SSANGYONG KYRON EURO 4 Engine D27DTP D27DT Full Service & Repair Manual

EURO 4 SERVICE MANUAL SECTION INDEX PYUNGTAEK, KOREA FOREWORD This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval. The right is reserved to make changes at any time without notice. D27DTP / D27DT ENGINE D20DT ENGINE G32D ENGINE G23D ENGINE KYRON SUPPLEMENT SERVICE MANUAL DIAGNOSIS 2 3 4 1 5 6

D27DTP / D27DT ENGINE Section 1 Section 1 Section 1 Section 1 Section 1 SYSTEM GENERAL INFORMATION D27DTP ENGINE FUEL SYSTEM INTAKE SYSTEM EXHAUST SYSTEM PRE - HEATING SYSTEM LUBRICATION SYSTEM COOLING SYSTEM SWITCHABLE ENGINE MOUNT ENGINE ECU DIAGNOSIS

SYSTEM 0000 TABLE OF CONTENTS SYSTEM .................................................................. 3 1. Major changes in D27DTP (POWERUP) engine (for more information, refer to engine service manual) ...... 3 2. Major changes in interior electric components ................. 4 3. Major changes in electric components and units ............. 5 4. Major changes in chassis .................................................. 6 5. Major changes in vehicle exterior ...................................... 7 6. Frame dimension ............................................................... 8

SYSTEM CHANGED BY EFFECTIVE DATE AFFECTED VIN SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 3 0000 D27DTP/D27DT (EU4) 1. MAJOR CHANGES IN D27DTP (POWERUP) ENGINE (FOR MORE INFORMATION, REFER TO ENGINE SERVICE MANUAL) 1431 BOOST PRESSURE SENSOR Mounting location and specification are changed due to the newly added throttle body. FUSE AND RELAY BOX Intake Intake ELECTRONIC THROTTLE BODY Normal: Open During engine stopping: Close When the engine is not running, the flap in the throttle body is closed to block the intake air to prevent the engine turning off with abnormal noise. This is directly controlled by ECU. GLOW PLUG The glow plug for quick preheating is used with AQGS (Incompatible). AQGS The glow plug for quick preheating function and CAN communication with ECU COMMON RAIL & FUEL PIPE Common Rail Fuel Pipe The diameter of fuel supply rail (including high pressure rail) is increased due to the increase of engine power and torque, and the orifice is installed in common rail and HP pump to prevent fuel pulsation. Orifice INJECTOR (C3I LABEL) C3I Two injection holes are added (currently 7 holes) to the injector and C3I coding is adopted to control the amount of injected fuel more precisely. ENGINE ECU - VERSION 3.2 E-EGR valve, throttle body and AQGS are adopted to D27DTP engine, along with two connectors to control the exhaust gas. Connector B Connector A VGT TURBO VACUUM MODULATOR Only the vacuum modulator that controls VGT turbo charger actuator is adopted in accordance with the electrically controlled E-EGR. 1913 VGT TURBOCHARGER This enhances the output power and torque, reduces the fuel consumption, and decreases the exhaust gas by changing the exhaust gas flow by controlling the vane in low and high speed range. PCV OIL SEPARATOR PCV oil separator with large capacity has been adopted to improve the separation efficiency for the oil and gas from crankcase. HFM SENSOR - VERSION 6.0 To control the engine more precisely, the digital signal for inlet air mass is newly adopted and the arrangement of connector pin is changed. E-EGR VALVE EGR COOLER PIPE The E-EGR valve electrically controls EGR valve, and transmits the location signal of EGR valve to ECU (Vacuum modulator for control eliminated). This reduces the content of NOx in EGR gas by decreasing the temperature. 1222 2330 1792 1792 1715 8410 1412 2820 1881 1881 1490 2433 Exhaust pipe (exhaust gas) Air cleaner (intake air) Intercooler (compressed air) Blow-by gas (to air duct hose) Cylinder head cover (oil + gas) Oil (to oil dipstick gauge pipe) EGR gas Coolant Coolant To EGR cooler From exhaust manifold 1533 IOP (OIL PAN) This is integrated in the front axle so that the center of gravity of the vehicle can be low- ered and NVH performance and power trans- fer can be improved. 2411 * CDPF SYSTEM (D27DT) In pursuit of the exhaust gas reduction policy, this system drastically reduces polluted material. This consists of CDPF assembly and sensors. SWITCHABLE ENGINE MOUNT & VACUUM SOLENOID VALVE This engine mounting system can be elec- tronically controlled in two stages (soft/hard) depending on the vehicle’s condition. Solenoid valve to draw or block the vacuum to the switchable engine mounting system by ECU control. LH/RH Switchable Engine Mount Vacuum Pump Connector 1990 Receiver Drier HIGH-CAPACITY WATER PUMP The EGR cooler and the coolant port (inside the cylinder block) are adopted to improve the cooling performance in high power engine. REFRIGERANT PRESSURE SENSOR With the continuous monitoring of refrigerant pressure, the engine ECU controls the air conditioner compressor precisely. Refrigerant Pressure Sensor 1520 6820 EGR cooler and connecting port CDPF Assembly Red

SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 CHANGED BY EFFECTIVE DATE AFFECTED VIN 0000 4 D27DTP/D27DT (EU4) 2. MAJOR CHANGES IN INTERIOR ELECTRIC COMPONENTS INSTRUMENT CLUSTER (BLACKFACE) OVERHEAD CONSOLE SWITCH This uses CAN communication and also has adopted new technologies (EAS, TPMS and EPB), along with the rel- evant warning lights and indicators. TPMS pressure value is displayed on the ODO (Trip Odometer) display window. (Press trip switch for two seconds in ODO display mode.) Sun roof can be opened in 2-step operation with this switch. In the 1st step, the sun roof is opened as much as it can minimize wind buffet phenomenon (2nd step: Fully Open). 8010 7770 ECU Motor DRIVER SEAT’S POWER WINDOW MOTOR Auto-up function and anti-trap function are adopted to the driver’s door glass. The system is initialized when the part is replaced or it is abnormally operated. 7120 REMOTE CONTROL SWITCH ON STEERING WHEEL The tip switch, which can shift the gear when the shift lever is in “M” position, has been added to the system. 8511 MULTIFUNCTION SWITCH Auto washer & wiper switch and auto hazard warning flasher switch have been added to the existing switches. 8511 4WD SWITCH The 4WD system with three different specifications can be used since All Wheel Drive (AWD) is adopted in D27DTP engine. The AWD system, the mechanical device without electric controls, has no TCCU and control switch (Distribution ratio of driving force to the front wheel and rear wheel = 40: 60). Part-time TOD AWD (Including 2WD) 8511 AIR CONDITIONER CONTROLLER (FATC) 6810 With FATC Air Conditioner Controller System adopted, Air Quality Sys- tem (AQS) automatically changes the air source by detecting the con- tamination degree of ambient air. AQS Switch AQS Sensor Air Conditioner Controller (Unit) MULTI-JACK STATION 8611 The multi-jack station has the digital clock and audio functions. It can be connected to the separate audio device with the stereo jack to listen to the music through the speakers in the vehicle. Moreover, USB memory stick can be connected to the multi-jack station for play- ing music (The MP3 USB memory port is optional). Ear- phone Stereo Jack MP3 USB port Clock & Multi Station Display Cellular phone MP3 RAIN & AUTO LIGHT SENSOR (INTEGRAL TYPE) As an integral sensor, this controls wiper by sensing the amount of rain drops and the exterior lights according to the ambient illumi- nation intensity (in Auto position). 8611 VARIABLE SEAT WARMER SYSTEM 8611 AUX Jack This system is similar to the one of CHAIRMAN, and its control units are installed in the front and rear area of vehicle. (AUX Jack between switches is available in AV system type.) IMMOBILIZER (REMOTE ENGINE STARTING FUNCTION ELIMINATED) It has the immobilizer function and its battery can be replaced unlike. 7010 SPWM UNIT This unit has the function that memorize and adjust driver’s seat and outside rearview mirror. In addition, it has the function that automatically lowers the outside rearview mirror by 3.5 degrees as well as the easy access function. SPWM unit (at the bottom of driver’s seat) 7410 Easy Access Button Seat Memory Button CRUISE CONTROL The cruise control is an automatic speed control system that main- tains a desired driving speed without using the accelerator pedal. The vehicle speed must be greater than 36 km/h to engage the cruise control. This feature is especially useful for motorway driving. 8511 TYPE A TYPE B CENTER FASCIA SWITCH 8511 Hill Descent Control (HDC) function is integrated into the ESP function, and the 2-corner EAS system is also adopted. ESP OFF Switch HDC Switch Outside Rearview Mirror & Rear Heated Glass Switch Windshield Heated Glass Switch HDC Switch Time setting & Multi-jack station Control Switch

SYSTEM CHANGED BY EFFECTIVE DATE AFFECTED VIN SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 5 0000 D27DTP/D27DT (EU4) AUDIO SYSTEM 3. MAJOR CHANGES IN ELECTRIC COMPONENTS AND UNITS AV HEAD UNIT PAS UNIT ENGINE ECU - VERSION 3.2 TV ANTENNA MODULE This unit controls three sensors made of piezo ceramic element in the rear bumper, and indicates the sensor’s malfunction with buzzer, not with LED (LED eliminated). The image quality of AV head unit has been improved by adopting 6.5 inch wide type TFT LCD panel. It can be connected to DSP amplifier and DVD changer with optic cables. 2-DIN type audio system is equipped in the vehicle as basic, and the tape slot is eliminated. The AUX button has been added to the system in accordance with introducing multi-jack station. RADIO ANTENNA MODULE 8931 This antenna module receives TV channels and transfers them to tuner after amplifying them. Those are located on the rear quarter upper panel. This amplifies the radio signal received from glass antenna and transfers it to tuner. It is installed on the rear right quarter upper panel. E-EGR valve, throttle body and AQGS are adopted to D27DTP engine, along with two connectors to control the exhaust gas. RK STICS As the remote engine starting function is eliminated, RE STICS is eliminated too. Auto hazard warning flasher, auto washer synchronized wiper, SPWM unit and other new technologies are newly adopted. RADIO ANTENNA MODULE TV ANTENNA MODULE SENSOR CLUSTER & CHIME BELL 8790 8711 1490 8711 8931 8931 LH RH Sensor Cluster Chime Bell WOOFER SPEAKER DSP AMPLIFIER TUNER REAR SEAT WARMER UNIT DVD CHANGER This device precisely tunes the input signal by filtering the signals from each antenna module. Installed at the bottom of passenger’s seat. It enforces mid-low sounds by receiving the output signal from DSP amplifier. Aside from the basic speaker control function, this exterior digital AMP can separate digital audio source to give digital effects. The front seat warmer unit and rear seat warmer unit are mounted respectively. This variable seat warmer system is controlled in 5 stages. 8-DVD changer is installed inside the rear left quarter lower panel. DVD Changer 8931 8611 8931 8611 8931 DSP Amplifier TCU Installed at the inner bottom of audio head unit, the yaw rate sensor and acceleration sensor are installed inside. Those sensors detect the vehicle stability to control ESP.

SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 CHANGED BY EFFECTIVE DATE AFFECTED VIN 0000 6 D27DTP/D27DT (EU4) REAR SUSPENSION Independent Suspension (IRS) Type: D27DTP FRONT TPMS ANTENNA REAR TPMS ANTENNA This system independently controls the vertical vibration of the vehicle in both sides. Accordingly, this suspension guarantees the vehicle stability even on the uneven road, and enhances the driving comforts by distributing the shocks from the road surface into the number of links. 5-line (rigid) Type: D27DT AWD 4520 EMERGENCY TIRE (TPMS MODULE UNEQUIPPED) 4. MAJOR CHANGES IN CHASSIS TPMS SYSTEM TPMS Wheel Module ESP HECU TPMS system aims to ensure the driving stability and performance in advance, to prevent the unnecessary fuel waste, and to reduce the tire wear, when inflation pressure values of each tire are different each other. This system enables a driver to check the tire condition before or during driving by indicating the abnormality or defects on the instrument cluster. TPMS ECU region TPMS Antenna 4190 EPB SYSTEM The existing mechanical parking brake is operated manually (by pulling up the lever). However, the vehicle with EPB system enables to automatically apply the parking brake by considering parking performance, driving speed, and the time when the main brake pedal is depressed. The parking brake system without EPB system is the same as the existing parking brake system. EPB Unit Auto Parking Switch EPB Control Switch 4920 EAS SYSTEM EAS Supply Unit Normal Level Easy Loading Level (30 mm Down) The EAS system in REXTON II adopts the air springs only on the rear wheels. (2-corner Open EAS system). 2-corner open EAS system enhances the driving comforts and driving stability by maintaining the height at the certain level irrespective of the road condition in the rear. The system is adopted to optimize the spring constant according to the load condition. 4480 TGS LEVER TGS Lever Knob TGS Lever Assembly Tip Switch Lever Lever Tip Switch The TGS lever of REXTON II communicates with Engine Control Unit (ECU), ESP Control Unit (ESP HECU) and instrument cluster. In addition, it is possible to select the gear manually in M position of shifting lever by fitting the tip switch on the lever knob and steering wheel. Steering Wheel Tip Switch 3721 Air Spring Height Sensor ALL WHEEL DRIVE (AWD) Adopted to the vehicle with D27DTP engine, this full-time 4-wheel drive system is the mechanical type which has no control unit, shift motor and other swift switches. Its power distribution ratio to the front and rear is 40:60. 3260 IWE LOCKING HUB SYSTEM This vacuum locking hub system engages or disengages the gears at the end of the drive shaft and the end of hub by using vacuum pressure. This system is used for the vehicle with 4WD system. 4116 Gear engaged Gear disengaged 4WD: Unlocked by vacuum pressure 2WD: Locked by vacuum pressure FRONT AXLE: INTEGRATED OIL PAN (IOP) AXLE & OTHER DEVICES RH Drive Shaft Intermediate Shaft IOP Axle IOP Connector IOP (oil pan) LH Drive Shaft Used for the vehicle with D27DTP (POWER-UP) engine, the engine oil pan and axle is integrated in the axle system. This system can lower the height of the mounted engine. In addition, engine vibration can be greatly reduced due to the mass increase effect under the condition that the front axle and engine are integrated. 4122 INDEPENDENT SUSPENSION REAR AXLE Independent suspension is used for the vehicle with D27DTP. Accordingly, rear axle types are varied. 4220

SYSTEM CHANGED BY EFFECTIVE DATE AFFECTED VIN SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 7 0000 D27DTP/D27DT (EU4) Antenna Glass Noise Shield Glass Solar Glass Privacy Glass 5. MAJOR CHANGES IN VEHICLE EXTERIOR ROOM LAMP (OVERHEAD CONSOLE LAMP) 18-INCH WHEEL (256/60R18) AND TPMS MODULE GLASS SPECIFICATION (SYMBOL) REAR GLASS ANTENNA & DEFOGGER SIDE SILL MOLDING HEAD LAMP 3.5° Blue Mirror AIMING DOWN BY 3.5° WHEN REVERSING TAIL LAMP Blue mirror is adopted to improve vehicle appearance and to reduce the beaming out of the head lamp of the vehicle behind. And when reversing, the outside mirror which downs the aiming by 3.5° is adopted. REAR BUMPER 18-inch wheel is adopted, and the wheel shape is also changed. The wheel module can be installed on the wheel by adopting the TPMS. SEAT BELT FENDER PANEL FRONT BUMPER Press each switch (1 or 2) to turn on or off the room lamp in driver side or passenger side. If pressing the door coupled lamp (3), the lamp comes on or off when opening or closing a front door. Front Door Coupled Lamp Spot Lamp Spot Lamp PAS Sensor High Beam (H1) 12V-55W (one at each side) Low Beam (H7) 12V-55W (one at each side) Position /Turn Signal Lamp Bulb 12V-8W/P21W (one at each side) Tail/Stop Lamp 12V-8W27W Tail Lamp 12V-5W Back-up Lamp 12V-W16W Stop Lamp 12V-27W Turn Signal Lamp 12V-27W Front End Member Lower Front Bumper Bumper Upper Garnish Rear Bumper Fascia Assembly Rear Bumper Beam Rear Upper Beam GLASS ANTENNA * Front bumper nudge bar and energy absorber eliminated. * Rear bumper energy absorber eliminated. RADIATOR GRILL 7910 7880 4190 7840 7770 8320 8310 7410 5720 7430 7870 SEAT 7410 CENTER CONSOLE 7630 ENGINE HOOD 6110 Hood Opening Lever The shape of radiator grill is changed, and the hood opening lever is located in the top right of the grill. FRONT FOG LAMP 8310 Fog Lamp Bulb 12V-H27W/2 Bulb

SYSTEM D27DTP/D27DT (EU4) SM - 2006.08 CHANGED BY EFFECTIVE DATE AFFECTED VIN 0000 8 D27DTP/D27DT (EU4) 6. FRAME DIMENSION IRS TYPE 5-LINK TYPE

SSANGYONG KYRON EURO 4 Engine D27DTP D27DT Full Service & Repair Manual

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