0000-00 01-3

1. SPECIFICATIONS AND IDENTIFICATION

1) Exterior Dimensions Unit: mm
Top view

Side view

Front view Rear view

GETtheMANUALS.org
01-4

2) Vehicle (Engine) Identification

The identification numbers including the vehicle identification number and the engine number are the
unique information of the vehicle. If you know this information, it is very convenient for making inquiries
about the vehicle or placing an order for a component or accessory.

(1) Certification label

The certification label includes information including the vehicle identification number, tire inflation
pressure, vehicle weight, and color necessary for maintaining the vehicle properly.

TYPE A TYPE B

The certification label is attached to the driver’s door sill (B pillar).

(2) Vehicle Identification Number (VIN)

The vehicle identification number (VIN) is the identification number that includes vehicle model,
manufacturing country and manufacturing year.

Vin Label

The VIN is stamped on top of the instrument panel.

GETtheMANUALS.org
 0000-00 01-5

(3) Engine number

The engine number is the identification number including the type of fuel, engine type and displacement,
etc.

Gasoline Engine Diesel Engine

The engine number is stamped on the bottom The engine number is stamped on the bottom
surface of the cylinder block behind the intake surface of the cylinder block behind the exhaust
manifold. manifold.

GETtheMANUALS.org
01-6

▶ Vehicle identification number

▶ Engine identification number

GETtheMANUALS.org
 0000-00 01-7

2. SPECIFICATIONS AND CHECK ITEMS

1) Specifications for Each Unit

* ( ) Options, vehicle weights and gross weights are based on the maximum values and they depend
on vehicle options and specifications.

GETtheMANUALS.org
01-8

GETtheMANUALS.org
 0000-00 01-9

GETtheMANUALS.org
01-10

2) Fluid Specifications And Capacity

- 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.

GETtheMANUALS.org
 0000-00 01-11

3) Scheduled Maintenance Services

(1) Diesel Engine (EU)

GETtheMANUALS.org
01-12

GETtheMANUALS.org
 0000-00 01-13

GETtheMANUALS.org
01-14

(2) Diesel Engine (GEN)

GETtheMANUALS.org
 0000-00 01-15

GETtheMANUALS.org
01-16

GETtheMANUALS.org
 0000-00 01-17

(3) Diesel Engine (under severe condition)

GETtheMANUALS.org
01-18

GETtheMANUALS.org
 0000-00 01-19

GETtheMANUALS.org
01-20

(4) Gasoline Engine

GETtheMANUALS.org
 0000-00 01-21

GETtheMANUALS.org
01-22

GETtheMANUALS.org
 0000-00 01-23

(5) Gasoline Engine (under severe condition)

GETtheMANUALS.org
01-24

GETtheMANUALS.org
 0000-00 01-25

GETtheMANUALS.org
01-26

3. SPECIAL TOOL
Part number and name Special Tool Use
Part no.: X9911 0010A
(G16DF, D16DTF)

Name:
Stopper - Flywheel ring gear

Usage:
Fixed on the flywheel ring gear to
prevent the engine from rotating
when tightening the crankshaft
pulley bolts and flywheel bolts.

Part no.: Y99220010A

Name:
Installation and removal
equipment for urea pump module
(ADM)

Usage:
Lock or unlock DCU & supply
module CamLock

Part no.: A99000532A

Name:
ACC radar calibration stand

Usage:
Calibrating ACC radar (reflector)

Part no.: X9948 0052A

Name:
Rear brake piston fitting tool

Usage:
Used to fit the brake piston when
installing the rear brake pad.

GETtheMANUALS.org
 0000-00 01-27

Part number and name Special Tool Use

Part no.: X9936 0080A
(G16DF, D16DTF)

Name:
AISIN 6 A/T housing bottom oil
filler adapter

Usage:
Oil filler adapter for filling with oil at
AISIN 6 A/T housing bottom

Part no.: X9936 0120A

(2WD, AWD A/T Only)

Name:
AISIN 6 A/T oil seal installer
(manual shaft)

Usage:
For fitting A/T manual shaft oil
seal

Part no.: X9936 0130A

Name:
AISIN 6A/T oil seal puller (LH &
RH side)

Usage:
For removing A/T LH & RH oil
seal

Part no.: X9936 0140A

Name:
AISIN 6 A/T oil seal puller (oil
pump)

Usage:
For removing A/T oil pump oil seal

GETtheMANUALS.org
01-28

Part number and name Special Tool Use

Part no.: X9941 0060A

Name:
HUF_TPMS wheel module
remover/installer

Usage:
Used to remove and fit valve body
of TPMS wheel module

GETtheMANUALS.org
 0000-00 01-29

4. GENERAL DEDICATED EQUIPMENTS

Part number and name Special Tools Usage
Part name:
Front camera module compensating
plate

Usage:
Calibrating front camera module

Seller:
http://www.toolntech.com

Part name:
Laser level (GLL3-80, Bosch)

Usage:
Determining vehicle centerline

Seller:
E-mail: [email protected]
Phone: +82 313 266144
Contact point: Bosch korea

Part name:
Tripod (BS-150)

Usage:
Mount laser level

Seller:
E-mail: [email protected]
Phone: +82 313 266144
Contact point: Bosch korea

Part name:
Digital goniometer (DWL-80E)

Usage:
Measuring angle of front radar
module (FRM)

Seller:
Available on the market

GETtheMANUALS.org
01-30

Part name Special Tools Usage

Name:
Jack for engine with transmission

Usage:
Supports the modules when
working with engine assembly,
fuel tank, subframe.

Name:
Engine crane (1 ton or more)

Usage:
Used to move the removed
engine module with transaxle to a
working area or an engine stand.
Use an equipment which is
designed to carry load of 1 tone or
more.

Name:
Engine stand (1 ton or more)

Usage:
Used to secure the removed
engine or engine with transaxle.
Use an equipment which is
designed to carry load of 1 tone or
more.

Name:
Engine support hanger

Usage:
Used to securely hold the engine
to prevent it from dropping when
working with the timing gear case
cover, engine mounting insulator,
or transmission.

GETtheMANUALS.org
 0000-00 01-31

Part number and name Special Tools Usage

Part no.:
Y99220082B
W99110230A

Name:
Valve spring complete

Y9922082B W99110230A
Part no.: Y99220182B

Name:
Valve stem seal remover

Usage:
Used to protect the stem seal
from damage when removing
the valve stem seal.

Part no.: A99110031B

Name:
Piston compression ring
clamping strap

Usage:
Used to insert the piston in the
cylinder block.

GETtheMANUALS.org
01-32

Part number and name Special Tools Usage

Name:
Fuel pump cover
installer/remover

Usage:
Used to install or remove the fuel
pump cover.

품번 및 품명 특수공구 용도
Part no.: SSM00701-001

Part Name:
High-pressure fuel pump gear &
timing tool
(D16DTF only)

Usage:
Used to remove and install
D16DF high-pressure pump gear
and check timing

Seller:
http://www.toolntech.com

Part no.: SSM00701-003

Part Name: Glow Plug

Socket(D16DTF only)

Usage: Used to remove and

install glow plug

Seller:
http://www.toolntech.com

GETtheMANUALS.org
 0000-00 01-33

Part number and name Special Tools Usage

Part no.: SSM00701-002

Part Name: Low-pressure fuel

pressure gauge

Usage: Used to measure low-

pressure fuel line's pressure

Seller:
http://www.toolntech.com

Part Name: Fuel filter wrench

Usage: Used to remove and

install D16DTF fuel filter.

GETtheMANUALS.org
 0000-00 04-3

1. GLOSSARY

GETtheMANUALS.org
04-4

GETtheMANUALS.org
 0000-00 04-5

GETtheMANUALS.org
04-6

GETtheMANUALS.org
 0000-00 04-7

GETtheMANUALS.org
04-8

GETtheMANUALS.org
 0000-00 04-9

GETtheMANUALS.org
04-10

GETtheMANUALS.org
 0000-00 04-11

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Category Specifications Remarks
Engine model G15DTF
Engine type / Number of cylinders In-line 4 cylinders
Displacement (cc) 1,497
Compression ratio 9.5
Max. power (PS) 163
Max. torque (Nm) 280
Removable cylinder block and bed
Cylinder block
plate (high-pressure die casting)
Valve system DOHC 16-valve / Dual CVVT
Timing chain 8 mm bush chain -

Intake manifold Plastic type + electric throttle

Exhaust manifold Integrated with cylinder head
8 mm offset
Crankshaft
(Crankshaft offset from piston)
Cooling system Inlet control (Thermostat)
Lubrication system With VOP
Engine oil capacity 4.5 ℓ
Coolant capacity 7.0 ℓ
Fuel tank capacity 50 ℓ

GETtheMANUALS.org
01-4

2. APPEARANCE
Front view Rear view

Right view Left view

GETtheMANUALS.org
 0000-00 01-5

3. MAJOR COMPONENTS
▶ Front view

Cam shaft adjuster solenoid

Oil dipstick gauge

Oil filter

Alternator

Water pump pulley

Idle pulley

Auto tensioner

A/C compressor pulley

Touch idler pulley

Crankshaft pulley

▶ Rear view

Vacuum pump

LH hanger bracket

Coolant temperature sensor

Electronic throttle body

High pressure pump

Cylinder head coolant outlet

port

Coolant pipe

Flywheel (M/T)
Drive plate (A/T)

Cylinder block coolant outlet

port

GETtheMANUALS.org
01-6

▶ Left view

RH hanger bracket

Turbocharger

Water pump

Front oxygen sensor

Cylinder block outlet port

Thermostat housing

Rear oxygen sensor

Oil pressure sensor

A/C compressor

▶ Right view

PCV

PCSV

Intake manifold

Electronic throttle body

Alternator

Oil pan

Oil drain plug

GETtheMANUALS.org
 0000-00 01-7

4. ENGINE COMPARTMENT LAYOUT

Brake fluid reservoir tank Fuse and relay box

Coolant reservoir tank

Engine oil filler cap

Air cleaner

Oil dipstick gauge Oil filter Battery

- When checking the engine compartment, be careful not to touch the hot components such
as engine, radiator, exhaust manifold, catalytic converter, and muffler immediately after the
engine has been stopped. Check the engine compartment after the engine has been cooled
down sufficiently.
- Regularly check the engine oil level and add Ssangyong genuine engine oil, if necessary.
- Clean the oil dipstick gauge with a clean cloth to prevent any foreign material from entering.

- Operating the vehicle with insufficient amount of engine oil will result in severe damage the engine.
Make sure that the engine oil level is correct and add oil, if necessary.

GETtheMANUALS.org
01-8

1) Major Check Items and Service Interval

Check item Daily check Weekly
Change interval
check
Change check 7,500 km of driving, then change at every
15,000 km of driving or 12 months whichever comes
Engine oil
Check - first.
and oil filter
Check the oil level randomly and add if necessary,
Service more frequently under severe conditions
Replace the oil filter when changing the engine oil.

Coolant Check - Change at every 5 years or 200,000 km of driving.

(Long life antifreeze)
Clean at every 10,000 km of driving and replace at every
Air cleaner 40,000 km of driving.
- Check Clean or service more frequently under severe
element
conditions such as driving on a dusty road or off-road.

Service at every 30,000 km of driving.

Fuel filter - - Region where bad fuel is used: Change at every 50,000
km

2) Fluid Specifications And Capacity

- Ssangyong genuine engine oil
Specifications
Engine oil - (ZIC
Approved
SYMC by5W-30,
ACEA ZIC
C2 SAE 0WFE
SYMC 305W-20)
Specifications
- Approved by MB 229.51 5W30, MB 229.52 5W30, API SN
Capacity Approx. 4.5 L
/ ILSAC GF-5 5W20
Ssangyong genuine coolant (Long life antifreeze)
Specifications
Coolant (water:antifreeze = 50:50)
Capacity Approx. 7.0 L

Severe conditions
- Driving at high engine rpm or high speed, Excessive idling
- Driving for more than 2 hours at constant high speed (higher than 80% of maximum speed)
- Driving on dusty roads (off-roads) or muddy roads
- Driving on salted roads (coastal road, snow-melt road)
- Driving with high load such as trailer towing, cargo loaded

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Category Items Specified value Remarks
Cylinder Cylinder head height 132 ± 0.08 mm
head
Cylinder head weight 13.5 kg
Bottom (combustion All 0.075 mm
chamber surface)
Range 0.03 mm
flatness
(100 x 100 mm)

Spark plug installation angle 8° to intake side

Head gasket thickness 0.55 mm
Camshaft Camshaft axial end Intake side
play 0.08 to 0.18 mm
Exhaust side
Connecting End play 0.100 to 0.300 mm
rod
-
Cylinder Weight 21.5 kg
block
Bore Ø76 mm
assembly
Stroke Ø82.5 mm
Bore pitch 85 mm
Bed plate height 63.5 mm
Cylinder block + Bed plate 274.36 mm
height (210.86 mm to 63.5 mm)
Crankshaft Crankshaft axial end play 0.100 to 0.266 mm

Piston ring End gap No. 1 compression 0.14 to 0.19 mm

ring
No. 2 compression 0.20 to 0.30 mm
ring
No. 3 oil ring 0.10 to 0.40 mm

GETtheMANUALS.org
02-4

2. ENGINE TIGHTENING TORQUE

Tool dimensions Bolt Specified
Components Remarks
Quantity torque (Nm)
Belt tensioner 17 mm 1 61 ± 2.0 Nm
200 Nm
Crankshaft pulley 27 mm 1
90°
Engine ground cable 10 mm 2 10 ± 1.0 Nm
Alternator 17 mm
15 1 61 ± 6.1 Nm
A/C compressor 13mm
17 mm 4
1 25 ± 2.5 Nm
Water
A/C pump pulley
compressor 10
13 mm 3
4 10 ± 2.5
25 1.0 Nm
Water pump pulley 5 mm
10hexagon
mm 3 10 ± 1.0 Nm
Water pump 5 10 ± 1.0 Nm
wrench
Water pump 5 mm hexagon 5 10 ± 1.0 Nm
Exhaust manifold heat wrench
10 mm 4 10 ± 1.0 Nm
protector
Exhaust manifold heat 10 mm 4 10 ± 1.0 Nm -
Turbocharger coolant
protector 17 mm 2 40 Nm
inlet
Exhaust manifold 12 mm 7 40 ± 5.0 Nm
Turbocharger coolant
17 mm
13 mm 1
3 402.5
25 ± NmNm
outlet
TOC coolant return pipe
10 mm 2 10 ± 1.0 Nm
(vehicle with A/T)
Coolant return pipe
10 mm 3 10 ± 1.0 Nm
(vehicle with M/T)
TOC coolant supply pipe
10 mm 2 10 ± 1.0 Nm
(vehicle with A/T)
Cylinder head outlet port 5 mm hexagon
3 10 ± 1.0 Nm
wrench
Cylinder block outlet port 5 mm hexagon
2 10 ± 1.0 Nm
wrench
4 Bolt length: 110 mm
Oil filter module 13 mm 25 ± 2.5 Nm
3 Bolt length: 40 mm
5 mm hexagon
Thermostat 2 10 ± 1.0 Nm
wrench
Electronic throttle body 10 mm 4 10 ± 1.0 Nm -
Fuel rail 13 mm 4 25 ± 2.5 Nm
Intake manifold 13 mm 5 25 ± 2.5 Nm

GETtheMANUALS.org
 0000-00 02-5

Tool dimensions Bolt Specified

Components Remarks
Quantity torque (Nm)
Knock sensor 13 mm 1 20 ± 5.0 Nm
Cam shaft adjuster
10 mm 4 8 ± 1.0 Nm
solenoid
Cam position sensor 10 mm 2 10 ± 1.0 Nm -

Ignition coil 10 mm 4 10 ± 1.0 Nm

Spark plug 16 mm 4 20 ± 2.5 Nm
Cylinder head cover 10 mm 19 10 ± 1.0 Nm

Cylinder head E16 10 45 ± 4.5 Nm Non-reusable

90° X 2 times
Camshaft sprocket 22 mm 2 30 Nm + 34°
Camshaft front bearing 10 mm 4 10 ± 1.0 Nm
cap
Camshaft bearing cap 10 mm 18 10 ± 1.0 Nm
Vacuum pump cap 10 mm 2 10 ± 1.0 Nm
2 10 ± 1.0 Nm Bolt length: 115 mm
10 mm 2 10 ± 1.0 Nm Bolt length: 105 mm
Oil pan
16 10 ± 1.0 Nm Bolt length: 25 mm
13 mm 2 25 ± 2.5 Nm Bolt length: 80 mm
3 58 ± 5.8 Nm Bolt length: 80 mm
15 mm
Timing gear case cover 1 58 ± 5.8 Nm Bolt length: 50 mm
1 25 ± 2.5 Nm Bolt length: 45 mm
13 mm
10 25 ± 2.5 Nm Bolt length: 30 mm
Timing chain tensioner 5 mm hexagon 2 10 ± 1.0 Nm
wrench
Tensioner rail T40 1 25 ± 2.5 Nm
Guide rail T40 3 25 ± 2.5 Nm
Sliding upper rail 5 mm hexagon -
2 10 ± 1.0 Nm
wrench
Baffle plate 10 mm 6 10 ± 1.0 Nm
Oil pump chain T40 1 25 ± 2.5 Nm
tensioner
VOP extension wiring 5 mm hexagon
1 10 ± 1.0 Nm
wrench

GETtheMANUALS.org
02-6

Components Tool dimensions Bolt Specified Remarks

Quantity torque (Nm)
Oil pump 6 mm hexagon 4 25 ± 2.5 Nm

Connecting rod cap 12-point socket 8 20 + 2.5 Nm

8 mm 90° + 5° -

Crankshaft position 5 mm hexagon 1 5 ± 1.0 Nm

sensor wrench
Drive plate T55 8 45 ± 5.0 Nm Non-reusable
45° ± 5°
Crankshaft rear seal 10 mm 6 10 ± 1.0 Nm -

Bed plate E10 10 25 ± 5.0 Nm

Non-reusable
Main journal 12-point socket 10 55 ± 5.0 Nm
13 mm 100° + 5°
starter motor 14 mm 2 45 ± 5.0 Nm

Oil filter Oil filter installation/ - 12 to 16 Nm

removal cup -

Cylinder block coolant 19 mm 1 30 Nm

screw plug
Flywheel T55 8 45 ± 5.0 Nm Non-reusable
90° ± 5°

GETtheMANUALS.org
 0000-00 02-7

3. PRECAUTIONS
1) When Lifting the Vehicle
- Pay close attention to the safety precautions when lifting the vehicle on a jack lift as the vehicle might
slip off the jack lift.
- When working with a 4-column vehicle lift, use the center of the vehicle as a support point and chock
the wheels to prevent the vehicle from rolling.
- When work with a 2-column vehicle lift, use the jack point as a support point.
- Take care not to spill the battery electrolyte and wear protective clothing when handling the battery.

2) When Working on the Exhaust System

- Wear protective gloves when removing the exhaust pipe.
- Make sure that the exhaust pipe has sufficiently cooled down before working on the exhaust pipe,
because the temperature of the exhaust pipe is very hot right after the engine has been stopped.

3) When Working on the Fuel System

- Disconnect the negative battery terminal and prepare the service plug grip before working on the fuel
system.
- Do not smoke and avoid flames nearby when working on the fuel system.
- Keep gasoline away from the parts made of rubber or leather.
- Be sure to avoid sputtering of the fuel when removing the pipe between the high-pressure side fuel
pump and the fuel rail.
- Never remove any part of the fuel system before releasing the pressure in the fuel system.
- Even after the fuel pressure has been released, wrap a cloth or equivalent around the mountings to
reduce the potential risk of fuel sputtering to a worker or engine compartment.
- Let the engine is cooled down sufficiently before proceeding to the next procedure since the fuel
pressure on the high-pressure side will not drop until the engine is cooled down.

4) When Working on the Cooling System

- Do not remove the radiator reservoir cap while the engine or radiator is hot since high-pressure hot
coolant or steam may cause severe burn.

GETtheMANUALS.org
02-8

5) When Working on the Lubrication System

- Repeated contact with the engine oil for an extended period of time may cause skin irritation.
- Take special care when changing the engine oil to minimize possible skin contact with the
used engine oil because hazardous materials that may cause skin cancer are contained in the
used engine oil.
- Always wear the oil-resistant protective clothing and gloves when handling the engine oil, and
completely remove the used engine oil from the skin with a lot of water or waterless hand cleaner.
Never use gasoline, dilute solution or solvent to wash your skin.
- Discard the used oil and used oil filter only in the designated area to protect environment.

6) When Tightening Bolts

Angle tighten the components of engine in a so-called final tightening operation. The tightening procedure
is as follows:

① Clean the contact surface and threads before tightening bolts and nuts.
② When angle tightening without a torque wrench tighten the bolt to the specified angle, marking
its position. (paint mark to assist the work)

The location and left/right position of components are based on the direction when viewed from the
rear side.
The cylinder block is made of aluminum and can be deformed and broken easily when excessive
force is applied. Therefore, always observe the specified torque when tightening the cylinder block
to prevent its thread from being damaged.
Do not over-tighten a self tapping screw bolt as it creates threads itself.
Never reuse the used bolt if it is a angle-tightened one.
(However, a bolt with specified reuse number with the specified torque is reusable.)

GETtheMANUALS.org
 0000-00 02-9

1. MAJOR COMPONENTS
▶ Front view

Cam shaft adjuster solenoid

Oil dipstick gauge

Oil filter

Alternator

Water pump pulley

Idle pulley

Auto tensioner

A/C compressor pulley

Touch idler pulley

Crankshaft pulley

▶ Rear view

Vacuum pump

LH hanger bracket

Coolant temperature sensor

Electronic throttle body

High pressure pump

Cylinder head coolant outlet

port

Coolant pipe

Flywheel (M/T)
Drive plate (A/T)

Cylinder block coolant outlet

port

GETtheMANUALS.org
02-10

▶ Left view

RH hanger bracket

Turbocharger

Water pump

Front oxygen sensor

Cylinder block outlet port

Thermostat housing

Rear oxygen sensor

Oil pressure sensor

A/C compressor

▶ Right view

PCV

PCSV

Intake manifold

Electronic throttle body

Alternator

Oil pan

Oil drain plug

GETtheMANUALS.org
 0000-00 02-11

2. EPC
▶ 1119 ENGINE UNIT (G15DTF)

1. ENGINE ASSY
2. BRKT-ENGINE HANGER FRT
3. BRKT-ENGINE HANGER RR
4. BOLT

GETtheMANUALS.org
02-12

▶ 1122 SHORT BLOCK (G15DTF)

1. SHORT BLOCK

GETtheMANUALS.org
 0000-00 02-13

▶ 1136 CYLINDER BLOCK (G15DTF)

1. BLOCK COMPL-CYLINDER 43.BOLT-BED PLATE

9. PIN-CYLINDRICAL 44.PLUG-SCREW
21.PIN-SPRING 45.PLUG-SCREW
22.NOZZLE ASSY-OIL INJECTION 46.SCREW
35.SEAL ASSY-CRANKSHAFT RR 47.RING-SEAL
36.GROMMET-CRANKSHAFT SEALING RR 48.DEFLECTOR-WATER
39.SENSOR ASSY-CRK/SHF POSN 49.SLEEVE
40.LINER-CYLINDER 51.BOLT
42.BOLT-MAIN BEARING CAP 55.BOLT

GETtheMANUALS.org
02-14

▶ 1132 CRANKSHAFT AND FLYWHEEL (G15DTF)

1. CRANKSHAFT 2.5CONNECTING ROD ASSY

2. PIN-CYLINDRICAL 27.BOLT-CONNECTING ROD
3. KEY-CRANKSHAFT PULLEY 33.PISTON ASSY
4. SPROCKET ASSY-CRANKSHAFT 34.RING SET-PISTON
7. DISC-CRK/SHF VIB DPR 35.SNAP RING
8. BOLT-CRANKSHAFT CTR 44.BEARING-CRK/SHF MAIN STD UPR
12.DAMPER ASSY-VIBRATION 45.BEARING-CRK/SHF MAIN STD LWR
13.FLYWHEEL ASSY-DUAL MASS 46.BEARING-CRK/SHF THRUST STD UPR
17.BOLT-FLYWHEEL MTG 50.BEARING-CONNECTING ROD STD
18.PLATE ASSY-DRIVE 55.RING-MAGNETIC TRIGGER
19.PLATE

GETtheMANUALS.org
 0000-00 02-15

▶ 1216 CYLINDER HEAD AND GASKET KIT (G15DTF)

1. HEAD ASSY-CYLINDER 34.SPRING-VALVE

5. PLUG-EXPANSION 35.RETAINER-VALVE SPRING UPR
7. BOLT 36.COTTER-VALVE
8. BOLT 39.FOLLOWER ASSY-FINGER
12.SLEEVE 40.ADJUSTER ASSY-HYDRAULIC LASH
13.BOLT-CYLINDER HEAD 44.RING-EXHAUST VALVE SEAT
22.GASKET-CYLINDER HEAD 45.BEARING-BALL
26.VALVE-INTAKE 47.RING-INTAKE VALVE SEAT
27.VALVE ASSY-EXHAUST 54.LIFTER-MECHANICAL VALVE
32.SEAL-VALVE STEM

GETtheMANUALS.org
02-16

▶ 1227 CYLINDER HEAD COVER AND CAMSHAFT (G15DTF)

1. COVER ASSY-CYLINDER HEAD 21.CAMSHAFT ASSY-EXHAUST

2. GASKET-CYLINDER HEAD COVER 22.CAMSHAFT ASSY-INTAKE
3. BOLT 26.VALVE-POSITIVE CRANKCASE VENT
4. CAP ASSY-OIL FILLER 28.HOSE-POSITIVE CRANKCASE VENT
14.HOSE ASSY-BLOW BY OUTLET 29.CLAMP
16.CLAMP

GETtheMANUALS.org
 0000-00 02-17

▶ 1312 CHAIN DRIVE (G15DTF)

1. CHAIN-TIMING 23.TENSIONER ASSY-TIMING CHAIN

2. RAIL-GUIDE 24.RAIL ASSY-SLIDING UPR
3. RAIL-TENSIONER 25.BOLT
10.SPROCKET ASSY-CRANKSHAFT 26.SOLENOID VALVE-CAM/SHF ADJ
12.CENTER BOLT ASSY-CAM/SHF ADJ 27.BOLT-COAT_M6x1.0x16
20.ADJUSTER ASSY-INTAKE CAMSHAFT 30.CHAIN-OIL PUMP
21.BOLT 32.ADJUSTER ASSY-EXHAUST CAMSHAFT
22.BOLT 34.TENSIONER ASSY-OIL PUMP CHAIN

GETtheMANUALS.org
02-18

▶ 1335 TIMING CASE (G15DTF)

1. COVER-TIMING GEAR CASE 25.PULLEY ASSY-IDLER

2. SEALING-CRANKSHAFT FRT 30.PLATE-OIL DIPSTICK
3. BOLT 31.SCREW
4. TENSIONER ASSY-BELT 32.BOLT-STUD
5. BOLT 33.RING-O
7. COVER-IDLER PULLEY 34.PLUG ASSY-SCREW
8. PULLEY ASSY-IDLER

GETtheMANUALS.org
 0000-00 02-19

▶ 1350 BELT SYSTEM

1. BELT-POLY GROOVED

▶ 1480 A/C COMPRESSOR

1. COMPRESSOR ASSY-A/CON
2. BOLT

GETtheMANUALS.org
02-20

▶ 1990 ENGINE MOUNTING

1. INSULATOR-ENGINE MTG 7. BOLT-ENGINE MTG

2. INSULATOR-ENGINE MTG 8. NUT
3. BRKT-ENGINE MTG 9. BOLT
4. INSULATOR-ENGINE MTG LWR 10.NUT-HEX FLG_M12x1.25
5. BOLT-HEX FLANGE 11.BOLT-ENGINE MTG
6. BOLT 12.INSULATOR-AIR CLEANER MTG NO1

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
Category Specifications
Fuel Gasoline
Fuel tank Capacity 50ℓ
Material Plastic
Fuel filter Type Micro paper type
Location Built in the fuel pump
Check every 30,000 km
Service interval Region where bad fuel is used: Change at every
50,000 km
Low pressure fuel Type Built in the tank, electric
pump
Drive system Electric motor
Fuel pressure 5 bar (110 ℓ/h)
Current consumption 7.5 A (12 V, 5 bar)
High-pressure fuel Flow velocity 0.76 ㎤/rev
pump
Cam profile / lift 4-lobe / lift 3.0 mm
Operating pressure 250 bar
Fuel pressure control valve 0.48~0.55Ω (20°C)
Fuel rail Capacity 67 cc
Fuel pressure Type Built in the fuel pump
regulator
Fuel pressure 5.0 ± 0.07 bar
Remaining pressure in 30 2.1 bar or higher
minutes after key OFF:
Injector Operating pressure 250 bar
Injection hole 7-hole
Rated operating mass flow 410.5 ± 5g/min @ 10Mpa N-Haptan
Injector type HDEV5.25evo

GETtheMANUALS.org
03-4

1. OVERVIEW
The fuel system consists of fuel tank, fuel pipe line, fuel filter, fuel pump, fuel pressure regulator,
injectors, fuel rail. The fuel system is a returnless control type system in which the fuel pressure regulator
is built in the fuel pump. This system is controlled by the engine ECU and each injector of the system
injects the fuel. The system also has a fuel evaporative control system which forces or blocks the vapor
gas stored in the canister to the combustion chamber using the operation of purge control solenoid valve
based on the engine load condition.

2. COMPONENTS

GETtheMANUALS.org
 0000-00 03-5

3. EPC
▶ 1891 Gasoline direct injection system (G15DTF)

1. PUMP ASSY-FUEL
3. BOLT
9. INJECTOR ASSY-FUEL
11.CLIP-INJECTOR
18.HIGH PRESSURE PIPE
23.RAIL ASSY-FUEL
25.BOLT
43.COVER-FUEL RAIL
44.SENSOR ASSY-FUEL PRESSURE

GETtheMANUALS.org
03-6

▶ 2211 Fuel tank (GSL)

1. TANK ASSY-FUEL 16.FILLER ASSY-FUEL

2. FUEL PUMP ASSY 17.CAP ASSY-FUEL FILLER
3. CANISTER COMPL 18.COVER-FUEL PUMP
4. HEAT SHIELD ASSY 19.NUT
5. TUBE ASSY-SUPPLY 20.WASHER
6. LOCK-RING 21.CLAMP-WRT_M52
7. TUBE ASSY-VAPOR TO PCSV 22.SCREW
8. WIRING ASSY-EXTENSION 23.NUT
9. COVER-FUEL PUMP PLATE 24.SCREW
10.O-RING 25.PUMP-FUEL
12.SCREW 26.SENDER ASSY
13.PAD-FUEL TANK 27.FILTER ASSY-FUEL PUMP
14.PAD-FUEL TANK 28.REGULATOR ASSY
15.STRAP ASSY-FUEL TANK

GETtheMANUALS.org
 0000-00 03-7

1. INPUT/OUTPUT DIAGRAM
The ECU determines fuel injection volume and injection timing based on the engine condition and
optimizes the engine operating conditions to reduce the emissions.

GETtheMANUALS.org
03-8

▶ Basic mapping

- Stepped control
The ECU calculates proper injection volume and timing by considering various parameters to achieve
the optimal combustion at each stage of operation.
- Starting injection volume control
The fuel injection volume during initial starting is calculated by considering the temperature and
engine cranking speed. The starting injection means the injection during the period from when
the ignition switch is turned ON until when the engine rpm reaches to the allowable minimum
speed.
- Driving mode control
The fuel injection volume during normal driving is calculated based on the accelerator pedal travel and
engine rpm and the drive map is used to match the drivers inputs with optimal engine power.

GETtheMANUALS.org
 0000-00 03-9

2. OPERAING PROCESS
1) Fuel System Flow Chart

GETtheMANUALS.org
03-10

2) Fuel Evaporative Control

The fuel evaporative control system stores the evaporative gas in the canister to prevent the evaporated
fuel being released into the atmosphere. This system diagnoses the internal system and checks for
abnormalities in the system by using the pressure sensor and canister shut-off valve installed to the fuel
tank. The purge control solenoid valve (PCSV) is operated by the engine ECU control according to the
engine load condition. The fuel evaporative gas, stored in the canister, is drawn into the engine due to
vacuum condition (negative pressure) of the engine when the PCSV is open while the fuel evaporative
gas in the fuel system is sucked and stored in the canister when the PCSV is closed.

GETtheMANUALS.org
 0000-00 03-11

3) Fuel Pump
▶ Fuel filter

The fuel filter is built in the fuel pump. This filer is a micro paper filter type. Service the fuel filter at every
30,000 km of driving.

Fuel filter

GETtheMANUALS.org
03-12

▶ Fuel pressure regulator

The fuel pressure regulator is installed on the bottom of the fuel filter in the fuel pump assembly.
This component keeps the fuel pressure in the fuel system at about 5.0 ± 0.07 bar when the
engine is running.

Fuel filter fitted Fuel pressure regulator

Fuel pressure regulator pressure gradient

GETtheMANUALS.org
 0000-00 03-13

▶ Fuel sender

The fuel sender is installed to the fuel pump assembly in the fuel tank. It measures the fuel level. The
float of the fuel sender moves up and down according to the fuel level in the fuel tank when the ignition is
turned ON. The fuel sender detects the resistance which changes as the float moves up and down and
sends this value to the instrument cluster module. The instrument cluster module calculates using this
resistance value and illuminates the fuel level indicator.

Fuel sender

GETtheMANUALS.org
03-14

Data output of fuel sender

GETtheMANUALS.org
GETtheMANUALS.org
03-16

3. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 03-17

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
Category Specifications
Spark plug Internal resistance 3 ~ 7.5 kΩ at 1 KV
Center electrode Iridium alloy
Ground electrode Platinum alloy
Electrode clearance 0.7 to 0.8mm
Change interval 60,000 km
(check and replace if necessary)
Heat range 6
Ignition coil Primary operating current /
14 ± 0.5 / Max. 13 A
voltage
Secondary voltage 36KV
Ignition type Independent ignition type
Ignition sequence 1-3-4-2

GETtheMANUALS.org
04-4

1. OVERVIEW
The ignition system is to supply high voltage generated from the ignition coils to the spark plugs. The
G15DTF engine is equipped with the independent direct ignition system in which each cylinder has its
own ignition coil and spark plug.

2. COMPONENTS
Knock sensor

T-MAP sensor

Ignition plugs (4 off) Ignition coils (4 off)

GETtheMANUALS.org
 0000-00 04-5

Camshaft position sensor (2 off)

ECU

Coolant temperature sensor

Crankshaft position sensor Accelerator pedal sensor

GETtheMANUALS.org
04-6

3. EPC
▶ 1442 ignition coil (G15DTF)

1. COIL-IGNITION
2. BOLT
3. SPARK PLUG

GETtheMANUALS.org
 0000-00 04-7

▶ 1412 Engine main wiring (G15DTF)

2. WIRING ASSY-ENGINE MAIN 17.BOLT

10.WIRING ASSY-ENGINE EARTH 18.BOLT
13.BRKT-ENGINE MAIN WIRING 20.BRKT-M/T
14.BRKT-IGNITION 21.BRKT-A/T
15.BRKT-ENGINE FRT 22.BRKT-ENGINE MAIN
16.BOLT

GETtheMANUALS.org
04-8

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 04-9

The default ignition timing for each cylinder is determined based on the signals from the camshaft
position sensor and crankshaft position sensor. The engine control unit (ECU) controls the ignition timing
more precisely by using the following information:
- Engine load
- Coolant temperature
- Intake air temp.
- Engine speed (rpm)
- Camshaft position sensor
- Crankshaft position sensor
If the engine ECU does not receive the signal from the crankshaft position sensor, the ignition coil and
fuel system will not work.

GETtheMANUALS.org
04-10

2. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 05-3

1. SPECIFICATIONS
Category Specifications
Filter type Dry, filter element

Air cleaner Filtering area 0.3m²

Element Clean at every 15,000 km of driving.
Service interval
Replace at every 30,000 km of driving
Weight 1.5kg
Air cleaner Operating temperature
-30 to 100°C
assembly
Internal capacity 9L
Core material Aluminum
Core size 620 x 134.7 x 63 (Width X Height X Thickness)
Intercooler
Tank material Plastic (injected)
Efficiency 85%

* Service more frequently under severe conditions, such as driving on a dusty road or off-road.

2. CAUTIONS

1. Service more frequently under excessive use or severe conditions, such as driving on a dusty road
2. or off-road, or driving in the rain for a long period of time.
Failure to follow the changing interval may cause:
- Insufficient engine power
- Excessive emissions
- Prematurely worn turbocharger, engine cylinder walls, pistons, piston rings and intake
valves

GETtheMANUALS.org
05-4

1. OVERVIEW
The intake system filters the air and supplies this to the engine. This system assures the engine
performance and the lifetime of the engine. The intake system is equipped with electronic throttle body.
The flap of the electronic throttle body is operated by the electric signals to improve the engine
performance.

2. COMPONENTS
Intake manifold assembly

T-MAP sensor PCSV

T-MAP sensor Electric throttle body

GETtheMANUALS.org
 0000-00 05-5

Air cleaner assembly & snorkel Air cleaner element

Water protector

GETtheMANUALS.org
05-6

3. EPC
▶ 2313 Air cleaner

1. AIR CLEANER ASSY 7. PROTECTOR-WATER

4. ELEMENT ASSY 8. HOSE ASSY-A/CLNR TO ENG
5. INSULATOR-AIR CLEANER MTG NO1 9. BOLT
6. SNORKEL ASSY 10.SCREW RIVET-RR FASCIA MTG

GETtheMANUALS.org
 0000-00 05-7

▶ 2331 Air intercooler (GSL)

1. INTERCOOLER ASSY 10.DUCT ASSY-I/COOLER TO ENG

2. HOSE ASSY-I/COOLER OUTLET 11.SCREW
3. CLAMP 12.NUT
5. HOSE ASSY-A/CLNR TO T/CHARG 13.SCREW
7. HOSE ASSY-T/CHARG TO I/COOLER

GETtheMANUALS.org
05-8

▶ 1744 intake manifold (G15DTF)

1. MANIFOLD ASSY-INTAKE 8. BOLT

2. BOLT 9. COVER ASSY-ACOUSTIC
5. BRKT-INTAKE MANIFOLD 10.GASKET-THROTTLE BODY
6. BOLT 11.GASKET-INTAKE MANIFOLD
7. THROTTLE BODY-ELECTRIC 27.BOLT

GETtheMANUALS.org
 0000-00 05-9

1. INPUT/OUTPUT DIAGRAM

System diagram

GETtheMANUALS.org
 0000-00 06-3

1. SPECIFICATIONS
Category Specifications Remarks
Exhaust manifold type Integrated with cylinder head
-
Catalyst CCC
Exhaust muffler Front exhaust pipe + Rear muffler

Ultra low emission vehicle in compliance with enhanced emissions standards

KULEV is an emission control regulation.

- Regulated emissions are carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxides (NOx) at
higher level compared with the previous regulation (KLEV).

Regulation limit (g/km) - based on manufactured

With
Item vehicle
time point
HC CO NOx
KULEV 2006 0.034 1.31 0.044

2. CAUTIONS
- Do not park the vehicle on flammable materials, such as grass, leaves and carpet.
- Do not touch the catalyst or the exhaust gas ignition system when the engine is running.
- If a misfire occurs in the combustion chamber or the emissions of pollutant exceeds the specified
level, the catalyst can be damaged.
- When servicing or replacing components of the exhaust system, make sure that the components
have certain spaces from all other parts of the under body.
- Be careful not to damage the exhaust system when lifting the vehicle from its side.
- All components and body parts of the engine exhaust system should be inspected for cracks,
damage, air hole, part loss and incorrect mounting locations. Also check for any deformation which
can result in exhaust gas drawn into the vehicle.
- Make sure that the exhaust pipe has been cooled down sufficiently before working because it is very
hot right after the engine has been stopped.
Wear protective gloves when removing the exhaust pipe.

GETtheMANUALS.org
06-4

1. OVERVIEW
This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants
and noise during that arise during combustion.
Harmful materials produced in the combustion process are treated and reduced in the exhaust system to
reduce emission levels.

2. COMPONENTS
CCC assembly

Front exhaust pipe

Center muffler complete

Rear muffler complete

GETtheMANUALS.org
 0000-00 06-5

3. EPC
▶ 2424 Exhaust system (GSL: G15F)

1. CCC COMPL 10.HANGER

2. PIPE ASSY-EXHAUST FRT 11.HEAT PROTECTOR-EXHAUST FRT
3. MUFFLER COMPL-CTR 12.HEAT PROTECTOR-EXHAUST CTR
4. MUFFLER COMPL-RR 13.HEAT PROTECTOR-RR MUFFLER
5. GASKET 14.NUT
6. HANGER 15.NUT
7. HANGER 18.BOLT
9. GASKET-RING 19.NUT

GETtheMANUALS.org
06-6

1. SYSTEM DIAGRAM

▶ Hazardous emissions

a. In relation to stoichiometric air-fuel-ratio

Category Lean Slightly lean Rich

Increased HC Increased NOx Increased CO, HC
Emissions
Reduced CO, NOx Reduced CO, HC Reduced NOx

b. In relation to engine temperature

Category Low temperature High temperature

Increased CO, HC Increased NOx
Emissions
Reduced NOx Reduced CO, HC

c. In relation to driving conditions

Category Idling Accelerating Decelerating

Increased CO, HC Increased CO, HC, NOx Increased CO, HC
Emissions
Reduced NOx - Reduced NOx

GETtheMANUALS.org
 0000-00 07-3

1. SPECIFICATIONS
Category Items Specifications
Max. temperature of turbine housing 980℃
Turbine housing outlet inner diameter 63 mm
Turbocharger
Compressor housing inlet inner diameter 60 mm
Cooling method Water-cooled
E-actuator Operation duty cycle 250 Hz

GETtheMANUALS.org
07-4

1. OVERVIEW
The EWGA (Electric Waste Gate Actuator) turbocharger fitted to the G15GDI engine has the turbine and
compressor with different angle in both ends of 1 axle. The compressor housing is connected to the
intake manifold and the turbine housing to the exhaust side. When the turbine is rotated by the exhaust
gas pressure, the compressor wheel on the suction side is also rotated. Therefore, the air nearby the
compressor wheel center is subjected to the centrifugal force, accelerated towards the outer periphery,
and enters the diffuser.
For the air supplied to the diffuser, since the passage has a large area, the velocity energy is converted
into the pressure energy and supplied to the cylinder, thereby improving the volume efficiency. In
addition, the exhaust efficiency is improved since the exhaust turbine rotates. The turbocharger is also
called as an exhaust turbine supercharger.
Diffuser: device to convert velocity energy of the fluid into pressure energy by widening the passage to
make flow slow.
The G15GDI engine has the EWGA turbocharger system to control the waste gate electronically in the
turbocharger to control the rotational speed of the turbine, thereby adjusting the intake air volume.

GETtheMANUALS.org
 0000-00 07-5

2. COMPONENTS
T-MAP sensor Electric throttle body Coolant temperature
sensor

eWGA turbocharger Accelerator pedal Engine ECU

sensor

GETtheMANUALS.org
07-6

3. EPC
▶ 1917 Turbocharger (G15DTF)

1. TURBOCHARGER ASSY 9. BOLT

2. BOLT-STUD 11.BOLT-HOLLOW_M10x1x23
3. NUT 15.GASKET-TURBO
4. TUBE ASSY-OIL SUPPLY 16.BRKT-TURBOCHARGER SUPT
5. BOLT 18.NUT
6. SEAL ASSY-RING 33.HEAT PROTECTOR-TURBO
7. TUBE ASSY-OIL RETURN 34.BOLT
8. GASKET-TURBO OIL RETURN

GETtheMANUALS.org
 0000-00 07-7

1. OPERATING PROCESS
▶ eWGA (Electric Waste Gate Actuator)

The EWGA operates the swing valve through

the signal from the ECU in the turbocharger to
control the compressed air volume sucked into
the engine.

▶ RCV (Recirculation Valve)

The RCV is fitted to the top of the inlet port of the

turbocharger. When it is operated by the signal
from the ECU, it bypasses the air sucked into the
turbocharger.
When the accelerator pedal is released, the
throttle valve is closed suddenly, the pressure in
the intake air line rises sharply. This causes the
compressed air to be flowed backward and
crash sound of the compressor wheel. At this
time, the RCV bypasses the compressed air to
prevent the pressure in the intake air line from
being increased rapidly.

GETtheMANUALS.org
07-8

2. CONFIGURATION DIAGRAM
▶ Compressor housing & turbine housing

1. Compressor housing: This induces fresh air to

the compressor wheel (Impeller) and supplies
the compressed air to the intercooler through
the hose.
2. Turbine housing: This is located on the
exhaust manifold and turns the turbine wheel
to send the exhaust gas to the exhaust pipe
using the pressure of exhaust gas.

▶ Impeller

1. The impeller is wings (wheel) installed on the

intake end and performs the role of
pressurizing air into the cylinder.
2. The radial type has the impeller plate
arranged in straight line at the center of shaft
and, compared to the backward type, is
being widely used as it is simple, easy to
manufacture and appropriate for high speed
rotation. As the impeller rotates in the
housing with the diffuser installed in it, the air
receives centrifugal force to be accelerated in
the direction of housing's outer circumference
and flows into the diffuser. As surface of the
passage increases, air flown into the diffuser
transforms its speed energy into pressure
energy and flows into the intake manifold
where the pressurized air is supplied to
cylinder each time the intake valve of cylinder
opens up. Therefore, the efficiency of
compressor is determined by the impeller
and diffuser.

GETtheMANUALS.org
 0000-00 07-9

▶ Turbine

The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the
compressor and performs the role of transforming heat energy of exhaust gas into torque energy. The
radial type is used as the turbine's wings.
Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it rotates
in high speed, it requires to have sufficient rigidity and heat resisting property. During operation of the
engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate by
coming in contact with the turbine's wings from the outer circumference within housing of the turbine and
is exhausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it
rotates.

▶ Floating bearing

Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 1 to 250,000 rpm. It
could be rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from
the engine.

GETtheMANUALS.org
07-10

3. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 08-3

1. SPECIFICATIONS
Category Specifications Remarks
OIL PUMP Lubrication method Gear pump, forced circulation
Type Vane type + Solenoid valve (VOP)
Number of sprocket teeth 33
Pressure valve opening 7.0 ± 1 bar
pressure
VOP Sol. On 2.7 ± 0.5 bar (pump outlet pressure)
pressure
Sol. Off 5.4 ± 0.5 bar (pump outlet pressure)
Oil filter Type Water and thermostat housing +
module Oil filter module
Oil flow rate About 40 L/min (80°C)
Bypass valve opening -
1.0 ± 0.2 bar
pressure
Non-return valve opening
0.2 ± 0.04 bar
pressure
Filter service interval After driving of 15,000 km
Engine oil Specifications Ssangyong genuine parts
(ACEA C2 0W30)
Type Ssangyong Motor genuine engine oil
Capacity (when changing) 3.5ℓ ~ 4.5ℓ
Change interval After first 7,500 km inspection, change
every 15,000 km (12 months)

GETtheMANUALS.org
08-4

1. OVERVIEW
The lubrication system supplies oil to various parts of the engine that require lubrication to reduce friction,
wear, heat on the surfaces in contact with each other. When the engine is running, frictional heat is
generated by moving parts. If this heat builds up, the bearing can be stuck. The lubrication system
creates an oil film on each contact surface of the two moving parts to convert solid friction to liquid friction
in order to reduce wear and prevent the temperature from increasing. The lubrication system is equipped
with a variable oil pump (VOP) which improves the fuel economy in low/moderate speed range and
ensures the reliability in high speed range.

2. COMPONENTS
Oil pressure switch Oil dipstick gauge Oil filter module

Baffle plate

Oil pan OIL PUMP VOP solenoid valve

VOP solenoid valve

GETtheMANUALS.org
 0000-00 08-5

3. EPC
▶ 1546 Oil filter (G15DTF)

1. FILTER & COOLER ASSY-OIL 25.VALVE ASSY-O/FLTR N/RTN

2. COVER-OIL FILTER 28.GASKET-OIL
3. RING-O 29.GASKET-OIL FILTER DRAIN
4. VALVE-OIL FILTER BYPASS 30.GASKET-COOLANT
9. ELEMENT KIT-OIL FILTER 31.BOLT
13.COOLER ASSY-OIL 32.OIL GASKET-OIL COOLER INLET
14.COOLANT GASKET-OIL COOLER 33.OIL GASKET-OIL COOLER OUTLET
15.BOLT 35.NIPPLE-OIL FILTER
19.SENSOR ASSY-OIL PRESSURE

GETtheMANUALS.org
08-6

▶ 1539 OIL PAN & PUMP (G15DTF)

1. OIL PUMP 45.COVER-DUST

8. PAN-OIL 48.PLATE-BAFFLE
10.BOLT 49.BOLT
11.PLUG-DRAIN 50.CONNECTOR ASSY-OIL PUMP
21.BOLT 51.BOLT
32.GAUGE ASSY-OIL DIPSTICK 52.RING-SEAL
33.RING-O

GETtheMANUALS.org
 0000-00 08-7

1. OPERATING PROCESS
1) Functions
The main functions of the engine oil are lubricating and cooling the important parts of the engine. It is
essential for smooth operation of the engine.

▶ Reducing wear
Friction is the resistance created between the surfaces of two moving objects that are in contact with
each other.
No matter how smooth the finished surface looks, the surface has bumps when viewed under a
microscope. These bumps get stuck on and break each other when directly contact with other surfaces.
This results in wear. Even if no bump exists on the surface, mechanical wear will occur when the surface
contacts with other surface and moves in relation to that surface. The engine oil supplied to the frictional
surfaces creates an oil film on each contact surface and converts the solid friction to liquid friction to
reduce wear.
▶ Cooling
The frictional energy is converted to heat energy. And the pistons and cylinders are heated up by the
combustion gases. The engine oil absorbs and dissipate the heat from these components.

▶ Sealing
The cylinders are sealed by the piston ring fitted to the pistons. The engine oil penetrates through the
small gaps between the piston ring and seating surfaces of the piston and completes the sealing. The oil
seal prevents pressure leaks and return flow of the combustion gases.

▶ Rust proofing
The engine oil creates a thin film on the metal surfaces and prevents the surfaces from contacting with
air, water, or corrosive gas which causes rust and corrosion.

▶ Cleaning
The engine oil circulates in the engine by the pressure from the oil pump. The oil keeps the frictional
surfaces clean by transporting the metal particles, oxides, and carbides generated from the surfaces.

2) Properties
The properties of the engine oil greatly affect the performance and efficiency of the engine. The
properties of the engine oil vary depending on the crude oil or refinement method. However, most of
widely used engine oils have been mixed with the different oil additives to improve its performance.

GETtheMANUALS.org
08-8

3) Required properties
Basically, the properties of engine oil differ by usage. In general, the following properties are required.

▶ Cleaning effect
Products of the combustion (e.g. carbon) and degradation products of oil contaminate the engine
causing problems related to poor lubrication which reduces the service life of the engine. Therefore, the
inside of engine needs to be kept clean and oil with proper cleaning effect is recommended.

▶ Oxidation stability
The engine is driven for a long time and hot. Therefore oil with high oxidation stability is recommended.
Oxidation of oil generates harmful substances which increase oil viscosity. This causes poor lubrication
resulting in severe corrosion or wear.

▶ Anti-corrosion
Products of the combustion (e.g. carbon) and degradation products of oil cause corrosion of the metal
surfaces. Therefore, oil with anti-corrosion additives is recommended.

▶ Anti-foaming
Bubbles in oil cause deterioration of oil pump, poor circulation of oil, and poor lubrication, resulting in
malfunctions.

▶ Viscosity index

Viscosity is a measure of oil thickness. Oil with high viscosity forms thick oil film which supports high
load. However, too high viscosity increases internal friction of lubricant which indicates increased
resistance, resulting in increased power loss. Alternatively, too low viscosity cannot form the oil film
which is essential for wear reduction.
The most important factor that determines the viscosity of lubricants is temperature. In general, the
viscosity of a lubricant decreases as temperature increases. The amount of viscosity change in relation
to temperature is called "Viscosity index". The viscosity change of the oil with high viscosity index is
lower than that of the oil with low viscosity index. The engine temperature varies greatly so oil with high
viscosity index is recommended.

4) Consumption
The engine oil is used up for various reasons. The amount of oil consumption is affected by oil viscosity,
oil quality, and driving conditions. The amount of consumption increases especially when the engine is
new or driven at high rpm.
When the engine is new, operation of the pistons, piston rings, and cylinders is not optimized. Therefore,
more oil will be used up. Check the engine oil level each time you fill the tank during the first 5,000 km as
much as possible. Make sure that the engine oil level is within the specified range before long journeys.

GETtheMANUALS.org
 0000-00 08-9

2. SYSTEM DIAGRAM

1. OIL PUMP
2. Oil cooler
3. Oil filter
4. Main journal bearing
5. Oil jet
6. Chain tensioner
Turbocharger 7. OCV
oil inlet 8. Cam journal bearing
9. HLA
10.Vacuum pump

Turbocharger
oil outlet

GETtheMANUALS.org
08-10

Exploded view

1. Bolt 10.Slide spring 18.O-ring

2. Sprocket 11.OPV plug 19.Knock bushing
3. Cover 12.OPV spring 20.Outlet gasket
4. Vane ring 13.OPV ball 21.Retainer
5. Rotor with shaft assembly 14.OPV insert 22.VOP solenoid valve
6. Slide seal support 15.Slide 23.Housing
7. Slide seal 16.Dowel pin 24.Oil screen assembly
8. Vane 17.Cap sealing 25.Cap plug
9. Pivot pin

GETtheMANUALS.org
 0000-00 08-11

3. OPERATING PROCESS

▶ When the VOP solenoid valve is ON

If the VOP solenoid valve is activated, then the valve will close the drain passage to the oil pan so that
the pressure can be sent to the 2nd chamber (F2). The discharge pressure of the oil pump will be sent to
the 1st chamber (F1). Therefore, the sum of both pressure (F1+F2) will be applied to the slide connected
to the spring and this force will compress the spring. At this time, the whole slide will move to increase
the gap with the rotor as shown in the right figure. Then the oil pressure will decrease because of the
changed volume ratio.

▶ When the VOP solenoid valve is OFF

If no power is supplied to the VOP solenoid valve, the oil from the main gallery will flow into the oil pan
through the VOP solenoid valve. Therefore, the pressure (F2) which compresses the spring will be lost
and the slide will move by the force from the released spring. Then the oil pressure will increase by the
changed volume ratio due to the reduced the gap between the rotor and the slide.

GETtheMANUALS.org
08-12

4. OIL WARNING LAMP COMES ON WHEN:

- Low engine oil level
- Faulty engine oil pressure switch
- Insufficient circulation of engine oil (oil filter or
oil passage clogged)
- Oil pump stuck

GETtheMANUALS.org
 0000-00 09-3

1. SPECIFICATIONS
Category Specifications Remarks
Cooler Type Forced circulation / water-cooled
Radiator Coolant flow type Cross flow
Core size (mm) 610W*470.3H*28T
Electric fan Type Electric
Capacity 350 W
Control type Resistor type (low/high)
Coolant reservoir Capacity 2.6ℓ
tank -
Cap type / pressure Screw type/1.4 bar
Thermostat Type Wax pellet type
Opening temperature 90 ± 2°C
Fully open temperature 100°C
Coolant Anti-freeze SYC1025 (LCC)
Anti-freeze mixture ratio 50:50
(water:antifreeze)
Coolant capacity Approx. 7.0ℓ

GETtheMANUALS.org
09-4

2. CAUTIONS

- If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity can
be decreased resulting in poor circulation in the cooling system which leads to overheated engine.
Use of non-recommended coolant could form scales in the cooling system because of chemical
- reaction. This restricts the flow in the cooling system and causes overheating and seizure of the
engine.
Hot coolant or steam can spray out with great force when the coolant reservoir tank cap is opened
- while the engine is running or hot, causing serious burns.
To open the coolant reservoir cap, wrap the cap with a wet towel or thick cloth after the engine has
- been cooled down sufficiently.
If cold water is added while the engine is overheated, the engine or radiator can be
- deformed.
Anti-freeze can damage the painted surface. Avoid contact with the painted surface.
- Anti-freeze and water should be mixed in proper mixture ratio. Never add only water when the
- coolant runs low.
If the anti-freeze concentration is too low, there is a danger of freeze-up. If the anti-freeze
- concentration is too high, it will reduce the cooling capacity of the system, resulting in overheating of
the engine.

GETtheMANUALS.org
 0000-00 09-5

1. OVERVIEW
The cooling system of the engine dissipates the heat generated by the running engine. The coolant is
forced to circulate by the water pump and cooled down in the radiator by heat exchange between the
coolant and the fresh air taken in through the fan. Properly cooled down coolant in the radiator flows into
the engine to maintain the optimized engine operating temperature. For a vehicle with A/T, the coolant
also flows into the transmission oil cooler (TOC) of the A/T through the heater core and absorbs the heat
enough to maintain the best operating temperature. The electric fan is equipped with a resistor. The
engine ECU controls the 2 electric fan relays which determine the speed of the fan (high speed and low
speed). It also controls the A/C compressor and electric fan according to the operation of A/C.

2. COMPONENTS

Radiator deaeration hose

Coolant reservoir tank

Radiator inlet hose

Radiator
Cooling fan

Resistor
Engine deaeration hose

Make-up hose

Air guide

Radiator outlet hose

TOC TO ENG hose

Air guide ENG TO TOC hose

GETtheMANUALS.org
09-6

Water pump Thermostat Cylinder head

outlet port

Coolant temperature sensor

With M/T With A/T

Coolant return pipe

Cylinder block TOC coolant TOC coolant

outlet port return pipe supply pipe

GETtheMANUALS.org
 0000-00 09-7

3. EPC
▶ 1526 Cooling system (G15DTF)

1. PUMP ASSY-WATER 18.HOSE-BYPASS

2. BOLT 20.PIPE ASSY-T/CHARG COOLG INLET
3. PULLEY-WATER PUMP 21.PIPE ASSY-T/CHARG COOLG OUTLET
4. BOLT 22.SEAL ASSY-RING
7. THERMOSTAT ASSY 23.BOLT-HOLLOW
9. PORT ASSY-COOLANT BLOCK OUTLET 30.PORT ASSY-COOLANT HEAD OUTLET
11.PIPE ASSY-COOLANT RETURN 31.BOLT
12.RING-O 33.HOSE-DEAERATION
14.PIPE ASSY-COOLANT TOC RETURN 34.PIPE ASSY-COOLANT TOC SUPPLY
15.BOLT-HEX W/WAVE_M6x1x15
17.CLAMP

GETtheMANUALS.org
09-8

▶ 2112 Radiator & cooling fan

1. RADIATOR ASSY-COOLING 6. T/SCREW-MODULE MTG UPR

2. FAN MODULE 7. AIR GUIDE
3. BRKT-MODULE MTG UPR 8. RESISTOR
4. INSULATOR-MODULE MTG UPR 9. SEAL-SIDE
5. INSULATOR-MODULE MTG LWR

GETtheMANUALS.org
 0000-00 09-9

▶ 2130 Radiator hose & pipe

1. HOSE-RADIATOR INLET 11.HOSE-ENGINE TO TOC

2. HOSE-RADIATOR OUTLET 12.HOSE-TOC TO ENGINE
3. HOSE-MAKE UP 12.HOSE ASSY-COOLANT OUTLET
4. HOSE-DEAERATION RADIATOR 13.TANK ASSY-RESERVOIR
5. TUBE-DEAERATION RADIATOR 14.CAP-RESERVOIR TANK
6. HOSE-DEAERATION CONNECTOR 15.BOLT
7. TUBE-DEAERATION RESERVOIR 16.CLAMP-WORM DRIVE TYPE SPRING
8. HOSE-DEAERATION RESERVOIR 17.CLAMP-WORM DRIVE TYPE SPRING
9. HOSE ASSY-DEAERATION ENGINE 18.CLAMP
10.CLIP-DEAERATION TUBE MTG 19.CLAMP

GETtheMANUALS.org
09-10

1. FLOW CHART

GETtheMANUALS.org
 0000-00 09-11

▶ Flow in cooling system

To cylinder block To oil filter module

Oil drain

Water pump supply

Water pump bypass inlet

Oil filter supply

Oil inlet

- Oil filter supply: Cylinder block to oil filter, Before filtering

- Oil inlet: Oil filter to cylinder block, After filtering

GETtheMANUALS.org
09-12

2. THERMOSTAT OPERATING PROCESS

Coolant temperature up to Coolant temperature 90 to Coolant temperature 100˚C or

90˚C 100˚C higher

GETtheMANUALS.org
 0000-00 09-13

3. OPERATING PROCESS
1) Overview
The electric fan is installed on the rear side of the radiator. It brings in fresh air using the motor and
dissipates the heat generated by the running engine to improve the cooling performance. The electric
fan is operated by the engine ECU which controls the 2 electric fan relays (high speed and low speed).

2) Mounting Location and Components

Electric fan

Fan resistor connector Fan resistor

Fan blade

Shroud

GETtheMANUALS.org
09-14

3) Electic Fan Internal Circuit Diagram

GETtheMANUALS.org
 0000-00 09-15

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 09-3

1. SPECIFICATIONS
Category Specifications
Battery Capacity 60 Ah
Type Maintenance free
Size 206 * 175 * 190
Weight 15.5 kg
Cold cranking ampere 500 A
Residual capacity 80 min
AGM battery Capacity 70 Ah
Weight 21 kg
Cold cranking ampere 760A
Residual capacity 110 min
Alternator Rated capacity 12 V / 130A
Weight 6.5 kg
Crankshaft pulley: 1 : 2.9
Alternator pulley ratio

GETtheMANUALS.org
09-4

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

2. COMPONENTS
Alternator Charge warning lamp on Battery ground cable
instrument cluster

Battery positive cable Battery

GETtheMANUALS.org
 0000-00 09-5

3. EPC
▶ 2610 BATTERY CABLE

1. BATTERY ASSY 11.BRKT-BATTERY POSITIVE

2. BOLT 12.BATTERY COVER
3. CLAMP-BATTERY 14.BATTERY COVER-PLASTIC
5. WIRING ASSY-BATTERY POSITIVE 15.SCREW
6. WIRING ASSY-BATTERY GROUND 17.NUT
7. CABLE ASSY-BATTERY SENSOR 18.NUT
8. BOLT 24.CAP-STARTER
10.TERMINAL-BATTERY POSITIVE 25.CAP-RING TERMINAL

GETtheMANUALS.org
09-6

▶ 1450 alternator (G15DTF)

1. ALTERNATOR ASSY
4. BOLT

GETtheMANUALS.org
 0000-00 09-7

1. INPUT/OUTPUT DIAGRAM
1) With smart key

GETtheMANUALS.org
09-8

2) For a vehicle with REKES key

GETtheMANUALS.org
 0000-00 09-9

2. OPERATING PROCESS
1) Alternator
The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge,
slip ring and brush.

▶ Charging time according to vehicle conditions and environment

Specification: Charging a fully depleted high-

capacity battery takes twice or more as long as
charging a fully depleted battery for small
vehicles.
Temperature The lower the temperature is, the
longer the time taken to charge the battery.
When connecting the battery charger to the cold
battery, the amount of current the battery can
accept initially is very small. As the battery gets
warmer, it can accept more current.

Charging capacity: Charging a battery with a low-capacity charger takes longer time than charging with
a high-capacity charger.
Charging status: Charging a fully depleted battery takes twice or more as long as charging a half-
depleted battery. Since the electrolyte in a fully depleted battery consists of nearly pure water and
conductor, only a very small amount of current can be accepted by the battery initially. The charging
current increases as the amount of acids in the electrolyte is increased by the charging current.

2) Alternator output diagram curve

Alternator 130A

GETtheMANUALS.org
09-10

3) Battery perfomance
▶ Reserve Capacity (RC)
Shows residual capacity of the battery, which is available in the event of failure of the vehicle's generator.
Duration time (min.) for which the fully charged battery is maintained at temperature of 25 ± 2℃
and discharged continuously at current of 25 A until its voltage drops to 10.5 V.

▶ Cold cranking ampere (A)

Shows engine start performance of the cranking battery. Discharge current at which voltage becomes
7.2 V when battery is discharged for 30 seconds at temperature of -18℃.

▶ Charging a fully depleted battery (removed from vehicle)

Comply with the working procedures to avoid replacing the good battery unnecessarily. Charge the
completely discharged battery by following the procedures specified below:

1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is 10 V or
lower, the charging current is very low. It takes some time for the battery to accept the current in
excess of a few milli-amperes. Refer to "required charging time" in this subsection. The ammeters
available in the field can't detect a very low current.
2. Set the battery to high settings.

Some battery chargers feature a polarity protection circuit which protects the charger until its lead is
correctly connected to the battery terminal. Even though the lead is properly connected, a completely
discharged battery has too low voltage to activate this circuit and the battery may not accept the
charging current. Therefore, follow the manufacturer’s instruction for bypassing or overriding
the circuit, so that the battery can be turned on and charged with a low voltage.

3. Keep charging the battery until the charging current can be measured. The battery charger changes
the amount of voltage and current provided. The time required for the battery to accept a measurable
charging current at various voltages is as follows:

Voltage (V) Time

16.0 or higher Up to 4 hours
14.0 ~ 15.9 Up to 8 hours
13.9 or lower Up to 16 hours

- If the charging current is not measured when the maximum charging time has been reached, the
battery should be replaced.
- If the charging current is measured during the charging time, the battery is in good condition. The
charging should be completed in the normal manner.
- If the charging current is still not measurable even after the charging time specified above has been
passed, the battery should be replaced.

GETtheMANUALS.org
 0000-00 09-11

3. INTERNAL CIRCUIT DIAGRAM

GETtheMANUALS.org
09-12

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 09-13

GETtheMANUALS.org
 0000-00 11-3

1. SPECIFICATIONS
Item Category Specifications
Start motor Rated voltage (ISG) 12 V 0.9 kw (12 V 1.4 kw)

GETtheMANUALS.org
11-4

1. OVERVIEW
The engine cannot start by itself. It needs starter motor which operates the crankshaft using external
force.
The starter (starter motor) starts the engine with rotational power by converting the electric energy to the
mechanical energy.
When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the
pinion gear clutch overruns to protect the pinion gear.

2. COMPONENTS
Battery positive cable Start motor ECU
(starter motor power
cable)

Battery Start relay

GETtheMANUALS.org
 0000-00 11-5

3. EPC
▶ 1463 STARTING MOTOR (G15DTF)

1. STARTER
2. BOLT

GETtheMANUALS.org
11-6

1. INPUT/OUTPUT CIRCUIT DIAGRAM

1) For a Vehicle with Smart Key
When the START/STOP button is pressed with the brake pedal applied and gear selector lever in P or N
position, the SKM performs the immobilizer verification. If it is valid, SKM sends the engine START
request signal to the ECU through the P-CAN and vehicle power status signal to the BCM through the B-
CAN. After the START signal from the SKM has been received, the ECU controls the start relay to drive
the starter motor.
The SKM cuts the power for IGN2 and ACC relays while the engine is cranking because cutting the
unnecessary electric load is required.

GETtheMANUALS.org
 0000-00 11-7

GETtheMANUALS.org
11-8

2) For a Vehicle with Ignition Key

When the ignition key is turned to ST position with the brake pedal (for a vehicle A/T) or clutch pedal (for
a vehicle M/T) applied and gear selector lever in P or N position, the TCU sends the engine START
signal to the ECU through the hard wire. The ECU controls the start relay to drive the starter motor.

GETtheMANUALS.org
 0000-00 11-9

2. START MOTOR OUTPUT

3. INTERNAL CIRCUIT DIAGRAM

GETtheMANUALS.org
11-10

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 11-11

GETtheMANUALS.org
 0000-00 12-3

1. SPECIFICATIONS
Category Specifications
Rated voltage DC 5 V - 0.1 A
Operating temperature -30℃~+80℃
RH steering wheel
CRUISE Push self-return type
Switch
Switch type +/RES
Up/Down self-return type
-/SET

GETtheMANUALS.org
12-4

2. CAUTIONS

- Take into consideration road safety while when driving at a constant speed using a cruise control
system. Always be prepare to depress the brake and accelerator pedals according to the
situations.
- The vehicle speed may vary and different from the set speed when driving up and down a hill.
Avoid using cruise control function when driving on hilly roads as much as possible. To ensure
safe driving and protect the vehicle, use the engine brake and foot brake properly when driving on
hilly roads.
- Always allow for extra distance between your vehicle and the vehicle ahead. Depress the brake
pedal, if needed.

3. WARNINGS
Use the cruise control system when the vehicle is driven on a motorway or highway with light traffic
where the driving status is not expected to change suddenly by pedestrians and traffic lights.

To prevent unexpected accidents due to uncontrollable situations, only use this function when
driving on motorways and highways with light traffic. Never use this function when driving under the
following conditions:
- Hard wind or crosswind
- Heavy traffic
- Slippery roads or hills

GETtheMANUALS.org
 0000-00 12-5

1. OVERVIEW
- The cruise control is an automatic speed control system that maintains a desired driving speed without
using the accelerator pedal.

- The control is located on the right hand side of the steering wheel and consists of the following buttons;
cruise control SET, ACCEL (+), cruise control RES (+), SET (-) and DECEL (-).

- In order to activate the cruise control system, the driver must enter the cruise control "readiness" status
first
by pressing the Cruise Control and Speed Limit switches. This is to prevent the driver from operating
the cruise control switch accidentally while operating the steering wheel.

Cruise control: Enables vehicle to cruise at set speed

GETtheMANUALS.org
12-6

2. COMPONENTS

Indicators and display HECU

ECU Cruise control switch

GETtheMANUALS.org
 0000-00 12-7

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
12-8

2. OPERATING PROCESS & LOGIC

1) How To Set Speed (Cruise Control ON)

Cruise control switch

CRUISE

SET (-)

1. Drive the vehicle at speed between 40 and 210 km/h by depressing the accelerator pedal to activate
the cruise control system.

2. How to set
a. When the ON/OFF button is pressed, the "READY" indicator lights up and the cruise control
system enters ready mode.
b. When the SET button is operated toward the (-) direction, the cruise control is activated while
maintaining the current speed, and the instrument panel displays the target speed. (Switches from
READY indicator to AUTO CRUISE indicator)
c. After that, the vehicle is driven at the set speed (speed set when activating the cruise control
system) without accelerator pedal depressed.

3. By operating the RES (+) / SET (-) button in the state of "b", you can increase or decrease cruise
control setting speed.

Operating the cruise control switch is carried out while the vehicle is driven. Therefore, make sure
that you fully understand and are familiar with the system before using the cruise control system.
Failure to do so may lead to fatal accidents.

GETtheMANUALS.org
 0000-00 12-9

2) Increasing Speed (ACCEL)

RES (+)

1. Operate the switch toward "RES+" until the desired speed is obtained while driving with the cruise
control set. Pressing and holding the switch (more than 0.8 sec) increases the speed by about 5 km/h
every 0.8 seconds.
2. To increase the speed in about 1 km/h increments, press the switch briefly (less than 0.8 sec).

3) Decreasing Speed (DECEL)

SET (-)

1. Operate the switch toward "RES +" until the desired speed is obtained while driving with the cruise
control set. Pressing and holding the switch (more than 0.8 sec) decreases the speed by about 5
km/h every 0.8 seconds.
2. To decrease the speed in about 1 km/h increments, press the switch briefly (less than 0.8 sec).

GETtheMANUALS.org
12-10

4) How to restore set speed (RESUME)

RES (+)

If the cruise control disable conditions are met while the cruise control is in active, the cruise control will be
deactivated. However, the previously set cruise control speed is stored in the ECU, and if you operate the
switch toward "RES+" it will return to the previous cruise control set speed.
The speed should be 40 km/h and the brake or accelerator pedal should not be depressed.

▶ RESUME (memorizing set speed value)

While the cruise control is in active, RESUME is not activated when it is turned off with the LIMIT switch.
RESUME is not activated if you press the CRUISE switch or LIMIT switch when the cruise control is in
READY mode.

Switch Operation type Switching to READY mode

ON/OFF Briefly While returning to set speed (RESUME) (set speed stored)
(CRUISE)
Briefly Current speed > set speed
(less than 0.8 s) - Increase set speed in increments of 1 km/h
+ / Res
Press and hold Current speed > set speed
(more than 0.8 s) - Increase set speed in increments of 5 km/h every
0.8 sec
Current speed < set speed
Briefly - Set to current vehicle speed
(less than 0.8 s) Current speed > set speed
- / Set - Decrease set speed in increments of 1 km/h

Press and hold Current speed > set speed

(more than 0.8 s) - Decrease set speed in increments of 5 km/h every
0.8 sec

GETtheMANUALS.org
 0000-00 12-11

5) How To Cancel (ACTIVE → READY)

- Depress the brake pedal or activate ESP
- Decelerate vehicle speed to below 40 km/h
- Apply parking brake while driving
- Depress clutch pedal for more than 3 seconds for vehicles with M/T
- Operate cruise switch once while cruise control in active

6) How To Deactivate (Cruise Control OFF)

ON/OFF
(CRUISE)

To deactivate
- Operate ON/OFF switch once while cruise control in READY state
- 15 sec elapsed after ING OFF

GETtheMANUALS.org
12-12

3. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 16-3

1. SPECIFICATIONS
Item Category Specifications
130A
77A/2,000rpm, 118A/4,000rpm,
Alternator Rated output
128A/6,000rpm
(100℃, 13.25V)

Capacity AGM 70Ah

Residual capacity (RC) 110 min
Battery
Cold cranking ampere (CCA) 760A
Weight 21kg
Operating voltage 9 ~ 18V (6 ~ 18V for LIN comm.)
Operating temperature -30℃ to +110℃
BSC(Battery Sensor
Operating current Max. 20mA
Cable)
Dark current Max. 0.19mA
LIN communication INTEL 2.0 standard 19.2kbps
Rated voltage 12V 1.8kw
Engage type Electric press-fit
Direction of rotation Clockwise (viewed from drive end)
Starting motor
Solenoid operating voltage Max. 8V
Weight 3.3kg
Reduction gear ratio 5.625 : 1
Input 7 ~ 12V
Shifting mode
Output 11 ~ 13V
(Max. current: 15A (B+), 50mA (ACC))
Input 9 ~ 16V
DC-DC converter
Bypass mode
Output 9 ~ 16V
(Max. current: 15A (B+), 50mA (ACC))
Operating temperature -30℃ to +75℃
Dark current Max. 0.5mA (with IGN & ACC OFF)

GETtheMANUALS.org
16-4

Item Category Specifications

Rated voltage DC 5V
Rated load 0.1A or less (DC 5V)
ISG OFF switch
(console RH LED load 20mA (DC 12V)
switch)
Operating temperature -30℃ to +80℃
Operation type Push-return type

GETtheMANUALS.org
 0000-00 16-5

1. OVERVIEW
The ISG system is applied to the vehicle together with the EEM system. It checks the overall condition of
the vehicle including the engine and the transmission when the vehicle is stopped. If the engine stop
conditions are met, the engine is stopped until the engine restarts. This will eliminate inefficient fuel
consumption and prevent the exhaust gas from being discharged fundamentally, thereby improving the
fuel economy and durability of the vehicle.
In vehicles equipped with an ISG system, the ISG function is activated by default. If you do not want to
use it, you can turn off the ISG function with the ISG OFF switch.
In addition, the EEM system monitors the electrical load and battery charge state through the BSC to
control the generating voltage of the alternator, thereby improving fuel economy, reducing CO2 and
improving battery efficiency.
The BSC is mounted on the battery (-) terminal and transmits information to the ECU via LIN
communication. The ECU controls the alternator using PWM signal, and when the charging system is
defective, the charging warning lamp is lit on the instrument panel via CAN communication.

- ISG: Idle Stop & Go

- EEM: Energy Efficiency Management
- BSC: Battery Sensor Cable
- ECU: Engine Control Unit
- PWM: Pulse Width Modulation

IP display (Standard instrument

Category Operating conditions
cluster)

Vehicle stop → engine stop Selector lever D position + brake

pedal applied

- Brake pedal released

- Apply brake pedal + move
Vehicle start → engine start selector lever to M or R
position

GETtheMANUALS.org
16-6

2. COMPONENTS
▶ ENGINE ROOM

Alternator Brake vacuum ECU BSC

pressure
sensor

Starting motor TCU Hood switch Battery

(1 & 2)

GETtheMANUALS.org
 0000-00 16-7

▶ INTERIOR

Cluster DC-DC converter SKM

BCM Brake switch ISG OFF switch

GETtheMANUALS.org
16-8

3. EPC
▶ 2610 BATTERY AND CABLE

1. BATTERY ASSY 8. BOLT

2. BOLT 10.TERMINAL-BATTERY POSITIVE
3. CLAMP ASSY-BATTERY 11.BRKT-BATTERY POSITIVE
5. WIRING ASSY-BATTERY POSITIVE 12.BATTERY COVER
6. WIRING ASSY-BATTERY NEGAITIVE 14.BATTERY COVER-PLASTIC
7. CABLE ASSY-BATTERY SENSOR 18.NUT

GETtheMANUALS.org
 0000-00 16-9

▶ 1451 ALTERNATOR(D16DTF)

1. ALTERNATOR ASSY
4. BOLT

▶ 1461 STARTING MOTOR(D16DTF)

1. STARTER ASSY
2. BOLT

GETtheMANUALS.org
16-10

▶ 4850 MASTER CYLINDER AND BOOSTER

1. MASTER BRAKE UNIT ASSY 8. O RING-BOOSTER MTG

2. BOOSTER ASSY-POWER BRAKE 9. HOSE ASSY-BOOSTER VACUUM
3. MASTER CYLINDER ASSY-POWER BRAKE 10.VALVE-BOOSTER NONRETURN
5. WASHER-BOOSTER MTG 12.CLIP
6. NUT-BOOSTER MTG 13.SCREW
7. GASKET-BOOSTER MTG

GETtheMANUALS.org
 0000-00 16-11

▶ 8510 SWITCH AND SENSOR - INSTRUMENT PANEL/CONSOLE

7. SWITCH ASSY-LWR MAIN 21.SWITCH ASSY-EPB

8. SWITCH ASSY-START 25.SWITCH ASSY-CONSOLE
9. BRKT-START 26.SWITCH ASSY-CONSOLE
10.SCREW 30.BLKG CVR-S/WARMER & VENT
11.SWITCH ASSY-GLOVE BOX 31.SWITCH ASSY-S/WARMER & VENT
17.SWITCH ASSY-PASSENGER AIR BAG
18.BLANKING COVER-PASSR A/BAG

GETtheMANUALS.org
16-12

▶ 8610 Application component (1)

1. LAMP ASSY-ROOM CTR 27.UNIT ASSY-DC-DC CONVERTER

2. LENS-ROOM LAMP 28.NUT
3. BULB-LED 30.DISPLAY ASSY-RR VIEW CAMERA
BULB 36.SOCKET ASSY-POWER
4. LAMP ASSY-GLOVE BOX 37.MICROPHONE ASSY
5. BULB 38.SOCKET ASSY-INVERTER
6. HORN ASSY 41.BOLT-HORN MTG
7. COVER ASSY-STYLING 42.NUT-HORN MTG
8. LAMP ASSY-SUNVISOR 45.UNIT ASSY-220V INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 48.SENSOR ASSY-ACC
14.LAMP ASSY-CRASH PAD MOOD 49.BOLT
18.LAMP ASSY-LUGGAGE 50.UNIT ASSY-FRT CAMERA
19.BULB-FESTON 8W 51.COVER-AEBS CAMERA

GETtheMANUALS.org
GETtheMANUALS.org
16-14

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 16-15

GETtheMANUALS.org
16-16

2. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
 0000-00 16-17

GETtheMANUALS.org
16-18

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 16-19

3. P-CAN INPUT/OUTPUT ELEMENTS

▶ ABS

▶ BCM

GETtheMANUALS.org
16-20

▶ ESP

GETtheMANUALS.org
 0000-00 16-21

▶ CPL

▶ GCU

GETtheMANUALS.org
16-22

▶ HVAC

▶ ACU

GETtheMANUALS.org
 0000-00 16-23

▶ PMS

GETtheMANUALS.org
16-24

▶ TCU

GETtheMANUALS.org
 0000-00 16-25

▶ CGW

GETtheMANUALS.org
16-26

▶ CGW

▶ SKM

GETtheMANUALS.org
 0000-00 16-27

▶ Diagnostic device

GETtheMANUALS.org
16-28

4. ISG OPERATING CONDITIONS

1) ISG System Transition

▶ IP display for each ISG status (3.5" instrument cluster)

GETtheMANUALS.org
 0000-00 16-29

2) ISG Auto Stop

▶ AUTO STOP conditions (2: engine running → 4: Stop)
(Judgement condition AND: All conditions must be met for AUTO STOP to be possible)

Item Status
Driver Vehicle speed Falls below 1 km/h from 9 km/h or higher (not
condition activated unless vehicle speed exceeds 9 km/h)

ISG OFF switch Not depressed (ISG ON)

Gear lever/brake - Brake pedal depressed with gear lever in
D/N position
- After start, lever should be placed to
D position at least once
- ISG initialized when lever moved to P/R
during driving
Driver door/seat belt Door closed
Seat belt fastened
Accelerator pedal OFF
EPS steering wheel angle Left/right: 180˚ or less
Engine rpm Idling rpm ~ 1,350 rpm
HVAC (Heater and A/C controller) Fan speed reduced level 1, A/C switch turned off

Brake pedal Depressed

Gear position N (neutral) / D (drive)
ACC (Adaptive Cruise Control) Not operating
operation
AUTO HOLD readiness Preparation(warning lamp: white) → Operation
(warning lamp: green)

GETtheMANUALS.org
16-30

Item Status
Vehicle Coolant temperature 20℃ ~ 100℃ (ISG disabled at below 15℃
condition and above 105℃)
Atmospheric pressure 2,800m or less (hysteresis: 2,500m)
Hood switch (SW1 & SW2) Hood closed
BSC (battery status) *BSC (battery) conditions for ISG operation
Brake vacuum pressure -330 hPa (-0.33 bar) or less
Road gradient ±12% or less
Delay time until ISG becomes -10 deg.: 80s, 10 deg.: 65s, 40 deg.: 65s,
operational according to coolant 43 deg.: 15s, 60 deg.: 10s, 90 deg.: 3s.
temperature after start-up

Travel speed before ISG Auto Stop 9km/h or higher

Minimum required time to stop vehicle 0.2 s or longer
before ISG Auto Stop
Minimum travel range after ISG restart 1m or longer

After DTC occurs Below 3 times (ISG STOP condition met only up
ISG Auto Stop to 2 times of engine failure)
Engine torque Below 250 Nm
Total number of cumulative starts Less than 300,000 times
Specific defects in ECU No defect
Accessory torque 60 Nm or less
Ambient temperature -6℃ or higher
ECU status Normal (not work during DPF regeneration)
ISG system-related fault Not occur

* BSC (battery) conditions for ISG operation

- Temperature: -5℃ to 60℃
- SOC (charge state): 80% or higher (hysteresis ±2%)
: ISG STOP requires more than 82% or higher charge
- SOH (performance state): 80% or higher
- SOF (minimum start voltage): 7.2V or higher
- EEM warning lamp: OFF
- When removing and reconnecting battery: Enabled when BSC monitors battery status after 4 hours

GETtheMANUALS.org
 0000-00 16-31

3) ISG Auto Stop Restriction

▶ AUTO STOP restriction conditions (2: engine running → 3: Stop restriction)
(Judgement condition OR: Restricted if at least one judgment condition met)

Item Status
ISG Auto Stop after engine-related DTC occurs 3 times or more (ISG STOP condition met only up
to 2 times of engine-related DTC)
ISG Auto Stop conditions not met When STOP (2→4) conditions not met, STOP
restricted
A/C system Specifications Maximum cooling / heating temperature and
blower motor in 6-speed or higher (however,
AUTO STOP available if A/C switch turned off and
blower motor in 1-speed)
Unit - Blower motor 6-speed or higher
(A/C switch turned ON)
- MAX A/C switch ON (with MTC)
Defrosting Defroster switch ON (A/C switch ON & blower
motor ON)
ISG OFF switch Pressed (ISG OFF)
ECU status Unsatisfied or during DPF regeneration
Brake vacuum pressure -330 hPa or higher
Driver door / seat belt / hood Ajar (unfastened)
BSC (battery status) Conditions not met
ISG system-related fault Failure occurs
Steering wheel Steering angle large (180˚ or greater when
stationary)
Others Driving on downhill or steep uphill

GETtheMANUALS.org
16-32

4) ISG Auto Start (conditions for restart)

▶ AUTO START conditions (4: Stop → 2: Start)
(Judgement condition OR: If any of judgment conditions met, ISG restarted)

Item Status
START Brake Brake pedal released with gear lever in D/N position
conditions (With EPB: Restart after AUTO HOLD released
by driver (green→white))

TGS lever position - Gear shift from N to D during braking

- Move gear level to R or M position
ISG OFF switch Depressed (ISG OFF)
HVAC (Heater and A/C controller) Defroster switch ON (A/C turned on & blower motor
ON)
Accelerator pedal AUTO HOLD activated, accelerator pedal depressed
while depressing brake pedal
Accelerator pedal depressed 2.5% or more
Driver door/seat belt Door closed→open
(Brake applied) Seat belt fastened→unfastened
EPS steering wheel angle Operate quickly at angular speed of 180˚/s or
more
Forced BSC (battery status) Battery SOC low due to excessive use of electrical
START devices (e.g., for more than 3 min in succession)
condition
Restart after certain period of Up to 5 min (after that, restarted)
time(STOP actuation time)
Brake vacuum pressure Vacuum as low as -330 hPa
Coolant temperature 110℃ or higher
Failure occurs DTC occurs at engine start group
Accessory torque 250 Nm or above
HVAC (Heater and A/C controller) - A/C switch ON and blower motor 6-speed or
higher
- MAX A/C switch ON (with MTC)
Certain vehicle speed detected Vehicle speed 1 km/h or higher after brake pedal
released (including downhill)

GETtheMANUALS.org
 0000-00 16-33

5) ISG Auto Start Restriction (Auto Restart Impossible)

▶ START restriction conditions (4: engine stop → 5: START restriction)
(Judgement condition OR: Restricted if at least one judgment condition met)

▶ Manual start using button/start key

Item Status
Vehicle Engine compartment hood Open or open to closed
condition
Engine stall by ECU 3 times or more (ISG Stop possible up to 2 times)
After DTC occurs Engine-related DTC occurs 3 times or more
(Start possible if engine failure occurs less than 3
times)

6) ISG System Failure

▶ Shutdown by ISG system failure (2,3,4,5 → 6: ISG system failure)
(Judgement condition OR: If any of judgment conditions met, judged as failure)

Item Status
PCAN communication PCAN comm timeout
ESP Longitudinal acceleration sensor value not detected
EPS Steering angle sensor value not detected
BSC BSC sensor error
LIN communication from BSC to ECU not respond
Starting motor 300,000 times of starting counts
(after 300,000 times: ISG error LED ON and DTC not set)
ECU detects DTC Brake, cam/crank, throttle, intake, lambda, accel pedal, start
circuit, coolant temperature, vehicle speed, etc.

GETtheMANUALS.org
16-34

7) ISG Operation Process Related To AUTO HOLD

▶ AUTO HOLD not activated, ISG Stop
→ Start (vehicle roll back prevention at ISG start)

A. If the vehicle is stopped by stepping on the brake, the ISG Stop will occur.
B. When the brake pedal is released, the ECU issues restart signal.
C. The vehicle is held and released for the time of Z1 to prevent vehicle from being rolled back.

GETtheMANUALS.org
 0000-00 16-35

▶ AUTO HOLD activated, ISG Stop

→ Start (ISG START by accelerator pedal)

A. When the vehicle is stopped by stepping on the brake pedal,

B. ISG stop is performed (warning lamp: white→green), after the time of Z2 after the AUTO HOLD
operation by the manual operation.
C. If the accelerator pedal is depressed at a certain degree after releasing the brake, (ISG START not
work during AUTO HOLD)
D. ECU issues restart signal, ISG START, and
E. AUTO HOLD released after the time of Z1 (warning lamp: green→white)

GETtheMANUALS.org
16-36

▶ AUTO HOLD OFF switch operated while ISG Stop → Start

(Vehicle roll-back prevention not work when performing ISG START by operating AUTO HOLD
OFF switch)

A. When the vehicle is stopped by stepping on the brake pedal,

B. AUTO HOLD performed (warning lamp: white→green), and ISG STOP performed.
C. If AUTO HOLD switch is turned off manually (indicator turned off)
D. when the brake pedal is released, the ECU issues restart signal
E. and ISG START is performed. (vehicle roll-back prevention not work during AUTO HOLD)

When the AUTO HOLD switch is turned off while ISG Stop & AUTO HOLD is operating, AUTO
HOLD rollback protect (Z1) does not work.

GETtheMANUALS.org
 0000-00 16-37

▶ If AUTO HOLD fails after AUTO HOLD operation, EPB is applied.

(If AUTO HOLD fails, it switches to EPB)

A. When the vehicle is stopped by stepping on the brake pedal,

B. AUTO HOLD performed (warning lamp: white→green), and ISG STOP performed.
C. At this time, if AUTO HOLD is faulty (warning lamp: green→yellow) EPB is applied.
D. When the brake pedal is released, the ECU issues restart signal
E. EPB released after ISG Start

GETtheMANUALS.org
16-38

5. ECU OPERATING
1) Overview & Mounting Location

ECU

The engine ECU is a main unit for controlling the ISG system. It receives information from the sensors
on the engine and vehicle including the BSC as well as other units, and checks whether the ISG STOP
is possible or not. If the conditions are met, it stops the engine.
In addition, in respect to the alternator control, the generating voltage is temporarily reduced during
acceleration depending on the driving conditions, and the battery discharge is induced by the reduced
voltage, thereby increasing the fuel efficiency and efficiency by lowering the vehicle load. Besides, it
increases the generating capacity to charge the battery capacity consumed during deceleration.

2) Voltage Control
Loading condition Control state Alternator voltage
Headlamp (LO/HI) Fixed control Fixed at 14.7 V
Blower motor Maximum speed Fixed control Fixed at 14.7 V
Rear glass defogger Fixed control Fixed at 14.7 V
Low speed Normal control -
Wiper
High speed Fixed control Fixed at 14.7 V

GETtheMANUALS.org
 0000-00 16-39

6. BCM OPERATING
1) Overview & Mounting Location

BCM

▶ BCM control by ISG signal

If the ISG Auto Stop is activated while the following features are active, the ECU sends an ISG Stop
signal to the BCM and the BCM stops/controls the features that are currently running.
- Wiper control
- Rear defogger (heating) control

GETtheMANUALS.org
16-40

2) Control by ISG Signal During Windshield Wiper Operation

Operation 1. When ISG engine stops during ISG engine STOP
ISG engine IDLE
LO/HI continuous operation, wiper operates in status
status (idling)
INT 1 stage (engine stop)
A. When ECU sends signal regarding ISG engine High Low INT 1 (3s)
status (engine stop) Low Low INT 1 (3s)
B. to BCM via PCAN during LO/HI continuous
operation of front wiper, Low INT 1 (3s) Low INT 1 (3s)
- (ECU→PCAN→CGW→CCAN→IP/EPS) Low INT 2 (7s) Low INT 2 (7s)
C. the wiper will operate in INT 1 stage (INT FAST:
Low INT 3 (11s) Low INT 3 (11s)
intermittent operation for 3 sec).
Low INT 4 (15s) Low INT 4 (15s)
Low INT 5 (19s) Low INT 5 (19s)

Operation 2. If ISG engine stops during INT operation wiper maintains previous operation mode

D. If signal indicating engine stop is received

E. due to ISG engine stop while the front wiper is in INT operation,
F. the wiper will maintain the previous operation state.

Operation 3. Normally operating when ISG engine stops

G. If front wiper switch status is changed
H. with the ISG engine stopped, the wiper will operate normally in changed mode.
I. If the signal indicating ISG engine idling is received with the ISG engine stopped, the wiper will operate
normally.
J. If the wiper switch input is received with the ISG engine stopped, the wiper will operate normally.

Engine stopped/restarted by ISG

The ECU sends the signal regarding ISG STOP/IDLE status to BCM/CGW via PCAN.
(ECU→PCAN→BCM)
(ECU→PCAN→CGW→CCAN→IP)

GETtheMANUALS.org
 0000-00 16-41

System Flowchart

GETtheMANUALS.org
16-42

3) Rear Defogger (Heating) Control (Active ISG)

Operation 1. (OFF for 2 min)
A. Rear defogger (heating) in operation
B. When engine stopped by ISG
- ECU transmits ISG engine STOP signal to different units
(ECU→PCAN→BCM, CPL, ESC, HVAC, SKM)
(ECU→PCAN→CGW→CCAN→EPS, IP)
C. The rear defogger (heating) is turned off for less than 2 minutes.
(rear defogger ON indicator stays on)

Operation 2.
A. Operation 1. When the engine is started by ISG
B. with the rear defogger (heating) turned off for 2 minutes,
C. the rear defogger will be operated.

Operation 3.
A. Operation 1. Pressing the rear defogger (heating) switch
B. with the rear defogger off for 2 minutes
C. immediately switches off the rear defogger.
(Rear defogger (heating) ON indicator goes off)

System Flowchart

GETtheMANUALS.org
 0000-00 16-43

7. BSC(BATTERY SENSOR CABLE)

1) Overview & Mounting Location

BSC
(Battery Sensor Cable)

The BSC is mounted on the battery's negative terminal and sends battery information (voltage, current,
temperature, state of charge, etc.) to the ECU via LIN communication and monitors it to operate the ISG
(Idle Stop & amp; Go) system and EEM.

GETtheMANUALS.org
16-44

2) Operating Process
▶ System layout

▶ Operating process

- The BSC connected to the negative (-) terminal of the battery sends battery information (voltage,
current, temperature and SOC) to the ECU via LIN communication.
- The ECU outputs the generating control signal (PWM) for the engine load based on the
information from the BSC and driving conditions (idle, acceleration, deceleration) to the
alternator terminal "L".
- The ECU controls the magnetic reluctance between the stator coil and the rotor coil by
controlling the current of the alternator rotor coil depending on the change of the PWM duty
value.
- The AC voltage induced in the stator coil is converted to a DC voltage by the rectifier and then output
to the "B" terminal of the alternator connected to the battery.

GETtheMANUALS.org
 0000-00 16-45

▶ Control for each driving conditions

The ECU judges the engine load according to the fuel injection amount and the engine rpm. When
decelerating, the battery is charged by increasing the generator voltage. During acceleration, the
generator voltage is lowered while consuming the charged battery voltage, which reduces the load on
the alternator driven by the engine output, thereby reducing fuel consumption.

▶ Battery charge warning light

The ECU checks the voltage generated from the alternator and the circuit, and transmits the battery
charge warning lamp ON signal to the instrument panel through the GWM via the CAN communication.
(ECU→PCAN→CGW→CCAN→ICM)

GETtheMANUALS.org
16-46

3) Features of BSC (Battery Sensor Cable)

▶ OCV (Open Circuit Voltage)

The OCV is the measured battery voltage when there is no battery, and there is a correlation between
the OCV and the SOC, which is measured at the stabilized battery. Therefore, it is possible to predict the
SOC based on the OCV. The BSC monitors the measured voltage over 3 hours after the battery has
stabilized without charging/discharging.

▶ SOH (State Of Health)

SOH indicates the aging degree of the battery. New batteries and batteries that have been used for a
certain period of time have different discharge rates. The aged battery will discharge quickly enough to
be difficult to use and should be replaced.

▶ SOC (State Of Charge)

The SOC represents the charged state of the battery, that is, the dischargeable capacity. (discharge
capacity)

▶ SOF (State Of Function)

SOF is the minimum start-up voltage (voltage drop) expected at the next start-up in the current battery
condition. Based on the current starting voltage/current, battery temperature, SOC and SOH (state of
health), the next start-up voltage is predicted depending on the BSC.

GETtheMANUALS.org
 0000-00 16-47

4) DTC Set Condition

▶ Charge warning light comes on when

1. IGN ON (engine stopped)

2. Terminal "L" wiring open/short circuit and alternator internal circuit open/short circuit (fixed control at
13.8V)
3. Terminal "F" wiring open/short circuit and feedback signal missing
4. No signal transmitted from BSC to ECU (LIN communication)
5. BSC error (invalid value sent to ECU)

For condition 1, this does not apply when the engine is stopped by ISG.

GETtheMANUALS.org
16-48

5) Charge Warning Light

The ECU sends a charge warning light ON signal to the instrument panel through the GWM via CAN
communication.
(ECU→PCAN→GWM→CCAN→ IP)

Charge warning light

▶ Charge warning light comes on when

- Pre-warning
- EEM system-related DTC(s)
- Alternator circuit open/short circuit
- No response from BSC
- BSC error (invalid value sent to BSC)

GETtheMANUALS.org
 0000-00 16-49

8. ALTERNATOR
1) Overview & Mounting Location

Alternator

The alternator is variably controlled by the ECU from its charging voltage to 11V to 15.5V. It charges the
battery by fixing the charging voltage when receiving the head lamp, blower motor, rear defogger, and
wiper operating signal.

2) Initial electricity generation

GETtheMANUALS.org
16-50

3) PWM Duty Value For Each Charging Voltage

The above figure shows the generating voltage output characteristics according to the engine ECU PWM
signal duty increase. It is controlled to 1~9% in low charge range and 91~99% duty in overcharge range
and charged to 13.6V.
The engine ECU outputs 5~95% PWM duty signal to the L terminal and fixes the output to 14.7 V at the
electrical load input (head lamp (LO / HI), wiper, rear defogger, blower running at its maximum speed).
However, when there is an alternator L terminal open circuit or short-circuit, it is fixed at 13.6V in 0~5%
and 95~100% duty range in fail-safe mode.

GETtheMANUALS.org
 0000-00 16-51

9. BATTERY
1) Overview

Battery

The battery charges and discharges the electric charge by receiving the charging voltage from alternator.

2) Determination of SOC (State Of Charge)

The charging capacity of battery is decreased as the time goes over.

SOC value is not the calculated value based on charging capacity as shown in the [Figure 1] but the
absolute value according to the battery condition as shown in the [Figure 2].

GETtheMANUALS.org
16-52

3) SOC management
The battery must be deteriorated as the time goes over.
EEM controls the charging capacity over 78% to provide initial starting. However, if the charging capacity
goes below 78%, EEM does not control the voltage generation.

▶ Charging mode

1. Mode 1 (Constant current control)

If the battery charging level is low, the system provides the high constant current to charge the battery
rapidly. The system controls the charging current according to the electric load conditions. If the
battery temperature increases over 40°C, the charging current is limited by 25A.

2. Mode 2 (Constant voltage control)

If the battery charging level is in middle range, the battery could be charged slowly when the control
voltage is low and the electrolyte could be deteriorated when the control voltage is high. If the electric
load increases very rapidly, the battery charging efficiency could be decreased.
To improve the charging/discharging efficiency and the fuel economy, do not maintain the constant
voltage control mode for a long time.

SOC
Mode
Initial Status Target Status
1 Below 78% 82%
2 Over 82% 92%
3 Below 92% 78%

GETtheMANUALS.org
 0000-00 16-53

3. Mode 3 (Voltage maintaining control)

If the battery is fully charged, the system tries to keep the current status. In this condition, the system
maintains the charging status with low charging voltage.
If the vehicle is accelerating, the system requires the discharging. The discharging is permitted only
when the SOC is over 78%. If the SOC is low (below 78%), the discharge control is not available.

▶ Limitation of charging current according to the temperature

Charging Discharging
Temperature
Current Time Current Time
Below 0°C 45 45
0 to 40°C 35 No limitation 35 No limitation

Over 40°C 25 25

▶ Activating BSC sensor

(battery (-) terminal disconnection, battery replacement, battery discharge, etc.)

- Remove the vehicle black box or other electrical devices that may consume battery dark current.
- Measure the dark current to check if it is below 50 mA.
- You should turn the ignition switch from ON position to OFF position, and the vehicle should be parked
for more than 4 hours at room temperature. Then, the BSC monitors the battery status and activates the
sensor.

▶ How to replace AGM battery to maintain vehicle performance

- When replacing the battery, be sure to replace it with a battery with the same specifications (capacity
and manufacturer) as the factory-installed battery.
- Otherwise, the ISG system may not operate properly due to the BSC sensor malfunction.

GETtheMANUALS.org
16-54

10. STARTING MOTOR

1) Overview & Mounting Location

Starting motor

The alternator is variably controlled by the ECU from its charging voltage to 11V to 15.5V. It charges the
battery by fixing the charging voltage when receiving the head lamp, blower motor, rear defogger, and
wiper operating signal.

▶ 300,000 times of starting counts

- The number of times the motor is started is counted and starting motor must be replaced after
300,000 counts. (ISG is disabled. However, ISG error LED nor lit DTC neither set)

GETtheMANUALS.org
 0000-00 16-55

2) Starting motor Output

▶ Vehicle without ISG

▶ Vehicle with ISG

GETtheMANUALS.org
16-56

11. BRAKE VACUUM PRESSURE SENSOR

1) Overview & Mounting Location

Brake vacuum pressure

sensor

The brake vacuum pressure sensor is fitted to bottom of the brake booster in the vehicle with the ISG.
When the ISG system operates, it detects the brake pressure. If the brake negative pressure is low
during ISG STOP, it sends a signal to the ECU, and the ECU performs forced ISG restart based on this
information.

2) Features

▶ Brake vacuum pressure

- For the ISG system to operate, the vacuum must be at least 333 hPa.

GETtheMANUALS.org
 0000-00 16-57

12. DC-DC CONVERTER

1) Overview & Mounting Location

DC-DC converter

The DC-DC converter is mounted on the IP frame at the rear side of the glove box assembly. When
voltage less than 12V is applied, boost voltage (12 ± 1V) is supplied for 0.02 to 1 second to
maintain stable voltage. It prevents reset of audio and instrument panel due to voltage drop during
engine restart by ISG Auto Start. Therefore, if the audio system and instrument panel are turned off due
to the voltage drop when the engine is restarted by ISG, the DC-DC converter can be diagnosed as
defective.

GETtheMANUALS.org
16-58

2) Operating Process
A. In the ISG OFF state, INPUT B+ is bypassed and output to T2 section output to OUPUT B+.
B. When the ISG switch of INPUT B+ is turned on and a start signal is detected, the system outputs the
converted power to compensate for the voltage drop.
C. The maximum delay time that can be converted from the bypass output to the conversion output is
within T1 (1 sec).
If INPUT B+ becomes greater than 12V ± 1V within T1 (1 sec), the system switches from
conversion mode to bypass mode.

Conversion section Bypass section

Mode that boosts B+ input to voltage with constant Mode that passes B+ input to B+ output
level and emits B+ output

GETtheMANUALS.org
GETtheMANUALS.org
16-60

13. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 16-61

GETtheMANUALS.org
 0000-00 13-3

1. SPECIFICATIONS
Item X150 GSL Remarks
Engine G15GDI -
Injector Solenoid injector (DEKA7) -
Ignition coil 1by1 -
Emission compliance KOBD -
ECU terminals Connector A: 50-pin -
ECU terminals
Connector B: 94-pin -

CPU 32-bit SPC563 single chip -

Flash Memory Internal 1.5 Mbyte -
Electronic throttle body Yes H-Bridge
CVVT (Intake) Yes PWM
CVVT (Exhaust) Yes PWM
Boost sensor (T-MAP) Yes -
Intake air temperature sensor (T-MAP) Yes NTC
Coolant temperature sensor Yes NTC
Cam position sensor Yes Camshaft - 4-tooth type
CRANKSHAFT POSITION SENSOR Yes Trigger ring 60-2
KNOCK SENSOR Yes 2-pin
Front/rear oxygen sensor
Oxygen sensor Yes

Fuel pump Yes -

Trip computer (CAN) Yes -
Fuel tank shut-off valve Yes KOBD
Fuel tank pressure sensor Yes KOBD
Purge control solenoid valve (PCSV) Yes -

Accelerator pedal sensor Yes 6-pin (potentiometers

No. 1 and 2)
Switchable engine mounting control NO -

GETtheMANUALS.org
13-4

Item X100 GSL Remarks

Immobilizer (SKM) Yes CAN

Start control Yes HSD and LSD for ISG

Malfunction indicator lamp (MIL) Yes CAN
ISG (Idle Stop & Go) Yes -
CRUISE CONTROL ACC/SET Yes -
DEC/RES Yes
CANCEL Yes
ON/OFF Yes
Alternator control (EEM) Yes -
On board diagnostic (OBD) Yes -
CAN diagnosis Yes UDS
Neutral switch / Clutch switch Yes A vehicle with M/T
Vehicle speed Yes ABS & ESP
Cooling fan Yes Resistor type
VARIANT CODING Yes -
Refrigerant pressure sensor Yes -
Blower switch input Yes -
A/C compressor control Yes Relay control

GETtheMANUALS.org
 0000-00 13-5

2. ENGINE SENSOR DATA LIST

Data Unit Value
0.436 V (at 130°C) to 4.896 V
Engine coolant temp. °C
(at -40°C)
-40 to 120°C
Intake air temp. °C (varies with ambient temperature and
engine mode)
Engine rpm rpm At idling: 700±50 (P/N)
Intake air flow mg/stk At idling: approx. 130.0 mg/stk
Intake manifold pressure bar At idling: Approx. 0.44 bar
Intake manifold voltage V At idling: Approx. 1.86V
Engine torque Nm At idling: Approx. 36.0 Nm
Injection time of injector ms At idling: Approx. 3.1 ms
Battery voltage V 13.5 to 14.1 V
Throttle position sensor
V At idling: Approx. 0.6V
1 voltage
Throttle position sensor
V At idling: Approx. 4.4V
2 voltage
Front oxygen sensor voltage mV 0 to 800mV
Intake/Exhaust CVVT duty % At idling: Approx. 70%
Short runner/
VIS operation At idling: Short runner
long runner
ignition time °CRK At idling: 1.8 to 3.0°CRK
Knock control level V At idling: 0.37 to 0.58V
Fuel tank level % 0 to 100%
VOP operation Operating/not operating -
Brake switch Operating/not operating -
Clutch switch Operating/not operating -
A/C compressor Operating/not operating -
FUEL PUMP RELAY Operating/not operating -
Cooling fan relay Low/High speed -

GETtheMANUALS.org
13-6

3. CODING LISTS WHEN REPLACING ELECTRONIC SYSTEMS

▶ With SKM

Smart key &

Category EMS registration Variant coding
transponder coding
Replace ECU Carried out in SKM - -
Replace BCM - Carried out in BCM -
Replace smart key - - Carried out in SKM
Replacing SKM Carried out in SKM - Carried out in SKM

▶ With REKES

EMS registration Remote control Transponder

Category Variant coding
coding coding
Carried out in
Replace ECU - - -
BCM
Replacing Carried out in BCM
- Carried out in BCM -
REKES key
Replace BCM Carried out in Carried out in BCM Carried out in BCM
Carried out in BCM
BCM

4. ECU SELF-DIAGNOSIS ITEMS

Catalytic monitoring system Engine cooling system monitoring
Misfire monitoring system Low-emissions at cold start mechanism monitoring
Evaporative system monitoring CVVT monitoring
Fuel system monitoring Other components monitoring
Oxygen sensor monitoring

GETtheMANUALS.org
 0000-00 13-7

1. SPECIAL TOOLS
Part no. and name Special tools Usage
Part no.: X99110010A

Name:
Stopper-flywheel ring gear

Usage:
Fixed on the flywheel ring gear to
prevent the engine from rotating
when tightening the crankshaft
pulley bolts and flywheel bolts.

Part no.: X99120090A

Name:
Camshaft retaining jig

Usage:
Used to secure the intake and
exhaust camshaft when installing
the timing chain, and to remove
the cam sprocket.

GETtheMANUALS.org
13-8

2. GENERAL DEDICATED EQUIPMENT

Part name General equipment
Name:
Jack for engine with
transmission

Usage:
Supports the modules when
working with engine assembly,
fuel tank, subframe.

Name:
Engine crane (1 ton or more)

Usage:
Used to move the removed
engine module with transaxle to
a working area or an engine
stand. Use an equipment which
is designed to carry load of 1
tonne or more.

Name:
Engine stand (1 tonne or more)

Usage:
Used to secure the removed
engine or engine with transaxle. Engine stand
Use an equipment which is
designed to carry load of 1 tone
or more.

Name:
Engine support hanger

Usage:
Used to securely hold the engine
to prevent it from dropping when
working with the timing gear
case cover, engine mounting
insulator, or transmission.

GETtheMANUALS.org
 0000-00 13-9

Part no. and name General equipment

Part no.:
Y99220082B
W99110230A

Name:
Y9922018
Valve spring complete

To intake valve

To exhaust valve
Y99220082B W99110230A
Part no.: Y9922018

Name:
Valve stem seal remover

Usage:
Used to protect the stem seal
from damage when removing
the valve stem seal.

Part no.: Y9922008

Name:
Valve stem seal installer

Usage:
Used to install the valve stem
seal.

GETtheMANUALS.org
13-10

Part no. and name General equipment

Part no.: A99110031B

Name:
Piston compression ring
clamping strap

Usage:
Used to insert the piston in the
cylinder block.

Part no.: X99220010A

Name:
Fuel pump cover
installer/remover

Usage:
Used to install or remove the
fuel pump cover.

Part no.: A99100032B

Dial gauge
Name:
Dial gauge

Usage:
Used to measure the
crankshaft end play.

GETtheMANUALS.org
 0000-00 13-11

1. OVERVIEW
The ECU receives signals from various sensors. Then, it analyzes and modifies them to allowable
voltage level to control various actuators. The ECU can control the engine power and exhaust gas
precisely because the micro processor in the ECU calculates the injection duration, injection timing, and
injection volume based on the engine piston speed and crankshaft angle using input data and a stored
map. The output signal from the ECU microprocessor drives the solenoid valve of the injector to control
the fuel injection volume and injection timing and control the ignition timing of the ignition coil so as to
control various actuators in response to the changes in the engine condition. In addition, many auxiliary
functions are added to the ECU in order to reduce emissions, improve fuel economy and ensure safety,
riding comfort and convenience. Some examples of such functions include cruise control (auto cruise)
and immobilizer. The ECU uses the CAN communication system to facilitate data exchange with other
electric systems such as A/T, braking device, and steering system. When servicing a vehicle, a
diagnostic equipment can be used to check the vehicle conditions and perform diagnosis. The normal
operating temperature for ECU ranges from -40 to +85°C. The ECU must be protected from oil,
moisture, electromagnetic interference, and external mechanical impact.

GETtheMANUALS.org
13-12

2. COMPONENTS
1) ECU Input Element
Rear oxygen sensor Coolant temperature Camshaft position Crankshaft
sensor sensor Position sensor

Front oxygen sensor Electric

throttle body
ECU

Knock sensor T-MAP sensor

Refrigerant pressure sensor CAN

Fuel tank pressure sensor communication
Oil pressure switch
Auto cruise switch
Fuel gauge (OBD control)
clutch pedal signal
Blower switch signal
Brake pedal signal
Vehicle speed

GETtheMANUALS.org
 0000-00 13-13

2) ECU Output Element

Intake / Exhaust OCV Start relay A/C compressor Injector
(Oil Control Valve)

VOP solenoid valve Ignition coil

ECU

Purge control Electric fan

Solenoid valve

Electric Canister shut-off valve CAN

throttle body Engine main relay communication
Fuel pump
Fuel metering valve (MSV)
E-WGA

GETtheMANUALS.org
13-14

3) Engine ECU Inputs/Outputs (Control Items)

GETtheMANUALS.org
 0000-00 13-15

3. EPC
▶ 1490 emission module (GSL)

1. ECU-ENGINE
2. BRKT-ECU
3. BOLT-FLANGE
4. NUT

GETtheMANUALS.org
13-16

▶ 1430 Sensors (GSL)

5. KNOCK SENSOR 14.SENSOR ASSY-CAMSHAFT POSITION

6. BOLT 15.BOLT
7. SENSOR ASSY-COOLANT 17.BRKT-CRANKSHAFT POSITION
8. RING-SEAL 18.BOLT
9. SENSOR ASSY-OXYGEN HEATED FRT 19.BOLT
10.BRKT-OXYGEN SENSOR 20.SENSOR ASSY-TEMPERATURE & MAP
11.SENSOR ASSY-OXYGEN RR 21.BOLT

GETtheMANUALS.org
 0000-00 13-17

▶ 2010 Accelerator control

1. PEDAL MODULE-ACCELERATOR
2. NUT
3. SCREW
4. CAP-ACCELERATOR PEDAL

GETtheMANUALS.org
13-18

1. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 13-19

GETtheMANUALS.org
13-20

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 13-21

2. CAN COMMUNICATION I/O ELEMENTS

▶ ABS & ESP

▶ BCM

GETtheMANUALS.org
13-22

▶ BCM

▶ AWD

▶ EPS

GETtheMANUALS.org
 0000-00 13-23

▶ FCM

▶ HVAC

GETtheMANUALS.org
13-24

▶ Instrument cluster

▶ SDM

GETtheMANUALS.org
 0000-00 13-25

▶ TCU

GETtheMANUALS.org
13-26

▶ SKM

▶ TPMS

▶ Diagnostic device

GETtheMANUALS.org
 0000-00 13-27

3. FUEL INJECTION VOLUME CONTROL

The ECU determines fuel injection volume and injection timing based on the engine condition and
optimizes the engine operating conditions to reduce the emissions.

GETtheMANUALS.org
13-28

▶ Basic mapping

- Stepped control
The ECU calculates proper injection volume and timing by considering various parameters to achieve
the optimal combustion at each stage of operation.
- Starting injection volume control
The fuel injection volume during initial starting is calculated by considering the temperature and
engine cranking speed. The starting injection means the injection during the period from when the
ignition switch is turned ON until when the engine rpm reaches to the allowable minimum speed.
Driving mode control
- The fuel injection volume during normal driving is calculated based on the accelerator pedal travel and
engine rpm and the drive map is used to match the drivers inputs with optimal engine power.

GETtheMANUALS.org
 0000-00 13-29

4. IGNITION TIMING CONTROL

The default ignition timing for each cylinder is determined based on the signals from the camshaft
position sensor and crankshaft position sensor. The engine control unit (ECU) controls the ignition timing
more precisely by using the following information:

1) Input/Output Element

GETtheMANUALS.org
13-30

▶ Features

1. Determination of ignition timing based on input signal

The ECU always analyzes the following elements when determining the ignition timing.
- Crankshaft position sensor
- Cam position sensor
- Coolant temperature sensor
- Intake air temperature / intake air flow

2. Warm-up of catalytic converter

The exhaust gas temperature needs to be increased for catalytic converter to reach the normal
operating temperature rapidly. For this purpose, the ignition timing is retarded during a certain period of
time using the coolant temperature and etc. when starting.

3. Idle speed control

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

4. Fuel cut-off when decelerating

The ignition timing control is retarded temporarily to prevent a rapid rise in torque when the combustion
is restarted.

5. Intake air temperature and coolant temperature correction control

The ignition timing is retarded to prevent engine knocking if the intake air temperature and coolant
temperature are high.

6. Electronic stability program (ESP) control mode

The ignition timing is retarded to reduce the engine torque as soon as possible in ESP control mode.

7. Knock control
If knocking occurs in a cylinder, the ignition timing of the corresponding cylinder will be retarded.

GETtheMANUALS.org
 0000-00 13-31

5. CCC (CLOSE COUPLED CATALYTIC CONVERTER)

WARM-UP CONTROL
In order to reach the active temperature of CCC, the idle ignition timing is retarded according to the
coolant temperature at cold start. When the selector lever position is at the P or N position, the ignition
timing is adjusted according to the following conditions:
- Coolant temperature
- Engine rpm
- Intake air flow
- Recognized idling status
- Selector lever position

1) Input/Output Element

GETtheMANUALS.org
13-32

6. WARM-UP CONTROL
▶ Idle speed control
The idle speed is controlled based on the fuel/air mixture when the engine load is changed, the power
steering wheel is turned to its end, the gear selector lever is in the D position and the A/C compressor is
operating. It is also controlled based on the charge level during the PCV operation.

▶ Ignition timing
The ignition timing can be retarded or advanced to help idle speed control.

▶ A/C compressor operation

The A/C control unit sends the A/C operation signal to the ECU to increase the throttle valve opening
angle in order to prevent a drop in engine speed when the A/C compressor is operating while the engine
is idling.

▶ Low voltage
If low voltage is detected by the ECU, the idle speed increases slightly in driving mode until the ignition
switch is turned off depending on the situation.

GETtheMANUALS.org
 0000-00 13-33

7. CRANKSHAFT POSITION SENSOR CONTROL

1) Features
- Hall sensor outputs the signal in the rectangular wave form.
- The magnetic trigger ring is magnetized, so be careful not to bring any magnetic material close to it.
That would affect the magnetic characteristic.
- The position of each cylinder is sensed based on the signal of the long tooth (60-2).

Magnetic trigger ring

Items Value
Power supply 12V
Output voltage 4.48V
Air gap 0.4 to 1.2mm

The triggering can lose magnetic properties easily by an external magnetic field or scratches on the
surface. Do not use magnetic tools or equipment near the trigger ring.

GETtheMANUALS.org
13-34

8. T-MAP SENSOR CONTROL

1) System Diagram

GETtheMANUALS.org
 0000-00 13-35

2) Features
▶ Features of intake air temperature sensor

Intake air Resistance (Ω)

temperature (°C)
-40 44373
-20 15141
0 5774
20 2448
40 1150
60 583
80 316
100 183

▶ Pressure sensor characteristics

GETtheMANUALS.org
13-36

9. BOOST PRESSURE (T-MAP) SENSOR

The boost pressure (T-MAP) sensor is mounted in the middle of the intercooler pipe and measures the
pressure and temperature between the turbocharger and the throttle body. It is used to determine the
intercooler operation and to correct the stability and precision of the throttle learning control. Its
characteristics are similar to ones of the intake manifold T-MAP sensor.

Boost pressure (T-MAP)

sensor

GETtheMANUALS.org
 0000-00 13-37

10. RAIL PRSSURE SENSOR

The rail pressure sensor is mounted on the fuel rail and detects the pressure inside the fuel rail. The
ECU supplies a 5 V of reference voltage to output a high signal voltage when the fuel pressure is high
and a low signal voltage when the fuel pressure low.

Rail pressure sensor

▶ Characteristics

Category Specified value

Output voltage 0.5 to 4.5V
Current consumption 12mA

GETtheMANUALS.org
13-38

11. eWGA (ELECTRIC WASTE GATE ACTUATOR)

The turbocharger system operates the eWGA according to the signals for engine rpm, accelerator pedal
position, atmospheric pressure, T-MAP, coolant temperature, intake air temperature and etc.
The eWGA is controlled by an ECU and the eWGA motor is PWM controlled via an H-bridge circuit.

Wastegate eWGA

▶ Characteristics

Category Specified value

Supply voltage 9 V to 16 V
Motor
Control type 1 kHz PWM control
Sensor type Hall effect type
Supply voltage 5V
Sensor
Power open circuit: 0.25 V or less
Failure recognition Output voltage
Ground open circuit: 4.87 V or higher

GETtheMANUALS.org
 0000-00 13-39

12. ERCV (ELECTRIC RECIRCULATION VALVE)

If the boost pressure suddenly rises due to abrupt throttle body closure, etc., the eRCV valve operates to
form a bypass circuit, thereby recirculating the air in the turbocharger to maintain the speed of the
compressor wheel normally.

▶ Features

Category Specified value

Current consumption 1.03 ± 0.05 A (25°C)

GETtheMANUALS.org
13-40

13. Fuel pressure control valve

It is mounted on a high-pressure pump and controls the amount of fuel injected into the injector by ECU
control signals calculated from various engine operating conditions. The fuel pressure control valve
constitutes the fuel pressure control valve drive circuit inside the ECU like the injector drive method and
controls both the power circuit (High side) and the ground circuit (Low side) for valve activation.

Fuel pressure control valve

Fuel rail assembly

▶ Feature

Category Specified value

Coil resistance 0.48~0.55Ω (20℃)

▶ Fail-safe when high pressure pump and rail pressure sensor is defective

The high pressure pump judges the reliability of the rail pressure control and the power stage
diagnostics, that is, the inconsistency of the control, so that the engine speed is restricted when an error
occurs. If the rail pressure sensor detects any fault such as electrical error (min / max), inspection range
(min / max), reliability, check fixation, etc., engine speed is limited.

GETtheMANUALS.org
 0000-00 13-41

14. COOLANT TEMPERATURE SENSOR CONTROL

1) System Diagram

2) Features
Coolant temperature
-40 -10 15 20 80 130 140
(°C)
Resistance (Ω) 45300 9200 3055 2500 327 90 72

GETtheMANUALS.org
13-42

3) Elements controlled in relation to coolant temperature

a. Injection time of injector
The idling speed is controlled according to the coolant temperature.

b. Fuel injection volume

The fuel amount is corrected according to coolant temperature.

c. Ignition timing control

When the coolant temperature is low, the ignition timing will be advanced in order to facilitate the catalytic
converter, oxygen sensor and engine warm-up process. If the coolant temperature is high, the ignition
timing will be retarded to prevent knocking.

d. T/M shift delay

The shift operation of the automatic transmission is delayed to help warm-up when the coolant
temperature is low.

e. Electric fan operation

When the engine is overheated due to high coolant temperature, the electronic fan will be operated to
cool down the engine.

f. A/C operation
Power supplied to the A/C compressor is cut off depending on the coolant temperature.

g. Displays on Instrument Cluster

The coolant temperature is displayed on the instrument panel via CAN communication.

GETtheMANUALS.org
 0000-00 13-43

15. ELECTRIC THROTTLE BODY CONTROL

1) Features
▶ Throttle position sensor output

▶ Characteristics of throttle motor & position sensor

Category Item Specified value

Resistance 2.35 Ω
DC motor Max. continuous current 1.7A
Current with unloaded (at idling) 0.8 A or lower
Resistance (1 and 2 parallel) 2 kΩ ± 20%
Idling 0.5 ± 0.1 V
Throttle position TPS 1
WOT 4.6 ± 0.1 V
sensor Voltage
Idling 4.5 ± 0.1 V
TPS 2
WOT 0.4 ± 0.1 V

GETtheMANUALS.org
13-44

▶ Throttle valve fail safe

a. When electrical fault occurs

- If a fault is detected in one of the potentiometers of the throttle valve, the valid signal from the
potentiometer is used instead of the implausible signal, and the hot-film air-flow sensor is used as
an alternative comparison value. At this time, the amount of opening of the throttle valve and the
engine torque are limited.
- If errors occur at both potentiometers, the engine speed is limited and the throttle valve is locked
only by the spring capsule of the actuator.

b. When mechanical fault occurs

If any fault occurs in the actuator motor or any problem occurs in the power supply, the throttle valve will
be shut off. The throttle valve is open slightly and the engine speed is limited by shutting off the injector
with no engine load.

GETtheMANUALS.org
 0000-00 13-45

16. KNOCK SENSOR CONTROL

1) Features
The knock sensor is not supplied with reference power, but generates voltage by using its piezoelectric
element to transmit the amount of engine vibration to the ECU.

Insulating resistance R > 1 MΩ

Resonance frequency ?30 kHz
Operating temperature -40 ~ 150℃
V1/5 kHz: 28.9 to 39.1 mV/29.4 m/s²
V2/15 kHz: 28.9 to 39.1 mV/29.4 m/s²
Output voltage V3/18 kHz: 28.5 to 42.8 mV/29.4 m/s²
V4/20 kHz: 29.9 to 44.8 mV/29.4 m/s²
V5/20 kHz: 31.8 to 47.8 mV/29.4 m/s²

* 0 v / 0 kHz: Voltage level per each vibration frequency range

* 29.4 m/s²: output voltage (mV) when vibration (movement) with acceleration of gravity of 3g
occurs

Functions
- Idle safety control
- Cylinder balancing control
- When the knock sensor is faulty:
The ECU determines the injection timing based on the MAP values including engine rpm,
intake air mass flow, coolant temperature.

GETtheMANUALS.org
13-46

17. OXYGEN SENSOR CONTROL

1) Overview
The upstream oxygen sensor is a wide band oxygen sensor and the downstream oxygen sensor is
composed of a binary oxygen sensor. The pumping current (IP) is applied for controlling the air-fuel ratio
by utilizing the generated voltage of the upstream oxygen sensor.
In order to operate the oxygen sensor normally, the temperature of the sensor tip should be maintained
at a certain temperature (usually 370°C) or higher. Therefore, a sensor heater of duty control type
is built in the sensor. This is used to heat the temperature of the sensor tip to a predetermined
temperature or higher so that the sensor operates normally when the exhaust gas temperature is low.

2) Features
Category Function Description
Upstream oxygen sensor sensing Exhaust gas air-fuel ratio
0.65 < λ < ∞
monitoring
Downstream oxygen sensor
3-way catalyst monitoring λ=1
sensing

GETtheMANUALS.org
 0000-00 13-47

18. ACCELERATOR PEDAL MODULE CONTROL

1) Kick Down Switch
This switch prevents loud engine noise and
deterioration of fuel efficiency due to increased
rpm and slipping on a slippery surface by
inhibiting unintentional downshift when rapidly
accelerating.

The kick down switch is a dummy switch

which is not connected to wirings.

Accelerator pedal 1 Accelerator pedal 2

Full resistance of 1.2 ㏀ ± 20% 1.7 ㏀ ± 20%
potentiometer (IDLE)
+ Measure the component resistance.
Service check + Depress the pedal with the component removed to check if the
resistance changes continuously.

Pedal position Specification

Idle 1V ± 1%
Accelerator pedal 1
Accelerator pedal fully depressed
4.2V ± 2.6%

Idle 0.5V ± 0.5%

Accelerator pedal 2
Accelerator pedal fully depressed
2.1V ± 1.3%

▶ Fail-safe in the event of accelerator pedal failure

If a fault occurs in one of signals No. 1 and No. 2 from the accelerator pedal sensor, the system will use
the normal accelerator pedal signal instead of the implausible signal. At this time, the throttle valve
opening amount is limited and opening of the throttle valve is carried out slowly with dynamic limiting.
When a fault occurs, the engine torque is limited.

GETtheMANUALS.org
13-48

19. ELECTRIC FAN AND A/C COMPRESSOR CONTROL

The engine ECU controls the electric fan to low or high speed by controlling two electric fan relays. The
engine ECU controls the electric fan to improve A/C cooling and engine torque. The ECU operates the
A/C compressor when the A/C switch signal is input from the A/C control module, and deactivates the
A/C compressor when the A/C system is overloaded to protect the system.

1) Input/Output Element

GETtheMANUALS.org
 0000-00 13-49

▶ A/C compressor deactivation conditions

- Coolant temperature of 115℃ or more

- For approx. 5 seconds after engine start
- During abrupt acceleration
- Refrigerant pressure
: Turns off at 2.0 kg/㎠ or less and then turns on at 2.4 kg/㎠ or higher
: Turns off at 32.0 kg/㎠ or higher and then turns on 26.0 kg/㎠ or less

GETtheMANUALS.org
13-50

20. KNOCKING CONTROL

When abnormal combustion occurs in any cylinder, the ignition timing of that cylinder is retarded to
control the knocking phenomenon in various conditions (from idling to full load condition). Anti-knock
control is controlled by the ECU internal program and begins when the coolant temperature
reaches 70℃. If the knocking persists, the ignition timing will be retarded continuously. The
amount of retard can be vary depending on the engine speed.

1) Input/Output Element

GETtheMANUALS.org
 0000-00 13-51

▶ Output signal

Cylinder ignition timing correction knocking control operates under various conditions such as coolant
temperature. When knocking is detected, the ignition timing of the corresponding cylinder is retarded
from the next ignition. If the knocking persists, the ignition timing will be retarded continuously. The
amount of retard can be vary depending on the engine speed.

▶ Knock control adaptation

- The knock control adaptation is operated by various factors such as the coolant temperature. The
data necessary to determine the ignition timing, such as correction value and current engine status,
are stored as the knocking is detected consistently.
- During rapid acceleration, the data will not be stored for a certain period of time to prevent application
of incorrect adaptation.
- If no signal is received from the knock sensor, the ignition timing of all cylinders will be retarded up to
the certain value and knock control and adaptation will be inhibited for safety.

GETtheMANUALS.org
13-52

21. MAXIMUM SPEED LIMITATION

The ECU receives the engine speed signal from the crank position sensor and controls the engine
speed by shutting off the injector under the following conditions to protect the engine and the drive train.

1) Input/Output Element

▶ Torque converter protection with gear selector lever in P or N position

The engine speed is limited to protect the torque converter from excessive pressure rise in the torque
converter when the gear selector lever is in the P or N position.

▶ Maximum engine speed limitation during driving

The engine speed is limited to prevent damage to the engine due to high engine revolution speed. The
data for the drive mode detection are sent from the ESP unit to the ECU.

▶ Safe fuel cut

If the throttle valve is found to be faulty, the injector will be shut off at a certain rpm or higher and re-
activated at 1,200 rpm or lower.

GETtheMANUALS.org
 0000-00 13-53

22. VOP CONTROL

For the fixed flow type oil pump, as the engine rpm increases, the oil flow increases proportionally. The
excessive flow generated by higher engine rpm raises the pressure in the oil circulation system. And
because of this increased pressure, more engine power is required to operate the oil pump. To overcome
this advantage, a variable oil pump (VOP) which adjusts the amount of oil discharged by the oil pump is
used. VOP is controlled in different speed ranges separately (low/moderate speed range, and high speed
range)
- Low/Moderate speed range (2,500 rpm or lower): Solenoid ON → ON (improve fuel economy)
- High speed range (higher than 2,500 rpm): Solenoid OFF → OFF (ensure reliability of lubrication)

GETtheMANUALS.org
13-54

▶ Operating process

a. When the VOP solenoid valve is ON

If the VOP solenoid valve is activated, then the valve will close the drain passage to the oil pan so that
the pressure can be sent to the 2nd chamber (F2). The discharge pressure of the oil pump will be sent to
the 1st chamber (F1). Therefore, the sum of both pressure (F1+F2) will be applied to the slide connected
to the spring and this force will compress the spring. At this time, the whole slide will move to increase
the gap with the rotor as shown in the right figure. Then the oil pressure will decrease because of the
changed volume ratio.

b. When the VOP solenoid valve is OFF

If no power is supplied to the VOP solenoid valve, the oil from the main gallery will flow into the oil pan
through the VOP solenoid valve. Therefore, the pressure (F2) which compresses the spring will be lost
and the slide will move by the force from the released spring. Then the oil pressure will increase by the
changed volume ratio due to the reduced the gap between the rotor and the slide.

GETtheMANUALS.org
 0000-00 13-55

23. CVVT CONTROL (INCLUDING OCV)

1) Overview
The Continuous Variable Valve Timing (CVVT) system incorporates an integrated oil control valve
(OCV) with center bolt to improve the responsiveness of intake and exhaust camshafts.
The oil control valve (OCV) receives the signal from the engine ECU and can control the oil flow into the
CVVT by the duty control to change to the advanced or retarded state of the intake and exhaust cam
shafts, thereby causing valve overlap or valve underlap. As a result, pumping loss is reduced,
combustion stability is improved, volume efficiency is improved, and the effect of reducing exhaust gas
as well as fuel economy is maximized.
The OCV has the same intake and exhaust sides, and the camshaft adjuster center bolt (OCV) and the
solenoid valve have the same intake and exhaust sides. The camshaft adjuster features that the internal
shape is reversed according to the operating direction.

2) Mounting Location and Components

Cam position rotor Exhaust camshaft adjuster

(exhaust CVVT)

Intake camshaft adjuster

(intake CVVT)

8 point cam

Intake OCV Exhaust OCV

GETtheMANUALS.org
13-56

3) CVVT Control Area-specific Characteristics

For CVVT control, the camshaft control solenoid valve is activated, based on the PWM control signal
from the ECU.

Category Control characteristics Effect

- Engine shutdown * Valve overlap minimized - Prevents fuel-air mixture
- Start-up - Intake CVVT: most retarded state from being flowed
- Idling - Exhaust CVVT: most advanced state backward to intake side
- Stabilizes engine rpm
- Improves fuel economy
* Valve overlap minimized - Prevents fuel-air mixture
At low load - Intake CVVT: retarded state from being flowed
- Exhaust CVVT: most advanced state backward to intake side
- Stabilizes engine rpm
- Improves fuel economy
* Valve overlap enlarged more - Improves internal EGR rate
At moderate load - Intake CVVT: advanced state - Reduces NOx
- Exhaust CVVT: advanced state - Improves fuel economy
* Valve overlap maximized
At high load Increase volume efficiency to
- Intake CVVT: most advanced state
increase torque
- Exhaust CVVT: most retarded state

4) Operation of CVVT
It can be divided into three phases, the most retarded state, the hold state, and the most advanced state
depending on the hydraulic pressure controlled by the OCV. The initial position of the CVVT is the most
retarded state for the intake CVVT, and the most advanced state for the exhaust CVVT.

GETtheMANUALS.org
 0000-00 13-57

1. Intake CVVT retarded to maximum position/Exhaust CVVT advanced to maximum

position
When the engine is not running or idling, the rotor is fixed to the housing by the lock-pin attached to each
CVVT to prevent the ignition timing from being advanced or retarded.
In order to fix the CVVT housing to the rotor, the intake CVVT supplies hydraulic pressure to the retard
chamber whereas the exhaust CVVT supplies the hydraulic pressure to the advance chamber. In
addition, the oil in the retard chamber or the advance chamber will be discharged when the retarded
state (intake CVVT) or the advanced state (exhaust CVVT) is changed to the opposite direction.

Intake CVVT Exhaust CVVT

GETtheMANUALS.org
13-58

2. Hold state
When the target position is reached, the camshaft control solenoid valve is controlled to supply oil to the
retarding chamber and the advancing chamber and maintains the current timing.
In the maintained state, the engine ECU uses the crank position sensor and the cam position sensor to
control an effective timing for sensing.

Intake CVVT Exhaust CVVT

GETtheMANUALS.org
 0000-00 13-59

3. Intake CVVT advanced to maximum position/Exhaust CVVT to maximum retarded

position
The camshaft control solenoid valve is controlled to 100% duty.
In order to fix the CVVT housing to the rotor, the intake CVVT supplies hydraulic pressure to the
advance chamber whereas the exhaust CVVT supplies the hydraulic pressure to the retard chamber. In
addition, the oil in the advance chamber or the retard chamber will be discharged when the advanced
state (intake CVVT) or the retarded state (exhaust CVVT) is changed to the opposite direction.

Intake CVVT Exhaust CVVT

GETtheMANUALS.org
13-60

5) Precautions for handing CVVT system and OCV

- Do not drop the CVVT system.
(If deformation occurs on the CVVT system because of external impact, CVVT may not operate)
- Do not disassemble the CVVT system components.
- Keep the CVVT system and oil passages to the CVVT system.
(for proper operation of the working parts and vane of the OCV and CVVT side)
- Align the dowel pin of the CVVT when installing the CVVT system to the camshaft.
- Hold the camshaft in place and tighten the center bolts for CVVT.
(Do not secure the CVVT system to tighten the center bolts)

GETtheMANUALS.org
 0000-00 13-61

24. FUEL EVAP CONTROL SYSTEM

The fuel evaporative control system stores the evaporative gas in the canister to prevent the evaporated
fuel being released into the atmosphere. This system diagnoses the internal system and checks for
abnormalities in the system by using the pressure sensor and canister shut-off valve installed to the fuel
tank. The purge control solenoid valve (PCSV) is operated by the engine ECU control according to the
engine load condition. The fuel evaporative gas, stored in the canister, is drawn into the engine due to
vacuum condition (negative pressure) of the engine when the PCSV is open while the fuel evaporative
gas in the fuel system is sucked and stored in the canister when the PCSV is closed.

GETtheMANUALS.org
13-62

▶ Major components

GETtheMANUALS.org
 0000-00 13-63

25. CONTROLLING CRUISE CONTROL

The engine ECU detects the cruise control switch position and monitors the brake operating conditions,
clutch conditions, and vehicle speeds, etc. The engine ECU maintains the set vehicle speed, increases,
or decreases the vehicle speed according to the signals from the cruise control switch, unless a fault is
detected during cruise control driving.

GETtheMANUALS.org
13-64

26. IMMOBILIZER CONTROL

1) For a Vehicle with Ignition Key
When turning the ignition key to the ON position, the power is supplied to the immobilizer unit and EMS
(ECU). The ECU communicates with the immobilizer unit to verify the key and transponder. If it is valid,
the ECU starts to control the engine or immobilizer indicator (illumination or flashing) when the ignition key
is turned to the START position.
Once the key is verified, valid key verification time is provided for 10 seconds and the engine can be
started by turning the ignition key to the engine START position during this verification time. If the ignition
key is turned to the START position again after the 10 seconds of verification time, the key verification
should be reperformed.

1. When the ignition key is inserted, the immobilizer unit requests the transponder verification through
the antenna.
2. The transponder sends the encrypted message to the immobilizer control unit.
3. The immobilizer unit compares the encrypted message received from the transponder to
the coded value through the logic circuit. If they are identical, it requests the transponder
approval.
4. When the ignition is turned ON, the EMS (ECU) requests immobilizer verification process through
the P-CAN.
5. The immobilizer control unit sends the encrypted message to the EMS (ECU).
6. The EMS controls the engine normally when the coded value and the encrypted message sent
from the immobilizer are identical.

When the immobilizer verification has failed, the verification signal will be sent 3 times for 2
seconds, and the verification procedure will be carried out up to 3 times by turning the ignition ON
within 10 seconds. If the three re-verifications fail, verification procedure will be stopped and
restarted after 10 seconds.

GETtheMANUALS.org
 0000-00 13-65

2) For a Vehicle with Smart Key

Key verification can be divided into two types, immobilizer key verification and smart key verification.
The immobilizer verification is applied to the smart key module (SKM) system, and verifies the
transponder built in the smart key. When the smart key is held over the START/STOP switch, the
verification is carried out, overriding the RF signal from the smart key.
When the START/STOP switch is pressed with the smart key held over the switch, the smart key
transponder verification is carried out by the transponder communication.
Once the key is verified, a valid key authentication time is provided for 10 seconds and the engine can be
started by pressing the START/STOP switch during this time. If pressing the START/STOP switch after
this 10 seconds, the key authentication process should be performed again.

1. When the ignition is turned ON, the EMS (ECU) sends the challenge message to the SKM through the
P-CAN.
(This is to verify whether the transponder of the smart key is valid. If the authentication fails, it transmits
the re-authentication signals 3 times for 2 seconds. If 3rd re-authentication fails, the authentication is
deactivated for 10 seconds and re-activated after that.)
2. The emergency antenna of the SKM system sends the encrypted cod to the transponder, and the
transponder re-sends the encrypted code to the emergency antenna.
3. The encrypted sent to the emergency antenna is transmitted to the SKM.
4. The SKM compares this code with the encrypted code randomly transmitted by the internal
logic.
(The system compares the signal from transponder and encrypted signal from the emergency
antenna)
5. Only when the two signals are identical, the SKM recognizes the key as the verified one and transmits
the positive message to the EMS (ECU).
6. The EMS (ECU) enables the engine to be started.

GETtheMANUALS.org
13-66

GETtheMANUALS.org
GETtheMANUALS.org
13-68

27. CIRCUIT DIAGRAM

▶ Engine main relay, fuel pump relay, fuel pump, oil control valve, ignition coil, oxygen sensor

GETtheMANUALS.org
 0000-00 13-69

GETtheMANUALS.org
13-70

▶ Injector, stop lamp switch, steering wheel switch, sensors (cam position, knock, coolant
temperature, T-MAP, oil pressure)

GETtheMANUALS.org
 0000-00 13-71

GETtheMANUALS.org
13-72

▶ Starting relay, GPF, E-WGA, sensors (crank position, fuel tank pressure, accelerator pedal,
fuel rail pressure, A/C refrigerant pressure)

GETtheMANUALS.org
 0000-00 13-73

GETtheMANUALS.org
13-74

▶ Cooling fan relay, A/C compressor relay, ISG

GETtheMANUALS.org
 0000-00 13-75

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Category Specifications Remarks
Engine model G16DF MPI
Engine type / Number of cylinders In-line 4 cylinders
Displacement (cc) 1,597
Compression ratio 10.5
Max. power (PS) 128
Max. torque (Nm) 160
Integrated with bed plate
Cylinder block
(Aluminum casting)
Valve system DOHC 16-valve / Dual CVVT
Timing chain Silent chain with 6.35 mm pitch -

Intake manifold VIS intake manifold

Exhaust manifold Integrated with MCC
8 mm offset
Crankshaft
(Crankshaft offset from piston)
Cooling system Inlet control (Thermostat)
Lubrication system With VOP
Engine oil capacity 4.0 ℓ
Coolant capacity 6.5 ℓ
Fuel tank capacity 47 ℓ

GETtheMANUALS.org
01-4

2. APPEARANCE
Front view Rear view

Right view Left view

GETtheMANUALS.org
 0000-00 01-5

3. MAJOR COMPONENTS
▶ Front view

Oil pressure control valve

Oil dipstick gauge

Oil filter

Alternator

Water pump pulley

Auto tensioner

A/C compressor pulley

Crankshaft pulley

▶ Rear view

Cam position sensor

LH hanger bracket

Coolant temperature sensor

Electronic throttle body

VIS solenoid valve

VIS actuator

Cylinder head coolant outlet

port

Coolant pipe

Drive plate

GETtheMANUALS.org
01-6

▶ Left view

RH hanger bracket

Water pump

Exhaust manifold

Thermostat housing

Cylinder block outlet port

Front oxygen sensor

Oil pressure switch

A/C compressor

▶ Right view

PCV

PCSV

T-MAP sensor

Intake manifold

Alternator

Oil pan

Oil drain plug

GETtheMANUALS.org
 0000-00 01-7

4. ENGINE COMPARTMENT LAYOUT

Brake fluid reservoir tank Fuse and relay box

Coolant reservoir tank

Engine oil filler cap

Air cleaner

Oil dipstick gauge Oil filter Battery

- When checking the engine compartment, be careful not to touch the hot components such as
engine, radiator, exhaust manifold, catalytic converter, and muffler immediately after the engine has
been stopped. Check the engine compartment after the engine has been cooled down sufficiently.
Regularly check the engine oil level and add Ssangyong genuine engine oil, if necessary.
- Clean the oil dipstick gauge with a clean cloth to prevent any foreign material from entering.
-

- Operating the vehicle with insufficient amount of engine oil will result in severe damage the engine.
Make sure that the engine oil level is correct and add oil, if necessary.

GETtheMANUALS.org
01-8

1) Major Check Items and Service Interval

Check item Daily check Weekly
Change interval
check
Change check 7,500 km of driving, then change at every
15,000 km of driving or 12 months whichever comes
Engine oil
Check - first.
and oil filter
Check the oil level randomly and add if necessary,
Service more frequently under severe conditions
Replace the oil filter when changing the engine oil.

Coolant Check - Change at every 5 years or 200,000 km of driving.

(Long life antifreeze)
Clean at every 15,000 km of driving and replace at every
Air cleaner 30,000 km of driving.
- Check Clean or service more frequently under severe
element
conditions such as driving on a dusty road or off-road.

Service at every 30,000 km of driving.

Fuel filter - - Region where bad fuel is used: Change at every 50,000
km

2) Fluid Specifications And Capacity

- Ssangyong genuine engine oil
(ZIC SYMC 5W-30, ZIC SYMC FE 5W-20)
Specifications
- Approved by MB 229.51 5W30, MB 229.52 5W30, API SN
Engine oil
/ ILSAC GF-5 5W20
Capacity Approx. 4.0 L (4.5 L at initial fill)
Ssangyong genuine coolant (Long life antifreeze)
Specifications
Coolant (water:antifreeze = 50:50)
Capacity Approx. 6.5 L

Severe conditions
- Driving at high engine rpm or high speed, Excessive idling
- Driving for more than 2 hours at constant high speed (higher than 80% of maximum speed)
- Driving on dusty roads (off-roads) or muddy roads
- Driving on salted roads (coastal road, snow-melt road)
- Driving with high load such as trailer towing, cargo loaded

GETtheMANUALS.org
 0000-00 01-9

5. TIGHTENING TORQUE BY BOLT STRENGTH

1) Metric bolt strength is stamped on the head of each bolt. The strength of bolt can be classified as 4T,
7T, 8.8T, 10.9T, 11T and 12.9T in general.
2) Observe the standard tightening torque during bolt tightening. You can determine the proper
tightening torque within 15 % of standard value, if necessary. Try not to over permitted maximum
tightening torque, if not required to do so.
3) Determine the proper tightening torque separately, if tightening with washer or packing is required.
When the bolts are needed to be tightened to the below materials, follow the tightening torque
4) specified below.

- Aluminum alloy: Tighten to 80 % of above torque table.

- Plastics: Tighten to 20 % of above torque table.

GETtheMANUALS.org
01-10

6. ENGINE TIGHTENING TORQUE

Tool dimensions Bolt Specified
Components Remarks
Quantity torque (Nm)
Belt tensioner 17 mm 1 61 ± 2.0 Nm

Crankshaft pulley 27 mm 1 220 Nm

90°
Engine ground cable 10 mm 2 10 ± 1.0 Nm
15 mm 1
Alternator 61 ± 6.1 Nm
17 mm 1
-
A/C compressor 13 mm 4 25 ± 2.5 Nm
Water pump pulley 10 mm 3 10 ± 1.0 Nm
5 mm hexagon
Water pump 5 10 ± 1.0 Nm
wrench
Exhaust manifold heat 10 mm 4 10 ± 1.0 Nm
protector
12 mm 7 40 ± 5.0 Nm Non-reusable
Exhaust manifold
13 mm 3 25 ± 2.5 Nm
TOC coolant return pipe 10 mm 2 10 ± 1.0 Nm
(vehicle with A/T)
Coolant return pipe 10 mm 3 10 ± 1.0 Nm
(vehicle with M/T)
TOC coolant supply pipe 10 mm 2 10 ± 1.0 Nm -
(vehicle with A/T)
Cylinder head outlet port 5 mm hexagon
2 10 ± 1.0 Nm
wrench
Cylinder block outlet port 5 mm hexagon
2 10 ± 1.0 Nm
wrench
1 Bolt length: 60 mm
Oil filter module 13 mm 1 25 ± 2.5 Nm Bolt length: 105 mm
3 Bolt length: 40 mm
5 mm hexagon
Thermostat 2 10 ± 1.0 Nm
wrench
Electronic throttle body 10 mm 4 10 ± 1.0 Nm
-
Fuel rail 13 mm 2 25 ± 2.5 Nm
3 bolts
Intake manifold 13 mm 25 ± 2.5 Nm
1 nut

GETtheMANUALS.org
 0000-00 01-11

Tool dimensions Bolt Specified

Components Remarks
Quantity torque (Nm)
Knock sensor 13 mm 1 20 ± 5.0 Nm
OCV 8 mm 2 8 ± 1.0 Nm
Cam position sensor 10 mm 2 10 ± 1.0 Nm
-
Ignition coil 10 mm 4 10 ± 1.0 Nm
Spark plug 16 mm 4 20 ± 2.5 Nm
Cylinder head cover 10 mm 16 10 ± 1.0 Nm

Cylinder head E16 10 30 ± 3.0 Nm Non-reusable

90° X 2 times
Camshaft sprocket M14 (12-point bit
2 110 ± 10 Nm
socket)
Camshaft front bearing 10 mm 4 10 ± 1.0 Nm
cap
Camshaft bearing cap 10 mm 16 10 ± 1.0 Nm
2 10 ± 1.0 Nm Bolt length: 115 mm
10 mm 2 10 ± 1.0 Nm Bolt length: 105 mm
Oil pan
16 10 ± 1.0 Nm Bolt length: 25 mm
13 mm 2 25 ± 2.5 Nm Bolt length: 80 mm
4 58 ± 5.8 Nm Bolt length: 80 mm
15 mm
Timing gear case cover 1 58 ± 5.8 Nm Bolt length: 50 mm
1 25 ± 2.5 Nm Bolt length: 45 mm
13 mm
9 25 ± 2.5 Nm Bolt length: 30 mm
Timing chain tensioner 5 mm hexagon 2 10 ± 1.0 Nm
wrench
Tensioner rail T40 1 25 ± 2.5 Nm
Guide rail T40 3 25 ± 2.5 Nm
Sliding upper rail 5 mm hexagon -
2 10 ± 1.0 Nm
wrench
Baffle plate 10 mm 6 10 ± 1.0 Nm
Oil pump chain T40 1 25 ± 2.5 Nm
tensioner
VOP extension wiring 5 mm hexagon
1 10 ± 1.0 Nm
wrench

GETtheMANUALS.org
01-12

Components Tool dimensions Bolt Specified Remarks

Quantity torque (Nm)
Oil pump 6 mm hexagon 4 25 ± 2.5 Nm

Connecting rod cap 12-point socket 8 20 + 5.0 Nm

8 mm 80° + 10° -

Crankshaft position 5 mm hexagon 1 5 ± 1.0 Nm

sensor wrench
Drive plate T55 8 45 ± 5.0 Nm Non-reusable
45° ± 5°
Crankshaft rear seal 10 mm 6 10 ± 1.0 Nm -

Bed plate E10 10 25 ± 5.0 Nm

Non-reusable
Main journal 12-point socket 10 55 ± 5.0 Nm
13 mm 100° + 5°
starter motor 14 mm 2 45 ± 5.0 Nm

Oil filter Oil filter installation/ - 12 to 16 Nm

removal cup -

Cylinder block coolant 19 mm 1 30 Nm

screw plug
Flywheel T55 8 45 ± 5.0 Nm Non-reusable
90° ± 5°

GETtheMANUALS.org
 0000-00 01-13

7. VARIANT CODING
When any ECU including engine ECU has been replaced, the variant coding is necessary.
If there is improper operation and error in a system, check the variant code first.

Variant Code Select Remark

Unleaded/leaded Unleaded Select “Unleaded".
Leaded
NC inhibit No inhibit Select “Inhibit".
Inhibit
MIL MIL not illuminate Select “MIL illuminate".
MIL illuminate
Tire Size 195/70R15 16 inch: Select “205/60R16".
18 inch: Select “215/45R18".
205/60R16
215/45R18
Undefined
Coding is completed YES Select "YES".
NO
Immobilizer & key Non-IMMO(Non-IMMO+BCM+Conv.key) Select the appropriate system.
BCM(Non-IMMO+BCM+Conv.key)
SKM(Non-IMMO+BCM+Smat key)
Reserved
Engine type G16DF Select "YES".
Transmission type MT MT: Select “MT ".
AT: Select “AT ".
AT
TPMS not equipped Select “not equipped” or
“equipped”.
equipped
ABS/ESP not equipped Select “ABS” or “ESP”.
ABS
ESP

GETtheMANUALS.org
01-14

Variant Code Select Remark

RON correction RON87~100 Select "RON95".
Drive Control System No system Select “No system” or “Cruise
control”.
Cruise control
ACC
Undefined
Vehicle speed max 180Km/h Select "180Km/h".
190Km/h
200Km/h
210Km/h
Cooling fan Relay Select "Relay".
PWM
Air-conditioning Not equipped Select “equipped”.
Equipped
Able signal of vehicle Not defined Select "YES".
variant message
NO
YES
Signal not valid
Platform Tivoli Select "Tivoli".
Transfer case 2WD Select “2WD” or “4WD”.
4WD
Electric power steering Short body G16DF Select the appropriate system.
Short body D16DTF
Long body G16DF
Long body D16DTF
Korea/Export Korea Select the region.
General export
EU export

GETtheMANUALS.org
 1118-01 02-3

1. SPECIFICATIONS
Category Items Specified value Remarks
Cylinder Cylinder head height 132 ± 0.1 mm
head
Cylinder head weight 11.5 kg
Bottom (combustion All 0.075 mm
chamber surface)
Range 0.05 mm
flatness
(100 x 100 mm)

Spark plug installation angle 8° to intake side

Head gasket thickness 0.55 mm
Camshaft Camshaft axial end Intake side
play 0.08 to 0.18 mm
Exhaust side
Connecting End play 0.100 to 0.300 mm
rod
-
Cylinder Weight 21.5 kg
block
Bore Ø76 mm
assembly
Stroke Ø88 mm
Bore pitch 85 mm
Bed plate height 63.5 mm
Cylinder block + Bed plate 274.36 mm
height (210.86 mm to 63.5 mm)
Crankshaft Crankshaft axial end play 0.100 to 0.266 mm

Piston ring End gap No. 1 compression 0.15 to 0.30 mm

ring
No. 2 compression 0.30 to 0.50 mm
ring
No. 3 oil ring 0.20 to 0.70 mm

GETtheMANUALS.org
02-4

2. TIGHTENING TORQUE
Components Tool Bolt Specified Remarks
dimensions quantity torque (Nm)
Belt tensioner 17 mm 1 61 ± 2.0 Nm

Crankshaft pulley 27 mm 1 220 Nm

90°
Engine ground cable 10 mm 2 10 ± 1.0 Nm
15 mm 1
Alternator 61 ± 6.1 Nm -
17 mm 1
A/C compressor 13 mm 4 25 ± 2.5 Nm
Water pump pulley 10 mm 3 10 ± 1.0 Nm
Water pump 5 mm hexagon 5 10 ± 1.0 Nm
wrench
Exhaust manifold heat 10 mm 4 10 ± 1.0 Nm
protector
12 mm 7 40 ± 5.0 Nm Non-reusable
Exhaust manifold
13 mm 3 25 ± 2.5 Nm
TOC coolant return pipe 10 mm 2 10 ± 1.0 Nm
(vehicle with A/T)
Coolant return pipe (vehicle -
10 mm 3 10 ± 1.0 Nm
with M/T)
TOC coolant supply pipe 10 mm 2 10 ± 1.0 Nm
(vehicle with A/T)
Cylinder head outlet port 5mm hexagon 2 10 ± 1.0 Nm
wrench
Cylinder block outlet port 5 mm hexagon 2 10 ± 1.0 Nm
wrench
1 Bolt length: 60 mm
Oil filter module 13 mm 1 25 ± 2.5 Nm Bolt length: 105 mm
3 Bolt length: 40 mm
Thermostat 5 mm hexagon 2 10 ± 1.0 Nm
wrench
Electronic throttle body 10 mm 4 10 ± 1.0 Nm -

Fuel rail 13 mm 2 25 ± 2.5 Nm

Intake manifold 13 mm 3 bolts 25 ± 2.5 Nm
1 nut

GETtheMANUALS.org
 1118-01 02-5

Components Tool Bolt Specified Remarks

dimensions Quantity torque (Nm)
Knock sensor 13 mm 1 20 ± 5.0 Nm
OCV 8 mm 2 8 ± 1.0 Nm
Cam position sensor 10 mm 2 10 ± 1.0 Nm
-
Ignition coil 10 mm 4 10 ± 1.0 Nm
Spark plug 16 mm 4 20 ± 2.5 Nm
Cylinder head cover 10 mm 16 10 ± 1.0 Nm

Cylinder head E16 10 30 ± 3.0 Nm Non-reusable

90° X 2 times
Camshaft sprocket M14 (12-point bit
2 110 ± 10 Nm
socket)
Camshaft front bearing cap 10 mm 4 10 ± 1.0 Nm

Camshaft bearing cap 10 mm 16 10 ± 1.0 Nm

2 10 ± 1.0 Nm Bolt length: 115 mm
10 mm 2 10 ± 1.0 Nm Bolt length: 105 mm
Oil pan
16 10 ± 1.0 Nm Bolt length: 25 mm
13 mm 2 25 ± 2.5 Nm Bolt length: 80 mm
4 58 ± 5.8 Nm Bolt length: 80 mm
15 mm
Timing gear case cover 1 58 ± 5.8 Nm Bolt length: 50 mm
1 25 ± 2.5 Nm Bolt length: 45 mm
13 mm
9 25 ± 2.5 Nm Bolt length: 30 mm
Timing chain tensioner 5 mm hexagon
2 10 ± 1.0 Nm
wrench
Tensioner rail T40 1 25 ± 2.5 Nm
Guide rail T40 3 25 ± 2.5 Nm
Sliding upper rail 5 mm hexagon -
2 10 ± 1.0 Nm
wrench
Baffle plate 10 mm 6 10 ± 1.0 Nm
Oil pump chain T40 1 25 ± 2.5 Nm
tensioner
VOP extension wiring 5 mm hexagon
1 10 ± 1.0 Nm
wrench

GETtheMANUALS.org
02-6

Components Tool Bolt Specified Remarks

dimensions Quantity torque (Nm)
Oil pump 6 mm hexagon 4 25 ± 2.5 Nm

Connecting rod cap 12 point socket 8 20 + 5.0 Nm

8 mm 80° + 10° -

Crankshaft position 5 mm hexagon 1 5 ± 1.0 Nm

sensor wrench
Drive plate T55 8 45 ± 5.0 Nm Non-reusable
45° ± 5°
Crankshaft rear seal 10 mm 7 10 ± 1.0 Nm -

Bed plate E10 10 25 ± 5.0 Nm

Non-reusable
Main journal 12 point socket 10 55 ± 5.0 Nm
13 mm 100° ± 5°
Starting motor 14 mm 2 45 ± 5.0 Nm

Oil filter Oil filter installation/ - 12 to 16 Nm

removal cup -

Cylinder block coolant 19 mm 1 30 Nm

screw plug
Flywheel T55 8 45 ± 5.0 Nm Non-reusable
90° ± 5°

GETtheMANUALS.org
 1118-01 02-7

3. PRECAUTIONS
1) When Lifting the Vehicle
- Pay close attention to the safety precautions when lifting the vehicle on a jack lift as the vehicle might
slip off the jack lift.
- When working with a 4-column vehicle lift, use the center of the vehicle as a support point and chock
the wheels to prevent the vehicle from rolling.
- When work with a 2-column vehicle lift, use the jack point as a support point.
- Take care not to spill the battery electrolyte and wear protective clothing when handling the battery.

2) When Working on the Exhaust System

- Wear protective gloves when removing the exhaust pipe.
- Make sure that the exhaust pipe has sufficiently cooled down before working on the exhaust pipe,
because the temperature of the exhaust pipe is very hot right after the engine has been stopped.

3) When Working on the Fuel System

- Disconnect the negative battery terminal and prepare the service plug grip before working on the fuel
system.
- Do not smoke and avoid flames nearby when working on the fuel system.
- Keep gasoline away from the parts made of rubber or leather.
- Be sure to avoid sputtering of the fuel when removing the pipe between the high-pressure side fuel
pump and the fuel injector.
- Never remove any part of the fuel system before releasing the pressure in the fuel system.
- Even after the fuel pressure has been released, wrap a cloth or equivalent around the mountings to
reduce the potential risk of fuel sputtering to a worker or engine compartment.
- Let the engine is cooled down sufficiently before proceeding to the next procedure since the fuel
pressure on the high-pressure side will not drop until the engine is cooled down.

4) When Working on the Cooling System

- Do not remove the radiator reservoir cap while the engine or radiator is hot since high-pressure hot
coolant or steam may cause severe burn.

GETtheMANUALS.org
02-8

5) When Working on the Lubrication System

- Repeated contact with the engine oil for an extended period of time may cause skin irritation.
- Take special care when changing the engine oil to minimize possible skin contact with the used
engine oil because hazardous materials that may cause skin cancer are contained in the used engine
oil.
- Always wear the oil-resistant protective clothing and gloves when handling the engine oil, and
completely remove the used engine oil from the skin with a lot of water or waterless hand cleaner.
Never use gasoline, dilute solution or solvent to wash your skin.
- Discard the used oil and used oil filter only in the designated area to protect environment.

6) When Tightening Bolts

Angle tighten the components of engine in a so-called final tightening operation. The tightening procedure
is as follows:

① Clean the contact surface and threads before tightening bolts and nuts.
② When angle tightening without a torque wrench tighten the bolt to the specified angle, marking
its position. (paint mark to assist the work)

The location and left/right position of components are based on the direction when viewed from the
rear side.
The cylinder block is made of aluminum and can be deformed and broken easily when excessive
force is applied. Therefore, always observe the specified torque when tightening the cylinder block
to prevent its thread from being damaged.
Do not over-tighten a self tapping screw bolt as it creates threads itself.
Never reuse the used bolt if it is a angle-tightened one.
(However, a bolt with specified reuse number with the specified torque is reusable.)

GETtheMANUALS.org
 1118-01 02-9

1. APPEARANCE
▶ Front view

Oil pressure control valve

Oil dipstick gauge

Oil filter

Alternator

Water pump pulley

Auto tensioner

A/C compressor pulley

Crankshaft pulley

▶ Rear view

Cam position sensor

LH hanger bracket

Coolant temperature sensor

Electronic throttle body

VIS solenoid valve

VIS actuator

Cylinder head coolant outlet port

Coolant Return pipe(M/T) /

TOC supply pipe(A/T)

Drive plate

GETtheMANUALS.org
02-10

▶ Left view

RH hanger bracket

Water pump

Exhaust manifold

Thermostat housing

Cylinder block outlet port

Front oxygen sensor

Oil pressure switch

A/C compressor

▶ Right view

PCV

PCSV

T-MAP sensor

Intake manifold

Alternator

Oil pan

Oil drain plug

GETtheMANUALS.org
 1890-01 03-3

1. SPECIFICATIONS
Category Specifications
Fuel Gasoline
Fuel tank Capacity 47 L
Material Plastic
Fuel filter Type Micro paper type
Location Built in the fuel pump
Service interval Inspect every 30000 km (if using poor quality of
fuel, replace every 50000 km)
Low pressure fuel Type Built in the tank, electric
pump
Drive Electric motor
Fuel pressure 3.8 bar (110 L/H)
Current consumption 6.5 A (12 V, 3.8 bar)
Fuel pressure Type Built in the fuel pump
regulator
Fuel pressure 3.8 ± 0.05 bar
Remaining pressure in 30 2.1 bar or higher
minutes after key OFF:
Injector Injection holes 4 holes
Component resistance 12 Ω ± 5%
Rated operating mass flow 2.60 g/sec
Injector type Deka 7

GETtheMANUALS.org
03-4

1. OVERVIEW
The fuel system consists of fuel tank, fuel pipe line, fuel filter, fuel pump, fuel pressure regulator,
injectors, fuel rail. The fuel system is a returnless control type system in which the fuel pressure regulator
is built in the fuel pump. This system is controlled by the engine ECU and each injector of the system
injects the fuel. The system also has a fuel evaporative control system which forces or blocks the vapor
gas stored in the canister to the combustion chamber using the operation of purge control solenoid valve
based on the engine load condition.

2. COMPONENTS

GETtheMANUALS.org
 1890-01 03-5

3. OPERATING PROCESS
The ECU determines fuel injection volume and injection timing based on the engine condition and
optimizes the engine operating conditions to reduce the emissions.

GETtheMANUALS.org
03-6

▶ Basic mapping
- Stepped control
The ECU calculates proper injection volume and timing by considering various parameters to
achieve the optimal combustion at each stage of operation.
- Starting injection volume control
The fuel injection volume during initial starting is calculated by considering the temperature and
engine cranking speed. The starting injection means the injection during the period from when the
ignition switch is turned ON until when the engine rpm reaches to the allowable minimum speed.
Driving mode control
- The fuel injection volume during normal driving is calculated based on the accelerator pedal travel
and engine rpm and the drive map is used to match the drivers inputs with optimal engine power.

GETtheMANUALS.org
 1890-01 03-7

4. SYSTEM DIAGRAM

GETtheMANUALS.org
03-8

5. FUEL EVAP CONTROL SYSTEM

The fuel evaporative control system stores the evaporative gas in the canister to prevent the evaporated
fuel being released into the atmosphere. This system Diagnosiss the internal system and checks for
abnormalities in the system by using the pressure sensor and canister shut-off valve installed to the fuel
tank. The purge control solenoid valve (PCSV) is operated by the engine ECU control according to the
engine load condition. The fuel evaporative gas, stored in the canister, is drawn into the engine due to
vacuum condition (negative pressure) of the engine when the PCSV is open while the fuel evaporative
gas in the fuel system is sucked and stored in the canister when the PCSV is closed.

GETtheMANUALS.org
 1444-01 04-3

1. SPECIFICATIONS
Category Specifications
Spark plug Internal resistance 3 ~ 7 kΩ
Center electrode NGK : SILZKR7B11, HEX16 M12x1.25, Iridium
Ground electrode Platinum alloy
Electrode clearance 1.1 mm
Change interval At every 100,000 km of driving
Ignition coil Primary operating current 7 ± 0.5 A
Generated voltage
Max 400 V / 5 to 20 kV
(primary/secondary)
Ignition type Independent ignition type
Ignition sequence 1-3-4-2

GETtheMANUALS.org
04-4

1. OVERVIEW
The ignition system is to supply high voltage generated from the ignition coils to the spark plugs. The
G16DF engine is equipped with the independent direct ignition system in which each cylinder has its
own ignition coil and spark plug.

2. COMPONENTS
T-MAP sensor

Knock sensor

Spark plug (4 off) Ignition coil (4 off)

GETtheMANUALS.org
 1444-01 04-5

Camshaft position sensor (2 off)

ECU

Coolant temperature sensor

Crankshaft position sensor Accelerator pedal sensor

GETtheMANUALS.org
04-6

3. OPERATING PROCESS
The default ignition timing for each cylinder is determined based on the signals from the camshaft position
sensor and crankshaft position sensor. The engine control unit (ECU) controls the ignition timing more
precisely by using the following information:
- Engine load
- Coolant temperature
- Intake air temperature
- Engine rpm
- Camshaft position sensor signal
- Crankshaft position sensor signal
If the engine ECU does not receive the signal from the crankshaft position sensor, the ignition coil and
fuel system will not work.

GETtheMANUALS.org
 1444-01 04-7

4. WIRING DIAGRAM

GETtheMANUALS.org
 1742-01 05-3

1. SPECIFICATIONS
Category Specifications Remarks
Intake system Variable control system
Filter type Dry, filter element

Air cleaner Filtering area 0.3 m²

element Clean every 15000 km, change every
Service interval 30000 km (But, shorten the service interval -
under severe conditions)
Weight 1.5 kg
Air cleaner
assembly Operating temperature -30 to 100°C
Capacity 9L

* Service more frequently under severe conditions, such as driving on a dusty road or off-road.

GETtheMANUALS.org
05-4

1. OVERVIEW
The intake system filters the air and supplies this to the engine. This system assures the engine
performance and the lifetime of the engine. The intake system is equipped with electronic throttle body.
The flap of the electronic throttle body is operated by the electric signals to improve the engine
performance. The system is also equipped with variable induction system (VIS) which improves engine
power across the whole driving conditions by controlling the inlet passage based on the engine rpm and
engine load.

2. COMPONENTS
Intake manifold assembly

PCSV

T-MAP sensor

T-MAP sensor Electronic throttle body

GETtheMANUALS.org
 1742-01 05-5

Air cleaner assembly & Snorkel Air cleaner element

Water protector

VIS solenoid valve VIS actuator

GETtheMANUALS.org
05-6

3. INPUT/OUTPUT DIAGRAM

System diagram

GETtheMANUALS.org
 1742-01 05-7

▶ Operating process

Low/High speed range (short runner) Moderate speed range (long runner)
Flap open/VIS solenoid valve OFF Flap closed/VIS solenoid valve ON

Runner length: 330 mm Runner length: 610 mm

Negative pressure in Air flow forced Negative pressure in vacuum

vacuum chamber(-80 kPa) to plenum chamber supplied

Solenoid
valve OFF Solenoid valve ON

VIS valve closed

VIS valve open

Actuator not activated with no Actuator driven by

negative pressure supplied negative pressure

Rod moves in the Lever arm position

direction of arrow with valve open
VIS when negative
Short runner
actuator pressure is supplied
(open/ (VIS open)
to actuator
closed)
Lever arm position with Long runner
valve closed Locus of travel of lever arm (VIS closed)

GETtheMANUALS.org
 1747-01 06-3

1. SPECIFICATIONS
Category Specifications Remarks
Exhaust manifold type Integrated with MCC (4-2-1 type)
Catalyst MCC+UCC -

Exhaust muffler Front exhaust pipe + Center muffler + Rear muffler

Ultra low emission vehicle in compliance with enhanced emissions standards

KULEV is an emission control regulation.

- Regulated emissions are carbon monoxide (CO), hydrocarbon (HC) and nitrogen oxides (NOx) at
higher level compared with the previous regulation (KLEV).

Regulation limit (g/km) - based on manufactured

Application vehicle
Item
time point
HC CO NOx
KULEV 2006 0.034 1.31 0.044

2. PRECAUTIONS
- Do not park the vehicle on flammable materials, such as grass, leaves and carpet.
- Do not touch the catalyst or the exhaust gas ignition system when the engine is running.
- If a misfire occurs in the combustion chamber or the emissions of pollutant exceeds the specified
level, the catalyst can be damaged.
- When servicing or replacing components of the exhaust system, make sure that the components
have certain spaces from all other parts of the under body.
- Be careful not to damage the exhaust system when lifting the vehicle from its side.
- All components and body parts of the engine exhaust system should be inspected for cracks,
damage, air hole, part loss and incorrect mounting locations. Also check for any deformation which
can result in exhaust gas drawn into the vehicle.
- Make sure that the exhaust pipe has been cooled down sufficiently before working because it is very
hot right after the engine has been stopped.
- Wear protective gloves when removing the exhaust pipe.

GETtheMANUALS.org
06-4

1. OVERVIEW
This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants
and noise during that arise during combustion.
Harmful materials produced in the combustion process are treated and reduced in the exhaust system to
reduce emission levels.

2. COMPONENTS
Exhaust manifold
(integrated with MCC)

Front exhaust pipe

UCC

Center muffler

Rear muffler

GETtheMANUALS.org
 1747-01 06-5

3. SYSTEM DIAGRAM

▶ Hazardous emissions

a. In relation to stoichiometric air-fuel-ratio

Category Lean Slightly lean Rich

Increased HC Increased NOx Increased CO, HC
Emissions
Reduced CO, NOx Reduced CO, HC Reduced NOx

b. In relation to engine temperature

Category Low temperature High temperature

Increased CO, HC Increased NOx
Emissions
Reduced NOx Reduced CO, HC

c. In relation to driving conditions

Category Idling Accelerating Decelerating

Increased CO, HC,
Increased CO, HC Increased CO, HC
Emissions NOx
Reduced NOx - Reduced NOx

GETtheMANUALS.org
 1538-01 07-3

1. SPECIFICATIONS
Category Specifications Remarks
Oil pump Lubrication Gear pump, forced circulation
Type Vane type + Solenoid valve (VOP)
Number of sprocket teeth 33

Pressure valve opening 7.0 ± 1 bar

pressure
VOP pressure 2.0 bar (SOL. ON)
(at about 140°C)
4.0 bar (SOL. OFF)
Oil filter Type Water and thermostat housing +
module Oil filter module
Oil flow rate About 40 L/min (80°C)
Bypass valve opening 1.0 ± 0.2 bar
-
pressure
Non-return valve opening 0.2 ± 0.04 bar
pressure
Filter service interval - When changing engine oil
- After 15,000 km of driving
(After initial check 7,500 km of driving)
- 12 months after previous replacement

Engine oil Specifications - Ssangyong genuine engine oil

(ZIC SYMC 5W-30, ZIC SYMC FE 5W-20)
- Approved by MB 229.51 5W30,
MB 229.52 5W30, API SN / ILSAC GF-5
5W20
Capacity 4.0 ℓ (4.5 ℓ at initial fill)
Service interval After initial 10,000 km of driving → At every
15,000 km of driving or 12 months

GETtheMANUALS.org
07-4

1. OVERVIEW
The lubrication system supplies oil to various parts of the engine that require lubrication to reduce friction,
wear, heat on the surfaces in contact with each other. When the engine is running, frictional heat is
generated by moving parts. If this heat builds up, the bearing can be stuck. The lubrication system
creates an oil film on each contact surface of the two moving parts to convert solid friction to liquid friction
in order to reduce wear and prevent the temperature from increasing. The lubrication system is equipped
with a variable oil pump (VOP) which improves the fuel economy in low/moderate speed range and
ensures the reliability in high speed range.

2. COMPONENTS
Oil pressure switch Oil dipstick gauge Oil filter module

Baffle plate

Oil pan Oil pump VOP solenoid valve

VOP solenoid valve

GETtheMANUALS.org
 1538-01 07-5

3. SYSTEM DIAGRAM

Before filtering
After filtering
Cam bearing
CVVT (Intake)

CVVT (Exhaust)

Oil filter

Chain
tensioner

Main bearing
Oil return

GETtheMANUALS.org
07-6

▶ CVVT and camshaft oil passages

Front view Rear view

OCV (Intake)
OCV (Intake)

OCV (Exhaust) OCV (Exhaust)

Refer to "ENGINE CONTROL" section in "G16DF ENGINE" chapter for detailed operation process
of the CVVT.

GETtheMANUALS.org
 1528-01 08-3

1. SPECIFICATIONS
Category Specifications Remarks
Cooler Type Forced circulation / water-cooled
Radiator Coolant flow type Cross flow
Core size (mm) A/T: 610W x 477.4H x 20T
Electric fan Type Electric
Capacity A/T 350 W
Control type Resistor type (low/high)
Coolant reservoir Capacity 2.6 L
tank -
Cap type / pressure Screw type / 1.4bar
Thermostat Type Wax pellet type
Opening temperature 90 ± 2°C
Fully open temperature 100°C
Coolant Anti-freeze SYC1025 (LCC)
Mixing ratio
50:50
(water:antifreeze)
Coolant capacity Approx. 6.5 L

GETtheMANUALS.org
08-4

2. PRECAUTIONS

- If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity
can be decreased resulting in poor circulation in the cooling system which leads to overheated
engine.
- Use of non-recommended coolant could form scales in the cooling system because of chemical
reaction. This restricts the flow in the cooling system and causes overheating and seizure of the
engine.
- Hot coolant or steam can spray out with great force when the coolant reservoir tank cap is opened
while the engine is running or hot, causing serious burns.
- To open the coolant reservoir cap, wrap the cap with a wet towel or thick cloth after the engine has
been cooled down sufficiently.
- If cold water is added while the engine is overheated, the engine or radiator can be
deformed.
- Anti-freeze can damage the painted surface. Avoid contact with the painted surface.
- Anti-freeze and water should be mixed in proper mixture ratio. Never add only water when the
coolant runs low.
- If the anti-freeze concentration is too low, there is a danger of freeze-up. If the anti-freeze
concentration is too high, it will reduce the cooling capacity of the system, resulting in overheating of
the engine.

GETtheMANUALS.org
 1528-01 08-5

1. OVERVIEW
The cooling system of the engine dissipates the heat generated by the running engine. The coolant is
forced to circulate by the water pump and cooled down in the radiator by heat exchange between the
coolant and the fresh air taken in through the fan. Properly cooled down coolant in the radiator flows into
the engine to maintain the optimized engine operating temperature. For a vehicle with A/T, the coolant
also flows into the transmission oil cooler (TOC) of the A/T through the heater core and absorbs the heat
enough to maintain the best operating temperature. The electric fan is equipped with a resistor. The
engine ECU controls the 2 electric fan relays which determine the speed of the fan (high speed and low
speed). It also controls the A/C compressor and electric fan according to the operation of A/C.

2. COMPONENTS

Radiator deaeration hose

Coolant reservoir tank

Radiator inlet hose

Radiator Cooling fan

Resistor
Engine deaeration hose

Make-up hose

Air guide

Radiator outlet hose

TOC coolant return hose

Air guide TOC coolant supply hose

GETtheMANUALS.org
08-6

Water pump Thermostat Cylinder head

outlet port

Coolant temperature sensor

For a vehicle with M/T For a vehicle with A/T

Coolant return pipe

TOC

Cylinder block TOC coolant TOC coolant

outlet port return pipe supply pipe

GETtheMANUALS.org
 1528-01 08-7

3. OPERATING PROCESS
1) System Diagram
▶ For a vehicle with M/T

GETtheMANUALS.org
08-8

▶ For a vehicle with A/T

GETtheMANUALS.org
 1528-01 08-9

▶ Flow in cooling system

To cylinder block To oil filter module

Water pump supply

Bypass line

Oil filter supply

Oil inlet

- Oil filter supply: Cylinder block to oil filter, Before filtering

- Oil inlet: Oil filter to cylinder block, After filtering

GETtheMANUALS.org
 1452-01 09-3

1. SPECIFICATIONS
Category Specifications Remarks
Battery Capacity(ISG) 60 Ah(70 Ah)
Type(ISG) Maintenance free(AGM)
Size 241 * 174 * 188
-
Weight 15.5 Kg
Cold cranking ampere 550 A
Reserve capacity 92 min
Alternator Rated capacity 14V - 120A

GETtheMANUALS.org
09-4

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

2. COMPONENTS
Alternator Charge warning lamp on Battery ground cable
instrument cluster

Battery positive cable Battery

GETtheMANUALS.org
 1452-01 09-5

3. OPERATING PROCESS
1) For a vehicle with smart key

GETtheMANUALS.org
09-6

2) For a vehicle with REKES key

GETtheMANUALS.org
GETtheMANUALS.org
09-8

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 1452-01 09-9

GETtheMANUALS.org
 1462-01 10-3

1. SPECIFICATIONS
Item Category Specifications
Starter motor Rated voltage(ISG) 12 V 0.9 kw(12 V 1.4 kw)

GETtheMANUALS.org
10-4

1. OVERVIEW
The engine cannot start by itself. It needs starter motor which operates the crankshaft using external force.
The starter (starter motor) starts the engine with rotational power by converting the electric energy to the
mechanical energy.
When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the
pinion gear clutch overruns to protect the pinion gear.

2. COMPONENTS
Battery positive cable Starter motor ECU
(starter motor power
cable)

Battery Start relay

GETtheMANUALS.org
 1462-01 10-5

3. OPERATING PROCESS
1) For a Vehicle with Smart Key
When the START/STOP button is pressed with the brake pedal applied and gear selector lever in P or N
position, the SKM performs the immobilizer verification. If it is valid, SKM sends the engine START
request signal to the ECU through the P-CAN and vehicle power status signal to the BCM through the B-
CAN. After the START signal from the SKM has been received, the ECU controls the start relay to drive
the starter motor.
The SKM cuts the power for IGN2 and ACC relays while the engine is cranking because cutting the
unnecessary electric load is required.

GETtheMANUALS.org
10-6

2) For a Vehicle with Ignition Key

When the ignition key is turned to ST position with the brake pedal (for a vehicle A/T) or clutch pedal (for
a vehicle M/T) applied and gear selector lever in P or N position, the TCU sends the engine START
signal to the ECU through the hard wire. The ECU controls the start relay to drive the starter motor.

GETtheMANUALS.org
GETtheMANUALS.org
10-8

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 1462-01 10-9

GETtheMANUALS.org
 8530-10 11-3

1. SPECIFICATIONS
Category Specifications
Rated voltage DC 5 V
Operating temperature -30°C to +80°C
Cruise control
SET+/RES - Up/Down self return type
switch
Switch type ON/OFF
Push self return type
CANC

GETtheMANUALS.org
11-4

2. TRAFFIC CONDITIONS
Use the cruise control system when the vehicle is driven on a motorway or highway with light traffic where
the driving status is not expected to change suddenly by pedestrians and traffic lights.

To prevent unexpected accidents due to uncontrollable situations, only use this function when
driving on motorways and highways with light traffic. Never use this function when driving under the
following conditions:
- Hard wind or crosswind
- Heavy traffic
- Slippery roads or hills

3. PRECAUTIONS

- Take into consideration road safety while when driving at a constant speed using a cruise control
system. Always be prepare to depress the brake and accelerator pedals according to the situations.
The vehicle speed may vary and different from the set speed when driving up and down a hill. Avoid
- using cruise control function when driving on hilly roads as much as possible. To ensure safe driving
and protect the vehicle, use the engine brake and foot brake properly when driving on hilly roads.
Always allow for extra distance between your vehicle and the vehicle ahead. Depress the brake
pedal, if needed.
-

GETtheMANUALS.org
 8530-10 11-5

1. OVERVIEW
The cruise control is an automatic speed control system that maintains a desired driving speed without
using the accelerator pedal. The operating switch assembly is located on the right side of the steering
wheel. The switch assembly consists of the buttons for speed up & set (SET +), speed down & return to
set speed (RES -), cruise ON/OFF, stop (CANC) modes.
Pressing the auto cruise ON switch activates the auto cruise ready mode. Press the auto cruise SET +
button to set the current vehicle speed as the target speed. To change the target speed, press the
+(ACCEL) or -(DECEL) button.

2. COMPONENTS
Indicators and display
regarding cruise control

Cruise control switch

ECU assembly

GETtheMANUALS.org
11-6

3. OPERATING PROCESS
1) Input/Output Elements
The engine ECU detects the cruise control switch position and monitors the brake operating conditions,
clutch conditions, and vehicle speeds, etc. The engine ECU maintains the set vehicle speed, increases,
or decreases the vehicle speed according to the signals from the cruise control switch, unless a fault is
detected during cruise control driving.

GETtheMANUALS.org
 8530-10 11-7

2) Display and Indicators

Instrument cluster display (with supervision)
Auto cruise ready Auto cruise set Auto cruise deactivated

Displayed when auto cruise is Displayed when auto cruise is Displayed when auto cruise is
ready activated turned off from READY or ON
state

Auto cruise READY indicator Auto cruise ON indicator

Comes on when cruise control is Comes on when auto cruise is

turned ON by cruise control activated
ON/OFF switch

GETtheMANUALS.org
11-8

4. HOW IT WORKS
1) How To Set Speed (Cruise Control ON)

Cruise control switch

1. Drive the vehicle at speed between 40 and 140 km/h (cruise control operating speed) by depressing
the accelerator pedal to activate the cruise control system.

2. Auto cruise set

a. Pressing the ON switch illuminates the auto cruise READY indicator on the instrument cluster
and puts the auto cruise system into READY mode.
b. To maintain current vehicle speed, press the SET switch. This turns off the auto cruise READY
indicator and turns on the auto cruise ON indicator on the instrument cluster.
c. After that, the vehicle is driven at the set speed (speed set when activating the cruise control
system) without accelerator pedal depressed.
3. Pressing the +/- button after the step "b" increases/decreases the set speed.

Operating the cruise control switch is carried out while the vehicle is driven. Therefore, make sure
that you fully understand and are familiar with the system before using the cruise control system.
Failure to do so may lead to fatal accidents.

GETtheMANUALS.org
 8530-10 11-9

2) Increasing Speed (ACCEL)

1. To increase the target speed, press the switch to +(ACCEL) until the desired speed is set with the
cruise control in READY mode.
2. To increase the speed in 1 Km/h increments, press the +(ACCEL) switch for less than 0.5 sec.

3) Decreasing Speed (DECEL)

1. To decrease the target speed, press the switch to -(DECEL) until the desired speed is set with the
cruise control in READY mode. If the vehicle speed is below 38 km/h, the cruise control function will be
deactivated.
2. To decrease the speed in 1 Km/h increments, press the -(DECEL) switch for less than 0.5 sec.

GETtheMANUALS.org
11-10

4) Restoring Set Speed (RESUME)

When the CANC (CANCEL) switch is pressed accidentally or the cruise control system is deactivated,
pressing the switch to RES- direction will restore the cruise control system to the speed before
deactivation. The speed should be 40 km/h and the brake or accelerator pedal should not be depressed.
(Deactivation by cruise control OFF switch will not restore the previous set speed)

To deactivate cruise control

- Depress the brake pedal or activate ESP.
- Drive the vehicle at less than 38 km/h.
- Apply the parking brake while the vehicle is driven.
- Depress the clutch pedal to change the gear.

GETtheMANUALS.org
 8530-10 11-11

5) To Cancel (CANCEL)

To cancel the cruise control operation, press the CANC (CANCEL) switch. If this is the case, the engine
ECU will remember the speed before cancellation. Pressing RES (RESUME) switch restores the cruise
control function to the previous speed.

6) How To Deactivate (Cruise Control OFF)

Pressing the OFF switch while the cruise control system is activated will deactivate the function. In this
case, the engine ECU will not remember the speed before deactivation. You need to set the speed again
when the cruise control system is activated later.

GETtheMANUALS.org
 1490-01 12-3

1. ENGINE ECU SPECIFICATIONS

Items GSL Remarks
Engine G16DF -
Injector Solenoid injector (DEKA7) -
Ignition coil 1 by 1 -
Emission compliance OBD -
ECU terminals Connector A: 50-pin -
Connector B: 94-pin -
CPU 32-bit SPC563 single chip -
Flash Memory Internal 1.5 MB -
Electronic throttle body Yes H-Bridge
CVVT (Intake) Yes PWM
CVVT (Exhaust) Yes PWM
MAP sensor (T-MAP) Yes -
Intake air temperature sensor (T-MAP) Yes NTC
Coolant temperature sensor Yes NTC
Cam position sensor Yes Camshaft - 4-tooth type
Crank position sensor Yes Trigger ring 60-2
Knock sensor Yes 2-pin
Oxygen sensor Yes Front/rear oxygen sensor

Fuel pump Yes -

Trip computer (CAN) Yes -
Fuel tank shut-off valve Yes OBD
Fuel tank pressure sensor Yes OBD
Purge control solenoid valve (PCSV) Yes -
Accelerator pedal sensor Yes 6-pin (Potentiometer
No. 1, No. 2)
Switchable engine mounting control No. -

GETtheMANUALS.org
12-4

Items GSL Remarks

Immobilizer (SKM) Yes CAN
Start control Yes HSD and LSD for ISG
Malfunction indicator lamp (MIL) Yes CAN
Idle stop & go (ISG) Yes EU
Cruise control ACC/SET Yes -
DEC/RES Yes
CANCEL Yes
ON/OFF Yes
Alternator control (EEM) Yes EU
On board diagnostic (OBD) Yes -
CAN diagnosis Yes UDS
Neutral switch / Clutch switch Yes A vehicle with M/T
Vehicle speed Yes ABS & ESP
Cooling fan Yes Resistor type
Variant coding Yes -
Refrigerant pressure sensor Yes -
Blower switch input Yes -
A/C compressor control Yes Relay control

GETtheMANUALS.org
 1490-01 12-5

2. ENGINE SENSOR DATA LIST

Data Unit Value
Engine coolant temperature °C 0.436 V (at 130°C) to 4.896 V
(at -40°C)
Intake air temperature °C -40 to 120°C
(varies with ambient
temperature and engine mode)
Engine rpm rpm At idling: 700±50 (P/N)
Intake air flow mg/stk At idling:
approx. 130.0 mg/stk
Intake manifold pressure bar At idling: approx. 0.44 bar
Intake manifold voltage V At idling: approx. 1.86 V
Engine torque Nm At idling: approx. 36.0 Nm
Injection time of injector ms At idling: approx. 3.1 ms
Battery voltage V 13.5 to 14.1 V
Throttle position sensor 1 voltage V At idling: approx. 0.6 V
Throttle position sensor 2 voltage V At idling: approx. 4.4 V
Front oxygen sensor voltage mV 0 to 800 mV
Intake/Exhaust CVVT duty % At idling: approx. 70%
VIS operation Short runner/ At idling: Short runner
Long runner
ignition time °CRK At idling: 1.8 to 3.0°CRK
Knock control level V At idling: 0.37 to 0.58 V
Fuel tank level % 0 to 100%
VOP operation Operating/not operating -
Brake switch Operating/not operating -
Clutch switch Operating/not operating -
A/C compressor Operating/not operating -
Fuel pump relay Operating/not operating -
Cooling fan relay Low/High speed -

GETtheMANUALS.org
12-6

3. CODING ITEMS FOR ELECTRICAL UNITS REPLACEMENT

▶ Vehicles with SKM

Category EMS registration Variant coding Smart key &

Transponder coding
carried out under SKM
When replacing ECU - -
menu
carried out under
When replacing BCM - -
BCM menu
When replacing smart key carried out under SKM
- -
menu
carried out under SKM carried out under SKM
When replacing SKM -
menu menu

▶ Vehicles with REKES key

EMS registration REKES key Transponder

Category Variant coding
coding coding
carried out under
When replacing - - -
BCM menu
ECU

carried out under carried out under

When replacing - -
BCM menu BCM menu
REKES key

carried out under carried out under carried out under carried out under
When replacing
BCM menu BCM menu BCM menu BCM menu
BCM

4. ECU SELF-DIAGNOSIS ITEMS

Catalytic monitoring system Engine cooling system monitoring
Misfire monitoring system Low-emissions at cold start mechanism monitoring
Evaporative system monitoring CVVT monitoring
Fuel system monitoring Other components monitoring
Oxygen sensor monitoring

GETtheMANUALS.org
 1490-01 12-7

1. OVERVIEW
The ECU receives signals from various sensors. Then, it analyzes and modifies them to allowable
voltage level to control various actuators. The ECU can control the engine power and exhaust gas
precisely because the micro processor in the ECU calculates the injection duration, injection timing, and
injection volume based on the engine piston speed and crankshaft angle using input data and a stored
map. The output signal from the ECU microprocessor drives the solenoid valve of the injector to control
the fuel injection volume and injection timing and control the ignition timing of the ignition coil so as to
control various actuators in response to the changes in the engine condition. In addition, many auxiliary
functions are added to the ECU in order to reduce emissions, improve fuel economy and ensure safety,
riding comfort and convenience. Some examples of such functions include cruise control (auto cruise)
and immobilizer. The ECU uses the CAN communication system to facilitate data exchange with other
electric systems such as A/T, braking device, and steering system. When servicing a vehicle, a
diagnostic equipment can be used to check the vehicle conditions and perform diagnosis. The normal
operating temperature for ECU ranges from -40 to +85°C. The ECU must be protected from oil,
moisture, electromagnetic interference, and external mechanical impact.

GETtheMANUALS.org
12-8

2. MAJOR COMPONENTS
1) ECU Input Components
Rear oxygen Coolant Camshaft position Crankshaft
sensor temperature sensor position sensor
sensor

Front oxygen Electronic

sensor throttle body
ECU

Knock sensor T-MAP sensor

Refrigerant pressure sensor CAN communication

Fuel tank pressure sensor
Oil pressure switch
Auto cruise switch
Fuel Gauge(OBD Control)
Clutch pedal signal
Blower switch signal
Brake pedal signal
Vehicle Speed

GETtheMANUALS.org
 1490-01 12-9

2) ECU Output Components

Oil control valve Start relay A/C compressor Injector
(OCV)

VIS solenoid Ignition coil

valve
ECU

Purge control Electric fan

Solenoid valve

Electronic Canister shut-off valve CAN communication

Throttle body Engine main relay
Fuel pump

GETtheMANUALS.org
12-10

3) Engine ECU Inputs/Outputs (Control Items)

GETtheMANUALS.org
 1490-01 12-11

3. CAN COMMUNICATION CONFIGURATION

The CAN topology communicate with system units. There are 2 types of CAN communication according
to the communication speed: P-CAN and B-CAN. Communication speed of the former is faster than that
of the latter.
The SKM, instrument cluster, BCM, and diagnostic connectors use both CAN communications to
communicate with other units. Other components such as ECU, ABS with ESP, TCU, EPS, FCM unit
use only P-CAN. Terminating resistors are installed in ECU and instrument cluster.

GETtheMANUALS.org
12-12

4. CAN INPUT/OUTPUT ELEMENTS

▶ ABS with ESP

▶ BCM

▶ A/C control module

GETtheMANUALS.org
 1490-01 12-13

▶ SKM

▶ Instrument cluster

GETtheMANUALS.org
12-14

▶ TCU

▶ Diagnostic equipment

▶ TPMS & EPS

GETtheMANUALS.org
 1490-01 12-15

5. FUEL INJECTION VOLUME CONTROL

The ECU determines fuel injection volume and injection timing based on the engine condition and
optimizes the engine operating conditions to reduce the emissions.

GETtheMANUALS.org
12-16

▶ Basic mapping
- Stepped control
The ECU calculates proper injection volume and timing by considering various parameters to
achieve the optimal combustion at each stage of operation.
- Starting injection volume control
The fuel injection volume during initial starting is calculated by considering the temperature and
engine cranking speed. The starting injection means the injection during the period from when the
ignition switch is turned ON until when the engine rpm reaches to the allowable minimum speed.
Driving mode control
- The fuel injection volume during normal driving is calculated based on the accelerator pedal travel
and engine rpm and the drive map is used to match the drivers inputs with optimal engine power.

GETtheMANUALS.org
 1490-01 12-17

6. IGNITION TIMING CONTROL

The default ignition timing for each cylinder is determined based on the signals from the camshaft
position sensor and crankshaft position sensor. The engine control unit (ECU) controls the ignition timing
more precisely by using the following information:
- Engine load
- Coolant temperature
- Intake air temperature
- Engine rpm
- Camshaft position sensor signal
- Crankshaft position sensor signal
If the engine ECU does not receive the signal from the crankshaft position sensor, the ignition coil and
fuel system will not work.

▶ Features
a. Warm-up of catalytic converter
The exhaust gas temperature needs to be increased for catalytic converter to reach the normal
operating temperature rapidly. To achieve this, the ignition timing is retarded for a certain period of time
based on the corresponding conditions.

b. Idle speed control

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

c. Fuel cut-off when decelerating

The ignition timing control is retarded temporarily to prevent a rapid rise in torque when the combustion
is restarted.

d. Intake air temperature and coolant temperature correction control

The ignition timing is retarded to prevent engine knocking if the intake air temperature and coolant
temperature are high.
The ignition timing is retarded in the following cases.
The ignition timing retard values due to high intake air temperature and high coolant temperature are
added up for correction.

e. Electronic stability program (ESP) control mode

The ignition timing is retarded to reduce the engine torque as soon as possible in ESP control mode.

f. Knock control
If knocking occurs in a cylinder, the ignition timing of the corresponding cylinder will be retarded.

GETtheMANUALS.org
12-18

▶ Input/output diagram

GETtheMANUALS.org
 1490-01 12-19

7. CATALYTIC CONVERTER WARM-UP CONTROL

When the engine is started, the ignition timing is retarded for a certain period of time determined by the
conditions such as coolant temperature and gear selector lever position (P, N) to make the temperature
of catalytic converter reach the normal operating temperature. Also, at this time the idle speed increases
by a certain amount due to the idle speed control. However, as soon as the gear selector lever is shifted
to the D position, the catalytic converter warm-up control will be inhibited.

The normal operating temperature is critical to the catalytic converter like the oxygen sensor. The
catalytic converter cannot perform its function until its temperature reaches about 250°C.
Therefore, when the cold engine is started, the engine ECU controls the ignition timing and idling
speed so that the catalytic converter can reach its normal operating temperature quickly.

GETtheMANUALS.org
12-20

8. WARM-UP CONTROL
▶ Idle speed control
The idle speed is controlled based on the fuel/air mixture when the engine load is changed, the power
steering wheel is turned to its end, the gear selector lever is in the D position and the A/C compressor is
operating. It is also controlled based on the charge level during the PCV operation.

▶ Ignition timing
The ignition timing can be retarded or advanced to help idle speed control.

▶ A/C compressor operation

The A/C control unit sends the A/C operation signal to the ECU to increase the throttle valve opening
angle in order to prevent a drop in engine speed when the A/C compressor is operating while the engine
is idling.

▶ Low voltage
If low voltage is detected by the ECU, the idle speed increases slightly in driving mode until the ignition
switch is turned off depending on the situation.

GETtheMANUALS.org
 1490-01 12-21

9. ELECTRIC FAN AND A/C COMPRESSOR CONTROL

The engine ECU controls the electric fan to low or high speed by controlling two electric fan relays. The
engine ECU controls the electric fan to improve A/C cooling and engine torque. The ECU operates the
A/C compressor when the A/C switch signal is input from the A/C control module, and deactivates the
A/C compressor when the A/C system is overloaded to protect the system.

GETtheMANUALS.org
12-22

▶ Electric fan control parameters

The cooling fan relay, high-speed relay, and low-speed relay are operated due to the electric fan speed
control. The electric fan is controlled by the serial/parallel circuit control.

Coolant temperature Refrigerant pressure

Items Electric fan Compressor

OFF Lower than 90℃ -

A/C
Low speed 90℃ or higher to -
switch
Lower than 105℃
OFF
High speed 105℃ or higher -
Low speed Lower than 18 bar
Lower than 105℃
A/C High speed 18 bar or higher ON
switch 105℃ or higher to
ON High speed -
Lower than 115℃
High speed 115℃ or higher - OFF (deactivated)

GETtheMANUALS.org
 1490-01 12-23

▶ A/C compressor deactivation conditions

- Refrigerant pressure signal from the A/C refrigerant pressure sensor:

* 2.0 kg/cm² or lower: OFF (2.3 kg/cm² or higher: ON)
* 31 kg/cm² or higher: OFF (26 kg/cm² or lower: ON)
- Coolant temperature: 118˚C or higher: OFF (111˚C or lower: ON)
- After the engine starts: OFF for about 5 seconds
- During rapid acceleration: OFF for 4 seconds
- Engine RPM of 400 rpm or lower: OFF (600 rpm or higher: ON)
- Intake negative pressure of higher than -0.2 kg/cm²: OFF for 4 seconds
- Ambient temperature of 2˚C or lower: OFF (5˚C or higher: ON) - controlled by DATC
- Evaporator temperature of about 0˚C or lower: OFF (about 2˚C or higher: ON) - controlled by
DATC
- When driving forward or stopping on a hill with a gradient of 15% or higher (D or 1st gear
engaged)
- When driving in reverse or stopping on a hill with a gradient of 15% or higher (Reverse gear
engaged)

▶ Output voltage in relation to refrigerant pressure

When the A/C pressure sensor value is between 0 and 32 kg/㎠ with the A/C ON, the output
voltage of the refrigerant pressure sensor ranges from 0.5 to 4.5 V.

▶ Electric fan control in relation to ATF temperature

ATF temperature Electric fan operation Remarks

110˚C or higher High speed -

GETtheMANUALS.org
12-24

10. KNOCK CONTROL

When abnormal combustion occurs in any cylinder, the ignition timing of that cylinder is retarded to
control the knocking phenomenon in various conditions (from idling to full load condition). Anti-knock
control is controlled by the ECU internal program and begins when the coolant temperature
reaches 70˚C. If the knocking persists, the ignition timing will be retarded continuously. The
amount of retard can be vary depending on the engine speed.

▶ Knock control adaptation

The knock control adaptation begins when the coolant temperature reaches 75˚C. The data
necessary to determine the ignition timing, such as correction value and current engine status, are
stored as the knocking is detected consistently.
- During rapid acceleration, the data will not be stored for about 2 seconds to prevent application of
incorrect adaptation.
- If no signal is received from the knock sensor, the ignition timing of all cylinders will be retarded
slightly and knock control and adaptation will be inhibited for safety.

▶ Automatic RON control

Research octane number (RON) refers to an octane value input and is corrected automatically. This
control function is performed by analyzing the stored data such as adaptation, ignition timing of all
cylinders, and number of controls at specific engine load and engine speed. If the control value is out of
the specified range, the RON value will be changed in one step or several steps. The adjusted value will
be maintained until the engine stops.

GETtheMANUALS.org
 1490-01 12-25

GETtheMANUALS.org
12-26

11. MAXIMUM SPEED LIMITATION

The ECU receives the engine speed signal from the crank position sensor and controls the engine
speed by shutting off the injector under the following conditions to protect the engine and the drive train.

▶ Torque converter protection with gear selector lever in P or N position

The engine speed is limited to protect the torque converter from excessive pressure rise in the torque
converter when the gear selector lever is in the P or N position.

▶ Maximum engine speed limitation during driving

The engine speed is limited to prevent damage to the engine due to high engine revolution speed. The
data for the drive mode detection are sent from the ESP unit to the ECU.

▶ Safe fuel cut

If the throttle valve is found to be faulty, the injector will be shut off at a certain rpm or higher and re-
activated at 1200 rpm or lower.

GETtheMANUALS.org
 1490-01 12-27

12. VIS CONTROL

The intake manifold is equipped with variable induction system (VIS) which improves engine power
across the whole driving conditions by controlling the inlet passage based on the engine rpm and engine
load. The ECU turns off the VIS solenoid valve to improve intake air charging efficiency in low and high
speed ranges. At this time, the negative pressure created in the intake manifold is stored in the vacuum
chamber (-80 kPa). The ECU turns on the VIS solenoid valve to improve volumetric efficiency by
maximizing intake inertia effect in moderate speed range. In this case, the vacuum actuator is activated
by the negative pressure in the vacuum chamber of the intake manifold.

GETtheMANUALS.org
12-28

▶ Operating process

Low/High speed range (short runner) Moderate speed range (long runner)
Flap open/VIS solenoid valve OFF Flap closed/VIS solenoid valve ON

Runner length: 330 mm Runner length: 610 mm

Negative pressure in Air flow forced Negative pressure in vacuum

vacuum chamber(-80 kPa) to plenum chamber supplied

Solenoid
valve OFF Solenoid valve ON

VIS valve closed

VIS valve open

Actuator not activated with no Actuator driven by

negative pressure supplied negative pressure

Rod moves in the Lever arm position

direction of arrow with valve open
VIS when negative
Short runner
actuator pressure is supplied
(open/ (VIS open)
to actuator
closed)
Lever arm position with Long runner
valve closed Locus of travel of lever arm (VIS closed)

GETtheMANUALS.org
 1490-01 12-29

13. VOP CONTROL

For the fixed flow type oil pump, as the engine rpm increases, the oil flow increases proportionally. The
excessive flow generated by higher engine rpm raises the pressure in the oil circulation system. And
because of this increased pressure, more engine power is required to operate the oil pump. To overcome
this advantage, a variable oil pump (VOP) which adjusts the amount of oil discharged by the oil pump is
used. VOP is controlled in different speed ranges separately (low/moderate speed range, and high speed
range)
- Low/Moderate speed range (2,500 rpm or lower): Solenoid ON → ON (improve fuel economy)
- High speed range (higher than 2,500 rpm): Solenoid OFF → OFF (ensure reliability of lubrication)

GETtheMANUALS.org
12-30

▶ Operating process

a. When the VOP solenoid valve is ON

If the VOP solenoid valve is activated, then the valve will close the drain passage to the oil pan so that
the pressure can be sent to the 2nd chamber (F2). The discharge pressure of the oil pump will be sent to
the 1st chamber (F1). Therefore, the sum of both pressure (F1+F2) will be applied to the slide connected
to the spring and this force will compress the spring. At this time, the whole slide will move to increase
the gap with the rotor as shown in the right figure. Then the oil pressure will decrease because of the
changed volume ratio.

b. When the VOP solenoid valve is OFF

If no power is supplied to the VOP solenoid valve, the oil from the main gallery will flow into the oil pan
through the VOP solenoid valve. Therefore, the pressure (F2) which compresses the spring will be lost
and the slide will move by the force from the released spring. Then the oil pressure will increase by the
changed volume ratio due to the reduced the gap between the rotor and the slide.

GETtheMANUALS.org
 1490-01 12-31

14. CVVT CONTROL

The continuous variable valve timing (CVVT) system controls the valve timing for optimal combustion.
The oil control valve (OCV) of this system supplies the oil to the advance/retard chamber in the camshaft
sprocket in accordance with the ECU signals based on the engine speed, load, and mapped valve
timing. The camshaft is adjusted continuously in the closed control loop. Typical phase adjustment range
is between 40° to 60° (crank angle). The set angle is stored in the data map of the ECU and the
electric solenoid controls this angle hydraulically by using the engine oil system. The camshaft position
sensor measures the camshaft position and sends this signal to the control unit. The camshaft position
sensor is installed on both the intake and exhaust sides, and controls the valve timing optimally based on
the engine speed and load. This leads to a significant decrease in fuel consumption and emissions,
resulting in substantially enhanced power and torque. Usually, the CVVT operating range is divided into
6 to 7 sections between the maximum advance and maximum retard, and these sections can be
categorized into three status: maximum advance status, hold status, and maximum retard status.

Internal exhaust gas recirculation (EGR)

The valve overlap, in which both the intake valve and exhaust valve are open, occurs around the
exhaust top dead center (TDC). When driving in the partial load, the EGR effect is created by the
return flow of exhaust gas due to this valve overlap.
Internal EGR control
The CVVT system optimizes the changing internal EGR effect by adjusting the amount of valve
overlap based on the engine operating conditions. The amount of EGR gas flow changes
significantly depending on the negative pressure in the intake manifold and the amount of overlap.
Oil temperature detection
For CVVT control, the oil temperature is determined, based on the map value without a separate oil
temperature sensor.

GETtheMANUALS.org
12-32

A. Engine stop/start/idle/under light load B. Under partial load

- Prevents return flow of exhaust gas in - Improves fuel economy by reducing

intake manifold pumping losses
- Stabilizes engine rpm - Reduces NOx emissions using internal EGR
- Improves fuel economy by reducing effect
pumping losses
C. Low speed under heavy load D. High speed under heavy load

Torque increases because of improved volumetric Increases power by improving volumetric

efficiency efficiency with over-boost effect due to intake
inertia

Refer to the graph shown on the previous page which presents those ranges in relation to the
engine load and rpm.

GETtheMANUALS.org
 1490-01 12-33

15. FUEL EVAP CONTROL SYSTEM

The fuel evaporative control system stores the evaporative gas in the canister to prevent the evaporated
fuel being released into the atmosphere. This system Diagnosiss the internal system and checks for
abnormalities in the system by using the pressure sensor and canister shut-off valve installed to the fuel
tank. The purge control solenoid valve (PCSV) is operated by the engine ECU control according to the
engine load condition. The fuel evaporative gas, stored in the canister, is drawn into the engine due to
vacuum condition (negative pressure) of the engine when the PCSV is open while the fuel evaporative
gas in the fuel system is sucked and stored in the canister when the PCSV is closed.

GETtheMANUALS.org
12-34

▶ Major components

The fuel evaporative gas is the fuel which is evaporated in the fuel tank and release into the
atmosphere. Its main component is hydrocarbon (HC).
- Approx. 15 % of the emissions is fuel evaporative gas.
- The gas is stored in the canister temporarily so that it is not released into the atmosphere when the
engine is stopped.
- When the engine starts to run, the evaporative gas in the canister is drawn into the engine for
combustion.

GETtheMANUALS.org
 1490-01 12-35

16. CRUISE CONTROL SYSTEM CONTROL

The engine ECU detects the cruise control switch position and monitors the brake operating conditions,
clutch conditions, and vehicle speeds, etc. The engine ECU maintains the set vehicle speed, increases,
or decreases the vehicle speed according to the signals from the cruise control switch, unless a fault is
detected during cruise control driving.

GETtheMANUALS.org
12-36

17. IMMOBILIZER CONTROL

1) For a Vehicle with Ignition Key
When turning the ignition key to the ON position, the power is supplied to the immobilizer unit and EMS
(ECU). The ECU communicates with the immobilizer unit to verify the key and transponder. If it is valid,
the ECU starts to control the engine or immobilizer indicator (illumination or flashing) when the ignition key
is turned to the START position.
Once the key is verified, valid key verification time is provided for 10 seconds and the engine can be
started by turning the ignition key to the engine START position during this verification time. If the ignition
key is turned to the START position again after the 10 seconds of verification time, the key verification
should be reperformed.

1. When the ignition key is inserted, the immobilizer unit requests the transponder verification through
the antenna.
2. The transponder sends the encrypted message to the immobilizer control unit.
3. The immobilizer unit compares the encrypted message received from the transponder to the
coded value through the logic circuit. If they are identical, it requests the transponder approval.
When the ignition is turned ON, the EMS (ECU) requests immobilizer verification process through
4. the P-CAN.
The immobilizer control unit sends the encrypted message to the EMS (ECU).
5. The EMS controls the engine normally when the coded value and the encrypted message sent
6. from the immobilizer are identical.

When the immobilizer verification has failed, the verification signal will be sent 3 times for 2 seconds,
and the verification procedure will be carried out up to 3 times by turning the ignition ON within 10
seconds. If the three re-verifications fail, verification procedure will be stopped and restarted after 10
seconds.

GETtheMANUALS.org
 1490-01 12-37

2) For a Vehicle with Smart Key

Key verification can be divided into two types, immobilizer key verification and smart key verification.
The immobilizer verification is applied to the smart key module (SKM) system, and verifies the
transponder built in the smart key. When the smart key is held over the START/STOP switch, the
verification is carried out, overriding the RF signal from the smart key.
When the START/STOP switch is pressed with the smart key held over the switch, the smart key
transponder verification is carried out by the transponder communication.
Once the key is verified, a valid key verification time is provided for 10 seconds and the engine can be
started by pressing the START/STOP switch during this time. If pressing the START/STOP switch after
this 10 seconds, the key verification process should be performed again.

1. When the ignition is turned ON, the EMS (ECU) sends the challenge message to the SKM through the
P-CAN. (This is to verify whether the transponder of the smart key is valid. If the verification fails, it will
transmit the re-verification signals 3 times for 2 seconds. If 3rd re-verification fails, the verification will be
deactivated for 10 seconds and re-activated after that.)
2. The emergency antenna of the SKM system sends the encrypted cod to the transponder, and the
transponder re-sends the encrypted code to the emergency antenna.
3. The encrypted sent to the emergency antenna is transmitted to the SKM.
4. The SKM compares this code with the encrypted code randomly transmitted by the internal logic. (The
system compares the signal from transponder and encrypted signal from the emergency antenna)
Only when the two signals are identical, the SKM recognizes the key as the verified one and transmits
5. the positive message to the ECU.
The ECU enables the engine to be started.
6.

GETtheMANUALS.org
12-38

18. KULEV (OBD ll)

1) Overview
On-board diagnosis (OBD) is a government-mandated standard that requires engines to actively
monitor and test emissions-related components and systems with ECU (on-board computer) to inform
the driver when malfunctions occur. OBD was introduced in 1994 in North America, and since 1996 this
standard has been required on all cars built in many countries. OBD is a part of environmental regulation
and equivalent to Korea Ultra low Emission Vehicle (KULEV).

▶ Features

- If a malfunction or problem is detected, the OBD system should illuminate a warning lamp on the
instrument cluster to inform the driver.
- This warning lamp should be located where the driver can see easily. Also the brightness of the lamp
should be sufficient to be noticeable and the lamp should not be turned off easily.
- The OBD system should also capture and store important information about the detected malfunction
such as diagnostic trouble code (DTC), related sensor signal values (freeze frame), and driving
conditions at the time that the malfunction occurred, so that a repair technician can accurately find
and fix the problem. And those data should not be cleared in an easy way
The check should be available with a diagnostic equipment used in a service center.
-
All these requirements are to reduce emissions generated by faulty or overheated emission-related
components.

Pin No. Function Pin No. Function

1 - 9 -
2 - 10 -
3 - 11 -
4 Ground (Chassis) 12 -
5 Ground (Sensor) 13 -
6 P-CAN Hi (J-2284) 14 P-CAN Lo (J-2284)
7 B-CAN Hi (J-2284) 15 B-CAN Lo (J-2284)
8 - 16 Battery power

GETtheMANUALS.org
GETtheMANUALS.org
12-40

2) Components

GETtheMANUALS.org
 1490-01 12-41

GETtheMANUALS.org
12-42

3) Function Description
(1) Catalytic monitoring system
a. Basic principle
The catalyst capacity of the manifold catalytic converter (MCC) is determined based on the monitored
oxygen sensor signal in the corresponding air-fuel ratio control cycle. The diagnostic value is a calculation
of cumulative sum of deviations from the rear oxygen sensor signals divided by the number of air-fuel
ratio control cycles. The catalyst with high efficiency has low diagnostic value because its high oxygen
storage capacity stabilizes the rear end oxygen sensor signal. The catalyst with low efficiency will has
high diagnostic value.

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- T-MAP sensor - Camshaft position sensor

- Oxygen sensors at the front and rear ends of - PCSV
the catalyst, Heating equipment - Coolant temperature sensor
- Throttle position sensor - Injector
- Vehicle speed - Ignition coil
- Fuel system - Thermostat
- Misfire
▶ The air-fuel ratio control is performed in the closed loop operation conditions and the
controlled value is within the range of maximum and minimum values
▶ The engine is running after warm-up, The vehicle speed is equal to or lower than a certain
speed
▶ The simulated (modeling) catalyst temperature is within the specified range
▶ After catalyst purge following the completed fuel cut-off
▶ No large fluctuations is observed in engine rpm, load, or throttle opening angle
▶ The engine rpm and load are within the specified ranges
▶ The warm up of the catalyst rear oxygen sensor is completed
▶ The PCSV is being opened or not being closed if the canister has a limited capacity under
maximum canister purge condition
▶ At altitudes equal to or lower than 2,500 m above sea level

GETtheMANUALS.org
 1490-01 12-43

c. Method
The diagnosis is performed based on the air-fuel ratio control. The diagnosis cycle stars when the rich
air-fuel ratio of the front oxygen sensor begins to be changed and ends when a cycle of air-fuel ratio
control is completed. If all diagnostic conditions are fulfilled during a cycle of air-fuel ratio control, the
average value for the signals from the rear oxygen sensor will be calculated. The cumulative sum of
deviations from the rear oxygen sensor signals is calculated as the average value for the previous air-fuel
ratio control cycles. The average deviation for each cycle is calculated by dividing the cumulative sum of
deviations from the rear oxygen sensor signals by the duration of the corresponding air-fuel ratio control.
The deviation ratio is calculated by dividing the default deviation determined by engine rpm and load by
the average deviation described above. The deviation ratio will be accumulated until all the required and
valid diagnosis cycles are completed.

(2) Misfire monitoring system

a. Basic principle
The misfire diagnosis is performed based on the difference in the angular velocity signals from a
misfiring cylinder and normal firing cylinder. The stroke time of a misfiring cylinder is longer than that of a
normal firing cylinder because of the reduced engine power. The engine roughness is calculated for
each stroke based on the calibrated values for the increased/decreased angular velocity. If the
calculated engine roughness value for a certain cylinder exceeds the threshold determined by the
engine rpm and load, then the cylinder will be determined to be a misfiring cylinder.

* The misfire threshold value is calculated based on the engine rpm and load and corrected by the
coolant temperature.

GETtheMANUALS.org
12-44

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- Crankshaft position sensor - T-MAP sensor (vacuum)

- Camshaft position sensor - Throttle position sensor

▶ The number of engine revolutions is higher than the minimum number of revolutions and
lower than the maximum number of revolutions
▶ The intake air amount is greater than the intake air amount (unloaded vehicle) at lower than
3,000 rpm, The air pressure in the intake manifold (unloaded vehicle) + 13.5 kPa at 6,500 rpm
There is no sudden change in engine load and throttle position sensor
▶ Not a condition for fuel cut-off
▶ Not a condition for driving on rough roads
▶ There is no sudden change in engine rpm
▶ The coolant temperature is higher than -6℃
▶ The fuel level in the fuel tank is not low
▶ The atmospheric pressure is higher than 750 hPa
▶

c. Stroke cycle learning

Stroke cycle learning is performed during deceleration in the fuel-cut condition to compensate the
mechanical tolerance of the target wheel used to measure the engine angular velocity. The stroke cycles
are learned and the difference between those cycles is used to calculate the engine roughness value for
more reliable misfire diagnosis.

d. Driving on rough roads detection (Vehicle signal detection)

When a vehicle is driven on a rough road, the vibrations and impact are transmitted from the wheels to
the engine through the drive train. In this case, the crankshaft stroke cycles can be affected by these
conditions. The calculated engine roughness value based on the affected stroke cycles may cause a
normal firing cylinder to be incorrectly interpreted as a misfiring cylinder. To prevent this and detect
whether the vehicle is driven on a rough road, the vehicle speed signal transmitted by the ESP unit is
used to calculate the engine roughness value.

GETtheMANUALS.org
 1490-01 12-45

(3) Evaporative system monitoring

a. Basic principle
The evaporative system monitoring procedures consist of checking the amount of evaporated fuel gas,
creating a vacuum, and checking for air leakage. The monitoring starts by checking the amount of
evaporated fuel gas based on the fuel temperature. Then, the PCSV is opened in stages to create and
maintain a vacuum in the evaporative system. After that, the evaporative system is checked for air
leakage which leads to a loss of vacuum.

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- Vehicle speed signal - Canister shut-off valve

- Coolant temperature sensor - T-MAP sensor (vacuum)
- PCSV - Fuel system monitoring
- Short term fuel correction - Injector
- Front oxygen sensor - Misfire
- Throttle position sensor - Crankshaft position sensor
- Fuel tank pressure sensor
▶ The altitude is not higher than the specified value
▶ The intake air temperature is higher than the specified value
▶ The engine is warmed up
▶ There is no malfunction regarding the evaporative purge control
▶ The canister is purged for the minimum specified time
▶ The minimum requirements are met before the evaporative system monitoring
(vehicle speed is higher than the specified speed, only for a predefined time
period)
▶ The amount of gas trapped in the canister is not too large
▶ The fuel level is within the specified range
▶ A certain amount of time has elapsed after the previous evaporative system monitoring
attempt
▶ The fuel tank pressure is within the specified range
▶ The vehicle is driven at low speeds constantly, When the engine is idling
▶ A certain amount of time has elapsed after the engine starts
▶
The battery voltage is normal

GETtheMANUALS.org
12-46

c. Method
▶ Checking amount of evaporated fuel gas
1. Stabilization phase
The PCSV and the canister shut-off valve are closed during the stabilization phase and the pressure
sensor is calibrated.
2. Evaporated fuel gas amount check phase
When the specified time period (T1) has elapsed, the system pressure is measured every 40 ms from
the initial phase (A) to the final phase (B). The least square method is used to calculate the slope of a
line that is fitted through the set of measured pressure values. If the pressure difference (B-A) calculated
from the line is below the threshold, then the PCSV will be determined to be stuck open.

▶ Air leakage check

3. Vacuum creation phase
The PCSV is opened in stages until the pressure decreases below the threshold. If the pressure does
not decrease below the threshold within the specified time period, then it will be determined that there is
excessive leakage from the evaporative system.
4. Standby phase
After the pressure has reached the specified level (DP_C), the canister purge valve is closed and the
system goes into standby phase until the pressure reaches the specified level (DP_D) before starting
the monitoring. If the pressure does not reach the level (DP_D) within the specified time period, then it
will be determined that there is no leakage in the evaporative system.
5. Air leakage check phase
During the air leakage check phase (T2), the system measures the pressure. The least square method
is used to calculate the slope of a line that is fitted through the set of measured pressure values. This
line is corrected by the amount of evaporated fuel gas confirmed in the evaporated fuel gas amount
check phase. The air leakage area is determined by the final slope of the line calculated for the pressure
increase in the fuel tank, considering the fuel volume in the fuel tank and the calculated atmospheric
pressure. The ECU determines whether there is any air leakage in the evaporative system based on
this area and stores fault codes related to this problem, if necessary.

GETtheMANUALS.org
 1490-01 12-47

(4) Fuel system monitoring

a. Basic principle
The monitoring system monitors the fuel correction (short term/long term). If the fuel correction value is
out of the specified range (long term) or fixed to the maximum/minimum value (short term), then the
system determines that there is a fault in the fuel system.

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- Throttle position sensor - Fuel injection system

- Crankshaft position sensor - Front end/Rear end oxygen sensor
- Coolant temperature sensor - Misfire
- T-MAP sensor - Input voltage of engine control unit
- Camshaft position sensor - Ignition coil
- PCSV - Fuel pump
▶ The closed loop air-fuel ratio control is performed
▶ The air fuel ratio learning control is activated
▶ The amount of engine oil in the calculated fuel volume is not sufficient
▶ The atmospheric pressure is higher than 750 hPa

GETtheMANUALS.org
12-48

c. Air-fuel ratio control malfunction (short term)

If the air-fuel ratio control value reaches the threshold within the specified time period, it will be determined
that there is a fault in the fuel system.

d. Air-fuel ratio control deviation malfunction (long term)

The air-fuel ratio learning control value is monitored. If the time counter reaches the maximum threshold
time within the specified monitoring time range, it will be determined to be a fault.

GETtheMANUALS.org
 1490-01 12-49

(5) Oxygen sensor monitoring system

(5.1) Front oxygen sensor: dynamic monitoring (response)
(P0133: Front oxygen sensor signal response delayed)
a. Basic principle
The dynamic monitoring of the oxygen sensor detects the dynamic behavior of the oxygen sensor signal
compared to the nominal behavior controlled by the air-fuel ratio control to determine if the response of
the front oxygen sensor is delayed. The delayed response of the oxygen sensor is caused by low sensor
temperature or excessive aging of the sensor.

b. Monitoring conditions
▶ The front oxygen sensor is activated
▶ The catalyst monitoring conditions are met (signal dynamic monitoring is performed with
catalyst monitoring)

c. Method
For each air-fuel ratio control cycle, the duration of rich state and the duration of lean state are
accumulated respectively and measured. The threshold is also added up as this duration is accumulated
because the duration is affected by mass flow rate and engine rpm. If the number of monitoring times
reach the predefined value, the accumulated time period of rich/lean state is compared with the
accumulated threshold. If the accumulated time period of rich/lean state is longer than the threshold, the
control frequency of oxygen sensor will be considered to be faulty.

When the sensor response is delayed

GETtheMANUALS.org
12-50

(5.2) Front oxygen sensor: signal monitoring during fuel cut

a. Basic principle
The oxygen sensor signals are monitored to determine if the signal is normal during fuel cut. If the output
voltage from the oxygen sensor is out of the specified range during fuel cut, the oxygen sensor will be
determined to be faulty. If the output voltage from the oxygen sensor is within the "invalid operating
voltage range during fuel cut", then this voltage will be considered as invalid. If this is the case, then the
corresponding fault code will be stored. If the output voltage from the oxygen sensor is above the
threshold during the fuel cut, then problem solving procedures will be carried out.

b. Monitoring conditions
▶ The engine is running
▶ The battery voltage is above the threshold
▶ The front oxygen sensor heating is activated
▶ The fuel cut is operating
▶ The exhaust gas temperature is above the threshold (based on modeling)

(5.3) Front oxygen sensor: signal monitoring for amplitude

a. Basic principle
The output voltages from the front oxygen sensor in lean and rich conditions are calculated to check the
single amplitude. If the amplitude is below the threshold, it is interpreted as a fault.

(5.4) Front oxygen sensor: heating monitoring (P0030: High resistance in front
oxygen sensor heater
a. Monitoring conditions
▶ The engine is running
▶ The battery voltage is above the threshold
▶ The front oxygen sensor heating is activated
▶ The front oxygen sensor is operating
▶ The exhaust gas temperature is above the threshold (based on modeling)

b. Method
If the resistance of the front oxygen sensor measured after the predetermined monitoring cycles is below
the threshold, the front oxygen sensor heating will be determined to be malfunctioning.

(5.5) Rear oxygen sensor: Signal response rate check, rich to lean (P0139)
When the fuel cut condition is met, the time taken for the rear oxygen sensor voltage to change (rich to
lean state) is measured at each start of fuel cut. If the average value calculated after three times of
measurement exceeds the threshold, then the signal will be considered as invalid.

GETtheMANUALS.org
 1490-01 12-51

(5.6) Rear oxygen sensor: signal response rate check, lean to rich (P0140)
This signal validation is performed after the fuel cut-off. The rich mixture is supplied to the catalyst by a
special air-fuel ratio control to reduce NOx emissions. The slope of line defined by the rear oxygen
sensor signals in lean to rich condition is monitored. If the maximum value of the slope does not exceed
the threshold, it will be determined to be a fault.

(5.7) Rear oxygen sensor: signal monitoring during fuel cut (P0140)
If the output voltage from the rear oxygen sensor exceeds the threshold, the signal will be considered as
invalid. (voltage check in lean condition)

(5.8) Rear oxygen sensor: heating validation

This validation is to find a fault in the oxygen sensor heating. If there is a fault in the oxygen sensor
heating, then the exhaust emission levels will increase beyond the permitted limits. The internal
resistance is measured to determine the temperature of the oxygen sensor. Immediately after the engine
starts, the internal resistance shows the greatest deviation from the reference value, because it is
affected by the heating operation. Therefore, this validation is performed during the warm-up of the
exhaust system and oxygen sensor after the engine starts.

a. Monitoring conditions
▶ The engine is running
▶ The battery voltage is above the threshold
▶ The rear oxygen sensor heating is activated
▶ The rear oxygen sensor is operating
▶ The exhaust gas temperature is above the threshold (based on modeling)

b. Method
If the resistance of the rear oxygen sensor measured after the predetermined monitoring cycles is below
the threshold, the rear oxygen sensor heating will be determined to be malfunctioning.

(6) Engine cooling system monitoring

(6.1) Thermostat monitoring
a. Basic principle
The thermostat control valve maintains a constant temperature value of the coolant and enables the
engine to be warmed up in shorter time. Typically, the thermostat is closed at cold start. The monitoring
is performed by comparing the measured coolant temperature with the simulated (modeling) coolant
temperature. If the thermostat is stuck open, it will be easily detected because the coolant temperature
will not increase during warm-up.

GETtheMANUALS.org
12-52

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- T-MAP sensor (pressure, intake air temperature)

- Vehicle speed signal
- Coolant temperature sensor
- Throttle position sensor
- Crankshaft position sensor

▶ The vehicle has stopped, or the engine rpm is not high (because coolant temperature can
decrease when the thermostat is normal)
▶ Low load in certain percentage (because coolant temperature can increase when the
thermostat is stuck open)
▶ High vehicle speed in certain percentage
▶ Fuel cut in certain percentage
▶ The intake air temperature during driving should be above a certain value (to avoid
monitoring when the vehicle is driven at very low ambient temperature after the engine is
warmed up)
▶ The coolant temperature should be within the specified range when the engine
starts
▶ The intake air temperature and the ambient temperature should be above the threshold
values specified range when the engine starts
▶ The battery voltage is 11 V or higher

GETtheMANUALS.org
 1490-01 12-53

c. Method
The measured coolant temperature is compared with the specified warmed-up coolant temperature after
a certain time. This time is determined based on the coolant modeling (function of the intake air mass). If
the simulated (modeling) temperature is above the thermostat set temperature and all other monitoring
conditions are met at the same time, then the monitoring will be considered to be valid. If the measured
coolant temperature is higher than the specified warmed-up coolant temperature, the thermostat will be
determined to be normal. Alternately, if the measured coolant temperature is lower than the specified
warmed-up coolant temperature, the thermostat will be determined to be stuck open.

GETtheMANUALS.org
12-54

(7) Low-emissions at cold start mechanism monitoring

The self diagnosis of mechanism for low-emissions at cold start monitors the elements (specified engine
rpm, specified ignition timing retard, etc.) for proper operation while the mechanism is activated.

(7.1) Ignition timing efficiency monitoring

- Required ignition timing efficiency (Ignition angle efficiency set value) = Driver's required torque /
(Driver's required torque + Torque for catalyst heating)
- Ignition timing efficiency difference = Required ignition timing efficiency - Actual ignition timing
efficiency
- The ignition timing efficiency difference is integrated during catalyst heating operation. If the
calculated ignition timing efficiency difference is above the threshold, then it will be determined to be a
fault.

GETtheMANUALS.org
 1490-01 12-55

(7.2) Idle speed at cold start monitoring

If the engine idle speed does not reach the target idle speed for catalyst heating during the catalyst
heating operation, the idle speed control value will be increased or decreased to reach the target speed.
If the deviation between the target idle speed and actual idle speed exceeds the threshold during the
catalyst heating operation and the idle speed control value is out of the specified range, then the idling at
cold start will be determined to be malfunctioning.

(8) CVVT monitoring

a. Basic principle
▶ The continuous variable valve timing (CVVT) monitoring consists of two parts:

- Monitoring timing deviation between the camshaft set value and actual camshaft position
- Monitoring response of the actual camshaft when the camshaft set position moves

b. Monitoring conditions
▶ No fault code regarding the following elements is stored in the ECU:

- Crankshaft position sensor

- Camshaft position sensor
- T-MAP sensor
- Throttle position sensor
- Coolant temperature sensor
- System voltage

▶ The engine speed should be within the specified range

▶ The engine oil temperature should be within the specified range
▶ The battery voltage should be within the specified range

GETtheMANUALS.org
12-56

c. Method
▶ Timing deviation

If the accumulated deviation between camshaft set value and measured camshaft value is above the
threshold after all monitoring conditions are met, the monitoring will be determined to be invalid.

▶ Low response rate

This is to check if the camshaft follows the camshaft set value correctly. If the camshaft set position
moves more than the threshold within the specified time, the actual camshaft position will be monitored
for this time period. If the actual camshaft position moves less than the threshold, then it will be
determined to be a fault.

GETtheMANUALS.org
 1490-01 12-57

(9) Other components monitoring

a. Basic principle
Sensors are important components that can affect the other systems and components used for
emissions control and monitoring. Therefore, the output voltage from the sensor is monitored for
continuity (connections) of circuits including short circuit to battery or ground, and open circuit, using the
specified range. Every operation unit also can affect emissions control and monitoring. Therefore, the
operating voltage of these units for a valid signal is monitored to check for malfunctions. For some
sensors and operation units, this monitoring can be used to ensure proper operation.

b. Monitoring conditions for electrical diagnosis

- Continuous monitoring
- The battery voltage is within the specified range

c. Sensor monitoring
If the output voltage from a sensor is out of the specified range, it will be determined to be a circuit fault
such as, short circuit to battery and ground, or open circuit.

d. Operation unit monitoring

An incorrect output signal from an operation unit with the voltage applied is determined to be a circuit
fault, such as short circuit to ground or open circuit.

e. Signal validation
▶ Throttle position sensor signal
If the deviation between the two throttle position sensor signals exceeds the threshold, the simulated
(modeling) air mass flow for each sensor position will be calculated based on the sensor position. If the
difference between simulated (modeling) air mass flow and actual air mass flow of one sensor is higher
than that of the other sensor, then the signal from the sensor with higher deviation will be determined to
be invalid.

GETtheMANUALS.org
12-58

▶ T-MAP sensor (load/throttle signal validation)

This validation is to verify the consistency between the load measured by T-MAP sensor and throttle
position sensor signals. To achieve this, the intake manifold control value is compared with the
corresponding reference value. The purpose of the intake manifold control is to make the simulated
(modeling) absolute manifold pressure equal to the measured absolute manifold pressure. If the
comparison value (or throttle opening area learned value) is above the threshold, corresponding
reference throttle opening area, it will be considered to be a fault in the system. Because throttle position
is confirmed through the two input terminals, the T-MAP sensor is considered to be faulty. If this is the
case, then the intake manifold control needs to be reset. (also, for the rest of the drive cycle)
This means that the intake manifold modeling is changed from closed loop to open loop. The air mass
flow is calculated based on the throttle position. The correction by ambient pressure is not allowed. The
simulated (modeling) absolute manifold pressure and throttle opening area assumed to be equal to the
measured values are also calculated. The amount of increase and reduction in measured throttle
opening area calculated based on the current throttle position sensor signal can be presented as the
deviation of the system.

▶ T-MAP sensor (intake air temperature)

1. Intake air temperature sensor signal stuck
The amount of heat build up in the intake manifold may be increased, reduced, or maintained at a
certain level according to the engine operating conditions. If the difference between the
maximum/minimum amount of heat and the signal fluctuation reaches the threshold, the intake air
temperature sensor will be considered to be faulty. (signal stuck)

▶ Coolant temperature sensor

1. Coolant temperature insufficient to enable closed loop fuel control
The self-diagnosis is performed only when the coolant temperature at engine start is equal to or lower
than the minimum temperature to enable the closed loop fuel control. If the coolant temperature calculated
based on the intake air mass reaches the minimum temperature to enable flow closed loop fuel control
after minimum time has elapsed after the engine start-up, the actual signal from the coolant temperature
sensor is compared with the corresponding threshold. If the actual signal is below the threshold (too low
signal from the coolant temperature sensor to enable closed loop fuel control), the coolant temperature
sensor will be considered to be faulty.
2. Coolant temperature signal at low temperature
The fluctuation of the coolant temperature sensor signal during warm up is compared with the changes in
the simulated (modeling) coolant temperature. If the comparison value is out of the specified range, the
coolant temperature sensor will be considered to be faulty. (signal stuck)
3. Coolant temperature stuck at high temperature
If the coolant temperature drops below the threshold after the vehicle is driven at different speeds under
various load conditions for a certain period of time, provided that the coolant temperature has reached
high temperature after engine start-up, the coolant temperature sensor will be considered to be faulty.

GETtheMANUALS.org
 1490-01 12-59

4. Comparison between coolant temperature sensor and other temperature sensors

If the difference between the signals from the coolant temperature sensor and other sensors exceeds the
threshold at the engine start-up after the vehicle has remained parked for a long time, the coolant
temperature sensor will be considered to be faulty.
5. Abnormal coolant temperature sensor signal
If there are large changes in actual coolant temperature value and the last coolant temperature value, the
coolant temperature sensor will be considered to be faulty.

▶ Fuel tank level

- Abnormal signal
When amount of fuel consumption reaches the target level, the fuel level deviation is checked for
abnormality. If the deviation is out of the specified range, the fuel tank level signal will be considered to
be abnormal.
- Signal stuck
When the fuel level signal is within the specified range, the engine ECU estimates the time delay
counter. If the signal is out of the specified range, the system is normal. If the fuel level is still within the
range even after the time counter, the signal will be considered to be stuck open right after the vehicle
speed reaches the threshold.

▶ Fuel tank pressure sensor

1. Abnormal signal
If the evaporative system monitoring has failed often because of the abnormal fuel tank pressure sensor,
the sensor will be determined to be faulty.
2. Signal stuck
If the signal from the fuel tank pressure sensor is within the specified range, while the PCSV is being
opened or closed, the fuel tank pressure sensor will be considered to be faulty. (signal stuck)
3. Signal stuck high
Usually, the pressure in the fuel tank slightly drops when the PCSV is open. If the fuel tank pressure is
too high at the start of the evaporative system monitoring under this condition, the fuel tank pressure
sensor will be considered to be faulty. (fuel tank pressure signal stuck in active canister purge condition)
If the pressure is too high in any conditions other than previously mentioned condition, the pressure
signal stuck high will be considered to be a fault.
4. Signal stuck low
The pressure in the fuel tank should be close to the atmospheric pressure when the PSCV is closed. If
the fuel tank pressure is too low at the start of the evaporative system monitoring under this condition,
the fuel tank pressure sensor will be considered to be faulty.

GETtheMANUALS.org
12-60

▶ PCSV stuck open

The fault related to the not fully closed PCSV can be detected during the evaporative system monitoring.
If the differential pressure of the fuel tank is dropping below the threshold in the evaporated fuel gas
amount check phase, the PCSV will be determined to be faulty. (mechanical failure of PCSV)

▶ PCSV stuck
- Stuck closed: If the differential pressure of the fuel tank is below the threshold, the it will be
determined to be stuck closed. (continuous monitoring)
- Stuck open: This failure is detected indirectly by excessive leakage during evaporative system
monitoring.

▶ CAN communication
If no signal is input after all monitoring conditions are met, it will be considered to be a fault.

▶ Over/low battery voltage

If the battery voltage is out of the specified range after all monitoring conditions are met, it will be
considered to be a fault.

▶ Accelerator pedal sensor

If the difference between the signals from the two pedal position sensors is above the threshold, the pedal
position sensor will be considered to be faulty.

▶ Vehicle speed signal

If no signal is input even when the engine speed and load are high, it will be considered to be a fault.

GETtheMANUALS.org
 1490-01 12-61

▶ Electronic throttle body control circuit

1. Operation terminal (Driver) monitoring (H-bridge)
The H-bridge IC of the electronic throttle valve checks continuously for open circuit, short circuit to ground
or battery voltage. In addition, the IC can detect a temperature rise. The engine ECU process this
information internally.
2. Spring check (initial phase)
The system checks for proper throttle spring operation and spring reached the throttle limp home position.
This check is performed at each initial phase of all drive cycles when the ignition is turned ON.
3. Learned value
The potential difference value of the limp home position (measured by potentiometer) and the lower
mechanically fixed position are learned at the first engine start-up and/or after a part replacement. This
learned values are stored in an inactive memory. If any condition is not met, a fault code will be stored.
4. Motor control performance
Too slow response and stuck throttle can be detected. If the given pulse width modulation (PWM) signal is
above the maximum value permitted to the position controller for longer than the specified time period
(shortest or longest time), a fault code will be stored. If the difference between the actual value and set
value of the throttle exceeds the maximum value, a fault code will be stored.

▶ Knock sensor
Knock sensor monitoring consists of three check phase to detect a fault.
- The first check is an absolute evaluation for knock signal. The output signal from the knock sensor is
compared with the threshold in this check phase.
- The second check is a relative evaluation. The instantaneous output signal from the knock sensor is
compared with the average value in this check phase. (distributed check for acquired signal) If there is
a fault, the peak signal from the knock sensor is below the normal value. (knock sensor circuit open,
short circuit to ground or battery) This check is done by comparing the voltage difference of the knock
sensor with the threshold.
- The third check is related to calculating knock one signal data. The knock signal is processed in a
special area of the engine ECU. To ensure the correct calculation, duplicated data will be detected.
For example, the transmitted data from the acquisition buffer to actual application are checked. If an
error regarding this check is detected, a fault code will be stored.

GETtheMANUALS.org
12-62

▶ Camshaft position sensor (Cam position sensor)

The camshaft position sensor monitoring is to check for electric malfunction, validity, signal edge position
relative to the crankshaft. The camshaft position sensor monitoring is performed by hall sensor and cam
target wheel with three teeth. The camshaft position sensor provides 3 upper signals and 3 lower signals
every 720 degrees of crankshaft rotation.
Below items are checked for both the intake and exhaust camshafts.

- Signal validation
- Signal stroke (segment) duration
- Signal synchronization loss
- Override during signal synchronization
- Reference value for crankshaft position sensor
- Mechanically displaced (jumped) chain

1. Camshaft position sensor signal validation

The edge counter of the intake and exhaust camshafts is checked once per combustion cycle. If the
edge counter does not change during the last cycle, it will be considered to be a fault and a fault code
related to intake/exhaust camshafts will be stored.
2. Camshaft and crankshaft synchronization monitoring (P0340, P0365)
If clearance of the crankshaft is detected for the first time, the engine position will be initialized based on
the information regarding the camshaft. One of the signals from the two camshafts is selected at the time
of engine start-up for the synchronization. Usually, the signal from the intake camshaft is selected. But if
an error is detected in the intake camshaft, then the signal from the exhaust signal will be selected. The
selected signal should be valid throughout the specified number of checks to ensure correct
synchronization. During the check, the crankshaft rotation angle is checked from the camshaft signal
edge to the next signal or from the camshaft signal edge to the crankshaft clearance. If the crankshaft
rotation angle is not matched to the designed camshaft signal edge, the check fails. At this time, the
camshaft and crankshaft learning is reset and the number of failed checks is increased. If this number of
failed checks reaches the threshold, a fault code related to the selected camshaft will be stored.
3. Camshaft position sensor stroke duration monitoring (P0341, P0366)
The signal edge of every camshaft position sensor is monitored at the last signal. If this duration is less
than the minimum duration, the stroke duration will be considered to be faulty and a fault code regarding
the intake or exhaust camshaft will be stored.
4. Camshaft position sensor synchronization loss monitoring
The ratio of measured signals between signal edges is compared with the ratio of theoretical signals
between signal edges. If this ratio is too high, the synchronization will be lost. This monitoring is
performed at every camshaft signal edge to check if the camshaft signal acquisition indicates
synchronization. If the camshaft is not synchronized, the number of monitoring times will be increased. If
the number of monitoring times reaches the threshold, it will be a synchronization error and a fault code
will be stored.

GETtheMANUALS.org
 1490-01 12-63

▶ Crankshaft position sensor

The crankshaft position sensor monitoring is to check for electric malfunction and validity. Following errors
are checked.

- Crankshaft position sensor signal loss

- Incorrect crankshaft angle signal
- Incorrect number of teeth
- Incorrect duration of teeth
- Synchronization error

1. Crankshaft position sensor signal validation and signal loss monitoring (P0335)
The crankshaft angle signal is checked for incorrect crankshaft signal. If the number of camshaft signal
edges with no valid crankshaft synchronization exceeds the threshold, the crankshaft angle signal will be
considered as invalid and a fault code will be stored. If a valid number of teeth of the camshaft has been
detected, the signal will be considered as invalid. If not, then the it will be considered as signal loss.
2. Incorrect number of teeth and synchronization error monitoring (P0336)
The number of teeth is checked every clearance. The number of teeth increases at each dropped signal
edge of the crank sensor. If one added or lost tooth is detected during the last 360 degrees rotation from
the clearance, the number of teeth of crank angle will be considered as incorrect and a fault code will be
stored. If two or more added or lost teeth are detected, the crank angle will be considered to be not
synchronized and a fault code will be stored.

GETtheMANUALS.org
12-64

▶ Vehicle exhaust gas self-diagnosis ratio

1. Generals
The standard vehicle exhaust gas self-diagnosis for the items required by the engine ECU regulations is
performed to get information about monitoring performance when the vehicle is driven.
2. Self-diagnosis components

- Catalyst
- Oxygen sensor: main oxygen sensor (front end of catalyst), auxiliary oxygen sensor (rear end of
catalyst)
- CVVT system
- Evaporative system
3. Self-diagnosis items
A. Diagnosis index: The number of monitoring times done by the exhaust self-diagnosis when the
monitoring conditions are met.
B. Drive index: The number of times the vehicle is driven.
General drive index
- Elapsed time after engine start-up > 600 seconds
- Elapsed time with the vehicle driven at equal to or more than 40 km/h > 300 seconds
- Continuous engine idling time > 30 seconds
- Altitude < 2,400 m
- Ambient temperature > -6℃
- Evaporative monitoring system
- Elapsed time after engine start-up > 600 seconds with ambient temperature between 4.5℃
and 35℃
- Engine starts with the coolant temperature between 4.5℃ and 35℃ and ambient temperature
> 7℃
C. Vehicle exhaust gas self-diagnosis ratio: Diagnosis index divided by drive index
D. Ignition cycle index: Increases within 10 seconds after the vehicle is started off

GETtheMANUALS.org
 0000-00 13-3

1. SPECIFICATIONS
Unit Description Specification
Alternator Rated output 120A(13.25V)
70A/2000rpm, 99A/4000rpm, 103A/6000rpm
Battery Capacity AGM 70Ah
Reserve capacity 110 minutes
Starting current (when 760 A
engine cooed)
Weight 21 Kg
BSC(Battery Sensor Operating current Maximum 20mA
Cable)
Dark current Maximum 0.35mA
Operating voltage 9~18V
Operating temperature -30~110ºC
Communication LIN 2.0

GETtheMANUALS.org
13-4

2. BASIC INSPECTION
1) Battery Terminal
- Make sure the terminal connections are
securely tightened. If the terminals are
corroded, clean them or replace the battery.

* Cleaning
Remove the corrosion or dirt with a wire brush
or sand paper, and then wash out with
lukewarm soapy water.

2) Measuring the Voltage Drop

▶ Measuring at battery terminal

Terminal (+) - Measure the voltage between battery

terminal (+. -) and wiring clamp.

Specified value below 0.3V

If the terminals are corroded, clean and

retightening them. If the specified tightening
torque cannot be kept, replace the clamp.

Terminal (-)

GETtheMANUALS.org
 0000-00 13-5

▶ Measuring at (-) wiring

- Measure the voltage between battery wiring

and body ground.

Specified value below 0.3V

If the voltage is out of the specified value,

Body Ground check the wiring mounting bolt for corrosion
and looseness. If there is a poor contact due
to corrosion or paint, wipe out the contact area
and retighten it.

Wiring mounting bolt to body

ground (-): 17 Nm

▶ Measuring the battery voltage

- Stop the engine and wait for 20 minutes.

Measure the voltage between terminal (+)
and terminal (-) with the ignition switch OFF
and all electric devices OFF.

Specified value over 12V

GETtheMANUALS.org
13-6

▶ Measuring the voltage drop between lines

- Measure the voltage drop between alternator B+ and battery B+.

Specified value below 0.3V

If the value is out of the specified value, check the terminal and clamp for looseness.

▶ Checking the charge warning lamp

1. Turn off all electric devices and put the ignition switch “ON” (Pre-warning).
2. Check if the charge warning lamp goes out.
- If the charge warning lamp does not go off, inspect the electric circuit.
3. Start the engine and check if the charge warning lamp keeps off.

GETtheMANUALS.org
 0000-00 13-7

3. INSPECTION - CHARGING CURRENT

- Perform the basic inspection.

▶ Setting up the testers

▶ Preparation

1. Set up the ammeter and voltmeter as

shown in the figure.

Make sure to set up the tester while keeping

its polarity.

GETtheMANUALS.org
13-8

▶ Inspection

1. Start the engine and turns on the headlamp, blower and heated wire at their full load. Then, measure
the maximum output current (MSM measurement value) when racing the engine to 2,700 rpm.

Specified value 60% of rated current (limit)

The output current may not reach the limit value due to various parameters (high temperature or
electric load etc.). Thus, do not perform the inspection with fully charged battery.

2. Turn the ignition OFF after inspection.

3. Disconnect the negative cable from the battery and remove the testers (ammeter and voltmeter).

▶ Characteristic curve (output from alternator)

GETtheMANUALS.org
 0000-00 13-9

4. INSPECTION - REGULATING VOLTAGE

- Perform the basic inspection.

▶ Setting up the testers

▶ Preparation

1. Set up the ammeter and voltmeter as shown

in the figure.

Make sure to set up the tester while keeping

its polarity.

▶ Inspection

1. Turn the ignition ON and measure the voltage on the voltmeter.

Specified value over 12V

2. Start the engine and turn all electric devices OFF.

3. Increase the engine speed to 2,700 rpm and maintain the speed. Measure the voltage when the
output current from alternator decrease below 30A.

Specified value 11.5 ~ 15.5V

GETtheMANUALS.org
13-10

5. INSPECTION - DARK CURRENT

- Perform the basic inspection.

1) When Using Multi-tester

▶ Setting up the tester

▶ Preparation
1. Disconnect the negative cable from the battery.
2. Set up the ammeter as shown in the figure above.

Connect the “+” probe to ground wiring and “-“probe to “-“terminal of battery.

▶ Inspection
1. Measure the current while removing the fuses one by one. If the current drops sharply when a certain
fuse is removed, inspect the affected circuit.

Specified value below 0.05A

GETtheMANUALS.org
 0000-00 13-11

2) When Using MSM

▶ Setting up the tester

▶ Preparation

1. Disconnect the negative cable from the

battery.
2. Set up the ammeter and MSM as shown in
the figure above.

Make sure to set up the tester while keeping

its polarity.

3. Connect the negative cable to the

battery.

Specified value below 0.05A

Measure the current while removing the fuses

one by one. If the current drops sharply when
a certain fuse is removed, inspect the affected
circuit.

GETtheMANUALS.org
13-12

6. INSPECTION - BATTERY
- Perform the basic inspection (all electric devices OFF).

1) Voltage Check (without load)

1. Connect one measuring clamp to “+”
terminal of battery first, then connect the
other one to “-“terminal. (Disconnect the
clamps in the reverse order).

2. Read the measurement.

over 11V: Normal

Specified 9 ~ 11V: Charging required
value below: 9V: Over discharged,
battery replacement required

GETtheMANUALS.org
 0000-00 13-13

2) Voltage Check (with load)

1. Push the load switch to ON (to arrow direction)

direction for less than 5 seconds.

To identify the battery capacity with the

voltage drop (V) value, discharge the fixed
load capacity (120A) for a certain period (5
seconds).

2. Read the measurement.

7 ~ 9V (Red): Over discharged

Specified or faulty
value 9 ~ 11V (Yellow): Charging
required
11 ~ 13V: Normal

GETtheMANUALS.org
13-14

7. DTC SETTING CONDITIONS

▶ Charge warning lamp ON condition

1. Turn the ignition ON (Engine stopped)

2. Open or short circuit of L terminal wiring, open or short internal circuit of alternator (fixed control of
13.8V)
3. Open or short circuit of F terminal wiring, no feedback output signal

GETtheMANUALS.org
 0000-00 13-15

1. LAYOUT
ECU Meter cluster (charge Battery sensor (BSC)
warning lamp)

Alternator (ALT)

GETtheMANUALS.org
13-16

2. OPERATING PROCESS
▶ System diagram

▶ Operation
- The EEM is designed to monitor the vehicle's electrical load, battery charge status, battery
temperature, voltage drop value at engine start-up and etc. to control the generating voltage. In this
way, it reduces CO₂ emissions and improve the battery efficiency through the ISG (Idle Stop
& Go) system and fuel economy improvement.
- BSC on “-“ terminal of battery sends the battery information (voltage, current, temperature
and SOC) to engine ECU with LIN communication.
- Engine ECU outputs the information from BSC and regulating control signal (PWM) according to the
engine load conditions to “L” terminal on alternator.
- Engine ECU controls the magnetic resistance between stator coil and rotor coil by controlling the
current in rotor coil according to PWM duty value.
- The alternating voltage induced to stator coil is converted to direct voltage by rectifier. And, BSC
outputs the charging voltage to “B” terminal on alternator.

GETtheMANUALS.org
 0000-00 13-17

▶ Basic control logic according to the driving conditions

Engine ECU determines the engine loads according to the fuel injection volume and engine speed. It
charges the battery by increasing the generating voltage during deceleration. To improve the fuel
economy by reducing the alternator load during acceleration, engine ECU decreases the generating
voltage and consumes the battery voltage.

▶ Operation of charge warning lamp

ECU checks the generating voltage from alternator and circuit conditions and sends the warning lamp ON
signal to meter cluster through CAN line.

GETtheMANUALS.org
13-18

3. CAN COMMUNICATION (Charge Warning Lamp)

▶ Overview

Meter cluster
(charge warning lamp)

The meter cluster receives the charge warning lamp ON signal from ECU through CAN line.

Charge warning lamp ON conditions

- Pre-warning
- When DTC related EEM set
- Open or short circuit in alternator

▶ Circuit diagram

GETtheMANUALS.org
 0000-00 13-19

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Category Specifications Remarks
Engine model D16DTF
Engine type / Number of cylinders In-line 4 cylinders
Displacement (cc) 1,597
Compression ratio 15.5
Max. power (PS) 136ps / 4,000rpm
M/T 300Nm / 1,500 ~ 3,000rpm
Max. torque (Nm)
A/T 324Nm / 1,500 ~ 2,500rpm
Cylinder block Cast iron
Valve system RFF & HLA -
Timing chain 9.525mm single bush chain
Intake manifold Plastic type + Electronic throttle body
Exhaust manifold Hi-SiMo

Crankshaft 8 mm offset
(Crankshaft offset from piston)
Cooling system Inlet control (Thermostat)
Lubrication system With VOP
Engine oil capacit 5.0 ℓ
Coolant capacity 7.5ℓ
Fuel tank capacity 47 ℓ

GETtheMANUALS.org
01-4

2. APPEARANCE
Front view Rear view

Left view Right view

GETtheMANUALS.org
 0000-00 01-5

3. MAJOR COMPONENTS
▶ Front view

Alternator

Vaccum pump

Oil dipstick gauge

Oil filter

Idle pulley

Water pump pulley

Belt tensioner

Air compressor pulley

Touch idler pulley

Crankshaft pulley

▶ Rear view

Electronic throttle body

Cam position sensor

High pressure pump and cover

Cylinder head coolant outlet port

E-EGR valve

EGR pipe

Intake duct

Flywheel (M/T)
Drive plate (A/T)

Cylinder block coolant outlet port

GETtheMANUALS.org
01-6

▶ Left view

Differential pressure sensor

E-VGT

Turbocharger

Electronic throttle body

Cylinder block outlet port

LNT & DPF

Oil cooler

Thermostat

A/C compressor

Oil filter and cooler module

▶ Right view

Intake manifold

EGR solenoid valve

Glow control unit

Alternator

EGR cooler

E-EGR valve

Oil pan

Drain plug

GETtheMANUALS.org
 0000-00 01-7

4. ENGINE COMPARTMENT LAYOUT

Brake fluid reservoir tank
Coolant reservoir tank Fuel filter

Engine oil filler cap

Air cleaner

Fuse and relay box

Oil dipstick gauge Oil filter Battery

- When checking the engine compartment, be careful not to touch the hot components such as
engine, radiator, exhaust manifold, catalytic converter, and muffler immediately after the engine has
been stopped. Check the engine compartment after the engine has been cooled down sufficiently.
Regularly check the engine oil level and add Ssangyong genuine engine oil, if necessary.
- Clean the oil dipstick gauge with a clean cloth to prevent any foreign material from entering.
-

- Operating the vehicle with insufficient amount of engine oil will result in severe damage the engine.
Make sure that the engine oil level is correct and add oil, if necessary.

GETtheMANUALS.org
01-8

1) Major Check Items and Service Interval

Check Daily Weekly Change interval
item check check
Change every 20000 km or 12 months (But, shorten
the service interval under sever condition)
EU Replace the oil filter: Same interval with the envine
Engine oil oil
and oil filter Check -
Initial change: 7500 km, change every 15000 km or
12 months (But, shorten the service interval under
Gen sever condition)
Replace the oil filter: Same interval with the envine
oil
Change at every 5 years or 200,000 km of driving.
Coolant Check -
(Inspect and replenish is necessary.)
Clean at every 20,000 km of driving and replace at
every 40,000 km of driving.
EU Clean or service more frequently under severe
conditions such as driving on a dusty road or off-
Air cleaner - road.
Check
element
Clean at every 15,000 km of driving and replace at
every 30,000 km of driving.
Gen Clean or service more frequently under severe
conditions such as driving on a dusty road or off-
road.
EU Change every 40000 km
Fuel filter - Change
Gen Change every 30000 km

GETtheMANUALS.org
 0000-00 01-9

2) Fluid Specifications And Capacity

- Ssangyong genuine engine oil
Specifications
Engine oil - Approved by ACEA C2 SAE 0W/30
Capacity ≒ 5.0L
Ssangyong genuine coolant (Long life antifreeze)
Specifications
Coolant (water:antifreeze = 50:50)
Capacity Approx. 7.5 L

Severe conditions
- Driving at high engine rpm or high speed, Excessive idling
- Driving for more than 2 hours at constant high speed (higher than 80% of maximum speed)
- Driving on dusty roads (off-roads) or muddy roads
- Driving on salted roads (coastal road, snow-melt road)
- Driving with high load such as trailer towing, cargo loaded
- Operating frequently in a place with heavy traffic
- Frequent stop-and-start driving (too many ISG operating times)
- Frequent rapid acceleration and rapid start

GETtheMANUALS.org
01-10

5. TIGHTENING TORQUE BY BOLT STRENGTH

1) Metric bolt strength is stamped on the head of each bolt. The strength of bolt can be classified as 4T,
7T, 8.8T, 10.9T, 11T and 12.9T in general.
2) Observe the standard tightening torque during bolt tightening. You can determine the proper
tightening torque within 15 % of standard value, if necessary. Try not to over permitted maximum
tightening torque, if not required to do so.
3) Determine the proper tightening torque separately, if tightening with washer or packing is required.
When the bolts are needed to be tightened to the below materials, follow the tightening torque
4) specified below.

- Aluminum alloy: Tighten to 80 % of above torque table.

- Plastics: Tighten to 20 % of above torque table.

GETtheMANUALS.org
 0000-00 01-11

6. ENGINE TIGHTENING TORQUE

Tool dimensions
Components Quantity Specified torque Remarks

Oil jet 10 mm 4 10 ± 1.0 Nm -

Main bearing cap

12-point,
10 1st: 60 ± 5.0 Nm Not reusable
13 mm 2nd: 90° ± 5°
Crankshaft rear seal 10 mm 7 10 ± 1.0 Nm -

Crankshaft position 5 mm hexagon

1 5 ± 1.0 Nm -
sensor wrench

Flywheel T55 8 1st: 45 ± 5.0 Nm Bolt length: 26 mm

2nd: 90° ± 5°

Drive plate T55 8 1st: 45 ± 5.0 Nm Bolt length: 22 mm

2nd: 45° ± 5°
Connecting rod cap
12-point, 8 mm 8 1st: 22.5 ± 2.5 Nm -
2nd: 85° + 5°
Ladder frame 12 mm 8 25 ± 2.5 Nm -
Oil pump chain T40 1 25 ± 2.5 Nm -
tensioner
Oil pump 13 mm 4 25 ± 2.5 Nm -

Cylinder head bolt E16 10 1st: 75 ± 5.0 Nm Not reusable

2nd: 90° + 90°(180°)
Camshaft - cam 10 mm 22 10 ± 1 Nm -
Intake camshaft T45 4 40 ± 4.0 Nm -
sprocket
Guide rail T40 3 25 ± 2.5 Nm -
Tensioner rail T40 1 25 ± 2.5 Nm -
5 mm hexagon
Chain tensioner 2 10 ± 1.0 Nm -
wrench
VOP extension 5 mm hexagon
1 10 ± 1.0 Nm -
wiring wrench
1 Bolt length: 90 mm
15 mm 58 ± 5.8 Nm
3 Bolt length: 80 mm
Timing gear case
5 Bolt length: 45 mm
13 mm 25 ± 2.5 Nm
6 Bolt length: 30 mm
Crankshaft center 27 mm 1 1st: 200 ± 20 Nm -
bolt 2nd: 85° ± 5°

GETtheMANUALS.org
01-12

Tool Specified torque

Components Quantity Remarks
dimensions
13 mm 2 25 ± 2.5 Nm Bolt length: 80 mm
2 Bolt length: 105 mm
Oil pan
10 mm 2 10 ± 1.0 Nm Bolt length: 115 mm
16 Bolt length: 25 mm
High pressure pump
19 mm 1 65 ± 5.0 Nm Left-handed screw
gear nut
High pressure pump 13mm 3 25 ± 2.5 Nm -
High pressure pump
10 mm 2 10 ± 1.0 Nm -
cover
Vacuum pump 10 mm 3 10 ± 1.0 Nm -
Cylinder head cover 10 mm 19 10 ± 1.0 Nm -
1st step: 10 Nm
Injector holder E10 2 Not reusable
2nd step: 120°
Cam position sensor 10 mm 1 10 ± 1.0Nm -
Glow plug 10 mm (length) 4 18 ± 2.0 Nm -
6mm hexagon
Fuel rail 2 25 ± 2.5 Nm -
wrench
Intake manifold 13 mm 9 25 ± 2.5 Nm -
Boost pressure sensor
10mm 1 10 ± 1.0Nm -

Intake air temperature

19mm 1 15 ± 3Nm -
sensor
3 Bolt length: 91 mm
EGR cooler 13 mm 25 ± 2.5 Nm
1 Bolt length: 16 mm
E-EGR valve 10 mm 3 10 ± 1.0 Nm -
Cylinder head outlet port 5 mm hexagon
2 10 ± 1.0 Nm -
wrench
Exhaust manifold 12 mm 10 40 ± 4.0 Nm Not reusable
Heat protector(on the 5 mm hexagon
2 10 ± 1.0 Nm -
exhaust manifold) wrench
Turbine / DPF / SCR /
17 mm 3 40 ± 5.0 Nm -
EGT sensor
Cylinder block outlet port 5 mm hexagon
3 10 ± 1.0 Nm -
wrench

GETtheMANUALS.org
 0000-00 01-13

Tool Specified
Components Quantity Remarks
dimensions torque
1 Bolt length: 105 mm
Oil filter module 13 mm 3 25 ± 2.5 Nm Bolt length: 120 mm
1 Bolt length: 45 mm
5 mm hexagon
Thermostat 2 10 ± 1.0 Nm -
wrench
5 mm hexagon
Water pump 5 10 ± 1.0 Nm -
wrench
Water pump pulley 10 mm 3 10 ± 1.0 Nm -
Oil filter cap 27 mm 1 25 Nm -
Idler pulley T50 1 23 ± 2 Nm -
Touch idler pulley 14 mm 1 45 ± 2 Nm -
EGR cooler inlet pipe 10 mm 3 10 ± 1.0 Nm -
Hot water pipe 10 mm 3 10 ± 1.0 Nm -
Heater return pipe 10 mm 2 10 ± 1.0 Nm -
TOC return pipe 10 mm 2 10 ± 1.0 Nm -
Intake duct bracket 13 mm 2 25 ± 2.5 Nm -
Intake duct 10 mm 4 10 ± 1.0 Nm -
Throttle body 10 mm 4 10 ± 1.0 Nm -
10 mm 2 10 ± 1.0 Nm Bolt length: 16 mm
EGR pipe
10 mm 2 10 ± 1.0 Nm Bolt length: 20 mm
13 mm 1 25 ± 2.5 Nm -
Wiring bracket
10 mm 3 10 ± 1.0 Nm -
High-pressure fuel pipe 17 mm 10 30 ± 3.0 Nm -
High-pressure fuel pipe
10 mm 1 10 ± 1.0 Nm -
bracket
EGR bypass solenoid valve
10 mm 2 10 ± 1.0 Nm -

Glow control unit 10 mm 2 10 ± 1.0 Nm -

Alternator 17 mm 2 61 ± 2.0 Nm -
A/C compressor 13 mm 4 25 ± 2.5 Nm -

GETtheMANUALS.org
01-14

Tool dimensions Specified

Components Quantity Remarks
torque
Belt tensioner 17 mm 1 61 ± 2.0 Nm -
Turbocharger 13 mm 3 25 ± 2.5 Nm Not reusable
Turbocharger oil supply pipe 14 mm 2 17 ± 2.0 Nm -
5 mm hexagon
Turbocharger oil return pipe 4 10 ± 1.0 Nm -
wrench
LNT & DPF 12 mm 3 29 ~ 34 Nm Not reusable
LNT & DPF bracket 14 mm 11 29 ~ 34 Nm -
Heat shield 5 mm hexagon
3 10 ± 1.0 Nm -
(on the turbocharger) wrench
Differential pressure sensor 10 mm 1 10 ± 1.0 Nm -
Brake vacuum hose 10 mm 2 10 ± 1.0 Nm -
Intake manifold temperature
19 mm 1 15 ± 3.0Nm -
sensor

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Category Items Specified value Remarks
Cylinder head height 127mm -
Cylinder head weight Approx. 11.7 kg -
Cylinder head flatness 0.1 mm or lower -

Cylinder head Combustion All 0.075mm -

chamber surface 0.05mm -
Range
flatness (100 x 100 mm)
Intake 0.1 mm -
Flatness on
(150 mm or less)
manifold side Exhaust side -
0.15 mm (total)

Head gasket Piston protrusion 0.325 ~ 0.602 1.15 t -

mm

Camshaft axial end Intake side -

Camshaft 0.08 ~ 0.18 mm
play Exhaust side -

Valve depth Intake side 0.709 ± 0.15 mm -

Valve
(retreat amount) Exhaust side 0.605 ± 0.15 mm -
Piston protrusion 0.454mm -
Bore Ø76 mm -
Cylinder block
Stroke Ø88 mm -
Bore pitch 85mm -
No. 1 compression -
0.18 ~ 0.28 mm
ring
Piston ring End gap No. 2 compression -
0.30 ~ 0.45 mm
ring
No. 3 oil ring 0.20 ~ 0.40 mm -

Crankshaft Crankshaft axial end play 0.100 ~ 0.266 mm -

GETtheMANUALS.org
02-4

2. TIGHTENING TORQUE
Tool dimensions
Components Quantity Specified torque Remarks

Oil jet 10 mm 4 10 ± 1.0 Nm -

Main bearing cap

12-point,
10 1st: 60 ± 5.0 Nm Not reusable
13 mm 2nd: 90° ± 5°
Crankshaft rear seal 10 mm 7 10 ± 1.0 Nm -

Crankshaft position 5 mm hexagon

1 5 ± 1.0 Nm -
sensor wrench

Flywheel T55 8 1st: 45 ± 5.0 Nm Bolt length: 26 mm

2nd: 90° ± 5°

Drive plate T55 8 1st: 45 ± 5.0 Nm Bolt length: 22 mm

2nd: 45° ± 5°
Connecting rod cap
12-point, 8 mm 8 1st: 22.5 ± 2.5 Nm -
2nd: 85° + 5°
Ladder frame 12 mm 8 25 ± 2.5 Nm -
Oil pump chain T40 1 25 ± 2.5 Nm -
tensioner
Oil pump 13 mm 4 25 ± 2.5 Nm -

Cylinder head bolt E16 10 1st: 75 ± 5.0 Nm Not reusable

2nd: 90° + 90°(180°)
Camshaft - cam 10 mm 22 10 ± 1 Nm -
Intake camshaft T45 4 40 ± 4.0 Nm -
sprocket
Guide rail T40 3 25 ± 2.5 Nm -
Tensioner rail T40 1 25 ± 2.5 Nm -
5 mm hexagon
Chain tensioner 2 10 ± 1.0 Nm -
wrench
VOP extension 5 mm hexagon
1 10 ± 1.0 Nm -
wiring wrench
1 Bolt length: 90 mm
15 mm 58 ± 5.8 Nm
3 Bolt length: 80 mm
Timing gear case
5 Bolt length: 45 mm
13 mm 25 ± 2.5 Nm
6 Bolt length: 30 mm
Crankshaft center 27 mm 1 1st: 200 ± 20 Nm -
bolt 2nd: 85° ± 5°

GETtheMANUALS.org
 0000-00 02-5

Tool Specified torque

Components Quantity Remarks
dimensions
13 mm 2 25 ± 2.5 Nm Bolt length: 80 mm
2 Bolt length: 105 mm
Oil pan
10 mm 2 10 ± 1.0 Nm Bolt length: 115 mm
16 Bolt length: 25 mm
High pressure pump
19 mm 1 65 ± 5.0 Nm Left-handed screw
gear nut
High pressure pump 13mm 3 25 ± 2.5 Nm -
High pressure pump
10 mm 2 10 ± 1.0 Nm -
cover
Vacuum pump 10 mm 3 10 ± 1.0 Nm -
Cylinder head cover 10 mm 19 10 ± 1.0 Nm -
1st step: 10 Nm
Injector holder E10 2 Not reusable
2nd step: 120°
Cam position sensor 10 mm 1 10 ± 1.0Nm -
Glow plug 10 mm (length) 4 18 ± 2.0 Nm -
6mm hexagon
Fuel rail 2 25 ± 2.5 Nm -
wrench
Intake manifold 13 mm 9 25 ± 2.5 Nm -
Boost pressure sensor
10mm 1 10 ± 1.0Nm -

Intake air temperature

19mm 1 15 ± 3Nm -
sensor
3 Bolt length: 91 mm
EGR cooler 13 mm 25 ± 2.5 Nm
1 Bolt length: 16 mm
E-EGR valve 10 mm 3 10 ± 1.0 Nm -
Cylinder head outlet port 5 mm hexagon
2 10 ± 1.0 Nm -
wrench
Exhaust manifold 12 mm 10 40 ± 4.0 Nm Not reusable
Heat protector(on the 5 mm hexagon
2 10 ± 1.0 Nm -
exhaust manifold) wrench
Turbine / DPF / SCR /
17 mm 3 40 ± 5.0 Nm -
EGT sensor
Cylinder block outlet port 5 mm hexagon
3 10 ± 1.0 Nm -
wrench

GETtheMANUALS.org
02-6

Tool Specified
Components Quantity Remarks
dimensions torque
1 Bolt length: 105 mm
Oil filter module 13 mm 3 25 ± 2.5 Nm Bolt length: 120 mm
1 Bolt length: 45 mm
5 mm hexagon
Thermostat 2 10 ± 1.0 Nm -
wrench
5 mm hexagon
Water pump 5 10 ± 1.0 Nm -
wrench
Water pump pulley 10 mm 3 10 ± 1.0 Nm -
Oil filter cap 27 mm 1 25 Nm -
Idler pulley T50 1 23 ± 2 Nm -
Touch idler pulley 14 mm 1 45 ± 2 Nm -
EGR cooler inlet pipe 10 mm 3 10 ± 1.0 Nm -
Hot water pipe 10 mm 3 10 ± 1.0 Nm -
Heater return pipe 10 mm 2 10 ± 1.0 Nm -
TOC return pipe 10 mm 2 10 ± 1.0 Nm -
Intake duct bracket 13 mm 2 25 ± 2.5 Nm -
Intake duct 10 mm 4 10 ± 1.0 Nm -
Throttle body 10 mm 4 10 ± 1.0 Nm -
10 mm 2 10 ± 1.0 Nm Bolt length: 16 mm
EGR pipe
10 mm 2 10 ± 1.0 Nm Bolt length: 20 mm
13 mm 1 25 ± 2.5 Nm -
Wiring bracket
10 mm 3 10 ± 1.0 Nm -
High-pressure fuel pipe 17 mm 10 30 ± 3.0 Nm -
High-pressure fuel pipe
10 mm 1 10 ± 1.0 Nm -
bracket
EGR bypass solenoid valve
10 mm 2 10 ± 1.0 Nm -

Glow control unit 10 mm 2 10 ± 1.0 Nm -

Alternator 17 mm 2 61 ± 2.0 Nm -
A/C compressor 13 mm 4 25 ± 2.5 Nm -

GETtheMANUALS.org
 0000-00 02-7

Tool dimensions Specified

Components Quantity Remarks
torque
Belt tensioner 17 mm 1 61 ± 2.0 Nm -
Turbocharger 13 mm 3 25 ± 2.5 Nm Not reusable
Turbocharger oil supply pipe 14 mm 2 17 ± 2.0 Nm -
5 mm hexagon
Turbocharger oil return pipe 4 10 ± 1.0 Nm -
wrench
LNT & DPF 12 mm 3 29 ~ 34 Nm Not reusable
LNT & DPF bracket 12 mm 6 29 ~ 34 Nm -
Heat shield 5 mm hexagon
3 10 ± 1.0 Nm -
(on the turbocharger) wrench
Differential pressure sensor 10 mm 1 10 ± 1.0 Nm -
Brake vacuum hose 10 mm 2 10 ± 1.0 Nm -
Intake manifold temperature
19 mm 1 15 ± 3.0Nm -
sensor

GETtheMANUALS.org
02-8

3. PRECAUTIONS
1) When lifting the vehicle
- Pay close attention to the safety precautions when lifting the vehicle on a jack lift as the vehicle might
slip off the jack lift.
- When working with a 4-column vehicle lift, use the center of the vehicle as a support point and chock
the wheels to prevent the vehicle from rolling.
- When work with a 2-column vehicle lift, use the jack point as a support point.
- Take care not to spill the battery electrolyte and wear protective clothing when handling the battery.

2) When working on the exhaust system

- Wear protective gloves when removing the exhaust pipe.
- Make sure that the exhaust pipe has sufficiently cooled down before working on the exhaust pipe,
because the temperature of the exhaust pipe is very hot right after the engine has been stopped.

3) When working on the fuel system

- Disconnect the negative battery terminal and prepare the service plug grip before working on the fuel
system.
- Do not smoke and avoid flames nearby when working on the fuel system.
- Keep gasoline away from the parts made of rubber or leather.
- Be sure to avoid sputtering of the fuel when removing the pipe between the high-pressure side fuel
pump and the fuel injector.
- Never remove any part of the fuel system before releasing the pressure in the fuel system.
- Even after the fuel pressure has been released, wrap a cloth or equivalent around the mountings to
reduce the potential risk of fuel sputtering to a worker or engine assembly.
- Let the engine is cooled down sufficiently before proceeding to the next procedure since the fuel
pressure on the high-pressure side will not drop until the engine is cooled down.

4) When working on the cooling system

- Do not remove the radiator reservoir cap while the engine or radiator is hot since high-pressure hot
coolant or steam may cause severe burn.

GETtheMANUALS.org
 0000-00 02-9

5) When working on the lubrication system

- Repeated contact with the engine oil for an extended period of time may cause skin irritation.
- Take special care when changing the engine oil to minimize possible skin contact with the used
engine oil because hazardous materials that may cause skin cancer are contained in the used
engine oil.
- Always wear the oil-resistant protective clothing and gloves when handling the engine oil, and
completely remove the used engine oil from the skin with a lot of water or waterless hand cleaner.
Never use gasoline, dilute solution or solvent to wash your skin.
- Discard the used oil and used oil filter only in the designated area to protect environment.

6) When tightening bolts

Angle tighten the components of engine in a so-called final tightening operation. The tightening procedure
is as follows:

1. Clean the contact surface and threads before tightening bolts and nuts.
2. When angle tightening without a torque wrench tighten the bolt to the specified angle, marking its
position. (paint mark to assist the work)

The location and left/right position of components are based on the direction when viewed from the
rear side.
The cylinder block is made of aluminum and can be deformed and broken easily when excessive
force is applied. Therefore, always observe the specified torque when tightening the cylinder block
to prevent its thread from being damaged.
Do not over-tighten a self tapping screw bolt as it creates threads itself.
Never reuse the used bolt if it is a angle-tightened one.
(However, a bolt with specified reuse number with the specified torque is reusable.)

GETtheMANUALS.org
02-10

1. APPEARANCE
▶ Front view

Alternator

Vaccum pump

Oil dipstick gauge

Oil filter

Idle pulley

Water pump pulley

Belt tensioner

Air compressor pulley

Touch idler pulley

Crankshaft pulley

▶ Rear view

Electronic throttle body

Cam position sensor

High pressure pump and cover

Cylinder head coolant outlet port

E-EGR valve

EGR pipe

Intake duct

Flywheel (M/T)
Drive plate (A/T)

Cylinder block coolant outlet port

GETtheMANUALS.org
 0000-00 02-11

▶ Left view

Differential pressure sensor

E-VGT

Turbocharger

Electronic throttle body

Cylinder block outlet port

LNT & DPF

Oil cooler

Thermostat

A/C compressor

Oil filter and cooler module

▶ Right view

Intake manifold

EGR solenoid valve

Glow control unit

Alternator

EGR cooler

E-EGR valve

Oil pan

Drain plug

GETtheMANUALS.org
02-12

2. MAIN CHARACTERISTICS

RFF+HLA valve system

(with intake camshaft
scissors gear) Cylinder head cover
With single bush chain (built-in oil separator)
system

TGCC (engine mount +

dipstick gauge)
Use ECO oil filter
5PK one belt system

Crankshaft With LNT & DPF

(8 mm offset) system

Variable oil pump (2-stage

solenoid operation)

Common rail system

(2,000 bar)
E-VGT

Plastic intake manifold

Ceramic glow plug

(Max. 1,200℃)

E-EGR assembly
(Bypass cooler + E-EGR)

Deep skirt type cylinder

block (cast iron)
Electric throttle actuator (DC
motor type)

GETtheMANUALS.org
 0000-00 02-13

3. EPC
▶ 1117 ENGINE UNIT(D16F)

1. ENGINE ASSY
2. BRKT ASSY-ENGINE HANGER FRT
3. BRKT ASSY-ENGINE HANGER RR
4. BOLT

GETtheMANUALS.org
02-14

▶ 1120 SHORT BLOCK(D16DTF)

1. SHORT BLOCK

GETtheMANUALS.org
 0000-00 02-15

▶ 1133 CYLINDER BLOCK(D16DTF)

1. BLOCK ASSY-CYLINDER 36.GROMMET-CRANKSHAFT SEALING RR

3. BOLT-MAIN BEARING CAP 39.SENSOR ASSY-CRK/SHF POSN
6. PLUG-EXPANSION 44.PLUG-SCREW
9. PIN-CYLINDRICAL 45.PLUG-SCREW
17.COVER ASSY-CRK/SHF SEALING RR 49.SLEEVE
18.SEALING-CRANKSHAFT RR 53.DAM-COOLANT
20.BOLT 55.BOLT
21.PIN-SPRING 60.COVER-CYLINDER BLOCK INTAKE
22.NOZZLE ASSY-OIL INJECTION 61.COVER-CYLINDER BLOCK EXHAUST
35.SEAL ASSY-CRANKSHAFT RR 62.BOLT-CYL BLOCK COVER

GETtheMANUALS.org
02-16

▶ 1130 CRANKSHAFT AND FLYWHEEL(D16DTF)

1. CRANKSHAFT 25.ROD ASSY-CONNECTING

2. PIN-CYLINDRICAL 27.BOLT-CONNECTING ROD
3. KEY-CRANKSHAFT PULLEY 30.BEARING-CONNECTING ROD STD UPR
4. SPROCKET-CRANKSHAFT 31.BEARING-CONNECTING ROD STD LWR
7. DISC-CRK/SHF VIB DPR 33.PISTON ASSY
8. BOLT-CRANKSHAFT CTR 34.RING SET-PISTON
12.DAMPER ASSY-VIBRATION 35.RING-SNAP
13.FLYWHEEL ASSY-DUAL MASS 44.BEARING-CRK/SHF MAIN STD UPR
17.BOLT-FLYWHEEL MTG 45.BEARING-CRK/SHF MAIN STD LWR
18.PLATE ASSY-DRIVE 46.BEARING-CRK/SHF THRUST STD UPR
19.PLATE 55.RING-TRIGGER

GETtheMANUALS.org
 0000-00 02-17

▶ 1215 CYLINDER HEAD AND GASKET KIT(D16DTF)

1. HEAD ASSY-CYLINDER 32.SEAL-VALVE STEM

5. PLUG-EXPANSION 33.RETAINER-VALVE SPRING LWR
6. BOLT-STUD 34.SPRING-VALVE
7. BOLT 35.RETAINER-VALVE SPRING UPR
9. PIN-CYLINDRICAL 36.COTTER-VALVE
12 SLEEVE 39.FOLLOWER ASSY-FINGER
13.BOLT-CYLINDER HEAD 40.ADJUSTER ASSY-HYDRAULIC LASH
24.GASKET-CYLINDER HEAD 47.TUBE-COOLING WATER OUTLET
26.VALVE-INTAKE 48.BEARING-BALL
27.VALVE-EXHAUST 49.NOZZLE-THROTTLE

GETtheMANUALS.org
02-18

▶ 1226 CYLINDER HEAD COVER AND CAMSHAFT(D16DTF)

1. COVER COMPL-CYLINDER HEAD 16.CLAMP

2. GASKET-CYLINDER HEAD COVER OTR 21.CAMSHAFT ASSY-EXHAUST
3. BOLT 22.CAMSHAFT ASSY-INTAKE
4. CAP ASSY-OIL FILLER 25.GASKET-CYLINDER HEAD COVER INR
14.HOSE ASSY-BLOW BY OUTLET

GETtheMANUALS.org
 0000-00 02-19

▶ 1316 CHAIN DRIVE(D16DTF)

1. CHAIN-BUSH LWR 15.TENSIONER ASSY-HYDRAULIC

2. RAIL-CLAMPING 16.CHAIN-BUSH UPR
3. RAIL-TENSIONER 17.BOLT
10.SPROCKET-INTAKE CAMSHAFT 19.BOLT
12.BOLT-CAMSHAFT SPROCKET

GETtheMANUALS.org
02-20

▶ 1338 TIMING CASE(D16DTF)

1. COVER-TIMING GEAR CASE 25.PULLEY ASSY-IDLER

2. SEALING-CRANKSHAFT FRT 28.COVER-IDLER PULLEY
3. BOLT 30.BOLT-STUD
4. TENSIONER ASSY-BELT 31.RING-O
5. BOLT 32.GAUGE ASSY-OIL DIPSTICK
7. COVER-IDLER PULLEY 33.PLATE-DIPSTICK TUBE
8. PULLEY ASSY-IDLER 34.SCREW

GETtheMANUALS.org
 0000-00 02-21

▶ 1610 VACUUM PUMP(DSL)

1. PUMP ASSY-VACUUM
3. BOLT

▶ 1480 A/C COMPRESSOR

1. COMPRESSOR ASSY-A/CON
2. BOLT

GETtheMANUALS.org
02-22

▶ 1990 ENGINE MOUNTING

1. INSULATOR-ENGINE MTG 7. BOLT-ENGINE MTG

2. INSULATOR-ENGINE MTG 8. NUT
3. BRKT-ENGINE MTG 9. BOLT
4. INSULATOR-ENGINE MTG LWR 10.NUT-HEX FLG_M12x1.25
5. BOLT-HEX FLANGE 11.BOLT-ENGINE MTG
6. BOLT 12.INSULATOR-AIR CLEANER MTG NO1

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
Category Specifications
Fuel Diesel
Type Integrated fuel heater and water separator
Service interval EU 40,000 km
GEN 30,000 km
Fuel filter
Water removal EU 20,000 km
GEN 15,000 km
Water storage capacity
Alarm activated when 50 cc or more

Injector System pressure 2,000 bar

Drive Gear
Crank revolution to
Number of chamber
2:4
(plunger) pump strokes
High pressure pump ratio
Operating temperature
-30 °C ~ 120 °C

Operating pressure Max. 2,000 bar

Type Built in the tank, electric
Drive Electric motor
Low fuel pressue
Fuel pump motor 5 ± 0.07 bar
(low pressure) regulator
Operating voltage 13 V
Voltage: 13 V, 173L/H, Max. current 10 A, Fuel
Basic
pressure 5 ± 1 bar
Material Plastic
Fuel tank
Capacity 47 L

GETtheMANUALS.org
03-4

2. CAUTIONS FOR DI ENGINE

1) Cautions for DI Engine
This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation
from engine, warning lights, symptoms when engine malfunctioning, causes and actions.

1. DI Engine
Comparatively conventional diesel engines, DI engine controls the fuel injection and timing electrically,
delivers high power and reduces less emission.

2. System Safety Mode

When a severe failure has been occurred in a vehicle, the system safety mode is activated to protect the
system. It reduces the driving force, restricts the engine speed (rpm) and stops engine operation. Refer
to "Diagnosis" section in this manual.

3. Engine CHECK Warning light

The Engine CHECK warning lamp on the instrument cluster comes on when the fuel or
major electronic systems of the engine are not working properly. As a result, the
engine’s power output may decrease or the engine may stall.

4. Fuel filter Warning light

When the water level inside water separator in fuel filter exceeds a certain level , this
warning light comes on and buzzer sounds.
Also, the driving force of the vehicle decreases (torque reduction). If these conditions
occur, immediately drain the water from fuel filter.

GETtheMANUALS.org
 0000-00 03-5

2) Cleanness
(1) Cleanness of DI engine fuel system
▶ Cleanness of DI engine fuel system and service procedures

The fuel system for DI engine consists of transfer (low pressure) line and high pressure line.
Its highest pressure reaches over 2,000 bar.
Some components in injector and HP pump are machined at the micrometer 100 μm of
preciseness.
The pressure regulation and injector operation are done by electric source from engine ECU.
Accordingly, if the internal valve is stuck due to foreign materials, injector remains open.
Even in this case, the HP pump still operates to supply high pressurized fuel. This increases the
pressure to combustion chamber (over 250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The
below figure shows the clearance between internal operating elements.

Hair
Valve actuator lift - 0.028 mm

Operating
clearance
0.002 mm
Diameter
Diameter
2.0 mm
0.04 mm

Nozzle hole

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

GETtheMANUALS.org
03-6

(2) Di engine and its expected problems and remedies can be caused by
water in fuel
▶ System supplement against paraffin separation

In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then
can stick on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply
summer fuel and winter fuel by differentiating mixing ratio of kerosene and other elements by region and
season. However, above phenomenon can be happened if stations have poor facilities or sell improper
fuel for the season. In case of DI engine, purity of fuel is very important factor to keep internal
preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging
due to paraffin separation, the fuel filter heater is mounted on top of the fuel filter.

▶ System supplement and remedy against water in fuel

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

▶ Water drain from water separator

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

Water separator For removing water, refer to "FUEL FILTER

ASSEMBLY" under "REMOVAL AND
INSTALLATION" subsection of "FUEL SUPPLY
SYSTEM" section.

GETtheMANUALS.org
 0000-00 03-7

3. SPECIAL TOOLS
Part number and name General equipments
Name:
Fuel pump cover
installer/remover

Usage:
Used to install or remove the
fuel pump cover.

GETtheMANUALS.org
03-8

1. OVERVIEW
The fuel system consists of fuel tank, fuel pipe line, fuel filter assembly (fuel heater), high pressure pump,
fuel pump (low pressure), fuel pressure regulator, injectors, fuel rail.
The low pressure fuel pump delivers the fuel to the fuel filter and then the high pressure pump through
the low pressure fuel line at low pressure (approx. 5 bar). The high-pressure pump feeds the fuel rail and
the injectors at high pressure (2,000 bar). Then the injectors inject the fuel into the combustion chamber
under pressure when the ECU sends the signal.

2. COMPONENTS
Injector return
Injector
Fuel temperature PLV return
sensor

PLV
Fuel high pressure
pump
Fuel rail
Fuel supply pipe

Fuel high pressure pump

return

Fuel filler cap

Service cover
Fuel filter Fuel pump & Bolt
sender cover (10 mm, 3 off)
O-ring
Fuel pump and
sender assembly Fuel filler assembly
Fuel return tube
Fuel tank module Clamp
Nut (10 mm)
Washer
Fuel return pipe (2 off) Bolt (10 mm)

Fuel supply pipe Extension wiring

Fuel return tube

Fuel tank strap
Nut
(14 mm, 4 off)
Fuel line holder Fuel line holder

GETtheMANUALS.org
 0000-00 03-9

3. EPC
▶ 2210 FUEL TANK(DSL)

1. TANK ASSY-FUEL 16.FILLER ASSY-FUEL

2. FUEL PUMP ASSY 17.CAP ASSY-FUEL FILLER
4. HEAT SHIELD ASSY 18.COVER-FUEL PUMP
5. TUBE ASSY-SUPPLY 19.NUT
6. TUBE ASSY-RETURN 20.WASHER
8. WIRING ASSY-EXTENSION 21.CLAMP-WRT_M52
9. COVER-FUEL PUMP PLATE 22.SCREW
10.O-RING 23.NUT
12.SCREW 24.SCREW
13.PAD-FUEL TANK 25.PUMP-FUEL
14.PAD-FUEL TANK 26.SENDER ASSY
15.STRAP ASSY-FUEL TANK 28.REGULATOR ASSY

GETtheMANUALS.org
03-10

▶ 2231 FUEL FILTER(DSL)

1. FILTER ASSY-FUEL
2. ELEMENT KIT-FUEL FILTER
3. BRKT ASSY-FUEL FILTER
4. GROMMET-FUEL FILTER MTG
5. NUT

GETtheMANUALS.org
 0000-00 03-11

▶ 1883 COMMON RAIL SYSTEM(D16DTF)

1. PUMP ASSY-FUEL 20.BRKT-FUEL PIPE UPR

3. BOLT 23.RAIL ASSY-FUEL
4. GEAR-FUEL PUMP 25.BOLT
5. COVER-FUEL PUMP 26.TUBE ASSY-FUEL RETURN
6. BOLT 31.RING-O
7. O RING-FUEL PUMP 40.VALVE-INLET METERING
8. NUT-GEAR MTG 41.PIPE ASSY-FUEL
9. INJECTOR ASSY-FUEL 42.NUT
10.WASHER 43.HOSE & TUBE ASSY-FUEL RETURN
11.CLAMP-INJECTOR 44.HOLDER-TUBE
12.BOLT-INJECTOR 45.HOSE ASSY-FUEL SUPPLY
15.PIPE ASSY-FUEL 46.HOLDER-TUBE
16.PIPE ASSY-FUEL 47.CORRUGATED TUBE-FUEL HOSE RR
18.PIPE ASSY-FUEL 48.HOLDER KIT-FUEL HOSE
19.BRKT ASSY-FUEL PIPE 50.INSULATION-INJECTOR

GETtheMANUALS.org
03-12

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 03-13

The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and
controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio
control based on these signals.
The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position)
sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal
depressed (driver's will) by receiving the electrical signals from the accelerator pedal sensor.
The mass air flow sensor detects the volume of intake air and sends the value to the ECU.
The major function of the ECU is controlling air-fuel ratio to reduce the emission level (EGR valve control)
by detecting instantaneous air flow change with the signals from the mass air flow sensor.
Also, the ECU uses the signals from the coolant temperature & air temperature sensors, booster pressure
sensor, atmospheric pressure sensor to: a) determine injection starting point and set value for pilot
injection, and b) deal with various operations and variable conditions.

GETtheMANUALS.org
03-14

2. OPERATING PROCESS
1) SYSTEM FLOW CHART I

GETtheMANUALS.org
 0000-00 03-15

2) SYSTEM FLOW CHART II

GETtheMANUALS.org
03-16

3) Delayed engine control

If the fuel pressure increases excessively and exceeds the limit value due to a failure condition in the fuel
system, the PLV (Pressure Limit Valve) of the high pressure pump is open and forcibly returns the fuel to
protect the fuel system. At this time, since fuel temperature increases sharply the fuel return line or
relevant parts in the fuel system may get damaged. In this case, the ECU limits the engine power using
delayed engine control.

▶ Troubleshooting

Description Vehicle symptom Control To be checked

IMV open circuit or control line Limit Wiring, connector
IMV open fully
short circuit to B+ power
Implausible fuel rail pressure
sensor signal (high/low) Sensor, wiring,
Limit connector
IMV open forcibly power
Abnormal supply voltage to
ECU
fuel rail pressure sensor
Fuel rail pressure above 2,200 bar Sensor, wiring,
Too high fuel rail pressure (PLV may not be open between Limit connector, IMV,
2,200 and 2,450 bar.) power ECU
Deviation error in fuel rail
pressure sensor IMV partial open Limit Sensor, wiring,
(high/low/delayed response) (PLV not open) power connector

▶ ECU control in the event of problem caused by fuel temperature increase with PLV open

- Reduce engine power

- Warning lamp ON

▶ Conditions for fuel pressure increase (Conditions to open PLV)

- IMV open circuit or control line short circuit to B+
- Implausible fuel rail pressure sensor signal (high/low)
Abnormal supply voltage to fuel rail pressure sensor

-
The PLV (Pressure Limiting Valve) is activated only when rail pressure control is not available due to
an excessively increased pressure.

GETtheMANUALS.org
 0000-00 03-17

4) Pressure limiting valve control

The PLV is mounted at the end of the fuel rail. It opens primarily and secondarily to control the rail
pressure rise, thereby suppressing the temperature rise due to the rail pressure rise.

Fuel rail assembly

PLV (built-in)

PLV return connector

Fuel rail

Internal structure of PLV

PLV operation graph

PLV opens PLV opens

primarily secondarily
(pressure limit (Limp-home
section) section)

GETtheMANUALS.org
03-18

3. FUEL PUMP AND SENDER ASSEMBLY

▶ Fuel pressure regulator

The fuel pressure regulator is installed in the reservoir cup of the fuel pump and sender assembly. This
component keeps the fuel pressure in the low pressure line at about 5 ± 1.0bar when the engine
is running.

Fuel pressure regulator

Plate assembly

Fuel motor mounting

Fuel pressure regulator

Exploded View

GETtheMANUALS.org
 0000-00 03-19

▶ Fuel sender

The fuel sender is installed to the side of the fuel pump reservoir cup in the fuel tank. It measures the fuel
level.
The float of the fuel sender moves up and down according to the fuel level in the fuel tank when the
ignition is turned ON or the engine is running. The fuel sender detects the resistance which changes as
the float moves up and down and sends this value to the instrument cluster.
The instrument cluster calculates using this resistance value and illuminates the fuel level indicator.

Fuel sender

GETtheMANUALS.org
03-20

Data output of fuel sender

GETtheMANUALS.org
 0000-00 03-21

Fuel sender resistance by fuel level

GETtheMANUALS.org
03-22

4. FUEL HIGH PRESSURE PUMP ASSEMBLY

1) Exploded Diagram
Internal components of fuel high pressure pump

Hydraulic head cap

IMV
Hydraulic head assambly

Plunger spring

Roller &
Plunger shoe

Nut

Front plate Drive shaft Housing

Inlet valve
Plunger

Hydraulic head assembly

Housing
Plunger return
spring
Spring seat
Inner seal
Shoe
Shoe guide
Outer seal
Roller
Drive shaft
Rear bearing
Front bearing

Front plate

GETtheMANUALS.org
 0000-00 03-23

2) Operation Principle of Plunger Type High-pressure Pump

Internal structure of hydraulic head The plunger does a linear reciprocating motion by
the eccentric cam of the drive shaft to create the
high-pressure fuel necessary for driving the
engine, and transmits it to the fuel rail.

Plunger lowered - Plunger lowered by eccentric cam of drive

(low-pressure fuel charge) shaft
- Outlet valve closed
- Inlet valve open

The inlet valve is open as the low-pressure

fuel in the hydraulic head cap moves in the
hydraulic head (charge) due to the internal
vacuum generated when the plunger is
lowered.

Plunger raised - Plunger raised by eccentric cam of drive shaft

(high-pressure fuel produced) Inlet valve closed
- Compresses fuel filled when plunger lowered
- Outlet valve open

The outlet valve changes from open to closed

when the pressure in the hydraulic head is
higher than the pressure in the fuel rail and
the high-pressure fuel is transmitted to the
fuel rail.

GETtheMANUALS.org
03-24

3) Lubrication and cooling of the HP pump

Lubrication and cooling of the pump are provided by the fuel circulation.

4) Phasing of the HP pump

Conventional fuel injection pumps ensure pressurizing and distribution of the fuel to the different
injectors. It is essential to set the pump (timing setting) in such a way that the injection occurs at the
required place during the cycle. The HP pump of the common rail system is no longer used for the fuel
distribution, it is therefore not necessary to set the pump in relation to the engine.
Nevertheless, the timing setting of the pump offers two advantages:

- It allows the torque variations of the camshaft and the pump to be synchronized in order to reduce the
stresses on the timing belt.
- It allows pressure control to be improved by synchronizing peak pressures produced by the pump
with pressure drops caused by each injection.

This phasing allows pressure stability to be improved, which helps to reduce the difference in flow
between the cylinders.

GETtheMANUALS.org
 0000-00 03-25

5) HP Pump Fuel Route

The fuel from the low-pressure fuel pump passes through the fuel filter where its temperature is
measured and goes into the high-pressure pump through the high-pressure pump inlet nipple. The IMV
controls the intake fuel flow and the fuel compressed by the high-pressure pump is transmitted to the
fuel rail where sends the fuel to each injector.

HP pump fuel route

IMV The fuel is sent to the high pressure side (hydraulic head)
and compressed by the plunger. And, goes into the common
rail through the high pressure pipe.
The IMV installed in the high pressure side (hydraulic head)
of HP pump precisely controls the fuel amount and delivers
the rail pressure feedback same as required amount. The
IMV is controlled by ECU.

GETtheMANUALS.org
03-26

6) PV Diagram of High Pressure Pump

The time required to obtain sufficient rail pressure for engine operation is changed based on system
volumes (including rail volume and pipe length).

PV diagram of HP pump

GETtheMANUALS.org
GETtheMANUALS.org
03-28

5. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 03-29

GETtheMANUALS.org
03-30

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
Category Specifications
Filter type Dry, filter element
Filtering area 0.3 m²
EU Clean at every 20,000 km of driving.
Air cleaner element
Service GEN Clean at every 15,000 km of driving.
interval EU Change at every 40,000 km of driving.
GEN Change at every 30,000 km of driving.
Weight 1.5kg
Air cleaner assembly Operating temperature -30 to 100℃

Capacity 9L
Core material Aluminum

Core size 620 x 134.7 x 63

Intercooler (Width X Height X Thickness)
Tank material Plastic (injected)
Efficiency 85%

1. Service more frequently under excessive use or severe conditions, such as driving on a dusty road
or off-road, or driving in the rain for a long period of time.
2. Failure to follow the changing interval may cause:
- Insufficient engine power
- Excessive emissions
- Prematurely worn turbocharger, engine cylinder walls, pistons, piston rings and intake valves

GETtheMANUALS.org
04-4

1. OVERVIEW
The intake system of this vehicle is equipped with electronic throttle body. The flap of the electronic
throttle body is operated by the electric signals to control the air flow entering the EGR system and block
the intake air flowing into the engine when the engine is turned off.

2. COMPONENTS
Intake manifold assembly

Intake manifold
Boost pressure
temperature sensor
sensor

Electronic throttle body Intercooler assembly

GETtheMANUALS.org
 0000-00 04-5

Intake duct Air cleaner element

HFM (Hot Film Air-Mass) sensor

Water protector Snorkel

GETtheMANUALS.org
04-6

3. EPC
▶ 2313 AIR CLEANER

1. AIR CLEANER ASSY 7. PROTECTOR-WATER

4. ELEMENT ASSY 8. HOSE ASSY-A/CLNR TO T/CHARG
5. INSULATOR-AIR CLEANER MTG NO1 9. BOLT
6. SNORKEL ASSY 10.SCREW RIVET-RR FASCIA MTG

GETtheMANUALS.org
 0000-00 04-7

▶ 2330 AIR INTERCOOLER (DSL)

1. INTERCOOLER ASSY 8. HOSE ASSY-I/COOLER TO ENG

2. INSULATOR-INTERCOOLER LWR 9. BRKT-HOSE MTG OUTLET
3. INSULATOR-MODULE MTG UPR 10.CLAMP
4. BRKT-MODULE MTG UPR 11.CLAMP-SPRING
5. HOSE ASSY-A/CLNR TO T/CHARG 12.BOLT-HOOD LATCH MTG
6. HOSE ASSY-T/CHARG TO I/COOLER 13.CLAMP-WORM DRIVE TYPE SPRING
7. BRKT-HOSE MTG INLET 14.SCREW

GETtheMANUALS.org
04-8

▶ 1741 INTAKE MANIFOLD(D16DTF)

1. MANIFOLD ASSY-INTAKE 17.BOLT

6. BOLT 29.DUCT ASSY-INTAKE
8. BOLT 31.BRKT ASSY-INTAKE DUCT
9. COVER ASSY-ACOUSTIC 42.VALVE ASSY-AIR CONT
10.BOLT 43.BOLT

GETtheMANUALS.org
 0000-00 04-9

1. INPUT/OUTPUT DIAGRAM

* For details, refer to "ENGINE CONTROL section".

GETtheMANUALS.org
04-10

2. OPERATING PROCESS

▶ Work Flow

GETtheMANUALS.org
 0000-00 05-3

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

GETtheMANUALS.org
05-4

1. OVERVIEW
This system purifies the exhaust gas generated by the combustion in the engine to reduce the pollutants
and noise during that arise during combustion.

GETtheMANUALS.org
 0000-00 05-5

2. COMPONENTS (FOR A AWD VEHICLE)

Exhaust manifold

LNT & DPF assembly

Front exhaust pipe

SCR catalyst

Center exhaust pipe

Rear exhaust muffler

GETtheMANUALS.org
05-6

3. EPC
▶ 1746 EXHAUST MANIFOLD(D16DTF)

1. MANIFOLD ASSY-EXHAUST
2. GASKET-EXHAUST MANIFOLD
3. NUT
10.BOLT
15.PROTECTOR-HEAT TOP
16.PROTECTOR-HEAT BOTTOM RR
17.PROTECTOR-HEAT BOTTOM FRT

GETtheMANUALS.org
 0000-00 05-7

▶ 2413 EXHAUST SYSTEM(DSL:urea)

1. LNT & CDPF COMPL 10.HANGER

2. PIPE ASSY-EXHAUST FRT 12.HEAT PROTECTOR-EXHAUST CTR
3. SCR ASSY-EXHAUST 13.HEAT PROTECTOR-RR MUFFLER
4. PIPE ASSY-EXHAUST CTR 14.NUT
5. MUFFLER COMPL-RR 15.NUT
6. GASKET 17.PIPE ASSY-DIFF PRESS
7. HANGER 18.BOLT
8. HANGER 19.NUT
9. GASKET-CDPF

GETtheMANUALS.org
05-8

▶ 1760 EXHAUST GAS RECIRCULATION SYSTEM(D16DTF)

1. HOSE ASSY-VACUUM INLET

2. HOSE ASSY-VACUUM OUTLET
3. HOSE ASSY-DIFF PRESS FRT
4. NUT
5. HOSE ASSY-DIFF PRESS RR

GETtheMANUALS.org
 0000-00 05-9

1. OPERATING PROCESS
1) Exhaust Gas Flow

2) Input & Output Devices

GETtheMANUALS.org
 0000-00 06-3

1. SPECIFICATIONS
Category Items Specifications
Max. temperature of turbine housing 800℃

Turbocharger Turbine housing outlet inner diameter Ø42.0

Compressor housing inlet inner diameter Ø41.0
Cooling method Air-cooled
E-actuator Operation duty cycle 250 Hz

GETtheMANUALS.org
06-4

1. OVERVIEW
A turbocharger is a centrifugal compressor powered by a high speed turbine that is driven by an engine's
exhaust gases. Its benefit lies with the compressor increasing the mass of air entering the engine (forced
induction), thereby resulting in greater performance (for either, or both, power and efficiency). As the
turbine, at exhaust end, is rotated by exhaust gas pressure the impeller, at intake end, gets rotated to
send air around center of the impeller, being circumferentially accelerated by the centrifugal force, into
the diffuser. The air, which has been introduced to the diffuser having a passage with big surface,
transforms its speed energy into the pressure energy while being supplied to the cylinder improving the
volume efficiency. Also, the exhaust efficiency improves as the exhaust turbine rotates. The
turbocharger is often referred to as the exhaust turbine turbocharger.
Diffuser: With the meaning of spreading out it is a device that transforms fluid's speed energy into the
pressure energy by enlarging the fluid's passage to slow down the flow.

The E-VGT turbocharger system installed to this vehicle variably controls the passages of the turbine
housing to regulate the flow rate of the exhaust gas. The actuator of E-VGT is a DC motor actuator (E-
Actuator) which controls more quickly and precisely than the previous vacuum type actuator.

GETtheMANUALS.org
 0000-00 06-5

1) Features
(1) Performance
1. Enhanced emission control: By temperature control with LNT & DPF system

(2) E-Actuator (Electric-Actuator, Rotary type)

1. Optimizes the exhaust gas flow rate by controlling the vanes inside the turbine housing with the E-
Actuator.
2. Has a faster response time than the conventional vacuum actuator

- Improved low speed torque, high speed power and fuel economy.
- Improved acceleration performance with rapid response time of vane

- Folding and unfolding of the

vane is controlled electrically
- Easy to get low speed air
Features volume
- Rapid response time
- Electric control

- Improved low speed torque

Improved low speed torque and
power
Benefits - Reduced exhaust gas
- Improved fuel consumption
- Improved acceleration
performance

GETtheMANUALS.org
06-6

2. COMPONENTS
Booster Intake manifold Coolant Accelerator
pressure temperature temperature pedal sensor
sensor sensor sensor

E-VGT turbocharger HFM Engine ECU

GETtheMANUALS.org
 0000-00 06-7

3. EPC
▶ 1915 TURBOCHARGER(D16DTF)

1. TURBOCHARGER ASSY 7. TUBE ASSY-OIL RETURN

2. GASKET-TURBO 8. GASKET-TURBO OIL RETURN
3. NUT 9. BOLT
4. TUBE ASSY-OIL SUPPLY 10.BRKT ASSY-TURBOCHARGER SUPT
5. BOLT-HOLLOW_M10x1x23 11.BOLT
6. RING-SEAL 15.BOLT

GETtheMANUALS.org
06-8

1. INPUT/OUTPUT CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 06-9

2. OPERATING PROCESS
In the low speed section, narrow the venturi tube to increase the flowing speed, which operates the
turbine. In the high speed section, widen the venturi tube and operate the turbine with the exhaust gas,
which improves the engine performance in the whole sections.

Control Area Low-speed Area High-speed Area

Driving Mechanism
Of Turbocharger

Reduces the passage of exhaust gas Increases the passage of exhaust gas
Control Method by narrowing the turbine blades by widening the turbine blades (vanes)
(vanes)
At a low-speed area in which the At a high-speed area in which the
amount of exhaust gas is small and amount of exhaust gas is large and
flow velocity is slow, the passage of flow velocity is fast, the passage of
exhaust gas is narrowed in order to exhaust gas is widened in order to
Operating Principle increase the flow velocity. This causes maximize the flow of exhaust gas,
the turbine to rotate fast, which results which causes the turbine to rotate fast
more intake air is supplied than normal and more intake air is supplied.
turbocharger. (using venturi principle)

Velocity energy increased as passage Exhaust gas flow maximized as

of exhaust gas being narrowed passage of exhaust gas being
→ Rotation speed of widened
Effects turbine/impeller increased to increase → Rotation speed of
compressive force of intake air turbine/impeller increased to increase
compressive force of intake air

Performance
Low-speed torque improved Maximum power improved
Improvement

Venturi's principle
When air flows in venturi tube, the flowing gets fast on
point A where the size gets small. In this condition, if
the bore of the venturi tube is narrowed, the speed
gets increased.

GETtheMANUALS.org
06-10

3. CONFIGURATION DIAGRAM
▶ Compressor housing & turbine housing

1. Compressor housing: This induces fresh air to

the compressor wheel (Impeller) and supplies
the compressed air to the intercooler through
the hose.
2. Turbine housing: This is located on the
exhaust manifold and turns the turbine wheel
to send the exhaust gas to the exhaust pipe
using the pressure of exhaust gas.

▶ Impeller

1. The impeller is wings (wheel) installed on the

intake end and performs the role of
pressurizing air into the cylinder.
2. The radial type has the impeller plate
arranged in straight line at the center of shaft
and, compared to the backward type, is
being widely used as it is simple, easy to
manufacture and appropriate for high speed
rotation. As the impeller rotates in the
housing with the diffuser installed in it, the air
receives centrifugal force to be accelerated in
the direction of housing's outer circumference
and flows into the diffuser. As surface of the
passage increases, air flown into the diffuser
transforms its speed energy into pressure
energy and flows into the intake manifold
where the pressurized air is supplied to
cylinder each time the intake valve of cylinder
opens up. Therefore, the efficiency of
compressor is determined by the impeller
and diffuser.

GETtheMANUALS.org
 0000-00 06-11

▶ Turbine

The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the
compressor and performs the role of transforming heat energy of exhaust gas into torque energy. The
radial type is used as the turbine's wings.
Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it rotates
in high speed, it requires to have sufficient rigidity and heat resisting property. During operation of the
engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate by
coming in contact with the turbine's wings from the outer circumference within housing of the turbine and
is exhausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it
rotates.

▶ Floating bearing

Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 1 to 250,000 rpm. It
could be rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from
the engine.

▶ Actuator (E-Actuator) and vane control

Vane Arm

Unison ring

Roller

Vane

The E-VGT does not use the waste gate. Instead, it controls the vane angle by using the E-Actuator
to regulated the turbine speed and boosting.
E-VGT has 10 vanes around the turbine. This vane is controlled by the actuator which receives the
command from the engine ECU.

GETtheMANUALS.org
06-12

The unison ring is designed to be capable to

rotate either clockwise or counterclockwise and
E-actuator to connect to the vane control actuator.
The variable turbine inlet vane is connected
through the unison ring and vane arm, 10 vanes
are rotated when the actuator is activated. 10
vanes are used as a passage for the exhaust gas
led to the turbine inlet. According to their rotation,
the flow passage area of exhaust gas varies. At
low speed, the flow passage is narrowed and the
flow speed of the exhaust gas increases,
resulting in increasing the delivery energy of
turbine. At high speed, the flow passage is
widened and the much exhaust gas is generated,
resulting in considerably increasing the delivery
energy of turbine.

Control Turbocharger Control Improved

driving Effect
range method performance
mechanism

Control Narrows the The flow rate is

direction flow passage increased as the
At low for the exhaust gas passes the
exhaust gas narrow passage Improved
speed
by folding the → Increased turbine & low speed torque
(Vane
Close) vanes impeller speed,
Increased compressive
force

Expands the
flow passage The flow rate is
At high for the increased due to the Improved
speed exhaust gas expanded passage → maximum
(Vane by unfolding Increased compressive power
Open) the vanes force
Control
direction

GETtheMANUALS.org
 0000-00 06-13

▶ Effect

1. Improved low speed torque

The VGT increases the output by 10% and
torque by 14% compared to the conventional
turbocharger.

2. Improved acceleration performance

The VGT reduces the turbocharger lag
which results in the improved acceleration
due to the faster response.

Turbocharger lag
The turbocharger is at idle speed when there
is no load or it is in the normal driving
condition. During this period, the amount of
exhaust gas passing through the turbine is not
enough to turn the compressor wheel
(impeller) fast. Therefore, the intake air is not
compressed as needed. Because of this, it
takes time for turbocharger to supply the
additional power after the accelerator pedal is
depressed. This is called "turbocharger lag".

GETtheMANUALS.org
06-14

3. Improved fuel consumption

The VGT reduces turbocharger lag which
results in the improved response. When the
accelerator pedal is pressed, the proper
mixture of fuel and air should be entered into
the combustion chamber. However, for the
conventional turbocharger, excessive fuel is
supplied when accelerating as the
compressor wheel (impeller) does not supply
enough compressed air. The VGT reduces
this phenomenon. (To supply the proper
amount of fuel, the VGT drives the turbine
wheel faster at low speed range so that the
amount of intake air is increased.)

4. Reduced exhaust gas

The shape of turbine blade is changed to increase the amount of intake air at low speed range.
Therefore, the exhaust gas and smoke due to excessive fuel supply is reduced.

▶ Conditions for inhibiting VGT operation

- When the engine speed is less than 700 rpm

- When the coolant temperature is below approx. 0℃
- When any part related to the E-EGR is defective
- When the VGT actuator is defective
- When the air mass flow (HFM) sensor is defective
- When the accelerator pedal sensor is defective

GETtheMANUALS.org
 0000-00 06-15

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 07-3

1. SPECIFICATIONS
ategory Specifications
Oil pump Lubrication Type Vane Pump feeding type, forced circulation
Number of sprocket teeth 33
VOP pressure 3.1 ± 0.3bar (SOL. ON)
(Oil Temp. at about 130℃)
5.6 ± 0.4bar (SOL. OFF)
Oil filter Type Full flow type/Paper filter element type
module
Bypass valve opening pressure 2.0 ± 0.4 bar

Non-return valve opening 0.2 ± 0.08 bar

pressure
Engine oil Specifications - Ssangyong genuine engine oil
- Approved by ACEA C2 SAE 0W/30
Capacity 5.0 L
Service interval EU Change every 20000 km or 12 months (But, shorten the
(including oil filter) service interval under sever condition)
Replace the oil filter: Same interval with the envine oil

GEN Initial change: 7500 km, change every 15000 km or 12

months (But, shorten the service interval under sever
condition)
Replace the oil filter: Same interval with the envine oil

Oil jet Opening pressure 1.8 ± 0.2 bar

Closing pressure 1.0 bar or less
Injection flow rate 3.0 ± 0.2 L/min at 3.7 bar
Oil Operating power 5V
pressure
Oil pressure pre-warning ACC/ON
sensor
Oil pressure warning light All ranges (including idling): 0.5 bar or
Turning ON condition: 2,500 rpm: 2.0 bar or less
4,000 rpm: 2.5 bar or less

GETtheMANUALS.org
07-4

1. OVERVIEW
The lubrication system supplies oil to various parts of the engine that require lubrication to reduce friction,
wear, heat on the surfaces in contact with each other.
When the engine is running, frictional heat is generated by the moving parts. If this heat builds up, the
bearing can be stuck. The lubrication system creates an oil film on each contact surface of the two
moving parts to convert solid friction to liquid friction in order to reduce wear and prevent the temperature
from increasing. The lubrication system is equipped with a variable oil pump (VOP) which improves the
fuel economy in low/moderate speed range and ensures the reliability in high speed range.

2. COMPONENTS
Oil pressure sensor Oil dipstick gauge Oil filter and cooler
assembly

Oil cooler

Ladder frame

Oil pan Oil pump VOP solenoid valve

VOP solenoid valve

GETtheMANUALS.org
 0000-00 07-5

3. EPC
▶ 1547 OIL FILTER(D16DTF)

1. FILTER & COOLER ASSY-OIL 32.GASKET-OIL COOLER & COOLANT

2. COVER-OIL FILTER 33.GASKET-OIL COOLER INLET
3. RING-O 34.GASKET-OIL COOLER OUTLET
4. VALVE-OIL FILTER BYPASS 35.NIPPLE-OIL FILTER
9. ELEMENT KIT-OIL FILTER 36.GASKET-OIL FILTER DRAIN
13.COOLER ASSY-OIL 37.GASKET-COOLANT
19.SENSOR ASSY-OIL PRESSURE 38.GASKET-OIL
31.BOLT

GETtheMANUALS.org
07-6

▶ 1537 OIL PAN & PUMP((D16DTF)

1. PUMP ASSY-OIL VARIABLE 44.SEALANT

6. RING-SEAL 45.COVER-DUST
8. PAN-OIL 48.LADDER FRAME
10.BOLT 50.CONNECTOR ASSY-OIL PUMP
11.PLUG-DRAIN 51.BOLT
19.TENSIONER ASSY-OIL PUMP CHAIN 55.COVER-OIL PAN
20.BOLT 56.BOLT-CYL BLOCK COVER
21.BOLT

GETtheMANUALS.org
 0000-00 07-7

1. ENGINE OIL
1) Functions
The main functions of the engine oil are lubricating and cooling the important parts of the engine. It is
essential for smooth operation of the engine.

▶ Reducing wear

Friction is the resistance created between the surfaces of two moving objects that are in contact with
each other.
No matter how smooth the finished surface looks, the surface has bumps when viewed under a
microscope. These bumps get stuck on and break each other when directly contact with other surfaces.
This results in wear. Even if no bump exists on the surface, mechanical wear will occur when the surface
contacts with other surface and moves in relation to that surface. The engine oil supplied to the frictional
surfaces creates an oil film on each contact surface and converts the solid friction to liquid friction to
reduce wear.

▶ Cooling

The frictional energy is converted to heat energy. And the pistons and cylinders are heated up by the
combustion gases. The engine oil absorbs and dissipate the heat from these components.

▶ Sealing

The cylinders are sealed by the piston ring fitted to the pistons. The engine oil penetrates through the
small gaps between the piston ring and seating surfaces of the piston and completes the sealing. The oil
seal prevents pressure leaks and return flow of the combustion gases.

▶ Rust proofing

The engine oil creates a thin film on the metal surfaces and prevents the surfaces from contacting with
air, water, or corrosive gas which causes rust and corrosion.

▶ Cleaning

The engine oil circulates in the engine by the pressure from the oil pump. The oil keeps the frictional
surfaces clean by transporting the metal particles, oxides, and carbides generated from the surfaces.

2) Properties
The properties of the engine oil greatly affect the performance and efficiency of the engine. The
properties of oil differ depending on the crude oil and refining process used.
However, most coolants in the market are mixed with various additives to improve the performance.

GETtheMANUALS.org
07-8

3) Required properties
Basically, the properties of engine oil differ by usage. In general, the following properties are required.

▶ Cleaning effect

Products of the combustion (e.g. carbon) and degradation products of oil contaminate the engine
causing problems related to poor lubrication which reduces the service life of the engine. Therefore, the
inside of engine needs to be kept clean and oil with proper cleaning effect is recommended.

▶ Oxidation stability

The engine is driven for a long time and hot. Therefore oil with high oxidation stability is recommended.
Oxidation of oil generates harmful substances which increase oil viscosity. This causes poor lubrication
resulting in severe corrosion or wear.

▶ Anti-corrosion

Products of the combustion (e.g. carbon) and degradation products of oil cause corrosion of the metal
surfaces. Therefore, oil with anti-corrosion additives is recommended.

▶ Anti-foaming

Bubbles in oil cause deterioration of oil pump, poor circulation of oil, and poor lubrication, resulting in
malfunctions

▶ Viscosity index

Viscosity is a measure of oil thickness. Oil with high viscosity forms thick oil film which supports high
load. However, too high viscosity increases internal friction of lubricant which indicates increased
resistance, resulting in increased power loss. Alternatively, too low viscosity cannot form the oil film
which is essential for wear reduction.
The most important factor that determines the viscosity of lubricants is temperature. In general, the
viscosity of a lubricant decreases as temperature increases. The amount of viscosity change in relation
to temperature is called "Viscosity index". The viscosity change of the oil with high viscosity index is
lower than that of the oil with low viscosity index. The engine temperature varies greatly so oil with high
viscosity index is recommended.

4) Consumption
The engine oil is used up for various reasons. The amount of oil consumption is affected by oil viscosity,
oil quality, and driving conditions. The amount of consumption increases especially when the engine is
new or driven at high rpm. When the engine is new, operation of the pistons, piston rings, and cylinders
is not optimized. Therefore, more oil will be used up. Check the engine oil level each time you fill the tank
during the first 5,000 km as much as possible. Make sure that the engine oil level is within the specified
range before long journeys.

GETtheMANUALS.org
 0000-00 07-9

2. SYSTEM DIAGRAM

GETtheMANUALS.org
07-10

Exploded View

1. Cover mounting bolt 12.Dowel pin

2. Sprocket 13.Cap sealing
3. Cover 14.O-ring
4. Vane ring 15.Knock bushing
5. Rotor and shaft assembly 16.Outlet gasket
6. Slide seal support 17.Retainer
7. Slide seal 18.VOP solenoid valve
8. Vane 19.Housing
9. Pivot pin 20.Oil screen assembly
10.Slide spring 21.Cap plug
11.Slide

GETtheMANUALS.org
 0000-00 07-11

3. ENGINE OIL FILTER ELEMENT

1) Overview
The oil filter removes the solid foreign materials (combustion residue, dust, metal particles, etc.) from the
engine oil and maintains lubrication performance of the oil during the service life.

Always replace the engine oil element whenever changing the oil.

2) Mounting Location and Components

Engine oil filter element

The filter bypass (1) valve is integrated into

the oil filter cover in order to prevent the
engine from being damaged by fire in the
event of low oil flow through the oil filter due
to the blockage of the filter element. The
opening pressure is 2 ± 0.4 bar.

No. Components
1 Oil filter bypass valve
2 Oil filter cap
3 O-ring
4 Oil filter element
Oil drain hole
5 (when replacing filter)

GETtheMANUALS.org
07-12

4. LADDER FRAME
1) Overview
The ladder frame is a kind of partition. It is installed in the oil pan. It prevents the oil in the oil pan from
sloshing when the vehicle starts off or is stopped. It also prevents the formation of oil bubbles by letting
the oil flows down the plate.

2) Mounting Location and Components

Exhaust side

Oil pump Intake side

Blowby hole

Ladder frame
Front view Rear view

GETtheMANUALS.org
 0000-00 07-13

5. OIL JET
1) Overview
The oil jet is secured in the cylinder block with bolt. It injects the oil into the piston to cool the piston down.
This improves the thermic efficiency and performance. Its opening pressure is about 1.8 bar, and the
closing pressure is 1.0 bar.

2) Mounting Location and Components

Oil jet

Pipe

Plate

Body

Piston

Check valve

Spring

Plug

GETtheMANUALS.org
07-14

6. OIL PUMP OPERATING PROCESS

▶ When the VOP solenoid valve is ON

If the VOP solenoid valve is activated, then the valve will close the drain passage to the oil pan so that
the pressure can be sent to the 2nd chamber (F2). The discharge pressure of the oil pump will be sent to
the 1st chamber (F1). Therefore, the sum of both pressure (F1+F2) will be applied to the slide connected
to the spring and this force will compress the spring. At this time, the whole slide will move to increase
the gap with the rotor as shown in the right figure. Then the oil pressure will decrease because of the
changed volume ratio.

▶ When the VOP solenoid valve is OFF

If no power is supplied to the VOP solenoid valve, the oil from the main gallery will flow into the oil pan
through the VOP solenoid valve. Therefore, the pressure (F2) which compresses the spring will be lost and
the slide will move by the force from the released spring. Then the oil pressure will increase by the changed
volume ratio due to the reduced the gap between the rotor and the slide.

GETtheMANUALS.org
 0000-00 07-15

7. BOOST PRESSURE SENSOR

The oil pressure sensor measures the oil
pressure which turns on the warning lamp.
It works in conjunction with the coolant
temperature sensor to control the VOP
according to the oil viscosity and temperature.

8. OIL WARNING LAMP COMES IN WHEN

- Low engine oil level
- Faulty engine oil pressure sensor
- Insufficient circulation of engine oil
(oil filter or oil passage clogged)
- Fixing the solenoid valve of the oil pump
- All ranges: 0.5 bar or less
- 2 bar or less at 2,000 rpm
- 2.5 bar or less at 2,500 rpm

GETtheMANUALS.org
 0000-00 08-3

1. SPECIFICATIONS
Category Specifications
Cooler Type Forced circulation / water-cooled
Radiator Coolant flow type Cross flow
Core size (mm) AT 610W X 477.4H X 20T
MT 610W X 476.8H X 11.5T
Electric fan Type Electric
Capacity 350 W
Control type Resistor type (low/high)
Coolant reservoir tank Capacity 2.6L
Cap type / pressure Screw type / 1.4 bar
Thermostat Type Wax pellet type
Opening temperature 90 ± 2℃
Fully open temperature 100℃
Coolant Anti-freeze SYC 1025 (LLC)
Mixing ratio
50 : 50
(water:antifreeze)
Coolant capacity Approx. 6.6 L

GETtheMANUALS.org
08-4

2. PRECAUTIONS

- If 100% of anti-freeze is added, the water pump vane can be damaged and thermal conductivity
can be decreased resulting in poor circulation in the cooling system which leads to overheated
engine.
- Use of non-recommended coolant could form scales in the cooling system because of chemical
reaction. This restricts the flow in the cooling system and causes overheating and seizure of the
engine.
- Hot coolant or steam can spray out with great force when the coolant reservoir tank cap is opened
while the engine is running or hot, causing serious burns.
- To open the coolant reservoir cap, wrap the cap with a wet towel or thick cloth after the engine has
been cooled down sufficiently.
- If cold water is added while the engine is overheated, the engine or radiator can be
deformed.
- Anti-freeze can damage the painted surface. Avoid contact with the painted surface.
- Anti-freeze and water should be mixed in proper mixture ratio. Never add only water when the
coolant runs low.
- If the anti-freeze concentration is too low, there is a danger of freeze-up. If the anti-freeze
concentration is too high, it will reduce the cooling capacity of the system, resulting in overheating
of the engine.

GETtheMANUALS.org
 0000-00 08-5

1. OVERVIEW
The cooling system of the engine dissipates the heat generated by the running engine. The coolant is
forced to circulate by the water pump and cooled down in the radiator by heat exchange between the
coolant and the fresh air taken in through the cooling fan. Properly cooled down coolant in the radiator
flows into the engine to maintain the optimized engine operating temperature.
For a vehicle with A/T, the coolant also flows into the transmission oil cooler (TOC) of the A/T through
the heater core and absorbs the heat from the ATF (automatic transmission fluid) enough to maintain the
best operating temperature.
The electric fan is equipped with a resistor. The engine ECU controls the 2 electric fan relays which
determine the speed of the fan (high speed and low speed).

2. COMPONENTS

Radiator deaeration hose Coolant reservoir tank

Radiator Radiator inlet hose EWP inlet hose

Resistor

Engine deae-
ration hose

Make-up hose

Electric water pump

Air guide

Radiator outlet hose

Urea injector cooling hose

TOC TO ENG hose

Air guide ENG TO TOC hose

GETtheMANUALS.org
08-6

Water pump Thermostat Oil cooler

EGR cooler Cylinder block Cylinder head

inlet pipe outlet port outlet port

Coolant temperature sensor

TOC return pipe Heater return pipe (for a Hot water outlet pipe (for
(for a vehicle with A/T) vehicle with A/T) a vehicle with M/T)

GETtheMANUALS.org
 0000-00 08-7

3. EPC
▶ 1527 COOLING SYSTEM(D16DTF)

1. PUMP ASSY-WATER 22.GASKET-COOLANT BLOCK OUTLET

11.THERMOSTAT ASSY 38.BOLT
14.BOLT 43.HOSE-EGR COOLER INLET
20.PULLEY-WATER PUMP 44.CLAMP
21.PORT ASSY-COOLANT BLOCK OUTLET 45.PORT ASSY-COOLANT HEAD OUTLET

GETtheMANUALS.org
08-8

▶ 2112 RADIATOR & COOLING FAN

1. RADIATOR ASSY-COOLING
2. FAN MODULE
3. BRKT-MODULE MTG UPR
4. INSULATOR-MODULE MTG UPR
5. INSULATOR-MODULE MTG LWR
6. T/SCREW-MODULE MTG UPR
7. AIR GUIDE
9. SEAL-SIDE

GETtheMANUALS.org
 0000-00 08-9

▶ 2130 RADIATOR HOSE & PIPE

1. HOSE-RADIATOR INLET 12.HOSE-TOC TO ENGINE

2. HOSE-RADIATOR OUTLET 13.TANK ASSY-RESERVOIR
3. HOSE-MAKE UP 14.CAP-RESERVOIR TANK
4. HOSE ASSY-DEAERATION RADIATOR 16.CLAMP-WORM DRIVE TYPE SPRING
9. HOSE ASSY-DEAERATION ENGINE 17.CLAMP-WORM DRIVE TYPE SPRING
10.CLIP-DEAERATION TUBE MTG 18.SCREW-HEX SEMS_M6X1X20
11.HOSE-ENGINE TO TOC 19.CLAMP

GETtheMANUALS.org
08-10

▶ 1794 E.G.R VALVE(D16DTF)

1. VALVE ASSY-EGR 33.METER-AIR MASS

2. GASKET-EGR VALVE 34.SCREW
3. BOLT 35.RING-O
5. PIPE ASSY-EGR 36.PIPE ASSY-EGR COOLER INLET
7. GASKET-EGR PIPE 37.BOLT
12.COOLER ASSY-EGR 38.PIPE ASSY-HEATER RETURN TO T/M OIL COOLER
19.GASKET-EGR COOLER 40.PIPE ASSY-HOT WATER OUTLET
20.BOLT 42.PIPE ASSY-TOC RETURN
21.BOLT 43.RING-O
22.BOLT

GETtheMANUALS.org
 0000-00 08-11

1. OPERATING PROCESS
▶ For a vehicle with A/T

GETtheMANUALS.org
08-12

▶ For a vehicle with M/T

GETtheMANUALS.org
 0000-00 08-13

▶ Flow in cooling system

Coolant inlet Coolant outlet

To cylinder block To oil filter module

Water pump outlet

Oil drain
(Replace oil filter)

Water pump Bypass line

Oil filter inlet

Oil filter outlet

Oil pump → Cylinder block → Oil inlet → Oil cooler → Oil filter → Oil outlet

GETtheMANUALS.org
08-14

2. THERMOSTAT OPERATING PROCESS

Coolant temperature up Coolant temperature Coolant temperature 100˚C or

to 90˚C 90 to 100˚C higher

GETtheMANUALS.org
 0000-00 08-15

3. ELECTRIC FAN OPERATING PROCESS

1) Overview
The electric fan is installed on the rear side of the radiator. It brings in fresh air using the motor and
dissipates the heat generated by the running engine to improve the cooling performance. The electric
fan is operated by the engine ECU which controls the 2 electric fan relays (high speed and low speed).

2) Mounting Location and Components

Electric fan

Fan resistor connector Fan resistor

Fan blade

Shroud

GETtheMANUALS.org
08-16

4. CIRCUIT DIAGRAM
Electric fan circuit diagram

GETtheMANUALS.org
 0000-00 09-3

1. SPECIFICATIONS
Category Non-ISG ISG
Battery Capacity 80 Ah 70Ah
Type MF AMG
(Maintenance Free) (Absorbent Glass Mat)
Size 259 X 175 X 200 276 X 174 X 189
Weight 18 kg 21kg
Cold cranking ampere 630 A 760A
Reserve capacity 135 min 110min
Alternator Rated capacity 14V - 130A 14V - 130A

GETtheMANUALS.org
09-4

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

2. COMPONENTS
Alternator Charge warning lamp on Battery ground cable
instrument cluster

Battery positive cable Battery

GETtheMANUALS.org
 0000-00 09-5

3. EPC
▶ 2610 BATTERY & CABLE

1. BATTERY ASSY 8. BOLT

2. BOLT 10.TERMINAL-BATTERY POSITIVE
3. CLAMP ASSY-BATTERY 11.BRKT-BATTERY POSITIVE
5. WIRING ASSY-BATTERY POSITIVE 12.BATTERY COVER
6. WIRING ASSY-BATTERY NEGAITIVE 14.BATTERY COVER-PLASTIC
7. CABLE ASSY-BATTERY SENSOR 18.NUT

GETtheMANUALS.org
09-6

▶ 1451 ALTERNATOR(D16DTF)

1. ALTERNATOR ASSY
4. BOLT

GETtheMANUALS.org
 0000-00 09-7

1. INPUT/OUTPUT DIAGRAM
1) For a Vehicle with Smart Key

GETtheMANUALS.org
09-8

2) For a vehicle without smart key

GETtheMANUALS.org
 0000-00 09-9

2. OPERATING PROCESS
1) Alternator
The alternator uses a new regulator which has three diodes. It consists of the delta stator, rectifier bridge,
slip ring and brush.

▶ Charging time according to vehicle conditions and environment

Specification: Charging a fully depleted high-

capacity battery takes twice or more as long as
charging a fully depleted battery for small
vehicles.
Temperature: The lower the temperature is, the
longer the time taken to charge the battery.
When connecting the battery charger to the cold
battery, the amount of current the battery can
accept initially is very small. As the battery gets
warmer, it can accept more current.

Charging capacity: Charging a battery with a low-capacity charger takes longer time than charging with
a high-capacity charger.
Charging status: Charging a fully depleted battery takes twice or more as long as charging a half-
depleted battery. Since the electrolyte in a fully depleted battery consists of nearly pure water and
conductor, only a very small amount of current can be accepted by the battery initially. The charging
current increases as the amount of acids in the electrolyte is increased by the charging current.

2) Alternator Output Diagram Curve

Alternator 130 A

GETtheMANUALS.org
09-10

3) Characteristics
▶ Class

Batteries can be divided into two classes:

1. Reverse capacity rating: Designated at the temperature of 27℃, which is the time that a fully
charged battery can supply current of 25 A or higher and voltage of 10.5 V or higher.
2. Cold cranking ampere rating: Determined from the test performed at the temperature of -18℃,
and this indicates the cranking load capaci.

▶ Reverse capacity

Shows residual capacity of the storage battery, which is available in the event of failure of the vehicle's
generator. Duration time (min.) for which the fully charged storage battery is maintained at
temperature of 25 ± 2℃ and discharged continuously at current of 25 A until its voltage drops to
10.5 V.

▶ Cold cranking ampere

Shows engine start performance of the storage battery for starting. Discharge current at which voltage
becomes 7.2 V when battery is discharged for 30 seconds at temperature of -18℃.

- Electric unit in the vehicle are left on overnight.

- Frequent low speed driving for a short period of time.
- When the vehicle's electrical load exceeds the alternator output, particularly with the addition of
aftermarket equipment.
- Faults in the charge system, such as short circuit, slipping alternator belt and a malfunction of
alternator or voltage regulator.
- Contamination or poor contact of battery cable terminal or careless handling, such as loose
clamp.
- Short circuit or pinched wires.

GETtheMANUALS.org
 0000-00 09-11

▶ Charging a fully depleted battery (removed from vehicle)

Comply with the working procedures to avoid replacing the good battery unnecessarily. Charge the fully
discharged battery according to the following procedures:

1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is 10 V or
lower, the charging current is very low. It takes some time for the battery to accept the current in
excess of a few milli-amperes. Refer to "Charging time required" in this section. The ammeter
available in the field can't detect a very low current.

2. Set the battery on the high setting.

Some battery chargers feature a polarity protection circuit which protects the charger until its lead is
correctly connected to the battery terminal. Even though the lead is properly connected, a fully
discharged battery has too low voltage to activate this circuit and the battery may not accept the
charging current. Therefore, follow the manufacturer’s instruction for bypassing or overriding
the circuit, so that the battery is turned on and charged with a low voltage.

3. Keep charging the battery until the charging current can be measured. The battery charger varies the
amount of voltage and current provided. The time required for the battery to accept a measurable
charging current at various voltages is as follows:

Voltage Time
16.0 or higher Up to 4 hours
14.0~15.9 Up to 8 hours
13.9 or lower Up to 16 hours

- If the charging current is not measured when the maximum charging time is reached, the battery
should be replaced.
- If the charging current is measured during the charging time, the battery is in good condition. The
charging should be completed in the normal manner.
- If the charging current is still not measurable even after the charging time, calculated using the
calculated by the above method, has been passed, the battery should be replaced.

GETtheMANUALS.org
09-12

3. INTERNAL CIRCUIT DIAGRAM

GETtheMANUALS.org
GETtheMANUALS.org
09-14

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 09-15

GETtheMANUALS.org
 0000-00 10-3

1. SPECIFICATIONS
Category Specifications
Type Ceramic glow plug
Control Closed Loop Control
Glow plug
Rated voltage 12 V
Operating temperature 1,180 ± 50℃
Glow plug control voltage 5.4 to 7 V

Glow control unit Operating voltage 6 to 16 V

(GCU) Operating temperature -40 to 125℃
Dark current Max. 1 mA

GETtheMANUALS.org
10-4

2. CAUTIONS

How to handle ceramic glow plug

The ceramic glow plug is very sensitive and damaged easily due to the material property of
the heater fin. Therefore, the following precautions must be observed.

Ceramic heater fin Marking Insulation bush

▶ Transport and storage

- Avoid bulk package and securely wrap the items individually using an air cap etc.
- Package, transport and handling should be carried out according to the relevant guidelines and
procedures.
- Remove the packaging just before installation.

▶ Removal and installation

- Work on the ceramic glow plug should be carried out by a trained and authorized personnel
only.
- Perform the insulation test between the marking on the ceramic glow plug and the insulation bush
before installation.
- Make sure not to apply voltage of 5 V or higher when measuring the resistance value before
installation.
- Visually check the ceramic heater fin for damage before installation.
- Even if the ceramic glow plug is not damaged visually, do not use the one which is subject to different
shocks such as being caught, being struck, dropping (including low height) during removal and
installation since it is extremely sensitive to shock and bending.
- If the ceramic heater fin is broken while removing and installing the ceramic glow plug, be sure to
clean the inside of the engine before installing the engine in order to protect the engine from being
damaged by the broken pieces.
- When storing the cylinder head with the ceramic glow plug fitted, take care not to apply a mechanical
load to the ceramic glow plug.
- Do not carry out removal and installation for measuring the compression pressure, since the ceramic
glow plug may be damaged easily.
- Observe the specified tightening torque when installing.
- Perform the ground resistance measurement test.

GETtheMANUALS.org
 0000-00 10-5

3. GENERAL DEDICATED EQUIPMENTS

Part number and name General equipments
Part no.: SSM00701-003

Part Name: Glow Plug

Socket(D16DTF only)

Usage: Used to remove and

install glow plug

Seller:
http://www.toolntech.com

GETtheMANUALS.org
10-6

1. OVERVIEW
The glow control unit (GCU) of D16DTF engine activates the glow plug in the cylinder head (combustion
chamber) to improve cold start performance and to reduce exhaust gas generated at cold starting.
The ECU receives various information including the engine revolutions, coolant temperature, and engine
torque through CAN communication during pre-heating, and the GCU controls the pre-heating, heating
during cranking, and post-heating through PWM control.
The glow plug used in the D16DTF engine is a CGP (Ceramic Glow Plug) type, which reach the
temperature needed for ignition of 1,000℃ (Max. 1,200℃) in less than 2 seconds and is
controlled by the GCU.

2. COMPONENTS
Glow control unit Glow plug indicator

Glow plug Engine ECU

GETtheMANUALS.org
 0000-00 10-7

3. EPC
▶ 1414 ENGINE WIRING(D16DTF)

1. PLUG-GLOW 24.BOLT
2. WIRING ASSY-ENGINE MAIN 25.BRKT-WIDEBAND LAMBDA
10.WIRING ASSY-ENGINE EARTH 26.BOLT-HEX W/WAVE_M6x1x15
18.UNIT ASSY-GLOW CONTROL 30.BRKT-M/T
20.BRKT-IGNITION 31.BOLT
21.BRKT-ENGINE 32.BRKT-A/T
22.BOLT 33.BOLT
23.BOLT

GETtheMANUALS.org
10-8

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 10-9

2. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
10-10

GETtheMANUALS.org
 0000-00 10-11

▶ Full names of acronyms and option description

GETtheMANUALS.org
10-12

3. P-CAN INPUT/OUTPUT ELEMENTS

▶ ECU

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 10-13

4. OPERATING PROCESS
▶ Pre-heating: Step 1

When the power from the battery is supplied to the IG terminal and the communication with the ECU is
established successfully within 1 sec., the glow plug is energized by the ECU control. The GCU uses the
battery power to make glow plugs reach about 1,000℃ within 2 seconds (Max. 1,200℃).
- The pre-heating time is controlled by the ECU.

Coolant
temperature -30℃ -25℃ -20℃ -10℃ -5℃ 0℃ 20℃
(approx.)
Operating time 28 sec. 25 sec. 15 sec. 5 sec. 2 sec. 2 sec. 0 sec.
Pre- (approx.)
heating
Deactiv After operating time has
ation been passed
Operating IGN ON
conditi IGN OFF
conditions B+: 16 V or lower
ons When the engine is cranking

Craning after glowing indication lamp off

▶ Cranking : step 2 and step 3

- Step 2 duration is fixed.

- Pre-heating time at certain coolant temperature varies according to the vehicle operating conditions.

▶ Post-heating: Step 4

Post-heating is performed to reduce HC/CO after engine starting. If the post-heating is continued after
900 seconds, the GCU cuts the power to each glow plug regardless of the requests from the ECU.

Coolant temperature
(approx.) -20℃ -10℃ 0℃ 20℃ 30℃
Post-
heating
Operating time
(approx.) 100 sec. 50 sec. 25 sec. 10 sec. 10 sec.

▶ Emergency heating

If no CAN signal is received for 1 second from the engine ECU after receiving the ignition switch signal,
the GCU performs emergency heating for 180 seconds.

GETtheMANUALS.org
10-14

▶ Glow plug temperature control

The closed loop system detects the difference between the target pre-heating temperature and glow
plug temperature (measured value) to compensate the glow plug control voltage.

1. Duty control area: Between

5 and 100%
2. Frequency: 30 Hz
3. Duty ratio = (RMS voltage)²
(Battery voltage)²

▶ Glow plug self-learning

The closed loop system measures the characteristic values of the each glow plug (CGP type) and
records the values in the GCU. The GCU improves the temperature control efficiency of the glow plug
based on these values.

▶ Self-learning is necessary when: (start SIW)

- When glow control unit is replaced

- When glow plug is replaced
- When a glow plug characteristic related DTC is stored

▶ Finger print

Check the characteristic values of the glow plug each time glow demand is received in order to check if
the glow plug has been replaced randomly. If the stored characteristic value of the glow plug is not
identical with the measured one, re-learning is carried out after the ignition is turned off and new
fingerprint is created.

▶ Initialization of glow plug

The learning process of glow plug is carried out for each cylinder. The learned values must be initialized
with a SIW device when replacing the glow plug.

▶ Default glowing

In the event of CAN communication interruption or error, preheat the glow plug to 900℃.

GETtheMANUALS.org
 0000-00 10-15

▶ Intermediate glowing

If the fuel is not injected into the engine during prolonged downhill (engine brake activated), the glow plug
is activated to reduce the emission of exhaust gases.

▶ After run

If a warmed up engine is started again, the residual heat is detected to protect the glow plug by reducing
the energy required to warm-up.

▶ Power line-to-ground line voltage

The GCU of closed loop system monitors the current value, voltage value, and the time to control. If the
wiring is old, the GCU uses the aging value feedback. In this case, the pre-heating temperature control
will be incorrect. (Normal line-to-line voltage: 20 to 50 mV)

- Cool down the engine sufficiently (characteristic value changes at hot).

- Normal glow plug status
- Check the glow control unit and glow plug connector condition.
- Check the battery voltage (11V or more).
- Do not start the engine during self-learning.
- Do not disconnect the connectors during self-learning
- Check the engine variant information.

When the glow control unit is installed incorrectly, the safe mode is activated to protect the ceramic
glow plugs.

GETtheMANUALS.org
10-16

5. SYSTEM DIAGRAM

SPS : Smart Power Swetch

GETtheMANUALS.org
 0000-00 10-17

6. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 11-3

1. SPECIFICATIONS
Items Category Specifications
Start motor Rated voltage Non-ISG 1.7kW
ISG 1.8kW

GETtheMANUALS.org
11-4

1. OVERVIEW
The engine cannot start by itself. It needs starter motor which operates the crankshaft using external
force.
The starter (starter motor) starts the engine with rotational power by converting the electric energy to the
mechanical energy.
When the engine is cranking, the pinion gear meshes with the ring gear. If the ring gear overruns, the
pinion gear clutch overruns to protect the pinion gear.

2. COMPONENTS
Starter motor Battery positive cable ECU
(starter motor power
cable)

Battery Start relay

GETtheMANUALS.org
 0000-00 11-5

3. EPC
▶ 1461 STARTING MOTOR(D16DTF)

1. STARTER ASSY
2. BOLT

GETtheMANUALS.org
11-6

1. INPUT/OUTPUT CIRCUIT DIAGRAM

1) For a Vehicle with Smart Key
When the START/STOP button is pressed with the brake pedal applied and gear selector lever in P or N
position, the SKM performs the immobilizer verification. If it is valid, SKM sends the engine START
request signal to the ECU through the P-CAN and vehicle power status signal to the BCM through the B-
CAN. After the START signal from the SKM has been received, the ECU controls the start relay to drive
the starter motor.
The SKM cuts the power for IGN2 and ACC relays while the engine is cranking because cutting the
unnecessary electric load is required.

GETtheMANUALS.org
 0000-00 11-7

2) For a Vehicle with Ignition Key

When the ignition key is turned to ST position with the brake pedal (for a vehicle A/T) or clutch pedal (for
a vehicle M/T) applied and gear selector lever in P or N position, the TCU sends the engine START
signal to the ECU through the hard wire. The ECU controls the start relay to drive the starter motor.

GETtheMANUALS.org
11-8

2. START MOTOR OUTPUT

3. INTERNAL CIRCUIT DIAGRAM

GETtheMANUALS.org
GETtheMANUALS.org
11-10

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 11-11

GETtheMANUALS.org
 0000-00 12-3

1. SPECIFICATIONS
Category Specifications
Rated voltage DC 5 V

Cruise control Operating temperature -30°C to +80°C

switch
Switch type RES+/SET- Up/Down self return type
CRUISE Push self return type

GETtheMANUALS.org
12-4

2. CAUTIONS

- Take into consideration road safety while when driving at a constant speed using a cruise
control system. Always be prepare to depress the brake and accelerator pedals according
to the situations.
- The vehicle speed may vary and different from the set speed when driving up and down a
hill. Avoid using cruise control function when driving on hilly roads as much as possible. To
ensure safe driving and protect the vehicle, use the engine brake and foot brake properly
when driving on hilly roads.
- Always allow for extra distance between your vehicle and the vehicle ahead. Depress the brake
pedal, if needed.

3. WARNINGS

- Use the cruise control system when the vehicle is driven on a motorway or highway with
light traffic where the driving status is not expected to change suddenly by pedestrians and
traffic lights.
- In the following road conditions, you must stop using since there is a high risk of accidents due to
inability to control and other factors.
* Hard wind or crosswind
* Heavy traffic
* Slippery roads or hills

GETtheMANUALS.org
 0000-00 12-5

1. OVERVIEW
- The cruise control is an automatic speed control system that maintains a desired driving speed
without using the accelerator pedal.

- The speed limit system, speed limit, is a function that controls the vehicle so as not to exceed the
driving speed set by the driver. When the vehicle exceeds the limit speed, it warns the driver until the
vehicle speed returns to the limit speed. (Cruise control and speed limit can not be operated at the
same time since they have opposite functions.)

- The control is located on the right hand side of the steering wheel and consists of the following
buttons; Cruise control on/off, cruise control RES (+), SET (-), SET (+) and LIMIT.

- In order to activate the cruise control system, the driver must enter the cruise control "readiness"
status first by pressing the Cruise Control and Speed Limit switches.
This enables the driver to set the current speed using the SET (-) button and increase or decrease the
set speed using the + (ACCEL) or - (DECEL) button. This is to prevent the driver from operating the
cruise control switch accidentally while operating the steering wheel.

Cruise control: Enables vehicle to cruise at set speed

Speed Limit: Function to limit vehicle speed so as not to exceed set speed (prevents speeding and
saves fuel)

GETtheMANUALS.org
12-6

2. COMPONENTS
Indicators and display HECU
regarding cruise control

ECU Cruise control switch

GETtheMANUALS.org
 0000-00 12-7

1. INPUT/OUTPUT CIRCUIT DIAGRAM

GETtheMANUALS.org
12-8

2. CRUISE CONTROL & SPEED LIMIT CONTROL

1) Function Transition Of Cruise Control & Speed Limit

▶ When Cruise control / Speed limit is turned off, RESUME is not activated. (Set speed value
deleted)

(A)Cruise control active: RESUME is not activated when it is turned off with the LIMIT switch.
(B)Speed limit active: RESUME is not activated when it is turned off with the CRUISE switch.
RESUME is not activated if you operate the (C) CRUISE switch or (D) LIMIT switch when the speed
limit or cruise control is in READY mode.

▶ The initial operation of cruise control and speed limit (if there is no set speed value)

(E)Only possible with the SET switch.

GETtheMANUALS.org
 0000-00 12-9

3. HOW IT WORKS
1) How To Set Speed (Cruise Control ON)

Cruise control switch

CRUISE

SET(-)

1. Drive the vehicle at speed between 40 and 210 km/h (cruise control operating speed) by depressing
the accelerator pedal to activate the cruise control system.

2. Auto cruise set

a. Pressing the ON switch illuminates the auto cruise READY indicator on the instrument cluster and
puts the auto cruise system into READY mode.
b. Pressing the SET switch in the - direction activates the auto cruise at the current vehicle speed.
This turns off the auto cruise READY indicator and turns on the auto cruise ON indicator on the
instrument cluster.
c. After that, the vehicle is driven at the set speed (speed set when activating the cruise control
system) without accelerator pedal depressed.

3. Pressing the RES(+)/SET(-) button after the step "b" increases/decreases the set speed.

Operating the cruise control switch is carried out while the vehicle is driven. Therefore, make sure
that you fully understand and are familiar with the system before using the cruise control system.
Failure to do so may lead to fatal accidents.

GETtheMANUALS.org
12-10

2) Increasing Speed (ACCEL)

RES(+)

1. Operate the switch toward "RES+" until the desired speed is obtained while driving with the cruise
control set. Pressing and holding the switch (more than 0.8 sec) increases the speed by about 5 km/h
every 0.8 seconds.
2. To increase the speed in about 1 km/h increments, press the switch briefly (less than 0.8 sec).

3) Decreasing Speed (DECEL)

SET(-)

1. Operate the switch toward "RES +" until the desired speed is obtained while driving with the cruise
control set. Pressing and holding the switch (more than 0.8 sec) decreases the speed by about 5
km/h every 0.8 seconds.
2. To decrease the speed in about 1 km/h increments, press the switch briefly (less than 0.8 sec).

GETtheMANUALS.org
 0000-00 12-11

4) How to restore set speed (RESUME)

RES(+)

If the cruise control disable conditions are met while the cruise control is in active, the cruise control will
be deactivated. However, the previously set cruise control speed is stored in the ECU, and if you operate
the switch toward "RES+" it will return to the previous cruise control set speed.
The speed should be 40 km/h and the brake or accelerator pedal should not be depressed.

▶ RESUME (memorizing set speed value)

While the cruise control is in active, RESUME is not activated when it is turned off with the LIMIT switch.
RESUME is not activated if you press the CRUISE switch or LIMIT switch when the cruise control is in
READY mode.

Switch Operation type Switching to READY mode

CRUISE Briefly while returning to set speed (RESUME) (set speed stored)
+ / Res Briefly When current speed higher than set speed
(less than 0.8 s) - Increase set speed in increments of 1 km/h
Press and hold When current speed higher than set speed
(more than 0.8 s) - Increase set speed in increments of 5 km/h every 0.8 sec
- / Set Briefly When current speed lower than set speed
(less than 0.8 s) - Set to current vehicle speed
When current speed higher than set speed
- Decrease set speed in increments of 1 km/h

Press and hold When current speed higher than set speed
(more than 0.8 s) - Decrease set speed in increments of 5 km/h every 0.8 sec

GETtheMANUALS.org
12-12

5) To Cancel (CANCEL)
Auto cruise stopping conditions (CANCEL) (auto cruise activated → auto cruise ready)
- Depress the brake pedal or activate ESP.
- Drive the vehicle at less than 40 km/h.
- Apply the parking brake while the vehicle is driven.
- Depress the clutch pedal to change the gear.
- ON/OFF switch operation (once) during auto cruise activation

6) How To Deactivate (Cruise Control OFF)

ON/OFF
(CRUISE)

Auto cruise deactivating conditions (auto cruise ready → auto cruise deactivated)
- OFF switch operation (once) in auto cruise ready mode
- 15 sec. after ING OFF

GETtheMANUALS.org
 0000-00 12-13

4. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 13-3

1. SPECIFICATIONS
Category Specifications
E-EGR valve Motor Driven by DC motor
Operating voltage 12 V
Maximum temperature 180℃
Maximum lift 6 mm
Position sensor Sensing type Hall sensor
Power supply 5 V ± 10%
Signal range 5% to 95%
Maximum power < 15 mA
consumption
E-EGR cooler Cooling fin type Wavy fin
Cooler type U-shaped
E-EGR bypass valve Driven by Vacuum (Solenoid valve)

GETtheMANUALS.org
13-4

1. OVERVIEW
The EGR (Electric-Exhaust Gas Recirculation) valve reduces the NOx emission level by recirculating
some of the exhaust gas to the intake system to increase the CO₂ concentration in the air.
To meet the enhanced environmental legislations, the capacity and response rate of EGR valve in the
engine have been greatly improved. The EGR cooler with high capacity reduces the Nox, and the
bypass valve reduces the CO and HC due to EGR gas before warming up.

▶ Benefits of E-EGR valve

- Improved accuracy and response through electric control
- Newly added feedback function of EGR valve (Potentiometer)
- Preventing chattering of EGR valve and improved durability
- Self-cleaning function

EGR cooler

EGR pipe EGR valve EGR bypass

GETtheMANUALS.org
 0000-00 13-5

2. COMPONENTS
E-EGR valve EGR bypass solenoid valve HFM sensor

EGR pipe EGR cooler and bypass

EGR bypass EGR cooler

GETtheMANUALS.org
13-6

3. EPC
▶ 1794 E.G.R VALVE(D16DTF)

1. VALVE ASSY-EGR 33.METER-AIR MASS

2. GASKET-EGR VALVE 34.SCREW
3. BOLT 35.RING-O
5. PIPE ASSY-EGR 36.PIPE ASSY-EGR COOLER INLET
7. GASKET-EGR PIPE 37.BOLT-HEX W/WAVE_M6x1x15
12.COOLER ASSY-EGR 38.PIPE ASSY-HEATER RETURN TO T/M OIL
19.GASKET-EGR COOLER COOLER
20.BOLT 40.PIPE ASSY-HOT WATER OUTLET
21.BOLT 42.PIPE ASSY-TOC RETURN
22.BOLT 43.RING-O

GETtheMANUALS.org
 0000-00 13-7

1. INPUT/OUTPUT DEVICES

GETtheMANUALS.org
13-8

2. OPERATION PROCESS
1) Schematic Diagram

GETtheMANUALS.org
 0000-00 13-9

2) E-EGR Cooler Assembly Operation

▶ At normal engine operating temperature

When the engine reaches normal operating temperature, the E-EGR bypass valve is closed and the hot
exhaust gas is cooled down when it passes through the U-shaped E-EGR cooler.
The wavy fin is installed inside the E-EGR cooler to maximize the cooling efficiency.

EGR valve bypass

(OFF)

▶ When the engine is cold

EGR valve bypass

(ON)

GETtheMANUALS.org
13-10

- Coolant temperature

At 65ºC or less of coolant temperature, bypass the coolant flow since the cylinder temperature is
low and exhaust gas temperature is low.

- Exhaust gas temperature

At 150ºC or less of the exhaust gas temperature, the soot/PM increases further as the EGR gas
will be cooled down at low exhaust gas temperature when the coolant passes the EGR cooler.

GETtheMANUALS.org
 0000-00 13-11

3) Control Logic
The EGR system controls the EGR amount based on the map values shown below:
※ Main map value: Intake air volume
※ Auxiliary map value:
- Compensation by the coolant temperature
- Compensation by the atmospheric pressure: Altitude compensation
- Compensation by the boost pressure deviation (the difference between the requested value and the
measured value of boost pressure)
- Compensation by the engine load: During sudden acceleration
- Compensation by the intake air temperature
The engine ECU calculates the EGR amount by adding main map value (intake air volume) and auxiliary
map value and directly drives the solenoid valve in the E-EGR to regulate the opening extent of the EGR
valve and sends the feedback to the potentiometer.

(1) Operating conditions

- Intake air temperature: between -10 and 50℃
- Atmospheric pressure: 0.92 bar or more
- Engine coolant temperature: between 0 and 100°C
- When there is no fault code related to EGR

(2) Shut off conditions

- Abrupt acceleration: with engine speed of 2600 rpm or more
- When the engine is idling for more than 1 minute
- Vehicle speed: 100 km/h or more
- Engine torque: 380 Nm or more

GETtheMANUALS.org
 0000-00 14-3

1. CAUTIONS
▶ Standard pattern of soot accumulation

(1) Abnormal Soot Accumulation (2) Normal Soot Combustion

▶ Cautions to protect the catalyst filter

- Use the designated fuel only.

- Observe the recommended service intervals of engine oil.
- Check the engine oil level frequently and add if necessary.
- Do not idle the vehicle unnecessarily.
- Do not turn off the engine while the vehicle is running.
- Do not shift the gear selector lever to neutral when going downhill.
- Do not use improper engine oil or fuel additives.
- Do not drive for a long time when the warning lamp is illuminated.
- Make sure no flammable material, such as dry grass or tissue paper, contacts with the catalyst filter
while the vehicle is parked.
- For the vehicles used in urban traffic, driving on the expressways for more than 1 hour at least once
per week is needed so that the PM inside CDPF isn't collected to one side only.
- Use only Ssangyong genuine engine oil or MB 229.51 approved oil.

GETtheMANUALS.org
14-4

1) Designated Engine Oil for CDPF (Low Ash Oil)

1. Reasons to use

- The vehicle equipped with the LNT & DPF system, which reduces the soot, primary cause of
particulate matter in the air, should use the designated engine oil in order to guarantee the engine
performance, fuel economy and service life of LNT & DPF system.
- The soot formed when sulfur of different inorganic additives used atthe engine oil is burnt is not
regenerated even in the DPF. When this soot is burnt, ash is generated and piled up in the filter,
which causes the filter to be blocked.

2. Features and benefits

- Minimize content of ingredients, which lead to ash, in engine oil determining service life of CDPF
system
- Improve fuel economy by high performance and low viscosity, reduce CO₂ emissions
- Increase life of engine oil by high temperature high shearing

3. Potential problems of using non-designated engine oil

- Decreases the life span of engine oil due to accumulated ash in DPF (around 30%)
- Decreases the fuel economy due to friction resistance, exhaust gas resistance and frequent
recycling process of DPF

The fuel with high sulfur content such as tax-free oil or boiler oil may cause the same problems.

GETtheMANUALS.org
 0000-00 14-5

2) Do Not Use Fuel With High Sulfur Content

1. Producing white smoke during recycling

- The sulfur in exhaust gas is changed to sulfate gas during exhaust process. This sulfate gas is
shown as white smoke.

2. Producing odor during recycling

- The sulfur after oxidation may produce the odor.

3. Accumulation of ash

- The sulfur accumulated in DPF cannot be recycled. It reduces the life span of DPF.

3) White Smoke
The white smoke can be generated when the exhaust gas is recycled in the vehicle with LNT & DPF.
There are two reasons as below:

1. Saturated vapor
During regeneration, water vapor in the exhaust gas is drained into the air and cooled by the air. The
cooled water vapor is saturated, which results in condensation. When this is drained with the
exhaust gas, it is seen in the form of the white smoke. This is not caused by the vehicle but naturally
occurs. It is necessary to inform the customer of this information.

2. Sulfate
If you use the fuel with high sulfur content, the sulfur in the exhaust gas is generated in the form of
SO₄, which is sulfated in the exhaust process and seen in the form of white smoke. In this
case, the rear muffler may be discolored by the sulfur and misuse of fuel can be assumed. In order
to avoid white smoke caused by a sulphate, use a normal fuel.

GETtheMANUALS.org
14-6

1. OVERVIEW
The harmful exhaust gas generated from the diesel engine includes carbon monoxide (CO),
hydrocarbons (HC), and nitrogen oxides (NOx), and particulate matters (PM).

- EURO-V regulation
The CDPF system oxidizes HC and CO with DOC (Diesel Oxidation Catalyst) and collects PM with DPF,
and burns the PM to reduce the PM. The system reduces NOx through EGR without using the
aftertreatment device.

- EURO-VI regulation
The LNT & DPF system uses the Lean NOx Trap (LNT) to reduce the NOx emission. The LNT reduces
NOx emission by absorbing NOx in lean condition and reducing in rich condition, repeatedly.

During regeneration, LNT is not regenerated only; both LNT and DPF are regenerated at the same time.
If the EGR valve with much larger capacity is used, the NOx amount may be decreased. But, pushing the
exhaust gas (combustion gas) into the intake manifold again itself does not help a perfect combustion,
which leads to reduction of engine power. Therefore, for Euro Ⅵ, the NOx is absorbed into the
absorbing catalyst named LNT and is regenerated with the DPF before being drained.
The LNT system is the unit with the function of DOC as well as reductant which can absorb the NOx
additionally.

GETtheMANUALS.org
 0000-00 14-7

GETtheMANUALS.org
14-8

2. COMPONENTS
Booster pressure Intake manifold temperature Engine ECU
sensor sensor

Differential sensor Front temperature sensor

GETtheMANUALS.org
 0000-00 14-9

A. Front oxygen sensor B. Electronic throttle body

C. LNT & DPF (CDPF)

E. Rear oxygen sensor D. Rear temperature sensor

GETtheMANUALS.org
14-10

3. EPC
▶ 2413 EXHAUST SYSTEM(DSL:urea)

1. LNT & CDPF COMPL 10.HANGER

2. PIPE ASSY-EXHAUST FRT 12.HEAT PROTECTOR-EXHAUST CTR
3. SCR ASSY-EXHAUST 13.HEAT PROTECTOR-RR MUFFLER
4. PIPE ASSY-EXHAUST CTR 14.NUT
5. MUFFLER COMPL-RR 15.NUT
6. GASKET 17.PIPE ASSY-DIFF PRESS
7. HANGER 18.BOLT
8. HANGER 19.NUT
9. GASKET-CDPF

GETtheMANUALS.org
 0000-00 14-11

1. INPUT/OUTPUT DIAGRAM

1. Turbine EGT sensor: The sensor is mounted to the exhaust manifold outlet side. It prevents the
turbocharger from being damaged via post injections.
2. DPF EGT sensor: The sensor monitors whether the regeneration of the device is possible or not.
Differential pressure sensor: The sensor is installed to the front and rear side of the DPF and
3. calculates the amount of PM based on the measured pressure.
Electronic throttle body: The electronic throttle body increases the exhaust gas temperature by
4. reducing the intake air flow when the CDPF is activated during idling.
Differential pressure sensor, intake air flow, boost pressure: The amount of PM is calculated based
5. on the signals from the differential pressure sensor usually, and also the intake air flow, boost
pressure, and EGR ratio.

GETtheMANUALS.org
14-12

2. OPERATING PROCESS
1) LNT & DPF assembly operating process
(1) Oxidation of DOC
The DOC oxidizes HC and CO of the exhaust gas in the two-way catalytic converter at 180℃ or
more, and performs best at the temperature between 400 and 500℃. The front EGT sensor
detects whether the DOC can burn (oxidize) the post-injected fuel or not, and sends the signal to the
ECU to maintain the DOC operating temperature between 300 and 500℃. The DOC reduces CO
and HC of the exhaust gas by redox reaction and also reduces small amount of PM.

1. Oxygen adheres to the catalyst materials: Less than 180℃

2. CO and HC are oxidized by the catalyst materials: More than 180℃

GETtheMANUALS.org
 0000-00 14-13

(2) LNT Operation process

The LNT (Lean NOx Trap) cleans the CO and HC in the exhaust gas and stores the NOx generated in
air fuel ratio lean (normal driving) condition in the LNT catalyst system to reduce the NOx. If the
absorbed NOx is saturated, the LNT converts NOx into N2 by allowing post-injection to achieve rich
condition (supplying reductant).
The catalyst consists of Pt, Pd, and Rh with enhanced heat resistant in addition to Ba which is NOx
adsorption material.

▶ Normal driving mode (lean): Oxidization of NOx like DOC (adsorption)

▶ NOx reduction mode (rich): Desorption of NOx by post-injection

GETtheMANUALS.org
14-14

▶ LNT system clean

Normal driving mode (lean): Oxidization of NOx like DOC (adsorption)

- Normal driving mode with lean condition leads to higher NOx than CO and HC in all speed ranges.
The NOx is adsorbed on the catalyst film containing materials including Pt, Pd, and Ba.

▶ NOx reduction mode (rich): Desorption of NOx by post-injection

In rich condition, post-injection is carried out for reduction of the NOx adsorbed on the LNT.

GETtheMANUALS.org
 0000-00 14-15

2) Collecting PM of DPF
There is a filter installed in the DPF and the PM filtered by this filter is burned (regeneration) when the
temperature of exhaust gas is increased due to post-injection. The filter has a honeycomb-like structure
to capture the particulate matter and the inlet and outlet of each channel are closed alternatively. Once
the exhaust gas enters to the inlet of a channel, it is released from the outlet of the adjacent channel
through the porous wall because of the closed outlet of the first channel, and the PM is collected in the
first channel.

[Collecting PM of CDPF]

Normally, when the driving distance becomes approx. 600 to 1,200 km, enough amount of soot to
be burned is filtered and accumulated in the CDPF. The ECU increases the amount of fuel post-
injection to increase the temperature of the exhaust gas up to 670°C, so that the soot is
burned. The soot is burned for 15 to 20 minutes (may differ by conditions).

GETtheMANUALS.org
14-16

3) PM Regeneration of DPF
The differential pressure sensor installed in the DPF measures the pressure values of inlet and outlet of
CDPF. And the amount of the PM collected in the filter is calculated based on the exhaust temperature,
intake air mass flow, booster pressure, etc.
The regeneration is started when the amount of the collected PM is 28 g or more.
The ECU commands post-injection to increase the temperature of CDPF to 670℃.

(1) When the amount of the collected PM is not enough: The DPF works
as a filter.

(2) When enough amount of PM is collected: The ECU commands post-

injection and increase the exhaust gas temperature to start
regeneration.

GETtheMANUALS.org
 0000-00 14-17

4) Fuel injection
a. Multiple injection
The injection is largely carried out in 3 steps. The pilot injection occurs before the main injection and the
post injection occurs after the main injection.

▶ Pilot injection ▶ Multiple injection

GETtheMANUALS.org
14-18

b. Pilot injection
It occurs before main injection and there is two pilot injections, 1st and 2nd.
Before starting main injection, a small amount of fuel is injected to help proper combustion. It is also
called as pre-injection or combustion injection. This injection is for reducing NOx, engine noise and
vibration and controlling idle stability.
In other words, it prevents a severe combustion (diesel knock) to reduce NOx and reduce the engine
noise and vibration (suppressing the surging).
Basic values for pilot injection are adjusted according to the coolant temperature and intake air pressure.

Pilot injection deactivation conditions

- Pilot injection overtakes too much main injection due to increased engine rpm
- Low injection volume (low injection pressure, insufficient fuel for main injection, engine brake)
- System failure (fuel system, brake system)

▶ Characteristic curve of combustion chamber pressure during pilot injection

- Before starting main injection, a small amount of fuel is injected to reduce the engine noise and
vibration and inhibits generation of exhaust gas by slowing down pressure rise ratio in the combustion
chamber.

1. Pilot injection
2. Main injection
1a. Burst pressure with pilot injection
2b. Burst pressure without pilot injection

GETtheMANUALS.org
 0000-00 14-19

c. Main injection
Actual output from engine is achieved by main injection.
The main injection determines the pilot injection has been occurred, then calculates the injection volume.
Accelerator pedal sensor, engine rpm, coolant temperature, intake air temperature, booster
pressure/temperature and atmospheric pressure are basic data to calculate the fuel injection volume in
main injection.

d. Post injection
Post injection occurs after main injection and there are 2 injections, post 1 and post 2. These are mostly
related to PM or smoke escaping though exhaust gas. It actually generates no power and activates the
fuel by injecting fuel to an unburned gas after main combustion. In this way, it reduces PM and smoke.
All these injections are not carried out while driving. Total 5 injections can occur within one cycle.
If all seven injections occur, there may be any loss in terms of exhaust gas as well as fuel economy.

GETtheMANUALS.org
14-20

3. DESCRIPTION ON REGENERATION
Number Sensor item data Unit Description

1 Total amount of soot 0 g Soot amount detected by ECU

(reference value)

Regeneration The regeneration distance/time is stored up to

information index (Start the last 5 events in sequence and the oldest
2 conditions/end 0 - one will be deleted if the number of events is
conditions/regeneration exceeded 5 times.
history) The currently displayed regeneration history
index value indicates where the regeneration
information is stored currently and the just
Regeneration previous value shows the last regeneration
information index information.
(driving distance/time E.g.) Regeneration history index value: 3
3 0 - (Last regeneration information stored at 2)
taken for
regeneration/amount of
fuel injected)

Engine running time Cumulative engine running time after

4 after last regeneration 0 sec regeneration

Distance driven
5 between regenerations 0 km
[0]
Distance driven
6 between regenerations 0 km
[1]
Distance driven
between regenerations Distance driven between end and start of
7 0 km
[2] regeneration for the last 5 times

Distance driven
8 between regenerations 0 km
[3]
Distance driven
9 between regenerations 0 km
[4]
10 Regeneration time [0] 0.0 sec
11 Regeneration time [1] 0.0 sec
Each regeneration time for the last 5 times
12 Regeneration time [2] 0.0 sec
(sec)
13 Regeneration time [3] 0.0 sec
14 Regeneration time [4] 0.0 sec

GETtheMANUALS.org
 0000-00 14-21

Number Sensor item data Unit Description

Regeneration Items for The regeneration start conditions are
15 start condition [0] starting - displayed
regeneration in the following items.
Regeneration Items for
16 start condition [1] starting - - Items for starting regeneration
regeneration No regeneration required / distance
Regeneration Items for driven / past history / amount of
17 start condition [2] starting - discharged soot / amount of trapped
regeneration soot / modeled value / forced
Regeneration regeneration / driving time /
Items for
start condition [3] - desulfurization / external conditions
18 starting
regeneration
Regeneration Items for
19 start condition [4] starting -
regeneration
Regeneration Items for
20 termination terminating -
condition [0] regeneration The regeneration termination conditions
are displayed in the following items.
Regeneration Items for
21 termination terminating -
- Items for terminating regeneration
condition [1] regeneration
Regeneration Items for
termination - Regeneration in progress / amount of
22 terminating
condition [2] trapped soot / modeled value / forced
regeneration
termination
Regeneration Items for
23 termination terminating -
condition [3] regeneration
Regeneration Items for
24 termination terminating -
condition [4] regeneration
Regeneration Success/failure -
25
history [0]
Regeneration Success/failure -
26
history [1]
Regeneration Success/failure - Information on whether success/failure of
27
history [2] last 5 regenerations
Regeneration Success/failure -
28
history [3]
Regeneration Success/failure -
29
history [4]

GETtheMANUALS.org
14-22

Number Sensor item data Unit Description

Information on Normal/
30 regeneration Low efficiency -
efficiency [0]
Information on Normal/
31 regeneration Low efficiency -
efficiency [1]
Information on Normal/
Information on whether Normal/Low
32 regeneration Low efficiency -
efficiency of last 5 regenerations
efficiency [2]
Information on Normal/
33 regeneration Low efficiency -
efficiency [3]
Information on Normal/
34 regeneration Low efficiency -
efficiency [4]
Fuel injection
35 amount between 0 L
regenerations [0]
Fuel injection
36 amount between 0 L
regenerations [1]
Fuel injection Fuel consumption between last
37 amount between 0 L regeneration and current regeneration
regenerations [2]
Fuel injection
38 amount between 0 L
regenerations [3]
Fuel injection
39 amount between 0 L
regenerations [4]
Displays the current status of
regeneration start conditions.

- Items for starting regeneration

Items for
Regeneration start starting - No regeneration required / distance
40 condition regeneration driven / past history / amount of
discharged soot / amount of trapped
soot / modeled value / forced
regeneration / driving time /
desulfurization / external conditions

GETtheMANUALS.org
 0000-00 14-23

Number Sensor item data Unit Description

Cumulative number of times of
Total number of times of
regeneration start by time when driving
41 regeneration start 0 Times
vehicle for a certain period of time
(driving time)

Total number of times of Total cumulative number of times of

42 regeneration start regeneration start by predetermined
0 Times
(distance driven) distance driven
Total number of times of
Total cumulative number of times of
regeneration start
43 regeneration start by differential
(differential pressure 0 Times
pressure sensor
sensor)
Total number of times of
regeneration start Total cumulative number of times of
44 regeneration start by discharged soot
(discharged soot amount) 0 Times
amount

Total number of times of Total cumulative number of times of

45 regeneration start 0 Times regeneration start by modeled soot
(modeled soot amount) amount
Total number of times of
Total cumulative number of times of
regeneration start Times
46 0 regeneration start by accumulated sulfur
(accumulated sulfur
amount in LNT
amount)
Total number of times of
Total cumulative number of times of
regeneration start Times
47 0 forced regenerations by diagnostic
(SIW, forced regeneration)
device

Total number of times of

Total number of times of forced
48 regeneration start 0 Times regeneration start by engine idle
(SIW, idle)
Total number of times of
Total number of times of regeneration
49 regeneration start 0 - start in driving mode
(SIW, driving)
Average temperature of previous
several times of regenerations and total
Total number of times of
- cumulative number of times of
50 regeneration start 0
regenerations by regeneration status
(History)
when average exhaust flow during
regeneration is low

GETtheMANUALS.org
14-24

Number Sensor item data Unit Description

Total number of times
regeneration termination Total number of times of idle
51 0 -
(Idle forced regeneration) regeneration termination

Total number of times Total number of times of regeneration

52 regeneration termination 0 - termination by modeled soot amount
(modeled soot amount)
Total number of times
Total number of times of regeneration
regeneration termination -
53 0 termination by differential pressure
(differential pressure
sensor
sensor)
Total number of times
Total number of times of regeneration
regeneration termination -
54 0 termination in driving mode
(driving forced
regeneration)
Number of times of ECU Number of times of ECU
55 0 Times
replacement initialization/replacement
Number of times of DPF Number of times of DPF
56 0 Times
replacement initialization/replacement
Number of times of Number of times of differential pressure
57 differential pressure sensor 0 Times sensor initialization/replacement
replacement
Driven distance since last Cumulative distance driven since
58 regeneration 0 Km termination of last successful/failed
(all) regeneration
Driven distance since last Cumulative distance driven since
59 regeneration 0 Km termination of last successful
(successful) regeneration
Cumulative regeneration
Total cumulative regeneration time until
time 0 sec
60 now when regeneration successfully
(successfully completed)
completed

Cumulative regeneration Total cumulative forced regeneration

61 time 0 sec time by diagnostic device
(forced regeneration)

GETtheMANUALS.org
 0000-00 14-25

Number Sensor item data Unit Description

Total cumulative regeneration time until
62 Cumulative regeneration 0 sec now
time (all)
(incl. failed regeneration)

63 Counter for excessive 0 - Counter to detect whether regeneration

regeneration occurs frequently

64 Excessive number of times 0 - Total number of times of excessive

of regeneration regeneration reset

65 Total amount of discharged 0 g Cumulative amount of soot discharged

soot from engine

66 Soot amount (distance 0 - Soot amount by distance driven and

driven) driving condition

67 Soot amount 0 - Soot amount compensated by modeling

(SSMD compensation)
Soot amount Soot amount used for troubleshooting
68 (differential pressure, for 0 g DPF
troubleshooting)
Soot amount Modeled soot amount for
69 (modeled vale, for 0 g troubleshooting DPF
troubleshooting)

70 Maximum soot amount 0 - Max. soot amount used for

(differential pressure) troubleshooting DPF
Time at which regeneration start
delayed due to unmet conditions from
71 Regeneration delay time 0 sec
regeneration reset to regeneration start

- Displays status in which DPF loading

72 DPF status
never occurs
FALSE/ Displays PM sensor cycle to check DPF
73 PM sensor cycle TRUE -
efficiency

74 Differential pressure sensor - Displays differential pressure sensor

learning status learning completed

75 Differential pressure sensor 0 - Learning value of differential pressure

learning value sensor

76 Number of times of 0 - Number of times ash learning

successful ash learning completed successfully

77 Number of times of failed 0 - Number of times ash learning failed

ash learning

GETtheMANUALS.org
14-26

Number Sensor item data Unit Description

78 Total cumulative injection 0 -

quantity
Total cumulative amount of injected fuel
Total cumulative injection
79 quantity 0 -
(Accurate)
Final cumulative injection Cumulative injection quantity at the end
80 quantity 0 L of ash learning
(fuel_learnt_coef)
Final cumulative injection Cumulative injection quantity at the end
81 quantity 0 L of regeneration
(last_regen_fuel)
Engine running time since Engine running time since last
82 end of last regeneration 0 sec regeneration ended

83 Distance driven at the time 0 Km Distance driven at the time of last ash
of last learning learning
Distance driven at the time Learned value of clean filter after ash
84 of end of A1 learning 0 Km learning

85 Equivalent pressure 0 kPa Soot amount used for troubleshooting

DPF
Soot amount correction
86 value 0 g
(SSMD_offset) Calculated value for compensating
Soot amount correction modeled soot amount
87 value 0 g
(SSMD_offset_1)

88 A1 correction value 0 1/ml Learned value of clean filter after ash

learning
Equivalent value of
Equivalent value of DPF differential
89 differential pressure 0 kPa pressure increase due to soot and ash
increase
in DPF
(soot, ash)
Equivalent value of
Equivalent value of DPF differential
90 differential pressure 0 kPa pressure increase due to soot in DPF
increase
(soot)

GETtheMANUALS.org
 0000-00 14-27

4. WARNING LAMP RELATED TO LNT & DPF

▶ LNT & DPF regeneration process (warning lamp NOT illuminated)

The LNT & DPF system enters the regeneration

mode when the driving distance becomes
approx. 600 to 1,200 km (may differ by the
driving condition and driving style). Then, the
engine ECU performs the LNT & DPF
regeneration operation. However, the driver is
not informed 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 (by the throttle
body) in order to increase the temperature of the
exhaust gas. The driver may not feel any
particular difference from the vehicle.

▶ Overload of LNT & DPF (warning lamp blinking)

1. If the LNT & DPF cannot reach the

regeneration temperature due to low speed
driving or other reason during the
regeneration process, the soot is
continuously accumulated in the LNT &
DPF. When this condition continues and
the LNT & DPF is overloaded with soot, the
engine warning lamp blinks to inform 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 LNT & DPF
regeneration process.
3. If the engine warning lamp on the
instrument cluster blinks, the LNT & DPF is
overloaded. In this case, perform the step 2.

GETtheMANUALS.org
14-28

▶ Excessive overload of LNT & DPF (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
accumulated in the LNT & DPF cannot be
burned as the LNT & DPF cannot reach the
regeneration temperature. Then, an excessive
amount of soot can be accumulated in the LNT
& DPF.
2. This case is much worse than the simple over-
load of the LNT & DPF. To inform this to the
driver, the engine warning lamp comes on and
the engine power is decreased to protect the
system.
3. To solve this problem, blow soot between the
engine 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.

GETtheMANUALS.org
 0000-00 14-29

5. POST-INJECTION AND AIR MASS CONTROL

A DPS (Differential Pressure Sensor) measures the pressure difference between before and after the
CDPF and detects whether the soot is collected in the CDPF or not. If PM is collected in the CDPF (In
this case the pressure difference between before and after the CDPF exceeds the specified value.
Normally, the system sends the signal when the driving distance becomes approx. 200 to 1,200 km),
the temperature of exhaust gas is increased and the post-injection is started for regeneration. The
amount of fuel post-injection is controlled by the exhaust gas temperature measured by the rear
temperature sensor. If the temperature is less than 600℃, the amount of post-injection is
increased to increase the regeneration temperature. Otherwise, the fuel injection amount is decreased
or the fuel is not injected.
When the engine is running with low load, the intake air amount is also controlled as well as fuel
injection amount. This function is used to increaser the combustion temperature by increasing the
amount of fuel post-injection with the lowest air amount within the specified control logic.

GETtheMANUALS.org
14-30

HFM sensor

Turbine EGT sensor DPF EGT sensor

Intake air
volume

ECU
Measures the temperature of
LNT & DPF.
Measures the
temperature of DOC. The sensor monitors whether
the regeneration of the device
The sensor is mounted to the
is possible or not.
exhaust manifold outlet side. It
prevents the turbocharger from
being damaged via post injections.
Injector (C3I)

Detecting
Differential pressure excess of PM
sensor
amount limit

Controls the
post-injection.
Boost pressure/
temperature Electric throttle body

Measures the pressure values of

before and after the LNT & DPF.
Boost pressure sensor
The sensor is installed to the front
and rear side of the DPF and
calculates the amount of PM based Controls the
on the measured pressure. intake air volume.

GETtheMANUALS.org
 0000-00 14-31

6. OPERATING TEMPERATURE

GETtheMANUALS.org
14-32

7. CONDITIONS FOR FORCED LNT & DPF REGENERATION

▶ Forced DPF regeneration (while idling)

Function to carry out DPF regeneration while idling

Item Condition
Vehicle status Idling
Vehicle speed 0km/h
Shift lever P
Accelerator pedal 0%
Coolant temperature 60℃ or higher
Trapped DPF amount Below 157%

▶ Forced DPF regeneration (while driving)

Function to carry out DPF regeneration while driving

Item Condition
Vehicle status Idling
Vehicle speed 0km/h
Coolant temperature 60℃ or higher
Trapped DPF amount Below 125%
Vehicle speed after mode activation 30 km/h or higher

▶ LNT Desulfurization

Function to carry out DPF desulfurization while driving

Item Condition
Vehicle status Idling
Vehicle speed 0km/h
Coolant temperature 70℃ or higher
Trapped LNT amount 60% or higher
Vehicle speed after mode activation 50 km/h or higher

GETtheMANUALS.org
 0000-00 15-3

1. SPECIFICATIONS
Item Item SPECIFICATIONS
Type BLDC motor & gear pump
Pressure 5.8 bar
Pump
Pumping volume 3 ℓ/h or more

Type Flexible silicone

DCU & supply Power consumption

85W (11V)
module Heater
2,700 sec. or less (at -25℃)
Thawing time 1,950 sec. or less (at -20℃)
1,200 sec. or less (at -15℃)
±2 mm (15 ~ 40 mm)
Sensor calculation
Level ±5% (40 ~ 350 mm)
Full level detected 11ℓ
Urea tank Volume 12ℓ
Urea injector Operating temperature -10 ~ 120℃
Resistance 2.7 ± 0.5 (20℃)
Urea supply (heating)
Current consumption 4.6 ± 0.9A
tube
Power consumption 55 ± 11W(12V)
Volume 20W

Electric water pump Control type PWM

Operating temperature -40 ~ 120℃
Noise 40 dB or less
Urea Type ISO 22241 or DIN 70070

GETtheMANUALS.org
15-4

2. NOTES

- When the ignition is turned off, the operating sound from the electric water pump (EWP) and the
pump for the DCU & supply module may be heard, which is to prevent the urea from being
crystallized. This is normal symptom.
- The urea is frozen at -11℃. If the urea in the urea tank is frozen, the urea pump (supply
module) does not work. The tank heater fitted to the supply module should heat to -10℃ or
higher before the pump for the DCU & supply module can be operated.

3. CAUTIONS

- Do not disassemble each part since the DCU & supply module is integral.
- Do not reuse the gasket or clamp to prevent the exhaust gas from being leaked.
- Take care not to let any other material than urea enter through the urea filler.
- Otherwise, harmful exhaust gas may be emitted and the SCR warning lamp may be lit while
operating the vehicle.
- When the low urea level warning message is displayed for the first time, replenish the urea within
2,400 km of driving. Even after the warning, if the urea is depleted in the tank without replenishing the
urea, it is impossible to restart the engine after the ignition is turned off.
- The urea should be stored in the bottle made of iron, copper, galvanized steel and copper alloy.
Caution should be taken not to allow foreign substances to enter the bottle. If foreign substances
(iron, calcium, copper, zinc, aluminum, etc.) are mixed or the urea is deteriorated, which may cause
the metal components to dissolve and damage the SCR system.
- When disposing of urea, it should be diluted with water more than 10 times by volume.
- Filling water, fuel, additive or other fluids into the urea tank causes the urea purity to be
spoiled, which may result in failure of the SCR system. Do not add any substance other than
urea.
- When the urea out of specifications or impurities are entered, it increases nitrogen oxides and
exhaust emissions and may lead to malfunction of the SCR system including the catalyst.
- When you drain the urea out of the urea tank, do not fill the drained urea into the urea tank again.
The purity of the drained urea is not guaranteed to be appropriate. When filling urea, always use new
one.

GETtheMANUALS.org
 0000-00 15-5

4. SPECIAL TOOLS
Part number and name Special tools Usage
Part no.: Y99220010A

Name:
Installation and removal
equipment for urea pump module
(ADM)

Usage:
Lock or unlock DCU & supply
module CamLock

GETtheMANUALS.org
15-6

1. OVERVIEW
The harmful exhaust gas generated from the diesel engine includes carbon monoxide (CO),
hydrocarbons (HC), and nitrogen oxides (NOx), and particulate matters (PM). To reduce these harmful
exhaust elements, the emission measurement method has been certified through the Worldwide
Harmonized Light-duty vehicle Test Procedure (WLTP) or Real Driving Emission (RDE).
According to the WLTP, test driving time increases from 1,180 seconds to 1,800 seconds and driving
distance increases from 11 km to 23.26 km compared to existing European fuel efficiency measurement
method. The average speed increases from 33.6 ㎞/h to 46.5 ㎞/h, the maximum speed from
120 ㎞/h to 131.3㎞/h.
The longer the driving distance is and the faster the vehicle speed, the higher the engine temperature
and the more emissions are generated. However, when it comes to the permissible emission standards,
the NOx emissions should be the same as at present, i.e., 0.08 g per kilometer. In addition, RDE test
measures and certifies the emission level on the diesel vehicle under various driving conditions such as
rapid acceleration and braking, hill driving, driving with the air conditioner on and at high and low
temperatures while driven on the road. The first phase, Tier 1, goes into effect on September 2017 and
this requires to meet less than 0.168 g/㎞ of NOx emissions, equivalent to 2.1 times the laboratory
standard. The stricter Tier 2 standards (0.12 g/km, which is 1.5 times that of the laboratory) will take
effect on January 2020.
The SCR system is used to cover the exhaust gas temperature range, which is difficult to reduce in LNT
when reducing nitrogen oxide (called NOx hereinafter) in conventional LNT & DPF system in order to
meet these ever-escalating emission controls.
The urea is injected from the urea injector mounted on the upstream of the SCR catalyst and is evenly
distributed in the SCR catalyst while passing through the mixer. As the exhaust gas passes through the
SCR catalyst, the harmful NOx in the exhaust gas chemically reacts with NH₃ in the SCR catalyst
to produce water and nitrogen, thereby reducing NOx.
The SCR system consists of the DCU & supply module, urea tank, urea injector, urea supply (heating)
tube, EWP (electric water pump) and SCR catalyst.

- WLTP: Worldwide Harmonized Light Vehicles Test Procedure

- RDE: Real Driving Emission
- SCR: Selective Catalytic Reduction
- DCU: Dosing Control Unit
- EWP: Electric Water Pump

GETtheMANUALS.org
 0000-00 15-7

1) Configurations

A. HFM sensor A. Swirl actuator

B. Actuator feedback B. EGR bypass actuator
C. Throttle position feedback C. EGR valve
D. Boost pressure sensor D. VGT actuator
E. Intake manifold temperature sensor E. DCU & supply module (pump)
F. Swirl control feedback F. EWP (electric water pump)
G. EGR valve feedback G. Urea injector
H. Turbine EGT sensor
I. Actuator feedback
J. Front oxygen sensor
K. DPF EGT sensor
L. Differential pressure sensor
M. Rear oxygen sensor
N. Front NOx sensor
O. SCR EGT sensor
P. PM sensor
Q. Rear NOx sensor

GETtheMANUALS.org
15-8

2. COMPONENTS
SCR catalyst

Urea tank assembly

DCU & supply module

GETtheMANUALS.org
 0000-00 15-9

EWP (electric water pump)

Urea injector

Urea supply (heating) tube

GETtheMANUALS.org
15-10

3. EPC
▶ 2250 Urea tank (DSL: urea)

1. UREA TANK MODULE

2. FILLER ASSY-UREA
3. CAP ASSY-UREA
4. NUT ASSY-WASHER
5. SCRIVET
6. SCREW-HEX SEMS_M6X1X20
7. O RING-SEAL
8. PUMP ASSY-UREA
10.NUT

GETtheMANUALS.org
 0000-00 15-11

▶ 2251 injector & line (DSL: urea)

1. TUBE ASSY-UREA SUPPLY

2. INJECTOR ASSY-UREA
3. CLAMP

GETtheMANUALS.org
15-12

▶ 2252 electric water pump system (DSL: urea)

1. HOSE ASSY-CONNECTOR TO EWP

2. HOSE ASSY-ENG TO CONNECTOR
3. TUBE ASSY-INJECTOR COOLING
4. WATER PUMP ASSY-ELECTRIC
5. BRKT-ELECTRIC WATER PUMP
6. NUT-HOOD LATCH MTG

GETtheMANUALS.org
 0000-00 15-13

▶ 2413 Exhaust system (DSL: urea)

1. LNT & CDPF COMPL 10.HANGER

2. PIPE ASSY-EXHAUST FRT 12.HEAT PROTECTOR-EXHAUST CTR
3. SCR ASSY-EXHAUST 13.HEAT PROTECTOR-RR MUFFLER
4. PIPE ASSY-EXHAUST CTR 14.NUT
5. MUFFLER COMPL-RR 15.NUT
6. GASKET 17.PIPE ASSY-DIFF PRESS
7. HANGER 18.BOLT
8. HANGER 19.NUT
9. GASKET-CDPF

GETtheMANUALS.org
15-14

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 15-15

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
15-16

GETtheMANUALS.org
 0000-00 15-17

▶ Full names of acronyms and option description

GETtheMANUALS.org
15-18

3. OPERATION PROCESS
1) Overview
The ECU determines the urea injection time according to the NOx emissions in the exhaust gas and
sends the request signal to the DCU. The DCU controls the urea injector to inject the urea. The ECU
enables the DCU to control the quantity injected from the urea injector using the feedback value provided
by the front and rear NOx sensors.
In addition, it adjusts the urea injection quantity depending on the SCR temperature and engine load.

2) Judgment of Urea Quality

The urea quality is judged by comparing the NOx concentration detected by the front/rear NOx sensors
with the urea injection degree. If the NOx concentration measured by the front and rear NOx sensors is
the same even though the urea is injected from the urea injector, the urea is judged as inadequate.

GETtheMANUALS.org
 0000-00 15-19

3) NOx Reducing Process

A. The ECU measures the exhaust gas temperature using the SCR EGT sensor and receives the
information on NOx amount as a CAN signal from the NOx sensor control unit.
B. The ECU detects the concentration difference between the front and rear NOx sensors, judges SCR
efficiency, determines urea injection quantity and gets the SCR efficiency to be calibrated to control
the urea injection feedback.
C. The DCU provides power to the urea injector as an electric signal to inject urea to the mixer in the
SCR catalyst.
D. The urea is spayed by the mixer and ammonia (NH₃) contained in the urea is absorbed into
the absorption plate in the SCR catalyst.
E. As the exhaust gas passes through the SCR complete, NOx chemically reacts with ammonia
(NH₃) and is reduced to nitrogen (N₂) and water (H₂O).
F. The exhaust gas with reduced NOx is discharged to the atmosphere through the muffler.
G. The urea injection quantity depends on the SCR temperature, ammonia content in SCR calculated by
the ECU and NOx emissions based on the engine load.

GETtheMANUALS.org
15-20

4. DCU (DOSING CONTROL UNIT) & SUPPLY MODULE

1) Function
- Urea tank heater control
- Urea supply (heating) tube control
- Urea line pressure control and urea purge
- Urea level detection
- DCU initialization and diagnosis

▶ Description

Supply pump

Urea level sensor

Urea filter

Magnetic float

Pressure sensor

Urea temperature sensor

Urea tank heater

DCU

GETtheMANUALS.org
 0000-00 15-21

(1) Urea tank heater control

The urea is frozen at the temperature of -11℃ or less. If so, the urea has to be thawed. The DCU
& supply module is equipped with the urea temperature sensor and tank heater. When the urea
temperature in the tank is low or becomes low while driving, the DCU turns on the tank heater. When the
urea temperature rises to an appropriate level, the DCU turns off the tank heater.

Tank heater OFF → ON

- Urea temperature in tank below -5℃

Tank heater ON → OFF

- Urea temperature in tank -3℃ or higher

GETtheMANUALS.org
15-22

(2) Urea supply (heating) tube control

If the urea is frozen at the temperature of -11℃ or less, it has to be thawed for use. Since the
urea supply tube is exposed to the outside, it may be frozen depending on the ambient temperature. The
power is supplied to the heater coil wound over the urea tube, based on the temperature data
(0℃ or lower) from the ambient temperature sensor to thaw the urea in the urea supply tube. The
urea supply tube heater must thaw the urea line continuously to supply the urea to the urea injector.
When the temperature measured at the ambient temperature sensor falls below 0℃, the urea
supply tube heater is turned on and when 0℃ or higher, it is turned off.

Supply tube heater OFF → ON

- Ambient temperature below 0℃

Supply tube heater ON → OFF

- Ambient temperature 0℃ or higher

GETtheMANUALS.org
 0000-00 15-23

(3) Urea supply pump

The DCU & supply module is equipped with the pressure sensor, check valve and urea pump. The urea
pump pumps up the urea and the check valve returns the urea to the tank to maintain the pressure. The
pressure sensor checks if the urea pressure is normal or not.

▶ Description

Urea line pressure: 5.8 bar

▶ Urea purge

The urea pump consists of the BLDC (BrushLess Direct Current) motor and gear pump. It pumps up the
urea into the urea supply tube. In winter, it rotates in reverse and empties the urea supply tube by
purging the urea in the urea supply tube to prevent the urea in the urea supply tube from being frozen
when the ignition is turned off.

GETtheMANUALS.org
15-24

(4) Urea level sensor

It is mounted on the DCU & supply module and uses a non-contact PWG (Pulse Wave Guide) sensor
method. The PWG type sensor uses a magnet to transmit the self-generated radio wave along a sensor
element, which is a waveguide (a metal tube used to transmit radio wave), and this signal is reflected at
the magnetic float position. The urea level is measured by using the fact that the interval between the
time the transmission started and the time the signal is reflected is proportional to the distance between
the starting point of the waveguide and the magnet.
The urea level is basic information for calculating the remaining drivable distance.

▶ Schematic diagram for measuring urea level

Urea empty Urea full (12ℓ)

GETtheMANUALS.org
 0000-00 15-25

(5) Urea Pressure Sensor

It maintains the urea pressure constant through the injector and urea supply tube and is required to drive
the urea pump.
It detects the relative pressure through the signal conditioning IC in it.

Pressure sensor

GETtheMANUALS.org
15-26

5. UREA INJECTOR
1) Internal Structure

1. Injector tip (nozzle)

2. Injector coil
3. Coolant inlet
4. Coolant outlet
5. Urea inlet

▶ Laws and regulations for urea injector

If the urea injector is exposed to a temperature of -15℃ for more than 7 days, you should idle the
engine for 20 minutes and the urea injector should be state of readiness.

State of readiness: Temperature of injector coil and its tip (nozzle) -10℃ or 10℃

GETtheMANUALS.org
 0000-00 15-27

2) Operation of Urea Injector

The urea injector upstream of the SCR injects the urea to spray the urea into the SCR and the mixer in
the SCR catalyst induces turbulence of the urea and exhaust gas so that they can be mixed optimally.

SCR catalyst SCR EGT sensor

Urea injector
Mixer

The urea injector is driven in PWM mode and the injector open time depends on the following conditions:

- SCR temperature
- Amount of ammonia accumulated in SCR
- NOx emissions from engine

GETtheMANUALS.org
15-28

3) PWM Control by Urea Injector

Item Minimum Nominal value Maximum Remarks
Nominal operating
9 8 16 -
voltage (V)
Required current (A) 0.4 0.5 1.2 13.8 V (at 20℃)
Max. holding current (A) - 1.2 - 13.8 V (at 20℃)
Electrical resistance (Ω) 11.4 1.2 12.6 At 20℃

GETtheMANUALS.org
 0000-00 15-29

6. EWP (Electric Water Pump)

The electric water pump supplies the coolant to the urea injector. The urea is frozen at the temperature
of -11℃. If the urea is frozen, the injection hole is blocked so that the urea can't be injected
properly. In addition, the urea injector is mounted on the exhaust line. If the temperature rises
120℃ or higher due to the high temperature of exhaust gas, it may affect the durability of the
injector. To prevent this problem, the electric water pump supplies coolant to the urea injector. The ECU
performs PWM control on the electric water pump in 10 stages, based on the exhaust gas temperature,
the coolant temperature and the ambient temperature.
The injector may be damaged due to a high temperature of exhaust gas. Therefore, when the ignition is
turned off, the electric water pump supplies the coolant to the urea injector to cool it down, which may
cause operating noise.

1) Coolant Flow

Urea injector Make-up hose

outlet tube

Urea injector inlet tube

EWP(electric water pump)

GETtheMANUALS.org
15-30

7. SCR CATALYST
The SCR catalyst has the absorption plate to absorbs ammonia (NH₃) contained in the urea. It
has also the mixer in its downstream so that the urea injected by the urea injector is sprayed evenly.
The SCR system reduces NOx emissions by injecting ammonia (NH₃) to chemically react with
the harmful NOx within the exhaust gas temperature range of 180℃ ~ 400℃. In the process,
nitrogen (N₂) and water (H₂O) is produced.

1) SCR Catalytic Reduction

GETtheMANUALS.org
 0000-00 15-31

8. SCR DRIVER ALERT SYSTEM

1) Classification
The driver alert system is activated by 5 different factors (urea level, urea dosing, urea dosing system,
incorrect urea, SCR efficiency) and is classified into 2 types according to the judgment process.

Type 1 (Low urea level)

- Urea level: Depleted urea in tank

Type 2 (SCR system failure)

- Urea dosing: implausible urea consumption

- Urea dosing system: malfunction detected
- Incorrect urea: incorrect urea used
- SCR efficiency: low SCR efficiency

If any abnormality is detected in the above classification, the driving restrictions can be activated as a
form of "Impossible to restart engine after a period of time". If driving restrictions are activated, number of
times of engine restart or drivable distance can be restricted. (However, engine start by the vehicle control
system does not apply, such as ISG (Idle Stop & Go).)
If driving restrictions are activated and the engine can't be restarted, replenish at least 10 liters of urea for
automatic initialization for type 1. For type 2, rectify the failure cause and initialize the system using a
diagnostic device. (However, drive the vehicle for a certain distance (up to 50 km) to see if the action is
appropriate. If the failure recurs, driving restrictions will be reactivated immediately.)

GETtheMANUALS.org
15-32

2) Type 1 SCR Driver Alert System

(1) Alert stages according to urea level
The driver alert system is divided into three stages according to the drivable distance, and the urea level
measured by the urea level sensor is used for drivable distance calculation. When the driver alert system
is activated, a certain amount of urea should be replenished for initialization. Alert stages and drivable
distances according to the urea level are as follows:

- The drivable distance is calculated by the urea level in the urea tank.
- If the urea is replenished and drivable distance exceeds 2,400 ㎞, the driver alert system is
deactivated.

(2) Initializing driving restriction

The driver alert system is activated in 3 stages according to the urea level.
- In order to reset the system, replenish the 6~10 liters of urea by stages.

GETtheMANUALS.org
 0000-00 15-33

(3) Judgment process in driver alert system

Drivable distance calculation

- The drivable distance is calculated based on the current urea level. If the drivable distance is
2,400 km or less, the system enters "Stage 1". (drivable distance calculated according to urea
injection amount under demanding conditions)
- If the driving conditions are improved at "Stage 1", "Stage 2" or "Stage 3" (i.e., urea injection
amount becomes smaller), the actual drivable distance may be increased but the calculated
one will not be updated.
- If the "Stage 3" drivable distance becomes 0 km, there may be some remaining urea in the
tank.

GETtheMANUALS.org
15-34

(4) Urea level

Transition for each step in 3-stage driver alert system is carried out progressively depending on the urea
level.

- The drivable distance displayed on the instrument cluster is calculated by the urea level in the urea
tank.
- 1~1.5 liters of urea is consumed when driving about 1,000 km. (The consumption depends on the
driving style and driving conditions.)

GETtheMANUALS.org
 0000-00 15-35

3) Type 2 Driver Alert System

(1) Judgment process in driver alert system

GETtheMANUALS.org
15-36

▶ Normal mode
- State where system operates normally

▶ PASS
- State where fault cleared and system diagnostics completed

▶ Recovery mode
- "Recovery mode" is a mode to monitor whether a failure recurs or not during three driving cycles
(ignition ON → normal operation of faulty part → ignition OFF → ignition ON). When the
system is switched to normal mode, the travel distance at the time of initial failure occurrence will be
reset.

▶ Test driving mode 1

- It is a mode to check if the fault has been repaired correctly, in which the system is monitored
for 50 km of driving and if the system is normal, it is switched to "Recovery mode" by the ”PASS”
signal.
- If monitoring shows that failure recurs before driving 50 km, system switched to [Stage 3 failure] when
restarting (restart not possible)
- When the vehicle is driving in "Test driving mode 1" which resulting from clearing the DTC(s) 3 times, if
"No PASS signal" is found after driving for more than 50 km, the system will be switched to "Test driving
mode 2 (torque reduction)". (switched to [Stage 3 failure] after ignition turned off)

▶ Test driving mode 2

- "Test driving mode 2" is a restricted mode to prevent misbehavior to clear the DTC(s) without
repairing any fault to drive the vehicle.
- The instrument cluster displays the message "Normal urea system diagnostics not possible and
engine restart impossible" and the vehicle speed is restricted up to 60 km/h by "torque reduction" in
"Test driving mode 2"
- The system is switched to "Test driving mode 2" when the number of DTC(s) deletions
exceeds 3 times (from 4th). (possible to switch to "recovery mode" by "PASS" signal during
test driving)
- When the vehicle is driving in "Test driving mode 1" which resulting from clearing the DTC(s) 3 times,
if "No PASS signal" is found after driving for more than 50 km, the system will be switched to "Test
driving mode 2 (torque reduction)". (switched to [Stage 3 failure] after ignition turned off)

▶ First failure (travel distance at time of first failure)

- The travel distance at time of first failure is stored and accumulated and displayed or restricted by the
driver alert system.
- If the vehicle travels more than 850 km from the point of the first failure, engine start will be limited. if
this first failure is normal for three "driving cycles" in recovery mode, the system will switch to "Normal
mode" and the record will be reset.

GETtheMANUALS.org
 0000-00 15-37

▶ No PASS signal
- When the vehicle is driving in "Test driving mode 1" which resulting from clearing the DTC(s) 1 or 2
times, if "No PASS signal" is found after driving for more than 50 km, the system will switch to [Stage
3 failure] after restart. (no torque reduction)
- When the vehicle is driving in "Test driving mode 1" which resulting from clearing the DTC(s) 3 times,
if "No PASS signal" is found after driving for more than 50 km, the system will be switched to "Test
driving mode 2 (torque reduction)". (switched to [Stage 3 failure] after ignition turned off)

▶ Driving cycle
- The cycle of engine start, engine stop and standby (at least 2 minutes after engine stop) is called as
"Driving cycle".

▶ Torque reduction
- If "No PASS signal" is found even after the test driving of 50 km or longer in "Test driving mode 2"
which resulting from clearing the DTC(s) 3 times or more, the torque reduction to 60 km/h will be
performed.

▶ Counting number of times of DTC(s) clearance

- Each time the DTC is cleared in [Stage 3 failure], the process of entering "Test driving mode 1" is
counted once. Then, the system will enter [Stage 3 failure] if the ignition is turned off. (After repeating
this 3 times and restarting (4th time), the system switches to "Test driving mode 2" and "Torque
reduction" is activated)
- "Test driving mode 1" after 1st and 2nd DTC clearance (no drivable distance limit) → [Stage 3
failure] after restarting
- "Test driving mode 1" after 3rd DTC clearance (driving for more than 50 km, no PASS signal)
→ "Test driving mode 2" (torque reduction) → [Stage 3 failure] after restarting (even if the fault
recurs, the vehicle can travel normally up to 50 km, but after that, the system will switch to "Test
driving mode 2")
- "Test driving mode 2" and torque reduction after number of times of DTC clearance exceeds 3 times
(from 4th time) → [Stage 3 failure] after restarting

▶ DTC(s) cleared more than 3 times

- When the DTC(s) is(are) cleared more than 3 times, the system will switch to "Test driving mode 2"
and torque reduction is activated. The system can enter "Recovery mode" when the failure is rectified
and the "PASS" signal is received. (when system enters "Recovery mode", memory that DTC(s) had
been cleared more than 3 times is reset)

GETtheMANUALS.org
15-38

▶ PASS or DTC(s) clearance

- In stages 1/2 failure, it may be more accurate to switch the "Recovery mode" by "PASS" signal
through driving after repairing the faulty part (DTC not cleared / warning lamp on). (It means that the
system automatically switches to "Recovery mode" to resolve the problem)
- In the above step, if the system enters "Recovery mode" with the warning lamp turned off
and enters "Normal mode" after 3 "driving cycles", the past DTC(s) should be cleared with the
diagnostic device.
- If the DTC(s) is(are) cleared with the diagnostic device in stage 1 or stage 2 failure, the system
immediately switches to "Recovery mode". However, since the system is not switched to "Recovery
mode" automatically, the problem is not completely resolved. (system may switch from "Recovery
mode" to "Failure mode")

▶ Emergency
- Since failure to restart may cause dangerous situations, engine restart is possible in [Stage 3 failure]
at temperature below -10°C

GETtheMANUALS.org
 0000-00 15-39

(2) Urea dosing

Determine whether there is a defect by comparing the urea consumption with the distance driven for the
same time.

GETtheMANUALS.org
15-40

(3) Urea injection (electrical fault)

It is activated when the urea injection system fails or difference between the injection demand and actual
injection quantity is 50% or greater.

GETtheMANUALS.org
 0000-00 15-41

(4) Urea injection system (implausible consumption)

Activated when it is judged that an incorrect urea is used for reducing NOx.

GETtheMANUALS.org
15-42

(5) SCR efficiency

Activated when it is judged that SCR catalyst is faulty.

GETtheMANUALS.org
 0000-00 15-43

4) Initializing Driving Restriction

Rectify the possible cause of the failure and clear any DTC using a SIW diagnostic device to reset the
driving restriction.
(However, in order to check whether the action was appropriate, if any failure is detected within up to 50
km of driving distance after initialization, the driving restriction is activated again.)

GETtheMANUALS.org
15-44

9. DCU BLOCK DIAGRAM

GETtheMANUALS.org
GETtheMANUALS.org
15-46

10. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 15-47

GETtheMANUALS.org
 0000-00 16-3

1. SPECIFICATIONS
Item Category Specifications
130A
77A/2,000rpm, 118A/4,000rpm,
Alternator Rated output
128A/6,000rpm
(100℃, 13.25V)

Capacity AGM 70Ah

Residual capacity (RC) 110 min
Battery
Cold cranking ampere (CCA) 760A
Weight 21kg
Operating voltage 9 ~ 18V (6 ~ 18V for LIN comm.)
Operating temperature -30℃ to +110℃
BSC(Battery Sensor
Operating current Max. 20mA
Cable)
Dark current Max. 0.19mA
LIN communication INTEL 2.0 standard 19.2kbps
Rated voltage 12V 1.8kw
Engage type Electric press-fit
Direction of rotation Clockwise (viewed from drive end)
Starting motor
Solenoid operating voltage Max. 8V
Weight 3.3kg
Reduction gear ratio 5.625 : 1
Input 7 ~ 12V
Shifting mode
Output 11 ~ 13V
(Max. current: 15A (B+), 50mA (ACC))
Input 9 ~ 16V
DC-DC converter
Bypass mode
Output 9 ~ 16V
(Max. current: 15A (B+), 50mA (ACC))
Operating temperature -30℃ to +75℃
Dark current Max. 0.5mA (with IGN & ACC OFF)

GETtheMANUALS.org
16-4

Item Category Specifications

Rated voltage DC 12V 50mA or less
ISG OFF switch Operating temperature -30℃ to +80℃
Operation type Push-return type

GETtheMANUALS.org
 0000-00 16-5

1. OVERVIEW
The ISG system is applied to the vehicle together with the EEM system. It checks the overall condition of
the vehicle including the engine and the transmission when the vehicle is stopped. If the engine stop
conditions are met, the engine is stopped until the engine restarts. This will eliminate inefficient fuel
consumption and prevent the exhaust gas from being discharged fundamentally, thereby improving the
fuel economy and durability of the vehicle.
In vehicles equipped with an ISG system, the ISG function is activated by default. If you do not want to
use it, you can turn off the ISG function with the ISG OFF switch.
In addition, the EEM system monitors the electrical load and battery charge state through the BSC to
control the generating voltage of the alternator, thereby improving fuel economy, reducing CO2 and
improving battery efficiency.
The BSC is mounted on the battery (-) terminal and transmits information to the ECU via LIN
communication. The ECU controls the alternator using PWM signal, and when the charging system is
defective, the charging warning lamp is lit on the instrument panel via CAN communication.

- ISG: Idle Stop & Go

- EEM: Energy Efficiency Management
- BSC: Battery Sensor Cable
- ECU: Engine Control Unit
- PWM: Pulse Width Modulation

IP display (Standard instrument

Category Operating conditions
cluster)

Vehicle stop → engine stop Selector lever D position + brake

pedal applied

- Brake pedal released

- Apply brake pedal + move
Vehicle start → engine start selector lever to M or R
position

GETtheMANUALS.org
16-6

2. COMPONENTS
▶ ENGINE ROOM

Alternator Brake vacuum ECU BSC

pressure sensor

Starting motor TCU Hood switch Battery

(1 & 2)

GETtheMANUALS.org
 0000-00 16-7

▶ INTERIOR

Cluster DC-DC converter SKM

BCM Brake switch ISG OFF switch

GETtheMANUALS.org
16-8

3. EPC
▶ 2610 BATTERY AND CABLE

1. BATTERY ASSY 11.BRKT-BATTERY POSITIVE

2. BOLT 12.BATTERY COVER
3. CLAMP-BATTERY 14.BATTERY COVER-PLASTIC
5. WIRING ASSY-BATTERY POSITIVE 15.SCREW
6. WIRING ASSY-BATTERY GROUND 17.NUT
7. CABLE ASSY-BATTERY SENSOR 18.NUT
8. BOLT 24.CAP-STARTER
10.TERMINAL-BATTERY POSITIVE 25.CAP-RING TERMINAL

GETtheMANUALS.org
 0000-00 16-9

▶ 1451 ALTERNATOR(D16DTF)

1. ALTERNATOR ASSY
4. BOLT

▶ 1461 STARTING MOTOR(D16DTF)

1. STARTER ASSY
2. BOLT

GETtheMANUALS.org
16-10

▶ 4850 MASTER CYLINDER AND BOOSTER

1. MASTER BRAKE UNIT ASSY 8. O RING-BOOSTER MTG

2. BOOSTER ASSY-POWER BRAKE 9. HOSE ASSY-BOOSTER VACUUM
3. MASTER CYLINDER ASSY-PWR BRK 10.VALVE-BOOSTER NONRETURN
4. RESERVOIR ASSY-BRAKE 11.VACUUM SENSOR
5. WASHER-BOOSTER MTG 12.CLIP
6. NUT-BOOSTER MTG 13.SCREW
7. GASKET-BOOSTER MTG

GETtheMANUALS.org
 0000-00 16-11

▶ 8511 SWITCH AND SENSOR - INSTRUMENT PANEL(2)

1. BLKG CVR-SEAT WARMER FRT 11.SWITCH ASSY-GLOVE BOX

2. SWITCH ASSY-SEAT WARMER FRT 17.SWITCH ASSY-PASSENGER AIR BAG
7. SWITCH ASSY-LWR MAIN 18.BLANKING COVER-PASSR A/BAG
8. SWITCH ASSY-START 27.SWITCH ASSY-FASCIA LWR
9. BRKT-START 29.SWITCH ASSY-FASCIA LWR
10.SCREW

GETtheMANUALS.org
16-12

▶ 8610 Application component

GETtheMANUALS.org
 0000-00 16-13

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY-LOW 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-115V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER FRT 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-HD RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
16-14

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 16-15

GETtheMANUALS.org
16-16

2. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
 0000-00 16-17

GETtheMANUALS.org
16-18

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 16-19

3. P-CAN INPUT/OUTPUT ELEMENTS

▶ ABS

▶ BCM

GETtheMANUALS.org
16-20

▶ ESP

GETtheMANUALS.org
 0000-00 16-21

▶ CPL

▶ GCU

GETtheMANUALS.org
16-22

▶ HVAC

▶ ACU

GETtheMANUALS.org
 0000-00 16-23

▶ PMS

GETtheMANUALS.org
16-24

▶ TCU

GETtheMANUALS.org
 0000-00 16-25

▶ CGW

GETtheMANUALS.org
16-26

▶ CGW

▶ SKM

GETtheMANUALS.org
 0000-00 16-27

▶ Diagnostic device

GETtheMANUALS.org
16-28

4. ISG OPERATING CONDITIONS

1) ISG System Transition

▶ IP display for each ISG status (3.5" instrument cluster)

GETtheMANUALS.org
 0000-00 16-29

2) ISG Auto Stop

▶ AUTO STOP conditions (2: engine running → 4: Stop)
(Judgement condition AND: All conditions must be met for AUTO STOP to be possible)

Item Status
Driver Vehicle speed Falls below 1 km/h from 9 km/h or higher (not
condition activated unless vehicle speed exceeds 9 km/h)

ISG OFF switch Not depressed (ISG ON)

Gear lever/brake - Brake pedal depressed with gear lever in
D/N position
- After start, lever should be placed to
D position at least once
- ISG initialized when lever moved to P/R
during driving
Driver door/seat belt Door closed
Seat belt fastened
Accelerator pedal OFF
EPS steering wheel angle Left/right: 180˚ or less
Engine rpm Idling rpm ~ 1,350 rpm
HVAC (Heater and A/C controller) Fan speed reduced level 1, A/C switch turned off

Brake pedal Depressed

Gear position N (neutral) / D (drive)
ACC (Adaptive Cruise Control) Not operating
operation
AUTO HOLD readiness Preparation(warning lamp: white) → Operation
(warning lamp: green)

GETtheMANUALS.org
16-30

Item Status
Vehicle Coolant temperature 20℃ ~ 100℃ (ISG disabled at below 15℃
condition and above 105℃)
Atmospheric pressure 2,800m or less (hysteresis: 2,500m)
Hood switch (SW1 & SW2) Hood closed
BSC (battery status) *BSC (battery) conditions for ISG operation
Brake vacuum pressure -330 hPa (-0.33 bar) or less
Road gradient ±12% or less
Delay time until ISG becomes -10 deg.: 80s, 10 deg.: 65s, 40 deg.: 65s,
operational according to coolant 43 deg.: 15s, 60 deg.: 10s, 90 deg.: 3s.
temperature after start-up

Travel speed before ISG Auto Stop 9km/h or higher

Minimum required time to stop vehicle 0.2 s or longer
before ISG Auto Stop
Minimum travel range after ISG restart 1m or longer

After DTC occurs Below 3 times (ISG STOP condition met only up
ISG Auto Stop to 2 times of engine failure)
Engine torque Below 250 Nm
Total number of cumulative starts Less than 300,000 times
Specific defects in ECU No defect
Accessory torque 60 Nm or less
Ambient temperature -6℃ or higher
ECU status Normal (not work during DPF regeneration)
ISG system-related fault Not occur

*BSC (battery) conditions for ISG operation

- Temperature: -5℃ to 60℃
- SOC (charge state): 80% or higher (hysteresis ±2%)
: ISG STOP requires more than 82% or higher charge
- SOH (performance state): 80% or higher
- SOF (minimum start voltage): 7.2V or higher
- EEM warning lamp: OFF
- When removing and reconnecting battery: Enabled when BSC monitors battery status after 4
hours

GETtheMANUALS.org
 0000-00 16-31

3) ISG Auto Stop Restriction

▶ AUTO STOP restriction conditions (2: engine running → 3: Stop restriction)
(Judgement condition OR: Restricted if at least one judgment condition met)

Item Status
ISG Auto Stop after engine-related DTC occurs 3 times or more (ISG STOP condition met only up
to 2 times of engine-related DTC)
ISG Auto Stop conditions not met When STOP (2→4) conditions not met, STOP
restricted
A/C system Specifications Maximum cooling / heating temperature and
blower motor in 6-speed or higher (however,
AUTO STOP available if A/C switch turned off and
blower motor in 1-speed)
Unit - Blower motor 6-speed or higher
(A/C switch turned ON)
- MAX A/C switch ON (with MTC)
Defrosting Defroster switch ON (A/C switch ON & blower
motor ON)
ISG OFF switch Pressed (ISG OFF)
ECU status Unsatisfied or during DPF regeneration
Brake vacuum pressure -330 hPa or higher
Driver door / seat belt / hood Ajar (unfastened)
BSC (battery status) Conditions not met
ISG system-related fault Failure occurs
Steering wheel Steering angle large (180˚ or greater when
stationary)
Others Driving on downhill or steep uphill

GETtheMANUALS.org
16-32

4) ISG Auto Start (conditions for restart)

▶ AUTO START conditions (4: Stop → 2: Start)
(Judgement condition OR: If any of judgment conditions met, ISG restarted)

Item Status
START Brake Brake pedal released with gear lever in D/N position
conditions (With EPB: Restart after AUTO HOLD released
by driver (green→white))

TGS lever position - Gear shift from N to D during braking

- Move gear level to R or M position
ISG OFF switch Depressed (ISG OFF)
HVAC (Heater and A/C controller) Defroster switch ON (A/C turned on & blower motor
ON)
Accelerator pedal AUTO HOLD activated, accelerator pedal depressed
while depressing brake pedal
Accelerator pedal depressed 2.5% or more
Driver door/seat belt Door closed→open
(Brake applied) Seat belt fastened→unfastened
EPS steering wheel angle Operate quickly at angular speed of 180˚/s or
more
Forced BSC (battery status) Battery SOC low due to excessive use of electrical
START devices (e.g., for more than 3 min in succession)
condition
Restart after certain period of Up to 5 min (after that, restarted)
time(STOP actuation time)
Brake vacuum pressure Vacuum as low as -330 hPa
Coolant temperature 110℃ or higher
Failure occurs DTC occurs at engine start group
Accessory torque 250 Nm or above
HVAC (Heater and A/C controller) - A/C switch ON and blower motor 6-speed or
higher
- MAX A/C switch ON (with MTC)
Certain vehicle speed detected Vehicle speed 1 km/h or higher after brake pedal
released (including downhill)

GETtheMANUALS.org
 0000-00 16-33

5) ISG Auto Start Restriction (Auto Restart Impossible)

▶ START restriction conditions (4: engine stop → 5: START restriction)
(Judgement condition OR: Restricted if at least one judgment condition met)

▶ Manual start using button/start key

Item Status
Vehicle Engine compartment hood Open or open to closed
condition
Engine stall by ECU 3 times or more (ISG Stop possible up to 2 times)
After DTC occurs Engine-related DTC occurs 3 times or more
(Start possible if engine failure occurs less than 3
times)

6) ISG System Failure

▶ Shutdown by ISG system failure (2,3,4,5 → 6: ISG system failure)
(Judgement condition OR: If any of judgment conditions met, judged as failure)

Item Status
PCAN communication PCAN comm timeout
ESP Longitudinal acceleration sensor value not detected
EPS Steering angle sensor value not detected
BSC BSC sensor error
LIN communication from BSC to ECU not respond
Starting motor 300,000 times of starting counts
(after 300,000 times: ISG error LED ON and DTC not set)
ECU detects DTC Brake, cam/crank, throttle, intake, lambda, accel pedal, start
circuit, coolant temperature, vehicle speed, etc.

GETtheMANUALS.org
16-34

5. ECU OPERATING
1) Overview & Mounting Location

ECU

The engine ECU is a main unit for controlling the ISG system. It receives information from the sensors
on the engine and vehicle including the BSC as well as other units, and checks whether the ISG STOP
is possible or not. If the conditions are met, it stops the engine.
In addition, in respect to the alternator control, the generating voltage is temporarily reduced during
acceleration depending on the driving conditions, and the battery discharge is induced by the reduced
voltage, thereby increasing the fuel efficiency and efficiency by lowering the vehicle load. Besides, it
increases the generating capacity to charge the battery capacity consumed during deceleration.

2) Voltage Control
Loading condition Control state Alternator voltage
Headlamp (LO/HI) Fixed control Fixed at 14.7 V
Blower motor Maximum speed Fixed control Fixed at 14.7 V
Rear glass defogger Fixed control Fixed at 14.7 V
Low speed Normal control -
Wiper
High speed Fixed control Fixed at 14.7 V

GETtheMANUALS.org
 0000-00 16-35

6. BCM OPERATING
1) Overview & Mounting Location

BCM

▶ BCM control by ISG signal

If the ISG Auto Stop is activated while the following features are active, the ECU sends an ISG Stop
signal to the BCM and the BCM stops/controls the features that are currently running.
- Wiper control
- Rear defogger (heating) control

GETtheMANUALS.org
16-36

2) Control by ISG Signal During Windshield Wiper Operation

Operation 1. When ISG engine stops during ISG engine STOP
ISG engine IDLE
LO/HI continuous operation, wiper operates in status
status (idling)
INT 1 stage (engine stop)
A. When ECU sends signal regarding ISG engine High Low INT 1 (3s)
status (engine stop) Low Low INT 1 (3s)
B. to BCM via PCAN during LO/HI continuous
operation of front wiper, Low INT 1 (3s) Low INT 1 (3s)
- (ECU→PCAN→CGW→CCAN→IP/EPS) Low INT 2 (7s) Low INT 2 (7s)
C. the wiper will operate in INT 1 stage (INT FAST:
Low INT 3 (11s) Low INT 3 (11s)
intermittent operation for 3 sec).
Low INT 4 (15s) Low INT 4 (15s)
Low INT 5 (19s) Low INT 5 (19s)

Operation 2. If ISG engine stops during INT operation wiper maintains previous operation mode

D. If signal indicating engine stop is received

E. due to ISG engine stop while the front wiper is in INT operation,
F. the wiper will maintain the previous operation state.

Operation 3. Normally operating when ISG engine stops

G. If front wiper switch status is changed
H. with the ISG engine stopped, the wiper will operate normally in changed mode.
I. If the signal indicating ISG engine idling is received with the ISG engine stopped, the wiper will operate
normally.
J. If the wiper switch input is received with the ISG engine stopped, the wiper will operate normally.

Engine stopped/restarted by ISG

The ECU sends the signal regarding ISG STOP/IDLE status to BCM/CGW via PCAN.
(ECU→PCAN→BCM)
(ECU→PCAN→CGW→CCAN→IP)

GETtheMANUALS.org
 0000-00 16-37

System Flowchart

GETtheMANUALS.org
16-38

3) Rear Defogger (Heating) Control (Active ISG)

Operation 1. (OFF for 2 min)
A. Rear defogger (heating) in operation
B. When engine stopped by ISG
- ECU transmits ISG engine STOP signal to different units
(ECU→PCAN→BCM, CPL, ESC, HVAC, SKM)
(ECU→PCAN→CGW→CCAN→EPS, IP)
C. The rear defogger (heating) is turned off for less than 2 minutes.
(rear defogger ON indicator stays on)

Operation 2.
A. Operation 1. When the engine is started by ISG
B. with the rear defogger (heating) turned off for 2 minutes,
C. the rear defogger will be operated.

Operation 3.
A. Operation 1. Pressing the rear defogger (heating) switch
B. with the rear defogger off for 2 minutes
C. immediately switches off the rear defogger.
(Rear defogger (heating) ON indicator goes off)

System Flowchart

GETtheMANUALS.org
 0000-00 16-39

7. BSC(BATTERY SENSOR CABLE)

1) Overview & Mounting Location

BSC
(Battery Sensor Cable)

The BSC is mounted on the battery's negative terminal and sends battery information (voltage, current,
temperature, state of charge, etc.) to the ECU via LIN communication and monitors it to operate the ISG
(Idle Stop & amp; Go) system and EEM.

GETtheMANUALS.org
16-40

2) Operating Process
▶ System layout

▶ Operating process

- The BSC connected to the negative (-) terminal of the battery sends battery information (voltage,
current, temperature and SOC) to the ECU via LIN communication.
- The ECU outputs the generating control signal (PWM) for the engine load based on the
information from the BSC and driving conditions (idle, acceleration, deceleration) to the
alternator terminal "L".
- The ECU controls the magnetic reluctance between the stator coil and the rotor coil by
controlling the current of the alternator rotor coil depending on the change of the PWM duty
value.
- The AC voltage induced in the stator coil is converted to a DC voltage by the rectifier and then output
to the "B" terminal of the alternator connected to the battery.

GETtheMANUALS.org
 0000-00 16-41

▶ Control for each driving conditions

The ECU judges the engine load according to the fuel injection amount and the engine rpm. When
decelerating, the battery is charged by increasing the generator voltage. During acceleration, the
generator voltage is lowered while consuming the charged battery voltage, which reduces the load on
the alternator driven by the engine output, thereby reducing fuel consumption.

▶ Battery charge warning light

The ECU checks the voltage generated from the alternator and the circuit, and transmits the battery
charge warning lamp ON signal to the instrument panel through the GWM via the CAN communication.
(ECU→PCAN→CGW→CCAN→ICM)

GETtheMANUALS.org
16-42

3) Features of BSC (Battery Sensor Cable)

▶ OCV (Open Circuit Voltage)

The OCV is the measured battery voltage when there is no battery, and there is a correlation between
the OCV and the SOC, which is measured at the stabilized battery. Therefore, it is possible to predict the
SOC based on the OCV. The BSC monitors the measured voltage over 3 hours after the battery has
stabilized without charging/discharging.

▶ SOH (State Of Health)

SOH indicates the aging degree of the battery. New batteries and batteries that have been used for a
certain period of time have different discharge rates. The aged battery will discharge quickly enough to
be difficult to use and should be replaced.

▶ SOC (State Of Charge)

The SOC represents the charged state of the battery, that is, the dischargeable capacity. (discharge
capacity)

▶ SOF (State Of Function)

SOF is the minimum start-up voltage (voltage drop) expected at the next start-up in the current battery
condition. Based on the current starting voltage/current, battery temperature, SOC and SOH (state of
health), the next start-up voltage is predicted depending on the BSC.

GETtheMANUALS.org
 0000-00 16-43

4) DTC Set Condition

▶ Charge warning light comes on when

1. IGN ON (engine stopped)

2. Terminal "L" wiring open/short circuit and alternator internal circuit open/short circuit (fixed control at
13.8V)
3. Terminal "F" wiring open/short circuit and feedback signal missing
4. No signal transmitted from BSC to ECU (LIN communication)
5. BSC error (invalid value sent to ECU)

For condition 1, this does not apply when the engine is stopped by ISG.

GETtheMANUALS.org
16-44

5) Charge Warning Light

The ECU sends a charge warning light ON signal to the instrument panel through the GWM via CAN
communication.
(ECU→PCAN→GWM→CCAN→ IP)

Charge warning light

▶ Charge warning light comes on when

- Pre-warning
- EEM system-related DTC(s)
- Alternator circuit open/short circuit
- No response from BSC
- BSC error (invalid value sent to BSC)

GETtheMANUALS.org
 0000-00 16-45

8. ALTERNATOR
1) Overview & Mounting Location

Alternator

The alternator is variably controlled by the ECU from its charging voltage to 11V to 15.5V. It charges the
battery by fixing the charging voltage when receiving the head lamp, blower motor, rear defogger, and
wiper operating signal.

2) Initial electricity generation

GETtheMANUALS.org
16-46

3) PWM Duty Value For Each Charging Voltage

The above figure shows the generating voltage output characteristics according to the engine ECU PWM
signal duty increase. It is controlled to 1~9% in low charge range and 91~99% duty in overcharge range
and charged to 13.6V.
The engine ECU outputs 5~95% PWM duty signal to the L terminal and fixes the output to 14.7 V at the
electrical load input (head lamp (LO / HI), wiper, rear defogger, blower running at its maximum speed).
However, when there is an alternator L terminal open circuit or short-circuit, it is fixed at 13.6V in 0~5%
and 95~100% duty range in fail-safe mode.

GETtheMANUALS.org
 0000-00 16-47

9. BATTERY
1) Overview

Battery

The battery charges and discharges the electric charge by receiving the charging voltage from alternator.

2) Determination of SOC (State Of Charge)

The charging capacity of battery is decreased as the time goes over.

SOC value is not the calculated value based on charging capacity as shown in the [Figure 1] but the
absolute value according to the battery condition as shown in the [Figure 2].

GETtheMANUALS.org
16-48

3) SOC management
The battery must be deteriorated as the time goes over.
EEM controls the charging capacity over 78% to provide initial starting. However, if the charging capacity
goes below 78%, EEM does not control the voltage generation.

▶ Charging mode

1. Mode 1 (Constant current control)

If the battery charging level is low, the system provides the high constant current to charge the battery
rapidly. The system controls the charging current according to the electric load conditions. If the
battery temperature increases over 40°C, the charging current is limited by 25A.

2. Mode 2 (Constant voltage control)

If the battery charging level is in middle range, the battery could be charged slowly when the control
voltage is low and the electrolyte could be deteriorated when the control voltage is high. If the electric
load increases very rapidly, the battery charging efficiency could be decreased.
To improve the charging/discharging efficiency and the fuel economy, do not maintain the constant
voltage control mode for a long time.

SOC
Mode
Initial Status Target Status
1 Below 78% 82%
2 Over 82% 92%
3 Below 92% 78%

GETtheMANUALS.org
 0000-00 16-49

3. Mode 3 (Voltage maintaining control)

If the battery is fully charged, the system tries to keep the current status. In this condition, the system
maintains the charging status with low charging voltage.
If the vehicle is accelerating, the system requires the discharging. The discharging is permitted only
when the SOC is over 78%. If the SOC is low (below 78%), the discharge control is not available.

▶ Limitation of charging current according to the temperature

Charging Discharging
Temperature
Current Time Current Time
Below 0°C 45 45
0 to 40°C 35 No limitation 35 No limitation

Over 40°C 25 25

▶ Activating BSC sensor

(battery (-) terminal disconnection, battery replacement, battery discharge, etc.)

- Remove the vehicle black box or other electrical devices that may consume battery dark current.
- Measure the dark current to check if it is below 50 mA.
- You should turn the ignition switch from ON position to OFF position, and the vehicle should be parked
for more than 4 hours at room temperature. Then, the BSC monitors the battery status and activates the
sensor.

▶ How to replace AGM battery to maintain vehicle performance

- When replacing the battery, be sure to replace it with a battery with the same specifications (capacity
and manufacturer) as the factory-installed battery.
- Otherwise, the ISG system may not operate properly due to the BSC sensor malfunction.

GETtheMANUALS.org
16-50

10. STARTING MOTOR

1) Overview & Mounting Location

Starting motor

The alternator is variably controlled by the ECU from its charging voltage to 11V to 15.5V. It charges the
battery by fixing the charging voltage when receiving the head lamp, blower motor, rear defogger, and
wiper operating signal.

▶ 300,000 times of starting counts

- The number of times the motor is started is counted and starting motor must be replaced after
300,000 counts. (ISG is disabled. However, ISG error LED nor lit DTC neither set)

GETtheMANUALS.org
 0000-00 16-51

2) Starting motor Output

▶ Vehicle without ISG

▶ Vehicle with ISG

GETtheMANUALS.org
16-52

11. BRAKE VACUUM PRESSURE SENSOR

1) Overview & Mounting Location

Brake vacuum pressure

sensor

The brake vacuum pressure sensor is fitted to bottom of the brake booster in the vehicle with the ISG.
When the ISG system operates, it detects the brake pressure. If the brake negative pressure is low
during ISG STOP, it sends a signal to the ECU, and the ECU performs forced ISG restart based on this
information.

2) Features

▶ Brake vacuum pressure

- For the ISG system to operate, the vacuum must be at least 333 hPa.

GETtheMANUALS.org
 0000-00 16-53

12. DC-DC CONVERTER

1) Overview & Mounting Location

DC-DC converter

The DC-DC converter is mounted on the IP frame at the rear side of the glove box assembly. When
voltage less than 12V is applied, boost voltage (12 ± 1V) is supplied for 0.02 to 1 second to
maintain stable voltage. It prevents reset of audio and instrument panel due to voltage drop during
engine restart by ISG Auto Start. Therefore, if the audio system and instrument panel are turned off due
to the voltage drop when the engine is restarted by ISG, the DC-DC converter can be diagnosed as
defective.

GETtheMANUALS.org
16-54

2) Operating Process
A. In the ISG OFF state, INPUT B+ is bypassed and output to T2 section output to OUPUT B+.
B. When the ISG switch of INPUT B+ is turned on and a start signal is detected, the system outputs the
converted power to compensate for the voltage drop.
C. The maximum delay time that can be converted from the bypass output to the conversion output is
within T1 (1 sec).
If INPUT B+ becomes greater than 12V ± 1V within T1 (1 sec), the system switches from
conversion mode to bypass mode.

Conversion section Bypass section

Mode that boosts B+ input to voltage with constant Mode that passes B+ input to B+ output
level and emits B+ output

GETtheMANUALS.org
GETtheMANUALS.org
16-56

13. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 16-57

GETtheMANUALS.org
 0000-00 17-3

1. ENGINE ECU SPECIFICATIONS

Items Diesel Remarks
Engine D16DTFP Power-up
Injector C3I -
Connector A: 60-pin -
ECU terminals
Connector B: 94-pin -
CPU 32-bit SPC563 single chip -
Flash Memory Internal 1.5 MB -
Electronic throttle body Yes H-Bridge
Fuel rail pressure sensor Yes -
Glow plug Yes -
Booster pressure sensor Yes -
Intake manifold temperature sensor Yes NTC

Coolant temperature sensor Yes NTC

Cam position sensor Yes Camshaft - 3-tooth type
Crank position sensor Yes Trigger ring 60-2
HFM Yes NTC
Oxygen sensor Yes Front/rear oxygen sensor
Fuel pump Yes -
Trip computer (CAN) Yes -
Glow control unit (GCU) Yes -
EGR valve Yes -
IMV Yes -
Accelerator pedal sensor Yes 6-pin (Potentiometer
No. 1, No. 2)
Exhaust gas temperature sensor Yes Turbine / DPF / SCR
PM sensor Yes Integrated with unit
Nox sensor Yes Front/Rear Nox sensor

GETtheMANUALS.org
17-4

Items Diesel Remarks

Immobilizer (SKM) Yes CAN
Start control Yes -
Malfunction indicator lamp (MIL) Yes CAN
Idle stop & go (ISG) Yes 2WD A/T only
ACC/SET Yes -
DEC/SET Yes -
Cruise control
CRUISE Yes -
LIMIT Yes -
Alternator control (EEM) Yes ISG only
On board diagnostic (OBD) Yes -
CAN diagnosis Yes UDS
Neutral switch / Clutch switch Yes A vehicle with M/T
Vehicle speed Yes ABS & ESP
Electric fan Yes Resistor type
Variant Coding Yes -
Refrigerant pressure sensor Yes -
Blower switch input Yes -
A/C compressor control Yes Relay control

GETtheMANUALS.org
 0000-00 17-5

2. ENGINE SENSOR DATA LIST

Data Unit Value
0.436 V (at 130°C) to 4.896 V (at
Engine coolant temperature °C
-40°C)
-40 to 120°C
Intake air temperature °C (varies with ambient temperature
and engine mode)
Engine rpm rpm At idling: 700±50 (P/N)

Intake air flow mg/stk At idling: approx. 130.0 mg/stk

Intake manifold pressure bar At idling: approx. 0.44 bar
Intake manifold voltage V At idling: approx. 1.86 V
Engine torque Nm At idling: approx. 36.0 Nm
Injection time of injector ms At idling: approx. 3.1 ms
Battery voltage V 13.5 to 14.1 V
Throttle position sensor 1 voltage
V At idling: approx. 0.6V

Throttle position sensor 2 voltage

V At idling: approx. 4.4V

Front oxygen sensor voltage mV 50 to 450mV

Rear oxygen sensor voltage mV 50 to 450mV
Fuel tank level % 0 to 100%
VOP operation Operating/not operating -
BRAKE SWITCH Operating/not operating -
Clutch switch Operating/not operating -
A/C compressor Operating/not operating -
FUEL PUMP RELAY Operating/not operating -
Cooling fan relay Low/High speed -

GETtheMANUALS.org
17-6

3. CODING LISTS WHEN REPLACING ELECTRONIC SYSTEMS

▶ With SKM

Smart key &

Category EMS Registration Variant Coding TRANSPONDER
CODING
ECU replacement Carried out by SKM - -
Carried out by BCM
BCM replacement - -

Smart key replacement

- - Carried out by SKM

carried out under SKM

When replacing SKM - Carried out by SKM
menu

▶ Vehicles with REKES key

Remote
EMS TRANSPONDER
Category controller coding Variant coding
Registration CODING

ECU replacement Carried out by

- - -
BCM
REKES key Carried out by Carried out by BCM
- -
replacement BCM
BCM replacement Carried out by Carried out by Carried out by BCM Carried out by
BCM BCM BCM

GETtheMANUALS.org
 0000-00 17-7

1. SPECIAL TOOLS
Part number and name Special tools Usage
PN: X99110010A
(G16DF, D16DTF)

Name:
Stopper - Flywheel ring gear

Use:
Fixed on the flywheel ring gear to
prevent the engine from rotating
when tightening the crankshaft
pulley bolts and flywheel bolts.

GETtheMANUALS.org
17-8

2. GENERAL DEDICATED EQUIPMENTS

Part name General equipments
Name:
Jack for engine with
transmission

Usage:
Supports the modules when
working with engine assembly,
fuel tank, subframe.

Name:
Engine crane (1 ton or more)

Usage:
Used to move the removed
engine module with transaxle to
a working area or an engine
stand. Use an equipment which
is designed to carry load of 1
tone or more.

Name:
Engine stand (1 ton or more)

Usage:
Used to secure the removed
engine or engine with transaxle.
Use an equipment which is
designed to carry load of 1 tone
or more.

Name:
Engine support hanger

Usage:
Used to securely hold the engine
to prevent it from dropping when
working with the timing gear
case cover, engine mounting
insulator, or transmission.

GETtheMANUALS.org
 0000-00 17-9

Part number and name General equipments

Part no.:
Y99220082B
W99110230A

Name:
Valve spring complete

Y99220082B W99110230A
Part no.: Y99220182B

Name:
Valve stem seal remover

Usage:
Used to protect the stem seal
from damage when removing
the valve stem seal.

GETtheMANUALS.org
17-10

Part number and name General equipments

Part no.: A99110031B

Name:
Piston compression ring
clamping strap

Usage:
Used to insert the piston in the
cylinder block.

Name:
Fuel pump cover
installer/remover

Usage:
Used to install or remove the
fuel pump cover.

GETtheMANUALS.org
 0000-00 17-11

1. OVERVIEW
The ECU receives signals from various sensors. Then, it analyzes and modifies them to allowable
voltage level to control various actuators. The ECU can control the engine power and exhaust gas
precisely because the micro processor in the ECU calculates the injection duration, injection timing, and
injection volume based on the engine piston speed and crankshaft angle using input data and a stored
map. The output signal from the ECU microprocessor drives the solenoid valve of the injector to control
the fuel injection volume and injection timing and control the ignition timing of the ignition coil so as to
control various actuators in response to the changes in the engine condition. In addition, many auxiliary
functions are added to the ECU in order to reduce emissions, improve fuel economy and ensure safety,
riding comfort and convenience. Some examples of such functions include exhaust gas recirculation,
boost pressure control, cruise control (auto cruise) and immobilizer. The ECU uses the CAN
communication system to facilitate data exchange with other electric systems such as A/T, braking
device, and steering system. When servicing a vehicle, a diagnostic equipment can be used to check
the vehicle conditions and perform diagnosis. The normal operating temperature for ECU ranges from -
40 to 85℃. The ECU must be protected from oil, moisture, electromagnetic interference, and
external mechanical impact.

GETtheMANUALS.org
17-12

2. MAJOR COMPONENTS
1) ECU Input Components

GETtheMANUALS.org
 0000-00 17-13

2) ECU Output Components

IMV E-VGT Electric Injector
throttle body

Electric fan GCU

ECU

E-EGR valve Start relay

CAN
communication
Refer to CAN
COMMUNICATION
I/O ELEMENTS

EGR bypass PTC heater Electric water VOP solenoid valve

Solenoid valve pump(EWP)

GETtheMANUALS.org
17-14

3) Engine ECU Inputs/Outputs (Control Items)

GETtheMANUALS.org
 0000-00 17-15

3. EPC
▶ 1491 EMISSION MODULE(D16DTF)

1. ECU-ENGINE
2. BRKT-ECU
3. BOLT-FLANGE
4. NUT

GETtheMANUALS.org
17-16

▶ 1433 SENSORS(D16DTF)

1. SENSOR ASSY-PRESSURE 17.SENSOR ASSY-EGT FRT

2. BOLT 19.SENSOR ASSY-EGT RR
3. SENSOR ASSY-CAMSHAFT POSITION 20.SENSOR ASSY-FRT O2
4. SENSOR ASSY-DIFF PRESS 21.SENSOR ASSY-RR O2
6. BOLT 22.RING-SEAL
7. SENSOR ASSY-COOLANT 32.SENSOR ASSY-TEMPERATURE
11.BRKT-CRANKSHAFT POSITION 33.SENSOR ASSY-PM
12.BOLT 34.NUT
14.VALVE-ELECTRIC SWITCH 40.BRKT ASSY-PM & NOX SENSOR
15.BOLT 41.COVER-PM & NOX SENSOR

GETtheMANUALS.org
 0000-00 17-17

▶ 1434 UREA SENSORS

1. SENSOR ASSY-NOX FRT

2. SENSOR ASSY-NOX RR
17.SENSOR ASSY-EGT SCR FRT
19.SENSOR ASSY-EGT LNT RR
20.SENSOR ASSY-OXYGEN FRT
21.SENSOR ASSY-OXYGEN RR

GETtheMANUALS.org
17-18

▶ 2010 ACCELERATOR CONTROL

1. PEDAL MODULE-ACCELERATOR
2. NUT
3. SCREW
4. CAP-ACCELERATOR PEDAL

GETtheMANUALS.org
 0000-00 17-19

1. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
17-20

GETtheMANUALS.org
 0000-00 17-21

▶ Full names of acronyms and option description

GETtheMANUALS.org
17-22

2. P-CAN INPUT/OUTPUT ELEMENTS

▶ ABS

▶ BCM

GETtheMANUALS.org
 0000-00 17-23

▶ ESP

GETtheMANUALS.org
17-24

▶ CPL

▶ GCU

GETtheMANUALS.org
 0000-00 17-25

▶ HVAC

▶ ACU

GETtheMANUALS.org
17-26

▶ PMS

GETtheMANUALS.org
 0000-00 17-27

▶ TCU

GETtheMANUALS.org
17-28

▶ CGW

GETtheMANUALS.org
 0000-00 17-29

▶ CGW

▶ SKM

GETtheMANUALS.org
17-30

▶ Diagnostic device

GETtheMANUALS.org
 0000-00 17-31

3. FUEL INJECTION VOLUME CONTROL

The ECU determines fuel injection volume and injection timing based on the engine condition and
optimizes the engine operating conditions to reduce the emissions.

1) Input/Output Diagram

GETtheMANUALS.org
17-32

2) Fuel Injection Volume Control

(1) Basic mapping
- Stepped control
The ECU calculates proper injection volume and timing by considering various parameters to
achieve the optimal combustion at each stage of operation.
- Starting injection volume control
The fuel injection volume during initial starting is calculated by considering the temperature and
engine cranking speed. The starting injection means the injection during the period from when the
ignition switch is turned ON until when the engine rpm reaches to the allowable minimum speed.
Driving mode control
- The fuel injection volume during normal driving is calculated based on the accelerator pedal travel
and engine rpm and the drive map is used to match the drivers inputs with optimal engine power.

(2) Determinants of fuel pressure

The fuel pressure is regulated by following two principles:

- After the fuel rail pressure is decided by engine operating conditions,

- Rail pressure reaches the desired value by regulating the IMV.

The pressure in fuel rain depends on the engine rpm and engine load:

- High engine rpm and load

The fuel is injected in high pressure for ideal combustion since turbulent flow is highly likely to occur.
Low engine rpm and load
- Turbulent flow is less likely to occur in these conditions. If the injection pressure is too high, the
penetration power becomes excessive when the fuel is injected from the injector and some of fuel is
condensed on the cylinder wall, resulting in incomplete combustion. This causes the smoke to be
generated and reduces engine durability

The fuel pressure is corrected by atmospheric pressure, coolant temperature and intake air temperature.
When driving in cold weather or at high altitudes, additional ignition time is considered. When starting the
engine, additional fuel injection is required. At this time, there is a special demand for pressure and
correction is carried out by temperature of the injected fuel or coolant.

GETtheMANUALS.org
 0000-00 17-33

(3) Fuel Pressure Control

▶ In open loop, the current to the actuator is determined to obtain the fuel flow required by the
▶ ECU.
In close loop, the difference between required fuel pressure and measured fuel pressure is
recognized to correct the current value.
- When the rail pressure is lower than actual pressure required, the current is reduced to increase the
- fuel supply to the high pressure pump,
and vice versa.

(4) Fuel Injection Control

Injection control is used to decide the characteristics of current pulse to the injector.
Injection control consists of:

- Injection timing
- Injection amount
- Factors which convert fuel injection timing and injection amount into values can be interpreted by
injector driver

▶ Main injection timing control

The engine rpm and pilot injection volume depend on the pulse needed for main injection.
The determinants are as follows:

- The first correction is determined based on the air and coolant temperature.
The injection timing is controlled by the engine operating temperature; In hot engine, the injection
timing is retarded in order to lower high combustion temperature and reduce the harmful materials
such as NOx. In cold engine, the injection timing is advanced so that optimum combustion can occur.
The second correction is determined by the atmospheric pressure.
- Change of atmospheric pressure based on altitudes is used to advance the injection timing.
The third correction is determined by the coolant temperature and time after starting.
- This is used to increase the injection volume by retarding the injection timing during engine warm-up
(30 sec.), at initial start and to reduce the misfire or unstable combustion which may occur on cold
engine.
The fourth correction is determined by the pressure.
- This correction prevents the diesel knocking which may occur when the fuel rail pressure is higher
than required by retarding the injection timing.
The fifth correction is determined by the EGR ratio.
- As the EGR ratio increases, injection timing is retarded to compensate for combustion (cylinder)
temperature drop.

The injection timing should be changed according to each determinant in order for combustion to occur
at position close to the TDC during engine starting. The determined injection timing has been mapped in
the ECU for optimum injection timing.

GETtheMANUALS.org
17-34

▶ Pilot injection timing control

The pilot injection timing is determined based on the engine rpm and total fuel flow.
The determinants are as follows:
- The first correction is determined based on the air and coolant temperature.
This correction allows the pilot injection timing to be adapted to the operating temperature of the
engine.
- The second correction is determined by the atmospheric pressure.
This correction adjusts the injection timing properly according to the change of atmospheric pressure
based on altitudes. The pilot injection timing is determined based on the engine rpm and the coolant
temperature when starting the engine.

(5) Fuel Control

a. Main fuel flow control
The main fuel flow means an amount of fuel which injected to the cylinder during main injection.
The pilot flow means an amount of fuel injected during pilot injection.

The total injection amount (main flow + pilot flow) during 1 cycle is determined as follows:

▶ When the driver depresses the accelerator pedal, the system judges the pedal position to
decide the fuel amount to be injected.
▶ When the driver releases the accelerator pedal, the idle speed controller decides the
minimum fuel amount to be injected in order to prevent the vehicle from being stalled.

The bigger of these two values is stored in the system, which will be compared with the minimum fuel
amount decided by the ESP (Electronic Stability Program) system afterwards.

If the actual amount of injected fuel is smaller than the minimum fuel amount decided by the ESP
system, the counter torque (braking torque by engine brake) to the driving wheel becomes larger than
the engine drive torque, which may cause the driving wheel to be locked.
The system chooses the larger of two values in order to prevent any damage which may occur during
abrupt deceleration.

GETtheMANUALS.org
 0000-00 17-35

The engine torque to the wheels exceeds vehicle's grip force as soon as the amount of fuel injected
becomes larger than the fuel amount limit decided by the ESP system, which may result in wheel slip.
The system chooses the smaller of two values in order to prevent any damage caused by vehicle control
during acceleration. Anti-oscillation strategy compensates for fluctuation of engine rpm temporarily. This
is determined by instant engine rpm and shift lever position and corrects the fuel amount to each
cylinder.

The switch enables to change from total fuel to an supercharged fuel according to the engine conditions.
- The system uses a supercharged fuel until engine warm-up is completed.
- The system uses total fuel once the engine operates normally.

Main injection volume is total injection volume minus pilot injection volume.
The mapping calculates the minimum fuel to control the injector as an action of fuel rail pressure.
When the main fuel drops below this value, the injector can't inject the amount of fuel requested and the
demand on fuel becomes 0.

GETtheMANUALS.org
17-36

b. Driver demand
The driver's will is changed to demand on fuel according to the accelerator pedal position.
This is calculated as an interaction between the accelerator pedal position and engine rpm. The driver's
will is filtered in order to avoid the response delay which may occur during sudden acceleration. Mapping
calculates the driver's will and fuel rail pressure to decide maximum fuel amount can be injected.
Since the fuel flow (fuel amount) is proportional to the root value of injection pressure, the fuel flow
should be limited according to the pressure in order to prevent the fuel being injected too long during
engine cycle.
The system compares the driver's will (pedal position) with the fuel limit value and chooses the smaller
one.
Then, the driver's will is corrected by the coolant temperature and this correction is strengthened again
the driver's will.

GETtheMANUALS.org
 0000-00 17-37

c. Idle speed controller

The idle speed controller consists of 2 basic modules:

- One decides the necessary idle speed according to the followings:

* Engine operating conditions (coolant temp., gear position)
* Electric system's operation (power steering, A/C, other electric systems)
* Battery voltage
* In the event of defective fuel rail pressure control and injection control, it increases idle
speed to prevent engine stall at low gears.
- The other enables the close loop control of the engine idle speed just by change of
minimum fuel at difference between the required idle speed and actual engine speed.

d. Flow limitation
The principles of flow limitation are as follows:

- The flow limitation is determined based on the engine rpm and air volume.
The smoke is reduced during stable driving.
- The flow limitation based on atmospheric pressure is determined by the engine rpm and atmospheric
pressure.
The smoke is reduced while driving at high altitude.
- The fuel curve at maximum torque is determined by which gear is engaged and engine rpm.
Maximum torque is generated in the limited engine operation.
- If the system has any fault for rail pressure and injection control, the operation will be limited and the
system operates as follows according to fault severity.
Reduced flow logic 1: guarantees 75% of performance without engine rpm limitation.
Reduced flow logic 2: guarantees 50% performance with rpm limited to 3,000 rpm.
Reduced flow logic 3: limits rpm to 2,000.

The system chooses the lowest among theses values.

The correction related to the coolant temperature is included in fuel control and this correction may
reduce the mechanical stress during engine warm-up.
This operation is determined by the coolant temperature after start-up, engine rpm, time required and
etc,.

e. Supercharger flow demand

The supercharge flow is calculated according to the engine speed and the coolant temperature.
A correction depending on the air temperature and the atmospheric pressure is made in order to
increase the supercharge flow during cold starts.
It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool.

GETtheMANUALS.org
17-38

f. Pilot flow control

The pilot flow indicates an amount of fuel injected into the cylinder during pilot injection and depends on
the engine speed and total flow.

- The first correction is determined based on the air and coolant temperature.
This correction allows the pilot injection timing to be adapted to the operating temperature of the
engine.
The ignition time is reduced since the temperature at the end of compression is high at hot engine.
The pilot flow is reduced since little combustion noise occurs at hot engine.
The second correction is determined by the atmospheric pressure.
- This correction is used to adapt the pilot flow according to the atmospheric pressure and the
altitude.

During starting, the pilot flow is determined on the basis of the engine rpm and the coolant temperature.

g. Cylinder balancing strategy

▶ Balancing of the point to point flows

The pulse of each injector is corrected according to the difference in instantaneous speed measured
between 2 successive injectors.
The instantaneous speeds on two successive injections are first calculated.
The difference between these two instantaneous speeds is then calculated.
Finally, the time to be added to the main injection pulse for the different injectors is determined. For each
injector, this time is calculated according to the initial offset of the injector and the instantaneous speed
difference.

▶ Detection of an injector which has stuck closed

The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The
difference in instantaneous speed between 2 successive injections then exceeds a predefined threshold.
In this case, a fault is signaled by the system.

GETtheMANUALS.org
 0000-00 17-39

h. MDP learning control

▶ MDP Learning

MDP means minimum power supply pulse which

can be injected by the injector. If MDP is learned
correctly, the system can control the fuel flow for
each injector precisely. For MDP learning, a
pulse over MDP slightly is supplied to detect the
angular speed from the cylinder. The crankshaft
position sensor detects the change of angular
speed from the engine after small amount of fuel
is injected. This is MDP learning.

- MDP learning is helpful to prevent engine

vibration, high emission and power reduction
through performing calibration based on
ageing of injectors.
- Adjust the pilot injection through MDP
control.
: During MDP learning, a little vibration and
noise can be occur for a while. This is
because the pilot injection stops and fuel
pressure is increased instantaneously so that
the exact engine vibration timing can be
detected. These symptoms may occur for a
while during learning process.

GETtheMANUALS.org
17-40

▶ MDP learning by SPC

The MDP learning carried out by the SPC

detects an angular speed of the piston for each
cylinder through the crankshaft position sensor,
unlikely the traditional APC learning.
When fuel-cut duration is longer than 7 seconds,
the learning by SPC is performed as follows:

- If the ECU sends the injection pulse (-B) less

than MDP,
- when an angular speed of each cylinder falls at
a fixed rate due to fuel-cut (A), the fuel is not
injected and angular speed of the cylinder
reduces evenly (-C).
- If the ECU sends MDP (B) and the fuel is
injected (D), angular speed of the cylinder
increases by an explosive power.
- In other words, MDP learning by SPC is a
minimum pulse value in the crank angular
speed variations (increase) during fuel-cut.

MDP (Minimum Drive Pulse): Minimum injection pulse of fuel

APC (Accelerometer Pilot Control): Pilot control by knock sensor
SPC (Speed Pilot Control): Pilot control by angular speed (crank position sensor) variations of each
cylinder

▶ MDP learning condition

Items Specifications
Battery voltage 11 ~ 15V
Engine speed 1500 ~ 2600rpm
Transmission 3rd or higher
Coolant temperature 70 ~ 105˚C
Fuel temperature 20 ~ 80˚C
Intake air temperature 15 ~ 60˚C
Intake manifold pressure 0.8 ~ 1.5bar
Atmospheric pressure 0.9 ~ 1.09bar

GETtheMANUALS.org
 0000-00 17-41

3) Accelerometer Control
(1) Resetting the pilot injection
The knocking control is used to reset the pilot injection flow in closed loop for each injector. This method
allows the correction of any injector deviations over a period of time. The principle of use of the knocking
control is based on the detection of the combustion noises.
The knock sensor detects the rotating angular speed of the engine after small amount of fuel is injected.

1. The accelerometer signal for each cylinder is used to establish the background noise level. This
must therefore be positioned at a moment when there cannot be any combustion.
2. It is used to measure the intensity of the pilot combustion. Its position is such that only the
combustion noises produced by the pilot injection are measured. It is therefore placed just before the
main injection.

The crankshaft position sensor detects the rotating angular speed of the engine after pilot injection. This
is called speed pilot control (SPC).
On the basis of this information, it is possible to efficiently correct the pilot flows through the SPC learning
control.

This is done periodically under certain operating conditions. When the resetting is finished, the new
minimum pulse value replaces the value obtained during the previous resetting. The first MDP value is
provided by the C3I. Each resetting then allows the closed loop of the MDP to be updated according to
the deviation of the injector.

GETtheMANUALS.org
17-42

4. IMV(Inlet Metering Valve) CONTROL

1) IMV Components
The IMV is located to the high pump front plate. This receives the fuel through the supply pump with 2
radial holes. The cylinder filter is secured to the supply orifice of IMV.
This protects all the components related to the injection system which are located to the LP actuator and
lower IMV passage. The IMV consists of the following:

- Piston is fixed to open fully by the spring.

- Piston filter is located to the inlet.
- 2 O-rings maintain sealing between the hydraulic head and IMV body.
- Body has 2 radial inlet holes and outlet hole.
- Coil

GETtheMANUALS.org
 0000-00 17-43

2) Functions
Regulating fuel amount to high pressure pump to control fuel pressure

3) Advantages
Lowers the fuel temperature in return line and improves the injection efficiency.

4) Characteristics
- Normally open when no power is supplied
- Flow reduces as current value increases

GETtheMANUALS.org
17-44

5) Operation Principle
The pressure measured by the fuel pressure sensor is controlled to meet the pressure demand from the
ECU. The LP actuator is used to regulate the fuel volume to the pumping unit of the high pressure pump.
Fuel volume to high pressure pump = fuel volume injected from injector + injector back leak fuel volume
+ injector control fuel volume. The IMV is open when the power supply is not applied. It cannot therefore
be used as a safety device to shut down the engine if required.
The IMV is controlled by current value.
The following is the graph of flow and current.

Engine status Fuel pressure IMV opening

Idle status Approx. 250bar 33 ~ 34%
At full load Approx. 1600bar 16.8%

6) Features
Coil resistance 5.3Ω ±10% (@20˚C)
Battery voltage (current control)
Power supply (it is prohibited to supply the battery voltage directly during
diagnostic test)
Max. current 1.3A
Operating
-30 ~ 120˚C
temperature
Control logic Normally open when no power is supplied

GETtheMANUALS.org
 0000-00 17-45

5. INJECTOR CONTROL
1) Characteristics
(1) C3I (Calibration Improved Individual Injector)
The injector in the common rail system is a very precise part. The injector can inject the fuel of 0.5~100
mg/st at pressure of approx. 2,000 bar. Therefore, the machining tolerance of the nozzle in the injector is
a very important factor. (in ㎛)
A little difference between injector machining can't be ruled out.
Change of magnetic force/mechanical frictional force of the
driving part (valve) may vary for each injector. It is necessary to
calibrates precisely the difference between machining of different
injectors, injection volume based on injector's initial
characteristics.
For this, you should know about injector's initial characteristics.
This initial characteristics are coded as C3I. The ECU calibrates
the current to the injector according to the difference of calibration
improved individual injector.

C3I [Improved Individual Injector Calibration]

C3I code 20 digits

Numbers (1 to 9) and alphabetical characters except I, O, Q, V
SPC learning During fuel cut-off
Injection nozzle 7 pcs

GETtheMANUALS.org
17-46

a. C3I code on injector

(A) Marks on (B) Marks on

injector cylinder head cover

ENG NO:00000000000000
112345678901234567890
212345678901234567890
312345678901234567890
ENG NO:00000000000000
412345678901234567890
The injector C3I code for each
C3I code printed
cylinder is printed on labels with
on top of the
the engine serial number.
injector

The C3I codes, which consists of 20 digits, are printed on the injector side and cylinder head cover.
Numbers (1 to 9) and alphabetical characters except I, O, Q, V are used for C3I code. (The first figure of
C3I code (21 digits) on the cylinder head cover indicates the cylinder number.)

b. Control preciseness of fuel injection and target value injection in C2I andC3I

Without C2I C2I C3I

If C2I code on the injector is Target value injection and It looks more similar to the
ignored, the engine ECU does actual fuel injection are target value than C2I coding
not inject the fuel to the target similar, compared to without and a precise control is
value according to each C2I coding. possible.
sensor or vehicle status. (reduced irregular injection for
each injector)

GETtheMANUALS.org
 0000-00 17-47

(2) Minimum drive pulse (MDP) learning by crankshaft position sensor

Measure minimum drive pulse value which the injector can inject. MDP learning enables SPC (Speed
Pilot Control) so it is possible to calibrate the pilot injection effectively.
Since the fuel volume at the pilot injection is 1 to 2 mm/st which is very small, it is difficult to control the
injection precisely if the injector is aged. Thus, MDP learning is necessary to control the injection volume
and its condition continuously and precisely as the injector is aged.
The MDP learning carried out by the crankshaft position sensor detects a rotating angular speed of the
engine through the crankshaft position sensor and uses it.

a. Purpose
It measures minimum drive pulse value which the injector can inject to reduce the engine vibration.
- Control the injection volume continuously and precisely as the injector is aged
- ECU calibrates pilot injection effectively using SPC control

(3) Curve of injection volume based on rail pressure

The graph above shows a function of pulse and rail pressure and it is called as a injector characteristics
curve. (The injected fuel volume is proportional to the square root of injection time and rail pressure.)

GETtheMANUALS.org
17-48

(4) Injection from injector

a. Fuel pressure
- Min. operating pressure: injection starts at 100 bar or above
- Max. normal operating pressure: 2,000 bar (max. operating inflow pressure under normal
conditions)
- Normal operating pressure limit: 2,100 bar

b. Max. injection volume per injector cycle

- Pilot injection ≤ 5 mm3
- Main injection ≤ 85 mm3 (@ 200 ~ 2,000 bar)
- Operating pressure: 2,100 bar

Injection angle of injector's injection nozzle

- The injector is very sensitive to cleanliness. When removing the connecting hose and pipe, the
openings must be sealed with a cap so that they are not exposed to the pollutants in the air.
When removing the injector, replace the copper washer on the bottom of the injector with new
- one.
You must tighten the mounting bolts for the injector fastening clamp to the specified torque.
- Do not drop the injector since it is weak to impact.
-

GETtheMANUALS.org
 0000-00 17-49

(5) Injector control

The coil has 2 control currents; one is pull-in current of approx. 20 A generated to lift the injector's
needle valve and the other is hold-in current of approx. 10 A flowing to maintain the needle valve to stay
operation.
The lower current helps to reduce the loss between the ECU and injector due to Joule effect. Pull-in
period is higher than hold-in period and the reason is as follows:

- The air gap between the valve and the coil is

reduced and the electromagnetic force to be
applied to the valve can thus be reduced. It is
no longer necessary to overcome the valve
inertia.

Joule Effect: The heat capacity generated by

resistance is proportional to the square root of
current and the resistance.
Heat capacity (H) = 0.24 I2RT

- Small injection separation: min. 200 ms

(duration between the end of pilot injection
and start of main injection)

- OD (Opening Delay)
Delayed time from applying operating
voltage to startof injection

GETtheMANUALS.org
17-50

▶ Injector drive circuit

The injectors receive operation power supply through the banks 1 and 2 in the ECU.
The No. 1 and 4 injectors of 4 injectors receive power supply from bank 1 and No. 2 and 3 from bank 2.
Therefore, if one coil has any problem such as short circuit and that bank power is affected, the injector
receiving power from that bank also encounters problem.

GETtheMANUALS.org
 0000-00 17-51

(6) Fuel injection

a. Multiple injection
The injection is largely carried out in 3 steps. The pilot injection occurs before the main injection and the
post injection occurs after the main injection.

▶ Pilot injection ▶ Multiple injection

GETtheMANUALS.org
17-52

b. Pilot injection
It occurs before main injection and there is two pilot injections, 1st and 2nd.
Before starting main injection, a small amount of fuel is injected to help proper combustion. It is also
called as pre-injection or combustion injection. This injection is for reducing NOx, engine noise and
vibration and controlling idle stability.
In other words, it prevents a severe combustion (diesel knock) to reduce NOx and reduce the engine
noise and vibration (suppressing the surging).
Basic values for pilot injection are adjusted according to the coolant temperature and intake air pressure.

Pilot injection deactivation conditions

- Pilot injection overtakes too much main injection due to increased engine rpm
- Low injection volume (low injection pressure, insufficient fuel for main injection, engine brake)
- System failure (fuel system, brake system)

▶ Characteristic curve of combustion chamber pressure during pilot injection

- Before starting main injection, a small amount of fuel is injected to reduce the engine noise and
vibration and inhibits generation of exhaust gas by slowing down pressure rise ratio in the
combustion chamber.
1. Pilot injection
2. Main injection
1a. Burst pressure with pilot injection
2b. Burst pressure without pilot injection

GETtheMANUALS.org
 0000-00 17-53

c. Main injection
Actual output from engine is achieved by main injection.
The main injection determines the pilot injection has been occurred, then calculates the injection volume.
Accelerator pedal sensor, engine rpm, coolant temperature, intake air temperature, booster
pressure/temperature and atmospheric pressure are basic data to calculate the fuel injection volume in
main injection.

d. Post injection
Post injection occurs after main injection and there are 2 injections, post 1 and post 2. These are mostly
related to PM or smoke escaping though exhaust gas. It actually generates no power and activates the
fuel by injecting fuel to an unburned gas after main combustion. In this way, it reduces PM and smoke.
All these injections are not carried out while driving. Total 5 injections can occur within one cycle.
If all seven injections occur, there may be any loss in terms of exhaust gas as well as fuel economy.

Not all of the seven injections take place while driving, but a total of five injections take place within
one cycle. If all seven injections occur, there may be any loss in terms of exhaust gas as well as fuel
economy.

GETtheMANUALS.org
17-54

6. HFM (HOT FILM AIR-MASS SENSOR) CONTROL

1) Operation Principle
The HFM is a sensor to measure the intake air flow and intake air temperature. It measures directly air
flow (mass) using the heater current consumption cooled by air flow passing through the bypass
passage in the sensor.
The diaphragm is located in the sensor element and it has heating zone in it. The heating zone is cooled
continuously by intake air. The controller or IC in the sensor supplies current to maintain the heating
temperature at constant and calculates this current consumption to measure the intake air flow.
In addition, negative characteristic (NTC) type intake air temperature sensor is built-in to calculate the
precise air density by measuring the intake air temperature.

Intake air flow diagram for HFM sensor

Diaphragm

2) Components

Electronics cover
Bypass cover

Bypass channel
Electronics board

Intake air
temperature
Sensor element sensor

GETtheMANUALS.org
 0000-00 17-55

3) Diagram

4) Features
▶ Feature of intake air flow sensor

Intake air flow Specified value (㎲)

15 kg/h 499.43
20 kg/h 484.29
90kg/h 373.10
220kg/h 289.90
440kg/h 212.44
850kg/h 124.05
1000kg/h 99.55

▶ Feature of intake air temperature sensor

Intake air temperature

Resistance (Ω)

-40 39650
0 5489
20 2419
80 336.1
100 197.3
130 97.11

GETtheMANUALS.org
17-56

7. CRANKSHAFT POSITION SENSOR CONTROL

1) Features
- Hall sensor outputs the signal in the rectangular wave form.
- The magnetic trigger ring is magnetized, so be careful no to bring any magnetic material close to it.
That would affect the magnetic characteristic.
- The angle between the long tooth and the No. 1 cylinder is 114˚.

Magnetic trigger ring

Items Value
Power supply 5V
Output voltage 4.48V
Air gap 0.3 to 1.3 mm

The triggering can lose magnetic properties easily by an external magnetic field or scratches on the
surface. Do not use magnetic tools or equipment near the trigger ring.

GETtheMANUALS.org
 0000-00 17-57

8. BOOST PRESSURE/INTAKE MANIFOLD TEMPERATURE

SENSOR CONTROL
1) Process Flow Diagram

2) Boost Pressure Sensor

▶ Characteristics

GETtheMANUALS.org
17-58

3) Intake Manifold Temperature Sensor

▶ Characteristics

Intake air temperature

Resistance (kΩ) Voltage (V)
(℃)
-40 204.12 4.928
0 27.598 4.510
25 10.000 3.846
85 1.4510 1.630
100 0.9672 1.219
150 0.2927 0.444
200 0.1102 0.177
250 0.0490 0.080

GETtheMANUALS.org
 0000-00 17-59

9. COOLANT TEMPERATURE SENSOR CONTROL

1) System Diagram

2) Features
Coolant temperature
-40 -10 15 20 80 130 140
(°C)
Resistance (Ω) 45300 9200 3055 2500 327 90 72

GETtheMANUALS.org
17-60

10. FUEL RAIL PRESSURE SENSOR CONTROL

1) Diagram

2) Feature
▶ Sensor output voltage

Sensor supply voltage 5 ± 0.25V

Sensor output voltage 2,200 bar 4.5V

0 bar 0.5V
0 ~ 900 bar ±0.8%

Max. output voltage 900~1,350 bar ±1.0%

Tolerance 1,350 ~ 2,200 bar ±1.3%
Ave. tolerance ±1.0%

▶ Sensor internal defect

In the event of sensor internal defect, the output signal is fixed at 0~0.2 V for low diagnostic area or
4.8~5 V for high diagnostic area.

GETtheMANUALS.org
 0000-00 17-61

11. ACCELERATOR PEDAL POSITION SENSOR (APS)

CONTROL
1) Features
1. Determines the fuel injection volume and timing by detecting the accelerator pedal position
ACC1: main sensor which determines the injection volume and timing (5.0 V)
ACC2: Checks for validity of the signal from the ACC1 (5.0 V)
2. Failure of one of ACC1 and ACC2
Controls the torque reduction by 50%
3. Failure of both ACC1 and ACC2
Changes to limp home mode (1,300 to 1,400 rpm)

2) Kick-down switch
This switch prevents loud engine noise and
deterioration of fuel efficiency due to increased
rpm and slipping on a slippery surface by
inhibiting unintentional downshift when rapidly
accelerating.

The kick down switch is a dummy switch

which is not connected to wirings.

Pedal position Specified value

IDLE 1 ± 0.05V
Accelerator pedal 1
When pedal fully depressed 4.2 - 0.13V ~ 4.2 + 0.105V
IDLE 0.5 ± 0.025V
Accelerator pedal 2
When pedal fully depressed 2.1 - 0.065V ~ 2.1 + 0.055V

GETtheMANUALS.org
17-62

12. E-EGR CONTROL

1) Input/Output Diagram

GETtheMANUALS.org
 0000-00 17-63

2) Bypass control for EGR cooler

(1) Coolant temperature
At 65℃ or less of coolant temperature, bypass the coolant flow since the cylinder temperature is
low and exhaust gas temperature is low.

(2) Exhaust gas temperature

At 150℃ or less of the exhaust gas temperature, the soot/PM increases further as the exhaust
gas will be cooled down at low exhaust gas temperature when the coolant passes the EGR cooler.

3) Control elements for EGR system

- Accelerator pedal (engine load) - Indicates the driver's intention and engine load. If the load goes up,
the EGR ratio is decreased.
- Booster pressure sensor - Boost pressure map stored in ECU Compensates the difference in boost
pressure by adjusting EGR ratio.
- Engine rpm - Used as the signal for determining EGR operating range and engine rpm and engine
load are calculated at the same time to obtain the EGR ratio.
- Coolant temperature - When the coolant temperature is low, NOx is decreased but PM could be
increased. So, to reduce PM, decrease EGR ratio when the coolant temperature is low.
- Intake air mass and temperature - HFM sensor measures the intake air mass to calculate the
actual EGR volume. If the air mass is larger than programmed value in map, EGR ratio will be
higher.
- EGR position sensor - Detects the actual opening angle of EGR valve and performs feedback function
according to PWM control by ECU.
- Wide band oxygen sensor - Detects the oxygen volume in exhaust gas to check if the EGR ratio is
proper.
- Electronic throttle body - Keeps EGR ratio to optimized level by controlling the throttle body in EGR
operating range (decreasing pressure in intake manifold).

GETtheMANUALS.org
17-64

4) EGR features

As EGR ratio goes up, smoke volume will be As EGR temperature goes up, the concentration
higher. But, this lowers the combustion chamber of NOx will be higher. Thus, it is necessary to cool
temperature and accordingly the concentration of down the exhaust gas. However, during engine
NOx is decreased. The point with highest NOx is cooled, it may cause large amount of PM. To
immediately after TDC. prevent this, the exhaust gas is bypassed the
EGR cooler.

GETtheMANUALS.org
 0000-00 17-65

5) E-EGR valve features

(1) Improved accuracy and responsiveness through engine ECU control
While the existing engines has the vacuum modulator between the engine ECU and EGR valve and
controls opening of the EGR valve using a vacuum generated at the vacuum pump, the E-EGR valve
receives the signal from the engine ECU directly to drive the DC-Motor in the E-EGR valve.
By driving the E-EGR valve directly, vacuum leakage or delayed responsiveness has been improved and
precise valve control is possible according to the electric signal.

(2) Feedback of E-EGR valve

The engine ECU controls the E-EGR valve directly and feedbacks the precise position of the operated
E-EGR valve to the ECU.
The EGR Valve use the non contact hall sensor for feedback to the ECU.
Valve position sensor characteristic is below.
This signal feedbacks opening of the E-EGR valve to the ECU.
Basically, the feedback signal which controls opening of the E-EGR valve is intake air flow from the HFM
sensor. (If the exhaust gas gets into the intake manifold when the EGR valve is open, the amount of
fresh air through HFM sensor should be decreased. The engine ECU receives change of air flow
passing through the HFM sensor based on opening of the EGR valve as a feedback signal.)

(3) Cleaning of EGR valve

The E-EGR valve chatters itself by operating the DC-motor during engine-off from high-middle speed in
order to remove the foreign materials such as carbon accumulated in the valve seat and housing. At this
time, some carbon and other foreign materials come away.

(4) EGR valve position learning based on carbon accumulation

The E-EGR valve monitors and analyses the valve position when the valve is closed and open before
the ignition is switched off and can compensate for the change of valve actuation position due to the
carbon or other materials.

GETtheMANUALS.org
17-66

6) Operation Zone
Since the operation zone and control zone of the E-EGR valve is based on the precise control logic
(MAP), this manual shows a typical operation and non-operation zones only.

1. Intake air temperature not too high or too low (approx. between -10˚C and 50˚C)
2. Atmospheric pressure not too low (approx. 0.92 bar or higher)
3. Engine coolant temperature in proper range (between 0˚C and 100˚C)
4. EGR deactivated during sudden acceleration (accelerator pedal depressed and engine rpm of 2,600 or
higher)
5. EGR valve deactivated during idling for more than about 1 minute
6. EGR valve deactivated at vehicle speed of 100 km/h or above
7. EGR valve deactivated at high-load range of engine torque (380 Nm or above)
8. EGR valve normal when no DTC related to EGR found

7) Fluctuations of intake air volume based on EGR operation

The intake air flow to the engine is measured by the HFM during EGR operation. The measured value is
different from one when the EGR is not operated.

Intake air volume during EGR operation and non-operation

Reference intake air
Category Remarks
volume
EGR operation Approx. 310 mg/str -
Revolution/EGR non-operation
EGR non-operation 400 ± 30 mg/str
zone

If the actual intake air volume differs from the reference intake air volume when checking sensor data,
the followings are suspected.

- Low intake air volume compared to reference value at EGR non-operation zone EGR valve
stuck open
- High intake air volume compared to reference value at EGR operation zone EGR valve stuck closed,
EGR cooler blocked

GETtheMANUALS.org
 0000-00 17-67

8) Control Logic
(1) Initial learning mode
When the position data on the EGR is not stored at the ECU, the initial learning is carried out.

Learning time key on

If the learned value does not exist at all, the

learning is carried out during initial key on. The
valve is positioned from initial position to its
lowest position by increasing the current
gradually. If the valve comes contact with the
valve seat, the current to operate the actuator is
increased, which leads the ECU to recognize
that the valve is in its lowest position.

GETtheMANUALS.org
17-68

(2) Learning mode during key off and Cleaning Mode

Learning period When EGR valve closed

When learning after key off is carried out, the valve

moves slowly to the closed position. In order to
prevent the valve from being open due to the back
pressure after the initial learning is carried out at the
closed position, the EGR valve is controlled at a
duty of 50% when the valve is closed.

GETtheMANUALS.org
 0000-00 17-69

13. E-EGR BYPASS SOLENOID VALVE CONTROL

1) Operation Principle

The solenoid valve turns on or off according

to signal from the ECU to transmit the
vacuum generated at the vacuum pump to
the EGR bypass valve.
Since the temperature of the EGR cooler
and engine is generally low before the
engine is warmed up, cooling is not
necessary and the EGR gas moves to the
intake manifold through the bypass passage
without passing through the EGR cooler.

2) Control Elements
(1) Coolant temperature sensor
At 65˚C or less of coolant temperature, bypass the coolant flow since the cylinder temperature is
low and exhaust gas temperature is low.

(2) Exhaust gas temperature sensor

At 150˚C or less of the exhaust gas temperature, the soot/PM increases further as the EGR gas
will be cooled down at low exhaust gas temperature when the coolant passes the EGR cooler.

GETtheMANUALS.org
17-70

14. E-VGT CONTROL

1) Input/Output Diagram

GETtheMANUALS.org
 0000-00 17-71

2) E-VGT System Control

The turbocharger system operates the E-VGT actuator according to the signals for engine rpm,
accelerator pedal position, atmospheric pressure, T-MAP, coolant temperature, intake air temperature
and etc,.
The turbocharger actuator is performed PWM control by ECU.
In general, the boost pressure feedbacks the turbocharger operation and the boost temperature is
used for calculating the precise density.
Since gas emissions is small and flow velocity is slow at low vehicle speed, the turbocharger is difficult
to do its best and has an effect to reduce turbo lag with a venturi tube effect.
At high vehicle speed, the inner diameter of the venturi tube is increased to minimize pumping loss.

Range Operating wave Vane condition Control

In low speed range,
retract the vane to
increase boost
pressure to maximum.
The vane has low (-)
Low duty, and the unison
speed ring moves to retract
the vane in weak
PWM signal.

The unison ring moves

to extend the vane in
strong PWM signal.
Maximum pressure is
High 3 bar and the system
speed controls it according to
the input signals.

The E-VGT actuator and turbocharger have a normally open vanes.

GETtheMANUALS.org
17-72

15. DIFFERENTIAL PRESSURE SENSOR CONTROL

1) Specifications
Specifications
Items
Min. Typ. Max. Unit
Pressure range 0 - 100 Kpa
Allowable
-40 - 130 ℃
temperature
Supply voltage 4.75 5 5.25 V
Supply current 10 14 17.5 mA
Output current -1 - 0.5 mA
Response time - 1 - Ms
0.25 0.3 0.35 V
Fixed voltage
4.65 4.7 4.75 V

2) Features

The differential pressure sensor detects the differential pressure of the DPF and sends the signal value
of 0.5 ~ 4.5 V to the ECU. The bigger difference of pressure between in the input port and output port is,
the closer the output voltage is to 4.5 V. The smaller, the closer to 0.5 V.

▶ Functions

- It is used as a signal to calculate the PM amount in the DPF.

- It measures the exhaust gas pressure after regeneration process and checks whether combustion
occurs actually in the DPF.

GETtheMANUALS.org
 0000-00 17-73

16. WIDE BAND OXYGEN SENSOR CONTROL

1) Input/Output Diagram

GETtheMANUALS.org
17-74

2) Features
Normal oxygen sensor uses a principle that if there is difference in oxygen concentration between in the
exhaust gas and in the air, the voltage is generated by movement of oxygen ions. The wide band
oxygen sensor also uses a similar property. That is, it fundamentally uses ZrO₂ and uses the
principle that the voltage is generated when the oxygen ions pass through adversely. If a certain voltage
is applied to the sensor, the movement of oxygen ions occurs regardless of the oxygen density. The
current generated through this flow of ions, is called pumping current (IP), and the oxygen sensor
measures this value.

- Nernst voltage (UN)

The measuring cell (Nernst cell) operated in same operating principle as one of the zirconia sensor
measures the remaining oxygen concentration in the exhaust gas. The Nernst voltage is the voltage
produced by the difference in the oxygen partial pressure in the exhaust gas and oxygen in reference
gap. The ECU adds the Nernst output value and virtual earth output value for judgement. The voltage
of approx. 450 mV is generated when λ is 1.
- Pumping current (IP)
If the air-fuel ratio (λ) is 1 and IP is 0, the Nernst voltage (UN) is 450 mV.
If the air-fuel ratio (λ) is higher than 1 (lean), the Nernst voltage (UN) is lower than 450 mV.
At this time, in order to balance the air-fuel ratio (λ), the ECU controls the polarity of voltage so
that (+) is applied to the exhaust gas side and (-) to the measuring cell. O₂ ions are pumped
from the diffusion gap to the exhaust gas side though the porous solid electrolyte. The ECU flows the
pumping current. This process lasts until the air-flow ratio (λ) becomes 1 at the diffusion
(measurement) gap.
If the air-fuel ratio (λ) lower than 1 (rich), the Nernst voltage (UN) is higher than 450 mV.
In this case, the ECU controls in opposition to the lean status to balance the air-flow ratio (λ). T
the O₂ ions are pumped from the exhaust gas side to the diffusion gap and the ECU flows
the pumping current adversely.

GETtheMANUALS.org
 0000-00 17-75

- Virtual earth (VM)

It is the voltage that is used as standard by the IC controlling the oxygen sensor. The voltage of
approx. 2.5 V is applied to each cell and the sum of the Nernst voltage and voltage on the virtual
earth terminal is sent to the ECU.
- Trimming resistance (RT) : 30~300 Ω
This resistance is used to calibrate the deviation which occurs when cutting with the laser in the
sensor manufacturing process. It is installed in the connector to the wide band oxygen sensor.
Heater
- Resistance in wide band oxygen sensor heater (3.2 ± 0.8 Ω)

▶ Air-fuel ratio / IP current value based on EGR and engine revolution

The air-fuel ratio (λ) is fixed at 1.004 initially. When the coolant temperature and exhaust gas
temperature reaches normal level and engine is warmed up, it changes to approx. 6.2~6.7.

+ The start-up status should be maintained for more than 3 minutes at initial start-up and restart
before the air-fuel ratio (λ) value and IP current value can be outputted.
- When the accelerator pedal is depressed after warm-up, the EGR valve is activated for about 1
minute and deactivated after 1 minute.
- If the air-fuel ratio (λ) value of the wide band oxygen sensor is lean, the current/voltage
values increase proportionately.

GETtheMANUALS.org
17-76

▶ IP curve based on air-fuel ratio

GETtheMANUALS.org
 0000-00 17-77

17. EXHAUST GAS TEMPERATURE SENSOR CONTROL

1) Features
▶ Turbine upstream exhaust temperature sensor

The turbine upstream exhaust temperature sensor is mounted between the exhaust manifold and
turbocharger.
It measures the exhaust gas temperature in the exhaust manifold. If the exhaust gas temperature is too
high, it may cause deteriorate durability of the turbocharger and temperature will be higher after the LNT.
Therefore, in order to protect the turbocharger, it is important to measure the initial exhaust gas
temperature.
If the temperature of exhaust gas exceeds approx. 800℃, internal bearing could be stuck by
burnt out. ECU monitors the signals from turbo upstream exhaust gas temperature sensor so that the
exhaust gas is not overheated. If necessary, ECU reduces the fuel injection volume or increases the
EGR gas volume to lower the temperature.

▶ DPF upstream exhaust temperature sensor

The DPF upstream exhaust temperature sensor is mounted between the LNT and DPF. It measures
exhaust gas temperature after the LNT. The exhaust gas temperature will be higher after the LNT due to
an oxidation process, etc. The higher the exhaust gas temperature before the gas passes through the
LNT is, the higher the exhaust gas temperature after the gas passes through the DOC and oxidation is.
When it is in the LNT & DPF regeneration zone due to pressure difference between differential pressure
sensors, the ECU commands to add post injection process to the fuel injection process to increase the
temperature of the exhaust gas. When it is in the low engine load zone where the temperature of the
exhaust gas is low, the amount of the intake air is also reduced by the throttle flap, and this permits the
fuel mixture rich to increase the combustion temperature. If the temperature value from the rear exhaust
temperature sensor is above 600℃ during the post injection process, the post injection is not or a
little performed. If the temperature value is below 600°C, the amount of post injection is increased
to adjust exhaust gas regeneration temperature of the LNT & DPF.

▶ SCR upstream exhaust temperature sensor

The most appropriate reaction temperature of the normal catalyst is between 180 and 400℃ in
the SCR system. The SCR upstream exhaust temperature sensor detects temperature change directly
at the ECU. If the exhaust gas temperature is 180℃ or higher,
it makes the dosing injector spray the urea through the DCU.
It has a similar characteristic with the front and rear exhaust gas temperature sensors.

GETtheMANUALS.org
17-78

▶ Features

Temperature (℃) Temperature (℃)

Resistance (Ω) Resistance (Ω)

-40 169.18 350 453.66

-20 184.64 400 487.56
0 200.0 450 520.87
25 219.07 500 553.60
50 237.99 600 617.30
100 275.40 700 678.66
150 312.22 800 737.68
200 348.46 830 754.93
250 384.11 850 766.31
300 419.18

GETtheMANUALS.org
 0000-00 17-79

18. ELECTRIC FAN AND A/C COMPRESSOR CONTROL

The engine ECU controls the electric fan to low or high speed by controlling two electric fan relays. The
engine ECU controls the electric fan to improve A/C cooling and engine torque. The ECU operates the
A/C compressor when the A/C switch signal is input from the A/C control module, and deactivates the
A/C compressor when the A/C system is overloaded to protect the system.

GETtheMANUALS.org
17-80

▶ Electric fan control parameters

The cooling fan relay, high-speed relay, and low-speed relay are operated due to the electric fan speed
control. The electric fan is controlled by the serial/parallel circuit control.

Coolant temperature Refrigerant pressure

Items Electric fan COMPRESSOR

OFF Lower than 90℃ -

A/C
90℃ or higher to -
switch Low speed
Lower than 105℃
OFF
High speed 105℃ or higher -
Low speed Lower than 18 bar
Lower than 105℃
High speed 18 bar or higher ON
A/C
switch High speed 105℃ or higher to
Lower than 115℃ -
ON
OFF (deactivated)
High speed 115℃ or higher -

GETtheMANUALS.org
 0000-00 17-81

▶ A/C compressor deactivation conditions

- Refrigerant pressure signal from the A/C refrigerant pressure sensor:

* 2.0 kg/㎠ or lower: OFF (2.3 kg/㎠ or higher: ON)
* 31 kg/㎠ or higher: OFF (26 kg/㎠ or lower: ON)
- Coolant temperature: OFF at 118℃ or higher (starts again at 111℃ or lower)
- Off for approx. 5 seconds after engine start
- Off for 4 seconds during abrupt acceleration
- Engine rpm: off at 400 rpm or less (starts again at 600 rpm or above)
- Off for 4 seconds when intake air negative pressure is higher than -0.2 kg/㎠
- Off at ambient temperature of 2℃ or less (starts again at 5℃ or higher) - controlled by DATC
- Off at evaporator temperature of 0℃ or less (starts again at approx. 2℃ or higher) - controlled
by DATC
- When driving forwards uphill with gradient of 15% or higher or stationary (D or 1st gear engaged)
When driving backwards downhill with gradient of 15% or higher or stationary (R gear engaged)
-

▶ Output voltage in relation to refrigerant pressure

When the A/C pressure sensor value is between 0 and 32 kg/㎠ with the A/C ON, the output
voltage of the refrigerant pressure sensor ranges from 0.5 to 4.5 V.

▶ Electric fan control in relation to ATF temperature

ATF temperature Electric fan operation Remarks

110℃ or higher High speed -

GETtheMANUALS.org
17-82

19. PTC HEATER CONTROL

1) Operation Process
This is a heater unit which uses a PTC effect. The ceramic PTC features that the resistance rises quickly
in a certain temperature range. The PTC heater has 3 circuits with power of 330 W. While only 1 circuit
in the PTC heater is connected during PTC1 operation, 2 circuits are connected during PTC2 operation.
The PTC heater operates as follows: temperature rises above specified level→resistance
increases→current decreases→calorific value decreases→temperature drops→resistance
increases→current increases→temperature rises.

GETtheMANUALS.org
 0000-00 17-83

2) Control Condition For PTC Heater

Operation Operating condition PTC heater status
PTC heater operates in
HI mode operation
- Coolant temperature < 15℃ "HIGH" mode if operating
(PTC2)
conditions are met
- Coolant temperature 15℃ ≤ 65℃ and
LO mode operation Intake air temperature ≤ -10℃
- Coolant temperature 15℃ < 65 ~ 60℃ and PTC heater operates in
(PTC1) "LOW" mode if operating
Intake air temperature < -10℃ ~ 0℃
- Coolant temperature 15℃ ≤ 60℃ and conditions are met
Intake air temperature ≤ 0℃ ~ 5℃
- Air conditioner blower switch OFF
- Faulty ambient temperature sensor
Conditions for (including open or shorted wiring)
Condition - Engine is cranking
- Battery voltage is 11 V or less
- Glow plug is being preheated
(Glow indicator comes on)

▶ Conditions for PTC heater "LOW" operation mode (2nd step)

GETtheMANUALS.org
17-84

20. CRUISE CONTROL SYSTEM CONTROL

The engine ECU detects the cruise control switch position and monitors the brake operating conditions,
clutch conditions, and vehicle speeds, etc. The engine ECU maintains the set vehicle speed, increases,
or decreases the vehicle speed according to the signals from the cruise control switch, unless a fault is
detected during cruise control driving.

GETtheMANUALS.org
 0000-00 17-85

21. IMMOBILIZER CONTROL

1) For a Vehicle with Ignition Key
When turning the ignition key to the ON position, the power is supplied to the immobilizer unit and EMS
(ECU). The ECU communicates with the immobilizer unit to verify the key and transponder. If it is valid,
the ECU starts to control the engine or immobilizer indicator (illumination or flashing) when the ignition key
is turned to the START position.
Once the key is verified, valid key verification time is provided for 10 seconds and the engine can be
started by turning the ignition key to the engine START position during this verification time. If the ignition
key is turned to the START position again after the 10 seconds of verification time, the key verification
should be reperformed.

1. When the ignition key is inserted, the immobilizer unit requests the transponder verification through
the antenna.
2. The transponder sends the encrypted message to the immobilizer control unit.
3. The immobilizer unit compares the encrypted message received from the transponder to the
coded value through the logic circuit. If they are identical, it requests the transponder approval.
When the ignition is turned ON, the EMS (ECU) requests immobilizer verification process through
4. the P-CAN.
The immobilizer control unit sends the encrypted message to the EMS (ECU).
5. The EMS controls the engine normally when the coded value and the encrypted message sent
6. from the immobilizer are identical.

When the immobilizer verification has failed, the verification signal will be sent 3 times for 2 seconds,
and the verification procedure will be carried out up to 3 times by turning the ignition ON within 10
seconds. If the three re-verifications fail, verification procedure will be stopped and restarted after 10
seconds.

GETtheMANUALS.org
17-86

2) For a Vehicle with Smart Key

Key verification can be divided into two types, immobilizer key verification and smart key verification.
The immobilizer verification is applied to the smart key module (SKM) system, and verifies the transponder
built in the smart key. When the smart key is held over the START/STOP switch, the verification is carried
out, overriding the RF signal from the smart key.
When the START/STOP switch is pressed with the smart key held over the switch, the smart key
transponder verification is carried out by the transponder communication.
Once the key is verified, a valid key authentication time is provided for 10 seconds and the engine can be
started by pressing the START/STOP switch during this time. If pressing the START/STOP switch after
this 10 seconds, the key authentication process should be performed again.

1. When the ignition is turned ON, the EMS (ECU) sends the challenge message to the SKM through the
P-CAN.
(This is to verify whether the transponder of the smart key is valid. If the authentication fails, it transmits
the re-authentication signals 3 times for 2 seconds. If 3rd re-authentication fails, the authentication is
deactivated for 10 seconds and re-activated after that.)
2. The emergency antenna of the SKM system sends the encrypted cod to the transponder, and the
transponder re-sends the encrypted code to the emergency antenna.
3. The encrypted sent to the emergency antenna is transmitted to the SKM.
4. The SKM compares this code with the encrypted code randomly transmitted by the internal logic.
(The system compares the signal from transponder and encrypted signal from the emergency antenna)
Only when the two signals are identical, the SKM recognizes the key as the verified one and transmits
5. the positive message to the ECU.
The ECU enables the engine to be started.
6.

GETtheMANUALS.org
 0000-00 17-87

22. LNT & DPF CONTROL

1) Overview
The harmful exhaust gas from the diesel engine contains CO, HC, NOx and etc,. To meet EURO-V
regulation, the oxidation catalyst (DOC) oxidizes CO and HC and DPF collects and removes the PM. On
the contrary, the NOx had been reduced by not the aftertreatment system but the EGR system. But,
NOx control becomes quite tricky in EURO-VI, requiring the separate aftertreatment system.

2) Components & Functions

Differential pressure Turbine EGT sensor

sensor

If the exhaust gas

temperature rises too high
Calculates pressure during LNT & DPF
difference between regeneration, limit post
before and after DPF to injection to protect the
check PM deposit. turbocharger from damage.

Front oxygen sensor Rear oxygen sensor DPF EGT sensor

Check whether the exhaust gas

temperature is appropriate
during LNT & DPF regeneration
Check the air-fuel ratio by post injection during LNT & DPF and desulfurization process.
regeneration and desulfurization process.

GETtheMANUALS.org
17-88

3) LNT & DPF System

The DPF is a device to remove the PM or soot from the exhaust gas from the diesel engine. The
performance depends on its type but it can remove the PM from 85% to approx. 100%.
It has a porous thin film and emits the exhaust gas generated during combustion and filters the PM
which is a byproduct of combustion to burn it when a certain amount of it is collected in the filter. When a
certain amount of the PM builds up, exposure to high exhaust gas temperature causes CO, the
fundamental ingredient in PM, to burn and release into the atmosphere in form of CO2.
The LNT is installed in front of the DPF, which oxidizes the CO and HC. The DPF performs regeneration
using the heat generated by oxidation.

4) Input/Output Diagram

GETtheMANUALS.org
 0000-00 17-89

5) LNT System Control

▶ Overview

The LNT (Lean NOx Trap) cleans the CO and HC in the exhaust gas and stores the NOx generated in
air fuel ratio lean (normal driving) condition in the LNT catalyst system to reduce the NOx. If the
absorbed NOx is saturated, the LNT converts NOx into N₂ by allowing post-injection to achieve
rich condition (supplying reductant).
The catalyst consists of Pt, Pd, and Rh with enhanced heat resistant in addition to Ba which is NOx
adsorption material.

- Normal driving mode (lean): Oxidization of NOx (absorption)

- NOx reduction mode (rich): Desorption of NOx by post-injection

- Normal driving mode (lean)

Normal driving mode with lean condition leads to higher NOx than CO and HC in all speed ranges. The
NOx is adsorbed on the catalyst film containing materials including Pt, Pd, and Ba.

- NOx reduction mode (rich)

In rich condition, post-injection is carried out for reduction of the NOx adsorbed on the LNT.

GETtheMANUALS.org
17-90

▶ NOx regeneration in LNT system

In LNT system, NOx absorption depends on the ECU model value.

If the absorption reaches the specified value, the ECU makes air-fuel ratio rich through the post injection
during driving. The oxygen sensor before LNT monitors this status. The NOx is desorbed by supplying
HC and CO from the fuel additionally through post injection. The front and rear oxygen sensors calculate
NOx absorption in LNT catalyst. NOx regeneration is carried out at speed of 70~100 km/h. If the NOx
absorption exceeds the specified value, the LNT absorbs NOx no longer and NOx is drained through the
muffler.
NOx regeneration is finished when the rear oxygen sensor detects rich air-fuel ratio indicating that there
is no NOx absorption. At this time, post injection time is limited approx. 10~15 seconds to maintain rich
condition. In addition, when the exhaust gas temperature is low, regeneration is finished based on the
model value set to ECU since the values from the front and rear oxygen sensors are rarely identical.

▶ Desulfurization of LNT system

SO₂ generated by combustion has a similar property as the NOx chemically due to the sulfur
ingredient in fuel. This sulfur ingredient interrupts NOx absorption resulting in reduced catalytic efficiency.
Therefore, in order to remove SOx, carry out the desulfurization mode periodically.
The high-temperature generated after DPF regeneration is used for desulfurization process which
requires high-temperature above 670℃. In other words, post injection is carried out continuously
after DPF regeneration to generate high-temperature to finish desulfurization process.
Change between lean and rich modes regularly in order to prevent high-temperature leakage. Do not
carry out desulfurization process in line with DPF regeneration and do it only when necessary.

GETtheMANUALS.org
 0000-00 17-91

23. PM SENSOR CONTROL

1) Overview
The ECU monitors PM particles by receiving signals from the PM sensor located at the rear side of DPF
through PM control unit. Most PM particles are filtered out by inner filer of DPF during passing through
the DPF to be combusted. But small portion of the particles pass through the DPF without filtering. This
PM particles build up in the PM sensor. The current of PM sensor increases as the PM particle amount
increases. If the current value of the PM sensor exceeds a certain value, the PM control unit heats up
the inner part of the PM sensor so that the PM particles accumulated in the sensor can be combusted
(cleaning process). This process is repeated when certain amount of PM particles builds up in the
cleaned PM sensor. This repeated cycle is called "regeneration time". This information is delivered to the
ECU through the PM sensor unit. Then the ECU determines if the system is normal or abnormal by
using the information regarding PM sensor regeneration cycle time.

PM (Particulate Matter):
PM or particulates are fine particles of solid that is generated during the combustion process of
diesel.

GETtheMANUALS.org
17-92

2) Operation Principle

GETtheMANUALS.org
 0000-00 17-93

3) Regeneration Process
As the amount of accumulated PM increases, the resistance of PM sensor decreases. If the resistance
on the PM sensor reaches a certain value, the PM control unit carries out regeneration process, which
burns the trapped PM, by heating the inner part of the PM sensor.
The PM control unit heats up the sensor until the PM particles are all burned up. This process is
repeated when certain amount of PM particles builds up in the cleaned PM sensor. The ECU judges
whether the DPF system is faulty or not through the periodic information on the PM sensor regeneration
time.

A. Outputs high resistance (11 MΩ) with no PM detected.

B. When enough PM accumulates that the electrode is conducting, the conductive pathway of the PM
will cause the resistance between the electrodes to begin to fall.
C. When the resistance falls below the threshold value (1.65 MΩ), the sensor regeneration starts
while the built-in heater is turned on and the accumulated PM is burned at high temperature.
D. When the regeneration process is completed, the area between the electrode plates of the sensor
becomes clean and the resistance returns to the original value.

▶ Status of DPF system based on PM sensor resistance value

- Less than 1.65 MΩ: Status in which DPF makes low efficiency such as cracking or leakage
(engine warning lamp turned on)
- 10 MΩ or higher: Normal status in which DPF makes high efficiency

GETtheMANUALS.org
17-94

4) Logic To Detect DPF Fault

In order to detect any abnormality of the DPF, two PM sensors, one is an actual PM sensor downstream
of the DPF and one is a virtual PM sensor upstream of the DPF, are used to compare the amount of PM
measured by those sensors.

▶ DPF with 99% efficiency (normal status)

If the DPF is intact, no matter how much PM accumulates in the virtual PM sensor, no PM is trapped in
the actual PM sensor through DPF regeneration. Therefore, the sensor regeneration does not occur.

GETtheMANUALS.org
 0000-00 17-95

▶ Detecting DPF fault

If the DPF has an efficiency of 0%, that is, it lost its functionality completely, the same amount of PM is
accumulated in the virtual PM sensor and the actual PM sensor. If the DPF has an efficiency of 90%, the
actual PM sensor performs the regeneration only once during the time the virtual PM sensor performs 10
times due to PM accumulation. Therefore, the sensor regeneration is performed with a period of 10 times,
compared with the case where the DPF has efficiency of 0%. (The sensor regeneration timing is
determined by the resistance value of the sensor (1.65 MΩ).)

DPF
with 0% PM
collection efficiency

DPF
with 90% PM
collection efficiency

If the DPF is in normal condition, no PM should be accumulated in the PM sensor and no regeneration
occur. Regeneration of the PM sensor means the DPF has lost or failed the PM trapping function.

GETtheMANUALS.org
17-96

24. DELAYED ENGINE CONTROL

If the fuel pressure rises excessively beyond the limit due to the failure of the fuel system, the fuel
temperature may rise sharply and damage to the fuel return line or each part may occur. At this time, the
limp-home PLV (pressure limiting valve) of the fuel rail is opened to protect the fuel system, and the fuel
pressure is lowered by further increasing the amount of fuel flow to the high-pressure pipe. In this case, the
ECU limits the engine power by controlling the emergency fuel system mode. Since the returned fuel
temperature is maintained above certain level, even when power is limited, the ECU gets the engine idling
to protect the fuel system from being damaged.

▶ ECU control in the event of problem caused by fuel temperature increase with PLV open

- Reduce engine power

- Warning lamp ON

▶ Conditions for fuel pressure increase (Conditions to open PLV)

- IMV open circuit or control line short circuit to B+
- Implausible fuel rail pressure sensor signal (high/low)
Abnormal supply voltage to fuel rail pressure sensor

-
The PLV (Pressure Limiting Valve) is activated only when rail pressure control is not available
due to an excessively increased pressure.

GETtheMANUALS.org
 0000-00 17-97

▶ Troubleshooting

Description Vehicle symptom Control To be checked

IMV open circuit or control line IMV open fully Limit power Wiring, connector
short circuit to B+
Implausible fuel rail pressure Sensor, wiring,
sensor signal (high/low) connector
Limit power
IMV open forcibly
Abnormal supply voltage to
ECU
fuel rail pressure sensor
Fuel rail pressure above 2,200 bar Sensor, wiring,
Too high fuel rail pressure (PLV may not be open between Limit power connector, IMV,
2,200 and 2,450 bar.) ECU
Deviation error in fuel rail
pressure sensor IMV partial open Limit power Sensor, wiring,
(high/low/delayed response) (PLV not open) connector

▶ Delayed engine control

- In the event of faulty IMV drive while driving (IMV open circuit)
- Check engine light illuminates on instrument cluster and changes to limp-home mode
(Limp-home mode: drives at minimum torque and engine speed limited to 1,300 ~ 1,400 rpm)

GETtheMANUALS.org
17-98

25. VOP CONTROL

For the fixed flow type oil pump, as the engine rpm increases, the oil flow increases proportionally. The
excessive flow generated by higher engine rpm raises the pressure in the oil circulation system. And
because of this increased pressure, more engine power is required to operate the oil pump. To overcome
this advantage, a variable oil pump (VOP) which adjusts the amount of oil discharged by the oil pump is
used. VOP is controlled in different speed ranges separately (low/moderate speed range, and high speed
range)
- Low/Moderate speed range (2,500 rpm or lower): Solenoid ON → ON (improve fuel economy)
- High speed range (higher than 2,500 rpm): Solenoid OFF → OFF (ensure reliability of lubrication)

GETtheMANUALS.org
 0000-00 17-99

▶ Operating process

a. When the VOP solenoid valve is ON

If the VOP solenoid valve is activated, then the valve will close the drain passage to the oil pan so that
the pressure can be sent to the 2nd chamber (F2). The discharge pressure of the oil pump will be sent to
the 1st chamber (F1). Therefore, the sum of both pressure (F1+F2) will be applied to the slide connected
to the spring and this force will compress the spring. At this time, the whole slide will move to increase
the gap with the rotor as shown in the right figure. Then the oil pressure will decrease because of the
changed volume ratio.

b. When the VOP solenoid valve is OFF

If no power is supplied to the VOP solenoid valve, the oil from the main gallery will flow into the oil pan
through the VOP solenoid valve. Therefore, the pressure (F2) which compresses the spring will be lost
and the slide will move by the force from the released spring. Then the oil pressure will increase by the
changed volume ratio due to the reduced the gap between the rotor and the slide.

GETtheMANUALS.org
17-100

26. WARM-UP CONTROL

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

▶ Ignition timing
The ignition timing can be retarded or advanced to help idle speed control.

▶ A/C compressor operation

The A/C control unit sends the A/C operation signal to the ECU to increase the throttle valve opening
angle in order to prevent a drop in engine speed when the A/C compressor is operating while the
engine is idling.

▶ Low voltage
The A/C control unit sends the A/C operation signal to the ECU to increase the throttle valve
opening angle in order to prevent a drop in engine speed when the A/C compressor is operating
while the engine is idling.

GETtheMANUALS.org
 0000-00 17-101

27. MAXIMUM SPEED LIMITATION

The ECU receives the engine speed signal from the crank position sensor and controls the engine
speed by shutting off the injector under the following conditions to protect the engine and the drive train.

▶ Torque converter protection with gear selector lever in P or N position

The engine speed is limited to protect the torque converter from excessive pressure rise in the torque
converter when the gear selector lever is in the P or N position.

▶ Maximum engine speed limitation during driving

The engine speed is limited to prevent damage to the engine due to high engine revolution speed. The
data for the drive mode detection are sent from the ESP unit to the ECU.

▶ Safe fuel cut

If the throttle valve is found to be faulty, the injector will be shut off at a certain rpm or higher and re-
activated at 1200 rpm or lower.

GETtheMANUALS.org
17-102

28. CIRCUIT DIAGRAM

▶ ENG Main Relay(IMV, O2 Sensor, HFM, EGR Cooler Bypass Valve, VGT) PM Sensor, NOx
Sensor(FRT, RR)

GETtheMANUALS.org
 0000-00 17-103

GETtheMANUALS.org
17-104

▶ Injector, Stop Lamp SW, Sensor(A/Pedal, Clutch Position, Delta Pressure, A/C Pressure,
Vacuum Pressure)

GETtheMANUALS.org
 0000-00 17-105

GETtheMANUALS.org
17-106

▶ Start Relay, DCU Relay, Sensor(DPF Temp, Fuel Filtler, Turbin Temp, Coolant Temp, SCR
Temp)

GETtheMANUALS.org
 0000-00 17-107

GETtheMANUALS.org
17-108

▶ Fuel Pump Relay, Cooling Fan Relay, PTC Relay, A/C Compressor Relay, ISG

GETtheMANUALS.org
 0000-00 17-109

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Items Specifications
Classification G15DTF G16DF D16DTF
Max. torque(Nm) 260 160 324
Oil level Overflow type
Manual shift control Yes
Stall rpm 2439 ± 150 2800 ± 150 2368 ± 150
Fluid Type AW-1
Capacity 6.2L 6.1L 6.6L
Change interval Maintenance-free, change-free
(However, check and change at every 100,000 km of
driving under demanding conditions)
Gear ratio 1st gear 4.459 4.044 4.188
2nd gear 2.508 2.371 2.416
3rd gear 1.556 1.556 1.556
4th gear 1.142 1.159 1.153
5th gear 0.851 0.852 0.852
6th gear 0.672 0.672 0.673
Reverse 3.185 3.193 3.203
Counter 0.906 1.061 0.942
Differential 3.867 3.867 3.533

GETtheMANUALS.org
01-4

Items Specifications
Specific
Flange Disc Plate Band
name
Configuration of disc clutch C1 1 ea 5 ea [4 ea] 5 ea [4 ea] -
[G15DTF]
C2 1 ea 4 ea [3 ea] 4 ea [3 ea] -
C3 1 ea 3 ea 3 ea -

Configuration of disc brake B1 - - - 1 ea

[G15DTF] B2 2 ea 5 ea [4 ea] 4 ea [3 ea] -
Configuration of one-way
F1 Roller type
clutch
Item Specification
Planetary gear unit 2 EA
Shift solenoid 2 EA (S1 and S2)

Solenoid Linear solenoid 6 EA (SL1, SL2, SL3, SL5 , SLT, SLU)

Electromagnetic oil
1 EA (EMOP)
pump (with ISG)

Shift solenoid
[S1, S2]

Linear solenoid
[SL1, SL2, SL3, SL5, SLT, SLU,
EMOP]

GETtheMANUALS.org
 0000-00 01-5

Item Specification
Line pressure Idle D 380~420 (kPa)

Input speed sensor High 12 mA ~ 16 mA

Output speed sensor Low 4 mA ~ 8 mA
40°C 1.8KΩ ~ 2.2KΩ
Oil temperature sensor
resistance 60°C 0.9KΩ ~ 1.1KΩ
80°C 0.45KΩ ~ 0.55KΩ

GETtheMANUALS.org
01-6

Serial number

A/T serial number

TCU serial number

Serial number

Serial number
positions for test
plug and A/T

GETtheMANUALS.org
 0000-00 01-7

2. CAUTIONS FOR OPERATION & HANDLING

1) Cautions For Working On Electronic Parts

- Before replacing the electronic parts, turn the ignition off and remove the negative (-) terminal
from the battery.
- Release the lock part first, and remove the connector. (prevent wiring from being pulled)
- Make sure that the connector is locked fully until a click is heard.
- Do not subject the electronic parts to impact. If it is dropped or subjected to impact, you must
replace it with a new one.

2) Handling Component With Care

- Do not store the A/T under the poor surroundings for a long time. (Long-term storage at high
humidity causes the corrosion of the internal parts)
- Before installation, remove the shipping cap. Do not store the components for a long time, with
the shipping cap removed.
- Do not put the A/T directly on the floor.

3) Dirt-protecting
- When removing the relevant components from the A/T, remove any dirt, sand and etc.
completely.
=- Place the components into the plastic bag or similar.
- When performing the work, do not use a cotton gloves or cloth, instead bare hands or plastic
gloves should be used.

4) To Protect Components From Damage

- When using the plastic hammer to remove the components, tap lightly it.
(Do not use the screwdriver as a leverage.)
- Do not pull the components such as the valve with an excessive force.
- Ensure refit the components without being damaged.

5) Cleaning
- All the components should be thoroughly cleaned, dried with a compressed air and applied the oil
only for A/T.
- Do not use an alkaline based cleaner to clean the aluminum and rubber parts.
- Do not use the waxing oil (unleaded gasoline) to clean the rubber part.

6) Cautions For Handling ATF

- Do not discharge the ATF when it is hot. (wait until it has cooled down)
- Wipe off any spilled ATF immediately since the floor is slippery and dangerous.
- Make sure to use the oil only for AW-1.

GETtheMANUALS.org
01-8

3. ESSENTIAL TIGHTENING TORQUES

Item Tightening torque (Nm) Size Quantity
Oil drain plug 5.9 ~ 8.8 Hexagon 17mm 1 ea
Oil overflow tube 34.0 ~ 60.0 T40mm 1 ea
Oil filler plug 23.5 ~ 54.9 T55mm 1 ea
A/T side cover 9.8~15.7 T40mm 13 ea
10mm 1 ea
Valve body assembly 8.0 ~ 12.0 10mm 2 ea
10mm 5 ea
Oil temperature sensor 6.0 ~ 8.0 8mm 1 ea
Valve body wire clamp 6.0 ~ 8.0 8mm 1 ea
Input speed sensor 3.9 ~ 6.9 10mm 1 ea
Oil cooler 16.8 ~ 25.2 Hexagon 5mm 3 ea
TCU 19.6 ~ 29.4 12mm 3 ea
Test plug 5.9 ~ 8.8 12mm 6 ea
Torque converter 44.0 ~ 51.0 13mm 6 ea
3-way solenoid valve (S1) 6.0 ~ 8.0 8mm 1 ea
3-way solenoid valve (S2) 6.0 ~ 8.0 8mm 1 ea

GETtheMANUALS.org
 0000-00 01-9

1) Oil Seal
Item Specification (oil seal depth)
Manual shaft - 0.3 to 0.4 mm
Oil pump - 0.2 ~ 0.2 mm

▶ Transmission diff. oil seal

Specification (oil seal depth)

Engine T/C
Housing Case
2WD 19.2 ~ 20.2 mm
G16DF 2.2 ± 3.2 mm
AWD 5.9 ~ 6.9 mm
2WD 3.4 ~ 4.4 mm 2.2 ~ 3.2 mm
G15DTF
AWD 6.2 ~ 7.2 mm 2.2 ~ 3.2 mm
2WD 22.3 ~ 23.3 mm 2.0 ~ 3.0 mm
D16DTFP
AWD 11.9 ~ 12.9 mm 2.0 ~ 3.0 mm

2) Distance Between A/T Housing And Torque Converter

GSL DSL
12.15 mm or longer 12.15 mm or longer

3) Acronyms And Abbreviations

Abbreviations Description
C1 Clutch1
C2 Clutch2
C3 Clutch3
B1 Brake1
B2 Brake2
F1 One-way clutch
S1 Shift solenoid1
S2 Shift solenoid2
SLT Line pressure control solenoid
SLU Lock-up control solenoid

GETtheMANUALS.org
01-10

4. SPECIAL TOOLS
PN & Name Special Tool Use
PN: X9936 0080A

Name:
AISIN 6 A/T housing bottom oil
filler adapter

Use:
Oil filler adapter for filling with oil
at AISIN 6 A/T housing bottom

품번 및 품명 특수공구 용도
PN: X9936 0120A

Name:
AISIN 6 A/T oil seal installer
(manual shaft)

Use:
For fitting A/T manual shaft oil
seal

PN: X9936 0130A

Name:
AISIN 6A/T oil seal puller (LH &
RH side)

Use:
For removing A/T LH & RH oil
seal

PN: X9936 0140A

Name:
AISIN 6 A/T oil seal puller (oil
pump)

Use:
For removing A/T oil pump oil
seal

GETtheMANUALS.org
 0000-00 01-11

1. OVERVIEW
The auto transaxle used for this vehicle is FF type 6 speed auto transaxle, which performs the lock-up
control self-learning control and manual shift control. The TCU is integrated into the non-contact type
shift position sensor, fitted to top of the A/T and uses a external oil cooler.

▶ Lock-up control
The output rpm signal, engine ECU (engine rpm and throttle opening) signals and vehicle speed are
used for smooth lock-up control.

▶ Self-learning control
The TCU performs the shift control learning and stationary-vehicle control learning to provide the smooth
clutch engagement during gear shift and the smooth and delicate shift during driving.

▶ Manual shift control

The driver can choose the desired gear by moving the shift lever from "D" range to manual shift position
and operating the tip switch + (up shift) or - (down shift) and feel the sportiness as in the manual
transmission.

Torque converter

A/T connector

Oil seal (RH Side)

A/T side cover

Oil cooler assembly

Breather hose

Oil seal (LH Side)

GETtheMANUALS.org
01-12

2. DESCRIPTION
▶ Mounting location

Auto transaxle assembly

GETtheMANUALS.org
 0000-00 01-13

3. EPC
▶ 3690 Automatic transmission (AISIN 6A/T)

1. T/M ASSY
2. T/M ASSY

GETtheMANUALS.org
01-14

▶ 3693 Valve body(AISIN 6A/T)

15.BODY ASSY-VALVE 36.BOLT

16.CLAMP 38.SENSOR-SPEED INPUT
17.BOLT 39.BOLT
18.BOLT 41.COVER-SUCTION
19.CLAMP 42.GASKET-SUCTION COVER
20.SCREW 43.SOLENOID ASSY-T/M 3WAY S1
21.COVER-TRANSAXLE SIDE 44.SOLENOID ASSY-T/M 3WAY S2
35.BOLT 45.BOLT-FLANGE

GETtheMANUALS.org
 0000-00 01-15

▶ 3691 Converter housing & oil cooler (AISIN 6A/T)

1. HOSE 22.CONVERTER ASSY-TORQUE

2. CLAMP 23.RING-O
3. BREATHER ASSY 24.PLUG SUB ASSY
4. PLUG 25.RING-O
5. RING-O 26.PLUG
6. SEAL-MANUAL SHIFT OIL 27.RING-O
7. UNIT-T/M CONTROL 28.COOLER ASSY-OIL
8. PLATE 29.WASHER-CONICAL SPRING
9. RING-O 30.SCREW
10.GASKET-TRANSAXLE CASE 31.WASHER
11.WIRING-T/M 32.RING-O
12.SEAL 33.PLUG
13.SEAL 34.RING-O
14.SEAL 37.BOLT
15.PLUG-BREATHER 40.GASKET-LIQUID OIL
16.RING-O

GETtheMANUALS.org
01-16

▶ 3724 Auto shift control (AISIN 6A/T)

1. LEVER ASSY-TGS A/T 7. PIN-SNAP

2. KNOB ASSY-TGS A/T 8. NUT
3. CABLE ASSY-TGS A/T 9. BOLT
4. BRKT ASSY-TGS CABLE MTG 10.NUT
5. LEVER ASSY-RANGE SELECT 11.NUT
6. SCREW-KNOB MTG 12.COVER-RR DECO

GETtheMANUALS.org
 0000-00 01-17

1. INPUT/OUTPUT DIAGRAM
It is consisted of various sensors that retrieve the information required to determine the shift, the ECU
that provides those values, the shift lever that inputs the driver's command to the TCU, the TCU that
finally sends a shift command through the hydraulic control and etc.

GETtheMANUALS.org
01-18

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 01-19

GETtheMANUALS.org
01-20

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 01-21

3. P-CAN COMMUNICATION I/O ELEMENTS

▶ ECU

GETtheMANUALS.org
01-22

▶ ABS

▶ CGW

▶ BCM

GETtheMANUALS.org
 0000-00 01-23

▶ ESP

▶ CPL

▶ PRNDI

▶ SKM

GETtheMANUALS.org
01-24

4. TCU CONTROL FUNCTION

1) Automatic Gear Change Control
The automatic gear change control turns S1 and S2 on or off and operates the SL1, SL2, SL3 and SL5
linearly according to the vehicle speed, throttle opening, information on brake signal, based on the each
gear pattern.

▶ Gear & solenoid operation

O: On (current on) / - : OFF (current off) / △ : Controlled

N.O: Normal Open

N.C: Normal Close

2) Manual Shift Control

Moving the shift lever from "D" position to manual shift position and changing to + (up shift) or - (down
shift) allows the driver to choose the required gear and feel the sportiness as in the manual transmission.
However, the TCU performs the lock-up control by up-shifting automatically and by down-shifting during
deceleration, in order to prevent the excessive rpm increase.

GETtheMANUALS.org
 0000-00 01-25

3) Neutral Control (N control)

If the vehicle stands to still with the selector lever in D, the transmission enters neutral by releasing the
clutch. This helps to reduce the engine load, improve fuel economy and reduce the vibration during idling
by reducing the drag loss of the torque converter.

- During neutral control, the C1 clutch is controlled by the linear solenoid independently.
- During neutral control on an uphill climb, the creep force is not generated and the B1 brake is
applied in order to prevent the vehicle from being pushed back and for safe vehicle start.
- The neutral control system operates when the engine is warmed up.
- The neutral control does not operate on a steep slope.

4) Lock-up Control
The smooth lock-up control is carried out through the linear control by the lock-up control solenoid [SLU],
based on the signals from engine ECU (engine rpm and throttle opening) and vehicle speed signals

Control Description
The control is carried out by lock-up control solenoid [SLU]. It turns on or off the
lock-up control solenoid valve [SLU] linearly.
The lock-up clutch in the torque converter is operated and pump impeller is
Lock-up control
connected to the turbine runner. This connects the engine to the auto transaxle.
The engine output is connected directly to the auto transaxle, reducing the loss of
output and improving the fuel economy.

GETtheMANUALS.org
01-26

5) Stationary-Vehicle Control
When the shift lever is moved from "N" to "D" or "R" position after the engine is started, the shift control
solenoids (SL1, SL2 and SL3) delivers the oil pressure required by the C1 and C3 clutches and properly
predefined oil pressure for smooth engagement to the clutch.

The shift time lag occurs since the first piston stoke resistance increases at cold engine. In this case,
the control is not performed to reduce the time lag. The impactless and smooth engagement is
achieved by controlling the oil pressure according to the piston stoke.

6) Reverse Control
When the shift lever is moved from "D" to "R" position and the auto transmission is shifted to reverse
during driving, the vehicle is extremely hazardous and the wheels become stuck. Therefore, the TCU
prevents the transmission from shifting to reverse during driving.

If the vehicle drives at higher speed of 11 km/h, the automatic transmission will not shift to reverse
when the shift lever is moved "D" to "R" position. When this control is activated, the C3 clutch is
released without operation of the shift control solenoid (SL3) to prevent the automatic transmission
from shifting to reverse. The reverse control has a higher priority than the shift control from "D" to "R"
position.

7) Self-Diagnosis Function
The TCU monitors the status of communication on the electronic components including each sensor
and ECU. In the event of malfunction, the TCU activates the warning lamp to warn the driver this and
stores the fault as a diagnostic trouble code (DTC).

On-board diagnosis If any fault occurs in the A/T, the TCU activates the warning lamp to inform
the driver of this.

Off-board diagnosis The TCU stores a DTC. The DTC and TCU data can be reviewed by
connecting the diagnostic device.

GETtheMANUALS.org
 0000-00 01-27

8) Fail-Safe Function
If any fault occurs at the A/T system, the fail-safe function will be activated and the TCU outputs the
control signal in order to get the vehicle to the nearest service center. If the shift solenoid is
malfunctioning, the TCU will no longer output the control signal If this happens, the gear change will be
controlled by the hydraulic circuit and the gear shifted from "R" position to reverse or from "D" position to
3rd.

Shift position Gear position

"R" Reverse
"D" 3rd gear

GETtheMANUALS.org
01-28

5. TCU BLOCK DIAGRAM

GETtheMANUALS.org
 0000-00 01-29

6. OPERATING PROCESS
1) Component Parts

GETtheMANUALS.org
01-30

2) Configuration and Designation of Planetary Gear

Designation Operation
Clutch C1 Connects front planetary gear carrier to rear planetary gear sun gear

C2 Connects input shaft to rear planetary gear carrier

C3 Connects front planetary gear carrier to rear planetary gear middle sun
gear
Brake B1 Fix rear planetary gear middle sun gear
B2 Fix rear planetary gear carrier
One-way clutch F1 Prevents rear planetary gear carrier from rotating anti-clockwise

GETtheMANUALS.org
 0000-00 01-31

3) Operation Element Chart

O : On (current on) / - : OFF (current off) / △ : Controlled

The lock-up applies to from 3rd gear to 6th gear.

GETtheMANUALS.org
01-32

7. POWER TRANSFER PROCESS

▶ 1st gear power transfer
A. Input shaft rotates clockwise (same revolutions as turbine runner in torque converter)
B. Front ring gear rotates clockwise (same revolutions as input shaft)
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C1 clutch engaged (front planetary gear carrier and rear sun gear are connected together and rotate
clockwise)
F. Rear sun gear rotates clockwise
G. Rear short pinion gear rotates anti-clockwise
(Rear planetary gear carrier locks anti-clockwise by one-way clutch F1)
H. Rear long pinion gear rotates clockwise
I. Rear ring gear rotates clockwise by rear long pinion gear
K. Counter drive gear rotates anti-clockwise
L. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Rear sun gear Carrier Ring gear

GETtheMANUALS.org
 0000-00 01-33

▶ 1st engine brake power transfer

When the engine brake is operated, the drive power is transmitted from the tires.
The rear planetary gear carrier is fixed as follows:

A. F1 (one-way clutch): offsets anti-clockwise rotation power

B. B2 (brake): Operates (fix rear planetary gear carrier)

GETtheMANUALS.org
01-34

▶ 2nd gear power transfer

A. Input shaft rotates clockwise
B. Front ring gear rotates clockwise
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C1 clutch engaged (front planetary gear carrier and rear sun gear are connected together and rotate
clockwise)
F. Rear sun gear rotates clockwise
G. Rear short pinion gear rotates anti-clockwise
H. Middle sun gear is fixed by B1 brake and rear planetary gear carrier rotates clockwise
I. Rear long pinion gear rotates clockwise
J. Rear ring gear rotates clockwise by rear long pinion gear
K. Counter drive gear rotates anti-clockwise
L. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Rear sun gear Middle sun gear Ring gear

GETtheMANUALS.org
 0000-00 01-35

▶ 3rd gear power transfer

A. Input shaft rotates clockwise
B. Front ring gear rotates clockwise
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C1 clutch engaged (front planetary gear carrier and rear sun gear are connected together)
F. C3 clutch engaged (front planetary gear carrier and rear middle sun gear are connected
together)
G. Rear short pinion and long pinion gears are fixed to body of revolution (rear sun gear and rear middle
sun gear) and rear planetary gear carrier rotates clockwise
H. Rear ring gear rotates clockwise by rear long pinion gear
I. Counter drive gear rotates anti-clockwise
J. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Rear sun gear, middle sun gear - Ring gear

GETtheMANUALS.org
01-36

▶ 4th gear power transfer

A. Input shaft rotates clockwise
B. Front ring gear rotates clockwise
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C1 clutch engaged (front planetary gear carrier and rear sun gear are connected together and rotate
clockwise)
F. C2 clutch engaged (rear planetary gear carrier rotates clockwise (same revolutions as input
shaft))
G. Rear short pinion gear rotates clockwise by rear sun gear
H. Rear long pinion gear rotates anti-clockwise
I. Rear ring gear rotates clockwise and its rotation speed is lower than rear planetary gear carrier due
to rear long pinion gear.
J. Counter drive gear rotates anti-clockwise
K. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Rear sun gear, carrier - Ring gear

GETtheMANUALS.org
 0000-00 01-37

▶ 5th gear power transfer

A. Input shaft rotates clockwise
B. Front ring gear rotates clockwise
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C3 clutch engaged (front planetary gear carrier and rear middle sun gear are connected together and
rotate clockwise)
F. C2 clutch engaged (rear planetary gear carrier rotates clockwise (same revolutions as input
shaft))
G. Rear long pinion gear rotates clockwise
H. Rear ring gear rotates clockwise and its rotation speed is higher than rear planetary gear carrier due
to rear long pinion gear.
I. Counter drive gear rotates anti-clockwise
J. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Carrier, middle sun gear - Ring gear

GETtheMANUALS.org
01-38

▶ 6th gear power transfer

A. Input shaft rotates clockwise
B. Rear middle sun gear fixed as B1 brake operates
C. C2 clutch engaged (rear planetary gear carrier rotates clockwise (same revolutions as input
shaft))
D. Rear short pinion gear is fixed due to fixed rear middle sun gear and rear long pinion gear rotates
clockwise
E. Rear ring gear rotates clockwise
F. Counter drive gear rotates anti-clockwise
G. Differential gear rotates clockwise

- Input Fixed Output

Front planetary gear - - -
Rear planetary gear Carrier Middle sun gear Ring gear

GETtheMANUALS.org
 0000-00 01-39

▶ Reverse power transfer

A. Input shaft rotates clockwise
B. Front ring gear rotates clockwise
C. Front pinion gear rotates clockwise
D. Front sun gear is fixed and front planetary gear carrier rotates clockwise
E. C3 clutch engaged (front planetary gear carrier and rear middle sun gear are connected together and
rotate clockwise)
F. Rear planetary gear carrier is fixed as B2 brake operates
G. Rear long pinion gear rotates anti-clockwise due to fixed rear planetary gear carrier
H. Rear ring gear rotates anti-clockwise
I. Counter drive gear rotates clockwise
J. Differential gear rotates anti-clockwise

- Input Fixed Output

Front planetary gear Ring gear Sun gear Carrier
Rear planetary gear Middle sun gear Carrier Ring gear

GETtheMANUALS.org
01-40

8. EMERGENCY MODE
If the A/T has a failure while driving, the self-learning control, lock-up control and gear change adaptation
control will be deactivated. The TCU stores the DTC if it can Diagnosis which fault has occurred and
sometimes the system enters the emergency mode.

▶ Emergency mode 1
If the linear solenoids (SL1, SL2, SL3 and SL5) are open or short circuit to B+ or ground, the gear will be
stuck at 3rd gear.

▶ Emergency mode 2
If there is a gear ratio error (1st ~ 6th), an abnormal gear change due to the linear solenoids (SL1, SL2,
SL3 and SL5) maximum pressure, or no signal from the output rotation sensor, the gear will be stuck at
5th gear.

▶ Emergency mode 3
If the S1, linear solenoid (SLT) is open or short circuit to B+ or ground, the input rotation sensor has a
electrical problem or sends no signal, in the event of high supply voltage to the battery, CAN
communication error or CAN bus off, the gear will be stuck at 3rd gear.

▶ Emergency mode 4
If the lever position sensor has a electrical problem, the gear will be stuck at 3rd gear.

▶ Emergency mode 5
In the event of low supply voltage to the battery, the gear will be stuck at 3rd gear for 1st to 3rd and at 5th
gear for 4th to 6th.

GETtheMANUALS.org
 0000-00 01-41

9. INTERNAL COMPONENTS
1) Torque Converter
The torque converter is fitted between the engine and auto transmission. It consist of the pump impeller,
turbine runner, stator, one-way clutch and lock-up clutch.
The torque converter contains a single plate lock-up clutch.
The lock-up clutch is controlled and engaged by the forward gears (3rd to 6th). The torque converter
transmits and amplifies the torque formed by the oil within it. The lock-up clutch connects the engine
directly to the auto transmission in order to improve the fuel economy.

Mounting location

Views
Front view Rear view

GETtheMANUALS.org
01-42

(1) Operation principle

- The impeller, which is driven by the engine, imparts a circular flow to the oil in the converter.
- This oil strikes the turbine wheel, which causes the flow to change its direction.
- The oil 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 that 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 speeds of 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 at the turbine wheel is
no higher than at the impeller.
- The stator, which is prevented from rotating backwards by a one-way clutch and the shaft in the auto
transmission housing, runs freely in the oil flow and overruns 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 via
the one-way clutch.

GETtheMANUALS.org
 0000-00 01-43

(2) Torque converter lock-up clutch

Internal components

- The torque converter lock-up clutch is a device that eliminates slip in the torque converter and
therefore helps to keep fuel consumption to a minimum.
- The torque converter lock-up clutch has a cooling nozzle which enables torque converter slip control.
This provides a partial torque converter lock-up mode at the lower speed than normal engine rpm,
which improves fuel economy.
- The torque converter lock-up clutch is engaged and released by the lock-up control system in the
TCU.
- Pressure at the torque converter lock-up clutch piston is determined by the lock-up control solenoid
(SLU) fitted to the valve body, based on the engine rpm, throttle opening signal, input speed sensor
(NIN) signal and output speed sensor signal (NOUT).
- The torque converter lock-up clutch can be controlled and engaged in any gear from 1st to 6th. When
the torque converter lock-up clutch is released, the pressure of the ATF behind the lock-up clutch
piston at the turbine part will become equal.
- In order to engage the torque converter lock-up clutch, the ATF flow direction should be changed by
the valve in the auto transmission pump. At the same time, the ATF at an area behind the torque
converter lock-up clutch piston will be drained. The oil pressure increases from the turbine part to the
torque converter lock-up clutch piston, ensuring that the piston is in contact with the torque converter
cover. This allows the turbine wheel between the piston and cover to be locked and slip with restricted
drive power can be transmitted to the planetary gear train under the normal operating conditions.

GETtheMANUALS.org
01-44

2) Oil Pump
The oil pump is of paracoid type which delivers ATF for each rotation. It is fitted between the torque
converter and A/T housing. The torque converter is supported to the oil pump by the plain bush bearing.
The oil pump is driven directly by the engine through the torque converter cover and delivers ATF directly
to the auto transmission and valve body. In addition, the oil pump draws in ATF through the filter and
delivers it to the valve body with high pressure.

Oil pump assembly

Oil filter

GETtheMANUALS.org
 0000-00 01-45

3) Front / Rear Planetary Gear Set

(1) Front planetary gear set
The front planetary gear set is driven by the input shaft and consists of the following components:
- 1 sun gear
- 4 pinion gears meshing with sun gear
- 1 carrier
- 1 ring gear

(2) Rear planetary gear set

The rear planetary gear set is driven by the input shaft and consists of the following components:
- 1 sun gear
- 4 short pinion gears meshing with sun gear, 4 long pinion gears meshing with ring gear
- 1 carrier
- 1 ring gear

Front planetary gear

Rear planetary gear

GETtheMANUALS.org
01-46

4) C1 and C3 Clutches, B1 Brake

- C1 clutch: Connects the front planetary gear carrier to the rear planetary gear sun gear.
- C3 clutch: Connects the front planetary gear carrier to the rear planetary gear middle sun gear.
- B1 brake: Holds the rear planetary gear middle sun gear.

B1 brake

C3 clutch

C1 clutch

GETtheMANUALS.org
 0000-00 01-47

C1 clutch configuration

GETtheMANUALS.org
01-48

C3 clutch configuration, B1 brake configuration

GETtheMANUALS.org
 0000-00 01-49

5) C2 clutch, B2 brake
- C2 clutch: Connects the input shaft to the rear planetary gear carrier.
- B2 brake: Holds the rear planetary gear carrier.

C2 clutch drum, C2 clutch

B2 brake

Mounting location of C2 clutch and B2 brake

C2 clutch

C2 clutch drum
B2 brake

GETtheMANUALS.org
01-50

C2 clutch configuration

GETtheMANUALS.org
 0000-00 01-51

B2 brake configuration

GETtheMANUALS.org
01-52

6) F1 One-way Clutch
- F1 one-way clutch: Prevents rear planetary gear carrier from rotating anti-clockwise.

F1 one-way clutch

Mounting location

One-way clutch

Rear planetary
gear

GETtheMANUALS.org
 0000-00 01-53

7) Input/Output Speed Sensor

The input/output speed sensor is located in the transmission case and outputs the waveform signal
according to the rpm. The TCU calculates the waveform signal frequency to determine the input/output
speed.
The input speed sensor [NIN] detects the C2 drum rpm of the intermediate shaft as a input shaft speed.
The output speed sensor [NOUT] detects the counter drive gear rpm as a output shaft speed.
These signals are transmitted to the TCU, which controls the engine torque, shift timing and lock-up
based on them.

▶ Input/output shaft speed sensor specifications

Specified
Signal
value
High 12 to 16 mA
Low 4 to 8 mA

GETtheMANUALS.org
01-54

8) Auto Transmission Wiring

(1) Auto transmission wiring
The auto transmission wiring is a grouped connector of the oil temperature sensor, speed sensor and
solenoid and fitted to the auto transmission case.
The oil temperature sensor integrated into the auto transmission wiring is fitted to the front valve body.
The oil temperature sensor detects the oil temperature directly at the hydraulic control circuit and sends
the signal based on that value. The TCU controls the gear shift at all temperature zones according to the
oil temperature change for smooth shift.

Auto transmission wiring

GETtheMANUALS.org
 0000-00 01-55

(2) Oil temperature sensor

The oil temperature sensor integrated with the auto transmission wiring is fitted in the front section of the
valve body. The ATF temperature sensor measures directly the oil temperature in the hydraulic control
circuit and sends the value to the TCU which controls the gear shift according to the oil temperature
change for smooth shift.

Mounting location

Oil temperature sensor

▶ Oil temperature sensor specifications

Item Temperature Specified value

40°C 1.8KΩ ~ 2.2KΩ
Oil temperature
60°C 0.9KΩ ~ 1.1KΩ
sensor resistance
80°C 0.45KΩ ~ 0.55KΩ

GETtheMANUALS.org
01-56

9) Valve Body Assembly

The valve body supply oil by switching the oil circuit for the hydraulic pressure generated by the oil
pump. Based on the control signal from the TCU, the 8 solenoid valves in the valve body are activated to
control the hydraulic pressure to the clutch and brakes, performing gear shift and lock-up. In addition, an
appropriate amount of oil is supplied to the torque converter, planetary gears and each lubricating parts.

GETtheMANUALS.org
 0000-00 01-57

(1) Mounting location

Mounting location of
valve body

Valve body assembly

Front view Rear view

GETtheMANUALS.org
01-58

(2) Mounting location of solenoid

▶ Shift solenoids [S1, S2]
The shift solenoids [S1, S2] are fitted to the front valve body and turn on and off based on the output
signal from the TCU. The 1st gear engine brake is activated or the gear shift occurs depending on the
S1 or S2 ON/OFF. In the event of the shift solenoid failure, the TCU does not perform the current control
for the solenoid as a fail safe function.

S2

S1

GETtheMANUALS.org
 0000-00 01-59

▶ Shift control solenoids [SL1, SL2, SL3, SL5]

The shift control solenoids [SL1, SL2, SL3, SL5] are mounted to the front valve body. The solenoid
controls the hydraulic pressure linearly, based on the output signal from the TCU. In this way, it controls
the clutches [C1, C2 and C3] and brakes [B1] using a hydraulic pressure for smooth shift. The auto
transmission shifts up or down from 1st to 6th, depending on the combination of ON/OFF status of the
shift control solenoids In the event of the shift solenoid failure, the TCU does not perform the current
control for the solenoid as a fail safe function.

SL1

SL2

SL3

SL5

GETtheMANUALS.org
01-60

▶ Line pressure control solenoid [SLT]

The line pressure control solenoid [SLT] is fitted to the front valve body. The solenoid controls the line
pressure linearly according to the duty ratio predefined by the TCU, based on the throttle opening and
engine torque signal. In this way, it controls the clutch and brake using a hydraulic pressure for smooth
shift. In the event of the line pressure solenoid failure, the TCU does not perform the current control for
the line pressure solenoid as a fail safe function. (The line pressure will be maximized when it is
impossible to control the current to the shift control solenoid in the event of failure excepting "stuck")

SLT

GETtheMANUALS.org
 0000-00 01-61

▶ Lock-up control solenoid [SLU]

The lock-up control solenoid [SLU] is fitted to the front valve body.
It controls the lock-up clutch hydraulic pressure linearly, based on the engine rpm, throttle opening
signal, input speed sensor [NIN] signal and output speed sensor [NOUT] signal.
In this way, it controls the lock-up. In the event of the lock-up control solenoid [SLU] failure, the TCU will
shut off the current to the solenoid as a fail safe function.

SLU

GETtheMANUALS.org
01-62

▶ Electromagnetic oil pump (EMOP) - With ISG

The EMOP (electromagnetic oil pump) is fitted to the front valve body.
The structure of the electromagnetic element is the same as that of the linear solenoid. The piston of
EMOP generates the hydraulic pressure in response to the ON/OFF signal from the TCM.
The hydraulic pressure generated by the EMOP is used only to engage the C1 clutch with the engine
stopped, allowing smooth transition from stoppage to traveling.
It is a fail-safe mechanism, meaning that the ISG system stops operating if any fault is detected.
Therefore, an electrical supply to the EMOP will be interrupted.

GETtheMANUALS.org
 0000-00 01-63

10) Shift Position Sensor (Integrated with TCU)

The 6 speed auto transmission fitted to this vehicle has a non-contact type shift position sensor
integrated with the TCU. The sensor detects the shift position using the hall effect which outputs voltage
depending on the position of the magnet at the shift positions (P, R, N and D).
The shift position sensor integrated into the TCU has the advantages as follows:

- A compact and lightweight unit can be achieved since the parts has been simplified (simplified
wiring).
- There is no wiring circuit between the TCU and shift position sensor, resulting improved reliability.

Shift position sensor part

When the TCU has been replaced or removed and fitted, "N" position learning should be performed.

GETtheMANUALS.org
01-64

10. TGS LEVER

1) Overview
The TGS lever changes the automatic transmission gear to the driver's desired driving condition
(Park/Reverse/Neutral/Forward). When the TGS lever is in manual mode, the driver can shift gear speed
(1st to 6th gear) directly.
Two safety functions have been installed; P Lock function which allows the driver to shift gears only
when the brake pedal is depressed with the lever in "P" position and R Lock function which the driver
can not shift the lever from "N" position to "R" position. The P lock and R lock functions can be
deactivated by pressing the knob button.

2) Mounting Location & Components

TGS lever knob

Knob button

TGS lever assembly

GETtheMANUALS.org
 0000-00 01-65

3) How TGS Lever Works

(1) Change TGS lever position
Operating pattern

Manual mode operation is self-return type

The position in which engine can start and vehicle is parked.

In order to move the lever from P position to other positions, always depress the brake
pedal and press the knob button with the ignition on.

The position used for reversing the vehicle. The gear ratio is 3.185(3.193) : 1 for reverse.

This position in which the engine does not transfer power to the wheels is for temporary
stopping or towing of the vehicle. The engine can be started in this position. When towing
the vehicle, the vehicle speed should be below 50 km/h and the towing distance should be
within 50 km.

Use this position in normal driving conditions. The transmission is automatically shifted from
1st gear through 6th gear according to the vehicle speed and how far the accelerator pedal
is depressed.

The shift lever can be manually shifted at driver's disposal. In order to enter the manual
mode, move the lever from the position D to the left (+/-). Push (+) or pull (-) the TGS lever
to shift the gear. The TGS lever is self-return type.

GETtheMANUALS.org
01-66

(2) Shifting gear in manual mode

Since the system recognizes the switch signal when the driver moves the TGS lever from D to manual
mode position and push (+) or pull (-) the lever, the driver can change the gear position and use the engine
brake, etc.

TGS lever in
manual mode

GETtheMANUALS.org
 0000-00 01-67

▶ Activate manual mode

Changing the shift lever from D to manual mode position and knob button on the TGS lever to + (up
shift) or - (down shift) allows the driver to choose the required gear and feel the sportiness as in the
manual transmission. However, the TCU performs the lock-up control by up-shifting automatically and by
down-shifting during deceleration, in order to prevent the excessive rpm increase.

- When the vehicle is stationary (0 km/h), the driver can engage up to 2nd gear and the vehicle can
start from 2nd gear on an icy road or a slippery road (for Winter mode).
- When the shift lever is moved to manual mode position while driving, the current gear position is
maintained and the driver can change the gear position by operating the TGS lever.
- In some cases, the gear change may not be made to secure the driving performance when changing
up. In addition, it may not be made to prevent the engine from over-revving when the driver shifts
down the gear depending on the vehicle speed.

▶ Selecting suitable gear

Driving at low speed Driving at middle speed Driving at high speed

Steep downhill (engine brake) Smooth road
High hill Gentle downhill
Off road (engine brake)

GETtheMANUALS.org
01-68

4) Shift Lock Function

(1) P Lock function
Unless the ignition switch is turned to the ON position or the brake pedal is depressed and the shift knob
button is operated, the locking solenoid and locking mechanism can't be activated by TGS with the
selector lever in "P" position, which causes the selector lever to stay locked.
You can move the TGS lever only while you're depressing the brake pedal and pressing down the shift
knob button and the ignition switch is in "ON" position when shifting, with the selector lever in "P"
position.

(2) R Lock function

Unless the shift knob button is pressed, the TGS lever stays locked by the locking mechanism when
moving the selector lever from "N" position to "R" position. This results in the selector lever to be
unmovable.
When moving the selector lever from "N" position to "R" position, the TGS lever can be moved only while
the ignition switch is in "ON" position and the shift knob button is pressed down. However, you should
keep depressing the brake pedal for safety reason.

(3) Shift lock solenoid operation logic

Input
Brake Lock
Lever Solenoid Other
Ignition pedal Speed position
position
actuation
- OFF - - - OFF -
P ON OFF - LOCK OFF P Lock
P ON ON - UNLOCK ON P Lock released
Use last available
P, R ON - - - OFF
position
R ON - - - OFF
Use last available
R, N ON - - - OFF
position
N ON - - - OFF -
Use last available
N, D ON - - - OFF
position
D ON - - - OFF -

GETtheMANUALS.org
 0000-00 01-69

(4) Deactivate shift lock

If you cannot shift out of the position "P" or "N"
with the ignition switch in ON position, the brake
pedal depressed and shift knob button pressed
down, move the lever manually as shown in the
figure below.

1. Turn off the engine and apply the parking

brake.
2. Depress the brake pedal, move the TGS
lever to another position by pressing TGS
knob button (B), with the activation part (lock
release button) (A) of the solenoid valve
pressed with your finger.

▶ Shift lock solenoid function

The shift lock solenoid is unlocked by the signal from the brake pedal. You can also release the lock
manually by pressing the lock release button with finger.

Unlock button Shift lock solenoid

Shift locked Shift unlocked

GETtheMANUALS.org
01-70

5) Driving Mode Switch

(1) Overview
The drive mode switch is mounted on the center low panel. Press briefly to toggle between NORMAL and
SPORT mode. Press and hold to switch to WINTER mode. To release WINTER mode, briefly press the
drive mode switch again.

(2) Mounting Location

Installed view Driving mode switch

GETtheMANUALS.org
 0000-00 01-71

Signal flow diagram

NORMAL mode
It is used for normal driving and provides smooth driving comfort.

SPORT mode
The driving force of the vehicle is increased forcibly by a certain amount in this mode. Turning the drive
mode dial will switch from NORMAL mode to SPORT mode and "SPORT mode activated" message is
displayed on the instrument cluster.

WINTER mode
When starting off the vehicle in this mode on icy roads, the 2nd gear is selected to prevent slipping.
Turning and holding the drive mode dial will enter WINTER mode and "WINTERT mode activated"
message is displayed on the instrument cluster.

When the ignition switch is cycled from OFF to ON, the system is switched to NORMAL mode
whatever the previous mode was.

GETtheMANUALS.org
01-72

11. TGS INDICATOR UNIT

1) Overview
The TGS unit receives the position signal input by the TGS lever from TCU and displays it so that the
driver can determine the current operation status. The position of the TGS lever is indicated by a red light.
The TGS unit is mounted on the rear side of the front console A/T upper fascia.

2) Input/Output Diagram

3) Mounting Location

TGS indicator unit

GETtheMANUALS.org
GETtheMANUALS.org
01-74

12. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 01-75

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Specifications
Item Remarks
D16DTF D16DTFG15DTF G16DF
G16DF
Total length 393.1 mm393.1 mm ← 385.1
385.1mm
mm -
Distance between shafts /
189 mm / 66.44 mm -
Differential deflection
Gear ratio 1st 3.538 3.538 ← 3.769
3.769 -
2nd 1.913 1.913 ← 2.080
2.080 -
3rd 1.152 1.152 ← 1.387
1.387 -
4th 0.829 0.829 ← 1.079
1.079 -
5th 0.689 0.689 ← 0.927
0.927 -
6th 0.587 0.587 ← 0.791
0.791 -
Reverse 3.000 3.000 ← 3.077
3.077 -
Types of 1st T: Triple type -
synchronizer ring for
2nd T: Triple type -
transmission
3rd S: Single type (carbon) -
4th S: Single type -
5th S: Single type -
6th S: Single type -
Reverse D: Double type -

GETtheMANUALS.org
02-4

Item Specifications Remarks

Shifting Type Remote control (Cable type) -
Shifting pattern Reverse:
Reverse ring
pull type

Transmission fluid Fluid specification

SAE 70W -

Oil volume 1.95 ℓ -

Service interval Check and add at every 60,000 km of driving
or 3 years.
Change is not required under normal driving -
conditions, but change at every 120,000 km
under severe conditions.

GETtheMANUALS.org
 0000-00 02-5

2. TIGHTENING TORQUE

Components Tightening torque Quantity

1. M/T upper mounting bolt (17 mm) 85 to 100 Nm 2
2. M/T lower mounting bolt (14 mm) 59 ± 3 Nm 4
3. M/T front mounting bolt (14 mm) 54 Nm + 20° 1
4. TGS shift cable bracket mounting bolt (12 mm) 17.7 to 21.6 Nm 3
5. Concentric slave cylinder mounting bolt (10 mm) 9.8 to 15.7 Nm 2
6. Oil filler plug (17 mm) 58.8 to 78.4 Nm 2
7. Oil drain plug (24 mm) 58.8 to 78.4 Nm 1
8. Control shaft assembly mounting bolt (12 mm) 26.5 to 33.4 Nm 2
9. Neutral switch (24 mm) 39.2 to 58.8 Nm 1
10. Backup lamp switch (24 mm) 39.2 to 58.8 Nm 1
11. Transmission case mounting bolt (12 mm) 19.6 to 26.46 Nm 19

GETtheMANUALS.org
02-6

1. OVERVIEW
This vehicle is equipped with T028S6 manual transmission which is integrated with axle for front-engine
front wheel drive (FF) use. This type of transmission is called a transaxle.
The driving force for the 1st to 6th gears is provided by the ring gear and transmitted through the input
shaft and output shaft (output shaft pinion gear). When the reverse gear is engaged, the direction of
rotation is changed by the input shaft and output shaft and the driving force is provided by the reverse
gear idler shaft (reverse pinion gear) and ring gear.
T028S6 manual transmission consists of an input shaft, an output shaft, and a reverse gear idler shaft.
With the combination of 6-speed forward gears and a reverse gear, the transmission optimizes engine
torque and gear ratio for improved driveability.

GETtheMANUALS.org
 0000-00 02-7

2. DESCRIPTION

Engine assembly (oil pan)

M/T assembly

Drive shaft (RH) Drive shaft (LH)

Sub frame assembly

Intermediate shaft Oil drain plug

Front view Rear view

GETtheMANUALS.org
02-8

3. EPC
▶ 3190 TRANSMISSION(6M/T)

1. T/M ASSY

GETtheMANUALS.org
 0000-00 02-9

▶ 3196 SHIFTER & EXTENSION (6M/T)

1. CASE-TRANSMISSION 8. RAIL & FORK ASSY-SHIFT

2. GASKET 9. RAIL & FORK ASSY-SHIFT
3. PLUG 10.BOLT-SEAL
4. SEAL-OIL 11.SWITCH ASSY-BACK UP LAMP
5. BOLT-FLANGE 12.SWITCH ASSY-BACK UP LAMP
6. SHAFT COMPLETE-CONTROL 13.BREATHER ASSY
7. RAIL & FORK ASSY-SHIFT 14.PLUG-SEAL

GETtheMANUALS.org
02-10

▶ 3110 T/M & T/C ATTACHMENT

1. BRKT-T/M MTG SUPPORT 7. BOLT

2. BOLT-FLANGE 8. ADAPTOR ASSY-AIR BLEED
3. BOLT 9. BRKT-POWER TRANSFER UNIT MTG
4. BOLT 10.BOLT
5. PIN-DOWEL 11.BOLT-UPR BALL JOINT
6. BOLT

GETtheMANUALS.org
 0000-00 02-11

▶ 3191 CLUTCH HOUSING(6M/T)

2. HOUSING-CLUTCH 12.SEAL-OIL
3. BUSHING 13.PLUG-DRIAN
4. SEAL-OIL 14.GASKET
8. GASKET 15.BOLT
9. PLUG 16.BOOT
11.HOUSING-CLUTCH

GETtheMANUALS.org
02-12

▶ 3192 INPUT SHAFT(6M/T)

1. BEARING-TAPER ROLLER 10.GEAR ASSY-4TH SPEED

2. SHAFT-INPUT 11.SLEEVE-5TH SPEED GEAR
3. BEARING-NEEDLE 12.GEAR ASSY-5TH SPEED
4. GEAR ASSY-3RD SPEED 13.SUB ASSY-HUB & SLEEVE
5. RING-SYNCHRO 14.GEAR ASSY-6TH SPEED
6. SUB ASSY-HUB & SLEEVE 15.SLEEVE-6TH SPEED GEAR
7. RING-SYNCHRO 16.BEARING-TAPER ROLLER
8. SLEEVE-4TH SPEED GEAR 17.BOLT-KNOCKING
9. BEARING-NEEDLE 18.SPACER-INPUT BEARING

GETtheMANUALS.org
 0000-00 02-13

▶ 3193 OUTPUT SHAFT (6M/T)

1. SHAFT ASSY-OUTPUT
2. SPACER-OUTPUT BEARING

▶ 3194 REVERSE IDLERSHAFT (6M/T)

1. BEARING-TAPER ROLLER 5. RING ASSY-DOUBLE CONE

2. SHAFT-REVERSE DRIVEN 6. SUB ASSY-HUB & SLEEVE
3. BEARING-NEEDLE 7. SPACER-REVERSE BEARING
4. GEAR ASSY-REVERSE SPEED

GETtheMANUALS.org
02-14

▶ 3195 DIFFERENTIAL (6M/T)

1. DIFFERENTIAL SUB ASSY

2. SPACER-DIFFERENTIAL BEARING
3. GEAR-DIFFERENTIAL DRIVE
4. BOLT SEAL-DIFF DRIVE GEAR
5. GEAR-DIFFERENTIAL DRIVE
6. SCREW-COUNTERSUNK HEAD

GETtheMANUALS.org
 0000-00 02-15

▶ 3710 MANUAL SHIFT CONTROL

1. LEVER ASSY-TGS M/T 6. TWIST PIN-SNAP

2. KNOB ASSY-M/T TGS 7. BOLT
3. CABLE ASSY-TGS M/T 8. NUT
4. BRKT ASSY-TGS CABLE MTG 9. PIN-SNAP
5. WASHER-TGS

GETtheMANUALS.org
02-16

1. POWER FLOWS
Internal structure
Reverse gear
3rd gear Clutch housing
4th gear

5th gear
Reverse output shaft
6th gear

Input shaft

Output shaft
Transmission 1st gear
case
2nd gear Differential assembly

Differential gear

1st gear

Input shaft

Output shaft

Differential gear

GETtheMANUALS.org
 0000-00 02-17

2nd gear

Input shaft

Output shaft

Differential gear

3rd gear

Input shaft

Output shaft

Differential gear

GETtheMANUALS.org
02-18

4th gear

Input shaft

Output shaft

Differential gear

5th gear

Input shaft

Output shaft

Differential gear

GETtheMANUALS.org
 0000-00 02-19

6th gear

Input shaft

Output shaft

Differential gear

Reverse

Input shaft

Output shaft

Reverse gear
idler shaft

Differential gear

▶ Reverse gear - power flow

1st gear input shaft → 1st gear output shaft → Reverse speed gear → Reverse shaft →
Differential gear

GETtheMANUALS.org
02-20

AWD(D16DTF only)

Flywheel (engine)

LH drive shaft RH drive shaft

PTU

GETtheMANUALS.org
 0000-00 02-21

2. FEATURES
- Consists of a input shaft and a output shaft
- Drives the clutch with a concentric slave cylinder (CSC).
- Shifting the transmission gears is performed through the remote control cable.
- When engaging reverse gear, the reverse gear ring on the shift lever should be pulled (pull type).

(1) Part name

1. Clutch housing 10.Oil filler plug (RH)

2. Transmission case 11.Oil filler plug (LH)
3. Input shaft 12.Oil drain plug
4. Concentric slave cylinder 13.Air breather
5. Shift lever 14.Oil seal (RH)
6. Selector lever 15.Oil seal (LH)
7. Wiring bracket 16.Control housing
8. Neutral switch 17.Neutral switch (ISG only)
9. Backup Lamp Switch

GETtheMANUALS.org
02-22

(2) Characteristics by specification

Since the diesel engine uses the thicker DMF (Dual Mass Flywheel) than SMF (Single Mass Flywheel)
for the gasoline engine, the clutch housing for the manual transmission with the diesel engine is longer.

Gasoline Diesel

Unit: mm Unit: mm

The manual transmission with the AWD model is equipped directly with the intermediate shaft and PTU
respectively and PTU attachment exists separately. Therefore, it has another separate power
transmission shaft through the offset gear, compared to the manual transmission with 2WD model.

2WD AWD(D16DTF only)

Intermediate shaft attachment PTU attachment

GETtheMANUALS.org
 0000-00 02-23

3. INTERNAL COMPONENTS

Reverse gear

3rd gear Clutch housing

4th gear

5th gear
Reverse output shaft
6th gear

Input shaft

Output shaft
Transmission 1st gear
case
2nd gear Differential assembly
LH drive shaft RH intermediate shaft

AWD(D16DTF only)
Final gear
Transfer drive
gear (input)
Clutch housing
Input shaft

Output shaft

Transmission Differential assembly

case Transfer driven gear
Reverse output shaft (output)

GETtheMANUALS.org
02-24

4. SHIFTING MECHANISM

Shift
Control shaft assembly

Selector

Selector lever
Shift lever

2nd, 4th, 6th gears

3rd & 4th gear, 5th & 6th

Neutral switch gear, reverse gear
control finger

1st, 3rd, 5th, Reverse gears

Backup Lamp Switch 1st & 2nd gear

control finger
3rd & 4th gear, 5th & 6th
gear shift fork rail Reverse gear shift rail

Reverse gear
shift fork

1st & 2nd gear shift rail

5th & 6th gear shift fork

3rd & 4th gear shift fork 1st & 2nd gear shift fork

GETtheMANUALS.org
 0000-00 02-25

5. GEAR SHIFT INDICATOR

The gear shift indicator (GSI) is a function designed to encourage fuel-efficient driving by indicating to the
driver the optimized points at which to shift gears. To achieve this, the ECU calculates the information
such as engine rpm and vehicle speed and sends the signal to the instrument panel via CAN
communication.

GSI display

This indicates the most appropriate timing for shifting to the 3rd gear (target) when
the vehicle is driven in 1st to 2nd gear.

This indicates the most appropriate timing for shifting to the 3rd gear (target) when
the vehicle is driven in 4th to 6th gear.

When the reverse gear is engaged, the selection is displayed on the LCD of the instrument
cluster.

GETtheMANUALS.org
02-26

6. INTERNAL GEAR COMBINATION AND ITS STRUCTURE

Control lever assembly installed

Backup lamp switch

Neutral switch

Gears installed

Input shaft
assembly
Reverse gear idler
shaft assembly

Output shaft Differential

assembly assembly

GETtheMANUALS.org
 0000-00 02-27

1) Gear Assembly
(1) Input shaft assembly
The input shaft assembly consists of 1st to 6th
gears, 3rd, 4th, 5th, 6th gear synchronizer ring
assembly, synchronizer hub, needle bearing, and
shaft. Each gear meshes with the gears of the
output shaft assembly.
All gears are helical gear type.

Input shaft

Input shaft

3rd gear 5th gear

Needle bearing Needle bearing

2nd gear

Engine side

1st gear

4th Gear 6th gear

Needle bearing Needle bearing

GETtheMANUALS.org
02-28

(2) Output shaft assembly

The output shaft assembly consists of 1st to 6th
gears, 1st, 2nd gear synchronizer ring assembly,
synchronizer hub, needle bearing, and shaft.
Each gear meshes with the gears of the input
shaft assembly and the reverse gear. The gear
on the shaft meshes with the differential drive
gear.
All gears are helical gear type.

Output shaft

Output shaft Output shaft

Pinion gear (1st to 6th
gear)

1st gear 3rd gear 5th gear

Needle bearing

Engine side

2nd gear 4th Gear 6th gear

Needle bearing

GETtheMANUALS.org
 0000-00 02-29

(3) Reverse gear idler shaft assembly

The reverse gear idler shaft assembly consists of
the reverse gear, synchronizer ring assembly,
synchronizer hub, needle bearing, and shaft. The
gear on the reverse gear idler shaft meshes with
the 1st gear of the output shaft assembly and
differential gear.

Reverse gear idler shaft

Reverse gear idler

shaft pinion gear

Reverse gear
idler shaft

Engine side

Reverse gear

Needle bearing

GETtheMANUALS.org
02-30

2) Synchronizer
(1) Mechanism
When the shift lever is shifted, the sleeve is moved by the shift fork. At this time, the protrusion of the
synchronizer key is seated on the inner groove of the sleeve (connected to the clutch hub). This
movement pushes the synchronizer key to the synchronizer ring side. This leads to the start of
synchronization. When the sleeve moves further the force which is applied to the sleeve overcomes the
spring tension of the synchronizer spring and makes the sleeve to be displaced. And then the chamfered
surface of the sleeve comes in contact with that of the synchronizer ring. This ensures that the gears
mesh easily because of the synchronization of the sleeve revolution with the drive gear revolution,
resulting in power transmission to the output shaft.

Step 1

Step 2

Step 3

GETtheMANUALS.org
 0000-00 02-31

(2) Synchronizer ring

The gears of the T028S6 manual transmission have the following types of synchronizer rings: (a) Triple-
cone for the 1st and 2nd gears; (b) Double-cone for the reverse gear; (c) Single-cone for the 3rd, 4th, 5th,
and, 6th gears.

Synchronizer rings for each speed gear

1st gear
Triple-cone

2nd gear
Triple-cone

3rd gear
4th gear
Single-cone
Single-cone
(Carbon)

5th gear 6th gear

Single-cone Single-cone

Reverse gear
Double-cone

GETtheMANUALS.org
02-32

(3) Synchronizer hub and sleeve

There are total 4 sets of synchronizer hub and sleeve. The reverse gear uses only one of the 4 sets.
Since each hub and sleeve have different installation directions, always make sure that they are facing
the right direction when assembling.

▶ Hub
All hubs should be installed with its 3 oil grooves facing the downward (engine side).

Upward/Transmission case Input shaft Output shaft Reverse gear

side idler shaft

Downward/Engine side

Downward / Engine side

▶ Sleeve

The 1st & 2nd gear sleeve should be installed with its deep grooves facing upward, and the rear gear
sleeve with its chamfered side facing upward. The 3rd & 4th gear and 5th & 6th gear sleeves are non-
directional.

Reverse gear idler shaft: The sleeve facing transmission case has a bevel angle.

Reverse gear
sleeve

Engine side

GETtheMANUALS.org
 0000-00 02-33

Output shaft: The 3rd & 4th gear and 5th & 6th gear sleeves are non-directional.

5th & 6th gear

sleeve

Engine side

3rd & 4th gear

sleeve

Engine side

Output shaft: The sleeve groove to 2nd gear is deeper than the groove to 1st gear.

1st & 2nd gear

sleeve

Engine side

GETtheMANUALS.org
02-34

3) Shift Fork, Shift Lug, Shift Rail

The total number of shift forks used in this system is the same with that of the synchronizer hubs (4). The
1st & 2nd gear shift fork is installed to a shift rail, and the 3rd & 4th gear and 5th & 6th gear shift forks are
installed to another shift rail, and the reverse gear shift fork is installed to the reverse gear shift rail.
The 3rd & 4th gear shift fork is fitted to the rail so that it can slide on the rail. The other shift forks for 1st &
2nd gear, 5th & 6th gear, and reverse gear are fixed to the shift rails with retaining pins.

1st & 2nd gear shift assembly

1st & 2nd gear

shift lug

1st & 2nd gear

shift fork

1st & 2nd gear

shift rail

3rd & 4th gear and 5th & 6th gear

Reverse gear shift assembly
shift assembly

Reverse gear shift lug 5th & 6th gear shift fork

Reverse gear
shift fork
3rd & 4th gear shift fork

3rd & 4th gear, 5th & 6th

gear shift lug
Reverse gear shift rail
3rd & 4th gear, 5th &
6th gear shift rail

GETtheMANUALS.org
 0000-00 02-35

4) Control Lever
The control lever is used for shifting gears and is
a essential element of a manual transmission. It
consists of selector lever and shift lever. The
neutral switch is fitted on this lever when installing
the transmission case.
The cover and the rail can often be separated
from each other when installing or removing the
control lever. If so, assemble them together
before performing any work.

▶ Shift mechanism assembly and control lever

1. Shift/selector lever
2. Shift rail
3. Shift fork
4. Shift lug
5. Control housing
6. Control shaft

GETtheMANUALS.org
02-36

5) Neutral Switch and Backup Lamp Switch

(1) Features of neutral switch
The neutral switch, used in a vehicle with a manual transmission, determines whether the gears are in
the neutral position or not, and sends the gear position signal to the engine ECU.
This switch offers the following features:
- To help the cold engine start smoothly by increasing the engine rpm when shifting gears: The engine
ECU increases the engine RPM by 100 to 200 rpm based on the received signals from the neutral
switch and data such as vehicle speed, clutch operating condition and engine coolant temperature.
The neutral signal is used for the Hill Start Assist (HSA) function of the ESP.
- The clutch switch and the neutral switch determine the shifting point and increase the engine RPM
- (100 to 200 rpm) for smooth starting off of the vehicle (at below 3 km/h). Operating conditions are as
follows:

1. The vehicle is stopped (vehicle speed below 3 km/h)

2. The clutch pedal is depressed (detected by clutch switch)
3. The shift lever is in position other than neutral position (detected by neutral switch)
4. Starting off with the clutch pedal released (detected by clutch switch)
5. The RPM increases according to the temperature of the engine coolant as shown below (detected
by engine coolant temperature sensor):
- -20℃ to 20℃: increased by about 100 rpm
- 20℃ to 60℃: increased by about 100 to 170 rpm
- About 80℃ (normal engine coolant temperature): increased by approx. 200 rpm
6. If the vehicle speed exceeds 3 km/h after the shifting has been carried out smoothly, the engine rpm
returns to the normal operating range.

Switches installed

Backup lamp switch

Neutral switch

(2) Features of backup lamp switch

When the gear selector lever is shifted to Reverse, the backup lamp switch sends the reverse signal to
turn on the backup lamp and the reverse gear indicator on the instrument cluster.

GETtheMANUALS.org
GETtheMANUALS.org
02-38

7. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 02-39

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
Specifications
Item
G16DF G15DTF D16DTF
Operation type Hydraulic ← ←
Clutch Pedal Type Suspended ← ←
Max. actuation 125 ± 3mm 135 ± 3mm ←
travel
Pedal free play 3 ~ 7mm ← ←
Lateral pedal free 2.5 mm or less ← ←
play
Clutch cover Type Conventional Self-adjusting type ←
Clutch Disc Type Torsional damper Single dry diaphragm ←
spring (Rigid Type)
Facing diameter 225mm 240mm ←
Facing quantity 2 2 ←
Weight 1.33kg 1.16kg ←
Flywheel Type SMF (Single Mass DMF(Dual Mass ←
Flywheel) Flywheel)
Clutch master Actuation travel 31.8 ± 0.6mm ← ←
cylinder
Inner diameter 15.875mm ← ←
Concentric Max. actuation 19.6mm ← ←
slave cylinder travel
Operating pressure Max. 40 bar ← ←

Clutch fluid Specification DOT 4 ← ←

Capacity Proper level ← ←
Clutch switch Air gap 2mm ← ←

GETtheMANUALS.org
03-4

2. TIGHTENING TORQUE
Item Tightening torque Quantity
Clutch housing mounting bolt Upper side 85 to 100 Nm 2
Front side 54 Nm + 20° 1
Lower side 59 ± 3 Nm 4
Pressure plate assembly mounting bolt 24 ± 3 Nm 6
Concentric slave cylinder mounting bolt 9.8 to 15.68 Nm 2
Clutch pedal mounting bolt and nut 7.84 to 17.64 Nm 3

GETtheMANUALS.org
 0000-00 03-5

1. OVERVIEW
The clutch system allows the shifting by shutting off the engine power transmitted to the M/T. The
system consists of the following elements.

▶ Driving Element

The driving element consists of two flat surfaces machined to a smooth finish.
One is the rear surface of the engine flywheel and the other is clutch pressure plate. The clutch pressure
plate is fitted to the clutch steel cover which is bolted down on the flywheel.

▶ Driven Element

The driven element is the clutch disc with a splined hub

which is free to slide horizontally along the same spline of the input shaft.
The driving and driven elements are held in contact by spring pressure. This pressure is exerted by the
diaphragm spring in the clutch pressure plate assembly.

▶ Operating Element

The clutch release system consists of clutch pedal and concentric slave cylinder.
This system directly releases the clutch by using hydraulic pressure while the conventional clutch system
releases the clutch by using release lever and release fork.
Therefore, this system provides higher efficiency and durability than the conventional clutch system.
- Clutch master cylinder (with clutch pedal)
- Concentric slave cylinder (built in transmission)

GETtheMANUALS.org
03-6

2. COMPONENTS
Air bleeder

Flywheel
G16DF(SMF) G15DTF/D16DTF(DMF)

Clutch cover and disc

G16DF G15DTF/D16DTF

GETtheMANUALS.org
 0000-00 03-7

Clutch oil tube

G16DF D16DTF

Clutch pedal

Concentric slave cylinder Clutch master cylinder

GETtheMANUALS.org
03-8

3. EPC
▶ 3010 Clutch disc and housing

1. DISC ASSY-CLUTCH
2. COVER ASSY-CLUTCH
3. BOLT
4. Washer

GETtheMANUALS.org
 0000-00 03-9

▶ 3030 CLUTCH PEDAL

1. PEDAL BOX ASSY-CLUTCH

2. NUT
3. BOLT
4. TWIST PIN-SNAP
5. PAD-CLUTCH PEDAL

GETtheMANUALS.org
03-10

▶ 3020 CLUTCH CONTROL

1. CYLINDER ASSY-CLUTCH MASTER

2. TUBE ASSY-CMC TO DAMPER
3. TUBE ASSY-CMC TO DAMPER
4. TUBE ASSY-DAMPER TO CSC
5. CLIP-WASHER HOSE MTG
6. HOLDER-BRAKE TUBE MTG

GETtheMANUALS.org
 0000-00 03-11

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
03-12

2. OPERATING PROCESS
If the driver depresses the clutch pedal, the hydraulic pressure is generated in the master cylinder. It is
transmitted to the concentric slave cylinder through the pipe, resulting in the cylinder being forced out. At
this time, the clutch disc is pushed by the cylinder when the cover is pushed. This, in turn, separate the
flywheel from the pressure plate. As a result, the power from the engine is cut off and the gear change
can be carried out.
When the clutch pedal is released, the clutch function is deactivated and the concentric slave cylinder
returns to its original position by the spring force in the cylinder.

The hydraulic pressure is transmitted in the following order:

Clutch pedal → Clutch master cylinder → Clutch pipe → Concentric slave cylinder →
Clutch cover & disc

GETtheMANUALS.org
GETtheMANUALS.org
03-14

3. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 03-15

GETtheMANUALS.org
 0000-00 05-3

1. SPECIFICATIONS
Category Items Specifications

Common for Joint type Inner: Tripod joint

Front drive Outer: Ball joint
2WD
shaft
and AWD Compensation for bending angle Same length shaft
Rear drive Joint type Inner: Tripod joint
shaft Outer: Ball joint
Type Split axle type (IRDA)
Reduction gear type Hypoid gear
Reduction gear ratio 2.533

Dedicated Diameter of ring gear Φ145mm

AWD Rear Hypoid gear oil
Oil type
differential (SAE 80W/90, API GL-5)
carrier
Hypoid offset 25mm
Hypoid gear backlash Max 0.15mm
Differential gear backlash Max 0.05mm
Air breather type Built-in type

GETtheMANUALS.org
05-4

1. OVERVIEW
The drive shaft transfers the power generated by the engine from the transmission to the wheels, and
the axle distributes the power between left and right sides through the hypoid type gear.
The drive shaft of this vehicle is divided into a front drive shaft and a rear drive shaft. The rear drive shaft
is only applied to the vehicles with AWD. The front drive shaft is equipped with an intermediate shaft to
maintain the same length and refracting angle of the front left and right drive shafts.

GETtheMANUALS.org
 0000-00 05-5

2. COMPONENTS
2WD model

Front hub assembly

Front view Rear view

Drive shaft (LH)

Front

Intermediate shaft

Rear

Drive shaft (RH)

Rear hub assembly

Front view Rear view

GETtheMANUALS.org
05-6

AWD model

Front hub assembly

Front view Rear view

Drive shaft(LH)

Front

Intermediate shaft

Rear

Drive shaft(RH)

Rear hub assembly

Front view Rear view

Rear axle

Rear drive shaft(RH)

GETtheMANUALS.org
 0000-00 05-7

3. EPC
▶ 4110 AXLE SHAFT

1. SHAFT ASSY-FRT AXLE

2. BOOT SET-INR
3. BOOT SET-OTR
4. SHAFT ASSY-INTERMEDIATE
5. BOLT
6. RING-SNAP

GETtheMANUALS.org
05-8

▶ 4220 REAR AXLE : AWD

1. RR AXLE ASSY 19.SPACER

3. SHAFT ASSY-RR AXLE 21.BEARING-PINION OUTER
4. DIFF CASE 22.SHIM-PINION OUTER
5. BOOT SET-RR AXLE SHAFT INR 23.OIL SEAL-PINION OUTER
6. PIN 25.OIL SEAL-SIDE
7. DIFF-PINION GEAR 26.NUT-LOCK
8. GEAR-DIFF SIDE 27.SHIM-SIDE
9. SHIM-PINION DIFF GEAR 28.BEARING-SIDE
10.SHIM-SIDE DIFF GEAR 29.GASKET
11.SHAFT-DIFF 30.PLUG
12.PINION GEAR 31.BOLT
13.RING GEAR 32.AIR BREATHER
16.BOLT-RING GEAR 35.COVER-IRDA
17.BEARING-PINION INR 38.BOLT
18.SHIM-PINION INR 39.BOLT-WHEEL BEARING

GETtheMANUALS.org
 0000-00 05-9

▶ 4320 REAR AXLE MOUNTING

1. BUSH-RR AXLE MTG FRT

2. BUSH-RR AXLE MTG RR
3. BOLT
4. WASHER
5. MASS DAMPER-RR AXLE MTG FRT
6. BOLT-WHEEL BEARING

GETtheMANUALS.org
05-10

1. TORQUE STEER
Torque steer is a condition in which a vehicle pulls to either side because of an inequality of traction
between the left and right driving wheels when a large torque is applied to the front wheels of a FWD or
4WD vehicle.
Especially for a FWD vehicle, this mechanical condition can cause the steering effect because of the
output torque (rotational force) produced by the gyroscope. This rotational force is due to the difference in
distance between the left/right front wheels and the transaxle, which leads to the change of the shaft
bending angle.
To prevent this, the intermediate shaft, called equivalent length shaft, is employed so that the bending
angle and the length are kept constant for both sides.

Gyroscope: Gyroscope is a device consists of a spinning mass like a top, usually mounted on a
gimbal so that its axis can turn freely in any directions and thereby maintain its orientation regardless
of any movement of the base.

GETtheMANUALS.org
 0000-00 05-11

2. SYSTEM DIAGRAM
▶ FRONT DRIVE SHAFT Exploded view

1. Shaft 5. Outer boot shaft clamp

2. Inner boot housing clamp 6. Drive shaft outer boot
3. Drive shaft inner boot 7. Outer boot housing clamp
4. Inner boot shaft clamp 8. Outer cap

▶ REAR DRIVE SHAFT Exploded view

1. Inner cap 6. Outer boot shaft clamp

2. Shaft 7. Drive shaft outer boot
3. Inner boot housing clamp 8. Outer boot housing clamp
4. Drive shaft inner boot 9. Outer cap
5. Inner boot shaft clamp

GETtheMANUALS.org
05-12

▶ REAR AXLE ASSEMBLY Exploded view

1. Oil seal 15.Washer

2. Lock nut 16.Differential side gear
3. Tail bearing 17.Lock pin
4. Shim 18.Differential spider shaft
5. Spacer 19.Cover assembly
6. Head bearing 20.Vent plug
7. Shim 21.Bolt
8. Pinion gear 22.Filler plug
9. Axle Housing Assembly 23.Oil seal
10.Drain plug 24.Bolt
11.Ring gear 25.Bearing cover
12.Differential case assembly 26.Shim
13.Washer 27.Differential side bearing
14.Differential spider gear 28.Bolt

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
Items Specifications
Structure 2-pieces type consisting of CV joint,
universal joint, rubber coupling
Weight D16DTF MT: 10.5kg,
D16DTF AT, G15DTF: 10.8kg
Joint type Constant velocity joint, cross-axis, rubber
coupling
Size Single axle
1,082.5mm x ø60mm
(Length x Diameter) (TM to universal joint)
Double axle 847mm x Ø60mm
(Universal joint to axle) (DSL MT : ø75)
Tube run-out (after installation) Max. 0.3 mm
Unbalance amount 80g.mm at 2,100rpm
(120 g.mm when re-measuring)
Universal joint Number 1 (installed to the center bearing)
Outside diameter Ø24mm
Total size Ø62.5mm
Starting torque 0.3Nm ~ 0.7Nm
Minimum starting angle 18°
Amount of charged grease in CV joint boot 110±10g

2. TIGHTENING TORQUE
Items Tightening torque
CV joint bolt to transmission 29.4 ~ 39.2Nm
Rubber coupling bolt/nut to rear axle 53.9 ~ 63.7Nm
Center bearing mounting bolt 58.8 ~ 68.6Nm

GETtheMANUALS.org
04-4

1. OVERVIEW
The propeller shaft is a thin steel pipe which transfers the power from the transmission to the E-coupling,
and has high resistance to torsion and bending. The propeller shaft is used at the AWD vehicle only. The
specifications such as length are same for both the propeller shaft installed to the vehicle with M/T and
one to the vehicle with A/T.
The propeller shaft has the constant velocity joint to compensate for the angle and length in order to
accommodate the height and length changes which occur as the shaft rotates at high speed. And the
rubber bushing for center bearing in the center of the propeller shaft keeps the balance of the shaft and
absorbs its vibration.

Function of propeller shaft

- Transmits driving torque.
- Compensates for angle change (joint type: universal joint / CV joint)
- Compensates for axial length change (CV joint).

GETtheMANUALS.org
 0000-00 04-5

2. MOUNTING LOCATION AND COMPONENTS

Propeller shaft

CV joint Universal joint Rubber coupling

& center bearing

GETtheMANUALS.org
04-6

3. EPC
▶ 3310 PROPELLER SHAFT

1. SHAFT ASSY-PROPELLER
2. BOLT
3. NUT
4. BOLT
5. BOLT-PROPELLER SHAFT

GETtheMANUALS.org
 0000-00 04-7

1. CONFIGURATION DIAGRAM

1. End cap 19.Dust shield

2. VL joint assembly 20.Center bearing assembly
3. Washer 21.Ball bearing
4. Bolt 22.Intermediate shaft
5. Circlip 23.Fork yoke
6. Clamp (Big end) 24.Rubber coupling
7. Boot 25.Aligning support
8. Clamp (Small end) 26.Bolt
9. Stub shaft 27.Washer
10.Bending absorber 28.Lock nut
11.DEADENER 29.Balance weight
12.Tube yoke 30.Protector
13.Oil seal 31.Tube
14.Spider 32.Tube
15.Bearing cap 33.Bending absorber
16.Intermediate yoke 34.Gasket
17.Bolt 35.DEADENER
18.Flat washer

GETtheMANUALS.org
04-8

GETtheMANUALS.org
 0000-00 06-3

1. SPECIFICATIONS
Specifications
Category Item M/T
A/T GSL A/T DSL
Gear ratio 2.53 2.533 1.333
Numbers of hypoid gear
34/19 38/15 28/21
(Ring gear/pinion gear)
PTU Numbers of helical gear
41/29 - -
(Power transfer unit) (Input shaft/idle shaft)
Oil specification 80W-90 API GL5
Approx. 0.6ℓ Approx. 0.25ℓ Approx. 0.5ℓ
Oil volume

Weight (including fluid) 16.0kg 12kg 10.9kg

Operation type Electronic magnetic
Torque capacity Max. 800Nm
Whole length 154.95mm
Input (external): 21T
Spline
/ output (internal): 21T
E-coupling
Input flange type 3-lobe(fixed to rubber coupling)
Connector type 2-pin
Weight 5.985kg
Oil specification AMSOIL FTH2-1
Oil capacity 100 ± 5 mL
Operation mode 4WD AUTO / 4WD LOCK
Communication mode CAN communication
E-coupling control unit
Diagnostic mode CAN diagnosis
Weight 230g
Size 160 x 87 x 37mm
4WD LOCK switch Type Self return type

GETtheMANUALS.org
06-4

2. NOTICES
1) Towing Vehicle
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 rear propeller shaft connected in place, the E-coupling's clutch could be
damaged.

2) Work On Vehicle Using Lift

When working on the vehicle using a lift, do not run the tires with all the wheels off the ground and the
parking brake applied, as this may damage the E-coupling's clutch.

GETtheMANUALS.org
 0000-00 06-5

1. OVERVIEW
The AWD system uses an electronically controlled coupling to distribute driving force between the front
and rear wheels, depending on road conditions and driving style for maximizing driving performance. It
delivers all driving force to the front wheels only for good fuel economy on the normal road while the
4WD mode is activated automatically when driving in snow and poor driving conditions for improved
straight-ahead driving stability and hill-climbing ability. In particular, the initial driving force is applied to
enable the vehicle to start smoothly without wheel spin when starting on the hill as well as to maximize
the AWD vehicle's advantages. It also has the self-protect feature that prevents the driving system from
being damaged in advance by decreasing the driving force to the rear wheels when the component
parts such as E-coupling become too hot due to a tire out of specification or malfunctioning AWD
system. When driving the vehicle on a rough road such as muddy road or off-road and slippery road with
rain or snow, the driver can select "Lock Mode" to deliver a larger driving force to the rear wheels than
AWD "Auto Mode" to achieve the vehicle posture stability. The AWD "Lock Mode" is designed to be
activated only at a slow speed (below 40 km/h) for safety and smooth driving. In addition, we focused on
the safety as well as its own intrinsic performance including to control the driving force from the AWD by
means of an organized control between ESP/ABS and AWD, thus helping ensure the vehicle's braking
performance. The E-coupling also has reduced the noise and vibration and improved the fuel economy
through a low drag torque.

GETtheMANUALS.org
06-6

2. COMPONENTS

4WD LOCK
4WD warning lamp 4WD LOCK switch
indicator lamp

Comes on during 4WD Comes on or blinks in the The 4WD lock switch is of dial type. When
LOCK mode event of malfunction of 4WD this switch is turned on, the torque to the
system rear wheels increases.

GETtheMANUALS.org
 0000-00 06-7

- 4WD warning lamp comes on when:

A temporary error occurs in the 4WD system or relevant system has any fault - For temporary
error, the 4WD system is normal if the lamp goes out after a certain time or when the engine is
restarted.
- 4WD warning lamp blinks:
This is for preventing the 4WD system from being damaged. When the lamp blinks, you must
stop operating the accelerator pedal immediately and cool down the 4WD system. If the 4WD
system is cooled down sufficiently, the lamp will go out and will start working normally again.

PTU E-coupling control unit E-coupling

In AWD vehicle, it transmits It receives and recognizes the It delivers the power to the
the engine power to the E- CAN signal from each unit (ECU, rear axle from the PTU and
coupling via the propeller ABS and EPS) to decide the controls the torque
shaft by changing its current value (clutch engagement distribution between the
direction 90°. force) to the electromagnet in the front wheel and rear wheel.
E-coupling.

GETtheMANUALS.org
06-8

3. EPC
▶ 3270 Power Transfer Unit(PTU) : AWD

1. POWER TRANSFER UNIT ASSY

2. BOLT-UPR BALL JOINT

▶ 3271 Power Transfer Unit(PTU) : AWD(1)

1. FLANGE 10.BOLT
2. OIL SEAL 11.BOLT
3. OIL SEAL 12.NUT-LOCK
4. PLUG 13.RETAINER
6. PLUG 14.SEAL-PINION OIL
7. GASKET 15.ADAPTOR
8. SHIM-RETANINER 16.COVER
9. AIR BREATHER 17.PIN-DOWL

GETtheMANUALS.org
 0000-00 06-9

▶ 3280 Electric Coupling : AWD

1. COUPLING ASSY-ELECTRIC
2. CONTROL UNIT-COUPLING
3. NUT
38.BOLT

▶ 3281 Electric Coupling : AWD(1)

12.SEAL-DUST
13.SEAL-OIL
14.FLANGE ASSY-COMPANION
15.WASHER
16.NUT-DRIVE PINION

GETtheMANUALS.org
06-10

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 06-11

2. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
06-12

GETtheMANUALS.org
 0000-00 06-13

▶ Full names of acronyms and option description

GETtheMANUALS.org
06-14

3. CAN INPUT/OUTPUT ELEMENTS

▶ ABS

▶ ECU

▶ TCU

GETtheMANUALS.org
 0000-00 06-15

▶ CGW

▶ ESP

GETtheMANUALS.org
06-16

4. MAJOR FUNCTIONS
1) Overheating Protect For E-coupling
The E-coupling control unit calculates the E-coupling's slip (input/output speed), ambient temperature,
magnetic coil resistance and etc. to protect the oil and clutch plate from being overheated. If the E-
coupling get too hot, the E-coupling control unit reduces the torque to the rear wheels and sets a
diagnostic trouble code (DTC).

Overheating reference temperature

(℃)
Initial temperature 25
Oil Overheating 140
warning
Warning 115
released
Clutch Overheating 200
plate warning
Warning 160
released

If the oil temperature in the E-coupling is above 140°C or the temperature of the clutch plate is
above 200°C, the warning lamp comes on which indicates the system has been overheated. If
the oil temperature drops below 115°C or the clutch plate temperature drops below 160°C, the
warning will be released.

2) Parking Brake Logic

If the rear wheels are not rotating correctly while driving with the parking brake applied, the E-coupling
control unit calculates the difference between the CAN signals on wheel speed to reduce the torque to
the rear wheels.

3) Detecting Tire Out Of Specification

When a tire out of specification such as the spare tire is installed, the E-coupling control unit calculates
the difference between the CAN signals on wheel speed to detect that the wrong tire has been installed.
At this time, it reduces the torque to the rear wheels and sets a diagnostic trouble code (DTC).

GETtheMANUALS.org
 0000-00 06-17

4) 4WD LOCK mode (4WD LOCK mode switch depressed)

In 4WD LOCK mode, the 4WD LOCK control
works in the same way as the AUTO mode, but
it increases the driving force to the rear wheels
more than in AUTO mode. If the rear wheel
speed is over 40 km/h in LOCK mode, the
vehicle enters into the 4WD AUTO mode
automatically. If the speed is below 40 km/h, the
vehicle returns to the 4WD LOCK mode.

5) PRND Logic
Function for reducing the noise and vibration
caused by an operation of the gear shift lever
from D to R, D to N, R to D and R to N.

GETtheMANUALS.org
06-18

6) Operating Voltage Range Detection

The E-coupling control unit detects the supply voltage to determine CAN diagnostic operation, hardware
diagnostic operation and functional operation range voltages. It restricts the functions of the 4WD and
sets a diagnostic trouble code (DTC) if the supply voltage is too high or too low.

GETtheMANUALS.org
 0000-00 06-19

5. POWER TRANSFER PROCESS

▶ Diesel (A/T)

Propeller
shaft

Transmission

▶ Gasoline & diesel (M/T)

Propeller
shaft

Transmission

GETtheMANUALS.org
06-20

6. EXPLODED VIEW
Gasoline (A/T)

1. Lock nut 15.Dowel pin

2. Companion flange 16.Adapter oil seal
3. Retainer 17.Side LH bearing
4. Retainer shim 18.Input shaft bearing
5. Pinion outer oil seal 19.Ring gear
6. Pinion outer bearing 20.Shaft RH oil seal
7. Pinion inner bearing 21.Side RH bearing
8. Spacer 22.Cover
9. Pinion gear 23.Bolt
10.Idle shaft 24.Gasket
11.Input shaft 25.Filler gasket
12.Air breather 26.Gasket
13.Bolt 27.Drain plug
14.Casing

GETtheMANUALS.org
 0000-00 06-21

Diesel (A/T)

1. Lock nut 16.Side LH oil seal

2. Companion flange 17.Side LH bearing
3. Retainer 18.Side LH shim
4. Retainer shim 19.Adapter
5. Pinion outer oil seal 20.Ring gear
6. Pinion outer bearing 21.Side RH shim
7. Pinion inner bearing 22.Side RH bearing
8. Pinion outer shim 23.Side RH oil seal
9. Spacer 24.Cover
10.Pinion gear 25.Gasket
11.Shaft 26.Filler gasket
12.Air breather 27.Bolt
13.Bolt 28.Gasket
14.Casing 29.Drain plug
15.Dowel pin

GETtheMANUALS.org
06-22

Gasoline & diesel (M/T)

1. Lock nut 14.Casing

2. Companion flange 15.Dowel pin
3. Pinion outer oil seal 16.Side bearing oil seal
4. Retainer 17.Side bearing LH shim
5. Retainer shim 18.Side LH bearing
6. Pinion outer bearing 19.Side RH bearing
7. Pinion inner bearing 20.Side bearing shim
8. Spacer 21.Cover
9. Pinion outer shim 22.Gasket
10.Pinion gear 23.Filler gasket
11.Shaft 24.Bolt
12.Air breather 25.Gasket
13.Bolt 26.Drain plug

GETtheMANUALS.org
 0000-00 06-23

7. OPERATION PROCESS

The driving force is delivered from the PTU to the input shaft via the propeller shaft and yoke flange. An
electromagnet is energized according to the control commands from the E-coupling control unit and at
the same time, magnetic flux is created in the coil based on the current value. The armature moves by a
magnetic induction effect which causes the primary clutch to be engaged. If this happens, when there is
a difference between the front axle and rear axle speeds, a speed difference between the base cam and
apply cam also occurs. Then, the ball will be sliding and rolling along the grooves on the base cam and
apply cam according to this relative speed deviation between the base cam and apply cam, and these
cams are pushed back. Therefore, the ball cam system with a cam thrust pushes against the secondary
clutch which is engaged between the housing and hub. The driving force is delivered from the housing to
hub, driving pinion and rear differential and finally to the rear axle through this process.

GETtheMANUALS.org
06-24

8. SECTIONAL VIEW

Primary clutch pack

Coil Armature Clutch housing

Input shaft

Back plate

Output shaft

Flange

Outer housing Ball Secondary clutch pack

Base cam Apply cam

GETtheMANUALS.org
 0000-00 06-25

9. INTERNAL GEAR CONFIGURATION

Nut Flange

Outer housing Armature Primary clutch pack

Washer Secondary clutch pack

Apply cam
Washer
Ball Bearing
Protector
Snap ring
Dust seal Coil

Bearing

Clutch housing Base cam

Third element Output shaft

Dust seal Back plate

GETtheMANUALS.org
06-26

10. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 06-27

GETtheMANUALS.org
 0000-00 07-3

1. SPECIFICATIONS
▶ Suspension

Item Specifications
Suspension type Macpherson Strut
Spring type Coil spring
Stabilizer bar type Torsion bar
Shock absorber Maximum length when Approx. 521 mm
extended
Minimum length when Approx. 369 mm
Front compressed
suspension
Coil spring Inner diameter (A) Upper: Approx. 90.5 mm
Lower: Approx. 96.0 mm
Outer diameter (B) Approx. 153.8 mm
Free height (C) GSL: Approx. 304.9 mm
DSL: Approx. 326.1 mm
Number of windings 4.75(3.625)
(effective windings)
Winding direction Rightward
Suspension type Torsion beam
Spring type Coil spring
Shock absorber Maximum length when Approx. 409 mm
extended
Minimum length when Approx. 284 mm
Rear compressed
suspension Coil spring Upper: Approx. 97.5 mm
Inner diameter (A)
(2WD) Lower: Approx. 70.6 mm
Outer diameter (B) Approx. 119.9 mm
Free height (C) Approx. 343.9 mm
Number of windings 7.07(5.92)
(effective windings)
Winding direction Rightward

GETtheMANUALS.org
07-4

Item Specifications
Suspension type Multi-link
Spring type Coil spring
Shock absorber Maximum length when Approx. 404 mm
extended
Minimum length when Approx. 284 mm
Rear
compressed
suspension
(AWD) Coil spring Inner diameter (A) Approx. 88.0 mm
Outer diameter (B) Approx. 112.2 mm
Free height (C) Approx. 279.3 mm
Number of windings 6.62 (5.32)
(effective windings)
Winding direction Rightward

GETtheMANUALS.org
 0000-00 07-5

▶ WHEEL ALIGNMENT

Item Specifications
GSL / DSL :
Trim Height
(404mm)/(411mm)
Camber (adjustment-
-0.5° ± 0.5°
free)
Front Caster (adjustment-
3.4° ± 0.5°
Suspension free )
0° ± 0.1°
Toe (0 mm ± 1.2 mm)
(Tie rod adjustment) Sum of left and right:
0° ± 0.2°
(0 mm ± 2.4 mm)

Trim Height 421mm

Camber (adjustment- -1.25° ± 0.1°
free)
Rear
suspension 0.205° ± 0.1°
(2WD) 2.75mm ± 1.2mm
Toe
(Sum of left and right)
(adjustment-free)
0.41° ± 0.2°
(5.5mm ± 2.4mm)

Trim Height 421mm

Camber (adjustment- -1.25 ± 0.5°
free)
Rear
suspension 0.025° ± 0.1°
(AWD) 1.8mm ± 1.2mm
Toe (adjustment) (Sum of left and right)
0.3° ± 0.2°
(Sum of left and right)
3.6mm ± 2.4mm

The trim height is figure for reference.

GETtheMANUALS.org
07-6

1. OVERVIEW
The suspension system connects the axles to the body to: (a) support the vehicle weight; (b) relieve the
impact from the road while driving; (c) prevent the vehicle from swaying from side to side while driving;
and (d) maximize the ride comfort by utilizing the good handling. The driving stability refers to a well-
balanced driveability and stability. The driving stability and ride comfort are significantly affected by the
components of the suspension system, along with the vehicle weight, vehicle speed, road conditions, tire
and the wheel alignment. It is called "front suspension" or "rear suspension" depending on the mounting
position.

2. COMPONENTS

Front suspension

Rear suspension

GETtheMANUALS.org
 0000-00 07-7

3. EPC
▶ 4410 FRONT SUSPENSION

1. ARM ASSY-FRT SUSPENSION LWR 7. BOLT-FRT LWR ARM MTG FRT

2. BUSH-FRT LWR ARM RR 8. BOLT-FRT LWR ARM MTG RR
3. BALL JOINT ASSY-FRT LWR ARM 9. NUT-GEAR MTG NO1
4. BUSH-FRT LWR ARM FRT 10.SNAP RING-FRT LWR ARM
5. BOLT 11.NUT
6. NUT

GETtheMANUALS.org
07-8

▶ 4411 FRONT SHOCK ABSORBER

2. DAMPER-FRT SUSPENSION 9. BUMPER STOPPER

3. COIL SPRING-FRT 10.DUST COVER
4. CAP-INSULATOR 11.SEAT-UPR BRKT
5. NUT 12.BOLT-SHOCK ABSORBER MTG FRT
6. INSULATOR ASSY-DAMPER FRT 13.NUT-GEAR MTG NO1
7. PAD-SPRING UPR 14.NUT
8. PAD-SPRING LWR

GETtheMANUALS.org
 0000-00 07-9

▶ 4420 STABILIZER BAR

1. STABILIZER BAR ASSY-FRT

2. BUSH-STABILIZER BAR MTG FRT
3. CLAMP-STABILIZER BAR FRT
4. BRKT-STABILIZER BAR MTG FRT
5. LINK-STABILIZER BAR FRT
6. BOLT-HEX SEMS_M10X1.25X30
7. NUT

GETtheMANUALS.org
07-10

▶ 4510 Rear Suspension

1. BEAM COMPL-RR SUSP TORSION 7. BRKT ASSY-S/ABR MTG

2. BRKT ASSY-TORSION BEAM MTG 8. BRKT-WSS MTG
3. WASHER-TORSION BEAM MTG BRKT 9. BRKT-WSS MTG
4. BUSH-TORSION BEAM 10.BRKT ASSY-SPRING SEAT
5. BOLT 11.BOLT
6. NUT 12.WASHER-TORSION BEAM MTG BUSH

GETtheMANUALS.org
 0000-00 07-11

▶ 4511 REAR SHOCK ABSORBER

1. SHOCK ABSORBER ASSY-RR GAS 6. CAP-BUMPER STOPPER

2. COIL SPRING-RR 7. BOLT-UPR ARM MTG
3. PAD-RR SPRING UPR 8. NUT-HEX FLANGE
4. PAD-RR SPRING LWR 9. BOLT
5. STOPPER-RR SUSPENSION BUMPER 10.BOLT

GETtheMANUALS.org
07-12

▶ 4520 REAR SUSPENSION(MULTI LINK)

1. ARM ASSY-RR SUSPENSION UPR 16.WASHER

2. BUSH-TRACK ROD 17.ARM ASSY-RR SUSPENSION LWR
3. STOPPER ASSY-RR SUSPENSION 18.BUSH-RR LWR ARM
4. TRAILING ARM ASSY-RR SUSP 19.BOLT-GEAR MTG NO1
5. BUSH-TRAILING 20.NUT-HEX FLANGE
6. BOLT-TRAILING ARM MTG 21.BOLT-GEAR MTG NO2
7. TRACK ROD ASSY-RR SUSPENSION 22.NUT-GEAR MTG NO1
8. BUSH-TRACK ROD 23.BRKT-STABILIZER BAR MTG RR
9. CAM BOLT-TRACK ROD 24.WHEEL CARRIER ASSY-RR SUSP
10.CAM WASHER-TRACK ROD 25.BALL JOINT ASSY-SPRING LINK
11.STABILIZER BAR ASSY-RR 26.BOLT
12.RUBBER BUSH-RR STABILIZER BAR 27.BOLT
14.LINK ASSY-STABILIZER BAR RR 28.BOLT
15.BOLT 29.NUT

GETtheMANUALS.org
 0000-00 07-13

▶ 4521 REAR SHOCK ABSORBER (MULTI LINK)

1. SHOCK ABSORBER ASSY-GAS RR 6. CAP-BUMPER STOPPER

2. COIL SPRING-RR 7. BOLT-UPR ARM MTG
3. PAD-RR SPRING UPR 8. NUT-HEX FLANGE
4. PAD-RR SPRING LWR 9. BOLT
5. STOPPER-RR SUSPENSION BUMPER 10.BOLT

GETtheMANUALS.org
07-14

1. WHEEL ALIGNMENT
The wheel alignment deals with geometric angles and basic measurements (camber, caster, and toe) to
achieve steering stability and improved ride comfort.

1) Toe-In
Toe-in refers to the front portion of the tires pointing in toward the centerline from a straight ahead
position, while the term toe-out refers to the front portion of the tires pointing outward. In the figure shown
below, the toe value is "B-A". Toe keeps the front wheels running parallel and reduces the reaction force
when the vehicle moves forward.
Incorrect toe causes tire wear and excessive fuel consumption. Any changes due to worn steering
components and suspension components because of excessive driving distance need to be
compensated by adjusting toe. Adjusting toe should be carried out at the last step.

Item LH/RH Total Adjustment

Wheel Front 0° ± 0.1° 0° ± 0.2° Adjustment
alignment (0mm ± 1.2mm) (0mm ± 2.4mm) (Tie rod end)
specification
Rear 0.205° ± 0.1° 0.41° ± 0.2° Adjustment
(Toe-in)
(2WD) 2.75mm ± 1.2mm 5.5mm ± 2.4mm (Track rod-Frame mounting)
Rear 0.15° ± 0.1° 0.30° ± 0.2° Adjustment
(AWD) (1.8mm ± 1.2mm) (3.6mm ± 2.4mm) (Track rod-Frame mounting)

▶ Function

1. Prevents uneven tire wear

2. Compensates side slip due to camber
3. Compensates for steering linkage wear or free play

GETtheMANUALS.org
 0000-00 07-15

2) Camber
Camber is the angle made by the wheels of a vehicle; specifically, it is the angle between the centerlines of
the wheel used for steering and a true vertical axis when viewed from the front of the vehicle. In general,
positive camber is required to counteract the force, which causes negative camber, due to curved roads,
occupant load, road surfaces, or certain alignment condition.

Item LH/RH Cross camber Adjustment

Wheel alignment Front Lower arm-Frame
-0.5° ± 0.5° 0° ± 0.5°
specification mounting
(Camber)
Rear Track rod-Frame
-0.5° ± 0.5° 0° ± 0.5°
mounting

▶ Positive camber: Top of the tire points outward

Advantages: - The axle is not bent when it is loaded.

- The force required to operate the steering wheel is reduced because of smaller contact
area (or load area) of the tire.
- Restoring force of the steering wheel is gained (when turning the steering wheel, the
circular movement of the tire generates the force to lift the frame rather than the force to
pull down the tire to the ground. In this case, the shock absorber contracts and the
restoring force is applied to the steering wheel.)
Disadvantages: - Cornering force decreases as the positive camber increases when the vehicle
makes turn.
- The hub bearing is worn unevenly if camber is excessive.

▶ Zero camber: Centerline of tire is perpendicular to road surface

GETtheMANUALS.org
07-16

▶ Negative camber: Top of the tire points inward

Advantages: - Better traction force due to wide load area (applicable for off-road vehicle)
- Better corner driving when the vehicle makes turn since the cornering force increases
(applicable for high-speed F1 vehicle)

Disadvantages: - The axle is easier to be bent and deviated in the negative camber than it is in the
positive camber when load is applied on the axle.
- Difficult to control due to wide load area.

3) Caster
Caster is the angle between the steering axis tilted forward and a true vertical axis, when viewed from
the side of the vehicle. Caster improves stability (straight ahead run) of the vehicle at high speed and
does not affect the tire wear. Factors including reduced stiffness of the springs and excessive load
influence caster. If the difference between the left and right caster values is great, drag of the steering
wheel or vehicle can occur.

Item LH/RH Total Adjustment

Wheel alignment Front 3.4° ± 0.5° 0° ± 0.5° Lower arm-Frame mounting
specification
(Caster) Rear - - -

▶ Positive caster:

Advantages: - Directional force to go straight (following control)

- Restoring force of the wheel (restored to the straight ahead direction)
- Prevention of wheel shimmy (wheels sway from side to side)

▶ Negative caster:

Advantages: - Smaller turning radius

Disadvantages: - Impact from the road is transferred to the steering wheel (steering wheel turns)
- Poor straight ahead run

GETtheMANUALS.org
 0000-00 07-17

4) Trim Height
Incorrect trim height may damage the suspension components or cause problems related to wheel
alignment. Therefore, check the trim height before checking wheel alignment when troubleshooting the
suspension.

Trim height: Distance (C) from the wheel center (A) to the point where an imaginary vertical line from
the wheel center meets the bottom of the wheel arch (B) with the vehicle unladen.

Position GSL DSL

Front 404mm 411mm
Rear 421mm

GETtheMANUALS.org
07-18

2. FRONT SUSPENSION ASSEMBLY

1) MacPherson Strut Type
The MacPherson Strut suspension is an independent suspension which has a spring on the strut with a
built-in shock absorber. The lower arm is installed on the sub frame and large strut damper is installed
on the knuckle to support the wheel.
This suspension is mostly used for the monocoque (unitary) light weight body construction, especially for
the FWD models. The upper part with a spring is fitted to the body mounting and the strut with integrated
shock absorber is mounted on top of the knuckle.

MacPherson Strut structure

Coil spring

Shock absorber

Stabilizer bar link

Knuckle Lower arm Stabilizer bar

▶ Advantages

1. Because the spring and the shock absorber are integrated,

2. this suspension provides major advantage in package space,
3. and its whole assembly is very simple with fewer parts than other systems. This suspension is widely
used for the FWD models with constant velocity joint.
4. In addition to its simple structure, the vibration of the vehicle can be controlled directly with no need for
the vibration to travel through initial members.
5. This leads to better ride comfort.

▶ Disadvantages

1. The MacPherson strut suspension is an independent suspension which has a spring on the strut with
a built-in shock absorber. But it needs higher hood because the vertical length of the strut is long, and
is very susceptible to external impact because there is only one swing arm which holds the wheel
axle.

GETtheMANUALS.org
 0000-00 07-19

3. REAR SUSPENSION ASSEMBLY

1) Torsion Beam Type (2WD)
The rear suspension maintains the ride comfort and the safety of the vehicle with the front suspension.
The rear suspension installed to this vehicle is a torsion beam type with an integrated axle, and consists
of torsion beam, shock absorber, and coil spring.

Torsion beam structure

Shock absorber

Torsion beam Coil spring

GETtheMANUALS.org
07-20

2) Multi-link Type (AWD)

Multi-link type suspension is equipped with several arms which are controlled independently of each
other. This type of suspension allows precise design and flexible layout, and is mostly used for rear
suspension. Internal force applied to the links are distributed and the optimal layout of the links allows
flexible adaptation to camber and toe changes and has the effect of a good road surface adherence.
The multi-link rear suspension of this vehicle consists of knuckle, upper arm, track rod, trailing arm,
stabilizer bar, stabilizer bar link, coil spring, shock absorber, and lower arm.

Configuration

Rear stabilizer bar

Rear upper arm

Rear track rod

Rear coil spring

Rear lower arm

Rear trailing arm

Rear shock absorber Wheel carrier Rear stabilizer bar link

GETtheMANUALS.org
 0000-00 07-21

4. SUSPENSION COMPONENTS AND TIGHTENING TORQUE

▶ Front suspension assembly

Shock absorber upper mounting

nut(14mm-3 off)
Tightening torque: 58.8 ~ 78.4Nm

Stabilizer bar link

nut (17mm-2 off)
Shock absorber lower mounting Tightening torque: 49 ~ 68.6Nm
bolt/nut(17mm-2 off/nut19mm-2 off)
Tightening torque: 137.2 ~ 156.8Nm
Stabilizer bar clamp bolt
(12mm-2 off)
Tightening torque: 39.2 ~58.8Nm

Lower arm (to sub frame front)

bolt (17 mm)
Tightening torque: 117.6 to 137.2Nm

Lower arm (knuckle side) Lower arm (to sub frame rear)
bolt/nut (19mm/19 mm) bolt/nut (19mm/19 mm)
Tightening torque: 107.8 to 127Nm Tightening torque: 107.8 to 137.2Nm

GETtheMANUALS.org
07-22

▶ Rear suspension assembly (2WD)

Rear shock absorber upper mounting

bolt/nut (19 mm)
Tightening torque: 78.5 to 98.0 Nm

Rear torsion beam bracket mounting

bolts (17 mm, 4 off)
Tightening torque: 39.2 to 58.8 Nm

Rear torsion beam bracket

bolt/nut (17mm)
Tightening torque: 107 to 127 Nm

Rear bumper stopper mounting

bolt (12mm)
Tightening torque: 14.7 to 16.7 Nm

Rear shock absorber lower mounting

bolt (19mm)
Tightening torque: 78.5 to 98.0 Nm

GETtheMANUALS.org
 0000-00 07-23

▶ Rear suspension assembly (AWD)

Rear shock absorber mounting (body) Rear upper arm mounting (sub frame)
bolt (19mm) bolt/nut (19mm/19 mm)
Tightening torque: 78.5 to 98Nm Tightening torque: 98.0 to 117.6Nm

Rear track rod mounting (sub frame)

Rear stabilizer bar bracket
Cam bolt/nut (15 mm/19 mm)
bolt (14 mm, 2 off)
Tightening torque: 98.0 to 117.6Nm
Tightening torque:
19.6 to 29.4Nm
Rear upper arm mounting (wheel carrier)
bolt/nut (19mm/19 mm)
Tightening torque: 98.0 to 117.6Nm

Rear track rod mounting

bolt/nut (19mm/19 mm)
Tightening torque: 98.0 to 117Nm Rear stabilizer bar link
nuts (17mm, 2 off)
Rear trailing arm mounting Tightening torque:
(wheel carrier) bolts (14mm, 3 off) 39.2 to 58.8Nm
Tightening torque: 49.0 to 68.6 Nm
Rear lower arm mounting
Rear trailing arm mounting (body) (sub frame)
bolts (14 mm, 2 off) cam bolt/nut (16mm/19 mm)
Tightening torque: 78.5 to 98Nm Tightening torque: 98.0 to 117.6Nm

Rear shock absorber mounting Rear lower arm mounting

(wheel carrier) bolt (19mm) (wheel carrier) bolt/nut (19mm/19 mm)
Tightening torque: 78.5 to 98.0Nm Tightening torque: 137.2 to 156.9Nm

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Category Item Specifications
Operation type Motor driven power steering system
Operating temperature -40°C to 85°C
Max. humidity 95%
Rated voltage 12 V
6.0 to 20.0 V
Operating Operating voltage 9.0 to 17.0 V (EPS 100%)
EPS ECU 8.3 to 9.0 V (EPS 20%)
voltage
Assist operating voltage 17.0 to 20.0 V
CAN network 8.3 to 20.0 V
Dark current 0.3 mA or lower (12.0 V, Unloaded)
Operating
Operating current 500 mA (12.0 V, Unloaded)
current
Max. output current 99 A (11.0 to 16.0 V)
Type Brushless type
Operating temperature -40°C to 85°C
Rated voltage 12 V
Rated voltage 70 A
BLAC motor
Turning torque 4.3 Nm (25°C)
4.1 Nm (85°C)
Rotational speed 1,100 RPM
Position sensor type Hall sensor type
Type Non-contact

Torque angle Rated voltage 5V

sensor Operating temperature -40°C to 125°C

Measuring angle range ±738°

(Torque: ±8°)

GETtheMANUALS.org
02-4

Category Item Specifications

Category Tilting angle Up
Item 2°
Specifications
Steering 2°
Steering
column
Up
Tilting angle Down
column Telescoping Down 2°
30mm
Type 4 spokes
Outside diameter Φ373 (D-CUT range: Φ368.5)
Type Simple ON/OFF
Rated voltage 13.5V ± 0.1V

Steering wheel Operating voltage 9.0V ~ 16.0V

Heated wire
unit Rated voltage Max. 12.4 A

Low voltage 7.5 V ± 0.5 V (No operation recovery after

turning off the LED and heated wire)

HI voltage 18.0 V ± 0.5 V

(16.5 V ± 0.5 V, Auto recovery)
Type Rack and pinion
Steering gear
Gear ratio 50.7
linkage
Rack stroke 148mm ± 1.5mm

Steering angle Inner 31.10° ± 1°

Outer 37.67° ± 1°
Lower shaft Type Sliding (Ball slip)

GETtheMANUALS.org
 0000-00 02-5

2. TIGHTENING TORQUE

Tightening
No. Item Remarks
torque
1 Steering wheel mounting nut 39.2 to 49.0 Nm 22 mm X 1 off
2 Steering Upper mounting nut 19.6 to 24.5 Nm 12 mm X 2 off
column shaft
3 Lower mounting bolt 44.1 to 49.0 Nm 14 mm X 1 off
4 Lower shaft Upper mounting bolt 27.4 to 32.3 Nm 12 mm
5 Lower mounting bolt 32.3 to 37.2 Nm 12 mm
6 Steering Mounting bolt 68.6 to 98.0 Nm 19 mm X 2 off
gear box
7 Mounting bolt 49.0 to 68.6 Nm 17 mm X 1 off
8 Tie rod mounting nut 63.7 to 83.5 Nm 22 mm
9 Tie rod end mounting nut 44.1 to 83.5 Nm 17 mm (Castle nut)

GETtheMANUALS.org
02-6

1. OVERVIEW
Recently, the enhanced steering system, called EPS (Electric Power Steering) is widely used to achieve
optimal steering assistance, reduce fuel consumption, and meet the environmental regulations. The EPS
does not have any belt-driven steering pump constantly running, so it is lightweight and the motor
consumes energy only when the steering wheel is turned by the driver, and this leads to improvement in
fuel efficiency. Also, the elimination of a belt-driven pump and its accessories greatly simplifies
manufacturing and maintenance. While offering these benefits, as it does not contain any steering oil,
the environment is not polluted both when the steering system is produced and discarded.
In other words, the EPS system uses the electric motor to assist the steering force. It functions
independently regardless of whether the engine is running or not, unlike the conventional hydraulic
power steering.
The EPS system generates an assist steering force variably depending on the driving conditions by
controlling the motor's operation, based on the input signals from the sensors such as torque sensor and
angle sensor. The EPS receives the torque signal by the driver’s input of the steering wheel as
well as the vehicle speed, and uses 3-phase BLAC motor to determine the motor torque. Then the EPS
controls the motor to reach the target torque with the phase current of the motor and the signal from the
rotation position sensor. Another features of EPS are fail-safe function, diagnosis function,
communication function between units, and interface function for external diagnostic device.
The EPS system components such as the torque sensor, steering angle sensor, fail-safe relay, etc. are
located in the steering column and EPS unit assembly.

▶ Advantages:
(1) Assurance of improved steering (2) Reduced fuel consumption
- Provides optimal steering force according to the - Consumes power only when the power assist
vehicle speed: is required:
For example, in low-speed driving conditions, Fuel economy improved
such as parking, EPS provides higher level of - Energy saving:
assistance than it does at higher speeds. The Saving up the energy compared to hydraulic
greater assist makes it easier to maneuver the steering
vehicle. On the contrary, when the vehicle - Elimination of pump, hose, pulley, oil reservoir,
speed is high, the electronic power assist is belt, fittings
gradually reduced for direct and precise
controlling.
- Enhanced steering stability while driving at high
speed
- Damping compensation control, friction
compensation control

GETtheMANUALS.org
 0000-00 02-7

2. COMPONENTS

Steering wheel Steering column shaft Lower shaft

Steering gearbox assembly

Tie rod end (LH) Steering gear part Tie rod end (RH)

Gear box (Rack and pinion)

GETtheMANUALS.org
02-8

3. EPC
▶ 4610 STEERING WHEEL & COLUMN

1. BODY ASSY-STEERING WHEEL 9. WASHER

2. HEATER MODULE-STEERING WHEEL 10.NUT
3. BEZEL-STEERING WHEEL 11.NUT
4. COLUMN & SHAFT ASSY-TILT 12.ECU-ELECTRONIC POWER STEERING
5. COLUMN ASSY-UPR 13.BOLT-ECU
6. SHAFT ASSY-LWR 14.WASHER-SPRING
7. BOLT-JOINT 15.WASHER
8. BOLT-STEERING COLUMN MTG

GETtheMANUALS.org
 0000-00 02-9

▶ 4620 STEERING GEAR LINKAGE

1. LINKAGE ASSY-GEAR & OBJ 6. BOLT

2. END ASSY-TIE ROD 7. PIN-SPLIT
3. NUT-TIE ROD 8. NUT
4. BOLT-GEAR MTG 9. BOOT KIT-P/STRG GEAR BOX
5. BOLT 10.HEAT SHIELD-STEERING

GETtheMANUALS.org
02-10

1. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
 0000-00 02-11

GETtheMANUALS.org
02-12

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 02-13

2. CAN INPUT/OUTPUT ELEMENTS

▶ ESC

▶ FCM

GETtheMANUALS.org
02-14

▶ CGW

▶ ACU

GETtheMANUALS.org
 0000-00 02-15

▶ AEB

▶ Instrument cluster

GETtheMANUALS.org
02-16

3. OPERATING PROCESS

Output torque = 1) Steering force (manual torque) + 2) Assist torque

When the driver turns the steering wheel, torque is generated and the torque sensor and the steering
angle sensor in the EPS system detect the intention of the driver to run the electric motor. At this time,
the worm gear connected to the motor drives the helical gear mounted to the steering column to
generate the assist torque for the steering column. This allows the driver to operate the steering wheel
easier.

GETtheMANUALS.org
 0000-00 02-17

4. INTEGRATED DRIVE MODE

The integrated drive mode improves the driver's convenience by integrating functions of TCU (driving
mode) and EPS (smart steering) into one. The EPS provides two modes (NORMAL, SPORT) of
steering force.

1) Driving Mode Switch

▶ Determining mode
- The signal from the drive mode switch is
transmitted to the instrument cluster and
hardwire and is input to the EPS unit via the
instrument cluster.
- The EPS determines the drive mode and
sends out the drive mode status to the TCU
and the instrument cluster.

▶ Switch type
- Push-return type switch

▶ Switch input
- If the switch input lasts more than 1 second, the
system switches to WINTER mode.
- If the switch input lasts less than 1 second, the
system switches between NORMAL and
SPORT modes.

2) Transition Process
A/T M/T

GETtheMANUALS.org
02-18

3) Operating Process
A/T

M/T

GETtheMANUALS.org
 0000-00 02-19

▶ Instrument cluster display

The integrated driving mode operates in 3 modes (NORMAL, SPORT and WINTER) for A/T vehicles
and 2 modes (NORMAL and SPORT) for M/T vehicles.

Instrument cluster Instrument cluster

Operating conditions
(Supervision) (Standard)

In NORMAL mode, the steering

force of the EPS is moderate,
and the TCU also operates in
normal mode.

In SPORT mode, the steering

force of the EPS is heavy
compared to NORMAL mode.
This mode is mainly used at
high speeds. The TCU
operates according to the shift
pattern of POWER mode.

In WINTER mode, the steering

force of the EPS is the same as
the steering force of the
NORMAL mode. The TCU
operates in a mode to minimize
slippage when starting from a
slippery surface.

- When changing driving mode during driving, all attention should be kept on the roadway
ahead.
- When changing the driving mode while turning the steering wheel, the selected mode is
displayed on the instrument cluster screen, but the steering force may not change
immediately.
If this is the case, the mode will be changed to the selected mode automatically after the steering
wheel has been operated.
- If the EPS system does not operate because of the malfunction in the system, the driving mode will
not be available.

GETtheMANUALS.org
02-20

5. ESP RELATED SYSTEM

- Dynamic Steering Torque Assist (DST)

The dynamic steering torque assist system compensate the braking force and additional torque for
steering on a slippery road.

Driving direction Steering wheel operation

When the brake pedal is depressed on a road where the surfaces contacting with the left and right
wheels are different from each other, the steering is turned toward the surface side with high friction,
resulting in veering off the carriageway. At this time, the DST system controls the ESP with EPS
together (generating torque required for correcting the steering angle).

GETtheMANUALS.org
 0000-00 02-21

- Cornering Brake Control (CBC)

When applying the brake to the vehicle driving on winding road at high speed, a slip occurs with the
vehicle load pulled toward the outside of the corner.
The cornering brake control (CBC) system minimizes the vehicle slip when the vehicle is turning by
applying more brake hydraulic pressure to the inner wheels.

Driving direction Steering wheel operation

When oversteer or understeer occurs while the vehicle is turning, the system generates the torque
required for correcting steering angle of the EPS along with the EPS operation to make the vehicle stay
in line.

GETtheMANUALS.org
02-22

6. COMPONENTS
(1) BLAC motor
The BLAC motor is a brushless type motor. The
magnet of the BLACK motor rotates while the
coil rotates for the conventional DC motor. In this
way, high power output, high responsiveness,
high speed, high torque performance and high
heat protection can be achieved.

▶ Advantages
- High power output density
- Low inertia (high responsiveness)
- High speed/torque performance
- Low maintenance cost
- High torque ratio/inertia ratio
- High heat dissipation efficiency

(2) Torque and angle sensor

The torque sensor is one unit together with the angle sensor. The torque sensor outputs the analogue
voltage and the angle sensor outputs two PWM signals.

▶ Torque angle sensor

- Operating temperature: -40 to 85°C
- Power supply: 5.0 V
- Output signal format
(Torque: SENT)
(Angle: SENT + PWM)
- Torque measuring range: ±8˚
(±16 Nm at 2 Nm/˚ of torsion bar stiffness)
- Angle measuring range: ±738˚

GETtheMANUALS.org
 0000-00 02-23

7. SENSOR CHARACTERISRICS
(1) Torque sensor
- Detection
When a magnetic field is applied to a current flowing through a conductor, the electric current carriers in
the conductor experience a force in a direction perpendicular to the magnetic field and current field. The
newly developed electric field results in a potential difference and this effect is called Hall-effect. A Hall-
effect sensor is based on this effect. The sensor converts the intensity of magnetic field into a voltage
value. The torque sensor for EPS system uses a linear type hall-IC to convert the value of intensity change
in magnetic field strength into a voltage value.
That is, the major function of the hall-effect type torque sensor is to detect the change in magnetic flux
around the hall IC in accordance with the twist amount (angle) between the input shaft and the output
shaft.

Structure of torque sensor

GETtheMANUALS.org
02-24

- Operation
The operation range of the torque sensor built in this system, is 2.5 rotations (± 900 degrees) on
each side (left & right) which is the same as that of the steering wheel. And this sensor should detect the
twist amount (up to ± 4.5 degrees) between the input shaft and the output shaft within the
operation range of the steering wheel.
The torque sensor consists of a permanently magnetized multi-pole (16 poles) magnet rotor with round
shape connected to the input shaft of the steering wheel, upper and lower stators connected to the output
shaft with a number of teeth which contact with the magnetized poles, a collector which collects the
magnetic flux induced to the stator which rotates as much as the steering wheel rotates into the hall IC,
and a hall IC sensor which converts the value of flux change into a voltage value.

GETtheMANUALS.org
 0000-00 02-25

If the twist amount is zero, the magnet rotor poles and the stator teeth are equally spaced. Thus the
magnetic flux generated by the permanent magnet cannot be induced to the hall IC.
That is, the flux value around the hall IC is zero. But, if the twist amount is not zero, a contact area
difference is made between the permanent magnet poles and the upper & lower stator teeth. This leads
to the change in the magnetic flux around the hall IC (with a value corresponding to the contact area
difference). As a result, the output voltage value from the hall IC is changed.

When the driver turns the steering wheel counterclockwise while the vehicle is stationary or driven
straight ahead, the permanent magnet rotor connected to the input shaft is turned counterclockwise in
conjunction with the input shaft; but the upper and lower stators do not rotate as much as the rotor
rotates.

If the amount of twist between the rotor and the stator reaches the maximum value (-4.5˚), an
upper stator tooth contacts completely with the South pole of the magnet and a lower stator tooth
contacts completely with the North pole. So the force of magnetic flows from the North pole on the lower
stator tooth to the upper stator tooth which rests against the South pole, through the collector. At this
time, the magnetic flux increases to its maximum level around the hall effect sensor positioned in the
collector.
The relation between the twist amount and the contact area of the stator teeth and the permanent
magnet is linear in the range between 0˚ and -4.5˚. And the contact area has linear relation to the
magnetic flux generated around the hall IC. The magnetic flux is converted into voltage as a output
value, therefore the output voltage and the twist amount also have a linear relation.

GETtheMANUALS.org
02-26

(2) Angle sensor

GETtheMANUALS.org
 0000-00 02-27

8. EPS ECU OPERATION

A. Warning lamp ON when IGN ON

B. System power supply ON upon engine operating signal input
C. Fail safe relay ON after initial check (0.7 sec.)
D. Starts PWM current control
E. Warning lamp OFF after motor full current control

GETtheMANUALS.org
02-28

9. EPS ECU
The ECU controls the electric power steering
system depending on the driving conditions,
based on the signals from the torque and angle
sensor.

- Mounting location: Steering column

- Operating voltage: 6.0 V to 20.0 V
- Operating temperature: -40 to 85°C

1) External Connection Terminal

Motor position (8 pins)

Motor power (3 pins)

Battery power Vehicle (8 pins)

supply (2 pins)

Torque angle sensor (8 pins)

GETtheMANUALS.org
 0000-00 02-29

10. WARNING LAMP ON CONDITIONS

Mode EPS lamp Remarks
Initial check ON -

Faulty EPS (Major fault) ON Serious faults, including a torque sensor signal error,
defective motor, internal defect, etc.
Faults that can be rectified such as problems
Faulty EPS (Mild 1 fault) ON regarding battery, insufficient ignition power, etc.

Faults that can be partially controlled such as incorrect

Faulty EPS (Mild 2 fault) OFF messages, issues regarding vehicle speeds, etc.

EPS in operation OFF -

Diagnostic mode Flashing (1 Hz) OHP or diagnostic mode
Normal condition OFF -
CAN error
(Signal nor received by Warning lamp ON when CAN error has occurred
ON
instrument cluster, BUS within the same ignition cycle
OFF, message time out)
EPS not reinstalled after ON See active lamp specifications
removal

GETtheMANUALS.org
02-30

11. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 02-31

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
Item Category Specifications Remarks
TPMS Voltage range 9 V to 16 V -
ECU
Current Active mode - -
consumption
Sleep mode Without SKM : <7mA -
With SKM : <4mA
CAN communication speed 500 Kbps/ -
High speed CAN
Modulation type FSK　 -
(Frequency Modulation)
Frequency 433.92 Mhz -
Wheel Pressure measuring range Up to 700 kpa -
module
Tolerance range for measured -15 kpa to 15 kpa -40°C to 100°C
pressure
-10 kpa to 10 kpa -20°C to 70°C
-20 kpa to 20 kpa 100°C to 120°C
Tolerance range for measured -5°C to 5°C -40°C to 120°C
temperature
-3°C to 3°C -20°C to 70°C
Temperature measuring range -40°C to 120°C -
Battery life Approx. 7 years -
Tire Inflation pressure 16 inch 35psi -
18 inch 35psi -

GETtheMANUALS.org
03-4

2. NOTES

- The wheel sensor sends a message for 15 minutes when the vehicle is stationary after driving. It is
not possible to check the tire pressure after turning the ignition off and on.
- The tire pressure check is not available when the ignition is turned from off to on. In order to check
the tire pressure, you should drive the vehicle for about 5~10 minute at a speed of 20 km/h or
higher.

Instrument cluster display

Pressure value displayed after detecting

At initial start
position automatically
Supervision Standard instrument Supervision Standard instrument
instrument cluster instrument cluster
cluster cluster

- The TPMS communicates with the wheel module and BCM (controls TPMS) via radio waves.
Therefore, the TPMS may not work properly when electronics which can electrically interfere with
the TPMS are installed to the vehicle body, or when the vehicle is driven through the areas with
high electromagnetic fields.

The specified tire pressure is 35 psi.

GETtheMANUALS.org
 0000-00 03-5

3. CAUTIONS

- If the vehicle is equipped with the TPMS, all wheels are equipped with the wheel modules. In this
case, the wheel module may be interfered with the wheel rim depending on the mounting surface
type of the rim. Therefore, always use the Ssangyong Motor Company genuine wheel and wheel
module for the vehicle.

Wheel module mounted Wheel module mounted

(from outside) (from inside)

- Make sure that the rim hole is clean without foreign materials when assembling the valve.
- Apply the soapy water which can reduce the friction force before assembling the valve. Avoid getting
the water or soapy water on the wheel module (housing).
- The sensor assembling direction and rim/rim hole should have the same angle when assembling the
valve.
- Make sure that the sealing part of the valve sits correctly on the rim hole after assembling the
valve.
- Always check that there is interference between the rim bead and wheel module after assembling the
valve.
- Always use a new valve and wheel module mounting screw.
- The removed parts cannot be used again.
- Do not use other special tools other than specified by Ssangyong Motor Company.
- Auto location is performed based on the wheel sensor history information from the BCM. Therefore, if
the wheel module has been replaced, you have to drive the vehicle for about 10 minutes after
stopping the vehicle for 15 minutes so that auto location is completed normally.

- If you have injected sealant into one of your tire for repairing,
drive the vehicle to a Ssangyong Authorized Service Center
located within a driving distance of 200 km at a speed of 80
km/h or slower and replace the repaired tire with a new one.
When replacing the sealant injected tire, the TPMS sensors
- should be checked for appearance and abnormality at a
Ssangyong Authorized Service Center.

GETtheMANUALS.org
03-6

4. SPECIAL TOOLS
The following torque wrench and connection adapter should be prepared when installing the TPMS
wheel module.

When fitting the wheel module, tighten the mounting bolt to the specified tightening torque (1.25 Nm).

- Excessive tightening torque may result in wheel module damage.

- Lack of tightening torque may result in the wheel module unit displaced from the valve during
driving.

Remover & installer tool for TPMS

wheel module &
valve body

Torque wrench (0.1 to 5.0 Nm)

Star socket T-10

How to use
Torque wrench To remove and install valve insert

To remove and install valve body

GETtheMANUALS.org
GETtheMANUALS.org
03-8

1. OVERVIEW
The tire pressure monitoring system (TPMS) is used to reduce the accident rate, enhance driving stability
and avoid an unnecessary fuel consumption and tire wear by monitoring the tire pressure and
temperature. The TPMS informs the driver of tire pressure information and its status through the
instrument cluster.
The wheel module fitted in the tire transmits the internal information of the tire to the TPMS ECU
periodically through the wireless transmission. The TPMS ECU can detect the position of the wheel
module fitted to each wheel automatically and sends the signal about the tire conditions through the CAN
line to the instrument cluster so that the driver can identify the wheel module in question.

2. COMPONENTS
Instrument cluster display (with supervision)

LCD display Global warning lamp

Instrument cluster display (standard)

LCD display Global warning lamp

GETtheMANUALS.org
 0000-00 03-9

BCM(TPMS control)

BCM(TPMS control)

Wheel module assembly

GETtheMANUALS.org
03-10

3. EPC
▶ 4190 TPMS PRESSURE MONITORING SYSTEM(TPMS)

1. WHEEL MODULE
2. VALVE ASSY-TPMS
3. CAP-TPMS

GETtheMANUALS.org
 0000-00 03-11

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
03-12

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 03-13

GETtheMANUALS.org
03-14

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 03-15

3. P-CAN COMMUNICATION I/O ELEMENTS

▶ ABS & ESP

▶ ACU

▶ ECU

GETtheMANUALS.org
03-16

▶ CGW

▶ SKM

GETtheMANUALS.org
 0000-00 03-17

▶ HVAC

▶ TCU

▶ TEST

GETtheMANUALS.org
03-18

4. DETECTING WHEEL MODULE POSITION

1) Description Of RF Transmission By Wheel Module & Mode
A. The algorithm of the TPMS (integrated with BCM) is an APC (Allocation Per Correlation) method,
which is an auto location logic that uses the ABS & ESP module via the vehicle P-CAN based on the
vehicle's wheel speed (tooth angle) to determine the wheel location.
- Each wheel of the vehicle operates independently of each other when driving (movement
characteristics of each wheel are different)
- TPMS sensor mounted on each wheel periodically transmits RF data in a specific direction of
corresponding wheel
- The TPMS sensor transmits the RF every 10 seconds in run mode and receives the phase angle of
the TPMS sensor (senses change in G value due to vehicle travel and wheel module rotation) and
signals on the angle of tooth wheel (amount of change for wheel tooth) of 4 wheels (FL/FR/RL/RR)
from the ABS & ESP.
- The TPMS (integrated with BCM) carries out the auto location by cumulatively analyzing the
correlation of the movement information (amount of change for wheel tooth) of each wheel based on
the phase angle information that the TPMS sensor receives RF every 10 seconds. (normally
completed within 5 to 10 minutes when driving at a speed of 20 km/h or higher)

Amount of change in
wheel speed sensors

Angle information from

TPMS sensor

GETtheMANUALS.org
 0000-00 03-19

2) Description Of RF Transmission By Wheel Module & Mode

A. Stationary mode: Vehicle stationary and no RF transmission
B. Run mode
- Run mode includes auto learn (finds 4 sensors) and auto location (locates 4 sensors).
- The RF signal repeats once in HS and twice in HR at intervals of 10 seconds.
- Run mode (auto location) always performed when driving with IGN off or after 15 min since vehicle
stationary

C. Normal mode: Auto location completed normally and tire pressure can be displayed
D. Temporary mode:
- Adjusting the tire air pressure in temporary mode will display the adjusted value on the instrument
cluster.
- When changing the tire position, the vehicle must be stopped for 15 minutes and then traveled
before the auto location can be completed normally.
- If the vehicle travels within 15 minutes, it is completed in the normal mode without the run mode
(auto location) through the wheel sensor history information stored in the TPMS built-in BCM
without the auto location message.
E. Emergency mode: RF transmitted once every second when tire pressure drops in normal mode

GETtheMANUALS.org
03-20

HS: status message (sensor ID, pressure, temperature, status information)

HR: auto location message (wheel module position, angle information)
AK: specification message (frame defined by manufacturer)

GETtheMANUALS.org
 0000-00 03-21

5. SPECIFIED TIRE PRESSURE

1) Conditions In Which Tire Pressure Warning Triggered And
Canceled
35psi
Specified value
Triggered when Canceled when
Check tire Operating tire pressure reduced
(Low pressure warning) by 20% or more
Insufficient tire pressure (Very low Tire pressure falls
Inflate tire pressure to 34 psi or
pressure warning) below 24 psi
higher of specified value
Operating tire pressure drops by
Flat tire (Puncture warning) more than 2.9 psi per minute

Excessive tire pressure Tire pressure 53 psi or Adjust tire pressure to less than
(High pressure warning) higher 48 psi
Adjust left and right air pressure
Tire pressure imbalance Left and right tire pressure
difference to 3 psi or less
(Axle imbalance warning) difference 4 psi or more

GETtheMANUALS.org
03-22

2) How To Display TPMS Warning

GETtheMANUALS.org
 0000-00 03-23

3) Relationship Between Tire Pressure and Temperature

(Operating Tire Pressure)
While the proper tire pressure in this vehicle is 35 psi, the BCM (controls TPMS) receives the ambient
temperature signal from the instrument cluster through CAN communication and calculates the proper
tire pressure to correct it since the tire pressure changes depending on the ambient temperature.

▶ At room temperature of 20˚C

GETtheMANUALS.org
03-24

6. TPMS PRESSURE VALUE DISPLAYING PROCESS

The wheel sensor sends the RF signal to the BCM (controls TPMS) as soon as the vehicle is driven.
Once the vehicle has been stopped, the sensor sends messages only for 5 minutes. (The wheel sensor
will not send signals 5 minutes after the vehicle is stopped.)
Once the vehicle stops, the wheel sensor does not send any message. (However, when 15 minutes
passed after the stop, the transmission mode of the wheel sensor is initialized and the sensor does not
send any message.) The tire pressure check is not available when the ignition is turned from off to on 15
minutes after the vehicle is stopped. The tire pressure will be displayed on the instrument cluster after the
vehicle has been driven for 10 minute at 20 km/h or higher.

System Flowchart

Under normal circumstances, it transmits the tire pressure value and temperature value together with
its ID (Identification) once every about 30 seconds to reduce the load on the wheel module's battery.
However, in the event of emergency or situation (ex: tire inflation pressure changes 2.9 psi per
minute) in which should give a warning to the driver, it transmits the data once every about 1 second.

▶ The tire pressure is displayed through the following sequence. The procedures shown below
are processed at the same time.

Auto learn is completed when the IDs of wheel modules are identified
Wheel module detection by checking the IDs of sensors installed to the wheels. (4 IDs
(Auto Learn & received) (Auto Learn)
The position of each sensor is determined by the strength of RF signal
Auto location)
(front/rear) and direction of the acceleration sensor (front/rear). (Auto
Location)

GETtheMANUALS.org
 0000-00 03-25

7. TPMS DISPLAY AND WARNING LAMPS

Instrument cluster display Instrument cluster display
(supervision) (standard)

Display on cluster Failures Remarks

A. Global warning - Faulty BCM (controls TPMS)
lamp - Faulty wheel module Lit up at interval of 0.2 sec for 70
- Wheel module auto learn disabled sec and corresponding tire
- Unable to receive signal because displayed in yellow
of RF noise

- Tire check
Lit up for 70 sec and
- Too low inflation pressure
corresponding tire shaded
- Flat tire
B. LCD of
Indicator of the corresponding tire
supervision instrument
- Low tire pressure comes on (displayed in yellow)
cluster

Indicator of the corresponding tire

- Flat tire flashes
- Too high inflation pressure (displayed in red)
Corresponding tire flashing
- Pressure out of balance
(shaded)
C. LCD of standard - Low tire pressure
Indicator of the corresponding tire
instrument cluster
flashes
(shaded)
- Flat tire -
- Too high inflation pressure
Corresponding tire flashing
(shaded)
- Pressure out of balance

GETtheMANUALS.org
03-26

There may be two types of errors depending on the vehicle conditions.

If this is the case, the warning messages are displayed in order of priority stated below.

Warning message display priority

1. Not displayed
2. Check
3. Low level
4. Flat tire
5. Over inflation
6. Pressure imbalance
7. Normal

GETtheMANUALS.org
 0000-00 03-27

▶ Instrument cluster display (supervision)

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Priority of alert messages
1. Not displayed
2. Check
3. Low pressure
4. Flat tire -
5. Over inflation
6. Pressure imbalance
7. Normal

Normal tire pressure

This indicator is displayed when
all the tire pressures are normal.

Tire pressure not displayed

The tire pressure value is
displayed as "- -" when no tire
pressure is measured.

Check tire
If the tire pressure is too low to
avoid an inspection, this message
will be displayed. The
corresponding tire pressure blinks
(inverted shading) for 70 seconds
and corresponding tire(s) will be
displayed in yellow.

GETtheMANUALS.org
03-28

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Low tire pressure
If the tire pressure is too low to
avoid an inspection, this message
will be displayed. At the same
time, the global warning light will
come on and the corresponding
tire(s) will be indicated in yellow.

Flat tire
When the current tire pressure
drops rapidly or when one or
more tires are flat, the global
warning lamp will come on and
the corresponding tire(s) will be
indicated in red.

Over inflation
This message is displayed when
the current tire pressure is too
high. The corresponding tire(s)
will be indicated in red.

Pressure imbalance
If the pressure difference between
LH and RH tires is 5 psi or more,
the corresponding tires on the
screen flash with the shading
inverted alternatively.

GETtheMANUALS.org
 0000-00 03-29

▶ Instrument cluster display (standard)

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Priority of alert messages
1. Not displayed
2. check
3. Low pressure
-
4. Flat tire
5. Over inflation
6. Pressure imbalance
7. Normal

Normal tire pressure

This indicator is displayed when
all the tire pressures are normal.

Tire pressure not displayed

The tire pressure value is
displayed as "- -" when no tire
pressure is measured.

Check tire
If the tire pressure is too low to
avoid an inspection, this message
will be displayed. The
corresponding tire pressure blinks
(inverted shading) for 70 seconds
and corresponding tire(s) will be
displayed in yellow.

GETtheMANUALS.org
03-30

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Low tire pressure
If the tire pressure is too low to
avoid an inspection, this
message will be displayed. At
the same time, the global
warning light will come on and
the corresponding tire(s) will be
indicated in yellow.

Flat tire
When the current tire pressure
drops rapidly or when one or
more tires are flat, the global
warning lamp will come on and
the corresponding tire(s) will be
indicated in red.

Over inflation
This message is displayed
when the current tire pressure
is too high. The corresponding
tire(s) will be indicated in red.

Pressure imbalance
If the pressure difference
between LH and RH tires is 5
psi or more, the corresponding
tires on the screen flash with
the shading inverted
alternatively.

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
Item Specifications
Tire 16 inch 205 / 65R16
18 inch 215 / 50R18
Tire inflation 16 inch 35psi
pressure 35psi
18 inch
Wheel 16 inch 6.0J X 16
PCD : Φ112
18 inch 6.5J X 18
Tightening torque for wheel nut 127.4 ~ 156.8Nm
Repair kit Compressor operating current 15A
Sealant capacity 300ml
Spare tire Full Size 16 inch 205 / 65R16
18 inch 215 / 50R18
Temporary tire T125/80D16(60psi)

Virtual circle Pitch Center Diameter (PCD): The diameter of a virtual

circle on which the same elements are arranged at even
angles.
Wheel bolt
mountings

GETtheMANUALS.org
04-4

1. OVERVIEW
The tire supports the vehicle load, and reduces the impact from various road surfaces. It also transmits
the driving power, braking power, and physical effort to the road surface. A radial tire has the design in
which the cord plies are arranged at 90 degrees to the direction of travel, or radially (from the center of
the tire). To ensure stability, the entire tire is surrounded by additional belts oriented closer to the direction
of travel, but usually at some spiral angle. Therefore the radial tire has high stiffness on the tread, and is
suitable for driving at high speeds. There is a wear limit mark on the tire, which protrudes as a strip shape
located approximately 1.6 mm away from the groove bottom. This wear limit mark is not seen from the
outside so there is additional "▲" mark on the shoulder to let the driver find the wear mark easily.
To measure the tire groove depth, measure at any point other than the point on which the wear limit mark
is located. The tire may be worn unevenly according to the driver's driving habit, improper servicing, low
tire inflation pressure, tire rotation, etc. This vehicle us equipped with the TPMS which is used to reduce
the accident rate, enhance driving stability and avoid an unnecessary fuel consumption and tire wear by
monitoring the tire pressure and temperature to inform the driver of tire pressure information and its
status through the instrument cluster.

For the detailed information on TPMS, refer to "TPMS" section in "CHASSIS" chapter.

GETtheMANUALS.org
 0000-00 04-5

2. CONFIGURATION
Valve insert Service kit fitted

1. Valve cap 4. Wheel module

2. Insert valve 5. Mounting bolt
3. Valve body

Date of manufacture Tire specification mark

Week of manufacture Radial tire

Year of manufacture Nominal section width Rim diameter

GETtheMANUALS.org
04-6

3. EPC
▶ 4170 TIRE AND WHEEL DISC

1. ALLOY WHEEL 8. COVER-STEEL WHEEL

2. ALLOY WHEEL 9. TIRE
3. ALLOY WHEEL 10.BOLT-WHEEL
4. ALLOY WHEEL 11.BOLT-SPARE TIRE MTG
5. CAP ASSY-WHEEL 12.COMPRESSOR ASSY-REPAIR KIT
6. VALVE 13.SEALANT-REPAIR KIT
7. WEIGHT BALANCE-STEEL WHEEL 14.STEEL WHEEL

GETtheMANUALS.org
 0000-00 04-7

1. TIRE STRUCTURE

Tread
Tread refers to the thick layer of the rubber on its circumference that makes contact with the road
surface. The rubber used in the tire has good anti-wear properties to expand the service life of the tire.
Also, it is resistant to abrasion, cut, and impact to protect the inner layers of the tire.

Shoulder
The shoulder is the part of the tire at the edge of the tread as it makes transition to the sidewall. This is
the thickest part of the tire. Because of this property, the heat generated inside the tire can be dissipated
easily.

Sidewall
The sidewall bridges between the tire shoulder and bead. The sidewall actually flexes and helps the
suspension absorb some of the shock to provide good ride comfort. Sidewalls are molded with tire type,
specifications, structure, pattern, manufacturer-specific detail, government mandated warning labels,
and other consumer information.

Bead
The bead is a part of the tire that contacts the rim on the wheel. The bead typically consists of bead wire,
core rubber, etc. It seats tightly against the two rims on the wheel to ensure that the tire holds the air
when the tire pressure drops rapidly.

Carcass
Carcass is the entire inner layer of cord fabric which is the most important framework of a tire. The
carcass supports the air pressure as well as the vertical load, and absorbs shocks.

Belt
The belt reduces the shocks from the road surface, and increases the tread rigidity by tightly winding
about the carcass to provide the driving stability.

GETtheMANUALS.org
04-8

2. TIRE SIZE

Aspect ratio (%)

= Section height (H) / Section width (W)
X 100

3. TIRE INFLATION PRESSURE

Proper Over inflation Under inflation

Tread width Tread width Tread width

The contact area between the The contact area between the The contact area between the
ground and tire faces the tread ground and tire is not sufficient, ground and tire is excessive, so
layer completely. Thus the so the tire is worn out unevenly a lot of heat is generated,
driving force and the braking and the tire is susceptible to resulting in damage. Also the
force are optimized, and the tire external impact. tire is worn out unevenly and
is worn out evenly resulting in abnormally.
increased service life.

GETtheMANUALS.org
 0000-00 04-9

4. TIRE ABNORMAL STATE

▶ Standing wave

16 inch
Specified tire inflation pressure 35psi
18 inch

During driving, the rotating tire repeats deformation and restoring movement within the tread width. This
happens when the tire pressure is low in high speed driving.
However, when the wheel rotating speed is high, the tire is deformed further even before it returns to its
original shape and the trembling wave appears on the tread portion. If this symptom lasts for an
extended period of time, the tire can be blown out in a short period of time.
If the standing wave symptom occurs on the tire, rubber on the tread comes off and eventually the tire
can be blown out which is very dangerous. When driving at high speeds, prevent the standing wave by
increasing the tire pressure. High tire pressure reduces the heat generation due to extension and
contraction movement of the tire, and the risk of hydroplaning.
To achieve this, it is recommended to increase the tire pressure 10 to 30 % higher than the specified
pressure value when driving at high speeds.

GETtheMANUALS.org
04-10

▶ Hydro Planing

Hydroplaning does not Partial hydroplaning The tire is totally up on

start until the vehicle starts at about 80 km/h. the film of water 100
speed reaches 60 km/h. km/h (hydroplaning).

When the vehicle is driven at high speed on a road surface covered with water, tires do not contact with
the road surface but rotates floating on a thin film of water.
This condition causes brake failure, lower traction force and loss of steering performance.
To prevent this, increase the tire inflation pressure, use tires with ribbed treads with good tread depth.
Above all, driving slowly in any circumstances is the safest way.

GETtheMANUALS.org
 0000-00 04-11

5. WHEEL BALANCE
If the vehicle load is not equally distributed to each wheel, unbalanced centrifugal force by the wheel
rotation produces vibrations. As the centrifugal force is produced proportional to the square of the rotating
speed, the load applied to the wheels should be balanced even at high speeds. There are two types of
the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur because of
unbalanced rigidity or size of tires.

▶ Static balance
When the free rotation of the wheel is allowed, the heavier part is stopped at the bottom provided that the
wheel weight is unbalanced. This is called "Static unbalance". Also, the condition in which tire's stop
position is different from the first stop position when the wheel is rotated again is called "Static Balance".

If the part A shown in the figure 1 is heavier than

other parts, the balance weight which
corresponds to the weight difference between
the part A and other parts should be added to the
part B located on the opposite side of the part A
to maintain the static balance. If the static
balance is not maintained, tramping (up and
down movement of the wheels) will occur.

[Figure 1]

▶ Dynamic balance
The static unbalance of the wheel creates the
vibrations in the vertical direction, while the
dynamic unbalance creates the vibrations in the
lateral direction. As shown in the figure 2 (a), if two
parts, (2) and (3), become heavier than other
parts while the static balance is maintained, the
condition will be changed to dynamic unbalance,
resulting in shimmy (left and right vibrations of the
wheels) and the torque Fxa applied to the axial
direction. To correct the dynamic unbalance, add
the same balance weights to the two points A and
B on the circumference of the rim, as shown in the
figure 2 (b). Then apply the torque in the opposite
direction of the torque Fxa to compensate the
(a) (b)
[Figure 2] torque. This ensures the smooth rotation of the
wheel.

GETtheMANUALS.org
04-12

6. FUNCTION OF TIRE
▶ Supports vehicle load

The tire supports the vehicle load, and reduces

the impact from various road surfaces. It also
transmits the driving power, braking power, and
physical effort to the road surface.
Tire is designed to endure the high load of a
vehicle and can be inflated.
In general, no tubes are installed on the inside of
the tire and rubber layer is added instead of
tubes. This type is called tubeless type.
When the tubeless tire is inflated, the tire seats
tightly against the wheel to prevent air leaks. This
type is needed to maintain proper air pressure to
ensure stability of the vehicle.

Road with Road with ▶ Transmits driving force and braking

constant friction uneven friction force to road surface
coefficient coefficient
The driving force from the engine is delivered to
the tire through the drive train. Then the tire
transmits this force to the road surface so that
the vehicle moves in the direction of the tread.

The braking force generated from the brake

system is transmitted to the tire to stop or
decelerate the vehicle.
The braking force is determined by the friction
force between the tire and road surface. It acts in
the opposite direction to motion.

GETtheMANUALS.org
 0000-00 04-13

▶ Absorbs impacts from road surface

The tire absorbs the vibrations and impacts from

the road surface first and then transmits them to
the suspension system.
Once the suspension system receives the
impacts, the spring is compressed and stretched
repeatedly and the shock absorber dampens the
spring movement.
The amount of impacts absorbed by the tire is
determined by the tire inflation pressure and the
flexibility of the tire sidewall.
If the tire pressure is low, the inside temperature
of the tire will be increased rapidly with high
rolling resistance. If the tire pressure is too high,
the tire will become less flexible resulting in poor
ride comfort.
The lower the aspect ratio is, the better the
driving performance is and the lesser the ride
comfort is.

GETtheMANUALS.org
 0000-00 05-3

1. SPECIFICATIONS
Front sub frame
Category Specifications Remarks

Weight 17.1kg -

Mounting 4-point mounting -

Sub
A 610mm -
frame
B 339.5mm -

C 950mm -

Impact
Weight 1.42 kg -
beam

Rear sub frame (AWD)

Category Specifications Remarks

Weight 17.1 kg -

Mounting 4-point mounting -

A 1033.6mm -

B 308.5mm -

C 707mm -

GETtheMANUALS.org
05-4

2. EPC
▶ 4012 FRONT SUB FRAME AND MOUNTING

1. SUB FRAME ASSY-FRT 10.BRKT-NOISE COVER MTG

2. BEAM ASSY-IMPACT BEAM 11.BRKT-DAMPER MTG
3. BEAM ASSY-IMPACT BEAM 12.DAMPER-FRT SUB FRAME
4. BOLT 13.BOLT
5. BOLT-BODY MTG 14.HEAT SHIELD-DAMPER
6. BOLT 15.BOLT
7. BRKT ASSY-SUB FRAME MTG FRT 16.DAMPER-FRT IMPACT
8. BRKT-LWR ARM MTG RR 17.BOLT
9. HANGER-EXHAUST PIPE MTG

GETtheMANUALS.org
 0000-00 05-5

▶ 4015 REAR SUB FRAME AND MOUNTING (AWD)

1. SUB FRAME ASSY-RR

2. BRKT-CAMBER LINK MTG
3. BRKT ASSY-TRACK ROD MTG
4. BRKT ASSY-SPRING LINK MTG
5. BRKT ASSY-AXLE MTG FRT
6. BRKT-STABILIZER BAR MTG RR
7. HANGER-EXHAUST PIPE MTG

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Category Item Specifications
Type Ventilated disc
Disc diameter Ø298 mm
Caliper cylinder bore diameter Ø57.2
Front brake
Disc thickness 23 mm (Wear limit: 21.4 mm)
Brake pad area 53.5 cm² or more
Pad wear indicator Mechanical
Type Solid disc
Disc diameter Ø284 mm
Caliper cylinder bore diameter Ø33.96
Rear brake
Disc thickness 10 mm (Wear limit: 8.4 mm)
Brake pad area 26.8 cm² or more
Pad wear indicator Mechanical
Type Vacuum assisted booster type
Brake booster Size Single 10"
Booster ratio 9:1
Type Tandem type
Master cylinder
Cylinder bore diameter Ø22.22
Max. actuation travel 150 ± 3 mm
Brake pedal Pedal proportion 3:1
Free play 4 to 6 mm
Specification DOT 4
Brake fluid
Capacity Approx. 0.7L

Change brake fluid: every 2 years

Change brake fluid: every 2 years

What are DOT ratings?
Ratings of brake fluid classified by US Department Of Transportation for proper quality and
usage of brake fluid. Also called "USDOT".

GETtheMANUALS.org
01-4

2. TROUBLESHOOTING
▶ Brake operation and noise
The following is a description of the noise symptoms which can occur when the brake system is
operated. Compare actual fault symptoms with the following symptoms to take a proper measure.

- Noise and its cause

Symptom 1. Depressing the brake pedal makes a "screeching" noise when the engine is cold,
and the noise disappears as the vehicle is driven over a period of time.

This mostly occurs in the morning; The vehicle windows are covered with frost as the temperature drops.
For the case of brake discs as well, moisture can be formed on the brake disc due to condensation. The
water on the brake disc oxidizes the iron in the brake disc and pad to produce ferric particles (invisible
rust) on the disc surface. When the driver depresses the brake pedal with the invisible rust formed on the
disc surface, a noise generated by the friction of the rust can be heard. After braking several times, the
noise usually disappears because of the warmed up disc and the rust stripped off. The sound becomes
louder when depressing the brake pedal slightly and smaller when depressing the pedal firmly,
depending on the driving conditions. This is just caused by a physical phenomenon, not the fault of the
brake system. This is called "morning effect". This is not a fault and is quite a common occurrence.

Symptom 2. "Screeching" noise or brake drag after replacing the brake pad.

This can often occur when the "bed-in" is not performed properly. The "bed-in" is the process of
deposing an even layer of brake compound from the brake pad on the rubbing surface of the rotor. The
even formation of the brake compound layer provides the full contact of brake pad with the rotor which
results in proper braking and reduced noise. This normally happens after the vehicle is driven about 300
km. Therefore, the driver may encounter the problems, such as reduction of braking force or noise
(abnormal sound) due to uneven contact of brake pad for some time after renewing the brake disc or
pad.

Symptom 3. "Groaning" sound when releasing the brake pedal slightly or depressing gently
in order to start off the vehicle at a low speed (for a vehicle with A/T).

The vehicle with M/T as well as the one with A/T can make a noise called as "creep groan" when
releasing the brake pedal slightly, for example, on the downhill slope or in neutral. This noise can often
occur at a low brake pressure and low speed. This may be because the adhesion and slip are occurred
repeatedly between the brake disc and friction material when braking with a low force at low speed,
which causes the friction force to fluctuate momentarily. This physical phenomenon is not a fault and
does not have anything to do with the braking performance.

GETtheMANUALS.org
 0000-00 01-5

3. BRAKE SYSTEM WARNING LIGHT

Supervision type instrument cluster Standard type instrument cluster

1. ABS warning lamp

2. Parking brake operating indicator (EBD warning lamp: both parking brake operating indicator
and ABS warning lamp come on at the same time)

Warning lamps Color Indicator Operating conditions

ABS warning Amber ON: Faulty ABS function

lamp

Parking brake Red ON: Parking brake applied

indicator

EBD warning lamp Amber + Red ON: Faulty EBD function

4. SPECIAL TOOLS
Part no. and name Special tools Usage
Part no.: X99480052A

Name:
Rear brake piston fitting tool

Usage:
Used to set the brake piston
when installing the rear brake
pad for vehicle with 2WD

GETtheMANUALS.org
GETtheMANUALS.org
 0000-00 01-7

1. OVERVIEW
If the power is cut while the vehicle is being driven, the vehicle will keep on moving for some distance
without stopping because of inertia. Therefore, the brake system is very important to reduce the vehicle
speed or stop the vehicle. The friction type brake system is typically used. This brake system converts the
kinetic energy to the thermal energy and uses the friction force for braking.
The brake system mainly consists of front and rear disc brakes, parking brake (mechanical), master
cylinder (for generating hydraulic pressure), brake pedal, feed lines (pipes and hoses), and brake pads.

▶ Hydraulic brake

This brake system uses the Pascal's principle

and leverage effect. When the driver depresses
the brake pedal, the brake pedal pressure is
increased by the brake booster and delivered to
the master cylinder which converts the pedal
pressure to hydraulic pressure.
The hydraulic pressure travels to the caliper
through the brake pipe or hose. Then, the pad is
pressed against the disc by the pressure sent to
the caliper pad to provide the braking force.

▶ Brake pedal

The brake pedal increases the force applied to

the master cylinder in order to achieve the large
braking force using the leverage effect.

GETtheMANUALS.org
01-8

2. COMPONENTS
Master cylinder & booster

HECU

Brake pedal
Manual Automatic
transmission transmission

Front brake assembly Front wheel speed sensor

Caliper assembly Disc

GETtheMANUALS.org
 0000-00 01-9

Indicator lamp on instrument cluster Parking brake lever

Parking brake
AWD (Shoe type) 2WD (Ball In Ramp type)

Rear brake assembly

Disc Caliper assembly

Rear wheel speed sensor

2WD AWD

GETtheMANUALS.org
01-10

3. EPC
▶ 4810 BRAKE PEDAL

1. PEDAL BOX ASSY-BRAKE

2. PAD-BRAKE PEDAL
9. SWITCH-BRAKE PADAL
21.NUT
22.BOLT
23.TWIST PIN-SNAP

GETtheMANUALS.org
 0000-00 01-11

▶ 4115 FRONT HUB & DISC

1. KNUCKLE 6. NUT
2. SHIELD-DUST BRAKE FRT 7. DISC-BRAKE FRT
3. SCREW 8. SCREW
4. HUB ASSY-FRT 9. BOLT-WHEEL BEARING
5. BOLT 10.NUT-ADJUST HUB

GETtheMANUALS.org
01-12

▶ 4221 REAR KNUCKLE & HUB

1. SHIELD-DUST BRAKE RR
2. SOLID DISC-BRAKE RR
3. HUB ASSY-RR
4. BOLT-WHEEL BEARING RR
5. SCREW
6. SCREW
7. NUT-HUB

GETtheMANUALS.org
 0000-00 01-13

▶ 4830 FRONT BRAKE

1. CALIPER ASSY-BRAKE FRT

2. PAD SET-FRT BRAKE
3. BOLT-CALIPER MTG FRT
4. WASHER-SPRING
5. PAD SPRING

GETtheMANUALS.org
01-14

▶ 4841 REAR BRAKE (DISC)

1. CALIPER ASSY-BRAKE RR
2. PAD SET-RR BRAKE
3. BOLT-CALIPER MTG RR
4. WASHER-SPRING
5. PAD SPRING
6. SPRING-RETURN
8. SHIM-CALIPER

GETtheMANUALS.org
 0000-00 01-15

▶ 4850 MASTER CYLINDER & BOOSTER

1. MASTER BRAKE UNIT ASSY 8. O RING-BOOSTER MTG

2. BOOSTER ASSY-POWER BRAKE 9. HOSE ASSY-BOOSTER VACUUM
3. MASTER CYLINDER ASSY-PWR BRK 10.VALVE-BOOSTER NONRETURN
4. RESERVOIR ASSY-BRAKE 11.VACUUM SENSOR
5. WASHER-BOOSTER MTG 12.CLIP
6. NUT-BOOSTER MTG 13.SCREW
7. GASKET-BOOSTER MTG

GETtheMANUALS.org
01-16

▶ 4825 BRAKE PEDAL

1. PIPE ASSY-M/CYL PRIMARY TO HM 13.GASET-BRAKE HOSE TO CALIPER

2. PIPE ASSY-M/CYL SEC TO HM 14.HOSE ASSY-BRAKE RR
3. PIPE ASSY-HM TO FRT 16.CLIP-BRAKE TUBE MTG
4. PIPE ASSY-HM TO 2W/CONN RR-LH 17.CLIP-BRAKE TUBE MTG
5. PIPE ASSY-HM TO 2W/CONN RR-RH 18.HOLDER-BRAKE TUBE MTG
9. HOSE ASSY-BRAKE FRT 19.HOLDER-BRAKE TUBE MTG
10.PIPE ASSY-2W/CONN TO RR-LH 20.HOLDER ASSY-BRAKE TUBE MTG
11.PIPE ASSY-2W/CONN TO RR-RH 21.CLIP-FLEXIBLE HOSE
12.EYE BOLT-HOSE TO CALIPER 22.NUT
23.BOLT

GETtheMANUALS.org
 0000-00 01-17

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
01-18

2. STRUCTURE
▶ Front brake

Dust shield

Brake disc

Air bleed screw

Brake caliper

Brake pad

Brake hose

Knuckle Assembly

▶ Rear brake(2WD)

Brake hose

Dust shield

Air bleed screw

Brake pad

Parking brake

Parking brake cable

Brake disc

Brake caliper

GETtheMANUALS.org
 0000-00 01-19

▶ Rear brake(AWD)

Dust shield

Parking brake shoe

Air bleed screw

Brake pad

Brake hose

Parking brake cable

Brake disc

Brake caliper

GETtheMANUALS.org
01-20

3. BRAKE HYDRAULIC LINE

▶ Hydraulic line

1. Brake booster 4. HECU (Hydraulic & Electric Control Unit)

2. Brake master cylinder with brake reservoir 5. Rear disc brake with caliper
3. Front disc brake with caliper

GETtheMANUALS.org
 0000-00 01-21

4. BRAKE SWITCH DIAGRAM

ESP: Electronic Stability Program

ABS: Anti-Lock Brake System

GETtheMANUALS.org
01-22

5. FEATURES
▶ Specifications

Item Information
Operating voltage 6V ~ 18V
Operating temperature -40℃ ~ 85℃
Dark current 0.1mA or less
Response speed 100 ms or less
Output current Brake lamp switch (lamp) 1A
Brake switch (auto cruise) 100mA
Output voltage Brake lamp switch (lamp) Approx. 80% of input voltage (12.6V)
(voltage drop)
Brake switch (auto cruise) Approx. 80% of input voltage (12.6V)

▶ Brake switch output

GETtheMANUALS.org
 0000-00 01-23

6. MASTER CYLINDER FUNCTIONS

The master cylinder converts the force applied to
the brake pedal to high hydraulic pressure. The
master cylinder used in this system is a tandem
type cylinder in which 2 pistons are connected in
series.
The pistons in the tandem master cylinder are
essential components which generate the
Secondary Primary piston hydraulic pressure. The piston cups are installed
piston to the piston to form an air-tight seal and prevent
leaks. Usually, the hydraulic pressure generated
from the primary piston goes to the front side and
the pressure from the secondary piston goes to
the rear side.

GETtheMANUALS.org
01-24

7. BRAKE BOOSTER
▶ Brake booster status at initial start up

The poppet assembly contacts tightly against the control plug and valve body, so no air flows in or out of
the front chamber at initial start up.

▶ Brake booster activated

When the brake is applied, the control plug moves forward to open the air valve allowing outside air into
the front chamber through the valve body. This outside air intake causes difference in pressure between
the front chamber and the rear chamber which is connected to front chamber through vacuum pump.
The air drawn into the front chamber applies pressure to the diaphragm plate through the diaphragm.
The diaphragm plate and valve body move forward at the same time because they are locked together.
Therefore, the force applied to the diaphragm plate amplifies the operator's foot force and this force is
applied to the output rod through the reaction disc, resulting in making the force as an input to the master
cylinder.

GETtheMANUALS.org
 0000-00 01-25

▶ Brake booster maintaining constant output

When the brake pressure is maintained, the reaction disc becomes deformed by the reaction force of the
output rod and the force applied to the valve body. Also, the control plug moves back closing the air valve.
After the valve is closed, the booster output remains at a constant level because a constant pressure is
applied to the diaphragm with no air flow into the front chamber.

▶ Brake booster released

The control plug and input rod are connected with each other by caulking. When the brake pedal is
released, the control plug moves rearward by the reaction force of the reaction disc and input rod spring
and closes the air valve after contacting the poppet assembly. The control plug keeps moving rearward to
open the vacuum valve. The rear chamber and front chamber are connected by the open valve and the
air in the front chamber is drained through the rear chamber.
When the levels of vacuum in both chambers become equal to each other, the booster returns to its
original position by the return spring.

GETtheMANUALS.org
01-26

8. BRAKE CALIPER CLEARANCE ADJUSTMENT

When the hydraulic pressure is applied to the
piston, the piston pushes the pad against the
disc. At this time, the piston seal contacting with
the piston moves along the piston.
The piston seal becomes deformed as it moves
because part of that seal is fixed to the groove of
the cylinder (see the left figure).
If the applied hydraulic pressure is released, the
piston returns to the rest position by the elasticity
and restoring force of the piston seal.
If a large amount of clearance is created
1. Piston between the brake disc and the brake pad
2. Piston seal because of the worn pad, the piston can travel a
3. Pad longer distance but the deformation amount of
a. Clearance the piston seal is limited.
Therefore, the piston always returns to its original
position after traveling a distance corresponding
to the deformation amount of the seal. This
keeps the clearance value unchanged.

GETtheMANUALS.org
GETtheMANUALS.org
01-28

9. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 01-29

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Item Specifications
Operation type Hand parking brake
AWD (Shoe type)
Type
2WD (Ball In Ramp type)
Specified value for applying parking brake lever 5 notches (14±1 kgf) (AWD)

2. CAUTIONS

- Before driving off, be sure to check that the parking brake warning light is turned off.
- Driving with parking brake applied could damage the brake system. Before driving, fully release the
parking brake.
- Do not attempt to replace the parking brake by placing the TGS lever in the P (park) position. When
parking/stopping the vehicle, always apply the parking brake.
If the TGS lever is in a place other than the P position when parking/stopping the vehicle, the vehicle
can be rolled away based on the external force applied or slopes of the road. Make sure to place the
TGS lever in P position when parking/stopping the vehicle.

GETtheMANUALS.org
02-4

1. OVERVIEW
The parking brake is a mechanical device that keeps the vehicle stationary after the vehicle is stopped or
parked. Pulling the hand parking brake lever at the front console works in such a way that the rear brake
disc is fixed.
It is divided into brake shoe type (AWD) and BIR (Ball In Ramp) type (2WD) according to specifications.

GETtheMANUALS.org
 0000-00 02-5

2. COMPONENTS
Parking brake lever and Rear parking brake cable
Instrument cluster
center brake cable

HECU Parking brake

AWD 2WD
(Shoe type) (Ball-in-Ramp type)

GETtheMANUALS.org
02-6

3. EPC
▶ 4840 REAR BRAKE (PARKING DRUM)

1. BRAKE ASSY-PARKING DRUM 23.SPRING-TENSION

5. BOLT-PAKRING BRAKE MTG 24.SPRING-TENSION
20.SHOE SET-RR BRAKE DRUM 25.PIN
21.ADJUSTER ASSY 26.SPRING
22.OPERATING LEVER ASSY

GETtheMANUALS.org
 0000-00 02-7

▶ 4910 PARKING BRAKE (HAND PARKING)

1. LEVER ASSY-PARKING BRAKE

2. CABLE ASSY-FRT
3. CABLE ASSY-PARKING BRAKE RR
4. CABLE ASSY-PARKING BRAKE RR
6. NUT
7. BOLT
8. SWITCH ASSY-PARKING BRAKE
9. RETAINER-SNAP

GETtheMANUALS.org
 0000-00 09-3

1. SPECIFICATIONS
Item Specifications
Operating voltage 10.0 ± 0.5 V to 16.0 ± 0.5 V
Operating temperature -40°C to 125°C
Max. allowed current 40 A
Dark current 0.1 mA
HECU
Pressure sensor Built-in
Motor power 270 W
Oil piping type X-Shape
Channel 4 channels
Front 0.3 to 1.3 mm
Air gap
Rear 0.5 to 1.5 mm
Operation frequency 1 to 2500 Hz
Wheel speed sensor
Sensor operating temperature -40°C to 150°C
Front 8 ± 2 Nm
Tightening torque
Rear 9.0 ± 1.5 Nm
Steering wheel angle sensor
None (EPS signal)

Sensor cluster None (SDM signal)

Longitudinal acceleration
Incorporated in HECU
sensor (G-sensor)

GETtheMANUALS.org
09-4

2. MAJOR FUNCTIONS
1) Term Definition
- ESP: Electronic Stability Program

- ABS: Anti-lock Brake System

- EBD: Electronic Brake-Force Distribution

- TCS: Traction Control System

- HBA: Hydraulic Brake Assist

- ARP: Active Rollover Protection

- HSA: Hill Start Assist

- ESS: Emergency Stop Signal

- CBC: Cornering Brake Control

- DST: Dynamic Steering Torque Assist

- FBC: Fading Brake Compensation

- HDC: Hill Decent Control

GETtheMANUALS.org
 0000-00 09-5

3. PRECAUTIONS

- Warning lamp flashing and warning sound during ESP operation

When the ESP is activated while the vehicle is driven, the ESP warning lamp on the instrument
panel flashes and a beep sounds. The ESP lamp operation is to inform the driver that the vehicle
is extremely unstable. The ESP system is just a supplementary system for the vehicle motion
and it cannot control the vehicle when it exceeds the physical limits. Do not solely rely on the
system. Driven in an unsafe manner, all vehicles can go out of control.
When the ESP is activated, a beep sounds to inform the driver of the danger.

Drive feeling during ESP operation

- When the ESP system is activated, the driving feeling can be different depending on vehicle
driving conditions.
For example, the feeling when the ESP system is activated with the ABS is activated and the
brake pedal depressed and the feeling when the ESP system is in control without the brake
pedal depressed can be different on the same curve.
If the ESP system is operated with the brake pedal depressed, additional brake pressure will be
applied to the wheels on which the braking pressure is already applied, for the ESP control. In
other words, the driver can feel more braking force when the ESP system is activated.

Noise and vibration that driver senses during ESP operation

The ESP system may transfer noise and vibration, due to the pressure changes because of the
- motor and valve operations in a very short period of time, to the driver. Extreme cornering will
trigger the ESP operation and this will make the driver feel a sudden brake application with
noises and vibrations. Also, the ESP system controls the engine output (same function with
conventional ASR system). So, the driver may notice decreased engine rpm and output even
when the accelerator pedal is depressed.

- When the ARP is activated

The ARP system prioritizes the vehicle safety (preventing roll-over). Therefore, ARP system
performs more enhanced engine control than ESP system does. This may result in the
decreased vehicle speed and lane departure.

GETtheMANUALS.org
09-6

1. OVERVIEW
The Electronic Stability Program (ESP) is used to make the vehicle stabilized by recognizing the
dangerous driving conditions. This system controls the brake for each wheel and the engine power
when the brake system or acceleration does not work in dangerous circumstances.

2. COMPONENTS
Indicator lamp on instrument Rear wheel speed sensor
cluster
2WD AWD

HECU ESP OFF switch Front wheel speed

GETtheMANUALS.org
 0000-00 09-7

3. EPC
▶ 4890 ABS SYSTEM

1. SENSOR-WHEEL SPEED FRT

2. SENSOR-WHEEL SPEED RR
3. SCREW
9. SENSOR-LONGITUDINAL
11.NUT

GETtheMANUALS.org
09-8

▶ 4892 HYDRAULIC MODULATOR (HECU)

1. HECU
2. BRKT ASSY-HECU MTG
3. BOLT-HECU MTG
4. NUT
5. BOLT-HECU MTG

GETtheMANUALS.org
 0000-00 09-9

1. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
09-10

GETtheMANUALS.org
 0000-00 09-11

▶ Full names of acronyms and option description

GETtheMANUALS.org
09-12

2. P-CAN INPUT/OUTPUT ELEMENTS

▶ ECU

GETtheMANUALS.org
 0000-00 09-13

▶ BCM

GETtheMANUALS.org
09-14

▶ CGW

GETtheMANUALS.org
 0000-00 09-15

▶ TCU

GETtheMANUALS.org
09-16

3. C-CAN INPUT/OUTPUT ELEMENTS

▶ ACU

GETtheMANUALS.org
 0000-00 09-17

▶ AEB

▶ BSD

GETtheMANUALS.org
09-18

▶ CGW

▶ EPS

GETtheMANUALS.org
 0000-00 09-19

▶ Instrument cluster

GETtheMANUALS.org
09-20

4. HECU BLOCK DIAGRAM

GETtheMANUALS.org
 0000-00 09-21

5. ESP SYSTEM WARNING LAMPS

Instrument cluster (10.25" Full LCD) Instrument cluster (3.5" Mono LCD)

1. ESP ON indicator/warning lamp

2. ESP OFF indicator
3. Parking brake operating indicator (EBD warning lamp: both parking brake operating indicator
and ABS warning lamp come on at the same time)
4. ABS warning lam

Warning lamps Color Indicator Operating conditions

ESP ON Amber ON: Failure of ESP system

indicator/warning Flashing: ESP activated
lamp

ESP OFF indicator Amber ON: ESP deactivated

Parking brake Red ON: Parking brake applied

indicator

ABS warning lamp Amber ON: Faulty ABS function

EBD warning lamp Amber + Red ON: Faulty EBD function

GETtheMANUALS.org
09-22

1) ABS Warning Lamp

The ABS warning lamp module performs self diagnosis for ABS function and displays the fault status.
The ABS warning lamp is turned ON when:

A. the ignition switch is turned ON (for 4 seconds). If the ABS is normal, the lamp will go off.
(Initialization mode)
B. there is a fault in the ABS.
C. the self-diagnosis function is activated.
D. the HECU connector is disconnected.
E. If the ABS warning lamp is turned on, the ABS function is deactivated and only normal braking is
available.
F. the communication with the warning lamp drive CAN module is not available.

2) EBD Warning Lamp

If the EBD system is malfunctioning, the ABS warning lamp ( ) and parking brake operating
indicator ( ) are turned on at the same time.

The EBD warning lamp is turned ON when:

A. the ignition switch is turned ON (for 4 seconds). If the EBD is normal, the lamp will go off. (Initialization
mode)
B. the parking brake switch is turned ON.
C. the brake fluid level is low.
D. the self-diagnosis function is activated.
E. the HECU connector is disconnected.
F. the EBD system is uncontrollable (EBD not operated). - In this case, the ABS warning lamp is also
turned on.
- faulty solenoid valve
- two or more sensors are malfunctioning
- faulty HECU
- overvoltage
- faulty valve relay
G. the communication with the warning lamp drive CAN module is not available.

3) ESP OFF Switch

Press and hold the ESP OFF switch (for more than 3 seconds) to deactivate ESP.
The switch will light up to indicate ESP deactivation.

GETtheMANUALS.org
 0000-00 09-23

4) ESP OFF Indicator

The ESP OFF indicator is turned ON when:
A. the ignition switch is turned ON (for 4 seconds).
B. the driver operates the ESP OFF switch.

5) ESP Warning Lamp

The ESP warning lamp is turned ON when:
A. the ignition switch is turned ON (for 4 seconds).
B. the ESP function is inhibited because of system fault.
C. The warning lamp flashes during ESP control. (buzzer sounds)
D. the self-diagnosis function is activated.
E. the communication with the warning lamp drive CAN module is not available.

GETtheMANUALS.org
09-24

6. WHEEL SPEED SENSOR

(1) 2WD (front/rear), AWD (front) wheel speed sensors
The wheel speed sensor consists of the permanent magnet (ring magnet) and magnetic resistance
element and is used to record the wheel speed. When the magnetic resistance element is under the
influence of the magnetic field, it is changed into a resistor. The ring magnet is seated on the plate of the
hub and connected to the tire wheel through the hub. As the magnetic field is changed by the rotational
movement of the internal gear magnet, the magnetic resistance element is changed to the resistor.
The HECU receives this information to control the ESP system. If it detects an open or short circuit of the
wheel speed sensor, it will stop the ABS operation and turn on the warning lamp.

Front Rear (2WD)

A. Wheel speed sensor

B. Magnetic wheel
C. Hub assembly
Magnetic wheel

Magnetic wheel

ON
MR (4X) bridge
Output voltage OFF

Resistance change by the ON: (+) bridge voltage

change in magnetic field
direction is converted to OFF: (-) bridge voltage
digital bridge voltage

GETtheMANUALS.org
 0000-00 09-25

(2) (Rear) Wheel Speed Sensor for AWD

▶ Block diagram

- Two hall elements with varying voltage according to magnetic field

- Power supply (12 V)
- Amplifier/Comparator
- Analog/digital converter

▶ Function of active wheel speed sensor system

Rear drive shaft tone wheel - Basically, the tone wheel or the magnetized
encoder wheel is required to activate the sensor.
When the wheel rotates, the magnetic flux is
changed as a sine wave form and this change is
converted to voltage value by the hall elements.
The voltage of sine wave form is amplified by the
amplifier and finally converted to rectangular
wave form by the comparator. This signal is
transmitted to the ABS control unit to measure
the speed.
When the vehicle wheel rotates, the tone wheel
- rotates, and this rotation of the wheels changes
the magnetic flux of the sensor and generates
the induced electromotive force.
The frequency of this duty waveform changes
relative to the number of the rotation counts, and
this frequency is controlled to detect the wheel
speed.

GETtheMANUALS.org
09-26

▶ Configuration of hall-type active wheel sensor

The IC consists of 2 hall elements and a plastic

housing with peripheral circuits integrated, and
there is a capacitor for EMI performance
improvements in the middle of the lead frame.
The 2 lead frames are for signal output and
power supply.

▶ Circuit diagram for wheel sensor

GETtheMANUALS.org
 0000-00 09-27

7. OPERATING PROCESS
ESP system consists of functions like ABS, EBD, and TCS. Each function is activated depending on the
driving situations. For example, when the brake pedal is depressed during cornering at 100 km/h, the
ABS system is activated instantly and the TCS system may be activated to reduce the driving force of
the slipping wheel. And when the yaw rate sensor detects the yaw rate exceeding 4°/sec, the
ESP system is activated to apply the brake force to the corresponding wheel to compensate the yaw
moment with the vehicle stability control function
When various systems operate simultaneously under a certain situation, there may be vehicle control
problems due to internal malfunctions of a system or simultaneous operations. In order to prevent such
problems, the ESP system sets the priority among the systems.
Priority: TCS > ESP > ABS
The ESP system is only operated when the vehicle moves forward.

GETtheMANUALS.org
09-28

1) Understeer

(1) What is understeer?

Understeer is a vehicle dynamics term used to describe the situation when the traction is lost at the front
wheels during cornering with constant turn angle of the steering wheel.
Generally, vehicles are designed to have understeer for safety reasons. Because of this design, the
vehicle can get back in line with a small corrective input to the steering wheel even when the front
wheels are slipped outward.
As the centrifugal force increases, the tires can easily lose the traction and the vehicle tends to slip
outward when the curve angle gets bigger and the speed increases.

(2) ESP control during understeer

The ESP system recognizes the direction with the steering wheel angle sensor and senses the vehicle
tracking during understeer with the yaw rate sensor and the lateral sensor. Then the ESP system applies
the braking force to the rear inner wheel to compensate the yaw moment value. In this way, the vehicle
is steered for the amount commanded by the driver.

GETtheMANUALS.org
 0000-00 09-29

2) Oversteer

(1) What is oversteer?

Oversteer means that the rear wheels of a vehicle are slipping outwards with a greater angle than the
front wheels do with a constant input by the driver.
An oversteer vehicle is hard to control during cornering and can spin due to the moment of the rear
wheels. Therefore, the rear tires lose traction and the vehicle speed increases.

(2) ESP control during oversteer

The ESP system recognizes the direction with the steering wheel angle sensor and senses the vehicle
tracking during oversteer with the yaw rate sensor and the lateral sensor. Then the ESP system applies
the braking force to the front outer wheel to compensate the yaw moment value. In this way, the vehicle
is steered for the amount commanded by the driver.

GETtheMANUALS.org
09-30

3) Vehicle Control During Cornering

The figure below shows the vehicle controls by the ESP system under various situations such as when
the brake pedal is depressed or not during cornering, when the ABS is activated or not and with the
braking force applied.
It also includes the vehicle conditions when the TCS, a part of the ESP system, is operating.

Operating
Understeer control Oversteer control
conditions

Only ESP in
operation
Brake pedal not
depressed

ESP +
Normal braking
(no ABS operation)

ESP + ABS
brake

ESP + ASR

GETtheMANUALS.org
 0000-00 09-31

8. HYDRAULIC CIRCUIT

MC2 MC1

MC2: Primary master cylinder

MC1: Secondary master cylinder
ESV: Electric shuttle valve
TC: Traction valve
LPA: Low pressure accumulator
NO: Normal open
NC: Normal close

GETtheMANUALS.org
09-32

▶ Warning lamp flashing and warning sound during ESP operation

When the ESP is activated while the vehicle is moving, the ESP warning lamp on the instrument panel
flashes and a buzzer sounds every 0.1 sec. The ESP lamp operation is to inform the driver that the
vehicle is extremely unstable.
The ESP system is just a supplementary system for the vehicle motion and it cannot control the vehicle
when it exceeds the physical limits.

▶ Drive feeling during ESP operation

When the ESP system is activated, the driving feeling can be different depending on vehicle driving
conditions.
For example, the feeling when the ESP system is activated with the ABS is activated and the brake
pedal depressed and the feeling when the ESP system is in control without the brake pedal depressed
can be different on the same curve If the ESP system is operated with the brake pedal depressed,
additional brake pressure will be applied to the wheels on which the braking pressure is already applied,
for the ESP control. In other words, the driver can feel more braking force when the ESP system is
activated.

▶ Noise and vibration that driver senses during ESP operation

The ESP system may transfer noise and vibration, due to the pressure changes because of the motor
and valve operations in a very short period of time, to the driver.
Extreme cornering will trigger the ESP operation and this will make the driver feel a sudden brake
application with noises and vibrations.
Also, the ESP system controls the engine output. So, the driver may notice decreased engine rpm and
output even when the accelerator pedal is depressed.

GETtheMANUALS.org
 0000-00 09-33

9. ANTI-LOCK BRAKE SYSTEM(ABS)

When you brake abruptly or brake on a slippery road, the vehicle tries to move forward but the wheels
are locked and unable to rotate. If this is the case, the vehicle will loose its steering or turn, resulting in an
accident. ABS controls the wheels properly so that they are not locked to stabilize the vehicle.
Do not solely rely on the ABS system. The ABS system cannot assure safety when certain physical
limits are reached. Driven in an unsafe manner, all vehicles can go out of control.

▶ Normal braking vs ABS operation

GETtheMANUALS.org
09-34

1) System Description
(1) ABS Control Logic
The principal ABS control logic is the determination of the reference speed by choosing one wheel
meeting a certain condition, while receiving the speed information from the 4 wheel speed sensors when
the vehicle is being driven.
For example, when the comparison of the reference speed with the front right wheel speed results in a
slip, the control signal is determined based on deceleration or acceleration of the vehicle. If the control
conditions are met, the braking of the front right wheel will be controlled by the system.

GETtheMANUALS.org
 0000-00 09-35

2) Basic Information
To understand the ABS, you need to get information about braking force, slip, and cornering force.

(1) Braking distance

▶ Braking distance and stopping distance

Stopping distance = Thinking distance + Braking distance

▶ Stopping distance

A certain distance (thinking distance + braking distance) is needed from the moment an obstacle
appears ahead until you bring your vehicle to a complete stop. This is called as stopping distance.

▶ Braking distance

Tire slip occurs when the brake is applied and continues until the vehicle stops
completely.
The distance that tire slipped is called "braking distance".

▶ Thinking distance

The thinking distance is the distance traveled for a certain period of time from the moment when the
driver sees the obstacles and prepares to depress the brake pedal to the moment when the brake pedal
is depressed.

(2) Braking force applied on a wheel

The maximum possible braking force on a wheel depends on the wheel weight and the coefficient of
friction between the tire and road surface. When the coefficient of friction is low, the braking force
obtained is very low. Think about driving on the roads in winter.

▶ Maximum braking force

Max. braking force =
Wheel weight FR x Friction coefficient Mh

The braking process cannot be described

accurately with the braking force calculated. The
value calculated from the above formula is based
on the wheels unlocked.
If the wheels are locked, the static friction force is
converted into the dynamic friction force,
resulting in increased braking distance. This loss
of friction is called "slip".

GETtheMANUALS.org
09-36

▶ Slip

The brake slip varies with the vehicle speed and the circumferential speed of the wheel. If the wheels are
stuck, the brake slip is 100%. If the wheels rotates freely without braking force applied, the slip is 0%.
The slip is calculated based on the vehicle speed (Vveh) and wheel speed (Vw).

Vveh - Vw
S= X 100%
Vveh

Vveh = 100km/h, Vw = 70km/h

Vveh - Vw
S= X 100%
Vveh
S = 30%

▶ Typical Slip Curves

For the various road conditions, the friction

coefficients were plotted. The typical course of
the curves is always the same. The only special
feature is shown by the curve for freshly fallen
snow, for this curve increases at 100 % slip. In a
vehicle without ABS, the wheel locks on braking
and therefore pushes a wedge before it. This
wedge of loose surface or freshly fallen snow
means and increased resistance and as a result
the stopping distance is shorter. This reduction in
stopping distance is not possible with a vehicle
with ABS, as the wheel does not lock. On these
surfaces the stopping distance with ABS is
longer than without ABS. The reason for this is
based in physics and not in the Anti-Lock
System.
However, as mentioned before, ABS is not about
the stopping distance, but maneuverability and
driving stability, for the vehicle with locking
wheels without ABS cannot be steered.

GETtheMANUALS.org
 0000-00 09-37

▶ KAMM circle

The maximum tire force transmissibility is 100%.

It is all the same for the tire whether we require
100 % in the direction of braking or in the
direction of the acting lateral force, e.g. when
driving round curves. However, if the vehicle is
driven on a road with sharp bends, the tires
cannot transmit the 100% braking force required.
Therefore, the vehicle moves out of the corner
even if the vehicle is equipped with ABS. The
relationship between braking force B and
cornering force S is shown very clearly in the
Kamm circle. If we put a vehicle wheel in this
circle, the relationship becomes even clearer. As
long as the acting forces and the resultant force
stay within the circle, the vehicle is stable to drive.
If one force exceeds the circle, the vehicle moves
out of the lane.

▶ Braking force and cornering force

- Braking force
When depressing the brake pedal the braking
force increases to the maximum, then the
braking force decreases until the wheel locks.
Cornering force
- The maximum cornering force is applied to
the vehicle when the wheel is turning freely
with zero slip. When braking, the cornering
force will fall to zero if the wheels are locked
(slip 100 %).
ABS operating range
- The operating range starts just before
applying the maximum braking force and
ends when the maximum braking force has
been applied. After that, the vehicle enters
into the unstable range. In this range, no
further modulation is possible. The ABS
controls the regulation of the brake pressure
so that the braking force only becomes great
enough for a sufficient proportion of cornering
force to remain.

GETtheMANUALS.org
09-38

10. ELECTRONIC BRAKE FORCE DISTRIBUTION(EBD)

Sudden braking while the vehicle is driven causes nose down in which the load of the vehicle is pulled to
the front axle. In this case, the friction on the rear wheels is larger than the friction on the front wheels.
Therefore the rear wheels are locked before the front wheels are locked, resulting in poor straight ahead
run. To resolve this problem, the vehicle is equipped with electronic brake force distribution (EBD)
system which is an advanced form of proportioning valve.
The proportioning valve can control the pressure but cannot control according to the vehicle loading,
number of occupants, cornering, and road conditions. But the EBD can control the braking force applied
on each wheel independently by receiving the wheel speed from the wheel speed sensor.
For a vehicle with EBD system, the HECU measures the wheel retardation continuously and the
separate program of the ABS controls the rear brake pressure to ensure good straight ahead run. The
EBD system works before the ABS is activated.

Braking force
Proportioning valve EBD

1) EBD control
The EBD control function detects the wheel speed, vehicle speed, slip, and vehicle retardation to
compare the sips of the front wheels and rear wheels. The brake pressure for the rear wheels is
determined by the slip comparison value. The rear braking is controlled depending on the cornering
control as follows:
- Braking while cornering: rear braking, independently
- Braking while cornering: rear braking, simultaneously

2) Advantage
- Implemented by the ABS system
- Effective response according to the driving conditions.
- Different pressure controls between the inside and outside of corner during cornering
control
- Constant braking force distribution over the life of the vehicle.
- Controls the brake pressure close to ideal distribution

GETtheMANUALS.org
 0000-00 09-39

11. TRACTION CONTROL SYSTEM (TCS)

The traction control system prevents excessive slip (abrupt acceleration and rapid start) by controlling
the brake pressure applied on the drive wheel to ensure stability of the vehicle when starting rapidly,
accelerating abruptly, or turning at high speed.

TCS control pattern

Separate slip control according to road

Simultaneous drive wheel slip control
conditions

Applies braking force to the corresponding wheel to reduce the excessive slip occurred.

GETtheMANUALS.org
09-40

12. HYDRAULIC BRAKE ASSIST (HBA) SYSTEM

The hydraulic brake assist (HBA) system increases the initial braking force to improve the ABS
performance when braking abruptly. For example, if the system determines that the driver applies the
brake pedal slowly in an emergency state, the ESP HECU controls the solenoid valve in the hydraulic
modulator to provide maximum brake pressure on each wheel. Because of this process, the initial
braking force is maximized by the booster, and the vehicle will stop abruptly with the brake pedal
depressed slightly. The HBA system prevents this by regulating the brake hydraulic pressure.

Driver pattern Brake pressure control

GETtheMANUALS.org
 0000-00 09-41

13. ACTIVE ROLLOVER PROTECTION (ARP)

The active rollover protection (ARP) system is a supplementary device for safety in ESP system and can
help minimize the rollover accidents by detecting a potential rollover situation through the brake and
engine controls when the vehicle suddenly changes the lane or turns too sharply. The ARP system
performs this function only by using a software, without any extra devices or switches.
Keep in mind that the ARP is also only an aid using the ESP system like ABS. The system is unable to
surpass the physical limits of the brake system.
The following figure shows the operation of the ARP system to prevent rollover of the vehicle. The ARP
system reduces the speed of the turning vehicle and then makes the vehicle understeer.

The operation of ARP system when the vehicle increases its speed while running at a constant turning
radius is the same with the ARP operation when the vehicle runs at a constant speed while the turning
radius is being decreased.

GETtheMANUALS.org
09-42

The ARP system prioritizes the vehicle safety (preventing roll-over). Therefore, the ARP system
performs more enhanced engine control than the ESP system does. This may result in the
decreased vehicle speed and lane departure.

GETtheMANUALS.org
 0000-00 09-43

14. HILL START ASSIST (HSA)

The hill start assist (HSA) prevents the vehicle from rolling backward by supplying the hydraulic pressure
to the wheels by the HECU for approx. 3 seconds after the brake pedal has been released when starting
off on uphill gradients.

Uphill (forward gears) Downhill (reverse gear)

GETtheMANUALS.org
09-44

15. MERGENCY STOP SIGNAL (ESS)

The emergency stop signal (ESS) informs other drivers of emergency situation. When the moving
vehicle is braked abruptly or the ESP system is activated, the HECU sends the emergency braking
signal to the BCM to turn on the hazard warning lamp.

The BCM turns ON or OFF the emergency braking as follows:

Operation 1

A. The hazard warning lamp does not operate when the vehicle speed is over 50 km/h upon the
emergency braking signal input.
B. If this is the case, the stop light flashes at 4 Hz (every 0.25 sec.).

Operation 2

C. If the vehicle speed is 50 km/h or lower upon the emergency braking signal input, the hazard warning
lamp will illuminate for 10 seconds (T1).
D. The stop lamp flashes at 4 Hz (every 0.25 sec.) upon the emergency braking signal input even if the
vehicle speed drops below 50 km/h after the operation B.

GETtheMANUALS.org
 0000-00 09-45

Operation 3
E. If the hazard warning lamp switch is turned off during the operation C, the emergency braking signal
output will be stopped.
F. If the hazard warning lamp switch is operated during the operation B or D, the stop light will stop
flashing and the hazard warning lamp will operate.
G. The stop light will not flash even if the condition for the operation B is met during the hazard warning
lamp operation.

- Priority: Manual operation of hazard warning lamp > Emergency braking signal > AUTO hazard
warning lamp
- The BCM operate the stop light upon the brake pedal switch ON signal input, regardless of the IGN
status.
- The emergency braking signal is switched off when the vehicle speed exceeds 10 km/h (if
emergency braking signal is input).

GETtheMANUALS.org
09-46

16. CORNERING BRAKE CONTROL (CBC)

When applying the brake to the vehicle driving on winding road at high speed, a slip occurs with the
vehicle load pulled toward the outside of the corner.
The cornering brake control (CBC) system minimizes the vehicle slip when the vehicle is turning by
applying more brake hydraulic pressure to the inner wheels.

CBC deactivated CBC activated

GETtheMANUALS.org
 0000-00 09-47

17. DYNAMIC STEERING TORQUE ASSIST(DST)

The dynamic steering torque assist system compensate the braking force and additional torque for
steering on a slippery road.
When the brake pedal is depressed on a road where the surfaces contacting with the left and right
wheels are different from each other, the steering is turned toward the surface side with high friction,
resulting in veering off the carriageway. At this time, the DST system controls the ESP with EPS together
(generating torque required for correcting the steering angle).

DST deactivated DST activated

GETtheMANUALS.org
09-48

18. FADING BRAKE COMPENSATION(FBC)

The fading brake compensation (FBC) system complements the reduced braking performance due to hot
brake pad with excessive braking.

FBC
activated

FBC
deactivated

The braking distance is reduced with the FBC system activated.

GETtheMANUALS.org
 0000-00 09-49

19. HILL DESCENT CONTROL (HDC)

The HDC (Hill Descent Control) system operates at the road such as a hill with steep grade (above 10%)
within the specified speed limits.
When the HDC is activated, the vehicle speed is as follows: current vehicle speed is maintained at a
speed limit range of 5~30 km/h, 5 km/h at 2~5 km/h and 30 km/h at 31~50 km/h. You can use the brake
pedal and accelerator pedal to adjust the vehicle speed at even reduced speed. (within the range of
vehicle speed under 5~30 km/h). At higher speed of 51 km/h, the HDC stops operating. When the vehicle
speed reaches 70 km/h or higher, the green HDC indicator goes off and HDC is deactivated.

HDC switch HDC indicator

HDC ON indicator HDC warning light

GETtheMANUALS.org
09-50

1) Operating Process
(1) Operating conditions

▶ Condition for HDC to be ready (A)

- When the HDC switch is turned on at a vehicle speed of 70 km/h or less, the HDC ON indicator lights
up.

▶ Condition for HDC to be unready (B)

- HDC switch in OFF position

- The green HDC indicator goes out when the vehicle speed reaches 70 km/h with HDC in readiness
(green indicator lights up).
- HDC ON warning lamp (red) comes on due to faulty HDC
- Estimated disc temperature is higher than 650°C due to prolonged operation of HDC

▶ Conditions for HDC operation (C + D + E)

- Green HDC indicator comes on

- Driving downhill with gradient of 10% or higher
- Vehicle speed of 2 ~ 50 km/h
- ABS/ESP/TCS not activated

Since the HDC is an auxiliary function for driving convenience, the ESP takes precedence over the
HDC.

GETtheMANUALS.org
 0000-00 09-51

▶ HDC target speed control (C): HDC system operates actually

When the HDC operating conditions are met, the HDC system is actually operating and the brake light
is turned on during its operation.

- In section D (2~5 km/h), the HDC system implements operation control to accelerate the vehicle up to
5 km/h, minimum speed at section C, and maintains this speed.
- In section E (30~50 km/h), the HDC system implements operation control to decelerate the vehicle to
30 km/h, maximum speed at section C, and maintains this speed.
- In section C (5~30 km/h), the HDC system implements operation control to maintain current speed.

The target speed can not be changed when backing up, which is fixed at 5 km/h (with A/T) and 7
km/h (with M/T).

GETtheMANUALS.org
09-52

(2) HDC(Hill Descent Control) Cautions for operating

The HDC system is an equipment for convenience, but you should familiar with the activating and
deactivating conditions, etc. since it is related to braking.
In addition, the noise generated during operation differs significantly from the noise generated during the
operation of the existing ABS/ESP. You should remember that mechanical noise and vibration, which
are harsh to ear, may occur since the braking force should be able to overcome the different physical
elements caused by the vehicle load in the steep slope.
The followings are summary (to be noted especially) of the operation procedures and precautions
described above.

- The HDC system has been developed for steep off-roads with gradient of 10% or more and should
not be used on public roads.
- Frequent use of HDC may degrade the durability of ESP HECU and related systems.
- When driving on a flat or public road, the HDC switch must be in the OFF position.
(As mentioned earlier, HDC can be operated temporarily by the G-sensor due to a momentary impact
when passing through a sudden turn or unevenness even on a public road.
In this case, the driver may be confused because the vehicle is instantaneously decelerated and the
vehicle is not controlled as intended by the driver.)
- While the HDC is in operation, loud noises and vibration may occur at HECU and brake system,
which is a normal symptom.

The percentage for gradient as below:

tanθ x 100 = Gradient (%)
1
tan θ X 100 = X 100 = 10 (%)
ex) 10

*1G = 9.8 m/s : acceleration

In other words, the gradient of 10% means that a road has 10m of width and 1m of altitude from
level ground.

GETtheMANUALS.org
GETtheMANUALS.org
09-54

20. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 09-55

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
1) Exterior lamp
Category Type Capacity Quantity
High beam LED 12W 2EA X 2
상향등
Low beam 벌브
LED 15W
H1 55W 3EA
1EA X 2
LED DRL LED 13.1W
12W 3EA X 2
Headlamp DRL & position하향등 10EA X 2
Position 벌브
LED 13.1W
15W 1EA X 2
헤드램프
LED 1W15.3W
White 10EA X 2
Turn
DRLsignal
& 포지션 lamp LED
(Amber)
벌브 W5W 1EA X 2
High beam Bulb H1 55W 1EA X 2
LED 1W Amber 10EA X 2
방향지시등
Low beam Bulb H7 55W 1EA X 2
벌브 PY21W 1EA X 2
DRL & position DRL LED 13.1W
Halogen 10EA X 2
(with DRL) Position LED 13.1W
headlamp
DRL & position DRL - - -
(without DRL) Position LED W5W 1EA X 2
Turn signal lamp Bulb PY21W 1EA X 2
LED 3W 3EA X 2
Front
Fog lamp Bulb H1619W 1EA X 2
Rear Bulb P21W 1EA X 1
Tail lamp/Stop lamp
(surface emission type) LED 0.2W 24EA X 2
Rear
Combination Stop lamp LED 0.5W 8EA X 2
lamp
Turn signal lamp Bulb PY21W 1EA X 2
Backup lamp Bulb W16W 1EA X 2
Outside turn signal lamp LED - -
Rear reflex reflector Lens - 1EA X 2
License lamp Bulb W5W 1EA X 2

High-mounted With spoiler LED 0.2W 22EA X 1

stop lamp Without spoiler LED 0.2W 10EA X 1

GETtheMANUALS.org
01-4

2. NOTES

▶ LED

- The LED stands for "Light Emitting Diode" or "Luminescent Diode." LED is a semiconductor
diode that emits incoherent narrow-spectrum light when electrically biased in the forward
direction of the p-n junction, as in the common LED circuit. In short, it is an element that
converts electric signals into light signals. Yellow, blue, red and white LEDs are currently
available.
- The followings are the features of LED.
It is not glaring and doesn't have short circuit unlike the conventional lamps.
It is semi-permanent and doesn't generate heat.
Its power consumption is much lower than that of conventional bulbs.

▶ Luminous intensity
- Luminous intensity is an expression of the amount of light power emanating from a point source
within a solid angle of one steradian. That is, this indicates an amount of light that passes through
the unit area for the unit time. The SI unit of luminous intensity is candela (cd).

▶ Luminance

- Luminance describes the amount of light that passes through, is reflected, or emitted from an
area, and falls within a given solid angle. It is measured in stilb (sb) or nit (nt).

▶ Illumination

- This indicates the amount of light reaching a given area. Measuring unit is lux (lx) and it is not
directly proportional to the brightness of the area as the reflection rate is not included.

GETtheMANUALS.org
 0000-00 01-5

1. OVERVIEW
The exterior lamp includes headlamp, rear combination lamp (quarter panel/tailgate), fog lamp, outside
turn signal lamp, high mounted stop lamp, license plate lamp.
The BCM and SKM controls the exterior lamps using the signals from the multifunction light switch,
AUTO light sensor, smart key, etc.
The headlamps are divided into LED lamps and bulb lamps depending on the specifications.
The AUTO light sensor is installed to the top center of the windshield glass. This sensor detects the
ambient brightness when the multifunction light switch is in the AUTO position, and sends the signals to
the BCM to turn on or off the tail lamps and headlamps automatically.

GETtheMANUALS.org
01-6

2. COMPONENTS

AUTO light sensor Headlamp leveling switch Outside turn signal lamp

Front fog lamp

LED

Bulb

Headlamp

LED Bulb

GETtheMANUALS.org
 0000-00 01-7

High-mounted stop lamp License lamp

Rear fog lamp

Rear combination lamp Reflex reflector

GETtheMANUALS.org
01-8

3. EPC
▶ 8310 FRONT LAMP

1. LAMP ASSY-HEAD 10.LAMP ASSY-FOG FRT

2. BULB 11.BULB
3. BULB 11.T/SCREW-PAN SEMS_M5x0x16
5. BULB 15.LAMP ASSY-SIDE REPEATER
6. BOLT-HEAD LAMP MTG 16.BULB-WY5W
7. SCREW-GROMMET 17.BRKT ASSY-FENDER MTG
8. BULB-D5S 18.BRKT ASSY-HEAD LAMP
9. SCREW

GETtheMANUALS.org
 0000-00 01-9

▶ 8320 REAR LAMP

1. COMBINATION LAMP ASSY-RR 11.BULB

2. BULB 13.SCREW
3. BULB-W16W 16.LAMP ASSY-HIGH MTD STOP INR
4. GROMMET 17.BOLT
5. SCREW 18.LAMP ASSY-HIGH MOUNTED STOP
6. RETAINER ASSY-RR COMBI MTG 20.LAMP ASSY-FOG RR
7. CLIP ASSY-RR COMBINATION MTG 21.BULB
9. RETAINER ASSY-RR COMBI MTG 24.T/SCREW-PAN SEMS_M5x0x16
10.LAMP ASSY-LICENSE PLATE

GETtheMANUALS.org
01-10

1. MULTIFUNCTION TURN SIGNAL LAMP

Headlamp ON
Headlamps, side-marker lamps, tail lamps,
license plate lamps, front fog lamps (with
front fog lamp switch ON), and other
interior lights come on.

Light switch

Lights OFF

Automatic light ON Tail lamp ON

Headlamps and tail lamps are Side-marker lamps, tail lamps, license
automatically turned on or off based on plate lamps, front fog lamps (with front
the intensity of the light analyzed by the fog lamp switch ON), and other interior
automatic light sensor. lights come on.

GETtheMANUALS.org
 0000-00 01-11

High beam ON / HBA ON Right turn signal indicator

- To turn on the headlamp high beam,
push the lever towards the instrument
cluster with the headlamps on.
- Push the light switch at the AUTO
position to activate the HBA function,
push it again to turn the HBA off and
turn the high beam on.

Fog lamp switch

Front fog light : When you place
the Light switch in the front fog light
position with the head light or the tail
Left turn signal indicator light on, the front fog light turns on.
Rear fog light : With the headlights
turned on, if you rotate the switch in
Passing / turning off high beam the rear fog light position, rear fog
lights turn on and the switch returns
- Passing: Regardless of the position of the light back in front fog light position. Rear
switch, if you pull and hold the lever toward and front fog lights turn on
your body, the headlights are on high beam simultaneously.
during the hold. OFF : The fog light turns off.
- High beam ON: Pull and release the switch
lever with the high beam turned on to turn it off.

GETtheMANUALS.org
01-12

2. AUTO LIGHT & RAIN SENSOR MODULE

The AUTO light sensor illuminates the headlamps and tail lamps as the ambient illumination becomes
low. When the ambient illumination becomes lower than this level, it dims the light on the instrument
panel.

▶ Operating process

- Headlamp & tail lamp: both lamps come on at 2,500 lux, and go off at 1,300 lux (These lamps only
operate based on the surrounding light level regardless of rain).
- Panel: dimming starts at 200 lux and is deactivated at 900 lux

The panel dimming refers to dimming the lights (instrument cluster, FATC and AV monitor) at night-
time which illuminate at daytime.

GETtheMANUALS.org
 0000-00 01-13

3. HEADLAMP LEVELING DEVICE

1. When the signal from the headlamp leveling switch in response to the driver operation is less than the
signal from the feedback position sensor, the motor runs forward to pull the slide & shaft. As a
consequence, the headlamp reflector is adjusted and the light aims lower.
2. When the signal from the headlamp leveling switch in response to the driver operation is higher than
the signal from the feedback position sensor, the motor runs backwards to push the slide & shaft. This
moves the headlamp reflector and the light aims higher.
3. When the two signals are equal, the motor & slide is deactivated.
4. The headlamp leveling switch is deactivated when the voltage reaches a level for each stage selected
by the driver.
5. Use of headlamp leveling switch for each stage
- Headlamp leveling switch '0': driver and front passenger occupied
- Headlamp leveling switch '1': fixed number of passengers occupied
- Headlamp leveling switch '2': fixed number of passengers occupied and laden up to
maximum load capacity
- Headlamp leveling switch '3': driver occupied and laden up to maximum load capacity

GETtheMANUALS.org
01-14

4. CIRCUIT DIAGRAM
1) Outside Mirror

GETtheMANUALS.org
 0000-00 01-15

GETtheMANUALS.org
01-16

2) Head lamp (W/ VSM)

GETtheMANUALS.org
 0000-00 01-17

GETtheMANUALS.org
01-18

3) Head lamp leveling

GETtheMANUALS.org
 0000-00 01-19

GETtheMANUALS.org
01-20

4) Tail lamp

GETtheMANUALS.org
 0000-00 01-21

GETtheMANUALS.org
01-22

5) Turn signal lamp / Hazard lamp

GETtheMANUALS.org
 0000-00 01-23

GETtheMANUALS.org
01-24

6) Fog lamp

GETtheMANUALS.org
 0000-00 01-25

GETtheMANUALS.org
01-26

7) Stop lamp

GETtheMANUALS.org
 0000-00 01-27

GETtheMANUALS.org
 0000-00 08-3

1. SPECIFICATIONS
Category Type Capacity Quantity

Front room lamp Bulb 10W 1EA × 2

(overhead console) LED 1W 1EA × 2
Bulb 10W 1EA × 1
Center room lamp
LED 1W 1EA × 1
Sun visor lamp Bulb 5W 1EA × 2
Glove box lamp Bulb 5W 1EA × 1
Luggage compartment lamp Bulb 5W 1EA X 1
Lens - 1EA × 2
Front door courtesy lamp
Bulb 5W 1EA × 2
Door mood lamp LED 0.5W 1EA × 2
IP mood lamp LED 0.2W 1EA × 1

GETtheMANUALS.org
08-4

2. NOTES

▶ LED

- The LED stands for "Light Emitting Diode" or "Luminescent Diode." LED is a semiconductor
diode that emits incoherent narrow-spectrum light when electrically biased in the forward
direction of the p-n junction, as in the common LED circuit. In short, it is an element that
converts electric signals into light signals. Yellow, blue, red and white LEDs are currently
available.
- The followings are the features of LED.
It is not glaring and doesn't have short circuit unlike the conventional lamps.
It is semi-permanent and doesn't generate heat.
Its power consumption is much lower than that of conventional bulbs.

▶ Luminous intensity

- Luminous intensity is an expression of the amount of light power emanating from a point
source within a solid angle of one steradian. That is, this indicates an amount of light that
passes through the unit area for the unit time. The SI unit of luminous intensity is candela
(cd).

▶ Luminance

- Luminance describes the amount of light that passes through, is reflected, or emitted from an area,
and falls within a given solid angle. It is measured in stilb (sb) or nit (nt).

▶ Illumination

- This indicates the amount of light reaching a given area. Measuring unit is lux (lx) and it is not
directly proportional to the brightness of the area as the reflection rate is not included.

GETtheMANUALS.org
 0000-00 08-5

1. OVERVIEW
The interior lamps include 2 front room lamps, a center room lamp, a glove box lamp, 2 sun visor lamps, a
luggage room lamp, 2 door courtesy lamps (front door), 2 door mood lamps (front door), an IP center
lower mood lamp. The BCM controls the lamps according to the signals with the front room lamp coupled
switch in door coupled operation side.

Interior lamp

GETtheMANUALS.org
08-6

2. COMPONENTS
Overhead Sun visor Glove box Center room lamp
console lamp lamp lamp

Door IP Door Luggage room lamp

mood lamp mood lamp courtesy lamp

GETtheMANUALS.org
 0000-00 08-7

3. EPC
▶ 8610 Application component (1)

GETtheMANUALS.org
08-8

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 08-9

▶ 7770 SUNSHADE & INSIDE MIRROR

1. SUNVISOR ASSY 13.ANTENNA ASSY-ETCS

2. SUNVISOR ASSY 16.BRKT KIT-I/S RR VIEW MIRROR
4. SCREW 20.CONSOLE ASSY-OVER HEAD
5. RETAINER ASSY-SUNVISOR 22.SCREW
10.MIRROR ASSY-I/S RR VIEW 23.BRKT-OVER HEAD CONSOLE MTG
11.COVER-I/S MIRROR 25.SPEAKER ASSY-ETCS UNIT
12.UNIT ASSY-ETCS 33.LENS-OVER HEAD CONSOLE

GETtheMANUALS.org
08-10

▶ 7115 FRONT DOOR TRIM

1. TRIM ASSY-FRT DR 12.LENS-DR COURTESY FRT

2. TRIM ASSY-FRT DR 13.LAMP ASSY-DR COURTESY FRT
5. PNL ASSY-A/REST FRT DR TRIM 14.BULB
6. MOLDING ASSY-FRT DR TRIM 20.BRKT ASSY-PULL HANDLE FRT
7. BEZEL-FRT DR TRIM 21.COVER-PULL HANDLE FRT
8. FOAM BLOCK-FRT DR TRIM 22.GROMMET
9. W/STRIP-FRT DR TRIM 23.SCREW
11.CLIP 24.SCREW-RIVET

GETtheMANUALS.org
 0000-00 08-11

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
08-12

2. FRONT/CENTER ROOM LAMP CONTROL (WITHOUT SKM)

▶ Circuit configurations for room lamp system operation

GETtheMANUALS.org
 0000-00 08-13

- When the front room lamp switch is in the door interlocked position and any door is opened,
the room lamp comes on.
- The interior indicator lamp control is capable of activation with IGN OFF.

1) Front/Center Room Lamp ON

Operation 1. (Door interlocked room lamp ON)
A. Any door open
B. The BCM activates the door interlocked room lamp control and the room lamp ground control.

Operation 2. (Conditions for Room lamp 30 s ON)

- Room lamp switch in door interlocked (ON) position
- All doors closed with ignition key removed (including theft deterrent)

C. When unlock signal is received from REKES key,

D. The BCM turns on the door interlocking room lamp control for 30 seconds and off it.
(Room lamp ground control also stays on.)
E. The interior room lamp lights on for 30 sec and then off.
F. When REKES key UNLOCK signal re-received while interior room lamp lights on for 30 seconds, the
interior room lamp output is extended for 30 seconds.

System Flowchart

GETtheMANUALS.org
08-14

2) Front/Center Room Lamp Fading to OFF and Immediate OFF

Operation 1. (dimmed off)
A. With IGN OFF and door interlocked switch ON
B. any of doors open and then all doors closed
C. The room lamp stays on for 2 seconds (T1) and then fades to off for 3 seconds (T2).

Operation 2. (instant off I)

D. All doors are closed with IGN ON.
E. The room lamp goes out immediately.

Operation 3. (instant off II)

F. IGN ON with dimmed off
G. The room lamp goes out immediately.

GETtheMANUALS.org
 0000-00 08-15

3) Front/Center Room Lamp Cut-Off Control

When the room lamp cut-off operation is activated, the BCM sends cut-off operation signal through
B-CAN to prevent the battery discharge.

Operation 1. (cut-off entering)

A. With ignition key removed
B. when 10 min elapsed without change in status of any of doors
C. front/center room lamps turned off and BCM enters theft deterrent mode.

Operation 2. (cut-off entering operation)

A. Room lamp (-) control is off.
B. BCM sends cut-off control ON signal.
C. The front room lamp is turned off immediately when signal is input that any of doors is open.
D. When open signal is received from the tailgate open switch, rear (luggage) room lamp is turned off.

Operation 3. (cut-off termination)

If the following conditions are met, room lamp cut-off operation is terminated.

A. UNLOCK signal received from REKES key

B. Signal received that any of doors open
C. IGN ON (sleep mode released)

Operation 4. (operation when cut-off terminated)

A. Room lamp (-) control is on.
B. BCM sends cut-off control OFF signal .

GETtheMANUALS.org
08-16

3. FRONT/CENTER ROOM LAMP CONTROL (WITH SKM)

▶ Circuit configurations for room lamp system operation

GETtheMANUALS.org
 0000-00 08-17

- When the front room lamp switch is in the door coupled position and any door is opened, the room
lamp comes on.
- The interior indicator lamp control is capable of activation with IGN OFF.

1) Front/Center Room Lamp ON

Operation 1. (Door coupled room lamp ON)
A. Any door open
B. The BCM activates the door coupled room lamp control and the room lamp ground control.
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)

Operation 2. (Conditions for Room lamp 30 s ON)

- Room lamp switch in door interlocked (ON) position
- All doors closed with IGN OFF or ACC (including theft deterrent)

C. BCM receives the following condition signals:

(SKM→BCAN→BCM)
Condition 1. Smart key UNLOCK signal received from SKM
Condition 2. Door handle switch operation signal received in theft deterrent mode
Condition 3. AUTO approach signal received in theft deterrent mode
D. The BCM turns on the door interlocking room lamp control for 30 seconds and off it.
(Room lamp ground control also stays on.)
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)
E. The interior room lamp lights on for 30 sec and then off.
F. Condition 1 and 3 signals re-received with interior room lamp lit for 30 sec
G. The interior room lamp output is extended for 30 seconds.

GETtheMANUALS.org
08-18

System Flowchart

The luggage room lamp is interlocked with the tailgate. The lamp is turned on or off when the
tailgate is open or closed.

GETtheMANUALS.org
 0000-00 08-19

2) Front/Center Room Lamp Fading to OFF and Immediate OFF

Operation 1. (dimmed off)
A. IGN OFF or ACC and door interlocked switch ON
B. All doors are closed after any door is open.
The room lamp stays on for 2 seconds (T1) and then fades to off for 3 seconds (T2).
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)

Operation 2. (instant off I)

D. All doors are closed with IGN ON.
E. The room lamp goes out immediately.

Operation 3. (instant off II)

F. When the ignition is turned on
G. during dimmed operation,
H. the room lamp goes out immediately.

Operation 4. (instant off III)

I. During dimmed operation,
J. when smart key lock signal and lock signal by door handle switch operation are received
K. the room lamp goes out immediately.

GETtheMANUALS.org
08-20

GETtheMANUALS.org
 0000-00 08-21

3) Front/Center Room Lamp Cut-Off Control

When the room lamp cut-off operation is activated, the BCM sends cut-off operation signal to SKM
through B-CAN to prevent the battery discharge.

Operation 1. (cut-off entering)

A. IGN OFF or ACC ON
B. 10 min elapsed without change in status of any of doors
front/center room lamps turned off and BCM enters theft deterrent mode.
(Unless the room lamp is turned on due to auto approach signal input)

Operation 2. (cut-off entering operation)

A. Room lamp (-) control is off.
B. BCM sends cut-off control ON signal.
(BCM→BCAN→SKM)
C. The front room lamp is turned off immediately when signal is input that any of doors is open.
D. When open signal is received from the tailgate open switch, rear (luggage) room lamp is turned off.

Operation 3. (cut-off termination)

If the following conditions are met, room lamp cut-off operation is terminated.

A. UNLOCK signal received from REKES key

B. Signal received that any of doors open
C. IGN ON (sleep mode released)

Operation 4. (operation when cut-off terminated)

A. Room lamp (-) control is on.
B. BCM sends cut-off control OFF signal .
(BCM→BCAN→SKM)

GETtheMANUALS.org
08-22

4. CIRCUIT DIAGRAM
▶ Interior lamp

GETtheMANUALS.org
 0000-00 08-23

GETtheMANUALS.org
08-24

▶ Mood lamp

GETtheMANUALS.org
 0000-00 08-25

GETtheMANUALS.org
 0000-00 03-3

1. CAUTIONS WHEN WORKING ON ELECTRICAL UNITS

- Remove the negative battery cable from the
battery before working on electrical units.

Make sure to turn "OFF" the ignition switch

and other lamp switches before
disconnecting or connecting the negative
battery cable. (Otherwise, semiconductor
parts can be damaged.)

- Do not drop or apply excessive impact to

sensors and relays.

80℃

- If a fuse is blown, replace it with a rated capacity

fuse. If you use a fuse with capacity higher than
the specification, corresponding parts can be
damaged or a fire can break out.

10A 15A

GETtheMANUALS.org
03-4

- Make sure a connector is connected

securely. Loose connection results in
malfunction.

- When disconnecting a connector equipped

with a lock, press it down to the direction in
the left figure.

- When checking voltage or continuity of the

connector terminal with a circuit tester, insert
the tester's probe from the harness side. For a
seal type connector, the probe should be
inserted through the hole in the rubber cap of
the wiring. At this time, take care not to
damage insulation of the wires and insert the
probe until it contacts with the end of the
connector terminal.

When inspecting the airbag system, make

sure to use a diagnostic device, not a circuit
tester.

GETtheMANUALS.org
 0000-00 03-5

2. CABLES AND WIRES CHECK

- Check for loose connection or rust.
- Check terminals and wires for corrosion due to electrolyte leakage.
- Check terminals and wires for open circuit.
- Check wire insulation and coat for damage, crack or deformation.
- Check that conducting parts of the terminals do not contact with other metal parts, such as vehicle
body or other parts.
- Check that the grounding part has continuity with mounting bolts and vehicle body.
- Check that wires are properly routed.
- Make sure that wires are securely fixed to avoid contact with sharp body parts and high-temperature
parts, such as the exhaust manifold and exhaust pipes.
- The rotating parts, such as pulley, belt and fan belt, perturbative parts and wiring should be secured
tightly at regular intervals.
- Wiring between fixed parts, such as the vehicle body, and vibrating parts, such as the engine, should
be fixed after making it slack to afford vibration.

GETtheMANUALS.org
03-6

1. OVERVIEW
The fuse and relay boxes in this vehicle are mounted on the left-hand side of the engine compartment
and the instrument panel (2 places in total). The capacities and its names for each fuse and relay are
marked on the each fuse and relay box cover.
The label attached on each fuse box indicates only major fuses and relays. For detailed information, see
the power distribution circuit diagram.

2. COMPONENTS

Engine compartment fuse box Interior fuse and relay box

GETtheMANUALS.org
GETtheMANUALS.org
03-8

1. CIRCUIT DIAGRAM FOR ENGINE COMPARTMENT FUSE BOX

1) ENGINE ROOM FUSE / RELAY BOX CIRCUIT(DIESEL)
▶ B+(SB2~SB5, COOLING FAN(HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-9

GETtheMANUALS.org
03-10

▶ B+(SB6~SB8, Ef14, Ef26, BLOWER RELAY, DEFOGGER RELAY)

GETtheMANUALS.org
 0000-00 03-11

GETtheMANUALS.org
03-12

▶ B+(SB10, SB12, SB13, Ef27, START RELAY)

GETtheMANUALS.org
 0000-00 03-13

GETtheMANUALS.org
03-14

▶ B+(SB11, Ef23~Ef24, ENG MAIN RELAY)

GETtheMANUALS.org
 0000-00 03-15

GETtheMANUALS.org
03-16

▶ B+(SB14~SB16, Ef12, Ef13, PTC RELAY, A/C COMPRESSOR RELAY, FUEL HEATER RELAY)

GETtheMANUALS.org
 0000-00 03-17

GETtheMANUALS.org
03-18

▶ B+(Ef1~Ef3, Ef5, Ef7~Ef8, HORN RELAY, FUEL PUMP RELAY)

GETtheMANUALS.org
 0000-00 03-19

GETtheMANUALS.org
03-20

▶ B+(Ef6, Ef9~Ef11, FRT WIPER(HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-21

GETtheMANUALS.org
03-22

▶ B+(Ef4, Ef15, Ef21~Ef22, H/LAMP (HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-23

GETtheMANUALS.org
03-24

▶ B+(Ef16~Ef17, Ef25, Ef30, TAIL LAMP(INTERIOR) RELAY, DCU RELAY)

GETtheMANUALS.org
 0000-00 03-25

GETtheMANUALS.org
03-26

2) ENGINE ROOM FUSE / RELAY BOX CIRCUIT(GASOLINE)

▶ B+(SB2~SB5, COOLING FAN(HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-27

GETtheMANUALS.org
03-28

▶ B+(SB6~SB8, Ef14, Ef26, BLOWER RELAY, DEFOGGER RELAY)

GETtheMANUALS.org
 0000-00 03-29

GETtheMANUALS.org
03-30

▶ B+(SB10, SB12, SB13, START RELAY)

GETtheMANUALS.org
 0000-00 03-31

GETtheMANUALS.org
03-32

▶ B+(SB11, Ef23~Ef25, ENG MAIN RELAY)

GETtheMANUALS.org
 0000-00 03-33

GETtheMANUALS.org
03-34

▶ B+(Ef1~Ef3, Ef5, Ef7~Ef8, HORN RELAY, FUEL PUMP RELAY)

GETtheMANUALS.org
 0000-00 03-35

GETtheMANUALS.org
03-36

▶ B+(Ef6, Ef9~Ef11, FRT WIPER(HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-37

GETtheMANUALS.org
03-38

▶ B+(Ef4, Ef15, Ef21~Ef22, H/LAMP (HI/LO) RELAY)

GETtheMANUALS.org
 0000-00 03-39

GETtheMANUALS.org
03-40

▶ B+(Ef13, Ef16, A/C COMPRESSOR RELAY, TAIL LAMP(INTERIOR) RELAY)

GETtheMANUALS.org
 0000-00 03-41

GETtheMANUALS.org
03-42

2. CIRCUIT DIAGRAM FOR INTERIOR FUSE BOX

GETtheMANUALS.org
 0000-00 03-43

GETtheMANUALS.org
03-44

GETtheMANUALS.org
 0000-00 03-45

GETtheMANUALS.org
03-46

GETtheMANUALS.org
 0000-00 03-47

GETtheMANUALS.org
03-48

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
▶ Power window main switch

Item Specification
Rated voltage 12V
Operating voltage 9 ~ 16V
Operating temperature -30℃ ~ +80℃
Power window main 정격부하 오토/수동 스위치
AUTO switch 10A(모터부하)
switch (with Safety) Check contact
Rated load Door lock switch
Manual switch
10 A (motor load)
Window Lock Switch

▶ Outside rearview mirror switch

Item Specification
Rated voltage 12V
Operating voltage 9 to 16V

Outside rearview Operating temperature -30℃ to +80℃

mirror switch
Rated load Outside
Outside rearview
rearview mirror
mirror switch 0.2A (motor load)
0.2A (motor load)
Rated load switch
Folding switch 0.13A

▶ Power window sub switch

Item Specification
Rated voltage 12V

Power window sub Operating voltage 9 to 16V

switch Operating temperature -30℃ to +80℃
Rated load Rated load
AUTO/MANUAL switch 10 A (motor load)

GETtheMANUALS.org
04-4

▶ Multifunction switch

Item Specification
Rated voltage 12V
Operating temperature -30℃~+80℃
Light switch
0.2A or less (BCM)
AUTO light switch
UP
Dimmer and 0.2A or less (relay load)
DOWN
passing switch
Multifunction light Rated load Passing
switch 0.2A or less (BCM)
Turn signal lamp switch
Hazard warning lamp switch 5mA or less (BCM)
Front fog lamp switch 0.2A or less (relay load)
Rear fog lamp switch 0.2A or less (BCM)
AUTO
Wiper switch LO 0.2A or less (BCM)

HI
AUTO wiper & washer switch 5mA or less (BCM)
Multifunction wiper Rated load Windshield washer switch
switch 0.2A or less (BCM)
Rear washer switch
Volume / sensitivity switch 25mA or less (BCM)
LO
Rear wiper 0.2A or less (BCM)
HI

▶ Lower fascia switch (LH/RH)

Item Specification
Rated voltage DC 12V 50 mA or less (resistance load)
Operating temperature -30℃ ~ +80℃
Operation method Push-return type

GETtheMANUALS.org
 0000-00 04-5

▶ Lower main switch

Item Specification
Rated voltage DC 12V
Resistance load 50mA or less (12V)
Operation range -30℃ ~ +80℃
Rheostat switch +/-
LKAS switch
ESP OFF switch
HDC switch
Lower main Rated load 12V to 50mA
switch Front PAS OFF switch (resistance load)
(+ ON indicator)
Headlamp leveling switch
Steering wheel heating switch
(+ indicator lamp)

▶ START/STOP switch

Item Specification
Rated voltage 12V
START/STOP Operating voltage 9V to 16V
Switch
Operating temperature -30℃ to +80℃

▶ Tailgate outside switch

Item Specification
12 V at 60 mA or lower
Tailgate Rated voltage
open switch
Operating temperature -30℃ to +80℃

GETtheMANUALS.org
04-6

▶ Steering wheel switch

Item Specification
Rated voltage DC 5 V at 0.1 A
Rated load DC 5 V at 0.1 A
Operating temperature -30℃ to +80℃

▶ Heater & A/C control assembly

Item Specification
Rated voltage DC 13.5V
Operating voltage DC 9 ~ 16 V
Operating temperature -30℃ to +80℃
Max. current consumption 2.5A or less
Dark current 1mA or less (12.6 V)

▶ Front seat heater and ventilation switch

Item Specification
Rated voltage DC 12 V
Operating temperature -30℃ to +80℃

Front seat heater and Driver seat warmer switch

ventilation switch Driver seat ventilation switch
Rated load 50mA to 12V
Passenger seat warmer switch (resistance load)

Passenger seat ventilation switch

GETtheMANUALS.org
 0000-00 04-7

▶ Rear seat warmer switch

Item Specification
Rated voltage 12V
Operating voltage 9 to 16V
Rear seat heater
Switch Operating temperature -30℃ to +80℃
Rated load 4 ~ 6 A (unit load)

▶ Driver seat lumbar support switch

Category Specifications
Rated voltage 12V (2.5A)
Operating temperature -30℃ to 80℃
Type Push-return

▶ Front seat manual switch

Item Specification
Rated voltage DC 12 V
Rated load 6A or less (DC 12V)
Operating temperature -30℃ to +80℃

GETtheMANUALS.org
GETtheMANUALS.org
 0000-00 04-9

1. OVERVIEW
The switch system allows the driver to drive the vehicle safely and comfortably by operating the switches
properly according to the driving conditions. The switch system is divided into following parts depending
on the mounting location.

1. Door panel switch (driver)

2. Door panel switch (passenger)
3. Door panel switch (rear)
4. IP panel switch
5. Steering wheel switch
6. Front console switch
7. Headlining switch
8. Tailgate switch
9. Seat switch
10.Other electronic equipment

GETtheMANUALS.org
04-10

2. COMPONENTS
Steering wheel switch Overhead console switch

Multifunction switch

Lower main switch

START/STOP switch

Outside rearview Power window Power window

mirror switch main switch sub switch

GETtheMANUALS.org
 0000-00 04-11

Heater & A/C control switch Front seat heater &

ventilation switch
DATC MTC

Power seat manual

switch

Lumbar support switch

Tailgate switch

Lower fascia LH switch Lower fascia RH switch Rear seat warmer

switch

GETtheMANUALS.org
04-12

3. EPC
▶ 8511 SWITCH AND SENSOR - INSTRUMENT PANEL (2)

1. SW ASSY-S/WARMER & VENT FRT 10.SCREW

2. SWITCH ASSY-SEAT WARMER FRT 11.SWITCH ASSY-GLOVE BOX
7. SWITCH ASSY-LWR MAIN 17.SWITCH ASSY-PASSENGER AIR BAG
8. SWITCH ASSY-START 18.BLANKING COVER-PASSR A/BAG
9. BRKT-START 27.SWITCH ASSY-FASCIA LWR
29.SWITCH ASSY-FASCIA LWR

GETtheMANUALS.org
 0000-00 04-13

▶ 8520 SWITCH & SENSOR - MOVING PARTS

1. SWITCH ASSY-PWR WDW MAIN 12.SWITCH ASSY-HOOD CONTACT

5. SWITCH ASSY-O/S MIRROR 14.SENSOR ASSY-AMBIENT
7. SWITCH ASSY-POWER WINDOW SUB 16.SWITCH ASSY-TAILGATE OPENING
8. SWITCH ASSY-DR CONTACT 18.SENSOR ASSY-SUN
9. SCREW 19.COVER-SUN SENSOR BLANK
10.SWITCH ASSY-SEAT WARMER RR

GETtheMANUALS.org
04-14

▶ 8530 SWITCH & SENSOR - STEERING WHEEL

1. TURN LIGHT ASSY-MULTI FUNCTION

2. WIPER ASSY-MULTI FUNCTION
5. SCREW
8. CONTACT COIL ASSY-STEERING
10.SW ASSY-AUDIO REMOTE CONT-RH
11.SW ASSY-AUDIO REMOTE CONT-LH
15.WIRING ASSY-AUDIO REMOTE CONT

GETtheMANUALS.org
 0000-00 04-15

▶ 8610 Application component (1)

GETtheMANUALS.org
04-16

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 05-3

1. SPECIFICATIONS
Category Item Specifications
Rated voltage 12V
Windshield wiper
Operating voltage 10 to 15V
motor
Lowest operating voltage Max. 8V
Rated voltage 12V
Rear wiper motor
Operating voltage 10 to 15V
Lowest operating voltage Max. 8V
Driver 600mm
Wiper Front
blade Passenger 450mm
length
Rear 250mm
Wiper arm and Change every 3 months or every 5,000
blade km of driving.
Service more frequently when the wiper
Wiper blade change interval
blades are used on a contaminated (oil,
wax, dust, etc.) or dry windshield, or in
rainy season.
Washer fluid
Volume 4.3 L
reservoir
Operating voltage 9 to 16V
Operating temperature -40 ~ 85℃
Vertical curvature Min. 1850mm
AUTO light and
Lateral curvature Min. 4130mm
rain sensor module
Windshield glass inclination angle 21 to 32˚
Windshield glass transmission rate
40 to 80% (at 880 mm)
(recommended)
Size 36 mm (W) x 56 mm (H) x 13 mm (T)

GETtheMANUALS.org
05-4

2. CAUTIONS

- During winter time, check if wiper blades are frozen to the windshield.
- Wiper operation with the blades frozen can damage the wiper blade and motor.
- The wiper operation on the dry windshield can scratch the glass and wear the blade prematurely.
Do not operate the wiper when the windshield is dry.
- When it does not rain, turn the wiper switch into the "OFF" position.
- Turn the wiper switch to the "OFF" position before any car wash to avoid unwanted operation of
the wipers.
- Check if the rain sensor is in position securely when removing, fitting and checking it.
- Be sure to use the wiper blade with specified size.
- Be careful so a misdetection does not occur due to the sticker and foreign materials in the rain
sensor sensing part at the windshield glass.
When cleaning the windshield over the sensor with damp clothes, the wiper may operate suddenly.
It could cause serious injury. Make sure to place the wiper switch to the OFF position and ignition
switch OFF when not in use.

▶ Irregular operation (abrupt operation)

- Check if the sensor is not displaced.

- Check if the rain sensor cover is securely installed.
- Check if the customer is familiar with how to control the wiper sensitivity.
That is, check if the user has set the wiper sensitivity to the 5th level (FAST).
- Check the wiper blades for wear.
- If the wiper blade cannot wipe the glass uniformly and clearly, it may cause the rain sensor to work
irregularly. Therefore, in this case, replace the wiper blade with a new one.

GETtheMANUALS.org
 0000-00 05-5

1. OVERVIEW
▶ Windshield wiper system

The wiper and washer system consists of the wiper switch, windshield wiper motor and linkage, wiper
arm and blade, rain sensor, wiper relay (LO/HI) and washer fluid reservoir. The rain sensor does not
directly operate the rain sensing wiper and it sends only the data of the rainfall to the BCM. The basic
operation of the wiper and washer is controlled by the BCM according to the signals from the
multifunction wiper switch operation (MIST, AUTO, LO/HI, washer, sensitivity adjustment).

▶ Rear wiper system

The rear wiper system consists of the wiper switch, rear wiper motor, wiper arm and blade, rear wiper
relay. The basic operation of the wiper and washer is controlled by the BCM according to the signals
from the multifunction wiper switch operation (LO/HI, washer).

GETtheMANUALS.org
05-6

2. COMPONENTS
Washer fluid reservoir Multifunction wiper switch

Windshield wiper motor

and Linkage

Windshield wiper arm Windshield washer nozzle

and blade

GETtheMANUALS.org
 0000-00 05-7

AUTO light and Rear washer nozzle

rain sensor module

Rear wiper motor

Washer motor Rear wiper arm and

blade

GETtheMANUALS.org
05-8

3. EPC
▶ 7810 WINDSHIELD WIPER

1. MOTOR ASSY-FRT WIPER

2. LINKAGE ASSY-WINDSHIELD WIPER
3. BOLT
4. ARM ASSY-W/SHLD WPR PASSR
5. NUT
6. CAP-WIPER ARM
7. BLADE ASSY-WINDSHIELD WIPER

GETtheMANUALS.org
 0000-00 05-9

▶ 7820 WINDSHIELD WASHER

1. TANK ASSY-WASHER RESERVOIR 22.NOZZLE ASSY-WINDSHIELD WASHER

2. MOTOR ASSY-WASHER PUMP 29.HOSE ASSY-TAILGATE WASHER
3. PACKING-PUMP 30.HOSE ASSY-TAILGATE WASHER FRT
6. NUT 33.NOZZLE ASSY-WASHER T/GATE
11.CAP-WASHER RESERVOIR 35.NOZZLE ASSY-WASHER TAILGATE
21.HOSE ASSY-WINDSHIELD WASHER

GETtheMANUALS.org
05-10

▶ 7830 BACK WINDOW WIPER

1. BLADE ASSY-RR WIPER

2. ARM ASSY-TAILGATE WIPER
3. MOTOR ASSY-RR WIPER
6. GROMMET-TAILGATE WIPER
8. NUT
9. CAP-TAILGATE WIPER

GETtheMANUALS.org
 0000-00 05-11

1. WINDSHIELD WIPER CONTROL

▶ Circuit diagram for front wiper & washer operation control

Input combinations between switch 1 and switch 2 are as follows:

A. Wiper OFF, AUTO, LO, HI operations are carried out by combinations between wiper switch 1 and
switch 2.

Wiper Mode SW1 SW2

Wiper OFF 0 0
INT_Auto Wiper 1 0
Wiper Low 1 1
Wiper High 0 1

WIPER & INT VOLUME SW

GETtheMANUALS.org
05-12

1) Front Wiper LO/HI Control (Multifunction lever)

Operation 1. (Windshield wiper LO operation)
A. Windshield wiper LO switch ON
B. The BCM sends the signal regarding front wiper LO switch status to the CGW via BCAN.
- (BCM→BCAN→CGW→CCAN→IP/FCM)
C. BCM controls front wiper LO relay (-) operation
D. While the wiper relay is energized,
E. the BCM sends the signal regarding wiper LO relay status via BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

System Flowchart

GETtheMANUALS.org
 0000-00 05-13

Operation 2. (Windshield wiper HI operation)

F. Windshield wiper HI switch ON
G. The BCM sends the signal regarding front wiper HI switch status to the CGW via B-CAN.
- (BCM→BCAN→CGW→CCAN→IP/FCM)
H. BCM controls front wiper HI relay (-) operation (LO relay stays ON)
I. The BCM sends the signal regarding wiper HI operation status via BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

System Flowchart

GETtheMANUALS.org
05-14

Operation 3. (Windshield wiper LO/HI OFF during operation)

J. Switch OFF during front wiper LO/HI operation (including IGN OFF)
K. The BCM sends the signal regarding front wiper OFF switch status to the CGW via B-CAN.
- (BCM→BCAN→CGW→CCAN→IP/FCM)
L. If BCM detects front wiper motor parking signal,
M. the BCM turns off the windshield wiper LO/HI relay through hard wire.
N. The BCM sends the signal regarding wiper OFF status via BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

Windshield wiper motor parking signal fail-safe function

The windshield wiper relay is turned off as soon as the parking signal remains the same for 5
seconds when the windshield wiper is turned off by the switch OFF and IGN OFF signals during
front wiper LO/HI operation.

System Flowchart

GETtheMANUALS.org
 0000-00 05-15

2. FRONT WIPER INT AUTO CONTROL

(WITHOUT RAIN SENSOR)
In the event of the vehicle without the AUTO light & rain sensor module or faulty rain sensor, perform the
front wiper INT auto control as follows:

1) Windshield Wiper INT AUTO Reminder

Operation 1.
A. IGN ON
B. Front wiper INT AUTO switch OFF → ON
C. BCM forcibly activates front wiper motor once
Operation 2.
D. Front wiper INT AUTO switch ON
E. IGN OFF → ON
F. BCM forcibly activates wiper motor once
Operation 3.
G. IGN ON and windshield wiper INT AUTO switch ON
H. INT volume switch moved to higher level
I. BCM activates wiper motor once
Operation 4.
J. The BCM informs the CGW of the INT AUTO switch status via BCAN while the ignition is turned on
and front wiper INT AUTO switch in ON position.
- (BCM→PCAN→CGW→CCAN→IP)
System Flowchart

GETtheMANUALS.org
05-16

2) Windshield Wiper INT AUTO Control (Speed Sensitive)

Operation 1.
A. IGN ON with INT AUTO switch in ON position
B. The wiper operation speed and rest time are controlled based on the vehicle speed calculated for
each stage of INT AUTO volume switch. (refer to table below for rest time)

- The INT AUTO volume switch can be positioned in one of the 5 stages.
- The wiper is operated continuously when the rest time is less than 1 sec. and intermittently when 1.5
sec. or more.

Graph for correlation between windshield wiper auto switch rest time
and vehicle speed

Wiper rest time depending on vehicle speed and volume settings

Vehicle speed
Stage 5 Stage 4 Stage 3 Stage 2 Stage 1

0km/h Approx. 3 s Approx. 7 s Approx. 11 s Approx. 15 s Approx. 19 s

70km/h Approx. 0 s Approx. 3 s Approx. 6 s Approx. 8 s Approx. 11 s

GETtheMANUALS.org
 0000-00 05-17

3. CONTROL BY ISG SIGNAL DURING WINDSHIELD WIPER

OPERATION
Operation 1. When ISG engine stops during ISG engine STOP
ISG engine IDLE
LO/HI continuous operation, wiper operates in status
status (idling)
INT 1 stage (engine stop)

A. When ECU sends signal regarding ISG engine High Low INT 1 (3s)
status (engine stop) Low Low INT 1 (3s)
B. to BCM via PCAN during LO/HI continuous
Low INT 1 (3s) Low INT 1 (3s)
operation of front wiper,
- (ECU→PCAN→CGW→CCAN→IP/EPS) Low INT 2 (7s) Low INT 2 (7s)
C. the wiper will operate in INT 1 stage (INT FAST: Low INT 3 (11s) Low INT 3 (11s)
intermittent operation for 3 sec).
Low INT 4 (15s) Low INT 4 (15s)

Operation 2. If ISG engine stops during INT Low INT 5 (19s) Low INT 5 (19s)
operation wiper maintains previous operation
mode
D. If signal indicating engine stop is received
E. due to ISG engine stop while the front wiper is in INT operation,
F. the wiper will maintain the previous operation state.

Operation 3. Normally operating when ISG engine stops

G. If front wiper switch status is changed
H. with the ISG engine stopped, the wiper will operate normally in changed mode.
I. If the signal indicating ISG engine idling is received with the ISG engine stopped, the wiper will
operate normally.
J. If the wiper switch input is received with the ISG engine stopped, the wiper will operate normally.

Engine stopped/restarted by ISG

The ECU sends the signal regarding ISG STOP/IDLE status to BCM/CGW via PCAN.
(ECU→PCAN→BCM)
(ECU→PCAN→CGW→CCAN→IP)

GETtheMANUALS.org
05-18

System Flowchart

GETtheMANUALS.org
 0000-00 05-19

4. WINDSHIELD WASHER SWITCH CONTROL

▶ Windshield washer switch operation during windshield wiper off and INT AUTO operation

Operation 1. (Windshield washer switch pulled for 0.1 to 0.59 sec.) (one wiping cycle)
A. Windshield washer switch ON signal input for 0.1 to 0.59 sec. (T4)
- Windshield washer motor activated as long as windshield (front) washer switch ON signal
received
B. Windshield wiper LO relay activated 0.3 sec (T1) after washer switch turned on
C. The BCM sends the signal via BCAN and PCAN while the wiper LO relay (-) is activated.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)
D. Windshield wiper LO relay deactivated after 1 revolution of windshield wiper motor (T5).
E. However, windshield wiper LO relay activates intermittent wiper operation after rest time (T6) when
intermittent wiper operation signal input by INT

System Flowchart

GETtheMANUALS.org
05-20

Operation 2. (Windshield washer switch pulled for more than 0.6 sec.) (wiper continuous
operation)

F. Windshield washer switch ON for more than 0.6 sec. (T5)

- Windshield washer motor activated as long as windshield (front) washer switch ON signal
received
G. Windshield wiper LO relay activated 0.3 sec (T1) after washer switch turned on
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)
H. After windshield washer switch turned off
I. Windshield wiper LO relay deactivated after windshield wiper motor operates 3 cycles (T3)
J. The windshield wiper LO relay activates the intermittent wiper operation after the rest time (T6) when
intermittent wiper operation signal is input by INT.

System Flowchart

- If the parking signal is not detected for more than 5 seconds during front washer coupled wiper
operation, the wiper will return to previous operation mode.
- When the washer switch signal input is activated during windshield wiper LO/HI operation, the
washer relay is activated as long as the signal is received. If the washer switch input is shut off,
then the system returns to the windshield wiper LO/HI operation.

GETtheMANUALS.org
 0000-00 05-21

- If the parking signal is not detected for more than 5 seconds during front washer coupled wiper
operation, the wiper will return to previous operation mode.
- When the washer switch signal input is activated during windshield wiper LO/HI operation, the
washer relay is activated as long as the signal is received. If the washer switch input is shut off, then
the system returns to the windshield wiper LO/HI operation.

GETtheMANUALS.org
05-22

5. FRONT AUTO WASHER CONTROL

Operation 1.
A. With IGN ON and windshield wiper AUTO switch OFF,
B. Windshield auto washer switch ON for 0.1 seconds or more (T1) and windshield washer motor ON for
2.0 seconds (T2)
C. The windshield wiper LO relay is activated 4 times (T5) 0.3 sec. (T4) after the windshield washer
motor has been activated.
D. The windshield washer motor is activated for 1.5 seconds (T3) and the windshield wiper LO relay is
deactivated after 3 times (T6) of operation.

- The windshield AUTO washer input is overridden during windshield washer motor operation.
- The windshield AUTO washer input is overridden again during windshield AUTO washer-
linked windshield wiper operation
- When the windshield wiper signal (LO, HI, INT) is received during windshield AUTO washer
operation, the windshield AUTO washer is deactivated and windshield wiper operation (LO,
HI, INT) starts.
- The windshield washer switch input is overridden during windshield AUTO washer
operation.
- If the washer switch signal is received during rain sensor-linked wiper operation, the rain sensor
signal is overridden and the operation output by the washer switch input is activated.

GETtheMANUALS.org
 0000-00 05-23

GETtheMANUALS.org
05-24

6. REAR WIPER CONTROL

▶ Circuit diagram for rear wiper & washer operation control

GETtheMANUALS.org
 0000-00 05-25

1) Rear Wiper LO/HI Control (Multifunction lever)

Operation 1. [Rear wiper LO (intermittent) operation]
A. Rear wiper LO switch ON
- BCM sends rear wiper LO signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
B. BCM controls rear wiper relay (-) through hard wire
- (at intervals of operating once and then OFF for 6 sec)

System Flowchart

Operation 2. [Rear wiper HI (continuous) operation]

C. Rear wiper HI switch ON
- BCM sends rear wiper LO signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
D. The BCM controls rear wiper relay (-) through hard-wire.

System Flowchart

GETtheMANUALS.org
05-26

Operation 3. (Rear wiper LO/HI OFF during operation)

E. IGN OFF or rear wiper OFF signal is received during rear wiper operation.
- BCM sends signal from rear wiper switch to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
F. If BCM detects (receives) rear wiper motor parking signal,
G. rear wiper relay turned off

System Flowchart

Rear wiper motor parking signal fail-safe function

- If OFF signal received during rear wiper LO (INT) operation and parking signal not received for 5
sec or longer, rear wiper operated for 6 sec and off for 5 sec. Wiper repeats this procedure twice
and then rear wiper relay turned off
- If the OFF signal is received during rear HI wiper operation and the parking signal is not received
for 5 seconds or longer, the rear wiper is turned off immediately.

GETtheMANUALS.org
 0000-00 05-27

2) Rear Washer Switch Control

Operation 1.
A. Rear washer switch ON with IGN ON
B. Rear washer relay activated

Operation 2.
C. Rear washer switch OFF
D. The rear wiper operates for 3 wipe cycles (T1) after the rear washer relay is turned off.

Rear wiper operation fail-safe function by rear washer switch

If the rear washer switch-linked wiper is operating and the parking signal is not received for 5 sec. or
more, the rear wiper relay is turned off immediately.

Other signal input during rear washer relay activation

If the windshield washer switch signal (including AUTO) is received during rear washer relay
activation, the rear washer relay is deactivated and the windshield washer relay is activated after 0.1
sec.

GETtheMANUALS.org
05-28

7. WINDSHIELD WIPER CONTROL (RAIN SENSOR COUPLED)

▶ Circuit diagram for rain sensor linked windshield wiper control

GETtheMANUALS.org
 0000-00 05-29

- The vehicle with the rain sensor detects the front wiper switch status and INT stage and sends it to
the rain sensor.
- The BCM communicates with the rain sensor via LIN and monitors the AUTO wiper message from
the rain sensor.
- The rain sensor is initialized within 0.7 seconds when the ignition is turned on.

1) Windshield Wiper INT AUTO Reminder(with rain sensor)

Operation 1. (Forcibly activates front wiper once)
A. IGN ON
B. INT AUTO switch OFF → ON
- BCM sends signal from wiper switch to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
C. The BCM forcibly activates the wiper motor once (T1).
- BCM sends wiper LO relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO relay (-) operation signal to ECU
(BCM→PCAN→ECU)

System Flowchart

Operation 2. (AUTO reminder limit)

D. INT AUTO switch is ON.
E. IGN OFF → ON
F. Front wiper does not operate.

GETtheMANUALS.org
05-30

Operation 3.
G. The rain sensor detects rain fall with IGN ON and INT AUTO switch in ON position.
- Rain sensor detects rain fall and sends this signal to BCM through LIN communication
H. INT volume switch is moved to higher level by 1 stage.
I. The BCM activates the wiper motor once (T1).
- BCM sends wiper LO relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO relay (-) operation signal to ECU
(BCM→PCAN→ECU)

The wiper motor operates one cycle even if one ore more level change occurs within 2 seconds
when operating INT switch.

System Flowchart

Wiper operation with faulty rain sensor

- External faults (related to poor installation signal)
(wiper LO relay is activated once when INT volume sensitivity switch is changed from stage 3 to
2)
- No signal from rain sensor
(wiper LO relay is activated once when INT volume sensitivity switch is changed from stage 4 to
3)

GETtheMANUALS.org
 0000-00 05-31

GETtheMANUALS.org
05-32

2) Windshield Wiper INT AUTO Control

It communicates with AUTO light and rain sensor through LIN communication with IGN ON regardless of
multifunction switch position (AUTO light, INT AUTO).

Operation 1.
A. IGN ON and INT AUTO switch in ON position
B. The rain sensor detects rain fall and sends this signal to the BCM through the LIN communication.
C. The BCM activates the wiper intermittent, LO, HI operation using the signal from the rain sensor.
- BCM sends wiper LO/HI relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO/HI relay (-) operation signal to ECU
(BCM→PCAN→ECU)

System Flowchart

Washer switch signal received during rain sensor coupled (rain drop detection) front wiper
operation
Rain sensor coupled (rain drop detection) front wiper operation stops and then front wiper operates
based on washer switch input

GETtheMANUALS.org
 0000-00 05-33

GETtheMANUALS.org
05-34

▶ System diagram for BCM and rain sensor

System Flowchart

Data recognition time

The LIN communication is established when the ignition is turned ON, regardless of the wiper and light
switch operation. Then the function for the LIN data is carried out with the wiper AUTO switch or AUTO
light switch in the AUTO position.
The data from the rain sensor is recognized as 2 consecutive data.

Operation when data is recognized

Data OFF: Lo/HI relay output OFF.
Low speed signal: LO relay output ON (ON for at least 1 revolution), HI relay output OFF.
High speed signal: HI relay output ON (ON for at least 1 revolution), LO relay output ON.
The washer input is overridden during continuous operation of wiper (washer coupled wiper operation
during intermittent operation).

GETtheMANUALS.org
GETtheMANUALS.org
05-36

8. CIRCUIT DIAGRAM
▶ FRT WIPER

GETtheMANUALS.org
 0000-00 05-37

GETtheMANUALS.org
05-38

▶ RR WIPER / WASHER

GETtheMANUALS.org
 0000-00 05-39

GETtheMANUALS.org
 0000-00 06-3

1. SPECIFICATIONS
Item Description Remarks
H/W WPC Ver. Ver. 1.2 Low Power (~5W) + Medium
(Qi standard) Power (~15W)
Charging coil WPC Litz wire, 3 coils LGE Coil Solution
Charging area WPC 60 x 20mm 95% of 60 x 20mm
Charging efficiency WPC 15W 60% (Max) 45~60%
(within charging area)
Charging distance 9mm Based on distance between
center of Tx coil and center of
Rx coil
Charging operating frequency 145 kHz (± 1%) -
Operating temperature -40 ~ 85°C -
Operating voltage 9V ≤ 1.5V ≤ 16V -
Standby power ≤ 0.2A -
Thermal Shutdown Temperature (A- 65°C MP to LP Switch:
surface) 63°C ± 5°C
LP to MP Switch:
56°C ± 5°C

Mech Size 130 x 85 x 25mm -

Weight 290g -
Mat (Anti-Slip Pad) - -
S/W Communication CAN -

- MP: Max Power Level

- LP: Low Power Level

GETtheMANUALS.org
06-4

2. CAUTIONS

- Make sure to position the mobile phone on the center of the wireless charging pad.
- If the mobile phone has the thick accessory cover, charging is not working or the phone may
generate excess heat.
- If the WPC detects any foreign object that may cause heating, it does not supply power for
charging.
- Charging may stop if the mobile phone is not securely pressed against the wireless charging
pad.
- Charging does not work on terminals that do not meet the Qi standard.
- Charging does not work while the vehicle is searching for the smart key.
- If more than one terminal is placed, charging does not work.
- Charging does not work at above a certain temperature, above a certain voltage or under a certain
voltage.

3. WARNINGS

- If there are magnetic products (credit card, check card, bankbook, ticket and etc.) around the
wireless phone charger, its information may be damaged.
- If a metal object is on the wireless charging pad, charging does not work or may stop. In addition, a
metal object may become hot during charging.
- If the terminal that complies with the Qi standard does not provide a full charge information, charging
may continue to generate heat.
- If ACC is not entered as "ON" or CAN message is not received to the WPC unit, the WPC does not
work and check for any abnormality.

GETtheMANUALS.org
 0000-00 06-5

1. OVERVIEW
This vehicle is equipped with the WPC (Wireless Phone Charger) that meets the Qi standard for the
WPC (Wireless Power Consortium) which enables wireless charging of mobile phones that support Qi.
It performs B-CAN communication via the MCU in it and sends and receives information such as
charger control, diagnostic information and charging status. It adjusts charging status depending on the
conditions such as temperature and voltage. The user can set it turn on and off using the instrument
cluster.

GETtheMANUALS.org
06-6

2. COMPONENTS
BCM Gateway module (CGW) SKM

Instrument cluster WPC module

GETtheMANUALS.org
 0000-00 06-7

3. EPC
▶ 8610 Electrical system parts (1)

GETtheMANUALS.org
06-8

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY-LOW 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-115V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER FRT 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-HD RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 06-9

1. INPUT/OUTPUT DIAGRAM

- RX: To be charged
- SPI: Serial Peripheral Interface

GETtheMANUALS.org
06-10

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 06-11

GETtheMANUALS.org
06-12

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 06-13

3. B-CAN COMMUNICATION I/O ELEMENTS

▶ SKM

GETtheMANUALS.org
06-14

▶ CGW

GETtheMANUALS.org
 0000-00 06-15

4. DETAILED DESCRIPTION
1) Overview
The WPC is a device that wirelessly charges electronic devices (such as mobile phone) that comply with
the Qi standard. When charging, charging status information is displayed on the instrument cluster
through CAN communication signal.

The wireless phone charger (WPC) equipped to this vehicle complies with Wireless Power
Consortium's Qi standard, Specification Volume 1 Version 1.2.

2) Charging Area
The charging area of the wireless phone charger is 60 x 20㎟ on the charging surface.
- Dead cell: Under 5%

The wireless phone charger (WPC) equipped to this vehicle uses Litz wire type (MP-A6).

GETtheMANUALS.org
06-16

3) System Efficiency
The system efficiency of the wireless phone charger is calculated based on the current consumption,
including the blocks other than charging such as MCU or CAN. Under normal charging conditions, the
maximum efficiency at the center of the WPC surface is 60% or higher.
- System efficiency (%) = (Output power of terminal / Input power of WPC) * 100

4) Charge Distance
Distance between WPC (Tx) and terminal (Rx), in other words, “Z-axis distance" means the
distance between Tx coil and Rx coil. Under normal conditions, the maximum chargeable distance
between the center of the Tx coil and center of the Rx coil is 9 mm. At further distances, charging may
be interrupted.

5) Charging Operating Frequency

The charging operating frequency that meets the Qi standard of WPC is 145 kHz (± 1%).

GETtheMANUALS.org
 0000-00 06-17

6) MCU Types & Functions

The WPC has 2 kinds of MCUs in it. The MCU which performs basic operation is called main MCU and
the MCU which is in charge of charging operation is called charging MCU. Two MCUs send and receive
data through SPI communication.

Main MCU
- MCU which performs basic operation.
- Used to control temperature through thermistor connection and check range of input voltage.
- Connected directly to CAN transceiver for CAN communication to establish CAN communication
- Controls reset pin of charging MCU (Charging-IC) to control charging MCU
- Sends and receives status information to/from charging MCU through SPI communication

Charging MCU
- Used to control whole charging operation.
- Detects FO (Foreign Object) or charging error and has charging information.
- Has reset pin connected with main ECU and controlled by main ECU.
- Sends charging information through SPI communication and receives status information to
control charging.
- Not directly connected to CAN communication.

▶ SPI (Serial Peripheral Interface) communication

It performs SPI communication between two MCUs in the WPC. In doing SPI communication, there are
master and slave. The main MCU is a master of SPI communication and sends and receives data
through SPI communication using another device (charging MCU) as slave.

- SCLK (Serial Clock): Clock signal line generated by master

- MOSI (Master Output, Slave Input): Serial data signal output by master.
- MISO (Master Input, Slave Output): Serial data signal received by master.
- SS: Slave Select
- SPI Speed: 4MHz

GETtheMANUALS.org
06-18

5. OPERATING MODES
The WPC performs charging when the main MCU and charging MCU are operating normally at the
same time.

Main MCU
The MCU communicates with the vehicle through CAN communication and checks temperature by the
value from the ADC. The wireless phone charger wakes-up during ACC ON or via CAN message.

Charging MCU
Detection of FO (Foreign Object) is performed during charging operation. If no FO is found, charging can
be performed or continued.

▶ Operating status diagram

- (※): Main MCU

- (＃): Charging MCU
- FO: Foreign object

GETtheMANUALS.org
 0000-00 06-19

1) WAKE
The WPC wakes-up when any of the following 2 conditions is met:

(1) ACC ON
- When ACC OFF is switched to ACC ON, the WPC wakes up and can operate normally.
- In order for ACC ON to be recognized, the ACC must be ON continuously for 100 ms (± 10
ms)
- or longer.
The WPC can establish CAN communication when CAN bus is operating normally.
(2) CAN Rx message
- When the CAN transceiver receives the Rx message, the WPC wakes up.
- If the WPC wakes up by CAN message only without ACC ON, it establishes CAN communication but
does not perform wireless charging.

2) Sleep
The conditions under which the WPC enters sleep mode are as follows.
- Check ACC OFF + reminder function to perform the operation.
- For the WPC to operate in ACC OFF, ACC OFF must be maintained for 100ms (± 10ms).
- When ACC signal becomes OFF, the WPC decides whether to perform reminder (*) or not and
enters sleep mode.
- When the WPC enters sleep mode, a relevant signal is received by CAN BUS and the MCU is turned off
if there is no CAN Rx.
- If the CAN Rx is present, even if the sleep conditions are met, the wireless phone charger (WPC) will not
enter sleep mode.

(*): Refer to 'Reminder' for more detailed information.

▶ ACC ON/OFF

GETtheMANUALS.org
06-20

3) Reminder
This feature notifies the user via CAN communication when he/she attempts to leave the vehicle while
charging a device such as a mobile phone using a wireless phone charger (WPC).

(1) Operating condition

- The ignition switch should be in the ACC OFF position for this function to work. This needs to be
switched at least once from ACC OFF to ACC ON.
- Function to be performed while checking sleep condition

(2) Perform (Sleep condition)

- During charging: Sends WPCReminderSts message, Activation (0x1) to CAN bus for 40
seconds.
- During non-charging: Sends WPCReminderSts message, Activation (0x0) to CAN bus for 5
seconds.

(3) Result
The WPC will notify the user via CAN communication that charging is in progress if he/she tries to leave
the vehicle while charging.

▶ Operation diagram of reminder

GETtheMANUALS.org
 0000-00 06-21

4) Remote Charging Stop

This is a function to stop wireless charging using the WPC in order to ensure the charging frequency for
the WPC does not affect while the vehicle searches and recognizes the smart key.
When SKM receives the B-CAN message, the WPC recognizes that the vehicle is searching for the smart
key and stops all operations related to charging.

5) Conditions For WPC OFF

The wireless phone charger (WPC) stops all operations and turns off when the following condition
are met:

A. ACC signal is not received from the input connector pin on the WPC and CAN communication is in
sleep mode.

GETtheMANUALS.org
06-22

6) WPC Operation Based On Voltage

The WPC protects a device to be charged by operating the following 2 functions depending on the
vehicle voltage. After that, it converts to charging operation or maintains charging stop condition
depending on the situation.

▶ UVP: Under Voltage Protection

The WPC has a low-voltage protection called UVP (Under Voltage Protection). When UVP is activated,
the WPC does not perform charging and stops charging until the voltage is restored to recovery under
voltage.
When voltage with reference to Under Voltage is maintained for a certain period of time, it stops
charging.

▶ OVP: Over Voltage Protection

The WPC has a high-voltage protection called OVP (Over Voltage Protection). When OVP is activated,
the WPC does not perform charging and stops charging until the voltage drops and is restored to
recovery over voltage.
When voltage with reference to Over Voltage is maintained for a certain period of time, it stops charging.

GETtheMANUALS.org
 0000-00 06-23

▶ Specified values for stopping charging and restoring

- UVP: If the charging voltage drops 7.0V or less for a certain period of time (300ms ± 30ms),
charging stops and the UVP is deactivated when the voltage is restored to 8.5V or higher.
- OVP: If the charging voltage rises to 18.5V or higher for a certain period of time (400ms ±
40ms), charging stops and the OVP is deactivated when the voltage is restored to 17.5V or lower.

GETtheMANUALS.org
06-24

7) WPC Operation Based On Temperature Change

The WPC activates the OTP function depending on the surface temperature measured by the thermistor
and changes the charging mode to MP or LP mode depending on the temperature condition.

▶ OTP: Over Temperature Protection

When the WPC charges the device to be charged (Rx), power delivery will cause a temperature rise.
The mode alternates between MP (Max Power) and LP (Low Power) depending on the temperature
change. It is called as OTP (Over Temperature Protection) where the charging stops when the surface
temperature measured by the thermistor reaches 65℃±5°C. In this case, all temperatures on the
WPC surface (contact surface with Rx) measured by the thermistor must be 56℃±5°C or less to
begin charging again. Refer to the table for temperature conditions for each mode.

Power switch mode Temperature (℃) Previous condition

MP→LP mode 63℃±5°C MP mode
Power switch mode P→MP 56℃±5°C LP mode
mode

GETtheMANUALS.org
 0000-00 06-25

6. INSTRUMENT PANEL SETTING AND DISPLAY

1) Set WPC Power To ON/OFF
The WPC instrument panel setup is used when the user controls the WPC power.
It can be set at [User setting->Functions for driver comfort→Tick or untick wireless charging
system] on the instrument cluster.

▶ Set WPC Power To OFF

It is used to refer to not to use the wireless phone charger. The WPC does not perform charging and
stores the power OFF state. It does not perform charging even if the WPC is newly turned on until the
value is changed to 'ON', and does not output the power of the WPC to 'ON'.

▶ Set WPC Power To ON

It means that the user will use the WPC in the future, and the WPC can store the power status 'ON' and
perform charging operation.

GETtheMANUALS.org
06-26

2) WPC Instrument Panel Display

Pop-up display Operating conditions
The WPC displays the status of the device to be charged as
"Charging in progress" normally.

The device to be charged transmits the signal indicating fully

charged to the WPC, which informs the user of that the device is
fully charged.

These message appears when there is a problem during charging

operation using the WPC. Common problem situations include:
1) FO detected between Tx and Rx
2) Communication not established between Tx and Rx
3) Rx sends message requesting end of charging (Error
Packet Transfer Message) to WPC
- If there is no change in the external condition on the WPC,
it sends the message Charging Error for 5 minutes.

It sends a message to the user that there is a device to be charged

on the WPC.

- Tx: Wireless phone charger

- Rx: Device to be charged
- FO: Foreign object

GETtheMANUALS.org
 0000-00 06-27

7. INTERNAL SCHEMATIC DIAGRAM

1. Top cover 8. Thermal Pad

2. PCB 9. Thermal Pad
3. Coil ferrite assembly 10.Thermal Pad
4. Coil bracket 11.Thermal Pad
5. PCB 12.Screw
6. Heat sink 13.Screw
7. Boom cover

GETtheMANUALS.org
06-28

8. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
▶ BCM

Category Condition Description

Rated voltage DC 12 V -

Operating voltage 9.0V to 16.0V -

(CAN and LIN comm: 7.0V to 18.0V)
Operating temperature
-30℃ to +80℃ -

Max. operating
95% -
humidity
With Without
When vehicle enters sleep mode
SKM SKM with all switches OFF, IGN OFF, all
Dark current
4.0mA or less 7.0mA or less doors locked, and all doors closed
(with locked) (with locked)

▶ Parking aid sensor

Category Condition Description

Rated voltage DC 12 V -

Operating voltage 9.0V to 16.0V -

(CAN and LIN comm: 7.0V to 18.0V)
Operating
-30℃ to +80℃ -
temperature
Max. operating
95% -
humidity
Operating
48kHz ± 1kHz -
frequency

GETtheMANUALS.org
01-4

▶ Wheel module sensor

Category Condition Description

Pressure
Up to 700 kpa -
measuring range
-15 kpa to 15 kpa -40°C to 100°C
Error range of
-10kpa ~ 10kpa -20°C to 70°C
measured pressure
-20kpa ~ 20kpa 100°C to 120°C

Error range of -5°C to 5°C -40°C to 120°C

measured temperature -3°C to 3°C -20°C to 70°C
Temperature
-40°C to 120°C -
measuring range
Battery service life Approx. 7 to 10 years -

GETtheMANUALS.org
GETtheMANUALS.org
01-6

1. OVERVIEW
The BCM (Body Control Module) is a unit which integrates several systems of the vehicle to control them.
It uses P-CAN and B-CAN communications to improve reliability of data transfer, communicates with the
TPMS module wirelessly and uses LIN communication for the data which is not sensitive to transfer
speed.
It also detects signals from various switches and sensors and controls different relays and lamps through
hard-wire and CAN communication.

2. COMPONENTS
BCM

With SKM

Without SKM

SKM Immobilizer antenna

assembly (for vehicles without
SKM)

REKES key Smart key

(for vehicles without SKM) (for vehicles with SKM)

GETtheMANUALS.org
 0000-00 01-7

Parking aid sensor

Interior speaker and buzzer

Supervision Standard
instrument cluster instrument cluster

Speaker Speaker

Buzzer Buzzer

Item Mounting location Unit

Exterior buzzer
(SKM buzzer)

Alarm horn

GETtheMANUALS.org
01-8

1. INPUT/OUTPUT CIRCUIT DIAGRAM

▶ Input diagram

GETtheMANUALS.org
 0000-00 01-9

▶ Output diagram

GETtheMANUALS.org
01-10

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 01-11

GETtheMANUALS.org
01-12

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 01-13

3. CAN COMMUNICATION I/O ELEMENTS

▶ ABS & ESP

▶ ACU

▶ ECU

GETtheMANUALS.org
01-14

▶ CGW

▶ SKM

GETtheMANUALS.org
 0000-00 01-15

▶ HVAC

▶ TCU

▶ TEST

GETtheMANUALS.org
01-16

4. B-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
 0000-00 01-17

GETtheMANUALS.org
01-18

▶ SKM

GETtheMANUALS.org
 0000-00 01-19

5. SYSTEM POWER MODE

▶ Circuit configurations for system power mode I/O operation

The battery power consists of the B+ (BCM_internal logic power), B+ (turn signal light power), B+
(brake lamp power) and B+ (exterior LED power).

A. B+ (BCM_LOGIC) (internal logic power)

- Uses voltage regulator in BCM to output 5V and provides necessary battery voltage to
internal IC
B. B+ (TURN_SIG_POWER) (turn signal light power)
- Power to operate turn signal light
- Back up power for B+(BCM_LOGIC)
C. B+(BRAKE_POWER) (brake lamp power)
- Power to operate brake lamp
D. B+ (Front/Rear LED Lamp) (exterior LED power)
- Power to operate exterior lamp and DRL
- Back up power to operate brake lamp
E. IGN2 input signal
- IGN2 status input signal
- Steering wheel heater voltage

GETtheMANUALS.org
01-20

The BCM monitors the status of battery and START/STOP switch and changes the system power mode.

The BCM monitors the status of battery and START/STOP switch and changes the system power
mode.

A) BCM initialization mode

- When voltage is supplied to the BCM, the 5 V regulator is activated. (BCM initialization)
- After the initialization, the system power mode is changed according to the switch status.
B) IGN OFF mode
- With SKM: START/STOP switch OFF or ACC ON
- Without SKM: IGN OFF
In IGN OFF mode, only the function in the B+ state operates. When all the functions are completed the
system enters standby mode.
C) IGN ON mode
- With SKM: START/STOP switch ON
- Without SKM: IGN ON
D) Standby mode
The system enters standby mode when the following conditions are met with IGN OFF:
- Different beeps OFF
- All outputs OFF
- All doors closed and locked
- No signals from tailgate switch, hazard warning lamp switch, and smart/REKES key RF signal
- Enters B-CAN network sleep mode

GETtheMANUALS.org
 0000-00 01-21

E) Power save mode

- If there is no change in the vehicle status for 6 seconds in standby mode, all the unnecessary power
supplies are turned off and the following items only are monitored:
(change in all doors (including tailgate) and lock switch status, hazard warning flasher switch,
smart/REKES key RF signal and tail lamp switch)
F) Software mode
- when connecting DMS

System power management fail safe mode

- If B+ (BCM_Logic) power source is abnormal, the power is supplied by B+ (Turn Signal power).

GETtheMANUALS.org
01-22

6. WINDSHIELD WIPER CONTROL

▶ Circuit diagram for front wiper & washer operation control

Input combinations between switch 1 and switch 2 are as follows:

A. Wiper OFF, AUTO, LO, HI operations are carried out by combinations between wiper switch 1 and
switch 2.

Wiper Mode SW1 SW2

Wiper OFF 0 0
INT_Auto Wiper 1 0
Wiper Low 1 1
Wiper High 0 1

WIPER & INT VOLUME SW

GETtheMANUALS.org
 0000-00 01-23

1) Front Wiper LO/HI Control (Multifunction lever)

Operation 1. (Windshield wiper LO operation)
A. Windshield wiper LO switch ON
B. The BCM sends the signal regarding front wiper LO switch status to the CGW via BCAN.
C. - (BCM→BCAN→CGW→CCAN→IP/FCM)
D. BCM controls front wiper LO relay (-) operation
E. While the wiper relay is energized, the BCM sends the signal regarding wiper LO relay status via
BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

System Flowchart

GETtheMANUALS.org
01-24

Operation 2. (Windshield wiper HI operation)

F. Windshield wiper HI switch ON
G. The BCM sends the signal regarding front wiper HI switch status to the CGW via B-CAN.
- (BCM→BCAN→CGW→CCAN→IP/FCM)
H. BCM controls front wiper HI relay (-) operation (LO relay stays ON)
I. The BCM sends the signal regarding wiper HI operation status via BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

System Flowchart

GETtheMANUALS.org
 0000-00 01-25

Operation 3. (Windshield wiper LO/HI OFF during operation)

J. Switch OFF during front wiper LO/HI operation (including IGN OFF)
K. The BCM sends the signal regarding front wiper OFF switch status to the CGW via B-CAN.
- (BCM→BCAN→CGW→CCAN→IP/FCM)
L. If BCM detects front wiper motor parking signal,
M. the BCM turns off the windshield wiper LO/HI relay through hard wire.
N. The BCM sends the signal regarding wiper OFF status via BCAN and PCAN.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)

Windshield wiper motor parking signal fail-safe function

The windshield wiper relay is turned off as soon as the parking signal remains the same for 5
seconds when the windshield wiper is turned off by the switch OFF and IGN OFF signals during
front wiper LO/HI operation.

System Flowchart

GETtheMANUALS.org
01-26

7. FRONT WIPER INT AUTO CONTROL

(WITHOUT RAIN SENSOR)
In the event of the vehicle without the AUTO light & rain sensor module or faulty rain sensor, perform the
front wiper INT auto control as follows:

1) Windshield Wiper INT AUTO Reminder

Operation 1.
A. Turn the ignition on.
B. Front wiper INT AUTO switch OFF → ON
C. BCM forcibly activates front wiper motor once
Operation 2.
D. Front wiper INT AUTO switch ON
E. IGN OFF → ON
F. The BCM forcibly activates the wiper motor once.
Operation 3.
G. IGN ON and windshield wiper INT AUTO switch ON
H. INT volume switch moved to higher level
I. The BCM activates the wiper motor once.
Operation 4.
J. The BCM informs the CGW of the INT AUTO switch status via BCAN while the ignition is turned on
and front wiper INT AUTO switch in ON position.
- (BCM→PCAN→CGW→CCAN→IP)
System Flowchart

GETtheMANUALS.org
 0000-00 01-27

2) Windshield Wiper INT AUTO Control (Speed Sensitive)

Operation 1.
A. IGN ON with INT AUTO switch in ON position
B. The wiper operation speed and rest time are controlled based on the vehicle speed calculated for
each stage of INT AUTO volume switch. (refer to table below for rest time)

- The INT AUTO volume switch can be positioned in one of the 5 stages.
- The wiper is operated continuously when the rest time is less than 1 sec. and intermittently when 1.5
sec. or more.

Graph for correlation between windshield wiper auto switch rest time
and vehicle speed

Wiper rest time depending on vehicle speed and volume settings

Vehicle
Stage 5 Stage 4 Stage 3 Stage 2 Stage 1
speed
0km/h Approx. 3 s Approx. 7 s Approx. 11 s Approx. 15 s Approx. 19 s
70km/h Approx. 0 s Approx. 3 s Approx. 6 s Approx. 8 s Approx. 11 s

GETtheMANUALS.org
01-28

8. CONTROL BY ISG SIGNAL DURING WINDSHIELD WIPER

OPERATION
Operation 1. When ISG engine stops during ISG engine STOP
ISG engine IDLE
LO/HI continuous operation, wiper operates in status
status (idling)
INT 1 stage (engine stop)
A. When ECU sends signal regarding ISG engine High Low INT 1 (3s)
status (engine stop) Low Low INT 1 (3s)
B. to BCM via PCAN during LO/HI continuous
operation of front wiper, Low INT 1 (3s) Low INT 1 (3s)
- (ECU→PCAN→CGW→CCAN→IP/EPS) Low INT 2 (7s) Low INT 2 (7s)
C. the wiper will operate in INT 1 stage (INT FAST:
Low INT 3 (11s) Low INT 3 (11s)
intermittent operation for 3 sec).
Low INT 4 (15s) Low INT 4 (15s)
Low INT 5 (19s) Low INT 5 (19s)

Operation 2. If ISG engine stops during INT operation wiper maintains previous operation mode

D. If signal indicating engine stop is received

E. due to ISG engine stop while the front wiper is in INT operation,
F. the wiper will maintain the previous operation state.

Operation 3. Normally operating when ISG engine stops

G. If front wiper switch status is changed
H. with the ISG engine stopped, the wiper will operate normally in changed mode.
I. If the signal indicating ISG engine idling is received with the ISG engine stopped, the wiper will operate
normally.
J. If the wiper switch input is received with the ISG engine stopped, the wiper will operate normally.

Engine stopped/restarted by ISG

The ECU sends the signal regarding ISG STOP/IDLE status to BCM/CGW via PCAN.
(ECU→PCAN→BCM)
(ECU→PCAN→CGW→CCAN→IP)

GETtheMANUALS.org
 0000-00 01-29

System Flowchart

GETtheMANUALS.org
01-30

9. WINDSHIELD WASHER SWITCH CONTROL

▶ Windshield washer switch operation during windshield wiper off and INT AUTO operation

Operation 1. (Windshield washer switch pulled for 0.1 to 0.59 sec.) (one wiping cycle)

A. Windshield washer switch ON signal input for 0.1 to 0.59 sec. (T4)
- Windshield washer motor activated as long as windshield (front) washer switch ON signal
received
B. Windshield wiper LO relay activated 0.3 sec (T1) after washer switch turned on
C. The BCM sends the signal via BCAN and PCAN while the wiper LO relay (-) is activated.
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)
D. Windshield wiper LO relay deactivated after 1 revolution of windshield wiper motor (T5).
E. However, windshield wiper LO relay activates intermittent wiper operation after rest time (T6) when
intermittent wiper operation signal input by INT

System Flowchart

GETtheMANUALS.org
 0000-00 01-31

Operation 2. (Windshield washer switch pulled for more than 0.6 sec.) (wiper continuous
operation)

F. Windshield washer switch ON for more than 0.6 sec. (T5)

- Windshield washer motor activated as long as windshield (front) washer switch ON signal
received
G. Windshield wiper LO relay activated 0.3 sec (T1) after washer switch turned on
- (BCM→PCAN→CGW→CCAN→FCM)
- (BCM→PCAN→ECU)
- (BCM→BCAN→CGW→CCAN→FCM)
H. After windshield washer switch turned off
I. Windshield wiper LO relay deactivated after windshield wiper motor operates 3 cycles (T3)
J. The windshield wiper LO relay activates the intermittent wiper operation after the rest time (T6) when
intermittent wiper operation signal is input by INT.

System Flowchart

- If the parking signal is not detected for more than 5 seconds during front washer interlocked wiper
operation, the wiper will return to previous operation mode.
- When the washer switch signal input is activated during windshield wiper LO/HI operation, the
washer relay is activated as long as the signal is received. If the washer switch input is shut off, then
the system returns to the windshield wiper LO/HI operation.

GETtheMANUALS.org
01-32

- If the parking signal is not detected for more than 5 seconds during front washer interlocked wiper
operation, the wiper will return to previous operation mode.
- When the washer switch signal input is activated during windshield wiper LO/HI operation, the
washer relay is activated as long as the signal is received. If the washer switch input is shut off, then
the system returns to the windshield wiper LO/HI operation.

GETtheMANUALS.org
 0000-00 01-33

10. FRONT AUTO WASHER CONTROL

Operation 1.
A. With IGN ON and windshield wiper AUTO switch OFF,
B. Windshield auto washer switch ON for 0.1 seconds or more (T1) and windshield washer motor ON for
2.0 seconds (T2)
C. The windshield wiper LO relay is activated 4 times (T5) 0.3 sec. (T4) after the windshield washer
motor has been activated.
D. The windshield washer motor is activated for 1.5 seconds (T3) and the windshield wiper LO relay is
deactivated after 3 times (T6) of operation.

- The windshield AUTO washer input is overridden during windshield washer motor operation.
- The windshield AUTO washer input is overridden again during windshield AUTO washer-linked
windshield wiper operation
- When the windshield wiper signal (LO, HI, INT) is received during windshield AUTO washer
operation, the windshield AUTO washer is deactivated and windshield wiper operation (LO,
HI, INT) starts.
- The windshield washer switch input is overridden during windshield AUTO washer
operation.
- If the washer switch signal is received during rain sensor-linked wiper operation, the rain sensor
signal is overridden and the operation output by the washer switch input is activated.

GETtheMANUALS.org
01-34

GETtheMANUALS.org
 0000-00 01-35

11. REAR WIPER CONTROL

▶ Circuit diagram for rear wiper & washer operation control

GETtheMANUALS.org
01-36

1) Rear Wiper LO/HI Control (Multifunction lever)

Operation 1. [Rear wiper LO (intermittent) operation]
A. Rear wiper LO switch ON
- BCM sends rear wiper LO signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
B. BCM controls rear wiper relay (-) through hard wire
- (at intervals of operating once and then OFF for 6 sec)

System Flowchart

Operation 2. [Rear wiper HI (continuous) operation]

C. Rear wiper HI switch ON
- BCM sends rear wiper LO signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
D. The BCM controls rear wiper relay (-) through hard-wire.

System Flowchart

GETtheMANUALS.org
 0000-00 01-37

Operation 3. (Rear wiper LO/HI OFF during operation)

E. IGN OFF or rear wiper OFF signal is received during rear wiper operation.
F. - BCM sends signal from rear wiper switch to instrument cluster via CGW
G. (BCM→BCAN→CGW→CCAN→IP)
If BCM detects (receives) rear wiper motor parking signal,
rear wiper relay turned off

System Flowchart

Rear wiper motor parking signal fail-safe function

- If OFF signal received during rear wiper LO (INT) operation and parking signal not received for 5
sec or longer, rear wiper operated for 6 sec and off for 5 sec. Wiper repeats this procedure twice
and then rear wiper relay turned off
- If the OFF signal is received during rear HI wiper operation and the parking signal is not received for
5 seconds or longer, the rear wiper is turned off immediately.

GETtheMANUALS.org
01-38

2) Rear Washer Switch Control

Operation 1.
A. Rear washer switch ON with IGN ON
B. Rear washer relay activated

Operation 2.
C. Rear washer switch OFF
D. The rear wiper operates for 3 wipe cycles (T1) after the rear washer relay is turned off.

Rear wiper operation fail-safe function by rear washer switch

If the rear washer switch-linked wiper is operating and the parking signal is not received for 5 sec. or
more, the rear wiper relay is turned off immediately.

Other signal input during rear washer relay activation

If the windshield washer switch signal (including AUTO) is received during rear washer relay
activation, the rear washer relay is deactivated and the windshield washer relay is activated after 0.1
sec.

GETtheMANUALS.org
 0000-00 01-39

12. WINDSHIELD WIPER CONTROL (RAIN SENSOR COUPLED)

▶ Circuit diagram for rain sensor linked windshield wiper control

GETtheMANUALS.org
01-40

- The vehicle with the rain sensor detects the front wiper switch status and INT stage and sends it to
the rain sensor.
- The BCM communicates with the rain sensor via LIN and monitors the AUTO wiper message from
the rain sensor.
- The rain sensor is initialized within 0.7 seconds when the ignition is turned on.

1) Windshield Wiper INT AUTO Reminder (with Rain Sensor)

Operation 1. (Forcibly activates front wiper once)
A. IGN ON
B. INT AUTO switch OFF → ON
- BCM sends signal from wiper switch to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
C. The BCM forcibly activates the wiper motor once (T1).
- BCM sends wiper LO relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO relay (-) operation signal to ECU
(BCM→PCAN→ECU)

System Flowchart

Operation 2. (AUTO reminder limit)

D. INT AUTO switch is ON.
E. IGN OFF → ON
F. Front wiper does not operate.

GETtheMANUALS.org
 0000-00 01-41

Operation 3.
G. The rain sensor detects rain fall with IGN ON and INT AUTO switch in ON position.
- Rain sensor detects rain fall and sends this signal to BCM through LIN communication
H. INT volume switch is moved to higher level by 1 stage.
I. The BCM activates the wiper motor once (T1).
- BCM sends wiper LO relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO relay (-) operation signal to ECU
(BCM→PCAN→ECU)

The wiper motor operates one cycle even if one ore more level change occurs within 2 seconds
when operating INT switch.

System Flowchart

Wiper operation with faulty rain sensor

- External faults (related to poor installation signal)
(wiper LO relay is activated once when INT volume sensitivity switch is changed from stage
3 to 2)
- No signal from rain sensor
(wiper LO relay is activated once when INT volume sensitivity switch is changed from stage
4 to 3)

GETtheMANUALS.org
01-42

GETtheMANUALS.org
 0000-00 01-43

2) Windshield Wiper INT AUTO Control

It communicates with AUTO light and rain sensor through LIN communication with IGN ON regardless of
multifunction switch position (AUTO light, INT AUTO).

Operation 1.
A. IGN ON and INT AUTO switch in ON position
B. The rain sensor detects rain fall and sends this signal to the BCM through the LIN communication.
C. The BCM activates the wiper intermittent, LO, HI operation using the signal from the rain sensor.
- BCM sends wiper LO/HI relay (-) operation signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
(BCM→PCAN→CGW→CCAN→FCM)
- BCM sends wiper LO/HI relay (-) operation signal to ECU
(BCM→PCAN→ECU)

System Flowchart

Washer switch signal received during rain sensor interlocked (rain drop detection) front
wiper operation
Rain sensor interlocked (rain drop detection) front wiper operation stops and then front wiper
operates based on washer switch input

GETtheMANUALS.org
01-44

GETtheMANUALS.org
 0000-00 01-45

▶ System diagram for BCM and rain sensor

System Flowchart

Data recognition time

The LIN communication is established when the ignition is turned ON, regardless of the wiper and light
switch operation. Then the function for the LIN data is carried out with the wiper AUTO switch or AUTO
light switch in the AUTO position.
The data from the rain sensor is recognized as 2 consecutive data.

Operation when data is recognized

Data OFF: Lo/HI relay output OFF.
Low speed signal: LO relay output ON (ON for at least 1 revolution), HI relay output OFF.
High speed signal: HI relay output ON (ON for at least 1 revolution), LO relay output ON.
The washer input is overridden during continuous operation of wiper (washer interlocked wiper operation
during intermittent operation).

GETtheMANUALS.org
01-46

13. AUTO LIGHT SENSOR-LINKED HEADLAMP CONTROL

▶ Circuit configurations for auto light sensor interlocked headlamp operation

GETtheMANUALS.org
 0000-00 01-47

Refer to below system flowchart for operation of the AUTO light sensor-linked (including FCM) headlamp
control.
The AUTO light sensor sends the headlamp operation (OFF, tail lamp, low beam) request signal to the
BCM through LIN communication based on the intensity of the light and visible light. The FCM sends the
high beam ON/OFF request signal to the BCM through P-CAN when the HBA switch is turned ON.

GETtheMANUALS.org
01-48

1) AUTO Light Control

It communicates with AUTO light & rain sensor via LIN when IGN ON and controls the tail lamp and
headlamp when the light switch is in AUTO position after receiving signal indicating whether the vehicle
has HBA or not via PCAN.

▶ With AUTO light & rain sensor , without HBA (non-functioning)

Operation 1. (Low beam ON)

A. AUTO light switch ON with IGN ON
- BCM sends AUTO light switch signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
B. AUTO light sensor sends low beam ON request signal to BCM through LIN communication
- (AUTO light sensor→LIN→BCM)
C. The BCM activates the low beam relay.
- BCM sends low beam ON signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
- BCM sends low beam ON signal to CGW, ECU and HVAC
(BCM→PCAN→CGW, ECU, HVAC)

System Flowchart

GETtheMANUALS.org
 0000-00 01-49

Operation 2. (High beam ON)

D. Operation 1. during Operation 1.
(Light switch pressed at auto light position)
- BCM sends high beam switch signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
E. The BCM activates high beam relay (maintaining low beam relay operation)
- BCM sends low beam ON signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
- BCM sends low beam ON signal to CGW, ECU and HVAC
(BCM→PCAN→CGW, ECU, HVAC)

System Flowchart

Operation 3. (Low/high beam OFF)

F. The low beam OFF request signal is Operation 1,
G. AUTO light sensor sends low beam OFF request signal to BCM through LIN communication
H. The BCM turns off the low beam and high beam relays.
(High beam switch signal is overridden in AUTO light position)

GETtheMANUALS.org
01-50

GETtheMANUALS.org
 0000-00 01-51

2) AUTO Tail Lamp Control

▶ With AUTO light and rain sensor, regardless of FCM

Operation 1.
A. AUTO light switch ON with IGN ON
B. The AUTO light sensor sends the following request signals to the BCM through LIN communication:
- Exterior tail lamp ON/OFF
C. BCM operates relay depending on exterior tail lamp ON/OFF signal
- BCM sends exterior tail lamp signal (ON/OFF) to BSD and instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→BSD, IP)

Operation 2.
D. AUTO light switch ON with IGN ON
E. The AUTO light sensor sends the following request signals to the BCM through LIN communication:
- Interior indicator lamp ON/OFF
F. BCM operates relay depending on exterior tail lamp ON/OFF signal
- BCM sends interior tail lamp signal (ON/OFF) to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

GETtheMANUALS.org
01-52

System Flowchart

GETtheMANUALS.org
 0000-00 01-53

14. HBA (HIGH BEAM ASSIST) CONTROL

1) Operating Conditions
The HBA control is enabled when all the following conditions are met:
A. HBA available signal input from FCM
- FCM sends HBA available signal to IP
(FCM→CCAN→IP)
- FCM sends HBA available signal to BCM via CGW
(FCM→CCAN→CGW→BCAN→BCM)
B. AUTO light switch ON status
- BCM sends AUTO light switch signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
C. At status of point B, high beam switch signal input
(At AUTO light position, press multifunction light switch to input signal, and then multifunction light
switch returns to its original state)
- BCM sends high beam switch signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
D. Headlamp switch feedback signal input from multifunction light switch
E. HBA indicator ON signal input from FCM
- FCM sends HBA ON indicator signal to IP
(FCM→CCAN→IP)
- FCM sends HBA ON indicator signal to BCM via CGW
(FCM→CCAN→CGW→BCAN→BCM)
System Flowchart

GETtheMANUALS.org
01-54

2) HBA Operation
Operation 1. (Low beam ON)
A. With HBA operation conditions met,
B. when "HBA ON & high beam OFF" signal received from FCM
- FCM sends HBA request signal (high beam OFF) to BCM via CGW
(FCM→CCAN→CGW→BCAN→BCM)
- FCM sends HBA request signal (high beam OFF) to IP
(FCM→CCAN→IP)
C. BCM controls high beam relay OFF through hard wire

System Flowchart

GETtheMANUALS.org
 0000-00 01-55

Operation 2. (High beam ON)

A. With the HBA operation conditions met,
B. when "HBA ON & high beam ON" signal received from FCM
(FCM sends HBA request signal to IP and CGW via C-CAN, CGW sends it to BCM via B-CAN
FCM→CCAN→CGW→BCAN→BCM
FCM→CCAN→IP)
C. BCM controls high beam relay (-) through hard-wire
(Low beam relay stays on)

System Flowchart

Conditions where HBA off and manual high beam on

- HBA system failure signal
- HBA not available signal
- HBA ON indicator OFF signal
Manual high beam mode in effect
- High beam switch signal re-received with HBA ON and high beam OFF

Conditions where HBA and high beam off

- Headlamp passing switch turned on and off with headlamp high beam relay on or off (i.e., pull
multifunction light switch and return to original position)
- IGN OFF and headlamp relay OFF
- Headlamp low beam relay turned off to on with headlamp high beam relay ON
- Headlamp high beam switch ON signal input with headlamp feedback switch signal OFF during
HBA operation

GETtheMANUALS.org
01-56

3) HBA Operation Process

GETtheMANUALS.org
 0000-00 01-57

15. IGNITION KEY REMINDER WARNING (WITHOUT SKM)

▶ Circuit configurations for ignition key reminder operation

Operation 1.
A. When driver door is open with ignition key inserted ignition key reminder warning signal outputted for
10 sec
- BCM sends ignition key reminder warning signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

System Flowchart

GETtheMANUALS.org
01-58

Operation 2.
B. When removing ignition key or closing driver door while ignition key reminder warning buzzer sounds,
warning signal stops.

Operation 3.
C. The ignition key reminder warning does not work when the ignition key is in ON position.

GETtheMANUALS.org
 0000-00 01-59

16. DOOR AJAR WARNING

▶ Circuit diagram for door ajar warning operation

GETtheMANUALS.org
01-60

A. BCM detects door open switch (all doors including hood and tailgate) and sends signal indicating
switch status to each unit through B-CAN, C-CAN and P-CAN

If any door is open when the vehicle is in the sleep mode, it triggers B-CAN wakeup and sends the
door open signal. At this time, driver seat and hood send the signal via P-CAN.

System Flowchart

GETtheMANUALS.org
 0000-00 01-61

17. SEAT BELT WARNING AND REMINDER WARNING

▶ Circuit diagram for seat belt reminder warning operation

GETtheMANUALS.org
01-62

- The driver seat belt warning applies to all the vehicle models.
- The driver seat belt warning can be applied by variant coding.
- The driver seat belt warning detects occupant presence through the seat occupancy sensor
(seating sensor) and triggers seat belt reminder depending on whether the seat belt is buckled or
not.

1) Front Seat Belt Reminder (Driver)

Operation 1. (IGN ON with driver seat belt unfastened)
A. IGN OFF → ON
B. BCM sends the front seat belt warning lamp ON / beep ON signal for 6 seconds.
- BCM sends front seat belt warning lamp ON / beep ON signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
C. BCM sends driver seat belt status signal when point B obtained
- BCM sends driver seat belt status signal as follows:
(BCM→PCAN→CGW→CCAN→FCM, ESC)
(BCM→PCAN→ECU, HVAC)

Operation 2. (IGN ON with driver seat belt fastened)

A. IGN OFF → ON
B. BCM sends the front seat belt warning lamp ON / beep OFF signal for 6 seconds.
- BCM sends front seat belt warning lamp ON / beep OFF signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
C. BCM sends driver seat belt status signal when point B obtained
- BCM sends driver seat belt status signal as follows:
(BCM→PCAN→CGW→CCAN→FCM, ESC)
(BCM→PCAN→ECU, HVAC)

Operation 3. (Driver seat belt status changed from unbuckled to buckled)

A. Driver seat belt status changed from unfastened to fastened at condition of Operation 1.
B. Warning lamp flashes for remaining time of 6 sec and off
C. Beep turned off as soon as Fastened signal input

GETtheMANUALS.org
 0000-00 01-63

Operation 4. (Driver seat belt fastened → unfastened)

A. Driver seat belt status changed from fastened to unfastened
B. BCM sends the front seat belt warning lamp ON / beep ON signal for 6 seconds.
- BCM sends front seat belt warning lamp ON / beep ON signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
C. BCM sends driver seat belt status signal when point B obtained
- BCM sends driver seat belt status signal as follows:
(BCM→PCAN→CGW→CCAN→FCM, ESC)
(BCM→PCAN→ECU, HVAC)

- Seat belt remains unbuckled

Beep OFF/warning lamp stays ON if seat belt not fastened 6 sec after reminder
- The seat belt reminder warning is activated when the vehicle speed is 10 km/h or more during seat
belt warning signal output.

GETtheMANUALS.org
01-64

2) Front Seat Belt Reminder (Passenger)

- The seating sensor is used to detect whether or not the passenger seat is occupied.
- The seat belt reminder is activated when a passenger is detected on the front passenger seat.

Operation 1. (IGN ON with passenger seat belt unfastened)

A. IGN OFF → ON
B. BCM sends the front seat belt warning lamp ON / beep ON signal for 6 seconds.
- BCM sends front seat belt warning lamp ON / beep ON signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
C. BCM sends passenger seat belt status signal when point B obtained
- BCM sends passenger seat belt status signal as follows:
(BCM→PCAN→CGW, HVAC)

System Flowchart

GETtheMANUALS.org
 0000-00 01-65

Operation 2. (IGN ON with passenger seat belt fastened)

A. IGN OFF → ON
B. BCM sends the front seat belt warning lamp flashing / beep OFF signal for 6 seconds.
- BCM sends front seat belt warning lamp flashing / beep OFF signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
C. BCM sends passenger seat belt status signal when point B obtained
- BCM sends passenger seat belt status signal as follows:
(BCM→PCAN→CGW, HVAC)

Operation 3. (Passenger seat belt unfastened → fastened)

A. Passenger seat belt status changed from unfastened to fastened at condition of Operation 1.
B. Warning lamp flashes for remaining time of 6 sec and off
C. Beep turned off as soon as Fastened signal input

Operation 4. (Passenger seat belt fastened → unfastened)

A. Passenger seat belt status changed from fastened to unfastened
B. Seat belt reminder warning light and beep do not work.

- Passenger seat belt remains unbuckled

Beep OFF/warning lamp stays ON if seat belt not fastened 6 sec after reminder
- The front seat belt reminder is not triggered if the passenger seat belt is unfastened during
driving.
- The seat belt reminder warning is activated when the vehicle speed is 10 km/h or more during seat
belt warning signal output.

GETtheMANUALS.org
01-66

3) Front Seat Belt Reminder Warning

Front seat belt reminder warning operating conditions

- IGN ON
- Engine running
- 10 km/h or higher of vehicle speed and selector lever in positions other than "R"
- Driver/passenger (occupant detected) seat belt unbuckled

Front seat belt reminder deactivation conditions

- Driver/passenger seat belt fastened
- Selector lever in "R" position signal received for more than 1.5 sec

Operation 1. (Warning lamp flashes and beep sounds)

A. The front seat belt warning lamp flashes and the beep sounds for 100 seconds when the front seat
belt reminder operation conditions are met.
- BCM sends seat belt reminder warning signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

Operation 2. (Warning lamp ON and beep OFF)

A. Seat belt reminder in operation even after 100 sec elapsed from Operation 1
B. Beep stops / warning lamp stays ON

Operation 3. (Warning lamp OFF and beep OFF)

A. Vehicle speed below 10 km/h within 100 seconds since seat belt reminder triggered
B. The seat belt warning lamp and warning buzzer outputs are deactivated.
C. However, if the vehicle speed reaches 10 km/h or higher, the seat belt warning lamp and warning
buzzer are activated again for 100 sec.

GETtheMANUALS.org
 0000-00 01-67

System Flowchart

GETtheMANUALS.org
01-68

18. SUNROOF WARNING LAMP CONTROL

▶ Circuit diagram for sunroof open warning operation

GETtheMANUALS.org
 0000-00 01-69

1) Sunroof Open Warning

Operation 1. (warning lamp ON)
Without SKM: Ignition key removed
With SKM: IGN OFF and ACC

A. Sunroof open
B. Open driver door detected (closed → open)
C. The BCM triggers the sunroof open warning for 10 seconds.
- BCM sends sunroof open warning signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

System Flowchart

Operation 2. (warning lamp OFF)

D. During Operation 1
E. When driver door and sunroof closed
F. Sunroof open warning output switched off immediately

Warning output does not work even if conditions for Operation 1 are met after warning lamp OFF.

GETtheMANUALS.org
01-70

GETtheMANUALS.org
 0000-00 01-71

19. REAR DEFOGGER (HEATING) CONTROL

(ISG NOT FUNCTIONING)
▶ Circuit configurations for rear defogger operation

GETtheMANUALS.org
01-72

1) Rear Defogger (Heated Wire) Timer Control

- The rear defogger heated wire is activated only when the engine is running.
- The rear defogger relay and the front deicer relay are activated at the same time depending on the
rear defogger (heated wire) switch ON/OFF operation.

Operation 1. (ON for 12 min)

A. With engine started,
B. when rear defogger (heating) switch ON
- HVAC sends rear defogger (heating) switch operation signal to BCM
(HVAC→PCAN→BCM)
C. Rear defogger (heating) output is triggered for 12 minutes (T1) and turned off.
(rear defogger indicator ON)
- BCM sends rear defogger (heating) ON signal to CGW, ECU and HVAC
(BCM→PCAN→CGW, ECU, HVAC)

System Flowchart

Operation 2. (OFF by switch)

D. When pressing rear defogger (heating) switch again during rear defogger (heating) operation,
E. Rear defogger (heating) is turned off immediately.

Operation 3. (OFF by engine)

F. When the engine rpm is low with IGN OFF or IGN ON,
G. Rear defogger (heating) is turned off immediately.

Operation 4. (OFF by time)

H. After 12 minutes of rear defogger (heating) operation,
I. Rear defogger (heating) is turned off immediately.

GETtheMANUALS.org
 0000-00 01-73

Operation 5. (Re-triggered for 6 min)

J. During 10 minutes (T2) after the 12 minutes (T1) of rear defogger (heated wire) operation.
K. When rear defogger (heating) switch ON
- HVAC sends rear defogger (heating) switch operation signal to BCM
(HVAC→PCAN→BCM)
L. Rear defogger (heating) output is re-triggered for 6 minutes (T3).
(rear defogger indicator ON)
- BCM sends rear defogger (heating) ON signal to CGW, ECU and HVAC
(BCM→PCAN→CGW, ECU, HVAC)

Excepting for engine stop with IGN OFF, turning off switch, 12 min of operation timer timed out

GETtheMANUALS.org
01-74

Rear defogger (heating) & front deicer (heating)

Rear defogger switch

Switch for vehicle with FATC Switch for vehicle with MTC

Rear defogger (with heated wire)

A. Outside rearview mirror heating

B. Rear defogger (with heated wire)

GETtheMANUALS.org
 0000-00 01-75

20. REAR DEFOGGER (HEATING) CONTROL

(ISG FUNCTIONING)
Operation 1. (OFF for 2 min)
A. Rear defogger (heating) in operation
B. Engine stopped by ISG
- ECU sends "Engine stop by ISG" signal to various units
(ECU→PCAN→BCM, CPL, ESC, HVAC, SKM)
(ECU→PCAN→CGW→CCAN→EPS, IP)
C. The rear defogger (heating) is turned off for up to 2 minutes.
(rear defogger (heating) ON indicator stays on)

Operation 2.
A. Operation 1. If the engine is turned off for 2 minutes
B. Running normally by ISG,
C. Rear defogger (heating) is turned on.

Operation 3.
A. Operation 1. If the engine is turned off for 2 minutes
B. Rear defogger (heating) switch is pressed,
C. Rear defogger (heating) is turned off immediately.
(rear defogger (heating) ON indicator off)

System Flowchart

GETtheMANUALS.org
01-76

21. TAIL LAMP CONTROL

▶ Circuit configurations for front/rear LED lamps operation

GETtheMANUALS.org
 0000-00 01-77

1) Control by Tail Lamp Switch

Operation 1.
A. It controls (turns on/off) the exterior/interior tail lamp relays depending on the tail lamp switch
ON/OFF.
B. For the vehicles with AUTO light, it controls (turns on/off) the exterior/interior tail lamp relays
depending on the AUTO light signal with the tail lamp switch ON.
C. Exterior tail lamp relay signal output
- BCM sends exterior tail lamp relay ON signal to BSD and IP via CGW
(BCM→BCAN→CGW→CCAN→BSD, IP)
D. Interior indicator lamp relay signal output
- BCM sends interior tail lamp relay ON signal to SKM and HVAC
(BCM→BCAN→SKM)
(BCM→PCAN→HVAC)
E. Controls interior/exterior tail lamp relays with tail lamp ON
- BCM sends tail lamp switch signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)

System Flowchart

GETtheMANUALS.org
01-78

2) Tail Lamp ON Warning

Operation 1.
A. Tail lamp switch ON
B. With SKM: after IGN OFF
Without SKM: after removing ignition key
C. Driver door closed → open
D. The BCM sends Tail lamp ON warning for 10 seconds.
- BCM sends Tail lamp ON signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

System Flowchart

GETtheMANUALS.org
 0000-00 01-79

Operation 2.
A. Operation 1. While tail lamp ON warning signal output,
B. Tail lamp switch turned off or driver door open and closed
C. Tail lamp ON warning output is turned off immediately.

When the driver door is open and then closed, the tail lamp ON warning is issued and the tail lamp is
turned off automatically.

System Flowchart

When the tail lamp switch is moved from OFF to ON position while tail lamp ON warning is active,
the tail lamp ON warning is not triggered again.

GETtheMANUALS.org
01-80

3) Tail Lamp AUTO OFF

Operation 1.
A. Without SKM: With ignition key inserted & ON and tail lamp switch ON
With SKM: With IGN ON and tail lamp switch ON
B. Without SKM: Ignition key removed and driver door open and then closed
With SKM: IGN OFF and driver door opened and then closed
C. Interior/exterior tail lamp relay off (auto off)
- BCM sends auto off signal to BSD and IP via CGW
(BCM→BCAN→CGW→CCAN→BSD, IP)

Operation 2. (After Operation 1 condition)

D. Without SKM: Ignition key inserted
With SKM: IGN ON
E. Exterior/interior tail lamp relay ON

Operation 3. (Tail lamp AUTO OFF activated)

H. The tail lamp switch is turned from OFF to ON.
I. The tail lamp AUTO OFF operation is not activated when the driver door is closed.

System Flowchart

GETtheMANUALS.org
 0000-00 01-81

GETtheMANUALS.org
01-82

4) Front Fog Lamp Control

Operation 1.
A. Exterior tail lamp relay activated
Front fog lamp switch ON
B. Front fog lamp relay activated
(BCM detects front fog lamp relay activation)
C. BCM sends front fog lamp ON signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

System Flowchart

GETtheMANUALS.org
 0000-00 01-83

22. DRL CONTROL

▶ Circuit configurations for DRL operation

GETtheMANUALS.org
01-84

1) DRL Lamp Comes On When: (With IGN ON)

A. EPB ON indicator goes off (deactivated) or blinks (fails)
- ECS sends EPB ON indicator signal to BCM via CGW
(ESC→CCAN→CGW→BCAN→BCM)
- ECS sends EPB ON indicator signal to instrument cluster
(ESC→CCAN→ICM)
B. Vehicle is in the following conditions even if EPB ON indicator is lit (activated)
1) Auto Hold not in OFF position
- ESC sends Auto Hold signal to BCM via CGW
(ESC→CCAN→CGW→BCAN→BCM)
- ESC sends Auto Hold signal to instrument cluster
(ESC→CCAN→ICM)
2) Vehicle speed 3 km/h or higher
C. Parking brake not applied

EPB (Electronic Parking Brake) and HPB (Hand Parking Brake) specifications are categorized by
CGW's variant coding.

2) DRL Lamp Comes On

A. When 0.4 sec elapsed after IGN ON or
B. Exterior tail lamp relay active and DRL lamp ON or
C. Exterior tail lamp relay inactive signal received,
D. DRL lamp will be lit.
- BCM sends DRL lamp ON signal to ECU and HVAC
(BCM→PCAN→ECU, HVAC)

GETtheMANUALS.org
 0000-00 01-85

3) DRL Lamp OFF Operation

A. IGN OFF
B. Front fog lamp ON signal input
C. Headlamp low beam and high beam ON signal input
D. When parking brake is applied
- EPB (Electronic Parking Brake) applied (AUTO hold not activated and vehicle speed of less
than 3km/h
- HPB (Hand Parking brake) applied

- Front fog lamp switch OFF

Default conditions - EPB/HPB not applied
- AUTO HOLD activated/deactivated

Condition M/F switch Tail lamp Low beam DRL (Daytime

Position Running Light)
OFF - - -
AUTO - - -
IGN OFF
Tail lamp operation - -
Low beam - - -
OFF operation - operation

IGN ON and AUTO operation operation -

Engine started Tail lamp operation - operation
Low beam operation operation -

DRL lamp is turned off when the front fog lamp ON signal is input and EPB/HPB is applied. If the
EPB activation is the case, AUTO hold should not be activated and vehicle speed should be less
than 3 km/h.

GETtheMANUALS.org
01-86

23. TURN SIGNAL LAMP FLASHING

▶ Circuit configurations for DRL operation

GETtheMANUALS.org
 0000-00 01-87

1) Left/right Turn Signal Lamp Control

Condition 1.
A. Left (right) turn signal lamp switch ON signal input with IGN ON
B. Flashes 3 times automatically (activates turn signal light at 75 times/min)
- BCM sends turn signal light output signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
- BCM sends turn signal light output signal to SKM
(BCM→BCAN→SKM)
C. When left (right) turn signal lamp switch is turned off, the turn signal lamp on the corresponding side
completes its operating cycle and goes out.

When the RH turn signal light switch signal is input during the LH turn signal light ON, the LH turn
signal light turns off immediately and the RH turn signal light flashes.

System Flowchart

GETtheMANUALS.org
01-88

Condition 2.
D. Operation 1. during Operation 1.
E. The BCM sends left (right) turn signal lamp signal at frequency of 120 times/min. (flashing).

- Turning left (right) turn signal lamp switch ON always makes the lamp flashes 3 times.
- If this switch is turned OFF during this flashing procedure, the turn signal lamp goes out after
completing the flashing procedure.
- If a signal of the opposite steering direction is sent from the switch during this flashing procedure, the
turn signal lamp goes out immediately and the turn signal lamp on the opposite side starts flashing.

GETtheMANUALS.org
 0000-00 01-89

2) Hazard Warning Lamp Switch Control

Operation 1.
A. Hazard warning lamp switch ON with ACC ON or IGN ON
B. The BCM sends hazard warning signal (left/right turn signal lamp) at frequency of 75 times/min.
(flashing) through hard wire.
- BCM sends hazard warning flasher ON signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
- BCM sends hazard warning flasher ON signal to SKM
(BCM→BCAN→SKM)
- BCM sends hazard warning flasher switch input signal to BSD and FCM via CGW
(BCM→BCAN→CGW→CCAN→BSD, FCM)
- BCM sends hazard warning flasher switch input signal to SKM
(BCM→BCAN→SKM)
C. When the hazard warning lamp switch is turned off, the hazard warning lamp completes its operating
cycle and goes out.

Condition 2.
D. Operation 1. during Operation 1.
E. The BCM sends the hazard warning signal (left/right turn signal lamp) at frequency of 120 times/min
(flashing).

- This function is available if the battery is connected (B+).

- The hazard warning lamp overrides the turn signal lamp.

GETtheMANUALS.org
01-90

System Flowchart

GETtheMANUALS.org
 0000-00 01-91

3) AUTO Hazard Warning Lamp Switch Control

Operation 1.
A. AUTO hazard warning lamp switch input for 0.1 to 0.59 sec. (T1) with IGN ON
B. The hazard warning lamp (left/right turn signal lamp) flashes 3 times (T3) at frequency of 75
times/min.
- BCM sends hazard warning flasher ON signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
- BCM sends hazard warning flasher ON signal to SKM
(BCM→BCAN→SKM)

Operation 2.
C. AUTO hazard warning lamp switch input for 0.6 sec. or more (T2) with IGN ON
D. The hazard warning lamp (left/right turn signal lamp) flashes 10 times (T4) at frequency of 75
times/min.
- BCM sends hazard warning flasher ON signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
- BCM sends hazard warning flasher ON signal to SKM
(BCM→BCAN→SKM)

- The AUTO hazard warning lamp can be controlled only with IGN ON.
(lamp goes off immediately when IGN is turned OFF)
- The AUTO hazard warning lamp is turned off immediately if any of the following signals is
received.
→ Left/right turn signal lamp switch signal input
→ Hazard warning lamp switch signal input
→ Emergency hazard warning lamp control signal input
- Priority of turn signal light control
(Hazard warning flasher control > LH/RH turn signal light > emergency hazard warning lamp
control > AUTO hazard warning lamp control)

GETtheMANUALS.org
01-92

System Flowchart

GETtheMANUALS.org
 0000-00 01-93

24. EMERGENCY BRAKE LAMP & EMERGENCY HAZARD

WARNING LAMP (INTERLOCKED WITH ESP)
The ESS (Emergency Stop Signal) warns a following vehicle at the time of abrupt braking or operating of
ESP system. The ABS/ESP unit sends the signal to the BCM through P-CAN. The BCM flashes the
stop lamp rapidly or the hazard warning flasher for a period of time depending on the vehicle condition.

Priority: Hazard warning flasher operation by switch → emergency braking signal →

emergency hazard warning lamp

Operation 1. (Emergency brake lamp)

A. At vehicle speed of 50 km/h or more
B. Emergency braking signal received
- ABS/ESP sends "Emergency braking" signal to BCM
(ABS/ESP→PCAN→BCM)
C. The BCM flashes the stop lamp at an interval of 0.4 sec via hard-wire.

GETtheMANUALS.org
01-94

Operation 2. (Emergency brake lamp)

C. Operation 1. the vehicle speed drops below 50 km/h.
D. The stop lamp stays flashing as long as the emergency braking signal input is active.
- ABS/ESP sends "Emergency braking" signal to BCM
(ABS/ESP→PCAN→BCM)

However, the emergency hazard warning lamp is operated when "Emergency braking completed" signal
received at vehicle speed of 50 km/h or less during emergency stop lamp operation.

- The stop lamp signal is overridden during emergency brake lamp operation.
- The emergency brake lamp signal is overridden during hazard warning lamp operation.
- If the hazard warning lamp switch signal is received during emergency brake lamp operation, the
emergency brake lamp stops working immediately and the hazard warning lamp starts operating.

System Flowchart

GETtheMANUALS.org
 0000-00 01-95

Operation 3. (emergency hazard warning lamp flashes)

A. At the time of completion of emergency braking
- ABS/ESP sends "Emergency braking completed" signal to BCM
(ABS/ESP→PCAN→BCM)
B. At vehicle speed of 50 km/h or lower
C. Hazard warning flasher (LH/RH turn signal lights) flashes for 10 seconds.
(LH/RH turn signal lights flash 10 times at intervals of 0.4 sec on and 0.4 sec off)
- BCM sends hazard warning flasher ON signal to instrument cluster and FCM via CGW
(BCM→BCAN→CGW→CCAN→IP / FCM)
- BCM sends hazard warning flasher ON signal to SKM
(BCM→BCAN→SKM)

System Flowchart

Emergency hazard warning lamp OFF conditions

- The vehicle speed increases to 10 km/h or more (at the time of emergency braking signal
input).
- Hazard warning lamp switch input
- Emergency hazard warning lamp flashes for 10 sec

GETtheMANUALS.org
01-96

GETtheMANUALS.org
 0000-00 01-97

25. STOP LAMP CONTROL

▶ Circuit configurations for stop lamp operation

GETtheMANUALS.org
01-98

Condition 1. (Stop lamp ON)

The stop lamp is turned ON when any of the following conditions are met:

A. The brake switch is turned ON by the brake pedal input.

B. When stop lamp ON signal input due to operation of AEBS
- ESP sends stop lamp ON request signal to BCM, CGW and TCU
(ESP→PCAN→BCM, CGW, TCU)
C. When stop lamp ON signal input due to application of EPB
- ESP sends stop lamp ON request signal to BCM via CGW
(ESP→CCAN→CGW→BCAN→BCM)

System Flowchart

- The stop lamp output voltage should not be 13.9 V or higher.

- The stop lamp normally works depending on the brake pedal even if BCM unit fails.

Condition 2. (Stop lamp OFF)

The stop lamp is turned OFF when all the following conditions are met:

A. Brake switch OFF by brake pedal

B. Stop lamp OFF signal input due to operation of AEBS
- ESP sends stop lamp OFF request signal to BCM, CGW and TCU
(ESP→PCAN→BCM, CGW, TCU)
C. When stop lamp OFF signal input due to application of EPB
- ESP sends stop lamp OFF request signal to BCM via CGW
(ESP→CCAN→CGW→BCAN→BCM)

GETtheMANUALS.org
 0000-00 01-99

26. IMMOBILIZER SYSTEM

1) System Diagram

GETtheMANUALS.org
01-100

2) Immobilizer Ignition Key Authentication

When turning the ignition key to the ON position, the power is supplied to the immobilizer unit, BCM and
EMS (ECU). The ECU communicates with the immobilizer unit to verify the key and transponder. If it is
valid, the ECU starts to control the engine or immobilizer indicator (illumination or flashing) when the
ignition key is turned to the START position.
Once the key is verified, valid key verification time is provided for 10 seconds and the engine can be
started by turning the ignition key to the engine START position during this verification time. If the ignition
key is turned to the START position again after the 10 seconds of verification time, the key verification
should be re-performed.

1. When the ignition key is inserted, the BCM requests the transponder verification through the
immobilizer antenna.
2. The transponder sends the encrypted message to the BCM through the immobilizer antenna.
3. The BCM compares the encrypted message received from the transponder to the coded
value through the logic circuit. If they are identical, it requests the transponder approval.
4. When the ignition is turned ON, the EMS (ECU) requests immobilizer verification process
through the P-CAN.
5. The BCM sends the encrypted message to the EMS (ECU).
6. The EMS (ECU) controls the engine normally when the coded value and the encrypted message
sent from the BCM are identical.

When the immobilizer verification has failed, the verification signal will be sent 3 times for 2 seconds,
and the verification procedure will be carried out up to 3 times by turning the ignition ON within 10
seconds. If the three re-verifications fail, verification procedure will be stopped and restarted after 10
seconds.

GETtheMANUALS.org
 0000-00 01-101

3) REKES Key Configuration

Key plate
Main cover

Battery (CR2032)
Remote controller PCB
Spring

Battery cover
Transponder

Side cover

▶ Battery replacement

Remove the battery cover with a flat-bladed screwdriver to replace the battery.

▶ Transponder replacement

- Remove the battery cover to remove the battery.

- Remove the key plate after removing the rubber cover and screws.
- Remove the side cover and main cover.
- Replace the transponder

GETtheMANUALS.org
01-102

1. When deleting the old code of the transponder registering an extra ignition key, please attend on the
site and observe the process personally.
2. In any cases, the immobilizer system cannot be removed from the vehicle. If you attempt to
remove it and damage the system, starting will be impossible. So never attempt to remove,
damage or modify it.
3. The remote engine starter cannot be installed to the vehicle equipped with the immobilizer
system.
4. Do not drop the key or subject it to impact the key, as it may damage the transponder inside
the key.
5. The engine cannot be started using a key with damaged transponder.
6. In the following cases, you may experience starting problem or a system error can occur.
- When two or more ignition keys come into contact with (each) other(s), or the key is close to any
device that sends/receives electromagnetic fields or waves.
- When the ignition key is close to any electromagnetic device, such as lighting equipment, security
keys or security cards.
- When the key is close to a magnetic, metal object, or battery.

GETtheMANUALS.org
 0000-00 01-103

27. PAS (PARKING AID SYSTEM)

▶ Circuit configurations for parking aid system operation

GETtheMANUALS.org
01-104

1) Overview
When the vehicle is being driven at a lower speed or reversing, the PAS (parking aid system) is
activated and 8 ultrasonic sensors installed to the bumpers (4 for front and 4 for rear) detect the distance
to any obstacle. The PAS detects the returning signals reflected by the obstacles at regular intervals to
provide both visual and audible alerts by phase based on the distance to the obstacles so as to allow
easy parking by securing safe distance for driver comfort.
In addition, the front PAS warning buzzer output may vary depending on the front PAS OFF switch
operation.
The specifications of the parking aid system are as follows:
(1) With rear PAS
(2) With front PAS + rear PAS
(3) Without PAS

▶ The sensor can not detect an object when:

- The sensor is frozen (operate normally when it's thawed)
- The sensor is covered with foreign materials such as snow or condensation
(if the foreign materials are removed, the sensor operates normally.)

▶ Not defective but improperly working

- When the sensing portion is frozen (operates normally after thawed)
- When reversing on rough roads, gravel roads, hills, or grass.
- When receiving other ultrasonic signals (metal sounds or air braking noises from heavy
commercial vehicles).
- When there is heavy rainfall or water drops.
- When the sensor is covered with snow.

▶ Certain obstacles that sensors cannot detect

- Thin and narrow objects, such as wires, ropes, or chains
- Cotton, sponge, clothes, snow that absorb ultrasonic waves.

▶ Weak Sensing Scopes

- When the ambient temperature is too high or too low.
- When a 1 m or less long small object with a diameter of 100 mm or less is detected.

GETtheMANUALS.org
 0000-00 01-105

2) Conditions For Controlling PAS (Parking Aide System) Power

A. The BCM supplies power to the front/rear PAS sensor when the ignition is turned ON.
B. When the power is supplied, the system is in standby mode after the LIN communication is
established and the system initialization is performed for 0.5 sec (only once).
C. After that, the front PAS sensor is powered continuously in all gear positions.
D. The rear PAS sensor is turned off when the transmission is in the "D" position. It is turned on again
when the transmission is in positions other than "D" and then the system is in standby mode after the
system initialization is performed for 0.5 seconds.

Transmission position signal

▶ A/T gear position signal
- TCU sends gear position signal to BCM
(TCU→PCAN→BCM)

▶ M/T gear position signal

- Instrument cluster sends gear position signal to BCM via CGW
(Instrument cluster→CCAN→CGW→PCAN→BCM)

3) PAS LIN Communication Initialization Diagnosis

A. When the PAS sensor is powered and the operating conditions for the front/rear PAS (with
transmission in R or D position) are met, the BCM sends the initial diagnosis command to each PAS
sensor once after 0.01 sec.
B. The BCM requests the diagnosis results to each PAS sensor 0.1 sec after the transmission of initial
diagnosis command.
C. The BCM receives the diagnosis results from each sensor. If no diagnosis results have been received,
the BCM tries to perform initialization up to 3 times.
D. When initial diagnostics are completed, BCM sends signal indicating whether PAS sensor
normal or faulty
- BCM sends signal indicating whether sensor normal or faulty to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)
E. If the initial diagnosis is failed, it is stored as a history DTC.

GETtheMANUALS.org
01-106

4) PAS LIN Measurement Mode

▶ PAS Operating conditions

Item Conditions
- Shift lever in D with IGN ON
- Shift lever in R with IGN ON
Front PAS - Disabled at 15 km/h or higher
- Enabled at less than 15 km/h
The vehicle speed should be slowed down under 10 km/h to activate
front PAS when it is disabled at 15 km/h or higher.
Rear PAS - Shift lever in R with IGN ON

▶ Rear PAS

A. The PAS sensor enters measurement mode after LIN communication initialization diagnostics are
completed.
(Continuous diagnosis mode is also activated when measurement mode is started)
B. Transmission shifted to R with IGN ON
C. The BCM sends measurement commands in the following order:
RL → RLC → RRC → RR
D. The BCM receives the measurement results from the corresponding sensors after 0.07 sec.
E. BCM sends measurement result signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

▶ Front PAS + Rear PAS

A. It is operated when the vehicle speed is 15km/h or less with IGN ON and the shift lever in "R" or "D"
position.
(OFF at speed of 15km/h or higher and then ON at speed of 10km/h below)
B. The BCM sends measurement commands in the following order:
(RL → RLC → RRC → RR → FL → FR → FLC → FRC)
C. The BCM receives the measurement results from the corresponding sensors after 0.07 sec.
D. BCM sends measurement result signal to instrument cluster via CGW
(BCM→BCAN→CGW→CCAN→IP)

- The audible alert of the highest warning level is produced according to the measuring results of
each sensor on the front/rear side.
- If no respond is received from each sensor after 4 attempts to communicate with sensors, the
system attempts to communicate once more after 0.1 sec. If no respond is received from each
sensor after another 4 attempts, a DTC is stored.

GETtheMANUALS.org
 0000-00 01-107

5) Front PAS Sensor ON/OFF

▶ Front PAS ON (indicator off)

A. The front PAS sensor operates normally when the front PAS OFF switch is turned on.
- BCM sends front PAS OFF switch ON signal to instrument cluster via CGW
(BCM→BCAN→ CGW→CCAN→IP)
B. The front PAS OFF switch indicator is turned off.

▶ Front PAS OFF (indicator on)

A. The front PAS sensor does not operate when the front PAS OFF switch is turned off.
- BCM sends front PAS OFF switch OFF signal to instrument cluster via CGW
(BCM→BCAN→ CGW→CCAN→IP)
B. The front PAS OFF switch indicator is turned on.

- The front PAS OFF switch operates normally (its indicator turned off) 0.7 seconds after the
ignition is turned from off to on with the front PAS OFF switch in "OFF" position (its indicator
on).
- The rear PAS sensor operates normally when the signal indicating that the shift lever is in "R"
position is received.

GETtheMANUALS.org
01-108

▶ Sensing distance of PAS

Item Level 1 Level 2 Level 3

CTR - 50cm ~ 100cm 30cm ~ 50 cm
Front
Side - 40cm ~ 60cm 30cm ~ 40cm
Distance
CTR 80cm ~ 120cm
Rear 50cm ~ 80cm 30cm ~ 50 cm
Side -
Buzzer Interval of 300 ms Interval of 150 ms Continuous sound

Display of instrument cluster

▶ Vertical sensing range of PAS

Front Rear

Height Ground to 20 cm 20cm ~ 30cm 30cm ~ 70cm

detected Impossible to detect Not detected detected

GETtheMANUALS.org
 0000-00 01-109

28. THEFT DETERRENT CONTROL (WITHOUT SKM)

- The theft deterrent control operates with the ignition key removed.
- If the ignition key is inserted, REKES key does not work. It works 1 second after the ignition key is
removed. (to prevent malfunction when removing IGN key)
- The exterior buzzer operated depending on the vehicle LOCK/UNLOCK can be set under the User
Settings menu in the instrument cluster.

1) Theft Deterrent Arming I

(With All doors Including Hood And Tailgate Closed)
A. More than 1 sec after ignition key removed
B. Lock signal is received from REKES key
C. BCM triggers all door LOCK relay outputs
D. All doors including hood and tailgate closed and all door lock switches in LOCK position
E. Turn signal lamp flashes twice at intervals of 0.5 sec ON and 0.5 sec OFF
F. BCM outputs theft deterrent mode entry signal as follows:
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
G. System enters theft deterrent mode

2) Entering Theft Deterrent Mode II

At theft deterrent mode entry I status

A. REKES key LOCK signal re-received within 4 sec

B. Turn signal lamp flashes twice at intervals of 0.5 sec ON and 0.5 sec OFF and exterior buzzer sounds
once for 0.01 sec
C. System enters theft deterrent mode

3) Theft Deterrent Mode Entry III (Enters Mode After Standby)

All doors closed or hood and tailgate open
A. Lock signal is received from REKES key
B. BCM triggers all door LOCK relay outputs
C. Theft deterrent arming standby mode
D. Hood and tailgate closed
E. All doors including hood and tailgate are closed and all doors are locked.
F. The turn signal lamp is turned ON for 0.5 seconds and then turned OFF for 0.5 seconds, and this
operation is repeated 2 times.
G. System enters theft deterrent mode

GETtheMANUALS.org
01-110

4) Disarmed Mode I (Pressing Key Twice Not Set Unlock)

A. When unlock signal is received from REKES key,
B. BCM triggers all door UNLOCK relay outputs
C. Release theft deterrent mode and
D. Flashes turn signal light for 1 sec

5) Disarmed Mode II (Pressing Key Twice Set Unlock)

A. When unlock signal is received from REKES key,
B. BCM triggers driver door UNLOCK relay only
C. Release theft deterrent mode and
D. Flashes turn signal light for 1 sec
E. REKES key UNLOCK signal re-received with driver door unlocked
F. BCM triggers all door UNLOCK relay outputs
(Turn signal light does not operate.)

6) Theft Deterrent Re-arming

A. In theft deterrent mode,
B. When system shifts to disarmed mode by REKES key UNLOCK signal
C. If any of doors (including hood and tailgate) is not open or ignition key stays removed for 30
seconds
D. BCM triggers all door LOCK relay outputs
E. Turn signal lamp flashes twice at intervals of 0.5 sec ON and 0.5 sec OFF and exterior buzzer
sounds once for 0.01 sec
F. System re-enters theft deterrent mode

7) Theft Deterrent Alarm Activation

When the following signals are detected in armed mode, the theft deterrent alarm is activated for 30 sec.
and the turn signal lamp is also activated during activation of this alarm.

A. Any door including hood and tailgate opened in theft deterrent mode
B. Any door's LOCK switch unlocked in theft deterrent mode
C. Status of any door or hood changes (from closed to open) or status of tailgate lock switch changes
(from locked to unlocked) after alarm is turned off (for 30 sec. of warning)

GETtheMANUALS.org
 0000-00 01-111

8) Theft Deterrent Alarm Deactivation

The theft deterrent alarm is deactivated when the following conditions are fulfilled when the alarm is
activated.

A. REKES key LOCK/UNLOCK signal received

B. REKES panic signal received
C. Immobilizer authentication completed after IGN ON

If there is no theft deterrent alarm deactivation signal input, the theft deterrent system returns to the
armed mode after 30 sec. of theft deterrent alarm operation.

GETtheMANUALS.org
01-112

29. THEFT DETERRENT CONTROL (WITH SKM)

▶ Circuit configurations for theft deterrent system operation

GETtheMANUALS.org
 0000-00 01-113

- The Theft deterrent control is available when IGN OFF or ACC.

(Theft deterrent triggered after power turned off by SKM with ignition in ACC)
- The exterior buzzer operated depending on the vehicle LOCK/UNLOCK can be set under the User
Settings menu in the instrument cluster.

1) Theft Deterrent Arming I

(With All doors Including Hood And Tailgate Closed)
When the all doors including hood and tailgate are closed,

A. when BCM receives the following signals from SKM

Condition 1. "Smart key LOCK" signal received from SKM
Condition 2. "Smart key auto LOCK" signal received from SKM
(only when "Smart door AUTO LOCK" function is enabled in instrument cluster)
Condition 3. "Door outside handle switch operation" signal received from SKM

Door outside handle "Unlock with key in 2 stages" under User settings menu
switch Enabled Disabled

Driver door When pressed 4 sec. after driver When pressed with driver door
door is unlocked* unlocked

Other than driver door When pressed with driver door When pressed with all doors
unlocked unlocked

* When the switch is pressed within 4 sec. after the driver door is unlocked, the signal for all doors
UNLOCK is sent out. Therefore, the door handle switch should be pressed after 4 sec. have
passed with "Unlock with key in 2 stages" function enabled.

B. BCM triggers all door LOCK relay outputs

C. All doors including hood sw(1, 2) and tailgate closed and all door lock switches in LOCK position
D. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
E. System enters armed mode

GETtheMANUALS.org
01-114

System Flowchart

GETtheMANUALS.org
 0000-00 01-115

2) Theft Deterrent Arming II (Hood And Tailgate Open)

When all doors excepting hood and tailgate are closed,

A. The BCM receives the following signals:

Condition 1. "Smart key LOCK" signal received from SKM
Condition 2. "Door outside handle switch operation" signal received from SKM

Door outside handle "Unlock with key in 2 stages" under User settings menu
switch Enabled Disabled

Driver door When pressed 4 sec. after driver When pressed with driver door
door is unlocked* unlocked

Other than driver door When pressed with driver door When pressed with all doors
unlocked unlocked

* When the switch is pressed within 4 sec. after the driver door is unlocked, the signal for all doors
UNLOCK is sent out. Therefore, the door handle switch should be pressed after 4 sec. have
passed with "Unlock with key in 2 stages" function enabled.

B. BCM triggers all door LOCK relay outputs

C. Theft deterrent arming standby mode
D. Hood and tailgate closed
E. All doors including hood sw(1, 2) and tailgate are closed and all doors are locked.
F. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
G. System enters theft deterrent mode

3) Disarmed Mode
A. When BCM receives the following signals in theft deterrent mode
- "Smart key UNLOCK" signal from SKM
- "Door outside handle switch operation" signal from SKM
B. BCM triggers all door UNLOCK relay outputs
C. Theft deterrent is disarmed
D. The turn signal lamp is turned ON for 1 sec. and external buzzer (SKM buzzer) sounds twice.

Refer to "Power Tailgate Control" under this chapter for power (smart) tailgate operation by theft
deterrent system status.

GETtheMANUALS.org
01-116

4) Theft Deterrent Re-arming

A. In theft deterrent mode,
B. When system shifts to disarmed mode by smart key or door handle switch
C. If any of doors (including hood and tailgate) is not open or ignition not turned on within 30
seconds
D. BCM triggers all door LOCK relay outputs
E. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
F. System re-enters theft deterrent mode

5) Theft Deterrent Alarm Activation

When the following signals are detected in armed mode, the theft deterrent alarm is activated for 30 sec.
and the turn signal lamp is also activated during activation of this alarm.

A. Any door including hood and tailgate is opened in armed mode.

B. The switch of any door including tailgate is set to UNLOCK in armed mode.
C. Status of any door or hood changes (from closed to open) or status of tailgate lock switch changes
(from locked to unlocked) after alarm is turned off (for 30 sec. of warning).

6) Theft Deterrent Alarm Deactivation

The theft deterrent alarm is deactivated when the following conditions are fulfilled when the alarm is
activated.

A. Smart key door LOCK/UNLOCK signal received

B. Driver passive LOCK/UNLOCK signal received
C. Passive LOCK signal for seat other than driver seat received
D. Tailgate open/close signal is received.
E. AUTO door LOCK signal is received.
F. IGN ON
G. Panic alarm button is pressed.

If there is no theft deterrent alarm deactivation signal input, the theft deterrent system returns to the
armed mode after 30 sec. of theft deterrent alarm operation.

GETtheMANUALS.org
 0000-00 01-117

30. BUZZER CONTROL

1) Buzzer Control Priority

Alarm horn Exterior buzzer

GETtheMANUALS.org
01-118

31. PANIC ALARM (FOR VEHICLES WITHOUT SKM)

Operation 1. (for vehicles without SKM)
The panic alarm is operated with the ignition key removed.

A. Panic alarm signal received from REKES key

B. Warning horn sounds and turn signal light flashes at cycles of 0.5 sec ON and 0.5 sec OFF
for 30 sec
C. REKES key LOCK / UNLOCK signal received during panic alarm operation
D. The received function will operated while the panic alarm is operating.
E. If a theft deterrent alarm is issued during panic alarm operation, the panic function is canceled and a
theft deterrent alarm is activated.
F. The panic alarm is deactivated only when REKES key panic signal is re-received, during panic alarm
operation.

Operation 2. (for vehicles with SKM)

The panic alarm is operated with the ignition turned off.

A. Panic alarm signal received from smart key

B. Warning horn sounds and turn signal light flashes at cycles of 0.5 sec ON and 0.5 sec OFF for 30 sec
Smart key LOCK / UNLOCK signal received during panic alarm operation
C. The received function will operated while the panic alarm is operating.
D. If a theft deterrent alarm is issued during panic alarm operation, the panic function is canceled and a
E. theft deterrent alarm is activated.
The panic alarm is deactivated only when smart key panic signal is re-received, during panic alarm
F. operation.

Operation 3. (Panic alarm ON by CCU)

The panic alarm operates with IGN OFF and the engine started by the remote control.
A. Remote panic alarm ON signal received by CCU
B. Warning horn sounds and turn signal light flashes at cycles of 0.5 sec ON and 0.5 sec OFF
for 30 sec
C. Panic function extended when remote panic alarm signal re-received
D. If a theft deterrent alarm is issued during panic alarm operation, the panic function is canceled and a
theft deterrent alarm is activated.

Operation 4. (Panic alarm OFF by CCU)

E. The panic alarm is turned off immediately when the remote panic alarm by CCU is received or smart
key panic signal is received during panic alarm operation.

The panic alarm does not operate with IGN ON.

GETtheMANUALS.org
 0000-00 01-119

Operation 5. (Panic alarm ON by CCU (only lamp))

The panic alarm operates with IGN OFF and the engine started by the remote control.

A. Remote panic alarm (only lamp) ON signal received by CCU

B. Turn signal light flashes at cycles of 0.5 sec ON and 0.5 sec OFF for 30 sec
C. Panic function extended when remote panic alarm signal re-received
D. If a theft deterrent alarm is issued during panic alarm operation, the panic function is canceled and a
theft deterrent alarm is activated.

Operation 6. (Panic alarm OFF (only lamp))

E. The panic alarm is turned off immediately when the remote panic alarm (only lamp) by CCU is
received or smart key panic signal is received during panic alarm operation.

- The panic alarm does not operate with IGN ON.

- The panic alarm (only lamp) does not operate during theft deterrent alarm operation.

GETtheMANUALS.org
01-120

32. FRONT/CENTER ROOM LAMP CONTROL (WITHOUT SKM)

▶ Circuit configurations for room lamp system operation

GETtheMANUALS.org
 0000-00 01-121

- When the front room lamp switch is in the door interlocked position and any door is opened,
the room lamp comes on.
- The interior indicator lamp control is capable of activation with IGN OFF.

1) Front/Center Room Lamp ON

Operation 1. (Door interlocked room lamp ON)
A. Any door open
B. The BCM activates the door interlocked room lamp control and the room lamp ground control.

Operation 2. (Conditions for Room lamp 30 s ON)

- Room lamp switch in door interlocked (ON) position
- All doors closed with ignition key removed (including theft deterrent)

C. When unlock signal is received from REKES key,

D. The BCM turns on the door interlocking room lamp control for 30 seconds and off it.
(Room lamp ground control also stays on.)
E. The interior room lamp lights on for 30 sec and then off.
F. When REKES key UNLOCK signal re-received while interior room lamp lights on for 30 seconds, the
interior room lamp output is extended for 30 seconds.

System Flowchart

GETtheMANUALS.org
01-122

2) Front/Center Room Lamp Fading to OFF and Immediate OFF

Operation 1. (dimmed off)
A. With IGN OFF and door interlocked switch ON
B. any of doors open and then all doors closed
C. The room lamp stays on for 2 seconds (T1) and then fades to off for 3 seconds (T2).

Operation 2. (instant off I)

D. All doors are closed with IGN ON.
E. The room lamp goes out immediately.

Operation 3. (instant off II)

F. IGN ON with dimmed off
G. The room lamp goes out immediately.

GETtheMANUALS.org
 0000-00 01-123

3) Front/Center Room Lamp Cut-Off Control

When the room lamp cut-off operation is activated, the BCM sends cut-off operation signal through
B-CAN to prevent the battery discharge.

Operation 1. (cut-off entering)

A. With ignition key removed
B. when 10 min elapsed without change in status of any of doors
C. front/center room lamps turned off and BCM enters theft deterrent mode.

Operation 2. (cut-off entering operation)

A. Room lamp (-) control is off.
B. BCM sends cut-off control ON signal.
C. The front room lamp is turned off immediately when signal is input that any of doors is open.
D. When open signal is received from the tailgate open switch, rear (luggage) room lamp is turned off.

Operation 3. (cut-off termination)

If the following conditions are met, room lamp cut-off operation is terminated.

A. UNLOCK signal received from REKES key

B. Signal received that any of doors open
C. IGN ON (sleep mode released)

Operation 4. (operation when cut-off terminated)

A. Room lamp (-) control is on.
B. BCM sends cut-off control OFF signal .

GETtheMANUALS.org
01-124

33. FRONT/CENTER ROOM LAMP CONTROL (WITH SKM)

▶ Circuit configurations for room lamp system operation

GETtheMANUALS.org
 0000-00 01-125

- When the front room lamp switch is in the door coupled position and any door is opened, the room
lamp comes on.
- The interior indicator lamp control is capable of activation with IGN OFF.

1) Front/Center Room Lamp ON

Operation 1. (Door coupled room lamp ON)
A. Any door open
B. The BCM activates the door coupled room lamp control and the room lamp ground control.
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)

Operation 2. (Conditions for Room lamp 30 s ON)

- Room lamp switch in door interlocked (ON) position
- All doors closed with IGN OFF or ACC (including theft deterrent)

C. BCM receives the following condition signals:

(SKM→BCAN→BCM)
Condition 1. Smart key UNLOCK signal received from SKM
Condition 2. Door handle switch operation signal received in theft deterrent mode
Condition 3. AUTO approach signal received in theft deterrent mode
D. The BCM turns on the door interlocking room lamp control for 30 seconds and off it.
(Room lamp ground control also stays on.)
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)
E. The interior room lamp lights on for 30 sec and then off.
F. Condition 1 and 3 signals re-received with interior room lamp lit for 30 sec
G. The interior room lamp output is extended for 30 seconds.

GETtheMANUALS.org
01-126

System Flowchart

The luggage room lamp is interlocked with the tailgate. The lamp is turned on or off when the
tailgate is open or closed.

GETtheMANUALS.org
 0000-00 01-127

2) Front/Center Room Lamp Fading to OFF and Immediate OFF

Operation 1. (dimmed off)
A. IGN OFF or ACC and door interlocked switch ON
B. All doors are closed after any door is open.
The room lamp stays on for 2 seconds (T1) and then fades to off for 3 seconds (T2).
- BCM sends room lamp control ON signal to SKM
(BCM→BCAN→SKM)

Operation 2. (instant off I)

D. All doors are closed with IGN ON.
E. The room lamp goes out immediately.

Operation 3. (instant off II)

F. When the ignition is turned on
G. during dimmed operation,
H. the room lamp goes out immediately.

Operation 4. (instant off III)

I. During dimmed operation,
J. when smart key lock signal and lock signal by door handle switch operation are received
K. the room lamp goes out immediately.

GETtheMANUALS.org
01-128

GETtheMANUALS.org
 0000-00 01-129

3) Front/Center Room Lamp Cut-Off Control

When the room lamp cut-off operation is activated, the BCM sends cut-off operation signal to SKM
through B-CAN to prevent the battery discharge.

Operation 1. (cut-off entering)

A. IGN OFF or ACC ON
B. 10 min elapsed without change in status of any of doors
front/center room lamps turned off and BCM enters theft deterrent mode.
(Unless the room lamp is turned on due to auto approach signal input)

Operation 2. (cut-off entering operation)

A. Room lamp (-) control is off.
B. BCM sends cut-off control ON signal.
(BCM→BCAN→SKM)
C. The front room lamp is turned off immediately when signal is input that any of doors is open.
D. When open signal is received from the tailgate open switch, rear (luggage) room lamp is turned off.

Operation 3. (cut-off termination)

If the following conditions are met, room lamp cut-off operation is terminated.

A. UNLOCK signal received from REKES key

B. Signal received that any of doors open
C. IGN ON (sleep mode released)

Operation 4. (operation when cut-off terminated)

A. Room lamp (-) control is on.
B. BCM sends cut-off control OFF signal .
(BCM→BCAN→SKM)

GETtheMANUALS.org
01-130

34. POWER WINDOW RELAY CONTROL

▶ Circuit diagram for power window operation

GETtheMANUALS.org
 0000-00 01-131

- The power window relay control is available when the ignition is turned on.

1) Time Lag Power Window Control

Operation 1.
A. IGN ON → OFF
B. The power window relay is activated (ON) for 30 sec. (T1) and turned OFF.

Operation 2. (During 30 sec. (T1) of power window relay ON)

C. The driver door or passenger door is opened.
D. The power window relay is deactivated immediately.

Operation 3. (During 30 sec. (T1) of power window relay ON)

E. When entering theft deterrent mode depending on following condition signal input
Condition 1. "REKES LOCK" signal received (for vehicles without SKM)
Condition 2. "Smart key LOCK" signal received (for vehicles with SKM)
Condition 3. "Smart door auto lock" signal received (for vehicles with SKM)
Condition 4. "Door handle switch operation" signal received (for vehicles with SKM)
F. The power window relay is deactivated immediately.

System Flowchart

GETtheMANUALS.org
01-132

GETtheMANUALS.org
 0000-00 01-133

35. DOOR LOCK/UNLOCK CONTROL

▶ Circuit configurations for door lock/unlock operation

GETtheMANUALS.org
01-134

▶ Door anti-LOCK control fail-safe conditions

The door LOCK switch and door open switch are faulty. The anti-LOCK function cannot be activated
when the 6th UNLOCK signal is received after 5 repetition of door LOCK operation for 1 min.

▶ Door anti-LOCK control fail-safe deactivation conditions

- All doors locked with all doors closed

- IGN ON → OFF or IGN OFF → ON

The door LOCK/UNLOCK control is not available regardless of the door LOCK switch status after
replacing the battery.

Smart key

Type A Type B
Door lock Door lock

Door unlocked Door unlocked

Panic
Power tailgate

Button name Short press Long press

Door lock Door lock
Door unlocked Door unlock (driver door only unlocked when safety unlock set)
Type A Tailgate Wiping stops Power tailgate open/closed
Type B Panic - Panic mode operation/release

Step 1: 0.03 to less than 1.5 sec. / Step 2: 1.5 sec. or more

GETtheMANUALS.org
 0000-00 01-135

Operation 1.
A. When driver door locked/unlocked
- BCM sends driver door LOCK/UNLOCK status signal
(BCM→BCAN→CGW, PTGM, SKM
B. When passenger door locked/unlocked
- BCM sends passenger door LOCK/UNLOCK status signal
(BCM→BCAN→CGW, PTGM
C. When rear door locked/unlocked
- BCM sends passenger door LOCK/UNLOCK status signal
(BCM→BCAN→CGW, PTGM

System Flowchart

GETtheMANUALS.org
01-136

1) LOCK/UNLOCK Control (Door Knob Switch)

Operation 1. (Door LOCK)
A. The driver and passenger door LOCK knob switches are set to LOCK from UNLOCK.
B. Door LOCK relay output is activated for 0.2 sec. (T1)

Door anti-LOCK operation

If any door is unlocked or open after the door LOCK relay output, the UNLOCK relay is activated for
0.2 sec.

Operation 2. (Door unlock)

C. The driver and passenger door LOCK knob switches are set to UNLOCK from LOCK.
D. Door UNLOCK relay output is activated for 0.2 sec. (T1)

Operation 3. (Door LOCK malfunction prevention function)

E. Driver/passenger doors open → within 1.0 sec (T2) after closed
F. Door LOCK signal input
G. The UNLOCK signal for all doors is output once for 0.2 seconds (T1).
(Door LOCK operation is not performed)

All doors always turn the unlock relay on if the battery has been removed and reconnected for the
first time.
However, the unlock relay output is not triggered at theft deterrent mode.

GETtheMANUALS.org
 0000-00 01-137

GETtheMANUALS.org
01-138

2) LOCK/UNLOCK Control (Center Door LOCK/UNLOCK Switch)

The center door LOCK switch is operated only when the theft deterrent is disarmed.

Operation 1. (Center door LOCK/UNLOCK)

A. Driver door unlocked (locked)
B. Center door LOCK switch pressed
C. Door LOCK (UNLOCK) relay activated for 0.2 sec. (T1)

Center door anti-LOCK operation

If any door is unlocked or open after the door LOCK relay output, the UNLOCK relay is activated for
0.2 sec.

GETtheMANUALS.org
 0000-00 01-139

3) LOCK/UNLOCK Control By REKES Key (Without SKM)

- For the vehicles without SKM, LOCK / UNLOCK control is performed by the REKES key with the
ignition key removed.
- The exterior buzzer operated depending on the vehicle LOCK/UNLOCK is set under the User
Settings menu in the instrument cluster.

Operation 1. (Door LOCK)

A. REKES key LOCK signal input
B. BCM triggers all door LOCK relays for 0.2 sec
C. All doors including hood and tailgate closed and all doors locked
D. Turn signal lamp flashes twice at intervals of 0.5 sec ON and 0.5 sec OFF and exterior buzzer sounds
once for 0.01 sec
E. System enters theft deterrent mode

Door anti-LOCK operation

If any door is unlocked or open after the door LOCK relay output, the UNLOCK relay is activated for
0.2 sec.

Door anti-lock fail operation

After operation is repeated 5 times in a minute and the door is locked, anti-lock will be inhibited due
to the faulty door LOCK switch and door open switch.

Door anti-lock fail release

If the following conditions are met after anti-lock fail is activated, anti-lock fail will be released:
1) All doors locked with all doors closed
2) IGN ON → OFF or IGN OFF → ON

Operation 2. (door UNLOCK) (safety UNLOCK not set)

- Theft deterrent mode

A. REKES key UNLOCK signal received

B. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
C. Turn signal light ON once for 1.0 sec and vehicle disarmed

GETtheMANUALS.org
01-140

Operation 3. (door UNLOCK) (safety UNLOCK set)

- Theft deterrent mode
- Safety UNLOCK is set in the instrument cluster.

A. REKES key UNLOCK signal received

B. BCM triggers driver door UNLOCK relay only for 0.2 sec
C. Turn signal light ON once for 1.0 sec and vehicle disarmed
D. REKES key UNLOCK signal input with driver door unlocked
E. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
F. Turn signal light ON once for 1.0 sec and vehicle disarmed

4) Lock/Unlock Control By Smart Key & Door Handle Switch

(With SKM)
- For vehicles with SKM, LOCK/UNLOCK control is made by the smart key or door handle switch with
IGN OFF.
- The exterior buzzer operated depending on the vehicle LOCK/UNLOCK is set under the User
Settings menu in the instrument cluster.

System Flowchart

GETtheMANUALS.org
 0000-00 01-141

Operation 1. (Door LOCK)

With all doors including hood and tailgate closed,

A. when BCM receives the following signals from SKM

Condition 1. "Smart key LOCK" signal received from SKM
Condition 2. "Smart key auto LOCK" signal received from SKM
(only when "Smart door AUTO LOCK" function is enabled in instrument cluster)
Condition 3. "Door outside handle switch operation" signal received from SKM

Door outside handle "Unlock with key in 2 stages" under User settings menu
switch Enabled Disabled
When pressed 4 sec. after driver When pressed with driver door
Driver door
door is unlocked* unlocked
When pressed with driver door When pressed with all doors
Other than driver door
unlocked unlocked

* When the switch is pressed within 4 seconds after the driver door is unlocked, the signal for all
doors UNLOCK is sent out. Therefore, the door handle switch should be pressed after 4
seconds have passed with "Unlock with key in 2 stages" function enabled.

B. BCM triggers all door LOCK relays for 0.2 sec

C. All doors including hood and tailgate closed and all door lock switches in LOCK position
D. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
E. System enters theft deterrent mode

GETtheMANUALS.org
01-142

System Flowchart

GETtheMANUALS.org
 0000-00 01-143

Door anti-LOCK operation

If any door is unlocked or open after the door LOCK relay output, the UNLOCK relay is activated for
0.2 sec.

Door anti-lock fail operation

After operation is repeated 5 times in a minute and the door is locked, anti-lock will be inhibited due
to the faulty door LOCK switch and door open switch.

Door anti-lock fail release

If the following conditions are met after anti-lock fail is activated, anti-lock fail will be released:
1) All doors locked with all doors closed
2) IGN ON → OFF or IGN OFF → ON

GETtheMANUALS.org
01-144

Operation 2. (Door unlock)

- Safety UNLOCK disabled
(Safety UNLOCK is set under User Settings in the instrument cluster.)
- Theft deterrent mode
A. The BCM receives the following signals:
Condition 1. "Smart key UNLOCK" signal received from SKM
Condition 2. "Door outside handle switch operation" signal received from SKM
B. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
C. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
D. Theft deterrent disarmed

System Flowchart

GETtheMANUALS.org
 0000-00 01-145

Operation 3. (Door unlock)

- Safety Unlock Set
(Safety UNLOCK is set under User Settings in the instrument cluster.)
- Theft deterrent mode

A. The BCM receives the following signals:

Condition 1. "Smart key UNLOCK" signal received from SKM
Condition 2. "Driver door outside handle switch operation" signal received from SKM
B. BCM triggers driver door UNLOCK relay only for 0.2 sec.
(Driver door only unlocked)
C. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice and then
vehicle disarmed

Operation 4. (Door unlock)

A. At status of Operation 3, (driver door only unlocked)
B. "Driver door outside handle switch operation" signal re-received from SKM within 4 sec
C. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
D. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)

Operation 5. (Door unlock)

A. At status of Operation 3, (driver door only unlocked)
B. "Smart key UNLOCK" signal re-received from SKM
C. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
D. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)

GETtheMANUALS.org
01-146

System Flowchart

GETtheMANUALS.org
 0000-00 01-147

Operation 6.
A. "Driver door handle switch ON" signal received from SKM 4 sec
B. after operation 3 (only driver door unlocked)
C. The BCM activates door LOCK relay for all doors for 0.2 sec.
D. All doors including hood and tailgate closed and all door lock switches in LOCK position
E. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
F. System enters armed mode

Operation 7.
A. "Driver door handle switch ON" signal received from SKM 4 sec
B. after operation 3 (driver door became locked)
C. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
D. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→BSD, IP)
E. Theft deterrent disarmed

GETtheMANUALS.org
01-148

5) AUTO Door LOCK Control by Vehicle Speed

Operation 1.
A. When any of doors unlocked with IGN ON
B. SKM sends vehicle speed signal to BCM via CGW
(Instrument cluster→CCAN→CGW→PCAN→BCM)
C. If "Vehicle speed >= set speed" condition remains for more than 1 second
D. BCM outputs all door lock signal for 0.2 seconds.

The AUTO door LOCK operation is not activated when all doors are already locked.

System Flowchart

Door lock fails

- If any door is not locked after door UNLOCK motor output, the BCM activates the door LOCK
output again up to 5 times at 1 sec. intervals.
- If a door is still unlocked after the 5 attempts of LOCK output, the door is regarded as
malfunctioning.
- The faulty door will be reset when the troubleshooted door status is changed from unlocked to
locked.
- If there is a faulty door, the AUTO door LOCK function is not available. If a malfunction occurs
when the vehicle is driven at the speed higher than the set value, the AUTO door LOCK will not
be activated even when the vehicle speed goes below the set speed and then increases to the
speed higher than the set speed.
- If there is another door unlocked within the 5 times of LOCK output, the BCK activates another 5
attempts of LOCK output for that door.
- The faulty door will be reset when the ignition is turned OFF.

GETtheMANUALS.org
 0000-00 01-149

6) AUTO Door LOCK Control with Shift Lever in Other Than P

Operation 1.
A. In the event of engine idling abnormality and any of doors unlocked
- ECU sends "Engine running status" signal to BCM
(ECU→PCAN→BCM)
B. Shift lever in position other than P or shifted from P to R
- TCU sends "Shift lever position" signal to BCM
(TCU→PCAN→BCM)
C. BCM outputs all door lock signal for 0.2 seconds.

System Flowchart

- The AUTO door LOCK is not activated when there is no shift lever signal.
- The AUTO door LOCK operation is not activated when all doors are already locked.
- If any of doors (including hood and tailgate) is open before auto door lock operation, lock operation
is not performed.
- If a door is unlocked by door knob switch and center door LOCK/UNLOCK switch operation after
AUTO door LOCK operation, the AUTO door LOCK signal output is not activated again.

GETtheMANUALS.org
01-150

7) AUTO UNLOCK Control by Impact Signal

Operation 1.
A. Any impact signal is ignored for the first 7 sec. after IGN ON.

Operation 2.
A. An impact signal is received.
- ACU sends impact signal to BCM
(ACU→PCAN→BCM)
B. The BCM activates the all doors UNLOCK relay for 5 sec. The relay remains activated for full 5 sec.
even if the ignition is turned OFF before the time ends.
C. The door LOCK signal is ignored during the all doors UNLOCK relay activation by impact signal.
D. The room lamp is illuminated (front, center) and the room lamp cut-off is not available.
The room lamp is turned ON when the rear room lamp switch is turned ON.
E. The LH (RH) turn signal lamp flashes 75 times per minute at 0.4 sec. intervals (ON/OFF).

Impact signal reset conditions

- Clear the DTC and disconnect the battery (BCM main power off).
- The air bag is deployed when either the hardware impact signal or CAN (ACU) impact signal is
received.

GETtheMANUALS.org
 0000-00 01-151

8) AUTO Door UNLOCK Control With IGN OFF

Operation 1.
A. Any door is locked with IGN OFF.
B. The UNLOCK signal for all doors is output for 0.2 seconds.

System Flowchart

GETtheMANUALS.org
01-152

9) AUTO Door UNLOCK Control Based On Shift Lever In "P" Position

Operation 1.
A. In the event of engine idling abnormality and any of doors locked
- ECU sends "Engine running status" signal to BCM
(ECU→PCAN→BCM)
B. Shift lever moved to "P" position
- TCU sends "Shift lever position" signal to BCM
(TCU→PCAN→BCM)
C. The UNLOCK signal for all doors is output for 0.2 seconds.

System Flowchart

- It does not work if all the doors are unlocked before auto unlock operation.
- If any of doors (including hood and tailgate) is locked before auto unlock operation, it performs
unlock control.

GETtheMANUALS.org
 0000-00 01-153

10) Door LOCK/UNLOCK Control By Mobile Application

(For Connected Car) (DOM Only)
- For vehicle with SKM, LOCK/UNLOCK control is made by the mobile application signal with IGN
OFF.

Operation 1. (Door LOCK)

A. LOCK signal input by mobile application
- CCU sends door lock signal to BCM via CGW
(CCU→ICAN→CGW→BCAN→BCM)
B. The BCM activates door LOCK relay for all doors for 0.2 sec.
C. All doors including hood and tailgate are closed and all doors are locked.
D. Turn signal lamp flashes twice at cycles of 0.5 sec ON and 0.5 sec OFF and exterior buzzer (SKM
buzzer) sounds once for 0.05 sec
(BCM→BCAN→PTGM, SKM)
(BCM→BCAN→CGW→CCAN→ BSD, IP)
E. System enters armed mode
- BCM sends theft deterrent mode ON signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→ CCU)

System Flowchart

GETtheMANUALS.org
01-154

Anti-lock operation
A. LOCK signal input by mobile application
B. If vehicle has following conditions:
- Any of doors open
- Faulty door LOCK switch
- IGN ON
C. BCM sends door lock fail signal.
- BCM sends door lock fail signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→CCU)

GETtheMANUALS.org
 0000-00 01-155

Operation 3. (Door unlock)

- Safety Unlock Not Set
- Theft deterrent mode
A. UNLOCK signal input by mobile application
- CCU sends door UNLOCK signal to BCM via CGW
(CCU→ICAN→CGW→BCAN→BCM)
B. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
C. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
D. Theft deterrent disarmed
- BCM sends theft deterrent mode deactivation signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→CCU)

System Flowchart

Anti-unlock operation
A. UNLOCK signal input by mobile application
B. If vehicle has following conditions:
- Faulty door UNLOCK switch
- IGN ON
C. BCM sends door lock fail signal.
- BCM sends door lock fail signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→CCU)

GETtheMANUALS.org
01-156

Operation 4. (Door unlock)

- Safety Unlock Set
- Theft deterrent mode

A. UNLOCK signal input by mobile application

- CCU sends door UNLOCK signal to BCM via CGW
(CCU→ICAN→CGW→BCAN→BCM)
B. BCM activates door unlock relay only for driver door for 0.2 sec.
C. Turn signal lamp flashes once for 1.0 sec and exterior buzzer (SKM buzzer) sounds twice
D. Theft deterrent disarmed
- BCM sends theft deterrent mode deactivation signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→CCU)

Operation 5. (Door unlock)

A. At status of Operation 3, (driver door only unlocked)
(driver door only unlocked)
B. UNLOCK signal re-received by mobile application
- CCU sends door UNLOCK signal to BCM via CGW
(CCU→ICAN→CGW→BCAN→BCM)
C. The BCM activates door UNLOCK relay for all doors for 0.2 sec.
D. Theft deterrent disarmed
- BCM sends theft deterrent mode deactivation signal to CCU via CGW
(BCM→BCAN→CGW→ICAN→CCU)

GETtheMANUALS.org
 0000-00 01-157

System Flowchart

GETtheMANUALS.org
01-158

36. TPMS
1) TPMS Pressure Value Display
The wheel sensor sends the signal as RF to the BCM as soon as the vehicle starts. When the vehicle
stops, it does not send any message. The tire pressure can't be checked right after the ignition is turned
from off to on. The tire pressure will be displayed on the instrument cluster after the vehicle has been
driven for 1 minute at 20 km/h or higher.

System Flowchart

Under normal circumstances, it transmits the tire pressure value and temperature value together with
its ID (Identification) once every about 30 seconds to reduce the load on the wheel module's battery.
However, in the event of emergency or situation (ex: tire inflation pressure changes 2.9 psi per
minute) in which should give a warning to the driver, it transmits the data once every about 1 second.

▶ The tire pressure is displayed through the following sequence. The procedures shown below
are processed at the same time.

Auto learn is completed when the IDs of wheel modules are identified
Wheel module detection by checking the IDs of sensors installed to the wheels. (4 IDs
(Auto Learn & received) (Auto Learn)
The position of each sensor is determined by the strength of RF signal
Auto location)
(front/rear) and direction of the acceleration sensor (front/rear). (Auto
Location)

GETtheMANUALS.org
 0000-00 01-159

37. HEADLAMP CONTROL

▶ Circuit diagram for headlamp operation

GETtheMANUALS.org
01-160

1) Headlamp Low Beam Control

A. The BCM supplies power to headlamp low beam (+).
B. The BCM outputs the operation signal when the headlamp low beam relay is energized.
- BCM sends low beam relay ON signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)
- BCM sends low beam relay ON signal to ESC and HVAC
(BCM→PCAN→ESC, HVAC)
C. Whether or not the headlamp low beam relay is energized is determined as follows:
1) Headlamp low beam ON signal input by auto light sensor
2) Headlamp feedback switch ON signal input
3) Headlamp feedback switch ON signal input with auto light OFF

The BCM outputs the operation signal to display the toast pop-up when the headlamp feedback
switch ON signal is received with auto light turned off.
(BCM→BCAN→CGW→CCAN→IP)

GETtheMANUALS.org
 0000-00 01-161

2) Headlamp High Beam Control (High Beam ON)

A. Headlamp low beam ON
B. Multifunction high beam switch signal input
C. High beam ON control (low beam stays ON (+) high beam control)
- BCM sends high beam relay ON signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)

3) Headlamp High Beam Control (High Beam OFF)

A. High beam ON
B. Multifunction passing switch turned on and off
C. High beam OFF control (low beam stays ON)
- BCM sends high beam relay signal to FCM via CGW
(BCM→BCAN→CGW→CCAN→FCM)

For vehicles with FCM, turning ON the high beam with headlamp switch in AUTO light position
activates the HBA system, and HBA system controls the headlamps (high beam, low beam).

GETtheMANUALS.org
01-162

4) Coming-Home Light Control

▶ Conditions for coming-home light ON

Operation 1.
A. Low beam ON
- Low beam switch on multifunction lever is ON (feedback signal input)
- Headlamp ON signal input from AUTO light and rain sensor
B. IGN ON → OFF
C. Low beam stays ON for set time

▶ Conditions for coming-home light OFF

Operation 1.
A. The low beam is turned off when all doors including tailgate are closed and the time set for coming-
home light under User settings menu has elapsed.

Operation 2.
B. Any doors including tailgate are opened and then closed during the time set for coming-home light
after IGN OFF.
C. The low beam is turned off after the time set for coming-home light has elapsed from the time point
where all doors are closed.

Operation 3.
D. The low beam is turned off 3 minutes after the open status of any doors including tailgate is changed
during the time set for coming-home light after IGN OFF.

Operation 4.
E. The low beam is turned OFF immediately when the light switch on the multifunction lever is set to
OFF position.
F. Immediately OFF when IGN ON

Operation 5.
E. Low beam OFF as soon as smart (REKES) key LOCK signal re-received after entering theft deterrent
mode

GETtheMANUALS.org
 0000-00 01-163

5) Leaving-Home Light Control

The coming-home light ON time is set under User settings of instrument cluster.

- User settings > Light > Leaving-home > Disable, 10 sec., 20 sec., 30 sec.

▶ Conditions for leaving-home light ON

Operation 1.
A. In theft deterrent mode,
B. Without SKM: UNLOCK signal received from REKES key
With SKM: UNLOCK signal received from SKM
C. Low beam stays ON for set time

▶ Conditions for leaving-home light OFF

Operation 1.
A. The leaving-home light set timer is timed-out.
B. LOCK signal received from smart (REKES) key
C. The theft deterrent is arming during leaving-home operation.
D. IGN ON (ignition key inserted) during leaving-home operation

GETtheMANUALS.org
01-164

38. TAILGATE CONTROL (WITHOUT SKM)

▶ Circuit diagram for tailgate operation

GETtheMANUALS.org
 0000-00 01-165

1) Basic Operating Conditions

- IGN OFF or ACC ON
- Vehicle speed of 3km/h or less with IGN ON

2) Tailgate Control
- For vehicles without power tailgate

Operation 1.
A. Following signals received
- Tailgate OPEN button on REKES key pressed
- Tailgate outside handle switch ON with driver door unlocked
B. The BCM controls tailgate open relay through hard wire.

System Flowchart

GETtheMANUALS.org
01-166

39. TAILAGATE CONTROL (WITH SKM)

▶ Circuit diagram for tailgate operation

GETtheMANUALS.org
 0000-00 01-167

1) Basic Operating Conditions

- IGN OFF or ACC ON
- Vehicle speed of 3km/h or less with IGN ON

2) Tailgate Control (Without Power Tailgate)

- For vehicles without power tailgate

Operation 1.
A. Tailgate OPEN button on smart key pressed
B. SKM sends tailgate ajar (relay control) signal
(SKM→BCAN→BCM)
C. The BCM controls tailgate open relay through hard wire.

System Flowchart

GETtheMANUALS.org
01-168

Operation 2.
A. Tailgate outside handle switch ON with all doors unlocked
B. The BCM controls tailgate open relay through hard wire.

System Flowchart

Operation 3.
A. Tailgate outside handle switch ON with all doors locked
BCM sends smart key authentication request signal to SKM through B-CAN
SKM sends tailgate open signal when valid smart key authenticated
B. For vehicles without power tailgate: SKM→BCAN→BCM
C. SKM sends tailgate ajar signal when valid smart key authenticated
(SKM→BCAN→BCM)
D. The BCM controls tailgate open relay through hard wire.

System Flowchart

GETtheMANUALS.org
 0000-00 01-169

40. OUTSIDE MIRROR FOLDING/UNFOLDING

▶ Circuit configurations for outside mirror folding/unfolding operation

GETtheMANUALS.org
01-170

1) By Switch Operation
Operation 1.
A. When the folding switch is pressed, the folding output is activated for a period of T1.

Operation 2.
B. When the unfolding switch is pressed, the unfolding output is activated for a period of T1.

Operation 3.
C. When unfolding (folding) signal is received during folding (unfolding) output.
D. The folding (unfolding) output is deactivated and the unfolding (folding) output is activated after 0.1
sec.

GETtheMANUALS.org
 0000-00 01-171

2) Auto Folding / Unfolding (Without SKM)

When the outside rearview mirror switch is in folding or unfolding position, AUTO folding/unfolding is
disabled. The AUTO folding/unfolding control works only when the switch is in the neutral position.

Operation 1. (AUTO folding)

A. REKES key LOCK signal is received.
B. The theft deterrent is armed after door LOCK operation.
C. The outside rearview mirror folding output is active for 16 sec.

If the unfolding signal or REKES key UNLOCK signal is received during AUTO folding operation, the
AUTO unfolding output is implemented after 0.1 sec

Operation 2. (AUTO unfolding)

A. REKES key UNLOCK signal is received.
B. The theft deterrent is disarmed after door UNLOCK operation.
C. The outside rearview mirror unfolding output is active for 16 sec.

If the folding signal or REKES key LOCK signal is received during AUTO unfolding operation, the
AUTO folding output is implemented after 0.1 sec

System Flowchart

GETtheMANUALS.org
01-172

3) Auto Folding / Unfolding (With SKM)

When the outside rearview mirror switch is in folding or unfolding position, AUTO folding/unfolding is
disabled. The AUTO folding/unfolding control works only when the switch is in the neutral position.

Operation 1. (AUTO folding)

A. The smart key LOCK signal, LOCK signal by door outside handle switch, and smart door AUTO
LOCK signal are received.
B. The theft deterrent is armed after door LOCK operation.
C. The outside rearview mirror folding output is active for 16 sec.

- When the outside rearview mirror is unfolded by the AUTO approach operation and the vehicle
status does not change for 30 sec., the AUTO folding output is activated for 16 sec. after AUTO
approach operation is turned OFF.
- If the unfolding switch signal or smart key UNLOCK signal is received during AUTO folding
operation, the AUTO unfolding output is activated for 16 sec. after 0.1sec.

GETtheMANUALS.org
 0000-00 01-173

Operation 2. (AUTO unfolding)

A. The smart key UNLOCK signal, UNLOCK signal by door outside handle switch, and AUTO approach
operation signal are received.
B. The theft deterrent is disarmed after door UNLOCK operation.
C. The outside rearview mirror unfolding output is active for 16 sec.

- If the folding switch signal or smart key LOCK signal is received during AUTO unfolding operation,
the AUTO folding output is activated for 16 sec. after 0.1sec.
- When the outside rearview mirror is unfolded by the theft deterrent disarmed mode and the vehicle
status does not change for 30 sec., the AUTO folding output is not activated after the theft deterrent
is armed again.

System Flowchart

GETtheMANUALS.org
01-174

41. KEY HOLE ILLUMINATION CONTROL (WITHOUT SKM)

▶ Circuit configurations for key hole illumination control operation

GETtheMANUALS.org
 0000-00 01-175

Operation 1.
A. A door is opened with IGN OFF.
B. The key hole lamp comes on.
C. The key hole lamp comes on for 10 seconds (T1) when the door is closed.

Operation 2.
D. The ignition is turned ON with the key hole lamp ON.
E. The key hole lamp goes out.

- Key hole illumination OFF when REKES key LOCK signal received
(enters theft deterrent mode)
- When the key hole lamp and immobilizer signals are received simultaneously, the immobilizer
signal overrides the key hole lamp signal.
- When the immobilizer confirmation is failed, regardless of the key hole lamp operation condition, it
flashes for 11 seconds at intervals of 0.5 sec. ON/0.5 sec. OFF.
- When the ignition is turned ON in virgin status, the key hole lamp flashes for 8 seconds at intervals
of 0.5 sec. ON/0.5 sec. OFF.

GETtheMANUALS.org
01-176

42. STEERING WHEEL HEATER CONTROL

▶ Circuit configurations for steering wheel heating control operation

GETtheMANUALS.org
 0000-00 01-177

The steering wheel heater is active only when the engine is running.

Operation 1. (Steering wheel heater ON control)

A. The steering wheel heater is turned from OFF to ON with engine running.
B. The BCM activates the steering wheel heater.
C. The BCM sends the steering wheel heater ON signal to IP via CGW when the heater is operated.
(BCM→BCAN→CGW→CCAN→IP)

- If the ignition is cycled from ON with steering wheel heater ON to OFF to ON (engine running), the
steering wheel heater returns to the previous status (ON) and the steering wheel heater signal is
sent to the instrument cluster.
- The maximum temperature of the steering wheel is 35 ± 4°C at room temperature (22 ± 1°C)

Operation 2. (Steering wheel heater OFF control)

The steering wheel heater is turned OFF when the following signals are received.

A. The steering wheel heater switch operation signal input during steering wheel heater ON
B. Engine stops
C. The BCM sends the steering wheel heater OFF signal to IP via CGW when the heater is deactivated.
(BCM→BCAN→CGW→CCAN→IP)

- When there is a fault due to open circuit/short circuit, the steering wheel heater indicator flashes at
0.5 sec. intervals (ON/OFF).
- When there is a fault due to reasons other than overvoltage, the system returns to normal state only
by the steering wheel heater switch.

System Flowchart

GETtheMANUALS.org
01-178

Operation 3. (Faulty steering wheel NTC sensor)

When the following failures occur, the heater indicator flashes at 0.5 sec. intervals (ON/OFF).

A. Steering wheel heater output less than 0.25V for more than 3 minutes due to open-circuit of NTC
temperature sensor
B. Steering wheel heater output less than 4.6V for more than 1 sec due to short-circuit of NTC
temperature sensor

Operation 4. (Steering wheel failure mode)

A. Heating open-circuit, overcurrent (12.4A or higher for more than 0.1 sec), operation terminated
immediately in the event of BCM internal driver IC (indicator operates at intervals of 0.5 sec ON and
0.5 sec OFF)
B. Operation terminated immediately when undervoltage (less than 7.5 ± 0.5 V) detected during
heater operation (indicator off)
C. Operation terminated immediately when overvoltage (17 ± 0.5 V or higher) detected for more
than 1 sec. during heater operation (indicator flashes at interval of 0.5 sec.)
D. Operated normally when IGN 2 voltage is 7.5 ± 0.5 V or higher after undervoltage due to
cranking detected
E. Operated normally when normal voltage detected after overvoltage detected

Internal circuit schematic diagram

GETtheMANUALS.org
 0000-00 01-179

Characteristics of NTC sensor

GETtheMANUALS.org
01-180

43. CIRCUIT DIAGRAM

▶ B/ALARM HORN RELAY, O/S MIRROR FOLDING/UNFOLDING RELAY

GETtheMANUALS.org
 0000-00 01-181

GETtheMANUALS.org
01-182

▶ DRIVER DR UNLOCK RELAY, DR LOCK/UNLOCK RELAY, TAILGATE OPEN RELAY

GETtheMANUALS.org
 0000-00 01-183

GETtheMANUALS.org
01-184

▶ POWER WINDOW RELAY, DEFOGGER RELAY

GETtheMANUALS.org
 0000-00 01-185

GETtheMANUALS.org
01-186

▶ FRT WIPER(HI)/(LO) RELAY, FRT WASHER RELAY, RR WASHER RELAY, RR WIPER RELAY

GETtheMANUALS.org
 0000-00 01-187

GETtheMANUALS.org
01-188

▶ H/LAMP RELAY, H/LAMP(W/ VSM), A/LIGHT & RAIN SENSOR, M/FUNCTION SW

GETtheMANUALS.org
 0000-00 01-189

GETtheMANUALS.org
01-190

▶ TAIL LAMP RELAY, FRT FOG LAMP RELAY, RR FOG LAMP RELAY

GETtheMANUALS.org
 0000-00 01-191

GETtheMANUALS.org
01-192

▶ ROOM LAMP, MAP LAMP, STOP LAMP SW, A/BAG UNIT, S/BUCKLE

GETtheMANUALS.org
 0000-00 01-193

GETtheMANUALS.org
01-194

▶ LOWER MAIN SW, PAS SENSOR

GETtheMANUALS.org
 0000-00 01-195

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
▶ SKM (Smart Key Module)

Category Item Specifications

SKM unit Rated voltage 12.0V
(Electrical properties)
Operating voltage Unit: 9 to 16 V
CAN: 7 to 18 V
LIN: 9 to 16 V
Operating temperature -30˚C to +80˚C

Max. operating 95%

humidity
Dark current 5mA or less
Voltage drop 1.0 V or less (ground terminal and all input/output
terminals)
SKM unit Receive frequency 5 ± 0.5 mA or less
(Wireless properties)
Reception range About 30 m (without obstacles)

▶ Emergency antenna (built-in in START button)

Category Item Specifications

Emergency antenna Rated voltage 12.0V
Operating current 1.2 A (at 13.5 V)
Operating temperature -30°C to +85°C

Coil inductance 440 uH ± 20 uH

Modulation type FSK
(Frequency Shift Keying)
Transmit/receive 125kHz ± 2.5kHz
frequency

GETtheMANUALS.org
02-4

▶ Smart key

Category Item Specifications

Operating voltage 3.0V
Smart key
Operating temperature -10˚C ~ +60˚C
(Electric)
Battery type CR2032

- RF(Radio Frequency) LF(Low Frequency)

transmission reception
Smart key Transmit/receive 433.92MHz ± 125kHz ± 2.5kHz
(wireless) frequency 0.0125MHz

Modulation type FSK

(Frequency Shift Keying)

* Smart key registration: up to 3

▶ LF (Low Frequency) antenna

Category Item Specifications

Operating frequency 125KHz
Smart key antenna
Current consumption Max. 1.2A
Operating temperature -30˚C ~ +80˚C
Operating voltage 5.0V
Door outside
Rated current 5 ~ 20mA
handle switch
Operating temperature -30˚C ~ +80˚C

▶ Exterior buzzer (SKM buzzer)

Category Item Specifications

Operating voltage 7.5V ~ 14.5V
Exterior buzzer
Operating temperature -30˚C ~ 80˚C
(SKM buzzer)
Sound level 83 dB

GETtheMANUALS.org
 0000-00 02-5

2. SMART KEY FEATURES BASED ON MODEL

Item With smart key
Indoor 2
LF antenna
Outdoor 3
Front door entry YES
Passive control Passive start YES
Tailgate YES
Lock YES
Smart key control Unlock YES
Panic YES
AUTO Approach lamp(w/ power outside mirror) YES
AUTO closing function YES
Key not detected inside vehicle YES
Smart key reminder YES
Gear in P position YES
Gear position YES
Warning related control Operation of brake pedal YES
Smart key authentication failure YES
Transponder authentication YES
Faulty SKM system YES
Smart key battery low YES

GETtheMANUALS.org
02-6

1. OVERVIEW
The SKM (Smart Key Module) system improves the driver's experience and only applies to the vehicles
equipped with smart key. This SKM unit communicates with various units through CAN communication
and hardwire communication to control the vehicle.

2. COMPONENTS
START/STOP switch and emergency antenna

START/STOP Emergency
SWITCH antenna

Smart key Exterior buzzer

(SKM buzzer)

SKM BCM

Smart key indicator/warning lamp

GETtheMANUALS.org
 0000-00 02-7

Interior (front) antenna

Interior (rear) antenna

Exterior (rear) antenna

Front door handle switch and antenna

GETtheMANUALS.org
02-8

3. EPC
▶ 8712 PASE system

1. TRANSMITTER ASSY-SMART KEY 9. ANTENNA-SMART KEY RR OTR

2. PCB PACKAGE ASSY-SMART KEY 10.EMERGENCY ANTENNA-SMART KEY
3. CASE ASSY-TRANSMITTER 14.BUZZER ASSY
4. UNIT ASSY-SMART KEY 15.ESCL ASSY
5. ANTENNA-SMART KEY FRT OTR 16.CLAMP ASSY
6. ANTENNA-SMART KEY 17.BOLT-CLAMP MTG
7. ANTENNA-SMART KEY CTR 18.SCREW
8. ANTENNA-SMART KEY 19.NUT
20.WIRING ASSY-SMART KEY

GETtheMANUALS.org
 0000-00 02-9

1. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
02-10

GETtheMANUALS.org
 0000-00 02-11

▶ Full names of acronyms and option description

GETtheMANUALS.org
02-12

2. P-CAN INPUTS AND OUTPUTS

▶ ABS & ESP

▶ ACU

▶ BCM

▶ CGW

GETtheMANUALS.org
 0000-00 02-13

▶ ECU

▶ HVAC

▶ TCU

GETtheMANUALS.org
02-14

3. B-CAN COMMUNICATION I/O ELEMENTS

▶ BCM

GETtheMANUALS.org
 0000-00 02-15

▶ CGW

GETtheMANUALS.org
02-16

4. PASSIVE ENTRY MANAGEMENT

- In the theft deterrent mode, the vehicle will be disarmed and door lock/unlock controlled after smart key
authorization (search) procedure according to the passive entry (front door handle switch status) signal
input.
- The smart key can be registered up to 3.

- The smart key search is performed as follows according to the vehicle status in order of registered
smart keys.
* Theft deterrent is armed: searching for silent smart key after searching the outside vehicle
* Theft deterrent mode is disarmed: outside searching after inside searching

1) Passive Function
(1) Passive entry actuation area
- The passive entry actuation area refers to the area where passive LOCK/UNLOCK can be
performed by pressing the switch on the door handle with a smart key carried by the driver.
- The passive tailgate open actuation area refers to the area where the tailgate can be opened by
pressing the tailgate switch with a smart key carried by the driver.

LF transmission: Authentication request signal

RF transmission: Response signal

- Passive entry function actuation area: Within 1m from the door handle antenna
- Passive tailgate open actuation area: Within 1m from the center of the bumper

GETtheMANUALS.org
 0000-00 02-17

(2) Passive start actuation area

Starting the engine by pressing the START/STOP switch with the shift lever in P or N position and the
brake pedal depressed (START/STOP switch READY: green) after the driver has entered the vehicle
carrying a smart key.

Interior(front) antenna Interior(rear) antenna

- The smart key authentication many not possible in an area where the communication is poor,
such as the seat cushion that the seat heated wire is operated, around the pedals and the
on the floor.
- The smart key system malfunctions may occur when generating radio waves around the smart key
or vehicle, or attaching an electronic device which generates radio waves on the smart key or
vehicle.

GETtheMANUALS.org
02-18

(3) Passive LOCK

The passive LOCK (door LOCK) is activated by the door handle switch with a valid smart key present
within the passive entry actuation area.

GETtheMANUALS.org
 0000-00 02-19

▶ Passive LOCK and authentication by door handle switch

1. Power OFF
2. Vehicle conditions that can enter passive lock are as follows:
- All doors closed (excluding hood and tailgate)
- Driver's door unlocked
- Theft deterrent system disarmed
3. Driver / passenger door handle switch pressed briefly
4. The SKM verifies if a smart key is outside the vehicle using the door handle antenna
(LF authentication).
(SKM searches for the last smart key used first, inside searching after outside searching)
5. The authentication signal (RF authentication) from the smart key is sent to the REKES antenna
of the SKM.
6. If authenticated smart key found outside vehicle
- SKM sends vehicle control request to BCM (passive lock)
7. The BCM controls the passive lock and then enters the theft deterrent mode or stays in standby
depending on the vehicle condition.
- Enters theft deterrent mode (all doors including hood and tailgate locked)
(hazard warning lamp flashes twice and buzzer sounds once)
- Theft deterrent system in standby (doors locked (hood and tailgate open)

- If no valid smart key is detected outside the vehicle, the passive LOCK process is stopped and
restarted when the next signal is received from the door handle switch. (if a valid smart key detected
in vehicle, "Smart Key Detected In Vehicle" warning issued)
- If any door is open, the passive lock by the door handle switch will not work.
- When passive lock signal is input, the inside of the vehicle is searched twice and then the outside of
the vehicle once for the presence of the smart key.
However, if the smart key is not detected when searching outside the vehicle, searching outside is
performed additionally.

GETtheMANUALS.org
02-20

(4) Passive UNLOCK

The passive UNLOCK (door UNLOCK) is activated by the door handle switch with a valid smart key
present within the passive entry actuation area.

GETtheMANUALS.org
 0000-00 02-21

▶ Passive UNLOCK and authentication by door handle switch

1. Vehicle conditions that can enter passive unlock are as follows:
- All doors closed (including hood and tailgate)
- Driver's door locked
- Theft deterrent system armed
2. Driver / passenger door handle switch pressed briefly
3. The SKM verifies if a smart key is outside the vehicle using the door handle antenna
(LF authentication).
The SKM searches for the last smart key used first.
4. The authentication signal (RF authentication) from the smart key is sent to the REKES antenna
of the SKM.
5. If a valid smart key is found outside the vehicle, the SKM sends request for vehicle control to the BCM
(passive unlock).
6. The BCM controls the passive UNLOCK.
If the theft deterrent is disarmed, the hazard warning lamp flashes once and chime sounds twice.

- If no smart key is identified as being outside the vehicle, the passive UNLOCK process is stopped
and restarted when the next signal is received from the door handle switch.
- If "Press key twice to unlock" is set on the instrument cluster, the BCM unlocks the door in 2 stages.

GETtheMANUALS.org
02-22

(5) Passive tailgate open

- The tailgate open control is activated by the tailgate external switch with a valid smart key present
within the passive entry actuation area.
- When you open the tailgate, with the theft deterrent system in standby mode, put a valid smart key in
the vehicle and close the tailgate, the SMART KEY DETECTED IN VEHICLE warning is issued.

▶ Passive tailgate (closed → open) operation and authentication

1. The tailgate external switch operation signal (open) is received.

2. The BCM sends the valid smart key authentication request signal to the SKM.
3. The SKM verifies if a smart key is outside the vehicle using the rear bumper antenna (LF
authentication) (The SKM searches the last smart key used first).
4. The authentication signal (RF authentication) from the smart key is sent to the REKES antenna
of the SKM.
5. If a valid smart key is found outside the vehicle (rear bumper side), the SKM sends request for vehicle
control to the BCM.
6. The BCM activates the tailgate open relay. For vehicles with PTG, power mode open operation is
activated. If the theft deterrent is armed, theft deterrent is disarmed only for the tailgate.

GETtheMANUALS.org
 0000-00 02-23

▶ Passive tailgate operation (open → close)

- The passive tailgate in open position is closed with the theft deterrent armed.
- The theft deterrent system is armed when a valid smart key is detected outside the vehicle (rear
bumper side)
If the theft deterrent is armed, the hazard warning lamp flashes twice and chime sounds once.
- If there is a valid smart key detected after the tailgate has been opened, the SKM sends the "Smart
Key Detected" warning to the BCM and instrument cluster to activate the buzzer and display warning
message.

- The passive tailgate operation stops working when no valid smart key is detected outside
the vehicle.
- If the tailgate in open position is closed after the arming theft deterrent request signal has been sent
with all doors closed, a valid smart key detected inside the vehicle, the instrument cluster and BCM
receive the request signal and arm the theft deterrent system.

GETtheMANUALS.org
02-24

5. SMART KEY FUNCTION LIMITATION (SILENT)

Function to restrict the passive unlock using the smart key.
1. Smart key LOCK button pressed (smart key LOCK) in vehicle
2. Smart key which actuated smart key LOCK detected in vehicle
3. Passive UNLOCK limited due to all smart keys detected in vehicle (Silent)

▶ Silent smart key activation

- All doors closed (B-CAN)

- Smart key LOCK (theft deterrent mode entered: B-CAN) request signal sent by a smart key
inside vehicle
- Smart key which activated smart key LOCK detected in vehicle
- All smart keys in the vehicle including the one that activated smart key LOCK are memorized as silent
smart keys, and the passive UNLOCK is not available.

▶ Silent smart key function

- Passive UNLOCK not available

- Passive start & power control available
- REKES function available

▶ Cancellation of silent smart key

- The silent smart key restores its function when the UNLOCK button on the smart key is pressed and
the ignition status is changed by the START/STOP switch.

GETtheMANUALS.org
 0000-00 02-25

6. SMART KEY DEACTIVATION

The smart key is disabled so that an outside intruder can not use the smart key in the vehicle.
1. BCM receives signal that theft deterrent system armed (REKES lock / passive lock)
2. Smart key, which output smart key lock is not detected and valid smart key detected inside
vehicle
3. The smart key detected inside the vehicle is deactivated.

▶ Smart key deactivation

- All doors closed (B-CAN)

- In the event of REKES LOCK (enters theft deterrent mode: B-CAN) request by smart key inside
vehicle
- The smart key activated door LOCK is not found in the vehicle.
- The system memorizes all smart keys found inside the vehicle as deactivated ones.
- The SKM activates "Smart key Not Detected" warning. Refer to "SMART KEY WARNING".

▶ Deactivated smart key function

- Passive entry not available

- Passive start & power control not available
- Smart key disabled

▶ Cancellation of smart key deactivation

- When the theft deterrent is disarmed using a smart key outside the vehicle, the deactivated smart key
functions returns to be available.

GETtheMANUALS.org
02-26

7. AUTO APPROACH FUNCTION

When the driver holding a smart key moves closer to the door handle in theft deterrent mode, the
approach lamp (puddle lamp) comes on.

▶ AUTO approach setup on instrument cluster

Vehicle settings under (User Setting) in instrument cluster → Convenience function →

Tick/untick Auto approach welcome

GETtheMANUALS.org
 0000-00 02-27

▶ AUTO approach function

1. With AUTO approach lamp enabled

2. BCM sends following vehicle status:
- All doors closed and 30 sec elapsed after entering theft deterrent mode
3. SKM searches for smart key outside the vehicle at a certain time* intervals
4. In the event of authorized smart key,
5. SKM sends request for vehicle control (AUTO approach lamp ON) to BCM
6. BCM activates AUTO approach lamp

GETtheMANUALS.org
02-28

* Certain period of time

Elapsed time after entry into

Category Search time
armed mode
1st Within 5 days Interval of 0.48 sec
2nd 5 to 14 days Interval of 0.72 sec
3rd More than 14 days Shutdown

- If there is a valid smart key detected in the vehicle, AUTO approach function is not activated.
- Smart key external search is not performed for 30 seconds during the auto approach
operation.
- The auto approach operates up to 2 times in 10 minutes, and does not operate more than 2 times in
10 minutes.
(it can be operated again if it operated before 10 minutes)

GETtheMANUALS.org
 0000-00 02-29

8. SMART DOOR AUTO LOCK FUNCTION

All doors and tailgate will be locked and the vehicle enter armed mode if the door is open and closed the
driver holding a smart key leaves a certain distance from the vehicle (driver/passenger door handles)
with arming conditions satisfied.

▶ Smart door AUTO LOCK setup on instrument cluster

Vehicle settings under (User Setting) in instrument cluster → Door / Tailgate → Tick/untick
Smart Door Auto Lock

GETtheMANUALS.org
02-30

▶ Smart door AUTO LOCK function

Operation 1.
1. Smart door auto lock setting and vehicle status
2. Change in driver door status
- Open (smart key not detected) → closed (smart key detected)
- Open (smart key detected) → closed (smart key detected)
3. Search for valid smart key in vehicle
4. When valid smart key not detected indoors
5. Search for valid smart key outside vehicle (up to 10 min)
6. When valid smart key detected and then not detected outside vehicle
7. Smart door auto lock enabled

System flowchart (Operation 1)

GETtheMANUALS.org
 0000-00 02-31

Conditions for enabling and disabling smart door auto lock

- Disabled: valid smart key detected in vehicle after 10 min (remains unlocked)
- Enabled: valid smart key not detected in vehicle after 10 min
However, if a valid smart key is not detected outside the vehicle within 10 minutes, smart door
auto lock is enabled.

Operation 2.
1. Smart door auto lock setting and vehicle status
2. Change in driver door status
- Door open (smart key detected) → closed (smart key not detected)
3. Search for valid smart key in vehicle
4. When valid smart key not detected indoors
5. Smart door auto lock enabled

Operation 3.
1. Smart door auto lock setting and vehicle status
2. Change in driver door status
- Open (smart key not detected) → closed (smart key not detected)
- Open (smart key not detected) → closed (smart key detected)
- Open (smart key detected) → closed (smart key not detected)
- Open (smart key detected) → closed (smart key detected)
3. Search for valid smart key in vehicle
4. When valid smart key detected indoors
5. Smart door auto lock disabled (remains unlocked)

GETtheMANUALS.org
02-32

▶ Smart door AUTO LOCK function

Smart door AUTO LOCK deactivation conditions

- Door LOCK/UNLOCK by pressing button on smart key
- Door open
- Theft deterrent is armed

The smart door AUTO LOCK function is not activated in the following situation:
- A valid smart key is detected inside vehicle.
- An impact signal is received from the air bag module.
- Smart key battery low voltage warning.

GETtheMANUALS.org
 0000-00 02-33

9. SMART KEY CONTROL

Pressing the smart key button activates the following functions:

Door lock

Door unlocked

Panic

Button name Time button pressed Vehicle operation

Door lock Tier 1 Door lock
Door unlocked Tier 1 Door unlocked
Panic Step 2 Panic

Step 1: 0.03 to 1.5 sec. / Step 2: 1.5 sec. or more

GETtheMANUALS.org
02-34

▶ Smart key lock

1. Press LOCK button on the smart key for more than 0.03 sec to send smart key lock signal
2. When SKM receives smart key LOCK signal, it sends smart key LOCK request signal to BCM
3. BCM outputs door LOCK

▶ Smart key unlock

1. Press LOCK button on the smart key for more than 0.03 seconds to send REKES lock signal
2. The SKM receives the REKES UNLOCK signal and sends the REKES UNLOCK request signal
to the BCM.
3. The BCM activates the door UNLOCK.

GETtheMANUALS.org
 0000-00 02-35

▶ Smart key panic

1. The panic signal is sent when the panic button on the smart key is pressed for 1.5 sec. or
longer (step 2).
2. The SKM receives the panic signal and sends the panic activation request signal to the BCM.
3. The BCM controls the panic operation.

The panic alarm stops when the panic button on the smart key is pressed during the panic alarm
operation.

GETtheMANUALS.org
02-36

10. SMART KEY AUTHENTICATION TIMER

Category Pre-authentication timer
Operating power Power OFF, ACC, IGN ON
Time for which the power control can be carried out under the verified
Function
conditions (30 seconds after the authentication)

1. All doors closed

2. START/STOP switch input
Input conditions 3. Brake switch signal input
4. Smart key searching completed
5. Engine start ON to OFF
Smart key searching completed after the following conditions are met:
1. Close signal input after opening any door
Authentication 2. Brake switch signal input
conditions 3. START/STOP switch signal input
4. After IGN OFF
5. Gear "P" position signal input when turning off engine

1. Pre-authentication timer exceeds 30 sec

2. Door handle switch ON
Deactivation
3. IGN ON
conditions
4. Theft deterrent armed/disarmed
5. Door status changed (open/closed)
If any condition for pre-authentication timer is met, no authentication process is required for 30 seconds
after each authentication process has been completed.

Operation before pre-authentication timer

- Passive LOCK/UNLOCK
- REKES LOCK/UNLOCK

Ignition status after immobilizer authentication

- The immobilizer authentication has been completed when the engine starts.
- The immobilizer authentication is not deactivated until the ignition is turned to ON, OFF or
ACC ON.
- The immobilizer is not deactivated when the key out warning condition is met while the engine is
running.

GETtheMANUALS.org
 0000-00 02-37

11. START & POWER MODE CONTROL

The ignition status is changed to OFF, ACC ON, IGN ON and engine cranking by one START/STOP
switch.

When parking with N position is required, turn the power off with gear in P position and then shift to N
position by performing TGS lever override (manual release).

GETtheMANUALS.org
02-38

▶ Power transition and engine start diagram

GETtheMANUALS.org
 0000-00 02-39

▶ Engine start

1. When the START/STOP button is pressed with the brake pedal applied (ON) and shift lever in P or N
position, the SKM performs the immobilizer verification and sends the engine START request signal to
the EMS if a normal coded smart key is found.
2. The SKM cuts off the power for IGN2 and ACC relays while the engine is cranking as cutting the
electric load is necessary.
3. The SKM turns on the ACC/IGN2 relays after the engine cranking and sends the signal for IGN after
starting to the BCM through the B-CAN.
4. Starting engine while driving
- The engine start request signal is sent when the START/STOP switch is pressed, provided
that the vehicle speed is less than 10 Km/h or no vehicle speed signal is input, the shift
lever is in P or N position and the brake switch is ON with IGN ON (authentication is not
required for 30 sec.).
- The engine start request signal is sent regardless of the brake signal input when the START/STOP
switch is pressed, provided that the vehicle speed is 10 Km/h or more and the shift lever is in N
position with IGN ON (authentication is not required for 30 sec.).

5. Impossible to start engine if:

- Brake signal not received (at vehicle speed below 10 km/h)
- START/STOP switch signal not received
- Shift lever in any position other than "P" or "N" position (at vehicle speed below 10 km/h)
- Smart key (immobilizer) validation fail or no engine variant value exists

6. Emergency engine start

- The emergency engine start is activated when pressing the START/STOP switch for more than
10 seconds, with ACC ON, provided that the shift lever is in P or N position and the brake signal is
not received due to a faulty brake switch.

The average vehicle speed calculated based on the signals from the wheel speed sensors sent to
the ABS/ESP is used.

GETtheMANUALS.org
02-40

▶ Engine shutdown

1. When the START/STOP switch is pressed briefly to stop the engine under a speed of 3 km/h,
the SKM turns ignition status to ACC. The SKM turns ignition OFF with a long press on the
switch.
2. When the vehicle speed is 3 km/h or more or no speed signal is input, the SKM performs the following
functions:

Vehicle status Condition

Engine emergency shutdown
- START/STOP switch is pressed for 3 sec. or more, the
ignition status is changed from IGN ON to ACC.
3 km/h or faster - START/STOP switch is pressed 3 times within 1.5 sec.
Restarting
- START/STOP switch is pressed once more, the ignition
status is changed from ACC to IGN ON.
- START/STOP switch is pressed for 3 sec. or more, the
Abnormal vehicle speed ignition status is changed from IGN ON to ACC.
(No or abnormal CAN signal) - START/STOP switch is pressed once more, the ignition
status is changed from ACC to IGN OFF.

▶ ACC ON to Power OFF

The SKM changes the ignition status to OFF with ACC ON and shift lever in P position when:
1. the engine START/STOP button is pressed with the brake pedal released after the ignition status is
changed from IGN ON to ACC ON and the shift lever is in P position.
2. the driver door is opened with ACC ON.
(Driver door open signal input through B-CAN)
3. 12 minutes have passed with ACC ON.
4. the doors are closed after the ignition is turned to ACC ON from IGN ON with doors open.

▶ System enters ISG mode when:

1. Engine started
2. Brake applied
3. Shift lever in D position

GETtheMANUALS.org
 0000-00 02-41

12. START/STOP SWITCH CONTROL

1) Power Status
▶ Ignition status indicator on START switch

Power condition Comes on when

OFF IGN off, engine started

READY Engine start possible with START/STOP switch operation

- Brake switch input & (IGN OFF / ACC ON / IGN ON)
ACC ACC ON
ON IGN2 ON with engine stopped

▶ START switch output with power on

Power OFF Engine

Power ACC Engine
Door Door IGN ON startable Error
status ON started
closed open state

Indicator
lamp
Red (ON),
Yellow Red (ON) Green
OFF OFF OFF flashing 5
(ACC) (READY)
times
Illumination
OFF ON OFF
lamp

- Illumination control for door coupled with START switch

- Illumination lamp comes on when driver door open (stays on as long as door open)
- Lamp goes out as soon as START switch is operated
- Lamp stays on for 10 sec. and goes out when driver door closed
- Timer is reset when driver door open

GETtheMANUALS.org
02-42

13. SKM WARNING CONTROL

1) Smart Key Not Detected Warning
▶ With ACC ON

Warning when no valid smart key detected with ACC ON

1. Door including tailgate status has been changed (open/closed).

2. The BCM sends the changed door status to the SKM through B-CAN.
3. The SKM searches for a valid smart key inside the vehicle using the indoor antenna.
4. If no valid key is detected, "smart key not detected" warning signal is sent once per 10 sec.
as follows:
- sent to instrument cluster through P-CAN.
- sent to BCM through B-CAN.
- SKM: searches for the valid smart key inside the vehicle at interval of 2 sec for 10 sec.
5. The instrument cluster and BCM activate the "Smart Key Not Detected" warning after receiving
"Smart Key Not Detected" warning signal.

GETtheMANUALS.org
 0000-00 02-43

"Smart Key Not Detected" warning deactivation conditions

- Over 10 sec. (timer expires)
- IGN OFF
- Valid smart key detected
The "Smart Key Not Detected" warning is also available when the START/STOP switch is pressed
by the driver with dead battery.

GETtheMANUALS.org
02-44

▶ IGN ON and engine running (Door open/closed status changed)

Warning when smart key not detected inside the vehicle with IGN ON and engine running

1. Door including tailgate status has been changed (open/closed).

2. The BCM sends the changed door status to the SKM through B-CAN.
3. The SKM searches for a valid smart key inside the vehicle using the indoor antenna.
4. If no valid key is detected, "Smart Key Not Detected" warning signal is sent once per 10 sec.
as follows:
- sent to instrument cluster through P-CAN.
- sent to BCM through B-CAN.
- SKM: searches for the valid smart key inside the vehicle at interval of 2 sec
5. The instrument cluster and BCM activate the "Smart Key Not Detected" warning after receiving "Smart
Key Not Detected" warning signal.

"Smart Key Not Detected" warning deactivation conditions

- IGN OFF
- Valid smart key detected
The "Smart Key Not Detected" warning is also available when the START/STOP switch is pressed
by the driver with dead battery. "Over 10 sec. (timer expires)" should be added to the warning
deactivation conditions.

GETtheMANUALS.org
 0000-00 02-45

2) Smart Key Detected Warning (Smart Key Found Indoors)

▶ Smart key deactivation warning

Warning that indicates there is a valid smart key detected in the vehicle during smart key lock

1. With the vehicle turned off,

2. All doors including tailgate are closed and a valid smart key exists in the vehicle.
3. Smart key LOCK signal input with a valid smart key from outside vehicle
4. The SKM sendsthe smart key LOCK signal to the BCM through B-CAN and
5. The BCM arms the vehicle and sends the theftdeterrent system armed signal to the SKM through B-
CAN.
6. The SKM searches for a valid smart key in the vehicle after receiving the theft deterrent system
armed signal. If a valid smart key is detected:
7. The SKM sends the "Smart Key Detected" warning signal as follows for 10 sec.:
(SKM → B-CAN → BCM)
(SKM → B-CAN → CGW → C-CAN → IP)
8. The instrument cluster and BCM activates the warning after receiving "Smart Key Detected" warning
signal.
- Instrument cluster: warning texts, sounds, indicator
- BCM: exterior buzzer control (ON/OFF at 0.5 sec. intervals for up to 5 sec.)

- The system memorizes all smart keys found inside the vehicle as deactivated ones.
- When the theft deterrent is disarmed using a smart key outside the vehicle, the deactivated smart
key function returns to be available.
- The smart key deactivation warning is deactivated after the timer expires (over 10 sec.).

GETtheMANUALS.org
02-46

▶ Smart Key Detected Inside Vehicle warning (with door outside handle switch pressed)

Warning that indicates there is a valid smart key detected in the vehicle during passive lock.

1. With IGN OFF, ACC, IGN ON

2. All doors including tailgate are closed and a valid smart key exists in the vehicle.
3. The door outside handle switch (trigger switch) is pressed without a valid smart key outside
the vehicle.
4. The SKM sends the "Smart Key Detected" warning signal as follows for 10 sec.:
(SKM → B-CAN → BCM)
(SKM → B-CAN → CGW → C-CAN → IP)
5. The instrument cluster and BCM activates the warning after receiving "Smart Key Detected" warning
signal.
- Instrument cluster: warning texts, sounds, indicator
- BCM: exterior buzzer control (ON/OFF at 0.5 sec. intervals for up to 5 sec.)

The smart key deactivation warning is deactivated after the timer expires (over 10 sec.).

▶ Smart Key Detected Inside Vehicle warning (with tailgate closed)

Warning that indicates there is a valid smart key inside the vehicle when the tailgate is being
closed.

1. The tailgate in open position is closed with the theft deterrent armed.
2. A valid smart key is detected inside vehicle.
3. The SKM sends the "Smart Key Detected" warning signal as follows for 10 sec.:
(SKM → B-CAN → BCM)
(SKM → B-CAN → CGW → C-CAN → IP)
4. The instrument cluster and BCM activates the warning after receiving "Smart Key Detected" warning
signal.
- Instrument cluster: warning texts, sounds, indicator
- BCM: exterior buzzer control (ON/OFF at 0.5 sec. intervals for up to 5 sec.)

The smart key deactivation warning is deactivated after the timer expires (over 10 sec.).

GETtheMANUALS.org
 0000-00 02-47

3) Smart Key Authentication Failure Warning

Warning that indicates there is no valid smart key inside the vehicle during the ignition cycle.

In the event of smart key authentication for power status change or engine start, the SKM sends the
"Smart Key Not Authenticated" signal to the instrument cluster through CGW for 10 seconds if the
authenticated smart key is not found.
(SKM → B-CAN → CGW → C-CAN → IP)

Smart key authentication failure warning is deactivated when:

- Authenticated smart key detected by START/STOP switch input signal while receiving smart key
authentication failure warning for 10 sec.

4) Transponder Authentication Fail Warning

Warning when no transponder is detected by emergency antenna
The SKM searches for transponder in front of the START/STOP switch (emergency antenna) according
to smart key authentication process. If no authenticated smart key is found, the SKM sends
authentication failure signal to the instrument cluster through CGW for 10 seconds.
(SKM → B-CAN → CGW → C-CAN → IP)

Transponder authentication failure warning deactivation conditions

- Transponder detected at START/STOP switch (emergency antenna) while transmitting
transponder authentication failure warning for 10 sec.

GETtheMANUALS.org
02-48

5) Transmission Position Warning

Warning when power transition in position other than P or N
The transmission position warning is displayed when the shift lever is in the position other than P or N at
the start-up of the vehicle. The SKM receives the signal through P-CAN and hard-wire with IGN on. If the
SKM receives the signal indicating that the shift lever is in other positions than "P" or "N" position when
starting engine, it outputs transmission position warning through CGW on the instrument cluster for 10
seconds.
(TCU → P-CAN → SKM → B-CAN → CGW → C-CAN → IP)
(Shift lever → Hard-wire → SKM)

Transmission position warning deactivated when:

- IGN OFF
- Shift lever in P or N position

6) Transmission P Position Warning

Warning that indicates shift lever should be in P position when turning engine OFF with shift
lever in position other than P

The transmission P position warning is displayed when the shift lever is in the position other than P at IGN
OFF.
The SKM receives the shift lever "P" position signal from TCU via PCAN and "P" position signal via hard-
wire at the same time when the START/STOP switch is changed from IGN ON to ACC ON.
Then, it detects "P" position signal through hard-wire in ACC or OFF state. The power transition to IGN
OFF occurs when opening the driver door.
If change in ACC ON status occurs in other positions than "P" position, transmission position warning is
sent to the instrument cluster for 10 seconds.

"Transmission P Position" warning deactivation conditions

- Over 10 sec. (timer expires)

GETtheMANUALS.org
 0000-00 02-49

7) Power Cut Off Warning

Warning when forcibly turning power OFF from ACC ON
- 12 minutes have passed with ACC ON.
- The driver door is opened with ACC ON.
- Power transition from IGN ON to ACC ON after driver door open with IGN ON
- Door closed,
- The SKM sends the power cut off warning (warning related to battery low) through CGW for 10 sec.
before turning the power off.
(SKM → B-CAN → CGW → C-CAN → IP)

"Power Cut Off" warning deactivation conditions

- IGN OFF within 12 minutes

8) SKM Error Warning

Warning due to faulty START/STOP switch
If the START/STOP switch fails because of an open circuit and/or short circuit, etc., the SKM sends
warning signal to the instrument cluster through CGW for 10 sec. The warning signal will be sent again
only when there is an additional failure.
(SKM → B-CAN → CGW → C-CAN → IP)
1. Faulty START/STOP switch

9) Brake Not Applied Warning

Warning when ignition cycle repeats with no brake signal
The Brake Not Applied warning signal is sent to the instrument cluster for 10 seconds through CGW
when the 2nd cycle starts after the 1st ignition cycle (OFF → ACC → IGN → ACC → OFF) has
been completed with the brake not applied.
(SKM → B-CAN → CGW → C-CAN → IP)

Brake Not Applied warning deactivated when:

- Brake pedal is depressed (warning and timer will be reset)
- Over 10 sec. (timer expires)

GETtheMANUALS.org
02-50

10) Smart Key Battery Voltage Low Warning

Smart key battery voltage low detection warning
When the smart key battery voltage goes under 2.7 V after a press of a smart key button (RF signal) or
RF signal input by detection of a smart key, the SKM sends warning signal to the instrument cluster
through CGW for 10 sec.
(SKM → B-CAN → CGW → C-CAN → IP)
The warning message displayed on the instrument cluster vary depending on the vehicle settings.

A. Smart door AUTO LOCK function enabled

- Low smart key battery voltage is detected over ten times
- The instrument cluster deactivates the smart door AUTO LOCK function at the same time as
displaying warning texts (1).

B. Smart door AUTO LOCK function disabled

- Low smart key battery voltage is detected over ten times
- The instrument cluster displays warning texts (2).
- Activating the smart door AUTO LOCK function does not change the status of the function. The
instrument cluster displays warning texts (type A) and the function returns to deactivation status.

Warning texts 1 on instrument cluster Warning texts 2 on instrument cluster

Smart key battery low voltage warning deactivation conditions

- Smart key battery voltage is normal
- Smart key battery is replaced with new one

GETtheMANUALS.org
 0000-00 02-51

11) Smart Door AUTO LOCK Function Warning

Warning when 2 or more smart keys are detected (smart door LOCK deactivation)
When 2 or more valid smart keys are detected with IGN OFF and open status of any door (excepting
hood and tailgate) changed, the SKM sends the warning signal to the instrument cluster through CGW
for 10 seconds.
(SKM → B-CAN → CGW → C-CAN → IP)
(if there is a valid smart key in the vehicle, the smart door AUTO LOCK is not activated.)

Smart door AUTO LOCK deactivation conditions

- A valid smart key is detected inside vehicle.

GETtheMANUALS.org
02-52

14. SKM IMMOBILIZER SYSTEM

1) System Description
The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine.
The transponder inside the key communicates with the SKM and EMS (ECU) through P-CAN
communication, and the system permits the engine to start after confirming the encrypted coding.
When the START/STOP switch is pressed with the smart key put to the front of emergency antenna e.g.
because of the smart key battery discharge, the SKM communicates with the EMS (ECU) through P-CAN,
and the EMS (ECU) starts to control the engine only when the signal is valid.
A valid key verification time is provided for 10 seconds and the engine can be started during this time. If
pressing the START/STOP switch again after this 10 seconds, the smart key authentication process
should be performed again.

2) Configuration

EMS (ECU) Starting motor

Emergency antenna SKM

Smart key

GETtheMANUALS.org
 0000-00 02-53

3) Operating Process
There are two different types of smart key authentications: immobilizer key and smart key.
The immobilizer authentication is applied to the smart key module (SKM) system, and verifies the
transponder built in the smart key. When the smart key is put to the front of the START/STOP switch, a
short-distance immobilizer authentication will be carried out between the transponder and the SKM. (LF
and RF has a higher priority than short-distance immobilizer authentication.)
Once the key is verified, a valid key authentication time is provided for 10 seconds and the engine can be
started by pressing the START/STOP switch during this time. If pressing the START/STOP switch after
this 10 seconds, the key authentication process should be performed again.
1. When the ignition is turned ON, the EMS (ECU) sends the challenge message to the SKM through the
P-CAN. (This is to verify whether the transponder of the smart key is valid. If the authentication fails, it
transmits the re-authentication signals 3 times for 2 seconds. If 3rd re-authentication fails, the
authentication is deactivated for 10 seconds and re-activated after that.)
2. The emergency antenna of the SKM system sends the encrypted cod to the transponder, and the
transponder re-sends the encrypted code to the emergency antenna.
3. The encrypted sent to the emergency antenna is transmitted to the SKM.
4. The SKM compares this code with the encrypted code randomly transmitted by the internal logic.
(The system compares the signal from transponder and encrypted signal from the emergency
antenna)
5. Only when the two signals are identical, the SKM recognizes the key as the verified one and transmits
the positive message to the EMS (ECU).
6. The EMS (ECU) enables the engine to be started.

GETtheMANUALS.org
02-54

15. INTERNAL CIRCUIT DIAGRAM

GETtheMANUALS.org
GETtheMANUALS.org
02-56

16. CIRCUIT DIAGRAM

▶ IGN1, IGN2, ACC RELAY, SKM ANTENNA

GETtheMANUALS.org
 0000-00 02-57

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
▶ Front camera module (FCM)

Item Specifications
Frame 36Hz
Field of view Height: 52°, width: 38°
Camera Size 1:3 inch
Image sensor Pixels 1280 x 960 pixels
Audio 115 dB Dynamic Range
Operating voltage 9 to 16V
Operating temperature -40℃ to 85℃
Storage temperature -40℃ to 105℃
Current consumption Normal condition: 200 mA (max. 1A)

MCU Freescale SPC5643L

(32 bit, Flash 1 MB, RAM 128 KB)
Memory 128 MB x 2 64 bit (DDR)
Communication C-CAN communication
Size 85 X 65 X 30.1 (mm)
Weight 130g

GETtheMANUALS.org
GETtheMANUALS.org
 0000-00 03-5

1. OVERVIEW
The front camera module (FCM) detects any object in front of the vehicle and operates the following
driving assist systems to enable the driver to drive safely:

- FCWS : Forward Collision Warning System

- AEBS : Autonomous Emergency Braking System
- LKAS : Lane Keeping Assist System
- LDWS : Lane Departure Warning System
- HBAS : High Beam Assist System
- FVSA : Front Vehicle Start Alert
- SDA : Safety Distance Alert
- DAA : Driver Attention Alert

GETtheMANUALS.org
03-6

2. EPC
▶ 8511 SWITCH AND SENSOR - INSTRUMENT PANEL (2)

1. SW ASSY-S/WARMER & VENT FRT 10.SCREW

2. SWITCH ASSY-SEAT WARMER FRT 11.SWITCH ASSY-GLOVE BOX
7. SWITCH ASSY-LWR MAIN 17.SWITCH ASSY-PASSENGER AIR BAG
8. SWITCH ASSY-START 18.BLANKING COVER-PASSR A/BAG
9. BRKT-START 27.SWITCH ASSY-FASCIA LWR
29.SWITCH ASSY-FASCIA LWR

GETtheMANUALS.org
 0000-00 03-7

▶ 8610 APPLICATION COMPONENT (1)

GETtheMANUALS.org
03-8

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 03-9

1. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
03-10

GETtheMANUALS.org
 0000-00 03-11

▶ Full names of acronyms and option description

GETtheMANUALS.org
03-12

2. C-CAN COMMUNICATION I/O ELEMENTS

1) FCM
▶ EPS

GETtheMANUALS.org
 0000-00 03-13

▶ CGW

GETtheMANUALS.org
03-14

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 03-15

▶ ESP

▶ AEB

GETtheMANUALS.org
03-16

3. FCWS (FORWARD COLLISION WARNING SYSTEM) &

AEBS (AUTONOMOUS EMERGENCY BRAKING SYSTEM)
1) Overview (FCWS & AEBS)
Autonomous Emergency Braking System (AEBS) has a Forward Collision Warning System (FCWS),
which uses data from the front camera module (FCM) to ensure a safe distance from the vehicle ahead
or a pedestrian and provides the driver with an audible warning in the event of a potential frontal collision,
along with an Emergency Braking System which actively brakes the vehicle.
The system helps the driver prevent or avoid a possible collision and reduces the risk of collision by
using the FCM and alerting the driver by means of visual and acoustic warnings.

2) Component Parts & Diagram (FCWS & AEBS)

GETtheMANUALS.org
 0000-00 03-17

GETtheMANUALS.org
03-18

3) Operation Process (FCWS & AEBS)

The conditions of the road surfaces or tires may cause collisions during the emergency braking.
Therefore, particular caution is required while braking.

GETtheMANUALS.org
 0000-00 03-19

4) Operating Conditions (FCWS & AEBS)

(1) Target
The system tracks the sensed object in the sensing area to form a target and eliminates the target if the
sensed object is out of the sensing area. The formed targets are divided into 4 characteristics: Moving,
Stopped, Stationary and Oncoming.
- Moving: if sensed object has speed, it is recognized as moving object
- Stopped: if speed of moving target becomes 0, it is recognized as stopped object
- Stationary: if target never have moving characteristics from when it was detected, it is recognized as
stationary object
- Oncoming: if moving target is approaching the vehicle equipped with sensor, it is recognized as
oncoming target

Moving Stopped Stationary Oncoming

Target recognized O O O O (pedestrian),

X (vehicle)

(2) Operating conditions

- Front camera module detects a valid target
- FCWS determines warning level based on relative speed of vehicle ahead and the distance to vehicle
ahead
- AEBS calculates retardation using speed of vehicle ahead and distance to vehicle ahead
- System sends retardation value to ABS & ESP units

GETtheMANUALS.org
03-20

(3) Deactivation conditions

When the system detects any intervention by the driver, the braking control is deactivated.

Item Deactivation conditions

Normal deactivation - AEBS set to off

- ESP set to off (AEBS auto off when ESP off)
- The vehicle speed exceeds the maximum operating speed
(60 km/h)
Deactivation by driver - Sharp turning of steering wheel (30° or greater)
- Shift lever in P or R position
- Accelerator pedal depressed 60% or more.
- AEBS relevant systems fault
Deactivation by system
- AEBS relevant units fault
malfunction
- CAN communication error

(4) Some operating conditions

The third warning (full braking) may not work depending on the radar or camera recognition.

Operational levels Operating conditions

Overlap between driver's vehicle and target vehicle 50% or less
Level 1 ~ 2
warnings Overlap between driver's vehicle and target pedestrian 20% or less

GETtheMANUALS.org
 0000-00 03-21

▶ Overlap

Vehicle
50%

Pedestrians
20%

(5) Detectable objects

▶ The AEBS can detect the followings:

- FCM: vehicle and pedestrian

- Vehicle: rear of vehicle (symmetrical - passenger cars, mini vans, special vehicles including trucks,
tractors, trailers)

▶ The AEBS cannot detect the followings:

- Bicycles, two-wheeled vehicles

- Buildings, overpasses, tunnels, guard rails, tollgate houses, container, etc.
- Trees, garden fences, streetlights, traffic lights, median barriers, traffic signs, bus stop
schedule signs, etc.
- Crosswalks, tunnel entry and exit points, markings on the roads, shadow under overpasses
- Man-made structures other than vehicles
- Vehicles with arbitrary shape
- Vehicles with additional lamps installed around the tail lamps or vehicles with unsymmetrical tail lamps

GETtheMANUALS.org
03-22

▶ AEBS can detect a pedestrian who:

- is over 0.8 m in height
- is shown at least above the knee point on the image captured by the front camera module
- is within 50 m during the daytime or 30 m at night from the camera module
- is within 3.5 m from the left and right sides of the camera module
- is in 70 lux of light illumination
- stands with arms spread out
- faces the front, left, right, or rear side in the view of the driver
- is raising one leg up

▶ AEBS cannot detect a pedestrian who:

- does not stand up straight
- blends well into the surrounding environments or exhibits unusual behavior
- is shown less than 70% of the body with the rest of the body blocked by the surrounding objects on
- the image captured by the front camera module
is outside the front camera angle of view

GETtheMANUALS.org
 0000-00 03-23

▶ Limit situation

Target not detected at beginning or

Breaking in at a close distance
end of slope

Near-field blind spot exists and adjacent lane Due to vertical angle limit, forward targets (vehicles
vehicle changes lanes at close range, which may or pedestrians) may not be detected on uphill and
cause risk of collision downhill hills

Intersection Road with large curve radii

Since the FCM targets the back side of the vehicle When driving on a road with large curve radii, the
ahead in the driving direction, an alarm is not shape of the rear of the preceding vehicle is not be
issued to the vehicle moving in the vertical detected properly and an alarm may not be issued
direction to the driving direction at the intersection
or the forward vehicle turning to the right

Target not detected due to Load protruding to rear side of vehicle

contaminated sensor (FCM/FRM)

Contaminants may block sensor, which results in If preceding vehicle is a special vehicle or luggage
vehicles colliding with preceding vehicle or is loaded in a special form, target is not determined
pedestrians due to sensor detection limit, which may lead to
collision

GETtheMANUALS.org
03-24

Thin-shaped object Front tail lamp not detectable

For front object with narrow width (e.g., Driving behind a vehicle with tail lamps off at night
motorcycle), it may not be detected due to or the tail lamp illumination of the preceding vehicle
limitations of camera is unsymmetrical

FCM difficult to obtain visibility Bad visibility

In situations where view of camera is limited such In an environment where the driver's field of view is
as backlight, reflected light, and darkness not secured (snow, rain, fog, etc.), if driver uses
AEB, vehicle may collide with front vehicle and
pedestrians due to limitations of sensor

Complex structures around road

driving through a construction zone, on railways,

on the roads with metal objects scattered on them
(e.g., tollgates, subway construction sites, tunnels,
and guard rails)

GETtheMANUALS.org
 0000-00 03-25

5) Warning Lamp & Indicator Lamp (FCWS & AEBS)

- The AEBS warning lamp flashes again for 5 seconds if a valid transition occurs while flashing for 5
seconds. For example, it flashes again for 5 seconds if a second warning occurs while the first
warning is in effect.
- The FCWS and AEBS are automatically turned OFF at the time of ESP OFF.
- Pressing the ESP OFF switch for 3 seconds or more turns off the ESP. To turn on the ESP, press
the switch again briefly.

6) Warning Beep (FCWS & AEBS)

GETtheMANUALS.org
03-26

4. LANE KEEPING ASSIST SYSTEM(LKAS)

1) Overview (LKAS)
The LKAS (Lane Keeping Assist System) is an assistive vehicle operation technology that detects
vehicles up ahead using the FCM (Front Camera Module), and when the system detects that the vehicle
is departing from the current lane without a lane change indication, the vehicle visually and audibly warns
the driver through the LDWS (Lane Departure Warning System), and if the vehicle continues to depart
from the lane, the vehicle maintains stays in the current lane by taking control using the EPS (Electronic
Power Steering) system. The system provides visual and audible alerts also when the driver is not
holding the steering wheel.

2) Component Parts & Diagram (LKAS)

GETtheMANUALS.org
 0000-00 03-27

GETtheMANUALS.org
03-28

3) Operating Process (LKAS)

The operation of LKAS switch, changing driving lanes, turning steering wheel, and depressing brake
pedal are considered as the intervention by the driver. If the driver activates the turn signal lamps or turns
the steering wheel toward the lane which the vehicle is about to cross, the system interprets this as
switching lanes.
The type of assist torque that LKAS is using is Reverse Torque Control. In this mode, the assist torque is
provided only when the vehicle is about to cross the left or right lane (see B in the figure below).

Lane departure: The front wheels of the vehicle crosses inner boundary of the lane marking detected by
the FCM as shown in the figure (B).
A. Lane departure without activation of turn signal lamp detected
B. Warns the driver with visual and audible alerts and controls EPS
C. The vehicle is steered toward the center of the lane.

GETtheMANUALS.org
 0000-00 03-29

4) Operating Conditions (LKAS)

▶ Operating conditions

Item Operating conditions

System status ON
Vehicle speed 60 to 175km/h
Lanes detection Both lanes
Lane color White, yellow and blue
Lane detection range 3 to 60m
Lane width 2.8 to 4.3m
Angle of rotation Up to 30°
Steering wheel Rotational speed Up to 30°/s
Driver's intervention 4 Nm or less
Lateral acceleration Up to 3.0 m/s²
Longitudinal deceleration 3 to 60m
Radius of rotation At least 125m
Turn signal light OFF (Hazard warning flasher OFF)
Driver status Hands on steering wheel

▶ Non-operating conditions

- The vehicle is driven around a sharp turn.

- Sudden braking and rapid lane switching
- ESP in operation (LKAS operable 2 sec after ESP operation completed)
- Steering wheel turning angle of 50° or more
- Steering wheel torque of 5Nm or greater
- Lateral acceleration of 3.2m/S² or more
- Longitudinal deceleration of 20m/S² or more
- Hazard warning flasher or turn signal light ON

GETtheMANUALS.org
03-30

▶ LKAS intervention alarm (when hands-off during driving)

When the driver's hands off the steering wheel during lane departure control, the LKAS beep sounds as
follows. As the alarm level goes up, the alarm sound increases cumulatively for 10 seconds.
When the driver hold the steering wheel normally, the increase in the number of alarm sounds is
canceled/initialized.

GETtheMANUALS.org
 0000-00 03-31

5) Lane Detection (LKAS)

▶ Conditions for detecting lane

- Clear, cloudy, environments where lanes are clearly visible to naked eye
- Time zone: Daytime, nighttime, dusk
- Road type: Straight line, curve and tunnel

▶ Factors that degrade lane detection performance

- Lanes with reflective material

- Markings other than lanes painted on road (e.g., milestones, arrows, crosswalk, numbers and
characters)
- Artificial structures around lanes (e.g., guard rail, tunnel's exterior wall, sidewalk median strip and lane
change prevention pillars)
- Artificial structures around lanes, trees and shadows by nearby vehicles
- Preceding vehicle and cut-in/cut-out vehicles
- Divaricated/merged lanes at intersection/junction
- Safety zones marked with diagonal lines at intersection/junction
- Not lanes, but edges or lines of road
- Boundary between concrete road and asphalt road
- Artificially eliminated lanes
- Traces after road construction
- Lanes at tunnel entry/exit sections (abrupt brightness change)

6) Indicator Lamp (LKAS)

7) Waning Lamp (LKAS)

GETtheMANUALS.org
03-32

5. LDWS(Lane Departure Warning System)

1) Overview
The Lane Departure Warning System (LDWS) uses FCM to detect the lane markings and warns the
driver with visual and audible alerts when the vehicle is about to move out of the lane boundaries without
the activation of turn signal lamps.

2) Component Parts & Diagram (LDWS)

GETtheMANUALS.org
 0000-00 03-33

3) Operating Process
A. Lane departure without activation of turn signal lamp detected
B. Visual and audible warnings

▶ LDWS warning area

4) Operating Conditions (LDWS)

Item Operating conditions
System status ON
Vehicle speed 60 to 175km/h
Lane detection Left or right lane marking detected
Lane color White, yellow and blue
Lane detection range 3 to 60m
Lane width At least 2.6 m (deactivated if 2.5 m or less)
Acceleration rate -
Radius of rotation At least 125 m (radius)
Turn signal light OFF

GETtheMANUALS.org
03-34

5) Lane Detection (LDWS)

▶ Conditions for detecting lane

- Clear, cloudy, environments where lanes are clearly visible to naked eye
- Time zone: Daytime, nighttime, dusk
- Road type: Straight line, curve and tunnel

▶ Factors that degrade lane detection performance

- Lanes with reflective material

- Markings other than lanes painted on road (e.g., milestones, arrows, crosswalk, numbers and
characters)
- Artificial structures around lanes (e.g., guard rail, tunnel's exterior wall, sidewalk median strip and lane
change prevention pillars)
- Artificial structures around lanes, trees and shadows by nearby vehicles
- Preceding vehicle and cut-in/cut-out vehicles
- Divaricated/merged lanes at intersection/junction
- Safety zones marked with diagonal lines at intersection/junction
- Not lanes, but edges or lines of road
- Boundary between concrete road and asphalt road
- Artificially eliminated lanes
- Traces after road construction
- Lanes at tunnel entry/exit sections (abrupt brightness change)

6) Indicator (LDWS)

7) Warning Lamp (LDWS)

GETtheMANUALS.org
 0000-00 03-35

6. HIGH BEAM ASSIST SYSTEM (HBAS)

1) Overview (HBAS)
The high beam assist system (HBAS)
automatically switches high beams to low beams
when approaching vehicles traveling in the
opposite direction or a preceding vehicle with
multifunction light switch in AUTO & high beam
position so that the drivers of these vehicles are
not dazzled.

2) Component Parts & Diagram (HBAS)

GETtheMANUALS.org
03-36

3) Operating Conditions (HBAS)

Item Operating conditions
AUTO & high beam ON
(System will be turned off if AUTO or high beam is turned OFF)

AUTO High beam

Low beam ON

- HBA system is started by low beam at first and switched

to high beam depending on ambient light source
High beam ON - When vehicle stationary, low beam lights on and can be
switched to high beam at vehicle speed of 45 km/h or higher
(deactivated at 35 km/h or less)
- No light source from oncoming traffic or preceding vehicle and
ambient light is dark for 3 seconds
- Generally 1 sec
High beam ON delay time - When the oncoming traffic moves out of the center of the image
after switching to low beam captured by FCM: 2 sec
- When the preceding vehicle moves out of the center of the
image captured by FCM: 3 sec

GETtheMANUALS.org
 0000-00 03-37

▶ Switching between high beam and low beam of HBA system

4) Indicator Lamp

GETtheMANUALS.org
03-38

7. DRIVER ATTENTION ALERT (DAA)

1) Overview (DAA)
The driver attention alert detects and analyzes the driving pattern of driver such as carelessness / driving
while drowsy by the lane information recognized by the front camera, various sensors, modules, and
switch status of the vehicle.
It is a system to judge the driving level of the driver by the operation pattern and notify the driver of the
break alarm, to provoke the driver's attention and encourage the driver to take the rest.

GETtheMANUALS.org
GETtheMANUALS.org
03-40

2) Component Parts & Diagram (DAA)

GETtheMANUALS.org
 0000-00 03-41

GETtheMANUALS.org
03-42

3) Driving Pattern Detection (DAA)

Item DTC set conditions
Zigzag driving Zigzag driving in driving lane
Sudden steering Sudden steering detected when driving
Steering torque Vehicle approaches lane in the way that there's no operation based on the
steering wheel torque and angle (steering wheel grasp torque decreased)

Steering torque Vehicle approaches lane in the way that there's no operation based on the
steering wheel torque and angle
Abrupt braking Sudden deceleration during driving
Non-stop driving Long time continuous driving without rest (driver's door open and closed)

4) Operating Conditions (DAA)

Item Operating conditions
System status ON (LKAS)
Vehicle speed Activated at 60 to 175km/h, deactivated at 180km/h or higher (At speed of 60
km/h or less, only abrupt braking and non-stop driving detected)
DAA level up Each time careless driving pattern is detected, level raised by one step
DAA level down When driving for more than 2.5 minutes normally without careless driving pattern,
level goes down by one step
Pattern detection - For 15 sec after careless driving pattern detected
disabled: - When driver seat belt unfastened and driver door open and closed
- For 10 sec after turn signal light / hazard warning flasher operated
(Ignored when turn signal light flashes for more than 10 sec)
Conditions judged to - Shift lever in P position for more than 5 min
be rest - Driver seat belt unfastened
- Driver door open and closed
Rest alarm If careless driving pattern detected even after DAA reaches level 5, rest alarm
sounds for 10 seconds and system returns to level 5
Re-alarm prevention Within 1 min after rest alarm

Initialized when: - Determined that driver is at rest

- "DAA" turned off at instrument cluster settings
DAA / rest alarm First 5 minutes of driving / 5 minutes after driver determined to be at rest
disabled when:
Lane detection Activated when: Lane detected for 2 sec consecutively
Deactivated when: Lane not detected for 5 min consecutively or on sharp curves

GETtheMANUALS.org
 0000-00 03-43

▶ Zigzag driving

When driving normally, the driver tries to center the vehicle in the lane. However, when the attention of
the driver becomes low, the lane center followability tends to be lowered. If the driver's vehicle shows a
zigzag driving pattern with a large lateral displacement within the lane, this is detected through the lane
information recognized by the camera. (excepting continuous lane placement)

Repeated deviations of centerline of lane for cumulative distance detected as zigzag driving

If lane departure warning (LDW) is repeatedly issued for a certain period of time, it is detected as a
zigzag driving

▶ Sudden steering

When driving normally, the driver tries to follow the lane with minimal steering to reduce vehicle drift.
However, in the state where the attention of the driver is decreased, the sustainability and the deviation
of the steering tend to be lowered, so that the understeer and the sudden steering may occur repeatedly.
When these sudden steering pattern is shown, the steering angle information of the vehicle is used to
detect it.

GETtheMANUALS.org
03-44

▶ Steering torque

In addition, if the driver's steering wheel grasp torque is very weak and the vehicle's behavior is not
normal, it can be determined as a careless / drowsy driving. The lane information detected by the
camera and vehicle's steering angle and steering torque are used to detect this.

▶ Sudden braking

If a sudden braking occurs more than necessary when driving at a speed within operation speed range
(60 to 175 km/h), it can be judged to be a careless / drowsy driving such as negligence of keeping eyes
forward or safety distance violation. The sudden braking pattern is detected in the event of the
emergency stop signal (ESS).

▶ Non-stop driving

It also detects when the driver continues to drive continuously without rest in order to prevent
carelessness / drowsy driving. It is detected when driving continuously without rest more than a certain
time (daytime: 80 minutes / nighttime: 60 minutes).

GETtheMANUALS.org
 0000-00 03-45

8. FRONT VEHICLE START ALERT (FVSA)

1) Overview (FVSA)
The front vehicle start alert is a function that the front camera module recognizes the start of the
preceding vehicle and notifies the driver with the visual / audible alarms when the driver's vehicle and the
preceding vehicle are stationary and waiting for the light to change.

2) Component Parts & Diagram (FVSA)

GETtheMANUALS.org
03-46

3) Operating Process (FVSA)

(1) Target
The system tracks the sensed object in the sensing area to form a target and eliminates the target if the
sensed object is out of the sensing area. The formed targets are divided into 4 characteristics: Moving,
Stopped, Stationary and Oncoming.

- Moving: if sensed object has speed, it is recognized as moving object

- Stopped: if speed of moving target becomes 0, it is recognized as stopped object
- Stationary: if target never have moving characteristics from when it was detected, it is recognized as
stationary object
- Oncoming: if moving target is approaching the vehicle equipped with sensor, it is recognized as
oncoming target

Moving Stopped Stationary Oncoming

Target recognized O O X X

▶ System-level transition

GETtheMANUALS.org
 0000-00 03-47

▶ Entry conditions (Standby)

- Driver vehicle stationary

- Shift lever in D position (positions other than N or R for M/T)
- Depress and hold brake pedal for 3 sec stationary by stopped preceding vehicle during ACC
operation

When judging whether the driver's vehicle is stationary or not, it should be excluded when the hand
parking brake is engaged, and the clutch pedal is depressed.

▶ Operating conditions (Warning ON)

- Entry conditions met

- Target preceding vehicle exists
- Driver's vehicle moves a certain distance (0m → 3m) at the same speed (5km/h or higher) as
preceding vehicle
- FVSA message and beep are triggered once.

▶ Deactivation conditions (Warning OFF)

- Driver turns system off

- Driver's vehicle moves
- Preceding vehicle not exist

GETtheMANUALS.org
03-48

9. CIRCUIT DIAGRAM
▶ FRT CAMERA MODULE

GETtheMANUALS.org
 0000-00 03-49

GETtheMANUALS.org
 0000-00 04-3

1. SPECIFICATIONS
Category Specifications Remarks
Operating voltage 9 ~ 16V -
Operating temperature -40℃ to +85℃ -
Frequency 24.05 ~ 24.25GHz -
Weight 130g -
Size (W)82×(H)75×(T)22.5 mm³
Sensor beam Up/down Up 20˚ / down 20˚ -
Area coverage
LH/RH LH: 85˚/RH: 85˚ -
There should be no metallic or plastic objects in the beam pattern area where the
radar sensor is mounted, except for the bumper.

GETtheMANUALS.org
04-4

2. CAUTIONS

There should be no ornaments or objects such as metal or plastic materials in front of the radar
sensor except for the bumper.

Image Description

Do not install double bumper.

Do not install ornaments on the outside of the bumper (sticker, bumper

guard, etc.)

Do not install ornaments on the inside of the bumper (noise shield, etc.)

The thickness should be consistent (putty work, etc.)

No overlapping elements (two or more) are allowed.

No sharp bends are allowed. Therefore, distorted or damaged bumper

should be replaced as soon as possible.

To reduce the noise level due to diffused reflection, make sure that the
angle between the sensor surface and the bumper surface is not large.
(a1-a2) < 40mm

GETtheMANUALS.org
 0000-00 04-5

3. GENERAL AND SPECIAL TOOLS

Part no. and name Special tools Usage
Name:
Equipment for checking BSD
mounting angle
1. Laser level
(GLL3-80, Bosch)
2. Tripod (BS-150)
3. Weight (BD-PB300)
4. Goniometer (BD-DR200)
5. Seal
6. Angle level (A-100)
Usage: Check parallel line Usage: Mount laser level
Seller:
E-mail: [email protected]
Phone: +82 313 266144
Contact point: Bosch korea

Usage: Check central point Usage: Measure contact angle

Usage: Measure BSD vertical

Usage: Make center line angle

GETtheMANUALS.org
04-6

1. OVERVIEW
BSD (Blind Spot Detection) system uses the 2 radar sensors installed to both sides of the vehicle rear
bumper inner side to measure the distance to the vehicle approaching from left or right rear side,
approaching speed and angle. It also informs the driver of the vehicle rear situation through audible and
visible signals for driver safety.
The BSD system has features such as:

▶ BSD (Blind Spot Detection) system

This system detects a vehicle which is in the area

where the driver cannot view though the outside
rearview mirror (1st warning). If the driver tries to
change the lane in this state, the system warns
the driver using a visible and audible warnings
(2nd warning). This function is useful for
acknowledging a vehicle in blind spot.

▶ LCA (Lane Change Assist) system

This system detects a vehicle which is

approaching at high speed or about to collide
from the left or right rear side of the vehicle (1st
warning). If the driver tries to change the lane in
this state, the system warns the driver using a
visible and audible warnings (2nd warning). This
function is useful for acknowledging a vehicle in
foggy, dark night, rainy conditions.

- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
 0000-00 04-7

▶ RCTA (REAR CROSS TRAFFIC ALERT) SYSTEM

When reversing the vehicle, the RCTA system

detects a vehicle approaching from the rear
left/right blind spot where the driver cannot view
though the room mirror or outside rearview mirror
and warns the driver using a visible and audible
warnings. This function is useful when reversing
out of a parking spot after front end parking.

▶ RCTAi (Rear Cross Traffic Alert Intervention)

Function to perform braking assistance if

collision is expected during RCTA warning

▶ EAF (Exit Assist Function)

Function that warns vehicle approaching from

the rear side when getting off after parking

- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
04-8

2. COMPONENTS

Outside rearview mirror

glass (BSD indicator)

BSD switch

Master radar sensor

Slave radar sensor

GETtheMANUALS.org
 0000-00 04-9

3. EPC
▶ 8790 PARKING AID SYSTEM & BSD

1. SENSOR ASSY-PARKING AID SYSTEM

5. HOLDER ASSY-PAS FRT
6. HOLDER ASSY-PAS RR
10.SENSOR ASSY-BSD MASTER
11.SENSOR ASSY-BSD SLAVE
12.NUT

GETtheMANUALS.org
04-10

▶ 8511 SWITCH AND SENSOR - INSTRUMENT PANEL (2)

1. SW ASSY-S/WARMER & VENT FRT 10.SCREW

2. SWITCH ASSY-SEAT WARMER FRT 11.SWITCH ASSY-GLOVE BOX
7. SWITCH ASSY-LWR MAIN 17.SWITCH ASSY-PASSENGER AIR BAG
8. SWITCH ASSY-START 18.BLANKING COVER-PASSR A/BAG
9. BRKT-START 27.SWITCH ASSY-FASCIA LWR
29.SWITCH ASSY-FASCIA LWR

GETtheMANUALS.org
 0000-00 04-11

▶ 7850 OUTSIDE MIRROR

1. MIRROR ASSY-O/S
2. MIRROR ASSY-O/S
3. GLASS HOLDER ASSY-O/S MIRR
4. BASE & HSG ASSY-O/S MIRR
5. SCALP-O/S MIRROR
7. NUT
12.COVER ASSY-INR

GETtheMANUALS.org
04-12

1. INPUT/OUTPUT DIAGRAM

GETtheMANUALS.org
 0000-00 04-13

GETtheMANUALS.org
04-14

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 04-15

GETtheMANUALS.org
04-16

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 04-17

3. C-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

▶ ESP

GETtheMANUALS.org
04-18

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 04-19

4. WARNING LEVEL
1) BSD / LCA Warning
▶ BSD / LCA warning level 1

Warning level 1
CASE 1 CASE 2 CASE 3 Vehicle condition

1. Driving speed of 1. Driving speed of 1. Driving speed of 30 to 1. Outside rearview

30 to 250km/h 30 to 250km/h 250km/h mirror warning
2. A vehicle is 2. Vehicles 2. Vehicles approaching indicator ON
approaching approaching left the adjacent lane
from behind at or right blind spot from outer lane
high speed area 3. Left or right lane next
to driver's car
Deactivation condition: Target vehicle moves out of BSD warning area -

▶ BSD / LCA warning level 2

Warning level 2
CASE 1 CASE 2 CASE 3 Vehicle condition

Operating condition: Turn signal lamp ON in Warning level 1 state 1. Outside rearview
mirror warning
Deactivation condition: Warning level 2 deactivated when turn signal lamp indicator flashes
OFF 2. Warning buzzer ON

GETtheMANUALS.org
04-20

2) RCTA Warning
Warning level 2
CASE Vehicle condition

Supervision Indicator Warning

instrument cluster lamp buzzer

Display
▶ Operating conditions 1. Outside rearview mirror warning lamp
1. Shifting to R (reverse) flashes
2. Vehicle speed: 10 km/h or lower 2. Warning indicator on instrument cluster
3. Detection range: Max. 25m flashes
4. A target vehicle or an obstacle 3. Warning buzzer ON
approaching the driving vehicle within 4. AVN display warning indicator flashes
detection area is detected 5. Warning on rear view camera screen
flashes
▶ Deactivation conditions
1. Target vehicle moves out of detection
area.
2. Target vehicle does not approach the
driving vehicle
3. Target vehicle approaching slows down

RCTA operates at level 2 without level 1.

GETtheMANUALS.org
 0000-00 04-21

3) BSD / LCA Deactivation Conditions by Radius of Curvature

The radius of curvature of the road is determined based on the yaw rate value through the ACU and
ESP unit. If the radius of curvature is less than the specified value, the BSD/LCA is not activated.

Category Operating conditions Non-operating conditions

Radius of curvature 100m or greater 70m or less

GETtheMANUALS.org
04-22

5. WARNING BUZZER AND INSTRUMENT CLUSTER DISPLAY

1) BSD / LCA / RCTA Warning Buzzer
- You can set warning function to ON or OFF under the RCTA (rear cross traffic alert) of driving assist
settings.
- You can set warning buzzer function to ON or OFF under the BSD (blind spot detection) system
audible alert of sound settings.

GETtheMANUALS.org
 0000-00 04-23

GETtheMANUALS.org
04-24

2) Instrument Cluster Display (Supervision Instrument Cluster)

▶ BSD/LCA system

Pop-up display Operating conditions

This message is displayed on the lower part of the main menu for 2
seconds according to the operation (ON/OFF) of BSD switch.

If there is a fault in the BSD system, this message is displayed on

the LCD screen for 5 seconds.

When the BSD system is turned on and the sensor does not
normally detect the blind spots, a message is displayed on the LCD
for about 5 seconds.

GETtheMANUALS.org
 0000-00 04-25

▶ RCTA system

Pop-up display Operating conditions

It is turned on/off depending on the RCTA and RCTAi settings

(check / uncheck) on the instrument cluster, and the message is
displayed for about 2 seconds in the lower part of the main menu.

This message is displayed on the LCD screen when a vehicle is

detected left and/or right side of the rear of the vehicle during the
operation of rear cross traffic alert system.

GETtheMANUALS.org
04-26

6. SYSTEM SETTINGS
1) BSD & LCA System ON/OFF Switch
▶ System ON/OFF by BSD & LCA ON/OFF switch

Category Switch Display of instrument cluster

(Supervision instrument cluster)

OFF

ON

Operation description
Outside rearview
Category Switch Instrument cluster
mirror
ON Warning lamp flashes None
IGN OFF → ON
OFF None None
OFF → ON Warning lamp flashes ON message displayed
IGN ON
ON → OFF None OFF message displayed

GETtheMANUALS.org
 0000-00 04-27

7. BSD (BLIND SPOT DETECTION) SYSTEM

This system detects a vehicle which is in the area where the driver cannot view though the outside
rearview mirror (1st warning). If the driver tries to change the lane in this state, the system warns the
driver using a visible and audible warnings (2nd warning). This function is useful for acknowledging a
vehicle in blind spot.

1) Activation/Deactivation Conditions
Category Operating conditions Non-operating conditions
BSD switch ON OFF
Vehicle speed 30 to 250km/h Below 25km/h, above 255km/h
Radius of curvature 100m or greater 70m or less
Category Operating conditions
Target vehicle speed - 10 km/h or less (driver's vehicle overtakes target vehicle with a
speed difference of less than 10 km/h), both vehicles driving at
same speed, target vehicle faster than driver's vehicle
Max. detectable distance 5m (distance from end of rear bumper to rear side)

▶ Radius of curvature
The radius of curved road where the vehicle is driving

▶ What (+) and (-) relative speed differences mean:

(-) speed: Speed at which driver's vehicle (S) overtakes target vehicle (T)
(+) speed: Speed at which target vehicle (T) overtakes driver's vehicle (S)
E.g.: Relative speed difference ≤ -10km/h = BSD will operate if driver's vehicle does not
overtake by more than 10 km/h faster than target vehicle (T).

GETtheMANUALS.org
04-28

2) BSD Warning Area

A. Vehicle center line

B. BSD warning OFF front line (front axle line): (G) + 1.5m
C. Rear bumper end line
D. Vehicle's left/right edge lines
E. *BSD warning ON outer line: (D) + 3~3.4m
F. BSD warning ON inner line: (D) + 0.4m
G. BSD warning ON front line: (B) - 1.5m
H. BSD warning ON rear line: (C) + 5m
I. BSD warning OFF outer line: (E) + 0.7m
J. BSD warning OFF inner line: (F) - 1m
K. BSD warning OFF rear line: (H) + 1m

*BSD warning ON outer line (E)

- At vehicle speed of 60km/h or lower: (D) + 3m
- At vehicle speed of 70km/h or higher: (D) + 3.4m

GETtheMANUALS.org
 0000-00 04-29

8. LCA (LANE CHANGE ASSIST) SYSTEM

This system detects a vehicle which is approaching at high speed or about to collide from the left or right
rear side of the vehicle (1st warning). If the driver tries to change the lane in this state, the system warns
the driver using a visible and audible warnings (2nd warning). This function is useful for acknowledging a
vehicle in foggy, dark night, rainy conditions.

1) Activation/Deactivation Conditions
Category Operating conditions Deactivation conditions
BSD switch ON OFF
Vehicle speed 30 to 250km/h Below 25km/h, above 255km/h
Radius of curvature 100m or greater 70m or less
Category Operating conditions
Target vehicle speed Within TTC of 4.5 sec. (regardless of speed); However, if the speed of
the target vehicle is too high, the target vehicle may leave the LCA area.

Max. detectable distance 70m (distance from end of rear bumper to rear side)

- Radius of curvature: The radius of curved road where the vehicle is driving
- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
04-30

2) LCA Warning Area

A. Vehicle center line

B. LCA warning OFF front line (front axle line): (G) + 1.5m (alarm OFF may be delayed
depending on target vehicle speed)
C. Rear bumper end line
D. Vehicle's left/right edge lines
E. *LCA warning ON outer line: (D) + 3~3.4m
F. LCA warning ON inner line: (D) + 0.4m
G. LCA warning ON front line: (B) - 1.5m
H. LCA warning ON/OFF rear line: (C) + 70m
I. LCA warning OFF outer line: (E) + 0.7m
J. LCA warning OFF inner line: (F) - 0.7m
K. TTC (+ in reference to rear bumper): 4.5 sec + 3 sec (if it falls below hysteresis time, warning
turned off)

*LCA warning ON outer line (E)

- At vehicle speed of 60km/h or lower: (D) + 3m
- At vehicle speed of 70km/h or higher: (D) + 3.4m

GETtheMANUALS.org
 0000-00 04-31

9. RCTA (REAR CROSS TRAFFIC ALERT) SYSTEM

1) Activation/Deactivation Conditions
When reversing the vehicle, the RCTA system detects a vehicle approaching from the rear left/right blind
spot where the driver cannot view though the room mirror or outside rearview mirror and warns the driver
using a visible and audible warnings. This function is useful when reversing out of a parking spot after
front end parking.

Operating Non-operating
Category
conditions conditions
Supervision Instrument cluster setting
IP settings turned on
Rear cross traffic alert instrument cluster OFF
Standard instrument Instrument cluster setting
IP settings turned on
cluster OFF
Vehicle speed 8km/h or lower 10km/h or higher
R position or
Gear position Non-operating positions
R → N position
Engine status Engine start ON Engine start OFF
Category Operating conditions
TTC 3 sec.
Max. detectable distance 25m

- The warning is not triggered by the people (except for people who walk quickly or run).
- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
04-32

2) RCTA Area

A. TTC pas-through point (based on vehicle axis): horizontally 0m / longitudinally (G)~(E)

B. Front axle line
C. Rear bumper end line
D. TTC line: (A) + 1m (predicted path of target vehicle should be between (D) and (A))
E. *RCTA TTC rear (+ in reference to rear bumper): (C) + 4.2~6m ± 1m
F. RCTA allowable maximum horizontal range (+ in reference to center axis when parking
vertically): 25m from (A)
G. RCTA TTC front (- in reference to rear bumper): (C) - 1.5m ± 1m
H. Max. TTC value: 3 sec (predicted path of target vehicle should be between (D) and (A))
I. TTC reference point minimum entry angle: 35˚ (No RCTA warning if less than minimum
entry angle)

* RCTA TTC rear range

- When target vehicle and driver vehicle are at an angle of 90˚: (C) + 6m ± 1m
- When target vehicle and driver vehicle are at an angle of 60˚: (C) + 5.2m ± 1m
- When target vehicle and driver vehicle are at an angle of 45˚: (C) + 4.2m ± 1m

GETtheMANUALS.org
 0000-00 04-33

10. RCTAi (Rear Cross Traffic Alert Intervention)

1) Activation/Deactivation Conditions
During back up, it detects vehicles or objects approaching from the rear side of the vehicle (blind spot
that can not be seen by the side mirrors and the room mirror), calculates TTC (Time To Collision), and
urgently brakes the vehicle itself if a collision is expected.

Non-operating
Category Operating conditions
conditions
Supervision Instrument cluster setting
IP settings turned on
instrument cluster OFF
RCTAi
Standard instrument Instrument cluster setting
IP settings turned on
cluster OFF
Between 0km/h and 10km/h
Vehicle speed Between 0km/h and 8km/h

Gear position Position R Non-operating positions

Engine status Engine start ON Engine start OFF

Vehicle status ESP not activated and ESP activated and

warning lamp OFF warning lamp ON
Category Operating conditions
TTC 0.8 sec.
Max. detectable distance 25m

- RCTAi works only when RCTA is activated.

- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
04-34

2) RCTAi Area

A. Vehicle center line

B. TTC line: (A) + 1m
C. Rear bumper end line
D. TTC rear line: (C) + 2~3.4m (2 + vehicle speed (m/s) × 0.5m)
E. Parallel filter angle: 35˚ (RCTA ON at higher angle)
F. RCTA allowable maximum horizontal range: 25m from (A)
G. Max. TTC value: 0.8 sec.

GETtheMANUALS.org
 0000-00 04-35

11. EAF (Exit Assist Function)

1) Activation/Deactivation Conditions
When getting off the vehicle after parking or stopping the vehicle, the RCTA system detects a vehicle
approaching from the rear left/right blind spot where the driver cannot view though the room mirror or
outside rearview mirror and warns the driver using a visible and audible warnings.

Operating Non-operating
Category
conditions conditions
Supervision Instrument cluster
IP settings turned on
Exit Assist Function instrument cluster setting OFF
Standard instrument Instrument cluster
IP settings turned on
cluster setting OFF
Vehicle speed Stationary (0km/h) 5km/h or higher
Gear position P or N position Non-operating positions
Door open detection switch ON OFF
Category Operating conditions
TTC 3 sec.
Max. detectable distance 35m

- It works only when opening (from closed to open) the door at the same side as the direction (left /
right) of the target vehicle approaching.
- TTC (Time To Collision): Expected time before collision between the driving vehicle and target
vehicle (vehicle entering warning activation zone)
- Driving vehicle (S): Subject vehicle with BSD system
- Target vehicle (T): Target vehicle that BSD system detects

GETtheMANUALS.org
04-36

2) EAF Warning Zone

A. Vehicle center line

B. TTC front line: Front axle line
C. TTC front line: Rear bumper end line
D. TTC inner line: Vehicle's left/right edge lines
E. TTC out line: (A) + 2m
F. TTC: 3s
G. Disable driver's vehicle lane warning: (C) + 35m
H. Warning permissible max. angle: 25˚ (EAF not work at higher angle)

GETtheMANUALS.org
GETtheMANUALS.org
04-38

12. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 04-39

GETtheMANUALS.org
 0000-00 05-3

1. SPECIFICATIONS
Category Specifications
Rated voltage DC 12.0V
Operating voltage DC 9.0 ~ 16.0V
CAN network operating voltage 20.1 V or less

Sound 6 different beeps

(buzzer / speaker)

Main LCD 10.25 inches

LCD type (speedometer, RPM gauge, warning lamp, pop-up)
Segment LCD Fuel gauge, coolant temperature gauge
Blue High beam indicator

Red Seat belt warning lamp, brake warning lamp and air bag
warning lamp
Left/right turn signal lamps (hazard warning flasher),
LED Green front fog lamp indicator, light ON indicator and HBAS
indicator
Immobilizer/smart key warning lamp, ABS warning lamp,
Amber warm-up indicator and low fuel level warning lamp

Charge warning lamp, engine oil pressure warning lamp,

4WD CHECK warning lamp, water separator warning
Warning lamp Red
lamp, EPS warning lamp and engine overheat warning
color
lamp

Green 4WD LOCK indicator, ISG indicator and

WINTER/SPORT mode indicator
Engine CHECK warning lamp, ESP ON
LCD indicator/warning lamp, ESP OFF indicator, AEBS
Amber warning lamp, AEBS OFF indicator, steering wheel
heating indicator, SCR warning lamp, Over
speed(120km) warning light, ISG OFF indicator
Green/Amber ISG ON indicator
Green/Red HDC ON indicator/warning light
Green/Amber/ LKAS
White

GETtheMANUALS.org
05-4

2. OPERATING RANGE OF INSTRUMENT CLUSTER

DEPENDING ON VOLTAGE

GETtheMANUALS.org
 0000-00 05-5

1. OVERVIEW
The instrument cluster is intended to inform the driver of warnings and current status of the vehicle by
communicating with various units through C-CAN, Multi media-CAN, and hard-wire communications.
The instrument cluster has the buzzer and speaker which make various warning sounds in its back side.

2. COMPONENTS

Supervision instrument cluster

Front side Rear side

A. 10.25" main LCD

B. Segment LCD
C. LED warning lamp
D. Speaker
E. Buzzer
F. Instrument cluster connector
G. LVDS connector (instrument cluster to AVN communication connector)

GETtheMANUALS.org
05-6

1. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 05-7

GETtheMANUALS.org
05-8

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 05-9

2. C-CAN COMMUNICATION I/O ELEMENTS

▶ AEB

▶ BSD

▶ ACU

GETtheMANUALS.org
05-10

▶ CGW

GETtheMANUALS.org
 0000-00 05-11

▶ CGW

GETtheMANUALS.org
05-12

▶ CGW

GETtheMANUALS.org
 0000-00 05-13

▶ CGW

GETtheMANUALS.org
05-14

▶ EPS

▶ ESP

GETtheMANUALS.org
 0000-00 05-15

▶ FCM

GETtheMANUALS.org
05-16

3. M-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
 0000-00 05-17

▶ AVN

GETtheMANUALS.org
05-18

4. SYSTEM WAKE UP AND SLEEP MODE

Outgoing signal Incoming signal

System status
activated activated
Network ON O O
Network OFF X X
Wake up (network start up) X O
Sleep mode (network shut down) X O

▶ Wake up (network start up) conditions

- UNLOCK (Remote) signal is received

- CAN BUS wake up conditions are met

▶ Wake up (network start up) conditions

- The network is turned on when the ignition is turned on.

- A network message request is received from the BSD, CGW and ESP.

▶ Network shutdown conditions

- No signal on CAN bus for 10 minutes after IGN off

- In the event of message request from the BSD, network does not shutdown. (up to 10 minutes)

▶ Sleep mode (network shut down) conditions

- CAN BUS sleep conditions are met based on the network type

GETtheMANUALS.org
 0000-00 05-19

5. WARNING LAMPS AND INDICATORS

- PW (Pre-Warning): Indicators which is illuminated for 4 sec. after the ignition is turned on
- TIME OUT: When no signal is received during 10 times repetition of cycle time (signal cycle)
(Multimedia CAN: 3.5 times)
→ X (HOLD): The status remains the same as before TIME OUT
→ O (ON) : The indicator is turned ON when TIME OUT occurs.
- Priority of warning lamps
Blinking > On > Off
- What is signal value display
(e.g., BCM (P-CAN → C-CAN)?
The BCM sends the corresponding signal to the CGW via P-CAN and the CGW to the instrument
cluster via C-CAN.)

GETtheMANUALS.org
05-20

1) LED Warning / Indicator

GETtheMANUALS.org
 0000-00 05-21

GETtheMANUALS.org
05-22

2) Warning / Indicator in LCD

GETtheMANUALS.org
 0000-00 05-23

GETtheMANUALS.org
05-24

GETtheMANUALS.org
 0000-00 05-25

6. WARNING SOUND DESCRIPTION

1) Overview
The instrument cluster is equipped with a speaker and a buzzer. The speaker emits 3 different sound
sources at 5 different intervals, and the buzzer emits only when receiving the signal.

- The buzzer and speaker sounds are reproduced by overlapping.

- The buzzer is divided into one group and stops immediately when the signal is interrupted.
- The speaker is fitted on the outside of the instrument cluster and its sounds are divided into 4 groups
and can be reproduced at the same time. However, the sounds are reproduced according to the
priority. When a sound source is completed, one with the next priority is reproduced.
In addition, there are 6 types of the speaker sound (Basic, Natural, Classic, Trendy, Korean, and
Luxury).

Speaker

Buzzer

GETtheMANUALS.org
05-26

2) Warning Buzzer Interval

Type A: Normal sound (* Dynamic client)

Type B: Outputs repeatedly and stops if deactivation conditions are met, PAS 3-stage output sound
Type C: Periodic output for predetermined time
Type D: Periodic output until deactivation conditions are met
Type E: Warning buzzer sounds only once and then stops

* Dynamic client: Audible signals which are heard when ignition is turned or off (Pre-Welcome,
Welcome, Goodbye with trip information and service interval alert).

GETtheMANUALS.org
 0000-00 05-27

3) Speaker Beep Priority

▶ Group 1: related to driving

- The WELCOME sound is heard for 4 seconds by default and can be heard up to 10 seconds depending
on the user setting.
- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
05-28

▶ Group 2: Related to driving assist

- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
 0000-00 05-29

▶ Group 3: Related to warning

GETtheMANUALS.org
05-30

- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
 0000-00 05-31

▶ Group 4: Voice guidance (priority of LCD pop-ups)

GETtheMANUALS.org
05-32

4) Warning Buzzer Priority

GETtheMANUALS.org
 0000-00 05-33

7. LCD MAIN MENU ITEMS

The LCD display has total 6 main menus. You can check the vehicle information and choose settings
using the switches on the right side of the steering wheel.

Position of switches Main Menu Description

- Trip A (mileage/driving speed/driving time)

- Trip B (mileage/driving speed/driving time)
- After departure / Driving time / Fuel
consumption
- Distance to empty/Average fuel
economy/Instantaneous fuel economy
- Tire pressure (TPMS) display
- Residual urea level display

Description
- Current vehicle speed displayed as digital
numbers (two different modes)

- Driver assistance system operation status

display (LDWS / LKAS / AUTO CRUISE)
Driver attention alert level display
-

- Display linked to AV

- Display linked to navigation

- Compass

- Driving assist setting

- Instrument cluster settings
- Display settings
- Vehicle settings
- Setup Initialization

GETtheMANUALS.org
05-34

8. LCD MAIN MENU DISPLAY

1) TRIP Computer Menu

Urea level
After entering into the menu, the system will be automatically changed
to Trip A when no switch operation for 15 sec. or more.
- The pop-up is displayed in the main area and trip computer symbol is
displayed as the door ajar symbol when the door/tailgate is open.

GETtheMANUALS.org
 0000-00 05-35

▶ Trip A/ Trip B (mileage/driving speed/driving time)

Item Supervision instrument cluster

Display

Display range - 0.0 to 9999.9 km

Mileage (A/B)
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
- When it exceeds 10000.0, it will be reset to 0.0
Driving speed Display range - 0 to 220 km/h
(average speed)
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
(A/B)
Display range - 00:00 ~ 99:59
Elapsed time (A/B) - Press Enter (OK) switch ( ) for more than 1 sec.
How to reset
- When it exceeds 100:00, it will be reset to 00:00

Mileage / driving speed reset

- Mileage / driving speed for trip B maintained even if trip A reset
- Mileage / driving speed for trip A maintained even if trip B reset
Mileage
The mileage is displayed on the LCD screen when the vehicle speed signal is received from the
ECU since the last reset.
Driving speed (average)
The average speed is calculated from the time and distance since the last reset. This value will be
updated on the LCD screen at every 10 seconds. The calculation of average speed is only carried
out when the engine is running.
Driving time
The driving time is the value accumulated since the last reset with engine running including idling
and is displayed on the LCD screen in the time format of 0:00 to 99:59 (HH:MM).

Trip vehicle speed signal input:

P-CAN C-CAN
Wheel speed sensor -> ESP ----------> CGW ----------> Instrument cluster

GETtheMANUALS.org
05-36

▶ After departure / Driving time / Fuel consumption

Item Supervision instrument cluster

Display

After Display range - 0.0 to 9999.9 km

departure How to reset - Ignition OFF → ON
Display range - 00:00 ~ 99:59
Driving time
How to reset - Ignition OFF → ON
Display range - 0.0 ~ 99.9L

Fuel consumption How to reset - Ignition OFF → ON

- When fuel consumption exceeds 100.0 after
departure it will be reset to 0.0

After departure
After reset (IGN OFF → ON), the distance driven is displayed on the LCD.

Driving time
After reset (IGN OFF → ON), the distance driven is displayed on the LCD.

Fuel consumption
After reset (IGN OFF → ON), the total amount of fuel consumption is updated at every 10
seconds and displayed on the LCD.

GETtheMANUALS.org
 0000-00 05-37

▶ Distance to empty / average fuel consumption / Instantaneous fuel consumption

Item Supervision instrument cluster

Display

- Displays distance to empty at every 1 sec

Display range - Below 50 km: displayed as "---"
Distance to empty
How to reset - Not possible

Display range - 0.0 to 30.0 km/L

Average fuel - 0.0 to 30.0 L/100 (Liters/100 km)
economy
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.

Display range - 0.0 to 30 km/L

Instantaneous - 0.0 to 30 L/100km
fuel economy
How to reset - Not possible

Initial calculating condition for average fuel economy

After the average fuel consumption reset, it is displayed when the vehicle moves for more than 50 m
and for more than 10 seconds. It is updated every 10 seconds and displayed on the LCD screen.

Initial calculating condition for instantaneous fuel economy

The instantaneous fuel consumption is displayed on the LCD screen by calculating the instantaneous
fuel consumption value for the last 0.6 seconds and updating it at every 0.2 seconds.

- The '---' flashes on the screen if the fuel sender input is outside the specified range for 20 seconds
or more during average fuel consumption calculation.
- If the instantaneous fuel consumption is higher than 30.0 km/L, it will be displayed as 30.0 km/L.

GETtheMANUALS.org
05-38

▶ TPMS

Select the trip computer sub menu (TPMS) under LCD main menu to check the current tire pressure.
After entering into the TPMS menu, the system will be automatically changed to Distance to empty when no
switch operation for 15 seconds or longer. (However, if another pop-up occurs within 15 seconds, the urea
level is displayed again for 15 seconds from the time the pop-up disappears.)
If the screen displays menu other than TPMS, the tire pressure normal pop-up message is displayed once
for 15 seconds after the normal pressure signal has been received.

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Priority of alert messages
1. Flat tire
2. Over inflation
3. Low pressure
4. check -
5. Unbalanced pressure
6. Not displayed
7. Normal

Normal tire pressure

This indicator is displayed when
all the tire pressures are normal.

Tire pressure not displayed

The tire pressure value is
displayed as "- -" when no tire
pressure is measured.

Check tire
If the tire pressure is too low to
avoid an inspection, this message
will be displayed. The
corresponding tire pressure blinks
(inverted shading) for 70 seconds
and corresponding tire(s) will be
displayed in yellow.

GETtheMANUALS.org
 0000-00 05-39

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Low tire pressure
If the tire pressure is too low to
avoid an inspection, this
message will be displayed. At
the same time, the global
warning light will come on and
the corresponding tire(s) will be
indicated in yellow.

Flat tire
When the current tire pressure
drops rapidly or when one or
more tires are flat, the global
warning lamp will come on and
the corresponding tire(s) will be
indicated in red.

Over inflation
This message is displayed
when the current tire pressure
is too high. The corresponding
tire(s) will be indicated in red.

Pressure imbalance
If the pressure difference
between LH and RH tires is 5
psi or more, the corresponding
tires on the screen flash with
the shading inverted
alternatively.

GETtheMANUALS.org
05-40

▶ Urea level

Select the trip computer sub menu (urea level) under LCD main menu to check the current urea level.
The urea level is automatically changed to the distance to empty after 15 seconds.
(However, if another pop-up occurs within 15 seconds, the urea level is displayed again for 15 seconds
from the time the pop-up disappears.)

Item Supervision instrument cluster

Display

20 bar 11L 10 bar 5.5L

19 bar 10.45L 9 bar 4.95L
18 bar 9.9L 8 bar 4.4L
17 bar 9.35L 7 bar 3.85L

Display range 16 bar 8.8L 6 bar 3.3L

(bar: number of units in level) 15 bar 8.25L 5 bar 2.75L
14 bar 7.7L 4 bar 2.2L
13 bar 7.15L 3 bar 1.65L
12 bar 6.6L 2 bar 1.1L
11 bar 6.05L 1 bar 0.55L
0 bar 0L
Input data ECU (P-CAN) → CGW (C-CAN) → ICM

- 1 to 2 levels are displayed in red and 3 or higher levels in blue.

- Rise: bar rises when capacity increases / Fall: bar falls when capacity decreases
- The urea consumption may depend on the driving style and surrounding environment.

GETtheMANUALS.org
 0000-00 05-41

Warnings and beeps occur in three stages depending on the remaining amount of the urea. If it
happens, replenish the urea immediately so that it does not affect the operation of the vehicle.

Step 1 - Warning lamp (not lit), warning beep (sounds), warning message (displayed)
- Warning issued when urea quantity is 3.8L (drivable distance: 2,400 km ~ 800 km)
- Occurs for 15 seconds every 200 km of driving or 4 hours.
- Immediately replenish at least 5 liters of urea when corresponding warning is issued.
(Warning deactivation conditions)

Step 2 - Warning lamp (lit), warning buzzer (stops after first output), warning message (displayed)
Drivable distance at time warning occurs: 800 km to 0 km
- Immediately replenish at least 7 liters of urea when corresponding warning is issued.
- (restart restriction lifted and warning lamp turned off)

Step 3 - Warning lamp (lit), warning buzzer (stops after first output), warning message (displayed)
Drivable distance at time warning occurs: 0 km
- It is impossible to operate the vehicle due to depletion of urea. Replenish the enough
- amount of urea immediately or have it inspected and serviced by Ssangyong Dealer or
Ssangyong Authorized Service Operation.

GETtheMANUALS.org
05-42

2) Digital Speedometer Menu

Item Supervision instrument cluster

Display type A

Display type B

0 to 220 km/h (in 1 km/h increments)

Digital speedometer display range (The vehicle speed is updated every 0.2 to 0.4 seconds
depending on the vehicle speed.)

- The current indicated vehicle speed is displayed in digital numbers (1 km/h) and updated every 0.2
to 0.4 seconds depending on the vehicle speed.

GETtheMANUALS.org
 0000-00 05-43

3) Driver Assistance Menu

When entering the driving assistance menu, the system is automatically set according to various
signals of the vehicle based on the lane keeping auxiliary system and the lane departure warning
system as follows.
- Lane departure warning system
- Lane keeping assistance system
- Speed limit
- Adaptive cruise control
- Intelligent cruise control

GETtheMANUALS.org
05-44

▶ LDWS (Lane Departure Warning System)

LDWS
Item
Main menu mode Pop-up mode
Display Display

Lane departure warning

system OFF
This message is displayed
when the LDWS is turned off.
-

Lane departure warning

system ready
The lanes are displayed as
shaded when the vehicle is
-
driven at a low speed of less
than 60 km/h or both lanes are
not detected with LDWS ON.

Lane departure warning

system not available
This message is displayed
when the system calibration
-
has not been carried out.

Lane departure warning

system check
This message is displayed after
the first 3 seconds of starting
the engine when there is a fault
in the lane departure warning
system.

GETtheMANUALS.org
 0000-00 05-45

▶ LDWS lane display area

ADAS lane display area (LDWS)

Item
Main menu mode Pop-up mode
Display Display
When the right lane is not
detected and the left lane only
detected, the corresponding
lane is displayed in green.
- Line: left lane displayed in -
green
- Warning beep: not
working

If your vehicle is approaching

the left lane without operating
the turn signal switch with the
left lane only detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

When the left lane is not

detected and the right lane only
detected, the corresponding
lane is displayed in green.
- Line: right lane displayed -
in green
- Warning beep: not
working

If your vehicle is approaching

the right lane without operating
the turn signal switch with the
right lane only detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

GETtheMANUALS.org
05-46

ADAS lane display area (LDWS)

Item
Main menu mode Pop-up mode
Display Display
When both lanes are detected,
they are displayed in green.
- Line: both displayed in
green
- Warning beep: not -
working

If your vehicle is approaching

the left lane without operating
the turn signal switch with both
lanes detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

If your vehicle is approaching

the right lane without operating
the turn signal switch with both
lanes detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

If your vehicle is approaching

the both lanes without operating
the turn signal switch with both
lanes detected, the lanes will
blink between green and red.
- Line: blinks between
green and red
- Warning beep: sound

GETtheMANUALS.org
 0000-00 05-47

▶ LKAS (Lane Keeping Assistance System)

Lane keeping assistance system

Item
Main menu mode Pop-up mode
Display Display

LKAS off
This message is displayed
when the LDWS is turned off.
-

Lane keeping assistance

system
ready
The lanes are displayed as
-
shaded when the vehicle is
driven at a low speed of less
than 60 km/h or both lanes are
not detected with LKAS
activated.
Lane keeping assistance
system
not available
This message is displayed -
when the system calibration
has not been carried out.

Lane keeping assistance

system
Check*
This message is displayed 3
seconds after starting the
engine when there is a fault in
the LKAS.

GETtheMANUALS.org
05-48

▶ LKAS lane display area

ADAS lane display area (LKAS)

Item
Main menu mode Pop-up mode
Display Display
When the right lane is not
detected and the left lane only
detected, the corresponding
lane is displayed in green. -
- Line: left lane displayed in
green
- Warning beep: not
working

If your vehicle is approaching

the left lane without operating
the turn signal switch with the
left lane only detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

When the left lane is not

detected and the right lane only
detected, the corresponding
lane is displayed in green. -
- Line: right lane displayed
in green
- Warning beep: not
working

If your vehicle is approaching

the right lane without operating
the turn signal switch with the
right lane only detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

GETtheMANUALS.org
 0000-00 05-49

ADAS lane display area (LKAS)

Item
Main menu mode Pop-up mode
Display Display
When both lanes are detected,
they are displayed in green.
- Line: both displayed in
green -
- Warning beep: not
working

If your vehicle is approaching

the left lane without operating
the turn signal switch with both
lanes detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

If your vehicle is approaching

the right lane without operating
the turn signal switch with both
lanes detected, the
corresponding lane will blink
between green and red.
- Line: blinks between
green and red
- Warning beep: sound

If your vehicle is approaching

the both lanes without operating
the turn signal switch with both
lanes detected, the lanes will
blink between green and red.
- Line: blinks between
green and red
- Warning beep: sound

GETtheMANUALS.org
05-50

▶ Cruise control

AUTO CRUISE
Item Main menu mode Pop-up mode
Display Display

Target speed symbol

Auto cruise ready (“---"

displayed as target speed)
Pressing the cruise control
ON/OFF switch with the engine
started displays the message at
the bottom of the main menu
and the target speed ready
symbol indicator appears at the
bottom of the speedometer.

Auto cruise set (Target speed

displayed)
When setting the auto cruise
control by operating the
adjustment switch with the auto
cruise control ready, the
message is displayed at the
bottom of the main menu and
the target speed symbol and
the speed appears at the
bottom of the speedometer.

Auto cruise deactivated

Deactivating the cruise control
with the cruise control ready
and set (activated) displays the
message at the bottom of the
main menu.

GETtheMANUALS.org
 0000-00 05-51

AUTO CRUISE
Item Main menu mode Pop-up mode
Display Display

Target speed symbol

After deactivating auto cruise

control
After deactivating the cruise
control, the LDWS and LKAS
are activated according to the
driver assistance system
settings. (Pop-up mode display
keeps showing the screen at
the time cruise control
deactivated)

GETtheMANUALS.org
05-52

▶ Lane keeping assistance system hands-off

Lane keeping assistance system hands-off

Item
Main menu mode Pop-up mode
Display Display
Level 1 warning
If the driver does not hold the
steering wheel for a certain
period of time with the lane
keeping assistance system -
activated, a warning pop-up
message is displayed.

Level 2 warning
If the driver does not hold the
steering wheel even after the
level 1 warning pop-up is
displayed, the level 2 warning -
pop-up will be displayed and a
beep will sound.

Forced deactivation of lane

keeping assistance system
After the level 2 warning, for
safe operation, the lane
maintenance assistant system
is forcibly deactivated and the
relevant pop-up is displayed.

GETtheMANUALS.org
 0000-00 05-53

▶ Driver Attention Alert (Cautious Driving Level)

Item Supervision instrument cluster

The driver's driving pattern and
driver status are analyzed
through various information,
and the driver's cautious driving
level is displayed in six levels.

When the DAA (Driver Attention

Alert) system is turned off or
faulty, corresponding message
is displayed.

GETtheMANUALS.org
05-54

4) AV Menu

GETtheMANUALS.org
 0000-00 05-55

Item Supervision instrument cluster

The instrument cluster is linked
to the AV system. Therefore,
the contents displayed on the
AV system are also displayed
on the screen of the instrument
cluster. The AV icon of the main
menu may vary depending on
the manufacturer of the device
connected to the system.

GETtheMANUALS.org
05-56

5) TBT Menu

GETtheMANUALS.org
 0000-00 05-57

6) User Settings Menu

When any vehicle check message is displayed, the user settings

symbol is changed to the master symbol.

GETtheMANUALS.org
05-58

9. USER SETTINGS
▶ Driving assist setting

- Rear cross traffic alert" and "rear cross traffic and emergency braking" modes can't be selected at
the same time.
- When the intelligent adaptive cruise control is deselected, only the auto cruise control is activated.
When selected, the intelligent cruise control + auto cruise control is activated.

GETtheMANUALS.org
 0000-00 05-59

▶ Instrument cluster settings

GETtheMANUALS.org
05-60

▶ Display settings

GETtheMANUALS.org
 0000-00 05-61

▶ Vehicle settings

GETtheMANUALS.org
05-62

10. FIXED DISPLAY

1) Odometer (Total Distance Driven)
Item Supervision instrument cluster

Display

Display range 0 to 999999km

Display unit 1 km
Input data Speed signal (ABS/ESP (P-CAN) → CGW (C-CAN) → ICM)

- Reset not possible (always displayed after IGN ON)

- If the indicated speed exceeds 300 km/h, the total mileage and trip meter stop working and the
speedometer indicates 0 km/h.

GETtheMANUALS.org
 0000-00 05-63

2) Ambient Temperature
Item Supervision instrument cluster

Display

Display range -30℃ to 90℃ (-22℉ to 194℉)

Display unit 1℃ (1℉)
Input data Ambient temperature sensor (5 V analog signal)
Ambient
temperature The instrument cluster sends the signal from the ambient
temperature sensor to BCM, CPL, ECU, ESP and HVAC through
Output data
CGW. (ICM (C-CAN) → CGW (P-CAN) → BCM, CPL, EMS,
ESP, HVAC)
It turns on or off depending on the ambient air temperature.
ICE symbol On: 5℃
Off: 7℃
It is displayed once after 3 seconds when the engine is started with
ICE pop-up
the ICE symbol turned on.

GETtheMANUALS.org
05-64

3) Digital Clock
Item Supervision instrument cluster

Display

Display range 0:00 to 12:00 (AM/PM)

0:00 to 21:00 (HH:MM)
Display unit 1 minute
Input data Clock information of audio received through Multi media-CAN

4) Gear
Item Supervision instrument cluster

Display

Display range P-R-N-D-1-2-3-4-5-6-▲-▼

(R position indicated by flashing)
The TCU sends the gear position signal to the instrument cluster
Input data (ICM) via the CGW.
(TCU (P-CAN) → CGW (C-CAN) → ICM)

GETtheMANUALS.org
 0000-00 05-65

5) Coolant Temperature
Item Supervision instrument cluster

Display

When temperature When temperature

Segment
rises temperature lowers temperature
(SEG) where light on where light off
8seg 126℃ 125℃
7seg 123℃ 122℃
6seg 120℃ 117℃
Display range
5seg 114℃ 113℃
4seg 70℃ 69℃
3seg 55℃ 54℃
2seg 48℃ 47℃
1seg 40℃ 39℃
0seg 39℃ 38℃

Display type Segment

The engine coolant temperature signal is sent to the instrument cluster
Input data (ICM) via the CGW.
(ECU (P-CAN) → CGW (C-CAN) → ICM)

- If the engine temperature exceeds 120℃ for 5 sec., engine overheat indicator flashes at 0.5
sec. interval with a buzzer sound.
- There is a hysteresis zone for the segments, so the segment may not be turned on/off immediately
even when the temperature is above/under the specified temperature.

GETtheMANUALS.org
05-66

6) Fuel Gauge
Item Supervision instrument cluster

Display

Filling with fuel Consuming fuel

Segment Others
Light-on capacity Light-off capacity
(SEG)

8seg 43L 45L -

7seg 38L 41L -
6seg 33L 36L -
5seg 28L 31L -
4seg 23L 26L -
Display range
3seg 18 L 21L -
2seg 13 L 16 L -
Low fuel level warning
lamp
1seg 3.5 L 11 L
OFF: 11L or higher
ON: 7.5L or less
5.5L -
0seg -
3L -

Display type Segment

Input data Fuel sender (analog signal)
1. IGN on after vehicle stops
Refueling check 2. Previous fuel reading remained for about 13 sec < when current fuel
reading is high (difference greater than 5L for more than 5 sec)
3. Display current reading by refueling

- Refueling is not possible during operation.

- The low fuel level warning lamp blinks in the event of the fuel sender open circuit.
- Diesel fuel tank capacity: 47L

GETtheMANUALS.org
 0000-00 05-67

11. LCD WARNING/INDICATOR PRIORITY

1) Level Priority
- Level 1 > Level 2 > Level 3 > Level 4 > Level 5 > Level 6 > Level 7 > Level 8 (warning message with
higher level priority overrides message with lower priority. If several messages with different levels
keep flowing in, display countdown starts again. (However, warning message with low level is
displayed for at least 0.5 seconds.)
- If there are 2 or more messages with the same level, the message with higher warning priority is
displayed first.

2) Warning Display Time Limit

- If the instrument cluster receives several messages with different levels, it displays the message with
the highest priority first for a specific time with a timer and then the message with next highest priority,
etc.
- If a timer does not show, then the message is displayed as long as the signal is present.
- The time on the timer is the maximum display time. (5 second pop-up means that the pop-up is
displayed for up to 5 seconds; pop-up disappears within 5 seconds when signal goes out.)
→ Exception: For rear-end collision alert, the pop-up is displayed for 5 seconds even f the
signal goes out within 5 seconds.
All pop-ups are displayed for at least 0.5 seconds.

3) Level 3 Group Display

- Two or more messages in this group are displayed for 4 seconds alternately.
- When new message of level 3 group is activated while the message of level 3 group is being displayed,
new message is displayed first for 4 seconds followed by the messages alternately.

4) Temporary Display Off

- When the instrument panel setting switch input signal or voice command signal is input while the
warning message is displayed, for some items (warning messages with low priority), the pop-up is
temporarily turned off for 4 seconds and after that displayed again.

5) Pop-ups That Temporarily Turned Off And Then Not Displayed

Again
- Normal TPMS (15 sec), Low washer fluid level (5 sec), Service interval alert (5 sec), Destination arrival
alert (5 sec) and Take a rest warning (5 sec)

GETtheMANUALS.org
05-68

6) Forced-off
- The display of the low-priority warning message may be delayed according to the priority, and may not
be displayed unless the low-priority warning message display condition is satisfied.

7) Saving Pop-up Messages

- Any pop-up message with an asterisk (*) will display the master symbol as soon as a signal is
received, and store the corresponding signal in the User settings menu. (Even if the pop-up is forced
off by other high-priority pop-ups, the signal is always stored.)
- When the ignition is turned off and on after the fault signal is stored, the pop-up will not be displayed.
The determination of whether the fault signal pop-up continues is carried out after 2 seconds from
IGN on.

8) Items Where Pop-ups Display In B+ Condition

- Sunroof open, exterior lamp on, hood open, tailgate open, door ajar, pop-up related to SKM and
vehicle exit alert
- If the pop-up signal is maintained even after IGN off, the above items are also maintained.

9) Pop-ups Displayed 3 seconds After Engine Start

- ESP check, Engine oil level check, Low fuel level warning, HBA check, LKAS check and AEBS
check

10) Toast Pop-Up

- Display by switch operation (input)
(Steering wheel heating, HDC mode, light mode, front wiper mode, rear wiper mode, rear side alarm
system, ESP off and auto cruise)
- Display linked to AV system
(Bluetooth phone call hold, 1 km to destination check and AV volume)
- When a high-level toast pop-up message is received while the low-level pop-up is displayed, the high-
level toast message is displayed for 5 seconds and the low-level toast pop-up is not displayed again.
When the toast pop-ups belonging to the same group occur at the same time, a new toast pop-up is
- displayed on the existing toast pop-up. (The existing toast pop-up is not displayed again.)
When the toast pop-up and pull pop-up occur at the same time, the toast pop-up is displayed on the
- pull pop-up.

GETtheMANUALS.org
 0000-00 05-69

GETtheMANUALS.org
05-70

GETtheMANUALS.org
 0000-00 05-71

GETtheMANUALS.org
05-72

12. LCD DYNAMIC CLIENT DISPLAY

1) Door Open Welcome
3.5" instrument cluster Operating conditions
1. Pre-Welcome sound
When the driver door is opened
after the theft deterrent mode is
disarmed
2. WELCOME
The driver door opened after
vehicle disarmed → our logo
displayed on LCD screen for 4
sec. when door closed

- The text WELCOME, name, picture, and sound on the Welcome screen can be customized to suit
individual preferences on the AVN.

GETtheMANUALS.org
 0000-00 05-73

13. LCD WARNING AND INDICATOR DISPLAY

1) Smart Key System
Pop-up display Operating conditions
If you lock the door using the registered smart key with another
registered smart key left inside the vehicle and all doors closed, this
message will be displayed for 5 seconds.

This message is displayed on the LCD screen when no valid smart

key is found inside the vehicle with ACC, IGN ON or engine
running.

If low smart key battery is detected with AUTO LOCK function

deactivated, this message is displayed on the LCD screen for 5
seconds.

The LCD display shows this message for 10 sec. when the ignition
switch is set to ACC position twice without depressing the brake
pedal to inform you that the brake pedal should be depressed when
starting the engine.

If the ignition switch is pressed and there is no valid smart key

detected inside the vehicle, this message is displayed on the LCD
screen for 10 sec.

GETtheMANUALS.org
05-74

Pop-up display Operating conditions

If the gear selector lever is not in P or N position when you start the
engine, this message is displayed on the LCD screen for 5 seconds
to inform you that the gear selector lever should be in P or N
position.

If the SKM receives no signals or faulty/incorrect signals from the

vehicle power supply control or ignition switch after the smart key
authentication, this message is displayed for 5 seconds.

If the gear selector lever is not in P position when you turn the
ignition OFF, this message is displayed on the LCD screen for 5
seconds to inform you that the gear selector lever should be in P
position to turn OFF the ignition.

This message is displayed for 5 seconds when ignition switch is in

ACC for 12 minutes or more or the driver door is opened with ACC
ON to prevent battery discharge.

GETtheMANUALS.org
 0000-00 05-75

Pop-up display Operating conditions

If low smart key battery is detected with AUTO LOCK function
activated, this message is displayed on the LCD screen for 10 sec.
This message is also displayed for 10 sec. when the AUTO LOCK
function is deactivated with low smart key battery.

When 2 or more valid smart keys are detected with IGN OFF and
open status of any door except for tailgate and hood changed, this
message is displayed for 10 seconds.

2) ISG System
Pop-up display Operating conditions
The message indicating the cumulative time that the engine has
stopped is displayed on the LCD screen while the ISG system is
normally operating.

The message is displayed on the LCD screen when the engine

stops and then is automatically restarted while the ISG system is
normally operating.

GETtheMANUALS.org
05-76

Pop-up display Operating conditions

Pressing the ISG OFF button deactivates the ISG system and
displays a message on the LCD display that the system has been
turned off.

If the current status of the vehicle does not meet the ISG system
operating conditions, a message is displayed on the LCD display.

The message is displayed on the LCD screen when the engine

stops and is not automatically restarted depending on the vehicle
status while the ISG system is normally operating.

If the ISG system is faulty, a message is displayed on the LCD

screen.

GETtheMANUALS.org
 0000-00 05-77

3) Parking Aid System (PAS)

Mode/pop-up display Operating conditions
1) Rear PAS
In R position Error When the shift lever is moved to
the R position with the IGN ON.
- When the shift lever is
moved to the R position, a
buzzer sounds briefly. If
obstacles are detected
behind the vehicle, the
existence of the obstacles is
displayed in 4 levels (Level
Lv0 Lv1 0, Level 1, Level 2, Level 3)
according to the distance
between the obstacles and
the vehicle and the location
of the obstacles.
(Level 1 of rear PAS:
Information of front PAS is
not displayed. Level 0 of
PAS: Only the shape of
Lv2 Lv3 vehicle is displayed.)
- If any error is detected
during initial diagnosis, it is
displayed as a question
mark (?). Other points
without errors are displayed
in the same way as the PAS
mode.

GETtheMANUALS.org
05-78

Mode/pop-up display Operating conditions

2) Front PAS
In D position Error The shift lever is moved to the D
position with the IGN ON:
- If obstacles are detected in
front of the vehicle (a) the
existence of the obstacles is
displayed in Level 2 and
Level 3 indicators according
to the distance between the
obstacles and the vehicle
Lv2 Lv3 and the location of the
obstacles; (b) no information
is displayed in Level 0 and
Level 1 within a certain
distance.
(Disabled when the vehicle
speed is 15 km/h or higher,
Enabled when the vehicle
speed is less than 10 km/h)
- If any error is detected
during initial diagnosis, it is
displayed as a question
mark (?). Other points
without errors are displayed
in the same way as the PAS
mode.

GETtheMANUALS.org
 0000-00 05-79

4) Display Tire Alignment

Mode/pop-up display Operating conditions
- This indicator helps the
Level 0 driver to predict the driving
direction by showing the tire
alignment on the instrument
cluster.
- When the ignition switch is
turned to ON from OFF
position, the level number
between 1 and 5 is indicated
according to the tire
Left level 5 Right level 5 direction. (The tire alignment
indicator is not displayed on
the screen when the level
is 0.)
- The indicator is displayed
for 5 sec. for up to level 2.
For level 3 to 5, the indicator
stays on until the tire
alignment conditions are
met.
- For vehicles with A/T, this
indicator is displayed only
when the shift lever is in P
or N.

GETtheMANUALS.org
05-80

5) Door Open (Door/Hood/Tailgate)

Mode/pop-up display Operating conditions
The indicators come on to inform
Driver door open Passenger door open the driver of the open door.

Rear LH door open Rear RH door open

Hood open Tailgate open

GETtheMANUALS.org
 0000-00 05-81

6) Other Information Display

Pop-up display Operating conditions
If there is a fault in the ESP system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the EBD system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the ABS system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the oil level and oil pressure 3 seconds after the
engine start, a warning message and warning indicator are
displayed on the LCD screen.

This message is displayed on the LCD screen when the driver door
is opened after the ignition has been turned OFF.

GETtheMANUALS.org
05-82

Pop-up display Operating conditions

The pop-up is displayed on the LCD screen along with the beep
when the sunroof is open with IGN off.

- If the fuel level is detected as being low 3 seconds after

the engine start, a warning message and warning indicator
are displayed on the LCD screen.
- When the distance to empty is about 30 km or less warning
lamp and message are displayed on the LCD screen.

If there is a fault in the HBA system 3 seconds after the engine start,
this warning message is displayed on the LCD screen.

- For the vehicle without driver attention alert system, the

warning messages is displayed on the LCD screen along
with the beep every 2 hours.
- For the vehicle with driver attention alert system, the
warning message is displayed on the LCD screen along
with the beep by the system.

GETtheMANUALS.org
 0000-00 05-83

7) Autonomous Emergency Braking System (AEBS)

Pop-up display Operating conditions
- When AEBS is activated, "Collision warning" is displayed on
the LCD display of the instrument cluster for 5 seconds and
the AEBS indicator flashes for 5 seconds.
- If the conditions for displaying warning message are met
again during the 5 seconds of the message display, the
new warning message will be displayed for 5 seconds
with the same flashing of the AEBS indicator.

This message is displayed after the vehicle has stopped by the

activation of emergency braking (maximum brake control) by the
3rd warning of AEBS.

LCD display shows this message after the first 3 sec. of starting the
engine when there is a fault in the AEBS. This message will stay on
for 5 sec.

This message is displayed when the front camera module cannot

detect the lane markings, preceding vehicles, people, etc. because
of the ice, snow, slush, mud, dirt or debris on the windshield glass.

GETtheMANUALS.org
05-84

8) Steering Wheel Heating

Pop-up display Operating conditions
This message is displayed on the upper part of the LCD screen for
about 5 sec. according to the operation (ON/OFF) of steering wheel
heater switch with IGN ON or engine running.

GETtheMANUALS.org
 0000-00 05-85

9) Driving Mode (Vehicle With AT)

Pop-up display Operating conditions
(Vehicle With AT)
"NORMAL", "SPORT" and "WINTER" are displayed on the LCD
screen depending on the operation of the driving mode dial during
driving.

GETtheMANUALS.org
05-86

10) Driving Mode (Vehicle With MT)

Pop-up display
Operating conditions
(Vehicle With AT)
"NORMAL" or "SPORT" is displayed on the LCD screen depending
on the operation of the driving mode switch during driving.

11) Bluetooth Phone Call Hold

Pop-up display Operating conditions
When there is an incoming call with handsfree phone connected to
the vehicle, the caller ID or phone number is displayed on the upper
part of the LCD screen for 5 sec.
(priority: ID > phone number)

GETtheMANUALS.org
 0000-00 05-87

12) HDC Warning

Pop-up display Operating conditions
If the HDC (Hill Descent Control) system is faulty, a message is
displayed on the LCD screen.

13) HDC ON/OFF

Pop-up display Operating conditions
This message is displayed on the lower part of the LCD screen for
about 5 seconds according to the operation (ON/OFF) of HDC
switch.
The indicator color may change based on the HDC operation
status.
- Green HDC indicator ON: HDC in ready status
- Green HDC indicator flashing: HDC in operation
- Red HDC warning lamp ON: HDC in overheating condition
and system error

14) 1 km To Destination Check

Pop-up display Operating conditions
This message is displayed when navigation is linked to the system
and the distance to the destination is 1 km.

GETtheMANUALS.org
05-88

15) Service Interval Alert

Pop-up display Operating conditions
This message is displayed once on the LCD screen when the
ignition is turned ON from OFF, provided that the check box for the
Service interval alert under the User settings menu is checked and
the distance to destination is 0 km.

16) Topping Up Washer Fluid

Pop-up display Operating conditions
This message along with the low washer fluid warning indicator are
displayed on the LCD screen if the washer fluid is low when the
ignition is turned ON.
(Shows pop-up only once when IGN on)

17) Destination Arrival Alert

Pop-up display Operating conditions
This message is displayed when navigation is linked to the system
with Turn By Turn (TBT) menu activated and the distance to the
destination is 0 km.

GETtheMANUALS.org
 0000-00 05-89

18) Light Mode

Pop-up display Operating conditions
The corresponding message is displayed on the lower part of the
main menu for about 5 seconds when changing the status of the
light multifunction switch.

GETtheMANUALS.org
05-90

19) Front Wiper Mode

Pop-up display Operating conditions
The corresponding message is displayed on the lower part of the
main menu for about 5 seconds when changing the status of the
front wiper multifunction switch.

GETtheMANUALS.org
 0000-00 05-91

20) Rear Wiper Mode

Pop-up display Operating conditions
The corresponding message is displayed on the lower part of the
main menu for about 5 seconds when changing the status of the
rear wiper multifunction switch.

GETtheMANUALS.org
05-92

21) BSD System

Pop-up display Operating conditions

This message is displayed on the lower part of the main menu for 2
seconds according to the operation (ON/OFF) of BSD switch.

If there is a fault in the BSD system, this message is displayed on

the LCD screen for 5 seconds.

When the BSD system is turned on and the sensor does not
normally detect the blind spots, a message is displayed on the LCD
for about 5 seconds.

GETtheMANUALS.org
 0000-00 05-93

22) Rear Cross Traffic Alert System

Pop-up display Operating conditions

This message is displayed on the lower part of the main menu for 2
seconds according to the operation (ON/OFF) of BSD switch.
(It is divided into rear cross traffic alert / rear cross traffic and
emergency braking depending on the driving assist system setting,
and it is not possible to select both modes at the same time.)

This message is displayed on the LCD screen when a vehicle is

detected left and/or right side of the rear of the vehicle during the
operation of rear cross traffic alert system.

GETtheMANUALS.org
05-94

23) RCTA & AEB

Pop-up display Operating conditions

This message is displayed on the lower part of the main menu for 2
seconds according to the operation (ON/OFF) of BSD switch.
(It is divided into rear cross traffic alert / rear cross traffic and
emergency braking depending on the driving assist system setting,
and it is not possible to select both modes at the same time.)

This message is displayed on the LCD screen along with the

vehicle control (apply the brake) when a vehicle is detected left
and/or right side of the rear of the vehicle during the operation of
rear cross traffic and emergency braking system.

GETtheMANUALS.org
 0000-00 05-95

24) Vehicle Exit Alert

Pop-up display Operating conditions
If you are about to open the door to leave the vehicle when a
vehicle is approaching from the rear side, the vehicle exit alert
system displays a message on the LCD screen and generates a
beep sound.
However, it operates only when the gear selector lever is in P (Park)
or N (Neutral) position.

GETtheMANUALS.org
05-96

25) Not Enough Fuel to Reach Destination

Pop-up display Operating conditions
This message is displayed when the fuel is not sufficient to drive to
the destination set on the navigation.

26) FVSA (Front Vehicle Start Alarm)

Pop-up display Operating conditions
If the driver does not perform any operation after a certain period of
time has elapsed since the front vehicle departed, a message is
displayed on the LCD screen along with a beep.

If there is a fault in the FVSA system, a message is displayed on

the LCD screen.

GETtheMANUALS.org
 0000-00 05-97

27) SCR warning lamp

Pop-up display Operating conditions
The corresponding message is displayed on the LCD screen when
the exhaust aftertreatment system is deposited with soot and etc.
and the aftertreatment system must be operated.

If the exhaust gas aftertreatment system is faulty, a message is

displayed on the LCD screen.

In the normal (warning message disappeared) state after an alert

has been issued due to an urea system failure, a message
indicating Urea system needs to be checked is displayed on the
LCD display for approximately 50 km of driving.

If the urea system is still faulty after checking the urea system while
driving the vehicle for 50 km, a corresponding warning message is
displayed on the LCD display.
At this time, the engine restart is not possible.

GETtheMANUALS.org
05-98

▶ Warning due to low urea level

Pop-up display Operating conditions

- Warning lamp: not lit
- Warning beep: sound
- Warning message: displayed
- Drivable distance at time warning occurs: 2,400 km to 800
km
- Occurs for 15 seconds every 200 km of driving or 4 hours.

- Warning lamp: lit

- Warning lamp (turned off after first output)
- Warning message: displayed
- Drivable distance at time warning occurs: 800 km to 0 km
- Continues until enough amount of urea is replenished.

- Warning lamp: lit

- Warning lamp (turned off after first output)
- Warning message: displayed
- Drivable distance at when warning occurs: 0 km
(impossible to operate vehicle)
- Impossible to operate the vehicle because urea is depleted.
Replenish the urea immediately.

GETtheMANUALS.org
 0000-00 05-99

Warnings and beeps occur in three stages depending on the remaining amount of the urea. If it
happens, replenish the urea immediately so that it does not affect the operation of the vehicle.

Step 1 - Warning lamp (not lit), warning beep (sounds), warning message (displayed)
- Warning issued when urea quantity is 3.8L (drivable distance: 2,400 km ~ 800 km)
- Occurs for 15 seconds every 200 km of driving or 4 hours.
- Immediately replenish at least 5 liters of urea when corresponding warning is issued.
(Warning deactivation conditions)
Step 2 - Warning lamp (lit), warning buzzer (stops after first output), warning message
(displayed)
- Drivable distance at time warning occurs: 800 km to 0 km
- Immediately replenish at least 7 liters of urea when corresponding warning is issued.
(restart restriction lifted and warning lamp turned off)
Step 3 - Warning lamp (lit), warning buzzer (stops after first output), warning message
(displayed)
- Drivable distance at time warning occurs: 0 km
- It is impossible to operate the vehicle due to depletion of urea. Replenish the enough
amount of urea immediately or have it inspected and serviced by Ssangyong Dealer or
Ssangyong Authorized Service Operation.

GETtheMANUALS.org
05-100

▶ Warnings due to faulty urea system, bad urea and poor catalyst efficiency

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the urea injection control unit fault and
electrical fault occur.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of
800 km to 0 km after the primary warning due to the faulty
urea injection control unit and electrical fault.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to the faulty urea injection
control unit and electrical fault.
- Impossible to operate vehicle

GETtheMANUALS.org
 0000-00 05-101

▶ Warning caused by faulty urea injector

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the urea injector is faulty.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning due to the faulty urea
injector.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to the faulty urea injector.
- Impossible to operate vehicle

GETtheMANUALS.org
05-102

▶ Warning due to low quality urea

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed while driving 50
km when incorrect urea is used.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning when incorrect urea is
used.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning when incorrect urea is used.
- Impossible to operate vehicle

GETtheMANUALS.org
 0000-00 05-103

▶ Warning due to low SCR catalyst purification efficiency

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the SCR catalyst purification efficiency is low.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning due to low SCR
catalyst purification efficiency.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to low SCR catalyst
purification efficiency.
- Impossible to operate vehicle

GETtheMANUALS.org
05-104

▶ Warning due to abnormal exhaust emissions

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed while driving 50
km when exhaust emissions are out of limits.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning when exhaust
emissions are out of limits.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning when exhaust emissions are
out of limits.
- Impossible to operate vehicle

GETtheMANUALS.org
 0000-00 05-105

14. ILLUMINATION AND BRIGHTNESS

1) Designations

A. 10.25-inch main LCD screen

B. LED warning / indicator
C. Coolant temperature segment LCD
D. Fuel gauge segment LCD

- Illumination of the instrument cluster is controlled in 1 to 20 steps at day and night modes.
- The illumination can be set by operating the lower main switch and a pop-up message is displayed
while setting. (Operating the switch changes the set value within about 0.1 seconds)
- The set value is saved after 5 seconds from the last signal input by operation of the illumination
setting switch.
- After cycling the ignition on and off and resetting the battery (removing and fitting), the instrument cluster
illumination remains at the last set value.
- The instrument cluster illumination and LCD will operate within approximately 0.4 seconds after
IGN on.
- Illumination can be set even when the ignition is off, unless the system is in sleep mode.
- When initializing the instrument cluster, illumination is initialized to level 12.

GETtheMANUALS.org
05-106

2) How To Set Illumination

(1) Location of instrument cluster illumination switch and how to use it

Switch Short press Long press

Instrument cluster 1 higher level
Increase continuously
illumination switch ▲
Instrument cluster 1 lower level
Decrease continuously
illumination switch ▼
- Stops when reaching 1 or 20
level and moves to next step
Go to next level when
Remarks when re-entering switch (20→1)
reaching 1 or 20 level (20
- Press and hold the switch to
↔ 1)
change the illumination level every
0.2 seconds.

- When the input is transmitted to the instrument cluster illumination switch, the setting status is
displayed as a pop-up. If no switch is operated, the pop-up disappears after 2 seconds.
- Illumination control always available when IGN on
- Control available only when IGN off (B+ on), tail lamp turned on
- The dim brightness is adjusted from 0% to 100% by the PWM output.

GETtheMANUALS.org
 0000-00 05-107

3) Illumination Setup By Step

(1) PWM setting value depending on illumination setting Unit: % (PWM)

- All other LEDs excepting green/white LED warning/indicator lamps are fixed in 12 steps.
- Resetting the instrument cluster initializes to the default brightness, 12 step.

GETtheMANUALS.org
05-108

4) Illumination Order

A. When IGN is on, all the LCDs are activated within T1 (0.4 sec) and the Start animation is displayed for
T4 (4 sec).
B. When IGN is off, all the LCDs are turned off after Goodbye animation is displayed for T4 (4 sec).

GETtheMANUALS.org
GETtheMANUALS.org
05-110

15. CIRCUIT DIAGRAM

▶ WARNING LAMP

GETtheMANUALS.org
 0000-00 05-111

GETtheMANUALS.org
05-112

GETtheMANUALS.org
 0000-00 05-113

GETtheMANUALS.org
 0000-00 06-3

1. SPECIFICATIONS
Category Specifications
Rated voltage DC 12.0V
Operating voltage DC 9.0 ~ 16.0V
CAN network operating voltage 20.1 V or less
Sound 6 different beeps
(buzzer / speaker)
LCD type 3.5-inch (320X240) MONO TFT LCD
Blue High beam indicator
Hands-off warning lamp, 4WD CHECK warning lamp,
charge warning lamp, engine overheat warning lamp,
Red
water separator warning lamp, EPS warning lamp, air
bag warning lamp, engine oil pressure warning lamp, seat
belt warning lamp
Turn signal indicator/hazard warning flasher, front fog
lamp indicator, light ON indicator, SPORT indicator,
Green
WINTER indicator, 4WD LOCK ON indicator, HBAS
indicator, Smart tailgate indicator
Warning lamp ABS warning lamp, warm-up indicator, low fuel level
color warning lamp, global warning lamp, engine CHECK
warning lamp, AEBS warning lamp, AEBS OFF indicator,
SCR warning lamp, immobilizer/smart key warning lamp,
Amber
ESP OFF indicator, ESP ON indicator/warning lamp,
steering wheel heating indicator, brake warning lamp,
Over speed(120km) warning light, ISG OFF warning
lamp
Green/Amber ISG indicator/warning light
Green/Red HDC ON indicator/warning light
Green/Amber/White Lane departure indicator

GETtheMANUALS.org
06-4

1. OVERVIEW
The instrument cluster is intended to inform the driver of warnings and current status of the vehicle by
communicating with various units through C-CAN, Multi media-CAN, and hard-wire communications.
The instrument cluster has the buzzer and speaker which make various warning sounds in its back side.

2. COMPONENTS

3.5" instrument cluster

Front side Rear side

A. Tachometer D. connector
B. LCD screen E. Speaker
C. Speedometer F. Buzzer

GETtheMANUALS.org
 0000-00 06-5

1. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
06-6

GETtheMANUALS.org
 0000-00 06-7

▶ Full names of acronyms and option description

GETtheMANUALS.org
06-8

2. C-CAN COMMUNICATION I/O ELEMENTS

▶ AEB

▶ BSD

▶ ACU

GETtheMANUALS.org
 0000-00 06-9

▶ CGW

GETtheMANUALS.org
06-10

▶ CGW

GETtheMANUALS.org
 0000-00 06-11

▶ CGW

GETtheMANUALS.org
06-12

▶ CGW

GETtheMANUALS.org
 0000-00 06-13

▶ EPS

▶ ESP

GETtheMANUALS.org
06-14

3. M-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
 0000-00 06-15

▶ AVN

GETtheMANUALS.org
06-16

4. SYSTEM WAKE UP AND SLEEP MODE

Outgoing signal Incoming signal

System status
activated activated
Network ON O O
Network OFF X X
Wake up (network start up) X O
Sleep mode (network shut down) X O

▶ Wake up (network start up) conditions

- UNLOCK (Remote) signal is received

- CAN BUS wake up conditions are met

▶ Wake up (network start up) conditions

- The network is turned on when the ignition is turned on.

- A network message request is received from the BSD, CGW and ESP.

▶ Network shutdown conditions

- No signal on CAN bus for 10 minutes after IGN off

- In the event of message request from the BSD, network does not shutdown. (up to 10 minutes)

▶ Sleep mode (network shut down) conditions

- CAN BUS sleep conditions are met based on the network type

GETtheMANUALS.org
 0000-00 06-17

5. WARNING LAMPS AND INDICATORS

- PW (Pre-Warning): Indicators which is illuminated for 4 sec. after the ignition is turned on
- TIME OUT: When no signal is received during 10 times repetition of cycle time (signal cycle)
(Multimedia CAN: 3.5 times)
→ X (HOLD): The status remains the same as before TIME OUT
→ O (ON) : The indicator is turned ON when TIME OUT occurs.
- Priority of warning lamps
Blinking > On > Off
- What is signal value display
(e.g., BCM (P-CAN → C-CAN)?
The BCM sends the corresponding signal to the CGW via P-CAN and the CGW to the instrument
cluster via C-CAN.)

GETtheMANUALS.org
06-18

GETtheMANUALS.org
 0000-00 06-19

GETtheMANUALS.org
06-20

GETtheMANUALS.org
 0000-00 06-21

GETtheMANUALS.org
06-22

6. WARNING SOUND DESCRIPTION

1) Overview
The instrument cluster sounds audible alerts at 5 different intervals and with 3 different sounds. The
speaker fitted in the instrument cluster outputs 5 types of sounds (warning sound - beep: 4, normal
sound: 1) and can output 3 different sounds at a time to inform the driver of vehicle conditions.
In addition, there are 6 types of the speaker beep (Basic, Natural, Classic, Trendy, Korean, and Luxury).

Connector Speaker

Buzzer

GETtheMANUALS.org
 0000-00 06-23

2) Warning Buzzer Interval

Type A: Normal sound (* Dynamic client)

Type B: Outputs repeatedly and stops if deactivation conditions are met, PAS 3-stage output sound
Type C: Periodic output for predetermined time
Type D: Periodic output until deactivation conditions are met
Type E: Warning buzzer sounds only once and then stops
* Dynamic client: Audible signals which are heard when ignition is turned or off (Pre-Welcome,
Welcome, Goodbye with trip information and service interval alert).

GETtheMANUALS.org
06-24

3) Warning Buzzer Priority

▶ Group 1

- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
 0000-00 06-25

▶ Group 2

- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
06-26

▶ Group 3

GETtheMANUALS.org
 0000-00 06-27

- Pop-up (P): buzzer sounds only when the corresponding message displayed on the LCD screen.
(When pop-up (P) is not displayed depending on the LCD display priority, a beep does not also sound. /
Even if the pop-up disappears, some voice guidance is played to the end.)
- Pop-up (S): Beep sounds when corresponding signal input
- The buzzer for PAS stage 1 or 2 will not sound during the activation of rear or front PAS stage 3.
- The warning buzzers of groups 1, 2, 3 and 4 can sound at the same time.
- The buzzer for warnings within the same group will sound based on the priority.

GETtheMANUALS.org
06-28

▶ Group 4 (priority of LCD pop-ups)

GETtheMANUALS.org
 0000-00 06-29

4) Warning Buzzer Priority

GETtheMANUALS.org
06-30

7. LCD MAIN MENU ITEMS

Main menu display Main Menu Description

TRIP computer menu

When you press the main menu switch - Distance to empty/Average fuel
( ), the entire group is displayed and the economy/Instantaneous fuel economy
selected menu is displayed in shaded. - Mileage A/Average vehicle speed/Driving
time
- Mileage B/Average vehicle speed/Driving
time
If there is no switch input signal for 5 seconds,
the set main menu symbol (1) is displayed and - After departure
the display is switched to the navigator bar (2). - ISG cumulative time
- TPMS
- Urea level
Position of switches
Digital speedometer menu
- Digital speedometer

Driving Assist Menu

- LKAS (LDWS / LKAS / AUTO CRUISE /
Speed limit / SSC)

AV menu
- Display linked to AV
Description

TBT (Turn By Turn) Menu

- Display linked to navigation

User settings menu

- Driving assist setting
- Language
- Door/Tailgate
- Light
- Convenience function
- Sound
- Service interval alert
- Instrument settings & information
- Initialization of all settings

GETtheMANUALS.org
 0000-00 06-31

8. LCD MAIN MENU DISPLAY

1) TRIP Computer Menu

TPMS / Urea level

After entering into the corresponding menu, the system will be automatically changed to Distance to
empty when no switch operation for 15 seconds or longer.

GETtheMANUALS.org
06-32

▶ Distance to empty/Average fuel economy/Instantaneous fuel economy

Item 3.5" instrument cluster

Display

- Displays distance to empty

Display range every 1 sec
Distance to empty - Below 50 km: displayed as "---"
How to reset - Not possible

Display range - 0.0 to 30.0 km/L

Average fuel economy - 0.0 to 30.0 L/100 (Liters/100 km)
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.

Display range - 0.0 to 30 km/L

Instantaneous fuel - 0.0 to 30 L/100km
economy
How to reset - Not possible

Initial calculating condition for average fuel economy

After the average fuel consumption reset, it is displayed when the vehicle moves for more than 50 m
and for more than 10 seconds. It is updated every 10 seconds and displayed on the LCD screen.

Initial calculating condition for instantaneous fuel economy

The instantaneous fuel consumption is displayed on the LCD screen by calculating the
instantaneous fuel consumption value for the last 0.6 seconds and updating it at every 0.2 seconds.

- The '---' flashes on the screen if the fuel sender input is outside the specified range for 20 seconds
or more during average fuel consumption calculation.
- If the instantaneous fuel consumption is higher than 30.0 km/L, it will be displayed as 30.0 km/L.

GETtheMANUALS.org
 0000-00 06-33

(1) Distance to empty

The Distance To Empty (DTE) displayed on the LCD screen is a calculated value based on the fuel
consumption (injection volume and distance driven) and measured fuel volume in the fuel tank.
The DTE value increases or decreases by 1 km.
The color of this value varies depending on the model and the distance as shown in the table below.

Supervision Standard
DTE
instrument cluster instrument cluster
100 km or longer Blue texts -
Below 100 km/h Yellow texts -
Below 50 km/h (warning) ‘---’ in red & flashing ‘---’ flashing

Digital input by user (information displayed on LCD screen)

- TRIP computer menu → Select from Distance to empty/Average fuel economy/Instantaneous
fuel economy
Input signal from vehicle (Calculation)
- CAN: Fuel consumption (vehicle speed, injector fuel injection data)
- Analog digital converter (ADC): Fuel volume

GETtheMANUALS.org
06-34

The DTE value displayed on the LCD may differ from the actual drivable distance of the vehicle,
because the DTE is an expected value based on accumulated data and current vehicle data.
- Accumulated data: Driving style (calculating accumulated learned fuel economy before/after
refueling)
- Current vehicle data: Input signal from vehicle

(2) Average fuel economy

The average fuel economy displayed on the LCD screen of the instrument cluster is a calculated value
based on the total amount of fuel used (injection volume signal from injector) and the distance driven since
reset.
Press and hold the 'enter' ( ) button on the right side of steering wheel to reset.
To get enough data after initialization, '--.-' is displayed on the LCD display until it is driven for more than 50
m and for more than 10 seconds, and then it is displayed according to the set display unit.
Select User Settings → Instrument cluster settings & Information → Fuel economy unit to select the
unit.

(3) Instantaneous fuel economy

The instantaneous fuel economy value is calculated based on the instantaneous fuel amount used and
the distance driven since the engine start and displayed on the LCD screen in the form of a bar graph.
When the vehicle speed is less than 10 km/h, only the bar graph is displayed in the unit selected.

Supervision Standard
Fuel economy unit
instrument cluster instrument cluster
- Km/L 1 SEG ←
L/100 km Full SEG ←

The instantaneous fuel economy value is calculated as follows with no reset, and it is updated at every
0.2 sec. interval.

GETtheMANUALS.org
 0000-00 06-35

▶ Mileage A or B/Average vehicle speed/Driving time

Item Standard instrument cluster

Display

Display range - 0.0 to 9999.9 km

Mileage A/B
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
- When it exceeds 10000.0, it will be reset to 0.0

Average Display range - 0 to 220 km/h

speed How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
Display range - 00:00 ~ 99:59
Driving time
How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
- When it exceeds 100:00, it will be reset to 00:00

Mileage / driving speed reset

- Mileage / driving speed for trip B maintained even if trip A reset
- Mileage / driving speed for trip A maintained even if trip B reset

Mileage
The mileage is displayed on the LCD screen when the vehicle speed signal is received from the
ECU since the last reset.

Driving speed (average)

The average speed is calculated from the time and distance since the last reset. This value will be
updated on the LCD screen at every 10 seconds. The calculation of average speed is only carried
out when the engine is running.

Driving time
The driving time is the value accumulated since the last reset with engine running including idling and
is displayed on the LCD screen in the time format of 0:00 to 99:59 (HH:MM).

Trip vehicle speed signal input:

P-CAN C-CAN
Wheel speed sensor → ESP ----------> CGW ----------> Instrument cluster

GETtheMANUALS.org
06-36

▶ After departure / Driving time / Fuel consumption

Item 3.5" instrument cluster

Display

After Display range - 0.0 to 9999.9 km

departure How to reset - Ignition OFF → ON
Display range - 00:00 ~ 99:59
Driving time
How to reset - Ignition OFF → ON
Display range - 0.0 ~ 99.9L

Fuel consumption - Ignition OFF → ON

How to reset - When fuel consumption exceeds 100.0 after
departure it will be reset to 0.0

After departure
After reset (IGN OFF → ON), the distance driven is displayed on the LCD.

Driving time
After reset (IGN OFF → ON), the distance driven is displayed on the LCD.

Fuel consumption
After reset (IGN OFF → ON), the total amount of fuel consumption is updated at every 10
seconds and displayed on the LCD.

GETtheMANUALS.org
 0000-00 06-37

▶ ISG cumulative time

Item 3.5" instrument cluster

Display

Display range - 00:00:00 to 99:59:59 (HH:MM:SS)

Auto stop
Cumulative time How to reset - Press Enter (OK) switch ( ) for more than 1 sec.
- When it exceeds 99:59:59, it will be reset to 0.0

Cumulative time for AUTO STOP

A message indicating the cumulative time when the engine is off is displayed while the ISG system is
operating.

GETtheMANUALS.org
06-38

▶ TPMS

Select the trip computer sub menu (TPMS) under LCD main menu to check the current tire pressure.
After entering into the TPMS menu, the system will be automatically changed to Distance to empty when no
switch operation for 15 seconds or longer. (However, if another pop-up occurs within 15 seconds, the urea
level is displayed again for 15 seconds from the time the pop-up disappears.)
If the screen displays menu other than TPMS, the tire pressure normal pop-up message is displayed once
for 15 seconds after the normal pressure signal has been received.

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Priority of alert messages
1. Flat tire
2. Over inflation
3. Low pressure
-
4. check
5. Unbalanced pressure
6. Not displayed
7. Normal

Normal tire pressure

This indicator is displayed when
all the tire pressures are
normal.

Tire pressure not displayed

The tire pressure value is
displayed as "- -" when no tire
pressure is measured.

Check tire
If the tire pressure is too low to
avoid an inspection, this
message will be displayed. The
corresponding tire pressure
blinks (inverted shading) for 70
seconds and corresponding
tire(s) will be displayed in
yellow.

GETtheMANUALS.org
 0000-00 06-39

Tire pressure (TPMS) display

Item
Main menu mode Pop-up mode
Display Display
Low tire pressure
If the tire pressure is too low to
avoid an inspection, this
message will be displayed. At
the same time, the global
warning light will come on and
the corresponding tire(s) will be
indicated in yellow.

Flat tire
When the current tire pressure
drops rapidly or when one or
more tires are flat, the global
warning lamp will come on and
the corresponding tire(s) will be
indicated in red.

Over inflation
This message is displayed
when the current tire pressure
is too high. The corresponding
tire(s) will be indicated in red.

Pressure imbalance
If the pressure difference
between LH and RH tires is 5
psi or more, the corresponding
tires on the screen flash with
the shading inverted
alternatively.

GETtheMANUALS.org
06-40

▶ Urea level

Select the trip computer sub menu (urea level) under LCD main menu to check the current urea level.
The urea level is automatically changed to the distance to empty after 15 seconds.
(However, if another pop-up occurs within 15 seconds, the urea level is displayed again for 15 seconds
from the time the pop-up disappears.)

Item 3.5" instrument cluster

Display

20bar 11L 10bar 5.5L

19bar 10.45L 9bar 4.95L
18bar 9.9L 8bar 4.4L
17bar 9.35L 7bar 3.85L
16bar 8.8L 6bar 3.3L
Display range 15bar 8.25L 5bar 2.75L
14bar 7.7L 4bar 2.2L
13bar 7.15L 3bar 1.65L
12bar 6.6L 2bar 1.1L
11bar 6.05L 1bar 0.55L
0bar 0L
Input data ECU(P-CAN) → CGW(C-CAN) → ICM

- Rise: bar rises when capacity increases / Fall: bar falls when capacity decreases
- The urea consumption may depend on the driving style and surrounding environment.

GETtheMANUALS.org
 0000-00 06-41

Warnings and beeps occur in three stages depending on the remaining amount of the urea. If it
happens, replenish the urea immediately so that it does not affect the operation of the vehicle.

Step 1 - Warning lamp (not lit), warning beep (sounds), warning message (displayed)
- Drivable distance at time warning occurs: 2400km to 800km
- Occurs for 15 seconds every 200 km of driving or 4 hours.
- Immediately replenish at least 5 liters of urea when corresponding warning is
issued.
(Warning deactivation conditions)
Step 2 - Warning lamp (lit), warning buzzer (stops after first output), warning message (displayed)
Drivable distance at time warning occurs: 800 km to 0 km
- Immediately replenish at least 7 liters of urea when corresponding warning is
- issued.
(restart restriction lifted and warning lamp turned off)

Step 3 - Warning lamp (lit), warning buzzer (stops after first output), warning message (displayed)
Drivable distance at time warning occurs: 0 km
- It is impossible to operate the vehicle due to depletion of urea. Replenish the enough
- amount of urea immediately or have it inspected and serviced by Ssangyong Dealer or
Ssangyong Authorized Service Operation.

GETtheMANUALS.org
06-42

2) Digital Speedometer Menu

Item 3.5" instrument cluster

Display

0 to 220 km/h (in 1 km/h increments)

Digital speedometer display range (The vehicle speed is updated every 0.2 to 0.4 seconds
depending on the vehicle speed.)

- Displays the number corresponding to the current vehicle speed.

- Pressing the SET button for 1 second or more turns on or off all indicators and illuminations except
the LCD screen itself.

GETtheMANUALS.org
 0000-00 06-43

3) Driver Assistance Menu

When entering the driving assistance menu, the system is automatically set according to various
signals of the vehicle based on the lane keeping auxiliary system and the lane departure warning
system as follows.
- Lane departure warning system
- Lane keeping assistance system
- Speed limit

GETtheMANUALS.org
06-44

▶ LDWS (Lane Departure Warning System)

Lane departure warning system

Item
Main menu mode Pop-up mode
Display Display

Lane departure warning

system OFF
This message is displayed
when the LDWS is turned off. -

Lane departure warning

system ready
The lanes are displayed as
shaded when the vehicle is
-
driven at a low speed of less
than 60 km/h or both lanes are
not detected with LDWS ON.

Lane departure warning

system not available
This message is displayed
when the system calibration -
has not been carried out.

Lane departure warning

system Check*
This message is displayed after
the first 3 seconds of starting
the engine when there is a fault
in the lane departure warning
system.

GETtheMANUALS.org
 0000-00 06-45

▶ LDWS lane display area

ADAS lane display area (LDWS)

Item
Main menu mode Pop-up mode
Display Display
This message is displayed
when only the left lane marking
has been detected.
- Line: left lane displayed in -
white
- Warning beep:
not working

This message is displayed

when only the left lane marking
has been detected.
- Line: left lane blinks in
white
- Warning beep: sound

This message is displayed

when only the right lane
marking has been detected.
- Line: right lane displayed -
in white
- Warning beep:
not working

This message is displayed

when only the right lane
marking has been detected.
- Line: right lane blinks in
white
- Warning beep: sound

GETtheMANUALS.org
06-46

ADAS lane display area (LDWS)

Item
Main menu mode Pop-up mode
Display Display
Displayed when both lanes are
detected.
- Line: left/right lane
displayed in white -
- Warning beep:
not working

Displayed when both lanes are

detected.
- Line: left lane blinks in
white
- Warning beep: sound

Displayed when both lanes are

detected.
- Line: right lane blinks in
white
- Warning beep: sound

Displayed when both lanes are

detected.
- Line: left/right lane blinks
in white
- Warning beep: sound

GETtheMANUALS.org
 0000-00 06-47

▶ LKAS (Lane Keeping Assistance System)

Lane keeping assistance system

Item
Main menu mode Pop-up mode
Display Display

LKAS off
This message is displayed
when the LDWS is turned off.
-

Lane keeping assistance

system ready
The lanes are displayed as
shaded when the vehicle is
-
driven at a low speed of less
than 60 km/h or both lanes are
not detected with LKAS
activated.

Lane keeping assistance

system not available
This message is displayed
when the system calibration -
has not been carried out.

Lane keeping assistance

system Check*
This message is displayed 3
seconds after starting the
engine when there is a fault in
the LKAS.

GETtheMANUALS.org
06-48

▶ LKAS (Lane Keeping Assistance System)

ADAS lane display area (LKAS)

Item
Main menu mode Pop-up mode
Display Display
This message is displayed
when only the left lane marking
has been detected.
- Line: left lane displayed in -
white
- Warning beep:
not working

This message is displayed

when only the left lane marking
has been detected.
- Line: left lane blinks in
white
- Warning beep: sound

This message is displayed

when only the right lane
marking has been detected.
- Line: right lane displayed -
in white
- Warning beep:
not working

This message is displayed

when only the right lane
marking has been detected.
- Line: right lane blinks in
white
- Warning beep: sound

GETtheMANUALS.org
 0000-00 06-49

ADAS lane display area (LKAS)

Item
Main menu mode Pop-up mode
Display Display
Displayed when both lanes are
detected.
- Line: left/right lane
displayed in white -
- Warning beep:
not working

Displayed when both lanes are

detected.
- Line: left lane blinks in
white
- Warning beep: sound

Displayed when both lanes are

detected.
- Line: right lane blinks in
white
- Warning beep: sound

Displayed when both lanes are

detected.
- Line: left/right lane blinks
in white
- Warning beep: sound

GETtheMANUALS.org
06-50

▶ Cruise control

AUTO CRUISE
Item Main menu mode Pop-up mode
Display Display

Target speed symbol

Auto cruise ready (“---”

displayed as target speed)
The message (toast pop-up) is
displayed on the upper part of the
LCD screen and the system
enters auto cruise ready mode
when the cruise control ON/OFF
switch is pressed with IGN ON.

Auto cruise set

(Target speed displayed)
The message (toast pop-up) and
set speed are displayed on the
upper part of the LCD screen and
auto cruise is activated when the
cruise control switch is operated
in auto cruise ready mode.

Auto cruise deactivated

The message (toast pop-up) is
displayed on the upper part of the
LCD screen when the cruise
control is switched off with cruise
control in READY mode and
active mode.

After deactivating auto cruise

control
After deactivating the cruise
control, the LDWS and LKAS are
activated according to the driver
assistance system settings.
(Pop-up mode display keeps
showing the screen at the time
cruise control deactivated)

GETtheMANUALS.org
 0000-00 06-51

▶ Lane keeping assistance system hands-off

Lane keeping assistance system hands-off

Item
Main menu mode Pop-up mode
Display Display
Level 1 warning
If the driver does not hold the
steering wheel for a certain
period of time with the lane -
keeping assistance system
activated, a warning pop-up
message is displayed.

Level 2 warning
If the driver does not hold the
steering wheel even after the
level 1 warning pop-up is -
displayed, the level 2 warning
pop-up will be displayed and a
beep will sound.

Forced deactivation of lane

keeping assistance system
After the level 2 warning, for
safe operation, the lane
maintenance assistant system
is forcibly deactivated and the
relevant pop-up is displayed.

GETtheMANUALS.org
06-52

▶ Driver attention alert level

Item Standard instrument cluster

The driver's driving pattern and
driver status are analyzed
through various information,
and the driver's cautious driving
level is displayed in six levels
on the LCD screen.

When the DAA (Driver Attention

Alert) system is turned off or
faulty, corresponding message
is displayed on the LCD screen.

GETtheMANUALS.org
 0000-00 06-53

4) AV Menu

GETtheMANUALS.org
06-54

Item 3.5" instrument cluster

Display

The instrument cluster is linked to the AV system. Therefore, the

Contents contents displayed on the AV system are also displayed on the LCD
screen of the instrument cluster. The AV icon of the main menu may
vary depending on the manufacturer of the device connected to the
system.

GETtheMANUALS.org
 0000-00 06-55

5) TBT Menu

3.5" instrument cluster

Item
Linked with navigation Navigation turned off

Display

The instrument cluster is linked to The compass is displayed when

the navigation system and the navigation is turned off.
TBT display range displays part of the navigation
screen information.

GETtheMANUALS.org
06-56

6) User Settings Menu

GETtheMANUALS.org
 0000-00 06-57

9. USER SETTINGS
▶ Driving assist setting

Rear cross traffic alert" and "rear cross traffic and emergency braking" modes can't be selected at
the same time.

GETtheMANUALS.org
06-58

▶ Language

▶ Door/Tailgate

GETtheMANUALS.org
 0000-00 06-59

▶ Light

▶ Functions for driver comfort

GETtheMANUALS.org
06-60

▶ Sound

GETtheMANUALS.org
 0000-00 06-61

10. FIXED DISPLAY

1) Odometer (Total Distance Driven)
Item 3.5" instrument cluster

Display

Display range 0 to 999999km

Display unit 1 km
Input data Speed signal (ABS/ESP (P-CAN) → CGW (C-CAN) → ICM)

- Reset not possible (always displayed after IGN ON)

- If the indicated speed exceeds 300 km/h, the total mileage and trip meter stop working and the
speedometer indicates 0 km/h.

GETtheMANUALS.org
06-62

2) Ambient Temperature
Item 3.5" instrument cluster

Display

Display range -30℃ to 90℃ (-22℉ to 194℉)

Display unit 1℃ (1℉)
Input data Ambient temperature sensor (5 V analog signal)
Ambient
temperature The instrument cluster sends the signal from the ambient
temperature sensor to BCM, CPL, ECU, ESP and HVAC through
Output data CGW.
(ICM (C-CAN) → CGW (P-CAN) → BCM, CPL, EMS, ESP,
HVAC)
It turns on or off depending on the ambient air temperature.
ICE symbol On: 5℃
Off: 7℃
It is displayed once after 5 seconds when the engine is started with
ICE pop-up
the ICE symbol turned on.

GETtheMANUALS.org
 0000-00 06-63

3) Digital Clock
Item Standard instrument cluster

Display

Display range 0:00 to 12:00 (AM/PM)

0:00 to 21:00 (HH:MM)
Display unit 1 minute
Input data Clock information of audio received through Multi media-CAN

4) Gear
Item Standard instrument cluster

Display

Display range P-R-N-D-1-2-3-4-5-6

(R position indicated by flashing)
The TCU sends the gear position signal to the instrument cluster
Input data (ICM) via the CGW.
(TCU (P-CAN) → CGW (C-CAN) → ICM)

GETtheMANUALS.org
06-64

5) Coolant Temperature
Item 3.5" instrument cluster

Display

When temperature When temperature

Segment
rises temperature lowers temperature
(SEG)
where light on where light off
8seg 126℃/126℃ 125℃/125℃
7seg 123℃/123℃ 122℃/122℃
6seg 120℃/120℃ 117℃/117℃
Display range 5seg 114℃/114℃ 113℃/113℃
4seg 70℃/80℃ 69℃/79℃
3seg 55℃/60℃ 54℃/59℃
2seg 48℃/50℃ 47℃/49℃
1seg 40℃/40℃ 39℃/39℃
0seg 39℃/39℃ 38℃/38℃

Display type Segment

The engine coolant temperature signal is sent to the instrument cluster
Input data (ICM) via the CGW.
(ECU (P-CAN) → CGW (C-CAN) → ICM)

- If the engine temperature exceeds 120℃ for 5 sec., engine overheat indicator flashes at 0.5
sec. interval with a buzzer sound.
- There is a hysteresis zone for the segments, so the segment may not be turned on/off immediately
even when the temperature is above/under the specified temperature.

GETtheMANUALS.org
 0000-00 06-65

6) Fuel Gauge
Item 3.5" instrument cluster

Display

Capacity Capacity
Segment when lit up when lit up
Remark
(SEG) during during
refueling consumption
8seg 43L/46L 45L/48L -
7seg 38L/40L 41L/44L -
6seg 33L/35L 36L/38L -
5seg 28L/29L 31L/33L -
Display range
4seg 23L/24L 26L/27L -
3seg 18L/18L 21L/22L -
2seg 13L/13L 16L/16L -
Low fuel level warning
1seg 7.5L/7.5L 11L/11L lamp
OFF: 11L or higher
ON: 7.5L or less
5.5L/5.5L -
0seg -
3L/3L -
Display type Segment
Input data Fuel sender (analog signal)

GETtheMANUALS.org
06-66

Item 3.5" instrument cluster

- When the IGN OFF or vehicle speed is about 0.2 km/h or less
(Displays the average fuel level on the screen by calculating
additional fuel level for 3 seconds after 10 minutes have passed
Automatic recognition - since the current fuel level is measured)
necessity of refueling - If the vehicle speed is 1km/h or more, the automatic recognition
mode (necessity of refueling) is deactivated.
- If the ignition is turned off after measuring the fuel level, the
system will enter sleep mode.
Cycle ignition off to on within 13 sec.: Previously measured value displayed
During IGN Cycle ignition off to on after 13 sec.: Currently measured value displayed
Refueling OFF
check
During IGN If vehicle is stationary at speed of about 0.5 km/h or less for more than 13
ON sec

- Refueling is not possible during operation.

- The low fuel level warning lamp blinks in the event of the fuel sender open circuit.
- Diesel fuel tank capacity is 47ℓ.
- Gasoline fuel tank capacity is 50ℓ.

GETtheMANUALS.org
 0000-00 06-67

11. LCD WARNING/INDICATOR PRIORITY

1) Level Priority
- Level 1 > Level 2 > Level 3 > Level 4 > Level 5 > Level 6 > Level 7 > Level 8 (warning message with
higher level priority overrides message with lower priority. If several messages with different levels keep
flowing in, display countdown starts again. (However, warning message with low level is displayed for
at least 0.5 seconds.)
- If there are 2 or more messages with the same level, the message with higher warning priority is
displayed first.

2) Warning Display Time Limit

- If the instrument cluster receives several messages with different levels, it displays the message with
the highest priority first for a specific time with a timer and then the message with next highest priority,
etc.
- If a timer does not show, then the message is displayed as long as the signal is present.
- The time on the timer is the maximum display time.
(5 second pop-up means that the pop-up is displayed for up to 5 seconds; pop-up disappears within 5
seconds when signal goes out.)
→ Exception: For rear-end collision alert, the pop-up is displayed for 5 seconds even f the
signal goes out within 5 seconds.

3) Level 3 Group Display

- Two or more messages in this group are displayed for 4 seconds alternately.
- When new message of level 3 group is activated while the message of level 3 group is being
displayed, new message is displayed first for 4 seconds followed by the messages alternately.

4) Temporary Display Off

- When the instrument panel setting switch input signal or voice command signal is input while the
warning message is displayed, for some items (warning messages with low priority), the pop-up is
temporarily turned off for 4 seconds and after that displayed again.

5) Pop-ups That Temporarily Turned Off And Then Not Displayed

Again
- Normal TPMS (15 sec), Low washer fluid level (5 sec), Service interval alert (5 sec), Destination
arrival alert (5 sec) and Take a rest warning (5 sec)

GETtheMANUALS.org
06-68

6) Forced-off
- The display of the low-priority warning message may be delayed according to the priority, and may not
be displayed unless the low-priority warning message display condition is satisfied.

7) Saving Pop-up Messages

- Any pop-up message with an asterisk (*) will display the master symbol as soon as a signal is
received, and store the corresponding signal in the User settings menu. (Even if the pop-up is forced
off by other high-priority pop-ups, the signal is always stored.)
- When the ignition is turned off and on after the fault signal is stored, the pop-up will not be displayed.
The determination of whether the fault signal pop-up continues is carried out after 2 seconds from
IGN on.

8) Items Where Pop-ups Display In B+ Condition

- Sunroof open, exterior lamp on, hood open, tailgate open, door ajar, pop-up related to SKM and
vehicle exit alert
- If the pop-up signal is maintained even after IGN off, the above items are also maintained.

9) Pop-ups Displayed 3 seconds After Engine Start

- ESP check, Engine oil level check, Low fuel level warning, HBA check, LKAS check, AEBS check
and ICE pop-up

10) Toast Pop-Up

- Display by switch operation (input)
(Steering wheel heating, HDC mode, light mode, front wiper mode, rear wiper mode, rear side alarm
system, ESP off and auto cruise)
- Display linked to AV system
(Bluetooth phone call hold, 1 km to destination check and AV volume)
- When a high-level toast pop-up message is received while the low-level pop-up is displayed,
the high-level toast message is displayed for 5 seconds and the low-level toast pop-up is not
displayed again.
- When the toast pop-ups belonging to the same group occur at the same time, a new toast
pop-up is displayed on the existing toast pop-up. (The existing toast pop-up is not displayed
again.)
- When the toast pop-up and pull pop-up occur at the same time, the toast pop-up is displayed on the
pull pop-up.

GETtheMANUALS.org
 0000-00 06-69

GETtheMANUALS.org
06-70

GETtheMANUALS.org
 0000-00 06-71

GETtheMANUALS.org
06-72

12. LCD DYNAMIC CLIENT DISPLAY

1) Door Open Welcome
3.5" instrument cluster Operating conditions
1. Pre-Welcome sound
When the driver door is opened after the theft deterrent mode is
disarmed
2. WELCOME
The driver door opened after vehicle disarmed → our logo
displayed on LCD screen for 4 sec. when door closed

- When the WELCOM logo is displayed, the color of 3-color LED light changes as an order of
red → green → blue.
- When the ignition is turned on while displaying WELCOM, the sound will be heard for the rest of the
operation time and the LCD screen is changed to the system check screen.

GETtheMANUALS.org
 0000-00 06-73

2) System Check When IGN ON

3.5" instrument cluster Operating conditions

Displays this message once for 4 seconds when the ignition is

turned on.

3) Vehicle Information And Service Interval Alert When IGN OFF

3.5" instrument cluster Operating conditions
- If you ticked "Show Driving Info" in User Settings menu, it
displays driving information for 5 seconds when ignition is
turned off and a sound "Goodbye" is heard.
- The "Low Fuel Level " message will be displayed when the
low fuel level warning lamp comes on.

- When you ticked "Enable Service Interval Notification" in

User Settings menu, the service interval notification (when
the set value is 300 km or less) message is displayed and a
sound "Goodbye" is heard.
- When it is past the due date, the number is preceded by '-'.

GETtheMANUALS.org
06-74

13. LCD WARNING AND INDICATOR DISPLAY

1) Smart Key System
Pop-up display Operating conditions
If you lock the door using the registered smart key with another
registered smart key left inside the vehicle and all doors closed, this
message will be displayed for 10 seconds.

This message is displayed on the LCD screen when no valid smart

key is found inside the vehicle with ACC, IGN ON or engine
running.

If low smart key battery is detected with AUTO LOCK function

deactivated, this message is displayed on the LCD screen for 10
sec.

The LCD display shows this message for 10 sec. when the ignition
switch is set to ACC position twice without depressing the brake
pedal to inform you that the brake pedal should be depressed when
starting the engine.

If the ignition switch is pressed and there is no valid smart key

detected inside the vehicle, this message is displayed on the LCD
screen for 10 sec.

GETtheMANUALS.org
 0000-00 06-75

Pop-up display Operating conditions

For the vehicle with A/T, the LCD display shows this message for
10 seconds when the ignition switch is switched to the ACC position
second time without depressing the clutch and the brake pedal to
inform you that the clutch and the brake pedal should be depressed
to start the engine.

If the gear selector lever is not in P or N position when you start the
engine, this message is displayed on the LCD screen for 10 sec. to
inform you that the gear selector lever should be in P or N position.

If the SKM receives no signals or faulty/incorrect signals from the

vehicle power supply control or ignition switch after the smart key
authentication, this message is displayed for 10 seconds.

If the gear selector lever is not in P position when you turn the
ignition OFF, this message is displayed on the LCD screen for 10
sec. to inform you that the gear selector lever should be in P
position to turn OFF the ignition.

This message is displayed for 10 sec. when ignition switch is in

ACC for 12 minutes or more or the driver door is opened with ACC
ON to prevent battery discharge.

GETtheMANUALS.org
06-76

Pop-up display Operating conditions

If low smart key battery is detected with AUTO LOCK function
activated, this message is displayed on the LCD screen for 10 sec.
This message is also displayed for 10 sec. when the AUTO LOCK
function is deactivated with low smart key battery.

When 2 or more valid smart keys are detected with IGN OFF and
open status of any door except for tailgate and hood changed, this
message is displayed for 10 seconds.

2) ISG System
Pop-up display Operating conditions
A message indicating the cumulative time when the engine is off is
displayed on the LCD screen.

A message is displayed on the LCD screen when the engine stops

and then is automatically restarted while the ISG system is
operating.

GETtheMANUALS.org
 0000-00 06-77

Pop-up display Operating conditions

The system OFF message is displayed on the LCD screen
depending on the ISG switch status (ON/OFF).

If the vehicle status does not meet the ISG system operating
conditions, a message is displayed on the LCD display.

A message is displayed on the LCD screen and the ISG system is

deactivated when the engine stops and the following vehicle
condition changes while the ISG system is operating.

If the ISG system is faulty, a message is displayed on the LCD

screen.

GETtheMANUALS.org
06-78

3) Parking Aid System (PAS)

Mode/pop-up display Operating conditions
1) Rear PAS
In R position When the shift lever is moved to
the R position with the IGN ON.
- When the shift lever is
moved to the R position, a
buzzer sounds briefly.
If any obstacle is detected
around the vehicle, the
existence of the obstacles is
displayed in 4 levels (Level
3, Level 2, Level 1 and Level
0) according to the distance
between the obstacles and
the vehicle and the location
of the obstacles. (Level 1 of
rear PAS: Information of
front PAS is not displayed.
Level 0 of rear PAS: Only
the shape of vehicle is
displayed.)
- If any error is detected
during initial diagnosis, it is
displayed as a question
mark (?).
Other points without errors
are displayed in the same
way as the PAS mode.

GETtheMANUALS.org
 0000-00 06-79

Mode/pop-up display Operating conditions

2) Front PAS
In D position The shift lever is moved to the D
position with the IGN ON:
- If obstacles are detected in
front of the vehicle (a) the
existence of the obstacles is
displayed in Level 2 and
Level 3 indicators according
to the distance between the
obstacles and the vehicle
and the location of the
obstacles; (b) no information
is displayed in Level 0 and
Level 1 within a certain
distance. (Disabled when
the vehicle speed is 15 km/h
or higher, Enabled when the
vehicle speed is less than
10 km/h.)
- If any error is detected
during initial diagnosis, it is
displayed as a question
mark (?).
Other points without errors
are displayed in the same
way as the PAS mode.

GETtheMANUALS.org
06-80

4) Display Tire Alignment

Mode/pop-up display Operating conditions
- This indicator helps the
driver to predict the driving
direction by showing the tire
alignment on the instrument
cluster.
- When the ignition switch is
turned to ON from OFF
position, the level number
between 1 and 5 is indicated
according to the tire
direction. (The tire alignment
indicator is not displayed on
the screen when the level is
0.)
- The indicator is displayed
for 5 seconds for up to level
2. For level 3 to 5, the
indicator stays on until the
tire alignment conditions are
met.
- For vehicles with A/T, this
indicator is displayed only
when the shift lever is in P
or N position.

GETtheMANUALS.org
 0000-00 06-81

5) Door Open (Door/Hood/Tailgate)

Mode/pop-up display Operating conditions
- The indicators come on to
inform the driver of the open
door.
- When the any doors, hood,
or tailgate is open, the open
door flashes on the screen.
- When all doors are closed,
the vehicle symbol indicating
all doors closed is displayed
for 1 second.

GETtheMANUALS.org
06-82

6) Other Information Display

Pop-up display Operating conditions
If there is a fault in the ESP system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the EBD system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the ABS system 3 seconds after the engine start,
a warning message and warning indicator are displayed on the
LCD screen.

If there is a fault in the oil level and oil pressure 3 seconds after the
engine start, a warning message and warning indicator are
displayed on the LCD screen.

This message is displayed on the LCD screen when the driver door
is opened after the ignition has been turned OFF.

GETtheMANUALS.org
 0000-00 06-83

Pop-up display Operating conditions

The pop-up is displayed on the LCD screen along with the beep
when the sunroof is open with IGN off.

- If the fuel level is detected as being low 3 seconds after

the engine start, a warning message and warning indicator
are displayed on the LCD screen.
- When the distance to empty is about 30 km or less warning
lamp and message are displayed on the LCD screen.

If there is a fault in the HBA system 3 seconds after the engine start,
this warning message is displayed on the LCD screen.

GETtheMANUALS.org
06-84

7) Autonomous Emergency Braking System (AEBS)

Pop-up display Operating conditions
- When AEBS is activated, "Collision warning" is displayed on
the LCD display of the instrument cluster for 5 seconds and
the AEBS indicator flashes for 5 seconds.
- If the conditions for displaying warning message are met
again during the 5 seconds of the message display, the
new warning message will be displayed for 5 seconds
with the same flashing of the AEBS indicator.

This message is displayed after the vehicle has stopped by the

activation of emergency braking (maximum brake control) by the
3rd warning of AEBS.

LCD display shows this message after the first 3 sec. of starting the
engine when there is a fault in the AEBS. This message will stay on
for 5 sec.

This message is displayed when the front camera module cannot

detect the lane markings, preceding vehicles, people, etc. because
of the ice, snow, slush, mud, dirt or debris on the windshield glass.

GETtheMANUALS.org
 0000-00 06-85

8) Steering Wheel Heating

Pop-up display Operating conditions
This message is displayed on the upper part of the LCD screen for
about 5 sec. according to the operation (ON/OFF) of steering wheel
heater switch with IGN ON or engine running.

GETtheMANUALS.org
06-86

9) Driving Mode (Vehicle With AT)

Pop-up display Operating conditions
(Vehicle With AT)
"NORMAL", "SPORT" and "WINTER" are displayed on the LCD
screen depending on the operation of the driving mode dial during
driving.

GETtheMANUALS.org
 0000-00 06-87

10) Bluetooth Phone Call Hold

Pop-up display Operating conditions
When there is an incoming call with handsfree phone connected to
the vehicle, the caller ID or phone number is displayed on the upper
part of the LCD screen for 5 sec.
(priority: ID > phone number)

11) HDC ON/OFF

Pop-up display Operating conditions
This message is displayed on the upper part of the LCD screen for
5 sec. according to the operation (ON/OFF) of HDC switch.
The indicator color may change based on the HDC operation
status.
- Green HDC indicator ON: HDC in ready status
- Green HDC indicator flashing: HDC in operation
- Red HDC warning lamp ON: HDC in overheating condition
and system error

12) 1 km To Destination Check

Pop-up display Operating conditions
This message is displayed when navigation is linked to the system
and the distance to the destination is 1 km.

GETtheMANUALS.org
06-88

13) Service Interval Alert

Pop-up display Operating conditions
This message is displayed once on the LCD screen when the
ignition is turned ON from OFF, provided that the check box for the
Service interval alert under the User settings menu is checked and
the distance to destination is 0 km.

14) Topping Up Washer Fluid

Pop-up display Operating conditions
This message along with the low washer fluid warning indicator are
displayed on the LCD screen if the washer fluid is low when the
ignition is turned ON.
(Shows pop-up only once when IGN on)

15) Destination Arrival Alert

Pop-up display Operating conditions
This message is displayed when navigation is linked to the system
with Turn By Turn (TBT) menu activated and the distance to the
destination is 0 km.

GETtheMANUALS.org
 0000-00 06-89

16) Light Mode

Pop-up display Operating conditions
These messages are displayed on the upper part of the LCD
screen for 5 sec. according to the corresponding operation of light
multifunction switch.

GETtheMANUALS.org
06-90

17) Front Wiper Mode

Pop-up display Operating conditions
These messages are displayed on the upper part of the LCD
screen for 5 sec. according to the corresponding operation of front
wiper multifunction switch.

GETtheMANUALS.org
 0000-00 06-91

18) Rear Wiper Mode

Pop-up display Operating conditions
These messages are displayed on the upper part of the LCD
screen for 5 sec. according to the corresponding operation of rear
wiper multifunction switch.

GETtheMANUALS.org
06-92

19) BSD System

Pop-up display Operating conditions
This message is displayed on the upper part of the LCD screen for
2 sec. according to the operation (ON/OFF) of BSD switch.

If there is a fault in the BSD system, this message is displayed on

the LCD screen for 5 seconds.

When the BSD system is turned on and the sensor does not
normally detect the blind spots, a message is displayed on the LCD
for about 5 seconds.

GETtheMANUALS.org
 0000-00 06-93

20) Rear Cross Traffic Alert System

Pop-up display Operating conditions

This message is displayed on the upper part of the LCD screen for
2 sec. according to the operation (ON/OFF) of BSD switch.
(It is divided into rear cross traffic alert / rear cross traffic and
emergency braking depending on the driving assist system setting,
and it is not possible to select both modes at the same time.)

This message is displayed on the LCD screen when a vehicle is

detected left and/or right side of the rear of the vehicle during the
operation of rear cross traffic alert system.

GETtheMANUALS.org
06-94

21) Not Enough Fuel to Reach Destination

Pop-up display Operating conditions
This message is displayed when the fuel is not sufficient to drive to
the destination set on the navigation.

22) FVSA (Front Vehicle Start Alarm)

Pop-up display Operating conditions
If the driver does not perform any operation after a certain period of
time has elapsed since the front vehicle departed, a message is
displayed on the LCD screen along with a beep.

If there is a fault in the FVSA system, a message is displayed on

the LCD screen.

GETtheMANUALS.org
 0000-00 06-95

23) SCR warning lamp

▶ Revising

Pop-up display Operating conditions

In the normal (warning message disappeared) state after an alert
has been issued due to an urea system failure, a message
indicating Urea system needs to be checked is displayed on the
LCD display for approximately 50 km of driving.

If the urea system is still faulty after checking the urea system while
driving the vehicle for 50 km, a corresponding warning message is
displayed on the LCD display.
At this time, the engine restart is not possible.

GETtheMANUALS.org
06-96

▶ Warning due to low urea level

Pop-up display Operating conditions

- Warning lamp: not lit
- Warning beep: sound
- Warning message: displayed
- Drivable distance at time warning occurs: 2400km to 800km
- Occurs for 15 seconds every 200 km of driving or 4 hours.

- Warning lamp: lit

- Warning lamp (turned off after first output)
- Warning message: displayed
- Drivable distance at time warning occurs: 800 km to 0 km
- Continues until enough amount of urea is replenished.

- Warning lamp: lit

- Warning lamp (turned off after first output)
- Warning message: displayed
- Drivable distance at when warning occurs: 0 km
(impossible to operate vehicle)
- Impossible to operate the vehicle because urea is depleted.
Replenish the urea immediately.

GETtheMANUALS.org
 0000-00 06-97

Warnings and beeps occur in three stages depending on the remaining amount of the urea. If it
happens, replenish the urea immediately so that it does not affect the operation of the vehicle.

Step 1 - Warning lamp (not lit), warning beep (sounds), warning message (displayed)
- Drivable distance at time warning occurs: 2400km to 800km
- Occurs for 15 seconds every 200 km of driving or 4 hours.
- Immediately replenish at least 5 liters of urea when corresponding warning is issued.
(Warning deactivation conditions)

Step 2 - Warning lamp (lit), warning buzzer (stops after first output), warning message
(displayed)
- Drivable distance at time warning occurs: 800 km to 0 km
- Immediately replenish at least 10 liters of urea when corresponding warning is issued.
(restart restriction lifted and warning lamp turned off)

Step 3 - Warning lamp (lit), warning buzzer (stops after first output), warning message
(displayed)
- Drivable distance at time warning occurs: 0 km
- It is impossible to operate the vehicle due to depletion of urea. Replenish the enough
amount of urea immediately or have it inspected and serviced by Ssangyong Dealer or
Ssangyong Authorized Service Operation.

GETtheMANUALS.org
06-98

▶ Warning due to urea injection control unit and electrical fault

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the urea injection control unit fault and
electrical fault occur.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning due to the faulty urea
injection control unit and electrical fault.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to the faulty urea injection
control unit and electrical fault.
- Impossible to operate vehicle

GETtheMANUALS.org
 0000-00 06-99

▶ Warning due to urea injector

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the urea injector is faulty.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning due to the faulty urea
injector.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to the faulty urea injector.
- Impossible to operate vehicle

GETtheMANUALS.org
06-100

▶ Warning due to low quality urea

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed while driving 50
km when incorrect urea is used.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of 800
km to 0 km after the primary warning when incorrect urea is
used.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning when incorrect urea is used.
- Impossible to operate vehicle

GETtheMANUALS.org
 0000-00 06-101

▶ Warning due to low SCR catalyst purification efficiency

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed for 50 km of
driving when the SCR catalyst purification efficiency is low.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of
800 km to 0 km after the primary warning due to low SCR
catalyst purification efficiency.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of 0 km
after the secondary warning due to low SCR catalyst
purification efficiency.
- Impossible to operate vehicle

GETtheMANUALS.org
06-102

▶ Urea

Pop-up display Operating conditions

- Warning lamp: lit
- Warning beep: sound
- Warning message: displayed
- Corresponding first warning is displayed while driving 50
km when exhaust emissionsare abnormal.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Secondary warning is displayed at drivable distance of
800 km to 0 km after the primary warning when exhaust
emissions are abnormal.

- Warning lamp: lit

- Warning beep: sound
- Warning message: displayed
- Tertiary warning is displayed at drivable distance of
0 km after the secondary warning when exhaust emissions
are abnormal.
- Impossible to operate vehicle

▶ Urea

Pop-up display Operating conditions

The corresponding message is displayed on the LCD screen when
the exhaust aftertreatment system is deposited with soot and etc.
and the aftertreatment system must be operated.

If the exhaust gas aftertreatment system is faulty, a message is

displayed on the LCD screen.

GETtheMANUALS.org
 0000-00 06-103

24) RCTA & AEB

Pop-up display Operating conditions

This message is displayed on the upper part of the LCD screen for
2 sec. according to the operation (ON/OFF) of BSD switch. (toast
pop-up) (It is divided into rear cross traffic alert / rear cross traffic
and emergency braking depending on the driving assist system
setting, and it is not possible to select both modes at the same
time.)

This message is displayed on the LCD screen along with the

vehicle control (apply the brake) when a vehicle is detected left
and/or right side of the rear of the vehicle during the operation of
rear cross traffic and emergency braking system.

GETtheMANUALS.org
06-104

25) Vehicle Exit Alert

Pop-up display Operating conditions
If you are about to open the door to leave the vehicle when a
vehicle is approaching from the rear side, the vehicle exit alert
system displays a message on the LCD screen and generates a
beep sound.
However, it operates only when the gear selector lever is in P (Park)
or N (Neutral) position.

GETtheMANUALS.org
 0000-00 06-105

26) Break Time Alert

Pop-up display Operating conditions
- For the vehicle without driver attention alert system, the
warning messages is displayed on the LCD screen along
with the beep every 2 hours.
- For the vehicle with driver attention alert system, the
warning messages is displayed on the LCD screen along
with the beep in the event of warning situations.

27) Safety Distance Reminder

Pop-up display Operating conditions
A message is displayed on the LCD screen when your vehicle is
approaching the preceding vehicle.

If there is a fault in the SDA system, a message is displayed on the

LCD screen.

GETtheMANUALS.org
06-106

14. ILLUMINATION AND BRIGHTNESS

1) Designations

A. LCD
B. Dial (including warning lamps)
C. Pointer
D. 6-color

- Illumination of the instrument cluster is controlled in 1 to 20 steps at day and night modes respectively.
The items are as follows:
(Main LCD screen, coolant/fuel gauge segment LCD, LED warning lamp/indicator (green, white))
- The illumination can be set by operating the lower main switch and a pop-up message is displayed
while setting. (Operating the switch changes the set value within about 0.1 seconds)
- The set value is saved after 5 seconds from the last signal input by operation of the illumination setting
switch.
- After cycling the ignition on and off and resetting the battery (removing and fitting), the instrument cluster
illumination remains at the last set value.
- The instrument cluster illumination and LCD will operate within approximately 0.4 seconds after
IGN on.
- Illumination can be set even when the ignition is off, unless the system is in sleep mode.
- When initializing the instrument cluster, illumination is initialized to level 12.

GETtheMANUALS.org
 0000-00 06-107

2) How To Set Illumination

(1) Location of rheostat switch and how to use it

Switch Short press Long press

Rheostat switch ▲ 1 higher level Increase continuously
Rheostat switch ▼ 1 lower level Decrease continuously
- Stop and go to next level when
Go to next level when reaching 1 or 20 level (20 ↔ 1)
Remarks reaching 1 or 20 level (20 - Press and hold the switch to
↔ 1) change the illumination level every
0.2 seconds.

- When the input is transmitted to the rheostat switch, the setting status is displayed as a pop-up. If no
switch is operated, the pop-up disappears after 2 seconds.
- Illumination control always available when IGN on
- Control available only when IGN off (B+ on), tail lamp turned on
- The dim brightness is adjusted from 0% to 100% by the PWM output.

GETtheMANUALS.org
06-108

3) PWM Value Depending On Illumination Setting

(1) Daytime illumination Unit: % (PWM)

The turn signal lamp of the green LED warning lamps does not apply to the dimming control.

GETtheMANUALS.org
 0000-00 06-109

(2) Nighttime illumination Unit: % (PWM)

The turn signal lamp of the green LED warning lamps does not apply to the dimming control.

GETtheMANUALS.org
06-110

(3) 6-color LED (when vehicle speed interlocking color adjustment menu
not selected, i.e., 6-color selected)

Unit: % (PWM)

GETtheMANUALS.org
 0000-00 06-111

(4) 3-color LED (when vehicle speed interlocking color adjustment menu
selected)

Unit: % (PWM)

When setting the vehicle speed interlocking color adjustment, the instrument cluster illumination
changes depending on the vehicle speed as follows:

GETtheMANUALS.org
06-112

4) Illumination Order

A. Pointer illumination fades in for 2 sec. (T3) after 0.4 sec. (T1) of IGN ON and WOW mode
operation
B. After 1 sec. (T2), the dial illumination fades in for 2 sec. (T3).
C. When the ignition is turned OFF, the dial illumination fades out for 2 sec (T3) and the LCD provides
information for 4 sec (T4) and turned off
D. After 1 second (T2), the pointer illumination fades out for 2 sec. (T3).

- The maximum brightness of fade in can be changed in the instrument cluster settings.
- Fade in/out: The illumination becomes bright/dims gradually.

What is WOW mode?

When the ignition is turned on, the speedometer and tachometer move at specific pattern, which is
called WOW mode.
→ Speedometer and tachometer: pointer moves from the lowest point to the highest point

GETtheMANUALS.org
GETtheMANUALS.org
06-114

15. CIRCUIT DIAGRAM

▶ WARNING LAMP

GETtheMANUALS.org
 0000-00 06-115

GETtheMANUALS.org
06-116

GETtheMANUALS.org
 0000-00 06-117

GETtheMANUALS.org
 0000-00 07-3

1. SPECIFICATIONS
Item Specifications
Rated voltage 13.5 ± 0.5V
Operating voltage 6.5 V to 18.0 V
Operating temperature -30℃ to +75℃
Dark current 0.2 mA or less (12V)

GETtheMANUALS.org
07-4

1. OVERVIEW
The gateway module (CGW) is the only control unit that enables communication between several
different CAN networks.
It is also responsible for the security of the vehicle, since the OBD connector, which is connected to the
diagnostic device outside the vehicle, and the CCU, which communicates with the remote server, can
communicate with other units via the gateway module only.

▶ Function

- CAN network interface

- CAN message / signal routing and control
- Network error detection
- Diagnostic device and remote diagnosis
- Variant coding control

GETtheMANUALS.org
 0000-00 07-5

2. COMPONENTS
▶ ENGINE COMPARTMENT

GCU ECU

ESP TCU

GETtheMANUALS.org
07-6

▶ Interior 1

Instrument cluster (ICM) Front camera module (FCM & AEB)

BCM Gateway module (CGW) SKM

GETtheMANUALS.org
 0000-00 07-7

▶ Interior 2

EPS AVN

PRND indicator (PRNDI) HVAC (Heater and A/C controller)

GETtheMANUALS.org
07-8

▶ Others

ACU E-coupling unit (CPL) PM sensor (PMS)

BSD DCU

GETtheMANUALS.org
GETtheMANUALS.org
07-10

3. EPC
▶ 8610 Application component

GETtheMANUALS.org
 0000-00 07-11

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
07-12

1. INPUT/OUTPUT DIAGRAM

The ACU/ESP/ICM/BCM/SKM connected to the two CAN lines also belong to the powertrain/
chassis/body control unit groups and establish communication via the gateway (CGW).

GETtheMANUALS.org
 0000-00 07-13

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
07-14

GETtheMANUALS.org
 0000-00 07-15

▶ Full names of acronyms and option description

GETtheMANUALS.org
07-16

3. P-CAN COMMUNICATION I/O ELEMENTS

▶ DCU

▶ ACU

▶ CPL

GETtheMANUALS.org
 0000-00 07-17

▶ GCU

▶ SKM

GETtheMANUALS.org
07-18

▶ HVAC

▶ ESP

GETtheMANUALS.org
 0000-00 07-19

▶ ECU

GETtheMANUALS.org
07-20

▶ ECU

▶ TCU

GETtheMANUALS.org
 0000-00 07-21

▶ BCM

GETtheMANUALS.org
07-22

▶ ABS

GETtheMANUALS.org
 0000-00 07-23

4. C-CAN COMMUNICATION I/O ELEMENTS

▶ FCM

GETtheMANUALS.org
07-24

▶ EPS

▶ AEB

GETtheMANUALS.org
 0000-00 07-25

▶ ESP

▶ ACU

GETtheMANUALS.org
07-26

▶ BSD

GETtheMANUALS.org
 0000-00 07-27

▶ Instrument cluster (ICM)

GETtheMANUALS.org
07-28

▶ Instrument cluster (ICM)

GETtheMANUALS.org
 0000-00 07-29

▶ Instrument cluster (ICM)

GETtheMANUALS.org
07-30

▶ Instrument cluster (ICM)

GETtheMANUALS.org
 0000-00 07-31

5. M-CAN COMMUNICATION I/O ELEMENTS

▶ AVN

GETtheMANUALS.org
07-32

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 07-33

6. B-CAN COMMUNICATION I/O ELEMENTS

▶ BCM

GETtheMANUALS.org
07-34

▶ BCM

GETtheMANUALS.org
 0000-00 07-35

▶ SKM

GETtheMANUALS.org
07-36

7. I-CAN COMMUNICATION I/O ELEMENTS

▶ CCU

GETtheMANUALS.org
 0000-00 07-37

▶ CCU

GETtheMANUALS.org
07-38

▶ CCU

GETtheMANUALS.org
 0000-00 07-39

8. D-CAN COMMUNICATION I/O ELEMENTS

▶ Diagnostic device

GETtheMANUALS.org
07-40

9. OPERATING PROCESS
1) CAN Network Interface
Item Function Connecting unit and connector
ECU, TCU, ESP, DCU, ACU, GCU,
Power-train CAN P-CAN Low, P-CAN High
PMS, HVAC, CPL, PRNDI, BCM, SKM
Chassis CAN C-CAN Low, C-CAN High ICM, EPS, FCM, BSD-LH
AVN (MP3 audio, smart audio, AVN
Multi-media CAN M-CAN Low, M-CAN High without CCU, AVN with CCU)
Body CAN B-CAN Low, B-CAN High BCM (TPMS), SKM
Infotainment CAN I-CAN Low, I-CAN High CCU
Diagnosis CAN D-CAN Low, D-CAN High OBD connector

GETtheMANUALS.org
 0000-00 07-41

2) CAN Message / Signal Routing

For detailed message /signal, refer to CAN COMMUNICATION INPUT/OUTPUT ELEMENTS.

3) Network Error Detection

The CGW (Gateway Module) detects the timeout, network connection error, limp home, CAN line error,
bus off conditions of each module, etc.

GETtheMANUALS.org
07-42

4) Diagnostic Device (OBD connector) & Remote Diagnosis

Connect the OBD connector to the diagnostic device to enable D-CAN to diagnose all CAN networks.
This vehicle (for only connected vehicle) provides the remote diagnosis where the CCU (Connected
Control Unit) collects the diagnostic information, sends to the server, analyzes and displays it.

Remote diagnosis is possible through the CCU, but diagnostics by connecting the diagnostic device
have higher priority than CCU. Therefore, the signal requested by the CCU is ignored when the
diagnosis is carried out by the diagnostic device.

5) Variant Coding Control

- Since the gateway module monitors the network for any error, it should store information related to
the network configuration.
- Types of variant coding: module variant coding and system variant coding
- How to do variant coding: Manual coding

▶ Module variant

CGW coding

▶ System variant

Manual / automatic transmission Project code DOM / EXP

No EPS / EPS ABS/ESP 2WD / 4WD
E-CALL BSD Non AV / Smart Audio & AVN
- MTC / DATC Smart key
TPMS Connected Position of steering wheel (LHD / RHD)
Tire specifications - -

GETtheMANUALS.org
GETtheMANUALS.org
07-44

10. CIRCUIT DIAGRAM

▶ Gateway

GETtheMANUALS.org
 0000-00 07-45

GETtheMANUALS.org
07-46

▶ P-CAN

GETtheMANUALS.org
 0000-00 07-47

GETtheMANUALS.org
07-48

▶ C-CAN, M-CAN, B-CAN, EU-6d CAN

GETtheMANUALS.org
 0000-00 07-49

GETtheMANUALS.org
 0000-00 08-3

1. SPECIFICATIONS
Item Category Specification
Operation voltage range 8.0 V ~ 16.0 V
Voltage for system diagnosis and SDM 8.0 V ~ 16.0 V
self diagnosis
Air bag unit (SDM) Voltage for communication between 7.0 V ~ 16.0 V
front and side impact sensors
Storage temperature -40°C ~ 90°C
Operating temperature -40°C ~ 85°C
Resistance at -35 to +85°C 2.0 ± 0.3 Ω
Air bag module Non-ignition current at +85°C 0.4 A for 10 seconds
All-ignition current at -35°C 1.75 A for 0.5 ms
Resistance at -35 to +85°C 2.0 ± 0.3 Ω
Seat belt pretensioner
and anchor pretensioner Non-ignition current at +85°C 0.4 A for 10 seconds
All-ignition current at -35°C 1.75 A for 0.5 ms
Operating temperature -40°C ~ 125°C

FIS / SIS Power voltage 5.0 ~ 11.0 V

Measurement range 5.0 ~ 11.0 V
Rated voltage 12.0 V
Operation voltage range 9.0 V ~ 16.0 V
Air bag circuit resistance 0.56 to 1.8 Ω
Contact Coil
Current capacity 10 ~ 30mA
2.1 rotations for each (LH/RH)
Rotation
direction
Replacement interval Change at every 10 years

GETtheMANUALS.org
08-4

2. CAUTIONS
(1) Cautions for air bag maintenance

- Whenever installing or removing the devices related to the air bag system, disconnect the negative
battery cable and wait for at least 30 seconds.
- Do not connect a tester probe to the inflator to measure the resistance of the component of the air
bag system. The detonator of the inflator may explode due to a sudden extra power supplied by the
tester.
- Note that the used components related to the air bag system, especially the air bag unit, should be
packed in an air tight container and prevent it from any impact or damage.
- When there is any deployed air bag (including curtain air bag, seat belt pretensioner and anchor
pretensioner), the entire system including the air bag unit should be replaced. The deployed air bag
unit should not be reused since it has status data when it is deployed, and the data cannot be
cleared with a diagnostic device.
- The air bag/seat belt pretensioner/anchor pretensioner contain explosive charges, so handle
carefully when disposing or replacing them.

(2) Cautions for operation

- Do not modify, change or apply impact on any air bag component. The air bag may be deployed
abruptly, causing serious injuries.
- Children and infants should ride in a rear seat. Seating in the passenger seat with carrying
a child or infant is strictly prohibited. An infant or a child could be severely injured by the air
bag deployment.
- A child restraint system must not be installed on the front seat. An infant or a child could be
severely injured by the air bag deployment when it is fitted to the passenger seat.
- Do not place any objects on the air bag inflation location. You may get injured by those objects
during deployment.
- Never put your arms around the front seat from behind, lean on the front seatback, or put your
arms out of the window. You can severely injured when the side air bag deploys.
- Never lean on the door since it becomes very dangerous when the side air bag deploys.
The side air bag deploys when there is a severe side collision.
- Do not slam the front door to close it. The side air bag may deploy unexpectedly.
- When an occupant fastens the seat belt in an unstable or inclined posture, the air bag
system cannot protect the occupant properly. Moreover, the occupant can be injured by
the air bag.

GETtheMANUALS.org
 0000-00 08-5

- Do not move your seat too close to the steering wheel or dashboard. Being too close to the
steering wheel or instrument panel during the air bag deployment could cause serious injury,
including death
- Hold only the outer rim of the steering so that the air bag can inflate without any hindrance.
- Do not place your face or chest near the steering wheel and dashboard. Also, do not allow anyone
to place their hands, leg or face on the dashboard. The air bag cannot work properly Do not hold
and operate the steering wheel by crossing your arms You could get seriously injured when the air
bag deploys.
- A large quantity of non-toxic gas (nitrogen gas) is generated with a loud noise when the air
bag/seat belt pretensioner/anchor pretensioner deploys. If these airborne particles irritate
your skin, eyes, nose, or throat, rinse the area with cool water. If the irritation continues,
see your doctor.
- The windshield glass may be broken when the passenger air bag deploys.
- The air bag is a unit to save an occupant's life from a sudden accident and it inflates at a very fast
speed by gas with high temperature, which might cause injury, such as an abrasion, bruise and
burn depending on the accident conditions.
- The air bag components will be very hot after deployment. Do not touch them.
- The deployed air bag/seat belt pretensioner/anchor pretensioner cannot deploy again.
- Once the air bag/seat belt pretensioner/anchor pretensioner are triggered, the triggered air bag
assembly should be removed from the vehicle and replaced with a new one.
- The air bag warning lamp is illuminated for 3 to 7 seconds after the engine is started to
check the system. If this warning lamp remains ON, then the system may be defective.
Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong
Authorized Service Operation.
- Incorrect inspection can result in serious injuries or malfunctions in the air bag/seat belt
pretensioner/anchor pretensioner systems.

GETtheMANUALS.org
08-6

1. OVERVIEW
The air bag system is divided into front air bag system and side air bag system. The system protects the
occupant's body by deploying the air bags in the event of a collision. The system consists of total 15
inflators including the 4 inflators of the seat belt pretensioner and 2 inflators of anchor pretensioner, ACU
(Air bag Control Unit), and 6 impact sensors on the front side and both sides of the vehicle.
The ACU determines the operation of each air bag module, seat belt pretensioner and anchor
pretensioner using the crash signals from the FIS (Front Impact Sensor) and PSIS (Pressure Side
Impact Sensor), SIS (Side Impact Sensor) in the event of a collision. The front and side air bag systems
are operated independently, and the BCM (Body Control Module) activates the auto door unlock
function, hazard warning lamp and room lamps, when the crash signal from the ACU is received to notify
others of emergency situation and let the occupant escape easily.
The ACU is equipped with self diagnosis function, and it performs the diagnosis on the internal/external
devices of the air bag system for a certain period of time after IGN ON. And it monitors the air bag
system regularly and turns on the air bag warning lamp on the instrument cluster when a fault is found in
the system, to notify the driver.

GETtheMANUALS.org
 0000-00 08-7

▶ Front air bag

- Driver/front passenger air bag (dual stage air bag used)

In the event of airbag deployment, the inflation pressure of the airbag is divided into low pressure
expansion (2-stage explosion) depending on the severity and extent of the collision and high pressure
expansion (single explosion) in order to minimize the secondary injury that can be caused by the
contact with the airbag
- Driver's knee air bag
Protects the driver's knees and lower legs under frontal collision
▶ Side air bag

- Curtain Air Bag

Protect heads of occupants in front and rear 1st row seats under side collision
- Front/rear 1st row seat side air bags
Protect heads and shoulders of occupants under side collision

▶ Pretensioner

- Front seat belt pretensioner

Rewinds the seat belt quickly to protect the occupant's face, chest and pelvic when a strong front or
side collision occurs
- Front seat anchor pretensioner
Assists the air bag system along with the seat belt pretensioner to protect the occupant's chest, face,
and pelvic under frontal collision
- Rear 1st row seat belt pretensioner
Rewinds the seat belt quickly to protect the occupant's face, chest and pelvic when a strong front or
side collision occurs

GETtheMANUALS.org
08-8

2. COMPONENTS
Driver air bag Passenger air bag FIS

Instrument cluster

Driver knee air bag BCM

GETtheMANUALS.org
 0000-00 08-9

Airbag unit(SDM) Seat belt pretensioner

Anchor pretensioner SIS

Curtain air bag Side air bag

GETtheMANUALS.org
08-10

3. EPC
▶ 8810 AIR BAG SYSTEM

1. UNIT ASSY-AIR BAG CONTROL 11.AIR BAG MODULE-INF CURTAIN

2. NUT 13.BOLT
3. AIR BAG MODULE-DRIVE 16.SENSOR ASSY-SIDE AIR BAG
6. AIR BAG MODULE-PASSENGER 17.BOLT-HOOD LATCH MTG
8. AIR BAG MODULE-DRIVER KNEE 20.AIR BAG MODULE-SIDE AIR BAG

GETtheMANUALS.org
 0000-00 08-11

▶ 8530 SWITCH & SENSOR - STEERING

1. TURN LIGHT ASSY-MULTI FUNCTION

2. WIPER ASSY-MULTI FUNCTION
5. SCREW
8. CONTACT COIL ASSY-STEERING
10.SW ASSY-AUDIO REMOTE CONT
11.SW ASSY-AUDIO REMOTE CONT
15.WIRING ASSY-AUDIO REMOTE CONT

GETtheMANUALS.org
08-12

1. INPUT/OUTPUT DIAGRAM

- ACU: Air bag Control Unit

- FIS: Front Impact Sensor
- SIS: Side Impact Sensor (Quarter)

GETtheMANUALS.org
 0000-00 08-13

2. CAN COMMUNICATION CONFIGURATION

GETtheMANUALS.org
08-14

GETtheMANUALS.org
 0000-00 08-15

▶ Full names of acronyms and option description

GETtheMANUALS.org
08-16

3. P-CAN INPUTS AND OUTPUTS

▶ CGW

▶ ESP

▶ ECU

GETtheMANUALS.org
 0000-00 08-17

▶ BCM

▶ SKM

GETtheMANUALS.org
08-18

4. C-CAN INPUTS AND OUTPUTS

▶ CGW

▶ EPS

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 08-19

▶ ESP

GETtheMANUALS.org
08-20

5. FRONT AIR BAG

(1) Front air bag system deployment conditions
▶ The air bag will be deployed when:
- the impact or type of a frontal collision is too much for the seat belt to protect the occupant.

▶ The air bag can be deployed when:

- there is underbody impact from the road surface, impact against the curb at a very high speed, or
dropping impact onto the road surface with a large angle.

▶ The air bag will not be deployed when:

- the vehicle rolls over or tips over sideward, or a side/rear collision occurs.
- the impact of the collision is low enough for the seat belt to protect the occupant properly.

▶ The air bag will be hardly deployed when:

- a collision to diagonal direction (not a frontal collision) occurs or the vehicle tips over.
- a minor collision which the air bag sensor cannot detect occurs (impact is lower than that of
operating condition).
- a collision against narrow objects, such as a telegraph pole or a tree, occurs.
- the vehicle goes into a drainage or a puddle.
- the vehicle wedges under a truck or a trailer or collides with the underbody of a heavy-duty
vehicle.
- the hood is hit by falling stones.
- the air bag warning lamp is on.

GETtheMANUALS.org
 0000-00 08-21

(2) Front air bag system deployment

When a collision occurs the air bag unit receives the signal from the front impact sensor and ignites the
front air bag to deploy the driver and driver knee air bags, passenger air bag, seat belt pretensioner and
anchor pretensioner.

- The front seat belt pretensioner and anchor pretensioner are not activated when the seat belt is not
buckled.
- The rear 1st row seat belt pretensioner is deployed whenever the impact is detected regardless of
the buckle switch status and malfunction.

(3) Component change after deployment

Air bag unit (ACU) and connection wirings (including connectors), anchor pretensioner and connection
wirings (including connectors), all front air bags, instrument panel, front impact sensor and other
damaged components

GETtheMANUALS.org
08-22

6. SIDE AIR BAG

(1) Side air bag system deployment conditions
▶ The air bag will be deployed when:
- a severe oblique collision occurs with a specific severity, angle, speed, and position.

▶ The air bag can be deployed when:

- the vehicle rolls over or tips over sideward with a severe impact.
- a rear collision occurs.
- a front collision occurs, which occupants cannot be protected by seat belt.

▶ The air bag will not be deployed when:

- the vehicle is stationary or a frontal collision occurs at low speed.

- a rear collision occurs.
- the impact of the collision is low enough for the seat belt to protect the occupant properly.

▶ The air bag will be hardly deployed when:

- a collision with oblique impact to the front seat direction or a frontal collision to the diagonal direction
occurs.
- a front/rear collision or crash occurs.
- the vehicle rolls over or tips over sideward with a minor impact.
- the air bag warning lamp is on.

GETtheMANUALS.org
 0000-00 08-23

(2) Side air bag system deployment

The side air bag system is activated in the event of a left side or right side collision. The side air bag
system consists of the seat side air bags installed to the driver and passenger seats and the curtain air
bags installed in the end of the roof (from A-pillar to quarter panel on both sides). The side air bags and
the curtain air bags are operated by the same signal. The air bags of the driver seat and passenger seat
are operated separately according to the impact position (left side, right side).

- The front seat belt pretensioner is not activated when the seat belt is not buckled.
- The rear 1st row seat belt pretensioner is deployed whenever the impact is detected regardless of
the buckle switch status and malfunction.

(3) Component change after deployment

▶ Side air bag deployed
Deployed side air bag, air bag unit (ACU), side impact sensor, seat belt pretensioner and connection
wirings (including connectors), air bag wiring, other damaged trim and seat components

▶ Curtain air bag deployed

Deployed curtain air bag, air bag unit (ACU) and connection wiring, side impact sensor, seat belt
pretensioner and connection wirings (including connectors), damaged trim, roof and headlining

GETtheMANUALS.org
08-24

7. AIR BAG SYSTEM DEPLOYMENT PROCEDURE

▶ General deployment of air bag

In general, the ACU transmits the ignition current to the ignition device of the corresponding air bag
inflator when a collision signal from the impact sensor is sent to the air bag unit
When the ignition device of the inflator is ignited, the gas generator generates nitrogen gas by being
burned, and this gas inflates the air bag cushion through the filter. The nitrogen gas used to inflate the air
bag exhausts through the vent hole immediately.

Cross section of driver air bag Air bag cover opening

Gas discharge hole

Omega ring (roll over protection for air bag deployment)

Cross section of steering wheel

Roll over protection for air bag deployment Air bag mounting
(omega ring, steering wheel armature hook) (Z-spacer, steering wheel armature hook)

GETtheMANUALS.org
 0000-00 08-25

▶ Seat belt pretensioner deployment

1. Original status
Pinion
The piston and pinion in the seat belt
pretensioner are disengaged and the tension of
the return spring in it holds the occupant.

Piston
MGG (Micro Gas
Generator)

2. Operation of pretensioner

When the ignition current is transmitted from the

ACU to the ignition device of the seat belt
pretensioner, gas is generated from the inflator
and this pushes up the piston.
When the piston gear engages with the pinion
gear, the clutch is integrated and winds the seat
belt.

3. Operation of load limiter

When the load on the seat belt increases and the

inner device stars being deformed, the pinion
rotates in reverse direction and the piston moves
downward. The residual pressure is released
through the vent hole of the piston when the
piston moves down. The gears of pinion and
piston are disengaged when the piston is located
at the lowest position.

GETtheMANUALS.org
08-26

▶ Deployment of anchor pretensioner

The anchor pretensioner retracts the seat belt instantly by igniting the inflator in the anchor pretensioner
when the air bag system is activated. It also improves the safety effect of the seat belt by preventing the
front seat occupants from moving forward and keeping occupants in a stable posture on collision.

- In the event of vehicle collision, when the

pretensioner deployment signal is received
from the air bag module, the gas produced by
the micro gas generator (MGG) pushes the
Tensioner cable piston in the cylinder.
- This pulls the tensioner cable integrated with
Anchor pretensioner the piston, and also the seat belt fastened to
connector the anchor pretensioner buckle.
- While the seat belt pretensioner restrains the
chest area, the anchor pretensioner restrains
the pelvic area to minimize the shock.

MGG Piston Cylinder

GETtheMANUALS.org
 0000-00 08-27

8. CORRELATION BETWEEN AIR BAG DEPLOYMENT

SIGNALS
The air bag deployment signal from the ACU is sent to the BCM. This signal triggers the flash of the
hazard warning lamp to notify others of emergency situation, and is used as a signal that turns on the
room lamps and activates auto door unlock function for the occupants.

GETtheMANUALS.org
08-28

(1) ACU crash output

▶ Input

- FIS (Front Impact Sensor) signal

- SIS (Side Impact Sensor) signal
- ACU internal acceleration sensor value

▶ Output

The crash signal is output in 20 ms intervals. During normal operation, 80% duty is output as a high
signal and 20% duty as a low signal. In the event of collision, the crash signal is output immediately
regardless of normal signal cycle as shown in the figure below. When this happens, on the contrary to
normal actuation signal, 20% duty is output as a high signal for 1 second in total.

When the LOW signal is outputting at the moment the collision occurs, the crash signal will be switched
to HIGH and 50 cycles completed in a second.

GETtheMANUALS.org
 0000-00 08-29

When the HIGH signal is outputting at the moment the collision occurs, the crash signal will be switched
to LOW and 50 cycles completed in a second.

GETtheMANUALS.org
08-30

(2) Auto UNLOCK control by impact signal

Operation 1.
A. Any impact signal is ignored for the first 7 sec. after IGN ON.

Operation 2.
B. An impact signal is received.
C. The BCM activates the all doors UNLOCK relay for 5 sec. The relay remains activated for full 5 sec.
even if the ignition is turned OFF before the time ends.
D. The door LOCK signal is ignored during the all doors UNLOCK relay activation by impact signal.
E. The room lamp is illuminated (front, center) and the room lamp cut-off is not available. The room lamp
is turned ON when the rear room lamp switch is turned ON.
F. The LH (RH) turn signal lamp flashes 75 times per minute at 0.4 sec. intervals (ON/OFF).

Impact signal reset conditions

- Clear the DTC and disconnect the battery (BCM main power off).
- The air bag is deployed when either the hardware impact signal or CAN (ACU) impact signal is
received.

GETtheMANUALS.org
 0000-00 08-31

9. SELF-DIAGNOSIS
1) ACU (Air Bag Control Unit) Self-Diagnosis
The ACU monitors the internal/external devices of the air bag system including battery voltage, limits
certain functions of the air bag, and turns on the air bag warning lamp on the instrument cluster
according to the conditions.

GETtheMANUALS.org
08-32

▶ Conditions for detecting and clearing faults

The time for detecting errors and clearing the errors is as follows:

Monitoring Diagnosis Time for Time for

Clearing fault by
system cycle detecting clearing
3 sec. 6 sec. Using diagnostic
Inflator circuit 300 ms
(10 times) (20 times) device
1 sec. 2 sec. Using diagnostic
Warning lamp circuit 100 ms
(10 times) (20 times) device
Impact sensor Refer to "External Monitoring"
Battery voltage Using diagnostic
10 ms 4 sec. 4 sec.
high/low device

- - Replacing ACU
Impact record
Immediately (diagnostic device
(air bag deployment)
doesn't help)

- - Replacing ACU
ACU internal fault Immediately (diagnostic device
doesn't help)

GETtheMANUALS.org
 0000-00 08-33

2) Air Bag Warning Lamp

The ACU turns on the air bag warning lamp on the instrument cluster for 6 seconds after IGN ON while
performing self diagnosis for the air bag system. If no fault is found in the system, it turns off the warning
lamp. After this, the unit monitors the system regularly, and notifies the driver by turning on the air bag
warning lamp when a fault is found in the system.

Air bag warning lamp * The air bag warning lamp comes on when:

- diagnosis is performed for the inside/external devices of the

system when the ignition is turned on
- the air bag system is malfunctioning (current malfunction)
- diagnostic device communicates with ACU
- frontal or side crash occurs (impact detected by impact sensor)

(1) Air bag warning lamp ON at initial IGN ON

▶ System normal
Comes on for 6 seconds after IGN ON and then goes out.

- ON time: 6 sec. ± 10%

- OFF time: 1 sec. ± 10%

GETtheMANUALS.org
08-34

▶ System malfunctioning
Comes on for 6 seconds after IGN ON and goes out for 1 second, and then remains on.

(2) Air bag warning lamp operation during driving

The air bag warning lamp comes on when the ACU detects a system malfunction. The warning lamp
goes out when the malfunction disappears.

GETtheMANUALS.org
 0000-00 08-35

3) Supply Voltage Monitoring

ACU monitors the battery voltage continuously with IGN ON. It limits certain functions of the air bag system
and outputs DTC and air bag warning lamp signal according to the result of the monitoring.

Abnormal voltage of the ACU (too high/too low) is determined to be fault only when the signal is
detected for continuous 4 seconds.

Emergency power function

The ACU has an emergency power function that ensures the internal operation of the central unit and
buffering firing circuits for a minimum of 150 ms after loss of battery power. Full emergency power
capability is available after the minimum specified operating voltage has been applied to the ACU
power line for 10 seconds, and from this point, air bag deployment is enabled.

GETtheMANUALS.org
08-36

4) Internal Monitoring
The ACU checks the status of the air bag system and monitors the system for internal errors. If an error
is detected by self diagnosis, this unit disables part of the air bag system functions and outputs a
diagnostic trouble code (DTC) and air bag warning lamp signal.
- Watchdog
The micro controller is monitored periodically. And if a fault is found, micro controller is reset, inflator
ignition function is limited, and the air bag warning lamp comes on.
- Internal acceleration sensor test
The ACU checks internal acceleration sensor when the ignition is turned on. The ACU determines
the deployment of the air bag for the collision signal input after the diagnosis.
- NVM (Non Volatile Memory) test
The ACU checks the values stored in the memory. If the values are not correct, the ACU sets a
diagnostic trouble code (DTC) and turns on the air bag warning lamp.

▶ Air bag operations for errors

Air bag operation

Internal errors
Front air bag system Side air bag system
X-axis acceleration sensor
Disabled
error
Disabled
Y-axis acceleration sensor
error Disabled

-X-axis acceleration sensor Disabled available available

error
ROM checksum error Disabled
RAM checksum error Disabled Disabled
NVM checksum error Disabled

GETtheMANUALS.org
 0000-00 08-37

5) External Monitoring
The ACU supplies a certain level of test current and monitors the resistance of the inflator circuit within a
specified range to deploy the air bag. It limits certain functions of the air bag, sets a DTC and turns on
the air bag warning lamp according to the conditions.

▶ Monitoring ACU resistance

GETtheMANUALS.org
08-38

▶ Impact sensor monitoring

The ACU supplies a certain level of test current to monitor the front and side impact sensors. If the wiring
is open/short circuited or no signal is input, or communication is malfunctioning, it sets a DTC and turns
on the air bag warning lamp.

Detecting failure
Time for clearing error
Faults Time for
Fault condition after fixing
detecting
Incorrect ID after IGN ON

Normal errors Faulty sensor after IGN ON

Approx. 2 sec.
Communication error (next IGN)

Incorrect ID Inconsistent ID after IGN ON Approx. 1 sec.

Communication Communication data error

Approx. 2 sec.
error Open/Short circuit (B+)
Short Circuit to Short Circuit to Ground Approx. 2 to 4 sec.
Ground

6) DTC and Air Bag Deployment Data Storing

▶ DTC storing

All DTCs of air bag system are stored in the ACU. Maximum number of DTCs that can be stored is 16. If
a new DTC is set after 16 DTCs are stored, the oldest stored code is erased first.

▶ Air bag deployment data storing

The air bag deployment data is stored in the ACU. Maximum number of data that can be stored is 8.

- The DTCs related to “low battery voltage” are not accumulated.

- The air bag deployment data due to a collision cannot be cleared. The ACU should be replaced.

GETtheMANUALS.org
 0000-00 08-39

10. EVENT DATA RECORDER (EDR)

The event data recorder (EDR) stores the driving information data from 5 seconds before the collision to
the moment of collision in the event of crash, when the acceleration sensor in the air bag unit detects a
sharp acceleration change which meets the EDR operating conditions, regardless of the air bag
deployment. The air bag unit always stores the driving information data and updates the data with new
one periodically. If a collision is detected by FIS, SIS and PSIS, the acceleration sensor in the ACU
detects the change in acceleration. The air bag unit stores the information on internal acceleration
sensor, driving status (ECU, ABS/ESP unit, CAN data from instrument cluster), and air bag deployment
at this time.

The EDR stores the driving information also when the acceleration sensor in the air bag unit detects
a sharp acceleration change in the event of a rear-end collision.

GETtheMANUALS.org
08-40

11. INTERNAL COMPONENTS

▶ Driver air bag

A. Cover assembly
B. Cushion assembly
C. Cushion ring
D. Housing assembly
E. Inflator
F. Nut
G. Spring

The inflator consists of a detonator, explosives, and the gas generator. It deploys the air bag
when the vehicle collides.

GETtheMANUALS.org
 0000-00 08-41

▶ Passenger air bag

A. Cushion assembly
B. Retainer ring
C. Housing assembly
D. Inflator
E. Nut
F. Lead wire assembly

GETtheMANUALS.org
08-42

▶ Driver knee air bag

A. Cover assembly
B. Cushion assembly
C. Inflator
D. Deflector
E. Housing assembly
F. Lead wire assembly
G. Nut

▶ Side air bag (Front, Rear 1st row)

A. Inflator
B. Inflator deflector
C. Cushion assembly
D. Cushion cover
E. Lead wire assembly

GETtheMANUALS.org
 0000-00 08-43

▶ Curtain air bag

A. Lamp bracket
B. Stud bolt
C. Inflator
D. Clamp ring
E. Cushion assembly

▶ Seat belt pretensioner

A. Anchor connector
B. Webbing
C. Stopper
D. CLT assembly
E. D-ring assembly
F. MGG assembly
G. Retractor assembly
H. Bolt and washer (16 mm)

CLT: Crash Locking Tongue

MGG: Micro Gas Generator

GETtheMANUALS.org
08-44

▶ Seat belt pretensioner

A. Anchor connector
B. Boot
C. Rivet
D. Bolt and washer (16 mm)
E. MGG assembly
F. Anchor PT assembly

MGG: Micro Gas Generator

GETtheMANUALS.org
 0000-00 08-45

12. SENSOR FUNCTIONS

▶ FIS (Front Impact Sensor)

- Acceleration value of the Y direction is

detected, the same direction that the
connector is engaged.

FIS and SIS are incompatible.

▶ SIS (Side Impact Sensor) - Quarter panel

- Acceleration value of the X direction is

detected, the same direction that the bolt is
installed.

FIS and SIS are incompatible.

GETtheMANUALS.org
08-46

13. CIRCUIT DIAGRAM

▶ FRT INPACT SENSOR, SIDE IMPACT SENSOR, A/BAG INFLATOR. ANCHOR PT, PAB OFF SW

GETtheMANUALS.org
 0000-00 08-47

GETtheMANUALS.org
08-48

▶ DRIVER S/BUCKLE, PASS S/BUCKLE, SIDE A/BAG INFLATOR, S/BELT PRETENSIONER

GETtheMANUALS.org
 0000-00 08-49

GETtheMANUALS.org
 0000-00 0-3

1. SPECIFICATIONS
1) MP3 Audio Head Unit
Category Specifications
Operating voltage 9 ~ 16V
Operating temperature -30 to 75℃
General information Current consumption 1A (max. 6.5A)
Dark current Up to 3mA (head unit only)
Weight 1.95kg
Display 103.5mm × 44mm (bezel open)
Display Resolution 282 × 110
Viewing angle LH: 44˚, RH/UP/DOWN: 40˚
FM 87.5 ~ 108.0
GEN
AM 531 ~ 1,602
FM 87.5 ~ 108.0
Radio Frequency EU
AM 522 ~ 1,620
FM 87.5 ~ 107.9
L/America
AM 530 ~ 1,710
USB Compatibility USB 2.0 (High speed)

GETtheMANUALS.org
0-4

2) Micro Pole Antenna

Category Specifications
Storage temperature -40 to 80℃
Operating temperature -30 to 60℃
Operating voltage AM/FM 10.5 ~ 16V
Current consumption AM/FM Max. 150mA
Output impedance AM/FM 75Ω (FM)

3) Door Speaker
Category Specifications
Size 5.25 inch
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 86 ± 2 dB

4) Tweeter Speaker
Category Specifications
Size 1.5 inches
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 91 ± 2 dB

GETtheMANUALS.org
 0000-00 0-5

5) Handsfree Microphone
Category Specification
Operating temperature -30 to 80℃
Storage temperature -40 to 85℃
Impedance Max. 2.2 kΩ
S/N ratio* 60dB or higher

* S/N ratio (Signal to Noise Ratio): Describes noise level in relation to the signal level in dB

6) LH Steering Wheel Switch

Category Specifications
Rated voltage 5V
Operating temperature -30 to 80℃
Combined Individual
Category
resistance resistance
Volume down 196 Ω ←
Volume up 1020 Ω ←
Mode 2210 Ω ←
Seek UP 4020 Ω ←
Seek DOWN 6980 Ω ←
Bluetooth handsfree ON 13300 Ω ←
Bluetooth handsfree OFF/MUTE 34800 Ω ←

GETtheMANUALS.org
0-6

2. CAUTIONS

- This mark indicates potentially hazardous situation which, if not observed, may result in serious
injury and material damage.
- Ssangyong is not liable for any personal injury and material damage, caused by violation of traffic
regulations or neglect of observing actual traffic and driving situations.

3. WARNINGS

- This mark indicates situation which, if not observed, may result in an accident or system
malfunction.
- Do not disassemble or modify this system.
Doing so may cause an accident, fire or electric shock.
- Do not use the system if it is malfunctioning (sound or video output problem).
Doing so may lead to an accident or electric shock.
Please contact a Ssangyong service dealer immediately.
- The system should be used only when the engine is started.
Using the system for an extended period of time with the engine off may discharge the
battery.
- Do not leave beverages or foreign materials around the system.
If they enter the system, they may cause a fire.
- The system may break down if a disc not supported by this system is inserted.
- Do not apply impact to or drop this system.
It may cause malfunction.
- Never leave the system in a hot or cold place for an extended period of time. Therefore, do not park
the vehicle in a hot or cold place. The ambient temperature should be -30℃ to +80℃ for
proper operation.

GETtheMANUALS.org
 0000-00 0-7

1. OVERVIEW
The MP3 audio system can play radio (FM1, FM2, AM) and other files stored in an external device, such
as iPod, through the Bluetooth (handsfree) and outside input port (USB). And, it has a micro pole
antenna and its own integrated amplifier to improve the radio frequency reception rate and to provide the
high-quality sound.

▶ Major functions

- Radio (FM/AM)
- USB audio
- iPod
- Bluetooth
- Bluetooth music

GETtheMANUALS.org
0-8

2. COMPONENTS
MP3 audio head unit USB jack assembly

LH steering wheel switch Handsfree microphone

GETtheMANUALS.org
 0000-00 0-9

Tweeter speaker Door speaker

Micro pole antenna

GETtheMANUALS.org
0-10

3. EPC
▶ 8530 SWITCH & SENSOR - STEERING WHEEL

1. TURN LIGHT ASSY-MULTI FUNCTION

2. WIPER ASSY-MULTI FUNCTION
5. SCREW
8. CONTACT COIL ASSY-STEERING
10.SW ASSY-AUDIO REMOTE CONT
11.SW ASSY-AUDIO REMOTE CONT-RH
15.WIRING ASSY-AUDIO REMOTE CONT

GETtheMANUALS.org
 0000-00 0-11

▶ 8610 Application component (1)

GETtheMANUALS.org
0-12

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 0-13

▶ 8910 Audio & AVN system - Interior

1. AUDIO ASSY
2. SMART AUDIO ASSY
4. BLANKING COVER-AUDIO
5. HEAD UNIT-AUDIO & VIDEO
6. SD CARD
7. SCREW
8. CABLE ASSY-USB
10.JACK ASSY-USB

GETtheMANUALS.org
0-14

▶ 8930 Audio & AVN system - Exterior

1. FEEDER CABLE-AUDIO & VIDEO FRT

2. FEEDER CABLE-AUDIO & VIDEO RR
26.ANTENNA ASSY-RADIO MICRO POLE
27.NUT-RADIO MICRO POLE MTG
28.ANTENNA ASSY
29.ANTENNA ASSY
41.NUT

GETtheMANUALS.org
 0000-00 0-15

4. FEEDER CABLE

GETtheMANUALS.org
0-16

1. SYSTEM DIAGRAM

GETtheMANUALS.org
 0000-00 0-17

GETtheMANUALS.org
0-18

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 0-19

GETtheMANUALS.org
0-20

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 0-21

3. M-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
0-22

▶ Instrument cluster

GETtheMANUALS.org
 0000-00 0-23

4. MP3 AUDIO SYSTEM BOOT-UP PROCESS

- Start ignition switch OFF → ACC
The audio head unit releases the sleep mode as soon as the ignition switch is turned to ACC position
in sleep mode and boot-up is completed in about 4 seconds.

- START switch ACC (ON) to OFF

If the start switch is turned off while the audio head unit is operating normally, the audio head unit
immediately is muted and enters sleep mode. However, if the communication is in progress, it will be
completed.

What is sleep mode?

All power supplies are cut off, except the power for the device used to inform reactivation of the
system in order to prevent the battery from being discharged.
※ Total dark current of audio system in low current consumption mode: Max. 1.0 [mA]

GETtheMANUALS.org
0-24

5. FUNCTIONS
1) Function For Each Button

No Designation Function
1 POWER - Power On: Press briefly in power-off state.
/VOLUME - Power Off: Press and hold for more than 1.5sec. in power-on
state.
- Mute : Press briefly in power-on state in RADIO mode.
- Play : Press briefly in paused-state in USB/iPod, BT Audio
mode.
- Pause : Press briefly in play-state in USB/iPod, BT Audio
mode.
- Volume control: Turn Left (Down) / Right (Up) to control
volume.

2 SETUP SETUP mode: Press briefly in power-on state.

- Back / Arkamys Sound / Tone Settings / Bluetooth / System
/ RDS / DAB

GETtheMANUALS.org
 0000-00 0-25

No Designation Function
3 ENTER 1. ENTER: Press briefly in power-on state in Setup mode.
SEEK / TUNE - End of setting or user selection in all setup menus.
2. SEEK / TUNE
- SEEK (Radio)
Turn Left (Down) / Right (Up) to find the station.
- TUNE Up/Down (Radio)
Press briefly → Turn Left (Down) / Right (Up).
- TRACK Up/Down (USB/iPod, BT Audio)
Turn Left (Down) / Right (Up).
- Song Search (USB/iPod)
Press briefly → Turn Left (Down) / Right (Up).
Press briefly to select desired song.
- FF/REW (USB/iPod)
Long Push → Turn Left (REW) / Right (FF).
- DAB station Up/Down
Turn Left (Down) / Right (Up).
- DAB station search
Press briefly → Turn Left (Down) / Right (Up).
Press briefly on desired station to select.
Note : DAB is EU region only.
4 Display Display the information in all modes.
5 RADIO Radio Band change
Press briefly (FM1 → FM2 → AM → DAB).
Note: DAB band is EU region only.
6 Preset - Listening
(1 ~ 6) buttons Press briefly on all radio bands (FM1,FM2, AM, DAB).
- Saving
Press and hold for more than 1.5sec. on all listening radio bands.
6-1 INFO 1. Song information (USB/iPod) : Press briefly.
- Show Album, Artist, Title
2. Preset memory No.1 call button (RADIO) : Press briefly.
6-2 REPEAT 1. Repeat mode rotation (USB/iPod) : Press briefly.
→ One Repeat → Folder Repeat → Repeat Off → ...
2. Preset memory No.2 call button (RADIO) : Press briefly.
6-3 RANDOM 1. Random mode rotation (USB/iPod) : Press briefly.
→ Folder Random → All Random → Random off → ...
2. Preset memory No.3 call button (RADIO) : Press briefly.
6-4 FOLDER 1. Folder Up / Down (USB) : Press Up / Down button briefly.
UP / DOWN → Press ENTER on desired folder.
2. Preset memory No.4, 5 call button (RADIO) : Press briefly.
6-5 EQ 1. Arkamys Sound effect select (USB/iPod , BT Audio) : Press briefly.
→ Natural Sound → Dynamic Sound → Effect Off → ...
2. Preset memory No.6 call button (RADIO) : Press briefly.

GETtheMANUALS.org
0-26

No Designation Function
7 SCAN 1. SCAN
/ AST Press briefly, to listen to accessible frequencies sequentially for 5 sec. on
all radio bands (FM1,FM2, AM).
2. AST (Autostore)
Press and hold for more than 1.5sec. in radio mode.
→ Save radio stations via preset buttons (1 ~ 6) automatically.
8 MEDIA 1. MEDIA mode change
Press briefly in power-on state.
→ USB/iPod → BT Audio → My Music → ...
This mode will be skipped when recorded files don't exist.
(Please see the DAB-My Music function)
2. USB/iPod and BT Audio mode will be skipped when not
available.
9 Call ON 1. Paired state
In power-on state.
→ Calling Menu Access (Redial / Phone Book / Call Lists) : Press
briefly.
→ Redial : Press and hold for more than 1.5sec..
2. Unpaired state
In power-on state.
→ Bluetooth pairing mode access : Press briefly.
→ Bluetooth pairing with most recent phone : Press and hold for
more than 1.5sec..
10 Hang Up 1. Hang Up (Calling state)
Press briefly.
2. Call Reject (Incoming Call state)
Press briefly.
3. Disconnect the phone
Press and hold for more than 1.5sec..

GETtheMANUALS.org
 0000-00 0-27

2) Function

No Designation Function
1 Volume Volume control 00(MIN)~41(MAX).
Up/Down - Volume Up : Push up.
- Volume Down : Push down.
2 Mode 1. Mode change : Press briefly in power-on state.
→ RADIO → USB / iPod →BT Audio →My Music →...
- USB/iPod and BT Audio mode will be skipped if not available.
- My Music mode is for EU region.
(This mode will be skipped when file doesn't exist.)
2. Radio Band change : Press and hold this button in the radio mode
for bands to change in order.
→ FM 1 → FM 2 → AM → DAB → ...
3 Seek 1. Recall using preset memory 1~6 (Radio).
Up/Down 2. Track Up / Down (Media).
: Push up / down.

GETtheMANUALS.org
0-28

No Designation Function
4 Call ON 1. Paired state : In power-on state.
- Calling Menu Access (Redial / Phone Book / Call Lists) :
Press briefly.
- Redial : Press and hold for more than 1.5sec..
2. Unpaired state : In power-on state.
- Bluetooth pairing mode access : Press briefly.
- Bluetooth pairing with most recent phone : Press and hold
for more than 1.5sec..
3. Incoming Call state : Receiving Call.
4. Calling state : Private Call mode.
5 Mute / 1. MIC Mute (Calling state) : Press briefly.
Call OFF 2. Reject Call (Incoming call state) : Press briefly.
3. Hang Up (Calling state) : Press and hold more than 1.5 sec..
4. Mute (Radio) : Press briefly.
5. Play / Pause (USB/iPod, BT Audio) : Press briefly.

GETtheMANUALS.org
 0000-00 0-29

3) Display Window
Radio Radio (automatic frequency)

1. Radio station band: FM1, FM2, AM 1. Radio station name: FM AUTO, AM AUTO
2. Digital clock 2. Digital clock
3. FM stereo reception display 3. FM stereo reception display
4. Assigned station number: CH 1 ~ CH 6 4. Assigned station number: CH 1 ~ CH 6
5. Station frequency currently being 5. Automatic frequency indicator
received 6. Station frequency currently being
received
7. Receiving radio station and region
indicator

BT Audio (Bluetooth music) USB/iPod

1. Device name: BT Audio 1. Device name: USB, iPod

2. Bluetooth connection 2. USB / iPod connection
3. Digital clock 3. Digital clock
4. Name of currently playing song 4. Play mode display
5. Artist RPR (Repeat): Repeat playback
6. Playback time RDM (Random): Random playback
5. Shows the number of music files
6. Name of currently playing folder
7. Name of currently playing song
8. Playback time

GETtheMANUALS.org
0-30

Phone (Bluetooth handsfree)

1. Device name: Phone

2. Bluetooth connection
3. Digital clock
4. Call in progress indicator
5. Name
6. Phone number

GETtheMANUALS.org
 0000-00 0-31

4) Calling and Receiving Calls Via Handsfree

Mode & Button Description & Display
Pairing Method 1. Pairing via setup menu.
Press (2) briefly in power-on state.
→ SETUP → 4. Bluetooth → 2. Pair
- Referance to "Setup - Bluetooth - Pair" menu.
2. Direct pairing access.
Press and hold (9) for more than 1.5 sec..

Pairing 1. Execute pairing preparation action according to chosen pairing method

(Radio).
2. Enable Bluetooth on mobile phone (Phone).
3. Find the "KORANDO" in device lists and select (Phone).
4. Check the code then confirm (Phone).
5. After a few moments, a pop-up window will appear asking if you want
to download phone book and call lists. If you want to download phone
book and call lists to radio, select "YES" (Phone).
6. When Bluetooth pairing is completed, Bluetooth logo, Handsfree icon,
and Bluetooth streaming icon are displayed in the display window
(Radio).

Making a Call 1. Making a call with connected mobile phone.

- Last call 1: Press and hold (9) for more than
1.5 sec..
- Last call 2: Press (9) briefly.
→ Select 1. Redial (press ENTER).
2. Search contacts via phone book and make a
call.
Press (9) briefly. → Select 2. Phone Book (press
ENTER).
→ Search contact to call with Enter dial.
→ Press ENTER. → Calling.
3. Search call lists and make a call.
Press (9) briefly. → Select 3. Call Lists (press
ENTER).
→ Search contact to call with Enter dial.
→ Press ENTER. → Calling.

GETtheMANUALS.org
0-32

Mode & Button Description & Display

Receiving a Call Receiving a call with connected mobile phone.
- Press (9) briefly when bell is ringing.
- Press (4) on steering wheel remote control.

Hanging up Hanging up with connected mobile phone.

Return to previouse mode automatically.
- Press (10) briefly during call.
- Press (5) more than 1.5 sec. on steering wheel
remote control.

▶ Using BT Audio streaming

Mode & Button Description & Display

Connecting It’s possible to use Bluetooth audio streaming where audio and mobile
phone are paired.
- Mobile phone sound source audio can be listened to by connecting to
Bluetooth.
- Referance to "Setup - Bluetooth" menu.
Play on Play: Press briefly again to select BT Audio mode.
→ USB/iPod → BT Audio → My Music → ...
- Artist / Title of the currently playing file will be
changed on the display.
- When playing the mobile phone sound source that
Bluetooth is connected to, audio can be listened to.
Song change Song change
Turn ENTER dial to change to previous or next song on mobile phone.
Pause / Play Pause / Play
Press (1) briefly to pause or play mobile phone songs.

GETtheMANUALS.org
 0000-00 0-33

(1) RDS
Mode & Button Description & Display
RDS RDS function is supported in areas where RDS service
is available and can make disable all RDS function in
RDS setup menu.
Support function: PS Name display, AF, Regional
On/Off, PTY Search, TA, TP Search, EON.
- PS Name: Broadcast station information is displayed.
- AF: Always finds the best station when moving.
(Broadcasting stations with nationwide network only.)
- Regional: Select whether you want to allow AF to be broadcast on the
same network but broadcast locally or differently (Default : Off).
→ On: Pohibit local broadcast reception.
→ Off: Allow local broadcast reception.
- PTY Search: Select one of 29 broadcasting genres.
→ SETUP → RDS → PTY → Select genre → PTY Search → ...
→ If selected genre cannot be found, No PTY is displayed and the
original state returned to.
- TA: When a traffic announcement is made while listening to FM radio,
USB or Bluetooth Audio, traffic broadcast reception mode is entered and
original mode returned to upon completion of announcement (Default :
On).
- TP Search: When TA On is selected, if the current receiving station
does not provide a traffic broadcast service, search is performed for a
station that can provide a traffic broadcast. (TP Search is EU Region
only.)
- EON: Switch to broadcasting station which provides traffic information
in other networks. After listening, radio returns to original mode.
- CT: Synchronize time information sent from broadcasters.
Please Turn off CT function when wrong time information is received
(Default: On).

▶ Entering E-CALL mode for EU Region

E-CALL mode

When entering E-CALL mode due to a car

accident, the radio mute the sound and displays
S.O.S logo.

GETtheMANUALS.org
0-34

(2) DAB for EU Region

Mode & Button Description & Display
DAB Supports DAB BAND III digital broadcast reception.
1. Select a band: Press the RADIO button to switch to
DAB band.
→ FM 1 → FM 2 → AM → DAB → ...
2. Station List Search: Radio will search available stations automatically
whenever power is on.
3. Select a station: Rotate Enter encoder select desired station.
4. Store station: If Preset (1-6) number is pressed for more than 2
seconds during broadcast, the receiving DAB station will be saved.
5. Set DAB option: SETUP DAB ...
- Service Follow: When DAB reception is impossible due to change of
the reception environment during the driving, a FM or DAB station of the
same contents is automatically switched to.
- DLS: Display text information sent from broadcasters at bottom of
screen (Default: On).
- Traffic Announcement: Select whether to allow traffic information
from broadcasters(Default: On).
- DAB My Music: While listening to DAB broadcast,
user can record and replay DAB broadcast clip.
· Record start: Press and hold (3) ENTER for
more than1.5 sec. on DAB reception mode.
· Record finish: Press and hold (3) for more than
1.5 sec..
- Recorded file Playback:
· Once Recording process is done, a new mode is
added in MEDIA mode as My Music.
· Select Media button until My Music mode is
appeared.
· Press (3) ENTER briefly and select 1. File Search.
· Rotate (3) ENTER dial and press (3) ENTER.
- File Information: DAB_Month/Date/Hour/Min/Sec.
- File Delete:
· Press (3) ENTER briefly and select File Delete.
· Rotate (3) Enter dial to select the file and press.

GETtheMANUALS.org
 0000-00 0-35

5) Audio Setup
(1) Entrance
Mode & Button Description & Display
Enterance SETUP mode: Press (2) briefly in power-on state.
- Reference to each of "Setup" menu item.
1. Back → 2. Arkamys Sound → 3. Tone Settings
→ 4. Bluetooth → 5. System → 6. RDS → 7. DAB

▶ Setup menu settings

Mode & Button Description & Display

Setup menu 1. Searching: Turn (3) Left (Up) / Right (Down) to find the Setup menu.
2. Settings: Press (3) briefly on desired Setup menu and change setting
with (3).
→ End of settings or selecting the User's selection on all setup menu.

Settings Return to the main display.

1. Back - The "SETUP" button itself also works as a "Back" function.

(2) Arkamys Sound

Mode & Button Description & Display
2. Arkamys Sound Arkamys Sound effect selection (Default : Natural).
1. Back → 2. Natural → 3. Dynamic → 4. Effect Off
- Effect selection can be made using (6) - 6 / EQ
button directly in USB/iPod, BT Audio mode.
- This button will operate preset No.6 in the RADIO
mode.

GETtheMANUALS.org
0-36

(3) Tone Settings

Mode & Button Description & Display
3. Tone Settings Tone Settings menu selection.
1. Back → 2. Bass → 3. Middle → 4. Treble
→ 5. Fader → 6. Balance

1. Back: Return to the Setup menu display.

Default : Return to default state.
2. Bass: Select "Bass" (press "ENTER").
→ Set Bass effect value.
3. Middle: Select "Middle" (press "ENTER").
→ Set Middle effect value.
4. Treble: Select "Treble" (press "ENTER").
→ Set Treble effect value.
- Each of effect value range can be controlled from
"-5" to "+5" using "ENTER" dial.

5. Fader: Select "Fader" (press "ENTER").

→ Set Fader effect value.
6. Balance: Select "Balance" (press "ENTER").
→ Set Balance effect value.
- Each of effect value range can be controlled from
"01" to "15" using "ENTER" dial.

GETtheMANUALS.org
 0000-00 0-37

(4) Bluetooth
Mode & Button Description & Display
4. Bluetooth Bluetooth menu selection.
1. Back → 2. Pair → 3. Pair Device → 4. Priority
→ 5. Delete → 6. Mic Volume
→ 7. Phone Book Download → 8. Ringtone

1. Back: Return to Setup menu display.

2. Pair: Select "Pair" (press "ENTER").
→ Enter pairing mode.

3. Pair Device: Select "Pair Device" (press

"ENTER").
→ Select one device from paired device lists
2., 3..
→ Connect.

4. Priority: Select "Priority" (press "ENTER").

→ Select device with top priority when
reconnected.
→ Connect automatically when power next
turned on.

5. Delete: Select "Delete" (press "ENTER").

→ Delete selected device.

GETtheMANUALS.org
0-38

Mode & Button Description & Display

4. Bluetooth 6. Mic Volume: Select "Mic Volume" (press
"ENTER").
→ Adjust Mic Volume from "1" to "5" (Default : 3).

7. Phone Book Download:

Select "Phone Book Download" (press "ENTER").
→ Download phone book from connected phone.

8. Ringtone: Select "Ringtone" (press "ENTER").

→ Select desired ringtone.

GETtheMANUALS.org
 0000-00 0-39

(5) System
Mode & Button Description & Display
5. System System menu selection.
1. Back → 2. Time → 3. Languages
→ 4. Auto Volume Control
→ 5. System Information

1. Back: Return to Setup menu display.

2. Time: Select "Time" (press "ENTER").
1. Back: Return to the System settings menu
display.
2. Set Time: Select "Set Time"(press "ENTER").
→ Adjust the "Hour" (with "ENTER" dial).
→ Setting Hour (press "ENTER").
→ Adjust the "Minute" (with "ENTER" dial).
→ Setting Minute (press "ENTER").
3. Set Time Format:
Select "Set Time Format" (press "ENTER").
- Press "ENTER" repeatly, setting "12h, 24h" time
format.

4. Set Date: Select "Set Date" (press "ENTER").

→ Adjust the "Year" (with "ENTER" dial).
→ Setting "Year" (press "ENTER").
→ Adjust the "Month" (with "ENTER" dial).
→ Setting "Month" (press "ENTER").
→ Adjust the "Day" (with "ENTER" dial).
→ Setting "Day" (press "ENTER").
5. Display Clock: Select "Display Clock"
(press "ENTER").
- Press "ENTER" repeatly, setting Display Clock "On,
Off".
- Set the clock display to be visible or invisible in
power-off state.
(In no-clock mode, LCD back lighting is turned off.)

GETtheMANUALS.org
0-40

Mode & Button Description & Display

5. System 3. Languages: Select system language.
→ Select "Languages" (press "ENTER").
1. Back → 2. English → 3. Turkish
- Press "ENTER" to choose either English or Turkish
setting.

4. Auto Volume Control:

Compensate for volume level during driving.
→ Select "Auto Volume Control" (press "ENTER").
1. Back: Return to System settings menu display.
2. Off: No effect.
3. Low: Compensated volume level low.
4. Medium: Compensated volume level medium.
5. High: Compensated volume level high.
- Press "ENTER" to set compensated volume level.
5. System Information:
- Shows applied software version information.
· CPU Ver. / Date / MCU Ver. / Arkamys Ver. /
LID Ver.
· EEPROM / DAB for EU Region.

6. Radio Region Setting:

- Select the region (General, Latin America).
→ Select "Radio Region Setting" (press "ENTER").
1. Back → 2. Latin America → 3. General
- Press "ENTER" to choose either General or Latin
America.
- The system reboots after the region setup process.

GETtheMANUALS.org
 0000-00 0-41

(6) RDS
Mode & Button Description & Display
6. RDS RDS menu selection (EU DAB Radio).
1. Back → 2. AF → 3. Regional → 4. PTY
→ 5. Traffic Announcement → 6. Clock
Synchronization
1. Back: Return to Setup menu display.
2. AF: AF operation On/Off selection (Default : On).
3. Regional: Regional AF operation On/Off selection
(Default: Off).
4. PTY: Program type selection menu.

5. Traffic Announcement: TA On/Off selection

(Default : On).
6. Clock Synchronization: RDS data clock
synchronization On/Off selection (Default: On).

RDS menu selection in Non EU region.

There is RDS function On/Off selection menu in Setup
menu.
1. Back → 2. RDS
1. Back: Return to Setup menu display.
2. RDS: RDS function On/Off selection
(Default : Off).
- To enable the RDS function, press 3. ENTER to
change to On.
- If RDS is On, RDS sub menu will be activated.
- RDS sub menu On/Off selection method is same as
EU radio shown above.

GETtheMANUALS.org
0-42

(7) DAB for EU Region

Mode & Button Description & Display
7. DAB DAB menu selection.
1. Back → 2. Service Follow → 3. DLS
→ 4. Traffic Announcemen
1. Back: Return to Setup menu display.
2. Service Follow: DAB to FM service follow
operation On/Off selection when DAB reception
status is poor (Default : On).
3. DLS: DAB text information display On/Off
selection(Default : On).
4. Traffic Announcement: TA On/Off selection
(Default: On).

GETtheMANUALS.org
 0000-00 0-43

6. OPERATING VOLTAGES

GETtheMANUALS.org
 0000-00 0-3

1. SPECIFICATIONS
1) Smart Audio Head Unit
Category Specifications
Operating voltage 9 ~ 16V
Operating temperature -30 ~ 75℃
Current consumption 2A
General information Dark current 3 mA or less (head unit only)
Weight 2.38kg
Internal storage
8GB
capacity
Size 8" TFT LCD
Aspect ratio 16:9
Display Resolution 800 × 480
Viewing angle Up: 60˚, down/left/right: 70˚
Touch screen type Capacitive
FM 87.5 ~ 108.0
GEN
AM 531 ~ 1,602
FM 87.5 ~ 108.0
Radio Frequency EU
AM 522 ~ 1,620
FM 87.5 ~ 107.9
L/America
AM 530 ~ 1,710
USB Compatibility USB 2.0 (High speed)

Frequency GPS: 1.57542 GHz

GPS GLONASS: 1598.0625 ~ 1609.3125 MHz
Channel 32 channels
Bluetooth Power supply 3.3V (30mA)

GETtheMANUALS.org
0-4

2) Combination Antenna
Category Specifications
Storage temperature -40 ~ 105℃
Operating temperature -30 ~ 85℃
GPS 4.5V ~ 5.5V
Operating voltage
AM/FM 10.5 ~ 16.0V

Current GPS Max. 30mA

consumption AM/FM Max. 100mA
GPS 50 Ω
Output impedance
AM/FM 75 Ω

3) Door Speaker
Category Specifications
Size 5.25 inch
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 86 ± 2 dB

4) Tweeter Speaker
Category Specifications
Size 1.5 inches
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 91 ± 2 dB

GETtheMANUALS.org
 0000-00 0-5

5) Handsfree Microphone
Category Specification
Operating temperature -30 ~ 85℃
Storage temperature -40 ~ 90℃
Impedance Max. 1 kΩ
S/N ratio* 65 dB or higher

* S/N ratio (Signal to Noise Ratio): Describes noise level in relation to the signal level in dB

6) LH Steering Wheel Switch

Category Specifications
Rated voltage 5V
Operating temperature -30 ~ 80℃
Combined resistance Individual resistance
Category

Volume down/MUTE 196Ω ←

Volume up 1020Ω ←
Mode 2210Ω ←
Seek UP 4020Ω ←
Seek DOWN 6980Ω ←
Bluetooth handsfree ON 13300Ω ←
Voice recognition 34800Ω ←

7) Rearview Camera
Category Specification
Power 6.5 V (5 to 12 V)
Angle Up/down: 108.7˚
Left/right: 139.9˚
Operating temperature -30 ~ 85℃
Storage temperature -40 ~ 95℃

GETtheMANUALS.org
0-6

8) USB Jack Assembly

Category Specification
Rated voltage DC 13.5V
Operating voltage DC 9V ~ 16V
Operating temperature -30℃ to 75℃
Charging port type CDP (12 Mbps)
Charging current Max. 2.1A (25℃)
Overcurrent/Short circuit detected 2.5A (±0.4A)
Output when overcurrent/short circuit detected
Output current limited to 2.5A (±0.4A)

Conditions for restoring Overcurrent/short circuit rectified

GETtheMANUALS.org
 0000-00 0-7

2. CAUTIONS

- This mark indicates potentially hazardous situation which, if not observed, may result in serious
injury and material damage.
- Ssangyong is not liable for any personal injury and material damage, caused by violation of traffic
regulations or neglect of observing actual traffic and driving situations.

3. WARNINGS

- This mark indicates situation which, if not observed, may result in an accident or system
malfunction.
- Do not disassemble or modify this system.
Doing so may cause an accident, fire or electric shock.
- Do not use the system if it is malfunctioning (sound or video output problem).
Doing so may lead to an accident or electric shock.
Please contact a Ssangyong service dealer immediately.
- The system should be used only when the engine is started.
Using the system for an extended period of time with the engine off may discharge the
battery.
- Do not leave beverages or foreign materials around the system.
If they enter the system, they may cause a fire.
- The system may break down if a disc not supported by this system is inserted.
- Do not apply impact to or drop this system.
It may cause malfunction.
- Never leave the system in a hot or cold place for an extended period of time. Therefore, do not park
the vehicle in a hot or cold place. The ambient temperature should be -30℃ to +80℃ for
proper operation.
- When cleaning the touch screen, turn off the system and clean the surface with a dry and soft cloth.
Never use any coarse cloth, hard cloth, chemical agent, volatile cleaning solvent (alcohol, benzene,
thinner) for cleaning the touch screen.
- The rear camera screen does not work during software update. Always stop the vehicle to update
the software and do not drive the vehicle until the update is completed.
- Be careful when reversing since the rear obstacle may be hidden by the warning messages and
parking guide lines if the rear camera system is activated.

GETtheMANUALS.org
0-8

Warning for safe driving

During driving, the video playback is limited and only sound is output for safe driving.
(vehicle speed of more than 0 km/h)

Warning for discharged battery

"Battery discharged" warning is displayed when operating the smart audio without starting the engine.
(Displayed at first 10 minute, then every 1 minute)

GETtheMANUALS.org
 0000-00 0-9

1. OVERVIEW
The smart audio system is a system in which the audio system and the mirroring system are combined
into one, thereby enhancing the user's convenience.
The smart audio head unit integrates radio, audio, Bluetooth, Apple CarPlay, Android Auto and OnCar
into one system.

▶ Major functions

- Radio (FM/AM)
- Media (USB/SD (Movie, Music, Image))
- Bluetooth
- Bluetooth music
- iPod
- Android Auto (only for Android phone)
- Apple CarPlay (for iPhone only)
- My Music (playing music in internal memory)

GETtheMANUALS.org
0-10

2. COMPONENTS
Smart audio head unit USB JACK ASSEMBLY

LH steering wheel switch Handsfree microphone

GETtheMANUALS.org
 0000-00 0-11

Tweeter speaker Door speaker

Combination antenna Rear view camera

GETtheMANUALS.org
0-12

3. EPC
▶ 8530 SWITCH & SENSOR - STEERING WHEEL

1. TURN LIGHT ASSY-MULTI FUNCTION

2. WIPER ASSY-MULTI FUNCTION
5. SCREW
8. CONTACT COIL ASSY-STEERING
10.SW ASSY-AUDIO REMOTE CONT
11.SW ASSY-AUDIO REMOTE CONT-RH
15.WIRING ASSY-AUDIO REMOTE CONT

GETtheMANUALS.org
 0000-00 0-13

▶ 8610 Application component (1)

GETtheMANUALS.org
0-14

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 0-15

▶ 8910 Audio & AVN system - Interior

1. AUDIO ASSY
2. SMART AUDIO ASSY
4. BLANKING COVER-AUDIO
5. HEAD UNIT-AUDIO & VIDEO
6. SD CARD
7. SCREW
8. CABLE ASSY-USB
10.JACK ASSY-USB

GETtheMANUALS.org
0-16

▶ 8930 Audio & AVN system - Exterior

1. FEEDER CABLE-AUDIO & VIDEO FRT

2. FEEDER CABLE-AUDIO & VIDEO RR
26.ANTENNA ASSY-RADIO MICRO POLE
27.NUT-RADIO MICRO POLE MTG
28.ANTENNA ASSY
29.ANTENNA ASSY
41.NUT

GETtheMANUALS.org
 0000-00 0-17

4. FEEDER CABLE

GETtheMANUALS.org
0-18

1. SYSTEM DIAGRAM

GETtheMANUALS.org
 0000-00 0-19

GETtheMANUALS.org
0-20

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 0-21

GETtheMANUALS.org
0-22

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 0-23

3. M-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
0-24

▶ TCU

GETtheMANUALS.org
 0000-00 0-25

4. SMART AUDIO SYSTEM BOOT-UP PROCESS

- Start ignition switch OFF → ACC
The smart audio head unit in sleep mode requires about 18 seconds to complete the booting
process after receiving the operating signal. To reduce the booting time, the system mode
needs to be changed from sleep mode to standby mode after receiving the door unlock and
ACC signals.
- START switch ACC (ON) to OFF
When the ignition key is turned OFF with the smart audio head unit ON, the smart audio head unit
enters standby mode. Then the system decides whether it enters sleep mode or normal mode based
on the conditions.

What is standby mode?

The standby mode means that the system maintains its settings for 3 minutes. And it includes the
following status:
1. Normal standby with the smart audio head unit screen OFF
2. Waiting for other operation signal input within 3 minutes after the ignition is turned OFF.

What is sleep mode?

All power supplies are cut off, except the power for the device used to inform reactivation of the
system in order to prevent the battery from being discharged.
※ Total dark current of smart audio system in low current consumption mode: Max. 3.0 [mA]

GETtheMANUALS.org
0-26

Smart audio head unit

Sleep mode deactivated and booting Enters sleep mode

GETtheMANUALS.org
 0000-00 0-27

5. FUNCTIONS
1) Functions For Each Button

No Designation Function
1 Touch screen Touch screen to operate functions displayed on screen
2 Power/volume - Press briefly to turn on power when power is off
- Press and hold (for more than 1.5 sec.) to turn off power
when power is on
- Press briefly to switch between AV OFF and AV ON
- Turn dial to the left/right to adjust volume (0 ~ 45)
3 Radio - Go to radio mode
- Press briefly in radio mode to shift modes as follows:
FM1 → FM2 → AM → FM1
4 Mode - Go to main screen
- Press and hold in main screen to go to last AV mode
5 SEEK/TUNE - Left / right rotation: (Low/high) Radio broadcast auto tuning
- Left / right rotation while pressing: Changes from currently
receiving frequency to frequency increased/decreased by
1 step

GETtheMANUALS.org
0-28

No Designation Function
6 Phone - Go to Bluetooth mode
- Short press in Bluetooth mode
* When you are not on a call, mode switches in following
order: Call history → Recent call numbers → Call
* When you are on a call: hands-free call shifted to secret
call mode
- Long press in Bluetooth mode
* When you are not on a call, mode switches to recent call
numbers
* During an incoming call: Call rejected
* During a call: Call terminated
7 Setup - Press and hold: Enter configuration mode
- Short press in radio mode: Enter radio setting mode
- Short press in audio mode: Enter audio setting mode
- Short press in video mode: Enter screen setting mode
- Short press in Bluetooth mode: Enter Bluetooth setting mode

GETtheMANUALS.org
 0000-00 0-29

2) Function

No Designation Function
1 B/T Operates Bluetooth Handsfree mode. During a Bluetooth Handsfree call,
(BLUETOOTH) press and hold to end the call.
2 SEEK UP / While playing
DOWN - press up/down to move the previous/next file.
(UP/DOWN) In Radio mode
- press up/down to move the previous/next preset.
- press and hold up/down to move the previous/next broadcast
frequency.
3 VOL + / VOL - Adjusts the volume.
MUTE(PUSH) During a handsfree call, press and hold VOL- to turn the mic off.
When not on a call, press and hold VOL- to mute the volume.
4 VOICE In Apply CarPlay mode
- operates Siri.
In Android Auto mode
- operates Google Voice.
5 MODE In any mode
- Each press of the key will change the mode in order of Radio →
Media → Bluetooth Music → iPod → My Music mode. (If the media
device is not connected, corresponding modes will be disabled)
In Radio mode
- Press and hold to change the radio mode in order of FM1 → FM2
→ AM → DAB mode.
In Media mode
- Press and hold to change the mode in order of USB Music → USB
Video → USB Image mode.

GETtheMANUALS.org
0-30

4) Basic Operation
(1) Starting the System
1. Press the engine start button once or set the
ignition key to the ON or ACC position.

2. The Ssangyong Motors logo is displayed and

the system will boot.

3. The last-operated user mode is displayed.

(Initial screen is Radio FM 1.)

- When the car is turned on, it automatically

operates in the last saved mode (the last
mode is not saved in some modes)
- The system will be shut off approximately 3
minutes after getting out of the vehicle.

When the system is restarted, some of the

information that has already been saved and
set is initialized. This is to ensure safety by
initializing the device, not a bad phenomenon.

GETtheMANUALS.org
 0000-00 0-31

(2) Shutting down the system

1. If you press and hold the front POWER/VOL

dial for more than 1.5 seconds during system
operation, the power is turned off.
Press shortly when you want to turn the AV
on/off while leaving the system power on.
When you turn off the power, the system saves
the current operating mode.

2. When the power is turned off, the current time

is displayed.

- When the car is turned on, it automatically

operates in the last saved mode (the last
mode is not saved in some modes)
- The system will be shut off approximately 3
minutes after getting out of the vehicle.

When the system is restarted, some of the

information that has already been saved and
set is initialized. This is to ensure safety by
initializing the device, not a bad phenomenon.

GETtheMANUALS.org
0-32

(3) Restarting the system

1. Press the RADIO and SETUP keys

simultaneously.

2. Power is shut down and the system reboots.

- When the car is turned on, it automatically

operates in the last saved mode (the last
mode is not saved in some modes)
- The system will be shut off approximately 3
minutes after getting out of the vehicle.

When the system is restarted, some of the

information that has already been saved and
set is initialized. This is to ensure safety by
initializing the device, not a bad phenomenon.

GETtheMANUALS.org
 0000-00 0-33

5) Selecting MODE
(1) Displaying the Main Mode
1. Press the MODE key to display the full menu
screen.

2. From the MODE screen, select the desired

mode.

(2) Radio
1. Plays radio broadcasts from
FM1/FM2/AM/DAB.

GETtheMANUALS.org
0-34

(3) DAB (EU only)

1. Press the DAB button on the radio mode
screen to enter DAB mode.

(4) Media
1. Media mode is used to play music, video,
image files within a USB device.
2. This feature will not operate unless there is at
least one music, video or image file in the USB
device.

(5) e-Manual
1. Select the desired menu from the list on the
left-side of the screen and use the left/right
buttons to make operations.

GETtheMANUALS.org
 0000-00 0-35

(6) My Music
1. Radio broadcasts can be played by saving
them using the Radio Recording feature.
2. Frequently played Music files can be stored in
the device by creating My Music lists.

(7) Voice Memo

1. The Voice Memo mode can be used to make
voice recordings.

(8) Bluetooth Phone

1. This feature allows the user to conveniently
make phone calls using Bluetooth.
2. Before you use the Bluetooth feature, you must
first pair/connect your mobile phone to your car.

GETtheMANUALS.org
0-36

(9) Climate(Option)
1. The Climate feature can be used to check the
A/C and heater temperature and fan direction.

(10) Bluetooth Music

1. Bluetooth music is available when Bluetooth is
connected.
2. Music plays automatically upon entering
Bluetooth Music mode when Bluetooth
becomes connected.
- If auto playback does not operate, try
pressing the button again.
- Auto playback may not be supported for
some music playback software used
within some connected device.

(11) iPod
1. You can enjoy music by connecting your iPod
device with the device.

GETtheMANUALS.org
 0000-00 0-37

(12) Android Auto

1. Android Auto can be used by connecting an
Android smartphone with the device.

(13) Connecting CarPlay, iPod and Android Auto

- When connecting USB Cable, use only

authentic connection Cable.
- When using iPod mode through an iPhone,
the Use CarPlay setting in iPhone Settings
must be disabled.

(14) Apple CarPlay

1. Connect your iPhone with the device to
conveniently use various features, including
Phone, Navigation, Messages, Music, and
Siri.

GETtheMANUALS.org
0-38

6. OPERATING PROCESS OF REAR VIEW CAMERA

For a vehicle equipped with rearview camera, the rear view is displayed on the monitor when shifting the
gear selector lever to "R" position, for safe parking.
The operating conditions are as follows:

▶ Characteristics of rearview camera

- The image of the rearview camera overrides the image of smart audio system.
- Even if the monitor is off, the power will be supplied to the monitor to display the rear view when
shifting the gear selector lever to "R" position. Under this condition, shifting the gear selector lever
to any position except "R", cuts off the power to the monitor.

▶ Operating conditions of rearview camera

- Even if the image of the rearview camera overrides the image of smart audio system, the rearview
camera cannot operate alone. If the gear selector lever stays in "R" position for more than 3
seconds with the ignition switch ON or engine running, the rear view is displayed on the monitor
automatically, no matter what is currently displayed.

▶ Rearview camera operation mode

- Automatic operation mode
When selecting R position while smart audio system is not in use (Ignition switch "ON" or engine
running): The LCD screen of smart audio system is automatically turned on to display rear area
of the vehicle. The screen is automatically turned off when shifting out from "R" position.

Switching mode
- When selecting R position while smart audio system is in use (Ignition switch "ON" or engine
running): The LCD screen of audio system is automatically changed to rearview monitoring
mode. The screen returns to the previous mode when shifting out from "R" position.
However, the audio stays on even in the rearview monitoring mode.

The actual distance may differ from what you see from the monitor because the rearview camera
uses a wide-angle lens to have a large clear view. Therefore, you should check the rearview mirrors
and the area behind the vehicle before and while moving backward. The rearview camera does not
show the entire area behind the vehicle.
Keep the camera lens clean using a camera lens cleaner so that the lens is free of foreign matter.

GETtheMANUALS.org
 0000-00 0-39

7. SYSTEM SETTINGS
(1) Settings Mode
1. Press and hold the SETUP key.

2. From Settings, select the desired settings

mode.

(2) Radio Settings

1. Sets RDS and PTY Seek settings.
2. Press the button at the topright side to
reset settings.

GETtheMANUALS.org
0-40

(3) Language Settings

1. In the Language screen, select the desired
language and apply.
The system will automatically restart using the
new system language.
2. Press the button at the top right side to
initialize the settings.

(4) Sound Settings

1. Use the left/right/front/back buttons to change
the Fader/Balance.
2. Press the button at the topright side to
reset settings.

(5) Display Settings

1. Used to set the illumination, ratio, screen off,
background, and other display settings.
2. Press the button at the top right side to
initialize the settings.

GETtheMANUALS.org
 0000-00 0-41

(6) Clock Settings

1. Sets the date and time.
2. Press the button at the topright side to
reset settings.

(7) System information

1. Used to check system information and
perform system reset/upgrade.

(8) Vehicle Sync Settings(Option)

1. Used to select cabin mood light settings.

GETtheMANUALS.org
0-42

8. CIRCUIT DIAGRAM
▶ Steering wheel switch, instrument cluster, driver's door lock actuator

GETtheMANUALS.org
 0000-00 0-43

GETtheMANUALS.org
0-44

▶ Speaker, rearview camera, hands-free microphone

GETtheMANUALS.org
 0000-00 0-45

GETtheMANUALS.org
 0000-00 0-3

1. SPECIFICATIONS
1) AVN Head Unit
Category Specifications
Operating voltage 9 ~ 16V
Operating temperature -30 ~ 75℃

General Current consumption 2A

information Dark current 3 mA or less (head unit only)
Weight 2.58kg
Internal storage capacity 16GB
Size 9" TFT HD (touch panel: 12.3")
Aspect ratio 16:9
Display Resolution 1,280 x 720
Viewing angle Up/down/left/right: 88˚
Touch screen type Capacitive
FM 87.5 ~ 108.0
GEN
AM 531 ~ 1,602
FM 87.5 ~ 108.0
Radio Frequency EU
AM 522 ~ 1,620
FM 87.5 ~ 107.9
L/America
AM 530 ~ 1,710
USB Compatibility 174MHz ~ 216MHz
GPS: 1.57542 GHz
Frequency
GPS GLONASS: 1598.0625 ~ 1609.3125 MHz
Channel 32 channels
Bluetooth Power supply 3.3V (30mA)
MAP TOM TOM
Navigation
MAP storage Micro SD (16GB)

GETtheMANUALS.org
0-4

2) Combination Antenna
Category Specifications
Storage temperature -40 ~ 105℃
Operating temperature -30 ~ 85℃
GPS 4.7 ~ 5.3V
Operating voltage
AM/FM 10.5 ~ 16.0V
GPS Max. 40mA
Current consumption
AM/FM Max. 100mA
GPS 50 Ω
Output impedance
AM/FM 75 Ω

3) Door Speaker
Category Specifications
Size 5.25 inch
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 86 ± 2 dB

4) Tweeter Speaker
Category Specifications
Size 1.5 inches
Max. input 40W
Rated impedance 4 ± 0.6 Ω
Output sound pressure level 91 ± 2 dB

GETtheMANUALS.org
 0000-00 0-5

5) Handsfree Microphone
Category Specification
Operating temperature -30 ~ 85℃
Storage temperature -40 ~ 90℃
Impedance Max. 1 kΩ
S/N ratio* 65 dB or higher

* S/N ratio (Signal to Noise Ratio): Describes noise level in relation to the signal level in dB

6) LH Steering Wheel Switch

Category Specifications
Rated voltage 5V
Operating temperature -30 ~ 80℃
Combined resistance Individual resistance
Category

Volume down 196Ω ←

Volume up 1020Ω ←
Mode 2210Ω ←
Seek UP 4020Ω ←
Seek DOWN 6980Ω ←
Bluetooth handsfree ON 13300Ω ←
Voice recognition 34800Ω ←

7) Rearview Camera
Category Specification
Power 6.5 V (5 to 12 V)
Angle Up/down: 90.1˚
Left/right: 140.1˚
Operating temperature -30 ~ 85℃
Storage temperature -40 ~ 95℃

GETtheMANUALS.org
0-6

8) USB Jack Assembly

Category Specification
Rated voltage DC 13.5V
Operating voltage DC 9V ~ 16V
Operating temperature -30℃ to 75℃
Charging port type CDP (12 Mbps)
Charging current Max. 2.1A (25℃)
Overcurrent/Short circuit detected 2.5A (±0.4A)
Output when overcurrent/short circuit
Output current limited to 2.5A (±0.4A)
detected
Conditions for restoring Overcurrent/short circuit rectified

GETtheMANUALS.org
 0000-00 0-7

2. CAUTIONS

- Always observe the traffic rules.

- The route provided by the navigation can be different from the actual roads.
- Never operate your navigation system while driving the car. A serious accident may occur due to
inattentive driving or lack of forward vision. Stop the vehicle before manipulating the navigation
system. Some menus on the touch screen will be deactivated when the vehicle is driven for safety
reasons. All menus will be activated again as soon as the vehicle stops.
- This system is only for a vehicle. Do not use this system in other than a vehicle.
- Installation or removal of this system requires special technique.
- When cleaning the touch screen, turn off the system and clean the surface with a dry and soft cloth.
Never use any coarse cloth, hard cloth, chemical agent, volatile cleaning solvent (alcohol, benzene,
thinner) for cleaning the touch screen. The screen surface can be damaged and discolored. If the
navigation system is faulty, have the system serviced by your authorized dealer or distributor..
Do not apply excessive force to or drop this system.
- Do not apply any impact and pressure to the monitor screen. The LCD panel or touch screen panel
- can be damaged.

GETtheMANUALS.org
0-8

3. WARNINGS

- Always pay attention to the actual traffic conditions and observe safe driving rules.
- Relying on the navigation alone could lead to a serious accident.
- Minimize the time looking at the navigation screen. Looking at the screen for too long time may
cause an accident.
- Never operate your navigation system while driving the car. A serious accident may occur due to
inattentive driving or lack of forward vision
- Stop the vehicle before manipulating the navigation system.
- Do not disassemble or modify this product. It may cause accidents, fire or electric shock.
- Protect the navigation system from water or foreign objects. It might cause malfunction.
If you see smoke or flames from the system due to water or foreign objects, stop using the system
immediately and have the system serviced by your authorized dealer or distributor.
This can lead to the system malfunctions.
- Do not use the system if it is malfunctioning (sound or video output problem). This can lead to the
critical system errors or serious accidents (fire, electrical shock).
- Never manipulate the system in a clear way. Not following this may lead to an accident.
- The rear camera screen does not work during software update. Always stop the vehicle to update
the software and do not drive the vehicle until the update is completed.
- Be careful when reversing since the rear obstacle may be hidden by the warning messages and
parking guide lines if the rear camera system is activated.

GETtheMANUALS.org
 0000-00 0-9

Warning for safe driving

During driving, the video playback is limited and only sound is output for safe driving.
(vehicle speed of more than 0 km/h)

Warning for discharged battery

"Battery discharged" warning is displayed when operating the AVN without starting the engine.
(Displayed at first 10 minute, then every 1 minute)

GETtheMANUALS.org
GETtheMANUALS.org
 0000-00 0-11

1. OVERVIEW
The navigation system has been incorporated into the AV (audio + video) system as an AVN system to
enhance the user comfort.
The AVN head unit integrates audio, video, CarPlay and navigation devices into one system.
The AVN head unit supports various multimedia such as video, music, photo, etc.

▶ Major features

- Radio (FM/AM)
- Navigation (TOM TOM)
- Media (USB music, USB video, USB image)
- Bluetooth
- Bluetooth music
- iPod
- Android Auto (only for Android phone)
- Apple CarPlay (for iPhone only)
- My Music (playing music in internal memory)

GETtheMANUALS.org
0-12

2. COMPONENTS
AVN head unit USB jack assembly

LH steering wheel switch Handsfree microphone

GETtheMANUALS.org
 0000-00 0-13

Tweeter speaker Door speaker

Combination antenna Rear view camera

GETtheMANUALS.org
0-14

3. EPC
▶ 8530 SWITCH & SENSOR - STEERING WHEEL

1. TURN LIGHT ASSY-MULTI FUNCTION

2. WIPER ASSY-MULTI FUNCTION
5. SCREW
8. CONTACT COIL ASSY-STEERING
10.SW ASSY-AUDIO REMOTE CONT
11.SW ASSY-AUDIO REMOTE CONT-RH
15.WIRING ASSY-AUDIO REMOTE CONT

GETtheMANUALS.org
 0000-00 0-15

▶ 8610 Application component (1)

GETtheMANUALS.org
0-16

1. LAMP ASSY-ROOM CTR 31.GARNISH-TAILGATE LICENSE PLATE

2. LENS-ROOM LAMP 32.BLANKING COVER-RR VIEW CAMERA
3. BULB 33.SCREW
4. LAMP ASSY-GLOVE BOX 34.CLIP-GARNISH
5. BULB 35.LIGHTER ASSY-CIGAR
6. HORN ASSY 36.SOCKET ASSY-POWER
7. LAMP ASSY-LUGGAGE 37.MICROPHONE ASSY-HANDS FREE
8. LAMP ASSY-SUNVISOR 38.SOCKET ASSY-INVERTER
9. SENSOR MODULE-A/LIGHT & RAIN 39.BLANKING COVER-SOCKET
10.COVER ASSY-STYLING 40.NUT-HORN MTG
15.LAMP ASSY-MOOD 41.BOLT-HORN MTG
16.LAMP ASSY-MOOD CTR LWR 45.UNIT ASSY-220V INVERTER
17.LENS-MOOD CTR LWR 50.UNIT ASSY-FRT CAMERA
22.SPEAKER ASSY 51.COVER-AEBS CAMERA
25.SPEAKER ASSY-TWEETER 52.PLUG ASSY-USB CHARGER
27.UNIT ASSY-DC-DC CONVERTER 54.UNIT ASSY-GATEWAY
28.NUT 55.SCREW
30.DISPLAY ASSY-RR VIEW CAMERA 56.UNIT ASSY-WIRELESS CHARGER

GETtheMANUALS.org
 0000-00 0-17

▶ 8910 Audio & AVN system - Interior

1. AUDIO ASSY
2. SMART AUDIO ASSY
4. BLANKING COVER-AUDIO
5. HEAD UNIT-AUDIO & VIDEO
6. SD CARD
7. SCREW
8. CABLE ASSY-USB
10.JACK ASSY-USB

GETtheMANUALS.org
0-18

▶ 8930 Audio & AVN system - Exterior

1. FEEDER CABLE-AUDIO & VIDEO FRT

2. FEEDER CABLE-AUDIO & VIDEO RR
26.ANTENNA ASSY-RADIO MICRO POLE
27.NUT-RADIO MICRO POLE MTG
28.ANTENNA ASSY
29.ANTENNA ASSY
41.NUT

GETtheMANUALS.org
 0000-00 0-19

4. FEEDER CABLE

GETtheMANUALS.org
0-20

1. SYSTEM DIAGRAM

GETtheMANUALS.org
 0000-00 0-21

GETtheMANUALS.org
0-22

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 0-23

GETtheMANUALS.org
0-24

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 0-25

3. M-CAN COMMUNICATION I/O ELEMENTS

▶ CGW

GETtheMANUALS.org
0-26

▶ TCU

GETtheMANUALS.org
 0000-00 0-27

4. BOOTING SEQUENCE
- Start ignition switch OFF → ACC
The AVN head unit in sleep mode requires about 18 seconds to complete the booting process after
receiving the operating signal. To reduce the booting time, the system mode needs to be changed
from sleep mode to standby mode after receiving the door unlock and ACC signals.
- START switch ACC (ON) to OFF
When the ignition key is turned OFF with the AVN head unit ON, the AVN head unit enters standby
mode. Then the system decides whether it enters sleep mode or normal mode based on the
conditions.

What is standby mode?

The standby mode means that the system maintains its settings for 3 minutes. And it includes the
following status:
1. Normal standby with the AVN head unit screen OFF
2. Waiting for other operation signal input within 3 minutes after ignition OFF

What is sleep mode?

All power supplies are cut off, except the power for the device used to inform reactivation of the
system in order to prevent the battery from being discharged.
※ Total dark current of AVN system in low current consumption mode: MAX 3.0 [mA]

GETtheMANUALS.org
0-28

AVN head unit

Sleep mode deactivated and booting Enters sleep mode

GETtheMANUALS.org
 0000-00 0-29

5. FUNCTIONS
1) Buttons

Button Description
HOME
1. Displays the HOME screen (PIP, Picture in Picture).
2. Press and hold (more than 1.5 seconds) to go to Favorites mode.

MODE
1. Switches to mode selection screen
2. In Navigation mode, press and hold (more than 1.5 seconds) to go to
the currently playing AV mode.

NAVI
1. Switches to Navigation mode regardless of whether AV is On/Off and
moves to the current position.
2. Press and hold (more than 1.5 seconds) to go to destination search.

PHONE
1. Goes the Bluetooth mode screen. (Displays connection screen when
Bluetooth is disconnected)
2. Press and hold (more than 1.5 seconds) to dial the most recent
number. (Displays connection screen when Bluetooth is disconnected)
SETUP
Press and hold in all modes to enter Setup mode.
Shortly press to operate in the following order.
(Radio → Radio Setup, Audio → Sound Setup, Video → Screen Setup)

GETtheMANUALS.org
0-30

Button Description
USER
1. If the user key is not registered, press shortly to enter the key
registration mode.
2. If the user key is registered, press shortly to enter registered mode.
3. Press and hold (more than 1.5 seconds) to enter the user key
registration mode.
POWER/VOL
1. Used to turn the product on or off or to adjust the volume level.
2. Press and hold (more than 1.5 seconds) to turn of the power.
3. Shortly press to turn AV Off or AV On.
4. Turn the dial to adjust the volume. (Volume range 0 ~ 45)

GETtheMANUALS.org
 0000-00 0-31

2) Function

No Designation Function
1 B/T Operates Bluetooth Handsfree mode. During a Bluetooth Handsfree
(BLUETOOTH) call, press and hold to end the call.
2 SEEK UP / While playing
DOWN - press up/down to move the previous/next file.
(UP/DOWN) In Radio mode
- press up/down to move the previous/next preset.
- press and hold up/down to move the previous/next broadcast
frequency.
3 VOL + / VOL - Adjusts the volume.
MUTE(PUSH) During a handsfree call, press and hold VOL- to turn the mic off.
When not on a call, press and hold VOL- to mute the volume.
4 VOICE In Apply CarPlay mode
- operates Siri.
In Android Auto mode
- operates Google Voice.
5 MODE In any mode
- Each press of the key will change the mode in order of Radio →
Media → Bluetooth Music → iPod → My Music mode.(If the media
device is not connected, corresponding modes will be disabled)
In Radio mode
- Press and hold to change the radio mode in order of FM1 → FM2
→ AM → DAB mode.
In Media mode
- Press and hold to change the mode in order of USB Music → USB
Video → USB Image mode.

GETtheMANUALS.org
0-32

3) Basic Operation
(1) Starting the System
1. Press the engine start button once or set the
ignition key to the ON or ACC position.

2. The boot screen and the logo screen are

displayed and the system will start.

3. A safety warning is displayed and the user

agreement button becomes active.

4. If you press Agree, the last-operated user

mode is displayed. (Initial screen is Radio
FM1.)

If Auto Disappear is pressed, display goes to

the end user mode even if "Agree" is not
pressed.

GETtheMANUALS.org
 0000-00 0-33

(2) Shutting down the system

1. If you press and hold the front POWER/VOL
dial for more than 1.5 seconds during system
operation, the power is turned off. Press
shortly when you want to turn the AV on/off
while leaving the system power on.
When power is turned off, the system will save
the current operating mode.

2. When the power is turned off, the current time

is displayed.

- The last mode operated before the vehicle

engine is turned off is saved by the device
and is the first mode operated the next time
the device is turned on.
(The last mode may not be saved in some
modes.)
- This system shuts off 3 minutes after the
vehicle engine is turned off.

GETtheMANUALS.org
0-34

(3) Restarting the System

1. Press the Reset key located on upper left of
the Micro SD slot.

2. Power is shut down and the system reboots.

When the system is restarted, some of the

information that has already been saved and
set is initialized. It is not bad because it is
initialized to ensure stability.

GETtheMANUALS.org
 0000-00 0-35

(4) Audio Off

1. Shortly press (less than 1.5 seconds) the
VOLUME dial with the audio on to turn the
audio off and display the current position
within the navigation map screen.

2. When the audio is turned off, the most recently

operated navigation mode screen is restored.

GETtheMANUALS.org
0-36

(5) Audio On
1. Shortly press (less than 1.5 seconds) the
VOLUME dial while the audio is off to turn the
audio on.

2. The system screen will maintain the navigation

screen and restore the audio mode that had
been last operated before audio had been
turned off. maintains navigation and the audio
executed before Audio Off is executed.

GETtheMANUALS.org
 0000-00 0-37

4) Selecting MODE
(1) HOME
1. Press the HOME key to display to the HOME
screen.

2. From the HOME screen, select the desired

menu.

GETtheMANUALS.org
0-38

(2) MODE
1. Press the MODE key to display to the mode
menu screen.

2. From the MODE screen, select the desired

menu.

GETtheMANUALS.org
 0000-00 0-39

(3) NAVI
1. Press the NAVI key to display the NAVI
screen.

2. From the NAVI screen, select the desired

menu.

(4) RADIO
1. Plays radio broadcasts from
FM1/FM2/AM/DAB.

GETtheMANUALS.org
0-40

(5) DAB
1. Press the DAB button on the radio mode
screen to enter DAB mode.

(6) Media
1. Media mode is used to play music, video,
image files within a USB device.
2. This feature will not operate unless there is at
least one music, video or image file in the USB
device.

(7) e-Manual
1. Select the desired menu from the list on the
left-side of the screen and use the left/right
buttons to make operations.

GETtheMANUALS.org
 0000-00 0-41

(8) My Music
1. Radio broadcasts can be played by saving
them using the Radio Recording feature.
2. Frequently played Music files can be stored in
the device by creating My Music lists.

(9) Voice Memo

1. The Voice Memo mode can be used to make
voice recordings.

(10) Bluetooth Phone

1. This feature allows the user to conveniently
make phone calls using Bluetooth.
2. Before you use the Bluetooth feature, you must
first pair/connect your mobile phone to your car.

GETtheMANUALS.org
0-42

(11) Climate(Option)
1. The Climate feature can be used to check the
A/C and heater temperature and fan direction.

(12) Bluetooth Music

1. Bluetooth music is available when Bluetooth is
connected.
2. Music plays automatically upon entering
Bluetooth Music mode when Bluetooth
becomes connected.
- If auto playback does not operate, try
pressing the button again.
- Auto playback may not be supported for
some music playback software used within
some connected device.

GETtheMANUALS.org
 0000-00 0-43

(13) iPod
1. You can enjoy music by connecting your iPod
device with the device.

▶ Connecting iPod

- When connecting USB Cable, use only

authentic connection Cable.
- When using iPod mode through an iPhone,
the Use CarPlay setting in iPhone Settings
must be disabled.

GETtheMANUALS.org
0-44

(14) Android Auto

1. Android Auto can be used by connecting an
Android smartphone with the device.

▶ Connecting Android Auto

- When connecting USB Cable, use only

authentic connection Cable.
- When using iPod mode through an iPhone,
the Use CarPlay setting in iPhone Settings
must be disabled.

GETtheMANUALS.org
 0000-00 0-45

(15) Apple CarPlay

1. Connect your iPhone with the device to
conveniently use various features, including
Phone, Navigation, Messages, Music, and
Siri.

▶ Connecting CarPlay

- When connecting USB Cable, use only

authentic connection Cable.
- When using iPod mode through an iPhone,
the Use CarPlay setting in iPhone Settings
must be disabled.

GETtheMANUALS.org
0-46

5) Settings
(1) Settings Mode
1. Press and hold the SETUP key.

2. From Settings, select the desired settings

mode.

(2) Radio Settings

1. Sets RDS and PTY Seek settings.
2. Press the button at the topright side to
reset settings.

GETtheMANUALS.org
 0000-00 0-47

(3) Clock Settings

1. Sets the date and time.
2. Press the button at the topright side to
reset settings.

(4) Sound Settings

1. Use the left/right/front/back buttons to change
the Fader/Balance.
2. Press the button at the topright side to
reset settings.

(5) Display Settings

1. Used to set the illumination, ratio, screen off,
background, and other display settings.
2. Press the button at the top right side to
initialize the settings.

GETtheMANUALS.org
0-48

(6) Favorites Settings

1. Used to add, delete or change Favorites.

(7) Language Settings

1. In the Language screen, select the desired
language and apply. The system will
automatically restart using the new system
language.
2. Press the button at the top right side to
initialize the settings.

(8) System information

1. Used to check system information and
perform system reset/upgrade.
2. In the Navigation settings screen, sets
whether to automatically start Navigation
upon system start-up.

GETtheMANUALS.org
 0000-00 0-49

(9) Vehicle Sync Settings (Option)

1. Used to select cabin mood light and
instrument cluster settings.

GETtheMANUALS.org
0-50

6) Rear View Camera

(1) To ensure safety, a rear view camera will operate when the vehicle is
driving in reverse.
- When the gear is shifted to reverse (R), the rear view camera will operate with priority over every
other mode.
- Once the shift gear is moved out of reverse (R), the device will restore the previously opeating mode.
Sound and mute features are supported while the rear view camera is operating.
-

1. Turn ignition switch to ON or IGN position.

2. Shift the gear position to reverse (R).

- The rear view shown through the device

display may differ from the actual
distance. Be sure to check your actual
surroundings when backing up for
additional safety.
- When operating the rear view camera, heed
caution as the warning text and parking
guide lines may make obstacles less visible.

- The rear view camera is unavailable

during updates. Make sure to park your
vehicle before conducting updates and
start driving only after the update is
complete.
- Only sound and incoming call features will
be available when the rear view camera is
operating.

GETtheMANUALS.org
GETtheMANUALS.org
0-52

6. CIRCUIT DIAGRAM
▶ Steering wheel switch, instrument cluster, driver's door lock actuator

GETtheMANUALS.org
 0000-00 0-53

GETtheMANUALS.org
0-54

▶ Speaker, rearview camera, hands-free microphone

GETtheMANUALS.org
 0000-00 0-55

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
▶ Seat

Front seat Rear seat

Item
Power Manual LH/RH CTR
Type Driver side 12-way 6-way 4:6 split type
Passenger seat - 4-way -
Sliding 240 mm (front 200 + rear 40) -
Tilting (cushion) 35mm - -
(driver seat)
Reclining Power Forward 20˚ + backward 50˚ -
Manual Forward 20˚ (10˚ + 2˚× 5 steps) + Backward 5˚
backward 50˚ (2˚ × 25 steps)
Height adjuster ±25 mm (Except for passenger -
manual seat)
Lumbar Protrusion 43mm (driver's) -
support
Vertical adjustment 70mm (driver's) -
Head Up/down 90mm (15×6 steps) 88mm 30mm
restraint (58+30 × (1 step)
2 steps)
Sliding 24.9mm -
(3 Steps: 7.6 + +8.4 + +8.9)
Seat Cushion Level 1 40%
ventilation
Level 2 55% -
duty
Level 3 70%
Seatback Level 1 40%
Level 2 45% -
Level 3 50%

GETtheMANUALS.org
01-4

Front seat Rear seat

Item
Power Manual LH/RH CTR
Seat warmer Front seat Rear seat
temperature
Cush Level 1 37 Low 37
Level 2 41
Hi 45
Level 3 45
Back Level 1 42 Low 42
Level 2 46
Hi 50
Level 3 50

▶ Seat heater and ventilation unit

Item Specifications
Item Front seat heater and
Rear seat warmer unit
ventilation unit
Rated voltage DC 13.5V
Operating voltage DC 9 to 16V
Operating temperature -40℃ to +80℃
Load Warmer 120 W ± 10% (DC 12 V, after 1 min.)
ventilation Max 1A (DC 13.5 V, Duty 70%) -
Over-current Warmer 10A
protection
Ventilation 3A -

GETtheMANUALS.org
 0000-00 01-5

2. CAUTIONS

- You can operate the power seat with the ignition switch OFF. However, frequent operation of the
seat switch with the engine stopped can result in battery becoming discharged.
- Operating more than one seat adjustment switch at the same time can cause damage to the seat
motor. Therefore, operate the seat switch only one at a time.
- Do not use organic solvents such as benzene, thinner, alcohol or gasoline to prevent the seat cover
from being damaged while cleaning.
- Do not operate the seat position adjustment switch forcefully when the seat does not move or it
contacts an object.
- If the power seat is not operated, check and correct the problem before driving off.

3. WARNINGS

- Adjust the driver seat before driving.

- Make sure that the seat is firmly secured after adjusting.
- Never drive the vehicle with the head restraint removed or lowered excessively. Otherwise,
your neck, spine or other parts of the body can be severely injured in the event of an
accident.
- If the seatback is reclined too much, the risk of sliding under the lap belt and being injured is
increased.
- Do not put any object that could damage the seat on the seat.
- The front and rear seats are equipped with the seat warmer. Using the seat heater system
excessively may cause minor burns. The following occupants should exercise special care
when using it.
- Infants, children, old or handicapped persons
- Persons with sensitive skin
- Exhausted persons
- Persons who is drunk or took medicine which causes drowsiness such as sleeping pills, cold
tablets, etc.
- Do not place anything on the seat that insulates against the heat, such as a blanket or
cushion.
- Make sure that the head restraints are in place and secured properly. Never drive the vehicle with
the head restraint removed.
- To minimize the injuries in a collision or an abrupt stop, make sure the seatback is in the upright
position before driving. If the seatback is reclined too much, the occupant could slide under the seat
belt in a collision or an abrupt stop and cannot be protected properly by the air bag system.

GETtheMANUALS.org
01-6

1. OVERVIEW
The seat directly contacts with the driver and other occupants in the vehicle. Therefore, it should provide
high level of comfort and safety. To accomplish this, the seat of this vehicle has various convenience and
safety systems.
The seat is divided into the front seat, which includes driver and passenger seats, and the rear seat.
There are two types of the front seat (power seat and manual seat) based on the operating method. It is
equipped with the heated wire and ventilation motor in the seat cushion and seatback. The control unit for
these elements is mounted underneath the driver seat.
The rear seat can be folded in 4:6, and the seat cushion and the seat back are integrated with the heater
element.
All the seat belts are of 3-point type. The front seat belt has a height adjuster which adjusts the shoulder
belt height based on the body size and intention of the occupant.

GETtheMANUALS.org
GETtheMANUALS.org
01-8

2. COMPONENTS
▶ Front seat

Front seat warmer Front seat warmer

& ventilation unit & ventilation switch

Lumbar support Front seat

switch assembly

GETtheMANUALS.org
 0000-00 01-9

▶ Rear seat

Rear seat Rear seat

assembly Warmer unit

Rear seat
Warmer switch

GETtheMANUALS.org
01-10

3. EPC
▶ 7410 FRONT SEAT

GETtheMANUALS.org
 0000-00 01-11

1. SEAT ASSY-FRT 18.WARMER ASSY-FRT SEAT BACK

2. SEAT ASSY-FRT-LH 19.WARMER ASSY-FRT SEAT CUSHION
3. SEAT ASSY-FRT-RH 20.WIRING ASSY-FRT SEAT CUSH
4. SEAT ASSY-FRT POWER-RH 21.BUNGEE ASSY-B/BOARD
5. HEAD REST ASSY-FRT SEAT 22.BLOWER-FRT SEAT CUSHION
6. GUIDE LOCK ASSY-FRT SAET H/REST 23.BLOWER ASSY-FRT SEAT BACK
7. SLEEVE ASSY-HEAD REST-RH 24.SWITCH ASSY-LUMBAR SUPPORT
8. BACK BOARD ASSY-FRT SEAT BACK 25.SENSOR-SEAT BELT REMINDER
9. BOLT 26.SWITCH ASSY-POWER SEAT
10.SHIELD COVER ASSY-FRT SEAT 27.UNIT ASSY-SEAT WARMER
11.COVER ASSY-FRT SEAT INR 28.UNIT ASSY-SEAT WARMER
12.LEVER-RECLINER 29.LUMBAR SUPPORT ASSY-FRT SEAT
13.LEVER-HEIGHT ADJUSTER 30.COVER ASSY-FRT CUSHION
14.CAP 31.COVER ASSY-FRT CUSHION
15.FRAME ASSY-FRT SEAT CUSHION 33.COVER ASSY-FRT BACK
16.FAN ASSY-FRT SEAT BACK 35.PAD ASSY-FRT SEAT CUSHION
17.FAN ASSY-FRT SEAT CUSHION 36.PAD ASSY-FRT SEAT BACK

GETtheMANUALS.org
01-12

▶ 7510 REAR SEAT

1. SEAT ASSY-RR CUSHION 14.GUIDE LOCK ASSY-RR SAET H/REST

2. SEAT ASSY-RR BACK-LH 15.GUIDE FREE ASSY-RR SEAT H/REST
3. SEAT ASSY-RR BACK-RH 16.COVER-ANCHOR TETHER
4. STRIKER ASSY-RR 1ST BACK 17.LEVER ASSY-FOLDING
5. BRKT ASSY-HINGE 18.HOUSING-FOLDING LEVER
6. SLEEVE ASSY-RR 1ST CUSHION MTG 19.COVER-SEAT BELT RR CTR GUIDE
7. BOLT 22.ARM REST ASSY-RR SEAT
8. NUT 24.WARMER ASSY-RR SEAT CUSHION
9. BOLT-HEX SEMS_M10X1.25X30 25.WARMER ASSY-RR SEAT BACK
10.BOLT 26.UNIT ASSY-SEAT WARMER RR
11.BOLT 30.COVERING ASSY-RR SEAT CUSHION
12.HEAD REST ASSY-RR SEAT OTR 33.COVERING ASSY-RR SEAT BACK
13.HEAD REST ASSY-RR SEAT CTR 34.COVERING ASSY-RR SEAT BACK

GETtheMANUALS.org
 0000-00 01-13

1. FRONT SEAT WARMER AND VENTILATION UNIT

1) Seat Adjustment
▶ Head restraint adjustment

Adjusting head restraint height

To raise the head restraint, pull upward on

the head restraint. To lower the head
restraint, push downward on the head
restraint with the head restraint sleeve (A)
pressed.
Head restraint sliding adjustment

The head restraint can be moved

forward/backward.

GETtheMANUALS.org
01-14

▶ Seat slide adjustment (forward/rearward)

Power seat Manual seat (passenger)

Moving the slide knob forward/backward moves To move the seat forward or backward, pull up and
the seat forward/backward by activating the slide hold the seat slide lever and move the seat to the
motor. desired position.

▶ Seatback reclining adjustment

Power seat Manual seat (passenger)

Moving the upper part of the recliner knob Pull the recliner knob upward and adjust the
forward/backward adjusts the seatback angle by seatback angle with the seatback lock released.
activating the recliner motor. Then release the recliner knob at the desired angle
to lock the seatback.

GETtheMANUALS.org
 0000-00 01-15

▶ To adjust seat height

Power seat Manual seat (passenger)

Moving the slide switch upward/downward moves Pulling the height knob upward/downward moves
the seat cushion upward/downward as the front & the seat upward/downward.
rear up/down motors rotate the rail.

▶ Seat cushion tilting (driver seat)

Power seat

Moving the seat tilt switch upward/downward

moves the front part of the seat cushion
upward/downward as the front up/down motors
rotate the rail.

GETtheMANUALS.org
01-16

▶ Lumbar support (driver)

Power seat

Adjust the switches (A) and (B) laterally to adjust Operate the switches (C) and (D) vertically to
the protrusion of the lumbar support. adjust the position of the lumbar support.

GETtheMANUALS.org
 0000-00 01-17

1) Convenience System
Front seat warmer Front heated seat switch

Seat back pocket

Front seat ventilation

Front seat ventilation switch

GETtheMANUALS.org
01-18

2. REAR SEAT
The rear seat can be folded in 4:6 split ratio. The headrest height adjustment and seatback folding and
reclining control is carried out manually. The operation of the heated wire in the seatback and seat cushion
can be controlled using the rear seat heater switch on the rear door trim on each side.

1) Operating Process

Adjusting head restraint height

You can raise the head restraint

without operating the sleeve (A)
or lower it in stages while
pressing the sleeve (A).

Seat backrest reclining adjustment

In order to fold the seat backrest, pull the latch lever (A)
located in the side of the seat upper part to release the
lock of the seat backrest. Pull the lever back fully to
slide the seat backrest rearward 5˚, with the lock
released.

Fixed Folded Reclining (rearward 5˚)

GETtheMANUALS.org
 0000-00 01-19

2) Rear Seat Warmer / Comfort Systems

Rear seat warmer

Rear armrest

Rear cup holder

Left Right

Seatback 4:6 split folding

GETtheMANUALS.org
01-20

3. FRONT SEAT HEATER AND VENTILATION UNIT

(1) Mounting location
The front seat heater and ventilation unit is installed to the bottom of the driver seat. It controls the front
seat heater and ventilation motor in stages when the heater and ventilation switch is operated. Press the
left part of the heater and ventilation switch to change the level of ventilation and press the right part of
the switch to change the level of heater.
This unit controls the operation of heater to keep the temperature of the seat within the specified range.
Also, it controls the rpm of the motor for seat ventilation using PWM (pulse width modulation) control.

Mounting location Warmer and ventilation unit

The front seat warmer unit is mounted in the same position as the front seat warmer and ventilation
unit.

GETtheMANUALS.org
 0000-00 01-21

(2) Front seat heater operating process

▶ Operating conditions

- IGN 1 and unit operation signal (activated when ignition turned on)

▶ Operation description

- You can press the seat heater and ventilation switch with engine running to select one of 4 levels in
the following sequence: level 3 → level 2 → level 1 → OFF. It operates in order for each level,
but turned off when it is pressed for more than 1 second in level 2 or 3.

▶ Operating process

- When operating the seat heater switch with operating conditions met, the unit monitors the
temperature sensor to control the voltage so that the voltage is within the specified range of the
corresponding level. If the temperature monitoring result is out of the operating range, it turns off the
heater.

▶ Temperature control by level

Warmer
Category
Step 1 Step 2 Step 3

Temperature measured Cushion 37℃ 41℃ 45℃

Temperature Seatback 42℃ 46℃ 50℃

The warmer and ventilation can't be operated simultaneously.

GETtheMANUALS.org
01-22

▶ FRONT SEAT WARMER SMART CONTROL

When the warmer is maintained at a high temperature for a long time, the operating level is controlled to
be lowered to prevent a low temperature burn.

- How to operate
A. Shifted to level 2 if maintained for 30 min in level 3
B. Shifted to level 1 if maintained for 60 min in level 2
C. Shifted to level 2 after 8 min, if you change to level 3 within 5 min after smart control (A)
D. Smart control (A) repeated if you change to level 3, 5 min after smart control (A)

GETtheMANUALS.org
 0000-00 01-23

(3) Front seat ventilation operation

▶ Operating conditions

- IGN 1 and unit operation signal (activated when ignition turned on)

▶ Operation description

- You can press the seat heater and ventilation switch with engine running to select one of 4 levels in
the following sequence: level 3 → level 2 → level 1 → OFF. It operates in order for each level,
but turned off when it is pressed for more than 1 second in level 2 or 3.

▶ Operating process

- When the seat ventilation switch is operated with the operating conditions fulfilled, the amount of the
ventilation motor voltage is controlled by the duty ratio.

▶ Duty control by level

Ventilation
Category
Step 1 Step 2 Step 3
Duty Cushion 40% 55% 70%
Seatback 40% 45% 55%

The warmer and ventilation can't be operated simultaneously.

GETtheMANUALS.org
01-24

(4) Operation flowchart

The heating and ventilation functions can't be operated simultaneously at a seat.

GETtheMANUALS.org
 0000-00 01-25

(5) Conditions for diagnosing heater unit

▶ When input data is fail (Time tolerance ± 10%)

Condition
NO Item
Detection time MIN TYP MAX Unit
1 Low voltage detection 8 8.5 9 V
2 Low voltage return Less than 9.5 10 10.5 V
3 High voltage detection 500 ms 16 16.5 17 V
4 High voltage return 14.5 15 15.5 V
5 Switch OFF 1s -

GETtheMANUALS.org
01-26

▶ When output data is Fail

(Time tolerance ± 10%)

GETtheMANUALS.org
 0000-00 01-27

(6) Diagnosis of heater unit

The heater and ventilation unit performs
Ventilation LED Warmer LED
diagnostic procedures for the initial output after 3
sec. (for heater) and 5 sec. (ventilation) of
operation and provides diagnosis result through
the indicator on the heater and ventilation switch.

- ■: ON, ▨: Blinking (1 time/s), □: OFF

- While the indicator (LED) is flashing, pressing the heater and ventilation switch once or for 1 sec.
turns off the indicator on the switch.

GETtheMANUALS.org
01-28

4. HEATER AND VENTILATION UNIT BLOCK DIAGRAM

▶ With warmer and ventilation unit

GETtheMANUALS.org
 0000-00 01-29

▶ With warmer

GETtheMANUALS.org
01-30

5. REAR SEAT HEATER UNIT

(1) Mounting location
It is fitted to the bottom of the rear center seat. The heating temperature of the seatback and seat cushion
can be controlled in stages using the heater switch on the door trim. This unit controls the heater of the
rear seat heater to keep the temperature of the seat within the specified range based on the signal from
the heater switch.

Mounting location Warmer unit

GETtheMANUALS.org
 0000-00 01-31

(2) Operating process

▶ Operating conditions

- IGN 1 and unit operation signal (activated when ignition turned on)

▶ Operation description

- You can press the seat heater switch with engine running to select one of 3 levels in the following
sequence: level 2 → level 1 → OFF.

▶ Operating process

- When operating the seat heater switch with operating conditions met, the unit monitors the
temperature sensor to control the voltage so that the voltage is within the specified range of the
corresponding level. If the temperature monitoring result is out of the operating range, it turns off the
heater.

▶ Temperature control by level

Warmer temperature
Category
Step 1 Step 2
Cushion 37℃ 45℃
Temperature measured
Temperature Seatback 42℃ 50℃

▶ Rear seat warmer smart control

When the warmer is maintained at a high temperature for a long time, the operating level is controlled to
be lowered to prevent a low temperature burn.

GETtheMANUALS.org
01-32

(3) Operation flowchart

(4) Conditions for diagnosing heater unit

▶ When input data is fail
(Time tolerance ± 10%)

Condition
NO Item
Detection time MIN TYP MAX Unit
1 Low voltage detection 8 8.5 9 V
2 Low voltage return Less than 9.5 10 10.5 V
3 High voltage detection 500 ms 16 16.5 17 V
4 High voltage return 14.5 15 15.5 V
5 Switch OFF 1s -

GETtheMANUALS.org
 0000-00 01-33

▶ When output data is Fail

(Time tolerance ± 10%)

GETtheMANUALS.org
01-34

(5) Diagnosis function

The heater unit performs diagnostic procedures
Warmer LED for the initial output after 3 sec. of operation and
provides diagnosis result through the indicator on
the rear heater switch.

- ■: ON, ▨: Blinking (1 time/s), □: OFF

- While the indicator (LED) is flashing, pressing the rear heater switch once or for 1 sec. turns off the
indicator on the switch.

GETtheMANUALS.org
 0000-00 01-35

6. HEATER UNIT BLOCK DIAGRAM

GETtheMANUALS.org
01-36

7. DRIVER LUMBAR SUPPORT

▶ Specifications

Protrusion (based on actuator 50 mm

operation)
Back and forth movement (s) (No 5s /
load) (In / Out) 4.5s
Vertical adjustment amount 65 mm
Up and down movement (s) 6s / 6s
(No load) (Up / Down)

▶ Operation principle

In/out shaft

In / Out
movement
In/out motor Flex strip

1. In/out motor operated

2. Upper bracket moves downwards by up to 43 mm when in/out shaft
operated
3. Flex strip bent
4. Protrusion formed

In/out shaft

Up /
Down movement
In/out motor Flex strip

1. Up/down motor operated

2. Flex strip assembly moves by about 65 mm along up/down shaft
3. Up/down movement

GETtheMANUALS.org
 0000-00 01-37

8. CHILD RESTRAINT SYSTEM (ISO FIX)

1) Child Restraint System Type
There are 2 types in the child restraint system.
- Fixing using seat belt
- Fixing using ISOFIX (for the vehicle with ISOFIX system)
- Fixing using: i-size

2) Table of Vehicle Handbook Information on Child Restraint

Systems Installation Suitability for Various Seating Positions

TYPE A TYPE B
Rear-facing child seat Forward-facing child seat Booster seat

Restraint device Front Passenger Rear Rear Out

Mass group
figure Air bag off Air bag on Centre Board

O ~ up to 10 kg Rear facing child

U X U U
(0 ~ 9 month) seat
O+ ~ up to 13 kg Rear facing child
U X U U
(0 ~ 2 year) seat
Rear facing /
I ~ 9 to 18 kg
Forward facing U X U U
(9 month ~ 4 year)
child seat
II ~ 15 to 25 kg
Booster seat U U U U
(4 year ~ 6 years)
III ~ 22 to 36 kg
Booster seat U U U U
(6 year ~ 12 years)

※ Child restraint system are classified into the 5 groups according to the ECE R44

- U: Suitable for “universal” category restraints approved for use in the mass group.
- UF: Suitable for forward-facing “universal” category restraints approved for use in the mass
group.
- L: Suitable for particular child restraints given on attached list. These restraints may be of the
“semi-universal” categories.
- X: Seat position not suitable for children in the mass group.

GETtheMANUALS.org
01-38

3) Table of Vehicle Handbook Information on ISOFIX Child Restraint

Systems Installation Suitability for Various ISOFIX Positions
Vehicle ISOFIX Positions
Size Class
Mass group Fixture Frt Rear Rear Out
Passenger Centre Board
F (1) ISO/L1 X X X
CARRYCOT
G (1) ISO/L2 X X X
E (2) ISO/R1 X X IL
GROUP 0
UP TO 10KG E (2) ISO/R1 X X IL
D (2) ISO/R2 X X IL
GROUP 0+
UP TO 13KG C (2) ISO/R3 X X IL
D (2) ISO/R2 X X IL
C (2) ISO/R3 X X IL
GROUP I
9 TO 18KG B (3) ISO/F2 X X IUF/IL
B1 (3) ISO/F2X X X IUF/IL
A (3) ISO/F3 X X IUF/IL

Key of letters be inserted in the above table

- Suitable for ISOFIX forward child restraints systems of universal category approved for use in this
mass group.
- IL: Suitable for particular ISOFIX child restraint systems (CRS) given in attached list.
These ISOFIX CRS are those of the “specific vehicle”, “restricted” or “semi-universal”
categories.
- X: ISOFIX position not suitable ISOFIX child restraint systems in this mass group and/or this
size class.

1. Some child seats are installed transversely and occupy two seats. Make sure that the feet of child
are facing the door.
2. Slide the front seat forward all the way to install the rear-facing child restraint. Then, slide the front
seat back as directed in the manual provided with the child restraint.
3. When using a forward-facing child restraint, do not slide the front seat backwards more than halfway
for child’s safety. In addition, do not tilt the front seat backrest backwards too far (max. 25°)
and raise it as high as possible.

GETtheMANUALS.org
 0000-00 01-39

4) List of Suitable Universal Child Restraint Systems (CRS)

Please read carefully the installation manual of your child restraint

Mass group Child Restraint Features

0 < 10 kg - -
0+ < 13 kg Maxi Cosi CabrioFix Belted Rearward facing
I 9 to 18 kg Romer King II LS Belted Forward facing
II 15 to 25 kg Romer KidFix XP Belted Forward facing
III 22 to 36 kg Romer KidFix XP Belted Forward facing

5) List of Suitable ISOFIX Child Restraint Systems (CRS)

Mass group Child Restraint Features
0 < 10 kg - -
ISOFIX & Support Leg
0+ < 13 kg Maxi Cosi CabrioFix & FamilyFix Rearward facing
ISOFIX & Top Tether
I 9 to 18 kg Romer Duo+
Forward facing
II 15 to 25 kg Romer KidFix XP ISOFIX & Belt Forward facing
III 22 to 36 kg Romer KidFix XP ISOFIX & Belt Forward facing

6) Table of Vehicle Handbook Information for Installation in Various

Seating Positions on i-Size Child Restraint Systems
Seating Posion i-Size Child Restraint Systems
Front Passenger Outboard X
Rear Outboard Left i-U
Rear Outboard Right i-U
Rear Center X

Key of letters to be inserted in the above table:

i-U: Suitable for i-Size “universal” Child Restraint Systems forward and rearward facing. (valid
position for forward facing and rearward facing child restrant systems approved under ECE R129)
i-UF: Suitable for forward-facing i-Size “universal” Child Restraint Systems only.
X: Seating position not suitable for i-Size “universal” Child Restraint Systems.(invalid position for
child restrant systems approved under ECE R129)

GETtheMANUALS.org
01-40

9. SECURING A CHILD RESTRAINT SYSTEM WITH

“ISOFIX/I-SIZE” SYSTEM AND “TETHER ANCHORAGE”
SYSTEM*
ISOFIX/i-Size system is a standardised method of fitting child seats that eliminates the need to use the
standard adult seatbelt to secure the seat in the vehicle.
This enables a much more secure and positive location with the added benefit of easier and quicker
installation. An ISOFIX/
i-Size-seat can only be installed if it has approval in accordance with the requirements of ECE R44 or
ECE R129.

1) Locations of ISOFIX/i-Size Lower Anchors and Top Tether

1 1. Two ISOFIX/i-Size lower anchors are installed at
the bottom of the seatback at each outboard
seat as shown in the figure.
2. The ISOFIX/i-Size lower anchors can be
identified by the symbol attached on the top
surface.

Top tether

3. Two (for EURO countries) or three (Australia)

ISOFIX/i-Size top tethers are installed at the
upper side of seatback.

GETtheMANUALS.org
 0000-00 01-41

2) How to use ISOFIX/i-Size Lower Anchor

1. Now, you can see the ISOFIX/i-Size lower

anchors.

The ISOFIX/i-Size lower anchor is exposed

when you widen the space between
seatback and cushion.

2. Insert the child restraint attachments into

the ISOFIX/i-Size lower anchors until it
Child seat clicks.
3. Adjust the seatback angle as desired.

Child restraint
- When using the ISOFIX/i-Size lower
attachment
anchor, make sure that no interference
are around the bar and the seat belt is
not stuck.
- Rock the child restraint to check if it is
securely installed. Refer to instructions
provided by the manufacturer of the
child restraint.
- Do not install the child restraint if it hinders
the operations of front seat.

GETtheMANUALS.org
01-42

3) How to Use Top Tether

1. Adjust the seatback angle as desired.

Top tether connector

2. Connect the top tether connector in child restraint to the top tether on the seatback of the second row
seat.
3. Securely tighten the child restraint by adjusting the webbing of top tether connector.

GETtheMANUALS.org
 0000-00 01-43

4) Warning for Child Restraint

1. Use only the officially approved child restraint.
Ssangyong is not responsible for the personal injury and property damage due to the defect of child
restraint.
2. These seats are subject to the ECE R44 or ECE R129 standard.
3. Use only the child restraint with proper type and size for your baby.
4. Use only the child restraint at proper location.
5. Child restraint has 5 categories based on the weight as below according to ECE
R44.:
GROUP 0: 0 ~ 10KG
GROUP 0+: 0 ~ 13KG
GROUP I: 9 ~ 18KG
GROUP II: 15 ~ 25KG
GROUP III: 22 ~ 36KG
6. Group 0 & 0+
Rear facing child restraint fitted on the rear seat
7. Group I
Rear facing or forward facing child restraint fitted on the rear seat
8. Group II & III
Booster seat fitted on the rear seat with seat belt fastened
Always follow the installation and use instructions provided by the manufacturer of the booster seat.
i-Size: child seats with i-Size approval must meet the requirements prescribed in the ECE
9. R129 standard in relation to installation and safety. Child seat manufacturers can tell you
which seats have i-Size approval for this vehicle.

- Top tether is the supplemental device to secure the child restraint system after engaging it by the
lower latches. Therefore, do not secure the child restraint system only with the top tether. The
increased load may cause the hooks or anchors to break, causing serious injury or death.
If a child restraint is not properly secured to the vehicle and a child is not properly restrained
- in the child restraint, the child could be seriously injured or killed in a collision. Always follow
the instructions provided by the manufacturer for installation.
Make sure the latches of the child restraint system are latched to the lower latches. In this case, you
- can hear the “click” sound.
The child restraint seat strap may not work properly if attached somewhere other than the correct top
- tether.
Make sure that the child restraint system is firmly secured by rocking it in different directions.
- Incorrectly installed child restraint system may cause an unexpected personal injury.
-

GETtheMANUALS.org
01-44

10. CIRCUIT DIAGRAM

▶ FRT SEAT WARMER & VENT ECU(DRIVER)

GETtheMANUALS.org
 0000-00 01-45

GETtheMANUALS.org
01-46

▶ FRT SEAT WARMER & VENT ECU(PASS)

GETtheMANUALS.org
 0000-00 01-47

GETtheMANUALS.org
01-48

▶ FRT SEAT WARMER ECU(DRIVER)

GETtheMANUALS.org
 0000-00 01-49

GETtheMANUALS.org
01-50

▶ FRT SEAT WARMER ECU(PASS)

GETtheMANUALS.org
 0000-00 01-51

GETtheMANUALS.org
01-52

▶ DRIVER POWER SEAT SW

GETtheMANUALS.org
 0000-00 01-53

GETtheMANUALS.org
01-54

▶ RR SEAT WARMER ECU

GETtheMANUALS.org
 0000-00 01-55

GETtheMANUALS.org
 0000-00 02-3

1. SPECIFICATIONS
Front seat belt
Front seat belt Rear center seat
Item (passenger Rear seat belt
(driver seat) belt
seat)
Fixing type 3-point 3-point 3-point 3-point
ELR O O O O
PT O O X X
Anchor PT O O X X
L/L O O O (EU) X
CLT O O X X
SCS X X X O

- ELR (Emergency Locking Retractor): Belt locked automatically when momentary force applied
- PT (Pretensioner): Prevents occupants from being thrown forwards in a collision, coupled
with air bag
- L/L (Load Limiter): Release the belt retracted by pretensioner
- CLT (Crash Locking Tongue): Function to hold seat belt by tongue locked in a collision
- SCS (Self Compensation Sensor): Function to prevent rear center seat belt from being locked when
rear seat back recliner in operation

GETtheMANUALS.org
02-4

2. WARNINGS

▶ Cautions for serving seat belt

The seat belt pretensioner/anchor pretensioner contain explosive charges, so handle carefully when
disposing or replacing them.

▶ Cautions for operating seat belt

- When an occupant fastens the seat belt in an unstable or inclined posture, the air bag
system cannot protect the occupant properly. Moreover, the occupant can be injured by
the air bag.
- A large quantity of non-toxic gas (nitrogen gas) is generated with a loud noise when the
seat belt pretensioner/anchor pretensioner deploys. If these airborne particles irritate
your skin, eyes, nose, or throat, rinse the area with cool water. If the irritation continues,
see your doctor.
- The components will be very hot after seat belt pretensioner operation. Do not touch them until
they cool down.

3. CAUTIONS

- The deployed seat belt pretensioner/anchor pretensioner cannot deploy again. It will work when an
additional impact is applied. Once the seat belt pretensioner/anchor pretensioner are triggered, the
triggered air bag assembly should be removed from the vehicle and replaced with a new one.
Incorrect inspection can result in serious injuries or malfunctions in the seat belt
- pretensioner/anchor pretensioner systems.

GETtheMANUALS.org
 0000-00 02-5

1. OVERVIEW
All of the seat belts of this vehicle are 3-point type, consisting of a front seat belt, a rear seat belt and a
rear center seat belt.
The front seat belt has a height adjuster which adjusts the shoulder belt height based on the body size
and intention of the occupant. The front seat belt is equipped with an anchor pretensioner.

GETtheMANUALS.org
02-6

2. COMPONENTS
▶ Front seat belt

Front seat belt (3-point type)

Height Front Front Anchor

adjuster seat belt buckle pretensioner

GETtheMANUALS.org
 0000-00 02-7

▶ Rear seat belt

Rear seat belt(3-point type)

Rear Rear Rear

Rear Rear RH buckle
center center center, LH buckle
seat belt
seat belt mini buckle

GETtheMANUALS.org
02-8

3. EPC

1. SEAT BELT ASSY-FRT

2. SEAT BELT ASSY-FRT
3. HEIGHT ADJ ASSY-FRT S/BELT
4. ANCHOR P/T ASSY-FRT
5. SCREW
6. BUCKLE ASSY-FRT

GETtheMANUALS.org
 0000-00 02-9

1. SEAT BELT ASSY-RR 1ST

2. SEAT BELT ASSY-RR 1ST
3. SEAT BELT ASSY-RR 1ST CTR
5. DOUBLE BUCKLE ASSY-RR 1ST
6. BUCKLE ASSY-RR 1ST
7. MINI BUCKLE ASSY-RR 1ST CTR
8. TONGUE ASSY-RR 1ST
9. SCREW

GETtheMANUALS.org
02-10

4. CIRCUIT DIAGRAM
▶ FRT INPACT SENSOR, SIDE IMPACT SENSOR, A/BAG INFLATOR. ANCHOR PT, PAB OFF SW

GETtheMANUALS.org
 0000-00 02-11

GETtheMANUALS.org
02-12

▶ DRIVER S/BUCKLE, PASS S/BUCKLE, SIDE A/BAG INFLATOR, S/BELT PRETENSIONER

GETtheMANUALS.org
 0000-00 02-13

GETtheMANUALS.org
 0000-00 03-3

1. SPECIFICATIONS
Operating voltage 9 ~ 16V
Operating current (open & close) Max. 6A
At no load Approx. 3A
Leakage current Max. 1 mA
루프 모터
Time 작동속도(열림
to open & close 및 닫힘시) Up to 1.1 ±(at
7 sec 0.5초/100 mm
room temperature)
Time to tilt Up to 2 sec (at room temperature)
Motor overload stop conditions At current of max. 25 A
1st step sliding open: 370 ± 5 mm
2-step opening amount
2nd step sliding open: 428 ± 5 mm
Vertical/horizontal tolerance for sunroof glass ± 2mm
panel

GETtheMANUALS.org
03-4

2. CAUTIONS
▶ Cautions during work

- Wear a clean work clothes and gloves.

- Any unauthorized modification or operational test is not allowed since the sunroof motor and control
unit are preset at the factory.
- Take care not to drop or stack vertically when removing the sunroof. This may cause the moving
parts to be damaged.

General precaution for sunroof

- Even though the sunroof can be operated when the engine is not running, operating the sunroof
repeatedly with the engine turned off will run down the battery. Operate the sunroof while the
engine is running.
- When the sunroof operation is completed, release the switch. Keeping pressing the switch can
result in malfunction.
Especially in winter, never operate the sunroof if operation areas are iced. Wait until melted.
- Make sure that the sunroof is completely closed when leaving the vehicle. Leaving the vehicle with
the sunroof open result in a theft. In addition, rain or snow can get into the vehicle through the open
sunroof.
- When the sunroof is fully open, wind buffeting symptom can be worse. In this case, try to adjust the
sunroof position manually or open the sunroof into first step until the wind buffeting is disappeared.
Parts of the body can be trapped in the sunroof and can be struck by passing objects. Do not stick
- hands, head or anything else out of the openings.
Remove any dirt and foreign material stuck on the edge of the sunroof glass periodically.
- Noise can occur due to friction when operating the sunroof.

GETtheMANUALS.org
 0000-00 03-5

1. OVERVIEW
The sunroof is a controllable window on the roof (above the front seats) for good interior ventilation and
anticipation of a pleasant drive to improve the driver's comfort. It can be opened, closed, and tilted (only
rear side of the sunroof can be tilted) with an operation of the switch.

GETtheMANUALS.org
03-6

2. SYSTEM LAYOUT
OPEN TILT

Sunroof switch Sunroof assembly Sunroof control unit &

motor

GETtheMANUALS.org
 0000-00 03-7

3. EPC
▶ 7340 SUN ROOF

1. SUNROOF ASSY 8. SUNSHADE A/S KIT

2. MOTOR ASSY-SUNROOF 10.BRKT-SUNROOF SUPT
3. WIND DEFLECTOR ASSY- 11.SCREW
SUNROOF 12.HOSE-SUNROOF DRAIN FRT
4. GLASS ASSY-SUNROOF 13.HOSE-SUNROOF DRAIN RR
5. PNL ASSY-SUNROOF SUNSHADE 16.GROMMET
6. WIND DEFLECTOR A/S KIT
7. BOLT-GLASS

GETtheMANUALS.org
03-8

1. OPERATING PROCESS
1) Sunroof Switch
▶ Sunroof switch

The sunroof switches are included in the overhead console switches and consists of the TILT,
CLOSE and OPEN switches.

▷ TILT
Opens only rear section of the sunroof.

▷ CLOSE
Closes the sunroof.

▷ OPEN
Opens the sunroof.

Sun shade panel

Sunroof glass

▶ Sunroof glass
The sunroof glass can be open in two steps and can be tilted by the switch operation.

▶ Sun shade panel

This can be closed or open manually to block sunlight when the sunroof function is not in use.

GETtheMANUALS.org
 0000-00 03-9

2) Sunroof Sliding Opening/Closing

Opening sunroof (sliding open: 2-stage)

- Push up the switch

- Push up the switch briefly: 2-step auto sliding open

When pushing up the switch briefly, the sunroof is automatically opened. Opening is carried out in
2 steps. In first step, the area 58mm behind the sunroof is not opened. Push up the switch once
again in order to open the sunroof completely. The sunroof operation stops if you operate the
switch during its operation.

- Push up and hold the switch: manual sliding open

The sunroof is opened as long as pushing up the switch.

Closing sunroof (Sliding close)

- Pull down the switch

- Pull down the switch briefly: auto sliding close

When pulling down the switch briefly, the sunroof is automatically closed. To stop the closing
sunroof, operate the switch to either direction.

- Pull down and hold the switch: manual sliding close

The sunroof is closed as long as pulling down the switch.

GETtheMANUALS.org
03-10

3) Sunroof Tilt Up/Down

This function is to raise or lower the rear section of the sunroof.

Tilt Up

- Pull down the switch

- The rear side of the sunroof is tilted up when pulling down the sunroof switch with the sunroof
closed.

Tilt Down

- Push up the switch

- The rear side of the sunroof is tilted down when pushing up the sunroof switch with the sunroof tilted
up.

GETtheMANUALS.org
 0000-00 03-11

4) Sunroof Safety Function

To prevent any body parts from being trapped by the sliding sunroof, an Anti-Pinch Function
automatically opens the sunroof when an object is trapped.

The anti-pinch function does not work for the area of 20 mm before the sunroof closes.
The sunroof safety function is just a safety supplementary system which cannot replace driver's
care and caution. Moreover, it may not be able to operate due to electric part or other conditions.

▶ Wind buffeting

- When you drive this vehicle with the window or sunroof open at a certain position, you may feel
some pressure upon your ears or hear some noises similar to those from a helicopter. This happens
because of an influx in air through the window or sunroof and its resonance effect. If this happens,
adjust by opening the window or sunroof.

GETtheMANUALS.org
03-12

2. SUNROOF CONTROL UNIT (SCU)

1) Functions
(1) Sunroof switch & rest position
OPEN switch TILT switch Position
Sliding stop X Auto, Manual 428 mm
X: inoperative
Slide Auto, Manual Auto, Manual Auto: one-touch 0 ~ 428 mm
Manual: as long as
Close Auto, Manual Auto, Manual 0 mm
switch is pressed
Tilt Manual Auto, Manual -38 ~ 0 mm
Tilt stop Manual X -38mm

(2) General conditions

▶ Switch debounce time (time in which switch operation is overridden)
- Operating the switch for less than 44 msec (±5 msec) is overridden.

▶ Automatic stop position

- The sunroof automatically stops at the following positions:
Slide 1st stop (370 mm), slide 2nd stop (428 mm), Close and Tilt stop

▶ Restriction
- If the running speed drops below the set value due to restriction or overload during operation, the
motor is stopped for protection.

▶ Overload
- If the motor does not rotate for certain period of time after power is supplied, the motor is stopped for
protection.

▶ Limitation of max. operating time

- If the motor operates to one direction for over 20 seconds, the unit considers this as malfunction and
stops the motor.

▶ Initialization
- Clearing position information
When pressing and holding the TILT switch for over 5 seconds (reset) provided that the sunroof panel
does not move any longer, the position information is cleared and the sunroof moves towards the tilt
direction.
- Zero-point setting
When the position information is cleared and the motor is restrained at the end of the tilting position,
the relay is automatically cut off and the zero-point setting is carried out. After that, the sunroof is
reversed to the tilting position, stops automatically, and then operates normally.

GETtheMANUALS.org
 0000-00 03-13

(3) Normal mode operation

- When the switch is pressed for more than 500 msec (±50 msec), the sunroof is operated until
the switch is released.

(4) One-touch operation

- If the switch is pressed for more than 45 msec (±5 msec) of debounce time and less than
500 msec (±50 msec), the sunroof keeps moving even without pressing the switch. When
the sunroof reaches the soft stop position or any switch is pressed while the sunroof is operating, it
will stop.
If the sunroof is closed in this mode, anti pinch function is activated.

(5) 1st Stop

- The sunroof stops at 370 mm automatically during opening.

(6) Sunroof open warning

- When the sunroof is opened, the alarm signal is sent to the instrument panel and a buzzer sounds to
inform the driver of this.

(7) Anti pinch mode

- The sunroof stops automatically and then moves to the original position when an obstacle is detected
while the sunroof is being closed.

GETtheMANUALS.org
03-14

3. CIRCUIT DIAGRAM

GETtheMANUALS.org
 0000-00 03-15

GETtheMANUALS.org
 0000-00 01-3

1. SPECIFICATIONS
Item Category Specifications
Heater Core size (㎣) 178 x 166 x 29
Capacity (kcal/h) 8,168 (9,500W)
Evaporator Core size (㎣) 216 x 199 x 48
Capacity (kcal/h) 4,729 (5,500W)
Blower motor Supply power (W) 240 + 10% Max (at 12 V)
Fan speed (rpm) 3,500+200/-100
(Rec. Mode: 510㎥/h)
PTC (D16DTF) Supply power 1kW
Condenser Core size (㎣) 625 x 325 x 16
Capacity (kcal/h) 13,200 (R1234yf), 14,900(R134a)
Capacity of receiver drier 260 cc
Compressor Volume 140 cc/rev
Diameter of pulley Ø110
Max. continuous speed 8,000 rpm
Voltage DC 12 V
Current consumption 3.4A
Heater and A/C control Rated voltage DC 13.5V
assembly
Operating voltage DC 9V to 16V
Operating temperature -30 ~ 80℃
Max. current consumption 3A or less
Dark current 1.1mA or less (12.6 ± 0.1V)
Button switch Type Push type (self-return)
Operating force 2.94 ± 0.98Nm
Temperature Type Dial type
control dial
Rotation angle 360˚

GETtheMANUALS.org
01-4

Item Category Specifications

Refrigerant A type (Volume) R-1234yf (530 ± 30g)
B type (Volume) R-134a (570 ± 30g)
Refrigerant fluid PAG (PS-D1 or equiv. 120cc)

GETtheMANUALS.org
 0000-00 01-5

1. OVERVIEW
The climate system in the vehicle is an air regulating system which keeps the indoor air pleasant through
the heating, ventilation and air conditioning systems. The air conditioning systems fall in to two
categories; DATC (Dual Automatic Temperature Control), which is a temperature control device which
receives signals from various sensors (interior temperature sensor, ambient temperature sensor, DAT
sensor, sun-load sensor, EAT sensor) and control switches to control the blower motor and all kinds of
actuator (mode door actuator, mix door actuator, air source door actuator) through MICOM in the DATC,
therefore, the interior temperature of the vehicle is kept to the temperature which is set by a driver and
MTC (Manual Temperature Control), which controls all the actuator and blower motor by the driver.

GETtheMANUALS.org
01-6

1) Overview For A/C System

The A/C system circulates a refrigerant by using a compressor (compression), a condenser
(condensation), an expansion valve (expansion), and an evaporator (evaporation), and cools air in the
cabin of the vehicle by using an evaporative latent heat of the refrigerant. The HVAC (Heating,
Ventilation and Air Conditioning) unit delivers heating, ventilation and air conditioning
(temperature/humidity control) functions to maintain the indoor air comfort.

GETtheMANUALS.org
 0000-00 01-7

2) Overview For Heater System

The air passing through the heater core absorbs heat from the engine coolant heated by combustion
heat of the engine, thereby the heater delivers warm air into the cabin. The HVAC (Heating, Ventilation
and Air Conditioning) unit delivers heating, ventilation and air conditioning (temperature/humidity control)
functions to maintain the indoor air comfort.

GETtheMANUALS.org
01-8

2. COMPONENTS
1) Exterior
Refrigerant pressure sensor

A/C compressor

Electric fan

GETtheMANUALS.org
 0000-00 01-9

Expansion valve

Engine ECU

Ambient temperature sensor A/C condenser & receiver drier

GETtheMANUALS.org
01-10

2) Interior
Sun-load sensor Heater and evaporator module

In-car sensor Heater and A/C control assembly

With DATC With MTC

GETtheMANUALS.org
GETtheMANUALS.org
01-12

3) Air Conditioner Module Layout

Blower motor Mode actuator Driver side temperature
actuator

MOS module Heater core PTC heater (D16DTF)

GETtheMANUALS.org
 0000-00 01-13

Passenger's temp A/C filter Intake actuator

actuator

EAT sensor Evaporator core

GETtheMANUALS.org
01-14

3. EPC
▶ 6810 AIR CONDITIONER MODULE

1. HTR & EVAP MODULE 15.HEATER ASSY-PTC

2. BLOWER ASSY-INTAKE 20.CONTROL ASSY
3. FILTER-AIR 22.INSERT ASSY-VENTILATION
5. BLOWER MOTOR ASSY 23.SENSOR-INCAR
6. MOS MODULE 24.SENSOR-INTAKE
7. EXPANSION VALVE ASSY 25.ACTUATOR ASSY-MIX-LH
8. CORE-EVAPORATOR 26.ACTUATOR ASSY-MIX-RH
9. WIRING ASSY-HTR & EVAP 27.DUCT-FOOT
12.ACTUATOR ASSY-MODE 40.COVER-AIR FILTER
13.CORE-HEATER 41.O RING-EXPANSION INLET
14.HOSE ASSY-DRAIN 42.O RING-EXPANSION OUTLET

GETtheMANUALS.org
 0000-00 01-15

▶ 6820 AIR CONDITIONER HOSE & PIPE

1. CONDENSER ASSY 22.SCREW

3. HOSE ASSY-DISCHARGE 25.LABEL-A/CON
5. HOSE ASSY-LIQUID & SUCTION 40.OIL RING
8. SCREW 41.OIL RING-DISCHARGE
9. HOSE ASSY-HEATER INLET 42.OIL RING-SUCTION
10.HOSE ASSY-HEATER OUTLET 43.OIL RING-LIQUID
11.CLAMP 44.OIL RING-SUCTION
13.NUT 50.CAP-CHARGE VALVE(HIGH/LOW)
21.SENSOR ASSY-AMBIENT

GETtheMANUALS.org
01-16

▶ 6830 AIR DISTRIBUTOR

1. DUCT ASSY-FOOT
3. DUCT ASSY-RR HEATING NO1-LH
4. DUCT ASSY-RR HEATING NO1-RH
5. DUCT ASSY-RR HEATING NO2-LH
6. DUCT ASSY-RR HEATING NO2-RH

GETtheMANUALS.org
 0000-00 01-17

▶ 1480 A/C COMPRESSOR

1. COMPRESSOR ASSY-A/CON
2. BOLT
3. BRKT ASSY-A/CON COMPRESSOR
4. BOLT

GETtheMANUALS.org
01-18

1. INPUT/OUTPUT DIAGRAM
▶ With DATC (auto A/C)

- EAT (Evaporator Air Temperature) sensor

GETtheMANUALS.org
 0000-00 01-19

GETtheMANUALS.org
01-20

▶ With MTC (Manual A/C)

GETtheMANUALS.org
 0000-00 01-21

GETtheMANUALS.org
01-22

2. CAN COMMUNICATION SCHEMATIC DIAGRAM

GETtheMANUALS.org
 0000-00 01-23

GETtheMANUALS.org
01-24

▶ Full names of acronyms and option description

GETtheMANUALS.org
 0000-00 01-25

3. P-CAN COMMUNICATION I/O ELEMENTS

▶ ACU

▶ BCM

GETtheMANUALS.org
01-26

▶ ECU

▶ CGW

GETtheMANUALS.org
 0000-00 01-27

▶ SKM

GETtheMANUALS.org
01-28

4. DATC KEY FEATURES

(1) DATC switch
In Full AUTO mode (Mode auto & blower auto), the DATC receives various signals such as the indoor
temperature, ambient temperature, engine coolant temperature, sunlight, from different sensors to
control the A/C compressor, mode door, intake actuator assembly, air mix door, blower motors, etc. to
keep indoor environments fresh.

1. AUTO switch
2. ON/OFF switch
3. A/C switch
4. Air distribution mode switch
5. Fan Speed Control Switch
6. Air source selection switch
7. SYNC switch (to sync with driver side set temperature)
8. Driver side temperature control dial
9. Passenger side temperature control dial
10.Defroster switch
11.Glass heater switch
12.Operation indicator display

GETtheMANUALS.org
 0000-00 01-29

(2) Temperature control

LCD display (temperature)

Temperature control dial

The blowing air temperature is controlled by the temperature actuator and the set temperature can be
checked via the LCD display.

▶ Manual control

The discharge air temperature is controlled by the temperature control switch. The driver can select
one of the 31 levels.

▶ Auto control

When pressing the AUTO switch, "AUTO" is shown on the display and the fan speed and air distribution
mode are adjusted automatically to keep interior temperature to the set temperature. In AUTO mode,
you can adjust the temperature by pressing the temperature control switch. And the DATC receives
various signals such as the indoor temperature, ambient temperature, engine coolant temperature,
sunlight from many sensors to automatically control the A/C compressor, mode actuator, intake actuator,
temperature actuator, blower motors, etc., so that the indoor environment is kept in fresh state.

GETtheMANUALS.org
01-30

▶ Max. cooling/heating control (AUTO mode)

If the temperature is set to the lowest level (Lo) or highest level (Hi), the system will go into the maximum
cooling or maximum heating mode regardless of the sensor signals.

Set A/C Air outlet Air inlet Blower TEMP

Temperature Compressor (mode) voltage actuator
Max. cooling
LO ON Vent Recirculation 10.5 V
position
Max. heating
HI OFF FOOT Fresh air 10.5 V
position

GETtheMANUALS.org
 0000-00 01-31

(3) Blower control

Fan speed indicator

Fan speed control switch

In AUTO mode, the blower motor is controlled automatically according to the set temperature and the
blower motor speed can also be controlled manually. The fan speed can be checked via the air
distribution display.

▶ Manual control

Blower motor Pressing up/down the blower button controls the

Blower level
voltage (V) motor manually. Each time you press the button
1 3.6 up/down, it increases or decreases by 1 step.
(Tolerance: ±0.5 V)
2 4.8
3 5.8
4 7.0
5 8.0
6 9.0
7 10.5
8 Batt

▶ Auto control

In AUTO mode, the fan speed is automatically controlled depending on the set temperature and
surrounding environment and the blower motor operates steplessly.

GETtheMANUALS.org
01-32

▶ Defrost control

When the defrost mode is selected with the blower dial in AUTO position, the blower motor voltage is
increased by 1.0V compared to the AUTO control voltage for a certain amount of time.

▶ Sun load compensation control

The system increases the fan speed by adding up 3 V of voltage in direct sunlight.

▶ Cooling start control

When the intake temperature sensor indicates over 30℃, the driver might feel uncomfortable by
the air flow from the vent. Therefore, at the initial operation stage, the hot air is discharged to the
windshield (DEF mode) for about 5 seconds.

▶ Heating start control

When the engine coolant temperature is low or the wind temperature is not warmed up sufficiently, the
driver might feel uncomfortable by the air flow from the vent. Therefore, the fan speed is set to the level 1
and the cool air is sent to the windshield until the DAT sensor increases to the proper level (DEF mode).
As the engine coolant temperature goes up, the mode is changed to Defrost & Foot mode or AUTO
mode to increase the speed of blower motor. This control is canceled when the output value of the water
temperature sensor is approximately 60℃. However, the control time must not exceed 10
minutes.

GETtheMANUALS.org
 0000-00 01-33

(4) Air source control

Recirculation / fresh air indicator

Air source selection switch

The air source selection is made by the intake actuator operation. The driver can see the selected air
source mode through the indicator.

▶ Manual control
The air source door can be controlled manually by pressing the air source mode switch. The air source
mode is switched between the fresh air and recirculation alternatively each time the switch is pressed.

▶ AUTO control
In auto mode, the basic setting for the air source is fresh air. When the ambient temperature is high
during cooling, the air source is changed from fresh air to recirculation to lower the temperature.

GETtheMANUALS.org
01-34

(5) Air distribution control

Air distribution display

Air distribution switch

The air distribution is changed by the mode actuator and the air distribution display and the indicator of
the defroster switch shows which air distribution modes is selected.

▶ Manual control

The driver can select one of 5 air distribution mode using the air distribution switch and defroster switch.

- Defroster switch: When this switch is pressed, the defroster mode (A/C ON, fresh air mode, fan
speed of 1 level or above) is activated. Pressing the switch again returns the unit to the previous
- status.
Air distribution switch: The mode is switched in the following order each time the switch is pressed:
Vent mode→Bi-level mode→Foot mode→Defroster & Foot mode.

GETtheMANUALS.org
 0000-00 01-35

Air distribution switch (switches in order)

▶ Auto control

The air distribution mode is controlled automatically in accordance with the vehicle indoor conditions.
But it is controlled as described below during initial driving (after overnight parking) in cold weather:

GETtheMANUALS.org
01-36

(6) A/C control

A/C operation indicator

AUTO switch A/C switch

The air conditioner is operated by the A/C compressor control of the engine ECU according to the signal
from the heater and A/C control assembly. The driver can see the air conditioner operation through the
LCD display and the indicator of the A/C switch.

▶ Manual control
Pressing the A/C switch or selecting defrost mode turns on the A/C.

▶ AUTO control
The A/C is controlled in accordance with the indoor temperature and ambient temperature.
If the EAT (Evaporator Air Temperature) sensor detects the freezing of the evaporator or the ambient
temperature is low (0℃ or below) in winter, the A/C compressor is turned off to protect the A/C
compressor.

GETtheMANUALS.org
 0000-00 01-37

(7) Self-diagnosis
The DATC has a self-diagnosis function that can diagnose the system by itself. If this system is
defective, the LCD display shows the diagnostic trouble code (DTC) to inform a driver of defects on the
device such as a sensor or actuator. The driver can see the each sensor data on the air conditioning
system after entering self-diagnosis mode. Before checking each component, be sure to check the
default code by using self diagnosis function.

▶ DTC

Code Defective part DTC

00 Normal Short circuit in sensor
21 Ambient temperature sensor
22 In-car sensor
23 Water temperature sensor
24 Intake sensor DTC
26 Faulty driver side temperature door
(control)
29 Faulty passenger side temperature door
(control) The DTC flashes twice and is displayed
repeatedly in order unless there is an
31 Mode door (vent)
input by operation.
32 Mode door (bi-level)
34 Mode door (foot)
35 Mode door (defrost & foot)
36 Mode door (defrost)
37 Intake door (fresh air)
38 Intake door (1/3)
39 Intake door (recirculation)

GETtheMANUALS.org
01-38

▶ How to enter self-diagnosis (step 1)

GETtheMANUALS.org
 0000-00 01-39

1. If the ON/OFF switch of the DATC is pressed for more than 5 seconds within 10 seconds after turning
the ignition key from the "OFF" position to the "ON" position, all the segments in LCD display come on
for 3 seconds.

Segments comes on for 3

sec.

Press for 5 seconds

2. The driver side temperature display shows "2" and starts to check the sensor and actuator in the air
conditioning system automatically.

3. The driver side temperature display shows whether there is fault. (“00" for normal)

4. The self diagnosis ends when turning the ignition key from the "OFF" position to the "ON" position or
pressing the AUTO mode switch.

GETtheMANUALS.org
01-40

▶ Check each door position, blower speed and compressor condition (STEP. 2)

1. After entering the self-diagnosis mode (STEP. 1) You can enter this mode when you press the UP
button of the driver set temperature SYNC switch at any time. The driver side temperature display
shows "41".

SYNC switch (to sync with

driver side set temperature)

2. Check if the number on the LCD display changes each time you press the defroster switch and
following items are changed as follows:

Display number
41 42 43 44 45 46

Air distribution Defroster

door Front side Bi-level Bi-level Footwell and footwell Defrost

Air source door Fresh air of Fresh air

Recirculation Recirculation Fresh air Fresh air
20%
Temperature
Cooling Cooling Heater Heater Heater Heater
control door
Blower fan 4.5V 10.5V 8.5V 8.5V 8.5V MAX
Compressor
ON ON OFF OFF ON ON
status

3. When you press the driver set temperature SYNC switch, the unit returns to the status at which self-
diagnosis mode is activated.

GETtheMANUALS.org
 0000-00 01-41

▶ Sensor data check (STEP. 3)

1. At Step. 2, pressing the UP button of the air source selection switch enters this mode. The LCD
displays "51".

Defroster switch

Driver side set temperature

control switch

2. The values for each sensor are shown in sequence each time the defroster switch is pressed.

The value of the sun load sensor is displayed after being converted to one tenth and its unit is
w/㎡.

3. When you press the DOWN button of the air source selection switch, the unit returns to the previous
step (Step 2).
4. Conditions for exiting self-diagnosis

- When restarting or turning IGN from OFF to ON

- When pressing AUTO mode switch

GETtheMANUALS.org
01-42

5. MAJOR FUNCTIONS
(1) Function of heater and A/C control assembly with MTC
The manual temperature control (MTC) system controls all the actuators (mode door actuator, mix door
actuator, intake door actuator) and blower motor with driver inputs. The driver can check the status of
A/C through the dial / button indicator of MTC.

1. Defroster switch
2. Glass heater switch
3. Fan speed dial
4. A/C switch
5. Temperature control dial
6. Air source selection switch
7. Defroster switch / air distribution switch
8. A/C MAX switch
9. Air distribution switch (face)
10.Air distribution switch (face and footwell)
11.Air distribution switch (footwell)
12.Dial indicator

GETtheMANUALS.org
 0000-00 01-43

(2) Temperature control

Temperature control dial

Dial indicator

The temp actuator controls the temperature of air discharged depending on the temperature control dial
operation by the driver. The driver can select one of the 8 levels.

(3) Blower control

Fan speed dial

Dial indicator

Blower level Blower motor voltage (V) The fan speed increments or decrements by 1
level per revolution of the fan speed dial
1 3.6
clockwise/anti-clockwise. (Unladen: ±0.5 V)
2 4.8
3 5.8
4 7.5
5 9.0
6 10.5
7 BATT

GETtheMANUALS.org
01-44

(4) Air source control

Air source selection switch

When pressing the air source selection switch, the air source mode is changed via the intake actuator's
operation. The air source mode is switched between the fresh air and recirculation alternatively each
time the switch is pressed.

GETtheMANUALS.org
 0000-00 01-45

(5) Air distribution control

Defroster switch / air

Defroster switch
distribution switch

Air distribution Air distribution switch Air distribution

switch (face) (face and footwell) switch (footwell)

The driver can select one of 5 air distribution modes using the 5 air distribution switches at both sides of
the MTC. The selected air distribution mode is changed by the mode actuator and acknowledged by the
indicator for each switch coming on

▶ Vent mode

If the vent mode switch is pressed, the indicator comes on while the air flows to the
upper part of the body.

▶ Vent / foot mode

If the vent / foot mode switch is pressed, the indicator comes on while the air flows
to the upper part of the body and footwell.

▶ Foot mode

If the foot mode switch is pressed, the indicator comes on while the air flows to the
footwell.

▶ Defroster & foot mode

If the defroster & foot mode switch is pressed, the indicator comes on while the air
comes from the footwell and the windshield vents and the fresh air mode is
activated.

▶ Defroster mode

This is used to remove the condensation from the windshield. When you press the
switch, the indicator comes on and the air distribution is changed to the windshield
at the same time, then the air conditioner starts to operate.

GETtheMANUALS.org
01-46

(6) A/C control

A/C MAX switch

A/C switch

The air conditioner is operated at the defroster mode and MAX air conditioner mode and when the A/C
switch is turned to "ON" position. It is controlled by the A/C compressor of the engine ECU according to
the signal from the heater and A/C control assembly. The driver can see that the A/C has been activated
when an indicator lamps at the A/C switch and MAX A/C switch comes on. If the intake sensor detects
the freezing of the evaporator core, it stops the air conditioner by turning off the compressor.

▶ MAX A/C control

This is designed for increasing driver comfort. When the switch is pressed, the indicator comes on and
at the same time the air conditioner starts in maximum cooling for setting temperature, face vent for air
distribution and recirculation mode for air source selection. And fan speed depends on the driver's
choice.

GETtheMANUALS.org
 0000-00 01-47

6. PTC HEATER OPERATION PROCESS

The engine ECU controls the PTC (Positive Temperature Coefficient) heater system by adjusting the
power supplied to the PTC system according to the two measured temperature values from the engine
coolant temperature sensor and HFM sensor. This system is mounted to the heater air outlet in the air
condition system module and heats the air which flows to the passenger room. Since the PTC system is
heated by the electrical power, the electric load and alternator capacity is greater than the conventional
one. The PTC is not operated when a) the engine is cranking, b) the battery voltage is below 11 V, c) the
glow plug is being preheated.

1) PTC Heater Input/Output Factors

The ceramic PTC features that the resistance rises quickly in a certain temperature range. The PTC
heater has 3 circuits with power of 330 W. While only 1 circuit in the PTC heater is connected during
PTC1 operation, 2 circuits are connected during PTC2 or PTC3 operation.
The PTC heater operates as follows: temperature rises above specified level → resistance
increases → current decreases → amount of heat generated decreases → temperature drops →
resistance increases → current increases → temperature rises, etc.

GETtheMANUALS.org
01-48

2) Control Condition for PTC Heater

Operation Operating condition PTC heater status
HI mode operation - Coolant temperature < 15℃ PTC heater operates in
(PTC2, 3) "HIGH" mode if operating
conditions are met
- Coolant temperature 15℃ ≤ 65℃ and
intake temperature ≤ -10℃
LO mode operation - Coolant temperature 15℃ < 65 ~ 60℃ and PTC heater operates in
(PTC1) intake temperature < -10℃ ~ 0℃ "LOW" mode if operating
- Coolant temperature 15℃ ≤ 65℃ and conditions are met
intake temperature ≤ 0℃ ~ 5℃
- Air conditioner blower switch OFF
- When the ambient temperature sensor is
Conditions for faulty (short or open circuit in the wiring)
deactivating - Engine is cranking
- Battery voltage is 11 V or less
- Glow plug is being preheated (Glow
indicator comes on)

▶ Conditions for PTC heater "LOW" operation mode (2nd step)

GETtheMANUALS.org
GETtheMANUALS.org
01-50

7. CIRCUIT DIAGRAM
1) A/C & HEATER CONTROL(DATC)
▶ SENSOR, ACTR

GETtheMANUALS.org
 0000-00 01-51

GETtheMANUALS.org
01-52

▶ BLOWER RELAY, A/C COMPRESSOR RELAY

GETtheMANUALS.org
 0000-00 01-53

GETtheMANUALS.org
01-54

2) A/C & HEATER CONTROL(MNL)

▶ SENSOR, ACTR

GETtheMANUALS.org
 0000-00 01-55

GETtheMANUALS.org
01-56

▶ BLOWER RELAY, A/C COMPRESSOR RELAY

GETtheMANUALS.org
 0000-00 01-57

GETtheMANUALS.org
 0000-00 02-3

1. MAJOR EXTERNAL DIMENSIONS

1) TIVOLI
Top view

Side view

Front view Rear view

GETtheMANUALS.org
02-4

2) XLV
Top view

Side view

Front view Rear view

GETtheMANUALS.org
 0000-00 02-5

2. JACK POINTS

GETtheMANUALS.org
02-6

3. SEALING APPLICATION POINTS

1) White Body, Dash Panel, Engine Tunnel, Floor, etc.
TIVOLI

GETtheMANUALS.org
 0000-00 02-7

XLV

GETtheMANUALS.org
02-8

2) Front & Rear Door Panel

GETtheMANUALS.org
 0000-00 02-9

3) Engine Hood Panel

Apply the white sealer along the edge line of the engine hood outer panel.
(approx. 4,680 mm)

4) Tailgate
TIVOLI XLV

(approx. 4,516.5 mm) (approx. 4,378 mm)

Apply the white sealer along the edge line of the tailgate outer and inner panels.

GETtheMANUALS.org
02-10

5) Roof Panel
TIVOLI

Rear

Tape mastic sealer

application area

Front

Spot sealer
application area

GETtheMANUALS.org
 0000-00 02-11

XLV

Rear
Tape mastic sealer
application area

Front

Spot sealer
application area

GETtheMANUALS.org
02-12

4. DEADENER APPLICATION POINTS

Asphalt 4.0t Asphalt 4.0t

Asphalt 4.0t

Asphalt 4.0t

Asphalt 3.0t

Magnetic 2.0t

* All other deadners: Asphalt 2.0t

GETtheMANUALS.org
 0000-00 02-13

XLV

Asphalt 2.0t

Asphalt 3.0t

GETtheMANUALS.org
02-14

5. UNDER COATING
TIVOLI(2WD)

TIVOLI(AWD)

GETtheMANUALS.org
 0000-00 02-15

XLV(2WD)

XLV(AWD)

GETtheMANUALS.org
02-16

6. MAJOR WELDING POINTS

1) Cross Sectional View of Major Panels
TIVOLI

GETtheMANUALS.org
 0000-00 02-17

XLV

GETtheMANUALS.org
02-18

2) Side Panel
TIVOLI

(Inside)

CO₂ weld zone

Plug weld zone Spot sealer application area

GETtheMANUALS.org
 0000-00 02-19

XLV

Plug weld zone CO₂ weld zone

Spot sealer application area

GETtheMANUALS.org
02-20

3) Front Panel

Bolt mountings 4/4 sites Bolt mounting 1/1 site

Bolt mountings 3/3 sites

Front bumper impact beam

Front end carrier assembly
assembly

Yield strength (N/ Tensile strength

Notation Material Grade of steel
㎟) (N/㎟)
A SPFC1500M Ultra high tensile 1050 1500

GETtheMANUALS.org
 0000-00 02-21

4) Apron Panel

GETtheMANUALS.org
02-22

5) Dash & Cowl Panels

GETtheMANUALS.org
 0000-00 02-23

6) Front H-Frame Panel

GETtheMANUALS.org
02-24

7) Front Floor Panel

Yield Tensile
Grade of steel Hardness
Notation Material strength strength
(Hv)
(N/㎟) (N/㎟)
Ultra high 1180 or higher
B SPFC1180CP 900 or higher 360~400
tensile

GETtheMANUALS.org
 0000-00 02-25

8) Rear Floor Panel

Yield Tensile
Hardness
Notation Material Grade of steel strength (N/ strength (N/
(Hv)
㎟) ㎟)
A PHS1500-AlSi Ultra high tensile 1180 1500 450

GETtheMANUALS.org
02-26

9) Rear End Panel

GETtheMANUALS.org
 0000-00 02-27

7. ULTRA HIGH TENSILE STEEL APPLICATION AREA

▶ Front view

▶ Rear view

GETtheMANUALS.org
02-28

▶ LH

▶ RH

GETtheMANUALS.org
 0000-00 02-29

▶ Upper side

▶ Lower side

GETtheMANUALS.org
02-30

▶ Frontal side (LH)

▶ Rear side (LH)

GETtheMANUALS.org
 0000-00 02-31

▶ Frontal side (RH)

▶ Rear side (RH)

GETtheMANUALS.org
02-32

8. ULTRA HIGH TENSILE STEEL APPLICATION AREA - XLV

▶ Frontal side (LH)

For ultra high tensile steel application area, there is a difference in the marked parts in red (A)
between TIVOLI AIR and TIVOLI.

GETtheMANUALS.org
 0000-00 02-33

9. MAJOR BODY DIMENSIONS

1) Under Body
TIVOLI(2WD)

Unit: mm

GETtheMANUALS.org
02-34

TIVOLI(AWD)

Unit: mm

GETtheMANUALS.org
 0000-00 02-35

XLV(2WD)

Unit: mm

GETtheMANUALS.org
02-36

XLV(AWD)

Unit: mm

GETtheMANUALS.org
 0000-00 02-37

2) Vehicle Structure
TIVOLI

Unit: mm

A-pillar inner Front seat belt Rear seat belt

location hole mounting hole mounting hole

IP mounting hole Cowl side panel Seat belt anchor hole

location hole

GETtheMANUALS.org
02-38

XLV

Unit: mm

A-pillar inner Front seat belt Rear seat belt

location hole mounting hole mounting hole

Cowl side panel

IP mounting hole Seat belt anchor hole
location hole

GETtheMANUALS.org
 0000-00 02-39

3) Side Structure
TIVOLI

Unit: mm

A-pillar section Rear wheel arch

location hole section location hole

XLV

Unit: mm

A-pillar section location Rear wheel arch

hole section location hole

GETtheMANUALS.org
02-40

4) Windshield Glass Area

TIVOLI

Unit: mm

Roof panel, side outer

panel edge

Windshield glass
mounting

GETtheMANUALS.org
 0000-00 02-41

XLV

Unit: mm

Roof panel, side outer

panel edge

Windshield glass
mounting

GETtheMANUALS.org
02-42

5) Tail Gate Area

TIVOLI

Unit: mm

Tailgate glass lift mounting Tailgate hinge Tailgate trim

hole mounting mounting hole

Tailgate trim Tailgate trim

mounting hole mounting hole

GETtheMANUALS.org
 0000-00 02-43

XLV

Unit: mm

Tailgate glass lift Tailgate hinge Tailgate trim

mounting hole mounting mounting hole

Tailgate trim Tailgate trim

mounting hole mounting hole

GETtheMANUALS.org
02-44

6) Front End

Unit: mm

FEM front Front impact beam

side mounting hole mounting hole

Stiffener front bumper

lower mounting hole

GETtheMANUALS.org
 0000-00 02-45

7) Engine Room

Unit: mm

Windshield clip
mounting hole

Front impact beam FEM front side

mounting hole mounting

GETtheMANUALS.org
02-46

8) Back Panel

Unit: mm

Back beam mounting hole

GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org
GETtheMANUALS.org