Ssangyong Korando (1996-2006) - Service Manual / Repair Manual View larger

Ssangyong Korando (1996-2006) - Service Manual / Repair Manual

English Service Manual to vehicles Ssangyong Korando.

--------- INSTANT DOWNLOAD ---------

LANGUAGE: English.
FORMAT: ZIP file
SIZE: 133.6 Mb.
COMPATIBILITY: All Versions of Windows, Mac, iOS, BB, Android, etc..
PRINTABLE: Yes

No shipping costs, instant downloadable manual!  

More details

9,95 €

More info

SSANGYONG KORANDO (1996-2006) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING - OWNER´S

- English Service Manual to vehicles Ssangyong Korando.

 
CONTENTS:


GENERAL INFORMATION
 
- 0B-1 Table of Contents
- 0B-2 Technical Data
- 0B-6 Vehicle Dimensions & Weights
- 0B-7 Standard Bokt Specification
- 0B-8 Maintenance & Lubrication
- 0B-9 Scheduled Maintenance Petrol Engine
- 0B-11 Scheduled Maintenance Diesel Engine
- 0B-13 While Operating the Vehicle
- 0B-14 Each Time the Oil is Changed
- 0B-15 Recommended Fluids & Lubricants
- 0B-16 General Repair Instructions
- 0B-17 Vehicle Identification Numbers
- 0B-18 Manufacturers Plate
- 0B-19 Engine Number
- 0B-20 Vehicle Lifting Procedure


ENGINE
 
- Section 1A1 M162 Engine
- Section 1A1 M162 Engine General Information
- 1A1-1 Table of Contents
- 1A1-2 Specifications
- 1A1-3 Front View
- 1A1-4 Side View
- 1A1-5 E32 Engine
- 1A1-6 Oil Leaks
- 1A1-7 Engine Cranking at Front of Crankshaft
- 1A1-8 Compression Test
- 1A1-10 Cylinder Pressure Leak Test
- 1A1-12 Cleanliness & Care
- Section 1B1 M162 Engine Mechanical
- 1B1-1 Table of Contents
- 1B1-2 Fastener Tightening Torques
- 1B1-4 Special Tools
- 1B1-7 Engine Assembly
- 1B1-14 Crankcase Ventilation System
- 1B1-16 Generator
- 1B1-17 Engine Mounts
- 1B1-18 Poly Vee Belt
- 1B1-20 Belt Tensioner
- 1B1-24 Cylinder Head Cover
- 1B1-26 Cylinder Head Front Cover
- 1B1-28 Cylinder Head
- 1B1-31 Timing Chain Cover
- 1B1-33 Rear Main Oil seal Cover
- 1B1-35 Belt Pulley & Damper
- 1B1-38 Crankshaft Front Radial Seal
- 1B1-40 Crankshaft Rear Radial Seal
- 1B1-41 Crankshaft
- 1B1-47 Flywheel Driven Plate
- 1B1-50 Camshaft Adjuster
- 1B1-59 Camshaft Timing Position
- 1B1-62 Valve Springs
- 1B1-66 Valve Stem Oil Seals
- 1B1067 Chain Tensioner
- 1B1-70 Timing Chain
- 1B1-75 Tensioner Rails
- 1B1-76 Cylinder Head Guide Rails
- 1B1-77 Crankcase Guide Rail
- 1B1-78 Crankshaft Sprocket
- 1B1-80 Pistons
- 1B1-83 Connecting Rods
- 1B1-85 Piston Rings
- 1B1-87 Oil Specifications
- 1B1-88 Oil Pan
- 1B1-90 Change Oil & Filter
- 1B1-92 Oil Filter
- 1B1-94 Oil Pump
- 1B1-96 Oil Pressure Relief Valve
- 1B1-97 Oil Non-Return Valve
- 1B1-98 Dipstick Tube
- 1B1-99 Oil Gallery in Crankcase
- 1B1-101 Oil Gallery in Cylinder Head
- 1B1-104 Core Plugs in Crankcase
- 1B1-106 Cylinder Bore
- 1B1-108 Crankcase Mating Surface
- 1B1-110 Cylinder Head Mating Surface
- Section 1D1 M162 Engine Cooling
- 1D1-1 table of Contents
- 1D1-2 Specifications
- 1D1-3 Special Tools Table
- 1D1-4 System Leakage Test
- 1D1-5 Drain & Refill
- 1D1-7 Coolant Connection Fitting
- 1D1-8 Water Pump
- 1D1-10 Thermostat
- 1D1-11 Oil Cooler Pipe Line
- 1D1-12 Cooling Fan & Viscous Clutch
- 1D1-14 Coolinmg Fan Shroud
- 1D1-15 Radiator
- Section 1E1 M162 Engine Electrical
- 1E1 Table of Contents
- 1E1-2 Specifications
- 1E1-3 Generator
- 1E1-4 Starter Motor
- 1E1-5 Battery
- 1E1-6 Sparking Plugs
- 1E1-8 Ignition Cable
- 1E1-11 Battery
- Section 1F1 M162 Engine Controls
- 1F1-1 Table of Contents
- 1F1-2 Engine & ECM Problem Check Report
- 1F1-3 Engine Data Display Table
- 1F1-4 Fastener Torque Specifications

- 1F1-5 Fuel System Specifications
- 1F1-6 Special Tools Table
- 1F1-7 ECM Diagram
- 1F1-14 Clearing Failure Codes
- 1F1-18 Ignition System
- 1F1-20 Ignition Coil
- 1F1-22 Crankshaft Position Sensor
- 1F1-26 Camshaft Position Sensor
- 1F1-30 Camshaft Actuator
- 1F1-32 Knock Sensor
- 1F1-34 Spark Plugs
- 1F1-38 System Voltage
- 1F1-39 Ignition Switch
- 1F1-40 Fuel System
- 1F1-42 Fuel Pump
- 1F1-46 Fuel Injector
- 1F1-50 Purge Control Valve
- 1F1-52 Fuel Rail
- 1F1-54 Fuel Pressure Regulator
- 1F1-56 Throttle Valve Actuator
- 1F1-60 HFH Sensor
- 1F1-64 Engine Coolant Temperature Sensor
- 1F1-68 Accelerator Pedal Module
- 1F1-71 Clutch Switch
- 1F1-72 Cooling Fan
- 1F1-73 AC Compresor Relay
- 1F1-74 Cruise Control Switch
- 1F1-75 Traction Control System
- 1F1-76 Resonance Flap
- 1F1-77 Stop Lamp Switch
- 1F1-78 Engine RPM
- 1F1-79 Catalytic Converter
- 1F1-80 Oxygen Sensor
- 1F1-86 Engine Control Module
- 1F1-88 Serial Data Communication
- 1F1-90 Internal Failure
- 1F1-92 Electronic Throttle Controller
- 1F1-94 Immobiliser
- 1F1-95 Release Fuel System Pressure
- 1F1-97 Fuel Tank
- 1F1-99 Fuel Rail & Injectors
- 1F1-101 Throttle Body
- 1F1-102 HFM Sensor
- 1F1-103 Pedal Position Sensor
- 1F1-104 Purge Control Valve
- Section 1G1 M162 Engine Intake & Exhaust
- 1G1-1 Table of Contents
- 1G1-2 Fastener Tightening Torques
- 1G1-3 Air Cleaner
- 1G1-5 Inyake Air Duct
- 1G1-7 Intake Manifold
- 1G1-9 Resonance Flap
- 1G1-11 Exhaust Manifold
- Section 1A2 M161 Engine
- Section 1A2 M161 Engine General Information
- 1A2-1 Table of Contents
- 1A2-11 Cylinder Pressure Leakage
- 1A2-13 Cleanliness & Care
- 1A2-2 Specifications
- 1A2-3 Front View

- 1A2-4 Side View
- 1A2-5 E23 Engine
- 1A2-7 Oil Leaks
- 1A2-9 Compression Test
- Section 1B2 M161 Engine Mechanical
- 1B2-1 Table of Contents
- 1B2-2 Tightening Torques
- 1B2-4 Special Tools
- 1B2-7 Engine Assembly
- 1B2-14 Crankcase Ventilation System
- 1B2-18 Generator
- 1B2-19 Engine Mounts
- 1B2-20 Poly Vee Belt
- 1B2-22 Tensioning Device
- 1B2-23 Tensioner Shock Absorber
- 1B2-24 Poly Vee Belt Inspection
- 1B2-26 Cylinder Head Cover
- 1B2-28 Cylinder Head Front Cover
- 1B2-30 Cylinder Head
- 1B2-34 Timing Gear Case Cover
- 1B2-37 Crankcase Sealing Rear Cover
- 1B2-39 Belt Pulley & Damper
- 1B2-42 Crankshaft Front Radial Seal
- 1B2-44 Crankshaft Rear Radial Seal
- 1B2-45 Crankshaft
- 1B2-51 Flywheel & Driven Plate
- 1B2-54 Camshaft Adjuster
- 1B2-57 Camshaft Sprocket Bolt
- 1B2-58 Camshaft
- 1B2-62 Camshaft Timing Position
- 1B2-63 Valve Springs
- 1B2-67 Valve Stem Oil Seals
- 1B2-68 Chain Tensioner
- 1B2-72 Timing Chain
- 1B2-77 Tensioning Rail
- 1B2-78 Cylinder Head Guide Rail
- 1B2-80 Crankcase Guide Rail
- 1B2-81 Crankshaft Sprocket
- 1B2-83 Pistons
- 1B2-86 Connecting Rods
- 1B2-88 Piston Rings
- 1B2-90 Oil Pan
- 1B2-97 Oil Pressure Relief Valve
- 1B2-98 Oil Non-Return Valve
- 1B2-99 Dipstick Tube
- 1B2-100 Crankcase Core Plugs
- 1B2-102 Cylinder Bore
- 1B2-104 Crankcase Mating Surface
- 1B2-106 Cylinder Head Mating Surface
- Section 1D2 M161 Engine Cooling
- 1D2-1 Table of Contents
- 1D2-2 Specifications
- 1D2-3 Special Tools Table
- 1D2-4 System Leakage Test
- 1D2-5 Drain & Replace Coolant
- 1D2-7 Cooling Fan & Viscous Clutch
- 1D2-9 Water Pump
- 1D2-11 Thermostat
- 1D2-12 Thermostat Housing
- 1D2-14 Fan Shroud
- 1D2-15 Remove & Replace Radiator
- Section 1E2 M161 Engine Electrical
- 1E2-1 Table of Contents
- 1E2-2 Specifications
- 1E2-3 Generator
- 1E2-4 Starter Motor
- 1E2-5 Battery
- 1E2-6 Spark Plugs
- 1E2-8 Ignition Cables
- 1E2-11 Battery
- Section 1F2 M161 Engine Engine Controls
- 1F2-1 Table of Contents
- 1F2-2 Engine & ECM Problem Check
- 1F2-3 Engine Data Display Table
- 1F2-4 Fastener Tightening Torques
- 1F2-5 Fuel System Specification
- 1F2-6 Special Tools Table
- 1F2-7 ECM Wiring Diagram
- 1F2-14 Clearing Failure Codes
- 1F2-18 Ignition System
- 1F2-20 Ignition Coil
- 1F2-22 Crankshaft Position Sensor
- 1F2-26 Camshaft position Sensor
- 1F2-32 Knock Sensor
- 1F2-34 Spark Olugs
- 1F2-38 System Voltage
- 1F2-39 Ignition Switch
- 1F2-40 Fuel System
- 1F2-42 Fuel Pump
- 1F2-46 Fuel Injector
- 1F2-50 Purge Control Valve
- 1f2-52 Fuel rail
- 1F2-54 Fuel Pressure Regulator
- 1F2-56 Throttle Valve Actuator
- 1F2-60 HFM Sensor
- 1F2-64 Coolant Temperature Sensor
- 1F2-68 Accelerator Pedal Module
- 1F2-72 Cooling Fan
- 1f2-73 AC Compressor Relay
- 1F2-74 Cruise Control Switch
- 1F2-75 Traction Control System
- 1F2-76 Stop Lamp Switch
- 1F2-77 Engine RPM
- 1F2-78 Catalytic Converter
- 1F2-80 Oxygen Sensor
- 1F2-86 Engine Control Module
- 1F2-88 Serial Data Communication
- 1F2-90 Internal Failure
- 1F2-92 Electronic Throttle Controller
- 1F2-94 Immobiliser
- 1F2-95 Releasing Fuel System Pressure
- 1F2-97 Fuel Tank
- 1F2-99 Fuel Rail & Injectors
- 1F2-101 Throttle Body
- 1F2-102 HFM Sensor
- 1F2-103 Pedal Position Sensor
- 1F2-104 Purge Control Valve
- Section 1G2 M161 Engine Intake & Exhaust
- 1G2-1 Table of Contents
- 1G2-2 Fastener Tightening Torques
- 1G2-3 Air Cleaner
- 1G2-5 Air Intake Shield
- 1G2-6 Intake Air Duct
- 1G2-8 Intake Manifold
- 1G2-10 Exhaust Manifold
- 1G2-12 Remove & Replace Exhaust
- Section1A3 OM600 Engine
- Section 1A3 OM600 Engine
- 1A3-1 Table of Contents General Engine Information
- 1A3-2 Engine Specifications
- 1A3-3 OM622LA Engine Front
- 1A3-5 OM661LA Engine Front
- 1A3-7 OM662LA Engine
- 1A3-8 OM661LA Engine
- 1A3-9 Special Tools & Equipment
- 1A3-10 Oil Leaks
- 1A3-11 Compression Test
- 1A3-13 Cylinder Pressure Leakage
- 1A3-15 Cleanliness & Care
- Section 1B3 OM600 Engine Mechanical
- 1B3-1 Table of Contents
- 1B3-2 Fastener Torque Specifications
- 1B3-5 Special Tools
- 1B3-12 Engine Assembly
- 1B3-21 Poly Vee Belt
- 1B3-23 Belt Tensioner
- 1B3-26 Belt Alignment & Inspection
- 1B3-29 Prechamber
- 1B3-32 Milling of Prechamber
- 1B3-35 TCS Sensor Bracket Setting
- 1B3-37 Cylinder Head
- 1B3-63 Timing Case Cover
- 1B3-71 Crankshaft End Cover
- 1B3-74 Crankshaft Damper & Hub
- 1B3-80 Crankshaft Front Radial Seal
- 1B3-82 Crankshaft Ball Bearing
- 1B3-83 Crankshaft
- 1B3-93 Flywheel
- 1B3-97 Maching Flywheel
- 1B3-98 Flywheel Ring Gear
- 1B3-101 Hydraulic Valve Clearence
- 1B3-103 Valve Tappets
- 1B3-105 Valve Spring Check
- 1B3-106 Valve Spring - Head Removed
- 1B3-109 Valve Spring - Head in Situ
- 1B3-112 Valve Stem Oil Seals
- 1B3-116 Valve Guides Check & Replace
- 1B3-122 Valve Seat Rings
- 1B3-127 Check & Machining of Valves
- 1B3-132 Machining of Valve Seats
- 1B3-137 Camshaft Timming Test
- 1B3-139 Camshaft
- 1B3-145 Chain Tensioner
- 1B3-147 Timing Chain
- 1B3-151 Tensioning Rail
- 1B3-152 Cylinder Head Guide Rail
- 1B3-156 Timing Cover Guide Rail
- 1B3-158 Cranshaft Sprocket
- 1B3-163 Pistons
- 1B3-169 Oil Filter
- 1B3-171 Oil Pan
- 1B3-174 Oil Spray Nozzle
- 1B3-175 Oil Pump
- 1B3-177 Cylinder Head Leakage Test
- 1B3-178 Facing Cyl-head Mating Surface
- 1B3-180 Replace Crankcase Core Plugs
- 1B3-182 Facing Crankcase Contacting Surface
- 1B3-183 Oil Gallery Steel Ball
- 1B3-187 Cylinder Bore Measurment
- Section 1D3 OM600 Engine Cooling
- 1D3-1 Table of Contents & Specifications
- 1D3-2 Cooling Circulation
- 1D3-4 System Leakage Test
- 1D3-5 Drain & Replace Coolant
- 1D3-6 Water Pump
- 1D3-8 Water Pump Housing
- 1D3-10 Cooling Fan Clutch
- 1D3-12 Radiator
- 1D3-14 Cooling Sub-System
- 1D3-16 Thermostat
- Section 1E3 OM600 Engine Electrical
- 1E3-1 Table of Contents
- 1E3-2 Tightening Torques
- 1E3-3 Glow Plugsl
- 1E3-6 Generator
- 1E3-8 Starteer Motor
- Section 1F3 OM600 Engine Controls
- 1F3-1 Table of Contents & Tightening Torques
- 1F3-2 Fuel System
- 1F3-3 Fuel Injection Pump Coding
- 1F3-4 Fuel Tank
- 1F3-10 Vacuum Pump Test
- 1F3-12 Vacuum Pump
- 1F3-14 Vacuum Unit Replace
- 1F3-15 Idle Speed Adjustment
- 1F3-17 Fuel Pump Test
- 1F3-20 Fuel Pump
- 1F3-21 Injector Nozzle Test
- 1F3-24 Injector Nozzles
- 1F3-26 Injector Nozzle Repair
- 1F3-29 Remove & Replace Timing Unit
- 1F3-34 Injection Timing Device
- 1F3-36 Start of Delivery Test
- 1F3-45 Fuel Injection Pump
- 1F3-5 Vacuum System Test


CHASSIS & BODY
 
- Section 2A Suspension Diagnosis
- 2A-1 Table of Contents
- 2A-2 General Diagnosis
- 2A-7 Hub & Bearing
- Section 2B Wheel Alignment
- 2B-1 Table of Contents
- 2B-2 Description & Operation
- 2B-3 Tyre Diagnosis
- 2B-4 Radial Tyre Lead & Pull
- 2B-6 Vibration Diagnosis
- 2B-7 Vehicle Ride Hieght
- 2B-8 Front Camber Check
- 2B-9 Wheel Alignment Specifications
- Section 2C Front Suspension
- 2C-1 Table of Contents
- 2C-2 Component Locator
- 2C-3 Ball Joint Inspection
- 2C-4 Front Hub Bearings
- 2C-7 Torsion Bar
- 2C-10 Lower Ball Joint
- 2C-11 Knuckle Assembly
- 2C-14 Hub & Bearing
- 2C-16 Fastener Tightening Torques
- 2C-17 Special Tools & Equipment
- Section 2D Rear Suspension
- 2D-1 Table of Contents
- 2D-2 Component Locator
- 2D-3 Excessive Friction Check
- 2D-4 Rear Stabiliser
- 2D-8 Fastener Tightening Torques
- 2D-9 Special Tools
- Section 2E Tires and Wheels
- 2E-1 Table of Contents
- 2E-2 Tyre & Wheel Balance
- 2E-3 Snow Chain Usage
- 2E-4 Tyre Labels
- 2E-5 Wheel Run-out
- 2E-6 Wheel
- 2E-10 Specifications
- Section 3A Front Axle
- 3A-1 Table of Contents
- 3A-2 Specifications
- 3A-3 Front Axle Assembly
- 3A-4 Auto Locking Hub
- 3A-5 Vacuum Line
- 3A-7 Steering Knuckle & Drive Shaft
- 3A-12 Front Axle Assembly
- 3A-16 Axle Housing
- 3A-23 CV Joint Seal
- 3A-25 Special Tools
- Section 3C Propeller Shaft
- 3C-1 Table of Contents
- 3C-2 Components Locator
- 3C-3 Propeller Shaft
- 3C-4 Front Propeller Shaft
- 3C-6 Propeller Shaft
- 3C-7 Specifications
- Section 3D Rear Axle
- 3D-1 Table of Contents
- 3D-2 Specifications
- 3D-3 Diagnostic I nformation & Procedures
- 3D-4 Rear Axle Assemlby
- 3D-5 Cross Sectional View
- 3D-6 Rear Axle Shaft Assembly
- 3D-8 Axle Shaft Assembly (Disc Brakes)
- 3D-11 Axle Shaft Assembly (Drum Brakes)
- 3D-13 Rear Axle Housing
- 3D-18 Axle Assembly
- 3D-20 Differential Gear Assembly
- 3D-25 Drive Shaft
- 3d-26 Special Tools Table
- Section 4A Hydraulic Brakes
- 4A-1 Table of Contents
- 4A-2 General Description
- 4A-3 Brake
- 4A-3 Warning Lamps
- 4A-5 Warning Lamp Diagnosis
- 4A-8 LCRV Valve
- 4A-10 Brake Bleeding
- 4A-13 Front Brake Hoses
- 4A-15 Specifications
- 4A-16 Fastener Tighting Torque
- Section 4B Master Cylinder
- 4B-1 Table of Contents
- 4B-2 General description
- 4B-3 Component Locator
- 4B-4 Reservoir Switch
- 4B-8 Specifications
- Section 4C Power Booster
- 4C-1 Table of Contents
- 4C-2 General description
- 4C-3 Component Locator
- 4C-4 Booster Test
- 4C-5 Booster Assembly
- 4C-6 Vacuum Hose
- 4C-7 Specifications
- Section 4D Front Brakes
- 4D-1 Table of Contents
- 4D-2 General Description
- 4D-3 Front Brake Assembly
- 4D-4 Caliper Assembly
- 4D-5 Pad Inspection
- 4D-6 Brake Pads
- 4D-7 Caliper
- 4D-8 Brake Caliper
- 4D-10 Fastener Tightening Torque
- Section 4E Rear Brakes
- 4E-1 Table of Contents
- 4E-2 Drum Brake
- 4E-3 Disc Brake
- 4E-4 Service Specifications
- 4E-5 Diagnostic Info
- 4E-6 Drum Brake
- 4E-8 Drum Brake (KDAC)
- 4E-9 Disc Brake
- 4E-10 Drum Brake
- 4E-11 Disc Brake
- 4E-12 Disc Brake Assembly
- 4E-17 Drum Brake Assembly
- 4E-22 Wheel Cylinder
- 4E-23 Parking Brake Lever
- 4E-24 Fastener Tightening Torques
- Section 4F Antilock Brake System and Traction Control System
- 4F-1 Table of Contents
- 4F-3 Description & Operation
- 4F-5 EBD System
- 4F-6 EBD Failure Matrix
- 4F-8 ABS 5.3
- 4F-11 ABS-TCS 5.3
- 4F-14 ABS, ABS-TCS 5.3
- 4F-15 Diagnosis Circuit Check
- 4F-18 ABS Warning Lamp Inoperative
- 4F-22 TCS Warning Lamp Inoperative
- 4F-26 EBD Warning Lamp Inoperative
- 4F-30 Power Supply to Control Module
- 4F-34 ABS Warning Lamp Remaining On
- 4F-36 Self Diagnosis
- 4F-38 DTC 03
- 4F-40 DTC 07
- 4F-42 DTC 04
- 4F-44 DTC 08
- 4F-46 DTC 05
- 4F-48 DTC 09
- 4F-50 DTC 06
- 4F-52 DTC 10
- 4F-54 11
- 4F-58 DTC 42
- 4F-60 DTC 43
- 4F-62 DTC 13-14
- 4F-64 DTC 15-16
- 4F-66 DTC 17-18
- 4F-68 DTC 19-20
- 4F-70 DTC 21-22
- 4F-72 DTC 23-24
- 4F-74 DTC 12
- 4F-76 DTC 24
- 4F-80 DTC 27
- 4F-84 DTC 28
- 4F-88 DTC 02
- 4F-90 ABS Without TCS
- 4F-91 ABS With TCS
- 4F-93 ABS-ABD
- 4F-95 EBCM Connector No TCS
- 4F-96 Hydraulic Modulator Connector
- 4F-99 Service Precautions
- 4F-100 ABS 5.3 Assembly
- 4F-101 Front Speed Sensors
- 4F-102 Acceleration Sensor
- 4F-103 Front Tooth Wheel
- 4F-104 Special Tools
- Section 4G Parking Brake
- 4G-1 Table of Contents
- 4G-2 Brake Caliper
- 4G-3 Component Locator
- 4G-4 Adjustment - Disc Brakes
- 4G-5 Parking Brake Lever
- 4G-6 Brake Cable
- 4G-7 Specifications
- Section 5A Automatic Transmission
- 5A-1 Table of Contents
- 5A-2 BTRA MT4 4WD Transmission
- 5A-10 Hydraulic Control Circuit
- 5A-18 Power Flows
- 5A-20 Park & Neutral
- 5A-22 Reverse
- 5A-24 Manual 1
- 5A-26 Drive 2
- 5A-28 Drive 2 & Manual 2
- 5A-30 Drive 3 & Manual 3
- 5A-32 Drive 3 & Lock-up & Manual 3 Lock-up
- 5A-34 Drive 4 (Overdrive)
- 5A-36 Drive 4 Lock-up
- 5A-38 Basic Knowledge Required
- 5A-40 Electrical Shift Tests
- 5A-41 Drive Faults
- 5A-42 Faulty Shift Pattern
- 5A-44 Shift Quality Faults
- 5A-46 After Strip Down Faults
- 5A-48 TCM Fault Codes Petrol Engine
- 5A-50 TCM System Overview Diesel Engine
- 5A-52 TCM Diagnostic Check
- 5A-54 Fault Code P0706
- 5A-56 Fault Code P0707
- 5A-58 Fault Code P0708
- 5A-62 Fault Code P0710
- 5A-66 Fault Code P0790
- 5A-70 Fault Code P01703
- 5A-72 Fault Code P1704
- 5A-74 Fault Code P1708
- 5A-76 Fault Code P1709
- 5A-78 Air Con Circuit Fault
- 5A-82 Kickdown Switch Circuit Fault
- 5A-86 Fault Code P1713
- 5A-88 Fault Code P1714
- 5A-89 Fault Code P1715
- 5A-90 Fault Code P1716
- 5A-92 Fault Code P1717
- 5A-93 Fault Code P1718
- 5A-94 Fault Code P1719
- 5A-96 Fault Code P1720
- 5A-98 Fault Code P1721
- 5A-100 Fault Code P1722
- 5A-102 Solenoid 1 open Circuit
- 5A-106 Solenoid 2 Open Circuit
- 5A-110 Solenoid 3 Open Circuit
- 5A-114 Solenoid 4 Open Circuit
- 5A-118 Solenoid 5 Open Circuit
- 5A-122 Solenoid 6 Open Circuit
- 5A-126 Solenoid 7 Open Circuit
- 5A-130 Solenoid 1 Short Circuit
- 5A-134 Solenoid 2 Short Circuit
- 5A-138 Solenoid 3 Short Circuit
- 5A-142 Solenoid 4 Short Circuit
- 5A-146 Solenoid 5 Short Circuit
- 5A-147 transmission
- 5A-150 Solenoid 6 Short Circuit
- 5A-154 Solenoid 7 Short Circuit
- 5A-160 rebuild Warnings
- 5A-161 Disassembly Procedure
- 5A-171 Assembly Procedure
- 5A-199 Brake Band Adjustment
- 5A-202 Gear Selector & kickdown Switch
- 5A-203 General Specifications
- 5A-205 Fastener Tightening Torques
- 5A-206 TCM Wiring Diagram Petrol Engine
- 5A-208 TCM Wiring Diagram Diesel Engine
- 5A-210 Connector End View
- 5A-211 Special Tools Table
- Section 5B Manual Transmission
- 5B-1 Table of Contents
- 5B-2 Shift Lever
- 5B-3 Specifications
- 5B-6 Diagnosis Table
- 5B-7 Cross Sectional View
- 5B-8 Power Flow
- 5B-9 Semi Remote Strip & rebuild
- 5B-10 Transmission External View
- 5B-11 Transmission Internal View
- 5B-14 Semi Remote Kit
- 5B-19 Transmission
- 5B-24 Major Unit
- 5B-40 Counter Shaft
- 5B-45 Inspection of Components
- Section 5C Clutch
- 5C-1 Table of Contents
- 5C-2 General Specifications
- 5C-3 Cluch Assembly
- 5C-5 Bleeding Clutch Hydraulics
- 5C-6 Clutch Plate
- 5C-10 Clutch Master Cylinder
- 5C-13 Clutch Pedal Assembly
- 5C-15 Diagnosis
- 5C-16 Difficult Pedal Operation
- 5C-17 Special Tools Table
- Section 5D1 Transfer Case TOD
- 5D1-1 Table of Contents
- 5D1-3 Pin Description
- 5D1-4 Components of TOC System Etc
- 5D1-7 Component Locator
- 5D1-8 Disassembled View
- 5D1-10 Control Unit
- 5D1-11 Self Diagnosis Tests
- 5D1-14 4WD Light Stays On
- 5D1-16 4WD Low Stays On
- 5D1-66 Changing Oil
- 5D1-67 TCCU
- 5D1-69 Shift Motor
- 5D1-70 Prop Shaft Speed Sensors
- 5D1-71 Transfer Case Overhaul
- Section 5D2 Transfer Case Part Time 4408
- 5D2-1 Table of Contents
- 5D2-2 4WD Operation Overview
- 5D2-3 System Structure
- 5D2-5 2H Mode
- 5D2-6 4H Mode
- 5D2-7 4L Mode
- 5D2-8 System Description
- 5D2-9 Specifications
- 5D2-10 General Diagnosis
- 5D2-11 Self Diagnosis
- 5D2-16 Cross Sectional View
- 5D2-17 TransferCase Assembly
- 5D2-18 Srip & Rebuild
- 5D2-20 On Vehicle Service
- 5D2-21 4H & L light & TCCU
- 5D2-22 transfer Case Assembly
- 5D2-25 Disassembly Procedure
- 5D2-25 TCCU
- 5D2-35 Assembly Procedure
- Section 6A Power Steering System
- 6A-1 Table of Contents
- 6A-2 General Description
- 6A-3 Component Locator
- 6A-4 Power Steering Pressure & Leak Tests
- 6A-5 Bleeding Etc
- 6A-6 PAS Reservoir
- 6A-7 PAS Pump & Hoses
- 6A-9 Specifications
- 6A-10 Special Tools
- Section 6B Power Steering Pump
- 6B-1 Table of Contents
- 6B-2 General Description
- 6B-3 Pump Diagnosis
- 6B-4 Serpentine Belt Replacement
- 6B-5 Remove & replace Pump
- 6B-6 Pump
- 6B-7 Fastener Tightening Torques
- Section 6C Power Steering Gear
- 6C-1 Table of Contents
- 6C-2 Power Rack & Pinion
- 6C-3 Component Locator
- 6C-4 Rack & Pinion Hissing Noise
- 6C-6 Bench Testing
- 6C-8 Rack & Pinion Assembly
- 6C-13 Rack & Pinion
- 6C-17 Fastener Tightening Torques
- 6C-18 Special Tools Table
- Section 6E Power Steering and Column
- 6E-1 Table of Contents
- 6E-2 Description & Operation
- 6E-3 Componet Locator
- 6E-4 Steering Wheel
- 6E-5 Steering Column
- 6E-9 Lighting & Indicator Switches
- 6E-10 Wiper Switch
- 6E-12 Steering Column
- 6E-14 Fastener Tightening Torques
- 6E-15Special Tools Table
- Section 7A Heating and Ventilation System
- 7A-1 Table of Contents
- 7A-2 Description & Operation
- 7A-3 Components Locator
- 7A-4 Heater System
- 7A-8 Blower Electrical
- 7A-10 Mode Controls Do Not Work
- 7A-12 Air Source Selection Not Controlled
- 7A-13 Temperature Controls Not Working
- 7A-14 Too Much Heat
- 7A-16 Blower Noise
- 7A-18 Temperature Controls
- 7A-19 Controls Illumination
- 7A-20 Mode Control Door Actuator
- 7A-23 Heater Inlet Hose
- 7A-24 Heater Matrix
- 7A-25 Specifications
- 7A-26 Schematic & routing Diagram
- 7A-28 Air Through Vents
- Section 7C AC and Heating
- 7C-1 Table of Contents
- 7C-2 Specifications
- 7C-3 Specifications 2
- 7C-4 Fan Motor Circuit
- 7C-6 Compressor Circuit
- 7C-9 Ventilation
- 7C-11 Heater System
- 7C-12 Diesel Engine System
- 7C-13 Petrol Enginw System
- 7C-14 Refrigerant Charging
- 7C-19 Condenser Replacement
- 7C-21 Reciever Dryer
- 7C-23 The Compressor
- 7C-24 The Control Box
- Section 7D AC and Heating Automatic
- 7D-1 Table of contents
- 7D-2 Refrigerant
- 7D-3 Pressure switch
- 7D-4 Service Specifications
- 7D-5 Circuit diagram
- 7D-6 FATC block diagram
- 7D-7 Ventilation system
- 7D-8 Function description
- 7D-9 Diagnosis test
- 7D-13 Control Panel
- 7D-16 Air Filter
- 7D-17 Trouble shooting
- Section 8A Seat Belts
- 8A-1 Table of Contents
- 8A-2 Description of operation
- 8A-3 Front Seat belt
- 8A-4 Rear Seat Belt
- 8A-5 On vehicle service
- 8A-8 Fastener tightening torques
- 8A-9 Seat belt reducer
- Section 8B Supplemental Restraits System
- 8B-1 Table of contents
- 8B-3 Supplemental Restraint
- 8B-5 Warning light
- 8B-6 SRS Components
- 8B-7 Diagnostic Information & Procedures
- 8B-10 SRS System check
- 8B-12 SDM Integrity Check
- 8B-14 Waning light stays on
- 8B-16 Internal fault code
- 8B-18 Fault code 01
- 8B-20 Fault code 02
- 8B-22 Fault code 03
- 8B-24 Fault code 04
- 8B-26 Fault code 26
- 8B-28 Fault code 06
- 8B-30 Fault code 07
- 8B-32 Fault code 08
- 8B-34 Fault code 17
- 8B-38 Fault code 18
- 8B-40 Fault code 19
- 8B-42 Fault code 20
- 8B-44 Fault code 21
- 8B-48 Fault code 22
- 8B-50 Fault code 23
- 8B-52 Fault code 24
- 8B-54 Fault code 46
- 8B-56 Fault code 47
- 8B-58 Service Precautions
- 8B-59 Accident no deployment
- 8B-60 Air bag module
- 8B-61 Clock spring
- 8B-62 Passenger air bag
- 8B-63 Air bag deployment
- 8B-65 Deploying an air bag
- 8B-66 Deployed air bag disposal
- 8B-67 Specifications
- 8B-68 Supplemental restraint
- 8B-69 Schematic Diagram
- Section 9A Body Wiring System
- 9A-1 Table of contents
- 9A-2 Wire colour chart
- 9A-3 Underbonnet fuses & relays
- 9A-5 Underbonnet fuse usage
- 9A-6 Interior fuse box
- 9A-7 Interior fuse usage
- 9A-8 Underbonnet fuse box diagram
- 9A-11 Engine compartment
- 9A-12 Main harness
- 9A-14 Main floor harness
- 9A-15 Roof harness
- 9A-16 Seat heater
- 9A-17 Door harness
- 9A-18 Tailgate harness
- 9A-19 Air conditioner harness
- 9A-20 Petrol engine harness
- 9A-21 Diesel engine harness
- 9A-22 Automatic transmission harness
- Section 9B Lighting System
- 9B-1 Table of contents
- 9B-2 Head lamps on reminder
- 9B-3 Backup lamps
- 9B-4 Components locator
- 9B-5 Lead lamps
- 9B-7 Fog lamps
- 9B-8 Tail Lamps
- 9B-11 Interior lamps
- 9B-13 door courtesy lamps
- 9B-14 Cogar lighters
- 9B-15 Head lamps
- 9B-16 Front combination lamps
- 9B-17 Rear combination lamps
- 9B-18 Interior lamps
- 9B-19 Luggage lamp
- 9B-20 Bulb specification chart
- 9B-21 Head lamp adjusting petrol
- 9B-22 Head lamp adjustment diesel
- 9B-23 Rear lamps
- 9B-24 Illumination switch
- 9B-25 Indicator switch
- 9B-26 Front fog lamps
- 9B-27 Rear fog lamps
- 9B-28 Stop lamps 1
- 9B-29 Stop lamps 2
- Section 9C Horns
- 9C-1 Table of contents
- 9C-2 Horns
- 9C-3 Horns
- 9C-4 Dual horns
- 9C-5 Horn wiring
- Section 9D Wiper, Washer System
- 9D-1 Table of contents
- 9D-2 Description of operation
- 9D-3 Washers & wipers
- 9D-4 Wiper blades & arms
- 9D-6 Windshield washers
- 9D-7 Rear wipers
- 9D-8 Fastener torques
- 9D-9 Wipers & washers
- Secting 9E Instruments
- 9E-1 Table of contents
- 9E-2 Description of guages etc
- 9E-3 Components locator
- 9E-5 Cigar lighter
- 9E-9 Instrument lights & indicators
- 9E-10 Centre Tray
- 9E-11 Cigar lighter
- 9E-12 Glove Box
- 9E-13 Lower dash panel
- 9E-14 Speedometer & Tachometer
- 9E-15 Temperature guage
- 9E-16 Instrument panel
- 9E-18 Bulb usage chart
- 9E-19 Instrument panel lighting
- 9E-20 Instrument cluster diesel
- 9E-21 Instrument cluster petrol
- 9E-22 Warning lamps TCS
- 9E-23 Indicators
- 9E-24 Warning lamps
- 9E-25 Digital clock
- 9E-26 Selector lever illuminator
- Section 9F Audio System
- 9F-1 Table of contents
- 9F-2 Description
- 9F-3 Audio system
- 9F-4 Radio & cassette
- 9F-5 Rear speakers
- 9F-6 Audio system
- Section 9G Interior Trim
- 9G-1 Table of contents
- 9G-2 Trim panels
- 9G-3 Interior trim
- 9G-4 Door trim panel
- 9G-6 Lower quarter panels
- 9G-7 Inner sill & floor trims
- 9G-9 Fastener tightening torques
- Section 9H Seats
- 9H-1 Table of contents
- 9H-2 Component locator
- 9H-3 Front seats
- 9H-4 Front seat back
- 9H-5 Front seat recliner
- 9H-6 Walk-in device
- 9H-7 Rear seat
- 9H-8 50 50 split rear seat
- 9H-9 Fastener tightening torques
- 9H-10 Seat heaters
- Section 9I Waterleaks
- 9I-1 Table of contents
- 9I-2 Specifications
- 9I-3 Water ingress
- 9I-6 Rectifying water leaks
- Section 9J Windnoise
- 9J-1 Table of contents
- 9J-2 Wind noise diagnosis
- 9J-3 Wind noise repair
- Section 9K Squeaks and Rattles
- 9K-1 Table of contents
- 9K-2 Diagnosis
- 9K-4 Repairing squeaks & rattles
- Section 9L Glass and Mirrors
- 9L-1 Table of contents
- 9L-2 Stationary glass
- 9L-3 Glass & mirror
- 9L-4 Windshield
- 9L-6 Rear glass
- 9L-8 Rear defogger
- 9L-9 Door glass
- 9L-10 Interior mirror
- 9L-11 Fastener tightening torques
- 9L-12 Defroster
- 9L-13 Auto interior mirror
- Section 9M Exterior Trim
- 9M-1 Table of contents
- 9M-2 Emblems & lettering
- 9M-3 Exterior trim
- 9M-4 B Pillar moulding
- 9M-5 Door moulding
- 9M-6 Side Steps
- 9M-7 Fastener tightening torques
- Section 9N Frame and Underbody
- 9N-1 Table of contents
- 9N-2 Fastener tightening torque
- 9N-3 Underbody dimensions
- 9N-7 Checking Alignment
- 9N-8 General construction
- Section 9O Bumpers & Facias
- 9O_6 Rear bumper impact bar
- 9O-1 Table of contents
- 9O-2 Bumpers
- 9O-3 Bumpers & valances
- 9O-4 Front bumper valance
- 9O-5 Rear bumper valance
- 9O-7 Fastener Tightening torques
- Section 9P Doors
- 9P-1 Table of contents
- 9P-2 Power door locks
- 9P-4 Door glass run
- 9P-5 Door striker plate adjustement
- 9P-7 Interior door handles
- 9P-8 Power window regulator
- 9P-9 Door hinges
- 9P-10 Door seal trim
- 9P-11 Fastener tightening torques
- 9P-12 Centre door lock system
- 9P-34 Doors
- Section 9Q Roof
- 9Q-1 Table of contents
- 9Q-2 Sunvisors
- 9Q-3 Roof
- 9Q-4 Pre-formed head cloth
- Section 9R Body Front End
- 9R-1 Table of contents
- 9R-2 Body front end
- 9R-3 Body front end
- 9R-4 Lubrication
- 9R-5 Cowl vent grille
- 9R-6 Bonnet hinges
- 9R-7 Fastener tightening torques
- Section 9S Body Rear End
- 9S-1 Table of contants
- 9S-2 Fuel filler door
- 9S-3 Fuel filler door
- 9S-4 Fuel filler door
- 9S-5 Fastener tightening torques
- Section 9T1 REKES
- 9T1-1 Table of contents
- 9T1-2 REKES & anti-theft system
- 9T1-3 REKES & STICS
- 9T1-4 Input memory
- 9T1-6 Reciever
- 9T1-7 STICS unit
- 9T1-8 Door switches
- 9T1-9 Wiring diagram
- Section 9T2 Immobilizer System
- 9T2-1 Table of contents
- 9T2-2 Description & operation
- 9T2-3 Immobiliser system
- 9T2-4 Antenna & transponder replacement
- 9T2-5 Diagram


ELECTRICAL

- How to use electrical wiring diagram
- Table of Contents
- How to Read Diagrams
- Circuit Identification
- Positions of Connectors and Ground Splice Packs and Joints
- 2-2 Connectors & grounds
- 2-4 Connector, ground & splice information
- 2-6 Harness location
- Section 3 Wiring Diagram for Power Supplies
- 3-1 Table of contents
- 3-2 Ignition switch
- 3-3 Fuse & relay circuits under bonnet
- Section 4 Usage and Capacity of Fuses in Fuse Box
- 4-1 Table of contents
- 4-2 Under bonnet fuse & relay box
- 4-3 Interior fuse box
- 4-4 Interior relay box
- Section 5 Electrical Wiring Diagram
- 5-1 Table of contents
- 5-2 Starting & charging
- 5-3 Diagnostic Connectors
- 5-4 Pre-heating system
- 5-5 EGR system
- 5-6 ECM (E23 MSE)
- 5-7 ECM (E32 MSE)
- 5-8 TCM diesel engine
- 5-9 TCM etrol
- 5-10 ABS
- 5-11 ABS ABD diesel engine
- 5-12 ABS ABD Petrol engine
- 5-13 ABS Europe
- 5-14 TCCU
- 5-15 Manual air conditioner diesel engine
- 5-15 TOD
- 5-16 Manual air conditioner petrol engine
- 5-17 Air Bag
- 5-18 Seat belt reducer
- 5-19 Cluster
- 5-20 STICS
- 5-21 Seat heater
- 5-22 Stop lamps
- 5-23 Power windows
- 5-24 Exterior mirror
- 5-25 Rear washer & wiper
- 5-26 Cigar lighter & horn
- 5-27 Headlamps
- 5-28 Headlamp levelling
- 5-28 Turn signal lamps
- 5-29 Tail lamp relay circuit
- 5-30 Front fog lamps
- 5-31 Rear fog lamps
- 5-32 Interior mirror & backup lamp
- 5-33 Audio
- 5-34 Immobiliser system