Kia Sportage: Direct Electro Hydraulic Actuator Coupling
Description and Operation
Description
4WD ECU processes signals from various sensors and determines the current
road and driving conditions. The ECU then
utilizes this information to implement precision control over the 4WD coupling's
multi-plate clutch and variably adjust the
amount of torque delivered to the rear wheels.
Four Wheel Drive (4WD) transfer mode selection
1. AUTO MODE:
- When driving in 4WD AUTO mode, the vehicle operates similar to
conventional 2WD vehicles under normal
operating conditions. However, if the system determines that there is a need
for the 4WD mode, the engine's driving
power is distributed to all four wheels automatically without driver
intervention.
- When driving on normal roads and pavement, the vehicle moves similar to
conventional 2WD vehicles
2. LOCK MODE:
- This mode is used for climbing or descending sharp grades, off-road
driving, driving on sandy and muddy roads, etc.,
to maximize traction.
- This mode automatically begins to deactivate at speeds above 30 km/h (19
mph) and is shifted to 4WD AUTO
mode at speed above 40 km h (25 mph). If the vehicle speed decelerates to
below 30 km/h (19 mph), however, the
transfer mode is shifted into 4WD LOCK mode again.
Electronic Coupling - 4WD Control (By Driving Condition)
1. Cruising (Auto Mode)
- Power is delivered mostly to the front wheels.
![2. Cornering (Auto Mode)](images/books/1921/1/index%2023.png)
2. Cornering (Auto Mode)
- Adjusts the amount of power to the rear wheels based on the turning
radius and cornering speed.
![3. Wheel Slip (Auto Mode)](images/books/1921/1/index%2024.png)
3. Wheel Slip (Auto Mode)
- If one or both of the front wheels lose fraction, the system transfers
an appropriate amount of power to the rear wheels
based on the slip amount at the front wheels.
![4. Lock Mode](images/books/1921/1/index%2025.png)
4. Lock Mode
- Maximizes rough terrain performance (active only at speeds below 40
km/h).
![Operation](images/books/1921/1/index%2026.png)
Operation
Electronic Coupling
[Inactive]
![[Active]](images/books/1921/1/index%2027.png)
[Active]
![Operation Order](images/books/1921/1/index%2028.png)
Operation Order
1. 4WD ECU receives CAN signals from the vehicle's sensors.
2. 4WD ECU calculates the necessary amount of rear-wheel torque and sends the
corresponding driving current to the
actuator (electronic motor and hydraulic pump).
3. Hydraulic pressure generated by the actuator moves the piston.
4. Friction from the piston's movement engages the clutch.
5. Power is delivered to the rear wheels.
Components and Components Location
Component Location
![](images/books/1921/1/index%2029.png)
- Automatic transaxle
- Transfer assembly
- Propeller shaft
- Coupling assembly
- Differential assembly
Components
![](images/books/1921/1/index%2030.png)
- Actuator
- Bleed valve
- Flange & Input
shaft
- Piston
- Clutch pack
- Oil seal cover
- Hub
Repair procedures
Inspection
NOTE
All units are filled up with coupling fluid (ultra-low viscosity ATF)
prior to shipping. Inspection, fill-up, and replacement of
coupling fluid is therefore not necessary (zero maintenance, lifetime fluid).
Removal
CAUTION
Coupling Maintenance Precautions
Maintain the coupling at a horizontal level.
- Refer to the handling caution level (A) when servicing the coupling
(removal, installation, replacement, etc.).
![](images/books/1921/1/index%2031.png)
- Remove the dipstick and then mount the coupling assembly to the rear
differential assembly.
- Maintain the coupling at a horizontal level after removing the
dipstick to prevent the fluid from spilling out.
![1. Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear](images/books/1921/1/index%2032.png)
1. Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear
propeller shaft (B).
Tightening torque: 49.0~68.6N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)
![2. Using a flat tool, separate the propeller shaft from 4WD coupling](images/books/1921/1/index%2033.png)
2. Using a flat tool, separate the propeller shaft from 4WD coupling
assembly.
3. Remove the electric magnetic clutch connector (A).
![4. Remove the 4WD coupling assembly mounting bolts (A-4ea).](images/books/1921/1/index%2034.png)
4. Remove the 4WD coupling assembly mounting bolts (A-4ea).
Tightening torque:
58.8~63.7N.m (6.0~6.5kgf.m, 43.4~47.0lb-ft)
![5. Using a flat tool, separate the 4WD coupling assembly from the rear](images/books/1921/1/index%2035.png)
5. Using a flat tool, separate the 4WD coupling assembly from the rear
differential carrier assembly.
Installation
1. Installation is the reverse of removal.
NOTE
- Grease the spline hole (A) of the coupling assembly.
Grease
Extreme Pressure (EP) grease containing molybdenum disulfide (MoS2)
- When installation the coupling, be careful not to damage the oil seal
(B).
![CAUTION](images/books/1921/1/index%2036.png)
CAUTION
After replacing the coupling, reset the 4WD ECU's clutch learing
using the GDS tool. (Refer to "Coupling assembly" in
4WD group).
Adjustment
Description
The friction material inside the coupling will degrade over time. Therefore,
corresponding compensation values must be
referenced and entered after replacing the controller or the coupling.
Compensation Requirement and Procedure
1. Simultaneous replacement of 4WD ECU (Controller) and coupling
- Does not require compensation.
2. Replacement of coupling only
- Reset the 4WD ECU's (Controller) clutch learing.
![](images/books/1921/1/index%2037.png)
![3. Replacement of 4WD ECU (Controller) only](images/books/1921/1/index%2038.png)
3. Replacement of 4WD ECU (Controller) only
- Before replacement: Check the ECU's clutch tearing.
![](images/books/1921/1/index%2039.png)
- After replacement: Enter the original ECU's clutch tearing into the
replacement ECU.
![Oil hydraulic Motor (Actuator)](images/books/1921/1/index%2040.png)
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The 4WD ECM controls the Pump Motor Pump (Actuator) to generating an oil
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Description and Operation
Description
The 4WD ECU makes a Motor Pump (Actuator) turn round for generating an oil
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SEE MORE:
When selecting a CRS for your child,
always:
Make sure the CRS has a label certifying
that it meets applicable Federal
Motor Vehicle Safety Standards
(FMVSS 213).
Select a child restraint based on your
child's height and weight. The
required label or the instructions for
use t
Repair procedures
Inspection
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad lower panel.
(Refer to the BD group - "Crash pad")
3. Remove the crash pad side switch assembly (A) after loosening 2 screws.
NOTE
Put on gloves to protect your hands.
4. R