1. 2010 Service Training

3. TYPE OF SUSPENSION McPherson Strut type Double Wishbone type The Mcpherson Strut type suspension is an independent suspension which has a spring on the strut with an integrated shock absorber. Because the spring and the shock absorber are integrated, this suspension provides major advantage in package space, and its whole assembly is very simple with fewer parts than other systems.

4. Front Suspension Arm assembly FR lower suspension Knuckle, FR Damper assembly, FR Link- Stabilizer bar, FR Stabilizer bar assembly, FR STRUCTURE OF SUSPENSION

5. Front Suspension System 1> Concept & Requirement) ① Concept ㉠ Macpherson Strut Type ㉡ Negative Kingpin Offset ② General Dimensions ㉠ Wheel Base : 2,650mm ㉡ Wheel Tread-Front : 1,555mm ㉢ Wheel Offset : 43mm ③ Specification ㉠ Wheel Stroke (Bump / Rebound) - 100mm / 80mm above ㉡ Turning Radius : 5.4±0.1m ㉢ Scrub Radius : -5 ~ -15 ㉣ Shock Radius : 50 ~ 60mm ㉤ Ackerman Tendency : 60 ~ 70% (Full Turn) ㉥ Percent Anti-Dive : 15% over ④ Assembly Requirement ㉠ Bolt Tightening Criterion - Bolt tightening of Link in condition 3-up Weight ㉡ Front Wheel Alignment Adjusting - Toe : adjustment with the Nut of Tie Rod - Camber : Non adjustment - Caster : Non adjustment SUSENSION SYSTEM Front Suspension

6. Lower Arm Assy-Front Knuckle Stabilizer Bar Assy Stabilizer Bar Link Assy Front Suspension System System composition (Configuration) ① Lower Arm Assy-Front - Lower Arm-Front - Bushing : 2EA - Ball Joint-Lower Arm ② Knuckle ③ Strut & Bumper Assy - Strut Assy - Bumper & Dust Cover - Spring Seat-Upper - Bearing - Pad-Spring Lower - Spring - Insulator Assy - Shock Absorber : Conventional Damper ④ Stabilizer Bar Assy - Stabilizer Bar : with Stopper - Bushing : 2EA ⑤ Clamp-Stabilizer Bar ⑥ Stabilizer Bar Link Assy SUSPENSION SYSTEM Front Suspension

7. Upper Link Assy Trailing Link Assy Spring Link Assy Stabilizer Bar Link Assy Stabilizer Bar Assy Wheel Carrier Assy (4WD) Wheel Carrier Assy (2WD) Track Rod Assy Rear Suspension System System Configuration ① Wheel Carrier Assy - Wheel Carrier - Ball Joint - Bushing-Spring Link - Bushing-Upper Arm ② Spring Link Assy - Spring Link - Bushing ③ Upper Link Assy ④ Track Rod Assy - Track Rod - Bushing ⑤ Trailing Link Assy - Trailing Link - Bushing - BRKT ⑥ Spring ⑦ Shock Absorber Assy - Conventional Damper - Bump Stopper ⑧ Stabilizer Bar Assy ⑨ Stabilizer Bar Link Assy ⑩ Stabilizer Bar BRKT SUSPENSION SYSTEM Rear Suspension

8. Arm assembly RR upper suspension Damper assembly, RR Track rod assembly Stabilizer bar assembly, RR Arm assembly RR lower suspension Arm assembly RR trailing suspension Caliper assembly STRUCTURE OF SUSPENSION

9. Transmission (rear) side mounting Engine (front) side mounting Front side body mounting Front side body mounting Front side body mounting Front side body mounting A. Body mountings : 4 bush mountings B. Engine mountings : 2 bush mountings C. Sub frame weight : 30.27 kg [4 body bush mountings, a engine mounting and a transmission mounting] STRUCTURE OF FRT SUB-FRAME Front Sub-frame The front sub frame consists of 4 body bush mountings and 2 engine bush mountings which reduce the vibration from the powertrain and road, and also control the torque.

10. [For 4WD: 4 body bush mountings and 4 direct axle mountings] Axle front side frame mounting Front side body mounting Rear side body mounting Axle rear side frame mounting A. Body mountings : 4 bush mountings B. Axle mountings : 4 direct mountings C. Sub frame weight : 19.30 kg STRUCTURE OF RR SUB-FRAME Rear Sub-frame (4WD) The rear sub frame system consists of body bush mountings and direct mountings which reduce the vibration transmitted from the powertrain and road to the vehicle body.

11. [For 2WD: 4 body direct axle mountings] Front side body mounting Rear side body mounting A. Body mountings : 4 bush mountings B. Spring link : Direct mounting to Rear cross member : No bracket C. Sub frame weight : 13.90 kg STRUCTURE OF RR SUB-FRAME Rear Sub-frame (2WD)

12. RH side Stabilizer HPS LH side RH side LH side EPS Stabilizer [Front sub frame for EPS] Rear axle assembl y E- coupling [Rear sub frame for 2WD] FRT STRUCTURE OF SUB-FRAME [Front sub frame for HPS] [Rear sub frame for 4WD]

13. [For 4WD][For 2WD] 1. Front drive shaft (LH) 2. Front drive shaft (RH) 3. Equivalent length shaft 7. Rear differential carrier 8. Rear drive shaft (LH) 9. Rear drive shaft (RH) SYSTEM CONFIGURATION 4. Power transfer unit 5. Propeller shaft 6. E-coupling

14. Front Wheel End (Drive Shaft) 1) IBJ (In Board Joint) - Inserting Type TJ (Tripod Joint) - Drive Shaft : Male - T/A : Female - Boot : CR (Rubber) - Max degree : 23 degree 2) OBJ (Out Board Joint) - Inserting Type BJ (Ball Joint) - Drive Shaft : Male - Hub : Female - Boot : TPE (Plastic) - Max degree : 46 degree 3) Specification for shaft length - LH : 2 type (M/T, A/T) - RH : 4type (M/T, A/T & 2WD, 4WD) 4) Equivalent Length Shaft application 5) 3 rd generation Bearing application Rear Wheel End (Drive Shaft) 1) 2WD (Wheel End) - 2 nd generation Bearing application 2) 4WD (Drive Shaft) 1>IBJ (In Board Joint) - Inserting Type CG (Cross Groove Joint)) - Drive Shaft : Male - Rear Axle : Female - Boot : CR (Rubber) - Max’ degree : 23 degree 2>OBJ (Out Board Joint) - Inserting Type BJ (Ball Joint) - Drive Shaft : Male - Hub : Female - Boot : TPE (Plastic) 3>Specification for Shaft length - LH/RH : 1 type (580.2mm) 4>3re generation Bearing application DRIVE SHAFT

15. System Configuration ① CV-Joint Assy : BCD Ø86 ② Serration Shaft ③ Tube : Ø60, 1.5t ④ Bending Absorber : in Tube ⑤ Tube Yoke ⑥ Universal Joint : Single Cardan ⑦ Mid Yoke ⑧ Center Bearing Assy (with BRKT) ⑨ Forked Tube Yoke ⑩ Alignment Support (Plastic Bush) ⑪ Rubber Coupling : BCD Ø90 ⑫ Deadener : 4 개 ①②③④⑤⑥⑦⑧⑨⑩⑪⑫ PTU Axle 128.0mm Center Bearing BRKT Rubber Coupling Propeller Shaft Assy (4WD Only) PROPELLER SHAFT

16. SYSTEM CONFIGURATION Equivalent length shaft Torque steer Equivalent length Shaft installation

17. SYSTEM CONFIGURATION Torque steer is a condition in which a vehicle pulls to either side because of an inequality of traction between the left and right driving wheels when a large torque is applied to the front wheel of a FWD or 4WD vehicle. Especially for a FWD vehicle, this mechanical condition can cause the steering effect because of the output torque (rotational force) produced by the gyroscope. This rotational force is due to the difference in distance between the left/right front wheels and the transaxle which leads to the change of the shaft articulation angle. To prevent this, the intermediate shaft, called equivalent length shaft, is adopted so that the articulation angle and the length are kept constant. What is Torque steer?

18. Steering wheel Column Pump Reservoir Hose & Tube Power rack & Pinion gear ECU Steering wheel Manual rack & Pinion gear Motor Torque sensor & Angle sensor (built-in) Column POWER STEERING Comparison Between EPS and HPS A. Hydraulic power steeringB. Electric power steering

19. WHEEL & TIRE 16-inch : 215/65R 1617-inch : 255/60R 1718-inch : 255/55R 18 Specification Wheel design ComponentsSpecificationsRemark Tire 16 inch215/65R 16Standard version 17 inch225/60R 17Optional 18 inch225/55R 18Optional Tire inflation pressure32 psi Wheel 16 inch6.5J x 16Standard version 17 inch6.5J x 17Optional 18 inch6.5J x 18Optional Weight balanceInternal insertion type Tightening torque for wheel bolt13 to 16 kgf.m 17 mm x 5 ea (length:100 mm)

20. Inject the sealant into the tire. Drive the vehicle to spread the sealant inside the tire. The puncture is filled with the sealant. SERVICE KIT Connect the service kit to the tire and activate the kit, then both air and sealant are injected into the tire automatically by the compressor. Drive the vehicle for short time to apply the sealant around the puncture site. The sealant becomes solid by the heat and vibration and the puncture will be filled with it.

21. a) Saving time If you change the flat tire with the spare tire, it takes about 30 minutes or so. But if you use the service kit, 10 minutes is enough. b) No need to be exposed to a dangerous place Because of the short working time, you don't have to wait for a towing vehicle or change the tire on a dangerous road with passing traffic. c) Less fuel due to the decreased weight The jack, spare tire and tools in the trunk can be replaced by only about five pounds of the service kit, and this leads to better fuel economy. Because the fuel economy is improved by 0.5 to 0.6% when the car weight is decreased by 1%. d) 90 percent of tire punctures can be repaired by the service kit e) Easy to use According to a survey, 66.2% of both men and women drivers and 97.2% of women drivers said he or she couldn't change a flat tire. This service kit is very easy to use, even for the women drivers. f) Easy to use and carry with compact size and light weight g) Can be used for all kinds of vehicle tires h) Enable to inject air and measure tire pressure In addition to flat tire repair, this kit can be used to add air and measure the tire pressure for safety. It is also possible to air up a tube. SERVICE KIT Advantages of service kit

23. A. Hydraulic power steering B. Electric power steering Hydraulic power steeringElectric power steering Steering detected byRotary valveTorque sensor Driven byOil pumpElectric motor Steered bySteering gear (Cylinder) Steering column (reducer) Steering gear Steering wheel Column Pump Reservoir Hose & Tube Power rack & Pinion gear ECU Steering wheel Manual rack & Pinion gear Motor Torque sensor & Angle sensor (built-in) Column POWER STEERING Comparison Between EPS and HPS The EPS receives the torque signal by the driver’s movements of the steering wheel, as well as the vehicle speed, and uses 3-phase BLAC motor to determine the motor torque. Then the EPS controls the motor to reach the target torque with the phase current of the motor and the signal from the rotation position sensor.

24. TYPES OF EPS SYSTEM C-EPSP-EPSR-EPS Photo Feature Assists the column to help the steering - Compact size - Typical for relatively light vehicles Assists the pinion of steering gear to help the steering - Typical for medium vehicle Assists the rack of steering gear to help the steering - Maximum steering force - Strong power transfer - Typical for heavy vehicles MOTOR

25. Motor Max 84Arms Ø90×112 Electric Control Unit Sine Wave Sub MCU (8bit) Reduction Gear Ratio : 18.5 Angle Sensor Non contact(MR IC) CAN 2.0b ESC Common Use possible Torque Sensor non contact (Hall IC) Column Below Type T/T Mechanism Roof Type MTG BRKT System Layout EPS ; Electric Power Steering POWER STEERING

26. DCBLAC Schematic diagram FeaturesCoil rotation (High inertia)Magnet rotation (Small inertia) Heat dissipationPoor (Convection & Conduction)Good (Conduction) Power Current supply limits (Heat dissipation) Enables high power State variable Angular velocityPosition sensor (Angle) BLAC MOTOR Specifications

27. Common point Rectification method Advantages / Disadvantages DC Output value linear to input current Mechanical contact type ■ Advantage: Low cost Simple power electronic circuit No high performance controller is required (MCU) ■ Disadvantage: Low durability High rotor inertia (long response time) Poor heat dissipation Low ratio of power to size BLAC Power electronic circuit ■ Advantage: High power density low inertia (short response time) High speed/torque capability Low maintenance cost High torque/inertia ratio Better heat dissipation ■ Disadvantage: High cost Rotor position sensor is required Complex power electronic circuit High performance controller is required (DSP) BLAC MOTOR

28. Yoke Stator core assembly Rotor assembly Bracket PCB assembly Coupling Bus ring card Bus ring card assembly Sensing plate assembly BLAC MOTOR

29. System overview itemscontentsremark 1operation temperature -40~ 80 ℃ 2rated voltage12 V 3Rated current85 Arms 4 Operation voltage Network8 ~ 16 V 5C-EPS ECU8 ~ 16 V 6Full Performance10 ~ 16 V 7 Motor methodBrushless 8Rated current/voltage85A / 12VIdle state : 0.5A 9Torque & Angle SensorNon contact 10 Column Operation methodTilt & Telescopic 11TiltLower Tilt 12Lower ShaftmetodSlidingBall Slip Type 13 Steering Gear Gear Ratio46.94mm/rev46.94 / 50.7 14Rack Stroke146mm EPS ; Electric Power Steering POWER STEERING

30. Outline decelerator Worm & Wormwheel ( 중수 : 2) MotorBLAC 84Arms (Ø90 x 112mm) T/SensorTorque & Angle Sensor (135 x 110 x 47mm) BLAC Motor G/Box Hsg Assy Input Shaft Assy TAS ECU Assy Tilt Hinge Hsg Cover Ass’y System Configuration 1>EPS Unit Assy EPS ; Electric Power Steering POWER STEERING

31. Outline ColumnLower Tilt/Telescopic : MSCL / ESCL T/LeverBelow Type : Plastic Lever Shaft specificationSliding Shaft Compression BRKT : Spring Retainer 추가 Lower BRKT : MTG Span 변경 Upper BRKT : MTG Span 변경 Tilt/Tele Lever System Configuration 2>Tilt & Telescopic Mechanism Assy EPS ; Electric Power Steering POWER STEERING

32. Outline Characteristic U/Joint : high output us Ball Slip and forging Yoke application Sliding specification : Plastic Bush + Ball Rolling Yoke specification : hot forging Forging Yoke Ball & Plastic Bush Shaft Joint Pipe Joint BallNeedle System Configuration 3>Universal Joint Assy EPS ; Electric Power Steering POWER STEERING

33. Steering system 1) Steering Wheel 1>Type : 3 Spoke 2>Armature : Mg (Magnesium) 3>Horn Switch : Floating Type 4>Weight : 2.1kg 2) Column Shaft 1>Power Assist Type - DOM : C-EPS (Option) - Europe export : C-EPS - General export : HPS 2>Lower Tilt Type (C-EPS) - Tilt & Telescopic - Friction Plate E/A - Steel Telescopic-Bush - Weight : Approx’ 13.5kg 3) Lower Shaft - Ball Slip Type POWER STEERING SYSTEM

34. 4) Steering Gear Box Specification (HPS) 1>IBJ to IBJ : 690.0mm 2>IBJ to OBJ : 346.8mm 3>Gear ratio : 46.94 4>Wheel Turn : 3.11 5>Rack Stroke : ±73 6>MTG Span & Type : 420mm 7>MTG method : 2 Point vertical Bush 8>Minimum rotation radius : 5.4m (Target) 5) Hose 1>High pressure Hose (HPS) - material : HNBR / HNBR - Swaging Part : Parallel 2 steps 토크 - Pump tightening part : Benjo Bolt 2>Low pressure Hose (HPS) - material : ACM / CSM Steering system POWER STEERING SYSTEM

35. Steering angle Steering effort Vehicle speed Manual torque + Assist torque = Output torque Steering effort ( ↓ ) = Load torque – Assist torque ( ↑ ) a. Steering effort (Manual torque) b. Assist torque c. Reaction force a + b EPS SYSTEM OPERATION The EPS system is similar to SSPS system, and this system controls the steering angle and steering force according to the vehicle speed. The system makes the steering effort slightly lighter with increased steering angle at the low vehicle speed, and makes the steering effort heavier with decreased steering angle at the high vehicle speed. Thus the steering can be controlled by the driver's will ensuring easier steering when parking and higher stability during driving.

36. Sizeø89 X 30 mm PackageTorque sensor & Absolute angle sensor Output value - Torque sensor: Analogue voltage - Steering angle sensor: 2 PWM signals Sub gear B Sub gear A PCB Assy SAS Magnet (2 ea) Lower case PCB guide Main gear Connector Middle case Stator holder Upper case Collector (2 ea) Rotor Assy Output shaft holder Stator tooth (2 ea) Yoke behind SAS (2 ea) TORQUE ANGLE SENSOR

37. Stator tooth Hall IC Collector Magnet Rotor yoke Structure of torque sensor 0 deg. position Alignment position: Center of stator tooth where both poles meet together Center of stator tooth Center of North pole Center of South pole Hall IC 22.5 deg. position Center of stator tooth Center of North pole Center of South pole Alignment position: Center of stator tooth which is the center of each pole TORQUE ANGLE SENSOR

38. Principles When a magnetic field is applied to a current flowing through a conductor, the electric current carriers in the conductor experience a force in a direction perpendicular to the magnetic field and current field. The newly developed electric field results in a potential difference and this effect is called Hall- effect. A Hall-effect sensor is based on this effect. The sensor converts the intensity of magnetic field into a voltage value. The torque sensor for EPS system uses a linear hall-IC to convert the value of intensity change in magnetic field strength into a voltage value. That is, the major function of the hall-effect type torque sensor is to detect the change in magnetic flux around the hall IC in accordance with the twist amount (angle) between the input shaft and the output shaft. TORQUE ANGLE SENSOR

39. LocationOn steering column Operating voltage rangeDC 8 V to 16 V Temperature range -40  C ~ 80  C Current consumption a. Operating currentat 0 N, DC 12 V500 mA b. Maximum input current at DC 11V with maximum output84 A c. Dark currentMax. 0.3 mA Part name 1Heat sink (Heat dissipation) 2Cover 3PCB 4Power module 5Motor connector 6Motor position sensor connector 7Signal connector (Vehicle + TAS) 8Power connector (DC battery) 9Bus pin module ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ EPS ECU Specifications Exploded view

40. CONTROL LOGIC DIAGRAM

42. GENERAL DESCRIPTION PTU AssyE-coupling E-coupling ECU Location: on the front LH floor Korando is similar to the conventional TOD system but it has additional systems including PTU which transfers power to the rear wheels and E-coupling (EMCD : Electro-Magnetic Control Device) which controls the power distribution.

43. The PTU is a device that transfers the power generated from the engine to the rear axle by changing the power flow direction by 90°. Specifications Overall length398.22 mm Weight21.5 kg (Including oil) Oil typeLW 80W-90 Capacity0.58 ± 0.02 L Oil change IntervalEvery 100,000 km Operating temperature-40 ~ 150°C PTU

44. Helical Gears Hypoid Gears Teeth : 22 Teeth : 39Teeth : 23 Teeth : 38 1>Function of PTU : Transferring engine torque to rear axle (90 degree) 2>PTU Oil Spec / Capacity : LW 80W-90 / 0.6L (Supplied with oil) 3>Operating temp. : -40~150 ℃ 4>PTU Gear Ratio : 2.929 = 39/22 (Helical Gears) X 38/23 (Hypoid Gears) T/A Front LH Front RH Rear P/Shaft PTU

45. Cover Hollow shaft Drive gear Hypoid gear Companion flange Helical gear shaft Pinion gear Pinion shaft PTU Power flow diagram

46. Components of PTU PTU [Cautions] - When installing the PTU to the transmission, apply the grease containing molybdenum to the PTU input shaft to prevent noise and damage. - Always pay attention while removing the PTU from the manual transmission, because the oil may runt out from the transmission. - When installing the propeller shaft to the PTU flange, align the markings on the joint of the propeller shaft and the PTU flange to keep the balance. - When towing the vehicle, load the vehicle on the towing truck or remove the propeller shaft. Otherwise, the E-coupling will be severely damaged or the clutch will be burned and stuck.

47. A. Specifications Overall length241.94 mm Weight8 kg (Including oil) Oil typeECF 107 Capacity0.145 L Torque 1000 Nm – 2.8 A at 50 rpm, 50 ℃ Operating temperature -40 ~ 120 ℃ Number of Mail clutch Outer clutch: 11 Inner clutch: 11 Number of pilot clutch Outer clutch: 4 Inner clutch: 3 E-COUPLING

48. Inner pilot Outer pilot Electro-magnetArmatureFriction plate Housing Cam Hub Input shaftMain clutchBallPilot clutch Pilot torque Ball ramp mechanism Housing Main clutch Friction plate Ball Cam Electro-magnet Rotor clutch Pilot clutch Armature Hub X-ring Oil Companion flange Rubber coupling Propeller shaft Drive pinion (to Rear diff.) E-COUPLING The E-coupling controls the torque distribution between the front wheel and the rear wheel. The slip control of the multi disc clutch is performed by the electro magnetic clutch and the ball ramp mechanism. 4WD Fail-safe mode : If the E-coupling is overheated or faulty, the mode is changed to the one similar to that of the 2WD to protect the inner components and the 4WD warning lamp is ON.

49. 1>Function of E-Coupling : Torque distribution control 2>Slip control of multi disc clutch : Electro-Magnetic Clutch & Ball-Ramp Mechanism 3>Max torque capacity : 1,000Nm 4>4WD fail safe mode : E-Coupling failed or overheated, E-coupling fixed to 2WD Mode and 4WD lamp turned on. 5>Operating temperature : -40~120 ℃ 6>Operating current : 3A E-Coupling E-COUPLING

50. ▶ CAN Connection E-Coupling E-COUPLING

51. ■ When the EMCD is not operated: - 2WD: The current is not supplied to the electro-magnet. Propeller shaft Rubber coupling Companion flange Drive pinion (to Re) diff. Housing PTU (Front) Hub Pilot clutch Electro-magnet Main clutch E-COUPLING Operation process Friction plate BallCam

52. ■ When the EMCD is operated: - AWD : The current is supplied to the electro-magnet. Propeller shaft Rubber coupling Companion flange Drive pinion (to Rear diff.) Housing PTU (Front) Hub Pilot clutch Electro-magnet Main clutch Magnetic flux Friction plate Ball Cam E-COUPLING Operation process

53. Mode Select Switch Vehicle speed 4WD Mode (E-Coupling) 4WD AutoNo limit4WD Auto 4WD Lock Over 40 kph4WD Auto Below 35 kph4WD Lock   4WD Auto & Lock Mode (Smart control by steering angle, wheel speed) ⓐ When rear wheel speed is over 40kph, 4WD auto mode ⓑ When rear wheel speed is below 35kph, 4WD lock mode 4WD Operation mode EMCD CONTROL MODE

54. E-coupling ECU E-coupling (EMCD solenoid) Diagnosis Tool Ignition Switch 4WD LOCK Switch HECU ECU (Engine) ICM Hard wire P-CAN E-COUPLING Software interface and diagram

56. FUNCTION OF ESP ABS Yaw Control (at cornering) TCS EBD HBA HSA ARP HDC (Remove this function)

57. ABS SYSTEM HCU Front Speed sensor ECU ENGINE HECU Front Speed sensor Rear Speed sensor Wheel speed sensor 종방향가속도 센서 (AWD only) 1. ABS : 4 Chanel, 8 Sol valve - Satisfaction of regulation (Vehicle weight)

58. POSITION OF ESP COMPONENT 1. HECU 2. Pressure sensor 3. Wheel speed sensor 4. Sensor cluster 5. Steering wheel angle sensor 6. ESP OFF switch ASR

59. ESP UNIT BLOCK DIAGRAM

60. ESP SYSTEM COMPONENT Pressure sensor HECU Steering wheel angle sensor

62. Snorkel Assy 1>Design - valid cross-section area : above 4,000mm 2 - Thickness : above 2.5mm (hardness secure 측면 ) - Material : PP Water Protector 1>Function - Pretension for water entering to engine at rainy day or snow day 2>Standard - Thickness : 2.5mm Air intake system Layout Air intake system components

63. Resonator Assy 1>Function - intake noise reduction at specific frequency - sound wave formation which have 180 degree at resonance frequency 2>MTG method - 2 Point - Insulator use (Insert method) 3>Design - Thickness 3.0mm - Rib and Bead application (hardness secure side) Hose - Air Cleaner to Turbocharger 1>Function - connection between Air Cleaner and Turbo Charger - Blow-By Gas inflow 2>Design - Bellows application for absorbing vibration - Blow-By Gas inflow Port composition - Thickness : 5.0mm Air intake system components Air intake system

64. Duct Assy - Turbocharger to Intercooler 1>Function - Connection between Turbo Charger and Intercooler - Absorption for engine vibration and shaking Hose Assy - Intercooler to Engine 1>Function - connection between Intercooler and Engine - Absorption for engine vibration and shaking Air intake system components Air intake system

65. Intercooler 1>Function - Increase engine output by improving efficiency of engine combustion chamber to supply cold air to engine after releasing high heat result from compressed air at turbo charger 2>Design base - whole size : 520W X 110H X 70t - Core size : 510W X 110H X 63t - Core material : Aluminum - Inlet material : PPA + Glass Fiber 30% - Outlet material : PA66 + Glass Fiber 30% - Tank material : Plastic (Injection) - Pressure Drop : 90mmHg - Rated air volume : 565kg/h (7.5m/s) - efficiency : 80% Air intake system components Air intake system

66. Cooling system overview ComponentsSpecRemark Radiator Core size 740W X 380H X 27t (above 281,200mm 2 ) Front Area Flow method Cross Flow Heat Rejection Radiator above 68,000kcal/h (Vw 60L/min, Va 8m/s, △ T 60 ℃ ) Spec : decision after test the car TOC above 3,850kcal/h (Gw 60L/min, Go 6L/min, ITD 30 ℃ ) Aluminum Plate Type (44W X 4ea) Fan Module size 220W (Ø360) + 150W (Ø360) Dual Fan control Series; low speed, Parallel; high Air Flow 4,200CMH at 100Pa, 13V Condenser Core size 650W X 350H X 16t Intercooler Core size 510W X 110H X 63t Reservoir Tank capacity above 2.2L Coolant Circuit Closed Type material PP (4t) high temp’/high pressure material pressure Cap Screw Type 1.4bar Hose material EPDM 4t A/T Hose material ACM + TSW + SUM24L + SPC Hose & Tube Integrated Type COOLING SYSTEM

67. Condenser Radiator Fan Module Hose - Radiator Outlet Hose - Make Up BRKT - Module MTG Upper Hose - Deaeration to Radiator Reservoir Tank Assy Insulator - Module MTG Upper Hose – Deaeration To Engine Tube - A/T Radiator Outlet Tube - A/T Radiator Inlet Insulator - Module MTG Lower Hose Assy - A/T Outlet Hose Assy – A/T Inlet Hose – Radiator Inlet Cooling Module Layout COOLING SYSTEM

68. Tube – A/T Radiator Inlet & Outlet TOC Radiator Tank Header Reinforcement Radiator Core Cooling Module Radiator or TOC 1>Function - Radiator : Engine Coolant Cooling - TOC : Auto T/M Oil Cooling 2>Radiator design - Core size : 740W X 380H X 27t - Flow Type : Cross Flow - material : Aluminum, PA66 + Glass Fiber 30% 3>TOC design - Location : Radiator Outlet Tank inside (Internal Type) - material : Aluminum (Plate Type) - size : 44(width) X 4ea COOLING SYSTEM

69. Motor Fan Blade Shroud Cooling Module components Electric Fan 1>Composition - Dual Fan - 220W (Ø360) + 150W (Ø360) 2>Operation - Low speed : Series connection - High speed : Parallel connection 3>Structure - Ring Type Fan - Blade deformation and Air back flow prevention COOLING SYSTEM

70. Cooling Module composition Sealing Pad 1>material : EPDM Sponge 2>size - TOP : 840W X 20H X 25t - Left/Right : 50W X 500H X 25t Coolant Reservoir Tank 1>Capacity : above 2.2L 2>Coolant Circuit : Closed Type 3>material : PP (4t, high temp’/high pressure material) 4>pressure Cap : Screw Type (1.4bar) 5>Silicate : 25g COOLING SYSTEM

71. Hose Inter nal Exter nal material Thickne ss Rad. InletØ32 EPDM4.0mm Rad. OutletØ32 Make UpØ13 Deaeration A/T InletØ16 ACM + TSW + SUM24L + SPC 3.2mm A/T OutletØ16 Hose-Deaeration to Radiator Hose-Deaeration to Engine Hose-Radiator Outlet Hose-Radiator Inlet Hose Assy-A/T Inlet & Outlet Hose-Make Up Cooling Module composition Hose 1>Structure - minimize route compared to C100 - ELV : Lead (Pb) ingredient none - TOC Tube MTG : Flange Bolt Type (W200 Type) 2>Specification COOLING SYSTEM

72. Cooling Module composition Module MTG 1>Upper MTG - Rubber & BRKT MTG - Front End Side Panel MTG 2>Lower MTG - Rubber MTG - Cross Member MTG 3>Rubber material : EPDM Upper MTG Lower MTG COOLING SYSTEM

73. Booster & Master Cylinder Assy Rear Brake Front Brake Brake system BRAKE SYSTEM

74. Front Brake Rear Brake Brake system component Caliper and Disc 1> Concept & Requirement ComponentFront Brake Rear Brake 2WD4WD Caliper TypeFloating Pot2 Pot1 Pot Housing material FCD(Spheroidal graphite cast iron) Cylinder diameterØ42.9 X 2 (Dual)Ø38.2 X 1 (Single) (Effective Radius)122.4mm113mm124mm Design mu (BEF) Dom’0.38 Exp’0.420.40 Pad area65cm 2 26.8cm 2 Pad material Dom’NAO(nonferrous metal) Exp’Low Steel Pad Wear IndicatorMechanical Disc SizeØ298 X 26tØ262 X 10tØ284 X 10t TypeVentilatedSolid Dust ShieldNew designNew design (Parking Back Plate monolithic) ※ BEF : Brake Effective Factor BRAKE SYSTEM

75. Brake system composition Booster & Master Cylinder Assy 1>Booster size : 8” + 9” (Tandem) 2>Master Cylinder size : Ø25.4 3>Master Cylinder structure - CBS use : Pressure Valve monolithic - ABS/ESP 용 : Pressure Sensor deletion (HECU internal type) 4>Reservoir Tank : new specification BRAKE SYSTEM

76. Parking Lever Assy BRKT-Parking Brake Parking Drum Brake Rear Parking Cable BRKT-Rear Cable MTGFront Parking Cable Parking Brake System System Layout BRAKE SYSTEM

77. Lever Button Switch Position Equalizer Parking Brake System Parking Lever Assy 1>Type : Guide - Cable 2>Lever Ratio : [241.7 : 37.3] = [6.5 : 1] (Variable Ratio) 3>Cable Stroke : 26~32mm 4>Full Stroke Angle : 40 degree 5>Full Notchs : 14 Notchs 6>Button (Lever) : Natural (none chrome coating ) 7>Front Cable : Ø19 (1 ea), PA Coating BRAKE SYSTEM

78. Dust Shield Operation Lever Lining Adjuster Assy Parking Brake System Parking Drum Brake Assy 1>specification Composition2WD4WD Drum size(diameter) Ø168 Ø190 Lining size(width) 30mm Friction coefficient (BEF) 5.7 Operation Lever Ratio 4.5 BRAKE SYSTEM

79. Accel Pedal 1) Type : Hanging Type 2) Stroke : 50mm 3) Effort : 4.0kgf 4) Kick Down : ECU control 5) Material : Plastic 6) Weight : 0.365kg Brake Pedal 1) Stroke : 140mm 2) Ratio : 3.8 3) material - Housing : Steel - Arm : 8t Press 4) Dash MTG part : Boss shape application 5) Weight : 2.18kg 6) Collision Concept : Upper MTG break away & reverse rotation structure Clutch Pedal 1) Stroke : 140mm 2) Ratio : 5.8 3) material - Housing : Steel - Arm : 6t Press 4) Dash MTG 부 : Boss shape application 5) T/Over Spring low weight : -2.0kgf 6) Vibration reduction plan : Oil Chamber application ACCEL / BRAKE / CLUTCH PEDAL

80. A/T TGS Lever 1) Tip Tronic type : E-Tronic Type 2) Tip Switch location : Steering Wheel, TGS Knob 3) Ratio & Stroke : 3.0 & 128.4mm (P ↔ D) 4) shift Position : 4 (P-R-N-D) 5) Control method : Cable Type 6) Top Cover : TGS monolithic type 7) Std/Winter Mode : structure 8) P-Lock composition : Solenoid Valve Type 9) Application T/M : DSI 6AT 10 Weight : 1.408kg 11) Knob Assy : separate Screw assembly 12) separate BRKT : not installed M/T TGS Lever 1) Shift Ratio & Stroke : 3.5 & 62.72mm 2) Select Ratio & Stroke : 3.0 & 35.78mm 3) Control method : Cable Type 4) Weight : 1.473kg 5) Knob Assy : Separate Screw assemblly 6) separate BRKT : not installed TGS LEVER

81. Bellows (Flexible Joint) CDPF Center Muffler Rear Muffler Exhaust system Layout EXHAUST SYSTEM

82. Rear temperature sensor Front temperature e sensor ① Deferential pressure sensor - Conducted CDPF recycling function If mass value is approx’ 28mg by occurring pressure difference of CDPF front/rear accordance with accumulating PM inside d inside CDP, - Recycling judgment element : pressure difference, exhaust gas temperature, EGR ratio ② Throttle Valve - CDPF control : Raise exhaust gas temperature by closing flap when operation CDPF - On/Off control : Prevent engine vibration when stopping engine - Duty control : Close flap to inhaul much EGR gas at EGR operation section ③ Temperature sensor - Front temperature sensor : lower exhaust gas in case that temperature is excessively high after measuring exhaust gas flowed in turbocharger - Rear temperature sensor : Check if the temperature is possible recycling after sensing exhaust gas temperature of front of DPF CDPF CDPF composition 2> composition function and control EXHAUST SYSTEM

83. 1) Regulator - Euro-V 2) Type - Saddle Type 3) Capacity - 60L (external capacity : 85L) 4) Material - Plastic, Monolayer & F Coating 5) assembly - Rear BIW Route 6) maintenance - 2 Strap (2 Bolting) 7) Fuel Pump - 1 개 8) Fuel Filler material - Plastic FUEL TANK

84. SUCTION FUEL LINE RETURN FUEL LINE FEED FUEL LINE ASSIST PUMP NOZZLE RETURN FUEL SUCTION FUEL

85. E N D