Table Of Contents - SSANGYONG 2004 Rexton 2.7XDi Workshop Manual

Table of Contents

General Information1
Table Of Contents1
Cleanness Of Di Engine Fuel System And Service Procedures2
Job Procedures3
System Supplement Against Paraffin Separation6
System Supplement And Remedy Against Water In Fuel6
Front View7
Structure7
Top View8
Left Side View9
Right Side View9
Engine Controls10
Ecu Related Components10
Engine And Sensors11
Electrical Components And Pre Heating System12
Intake System13
Intake Air Flow Chart14
Exhaust Air Flow Chart16
Lubrication System17
Cooling System18
Coolant Flow Chart19
Fuel System20
Fuel Supply System21
General Specifications22
Vehicle Specifications22
Vehicle Dimension22
Specifications23
Maintenance25
Major Components And Service Interval25
Lubrication Chart26
Vehicle Identification Number27
Certification Label27
Engine Serial Number28
Manual Transmission Number28
Automatic Transmission Number28
Transfer Case Number28
Manual Description29
Consists Of Small Group29
Guidelines For Service Work Safety30
General30
Cautions On Inspection/Service30
Guidelines On Engine Service31
Cautions Before Service Works31
Engine And Accessories31
Fuel And Lubrication System31
During Service Work - Inspection32
During Service Work For Electric Devices34
Lifting Points35
Lifting Positions35
4-Post Lift35
Safety Jack And Safety Stand35
Tightening Torque Of Standard Bolts36
Tightening Torque By Bolt Specification36
Engine Assembly37
Structure And Function Descriptions38
D27Dt Engine38
Major Components In Engine And Engine Compartment38
Engine Structure39
Engine Performance Curve43
Output And Torque43
Oil Temperature/Pressure And Boost Pressure44
General Diagnosis45
Diagnostic Information And Procedure50
Oil Leak Diagnosis50
Finding The Leak50
Repairing The Leak50
Compression Pressure Test51
Cylinder Pressure Leakage Test53
Permissible Pressure Leakage53
Tightening Torque54
Removal And Installation57
Engine Mounting57
Engine Assembly - Removal58
Disassembly And Reassembly67
Components And Special Tools67
Inspection Before Disassembly And Reassembly68
Preparations And Preceding Works68
Accessories - Removal And Installation69
Removal And Installation Order Of Major Accessories70
Engine - Disassembly And Reassembly83
Engine Housing97
Cylinder Head/Cylinder Block98
System Characteristics98
Cylinder Head Pressure Leakage Test99
Cylinder Head Parting Surface Check100
Cylinder Head - Disassembly And Reassembly101
Intake/Exhaust - Removal/Installation109
Special Tools And Equipment110
Camshaft Assembly112
Camshaft Position Sensor113
Removal114
Installation117
Timing Chain Assembly120
Chain Drive System120
System Layout120
Chain121
Chain Tensioner121
Guide Rail121
Timing Setting122
Cylinder Block124
Knock Sensor125
Circuit Diagram Of Knock Sensor126
Crankshaft127
Arrangement Of Thrust Washers And Bearings128
Dimensions Of Crankshaft Main Bearing129
Bearing Clearance129
Matching The Fit Bearing Journal Width To Thrust Washers129
Matching The Crankshaft Bearing Shells To Basic Bearing Bore In Crankcase129
Selection Of Upper Main Bearing Shell130
Selection Of Lower Main Bearing Shell130
Crankshaft Position Sensor131
Circuit Diagram Of Crankshaft Position Sensor132
Torsional Vibration Damper133
Crankshaft - Disassembly134
Crankshaft - Reassembly135
Piston And Connecting Rod137
Piston Ring138
Replacement Of Piston Ring138
Cylinder Inner Diameter And Piston Size139
Piston - Reassembly140
High Pressure Pump (Hpp)144
Components Locator144
Hp Pump - Disassembly And Reassembly145
Air Flows151
Work Flow Of Intake System151
Intake System Layout152
Air Cleaner153
Air Cleaner Element - Replacement154
Air Cleaner Housing - Removal And Installation155
Air Cleaner Housing/Element - Check155
Air Flow Sensor (Hot Film Air Mass Sensor)156
Structure Of Ci Type Hfm Sensor157
Circuit Diagram Of Hfm Sensor158
Hfm Sensor - Removal And Installation159
Intake Air Outlet Hose (Turbo Charger) - Removal And Installation160
Intake Air Inlet Duct (Air Cleaner) - Removal And Installation161
Intake Air Inlet Duct (Intake Manifold) - Removal And Installation161
Intercooler162
Intercooler - Removal And Installation163
Intake Manifold Assembly164
Intake Manifold - Removal/Installation166
Exhaust System169
Exhaust System Layout170
Exhaust Gas Flows171
Exhaust Manifold - Removal And Installation172
Turbo Charger Assembly173
Operating Principle Of Turbo Charger173
Construction Of Turbo Charger174
Impeller175
Turbine175
Floating Bearing175
Booster Pressure Control Valve Unit (Turbo Charger Actuator)176
Booster Pressure Control Valve Unit And Vacuum Modulator176
Diagnosis And Maintenance For Turbo Charger System177
Cautions During Driving177
Inspection Of Turbo Charger177
Inspection Of Turbine178
Path Of Turbo Charger Defect179
Turbine Side181
Defects Caused By Reasons Other Than That Of The Turbo Charger182
How To Diagnose183
Cautions When Examining The Defects183
Diagnosis And Measure184
Before Diagnosis185
When Engine Exhaust Gas Shows White Smog Or Blue Smog187
Excessive Consumption Of Engine Oil187
Abnormal Noise From Turbo Charger System188
Poor Rotation Of The Turbo Charger189
Oil Leakage At Turbine In Turbo Charger189
Oil Leakage At Compressor In Turbo Charger190
Wear In Turbo Charger Inner Diameter And Shaft Journal191
Turbo Charger Assembly - Removal And Installation192
Egr Valve And Vacuum Modulator194
Egr System194
Egr Valve And Turbo Charger Actuator Control Vacuum Circuit195
Vacuum Modulator195
Di Engine Vacuum Modulator195
Idi Engine Vacuum Modulator (Hoover Egr System - K2004)195
Vacuum Modulator And Vacuum Hose196
Related With Egr Valve196
Related With Turbo Charger Actuator196
Egr System Diagram197
Egr Valve197
Egr Modulator197
Operation Principle Of Vacuum Modulator198
Operating Principle199
Vacuum Consumption199
Output Characteristics199
Operating Conditions200
Control Logic200
Shut-Off Conditions200
Egr Valve And Pipe - Removal And Installation201
Vacuum Modulator - Removal And Installation202
Exhaust System And Muffler203
System Overview204
Doc (Diesel Oxidation Catalyst)204
Heat Shield204
Hanger204
Catalytic Converter Structure205
Catalytic Converter And Temperature206
Purification Of Catalytic Converter206
Chemical Reaction Formula206
Method For Reduction Of Nox207
#1 Exhaust Pipe - Removal And Installation208
Catalytic Converter - Removal And Installation209
#2 Exhaust Pipe - Removal And Installation209
Lubrication System Layout212
Lubrication Diagram213
Oil Pressure Switch214
Oil Pump215
Oil Cooler215
Blow-By Gas Reduction Device216
Cylinder Head Cover216
Oil Separator217
Engine Oil Pressure Check217
Engine Oil Change218
Engine Oil Changing Procedures218
Engine Oil Filter Change219
Oil Filter And Cooler - Removal And Installation220
Oil Pump - Removal And Installation222
Oil Dipstick Guide Tube - Removal And Installation223
Oil Spray Nozzle224
Disassembly224
Oil Pan Assembly225
Trouble Diagnosis226
Engine Cooling System230
Ffh Engine Coolant Flows230
Function Description231
Radiator232
Water Pump232
Coolant Reservoir232
Thermostat233
When Closed (Up To 85°C)234
When Partially Opened (85°C ~ 100°C)234
When Fully Opened (Above 100°C)234
Engine Coolant Temperature Sensor235
Viscous Fan Clutch235
Coolant Level Check237
Coolant Temperature Sensor238
Inspection And Repair241
Coolant Temperature Gauge Unit242
Coolant Hose (Inlet/Outlet)243
Shroud And Cooling Fan/Clutch244
Water Pump - Assembly246
Water Pump Housing250
Draining And Adding Of Coolant255
Preheating System256
Overview257
Preheating Relay257
Preheating System Diagram258
Function259
Pre-Heating259
K-Line Communication259
Operating Time259
Cautions For Di Engine261
Di Engine261
System Safety Mode261
Water Separator Warning Light261
Priming Pump262
Conditions For Using Priming Pump262
Fuel Filter And Water Separator262
Draining The Water From Fuel Filter263
Fuel Injection System264
Electronic Control Of Fuel System264
Composition Of Fuel System265
Fuel Line System265
Hydraulic Cycle In Fuel Line (Transfer And High Pressure Line)266
Components Of Low Pressure Transfer Line267
Fuel Tank267
Fuel Filter267
Components Of High Pressure Transfer Line268
High Pressure Pump (Including Imv And Limit Valve)268
Common Rail (Including Pressure Sensor)268
High Pressure Pipe (Fuel Pipe)268
Injectors269
Transfer Pump269
Fuel Filter Replacement269
Fuel Transfer Line270
Sectional View Of Fuel Pump270
Sectional View Of Transfer Pump270
Principle Of Operation271
Characteristics Of The Transfer Pump271
Inlet Metering Valve (Imv)272
Composition Of Imv273
High Fuel Pressure Line275
High Pressure Pump275
Fuel Input276
Pressurize276
Inlet Valve And Delivery Valve277
Lubrication And Cooling Of The Hp Pump277
Phasing Of Hp Pump Required And Offer 2 Advantages277
Hp Pump Fuel Route278
When Need High Fuel Pressure (Acceleration)278
When Do Not Need High Fuel Pressure (Deceleration)279
Performance Curve Of Hp Pump279
Pressure Curve Of Hp Pump279
Sectional View Of Hp Pump280
Imv Valve And High Pressure Pump (Drive Shaft)280
Inlet Valve, Outlet Valve, Shoe And Roller, Temperature Sensor281
Hydraulic Head281
Change Interval: 30,000 Km297
Water Separation And Storage Function297
Water Sensor297
Fuel De-Waxing – Improving Starting Performance In Cold Weather297
Relations Between Pressure And Temperature In Fuel Transfer Line299
High Pressure Accumulator (Common Rail)300
High Fuel Pressure Pipe301
Fuel Pressure Sensor303
Operation Principle Of Fuel Pressure Sensor304
Sensor Voltage304
Circuit Diagram Of Fuel Pressuer Sensor304
Fuel Temperature Sensor305
Circuit Diagram Of Fuel Temperature Sensor305
Injector306
Valve307
Spacer307
Injector At Rest308
Solenoid Valve Control308
Start Of Injection309
End Of Injection309
Injecting Process310
Fuel Pressure315
Maximum Fuel Volume At Each Injector Cycle315
Injector Control316
Fuel Injection317
Pilot Injection317
Main Injection317
Ecu Wiring Diagram319
Engine Control System320
Sensors For Diagnosis321
Engine Ecu And Other Components321
Side View323
Ecu324
Ecu Inputs-Outputs327
Structure And Function Of Ecu327
Control Function Of Ecu328
Ecu - Removal And Installation329
Fuel Pressure Control330
Fuel Pressure Control Elements330
Fuel Injection Control331
Main Injection Timing Control331
Pilot Injection Timing Control331
Fuel Flow Control332
Main Flow Control332
Driver Demand333
Idle Speed Controller334
Flow Limitation334
Pilot Flow Control334
Cylinder Balancing Strategy335
Accelerometer Strategy335
Balancing Of The Point To Point Flows335
Resetting The Pilot Injection335
Detection Of Leaks In The Cylinders336
Detection Of An Accelerometer Fault336
Individual Injector Calibration (C2I)337
Minimum Drive Pulse (Mdp) Learning339
Learning Conditions339
Trouble Codes339
Accelerator Pedal Sensor340
Output Characteristics Of Coolant Temperature Sensor341
Circuit Diagram Of Coolant Temperature Sensor341
Boost Pressure Sensor342
Location Of Boost Pressure Sensor342
Output Characteristics Of Sensor342
Vehicle Speed Sensor343
Barometric Pressure Sensor344
Other Switches344
Brake Switch344
Clutch Pedal Switch344
Electric Devices And Sensors345
Sensors In Engine Compartment346
Electric Devices In Engine Compartment347
Circuit Diagram Of Preheating System349
Circuit Diagram Of Starting And Alternator350
Alternator353
Starter355
Preheating Time Relay359
Glow Plug360
Purposes Of Use360
Conditions For Glow Plugs360
Scan-I Operating Procedures - Xdi270 Engine363
Entering Diagnosis Procedures364
Function Selection366
Check The Trouble Code366
Sensor Data Check367
Actuator Check368
Trouble Code Clear370
Ecu Identification372
Injector Coding (C2I)373
Leak Detection375
Variant Coding376
Ecu Replace378
Trouble Diagnosis Table383
Index Of Dtc384
P0102 Low Hfm Sensor Signal (Circuit Open)387
P0103 High Hfm Sensor Signal (Circuit Short)387
P0100 Air Mass Flow (Hfm) Malfunction388
P0344 Cam Position Sensor Malfunction388
P0341 Cam Position Sensor Malfunction (Poor Synchronization)388
P 0219 Too Small Clearance Of Crank Angle Sensor388
P0336 Too Large Clearance Of Crank Angle Sensor389
P0372 Crank Angle Sensor Malfunction389
P1107 Barometric Sensor Circuit Short/Gnd Short389
P1108 Barometric Sensor Circuit Short389
P0562 Low Battery Voltage390
P0563 High Battery Voltage390
P0560 Battery Voltage Malfunction390
P0109 Low Booster Pressure Sensor Signal391
P0106 High Booster Pressure Sensor Signal391
P0107 Booster Pressure Sensor Open/Gnd Short392
P0108 Booster Pressure Sensor Short392
P0105 Supply Voltage Fault To Booster Pressure Sensor393
P1106 Booster Pressure Sensor Malfunction393
P1109 Booster Pressure Sensor Initial Check Fault394
P0571 Brake Pedal Switch Fault394
P1572 Brake Lamp Signal Fault395
P1571 Brake Lamp Signal Fault395
P1286 Low Resistance For Injector #1 Wiring Harness395
P1287 High Resistance For Injector #1 Wiring Harness396
P1288 Low Resistance For Injector #2 Wiring Harness396
P1289 High Resistance For Injector #2 Wiring Harness396
P1292 Low Resistance For Injector #4 Wiring Harness397
P1293 High Resistance For Injector #4 Wiring Harness397
P1294 Low Resistance For Injector #5 Wiring Harness397
P1295 High Resistance For Injector #5 Wiring Harness398
P1290 Low Resistance For Injector #3 Wiring Harness398
P1291 High Resistance For Injector #3 Wiring Harness398
P0704 Clutch Switch Malfunction398
P1115 Coolant Temperature Sensor Malfunction399
P0118 Coolant Temperature Sensor Malfunction - Short399
P0117 Coolant Temperature Sensor Malfunction - Open400
P0685 Main Relay Malfunction400
P1405 Egr Solenoid Valve Malfunction - Short To Ground400
P1406 Egr Solenoid Valve Malfunction - Short To+Batt400
P1480 Condenser Fan #1 Circuit Malfunction - Open401
P1481 Condenser Fan #1 Circuit Malfunction - Short401
P1526 Condenser Fan #2 Circuit Malfunction - Open401
P1527 Condenser Fan #2 Circuit Malfunction - Short401
P0325 Accelerometer #1 (Knock Sensor) Malfunction402
P0330 Accelerometer #2 (Knock Sensor) Malfunction402
P1611 Injector Bank #1 Malfunction - Low Voltage402
P1612 Injector Bank #1 Malfunction - High Voltage403
P1618 Injector Bank #2 Malfunction - Low Voltage403
P1619 Injector Bank #2 Malfunction - High Voltage403
P1203 Injector #3 Circuit Short406
P0182 Fuel Temperature Sensor - Short To Ground406
P0183 Fuel Temperature Sensor - Short To B+406
P0180 Fuel Temperature Sensor - Malfunction407
P1678 Glow Plug Malfunction - Open407
P1679 Glow Plug Malfunction - Short407
P1680 Glow Plug Malfunction - Short To Ground407
P1254 Maximum Rail Pressure Control Malfunction (Imv Fault)409
P1253 Minimum Rail Pressure Control Malfunction (Imv Fault)409
P0113 Intake Air Temperature Circuit Malfunction - Short413
P0112 Intake Air Temperature Circuit Malfunction - Open414
Hmf Sensor Signal Fault (Electric Failure)434
Cam Position Sensor (Missing Event)435
Cam Position Sensor Malfunction (Poor Synchronization Of Crank And Cam)436
P0341 Cam Position Sensor Malfunction436
Too Small Clearance Of Crank Angle Sensor437
Too Large Clearance Of Crank Angle Sensor . Di10-29438
Crank Angle Sensor Malfunction439
Barometric Sensor Malfunction (Out Of Range, Using Strategy Of Restoring By Map Sensor)440
Battery Voltage Monitoring Signal Malfunction441
Booster Pressure Sensor Malfunction (Out Of Range With Key On)443
Booster Pressure Malfunction (Implausible Signal)447
Brake Pedal Switch Malfunction449
High Wiring Resistance (Injector #1)451
High Wiring Resistance (Injector #2)452
High Wiring Resistance (Injector #3)453
High Wiring Resistance (Injector #4)454
High Wiring Resistance (Injector #5)455
Clutch Switch Malfunction456
Coolant Temperature Sensor Malfunction457
Coolant Temperature Sensor Malfunction (Electric Fault)458
Too Fast Or Low Main Relay Operation459
Main Relay Malfunction459
Egr Actuator Malfunction460
Condenser Fan Driving Signal Fault (Type 1)461
Short To Ground461
Condenser Fan Driving Signal Fault462
Accelerometer #1 (Knock Sensor)463
Accelerometer #2 (Knock Sensor)463
Idling Signal/Too Small Noise Ratio463
Malfunction463
Injector Bank 1 Malfunction (Short To Ground Or B+)465
Injector Bank 2 Malfunction (Short To Ground Or B+)467
Cylinder Balancing Fault (Injector #1) = Clogged Air Intake System469
Cylinder Balancing Fault (Injector #2) = Clogged Air Intake System470
Cylinder Balancing Fault (Injector #4) = Clogged Air Intake System471
Cylinder Balancing Fault (Injector #5) = Clogged Air Intake System472
Cylinder Balancing Fault (Injector #3) = Clogged Air Intake System473
Open Circuit (Injector #1)474
P0201 Injector #1 Circuit Open474
Injector #2 Circuit Open474
Open Circuit (Injector #2)475
Open Circuit (Injector #4)476
P0204 Injector #4 Circuit Open476
Injector #5 Circuit Open476
Open Circuit (Injector #5)477
Open Circuit (Injector #3)478
Hsd Circuit Short To Lse (Injector #1)479
Hsd Circuit Short To Lse (Injector #2)480
Hsd Circuit Short To Lse (Injector #4)481
Hsd Circuit Short To Lse (Injector #5)482
Hsd Circuit Short To Lse (Injector #3)483
Fuel Temperature Sensor Malfunction484
Glow Plug Malfunction (Driving Signal)485
Heater 1 Malfunction (Driving Signal)486
Heater 2 Malfunction (Driving Signal)487
Rail Pressure Control Fault (Too High Pressure)488
Rail Pressure Control Fault (Too High Imv Current Trim, Drift)490
Rail Pressure Control Fault (Too Slow Pressure Build Up While Cranking)492
Imv Operation Fault (Electrical Fault)494
Intake Air Temperature Sensor Fault (Electric Fault)495
Mdp Fault (Injector #1)496
Mdp Fault (Injector #2)496
Mdp Fault (Injector #4)497
Mdp Fault (Injector #5)497
Mdp Fault (Injector #3)498
Rail Pressure Fault (Too High)499
Accelerator Pedal Sensor Malfunction (Relationship Between Track 1 And Track 2)501
Accelerator Pedal Sensor Malfunction (Limp Home Mode Operation)502
Accelerator Pedal Sensor Malfunction (Torque Reduction Mode Operation)503
Accelerator Pedal Sensor Malfunction (Electrical Fault, Pedal Stuck)504
Accelerator Pedal Sensor Malfunction (Electrical Fault, Track 1)505
Accelerator Pedal Sensor Malfunction (Electrical Fault, Track 2)506
Fuel Rail Pressure Sensor Malfunction (Out Of Range, Adc Or Vref)507
Fuel Rail Pressure Sensor Malfunction (Out Of Range When Key On)509
Main Relay Malfunction - Stuck511
Vehicle Speed Fault512
5V Supply Voltage 1 Fault513
5V Supply Voltage 2 Fault514
2.5V Supply Voltage Fault515
Turbo Charger Actuator Operation Fault (Signal)516
Ecu Watchdog Fault517
Ecu Watchdog Fault (Injector Cut-Off)518
Ecu Watchdog Fault (Watchdog Trip)519
Ecu Non-Volatile Memory Fault520
Ecu Memory Integration Fault521
Accelerometer Learning Fault522
Egr Valve Control Fault523
Vgt Operation Fault524
Tbd526
No Crank Signal527
High Torque Trim528
Glow Plug Module Communication Fault529
Glow Plug Module Circuit Malfunction - Open530
Glow Plug Module Circuit Malfunction - Short (B+)531
Tcu Signal Fault532
Air Conditioner Operating Circuit Fault533
Excessive Water In Fuel Filter534
Immobilizer Malfunction535
Fuel System Diagnosis536
Fuel Pressure System538
Example Of Too Much Injector Back Leak539
Example Of Pressure/Volume Loss In Pump540
Fuel System Pressure Test541
Test Tool Kit541
For High Pressure Line541
For Transfer Line541
Prerequisite542
Fuel System Test Process542
Fuel System Check Process543
High Pressure System Pressure Test544
Fuel Rail Pressure Test544
How To Use Pressure Tester545
Transfer Fuel System Test546
Test Procedures546
Static Test For Injector Back Leak Volume547
Dynamic Test For Injector Back Leak Volume549
High Pressure Pump Test550
Pressure Leakage Test With Scan-100552
Dc 5-Speed Automatic Transmission554
Characteristics556
Performance Curve And General Characteristics558
Power Flow561
Sectional View561
Shifting Elements561
1St Gear (3.932)562
2Nd Gear (2.408)563
3Rd Gear (1.486)564
4Th Gear (1.000)565
5Th Gear (0.830)566
Reverse 1St Gear (3.160, "S" Mode)567
Reverse 2Nd Gear (1.930, "W" Mode)568
Function And Description569
Selector Lever569
Parking And Starting Position569
Reverse Driving569
Torque Converter570
Function (4Wd)570
Lockup Clutch572
Lockup Clutch Regulating Valve573
Planetary Gear Set574
Relatively High Step-Down Ratio574
Relatively Low Step-Down Ratio574
Direction Reversal And Step-Down Ratio574
Multiple-Disc Clutch575
Location575
Funtion And Description575
Freewheel576
Sensors And Controls577
Shift Pressure Control Solenoid Valve578
Characteristics Of Up/Downshift Solenoid Valve579
Circuit Diagram579
Modulating Pressure (Mp) And Shift Pressure (Sp) Control Solenoid Valve580
Lockup Solenoid Valve582
Rpm Sensor583
Oil Temperature Sensor585
Starter Lock-Out Contact586
Kick-Down Control587
Mode Switch588
Reverse/Parking (R/P) Lock System589
Function Of Reverse (R) Lock590
Parking Lock Mechanism591
Function Of Parking (P) Lock591
Selector Lever Control Unit592
Terminals592
Can (Controller Area Network )594
Tcu (Transmission Control Unit)595
Tcu Block Diagram596
Characteristics Of Tcu And Automatic Transmission (Emergency Driving Mode)597
Electrical Defective597
Mechanical/Hydraulic Pressure Defective597
Connector Arrangement And Pin Functions598
Oil Level Control599
Other Functions599
Oil Check And Specification600
Checking And Adding Tip600
Automatic Transmission Fluid Capacity And Specification600
Shift Rod Adjustment601
Starter, Selector Lever, Can Communication602
Solenoid, Oil Temperature Sensor, Rpm Sensor (N2, N3)603
Trouble Diagnosis With Scanner604
Trouble Code And Diagnosis604
Tcu Coding For Dc 5-Speed Automatic Transmission605
Dtc (Diagnosis Trouble Code) Of Dc5At607
Hydraulic System613
Structure Of Valve Body613
Hydraulic Circuit614
Oil Pressure616
Operating Pressure (P-A)616
Lubricating Pressure (P-Sm)617
Control Valve Pressure (P-Rv)617
Modulating Pressure (P-Mod)617
Shift Pressure (P-S)617
Shift Groups618
Hydraulic Circuit When Starting Engine619
Selector Lever "N"619
Hydraulic Circuit When Moving Selector Lever from "N" to "D" (Shift Phase)620
Hydraulic Circuit When Selector Lever Is in "D" Position (1St Gear)621
Hydraulic Circuit After Shifted To 1St Gear622
Hydraulic Circuit During Shift Phase623
Hydraulic Circuit After Completed Gear Change624
Structure Of Electro-Hydraulic Control Module (Shift Plate)625
Rear Section625
Left Section626
Right Section626
Removal And Installation (Dc 5-Speed A/T)628
Selector Assembly - Removal And Installation634
Disassembly And Reassembly (Dc 5-Speed A/T)635
Components635
Components Assembly636
Friction Disc637
Valve Body Assembly638
Converter Housing And Transmission Housing642
Converter Housing Assembly645
Transmission Housing Assembly649
Components Of Each Assembly653
Btra 4 Auto Transmission661
Btra M74 4Wd Automatic Transmission662
Description And Operation662
Operators Interfaces663
Gear Shift Control Lever663
Driving Mode Selector663
Indicator Light663
Control Systems664
Electronic Control System664
Transmission Control Module (Tcm)664
Processing Logic664
Hydraulic Control System665
Data Link Connector (Dlc)665
Hydraulic Control Circuit666
Valve Body667
Manual Valve667
1-2 Shift Valve667
2-3 Shift Valve667
4-3 Sequence Valve668
Solenoid Supply Pressure Regulator Valve668
Line Pressure Control Valve668
Clutch Apply Feed Regulator Valve668
Reverse Lockout Valve669
Pump Cover669
Primary Regulator Valve669
Power Train System670
Converter Clutch Regulator Valve670
Converter Clutch Control Valve670
B1R Exhaust Valve670
Clutch Packs673
Bands674
One Way Clutches674
Parking Mechanism674
Power Flows675
Park And Neutral676
Power Flow - Park And Neutral677
Control677
Reverse678
Power Flow - Reverse679
Manual 1680
Power Flow - Manual 1681
Drive 1682
Power Flow - Drive 1683
Power Flow - Drive 2 And Manual 2685
Drive 2 And Manual 2685
Drive 3 And Manual 3686
Power Flow - Drive 3 And Manual 3687
Drive 3 Lock Up And Manual 3 Lock Up688
Power Flow - Drive 3 Lock Up And Manual 3 Lock Up689
Drive 4 (Overdrive)690
Power Flow - Drive 4 (Overdrive)691
Drive 4 Lock Up692
Power Flow - Drive 4 Lock Up693
Diagnostic Information And Procedures694
Basic Knowledge Required694
Functional Check Procedure694
Fluid Leak Diagnosis And Repair695
Methods For Locating Leaks695
Dye And Black Light Method695
Repairing The Fluid Leak695
Transmission Fluid Level Service Procedure697
Fluid Level Diagnosis Procedure697
Fluid Level Set After Service697
Electrical / Garage Shift Test699
Road Test Procedure699
Electronic Adjustments699
Throttle Clearing699
Symptom Diagnosis701
Drive Faults701
Faulty Shift Pattern702
Shift Quality Faults704
After Teardown Faults706
Tcu Diagnostic System Overview708
Clearing Trouble Codes708
Diagnostic Trouble Codes708
Trouble Code Diagnosis - Gasoline Vehicle708
Trouble Code Diagnosis - Disel Vehicle709
Tcm Diagnostic System Overview709
On-Vehicle Service710
Transmission Removal And Installation Procedure710
Repair Instructions710
Transmission Disassembly Procedure711
Transmission Case713
Forward Clutch Cylinder715
C3 Clutch Cylinder716
Planet Carrier Assembly And Centre Support717
Pump718
Unit Repair721
Rebuild Warnings721
Assembly Procedure722
Output Shaft And Gear Assembly725
Rear Band Assembly726
Rear Servo Assembly726
Adaptor Housing Assembly728
Front Servo Assembly728
Front Band Assembly729
C2/C4 Clutch Assembly730
C3 Clutch And Reverse Sun Gear Assembly734
Forward Sun Gear And C3 Clutch Pack Assembly736
C1 Clutch Overdrive Shaft And Input Shaft Assembly737
Pump Cover And Converter Support739
Oil Filter And Pan Assembly748
Torque Converter And Housing Assembly749
Output Flange Assembly (2Wd Mode)749
Front And Rear Band Adjustment750
Front Band Setting Procedure750
Rear Band Setting Procedure751
Kickdown Switch754
Transmission Control Module754
General Specification756
Clutch Pack Details757
Model Part Numbers And Applications757
E32 Gasoline Engine758
662La Diesel Engine759
Fastener Tightening Specifications760
Schematic And Routing Diagrams761
Tcu Wiring Diagram (Gasoline Engine-1 Or 2)761
Tcu Wiring Diagram (Gasoline Engine-2 Or 2)762
Connector End View765
Manual Transmission768
Features769
System Components771
Gear Combinations771
Shift Fork And Rail Combinations771
Idi Engine Equipped Vehicle - 4Wd774
Idi Engine Equipped Vehicle - 2Wd776
Cross Sectional Diagram Of Major Components779
Shift Rail And 5/R Gear779
Offset Lever779
Shifting Mechanism783
Interlock System783
Reverse Interlock System783
Offset Lever And Rolling Plunger784
Backup Lamp Switch785
Shift Check Device785
Gear Pump Out Locking Device785
Synchronizer786
Synchronizer Element787
Bearing788
End Play Of Taper Roller Bearing788
Thrust Ring (Washer)789
Lubrication789
Diagnosis Table793
Circuit Diagram (Backup Lamp)794
Oil Check/Change795
Inspection Before Installation801
Manual Transmission Assembly802
Inspection Before Reassembly813
Top Cover Assembly834
Extension Housing Assembly838
Transmission Adaptor840
Shim Adjustment841
Inspection/Maintenance841
Clutch846
Driving Elements847
Operating Elements847
General Description And Operation847
Cross Sectional View Of Clutch Assembly850
Clutch Components851
Bleeding Of Clutch System852
Clutch Master Cylinder855
Clutch Pedal856
Clutch Fluid Pipe859
Clutch Disc860
Inspection Procedure860
Part Time - T/C863
Operation864
Sectional Diagram866
Shift Motor867
Speed Sensor And Clutch Coil867
Tccu868
Appearance And Function868
Transfer Case Control Unit (Tccu)870
4Wd Operation870
System Operation870
Transfer Case Block Diagram871
Tccu System873
Position Encoder873
Tccu Initialization And Operation873
Function Of Indicating Lamp During Shifting873
Shift Conditions874
Motor Controls874
Synchronization874
Compensation874
2H Mode (Rear Wheel Drive)876
4H Mode (4Wd Drive - High Speed)877
4L Mode (4Wd Drive - Low Speed)878
Shift Motor Test880
Transmission System Timeout Test880
Position Encoder Test880
Rear Speed Sensor Test880
Trouble Diagnosis Test880
Self-Diagnosis Test881
Trouble Code Reading882
How To Clear The Trouble Code882
Diagnostic Trouble Code883
Circuit Diagram (Di & 5-Speed A/T)885
Oil Level Check And Change886
Maintenance And Repair886
4H, 4L And 4Wd Check Indicator886
Removal And Installation Of Transfer Case887
Component Locator887
Exploded View888
Transfer Case890
Speed Sensor895
Tod898
Distribution Of Driving Force According To Road Surface899
4Wd Operation Overview900
Selection Mode900
4L Mode900
Releasing The 4L Mode900
Cross Sectional Diagram (Tod Transfer Case)902
Electro Magnetic Clutch (Emc)905
Electric Shift System Operation911
Shift Requirements911
Range Change911
Compensation Mode912
Electric Shift Default Mode912
Indicator Function On Shifting912
Tod System Operation913
Touch-Off Torque913
Brake/Abs Strategy913
4L Strategy913
Shifting Sequence914
Flow Chart914
Reading Position Encoder915
Self Diagnosis Test919
Front Sensor Speed Test920
All Troubles From Speed Sensor920
Emc Test920
Can Tps Test921
Transmission Neutral Test921
Stuck In Low Test921
Can Bus Off Test921
Coding On Tod Control Unit922
What's Coding?922
Coding Required922
Coding Method922
Tod Removal And Installation929
Tccu Removal And Installation931
Shift Motor Removal And Installation932
Speed Sensor Removal And Installation934
Front Axle937
Front Axle Specifications938
Front Axle Housing939
Axle Shaft (Drive Shaft)940
Front Axle Shaft (For Part Time T/C) Removal941
Front Axle Shaft (For Part Time T/C) Installation945
Axle Housing Assembly948
Vacuum Line950
Vacuum Line Removal And Installation Notice951
Inspection Of Ring Gear Tooth Contact Pattern956
Differential Joint Assembly959
Wheel Joint Disassembly961
Wheel Joint Assembly962
Rear Axle966
Rear Axle Specifications967
Rear Axle Cross Sectional View969
Rear Axle Shaft970
Disc Brake Equipped Vehicle970
Rear Axle Housing Removal977
Rear Axle Housing Installation979
Rear Axle Assembly984
Propeller Shaft991
Wheel & Tire1004
Wheel & Tire General1005
Tire And Wheel Balancing1005
General Balance Precautions1005
Structure Of Tubeless Tube1005
Conventions For Radial Tire1006
The Relations Between Inflation Pressure And Tire1006
The Relations Between Load And Tire1006
Tire's Abnormal Action1008
Standing Wave1008
Hydroplaning1008
Wheel Alignment1009
Toe-In1009
Camber1009
Caster1010
Tire Removal And Installation1011
Spare Tire1012
Tire Separation1013
Tire Maintenance1014
Visual Check1018
Tread1020
Tire Wear1020
Tire Inflation Pressure1020
Wheel Runout1021
Wheel Balance1021
Rotation Of Tires1022
Cautions When Replacing Tires1022
Steering Column1024
Steering Wheel1025
Column And Shaft Assembly1025
Lower Shaft1025
Steering Column Assembly1026
Steering Column - Removal1029
Steering Column - Installation1032
Steering Lower Shaft - Removal And Installation1035
Ecps (Electronic Control Power Steering)1039
Input/Output Of Ecps Control Unit1041
Ecps Configuration1041
Pcv (Pressure Control Valve)1041
Reaction Device1041
Solenoid Valve1042
Ecps Control Unit1043
Power Steering Solenoid Valve1046
Electric Current Check1046
Fail Safe Function1049
S.s.p.s (Speed Sensitive Power Steering)1050
Removal And Installation Of Ecps Control Unit1051
Power Steering1052
Power Steering Pump1053
Power Steering Gear Assembly1053
Oil Reservoir1053
Sectional View Of Steering Gear Box1056
Steering Gear Pump1057
Power Steering Pipe And Hose1061
Power Steering Gear Box1062
Rack Gear Shaft1068
Power Steering Gear Preload Adjustment1071
Power Steering Wheel Free Play Check1071
Steering Effort Check1072
Steering Angle Check1072
Belt Tension Check/Adjustment1072
Oil Pump Pressure1073
Oil Level Check1074
Oil Change1074
Front Suspension1076
Description And Operation Of Front Suspension1077
Stabilizer1077
Coil Spring1077
Shock Absorber1077
Upper Arm And Lower Arm Assembly1078
Sectional View Of Shock Absorber Assembly1081
Stabilizer Removal1084
Stabilizer Installation1085
Shock Absorber Assembly Removal1086
Shock Absorber Assembly Installation1087
Upper Arm And Lower Arm Assembly Removal1088
Upper Arm And Lower Arm Assembly Installation1089
Front Coil Spring Disassembly1090
Disassembly And Assembly1090
Front Coil Spring Reassembly1091
Hub And Bearing Disassembly And Reassembly1092
Rear Suspension1098
Rear Suspension Assembly1101
Brake System1113
Brake System Description And Operation1114
Hydraulic Brake1114
Brake Pedal1114
Master Cylinder1114
Brake Booster1115
Pressure Distribution At Working1115
Pressure Distribution After Working1115
System Layout (Hydraulic Line)1116
Brake System Components Locator1117
Master Cylinder And Booster1119
Air Bleeding (With Abs)1120
After Replacing Master Cylinder1121
After Replacing Hydraulic Unit1121
Brake Booster Vacuum Hose Removal1122
Brake Fluid Level Switch Removal And Installation1123
Brake Fluid Reservoir Removal And Installation1124
Master Cylinder Removal1125
Master Cylinder Installation1126
Brake Booster Removal And Installation1127
Stop Lamp Switch Removal And Installation1128
Brake Pedal Removal And Installation1129
Brake Hose/Pipe Removal1130
Brake Hose/Pipe Installation1131
Brake Pedal Check1132
Pedal Height/Maximum Stroke1132
Stop Lamp Switch Check1133
Brake Booster Check1133
Front Brake1135
Caliper1136
Adjustment Of Clearance1136
Front Brake Removal1138
Brake Pad Change1139
Brake Disc Run-Out1141
Inner Diameter Of Caliper Housing1141
Pad Thickness1142
Brake Disc Thickness1142
Rear Brake1145
Drum Brake1146
Brake Drum1146
Wheel Cylinder1146
Disc Brake1147
Brake Lining1147
Wheel Cylinder Disassembly And Reassembly1164
Parking Brake Lever1165
Drum Brake Type1166
Parking Brake1171
Parking Brake Switch And Indicator1172
Checking The Braking Force1178
Abs1180
Driving Physics1181
The Stopping Distance1181
Brake Force On A Wheel1181
Maximum Brake Force1181
Ebd (Electronic Brake Force Distribution) System1182
The Benefits Of Ebd1182
Service Precautions1183
Electronic System Service Precautions1183
General Service Precautions1183
Bleeding System1183
Input And Output Diagram Of Abs Unit1185
Electric Circuit Diagram1186
Wheel Speed Sensor, Stop Lamp Switch, Diagnostic Connector, Warning Lamp (Abs/Esp)1186
Abs Hydraulic Circuit Diagram1187
Hydraulic Pressure Circuit When Abs Is Not Operating1188
No Hydraulic Pressure Circuit When Abs Is Operating1188
Pressure Decreases In The Circuit When Abs Is Operating1189
Pressure Increases In The Circuit When Abs Is Operating1189
Hecu (Hydraulic & Electronic Control Unit)1191
Motor Pump1191
Ecu (Including Solenoid Valves – Esp Equipped Model)1192
Wheel Speed Sensor1193
Active Wheel Sensor1193
Function Of Active Wheel Sensor1193
Hydraulic Device/Hecu Assembly1195
Front Wheel Speed Sensor Removal And Installation1196
Rear Wheel Speed Sensor Removal And Installation1196
System Fuse1197
Indicators1197
Abs Front Tooth Wheel Removal1198
Abs Front Tooth Wheel Installation1198
Esp System1200
Components Location1202
Comparison For Specifications1203
Input And Output Diagram Of Esp Unit1204
Esp Control1205
Understeering1205
Esp Controls During Under Steering1205
Oversteering1206
Esp Controls During Oversteering1206
Vehicle Control During Cornering1207
Hydraulic Diagram Of Esp1208
The Warning Lamp Comes On And Warning Beep Sounds When The Esp Is Operating1209
Driving Feeling When The Esp Is Operating1209
Noise And Vibration That Driver Senses When The Esp Is Operating1209
Esp Hydraulic Unit In Idling And Normal Braking Position1210
When Applied Abs (Decreased Pressure)1211
When Applied Abs (Maintained Pressure)1212
When Applied Abs (Increased Pressure)1213
Hba (Hydraulic Brake Assist System)1214
Hydraulic Diagram Of Hba1215
Ecu (Electronic Control Unit)1216
Hydraulic Control Unit1216
Comparison Between Esp Hecu And Abs/Ebd Hecu1217
Connector1218
Function Of Active Sensor System1219
Active Sensor Element Of Encoder Wheel1219
Steering Wheel Angle Sensor (Swas)1220
Sensor Cluster1224
Internal Electric Circuit Of Sensor Cluster1224
Sensor Cluster Circuit1225
Yaw Rate Sensor1225
Lateral/Longitudinal Acceleration Sensor1226
Pressure Sensor1228
Warning Lamp And Indicator1231
Esp Warning Lamp Blinking In Control1231
Esp System Cancellation Using The Esp Off Switch1231
Resuming The Esp System By Using The Esp Off Switch1232
Esp Off Switch Monitoring1233
Esp Warning Lamp Operation Depending On System Conditions1233
Air Bleeding From Brake System1234
Air Bleeding Should Be Done When1234
Air Bleeding Procedures1234
Initialization1242
Air Bleeding1244
Code Clear1245
Abs/Esp1246
Brake Pressure Sensor, Steering Wheel Angle Sensor, Sensor Cluster, Esp Off Switch1247
Fuses And Relays1252
Fuse Box In Engine Compartment1252
Interior Fuse Box1253
Interior Relay Box1254
Electric Components Locator1261
Electric System1262
Ignition Key And Remote Control Key1263
Remote Keyless Entry System (Rekes)1263
Battery Replacement1263
Immobilizer System1264
Transponder Code1264
When Lost The Keys1264
When The Transponder Has Damaged1264
Rekes + Stics (Rkstics)1265
Rated Load1266
Chattering Of Input Signals1267
Ignition Key Reminder1268
Chime Bell Control1268
Door Control1269
Mark Lamp Left On Warning1270
Buzzer Control1270
Door Ajar Warning1272
Seatbelt Warning Timer1273
Parking Brake Warning1274
Door Lock/Unlock By Door Lock Switch1275
Lock/Unlock By Rekes (Remote Keyless Entry System)1276
Auto Door Lock1277
Auto Door Unlock (Unlocking When Taking An Impact)1278
Ignition Key Hole Illumination1279
Battery Saver1279
Rear Defogger Timer1280
Time Lag Power Window Control1281
Rekes1282
Specifications Of Transmitter1282
Specifications Of Receiver1282
Registration Of Receiver Code1283
Code Output Requirements1283
Theft Warning1284
Description Of Theft Warning Function1284
Armed Mode Cancellation Requirements1285
Rk-Stics1288
Tail Lamp And Switch1288
Warning Lamps1289
Wiper, Door Switch, Lamps (Room Lamp, Map Lamp), Door Ajar Warning Lamp1290
Door Lock, Heated Wire1291
Central Door Locking Device1292
Transponder1296
Coil Antenna1296
Immobilizer Rf Ic1296
Immobilizer Unit1296
Schematic Diagram1297
Instrument Panel And Multi-Meter1298
Cluster1299
Black-Face Type Cluster1300
Direct Injection Diesel Engine Equipped Vehicle1302
Circuit Diagram And Connecter Pin Arrangement1303
Clear Glass Type Cluster1304
Direct Injection Diesel Engine Equipped Vehicle (With Can Communication)1304
Di Engine Equipped Vehicle1305
Indirect Injection Diesel Engine Equipped Vehicle1306
Idi Engine Equipped Vehicle (Without Can Communication)1307
Speedometer1308
Tachometer1308
Fuel Gauge1309
Checking The Fuel Sender Resistance1309
Fuel Sensor1309
Temperature Gauge1310
Checking The Temperature Sensor Resistance1310
Trip Odometer And Odometer1311
Battery Voltage1311
Battery Current1311
Odometer1311
Colors And Sizes Of Indicators1312
Warning Lamp: Led Emifting1312
Parking Brake Switch1314
Door Switch1314
Engine Oil Pressure Warning Light1316
Battery Charge Warning Light1316
Seat Belt Reminder1317
Winter Mode Indicator1317
Auto Shift Indicator1317
Wd Check Warning Light1317
Door Open Warning Light1319
Air Bag Warning Light1319
High Beam Indicator1319
Brake System Warning Light1320
Low Fuel Level Warning Light1320
Ebd Warning Light1321
Abs Warning Light1321
Esp Warning Light1322
Ssps Warning Light1322
How To Drain The Water From Fuel Filter (Direct Injection Diesel Engine Equipped Vehicle)1324
Engine Check Indicator1325
Rheostat (Black-Face Type)1325
Multi-Meter1326
Electronic Compass1327
Turning Calibration1327
Release Conditions For Turning Calibration1327
Speed Sensing Indicator1328
Barometer1328
Altimeter (Absolute Altimeter)1329
How To Calibrate The Altitude1329
How To Erase The Calibrated Altitude Value1329
Altitude Calibration Ranges1329
Relative Altimeter1330
Mode Setting Of The Relative Altimeter1330
To See the Destination's Altitude1330
Coming Out Order Of The Road Signs1330
Switches1332
Center Switches1333
Seat Warmer Switch1335
Esp Off Switch1336
Circuit Diagram And Connector Pin Arrangement1337
Stopping Esp Function With Esp Off Switch1337
Resuming Esp Function With Esp Off Switch1337
Front Fog Lamp Switch1338
Outside Rearview Mirror & Tailgate Glass Defogger Switch1339
4Wd Switch1340
Vehicle Equipped With Manual Transmission1340
Vehicle Equipped With Automatic Transmission1340
Mode Switching1340
4Wd Check Warning Light1341
Hazard Warning Switch1342
Digital Clock1344
Time Setting1344
Tailgate Window Wiper Switch1346
Left Switch Panel1346
Outside Rearview Mirror Control Switch1347
Steering Wheel Remote Control Switch1349
Multi-Function Switch1354
Light Switch1355
High Beam Switch1355
Passing Light Switch1356
Turn Signal Light Switch1356
Washer Switch (Windshield Glass)1357
Wiper Switch (Windshield Glass)1357
Automatic Wiper Control Switch1358
Auto Light Switch1358
Rain Sensing Wiper System1361
System Diagram1361
Operational Characteristics Of Rain Sensor1363
Rain Sensor Unit Inspection1364
Checking Sensitivity Selection (Checking Variable Resistance Knob Position)1364
Wiper Blade1364
Coupler1364
Rear Wiper Control System1365
Wiping Mode1366
Parking Mode Operation1366
Washer Mode Operation1366
Limit Switch On Mode Operation1366
Washer Coupled Mode1367
Limit Switch On/Off Mode Operation1367
Auto Light System1369
Auto Light Sensor Unit Terminal1370
Auto Light Operation And Turning On Condition1370
Operational Characteristics1371
Seat Position Memory Setting And Operation1372
Storing Memory Settings1373
Operating Memory Settings1373
Seat Position And Warmer Unit1374
Window Switch1377
Front (Driver's) Window Switch1377
Passenger's/Rear Window Switch1377
Lamps1379
Lamp Locations1380
Exterior Lamps1380
Headlamp Aiming1382
When Using A Beam Setting Device1382
When Using A Screen (Unit: Mm)1383
Measurement Of Headlamp Aiming1384
Headlamp - Removal And Installation1387
Front Turn Signal Lamp/Fog Lamp - Removal And Installation1388
Rear Combination Lamp - Removal And Installation1389
License Plate Lamp - Removal And Installation1389
Side Turn Signal Lamp - Removal And Installation1390
High Mounted Stop Lamp - Removal And Installation1390
Interior Lamps1391
Door Lamp - Removal And Installation1392
Glove Box Lamp - Removal And Installation1392
Interior Lamp - Removal And Installation1393
Front Lamp1393
Center/Rear Lamp1394
Wiper & Wiper Motor/Horn1395
Front Wiper Assembly1397
Rear Wiper Assembly1398
Front Wiper Motor Speed1400
Front Wiper Auto Stop1400
Passenger's Door and Rear Sub Switches1401
Power Window Motor1401
Tailgate And Side Quarter Glass Defogger1402
Repairing The Tailgate Defogger Grid Line1403
Ffh/Ptc System1407
Fuel Fired Heater (Ffh) System1408
Initial And Repeat Operating Conditions Of Ffh1413
Ffh Operations According To The Changes Of Coolant Temperature1413
Coolant Circulating Route1414
Connecting The Coolant Circuit1414
Control And Safety Mode1416
Technical Data - Water Pump1416
Characteristic Curve Of Water Pump (12 V)1416
Function Diagram1417
Sectional Drawing According To The Temperatures1417
When Faults Occur, First Check...1418
Controller Lock1418
Cancel The Controller Lock1418
Testing Equipment1418
Fault Diagnosis With The Diagnosis Instrument1419
Connecting Up The Diagnosis Instrument1420
Querying The Fault Memory1420
Delete Fault Memory1420
Canceling The Controller Lock1420
Trouble Code1421
Fuel Pump - Removal And Installation1430
Ambient Temperature Switch - Removal And Installation1431
Ffh Unit - Removal And Installation1432
Ptc System1435
Positive Temperature Coefficient (Ptc) System1435
Heater & Ventilation System1440
Manual Air Conditioner1442
Fan Speed Control Switch1443
Temperature Control Switch1443
Air Conditioner Switch1443
Air Source Selection Switch (Amb Switch)1444
Rear Air Conditioner Switch1444
Automatic Air Conditioner1445
Auto Switch1446
Amb Switch1447
Off Switch1447
Defrost Switch1448
Air Source Selection Switch1448
Automatic Heating And Air Conditioning1449
Air Flows Through Vents (Mode Switch Operations)1450
Air Distribution1452
Mode Door Motor1452
Air Source Door Motor1452
Air Mix Door Motor1452
Blower Motor1454
Insufficient Heating Or Defrosting1455
Blower Noise1461
Air Duct Assembly1463
Rear Cooler Duct1464
Heater And Blower Module Assembly1465
Front Hoses1465
Front Heater And Blower Module Assembly1466
Rear Blower Motor Assembly1467
A/C System1468
Compressor Specifications1469
Precautions For Working With R-134A1470
General Refrigerant Precautions1470
Handling O-Ring1470
Handling Refrigerant1470
Handling Of Refrigerant Lines And Fittings1471
Maintaining Chemical Stability In The Refrigeration System1471
Diagnosis Using The Manifold Gauge1480
Refrigerant Charging1482
Evacuating Refrigeration System1482
Installation Of Manifold Gauge1482
Discharging Refrigerant1482
Check For Refrigerant Leaks1483
How To Use The Tap Valve1483
Charging Refrigerant1484
Charging For Gas1484
Charging For Liquid1484
Before Oil Replacement1486
Replacement Of Oil1486
Handling Oil1486
Circulating Oil1486
Replacement Of Refrigerant Connection1487
Replacement Of Air Conditioner Filter1488
Receiver Drier And Refrigerant Pressure - Removal And Installation1492
Condenser - Removal And Installation1493
Compressor - Removal And Installation1495
High And Low Pressure Lines - Removal And Installation1496
Compressor Disassembly And Reassembly1497
Manual Air Conditioning System1499
Compressor1499
Magnetic Clutch1499
V-5 Compressor-Operation1499
Condenser Core1500
Receiver-Drier1500
Expansion Valve1500
Evaporator1500
Pressure Relief Valve1500
Insufficient Cooling Diagnosis1502
Control Switch Assembly1505
Automatic Air Conditioner System1506
Fatc Control1506
Fatc Input/Output Routing Diagram1507
Fatc System Characteristic1508
Display Performance Enhancement1508
Airflow Control Enhancement1508
Self-Diagnostic Circuit Check1508
Set Temperature Control1509
Airflow Control1509
Automatic Control1509
Vent Rate Control By Heating Operation1509
Manual Control1509
Vent Rate Control By Cooling Operation1510
Defroster Calibration1510
Vehicle Speed Calibration1510
Ambient Temperature Display1510
Vent Outlet Control1511
A/C Control1511
Full Cold/Hot Control1511
Control By The Vehicle Speed1511
Wiper Calibration Control1512
Fatc Controller Illumination Control1512
Controller Assembly1513
Sensors And Motors1513
Inside Air Temperature Sensor1513
Ambient Air Temperature Sensor1513
Sun Sensor1514
Intake Control Door Motor1514
Photo Diode1514
Mode Control Motor1515
Power Transistor1516
General A/C Diagnosis1518
Mode Controls Does Not Work1526
Abnormal Refrigerant Pressure1527
Compressor Magnetic Clutch Does Not Engage1528
Inside Air Temperature Sensor Error1528
Ambient Air Temperature Sensor Error1528
Coolant Temperature Sensor Error1529
Air Mix Door Error1529
Sun Sensor Error1531
Power Transistor Error1531
Max-High Relay Error1532
High Speed Relay In Blower Motor1535
Intake Door Actuator1536
Mode Control Door Actuator1536
Ambient Air Temperature Switch1538
Body1539
Waterleak Test1542
Leak Test1542
Spot Test1542
Water Hose Test1542
Air Hose Test1543
Waterleak Repair1543
General Repair1543
Windnoise Repair1545
Squeak And Rattle Repair1545
Waterleak Diagnosis1547
Windnoise Diagnosis1547
Body Dimensions1550
Underbody (Frame)1550
Frame1551
Side Structure Complete1552
Engine Compartment1554
Windshield And Tailgate Glass1555
Tailgate1556
Gap Chart1557
Undercoating1559
Body Mountings1560
Wiring Harness1561
Engine Compartment 11561
Engine Compartment 21562
Instrument 11563
Instrument 21564
Instrument 31565
Air Conditioner1566
Seat1567
Front Door1568
Rear Door1569
Roof1571
Driver Side1572
Passenger Side1574
Vehicle Interior1575
Seat Position/Seat Warmer Unit1577
Seat Position Memory Switch1579
Seat Warmer1580
Outside Rearview Mirror Folding/Unfolding1581
Front Seat1582
Second Seat1583
Third Seat1585
Driver's Seat1586
Passenger' Seat/Second Seat (for 1 Person)1588
Second Seat (For 2 Persons)1589
Replacing The Seat Motor From The Seat Guide Rail1591
Seat Belt1592
Layout1592
Front Seat Belt1593
Second Seat Belt1595
Third Seat Belt1597
Convenient Devices1598
Sun Visor1599
Hand Grip1599
Room Mirror1599
Overhead Console1600
Other Components1601
Cup Holder1602
Front Power Outlet1603
Center Console1603
Multi-Purpose Box1606
Interior Trim And Roof Assembly1607
Removal And Installation Of Trim/Roof1608
A-Pillar Trim1608
B-Pillar Trim1608
Side Cowl Trim1609
Roof (Headlining)1609
Lower Quarter Trim1609
Upper Quarter Trim1610
Door Scarf Trim1611
Instrument Assembly1612
Exterior1617
Front Bumper1618
Flip-Up System1620
Hood1622
Sub Roof And Roof Rack1623
Molding1624
Hood Assembly1625
Hood Shock Absorber1626
Hood Latch And Cable1626
Hood Hinge Adjustment1627
Hood Latch Adjustment1627
Replacement Of Hood Insulation Pad1628
Cowl Grille1629
Radiator Grille1630
Front Bumper Assembly1631
Fender1635
Fuel Filler Lid Opener1637
Roof Carrier1638
Side Step1639
Side Molding/Wheelhouse Molding1640
Outside Rearview Mirror1641
Front Door Assembly1643
Door Trim1645
Door Speaker1646
Window Regulator Assembly1646
Door Opening Weatherstrip1648
Door Lock Striker Adjustment1649
Fore/Aft Adjustment1650
Up/Down Or In/Out Adjustment1651
Rear Bumper Assembly1652
Back Beam / Rear Bumper1654
Tailgate Crank1655
Tailgate Glass1657
Tailgate Air Spoiler1658
Front Door Glass1660
Front Door Glass Run And Regulator1661
Rear Window1662
Rear Glass Run / Regulator / Channel1664
Windshield Removal1665
Front Quarter Glass1670
Rear Quarter Glass1672
Sun Roof1678
Motor And Relay Box1679
Glass Panel1681
Sun Shade1683
Airbag System1685
Sir System1686
General Precautions1686
Cautions With The Air Bag1687
Side Airbag Operation1687
Front Airbag Operation (Driver's and Passenger's)1687
Airbag Module Discard1689
Airbag Module Discard (Driver)1689
Deployed Airbag Module Disposal Procedure1690
Airbag Module Discard (Passenger)1690
Airbag Module Deployment (Outside Vehicle)1690
Back (Cushion)1691
Module Cover/Housing1691
Inflator1691
Airbag Module1691
Acceleromenter Sensor1692
Safety Sensor1692
Micro Controller1692
Contact Coil1692
Airbag Warning Lamp1693
Wiring Harness Connectors1693
Belt Pretensioner1693
Front Air Bag1694
General Description1694
Airbag Components1694
Frontal Airbag Cross Sectional View1695
Passenger Airbag Assembly1696
Side Air Bag1697
Driver's Air Bag Module1698
Passenger's Air Bag Module1701
Air Bag Control Module (Sdm)1703
Warning Lamp Check1704
Fault Indication1704
Clearing Fault Codes1704
Microprocessor-Independent Lamp Activation1704
How To Use Electrical Wiring Diagram1710
How To Read Electrical Wiring Diagram1711
Contents Of Electrical Wiring Diagram (Circuit)1712
How To Check Terminal Number Of Connector1714
Part Location According To Part Number1715
Electric Symbols1716
Abbreviations1717
Position Of Connectors And Grounds1721
Position Of Connector, Ground & Splice Pack1722
Connector, Ground & Splice Pack Information1723
Wiring Harness, Connector & Ground Location1728
Splice Pack1742
Connector Identification Symbol & Pin Number Position1747
Wiring Diagram For Power Supplies1755
Power Wiring Diagram (Dsl)1756
Model1756
2) 2003 Model1760
Power Wiring Diagram (Xdi, 2003 Model)1764
Eng Room & Fuse Box1764
Ef10 ~ Ef141768
Ef15 ~ Ef201769
Ef21 ~ Ef261770
Fuse Box1771
F1 ~ F51771
F6 ~ F151772
F16 ~ F211773
F22 ~ F281774
F29 ~ F311775
Engine Room Fuse & Realy Block1784
Usage Of Fuse In Engine Room Fuse Box1786
Usage And Capacity Of Fuses In Fuse Block1792
I.p. Fuse & Relay Box1793
Electrical Wiring Diagrams1799
Starting & Charging1804
Connector Identification Symbols & Pin Number Position1809
Preheating Unit Circuit1810
Egr (Exhaust Gas Recirculation) Control Circuit (Dsl)1814
Huber Egr1816
Ecu (Electronic Control Unit) (E23)1818
Digital Clock, Eng Temp Sensor, Immobilizer Circuit1820
Tcu (Transmission Control Unit) (4-Speed)1846
Tccu (Transfercase Control Unit)1856
Tod (Torque On Demand)1862
A/T Shift Lock Circuit1872
Air Bag & Side Air-Bag Circuit1874
Rain Sensing Wiper Circuit1886
Power Seat Circuit1890
Frt Seat Warmer (W/O Memory)1892
Power O/Side Mirror, Defogger Seat Warmer Circuit (W/ Memory)1894
Power O/Side Mirror, Defogger Circuit (W/O Memory)1896
Central Door Locking System1900
Seat Belt, Tension Reducer Circuit1902
Passenger Power Seat Circuit1904
Auto Light Control Circuit1906
Stics1910
Power Window Circuit1922
Rear Glass Wiper & Washer Circuit1924
Horn Circuit1928
Cigar Light Circuit1930
Pekes Circuit1932
Sun Roof Circuit1934
Head Lamp Circuit1936
Head Lamp Leveling Device Circuit1938
Drl (Day Time Running Light) Unit1940
Tail Lamp Circuit1942
Turn Signal & Hazard Lamp Circuit1946
Fog Lamp Circuit1950
Stop & Back Up Lamp Circuit1954
Interior Lamp Circuit1956
Auto Dimming Room Mirror Circuit1958
Audio, Digital Clock Circuit1960
Audio (Multi Vision)1962
Air-Con (Manual, Dsl)1966
Fatc (Full Auto Temperature Control) Circuit1974
Parking Aid Circuit1982
Trailer Connector Circuit1984
P.t.c. Heater (Positive Temperature Coefficient)1986
F.f.h. (Fuel Fired Heater)1988
S.s.p.s1990