PL2 - Basic Chassis - Slide - H - Eng2

SDP PL-Ⅱ Chassis Basic
Basic Chassis Technology

Course Introduction 2
Housekeeping
Housekeeping
Course Objectives
At the end of the session, you will be able to
Describe the system layout and list the locations,

mechanisms and functions of components.
Read the manual and use appropriate tools to measure

the standard values of parts.
Take necessary actions after a part change and list the

cautionary measures required for maintenance.
Learning Modules
Module 1. AT Module 2. 4WD Module 3. ESC Module 4. EPB
Module 5. MDPS Module 6. ECS Module 7. TPMS

Training Plan
Basic Chassis Technology
Presentation
System System
Course Intro & Wrap Up
Knowledge Practice
Consolidation
Lecture Room Practice Room Lecture Room

Training Plan
System Layout
System
Location of Components
Knowledge Maintenance Function and
Precautions Overview Configuration
System Practice
Maintenance Components
Restoration Torque
Km/h
Presentation
& Steering angle
Consolidation Control
System Control
Training Plan
System
Knowledge
System Practice
• Post-part-change • Measure standard

Requirements values of each part
Presentation
&
Consolidation
Training Timetable
Day Time Module
09:00~09:15 　 Course Intro
1 Day 09:15~13:30 AT
13:30~17:00 4WD
09:00~11:30 ESC
2 Day 11:30~15:00 EPB
15:00~17:00 MDPS
09:00~13:40 ECS
3 Day 13:40~16:00 TPMS
16:00~17:00 　 Wrap Up
Module 1. AT ( Automatic Transmission )
 Explain the system mechanism by observing a transmission

layout.
 List the locations, mechanisms and functions of
Learning components.
Objective  Explain the power flow in each gear shift by observing the
solenoid valve operation chart.
 Take necessary actions after a part change and list the
Automatic Transmission 10
Introduction
Power Power
generating transmission
device device
Engine  Transmission  Thrust shaft  Final gear & Differential gear

 Wheels Changes and transmits the torque
and rotation speed of the engine
to the wheels according to a
vehicle's driving environment
Specification
Categories A6GF1 A6MF1
Applicable Engines ν-1.8MPI, γ-1.6 MPI Lambda- 3.3, / 3.8
Allowed Max. Torque (kg.m) 18kgf-m 33.5/45kgf-m
Length (mm) 373 387

Weight (kg) 73 94
1st 4.400 4.651
2nd 2.726 2.833
3rd 1.834 1.842
Gear
4th 1.392 1.387
Ratio
5th 1.000 1.000
6th 0.774 0.722
R 3.440 3.390
Clutch 2 Set (OD, 35R) 2 Set (OD, 35R)
Compon
Brake 3 Set (UD, LR, 26) 3 Set (UD, LR, 26)
ent
OWC 1 Set 1 Set
Features
 Roller type OWC
converter
housing  Plate type return
shift cable
solenoid valve bracket spring
connector
manual  Flat type torque
air control lever
converter with slip
breather
control
T/M case
 Integrated seal &
Inhibitor
piston
switch
 Paracoid oil pump
rear
valve body cover  Eliminated oil level
cover feed gauge
tube
 Wiring harness
module
 Closed type side gear
 Valve body with

hydraulic pressure
adjusting screw
4 pinion type (A6M/LFx) 2 pinion type (A6GF1)
Layout
RR Planet Carrier
Oil Pump Ass’y
MID Planet Carrier
Converter Housing
L/R Brake FRT Planet Carrier
Torque Converter
OWC
O/D Clutch
2/6 Brake
35R Brake
U/D Brake
Input Shaft
Bear Cover
T/M Case
Output Shaft
Diff. Drive Gear

T/F Drive
Diff. Ass’y
T/F Driver
Parking Gear
AT Procedure to control the gear shift
Hydraulic Mechanical
Electronic Section
Section Section
Solenoid Clutch & Planetary

Input Signal Control Unit
Valve Brake Gear
In & Out speed UD & OD & UD & 26 & LR/B Front

Oil Temperature TCM or PCM 35R & 26 35R & OD/C Middle
Switch SSA & SSB OWC Rear
Input & Output Elements

VFS (UD)
Power & Ground
VFS (OD)
Input & Output

VFS (35R)
Speed sensors
Wire Wire
VFS (26)
Oil Temperature
Sensor TCM
VFS (PCV)
Inhibitor Switch VFS (T/C)
SS-A
Sports mode Switch
CAN
SS-B
ECM
ABS/ESC
Engine RPM
TPS / APS -Vehicle Speed
Intake air flow
Torque Convertor - Mechanical Components
Damper
Clutch
turbine
Fluid Clutch
Impeller
① Impeller
② Turbine
Stator ③ Stator
External appearance Internal Structure
 Can shift gears without cutting off engine power
 Absorbs sudden torque change that can occur
during gear shift
 Absorbs sudden weight load change on the drive
axle
 Improved acceleration at low speed through torque
increase
Mechanism
Damper Clutch - Mechanical Components

Piston moves
Slightly foRearard
Turbine Turbine
Impeller Impeller
Stator Stator
Input shaft Input shaft
Apply pressure Apply pressure
Vented
Vented
Damper clutch applied Damper clutch released

Planetary Gear - Mechanical Components
Ring gear
Sun gear
Carrier
Pinion gear
Deceleration, acceleration and A power transmission device that changes

constant-speed driving the gear ratio for different gear shifts
take place without gear shifts
Brake & Clutch - Mechanical Components

O/D clutch OWC
(roller type) 35R clutch
26 brake
LR brake
U/D brake
not applied applied
Location Operating Principle
Under drive brake Holds sun gear of first planetary gear set
Brake Pack
Low & reverse
Holds rear planetary carrier & Clutch Pack
brake
(Plate & Disk)
2/6 brake Holds sun gear of second planetary gear set
One way clutch Holds planetary carrier of third planetary gear set
Connects sun gear of middle planetary gear set to

3/5/R clutch
input shaft
Connects planetary carrier of rear planetary gear set to input One Way Clutch
Over drive clutch
shaft
Oil Pump - Hydraulic Control Components
Oil Flow
L/UP clutch
release
L/UP clutch apply

O/Pump Hsg Contact DR Pressure
Lubrication Surface
35R clutch
26 brake ① ②
③
Outlet
Inlet from valve body

① DA Pressure
Inlet from oil filter 35R Clutch / 26 Brake
② LUB(FRT) Contact Surface
③ 35R Pressure
Location 26 Brake Pressure ② LUB (FRT)

③ 35R pressure
Valve Body - Hydraulic Control Components
35R PCV
26 PCV
T/CON(VFS,N/L)
35R(VFS,N/H)
26(VFS,N/L)
UD(VFS,N/H)
REGULATOR
VALVE OD(VFS,N/H)
SS-B(ON/OFF)
SS-A(ON/OFF)
LINE Pressure
REDUCING (VFS,N/H)
UD PCV
VALVE
OD PCV
Valve Body Comparison - Hydraulic Control Components

Categories A5HF1 A5CF2 (New alpha 5-Speed
A6GF1, A6MLFx
(HIVEC 5-Speed) for Small-Sized Sedans)
Valve Body
Assembly
Structure (Pieces) 3 PCS 2 PCS 3 PCS
Line pressure variable control Line pressure variable control Line pressure variable control
Control
T/CON release control T/CON apply control T/CON apply control
VFS: 6 Pcs. VFS: 1Pc. VFS: 1Pc.
Solenoid valve
ON/OFF SOL: 2 Pcs PWM: 6 Pcs. PWM: 6 Pcs.
7 Components 2 Components 2 Components

Pressure Control Line Pressure (1), Reducing Pr Line Pressure (1), Reducing Pr Line Pressure (1), Reducing
essure (2), and PCV (4) essure (1) Pressure (1)
Terminal Module Terminal Connection Module
Location A/T Side A/T Side A/T Bottom
Fail-Safe D4 D3 D3
Main Valve - Hydraulic Control Components
Regulator valve Manual Valve
Adjusts line pressure generated Connected to the gear shift level in the driver's seat for line
by oil pump into hydraulic pressure supply to valves by converting flow according to
pressure suitable for gear shifts gear shifts
Solenoid valve Pressure Control Valve
Control Exhaust
Supply
Uses hydraulic pressure received from the

Controls the pressure control valve according to pressure valve to operate the clutch and
gear shifts brakes for gear shifts
Accumulator - Hydraulic Control Components
Inner valve
To Clutch or Brake body
N-D
accumulator
Spring
Piston spring & piston
T/M case
Accumulator
spring &
piston (5EA)
Input & Output Speed Sensor - TCU Input Components
Output speed sensor
0.7V 1.4V Hall Effect
Integrated one unit
Input speed sensor Sensor power

: 8~9V
Specification category A : Output speed sensor

Model Item Number B : Input speed sensor
PG-A Cup PG-B Cup A B
42620-3B100 - Black Black Black
A6LF1/2
42620-3B110 - Green Green Green
42620-3B300 - Black Black Black
A6LF3
42620-3B310 - Green Black Green PG-B cup PG-A cup
42620-3B600 - Blue Blue Blue
A6MF1/2 42620-3B610 - Brown Brown Brown
42620-3B620 - Gray Gray Gray
42620-26000 Yellow Red Red Red
A6GF1
42610-26010 Yellow Blue Blue Blue
Color B Color A
Inhibitor Switch - TCU Input Components

Inhibitor switch Cable Adjustment
is needed
P
+ R Shift lever
N
D
- Cable
< Shift lever operation > Inhibitor Switch
Inhibitor Switch
Range P R N D
Signal 1 Signal 2 Signal 3 Signal 4
S1 1 0 0 0
S2 0 1 0 0
S1 S2 S3 S4 S3 0 0 1 0
PCM S4 0 0 0 1
Switch Signal
Switch Circuit
OTS (Oil Temperature Sensor) - TCU Input Components
Oil Temperature
Sensor
TCU 5V
43 Ω
R1
Low
resist Inversely
V out ance proportional
(Ω) relation
R_sensor R2
4.68 Ω
-40 ℃ 165℃
Temperature (℃)
Solenoid Valve - TCU Output Components
PCM
Internal resistance 17
LP VFS (-)
(Ω) at RT
- VFS: 5.1±0.3 16
UD VFS (-)
Line Pressure - On-Off: 10~11 OTS

5
(VFS, N/H) Sol. Power
1
11
26 VFS (-)
12
SS-B (-)
SS-A
(ON/OFF) Input 2
speed T/C VFS (-)
7
T/CON OD VFS (-)
SS-B
(ON/OFF) (VFS, N/L) 10
Sol. Power
OD (VFS, 2
N/H) 35R 6
UD (VFS, 35R VFS (-)
N/H) 26 (VFS,
N/L) (VFS, N/H)
18
Output SS-A (-)
speed
Solenoid Valve Description - TCU Output Components
Category Item Feature Shape
Non-control of solenoid
N/H (Normally High) valve(0~50mA) Hydraulic pressure
VFS supply (26B, T/Con)
(Variable
Force
Solenoid) Control of solenoid valve(850mA)
N/L (Normally Low) Hydraulic pressure supply (Line
pressure, 35R, UD, OD) Line 35R, UD,
pressure OD
SS-A
LR/B operation converts operating
(Shift Control Solenoid
pressure of OD/C & LR/B to LR/B
Valve-A)
On/off sol.
SS-B
35R/C operation changes flow
(Shift Control Solenoid
direction to current gear shift
Valve-B)
Solenoid Valve Control - TCU Output Components
Solenoid Valve Operation Table
Element Solenoid Valve Operation
1st
UD/B OD/C 35R/C 26/B LR/B OW SS-B SS-A T/CON LP 35R/C 26/B OD/C UD/B
C
P/N ○ Off On 0 0 852 0 0 0
R ○ ○ On Off 0 0 0 0 852 852
1 ○ △ ○ Off Off 0 0 852 0 852 0
2 ○ ○ Off Off 0 0 852 852 852 0
3 ○ ○ On Off 0 0 0 0 852 0
D/S
4 ○ ○ Off Off 0 0 852 0 0 0
5 ○ ○ On Off 0 0 0 0 0 852
6 ○ ○ Off Off 852 0 852 852 0 852
• 1st OWC : ON (8kph↑), OFF (6kph↓)

• Failsafe of solenoid valve failure: 4th gear hold.
Clutch & Brake Operation Table
Brake Clutch
Range OWC
LR UD 26 O/D 35R
P/N ▲
R ● ●
D 1 ●X ● ●
1 ● ●
2 ● ●
3 ● ●
D/S
4 ● ●
5 ● ●
6 ● ●
●: Hydraulic pressure is applied. ▲: Hydraulic pressure is applied but no power is transmitted.

Power Flow – 1st Speed
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
Power Flow – 2nd Speed
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
Power Flow – 3rd Speed
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
Power Flow – 4th Speed
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
Power Flow – Reverse Speed
F1 B2
(LR/B) B3 B1
(UD/B) (26/B)
Out
C2
C1
(OD/C)
(35R/C)
PG3 PG2 PG1
IN
Oil Level Adjustment ※Oil Filler Cap

Close: Parallel to oil pan.
Open: Perpendicular to oil pan.
1. Open the oil filler cap and
add 700cc of ATF (SP-IV) at first.
2. Start the engine and keep idle speed.

(Do not warm up by stall test)
3. Warm up until oil temperature is 55℃ (50~60℃)

(Using the scanner)
4. Move the shift lever from P to D two times and

put on P range.
5. Lift up the vehicle and remove the overflow plug.
6. If oil drops, assemble the overflow plug

because it is normal.
7. OtheRearise, add some oil and repeat from step

1 Caution
until it drops. - Overflow gasket should be replaced with new
※ If oil was totally drained, pour 5ℓ and then perform
the above procedure. one.
- Tightening torque of overflow plug: 3.5~4.5 Nm
TCM Learning
[ Auto T/A Reset]
Time to perform TCM Learning: To reset after replace the Auto T/A.
 A/T assembly replacement [ Conditions ]

1. ACC on
 TCM replacement 2. Shift lever is on P
3. Vehicle speed 0 km/h
 TCM reprogramming 4. Engine off
Category Shift Conditions Repeat Common Conditions
Engine speed < 700RPM.

UD/B ND
Stay in N for more than2 sec
Oil Temp. = 40~90℃
3~4 times There must be no APS
26/B 12 change during shifts
APS = 10~30% (15~20% (within 3%).
35R/C 23
recommended)
OD/C 34
Practice
Theory Revision
 The necessity of an automatic transmission

 Process of gear shifts based on fluid movement
 Gear shift power flow (reference: Brakes/Clutch Operation Chart)
Measurement
 Input/output speed sensor waveform measurement

 Create inhibitor switch signal codes
 Create oil temperature sensor graphs
 Measure solenoid valve currents according to gear shift power transmission
Service Procedure
 Check current data

 TCM Learning
Module 2. 4WD (Four Wheel Drive)
 Explain the function of each of the four types of 4WD.

 Describe the system layout and list the locations,
Learning mechanisms and functions of components.
Objective  Explain the difference between ITM, ITCC and DEHA.
Four Wheel Drive 43
Introduction
2 Wheel Drive 4 Wheel Drive

Four Wheel Drive 44
Benefit of 4WD
< 2WD > < 4WD >
 Delivers power to all four wheels in harsh driving conditions for a stable start-
off
 Stable high-speed driving
 Prevents uneven distribution of power during acceleration after cornering for stable driving
Four Wheel Drive 45
4WD Types
Four Wheel Drive 46
History of 4WD
EST  2H ↔ 4H: Moving vehicle

(selective 4WD)  4H ↔ 4L: Activate switch after
stopping
TOD  AUTO ↔ LOW: Activate switch after

(constant 4WD) stopping
 Switch off: AUTO mode on

ITM & ITCC & DEHA
 Switch on: FW/Rear power distribution
(constant 4WD)
fixed at 50:50 (speed 40km/h↑: power
distribution automatically changed to
100:0)
Four Wheel Drive 47
Layout
CAN Communication
Transfer •ECM
Drive case •ABS / ESC
shaft •TCM
•Cluster
warning lamps
Propeller
Shaft
Engine
4WD coupling Rear

differential
Transmission
control module
(location differs by system)
Four Wheel Drive 48
Main Components
Output to
front right wheel
Transfer
case
Prop shaft
Rear differential
4WD coupling
Front
differential
Output to Engine
front left wheel
Four Wheel Drive 49
Transfer case
2 Axis Type 1 Axis Type

Four Wheel Drive 50
Type of 4WD Coupling
Input 4WD ECU 4WD coupling
Judge the Decide an optimal

4WD operation
driving state torque distribution
ITM ITCC DEHA

(Interactive Torque (Intelligent Torque (Direct Electro
Management) Controlled Coupling) Hydraulic Actuator)
Four Wheel Drive 51
4WD Lock Switch & Lamp
4WD Lock Switch
Mode Torque Remark

Distribution
Auto 0:100 ~ 50:50 -
4WD 50:50 (fixed) 30kph or less
Lock
4WD Warning 4WD Lock

Lamp Lamp
Four Wheel Drive 52
Input & Output
 Types of 4WD – ITM & ITCC & DEHA
Wire
Battery & EMC
Ignition Power (Electro Magnetic Clutch)
Wire In case of ITM, ITCC
Hydraulic Motor
4WD Lock Switch 4WD ECU In case of DEHA
Pressure sensor Diagnosis

Only DEHA
CAN
ECM ABS/ESC TCM MDPS Cluster

Engine RPM ABS/ESC Active Gear position Steering Angle Sensor 4WD Lock lamp
Engine torque Wheel Speed Sensor Only ITM & DEHA 4WD Warning Lamp
Only ITM & DEHA
TPS (APS)
Four Wheel Drive 53
4WD Operation
Normal driving Cornering
Wheel slip Locking

Four Wheel Drive 54
Comparison ITM & ITCC & DEHA
Wia Magna powertrain

Manufacturer` BorgWarner (US) JTEKT (Japan)
(ROKorea)
ITM(Interactive Torque ITCC(Intelligent Torque DEHA (Direct Electro
System name
Management) Controlled Coupling) Hydraulic Actuator)
Applied Model Tucsan(JM) / SM Tucson ix(LM, 2010) / EN Tucson ix(LM, 2011~) /DM
Operating Electronic magnetic coil Electronic magnetic coil
Electro-hydraulic motor type
method (EMC: Electronic magnetic coil) (EMC: Electronic magnetic coil)
Operating mode AUTO / 4WD LOCK AUTO / 4WD LOCK AUTO / 4WD LOCK
Weight Approx. 8.0 kg 9.125 kg 8.2 kg
ECU / magnetic coil / ECU / magnetic coil / ECU / motor / hydraulic pump /
Inspect
ball lamp / wet friction material ball lamp / wet friction material piston / wet friction material
Wheel speed sensor Wheel speed sensor Wheel speed sensor
Input sensor
APS, SAS APS APS, SAS
External
appearance
Four Wheel Drive 55
ITM Overview
Front Axle
TPS
Active Wheel
4WD Lock switch Speed Sensors
Steering Angle
4WD Lock Lamp
Sensor
Transfer Case ITM Coupling Control Module Rear Differential
* ITM (Interactive Torque Management)

Four Wheel Drive 56
ITM Coupling Structure
Armature Base cam

Electro Magnetic Clutch under the driver seat
Clutch
housing
Input shaft
Secondary plates (10 EA)
Secondary clutches (10 EA)
Output shaft
Primary Apply cam

clutches (3EA)
Primary plates (3EA) Steel balls (6EA)
Four Wheel Drive 57
ITM coupling operation
Primary torque
in base cam
Clutch housing
Apply cam ② Apply Ball cam at rest
Force
Base cam
Back
plate
Secondary clutch
③ Output torque
① Primary torque to Rear Axle
in base cam
Four Wheel Drive 58
ITCC Overview
4WD ECU
Transfer ITCC Coupling
located in driver side
case
4WD Lock switch (LH) dash panel & Rear differential
4WD Lock TPS

Lamp
4WD Warning Active Wheel

Lamp Speed Sensors
* ITCC (Intelligent Torque Controlled Coupling)

Four Wheel Drive 59
ITCC Coupling Structure
Control Cam
Ball
Main Cam
under the driver seat
Shaft
Front H/G
Rear H/G
Electro-magnetic Coil
Main Clutch
Armature Control Clutch

Four Wheel Drive 60
ITCC coupling operation
Zero Current
current flows
Magnetic Flux
Torque ECU
Pilot cam Primary torque
at rest in base cam
Input
Output
Four Wheel Drive 61
DEHA Overview
4WD ECU
Transfer located in the DEHA Coupling
case right of the dash & Rear differential
4WD Lock switch
panel
4WD Lock TPS

Lamp
4WD Warning Active Wheel

Lamp Steering Angle Speed Sensors
Sensor
* DEHA (Direct Torque Controlled Coupling)

Four Wheel Drive 62
DEHA Coupling Structure
Pressure
Sensor
under the driver seat
Actuator Clutch pack
Bleed valve Oil seal cover
Flange and input shaft Hub
Piston
Four Wheel Drive 63
DEHA coupling operation
4WD ECU
② ①
Vehicle drive
Actuator
③ ④
⑤
Propeller shaft Input Output Rear differential
Clutch clamped
Piston
Four Wheel Drive 64
Towing of 4 WD vehicles
FROM FRONT
FROM REAR
METHOD 1. FLAT BED TRUCK

METHOD 2. WHEEL LIFT TYPE TRUCK
Four Wheel Drive 65
Clutch Wear Compensation Only DEHA
① When replacing the coupling only
Replace  Reset the mileage
② When replacing the ECU only ③ When replacing the ECU and
coupling at the same time
Check the mileage  Replace the ECU

 Enter the mileage in new ECU No compensation Procedure
Four Wheel Drive 66
Cautions
 Keep horizontal position !!
- When remove, replace coupling
- Warning label attached
CAUTION !
Keep the unit in HORIZONTAL POSITION
Caution! Keep the unit in a horizontal position
 Never attempt to check, refill, replace coupling oil !!

- Filled for life
Apply grease
(Coupling input spline side)
 Apply grease
- Apply grease to coupling input spline
when re-assembling coupling
Four Wheel Drive 67
Practice
Theory Revision
 The Purpose of 4WD and the Necessity of Differentials

 Difference between the four modes (normal, cornering, wheel slip, locking)
 4WD operation by coupling type
Measurement
 Measure throttle position with lock on/off, driver torque and clutch duty
 Measure EMC duty during idle mode, 4WD mode and acceleration
Service Procedure

 Clutch Learning Reset & Reset & Write
Module 3. ESC (Electronic Stability Control)
 Describe the history of ESC.
 Describe the system layout and list the locations, mechanisms

Learning and functions of components.
Objective  Describe the valve operation that takes place in the oil pressure
circuit during normal operation, ABS operation and ESC
operation.
 Take the necessary measures after changing parts.
Electronic Stability Control 69
Introduction
A system that stabilizes

the vehicle’s behavior
Evolution of Active Safety System
ABS ESC VSM (ESC + MDPS)
Anti-wheel lock Independent wheel control Wheel/steering wheel control

ESC Control Logic
① Driver’s Intension
-Steering Wheel Angle
-Braking Pressure
-Brake Pedal On or OFF ③ Comparison
Difference
is large
② Actual Vehicle Difference

Behavior is small
-Vehicle Rotation Angle
-Vehicle Speed ⑤ Brake & Engine
Control
④ Not control
Understeering & Oversteering
Understeering Oversteering
System Components
Steering
Angle Sensor
HECU
Yaw Rate -
Pressure G Sensor
Sensor
Wheel Speed
Sensor
Cluster
Brake
ESC OFF Switch
Switch
Wheel Speed Sensor Wheel Speed Sensor
Passive Type
Hub
Tone
Wheels
Active Type
Category Passive Type Active Type
Output
waveform
Coil Hall IC
Function Detects vehicle speed and wheel-locks

Yaw-rate & 2 G-Sensor
Yaw Rate Sensor

Measures steering
angle speed with the
vertical axis as the Location
center when
cornering
Lateral G-Sensor Facing ahead
G-Sensor Longitudinal Measures lateral

acceleration caused
Measures
by centrifugal force
longitudinal
acceleration caused
by sudden braking or
sloped surfaces
Lower section of console

(within 3cm of the vehicle
center)
Steering Angle Sensor
MDPS
Complete
Torque Sensor Absolute Angle Sensor
Rotor (output)
Magnet (input)
Angle sensor
Torque sensor
ESC OFF Switch
On the Dashboard
Lift Up or brake test bench Dynamic Driving Snow Chains
Multi-Level Switch Control
Stage 1 OFF
1-STEP 1-STEP 2-STEP Engine Torque Control OFF
Display Type Brake Control ON
ESC
ESC Change Change
Stage 2 OFF
OFF
OFF
Engine Torque Control OFF
Brake Control OFF
ESC HECU
Motor
HCU Operates the
Solenoid Valves Hydraulic pump
Opens/closes to regulator
control pressure in
each of the four
wheels
Pump
Pumps and
returns oil to the
ECU master cylinder
Uses signals from
input elements and Pressure sensor
controls hydraulic
Measures braking
pressure when in pressure when
danger
sudden braking
Hydraulic circuit
Pressure Sensor
ESV TCV TCV ESV
Pump Element Pump Motor Pump Element
ISV ISV ISV ISV
OSV OSV OSV OSV
Left rear Right front Left front Right rear

Normal braking
Valve Electrically Condition
ESV Off closed
TCV Off open
ISV (LR) Off open
ISV (RF) Off open
OSV (LR) Off closed
OSV (RF) Off closed
ESV TCV TCV ESV
ISV ISV ISV ISV
OSV OSV OSV OSV

ABS braking
① Normal braking ② Hold Mode ③ Dump Mode

Valve Electrically Condition Valve Electrically Condition Valve Electrically Condition
TCV Off open TCV Off open TCV Off open
ISV Off open ISV On closed ISV On closed
OSV Off closed OSV Off closed OSV On open

ESV Off closed ESV Off closed ESV Off closed
ESV TCV TCV ESV
ISV ISV ISV
OSV OSV
Normal braking Hold Mode Dump Mode

ESC Braking
① Primary circuit
TCV On closed
ESV On open
ISV (LR) Off open
ISV (RF) On closed
OSV (LR) Off closed

ESV TCV TCV ESV
OSV (RF) Off closed
② Secondary circuit
ISV ISV ISV ISV
TCV On closed
OSV
ESV On open
ISV (LR) Off open
ISV (RF) On closed
OSV (LR) Off closed
OSV (RF) Off closed

Warning Lamp & Indicator Lamp
DBC ABS
ESC ESC EBD

OFF
Maintenance
Variant HCU Air G-Sensor SAS

Coding Bleeding Calibration Calibration
Prevents
bubbles in brake oil  After replacing ESC
HECU
 After replacing MDPS
 When zero-point
calibration is required
 After replacing ESC HECU
 After wheel alignment
 After replacing Yaw-rate & 2 G-Sensor
Practice
Theory Revision
 The Purpose of 4WD and the Necessity of Differentials

 Difference between the four modes (normal, cornering, wheel slip, locking)
 4WD operation by coupling type
Measurement
 Waveform measurement using a wheel speed sensor
Service Procedure

 Variant coding feature
 HCU Air Bleeding
 G Sensor Calibration
 SAS Calibration
Module 4. EPB (Electronic Parking Brake)
 Explain the difference between the two types of EPB.

Objective
 Describe EPB's functions and the purpose of AVH.
Electronic Parking Brake 87
Introduction
Mechanical Parking Brake Electronic Parking Brake

Comparison of EPB Type
CALIPER TYPE CABLE TYPE

Caliper Type Layout
EPB
EPB MIL Lamp
S/W State Actuator

Operation
EPB Switch EPB ECU EPB Actuator

In Disc Brake
System Components
Neutral Switch
AVH Switch (M/T Vehicle)
EPB Switch
EPB Actuator
(LH, RH)
Clutch Sensor
(M/T Vehicle) EPB ECU
EPB & AVH Switch
Pull
 Apply
EPB
Switch
Push
 Release
AVH Switch
In case of M/T Vehicle
Clutch Sensor Neutral switch
Potentiometer
Lever mechanism
EPB Actuator
EPB Caliper
Hydraulic pressure
 Braking
Powers up
actuator motor EPB Actuator
Motor  Parking
EPB ECU
brake
Components and Functioning Order
DC Nut Brake
Gears Spindle Piston
Motor Spindle pad
EPB Lamp & AVH Lamp
EPB
AUTO
HOLD
EPB Warning Lamp AVH Warning Lamp

Switch not working Switch working Failure Standby Active Failure
AUTO AUTO AUTO

EPB EPB EPB
HOLD HOLD HOLD
In/Output Elements
Wire
EPB Switch EPB Actuator
Wire (RH)
AVH Switch
EPB ECU
EPB Actuator
Clutch Sensor
(LH)
(M/T Vehicle)
Neutral Switch
(M/T Vehicle)
CAN
ESC ECM TCM Cluster

Cable Type Layout
EPB
EPB MIL Lamp
S/W State Actuator Parking

Operation EPB
EPB ECU
Actuator
EPB Switch EPB Unit Drum Brake

= EPB ECU + EPB Actuator
System Components
Neutral Switch
AVH Switch (M/T Vehicle)
EPB Switch
EPB Unit
(EPB ECU + EPB Actuator)
Clutch Sensor
(M/T Vehicle)
EPB Unit
EPB Actuator
EPB Unit
Rear Suspension Frame EPB ECU
Force
Sensor
Parking
DC Motor Gear Box Cable
(Left & Right)
In/Output Elements
Wire
EPB Switch
AVH Switch
Integrated EPB Actuator
EPB ECU with ECU
Clutch Sensor
(M/T Vehicle)
Neutral Switch
(M/T Vehicle)
CAN
ESC ECM TCM Cluster

EPB Functions
Item Function
While stationary, manually control the EPB switch to engage

Static Apply & Release
or release the parking brake.
Auto Apply Automatically engages parking brake without switch control
Drive Away Release Automatically releases parking brake without switch control
Reduced Clamp Force on Flat Controls the parking brake force corresponding to the incline
Surface of the road
Hydraulic brake is applied for the duration of holding down the

Electric Controlled Deceleration
EPB switch in an emergency situation (linked with ESC)
In case of vehicles without ESC, or in case of ESC failure,
Rear Wheel Unlocker deceleration is achieved by activating the actuator when EPB
switch is pulled.
If vehicle speed data is not available due to system failure, the
Dynamic Standstill Detection vehicle stopped state is determined through acceleration
sensor signal and EPB is activated.
If vehicle slide is detected while EPB is engaged, EPB is
Roll Away Reclamp
activated again for increased brake force.
AVH (Automatic Vehicle Hold)

After stop, Vehicle stop Push the Vehicle can start
Pull brake pedal holding acceleration pedal
AVH Switch ESC HECU Hydraulic Brake
CAN
EPB Cluster
Brake Pad Change (Caliper Type)
To replace the
brake pad
2. Nut spindle back

1. Worn brake pad
with GDS
3. Piston back 4. Change brake pad

BED-IN (Cable Type)
Adjusts drum-lining
clearance
2. Press Foot Brake 3rd
1. Ignition on, Engine on times (10 seconds↓)
3. After Applying EPB S/W

4th times, Release EPB S/W 4. Driving at 50kph↓
3rd times (10 seconds↓)
Practice
Theory Revision
 Caliper/cable-type Layout
 EPB/AVH warning lamp
 Purpose of Secondary Functions
Service Procedure

 Brake pad change (caliper-type)
 Bed-in mode (cable-type)
Module 5. MDPS (Motor Driven Power Steering)
 Describe the history of MDPS.

Objective  Verify the control logic in the current data.
Motor Driven Power Steering 106
Introduction
Appropriate direction and

torque are required for
turning in a desired direction
Steering wheel operation Motor Start Enables wheel-turning

Development background
Steering Wheel
Steering Wheel
Column
Motor
Column
ECU
Reservoir Hose & Tube Shaft
Shaft Torque & Angle

Sensor
Pump
R&P Gear
Rack & Pinion Gear
• No oil leakage,
replacement not
required
< Hydraulic Power Steering > • Electric power steering < Electric Power Steering >
• Enhanced fuel efficiency
• Reduced components
(lightweight)
Categorization by Motor Location
Column-type Pinion-type Rack-type
Suitable for small and Suitable for mid-size

Suitable for large vehicles
medium vehicles vehicles
System Configuration
2 Torque & Angle Sensor
Detect steering torque and
directions
1.Steering Wheel
Driver’s inputs
(Steering torque
4.BLAC Motor and direction)
Convert electric force
to mechanical force
5. Shaft 3.Electronic Control Unit

Transfer the torque Controls the DC motor
from worm gear with torque, steering angle
to pinion and vehicle speed
6. Rack & Pinion Gears

Convert the pinion torque
to rack movement
Mechanism
1) Steering Effort
(Manual Torque)
Torque, Angle Power
Vehicle speed
ECU Engine Speed
Torque &
Angle Sensor
Motor drive
Motor location detection
(Assist Torque)
2) Assist
Torque Motor
1) + 2)
Manual Torque + Assist Torque

= Output Torque
3) Tire Reaction Force 3) Tire Reaction Force

MDPS Assembly
BLAC motor
Input shaft
Output shaft
ECU Torque & Steering

Angle Sensor
MDPS Assembly
Torque & Angle sensor assembly

Torque & Angle sensor assembly
: Two in One package model
: Separated output
Torque – Two analogue voltage
Angle – Two PWM signals
[ Torque Sensor + Absolute Angle Sensor ]
Rotor (output)
Magnet (input)
Angle sensor
Torque sensor
Torque sensor mechanism
Torsion-bar
distortion
Magnet rotation
T2
Magnetic field
intensity change
Voltage output
through hall IC
Collector
Collector
Stator
Stator (output)
(output)
Hall
Hall IC
IC
N S N S N S
T1
Magnet
Magnet (input)
(input)

Mechanism
Main Gear
Hall IC 1
Steering turn
Hall IC 2
Hall IC 1
Gear 2
Main gear
rotation
Gear 1
Rotation of two Magnet Hall IC 2
planetary gears
(different numbers
of gears)
Rotating angle
detection (hall
IC)
Steering angle
calculation
Motor
Rotor
Brushed Motor
Stator
Calculating
Steering
Torque Assist
angle
Torque BLAC Motor
INPUT & OUTPUT
Power, Ground
M Motor Assist
D Control
Torque & Angle
Sensor P
S
IGN ON E Warning lamp Control
(Cluster)
C
U
Vehicle speed,
ECM
Engine speed
CAN
Control logic
OVER HEAT PROTECTION OVER LOAD PROTECTION

100%
Operating torque(6Nm)
Motor Assist Torque
Torque
Releasing torque(2Nm)
85%
Time
Rated current(35A)
Current
Minimum current(10A)
-30 0 50 80
Unit Temperature Time
Control logic
Speed-Sensitive Assist Control Restoration Control
Vehicle Speed Increase (kph)
Restoration Torque
Assist Torque (N.m)
Km/h
Steering angle
Maintenance
Variant Vehicle ASP DTC

Coding Alignment Calibration Clear
Normal (Average) 1. Set the steering wheel

straight ahead
Sport (Heavy)
2. Ignition key ON, Engine Stop
Comfort (Light)
3. Press ‘reset’ button on the
scanner
4. Turn the steering wheel until
the next message shows
5. IGN OFF for 10 sec
6. IGN ON and click ‘OK’ button
Flex Steer
Current
Wire CAN
Vehicle
speed
Practice
Theory Revision
 History of MDPS
 Operating Order of System Components
 Input/output Elements
Service Procedure

 Variant Coding
 Steering angle sensor calibration
 Vehicle Alignment
Module 6. ECS (Electronic Control Suspension)
 Describe the history of ECS and different types of control.
 Describe the system layout and list the locations, mechanisms

Learning and functions of components.
Objective  Create a pneumatic circuit for vehicle height control by ECAS.

Electronic Control Suspension 123
Introduction
Coil spring or air spring
ECS ECU
Rear wheel
suspension
Variable damping shock

Front wheel
absorber
suspension
Conventional suspension system ECS (Electric Control Suspension)
Cannot provide both ride comfort and Controlled to suit different driving
driving stability conditions
for both ride comfort and driving stability
History of ECS
Electronically
Controlled Air Damping Control
Suspension
Variable damping Tire

Coil spring ECU
shock absorber
Electronic Control Air Damping + Height Control

Suspension
Air spring Variable damping Tire ECU

shock absorber
Electronic Control Suspension - Layout
Output
Input
ECS Lamp
Body G Sensor ECS ECU

(FL, FR, RR)
Continuously
CAN
Variable Damper
ECS Switch
Wheel G Sensor
ESC(ABS)
(FL, FR) EMS (for WSS & MDPS
(for RPM & TPS) (for SAS)
brake switch)
Front wheel Rear Wheel
Continuously Variable Damper
Spool valve
9
- Hard Mode
- Soft Mode
Damping
force
Solenoid (Kgf)
valve
0.3 0.8 1.3
Current (A)
Oil Flow
Soft Mode Mode Hard Soft
Hard Mode
Shock Absorber Common Orifice width
Sensors according to ECS
Front wheel CDC
FR FL RL
Identifies wheel
Detects vehicle's
operation
top/bottom movement
and damper speed
Body G sensor (FL, FR, RL) Wheel G sensor

(FL, FR)
Detects vehicle speed
Detects roll
SAS WSS
(Steering Angle Sensor) (Wheel Speed Sensor)
ECS Mode Switch & ECS Lamp
 Push : Sport Mode

 Return: Auto Mode
ECS mode switch ECS Lamp

Body G sensor
ESS relay
(FL, FR, RR)
Wire Wire
Damping force
Wheel G sensor
(FL, FR) ECS ECU variable solenoid
(FL, FR, RL, RR)
ECS mode switch ECS Lamp
CAN
ECM ABS/ESC
MDPS
Engine RPM -Vehicle Speed
TPS -Brake switch
System Control
Item Description Input element Control
Body G Sensor (3EA)

Top/bottom vibration suppression when
Wheel G Sensor (2EA)
driving on an inflected surface
ECS mode switch
Ride control logic (pitch, bounce) Road Detection 
Skyhook Control

Left/right vibration suppression during turns
ECS mode switch
Anti-roll control logic
Wheel Speed Sensor

Front/rear vibration suppression in braking
-Brake switch
Anti-dive control logic
Solenoid control 
Front/rear vibration suppression in sudden
TPS Switch to hard damping
start-offs
force
Anti-squat control logic
Improved driving stability in high-speed

ECS mode switch
driving
Speed sensitive control logic
Skyhook
CDC Damper
General damper
(SKYHOOK)
Control
Input
soft soft
ECS System
Body Movement Up Up Down Down Up Down
Damping Force Soft Hard Soft Hard Hard Hard Conventional
Electronic Control Air Suspension
Category Past (XG, LZ) Current
System Control Open Loop Control Closed Loop Control
Response time 21 - 26 sec Approx. 5 sec
Vehicle height control Step 4 Step 3

mode (Low, Normal, High, Ex-High) Low, Normal, High)
Step 4
Damping force mode Non-staged control
(Soft, Auto Soft, Medium, Hard)
Air spring
Air spring
Coil spring
Spring shape
solenoid valve
Damp
(external)
er
Components
Rear Wheel
Variable ECU
Air Filling valve Front Air Strut Damper G sensor
(3EA)
Air Filling valve
Vehicle
height Air Tube
Compressor and sensor Rear Wheel Air
Air Tank Spring
Solenoid Valve (4EA)
Layout Control Section
G Sensor Height Pressure Switch

Sensor sensor
SPORT High
ECS ECU ECS Lamp

Air Pressure Section
Air Filter Solenoid Absorption Section

Valve
Air spring (rear-wheel)

Air Tank Air filling valve
compressor Air spring + variable damper (front-wheel)
Absorption Section
Body
Variable
air spring damper
Damping force
Real-time
adjustment
vehicle height
adjustment according to road
surface types
Air Tube
Joint
Variable damper
air spring
air spring
Variable
damper
Front Air Strut Rear air spring, variable
(integrated air spring and variable damper) damper (detachable)
Absorption Section - Continuously Variable Damper
Current input
Plunger
 Plunger moves
- Hard Mode
 Orifice-passing volume control
- Soft Mode
 Damping force control
Piston Valve
0.0_A
Elongation
Control
Valve
1.6_A
Speed
1.6_A
Orifice
0.0_A
Compressed
Mode Hard Soft
Orifice width
Air Pressure Section

Air filter (gray)
Air Filling valve FR spring (red) RR spring (green)
#4
RL0 spring (yellow)
Air Tank
Air Tube
Compressor (blue) Pressure sensor (internal)
Gasket
(Vertical piston movement  Air compression)
Air Dryer Air port
Pressure release Filter paper

valve
Reversing
Compressor valve
Air
motor Pressure
Pressure Sensor solenoid valve Discharge
< Compressor > < Valve Block > < Air filter >
Control Section
Located inside
the valve block
Pressure sensor
Shaft
Magnet
HALL IC
Measures vehicle
Measures vehicle height body's top/bottom
change through hall IC acceleration
Height Sensor Acceleration Sensor
Control Section - ECS Mode Switch & ECS Lamp
High
Vehicle height
control switch
(High / Normal)
On the cluster
Damping force
control switch SPORT
(Auto / Sport)
ECS Mode Switch

On the cluster
ECS Lamp
Solenoid Valve(4EA)
Vehicle height sensor
(4EA)
Exhaust valve (1EA)
G sensor (3EA) Wire Wire
TCM Reversing valve (2EA)
Pressure sensor
Compressor relay
ECS mode Switch

Variable damper valve
CAN (4EA)
ECM ABS/ESC
MDPS
Engine RPM -Vehicle Speed
TPS -Brake switch
System Control
Automatic/manual vehicle height control
Vehicle Level Control through air spring control (air supply/discharge)
CDC damper's variable damping force controlled

Damping Control for ride comfort and driving stability
Compre Tension
ssion
Vehicle Level Control
+30mm
Level Operating Mode
Offroad mode Maintain specific vehicle clearance
HMI switch (Vx≤70kph) Vehicle height adjustment (HMI/vehicle speed)
HMI switch
Vx>70kph for 10s
(Vx≤70kph)
DRIVE state
Drive Stopped
0mm
STANDSTILL state
Normal mode
ENG ON ENG OFF
Vx>120kph for 10s Vx<80kph for 5s
Vx<40kph IGNITION state
IGN ON IGN OFF
WAKENING state CARLIFT state

Highway mode
Wakeup ON Wakeup OFF
-15mm
SLEEP state
• STANDSTILL balancing
• DRIVE balancing
Air Pressure Circuit
Open Loop (past) Closed Loop (current)
Air spring
Air spring
Atmosphere
compressor
Reservoir
Compressor
 Exchange with external air at every supply  Exchange with external air from leakage and
discharge temperature adjustment only
 High-pressure system
 Low/high-pressure system
 Repeated vehicle height control at a consistent
 Limited number of vehicle height control at a speed
consistent speed
 High energy efficiency
 Low energy efficiency  Compressor operation time/volume optimized
 Complex system
Air Flow - air injection
air filter Air spring
13
12
Compressor
7
4
10 9
1 8
3
2 Solenoid valve block

6
5 11 Air Filling
Reservoir
valve
11. Air Filling valve  6. Reservoir  5. Reversing Valve  1 Compressor

 4. Reversing valve  8. Solenoid valve block  Air spring
Air Flow – Vehicle height increase
13
12
Compressor
7
4
10 9
1 8
3

6
5 11 Air Filling
Reservoir
valve
6. Reservoir  5.Reversing valve  1. Compressor  4. Reversing Valve

 8. Solenoid valve block  Air spring
Air Flow – Vehicle height decrease
13
12
Compressor
7
4
10 9
1 8
3

6
5 11 Air Filling
Reser
valve
voir
Air spring  4. Reversing Valve  1 Compressor  2. Dryer

 3. Check valve  5. Reversing Valve  6 Reservoir
Air Flow – air injection
13
12
Compressor
7
4
10 9
1 8
3

6
5 11 Air Filling
Reser
valve
voir
13. Air filter  1. Compressor  2. Dryer

 3. Check valve  5. Reversing Valve  6 Reservoir
Air Flow – Air discharge
13
12
Compressor
7
4
10 9
1 8
3

6
5 11 Air Filling
Reser
valve
voir
6. Reservoir  5. Reversing Valve  3 Throttle  2. Dryer

 4. Reversing valve  7. Barometic pressure valve  13. air filter
Air Flow - Practice

Air supply unit
Sol. Valve Block
Draw air flow in hands-on training notebook
RR AIR AIR FILTER

FR AIR SPRING
AIR
SPRING
COMPRESSOR
ECU SOL VALVE

RESERVOIR
Cautionary Measures for Handling Different Parts
Buckled spring
Air In-flow
Dropped vehicle body Buckling Remove spring and

install a new one Do not hold when loading/moving
Rear air spring Front Air Strut

Designated tools
O-ring damage Classification
Contaminant-blocking plug prevention Cut surface Code
Check color match Marking (check color)
solenoid valve Air Tube

Air Filling
If air is filled with the vehicle body dropped down:

Air spring buckling can occur
Attached to vehicle body or

10-20mm apart
Normal Faulty
① Check air spring state ② Vehicle lift-up
Air Flow
Air-filling process
Air Tank
Air Filling valve
Diagnostics
Device Front-wheel air spring
(Injection pressure
12± 2 Bar)
Rear Wheel Air Spring
Air Tank
③ Connect diagnostic device ④ Connect GDS and fill air
Height Sensor Calibration
Initialization timing Objective

 Reinstalling the air spring for a replacement or
 Maintain specific vehicle clearance
disassembly
  Maintain stable control
Replacing the vehicle height sensor
  Improved ride comfort
Replacing the lower arm, knuckle, or other
suspension parts
 Replacing the ECU with a new one
Vehicle height input (Normal Level)
Top edge of
wheel housing
Reference
height (mm)
GDS connection
Wheel center
Maintenance Measures by Case

 ESC ECU change
Component Variant Height Sensor

ECU Reset Adjustment
Normal
change coding
 Pneumatic unit/buffering unit change
Component Height Sensor

Exhaust Air Filling Adjustment Normal
change
Reservoir  Air spring air discharge

Cautionary Measures for Towing

Moving the vehicle before filling air Towing the vehicle to a service center
- The angle at which the vehicle can be
- Air spring crumpling/falling-out
towed depends on its state (possible
- Air spring damage interference)
Normal mode  10° or less Off-road mode  13° or less Fullbump  7° or less
Fullbump_Offroad  5° or less Offroad_Fullbump  6° or less

Practice
Theory Revision
 Purpose and Mechanism of the Variable Damper and Air Spring of ECS
 Skyhook Control Mechanism
 Vehicle Control Conditions and Air Flow Control
Measurement
 Measurement of input currents in the variable damper for damping force
control
Service Procedure

 Air filling
 Variant Coding
 Height Sensor Calibration
Module 7. TPMS (Tire Pressure Monitoring System)
 Explain the difference between the low line and high line of
TPMS.
Objective  Describe the mechanism of the main functions.
Tire Pressure Monitoring System 157
Introduction
Insufficient Tire Pressure
Prevention
Alarm on Cluster
Air Pressure is Low
Air Pressure is Low

USA Regulation / EU Regulation Alarm set level (RED LINE)
USA EU
• Alarm set threshold at PUS below 25% • Alarm set threshold at PEU below 20%
(PUS = Independent Value of tire (PEU = Value Depending on tire temperature)
temperature)
TPMS variation
Receiver
Sensor x 4
On the cluster
Low-Line High-Line
Warning Lamp Position Lamp Warning Lamp

System Layout (High Line)
 High Line TPMS : 1 Receiver, 2 Lamps, 4 Tire Pressure Sensors

 Low Line TPMS : 1 Receiver, 1 Lamp, 4 Tire Pressure Sensors
Receiver
(TPMS ECU) On Cluster
CAN
Into crash board
on passenger side
Position Lamp Warning Lamp

(High Line)
NO Initiators
EMS ESC(ABS)
(for vehicle (for wheel pulse
speed) signal)
Tire Pressure sensor (4EA)

= WE sensor
(Wheel Electronics Sensor) < Components Location >
Tire Pressure Sensor

 Pressure
 Temperature
 Acceleration
 Voltage of Sensor
battery
 Sensor ID
< Location >

Pressure Sensor Receiver
 TPMS WE Sensors have 4 modes as described in the following table.

Transmission
No Mode Description
Interval
13 Hours
1
MP • Keeping no motion status for 15 min.
(means almost
(Parking Mode) • Mode for parking and A/S part.
none)
• In MP, if sensor notice a change over 4g, MFB is activated.
2
MFB • This mode is kept only for about 10min. 16 s
(First Block Mode)
• Mode for Auto Learning / Location.
• In MFB Mode, it keeps moving condition (>4g) for 10min,
3
MD enter into MD mode. 64 s
(Driving Mode)
• In MI, if sensor notice a change over 4g, MD is activated.
• In MD or MFB, if it notice no motion (<3g), enter into MI
4
MI immediately.
None
(Interim Mode) (Preparing Mode)
• Mode for preparing
Tire Pressure Sensor Mode Example
① ② ③ ⑤ ⑥ ④
① First MP  MFB : If acceleration value is over 4g, it change to MFB.

② MFB  MD : If driving for about 10 minutes, it change to MD.
③ First MI : If no motion in MD, it is entered into MI immediately.
④ Second MP : If in MI mode for appox.15 min or longer, change to MP mode
⑤ Second MD : If sensor notices a change over 4g in MI, revert to MD mode.
⑥ Second MI : Same as number 3.
Receiver (TPMS ECU)

30 / 31psi
25% ↓ Hysteresis
= 4psi
26 / 27psi
Tire Pressure
CAN
< Location >
Position Lamp &
Receiver
Warning Lamp
 TPMS Receiver has 3 modes as described in the following table. (MODE for RECEIVER not sensor)
NO Mode System Remark

-TPMS operation test
1 Test Mode Normal
- Mode for factory Line
- A Sensor ID is not registered
2 Virgin Mode Not operated
- Mode for A/S part
- Registered Sensor ID
3 Normal Mode Normal
- Normal Operating Status
Warning Lamp
Warning Lamp
Position Lamp
Normal operation Wrong operation
Normal mode
(Start up check mode)
TPMS doesn’t learned sensor ID(s)
Virgin mode
(A sensor ID isn’t stored)
No low pressure tire Low pressure lamp on operation
Low pressure lamp
Normal operation Malfunction lamp on operation
Malfunction lamp
Primary Function
No Function Description Remark
Under-inflation Warn on = RCP × 75% + 7kpa = 172kpa(25psi) Margin exists for hysteresis
1
detection Warn off = RCP - 14kpa = 207kpa(30psi) (+7, -14kpa)
Only Activating in driving

Tire fast leak
2 Sensing a rapid air leak over 20kPa/min (3psi/min) (To avoid activating a driver
detection
deflate a tire on purpose)
VS over 25kph / 1 RF Frame (Known ID)

VS over 25kph / 8 RF Frame (Unknown ID) Failure condition
3 Auto Learning : about 10 min
* VS : Vehicle Speed
VS over 25kph / 10~40 RF frame

Failure condition
4 Auto Location Accumulating information of wheel pulse from
ESC/ABS every 16 sec
: 40 times (40*16=660sec=11min)
Turning on warning lamp via system diagnosis.

5 Self-Diagnosis DTC set.
Refer to DTC Sheet.
Auto Learning
FL Sensor ID FR Sensor ID
#99900001 #99900002
Stored ID
In Receiver
Matching
# 99900001 RL Sensor ID RR Sensor ID
# 99900002 #99900003 #99900004
# 99900003
# 99900004
#99900005
RR Sensor Replace
#99900005
After RR Sensor is replacing,
if completing Auto Learning,
ID 99900004 is deleted and
ID 99900005 is newly stored
automatically.
* This is example for Auto Learning.

IDs are randomly assigned.
Auto Learning
 
25 kph ↑
Driving
Minimum 15 minute Parking Auto Learning Done
 Learning ID of WEs equipped with vehicle, then storing it in ECU

 Known sensor : 1RF signal over 25kph in MFB. (it takes less 1min including time for mode
changing)
 Unknown sensor : 8RF signal over 25kph in MFB.
Auto Location
FL Sensor ID FR Sensor ID
#99900001 #99900002
Stored ID
In Receiver Location
# 99900001 - FL Matching
RL Sensor ID RR Sensor ID
# 99900002 - FR
#99900003 #99900004
# 99900003 - RL
# 99900004 - RR Change
Tire Location Change
After tire location is changed,

if completing Auto Location,
ID 99900004 is newly stored for RL and
ID 99900003 is newly stored for RR
automatically.
* This is example for Auto Location .
IDs are randomly assigned.
TPMS Receiver replaced
OR
Tread lamp off
Register ID,…
A/S new ID registered

part (Normal
(Virgin X mode)
4EA
mode)
OR
VS>25kph
after 15min parking
Tire Pressure Sensor replaced
3 ways exist for registering sensor ID into Receiver Sensor ID
< 1. Automatic Input by Exciter and GDS > < 2. Manual Input by GDS >
VS>25kph
after 15min parking
< 3. Auto Learning >

GDS in TPMS
Double Click  Input ID
Manual registering
sensor ID
Automatic registering
sensor ID
Can read sensor

status data
Sensor mounting (1/2)

Step1 Step2
Step3 Caution
OK NG Caution :
If you push the
front side of
housing to rim
direction, valve
can be off original
position.
Sensor mounting (2/2)

Step4 Step5
Step6
Handling Cautions
Put a removal guide to the

position which has a some
distance from the sensor
[A destroyed sensor during tire Pressure sensor

removal from the wheel]
Guide should position behind the sensor
Rotating
direction
Sensor position
Practice
Theory Revision
 Warning lamp difference in the low-line and high-line

 Location and Layout of Components
 Mechanism of Auto Learning and Auto Location
Service Procedure

 Wheel Sensor ID Writing
 Sensor Status
 Register Sensor

PL2 - Basic Chassis - Slide - H - Eng2

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SDP PL-Ⅱ Chassis Basic

Basic Chassis Technology

At the end of the session, you will be able to

Describe the system layout and list the locations,

Read the manual and use appropriate tools to measure

Take necessary actions after a part change and list the

Module 1. AT Module 2. 4WD Module 3. ESC Module 4. EPB

Module 5. MDPS Module 6. ECS Module 7. TPMS

Basic Chassis Technology

Lecture Room Practice Room Lecture Room

• Post-part-change • Measure standard

Day Time Module

09:00~09:15 Course Intro

2 Day 11:30~15:00 EPB

3 Day 13:40~16:00 TPMS

 Explain the system mechanism by observing a transmission

Engine  Transmission  Thrust shaft  Final gear & Differential gear

Applicable Engines ν-1.8MPI, γ-1.6 MPI Lambda- 3.3, / 3.8

Allowed Max. Torque (kg.m) 18kgf-m 33.5/45kgf-m

Length (mm) 373 387

 Closed type side gear

 Valve body with

Diff. Drive Gear

AT Procedure to control the gear shift

Solenoid Clutch & Planetary

In & Out speed UD & OD & UD & 26 & LR/B Front

Input & Output Elements

Input & Output

Inhibitor Switch VFS (T/C)

Torque Convertor - Mechanical Components

Damper Clutch - Mechanical Components

Damper clutch applied Damper clutch released

Planetary Gear - Mechanical Components

Deceleration, acceleration and A power transmission device that changes

Brake & Clutch - Mechanical Components

not applied applied

Location Operating Principle

Connects sun gear of middle planetary gear set to

Oil Pump - Hydraulic Control Components

L/UP clutch apply

Inlet from valve body

Location 26 Brake Pressure ② LUB (FRT)

Valve Body - Hydraulic Control Components

Valve Body Comparison - Hydraulic Control Components

Structure (Pieces) 3 PCS 2 PCS 3 PCS

7 Components 2 Components 2 Components

Main Valve - Hydraulic Control Components

Regulator valve Manual Valve

Solenoid valve Pressure Control Valve

Uses hydraulic pressure received from the

Accumulator - Hydraulic Control Components

Input & Output Speed Sensor - TCU Input Components

Output speed sensor

0.7V 1.4V Hall Effect

Integrated one unit

Input speed sensor Sensor power

Specification category A : Output speed sensor

Inhibitor Switch - TCU Input Components

< Shift lever operation > Inhibitor Switch

OTS (Oil Temperature Sensor) - TCU Input Components

Solenoid Valve - TCU Output Components

Line Pressure - On-Off: 10~11 OTS

09:00~09:15 　 Course Intro