CÔNG TY CỔ PHẦN Ô TÔ TRƯỜNG HẢI

KHÓA ĐÀO TẠO NEW MODEL

MAZDA 3 (CKD) & CX-5 (CBU)

BỘ PHẬN ĐÀO TẠO

PHÒNG DV-PT THACO PC

05/2012
 MỤC LỤC

PHẦN 1: Giới thiệu tổng quan về xe mazda CX-5 01

PHẦN 2: Công nghệ SkyActive 08

PHẦN 3: Động cơ 28

PHẦN 4: Hệ thống treo 76

PHẦN 5: Hệ thống truyền động 88

PHẦN 6: Hệ thống phanh 101

PHẦN 7: Hộp số AT 107

PHẦN 8: Hộp số MT 133

PHẦN 9: Hệ thống lái 154

PHẦN 10: Hệ thống điều hòa 159

PHẦN 11: Hệ thống túi khí 165

PHẦN 12: Thân xe & Phụ kiện 169

PHẦN 13: Hệ thống giao tiếp phức hợp 199

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Forward
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Cx-5
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Cx-5
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Cx-5
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Item CX-5 CX-7 CX-9

L5
SKYACTIV-G 2.0
Engine L3-Turbo MZI-3.7
SKYACTIV-D 2.2
MZR-CD 2.2
6EAT 6EAT
T/M 6EAT
6MT 6MT
Length (mm) 4,540 4,695 5,099
Width (mm) 1,840 1,870 1,936
Height (mm) 1,705 1,645 1,728
Wheel base (mm) 2,700 2,750 2,857
Tread: FR (mm) 1,585 1,615 1,654
Tread: RR (mm) 1,585/1590 1,610 1,644
215 (2WD) 215 (2WD)
Clearance 206/208
210 (4WD) 210 (4WD)
Weight (kg) 1,440 – 1,610 1,660 – 1,760 1,939 – 1,974
225/65R17 245/60R18
Tire size 235/60R18
225/55R19 245/50R20

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Cx-5
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CX-5
Item
Engine SKYACTIV-G 2.0 SKYACTIV-D 2.2
6EAT (FW6A-EL/FW6AX-EL) 6EAT (GW6A-EL/GW6AX-EL)
T/M
6MT (C66M-R/C66MX-R) 6MT (D66M-R/D66MX-R)
Length 4,540 mm
Width 1,840 mm
Height 1,705 mm
Wheel base 2,700 mm
Tread: FR 1,585 mm
Tread: RR 1,585 mm /1590 mm
Clearance 210 mm
Weight (kg) 1,440 - kg
Tire size 225/65R1, 225/55R19

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Major components, SKYACTIV
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VIN
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Vehicle identification Number (VIN)

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 VIN
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Vehicle identification Number (VIN)

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Battery disconnection
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Required procedure
Conditions after
Before
disconnecting the After connecting
System name disconnecting Remark
negative battery negative battery
negative battery
cable cable
cable
Power window Reset to initial setting Perform the power
system and auto-function is window system initial
disabled. setting.
Sunroof system Reset to initial setting Perform the sunroof
and function is system initial setting.
disabled.
Clock and audio Clock display and Verify the setting Set the verified
audio system memory content. content before
are reset. disconnecting
negative battery
cable.
Tire pressure The tire pressure Perform the tire
monitoring Monitoring system pressure monitoring
system (TPMS) detection accuracy system initialization.
decreases.
i-stop system Specified information Verify PID Perform battery Only vehicles
in the PCM cleared “BATT_SOC” value condition initial setting with i-stop
and the i-stop does and record. *1 (i-stop setting). *2
not operate normally.

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Schedule maintenance
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Scheduled maintenance table (for General)

regular replacement
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Item Specification
API: SG/SH/SJ/SL/SM/SN or
ILSAC: GF-2/GF-3/GF-4/GF-5
SKYACTIV-G
SAE: 10W-30, 10W-40, 10W-50, 5W-20,
Engine oil
5W-30, 5W-40, 0W-20, 0W-30
ACEA: C3/C1 or JASO: DL-1
SKYACTIV-D
SAE: 0W-30, 5W-30
SKYACTIV-G PE01 14 302
Engine oil filter
SKYACTIV-D SH01 14 302
MTX – Gear oil API: GL-4, SAE: 75W-80
ATX – ATF ATF-FZ
Rear differential oil API: GL-5, SAE: 80W-90
Transfer oil API: GL-5, SAE: 80W-90
PE01 18 110 (NGK)
Spark plug SKYACTIV-G
PE02 18 110 (DENSO)
55D23L (Panasonic, GS Yuasa)
SKYACTIV-G 75D23L (GS Yuasa)
Battery
Q-85 (Panasonic)*
SKYACTIV-D T-110 (GS Yuasa)*

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Major features
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Category Major features Availability for your market

SKYACTIV-G 2.0 All markets
01 ENGINE
SKYACTIV-D 2.2
SKYACTIV-Chassis All markets
02 SUSPENSION
TPMS All markets
03 DRIVELINE/AXLE 4WD
SCBS
04 BRAKES
Secondary Collision Reduction
FW6A-EL/FW6AX-EL
6AT
TRANSMISSION/ GW6A-EL/GW6AX-EL
05
TRANSAXLE C66M-R/C66MX-R
6MT
D66M-R/D66MX-R
06 STEERING EPS All markets
Electric water pump
07 HVAC HFO1234yf
PTC heater
08 RESTRAINTS Side airbag
SYACTIV-Body All markets
Main beam control
LDWS
09 BODY & ACCESSORIES
RVM
Auto-dimming mirror
Push button start All markets
Multiplex communication
SSU, FBCM, RBCM All markets
10 system
11 i-stop

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SKYACTIV TECHNOLOGY

SKYACTIV technology
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SKYACTIV TECHNOLOGY is a blanket term for Mazda’s innovative new-

generation technologies that are being developed under the company’s
long-term vision for technology development, Sustainable Zoom-Zoom.
All the technologies that are developed based on the Building Block
Strategy will fall under the SKYACTIV TECHNOLOGY umbrella.

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SKYACTIV technology
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SKYACTIV technology
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SKYACTIV technology
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SKYACTIV-G
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SKYACTIV-G
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SKYACTIV-G
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SKYACTIV-G
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SKYACTIV-G
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SKYACTIV-G
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With a compression ratio of 10:1, a residual gas temperature

of 750ºC, and an intake air temperature of 25ºC, if 10% of the
exhaust gas remains, the temperature inside the cylinder
before compression increases by roughly 70ºC, and the
temperature at compression TDC is calculated to increase by
roughly 160ºC.

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SKYACTIV-G
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If residual gas is reduced from 8% to 4%...

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SKYACTIV-G
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SKYACTIV-G
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SKYACTIV-Drive
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SKYACTIV-Drive
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SKYACTIV-Drive
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Items to be improved New features

- Widened lock-up range

Fuel economy - High efficient gear train
- Reduced clutch resistance

Start-up - Small size torque converter

- Improved clutch response
Direct feel
- Improved solenoid valve response
- Improved parts accuracy
Smooth shifting
- Employed direct linear solenoid valves

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SKYACTIV-Drive
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Observed that 49% of driving time for FS5A-EL is in the lock-

up range, while SKYACTIV-Drive is 82%.

JC08 mode 10-15 mode

Average vehicle speed 24.4km/h 22.7km/h
Maximum vehicle speed 81.6km/h 70km/h
Time for test mode completion 1204 sec 660 sec
Total mileage 8.172km 4.165km

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SKYACTIV-Drive
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Deceleration Slip
Type of ATX/AT Gear Lock-up
Lock-up
GF4A-EL 4 4GR NA
FN4A-EL 4 4GR (3GR, 4GR for some models) Available
RC4A-EL 4 3GR, 4GR NA
FS5A-EL 5 4GR, 5GR Available
SJ6A-EL 6 5GR, 6GR Available
AW6A-EL 6 4GR, 5GR, 6GR Available
FW6A-EL 6 1GR, 2GR, 3GR, 4GR, 5GR, 6GR Available

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SKYACTIV-MT
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SKYACTIV-MT
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SKYACTIV-MT
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SKYACTIV-Chassis
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SKYACTIV-Chassis
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SKYACTIV-Chassis
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SKYACTIV-Chassis
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Yaw-gain: the degree of yaw rate change with respect to the angle of
steering (deg./sec/deg.). The higher the yaw-gain, the more the vehicle
tends to turn easily.
Lateral-G: the acceleration applying in lateral direction of the vehicle that
increase or decrease in response to turning movement of the vehicle
Yaw rate: the degree of change of turning angle per second that occurs
due to yawing (deg./sec)

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SKYACTIV-Chassis
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SKYACTIV-Chassis
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The geometry of the rear suspension links is optimized to effectively use

compliance steer in order to increase cornering power in rear tires without
sacrifice of the lateral rigidity.

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SKYACTIV-Chassis
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The timing of the weight transfer in rear tires is advanced by reducing the
hysteresis characteristics of the suspension cross mount bushing.

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SKYACTIV-Chassis
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Caster angle and caster trail are increased to ensure the proper amount of
required steering effort that varies according to the vehicle speed, while
the stability of straight-ahead driving is improved.

CX-5 CX-7 CX-9

3°04′ (2WD)
Caster angle 6°29’ 2°57’
3°05′ (4WD)
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SKYACTIV-Chassis
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SKYACTIV-Chassis
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SKYACTIV-Chassis
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SKYACTIV-Chassis (Brakes)
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 Oneness with the vehicle (controllability)

 Stability & Safety (Brake effectiveness)
 Comfortableness (Brake Noise and Vibration)

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SKYACTIV-Chassis (Brakes)
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 Weight reduction with cooling capability (thermal control)

1) By efficiently directing air to cool down the brake
2) Improving cooling performance of brake disc rotor
 Brake effectiveness with brake noise and vibration
1) By identifying the structure generating the least vibration energy
2) By establishing the brake structure design for suppressing noise

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SKYACTIV-Chassis (Brakes)
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As part of contribution of SKYACTIV-Chassis, a greater anti-lift force than

that of existent models is produced.

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SKYACTIV-Body
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 The highest level of collision safety performance

 Pedestrian protective bonnet
 Realized a light-weight body, while it ensures the world highest level of
collision safety performance.
(Weight of the white body is reduced by 8 % as compared with existent
models.)

Chassis dynamics
By improved aerodynamics, the Coefficient of drag (Cd) of 0.335 is
realized by, in a well-balanced way, minimizing trailing vortexes, which are
generated upward or downward in the rearward of the vehicle. This
improvement contributes to better fuel economy.

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SKYACTIV-Body
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Body framework & rigidity

 Straight frame
 Rigidity of mounting portions
 Multi-load path

Existent model

CX-5

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SKYACTIV-Body
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Upper Path: - A structure for impact absorption by utilizing the apron portion
Mid Path (main): - A high collisional energy absorption and weight reduction are
realized by adopting cruciform section
- Designed a load-dispersive load path that can stably absorb collisional energy by
steady deformation
Lower Path: - In addition to body related parts, an extension for impact absorption
is equipped with the front suspension cross member

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SKYACTIV-Body
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01G Engine

01 Engine (SKYACTIV-G)

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 Specification
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Item Specification
Engine type SKYACTIV-G 2.0
Type Gasoline, 4-cycle
In-line 4 cylinders,
Cylinder arrangement and number
transverse-mounted
Combustion chamber Pent roof
Displacement (L) 1.997
Bore x Stroke (mm) 83.5 x 91.2
Compression ratio 13.0
Compression pressure (kPa [rpm]) 827 [300]
Max power [net] (kW/rpm) 113/6,200
Max torque [net] (Nm/rpm) 194/4,100
Open BTDC (º) -32 – 42
IN
Valve Close ABDC (º) 110 – 36
timing Open BBDC (º) 54 – 11
EX
Close ATDC (º) 7 – 50
IN (mm) 0 (HLA)
Valve clearance [cold]
EX (mm) 0 (HLA)

01 Engine (SKYACTIV-G)

New features
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 New features
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01 Engine (SKYACTIV-G)

New features
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Mechanical resistance is substantially reduced.

Piston-Crank  Reduced crank journal diameter

 Improved piston skirt rigidity
 Reduced piston ring expansion force
 Low tension piston ring
Cam  Mirror-like surface finishing
Valves  Adopted roller follower HLA (Hydraulic Lash Adjuster)
 Reduced valve spring loads
Timing chain  Adopted a high rigidity straight chain guide
 Reduced timing chain tensile force
Cooling  Reduced resistance in the engine coolant flow
 High efficient molded plastic water pump impeller
FEAD*  Lowered tension drive belt
Lubrication  Oil pump discharge pressure control by dual-stage
switching
 Reduced resistance of the oil passages
 Decreased hydraulic pressure demanded by hydraulic
devices
* FEAD: Front End Auxiliary Drive

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 New features
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Pumping loss is reduced.

Variable Valve Timing Intake: electrically-driven, Exhaust hydraulic-driven.

Retarded intake valve closed timing

01 Engine (SKYACTIV-G)

1 Engine
2 Drive belt auto tensioner
3 Drive belt
4 OCV
5 Plug hole plate
6 Hydraulic variable valve timing actuator
7 Electric variable valve timing actuator
8 Hydraulic lash adjuster (HLA)
9 Cylinder head gasket
10 Rear oil seal
11 Timing chain
12 Front oil seal
13 Electric variable valve timing motor/driver

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Cylinder head
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01 Engine (SKYACTIV-G)

Cylinder block
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Piston
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01 Engine (SKYACTIV-G)

Piston
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Crank shaft
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01 Engine (SKYACTIV-G)

Activity 01G
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Activity 01

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Connecting rod
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01 Engine (SKYACTIV-G)

Valve mechanism
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01 Engine (SKYACTIV-G)

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HLA
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01 Engine (SKYACTIV-G)

Activity 01G
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Activity 01G

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Activity 01G
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Activity 01

Variable valve timing

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01 Engine (SKYACTIV-G)

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Variable valve timing Actuator
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01 Engine (SKYACTIV-G)

Variable valve timing Actuator

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Principle of valve timing
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Intake Valve Opening Timing

Advanced: Improve volumetric efficiency and scavenging efficiency, but may sacrifice stability by increased
valve overlap.

Retarded: Improve stability by reduced valve overlap. Reduce pumping loss by integrally modified exhaust
valve closing timing
Intake Valve Closing Timing

Advanced: Improve volumetric efficiency by reducing intake-air blown back to the intake manifold.

Retarded: Reduce pumping loss by increased intake-air blown back out of the combustion chamber; reduce
pre-ignition or knocking by reducing effective compression ratio; Improve internal EGR effectiveness

Exhaust Valve Opening Timing

Advanced: Exhaust loss is reduced by allowing the exhaust gas, which is still high in pressure, to flow into the
exhaust port.

Retarded:
Exhaust Valve Closing Timing

Advanced: The amount of the exhaust gas remained in the combustion chamber increases. The residual
exhaust gas raises the cylinder temperature, contributing to stabling the combustion.

Retarded: Improve internal EGR effectiveness by exhaust gas blown back into the combustion chamber.

01 Engine (SKYACTIV-G) Ref Trainers

Principle, Planetary gear

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01 Engine (SKYACTIV-G) Ref Trainers

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Principle, Planetary gear
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01 Engine (SKYACTIV-G) Ref Trainers

Principle, Planetary gear

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01 Engine (SKYACTIV-G) Ref Trainers

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Activity 01G
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Activity 01

Valve timing control zone

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Valve timing diagram
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01 Engine (SKYACTIV-G) Ref Trainers

Idling/Low-load
30

Valve overlap is reduced to avoid the exhaust gases back into the
Intake manifold through the combustion chamber. Stabling
combustion even before warming-up by appropriate valve timing
contributes to lower fuel consumption.

Low load
By retarded intake valve and exhaust valve closing timings,
pumping loss is reduced to improve fuel economy.
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Mid-load (HOT)
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By retarded intake valve and exhaust valve closing timings,

pumping loss is reduced to improve fuel economy.

01 Engine (SKYACTIV-G)

Mid-load (Cold)
32

Effective pressure is increased by advanced intake valve

closing timing. By reducing valve overlap, combustion is made
stable.

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High-load, Low/mid-speed
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Intake valve closing timing is advanced to prevent intake air from

returning back into the Intake manifold through the combustion
chamber. Exhaust valve closing timing is retarded to scavenge
residual exhaust gases in the combustion chamber, contributing
improving volumetric efficiency, which ensures sufficient engine
torque for low/mid-speed range.

01 Engine (SKYACTIV-G)

High-load, High-speed
34

Intake valve closing timing is retarded to improve inertia

charging effect to generate more sufficient engine power.

01 Engine (SKYACTIV-G)

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Miller-cycle engine
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The Miller cycle engine is a high-efficiency engine which

realizes high fuel economy performance by obtaining a high-
expansion ratio. By retarding the intake air valve close timing
substantially, a high-expansion ratio without increasing its
effective compression ratio is made possible.

01 Engine (SKYACTIV-G)

Activity 01G
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Activity 01

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Wiring diagram, Variable Valve
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01 Engine (SKYACTIV-G)

Wiring diagram, Variable Valve

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Mode Description Control conditions

Feedback mode Determine duty cycle ratio Except when neither
based on the monitored gap of Electricity cut-off
between target valve timing mode or Phase-
and actual valve timing locked mode is not
executed
Energize cut Hold the intake valve timing When a malfunction
mode in the most retarded in Eclectic Variable
position to stable engine Valve Timing driver
speed is detected
Phase holding Hold the phase of Eclectic After the engine has
mode Variable Valve Timing stopped
actuator in the middle after
the engine has stopped

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Activity 01G
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Activity 01

Activity 01G
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Activity 01

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Activity 01G
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Activity 01

Drive belt
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Activity 01G
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Activity 01

Lubrication system
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 Pressure loss is reduced by optimizing the oil passage.

 With the adoption of the chain drive type oil pump, oil pump
drive force has been reduced.
 With the adoption of the oil shower pipe, sliding resistance
has been reduced.
 With the adoption of the engine oil solenoid valve, oil pump
discharge pressure can be controlled (hydraulic 2-step
control).

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Lubrication system
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01 Engine (SKYACTIV-G)

Lubrication system
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Item Specification
Full-flow filtered and
Type of lubrication
pressure fed
Oil pressure (reference) (kPa) [rpm] 110 – 175 [1,500]
Relief pressure (kPa) [rpm] 300 – 430 [4,500]
Oil pump
Type Trochoid gear
Type Full-flow
Oil filter
Bypass pressure (kPa) 78 – 118
Engine oil Total (Dry engine) 4.9
(reference） Oil replacement 4
(L) Oil and oil filter replacement 4.2

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Lubrication system
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01 Engine (SKYACTIV-G)

Lubrication system
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Item Description
Oil gallery Reduced pressure loss in the oil gallery; Pressure loss
can be reduced by shortening the length of oil gallery in
the cylinder block. The structure of the cylinder block
was totally changed and oil gallery was shortened by
positioning the oil filter behind the drive shaft.
Hydraulic Lowered required pressure for hydraulic devices. If
device devices can work with lower pressure, oil pump can be
downsized. Required oil pressure was reduced by 10%
by adjusting crankshaft metals, Variable Valve Timing,
and HLA.
Discharge 1. Feedback control: The maximum oil pressure required
for driving condition is determined based on the oil
pressure in the main gallery.
2. The engine oil pressure is regulated based on the
ECT, RPM, and volumetric efficiency.

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Engine oil flow
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01 Engine (SKYACTIV-G)

Oil pump
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01 Engine (SKYACTIV-G)

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Engine oil control
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01 Engine (SKYACTIV-G)

Engine oil control

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Condition Description
High oil pressure for crankshaft journal
Engine speed
and pins is required when in Mid/High
4,000rpm or higher
speed zone
Ensure the pressure of engine oil being
Low speed/High load injected from the oil jets to the pistons to
avoid temperature rise
ECT is at 98ºC or Cool down the engine and lubricate the
higher rotational parts for improving reliability
Open circuit, solenoid
When a malfunction is detected, engine oil
valve
pressure is adjusted to HI, improving
Other system
reliability
malfunctions

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Engine oil sol. Valve: ON
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01 Engine (SKYACTIV-G)

Engine oil sol. Valve: OFF

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Engine oil sol. Valve: ON
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01 Engine (SKYACTIV-G) Ref Trainers

Engine oil sol. Valve: OFF

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01 Engine (SKYACTIV-G) Ref Trainers

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Cooling system
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01 Engine (SKYACTIV-G)

Cooling system
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Item Specification
Cooling system type Liquid cooled, Electric fan
Total amount of (reference) (L) 8.1
Water pump Type Centrifugal, Belt driven
Type Wax
Temp. open (°C) 80.5 – 83.5
Thermostat
Temp. full-open (°C) 95
Lift at full-open (mm) 8.5 or more
Supplier Visteon
Radiator
Type Colgate (Sealed)
Cooling system
Pressure, open (kPa) 90 – 110
cap
Supplier BOSCH
Type Electrically-driven
Cooling fan
No. of blade 7
Outer diameter (mm) 390

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Water pump
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01 Engine (SKYACTIV-G)

Coolant passage
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01 Engine (SKYACTIV-G)

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Water inlet pipe stay bolt
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Technical tip
Water inlet pipe stay bolt
Water inlet pipe stay bolt is not reusable. Replace it with new one when removed.

01 Engine (SKYACTIV-G)

Activity 01G
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Activity 01

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Intake system
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01 Engine (SKYACTIV-G)

Fuel system
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Fuel system
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01 Engine (SKYACTIV-G)

Fuel system
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Item Specification
Supplier DENSO
Type Multi-hole (6 holes)
Fuel injector
Type of fuel delivery Top feed
Drive type Electronic
Regulated pressure
High pressure fuel 20
(MPa)
pump
Relief pressure (MPa) Approx. 23.5
Regulating pressure (kPa) Approx. 430
Electric (Variable
Fuel pump type
speed)
56 (2WD)
Fuel tank capacity (L)
58 (4WD)
Fuel type Regular unleaded

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Fuel system
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01 Engine (SKYACTIV-G)

High pressure Fuel pump

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1 Quick release connector 5 Seal rubber

2 High pressure fuel pipe 6 O-ring
3 High pressure fuel pump cover 7 Tension collar
4 High pressure fuel pump 8 Rear housing
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Fuel injector
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01 Engine (SKYACTIV-G)

Fuel pump control

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Relay ON/OFF Control conditions

When any of the following conditions is met:
- When ignition is switched ON (for approx. 1 sec)
ON - During engine cranking
- While engine is running
- When engine is stopped by i-stop control
When engine is stopped (excludes engine stop by i-stop
OFF
control)
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Fuel pump control
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Duty cycle Fuel pump speed Operational condition

When any of the following conditions is
met:
95% MAX - At engine start
- Fuel pump control module malfunction
(if request voltage is unobtainable)
- Feedback value from fuel pressure
sensor is the specified value or more
Depending on (Determined that high pressure fuel
10% – 90%
the duty cycle pump compression is high.)
- Except for control conditions with
output duty ratio of 5% or 95%
When engine is stopped (excludes engine
5% 0 stop by i-stop control for SKYACTIV-G with i-
stop)

01 Engine (SKYACTIV-G)

Fuel Injection control

72

Uniform combustion: Fuel injected during intake stroke is well mixed with intake
air, avoiding uneven air-fuel mixture. In general, homogenous combustion
contributes to generating more power, but less contribution to improving fuel
economy. It is also known as Homogeneous combustion.
Stratified combustion: The spark plug ignites richer air-fuel mixture, producing a
frame which is strong enough to grow the frame with leaner air-fuel mixture.
Generally, stratified combustion is used for lean combustion.

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Activity 01G
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Activity 01

Activity 01G
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Activity 01

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Exhaust system
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4-2-1 exhaust system

01 Engine (SKYACTIV-G)

Emission system
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01 Engine (SKYACTIV-G)

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Emission system
77

01 Engine (SKYACTIV-G)

Emission system
78

01 Engine (SKYACTIV-G)

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Ignition system
79

01 Engine (SKYACTIV-G)

Ignition system
80

Item Specification
Type Direct ignition
Ignition system Spark advance Electronically-controlled
Firing order 1-3-4-2 (Sequential ignition)
PE01 18 110 (DILKAR7F8)
Type
PE02 18 110 (FC20HPR8)
Spark plug
NGK PE01 18 110 (DILKAR7F8)
Supplier
DENSO PE02 18 110 (FC20HPR8)

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Pre-ignition & Knocking
81

Pre-ignition: Air-fuel mixture is ignited due to excessive heat before the ignition by
sparks.
Knocking: It is a collision between the intended combustion propagations and
unintended combustion propagation such as self-ignition due to high compressed
end gas.

01 Engine (SKYACTIV-G)

Ion sensor
82

01 Engine (SKYACTIV-G)

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Ion sensor
83

The ionic electrical current (2) is detected by applying the voltage, which is
accumulated in the capacitor (1) due to the secondary ignition current.
Electric current (4), which is amplified by the ion detection circuit (3) is pulled in to
the ignition coil from the PCM.
The PCM detects the amount of ion produced in the combustion chamber by
measuring and converting the current (4) into voltage.
.

01 Engine (SKYACTIV-G)

Control System
84

Location in this
New parts, devices, control items
textbook
New Fuel pump control module Fuel system
parts/devices
Ion sensor Ignition system

Electric variable valve timing driver Mechanical

Electric variable valve timing motor &
Mechanical
actuator
Intake camshaft position sensor Mechanical
Exhaust camshaft position sensor Mechanical
Lubrication
Engine oil solenoid valve
system
New control Variable valve timing control Mechanical
items Fuel pump control Fuel system
Lubrication
Engine oil control
system

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 output devices
85

1 Fuel injector
2 Electric variable valve timing
motor/driver
3 OCV
4 Ignition coil
5 Purge valve
6 Spill valve control solenoid
valve
7 Relay and fuse block
8 Generator
9 Starter motor
10 Throttle valve actuator
11 DC-DC converter

Fuel pump relay, Starter relay, Electric variable valve timing relay, Fuel injector relay, main relay, A/C relay, Cooling fan
relay No.1, Cooling fan relay No.2, Cooling fan relay No.3

01 Engine (SKYACTIV-G)

output devices
86

1 Fuel pump control module

2 HO2S heater
3 A/F sensor heater
4 Engine oil solenoid valve

01 Engine (SKYACTIV-G)

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 Input devices
87

1 Electric variable valve timing

motor/driver
2 Refrigerant pressure sensor
3 Ion sensor
4 Power brake unit vacuum sensor
5 Intake CMP sensor
6 ECT sensor
7 Exhaust CMP sensor
8 PCM (BARO sensor)
9 Current sensor
10 Power brake unit vacuum sensor
11 Fuel pressure sensor
12 Generator
13 KS
14 Ambient temperature sensor
15 MAP sensor/IAT No.2 sensor
16 TP sensor
17 Neutral switch No. 1 (MTX)
18 MAF sensor/IAT No.2 sensor
19 Neutral switch No. 2 (MTX)
20 DC-DC converter

01 Engine (SKYACTIV-G)

Input devices
88

1 Starter interlock switch (MTX)

2 Clutch stroke sensor
3 CPP switch (MTX)
4 Brake switch
5 APP sensor
6 i-stop OFF switch
7 A/F sensor
8 CKP sensor
9 HO2S
10 Transaxle range sensor (ATX)

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 output devices
89

1 Throttle valve actuator

Generator field coil, DC-DC converter*, Cooling fan relay No. 1, No. 2 Purge solenoid valve
2, No. 3, Fuel pump relay, Starter, Starter relay, Electric variable 3 Electric variable valve timing motor/driver
valve timing relay, Fuel injector relay, Main relay, A/C relay, CAN 4 Ignition coil No. 1 – No. 4
5 Spill valve control solenoid valve
*: Vehicles with i-stop system
6 OCV
7 Fuel pump control module
8 Fuel injector No. 1 – No. 4
9 Engine oil solenoid valve
10 A/F sensor heater
11 HO2S heater
01 Engine (SKYACTIV-G)

output devices
90

1 MAF sensor/IAT sensor No. 1

2 TP sensor No. 1, No. 2
3 MAP sensor/IAT sensor No. 2
4 Electric variable valve timing
motor/driver
5 Intake CMP sensor
6 Ion sensor No. 1 – No. 4
APP sensor No. 1, No. 2, IG1 relay, Generator (Stator coil), Brake switch 7 Exhaust CMP sensor
(No. 1 signal, No. 2 signal), Battery, Refrigerant pressure sensor, Ambient 8 ECT sensor
temperature sensor, Transaxle range sensor, Starter interlock switch (MTX), 9 Fuel pressure sensor
Neutral switch No. 1(MTX), Neutral switch no. 2 (MTX)*, CPP switch (MTX), 10 KS
Clutch stroke sensor (MTX)*, CAN 11 CKP sensor
*: Vehicles with i-stop system 12 Oil pressure switch
13 A/F sensor
14 HO2S
15 BARO sensor
01 Engine (SKYACTIV-G)

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 output devices
91
Output devices Input devices
associated with associated with
the control items the control items

01 Engine (SKYACTIV-G)

Control System
92

01 Engine (SKYACTIV-G)

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Control System
93

With i-stop system

01 Engine (SKYACTIV-G)

Control System
94
With i-stop system

With i-stop system

01 Engine (SKYACTIV-G)

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Control System
95

01 Engine (SKYACTIV-G)

Activity 01G
96

Activity 01

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02 Suspension

Front suspension
2

02 Suspension

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Front suspension
3

Item Specification
Type Strut type
Spring type Coil spring
Low-pressure gas charged,
Shock absorber type
cylindrical, double-acting
Type Torsion bar
Stabilizer 21.0 {0.827} (SKYACTIV-G)
Diameter (mm {in})
22.0 {0.866} (SKYACTIV-D)
Tire (mm {in})
2 {0.08}
[Tolerance ±4 {0.2}]
Total toe-in
[Tolerance ±4 Rim inner (mm {in}) With 17 inch wheel: 1.4 {0.04}
{0.2}] [Tolerance ±3 {0.1}] With 19 inch wheel: 1.4 {0.04}
Wheel (Degree) 0°10’ ±0°20’
alignment Maximum steering angle Inward 37.80°
(Unloaded) [Tolerance ±3°] Outward 30.90°
Caster angle [Tolerance ±1°] 6°29’±45’ (Reference)
Camber angle [Tolerance ±1°] -0°22’±45’ (Reference)
Steering axis inclination 12°00’ (Reference)
02 Suspension

Rear suspension
4

2WD

4WD

02 Suspension

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Rear suspension
5

Item Specification
Type Multi-link
Spring type Coil spring

Low-pressure gas charged,

Shock absorber type
cylindrical, double-acting

Type Torsion bar

Stabilizer 2WD: 18.0 {0.709in}
Diameter (mm {in})
AWD: 19.0 {0.748in}
Tire (mm {in})
2 {0.08}
[Tolerance ±4 {0.2}]
Total toe-in With 17 inch wheel: 1.4
Wheel [Tolerance ±4 Rim inner (mm {in}) {0.04}
alignment {0.2}] [Tolerance ±3 {0.1}] With 19 inch wheel: 1.4
(Unloaded) {0.04}
(Degree) 0°10’ ±0°20’
Camber angle [Tolerance ±1°] -1°01’ (Reference)
Thrust angle [Tolerance ±0°48’] 0°00’
02 Suspension

Tire & wheels

6

Item Specification
Tire size 225/65R17 102V 225/55R19 99V
Supplier Yokohama Toyo
Front 230 250
Tire air pressure (kPa)
Rear 230 250
Wheel size 17×7J 19×7J
Material Steel Aluminum alloy
Offset (mm {in}) 50 {in}
Pitch Circle Diameter (mm {in}) 114.3 {4.50}
Hub diameter (mm {in}) 67 {in}

Temporary spare tire & wheel (Except Mexico specs)

Item Specification
Tire size T145/90D16 106M T155/90D18 103M
Wheel size 16 x 4T 18 x 4T
Inset (mm {in}) 40 {1.6}
Pitch Circle Diameter (mm {in}) 114.3 {4.50}
Material Steel

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 tire air pressure
7

(kPa {bar <psi>}) 225/65R17 102V 225/55R19 99V

Front Up to 3 persons 230 {2.3, <33>}*3 250 {2.5, <36>}
250 {2.5, <36>}*3
Full load 260 {2.6, <38>}*3 260 {2.6, <38>}
270 {2.7, <39>}*3
Rear Up to 3 persons 230 {2.3, <33>}*3 250 {2.5, <36>}
250 {2.5, <36>}*3
Full load 280 {2.8, <41>}*3 290..9, <42>}
290 {2.9, <42>}*3

02 Suspension

TPMS
8

The tire pressure monitoring system, which indirectly detects tire air
pressure drop, is a supplementary system which notifies the driver that a
tire pressure has decreased.
The tire pressure monitoring system warns the driver if a difference occurs
between the previously determined tire pressures compared to the actual
tire air pressures.
A switch for initializing the tire pressure monitoring system after the tire
pressures have been adjusted is installed to the instrument cluster.

02 Suspension

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TPMS
9

02 Suspension

TPMS warning light

10

 Illuminates or flashes based on the DSC HU/CM command.

 Illuminates if a tire pressure decreases below the specified value based
on the initialization.
 flashes for 1 min if a malfunction in the tire pressure monitoring system
is detected, and then it illuminates.
 The initialization is to be performed if TPMS warning light has
illuminated by pressing TPMS set switch. If it is not performed, the
TPMS light will illuminate again when the ignition is switched from OFF
to ON.

02 Suspension

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TPMS operation chart
11

02 Suspension

misuse prevention
12

02 Suspension

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TPMS
13

TPMS initialization
Learning value can be reset (TPMS initialization) by TPMS set switch
located in the
cabin.
TPMS initialization must be performed when any of the following is met:
 Tire air pressure is adjusted
 Tire rotation is performed
 Tire or wheel is replaced
 DSC/ABS unit is replaced
 The battery is replaced or completely dead
 Wheel speed sensor is replaced
 TPMS warning light comes on “Perform it after tire air adjustment”

02 Suspension

TPMS
14

02 Suspension

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TPMS
15

02 Suspension

TPMS
16

02 Suspension

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TPMS
17

TPMS will not work properly under the following conditions:

Size, manufacturer, or the type of tires is different from the specified ones
Size, manufacturer, or the type of a tire is different from the others, or the level of
tire wear is excessively different between them
A run-flat tire, studless tire, snow tire, or tire chains are used
An emergency tire is used (The tire pressure monitoring system warning light
may flash and then continue illuminating)
A tire is repaired using the emergency flat tire repair kit
Tire pressure is excessively higher than the specified pressure, or the tire
pressure is suddenly lowered for some reason such as a tire burst during driving
Vehicle speed is less than about 15 km/h (including when the vehicle is
stopped), or the drive period is shorter than 5 minutes
Vehicle is driven on an extremely rough road or a slippery, icy road
Hard steering and rapid acceleration/deceleration are repeated such as during
aggressive driving on a winding road.
02 Suspension

TPMS
18

Direct TPMS Indirect TPMS Indirect TPMS

for CX-5

Pressure sensor with Wheel speed sensor, Wheel speed sensor,

transmitter sensing wheel speeds sensing wheel speeds and
torsional-vibration

02 Suspension

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TPMS
19

02 Suspension

TPMS
20

02 Suspension

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TPMS
21

02 Suspension

TPMS, operational record

22

02 Suspension

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TPMS, operational record
23

If there is no record of TPMS warning light illumination, “65535 days” is indicated.

“65535” is a default value of the system.
02 Suspension

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03 Driveline/Axle

Specification
2
Item SKYACTIV-G 2.0 SKYACTIV-D 2.2
Front axle type Wheel bearing type Angular ball bearing
Rear axle type Wheel bearing type Angular ball bearing
Joint Wheel side Bell joint
type Differential side Tripod joint
Shaft LH: 26.0 {1.024} LH: 27.0 {1.063}
Front drive shaft ATX
diameter RH: 27.5 {1.08} RH: 29.0 {1.142}
(mm LH: 27.0 {1.063}
MTX
{inc.}) RH: 29.0 {1.142}
Joint Wheel side Bell joint
Rear drive shaft
type Differential side Tripod joint
(4WD)
Joint diameter (mm {inc.}) 22.0 {0.87}
Reduction gear type Hypoid gear
Differential gear type Straight bevel gear
Ring gear size (inc.) 7.4
Final reduction ratio 2.928
Rear differential No. of Drive pinion 14
teeth Ring gear 41
Genuine long-life hypoid
Differenti Type
API GL-5, SAE 80W-90
al oil
Qty. (L) 0.45 (Reference)
Genuine long-life hypoid
Transfer Type
Transfer API GL-5, SAE 80W-90
oil
03 Driveline/Axle Qty. (L) 45.Reference)

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Specification
3

Item SKYACTIV-G 2.0 SKYACTIV-D 2.2

L1 741.5 {29.19}
Length (mm {inc.})
L2 1353.8 {53.299}
Propeller Shaft Outer diameter D1 75 {3.0}
(4WD) (mm {inc.}) D2 68 {2.7}
Joint type CV joint with hook joint
CV joint Double-offset joint

03 Driveline/Axle

Axle
4

An angular ball bearing, with a low rotational resistance, has been

adopted, improving drivability.
A unit bearing that does not require pre-load setting has been adopted,
improving serviceability.

03 Driveline/Axle

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Axle
5

03 Driveline/Axle

Overview
6

03 Driveline/Axle

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Overview
7

03 Driveline/Axle

Transfer
8

A transfer with simple, one-axis construction has been adopted for size
and weight reduction.
A thinner transfer case has been adopted for weight reduction.

03 Driveline/Axle

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Rear differential
9

 Rear differential and coupling component are integrated to reduce size and
weight.
 Differential carrier made of aluminum alloy contributes to reducing weight.

03 Driveline/Axle

Rear differential
10

03 Driveline/Axle

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Rear differential
11

03 Driveline/Axle

Rear differential
12

03 Driveline/Axle

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4WD
13

03 Driveline/Axle

4WD
14

03 Driveline/Axle

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4WD
15

03 Driveline/Axle

4WD
16

03 Driveline/Axle

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4WD
17

Normal Control
When starting off or accelerating during straight-ahead driving, torque
transmitted to the rear wheels is optimally controlled to ensure sufficient
acceleration performance. Due to this, standing-start and acceleration
performance is improved.
If a parking brake signal input to the 4WD CM indicates, the module
controls the torque transmitted to the rear wheels.
Tight Cornering Control
When the 4WD CM determines, based on the four-wheel speed signal,
that the vehicle is in tight cornering, it reduces the torque transmitted to the
rear wheels to avoid tight corner braking characteristics.

03 Driveline/Axle

4WD
18

Integrated DSC Control

If a signal from the DSC HU/CM input to the 4WD CM indicates that ABS
control is activated, the module controls the torque transmitted to the rear
wheels to prevent undue influence on ABS control.
Also, when a coupling torque request signal is received from the DSC CM,
the module controls the torque transmitted to the rear wheels to match the
amount of requested torque.
Other Control
In case the rear differential oil temperature exceeds the specified amount,
or when there is an unusually large variation in the rotation speed of the
front and rear wheels (ex. when trying to get unstuck), control is
temporarily suspended in order to protect the 4WD system. When this
occurs, the 4WD warning light flashes to indicate the situation to the driver.

03 Driveline/Axle

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4WD
19

03 Driveline/Axle

4WD
20

The electronic control coupling basically consists of an electromagnetic clutch, a

cam mechanism and a torque transmission system.
The electromagnetic clutch consists of a 4WD solenoid (electromagnetic coil), rear-
housing that forms a magnetic path, pilot clutch, and armature. The cam
mechanism consists of a pilot cam, balls, and main cam.
The torque transmission system consists of a main clutch and hydraulic oil (ATF).

03 Driveline/Axle

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4WD
21

03 Driveline/Axle

4WD
22

To distribute torque to the rear wheels, the 4WD CM energizes the 4WD solenoid.
The pilot cam is locked by the pilot clutch when 4WD solenoid is energized. The
difference in speed between Pilot cam and Main cam produces a wedge effect
through the balls. This wedge effect generates clutch force of the main clutch.

03 Driveline/Axle

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4WD
23

03 Driveline/Axle

4WD
24

03 Driveline/Axle

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Rear differential
25

03 Driveline/Axle

Rear differential
26

03 Driveline/Axle

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04 Brake

Overview
2

 Brake pedal intrusion is minimized to improve driver safety.

 Master cylinder with a small diameter and long stroke is employed to
improve operability and response.
 A vacuum pump is employed to ensure braking force.

04 Brake

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Specification
3

Item Specification
Type Suspended
Brake pedal Pedal lever ratio 2.8
Maximum stroke (mm) 132.7
Type Tandem
Master cylinder
Cylinder inner diameter (mm) 20.64
Type Ventilated disc
Cylinder inner diameter (mm) 60.3
Brake pad (area x thickness)
6,000 x 10.0
Front brake (mm2 x mm)
Brake disc
(outer diameter x thickness) 297 x 28
(mm)

04 Brake

Specification
4

Item Specification
Brake pedal Type Suspended
Type Slid disc
Cylinder inner diameter (mm) 38.1
Brake pad (area x thickness)
Rear brake 2,800 × 8.5
(mm2 x mm)
Brake disc
303 × 10
(outer diameter x thickness) (mm)
Type Vacuum
Power brake unit
Outer diameter (inc) 9.8
Brake force control EBD (Electronic brake
Type
force distribution)
Brake piping Piping Diagonal
Mechanical, rear two
Type
wheels
Parking brake
Operating method Manual lever
Adjusting mechanism Auto-adjuster
Brake fluid Type Genuine BF-3
04 Brake

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Specification
5

Vacuum pump maximum vacuum (reference value)

Condition Specification

While idling 93.3 kPa [700 mmHg, 27.6 inHg] or more

04 Brake

Vacuum pump
6

04 Brake

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Vacuum pump
7

04 Brake

HLA: Hill Launch Assist

8

 The hill launch assist (HLA) is a function provided by using the

system and components such as DSC HU/CM already equipped with
the vehicle. Without using any new and particular components, HLA
functions to assist the driver to safely start the vehicle on a slope of
7% or more. The major features are:
 The traction control solenoid valve in the DSC HU/CM is activated to
maintain or reduce brake fluid pressure for a specified time.
 The hill launch assist (HLA) operates constantly without affecting the
TCS OFF switch operation.
 HLA does not operate when the parking brake is applied or when the
DSC indicator light illuminates.
 G-sensor is initialized at the point of production. In addition, there is
self-learning function to correct changes due to aging.

04 Brake

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 HLA: Hill Launch Assist
9

04 Brake

HLA: Hill Launch Assist

10

04 Brake

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 HLA: Hill Launch Assist
11

04 Brake

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05A Automatic transaxle

Outline
2

05 Automatic Transaxle (SKYACTIV-Drive)

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Specification
3

Item Specification
FW6A-EL (2WD), GW6A-EL (2WD),
Transaxle type
FW6AX-EL (4WD) GW6AX-EL (4WD)
Engine type SKYACTIV-G 2.0 SKYACTIV-D 2.2
1GR 3.552 3.487
2GR 2.022 1.992
3GR 1.452 1.449
Gear ratio 4GR 1.000 1.000
5GR 0.708 0.707
6GR 0.599 0.600
R 3.893 4.090
Final gear ratio 4.624 4.090
Type Genuine ATF FZ
7.8 L {8.2 US qt, 8.0 L {8.5 US qt,
Capacity (approx. quantity)
6.9 lmp qt} 7.0 lmp qt}
ATF
Added amount if ATF is 3.5-4.9 L 3.5-4.9 L
drained from drain plug {3.7-5.1 US qt, {3.7-5.1 US qt,
(approx. quantity) 3.1-4.3 lmp qt} 3.1-4.3 lmp qt}
05 Automatic Transaxle (SKYACTIV-Drive)

Specification
4

Item Specification
Hydraulic Clutch 2
components Brake 3
Linear/Duty 5/0
Solenoid valve
ON-OFF 1
D, M (1GR) 330-470 {3.37-4.79, 47.9-68.2}
Line Idle
R 500-700 {5.10-7.13, 72.6-101.0}
pressure
(kPa) D, M (1GR) 970-1,170 {9.90-11.93, 141.0-169.6}
Stall
R 1,790-2,100 {18.26-21.41, 259.7-304.5}
D range
1,900-2,600 2,100-3,100
Stall speed (rpm) M range
R range 1,700-2,200 1,800-2,400
Stall torque ratio 1.82 1.88
Weight (kg) [reference] 86 -

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Activity 05A
5

Activity 05A

Planetary gear unit

6

Item Specification
FW6A-EL (2WD), GW6A-EL (2WD),
Transaxle type
FW6AX-EL (4WD) GW6AX-EL (4WD)
Internal gear 97 97
Front planetary
Pinion gear 29 29
gear
Sun gear 38 39
Internal gear 95 95
Rear planetary
Pinion gear 27 27
gear
Sun gear 40 41
Internal gear 109 109
Reduction
Pinion gear 21 22
planetary gear
Sun gear 68 66

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Control system wiring diagram
7

05 Automatic Transaxle (SKYACTIV-Drive)

system diagram
8

05 Automatic Transaxle (SKYACTIV-Drive)

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Activity 05A
9

Activity 05A

Activity 05A
10

Activity 05A

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Activity 05A
11

Activity 05A

Cross section diagram

12

05 Automatic Transaxle (SKYACTIV-Drive)

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Friction elements & Planetary gear unit
13

05 Automatic Transaxle (SKYACTIV-Drive)

Friction elements & Planetary gear unit

14

Friction element
FW6A-EL GW6A-EL
FW6AX-EL GW6AX-EL
Multiple-disc Low clutch 5/5 5/5
clutch High clutch 5/5 5/5
R-3-5 brake 3/3 4/4
Multiple-disc 2-6 brake 4/4 5/5
brake
Low & reverse
4/4 5/5
brake

(Number of drive plates/Number of driven plates)

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Friction elements & Planetary gear unit
15

05 Automatic Transaxle (SKYACTIV-Drive)

Friction elements
16

Components Description
It is activated when in 1GR, 2GR, 3GR, and 4GR,
Low clutch transmitting power from the turbine shaft to the sun
gear.
It is activated when in 4GR, 5GR, and 6GR,
High clutch transmitting power from the turbine shaft to the rear
planetary carrier.
Low & reverse It is activated when in 1GR and Reverse, holding
brake the front internal gear and the rear planetary carrier.
It is activated when in 2GR and 6GR, holding the
2-6 brake
rear and the reduction planetary gear.
It is activated when in 5GR, holding the reduction
R-3-5 brake
internal gear.
It functions when in 1GR, holding the front internal
One-way clutch
gear. (It does not rotate counterclockwise.)

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Operation chart
17

05 Automatic Transaxle (SKYACTIV-Drive)

Operation chart
18

05 Automatic Transaxle (SKYACTIV-Drive)

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Solenoid valve
19

Direct linear solenoid No. 1 Normally-closed type; when it is ON, it opens

its hydraulic passage to activate low clutch.
Direct linear solenoid No. 2 Normally-closed type; when it is ON, it opens
its hydraulic passage to activate 2-6 brake.
Direct linear solenoid No. 3 Normally-closed type; when it is OFF, it opens
its hydraulic passage to activate R3-5 brake.
Direct linear solenoid No. 4 Normally-open type: when it is OFF, it opens
its hydraulic passage to activate Low &
reverse brake or High clutch. Whether it is Low
& reverse brake or High clutch depends on the
status of On/OFF solenoid.

ON/OFF solenoid Normally open type: when it is OFF, Low &

reverse brake is activated. When it is ON, High
clutch is activated.

05 Automatic Transaxle (SKYACTIV-Drive)

Torque converter
20

05 Automatic Transaxle (SKYACTIV-Drive)

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Torque converter clutch
21

05 Automatic Transaxle (SKYACTIV-Drive)

Torque converter clutch

22

05 Automatic Transaxle (SKYACTIV-Drive)

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Torque converter clutch
23

Inhibition of TCC control

If any one of the following conditions is met, the torque
converter clutch control is inhibited.
― TCC solenoid malfunction
― ATF temperature is specification or less
― Engine speed signal is specification or less
― Turbine shaft speed is specification or less
― Other than D/M position

05 Automatic Transaxle (SKYACTIV-Drive)

One-way clutch
24

05 Automatic Transaxle (SKYACTIV-Drive)

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 Low clutch/High clutch
25

05 Automatic Transaxle (SKYACTIV-Drive)

Control valve body

26

05 Automatic Transaxle (SKYACTIV-Drive)

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Control valve body
27

05 Automatic Transaxle (SKYACTIV-Drive)

TFT sensor
28

05 Automatic Transaxle (SKYACTIV-Drive)

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TCM
29

05 Automatic Transaxle (SKYACTIV-Drive)

Activity 05A
30

Activity 05A

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TR switch
31

05 Automatic Transaxle (SKYACTIV-Drive)

TSS/OSS
32

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Oil pressure switch
33

05 Automatic Transaxle (SKYACTIV-Drive)

Oil pressure switch

34

Oil pressure switch Friction element 1GR 2GR 3GR 4GR 5GR 6GR

No.2 2-6brake ON ON
A
No.3 R-3-5brake ON ON

No.1 Low clutch ON ON ON ON

B
No.4 High clutch ON ON ON

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Control items
35

05 Automatic Transaxle (SKYACTIV-Drive)

Control items
36

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Control items
37

05 Automatic Transaxle (SKYACTIV-Drive)

Control items
38

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Block diagram
39

05 Automatic Transaxle (SKYACTIV-Drive)

AAS (Cornering)
40

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AAS (Merging into ex. way)
41

05 Automatic Transaxle (SKYACTIV-Drive)

Power flow: 1GR

42

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Power flow: 2GR
43

05 Automatic Transaxle (SKYACTIV-Drive)

Power flow: 3GR

44

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Power flow: 4GR
45

05 Automatic Transaxle (SKYACTIV-Drive)

Power flow: 5GR

46

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Power flow: 6GR
47

05 Automatic Transaxle (SKYACTIV-Drive)

Power flow: R
48

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Configuration
49

TCM configuration can be performed from Configuration/PMI menu

If communication is not established due to TCM malfunction or else, it is
possible to do it by entering As-built data after TCM replacement.

Replaced component Configuration TCM initial learning

Control valve body assembly Necessary Necessary

ATX complete (new) No need No need

ATX complete (Rebuilt) TBD TBD

Oil pressure switch A/B No need Necessary

ON/OFF solenoid No need No need

Lower harness with TFT sensor No need No need

05 Automatic Transaxle (SKYACTIV-Drive)

Activity 05A
50

Activity 05A

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Activity 05A
51

Activity 05A

Activity 05A
52

Activity 05A

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05M Manual transaxle

C66M-R (2WD), C66MX-R (4WD) for SKYACTIV-G

Outline
2

(1) Short stroke and increased lever ratio

 Shortened the shift stroke, increased lever ratio to reduce
required effort, and downsized synchromesh mechanisms
with lowered stroke.
 Reduced sliding friction between the shift lock ball and
detent plate when selecting (shift lever's lateral movement
left-right)
 When shifting up, required effort for moving the shift lever is
reduced by utilizing the weight of the shift change
mechanism.

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Outline
3

(2) Downsized by optimized gear composition

 A single input gear is commonly used for 2nd gear and 3rd
gear, contributing to reducing the length of the secondary
shaft by 20% as compared with the previous types.
 A single gear is commonly used as 1st gear and reverse
idle gear

05 manual Transaxle (SKYACTIV-MT)

Outline
4

(3) Fuel economy improvement

 The transmission weight is reduced by approximately 30%
due mainly to the new design transmission case.
 Lubricated with less amount of gear oil, reducing losses
caused by a stir of gear oil
 Adopted ball bearings to reduce the primary shaft rolling
resistance

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Specification
5

Item Specification
Transaxle type C66M-R (2WD), C66MX-R (4WD)
Engine type SKYACTIV-G 2.0
1GR 3.700
2GR 1.947
3GR 1.300
Gear ratio 4GR 1.029
5GR 0.837
6GR 0.680
R 3.724
Final gear ratio 4.388 (2WD), 4.705 (4WD)
Manual transaxle oil grade API service GL-4
Manual transaxle oil viscosity SAE 75W-80
Manual transaxle oil capacity
1.65 L {1.74 US qt, 1.45 lmp qt}
(approx. quantity)
05 manual Transaxle (SKYACTIV-MT)

Overview
6

05 manual Transaxle (SKYACTIV-MT)

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Overview
7

05 manual Transaxle (SKYACTIV-MT)

Overview
8

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Overview
9

05 manual Transaxle (SKYACTIV-MT)

Shift control module

10

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Power flow
11

05 manual Transaxle (SKYACTIV-MT)

Power flow
12

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Shift control module
13

05 manual Transaxle (SKYACTIV-MT)

Slide ball bearing

14

05 manual Transaxle (SKYACTIV-MT)

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1GR
15

05 manual Transaxle (SKYACTIV-MT)

1GR
16

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2GR
17

05 manual Transaxle (SKYACTIV-MT)

2GR
18

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3GR
19

05 manual Transaxle (SKYACTIV-MT)

3GR
20

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4GR
21

05 manual Transaxle (SKYACTIV-MT)

4GR
22

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5GR
23

05 manual Transaxle (SKYACTIV-MT)

5GR
24

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6GR
25

05 manual Transaxle (SKYACTIV-MT)

6GR
26

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Reverse
27

05 manual Transaxle (SKYACTIV-MT)

Reverse
28

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Synchronizer mechanism
29

Triple cone synchronizer mechanism (1ST/2ND)

05 manual Transaxle (SKYACTIV-MT)

Synchronizer mechanism
30

Synchronizer mechanism (3RD/4TH)

05 manual Transaxle (SKYACTIV-MT)

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Synchronizer mechanism
31

Synchronizer mechanism (5TH/6TH)

05 manual Transaxle (SKYACTIV-MT)

Synchronizer mechanism
32

Synchronizer mechanism (Reverse)

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Detent ball type sync. key
33

Except for the reverse gear.

A crisp feel
Smaller than the conventional synchronizer key, shortened the
primary and secondary shafts.
Reduced the stroke amount of the clutch hub sleeve, the stroke of the
shift lever in the cabin has been shortened.

05 manual Transaxle (SKYACTIV-MT)

Detent ball type sync. key

34

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1st/2nd
35

05 manual Transaxle (SKYACTIV-MT)

1st/2nd
36

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1st/2nd
37

05 manual Transaxle (SKYACTIV-MT)

1st/2nd
38

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3rd,4th, 5th, 6th, Reverse
39

05 manual Transaxle (SKYACTIV-MT)

3rd,4th, 5th, 6th, Reverse

40

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Case
41

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06 Steering

Overview
2

 High geared steering gear

 Quick response at low and mid speed ranges

06 Steering

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EPS
3

 Supplied by JTECT
 Improved motor output
 Improved rigidity of the intermediate shaft
 Reduced inertia force by adopting brushless motor
 Automatic configuration function
When the ignition is switched to ON or the engine is started after the
EPS CM have been replaced, the EPS CM reads data from the
instrument cluster via CAN communication to perform automatic
configuration.
 Steering wheel angle neutral position automatic learning function
When the ignition is switched from OFF to ON and the vehicle is driven
normally, the steering wheel angle neutral position is detected
automatically based on the signal from the torque sensor.

06 Steering

EPS
4

06 Steering

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EPS
5

06 Steering

EPS
6

06 Steering

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EPS
7

06 Steering

Steering lock
8

Steering lock mechanism is integrated into SSU. Lock or unlock is

controlled by the SSU directly.

06 Steering

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Steering lock
9

06 Steering

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07 HVAC

Air-conditioning system
2

Performance is improved as compared with existent models.

 Cooling capacity is improved by 6%
 Weight is reduced by 13%

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Air-conditioning system
3

07 HVAC

Air-conditioning system
4

07 HVAC

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Full-auto air conditioner
5
Overview

07 HVAC

Full-auto air conditioner

6
System
wiring
diagram

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Full-auto air conditioner
7
Block diagram

07 HVAC

Manual auto air conditioner

8
Overview

07 HVAC

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Manual auto air conditioner
9
System wiring diagram

07 HVAC

Manual auto air conditioner

10
Block diagram

07 HVAC

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Refrigerant pressure sensor
11

A capacitance type A/C pressure sensor is employed. This converts refrigerant

pressure into a linear electric signal.
The pressure detecting part is a variable capacity condenser, which changes
capacitance according to the pressure. The signal processing part detects the
capacitance of pressure detecting part, converts it to voltage, then outputs it to the
climate control unit

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08 RESTRAINTS

Overview
2

08 RESTRAINTS

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Overview
3

08 RESTRAINTS

Overview
4

08 RESTRAINTS

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System wiring diagram
5

08 RESTRAINTS

Front air bag

6

1. Driver/Front passenger inflators and air bags

2. Crash sensors, and diagnostic module (SAS unit)
3. Front seat belt pre-tensioners
4. Front air bag sensors
5. Side crash sensors
6. Air bag/front seat belt pre-tensioner system warning light
7. Side and curtain inflators and air bags
8. Front passenger air bag deactivation indicator light
9. Front passenger air bag deactivation switch
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Front air bag
7

08 RESTRAINTS

Front air bag

8

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09 Body & accessories

Contents
2

09 Body & Accessories

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Body panel
3
Triple H-shaped structure
An H-shaped structure has been adopted in which reinforcements are
equipped in the floor, side frame, and roof, and each connection area is
strengthened. The combination of these three structural areas provides the
strong triple H-shaped structure. The triple H structure distributes the impulse
force at the side collision to reinforcement of the roof, cabin side frame, and
floor. The triple H-shaped structure controls the twisting of the cabin while
driving.

09 Body & Accessories

Body panel
4
Crushable structure
Engine mounting brackets and front suspension crossmember are made to
break away during a collision.

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Body panel
5
Ring structure
For the ring structure, the basic framework is thoroughly straightened, and
the frames are circularly linked.

09 Body & Accessories

Body panel
6
Multi-load path
The multi-load path is stabilized during a collision, and has set the load
distribution load path which carries out energy absorption.
The front side frame, front B frame and rear side frame are made into straight
forms.
The front side frame is supported by the side sill, front B frame and side
member.

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Body panel
7
Bonnet
The bonnet is constructed with a large space between the front end of the
bonnet and the engine to absorb an impact.

09 Body & Accessories

Door impact
8

09 Body & Accessories

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Inner press door
9

09 Body & Accessories

Power outer mirror

10

The design of the retract switch for CX-5 is different from those of existent
models.
The retract switch is integrated into the power outer mirror switch. The
symbol of retract switch is found on the outer dial of the power outer mirror
switch.

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Auto-dimming mirror
11

09 Body & Accessories

Seat
12

09 Body & Accessories

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Power Seat switch layout
13

09 Body & Accessories

Security & Lock

14

Keyless entry system

 Key cylinder is directly connected to the latch. Column BCM and

Electric steering lock are integrated.
 A commonly designed transmitter is adopted for Remote Keyless Entry
and Advanced Keyless Entry
 The means of key authentication
The new structure, which the key cylinder is directly connected, is adopted
to the latch for theft prevention

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Security & Lock
15

Comparison between Advanced Keyless Entry and Keyless Entry

Item WITH WITHOUT

Door unlock/lock by request
switch Available None

Are departure auto-lock

control Available None
(Personalization function)
Transmitter left-in-car
Available None
prevention
Door lock beep answer back Available None

Theft deterrent alarm Available None

09 Body & Accessories

Advanced keyless system

16

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Advanced keyless system
17

09 Body & Accessories

Advanced keyless system

18

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Advanced keyless system
19

09 Body & Accessories

Exterior trim
20

09 Body & Accessories

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Exterior trim
21

09 Body & Accessories

Interior trim
22

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Interior trim
23

09 Body & Accessories

Interior trim
24

09 Body & Accessories

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Wiper Washer system
25

09 Body & Accessories

Wiper Washer system

26

09 Body & Accessories

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Wiper Washer system
27

09 Body & Accessories

Wiper Washer system

28

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Entertainment
29

 AM/FM shark fin antenna is employed.

 Two types of audio units are available as follows:

09 Body & Accessories

Entertainment
30

WITHOUT COLOR LCD WITH COLOR LCD

Radio, CD, Line-in/USB port Radio, CD, Line-in/USB port,
Navigation, Phone (Bluetooth)
(1) Applicable to USB/iPod as (1) USB connection
standard
(2) iPod connection
(2) Music in AAC format is
(3) Bluetooth connection
playable
(4) HD Radio
(3) Displaying in Latin characters
(5) Vehicle customization
(4) Improving reception
performance by on-board radio (6) Improved functions of car
tuner navigation system

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Entertainment
31

09 Body & Accessories

Entertainment
32

09 Body & Accessories

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Entertainment
33

Shark-fin shape aerial is adopted to improve aerodynamics. An amplifier

and band pulse filter are built in the shark-fin shape aerial, ensuring
reception performance.

09 Body & Accessories

Instrumentation/Driver info
34

09 Body & Accessories

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Instrumentation/Driver info
35

09 Body & Accessories

Instrumentation/Driver info
36

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Instrumentation/Driver info
37

09 Body & Accessories

Instrumentation/Driver info
38

09 Body & Accessories

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Instrumentation/Driver info
39

The light illuminates continuously if any one of the following occurs.

 There is a malfunction in the deceleration regeneration system.
 There is a malfunction in the battery management system.
 There is a malfunction in the brake switch.
The customer will be notified that there is a malfunction by the master
warning light. Actions that the customer is required vary according to the
specification of the instrument cluster type.

09 Body & Accessories

Instrumentation/Driver info
40

w/ TFT LCD display (Type A)

It is required to check the details with the display because of a hazardous
condition or a system malfunction. Following the instruction on the display
or the instruction manual, it is necessary to take proper actions.
w/o TFT LCD display (Type B)
It is required to have the vehicle inspected due to a system malfunction as
follows:
Current sensor (CX-5 with i-stop)
Stop lamp
Engine oil control (SKYACTIV-D 2.2)
Engine timing chain (SKYACTIV-D 2.2)
Blow-by heater (SKYACTIV-D 2.2)

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Instrumentation/Driver info
41

09 Body & Accessories

Push button start system

42

Push button start system

Push button start system is adopted for all market for all types by utilizing
advantages of common architecture of the electric platform.
(1) The system adopted Start Stop Unit (SSU) consisting of F-BCM and electric
steering lock, and optimized location of Long-frequency (LF) antenna forms an
area in the cabin where push button start is activated with a single via LF antenna.
(2) The components formation is optimized that can establish Advanced Keyless
Entry system by adding LF control unit (LFU), LF antenna, and other components
to the basic systems. (Basic systems: Remote keyless and push button start)
(3) No IG key cylinder

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Push button start system
43

09 Body & Accessories

Push button start system

44

The engine may not start if the key is placed in the following areas:
 Around the instrument panel
 In the storage compartments such as the glove box
 On the rear parcel shelf
 In the luggage compartment

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Push button start system
45

LFU（LF Control Unit）

It is equipped with the vehicles with advance keyless entry. It is used for
transmitting a request signal based on the request signals via keyless
antenna, and for controlling the keyless buzzer.
It also sends signals of door lock/unlock to the R-BCM based on the
location of the key recognized outside the vehicle.

09 Body & Accessories

Push button start system

46

09 Body & Accessories

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Push button start system
47

When the battery for advanced key is weak or dead, it is necessary to

carry out the procedure for key identification to start the engine. This
procedure for CX-5 is different from that of existent models. The customer
may be confused when encountering such case.

09 Body & Accessories

Push button start system

48

09 Body & Accessories

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Push button start system
49

09 Body & Accessories

Push button start system

50

09 Body & Accessories

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 Sensor calibration
51

09 Body & Accessories

Sensor calibration
52

09 Body & Accessories

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 Operational record
53

09 Body & Accessories

Operational record
54

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 Operational record
55

09 Body & Accessories

Operational record
56

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 Operational record
57

09 Body & Accessories

Operational record
58

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 Operational record
59

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10 Multiplex
communication system

HS-CAN
2

 PCM
 DSC HU/CM
 TCM (ATX vehicles)
 AFS control module (with AFS system)
 Front body control module (FBCM)
 4WD control module (4WD vehicles)
 Laser sensor (with smart city brake support system)
 Forward sensing camera (with hi-beam control (HBC) system)
 SSU
 EPS control module
 SAS control module
 Instrument cluster
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MS-CAN
3

 Rear body control module (RBCM)

 Rear mount camera (with rear mount camera)
 BSM control module (LH) (with BSM system)
 Rear vehicle monitoring control module (RH) (with rear vehicle
monitoring system)
 BSM control module (RH) (with BSM system)
 Parking sensor control module (with parking sensor system)
 Climate control unit (with full-auto air conditioner)
 Clock (with manual air conditioner)
 Audio unit (with audio unit (color LCD))
 Instrument cluster

10 multiplex communication system

MS-CAN
4

10 multiplex communication system

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Location
5

10 multiplex communication system

Location
6

10 multiplex communication system

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HS-CAN
7

10 multiplex communication system

MS-CAN
8

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Connection
9

10 multiplex communication system

BCM
10
Advantage of employing the 3 BCMs
In view of reducing cost and improving performance, the new architecture was
developed with 3 modules.
 Module is located in place close to the output and input devices
 The BCM which is the core to execute control items is in place close to the load

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BCM
11

10 multiplex communication system

BCM
12

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BCM
13

10 multiplex communication system

BCM
14

10 multiplex communication system

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BCM
15

10 multiplex communication system

BCM
16

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BCM
17

Control item FBCM RBCM SSU

Defroster X
Blower motor X
Front combination light X
Front fog light X
Auto-light system X
Front wiper X
Horn X
Power door lock X
Room light control X
Rear wiper X
Advanced keyless entry X
Keyless entry X
Push button start X
Immobilizer X
Input of combination switches X
Input of steering switches X
10 multiplex communication system

Programmable module
18

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 Others
19

10 multiplex communication system

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