WIPER
AV
Rear LH door Window Switch
Window lock switch If this switch is pressed, only the main switch of drivers door side is operated. (Sub and RR is not operated by pressing in the main switch)
S/W
CLUSTER
Door lock/unlock switch When the door lock/unlock switch is pressed while all doors including the tailgate are locked, all doors will be unlocked. When the switch is pressed again, all doors will be locked.
SPWM
IMMO
STICS
1. LOCATIONS AND FUNCTIONS
EL
SWITCH ASSEMBLY ON DRIVERS DOOR ARMREST
54
8510
2. SWITCH ARRANGEMENT AND APPEARANCE

Power Window Connector
Rated Current
Power window switch (motor operation) Door lock switch (actuator operation) Window lock switch (motor operation) 10 A (operating voltage) 0.4 A (operating voltage) 10 A (operating voltage)
Maximum Current
20 A (restricted current) 0.7 A (actuator voltage) 20 A (restricted current)
Switch Assembly
Front View
Rear View
Side View
Connector

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55
3. POWER WINDOW OPERATIONS

Power Window Auto-down
When the front of the switch is lightly pressed, the window will be lowered while the switch is pressed. When pressed to its end, the window will open automatically until it is fully open. If you want to stop the window while automatic lowering, lightly press the switch again or pull up the switch. Power window versions in this vehicle: Auto Down, Auto Down/Up The circuit diagram shows the Auto Down version.
STICS EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
56
8510
4. CIRCUIT DIAGRAM OF POWER WINDOW

KYRON SM - 2005.09
8510
57
Time Lag Power Window Control

1. The power window relay output is ON when turning on the IGN 1 switch. 2. The power window relay output is ON for 30 seconds for T1 when turning off the IGN 1 switch. The power window relay output is OFF when opening the driver's door or the passenger's door. The power window relay is turned OFF when receiving the remote control key lock signal (armed mode) during its extended operation period of 30 seconds.
STICS A / CRUISE
ING1 SW
ON OFF
Dr/Ps DOOR SW
OPEN CLOSE T1 ON T2
T1: 30 sec.
T2: OFF during T1 output

WIPER

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
P/WINDOW RELAY
OFF
S/W
CLUSTER
SPWM
IMMO
EL
58
8510
5. CENTRAL DOOR LOCK/UNLOCK SWITCH

Switch Arrangement and Functions
This vehicle has five door lock/unlock actuators including tailgate actuator. The doors can be opened separately. However, the door lock switch on drivers door armrest locks/unlocks all doors with STICS control. This is a same control type with Auto door lock function that locks the doors when the vehicle speed exceeds 50 km/h.
Door Lock/Unlock Relay

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59
Door LOCK/UNLOCK Control

Door Lock/Unlock by Door Lock Switch
1. The door lock system outputs LOCK for 0.5 second when positioning the drivers or passengers door lock switch to lock position. 2. The door lock system outputs UNLOCK for 0.5 second when positioning the drivers or passengers door lock switch to unlock position. 3. LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other functions. 4. All door lock signals are UNLOCK for 0.5 second just for once when receiving the LOCK signal within 0.5 second after closing the drivers or passengers door. (with the ignition key removed)
STICS A / CRUISE
DR DOOR LOCK SW
LOCK UNLOCK
PS DOOR LOCK SW
LOCK UNLOCK OPEN T1

WIPER AV
DR/PS DOOR SW
CLOSE ON OFF
T3
T2 UNLOCK RELAY ON OFF T1: 0.5 sec T2: 0.5 sec T3: Within 0.5 sec
T4
T4: 0.5 sec

LAMP

KYRON SM - 2005.09
S E AT
S / ROOF
PAS
R / SENSOR
LOCK RELAY
S/W
CLUSTER
SPWM
IMMO
EL
60
8510
Door Lock/Unlock by Central Door Lock Switch

1. The door lock system outputs LOCK/UNLOCK for 0.5 second when pressing LOCK/UNLOCK button on the central door lock switch. (However, the door lock system outputs UNLOCK signal when the front doors are locked, and vice versa.) 2. The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored.
CENTRAL LOCK SW
ON OFF
MONITORING
LOCK UNLOCK T1
LOCK RELAY
ON OFF T2
UNLOCK RELAY
ON OFF T1: 0.5 sec T2: 0.5 sec

KYRON SM - 2005.09
8510 Door LOCK/UNLOCK by Remote Control Key
61
1. The door lock system outputs LOCK for 0.5 second when receiving LOCK signal from the remote control key.
STICS A / CRUISE
2. The door lock system outputs UNLOCK signal for 0.5 second when receiving UNLOCK signal from the remote control key.
TX signal
LOCK NO SIGNAL ESCORT T2
ON OFF
UNLOCK RELAY
ON OFF
OFF T6 HAZARD RELAY ON OFF T2: 0.5 sec T3: 0.5 sec T4: 40 ms T5: 0.5 sec T6: 1.0 sec T5 T5 T5

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
HORN RELAY
ON
AV
T4
S/W
CLUSTER
LOCK RELAY
SPWM
IMMO
EL
62
8510
Auto Door Lock

1. The STICS outputs LOCK when the vehicle speed stays over 50 km/h. However, it doesn't output LOCK when all doors are locked or failed. 2. If any of doors is unlocked after outputting LOCK in step 1, outputs LOCK up to 5 times (except step 1) with interval of one second. 3. If any of doors is unlocked after 5 times of LOCK outputs, the door (driver/passenger/rear/tailgate) is regarded as FAIL. 4. If the door that was regarded as fail changes (UNLOCK to LOCK) to unlock, only one LOCK output will be done. 5. If any door is regarded as FAIL, the auto door lock function does not work (if it is occurred when the vehicle speed is over 50 km/h, the auto door lock output does not occur even if the vehicle speed falls below 50 km/h and accelerates again to over 50 km/h). Nonetheless, the central door lock function works properly. 6. When the system receives UNLOCK signal from a door switch, it outputs five LOCK signals. If additional LOCK signal from another door switch is detected during the period, the system outputs five LOCK signals for the door. 7. The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this function or the key is cycled (IGN1 = ON OFF) (even when there is no Lock output while the vehicle speed stays over 50 km/h under lock condition). However, when the ignition key is turned to OFF position, the lock output conditions will be canceled. 8. The FAIL condition of the door will be erased when the ignition key is turned to OFF position.
IGN1 SW
ON OFF
VEHICLE SPEED
OVER 50 km/h BELOW 50 km/h
DOOR LOCK SW (*1)
UNLOCK LOCK T1 T2 ON OFF T2 T2 T2 5 time T2
LOCK OUTPUT
T2: 0.5 sec 1 LOCK: Dr & Ps & Rr & T/GATE DOOR LOCK SW = LOCK UNLOCK: Dr or Ps or Rr or T/GATE DOOR LOCK SW = UNLOCK

KYRON SM - 2005.09
8510
63
Electrical Wiring Diagram

EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
64
8510
6. REMOVAL AND INSTALLATION OF POWER WINDOW SWITCH

Location
Drivers Door Power Windows Switch Passengers Door Power Windows Switch
Rear Door Window Switch (LH/RH)

KYRON SM - 2005.09
8510
65
Front Door (Drivers)

1. Remove the drivers door trim. NOTE
Be careful not to damage the door trim. For more information, refer to the Body section.
IMMO STICS
Location Inner door handle assembly

S/W
Power Window Switch Assembly

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
Door trim armrest
R / SENSOR
WIPER
AV
CLUSTER
SPWM
EL
66
8510
2. Unscrew ten mounting screws on the inner door handle of the door trim.
3. Remove the inner door handle and the memory seat switch assembly.
Switch Assembly
Door Trim Armrest

KYRON SM - 2005.09
8510
4. Remove the switch from the memory seat switch assembly.
67
Front View
Connector
Side View

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
Unscrew two mounting screws and remove the switch.
IMMO
STICS
EL
68
8510
Front Door (Passengers)

1. Remove the passengers door trim. NOTE
Be careful not to damage the door trim. For more information, refer to the Body section.
2. Unscrew the mounting screws and remove the inner door handle and the memory seat switch assembly from the passengers door trim.
Door trim armrest Power window switch

KYRON SM - 2005.09
8510
69
3. Remove the switch from the power window switch assembly.

STICS
Front View
Connector
Side View
S / ROOF

KYRON SM - 2005.09
A / CRUISE
S E AT
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
70
8510
Rear Door Power Window Switch

1. Separate the power window switch assembly with a special tool.
2. Disconnect the switch connector and remove the switch assembly.

KYRON SM - 2005.09
8510
71
3. Remove the switch.

STICS
Connector
Side View

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Front View
S/W
CLUSTER
SPWM
IMMO
EL
72
8510
SEAT POSITION MEMORY SWITCH

1. LOCATION AND FUNCTIONS
The position memory is available for up to three drivers. Each driver can set his/ her own driver's seat, outside rearview mirror positions and it will be separately stored in the integrated computer. If somebody has moved the seat, the memory positions can be recalled automatically by pressing the position button.
Drivers Seat Memory Function

STOP button SET button Position buttons (1, 2, 3)
To Store the Memory Settings

1. Place the selector lever in P (automatic transmission) or N (manual transmission) position, and apply the parking brake with the ignition switch ON. 2. Adjust the drivers seat and outside rearview mirrors to the desired positions. 3. Press the SET button. Indicating light on the button will come on. 4. Within 5 seconds, press the button ( ( ) you want to set. ), ( ) or
To Operate the Memory Settings

1. Press and hold the one of position buttons ( , or ) for approx. 1.5 seconds.) At this moment, the buzzer sounds once. 2. The driver's seat and the outside rearview mirrors start to move. (The memory function stops during its operation when driving off the vehicle) 3. Wait until they stop moving (The buzzer sounds twice).

KYRON SM - 2005.09
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73
The drivers seat position memory switch is installed in door trim and its connector (4 pins) is connected to the SPWM (Seat Position With Memory) unit.
EL A / CRUISE
Drivers Seat Memory Switch

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
74
8510
3. EXPLODED VIEW
Memory switch cover
PCB assembly
1 4-pin connector
Memory switch button
Memory switch box
2 6
Clear lens Tact switch LED
4. OUTPUT VOLTAGE IN EACH SWITCH POSITION

The memory switch connector receives the position switch signal at the pin no. 1 and the resistance value and output voltage in each switch differs from others. The table below shows the output voltage for each switch and the supply voltage is 5 V. Output Voltage
Function SET
2.2K 560 330 1 3 1K 3K VCC
Output voltage 0 ~ 100 mv 0 ~ 100 mv 0.12 ~ 1.36 mv 2.12 ~ 2.59 mv 3.4 ~ 4.15 mv
STOP Position 1 Position 2 Position 3
STOP
SW 3
SW 2
SW 1
SET
LED
1K 4 UNIT

KYRON SM - 2005.09
8510
75
5. FUNCTIONS AND OPERATIONS

NOTICE
STICS A / CRUISE S E AT S / ROOF LAMP PAS
KYRON SM - 2005.09
The position memory recall is canceled when operating the seat or the outside rearview mirrors during its operation. In the vehicle equipped with automatic transmission, the position memory recall is not available when the parking brake is released and the gear shift lever is not in "P" position. In the vehicle equipped with manual transmission, the position memory recall is not available when the parking brake is released. The memory recall is canceled if any position switch is not pressed within 5 seconds after pressing "SET" switch.
Seat Position Memory Operation

1. To store the seat position and the outside rearview mirror position, press the SET button and, within 5 seconds, press one of position switches. The memory setting is available up to 3 different drivers. 2. The memory set mode is only available within 5 seconds after pressing the SET button.
over 100 ms MEMORY SW OFF

AV
ON Memory set mode over 100 ms Cannot memorize
OFF 5 sec 5 sec
3. If any of the following conditions is established, the memory set mode is canceled. 1) No switch inputs within 5 seconds after pressing SET button. 2) When adjusting the seat or outside rearview mirror positions during the memory recall operation. 3) When turning off the ignition switch. 4) When pressing the STOP button 5) When the memory setting is completed. 4. The memory recall is not available when the vehicle speed is over 3 km/h or the gear shift lever is not in P position with the parking brake released. 5. The memory set can be unlimitedly renewed. 6. The stored positions are erased when disconnecting the battery cables. 7. The buzzer sounds once when the memory set mode is activated. 8. The buzzer sounds twice when the memory setting/recalling is completed. 9. The buzzer sounds three times when an error is found from the sensor during the memory recall operation.
R / SENSOR
POSITION SW
ON
WIPER
S/W
CLUSTER
SPWM
IMMO
EL
76
8510
Seat Memory Recall Operation

1. When pressing the position switch with the ignition switch ON, the seat and outside rearview mirrors move to the memorized positions. 2. When pressing another position switch during previously activated memory recall operation, the newly pressed position switch takes priority and recalls its stored positions. 3. The buzzer sounds once when a position switch is pressed. 4. If any of the following conditions is established, the memory recall function is deactivated. 1) When turning off the ignition switch. 2) When the gear shift lever is not in P position with the parking brake released. 3) When the parking brake is released (only for the vehicle equipped with manual transmission) 4) When the vehicle speed is over 3 km/h. 5) When pressing the STOP button during the memory recall operation. 6) When adjusting the seat or outside rearview mirrors during the memory recall operation. 5. Timing Chart
ON IGN SW OFF 1.5 0.2 sec
ON POS SW OFF
ON BUZZER OFF
1 time
2 times
Seat & Outside Rearview Mirror Manual Operation
ON OFF
OVER 3 Km/h Vehicle Speed BELOW 3 Km/h
STOP SW
ON OFF
ON Recall OFF

KYRON SM - 2005.09
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77
6. REMOVAL AND INSTALLATION OF SEAT POSITION MEMORY SWITCH

Preceding Works: Disconnect the negative battery cable. 1. Remove the drivers door trim. NOTE
For details, refer to the Body section.
EL
Location
Memory seat switch
Power window switch
Memory Seat Switch

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
Speaker
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
78
8510
2. Remove the memory seat switch from the door trim.
Switch Arrangement
Memory switch cover
PCB assembly
Memory switch button
4-pin Connector Memory switch box

KYRON SM - 2005.09
8510
79
7. ELECTRICAL DIAGRAM OF POWER SEAT & OUTSIDE REARVIEW MIRROR

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
80
8510

KYRON SM - 2005.09
8510
81
POWER
Turns on and off the audio system.
MUTE
Stops audio output from audio system. To resume the audio output, press the button again.
WIPER A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR
MODE
Changes the audio mode in order.
VOL VOL Increases or decreases the volume.
SEEK
SEEK
In radio mode - Press briefly: Manual searching for a station. - Press and hold: Automatic searching for a station. In CD (DVD) player/Cassette tape mode - Press briefly: Replay next/previous track. - Press and hold: Move forward/backward in current tract.

KYRON SM - 2005.09
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. LOCATIONS AND FUNCTIONS
EL
AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL
82
8510
2. COMPONENTS
The remote audio control switch is installed on the the steering wheel. Its rated voltage is 5 V and has three connectors.
Main Connector
Connector and cable
Pin No. 31 32 33
Output voltage Audio signal Audio ground Tail lamp power
Switch & PCB
Switch & PCB
35
36 33 32
43 31
34

KYRON SM - 2005.09
8510
83
3. CIRCUIT DIAGRAM
EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
84
8510

Preceding Works: Disconnect the negative battery cable. 1. Remove the airbag module assembly from the steering wheel.

KYRON SM - 2005.09
8510
85
2. Unscrew mounting screws at both sides of the removed airbag module and remove the audio remote control switch.
STICS

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
86
8510
MULTIFUNCTION SWITCH
1. OVERVIEW
The multifunction switch in this vehicle contains basic multifunction switch functions, Auto washer & wiper, fog lamp switch and Auto hazard lamp switch. When serving the multifunction switch, pay particular attention not to damage the air bag spring clock installed on the multifunction switch.
Mounted View
Front auto washer and wiper switch When the front wiper switch is off and this switch is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times. Then, the fluid will be sprayed again and the wiper will automatically operate 3 times.
Front fog lamp switch
<For detailed operation logics, refer to STICS>

KYRON SM - 2005.09
8510
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2. FUNCTIONS AND OPERATIONS

AUTO Light Function
AUTO
STICS EL
AUTO Light & Rain Sensor This senses the ambient illumination intensity to determine the timing for turning the headlamps and tail lamps on or off automatically when the light switch is set to AUTO (integrated with rhe rain sensor).
Emitter lens
Light Switch
Headlamp ON Headlight, position, tail, license plate, fog and instrument panel lights are illuminated. Tail lamp ON Position, tail, license plate, fog and instrument panel lights are illuminated.
All lights are off.

KYRON SM - 2005.09
A / CRUISE
Automatic light ON Headlamps and tail lamps automatically turn on or off based upon the intensity of the sunlight analyzed by the automatic light sensor.
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AUTO light sensor
AV
S/W
CLUSTER
These senses the ambient illumination intensity to determine the timing for turning the headlamps and tail lamps on or off automatically when the light switch is set to AUTO.
SPWM
IMMO
88
8510
Headlamp High Beam To turn on the headlamp high beam, push the lever towards the instrument panel with the headlamp low beam on. The headlamp high beam indicator in instrument panel comes on when the headlamp high beam is turned on.
Right Turn Signal Switch Front Fog Lamp Switch To turn on the fog lamps, turn this switch while the tail lamps or headlamps are turned on.
Passing To flash the high beam, pull the lever towards the steering wheel and release it. The lever will return to the normal position when released. The high beam headlights stay on as long as you hold the lever.
Left Turn Signal Switch
Front Wiper Switch

MIST
When moving up the wiper lever, the wipers operate once. The lever will return to the OFF position when released. Front Automatic Wiping Speed Control Switch Fast: Fast interval Slow: Slow interval
OFF
Stop the operation.
AUTO
Operates automatically according to the vehicle speed or amount of rain.
LO
Continuous wipe, slow operation
HI
Continuous wipe, fast operation

KYRON SM - 2005.09
8510
89
Front Auto Washer Switch (AFW) When the front wiper switch is off and this switch is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times. Then, the fluid will be sprayed again and the wiper will automatically operate 3 times.
Rear Washer and Wiper Switch When the switch is fully turned, washer fluid will be sprayed onto the rear window glass and the wiper will also operate. When the switch is released, it will stop in the Rear Wiper Operation mode and only the wiper will keep operating. Rear Wiper Operaes
Wiper and Washer Coupled Operation Pull the lever briefly (below 0.6 seconds): One wiping cycle Pull and hold the lever for more than 0.6 seconds: Three wiping cycles with washer spray
S/W A / CRUISE
Rear Wiper Stops
Rear Washer and Wiper Switch When the switch is fully turned, washer fluid will be sprayed onto the rear window glass and the wiper will also operate. When the switch is released, it will return to the OFF position and turn off the wiper and washer.
WIPER
When the wiper switch is in the AUTO position, this sensor detects the amount of rain, turns on the wiper, and controls the intermittent wiper intervals. For details, refer to "Rain Sensor" section.
Rain & AUTO Light Sensor
Wiper Switch AUTO Position AUTO

LAMP
KYRON SM - 2005.09
S E AT
It controls the wiping speed by detecting the amount of rain drops.
S / ROOF
PAS
R / SENSOR
AV
CLUSTER
SPWM
IMMO
STICS
EL
90
8510
3. OPERATING RANGE
29 30 Airbag clock spring Audio remote control /Auto cruise
Steering wheel angular sensor
46 44 45 48 47
29 Air bag (-) 30 Air bag (+) 43 Sound switch 37 ~ 42 Auto cruise 31 ~ 33 Audio remote control 44 ~ 48 Steering wheel angular sensor

KYRON SM - 2005.09
8510
91
4. CONNECTOR PIN ARRANGEMENT

EL

KYRON SM - 2005.09
A / CRUISE
S E AT
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
EB HL HU HS(2) TS HS(1) AUTO E TB TL TR FOG HA LO HI S AUTO (W) INT (T) INT (E) W IG MS AW IGR RW RWA
AUTO washer switch IGR Rear wiper Rear wiper & washer
S / ROOF
Dimmer and passing ground Headlamp low beam Headlamp high beam Passing Tail lamp switch Headlamp switch AUTO light Light/fog/hazard warning switch ground Flasher unit power Turn signal (LH) lamp switch Turn signal (RH) lamp switch Front fog lamp switch Hazard switch Low wiper speed High wiper speed Wiper stop Intermittent wiper Intermittent wiper Intermittent wiper ground Front washer switch IG Low wiper speed
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
92
8510

Preceding Work: Disconnect the negative battery cable. 1. Remove the air bag module and steering wheel.
Air bag Module Assembly
Steering Wheel Assembly
NOTICE
Be careful not to drop or shock the air bag module during removal procedures.
Lift up the hook when disconnecting the air bag contact coil connector (A).
Put an installation mark on the steering wheel, column shaft and nut when removing the steering wheel. Place the steering wheel to the straight forward direction.

KYRON SM - 2005.09
8510
93
2. Remove the driver side instrument lower panel, inner bracket and lower undercover. For details, refer to the Body section.
STICS
Instrument lower panel

SPWM
Lower undercover
3. Unscrew four screws from the steering column cover and remove the upper and lower covers. 4. Unscrew four screws and remove the air bag contact coil assembly.

KYRON SM - 2005.09
A / CRUISE
S E AT
For installation, align the steering wheel to the installation mark and tighten the nut to the specified tightening torque.
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
IMMO
Inner bracket
EL
94
8510
5. Remove the mounting screws (3 EA) from the steering will steering wheel sensor and the multifunction switch (4 EA) at this moment, disconnect the connectors.
Multifunction switch Multifunction switch connector
Steering wheel angular sensor connector
Light switch
Turn signal & wiper switch Steering wheel angular sensor
6. Remove the steering wheel angular sensor from the removed multifunction switch assembly.
Light switch
Turn signal & wiper switch

KYRON SM - 2005.09
8510
95
MEMO
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KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
STICS
EL
96
8510
DIGITAL CLOCK
Rated voltage: DC 12 V Operating voltage: DC 8 V ~ DC 16 V Time difference: 2 sec/day (room temp.) Current consumption: Max. 150 mA with IGN ON Max. 2.5 mA with IGN OFF Display type: VFD Brightness: 100% with Tail lamp OFF 40% with Tail lamp ON Blinking cycle of Colon: Once per second
Digital Clock
1. Remove the center fascia panel (refer to the Switch section).
Remove the panel from bottom
Disconnect the connector.

KYRON SM - 2005.09
8510
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3. Unscrew three mounting screws and remove the digital clock from the center fascia panel.
Digital Clock

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
2. Disconnect the digital clock connector.
EL
98
8510
CIGARETTE LIGHTER
Cigarette Lighter
1. Remove the center console cover.
Remove the panel from bottom

KYRON SM - 2005.09
8510
99
2. Disconnect the cigarette lighter connector.

STICS
3. Remove the cigarette lighter from the cover.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
100
8510
POWER OUTLET
1. Cap 2. Cap cover 3. Socket 4. Installation holder 5. Insulator 6. (+) terminal 7. (-) terminal 8. Connector
Rated voltage: over DC 12 V, Max. operating current: 10 A, Resistance: over 5 M
Front Power Outlet

1. Remove the power outlet bracket from the center console (passenger side).
2. Disconnect the power outlet connector.
3. Remove the power outlet from the bracket.

KYRON SM - 2005.09
8510
101
Rear Power Outlet

1. Remove the rear lower quarter panel (RH) and disconnect the power outlet connector.
STICS A / CRUISE
2. Unscrew eight screws and remove the power outlet mounting bracket.
3. Remove the power outlet from the bracket.

LAMP

KYRON SM - 2005.09
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
102
8510
Electrical Wiring Diagram of Cigarette and Power Outlet

KYRON SM - 2005.09
8510
103
Horn Assembly
Theft Deterrent Horn

WIPER
Horn Horn
Tone adjusting screw

Connector Connector

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
Horn
PAS
R / SENSOR
Connector
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. LOCATION
EL
HORN (INCLUDING THEFT WARNING HORN)
104
8510
2. ELECTRICAL WIRING DIAGRAM OF HORN

Location of horns: One at each side in engine compartment Location of theft deterrent horn: Under the battery tray in engine compartment The theft deterrent horn is controlled by STICS in armed mode regardless of horn relay operation.

KYRON SM - 2005.09
8510
105
3. STICS CONTROL FOR THEFT DETERRENT MODE

Functions in Theft Deterrent Mode
1. Door OPEN/CLOSE Door OPEN: Any of door switches (engine hood, front doors, rear doors, tailgate) output OPEN signal.
IMMO A / CRUISE
Door CLOSE: All door switches (engine hood, front doors, rear doors, tailgate) output CLOSE signal. 2. Door LOCK/UNLOCK Door LOCK: Any of door lock switches (front doors, rear doors, tailgate) output LOCK signal. Door UNLOCK: All lock switches (front doors, rear doors, tailgate) output UNLOCK signal.

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
STICS
Definitions in theft deterrent mode
EL
106
8510
Description of Theft Deterrent Function

1. Armed mode activation requirements 1) The LOCK output is ON when receiving the LOCK signal from transmitter while the ignition key is removed and all doors are closed. The armed mode is activated when the door lock switch is locked (theft deterrent horn output: once, hazard relay output: twice). 2) The theft deterrent horn and hazard relay outputs are ON when receiving the LOCK signal from the remote control key again in armed mode (theft deterrent horn output: once, hazard relay output: twice). 3) When receiving LOCK signal from the remote control key while any of doors is not closed, only the LOCK output can be done and then activates the armed ready mode (without theft deterrent horn and hazard warning flasher). At this moment, if the ignition key is in the ignition switch or the door lock switch is unlocked, cancels the armed mode and activates the normal mode. However, in these cases, if closing the door, the theft deterrent horn outputs once and the hazard warning flasher outputs twice and then activates armed mode. 4) When the door is not opened or the ignition key is not inserted into ignition switch for 30 seconds after receiving UNLOCK signal, outputs LOCK and then activates armed mode (RELOCK operation). Also, at this moment, the system outputs the theft deterrent horn and hazard warning flasher. 5) The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key.
REMOTE CONTROL KEY SIGNAL LOCK NO SIGNAL UNLOCK OPEN ENTRANCE DOOR SW CLOSE LOCK UNLOCK ON OFF ON OFF ON HAZARD RELAY OFF ON HORN OFF ARMED MODE OTHERS T1: 0.5 sec SWITCHES / ELECTRIC DEVICES
KYRON SM - 2005.09
T5
ENTRANCE DOOR LOCK SW
DOOR LOCK RELAY
(Dr) UNLOCK RELAY
T1
T2
T4
T3
OPERATION STATUS
T2: 1.0 sec
T3: 50 ms
T4: 1.0 sec
T5: 30 sec
CHANGED BY
EFFECTIVE DATE AFFECTED VIN
8510
2. Armed mode cancellation requirements
107
3. Warning operation requirements 2) When unlocking the door lock switch not by the remote control in armed mode 3) When closing and then opening the door after completion of warning (27 seconds) 4. Warning operation 1) The theft deterrent horn and hazard warning flasher output is ON for 27 seconds with the interval of 1 second. 5. Warning cancellation requirements 1) Cancels warning by using any signal from the remote control key (LOCK, UNLOCK, PANIC, ESCORT) during warning operation. 2) Cancels warning after 27 seconds (remaining period) while the ignition key is turned to "ON" position. 3) If the ignition switch is turned to ON position when the warning is activated in armed mode, the warning is canceled immediately and the warning buzzer stops after 27 seconds (remaining time). 6. Operation when warning is cancelled 1) The theft deterrent horn and hazard warning flasher outputs are OFF.
S/W STICS
1) When opening the door in armed mode
WARNING REQUIREMENTS
NO ESTABLISHED
WIPER
ESTABLISHED WARNING CANCELLANO ESTABLISHED TION THEFT DETERRENT STATE HAZARD RELAY WARNING ARMED NORMAL ON OFF ON HORN OFF T3 OPERATION STATUS WARNING OTHERS T1: 0.5 sec T2: 1.0 sec T3: 27 sec T3 T1
T2

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
ESTABLISHED
CLUSTER
SPWM
IMMO
EL
1) Unlocking by remote control key or engine starting.
108
8510
7. Operations when removing and installing the battery Installed Removed

Normal Armed Armed Ready Armed Warning Warning Completion RELOCK Ready
Normal
Armed
Warning
Remark
If the system is in armed mode while installing a battery, the horn sounds and the emergency warning lamp blinks (Same operations with warning in armed mode). RELOCK operation It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key, the system outputs LOCK signal and activates the armed mode.
PANIC Warning
1. The PANIC warning output is ON (theft deterrent horn) for 27 seconds when receiving the PANIC signal from the remote control key (pressing PANIC button. 2. The PANIC warning output is OFF when receiving any signal from the remote control key during PANIC warning. 3. Followings are theft deterrent warnings: 1) The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft deterrent. 2) The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning (PANIC output is OFF). 3) The PANIC warning output is ON when receiving the PANIC signal from the remote control key in Armed Ready / Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode). 4. This function operates only in armed mode.
PANIC TX SIGNAL (REMOTE CONTROL NO SIGNAL KEY SIGNAL) THEFT DETERRENT MODE WARNING OTHERS T1 T2 ON HORN OFF T3 T1: 27 sec SWITCHES / ELECTRIC DEVICES
KYRON SM - 2005.09
T1
T2: 0.5 sec
T3: 1.0 sec

8510
109
Electrical Wiring Diagram of Theft Warning Horn

EL

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
110
8510

Horn Assembly
Preceding Works: Disconnect the negative battery cable. 1. Disconnect the horn connector and unscrew the mounting bolt (10 mm) to remove the horn assembly.
Theft Deterrent Horn Assembly

Preceding Works: Disconnect the battery negative cable. 1. Disconnect the theft deterrent horn connector and unscrew the mounting bolt (10 mm) to remove the theft warning horn assembly.
Horn
Theft Warning Horn
Connector Tone adjusting screw
Connector

KYRON SM - 2005.09
AV SYSTEM
AV SYSTEM .............................................................. 2
1. 2. 3. 4. 5. 6. AV head unit ....................................................................... 2 AV system configuration ..................................................... 3 Head unit ............................................................................. 6 Tuner and DSP amplifier .................................................. 13 Subwoofer ......................................................................... 15 Removal and installation of AV system ............................. 16
8932
AV SYSTEM
1. AV HEAD UNIT
DVD + Cassette player: 10 speakers (center speaker, woofer speakers, tweeter speakers)
1. AV head unit DVD + Cassette + Radio MUTE button
DVD title insert slot Cassette tape slot
6.5 inch TFT LCD
2. Tuner
3. DSP amplifier
4. DVD 6 DISC changer
5. Subwoofer
AV SYSTEM
KYRON SM - 2005.09
8932
2. AV SYSTEM CONFIGURATION
AV System (DVD Head Unit + DVD Changer)
Front speaker Front tweeter speaker DSP Amplifier and Tuner
STICS A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV S/W CLUSTER SPWM IMMO EL
DVD change Subwoofer with built-in amplifier
Radio antenna module
Front center speaker Steering wheel remote control switch
TV antenna module AV Head Unit Rear speaker Rear tweeter speaker
DVD, RADIO and TAPE + TV
Audio System - 6 Speakers

Front speaker Front tweeter speaker Rear speaker
Steering wheel remote control switch
Audio Head Unit 1. 6 DISC changer + TAPE + RADIO
2. CD + RADIO 6 DISC changer CD slot
Tape
AV SYSTEM
KYRON SM - 2005.09
8932
DVD changer It is installed in the center console. Audio signal of DVD changer outputs to corresponding speakers through the cable. Video signal is transmitted to the monitor of AV head unit.
Send
Cable
Receive AV head unit (with built-in 6.5 TFT LCD monitor) Tuner TV video data DVD slot
Sound communication line (Bus line)
AM/FM radio antenna AMP The heated wire and radio antenna is integrated in the tailgate glass. The antenna transmits AM/ FM audio signals to tuner.
TV antenna AMP (LH and RH) The glass antennas at both rear quarter glasses are to receive TV and AM radio (quarter RH glass) signals and transmits each 2-channel video and audio signals to tuner. Each AMP amplifies receives TV signals and then transmits to tuner.
AV SYSTEM
KYRON SM - 2005.09
8932
Front speaker (LH)
Tweeter speaker (FL)
Front speaker (RH)
Tweeter speaker (FR)

AV
Rear speaker (LH)
Tweeter speaker (RL) AMP (with built-in DSP) Power AMP in the DVD system has built-in DSP function that digitalizes sound to divide and control. It amplifies sound goes to each speaker and has function of allowing dynamic and vivid sound.
Rear speaker (RH)
Center speaker (LH)
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
Subwoofer (without built-in AMP) Woofer is installed at the bottom of passengers seat. It enforces mid-low sounds.
S / ROOF
LAMP
PAS
Tweeter speaker (RR)
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8932
3. HEAD UNIT
Functions
AV system head unit operates Radio, TV, Audio CD, DVD and Video CD. The touch screen type 6.5 TFT LCD monitor is installed on the system.
DVD slot
Power ON/OFF, Volume control AV replay, AV reset screen Replay mode selection (briefly press), Current replay mode (press and hold) Next channel (radio or TV) or next track (audio or video)
The monitor moves to parking position when turning the ignition switch to OFF position. It moves to the preset position when turning the ignition switch to ON position again.
Display when turning on the monitor
AV SYSTEM
KYRON SM - 2005.09
8932
Wiring Connection
GPS connector terminal Fan
STICS
DVD CHANGER
TUNER
DSP amplifier
AV
4 8
3 7
2 6
1 5 9 3
7 8 5 2
6 1 4
4 8
3 7
2 6
1 5 9
12 11 10 13
12 11 10 13
1. BACK UP 2. BACK UP 3. VIDEO GND 4. VIDEO signal 5. GND 6. 7. RESET 8. SPDIF GND 9. SPDIF signal 10. CAN -GND 11. CAN-HI 12. CAN-LO 13. DVDC ON
1. TUNER ON 2. BACK UP + 3. VIDEO GND 4. VIDEO SIGNAL 5. GND 6. BACK UP 7. R/V VIDEO 8. R/V GND
1. MUTE 2. NAVI ON/OFF 3. NAVI Voice GND 4. NAVI voice 5. GND 6. 7. RESET 8. SPDIF GND 9. SPDIF signal 10. CAN -GND 11. CAN-HI 12. CAN-LO 13. AMP ON
1. CAN-HI 2. 3. Illumination (+) 4. ACC+ 5. BACK UP + 6. 7. Speed pulse 8. Reverse 9. CAN-LO 10. 11. Illumination (-) 12. 13. 14. GND 15. ALT D+ 16. Steering wheel remote control 17. Steering wheel remote control GND 18. PARKING SENSOR
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
EL
8932
Head Unit Wiring Connector
Tuner
DSP amplifier
DVD changer
GPS antenna connector
AV SYSTEM
KYRON SM - 2005.09
8932 Usable Discs (DVD Head Unit)

Following disc types can be used on the system. Disc Type and Logo Disc Size Play Time (Max.)
approx. 133 minutes (SS/SL) approx. 242 minutes (SS/DL) approx. 266 minutes (SD/SL) DVD video approx. 484 minutes (DS/DL) SS = Single side SL = Single layer DL = Double layer Video CD Audio CD CD-R CD-ROM 5 inch (12 cm) 5 inch (12 cm) 5 inch (12 cm) Video CD spec 2.0 PCB compatible disc approx. 74 minutes Support MP3, WMA, MP3 + WMA ISO / IEC 10148 (Yellow book)
DVD head unit and DVD changer cannot play following discs. 1. DVD-R 2. DVD-RAM 3. DVD-ROM 4. DVD-Audio 6. Mlxed CD (Date) 7. Active Audio (Date) 8. VSD 9. Multi-section disc 10. DVD with region code other than (2), (3) or (6) Bulk CD-R or CD-RW that their quality cannot be secured may not be recognized. 5. CD-G
Region code (2, 3, 6)

LAMP A / CRUISE S E AT S / ROOF
DVD player and DVD video disc has designated region code. If region code is different, the disc cannot be played. This system cannot play the disc if the region code is other than (2), (3) or (6). Region Code: 2 Middle East, 3 General Area, 6 China
PBC (Play back control) - compatible video CD

This system can play PBC - compatible video CD. Typical audio and video CDs can be played and PBC-compatible video CD uses recorded PBC menu on the disc to play the CD interactively.
Double layer DVD video disc

When playing the double layer disc, there occurs time lag between at the end of first layer and start of second layer causing broken display and sound for seconds. It normal for double layer disc so it is not malfunction of the system.
AV SYSTEM
KYRON SM - 2005.09
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
10
8932
Functions of AV Unit
Display 6.5 Wide TFT LCD Aspect ratio: Full/16x9/4:3 Touch screen key: Full touch TV Diversity Antenna with high reception performance Automatic station selection Radio Automatic station selection Station memory: 8 channels in each band (AM1, AM2, FM1, FM2) DVD Automatic replay: Audio CD, DVD title Playback control supported Sub woofer speakers DVD Changer (option) Install 6-discs in the magazine Automatic replay: Audio CD, DVD title Others DSP function, Equalizer function
AV SYSTEM
KYRON SM - 2005.09
8932 Function Settings on Touch Panel (Example)
11
Setting/Adjustment 2 5
STICS
10
11
12
14
13
AV
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Equalizer setting: Preset value, Treble/Medium/Bass Balance setting DSP (Digital Signal Process) setting Volume control of sub woofer and center speakers Screen setting: brightness, colors, gamma, contrast Aspect ratio setting: 16:9/4:3/ZOOM1/ZOOM2 Initial screen setting of DVD title: sound, caption etc. Turning OFF the screen (however, audio system still operates) Turning OFF/ON the button operating sound (Beep sound) Turning OFF/ON the speakers Turning OFF/ON the PBC function Turning OFF/ON the driving restriction Moves to replay mode out from SET/ADJUSTMENT mode Audio OFF
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
EL
12
8932 Basic display

Turn the AV system ON. Press MODE button to select a mode. When pressing RADIO section on the screen, the RADIO mode screen is displayed.
DSP control
Selecting an acoustic perspective Press DSP SETTING button in SET/ADJ screen and select one acoustic perspective (HALL, STADIUM, THEATER, CHURCH, CLUB). Press OFF button to cancel the DSP function.
EQ control
Adjusting the sound according to the music genre Press EQ SETTING button in SET/ADJ screen and adjust the sound. To adjust the tone, press TONE button. The tone can be adjusted by BAS/MID/TRE bars on the screen.
BALANCE/POSITION control
Adjusting the sound according to the seated position. Press BAL/POS button in SET/ADJ screen and select a seat position (drivers, passengers, rear seats, all seats) on the screen (Position setting). To, adjust the balance, use the arrows on the screen. * BALANCE function and POSITION function cannot be used simultaneously.
AV SYSTEM
KYRON SM - 2005.09
8932
13
4. TUNER AND DSP AMPLIFIER

EL
Side View
Rear View
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
Front View
14
8932
8. S/PDIF GND 9. S/PDIF signal 10. CAN -GND 11. CAN-HI 12. CAN-LO 13. ACC ON
4 8 3 7 2 6 1 5 9
1. MUTE 2. 3. 4. 5. GND 6. 7. RESET
12 11 10 13
1. 2. 3. 4. 5. 6. 7. 8. 9.
SPEAKER FR + SPEAKER RR + WPEAKER WOOFER 1+ SPEAKER WOOFER 2+ BACK UP BACK UP SPEAKER RL + SPEAKER FL + SPEAKER FR -
10. 11. 12. 13. 14. 15. 16. 17. 18.
SPEAKER RR SPEAKER WOOFER 1SPEAKER WOOFER 2GND GND SPEAKER CENTER + SPEAKER CENTER SPEAKER RL SPEAKER FL -
Audio Terminal White: AUDIO L channel output Red: AUDIO R channel output
Rearview camera (not applied)
Tuner wiring
7 3 5 8 2
6 1 4
1. ACC ON 2. B+ 3. VIDEO GND 4. VIDEO SIG 5. CHASSIS GND 6. B+ (BACKUP) 7. RV VIDEO 8. RV GND
TV antenna module LH CAN Wiring Radio antenna module TV antenna module RH CAN-HI ANT-ON CAN-LO
AV SYSTEM
8932
15
5. SUBWOOFER
EL
Passengers Seat
3. Subwoofer_2 (+) 4. Subwoofer_2 ()
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
1. Subwoofer_1 (+) 2. Subwoofer_1 ()
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
16
8932
6. REMOVAL AND INSTALLATION OF AV SYSTEM

AV Head Unit
Preceding Work: 1. Remove the center panel. 2. Remove the center fascia panel. 1. Unscrew four mounting screws from the AV head unit and AC control panel.
2. Disconnect the head unit harness connector and the fiber optic cable.
AV SYSTEM
KYRON SM - 2005.09
8932
17
3. Remove the AV head unit.
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
18
8932
Tuner Assembly
Preceding Work: Remove the negative battery cable. 1. Remove the service cover from the right lower quarter panel in the luggage compartment.
2. Remove the OVM tool box.
3. Unscrew eight mounting nuts from the tuner/amplifier deck assembly.
AV SYSTEM
KYRON SM - 2005.09
8932
4. Disconnect the harness connectors and the fiber optic cable from the tuner/amplifier deck assembly. 1) Fiber optic cable and connectors for DSP amplifier
19
Fiber optic cable
Connectors
2) Radio antenna cable, TV antenna cables and connectors
Radio antenna cable
NOTICE
Use the pliers as shown in figure when disconnecting the TV antenna cables.
PAS
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
R / SENSOR
TV antenna cables
WIPER
AV
S/W
CLUSTER
When removed
SPWM
IMMO
STICS
EL
20
8932
5. Unscrew the mounting screws from the removed tuner/amplifier deck assembly and remove the tuner assembly.
NOTE
Match the colors when inserting TV antenna cables into the connections.
AV SYSTEM
KYRON SM - 2005.09
8932 DSP Amplifier

21
Check if the fiber optic cable is defective. If the red lamp comes on when the ignition switch is in ON position, the system receives the normal input signal.
Output signal from AV head unit
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
Optical sensor input
Main connectors
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Unscrew six mounting bolts (10 mm) from the amplifier.
S/W
CLUSTER
SPWM
IMMO
STICS
1. Disconnect the connectors and the fiber optic cable from the AV head unit. Unscrew the mounting bolts and remove the amplifier assembly.
EL
22
8932
DVD Changer
DVD changer box
1. Remove the glove box lamp and release the locking device to lower the glove box.
AV SYSTEM
KYRON SM - 2005.09
8932
23
3. Unscrew the inner and outer mounting screws from the glove box and remove the lower instrument panel.
S/W
4. Open the DVD changer cover. Unscrew the mounting screws and remove the inner cover and outer cover.
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
CLUSTER
SPWM
IMMO
STICS
EL
2. Remove the side instrument panel in passenger compartment and unscrew the mounting screws for lower instrument panel.
24
8932
5. Remove the DVD changer cover.
6. Unscrew the mounting screws from the DVD changer.
7. Disconnect the fiber optic cable from the DVD changer through the opening of lower instrument panel.
AV SYSTEM
KYRON SM - 2005.09
8932
8. Slide out the DVD changer and unscrew the mounting screws from the DVD changer case.
25
9. Disconnect the harness connector and pull out the DVD changer with case.
10. Separate the case from the DVD changer.
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
26
8932
DVD Changer
Front view
Fiber optic cable terminal
Connector
AV SYSTEM
KYRON SM - 2005.09
8932
27
Speaker
Front (Center Speaker)
Preceding Work: Disconnect the negative battery cable. 1. Remove the center speaker cover.
IMMO STICS EL
2. Unscrew the mounting screws and disconnect the harness connector to remove the center speaker.
Components
PAS
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
Speaker cover
Speaker assembly
S / ROOF
LAMP
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
28
8932
Sun Woofer Speaker

Preceding Work: Disconnect the negative battery cable and remove the passengers seat. 1. Disconnect the harness connector and unscrew the mounting nuts to remove the sub woofer speaker.
Components
Connection
Volume control lever
AV SYSTEM
KYRON SM - 2005.09
8932 Front/Rear Door Speakers

Preceding Work: Disconnect the negative battery cable and remove the door trim.
29
Rear door speaker
40W/2
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
Front door speaker
40W/2
PAS
R / SENSOR
WIPER
AV
S/W
2. Unscrew four mounting screws and disconnect the harness connector to remove the speakers from the front and rear doors.
CLUSTER
SPWM
IMMO
STICS
1. Disconnect the harness connector from the speaker.
EL
30
8932
Door Tweeter Speaker

Preceding Work: Disconnect the negative battery cable and remove the door trim. (For details, refer to Body section.) 1. Unscrew the mounting screws (2 EA) from the removed door trim and remove the speaker.
AV SYSTEM
KYRON SM - 2005.09
8932 TV Antenna Module (LH/RH)

Preceding Work: Remove the rear quarter upper panel.
31
Radio Antenna Module

Preceding Works: 1. Remove the luggage room lamp assembly. 2. Remove the third row and fourth row seats. 3. Remove the rear quarter upper and lower trims. 4. Remove the rear headlining.
EL
TV antenna module TV antenna module
TV antenna connection at tuner
Radio antenna connection at tuner
AV SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
MEMO
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WIPER & WASHER SYSTEM

WIPER AND WASHER SYSTEM ............................. 2
1. 2. 3. 4. System layout of wiper and washer (with rain sensor) ....... 4 Wiper & washer related function and specification ............ 6 Wiper and washer system related circuit .......................... 11 Removal and installation .................................................. 12
7810
WIPER AND WASHER SYSTEM

The wiper and washer system are controlled by STICS according to drivers wiper switch operation. And the detection of rain drops by rain sensor is transmitted to STICS as the signal for wiper system control. The characteristics of the wiper and washer system including basic functions of manual wiper are as follows. 1. Wiper function coupled auto washer
Rear wiper/washer operation location Auto washer operation switch (press)
When the front wiper switch is off and this switch is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times. Then, the fluid will be sprayed again and the wiper will automatically operate 3 times.
2. Integrated auto light sensor in rain sensor unit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity. To control the system, the sensed values of rain sensor and auto light sensor are sent to pin no. 63 in STICS unit.
Rain sensor emitter lens
Light receiving area of auto light sensor
3. Rear washer fluid supply system There is no separate washer fluid reservoir for the rear washer system in this vehicle. The rear washer system uses the front washer fluid reservoir. Because of this, the washer hose is supposed to be long between front reservoir tank and rear washer nozzle. To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone
Rear washer hose and roof wiring harness are fixed at the headlining section with silicone.

KYRON SM - 2005.09
7810
4. Fluidic washer nozzle Fluidic Washer Nozzle is applied to the front washer spray system in this vehicle. The inside of nozzle is designed to utilize the fluidic movement.
STICS A / CRUISE S E AT S / ROOF
KYRON SM - 2005.09
This is a shape of the inside of nozzle. It is designed to change the spraying direction continuously according to the spraying time (fan-shape). The figure below shows the changes of spraying direction according to the spraying time.
Whirlwind
Washer fluid outlet Passage Counter-current
Spray passage
Washer fluid inlet
It is designed to be changed spraying direction using the whirlwind and backflow generated in nozzle.
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
7810
1. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR)

Multifunction Wiper and Washer Switch
Auto washer switch When the front wiper switch is off and this switch is pressed, washer fluid will be sprayed and the wiper will automatically operate 4 times. Then, the fluid will be sprayed again and the wiper will automatically operate 3 times.
Rain Sensor Unit
Front Nozzle Assembly
The rain sensor unit is integrated into the auto light sensor. It sends the amount of rain drops to STICS.
Front nozzle The washer nozzles are installed at both sides of engine hood. The spraying pattern is specially designed to improve the spraying performance.
Washer Reservoir Tank Assembly
Washer reservoir tank There is no separate washer reservoir tank for the rear washer fluid. The rear washer system uses the front washer fluid reservoir.
7810
Rear washer hose mounting There is no separate washer fluid reservoir for the rear washer system in this vehicle. The rear washer system uses the front washer fluid reservoir. Because of this, the washer hose is supposed to be long between front reservoir tank and rear washer nozzle. To avoid being damaged or interfered while in assembling the vehicle, the rear washer hose is fixed on headlining with silicone.
Rear Washer Hose Mounting

STICS
Rear Washer Nozzle and Check Valve
Rear nozzle assembly

AV
Check valve Rear nozzle
STICS
STICS STICS receives the rain sensing data from the rain sensor and controls the wiper and washer systems.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
EL
7810
2. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION

Wiper and Washer Fluid Switch Operation
Wiper speed control switch When turning to FAST, wiping speed gets faster and when turing to SLOW, wiping speed gets slower.
MIST
When turning up the switch, the wiper operates once. When releasing the switch, the pointers return back to OFF position.
OFF
Wiping stops
AUTO
Wiper speed controls automatically according to the vehicle speed or amount of rain (rain sensing wiper).
LO
Wiping speed gets slower when placing the pointer at the LO positon. Wiping speed gets faster when placing the pointer at the HI positon.
HI
Wiper and washer fluid for rear windshield operate simultaneously Only wiper operates
Auto washer switch If pressing the switch when the wiper switch turns to the OFF position, washer fluid is sprayed once and wiper operates 4 times. After a while, washer fluid is sprayed one more and the wiper operates 3 times.
Wiping stops Washer fluid for rear windshield operates once.
Wiper washer fluid coupled function Pull the lever briefly (below 0.6 seconds) : Only wiper operates Pull and hold the lever for more than 0.6 seconds : Wiper operates 3 times Washer fluid coupled operation

KYRON SM - 2005.09
7810
STICS Control Logic Related to Wiper and Washer

Wiper MIST and Front Washer Coupled Wiper
1. The wiper relay is turned on 0.3 seconds after turning ON the washer switch for 0.1 ~ 0.59 seconds with the ignition key ON, and it is turned off when the parking terminal is turned off.
STICS A / CRUISE
KYRON SM - 2005.09
KEY IN & IGN2 SW
ON OFF ON
WASHER SW OFF ON OFF ON OFF T1: 0.3 T2: 0.1 ~ 0.59 sec T1
WIPER MOTOR PARKING
WIPER LOW RELAY
OFF T2 ON
WASHER SW OFF T3 WIPER MOTOR PARKING ON OFF ON OFF T1: 0.3 sec T2: over 0.6 sec T3: one wiper cycle T1
WIPER LOW RELAY
S E AT
S / ROOF
LAMP
PAS
KEY IN & IGN2 SW
ON
R / SENSOR
2. The wiper relay is turned on 0.3 seconds after turning ON the washer switch over 0.6 seconds with the ignition key ON, and it is turned on three times immediately after turning off the washer switch.
WIPER
AV
S/W
CLUSTER
SPWM
T2
IMMO
EL
7810
3. When the washer switch is ON for more than 0.6 seconds during the wiper operation by the INT switch, the operation in step (2) is performed. When it is ON for a certain period of time (0.1 to 0.59 seconds), the operation in step (1) is performed.
KEY IN & IGN2 SW ON OFF ON INT SW OFF T2 WASHER SW ON OFF T4 WIPER MOTOR PARKING ON OFF ON OFF T1 T5 T1 T5 T3
WIPER LOW RELAY
T1: within 0.3 sec
T2: 0.1 ~ 0.59 sec
T3: over 0.6 sec
T4: 3 cycles
T5: pause
Rear Washer Motor Control

1. When the rear washer switch is turn on with the ignition switch ON, the rear washer motor relay output is activated from the time when the rear washer switch is turned on, and it is deactivated when the rear washer switch is turned off. 2. It cannot be activated while the front washer switch or the auto washer and wiper (AFW: Advanced Fast Washer) is in operation.
ON OFF ON OFF
KEY IN & IGN2 SW
REAR WASHER SW
REAR WASHER MOTOR RELAY
ON OFF

KYRON SM - 2005.09
7810 Auto Washer and Wiper Switch (AFW)
OFF AUTO
INT SW AUTO AUTO WASHER SWITH ON
OFF ON OFF
T1
T6 WASHER MOTOR OPERATING ON OFF T2 T2
WASHER MOTOR PARKING
ON OFF T4 T5 ON OFF T3
WIPER LOW RELAY
T1: over 100 ms
T2: 1.0 0.1 sec
T3: within 0.3 sec
T4: 4 cycles
T5: 3 cycles
T6: 0.5 0.1 sec

LAMP

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
KEY IN & IGN2 SW
ON
IMMO
STICS
1. When the auto washer switch is turned on with the ignition switch ON and the INT switch OFF, the washer motor output is activated for 1 second. If the system recognizes this output, the wiper relay output is activated during 4 cycles and the washer motor output is activated for 1 second. Then, the wiper relay output is deactivated after 3 cycles.
EL
10
7810
2. The auto washer switch output is overridden during the washer coupled wiper operation. 3. The auto washer switch input is overridden during the auto washer coupled wiper operation. 4. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive INT wiper operation. 5. When the auto INT switch input is received during the auto washer operation, the auto washer operation stops and the auto INT operation is activated.
KEY IN & IGN2 SW INT AUTO WITCH
ON OFF ON OFF ON T1 OFF ON T2 OFF
FRONT WASHER SW
AUTO WASHER SW
WASHER MOTOR OUTPUT WIPER MOTOR PARKING
ON OFF ON OFF T4 ON OFF T3 T3
WIPER LOW RELAY
T1: over 0.6 sec
T2: over 100 ms
T3: within 0.3 sec
T4: 3 cycles
Priorities in Washer Operations

1. The rear washer switch input is overridden during the front washer operation. 2. The rear washer switch input is overridden during the auto washer and wiper (AFW) operation. 3. The front washer switch input is overridden during the rear washer operation. 4. The auto washer switch input is overridden during the rear washer operation. 5. The front washer switch input is overridden during the auto washer and wiper (AFW) operation. 6. The auto washer switch input is overridden during the front washer operation.

KYRON SM - 2005.09
7810
11
3. WIPER AND WASHER SYSTEM RELATED CIRCUIT

EL
STICS
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
12
7810

Front Wiper Assembly
Preceding Work: Disconnect the negative battery cable. 1. Disconnect the mounting nut from the wiper blade assembly and then unscrew the mounting nut. At this moment, perform the work with the engine hood removed or opened.
Wiper blade assembly
2. Close the engine hood and then remove the wiper blade asembly.
Driver side
Passenger side

KYRON SM - 2005.09
7810
3. Remove the cowl mounting molding.
13
4. Remove the cowl mounting clip and then disconnect the cowl from the left (driver side).
Driver side cowl Passenger side cowl
5. Disconnect the wiper motor connector (1) and front windshield heated wire connector (2) connected to the wiper link assembly.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
14
7810
6. Unscrew the mounting nut (10 mm - 3EA) from the wiper link assembly.
7. Unscrew the mounting nut (10 mm - 1EA) and bolts (8 mm - 3EA) from the removed wiper linkage assembly and then remove the wiper motor.
Mark the adjustment mark before unscrewing the wiper motor center mounting nut.

KYRON SM - 2005.09
7810
Layout of Front Wiper Assembly Linkage aseembly
15
Wiper motor Passenger seat cowl Driver seat cowl
Wiper blade (Passenger side)
Wiper blade (driver side)
Wiper Motor Assembly

WIPER
Connector

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
16
7810
Rear Wiper Assembly

Preceding Work: Disconnection of negative battery cable 1. Disconnect the mounting screws from the each tailgate trim part.
4. Upper mounting screw on the tailgate lower trim
1. Remove the tailgate upper trim.
5. Lower mounting screw on the tailgate lower trim
3. Disconnect the mounting clip underside the tailgate.
2. Remove the inner tailgate handle.

KYRON SM - 2005.09
7810
2. Disconnect the mounting screw and then remove trim and vinyl cover from the tailgate underside.
17
Mounting Piece Position

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
18
7810
3. Close the tailgate and then remove the wiper blade assembly.
Open the cap
Unscrew the nut (10 mm - 1EA)
4. Remove the wiper blade and then unscrew the wiper motor cap and the mounting nut (17 mm - 1EA).
Disconnect the cap
Disconnect the nut

KYRON SM - 2005.09
7810
19
5. Open the tailgate, unscrew the connector and mounting bolts (10 mm - 2EA) and then remove the wiper motor.
EL
Rear Wiper Assembly Passenger seat wiper blade assembly
Splasher ring-tailgate wiper Mounting nut

AV
Spacer ring-tailgate wiper
Rear wiper motor and linkage assembly
Front
LAMP
Inside
Rear

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
20
7810
Reservoir Tank and Nozzle Assembly

Preceding Work: 1. Disconnect the battery negative cable. 2. Remove the tire.
Reservoir Tank
1. Remove the front wheel house cover.
2. Remove the washer motor from the reservoir tank and then drain the washer fluid.

KYRON SM - 2005.09
7810
21
4. Disconnect the washer hose connecting the reservoir tank and nozzle from the reservoir tank wheel house. Unscrew the washer reservoir tank mounting bolt and then remove it.
Disconnect Wiper Motor Connector Upper Mounting Bolt
Be careful not to damage when disconnecting
Rear hose
Front hose
LAMP
KYRON SM - 2005.09
Connection Hose on the Wheel House Side
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
3. Disconnect the washer motor connector from the reservoir tank. Be careful not to contact the washer fluid or foreign materials into the motor and connector after disconnecting.
22
7810
Nozzle and Hose

Front Side
1. Open the engine hood and then disconnect the hose.
Nozzle Side
Connection Point
2. Remove the nozzle by pressing the right/left nozzle located at the engine hood as shown in the figure.

KYRON SM - 2005.09
7810 Rear Side

Preceding Work: 1. Remove the tailgate spoiler. 2. Remove the tailgate upper trim. 1. Open the tailgate and then disconnect the nozzle hose from the check valve.
23
2. Close the tailgate and then remove the nozzle with a flat blade screwdriver or special tool.
AV
Be careful not to damage the body and the nozzle.

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
NOTICE
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
MEMO
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RAIN SENSOR UNIT (WITH AUTO LIGHT SENSOR)

RAIN SENSING SYSTEM (WITH AUTO LIGHT SENSOR) ............................... 2
1. 2. 3. 4. 5. 6. 7. 8. 9. System layout and overview .................................................. 2 Rain sensor operation ........................................................... 4 Rain sensor related circuit ....................................................5 Functions and specifications of rain sensing wiper ...............6 Operation mode of rain sensing wiper system .................... 11 Functions and checks of rain sensor .................................. 12 Diagnosis procedures ......................................................... 14 Trouble shooting ................................................................. 15 Electrical wiring diagram ..................................................... 18
8610
RAIN SENSING SYSTEM (WITH AUTO LIGHT SENSOR)

1. SYSTEM LAYOUT AND OVERVIEW
The rain sensing wiper unit in this vehicle doesnt control the wiper directly. The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
Rain sensing unit (Auto light sensor integrated type) Multifunction wiper switch: AUTO and sensitivity control
A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section (rain sensor mounting section on the windshield) with photodiode. The auto light sensor is Integrated into the rain sensor. (refer to the below picture)
AUTO: Wiper operates automatically by rain sensor FAST <-------> SLOW: Auto delay/Auto speed control. A position that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly.
Emitter lens The LED emits the infrared rays is located at bottom and the lens guides the infrared rays to target point.
Horizon autolight sensor Auto light sensor Vertical autolight sensor Enlarged auto light sensor section
RAIN SENSOR UNIT (WITH AUTO RIGHT SENSOR)
8610
The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. At this moment, STICS determines the wiper operation mode (washer, MIST, AUTO), then sends the information to the rain sensor.
Wiper relay (HI)
Wiper relay (LO)
STICS
Engine compartment fuse box
Rear washer relay
Front washer relay
Auto Light Sensor And Rain Sensor Coupled Control

1. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically. 2. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (For example, the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.)

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
STICS
EL
8610
2. RAIN SENSOR OPERATION

The rain sensor is installed on the specific heat treated windshield that has minimum 13% of transmittance rate with specified intensity of radiation. It is installed on the glass with a adhesive of Sorepa. It communicates with STICS and makes the wipers to operate automatically under the rain sensing mode (multifunction switch wiper: AUTO mode). The emitting section of the rain sensor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode. The difference compared with the conventional rain sensor is that the auto light sensor is Integrated into the rain sensor. Followings are the components and functions of the rain sensor unit
Rain Sensor Unit (Including Cover)

Rear Front
PCB Assembly and Emitter Lens Emitter Lens The LED emits the infrared rays is located at bottom and the lens guides the infrared rays to target point.
Unit Latch
Rain Sensor Unit
Housing and PCB
Housing and Receiver Lens Enlarged auto Light Sensor Section Receiver Lens The receiver lens guides the reflected infrared rays from windshield to photodiode.

KYRON SM - 2005.09
8610
3. RAIN SENSOR RELATED CIRCUIT

The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram. However, in this vehicle, the terminal No. 1 and No. 2 are for communications between STICS and the rain sensor; the No. 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor. No. 2 terminal sends the wiper and washer operation information such as washer operation mode, wiper relay, or multifunction wiper switch is in AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode.
SPWM IMMO EL A / CRUISE S E AT S / ROOF LAMP PAS
KYRON SM - 2005.09
Multifunction Switch
CLUSTER
Auto washer switch
IGN 1
WIPER
Washer switch Volume (resistance)
RK STICS
NC Parking Figure control
Rain Sensor
Low speed
High speed
Wiper Motor
R / SENSOR
AV
INT auto switch
S/W
STICS
8610
4. FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING WIPER

Power-up Reminder Wiper
1. When turning off and on the auto INT switch, the system drives the wiper motor through LOW relay regardless of communication with rain sensor. 2. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the wiper switch to AUTO position from any other positions (while the ignition key is in ON position). When the wiper switch is turned to ON position again from other positions, the system Drives the wiper motor through LOW relay one cycle only when the rain sensor detects the Rain Detected signal.
KEY IN & IGN2
ON OFF ON OFF Rain detected OFF T1 T1 T1 ON OFF
INT AUTO SW
WIPER LOW RELAY
T1: 1 cycle

KYRON SM - 2005.09
8610
Washer Coupled Wiper in the Rain Sensing Mode

1. The washer coupled wiper is operated when receiving the washer switch input with the ignition switch ON and the auto INT switch ON in rain sensing mode. At this moment, the communication with the rain sensor is overridden. However, the washer switch input is overridden during continuous operation. 2. The operation data is sent to the rain sensor even during the washer coupled wiper operation.
STICS A / CRUISE
WASHER SW
ON OFF ON OFF ON OFF Ignore Rain
WIPER P-POS
WIPER LOW RELAY RAIN SENSOR
Rain Sensing

KYRON SM - 2005.09
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
INT AUTO SW
OFF AUTO OFF
SPWM
KEY IN & IGN2
ON
IMMO
EL
8610
Rain Sensing Sensitivity Control

1. The wiper relay (LO) is turned on and the wiper motor runs one cycle when the volume sensitivity is increased (ex: from 0 to 1) (while the ignition key is in ON position, the wiper switch is in AUTO position, and the wiper motor is in Parked position). However, the wiper motor can be operated only when the rain sensor detects the Rain Detected signal. * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle.
SENSITIVITY
Rain Detected OFF
T1 ON WIPER LOW RELAY OFF
T1
T1
T1 : 1 cycle
Auto Light Control

1. Only when the auto light switch is in AUTO position, control the tail lamp and headlamp by communicating with the rain sensor (while the ignition key is in ON position).
KEY IGN2 SW AUTO LIGHT SW RAIN SENSOR Data TAIL LAMP RELAY HEAD LAMP RELAY
ON OFF AUTO OFF LIGHT TAIL OFF ON OFF ON OFF

KYRON SM - 2005.09
8610 Wiper Operation When the Wiper Parking Terminal Is Grounded
1. The wiper system continuously outputs the parking signal of current sensitivity when the parking terminal is grounded (while the ignition key is in ON position and the INT switch is in ON position). * The wiper motor runs only when the rain sensor requires.
STICS
GND (Stop)
SENSITIVITY
SEN.2
* The wiper motor runs only when the rain sensor requires.
WIPER PARKING GND (Stop)

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
SENSITIVITY
SEN.2
LAMP
PAS
IGN (Operation)
R / SENSOR
2. When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity for 2 seconds, then continuously outputs the parking signal of current sensitivity (while the ignition key is in ON position and the INT switch is in ON position).
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
WIPER PARKING
IGN (Operation)
EL
10
8610
Defective Rain Sensor

1. The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 3 during receiving the malfunction signal (1) from the rain sensor (while the ignition key is in ON position and the INT switch is in ON position).
SENSITIVITY
R_RSFAULT
OTHERS
T1 ON WIPER LOW RELAY OFF T1 : cycle
2. The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in ON position and the INT switch is in ON position).
SENSITIVITY
S_COMMFAULT
OFF
T1 ON WIPER LOW RELAY OFF T1 : cycle

KYRON SM - 2005.09
8610
11
5. OPERATION MODE OF RAIN SENSING WIPER SYSTEM

Driver Switch Positions
MIST (Transmits the manual operation mode signal to sensor)
Operation Mode
As long as the switch is in MIST position, the wiper motor operates in low speed. The wiper blade returns to parking position if the switch returns to the original position. The rain sensor ignores inputs during parking signal periods. The wiper motor rotates in low speed until it returns to parking position. When the system is in manual mode, the sensitivity of sensor will be set to 2 (AUTO 2) internally. By doing so, immediate wiping with proper intervals is possible when a driver sets the system from OFF to AUTO. Auto delay/auto speed control. Low sensitivity against rains on windshield. When the switch is in AUTO position, the sensor transmits the wiping request signal to STICS. Auto delay/auto speed control. Low/medium sensitivity against rains on windshield. Auto delay/auto speed control. Medium sensitivity against rains on windshield. Auto delay/auto speed control. Medium/high sensitivity against rains on windshield.
OFF (Transmits the manual operation mode signal to sensor)
AUTO 1 (low sensitivity) AUTO 2 (low/med sensitivity) AUTO 3 (medium sensitivity) AUTO 4 (med/hi sensitivity) AUTO 5 (high sensitivity)
SLOW
FAST
Auto delay/auto speed control. High sensitivity against rains on windshield. The wiper motor rotates continuously in low speed of approx. 45 rev./ minute at B+=13.5V (in the normal battery voltage). The rain sensor operations are same as in MIST. The wiper motor rotates continuously in high speed of approx. 70 rev./ minute at B+=13.5V (in the normal battery voltage). The rain sensor operations are same as in MIST.
LOW SPEED (transmits the manual operation mode signal to sensor) HI SPEED (transmits the manual operation mode signal to sensor)
1. Rain detected headlamp: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically. 2. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level. (i.e. the AUTO wiper switch is at the 3rd level, but the wiper operates at the 4th level.)

KYRON SM - 2005.09
EL
12
8610
6. FUNCTIONS AND CHECKS OF RAIN SENSOR

Front Windshield Glass and Coupler Attachment
Check the outer windshield surface of sensing area for wear, damage and scratch. The sensor is able to compensate the wear up to a specific level. Check the coupler attached surface of windshield for porosity. If the porosity exists, the sensor cannot function properly. NOTE
If the installed wiper brushes are out of specification (size and length), the rain sensing area cannot be fully wiped. In this case, the rain sensors sensitivity could be decreased and the wipers are not properly operated.
Recognition of AUTO Mode

1. When the engine is started with the multifunction wiper switch AUTO position, the wiper operates one cycle to remind a driver that the wiper switch is in AUTO position. 2. When the wiper switch is turned to AUTO from OFF, the wiper operates one cycle. It always operates one cycle for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF. However, the wiper operates up to 5 minutes after rain stops. 3. If this function does not occur, check No. 2 terminal on the rain sensor. If any defective cannot be found, check the wiper relay (LOW) for defective. NOTE
As described, the STICS recognizes the wiper switch AUTO position. If there are not any problem, go to diagnosis mode in STICS and check the terminal that receives signal from wiper and communication lines between rain sensor unit and STICS.
Instant Wipe Function

When the variable resistance knob on the multifunction wiper switch is turned by each 1 stage from low sensitivity (S mark) to high sensitivity (F mark), the wiper operates one cycle. And, the wiper also operates during raining up to 5 minutes after rain stops. NOTE
When the variable resistance knob is rotated by 4 stage from 0 stage without stoping, the wiper operates one cycle. The wiper operates one cycle when changing the wiping stage (0 1, 1 2, 2 3).

KYRON SM - 2005.09
8610
13
Washer Coupled Wiper Function

Check the washer coupled wiper operation by pressing the washer switch.
Irregular Operations (Abrupt Operations)

1. Check the sensor for coming off. 2. Check the rain sensor cover installation. 3. Check that the customer is familiar to how to control the wiper sensitivity. Check that the customer can select the sensitivity by selecting the variable resistance value (stage 1 to stage 5), that is, the wiper sensitivity control value. And, also check whether the sensitivity is selected to the highest value of FAST (stage 5). 4. Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, the irregular operations could be occurred. And, the wiper blade should be replaced with new one with same specifications.
Poor Sensing
Position the wiper switch to AUTO position and rotate the variable resistance knob from FAST toward SLOW by one step. At this moment, check if the wiper operates one cycle. The wiper operates when the windshield glass is excessively worn or scratched, the windshield glass is not cleared wiped due to using worn wiper blade or different wiper blade, or the rain sensor is not improperly installed.
WIPER A / CRUISE
Poor Sensor
Rotate the variable resistance knob toward SLOW by 1 more steps. At this moment, check if the wiper operates one cycle. If the wiper operates, this causes when the sensor is defective or the sensor has the communication problem with STICS.
LAMP S E AT S / ROOF

KYRON SM - 2005.09
PAS
R / SENSOR
AV
Self Diagnosis
S/W
CLUSTER
SPWM
IMMO
STICS
EL
14
8610
7. DIAGNOSIS PROCEDURES
1. Check the glass and coupler for proper installation.
2. Check the power up function.
3. Check the instant wipe function.
4. Check the washer coupled wiper function.
5. Check the high speed.
6. Find the causes for irregular operations (abrupt operations).
7. Check the system with self-diagnosis function.

KYRON SM - 2005.09
8610
15
8. TROUBLE SHOOTING
Symptom 1. The wiper does not operate one cycle when turning the multifunction wiper switch to the AUTO from the OFF position or starting the engine while the wiper switch is in the AUTO position.
EL
Symptom 2.
It rains but the system does not work in the AUTO position.
1. Check whether the multifunction wiper switch is in the AUTO position. 2. Check the power to the sensor. Check the conditions of the pin 3 (Ground) and the pin 4 (IGN). 3. Check the wiper relay for defective.
Symptom 3.
The wiper operates 3 or 4 times at high speed abruptly.

AV A / CRUISE S E AT S / ROOF LAMP
KYRON SM - 2005.09
Symptom 4.
The wiper operates continuously even on the dry glass.
1. Check the wiper blade for wear. If the wiper blade cannot wipe the glass uniformly and clearly, this problem could be occurred. In this case, replace the wiper blade with a new one. 2. Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity.
Symptom 5.
The wiper does not operate at high speed even in heavy rain.
Check if the wiper operates at high speed when grounding pin 1 and pin 2.
Symptom 6.
The wiper responses are too fast or slow.
Check whether the variable resistance knob on the wiper switch is set in FAST" or "SLOW. Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage.
PAS
R / SENSOR
WIPER
Check whether the variable resistance knob on the multifunction wiper switch is set in FAST. The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity.
S/W
CLUSTER
SPWM
2. When the wiper switch is turned to AUTO from OFF, the wiper operates one cycle. It always operates one cycle for the initial operation, however, the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF. However, the wiper operates up to 5 minutes after rain stops. If this function does not occur, check No. 8 pin. If the pin is normal, check the wiper relay related terminals in the ICM box.
IMMO
1. When starting the engine with the multifunction wiper switch in the AUTO position, the wiper operates one cycle to remind a driver that the wiper switch is in the AUTO position.
STICS
16
8610
Removal and Installation of Rain Sensor

1. Pry off the rain sensor cover by inserting a small flat-blade screwdriver into service holes at both sides (refer to picture). NOTICE
Otherwise, the cover or rain sensor components could be damaged.
Service hole
2. Disconnect the connector from the rain sensor unit located at the front windshield glass and then lift up the rain sensor unit to disconnect from the glass.

KYRON SM - 2005.09
8610
Components of the Rain Sensor Unit PCB Assembly and Emitter Lens Auto light sensor
17
Emitter lens
Housing and Receiver Lens
Receiver lens
PAS

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
18
8610
9. ELECTRICAL WIRING DIAGRAM

KYRON SM - 2005.09
PARKING AID SYSTEM

PARKING AID SYSTEM (PAS) ................................ 2
1. 2. 3. 4. 5. 6. 7. System configuration ............................................................2 Component specifications ..................................................... 4 Alarm interval ........................................................................5 Troubleshooting of sensor ..................................................... 5 Cautions on parking aid system ............................................ 6 Removal and installation of parking aid .................................7 Circuit diagram .................................................................... 12
8790
PARKING AID SYSTEM (PAS)

1. SYSTEM CONFIGURATION
The parking aid device is integrated in the rear bumper and it uses three Piezoelectric elements to measure vertical and horizontal distance to obstacles. When placing the gear selector lever to R position, the designated unit (PAS unit) activates the parking aid sensors to measure the distance to obstacles.
Gear Selector Lever (R Position)
PAS buzzer
STICS
PAS piezoelectric buzzer
PARKING AID SYSTEM

KYRON SM - 2005.09
8790
Left/Right/Center Sensor Location

STICS
Parking Aid Unit
Left sensor
Center sensor Connector Right sensor
PARKING AID SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
Center sensor
CLUSTER
SPWM
IMMO
EL
8790
2. COMPONENT SPECIFICATIONS
The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval and detects the reflected signals from obstacles while the gear selector lever is in R position. The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches. This supplementary system is to secure the safety distance for parking. Descriptions
Rated voltage Operating voltage Current consumption Unit Sensor
Value
DC 12 V DC 9 V ~ 16 V Below 100 mA Below 20 mA (each) Over 5 MW
Descriptions
Operating temperature Storage temperature Relative humidity Weight Unit Sensor
Value
-30C ~ +80C -40C ~ +85C 95% RH max 160g 10g max 70g 10g max
Sensor insulating resistance
Parking Aid Unit

Detecting type: Super sonic wave Detecting distance: 25 cm ~ 120 cm (distance between sensor and obstacle)
Parking Aid Sensor

1. Type: Piezo ceramic element 2. Frequency: 40 KHz 2 KHz 3. Detecting range (13.5 V) 1) Horizontal: Min. 20 at 110 5 cm Min. 100 at 50 5 cm 2) Vertical: Min. 20 at 110 5 cm Min. 60 at 50 5 cm
PARKING AID SYSTEM

KYRON SM - 2005.09
8790
3. ALARM INTERVAL
Alarm interval and display changes according to the distance as below: While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 2, the warning beep sounds with short intervals and if within stage 3, the warning beep sounds continuously. Stage L, C, R sensor Interval (msec) Remark
EL
81 ~ 120 cm
Beep
Beep -, 2 51 ~ 80 cm Beep -, Beep -
4. TROUBLESHOOTING OF SENSOR
When the power is applied (gear selector lever is in R position), the sensor will be diagnosed once. If found any failure due to open circuit to sensor or communication error, warning buzzer sounds for 3 seconds and the data on failed sensor transmits to the instrument panel to light up the corresponding LED. If normal, the warning buzzer sounds only for 65 ms. 1. Whenever the power is applied, the diagnosis mode is initiated. 2. Sensor failure conditions (conditions for warning beep due to failure) 1) Sensor failure conditions (conditions for warning beep due to failure) 2) Open in sending circuit 3) Open in receiving circuit 4) Open in power circuit (+, -)
Back sonar (RH) Back sonar (LH)
Warning beeps
When failed (also when diagnosing the unit)
When normal
PARKING AID SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Back sonar (center)
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
25 ~ 50 cm
Beep
CLUSTER
SPWM
IMMO
STICS
8790
5. CAUTIONS ON PARKING AID SYSTEM

Cautions
Note that the display does not show everything in the rear area. Always check nobody, especially animals and children, is behind the vehicle. If you can not properly check back, get out of the vehicle and then check it.
1. The parking aid system is just a supplemental device to help your parking operation. 2. Always keep the safety precautions. 3. Do not press or shock the sensors by hitting or high-pressure water gun while washing, or the sensors will be damaged. 4. If the system is in normal operating conditions, a short beep sounds when the gear selector lever is moved into R position with the ignition key ON. 5. If the system is in abnormal operating conditions, a beep sounds for 3 seconds when the gear selector lever is moved into R position with the ignition key ON or engine running. However, it is also occurred when the obstacle is within 50 cm from the rear bumper.
The parking aid system will not work or improperly work under following cases:
1. Certain obstacles that sensors can not detect 1) Wires, ropes, chains. 2) Cotton, sponge, clothes, snow that absorb ultrasonic waves. 3) Obstacles lower than the bumper. (ex. drain ditch or mud puddle) 2. Not defective but improperly working 1) When the sensing portion is frozen. (operates normally after thawed) 2) When the sensing portion is covered by rain, water drops, snow or mud. (operates normally after cleaned) 3) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). 4) When a high-power radio is turned on. 3. Narrowed sensing area 1) When the sensing portion is partially covered by snow or mud. (operates normally after cleaned) 2) Surrounding temperature of sensor is too high (approx. over 80 C) or too low (approx. below -30 C). 4. Not defective but may occur improper working 1) When driving on the rough roads, gravel road, hill and grass. 2) When the bumper height is changed due to the heavy load. 3) When the sensing portion is frozen. 4) When the sensing portion is covered by rain, water drops, snow or mud. 5) When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). 6) When a high-power radio is turned on. 7) When some accessories are attached in detecting ranges
PARKING AID SYSTEM

KYRON SM - 2005.09
8790
6. REMOVAL AND INSTALLATION OF PARKING AID

Parking Aid Sensor
Center PAS Sensor
Preceding Work: Disconnect the negative battery cable and remove the spare tire.
EL
Center PAS sensor
1. Disconnect the harness connector and then remove the center sensor by turning the mounting cover.
AV
Sensor assembly
Connector
LAMP
PARKING AID SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
8790
RH/LH PAS Sensor

Preceding Work: Disconnect of negative battery cable. 1. Disconnect the center connector and then remove the cover by turning it.
LH sensor
RH sensor
2. Remove the RH/LH sensor mounting cover and spring and then remove the sensor from the bumper.
PARKING AID SYSTEM

KYRON SM - 2005.09
8790
Components of PAS Sensor PAS sensor
PARKING AID SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Connector
S/W
PAS sensor lower mounting cover
Spring
PAS sensor upper mounting cover
CLUSTER
SPWM
IMMO
STICS
EL
10
8790
Precautions When Installing LH/RH Sensors Fit The Sensor Into The Mounting Hole.
When Extended
When Compressed
1. Align the sensor lower cover with the sensor groove.
2. Insert the sensor upper cover into the sensor groove.
Align Wigh the Groove
PARKING AID SYSTEM

KYRON SM - 2005.09
8790
11
PAS Unit
Preceding Work: 1. Disconnection of negative battery cable
STICS EL
2. Removal of rear lower quarter panel and seat belt. (For removal and installation, refer to the BODY section.)
1. Disconnect the connector and mounting bolts (10 mm - 2EA) and then remove the PAS unit.
Connector
Connector
PARKING AID SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
Disconnection of connector
Removal of mounting bolt
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
12
8790
7. CIRCUIT DIAGRAM
PARKING AID SYSTEM

KYRON SM - 2005.09
ELECTRIC SYSTEM
ELECTRIC SYSTEM LAYOUT ................................ 2
1. 2. 3. 4. 5. 6. 7. 8. 9. Locations of interior units and sensors ..................................2 Switches, units and sensors in engine compartment ............4 Interior switches .................................................................... 6 Audio & video system ........................................................... 8 Electric components and layout .......................................... 10 Fuses and relays ................................................................ 12 Interior fuse box .................................................................. 15 Diagnostic connector .......................................................... 18 Electrical wiring diagrams ................................................... 20
8000
ELECTRIC SYSTEM LAYOUT

1. LOCATIONS OF INTERIOR UNITS AND SENSORS
Under Instrument Panel Steering Wheel Angular Sensor / Immobilizer
Steering wheel angular sensor Door lock relay Chime bell Curtain air bag module Buzzer for PAS
Immobilizer
Sun sensor TV antenna amplifier RK STICS
PAS Unit
TCCU and TCU Driver Seat Memory Switch
TCCU
TCU
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
Rain Sensing Unit (Including Auto Lignt) and ECM
Sensor Cluster
Sun Roof Unit and Motor
Sun roof unit
Sun roof motor
Air Bag ECU
Curtain air bag module

AV
TV antenna amplifier DVD changer

WIPER A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR
Curtain Air Bag Sensor
DSP amp Sub woofer
TV tuner
Engine ECU and SSPS Unit
Interior Temperature and Humidity Sensor
SSPS unit (under the engine ECU)

ELECTRIC SYSTEM
KYRON SM - 2005.09
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8000
2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT

FFH Assembly
Receiver Drier and Triple Pressure Switch
Horn (RH)
AQS Sensor and FFH Ambient Temperature Sensor FFH ambient temperature sensor
AQS sensor (ambient temperature sensor integrated type)

ELECTRIC SYSTEM
8000
ESP Pressure Sensor / Primary, Secondary
ABS (ESP) HECU
IWE Vacuum Solenoid Valve (4WD)

AV
Hood Contact Switch
Horn (LH)
(on battery tray)

PAS
Theft Deterrent Horn (Under the Battery)
Fuse and Relay Box
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8000
3. INTERIOR SWITCHES
Remote Control Switch on the Steering Wheel
Audio remote control switch
Audio remote control switch
Bezel Assembly on Outside Rearview Mirror Adjusting Switch Outside rearview mirror folding switch ESP OFF switch
Outside rearview mirror adjusting switch
Seat Position Memory Switch (Drivers Door)
Drivers Power Window Main Switch
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
Sun Roof Switch

STICS
Room lamp main switch Sun roof switch
Bezel Assembly on Hazard Switch
HDC switch
Outside rearview mirror and rear glass heated switch
TRIP switch Front defogger switch
Hazard switch
R / SENSOR
4WD switch
LAMP
Passengers Power Window Switch
Passenger seat warmer switch
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Driver seat warmer switch
PAS
Center Fascia Switch
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
8000
4. AUDIO & VIDEO SYSTEM

AV System
Audio remote control switches
Center speaker
DVD changer
AV Head Unit
Front speaker (RH) Tweeter speaker Sub woofer (amplifier integrated type) DVD changer
DVD+tape
Center speaker
AV head unit
Sub Woofer
Tweeter speaker (LH) Front speaker (LH)
Other Audio Head Unit 1. 6-INDASH CD+TAPE+RADIO 6-Indash changer 2. CD+RADIO CD slot
Tape
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
Location: Inside of panel above glove box

STICS
6 DVD changer
Rear speaker (RH)
Tuner/Amp
Radio antenna amplifier

AV
AV System
DSP integrated amplifier

LAMP
Tweeter speaker (LH)
TV antenna amplifier (LH)
Rear speaker (LH) Tuner
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
S/W
Tweeter speaker
CLUSTER
TV antenna amplifier (RH)
SPWM
IMMO
EL
10
8000
5. ELECTRIC COMPONENTS AND LAYOUT

Wiring Harness Arrangement
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
11
Components Locator
STICS
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
12
8000
6. FUSES AND RELAYS

There are three fuse and relay boxes in this vehicle (one at each side of instrument panel and one in engine compartment). The designation and capacity of relays and fuses is shown on the fuse and relay box cover.
Fuse and Relay Box in Engine Compartment
Fuses and Relays
Connector Arrangement
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
13
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
14
8000

1. Disconnect the negative battery cable, open the fuse and relay box cover in engine compartment, and unscrew the mounting nuts.
2. Lift the fuse and relay box assembly and disconnect connectors behind the assembly.
3. Remove the fuse and relay box assembly.
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
15
7. INTERIOR FUSE BOX

EL
Fuse and Relay Box (LH)
Fuse and Relay Box (RH)
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
16
8000
Designation and Capacity

Driver Side
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
17
Passenger Side
STICS
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
18
8000
8. DIAGNOSTIC CONNECTOR
Connection Between Scan-100 and Diagnostic Connector
Scan-100
Diagnostic connector
Additional cable for CAN module
CAN module
Additional Devices of Scan-100 (Diagnosis: EAS, EPB Only)

CAN module
Connection of Scan-100 (Including CAN Module and Additional Cable)
CAN module connecting cable
ELECTRIC SYSTEM
KYRON SM - 2005.09
8000
19
Pin Arrangement of Diagnostic Connector

It is installed under the instrument panel and consists of 16 pins. The REKES key coding should be performed with Scan-100.
Pin no. 2 Pin no. 3 Pin no. 4 Pin no. 5 Pin no. 6 Pin no. 7 Pin no. 8 Pin no. 9 Pin no. 10 Pin no. 11 Pin no. 12 Pin no. 13 Pin no. 14 Pin no. 15 Pin no. 16
FFH forced driving Ground Signal ground CAN - HIGH Engine ECU ABS / ESP Air bag TGS lever position unit TCU SSPS TCCU CAN - LOW REKES coding Battery +
ELECTRIC SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
Pin no. 1
FFH diagnosis
AV
Functions of Terminal
S/W
CLUSTER
SPWM
IMMO
STICS
EL
20
8000
ELECTRIC SYSTEM
KYRON SM - 2005.09
LAMP
LAMPS ..................................................................... 2
1. Locations of exterior lamps and specifications ................... 2
FRONT LAMPS ........................................................ 6

1. Compositions of front lamps ............................................... 6 2. Aiming and adjustment of front lamp .................................. 8 3. Removal and installation of headlamps ............................ 11
REAR COMBINATION LAMP ................................. 18

1. Composition of rear combination lamp ............................. 18 2. Removal and installation of rear combination lamp ......... 20
INTERIOR LAMPS .................................................. 28

1. Composition of interior lamps ........................................... 28 2. Removal and installation of interior lamps ....................... 30
8310
LAMPS
1. LOCATIONS OF EXTERIOR LAMPS AND SPECIFICATIONS
Headlamp Assembly
Low Beam one at each side (12V / 55W)
High Beam one at each side (12V/55W) Position Lamp EU: one at each side (12V/W5W)
Position lamp and Turn Signal Lamp General: one at each side (12V/28W/8W) EU: one at each side (12V/P21W)
Fog Lamp Assembly Fog lamp angle adjustment
Fog Lamp General: one at each side (12V/27W) EU: one at each side (12V/H27W)
Turn Signal Lamp/Stop Lamp Assembly
T/Stop Lamp General: LH-1 (12V/27W/8W) EU: LH-1 (12V/P21W/5W)
Turn Signal Lamp

General: one at each side (12V/27W) EU: one at each side (12V/PY21W)
LAMP
8310
Side Repeater Assembly
EU: one at each side (12V/W5W)
General: one at each side (12V/5W) EU: one at each side (12V/W5W)
Tail Lamp / Reversing Lamp / Rear Fog Lamp Assembly
General: one at each side (12V/27W/8W) EU: one at each side (12V/P21W/5W)
Reversing Lamp General: one at each side (12V/16W) Rear Fog Lamp General: one at each side (12V/P21W)
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Tail Lamp
LAMP
PAS
R / SENSOR
WIPER
License Plate Lamp Assembly
Reflector Assembly
AV
S/W
CLUSTER
SPWM
High Mounted Stop Lamp Assembly
IMMO
General: one at each side (12V/5W)
STICS
EL
8310
INTERIOR LAMPS
Front Room Lamp Center and Luggage Room Lamp Toward tailgate Toward dirver side Center room lamp (Lamp: ON) Luggage room lamp (coupled operation with tailgate)
Center room lamp (coupled operation with door) Luggage room lamp (Lamp: OFF)
12V/10W -Two at each lamps The drivers room lamp and the passengers room lamp are separately turned on when pressing the switch (1, 2). However, the front lamps are turned on when opening a door and turned off when closing it. The front room lamps and center are turned on when pressing the room lamp main switch (3).
12V/10W - One at each lamp
Center Room Lamp When this switch is pushed towards the rear of the vehicle, the lamp comes on. If the switch is pushed to the opposite direction, the lamp will go off. But, when any door is open, the lamp comes on and stays for 30 seconds. When the door is closed, the lamp will go off.
Luggage Room Lamp When this switch is pushed towards the tailgate, the lamp comes on when the tailgate is open. If the switch is pushed to the opposite direction, the lamp will go off and will not come on even if the tailgate is open.
Glove Box
Door Courtesy Lamp
12V/5W - One at glove box

LAMP
KYRON SM - 2005.09
12V/5W - one at each door

8310
Room Lamp Control

The overhead console lamp (front room lamp) and the center room lamp come on when opening the door while the center/luggage room lamp switch is at coupled operating position and the key reminder switch is OFF. 1. When the door (Drivers/Passengers/Rear door) is opened, the front and center room lamps come on and automatically go off after 30 seconds. 2. The room lamp stays on for 2 seconds and then decays through 3 seconds when closing the drivers door, passengers door or rear doors. 3. The decaying operation must have greater than 32 steps per one second. 4. The room lamp output should stop immediately after turning on the ignition key during decaying operation. 5. The front room lamp and center room lamp come on for 30 seconds when receiving the unlock signal from the remote control key while the door is closed. 6. The front room lamp and center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output. (The lamp stays on when unlocked by the remote control key). 7. When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2. 8. The room lamp output stops immediately after receiving the lock signal from drivers door, passengers door and rear doors lock switch while the drivers door, passengers door and rear doors are closed. 9. The luggage room lamp comes on when opening the tailgate while the tailgate coupled luggage room lamp switch is pressed.
SPWM A / CRUISE
OPEN CLOSE
WIPER
Dr or Ps DOOR SW
ON IGN KEY REMINDER SW OFF
REMOCON UNLOCK
RECEIVE NO SIGNAL
OFF
ON CENTER ROOM LAMP T1 OFF T2 T3 T4
LAMP
KYRON SM - 2005.09
S E AT
S / ROOF
UNLOCK OUTPUT
ON
LAMP
PAS
R / SENSOR
AV
S/W
CLUSTER
IMMO
STICS
EL
8310
FRONT LAMPS
1. COMPOSITIONS OF FRONT LAMPS
Headlamp Assembly Lamp cap High beam bulb
Low beam bulb
EU: Position lamp
Connector
Lamp General: Positon lamp and turn signal lamp bulb
Front Fog Lamp Fog lamp bulb
Connector
Lamp and case
LAMP
KYRON SM - 2005.09
8310
Connection Connector When Installing
Positon lamp and turn signal lamp connector
Headlamp connector
WIPER
Side Repeater
PAS
Lamp Lamp cover
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
Connector
S / ROOF
LAMP
R / SENSOR
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
8310
2. AIMING AND ADJUSTMENT OF FRONT LAMP

Headlamp Aiming
Headlamp Aiming : Adjust the headlamp aiming while turning the aiming screws (up/down/left/right) in turn with a screwdriver. Headlamp aiming requirements: 1. parking on a flat surface 2. specified tire pressure 3. one passenger (driver, 75 kg), 4. spare tire and OVM tools loaded (unlade all other loads)
Adjustment of Low Beam
No. 1 adjustment hole: Up and Down No. 2 adjustment hole: Left and Right
Adjustment of High Beam
No. 3 adjustment hole: Up and Down No. 4 adjustment hole: Left and Right
Adjustment Direction
Low Beam 1: Left / 2: Right
Low Beam A: Up / B: Down
High Beam 1: Left / 2: Right

LAMP
KYRON SM - 2005.09
High Beam A: Up / B: Down
8310
Aiming Procedures When Using a Screen

Install a screen (2 m 1.5 m) in front of the headlamps in vertical by 3 m away and align the center lines of the vehicle and the screen.
EL A / CRUISE S E AT S / ROOF LAMP PAS R / SENSOR WIPER AV
< : mm> Unit: mm
<LOW BEAM>
Center line of vehicle Vertical of headlamp

1342 Vertical line of headlamp bulb 36
Center line of vehicle and screen

bulb
Screen
Horizontal line of headlamp focus
Ground
<HIGH BEAM>
LH 45 90 1078 90 90 RH
30 A A 85
Allowable focusing area
Allowable focusing area
Ground
Unit: mm < : mm>
If the focus deviates the A point, adjust the headlamp aiming by rotating the aiming screws (Up, Down, Left, Right) in turn with a screwdriver.
LAMP
KYRON SM - 2005.09
S/W
CLUSTER
SPWM
IMMO
STICS
10
8310
Fog Lamp Aiming Adjustment

The front fog lamps are installed in the front bumper. Front fog lamp aiming (up/down) can be adjusted by the control knob installed on the fog lamp.
Up
Down
Down The lamp aiming moves down and the light faces downward when the knob is turned counterclockwise.
Up The lamp aiming moves up and the light faces upward when the knob is turned clockwise.
LAMP
KYRON SM - 2005.09
8310
11
3. REMOVAL AND INSTALLATION OF HEADLAMPS

Headlamp Assembly
Preceding Work: Disconnect the negative battery cable. 1. Open the engine hood and unscrew two headlamp upper mounting bolts (10 mm).
STICS EL
2. Remove the headlamp lower cover from the upper front bumper and unscrew the headlamp lower mounting nut (10 mm).
Be careful not to damage the headlamp cover when removing it in order of the above number.
3. Disconnect two headlamp connectors (Turn signal lamp/Position lamp, Low beam/High beam).
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
NOTICE
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
12
8310
4. Be careful not to damage the headlamp assembly when removing it.
Headlamp Assembly
High beam
Low beam
Turn signal lamp and Position lamp (General)
Turn signal lamp and Position lamp
Position lamp (EU)
NOTICE
High beam Low beam If the lamp cover rubber ring is damaged while installing, replace it with new one.
LAMP
KYRON SM - 2005.09
8310
13
Replacement of Headlamp Bulb

1. Remove the headlamp dust cover. NOTE
To make the bulb replacement easier, remove the headlamp assembly.
EL
2. Disconnect the high/low beam connectors from the headlamp assembly.

Low Beam Side High Beam Side
3. Remove the clamps.

LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
14
8310
4. Remove the bulb from the headlamp assembly.

NOTICE
Use only specified bulb for replacement. Do not touch the bulb with bare hands when it is hot. You may get burnt.
5. Position/turn signal lamp bulb should be removed after removing the headlamp assembly.
NOTICE
Use only specified bulb for replacement. Do not touch the bulb with bare hands when it is hot. You may get burnt.
LAMP
KYRON SM - 2005.09
8310 Fog Lamp Assembly

Preceding Work: Disconnect the negative battery cable. 1. Remove the front wheel house and then remove the horn assembly.
15
Rear View Fog lamp bulb and connector
Lamp and case

LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
Front View
S/W
2. Disconnect the connector and unscrew four mounting screws to remove the front fog lamp assembly.
CLUSTER
SPWM
IMMO
STICS
EL
16
8310
Replacement of Fog Lamp Bulb

: Disconnect the fog lamp connector located on the front bumper.
Side Repeater
Preceding Work: Disconnection of negative battery cable 1. Push out the side repeater assembly.
Rear
Front
2. Disconnect the connector and remove the lamp.
Connector
Lamp (12V/5W)
Side repeater cover

LAMP
8310
17
MEMO
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LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
STICS
EL
18
8310
REAR COMBINATION LAMP

1. COMPOSITION OF REAR COMBINATION LAMP
Turn Signal Lamp/Stop Lamp Assembly
Turn signal lamp (valve) Bulb holder & connector
Stop lamp bulb Combination lamp
License Plate Lamp Assembly Connector
Bulb
Lamp
LAMP
KYRON SM - 2005.09
8310
19
Tail Lamp/Back-up Lamp Assembly Bulb (tail lamp) Bulb holder & Connector
Combination lamp
LAMP
KYRON SM - 2005.09
A / CRUISE
Bulb Passenger: Back-up lamp Driver: RR Fog Lamp
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
High Mounted Stop Lamp
EL
20
8310
2. REMOVAL AND INSTALLATION OF REAR COMBINATION LAMP

Turn Signal Lamp/Stop Lamp
Preceding Work: Disconnect the negative battery cable. 1. Open the tailgate and unscrew two mounting screws to remove the rear combination lamp assembly.
2. Disconnect the connector and remove the rear combination lamp assembly.
LAMP
KYRON SM - 2005.09
8310
21
3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs.
NOTICE
Use only specified bulb for replacement.
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
22
8310
Tail Lamp/Back-up Lamp/RR Fog Lamp

Preceding Work: Disconnect the negative battery cable. 1. Open the tailgate and remove the bolt cover. Then, unscrew three mounting nuts (10 mm) and remove the rear combination lamp assembly (tail lamp/back-up lamp/RR fog lamp).
2. Disconnect the connector and remove the rear combination lamp assembly.
3. Open the bulb holders/connectors by turning them counterclockwise and remove the bulbs.
NOTICE
LAMP
KYRON SM - 2005.09
8310 License Plate Lamp Assembly

Preceding Work: Disconnect the negative battery cable
23
Inside
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
Outside
LAMP
PAS
R / SENSOR
Tailgate Rear Garnish Assembly
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. Remove the upper and lower trim of the tailgate. Disconnect the connectors and unscrew eight mounting nuts (10 mm) to remove the rear garnish assembly.
EL
24
8310
2. Disconnect the bulb and bulb cable from the removed rear garnish assembly and then remove the lamp by pressing (A) section of the lamp.
Disconnect the Bulb Connector
Remove the Lamp
Exploded View
Tailgate garnish
Connector
Lamp
LAMP
KYRON SM - 2005.09
8310
3. Install the bulbs into the license plate lamp. Make sure the location and "LOCK" direction are correct.
25
Replacement of Bulb
1. Pry off the license plate lamp with a flat bladed screwdriver.
NOTICE
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
2. Remove the bulb from the removed license plate lamp.
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
26
8310
High Mounted Stop Lamp

Preceding Work: Disconnect the negative battery cable. NOTE
In the vehicle with tailgate air spoiler, the LED type high mounted stop lamp is integrated in the tailgate air spoiler. It should be replaced with the tailgate upper garnish assembly.
1. Open the tailgate, remove the upper trim and then disconnect the high mounted stop lamp connector.
2. Disconnect the rear washer nozzle hose.
LAMP
KYRON SM - 2005.09
8310
3. Unscrew four mounting nuts (10 mm)/three cap nuts and remove the air spoiler from the tailgate.
27
Cap nut
4. Remove the tailgate upper garnish assembly from the removed air spoiler.
5. Replace the tailgate upper garnish assembly with new one. NOTICE
In the vehicle with tailgate air spoiler, the LED type high mounted stop lamp is integrated in the tailgate air spoiler. It should be replaced with the tailgate upper garnish assembly. In the vehicle without tailgate air spoiler, the bulb type high mounted stop lamp is used. It can be replaced with new one after removing the tailgate upper garnish assembly.
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
28
8310
INTERIOR LAMPS
1. COMPOSITION OF INTERIOR LAMPS
Front Room Lamp Assembly Front room lamp cover
Sunglasses box
Front room lamp bulb
Interior Room/Luggage Room Lamp Assembly
Lamp (lens)
luguage room
Bulb
Front view
Rear view
LAMP
KYRON SM - 2005.09
8310
29
Glove Box Lamp Assembly Bulb
Door Courtesy Lamp Assembly
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
30
8310
2. REMOVAL AND INSTALLATION OF INTERIOR LAMPS

Front Room Lamp
Preceding Work: Disconnect the negative battery cable. 1. Open the sunglasses box and remove two front room lamp assembly mounting screws.
2. Disconnect the connector and remove the front room lamp assembly.
LAMP
KYRON SM - 2005.09
8310
31
Replacement of the Front Room Lamp Bulb

1. Remove the front room lamp cover. NOTICE
The tab can be damaged when removing the room lamp abnormally.
STICS
NOTICE
AV
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
2. Carefully remove the bulb from the lamp and replace it with new one.
CLUSTER
SPWM
IMMO
EL
32
8310
Center/Luggage Room Lamp

Preceding Work: Disconnect the negative battery cable. 1. Remove the lamp cover. NOTICE
Use the slot around the cover when replacing the lamp (bulb).
Slot
Slot
2. Unscrew the lamp mounting screws (luggage room lamp) and nuts (center room lamp).
Center room lamp
Luggage room lamp
3. Disconnect the connector and remove the lamp assembly.
LAMP
KYRON SM - 2005.09
8310
33
Center Room/Luggage Room Lamp Assembly

STICS
Replacement of Bulb
1. Remove the lamp cover and then carefully remove the bulb. Replace it with new one.
Center room lamp Luggage room lamp
AV
LAMP
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
NOTICE
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
EL
34
8310
Door Courtesy Lamp Assembly

Preceding Work: Disconnect the negative battery cable. 1. Disconnect the door courtesy lamp cover (1) from the door trim and remove the bulb (2). Replace the bulb with new one.
* Location: Toward tailgate use the slot around the lens when replacing the lamp (bulb)
12V-5W
Glove Box Lamp Assembly

Preceding Work: Disconnect the negative battery cable. 1. Open the glove box and remove the lamp cover by pressing both sides of the lamp as shown in the figure. 2. Disconnect the connector and remove the lamp assembly. Replace the bulb with new one.
12V-5W
LAMP
KYRON SM - 2005.09
SUNROOF SYSTEM
SUNROOF ASSEMBLY ........................................... 2
1. 2. 3. 4. 5. Components and locations ....................................................2 Operation and function ..........................................................3 Trouble diagnosis ..................................................................6 Removal and installation of sunroof assembly ....................... 7 Circuit diagram .................................................................... 21
7340
SUNROOF ASSEMBLY
1. COMPONENTS AND LOCATIONS
Sunroof Motor Sunroof Control Unit (SCU)
Sunroof Switch
Sunroof Assembly
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
Close
IMMO
Open
Sunroof Sliding Operation

Open
To fully open the sunroof, briefly rotate the sunroof switch clockwise (OPEN direction) with the sunroof closed. To partially open the sunroof, rotate and hold the sunroof switch until it reaches at the desired position.
Sunroof Tilting Operation

Tilt-up
To tilt-up the sunroof, rotate the sunroof switch counterclockwise (CLOSE direction) with the sunroof fully closed.
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
Anti-trap function is built in SCU
S E AT
S / ROOF
To prevent any body parts from being trapped by the sliding sunroof, an Anti-Trap function automatically opens the sunroof when an object is trapped. However, if the force against the sunroof is less than the specified value, the Anti-Trap function doesn't operate.
LAMP
Anti-trap Function
PAS
To fully close the sunroof, briefly rotate the sunroof switch counterclockwise (CLOSE direction) with the sunroof open. To partially close the sunroof, rotate and hold the sunroof switch until it reaches at the desired position.
To tilt-down the sunroof, rotate the sunroof switch clockwise (OPEN direction) with the sunroof tilted-up.
R / SENSOR
Close
Tilt-down
WIPER
AV
S/W
CLUSTER
SPWM
STICS
2. OPERATION AND FUNCTION
EL
7340
Hazard (Manual) Operation

The sunroof can be operated by rotating the motor operating hole on the sunroof motor with a proper tool.
Circuit Diagram
Motor drive A Power supply conditioner
Motor drive B
Supply voltage monitor
Close position Sensing Tilt Logic input Slide Puls input
Controller assembly
Motor (HALL I.C & MICROSWITCH)
SCU Main Connector
Motor Connector (SCU)
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
Resetting of Sunroof Control Unit

If the sunroof does not operate properly, check and reset the sunroof control unit. 1. To prevent any parts damage and personal injury, the sunroof setting is canceled 1) When the battery voltage is disconnected, the fuse is blown, or the abrupt voltage drop occurs due to old battery while operating the sunroof. 2) When an undesired cancellation occurs due to mistake by a technician. 3) When parts damage, shorted circuit, or electric leakage occurs. 4) When keeping the sunroof switch at "OPEN" position. 2. Symptoms when the sunroof setting is canceled 1) The one-touch operation cannot be activated. 2) The sunroof is tilted even after completion of closing operation when closing it. 3) The sunroof opening and tilting level is significantly low. 4) The sunroof does not operate properly when operating the sunroof switch. 3. [0] point reset of sunroof 1) Close the sunroof with the sunroof switch and keep the position for approx. 10 seconds. If the [0] point setting is successfully completed, the sunroof should be properly opened from this position. 2) Check if the sunroof is fully closed. Tilt the sunroof with the sunroof switch and keep it at the position for 10 seconds ([0] point setting). 3) Close the sunroof with the sunroof switch. 4. Checking after reset 1) If the sunroof does not operate properly, check the power supply system. 2) If the sunroof does not operate or operates only during the switch operation even the power supply system is in normal conditions, check if the ground circuit of switch is securely tightened and reset the sunroof system again. NOTE
If the power supply system is in normal conditions, replace the sunroof motor or the sunroof control unit. Replace the sunroof control unit with new one and check if the sunroof operates properly before replacing the sunroof motor.
LAMP A / CRUISE
SUNROOF SYSTEM
KYRON SM - 2005.09
S E AT
S / ROOF
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
7340
Symptom
Leakage
Cause
Clogged or bent drain hose Gap and clearance between panel and glass
Action
Check and correct drain hose condition. Readjust glass location. Readjust glass location. Check and replace/repair. Replace it. Reinstall sun shade and side cover. (Replace damaged parts.) Remove foreign material. Reinstall sun shade and side cover. (Replace damaged parts.) Check interference of body and wind deflector. (Relieve spring tension.) Replace it. Reinstall sun shade and side cover. (Replace damaged parts.) Install sponge to drain hose. Apply sealant between vehicle body and roof panel. Readjust glass location.
Wind noise Improper operations
Gap and clearance between panel and glass Malfunction of wire, fuse and ground Malfunction of relay, motor and unit Damaged side cover by dislocation of sun shade Foreign material in rail
Malfunction
Caught side cover by dislocation of sun shade Improper operation of anti-trap function Improper operation of motor
Operation noise
Caught side cover by dislocation of sun shade Interference between drain hose and vehicle body Interference between vehicle body and roof panel Gap and clearance between roof panel and glass
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
4. REMOVAL AND INSTALLATION OF SUNROOF ASSEMBLY

Exploded View
STICS EL
Seal - glass panel Glass Glass panel

CLUSTER
Drain channel support bar RH Return spring Front lever spring Front lever LH Retraction bar Pin Drain lever Slider LH Drain lever LH Main lever LH Breed nail
Wind deflector Side cover - outer Side cover - inner
Sunshade assembly Ventilation roof
Drain channel
Frame assembly
Seal - drive tube
Tube cable guide Drive tube Sunroof motor Sunroof control unit Frame assembly
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
Drain channel support bar pin
Panel curve on Rivet roll
AV
Drain channel support
S/W
SPWM
IMMO
7340
Wind Deflector
1. Fully open the sunroof. NOTICE
Work only when the sunroof is open.
With Sunroof Opened
2. Unhook the wind deflector side locks at both sides.
3. Unhook the wind deflector bottom locks as shown in figure (A).
Wind deflector
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
Glass Panel Assembly
Work only when the sunroof is tilted-up.
Inside Cover of Glass Panel Assembly

1. Remove the inner side covers at both sides by pushing them rearward.
2. Remove the three mounting bolts (TORX bolts) of the glass panel with a special wrench (25 T).
Tightening torque: 5 Nm
AV
3. Remove the glass panel.
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
NOTICE
10
7340
Outside Cover of Glass Panel

Preceding Work: Removal of glass panel and inside cover 1. Cut off the locks on the outside cover with a cutter and remove the outside cover.
2. Insert the locks of the new outside cover into the mounting holes.
Sunroof mechanism
3. Push down the outside cover to install into the roof panel and lock it to the sunroof system with a pliers.
SUNROOF SYSTEM
KYRON SM - 2005.09
7340 Installation of Glass Panel
11
1. Place the glass panel with the sunroof tilted-up and temporarily tighten the three TORX bolts (T25) at both sides. At this moment, the logo on the glass panel should face the rear side of the vehicle. 2. Completely close the sunroof using the sunroof switch.
STICS
3. Adjust the following items with the specified value and tighten the bolts.
Gap: Distance from roof panel to glass 1) Front gap (-1 ~ 0 mm)
WIPER
2) Rear gap (0 ~ 1 mm)

LAMP
NOTE
To prevent the wind noise during high speed driving (over 100 km/h), the rear gap should be greater than front gap.
S / ROOF
Rear
Front
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
PAS
Front
R / SENSOR
Rear
AV
Gap Between Front and Rear Glass Panel
S/W
CLUSTER
SPWM
IMMO
EL
12
7340
Front/Rear Gap of Glass Panel

To avoid the abnormal noise due to interference between roof panel and rear section of sunroof glass panel while driving, the installation gap should be maintained the ratio of 4:6 (front:rear) when installation.
Re Re
ar Ga p:F Fro 6 : ront nt 4 Ga p
ar
After Assembly
Measure the interference between roof and glass panel while moving the glass panel. Gap between roof and glass panel should be approx. 5 mm. If this gap is too small, the glass panel may be scratched or the interferencing noise may sound.
Gap between roof and glass panel: approx. 5 mm
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
13
Drain Channel
Preceding Work: Removal of glass panel
With Sunroof Tilted-up

EL
Tightening torque: 1.2 Nm
2. Unhook the locks (A) and remove the drain channel.
3. When installing
LAMP
Hook the locks (B) of the drain channel.
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
in Dra el nn cha
S / ROOF
PAS
R / SENSOR
WIPER
in Dra el nn cha
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. Remove the two mounting bolts (TORX bolt) at both sides on the drain channel with the glass panel removed.
14
7340
Sun Shade Panel

Preceding Work: Removal of glass panel and drain channel
With Sunroof Tilted-up
1. Move the sun shade panel forward and remove the slide blocks of the sun shade panel from the guide rail with a flat bladed screwdriver as shown in the figure.
2. Remove the sun shade panel from the sunroof.
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
15
Sunroof Control Unit (SCU) and Motor

Preceding Work: 1. Fully close the sunroof with sunroof switch.
With Sunroof Fully Closed

EL
NOTICE
Work only when the sunroof is closed.
SCU Assembly
1. Disconnect the connector from the sunroof control unit.
SPWM
Sunroof control unit
Sunroof motor
2. Unscrew the mounting screw and remove the SCU assembly.

WIPER
3. When installing, completely fit the sunroof rail into the slot of sunroof control unit and tighten the screw. NOTICE
Completely fit the sunroof rail into the slot of sunroof control unit. Slot Completely fit the tab.
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
S/W
CLUSTER
IMMO
STICS
2. Remove the sun visor/passengers hand grip/A pillar headlining/B pillar headlining to deflect the front section of the headlining. (Be careful not to damage the headlining.)
16
7340
Motor Assembly
NOTICE
Work only when the sunroof is closed.
1. Disconnect the connector from the SCU.
2. Unscrew the three mounting bolts (25T) with a special wrench and remove the motor assembly.
NOTICE
To make the motor positioning easier, do not operate the motor (even for the testing) before installation.
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
17
Sunroof Drain Hose

Removal and installation procedures of drain hoses:
Front Drain Hose Rear Drain Hose
- Remove headlining and rear trim.
Release the clamps and remove hoses. (However, the fastener at rear side of rear hose should be removed.)
Rear Hose
Front Hose
AV
When installing, be careful not to kink, damage and twist the hose.
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
Not allowed
S / ROOF
LAMP
PAS
NOTICE
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
- Remove only A pillar, sun visor, sunroof molding and front section of headlining.
EL
18
7340
Note
Fastener location of rear drain hose
The rear drain hose can be removed after releasing the fasteners.
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
19
Sunroof Assembly
Preceding Work: Removal of headlining 1. Disconnect the front and rear drain hoses with the sunroof closed.
STICS
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
2. Unscrew the two bracket mounting bolts (10 mm) at both sides.
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
20
7340
3. Unscrew the mounting bolts (10 mm) at both sides. Installation Notice
4. Remove the sunroof assembly from the vehicle.
Sunroof Assembly
SUNROOF SYSTEM
KYRON SM - 2005.09
7340
21
5. CIRCUIT DIAGRAM
EL
SUNROOF SYSTEM
KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
MEMO
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SEAT & SEAT BELT

SEAT ASSEMBLY ................................................... 3
1. 2. 3. 4. 5. Seat mounting points ............................................................3 Composition of seat .............................................................. 4 Removal and installation of seat .......................................... 11 Seat heating ....................................................................... 17 Seat arrangement ............................................................... 17
SEAT BELT ........................................................... 18

1. Seat belt locations .............................................................. 18 2. Removal and installation of seat belt ................................... 20
7410
Front Seat
Second Row Seat

AV
Third Row Seat

Mounting bolts
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
1. SEAT MOUNTING POINTS
EL
SEAT ASSEMBLY
7410
2. COMPOSITION OF SEAT
Front Seat (Drivers Seat)
Reclining Motor Lumbar support lever SPWM (Seat Position With Memory) Unit
Seat Cushion Motor (Front)
Seat cushion up/ down bar (rear)
Sliding rail
Sliding rail
Seat cushion up/ down bar (front)
Seat Cushion Motor (Rear) Sliding motor
Reclining lever
Seat cushion angle adjusting lever (rear)
Seat cushion angle adjusting lever (front)
Seat height control switch Sliding lever
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
Location of Seat Position With Memory Unit (Bottom of Driver Seat)

STICS
SPWM unit
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
7410
Front Seat (Passenger Seat)
Reclining Motor
Reclining lever
Sliding rail
Sliding rail
Sliding lever (No seat height control function) Sliding motor
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
Functions
Switches and Functions of Driver Seat
1. Seat Sliding Adjustment
STICS EL
2. Seat Cushion Height Adjustment
3. Seat Cushion Angle Adjustment
4. Seatback Reclining Adjustment

PAS
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
7410
Switches and Functions of Passenger Seat
1. Headrest Height Adjustment To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (1) on top of seatback and push the headrest down.
3. Seat Sliding Adjustment
SEAT & SEAT BELT

KYRON SM - 2005.09
7410 Second Row Seat

1. Headrest Height Adjustment
To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (1) on top of seatback and push the headrest down.

AV
To change the seatback angle, lean forward slightly and raise the lever. Then, lean back to the desired angle and release the lever.
Full Flatting the Second Row Seat
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
S/W
CLUSTER
SPWM
IMMO
STICS
EL
10
7410
Third Row Seat

1. Headrest Height Adjustment
To raise the headrest, pull it up without pressing the release button. To lower the headrest, press the release button (A) on top of seatback and push the headrest down. 2. Full flat lever for third row seat
Unfolding/Folding of Third Row Seat
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
11
3. REMOVAL AND INSTALLATION OF SEAT

Drivers Seat (Power Seat)
STICS
1. Move the seat rearward as far as possible and unscrew the two front mounting bolts (14 mm) at both sides. Installation Notice
2. Move the seat forward as far as possible and unscrew the two rear mounting bolts (14 mm) at both sides. Installation Notice
3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly.
Disconnect the connector
Connector (seat side)
Main connector
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
EL
12
7410
Passengers Seat (Power Seat)

1. Move the seat backward as far as possible and unscrew the two front mounting bolts (14 mm) at both sides. Installation Notice
2. Move the seat forward as far as possible and unscrew the two rear mounting bolts (14 mm) at both sides. Installation Notice
3. Lay down the seatback and disconnect the connector under the seat and then remove the seat assembly.
SEAT & SEAT BELT

KYRON SM - 2005.09
7410 Second Row Seat

1. Slide the front seats forward and remove the four front mounting nuts (14 mm) of the second row seat. Installation Notice
13
2. Lay down the seatback of the second row seat and remove the eight rear mounting nuts (14 mm). Insert a wrench between seatback and cushion to remove the mounting bolts with arrow mark.
3. Remove the second row seat from the vehicle.
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
14
7410
Third Row Seat

1. Unscrew the six mounting bolts (10 mm) and remove the storage box from the luggage compartment.
2. Unscrew the mounting bolts and remove the third row seat.
SEAT & SEAT BELT

KYRON SM - 2005.09
7410 Power Seat Switch

15
2. Disconnect the switch connector and remove the seat side cover.
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. Slide the front seat forward and unscrew the mounting screws of seat side cover.
EL
16
7410
3. Remove the power seat switch cover and unscrew the two mounting screws to remove the switch.
Composition of Power Seat Switch
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
17
4. SEAT HEATING
EL
Drivers Seat Heating Switch
Passengers Seat Heating Switch
Press the button to warm the seat, and press it again to stop the operation. The indicator on the switch comes on during operation.
5. SEAT ARRANGEMENT
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
STICS
18
7410
SEAT BELT
1. SEAT BELT LOCATIONS
3 Point type seat belt: drivers seat, passengers seat, window side seats of second row seat, third row seat 2 Point type seat belt: center seat of second row seat Pretensioner: Installed at front seats. The seat belt pretensioner rewinds the seat belt immediately to protect occupants face and chest when a strong frontal collision occurs.
Seat Belt (3 point type)
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
19
Seat Melt in Front Seats
Seat belt anchor
Seat belt anchor Seat belt Seat belt Seat belt Oring Seat belt O-ring
Pre-tensioner
Buckle of 3 point type seat belt
Seat Belt (2 Point Type)

2 point type seat belt is installed only in the center seat of second row seat.
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
Buckle of 2 point type seat belt
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
Bracket
IMMO
Seat Belt in Second Row Seat
Seat Belt (Window Side) in Third Row Seat
STICS
Seat Belt (3 Point Type)
EL
20
7410
2. REMOVAL AND INSTALLATION OF SEAT BELT

Front Seat Belt
Preceding Work: Removal of front seat 1. Remove the seat belt D-ring cover. NOTICE
In order not to damage the O-ring cover, be sure to observe the following procedures.
1) Press both sides of button (1) and push the bottom of D-ring cover (arrow) to release the upper hook (2).
2) Raise the arrow section and remove the D-ring cover.
SEAT & SEAT BELT

KYRON SM - 2005.09
7410
21
2. Open the bolt cap and unscrew the seat belt anchor bolt.
Bolt cap
3. Remove the B pillar (lower) and disconnect the pretensioner connector.
4. Unscrew the seat belt upper mounting bolt from the height adjuster.
WIPER
5. Carefully lower the seat belt and unscrew the mounting screws and bolts to remove the seat belt.
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
AV
S/W
CLUSTER
SPWM
IMMO
STICS
EL
22
7410
6. Unscrew the mounting screws and remove the B pillar (upper).
7. Unscrew the mounting bolts and remove the height adjuster.
Composition of Front Seat Belt
Seat belt
Seat belt anchor bolt (35 ~ 55 Nm)
Height adjuster
D-ring
Seat belt mounting bolt (35 ~ 55 Nm)

SEAT & SEAT BELT
7410 Rear Seat Belt

Preceding Work: Removal of second row seat and third row seat
23
2. Unscrew the lower anchor bolt of the rear seat belt.
Anchor bolt
Seat belt
D-ring D-ring
SEAT & SEAT BELT

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
O-ring bracket
LAMP
PAS
R / SENSOR
WIPER
3. Remove the rear quarter panel and unscrew the guide pin screw and mounting bolts to remove the seat belt.
AV
S/W
CLUSTER
SPWM
IMMO
STICS
1. Open the bolt cap and unscrew the upper mounting bolt.
EL
24
7410
Buckles and Center Seat Belt

Reel Type Buckles and Center Seat Belt
Buckles for third row seat
Seat belt latch
Buckle for 3 point type seat belt in second row seat Buckle for 2 point type seat belt in second row seat
Buckle for 3 point type seat belt in second row seat
Center seat belt
Fixed Type Buckle (Front Seat)
Buckle
Cover
Buckle mounting bolt: 35 ~ 55 Nm
SEAT & SEAT BELT

KYRON SM - 2005.09
AUTO CRUISE SYSTEM
TABLE OF CONTENTS
AUTO CRUISE ASSEMBLY .................................... 2
1. 2. 3. 4. Cruise control system ........................................................... 2 Curise control switch ............................................................2 Removal and installation of cruise control switch ..................2 Electrical wiring diagrams ..................................................... 3
AUTO CRUISE ASSEMBLY

1. CRUISE CONTROL SYSTEM
The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver. When the cruise control is activated, speed is maintained or increased by means of an electrically controlled cable attached to the accelerator assembly. If the vehicle must be slowed to maintain the speed that was set by the driver, the cruise control system allows the throttle return spring to close the throttle return spring to close the throttle. Of driving conditions require sudden acceleration after the cruise control had been set, speed can be increased in the normal manner by manually pressing the accelerator. The cruise control is disengaged if the brakes (or clutch, with manual transaxle) are applied. The minimum speed for setting the cruise control is 38.6 km/h (24 mph). When cruise control is operating, the cruise indicator lamp is on in the instrument cluster. The cruise control system is capable of monitoring internal software and hardware faults as well as external faults in the connectors and wire harness. If a fault is detected, creise control is stopped immediately, and the program logic and hardware logic independently prevent the cruise control from opening the throttle. The cruise control will function in temperatures ranging from -40C (-40F) to 80C (185F) maximum temperature could cause the regulation properties to be out of tolerance, but the safety shutdown will still be operational under maximum temperature conditions. If high temperature interferes with cruise control operation, the actuator electromagnetic clutch will open, and the throttle, unless the accelerator pedal is pressed.
2. CURISE CONTROL SWITCH

The cruise control switch located under the steering wheel.
3. REMOVAL AND INSTALLATION OF CRUISE CONTROL SWITCH

Cruise Control Switch
1. Disconnect the negative battery cable. 2. Remove the steering wheel air bag and cruise switch cover. 3. Remove the crew with control switch. 4. Remove the control switch 5. Installation should follow the removal procedure in the reverse order.
AUTO CRUISE SYSTEM

KYRON SM - 2005.09

Diesel
STICS EL
Gasoline
AUTO CRUISE SYSTEM

KYRON SM - 2005.09
A / CRUISE
S E AT
S / ROOF
LAMP
PAS
R / SENSOR
WIPER
AV
S/W
CLUSTER
SPWM
IMMO
MEMO
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BODY INTERIOR
7730 / 7610 / 7330 / 7630 / 7632 / 7850 / 7770 TABLE OF CONTENTS
INTERIOR TRIM ...................................................... 2
1. Locations .............................................................................. 2
INSTRUMENT PANEL ............................................ 4

1. Removal and installation of instrument panel ........................ 4
SUN VISOR ........................................................... 11

1. Removal and installation of sun visor ................................... 11
REAR QUARTER TRIM AND PILLAR .................. 12

1. Removal and installation of rear quarter trim and pillar ........ 12
HEADLINING ASSEMBLY .................................... 14

1. Removal and installation of headlining ................................. 14
CENTER CONSOLE (A/T - DELUXE MODEL) ..... 18

1. Removal and installation of center console (A/T) ................. 18
CENTER CONSOLE (MANUAL TRANSMISSION) 20

1. Removal and installation of center console (M/T) ................ 20
OUTSIDE REARVIEW MIRROR ........................... 22

1. Removal and installation of outside rearview mirror ............. 22
INSIDE REARVIEW MIRROR ............................... 24

1. Removal and installation of inside rearview mirror ................ 24
7730
INTERIOR TRIM
1. LOCATIONS
Instrument Panel Assembly Center Console (A/T) - Deluxe Type
B Pillar Trim (Upper/Lower)
C Pillar Trim
Rear Quarter Panel
Door Trim (Driver Side Door)
BODY INTERIOR
KYRON SM - 2005.09
7730
Hand Grip
Sun Visor
A Pillar Trim
Door Trim (Passenger Side Door, Rear Doors)
Headlining Assembly
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
7730
INSTRUMENT PANEL
1. REMOVAL AND INSTALLATION OF INSTRUMENT PANEL
Step 1
1) Insert a flat blade screwdriver into the groove (A) and pry off the instrument side cover. NOTICE
Be careful not to damage the components around the instrument panel and clips. B B
A A
2) Disconnect the cables for parking brake release lever (A), fuel lid opening lever (B), and engine hood release lever (C). Unscrew four mounting screws and remove the lower panel.
Hood Release Lever
Fuel Lid Opening Lever
Parking brake release lever Slot Guide groove Insert tab Cable
3) Unscrew the mounting bolts and nuts and remove the undercover and bracket.
Parking brake release lever Guide bracket
Parking brake pedal
BODY INTERIOR
KYRON SM - 2005.09
7730
4) Remove the right side panel from the center fascia.
6) Remove the panel assembly of outside rearview mirror switch bezel (Refer to Switch section.).
Center Speaker
7) Remove the DVD changer and passenger side lower instrument panel (Refer to AV System section.).
8) Remove the center console assembly and the center fascia lower tray.
9) Remove the steering wheel assembly (steering angle sensor, air bag, air bag contact coil, multifunction switch).
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
5) Unscrew three mounting screws and remove the left side panel from the center fascia panel and AV head unit.
7730
Step 2
1) Disconnect the harness and remove the sun sensor. 2) Unscrew the center bolt in the instrument panel.
3) Unscrew the mounting nuts and screws from the fuse/relay box and side instrument panel (at driver side).
4) Remove the parking brake lever bracket and fuse/ relay box assembly.
Parking Brake Lever Bracket Driver Side Fuse/ Relay Box
5) Unscrew the meter cluster mounting nuts and lower instrument panel mounting bolts.
BODY INTERIOR
KYRON SM - 2005.09
7730
6) Remove the center speaker from the instrument panel (Refer to AV System section.).
7) Unscrew the nuts from the center fascia.

INT
8) Unscrew the mounting nuts from the DVD changer in passenger side instrument panel.
9) Unscrew the mounting nuts and screws from the fuse/ relay box and side instrument panel (at passenger side).
10) Disconnect the GPS antenna connector.
11) Remove the instrument panel assembly.
GPS Antena
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
7730
Step 3
1) Unscrew the mounting bolts from the driver side instrument panel frame. 5) Disconnect the A/C main (A) cable and the sensor cluster (B) connector and the frame mounting bolt (center side).
2) Unscrew the mounting bolts from the driver side steering column bracket.
3) Disconnect the main wiring connector (A) and air bag connector (B).
4) Disconnect the center wiring connector and unscrew the mounting bolt.
BODY INTERIOR
KYRON SM - 2005.09
7730
7) Unscrew the mounting bolts (A, B) from the passenger side instrument panel frame and air conditioner module.
8) Unscrew the center mounting bolts at both sides in the instrument panel frame.
9) Disconnect the main wiring, the optical cable and the SSPS connector etc. on the passenger side.
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
6) Disconnect the air bag connector (A) and A/T connector (B), ground cable (C) and air bag ground cable (D), then release the clamp (E) from console box.
10
7730
10) Remove the instrument panel frame.
Instrument Panel and Panel Frame Assembly
BODY INTERIOR
KYRON SM - 2005.09
7730
11
1. REMOVAL AND INSTALLATION OF SUN VISOR

Unscrew the screws and disconnect the vanity mirror lamp connector. Remove the sun visor and sun visor hook.
EXT R E PA I R
Mounting Screws (3)
Vanity Mirror Lamp Connector
Sun Visor Components
Driver side
Passenger side
BODY INTERIOR
KYRON SM - 2005.09
INT
SUN VISOR
12
7730
REAR QUARTER TRIM AND PILLAR

1. REMOVAL AND INSTALLATION OF REAR QUARTER TRIM AND PILLAR
Preceding Works: Disconnect the negative battery cable and remove the seats. For seat belt, refer to Seat and Seat Belt section.
Rear Quarter Trim

Remove the seat belt and D pillar before removing the rear quarter trim. Disconnect the power outlet connector before removing the passenger side rear quarter trim. 1. Unscrew the mounting screws and remove the rear quarter trim.
A. Upper Bolt (D Pillar Side) D Pillar Assembly
C Pillar Assembly
B. Side Bolt
Rear Quarter Trim Assembly
C. Lower Bolt (Tailgate Side)
Remove the tailgate scuff trim before removing the lower screw of rear quarter trim.
BODY INTERIOR
7730 B Pillar Trim

Remove the front and rear scuff trims (A) and remove the lower B pillar.
13
Unscrew the upper screw and remove the upper B pillar.
A Pillar
Remove the door weather strip and unscrew the mounting screws to remove the A pillar.
B Pillar Assembly
A Pillar Assembly
C Pillar
Remove the seat belt and unscrew the mounting screws to remove the C pillar.
D Pillar
Be careful not to damage the pillars and fasteners.

BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
14
7730
HEADLINING ASSEMBLY
1. REMOVAL AND INSTALLATION OF HEADLINING
Preceding Work: Disconnect the negative battery cable. 1. Remove the components shown in the figure below (Refer to Body and Lamp sections.).
Room lamps
D pillar Hand grip
Sunroof Hand grip
C pillar Sun visor
Sun visor Inside rearview mirror
B pillar (upper)
A pillar
Pillars
Headlining Luggage room lamp connector Sunroof unit connector Room lamp connector
Front room lamp connector Rear washer fluid hose
Rear washer fluid hose Roof wiring connector Rear washer fluid hose
BODY INTERIOR
KYRON SM - 2005.09
7730
15
2. Disconnect the connectors and washer fluid hoses from the headlining and remove the fasteners.
EXT
Fastener
R E PA I R
Rear Washer Fluid Hose
Sunroof Unit Connector
Rear Washer Fluid Hose and Roof Wiring Connector
* Use only designated special tool when removing the fasteners.
BODY INTERIOR
KYRON SM - 2005.09
INT
16
7730
1) Remove the sunroof molding and disconnect the sunroof unit connector.
2) Disconnect the rear washer fluid hose (nozzle side).
3) Remove the roof wiring connector (A) and rear washer fluid hose (B) in driver side.
BODY INTERIOR
KYRON SM - 2005.09
7730
17
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
4) Pull out the fasteners (rear - 4, front - 2, luggage compartment - 4 at each side) and remove the headlining assembly.
18
7730
CENTER CONSOLE (A/T - DELUXE MODEL)

1. REMOVAL AND INSTALLATION OF CENTER CONSOLE (A/T)
1. Place the gear selector lever to D position and remove the lever knob. Move the gear selector lever to N position. To remove the lever knob, pull up the knob after turning the fastener
Fastener
2. Disconnect the cigarette lighter connector and remove the console fascia cover.
3. Remove the gear selector lever cover and storage box.
BODY INTERIOR
KYRON SM - 2005.09
7730
4. Unscrew two mounting screws from the center storage box.
19
6. Remove the storage box cover and disconnect two mounting bolts (10 mm) in center console.
7. Remove the center console.
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
5. Remove the screw caps and unscrew the mounting screws at both sides of center console.
20
7730
CENTER CONSOLE (MANUAL TRANSMISSION)

1. REMOVAL AND INSTALLATION OF CENTER CONSOLE (M/T)
1. Remove the gear shift lever knob by turning it counterclockwise.
Center Console Assembly
2. Remove the rear duct adapter (A) and center console cover (B).
3. Remove the storage box in center console.
4. Unscrew two mounting screws in center storage box.
BODY INTERIOR
KYRON SM - 2005.09
7730
21
5. Unscrew the mounting screws at both sides of center console.
6. Remove the storage box cover and unscrew the mounting bolts in center console.
EXT
7. Slacken the equalizer adjusting nut so that the parking brake lever can be raised all the way.
8. Disconnect the cigarette lighter connector and remove the center console assembly.
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
INT
22
7730
OUTSIDE REARVIEW MIRROR

1. REMOVAL AND INSTALLATION OF OUTSIDE REARVIEW MIRROR
Components Outside Rearview Mirror Switch Assembly Outside Rearview Mirror Assembly UP
Left
Right
Down
For removal/installation of switch, refer to Switch section.
1. Remove the inner cover and disconnect the outside rearview mirror connector.
BODY INTERIOR
KYRON SM - 2005.09
7730
23
2. Remove the door trim and then remove the inner cover of outside rearview mirror.
Unscrew the mounting screws with dotted circle and remove the door trim from lower side (For details, refer to Door section.).
3. Unscrew five mounting bolts (10 mm) and remove the outside rearview mirror.
BODY INTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
24
7730
INSIDE REARVIEW MIRROR

1. REMOVAL AND INSTALLATION OF INSIDE REARVIEW MIRROR
1. Pry off the room mirror cover with a flat blade screwdriver.
2. Disconnect the harness connector and remove the inside rearview mirror.
Inside Rearview Mirror
ECM sensor
BODY INTERIOR
KYRON SM - 2005.09
BODY EXTERIOR
BODY EXTERIOR..................................... 2
1. Front .................................................................... 2 2. Rear ..................................................................... 3
FENDER.................................................. 26
1. Removal and installation of fender ................... 26
FRONT DOOR ........................................ 28 BUMPER ................................................... 4

1. Construction ....................................................... 4 2. Removal and installation of bumper ................... 6 1. 2. 3. 4. Removal and installation of front door .............. Removal and installation of front door trim ....... Components of front door opening system ...... Front window regulator ..................................... 28 29 30 31
HOOD ASSEMBLY ................................. 11

1. Construction ...................................................... 11 2. Removal and installation of hood assembly ..... 12
REAR DOOR ........................................... 33

1. 2. 3. 4. Removal and installation of rear door ............... Removal and installation of rear door trim ........ Components of rear door opening system ....... Rear window regulator ...................................... 33 34 35 36
ROOF FASHION RAIL ............................ 16

1. Construction ..................................................... 16 2. Removal and installation ................................... 16
FUEL TANK ............................................ 38 TAILGATE................................................ 17

1. Tailgate assembly ............................................. 17 1. Removal and Installation of Fuel Tank (for removing rear left upper arm and lower arm) ............. 38
REAR AIR SPOILER .............................. 23 SIDE SEAL MOLDING ........................... 24

1. Construction ..................................................... 24
SPARE TIRE ........................................... 40

1. Removal and Installation of Spare Tire ............. 40
5110
BODY EXTERIOR
1. FRONT
Sunroof Engine Hood
Front Fender
Front Door
Front Section
Cover - Front end member, lower Energy absorber - Front bumper
Fog lamp Front bumper Front bumper grille Headlamp assembly Front bumper garnish
BODY EXTERIOR
KYRON SM - 2005.09
5110
2. REAR
Rear Door Rear Air Spoiler
EXT
KYRON SM - 2005.09
Tailgate
Roof Fashion Rail
Rear Bumper Assembly Parking aid sensors Rear bumper fascia
Energy absorber
Impact beam
Parking aid sensor wiring
BODY EXTERIOR
R E PA I R
INT
5110
BUMPER
1. CONSTRUCTION
Front Bumper
Cover - Front end member, lower Energy absorber - Front bumper
Scrivet
Screw
Grommet - Screw
Screw Fascia assembly - Front bumper Bolt
BODY EXTERIOR
KYRON SM - 2005.09
5110
Rear Bumper
Bracket - Rear bumper, upper
Energy absorber - Rear bumper
Cover - Rear bumper guide
Grommet - Screw Scrivet
Grommet - Screw Screw
Screw
Bolt
Screw
Lamp assembly Reflector
Fascia assembly - Rear bumper
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
5110
2. REMOVAL AND INSTALLATION OF BUMPER

Front Bumper
Preceding Work: Disconnect the negative battery cable and remove the headlamps and fog lamps.
1. Unscrew the bumper mounting bolts around headlamps.
2. Unscrew the center mounting bolts (10 mm).
Bolt Bolt Bolt
3. Unscrew the lower mounting bolts (10 mm). 4. Remove the scrivets ( ) from the upper cover.
BODY EXTERIOR
KYRON SM - 2005.09
5110
5. Unscrew the mounting screws from the wheelhouse and remove the front bumper assembly.
Screws (Upper Side)
EXT R E PA I R
Fasteners (Lower Side)
6. Install the front bumper in the reverse order of removal.
Cover - Front end member, lower
Energy absorber Front bumper
Front bumper Fog lamp
Front bumper grille
Headlamp assembly
Front bumper garnish

BODY EXTERIOR
KYRON SM - 2005.09
INT
5110
Rear Bumper
Preceding Work: Disconnect the negative battery cable and remove the rear combination lamps. 1. Unscrew the mounting bolts from the rear bumper. (arrow Unscrew the mounting screw from the rear bumper. (arrow
2. Remove the scrivets (
) from the rear bumper.
3. Unscrew the mounting screws from the wheelhouse.
4. Unscrew the lower mounting screws from the bumper.
BODY EXTERIOR
KYRON SM - 2005.09
5110
5. Disconnect the parking aid sensor connector.

Left / Right / Center
6. Unscrew the lower mounting bolts from the bumper.

EXT
7. Remove the rear bumper fascia and the energy absorber.
Parking aid sensor
Rear bumper fascia Energy absorber
Energy absorber
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
INT
10
5110
8. Disconnect the rear main wiring (parking aid sensor) connector and unscrew the two mounting bolts (12 mm) at both sides of rear bumper beam. Carefully remove the rear bumper beam assembly.
Rear Bumper Beam Bolts (LH) Tightening Torque: 42 ~ 62 Nm
Rear Bumper Beam Bolts (RH) Tightening torque: 42 ~ 62 Nm
Do not remove the upper bolt.
Do not remove the lower bolt.
A. Disconnect the rear main wiring (parking aid sensor) connector. At this moment, the side fastener for the connector should be removed.
9. Install the rear bumper beam assembly in the reverse order of removal.
BODY EXTERIOR
5110
11
1. CONSTRUCTION
EXT
Hood hinge Rear seal - Hood, rear
Hood panel
Hood insulator Fastener - Hood insulator pad Bracket - Hood lifter mounting Hood hinge
Bolt Screw Hood lifter Seal - Hood, front Seal - Hood, front sub Hood guide bumper Overslam bumper Trunk lid Hood latch release handle
Hood latch
Screw
Hood latch release cable Clip
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
INT
HOOD ASSEMBLY
12
5110
2. REMOVAL AND INSTALLATION OF HOOD ASSEMBLY

Preceding Work: Cover the vehicle body and place the chocks under the tires.
Hood
1. Disconnect the washer fluid nozzle from the engine hood. 2. Unscrew the two shock absorber mounting bolts (10 mm) from the engine hood.
3. Slacken the mounting bolts on the hood hinge (Do not remove the bolts.) NOTICE
Make an alignment mark on the hood and hinge for installation. Alignment mark
4. Carefully remove the engine hood.

Pay particular attention to avoid vehicle damage and personal injury.
BODY EXTERIOR
KYRON SM - 2005.09
5110 Hood Shock Absorber

Release the upper (hood) and lower (vehicle body) clips from the shock absorber and remove the hood shock absorber. CAUTION
The hood may drop due to its weight. Make sure to support it with a safety device.
13
Hood Adjustment
1. Up/Down/Left/Right : Slacken the hood hinge mounting bolts and adjust the hood position until it is placed to the desired location.
2. Hood height : To adjust the height of hood front end, turn the overslam bumper.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
14
5110
Hood Insulation Pad

1. Remove the fasteners and remove the insulation pad.
BODY EXTERIOR
KYRON SM - 2005.09
5110 Hood Latch and Cable

Preceding Work: Remove the front bumper assembly (including headlamp). 1. Remove the lower instrument panel in front of drivers seat and disconnect the hood release lever cable.
Hood release lever
15
2. Unscrew the three hood latch bolts (10 mm), disconnect the hood release cable, and remove the hood latch.
3. Remove the hood cable from the vehicle.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
16
5110
ROOF FASHION RAIL

1. CONSTRUCTION
CAUTION
To prevent water leaks, apply the liquid sealant to the bolt thread when installing the roof fashion rail.

Preceding Work: Remove the headlining assembly. Unscrew the front and rear mounting nuts (10 mm) and remove the roof fashion rail. The front mounting nut is located behind the hand grip bracket.
BODY EXTERIOR
KYRON SM - 2005.09
5110
17
1. TAILGATE ASSEMBLY
EXT
Nut
Tailgate handle, outside Tailgate weather strip Tailgate lifter
Tailgate overslam bumper Ball stud Tailgate overslam bumper, center
Tailgate side guide Bolt
Body side guide
Tailgate handle, inside Tailgate actuator rod
Screw Striker
Cap - Tailgate handle, inside Tailgate latch assembly
Shim - Door striker
Nut
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
INT
TAILGATE
18
5110
Removal and Installation of Tailgate Assembly

Operating Mechanism
Construction - Inside View
Construction - Outside View
Tailgate handle, outside
Tailgate handle and rod, inside Actuator
Actuator Safety crank assembly Latch assembly

BODY EXTERIOR
KYRON SM - 2005.09
5110
19
Tailgate Trim
1. Unscrew the scrivets and remove the upper trim from the tailgate.
2. Remove the inside handle.
3. Remove the scrivets.
4. Remove the fasteners and then remove the lower trim.
Locations of Fasteners
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
20
5110
Tailgate Assembly
Preceding Work: Remove the upper and lower trims from the tailgate. 1. Disconnect the main wiring connector (A), ground (B), heated wire (C) and heated wire ground (D). Remove the wiring harness.
3. Disconnect the stop lamp connector from the rear air spoiler.
BODY EXTERIOR
KYRON SM - 2005.09
5110
21
5. Release the fixing clips and remove both shock absorbers.
6. Unscrew the two hinge bolts (10 mm) and remove the tailgate assembly.
CAUTION
Pay particular attention to avoid vehicle damage and personal injury.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
4. Disconnect the ground (A) and heated wire cable (B) from the tailgate.
INT
22
5110
Tailgate Latch and Actuator

Preceding Work: Remove the trim.
Latch
1. Disconnect the connecting rod in tailgate. 2. Remove the latch assembly.
Actuator
Disconnect the actuator rod and connector and remove the actuator assembly.
BODY EXTERIOR
KYRON SM - 2005.09
5110
23
1. Unscrew four mounting nuts (10 mm) and three cap nuts (10 mm) from the rear air spoiler.
2. Remove the upper trim and disconnect the high mounted stop lamp.
4. Remove the rear air spoiler from the tailgate.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
REAR AIR SPOILER
24
5110
SIDE SEAL MOLDING

1. CONSTRUCTION
Fender panel
Quadrant cover assembly
Clip - Side seal molding mounting
Garnish assembly - Front door Garnish assembly - Front side seal Clip - Door garnish mounting Clip - Side seal molding mounting Clip - Side seal molding mounting, lower Garnish assembly - Rear door
Clip - Door garnish mounting
Screw
Clip - Side seal molding mounting Screw Clip - Side seal molding mounting, lower Screw Clip - Door garnish mounting
Grommet - Screw Screw
Garnish assembly - Rear side seal
BODY EXTERIOR
KYRON SM - 2005.09
5110
25
Side Seal Molding

All side moldings can be removed/installed with a similar procedure.
1. Unscrew the mounting screw in wheelhouse.
2. Unscrew four mounting screws from the front/rear side seal moldings.
3. Carefully remove the side molding seal.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
26
5110
FENDER
1. REMOVAL AND INSTALLATION OF FENDER
Preceding Work: Disconnect the negative battery cable and remove the headlamps, front bumper and cowl. 1. Remove the tires and wheelhouse cover.
2. Remove the quadrant cover.
CAUTION
Be careful not to damage the fasteners.
3. Remove the insulator sponge in fender.
4. Disconnect the side repeater connector and remove the lamp assembly.
BODY EXTERIOR
KYRON SM - 2005.09
5110
27
5. Unscrew the quadrant cover bolts (A) and cowl bolt (B).
6. Unscrew the lower mounting bolts in fender.
7. Unscrew the mounting bolt on the fender near the headlamp.
8. Unscrew the bolts and screws from the fender wheelhouse.
9. Unscrew the upper bolts from the fender.
10. Remove the fender from the vehicle.
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
EXT
INT
28
5110
FRONT DOOR
1. REMOVAL AND INSTALLATION OF FRONT DOOR
1. Unscrew the mounting bolt from the door check link (vehicle side). 2. Remove the main wiring harness cover and disconnect the door main connector.
Disconnect the Door Wiring Harness.
3. Unscrew the upper and lower hinge bolts and remove the door assembly.
Upper Door Mounting Bracket Lower Door Mounting Bracket
BODY EXTERIOR
KYRON SM - 2005.09
5110
29
2. REMOVAL AND INSTALLATION OF FRONT DOOR TRIM

Front
1. Unscrew seven mounting screws from the door trim (refer to figure below).
Remove the components as in order shown in figure below.
3. Separate the bottom of door trim and pull it up to remove.
Locations of Fasteners
BODY EXTERIOR
KYRON SM - 2005.09
R E PA I R
2. Remove the door handle cable (A), door courtesy lamp connector (B), door tweeter speaker/memory seat position switch connector (C) and power window switch (D) from the removed door trim.
EXT
INT
30
5110
3. COMPONENTS OF FRONT DOOR OPENING SYSTEM
Front door outside handle assembly
Front door checker assembly Nut
Nut - Front door outside handle Bolt - Flange Overslam bumper Screw - Door striker mounting Inside handle assembly - front door
Door striker
Door striker shim Rod - Front door outside handle Clip - Door actuator rod
Cable assembly Front door safety lock knob Bolt - Door latch mounting Cable assembly Front door inside handle Cable holder Door latch and cable assembly
BODY EXTERIOR
KYRON SM - 2005.09
5110
31
Dual Rail with Regulator

1. The dual rail with regulator is installed to this vehicle. Its advantages are as below: 1) Smooth operation 2) Safety operation 3) Preventing the glass pinch 4) Preventing the glass tilting 5) Reduced the length of glass run 6) Increased durability of lifting mechanism (including glass run) 7) No contamination due to grease (applied solid coating)
Components Driver Side Window and Regulator Window assembly Window motor
Window mounting bracket
Window guide rail Window mounting bracket Window cable
Passenger Side Window and Regulator Window assembly
Window mounting bracket Window mounting bracket Window motor Window guide rail
Window cable
BODY EXTERIOR
KYRON SM - 2005.09
REPAIR
EXT
INT
4. FRONT WINDOW REGULATOR
32
5110
Removal and Installation of Window Regulator

Preceding Work: Disconnect the negative battery cable. 1. Lower the window until the window mounting bracket can be seen. Unscrew the nuts from the window mounting bracket and remove the window.
2. Disconnect the window motor connector and unscrew the mounting bolts from the window regulator.
Passenger Side Window Motor
Driver Side Window Motor
3. Remove the window regulator from the door.

Driver Side Passenger Side
BODY EXTERIOR
KYRON SM - 2005.09
5110
33
1. REMOVAL AND INSTALLATION OF REAR DOOR

1. Remove the lower B pillar and the front seat belt and disconnect the rear door main connector. 2. Unscrew the mounting bolts from the door check link (vehicle side).
EXT REPAIR
Disconnect the Door Wiring Harness.
3. Unscrew the upper and lower hinge bolts and remove the door assembly.
Upper Door Mounting Bracket Lower Door Mounting Bracket
BODY EXTERIOR
KYRON SM - 2005.09
INT
REAR DOOR
34
5110
2. REMOVAL AND INSTALLATION OF REAR DOOR TRIM

1. Unscrew five mounting screws from the door trim (refer to the figure below). Installation Notice
2. Separate the power window switch connector and disconnect the connector. Remove the door trim.
3. Remove the door handle cable (A) and the door tweeter speaker (B) as in order shown in figure below.
Locations of fasteners
BODY EXTERIOR
KYRON SM - 2005.09
5110
35
Rear door checker assembly Nut
Bolt - Flange
Overslam bumper
Screw bolt Door striker Door striker shim
Rear door outside handle Label Child safety lock Cable assembly Rear door safety lock knob Cable assembly Rear door inside handle
Rod - Rear door outside handle
Cable holder Door latch and cable assembly
Bolt
BODY EXTERIOR
KYRON SM - 2005.09
REPAIR
Rear door outside handle assembly
EXT
INT
3. COMPONENTS OF REAR DOOR OPENING SYSTEM
36
5110
4. REAR WINDOW REGULATOR

Preceding Work: Disconnect the negative battery cable. 1. Lower the window. Unscrew the mounting screw and bolts from and remove the guide channel and windshield dam.
Mounting screw
2. Disconnect the motor connector and unscrew the mounting screws from the window guide to remove the rear window.
3. Unscrew the window motor nut (A) and guide rail nut (B) and remove the window regulator from the door.
BODY EXTERIOR
KYRON SM - 2005.09
5110
37
Components
Fixed glass assembly Window motor
Guide channel
Window cable Guide rail
Window mounting bracket
BODY EXTERIOR
KYRON SM - 2005.09
REPAIR
EXT
Window assembly
INT
38
5110
FUEL TANK
1. REMOVAL AND INSTALLATION OF FUEL TANK (FOR REMOVING REAR LEFT UPPER ARM AND LOWER ARM)
Preceding Works: 1. Remove the tires and place the safety jack under the fuel tank. 2. Drain all fuel. 1. Disconnect the fuel sender connector (A) and supply/return pipe (B).
2. Disconnect the fuel supply hose (C) and air breather hose (D).
NOTICE
Kyron does not have service hole from passenger compartment to fuel tank. So, fuel tank must be disassembled for fuel sender related job.
BODY EXTERIOR
KYRON SM - 2005.09
5110
3. Remove the two bolts (14 mm) from the fuel tank and unscrew the fuel tank bracket bolt (F: 14 mm).
39
4. Seal the fuel hose opening and carefully lower the fuel tank.
Fuel Tank Assembly
BODY EXTERIOR
KYRON SM - 2005.09
REPAIR
EXT
INT
40
5110
SPARE TIRE
1. REMOVAL AND INSTALLATION OF SPARE TIRE
NOTICE
Always install the safety stand under the vehicle body before starting this operation.
1. Remove the butterfly nut from the spare tire carrier and loosen the lock bolt until the hook is released.
BODY EXTERIOR
KYRON SM - 2005.09
5110
2. Remove the spare tire by pulling down the carrier. 3. Install in the reverse order of removal.
41
4. The spare tire carrier can be removed by pulling out the lock pin (arrow).
BODY EXTERIOR
KYRON SM - 2005.09
REPAIR
EXT
INT
MEMO
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BODY REPAIR
BODY REPAIR ......................................................... 3
1. 2. 3. 4. 5. Dimensions ......................................................................... 3 Jack-up points ..................................................................... 4 Design changes for improving NVH performance .............. 6 Frame ................................................................................ 10 Body repair ....................................................................... 21
5110
1. DIMENSIONS
Unit: mm ( ): only for the vehicle with roof fashion rail

EXT
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
INT
BODY REPAIR
5110
2. JACK-UP POINTS
IRS - Lifting Point (Dotted Circles)
BODY REPAIR
KYRON SM - 2005.09
5110
5 Link System - Lifting Point (Dotted Circles)
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
INT
5110
3. DESIGN CHANGES FOR IMPROVING NVH PERFORMANCE

Dual Type Dash Panel and Engine Tunnel with Foaming Pad
Blocks the noise from engine and transmission and improves the reinforcement of vehicle body.
Dash panel
Deadening sheet
Dash reinforcement
Added an additional member to the bottom of dash panel to minimize the possibility of engine retreat when collision.
BODY REPAIR
KYRON SM - 2005.09
5110
Improved Reinforcement and NVH According to the Introducing of Front Floor and Rear Floor
Applied BPR (Body Panel Reinforcement) Sealer to the Door Outer Panel
BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise.
BPR sealer to reinforce the body panel and reduce the noise
Door impact beam reinforcement to reinforce the door impact beam
Door impact beam to protect the passengers in case of side collision
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
INT
5110
Applied BPR (Body Panel Reinforcement) Sealer to the Body Panel

BPR sealer is sprayed by robot and is designed to reinforce the body panel and reduce the noise.
Anti-vibration pads (6 positions)
Insulation pad
Foaming pad
Foaming pad
Foaming pad
The foaming pads are applied to the symmetry surface of the vehicle. Thus, totally 6 foaming pad are applied to the vehicle body.
BODY REPAIR
KYRON SM - 2005.09
5110
Applied the Asphalt to the Body Panel (Improved Anti-Vibration)

INT
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
10
5110
4. FRAME
Components
5-Link Type Suspension Frame
Frame assembly - chassis
Beam assembly - rear impact bumper, rear
Cross member assembly - No. 6 Bracket - cross member support Cross member assembly steering gear box Bracket - 2-way connector mounting Bracket - front upper arm Bracket - front coil spring Bracket - front upper arm Bracket assembly radiator Bolt
Bracket - clutch and brake tube Hanger exhaust pipe, front Cross member - T/ M
Bracket - body mounting No. 1
Bolt
Cap - bumper stopper
Bracket - spare tire stopper Bracket - spare tire carrier, front
Bracket - body mounting No. 2 Bracket - T/M cross member
Cro ass ss m em emb bly e -N r o.5 Cross member assembly - No.4
Hook Bracket - front brake hose Bracket - rear shock absorber
Bracket - fuel tank Cross member assembly - No.3
Bracket assembly - lateral rod Bracket - clutch hose Bracket - step bar frame, rear Bracket - body mounting No. 1 Bracket - front upper arm Bracket assembly - front lower arm, rear Bracket - front coil spring Beam assembly impact front bumper Bracket - ABS center cable Bracket - bumper beam mounting Hook - towing Bracket assembly - radiator Bracket - body mounting No. 2 Bracket - rear lower link
Cross member assembly - No. 2
Bracket assembly engine and front axle
BODY REPAIR
KYRON SM - 2005.09
5110
11
Cross member assembly - No. 6 Beam assembly - impact rear bumper, rear
Bracket - sub frame mounting, rear
Bracket - rear lower link
Bracket - sub frame mounting, front Bolt Bracket - step bar frame, rear
Cross member assembly - No. 3
Bolt
Bracket - sub frame mounting, rear
Bracket - thrust link
Beam assembly - impact front bumper Frame assembly - chassis Cross member assembly - No. 2
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
IRS (Independent Rear Suspension) Type Suspension Frame
INT
12
5110
Frame Dimensions
5-Link Suspension Frame
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
13
Unit: mm
EXT
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
INT
14
5110
Sectional Drawing
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
15
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
INT
16
5110
IRS Suspension Frame

Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
17
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
R E PA I R
EXT
INT
18
5110
Sectional Drawing
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
19
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
20
5110
Frame Body Mounting
Body No. 2 mounting
Body No. 1 mounting
Body No. 5 mounting
Body No. 4 mounting Body No. 3 mounting
Body No. 1 mounting
Body No. 2 mounting
Body No. 3 mounting
Body No. 4 mounting
Body No. 5 mounting
1.
Washer & tube assembly - body No. 1 Insulator -
Washer & tube assembly - body No. 2 Insulator body No. 2, upper
2. body No. 1,
upper
3. body, lower
Washer plain body mounting
Insulator -
Insulator body, lower
Insulator body, lower Washer plain body mounting
Insulator body, lower Washer plain body mounting Bolt
Insulator body, lower
4.
Washer plain body mounting
Washer plain body mounting Bolt Tightening torque 60 ~ 80 Nm
5.
Bolt Tightening torque 60 ~ 80 Nm
BODY REPAIR
KYRON SM - 2005.09
5110
21
White Body
Without sunroof
With sunroof
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
5. BODY REPAIR
22
5110
Body Dimensions
Side Structure Complete
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
23
Engine Compartment
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
24
5110
Front End
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
25
Windshield Glass Mounting Panel
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
26
5110
Tailgate
Unit: mm
BODY REPAIR
KYRON SM - 2005.09
5110
27
Body Gaps
INT
Closely adhered against windshield (no coming-off) Especially, any coming-off between cowl grille end and windshield glass end is not permissible.
Permissible Gap: 0 mm
Permissible Gap: 4.5 0.5 mm
Difference: below 1 mm Permissible Gap: Approx. 3.9 mm Permissible Gap: 1.5 0.5 mm Seal should not be protruded and rolled.
Permissible Gap: Approx. 4 mm Difference between both fenders: below 1 mm
Permissible Gap: Approx. 3.9 mm
Permissible Gap: Approx. 5.1 mm Difference between headlamp and hood: below 1.5 mm Seal should not be protruded and rolled.
Permissible Gap: Approx. 4 mm
Permissible Gap: Approx. 2.3 mm Difference between both sides: below 1 mm
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
28
5110
Difference between both sides: below 1.5 mm Permissible Gap: Approx. 6 mm
Permissible Gap: 0 mm
Permissible Gap: 4.0 1.0 mm Difference: below 1 mm
Permissible Gap: 4.0 1.0 mm Difference: below 1 mm
Permissible Gap: Approx. 8.7 1.0 mm
Permissible Gap:2.8 0.5 mm
BODY REPAIR
KYRON SM - 2005.09
5110
29
Door Components (Including Engine Hood)

Front Door
INT
Panel assembly front door Nut assembly - door outside handle mounting
Hinge assembly front door, upper
Hinge assembly - front door, lower
Clip - door outside rod
Bolt
Bolt
Checker assembly front door
Nut Nut assembly - door outside handle mounting
Bolt - flange
Overslam bumper
Screw - door striker mounting Door striker Door striker shim Inside handle assembly front door
Door outside handle rod
Clip - door actuator rod
Cable assembly - front door safety lock knob Bolt - door latch mounting Cable assembly - front door inside handle
Door latch and cable assembly
Cable holder
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
30
5110
Glass run - front door window
Regulator - front door power window
Motor assembly power window, front
Bolt
Trim assembly - front door
Screw Weather strip front door trim
Cap - front door trim
Cap - front door trim
Bezel - front door, center Panel assembly armrest, front door trim Cap - door trim, center
Clip Holder assembly - bulb
Bulb
Lens - door courtesy lamp
Bracket - front door pull handle mounting
Screw Grommet
BODY REPAIR
KYRON SM - 2005.09
5110 Rear Door
31
Panel assembly rear door
Hinge assembly rear door, upper
Hinge assembly - rear door, lower Handle assembly rear door, outside Bolt Bolt
Rear door checker assembly Bolt - flange Nut
Overslam bumper
Screw Door striker Door striker shim Handle assembly rear door, Inside
Door outside handle rod
Label - child safety Cable assembly - rear door safety lock knob Cable assembly - rear door inside handle Cable holder Door latch and cable assembly Bolt
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
32
5110
Glass run - rear door window
Regulator - rear door power window
Rear power window motor Bolt - serrated
Nut Bolt
Trim assembly - rear door
Screw Weather strip - rear door trim
Cap - rear door trim
Bezel - rear door, center Panel assembly armrest, rear door trim Cap - door trim, center Clip Grommet Screw
Bracket - rear door pull handle mounting
BODY REPAIR
KYRON SM - 2005.09
5110 Tailgate
33
Hinge assembly - tailgate Hinge assembly - tailgate Nut Nut Panel assembly - tailgate
Bolt Nut
Sill trim - tailgate
Trim assembly tailgate, upper Bracket tailgate, lower Clip - trim mounting
Screw Clip Screw - rivet
Trim assembly tailgate, lower
Strap assembly - tailgate, lower Cover tailgate, lower Screw Bracket - strap mounting Nut Grommet - screw Screw Cover - strap
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
34
5110
Nut
Handle assembly tailgate, outside
Lifter assembly tailgate Tailgate molding Ball stud
Tailgate overslam bumper Bumper assembly - guide body, side
Bumper assembly - tailgate overslam, center Bolt Handle - tailgate, inner
Bumper assembly - guide tailgate, side
Cap - tailgate inside handle
Screw
Rod - tailgate actuator
Tailgate striker Tailgate striker shim
Bolt Latch assembly tailgate
Crank assembly - tailgate safety lock
Nut
BODY REPAIR
KYRON SM - 2005.09
5110 Engine Hood
35
Hood hinge
Sill assembly - hood rear
Hood panel assembly
Hood insulator Bracket - lifter mounting Fastener - hood insulator pad Hood hinge
Bolt Screw Lifter assembly - hood Sill assembly - hood, front Sill assembly - hood front sub Bumper - hood guide Bumper - trunk lid overslam Hood latch assembly Cable assembly - hood latch release Screw Clip Handle assembly - hood latch release
Screw
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
36
5110
Body Panels
Firewall, Fender and Front End
Panel assembly front apron
Member - cowl side upper
Panel assembly dash & cowl
Member - cowl side upper
Bracket - fender mounting
Panel Assembly - Front End

Member assembly - headlamp, upper Member assembly front end, upper Bolt Member assembly headlamp, upper
Panel assembly front apron
Panel assembly cowl side inner
Bolt Pad - fender mounting sealing Panel front end Member assembly front end, center
Bolt
Panel assembly front end, inner
Bracket - fender mounting Panel - fender
BODY REPAIR
KYRON SM - 2005.09
5110
37
Floor Panels
Front Floor
Bracket - parking cable pivot
Bracket - parking cable guide
Member assembly body mounting No. 3
Member assembly - front seat mounting, rear Bracket - center support Member assembly - front seat mounting, front Panel - front floor
Bracket - third row seat front mounting Bracket - third row seat front mounting Bracket - third row seat front mounting Bracket - third row seat front mounting
Member assembly - front seat mounting Member assembly body mounting No. 2 Bracket - TCU & TCCU mounting Member assembly - front seat mounting, front
Member assembly body mounting No. 2
Panel assembly - side sill, inner
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
38
5110
Rear Floor
Panel - rear floor
Cross member assembly rear floor No. 4
Reinforcement rear floor, corner Cross member assembly - rear floor No. 4, upper Panel assembly back, outer Extension - rear floor, side Cross member assembly rear floor No. 4, lower Extension assembly rear floor, corner Reinforcement rear floor, corner
Member assembly rear floor
Panel - container Cross member assembly - rear floor No. 1 Cross member assembly rear floor No. 3
Cross member assembly - rear floor No. 2
Bracket - third row seat
Member assembly rear floor
Extension assembly rear floor, corner Extension rear floor, side
BODY REPAIR
KYRON SM - 2005.09
5110 Roof Panel

Roof Panel without Sunroof
Panel - roof
39
Rail assembly - roof, rear Rail - roof, center No. 3 Rail - roof, center No. 2 Rail - roof, center No. 1
Rail assembly - roof, front
Roof Panel with Sunroof
Panel - roof
Rail assembly - roof, rear Rail - roof, center No. 3 Rail - roof, center No. 2
Reinforcement assembly - sunroof
Rail assembly - roof, front
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
40
5110
Side Panel
Reinforcement assembly quarter, inner rear, upper
Reinforcement - D pillar, outer upper
Pillar assembly - D, outer
Panel assembly quarter, inner Reinforcement assembly C pillar, inner Pillar assembly A & B, inner
Housing assembly fuel filler
Bracket - fender mounting, rear upper
Bracket - rear bumper mounting, lower
Panel assembly side, outer
Panel assembly wheelhouse, rear
Bracket, fender mounting, lower
BODY REPAIR
KYRON SM - 2005.09
5110 Engine Mounting Bracket

Transmission Side
Heat shield - insulator
41
Bolt Cross member assembly T/M mounting
Bolt
Insulator - engine mounting, rear
Bolt
Nut
Engine Insulator Mounting

Insulator - engine mounting, front
Bolt
Washer
Insulator - engine mounting, front Bolt
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
Bracket - engine mounting, rear
INT
42
5110
Bumper
Front Bumper
Cover - front end member, lower Energy absorber front bumper
Scrivet
Bolt
Grommet - screw
Screw Fascia assembly front bumper Bolt
Rear Bumper (Excluding PAS)

Bracket - rear bumper, upper Energy absorber rear bumper
Cover - rear bumper guide
Grommet screw Scrivet
Grommet - screw Screw
Screw
Bolt
Screw
Lamp assembly reflex reflector
Fascia assembly - rear bumper
BODY REPAIR
KYRON SM - 2005.09
5110 Glass
43
Plate - inside rearview mirror base Molding assembly - windshield
Glass - front door drop Glass - rear door drop Glass - rear door fixed Glass assembly - quarter Nut - side glass mounting
Bolt - door glass mounting Grommet - door glass mounting Glass assembly - tailgate, tinted
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
Glass assembly windshield
INT
44
5110
Key Set
Ignition lock and cylinder mounting bolt Key set
Ignition key box
Drivers door
Passengers door
Key hall illumination
Immobilizer unit
Blank key
Blank key
Transponder Bulb
Immobilizer key
BODY REPAIR
KYRON SM - 2005.09
5110 Others (I)

Molding assembly - roof (without roof fashion rail) Molding assembly roof No. 1 Molding assembly - roof No. 2 Molding assembly - roof No. 3 Rail assembly - fashion Molding assembly - roof No. 4 Molding assembly - roof No. 5
45
With roof fashion rail Tape - door tooling hall sealing Nut Plug - tailgate tooling hall Nut - Hex flange cap Nut Garnish assembly tailgate, upper
Spoiler assembly
Cover - upper
Cover assembly - front wheelhouse
Cover assembly - rear wheelhouse Garnish assembly tailgate
Cover - rear wheelhouse, front Screw Scrivet
Cover assembly - rear wheelhouse, rear Scrivet
Screw Grommet - screw
BODY REPAIR
KYRON SM - 2005.09
REPAIR
EXT
INT
46
5110
Others (II)
Grille - radiator
Cover assembly - quadrant Screw (backside from bumper fascia) Clip - side sill molding mounting
Garnish assembly - front side sill Garnish assembly - front door
Clip - side sill molding mounting Clip - side sill molding mounting, lower
Clip - door garnish mounting Garnish assembly - rear door
Clip - door garnish mounting Screw
Clip - side sill molding mounting Screw Clip - side sill molding mounting, lower Grommet - screw Screw Screw Clip - door garnish mounting
Garnish assembly - rear side sill
BODY REPAIR
KYRON SM - 2005.09

Ssangyong+Kyron Manual

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GENERAL INFORMATION

Automatic Transmission * ( ) Optional

Model Operating type

CHANGED BY EFFECTIVE DATE AFFECTED VIN

CHANGED BY EFFECTIVE DATE AFFECTED VIN

The certification label is located on the drivers door sill.

Engine Number (D20DT)

Engine Number (D27DT)

1. Vehicle Identification Number

S .. Check Digit 5 .. Model Year P .. Plant Code 122357

CHANGED BY EFFECTIVE DATE AFFECTED VIN

3. Engine Serial Number

4. Manual Transmission Number

5. Automatic Transmission Number

6. Transfer Case Number

CHANGED BY EFFECTIVE DATE AFFECTED VIN

* Use only approved Ssangyong genuine parts.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

* Use only approved Ssangyong genuine parts.

CHANGED BY EFFECTIVE DATE AFFECTED VIN

RECOMMENDED FLUIDS AND LUBRICANTS

Engine Coolant Automatic Transmission Fluid Manual Transmission Fluid

Automatic Transmission Manual Transmission

1.4 1.4 1.9

1.4 ~ 1.5 1.4 2.2

Ssangyong genuine oil (API GL-5 or SAE 80W/90)

Solid Axle Suspension

Power Steering Fluid

CHANGED BY EFFECTIVE DATE AFFECTED VIN

AUTOMATIC TRANSMISSION (DC 5-SPEED)

SPECIAL TOOLS AND EQUIPMENT .... 68 VALVE BODY .......................................... 72

AUTOMATIC TRANSMISSION (DC 5-SPEED) .......................................... 4

HYDRAULIC CIRCUIT ........................... 80

FUNCTION AND DESCRIPTION........... 19

REMOVAL AND INSTALLATION ........... 33

CHANGED BY EFFECTIVE DATE AFFECTED VIN

Releasing Lock-up Solenoid Valve

Standard Mode / Winter Mode

CHANGED BY EFFECTIVE DATE AFFECTED VIN

AUTOMATIC TRANSMISSION (DC 5-SPEED)

With Torque Converter Without Torque Converter

CHANGED BY EFFECTIVE DATE AFFECTED VIN

CHANGED BY EFFECTIVE DATE AFFECTED VIN

2. STRUCTURE AND SPECIFICATIONS

5-Speed Automatic Transmission D20DT D27DT

CHANGED BY EFFECTIVE DATE AFFECTED VIN

5-Speed Automatic Transmission

CHANGED BY EFFECTIVE DATE AFFECTED VIN

Characteristics of Automatic Transmission

Lockup Mode (Open/Slipping)

CHANGED BY EFFECTIVE DATE AFFECTED VIN

FAST OFF 4-5

FAST OFF 3-4

FAST OFF 2-5 4-5

Dynamic shift zone:

3-2 2-3 FAST OFF 1-2 1-2

Lockup Mode (Open/Slipping)

5rd GEAR OPEN

5rd GEAR SLIPPING 4rd GEAR OPEN

4rd GEAR SLIPPING 3rd GEAR OPEN