- Technical Highlight -

Chonan Technical Service Training Center

BL-1 : 15

1. Greeting.

- General

- Brief course introduction

- First impression (Korea and center)

2. My introduction. Including Choan Training center.

- E-mail address

- Web site

3. Try to make them comfortable and relax

1.

Good morning, gentlemen. Im 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 Ill 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 weve 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 technical center ?

2.

Now, Id like to introduce myself briefly.

My name is Andy Kim and and Im 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 E-mail , andykim@kia.co.kr (Wrighting down) or you

can connect to our web site. http://training.kia.co.kr.

Lets go to the Sorentos world together.

Sorento

Development

Name

(High styling, High Performance with Hi-Tech)

Line-Up: LX, TLX, LIMITED

Brand

Name

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

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

Front View

High dignity and Excellent quality

High power and High prestige

Cd = 0.435

O.A.W. : 1863 mm (1884mm: Side garnish)

BL-3~6 : 10

: .

Introduce the developing concept and bench marking model

When it comes to Sorentos 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.

.

.

Side View

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

Powerful front view and elegance rear view with highly roominess interior space

140 COMMON RAIL A TCI ENGINE.

TREND

SHARP EDGE IMAGE LINE STYLEISH

APPERANCE

Wheel base .

Rear View

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)

Rear glass flip open type and computer controlled rear wiper

Sorento leads the style of SUV in the world automotive market

Sorento

X-5

(BMW)

ML320

(BENZ)

RX300

(LEXUS)

Sorento

Interior

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

Sorento

Active NVH reduction and simple modulated in-panel. The modulated in-pal is

supplied by Hyundai Mobis.

Now Lets look at the competitive models of the Sorento. Emblem .

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

Sorento

Maximized space for Convenience

Sorento

Upper tray

Ticket holder

Center tray

Ash tray

(Automatic)

Drivers

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

Package

Sorento

L X W X H

456718631726

Power Train

A2.5 CRDi, 3.5, S-II 2.4

Suspension

Front: Double Wishbone, Rear: 5Link Coil

Tire

P245/70R16, P225/75R16

1580

1863

2710

887

1030

60

4567

Sorento

Driving Performance

Model

Item

Acceleration

A2.5 CRDi3.5S 2.42WD4WD2WD4WD4WD2WD5M/T4A/T5M/T4A/T4A/T4A/T5M/T4A/TMax. Speed (Km/h)1681711681701921921671580 400m19.019.119.219.416.917.019.218.70 100Km/h14.314.214.614.59.710.215.714.260 100Km/h9.38.59.58.85.65.815.18.7Fuel Efficiency100km Const. (5th, D4)11.413.111.212.49.28.88.910.5

NVH Improvement

Same level of NVH as High leveled Gasoline Vehicle

Sorento

Cylinder block

shield

Reduce Engine Side Noise

Reduce Engine Vibration

Balance Shaft

Chain cover

shield

Remove Timing Chain Noise

Reduce Engine Noise

Bed plate

Silent Idle

Sorento

Idle Vibration

(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

Power train

Above available spec. by regions could be changeable in final fixing stage.

Sorento

BODYEng.T/MT/FNorthAmericaEuropeGeneralLHDRHDLHDRHD4Door5SeatA2.5TCI(CRDI)5MT4WD4AT4WD3.5(V6)4AT4WD2WDSIRIUS-(2.4 I4)5MT4WD2WD4AT2WD

BL-9 power train schedule

: / 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 2 2.4 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.

Engine view 3.5 (V6)

Sorento

Engine view Sirius- (2.4)

Sorento

Engine view A 2.5 TCI (CRDI)

Sorento

BL-10 ~12 Engine view

: engine .

This is A-engines front view. Next is Sigma 3.5 liter and the last is

for Sirius 2 2.4 liter

A-2.5 TCI (CDRI) High Speed Direct Injection

Sorento

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

High Pressure Line Common Rail

Sorento

Comparison

Sorento

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

: price range

1. Competitive models in each contury.(SUV position map )

2. Sigma 3.5 and Sirius 2.4

What is the Sorentos 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 Sorentos 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.

Im not sure there is the Rexton by Daewoo in your contruy but the rexton uses

Benzs IDI( in direct injection) diesel engine. Comparing to the Sorentos maxium

output the Sorentos 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.

Engine Specification

Sorento

Items / ModelA 2.5 TCICRDI3.5(V6)SIRIUS-(2.4 I4) TypeIN-LINE 4 CylinderV6IN-LINE 4 Cylinder Valve systemDOHCDOHCDOHC Max. Power (Ps/rpm)145/4000195/5500140/5500 Max. Torque (kg-m/rpm)33/200030/300020.2/3000 Injection TypeDirect InjectionMPIMPI Displacement (cc)2,4973,4972,361 Bore x Stroke (mm)91x9693x85.886.5x100 Compression ratio17.7:110:110:1 ValvetimingIntakeOpen(BTDC)811.512Close(ABDC)3860.556ExhaustOpen(BBDC)5243.554Close(ATDC)820.514 Valve clearance0,(HLA)0,(HLA)0,(HLA) Idle Speed (rpm)8005070010080050 Ignition Timing (BTDC)-10 252 Ignition Order1-3-4-21-2-3-4-5+61-3-4-2

BL-8 Engine specification

: Sorento 3 engine

1. A-2.5 common rail

2. Sigma 3.5 liter

3. Sirius 2.4 liter

The sorentos 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 2 2.4 liter.

(Point out the each line and explain shortly, looking at the slide)

Detailed information in each system will be discussed later

Transmission

The same transmission is adapted regardless of the Engine variation.

Sorento

Manual Transmission :

M5UR1

Auto Transmission :

30-40LEI

BL-13~23A/T and convenience items

: engine .

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. Its 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 ------.

4 Wheel Drive

Sorento

Electronic

TRANSFER

FRONT P/SHAFT

REAR P/SHAFT

REAR AXLE

FRONT AXLE

T/M

EST

Sorento

Electronic Shift Transfer

Manual control

Between 2wd 4wd

Mode : 2H, 4H, 4L

Maker: Borg Warner in USA

Electrical gear shifting by drivers lever operation

TM input

Front input

Rear output

Planetary gear

(4 LOW)

Components

EST

Sorento

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

- 0:100 / 50:50

Mode : Auto, Low

TOD

Sorento

TOD or ATT (Active torque transfer)

TOD

Sorento

T/M input

Front output shaft

Rear output shaft

Planetary gear

(LOW)

Multiple
discs

AUTO-LOW control

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

Sorento

EBD Modulation * EBD control example

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

Advantages of EBD

Sorento

S.R.S.

Sorento

PAB

Belt buckle sensor

Frontal crash sensor

ACU

Pretensioner

Load limiter

Pretensioner

Load limiter

Curtain airbag

DAB

Supplemental Restraint System

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.

Sorento

?

AIRBAG SYSTEM OPERATING SEQUENCE

Sorento

105m Sec

Vent Gas (Bag Deflation)

Airbag System Completed

3m Sec

Crash

Crash Sensing

20m Sec

35m Sec

40m Sec

Bag Deploying

Ignite the Inflator

Full Deployment of the Bag

Produce Nitrogen Gas to Inflate the Bag

Protect the Occupants

msec

1/10 1/100 1/1000 1/1000

Sorento

Applied Depowered air bag

: 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

Sorento

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

Air-conditioning System

Sorento

Manual Air conditioner

Auto Air conditioner (FATC)

Sorento

Detects exhaust & harmful gasAutomatic operatingEasy installation on the existing vehicle. -Manual operation available.

Air Quality Sensor

Humidity sensor detects the relative humidity of the cars 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.

,
IG KEY ON AQS IG (12V) AQS 35 . AQS AQS FATC . .

, NOX, SO2, CXHY, CO 1 .

ETACS

REAR WIPER SYSTEM

AUTO LIGHT CONTROL SYSTEM

RAIN SENSOR

MULTIMETER

BODY ELECTRICAL

Sorento

ETWIS ETACS

junction Box , ECM

Control Module Control Module Communication

Head light On Off Auto light System

Rain Sensor Wiper Motor System

.

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

Sorento

Rear Wiper Control

Sorento

- There are two relays in the

controller to control the motor

rotation to clockwise or

counterclockwise according to the

potentiometer signal.

Auto Light Control

Sorento

- While the switch is in auto position

tail lamp and head lamp in on / off

automatically regardless of the

drivers intention according to the

surrounding brightness.

RAIN SENSOR

Sorento

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

Rain Sensor Components .

Driving Room Windshield glass .

Wiper Blade

Wiper Blade

.

Multi-meter

- Vehicle multi-meter is mounted
on the roof trim giving driver
accurate reading at a glance.

Operating Items

- Compass
- Altitude
- Barometric pressure
- Ambient temperature

Sorento