SSANGYONG REXTON 2007.09 Manual

page of 768

/ 768
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

VEHICLE GENERAL

1. DIMENSIONS........................................

2. SPECIFICATIONS.................................

3. VEHICLE IDENTIFICATION...................

4. MAINTENANCE......................................

5. RECOMMENDED FLUIDS AND

LUBRICANTS........................................

6. JACK-UP POINTS (DOTTED CIRCLES).

7. PIN ARRANGEMENT OF DIAGNOSTIC

CONNECTOR........................................

8. ELECTRIC COMPONENTS AND

LAYOUT................................................

9. TIGHTENING TORQUE OF

STANDARD BOLTS...............................

VEHICLE GENERAL

0000-00

VEHICLE GENERAL

Chapters

Table of Contents

Summary of Contents for SSANGYONG REXTON 2007.09

Page 1: Table Of Contents
VEHICLE GENERAL 0000-00 VEHICLE GENERAL VEHICLE GENERAL 1. DIMENSIONS........2. SPECIFICATIONS......... 3. VEHICLE IDENTIFICATION....4. MAINTENANCE........5. RECOMMENDED FLUIDS AND LUBRICANTS........6. JACK-UP POINTS (DOTTED CIRCLES). 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR........8. ELECTRIC COMPONENTS AND LAYOUT..........9. TIGHTENING TORQUE OF STANDARD BOLTS.......
Page 3: Dimensions
01-3 0000-00 0000-00 VEHICLE GENERAL GENERAL 1. DIMENSIONS VEHICLE GENERAL undefined...
Page 4: Specifications
01-4 0000-00 2. SPECIFICATIONS * ( ): Optional, [ ]: 2WD, D27DTP: Diesel 2.7 Power-Up, D27DT: Diesel 2.7, G32D: Gasoline VEHICLE GENERAL undefined...
Page 5 01-5 0000-00 ▶Specifications (Cont'd) VEHICLE GENERAL undefined...
Page 6: Vehicle Identification
01-6 0000-00 3. VEHICLE IDENTIFICATION 1. Engine Number 2. Chassis Number Gasoline Engine: The engine The chassis number is stamped on number is stamped on the the frame behind the front right tire. lower area of cylinder block in exhaust manifold side. 3.
Page 7: Maintenance
0000-00 4. MAINTENANCE 1) Diesel Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
Page 8 01-8 0000-00 * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
Page 9 01-9 0000-00 * Use only approved Ssangyong genuine parts. CHASSIS AND BODY Chart Symbols: I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R - Replace or change. (3)* Refer to "Recommended fluids and lubricants".
Page 10 01-10 0000-00 2) Gasoline Engine * Use only approved Ssangyong genuine parts. Maintenance service and record retention are the owner's responsibility. You should retain evidence that proper maintenance has been performed on your vehicle in accordance with the scheduled maintenance service chart.
Page 11 01-11 0000-00 * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
Page 12 01-12 0000-00 * EU Countries: Only countries that belong to EU. (It does not apply to all countries in EU.) CHASSIS AND BODY Chart Symbols: I -Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
Page 13: Recommended Fluids And Lubricants
0000-00 5. RECOMMENDED FLUIDS AND LUBRICANTS - Use only Ssangyong recommended fluids and lubricants. - Keep the specified levels when adding or replacing the fluids. - Do not mix any different types or brands of oils or fluids. This may cause damages.
Page 14: Jack-Up Points (Dotted Circles)
01-14 0000-00 6. JACK-UP POINTS (DOTTED CIRCLES) IRS type 5-link type VEHICLE GENERAL undefined...
Page 15: Pin Arrangement Of Diagnostic Connector
01-15 0000-00 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR It is installed under the instrument panel and consists of 16 pins. The REKES key coding should be performed with SCAN-TOOLS. Diagnostic connector Functions of Terminal VEHICLE GENERAL undefined...
Page 16: Electric Components And Layout
01-16 0000-00 8. ELECTRIC COMPONENTS AND LAYOUT 1) Wiring Harness Arrangement VEHICLE GENERAL undefined...
Page 17 01-17 0000-00 2) Components Locator VEHICLE GENERAL undefined...
Page 18: Tightening Torque Of Standard Bolts
01-18 0000-00 9. TIGHTENING TORQUE OF STANDARD BOLTS ▶Tightening Torque By Bolt Specification Metric bolt strength is embossed on the Determine extra proper tightening torque head of each bolt. The strength of bolt if tightens with washer or packing. can be classified as 4T, 7T, 8.8T, 10.9T, If tightens bolts on the below materials, 11T and 12.9T in general.
Page 19 01-3 0000-00 1113-01 ENGINE ASSEMBLY GENERAL 1. DESCRIPTION AND OPERATION 1) Cleanliness and Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation.
Page 20 01-4 1113-01 2) On-engine Service Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
Page 21 01-5 0000-00 2. G23D ENGINE ASSEMBLY Front View Rear View ENGINE ASSEMBLY undefined...
Page 22 01-6 1113-01 LH Side View RH Side View ENGINE ASSEMBLY undefined...
Page 23 01-7 0000-00 3. G23D ENGINE STRUCTURE Front View Side View ENGINE ASSEMBLY undefined...
Page 24 01-8 1113-01 Front View ▶ FUNCTION FUNCTION HFM Sensor Intake Manifold Intake Air Duct Cylinder Head Cylinder Head Cover Exhaust Manifold Ignition Coi Dipstick Guide Tube and Gauge Spark Plug Connector Connecting Rod Fuel Distributor Crankshaft Injector Engine Mounting Bracket Exhaust Camshaft Starter Intake Camshaft...
Page 25 01-9 0000-00 4. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Oil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair.
Page 26 01-10 1113-01 ▶ Black Light and Dye Method A dye and light kit is available for finding leaks, Refer to the manufacturer's directions when using the kit. Pour the specified amount of dye into the engine oil fill tube. Operate the vehicle normal operating conditions as directed in the kit. Direct the light toward the suspected area.
Page 27 01-11 1113-01 2) Compression Pressure Test ▶ Standard Service Data A9912 0012B (001 589 76 21 00) Compression Pressure Tester Measuring Procedure ▶ Warm the engine up to normal operating temperature. Remove the spark plugs using the spark plug wrench. Place the diagram sheet to compression pressure tester A9912 0012B (001 589 76 21 00).
Page 28 01-12 1113-01 3) Cylinder Pressure LeakageTest ▶ Permissible Pressure Leakage At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max. 20 % Cylinder Number ▶ 1, 4 OT (TDC) 2, 3 UT (BDC 180 °) ▶...
Page 29 01-13 1113-01 ▶ Leakage Test Warm the engine up to normal operating temperature. Disconnect the negative battery cable. Remove the spark plugs. Check the coolant level by opening the coolant reservoir cap and replenish if insufficient. Open the engine oil filler cap. Connect the tester to air pressure line and adjust the scale of tester.
Page 30 01-14 0000-00 5. GENERAL DIAGNOSIS ENGINE ASSEMBLY undefined...
Page 31 01-15 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 32 01-16 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 33 01-17 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 34 01-18 1113-01 ▶ General Diagnosis (Cont'd) ENGINE ASSEMBLY undefined...
Page 35 01-19 0000-00 6. SPECIFICATIONS 1) Engine Specifications MSE : Engine Control Module 3.53D : 4 Cylinder Version ENGINE ASSEMBLY undefined...
Page 36 01-20 1113-01 2) Fastener Tightening Specifications ENGINE ASSEMBLY undefined...
Page 37 01-21 1113-01 ▶ Fastener Tightening Specifications (Cont'd) ENGINE ASSEMBLY undefined...
Page 38 01-22 1113-01 2) Performance Curve ENGINE ASSEMBLY undefined...
Page 39 02-3 0000-00 0000-00 ENGINE INTAKE SYSTEM GENERAL 1. SPECIFICATIONS (1) Fastener Tightening Specifications ENGINE INTAKE SYSTEM undefined...
Page 40 03-3 0000-00 2420-01 ENGINE EXHAUST SYSTEM GENERAL 1. SPECIFICATION (1) Fastener Tightening Specifications ENGINE EXHAUST SYSTEM undefined...
Page 41 03-4 0000-00 OVERVIEW AND OPERATION PROCESS 1. DESCRIPTION AND OPERATION 1) Exhaust System When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials.
Page 42 03-5 2420-01 ▶ Catalytic Converter and Temperature Catalytic converter has the normal function of purification at a range of the temperature. Because it has a weak point of decreasing of the purification rate in the condition of continuous high temperature, it should keep the temperature range of 400 to 500°C normal condition.
Page 43 03-6 2420-01 ▶ Method for Reduction of NOx NOx is generated a great deal in case that combustion temperature and excess air factor are high. EGR valve can decrease NOx (30 to 35% decrease) by making temperature of combustion chamber fall by means of exhaust gas re-circulation. EGR valve is installed on the diesel engine of Musso, Korando, Istana and Rexton.
Page 44 04-3 0000-00 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM undefined...
Page 45 04-4 0000-00 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE COOLING SYSTEM undefined...
Page 46 04-5 0000-00 OVERVIEW AND OPERATION PROCESS 1. COMPONENT LOCATOR 1. Reserver Tank 9. Radiator 2. Deaeration Tube 10. Lower Radiator Insulator 3. Inlet Hose 11. Plate 4. Outlet Hose 12. Clip 5. 3 way Hose 13. Upper Radiator Insulator 6. Clamp 14.
Page 47 04-6 0000-00 2. DESCRIPTION AND OPERATION 1) General Description The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly.
Page 48 04-7 2112-01 4) Water Pump The belt-driven centrifugal water pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bearing. The water pump is serviced as an assembly and, therefore, cannot be disassembled. 5) Thermostat A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system.
Page 49 04-8 2112-01 The cooling fans are mounted behind the radiator in the engine compartment. The electric cooling fans increase the flow of air across the radiator fins and across the condenser on air conditioned (A/C)-equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds. All models have two fans.
Page 50 04-9 0000-00 3. PWM (PULSE WIDTH MODULATION) ELECTRIC FAN OPERATION 1) Function The PWM (Pulse Width Modulation) high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise. 2) Mounting Location Fan shroud PWM unit Electric fan...
Page 51 04-10 2112-01 3) PWM Electric Fan (1) Advantages and Disadvantages of the PWM Electric Fan ▶ Advantages Enhanced A/C performance: at low speed, at idling, driving in city Reduction vibration/noise: activated by PWM only when necessary Reduction of engine consuming power (V/Fan driving force) by 4 Hp - Cost saving ▶...
Page 52 04-11 2112-01 5) Shutting-off Condition of the A/C Compressor Coolant temperature ▶ When coolant temperature is below 20°C or over 115°C, engine speed is below 650 rpm or over 4500 rpm for 4 seconds after engine starting, abrupt acceleration and A/C refrigerant pressure sensor detecting the followings A/C compressor is turned off when the refrigerant pressure is below 2.0 kg/cm2 and then is turned on when the refrigerant pressure is over 2.4 kg/cm2.
Page 53 05-3 0000-00 0000-00 ENGINE ELECTRIC DEVICES GENERAL 1. DIAGNOSTIC INFORMATION AND PROCEDURE 1) Ignition System ENGINE ELECTRICAL SYSTEM undefined...
Page 54 05-4 1452-01 2) Ignition System (Cont'd) ENGINE ELECTRICAL SYSTEM undefined...
Page 55 05-5 0000-00 OVERVIEW AND OPERATION PROCESS 1. DESCRIPTION AND OPERATION 1) Battey The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed, except for two small vent holes in the sides. These vent holes allow the small amount of gas produced in the battery to escape.
Page 56 05-6 1452-01 (2) Cold Cranking Amperage The cold cranking amperage test is expressed at a battery temperature of -18 °C (0 °F). The current rating is the minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts.
Page 57 05-7 1452-01 4) Charging a Completely Discharged Battery (Off the Vehicle) Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced. The following procedure should be used to recharge a completely discharged battery: Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milliamperes.
Page 58 05-8 1452-01 5) Jump Starting Procedure Position the vehicle with the charged battery so that the jumper cables will reach from the charged battery to the battery that requires charging. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Leave the hazard flasher on if jump starting where there may be other traffic and any other lights needed for the work area.
Page 59 05-9 1452-01 6) Alternator Alternators are equipped with internal regulators. Unlike three-wire generators, the alternator may be used with only two connections: battery positive and an "D+" terminal to the charge indicator lamp. As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to RUN, and goes out when the engine is running.
Page 60 05-10 1452-01 9) Starting System The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular component, refer to that component section of the service manual. The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related electrical wiring.
Page 61 07-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 62 07-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 63 07-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 64 07-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 65 07-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 66 07-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 67 07-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 68 07-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 69 ENGINE INFORMATION 0000-00 ENGINE INFORMATION GENERAL 1. COMPONENT LOCATOR....... 2. DESCRIPTION AND OPERATION..
Page 72 01-4 0000-00 0000-00 ENGINE GENERAL GENERAL 1. COMPONENT LOCATOR 1) Front View ENGINE INFORMATION undefined...
Page 73 01-5 0000-00 ▶ Front View FUNCTION FUNCTION HFM sensor Intake manifold Intake air duct Connecting rod Resonance flap Exhaust manifold Cylinder head cover Crankshaft Exhaust camshaft Engine mounting Intake camshaft Starter Cylinder head Crankcase Spark plug connector Oil pump sprocket Valve tappet Oil strainer Injector...
Page 74 01-6 0000-00 2) SIDE VIEW FUNCTION FUNCTION Camshaft adjuster Oil pump drive chain Cooling fan and viscous clutch Oil return pipe Piston Timing chain Flywheel of drive plate ENGINE INFORMATION undefined...
Page 75 01-7 0000-00 2. DESCRIPTION AND OPERATION 1) Cleanliness And Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation.
Page 77 02-3 0000-00 1113-01 ENGINE ASSEMBLY GENERAL 1. SPECIFICATIONS 1) ENGINE SPECIFICATIONS ENGINE ASSEMBLY undefined...
Page 78 02-4 0000-00 2) PERFORMANCE CURVE ENGINE ASSEMBLY undefined...
Page 79 02-5 0000-00 2. SPECIAL TOOLS AND EQUIPMENT ENGINE ASSEMBLY undefined...
Page 80 02-6 0000-00 ENGINE ASSEMBLY undefined...
Page 81 02-7 0000-00 Name and Part Number A9917 0012B (DW110-120)Holding Pin ENGINE ASSEMBLY undefined...
Page 82 02-8 0000-00 3. FASTENER TIGHTENING SPECIFICATIONS ENGINE ASSEMBLY undefined...
Page 83 02-9 0000-00 1) Fastener Tightening Specifications (Cont'd) ENGINE ASSEMBLY undefined...
Page 84 03-3 0000-00 2211-22 ENGINE FUEL SYSTEM OVERVEIW AND OPERATION PROCESS 1. FUEL SYSTEM SPECIFICATION ▶ Use Only Unleaded Fuel Rated at 89 Octane or Higher Fuel quality and additives contained in fuel have a significant effect on power output, drivability, and life of theengine.
Page 85 03-4 0000-00 ▶ temperature vs resistance ENGINE FUEL SYSTEM undefined...
Page 86 NO DATA...
Page 87 05-3 0000-00 2420-01 ENGINE EXHAUST SYSTEM GENERAL 1. OVERVIEW OF EXHAUST SYSTEM When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor panel and possible damage to the passenger compartment insulation and trim materials.
Page 88 05-4 0000-00 4. FASTENER TIGHTENING SPECIFICATIONS ENGINE EXHAUST SYSTEM undefined...
Page 89 06-3 0000-00 9210-01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1. OIL CIRCULATION LUBRICATION SYSTEM undefined...
Page 90 06-4 0000-00 ▶ OIL CIRCULATION FUNCTION FUNCTION Oil pump Oil supply (to exhaust camshaft) Oil gallery (to oil filter) Oil supply (to intake camshaft) Oil supply Oil filter (to exhaust camshaft bearing) Oil supply Oil pressure switch (to intake camshaft bearing) Oil gallery Main oil gallery (oil supply to exhaust valve tappet)
Page 91 07-3 0000-00 2110-01 ENGINE COOLING SYSTEM GENERAL 1. GENERAL SPECIFICATIONS COOLING SYSTEM undefined...
Page 92 07-4 0000-00 2. SPECIAL TOOLS AND EQUIPMENT COOLING SYSTEM undefined...
Page 93 07-5 0000-00 3. FASTENER TIGHTENING SPECIFICATIONS COOLING SYSTEM undefined...
Page 94 07-6 0000-00 OVERVIEW AND OPERATION PROCESS 1. GENERAL DESCRIPTION The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly. The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat and housing, a water pump, and a water pump drive belt.
Page 95 07-7 0000-00 2. COMPONENT LOCATOR COOLING SYSTEM undefined...
Page 96 07-8 0000-00 Radiator Inlet hose Electric fan Outlet hose Shroud 3 way hose Deaeration tube Deaeration hose (reserver tank) Clamp Clamp Deaeration hose (radiator) Clamp Electric fan mounting bracket Make up hose holder Bolt (M6, 8 pieces) Reserver tank Bolt (M6, 4 pieces) Bolt (M6, 2 piece) Bolt (M6, 4 pieces) Cooling fan...
Page 97 08-3 0000-00 1452-01 ENGINE ELECTRIC DEVICES GENERAL 1. GENERAL SPECIFICATIONS ENGINE ELECTRIC DEVICES undefined...
Page 98 08-4 0000-00 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE ELECTRIC DEVICES undefined...
Page 99 08-5 0000-00 OVERVIEW AND OPERATION PROCESS 1. CHARGING SYSTEM OPERATION Alternators use a new type of regulator that incorpo-rates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier alternators. A conventional pulley and fan are used.
Page 100 08-6 0000-00 3. IGNITION SYSTEM OPERATION This ignition system does not use a conventional distributor and coil. It uses a crankshaft position sensor input to the Engine Control Module (ECM). The ECM then determines Electronic Spark Timing (EST) and triggers the electronic ignition system ignition coil.
Page 101 08-7 0000-00 4. STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) CIRCUIT ENGINE ELECTRIC DEVICES undefined...
Page 102 09-3 0000-00 1522-16 ENGINE CONTROL SYSTEM GENERAL 1. ENGINE DATA DISPLAY TABLE ENGINE CONTROL SYSTEM undefined...
Page 103 09-4 0000-00 1) TEMPERATURE VS RESISTANCE 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE CONTROL SYSTEM undefined...
Page 104 10-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 105 10-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 106 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 107 10-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 108 10-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 109 10-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 110 10-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 111 10-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 112 ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. STRUCTURE AND COMPARISON..2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE......3. TIGHTENING TORQUE......4. MAJOR CHANGES IN D27DTP(POWER UP ENGINE(COMPARED TO D27DT)..OERVIEW AND OPERATION PROCESS 1. ENGINE COMPARTMENT..... 2. SYSTEM IN ENGINE COMPARTMENT.
Page 114: Structure And Comparison
01-3 0000-00 0000-00 ENGINE GENERAL GENERAL 1. STRUCTURE AND COMPARISON ▶D27DT (EU IV) Engine - Front View ▶D27DT (EU IV) Engine - Top View ENGINE GENERAL undefined...
Page 115 01-4 0000-00 ▶D27DT (EU IV) Engine - Side View ▶D27DT (EU IV) Engine - Left Side View ENGINE GENERAL undefined...
Page 116 01-5 0000-00 ▶D27DT Engine (General) - Front View ▶D27DT Engine (General) - Top View ENGINE GENERAL undefined...
Page 117 01-6 0000-00 ▶D27DT Engine (General) - Side View ▶D27DT Engine (General) - Left Side View ENGINE GENERAL undefined...
Page 118: Engine Specifications And Performance Curve
01-7 0000-00 2. ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1) Specifications ENGINE GENERAL undefined...
Page 119 01-8 0000-00 2) D27DT Engine Performance Curve (1) Output and Torque (2) Oil Temperature/Pressure and Boost Pressure ENGINE GENERAL undefined...
Page 120: Tightening Torque
01-9 0000-00 3. TIGHTENING TORQUE This table shows the tightening torques for removal/mounting and disassembly/reassemly of the engine. ENGINE GENERAL undefined...
Page 121 01-10 0000-00 ENGINE GENERAL undefined...
Page 122 01-11 0000-00 ENGINE GENERAL undefined...
Page 123: Major Changes In D27Dtp(Power Up Engine(Compared To D27Dt)
01-12 0000-00 MAJOR CHANGES IN D27DTP (POWER UP) ENGINE (COMPARED TO D27DT) The shape and size of D27DTP (POWER UP) are slightly different from those of D27DT engine but the basic configuration of two systems is almost same. 1) Engine Assembly ENGINE GENERAL undefined...
Page 124 01-13 0000-00 2) Major Changes and Summary ENGINE GENERAL undefined...
Page 125 01-14 0000-00 ENGINE GENERAL undefined...
Page 126 01-15 0000-00 ENGINE GENERAL undefined...
Page 127 01-16 0000-00 ENGINE GENERAL undefined...
Page 128 01-17 0000-00 ENGINE GENERAL undefined...
Page 129 01-18 0000-00 ENGINE GENERAL undefined...
Page 130 01-19 0000-00 ENGINE GENERAL undefined...
Page 131 01-20 0000-00 ENGINE GENERAL undefined...
Page 133: Engine Compartment
01-22 0000-00 OVERVIEW AND OPERATION PROCESS 1. ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows: ENGINE GENERAL undefined...
Page 134 01-23 0000-00 ENGINE GENERAL undefined...
Page 135 01-24 0000-00 ▶Engine Compartment Layout Engine assembly FFH Assembly (Only for vehicle with FFH) Engine oil dipstick Power steering oil tank Vacuum pump Engine oil filler cap Oil filter and cooler Fan shroud Fuel filter and priming pump E-EGR Valve Brake booster High-capacity PCV oil separator Brake oil tank...
Page 136 01-25 0000-00 ▶Major Sensors and Components ENGINE GENERAL undefined...
Page 137: System In Engine Compartment
01-26 0000-00 2. SYSTEMS IN ENGINE COMPARTMENT 1) Engine Accessories Related to ECU ENGINE GENERAL undefined...
Page 138 01-27 0000-00 ENGINE GENERAL undefined...
Page 139 01-28 0000-00 2) Preheat System ENGINE GENERAL undefined...
Page 140 01-29 0000-00 3) Fuel System ENGINE GENERAL undefined...
Page 141 01-30 0000-00 ▶Fuel Supply System ENGINE GENERAL undefined...
Page 142 01-31 0000-00 4) Lubrication System ENGINE GENERAL undefined...
Page 143 01-32 0000-00 5) Cooling System ENGINE GENERAL undefined...
Page 144 01-33 0000-00 6) Intake System ENGINE GENERAL undefined...
Page 145 01-34 0000-00 7) Exhaust System ENGINE GENERAL undefined...
Page 146 02-3 0000-00 1881-09 ENGINE FUEL SYSTEM OVERVIEW AND OPERATION PROCESS MAJOR CHANGES IN FUEL SYSTEM OF D27DTP (POWER UP) ENGINE There are some changes in the parts related to the fuel system due to the newly adopted D27DTP (POWER UP) engine. The major changes are as follows. Refer to the next pages for further details.
Page 147 02-4 0000-00 2) Common Rail The orifice is added to the connection to · D27DTP & D27DT (EU IV) the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume.
Page 148 02-5 0000-00 3) Fuel Rail - Chrome Color · The I.D and O.D of the fuel rail between D27DTP & D27DT (EU IV) HP pump and common rail are increased * Fuel pipe (Common rail → Injector) according to the increased amount of fuel injection.
Page 149 02-6 0000-00 2. COMPONENTS OF FUEL SYSTEM ENGINE FUEL SYSTEM undefined...
Page 150 02-7 0000-00 ▶Fuel Flow of D27DTP (Power Up) Engine Fuel Supply System ENGINE FUEL SYSTEM undefined...
Page 151 03-3 0000-00 2321-01 ENGINE INTAKE SYSTEM OVERVIEW AND OPERATION PROCESS 1. INTAKE SYSTEM LAYOUT The intake system for the D27DTP (POWER UP) engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off. Therefore, the structure of the intake manifold has been changed.
Page 152 04-3 1792-01 1792-01 ENGINE EXHAUST SYSTEM OVERVIE AND OPERATION PROCESS 1. COMPONENTS The components of the exhaust system for the D27DTP (POWER UP) engine have been changed as follows: 1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum modulator control has been deleted) 2.
Page 153 05-3 0000-00 1725-12 CDPF(Catalytic Disel Particulate Filter) GENERAL 1. Specifications for engine with CDPF CDPF(Catalytic Disel Particulate Filter) undefined...
Page 154 05-4 0000-00 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW As the solution for environmental regulations and PM Particla Material) of diesel engine, the low emission vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxydation Catalyst) is reduced.
Page 155 05-5 0000-00 2. COMPONENTS Differential Pressure CDPF Assembly and Rear Exhaust Gas Temperatiure Sensor Sensor CDPF(Catalytic Disel Particulate Filter) undefined...
Page 156 05-6 0000-00 3. MAJOR CHANGES The CDPF system is only installed to the D27DT engine, and the major changes comparing to the previous D27DT engine is as follows: CDPF (Catalyst & Diesel Particulate Filter) and Sensors Engine ECU Fuel Common Rail and Fuel Rail (Between Common Rail and Injector) The engine ECU has been revised since The I.D and O.D of fuel rail has changed...
Page 157 05-7 0000-00 CDPF(Catalytic Disel Particulate Filter) undefined...
Page 158 05-8 0000-00 4. OPERATION PROCESS 1) Combustion Temperature and Procedures As the soot is filtered in the CDPF, it is burnt and removed, and the CDPF is returned to the initial state to collect the soot. Therefore, the burning procedures in the CDPF can be called as recycling.
Page 159 05-9 0000-00 2) Sytem Composition for Soot Combustion When the engine is running in low load range, the temperature of exhaust gas is decreased as the amount of fuel supplied is decreased. To burnt the soot filtered in the CDPF, the control system should be installed to check the operating range and increase the temperature of exhaust gas by controlling the amount of fuel supplied and and intake air.
Page 160 05-10 0000-00 4) Throttle Body for Different Engines The throttle body is not installed in the D27DT engine (general), but is installed in the following engines: 1) D27DT (EU IV) engine 2) D27DTP (POWER UP) engine 3) D27DTP (POWER UP) engine + CDPF Both engines are equipeed with the throttle body, but its appearance and the related control system are differ.
Page 161 05-11 0000-00 5) Operating Procedures of CDPF The most efficient and practical technology for now is adopted to the diesel particulate filter (DPF). This system collects the soot from the diesel engine to the filter and burns the soot so that over than 95% of soot can be removed from the exhaust gas.
Page 162 05-12 0000-00 6) CDPF Over Load (Notice of Beginning CPF Regeneration Mode - P1430) The CDPF system enters the regeneration mode when the mileage is around 600 ~ 1,200 km, depending on the driving condition and driving habits. At this moment, the ECU performs the CDPF regeneration process;...
Page 163 NO DATA...
Page 164 07-3 0000-00 1520-01 ENGINE COOLING SYSTEM OVERVIEW AND OPERATION PROCESS 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE For the D27DTP (POWER UP) engine, the cooling system is equipped with E-EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block.
Page 165 07-4 0000-00 ▶Comparison D27DTP (POWER UP) & D27DT (EU IV) Engine D27DT Engine ENGINE COOLING SYSTEM undefined...
Page 166 NO DATA...
Page 167 NO DATA...
Page 168 10-3 8510-23 8510-23 CRUISE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1. CRUISE CONTROL SWITCH The purpose of the cruise control system is to automatically maintain a vehicle speed set by the driver, without depressing the accelerator pedal. The cruise control switch is located under the right side of the steering wheel, and when this switch is operating "AUTO CRUISE"...
Page 169 10-4 8510-23 1) When To Use Use the cruise control system only when (a) the traffic is not jammed, (b) driving on motorways or highways where there is no sudden change in the driving condition due to traffic lights, pedestrian, etc. Use the cruise control system only when driving on motorways or highways.
Page 170 10-5 8510-23 2. CIRCUIT DIAGRAM 1) Configuration CRUISE CONTROL SYSTEM undefined...
Page 171 10-6 8510-23 3. HOW TO OPERATE CRUISE CONTROL SWITCH 1) How To Set Speed To operate the cruise control system, accelerate the vehicle to the speed within the specified range below with depressing the accelerator pedal. - Cruise control operating range: between 36 km/h (22.37 mph) and 150 km/h (93.207 mph) When the desired speed is reached, which should be within the above range, push up the cruise control switch lever to ACCEL side (upwards arrow), or push down the switch lever to DECEL side (downwards arrow).
Page 172 10-7 8510-23 2) Accelerating with the Cruise Control System (1) While the cruise control system is running To increase the set speed, push up the cruise control switch lever to ACCEL side and hold it until the desired speed is reached without depressing the accelerator pedal. When the desired speed is set, release the switch lever.
Page 173 10-8 8510-23 3) Decelerating with the Cruise Control System (1) While the cruise control system is running To decrease the set speed, push down the cruise control switch lever to DECEL side and hold it until the desired speed is reached without depressing the brake pedal. But the cruise control system cannot maintain the cruise function at less than 34 km/h (21.13 mph).
Page 174 10-9 8510-23 4) Recovery of Set Speed (RESUME) Even if the cruise control is cancelled, the previous set cruise speed can be recovered by operating the cruise control switch lever like below: - Pull the switch lever in the arrow direction shown in the illustration. This RESUME function works only when the vehicle speed is more than 36 km/h (22.37 mph) without using the accelerator or brake pedal.
Page 175 10-10 8510-23 5) Normal Cancellation of the Cruise Control (OFF ↔ ON) The cruise control system will be cancelled when the button on the side of the switch is pressed, or when one of the following conditions is met: When the brake pedal is depressed or ESP is activated. When the vehicle speed is less than 34 km/h (21.13 mph).
Page 176 NO DATA...
Page 177 02-3 0000-00 8710-08 RKSTICS GENERAL 1. SPECIFICATIONS 1) Electrical Performance 2) Characteristics of Radio Wave Transmitting frequency: 447.800 ± 0.0125 MHz Channel width: below 12.5 KHz Frequency bandwidth: below 8.5 KHz Modulation method: FSK (Frequency Shift Keying) Receiving distance: Approx. 10 ~ 15 m (In case there are not obstacles around the system) RKSTICS...
Page 178 02-4 0000-00 3) Rated Load RKSTICS undefined...
Page 179 02-5 0000-00 4) Input Signals RKSTICS undefined...
Page 180 02-6 0000-00 5) Chattering of Input Signals Vehicle speed input: The vehicle speed is the average value of 4 pulse among 6 pulse inputs regardless of the input for 1.0 second after IGI 1 ON. The time indicated in each function does not include the vehicle speed calculating time.
Page 181 02-7 0000-00 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The RKSTICS (REKES + STICS (Super Time & Integrated Control System)) communicates with the transmitter (remote controller) and other electronic systems to transmit and receive the data. The STICS also includes a diagnosis function that can inspect the error for related devices. 2.
Page 182 02-8 0000-00 3. FUNCTIONS ▶ Wiper and Washer Operations RKSTICS undefined...
Page 183 02-9 0000-00 ▶ Wiper MIST and Front Washer Coupled Wiper The wiper relay is turned on at 0.3 seconds after from the time when the washer switch is turned on for 0.1 to 0. 59 seconds (T2) with the ignition switch "ON", . If the wiper parking terminal gets off, the wiper relay is turned off.
Page 184 02-10 0000-00 When the washer switch is turned on for more than 0.6 seconds during the wiper operation by AUTO switch, the wiper operates three times. When it is turned on for a certain period of time (0.1 to 0.59 seconds), the wiper operates once. RKSTICS undefined...
Page 185 02-11 0000-00 ▶ Auto Washer and Wiper Switch When the auto washer switch is turned on with the ignition switch "ON" and the AUTO switch "OFF", the washer motor output gets ON for 1 second. If the system recognizes the output signal, the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second.
Page 186 02-12 0000-00 The auto washer switch output is overridden during the washer coupled wiper operation. The auto washer switch input is overridden during the auto washer coupled wiper operation. The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive AUTO wiper operation.
Page 187 02-13 0000-00 ▶ Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor, it has following operation system. System layout RKSTICS undefined...
Page 188 02-14 0000-00 ▶ Auto Switch Position Reminder (Power-Up Reminder Wiper) When turning off and on the IGN2 switch with the auto switch on, the system drives the wiper motor through LOW relay one cycle regardless of communication with rain sensor. The wiper relay (LOW) is turned on and the wiper motor runs one cycle when changing the auto switch from "OFF"...
Page 189 02-15 0000-00 Rain sensing unit Multifunction wiper switch: (auto light integrated type) AUTO and sensitivity control A sensor that emits infrared rays through AUTO: Wiper operates automatically by LED and then detects the amount of rain rain sensor FAST SLOW: Auto ↔...
Page 190 02-16 0000-00 ▶ Washer Coupled Wiper in Rain Sensing Mode The washer coupled wiper is operated when receiving the washer switch input with the ignition switch "ON" and the AUTO switch "ON" in the rain sensing mode. At this moment, the communication with the rain sensor is overridden.
Page 191 02-17 0000-00 ▶ When the Wiper Parking Signal is Abnormal The wiper system continuously outputs the wiper parking signal when the wiper parking terminal is grounded (while the ignition key is in "ON" position and the AUTO switch is in "ON" position).
Page 192 02-18 0000-00 ▶ Defective Rain Sensor The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 2 from 3 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON" position and the AUTO switch is in "ON" position). The wiper relay (LOW) is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor (while the ignition key is in "ON"...
Page 193 02-19 0000-00 ▶ Auto Light Control The tail lamps and headlamps can be controlled by the communication with the rain sensor only when the auto light switch is in "AUTO" position with the ignition switch "ON". Rain detected headlamp: If it rains heavy which requires the highest AUTO speed, the headlamps are turned on automatically (while the light switch is in "AUTO"...
Page 194 02-20 0000-00 ▶ Speed Sensitive AUTO Wiper For RKSTICS without the rain sensor, perform the following operation: 1. Controls the wiper intermittent operation by the values from the vehicle speed and the volume. Calculates and converts the Intermittent interval automatically by using the AUTO VOLUME when the ignition switch is in the "ON"...
Page 195 02-21 0000-00 Pause time of vehicle speed sensitive INT wiper AUTO Pause time Speed sensitive AUTO wiper 1) The wiper relay continues to output for remaining "ON" time even when the AUTO switch is turned off. 2) IGN 2 switch "ON", AUTO switch "OFF": Resume the intermittent time when turning "ON" 3) IGN 2 switch "OFF", AUTO switch "ON": Resume the intermittent time when turning "ON"...
Page 196 02-22 0000-00 ▶ Ignition Key Reminder Warning (The ignition key reminder warning has priority over the "TAILLAMP ON WARNING".) The chime bell sounds continuously with the interval of 0.3 seconds when opening the driver's door while the ignition key is in ignition switch. When removing the ignition key or closing the driver's door during chime buzzer operation, the buzzer stops.
Page 197 02-23 0000-00 ▶ Ignition Key Reminder The system outputs "UNLOCK" signal for 5 seconds after the driver's door is opened and the door lock switch is changed to "LOCK" (while the ignition key is in ignition switch). The system outputs "UNLOCK" signal for 5 seconds (T2) when the door lock switch is changed to "LOCK"...
Page 198 02-24 0000-00 ▶ All Door Lock Prevention Function when a Door is Open All doors, except the tailgate and hood, output "UNLOCK" signal for 5 seconds when the "LOCK" signal is inputted (while the ignition key is removed and one of any doors is open). When the door is closed during the UNLOCK output, the UNLOCK output stops immediately.
Page 199 02-25 0000-00 ▶ Tail Lamp Left On Warning The buzzer sounds with the interval of 0.3 second when opening the driver's door while the tail lamp is turned on and the ignition key is removed. The buzzer output stops when turning off the tail lamp and closing the driver's door. The system outputs "UNLOCK"...
Page 200 02-26 0000-00 ▶ Door Ajar Warning The warning light in instrument panel comes on when opening any of doors including tailgate while the vehicle speed is below 10 km/h. The warning light goes off when closing the door under step 1. The warning light blinks when the vehicle speed is over 10 km/h while the warning light is turned on.
Page 201 02-27 0000-00 ▶ Seat Belt Warning The seat belt warning light comes on and the chime bell sounds for 6 seconds when turning the ignition key to "ON" from "OFF". If the seat belt is fastened before turning the ignition key to the the "ON" position, the warning light in the instrument panel blinks, however, the chime bell does not sound.
Page 202 02-28 0000-00 ▶ Parking Brake Warning The parking brake warning light comes on for approx. 4 seconds when turning the ignition key from the "OFF" to the "ON" position regardless of the vehicle speed and the parking brake switch position. After this 4 seconds, the warning lamp comes on, goes off or blinks according to the vehicle speed and the parking brake switch position.
Page 203 02-29 0000-00 Vehicle with Hand Operated Type Parking Vehicle with EPB (Operates in EPB Brake module with separate control logic) RKSTICS undefined...
Page 204 02-30 0000-00 ▶ Front/Center Room Lamp Control overhead console lamp (front room lamp) comes when opening door(driver's/passenger's) while the door coupled front rooom lamp switch is at the coupled operating position and the key reminder switch is "OFF". When the door (Driver's/Passenger's) is opened, the front room lamp comes on. The room lamp stays on for 2 seconds and then dims out through 3 seconds when closing the opened door.
Page 205 02-31 0000-00 Front Room Lamp Center Room Lamp Door coupled switch Front room lamp (driver's or passenger's) is If the switch is at the door coupled position, turned on and off when pressing the switch (1 or the center room lamp comes on when a rear 2).
Page 206 02-32 0000-00 Opening Driver's or Passenger's Door Key hole illumination Wiring Circuit of STICS (Related to Tail Lamp Auto Cut (Battery Saver)) ▶ RKSTICS undefined...
Page 207 02-33 0000-00 ▶ Tail Lamp Auto Cut (Battery Saver) The tail lamp is turned on or off according to the operations of the tail lamp switch. The tail lamp relay is turned off (auto cut) when opening and closing the driver's door after removing the ignition key without turning off the tail lamp.
Page 208 02-34 0000-00 ▶ Circuit Diagram of STICS (Related to Front/Rear Defogger Timer) The defogger system defrosts or demists the window glass with the heated wire integrated in glass. When operating the defogger switch, STICS controls the operating time only in IGN2 position.
Page 209 02-35 0000-00 ▶ Windshield heated glass (deicer) switch The front defogger output is "ON" when turning "ON" the front defogger (heated glass) switch while the ignition switch is "ON" (with engine running). The output stops when turning on the front defogger (heated glass) switch again during its operation.
Page 210 02-36 0000-00 ▶ Rear Defogger Timer The rear defogger output is "ON" when turning "ON" the rear defogger switch while the IGN 2 switch is "ON" (with engine running). The output is "OFF" when turning "ON" the rear defogger switch again during output. The output is "ON"...
Page 211 02-37 0000-00 ▶ Door Lock/Unlock Control by Door Lock Switch The door lock system outputs "LOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the lock position. The door lock system outputs "UNLOCK" signal for 0.5 seconds when positioning the driver's or passenger's door lock switch to the unlock position.
Page 212 02-38 0000-00 Driver's door lock/unlock switch Passenger's door lock/unlock switch ▶ Door Lock/Unlock by Central Door Lock Switch The door lock system outputs "LOCK/UNLOCK" signal for 0.5 seconds when operating the central door lock switch. (However, if the door lock switch (front doors) is at LOCK position, the system outputs UNLOCK signal, and vice versa.) The "LOCK"...
Page 213 02-39 0000-00 ▶ Door LOCK/UNLOCK by Remote Control Key The door lock relay output is "ON" for 0.5 seconds when receiving the remote control lock signal. The door unlock relay output is "ON" for 0.5 seconds when receiving the remote control unlock signal.
Page 214 02-40 0000-00 ▶ Auto Door Lock The door lock system outputs "LOCK" when the vehicle speed maintains over 50 km/h. However, it doesn't output "LOCK" when all doors are locked or failed. If any of doors is unlocked after outputting "LOCK" in step 1, outputs "LOCK" up to 5 times (except step 1) at the interval of one second.
Page 215 02-41 0000-00 ▶ Auto Door Unlock (Crash Unlock) The air bag collision signal input cannot be accepted within 7 seconds after turning the ignition key to "ON" position. After this period, the door lock system outputs "UNLOCK" for all doors for 5 seconds from 40ms after receiving the air bag collision signal.
Page 216 02-42 0000-00 ▶ Time Lag Power Window Control The power window relay output is "ON" when turning on the ignition switch. The power window relay output is "ON" for 30 seconds when turning off the ignition switch. The power window relay output is "OFF" when opening the driver's door or the passenger's door.
Page 217 02-43 0000-00 ▶ Power Sleep Mode 1. Entering Condition 1) When all the doors including the hood are closed. 2) When the ignition key is in "OFF" position. 3) When there is no key in the driver's/passenger's door key cylinder. 4) The system enters into the sleep mode for saving power if there is any change for 6 seconds while the driver's/passenger's/rear doors and tailgate are locked with the above three conditions met.
Page 218 02-44 0000-00 ▶ Description of Burglar Alarm Function 1. Armed mode activation requirements 1) The "LOCK" output is "ON" when receiving the "LOCK" signal from transmitter while the ignition key is removed and all doors are closed. The armed mode is activated when the door lock switch is locked (hazard relay output: twice).
Page 219 02-45 0000-00 2. Armed mode cancellation requirements 1) Unlocking by remote control key 2) Door unlocking by the driver's and passenger's key cylinder switch 3) The armed mode is cancelled when turning the ignition key "ON". The siren is deactivated in 27 seconds.
Page 220 02-46 0000-00 7. Operations when removing and installing the battery If the system is in armed mode while installing a battery, the siren sounds and the emergency warning lamp blinks. (Same operations with warning in armed mode). RELOCK Operation: It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key, the system outputs "LOCK"...
Page 221 02-47 0000-00 ▶ Specifications of Remote Control Key When any of switches on remote control key is pressed, the integrated CPU in remote control key sends the coded control message to the CPU in receiver to control the vehicle. Switch Functions on Remote Control Key Door Lock Button Lock (briefly press) If you press this button briefly, all doors and the...
Page 222 02-48 0000-00 ▶ Remote Door Lock All doors are locked when briefly pressing the door LOCK switch on remote control key (less than 0.5 seconds). The system outputs LOCK signal immediately after receiving the door lock message from the remote control key. The system activates the theft deterrent mode when all doors are locked while they are fully closed (the hazard warning lamps blink twice.).
Page 223 02-49 0000-00 ▶ Door Unlock The door unlock operates when pressing the door unlock switch on the remote control key for less than 0.5 seconds. The door unlock relay is "ON" for 0.5 seconds when receiving the door unlock message from the remote control key.
Page 224 02-50 0000-00 4. CIRCUIT DIAGRAM OF STICS RKSTICS undefined...
Page 225 02-51 0000-00 ▶ Output Signals (except STICS) RKSTICS undefined...
Page 226 03-2 0000-00 8710-08 IMMOBILIZER SYSTEM OVERVIEW AND OPERATION PROCESS 1. OVERVIEW ▶ What is the immobilizer system? The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
Page 227 03-3 0000-00 2. BASIC FUNCTIONS OF IMMOBILIZER KEY (REKES FUNCTION) The information below is the function that applies to the REKES key and immobilizer key. Door Lock Button Lock (briefly press) If you press this button briefly, all doors and the tailgate are locked and the theft deterrent mode is activated.
Page 228 03-4 0000-00 3. OTHER FUNCTIONS IN SYSTEM ▶ Immobilizer Function The immobilizer system prevents the vehicle theft by allowing only the authorized key to start the engine. The transponder inside the key communicates with the immobilizer installed in the key box, and the system permits the engine to start after confirming the encrypted coding from the engine ECU.
Page 229 03-5 0000-00 Immobilizer and Warning Lamp This indicator comes on when the ignition key ▶ is communicating with the engine control unit (during engine starting) and goes out after starting the engine. Lamp ON: in communication Blinking twice for one second: immobilizer system failure Blinking once for two seconds: immobilizer unit is not coded...
Page 230 04-3 0000-00 8010-01 CLUSTER GENERAL 1. INDICATOR COLORS AND LED SPECIFICATIONS CLUSTER undefined...
Page 231 04-4 0000-00 2. SIGNALS AND LIGHT-ON RELATIONS FOR THE CAN COMMUNICATIONOF THE INSTRUMENT PANEL CLUSTER undefined...
Page 232 04-5 0000-00 CLUSTER undefined...
Page 233 04-6 0000-00 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The instrument cluster uses the CAN communication. The HDC warning lights (green & red) are added since the HDC function has been introduced into ESP system. CLUSTER undefined...
Page 234 04-7 0000-00 2. LOCATION AND CONFIGURATION CLUSTER undefined...
Page 235 04-8 0000-00 3. DESCRIPTIONS OF INDICATOR DISPLAY 1) Deluxe Version 1. ESP warning light 22. Automatic parking brake setting indicator 2. Left turn signal indicator 23. Brake warning light 3. Right turn signal indicator 24. Seat belt reminder (driver's seat) 4.
Page 236 04-9 0000-00 2) Standard Version 1. RPM gauge 16. Gear display/Odometer 2. ESP warning light 17. Right turn signal indicator 3. Left turn signal indicator 18. High beam indicator 4. Immobilizer indicator 19. Front fog lamp indicator 5. ABS warning light 20.
Page 237 04-10 0000-00 4. CONFIGURATION Deluxe Version ▶ Standard Version ▶ CLUSTER undefined...
Page 238 04-11 0000-00 5. WARNING LIGHTS AND INDICATORS 1) Engine Tachometer The tachometer indicates engine speed in revolutions per minute. Multiply 1,000 to the current number, then it will be the current number of engine revolutions. Under the normal engine operating temperature, the proper idling speed is 750 ± 50 rpm for D27DT engine.
Page 239 04-12 0000-00 2) Speedometer Gauge The speedometer indicates the vehicle speed by calculating the signals from the rear wheel speed sensors through ABS or ESP unit (speed signal cycle: 21 ms). If the speedometer gauge vibrates, stops at a certain range or makes an abnormal noise, there could be defectives in speedometer.
Page 240 04-13 0000-00 3) Fuel Level Gauge Fuel tank: 78 liters Service hole for removing fuel sender (under the rear left seat) The fuel level gauge displays the resistance value of the float on the fuel sender in the fuel tank through a pointer.
Page 241 04-14 0000-00 ▶ Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value changes by fuel level in normal conditions. Therefore, the differences that can be occurred by the road conditions and fuel fluctuations are ignored.
Page 242 04-15 0000-00 4) Coolant Temperature Gauge Using a needle, it displays the coolant temperature obtained from the engine coolant temperature sensor. The PTC resistance value of the coolant temperature sensor is transmitted to the engine ECU and then to the cluster as CAN signal. The angle of guage that can be varied by coolant temperature is as shown below.
Page 243 04-16 0000-00 6. WARNING & INDICATOR PANEL CLUSTER undefined...
Page 244 04-17 0000-00 CLUSTER undefined...
Page 245 04-18 0000-00 7. INSTRUMENT CLUSTER OPERATION PROCESS 1) TRIP Odometer (TRIP A, TRIP B) and Odometer Vehicle with A/T Vehicle with M/T ▶ Press "RESET button" to go the each mode. Mode changes 0 (Zero) setting when pressing and holding the RESET button in TRIP A/B mode for less than...
Page 246 04-19 0000-00 2) Cluster Brightness Adjustment Mode (Rheostat) For the black face type cluster, the brightness can be adjusted in 6 steps each in day time mode and night time mode. The tail lamp ON condition is used to determine whether it should be the day time mode or the night time mode.
Page 247 04-20 0000-00 3) Operation of HDC Indicator Controller This table describes the coming-on and blinking mode of HDC indicator according to the HDC switch operation (ON/OFF). The HDC indicator on the instrument panel has two modes; green (function lamp) and red (warning lamp). The HDC switch is a push &...
Page 248 04-21 0000-00 4) ESP Warning Lamp (1) ESP Warning Lamp Blinking in Control ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to warn the driver. The ESP warning lamp goes off when ESP function is deactivated.
Page 249 04-22 0000-00 (3) Resuming the ESP System by Using the ESPOFF Switch The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESPOFF switch at the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating.
Page 250 04-23 0000-00 (4) ESPOFF Switch Monitoring When the ESP unit recognizes that the ESPOFF switch is pushed for over 10 seconds, the ESP unit determines it as a ESPOFF switch malfunction. When the ESPOFF switch is pushed, the ESP system is resumed after 10 seconds. However, the ESP warning lamp comes on when the ESPOFF switch is pushed (for over 150 ms) and then goes out when the ESP system is resumed.
Page 251 04-24 0000-00 (5) ESP Warning Lamp Operation Depending on System Conditions The table shows ESP warning lamp operations when the ESP system is defective or ESP (including TCS function) is working. When the driver presses the brake pedal during the ESP OFF mode, the yaw control is performed to compensate the vehicle stability (posture) during ESP operation.
Page 252 04-25 0000-00 8. CIRCUIT DIAGRAM 1) Connector Pin Arrangement (for Deluxe version) These connectors are viewed from the cluster body. The arrangement of the pin in the main connector is the same as the one of the sub connector. The common specifications for CAN communication are: Protocol: Standard format CAN 2.0B (2.0A included) Communication speed: 500 Kbps ±...
Page 253 04-26 0000-00 2) Circuit Diagram (Deluxe version) ▶ Internal Electric Circuit This circuit diagram shows the parts controlled through the MICOM and the parts controlled by the switches. CLUSTER undefined...
Page 254 04-27 0000-00 ▶ External electric circuit However, if the fuel filter is filled with water, the buzzer sounds for 6 seconds when engine speed is over 400 rpm during engine starting. CLUSTER undefined...
Page 255 05-3 0000-00 7410-32 SPWM(Seat Position With Memory) UNIT GENERAL 1. SPECIFICATIONS 1) Driver's Power Seat 2) Actuator SPWM undefined...
Page 256 05-4 0000-00 3) Outside Rearview Mirror ▶ Manual Mode (Normal): 12V ▶ Position Sensor and Folding Switch ▶ Motor SPWM undefined...
Page 257 05-5 0000-00 Motor Output (normal mode: ground) ▶ 4) Buzzer 1. Output time: 2Hz, DUTY 20% (ON: 0.1 sec., OFF: 0.4 sec.) 2. Buzzer output conditions When the memory operation is permitted (memory switch ON): once Buzzer After completing the memory recall (position switch ON): twice When starting to recall the memory (position switch ON): once...
Page 258 06-3 0000-00 8511-17 SEAT WARMER OVERVIEW AND OPERATION PROCES 1. LOCATION The variable seat warmer system controls the temperature in 5 levels. Seat Warmer Switch It is located on the lower side of the center switch panel. Seat Warmer Unit It is installed under the passenger's seat (for vehicle equipped with SPWM unit).
Page 259 06-4 0000-00 2. OPERATING CHARACTERISTICS The variable seat warmer system operates when the ignition is ON. The unit heats the seat in each level according to the resistance based on each switch operation. 1) Operation Characteristics 2) Temperature and sensor output value in each switch level SEAT WARMER undefined...
Page 260 06-5 0000-00 3. FUNCTION AND DESCRIPTION The seat wamer switch is the rotary type Seat wamer variable switch. The seat cushion and the switch seatback is heated by operating the switch and the temperature of the seat can be adjusted in five levels. The temperature of the seat surface should be rised to over 20°C within 3 minutes while sitting on the seat (driver's height: 175 ±...
Page 261 06-6 0000-00 4. CIRCUIT DIAGRAM The variable seat warmer unit is supplied the ignition power and the battery power without its own relay. SEAT WARMER undefined...
Page 262 07-2 0000-00 8511-29 SWITCH OVERVIEW AND OPERATION PROCESS 1. OVERVIEW SWITCH undefined...
Page 263 07-3 0000-00 SWITCH undefined...
Page 264 08-3 0000-00 7810-01 WIPER AND WASHER OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The wiper and washer system are controlled by STICS according to driver's wiper switch operation. And the detection of rain drops by rain sensor is transmitted to STICS as the signal for wiper system control.
Page 265 08-4 0000-00 2. SYSTEM LAYOUT WIPER undefined...
Page 266 08-5 0000-00 ▶ Layout of Front Wiper WIPER undefined...
Page 267 08-6 0000-00 3. CIRCUIT DIAGRAM 1) Front Wiper and Washer WIPER undefined...
Page 268 08-7 0000-00 2) Rear Wiper and Washer (DPS) (STD) WIPER undefined...
Page 269 09-3 0000-00 8611-09 RAIN SENSOR OVERVIE 1. SYSTEM LAYOUT AND OVERVIEW The rain sensing wiper unit in this vehicle doesn't control the wiper directly. The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly.
Page 270 09-4 0000-00 1) Internal Components Emitter lens The LED which is located at bottom emits the infrared rays and the lens guides the infrared rays to target point. Auto light sensor (Vertical) Auto light sensor (Horizon) Enlarged auto light sensor section RAIN SENSOR UNIT undefined...
Page 271 09-5 0000-00 2) Related Components The rain sensing unit detects the amount of rain drops and sends the operating signal to STICS, and STICS drives the wiper directly. At this moment, STICS determines the wiper operation mode (washer, MIST, AUTO), then sends the information to the rain sensor. Engine Compartment Fuse and Relay Box Front wiper lower relay...
Page 272 09-6 0000-00 3) Auto Light Sensor and Rain Sensor Coupled Control Rain detected headlamp: If it rains heavy which requires the intermediate INT speed, the headlamps are turned on automatically. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level.
Page 273 09-7 0000-00 2. OPERATION MODE OF RAIN SENSING WIPER SYSTEM 1. Rain detected head light: If it rains heavy which requires the highest INT speed, the headlamps are turned on automatically. 2. Night detected wiping: When the auto light control turns on the headlamps and the rain sensor detects the rain, the wiper sensitivity is automatically increased by one level.
Page 274 09-8 0000-00 3. FUNCTIONS AND CHECKS OF RAIN SENSOR The followings are the detailed description of the functions and operations of the rain sensing wiper control. 1) Front Windshield Glass and Coupler Attachment Check the outer windshield surface of sensing area for wear, damage and scratch. The sensor is able to compensate the wear up to a specific level.
Page 275 09-9 0000-00 4) Washer Coupled Wiper Function Check the washer coupled wiper operation by pressing the washer switch. 5) Irregular Operations (Abrupt Operations) Check the sensor for coming off. Check the rain sensor cover's installation status. Check that the customer is familiar to how to control the wiper sensitivity. Check that the customer can select the sensitivity by selecting the variable resistance value (stage 1 to stage 5), that is, the wiper sensitivity control value.
Page 276 10-3 0000-00 8310-01 LAMP GENERAL 1. BULB SPECIFICATIONS LAMP undefined...
Page 277 11-3 0000-00 8611-41 MULTI JACK STATION GENERAL 1. HARDWARE SPECIFICATIONS MULTI JACK STATION undefined...
Page 278 11-4 0000-00 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The multi jack station is an integrated unit of digital clock and various audio play devices. It also includes the stereo jack which can be connected to an external audio device and the MP3 USB jack which can be connected to the USB flash drive for playing music through the speakers on vehicle.
Page 279 11-5 0000-00 3. ELECTRICAL PERFORMANCE AND CONFIGURATION 1) Electrical Performance 2) Configuration MULTI JACK STATION undefined...
Page 280 11-6 0000-00 4. DEFINITION OF INPUT/OUTPUT SIGNALS Time Tolerance ▶ For the time in which the tolerance is not specified, the tolerance is ±10%. For the time within 500 ms, the tolerance is ±100 The time specfied in each function does not include the lapse from the switch input to the chattering process time.
Page 281 11-7 0000-00 5. APPEARANCE ▶ Internal Appearance when Installed ▶ Apperance when Removed ▶ PCB and Internal Components MULTI JACK STATION undefined...
Page 282 11-8 0000-00 6. CIRCUIT DIAGRAM ▶ Vehicle with MP3 Audio System ▶ Vehicle with A/V System MULTI JACK STATION undefined...
Page 283 11-9 0000-00 ▶ A/V Specification MULTI JACK STATION undefined...
Page 284 11-10 0000-00 7. PANEL AND BUTTONS MULTI JACK STATION undefined...
Page 285 11-11 0000-00 8. FUNCTIONAL SPECIFICATION 1) Functions Clock (including date and year) adjustment Audio output through the stereo jack File search and play through the USB flash drive 2) Multi Jack Station Specifications (Identified by USB port) For the vehicle with common audio system, press the AUX button on upper side of the audio unit to enter the multi jack station mode.
Page 286 12-3 0000-00 8790-04 PARKING AID SYSTEM GENERAL 1. SPECIFICATIONS The parking aid system emits the supersonic wave signals from the sensors on the rear bumper with a specific interval and detects the reflected signals from obstacles while the gear selector lever is in "R"...
Page 287 12-4 0000-00 2. CAUTIONS ON PARKING AID SYSTEM Note that the display does not show everything in the rear area. Always check nobody, especially animals and children, is behind the vehicle when parking or reversing. If you can not properly check the vehicle behind, get out of the vehicle and then visually check it.
Page 288 12-5 0000-00 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW The parking aid device is integrated in the Outside rearview rear bumper and it uses three Piezoelectric mirro aiming down elements to measure vertical and horizontal by 3.5° distance to obstacles. When placing the gear selector lever to "R" position, the designated unit (PAS unit in the rear right quarter panel) activates the parking aid sensors to measure the distance...
Page 289 12-6 0000-00 2. ALARM INTERVAL AND TROUBLESHOOTING OF SENSOR 1) Alarm Interval Alarm interval and display changes Detection range according to the distance as below: While reversing, if obstacles are within stage 1, the warning beep sounds with long intervals. If within stage 20 cm from 25 cm from bumper 2, the warning beep sounds with short...
Page 290 12-7 0000-00 When sensor fails self-diagnosis PARKING AID SYSTEM undefined...
Page 291 12-8 0000-00 3. CIRCUIT DIAGRAM PARKING AID SYSTEM undefined...
Page 292 WOOFER SPEAKER (DVD SYSTEM) 8611-26 Disconnect the negative battery cable and remove the passenger seat. Disconnect the connector and four mounting nuts (10 mm) to remove the subwoofer speaker. ▶ Components Sound volume Connector lever Circuit ▶ AV SYSTEM REXTON 2007.09...
Page 293 4. Navigation unit 5. 8-DVD changer 6. Multi jack station (including MP3 USB) 7. GPS antenna 8. AUX terminal (1 video terminal, 2 audio terminals) * Some functions may not be included according to the model. AV SYSTEM REXTON 2007.09...
Page 294 13-5 0000-00 2. MAJOR COMPONENTS AND LOCATIONS OF AV SYSTEM 1) AV System AV SYSTEM REXTON 2007.09...
Page 295 13-6 0000-00 2) Audio System AV SYSTEM REXTON 2007.09...
Page 296 01-3 3650-01 3650-01 DC-5 SPEED AUTOMATIC TRANSMISSION GENERAL 1. SPECIFICATIONS DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 297 01-4 3650-01 DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 298 TCU by cylindrical 13-pin connector. * DCAG 5-speed automatic transmission offers the following advantages: 1. Improved shifting quality 2. More gears 3. Extended working life and reliability 4. Reduced fuel consumption DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 299 01-6 3650-01 2. CHARACTERISTICS DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 300 15. Electric control unit (valve body) 4. Disc brake B1 Output shaft 16. Freewheel F1 5. Disc clutch C1 Parking lock gear 17. Stator shaft 6. Disc clutch C2 Intermediate shaft 18. Converter lockup clutch DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 301 Rev. 2nd gear: 1.926 3rd gear: 1.405 4th gear: 1.000 5th gear: 0.831 Axle ratio: 3.31 WINTER Mode: Standard Mode Allowable shifting point: Upshift Downshift Lockup (sleeping) Unlock (open) FAST OFF Dynamic shift range Pedal value (%) DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 302 When operating the accelerator pedal, the 4 → 3 shift is completed by kick-down signal after completion of 4 → 4 shift. When promptly operating the accelerator pedal, the 4 → 3 shift is done in shaded arae. DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 303 01-10 3650-01 5. POWER FLOW ▶Sectional View B1 C1 C2 B3 C3 B2 ▶Shifting elements 1) Selector program switch: "S" mode 2) Selector program switch: "W" mode 3) Overrun DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 304 * Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Clockwise rotation with reduced speed * Center ring gear: Clockwise rotation * Center sun gear: Locked by B2, Rotation with reduced speed * Output shaft: Clockwise rotation 3) Overrun DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 305 * Rear sun gear: Locked by F2 and B2, Planetary gear carrier: Rotation with reduced speed * Center ring gear: Clockwise rotation * Sun gear: Locked by B2, Planetary gear carrier: Rotation with reduced speed * Output shaft: Clockwise rotation 3) Overrun DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 306 * Front ring gear: Clockwise rotation * Center ring gear: Clockwise rotation by clutch 2 activation (direct connection) * Center sun gear: Locked by B2, Planetary gear carrier: Clockwise rotation with reduced speed * Output shaft: Clockwise rotation DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 307 * Rear sun gear: Rotation by ring gear and planetary gear carrier (direct connection) * Center ring gear: Clockwise rotation by C3 activation * Planetary gear carrier: Clockwise rotation by center sun gear and ring gear (direct connection) * Output shaft: Clockwise rotation DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 308 * Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increasedspeed) * Center sun gear: Clockwise rotation with increased speed by C3 activation * Center planetary gear carrier: Clockwise rotation (increased speed) * Output shaft: Clockwise rotation (increased speed) DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 309 * Rear planetary gear carrier: Locked by B3 * Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) * Center ring gear: Locked by B3 * Center planetary gear carrier: Counterclockwise rotation (reduced speed) * Output shaft: Counterclockwise rotation DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 310 * Rear planetary gear carrier and center ring gear: Locked by brake B3 * Rear sun gear and center sun gear: Counterclockwise rotation (increased speed) * Center planetary gear carrier: Counterclockwise rotation (reduced speed) * Output shaft: Counterclockwise rotation DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 311 01-18 3650-01 6. CIRCUIT DIAGRAM 1) Starter, Selector Lever, CAN Communication DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 312 01-19 3650-01 2) Solenoid, Oil Temperature Sensor, RPM Sensor (N2, N3) DC 5-SPEED AUTO TRANSMISSION REXTON 2007.09...
Page 313 NO DATA...
Page 314 03-3 3170-01 3170-01 MTMANUAL TRANSMISSION GENERAL 1. SPECIFICATIONS 1) General Specifications 2) Tightening Torque MANUAL TRANSMISSION REXTON 2007.09...
Page 315 5th gear when shifting to reverse gear. It also prevents the break and wear. MANUAL TRANSMISSION REXTON 2007.09...
Page 316 03-5 3170-01 2. SYSTEM COMPONENTS 1) Gear Combinations 2) Shift Fork and Rail Combinations MANUAL TRANSMISSION REXTON 2007.09...
Page 317 03-6 3170-01 3) Sectional View MANUAL TRANSMISSION REXTON 2007.09...
Page 318 32. Single synchro sleeve 69. Shift lever 33. Retainer ring 70. Detent pin 34. Adaptor dowel pin 71. Joint pin 35. Reverse idler shaft 72. Retainer ring 36. Dowel pin 73. Semi remote lever assembly 37. Needle bearing MANUAL TRANSMISSION REXTON 2007.09...
Page 319 03-8 3170-01 ▶IDI Engine equipped vehicle - 4WD MANUAL TRANSMISSION REXTON 2007.09...
Page 320 69. Shift lever 33. Retainer ring 70. Detent pin 34. Adaptor dowel pin 71. Joint pin 35. Reverse idler shaft 72. Retainer ring 36. Dowel pin 73. Semi remote lever assembly 37. Bearing 74. Rear flange MANUAL TRANSMISSION REXTON 2007.09...
Page 321 03-10 3170-01 ▶IDI Engine equipped vehicle - 2WD MANUAL TRANSMISSION REXTON 2007.09...
Page 322 71. Joint pin 34. Adaptor dowel pin 72. Retainer ring 35. Reverse idler shaft 73. Semi remote lever assembly 36. Dowel pin 74. Rear flange 37. Bearing 75. Ball bearing 38. Reverse idler gear 76. Lock nut MANUAL TRANSMISSION REXTON 2007.09...
Page 323 15. Counter shaft (tightening torque: 30 ~ 40 Nm) 16. Reverse idler assembly Shift rail (3 & 4th) 17. Spring pin (6 x 25) Interlock bolt 18. Spring pin (6 x 25) (tightening torque: 40 ~ 50 Nm) MANUAL TRANSMISSION REXTON 2007.09...
Page 324 (tightening torque: 30 ~ 40 Nm) (tightening torque: 30 ~ 35 Nm) Lock washer TGS bushing Apply Long-term grease MoS2 Outer spring pin when installing the offset lever. TGS pin Lock bolt (tightening torque: 17 ~ 26 Nm) MANUAL TRANSMISSION REXTON 2007.09...
Page 325 03-14 3170-01 6) Power Flows 1st gear Counter shaft 2nd gear MANUAL TRANSMISSION REXTON 2007.09...
Page 326 03-15 3170-01 7) Power Flows (Cont'd) 3rd gear 4th gear MANUAL TRANSMISSION REXTON 2007.09...
Page 327 03-16 3170-01 8) Power Flows (Cont'd) 5th gear Reverse gear MANUAL TRANSMISSION REXTON 2007.09...
Page 328 3170-01 3. SHIFTING MECHANISM 1) Interlock System Interlock system prevents the gears from meshing over two sets. 2) Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward. MANUAL TRANSMISSION REXTON 2007.09...
Page 329 To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected. 1. Offset lever 3. Shift shaft 2. Shift lever 4. Rolling plunger (rolling plunger return spring and ball) MANUAL TRANSMISSION REXTON 2007.09...
Page 330 Guiding a control direction and preventing an over stroke 4) Backup Lamp Switch It is normal open type switch. Its circuit is formed when the reverse gear is selected. Sealant: Loctite DRI LOC 200 Tightening torque: 3 kg.m ~ 4 kg.m MANUAL TRANSMISSION REXTON 2007.09...
Page 331 4. Synchronizer key Be careful not to mix up the 1/2 shift synchronizer sleeve with 3/4 or 5/R shift synchronizer sleeve. The 3/4 synchronizer hub also different from 1/2 and 5/R synchronizer hub (different oil gallery). MANUAL TRANSMISSION REXTON 2007.09...
Page 332 Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at different speeds. By using synchronizers, the possibility of broken or damaged teeth is reduced and shifting effort is lowered. [1st step] [2nd step] [3rd step] MANUAL TRANSMISSION REXTON 2007.09...
Page 333 (Specified range of end play: 0.05 ~ 0.1 mm) For input shaft: 0.75 ~ 1.45 mm (15 spacers with increment of 50 μm) For output shaft: 0.4 ~ 1.45 mm (10 spacers with increment of 50 μm) MANUAL TRANSMISSION REXTON 2007.09...
Page 334 Transmission oil: SAE 75W/90 Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm MANUAL TRANSMISSION REXTON 2007.09...
Page 335 03-24 3170-01 1. Oil filler plug 2. Air vent Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm MANUAL TRANSMISSION REXTON 2007.09...
Page 336 03-25 3170-01 4. CIRCUIT DIAGRAM (BACKUP LAMP) MANUAL TRANSMISSION REXTON 2007.09...
Page 337 04-3 0000-00 0000-00 CLUTCH GENERAL 1. SPECIFICATIONS 2. TIGHTENING TORQUE CLUTCH REXTON 2007.09...
Page 338 This system provides higher efficiency than conventional clutch system, and its durability is superior. Clutch release cylinder pipe (mounted on transmission case) Concentric slave cylinder pipe (mounted inside of transmission) Concentric slave cylinder CLUTCH REXTON 2007.09...
Page 339 04-5 0000-00 2. COMPONENTS AND LOCATIONS B. Concentric slave cylinder pipe A. Adaptor D. Clutch assembly C. Concentric slave cylinder CLUTCH REXTON 2007.09...
Page 340 04-6 0000-00 ▶CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY 1. Transmission housing 4. Bolt 2. Clutch disc assembly 5. Washer 3. Clutch disc cover assembly 6. Bolt CLUTCH REXTON 2007.09...
Page 341 1. Clutch pedal 7. Clutch housing 2. Clutch master cylinder 8. Concentric slave cylinder cover 3. Clutch hydraulic line 9. Concentric slave cylinder 4. Clutch fluid chamber 10. Clutch cover 5. Clutch fluid hose 11. Clutch disc 6. Adaptor CLUTCH REXTON 2007.09...
Page 342 05-3 3240-01 3240-01 PART TIME TRANSFER CASE GENERAL 1. SPECIFICATIONS PART TIME TRANSFER CASE REXTON 2007.09...
Page 343 "LOW". The silent chain in transfer case transfers the output power to front wheels. Simple operation of switches on instrument panel allows to shift to "2H", "4H" and "4L" easily while driving. The warning lamp alarms the driver when the system is defective. 2. OPERATION PART TIME TRANSFER CASE REXTON 2007.09...
Page 344 05-5 3240-01 3. SECTIONAL DIAGRAM Planetary gear set Oil pump Magnetic clutch Input shaft 4H-4L 2H-4H Shift fork Shift fork (Reduction shift fork) (lockup fork) Shift motor Front output shaft PART TIME TRANSFER CASE REXTON 2007.09...
Page 345 The coil magnetized by this electric current pull in the lockup hub to engage into output spline. Accordingly, the power is transferred to front wheels. Rear view of Speed Sensor and Clutch Coilconnector PART TIME TRANSFER CASE REXTON 2007.09...
Page 346 4. SYSTEM LAYOUT Indicators 4WD switch Output Input Automatic transmission Magnet clutch Oil pump Drive gear Input shaft Speed sensor (4L) Planetary gear set Shift position 2H-4H shift fork Front output shaft Shift motor PART TIME TRANSFER CASE REXTON 2007.09...
Page 347 · panel from 4H to 2H. This shift is available during driving. · · "4WD HIGH" indicator in meter cluster goes out. "4WD CHECK" warning lamp comes · on when the system is defective. PART TIME TRANSFER CASE REXTON 2007.09...
Page 348 4H to 4L. · "4WD LOW" warning lamp in meter cluster flickers during this process, then goes out when the shift is completed. · "4WD CHECK" warning lamp comes on when the system is defective. PART TIME TRANSFER CASE REXTON 2007.09...
Page 349 05-10 3240-01 2) Transfer Case Block Diagram PART TIME TRANSFER CASE REXTON 2007.09...
Page 350 05-11 3240-01 PART TIME TRANSFER CASE REXTON 2007.09...
Page 351 Operation diagram of "4H" indicator when changing the switch to 4H from 4L. Operation diagram of "4L" indicator when changing the switch to 4L from 2H/4H. PART TIME TRANSFER CASE REXTON 2007.09...
Page 352 - Clutch coil stops its operation 5 seconds after the hub solenoid is activated. ▶Compensation The motor stops when the encoder related troubles are detected during shift operation. It moves toward LOW-HIGH direction for 5 seconds so that the motor is not left in unidentified position. PART TIME TRANSFER CASE REXTON 2007.09...
Page 353 05-14 3240-01 6. POWER FLOW ▶POWER FLOW PART TIME TRANSFER CASE REXTON 2007.09...
Page 354 05-15 3240-01 1) 2H MODE (REAR WHEEL DRIVE) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) ▶ Power Flow ↓ PART TIME TRANSFER CASE REXTON 2007.09...
Page 355 05-16 3240-01 2) 4H MODE (4WD DRIVE - HIGH SPEED) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) ▶ Power Flow PART TIME TRANSFER CASE REXTON 2007.09...
Page 356 05-17 3240-01 3) 4L MODE (4WD DRIVE - LOW SPEED) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) ▶ Power Flow PART TIME TRANSFER CASE REXTON 2007.09...
Page 357 05-18 3240-01 7. CIRCUIT DIAGRAM (DI & 5-SPEED A/T) PART TIME TRANSFER CASE REXTON 2007.09...
Page 358 06-3 3240-01 3240-01 TORQUE ON DEMAND(TOD) GENERAL 1. SPECIFICATIONS TORQUE ON DEMAND REXTON 2007.09...
Page 359 TOD control unit receives the wheel speed signals from the speed sensors in propeller shaft of transfer case and engine output information from the engine control unit. TOD control unit changes the pressure force of the electromagnetic clutch based on the analyzed data. TORQUE ON DEMAND REXTON 2007.09...
Page 360 4WD mode. Distribution ratio: 50 % for front wheels and 50 % for rear wheels. TORQUE ON DEMAND REXTON 2007.09...
Page 361 50 : 50 of which gear ratio is 2.48:1. 3) 4WD Operation Overview To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode switch, and move the selector lever with the sequence of [N-P-N]. TORQUE ON DEMAND REXTON 2007.09...
Page 362 06-7 3240-01 2. POWER FLOW ▶ System Layout Instrument Panel 4WD Switch Output Input Rear Speed Manetic Clutch Motor Front Output Front Speed TORQUE ON DEMAND REXTON 2007.09...
Page 363 06-8 3240-01 ▶ 4H Mode (4WD Drive - High Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) TORQUE ON DEMAND REXTON 2007.09...
Page 364 06-9 3240-01 ▶ 4L Mode (4WD Drive - Low Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) TORQUE ON DEMAND REXTON 2007.09...
Page 365 06-10 3240-01 3. CIRCUIT DIAGRAM TORQUE ON DEMAND REXTON 2007.09...
Page 366 07-3 3260-01 3260-01 ALL WHEEL DRIVE GENERAL 1. SPECIFICATIONS ALL WHEEL DRIVE REXTON 2007.09...
Page 367 TCCU (Transfer Case Control Unit), it delivers the driving force to the front and rear propeller shafts according to the gear ratio based on the gear combinations. The distribution ratio of driving force is 40:60 (front wheels:rear wheels). ALL WHEEL DRIVE REXTON 2007.09...
Page 368 07-5 3260-01 2. LOCATION ▶ Distribution of Driving Force in AWD ALL WHEEL DRIVE REXTON 2007.09...
Page 369 07-6 3260-01 3. STRUCTURE 1) Sectional View ALL WHEEL DRIVE REXTON 2007.09...
Page 370 5. Front sun gear 16. Retaining ring 6. Differential carrier assembly 17. Driven sprocket 7. Thrust washer 18. Chain 8. Rear sun gear 19. Clip 9. Snap ring 20. Bolt 10. Cover assembly 21. Plug 11. Oil seal ALL WHEEL DRIVE REXTON 2007.09...
Page 371 07-8 3260-01 4. POWER FLOW ▶ Distribution of Front Output Torque Distribution of Rear Output Torque ▶ ALL WHEEL DRIVE REXTON 2007.09...
Page 372 The ESP also operates the wheel slip under control in order to keep the vehicle stable under severe conditions such as icy road. ALL WHEEL DRIVE REXTON 2007.09...
Page 373 (19T/13T) should rotate faster than the pinion (13T) in relation to the carrier's movement. This function is similar to the regular differential function, which also compensates the revolution difference while maintaining the torque ratio in 40:60 (front:rear). ALL WHEEL DRIVE REXTON 2007.09...
Page 374 NO DATA...
Page 375 09-3 4210-01 4120-01 AXLE GENERAL 1. SPECIFICATIONS 1) FRONT AXLE 2) REAR AXLE AXLE REXTON 2007.09...
Page 376 1. Axle tube assembly 7. Inner shaft (LH) 2. Snap ring 8. Inner shaft (RH) 3. Ball bearing 9. Bolt 4. Oil seal 10. Front axle bracket (LH) 5. Protector 11. Front axle bracket (RH) 6. Oil seal AXLE REXTON 2007.09...
Page 377 4120-01 2) Axle Shaft (Drive Shaft) 1. Drive shaft 7. Boot band 2. Housing (inboard) 8. Boot band 3. Boot (outboard) 9. Boot band 4. Boot (inboard) 10. Seal 5. Shaft 11. Ball joint 6. Boot band AXLE REXTON 2007.09...
Page 378 09-6 4220-01 REAR AXLE 4220-01 1) COMPONENTS LOCATOR 1. Axle shaft/Tube 5. Shock absorber 2. Stabilizer bar 6. Lateral rod 3. Spring seat and spring 7. Flange 4. Upper arm 8. Axle housing AXLE REXTON 2007.09...
Page 379 1. Rear axle shaft assembly 6. Coil spring seat (lower) 2. Brake assembly (parking brake) 7. Carrier assembly 3. Oil seal - inner 8. Input shaft/Flange 4. Bolt 9. Rod mounting bracket 5. Axle shaft tube 10. Wheel speed sensor AXLE REXTON 2007.09...
Page 380 IOP/IRDA AXLE 4220-01/4222-01 IOP/IRDA AXLE GENERAL 1. SPECIAL TOOLS AND EQUIPMENT..CONFIGURATION AND FUNCTIONS 4122-01 IOP (INTEGRATED OIL PAN) FRONT AXLE....... 4220-01 INDEPENDENT SUSPENSION TYPE REAR AXLE....... 4122-01 OIL CHANGE........ REMOVAL AND INSTALLATION 4220-01 TROUBLE DIAGNOSIS....4122-01 OIL CHANGE OF IOP (INTEGRATED OIL PAN) FRONT AXLE...........
Page 382: General
10-3 4122-01 4122-01 IOP/IRDA AXLE GENERAL 1. SPECIAL TOOLS AND EQUIPMENT IOP/IRDA AXLE REXTON 2007.09...
Page 383: Configuration And Functions
IOP (INTEGRATED OIL PAN) FRONT AXLE 4122-01 1) OVERVIEW The IOP front axle is integrated with the engine oil pan so that the engine mounting height is lowered and the engine vibration is reduced. Components Location IOP/IRDA AXLE REXTON 2007.09...
Page 384 This system provides simple and proper installation layout since the power is directly transferred from transfer case to IOP axle through the propeller shafts. Therefore, any complicated connecting mechanism is not required and the power can be transferred without any interruption. IOP/IRDA AXLE REXTON 2007.09...
Page 385 10-6 4122-01 3) POWER FLOW IOP/IRDA AXLE REXTON 2007.09...
Page 386 35. Differential side gear thrust washer 16. Pinion flange 36. Differential side gear 17. Pinion flange washer 37. Ring gear bolt 18. Pinion flange nut 38. Differential case bearing 19. Fill plug O-ring 20. Fill plug IOP/IRDA AXLE REXTON 2007.09...
Page 387: 4220-01 Independent Suspension Type Rear Axle
10-8 4220-01 INDEPENDENT SUSPENSION TYPE REAR 4220-01 AXLE 1) OVERVIEW The IRDA (Independent Rear Drive Axle) is adopted for the independent type suspension in this vehicle. IOP/IRDA AXLE REXTON 2007.09...
Page 388 10-9 4220-01 2) EXPLODED VIEW IOP/IRDA AXLE REXTON 2007.09...
Page 389 19. Vent connector 42. Differential case side bearing snap ring 20. Cover pan bolt 43. Shaft seal assembly 21. Dowel pin 44. Output shaft snap ring 22. Pinion spacer 45. Output shaft 23. Pinion head bearing assembly IOP/IRDA AXLE REXTON 2007.09...
Page 390 10-11 4220-01 ▶ Sectional Drawing IOP/IRDA AXLE REXTON 2007.09...
Page 391 10-12 4220-01 3) COMPONENTS LOCATION IOP/IRDA AXLE REXTON 2007.09...
Page 392: 4122-01 Oil Change
If water has entered inside the axle through the air breather when driving on puddle or water If abnormal noise from the axle is heard, check the oil level. Then, if necessary, check if any foreign material exists in axle. IOP/IRDA AXLE REXTON 2007.09...
Page 393 After draining the oil completely, check the oil measuring container. the oil conditions and foreign material in oil measuring container. If the oil change is required, measure the drained oil level in the oil measuring container. IOP/IRDA AXLE REXTON 2007.09...
Page 394 (if there is no leakage). If there is leakage, refill the specified oil (approx. 0.78 L). Make sure thah the oil with specified specification is refilled. Oil specification: Shell Synthtic Fuel Efficient GL 75W/90 IOP/IRDA AXLE REXTON 2007.09...
Page 395: Removal And Installation
10-16 4220-01 REMOVAL AND INSTALLATION TROUBLE DIAGNOSIS 4220-01 IOP/IRDA AXLE REXTON 2007.09...
Page 396 4220-01 ▶ Inspection of Ring Gear Tooth Contact Pattern Normal contact Apply gear-marking compound (Prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal contact IOP/IRDA AXLE REXTON 2007.09...
Page 397: 4122-01 Oil Change Of Iop
10-18 4122-01 OIL CHANGE OF IOP (INTEGRATED OIL PAN) 4122-01 FRONT AXLE The inner diameter of seals are different from each other. Therefore, be careful not to mix them when installing. IOP/IRDA AXLE REXTON 2007.09...
Page 398 A large tool should be used to remove the seal in the axle housig. Secure the adjuster in its location when removing or installing the seal. Do not scratch inside the seal surface. 2. Install new oil seal and adjust its level. IOP/IRDA AXLE REXTON 2007.09...
Page 399 IOP axle, the repair work can be performed on the vehicle with the left drive shaft removed. When there is leakage in the right oil seal of the IOP axle, the oil can be found around the IOP connector. IOP/IRDA AXLE REXTON 2007.09...
Page 400: 4122-01 Iop (Integrated Oil Pan) Front Axle
(IOP axle side) to the rear side (T/C side) so that the front side is separated first. Remove the oil drain plug and drain the axle oil completely to the measuring container (special tool). IOP/IRDA AXLE REXTON 2007.09...
Page 401 3. Remove the tires and remove the split pin and mounting nut on the knuckle. Removal of Split Pin Removal of Mounting Nut 4. Separate the upper arm and the upper seat of the knuckle. 5. Remove drive shafts (LH/RH) from the axle using a special tool. IOP/IRDA AXLE REXTON 2007.09...
Page 402 6. Unscrew four bolts at the right side of the oil pan and remove the connector assembly. 7. Push out the intermediate shaft. When removing the intermediate shaft, make sure not to contact the differential case cross pin. IOP/IRDA AXLE REXTON 2007.09...
Page 403 10-24 4122-01 Removal of Intermediate Shaft 8. Unscrew the mounting bolts and remove the IOP front axle assembly. Mounting Location IOP/IRDA AXLE REXTON 2007.09...
Page 404 10-25 4122-01 Front Axle Layout IOP/IRDA AXLE REXTON 2007.09...
Page 405: 4220-01 Rear Axle
70 ~ 80 Nm Separate the air breather hose from the clamp. 3. Unscrew the mounting bolts (LH/RH: 6EA) and remove the rear drive shaft. Install the hydraulic jack under the axle housing to support it. IOP/IRDA AXLE REXTON 2007.09...
Page 406 Remove the rear axle by lowering the hydraulic jack. Unscrew three mounting bolts from the rear axle and remove the bracket, screw three mounting in the reverse order when intalling. IOP/IRDA AXLE REXTON 2007.09...
Page 407: 4220-01 Rear Axle Shaft
(LH/RH: 6EA). 2. Stretch out the bent point in the axle shaft lock nut and remove the lock nut. 3. Lower the axle shaft and pull it out. IOP/IRDA AXLE REXTON 2007.09...
Page 408 11-3 3310-01 3310-01 PROPELLER SHAFT GENERAL 1. SPECIFICATION PROPELLER SHAFT REXTON 2007.09...
Page 409 Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length. The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration. PROPELLER SHAFT REXTON 2007.09...
Page 410 3310-01 2. COMPONENT LOCATOR ▶ Cross Sectional View Flange yoke Split washer Journal bearing cap Slip tube shaft Spider journal Tube Slip yoke assembly Tube yoke Grease nipple Flange yoke Dust cap Center bearing Oil seal PROPELLER SHAFT REXTON 2007.09...
Page 411 11-6 3310-01 ▶ PROPELLER SHAFT ASSEMBLE Bolt Bolt Front propeller shaft Rear propeller shaft Bolt Bolt Transfer case PROPELLER SHAFT REXTON 2007.09...
Page 412 12-3 4620-01 4620-01 STEERING SYSTEM GENERAL 1. SPECIFICATIONS STEERING SYSTEM REXTON 2007.09...
Page 413 12-4 4620-01 2. TIGHTENING TORQUE STEERING SYSTEM REXTON 2007.09...
Page 414 "LOCK" position, the lock cylinder locks the steering wheel. 1) Steering Wheel The vibration damper absorbs the vibration from vehicle to minimize it. 2) Column and Shaft Assembly 3) Lower Shaft This minimizes the torque changes due to angular speed changes. STEERING SYSTEM REXTON 2007.09...
Page 415 12-6 4620-01 2. COMPONENT LOCATOR 1) System Layout Installation point Steering components STEERING SYSTEM REXTON 2007.09...
Page 416 12-7 4620-01 2) Sctional View of Steering Gear Box Tie rod end Tie rod end Tie rod Tie rod Bellows Cylinder tube Rack housing Valve assembly Feed tube ECPS solenoid valve Mounting bracket STEERING SYSTEM REXTON 2007.09...
Page 417 12-8 4620-01 3) Steering Column Assembly 1. Steering wheel 4. Steering gear assembly 2. Column shaft assembly 5. ECPS solenoid valve 3. Lower shaft assembly STEERING SYSTEM REXTON 2007.09...
Page 418 13-3 4411-01 4411-01 SUSPENSION GENERAL 1. SPECIFICATIONS 1) FRONT SUSPENSION SPECIFICATIONS SUSPENSION REXTON 2007.09...
Page 419 13-4 4411-01 2) REAR SUSPENSION SPECIFICATIONS SUSPENSION REXTON 2007.09...
Page 420 NO DATA...
Page 421 The power steering control unit adjusts the hydraulic pressure to reaction plunger by controlling the pressure solenoid valve located in gear box to optimize the steerability. 1. Pump 3. Control unit 2. Solenoid valve 4. Jack bracket ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 422 15-4 4620-01 2. INPUT/OUTPUT OF ECPS CONTROL UNIT ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 423 This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV. Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from ECPS control unit. ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 424 (A port) is not able to flow to the reaction plunger (C port). As a result, the pressing force from reaction plunger disappears and the steerability enhances. ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 425 Then, the spool located PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C port ) through B port. As a result, the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier. ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 426 15-8 4620-01 5. CIRCUIT DIAGRAM ELECTRONIC CONTROL POWER STEERING REXTON 2007.09...
Page 427 This hydraulic pressure pushes the brake calipers, accordingly the caliper pads are contacted to brake disc to generate the braking force. (3) Brake Pedal Brake pedal uses the leverage effect to apply bigger force to the brake master cylinder. BRAKE SYSTEM REXTON 2007.09...
Page 428 (3) is separated from the poppet (2). And then the air valve (6) opens and air flows into the chamber (B) through filter. Then, the power piston (5) pushes the master cylinder push rod (7) to assist the brake operation. BRAKE SYSTEM REXTON 2007.09...
Page 429 (A) and (B) in power cylinder is eliminated. Accordingly, the power piston (5) returns back to original position by the reaction of master cylinder (10) and the diaphragm return spring (8). BRAKE SYSTEM REXTON 2007.09...
Page 430 1. Brake booster 2. Brake reservoir and master cylinder 3. ABS control unit 4. Front disc brake and caliper 5. Load conscious reducing valve (LCRV) 6. 3-way connector 7. Rear drum (disc) and wheel cylinder (caliper) BRAKE SYSTEM REXTON 2007.09...
Page 431 16-7 4850-01 3. BRAKE SYSTEM COMPONENTS LOCATOR BRAKE SYSTEM REXTON 2007.09...
Page 432 13. Stop lamp switch 14. Pedal assembly 15. Pedal bracket assembly 16. Brake pedal pad 17. Brake pedal 18. Brake pedal spring 19. Rear brake hose 20. Clip 21. Front brake hose 22. Union bolt 23. Plane washer BRAKE SYSTEM REXTON 2007.09...
Page 433 Avoid spilling brake fluid on any the vehicle's painted surfaces, wiring, cables or electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area with water to lessen the damage. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 434 If air enters the hydraulic modulator, or if an unfilled modulator is installed, use the brake bleeding program in the scan tool to bleed the modulator. Manual bleeding of the hydraulic modulator is not possible. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 435 You are bound to know the result already from driving on winter roads. With a high adhesion coefficient on a dry road, the brake force, which can be obtained, is considerably higher. The brake force, which can be obtained, can be calculated from below formula: ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 436 0 %. Slip can be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is: X 100 % = 100 km/h, V = 70 km/h 100 - 70 X 100 % ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 437 In this relationship: as long as the acting forces and the resulting force remain within the circle, the vehicle is stable to drive. If a force exceeds the circle, the vehicle leaves the road. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 438 Applications of the ABS control unit The signals produced by the wheel sensors are evaluated in the electronic control unit. From the information received, the control unit must first compute the following variables: Wheel speed Reference speed Deceleration Slip ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 439 ▶ Selector low control This control is used for regulating the brake pressure for rear axle during ABS operation. This control uses lower adhesion coefficient to prevent the rear wheels from locking. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 440 (Hydraulic and Electronic Control Unit) compared to existing ABS. And, the wheel speed sensor uses different method to detect wheel speed. The basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking has not been changed. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 441 17-11 4892-01 1) SYSTEM FUSE The ABS/TCS system fuse and SB2 is located at the fuse box in engine compartment. 2) INDICATORS The ABS and TCS indicators are in instrument cluster. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 442 17-12 4892-01 3. INPUT AND OUTPUT DIAGRAM OF ABS UNIT ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 443 The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors, one inlet valve and one outlet valve. This system is similar to the one from the previous model. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 444 To prevent the rear wheels locking when braking, HECU receives the signals from wheel speed sensors and brake signals to calculate the reduced braking speed, and controls the brake pressure to rear wheels by operating the intake 2-channel valve to provide the optimal braking conditions. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 445 At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic pressure. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 446 This operation continues repetitively until there are no signs that the ECU is locking the wheels. When the ABS hydraulic pressure control takes place, there may be some vibration and noises at the brake pedal. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 447 EBD function is monitored via ABS safety logic (conventional proportioning valves are not monitorable). "Keep alive" function. ▶ Service precautions Observe the following general precautions during any ABS/ TCS service. Failure to adhere to these precautions may result in ABS/TCS system damage. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 448 Do not use petroleum based fluids in the master cylinder. Do not use any containers previously used for petroleum based fluids. Petroleum causes swelling and distortion of the rubber components in the hydraulic brake system, resulting in water entering the system and lowering the fluid boiling point. ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 449 17-19 4892-01 6. ELECTRIC CIRCUIT DIAGRAM 1) ABS ▶ W/SPEED SENSOR, STOP LAMP SW, DIAGNOSIS, HDC, TPMS (ABS/ESP) ANTI-BRAKE SYSTEM REXTON 2007.09...
Page 450 18-3 4892-01 4892-01 ESP(Electronic Stability Program) SYSTEM GENERAL 1. SPECIFICATIONSS ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 451 The system also controls during cornering by detecting the moment right before the spin and automatically limiting the engine output (coupled with the ASR system). ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 452 18-5 4892-01 2. COMPONENTS LOCATION ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 453 18-6 4892-01 3. INPUT AND OUTPUT DIAGRAM OF ESP UNIT ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 454 ABS. The order may be changed depending on the vehicle driving situations and driving conditions. As the single-track vehicle model used for the calculations is only valid for a vehicle moving forward, ESP intervention never takes place during backup. 1) Understeering ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 455 Then the ESP system applies the brake at the rear inner wheel to compensate the yaw moment value. In this way, the vehicle does not lose its driving direction and the driver can steer the vehicle as driver intends. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 456 Then the ESP system applies the brake at the front outer wheel to compensate the yaw moment value. In this way, the vehicle does not lose its driving direction and the driver can steer the vehicle as he or she intends. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 457 (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operating during braking. It also includes the vehicle conditions when the TCS that is included in the ESP system is operating. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 458 18-11 4892-01 5. HYDRAULIC DIAGRAM OF ESP ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 459 ESP operation and this will make the driver feel noise and vibration due to sudden brake application. Also, the ESP system controls the engine output. So, the driver may notice the engine output decrease even when the accelerator pedal is being applied. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 460 In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed. When the brake is applied under these conditions, the brake fluid will be sent to each wheel via the separation valve and inlet valve. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 461 ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied. Then the pump operates to allow fast oil drainage . ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 462 By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more. During ESP operation, the separation valve closes and only the shuttle valve at the pump opens. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 463 The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is operated. When ESP operates while the ABS is operating, the pressure will be increased continuously until just before the corresponding wheel gets locked. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 464 . If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only the conventional brake system with booster is activated. ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 465 18-18 4892-01 ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 466 Then, the pressure in the pump increases until just before the corresponding wheel gets locked. The motor still keeps rotating and the outlet valve and the separation valve are will stay closed. When the wheel starts to lock, the HBA function cancels and switches to ABS operation ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 467 18-20 4892-01 7. ELECTRIC CIRCUIT DIAGRAM ▶ Wheel Speed Sensor, Stop Lamp Switch, Diagnostic Connector, Warning Lamp (ABS/ESP) ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 468 18-21 4892-01 ▶ Brake Pressure Sensor, Steering Wheel Angle Sensor, Sensor Cluster, ESP OFF Switch ELECTRONIC STABILITY PROGRAM REXTON 2007.09...
Page 469 01-3 6820-11 6820-11 AIR CONDITIONER GENERAL 1. SPECIFICATIONS AIR CONDITIONER REXTON 2007.09...
Page 470 If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant to come in contact with Styrofoam parts. Damage may result. AIR CONDITIONER REXTON 2007.09...
Page 471 Always work in a well-ventilated area. If you have difficulty breathing, seek medical attention immediately. If refrigerant comes in contact with any part of your body, flush the exposed area with water. If a rush or pain develops seek medical attention. AIR CONDITIONER REXTON 2007.09...
Page 472 When opening an A/C system, have everything needed to perform all operations ready. Do not leave the A/C system open any longer than necessary. Evacuate and recharge any A/C system that has been opened. AIR CONDITIONER REXTON 2007.09...
Page 473 01-7 6820-11 OVERVIEW AND OPERATION PROCESS 1. OVERVIEW Cooler Outlet Cooler Outlet Cooler Outlet Cooler Outlet Outlet Port Engine Inlet Port Cooling Fan AIR CONDITIONER REXTON 2007.09...
Page 474 01-8 6820-11 2. AIR FLOWS ▶Refrigerant Flows AIR CONDITIONER REXTON 2007.09...
Page 475 8. Rear cooler assembly 3. Compressor 9. Rear cooler duct 4. Air conditioner/Heater (Blower) module 10. Suction rear pipe line 5. Defrost nozzle 11. Liquid rear pipe line 6. Front air conditioner controller 12. Rear cooler controller AIR CONDITIONER REXTON 2007.09...
Page 476 When a compressor is removed from the vehicle for servicing, the amount of oil remaining the compressor should be drained, measured and recorded. This should then be discarded and new polyalkaline glycol (PAG) refrigerant oil added to the compressor. AIR CONDITIONER REXTON 2007.09...
Page 477 An oil bleed hole is located near the bottom of the receiver-drier outlet pipe to provide an oil return path to the compressor. The receiver drier is serviceable as an assembly. AIR CONDITIONER REXTON 2007.09...
Page 478 Raise the temperature of the air entering the vehicle by sliding to the right or the red portion of the knob. Varies the mix of the fresh air from outside the vehicle with the heated air from inside the vehicle to suit individual performance. AIR CONDITIONER REXTON 2007.09...
Page 479 - Operates completely independently from both the mode control knob and temperature control knob. - Changes the fan speed in any mode and at any speed. ▶A/C System Delay Relay This relay controls the current to A/C system and instantly delays the A/C operation during starting the engine. AIR CONDITIONER REXTON 2007.09...
Page 480 01-14 6820-11 5. CIRCUIT DIAGRAM 1) Automatic Air Conditioner ▶CONDENSOR FAN, SENSOR (D27DT, GSL) AIR CONDITIONER REXTON 2007.09...
Page 481 01-15 6820-11 ▶CONDENSOR FAN, SENSOR (D27DTP) AIR CONDITIONER REXTON 2007.09...
Page 482 01-16 6820-11 ▶MOTOR (MODE, INTAKE), BLOWER, POWER TR AIR CONDITIONER REXTON 2007.09...
Page 483 01-17 6820-11 2) Manual Air Conditioner ▶Power, A/C Compressor, Motors (Mode, Interior/Ambient, Air Mix) AIR CONDITIONER REXTON 2007.09...
Page 484 01-18 6820-11 ▶Blower Motor (Front, Rear) AIR CONDITIONER REXTON 2007.09...
Page 485 02-3 8511-14 8511-14 FULL AUTO TEMPERATURE CONTROL GENERAL 1. SPECIFICATIONS FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 486 02-4 8511-14 OVERVIEW AND OPERATION PROCESS 1. FATC SYSTEM LAYOUT ▶ Configuration and Characteristic of A/C Controller FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 487 02-5 8511-14 ▶ A/C System Related Devices FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 488 1. Manual Control When you push the blower switch, you can control the blower motor manually and it increases or decreases each step by moving the switch to HI/LO. (with the ignition ON) FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 489 When the temperature of the engine coolant is low or it's difficult to obtain the desired hot air in winter, the system controls to prevent the cold airflow from the outlet due to the cold air give a negative effect to the heating performance. FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 490 When you push the I/A control switch, you can control the I/A door manually and the I/A door changes between the recirculation air and the fresh air flow alternately by the control switch. 2. AUTO control FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 491 For stabilization of the AQS sensor, the signal from the AQS sensor is overridden and the recirculation mode is maintained for 1 minute after turning the ignition ON. Gas detected - Exhaust gas for diesel engine: NO, NOx, SO2... - Exhaust gas for gasoline and LPG engine: CxHY, CO... FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 492 5) A/C Control 1. Manual control When you pushed the A/C switch "ON" or the Def switch "ON", A/C starts to operate. 2. AUTO control Basic Control: A/C "ON" has the priority for the initial operation. FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 493 However, if it is in the auto foot mode, it is changed to the Front defrost mode. ? Then, if the A/C is turned off after switched to the front defrost mode, it is changed to the foot mode automatically. FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 494 02-12 8511-14 3. CIRCUIT DIAGRAM ▶ FATC (Full Auto Temperature Control) FULL AUTO TEMPERTURE CONTROL REXTON 2007.09...
Page 495 03-3 6910-03 6910-03 FFH SYSTEM GENERAL 1. SPECIFICATIONS FFH SYSTEM REXTON 2007.09...
Page 496 Therefore, a certain period of FFH operation after stopping the engine is not a malfunction. 2. COMPONENTS LOCATOR FFH assembly Diagnostic connector Coolant circulation pump Ambient temperature Fuel pump switch FFH SYSTEM REXTON 2007.09...
Page 497 10. Fuel pipe No.1 4. FFH No.2 bracket assembly 11. Fuel pipe No.2 5. Silencer and pipe assembly 12. Pump outlet hose 6. Fuel pump assembly 13. FFH inlet/outlet hose assembly 7. Fuel pump bracket assembly FFH SYSTEM REXTON 2007.09...
Page 498 03-6 6910-03 ▶ Exploded View FFH SYSTEM REXTON 2007.09...
Page 499 29. Screw (M4 x 55 TORX/2x) 30. Screw (M4 x 16 TORX/2x) 31. Screw (M4 x 12 TORX/2x) 32. Screw (M4 x 16 TORX/4x) 33. Screw (M4 x 44 TORX/4x) 34. Controller cable harness 35. Insulation washer FFH SYSTEM REXTON 2007.09...
Page 500 80°C and starts to be operated in LO mode (low output: approx. 2300 W) from 81°C. When the coolant temperature reaches at approx. 85°C, FFH stops its operation until the operating conditions will be met again. FFH SYSTEM REXTON 2007.09...
Page 501 Fill the heater and water hoses with coolant before connecting to the coolant circuit. When routing the coolant pipes, observe a sufficient clearance to hot vehicle parts. Protect all coolant hoses/coolant pipes from chafing and from extreme temperatures. Secure all hose connections with hose clips. FFH SYSTEM REXTON 2007.09...
Page 502 (switch) that provides important signals for the initial and repeat operations. For diagnosis, remove the FFH system connector and install the scan tool. Currently, the K-Line that is connected to the diagnostic connector is not available. FFH SYSTEM REXTON 2007.09...
Page 503 "Diagnosis Procedures" section. [Emergency shutdown] If an emergency shutdown -EMERGENCY OFF- is necessary during operation, proceed as follows; - Pull the fuse (Ef23: 20A) out. - Disconnect the heater from the battery. ▶Technical Data - Water Pump FFH SYSTEM REXTON 2007.09...
Page 504 03-12 6910-03 7) Characteristic Curve of Water Pump (12 V) 8) Function Diagram FFH SYSTEM REXTON 2007.09...
Page 505 03-13 6910-03 9) Sectional Drawing according to the Temperatures FFH SYSTEM REXTON 2007.09...
Page 506 ▶Check control and overheating sensor Check the control and overheating sensor with a digital multimeter. If the resistance according to the changes of flame sensor temperature is out of specified values, the flame sensor is defective. FFH SYSTEM REXTON 2007.09...
Page 507 If the resistance of flame sensor is out of specified values, the flame sensor is defective. ▶Specifiedl value 4) Controller The surface heater and cable harness make up one component. 1. Controller 2. Jacket 3. Combustion chamber housing 4. Screw FFH SYSTEM REXTON 2007.09...
Page 508 2. Combustion chamber 3. Combustion chamber housing 4. Insulation washer 5. Seal - combustion chamber / combustion air fan 6. Seal - combustion chamber / heat exchanger 7) Flame sensor 1. Flame sensor 2. Graphite bush 3. Bush FFH SYSTEM REXTON 2007.09...
Page 509 Check the surface sensor with a digital multimeter. If the resistance of flame sensor is out of specified values, the flame sensor is defective. ▶Specifiedl value 8) Combustion air fan 1. Combustion chamber 2. O-ring 3. Rubber seal 4. Combustion air fan FFH SYSTEM REXTON 2007.09...
Page 510 2. Heat exchanger 3. Combustion chamber with flame tube 4. Seal - combustion chamber / heat exchanger 5. O-ring (for heat exchanger) 11) Heat exchanger 1. Heat exchanger 2. Jacket 3. Stopper 4. Groove (bottom of heat exchanger) FFH SYSTEM REXTON 2007.09...
Page 511 (12 V ~ 75 A / 90 A to 12 V ~ 140 A). Non- operational Condition During engine cranking Too low battery voltage (below 11 V) During preheating process of glow plugs PTC SYSTEM REXTON 2007.09...
Page 512 04-4 6810-21 2. COMPONENTS LOCATOR PTC operating relay PTC unit Engine ECU PTC SYSTEM REXTON 2007.09...
Page 513 04-5 6810-21 3. COMPONENTS CHARACTERISTICS OF PTC ▶ PTC SYSTEM REXTON 2007.09...
Page 514 04-6 6810-21 4. CIRCUIT DIAGRAM PTC SYSTEM REXTON 2007.09...
Page 515 · The front of the vehicle crashes into high impact point vehicle such as a truck · · Impact on the hood by falling stones The air bag warning lamp is on · AIR BAG AND SEAT BELT REXTON 2007.09...
Page 516 · after 3 to 7 seconds when the system is normal. If this warning lamp stays ON, then the system may be defective. Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation. The seat belt and air the bags are the most effective when you are sitting well back and ·...
Page 517 When any repairs are needed for the steering wheel, or when an accident occured without the · air bag deployment, have the air bag system checked by Ssangyong Dealer or Ssangyong Authorized Service Operation. The windshield glass may be broken when the passenger's air bag is deployed.
Page 518 Now that the free ends of the 10 meters (33 feet) wires are spliced to the airbag module wires and the ends that are twisted together are near the deployment battery, clear the area. Untwist the wires that near the deployment battery. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 519 13 mm (0.5 inch) of the insulation from the end of the wires leading to the airbag module. Refer to "DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURE" in this section. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 520 This includes those in a whole vehicle being scrapped. If the vehicle is still within the warranty period contact the SsangYong regional service manager for approval or special instructions before deploying an airbag module or pretensioner.
Page 521 Failure to follow all service procedures in the correct sequence can cause the airbag system to deploy unexpectedly and possibly cause a serious injury. Only trained personnel at franchised SsangYong dealers and authorized SsangYong · service dealerships may service the airbag system.
Page 522 SIR system consists of 6-Loop (DAB, PAB, 2*SAB, 2*PRET) fully and the block diagram is as shown below. On this diagram, SDM sends the output signal to DAB, PAB, 2*SAB, 2*PRET and receives the input of side impact from 2*SIS (Side Impact Seasor). Abbreviation AIR BAG AND SEAT BELT REXTON 2007.09...
Page 523 Thus, the inflator output must be optimized according to the characteristic of the vehicle and passenger moving. The discharge gas has no toxicity or inflammability and also it is the important parameter to · control the high temperature for gas firing. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 524 The driver and passenger side airbag is inside each seat. Do not disassemble the airbag module because unintentional deployment of the airbags resulting from any damage or interference of the module can cause injury. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 525 This device always monitors the airbag system in conduction with the diagnostic circuit. When it is detected any problem, it illuminates the airbag warning indicator to inform driver of the fault and stores the fault information. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 526 Turn the label of the clock spring clockwise to lock and turn the label of the clock spring counterclockwise approximately 2.9 ± 0.2 turns to the neutral positions with the front wheels ahead. Align the pointed marks "▶◀". AIR BAG AND SEAT BELT REXTON 2007.09...
Page 527 The SDM performs a turn-on test when the ignition is turned ON. The SDM flashes the AIRBAG indicator seven tomes by supplying an intermittent ground to the indicator lamp circuit. After flashing seven times, the AIRBAG indicator will turn off if no more malfunctions have been detected. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 528 (SRS) before beginning any service procedure. 12) Belt Pretensioner The belt pretensioner enables to retract the driver and the passenger seat belt webbing to reduce any personal impact when accounted a frontal collision. AIR BAG AND SEAT BELT REXTON 2007.09...
Page 529 06-3 8510-31 8510-31 SEAT GENERAL 1. SPECIFICATIONS SEAT REXTON 2007.09...
Page 530 06-4 8510-31 OVERVIEW AND OPERATION PROCESS 1. SEAT ARRANGEMNT SEAT REXTON 2007.09...
Page 531 NO DATA...
Page 532 NO DATA...
Page 533 NO DATA...
Page 534 10-3 4012-01 4012-01 BODY DIMENSIONS GENERAL 1. DIMENSIONS Unit: mm, ( ): Option BODY REPAIR REXTON 2007.09...
Page 535 10-4 4012-01 2. JACK-UP POINTS (DOTTED CIRCLES) IRS type 5-link type BODY REPAIR REXTON 2007.09...
Page 536 10-5 4012-01 3. APPLIED THE ASPHALT TO THE BODY PANEL (IMPROVED ANTI-VIBRATION) BODY REPAIR REXTON 2007.09...
Page 537 ECU-GASOLINE 0000-00 ECU-GASOLINE 1. ECU-GASOLINE........
Page 539 0000-00 0000-00 ECU-GASOLINE DIAGNOSIS 1. ECU-GASOLINE ECU-GASOLINE REXTON 2007.09...
Page 540 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 541 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 542 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 543 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 544 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 545 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 546 0-10 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 547 0-11 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 548 0-12 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 549 0-13 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 550 0-14 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 551 0-15 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 552 0-16 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 553 0-17 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 554 0-18 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 555 0-19 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 556 0-20 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 557 0-21 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 558 0-22 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 559 0-23 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 560 0-24 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 561 0-25 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 562 0-26 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 563 0-27 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 564 0-28 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 565 0-29 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 566 0-30 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 567 0-31 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 568 0-32 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 569 0-33 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 570 0-34 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 571 0-35 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 572 0-36 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 573 0-37 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 574 0-38 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 575 0-39 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 576 0-40 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 577 0-41 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 578 0-42 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 579 0-43 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 580 0-44 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 581 0-45 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 582 0-46 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 583 0-47 0000-00 ECU-GASOLINE REXTON 2007.09...
Page 585 ECU-DIESEL 0000-00 ECU-DIESEL DIAGNOSIS 1. ECU-DIESEL..........
Page 587 0000-00 0000-00 ECU-DIESEL DIAGNOSIS 1. ECU-DIESEL ECU-DIESEL REXTON 2007.09...
Page 588 0000-00 ECU-DIESEL REXTON 2007.09...
Page 589 0000-00 ECU-DIESEL REXTON 2007.09...
Page 590 0000-00 ECU-DIESEL REXTON 2007.09...
Page 591 0000-00 ECU-DIESEL REXTON 2007.09...
Page 592 0000-00 ECU-DIESEL REXTON 2007.09...
Page 593 0000-00 ECU-DIESEL REXTON 2007.09...
Page 594 0-10 0000-00 ECU-DIESEL REXTON 2007.09...
Page 595 0-11 0000-00 ECU-DIESEL REXTON 2007.09...
Page 596 0-12 0000-00 ECU-DIESEL REXTON 2007.09...
Page 597 0-13 0000-00 ECU-DIESEL REXTON 2007.09...
Page 598 0-14 0000-00 ECU-DIESEL REXTON 2007.09...
Page 599 0-15 0000-00 ECU-DIESEL REXTON 2007.09...
Page 600 0-16 0000-00 ECU-DIESEL REXTON 2007.09...
Page 601 0-17 0000-00 ECU-DIESEL REXTON 2007.09...
Page 602 0-18 0000-00 ECU-DIESEL REXTON 2007.09...
Page 603 0-19 0000-00 ECU-DIESEL REXTON 2007.09...
Page 604 0-20 0000-00 ECU-DIESEL REXTON 2007.09...
Page 605 0-21 0000-00 ECU-DIESEL REXTON 2007.09...
Page 606 0-22 0000-00 ECU-DIESEL REXTON 2007.09...
Page 607 0-23 0000-00 ECU-DIESEL REXTON 2007.09...
Page 608 0-24 0000-00 ECU-DIESEL REXTON 2007.09...
Page 609 0-25 0000-00 ECU-DIESEL REXTON 2007.09...
Page 610 0-26 0000-00 ECU-DIESEL REXTON 2007.09...
Page 611 0-27 0000-00 ECU-DIESEL REXTON 2007.09...
Page 612 0-28 0000-00 ECU-DIESEL REXTON 2007.09...
Page 613 0-29 0000-00 ECU-DIESEL REXTON 2007.09...
Page 614 0-30 0000-00 ECU-DIESEL REXTON 2007.09...
Page 615 0-31 0000-00 ECU-DIESEL REXTON 2007.09...
Page 616 0-32 0000-00 ECU-DIESEL REXTON 2007.09...
Page 617 0-33 0000-00 ECU-DIESEL REXTON 2007.09...
Page 618 0-34 0000-00 ECU-DIESEL REXTON 2007.09...
Page 619 0-35 0000-00 ECU-DIESEL REXTON 2007.09...
Page 620 0-36 0000-00 ECU-DIESEL REXTON 2007.09...
Page 621 0-37 0000-00 ECU-DIESEL REXTON 2007.09...
Page 622 0-38 0000-00 ECU-DIESEL REXTON 2007.09...
Page 623 0-39 0000-00 ECU-DIESEL REXTON 2007.09...
Page 624 0-40 0000-00 ECU-DIESEL REXTON 2007.09...
Page 625 0-41 0000-00 ECU-DIESEL REXTON 2007.09...
Page 626 0-42 0000-00 ECU-DIESEL REXTON 2007.09...
Page 627 0-43 0000-00 ECU-DIESEL REXTON 2007.09...
Page 628 0-44 0000-00 ECU-DIESEL REXTON 2007.09...
Page 629 0-45 0000-00 ECU-DIESEL REXTON 2007.09...
Page 630 0-46 0000-00 ECU-DIESEL REXTON 2007.09...
Page 631 0-47 0000-00 ECU-DIESEL REXTON 2007.09...
Page 632 0-48 0000-00 ECU-DIESEL REXTON 2007.09...
Page 633 0-49 0000-00 ECU-DIESEL REXTON 2007.09...
Page 634 0-50 0000-00 ECU-DIESEL REXTON 2007.09...
Page 635 0-51 0000-00 ECU-DIESEL REXTON 2007.09...
Page 636 0-52 0000-00 ECU-DIESEL REXTON 2007.09...
Page 637 0-53 0000-00 ECU-DIESEL REXTON 2007.09...
Page 638 0-54 0000-00 ECU-DIESEL REXTON 2007.09...
Page 639 0-55 0000-00 ECU-DIESEL REXTON 2007.09...
Page 640 0-56 0000-00 ECU-DIESEL REXTON 2007.09...
Page 641 0-57 0000-00 ECU-DIESEL REXTON 2007.09...
Page 642 0-58 0000-00 ECU-DIESEL REXTON 2007.09...
Page 643 0-59 0000-00 ECU-DIESEL REXTON 2007.09...
Page 644 0-60 0000-00 ECU-DIESEL REXTON 2007.09...
Page 645 0-61 0000-00 ECU-DIESEL REXTON 2007.09...
Page 646 0-62 0000-00 ECU-DIESEL REXTON 2007.09...
Page 647 0-63 0000-00 ECU-DIESEL REXTON 2007.09...
Page 648 0-64 0000-00 ECU-DIESEL REXTON 2007.09...
Page 649 0-65 0000-00 ECU-DIESEL REXTON 2007.09...
Page 650 0-66 0000-00 ECU-DIESEL REXTON 2007.09...
Page 651 0-67 0000-00 ECU-DIESEL REXTON 2007.09...
Page 652 0-68 0000-00 ECU-DIESEL REXTON 2007.09...
Page 653 0-69 0000-00 ECU-DIESEL REXTON 2007.09...
Page 654 0-70 0000-00 ECU-DIESEL REXTON 2007.09...
Page 655 0-71 0000-00 ECU-DIESEL REXTON 2007.09...
Page 656 0-72 0000-00 ECU-DIESEL REXTON 2007.09...
Page 657 0-73 0000-00 ECU-DIESEL REXTON 2007.09...
Page 658 0-74 0000-00 ECU-DIESEL REXTON 2007.09...
Page 659 0-75 0000-00 ECU-DIESEL REXTON 2007.09...
Page 660 0-76 0000-00 ECU-DIESEL REXTON 2007.09...
Page 661 0-77 0000-00 ECU-DIESEL REXTON 2007.09...
Page 662 0-78 0000-00 ECU-DIESEL REXTON 2007.09...
Page 663 BRAKE 0000-00 BRAKE DIAGNOSIS 1. BRAKE...........
Page 665 0000-00 0000-00 BRAKE DIAGNOSIS 1. BRAKE BRAKE REXTON 2007.09...
Page 666 0000-00 BRAKE REXTON 2007.09...
Page 667 0000-00 BRAKE REXTON 2007.09...
Page 668 0000-00 BRAKE REXTON 2007.09...
Page 669 0000-00 BRAKE REXTON 2007.09...
Page 670 0000-00 BRAKE REXTON 2007.09...
Page 671 0000-00 BRAKE REXTON 2007.09...
Page 672 0-10 0000-00 BRAKE REXTON 2007.09...
Page 673 0-11 0000-00 BRAKE REXTON 2007.09...
Page 674 0-12 0000-00 BRAKE REXTON 2007.09...
Page 675 AIR-BAG 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG..........
Page 677 0000-00 0000-00 AIR-BAG DIAGNOSIS 1. AIR-BAG AIR-BAG REXTON 2007.09...
Page 678 0000-00 AIR-BAG REXTON 2007.09...
Page 679 0000-00 AIR-BAG REXTON 2007.09...
Page 680 0000-00 AIR-BAG REXTON 2007.09...
Page 681 0000-00 AIR-BAG REXTON 2007.09...
Page 682 0000-00 AIR-BAG REXTON 2007.09...
Page 683 0000-00 AIR-BAG REXTON 2007.09...
Page 684 0-10 0000-00 AIR-BAG REXTON 2007.09...
Page 685 CCCS 0000-00 CCCS DIAGNOSIS 1. CCCS.............
Page 687 0000-00 0000-00 CCCS DIAGNOSIS 1. CCCS CCCS REXTON 2007.09...
Page 688 0000-00 CCCS REXTON 2007.09...
Page 689 0000-00 CCCS REXTON 2007.09...
Page 690 0000-00 CCCS REXTON 2007.09...
Page 691 0000-00 CCCS REXTON 2007.09...
Page 692 0000-00 CCCS REXTON 2007.09...
Page 693 0000-00 CCCS REXTON 2007.09...
Page 694 0-10 0000-00 CCCS REXTON 2007.09...
Page 695 0-11 0000-00 CCCS REXTON 2007.09...
Page 696 0-12 0000-00 CCCS REXTON 2007.09...
Page 697 0-13 0000-00 CCCS REXTON 2007.09...
Page 698 0-14 0000-00 CCCS REXTON 2007.09...
Page 699 0-15 0000-00 CCCS REXTON 2007.09...
Page 700 0-16 0000-00 CCCS REXTON 2007.09...
Page 701 0-17 0000-00 CCCS REXTON 2007.09...
Page 702 0-18 0000-00 CCCS REXTON 2007.09...
Page 703 0-19 0000-00 CCCS REXTON 2007.09...
Page 704 0-20 0000-00 CCCS REXTON 2007.09...
Page 705 0-21 0000-00 CCCS REXTON 2007.09...
Page 706 0-22 0000-00 CCCS REXTON 2007.09...
Page 707 0-23 0000-00 CCCS REXTON 2007.09...
Page 708 0-24 0000-00 CCCS REXTON 2007.09...
Page 709 0-25 0000-00 CCCS REXTON 2007.09...
Page 710 0-26 0000-00 CCCS REXTON 2007.09...
Page 711 0-27 0000-00 CCCS REXTON 2007.09...
Page 713 FATC 0000-00 FATC DIAGNOSIS 1. SELF DIAGNOSIS........
Page 715 1) Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds. Check LED segments on the vacuum fluorescent display (VFD). Press OFF switch more than 5 seconds. FATC REXTON 2007.09...
Page 716 If any failure exists, the appropriate trouble code is displayed as below. The symbol "-" in front of step number "2" means a short circuit of the blinking sensor. Short-circuit in the ambient air temperature sensor Trouble Code FATC REXTON 2007.09...
Page 717 Slightly turn the TEMP switch in step 3 until "41" is displayed on the display window. When pressing DEF switch , mode changes as shown below in turns to check each function. Slightly turn the TEMP dial to the right to set in the trouble diagnosis step 4 FATC REXTON 2007.09...
Page 718 (other than TEMP switch) in step 5. Starts the trouble Compensates the diagnosis step 6 temperature turning turning TEMP speed dial. dial. Min. temperature Max. temperature Step 6 compensation value compensation value FATC REXTON 2007.09...
Page 719 0000-00 DIAGNOSIS 1. FFH............
Page 721 0000-00 0000-00 DIAGNOSIS 1. FFH REXTON 2007.09...
Page 722 0000-00 REXTON 2007.09...
Page 723 0000-00 REXTON 2007.09...
Page 724 0000-00 REXTON 2007.09...
Page 725 P/TRUNK 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK..........
Page 727 0000-00 0000-00 P/TRUNK DIAGNOSIS 1. P/TRUNK P/TRUNK REXTON 2007.09...
Page 728 0000-00 P/TRUNK REXTON 2007.09...
Page 729 RAIN SENSOR 0000-00 RAIN SENSOR DIAGNOSIS 1. TROUBLE SHOOTING......
Page 731 Check whether the variable resistance knob on the multifunction wiper switch is set in "FAST". The "FAST" is the highest stage of the ensitivity and very sensitive to small amount of rain drops. Therefore, change the knob to the low sensitivity. RAIN SENSOR REXTON 2007.09...
Page 732 The wiper responses are too fast or slow. Check whether the variable resistance knob on the wiper switch is set in "FAST" or "SLOW". Notify that the customer can select the sensitivity by selecting the variable resistance value. And, select a proper stage. RAIN SENSOR REXTON 2007.09...
Page 733 STICS 0000-00 STICS DIAGNOSIS 1. STICS............
Page 735 0000-00 0000-00 STICS DIAGNOSIS 1. STICS STICS REXTON 2007.09...
Page 736 0000-00 STICS REXTON 2007.09...
Page 737 0000-00 DIAGNOSIS 1. TC............
Page 739 0000-00 0000-00 DIAGNOSIS 1. TC REXTON 2007.09...
Page 740 0000-00 REXTON 2007.09...
Page 741 0000-00 REXTON 2007.09...
Page 742 0000-00 REXTON 2007.09...
Page 743 0000-00 DIAGNOSIS 1. TCU............
Page 745 0000-00 0000-00 DIAGNOSIS 1. TCU REXTON 2007.09...
Page 746 0000-00 REXTON 2007.09...
Page 747 0000-00 REXTON 2007.09...
Page 748 0000-00 REXTON 2007.09...
Page 749 0000-00 REXTON 2007.09...
Page 750 0000-00 REXTON 2007.09...
Page 751 0000-00 REXTON 2007.09...
Page 752 0-10 0000-00 REXTON 2007.09...
Page 753 0-11 0000-00 REXTON 2007.09...
Page 754 0-12 0000-00 REXTON 2007.09...
Page 755 0-13 0000-00 REXTON 2007.09...
Page 756 0-14 0000-00 REXTON 2007.09...
Page 757 0-15 0000-00 REXTON 2007.09...
Page 758 0-16 0000-00 REXTON 2007.09...
Page 759 0-17 0000-00 REXTON 2007.09...
Page 760 0-18 0000-00 REXTON 2007.09...
Page 761 0-19 0000-00 REXTON 2007.09...
Page 763 TGS LEVER 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER...........
Page 765 0000-00 0000-00 TGS LEVER DIAGNOSIS 1. TGS LEVER TGS LEVER REXTON 2007.09...
Page 766 0000-00 TGS LEVER REXTON 2007.09...
Page 767 0000-00 TGS LEVER REXTON 2007.09...
Page 768 0000-00 TGS LEVER REXTON 2007.09...

SSANGYONG REXTON 2007.09 Manual

Vehicle General 0000-00

Engine General 0000-00

General

General

Process

Oerview and Operation

Process

Oerview and Operation

Iop/Irda Axle 4220-01/4222-01

Configuration and Functions

Removal and Installation

Quick Links

Chapters

Summary of Contents for SSANGYONG REXTON 2007.09

Page 1: Table Of Contents

Page 3: Dimensions

Page 4: Specifications

Page 6: Vehicle Identification

Page 7: Maintenance

Page 13: Recommended Fluids And Lubricants

Page 14: Jack-Up Points (Dotted Circles)

Page 15: Pin Arrangement Of Diagnostic Connector

Page 16: Electric Components And Layout

Page 18: Tightening Torque Of Standard Bolts

Page 114: Structure And Comparison

Page 118: Engine Specifications And Performance Curve

Page 120: Tightening Torque

Page 123: Major Changes In D27Dtp(Power Up Engine(Compared To D27Dt)

Page 133: Engine Compartment

Page 137: System In Engine Compartment

Page 382: General

Page 383: Configuration And Functions

Page 387: 4220-01 Independent Suspension Type Rear Axle

Page 392: 4122-01 Oil Change

Page 395: Removal And Installation

Page 397: 4122-01 Oil Change Of Iop

Page 400: 4122-01 Iop (Integrated Oil Pan) Front Axle

Page 405: 4220-01 Rear Axle

Page 407: 4220-01 Rear Axle Shaft

SSANGYONG REXTON 2007.09 Manual

Vehicle General 0000-00

Engine General 0000-00

General

General

Process

Oerview and Operation

Process

Oerview and Operation

Iop/Irda Axle 4220-01/4222-01

Configuration and Functions

Removal and Installation

Quick Links

Chapters

Related Manuals for SSANGYONG REXTON 2007.09

Summary of Contents for SSANGYONG REXTON 2007.09

Table of Contents