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Ssangyong Kyron Service Repair Workshop Manual

SsangYong Kyron

THIS IS THE SAME TYPE OF MANUAL USED BY TECHNICIANS AT YOUR LOCAL DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.

Ssang Yong Kyron Service Manual, Workshop Manual pdf, Repair Manual pdf, Electrical Wiring Diagrams pdf, Owner Manual. Service manual Ssang Yong Kyron 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.

COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!

ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. FACTORY HIGHLY DETAILED REPAIR MANUAL WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.

CONTENTS:

SERVICE MANUAL

GENERAL
– GENERAL
– 1. dimensions
– 2. specifications
– 3. vehicle identification
– 4. maintenance interval
– 5. recommended fluids and lubricants
– 6. jack-up points
– 7. pin arrangement of diagnostic connector
– 8. electric components and layout
– 9. standard bolts specifications
ENGINE GENERAL
– GENERAL
– 1. engine assembly layout
– 2. engine controls layout
– 3. electrical components and preheating system
– 4. intake system layout
– 5. exhaust system layout
– 6. lubrication system layout
– 7. cooling system layout
– 8. fuel system layout
– 9. fuel supply system
– 10. cleanness
– 11. maintenance and repair
– 12. guidelines for service work safety
– 13. during service work for inspection
– 14. during service work for electric devices
– 15. owner inspections and services
– 16. standard bolts specifications
ENGINE ASSEMBLY
– GENERAL
– 1. major components in engine and engine compartment
– 2. specifications and performance curve
– 3. tightening torque
ENGINE FUEL SYSTEM
– GENERAL
– 1. cautions for di engine
– OVERVIEW AND OPERATION PROCESS
– 1. electronic control of fuel system
– 2. composition of fuel system
– 3. hydraulic cycle in fuel line (transfer and high pressure line)
– 4. components of low pressure transfer line
– 5. components of high pressure transfer line
– 6. circuit diagram
ENGINE INTAKE SYSTEM
– GENERAL
– 1. engine intake specifications
– OVERVIEW AND OPERATION PROCESS
– 1. intake system layout
– 2. air flows
ENGINE EXHAUST SYSTEM
– GENERAL
– 1. inspection before diagnosis
– OVERVIEW AND OPERATION PROCESS
– 1. exhaust system layout
LUBRICATION SYSTEM
– GENERAL
– 1. specifications
– 2. oil pressure switch
– OVERVIEW AND PERATION PROCESS
– 1. layout and overview
– 2. lubrication diagram
ENGINE COOLING SYSTEM
– GENERAL
– 1. engine cooling specifications
– OVERVIEW AND OPERATION PROCESS
– 1. components engine cooling
– 2. cooling system flow
– 3. function description of cooling system
ENGINE ELECTRICAL SYSTEM
– GENERAL
– 1.specifications of engine electric
– OVERVIEW AND OPERATION PROCESS
– 1. components of electric in engine
– 2. components of electric devices in engine
– 3. circuit diagram of preheating system
– 4. circuit diagram of starting and alternator
ENGINE CONTROL SYSTEM
– GENERAL
– 1. engine ecu and other components
– 2. top view
– 3. side view
– OVERVIEW AND OPERATION PROCESS
– 1. ecu inputs/outputs
– 2. structure and function of ecu
– 3. control function of ecu
– 4. fuel pressure control
– 5. fuel injection control
– 6. fuel flow control
– 7. individual injector calibration (c2i)
– 8. minimum drive pulse (mdp) learning
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
ENGINE ASSEMBLY
– GENERAL
– 1. major components in engine and enginecompartment
– 2. specifications and performance curve
– 3. tightening torque
– 4. major changes in d20dt (eu-iv) engine (compared to d20dt)
ENGINE FUEL SYSTEM
– GENERAL
– 1. major changes in fuel system of engine
– OVERVIEW AND OPERATION PROCESS
– 1. components of fuel system
– 2. fuel flow of d20dt (eu-iv) engine
ENGINE INTAKE SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2. intake system layout
ENGINE EXHAUST SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. components
CDPF
– GENERAL INFORMATION
– 1. overview for cdpf (eu-iv)
– 2. cdpf (eu-iv) system
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2.cdpf (eu-iv) system control
– 3. soot filtering and burning procedures
– 4. components of cdpf system
LUBRICATION SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. overview oil separators
ENGINE COOLING SYSTEM
– COOLING SYSTEM
– 1. comparison in cooling system for each engine
– WATER PUMP
– 1. overview
ENGINE ELECTRIC DEVICES
– OVERVIEW AND OPERATION PROCESS
– 1. overview of engine ecu
– 2. d20dt (eu-iv) engine’s ecu circuit
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
ENGINE GENERAL
– GENERAL
– 1. engine assembly layout
– 2. components in d20dt engine and d27dt engine
– 3. engine controls layout
– 4. electrical components and preheating system
– 5. intake system layout
– 6. exhaust system layout
– 7. lubrication system layout
– 8. cooling system layout
– 9. fuel system layout
– 10. fuel supply system
– 11. cleanness
– 12. maintenance and repair
– 13.guidelines for service work safety
– 14. during service work for inspection
– 15. during service work for electric devices
– 16. owner inspections and services
– 17. standard bolts specifications
ENGINE ASSEMBLY
– GENERAL
– 1. major components in engine and engine compartment
– 2. engine structure
– 3. specifications and performance curve
– 4. tightening torque
ENGINE FUEL SYSTEM
– GENERAL
– 1. cautions for di engine
– OVERVIEW AND OPERATION PROCESS
– 1. electronic control of fuel system
– 2. composition of fuel system
– 3. hydraulic cycle in fuel line (transfer and high pressure line)
– 4. components of low pressure transfer line
– 5. components of high pressure transfer line
ENGINE INTAKE SYSTEM
– GENERAL
– 1. engine intake specifications
– OVERVIEW AND OPERATION PROCESS
– 1. engine intake components locator
– 2. air flows
– OVERVIEW AND OPERATION PROCESS
– 2321-01 air flow sensor(hot film air mass sensor)
– 2330-01 intercooler
– 1715-01 intake manifold assembly
ENGINE EXHAUST SYSTEM
– GENERAL
– 1. inspection before diagnosis
– OVERVIEW AND OPERATION PROCESS
– 1. components locator of exhaust system
– 2. exhaust gas flows
ENGINE LUBRICATION SYSTEM
– GENERAL
– 1.specifications of engine lubrication
– OVERVIEW AND OPERATION PROCESS
– 1. components of lubrication system
– 2.lubrication system layout
– 3. lubrication diagram
ENGINE COOLING SYSTEM
– GENERAL
– 1. engine cooling specifications
– OVERVIEW AND OPERATION PROCESS
– 1. components engine cooling
– 2. cooling system flow
– 3. function description of cooling system
ENGINE ELECTRIC SYSTEM
– GENERAL
– 1.specifications of engine electric
– OVERVIEW AND OPERATION PROCESS
– 1. components of electric in engine
– 2. components of electric devices in engine
– 3. circuit diagram of preheating system
– 4. circuit diagram of starting and alternator
ENGINE CONTROL SYSTEM
– GENERAL
– 1. engine ecu and other components
– OVERVIEW AND OPERATION PROCESS
– 1. ecu inputs/outputs
– 2. structure and function of ecu
– 3. control function of ecu
– 4. fuel pressure control
– 5. fuel injection control
– 6. fuel flow control
– 7. individual injector calibration (c2i)
– 8. minimum drive pulse (mdp) learning
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
ENGINE GENERAL
– GENERAL
– 1. structure and comparison
– 2. engine specifications and performance curve
– 3. tightening torque
– 4. major changes in d27dtp (power up) engine (compared to d27dt)4.
– OVERVIEW AND OPERATION PROCESS
– 1. engine compartment
– 2. systems in engine compartment
ENGINE FUEL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. major changes in fuel system of d27dtp(power up) engine
– 2. components of fuel system
ENGINE INTAKE SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. intake system layout
ENGINE EXHAUST SYSTEM
– OVERVIE AND OPERATION PROCESS
– 1. components
CDPF
– GENERAL INFORMATION
– 1. overview for cdpf (eu-iv)
– 2. cdpf (eu-iv) system
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2.cdpf (eu-iv) system control
– 3. soot filtering and burning procedures
– 4. components of cdpf system
ENGINE COOLING SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. comparison in cooling system for each engine
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
ENGINE INFORMATION
– GENERAL
– 1. component locator
– 2. description and operation
ENGINE ASSEMBLY
– GENERAL
– 1. specifications
– 2. special tools and equipment
– 3. fastener tightening specifications
– 4. fastener tightening specifications (cont’ d)
ENGINE FUEL SYSTEM
– OVERVEIW AND OPERATION PROCESS
– 1. fuel system specification
ENGINE EXHAUST SYSTEM
– GENERAL
– 1. overview of exhaust system
– 2. overview of muffler
– 3. overview of catalytic converter
– 4. fastener tightening specifications
ENGINE LUBRICATION SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. oil circulation
ENGINE COOLING SYSTEM
– GENERAL
– 1. general specifications
– 2. special tools and equipment
– 3. fastener tightening specifications
– OVERVIEW AND OPERATION PROCESS
– 1. general description
– 2. component locator
ENGINE ELECTRIC DEVICES
– GENERAL
– 1. general specifications
– 2. fastener tightening specifications
– OVERVIEW AND OPERATION PROCESS
– 1. charging system operation
– 2. starting system operation
– 3. ignition system operation
– 4. starting and charging system (gasoline engine) circuit
ENGINE CONTROL SYSTEM
– GENERAL
– 1. engine data display table
– 2. fastener tightening specifications
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
– REMOVAL AND INSTALLATION
– 8510-23 cruise control switch
ENGINE ASSEMBLY
– GENERAL
– 1. description and operation
– 2. g23d engine assembly
– 3. g23d engine structure
– 4. diagnostic information and procedure
– 5. general diagnosis
– 6. specifications
ENGINE INTAKE SYSTEM
– GENERAL
– 1. specifications
ENGINE EXHAUST SYSTEM
– GENERAL
– 1. specification
– OVERVIEW AND OPERATION PROCESS
– 1. description and operation
ENGINE COOLING SYSTEM
– GENERAL
– 1. general specifications
– 2. fastener tightening specifications
– OVERVIEW AND OPERATION PROCESS
– 1. component locator
– 2. description and operation
– 3. pwm (pulse width modulation) electric fan operation
ENGINE ELECTRIC DEVICES
– GENERAL
– 1. diagnostic information and procedure
– OVERVIEW AND OPERATION PROCESS
– 1. description and operation
CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
– 1. cruise control switch
– 2. circuit diagram
– 3. how to operate cruise control switch
ELECTRIC SYSTEM
– ELECTRIC GENERAL
– 1. locations of interior units and sensors
– 2. switches, units and sensors in engine compartment
– 3. interior switches
– 4. audio / video system
– 5. electric components and layout
FUSE AND RELAY
– GENERAL INFORMATION
– 1. general information
– OVERVIEW AND OPERATING PROCESS
– 1. overview
– 2. fuse and relay mounting location
– 3. capacity and name of fuse and relay in engine compartment
– 4. capacity and name of interior fuse and relay
– 5. operating process of icm box
RKSTICS/STICS
– GENERAL
– 1. stics overview
– 2. specifications
IMMOBILIZER SYSTEM
– GENERAL
– 1. immobilizer overview
– 2. basic functions of immobilizer key (rekes function)
SEAT POSITION WITH MEMORY
– GENERAL
– 1. seat position with memory overview
CLUSTER
– GENERAL
– 1. descriptions of indicator display
– 2.warning / indicator pane
LAMP
– GENERAL
– 1. locations of lamps and specifications
SWITCH
– GENERAL
– 1. switch arrangement
WIPER & WASHER
– GENERAL
– 1. wiper and washer system overview
– OVERVIEW AND OPERATING PROCESS
– 1. system layout of wiper and washer (with rain sensor)
– 2. wiper / washer related function and specification
– 3. wiper and washer system related circuit
– 4. rear wiper
RAIN SENSOR
– GENERAL
– 1. rain sensing system (with auto light sensor) overview
– OVERVIEW AND OPERATION PROCESS
– 1. functions and specifications of rain sensing wiper
– 2. operation mode of rain sensing wiper system
– 3. electrical wiring diagram
PAS(PARKING AID SYSTEM)
– GENERAL
– 1. component specifications
– OVERVIEW AND OPERATION PROCESS
– 1. system configuration
– 2. alarm interval and trouble shooting
– 3. cautions on parking aid system
– 4. circuit diagram
AV
– GENERAL
– 1. av head unit overview
– OVERVIEW AND OPERATION PROCESS
– 1. av system configuration
– 2. av head system circulation
– 3. av system functions
– 4. av system specifications and control
AUDIO SYSTEM
– OVERVIEW AND INSTALLATION
– 1. audio system overview
ION 4-SPEED
– GENERAL
– 1. specifications
– 2. fastener tightening specifications
– OVERVIEW AND OPERATION PROCESS
– 1. description and operation of automatic transmission
– 2. appearance
– 3. shift pattern diagram
– 4. operators interfaces
– 5. control systems
– 6. electronic control system
– 7. hydraulic control system
– 8. power flows
AUTOMATIC TRANSMISSION(DC 5-SPEED)
– GENERAL
– 1. automatic transmission overview
– 2. automatic transmission (dc 5-speed) appearance
– 3. automatic transmission structure
– OVERVIEW AND OPERATION PROCESS
– 1. power flow
DSI M78 6-SPEED A/T
– GENERAL INFORMATION
– 1. dsi m78 6-speed automatic transmission general
– 2. structure characteristics and specifications
– 3. tightening torque
– OVERVIEW AND OPERATION PROCESS
– 1. general description
– 2. advanced six speed features
– 3. function of each mode
– 4. limp home mode
– 5. transmission electronic control system
– 6. configuration of can related to tcu
– 7. power train
– DIAGNOSIS AND TESTING
– 1. wiring diagram
– 2. wire harness connector chart
– 3. unit connector description
– TROUBLE CODE EIAGNOSIS
– 1. diagnostic trouble code list
– 2. system diagnosis
– MAINTENANCE OPERATIONS
– 1. oil test
– 2. stall test
– 3. transmission reset procedure(replacement transmission)
– 4. fluid level inspection
– 5. transmission cooler and hydraulic line flushing procedure
– 6. lubrication
– 7. transmission cooler and hydraulic line flushing procedure(new transmission)
TGS LEVER
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2. locations and components
– 3. input/output of tgs lever
T/M LEVER
– OVERVIEW AND OPERATIONP ROCESS
– 1. circuit of ion 4-speed automatic t/m
– 2. circuit of shift inter lock
MANUAL TRANSMISSION
– GENERAL
– 1. overview and characteristics of manual transmission
– 2. specifications and tightening torque of manual transmission
– OVERVIEW AND OPERATION PROCESS
– 1. manual transmission system
CLUTCH
– GENERAL
– 1. clutch specifications
– 2. tighttening torque
– OVERVIEW AND OPERATION PROCESS
– 1. function and overview
AXLE
– GENERAL
– 1. axle specifications
– OVERVIEW AND OPERATION PROCESS
– 1. axle overview
AXLE (IOP)
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2. wheel alignment
PART TIME TRANSFER CASE & LOCKING HUB SYSTEM
– GENERAL
– 1. part time transfer case overview
– 2. part time transfer case specifications
– OVERVIEW AND OPERATION PROCESS
– 1. structure
– 2. system layout and functions
– 3. locking hub system
– 4. power flow
PROPELLER SHAFT
– GENERAL
– 1. specification
– OVERVIEW AND OPERATION PROCESS
– 1. overview
– 2. component locator
– 3310-01 front propeller shaft
– 3310-06 rear propeller shaft
– 3310-00 disassembly and reassembly propeller shaft
SUSPENSION
– GENERAL
– 1. front suspension specifications
– 2. rear suspension specifications
ESP
– GENERAL
– 1. brake system general information
– 2. brake system specifications
– 3. brake operation and noise
– 4. esp system related precautions
– OVERVIEW AND OPERATION PROCESS
– 1. esp system of general information
– 2. principle of esp
– 3. hba (hydraulic brake assist system)
– 4. arp (active roll-over protection)
– 5. hdc (hill descent control)
– 6. esp components and locations
– 7. input/output signals for hdc operation
– 8. esp hydraulic circuit diagram
– 9. hydraulic pressure for each esp operating range
– 10. hydraulic circuit of hba(hydraulic brake assist)
– 11. general information of abs system
– 12. configuration of abs system
– 13. input and output diagram of abs
– 14. hydraulic circuit of abs
– 15. abs circuit in each operation range
STEERING
– GENERAL
– 1. power steering system overview
– 2. power steering specipications
– OVERVIEW AND OPERATION PROCESS
– 1. power steering system layout
– 2. ssps (speed sensing power steering) overview and functions
– 3. s.s.p.s operations
AIR CONDITIONER
– OVERVIEW AND OPERATION PROCESS
– 1. system layout and components
– 2. ventilation system components
– 3. air conditioner module wiring and layout
– 4. ptc heater and ffh heater layout
– 5. ambient temperature sensor
– 6. sensors and actuators
– 7. air conditioner system diagram
– 8. air conditioner module sensors and actuators
– 9. ffh (fuel fired heater) system components
– 10. ffh operating process
AIR BAG
– GENERAL
– 1. reminder for air bag related component replacement
– OVERVIEW AND OPERATION PROCESS
– 1. air bag systems (including curtain air bags) overview
– 2. air bag system locations and related components
– 3. air bag system operation process
– 4. air bag module and other components
– 5. air bag system deploy (firing loop)
– 6. air bag deployment signal output (crash out)
– 7. air bag warning lamp operational conditions
– 8. air bag electrical wiring diagram
ECU-GASOLINE
– DIAGNOSIS
– 1. ecu-gasoline
ECU-DIESEL
– DIAGNOSIS
– 1. ecu-diesel
BRAKE
– DIAGNOSIS
– 1. brake
AIR-BAG
– DIAGNOSIS
– 1. air-bag
CCCS
– DIAGNOSIS
– 1. cccs
FATC
– DIAGNOSIS
– 1. self diagnosis
FFH
– DIAGNOSIS
– 1. ffh
P/TRUNK
– DIAGNOSIS
– 1. p/trunk
RAIN SENSOR
– DIAGNOSIS
– 1. trouble shooting
STICS
– DIAGNOSIS
– 1. stics
TC
– DIAGNOSIS
– 1. tc
TCU
– DIAGNOSIS
– 1. tcu
TGS LEVER
– DIAGNOSIS
– 1. tgs lever

ELECTRICAL MANUAL
GENERAL INFORMATION
– GENERAL INFORMATION
– 1. How To Read Electrical Wiring Diagram
CONNECTOR/GROUND
– WIRING HARNESS
– 0000-00 Wiring Harness, Components Location
POWER DISTRIBUTION
– FUSE / RELAY
– 8210-00 Engine Room Fuse / Relay Box
– 8410-00 I/P – Lh Fuse / Relay Box
– 8410-00 I/P – Rh Fuse / Relay Box
ELECTRICITY DIVIDE
– 8210-00 ENGINE ROOM FUSE / RELAY BOX CIRCUIT
– 8410-00 I/P – LH FUSE / RELAY BOX CIRCUIT
– 8410-00 I/P – RH FUSE / RELAY BOX CIRCUIT
– 8410-00 ICM RELAY BOX CIRCUIT
CIRCUIT
– ENGINE
– 1461-00 Starting / Charging
– 2820-00 Preheating Circuit
– 1491-00 Ecu (Engine Control Unit – D20/D27dt Eu-Iv)
– 1491-00 Ecu (Engine Control Unit – D20/D27dt)
– 1490-00 Ecu (Engine Control Unit – Gsl G32)
– 1490-00 Ecu (Engine Control Unit – Gsl G23)
– 8210-00 Diagnosis Circuit
CHASSIS
– 3110-00 TCU (6-A/T)
– 3110-00 TCU (5-A/T)
– 3110-00 TCU (4-A/T)
– 3740-00 A/T SHIFT LOCK (4-A/T)
– 3410-00 TCCU
– 4892-00 ABS/ESP
– 4620-00 S.S.P.S (SPEED SENSITIVE POWER STEERING
ELECTRIC
– 8810-00 AIR-BAG (CURTAIN AIR-BAG)
– 8010-00 CLUSTER
– 7410-00 POWER SEAT – DRIVER (W/ MEMORY)
– 7410-00 POWER SEAT – DRIVER (W/O MEMORY)
– 7410-00 POWER SEAT – PASSENGER
– 8510-00 ELECTRIC OUTSIDE MIRROR / FOLDING(W/O MEMORY)
– 8510-00 FRT SEAT WARMER
– 8610-00 RR SEAT WARMER
– 8710-00 STICS
– 7830-00 RR WIPER CIRCUIT
– 8510-00 POWER WINDOW CIRCUIT
– 8610-00 HORN
– 7632-00 CIGAR LIGHTER / POWER OUTLET CIRCUIT
– 7340-00 SUN ROOF CIRCUIT
– 8310-00 HEAD LAMP ＆ DRL(DAY TIME RUNNING LIGHT) UNIT CIRCUIT
– 8510-00 HLLD (HEAD LAMP LEVEL G DEVICE) CIRCUIT
– 8320-00 TAIL LAMP CIRCUIT
– 8410-00 TURN SIGNAL / HAZARD LAMP CIRCUIT
– 8210-00 TRAILER LAMP CIRCUIT
– 8310-00 FOG LAMP CIRCUIT
– 4810-00 STOP / BACK-UP LAMP CIRCUIT
– 7770-00 INTERIOR LAMP CIRCUIT
– 7770-00 AUTO DIMMING ROOM MIRROR CIRCUIT
– 8910-00 AUDIO / CLOCK CIRCUIT
– 8790-00 PARKING AID CIRCUIT
– 6810-00 PTC HEATER(POSITIVE TEMPERATURE COEFFICIENT)
– 6810-00 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT
– 6810-00 AIR-CON (MANUAL) CIRCUIT

Language: English
File: PDF
Pages: 2046

Ssangyong Kyron Service Repair Workshop Manual