Kia Stinger: Body Electrical System / Power Tailgate System

Kia Stinger CK 2018-2020 Service Manual / Body Electrical System / Power Tailgate System

Components and components location
Components

1. Anti pinch strip (2EA)
2. Power tailgate spindle (2EA)
3. Power tailgate buzzer
4. Side crash pad switch
5. Outside handle switch
6. Cluster (USM)
7. Power tailgate module (PTGM)
8. Power tailgate latch & power closing unit assembly
9. Power tailgate inner switch

Description and operation
Description

Power Tailgate system is an electro-mechanical system that can open and close the tailgate automatically, by using local switch (push button switch inside of the tailgate, and outside handle switch), and wireless remote key (FOB), or can halt the tailgate. The Power Tailgate module (PTGM) sends and receives the vehicle’s information via BCM, instrument panel, SJB and CAN communication, so that it can decide the opening/closing of the tailgate and self diagnosis.

There’s a safety function to reverse its direction, when an obstacle is detected during the operation.

If power mode is disabled due to discharged battery or disabled Power Tail Gate Module (PTGM), manual opening/closing is possible by using the emergency lever on the liftgate latch after unlocking the tailgate.

Location and Direction of the Tailgate

PTG system measures the location of the tailgate through the total hall sensor inside of the spindle unit motor.

Also, the direction of the tailgate can be confirmed by analyzing the direction of spindle operation.

The signal counting (location confirmation) of the hall sensor is valid both in power operation mode and general operation mode.

PTG automatic operation mode can be changed to Manual operation mode by changing the cluster settings.

Components

1.

Power Tailgate Module (PTGM)

PTGM is installed inside the right-hand side luggage side trim in the back.

PTGM operates two spindle drive motors.

It also controls the anti-pinching function by analyzing anti-pinch sensor and the hall sensor in the spindle.

2.

PTG Latch Assembly

PTG latch assembly consists of power latch (A) and power closing unit (B).

PTG latch assembly is installed at the end of the tailgate and operates power lock/unlock mode under the PTGM control.

3.

PTG Spindle

PTG spindle controls the tailgate’s opening and closing using the torque of the motor inside.

Recognize the tailgate's driving direction by sending motor's revolving direction signal inside of spindle to PTGM.

4.

Anti-pinch Strip

APS(Anti-pinch strip) is installed on the left and righthand sides of the tailgate and detects jamming of an object during Power Tailgate closing operation.

When jamming is detected, PTGM will immediately reverse tailgate to full open status.

Antipinch strip does not operate when tailgate is fully closed or fully open, is stationary or while opening.

5.

Wireless Transmitter

Tailgate will start the Power Opening function when the tailgate opening button on the wireless transmitter is pressed for more than 1.0 second.

If the button is pressed shortly while the power tailgate is opening or closing, the power tailgate will stop its movement.

If the button is pressed for 1.0 second while the power tailgate is opening or closing, the power tailgate will reverse its direction.

6.

Side Crash Pad Switch

If the side crash pad switch is pushed for 1.0 second, the tailgate will operate power opening or closing function.

If the side crash pad switch is pressed shortly while the power tailgate is opening or closing, the power tailgate will stop its movement.

If the side crash pad switch is pressed for 1.0 second while the power tailgate is opening or closing, the power tailgate will reverse its direction.

7.

Power Tailgate Inner Switch

If the switch inside of the tailgate is pushed, the tailgate will start the power closing function.

8.

Power Tailgate Buzzer

When an obstacle is detected or power function is not performed properly in accordance to the user's order, the alarming buzzer will sound for 3 times.

And when power function is performed properly, the alarming buzzer will sound twice.

Operating Principle

Opening of the Power Tailgate

Primary switch signal is sent to PTGM via CAN communication. (sent by SJB)

Power Tailgate Opening Process

1.

Opening will start after signals from crash pad lower switch, tailgate handle switch, or wireless remote key(FOB) are received.

2.

The latch motor will unlatch the tailgate by releasing the striker (via the SJB).

3.

To open the tailgate, the PTG module will activate the tailgate spindle motors.

4.

The speed of the spindle motors is monitored via a hall sensor in the motor.

5.

Opening angle of the tailgate will be calculated from the number of pulses of the hall sensor.

  

When the motor’s movement is restricted PTGM will sense it as an obstacle and either reverse in opposite direction or halt the motor movement.

Power Tailgate closing

Power Tailgate Procedure :

1.

Closing will start after signals from crash pad switch, tailgate inner switch, or wireless remote key(FOB) are received.

2.

To close the tailgate, the PTGM will operate the Spindle motors.

3.

The PTGM monitors the Closing angle of the tailgate by counting the pulses from the hall sensors.

4.

The tailgate latch is put on the striker, and if the seal force is not too weak the latch will be on the Half Lock position. (latch full open → latch half lock)

5.

After the Half Lock switch signal from the latch is received, PTGM will stop the tailgate spindle motor operation.

6.

PTGM will engage voltage to PCU and the PCU will start cinching operation until PTGM receives Full Lock signal from the latch.

7.

The tailgate is fully closed, and the latch is fully locked.

Learning/Calculation/Program Location

1.

Maximum Point for Opening

The movement of opening direction beyond this position will make the tailgate to reach the maximum basic position, and overload the mechanical system(hinge).

So, opening movement beyond this position is impossible.

But, if the movement started from lower position, the tailgate will move beyond this point.

2.

Learned Mechanical End Position

Mechanical End Position is the mechanical limited position, and is regarded as 100% opened.

This position is being Learnt in the process of the first opening of the tailgate.

After the learning, the tailgate will not go beyond the maximum basic position that is defined as soft stop.

All of the positions will be defined by parameters that are designated by ECU.

Open maximum Programming (Garage Position)

1.

After mechanical End Position is learned, the basic position defined by user will be regarded as same as the maximum basic position.

The user may shift the learned basic position to any position. (within the range between Maximum position For Closing and Maximum Basic Position)

If the user wishes to move the new basic position lower than the old basic position, he or she has to move the tailgate to the new position automatically or manually and push the internal switch of the tailgate for five seconds. (Time may differ in accordance with parameters.)

If the user wishes to set the tailgate position above the maximum basic position, ECU will set the basic position as the maximum basic position.

System Parameter

Before the normal operation is guaranteed, mechanical tolerance and adjustment at vehicle production line and the maximum movement range correction by Power Tailgate assembling are required.

From the end point that is limited by mechanical binding when the tailgate is fully closed (latch locked), the maximum movement range of the tailgate in operation is expressed by the number of the hall pulse signal of spindle speed and location sensor that are sent by ECU.

Calibration Mode

Manual De-calibration Mode

Buzzer Operation Mode

Operation
Request source
Number of buzzer cycles
Number of hazard cycles
Comment
Start opening
Outside Switch
2
2
Delay start of tailgate until first cycle is over
Inner Switch
 
Console Switch
Remote Key
Smart Key
Start closing
Outside Switch
2
2
 
Inner Switch
Console Switch
Remote Key
Smart Key
Direct direction change
(Open -> Close)
(Area : Closed - Maximum end point for closing)
Outside Switch
2
2
No delay (Reversing and buzzing at the same time)
- Only delay due to mechnical system
Inner Switch
Console Switch
Remote Key
Smart Key
Obstacle detection
(Reverse operation start)
-
3
-
-
Vehicle speeds when tailgate is open
-
10
-
Stop condition
1. Complete 10 times.
2. Tailgate full lock.
Adjust height
Inner Switch
2
-
-
Initialization
(Deleting end position and basic position)
Inner Switch & Outside Switch
1
-
-
Initialization
(Learning end point)
-
-
2
-
Initialization
(During calibration)
-
Continuous
-
-
Tailgate not closed
-
10
10
Tailgate closed but lock switch not off (Still open)
Error detect
-
3
-
- APS error
- Spindle error
- Hall sensor error
- System error (EEPROM error)
- Voltage error (Over/Under)
- PCU error
- Latch position error
- Stuck switches. (Switch pressed more than 30 sec)
- Thermal protection

Troubleshooting
Failure Inspection

Diagnosis With KDS

1.

In the body electrical system, failure can be quickly diagnosed by using the vehicle diagnostic system (KDS).

The diagnostic system (KDS) provides the following information.

(1)

Self diagnosis : Checking failure and code number (DTC)

(2)

Current data : Checking the system input/output data state

(3)

Actuation test : Checking the system operation condition

(4)

Additional function : Controlling other features including system option setting and zero point adjustment

2.

Select the 'Car model' and the 'Power tailgate Module' to be checked in order to check the vehicle with the tester.

3.

Select the 'Current Data' menu to search the current state of the input/output data.

4.

To forcibly actuate the input value of the module to be checked, select option 'Actuation Test'

Mode Change (Power Tailgate System)

1.

After replacing with a new power tailgate module, check for DTC code at all times.

If DTC code B24B0 exists, perform power tailgate mode change.

2.

After connecting the KDS, select the "Power Tailgate Mode Change" procedure.

3.

Perform the tailgate mode change procedure according to displayed messages on KDS.

  

If power tailgate system is operated with factory mode, it makes the abnormal warning sound.

System Initialization

System initialization is needed to recognize the closing position of the tailgate to power tailgate module.

The initialization process after battery power reset, system initialization is needed to recognize the maximum opening and closing tailgate position exactly.

The power tailgate operates normally after system initialization is completed.

Procedure :

Inspection and Test - Power Tailgate System

Power Tailgate system is a complex system that consists of several components. To get an accurate test result, the control module of the Power Tailgate must be inspected.

The most trustworthy, effective and accurate method is using KDS required by power tailgate.

KDS helps technicians when inspecting a disabled switch, and enables to check the current status record of the switch ofPower Tailgate control module.

The battery must be fully charged before conducting all of the test on power tailgate, and all of the interfering elements of the system must be shown and understood. (refer to the explanation of smart tailgate) Refer to the analysis reference table when inspecting and testing the smart tailgate.

Status
Cause
Solution
Sudden opening of tailgate
Activation by mistake or malfunction of open/close switch
Check for short or malfunction of short circuit of switch
Latch assembly failure
Check for wiring connection
Check for failure code, and replace the latch if needed
Failure of Smart Tailgate or the body control module
Reset the module fuse or reconnect the battery. If it does not operate properly, check the wiring connection and analyze manual.
Unable to power open and close the tailgate
False indication, or not parked status
Check a switch status using analyzing device
Low voltage of the Power Tailgate module battery
Check for proper voltage of the Power Tailgate
Battery charged
Swelling of the fuse
Check if the fuse is swollen
Malfunction of PTG spindle
Check for PTG spindle status
Critical code failure at IBU/tailgate control module
Check for code status using KDS
Latch assembly failure
Check if the wiring connection of fuse are swollen.
Check if there's any alien object interfering with the operation of latch assembly.
Unable to open and close of the tailegate
Failure in motor assembly
Check for motor assembly
Interference of the consisting components
Replace the needed parts or reset the affected position.
Wiring problem (system or vehicle)
Resolve the problem using the wiring map.
Refer to wiring diagram.
Loss of electricity during the tailgate operation
Wiring problem (system or vehicle)
Resolve the problem using the wiring map.
Refer to wiring diagram.
Low voltage of vehicle battery
Check for proper voltage of PTGM.
Charge the battery
Failure in Power Tailgate or IBU
Check for failure code using analyzing device
Failure in motor assembly
Test the motor assembly
Power latching unable at Primary/Secondary position
Latch assembly failure
Check if the wiring connection of fuse are swollen.
Check for failure code using analyzing device
Resolve the problem using a vehicle analyzing manual.
Replace the latch assembly if needed.
Interference of the consisting components
Replace the needed parts or reset the affected position.
Failure in Power Tailgate or IBU
Check for failure code using analyzing device
Excessive sealing force of the tailgate
Check for shock on sealing, assembly failure, alien object or other possible factors.
Failure in motor assembly
Check the motor assembly
Unable to unlock the latch at Primary position
False indication, or not parked status
Check switch status using analyzing device
Low voltage of the Power Tailgate module battery
Check for proper voltage of the Power Tailgate
Battery charged
Swelling of the fuse
Check if the fuse is swollen
Latch assembly failure
Check switch status using analyzing device
Check for alien object interfering with the latch assembly operation or shock on components.
Resolve the problem using a vehicle analyzing manual.
Remove the latch assembly if needed.
Failure in outside handle connection
Check for handle joint and wiring connection.
Failure of Power Tailgate or the body control module
Check for the failure code or cycle using analyzing device.
Interference of the consisting components
Replace the needed parts or reset the affected position.
Tailgate operation using pop/console switch unavailable.
Swelling of the fuse
Check if the fuse is swollen
Low voltage of PTGM
Check for proper voltage of PTGM.
Charge the battery
Unable to unlock the electric lock
Failure on the latch assembly
Check for alien object interfering with the latch assembly operation or shock on components.
Check for the failure code or cycle using analyzing device.
Check for pole/latch switch using analyzing device.
Resolve the problem using the vehicle inspection manual
Unable to unlock the electric lock
Failure of Power Tailgate module
Resolve the problem using the vehicle inspection manual
Failure of Integrated body control unit (IBU
Resolve the problem using the vehicle inspection manual
Replace IBU if needed
Malfunctioning of wireless remote control key
Rewrite the wireless remote control key program
Replace the wireless remote control key
Malfunctioning of the tailgate motor assembly
Check for alien object interfering with the motor assembly operation.
Check for wiring connection
Change the assembly if motor clutch is not operable
Replace the switch if the full opening switch is not working
Resolve the problem using the vehicle inspection manual
Replace the motor if needed
Unable to maintain opened status of the tailgate
Failure on PTG spindle
Replace PTG spindle
Check if attached objects are damaged
Excessive operating force when opening and closing
Failure on PTG spindle
Replace PTG spindle
Check if attached objects are damaged
Interference of the consisting components
Replace the needed parts or reset the affected position.
When tailgate keeps cinching lock mode
Failure on the latch assembly
Check if wiring connection and fuse are swollen
Check the switch with analyzing device
When tailgate keeps electric lock mode
Failure on the latch assembly
Check for wiring connection
Check for any alien object
Resolve the problem using the vehicle inspection manual
Malfunctioning of the control module
Check for failure code using analyzing device
Wiring problem (system or vehicle)
Resolve the problem, referring an electric circuit
Refer to wiring diagram.
Check for the vehicle inspection manual for detailed process
Failure of the motor assembly
Check for operating environments constantly
Wiring problem (system or vehicle)
Resolve the problem, referring an electric circuit
Refer to wiring diagram.
Very slow opening of the tailgate
Vehicle battery voltage too low
Check for proper voltage of PTGM.
Charge the battery
Malfunctioning of the tailgate PTG spindle
Replace the tailgate PTG spindle if needed
Interference of the consisting components
Replace the needed parts or reset the affected position.
Vehicle angle too steep for electric operation
Operate the tailgate manually
Malfunctioning of the tailgate motor assembly
Replace the motor assembly if needed
Rattling or squeaky sound
Alien object jammed in tailgate components
Remove the alien object
Excessive tightening or loosening of the components
Resolve the excessive tightness or looseness

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