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1 - Technical Highlight -
BL-1 : 소요시간 15분 1. Greeting. - General -         Brief course introduction -         First impression (Korea and 천안 center) 2. My introduction. Including Choan Training center. - address -         Web site 3. Try to make them comfortable and relax 1. Good morning, gentlemen. I’m so pleased to be with you with the Sorento New vehicle training course. We will have 5 day training schedule starting from Monday to Friday. From Monday to Wensday I’ll be with you and Chassis and Auto transmission with TOD lessons will be followed. The overall time schedule during your training term is like the table that we’ve already passed over. How was your trip to Korea? Is it your first time to visit Korea? Raise your hand! Who are the first time visitors? (Point out the person and ask his or her first impression) Mr How about your first impressoion on this contry and 천안 technical center ? 2. Now, I’d like to introduce myself briefly. My name is Andy Kim and and I’m in charge of overseas engine training section. If you have any question on this subject, please feel free to contact me anytime. You can easily reach me by , (Wrighting down) or you can connect to our web site. Let’s go to the Sorento’s world together. - Technical Highlight - Chonan Technical Service Training Center

2 Sorento

3 Development Working Period Name Brand
“ 22months work ” Model Fixing : Mar. ‘00 Design Completion : Aug. ’00 Pilot Model : Oct. ’00 ~ Jun.’01 P1 : Sep. ‘01 P2 : Nov. ‘01 PP : Dec. ’01 Mass Production : Mar. ’02. Working Period Name (High styling, High Performance with Hi-Tech) Line-Up: LX, TLX, LIMITED Brand

4 Style Exterior ● Aggressive and Strong Characteristics
- High and Enough Volume Hood - Solid type & Hi-Tech image Head Lamp - Simple Body color bumper guard ● Simple body line & Empathized edge - Side window graphic emphasized Sporty looking - Sufficient Volume & Hard Side view - Enlarged Side-garnish ● Wide opening & Highly Stable feeling - Emphasized Back door volume & edge line - Solid type large rear combination lamp - One body Rear step with bumper & Sporty Rear-Spoiler

5 Front View ⊙ High dignity and Excellent quality
BL-3~6 : 소요시간 10분 강의목표 : 슬라이드를 보면서 간단히 설명 위주로 진행. Introduce the developing concept and bench marking model When it comes to Sorento’s bench marking models, Toyota 4 runner for performance and style, Grand Cherokee and Lexus RX300 for interior and convenience are there. Outstanding image line with big size radiator grills give us high performance SUV impression. . ⊙ High dignity and Excellent quality ⊙ High power and High prestige ⊙ Cd = 0.435 ⊙ O.A.W. : 1863 mm (1884mm: Side garnish)

6 Side View ⊙ Slant Edge and thick image line of stylish appearance
Powerful front view and elegance rear view with highly roominess interior space 140 마력의 신형 COMMON RAIL 방식의 A – TCI ENGINE. 도전적이고 남성적 이미지의 북미 TREND 반영 SHARP한 EDGE 와 특징적인 IMAGE LINE 구성으로 인한 STYLEISH APPERANCE Wheel base 증대 및 넓은 전폭으로 거주성 확보. ⊙ Slant Edge and thick image line of stylish appearance ⊙ Enjoying out-door activity and leisure ⊙ O.A.L. : 4567 mm (4625mm : Bumper guard) ⊙ Wheel Base : 2710 mm

7 Rear View Rear glass flip open type and computer controlled rear wiper ⊙ Distinguished luxury rear view styling with modern and refined image ⊙ Rear glass flip open type ⊙ Electronic controlled rear wiper by ETACS ⊙ O.A.H. : 1726mm (1806mm : Roof rack)

8 Sorento Sorento leads the style of SUV in the world automotive market
ML320 (BENZ) X-5 (BMW) RX300 (LEXUS)

9 Sorento Interior Active NVH reduction and simple modulated in-panel. The modulated in-pal is supplied by Hyundai Mobis. Now Let’s look at the competitive models of the Sorento. Emblem 적용 안된 사진. ⊙ Sensible interior image with practicality and dignity ⊙ 4-poke leather steering wheel ⊙ Easy control and combination for best drive condition ⊙ Human Sensitibility Engineering Technology ⊙ Highly roominess interior space with simply Modulated in-panel

10 Various function & High quality for Seats
Sorento Various function & High quality for Seats ● Improved Rear Seat - Movable Center Head-rest & Arm-rest ● Strengthen Seat Design - Style / Feeling / Comfortable ● Enlarged Rear trunk space - Luggage Rail – Easy loading - Clean & Smart image

11 Maximized space for Convenience
Sorento Maximized space for Convenience Upper tray Ticket holder Center tray Ash tray (Automatic) Driver’s Tray Glove box (2 story tray) Floor net tray Open tray (On center console) Big sized cup holder 2 Story console box Seat under tray Front seatback tray Rear arm rest tray Front door pocket Rear door pocket Rear side tray Rear net tray

12 Front: Double Wishbone, Rear: 5Link Coil
Sorento Package L X W X H 4567×1863×1726 Power Train A2.5 CRDi, Σ3.5, S-II 2.4 Suspension Front: Double Wishbone, Rear: 5Link Coil Tire P245/70R16, P225/75R16 1580 1863 2710 887 1030 60˚ 4567

13 Sorento Driving Performance A2.5 CRDi Σ3.5 S 2.4 2WD 4WD 5M/T 4A/T
Max. Speed (Km/h) 168 171 170 192 167 158 0 → 400m 19.0 19.1 19.2 19.4 16.9 17.0 18.7 0 →100Km/h 14.3 14.2 14.6 14.5 9.7 10.2 15.7 60 →100Km/h 9.3 8.5 9.5 8.8 5.6 5.8 15.1 8.7 Fuel Efficiency 100km Const. (5th, D4) 11.4 13.1 11.2 12.4 9.2 8.9 10.5 Model Item Acceleration

14 Same level of NVH as High leveled Gasoline Vehicle
Sorento NVH Improvement Same level of NVH as High leveled Gasoline Vehicle Reduce Engine Vibration Balance Shaft Remove Timing Chain Noise Chain cover shield Reduce Engine Side Noise Cylinder block shield Reduce Engine Noise Bed plate

15 Sorento Silent Idle Idle Vibration Idle Noise (dB) Sorento Rexton
Santafe S/Wheel 107 120 118 Floor 93 106 102 Front Damping Sheet Strengthen Frame & Structure Idle Noise (dB) Sorento Rexton Santafe Noise 47 48 50 Booming 70 87 83 2 folds Dash Panel Structure 3 Points Mounting

16 Sorento Power train BODY Eng. T/M T/F North Europe General LHD RHD
America Europe General LHD RHD 4Door 5Seat A2.5TCI (CRDI) 5MT 4WD 4AT Σ3.5 (V6) 2WD SIRIUS-Ⅱ (2.4ℓ I4) BL-9 power train schedule 강의목표 : 각 국별 적용시기 / 적용 power train 1.     Introduction for scheduled mass production time. 2.     Mention this information for reference. This slide is for the available time of the mass production by each power train. Firstly CRDI A-2.5 liter engine is introduced on April 1st. for Europe and General area. On June 1st, Sigma 3.5 liter engine in Sorento is scheduled for KMA. Sirius liter will be developed by July 1. RHD model and 3.5 liter for general and European market is scheduled on September 1st. As you may know through this slide there is only one M/T with Sirius 2. The sigma 3.5 liter engine for general and European market has only A/T. All mentioned and explained M/P time and available power train will be changeable in the final stage. Just use this information for your reference. ※ Above available spec. by regions could be changeable in final fixing stage.

17 Sorento Engine view – Σ 3.5 (V6)

18 Sorento Engine view – Sirius-Ⅱ (2.4ℓ)

19 Sorento Engine view – A 2.5 TCI (CRDI) BL-10 ~12 Engine view
This is A-engine’s front view. Next is Sigma 3.5 liter and the last is for Sirius liter

20 Sorento A-2.5 TCI (CDRI) – High Speed Direct Injection
■ Increasing specific power and fuel economy - DOHC 4 valve swing arm with roller and Direct-Injection(DI) - Turbocharger with intercooler - State-of-the-art Electronic Diesel Control(EDC) by Bosch with Common Rail - Electronically controlled high precise injectors - High injection pressure up to approx. 1,350 bar ■ Decreased Low emission and NVH - Pilot injection prior to main injection - Balance shafts and rubber case - EGR system with oxidation catalytic converter - Cam carrier and leather frame

21 Sorento High Pressure Line – Common Rail

22 Sorento Comparison Competitive Models(Diesel) 112/4,000 160/3,800
115/3,800 120/4,000 103/3,800 145/4,000 M.Power(Ps) 26.5/1,750 38/2,000 26.5/1,900 25.5/2,400 24/2,000 33/2,000 M.Torque(kg-m) 2,874 Daewoo Rexton 1,950 3,200 2,171 2,476 2,497 Displacement (cc) LandRover Freelander Mitsubishi Pajero Opel Frontera Hyundai Teracan Kia Sorento Maker/Model BL-7 Competitive models 강의목표 : 각 국별 경쟁모델 및 판매량 price range 확인 – 질문사용 1.     Competitive models in each contury.(SUV position map 자료 활용) 2.     Sigma 3.5 and Sirius 2.4 What is the Sorento’s competitive models in your country ? Is it common using the common rail diesel system ? (showing the position map and ask to the trainee on this question) Point out someone and get the answer with price range and sales volmun. In my study, the Sorento’s competitive models are like these shown in the slide (Point out the each line in the slide). Actually the Sorento is in the middle low grade of SUV by size. Besides mentioned vehicles in the slide there are several more competitives such as Nissan X-terra and Isuze rodeo. I’m not sure there is the Rexton by Daewoo in your contruy but the rexton uses Benz’s IDI( in direct injection) diesel engine. Comparing to the Sorento’s maxium output the Sorento’s is better than that of the Rexton by 25 in power. When it comes to the Teracan of Hyundai, it utilizes the same Common Rail engine with carnival for European market. But the maxium output power is a little bit better than that of carnival because of the balance shaft. Another difference is Carnival uses the Delphi common rail system. Moe detail things will be followed later.

23 Sorento Engine Specification Type Valve system DOHC
Items / Model A 2.5 TCI CRDI Σ3.5 (V6) SIRIUS-Ⅱ (2.4ℓ I4) Type IN-LINE 4 Cylinder V6 Valve system DOHC Max. Power (Ps/rpm) 145/4000 195/5500 140/5500 Max. Torque (kg-m/rpm) 33/2000 30/3000 20.2/3000 Injection Type Direct Injection MPI Displacement (cc) 2,497 3,497 2,361 Bore x Stroke (mm) 91x96 93x85.8 86.5x100 Compression ratio 17.7:1 10:1 Valve timing Intake Open(BTDC) 8’ 11.5’ 12’ Close(ABDC) 38’ 60.5’ 56’ Exhaust Open(BBDC) 52’ 43.5 54’ Close(ATDC) 20.5’ 14’ Valve clearance 0,(HLA) Idle Speed (rpm) 800±50 700±100 Ignition Timing (BTDC) - 10’ ± 2’ 5’±2’ Ignition Order BL-8 Engine specification 강의목표 : Sorento에 탑재된 3가지 engine에 대한 간략한 설명 1.     A-2.5 common rail 2.     Sigma 3.5 liter 3.     Sirius 2.4 liter The sorento’s diesel engine is adapted the common rail direct injection system. The electronic control system is from Bosch. Except the A-2.5 Diesel engine, there are two more gasoline engines in the Sorento. Sigma 3.5 liter and Sirius liter. (Point out the each line and explain shortly, looking at the slide) Detailed information in each system will be discussed later

24 Sorento Transmission ■ Manual Transmission : → M5UR1
■ Auto Transmission : → 30-40LEI BL-13~23A/T and convenience items 강의목표 : 각 engine 별 단품 사진 소개. Next several pages are for A/T system and convenience devices. You can have some time to know these kinds of things in Chassis and Electric lessons so I want to skip these slides. Just go to the page 21 in your text book. It’s time to know about basic diesel fundermental together. Before we go to the basic diesel theory, how about having a 10 minutes break. Next class will start from ※ The same transmission is adapted regardless of the Engine variation.

25 Sorento 4 Wheel Drive REAR AXLE REAR P/SHAFT T/M Electronic TRANSFER
FRONT P/SHAFT REAR P/SHAFT REAR AXLE FRONT AXLE T/M

26 Sorento EST Electronic Shift Transfer Manual control Between 2wd ↔ 4wd
Mode : 2H, 4H, 4L Maker: Borg Warner in USA Electrical gear shifting by driver’s lever operation

27 Sorento EST Components Planetary gear (4 LOW) Rear output TM input
Front input

28 Sorento TOD Mode : Auto, Low Full time 4wheel drive system
TOD: Torque on demand Maker: Borg Warner in USA TCCM: Transfer case control module TCCM controls load distribution to front wheel variously - 0: / :50 Mode : Auto, Low

29 TOD or ATT (Active torque transfer)
Sorento T/M input Front output shaft Rear output shaft Planetary gear (LOW) Multiple discs AUTO-LOW control TOD TOD or ATT (Active torque transfer)

30 Sorento ABS(Anti-Lock Brake System) ■ Bosch ABS 5.3
- 4-Sensor 4-Channel type - ABS with EBD type ■ Functions - Steerability - Stability - Stop Distance ■ EBD Electronic Brake force Distribution Brake force distributed by HECU instead of proportioning valve

31 EBD Modulation * EBD control example

32 Sorento Advantages of EBD
Significant improvements have been made in brake performance EBD with weight distribution sensor has been incorporated for the optimum function of 4 channel 4 sensor type. Approach to ideal brake-force distribution Adaptive to different loading conditions Constant brake-force distribution during vehicle life time Monitoring of EBD-function Minimal extension of ABS hardware required

33 Sorento S.R.S. Supplemental Restraint System PAB Curtain airbag
DAB PAB Belt buckle sensor Frontal crash sensor ACU Pretensioner Load limiter Curtain airbag Supplemental Restraint System

34 Sorento FUNCTIONS of SRS Absorbs kinematics energy of occupants.
Protects occupants from interior trims. Protects occupants from broken glass. Reduces occupants neck load by kinematically restraining spin of neck. 에어백의 목적 탑승객의 동적인 움직임 즉 충돌시 앞으로 튀어나가는 힘을 흡수한다 차량 내부의 트림이나 장식으로 부터 탑승객을 보호한다 깨지는 유리로 부터 승객을 보호한다 과거 초창기 차량은 지금 창문에 사용하는 유리를 사용했다 그당시 교통사고가 나면 차량 유리에 찔려 중상과 출혈이 아주 심했슴 그럼 지금의 안전 유리의 제작 원리를 아시는 분은 ? 어떻게 나오게 되었나요 실험실의 비이커에 접착제를 넣어 놓운것이 약간 경화돤상태에서 높은곳에서 떨어지니까 유리가 금만가고 떨어지지 않는것에 아이디어를 얻음 지금의 유리는 한장의 유리에 투명한 접착제를 바르고 다시 한장의 유리를 붙이는 것임

35 Sorento AIRBAG SYSTEM OPERATING SEQUENCE Crash Crash Sensing 20m Sec
Bag Deploying Ignite the Inflator Full Deployment of the Bag Produce Nitrogen Gas to Inflate the Bag Protect the Occupants 이 페이지에서는 그림으로 보면서 앞장에서 본 것을 시간 대별로 볼수있습니다 여기에 있는 msec는 몇초를 의미 하나요 아시는분 먼저 1/10초 1/100초 1/1000초 1/1000초 어떤것이 맞나요 우리가 파형을 분석 할때 많이 보는 단위 입니다 105m Sec Vent Gas (Bag Deflation) Airbag System Completed

36 Sorento DAB & PAB ● Applied Depowered air bag Curtain Airbag
: Deployment pressure is 20~30% decreased in order to avoid passengers from injury by the Airbag itself - DAB : Membrane type - PAB : Invisible type DAB & PAB ● Protect passengers from Side impact - The curtain airbag will be deployed from roof trim to protect the occupants from side impact Curtain Airbag

37 Sorento Front Impact Sensor Seat belt system ● More accurate & Safe
- Newly developed safety device - The FIS senses a crash and send signal to ACU to deploy the Airbag FIS equipped No FIS FIS Front Impact Sensor Pretensioner & Load limiter Buckle sensor ● Pretensioner ● Load limiter ● Buckle sensor Seat belt system

38 Sorento Air-conditioning System ■ Auto Air conditioner (FATC)
■ Manual Air conditioner

39 Sorento Air Quality Sensor Humidity Sensor
Detects exhaust & harmful gas Automatic operating Easy installation on the existing vehicle. -Manual operation available. Air Quality Sensor Humidity sensor detects the relative humidity of the car’s cabin. This sensor converts it into the voltage signal and sends the signal to the FATC controller. Humidity Sensor THE OUTLINE OF AQS (AIR QUALITY SYSTEM) Most drivers generally select the recirculation or open air mode manually to intercept the inflow of harmful exhaust gas, in spite of inconvenience and danger, while driving. These harmful gases can be causes of tiredness, drowsiness or cough while driving. Although they detect the exhaust gas and manually close the inlet of the vehicles trapping the fumes inside, it is far too late to protect their health because they already inhaled the exhaust gas. Inversely, if driving with the inlet of the car closed completely, the shortage of air and the accumulation of carbon dioxcide (CO2) will be occurred. This causes fatigue, headache, enervation, and drowsiness. AQS gives a perfect solution to these problems. The Air Quality System detects exhaust gas of neighboring vehicles and intercepts automatically. AQS controls the inlet of car automatically and can be easily installed to the existing vehicle. Manual operation is also available. 센서 작동 원리는, 일단 IG KEY ON을 하면 AQS에 IG 전원(12V)이 인가 되고 AQS 내부의 가열 판을 35초 정도 예열을 하게 된다. 예열 완료 후 가열 판에 공기가 닿으면서 계속 연소하게 되는데 이 때 AQS 스위치를 선택하게 되면 AQS는 가열판 연소 가스를 감지하여 유해 가스 유무에 대한 신호를 FATC 컴퓨터로 전달하게 된다. 이 신호에 의해 내외기 엑츄에이터가 작동 하게 된다. 감지 대상 가스로는, 디젤 엔진 배기 가스인 NOX, SO2, 가솔린 엔진 배기 가스인 CXHY, CO 등이 있으며 가스 감지 후 반응 시간은 1초 이하이다.

40 Sorento BODY ELECTRICAL ■ ETACS ■ REAR WIPER SYSTEM
■ AUTO LIGHT CONTROL SYSTEM ■ RAIN SENSOR ■ MULTIMETER 이번 교육의 구성은 그 동안 기아자동차에 적용된 ETWIS 기능과 같은 ETACS의 제어하는 항목 및 그 상세 내용과 junction Box의 구성과 점검 방법, ECM에서 제어하는 충전장치의 구성 Control Module 과 Control Module과의 Communication 관계 Head light의 자동 On Off 제어기능인 Auto light System Rain Sensor에 의해 제어되는 Wiper Motor System으로 구성되어져 교육이 진행됩니다.

41 Sorento ■ ETACS : Electronic Time Alarm Control System
ETACS controls following items ; - Super lock function - Panic function - Two turn unlock - Washer related wiper - Variable Intermittent wiper - Seat belt warning - Ignition key hall illumination lamp control - Power window time lag - Battery saver (TNS function) - Keyless receiver

42 Sorento Rear Wiper Control - There are two relays in the
controller to control the motor rotation to clockwise or counterclockwise according to the potentiometer signal.

43 Sorento Auto Light Control - While the switch is in auto position
tail lamp and head lamp in on / off automatically regardless of the driver’s intention according to the surrounding brightness.

44 Sorento RAIN SENSOR  Function Detection of amount of rain
- By the Refract Ratio By the Rain drop times - By the Rain drop distance  Operation - Low, Mid, High speed – Auto mode Automatic Intermittent operation Selective Manual operating 이것은 Rain Sensor의 Components를 보여주고 있다. 이 센서의 위치는 Driving Room Windshield glass에 부착되어 비의 양을 감지 한다. 정확히 부착 위치는 Wiper Blade가 작동하는 범위 내에 부착 되어야만 한다 그 것은 Wiper Blade가 지나가 빗물이 씻긴 후 다시 덜어지는 비의 양을 감지 하여야 하기 때문이다.

45 Sorento Multi-meter  Operating Items
- Vehicle multi-meter is mounted on the roof trim giving driver accurate reading at a glance.  Operating Items - Compass - Altitude - Barometric pressure - Ambient temperature


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