Engine

ENGINE
GENERAL INFORMATION ............. 01-3P

CDPF (EURO IV) ............................
1725/2412 02-3P
ENGINE CONTROL........................
1491 03-3P
C-145: 2008.07 ~
GENERAL INFORMATION
0000-00
General information for vehicle

1. Specifications and identification ....................... 3
2. Specifications and check items ....................... 5
Changes
1. Major changes for engine and chassis ........... 14
2. DSI M78 6-speed automatic transmission ...... 16
3. Major changes for electrical
system and body ........................................... 18
0000-00 01-3
GENERAL INFORMATION 0000-00
GENERAL
General Information for Vehicle
1. SPECIFICATIONS AND IDENTIFICATION
FUSE
A. Exterior Dimensions
Unit: mm
Top View
1,880
Side View
1,765
2,740
4,455
Front View Rear View
1,570 1,570
GENERAL INFORMATION
ACTYON SM - 2008.07
01-4 0000-00
B. Vehicle Identification
1. Engine Number (D20DT) 1. Engine Number (G23D)
The engine number is stamped on the The engine number is stamped on the up-
lower area of cylinder block in the intake per rear left-hand side of the cylinder block.
manifold side.
3. Certification Label 2. Chassis Number
The certification label is located on the The chassis number is stamped on the
driver’s door sill (B pillar). frame behind the front right tire.
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-5
2. SPECIFICATIONS AND CHECK ITEMS
GENERAL
A. Specifications
* ( ) Optional, [ ] 2WD, < >: DPF
ACTYON ACTYON SPORTS

Descriptions
D20DT G23D D20DT
FUSE
General Overall length (mm) 4,455 ← 4,965
Overall width (mm) 1,880 ← 1,900
Overall height (mm) 1,735 (1,765) ← 1,755
Gross vehicle A/T 2,520 ← 2,740 [2,640]
weight (kg) M/T 2,520 ← 2,740 [2,640]
Curb vehicle A/T 1,974 [1,865] 1,957 [1,848] 2,016 [1,907]
weight (kg) M/T 1,952 [1,843] 1,935 [1,826] 1,963 [1,854]
Fuel Diesel Gasoline Diesel
Fuel tank capacity ( ) 75 ← ←
Min. turning radius (m) 5.6 ← 6.18
Engine Numbers of cylinders/
4 / 17.5:1 4 / 10.4 : 1 4 / 17.5:1
Compression ratio
Total displacement (cc) 1,998 2,295 1,998
Camshaft arrangement DOHC ← ←
Max. power 141 PS / 4,000 rpm
150 PS / 5,500 rpm 141 PS / 4,000 rpm
<138 PS / 4,000 rpm>
Max. torque 310 Nm / 214 Nm / 310 Nm /
1,800 ~ 2,750 rpm 3,500 ~ 4,600 rpm 1,800 ~ 2,750 rpm
Idle speed 780 ± 50 rpm 750 ± 50 rpm 780 ± 50 rpm
Cooling system Water- cooled /
← ←
forced circulation
Coolant capacity ( ) 10.5 ~ 11.0 ← ←
Lubrication type Gear pump,
← ←
forced circulation
Max. oil capacity ( )
8.2 7.9 8.2
(when shipping)
Turbocharger and Turbocharger,
← ←
cooling type air-cooled
Manual Operating type Semi- Remote control,
← ←
Transmission floor change type
Gear ratio 1st 4.315 ← ←
2nd 2.475 ← ←
3rd 1.536 ← ←
4th 1.000 ← ←
5th 0.807 ← ←
Reverse 3.919 ← ←
GENERAL INFORMATION
ACTYON SM - 2008.07
01-6 0000-00
* ( ) Optional, [ ] 2WD
ACTYON
ACTYON
Descriptions SPORTS
D20DT G23D D20DT
Automatic Model Electronic, 6-speed ← ←
Transmission Operating type Floor change type ← ←
2nd 2.143 ← ←
3rd 1.478 ← ←
4th 1.156 ← ←
5th 0.866 ← ←
6th 0.677 ← ←
Transfer Case Model 2WD, Part-time Part-time ←
Type Planetary gear type ← ←
Gear ratio High (4H) 1.000 : 1 ← ←
Low (4L) 2.483 : 1 ← ←
Clutch (M/T) Operating type Hydraulic type ← ←
Disc type Dry single diaphragm type ← ←
Power Steering Type Rack and pinion ← ←
Steering angle Inner 35.7° ← ←
Outer 32.1° ← ←
Front Axle Drive shaft type Ball joint type ← ←
Axle housing type Build-up type ← ←
Rear Axle Drive shaft type Solid axle
Semi-floating type ← ←
suspension
Brake Master cylinder type Tandem type ← ←
Booster type Vacuum assisted booster type ← ←
Brake type Front wheels Disc type ← ←
Rear wheels Drum (disc) ← ←
Parking brake Cable type
← ←
(internal expansion)
Suspension Front suspension Wishbone + coil spring ← ←
Rear Solid axle
5-link + coil spring ← ←
suspension suspension
Air Conditioner Refrigerant (capacity) R-134a (650 ± 30g) ← ←
Electrical Battery type / Capacity (V-AH) MF / 12 - 90 ← ←
Starter capacity (V-kW) 12 - 2.2 12 - 1.2 12 - 2.2
Alternator capacity (V-A) 12 - 115 ← ←
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-7
B. Specified Oil (Fluid) and Capacity
GENERAL
Descriptions Capacity Specifications
Engine Oil Quality class: Ssangyong genuine engine oil
D20DT 7.5 (Approved by MB Sheet 229.1 or 229.3 or 229.31
for DSL/GSL ENG without CDPF)
FUSE
(Approved by MB Sheet 229.31 for DSL ENG
G23D 7.5 with CDPF)
Viscosity: MB sheet No. 224.1
Engine Coolant D20DT Ssangyong genuine coolant
10.5 ~ 11.0
G23D (Anti-freeze:SYC-310, Anti-freeze:water = 50:50)
Automatic Transmission Fluid 4 A/T 9.5 Ssangyong genuine oil (CASTROL TQ 95)
6 A/T 9.5 Ssangyong genuine oil (CALTEX PED 1712)
Manual Transmission Fluid 4WD 3.6
Ssangyong genuine oil (ATF DEXRON II)
2WD 3.4
Transfer Case Fluid 1.4 Ssangyong genuine oil (ATF DEXRON II or III)
Axle Oil Front Automatic Transmission 1.4
Ssangyong genuine oil (SAE 80W/90, API GL-5)
Manual Transmission 1.4
Rear Solid Axle D20DT M/T,
1.9
G23D M/T
Suspension D20DT A/T, Ssangyong genuine oil (SAE 80W/90, API GL-5)
2.0
G23D A/T
LD 1.8
Brake / Clutch Fluid As required Ssangyong genuine oil (DOT4)
Power Steering Fluid 1.0 Ssangyong genuine oil (ATF DEXRON II or III)
NOTICE
• Use only Ssangyong recommended fluids and lubricants.
• Do not mix any different types or brands of oils or fluids. This may cause damages.
• Keep the specified levels when adding or replacing the fluids.
GENERAL INFORMATION
ACTYON SM - 2008.07
01-8 0000-00
C. Maintenance Schedule
Diesel Engine
* Use only approved Ssangyong genuine parts.
Maintenance service and record retention are the owner’s responsibility. You should retain evidence that proper
maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
* EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.)
MAINTENANCE Kilometers (miles) or time in months, whichever comes first

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
MAINTENANCE x1,000 miles 10 20 30 40 50 60 70 80
ITEM Months 12 24 36 48 60 72 84 96
ENGINE CONTROL SYSTEM
Drive belt I I I I I I I I
*1
* Engine oil & filter EU Initial check: 5,000 km, and replenish if necessary, change every 15,000 km
(1)* (3)* (4)* or 12 months (But, shorten the service interval under severe conditions)
General Initial change: 5,000 km, change every 10,000 km or 12 months
(But, shorten the service interval under severe conditions)
Cooling system hose & connections I I I I I I I I
Engine coolant (3)* (4)* Change every 60,000 km or 3 years. And, inspect and replenish if necessary.
* Fuel filter Direct Injection EU I R* I R* I R* I R*
(Diesel Engine) General Replace every 25,000 km
(Draining water from fuel filter: whenever replacing the engine oil)
Additional water separator (if equipped) Replace every 150,000 km or 5 years
(Drain the water whenever replacing the engine oil)
Fuel line & connections I I I I I I I I
Air cleaner (2)* EU Initial clean: 5,000 km, clean every 15,000 km, replace every 30,000 km
General Initial clean: 5,000 km, clean every 10,000 km, replace every 30,000 km
Injection timing (See NOTE 1) I I I I I I I I
NOTE 1: Adjust as required; - When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
*1 Check the engine oil level and leak every 3,000 km (2,000 miles) or before starting a long trip.
R - Replace or change.
(1)* If vehicle is operated under severe condition:
Shorten the service interval.
- Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below 16 km when the outside
temperature remains below freezing
- Driving in a hilly or mountainous terrain, sandy, or dusty area
- High load driving such as trailer towing
- Taxi, patrol service or delivery service (extended idling and excessive driving with low speed)
(2)* If vehicle is operated under severe condition, driving in dusty condition or sandy condition, pollutant area or off-road driving, fre-
quently inspect the air cleaner, if necessary, change the air cleaner.
(3)* More frequent maintenance is required if under dusty driving condition.
(4)* Refer to “Recommended fluids, coolant and lubricants”.
* Water separator: When replace the engine oil, also drain the water from the fuel filter.
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-9
GENERAL

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
MAINTENANCE
FUSE
x1,000 miles 10 20 30 40 50 60 70 80
ITEM Months 12 24 36 48 60 72 84 96
CHASSIS AND BODY
Exhaust pipes & mountings I I I I I I I I
Brake / Clutch fluid (3)* Change every: 2 years (inspect frequently)
Parking brake / Brake pads EU Periodic check: every 15,000 km, adjust or replace if necessary.
(Front & Rear) (4)* General Periodic check: every 10,000 km, adjust or replace if necessary.
Brake line & connections (including booster) Inspect every 15,000 km or 1 years, adjust or replace if necessary
Manual transmission oil (5)* I I I R I I I R
Clutch & brake pedal free play I I I I I I I I
Front & Rear differential fluid (3)* Inspect frequently, change every 30,000 km
Transfer case fluid (3)* Inspect every 15,000 km, change every 60,000 km (Frequnt check of oil leak)
Automatic transmission fluid (6)* Inspect every 30,000 km or 12 month
(But change every 60,000 km under severe condition)
Chassis & underbody bolts & nuts tight / Secure (7)* Check frequntly and adjust or replace if necessary
Tire condition & inflation pressure Check frequntly and adjust or replace if necessary
Wheel alignment (8)* Inspect when abnormal condition is noted
Steering wheel & linkage I I I I I I I I
Power steering fluid & lines (3)* I I I I I I I I
Drive shaft boots (9)* I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I
Lubricate locks, hinges & bonnet latch Check frequntly and adjust or replace if necessary
Wheel bearing grease I I I I I I I I
Propeller shaft grease - EU I I I I I I I I
Front / Rear (10)* General Inspect every 10,000 km
Air conditioner filter Change every 10,000 km
(The service interval should be shortened under severe conditions)
Chart Symbols:
(3)* Refer to “Recommended fluids and lubricants”.
(4)* More frequent maintenance is required if the vehicle is operated under any of the following conditions:
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or moutainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(5)* Inspect manual transmission fluid every 15,000 km (Inspect the leak of fluid at any time,occasionally), then change every 60,000 km
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly driven under severe conditions: Towing a trailer or
off-road driving (Inspect the leak of fluid at any time,occasionlly)
(7)* After completion of off-road operation, the underbody of the vehicle should be throughly inspected. Examine threaded fasteners for
looseness.
(8)* If necessary, rotate and balance wheels.
(9)* After completion of off-road operation, the drive shaft boots should be inspected.
(10)* Inspect propeller shaft grease every 5,000 km or 3 months if the vehicle is mainly driven under severe condition.
- In off-road or dusty road, or
- In hilly or moutainous terrain.
Severe Conditions in Air Conditioner Filter
- Pollutant area or off-road driving, extended air conditioner or heater operation
GENERAL INFORMATION
ACTYON SM - 2008.07
01-10 0000-00
Gasoline Engine

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
ITEM Months 12 24 36 48 60 72 84 96
Engine oil & engine oil filter (1)* (3)*
R** R R R R R R R
(Initial change: 10,000 km)
Engine coolant (3)* Change every 60,000 km or 3 years. And, inspect replenish if necessary.
Fuel filter (2)* Replace every 100,000 km (if using poor quality of fuel, replace every 30,000 km)
Air cleaner (2)* I I I R I I I R
Ignition timing I I I I I I I I
Spark plugs (G23D) - R - R - R - R
Charcoal canister & vapor lines - - I - - I - -
Chart Symbols:
** - In order to secure engine long life and effective break-in, first oil (factory filled) would be recommended to drain with in 10,000 km.
(1)* If vehicle is operated under severe condition: short distance driving, extensive idling or driving in dusty condition, shorten the service
interval.
(2)* If vehicle is operated under severe condition, pollutant area or off-road driving, driving in dusty condition or sandy condition, fre-
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-11
GENERAL

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
ITEM Months 12 24 36 48 60 72 84 96
FUSE
CHASSIS AND BODY
Parking brake / Brake pads EU Periodic check: every 15,000 km, adjust or replace as necessary.
(Front & Rear) (4)* General Periodic check: every 10,000 km, adjust or replace as necessary.
Front & Rear Front EU Periodic check: every 15,000 km, adjust or replace if necessary.
differential General Periodic check: every 10,000 km, adjust or replace if necessary.
fluid (3)* Rear EU Periodic check: every 15,000 km, adjust or replace if necessary.
General Periodic check: every 10,000 km, adjust or replace if necessary.
Transfer case fluid (3)* Inspect every 15,000 km, change every 60,000 km (Frequent check of oil leak)
Automatic transmission fluid (6)* Inspect every 30,000 km or 12 month (But change every 60,000 km under severe condition)
Chart Symbols:
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly driven under severe conditions. (Inspect the
leak of fluid at any time, occasionlly)
looseness.
GENERAL INFORMATION
ACTYON SM - 2008.07
01-12 0000-00
D. Wheel Alignment Specification
DRIVE Chairman Rexton Rexton II Kyron
Camber Left Handle Type Front -0.38° ± 0.15° 0° ± 0.5° -0.12° ± 0.25°(LH) -0.19° ± 0.25°(LH)
-0.00° ± 0.25°(RH) -0.29° ± 0.25°(RH)

(CROSS: 0.5°) (CROSS 0.5°)
Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5°(COIL) -0.79° ± 0.5°
-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

(CROSS: 0.5°)
Right Handle Type Front -0.38° ± 0.15° 0° ± 0.5° -0.12° ± 0.25°(LH) -0.19° ± 0.25°(LH)
-0.12° ± 0.25°(RH) -0.19° ± 0.25°(RH)

(CROSS: 0.5°) (CROSS 0.5°)
Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5° (COIL) -0.79° ± 0.5°
-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

(CROSS: 0.5°)
Caster Left Handle Type 10.35° ± 0.5° 2.75° ± 0.5° 4.28° ± 0.4°(LH) 4.4° ± 0.4°(LH)
4.38° ± 0.4°(RH) 4.5° ± 0.4°(RH)

(CROSS: 0.5°) (CROSS: 0.5°)
Right Handle Type 10.35° ± 0.5° 2.75° ± 0.5° 4.28° ± 0.4°(LH) 4.4° ± 0.4°(LH)
4.28° ± 0.4°(RH) 4.4° ± 0.4°(RH)

(CROSS: 0.5°) (CROSS: 0.5°)
Toe-in Front degree 0.175° ± 0.075° 0.065° ± 0.065° 0.065° ± 0.065° 0.065° ± 0.065°
(LH/RH each Toe)
mm - 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
Rear degree 0.2° ± 0.04° - 0.08° ± 0.09° (COIL) 0.095° ± 0.09°
(LH/RH each Toe)
mm - - 0.095° ± 0.085° (EAS) 3 mm ± 3 mm
(Total Toe)
(LH/RH each Toe 2.5 mm ± 3 mm (COIL)
= Total Toe / 2) 3 mm ± 2.5 mm (EAS)
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-13
GENERAL
Actyon &
DRIVE Rodius & Stavic Musso Korando
Actyon Sports
Camber Left Handle Type Front -0.19° ± 0.25°(LH) 0° ± 0.5° 0° ± 0.5° 0° ± 0.5°
-0.29° ± 0.25°(RH)
FUSE
(CROSS 0.5°)
Rear (IRS) - -1° ± 0.25° - -
Right Handle Type Front -0.19° ± 0.25°(LH) 0° ± 0.5° 0° ± 0.5° 0° ± 0.5°

-0.19° ± 0.25°(RH)
(CROSS 0.5°)
Rear (IRS) - -1° ± 0.25° - -
Caster Left Handle Type 4.4° ± 0.4°(LH) 4.5° ± 0.5° 2.5° ± 0.5° 2.5° ± 0.5°
4.5° ± 0.4°(RH)
(CROSS: 0.5°)
Right Handle Type 4.4° ± 0.4°(LH) 4.5° ± 0.5° 2.5° ± 0.5° 2.5° ± 0.5°
4.4° ± 0.4°(RH)
(CROSS: 0.5°)
(LH/RH each Toe)
mm 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
Rear degree - 0.2° ± 0.04° - -
(LH/RH each Toe)
mm - 6 mm ± 1 mm - -
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
GENERAL INFORMATION
ACTYON SM - 2008.07
01-14 0000-00
Changes
1. MAJOR CHANGES FOR ENGINE AND CHASSIS
Engine ECU Inhibitor Switch

The engine ECU used
for the D27DTP and
D27DT engines are ver-
sion 3.2 and has the ter-
minal related to the
CDPF (front/rear ex-
haust gas temperature
sensor and differential
pressure sensor).
DSI 6AT TGS Lever

For the DC 5 AT model, the
TGS lever sends signals for
the backup lamp operation
and parking aid system in
the position “P” and engine
starting in the position “N”.
However, this function is
performed by the inhibitor
switch for the vehicle
equipped with the 6-speed
A/T.
E-Tronic 6A/T Transmission
4WD Oil cooler return 2WD

Oil cooler outlet Servo
Torque converter
Inhibiter Adapter
switch housing
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-15
GENERAL
Rear pressure port Front pressure port
FUSE
Rear Exhaust Gas
Temperature Sensor Differential Pressure Sensor
(DP sensor)
As the soot is filtered in the CDPF, the

pressure between the front side and
the rear side of the filter is different
from each other. If the amount of soot
is over 32 g, the soot is burnt in the
CDPF. The combustion is determined
depending on the pressure difference,
temperature of exhaust gas and EGR
ratio. According to these, the soot fil-
tered by post injection of injector is
burnt at 600°C.
CDPF Temperature sensor
Rear Exhaust Gas Front Exhaust Gas

Temperature Sensor Temperature Sensor
The two temperature sensors in- Measures the increased exhaust Measures the exhaust gas tem-
side the CDPF are installed in ex- gas temperature after the oxidation perature of the exhaust manifold.
haust manifold (front exhaust gas process of DOC. If the temperature As it isinstalled in front of the VGT
temperature sensor) and in DOC is below 600°C, the post injection turbocharger, it also monitors the
(rear exhaust gas temperature amount is increased to increase exhaust gas temperature coming to
sensor), and performs the follow- the temperature. the turbocharger. If the temperature
ing functions. of the exhaust gas flowing to the
turbocharger is higher than the
regulation, the engine lowers the
exhaust gas temperature.
GENERAL INFORMATION
ACTYON SM - 2008.07
01-16 0000-00
2. DSI M78 6-SPEED AUTOMATIC TRANSMISSION
Torque Converter Oil Pump
The torque converter is installed between the en- The hydraulic oil pump transfers transmission oil
gine and the transmission. It is consisted of the (approximately 17.6 cc per revolution) and is in-
impeller, turbine, stator, lockup clutch, and one- stalled between the torque converter and the trans-
way clutch. mission housing.
Inhibitor Switch
The inhibitor switch is installed on the side of the

transmission. Depending on the position of the
Selector Lever, it sends out different signals to the
TCU. Also, it prevents the engine from starting when
the lever is not engaged in either the “P” or “N”
position.
Valve Body
Variable Bleed Solenoid

Detent Spring – Normal Low
Manual Valve Variable Bleed Solenoid
Variable Bleed Solenoid – Normal Low – Normal High
Input Speed Sensor Variable Bleed Solenoid
Intake Port – Normal High
Variable Bleed Solenoid – Normal Low
– Normal High
ON/OFF Solenoid
The valve body has four ON/OFF solenoid valves and six variable bleed solenoid valves.
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-17
GENERAL
Clutch Pack
Clutch 1 Clutch 2 Clutch 3
FUSE
The three multi-plate clutches are the front (C1), center (C2) and rear (C3) clutches. They are set to the planetary
gear. Each multi-plate clutch has an internal friction disk and an external friction disc. The former is installed to
the internal friction disc carrier, and the latter is installed to the external friction disc carrier. When hydraulic
pressure is applied to the piston of the multi-plate disc clutch, the pressure is also applied to the inside of the
disc and the external disc.
Double Planetary Gear Set
The double planetary gear set is installed to

the spline unit of the output shaft. The set
has the sun gear (forwarding/reversing), pin-
ion gear, carrier, and ring gear.
Simple Planetary Gear Set
The simple planetary gear set is driven by

the input shaft, and it has the sun gear, pin-
GENERAL INFORMATION
ACTYON SM - 2008.07
01-18 0000-00
3. MAJOR CHANGES FOR ELECTRICAL SYSTEM AND BODY
ICM Box Bag Hook
As the ICM box is newly installed, the following relays are

integrated into the ICM box.
- Door lock relay (previously installed to STICS bracket)¡¡ It is newly installed to let a passen-
- Windshield de-icer relay (previously installed under floor on the ger hang his/her bag.
driver side)
- Turn signal lamp relay (previously installed to passenger side
fuse & relay)
GENERAL INFORMATION
ACTYON SM - 2008.07
0000-00 01-19
GENERAL
Side Repeater Chrome Muffler
FUSE
It is now equipped with two LEDs instead of bulb
(12 V/5 W) for better durability. Chrome is applied to the end of the muffler.
Wheel & Tire Rear Air Dam
Newly designed wheel are tire are installed.

However, there is no change in their sizes. There air dam is newly installed.
GENERAL INFORMATION
ACTYON SM - 2008.07
MEMO
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CDPF (EURO IV)
1725-12/2412-02/2412-20/2412-42/
General information Removal and installation

1. Overview for CDPF (EURO IV) ......................... 3 1725-12 Removal and installation of front
exhaust gas temperature sensor -
2. CDPF (EURO IV) system ................................ 4
CDPF (EURO IV) ................................. 23
Overview and operation process 2412-42 Removal and installation of rear
exhaust gas temperature sensor -
1. Overview ........................................................... 6 CDPF (EURO IV) ................................. 25
2. CDPF (EURO IV) system control ..................... 7 2412-20 Removal and installation of differential
pressure sensor - CDPF (EURO IV) ..... 26
3. Soot filtering and burning procedures ............. 10
2412-02 Removal and installation of CDPF
4. Components of CDPF system ....................... 14 assembly - CDPF (EURO IV) .............. 28
Configuration and functions

1725-12 Front exhaust gas temperature
sensor - CDPF (EURO IV) ................... 15
2412-42 Rear exhaust gas temperature
sensor .................................................. 17
2412-20 Differential pressure sensor - CDPF
(EURO IV) ........................................... 19
2412-02 02-3
CDPF (EURO IV) 2412-02
GENERAL
General Information
1. OVERVIEW FOR CDPF (EURO IV)
CDPF
A. General Description
The CDPF (Catalyst & Diesel Particulate Filter) was installed to the Rexton II D27DTP engine previously.
However, it is now installed to the all 2009 DI engine models, except the Actyon Sports. The DI engine types
ECU
installed to Rexton are D27DTP, D27DT and D20DT, and their CDPF, related sensor and operation logic are
the same.
This section describes the CDPF system (based on Euro IV) which is installed to the Rexton II D27DTP
engine (older model).
B. Compatibility of CDPF System by Vehicle Model

Rexton II: Same CDPF system for D27DTP and D27DT engines (including its components)
Kyron & Actyon: Same CDPF system for D27DT and D20DT engines (including its components)
NOTE
• The CDPF assemblies installed to the Euro IV D27DTP Rexton II and 2009 Rexton II are different in their
mounting layout, but their front/rear exhaust temperature sensors and differential pressure sensors
are same.
C. System Met with EURO IV Regulations

The Ssangyong vehicles installed with the D27DT engine manufactured from July 2007 to December 2007
comply with the EURO IV regulations. Modified components from the old engine model are as follow:
- E-EGR valve
- EGR cooler
- Engine ECU (Ver. 3.2)
- HFM sensor
- C3I injector
- Electronic throttle valve (body)
- Other engine mounting components
For details about the modified components and system related to the EURO IV regulations, refer to the 2008
Rodius engine service manual.
CHANGED BY CDPF
EFFECTIVE DATE ACTYON SM - 2008.07
AFFECTED VIN
02-4 2412-02
2. CDPF (EURO IV) SYSTEM

The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous
D27DT engine is as follows:
CDPF (Catalyst & Diesel Particulate Filter) and Sensors
Differential Pressure Sensor (ΔP sensor)
Under air cleaner in right side

of engine compartment
As the soot is filtered in the CDPF, the pressure between the front side and the rear side of the filter is
different from each other. If the amount of soot is over 28 g, the soot is burnt in the CDPF. The combustion
is determined depending on the pressure difference, temperature of exhaust gas and EGR ratio. According
to these, the soot filtered by post injection of injector is burnt at 600°C.
Rear pressure port
Front exhaust gas

temperature sensor
Front pressure port
CDPF rear exhaust gas

temperature sensor
CDPF Exhaust Gas Temperature Sensor
Front Exhaust Gas Tempera- Rear Exhaust Gas Tempera-

ture Sensor: ture Sensor:
Measures the exhaust gas tem- Measures the increased ex-
perature of the exhaust manifold. haust gas temperature after the
As it is installed in front of the oxidation process of DOC. If the
The two temperature sensors in- VGT turbocharger, it also moni- temperature is below 600°C, the
side the CDPF are installed in tors the exhaust gas tempera- post injection amount is increased
exhaust manifold (front exhaust ture coming to the turbocharger. to increase the temperature.
gas temperature sensor) and in If the temperature of the exhaust
DOC (rear exhaust gas tempera- gas flowing to the turbocharger
ture sensor), and perform the fol- is higher than the specification,
lowing functions. the engine lowers the exhaust
gas temperature.
CDPF CHANGED BY
ACTYON SM - 2008.07 EFFECTIVE DATE
AFFECTED VIN
2412-02 02-5
GENERAL
Throttle Body
CDPF system controls the amount of intake air by control-

ling the electronic throttle body. The electronic throttle body
has the following main functions.
CDPF
CDPF control - added a function that increases the exhaust
gas temperature by closing the throttle valve flap to minimize
the intake air amount by the fuel injection amount during the
CDPF regeneration range with the low engine load range.
ECU
ON/OFF control - prevents the engine from turning off with
vibration and noise by closing the throttle body flap to block
Sensor (-) the intake air when the engine is stopped.
Sensor output Motor (-)
Sensor (+) Motor (+) Duty control - controls the valve inside the throttle body to
burn more EGR gas in the EGR valve operating range.
VGT Turbocharger and Front Exhaust Gas Temperature Sensor
Turbocharger may become weaker if high tem- Front exhaust gas

perature exhaust gas passes through the tur- temperature sensor
bocharger for DPF regeneration process.
The front exhaust gas temperature sensor moni-
tors the temperature of the exhaust gas that
flows into the turbocharger.
If the temperature of the exhaust gas that
passes through the exhaust manifold is higher
than the specification, the ECU decreases the
fuel injection amount and increases the EGR
gas intake amount to decrease the exhaust gas
temperature.
CHANGED BY CDPF
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02-6 2412-02
Overview and Operation Process
1. OVERVIEW
As the solution for environmental regulations and PM (Particla
Material) of diesel engine, the low emission vehicle is getting
popular. This vehicle is equipped with an extra filter to collect the
soot and burn it again so that the amount of PM in the exhaust
gas passed through the DOC (Diesel Oxydation Catalyst) is
reduced. The CDPF (Catalyst & Diesel Particulate Filter) is an
integrated filter including DOC (Diesel Oxydation Catalyst) and
DPF (Diesel Particulate Filter).
Comparison of throttle body functions based on exhaust emission regulation

Regulated parts are carbon monoxide (CO), nitrogen oxide (NOx), particular matter (PM) and soot in the
exhaust emission, and the particulars of the regulations are prescribed in the following table.
Engine Control method Function

D27DTP + CDPF ECU's electric signal ON/OFF control - prevents the engine from
D27DT + CDPF (Duty and On/Off control) turning off with vibration and noise by closing
D20DT + CDPF + Throttle flap control during the throttle body flap to block the intake air
CDPF operation when the engine is stopped
Duty control - controls the valve inside the
throttle body to burn more EGR gas in the
EGR valve operating range.
CDPF control - added a function that in-
creases the exhaust gas temperature by
closing the throttle valve flap to minimize the
intake air amount by the fuel injection amount
during the CDPF regeneration range with the
low engine load range.
D27DT engine ECU's electric signal ON/OFF control - prevents the engine from
(EU IV) (Duty and On/Off control) turning off with vibration and noise by closing
the throttle body flap to block the intake air
when the engine is stopped
Duty control - controls the valve inside the
throttle body to burn more EGR gas in the
EGR valve operating range.
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2. CDPF (EURO IV) SYSTEM CONTROL
GENERAL
A. Combustion Temperature and Procedures
As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to
collect the soot. Therefore, the burning procedures in the CDPF can be called as regeneration.
The CDPF assembly is integrated with DOC (at front side) and DPF (at rear side).
CDPF
The DPF burns the soot with high-temperature exhaust gas (over 600°C). The rear exhaust gas temperature
sensor monitors the temperature of DPF section. If this temperature is below the regeneration temperature,
the ECU increases the post injection period to increase the fuel injection amount, and consequently to
increase the exhaust gas temperature.
ECU
Front exhaust gas temperature sensor
(Measuring temperature of exhaust gas
in exhaust manifold)
DOC section DPF section
Rear exhaust gas temperature sensor

escaping DOC)
NOTICE
• Normally, when the vehicle is driven for 600 ~ 1,200 km, the enough amount of soot to be burnt is
filtered and accumulated in the CDPF. The ECU increase the amount of post injection to increase the
tempeature of exhaust gas up to 600°C so that the soot is burnt. The soot is burnt for 15 ~ 20 minutes.
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B. Sytem Composition for Soot Combustion

When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of
fuel supplied is decreased. To burn the soot filtered in the CDPF, the control system should be installed to
check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel
supplied and intake air.
Two temperature sensors and one differential pressure sensor monitor the CDPF's operating range. According
to these sensors' information, the throttle flap decreases the intake air entered to the throttle body. Also, the
fuel injection pattern is added to increase the temperature of exhaust gas for soot combustion.
There are three fuel injection patterns (pilot injection, pre-injection and main injection). As the CDPF is
installed, the post injection pattern is added.
C. Post Injection and Air Mass Control

When the differential pressure sensor detects the pressure difference between the front and the rear side of
CDPF, the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise
the temperature of exhaust gas. The amount of fuel injected is determined according to the temperature of
exhaust gas detected by the rear temperature sensor. If the temperature is below 600°C, the amount of fuel
injected is increased to raise the temperature. If the temperature is over 600°C, the amount of fuel injected is
decreased or not controlled.
When the engine is running in low load range, the amount of post injection and the amount of intake air are
controlled. It is to raise the temperature by increasing the amount of fuel while decreasing the amount of
intake air.
Differential
pressure sensor
Heating
exhaust Burning collected PM
gas
Engine DOC DPF
Front exhaust Rear exhaust

gas tempera- gas temperature
ture sensor
sensor
Performing
post-injection
ECU Intake air flow
Booster pressure sensor value
Detecting excess of
PM amount limit
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NOTE
GENERAL
Throttle bodies by engine type
• The throttle valve is controlled by electric signals sent from the engine ECU for optimal fuel injection
volume, engine load and effective combustion of EGR gas according to the Euro 4 regulations. It has
following functions by the engine type.
CDPF
Engine Control Method Function
D27DTP + CDPF ECU's electric signal CDPF control - added a function that increases
D27DT + CDPF (Duty and On/Off control) + the exhaust gas temperature by closing the
D20DT + CDPF Throttle flap control during throttle valve flap to minimize the intake air
CDPF operation amount by the fuel injection amount during the
ECU
CDPF regeneration range with the low engine
load range.
ON/OFF control - prevents the engine from turn-
ing off with vibration and noise by closing the
throttle body flap to block the intake air when
the engine is stopped.
EGR gas amount control - Close the valve to
decrease the intake air amount and lets more
EGR gas flows to burn more EGR gas at EGR
valve operating range.
D27DT engine ECU's electric signal ON/OFF control - prevents the engine from turn-
(EU IV) (Duty and On/Off control) ing off with vibration and noise by closing the
throttle body flap to block the intake air when
the engine is stopped.
EGR gas amount control - Close the valve to
decrease the intake air amount and lets more
EGR gas flows to burn more EGR gas at EGR
valve operating range.
D27DT engine No throttle body installed
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3. SOOT FILTERING AND BURNING PROCEDURES

A. Operating Procedures of CDPF
The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF).
This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of
soot can be removed from the exhaust gas. However, the durability and the cost of additional system remain
as problems.
Firstly, the exhaust gas is passed through the DOC and its temperature is increased as it is oxidized. The
ECU detects the temperature change with two temperature sensors. The CO, HC and partial particulate
material are removed from the exhaust gas (this procedures are the sames as the ones for the conventional
DOC and no sensor is required).
After the exhaust gas is passed through the DOC and oxidized, most of the harmful material is removed from
the exhaust gas. However, to meet the environmental regulations in the future, the soot is filtered and burnt
again in DPF to decrease the particulate material further.
DOC section DPF section
Exhaust
gas
Rear exhaust gas temperature sensor

escaping DOC)
NOTICE
• The filtered soot is burned whenever the vehicle is driven for 600 ~ 1200 km. The driving distance can
be differed depending on the vehicle’s driving conditions. The soot is burnt for 15 ~ 20 minutes.
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GENERAL
Front temperature sensor Rear temperature sensor
(Measuring the temperature (Measuring the temperature of
of exhaust gas passed exhaust gas passed through DOC)
through exhaust manifold)
CDPF
DOC DPF
ECU
Differrential pressure sensor Differrential pressure sensor
(Front pressure port) (Rear pressure port)
The exhaust gas enters into When the exhaust gas enters The engine ECU detects the
CDPF assembly after passing into the CDPF assembly, its amount of particulate material
through the exhaust manifold. CO, HC and particulate mate- colected by the information
(Normal temperature of ex- rial are reduced as it is oxi- from temperature sensors and
haust gas: approx. 250°C) dized in DOC. The remaining differential pressure snesor.
particulate material is filtered When the soot is accumulated,
and collected in DPF and the the pressure difference be-
temperature of exhaust gas is tween the front and the rear
increased to approx. 450 ~ side occurs. Then, the engine
500°C. ECU performs the post injec-
tion to raise the exhaust gas
temperature and burn the col-
lected soot at approx. 600°C.
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B. Fuel Injection During CDPF Regeneration
22A
7A
0A
Pilot Pre Main Post
Injection Effect
Pilot injection Decrease of PM by fuel mixture
Decrease of noise from engine combustion
Pre-injection Decrease of NOx by shortening main injection delay due to flammability
Decrease of noise from engine combustion
Main injection Main power source
Post-injection Activation of CDPF by increasing exhaust gas temperature and supply-
ing reduction material
C. Warning Lamp Related To CDPF

CDPF regeneration process (warning lamp NOT illuminated)
The CDPF system enters the regeneration mode

when the driving distance becomes approx. 600 to
80
1,200 km (may differ by the driving condition and driv-
5 6
4 7
60
2
3 x1000rpm
8
40
km/h
ing style). Then, the engine ECU performs the CDPF
20 200
0 0 220
regeneration operation. However, the driver is not in-
formed with this operation by any engine warning lamp
or vehicle signal, so he/she may not detect this
operation. The control logic at the post-injection dur-
ing the regeneration process is to increase the fuel
injection volume and control the intake air volume
No illumination
(by the throttle body) in order to increase the tem-
perature of the exhaust gas. The driver may not feel
any particular difference from the vehicle.
CDPF CHANGED BY
AFFECTED VIN
2412-02 02-13
Overload of CDPF (warning lamp blinking)
GENERAL
1. If the CDPF cannot reach the regeneration tem-
perature due to low speed driving or other reason
4
5 6
7
8 60
80 during the regeneration process, the soot is con-
3 x1000rpm km/h
2
40
20 200
tinuously accumulated in the CDPF. When this
0 0 220
condition continues and the CDPF is overloaded
CDPF
with soot, the engine warning lamp blinks to in-
form this situation to the driver.
2. In order to solve this problem, drive the vehicle at
a speed of approx. 80 km/h for 15 to 20 minutes
to perform the CDPF regeneration process.
Blinking
ECU
3. If the engine warning lamp on the instrument clus-
ter blinks, the CDPF is overloaded. In this case,
perform the step 2.
Excessive overload of CDPF (warning lamp illuminated)
1. If the vehicle is driven at a speed of 5 to 10 km/h

for an extended period of time, the soot accumu-
4
5 6
7
60
80 lated in the CDPF cannot be burnt as the CDPF
8
3 x1000rpm km/h
2
40
20 200
cannot reach the regeneration temperature. Then,
0 0 220
an excessive amount of soot can be accumulated
in the CDPF.
2. This case is much worse than the simple over-
load of the CDPF. To inform this to the driver, the
engine warning lamp comes on and the engine
Illumination power is decreased to protect the system.
3. To solve this problem, blow soot between the en-
gine and exhaust system several times and erase
the related DTC. Then, check if the same DTC is
regenerated again. If so, check the DTC related to
the differential pressure sensor.
Actually, the DTC for the CDPF is generated more often by the component related to the CDPF system, such
as the differential pressure sensor, than by excessive soot in the CDPF.
CHANGED BY CDPF
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4. COMPONENTS OF CDPF SYSTEM

Mounting condition and location
Differential Pressure Sensor
Engine compartment (RH) Rear exhaust gas

temperature sensor
Rear pressure port
Differential
pressure
Front pressure port sensor
CDPF assembly
Front Exhaust Gas Temperature Sensor Throttle Body
Front exhaust
gas temperature
sensor
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Configuration and Functions
GENERAL
1725-12 FRONT EXHAUST GAS TEMPERATURE SENSOR -
CDPF (EURO IV)
CDPF
A. Overview
Once CDPF system is installed, the front exhaust gas temperature sen-
sor is installed in the exhaust manifold and the rear exhaust gas tem-
perature sensor is installed in the CDPF assembly. These sensors are
similar in appearance, but the sensing part of the rear exhaust gas
ECU
temperature sensor is longer than the one of the front exhaust gas tem-
perature sensor.
The front exhaust gas temperature sensor measures the exhaust gas
temperature inside the exhaust manifold. High temperature exhaust gas
Front exhaust may weaken the turbochager. Moreover, if the gas passes through DOC,
gas temperature
the temperature is increased further. Therefore, this sensor is to moni-
sensor
tor the exhaust gas temperature and protect the turbocharger.
Rear exhaust If the temperature of the exhaust gas becomes higher than 800 oC, the
gas temperature bearing inside the turbocharger may be seized. Therefore, the ECU moni-
sensor
tors the front exhaust gas temperature sensor to adjust the fuel injec-
tion amount and intake EGR gas amount. When the temperature is
high, the fuel injection amount is decreased. When the temperature is
low, the EGR gas amount is increased.
B. Connecting Port and Mounting Location

Mounting Location
40 Nm ± 5 Nm
Front exhaust gas

Exhaust manifold temperature sensor
VGT turbocharger
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C. Circuit Connecting ECU and Front Exhaust Gas Temperature

Sensor
The front exhaust gas temperature sensor is installed inside the exhaust manifold and sends signals to the
ECU with voltage values by using the resistance changes as the exhaust gas temperature changes.
5V
E
A06 + signal (output voltage): BrG 1
C Ground
A30
- ground (output voltage): RG 2
U
Front exhaust
gas temperature Output signal
sensor
D. Resistance by Temperature
CDPF temperature Ω)
Resistance (Ω Remark
-40 169.18
-20 184.64
0 200.0
25 219.07
50 237.99
100 275.4
150 312.2
200 348.5
250 384.1
300 419.2
350 453.7
400 487.6
450 520.9
500 553.6
600 617.3
700 678.7
800 737.7
830 754.9
850 766.3
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2412-42 REAR EXHAUST GAS TEMPERATURE SENSOR
GENERAL
A. Overview
The rear exhaust gas temperature sensor is installed in the DPF to
measure the exhaust gas temperature after the exhaust gas passes
CDPF
through DOC. Once the exhaust gas escapes DOC, its temperature is
higher than before entering DOC due to oxidation, etc. The higher the
gas temperature is before DOC, the higher it becomes due to oxidation
process.
When the pressure difference is detected by the differential pressure
ECU
sensors and the system enters the CDPF generation mode, the ECU
Front exhaust adds post injection process to increase the exhaust gas temperature.
gas temperature
When the engine is running at low load range, the throttle flaps are
sensor
closed to decrease the intake air amount, and consequently to increase
Rear exhaust the combustion temperature. During post injection process, if the tem-
gas temperature perature value from the rear exhaust gas temperature sensor is higher
sensor than 600oC, the post injection is not performed or the fuel injection amount
is decreased.If the temperature is lower than 600oC, the fuel injection
amount is increased to control the soot combustion temperature in
CDPF.
B. Connecting Port and Mounting Condition
Front exhaust gas

temperature sensor
40 Nm ± 5 Nm Rear exhaust gas

temperature sensor
Rear exhaust gas
temperature sensor
Front pressure Differential

connecting port pressure
sensor
Rear pressure
connecting port
NOTICE
• Its temperature sensing part’s length is longer than the one of the front exhaust gas temperature
sensor.
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C. Circuit Connecting ECU and Rear Exhaust Gas Temperature

Sensor
The rear exhaust temperature sensor measures the temperature of the exhaust gas that passes through
DPF. If the exhaust gas temperature is low (below 600°C) , the ECU decreases the intake air amount and
increases the post injection period to increase the gas temperature. The rear exhaust gas temperature
sensor is installed inside the exhaust manifold and sends signals to the ECU with voltage values by using the
resistance changes as the exhaust gas temperature changes.
5V
E
A23
A42 + signal (output voltage): G 1
Ground
C
A42
A23
U - ground (output voltage): GR 2

Rear exhaust
Output signal
gas temperature
sensor
D. Resistance by Temperature
CDPF temperature Ω)
Resistance (Ω Remark
-40 169.18
-20 184.64
0 200.0
25 219.07
50 237.99
100 275.4
150 312.2
200 348.5
250 384.1
300 419.2
350 453.7
400 487.6
450 520.9
500 553.6
600 617.3
700 678.7
800 737.7
830 754.9
850 766.3
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2412-20 DIFFERENTIAL PRESSURE SENSOR - CDPF (EURO IV)
GENERAL
A. Overview
View From RH Tire Under Air Cleaner In Right Side Of Engine
CDPF
ECU
Front pressure port Rear pressure port
The differential pressure sensor is connected to CDPF through two ports.

It can be found behind the front left tire (on the frame in front of the coil spring).
This sensor detects the pressure difference between the front and the rear side of CDPF. When the soot is
collected in CDPF, the pressure difference is increased and this difference, as a signal, is sent to ECU to
perform the post injection.
The differential pressure sensor monitors the pressure of the opening of DOC and the end of DPF. When the
soot is collected as the exhaust gas is passed through CDPF, the sensor sends the combustion timing to the
ECU. Then, the ECU performs the post injection to increase the temperature in CDPF up to 600°C. At this
time, the temperature is monitored by rear temperature sensor. According to the temperature monitored, the
amount of post injection is increased or decreased, or the post injection is ceased.
NOTICE
1. When the engine is running in high load/speed range, the temperature of exhaust gas passed through
DOC can be over 600°C. If it happens, the collected soot is burnt without post injection.
2. The filtered soot is burnt normally after the vehicle is driven for 600 ~ 1,200 km.
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B. Differential Pressure Sensor Connecting Port and Mounting

Condition
Differential Rear pressure

pressure sensor
sensor
Rear pressure port

Front pressure port
Sensor Section Connector Section
Sensor voltage (5V)

Sensor signal
Sensor ground
Rear pressure port
Front pressure port
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C. Output Voltage by Pressure Difference Detected By Differential
GENERAL
Pressure Sensor
Sensor signal voltage (V)
4.5
CDPF
ECU
0.5
0 0.5bar 1bar
Δ P sensor)
CDPF pressure difference between front and rear (Δ
The differential pressure sensor sends output voltage value (0.5 ~ 4.5 V) to the ECU based on pressure
difference before and after the CDPF.
The pressure ports installed before and after the CDPF are not sensors, but the connecting passages to send
the pressure to the differential pressure sensor.
The front and rear ports send the exhaust gas pressure before and after the CDPF to the differential pressure
sensor. Then, the differential pressure sensor compares these values and sends the pressure difference value
to the ECU.
As the soot is collected, the pressure difference gets greater. When the ECU receives the pressure difference
signal indicating that the soot mass exceeds the limit (normally 28 g but may vary depending on the conditon),
it starts the CDF regeneration process. (The ECU also receives signals for EGR ratio and exhaust gas
temperature.) As the CDPF regeneration process is performed, the post injection occurs even when the
engine is idling. It also closes the flap doors on the throttle body during engine idling to decrease the intake
air amount.
As shown on the above graph, the smaller the pressure difference is, the output voltage (signal) from the
differential pressure sensor is lowered. When the pressure difference increases, the output voltage is in-
creased and maximum 4.5 V is sent to ECU.
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D. Port Mounting Location for Measuring CDPF Pressure

The pressure ports installed to measure pressure difference before and after the CDPF are mounted similar to
the temperature sensors. However, these are simply pipe connecting ports to send pressure inside CDPF to
the differential pressure sensor.
Rear connecting port (After CDPF - Front connecting port (Before CDPF -
connected to differential pressure sensor) connected to differential pressure sensor)
45 Nm ± 4.5 Nm 45 Nm ± 4.5 Nm
E. Circuit Connecting ECU and Differential Pressure Sensor

The front and rear connecting ports send the pressure values of “before CDPF” and “after CDPF” to differential
pressure sensor. Then, the differential pressure sensor compares these values and sends the pressure differ-
ence value to ECU.
E
A53 Voltage (5V) (output voltage) 1
C A05 + signal (output voltage) 2
Sensor voltage A31 - ground 3

(5V) U
Output signal
Ground Differential
pressure sensor
Specifications
- Pressure measuring range: 0 ~ 100 Kpa

- Supplying voltage: 5.25 V
- Operating temperature range: -40 ~ 125°C
- Sensor output signal: 0.5 ~ 4.5V
- Supplying current: 20 mA
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Removal and Installation
GENERAL
1725-12 REMOVAL AND INSTALLATION OF FRONT EXHAUST
GAS TEMPERATURE SENSOR - CDPF (EURO IV)
CDPF
Disconnect the battery ground cable.
Mounting View
ECU
Front Exhaust Gas
Temperature Sensor
1. Disconnect the front exhaust gas temperature sen-

sor connector (A) and remove it from its mounting
bracket (B).
2. Remove the front exhaust gas temperature sensor.

a. Insert a 14 mm spanner (B) between the turbo-
charger oil supply pipe (A) and turbocharger to
unscrew the sensor.
40 Nm ± 5 Nm
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b.Remove the front exhaust gas temperature sen-

sor by pulling it from the exhaust manifold.
3. Install in the reverse order of removal.
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2412-42 REMOVAL AND INSTALLATION OF REAR EXHAUST
GENERAL
GAS TEMPERATURE SENSOR - CDPF (EURO IV)
1. Disconnect the negative battery cable with the engine off.
2. Make sure that the CDPF and its related exhaust system are sufficiently cooled down.
CDPF
3. Lift the vehicle with a lift.
1. Disconnect the rear exhaust gas temperature sen-

sor connector (A) (wiring side) and remove the con-
nector on the sensor side from its mounting holder
(B).
ECU
Mounting View of Rear Exhaust
Gas Temperature Sensor
2. Unscrew the rear exhaust gas temperature sensor and remove it from the CDPF assembly.
NOTICE
• When removing it, make sure the exhaust system is sufficiently cooled down.
40 Nm ± 5 Nm
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2412-20 REMOVAL AND INSTALLATION OF DIFFERENTIAL

PRESSURE SENSOR - CDPF (EURO IV)
Differential Pressure Sensor
1. Remove the air cleaner by lifting it up.
2. Disconnect the differential pressure sensor

connector.
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3. Unscrew the differential pressure sensor bracket
GENERAL
mounting bolt (12 mm).
CDPF
ECU
4. Disconnect the sensor hose using pliers with the
sensor pried off backward.
A. Front pressure port hose
B. Rear pressure port hose
5. Remove the differential pressure sensor from the

vehicle body.
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2412-02 REMOVAL AND INSTALLATION OF CDPF ASSEMBLY -

CDPF (EURO IV)
Disconnect the battery ground cable and lift the vehicle with a lift.
NOTICE
• Make sure that the exhaust system is sufficiently cooled down before servicing the CDPF.
Automatic
Transmisson
Muffler
CDPF assembly
1. Disconnect the connector (C) to the rear exhaust

gas temperature sensor wiring, which is located
in (A), and remove the connector on the sensor
side from its mounting holder (D).
2. Disconnect the differential pressure sensor hoses

(FRT/RR) in the section (B).
Rear
Front
CDPF CHANGED BY
AFFECTED VIN
2412-02 02-29
3. Remove the rubber (A) of the CDPF assembly
GENERAL
mounting rubber hanger with a lever.
CDPF
ECU
4. Unscrew the two mounting nuts (14 mm) from the
front exhaust pipe (B) and CDPF assembly (C).
38 Nm ~ 45 Nm
5. Unscrew the two mounting nuts (14 mm) from the

rear muffler (D) CDPF assembly (C).
38 Nm ~ 45 Nm
6. Remove the CDPF assembly by guiding it over

the A/T center member.
CHANGED BY CDPF
AFFECTED VIN
02-30 2412-02
Front exhaust gas port Rear exhaust gas port
Rear exhaust gas

temperature sensor
NOTICE
• Make sure not to damage the rear exhaust gas temperature sensor when removing it.
CDPF CHANGED BY
AFFECTED VIN
ENGINE CONTROL
1491-01
Configuration and functions Removal and installation

1491-01 Engine ECU - CDPF (EURO IV) ............ 3 1491-01 Removal and installation of engine
ECU - CDPF (EURO IV) ...................... 10
1491-01 Connector pin of engine ECU - CDPF
(EURO IV) ............................................. 4
1491-01 ECU (engine control unit - D20DT EU IV) . 7
1491-01 03-3
ENGINE CONTROL 1491-01
GENERAL
CDPF
1491-01 ENGINE ECU - CDPF (EURO IV)
A. Overview
The engine ECUs are various according to the engine model (D27DT engine, D27DT (EU IV), D27DTP engine
ECU
with CDPF and D27DTP (POWER UP) engine). For the D27DT engine with CDPF, the CDPF's function is
controlled by the engine ECU with its extra pin. For the D27DTP (POWER UP) engine, one connector is
added to the engine ECU (2 connectors total) to control the additional sensor, actuator and exhause gas
control function.
D27DTP (POWER UP) &

D27DT (EU IV) Engine ECU - Ver. 3.2
The engine ECU used for the D27DTP

and D27DT engines are version 3.2 and
has the terminal related to the CDPF
(front/rear exhaust gas temperature sen-
sor and differential pressure sensor).
CHANGED BY ENGINE CONTROL

AFFECTED VIN
03-4 1491-01
1491-01 CONNECTOR PIN OF ENGINE ECU - CDPF (EURO IV)
A. Function of Pin Terminal by ECU Specifications

Function of pin terminal for D20DT engine ECU (EURO IV)
ECU Connector A ECU Connector B

(No.1 ~ 96) (No.1 ~ 58)
Connector A Connector B
Pin No. Description Remarks Pin No. Description Remarks
A1 Injector #3 (power supply) B1 Main power (B+)
A2 Injector #2 (power supply) B3 Main power (B+)
A3 - B5 Main power (B+)
A4 - B2 Main ground
A5 CDPF diff. pressure sensor signal B4 Main ground
A6 CDPF FRT Ex: Gas temp. sensor signal B6 Main ground
A7 - B7 -
A8 Fuel temperature sensor signal B8 PTC #1 relay control
A9 E-EGR valve ground B9 -
A10 - B10 #2 Accelerator pedal sensor
reference voltage
A11 - B11 Auto cruise operation voltage
A12 - B12 -
A13 - B13 #2 Accelerator pedal sensor signal
A14 Camshaft position sensor ground B14 #2 Accelerator pedal sensor ground
A15 - B15 Auto cruise signal input
A16 - B16 Auto cruise ground
A17 - B17 Blower switch signal
A18 - B18 -
A19 - B19 Ignition key signal
A20 Throttle body reference voltage B20 -
A21 - B21 -
A22 Throttle body flap position sensor signal B22 Air conditioner operation signal
A23 CDPF RR Ex. gas temp. sensor signal B23 Brake switch operation signal
A24 - B24 #1 Accelerator pedal sensor
reference voltage
A25 Injector #1 (power supply) B25 #1 Accelerator pedal sensor signal
A26 Injector #4 (power supply) B26 #1 Accelerator pedal sensor ground
A27 - B27 -
ENGINE CONTROL CHANGED BY

AFFECTED VIN
1491-01 03-5
GENERAL
A28 - B28 -
A29 - B29 Air conditioner refrigerant pressure
sensor reference voltage
A30 CDPF FRT Ex. Gas temp. sensor B30 -
CDPF
ground
A31 CDPF diff. pressure sensor ground B31 Diagnosis connector
A32 Fuel temperature sensor ground B32 -
A33 E-EGR valve reference voltage B33 -
A34 HFM temperature sensor signal B34 -
ECU
(Analog)
A35 - B35 -
A36 - B36 Air conditioner pressure switch
ground
A37 Camshaft position sensor B37 -
reference voltage
A38 Camshaft position sensor signal B38 -
A39 - B39 Brake pedal switch
A40 - B40 Condenser fan (Lo) relay
A41 - B41 Air conditioner refrigerant input
sensor signal
A42 CDPF RR Ex. Gas temp. sensor B42 -
ground
A43 - B43 -
A44 - B44 ECU main power relay
A45 - B45 A/C operating signal
A46 #1 Knock sensor signal B46 Brake switch operating signal
A47 #1 Knock sensor ground B47 CAN-LO
A48 - B48 CAN-HI
A49 Injector #2 ground B49 -
A50 - B50 -
A51 Injector #4 ground B51 -
A52 - B52 Immobilizer (K-Line)
A53 CDPF diff. pressure sensor B53 -
(supply voltage)
A54 HFM sensor temperature sensor B54 -
(Digital)
A55 - B55 Air conditioner compressor relay
A56 Coolant temperature sensor ground B56 PTC #2 relay control
A57 Coolant temperature sensor signal B57 Condenser fan HI relay
A58 - B58 -
A59 Rail pressure sensor signal - -
A60 Booster pressure sensor reference - -
voltage
A61 HFM sensor ground - -
A62 - - -

AFFECTED VIN
03-6 1491-01
A63 Booster pressure sensor signal - -
A64 - - -
A65 - - -
A66 - - -
A67 - - -
A68 Dreheat control relay driver - -
A69 - - -
A70 HFM sensor signal input - -
A71 WGT vacuum modulator - -
A72 - - -
A73 Injector #3 ground - -
A74 Injector #1 ground - -
A75 Throttle body drive (+) - -
A76 IMV PWM control - -
A77 - - -
A78 - - -
A79 Fuel filter water detection signal - -
A80 - - -
A81 Throttle body sensor ground - -
A82 E-EGR valve sensor signal - -
A83 Boost pressure sensor ground - -
A84 Rail pressure sensor signal ground - -
A85 - - -
A86 Rail pressure sensor reference - -
voltage
A87 Crankshaft position sensor (-) - -
A88 Crankshaft position sensor (+) - -
A89 - - -
A90 - - -
A91 - - -
A92 - - -
A93 - - -
A94 - - -
A95 - - -
A96 - - -

AFFECTED VIN
1491-01 03-7
1491-01 ECU (ENGINE CONTROL UNIT - D20DT EU IV)
GENERAL
Eng Main Relay, Intake Throttle, A/Cruise SW, Valve (EGR, Waste Gate, Inlet
Metering), Sensor (HFM, Pedal)
CDPF
ECU

AFFECTED VIN
03-8 1491-01
Sensor (Fuel Pressure, CAM Shaft, Booster Pressure, Crank Shaft, Knock, Fuel
Temp, Fuel Filter Warning), PTC Relay
D20DT ECU (EU IV)

AFFECTED VIN
1491-01 03-9
Injector, Stop Lamp, Immobilizer, Cluster, Preheating Unit, Sensor, Tripple Pressure
GENERAL
SW, Sensor (E-GAS)
CDPF
ECU

AFFECTED VIN
03-10 1491-01
1491-01 REMOVAL AND INSTALLATION OF ENGINE ECU -

CDPF (EURO IV)
Engine ECU
1. Pull off the floor carpet on the passenger side and

unscrew the two mounting nuts (10 mm).
2. Unscrew the two engine ECU mounting nuts

(10 mm).

AFFECTED VIN
1491-01 03-11
3. Remove the engine ECU.
GENERAL
a. Unlock the engine ECU connectors.
CDPF
ECU
Connector B b. Disconnect the connector A and B of the en-
gine ECU.
Connector A
c. Remove the engine ECU.

5. When replacing the engine ECU with a new one,
backup the following data in advance.
- Data from older ECU
- Chassis number
- Variant coding data
Then, enter this data to the new ECU. For the
vehicle equipped with the immobilizer, make
sure to perform the coding additionally.
NOTICE
• Refer to the previously distributed service
manual for the engine ECU coding and backup
process.

AFFECTED VIN
MEMO
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ELECTRONIC
FUSE AND RELAY ..........................

8210/8410/8402 01-3P
C-145: 2008.07 ~
FUSE AND RELAY
8210-01/8410-02/8410-04/8402-06/
General information Configuration and functions

1. General information .......................................... 3 8210-01 Configuration of PCB in ICM box and
function of connector ............................ 12
Overview and operating process 8410-02 Circuit diagram for fuse & relay box in
engine compartment ............................ 13
1. Overview ........................................................... 4
8410-04 Circuit diagram for interior fuse & relay
2. Fuse & relay mounting location ....................... 4 box on driver side ................................. 17
3. Capacity and name of fuse and relay in engine 8402-06 Circuit diagram for interior fuse & relay
compartment ................................................... 5 box on passenger side ......................... 20
4. Capacity and name of interior fuse and relay ... 6
5. Operating process of ICM box ......................... 8
Removal and installation
8210-01 Removal and installation of ICM box .... 21
8410-02 01-3
FUSE AND RELAY 8410-02
FUSE
General information
1. GENERAL INFORMATION
The ICM (Integrated Control Module) box installed to the new Actyon model is integrated with some relays of
previous model and is installed to the back of the STICKS.
As the ICM box is newly installed, the following relays are integrated into the ICM box.
- Door lock relay (previously installed to STICKS bracket)
ECU
- Windshield de-icer relay (previously installed next to floor on the driver side)
- Turn signal lamp relay (previously installed to passenger side fuse & relay box)
PREVIOUS MODEL
Turn signal
Door lock relay lamp relay
Windshield
de-icer relay
NEW MODEL
Hands-free unit
(For DOM.)
ICM box STICS
PAS buzzer
ICM box
Turn signal
lamp relay
Windshield Door lock

de-icer relay relay
Inner view of ICM PCB
* Some relays have been integrated into the ICM box.
CHANGED BY FUSE AND RELAY

AFFECTED VIN
01-4 8410-02
Overview and Operating Process
1. OVERVIEW
The ICM (Integrated Control Module) mounted to the back of the STICS is integrated with the door lock relay,
windshield de-icer relay and turn signal lamp relay. There are four fuse & relay units.
2. FUSE & RELAY MOUNTING LOCATION

In engine compartment
Fuse & Relay Box In Interior Fuse & Relay Box

Engine Compartment On The Driver Side (RH)
In vehicle
Interior Fuse & Relay Box

Mounting Location of ICM
On The Driver Side (LH)
FUSE AND RELAY CHANGED BY

AFFECTED VIN
SPARE SPARE SPARE SPARE SPARE
30A 20A 15A 10A 7.5A
30A 40A 30A 30A
CABIN 30A CABIN
POWER IGN
CHANGED BY
POWER ABS/ESP
AFFECTED VIN
F/BOX F/BOX
EFFECTIVE DATE
WINDOW WINDOW (B+POWER3) (B+POWER1) Key 1
ALTERNATOR
(DSL +PTC : 125A) RLY 18
Hazard Head
(GSL/DSL +FFH : 125A) ABS/ESP LP LP
HEAD LP TAIL LP REAR WASHER WIPER (HI)

30A
(LOW) RLY 16 (5P) (5P)
MEMORY BLOWER *PTC
RLY 17 RLY 14 RLY 13
7.5A HEATER 2, 3
HEAD LP STOP LP TAIL LP (RH) TAIL LP (LH) FRT FOG HORN COMPRESSOR DEICER ***S/A PUMP
(LH) RLY 12
COMPARTMENT
HEAD LP FRT WASHER WIPER (LO)

FRT FOG LP HORN COMPRESSOR
(RH) (5P) (5P)
RLY 10 RLY 9 RLY 8 * 40A
RLY 7 RLY 6
PTC
30A ****DRV Heater 3
30A 30A 30A * 40A * 40A
CABIN P/SEAT
FUSE F/BOX C/FAN TCCU C/FAN S/ROOF IGN PTC P/Outlet PTC
PULLER (B+POWER2) LH RH KEY2 Heater 2 Heater 1
** FFH
40A
C/FAN C/FAN MOTOR C/FAN * PTC
REAR STARTER
HIGH LOW (5P) HEATER 1
DEFOGGER RLY2
RLY 5 RLY 4 RLY 3 RLY 1
*: PTC(DSL) **: FFH(DSL) ***: EU-IV(GSL) ****: SEAT MEMORY
following pages.
relays than indicated.
3. CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE
8410-02
distribution circuit diagram on the

For details about the connection of
fuses and relays, refer to the power
Therefore, there are more fuses and
The label attached on each fuse box
indicates only major fuses and relays.
01-5
FUSE AND RELAY

ACTYON SM - 2008.07
ECU FUSE
01-6 8410-02
4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY

A. Interior Fuse and Relay Box On the Driver Side
24 41 O/SIDE MRR
A/BAG D/ CLOCK
10A 7.5A ECM MRR, S/ROOF
25 CLUSTER 42 PWR OUTLET

7.5A STICS 20A C/LIGHTER
26 43
ENG ROOM AUDIO
10A FUSE & RLY BOX 10A
FLASHER RR FOG LAMP
*GSL *GSL
UNIT 27 ALTERNATOR 44
IMMOBILIZER FUEL PUMP
7.5A 20A
S/LAMP
28 T/SIGNAL 45
ENG ECU
10A
BACK UP LP 10A
*GSL
29 46
TCU, TCCU INJECTOR
10A 20A
*GSL
-
30 47
RR WIPER ENG ECU SENSOR
10A 15A
31 48
- -
32 SEAT UNIT 49
DRL RELAY
BURGLAR HORN 7.5A EAS, EPB 7.5A
33 50 HEAD LP
ABS/ESP
10A 15A (HIGH)
*HDC 34 HEAD LP 51
R/SNR& AUTO LIGHT RR FOG LAMP
7.5A DRL 10A INTERIOR LAMP
HDC
35 52 IMMOBILIZER
S/WARMER
15A 7.5A BUZZER, CHIME
36 FRT WIPER 53 DOOR LOCK

HEAD LP 20A WASHER 15A B/HORN
(HIGH)
37 54 FOLDING
A/CON
7.5A 7.5A DIAGNOSIS
38 55
RR WIPER *GSL
10A -
TAIL GATE F/PUMP
UNLOCK 39 STICS 56 STARTER
FRT & RR
7.5A GLASS HEATER 10A GSL ECU
*DSL
40 57 DEF IND
ALTERNATOR
7.5A 7.5A O/S MRR DEF
* PLEASE USE THE DESIGNATED FUSES AND RELAYS

AFFECTED VIN
8410-02 01-7
FUSE
B. Interior Fuse and Relay Box On the Passenger Side
ECU
58 65
- -
59 66
*DSL HAZARD LAMP
- 15A
SHIFT
ENG ECU 60 67 LOCK
PASS P/SEAT (A/T)
- 20A
61 68
- -
62 69
- -
63 *DSL 70
ENG ECU AUDIO UNIT BLOWER
7.5A 15A
64 *DSL 71
ENG ECU
7.5A
*GSL *GSL
FOLDING UNFOLDING SENSOR INJECTOR
* PLEASE USE THE DESIGNATED FUSES AND RELAYS

AFFECTED VIN
01-8 8410-02
5. OPERATING PROCESS OF ICM BOX

A. Overview
B. Mounting Location
Turn signal
lamp relay
Hands-free unit (For DOM.)
de-icer relay relay
STICS

ICM box
NOTE
• Relays in the ICM box cannot be replaced respectively; so if the components on the PCB are
defective, the ICM box should be replaced as an assembly.

AFFECTED VIN
8410-02 01-9
C. Operating Process By Power Supply Of ICM Box
FUSE
(1) Door lock relay
ALT
D
B
ICM Box
SB FUSE
Windshield de-icer Relay Windshield de-icer
[Ef14] 30 87 1
NO.7
Windshield de-icer SW
10 86 85 3
10A
ECU
Hazard Lamp Relay
30 86 85 87 87
[SB 3] 16 Turn Signal Lamp(LH)
SB.12 NO.66 18 7
15A Turn Signal Lamp(RH)
30A 17
[40A]
Door Lock
[SB9]
SB.07 NO.53 12 LOCK UNLOCK
30A 15A 87
Door Lock 13 30
IGN SW 87a
[SB12] 86 87
ST 86
SB.04 AM2 30i 11
IG2 Door Unlock
30A (B1) 85 87a
85
150A
ALT 14
(125A) (GND)
IG1 6 67 45
[SB 6] 42 (UNLOCK) [A26] [A4]
SB.09 AM1 ACC [A1]
30A (B1) 15
20 (LOCK)
OFF DRL [B3]
[SB 5]
SB.10 NO.49 2 E C 8 STICS
30A 7.5A
B
9 Tail Lamp Relay
[B24]
[ ] : EWD No.
DRL Unit
(For EXP.)
As the ICM box is supplied with power from the fuse (12-pin) and STICS (6-pin, 15-pin), it operates the door
actuator (11-pin, 13-pin) through its door lock relay to lock/unlock the door.
In order to check the operation of the relay, measure the voltage at the connector of the ICM box and check
the output through the ICM box after operating the corresponding door.
Of course, the components for the corresponding system should be checked in advance.

AFFECTED VIN
01-10 8410-02
(2)Turn signal lamp (hazard warning lamp operation)
ALT
D
B
ICM Box
SB FUSE
[Ef14] 30 87 1
NO.7 Windshield de-icer SW
10 86 85 3
10A
Hazard Lamp Relay
30 86 85 87 87
[SB 3] 16
Turn Signal Lamp(LH)
SB.12 NO.66 18 7
30A 17
[40A]
Door Lock
[SB9]
30A 15A 87
13 30
Door Lock
IGN SW 87a
[SB12] 86 87
SB.04 AM2 ST 86
30i 11
(B1) IG2 Door Unlock
30A 85 87a
85
150A
ALT 14
(125A) (GND)
[SB 6] IG1 6 67 45
42 (UNLOCK) [A26] [A4]
SB.09 AM1 ACC [A1]
30A (B1) 15 20 (LOCK)
OFF DRL [B3]
[SB 5] STICS
SB.10 NO.49 2 E C 8
30A 7.5A
B
9
Tail Lamp Relay
[B24]
[ ] : EWD No. DRL Unit

(For EXP.)
- When the hazard warning lamp switch is pressed for approx. 0.1 to 0.59 seconds, the hazard warning lamp
blinks 3 times at an interval of 0.35 seconds.
- When the hazard warning lamp switch is pressed for approx. 0.6 seconds or longer, the hazard warning
lamp blinks 10 times at an interval of 0.35 seconds.
- This function is only available when the ignition key is in the "ON" position.
- If the ignition key is turned to the "OFF" position during this function is activated, this function is immediately
deactivated.
- If the system receives signals for the turn signal lamp operation during this function is activated, this
function is immediately deactivated.
- While the turn signal lamp signals are already inputted, pressing the hazard warning lamp switch does not
activate the hazard warning lamp function.

AFFECTED VIN
8410-02 01-11
(3)Windshield de-icer operation
FUSE
ALT
D
B
ICM Box
SB FUSE
[Ef14] 30 87 1
10 86 85 3
10A
Hazard Lamp Relay
ECU
30 86 85 87 87
SB.12 NO.66 18 7 Turn Signal Lamp(RH)
30A 15A
[40A] 17
Door Lock
[SB9]
30A 15A 87
13 30
Door Lock
IGN SW 87a
[SB12]
ST 86 86 87
SB.04 AM2 30i 11
30A
85 85 87a
150A
ALT 14
(125A) (GND)
[SB 6] IG1 6 67 45
SB.09 42 (UNLOCK) [A26] [A4]
AM1 ACC [A1]
30A (B1)
15
20 (LOCK)
[SB 5] OFF DRL [B3]
SB.10 NO.49
STICS
2 E C 8
30A 7.5A
B
9 Tail Lamp Relay
[B24]
DRL Unit
[ ] : EWD No.
(For EXP.)
Pressing the windshield de-icer switch activates the de-icer for 12 minutes and pressing the switch again
deactivates the de-icer. At this time, pressing the switch again activates the de-icer for 12 minutes from the
time the switch is pressed again.

AFFECTED VIN
01-12 8210-01
8210-01 CONFIGURATION OF PCB IN ICM BOX AND

FUNCTION OF CONNECTOR
Turn signal
lamp relay
de-icer relay relay
STICS

ICM box
NOTE
Pin No. Function

1 Windshield de-icer
2 DRL (Daytime Running Light) B+
3 STICS unit windshield de-icer (45-pin)
4 -
5 -
6 STICS unit door unlock (42-pin)
7 Turn signal lamp
8 DRL (Daytime Running Light) unit
9 STICS unit DRL (41-pin)
10 Windshield de-icer B+
11 Door actuator
12 Door lock relay B+
13 Door actuator
14 Ground
15 STICS unit door lock (20-pin)
16 Turn signal lamp (LH)
17 STICS unit hazard warning lamp relay (67-pin)
18 Hazard warning lamp relay B+

AFFECTED VIN
8410-02 01-13
8410-02 CIRCUIT DIAGRAM FOR FUSE & RELAY BOX IN
FUSE
ENGINE COMPARTMENT
A. Fuse & Relay Box In Engine Compartment I
Interior Fuse Box LH

(Outside Rear View Mirror)
Defogger Control System Remark
ECU
Defogger
Stics(Pin 62)[A21]
ICM Box
Deicer Deicer SW(SW IND)
Deicer
Stics(Pin 45)[A4]
Engine Compartment Fuse
& Relay Box
[SB16]
Multifunction SW(P)
Wiper Motor-LO
[Ef14] Stics(Pin 55)[A14]
Front Wiper Motor(P)
Stics(Pin 45)[A2]
Multifunction (MIST,LO)
Wiper Motor-HI
Front Wiper Motor(LO)
Front Wiper Motor(HI)
Multifunction (HI)
Stics(Pin 44)[A3]
Washer Motor SW
Front Wiper Motor

[SB3]
Front Washer
Front Washer Motor
[SB9] Washer Motor(+)
Stics(Pin 35)[B18]
GND
Rear Washer
Washer Motor(-)
Engine Wiring Floor Wiring
: Additional Major Changes

[ ] : EWD No.

AFFECTED VIN
01-14 8410-02
B. Fuse & Relay Box In Engine Compartment II
Engine Compartment Fuse & Relay Box
Control System Remark
DI Engine ECU(Pin62)/
DI Engine(EU-IV)[B56]
[SB15]
Compressor
[Ef13] A/C Compressor
[Ef12]
Rear Fog Lamp Relay
Cluster
Front Fog Lamp Front Fog Lamp (RH)

[Ef10]
Front Fog Lamp (LH)
Front Fog Lamp SW
DRL Unit No.2
Position Lamp (RH)
Tail Lamp RLY Tail Lamp (LH)

[Ef9]
[Ef8] Trailer
Tail lamp(RH)&
license plate
Position Lamp (LH)
Stics (Pin 41)[B24]
[ ] : EWD No. Engine Wiring Floor Wiring

AFFECTED VIN
8410-02 01-15
C. Fuse & Relay Box In Engine Compartment III
FUSE
(From LH Fuse Box)
Condenser Fan Relay(LO) Control System Remark
[SB11]
Condenser Fan Motor(LH)
Condenser Fan Relay(HI)

[SB10]
ECU
Condenser Fan Motor(RH)
Condenser Fan Relay Condenser Fan Motor(LH)
Power Window Power Window Motor (RH)

[SB2]
Power Window Motor (LH)
Stics (Pin 18)[B1]

Power Window Anti-trap
[Ef2]
[SB4]
Starter
[SB12]
Starter Solenoid
Clutch SW
Inhibitor SW
[SB7]
Blower Motor
[SB8]
PWM Motor
[Ef1]
[Ef22]
Power Outlet (FRT&RR)
[Ef21]
[Ef20]
Sunroof(Pin 1)
[Ef19]
Driver side Power Seat
[Ef18]
[Ef15]
[Ef7]
Stop Lamp
HDC Operation Relay

[ ] : EWD No.

AFFECTED VIN
01-16 8410-02
D. Fuse & Relay Box In Engine Compartment IV

[Ef23]
Cluster
[SB1]
Hands-Free Unit(Pin 4) DOM
Stics(Pin 50)[A9]
Memory
[Ef6]
Blowe Unit
[SB6] Digital Clock
[SB5]
DRL Unit (Pin4)
Head Lamp LO(RH)

[Ef17]
Head Lamp (LO)
Head Lamp LO(LH)

[Ef16]
MultiFunction Light(HS1)
Stics(Pin 22)[B5]
IGN2 Fuse No.34

Starter
Head Lamp HI(LH,RH)
[Ef5]
DRL Unit(Pin.01)
[Ef4]
Hazard Lamp
Horn Horn(RH)
[Ef11]
Horn(LH)
Horn SW(For Vehicle
without airbag option)

AFFECTED VIN
8410-04 01-17
8410-04 CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY
FUSE
BOX ON DRIVER SIDE
A. Interior Fuse and Relay Box On the Driver Side I
Interior(LH: Driver Seat) Fuse&Relay Box

Airbag ECU(Pin5)
Cluster(B-20)
Stics(Pin 49)[A8]
ECU
Fuel Filter(Pin 3)
Glow Plug Unit
PTC Relay
A/C Compressor Relay
Wheel Speed Sensor
Alt.D(Cluster A-10)
Stop Lamp SW(Normal Close)
Auto Cruise SW
Immobilizer (Pin2)
A/T Shift Lock Relay

Backup Lamp& back sonar
Turn Signal Lamp
TGS Lever
GSL Engine ECU(Pin 11)
GSL Sensor & Injector RLY
GGFuse No.38 Fuel Pump Relay
Fuse No.56
Fuse No.41/ Hands-Free Unit DOM

42/43
Rain sensor & Auto Light

Head Lamp Relay(LO,HI)
Head Lamp Leveling Device SW
Front Seat Warmer LH

Front Seat Warmer RH
Front Wiper Motor
Washer Motor
Power Outlet Relay
[ ] : EWD No.
Blower Relay
A/C Wiring Relay
Head Lamp(HI) Fuel Pump Rear Seat Warmer Relay
Relay (GSL)Relay

AFFECTED VIN
01-18 8410-04
B. Interior Fuse and Relay Box On the Driver Side II
Fuse No.34
Fuse No.35/36/37 Fuse No.30
DI Engine ECU(Pin 37)
Fuel Pump Relay
Interior(LH:Driver Seat) Fuse&Relay Box Control System Remark
Rear Wiper Motor(B)

Rear Wiper
Rear Wiper Rear Washer SW
Motor(P)
Rear Wiper
SW(M/F SW)
Rear Wiper
MTR(S)
GND
Stics(Pin48)
Rear Defoger Relay
Deicer Relay
ALT. D(Cluster A-10)
Sunroof SW
Digital Clock
Inside Room Mirror(ECM)
Outside rear view Motor
C/Light
Audio
A/V Head Unit
Fuel pump(GSL)
Fuel pump Motor(GSL)
Gasoline Eng.ECU(Pin33)
Gasoline Eng.ECU (Pin 12)

DI Engine Main Relay
Gasoline Injector/Spark Plug

Gasoline Sensor & O2 Sensor
Spare
ICM Box DRL Relay
DRL Unit(Pin 3)
M/Function DRL Relay
Head Lamp HI Light
SW(TS)
Head Lamp(LH/RH)
M/Function
Light
SW(HU)
Engine Compartment Fuse&

Relay Box(B+),S/B10-30A

AFFECTED VIN
8410-04 01-19
C. Interior Fuse and Relay Box On the Driver Side III
FUSE
Interior(LH:Driver Seat) Fuse&Relay Box
HeadLamp HI(LH/RH)
Sunvisor Lamp LH
ECU
Passenger Door Courtesy Lamp
M/Function Driver Door Courtesy Lamp
SW(TB)
Hazard Warning Map Lamp
Lamp SW(FL)
Hazard Warning Room Lamp

Lamp SW(FB)
Luggage Room Lamp
(EXP) Sunvisor Lamp

Flasher Unit Rear Fog Lamp Relay
Rear fog Lamp(IND)
Rear fog Lamp(LH/RH)
Front
Fog Rear Fog Lamp SW
Lamp
Immobilizer
Key Reminder
Door Lock(ICMBox)
XY Buzzer
Chime Bell
Door
Un Lock
Door Stics
Lock Stics
Stics
(Pin 69)
Tail Gate UnLock
Tailgate Unlock
Stics
(Pin 17)
O/S Mirror folding/Unfolding RLY
Diagnosis Conneator(pin16)
Rear Seat Warmer
Starting Solenoid
GSL Engine ECU(pin 2)
Rear Defogger SW(IND)

Outside rear view mirror
defogger (LH/RH)
Stop Lamp

AFFECTED VIN
01-20 8402-06

BOX ON PASSENGER SIDE
A. Interior Fuse and Relay Box On the Passenger Side I
Interior(Driver Seat) Fuse&Relay Box

(No.44/45/46/47/48/49)
Interior(LH:Passenger Seat) Fuse&Relay Box
Front Control System Remark
Power Outlet Power Outlet
Rear
Power Outlet
GND
Inlet Metering Valve(IMV)
Main(DSL) DI Engine(EU-IV)[B1]
DI(EU-IV)[B44] DI Engine(EU-IV)[B5]
Theft deterrent horn
(Hazard Warning)
Turn signal lamp-LH

Turn signal lamp-RH
Hazard Warning Lamp Relay
[A26]
ICM Box
A/V DSP&AMP(Kalosnett)
Audio Head Unit
TGS Lever
OutPut Stop Lamp SW TGS Lever
(Shift Lock)
TGS Lever
(”P” SW)
Blower
Blower Motor
GND
Gasoline Injector
Injector(EXP)
Ignition coil (GSL)(EXP)
Injector(EXP)
Engine Sensor(EXP)

[ ] : EWD No.

AFFECTED VIN
8210-01 01-21
FUSE
8210-01 REMOVAL AND INSTALLATION OF ICM BOX
1. Disconnect the negative cable from the battery.

2. Disconnect the OBD connector from the undercover.
ECU
ICM Box
1. Remove the IP undercover on the driver side.
a.Remove the IP side cover.
NOTICE
• Remove it by inserting a flat-bladed screw-
driver into the groove (A).

AFFECTED VIN
01-22 8210-01
b.Unscrew the one mounting screw (A), two

mounting bolts (B) and one mounting nut (C).
c.Separate the IP undercover mounting clips (D) on the driver side carefully.
Mounting clip (D)
d.Remove the fuel filler opening lever (E) and en-

gine hood opening lever (F).

AFFECTED VIN
8210-01 01-23
2. Unscrew and remove the two mounting bolts of

the driver side foot duct.
FUSE
ECU
3. Remove the three mounting bolts of the ICM mount-
ing bracket.
4. Disconnect the ICM connector.
5. Installation is in the reverse order of removal.

AFFECTED VIN
MEMO
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CHASSI
DSI M78 6-SPEED A/T

.........................................................
3110/3650/3660/3680/3721/9210 01-3P
C-145: 2008.07 ~
DSI M78 6-SPEED A/T
3110-01/3650-01/3660-01/3680-01/3721-01/9210-01
GENERAL INFORMATION 3650-01 DSI M78 6-SPEED A/T ASSEMBLY .... 76

3660-01 VALVE BODY ..................................... 78
1. DSI M78 6-SPEED AUTOMATIC TRANSMIS-
SION GENERAL .............................................. 2 3110-01 TCU ..................................................... 80
2. STRUCTURE CHARACTERISTICS AND SPECI- 3721-01 TGS LEVER ........................................ 81

FICATIONS ...................................................... 4 3650-01 INHIBITOR SWITCH ............................. 87
3. TIGHTENING TORQUE .................................... 8 3110-01 TROUBLE CODE DIAGNOSIS ............. 91
OVERVIEW AND OPERATION DIAGNOSIS AND TESTING

PROCESS
1. WIRING DIAGRAM ........................................ 93
1. GENERAL DESCRIPTION ............................... 9 2. WIRE HARNESS CONNECTOR CHART ....... 94
2. ADVANCED SIX SPEED FEATURES ............ 10 3. UNIT CONNECTOR DESCRIPTION ............... 94
3. FUNCTION OF EACH MODE ......................... 12
4. LIMP HOME MODE ....................................... 14 TROUBLE CODE DIAGNOSIS
5. TRANSMISSION ELECTRONIC CONTROL 1. DIAGNOSTIC TROUBLE CODE LIST ............ 98
SYSTEM ........................................................ 15
2. SYSTEM DIAGNOSIS .................................. 100
6. CONFIGURATION OF CAN RELATED TO TCU
...................................................................... 18
MAINTENANCE OPERATIONS
7. POWER TRAIN ............................................. 19
1. OIL TEST ......................................................143
CONFIGURATION AND FUNCTIONS 2. STALL TEST ................................................. 144
3721-01 TGS LEVER ........................................ 46 3. TRANSMISSION RESET PROCEDURE
(REPLACEMENT TRANSMISSION) ............. 145
3680-01 DSI M78 6-SPEED A/T ASSEMBLY .... 56
4. FLUID LEVEL INSPECTION ......................... 146
3680-01 VALVE BODY ..................................... 66
5. TRANSMISSION COOLER AND HYDRAULIC
3110-01 TCU ..................................................... 70 LINE FLUSHING PROCEDURE ....................147
3650-01 INHIBITOR SWITCH ............................. 73 6. LUBRICATION ...............................................147
7. TRANSMISSION COOLER AND HYDRAULIC
REMOVAL AND INSTALLATION LINE FLUSHING PROCEDURE (NEW
TRANSMISSION) ..........................................148
9210-01 FLUID LEVEL INSPECTION ................ 74
3650-01 TRANSMISSION RESET PROCEDURE
(REPLACEMENT TRANSMISSION) .... 75
01-2 3650-01
AUTOMATIC TRANSMISSION 3650-01

GENERALS
1. DSI M78 6-SPEED AUTOMATIC TRANSMISSION GENERAL
Six Speed Automatic Transmission
The six speed automatic (M78) transmis-

sion is available in two variants: four wheel
drive and two wheel drive.
The transmission has the following
features:
• Six Forward Speeds

• One reverse gear
• A torque converter with an integral converter lock-
up clutch
• Electronic shift and pressure controls
• A single planetary gear-set
• A double planetary gear-set
• Two hydraulically controlled brake bands
• Three multi-plate clutches
• All hydraulic functions are directed by electronic
solenoids to control:
- Engagement feel Tip Switch on Steering Wheel
- Shift feel
- Shift scheduling
- Modulated torque converter clutch applications
Shift down Shift up
TCU (Installed under the driver’s seat)

The TCU receives input signals from certain transmission- TCU
related sensors and switches. The TCU also uses these sig-
nals when determining transmission operating strategy.
Using all of these input signals, the TCU can determine when
the time and conditions are right for a shift, or when to apply
or release the torque converter clutch. It will also determine
the pressure needed to optimise shift feel.
DSI M78 6-SPEED AUTO TRANSMISSION CHANGED BY

AFFECTED VIN
3650-01 01-3
Instrument Cluster
DSI M78
6 A/T
Gear Position Indicator
(for automatic transmission)
This indicator shows the current
4
5 6
7
8 60
80 position of the gear.
3 x1000rpm km/h
40
2
20 200
0 0 220
P: Parking 6: 1~6th Gear shifting

R: Reverse 5: 1~5th Gear shifting
N: Neutral 4: 1~4th Gear shifting
D: Driving 3: 1~3rd Gear shifting
(1 ~ 6th gear 2: 1~2nd Gear shifting
shifting) - 6A/T
1: 1st Gear
TGS Lever
Tip Switch on Gear Selector Lever

Tip Switch
Shift up (Manual Gear Adjustment)
M
The shiftable gear can be adjusted by this
switch when the gear selector lever is in “M”
Shift down position.
Winter Mode
When winter mode is selected, Shift Lock Release Button
starting in second gear is facilitated Hole when Locked in the “P”
and the WINTER mode indicator Position
light is switched ON. To prevent
wheel spin on slippery surfaces, If you cannot move the selector lever
the transmission will not allow first from the “P” position, try to move the
gear unless manually overridden. lever while pushing down here with a
sharp object such as a ballpoint pen.
For your safety, turn off the engine
Standard Mode and depress the brake pedal before
the attempt.
Standard Mode is selected when the lever is in the D
Shift from the “P” Position
position with the mode switch in the standard (S)
position and the transmission is within normal tem- To shift into any other positions from
perature ranges. Shift schedule points are optimised the “P” position after stopping the
for fuel efficiency and general driving conditions. vehicle, you have to depress the brake
pedal with the ignition switch “ON”.
CHANGED BY DSI M78 6-SPEED AUTO TRANSMISSION

AFFECTED VIN
01-4 3650-01
2. STRUCTURE CHARACTERISTICS AND SPECIFICATIONS

A. Specifications
Description DSI M78 6A/T REMARK

Gear ratios 1st 3.536 : 1
2nd 2.143 : 1
3rd 1.478 : 1
4th 1.156 : 1
5th 0.866 : 1
6th 0.677 : 1
Reverse 3.094 : 1
Torque converter Diamerter 260 (mm)
Number of element 3 EA
Number of Step 1 EA
Number of Phase 2 EA
Transmission Planetary gear set 2 EA
component One-way clutch 1 EA
Multi disc clutch 3 EA
Band brake 2 EA
Weight Including oil 79 kg
Oil Fluid specification CALTEX PED 1712 ATF
Fluid capacity Approx. 9.5
Change interval At every regular check-up
(every 30,000 km or 1 year)
Check fluid level, leakage
and fluid condition.
Change if necessary
Resistance of oil -20°C 430.7 ~ 533.9 Ω
temperature sensor 0°C 146.8 ~ 175.7 Ω
20°C 56.74 ~ 65.86 Ω
100°C 3.201 ~ 3.399 Ω
Resistance of gear 1 -
position sensor 2 -
3 -
D gear position 2.686 kΩ ± 8%
N gear position 5.036 kΩ ± 8%
R gear position 8.953 kΩ ± 8%
P gear position 16.786 kΩ ± 8%

AFFECTED VIN
3650-01 01-5
B. Appearance
DSI M78
6 A/T
4WD Automatic Transmission
Torque converter
Oil cooler outlet Oil cooler return
Servo
Adapter housing
Inhibiter switch

AFFECTED VIN
01-6 3650-01
C. INTERNAL ASSEMBLY FIGURE
4WD
2WD

AFFECTED VIN
3650-01 01-7
D. SHIFT PATTERN
DSI M78
6 A/T
100
90
80
70 up2 Dn1
up3 Dn2
up4 Dn3
60 up5 Dn4
up6 Dn5
1L 1LS
2L 2LS
50
3L 3LS
4L 4LS
5L 5LS
40
6L 6LS
10S 10
20S 20
30 30S 30
40S 40
50S 50
60S 60
20
10
Vehicle Speed (Km/h)
20 40 60 80 100 120 140

0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Output Shaft Speed (rpm)

AFFECTED VIN
01-8 3650-01
3. TIGHTENING TORQUE
Component Size Torque (Nm)
TC housing M12 x 32 54 ~ 68
Extension housing M12 x 32 54 ~ 68
Oil pan M6 x 16 4~6
Tightening valve body and transmission housing M6 x 26 8 ~ 13
Tightening valve body and transmission housing M6 x 45 8 ~ 13
Tightening center support and transmission housing M10 x 34 20 ~ 27
Output shaft locking nut M24 x 15 100 ~ 110
Tightening oil pump and pump cover M8 x 55 24 ~ 27
Tightening pump cover and transmission housing M8 x 40 24 ~ 34
Tightening pump cover and transmission housing M8 x 58 24 ~ 34
Tightening upper valve body and lower valve body M6 x 30 15 ~ 17
Fixing detent spring M8 x 16 20 ~ 25
Fixing VBS & speed sensor M4 x 12 2.8 ~ 3.2
Transmission oil level plug 30 ~ 35
Fixing front transmission cooler line and 25 ~ 35
transmission cooler connector
Fixing rear transmission cooler line and 25 ~ 35
transmission cooler connector
Fixing torque converter and drive plate 40 ~ 42
Tightening transmission selector lever and shaft rod 14 ~ 20

AFFECTED VIN
3650-01 01-9
DSI M78
6 A/T
1. GENERAL DESCRIPTION
The six speed automatic (M78) transmission is avail-
able in two variants: four wheel drive and two wheel
drive.
The transmission has the following features:
4WD
• Six Forward Speeds

• One reverse gear
• A torque converter with an integral converter lock-up clutch
• Electronic shift and pressure controls
• A single planetary gear-set
• A double planetary gear-set
• Two hydraulically controlled brake bands
• Three multi-plate clutches
• All hydraulic functions are directed by electronic solenoids to control:
- Engagement feel
- Shift feel
- Shift scheduling
- Modulated torque converter clutch applications
The transmission contains fully synthetic automatic transmission fluid (ATF) and is filled for life; therefore it
does not require periodic servicing.
Engine power reaches the transmission via a torque converter with integral converter lock-up clutch.
The six forward gears and one reverse gear are obtained from a single planetary set, followed by a double
planetary set. This type of gear-set arrangement is commonly known as Lepelletier type gear-set.
The automatic transmission is electronically controlled. The control system is comprised of the following
elements:
• External transmission control unit (TCU)
• Internal embedded memory module (EMM)
• Input and output speed sensors
• Valve body unit comprised of four on/off solenoid valves and six variable bleed solenoids
• Torque converter

AFFECTED VIN
01-10 3650-01
2. ADVANCED SIX SPEED FEATURES

A. Characteristics
Early Downshifts with Hard Braking and Skip Shifts

When heavy braking is detected, the transmission downshifts early and skips gears to provide increased
engine braking to provide gear selection for tip-in.
Gear Hold Going Uphill/Downhill

If the accelerator pedal is released when travelling uphill, upshifts are prevented to reduce busyness on
grades. If the accelerator pedal is released when travelling downhill, upshifts are prevented to enhance engine
braking.
Upshift Prevention with Fast-off Accelerator Pedal

Upshifts are prevented when the throttle is backed off very quickly to reduce busyness in sporty driving.
Drive and Reverse Engagement

A soft engagement feature avoids harsh take up of drive when selecting Drive or Reverse. This is achieved by
limiting engine speed and engine torque which results in a rapid, but progressive engagement of either Drive
or Reverse when moving from the Park or Neutral positions. Drive and Reverse engagements from either Park
or Neutral are performed in less than 2.2 seconds.
There is no drive engagement prevention strategy implemented on the transmission system as there is sufficient
engine strategy to protect the system. However, reverse engagement is prevented until engine speed is less
than 1400 rpm and the accelerator pedal position is less than 12% and vehicle speed is less than 10 km/h.
Converter Clutch Lock-Up In All Gears

The transmission features converter clutch lock-up in all gears. This feature provides improved fuel economy
and vehicle performance. It also improves transmission cooling efficiency when towing heavy loads at low
speeds, e.g. in city driving or hill terrain.
Embedded Memory Module

The embedded memory module (EMM) is matched to the transmission's valve bodies during transmission
assembly to ensure refined shift quality. The EMM is integrated into the input speed sensor which is mounted
on the valve body in the transmission. The EMM is used to store data such as valve body calibration data and
valve body serial number.
Upon installation, the TCU will download the data from the EMM and utilise this data in the operation of the
transmission.

AFFECTED VIN
3650-01 01-11
B. Transmission Cooling
DSI M78
6 A/T
The transmission cooling system ensures rapid warm-up and constant operating temperature resulting in
reduced fuel consumption and refined shift quality.
It also includes a cooler by-pass within the hydraulic system to allow sufficient cooling and lubrication to the
transmission drivetrain in the event of a blockage in the transmission cooler.
C. Shift Strategy
Gear Change
Transmission gear change is controlled by the TCU. The TCU receives inputs from various engine and vehicle
sensors to select shift schedules and to control the shift feel and torque converter clutch (TCC) operation at
each gear change.
Coastdown
Coastdown downshifts occur at 0% pedal when the vehicle is coasting down to a stop.
Torque Demand
Torque demand downshifts occur (automatically) when the driver demand for torque is greater than the engine
can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration.

AFFECTED VIN
01-12 3650-01
3. FUNCTION OF EACH MODE

A. Description
1. Shift Lock Release Button Hole when Locked in the "P" Position
If you cannot move the selector lever from the "P" position, try to move the lever while pushing down here with
a sharp object such as a ballpoint pen. For your safety, turn off the engine and depress the brake pedal before
the attempt.
Shift from the "P" Position

To shift into any other positions from the "P" position
after stopping the vehicle, you have to depress the brake
pedal with the ignition switch "ON".
2. Selection of Manual / Automatic Shift Function

• D : Automatic shift according to the driving condition
• M : Manual shift
3. Mode Switch
• W : Winter mode
• S : Standard mode
Use the standard mode in normal driving conditions.
4. Gear Position
• P : Parking
• R : Reverse
• N : Neutral
• D : Driving
5. Tip Switch (Manual Gear Adjustment)

The shiftable gear can be adjusted by this switch when the gear
selector lever is in "M" position.

AFFECTED VIN
3650-01 01-13
B. Range Mode (Manual Mode)
DSI M78
6 A/T
This allows the driver to define the highest possible gear by selecting "+" or "-" on the gear selector when the
lever is in the "M" position. When the lever is first moved to the manual "M" position the transmission will
select the lowest possible gear.
When maximum engine rpm is reached the transmission will upshift automatically regardless of the driver
selected limit. 4WD models with low range will not automatically upshift when low range is selected.
NOTE
Kickdown Function
If you need to accelerate rapidly, depress the accelerator pedal completely to the floor.
Then, a one- or two-lever gear will automatically be engaged. This is called the Kickdown function.
1st Gear State

The 1st gear state will display on the instrument cluster. Unlike the normal 1st gear, engine braking will be
available in this manual 1st state.
2nd Gear State

The 2nd gear state will display on the instrument cluster. 2-1 automatic kick-down shifts are available. 2nd
gear has engine braking available.
3rd Gear State

The 3rd gear state will display on the instrument cluster. 3-2 and 3-1 automatic kick-down shifts are available.
3rd gear has engine braking available.
4th Gear State

The 4th gear state will display on the instrument cluster. 4-3, 4-2 and 4-1 automatic kick-down shifts are
available. 4th gear has engine braking available.
5th Gear State

The 5th gear state will display on the instrument cluster. 5-4, 5-3 automatic kick-down shifts are available. 5th
6th Gear State


AFFECTED VIN
01-14 3650-01
4. LIMP HOME MODE

In case of transmission malfunction
1. If a serious fault occurs in the automatic transmission, the TCU enters the limp home mode to secure safe
driving and protect the automatic transmission.
2. As power is no longer supplied to the solenoid, the current basic function (P, R, N, D) is maintained and the
4th gear can be maintained only by the operation of the hydraulic system without electrical operation.
3. The ECU communicates with other electric modules with CAN. If a serious fault occurs, the transmission
automatically enters the limp home mode for service.
4. The TCU monitors all factors which can affect the transmission and diagnoses the system to comply with
the OBD II regulations.
In case of overheated transmission

1. The TCU enters the limp home mode when the batter voltage drops below 8 V.
2. If the transmission is overheated, the shift pattern is changed to the hot mode to cool the transmission more
efficiently.
3. While the transmission is overheated, the selector lever symbol and engine temperature warning lamp on
the instrument cluster blink until the transmission is cooled down to the normal operation temperature. If
the transmission is excessively overheated, the gear cannot be shifted but remains in the neutral position.
Towing vehicle equipped with A/T
NOTICE
The best way to transport the vehicle is to load it to a truck and transport it, especially if the vehicle is 4WD.
• If towing the vehicle with the propeller shaft connected, the transmission or oil pump of transfer
case may malfunction, resulting in internal damage due to poor lubrication.

AFFECTED VIN
3650-01 01-15
5. TRANSMISSION ELECTRONIC CONTROL SYSTEM
DSI M78
6 A/T
A. General FATCS About TCU
The transmission control unit (TCU) and its input/output network control the following transmission operations:
• Shift timing
• Line pressure
• Clutch pressure (shift feel)
• Torque converter clutch
In addition, the TCU receives input signals from certain transmission-related sensors and switches. The TCU
also uses these signals when determining transmission operating strategy.
Using all of these input signals, the TCU can determine when the time and conditions are right for a shift, or
when to apply or release the torque converter clutch. It will also determine the pressure needed to optimise
shift feel. To accomplish this, the TCU operates six variable bleed control solenoids and four on/off solenoids
to control transmission operation.
The following provides a brief description of each of the sensors and actuators used to control transmission
operation.
B. Transmission Control Unit

Caution: If the TCU requires reprogramming the handbrake must be firmly applied and the transmission placed in
Park (P).
The transmission control unit (TCU) is mounted under the left-hand front seat and controls the operation of the
transmission.
The TCU is activated and deactivated by the ignition power supply and is connected to the transmission link
harness by a 26 pin connector.
The TCU processes information received from internal sensors and signals received across the CAN bus in
analogue and digital forms such as:
• Transmission input speed
• Transmission output speed
• Accelerator pedal position
• Gear selector position
• Engine torque
• Engine speed
• Transmission fluid temperature
• Brake pedal status
• Engine oil temperature
• Engine coolant temperature
• Ambient air temperature
• Barometric pressure
This information is used by the TCU to decide which shift pattern to select and for shift energy management.
Electro-hydraulic solenoid valves and variable bleed solenoids control the transmission gear changes.
Six variable bleed solenoids and four on/off solenoids are used to direct transmission fluid flow to control the
fluid pressure within the three clutches and two bands. Separate pressure regulators are used exclusively for
torque converter clutch control and main transmission line pressure.
The TCU monitors all TCU inputs and outputs to confirm correct system operation. If a fault occurs the TCU
is able to perform default action and inform the driver of the problem through the instrument cluster warning
lights. Detailed information is available via trouble codes which can be read with the service tool.

AFFECTED VIN
01-16 3650-01
C. Transmission Control Monitoring System

The TCU monitors all input and outputs to identify possible failures. If a fault is detected, the TCU takes the
appropriate action to ensure the transmission maintains a safe mode of operation, without sacrificing trans-
mission durability or driver safety.
Supply Monitoring
If the battery voltage is either too great or too low, the TCU will detect a fault condition.
Solenoid Supply Monitoring

While the solenoid operating transistors are being activated, checks are run for open circuits, shorts circuits
to ground and short circuits to supply. The monitoring function evaluates the voltage characteristics during the
switch ON process checking for the above faults.
Gear Ratio Monitoring

The gear ratio diagnostic checks if each gear ratio is correctly engaged. Also, following a gear shift the
diagnostic checks if the transmission has engaged the target gear within the allowed time.
Torque Converter Monitoring

The TCU checks if the torque converter can be locked correctly. If torque converter lock-up does not occur
correctly the TCU performs the appropriate fail-safe action of opening the torque converter clutch.
D. Shift Energy Management

This function involves reducing or increasing the engine output torque during shifting. The aim when upshifting
is to reduce the energy which is dissipated in the friction elements of the transmission. This is done by
reducing the engine torque during the ratio change without interrupting the tractive drive. This function is used
for:
• Increasing the transmission service life by shortening the slipping time
• Improving the shift comfort by reducing the step change in torque caused by the gearshift
• Transferring a higher engine power, this is allowed by the mechanical in-gear strength of the transmission
Real-time control of engine torque is required to maintain maximum shift quality and transmission durability.
The TCU has the ability to control the engine torque during the gearshift to synchronise with the operation of
the transmission clutches.
Pressure Modulation
To provide a high level of shift comfort and durability, the hydraulic pressure in the shift related friction ele-
ments of the transmission must be matched accurately to the transmission input torque. This hydraulic
pressure is composed of a hydraulically pre-set basic pressure and a controlling pressure which is set by one
of the variable bleed solenoids.
The transmission input torque can be directly calculated from the following operating parameters: engine
torque signals, engine speed or any signals transmitted from the engine management ECU by CAN, and
converter slip. Separate pressure characteristics for each gear change make it possible to adapt precisely to
the particular shift operation.
High and Low range operation has different parameters to optimise shift quality.

AFFECTED VIN
3650-01 01-17
E. Shift Map Selection
DSI M78
6 A/T
The driver can manually select between normal (S) and winter modes (W) via the mode switch. Depending on
the transmission temperature, uphill and downhill grades and altitude, shift maps will be selected by the TCU
to suit the driving conditions. The following maps are available.
Normal Mode
Normal Mode is selected when the lever is in the D position with the mode switch in the normal (S) position
and the transmission is within normal temperature ranges. Shift schedule points are optimised for fuel effi-
ciency and general driving conditions.
Uphill and Downhill Mode

In this mode, depending on the load of the vehicle, adaptive shift maps are selected to progressively adjust the
shift points and torque converter lock points.
Altitude Mode
Shift points are automatically adjusted at higher altitudes to compensate for changes in engine torque where
the torque produced by the engine is greatly reduced by the effects of reduced barometric pressure and
temperature.
Winter Mode
When winter mode is selected, starting in second gear is facilitated and the WINTER mode indicator light is
switched ON. To prevent wheel spin on slippery surfaces, the transmission will not allow first gear unless
manually overridden.
Low Range Schedule

When the transfer case is in 4L position, the transmission uses a different shift map to optimise low range
driving. Similar to winter mode, 1st gear is inhibited. The transmission may skip gears, e.g. 2-4, to optimise
engine rpm.
Warm up Schedule
Used typically when transmission fluid temperature is below 20°C.
The torque converter will not lock-up below 20°C to assist in transmission warm-up.
Hot Mode
The hot mode is progressively applied between temperatures of 110° - 145°C. The torque converter lock-up is
increased to prevent heat generation by the torque converter.
As additional assistance to the hot mode, the following are activated:
• Above 110°C - the electrical radiator fans are switch ON
• Above 130°C - the engine torque will be reduced and the WINTER light on the instrument cluster will flash
• Above 145°C - the transmission will neutralise until the fluid temperature falls below 120°C as a final
protection.
Activation of the hot mode inhibits other transmission performance features including uphill and downhill
compensation and altitude compensation. Some degradation in shift feel may be experienced as the torque
converter is not unlocked during shifting. The fluid temperature must be below 105°C to exit all hot modes.
Cruise
When cruise control is activated the engine ECU may request the transmission to downshift under trailing
throttle conditions to increase engine braking.

AFFECTED VIN
01-18 3650-01
6. CONFIGURATION OF CAN RELATED TO TCU

A. Communication Network
Instrument
Engine ECU
Cluster
(Termination)
(Termination)
Transmission
Transfer ECU ABS ECU
ECU
The TCU sends signals to be used by other vehicle systems via the CAN bus, such as:
• Selector lever position
• Selected gear state
• Manual mode activation
• Output torque
• Input speed
• Output speed
• Transmission fluid temperature
• Engine torque reduction requests
B. Embedded Memory Module
The embedded memory module (EMM) is matched

to the transmission valve body during manufacture.
The EMM is integrated into the input speed sensor
which is mounted on the valve body in the
transmission.
The EMM data contains transmission specific
characterisation information. Upon installation, the
TCU will upload the data from the EMM and utilise
this data in the operation of the transmission.
Input Speed Sensor

/Embeded Memory Module

AFFECTED VIN
3650-01 01-19
7. POWER TRAIN
DSI M78
6 A/T
The various power train of the transmission is as follow:
- Power train - M 1st gear
- Power train - D 1st gear
- Power train - D 2nd gear
- Power train - D 2nd gear - lockup
- Power train - D 3rd gear
- Power train - D 4th gear - D 4th gear - limp home mode
- Power train - D 5th gear
- Power train - D 6th gear
Gear States Summary
Engaged elements (clutches & bands) Shift ON/OFF solenoids

Gear Ratio
C1 C2 C3 B1 B2 1-2 OWC S1 S2 S3 S4
M1 3.536 ON ON ON
1st 3.536 ON ON ON
2nd 2.143 ON ON ON ON
3rd 1.478 ON ON ON ON
4th 1.156 ON ON
5th 0.866 ON ON ON
6th 0.677 ON ON ON ON
Reverse -3.094 ON ON ON ON ON
Variable Pressure Solenoid Valve

Gear Ratio
S5(A) S6(A) S7(A) S8A) S9A) S10(A)
M1 3.536 1 0 1
1st 3.536 1 0 0-1
2nd 2.143 1 0 1 0-1
3rd 1.478 1 0 1 0-1
4th 1.156 0 0 0-1
5th 0.866 0 1 1 0-1
6th 0.677 0 1 1 0-1
Reverse -3.094 1 1 1 0-1

AFFECTED VIN
01-20 3650-01
Overall Hydraulic Circuit

AFFECTED VIN
3650-01 01-21
Solenoids
DSI M78
6 A/T
• There are in total 10 solenoids used to control the transmission. All solenoids are located in the Valve Body.
• Solenoids S1, S2, S3 & S4 are ON/OFF solenoids. They determine the static gear position of the transmis-
sion by controlling the shift valves.
• Solenoids S5, S6, S7 & S8 are Variable Bleeding Solenoids (VBS) which ramp pressure via a current
change during gear shifting. They direct pressure to the regulator valves and are the primary means of
controlling gear shift quality.
• Solenoids S9 is also a variable bleeding solenoid. It controls Line Pressure.
• Solenoid S10 is a variable bleeding solenoid as well and is used for controlling the application of the Torque
Converter lock-up clutch.
• ON/OFF Solenoids:
- S1 controls apply/release of the C1 Clutch.
- S2 controls apply/release of the C2 Clutch
- S3 controls apply/release of the C3 Clutch & B2 Band
- S4 controls apply/release of the B1 Band
• VBS Solenoids are generally used for regulating and ramping pressure to different shift elements (clutch/
band) :
- S5 regulates pressure supplied to the C1 Clutch
- S6 regulates pressure supplied to the C2 Clutch
- S7 regulates pressure supplied to the C3 Clutch & B2 Band
- S8 regulates pressure supplied to the B1 Band
Gear States Summary
Engaged elements (clutches & bands) Shift ON/OFF solenoids

Gear Ratio
C1 C2 C3 B1 B2 1-2 OWC S1 S2 S3 S4
M1 3.536 ON ON ON
1st 3.536 ON ON ON
2nd 2.143 ON ON ON ON
3rd 1.478 ON ON ON ON
4th 1.156 ON ON
5th 0.866 ON ON ON
6th 0.677 ON ON ON ON
Reverse -3.094 ON ON ON ON ON

AFFECTED VIN
01-22 3650-01
A. Power Train - "M" (Manual) Position

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
Sun gear OWC Forward
IN Sun OUT
Functioning elements
• C2 applied, drives FSG
• B2 applied to hold Rear Planet Carrier held stationary.
• This gear state provides engine breaking.
Control
• S1 is ON, S7 is ON
• S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch.
• S1 ON moves B2 Shift Valve to its left-end position allowing an application of the B2 Band. (S7 must be ON as well).
• C2 Shift Valve (S2 OFF) is open allowing drive oil to engage C2 Clutch.
• Drive oil that engages C2 Clutch is regulated by VBS S6.
NOTICE
• Manual 1st is not achieved by moving the Manual Valve into a certain position. This gear state is ob-
tained electronically by solenoids S1 & S7.
Connecting Components
Elements engaged ON / OFF solenoids Variable pressure sol. valve-VBS

Gear
B1 B2 CONV S5 S6 S7 S8 S9 S10
ratio C1 C2 C3 OWC S1 S2 S3 S4
AO AI R AO AI CLU (A) (A) (A) (A) (A) (A)
3.536 ON ON ON ON 1 0 1 0-1

AFFECTED VIN
Line / Drive
CHANGED BY
Pressure
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
Cooler C1 Regulator Valve C2 Regulator Valve B2AI B1
Manual 1st - C2 & B2 ON (3.536)
S5
S6
Cooler
S5
B1AI-EX
Bypass
Valve Cooler Bypass NH VBS
B2AI C3 Front serv
C1S DR25 BAF(B1AO)
DR1
S6 DR35 DR36
DR2 NH VBS
Rear serv B1 Quick
Converter Apply Release Valve
Cooler/Lube C1S
Regulator DR33 C2S
C1 Shift S1
Valve Reverse
C2 Shift Valve S2
Converter Release LHM Valve
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
S10 C2 Subsystem Blow Off
Convertor Valve
Shift S3
DR31
C1 Subsystem C3S B1 Regulator Valve
Release
Limit S8
S10 NL VBS
Convertor Regulator NL VBS DR17 DR37
Regulator S10 DR34 C3/B2 Regulator Valve
Drive DR24
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
DR42 DR8
S7
NL VBS
Pump Cover Valves S10 & CSV Subsystem
Drive
B1 Shift Valve
S9 NH VBS S3
S9 DR26
REV Supply Ball
Line
S4
S4
DR38 NL D/I
DR18 L500
Blocked
S9 Subsystem Line
B2 & C3 Subsystem
Primary Regulator Valve
Line
Suction
Suction
SOL Supply Valve
DR19
B1 Subsystem
Pump Line Line
REV
Drive
Line
Line
3650-01
Filter Pump Cover Solenoid Supply Valve Subsystem Exhaust
P N
R D
Manual Valve
Dowel
Manual Valve Subsystem
01-23
ACTYON SM - 2008.07
DSI M78 6-SPEED AUTO TRANSMISSION
DSI M78
6 A/T
01-24 3650-01
B. Power Train - "D" (Drive) 1st (Auto)

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• Rear Planet Carrier held via 1-2 OWC
Control
• S1 is ON, S2 is OFF
• S1 ON moves C1 Shift Valve to the left end not allowing an application of the C1 Clutch.
• C2 Shift Valve (S2 OFF) is open allowing drive oil to engage C2 Clutch.

Gear
3.536 ON ON ON 1 0 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
S5
Auto 1st - C2 & OWC ON (3.536)
S6
Cooler
Bypass S5
NH VBS
B1AI-EX
Valve Cooler Bypass C3

B2AI
Front serv
C1S DR25 BAF(B1AO)
DR1
DR35 DR36
DR2 S6
NH VBS Rear serv B1 Quick
Cooler/Lube C1S
Regulator DR33 C2S
C1 Shift S1
Reverse
Valve C2 Shift Valve S2
LHM Valve
Converter Release B2 Supply Ball
S1
S2 B2 feed
NL D/I
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
C2 Subsystem Blow Off
Convertor S10 Valve
Shift S3
C1 Subsystem DR31
C3S B1 Regulator Valve
Release
Limit S8
Convertor Regulator S10 DR17 DR37 NL VBS
Regulator S10 NL VBS
DR34 C3/B2 Regulator Valve
DR24
B1S
Drive
S10 Feed DR30
Converter DR23
Supply Valve
DR42 DR8
S7
Pump Cover Valves S10 & CSV Subsystem Drive NL VBS
B1 Shift Valve
S9 NH VBS S3
Line DR26
REV Supply Ball
S9
S4
DR38 S4
NL D/I
DR18
L500
Blocked
Primary Regulator Valve S9 Subsystem B2 & C3 Subsystem
Line
Line
Suction
Suction
SOL Supply Valve
DR19
B1 Subsystem
Pump Line Line
REV
Line
Drive
Line
3650-01
P N
R D
Manual Valve
Dowel
01-25
ACTYON SM - 2008.07
DSI M78
6 A/T
01-26 3650-01
C. Power Train - "D" (Drive) 2nd

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• B1 applied to hold RSG stationary
Control
• S1 is ON, S2 is OFF & S4 is ON.
• S1 ON moves C1 Shift Valve to its left-end position not allowing the application of the C1 Clutch.
• C2 Shift Valve is OPEN (S2 OFF) allowing drive oil to engage C2 Clutch.
• S4 ON moves B1 Shift Valve to its left-end position allowing engagement of B1 Band.
• Drive oil that engages B1 Band is regulated by VBS S8.

Gear
2.143 ON ON ON ON 1 0 1 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
Auto 2nd - C2 & B1 ON (2.143)
To cooler
S5
S6
Cooler S5
Bypass NH VBS
B1AI-EX
Valve Cooler Bypass C3

B2AI
Front serv
C1S DR25
BAF(B1AO)
DR1
DR35 DR36
S6
DR2 NH VBS
Rear serv B1 Quick
Cooler/Lube C1S
Regulator DR33 C2S
C1 Shift S1
Reverse
LHM Valve
Converter Release B2 Supply Ball
S1
S2 B2 feed
NL D/I
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor S10 Valve
Shift S3
DR31
Release
Limit S8
Regulator S10 DR17 DR37 NL VBS
Convertor NL VBS
Regulator S10 DR34 C3/B2 Regulator Valve
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
DR42 DR8
S7
Pump Cover Valves S10 & CSV Subsystem Drive NL VBS
B1 Shift Valve
S9 NH VBS S3
DR26
Line REV Supply Ball
S9 S4
DR38
S4
DR18 NL D/I
L500
Blocked
Primary Regulator Valve S9 Subsystem Line

B2 & C3 Subsystem
Line
Suction
Suction
SOL Supply Valve
DR19
Pump B1 Subsystem
Line Line
REV
Line
Drive
Line
3650-01
Filter Pump Cover Solenoid Supply Valve Subsystem

Exhaust
P N
R D
Manual Valve Dowel

01-27
ACTYON SM - 2008.07
DSI M78
6 A/T
01-28 3650-01
D. Power Train - "D" (Drive) 2nd - Lockup

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT

Gear
2.143 ON ON ON ON ON 1 0 0 1 0-1 1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
Solenoid Suppl
EFFECTIVE DATE
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
S5
2nd Lockup - C2, B1 & TCC ON
S6
Cooler S5
B1AI-EX
Bypass Cooler Bypass NH VBS C3

Valve
B2AI Front serv
C1S DR25 BAF(B1AO)
S6 DR35 DR36
NH VBS
Rear serv B1 Quick
C1S DR33
Cooler/Lube
Regulator C2S
C1 Shift
Valve S1 Reverse
C2 Shift Valve S2
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor
S10 Valve
Shift S3
DR31
Release
Limit S8
S10 DR17 NL VBS
Convertor Regulator DR37
S10 NL VBS
Regulator DR34 C3/B2 Regulator Valve
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
DR42 DR8 Supply Valve
S7
NL VBS
Drive
Pump Cover Valves S10 & CSV Subsystem B1 Shift Valve

S9 NH VBS S3
S9 DR26
DR11 DR10 Line REV Supply Ball
DR9 S4
DR38 S4
NL D/I
DR41 DR18 L500
Blocked

Line
Line
Suction
Suction
SOL Supply Valve
DR19
Pump
B1 Subsystem
Line Line
REV
Line
Drive
3650-01
Line
P N
R D Dowel
Manual Valve
01-29
ACTYON SM - 2008.07
DSI M78
6 A/T
01-30 3650-01
E. Power Train - "D" (Drive) 3rd

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• C3 applied, drives Rear Planet Carrier
• Rear Planetary Gear Set is locked and the output is equal to the ratio of the Front Gear Set.
Control
• S1 ON moves C1 Shift Valve to the left end not allowing the application of the C1 Clutch.
• C2 Shift Valve is open allowing drive oil to engage C2 Clutch (S2 OFF).
• S3 & S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch.
NOTICE
• C3 Clutch cannot be engaged without S7 being ON and supplying pressure to the C3 Regulator Valve.

Gear
1.478 ON ON ON ON 1 0 1 0-1

AFFECTED VIN
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Line / Drive
Pressure
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
3rd Gear - C2 & C3 ON (1.478)

S5
S6
Cooler S5
Cooler Bypass
B1AI-EX
Bypass NH VBS B2AI C3

Valve Front serv
C1S DR25 BAF(B1AO)
DR35 DR36
S6
Cooler/Lube C1S
Regulator DR33 C2S
C1 Shift
S1 S2 Reverse
Valve C2 Shift Valve
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor S3 Valve
Shift
DR31
Release
Limit S10 S8
Convertor Regulator NL VBS DR17 NL VBS
Regulator S10 DR37
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
DR42 DR8
S7
NL VBS
Drive
B1 Shift Valve
S9 NH VBS S3
S9 Line DR26
DR11 DR10 REV Supply Ball
DR9 S4
S4
DR38 NL D/I
DR41 DR18 L500

Blocked
Primary Regulator Valve S9 Subsystem Line

B2 & C3 Subsystem
Suction
Line
Suction
SOL Supply Valve
DR19
Pump B1 Subsystem
Line Line
REV
Line
Drive
3650-01
Line
P N
R D
Manual Valve
Dowel
01-31
ACTYON SM - 2008.07
DSI M78
6 A/T
01-32 3650-01
F. Power Train - "D" (Drive) 4th - "D" (Drive) 4th Limp Home Mode
Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
Control
• S1 is OFF, S2 is OFF.
• Drive oil that engages C1 & C2 Clutches is regulated by S5 & S6 VBS, respectively for each clutch.
NOTICE
th
• 4 GEAR is used as a LHM state.

Gear
1.156 ON ON 0 0 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 DR22 DR39 DR40 C2 DR14
Rear serv
To cooler
Cooler C1 Regulator Valve C2 Regulator Valve
B2AI B1
S5
S6
Cooler S5 DR29
Cooler Bypass
B1AI-EX
Bypass NH VBS C3
Valve
B2AI
Front serv
4th & 4th LHM - C1 & C2 ON (1.156)
C1S DR25
BAF(B1AO)
S6 DR35 DR36
Cooler/Lube C1S
Regulator DR33 C2S
C1 Shift
Valve S1 S2 Reverse
Converter Release C2 Shift Valve LHM Valve
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor Valve
Shift S3
DR31
Release
Limit S10
Convertor Regulator NL VBS DR17
Regulator S10 DR37 S8
DR24 NL VBS
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
DR42 DR8
S7
S10 & CSV Subsystem NL VBS
Pump Cover Valves
Drive
B1 Shift Valve
S9 NH VBS S3
S9 DR26
DR11 DR10 Line REV Supply Ball
DR9
S4
S4
DR38 NL D/I
DR41 DR18 L500
Blocked

Line
Suction
Line
Suction
SOL Supply Valve
DR19
Pump B1 Subsystem
Line Line
REV
Line
Drive
3650-01
Line
P N
R D
Manual Valve
Dowel
01-33
ACTYON SM - 2008.07
DSI M78
6 A/T
01-34 3650-01
G. Power Train - "D" (Drive) 5th

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• C3 applied, drives RSG
Control
• S1 is OFF,S2 is ON, S3 is ON.
• C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch
• S3 ON and with S7 ON moves C3 Shift Valve to the left end allowing the application of C3 Clutch.
Elements engaged ON / OFF sole- Variable pressure valve-VBS

Gear
0.866 ON ON ON ON 0 1 1 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
5th Gear - C1 & C3 ON (0.866)
To cooler
B2AI B1
S5
S6
Cooler S5
Cooler Bypass
B1AI-EX
Bypass NH VBS C3
Valve
B2AI
Front serv
C1S DR25
BAF(B1AO)
S6 DR35 DR36
Cooler/Lube C1S
Regulator C2S
C1 Shift
Valve S1 Reverse
C2 Shift Valve S2
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
S3 Valve
Convertor
Shift
DR31
Release
Limit S8
Regulator S10 NL VBS
Convertor DR17
S10 NL VBS
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
S7
NL VBS
Drive
B1 Shift Valve
S9 NH VBS S3
S9 DR26
S4
S4
NL D/I
DR18 L500
Blocked
Primary Regulator Valve S9 Subsystem Line B2 & C3 Subsystem
Suction
Line
Suction
SOL Supply Valve
DR19
Pump
B1 Subsystem
Line Line
REV
Line
Drive
3650-01
Line
P N
R D
Manual Valve
Dowel
01-35
ACTYON SM - 2008.07
DSI M78
6 A/T
01-36 3650-01
H. Power Train - "D" (Drive) 6th

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• B1 applied to hold RSG
Control
• S1 is OFF, S2 is ON, S4 is ON.
• C1 Shift Valve is OPEN (S1 OFF) allowing drive oil to engage C1 Clutch
• S4 ON moves B1 Shift Valve to its left-end position allowing the engagement of B1 Band.

Gear
0.677 ON ON ON ON 0 1 1 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
6th Gear - C1 & B1 ON (0.677)

B2AI B1
S5
S6
Cooler S5
Cooler Bypass NH VBS
B1AI-EX
Bypass B2AI C3
Valve Front serv
C1S DR25
BAF(B1AO)
S6 DR35 DR36
NH VBS
Rear serv B1 Quick
C1S
Cooler/Lube
C2S
Regulator
C1 Shift
Valve S1 Reverse
C2 Shift Valve S2
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
S10 Valve
Convertor S3
Shift
DR31
Release
S8
Limit S10 DR17 DR37 NL VBS
Convertor Regulator NL VBS
S10
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
S7
NL VBS
Drive

B1 Shift Valve
S9 NH VBS S3
S9 DR26
S4
S4
NL D/I
DR18 L500
Blocked

Line
Line
Suction
Suction
SOL Supply Valve
DR19
Pump
B1 Subsystem
Line Line
REV
Drive
Line
Line
3650-01
P N
R D
Manual Valve
Dowel
01-37
ACTYON SM - 2008.07
DSI M78
6 A/T
01-38 3650-01
I. Power Train - Reverse

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT
• C3 applied, drives RSG
• B2 applied, holds Rear Planet Carrier stationary
Control
• S1 is ON, S2 is ON, S3 is ON.
• Line pressure is directed via Manual Valve to apply B2 Band directly.
• S3 ON allows ramping and regulating pressure supplied to the C3.
• S1 & S2 are ON not allowing engagement either C1 or C2 Clutch at any circumstances.

Gear
3.094 ON ON ON ON ON ON 1 1 1 0-1

AFFECTED VIN
Line / Drive
CHANGED BY
Pressure
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
Reverse - C3 & B2 ON (-3.094)

S5
S6
Cooler
S5
B1AI-EX
Bypass
Valve Cooler Bypass NH VBS B2AI Front serv
C3
DR25
C1S BAF(B1AO)
DR35 DR36
S6
C1S
Cooler/Lube C2S
Regulator C1 Shift
S1 S2 Reverse
Valve
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor S3 Valve
Shift
DR31
Release
S8
S10 Limit S10 DR17
Convertor DR37 NL VBS
Regulator NL VBS
Drive DR24
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
S7
NL VBS
S9 NH VBS S3
Drive
S9 DR26
S4 S4
DR38 NL D/I
DR18 L500
Blocked
Line
Suction
Suction
SOL Supply Valve
Pump DR19
Line
B1 Subsystem
Line
REV
Line
Drive
Line
3650-01
Filter Pump Cover Solenoid Supply Valve Subsystem

Exhaust
P N
R D
Manual Valve
Dowel

01-39
ACTYON SM - 2008.07
DSI M78
6 A/T
01-40 3650-01
J. Power Train - Reverse (Limp Home Mode)

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT

Gear
3.094 ON ON ON 0 0 0 0 0 0

AFFECTED VIN
Line / Drive
CHANGED BY
Pressure
AFFECTED VIN
EFFECTIVE DATE
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
Reverse at LHM - C3 & B2 ON
To cooler
S5
S6
Cooler
S5
B1AI-EX
Bypass
Valve Cooler Bypass NH VBS B2AI C3 Front serv
C1S DR25
BAF(B1AO)
S6 DR35 DR36
C1S
Cooler/Lube C2S
Regulator C1 Shift
Valve S1 S2 Reverse
B2 Supply Ball
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
Convertor S3 Valve
Shift
DR31
Release S8
S10 Limit S10 DR17 NL VBS
NL VBS DR34
Regulator C3/B2 Regulator Valve
Drive DR24
DR30 B1S
S10 Feed
DR23
Converter
Supply Valve
S7
NL VBS
Drive
S9 NH VBS S3
S9 DR26
S4 S4
DR38 NL D/I
DR18 L500
Blocked
Line
Suction
Suction
SOL Supply Valve
Pump DR19
B1 Subsystem
Line Line
REV
Line
Drive
Line
3650-01
P N
R D
Manual Valve
Dowel
01-41
ACTYON SM - 2008.07
DSI M78
6 A/T
01-42 3650-01
K. Power Train - Parking

Power flow diagram
B1 B1
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT

Gear
N/A ON ON ON 1

AFFECTED VIN
Park
CHANGED BY
AFFECTED VIN
Line / Drive
EFFECTIVE DATE
Pressure
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
S5
S6
S5
B1AI-EX
Cooler NH VBS
Bypass Cooler Bypass C3
Valve B2AI Front serv
C1S BAF(B1AO)
DR36
S6
C1S
Cooler/Lube C2S
Regulator
C1 Shift
S1 Reverse
Converter Release B2 Supply Ball LHM Valve
S1 S2
NL D/I B2 feed
Blocked NL D/I
B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
S10 S3 Valve
Convertor
Shift
DR31
C1 Subsystem L500 B1 Regulator Valve
C3S
Release
Limit S8
S10 DR17 NL VBS
S10 NL VBS
DR24
Drive B1S
DR30
S10 Feed
Converter DR23
Supply Valve
S7
NL VBS
S9 NH VBS S3
S9 Line REV Supply Ball
Drive
S4
S4
L500 NL D/I
DR18
Blocked

Line
Suction
Line
L500
Suction
SOL Supply Valve
DR19
Pump B1 Subsystem
Line Line
REV
Drive
Line
Line
3650-01
P N
R D
Manual Valve
Dowel

01-43
ACTYON SM - 2008.07
DSI M78
6 A/T
01-44 3650-01
L. Power Train - Neutral

Power flow diagram
B1 B2
C3 Ring gear
C2
Long Pinion
Ring gear
C1 Reverse Short
Pinion Sun
1-2 Pinion
IN Sun OUT

Gear
N/A ON ON ON 0-1

AFFECTED VIN
Line / Drive
Pressure
CHANGED BY
AFFECTED VIN
EFFECTIVE DATE
Neutral
Solenoid Suppl
Pressure
Culture Pressure
Cooler Pressure
C1 C2
Rear serv
To cooler
S5
S6
Cooler
S5
B1AI-EX
Bypass
Valve Cooler Bypass NH VBS
B2AI C3 Front serv
C1S DR25
BAF(B1AO)
DR35 DR36
S6
C1S
Cooler/Lube C2S
Regulator C1 Shift
Valve S1 Reverse
C2 Shift Valve S2
B2 Supply Ball
S1 S2
NL D/I B2 feed
NL D/I
Blocked B2 Shift Valve
DR21
C3 Shift Valve
Exhaust
S10 S3 Valve
Convertor
Shift
DR31
Release
Limit S8
S10 S10 DR17
Regulator DR37 NL VBS
Convertor NL VBS
DR24
Drive
DR30 B1S
S10 Feed
Converter DR23
Supply Valve
S7
NL VBS
Drive
S9 NH VBS S3
S9 DR26
S4
DR38 S4
NL D/I
DR18 L500
Blocked

Line
Line
Suction
Suction
SOL Supply Valve
DR19
Pump B1 Subsystem
Line Line
REV
Line
Drive
Line
3650-01
Pump Cover Solenoid Supply Valve Subsystem Exhaust

Filter
P N
R D
Manual Valve Dowel

01-45
ACTYON SM - 2008.07
DSI M78
6 A/T
01-46 3721-01
3721-01 TGS LEVER
A. Overview
The TGS lever prevents inappropriate or unexpected shifting of gears to increase safety. It also helps the driver
safely select a needed gear. The solenoid of the TGS lever has the factory-installed “P” Lock function which
allows the driver to shift gears from the "P" ± position only when the brake pedal is depressed.
Because drivers of vehicles without this system can shift gears by only operating the gear selection lever,
their safety and convenience are limited. Sometimes, the vehicles’ gears can be changed unexpectedly or
unintentionally by various factors. Therefore, two tip switches are installed to prevent such changes from
happening.
For instance, when a vehicle is running on a severely curved road, the driver must hold the steering wheel with two
hands. Shifting gears or using the engine brake while driving on the road will be dangerous. So, one tip switch is
installed on the steering wheel. The other tip switch is installed on the knob to prevent unintended gear shifting.
This system is only activated when the TGS lever is engaged in the “M” position. When the lever is pushed to
the “D” position, the tip switches will not change gears.
Mounting Location and Components
Tip switch (-) Tip switch (+) TGS lever knob
TGS lever

AFFECTED VIN
3721-01 01-47
B. Functions of Selector Lever
DSI M78
6 A/T
P D D M
P: Parking
The engine can start. The parking pole stops the driving wheels from rolling.
To move the lever from “P” to another position, the brake pedal must be depressed (Parking Lock System).
R: Reverse
By switching between the Standard and Winter switches, the reverse speed can be changed. The change
should be made before shifting the selector lever to the “P” position.
N: Neutral, Engine Starting or Towing
It is possible to start the engine. This position is also for a brief stop or towing the vehicle. When towing the
is vehicle, the towing speed should be 50 km/h or less and the towing distance should not exceed 50
kilometers. It is more recommended to load this vehicle on a flat-bed towing vehicle.
D: 1~6 Gears
This position is for normal driving on paved roads or high speed driving. The gear ratio of the 6th gear is 0.68:1.

AFFECTED VIN
01-48 3721-01
C. Manual Mode (M) of TGS Lever
TIP(+)
TIP(-)
This allows the driver to define the highest possible gear by selecting "+" or "-" on the gear selector when the lever is
in the "M" position. When the lever is first moved to the manual "M" position the transmission will select the lowest
possible gear.
When maximum engine rpm is reached the transmission will upshift automatically regardless of the driver
selected limit. 4WD models with low range will not automatically upshift when low range is selected.
6: 1~6 gears (only available in the “M” position)
The 4th gear state will display on the instrument cluster. 4-3, 4-2 and 4-1 automatic kick-down shifts are
available. 4th gear has engine braking available.
The 3rd gear state will display on the instrument cluster. 3-2 and 3-1 automatic kick-down shifts are available.
3rd gear has engine braking available.
The 2nd gear state will display on the instrument cluster. 2-1 automatic kick-down shifts are available. 2nd
1: 1 gears (only available in the “M” position)
The 1st gear state will display on the instrument cluster. Unlike the normal 1st gear, engine braking will be
available in this manual 1st state.

AFFECTED VIN
3721-01 01-49
D. Shift Mode
DSI M78
6 A/T
(1) Activating the Manual Mode (M Mode)
To prevent any wrong shifting down or up in the “D” position, the manual mode can be activated only in the “M”
position.
When both tip switches on the steering wheel and the knob send out shifting up or down signals in the M
mode to the controller of the selector lever, the controller only accepts the first signal and ignores the second
signal.
When the driver briefly touches or continuously pushes one of the up or down shifting tip switch in the M
mode, the signal is sent to the TCU. When the driver pushes and holds the switch, the TCU shifts down one
or two gears without any jerking. If the driver briefly touches the switch once, the TCU shifts up or down gears
one by one.
(2) When switching from D to M

When the selector lever is pushed from the D position to the M mode, the M mode sensor detects this change
and sends a signal to the TCU, and the TUC shifts down one or two gears without any jerking. This means the
newly engaged gear in the M mode is the one-level lower gear from the D position.
For example, when the selector lever is pushed from the D position to the M mode, the transmission will
automatically switch the 3rd gear to the 2nd gear. This basic working algorithm can automatically be adjusted
depending on various driving conditions, and the same gear will be used after switching to the M mode. For
example, if the vehicle is moving at high speed with the 6th gear in the D position, the same gear will still be
used in the M mode to protect the transmission.
(3) When switching from M to D

When the selector lever is pushed to the D position from the M mode, the M position sensor detects the
change and sends another signal to the TCU. Then, the TCU enables the transmission to choose from all
available gears including the highest one (the D position).

AFFECTED VIN
01-50 3721-01
Circuit description
6AT Inhibitor SW
To Start Relay J3(7)

2 6
(Output Ignition Signal)
J3(17)
1 5
IGN Power Backup Lamp SW
4 3
TCU
UP/Down Tip SW J2(4)
IGN Power
Winter Mode SW
J3(6)
Brake Signal Range Active(M)
J2(10)
4 5 8 3 1 2 6
TGS
Steering Wheel Range SW
NOTE
For the MB 5 AT model, the TGS lever sends signals for the backup lamp operation and parking aid sys-
tem in the position “P” and engine starting in the position “N”. However, this function is performed by the
inhibitor switch for the vehicle equipped with the 6-speed A/T.
10
9
1

AFFECTED VIN
3721-01 01-51
E. Mode Switch
DSI M78
6 A/T
The mode switch is installed next to the Selector Lever as shown in the picture. It has the Standard (S) and
Winter (W) modes.
• The S mode is for driving under normal conditions and uses the 1st gear to start off. It also ensures more
enjoyable driving by analyzing the driver’s driving habits and changing shifting patterns according to the
habits.
(Degree holding on a hilly road: approximately 11~13.5% or less)
• When the W mode is selected, the Winter lamp comes on the instrument panel. The mode uses the 2nd
gear for the vehicle’s smooth driving off.
With the Winter mode, 2WD- and AWD-models have fast up-shifts and slow down-shifts to increase gas
mileage. When these models use the full throttle, the Winter mode automatically switches to the Standard
mode. However, in case of 4WD-models, the Winter mode will stay on even with the full throttle.
In spite of the Winter mode being selected, the transmission will use only the 1st gear to start off under the
following conditions:
1. When the Selector Lever is engaged to the M mode and a tip switch is used to shift down to the 1st gear
2. In case of 4WD-models (inapplicable to 2WD- or AWD-models), when the full throttle is attempted at 25
Km/h or slower speed, the Mode switch sends out a control signal from the Selector Lever unit to the TCU
through hard wires.

AFFECTED VIN
01-52 3721-01
F. Parking lock system

Function description
1. Selector Lever
2. Shift Pattern Display
3 3. Selector Lever Handle
4. Parking Lock Release Flap
5. Selector Lever Control Unit
1 (Internally Installed)
6. Mode Switch
6 2
4
5
The parking lock system is built in the selector lever unit as shown in the figure.
The wiring to detect the brake switch is connected to the selector lever unit so that the system detects the
brake switch operation signal for allowing shift from the “P” to other positions.
This system is a safety measure to prevent the selector lever from moving unless the brake pedal is depressed.
Shift Lock Solenoid Function

Unless the ignition switch is turned to “ON” and the
brake pedal is pressed, the Selector Lever Unit does
not activate the P Locking solenoid and the Selector
Lever (A) stays locked. In this situation, the lock le-
ver (D) is engaged to the P Lock position and the
Locking Lever Tap (C) holds the Lock Lever (B).
Therefore, the Selector Lever cannot be shifted to
other positions.

AFFECTED VIN
3721-01 01-53
Shift Lock Solenoid Function
DSI M78
6 A/T
Input Output
Lever Speed (Lock Solenoid Others
Ignition Brake
Position (Km/h) Position)
X OFF X X 1 OFF
P ON OFF X 1 OFF P LOCK
P ON ON X 2 ON
P-R ON X X The last: utilize useful
gear positions
R ON X X 2 OFF
R-N ON X X The last: utilize useful
gear positions
N ON X X 2 OFF
N-D ON X X The last: utilize useful
gear positions
D ON X X 2 OFF
Lock Position P
1 LOCK
2 UNLOCK

AFFECTED VIN
01-54 3721-01
G. Selector Lever Control Unit

Function and Usage
The Selector Lever Unit performs the following:
A. Informs the TCU of the Selector Lever’s position between the D and M modes though hard wires
B. Turns on the Selector Lever Illumination
C. Activates the Parking Lock system
10
9
1
Each Pin’s Function
Pin number Function Reference

1 W/S Switch Output TCU
2 Manual Mode Output TCU
3 Up/Down Tip Shift Output (KNOB) TCU
4 Ground
5 Brake Pedal Switch Signal Input Parking Lock Operation
6 Ground (M/MODE, W/S TIP SWITCH)
7 Not used
8 Ignition (Power)
9 No pin
10 No pin

AFFECTED VIN
3721-01 01-55
Electric Circuit
DSI M78
6 A/T
6A/T Valve Body
J2(12) VBS Solenoid 9
Diagnosis Connector J1(1) J4(6)
VBS Solenoid 10
J1(2) J4(7)
6AT Inhibitor SW
VBS Solenoid 7
J1(3) J4(4)
Starting Gear Lever SIG
J5(2) J5(6) J3(7)
Relay VBS Solenoid 8
J1(4) J4(5)
J5(1) J5(5) Gear Lever GND
J1(5) J4(2)
VBS Solenoid 6
J1(6) J4(3)
J5(4) J5(3) Backup Lamp
Backup Lamp Signal Power VBS Solenoid GND
J1(7) J4(1)
ON/OFF Solenoid 2
J1(9) J4(22)
LO J2(7)
CAN ON/OFF Solenoid1
HI J2(1) J1(10) J4(21)
TCU J1(11)
ON/OFF Solenoid 4
J4(24)
TGS Range Control ON/OFF Solenoid 3
J2(4) J1(12) J4(23)
IGN Winter Mode (DSL)
J3(6)
Range Active(M) J1(15) ON/OFF Solenoid GND J4(20)
Stop Lamp SW J2(10)
Input Speed Sensor
J3(1) J4(10)
4 5 8 3 1 2 6 EMM/Speed Sensor Supply Votage
J3(2) J4(9)
Input Speed Signal

TGS Lever(DURA) J3(3) J4(11)
EMM Data
J3(4) J4(12)
GND J3(15) Input Fluid Temperature Sensor
J3(8) J4(26)
Steering Wheel EMM/Speed Sensor GND
J2(9) J3(12) J4(8)
Steering Wheel Range
EMM Clock
J3(14) J4(13)
J1(8) Fluid Temperature Sensor Return
J3(18) J4(25)

AFFECTED VIN
01-56 3680-01
3680-01 DSI M78 6-Speed A/T Assembly
A. Appearance
Torque converter
Oil cooler outlet Oil cooler return
Servo
Adapter housing
Inhibiter switch

AFFECTED VIN
3680-01 01-57
B. INTERNAL ASSEMBLY FIGURE
DSI M78
6 A/T
4WD
2WD

AFFECTED VIN
01-58 3680-01
C. DSI M78 6-Speed Automatic Transmission
Oil Pump
The hydraulic oil pump transfers transmission oil

(approximately 17.6 cc per revolution) and is installed
between the torque converter and the transmission
housing.
Torque Converter
The torque converter is installed between the en-

gine and the transmission. It is consisted of the
impeller, turbine, stator, lockup clutch, and one-
way clutch.
Valve Body

Variable Bleed Solenoid – Normal Low – Normal High
Input Speed Sensor Variable Bleed Solenoid
Intake Port – Normal High
Variable Bleed Solenoid – Normal Low
– Normal High
ON/OFF Solenoid
The valve body has four ON/OFF solenoid valves and six variable bleed solenoid valves.

AFFECTED VIN
3680-01 01-59
DSI M78
6 A/T
Clutch Pack
The three multi-plate clutches are the front (C1), center (C2) and rear (C3) clutches. They are set to the planetary
gear. Each multi-plate clutch has an internal friction disk and an external friction disc. The former is installed to
the internal friction disc carrier, and the latter is installed to the external friction disc carrier. When hydraulic
pressure is applied to the piston of the multi-plate disc clutch, the pressure is also applied to the inside of the
disc and the external disc.
Double Planetary Gear Set
The double planetary gear set is installed to

the spline unit of the output shaft. The set
has the sun gear (forwarding/reversing), pin-
Inhibitor Switch Simple Planetary Gear Set

The inhibitor switch is installed on the side of the
transmission. Depending on the position of the Se-
lector Lever, it sends out different signals to the TCU. The simple planetary gear set is driven by
Also, it prevents the engine from starting when the the input shaft, and it has the sun gear, pin-
lever is not engaged in either the “P” or “N” position. ion gear, carrier, and ring gear.

AFFECTED VIN
01-60 3680-01
D. Components of DSI M78 6-speed A/T Assembly

(1) PLANERTARY GEAR SET
Single Planetary Gear-set
The single planetary gear-set overdrive carrier is driven

F5#☯᳻᚟ by the input shaft.
C2 Cylinder
F5#☯᳻᚟#
Ring Gear
ᴌᅻ⣿
Pinion Planet
The single planetary gear-set consists of:
㢇ᘓ⤃#ᅻ⣿
Input Shaft Sun⑫ᅻ⣿
Gear • One sun gear
⫐᭰ム
• Three planetary gears meshing with sun gear
(C2 cylinder)
• One planetary gear carrier
• One ring gear (C1 cylinder)

AFFECTED VIN
3680-01 01-61
DSI M78
6 A/T
Double Planetary
The double planetary gear-set is splined to the out-

put shaft.
⨛⨳⪿㎿ᬷㆣ
One Way Clutch Ring Gear
ᴌ#ᅻ⣿ The double planetary gear-set consists of:
Pinion Planet Long
ᮼ#㢇ᘓ⤃#ᅻ⣿ • Two sun gears (forward and reverse)
㨏ⴏ#⑫ᅻ⣿
Reverse Sun Gear • Three short planetary gears meshing with sun gears
• Three long planetary gears meshing with sun gears
• One planetary gear carrier
• One ring gear
Forward
⭏ⴏ#⑫ᅻ⣿ Sun Gear
Pinion Planet Short

ⴲ⪋#㢇ᘓ⤃#ᅻ⣿
㈳㘃ᮯ#⑧㜷㘃
Centre Support

AFFECTED VIN
01-62 3680-01
(2) Clutches and Brake Bands
Other shift elements in addition to the torque con-

verter lock-up clutch are:
F4#㎿ᬷㆣ#㡗᭓⪿㘃
C2 Cylinder C1 Clutch Plate Cluster
㎿ᬷ◯㑻
• Three rotating multi-plate clutches C1, C2 & C3
F5#☯᳻᚟
- C1 Clutch drives the Rear Planet Carrier (4th, 5th
C1 Piston
F4#㢇◯㓯
& 6th gear).
Space for
ᘯ⪿Ꮳὄ#⩫⢠#
Dynamic - C2 Clutch drives the Forward Sun Gear (1st, 2nd,
ᄫᠼ㦟᳇#⩏㢧
Pressure
၀ཏ
Equalisation
3rd & 4th gear).
Input Shaft
⫐᭰ム F5#၀ᅔ
C2 Feed
- C3 Clutch drives the Reverse Sun Gear (3rd, 5th
& REVERSE).
• Two brake bands (front and rear)
- B1 (Front) Band holds the Reverse Sun Gear
Converster
㈳῏㑻 C1 Feed
F4#၀ᅔ
Release
(RSG) stationary when activated (2nd & 6th gear)
㢿⭧
- B2 (Rear) Band holds the Rear Planet Carrier
stationary when activated (MANUAL 1 st &
REVERSE).
Struts
◯㘃ᬷ㘃 C3 Cylinder
F6#☯᳻᚟
The multi-plate clutches are equalised in terms of
dynamic pressure. Its piston is exposed to the trans-
Reverse Sun Gear
㨏ⴏ#⑫ᅻ⣿
mission fluid flow on both sides in order to prevent
Forward Sun Gear
⭏ⴏ#⑫ᅻ⣿ pressure build up in the clutch as the speed of rota-
tion increases. This pressure equalisation is achieved
by a piston dam. The advantages of this dynamic
pressure equalisation are:
• Reliable clutch engagement and release in all
speed ranges
Front
㡏ᬻ㘃#὿ᠧBand • Improved shift refinement
C3 Sealing Rings
F6#☯ᴌ#ᴌ

AFFECTED VIN
3680-01 01-63
(3) Torque Converter
DSI M78
6 A/T
The torque converter contains a single plate lock-up
㓫⥯㎷#㈳῏㑻 clutch. The lock-up clutch can be controlled and en-
Torque Converter
ᮨ⤐#㎿ᬷㆣ⤛#
Lock-up Clutch ㈯῏
Cover
gaged in any forward gear. The clutch is applied by
⤻࿻ᝧ#㡗᭓⪿㘃
Lined Plate removing transmission fluid pressure from one side
㑻↓
Turbine of the plate and applying pressure to the other. The
torque converter transmits and multiplies torque. The
Impeller
⫏㛫ᬷ
torque converter is a three-element device consist-
ing of:
Lock-up • Impeller assembly
ᮨ⤐#㎿ᬷㆣ#
Clutch ◯㒗⪿㑻#
Stator
㢇◯㓯Piston • Turbine assembly
Space • Stator assembly
Behind ◯㒗⪿㑻#
Stator-One
ᮨ⤐#㎿ᬷㆣ#
Lock-up ⨛⨳⪿#
Way Clutch
៯⸈#၀ཏ
Clutch ㎿ᬷㆣ

AFFECTED VIN
01-64 3680-01
Operation description
The standard torque converter components operate as follows:
• The impeller, which is driven by the engine, imparts a circular flow to the transmission fluid in the converter.
• This transmission fluid strikes the turbine wheel, which causes the flow to change its direction.
• The transmission fluid flows out of the turbine wheel close to the hub and strikes the stator where its
direction is changed again to a direction suitable for re-entering the impeller.
• The change in direction at the stator generates a torque reaction which increases the torque reaching the
turbine.
• The ratio between turbine and impeller torque is referred to as torque multiplication or conversion.
• The greater the difference in speed or rotation at the impeller and turbine, the greater the increase in torque.
The maximum increase is obtained when the turbine wheel is stationary. As turbine wheel speed increases,
the amount of torque multiplication gradually drops.
• When the turbine wheel is rotating at about 85% of the impeller speed, torque conversion reverts to one,
that is to say torque at the turbine wheel is no higher than the torque at the impeller.
• The stator, which is prevented from rotating backwards by a one-way clutch and the shaft in the transmis-
sion housing, runs freely in the transmission fluid flow and overruns on the one-way clutch. From this point
on, the converter acts only as a fluid coupling.
• During the torque conversion process, the stator ceases to rotate and bears against the housing by the
one-way clutch.
Torque Converter Lock-up Clutch

- The torque converter lock-up clutch is a device which eliminates slip in the torque converter and therefore
helps to keep fuel consumption to a minimum.
- The torque converter lock-up clutch includes a cooling nozzle which allows for torque converter slip control.
This functionality allows for partial torque converter lock-up at lower than normal engine rpm, which im-
proves fuel economy.
- The torque converter lock-up clutch is engaged and released via the control system.
Pressure at the torque converter lock-up clutch piston is determined by an electronic variable bleed sole-
noid (VBS).
The torque converter lock-up clutch can be controlled and engaged in any forward gear.
- When the torque converter lock-up clutch is released, transmission fluid pressure behind the lock-up clutch
piston turbine area is equalised. The direction of flow is through the turbine hub and the area behind the
piston into the turbine area.
To engage the torque converter lock-up clutch the direction of transmission fluid flow is changed by a valve
in the transmission pump.
- At the same time the space behind the torque converter lock-up clutch piston is vented. Fluid pressure
extends from the turbine area to the torque converter lock-up clutch piston and presses it against the cover
of the torque converter. This locks the turbine wheel between the piston and the cover and enables the drive
to pass with limited slip to the planetary gear train in normal operating conditions.

AFFECTED VIN
3680-01 01-65
(4) Fluid Pump
DSI M78
6 A/T
- The fluid pump is a parachoidal type pump deliv-
ering approximately 17.6 cc of transmission fluid
Pump Body
㛗㡏#Ὗᡟ per revolution.
It is located between the torque converter and the
ᠧ᳷⅛#ᅻ⣿
Driven Gear
Driving Gear transmission housing.
ᠧ᫇⪿↤#ᅻ⣿
Sun Gear - The torque converter is supported in the fluid pump
Seal Oil-Front Pump
⥯⫇#☯#㡏ᬻ㘃#㛗㡏 ⑫ᅻ⣿
by a plain bush bearing. The fluid pump is driven
directly from the engine by the torque converter
Plain Bush
㡗᫣⫃#⃋☧ cover and supplies transmission fluid directly to
Bearings
Ύ⣿ᴌ
the valve body and transmission.
- The fluid pump draws in transmission fluid through
Support
⑧㜷㘃#㗧⅗ Tube
a filter and delivers it at high pressure to the valve
body.
Oil Ring-Square
⥯⫇#ᴌ#⏷ཌ#⒄⒣Section
+㛗㡏Ὗᡟ,(Pump Body)
Oil Seal
⥯⫇#☯

AFFECTED VIN
01-66 3680-01
3680-01 VALVE BODY
A. Overview
The valve body contains four on/off solenoid valves and six variable bleed solenoids. The on/off solenoid valves
are actuated by the TCU and maintain two positions; open and closed. These valves are used to switch the
shift valves.
The variable bleed solenoids convert an electric current into a proportional hydraulic pressure. They are
energised by the TCU and supply variable pressure to each of the clutch or bands dedicated regulator valves.
Mounting view
Detent Spring Embedded Memory Module
Manual Valve
Input Speed Sensor

Intake Port
NOTE
Location of valve body wiring connector
Unit view

Variable Bleed Solenoid – Normal High
– Normal Low
Input Speed Sensor – Normal High
Intake Port Variable Bleed Solenoid
– Normal Low
ON/OFF Solenoid
– Normal High

AFFECTED VIN
3680-01 01-67
B. Description of Connector Pins
DSI M78
6 A/T
Connector Front View
Connector J4
Terminal / Pin Function Terminal / Pin Function

J4-1 VBS Solenoid Return J4-14 -
J4-2 VBS Solenoid 5 J4-15 -
J4-7 VBS Solenoid 10 J4-20 On/Off Solenoid Return
J4-8 EMM Data / Speed Sensor Ground J4-21 On/Off Solenoid
J4-9 EMM / Speed Sensor Supply Voltage J4-22 On/Off Solenoid
J4-10 Output Speed J4-23 On/Off Solenoid
J4-11 Input Speed J4-24 On/Off Solenoid
J4-12 Embedded Memory Module Data J4-25 Transmission Fluid Temperature Return
J4-13 Embedded Memory Module Clock J4-26 Transmission Fluid Temperature Input

AFFECTED VIN
01-68 3680-01
C. Sensor Inputs
Brake Pedal Position Switch
The brake pedal position (BPP) switch tells the TCU when the brakes are applied. The BPP is also used to
disengage the transmission gear selector (TGS) interlock when moving out of the Park position and as part of
the shifting strategy.
Engine Intake Temperature Sensor

The engine intake temperature (EIT) sensor detects intake air temperature and supplies the information to the
TCU.
Barometric Pressure Sensor

The barometric pressure (BARO) sensor detects the current air pressure and supplies the information to the
TCU.
Accelerator Pedal Position Sensor

The accelerator pedal position (APP) sensor is a potentiometer mounted on the accelerator pedal. The APP
sensor detects the position of the accelerator pedal and sends this information to the TCU. The APP sensor
signal is used for shift scheduling and TCC lock-up.
Input Shaft Speed Sensor

The input shaft speed (ISS) sensor is a hall effect type sensor.
The ISS sensor is mounted internally in the transmission and is located on the valve body.
Input Speed Sensor /

Embedded Memory Module

AFFECTED VIN
3680-01 01-69
Output Shaft Speed Sensor
DSI M78
6 A/T
The output shaft speed (OSS) sensor is a hall effect
type sensor.
The OSS sensor is mounted internally in the trans-
mission and is located at the rear of the transmis-
sion main case.
Transmission Fluid Temperature Sensor

The TCU utilises one transmission fluid temperature sensor located in the valve body wiring loom. The TCU
uses the sensor input to activate various shift strategies. The sensor is in the form of a temperature dependant
resistor.
The temperature sensor performs plausibility checks on each sensor reading. If the inputs from the tempera-
ture sensor are outside the working range it is possible the sensor is either short or open circuit.

AFFECTED VIN
01-70 3110-01
3110-01 TCU
A. Mounting location
TCU
TCU (Installed under the driver’s seat)
B. Unit Connector Description
(A) (B) (C)
( ) : EWD
Connector J1 (A)

J1-1 VBS Solenoid 9 J1-9 On / Off Solenoid 2
J1-7 VBS Solenoid Return J1-15 On / Off Solenoid Return
J1-8 Ground J1-16 Ignition Supply Voltage

AFFECTED VIN
3110-01 01-71
Connector J2 (B)
DSI M78
6 A/T
J2-1 CAN High J2-7 CAN Low
J2-2 - J2-8 -
J2-3 - J2-9 Steering Wheel Range Control
J2-4 Transmission Gear Selector Range Control J2-10 Range Active
J2-5 - J2-11 -
J2-6 - J2-12 -
Connector J3 (C)

J3-1 Output Speed J3-11 -
J3-2 EMM / Speed Sensor Supply Voltage J3-12 EMM / Speed Sensor Ground
J3-3 Input Speed J3-13 -
J3-4 Embedded Memory Module Data J3-14 Embedded Memory Module Clock
J3-5 - J3-15 Switch Ground
J3-6 Mode J3-16 -
J3-7 Gear Lever J3-17 Gear Lever Ground
J3-8 Transmission Fluid Temperature J3-18 Transmission Fluid Temperature Return
J3-9 - J3-19 -
J3-10 - J3-20 -

AFFECTED VIN
01-72 3110-01
C. Electric Circuit
Wiring Diagram
6A/T Valve Body

Diagnosis Connector J1(1) J4(6)
VBS Solenoid 10
J1(2) J4(7)
6AT Inhibitor SW
VBS Solenoid 7
J1(3) J4(4)
Starting Gear Lever SIG
J5(2) J5(6) J3(7)
Relay VBS Solenoid 8
J1(4) J4(5)
J5(1) J5(5) Gear Lever GND
J1(5) J4(2)
VBS Solenoid 6
J1(6) J4(3)
J5(4) J5(3) Backup Lamp
Backup Lamp Signal Power VBS Solenoid GND
J1(7) J4(1)
ON/OFF Solenoid 2
J1(9) J4(22)
LO J2(7)
CAN ON/OFF Solenoid1
HI J2(1) J1(10) J4(21)
TCU J1(11)
ON/OFF Solenoid 4
J4(24)
TGS Range Control ON/OFF Solenoid 3
J2(4) J1(12) J4(23)
IGN Winter Mode (DSL)
J3(6)
Range Active(M) J1(15) ON/OFF Solenoid GND J4(20)
Stop Lamp SW J2(10)
Input Speed Sensor
J3(1) J4(10)
4 5 8 3 1 2 6 EMM/Speed Sensor Supply Votage
J3(2) J4(9)
Input Speed Signal

TGS Lever(DURA) J3(3) J4(11)
EMM Data
J3(4) J4(12)
GND J3(15) Input Fluid Temperature Sensor
J3(8) J4(26)
Steering Wheel EMM/Speed Sensor GND
J2(9) J3(12) J4(8)
Steering Wheel Range
EMM Clock
J3(14) J4(13)
J1(8) Fluid Temperature Sensor Return
J3(18) J4(25)

AFFECTED VIN
3650-01 01-73
3650-01 INHIBITOR SWITCH
DSI M78
6 A/T
The TCU uses the position of this switch to deter-
mine the position of the selector lever.
The selector lever is connected to the transmission
via a linkage mechanism which operates the trans-
mission selector shaft between positions Park,
Reverse, Neutral and Drive.
The inhibitor switch contains set resistances for each
position which are read by the TCU. The TCU uses this
information to control the shifts to reverse and drive.
For models equipped with manual mode, the TCU
detects the driver's choice of manual range selection
Inhibitor Switch (+ or -) by means of switches directly connected to
the selector lever and/or steering wheel.
Movement of the lever between Park, Reverse, Neu-
tral and Drive manually controls the flow of transmis-
sion fluid, the TCU having control of the forward gear
selected in Drive.
If the lever is not in the Park or Neutral positions, or
if the switch is disconnected, starting of the engine
is inhibited.
(1) Description of Connector Pins
Connector J5

J5-1 Reverse Ground J5-4 Gear Lever Ground
J5-2 Starter Circuit J5-5 Gear Lever
J5-3 Starter Ground J5-6 Reverse Circuit

AFFECTED VIN
01-74 9201-01
9201-01 FLUID LEVEL INSPECTION
NOTE
• As the temperature of the transmission fluid greatly affects the fluid level, this procedure must only be
carried out with the transmission fluid temperature below 50°C). If the transmission fluid temperature
is greater than 50°C and the correct procedure is not followed, the result could be a false reading of
the fluid level.
• Fluid level inspection must be carried out with the vehicle level.
• Caltex PED 1712 ATF must be used.
1. Raise the vehicle on a certified hoist.

2. Place a drain container below the fluid level hole
and remove the transmission fluid level plug (1).
3. If fluid starts to drain from the fluid level hole, rein-
stall the fluid level plug. If no fluid drains from the
fluid level hole, fill the transmission until fluid starts
to drain from the level hole and reinstall the plug.
4. Drive the vehicle for approximately five minutes.
5. Connect the vehicle’s diagnostic scan tool to the
vehicles diagnostic connector. Refer to the vehicle
repair manual for information on connecting the
scan tool.
A
6. With the gear select lever in the Neutral position,
start the engine and allow to run at idle until the
transmission fluid temperature reaches 50°C.
8. When the transmission fluid temperature reaches
50°C turn off the engine.
and remove the transmission fluid level plug. Al-
low transmission fluid to drain from the fluid level
hole for 50 seconds. 30 ~ 35 Nm
10.Reinstall the fluid level plug and tighten the plug
to the correct torque specification.
Transmission fluid level plug

30 ~ 35 Nm
torque specification
11. Lower the vehicle to the ground and road test the vehicle to check vehicle operation and for fluid leaks.
NOTICE
• The oil level should be checked while the vehicle is stationary on a level ground.

AFFECTED VIN
3650-01 01-75
3650-01 TRANSMISSION RESET PROCEDURE
DSI M78
6 A/T
(REPLACEMENT TRANSMISSION)
It is necessary to reset the adaptive data stored within the transmission control unit (TCU) when the transmis-
sion and or TCU have been replaced.
A. Green Offset Reset

Carried out when a replacement transmission has been installed in a vehicle.
Green Offset Reset Procedure

To perform a green offset reset procedure, proceed as follows:
1. Connect the vehicle’s diagnostic scan tool to the vehicles diagnostic connector. Refer to the vehicle repair
manual for information on connecting the scan tool.
2. With the transmission gear select (TGS) lever in Park, turn the ignition key to the ON position (engine not
running).
3. Using the scan tool, set the parameter Set Km Travelled to 0Km.
4. Run the task Activate Adaptive Green Offset.
5. Turn the ignition key to the OFF position.
6. Start the vehicle and check for normal operation.
B. Adaptive Reset
Carried out when one of the following has occurred:
• Replace transmission
• Replace TCU
Adaptive Reset Procedure

To perform an adaptive reset procedure, proceed as follows:
running).
3. Set the parameter Set Km Travelled to 0 Km.
4. Run the task Reset Adaptive Data.

AFFECTED VIN
01-76 3650-01
3650-01 DSI M78 6-SPEED A/T ASSEMBLY

Remove the transfer in case of 4-wheel drive vehicle. For removal and installation of the
transfer case, refer to the “Transfer Case” section.
1. Disconnect the transmission connector.
2. Remove the locking pin from the shift lever

onnecting rod.
3. Remove the caps from the torque converter mounting bolt hole and then remove six mounting bolts (13M)
from the torque converter.
NOTICE
• Turn the crankshaft so that each mounting bolt
is placed at bolt hole, and remove one by one.
Torque converter
mounting bolt hole

AFFECTED VIN
3650-01 01-77
DSI M78
6 A/T
4. Remove two union bolts from the oil cooler pipe.
5. Remove mounting bolts from the oil cooler pipes (LH/RH).
6. Unscrew the mounting bolts and remove the automatic transmission housing.

AFFECTED VIN
01-78 3660-01
3660-01 VALVE BODY
1. Remove the negative battery cable.

2. Remove the drain plug and drain the oil completely.
25 ~ 35 Nm (18 ~ 26 lb-ft)
3. Unscrew nine mounting bolts and remove the oil

pan.
4 ~ 6 Nm
NOTICE
• Remove the oil pan slowly while keeping its
level not to spill oil from it.
4. Remove the mounting clamp from the oil filter.
5. Remove the oil filter.

AFFECTED VIN
3660-01 01-79
DSI M78
6 A/T
6. Disconnect the solenoid valve connectors.
7. Remove the bolt from the valve body ground.
8 ~ 13 Nm
8. Unscrew the mounting bolts and remove the valve

body from the transmission.

AFFECTED VIN
01-80 3110-01
3110-01 TCU
Disconnect the negative battery cable.
1. Move the driver's seat forward and unfold the cut

section of the carpet.
2. Remove the TCU mounting bolts (10 mm, LH/RH).
10 Nm
4. Disconnect the connector and remove TCU.

AFFECTED VIN
3721-01 01-81
3721-01 TGS LEVER
DSI M78
6 A/T
- Disconnect the battery ground cable.
- Place the selector lever into the position “D”.
Apply the parking brake lever.
Center fascia lower cover
TGS lever knob
Center console
TGS lever knob
Selector lever cover
1. Remove the TGS lever knob.

a. Open the TGS lever knob cover and remove the
mounting screw with a cross-slotted screwdriver.
NOTICE
• Apply LOCTITE to the mounting screw when
installing it.
b. Remove the TGS lever knob by pulling it up.

AFFECTED VIN
01-82 3721-01
2. Remove the selector lever cover.

a. Pry it off with a scraper.
NOTICE
• Be careful not to damage any part during
removal.
b. Remove the selector lever cover.
3. Remove the center fascia lower cover.

a. Pry it off with a scraper.
b. Lift the center fascia lower cover up, discon-

nect the AUX/USB module connector (A), and
then remove it.

AFFECTED VIN
3721-01 01-83
DSI M78
6 A/T
4. Remove the center console.
a. Unscrew the two mounting screws from the
storage box.
b. Unscrew the mounting screw on the left side

of the center console (same for the right side).
c. Unscrew the two center console mounting

bolts (10 mm).
d. Remove the center console cover by lifting it

up.

AFFECTED VIN
01-84 3721-01
e. Disconnect the cigarette lighter connector (A)

from the center console. Then, remove the
center console.
5. Remove the TGS lever cover.
6. Disconnect the connector (B) from the TGS lever assembly. Then, unscrew the three TGS lever assembly
mounting bolts (10 mm).

AFFECTED VIN
3721-01 01-85
DSI M78
6 A/T
7. Remove the clip with the TGS lever assembly
pried backward.
8. Disconnect the connecting rod and remove the

TGS lever assembly.

10. Adjust the TGS shift rod as follow after
installation:

AFFECTED VIN
01-86 3721-01
Shift Rod Position Adjustment
TGS Lever assembly
Shift load
Range lever
1. Remove the shift rod from the range lever and align the range lever with the D position.
2. Align the Selector Lever to the D position.
3. Insert the shift rod into the range lever and fasten it with nuts.
4. Move the Selector Lever to the P, R, N, or D positions and check if its position is the same with what is
indicated on the instrument panel.
5. Check if the engine can start in the P or N position.

AFFECTED VIN
3650-01 01-87
3650-01 INHIBITOR SWITCH
DSI M78
6 A/T
- Disconnect the battery ground cable.
- Place the selector lever into the position “D”.
Front propeller shaft
Inhibitor switch
1. Remove the front propeller shaft.

a. Place an installation mark on the axle side of
the front propeller shaft (A). Then, unscrew the
four mounting bolts/nuts (14 mm).
b. Place an installation mark on the transfer case

side of the front propeller shaft (B). Then, un-
screw the mounting bolts (17 mm).

AFFECTED VIN
01-88 3650-01
Valve body connector
Inhibitor switch connector
2. Disconnect the inhibitor switch connector (B).
3. Remove the shift rod pin which is connected to

the inhibitor switch range lever (C) in the section
(A).

AFFECTED VIN
3650-01 01-89
DSI M78
6 A/T
4. Unscrew the range lever mounting bolt (13 mm).
14 ~ 20 Nm
5. Remove the range lever (A).
6. Unscrew the two inhibitor switch mounting bolts

(8 mm).
2.3 ~ 3.4 Nm
7. Remove the inhibitor switch.

9. Adjust the TGS shift rod as follow after installation:

AFFECTED VIN
01-90 3650-01
Shift Rod Position Adjustment
TGS Lever assembly
Shift load
Range lever
1. Remove the shift rod from the range lever and align the range lever with the D position.
2. Align the Selector Lever to the D position.
3. Insert the shift rod into the range lever and fasten it with nuts.
4. Move the Selector Lever to the P, R, N, or D positions and check if its position is the same with what is
indicated on the instrument panel.
5. Check if the engine can start in the P or N position.

AFFECTED VIN
3110-01 01-91
3110-01 TROUBLE CODE DIAGNOSIS
DSI M78
6 A/T
Diagnostic Trouble Code List
DTC Description Sub System

P0603 TCU Adaptive Data Memory Error TCU
P0604 TCU Adaptive Data Limit Reached
P0700 Transmission Control System (MIL Request)
P0707 Gear Lever Position Sensor Error Low
P0708 Gear Lever Position Sensor Error High Inhibitor Switch Assembly
P0711 Transmission Oil Temp Over Temp
P0712 Transmission Oil Temperature Sensor Error Low Transmission Cooling
P0713 Transmission Oil Temperature Sensor Error High (Open Circuit) Transmission Oil Tempera-
P0716 Input Shaft/Turbine Speed Value ture Sensor
P0717 Input Shaft/Turbine Speed Sensor Erratic Input Speed Sensor
P071D Manual Shift Control Up/Down (TGS) Switch Stuck
P071E Manual Shift Control Up/Down (TGS) Switch Signal Low Transmission Gear Select
P071F Manual Shift Control Up/Down (TGS) Switch Signal High (TGS) Lever
P0721 Output Shaft Speed Sensor Value
P0722 Output Shaft Speed Sensor Erratic Output Speed Sensor
P0729 Gear 6 Incorrect Ratio
P0731 Gear 1 or M1 Incorrect Ratio Gear Engagement
P0736 Reverse Incorrect Ratio
P0741 Torque converter clutch circuit stuck off
P0742 Torque converter clutch circuit stuck on Torque Converter Control
P0744 Torque converter clutch Slip Error
P0826 Manual Shift Control Up/Down (Steering Wheel) Switch Stuck
P0827 Manual Shift Control Up/Down (Steering Wheel) Switch Signal Low Steering Wheel
P0828 Manual Shift Control Up/Down (Steering Wheel) Switch Signal High
P0962 Solenoid S9 Over Current
P0963 Solenoid S9 Low Current Variable Bleed Solenoids
P0967 Solenoid S10 Low Current

AFFECTED VIN
01-92 3110-01

P0973 Solenoid S1 Over Current ON / OFF Solenoids
P0985 Solenoid S5 Over Current Variable Bleed Solenoids
P099B Solenoid S7 Over Current
P099C Solenoid S7 Low Current
P099E Solenoid S8 Over Current
P099F Solenoid S8 Low Current
P1604 TCU EMM Data Error TCU
P1605 EMM Data Mismatch Input Speed Sensor
P1610 EMM Comms Error
P1611 EMM Data Error
P1701 TCU Supply Voltage Low TCU
P1703 TCU Supply Voltage High
U0100 Cyclic CAN messages from Engine Management ECU are CAN Network
unavailable
U0102 Cyclic CAN messages from Transfer Case ECU are unavailable
U0103 Cyclic CAN messages from TGS ECU are unavailable
U0121 Cyclic CAN messages from Brake System ECU (ABS/
ESP/TCS) are unavailable
U0401 CAN signals from EMS are out of range or Invalid
U0403 CAN signals from Transfer Case are out of range or Invalid
U404 CAN signals from Gear Lever ECU are out of range or Invalid
U0415 CAN signals from Brake System ECU (ABS/ESP/TCS) are
out of range or Invalid
U1600 ECU Application Software Missing TCU Calibration
U1601 ECU Application Software Missing or Corrupted
U1606 TCU Calibration Error - Platform
U1607 TCU Calibration Error - Active Variant
U1608 TCU VIN Coding Error
U1609 TCU Hardware (pcb) Calibration Error

AFFECTED VIN
3110-01 02-93
DIAGNOSIS AND TESTING 3110-01
GENERAL
1. WIRING DIAGRAM
DSI M78
Steering Wheel (SW)
6 A/T
3.24K
Inhibitor SW ASSY Range- Range-
845 1.65K
Lever
Reverse Starter
GND
J5-5 J5-4 J5-6 J5-1 J5-2 J5-3 Transmission Gear Select Lever (TGS)
Starter
Motor
KL50 3.24K
Range- Range- Winter Range
845 1.65K Mode Active
Starter
Relay
J3-7 J3-17 J2-9 J3-15 J2-4 J3-6 J2-10 TCU

SW Range CTRL
TGS Range CTRL

Gear Lever GND
Switch GND
Mode
Range Active
Gear Lever
EMM Speed Sensor Supply

EMM Speed Sensor GND
Trans Oil Temp Return

OnOff SOL Return
VBS SOL Return
Trans Oil Temp

Output Speed
Ignition KL 15
OnOff SOL 1
OnOff SOL 2
OnOff SOL 3
OnOff SOL 4
VBS SOL 10
Input Speed
EMM Clock
GND KL 31
VBS SOL 5
VBS SOL 6
VBS SOL 7
VBS SOL 8
VBS SOL 9
EMM Data
CAN H
CAN L
J1-16 J1-8 J1-7 J1-5 J1-6 J1-3 J1-4 J1-1 J1-2 J1-15 J1-10 J1-9 J1-12 J1-11 J3-4 J3-14 J3-12 J3-2 J3-3 J3-1 J3-8 J3-18 J2-1 J2-7
To Ignition source To Can Network
To Vehicle GND To Can Network
J4-1 J4-2 J4-3 J4-4 J4-5 J4-6 J4-7 J4-20 J4-21 J4-22 J4-23 J4-24 J4-12 J4-13 J4-8 J4-9 J4-11 J4-10 J4-26 J4-25
EMM
VBS5 VBS6 VBS7 VBS8 VBS9 VBS10 OnOff1 OnOff2 OnOff3 OnOff4
t
Input Output
Shaft Shaft Trans.
Speed Speed Fluid
Sensor Sensor Temp
Sensor
* TCU Connector Transmission

SM J1 = EWD A
SM J2 = EWD B
SM J3 = EWD C
(SM: Service Manual, EWD: Electrical Wiring Diagram)

AFFECTED VIN
02-94 3110-01
2. WIRE HARNESS CONNECTOR CHART
3. UNIT CONNECTOR DESCRIPTION

A. Transmission Control Unit
(A) (B) (C)
( ) : EWD
Connector J1 (A)

J1-7 VBS Solenoid Return J1-15 On / Off Solenoid Return
J1-8 Ground J1-16 Ignition Supply Voltage

AFFECTED VIN
3110-01 02-95
Connector J2 (B)
GENERAL
J2-1 CAN High J2-7 CAN Low
J2-2 - J2-8 -
J2-3 - J2-9 Steering Wheel Range Control
DSI M78
6 A/T
J2-4 Transmission Gear Selector Range Control J2-10 Range Active
J2-5 - J2-11 -
J2-6 - J2-12 -
Connector J3 (C)

J3-1 Output Speed J3-11 -
J3-2 EMM / Speed Sensor Supply Voltage J3-12 EMM / Speed Sensor Ground
J3-3 Input Speed J3-13 -
J3-4 Embedded Memory Module Data J3-14 Embedded Memory Module Clock
J3-5 - J3-15 Switch Ground
J3-6 Mode J3-16 -
J3-7 Gear Lever J3-17 Gear Lever Ground
J3-8 Transmission Fluid Temperature J3-18 Transmission Fluid Temperature Return
J3-9 - J3-19 -
J3-10 - J3-20 -

AFFECTED VIN
02-96 3110-01
B. Transmission
Connector J4

J4-1 VBS Solenoid Return J4-14 -
J4-7 VBS Solenoid 10 J4-20 On/Off Solenoid Return
J4-8 EMM Data / Speed Sensor Ground J4-21 On/Off Solenoid
J4-9 EMM / Speed Sensor Supply Voltage J4-22 On/Off Solenoid
J4-10 Output Speed J4-23 On/Off Solenoid
J4-11 Input Speed J4-24 On/Off Solenoid
J4-12 Embedded Memory Module Data J4-25 Transmission Fluid Temperature Return
J4-13 Embedded Memory Module Clock J4-26 Transmission Fluid Temperature Input

AFFECTED VIN
3110-01 02-97
C. Inhibitor Switch
GENERAL
DSI M78
6 A/T
Connector J5

J5-1 Reverse Circuit J5-4 Gear Lever Ground
J5-2 Starter Circuit J5-5 Gear Lever
J5-3 Starter Circuit J5-6 Reverse Circuit

AFFECTED VIN
02-98 3110-00
TROUBLE CODE DIAGNOSIS 3110-00

1. DIAGNOSTIC TROUBLE CODE LIST
P0603 TCU Adaptive Data Memory Error TCU (see page 68)
P0604 TCU Adaptive Data Limit Reached
P0700 Transmission Control System (MIL Request)
P0707 Gear Lever Position Sensor Error Low
P0708 Gear Lever Position Sensor Error High Inhibitor Switch Assembly
P0711 Transmission Oil Temp Over Temp (see page 71)
P0712 Transmission Oil Temperature Sensor Error Low Transmission Cooling
(see page 74)
P0713 Transmission Oil Temperature Sensor Error High (Open Circuit) Transmission Oil Tempera-
P0716 Input Shaft/Turbine Speed Value ture Sensor (see page 75)
P0717 Input Shaft/Turbine Speed Sensor Erratic Input Speed Sensor
P071D Manual Shift Control Up/Down (TGS) Switch Stuck (see page 78)
P071E Manual Shift Control Up/Down (TGS) Switch Signal Low Transmission Gear Select
P071F Manual Shift Control Up/Down (TGS) Switch Signal High (TGS) Lever
(see page 82)
P0721 Output Shaft Speed Sensor Value
P0722 Output Shaft Speed Sensor Erratic Output Speed Sensor
P0729 Gear 6 Incorrect Ratio (see page 85)
P0731 Gear 1 or M1 Incorrect Ratio Gear Engagement
P0732 Gear 2 Incorrect Ratio (see page 87)
P0736 Reverse Incorrect Ratio
P0741 Torque converter clutch circuit stuck off
P0742 Torque converter clutch circuit stuck on Torque Converter Control
P0744 Torque converter clutch Slip Error (see page 90)
P0826 Manual Shift Control Up/Down (Steering Wheel) Switch Stuck
P0827 Manual Shift Control Up/Down (Steering Wheel) Switch Signal Low Steering Wheel
P0828 Manual Shift Control Up/Down (Steering Wheel) Switch Signal High (see page 92)
P0963 Solenoid S9 Low Current Variable Bleed
P0966 Solenoid S10 Over Current Solenoids
P0967 Solenoid S10 Low Current (see page 95)

AFFECTED VIN
3110-00 02-99
GENERAL
DSI M78
6 A/T
P0973 Solenoid S1 Over Current ON / OFF Solenoids
P0985 Solenoid S5 Over Current Variable Bleed Solenoids
P099B Solenoid S7 Over Current
P099C Solenoid S7 Low Current
P099E Solenoid S8 Over Current
P099F Solenoid S8 Low Current
P1604 TCU EMM Data Error TCU (see page 68)
P1605 EMM Data Mismatch Input Speed Sensor
P1610 EMM Comms Error (see page 82)
P1611 EMM Data Error
P1701 TCU Supply Voltage Low TCU (see page 68)
P1703 TCU Supply Voltage High
U0100 Cyclic CAN messages from Engine Management ECU are CAN Network
unavailable (see page 106)
U0102 Cyclic CAN messages from Transfer Case ECU are unavailable
U0103 Cyclic CAN messages from TGS ECU are unavailable
U0121 Cyclic CAN messages from Brake System ECU (ABS/
ESP/TCS) are unavailable
U0401 CAN signals from EMS are out of range or Invalid
U0403 CAN signals from Transfer Case are out of range or Invalid
U404 CAN signals from Gear Lever ECU are out of range or Invalid
U0415 CAN signals from Brake System ECU (ABS/ESP/TCS) are
out of range or Invalid
U1600 ECU Application Software Missing TCU Calibration
U1601 ECU Application Software Missing or Corrupted (see page 109)
U1606 TCU Calibration Error - Platform
U1607 TCU Calibration Error - Active Variant
U1608 TCU VIN Coding Error
U1609 TCU Hardware (pcb) Calibration Error

AFFECTED VIN
02-100 3110-00
2. SYSTEM DIAGNOSIS
A. TCU
The transmission control unit (TCU) controls transmission gear selection via variable bleed solenoids and On/
Off solenoids. The TCU operating voltage is 8-16 V, with current draw typically being less than 4 amps but
reaching as high as 10 amps during gear shifts.
As the mechanical components of the transmission change due to wear etc, the TCU adapts its shift data to
accommodate these changes and maintain shift quality over the life of the vehicle. If a transmission compo-
nent degrades to a point whereby the TCU is unable to adapt its shift data to maintain shift quality, the TCU
will set a DTC.
DTC Title System Action

P0603 TCU Adaptive Data Memory Error • MIL - OFF
• Normal transmission operation with degraded
shift quality
P0604 TCU Adaptive Data Limit Reached • MIL - OFF
shift quality
P0700 Transmission Control System (MIL Request) • MIL - ON
P1604 TCU EMM Data Error • MIL - ON
• Transmission in LHM
P1701 TCU Supply Voltage Low • MIL - ON
P1703 TCU Supply Voltage High • MIL - ON
DTC Description
DTC Description
P0603 TCU is not able to store adaptive (learning) data.
P0604 TCU shift adaptation is applying maximum effort. This may be because the transmission
operation has degraded significantly.
P0700 The transmission control system has a sufficient number, and DTC type of faults to turn the
MIL light ON.
P1604 The EMM Data image stored in the TCU is corrupted or missing.
P1701 The battery voltage sensor is reporting a value too low to operate the solenoids correctly.
P1703 The battery voltage sensor is reporting a value too high for continuous operation of
solenoids. The solenoids will be disabled and the transmission in LHM during this condition.

AFFECTED VIN
3110-00 02-101
Schematic
GENERAL
DSI M78
6 A/T
Connector Details

AFFECTED VIN
02-102 3110-00
DTC Details
DTC Evaluation Condi- Possible Causes Actions

P0603 Ignition key in ON TCU • Clear DTC and check if DTC sets
TCU Adaptive Data position within the evaluation conditions
Memory Error • Replace TCU
P0604 Ignition key in ON Transmission • Clear DTC and check if DTC sets
TCU Adaptive Data position within the evaluation conditions
Limit Reached • Service transmission
P0700 Ignition key in ON Other DTC's requiring • Clear DTC and check if DTC sets
TM Control position the MIL to be turned within the evaluation conditions
System ON are set. • Check if any DTC's requiring the MIL
(MIL Request) to be turned ON are set
• Replace TCU
P1604 Ignition key in ON • Embedded Memory • Clear DTC and check if DTC sets
TCU EMM Data position Module (EMM). within the evaluation conditions
Error • TCU • Replace TCU
P1701 • Ignition key in • Vehicle charging • Clear DTC and check if DTC sets
TCU Supply ON position system within the evaluation conditions
Voltage Low • Engine speed > • Vehicle battery • Check vehicle charging system
300 rpm • TCU to Transmis- • Check vehicle battery
• TCU supply voltage sion harness and/ • Check circuit between terminal J1-8
<8 V for 0.5 seconds or connector fault and vehicle ground
• TCU • Check circuit between terminal J1-16 and
ignition source. Refer to vehicle electrical
section for circuit specific information
• Check supply voltage at TCU
• Replace TCU
P1703 Ignition key in ON • Vehicle charging • Clear DTC and check if DTC sets
TCU Supply position system within the evaluation conditions
Voltage High TCU supply voltage • Vehicle battery • Check vehicle charging system
>17 V for 60 sec- • TCU to Trans- • Check vehicle battery
onds mission harness • Check circuit between terminal J1-8
and/or connector and vehicle ground
fault
• Check circuit between terminal J1-16 and
• TCU ignition source. Refer to vehicle electrical
section for circuit specific information
• Check supply voltage at TCU
• Replace TCU
DTC Clearing
DTC Conditions
P0603, P0604, • Ignition ON
P0700, P1604, • Engine stopped
P1701 & P1703
• Scan tool

AFFECTED VIN
3110-00 02-103
B. Inhibitor Switch Assembly
GENERAL
The inhibitor switch assembly provides gear position data to the transmission control unit (TCU), inhibits
starter motor operation when the transmission gear select (TGS) lever is not in the neutral or park position,
and enables reverse light operation when the TGS lever is in the reverse position. The inhibitor switch has an
individual circuit for each of these functions, with only the gear lever position circuit being connected directly
to the TCU.
DSI M78
6 A/T
The TCU supplies a 5 V reference signal to the gear lever position circuit (inhibitor switch) and measures the
voltage drop in the circuit to determine the gear lever position. There is a different resistance value for each
position of the TGS lever.

P0707 Gear Lever Position Sensor Error Low • MIL - ON
P0708 Gear Lever Position Sensor Error High • MIL - ON
DTC Description
DTC Description
P0707 The Gear Lever Position sensor (Inhibitor Switch) is giving a value indicative of a short circuit to
P0708 ground
Schematic
Connector Details

AFFECTED VIN
02-104 3110-00
Resistance Values
Gear Lever Position Sensor Specifications
Gear Position Value

P 16.786 kΩ ± 8%
R 8.953 kΩ ± 8%
N 5.036 kΩ ± 8%
D 2.686 kΩ ± 8%
DTC Details
DTC Evaluation Conditions Possible Causes Actions

P0707 Ignition key in ON • TCU to Inhibitor • Clear DTC and check if DTC sets
Gear Lever position Switch Assy within the evaluation conditions
Position Sensor harness and/or • Disconnect connector J5 from the
Error Low connector fault inhibitor switch assembly. Check
• Inhibitor Switch resistance of inhibitor switch assem-
Assy bly between terminals 4 and 5 for
• TCU each position of TGS lever. Refer to
the resistance table above for
specifications. Replace transmission
if the resistance values are outside of
the specified range.
• Check circuit between terminals J5-4
and J3-17 for short or open condition
• Disconnect connector J5 from inhibitor
switch assembly and measure voltage
across J5-4 and J5-5 with the ignition
key in the ON position. Voltage
reading should be 5 V ± 0.1 V. If
voltage reading is outside
specifications, replace TCU
P0708 Ignition key in ON • TCU to Inhibitor • Clear DTC and check if DTC sets
Gear Lever position Switch Assy within the evaluation conditions
Position Sensor harness and/or • Disconnect connector J5 from the
Error High connector fault inhibitor switch assembly. Check
• Inhibitor Switch resistance of inhibitor switch assem-
Assy bly between terminals 4 and 5 for
• TCU each position of TGS. Refer to the
resistance table above. Replace
transmission assembly if the resis-
tance values are outside of the
specified range.
• Replace TCU

AFFECTED VIN
3110-00 02-105
DTC Clearing
GENERAL
DTC Conditions
P0707 & P0708 • Ignition ON
• Engine stopped
• Scan tool
DSI M78
6 A/T

AFFECTED VIN
02-106 3110-00
C. Transmission Cooling
The transmission control unit (TCU) monitors the transmission oil temperature. If the vehicle cooling system
is unable to maintain a satisfactory transmission oil temperature the TCU will take precautionary measures to
prevent damage to the transmission and other vehicle components.
The TCU also monitors the rate of temperature change according to current operating conditions (performance).
If the temperature sensor performance is outside a pre-determined set of values, DTC P0711 will set.

P0711 Transmission Oil Temp Over Temp • MIL - ON
shift quality and “WINTER” indicator flashing
when transmission oil temperature is >130°C.
• When the transmission oil temperature is >
145°C the TCU will disable gear engagement
until transmission oil temperature is <120°C
DTC Description
DTC Description
P0711 Transmission Oil Temperature is high enough to cause degraded transmission operation
DTC Details

P0711 • Ignition key in • Transmission • Clear DTC and check if DTC sets
Transmission Oil ON position cooler blocked within the evaluation conditions
Temp Over Temp • Transmission oil • Transmission cooler • Inspect transmission oil level and oil qual-
temperature is > lines restricted ity
130°C • Engine cooling • Inspect transmission cooling system
system fault • Inspect engine cooling system
DTC Clearing
DTC Conditions
P0711 • Ignition ON
• Engine stopped
• Scan tool

AFFECTED VIN
3110-00 02-107
D. Transmission Oil Temperature Sensor
GENERAL
The automatic transmission fluid temperature (TFT) sensor is mounted in the valve body harness tray. The
TFT sensor is a negative coefficient thermistor.
The transmission control unit (TCU) supplies a 5 V reference signal to the sensor and measures the voltage
drop in the circuit. When the transmission fluid is cold, the sensor resistance is high, with the sensor resis-
tance decreasing as the fluid temperature increases.
DSI M78
6 A/T
P0712 Transmission Oil Temperature Sensor Error Low • MIL - ON
P0713 Transmission Oil Temperature Sensor Error High • MIL - ON
DTC Description
DTC Description
P0712 Transmission oil temperature sensor is giving a value indicative of a short circuit to ground.
P0713 Transmission oil temperature sensor is giving a value indicative of an open circuit.
Schematic
Connector Details

AFFECTED VIN
02-108 3110-00
Resistance Values
Temperature Minimum Resistance Value Maximum Resistance Value

-40°C 1.467 MΩ 1.896 MΩ
-30°C 778.4 kΩ 984.2 kΩ
-20°C 430.7 kΩ 533.9 kΩ
-10°C 247.3 kΩ 301.1 kΩ
0°C 146.8 kΩ 175.7 kΩ
10°C 89.95 kΩ 106 kΩ
20°C 56.74 kΩ 65.86 kΩ
30°C 36.76 kΩ 42.10 kΩ
40°C 24.43 kΩ 27.61 kΩ
50°C 16.60 kΩ 18.54 kΩ
60°C 11.53 kΩ 12.73 kΩ
70°C 8.161 kΩ 8.916 kΩ
80°C 5.880 kΩ 6.360 kΩ
90°C 4.306 kΩ 4.614 kΩ
100°C 3.210 kΩ 3.399 kΩ
110°C 2.392 kΩ 2.562 kΩ
120°C 1.811 kΩ 1.955 kΩ
130°C 1.388 kΩ 1.510 kΩ
140°C 1.075 kΩ 1.179 kΩ
150°C 0.843 kΩ 0.930 kΩ

AFFECTED VIN
3110-00 02-109
DTC Details
GENERAL
P0712 Ignition key in ON • TCU to Trans- • Clear DTC and check if DTC sets
Transmission Oil position mission harness within the evaluation conditions
Temperature and/or connector • Check circuit between terminal’s J3-8
DSI M78
Sensor Error Low fault and J4-26 for short condition
6 A/T
• Transmission in- • Check circuit between terminal’s J3-
ternal harness 18 and J4-25 for short condition
and/or connector
• Disconnect transmission connector
fault
J4. Check resistance of transmission
• Temperature oil temp. sensor between terminals
sensor J4-25 and J4-26. Refer to the resis-
• TCU tance table above for specifications.
Replace transmission assembly if the
resistance values are outside of the
specified range
• Disconnect connector J3 from the TCU and
measure voltage across TCU terminals
(TCU side) J3-8 and J3-18 with the ignition
key in the ON position. Voltage reading
should be 5 V ± 0.1 V. If voltage reading is
outside specifications, replace TCU
Transmission Oil position mission harness within the evaluation conditions
Temperature and/or connector • Check circuit between terminal’s J3-8
Sensor Error fault and J4-26 for open condition
High • Transmission in- • Check circuit between terminal’s J3-
ternal harness 18 and J4-25 for open condition
and/or connector
• Disconnect transmission connector
fault
J4. Check resistance of transmission
• Temperature oil temp. sensor between terminals
sensor J4-25 and J4-26. Refer to the resis-
• TCU tance table above for specifications.
Replace transmission assembly if the
resistance values are outside of the
specified range
• Disconnect connector J3 from the TCU and
measure voltage across TCU terminals
(TCU side) J3-8 and J3-18 with the ignition
key in the ON position. Voltage reading
should be 5 V ± 0.1 V. If voltage reading is
outside specifications, replace TCU
DTC Clearing
DTC Conditions
• Engine stopped
• Scan tool

AFFECTED VIN
02-110 3110-00
E. Input Speed Sensor

The ISS sensor is a Hall Effect type sensor and is mounted on the valve body in the transmission.
The EMM is matched to the transmission valve body during manufacture. The EMM is integrated into the
input speed sensor.
The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 36 times per
revolution of the C2 cylinder.

P0716 Input Shaft/Turbine Speed Value • MIL - ON
• Closed loop torque converter clutch slip
control is disabled
• Adaptive learning is disabled
• Engine speed is used to estimate input shaft
speed for gear shifting
P0717 Input Shaft/Turbine Speed Sensor Erratic • MIL - ON
• Closed loop torque converter clutch slip
control is disabled
• Adaptive learning is disabled
• Engine speed is used to estimate input shaft
speed for gear shifting
P1605 EMM Data Mismatch • MIL - OFF
P1610 EMM Comms Error • MIL - OFF
P1611 EMM Data Error • MIL - ON
• Last known valid EMM data in TCU used
• Normal transmission operation
DTC Description
DTC Description
P0716 The input shaft speed (ISS) is compared to engine speed and validated for plausibility
P0717 The input speed sensor is receiving intermittent or spurious pulses.
P1605 The Embedded Memory Module (EMM) data stored in the TCU does not match the EMM
module in the transmission
P1610 The TCU was unable to communicate with EMM
P1611 The data stored in the EMM is corrupted or missing or invalid

AFFECTED VIN
3110-00 02-111
Schematic
GENERAL
DSI M78
6 A/T
Connector Details

AFFECTED VIN
02-112 3110-00
DTC Details

P0716 • Ignition key in • TCU to Trans- • Clear DTC and check if DTC sets
Input Shaft/ ON position mission harness within the evaluation conditions
Turbine Speed • Engine speed > and/or connector • Check circuit between terminals J3-3
Value 3000 rpm fault and J4-11 for short or open condition
• Transmission in- • Check circuit between terminals J3-2
ternal harness and J4-9 for short or open condition
and/or connector • Check circuit between terminals J3-12
fault and J4-8 for short or open
• Disconnect transmission connector J4.
• Input speed
Measure the voltage across terminals
sensor
J4-8 and J4-9 with ignition key in ON
• TCU position. Voltage reading should be >
10 V. Replace the TCU if the reading is
<10 V
• Measure the voltage across terminals
position. Voltage reading should be 5
V ± 0.1 V .Replace the TCU if the
reading is not within specification
• Reconnect transmission connector J4.
Connect an oscilloscope to J3-3 and J3-
12 and start the engine. Increase engine
rpm and observe the square wave
pattern. If the pattern shows switching
from 5 V to 0 V, replace the TCU. If the
pattern does not show switching, re-
place the transmission
P0717 • Ignition key in • TCU to Trans- • Clear DTC and check if DTC sets
Input Shaft/ ON position mission harness within the evaluation conditions
Turbine Speed • Engine speed is and/or connector • Check circuit between terminals J3-3
Sensor Erratic >3000 rpm fault and J4-11 for short or open condition
• Disconnect transmission connector J4.
• Input speed sen-
Measure the voltage across terminals
sor
• TCU position. Voltage reading should be >
10 V. Replace the TCU if the reading is
<10 V
• Measure the voltage across terminals
position. Voltage reading should be 5
V ± 0.1 V. Replace the TCU if the
reading is not within specification
• Reconnect transmission connector J4.
Connect an oscilloscope to J3-3 and J3-
12 and start the engine. Increase engine
rpm and observe the square wave
pattern. If the pattern shows switching
from 5 V to 0 V, replace the TCU. If the
pattern does not show switching, re-
place the transmission

AFFECTED VIN
3110-00 02-113
GENERAL
P1605 Ignition key in ON EMM data stored in the • Clear DTC and check if DTC sets
EMM Data position TCU does not match within the evaluation conditions
Mismatch the EMM module in • Replace the transmission
the transmission. This
indicates that the
DSI M78
transmission or TCU
6 A/T
has been replaced.
P1610 Ignition key in ON • TCU to Transmis- • Clear DTC and check if DTC sets
EMM Comms position sion harness and/ within the evaluation conditions
Error or connector fault • Check circuit between terminals J3-2
• Transmission inter- and J4-9 for short or open condition
nal harness and/or • Check circuit between terminals J3-12
connector fault and J4-8 for short or open
• EMM • Check circuit between terminals J3-4
• TCU and J4-12 for short or open condition
• Replace the transmission
P1611 Ignition key in ON • EMM • Clear DTC and check if DTC sets
EMM Data Error position within the evaluation conditions
• Replace the transmission
DTC Clearing
DTC Conditions
P1605, P1610 & • Engine stopped
P1611
• Scan tool

AFFECTED VIN
02-114 3110-00
F. Transmission Gear Select Lever

The transmission gear select lever contains the mode switch, manual mode active switch and up/down
switches. These switches are connected directly to the TCU.

P071D Manual Shift Control Up/Down (TGS) • MIL - OFF
Switch Stuck • Manual shift control (TGS) switches disabled
P071E Manual Shift Control Up/Down (TGS) • MIL - OFF
Switch Signal Low • Manual shift control (TGS) switches disabled
P071F Manual Shift Control Up/Down (TGS) • MIL - OFF
Switch Signal High • Manual shift control (TGS) switches disabled
DTC Description
DTC Description
DTC The Manual Shift Control Up/Down switch (TGS) has been depressed for more than 120 sec-
P071D onds continuously. This may indicate a faulty switch
DTC The Manual Shift Control Up/Down (TGS) switch signal is giving a value indicative of a short circuit
P071E
DTC The Manual Shift Control Up/Down (TGS) switch signal is giving a value indicative of an open
P071F circuit
Schematic

AFFECTED VIN
3110-00 02-115
Connector Details
GENERAL
DSI M78
6 A/T
Resistance Values
Transmission Gear Select Lever
Switch Value
Range up (press and hold) 1.08 kΩ ± 10%
Range down (press and hold) 555 kΩ ± 10%
Range up / down at rest position 3.24 kΩ ± 10%
DTC Details

P071D Ignition key in ON • Shift Control Up/
Manual Shift Con- position Down switch
trol Up/Down (TGS) (TGS)
Switch Stuck • TCU to Shift Con-
trol Up/Down
switch harness
and/or connector
fault
• TCU

AFFECTED VIN
02-116 3110-00

P071E Ignition key in ON • Shift Control Up/ • Clear DTC and check if DTC sets
Manual Shift Con- position Down switch within the evaluation conditions
trol Up/Down (TGS) • Check up/down switch (TGS) me-
(TGS) Switch Sig- • TCU to Shift Con- chanical operation
nal Low trol Up/Down • Check circuit between terminal J2-4
switch harness and Shift Control Up/Down switch
and/or connector (TGS) for short or open condition
fault
• Check circuit between terminals J3-15 and
• TCU TGS Lever for short or open condition
• Disconnect TCU connectors J2 & J3 and
measure resistance across terminals
J2-4 and J3-15. Refer to the resistance
table above for specifications. Replace
TGS lever if the resistance values are
outside of the specified range
• Replace TCU
P071F Ignition key in ON • Shift Control Up/ • Clear DTC and check if DTC sets
Manual Shift Con- position Down switch within the evaluation conditions
trol Up/Down (TGS) • Check up/down switch (TGS) me-
(TGS) Switch Sig- • TCU to Shift Con- chanical operation
nal High trol Up/Down • Check circuit between terminal J2-4
switch harness and Shift Control Up/Down switch
and/or connector (TGS) for short or open condition
fault
• Check circuit between terminals J3-15 and
• TCU TGS Lever for short or open condition
measure resistance across terminals
J2-4 and J3-15. Refer to the resistance
table above for specifications. Replace
TGS lever if the resistance values are
outside of the specified range
• Replace TCU
DTC Clearing
DTC Conditions
P071D, P071E, • Ignition ON
P071F • Engine stopped
• Scan tool

AFFECTED VIN
3110-00 02-117
G. Output Speed Sensor
GENERAL
The OSS sensor is a Hall Effect type sensor and is mounted at the rear of the transmission main case.
The hall effect sensor drives the signal low. The TCU then pulls the signal up to 5 V via a resistor, 22 times per
revolution of the transmission output shaft.
DSI M78
6 A/T
P0721 Output Shaft Speed Sensor Value • MIL - ON
P0722 Output Shaft Speed Sensor Erratic • MIL - ON
DTC Description
DTC Description
P0721 The output shaft speed (OSS) sensor is compared to external equivalent speed signals and
validated for integrity
P0722 The output speed sensor is receiving intermittent or spurious pulses.
Schematic
Connector Details

AFFECTED VIN
02-118 3110-00
DTC Details

Output Shaft position mission harness within the evaluation conditions
Speed Sensor and/or connector • Check circuit between terminals J3-1
Value fault and J4-10 for short or open condition
• Disconnect connector J4 from transmis-
• Output speed
sion and measure voltage across ter-
sensor
minals J4-8 and J4-9. If reading is not >
• TCU 10 V, replace TCU
• Measure voltage across terminals J4-
8 and J4-10. If reading is not 5 V ± 0.1
V, replace TCU
• Connect connector J4 to transmission,
start engine, and connect oscilloscope to
terminal J3-3. Shift TGS to Park position,
increase engine speed and observe square
wave switching from 5 V to 0 V. If correct,
replace TCU. If not, replace transmission
Output Shaft position mission harness within the evaluation conditions
Speed Sensor and/or connector • Check circuit between terminals J3-1
Erratic fault and J4-10 for short or open condition
• Output speed • Disconnect connector J4 from transmis-
sion and measure voltage across ter-
minals J4-8 and J4-9. If reading is not >
10 V, replace TCU
• Measure voltage across terminals J4-
8 and J4-10. If reading is not 5 V ± 0.1
V, replace TCU
• Connect connector J4 to transmission,
start engine, and connect oscilloscope
to terminal J3-3. Shift TGS to Park
position, increase engine speed and
observe square wave switching from 5
V to 0 V. If correct, replace TCU. If not,
DTC Clearing
DTC Conditions
• Engine stopped
• Scan tool

AFFECTED VIN
3110-00 02-119
H. Gear Engagement
GENERAL
Transmission gear change is controlled by the TCU. The TCU receives inputs from various engine and vehicle
sensors to select shift schedules and to control the shift feel and torque converter clutch (TCC) operation at
each gear change.
DSI M78
6 A/T
P0729 Gear 6 Incorrect Ratio • MIL - ON
P0731 Gear 1 or M1 Incorrect Ratio • MIL - ON
P0736 Reverse Incorrect Ratio • MIL - ON
DTC Description
DTC Description
P0729 The observed gear ratio in GEAR 6 when not shifting is outside nominal values +/-10% for
more than 0.5 seconds.
P0731 The observed gear ratio in GEAR 1 or GEAR MANUAL 1 when not shifting is outside nominal
values +/-10% for more than 0.5 seconds.
P0736 The observed gear ratio in REVERSE when not shifting is outside nominal values +/-10% for

AFFECTED VIN
02-120 3110-00
DTC Details

P0729 • Ignition key in ON position • Low oil level • Clear DTC and check if DTC
The observed • Engine speed >300 rpm • Contaminated oil sets within the evaluation
gear ratio in conditions
• Engine not in LHM • Mechanical
GEAR 6 is damage • Check oil level
• Transmission oil temperature >0°C
incorrect • Check oil quality
• Transmission output shaft • TCU
speed >300 rpm • Check for mechanical damage
• Transmission gear select lever • Replace transmission
NOT in Neutral
GEAR 1 or damage • Check oil level
GEAR MANUAL • Check oil quality
1 is incorrect • Transmission output shaft • TCU
NOT in Neutral
NOT in Neutral
NOT in Neutral
NOT in Neutral

AFFECTED VIN
3110-00 02-121
GENERAL
• TCU
DSI M78
• Transmission output shaft
6 A/T
NOT in Neutral
REVERSE is damage • Check oil level
NOT in Neutral
DTC Clearing
DTC Conditions
P0734, P0735 &
• Scan tool
P0736

AFFECTED VIN
02-122 3110-00
I. Torque Converter Control

The torque converter lock-up clutch is engaged and released via the hydraulic control system.
Pressure at the torque converter lock-up clutch piston is determined by an electronic variable bleed solenoid
(VBS). During operation, the TCU evaluates torque converter slip speed and compares this against what is
expected. If torque converter slip is not within predefined parameters, a DTC will set to indicate a torque con-
verter lock-up problem.

P0741 Torque converter clutch circuit stuck OFF • MIL - ON
• Torque converter remains in open state
P0742 Torque converter clutch circuit stuck ON • MIL - ON
• Torque converter remains in open state with
Solenoid S3 disabled
P0744 Torque converter clutch Slip Error • MIL - ON
• Torque converter remains in open state
DTC Description
DTC Description
P0741 Torque converter stuck open when requested to lock. Slip speed is greater than 50 rpm for
more than 0.5 seconds while locked state requested.
P0742 Torque converter stuck locked when requested to open. Slip speed is less than 150 rpm and
engine torque is greater than 150 Nm for more than 0.5 seconds while open state requested.
P0744 Torque converter slip speed cannot be controlled for more than 0.5 seconds.

AFFECTED VIN
3110-00 02-123
DTC Details
GENERAL
Torque converter • Engine speed >300 rpm • Contaminated oil sets within the evaluation
clutch circuit conditions
DSI M78
stuck OFF • Check oil level
6 A/T
• Transmission oil temperature >0°C damage
• TCU • Check oil quality
• Transmission NOT shifting
• Check for mechanical damage
• Transmission gear select lever
in Drive • Replace transmission
clutch circuit conditions
stuck ON damage • Check oil level
clutch Slip Error conditions
damage • Check oil level
DTC Clearing
DTC Conditions
P0741, P0742 & • Ignition ON
P0744 • Engine stopped
• Scan tool

AFFECTED VIN
02-124 3110-00
J. Steering Wheel
The steering wheel contains transmission gear select (TGS) up/down switches and are directly connected to
the TCU. These switches operate in parallel with the TGS lever switches directly to the TCU.

P0826 Manual Shift Control Up/Down • MIL - OFF
(Steering Wheel) Switch Stuck • Manual shift control (steering wheel) switches
disabled
(Steering Wheel) Switch Signal Low • Manual shift control (steering wheel) switches
disabled
(Steering Wheel) Switch Signal High • Manual shift control (steering wheel) switches
disabled
DTC Description
DTC Description
P0826 The Manual Shift Control Up/Down (Steering Wheel) switch has been depressed for more than
120 seconds continuously. This may indicate a faulty switch
P0827 The Manual Shift Control Up/Down (Steering Wheel) switch signal is giving a value indicative of
a short circuit
P0828 The Manual Shift Control Up/Down (Steering Wheel) switch signal is giving a value indicative of
an open circuit
Schematic

AFFECTED VIN
3110-00 02-125
Connector Details
GENERAL
DSI M78
6 A/T
Resistance Values
Switch Value
Range up (press and hold) 1.08 kΩ ± 10%
Range down (press and hold) 555 kΩ ± 10%
Range up / down at rest position 3.24 kΩ ± 10%
DTC Details

P0826 Ignition key in ON • Shift Control Up/ • Clear DTC and check if DTC sets
Manual Shift position Down Switch within the evaluation conditions
Control Up/Down (steering wheel) • Check up/down switch (steering
(Steering Wheel) • TCU to Shift Control wheel) mechanical operation
Switch Stuck Up/Down switch • Check circuit between terminal J2-9
harness and/or con- and Shift Control Up/Down switch
nector fault (steering wheel) for short or open
• TCU condition
and steering wheel for short or open
condition
measure resistance across terminals J2-
9 and J3-15. Refer to the resistance table
above for specifications. Replace range
up/down switch (steering wheel) if the re-
sistance values are outside of the speci-
fied range
• Replace TCU

AFFECTED VIN
02-126 3110-00

Control Up/Down (steering wheel) • Check up/down switch (steering
(Steering Wheel) • TCU to Shift Control wheel) mechanical operation
Switch Signal Low Up/Down switch • Check circuit between terminal J2-9 and
harness and/or con- Shift Control Up/Down switch (steering
nector fault wheel) for short or open condition
• TCU • Check circuit between terminals J3-15 and
steering wheel for short or open condition
measure resistance across terminals J2-9
and J3-15. Refer to the resistance table above
for specifications. Replace range up/down
switch (steering wheel) if the resistance val-
ues are outside of the specified range
• Replace TCU
Control Up/Down (steering wheel) • Check up/down switch (TGS) me-
(Steering Wheel) • TCU to Shift Control chanical operation
Switch Signal Up/Down switch • Check circuit between terminal J2-4
High harness and/or con- and Shift Control Up/Down switch
nector fault (TGS) for short or open condition
• TCU • Check circuit between terminals J3-15 and
TGS Lever for short or open condition
measure resistance across terminals J2-9
and J3-15. Refer to the resistance table above
for specifications. Replace range up/down
switch (steering wheel) if the resistance val-
ues are outside of the specified range
• Replace TCU
DTC Clearing
DTC Conditions
P0826, P0827 & • Ignition ON
P0828 • Engine stopped
• Scan tool

AFFECTED VIN
3110-00 02-127
K. Variable Bleed Solenoids
GENERAL
The transmission control unit uses variable bleed solenoids to regulate hydraulic pressure. This hydraulic pres-
sure controls torque flow through clutch elements within the transmission.
The TCU is able to vary the amount of torque applied to the clutch elements by controlling the current to the
variable bleed solenoid windings. The clutch element torque transfer is directly related to the current applied to
the solenoids.
DSI M78
6 A/T
During operation, the TCU evaluates the actual current delivered to the solenoid and compares this against what
is expected. If the current is not within predefined parameters, a DTC will be set to indicate the load on the TCU
is abnormal.

P0962 Solenoid S9 Over Current • MIL - ON
P0963 Solenoid S9 Low Current • MIL - ON
P099B Solenoid S7 Over Current • MIL - ON
P099C Solenoid S7 Low Current • MIL - ON
P099E Solenoid S8 Over Current • MIL - ON
P099F Solenoid S8 Low Current • MIL - ON

AFFECTED VIN
02-128 3110-00
DTC Description
DTC Description
P0962 The Variable Bleed Solenoid S9 feedback indicates a short circuit.
P0963 The Variable Bleed Solenoid S9 feedback indicates an open circuit
P0966 The Variable Bleed Solenoid S10 feedback indicates a short circuit
P099B The Variable Bleed Solenoid S7 feedback indicates a short circuit
P099C The Variable Bleed Solenoid S7 feedback indicates an open circuit
P099E The Variable Bleed Solenoid S8 feedback indicates a short circuit
P099F The Variable Bleed Solenoid S8 feedback indicates an open circuit
Schematic
Connector Details

AFFECTED VIN
3110-00 02-129
DTC Details
GENERAL
P0962 • Ignition key in ON • TCU to Transmis- • Clear DTC and check if DTC sets
Solenoid S9 Over position sion harness and/ within the evaluation conditions
Current • Solenoid energised or connector fault • Check circuit between terminals J4-6
DSI M78
• Transmission inter- and J1-1 for short or open condition
6 A/T
• TCU supply
voltage OK nal harness and/or • Check circuit between terminals J4-1
connector fault and J1-7 for short or open condition
• VBS9 • Check between terminals J4-1 and
• TCU J4-6 for solenoid resistance of 4.14 ±
0.3 Ω. Replace transmission if value
is outside of this range.
• Replace TCU
Solenoid S9 Low position sion harness and/ within the evaluation conditions
• TCU supply • Transmission inter- and J1-1 for short or open condition
• Replace TCU
Solenoid S10 position sion harness and/ within the evaluation conditions
Over Current • Solenoid energised or connector fault • Check circuit between terminals J4-7
• Replace TCU
Solenoid S10 position sion harness and/ within the evaluation conditions
Low Current • Solenoid energised or connector fault • Check circuit between terminals J4-7
• Replace TCU

AFFECTED VIN
02-130 3110-00

P0985 • Ignition key in • TCU to Transmis- • Clear DTC and check if DTC sets
Solenoid S5 Over ON position sion harness and/ within the evaluation conditions
Current • Solenoid or connector fault • Check circuit between terminals J4-2
energised • Transmission inter- and J1-5 for short or open condition
• TCU supply nal harness and/or • Check circuit between terminals J4-1
voltage OK connector fault and J1-7 for short or open condition
• Replace TCU
Solenoid S5 Low ON position sion harness and/ within the evaluation conditions
• Replace TCU
• Replace TCU
• Replace TCU

AFFECTED VIN
3110-00 02-131
GENERAL
P099B • Ignition key in • TCU to Transmis- • Clear DTC and check if DTC sets
DSI M78
6 A/T
• Replace TCU
P099C • Ignition key in • TCU to Transmis- • Clear DTC and check if DTC sets
• Replace TCU
P099E • Ignition key in • TCU to Transmis- • Clear DTC and check if DTC sets
• Replace TCU
P099F • Ignition key in • TCU to Transmis- • Clear DTC and check if DTC sets
• Replace TCU

AFFECTED VIN
02-132 3110-00
DTC Clearing
DTC Conditions
P0962, P0963, P0966, • Ignition ON
P0967, P0985, P0986, • Engine stopped
P0998, P0999, P099B,
• Scan tool
P099C, P099E & P099F

AFFECTED VIN
3110-00 02-133
L. On/Off Solenoids
GENERAL
The TCU uses on/off solenoids to select between different clutch elements within the transmission.
During operation, the TCU evaluates the actual current delivered to the on/off solenoid and compares this
against what is expected. If the current is not within predefined parameters, a DTC will be set to indicate the
load on the TCU is abnormal.
DSI M78
6 A/T
DTC Description
DTC Description
P0973 The On/Off Solenoid S1 feedback indicates a short circuit
P0974 The On/Off Solenoid S1 feedback indicates an open circuit

AFFECTED VIN
02-134 3110-00
Schematic
Connector Details

AFFECTED VIN
3110-00 02-135
DTC Details
GENERAL
DSI M78
• Transmission and J1-10 for short or open condition
6 A/T
• TCU supply
voltage OK internal harness • Check circuit between terminals J4-20
and/or connector and J1-15 for short or open condition
fault
• Check between terminals J4-20 and J4-
• On/Off Solenoid 1 21 for solenoid resistance of 22.0 ± 1.2
• TCU Ω. Replace transmission if value is
outside of this range.
• Replace TCU
• TCU supply • Transmission and J1-10 for short or open condition
fault
• Replace TCU
fault
• Replace TCU
fault
• Replace TCU

AFFECTED VIN
02-136 3110-00

energised • Transmission and J1-12 for short or open condition
• TCU supply internal harness • Check circuit between terminals J4-20
voltage OK and/or connector and J1-15 for short or open condition
fault
• Replace TCU
fault
• Replace TCU
fault
• Replace TCU
fault
• Replace TCU

AFFECTED VIN
3110-00 02-137
DTC Clearing
GENERAL
DTC Conditions
P0979, P0980,
• Scan tool
DSI M78
P0982 & P0983
6 A/T

AFFECTED VIN
02-138 3110-00
M. CAN Network
The Controller Area Network (CAN) bus is used to share vehicle system information between the control units
connected to the bus. The TCU obtains the majority if its information via this network. If the TCU does not
receive information at regular intervals from the electronic control units connected to the bus, the TCU will set
a communication DTC.

U0100 Cyclic CAN messages from Engine ECU • MIL - OFF
are unavailable • Transmission in LHM
U0102 Cyclic CAN messages from Transfer • MIL - OFF
Case Control Unit are unavailable • Transmission in LHM
U0103 Cyclic CAN messages from TGS ECU • MIL - OFF
are unavailable • Transmission in LHM
U0121 Cyclic CAN messages from Brake System • MIL - OFF
Control Unit (ABS/ESP/TCS) are unavailable • Transmission in LHM
U0401 CAN signals from Engine ECU are out of • MIL - OFF
range or Invalid • Transmission in LHM
U0403 CAN signals from Transfer Case Control • MIL - OFF
Unit are out of range or Invalid • Transmission in LHM
U0404 CAN signals from Gear Lever ECU are • MIL - OFF
out of range or Invalid • Transmission in LHM
U0415 CAN signals from Brake System Control Unit • MIL - OFF
(ABS/ESP/TCS) are out of range or Invalid • Transmission in LHM
DTC Description
DTC Description
U0100 CAN Message not available

AFFECTED VIN
3110-00 02-139
Schematic
GENERAL
ECU
HFX CLUSTER
ဏᅻ㙛
DSI M78
6 A/T
TCCU
WFFX HECU
KHFX TCU
WFX
Connector Details
DTC Details

U0100 • Ignition key in • Wiring harness • Clear DTC and check if DTC sets
Cyclic CAN ON position for and/or connector within the evaluation conditions
messages from longer than 1 fault • Check Engine ECU system
Engine ECU are second • Engine ECU • Check circuit between terminal J2-1
unavailable • CAN Message system fault and Engine ECU for short or open
U0401 from Engine ECU • TCU condition. Refer to vehicle CAN
not received for communication diagnostics for further
CAN signals from
five message information
Engine ECU are
cycles
out of range or • Check circuit between terminal J2-7
Invalid and Engine ECU for short or open
condition. Refer to vehicle CAN
communication diagnostics for further
information
• Replace TCU

AFFECTED VIN
02-140 3110-00

U0102 • Ignition key in ON • Wiring harness • Clear DTC and check if DTC sets
Cyclic CAN position for longer and/or connector within the evaluation conditions
messages from than 1 second fault • Check Transfer Case Control Unit
Transfer Case • CAN Message • Transfer Case • Check circuit between terminal J2-1
Control Unit are from Transfer system fault and Transfer Case Control Unit for
unavailable Case Control short or open condition. Refer to
• TCU
Unit not received vehicle CAN communication diagnos-
U0403
for five message tics for further information
CAN signals from
cycles • Check circuit between terminal J2-7
Transfer Case
and Transfer Case Control Unit for
Control Unit are
short or open condition. Refer to
out of range or
vehicle CAN communication diagnos-
Invalid
tics for further information
• Replace TCU
messages from than 1 second fault • Check engine management system
TGS ECU are • CAN Message • Brake system • Check circuit between terminal J2-1
unavailable from ECU not fault and transmission gear select ECU for
received for five short or open condition. Refer to
U0404 • TCU
message cycles vehicle CAN communication diagnos-
CAN signals from
Gear Lever ECU
• Check circuit between terminal J2-7
are out of range
and transmission gear select ECU for
or Invalid
vehicle CAN communication diagnos-
• Replace TCU
messages from than 1 second fault • Check Brake System Control Unit
Brake System • CAN Message • Brake system DTC’s
Control Unit from Brake fault • Check circuit between terminal J2-1
(ABS/ESP/TCS) System Control • TCU and Brake System Control Unit for
are unavailable Unit not received short or open condition. Refer to
U0415 for five message vehicle CAN communication diagnos-
cycles tics for further information
CAN signals from
• Check circuit between terminal J2-7
Brake System
and Brake System Control Unit for
Control Unit
(ABS/ESP/TCS)
are out of range vehicle CAN communication diagnos-
or Invalid tics for further information
• Replace TCU
DTC Clearing
DTC Conditions
U0100, U0102, • Ignition ON
U0121, U0401, • Engine stopped
U0403, & U0415 • Scan tool

AFFECTED VIN
3110-00 02-141
N. TCU Calibration
GENERAL
TCU software or calibration may be upgraded at service. These DTC’s protect the TCU against corrupted files
being loaded into the TCU. They also ensure only the correct calibration parameters are used with the
software version currently loaded into the TCU.
DSI M78
6 A/T
U1600 ECU Application Software Mismatch • MIL - OFF
U1601 TCU Application Software Missing or • MIL - OFF
Corrupted • Transmission in LHM
U1606 TCU Calibration Error – Platform • MIL - ON
U1607 TCU Calibration Error - Active Variant • MIL - ON
U1608 TCU VIN Coding Error • MIL - ON
U1609 TCU Hardware (pcb) Calibration Error • MIL - ON
DTC Description
DTC Description
U1600 The TCU Software and Calibration are not compatible
U1601 During initialisation, the TCU software was found to be missing or corrupted. In this condi-
tion the TCU will not operate, and the transmission will be in LHM
U1606 Platform calibration data CRC check failed at initialisation of TCU. This is normal for a
development TCU
U1607 Active Variant calibration data CRC check failed at initialisation of TCU.
This is normal for a development TCU
U1608 VIN based variant could not be determined. TCU will use default VIN calibration
U1609 Calibration for TCU hardware (pcb) is missing or corrupted. TCU will use default calibration

AFFECTED VIN
02-142 3110-00
DTC Details

U1600 • Ignition key in • TCU calibration • Clear DTC and check if DTC sets
ECU Application ON position within the evaluation conditions
Software Mis- • Message not • Update TCU calibration software.
match received for 5 x Refer to vehicle scan tool documenta-
U1601 cycle time tion for further information
TCU Calibration • Replace TCU
Error – Platform
TCU Calibration ON position within the evaluation conditions
Error – Platform • CRC not Valid • Update TCU calibration software.
U1607 Refer to vehicle scan tool documenta-
TCU Calibration tion for further information
Error - Active • Replace TCU
Variant
TCU VIN Coding ON position within the evaluation conditions
Error • VIN not compat- • Update TCU calibration software.
ible with calibra- Refer to vehicle scan tool documenta-
tion tion for further information
U1609 • Ignition key in • TCU • Clear DTC and check if DTC sets
TCU Hardware ON position within the evaluation conditions
(pcb) Calibration • TCU manufactur- • Replace TCU
Error ing information
not present
DTC Clearing
DTC Conditions
U1600, U1601, • Ignition ON
U1606, U1607, • Engine stopped
U1608 & U1609
• Scan tool

AFFECTED VIN
3680-01 02-143
MAINTENANCE OPERATIONS 3680-01
GENERAL
1. OIL TEST
A. Hydraulic System
DSI M78
6 A/T
If there is a problem in the hydraulic system, perform the following:
• Test transmission oil
• Inspect the manual linkage adjustment
• Check the engine’s idling speed
• Perform the stall test
• Perform the driving test
B. Oil Test
Check the Amount of Oil
This check must be performed when the engine is warm. If there is insufficient oil and the vehicle moves, shift
loss or delay may happen.
First, check the transmission malfunction code. If there is a problem with the shaft speed, insufficient oil may
cause the problem.
When there is an abnormal shift delay or loss of driving power during driving or reversing, perform the driving
test. When the level of oil is low and this vehicle is moving on a corner, there will be a brief driving power loss.
When both oil temperature and level are low, there will be loss of driving power. Replenish oil if the engine is
completely warmed up and there is no loss of driving power, but there is still a problem with the vehicle speed.
Oil Check and Replenishment

When replenishing or changing transmission oil, a genuine recommended oil must be used.
If non-approved oil is used, it will have fatal impacts on the transmission’s performance and life. Never use
such oil. Wrong oil can damage the transmission.
When the transmission oil is hot, do not remove the filler plug. Wait for 2 hours to cool down the oil. Then, remove
the plug.
1. When the engine is hot, wait for 2 hours before replenishing transmission oil. Then, the transmission’s
temperature also becomes cooled down to a proper range. When the filler plug is removed while the tem-
perature of oil is hot, oil will flow out and its level in the transmission will go down.
2. Push the selection lever to the “P” position and shut off the engine.
3. Raise up the vehicle with a proper lift.
4. Clean up the surroundings of the filler plug before removing the plug. After removing the plug, clean up the
plug thoroughly and inspect the O-ring for any damage.
5. After attaching the filler pump to the transmission, lower the vehicle and replenish oil. Engage the parking
brake, start the engine while the selection lever is engaged to “P”, and press the foot brake. Then, start
shifting the selection lever to all positions. Replenish oil until you can sense moving of the transmission
gears.
6. Shut off the engine again and raise up the vehicle. Ensure that the vehicle maintains horizontal balance.
7. Shut off the engine, wait for at least 3 minutes (within 1 hour), and remove the filler pump. If oil reaches to
just below the filler inlet, it is appropriate. If not, replenish oil until it reaches this level.
8. Replace the filler plug with a new one. Wipe off oil on the transmission or other parts of the vehicle.
9. Apply the specified torque to tighten up the filler plug (30 ~ 35 Nm).

AFFECTED VIN
02-144 3680-01
Oil check/Replenishment when there is an insufficient amount of oil

1. Engage the shift lever to the “P” position and shut off the engine.
2. Raise this vehicle with an appropriate lift.
3. Clean up the surroundings of the filler plug before removing the plug. After removing the plug, clean up the
plug thoroughly and inspect the O-ring for any damage. Then, attach the filler pump to the oil inlet.
4. After attaching the filler pump to the transmission, lower this vehicle and replenish oil.
a. When the transmission torque converter has no oil: 9.5
b. When the transmission torque converter is filled with oil: 4.5
5. Engage the parking brake, start the engine while the selection lever is engaged to “P”, and depress the
foot brake. Then, start shifting the selection lever to all positions. Replenish oil until you can sense
moving of the transmission gears.
6. Add a 0.5 of recommended oil.
7. Shut off the engine and raise this vehicle with an appropriate lifte. Detach the filler pump. Replace the filler
plug with a new one (Tightening torque: 30 ~ 35 Nm).
8. When this vehicle travels 3.5 ~ 4.5 kilometers with the engine’s RPM below 2500, the temperature of the
transmission will reach to 50 ~ 60°C.
9. With the engine idling, press the brake pedal and shift the transmission selector lever to all positions
several times.
10. Shut off the engine and raise the vehicle with an appropriate lift. Maintain horizontal balance of the vehicle
if possible.
11. Remove the filler plug 3 minutes after shutting off the engine. If oil reaches just below the filler inlet, it is
appropriate. If not, replenish oil until it reaches this level.
12. Replace the filler plug with a new one. Wipe off oil on the transmission or other parts of the vehicle. Apply
the specified torque to tighten up the filler plug (30 ~ 35 Nm).
2. STALL TEST
Stall testing can be performed on the Model 78 6 speed automatic transmission to determine whether the
transmission clutches can hold the full engine torque without slipping.
Stall testing should be performed for a period no longer then 10 seconds.
• Apply Hand Brake
• Start Engine
• Press Brake Pedal
• Shift to “DRIVE”
• Press Accelerator Pedal to 100 % for 6 seconds
• Observe Engine speed
• Release Accelerator Pedal
• Shift To Reverse
• Press Accelerator Pedal to 100 % for 6 seconds
• Observe Engine speed
If engine speed is observed > 3000 rpm; transmission hardware failure

AFFECTED VIN
3680-01 02-145
3. TRANSMISSION RESET PROCEDURE (REPLACEMENT
GENERAL
TRANSMISSION)
It is necessary to reset the adaptive data stored within the transmission control unit (TCU) when the transmis-
sion and or TCU have been replaced.
DSI M78
6 A/T
Green Offset Reset
Carried out when a replacement transmission has been installed in a vehicle.
Adaptive Reset
Carried out when one of the following has occurred:
• Replace transmission
• Replace TCU
Green Offset Reset Procedure

To perform a green offset reset procedure, proceed as follows:
running).
3. Using the scan tool, set the parameter Set Km Travelled to 0Km.
4. Run the task Activate Adaptive Green Offset.
Adaptive Reset Procedure

To perform an adaptive reset procedure, proceed as follows:
running).
3. Set the parameter Set Km Travelled to 0 Km.
4. Run the task Reset Adaptive Data.

AFFECTED VIN
02-146 3680-01
4. FLUID LEVEL INSPECTION
NOTE
• As the temperature of the transmission fluid greatly affects the fluid level, this procedure must only be
carried out with the transmission fluid temperature below 50°C). If the transmission fluid temperature
is greater than 50°C and the correct procedure is not followed, the result could be a false reading of
the fluid level.
• Fluid level inspection must be carried out with the vehicle level.
• Caltex PED 1712 ATF must be used.

and remove the transmission fluid level plug (1).
3. If fluid starts to drain from the fluid level hole, rein-
stall the fluid level plug. If no fluid drains from the
fluid level hole, fill the transmission until fluid starts
to drain from the level hole and reinstall the plug.
4. Drive the vehicle for approximately five minutes.
5. Connect the vehicle’s diagnostic scan tool to the
vehicles diagnostic connector. Refer to the vehicle
repair manual for information on connecting the
scan tool.
6. With the gear select lever in the Neutral position,
start the engine and allow to run at idle until the
transmission fluid temperature reaches 50°C.
NOTE
Use the scan tool to monitor the transmission
fluid temperature.

8. When the transmission fluid temperature reaches 50°C turn off the engine.
9. Place a drain container below the fluid level hole and remove the transmission fluid level plug. Allow trans-
mission fluid to drain from the fluid level hole for 50 seconds.
10.Reinstall the fluid level plug and tighten the plug to the correct torque specification.
Transmission fluid level plug

30 ~ 35 Nm
11. Lower the vehicle to the ground and road test the vehicle to check vehicle operation and for fluid leaks.

AFFECTED VIN
3680-01 02-147
5. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING
GENERAL
PROCEDURE
NOTE
To prevent transmission damage due to contaminants being present in the transmission cooler and/or
hydraulic lines, the cooler and lines must be flushed.
DSI M78
6 A/T
1 Raise the vehicle on a certified hoist.
2 Using compressed air, clear the cooler lines of any residual fluid.
3 Connect the front transmission cooler line to the transmission.
Front transmission cooler

line to transmission fitting 25 ~ 35 Nm
4 Connect one end of a rubber hose to the end of the rear cooler line and place the other end in a suitable
container to collect the transmission fluid as it is pumped out.
5 Start the engine and run for approximately 30 seconds at idle. (With ATF at 50¡ÆC temperature, a minimum
of 2.5litres oil flow after 30 seconds.)
6 Whist the engine is running, have an assistant pump transmission fluid into the transmission fluid level
hole.
7 Connect the rear transmission cooler line to the transmission.
Rear transmission cooler line

to transmission fitting torque 25 ~ 35 Nm
specification
8 Check the transmission fluid level; refer to Fluid Level Inspection on page 69.
6. LUBRICATION
Automatic transmission fluid ............................... Caltex PED 1712 ATF

AFFECTED VIN
02-148 3680-01
7. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING

PROCEDURE (NEW TRANSMISSION)
Items Size Torque (Nm)
TC Housing M12 x 32 54 ~ 68
Extension Housing M12 x 32 54 ~ 68
Oil Pan M6 x 16 4~6
Valve Body to Case M6 x 26 8 ~ 13
Valve Body to Case M6 x 45 8 ~ 13
Center Support to Case M10 x 34 20 ~ 27
Output Shaft Locking Nut M24 x 15 100 ~ 110
Pump to Pump Cover M8 x 55 24 ~ 27
Pump Cover to Case M8 x 40 24 ~ 34
Pump Cover to Case M8 x 58 24 ~ 34
Upper Valve Body to Lower M6 x 30 15 ~ 17
Detent Spring M8 x 16 20 ~ 25
VBS & Speed Sensor M4 x 12 2.8 ~ 3.2
Transmission Oil Level Plug 30 ~ 35
Front Transmission Cooler Line to Transmission 25 ~ 35
Connector
Rear Transmission Cooler Line to Transmission 25 ~ 35
Cooler Connector
Torque Converter to Drive Plate Bolt 40 ~ 42
Transmission Selector Lever to Cross Shaft Nut 14 ~ 20

AFFECTED VIN
ELECTRONIC
# #
GENERAL INFORMATION ............. 01-3P

FUSE AND RELAY ..........................
8210/8410/8402 02-3P
Q-145: 2008.07 ~
GENERAL INFORMATION
0000-00
General information for vehicle

1. Specifications and identification ....................... 3
2. Specifications and check items ....................... 5
Changes
1. Major changes for electrical
system and body ........................................... 14
0000-00 01-3
GENERAL INFORMATION 0000-00
GENERAL
General Information for Vehicle
1. SPECIFICATIONS AND IDENTIFICATION
FUSE
A. Exterior Dimensions
Unit: mm
Top View
1,900
Side View
1,755
3,060
4,965
Front View Rear View
1,570 1,570
GENERAL INFORMATION
ACTYON SPORTS SM - 2008.07
01-4 0000-00
B. Vehicle Identification
1. Engine Number (D20DT) 1. Engine Number (G23D)
The engine number is stamped on the The engine number is stamped on the up-
lower area of cylinder block in the intake per rear left-hand side of the cylinder block.
manifold side.
3. Certification Label 2. Chassis Number
The certification label is located on the The chassis number is stamped on the
driver’s door sill (B pillar). frame behind the front right tire.
GENERAL INFORMATION
0000-00 01-5
2. SPECIFICATIONS AND CHECK ITEMS
GENERAL
A. Specifications
* ( ) Optional, [ ] 2WD, < >: DPF
ACTYON ACTYON SPORTS

Descriptions
D20DT G23D D20DT
FUSE
General Overall length (mm) 4,455 ← 4,965
Overall width (mm) 1,880 ← 1,900
Overall height (mm) 1,735 (1,765) ← 1,755
Gross vehicle A/T 2,520 ← 2,740 [2,640]
weight (kg) M/T 2,520 ← 2,740 [2,640]
Curb vehicle A/T 1,974 [1,865] 1,957 [1,848] 2,016 [1,907]
weight (kg) M/T 1,952 [1,843] 1,935 [1,826] 1,963 [1,854]
Fuel Diesel Gasoline Diesel
Fuel tank capacity ( ) 75 ← ←
Min. turning radius (m) 5.6 ← 6.18
Engine Numbers of cylinders/
4 / 17.5:1 4 / 10.4 : 1 4 / 17.5:1
Compression ratio
Total displacement (cc) 1,998 2,295 1,998
Camshaft arrangement DOHC ← ←
Max. power 141 PS / 4,000 rpm
150 PS / 5,500 rpm 141 PS / 4,000 rpm
<138 PS / 4,000 rpm>
Max. torque 310 Nm / 214 Nm / 310 Nm /
1,800 ~ 2,750 rpm 3,500 ~ 4,600 rpm 1,800 ~ 2,750 rpm
Idle speed 780 ± 50 rpm 750 ± 50 rpm 780 ± 50 rpm
Cooling system Water- cooled /
← ←
forced circulation
Coolant capacity ( ) 10.5 ~ 11.0 ← ←
Lubrication type Gear pump,
← ←
forced circulation
Max. oil capacity ( )
8.2 7.9 8.2
(when shipping)
Turbocharger and Turbocharger,
← ←
cooling type air-cooled
Manual Operating type Semi- Remote control,
← ←
Transmission floor change type
2nd 2.475 ← ←
3rd 1.536 ← ←
4th 1.000 ← ←
5th 0.807 ← ←
GENERAL INFORMATION
01-6 0000-00
* ( ) Optional, [ ] 2WD
ACTYON
ACTYON
Descriptions SPORTS
D20DT G23D D20DT
Automatic Model Electronic, 6-speed ← ←
Transmission Operating type Floor change type ← ←
2nd 2.143 ← ←
3rd 1.478 ← ←
4th 1.156 ← ←
5th 0.866 ← ←
6th 0.677 ← ←
Transfer Case Model 2WD, Part-time Part-time ←
Type Planetary gear type ← ←
Gear ratio High (4H) 1.000 : 1 ← ←
Low (4L) 2.483 : 1 ← ←
Clutch (M/T) Operating type Hydraulic type ← ←
Disc type Dry single diaphragm type ← ←
Power Steering Type Rack and pinion ← ←
Steering angle Inner 35.7° ← ←
Outer 32.1° ← ←
Front Axle Drive shaft type Ball joint type ← ←
Rear Axle Drive shaft type Solid axle
Semi-floating type ← ←
suspension
Brake Master cylinder type Tandem type ← ←
Booster type Vacuum assisted booster type ← ←
Brake type Front wheels Disc type ← ←
Rear wheels Drum (disc) ← ←
Parking brake Cable type
← ←
(internal expansion)
Suspension Front suspension Wishbone + coil spring ← ←
Rear Solid axle
5-link + coil spring ← ←
suspension suspension
Air Conditioner Refrigerant (capacity) R-134a (650 ± 30g) ← ←
Electrical Battery type / Capacity (V-AH) MF / 12 - 90 ← ←
Starter capacity (V-kW) 12 - 2.2 12 - 1.2 12 - 2.2
Alternator capacity (V-A) 12 - 115 ← ←
GENERAL INFORMATION
0000-00 01-7
B. Specified Oil (Fluid) and Capacity
GENERAL
Descriptions Capacity Specifications
Engine Oil Quality class: Ssangyong genuine engine oil
D20DT 7.5 (Approved by MB Sheet 229.1 or 229.3 or 229.31
for DSL/GSL ENG without CDPF)
FUSE
(Approved by MB Sheet 229.31 for DSL ENG
G23D 7.5 with CDPF)

Viscosity: MB sheet No. 224.1
Engine Coolant D20DT Ssangyong genuine coolant
10.5 ~ 11.0
G23D (Anti-freeze:SYC-310, Anti-freeze:water = 50:50)
Automatic Transmission Fluid 4 A/T 9.5 Ssangyong genuine oil (CASTROL TQ 95)
6 A/T 9.5 Ssangyong genuine oil (CALTEX PED 1712)
Manual Transmission Fluid 4WD 3.6
Ssangyong genuine oil (ATF DEXRON II)
2WD 3.4
Transfer Case Fluid 1.4 Ssangyong genuine oil (ATF DEXRON II or III)
Axle Oil Front Automatic Transmission 1.4
Ssangyong genuine oil (SAE 80W/90, API GL-5)
Manual Transmission 1.4
Rear Solid Axle D20DT M/T,
1.9
G23D M/T
Suspension D20DT A/T, Ssangyong genuine oil (SAE 80W/90, API GL-5)
2.0
G23D A/T
LD 1.8
Brake / Clutch Fluid As required Ssangyong genuine oil (DOT4)
Power Steering Fluid 1.0 Ssangyong genuine oil (ATF DEXRON II or III)
NOTICE
• Use only Ssangyong recommended fluids and lubricants.
• Do not mix any different types or brands of oils or fluids. This may cause damages.
• Keep the specified levels when adding or replacing the fluids.
GENERAL INFORMATION
01-8 0000-00
C. Maintenance Schedule
Diesel Engine

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
ITEM Months 12 24 36 48 60 72 84 96
*1
* Engine oil & filter EU Initial check: 5,000 km, and replenish if necessary, change every 15,000 km
(1)* (3)* (4)* or 12 months (But, shorten the service interval under severe conditions)
General Initial change: 5,000 km, change every 10,000 km or 12 months
Engine coolant (3)* (4)* Change every 60,000 km or 3 years. And, inspect and replenish if necessary.
* Fuel filter Direct Injection EU I R* I R* I R* I R*
(Diesel Engine) General Replace every 25,000 km
(Draining water from fuel filter: whenever replacing the engine oil)
Additional water separator (if equipped) Replace every 150,000 km or 5 years
(Drain the water whenever replacing the engine oil)
Air cleaner (2)* EU Initial clean: 5,000 km, clean every 15,000 km, replace every 30,000 km
General Initial clean: 5,000 km, clean every 10,000 km, replace every 30,000 km
Injection timing (See NOTE 1) I I I I I I I I
NOTE 1: Adjust as required; - When excessive smoke is visible (black or white)
- Poor performance/economy
Chart Symbols:
*1 Check the engine oil level and leak every 3,000 km (2,000 miles) or before starting a long trip.
(1)* If vehicle is operated under severe condition:
Shorten the service interval.
- Frequent stop-and-go traffic, extended idling, short driving distance below 6 km, driving distance below 16 km when the outside
temperature remains below freezing
- Driving in a hilly or mountainous terrain, sandy, or dusty area
- High load driving such as trailer towing
- Taxi, patrol service or delivery service (extended idling and excessive driving with low speed)
(2)* If vehicle is operated under severe condition, driving in dusty condition or sandy condition, pollutant area or off-road driving, fre-
(3)* More frequent maintenance is required if under dusty driving condition.
(4)* Refer to “Recommended fluids, coolant and lubricants”.
* Water separator: When replace the engine oil, also drain the water from the fuel filter.
GENERAL INFORMATION
0000-00 01-9
GENERAL

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
MAINTENANCE
FUSE
x1,000 miles 10 20 30 40 50 60 70 80
ITEM Months 12 24 36 48 60 72 84 96
CHASSIS AND BODY
Parking brake / Brake pads EU Periodic check: every 15,000 km, adjust or replace if necessary.
(Front & Rear) (4)* General Periodic check: every 10,000 km, adjust or replace if necessary.
Front & Rear differential fluid (3)* Inspect frequently, change every 30,000 km
Transfer case fluid (3)* Inspect every 15,000 km, change every 60,000 km (Frequnt check of oil leak)
Automatic transmission fluid (6)* Inspect every 30,000 km or 12 month
(But change every 60,000 km under severe condition)
Chart Symbols:
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly driven under severe conditions: Towing a trailer or
off-road driving (Inspect the leak of fluid at any time,occasionlly)
looseness.
GENERAL INFORMATION
01-10 0000-00
Gasoline Engine

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
ITEM Months 12 24 36 48 60 72 84 96
Engine oil & engine oil filter (1)* (3)*
R** R R R R R R R
(Initial change: 10,000 km)
Engine coolant (3)* Change every 60,000 km or 3 years. And, inspect replenish if necessary.
Fuel filter (2)* Replace every 100,000 km (if using poor quality of fuel, replace every 30,000 km)
Air cleaner (2)* I I I R I I I R
Ignition timing I I I I I I I I
Spark plugs (G23D) - R - R - R - R
Charcoal canister & vapor lines - - I - - I - -
Chart Symbols:
** - In order to secure engine long life and effective break-in, first oil (factory filled) would be recommended to drain with in 10,000 km.
(1)* If vehicle is operated under severe condition: short distance driving, extensive idling or driving in dusty condition, shorten the service
interval.
(2)* If vehicle is operated under severe condition, pollutant area or off-road driving, driving in dusty condition or sandy condition, fre-
GENERAL INFORMATION
0000-00 01-11
GENERAL

INTERVAL x1,000 km 15 30 45 60 75 90 105 120
ITEM Months 12 24 36 48 60 72 84 96
FUSE
CHASSIS AND BODY
Parking brake / Brake pads EU Periodic check: every 15,000 km, adjust or replace as necessary.
(Front & Rear) (4)* General Periodic check: every 10,000 km, adjust or replace as necessary.
Front & Rear Front EU Periodic check: every 15,000 km, adjust or replace if necessary.
differential General Periodic check: every 10,000 km, adjust or replace if necessary.
fluid (3)* Rear EU Periodic check: every 15,000 km, adjust or replace if necessary.
General Periodic check: every 10,000 km, adjust or replace if necessary.
Transfer case fluid (3)* Inspect every 15,000 km, change every 60,000 km (Frequent check of oil leak)
Automatic transmission fluid (6)* Inspect every 30,000 km or 12 month (But change every 60,000 km under severe condition)
Chart Symbols:
(6)* Change automatic transmission fluid and every 60,000 km if the vehicle is mainly driven under severe conditions. (Inspect the
leak of fluid at any time, occasionlly)
looseness.
GENERAL INFORMATION
01-12 0000-00
D. Wheel Alignment Specification
DRIVE Chairman Rexton Rexton II Kyron
Camber Left Handle Type Front -0.38° ± 0.15° 0° ± 0.5° -0.12° ± 0.25°(LH) -0.19° ± 0.25°(LH)
-0.00° ± 0.25°(RH) -0.29° ± 0.25°(RH)

(CROSS: 0.5°) (CROSS 0.5°)
Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5°(COIL) -0.79° ± 0.5°
-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

(CROSS: 0.5°)
Right Handle Type Front -0.38° ± 0.15° 0° ± 0.5° -0.12° ± 0.25°(LH) -0.19° ± 0.25°(LH)
-0.12° ± 0.25°(RH) -0.19° ± 0.25°(RH)

(CROSS: 0.5°) (CROSS 0.5°)
Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5° (COIL) -0.79° ± 0.5°
-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

(CROSS: 0.5°)
Caster Left Handle Type 10.35° ± 0.5° 2.75° ± 0.5° 4.28° ± 0.4°(LH) 4.4° ± 0.4°(LH)
4.38° ± 0.4°(RH) 4.5° ± 0.4°(RH)

(CROSS: 0.5°) (CROSS: 0.5°)
Right Handle Type 10.35° ± 0.5° 2.75° ± 0.5° 4.28° ± 0.4°(LH) 4.4° ± 0.4°(LH)
4.28° ± 0.4°(RH) 4.4° ± 0.4°(RH)

(CROSS: 0.5°) (CROSS: 0.5°)
(LH/RH each Toe)
mm - 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
Rear degree 0.2° ± 0.04° - 0.08° ± 0.09° (COIL) 0.095° ± 0.09°
(LH/RH each Toe)
mm - - 0.095° ± 0.085° (EAS) 3 mm ± 3 mm
(Total Toe)
(LH/RH each Toe 2.5 mm ± 3 mm (COIL)
= Total Toe / 2) 3 mm ± 2.5 mm (EAS)
GENERAL INFORMATION
0000-00 01-13
GENERAL
Actyon &
DRIVE Rodius & Stavic Musso Korando
Actyon Sports
Camber Left Handle Type Front -0.19° ± 0.25°(LH) 0° ± 0.5° 0° ± 0.5° 0° ± 0.5°
-0.29° ± 0.25°(RH)
FUSE
(CROSS 0.5°)
Rear (IRS) - -1° ± 0.25° - -
Right Handle Type Front -0.19° ± 0.25°(LH) 0° ± 0.5° 0° ± 0.5° 0° ± 0.5°

-0.19° ± 0.25°(RH)
(CROSS 0.5°)
Rear (IRS) - -1° ± 0.25° - -
Caster Left Handle Type 4.4° ± 0.4°(LH) 4.5° ± 0.5° 2.5° ± 0.5° 2.5° ± 0.5°
4.5° ± 0.4°(RH)
(CROSS: 0.5°)
Right Handle Type 4.4° ± 0.4°(LH) 4.5° ± 0.5° 2.5° ± 0.5° 2.5° ± 0.5°
4.4° ± 0.4°(RH)
(CROSS: 0.5°)
(LH/RH each Toe)
mm 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm 2 mm ± 2 mm
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
Rear degree - 0.2° ± 0.04° - -
(LH/RH each Toe)
mm - 6 mm ± 1 mm - -
(Total Toe)
(LH/RH each Toe
= Total Toe / 2)
GENERAL INFORMATION
01-14 0000-00
Changes
1. MAJOR CHANGES FOR ELECTRICAL SYSTEM AND BODY
ICM Box Bag Hook
As the ICM box is newly installed, the following relays are

integrated into the ICM box.
- Door lock relay (previously installed to STICS bracket)¡¡ It is newly installed to let a passen-
- Windshield de-icer relay (previously installed under floor on the ger hang his/her bag.
driver side)
- Turn signal lamp relay (previously installed to passenger side
fuse & relay)
GENERAL INFORMATION
0000-00 01-15
GENERAL
Side Repeater Chrome Muffler
FUSE
It is now equipped with two LEDs instead of bulb
(12 V/5 W) for better durability. Chrome is applied to the end of the muffler.
Rear Air Dam
There air dam is newly installed.
GENERAL INFORMATION
MEMO
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FUSE AND RELAY
8210-01/8410-02/8410-04/8402-06/
General information Configuration and functions

1. General information .......................................... 3 8210-01 Configuration of PCB in ICM box and
function of connector ............................ 12
Overview and operating process 8410-02 Circuit diagram for fuse & relay box in
engine compartment ............................ 13
1. Overview ........................................................... 4
8410-04 Circuit diagram for interior fuse & relay
2. Fuse & relay mounting location ....................... 4 box on driver side ................................. 17
3. Capacity and name of fuse and relay in engine 8402-06 Circuit diagram for interior fuse & relay
compartment ................................................... 5 box on passenger side ......................... 20
4. Capacity and name of interior fuse and relay ... 6
5. Operating process of ICM box ......................... 8
Removal and installation
8210-01 Removal and installation of ICM box .... 21
8410-02 02-3
FUSE AND RELAY 8410-02
GENERAL
General information
1. GENERAL INFORMATION
FUSE
ECU
PREVIOUS MODEL
Turn signal
Door lock relay lamp relay
Windshield
de-icer relay
NEW MODEL
ICM box STICS
PAS buzzer
ICM box
Turn signal
lamp relay

de-icer relay relay
* Some relays have been integrated into the ICM box.

EFFECTIVE DATE ACTYON SPORTS SM - 2008.07
AFFECTED VIN
02-4 8410-02
1. OVERVIEW
The ICM (Integrated Control Module) mounted to the back of the STICS is integrated with the door lock relay,
windshield de-icer relay and turn signal lamp relay. There are four fuse & relay units.
2. FUSE & RELAY MOUNTING LOCATION

In engine compartment
Fuse & Relay Box In Interior Fuse & Relay Box

Engine Compartment On The Driver Side (RH)
In vehicle
Interior Fuse & Relay Box

Mounting Location of ICM
On The Driver Side (LH)

ACTYON SPORTS SM - 2008.07 EFFECTIVE DATE
AFFECTED VIN
SPARE SPARE SPARE SPARE SPARE
30A 20A 15A 10A 7.5A
CHANGED BY
40A 30A
AFFECTED VIN
30A 30A
30A
EFFECTIVE DATE
POWER CABIN CABIN
POWER F/BOX ABS F/BOX IGN
WINDOW WINDOW (B+POWER3) (B+POWER1) Key 1
RLY 18
Hazard Head
=125A ABS LP LP
HEAD LP 30A WIPER (HI)

TAIL LP
(LOW) BLOWER (5P)
MEMORY RLY 16
RLY 17 MOTOR RLY 13
7.5A PTC
HEATER 2, 3
HEAD LP STOP LP TAIL LP (RH) TAIL LP (LH) FRT FOG HORN COMPRESSOR DEICER
COMPARTMENT
RLY 12
(LH)
HEAD LP WIPER (LO)

FRT FOG LP HORN COMPRESSOR
(RH) (5P)
RLY 10 RLY 9 RLY 8 40A
RLY 6
PTC
30A Heater 3
30A 40A 40A
60A CABIN
C/FAN FUSE F/BOX TCCU IGN PTC PTC
PULLER (B+POWER2) KEY2 Heater 2 Heater 1
30A
C/FAN PTC
REAR STARTER
(5P) HEATER 1
DEFOGGER RLY2
RLY3 RLY 1
following pages.
relays than indicated.
3. CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE
8410-02
distribution circuit diagram on the

For details about the connection of
fuses and relays, refer to the power
Therefore, there are more fuses and
The label attached on each fuse box
indicates only major fuses and relays.
02-5
FUSE AND RELAY

ECU FUSE GENERAL
02-6 8410-02
4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY

A. Interior Fuse and Relay Box On the Driver Side
24 41 O/SIDE MRR
A/BAG D/CLOCK
10A 7.5A ECM MRR S/ROOF
25 42
CLUSTER
C/LIGHTER
7.5A STICS 15A
26 43
ENG ROOM AUDIO
10A FUSE & RLY BOX 10A
FLASHER RR FOG LAMP
UNIT 27
IMMOBILIZER 44
PWR
7.5A S/LAMP 15A OUTLET
28 T/SIGNAL 45
ENG ECU
10A
BACK UP LP 10A
29 46
TCU, TCCU
10A -
30 47
ENG ECU
10A -
31 48
- -
32 49
DRL RELAY
BURGLAR HORN - 7.5A
33 50
HEAD LP
ABS
10A 15A (HIGH)
34 HEAD LP 51
RR FOG LAMP
R/SNR& AUTO LIGHT
7.5A DRL 10A INTERIOR LAMP
35 52
IMMOBILIZER
S/WARMER
15A 7.5A BUZZER, CHIME
36 53
FRT WIPER DOOR LOCK
20A WASHER 15A B/HORN
HEAD LP (HIGH)
37 54
FOLDING
A/CON
7.5A 7.5A DIAGNOSIS
38 55
- -
39 STICS 56
FRT & RR STARTER
7.5A GLASS HEATER 10A
40 57
DEF IND
ALTERNATOR
7.5A 7.5A O/S MRR DEF
* PLEASE USE THE DESIGNED FUSE AND RELAY.

AFFECTED VIN
8410-02 02-7
GENERAL
B. Interior Fuse and Relay Box On the Passenger Side
FUSE
ECU
58 65
- -
59 66
*DSL HAZARD LAMP
- 15A
ENG ECU 60 67
PASS P/SEAT
- 20A
61 68
- -
62 69
- -
63 70
ENG ECU AUDIO UNIT BLOWER
7.5A 15A
64 71
ENG ECU
7.5A -
FOLDING UNFOLDING
* PLEASE USE THE DESIGNED FUSE AND RELAY.

AFFECTED VIN
02-8 8410-02
5. OPERATING PROCESS OF ICM BOX

A. Overview
B. Mounting Location
Turn signal
lamp relay
de-icer relay relay
STICS

ICM box
NOTE

AFFECTED VIN
8410-02 02-9
C. Operating Process By Power Supply Of ICM Box
GENERAL
(1) Door lock relay
ALT
D
FUSE
B
ICM Box
SB FUSE
[Ef14] 30 87 1
NO.7
Windshield de-icer SW
10 86 85 3
10A
ECU
Hazard Lamp Relay
30 86 85 87 87
SB.12 NO.66 18 7
30A 17
[40A]
Door Lock
[SB9]
30A 15A 87
Door Lock 13 30
IGN SW 87a
[SB12] 86 87
ST 86
SB.04 AM2 30i 11
IG2 Door Unlock
30A (B1) 85 87a
85
150A
ALT 14
(125A) (GND)
IG1 6 67 45
[SB 6] 42 (UNLOCK) [A26] [A4]
SB.09 AM1 ACC [A1]
30A (B1) 15
20 (LOCK)
OFF DRL [B3]
[SB 5]
SB.10 NO.49 2 E C 8 STICS
30A 7.5A
B
9 Tail Lamp Relay
[B24]
[ ] : EWD No.
DRL Unit
(For EXP.)
As the ICM box is supplied with power from the fuse (12-pin) and STICS (6-pin, 15-pin), it operates the door
actuator (11-pin, 13-pin) through its door lock relay to lock/unlock the door.
In order to check the operation of the relay, measure the voltage at the connector of the ICM box and check
the output through the ICM box after operating the corresponding door.
Of course, the components for the corresponding system should be checked in advance.

AFFECTED VIN
02-10 8410-02
(2)Turn signal lamp (hazard warning lamp operation)
ALT
D
B
ICM Box
SB FUSE
[Ef14] 30 87 1
10 86 85 3
10A
Hazard Lamp Relay
30 86 85 87 87
[SB 3] 16
Turn Signal Lamp(LH)
SB.12 NO.66 18 7
30A 17
[40A]
Door Lock
[SB9]
30A 15A 87
13 30
Door Lock
IGN SW 87a
[SB12] 86 87
SB.04 AM2 ST 86
30i 11
30A 85 87a
85
150A
ALT 14
(125A) (GND)
[SB 6] IG1 6 67 45
42 (UNLOCK) [A26] [A4]
SB.09 AM1 ACC [A1]
30A (B1) 15 20 (LOCK)
OFF DRL [B3]
[SB 5] STICS
SB.10 NO.49 2 E C 8
30A 7.5A
B
9
Tail Lamp Relay
[B24]
[ ] : EWD No. DRL Unit

(For EXP.)
- When the hazard warning lamp switch is pressed for approx. 0.1 to 0.59 seconds, the hazard warning lamp
blinks 3 times at an interval of 0.35 seconds.
- When the hazard warning lamp switch is pressed for approx. 0.6 seconds or longer, the hazard warning
lamp blinks 10 times at an interval of 0.35 seconds.
- This function is only available when the ignition key is in the "ON" position.
- If the ignition key is turned to the "OFF" position during this function is activated, this function is immediately
deactivated.
- If the system receives signals for the turn signal lamp operation during this function is activated, this
function is immediately deactivated.
- While the turn signal lamp signals are already inputted, pressing the hazard warning lamp switch does not
activate the hazard warning lamp function.

AFFECTED VIN
8410-02 02-11
(3)Windshield de-icer operation
GENERAL
ALT
D
B
ICM Box
SB FUSE
FUSE
[Ef14] 30 87 1
10 86 85 3
10A
Hazard Lamp Relay
ECU
30 86 85 87 87
SB.12 NO.66 18 7 Turn Signal Lamp(RH)
30A 15A
[40A] 17
Door Lock
[SB9]
30A 15A 87
13 30
Door Lock
IGN SW 87a
[SB12]
ST 86 86 87
SB.04 AM2 30i 11
30A
85 85 87a
150A
ALT 14
(125A) (GND)
[SB 6] IG1 6 67 45
SB.09 42 (UNLOCK) [A26] [A4]
AM1 ACC [A1]
30A (B1)
15
20 (LOCK)
[SB 5] OFF DRL [B3]
SB.10 NO.49
STICS
2 E C 8
30A 7.5A
B
9 Tail Lamp Relay
[B24]
DRL Unit
[ ] : EWD No.
(For EXP.)
Pressing the windshield de-icer switch activates the de-icer for 12 minutes and pressing the switch again
deactivates the de-icer. At this time, pressing the switch again activates the de-icer for 12 minutes from the
time the switch is pressed again.

AFFECTED VIN
02-12 8210-01
8210-01 CONFIGURATION OF PCB IN ICM BOX AND

FUNCTION OF CONNECTOR
Turn signal
lamp relay
de-icer relay relay
STICS

ICM box
NOTE
Pin No. Function

1 Windshield de-icer
2 DRL (Daytime Running Light) B+
3 STICS unit windshield de-icer (45-pin)
4 -
5 -
6 STICS unit door unlock (42-pin)
7 Turn signal lamp
8 DRL (Daytime Running Light) unit
9 STICS unit DRL (41-pin)
10 Windshield de-icer B+
11 Door actuator
12 Door lock relay B+
13 Door actuator
14 Ground
15 STICS unit door lock (20-pin)
16 Turn signal lamp (LH)
17 STICS unit hazard warning lamp relay (67-pin)
18 Hazard warning lamp relay B+

AFFECTED VIN
8410-02 02-13
8410-02 CIRCUIT DIAGRAM FOR FUSE & RELAY BOX IN
GENERAL
ENGINE COMPARTMENT
A. Fuse & Relay Box In Engine Compartment I
FUSE
Interior Fuse Box LH
(Outside Rear View Mirror)
Defogger Control System Remark
ECU
Defogger
Stics(Pin 62)[A21]
ICM Box
Deicer Deicer SW(SW IND)
Deicer
Stics(Pin 45)[A4]
Engine Compartment Fuse
& Relay Box
[SB16]
Multifunction SW(P)
Wiper Motor-LO
[Ef14] Stics(Pin 55)[A14]
Front Wiper Motor(P)
Stics(Pin 45)[A2]
Multifunction (MIST,LO)
Wiper Motor-HI
Front Wiper Motor(LO)
Front Wiper Motor(HI)
Multifunction (HI)
Stics(Pin 44)[A3]
Washer Motor SW
Front Wiper Motor

[SB3]
Front Washer
Front Washer Motor
[SB9] Washer Motor(+)
Stics(Pin 35)[B18]
GND
Rear Washer
Washer Motor(-)

[ ] : EWD No.

AFFECTED VIN
02-14 8410-02
B. Fuse & Relay Box In Engine Compartment II
[SB15]
Compressor
[Ef13] A/C Compressor
[Ef12]
Rear Fog Lamp Relay
Cluster
Front Fog Lamp Front Fog Lamp (RH)

[Ef10]
Front Fog Lamp (LH)
Front Fog Lamp SW
DRL Unit No.2
Position Lamp (RH)
Tail Lamp RLY Tail Lamp (LH)

[Ef9]
[Ef8] Trailer
Tail lamp(RH)&
license plate
Position Lamp (LH)
Stics (Pin 41)[B24]

AFFECTED VIN
8410-02 02-15
C. Fuse & Relay Box In Engine Compartment III
GENERAL
(From LH Fuse Box)
Condenser Fan Relay(LO) Control System Remark
FUSE
[SB11]
Condenser Fan Motor(LH)
Condenser Fan Relay(HI)

[SB10]
ECU
Condenser Fan Motor(RH)
Condenser Fan Relay Condenser Fan Motor(LH)
Power Window Power Window Motor (RH)

[SB2]
Power Window Motor (LH)
Stics (Pin 18)[B1]

Power Window Anti-trap
[Ef2]
[SB4]
Starter
[SB12]
Starter Solenoid
Clutch SW
Inhibitor SW
[SB7]
Blower Motor
[SB8]
PWM Motor
[Ef1]
[Ef22]
Power Outlet (FRT&RR)
[Ef21]
[Ef20]
Sunroof(Pin 1)
[Ef19]
Driver side Power Seat
[Ef18]
[Ef15]
[Ef7]
Stop Lamp
HDC Operation Relay

[ ] : EWD No.

AFFECTED VIN
02-16 8410-02
D. Fuse & Relay Box In Engine Compartment IV

[Ef23]
Cluster
[SB1]
Hands-Free Unit(Pin 4) DOM
Stics(Pin 50)[A9]
Memory
[Ef6]
Blowe Unit
[SB6] Digital Clock
[SB5]
DRL Unit (Pin4)
Head Lamp LO(RH)

[Ef17]
Head Lamp (LO)
Head Lamp LO(LH)

[Ef16]
MultiFunction Light(HS1)
Stics(Pin 22)[B5]
IGN2 Fuse No.34

Starter
Head Lamp HI(LH,RH)
[Ef5]
DRL Unit(Pin.01)
[Ef4]
Hazard Lamp
Horn Horn(RH)
[Ef11]
Horn(LH)
Horn SW(For Vehicle
without airbag option)

AFFECTED VIN
8410-04 02-17
GENERAL
BOX ON DRIVER SIDE
A. Interior Fuse and Relay Box On the Driver Side I
FUSE
Interior(LH: Driver Seat) Fuse&Relay Box
Airbag ECU(Pin5)
Cluster(B-20)
Stics(Pin 49)[A8]
ECU
Fuel Filter(Pin 3)
Glow Plug Unit
PTC Relay
A/C Compressor Relay
Wheel Speed Sensor
Alt.D(Cluster A-10)
Stop Lamp SW(Normal Close)
Auto Cruise SW
Immobilizer (Pin2)
A/T Shift Lock Relay

Backup Lamp& back sonar
Turn Signal Lamp
TGS Lever
GSL Engine ECU(Pin 11)
GSL Sensor & Injector RLY
GGFuse No.38 Fuel Pump Relay
Fuse No.56
Fuse No.41/ Hands-Free Unit DOM

42/43
Rain sensor & Auto Light

Head Lamp Relay(LO,HI)
Head Lamp Leveling Device SW
Front Seat Warmer LH

Front Seat Warmer RH
Front Wiper Motor
Washer Motor
Power Outlet Relay
[ ] : EWD No.
Blower Relay
A/C Wiring Relay
Head Lamp(HI) Fuel Pump Rear Seat Warmer Relay
Relay (GSL)Relay

AFFECTED VIN
02-18 8410-04
B. Interior Fuse and Relay Box On the Driver Side II
Fuse No.34
Fuse No.35/36/37 Fuse No.30
DI Engine ECU(Pin 37)
Fuel Pump Relay
Interior(LH:Driver Seat) Fuse&Relay Box Control System Remark
Rear Wiper Motor(B)

Rear Wiper
Rear Wiper Rear Washer SW
Motor(P)
Rear Wiper
SW(M/F SW)
Rear Wiper
MTR(S)
GND
Stics(Pin48)
Rear Defoger Relay
Deicer Relay
ALT. D(Cluster A-10)
Sunroof SW
Digital Clock
Inside Room Mirror(ECM)
Outside rear view Motor
C/Light
Audio
A/V Head Unit
Fuel pump(GSL)
Fuel pump Motor(GSL)
Gasoline Eng.ECU(Pin33)
Gasoline Eng.ECU (Pin 12)

DI Engine Main Relay
Gasoline Injector/Spark Plug

Gasoline Sensor & O2 Sensor
Spare
ICM Box DRL Relay
DRL Unit(Pin 3)
M/Function DRL Relay
Head Lamp HI Light
SW(TS)
Head Lamp(LH/RH)
M/Function
Light
SW(HU)
Engine Compartment Fuse&

Relay Box(B+),S/B10-30A

AFFECTED VIN
8410-04 02-19
C. Interior Fuse and Relay Box On the Driver Side III
GENERAL
Interior(LH:Driver Seat) Fuse&Relay Box
FUSE
HeadLamp HI(LH/RH)
Sunvisor Lamp LH
ECU
Passenger Door Courtesy Lamp
M/Function Driver Door Courtesy Lamp
SW(TB)
Hazard Warning Map Lamp
Lamp SW(FL)
Hazard Warning Room Lamp

Lamp SW(FB)
Luggage Room Lamp
(EXP) Sunvisor Lamp

Flasher Unit Rear Fog Lamp Relay
Rear fog Lamp(IND)
Rear fog Lamp(LH/RH)
Front
Fog Rear Fog Lamp SW
Lamp
Immobilizer
Key Reminder
Door Lock(ICMBox)
XY Buzzer
Chime Bell
Door
Un Lock
Door Stics
Lock Stics
Stics
(Pin 69)
Tail Gate UnLock
Tailgate Unlock
Stics
(Pin 17)
O/S Mirror folding/Unfolding RLY
Diagnosis Conneator(pin16)
Rear Seat Warmer
Starting Solenoid
GSL Engine ECU(pin 2)
Rear Defogger SW(IND)

Outside rear view mirror
defogger (LH/RH)
Stop Lamp

AFFECTED VIN
02-20 8402-06

BOX ON PASSENGER SIDE
A. Interior Fuse and Relay Box On the Passenger Side I
Interior(Driver Seat) Fuse&Relay Box

(No.44/45/46/47/48/49)
Interior(LH:Passenger Seat) Fuse&Relay Box
Front Control System Remark
Power Outlet Power Outlet
Rear
Power Outlet
GND
Inlet Metering Valve(IMV)
Main(DSL) DI Engine(EU-IV)[B1]
DI(EU-IV)[B44] DI Engine(EU-IV)[B5]
Theft deterrent horn
(Hazard Warning)
Turn signal lamp-LH

Turn signal lamp-RH
Hazard Warning Lamp Relay
[A26]
ICM Box
A/V DSP&AMP(Kalosnett)
Audio Head Unit
TGS Lever
OutPut Stop Lamp SW TGS Lever
(Shift Lock)
TGS Lever
(”P” SW)
Blower
Blower Motor
GND
Gasoline Injector
Injector(EXP)
Ignition coil (GSL)(EXP)
Injector(EXP)
Engine Sensor(EXP)

[ ] : EWD No.

AFFECTED VIN
8210-01 02-21
GENERAL
8210-01 REMOVAL AND INSTALLATION OF ICM BOX
1. Disconnect the negative cable from the battery.
FUSE
2. Disconnect the OBD connector from the undercover.
ECU
ICM Box
1. Remove the IP undercover on the driver side.
a.Remove the IP side cover.
NOTICE
• Remove it by inserting a flat-bladed screw-
driver into the groove (A).

AFFECTED VIN
02-22 8210-01
b.Unscrew the one mounting screw (A), two

mounting bolts (B) and one mounting nut (C).
c.Separate the IP undercover mounting clips (D) on the driver side carefully.
Mounting clip (D)
d.Remove the fuel filler opening lever (E) and en-

gine hood opening lever (F).

AFFECTED VIN
8210-01 02-23
2. Unscrew and remove the two mounting bolts of
GENERAL
the driver side foot duct.
FUSE
ECU
3. Remove the three mounting bolts of the ICM mount-
ing bracket.
4. Disconnect the ICM connector.
5. Installation is in the reverse order of removal.

AFFECTED VIN
MEMO
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EDITION HISTORY
No. PART NO. CODE NO. PRINTING DATE MODEL NAME REMARKS
1 C145SMsp0807E AC1-8SMsp0E-8G-35A July. 2008 C145 / Q145 09 M/Y
ACTYON / ACTYON SPORTS

SUPPLEMENT SERVICE MANUAL
ISSUED BY
OVERSEAS SERVICE TEAM
SSANGYONG MOTOR CO., LTD.
150-3, CHILGOI-DONG, PYUNGTAEK-SI

GYEONGGI-DO, 459-711 KOREA
TELEPHONE : 82-31-610-2740
FACSIMILE : 82-31-610-3762
NOTE:All rights reserved. Printed in SSANGYONG Motor Co., Ltd.

No part of this book may be used or reproduced without the
written permission of Overseas Service Team.

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ENGINE

GENERAL INFORMATION ............. 01-3P

General information for vehicle

GENERAL INFORMATION 0000-00

1. SPECIFICATIONS AND IDENTIFICATION

Front View Rear View

1. Engine Number (D20DT) 1. Engine Number (G23D)

3. Certification Label 2. Chassis Number

2. SPECIFICATIONS AND CHECK ITEMS

ACTYON ACTYON SPORTS

B. Specified Oil (Fluid) and Capacity

MAINTENANCE Kilometers (miles) or time in months, whichever comes first

MAINTENANCE Kilometers (miles) or time in months, whichever comes first

MAINTENANCE Kilometers (miles) or time in months, whichever comes first

MAINTENANCE Kilometers (miles) or time in months, whichever comes first

D. Wheel Alignment Specification

DRIVE Chairman Rexton Rexton II Kyron

-0.00° ± 0.25°(RH) -0.29° ± 0.25°(RH)

Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5°(COIL) -0.79° ± 0.5°

-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

-0.12° ± 0.25°(RH) -0.19° ± 0.25°(RH)

Rear (IRS) -1.3° ± 0.25° - -0.5° ± 0.5° (COIL) -0.79° ± 0.5°

-0.78° ± 0.5° (EAS) (CROSS: 0.5°)

4.38° ± 0.4°(RH) 4.5° ± 0.4°(RH)

4.28° ± 0.4°(RH) 4.4° ± 0.4°(RH)

Rear (IRS) - -1° ± 0.25° - -

Right Handle Type Front -0.19° ± 0.25°(LH) 0° ± 0.5° 0° ± 0.5° 0° ± 0.5°

Rear (IRS) - -1° ± 0.25° - -

1. MAJOR CHANGES FOR ENGINE AND CHASSIS

Engine ECU Inhibitor Switch

DSI 6AT TGS Lever

E-Tronic 6A/T Transmission

4WD Oil cooler return 2WD

As the soot is filtered in the CDPF, the

CDPF Temperature sensor

Rear Exhaust Gas Front Exhaust Gas

2. DSI M78 6-SPEED AUTOMATIC TRANSMISSION

Torque Converter Oil Pump

The inhibitor switch is installed on the side of the

Variable Bleed Solenoid

Clutch 1 Clutch 2 Clutch 3

Double Planetary Gear Set

The double planetary gear set is installed to

Simple Planetary Gear Set

Simple Planetary Gear Set

The simple planetary gear set is driven by

3. MAJOR CHANGES FOR ELECTRICAL SYSTEM AND BODY

ICM Box Bag Hook

As the ICM box is newly installed, the following relays are

Wheel & Tire Rear Air Dam

Newly designed wheel are tire are installed.

General information Removal and installation

Configuration and functions

CDPF (EURO IV) 2412-02

1. OVERVIEW FOR CDPF (EURO IV)

B. Compatibility of CDPF System by Vehicle Model

C. System Met with EURO IV Regulations

2. CDPF (EURO IV) SYSTEM