SSANGYONG RODIUS 2005.07 Manual
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SSANGYONG RODIUS 2005.07 Manual

SSANGYONG RODIUS 2005.07 Manual

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Table of Contents

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GENERAL INFORMATION
0000-00
GENERAL INFORMATION
GENERAL INFORMATION
1. HOW TO READ ELECTRICAL WIRING
DIAGRAM...............................................
3

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Summary of Contents for SSANGYONG RODIUS 2005.07

  • Page 1 GENERAL INFORMATION 0000-00 GENERAL INFORMATION GENERAL INFORMATION 1. HOW TO READ ELECTRICAL WIRING DIAGRAM..........
  • Page 3 - Internal circuit of component (Switch) (Component Name, Terminal Number and Connecting Wiring Circuit) - Lower horizontal line : Ground line ·Ground position (G101 ~ G402) ·B : Body Ground ·Refer to Major Ground Position (Section2) GENERAL INFORMATION RODIUS 2005.07...
  • Page 4 Battery Voltage (B+) supply in Ignition Switch “ON” and “ACC” Battery Voltage (B+) supply directly regardless of Ignition Switch Ground connected to battery (-) Battery Voltage (B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit) GENERAL INFORMATION RODIUS 2005.07...
  • Page 5 □ 9□□ In the locating section, the assignment for part number startsfrom left bottom and proceeds clockwise. In the fuse and relay box or the instrument panel, the partnumber is assigned from left top to light bottom. GENERAL INFORMATION RODIUS 2005.07...

  • Page 7: Table Of Contents

    CONNECTOR/GROUND 8201-00/8210-02/8210-01/8210-03/8210-04/8210-06/8210-07/6810-11/6811-07/8210-09/8210-08/7421-60 CONNECTOR/GROUND WIRING 8201-00 WIRING HARNESS, COMPONENTS LOCATION..CONNECTOR/GROUND 8210-02 W/H ENGINE ROOM..... 8210-01 W/H MAIN........8210-03 W/H FLOOR (LH)......8210-04 W/H FLOOR (RH)......8210-06 W/H DOOR (LH/RH)...... 8210-07 W/H RR DOOR......6810-11 W/H FRT AIR-CON......6811-07 W/H RR AIR-CON......8210-09 W/H TAIL GATE......

  • Page 8: 8201-00 Wiring Harness, Components Location

    0000-00 WIRING HARNESS WIRING HARNESS, COMPONENTS LOCATION 8201-00 2) COMPONENTS LOCATION 1) POSITION OF CONNECTOR, GROUND & SPLICE PACK CONNECTOR/GROUND RODIUS 2005.07...

  • Page 9: Connector/Ground

    8201-00 3) CONNECTOR, GROUND & SPLICE PACK INFORMATION ▶ CONNECTOR CONNECTOR/GROUND RODIUS 2005.07...
  • Page 10 8201-00 ▶ GROUND ▶ SPLICE PACK CONNECTOR/GROUND RODIUS 2005.07...
  • Page 11 8201-00 4) CONNECTOR ▶ C104 ▶ C101 ▶ C102 ▶ C105 ▶ C103 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 12 8201-00 ▶ C109 ▶ C106 ▶ C110 ▶ C107 C108 ▶ ▶ C111 ▶ C112 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 13 8201-00 ▶ C113 ▶ C115 ▶ C114 (DSL) ▶ C116 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 14 8201-00 ▶ C201 ▶ C203 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 15 8201-00 ▶ C204 ▶ C205 ▶ C206 ▶ C207 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 16 0-10 8201-00 ▶ C210 ▶ C211A (16 PIN) MANUAL C211 ▶ C211B ▶ ▶ C211A (13 PIN) FATC C212 ▶ CONNECTOR/GROUND RODIUS 2005.07...
  • Page 17 0-11 8201-00 ▶ C213 ▶ C218 ▶ C216 C219 ▶ ▶ C217 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 18 0-12 8201-00 ▶ C220 ▶ C301 ▶ C301A ▶ C302 ▶ C221 ▶ C303 ▶ C304 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 19 0-13 8201-00 ▶ C305 ▶ C361 ▶ C306 ▶ C371 ▶ C351 ▶ C381 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 20 0-14 8201-00 ▶ C401 ▶ C901 C902 ▶ ▶ C402 ▶ C903 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 21 0-15 8201-00 ▶ S904 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 22 0-16 8201-00 5) SPLICE PACK ▶ S202 ▶ S204 (ILL) ▶ S205 (CAN) S203 (GND) ▶ ▶ S206 (GND) CONNECTOR/GROUND RODIUS 2005.07...
  • Page 23 0-17 8201-00 ▶ S207 ▶ S301 (EPB/EAS, CAN) CONNECTOR/GROUND RODIUS 2005.07...

  • Page 24: 8210-02 W/H Engine Room

    0-18 8210-02 CONNECTOR W/H ENGINE ROOM 8210-02 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 25: 8210-01 W/H Main

    0-19 8210-01 W/H MAIN 8210-01 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 26 0-20 8210-01 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 27: 8210-03 W/H Floor (Lh)

    0-21 8210-03 W/H FLOOR (LH) 8210-03 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 28: 8210-04 W/H Floor (Rh)

    0-22 8210-04 W/H FLOOR (RH) W/H DOOR (LH/RH) 8210-04 8210-06 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 29: 8210-07 W/H Rr Door

    0-23 8210-07 W/H RR DOOR W/H FRT AIR-CON 8210-07 6810-11 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 30: 6811-07 W/H Rr Air-Con

    0-24 6811-07 W/H RR AIR-CON W/H TAIL GATE 6811-07 8210-09 CONNECTOR/GROUND RODIUS 2005.07...

  • Page 31: 8210-08 W/H Roof

    0-25 8210-08 W/H ROOF 8210-08 W/H SEAT 7421-60 CONNECTOR/GROUND RODIUS 2005.07...
  • Page 33 POWER DISTRIBUTION 8410-02/8410-05 POWER DISTRIBUTION FUSE/RELAY 8410-02 ENGINE ROOM FUSE ＆ RELAY BOX......... 8410-05 I.P FUSE ＆ ICM BOX (IP RELAY BOX)......ELECTRICITY DIVIDE 8210-02 ENG ROOM FUSE BOX....8410-04 I.P FUSE BOX......

  • Page 35: Fuse/Relay

    8410-02 FUSE ＆ RELAY 3) FUSE & RELAY POSITION 8410-02 ENGINE ROOM FUSE ＆ RELAY BOX 1) FRONT (1) XDi ENGINE 2) REAR POWER DISTRIBUTION RODIUS 2005.07...
  • Page 36 8410-02 4) USAGE OF FUSE IN ENGINE ROOM FUSE BOX (2) GSL (G23) ENGINE 5) ENGINE ROOM FUSE BOX CONNECTOR NUMBER POWER DISTRIBUTION RODIUS 2005.07...

  • Page 37: Fuse ＆ Icm Box (Ip Relay Box)

    8410-05 8410-05 I.P FUSE ＆ ICM BOX (IP RELAY BOX) 3) ICM BOX 1) FUSE BOX 4) ICM BOX (POWER SUPPLY) 2) POWER SUPPLY (1) C203 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 38 8410-05 POWER DISTRIBUTION RODIUS 2005.07...

  • Page 39: Electricity Divide

    8410-02 ELECTRICITY DIVIDE ENG ROOM FUSE BOX 8210-02 (1) SB1 ~ SB5 (2) SB6 ~ SB11 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 40 8410-02 (3) Ef1 ~ Ef4 (4) Ef5 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 41 8410-02 (5) Ef6 ~ Ef10 (6) Ef11 ~ Ef18 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 42 0-10 8410-02 (7) Ef19 ~ Ef21 (8) Ef22 ~ Ef26 POWER DISTRIBUTION RODIUS 2005.07...

  • Page 43: I.p Fuse Box

    0-11 8410-04 I.P FUSE BOX 8410-04 (1) F1 ~ F5 (2) F6 ~ F12 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 44 0-12 8410-04 (3) F13 ~ F16 (4) F17 ~ F24 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 45 0-13 8410-04 (5) F25 ~ F31 (6) F32 ~ F35 POWER DISTRIBUTION RODIUS 2005.07...
  • Page 47 CIRCUIT 1461-01/2820-01/1491-01/1491-01/8210-01/3670-01/3670-03/3410-01/4891-01/4920-01/4480-01/8810-01/8010-01/8610-04/8610-11/7421-60/8510-52/8610-17/8510- 8710-03/8510-03/8710-03/8510-12/8610-09/7630-02/7340-03/8310-01/8510-00/8320-01/8510-26/8510-24/4810-10/8610-01/7770-07/8910-01/8730-01/6810-21/6910- CIRCUIT 6810-30/6810-30 ENGINE 8910-01 AUDIO (MULTI VISION)....1461-01 STARTING ＆ CHARGING.... 8610-17 DEFFOGER (FRT GLASS, RR 8910-01 AUDIO.......... 2820-01 PREHEATING UNIT CIRCUIT GLASS, OUTSIDE MIRROR)..8730-01 PARKING AID CIRCUIT....(XDi))..........8510-20 FRT SEAT WARMER....6810-21 PTC HEATER (POSITIVE 1491-01 ECU (ENGINE CONTROL UNIT - 8510-20 AUTO LIGHT CORTROL CIRC..

  • Page 49: Starting ＆ Charging

    1461-01 1461-01 STARTING ＆ CHARGING 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 50: Preheating Unit Circuit (Xdi)

    2820-01 PREHEATING UNIT CIRCUIT (XDi) 2820-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 51: Ecu (Engine Control Unit - Xdi)

    1491-01 ECU (ENGINE CONTROL UNIT - XDi) 1491-01 1) ENG MAIN RELAY, PEDAL MODULE, HAN SENSORS, VALVE (1) CONNECTOR INFORMATION (1) TRUBO CHARGER BOOSTER, VACUUM MODULE, INLETMETERING VALVE (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 52 1491-01 2) FUEL FILTER WARNING LAMP, IMMOBILIZER, SENSOR CIRCUIT (FUEL PRESSURE, SHAFT, BOOSTER (1) CONNECTOR INFORMATION PRESSURE, CRANK SHAFT, KNOCK, COOLANT TEMP., FUEL TEMP.) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 53 1491-01 3) INJECTOR, CAN LINE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 54: Ecu (Gsl G32)

    1491-01 ECU (GSL G32) 1491-01 IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 55 1491-01 2) O₂SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 56 0-10 1491-01 INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 57: Diagnosis Circuit

    0-11 8210-01 DIAGNOSIS CIRCUIT 8210-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 58: Tcu (5-Speed)

    0-12 3670-01 TCU (5-SPEED) 3670-01 1) START MOTOR, TGS LEVER, CAN LINE (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 59 0-13 3670-01 2) SOLENOID, OIL TEMP SENSOR, SPEED SENSOR (N2, N3) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 60: Tod

    0-14 3670-03 3670-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 61: Tccu

    0-15 3410-01 TCCU 3410-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 62: Abs/Esp

    0-16 4891-01 ABS/ESP 4891-01 WHEEL SPEED SENSOR, STOP LAMP SW, DIAGNOSIS, WARNING LAMP (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 63 0-17 4891-01 2) SOLENOID, OIL TEMP. SENSOR, SPEED SENSOR (N2, N3) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 64: Epb

    0-18 4920-01 4920-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSI CIRCUIT RODIUS 2005.07...

  • Page 65: Eas

    0-19 4480-01 4480-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 66: Air-Bag

    0-20 8810-01 AIR-BAG 8810-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 67: Cluster

    0-21 8010-01 CLUSTER 8010-01 1) GAUGE(SPEED, RPM, FUEL, TEMP, WARNING LAMP(4WD, (1) CONNECTOR INFORMATION FUEL FILTER, ABS/ESP) (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 68 0-22 8010-01 2) WARNING (EAS, EPB, TGS LEVER, AUTO PARK’G) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 69 0-23 8010-01 WARNING (BAT CHANGE, OIL, BRAKE ENG CHCK, AIR BAG, (1) CONNECTOR INFORMATION IMMOM SEAT-BELT) TURN SIGNAL, DEFOGGER, DOOR OPEN (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 70: Multi Meter

    0-24 8610-04 MULTI METER 8610-04 (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 71: Rain Sensing Wiper Circuit

    0-25 8610-11 RAIN SENSING WIPER CIRCUIT 8610-11 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 72: Driver Power Seat Circuit

    0-26 7421-60 DRIVER POWER SEAT CIRCUIT 7421-60 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 73: Electric Outside Mirror & Folding Circuit

    0-27 8510-52 null ELECTRIC OUTSIDE MIRROR & FOLDING 8510-52 1) CONNECTOR INFORMATION CIRCUIT 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 74: Deffoger (Frt Glass, Rr Glass, Outside Mirror)

    0-28 8610-17 DEFFOGER (FRT GLASS, RR GLASS, OUTSIDE 　 8610-17 1) CONNECTOR INFORMATION MIRROR) 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 75: Frt Seat Warmer

    0-29 8510-20 FRT SEAT WARMER 8510-20 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 76: Auto Light Cortrol Circ

    0-30 8510-20 AUTO LIGHT CORTROL CIRC 8510-20 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 77: Stics

    0-31 8710-03 STICS 8710-03 (1) CONNECTOR INFORMATION 1) ESCORT, PANIC, POWER WINDOW, WARNING LAMP (PARKING BRAKE, SEAT BELT), ILL, KEY REMINDER SW (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 78 0-32 8710-03 WIPER. DOOR SW, LAMP(DOOR COURTESY, G/HANDLE) DOOR OPEN WARNING LAMP (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 79 0-33 8710-03 3) DOOR LOCK, DEFOGGER (1) CONNECTOR INFORMATION CIRCUIT RODIUS 2005.07...
  • Page 80 0-34 8710-03 (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 81: Power Window Circuit

    0-35 8510-03 POWER WINDOW CIRCUIT 8510-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 82: Central Door Locking Circuit

    0-36 8710-03 CENTRAL DOOR LOCKING CIRCUIT 8710-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 83: Rr Wiper ＆ Washer Circuit

    0-37 8510-12 8510-12 RR WIPER ＆ WASHER CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 84: Horn

    0-38 8610-09 HORN 8610-09 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 85: Cigar Lighter, Power Outlet

    0-39 7630-02 CIGAR LIGHTER, POWER OUTLET 7630-02 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 86: Sun Roof Circuit

    0-40 7340-03 SUN ROOF CIRCUIT 7340-03 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 87 0-41 8310-01 HEAD LAMP & DRL HEAD LAMP ＆ DRL 8310-01 (DAY TIME RUNNING LIGHT) UNIT CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 88: Head Lamp Leveling Device Circuit

    0-42 8510-00 HEAD LAMP LEVELING DEVICE CIRCUIT 8510-00 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 89: Tail Lamp Circuit

    0-43 8320-01 TAIL LAMP CIRCUIT 8320-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 90: Turn Signal ＆ Hazard Lamp Circuit

    0-44 8510-26 8510-26 TURN SIGNAL ＆ HAZARD LAMP CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 91: Fog Lamp Circuit

    0-45 8510-24 FOG LAMP CIRCUIT 8510-24 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 92: Stop ＆ Back-Up Lamp Circuit

    0-46 4810-10 4810-10 STOP ＆ BACK-UP LAMP CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 93: Interior Lamp(Room, G/Hendle, Door Courtesy) Circuit

    0-47 8610-01 INTERIOR LAMP(ROOM, G/HENDLE, DOOR 8610-01 　 COURTESY) CIRCUIT 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 94: Auto Dimming Room Mirror Circuit

    0-48 7770-07 AUTO DIMMING ROOM MIRROR CIRCUIT 7770-07 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 95: Audio (Multi Vision)

    0-49 8910-01 AUDIO (MULTI VISION) 8910-01 A/V HEAD UNIT, NAVI UNIT, DVD CHANGER, GPS, RR VIEW 1) CONNECTOR INFORMATION CAMARA CIRCUIT RODIUS 2005.07...
  • Page 96 0-50 8910-01 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 97 0-51 8910-01 (1) CONNECTOR INFORMATION 2) A/V HEAD UNIT, DSP/AMP, TUNER UNIT, WOOFER AMP (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 98: Audio

    0-52 8910-01 AUDIO 8910-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSI CIRCUIT RODIUS 2005.07...

  • Page 99: Parking Aid Circuit

    0-53 8730-01 PARKING AID CIRCUIT 8730-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 100: Ptc Heater (Positive Temperature Coefficient)

    0-54 6810-21 PTC HEATER 6810-21 (POSITIVE TEMPERATURE COEFFICIENT) 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 101: Ffh (Fuel Fired Heater)

    0-55 6910-01 FFH (FUEL FIRED HEATER) 6910-01 1) CONNECTOR INFORMATION 2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 102: Control) Circuit

    0-56 6810-30 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT (1) CONNECTOR INFORMATION 6810-30 1) CONDENSOR FAN, AIR MIX MOTOR, SUN SENSOR, WATER TEMP SENSOR (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 103 0-57 6810-30 2) FRT BLOWER, ACTUATOR (MODE, INTAKE) AQS SENSOR (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 104 0-58 6810-30 3) RR AIR CON (BLOWER, MODE ACTIATOR) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...

  • Page 105: Air-Con (Manual)

    0-59 6810-30 AIR-CON (MANUAL) 6810-30 1) POWER A/C, COMP., MOTOR (MODE, INTAKE, AIR MIX) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 106 0-60 6810-30 2) BLOWER MOTOR (FRT, RR) (1) CONNECTOR INFORMATION (2) CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION CIRCUIT RODIUS 2005.07...
  • Page 108 ENGINE GENERAL 0000-00 ENGINE GENERAL GENERAL 1. COMPONENTS LOCATOR....2. DESCRIPTION AND OPERATION..
  • Page 110 12. Intake manifold 19. Oil pump sprocket 5. Exhaust camshaft 13. Connecting rod 20. Oil strainer 6. Intake camshaft 14. Exhaust manifold 21. Oil pan 7. Cylinder head 15. Crankshaft 22. Drain plug 8. Spark plug connector ENGINE GENERAL RODIUS 2005.07...
  • Page 111 01-4 0000-00 2) SIDE VIEW 23. Camshaft adjuster 27. Oil pump drive chain 24. Cooling fan and viscous clutch 28. Oil return pipe 25. Piston 29. Timing chain 26. Flywheel of drive plate ENGINE GENERAL RODIUS 2005.07...
  • Page 112 Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. ENGINE GENERAL RODIUS 2005.07...
  • Page 114 02-3 1113-01 1311-01 ENGINE ASSEMBLY 1. ENGINE SPECIFICATIONS MSE: Engine Control Module 3.63D: 6 Cylinder Version ENGINE ASSEMBLY RODIUS 2005.07...
  • Page 115 12. Intake manifold 19. Oil pump sprocket 5. Exhaust camshaft 13. Connecting rod 20. Oil strainer 6. Intake camshaft 14. Exhaust manifold 21. Oil pan 7. Cylinder head 15. Crankshaft 22. Drain plug 8. Spark plug connector ENGINE ASSEMBLY RODIUS 2005.07...
  • Page 116 02-5 1113-01 2) SIDE VIEW 23. Camshaft adjuster 27. Oil pump drive chain 24. Cooling fan and viscous clutch 28. Oil return pipe 25. Piston 29. Timing chain 26. Flywheel of drive plate ENGINE ASSEMBLY RODIUS 2005.07...
  • Page 117 Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. ENGINE ASSEMBLY RODIUS 2005.07...
  • Page 118 02-7 1113-01 4. PERFORMANCE CURVE ENGINE ASSEMBLY RODIUS 2005.07...
  • Page 119 07-3 2110-01 2110-01 ENGINE COOLING SYSTEM 1. GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 120 07-4 2110-01 2. FASTENER TIGHTENING SPECIFICATIONS ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 121 Inlet hose Cooling fan Electric fan mounting bracket Outlet hose Viscous clutch Bolt (M6, 8 pieces) 3 way hose Bolt (M6, 1 piece) Bolt (M6, 4 pieces) Deaeration hose (reserver tank) Bolt (M6, 3 piece) ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 122 On vehicles equipped with automatic transaxles, the transaxle fluid cooler lines run through the radiator tank. A radiator drain plug is on this radiator. To drain the cooling system, open the drain plug. ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 123 As the wax pellet cools, the contraction allows a spring to close the valve. The thermostat begins to open at 82°C (180°F) and is fully open at 95°C (203°F). The thermostat closes at 80°C (176°F). ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 124 95°C (203°F) and at high speed when the coolant temperature reaches 105°C (221°F). The ECM will change the cooling fans from high peed to low speed at 100°C · (212°F) and will turn the cooling fans off at 90°C (194°F). ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 125 The Engine Coolant Temperature (ECT) sensor uses a temperature to control the signal voltage to the Engine Control Module (ECM). 10) COOLANT TEMPERATURE GAUGE The coolant temperature gauge controls the instrument panel temperature indicator. The coolant temperature gauge is located with ECT sensor. ENGINE COOLING SYSTEM RODIUS 2005.07...
  • Page 126 04-3 1715-01 0000 ENGINE INTAKE 1. FASTENER TIGHTENING SPECIFICATIONS ENGINE INTAKE SYSTEM RODIUS 2005.07...
  • Page 127 04-4 1715-01 1. AIR CLEANER AND INTAKE AIR DUCT ▶ Specifications ENGINE INTAKE SYSTEM RODIUS 2005.07...
  • Page 128 The switch valve (7) will not be adjusted by ECU and resonance falp (5) will be open. The collected air in the air collection housing (8) will not be divided and intaking air passage will be shorten. ENGINE INTAKE SYSTEM RODIUS 2005.07...
  • Page 129 05-3 2411-01 0000 ENGINE EXHAUST 1. FASTENER TIGHTENING SPECIFICATIONS ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 130 The oxidation catalyst is coated with a catalytic material containing platinum and palladium, which reduces levels of hydrocarbon (HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx). ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 131 Generally Alumina (AL2 O3) is used as a raw material and its 7 phases of gamma, delta, theta have big areas and high stability for the temperature, and nowadays gamma Alumina is used usually. ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 132 CO purification rate becomes the best near the temperature of 450°C, and NOx does so near the temperature of 400 to 500°C. ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 134 HC and CO. · Oxygen adheres to catalytic material : below 180°C Catalytic material supplies each CO and · HC with O2 for their oxidation : above 180°C Catalytic material conversion process by · ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 135 EGR valve is installed on the diesel · engine of Musso, Korando, Istana and Rexton. And micro switch is installed together to control EGR valve. · The setting method of micro switch is identical with the existing one. ENGINE EXHAUST SYSTEM RODIUS 2005.07...
  • Page 136 9210-01 0000 LUBRICATION SYSTEM 1. ENGINE OIL SPECIFICATION 1) components 1. Drain plug ........25 Nm (18 lb-ft) 3. Engine oil filler cap 2. Oil filter 4. Dipstick gauge 2) Specifications ENGINE LUBRICATION SYSTEM RODIUS 2005.07...
  • Page 137 Pour the engine oil through the engine oil filler hole. Run the engine and check for oil leakage at normal operating temperature. Stop the engine and wait for 5 minutes. Check the oil level and add if necessary. ENGINE LUBRICATION SYSTEM RODIUS 2005.07...
  • Page 138 9210-01 2. SPECIFICATIONS 1) FASTENER TIGHTENING SPECIFICATIONS ENGINE LUBRICATION SYSTEM RODIUS 2005.07...
  • Page 139 9210-01 2) Fastener Tightening Specifications (Cont’d) ENGINE LUBRICATION SYSTEM RODIUS 2005.07...
  • Page 140 15. Oil gallery (at cylinder head) c. Oil return line (oil returns to the oil pan when 16. Ball (φ 15mm) replacing the filter element) 17. Oil restriction inner (φ 4mm) 18. Oil supply (to exhaust camshaft) ENGINE LUBRICATION SYSTEM RODIUS 2005.07...
  • Page 141 08-3 1452-01 1452-01 ENGINE ELECTRICAL SYSTEM 1. SPECIFICATIONS 1) GENERAL SPECIFICATIONS ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 142 08-4 1452-01 2) FASTENER TIGHTENING SPECIFICATIONS ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 143 The battery is not designed to last indefinitely. However, with proper care, the battery will provide many years of service. If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the following factors may point to the cause of the trouble: ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 144 Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, the current accepted by the battery is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase. ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 145 (AH) to restore the battery to a usable state. If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced. ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 146 At high speeds, the on-time may be 10 percent and the off- time 90 percent. At low speeds, with high electrical loads, the on-time may be 90 percent and the off-time 10 percent. ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 147 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. All of these components are connected electrically. ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 148 08-10 1452-01 2. SCHEMATIC AND ROUTING DIAGRAMS 1) STARTING AND CHARGING SYSTEM (GASOLINE ENGINE) ENGINE ELECTRIC SYSTEM RODIUS 2005.07...
  • Page 149 09-3 0452-01 0452-01 ENGINE CONTROLS 1. ENGINE AND ECM PROBLEM CHECK REPORT 1) Vehicle And Customer Information 2) Mil Information 3) Problem Description 4) Condition When Problem Occurs ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 150 09-4 0452-01 2. SPECIFICATIONS 1) Engine Data Display Table ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 151 09-5 0452-01 2) Fastener Tightening Specifications ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 152 It is therefore recommended that earthed pumps with integrally earthed hoses be used, and that storage containers be properly earthed during all noncommercial fueling operations. ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 153 09-7 0452-01 4) Temperature Vs Resistance ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 154 These systems use the EST signal from the ECM to control the EST. The ECM uses the following information: Engine load (mass air flow sensor). Engine temperature. Intake air temperature. Crankshaft position. Engine speed (rpm). ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 155 “closed loop” system. The ECM uses voltage inputs from several sensors to determine how much fuel to provide to the engine. The fuel is delivered under one of several conditions, called ‘‘modes”. ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 156 6) Deceleration Mode The ECM responds to changes in throttle position and airflow and reduces the amount of fuel. When deceleration is very fast, the ECM can cut off fuel completely for short periods of time. ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 157 The exhaust gases flow through the catalytic converter and, in so doing, coming into contact with rare metals (Pt and Rh). The following chemical reaction are produced. CO + O2 → CO2 HC + O2 → CO2 + H2O NOx → N2 + O2 ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 158 If the actuator is deenergized, the throttle valve is resting against the spring capsule. Consequently, the throttle valve opening is a constant 10 ~ 12° approximately. At no load, this produces an engine speed of about 1,800 rpm ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 159 The function of the EA (electronic accelerator) in the ECM determines the opening angle of the throttle valve through the throttle actuator. Further functions are Idle speed control Cruise control Reducing engine torque for ASR/ABS operation Electronic accelerator emergency running Storing faults Data transfer through CAN ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 160 09-14 0452-01 5. SCHEMATIC AND ROUTING 1) Diagnosis Circuit DIAGRAMS ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 161 09-15 0452-01 2) ECU (GSL G32) IGN COIL, CPS, AIR FLOW SENSOR, THROTTLE SENSOR, TPS ▶ ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 162 09-16 0452-01 SENSOR, PEDAL MODULE, CRUISE CONTROL SW, STOP LAMP SW ▶ ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 163 09-17 0452-01 INJECTOR, KNOCK SENSOR, IMMOBILIZER, CANISTER PURGE VALVE ▶ ENGINE CONTROL SYSTEM RODIUS 2005.07...
  • Page 164 The internal sensors and controls are connected to TCU by cylindrical 13-pin connector. ▶ DCAG 5-speed automatic transmission offers the following advantages Improved shifting quality More gears Extended working life and reliability Reduced fuel consumption DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 165 Center planetary gear set Input shaft Disc brake B2 Electric control unit (valve body) Disc brake B1 Output shaft Freewheel F1 Disc clutch C1 Parking lock gear Stator shaft Disc clutch C2 Intermediate shaft Converter lockup clutch DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 166 3650-01 3. PERFORMANCE CURVE AND GENERAL CHARACTERISTICS Standard mode Lockup mode (open/sleeping) 4-LOW mode DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 167 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 168 3650-01 4. SPECIFICATIONS DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 169 3650-01 DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 170 3650-01 1) Friction Disc 2) Tightening Torque DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 171 W 116 589 06 59 00 Fixing automatic transmission Assembly stand W 140 589 12 15 00 Installation of sealing ring Arbor W 001 589 50 33 00 Removal and installation of transmission housing ball housing Puller DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 172 Collet chuck W 140 589 13 43 00 Removal and installation of B1, B2, B3 piston Piston puller W 126 589 02 09 00 Removal and installation of collar nut for output shaft Socket DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 173 Measuring the clearance between ball bearing and parking lock gear Measuring bridge W 208 589 00 21 00 Compressing clutch and disc brake Compressor W 140 589 15 21 00 Measuring the oil level Pipstick guage DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 174 0-13 3650-01 2) Fixing Plate Assembly Stand W 140 589 34 63 00 DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 175 0-14 3650-01 1. COMPONENTS OF AUTO TRANSMISSION (DC 5-SPEED A/T) DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 176 0-15 3650-01 2. POWER FLOW Sectional View ▶ ▶ Shifting elements 1) Selector program switch: “S” mode 2) Selector program switch: “W” mode 3) Overrun DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 177 0-16 3650-01 DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 178 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 179 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 180 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 181 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 182 Rear sun gear: Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear (increased speed) 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) 3) Overrun DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 183 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 3) Overrun DC 5-SPEED AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 184 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 AUTOMATIC TRANSMISSION RODIUS 2005.07...
  • Page 185 3410-01 3410-01 PART TIME TRANSFER CASE 1. SPECIFICATIONS TRANSFER CASE RODIUS 2005.07...
  • Page 186 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. TRANSFER CASE RODIUS 2005.07...
  • Page 187 3410-01 2. OPERATION 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]. TRANSFER CASE RODIUS 2005.07...
  • Page 188 3410-01 3. SYSTEM LAYOUT TRANSFER CASE RODIUS 2005.07...
  • Page 189 3410-01 4. SECTIONAL DIAGRAM TRANSFER CASE RODIUS 2005.07...
  • Page 190 3410-01 5. EXPLODED VIEW TRANSFER CASE RODIUS 2005.07...
  • Page 191 Locking clip Asm. -fork, shift Connector Cam, electric shift Bolt, hex head Spring, torsion Capscrew, hex head Spacer Asm. -motor, electric Shaft, shift Seal, oil Ring, retaining Plug, pipe Asm. -case, transfer Sealing Compound Barb, breather TRANSFER CASE RODIUS 2005.07...
  • Page 192 0-10 3410-01 6. POWER FLOW TRANSFER CASE RODIUS 2005.07...
  • Page 193 0-11 3410-01 1) 2H Mode (Rear Wheel Drive) ▶ Power Flow TRANSFER CASE RODIUS 2005.07...
  • Page 194 0-12 3410-01 2) 4H Mode (4Wd Drive - High Speed) ▶ Power Flow TRANSFER CASE RODIUS 2005.07...
  • Page 195 0-13 3410-01 3) 4L Mode (4Wd Drive - Low Speed) ▶ Power Flow TRANSFER CASE RODIUS 2005.07...
  • Page 196 0-14 3410-01 7. TRANSFER CASE BLOCK DIAGRAM TRANSFER CASE RODIUS 2005.07...
  • Page 197 0-15 3410-01 TRANSFER CASE RODIUS 2005.07...
  • Page 198 Change the 4WD switch in instrument 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. TRANSFER CASE RODIUS 2005.07...
  • Page 199 Change the 4WD switch in instrument panel from 4H to 4L. “4WD LOW” warning lamp in meter cluster blinks during this process, then remains when the shift is completed. “4WD CHECK” warning lamp comes on when the system is defective. TRANSFER CASE RODIUS 2005.07...
  • Page 200 3170-01 3710-01 MANUAL TRANSMISSION 1. SPECIFICATIONS 1) General Specifications 2) Tightening Torque MANUAL TRANSMISSION RODIUS 2005.07...
  • Page 201 TSM54/52 transmission uses linkage type shift elements directly connected to the transmission. It prevent the transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear. It also prevents the break and wear. MANUAL TRANSMISSION RODIUS 2005.07...
  • Page 202 The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according to the vehicle model. New Rexton uses the fork type clutch release system. The semi-remote control type gear shift mechanism is used to prevent incorrect shifting. MANUAL TRANSMISSION RODIUS 2005.07...
  • Page 203 3170-01 2. CIRCUIT DIAGRAM (BACKUP LAMP) MANUAL TRANSMISSION RODIUS 2005.07...
  • Page 204 3010-01 3010-01 CLUTCH 1. CLUTCH SPECIFICATIONS 2. TIGHTENING TORQUE CLUTCH RODIUS 2005.07...
  • Page 205 This system provides higher efficiency than conventional clutch system, and its durability is superior. Adaptor (mounted on transmission case) Concentric slave cylinder pipe (mounted inside of transmission) Concentric slave cylinder (mounted inside of transmission) CLUTCH RODIUS 2005.07...
  • Page 206 Identify the SAT clutch with adjusting equipment around the clutch cover. Adapt the zig set(4 pieces) between the clutch cover and diaphram spring around (Refer to the picture). Diaphram Adjusting equipmen Cover Zig for clutch removal and installation CLUTCH RODIUS 2005.07...
  • Page 207 Rexton applied SAC (Self Adjusting Clutch) system. This clutch system also requires to replace both clutch cover and disc when the disc need to be replaced. However, for disc re-usage, special zig set is not necessary. This is different point with SAT system. CLUTCH RODIUS 2005.07...
  • Page 208 8. Pipe 14. Bracket 3. Clutch cover 9. Clutch fluid chamber 15. Clutch pedal 4. Clutch disk 10. Clutch hydraulic line 16. Clutch pedal pad 5. Adaptor 11. Clutch pin (B) 6. Clutch master cylinder 12. Clutch housing CLUTCH RODIUS 2005.07...
  • Page 209 0000-00 4120-01 AXLE SYSTEM 1. FRONT AXLE SPECIFICATION 2. REAR AXLE SPECIFICATION AXLE SYSTEM RODIUS 2005.07...
  • Page 210 3240-01 3240-01 TOD(TORQUE ON DEMAND) 1. SPECIFICATIONS TORQUE ON DEMAND RODIUS 2005.07...
  • Page 211 3240-01 1. TOD SYSTEM LAYOUT TORQUE ON DEMAND RODIUS 2005.07...
  • Page 212 At this moment, some of torques is also distributed to front wheels so that the vehicle could maintain safe ground grab capacity against side winds and rain. Distribution ratio: 15 % for front wheels and 85% for rear wheels. TORQUE ON DEMAND RODIUS 2005.07...
  • Page 213 4WD mode. Distribution ratio: 44 % for front wheels and 56 % for rear wheels. TORQUE ON DEMAND RODIUS 2005.07...
  • Page 214 TOD control unit controls electromagnetic clutch to transmit driving force to front wheels. At this time, ball slant cam is moved to compress multi-disc located in clutch disc to transmit driving force to front wheels. TORQUE ON DEMAND RODIUS 2005.07...
  • Page 215 EMC consists of coil and housing. TOD control unit controls EMC by controlling duty cycle according to the road and driving conditions. These controls use the continuity time and amount of electric current to determine the torque to be transmitted to front wheels. Basic controls in EMC ▶ TORQUE ON DEMAND RODIUS 2005.07...
  • Page 216 3240-01 3) Signal Flow TORQUE ON DEMAND RODIUS 2005.07...
  • Page 217 0-10 3240-01 4) Power Flow (1) 4H Mode (4WD Drive - High Speed) TORQUE ON DEMAND RODIUS 2005.07...
  • Page 218 0-11 3240-01 (2) 4H Mode (4WD Drive - Low Speed) TORQUE ON DEMAND RODIUS 2005.07...
  • Page 219 0-12 3240-01 3. OPERATION 1) System Layout TORQUE ON DEMAND RODIUS 2005.07...
  • Page 220 1:1 to 2.48:1 by planetary gear set. Releasing the 4L Mode ▶ When selecting 4H mode, 4L drive mode is released and 4H mode is resumed. · “4H” switch: Self-return type · “4L” switch: Push lock type TORQUE ON DEMAND RODIUS 2005.07...
  • Page 221 0-14 3240-01 4. CIRCUIT DIAGRAM TORQUE ON DEMAND RODIUS 2005.07...
  • Page 222 The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration. 2. SPECIFICATION PROPELLER SHAFT RODIUS 2005.07...
  • Page 223 1) Front Prepeller Shaft Assembly Bolt Bolt Front propeller shaft assembly Universial joint CV joint 2) Rear Prepeller Shaft Assembly 2nd rear propeller shaft CV joint 1st rear propeller shaft Bolt/was her/nut Universial joint Center bearing assembly Universial joint Bolt PROPELLER SHAFT RODIUS 2005.07...
  • Page 224 4111-01 4410-01 SUSPENSION SYSTEM 1. FRONT SUSPENSION SPECIFICATION SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 225 4111-01 2. REAR SUSPENSION SPECIFICATION SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 226 4111-01 3. STRUCTURE OF SHOCK ABSORBER AND COIL SPRING 1) front coil spring ▶ Specification SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 227 4111-01 2) front shock absorber assembly ▶ Specification SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 228 4111-01 3) rear shock absorber · Keep the suitable distance when compressed and expanded. Minimum length is 10 mm longer than the minimum length under compression. · ▶Specification Marking Point SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 229 4111-01 4) rear coil spring Steel for high tensional spring is adapted. · · Maintain more than 20 mm of freeplay when compressed. Spring seat applied. · ▶ Specification SUSPENSION SYSTEM RODIUS 2005.07...
  • Page 230 4830-01 4830-01 BRAKE SYSTEM 1. SPECIFICATION BRAKS SYSTEM RODIUS 2005.07...
  • Page 231 4830-01 1. COMPONENTS OF BRAKE SYSTEM BRAKS SYSTEM RODIUS 2005.07...
  • Page 232 4830-01 BRAKS SYSTEM RODIUS 2005.07...
  • Page 233 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. BRAKS SYSTEM RODIUS 2005.07...
  • Page 234 (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). BRAKS SYSTEM RODIUS 2005.07...
  • Page 235 <Vehicle with ESP> Brake fluid reservoir tank Master cylinder Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled. After reinstall the reserver tank perform a air bleeding of brake system BRAKS SYSTEM RODIUS 2005.07...
  • Page 236 1) Specifications Of Pressure Sensor 2) Specifications Of Sensor Cluster (sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor) 3) Specifications Of Wheel Speed Sensor 4) Specifications Of Steering Wheel Angle sensor ESP SYSTEM RODIUS 2005.07...
  • Page 237 ESP Warning lamp 4. Sensor cluster: 5. Steering wheel angle 6. ESP off switch (Electronic (Yaw rate + lateral sensor + sensor Stability Program Switch) longitudinal sensor) 2WD vehicle has the longitudinal sensor in the HECU. ESP SYSTEM RODIUS 2005.07...
  • Page 238 4892-01 2. INPUT AND OUTPUT DIAGRAM ESP SYSTEM RODIUS 2005.07...
  • Page 239 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. ESP SYSTEM RODIUS 2005.07...
  • Page 240 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. ESP SYSTEM RODIUS 2005.07...
  • Page 241 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. ESP SYSTEM RODIUS 2005.07...
  • Page 242 (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. ESP SYSTEM RODIUS 2005.07...
  • Page 243 When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver, the vehicle will make abrupt stopping under normal braking situation due to high braking pressure at each wheels. ESP SYSTEM RODIUS 2005.07...
  • Page 244 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. ESP SYSTEM RODIUS 2005.07...
  • Page 245 0-12 4892-01 5) Comparison with ABS System ESP SYSTEM RODIUS 2005.07...
  • Page 246 0-13 4892-01 6) Hydraulic Circuit Diagram ESP SYSTEM RODIUS 2005.07...
  • Page 247 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. ESP SYSTEM RODIUS 2005.07...
  • Page 248 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. ESP SYSTEM RODIUS 2005.07...
  • Page 249 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. ESP SYSTEM RODIUS 2005.07...
  • Page 250 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. ESP SYSTEM RODIUS 2005.07...
  • Page 251 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. ESP SYSTEM RODIUS 2005.07...
  • Page 252 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. ESP SYSTEM RODIUS 2005.07...
  • Page 253 0-20 4892-01 4. ELECTRICAL CIRCUIT DIAGRAM ▶Wheel Speed Sensor, Stop Lamp, Diagnosis, Warnung Lamp (ABS/ESP) ESP SYSTEM RODIUS 2005.07...
  • Page 254 0-21 4892-01 ▶Brake Pressure Sensor, ESP Sensor, Sensor Cluster, ESP OFF Switch ESP SYSTEM RODIUS 2005.07...
  • Page 255 4892-01 4892-01 1. SPECIAL TOOLS AND EQUIPMENT ABS SYSTEM RODIUS 2005.07...
  • Page 256 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: ABS SYSTEM RODIUS 2005.07...
  • Page 257 0 %. Slip can be calculated from the vehicle speed Vveh and the wheel speed Vw. The equation for this is: X 100 % Vveh = 100 km/h, Vw = 70 km/h 100 - 70 X 100 % The slip is 30 %. ABS SYSTEM RODIUS 2005.07...
  • Page 258 ABS cannot be steered. So what use then is the shorter stopping distance if the vehicle has already hit the car in front, because you did not have a chance to steer round the obstacle? ABS SYSTEM RODIUS 2005.07...
  • Page 259 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. ABS SYSTEM RODIUS 2005.07...
  • Page 260 With ABS we remain in the Kamm circle as long as the car is driving sensibly. We will leave driving physics with these statements and turn to the braking systems with and without ABS. ABS SYSTEM RODIUS 2005.07...
  • Page 261 ▶ 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. ABS SYSTEM RODIUS 2005.07...
  • Page 262 Fasteners that are not reused, and those requiring thread-locking compound will be called out. The correct torque values must be used when installing fasteners that require them. If the above procedures are not followed, parts or system damage could result. ABS SYSTEM RODIUS 2005.07...
  • Page 263 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. ABS SYSTEM RODIUS 2005.07...
  • Page 264 (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. ABS SYSTEM RODIUS 2005.07...
  • Page 265 0-13 4892-01 1) System Fuse The ABS/TCS system fuse and SB2 is located fuse engine compartment. 2) Indicators The ABS and TCS indicators are in instrument cluster. ABS SYSTEM RODIUS 2005.07...
  • Page 266 0-14 4892-01 2. INPUT AND OUTPUT DIAGRAM ABS SYSTEM RODIUS 2005.07...
  • Page 267 Vehicle approaches the ideal brake force distribution (front to rear). Constant brake force distribution during vehicle lifetime. EBD function is monitored via ABS safety logic (conventional proportioning valves are not monitorable). “Keep alive” function. ABS SYSTEM RODIUS 2005.07...
  • Page 268 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. ABS SYSTEM RODIUS 2005.07...
  • Page 269 0-17 4892-01 (3) ELECTRICAL CIRCUIT ABS SYSTEM RODIUS 2005.07...
  • Page 270 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. ABS SYSTEM RODIUS 2005.07...
  • Page 271 At this moment, the outlet valve is closed. This procedure helps the wheel to maintain a stable hydraulic pressure. ABS SYSTEM RODIUS 2005.07...
  • Page 272 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. ABS SYSTEM RODIUS 2005.07...
  • Page 273 The cam-shaped output shaft of the motor enables the brake system to receive and supply the brake fluid during the motor operation. ▶ Valve Body The cam bushing is installed between plungers and it draws and discharges the brake fluid. ABS SYSTEM RODIUS 2005.07...
  • Page 274 ECU lower cover) The electrical components are weak to moisture. To protect ECU, GoreTex-based plate is used at ECU lower cover. The vent hall (arrow) allows air to ventilate but does not allow moisture to penetrate. ABS SYSTEM RODIUS 2005.07...
  • Page 275 4610-00 4610-00 POWER STEERING SYSTEM 1. SPECIFICATION POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 276 4610-00 2. TIGHTENING TORQUE 3. SPECIAL TOOLS AND EQUIPMENT POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 277 In this case, the operating force of steering wheel is conveyed to pinion, and the movement of pinion moves the rack through pinion gear combined to rack gear. 5. COMPONENTS POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 278 4610-00 1. COMPONENTS OF POWER STEERING ASSEMBLY POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 279 The control valve controls the directions and operations of power cylinder. Additionally, the safety check valve is installed so that the system can be operated manually when the system is defective. POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 280 The oil reservoir sends the oil to the power steering pump and receives the oil from the power steering gear. The oil level in the reservoir depends on the steering wheel positions. therefore, measure the oil level when the steering wheel is positioned at straight ahead direction (neutral). Steering pump Reservoir tank POWER STEERING SYSTEM RODIUS 2005.07...
  • Page 281 35 psi Front 0 ~ 4 mm Toe-in Rear 0.4° ± 0.08° (5 mm ± 1 mm) Wheel alignment Front 0° ± 30' (0° ± 0.5°) Camber Rear -1° ± 30' (-1° ± 0.5°) Caster 4.5° ± 30' WHEEL RODIUS 2005.07...
  • Page 282 It is a strong rubber coat made of high anti- abrasion rubber. Its running performance depends on is surface profile. Breaker A cord belt between tread and carcass prevents damages of inner code due to outer shock and vibration. WHEEL RODIUS 2005.07...
  • Page 283 Bead A steel wire winding the ending part of carcass code, coated with rubber film and wrapped with nylon cord papers. It fixes tire to a rim. 3) Conventions for Radial Tire WHEEL RODIUS 2005.07...
  • Page 284 4710-09 4) The Relations Between Inflation Pressure and Tire 5) The Relations Between Load and Tire WHEEL RODIUS 2005.07...
  • Page 285 This is so-called hydroplaning. It causes brake failure, lower tractive force and losing the steering performance so it is very vulnerable condition. WHEEL RODIUS 2005.07...
  • Page 286 If the vehicle has too much positive camber, the outside shoulder of the tire will wear. If the vehicle has too much negative camber, the inside shoulder of the tire will wear. Camber is measured in degrees and is not adjustable. WHEEL RODIUS 2005.07...
  • Page 287 One wheel with more positive caster will pull toward the center of the car. This condition will cause the car to move or lean toward the side with the least amount of positive caster. Caster is measures in degrees and is not adjustable. WHEEL RODIUS 2005.07...
  • Page 288 ELECTRIC GENERAL ELECTRIC GENERAL ELECTRIC GENERAL ELECTRIC GENERAL 0000-00 ELECTRIC GENERAL GENERAL 1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT..2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT (EXCEPT ENGINE RELATED SENSORS AND UNITS)........... 3. SWITCHES IN PASSENGER COMPARTMENT........4.

  • Page 291: Locations Of Units And Sensors In Passenger Compartment

    0000-00 0000-00 ELECTRIC GENERAL 1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT ELECTRIC GENERAL RODIUS 2005.07...
  • Page 292 0000-00 ELECTRIC GENERAL RODIUS 2005.07...

  • Page 293: Switches, Units And Sensors In Engine Compartment (Except Engine Related Sensors And Units)

    0000-00 2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT (EXCEPT ENGINE RELATED SENSORS AND UNITS) ELECTRIC GENERAL RODIUS 2005.07...
  • Page 294 0000-00 ELECTRIC GENERAL RODIUS 2005.07...

  • Page 295: Switches In Passenger Compartment

    0000-00 3. SWITCHES IN PASSENGER COMPARTMENT Audio remote control switch on the steering wheel ELECTRIC GENERAL RODIUS 2005.07...
  • Page 296 0000-00 ELECTRIC GENERAL RODIUS 2005.07...

  • Page 297: System Layout (Based On Dvd System Equipped Vehicle)

    0-10 0000-00 4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED VEHICLE) ELECTRIC GENERAL RODIUS 2005.07...
  • Page 298 0-11 0000-00 ELECTRIC GENERAL RODIUS 2005.07...

  • Page 299: Wiring Harness Arrangement

    0-12 0000-00 5. WIRING HARNESS ARRANGEMENT ELECTRIC GENERAL RODIUS 2005.07...

  • Page 300: Components Locator

    0-13 0000-00 6. COMPONENTS LOCATOR ELECTRIC GENERAL RODIUS 2005.07...
  • Page 301 Especially, ICM box, an integrated circuit of relays, is mounted along with STICS behind the driver side instrument panel. Connector arrangement Back of the fuse and relay box (after removal) Fuses and relays FUSE AND RELAY RODIUS 2005.07...
  • Page 302 01-4 8410-05 1) Arrangement of Fuses and Relays 2) Descriptions of Fuses and Relays FUSE AND RELAY RODIUS 2005.07...
  • Page 303 2. INTERIOR FUSE COMPARTMENT · The interior fuse box is located in the lower area of driver side instrument panel. · To check the fuses, open the driver side door and remove the fuse box cover. FUSE AND RELAY RODIUS 2005.07...
  • Page 304 Relays in the ICM box cannot be replaced respectively; so when the internal components (including relay) are defective, ICM box should be replaced as an assembly. RK STICS ICM box FUSE AND RELAY RODIUS 2005.07...
  • Page 305 The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled. The relays cannot be disassembled and replaced respectively; so the ICM box should be replaced as an assembly when any internal components are defective. (1) Front view FUSE AND RELAY RODIUS 2005.07...
  • Page 306 01-8 8410-05 (2) Rear view FUSE AND RELAY RODIUS 2005.07...
  • Page 307 01-9 8410-05 4. WIRING HARNESS, CONNECTOR & GROUND LOCATION 1) W/H Engine room FUSE AND RELAY RODIUS 2005.07...
  • Page 308 01-10 8410-05 2) W/H Main FUSE AND RELAY RODIUS 2005.07...
  • Page 309 01-11 8410-05 3) W/H Floor (LH) FUSE AND RELAY RODIUS 2005.07...
  • Page 310 01-12 8410-05 4) W/H Floor (RH) FUSE AND RELAY RODIUS 2005.07...
  • Page 311 01-13 8410-05 5) W/H Air-con (1) Front air-con FUSE AND RELAY RODIUS 2005.07...
  • Page 312 01-14 8410-05 (2) Rear air-con FUSE AND RELAY RODIUS 2005.07...
  • Page 313 01-15 8410-05 6) W/H Door (1) Front door (2) Front door (3) Tailgate door FUSE AND RELAY RODIUS 2005.07...
  • Page 314 01-16 8410-05 7) W/H Roof FUSE AND RELAY RODIUS 2005.07...
  • Page 315 01-17 8410-05 8) W/H Seat Driver’s Passenger’s FUSE AND RELAY RODIUS 2005.07...
  • Page 316 If not indicated, time tolerance will be ± 10%. However, if less than 500 ms, time tolerance will be ± 50 ms. The time indicated in each function does not include chattering processing time from switch input changing point. STICS RODIUS 2005.07...
  • Page 317 8710-01 4) Input Signals Of Rk Stics STICS RODIUS 2005.07...
  • Page 318 Theft deterrent horn ICM module REKES Installed under the battery. This This module contains horn works only for the theft various relays, chime and deterrent function, panic buzzer controlled Added escort function, and remote starting. STICS panic function STICS RODIUS 2005.07...
  • Page 319 8710-01 2. DESCRIPTIONS Below table shows the major differences compared to the previous vehicle model before year 2004. For whole functions and details, refer to corresponding section. STICS RODIUS 2005.07...
  • Page 320 The wiper relay is turned on 0.3 seconds (T1) after turning “ON” the washer switch over 0.6 seconds (T2) with the ignition key “ON”, and it is turned on three times immediately after turning off the washer switch. STICS RODIUS 2005.07...
  • Page 321 If the washer operating signal is inputted while the wipers are operating in intermittent or AUTO mode, the system stores the previous intermittent interval and operates the washer coupled wiper. After then, the wiper operation returns back to intermittent or AUTO mode with the stored operating interval. STICS RODIUS 2005.07...
  • Page 322 LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly. For more details, refer to rain sensing wiper section in this manual. STICS RODIUS 2005.07...
  • Page 323 “AUTO” position, and the wiper motor is in “Parked” position). However, the wiper motor can be operated only when the rain sensor detects the “Rain Detected” signal. * If the volume sensitivity is changed more than 2 stages within 2 seconds, the wiper motor runs only one cycle. STICS RODIUS 2005.07...
  • Page 324 When the parking terminal is fixed to IGN (HIGH), the wiper system outputs the operating signal of current sensitivity for 2 seconds, then continuously outputs the parking signal of current sensitivity The wiper motor runs only when the rain sensor requires. STICS RODIUS 2005.07...
  • Page 325 The wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal (2) from the rain sensor (while the ignition key is in “ON” position and the wiper switch is in “AUTO” position). STICS RODIUS 2005.07...
  • Page 326 Also, the wiper relay (LO) is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain sensor. STICS RODIUS 2005.07...
  • Page 327 The pause time is calculated by the vehicle speed and VOLUME value as shown in the table in next page. · If the pause time is below 1.0 second, the wipers operate without pause. · If the pause time is over 1.5 seconds, the wipers operate intermittently. STICS RODIUS 2005.07...
  • Page 328 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is “ON” (INT switch = ON or Washer switch = ON) (The output stops immediately after turning off the switch) STICS RODIUS 2005.07...
  • Page 329 (T1) (while the ignition key is in ignition switch). Operating conditions for (*1) and (*2) (*1): Driver’s door is opened and driver’s door lock switch is turned to LOCK (*2): Passenger’s door is opened and passenger’s door lock switch is turned to LOCK STICS RODIUS 2005.07...
  • Page 330 5 seconds (T1) when the “LOCK” signal is inputted (while the ignition key is removed and a of door is opened). When the door is closed during unlock output for 5 seconds, the unlock output stops. STICS RODIUS 2005.07...
  • Page 331 The system outputs “UNLOCK” for 5 seconds when the driver’s and passenger’s door lock switch is locked (while the tail lamp is turned on and the driver’s door is opened). This function is not available when the ignition key is in “ON” position. STICS RODIUS 2005.07...
  • Page 332 The warning light blinks when a door is opened while the vehicle speed is over 10 km/h (V1) (while the warning light is turned off). The warning light goes off when closing the door under step 3. The warning light comes on when the vehicle speed is below 3 km/h (V2) under step 3. STICS RODIUS 2005.07...
  • Page 333 The chime buzzer stops and the seat belt warning light stays on for the specified duration (6 seconds) when fastening the seat belt during the warning operation. The seat belt warning light comes on and the chime buzzer sounds for 6 seconds again when unfastening the seat belt during fastening operation. STICS RODIUS 2005.07...
  • Page 334 The warning light comes on and the chime buzzer stops when the vehicle speed goes down below 7 km/h (V2) under step 4. This function is not available when the ignition key is turned to “OFF” position. STICS RODIUS 2005.07...
  • Page 335 When a door is opened during its extended period, the lamp stays on. If closed, operates as in step 2. The room lamp output stops immediately after receiving the lock signal from driver’s door and passenger’s door lock switch while the driver’s door and passenger’s door are closed. STICS RODIUS 2005.07...
  • Page 336 The room lamp output stops immediately after Door coupled front receiving the lock signal from the rear door lock room lamp switch switch or the remote control key while the rear door is closed. STICS RODIUS 2005.07...
  • Page 337 The ignition key hole illumination stays on for 10 seconds when closing the door after step 1. The output stops when the ignition key is turned to “ON” position. The output stops when receiving the lock signal from the remote control key (under armed mode). STICS RODIUS 2005.07...
  • Page 338 Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation. The tail lamp relay is turned off (auto cut) when opening and closing the driver’s door while the ignition key is removed and the tail lamp is turned on. STICS RODIUS 2005.07...
  • Page 339 When turning on the defogger switch again within 10 minutes (T2) after completion of initial 12 minutes (T1) of output, the output comes on for 6 minutes (T3) again once only. The output stops when the IGN 2 switch is turned to “OFF” position or the ALT is “OFF”. STICS RODIUS 2005.07...
  • Page 340 This vehicle has the windshield heated glass and the tailgate and outside rearview mirror heated glass. The heater relay in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse (15A) is located in the engine compartment fuse box. Defogger switch STICS RODIUS 2005.07...
  • Page 341 “LOCK” signal within 0.5 seconds (T3) after closing the driver’s or passenger’s door. However, this operation is regardless of the ignition key positions. This function prevents the door from locking by shock when slamming a door while the ignition key is inserted into the key switch hole. STICS RODIUS 2005.07...
  • Page 342 The door lock system outputs “UNLOCK” for 0.5 seconds (T2) when pressing “UNLOCK” button on the central door lock switch. The “LOCK” or “UNLOCK” inputs from the central door lock switch in armed mode are ignored. STICS RODIUS 2005.07...
  • Page 343 The door lock system outputs “LOCK” for 0.5 seconds (T2) when receiving “LOCK” signal from the remote control key. The door lock system outputs “UNLOCK” signal for 0.5 seconds (T3) when receiving “UNLOCK” signal from the remote control key. STICS RODIUS 2005.07...
  • Page 344 “Lock” output while the vehicle speed stays over 50 km/h under lock condition). However, when the ignition key is turned to “OFF” position, the lock output conditions will be cancelled. The “FAIL” condition of the door will be erased when the ignition key is turned to “OFF” position. STICS RODIUS 2005.07...
  • Page 345 Even though the “LOCK/UNLOCK” output is requested, the door lock system cannot output “LOCK/UNLOCK” when all door lock switches are locked/unlocked. Also, even though the “UNLOCK” output for the driver’s door is requested, the door lock system cannot output “UNLOCK” when the driver’s door is unlocked. STICS RODIUS 2005.07...
  • Page 346 90 seconds (T2) just for once when opening the door during its extended operation period of 90 seconds (T1). The power window relay is turned “OFF” when closing the door during its extended operation period of 90 seconds (T2). STICS RODIUS 2005.07...
  • Page 347 Door lock button Door unlock Door locking and theft deterrent Unlocking all doors and tailgate armed mode Press door lock button to release. Panic button: Operates under the theft deterrent armed mode. Theft deterrent horn: Sounds approx. 27 seconds. STICS RODIUS 2005.07...
  • Page 348 0-35 8710-01 ▶ Dual - REKES Coding Connect the SCAN-Tool the diagnostic connector as shown in the figure blow and perform the coding operation. (when replaced REKES transmitter and receiver) Diagnosis connector STICS RODIUS 2005.07...
  • Page 349 0-36 8710-01 STICS RODIUS 2005.07...
  • Page 350 Press [YES] button to start the second REKES key coding. Turn off SCAN-100 and remove it from the diagnostic connector. Check if the remote controllers are functioning properly. If the remote controllers are not properly working, perform the REKES coding process again. STICS RODIUS 2005.07...
  • Page 351 (RELOCK operation). Also, at this moment, the system outputs the theft deterrent horn and hazard warning flasher. The armed mode will not be activated except above conditions. Ex) The armed mode will not be activated when the door is locked by the ignition key. STICS RODIUS 2005.07...
  • Page 352 START, STOP, PANIC, CHECK) during warning operation. Cancels warning after 27 seconds (remaining period) while the ignition key is turned to “ON” position. ▶ Operation when warning is cancelled The theft deterrent horn and hazard warning flasher outputs are “OFF”. STICS RODIUS 2005.07...
  • Page 353 Armed Ready / Armed / Warning Completion / Relock Ready mode (maintaining the theft deterrent mode). This function operates only in armed mode. The system sends the current vehicle conditions (LOCK, engine running) when the PANIC warning is turned off by the remote control key. STICS RODIUS 2005.07...
  • Page 354 0-41 8710-01 16) Auto Light Function The lights automatically come on and off according to the ambient brightness when the multifunction light switch is in “AUTO” position while the ignition key is in “ON” position. STICS RODIUS 2005.07...
  • Page 355 The instrument panel in this vehicle is different from conventional type of instrument panel. The meter cluster and indicator display are separated. The meter cluster is located at the center of the dash panel, and the indicator display is located in front of driver’s seat. Meter cluster Warning lamps and indicators CLUSTER RODIUS 2005.07...
  • Page 356 9. Cruise control indicator* 22. Water separator warning light 10. 4WD CHECK warning light 23. ABS warning light 11. 4WD HIGH indicator 24. EBD warning light 12. 4WD LOW indicator 25. ESP warning light 13. Brake warning light CLUSTER RODIUS 2005.07...
  • Page 358 8010-10 3. WARNING & INDICATOR PANEL CLUSTER RODIUS 2005.07...
  • Page 359 8010-10 CLUSTER RODIUS 2005.07...
  • Page 360 If the tachometer pointer vibrates, stands at a certain range or sounds abnormal noise, there could be defectives in tachometer. If there is a difference between actual engine speed (rpm) and reading from tachometer, connect a scanner and then compare the value on tachometer with the reading from scanner. CLUSTER RODIUS 2005.07...
  • Page 361 Check if the speedometer pointer is shaking and the abnormal noise sounds. Eliminate the hysteresis by tapping the speedometer. The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range. CLUSTER RODIUS 2005.07...
  • Page 362 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. CLUSTER RODIUS 2005.07...
  • Page 363 100°C : 112 Ω ±5 % When the resistance value by coolant temperature is within the specified range, check thermostat, water pump, radiator related coolant circuit for normal operation. Also, check the wiring harnesses and connectors for proper connection. CLUSTER RODIUS 2005.07...
  • Page 364 A” and “TRIP B” will be reset to 0. (However, only the corresponding driving range will be set to 0.) Press shortly (between 0.1 ~ 1 sec.) The mode changes in order as shown in the figure. CLUSTER RODIUS 2005.07...
  • Page 365 0-13 8010-10 5. CIRCUIT DIAGRAM OF INDICATOR DISPLAY CLUSTER RODIUS 2005.07...
  • Page 366 8310-01 8310-01 LAMP 1. COMPONENTS OF EXTERIOR LAMPS LAMP RODIUS 2005.07...
  • Page 367 8310-01 2. COMPONENTS OF INTERIOR LAMPS LAMP RODIUS 2005.07...
  • Page 368 8310-01 1. LOCATIONS OF EXTERIOR LAMPS 1) Front Lamps LAMP RODIUS 2005.07...
  • Page 369 8310-01 2) Rear Lamps LAMP RODIUS 2005.07...
  • Page 371 Four rear room lamps are turned on when opening a rear door with this switch pressed Center console lamp is turned on when in. The rear room lamps are turned off when opening a door. closing the door. LAMP RODIUS 2005.07...
  • Page 372 : one at center (12V - 5W) 6. Door courtesy lamp : one at each door (12V - 5W) Door courtesy lamp is turned on when opening a door while the ignition switch is in “ON” position. LAMP RODIUS 2005.07...
  • Page 373 No.2 adjustment: No.3 adjustment: No.4 adjustment: Direction A - Up Direction C - Left Direction E - Up Direction G - Left Direction B - Down Direction D - Right Direction F - Down Direction H - Right LAMP RODIUS 2005.07...
  • Page 374 ▶When using a beam setting device Align the vehicle and beam setting device according to the operating instructions provided by the manufacturer. Adjust the headlamp aiming by rotating the direction control levers (Up, Down, Left, Right) in turn with a screwdriver. LAMP RODIUS 2005.07...
  • Page 375 At this moment, the focus of the headlamp should aim the “A” point. If the focus deviates the “A” point, adjust the headlamp aiming by rotating control levers (Up, Down, Left, Right) in turn with a screwdriver. LAMP RODIUS 2005.07...
  • Page 376 0-13 8310-01 (2) Fog Lamp Aiming Adjustment LAMP RODIUS 2005.07...
  • Page 377 (2) pressed in. The lamps are dimmed out after closing the door. Rear and luggage room lamps are turned on only when the side room lamp coupled switch is pressed in. LAMP RODIUS 2005.07...
  • Page 378 8510-01 8510-01 SWITCH 1. INTERIOR SWITCH COMPARTMENT SWITCH RODIUS 2005.07...
  • Page 379 8510-01 SWITCH RODIUS 2005.07...
  • Page 380 FAST <-------> SLOW section(rain sensor mounting section on the : Auto delay/Auto speed control. A position windshield)with photodiode. that can control sensitivity against rains on the windshield and transmits wiping demand signal accordingly. RAIN SENSOR RODIUS 2005.07...
  • Page 381 At this moment, STICS determines the wiper operation mode (washer, MIST, AUTO), then sends the information to the rain sensor. ICM box The wiper related relays are installed in ICM box. Relay6 (Wiper High) Relay5 (Wiper INT-Low) RAIN SENSOR RODIUS 2005.07...
  • Page 382 Housing and receiver lens Receiver lens The receiver lens guides the reflected infrared rays from Housing and PCB windshield to photodiode. RAIN SENSOR RODIUS 2005.07...
  • Page 383 8610-11 3. OPERATION MODE OF RAIN SENSING WIPER SYSTEM RAIN SENSOR RODIUS 2005.07...
  • Page 384 When the variable resistance knob on the multifunction wiper switch is turned by each 1 stage from low sensitivity (Smark) to high sensitivity (F mark), the wiper operates one cycle. And, the wiper also operates during raining up to 5 minutes after rain stops. RAIN SENSOR RODIUS 2005.07...
  • Page 385 ▶Poor sensor Rotate the variable resistance knob toward “SLOW” by 2 more steps. At this moment, check if the wiper operates one cycle. The wiper operates when the sensor is defective. RAIN SENSOR RODIUS 2005.07...
  • Page 386 8610-11 5. DIAGNOSIS PROCEDURES RAIN SENSOR RODIUS 2005.07...
  • Page 387 No.2 terminal sends the wiper and washer operation information such as washer operation mode, MIST mode, or AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode. RAIN SENSOR RODIUS 2005.07...
  • Page 388 0000-00 7810-01 WIPER/WASHER SYSTEM 1. SPECIFICATIONS OF WIPER WIPER/WASHER SYSTEM RODIUS 2005.07...
  • Page 389 0000-00 1. SYSTEM LAYOUT OF WIPER AND WASHER Front wiper and washer assembly Rear wiper and washer assembly WIPER/WASHER SYSTEM RODIUS 2005.07...
  • Page 390 0000-00 2. COMPONENTS LOCATOR OF FRONT WIPER ASSEMBLY Wiper blade Wiper linkage Wiper motor WIPER/WASHER SYSTEM RODIUS 2005.07...
  • Page 391 0000-00 3. COMPONETS LOCATOR OF REAR WIPER ASSEMBLY Wiper blade assembly Rear wiper motor Rear wiper assembly WIPER/WASHER SYSTEM RODIUS 2005.07...
  • Page 392 0000-00 4. CIRCUIT DIAGRAM OF WIPER & WASHER WIPER/WASHER SYSTEM RODIUS 2005.07...
  • Page 393 - Detecting range (13.5 V) * Horizontal: Min. 20° at 110 ± 5 cm Min. 100° at 50 ± 5 cm * Vertical: Min. 20° at 110 ± 5 cm Min. 60° at 50 ± 5 cm PARKING AID SYSTEM RODIUS 2005.07...
  • Page 394 When selecting R position while A/V system is not in use: Both monitors are automatically turned on to display rearview. Both monitors are automatically turned off when shifting out from “R” position. Grear selector lever Applies power to parking aid system PARKING AID SYSTEM RODIUS 2005.07...
  • Page 395 The rearview camera sends the rearview to the monitor by using wide angle lens. PAS unit It is a control unit for the parking aid system (PAS) and transmits the signals from sensors to multimeter and buzzer.(installed in tuner/amplifier bracket) PARKING AID SYSTEM RODIUS 2005.07...
  • Page 396 1) parking AID SYSTEM COMPOSITION Multi-meter Rear center obstacles Rear right obstacles Rear left obstacles Rear left sensor Rear right sensor Rear center sensor The inside of the ICM BOX The outside of the ICM BOX Parking aid buzzer PARKING AID SYSTEM RODIUS 2005.07...
  • Page 397 The message on MULTI-METER Right sensor Left sensor Center sensor This unit controls the parking aid system. One of 3 LEDs comes on when the corresponding parking aid sensor is defective and shows below message on multi-meter. PARKING AID SYSTEM RODIUS 2005.07...
  • Page 398 (conditions for warning beep due to failure) (a) Open in sending circuit (b) Open in receiving circuit (c) Open in power circuit (+, -) Back sonar (RH) Back sonar (LH) Back sonar (center) ▶Warning beeps PARKING AID SYSTEM RODIUS 2005.07...
  • Page 399 - When the sensing portion is covered by rain, water drops, snow or mud. - When receiving other ultrasonic signals (metal sound or air braking noises from heavy commercial vehicles). - When a high-power radio is turned on. - When some accessories are attached in detecting ranges PARKING AID SYSTEM RODIUS 2005.07...
  • Page 400 0-10 8790-04 4. PARKING AID SYSTEM CONTROL 1) Parking Aid Unit 2) Parking Aid Sensor PARKING AID SYSTEM RODIUS 2005.07...
  • Page 401 The real distance is different from what you see in monitor because the camera uses wide-angle lens. Note that the display does not show everything in the rear area. Keep the camera lens clean with a lens cleaner. PARKING AID SYSTEM RODIUS 2005.07...
  • Page 402 The real distance is different from what you see in monitor because the camera uses wide- angle lens. Note that the display does not show everything in the rear area. Keep the camera lens clean with a lens cleaner. PARKING AID SYSTEM RODIUS 2005.07...
  • Page 403 The AV unit receives the power from battery and if it receives the reverse signal, supplies the power to rearview camera. When the rearview camera operates, it transmits color video signal to the A/V unit then the rearview is displayed on the monitor. PARKING AID SYSTEM RODIUS 2005.07...
  • Page 404 0-14 8790-04 7. CIRCUIT DIAGRAM PARKING AID SYSTEM RODIUS 2005.07...
  • Page 405 DVD head unit and can play audio CD, video CD, MP3 CD and DVD CD. Followings are AV systems and will be described based on the vehicle equipped with DVD system. AV SYSTEM RODIUS 2005.07...
  • Page 406 8930-08 2. AV SYSTEM BY VEHICLE MODEL 1-DIN head unit and 2-DIN head unit DVD head unit + Navigation equipped with CD player + DVD changer AV SYSTEM RODIUS 2005.07...
  • Page 407 8930-01 3. SPECIFICATIONS OF AV HEAD UNIT AV SYSTEM RODIUS 2005.07...
  • Page 408 8930-08 1. SYSTEM LAYOUT (BASED ON DVD EQUIPPED SYSTEM) Subwoofer with built-in amplifier AV SYSTEM RODIUS 2005.07...
  • Page 409 8930-01 AV SYSTEM RODIUS 2005.07...
  • Page 410 8930-01 2. DVD SYSTEM SIGNALS AND DATA PROCESSING AV SYSTEM RODIUS 2005.07...
  • Page 411 8930-01 AV SYSTEM RODIUS 2005.07...
  • Page 412 6810-20 6910-20 AIR CONDITIONING SYSTEM 1. FFH SPECIFICATION AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 413 6810-20 2. SYSTEM LAYOUT AND COMPONENTS Front air conditioner module assembly - inside instrument panel AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 414 6810-20 Rear air conditioner module assembly - bottom of rear left AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 415 FFH system operates up to more than 2 minutes to burn the residual fuel inside the system when driver stop the engine during its operation. Therefore, a certain period of FFH operation after stopping the engine is not a malfunction. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 416 6810-20 4. COMPONENTS AND LOCATIONS AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 417 6810-20 1. VENTILATION SYSTEM COMPONENTS 1) Locations of Vents ▶ Front Ventilation ▶ Rear ventilation AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 418 6810-20 2) Ventilation Modes Vent mode Bi-level mode Floor mode Defrost and floor mode Defrost mode Rear air conditioning mode AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 419 0-10 6810-20 2. AIR CONDITIONER MODULE WIRING AND LAYOUT 1) Front Air Conditioner Module Wiring layout Components Air conditioner filter Evaporator Air source selection door actuator Blower motor Blower high speed relay Heater core AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 420 0-11 6810-20 2) Rear Air Conditioner Module Wiring layout Components Roof air conditioner duct Blower motor Air mixer door actuator Rear floor heater duct Mixer door Evaporator Heater & air conditioner pipes Heater core AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 421 0-12 6810-20 3. AIR CONDITIONER AND HEATER PIPE LAYOUT AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 422 Measure the voltage to the sun sensor from FATC connector. (approx. 2.5 V under sunlight and 4.8 V under shade.) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 423 FATC controller. ▶ Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 424 FATC controller connector. (standard: approx. 2 V at 25°C) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 425 However, if the voltage is not changed, replace the humidity sensor. In addition, if the output voltage is extremely high or low even in the specified range, replace the humidity sensor. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 426 (fresh air), and air source LED ON (recirculation). The figure shows that the mode has been changed to the recirculation mode from fresh air mode under AQS mode (AQS LED ON) after detecting the polluted outside air. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 427 AQS switch is turned on and the AQS function is activated. When the polluted outside air is detected, the AQS operates and converts the air source to recirculation mode automatically. At this moment, the recirculation mode indicator comes on in the display. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 428 The air source is not changed when pressing the AQS and air source selection switch in “AUTO” mode. To change the air source to recirculation mode in AUTO mode, get into Manual mode first, then press the air source selection switch. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 429 FATC controller connector. (standard: approx. 2 V at 25°C) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 430 FATC controller connector. (standard: approx. 2 V at 25°C) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 431 Measure the voltage between terminals while changing the fan speed from stage 1 to stage The specified voltage value in each stage: If the voltage is out of specified value, check the circuit for open. If the circuit is in normal condition, replace the power transistor. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 432 FLOOR and DEF mode to change the air flow directions according to FATC controller. Under the FATC controller AUTO mode, it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 433 Connect the positive (+) and negative (-) cables of temporary power supply to the door mode actuator. And, connect the negative cable to each terminal (P1 through P5) to check its operation. (If it operates as shown in above figure, it is normal.) AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 434 0-25 6810-20 4) Air Door Actuator The air door actuator sets the intake door mode according to the control signals from FATC. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 435 And, connect the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output. Air source Mode Bc resistance Fresh air P1 (-), P2 (+) below 300 Ω Recirculation P1 (+), P2 (-) over 2.4 kΩ AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 436 0-27 6810-20 5) Air Mix Door Actuator The air mix door actuator controls the discharging air temperature properly by closing/opening the damper according to the control signals from FATC. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 437 Connect the positive (+) and negative (-) cables of temporary power supply to the air mix door actuator. And, connect the cable to each terminal (P1 and P2) in turn to check the motor operation and terminal output. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 438 And measure the voltage between terminal A12 and A11 on the FATC controller connector. (standard: approx. 12 V) If the voltage value cannot be measured, check the circuit for open. If the measured value is within the specified range, replace the FATC controller. AIR CONDITIONING SYSTEM RODIUS 2005.07...
  • Page 439 8810-01 8810-01 AIR BAG SYSTEM 1. AIRBAG OVERVIEW Height adjuster (Driver/passenger) Passenger’s airbag Passenger’s Airbag unit (SDM) Driver’s Front seat Driver’s airbag AIR BAG SYSTEM RODIUS 2005.07...
  • Page 440 8810-01 Pretensioner Retractor AIR BAG SYSTEM RODIUS 2005.07...
  • Page 441 8810-01 1. COMPONENTS OF DRIVER'S AIRBAG MODULE AIR BAG SYSTEM RODIUS 2005.07...
  • Page 442 8810-01 2. COMPONENTS OF PASSENGER'S AIRBAG MODULE AIR BAG SYSTEM RODIUS 2005.07...
  • Page 443 (The airbag reaction is absorbed generally to the steering wheel or instrument panel). The module cover must be considered in a viewpoint of protection between exterior, · internal units and cushion. Also the module cover should be designed not to cause any personal injury for deployment. AIR BAG SYSTEM RODIUS 2005.07...
  • Page 444 Self-diagnosis function Illuminate the AIRBAG indicator to alert the driver to any fault. · Power supply function Provide a reserve power source to deploy the airbags and · pretensioners if an accident has disabled the normal power source. AIR BAG SYSTEM RODIUS 2005.07...
  • Page 445 The safety sensor is safety device made up of a dualcontact, electro-mechanical switch that: Acts independently of the electronic components. Connects the acceleration sensor in series in order to make up for the weak points in the current electronic sensor. AIR BAG SYSTEM RODIUS 2005.07...
  • Page 446 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 SYSTEM RODIUS 2005.07...
  • Page 447 The shorting bar is only a backup safety device. Always disable the supplemental restraints system (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 SYSTEM RODIUS 2005.07...
  • Page 448 The vehicle falls into a drainage or a puddle · 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 SYSTEM RODIUS 2005.07...
  • Page 449 7410-01 7410-01 SEAT 1. SEAT OVERVIEW Front seat belt Passenger’s Driver’s Front seat Fixed type buckle Belt type buckle SEAT RODIUS 2005.07...
  • Page 450 7410-01 Swivel seat (Rear 1st seat) Rear 1st seat Rear 2nd seat Rear 3rd seat Rear 1st seat Rear 2nd seat Rear 3rd seat SEAT RODIUS 2005.07...
  • Page 451 7410-01 1. COMPONENTS OF SEAT Seat control switch Sliding control Seat position control Seat height control Reclining control Sliding adjust lever Seat warmer switch Back supporter Back flat adjust lever (Driver’s seat) SEAT RODIUS 2005.07...
  • Page 452 7410-01 Head rest Back folding adjust lever Rear 3rd seat back folding adjust lever Seat sliding adjust lever Seat swivel control lever SEAT RODIUS 2005.07...
  • Page 453 2. COMPONENTS OF SEAT BELT 1) 11 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point + 2 point) ▶ Rear 2nd row (3 point + 2 point) ▶ Rear 3rd row (3 point + 2 point) SEAT RODIUS 2005.07...
  • Page 454 7410-01 2) 9 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point) ▶ Rear 2nd row (3 point) ▶ Rear 3rd row (3 point + 2 point) SEAT RODIUS 2005.07...
  • Page 455 7410-01 3) 7 Passengers ▶ Front Seat Belt (3 point) ▶ Rear 1st row (3 point) ▶ Rear 2nd row (3 point + 2 point) SEAT RODIUS 2005.07...
  • Page 456 3. SEAT LAYOUT 1) Layout - 11 Passengers Front seat : Move 36 mm from the far end to the front · Rear 1st seat : Movable · Rear 2nd seat: Movable · Rear 3rd seat : Fixed · SEAT RODIUS 2005.07...
  • Page 457 7410-01 2) Layout - 9 Passengers Front seat : Move 36 mm from the far end to the front · · Rear 1st seat : Movable Rear 2nd seat: Movable · Rear 3rd seat : Fixed · SEAT RODIUS 2005.07...
  • Page 458 0-11 7410-01 3) Layout - 7 Passengers SEAT RODIUS 2005.07...
  • Page 459 Rear 1st seat : Move to the far · front Remove head rest Back full flat Rear 2nd seat: Move to the far · end Back semi full flat Rear 3rd seat : Fixed · SEAT RODIUS 2005.07...
  • Page 460 ▶ Rear 1st swiveled and rear 2nd seat back folding while driving Rear 1st seat : Move to the far end · Center seat jumping Swiveled Rear 2nd seat: Move to the far end · Back folding · Rear 3rd seat : Fixed SEAT RODIUS 2005.07...
  • Page 461 ▶ 8 passengers with loading ? Front seat : Move 36 mm from the · far end to the front ? Rear 1st seat : Middle · ? Rear 2nd seat: Middle · ? Rear 3rd seat : Double folding · SEAT RODIUS 2005.07...
  • Page 462 Front seat : Move to the far end / · Back folding · Rear 1st seat : Middle / Back folding Rear 2nd seat: Middle / Back folding · Rear 3rd seat : Middle / Back folding · SEAT RODIUS 2005.07...
  • Page 463 0-16 7410-01 5) Entry Way Rear 1st seat : Folding center seat Rear 2nd seat : Folding center seat Rear 3rd seat : Fixed SEAT RODIUS 2005.07...
  • Page 464 0-17 7410-01 6) Sliding of Rear 1st and 2nd Seat - 4 rail (1.610mm) for rear 1st and 2nd seat sliding - Rail mounting : Floor bolt type SEAT RODIUS 2005.07...
  • Page 465 0-18 7410-01 4. OPERATION OF FRONT SEAT(DRIVER'S SEAT) 1) Components Seat warmer connector Seat position (up/down Seat position motor) (front up/down rail) Seat position (up/down rail) Sliding rail Seat position (rear up/down motor) Sliding motor Reclining motor SEAT RODIUS 2005.07...
  • Page 466 Seat position (front up/down) · Front side of seat moves up/down controlled by seat position control switch · Seat position (rear up/down) Rear side of seat moves up/down controlled by seat position control switch SEAT RODIUS 2005.07...
  • Page 467 0-20 7410-01 · Seat height (up/down) Seat moves up/down controlled by seat height control switch Seat reclining motor · Reclining Seat back reclining controlled by seat reclining control switch SEAT RODIUS 2005.07...
  • Page 468 1) If the power supply has no problem, remove the seat. 2) Check the motor and wiring if damaged. 3) Connect the battery to the seat connector. 4) Control the seat switch and check the opration. - Electrical parts are not supplied by a part separately. SEAT RODIUS 2005.07...
  • Page 469 - Pull up the center seat when to jump - Push down the center seat when to seat 5) Removal and installation of center seat (jumping seat) - Unscrew 4 mounting nuts to remove the center seat SEAT RODIUS 2005.07...
  • Page 470 0-23 7410-01 5. OPERATION OF REAR SEAT 1) Rear 1st seat (swivel seat) Seat back folding cable Seat back flat cable Jumping mechanism Sliding cable Sliding lever Swivel lever SEAT RODIUS 2005.07...
  • Page 471 0-24 7410-01 2) Operation of rear seat (Rear 1st and 2nd seat) Seat sliding Front Rear SEAT RODIUS 2005.07...
  • Page 472 -When to recline or to flat fully. Rear 1st Rear 2nd 4) Seat back folding - Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table. Rear 1st/2nd seat SEAT RODIUS 2005.07...
  • Page 473 - Pull the lever behind back seat to fold the back seat. - Pull the lever under back seat to fold up the seat - As the seat is folded, disconnect hook and spread out the board SEAT RODIUS 2005.07...
  • Page 474 7340-01 7340-01 SUN ROOF 1. SUNROOF LAYOUT SUNROOF RODIUS 2005.07...
  • Page 475 7340-01 2. COMPONENTS OF SUNROOF SUNROOF RODIUS 2005.07...
  • Page 476 7340-01 3. COMPONENTS AND LOCATIONS Drain hose Control switch Sun shade & glass Control unit Sun roof motor SUNROOF RODIUS 2005.07...
  • Page 477 Push the rear side of the button to put down the glass. Motor actuates the operating cable Mechanical equipment lifts up & down the glass SUNROOF RODIUS 2005.07...
  • Page 478 7340-01 2) Sliding push the rear side of the button to slide the door back. Motor actuates the operating cable Mechanical equipment slides the glass back and forth SUNROOF RODIUS 2005.07...
  • Page 479 NO DATA...
  • Page 480 06-3 7115-01 7115-01 BODY EXTERIOR 1. COMPONENTS AND LOCATION OF EXTERIOR BODY EXTERIOR RODIUS 2005.07...
  • Page 481 06-4 7115-01 BODY EXTERIOR RODIUS 2005.07...
  • Page 482 06-5 7115-01 1. DOOR SYSTEM 1) LAYOUT - FRONT DOOR BODY EXTERIOR RODIUS 2005.07...
  • Page 483 06-6 7115-01 BODY EXTERIOR RODIUS 2005.07...
  • Page 484 06-7 7115-01 2) LAYOUT - REAR DOOR BODY EXTERIOR RODIUS 2005.07...
  • Page 485 (1) Operating Process Power window motor (1) which is controlled by the window switch draws up and down the window regulator (2) and operating cable. The window glass move up and down with the window regulator. BODY EXTERIOR RODIUS 2005.07...
  • Page 486 (1) Front Door Connecting rod - key cylinder Door key cylinder Outside door handle Lock / Unlock cable Connecting rod - outside handle Operating cable - Inside handle Door latch Lock / Unlock Inside door handle BODY EXTERIOR RODIUS 2005.07...
  • Page 487 Operation of Inside handle Operating cable Latch open mode Outside handle Operation of outside handle Connecting rod - outside handle Latch open mode Key cylinder Insert key & operation Connecting rod - key cylinder Latch lock / Unlock BODY EXTERIOR RODIUS 2005.07...
  • Page 488 06-11 7115-01 (2) Rear Door Outside door handle Operating cable - Inside handle Connecting rod - Outside handle Rock / Unlock cable Lock / Unlock Inside door handle CHILD / SAFETY mode BODY EXTERIOR RODIUS 2005.07...
  • Page 489 Lock / Unlock (Inside door handle) Lock button Operating cable Latch lock / Unlock Inside handle Operation of handle Operating cable Open mode - Latch CHILD / SAFETY mode Safety (FREE) mode Latch & Crank in operation BODY EXTERIOR RODIUS 2005.07...
  • Page 490 When switch-rear view mirror is operated, two motors which of one moves up and down and the other one moves left and right are shifted to the direction the driver intended (Refer to the picture below). ▶Folding Motor is operated to fold the rear view mirrow when switch is pushed. BODY EXTERIOR RODIUS 2005.07...
  • Page 491 06-14 7115-01 2. TAILGATE 1) OPERATION - TAILGATE Tailgate handle Actuator Connecting - tailgate handle Key cylinder Connecting rod - actuator handle Connecting rod - key cylinder Door latch BODY EXTERIOR RODIUS 2005.07...
  • Page 492 06-15 7115-01 2) LAYOUT - TAILGATE Washer nozzle Rear view camera Rear spoiler Wipre & motor Key cylinder BODY EXTERIOR RODIUS 2005.07...
  • Page 493 06-16 7115-01 Shock absorber Door latch Door hinge Door striker BODY EXTERIOR RODIUS 2005.07...
  • Page 494 06-17 7115-01 3. LAYOUT - COWL ASSY / HOOD BODY EXTERIOR RODIUS 2005.07...
  • Page 495 06-18 7115-01 4. LAYOUT - FRONT BUMPER BODY EXTERIOR RODIUS 2005.07...
  • Page 496 06-19 7115-01 5. LAYOUT - REAR BUMPER BODY EXTERIOR RODIUS 2005.07...
  • Page 497 06-20 7115-01 6. KEY CYLINDER 1) COMPONENTS Door handle - Front Key cylinder Key cylinder - Tailgate Starting key cylinder & key Key cylinder Door handle - Front BODY EXTERIOR RODIUS 2005.07...
  • Page 498 5710-01 5710-01 BODY REPAIR 1. BODY DIMENSION (unit: mm) BODY REPAIR RODIUS 2005.07...
  • Page 499 5710-01 2. BODY JACK POINT Rear Front Be sure to lift the vehicle only on the deginated jack point otherwise, the vehicle could be body damaged. BODY REPAIR RODIUS 2005.07...
  • Page 500 SPECIAL SERVICE TOOLS 0000-00 SPECIAL SERVICE TOOLS GENERAL 1. AIR BAG SYSTEM.........
  • Page 502 0000-00 0000-00 SPECIAL SERVICE TOOLS 1. AIR BAG SYSTEM 1) SPECIAL TOOLS AND EQUIPMENT Name and Part Number SPECIAL SERVICE TOOLS RODIUS 2005.07...

Table of Contents