brake sensor SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

02-70000-00
3. CHECK AND INSPECTION
1) Cylinder
(1) Compression pressure test
Specified value ▶
Compression ratio16.5 : 1
Test conditionat normal operating temperature (80˚C)
Compression pressureStandard32 bar
Minimum18 bar
Differential limit between cylindersMaximum 3 bar
The compression pressure test is to check the conditions of internal components (piston, piston
ring, intake and exhaust vale, cylinder head gasket). This test provides current engine operating
status.
Before cranking the engine, make sure that the test wiring, tools and persons are keeping
away from moving components of engine (e.g., belt and cooling fan).
Park the vehicle on the level ground and apply the parking brake.
Do not allow anybody to be in front of the vehicle. -
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Measurement ▶
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47004f005f005700b6006a00500055>
Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
Remove the air cleaner duct and glow plugs. -
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Place the diagram sheet to compression
pressure tester and install it into the plug
hole. 1.

15-30000-00
1. ENGINE DATA LIST
Data Unit Value
Coolant temperature℃ 0.436 V (130℃) to 4.896 V (-40℃)
Intake air temperature℃ -40 to 130℃ (varies by ambient air
temperature or engine mode)
Idle speed rpm750 ± 20
Engine load % 18~25%
Mass air flow kg/h 16 to 25 kg/h
Throttle position angle°TA 0° (Full Open) to 78° (Close)
Engine torque Nm varies by engine conditions
Injection time ms 3 to 5ms
Battery voltage V 13.5 V to 14.1 V
Accelerator pedal position 1 V 0.4. to 4.8V
Accelerator pedal position 2 V 0.2 to 2.4 V
Throttle position 1 V 0.3 to 4.6 V
Throttle position 2 V 0.3 to 4.6 V
Oxygen sensor mV 0 to 5 V
A/C compressor switch 1=ON / 0=OFF -
Full load 1=ON / 0=OFF -
Gear selection (A/T) 1=ON / 0=OFF -
Knocking control 1=ON / 0=OFF -
Brake switch 1=ON / 0=OFF -
Cruise control 1=ON / 0=OFF -

15-70000-00
Fuel rail pressure
sensor
(2) Components for ECU Input
CAN
- ABS & ESP
- GCU
- Instrument
cluster
- TCUSwirl valve position
sensor
Differential
pressure sensorE-EGR valve
position sensorCamshaft position
sensorCoolant
temperature senso
r
Exhaust gas
temperature senso
r
HFM sensorOxygen sensorT-MAP sensor
Crankshaft position
sensor
Accelerator pedal
sensorThrottle position
sensorKnock sensor
-Auto cruise switch
- Rear right wheel
speed (without ABS)
- Refrigerant pressure
sensor
- Clutch pedal signal
- Blower switch signal
- Brake pedal signal
Water sensor

15-90000-00
2) ECU Control
(1) Function
a. ECU Function
ECU receives and analyzes signals from various sensors and then modifies those signals into
permissible voltage levels and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston
speed and crankshaft angle based on input data and stored specific map to control the engine
power and emission gas.
Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure
and activates injector solenoid valve to control the fuel injection period and injection timing; so
controls various actuators in response to engine changes. Auxiliary function of ECU has adopted
to reduce emission gas, improve fuel economy and enhance safety, comforts and conveniences.
For example, there are EGR, booster pressure control, autocruise (export only) and immobilizer
and adopted CAN communication to exchange data among electrical systems (automatic T/M
and brake system) in the vehicle fluently. And Scanner can be used to diagnose vehicle status
and defectives.
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47009b009600470052005f005c00b6006a004700880095008b> protected from factors like oil,
water and electromagnetism and there should be no mechanical shocks.
To control the fuel volume precisely under repeated injections, high current should be applied
instantly so there is injector drive circuit in the ECU to generate necessary current during injector
drive stages.
Current control circuit divides current applying time (injection time) into full-in-current-phase and
hold-current-phase and then the injectors should work very correctly under every working
condition.
b. Control Function
Controls by operating stages
To make optimum combustion under every operating stage, ECU should calculate proper
injection volume in each stage by considering various factors.
Starting injection volume control
During initial starting, injecting fuel volume will be calculated by function of temperature and
engine cranking speed. Starting injection continues from when the ignition switch is turned to
ignition position to till the engine reaches to allowable minimum speed.
Driving mode control
If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel
and engine rpm and the drive map will be used to match the drivers inputs with optimum
engine power. -
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02-4
Input Signals ▶
NO. Input Signal Name Logic Status
1 IGN1 ON = BAT
(IGN ON or START)
2 IGN2 ON = BAT (IGN ON)
3 ALT_D ON = BAT (engine started)
4 Key reminder switch IN = BAT (key in)
5 Driver's door switch OPEN = GND, CLOSE = OPEN
6 Passenger's door switch OPEN = GND, CLOSE = OPEN
7 Rear door switch - OPEN (one of rear doors) = GND
- CLOSE (all rear doors) = OPEN
8 Hood switch OPEN = GND, CLOSE = OPEN
9 Driver's door lock/unlock switch LOCK = OPEN, UNLOCK = GND
10 Passenger's door lock/unlock switch LOCK = OPEN, UNLOCK = GND
11 Rear door lock/unlock switch - UNLOCK (one of rear doors)
= GND
- LOCK (all rear doors) = OPEN
12 Tailgate lock/unlock switch LOCK = OPEN, UNLOCK = GND
13 Rear defogger switch ON = GND, OFF = OPEN
14 Seat belt switch Unfastened = GND, Fastened = OPEN
15 Sunroof open switch ON = GND, OFF = OPEN
16 Parking brake switch ON = GND, OFF = OPEN
17 Air bag collision sensor ON = 200 ms output (LOW), OFF = OPEN
18 Wiper motor (parking) switch STOP = BAT VOLTAGE, ROTATING = GND
19 Washer switch ON = BAT, OFF = OPEN
20 INT-AUTO switch ON = BAT, OFF = OPEN
21 Auto washer switch ON = BAT, OFF = OPEN
22 Intermittent resistance 0W ~ 51KW (for intermittent wiper)
23 Speed sensor ON = GND (PWM), OFF = OPEN
24 Mirror lock/unlock switch ON = GND, OFF = OPEN
25 Front defogger switch ON = GND, OFF = OPEN
26 Auto hazard switch ON = GND, OFF = OPEN

04-218210-01
ABS Warning Light
This warning light comes on
when the ignition switch is
turned to "ON" position and
should go out if the system is
normal.
The vehicle with ABS performs
self-diagnosis. During this
diagnosis, brake pedal
vibration and noise may be
apparent when the driving
motors discharges the
hydraulic pressure from the
internal hydraulic device.4WD IndicatorLow Fuel Level
Warnig Light
This warning light
comes on when the
fuel will soon be
exhausted. The time
it takes turn on,
however, varies
according to the
gradient of the
vehicle.
4WD HIGH Indicator
The lamp blinks momentarily during
the change of driving mode.
4WD LOW Indicator
The lamp blinks momentarily during
the change of driving mode.
4WD CHECK Warning Light
This indicates that there is
something wrong in the transfer
case system. (check the system) -
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Auto Cruise Control
Indicator
Operating the cruise
control switch turns on
the indicator lamp to
indicate the cruise
control system is
activated.
Water Separator Warning Light
This lamp comes on to warn the driver of
water in the fuel tank which causes the
loss of engine power. When a certain
amount of water is accumulated, the lamp
comes on and a chime sounds.
Engine CHECK Warning Light
This warning light comes on when
the ignition switch is turned to "ON"
position and should go out if the
system related to engine control is
normal.
This comes on when different
sensors and devices related to
engine control are defective.
Winter Mode
Indicator
Pressing the "W" side of the
automatic transmission mode
selector switch switches the
driving mode to winter mode and
turns on the indicator lamp.
Use this mode to drive off
smoothly on icy and slippery
roads.
Charge Warning Light
This warning light comes on when the
ignition switch is turned on and go off
when the engine is started.
If this light doesn't go off after engine
starting, it means there is a malfunction in
the system.
Engine Hood Open Warning Light
When the engine hood is open, this light
comes on to inform the driver.

01-33680-01
1. GENERAL INFORMATION
Six forward speeds
One reverse gear
A toruqe converter with an integral converter
lock-up clutch
Electronic shift and pressure controls
A single planetary gear-set
A double planetary gear-set
Two hydraulically controlled brake bands
Three multi-plate clutches
All hydraulic functions are directed by
electronic solenoids to control -
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- Automatic transaxle (DSI M78) ▶
TCU ▶
TCU is located under the driver's seat and controls the operations of transmission.
TCU receives the ignition voltage and has three connectors (16-pin, 12-pin, 20-pin).
TCU receives input signals from certain transmission-related sensors, gear select lever and
inhibitor switch. TCU also uses these signals when determining transmission operating strategy.
TCU uses PCAN to communicate with other units. And, TCU communicates with engine ECU,
ESP unit, TCCU and instrument cluster through CAN lines to control the gear shifting and to
recognize the current gear position.
DSI M78 Automatic Transmission is based on the transmission in the vehicle with D20DT engine
for EURO III or EURO IV or EURO V.
Differences: changed some components (torque converter and torque converter housing, some
pinion gears, sun gear), increased torsional damping force.
TCU

01-113680-01
1. OVERVIEW
The six speed automatic (M78) transmission
is available in two variants: four wheel drive
and two wheel drive.
The transmission has the following features:
Six Forward Speeds
One reverse gear
A torque converter with an integral converter lock-up clutch
Electronic shift and pressure controls
A single planetary gear-set
A double planetary gear-set
Two hydraulically controlled brake bands
Three multi-plate clutches
All hydraulic functions are directed by electronic solenoids to control: -
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Engagement feel
Shift feel
Shift scheduling
Modulated torque converter clutch applications ·
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The transmission contains fully synthetic automatic transmission fluid (ATF) and is filled for life;
therefore it does not require periodic servicing.
Engine power reaches the transmission via a torque converter with integral converter lock-up
clutch.
The six forward gears and one reverse gear are obtained from a single planetary set, followed by
a double planetary set. This type of gear-set arrangement is commonly known as Lepelletier type
gear-set.
The automatic transmission is electronically controlled. The control system is comprised of the
following elements:
External transmission control unit (TCU)
Internal embedded memory module (EMM)
Input and output speed sensors
Valve body unit comprised of four on/off solenoid valves and six variable bleed solenoids
Torque converter -
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09-34850-01
1. SPECIFICATION
Unit Description Specification
Front brake Type Ventilated disc
Outer diameter of discØ294 mm
Inner diameter of caliper cylinderØ43.0 x 2 mm
Thickness of disc 28 mm (wear limit: 25.4 mm)
Area of brake pad Above 60 cm2
Pad wear indicator Mechanical type
Rear brake Type Solid disc
Outer diameter of discØ299 m
Thickness of disc 10.4 mm (wear limit: 8.5 mm)
Area of brake pad Above 28.8 cm2
Pad wear indicator Mechanical type
Brake booster Type Vacuum assist type
Size8” + 9” (Tandem)
Master cylinder Type Tandem type(integrated level sensor)
Inner diameter of cylinderØ26.99 mm
Brake pedal Maximum operating stroke 150 mm
Pedal ratio 4 : 1
Free play 3 to 10 mm
Parking brake Type Mechanically expanded rear lining
Operating type Hand operated type
Inner diameter of drumØ190 mm
Brake oil Specification DOT 4
Capacity 0.7 to 0.8 liters
Service Interval: Change the brake oil at every 2 years
DOT?
It is the quality grade of brake fluid established by US Department of Transportation.

09-28
Front Brake AssemblyFront Wheel Speed Sensor (4WD)
HECU
2. SYSTEM LAYOUT
Master Cylinder and Booster
Brake Pedal