Ssangyong Actyon (2006-2012) - Workshop Manual - Wiring Schematics - User Manual

SSANGYONG ACTYON (2006-2012) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING - OWNER´S

- English Workshop Manual, Wiring Schematics and User Manual to vehicles Ssangyong Actyon.

 
INDEX:

SERVICE MANUAL

GENERAL
- GENERAL INFORMATION
- 1. Dimensions
- 2. Specifications
- 3. Vehicle Identification
- 4. Maintenance Interval
- 5. Recommended Fluids And Lubricants
- 6. Jack-Up Points
- 7. Pin Arrangement Of Diagnostic Connector
- 8. Electric Components And Layout
- 9. Standard Bolts Specifications
GLOSSARY
- OVERVIEW AND OPERATING PROCESS
- 1. Glossary
ENGINE GENERAL
- GENERAL INFORMATION
- 1. Engine Layout
- 2. Major Components
- 3. Engine Compartment Layout
- 4. Caution When Servicing The Engine
- 5. Standard Bolts Specifications
- 6. Tightening Torque
- 7. Coding And Initialization
- SPECIAL SERVICE TOOLS
- 1. Special Service Tools
- 2. Normal Equipments
ENGINE ASSEMBLY
- GENERAL INFORMATION
- 1. Specification
- 2. Tightening Torque
- 3. Check And Inspection
- 4. Guidelines On Engine Service
- OVERVIEW AND OPERATING PROCESS
- 1. Belt Layout
- 2. Vacuum Pump
- 3. Engine Mounting
- 4. Intake/Exhaust Manifold
- 5. Cylinder Head Cover And Oil Separator
- 6. Cylinder Head
- 7. Chain And Gear Drive System
- 8. Oil Pan
- 9. Dual Mass Flywheel (Dmf) & Drive Plate
- 10. Piston/Crankshaft/Cylinder Block
- CONFIGURATION
- 1115-00 Engine Assembly (D20dtr)
- 1120-01 Short Block (D20dtr)
- 1127-00 Cylinder Block (D20dtr)
- 1130-00 Crankshaft And Flywheel
- 1214-00 Cylinder Head And Gasket Kit(D20dtr)
- 1225-00 Cylinder Head Cover And Camshaft(D20dtr)
- 1315-00 Chain Drive (D20dtr)
- 1336-00timing Case (D20dtr)
- 1350-01 Belt
- 1610-00 Vacuum Pump (D20dtr)
- 1990-00 Engine Mounting
- REMOVAL AND INSTALLATION
- 1336-00 Belt
- 1610-01 Vacuum Pump Assembly
- 1130-12 Isolation Damper Assembly
- 1990-00 Engine Mounting Insulator
- 1225-01 Cylinder Head Cover
- 1214-01 Cylinder Head Assembly
- 1130-13 Dual Mass Flywheel (Dmf) Assembly
- 1115-01 Engine Assembly
- 1127-01 Engine Overhaul
FUEL SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Maintenance And Inspection
- 3. Cautions For Di Engine
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. System Layout And Operation
- CONFIGURATION
- 2210-01 Fuel Tank Assembly
- 2210-06 Fuel Sender Assembly
- 1882-15 Fuel Pipe Assembly
- 1882-23 Fuel Rail Assembly (Common Rail)
- 1882-01 High Pressure Pump Assembly
- 2231-01 Fuel Filter Assembly
- REMOVAL AND INSTALLATION
- 2210-01 Fuel Tank Assembly
- 2210-06 Fuel Sender Assembly
- 1882-01 High Pressure Pump Assembly
- 1882-23 Fuel Rail Assembly
- 2231-01 Fuel Filter Assembly
- 2231-13 Fuel Filter Element
INTAKE SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Inspection
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Component
- 3. Input/Output Of Intake System
- 4. Operating Process
- CONFIGURATION AND FUNCTION
- 2313-01 Configuration And Function
- 2330-01 Intercooler
- 1719-40 Intake Manifold
- REMOVAL AND INSTALLATION
- 2313-04 Air Cleaner Element
- 2330-01 Intercooler
- 1719-01 Intake Manifold Assembly
ENGINE EXHAUST SYSTEM
- GENERAL INFORMATION
- 1. Troubleshooting
- 2. Cautions
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Layout
- 3. Operating Process
- CONFIGURATION AND FUNCTION
- 1729-01 Exhaust Manifold Assembly
- 2412-00 Exhaust Pipe Assembly
- REMOVAL AND INSTALLATION
- 1729-01 Exhaust Manifold

- 2412-01 Exhaust Front Pipe Assembly
- 2412-03 Muffler Assembly
- 2412-10 Exhaust Tail Pipe Assembly
TURBOCHARGER
- GENERAL INFORMATION
- 1. Specification
- 2. Inspection
- 3. Troubleshooting
- OVERVIEW AND OPERATING PROCESS
- 1. System Description Of E-Vgt (Electric-Variable Geometry Turbine)
- 2. Components
- 3. Input/Output Devices
- 4. Operating Principles
- CONFIGURATION AND FUNCTION
- 1914-01 Turbocharger Assembly
- REMOVAL AND INSTALLATION
- 1914-01 Turbocharger Assembly
LUBRICATION SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Maintenance
- OVERVIEW AND OPERATING PROCESS
- 1. System Description
- 2. Functions Of Lubrication
- CONFIGURATION AND FUNCTION
- 9210-01 Engine Oil
- 1543-01 Oil Filter Module
- 1543-13 Oil Cooler Assembly
- 1543-09 Engine Oil Filter Element
- 1533-30 Oil Pressure Switch
- 1533-01 Oil Pump Assembly
- 1533-08 Oil Pan Assembly
- 1127-22 Oil Injection Nozzle
- REMOVAL AND INSTALLATION
- 1543-09 Engine Oil Filter Element And Engine Oil Change
- 1543-01 Oil Filter And Cooler Module
- 1543-13 Oil Cooler Assembly
- 1533-30 Oil Pressure Switch
- 1533-08 Oil Pan Assembly
COOLING SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Inspection
- 3. Cautions
- OVERVIEW AND OPERATING PROCESS
- 1. System Description
- CONFIGURATION AND FUNCTION
- 2112-01 Radiator Assembly
- 2112-02 Pwm Electric Fan
- 1520-11 Thermostat Assembly
- 1520-01 Water Pump Assembly
- 2130-07 Reservoir Assembly
- 9210-05 Replenishment
- 9210-05 Air Bleeding
- REMOVAL AND INSTALLATION
- 2112-01 Radiator Assembly
- 2112-02 Pwm Electric Fan
- 1520-11 Thermostat Assembly
- 1520-01 Water Pump Assembly
- 1520-21 Coolant Outlet Port
CHARGING SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Inspection
- OVERVIEW AND OPERATING PROCESS
- 1. System Description
- 2. Operating Process
- 3. Circuit Diagram
- CONFIGURATION AND FUNCTION
- 1451-01 Alternator Assembly
- 2610-01 Battery
- REMOVAL AND INSTALLATION
- 1543-09 Alternator Assembly And Pulley
- 2610-01 Battery
- 2610-05 Battery Positive Cable Assembly
D20DTR PRE-HEATING
- GENERAL INFORMATION
- 1. Specification
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. System Operation
- CONFIGURATION AND FUNCTION
- 1413-01 Glow Plug
- 1413-18 Glow Plug Control Unit
- REMOVAL AND INSTALLATION
- 1413-01 Glow Plug
- 1413-18 Glow Plug Control Unit
STARTING SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Troubleshooting
- OVERVIEW AND OPERATING PROCESS
- 1. System Description
- 2. Operating Process
- CONFIGURATION AND FUNCTION
- 1461-01 Start Motor
- REMOVAL AND INSTALLATION
- 1461-01 Start Motor
CRUISE CONTROL SYSTEM
- OVERVIEW AND OPERATION PROCESS
- 1. Cruise Control Switch
- 2. How To Operate Cruise Control Switch
- REMOVAL AND INSTALLATION
- 8510-23 Cruise Control Switch
E-EGR SYSTEM
- GENERAL INFORMATION
- 1. Specification
- OVERVIEW AND OPERATING PROCESS
- 1. System Description
- 2. Operating Process
- CONFIGURATION AND FUNCTION
- 1793-12 E-Egr Cooler Assembly And Bypass Valve
- REMOVAL AND INSTALLATION
- 1793-12 E-Egr Cooler Assembly
CDPF SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. Cautions
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Component
- 3. Input/Output Devices
- 4. Post-Injection And Air Mass Control
- 5. Operating Process
- 6. Electric Circuit Diagram
- CONFIGURATION AND FUNCTION
- 2412-00 Cdpf
- REMOVAL ANC INSTALLATION
- 2412-02 Cdpf Assembly
ENGINE CONTROL
- GENERAL INFORMATION
- 1. Engine Data List
- OVERVIEW AND OPERATINF PROCESS
- 1. Major Components
- 2. System Operation
- CONFIGURATION AND FUNCTION
- 1491-01 Ecu
- 1882-09 Injector (C3i)
- 2330-08 Hfm (Hot Film Air Mass Sensor)
- 1432-01 T-Map (Temperature-Manifold Air Pressure) Sensor
- 1432-07 Coolant Temperature Sensor
- 1882-23 Fuel Rail Pressure Sensor
- 1882-01 Fuel Temperature Sensor
- 2231-01 Water Sensor In Fuel Filter
- 1432-08 Wide Band Oxygen Sensor
- 1432-04 Differential Pressure Sensor
- 1432-17 Egt (Exhaust Gas Temperature) Sensor
- 1793-01 E-Egr (Electric-Exhaust Gas Recirculation) Valve
- 1719-16 Electronic Throttle Body
- 1432-14 Egr Bypass Solenoid Valve
- 1719-02 Variable Swirl Actuator
- 1914-01 E-Vgt Control Actuator
- 1432-03 Camshaft Position Sensor
- 1127-35 Crankshaft Position Sensor
- 2010-01 Accelerator Pedal Position Sensor
- 1882-21 Inlet Metering Valve (Imv)
- 1432-05 Knock Sensor
- REMOVAL AND INSTALLATION
- 1491-01 Ecu (D20dtr)
- 1882-09 Injector
- 2330-08 Hfm (Hot Film Air-Mass) Sensor
- 1432-01 T-Map (Temperature-Manifold Air Pressure) Sensor
- 1432-07 Coolant Temperature Sensor
- 1432-08 Wide Band Oxygen Sensor
- 1432-04 Differential Pressure Sensor
- 1432-17 Egt (Exhaust Gas Temperature) Sensor
- 1793-01 E-Egr (Electric-Exhaust Gas Recirculation) Valve Assembly
- 1719-16 Electric Throttle Body
- 1432-14 E-Egr Bypass Solenoid Valve
- 1729-02 Variable Swirl Actuator
- 1432-03 Camshaft Position Sensor
- 1127-35 Crankshaft Position Sensor
- 2010-01 Accelerator Pedal Position Module
- 1882-01 Imv (Inlet Metering Valve)
- 1432-05 Knock Sensor
ENGINE ASSEMBLY
- GENERAL
- 1. Description And Operation
- 2. G23d Engine Assembly
- 3. G23d Engine Structure
- 4. Diagnostic Information And Procedure
- 5. General Diagnosis
- 6. Specifications
- CONFIGURATION AND FUNCTIONS
- 1113-01 Crankcase Ventilation System
- 1532-00 Oil Circulation
- REMOVAL AND INSTALLATION
- 1113-01 Engine Assembly
- 1452-01 Alternator
- 1113-01 Engine Mount
- 1130-07 Poly V-Belt
- 1130-07 Poly V-Belt Inspection
- 1332-18 Tensioning Device
- 1332-18 Tensioning Device Shock Absorber
- 1221-01 Cylinder Head Cover
- 1221-02 Cylinder Head Front Cover
- 1221-02 Cylinder Head
- 1332-01 Timing Gear Case Cover
- 1124-17 Crankshaft Sealing Rear Cover
- 1130-07 Belt Pulley And Vibration Damper
- 1131-02 Crankshaft Front Radial Seal
- 1124-16 Crankshaft Rear Radial Seal
- 1130-01 Crankshaft
- 1130-11 Arrangement Of The Thrust Bearing And The Main Bearing
- 1130-09 Flywheel/ Drive Plate
- 1311-31 Camshaft Adjuster
- 1221-21 Camshaft
- 1221-21 Inspection And Adjustment Of Camshaft Timing Position
- 1211-32 Valve Spring
- 1211-30 Valve Stem Seal
- 1532-19 Chain Tensioner
- 1311-01 Timing Chain
- 1311-04 Tensioning Rail
- 1311-09 Cylinder Head Guide Rail
- 1311-05 Crankcase Guide Rail
- 1130-04 Crankshaft Sprocket
- 1130-20 Piston
- 1130-13 Connecting Rod
- 1130-21 Piston Ring
- 1532-24 Oil Pan
- 1532-00 Engine Oil And Oil Filter Element
- 1532-00 Oil Pump
- 1532-00 Oil Pressure Relief Valv
- 1532-00 Oil Non-Return Valve
- 1532-00 Oil Dipstick Guide Tube
- 1311-31 Repair Of Core Plugs In Crankcase
- 1124-01 Cylinder Bore
- 1311-31 Crankcase Mating Surface
- 1211-02 Cylinder Head Mating Surface
ENGINE FUEL SYSTEM
- GENERAL
- 1. Fuel System Specification
- OVERVIEW AND OPERATIONPROCESS
- 1. Fuel System
- CONFIGURATION AND FUNCTIONS
- 2211-06 Fuel Pump
- 2241-20 Fuel Injector
- 1623-06 Purge Control Valve
- 2241-01 Fuel Rail
- 2241-08 Fuel Pressure Regulator
- REMOVAL AND INSTALLION
- 2241-08 Discharging The Pressure In Fuel System
- 2210-06fuel Pump Assembly
- 2221-01 Fuel Filter
- 2210-01 Fuel Tank Assembly
- 2241-08 Fuel Pressure Regulator
- 2241-20 Fuel Rail And Injectors
- 1623-06 Purge Control Valve
- 2221-09 Canister
ENGINE INTAKE SYSTEM
- GENERAL
- 1. Specifications
- CONFIGURATION AND FUNCTIONS
- 2312-01 Air Cleaner And Intake Air Duct
- REMOVAL AND INSTALLATION
- 2312-01 Air Cleaner And Intake Air Duct
- 1713-03 Intake Manifold
ENGINE EXHAUST SYSTEM
- GENERAL
- 1. Specification
- OVERVIEW AND OPERATION PROCESS
- 1. Description And Operation
- REMOVAL AND INSTALLATION
- 2420-01 Exhaust Line
LUBRICATION SYSTEM
- OVERVIEW AND OPERATION PROCESS
- 1. Oil Circulation
- CONFIGURATION AND FUNCTIONS
- 1531-24 Oil Pan
- REMOVAL AND INSTALLION
- 1541-03 Engine Oil And Oil Filter Element
- 1531-01 Oil Pump
- 1531-07 Oil Pressure Relief Valve
- 1311-00 Oil Non-Return Valve
- 1531-31 Oil Dipstick Guide Tube
ENGINE COOLING SYSTEM
- GENERAL
- 1. General Specifications
- 2. Fastener Tightening Specifications
- OVERVIEW AND OPERATION PROCESS
- 1. Component Locator
- 2. Description And Operation
- 3. Pwm (Pulse Width Modulation) Electric Fan Operation
- REMOVAL AND INSTALLATION
- 2110-01 Dtc For Pwm Electric Fan
- 2110-01 Diagnostic Information And Procedure
- 2110-01 Repair Instructions On-Vehicle Service
- 1522-18 Water Pump
- 1522-10 Thermostat And Thermostat Housing Assembly
- 2110-00 Pwm Controller Unit
- 2110-07 Pwm Electric Fan And Shroud Assembly
ENGINE ELECTRIC DEVICES
- GENERAL
- 1. Diagnostic Information And Procedure
- OVERVIEW AND OPERATION PROCESS
- 1. Description And Operation
- REMOVAL AND INSTALLATION
- 1452-01 Generator Repair Instructions
- 1462-01 Starter Repair Instructions
- 2610-01 Battery Repair Instructions
- 1440-01 Spark Plug And Ignition Coil Repair Instructions
CRUISE CONTROL SYSTEM
- OVERVIEW AND OPERATION PROCESS
- 1. Cruise Control Switch
- 2. How To Operate Cruise Control Switch
- REMOVAL AND INSTALLATION
- 8510-23 Cruise Control Switch
ENGINE CONTROL SYSTEM
- GENERAL
- 1. Engine Data Display Table
- 2. Fastener Tightening Specifications
- CONFIGURATION AND FUNCTIONS
- 1490-01 Engine Control Module
- 1521-26 Engine Coolant Temperature Sensor
- 1311-25 Camshaft Actuator
- 2010-01 Accelerator Pedal Module
- 1712-06 Knock Sensor
- 1430-01 Crankshaft Position Sensor
- 1311-25 Camshaft Position Sensor
- 8510-23 Cruise Control Switch
- REMOVAL AND INSTALLATION
- 1490-01 Engine Control Module
- 1712-06 Knock Sensor
- 1430-01 Crankshaft Position Sensor
- 1311-25 Camshaft Position Sensor
- 1490-01 Strategy-Based Diagnostics
- 1491-01 System Diagnosis
ELECTRIC GENERAL
- GENERAL
- 1. Locations Of Interior Units And Sensors
- 2. Location And Compartment Of Interior Switches
- 3. Switches, Units And Sensors In Engine Compartment
- 4. Electric Components And Layout
- 5. Diagnostic Connector
FUSE AND RELAY
- GENERAL INFORMATION
- 1. Cautions When Working On Electrical Units
- 2. General Information
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Fuse & Relay Mounting Location
- CONFIGURATION AND FUNCTIONS
- 8410-02 Engine Room Fuse / Relay Box
- 8410-02 Engine Room Fuse / Relay Box Circuit
- 8410-04 Capacity And Name Of Interior Fuse And Relay
- 8410-04 I/P - Lh Fuse / Relay Box Circuit
- 8410-06 Interior Fuse And Relay Box On The Passenger Side
- 8410-06 I/P - Rh Fuse / Relay Box Circuit
- 8410-08 Operating Process Of Icm Box
- 8410-08 Icm Relay Box Circuit
- REMOVAL AND INSTALLATION
- 8410-08 Icm Box
STICS
- GENERAL
- 1. Overview
- 2. Specifications
- OVERVIEW AND OPERATION PROCESS
- 1. Overview
- 2. Functions And Specifications
- 3. Circuit Diagram
- REMOVAL AND INSTALLATION
- 8710-01 Rekes Key Coding
- 8710-01 Diagnosis Trouble Code And Help Tips
- 8710-01 Stics
IMMOBILIZER SYSTEM
- OVERVIEW AND OPERATION PROCESS
- 1. Overview
- 2. Basic Functions Of Immobilizer Key(Rekes Function)
- 3. Other Functions In System
- 4. Rekes Operation Logic
- 5. Circuit Diagram
- REMOVAL AND INSTALLATION
- 7010-06 Replacing Electric Head Of Key
- 7010-06 Rekes Key Coding
- 7010-06 Immobilizer Unit
CLUSTER
- GENERAL
- 1. Specifications
- OVERVIEW AND OPERATING PROCESS
- 1. Descriptions Of Indicator Display
- 2. Configuration
- 3. Warning Lights And Indicators
- 4. Self-Diagnosis Check
- 5. Buzzer Output Spec
- 6. Circuit Diagram
- REMOVAL AND INSTALLATION
- 8210-01 Cluster
LAMP
- GENERAL
- 1. Specifications
- CONFIGURATION AND FUNCTIONS
- 8310-01 Front Lamps
- 8320-01 Rear Lamps
- 8610-01 Interior Lamps
- REMOVAL AND INSTALLATION
- 8310-01 Headlamps
- 8310-10 Fog Lamp / Drl
- 8310-13 Side Repeater
- 8320-01 Rear Combination Lamp
- 8320-12 License Plate Lamp
- 8320-16 High Moounted Stop Lamp
- 8320-19 Rear Fog Lamp
- 8610-01 Interior Lamps
- 8310-01 How To Adjust Angle Of Headlamp And Fog Lamp
SWITCH
- GENERAL
- 1. Switch Arrangement
- CONFIGURATION AND FUNCTIONS
- 8510-31 Center Fascia & Bezel Switch Assembly
- 8510-52 Outside Rearview Mirror Switch Bezel Assembly
- 7770-20 Interior Lamp Switch
- 8510-05 Main Power Window Switch
- 8510-01 Audio Remote Control Switch On Steering Wheel
- 8510-21 Multifunction Switch1
- 8510-13 Tail Gate Open Switch
- 8610-08 Digital Clock
- 8610-06 Horn (Including Theft Deterrent Horn)
- REMOVAL AND INSTALLATION
- 8510-31 Hazard & Switch Assembly
- 8510-52 Outside Rearview Mirror Switch Bezel Assembly
- 8510-52 Outside Rearview Mirror Folding Unit
- 7770-20 Overhead Console Switch
- 8510-05 Main Power Window Switch
- 8510-01 Audio Remote Control Switch
- 8510-21 Multifunction Switch
- 8510-13 Tailgate Open Switch
- 7632-16 Cigarette Lighter
- 7610-54 Power Outlet
- 7610-54 Rear Power Outlet
- 8610-08 Digital Clock
- 8610-06 Horn (Including Theft Deterrent Horn)
WIPER & WASHER
- OVERVIEW AND OPERATION PROCESS
- 1. System Layout And Function
- 2. Configuration (Including Rain Sensor)
- 3. Wiper & Washer Related Function And Specification
- 4. Wiper And Washer System Related Circuit Diagram
- REMOVAL AND INSTALLATION
- 7810-01 How To Correct Angle Of Front Wiper Arm
- 7810-01 Front Wiper Assembly
- 7830-01 Rear Wiper Assembly
- 7820-01 Reservoir Tank
- 7820-22 Nozzle And Hose
RAIN SENSOR
- OVERVIEW AND OPERATION PROCESS
- 1. System Layout And Overview
- 2. Rain Sensing Operation
- 3. Rain Sensor Related Circuit
- 4. Functions And Specifications Of Rain Sensing Wiper
- 5. Operation Mode Of Rain Sensing Wiper System
- REMOVAL AND INSTALLATION
- 8610-09 Functions And Checks Of Rain Sensor
- 8610-09 Diagnosis Procedures
- 8610-09 Rain Sensor
PAS
- GENERAL
- 1. Component Specifications
- 2. Cautions On Parking Aid System
- OVERVIEW AND OPERATION PROCESS
- 1. System Overview
- 2. Alarm Interval
- 3. Troubleshooting Of Sensor
- 4. Circuit Diagram
- REMOVAL AND INSTALLATION
- 87902-03 Parking Aid Sensor
AUDIO SYSTEM
- OVERVIEW AND INSTALLATION
- 1. Audio System Overview
- CONFIGURATION AND FUNCTIONS
- 4610-00 Audio Control Switch On Steering Wheel
- 8610-26 Radio Antenna
- 8910-07 Usb/Aux Module
- REMOVAL AND INSTALLATION
- 4610-01 Audio Control Switch
- 8930-01 Audio Assembly
- 8610-22 Front Door Speaker And Rear Door Speaker
- 8620-22 Door Tweeter Speaker
- 8910-07 Usb/Aux Module
- 8610-26 Micro-Pole Antenna
MB 5 AUTO TRANSMISSION
- GENERAL INFORMATION
- 1. Specifications
- 2. Tightening Torque
- OVERVIEW AND OPERATION PROCESS
- 1. Overview
- 2. Power Flow
- 3. Circuit Diagram
- CONFIGURATION AND FUNCTION
- 3650-01 Mb 5-Speed Assembly
- 3660-01 Valve Body
- 3721-01 Tgs Lever
- 3110-01 Tcu (Transmission Control Unit)
- REMOVAL AND INSTALLATION
- 3650-01 Oil Check And Specification
- 3110-01 Tcu
- 3650-01 Transmission Assembly (Mb 5-Speed)
- 3721-01 Tgs Lever
- 3650-01 Disassembly And Reassembly (Dc 5-Speed A/T)
- 3650-01 Valve Body Assembly
- 3660-01 Valve Body Overhaul
- 3110-01 Dtc (Diagnosis Trouble Code) Of Mb5at
- 3721-01 Dtc For Selector Lever
DSI 6 A/T
- GENERAL
- 1. General Information
- 2. Features And Specifications
- 3. Tightening Torque
- 4. Shift Pattern Diagram
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Features
- 3. Mode Descriptions
- 4. Limp Home Mode
- 5. Electronic Control System
- 6. Power Flow
- CONFIGURATION AND FUNCTION
- 3722-01 Tgs Lever
- 3680-01 Dsi M78 6-Speed A/T Assembly
- 3683-01 Valve Body
- 3110-01 Tcu
- 3682-18 Inhibitor Switch
- REMOVAL AND INSTALLATION
- 9210-02 Fluid Level Inspection
- 3680-01 A/T Assembly
- 3683-01 Valve Body Assembly
- 3110-01 Tcu
- 3722-01 Tgs Lever
- 3682-18 Inhibitor Switch
- 3110-01 Trouble Diagnosis Code
- DIAGNOSIS AND TESTING
- 1. Wiring Schematics
- 2. Wire Harness Connector Chart
- 3. Unit Connector Description
- TROUBLE CODE DIAGNOSIS
- 1. Diagnostic Trouble Code List
- 2. System Diagnosis
MANUAL TRANSMISSION (5 M/T)
- GENERAL
- 1. Overview And Characteristics Of Manualtransmission
- 2. Specifications And Tightening Torque Ofmanual Transmission
- OVERVIEW AND OPERATION PROCESS
- 1. Manual Transmission System
- CONFIGURATION AND FUNCTIONS
- 3170-01 Manual Transmission Location
- 3170-01 Manual Transmission System Components

- 3170-01 Shifting Mechanism
- REMOVAL AND INSTALLATION
- 3170-01 Diagnostic Information And Procedure
- 3170-01 Oil Check/Change Of Manual Transmission
- 3170-01 Manual Transmission
- 3170-01 Manual Transmission Overhaul
- 3660-01 Transmission Adapter
- 3170-01 Shim Adjustment
MANUAL TRANSMISSION (6 M/T)
- GENERAL INFORMATION
- 1. Specification
- 2. Special Service Tools
- 3. Tightening Torque
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Power Flow
- 3. Shifting Mechanism
- CONFIGURATION AND FUNCTION
- 3170-01 Mounting Location
- 3170-01 Manual Transmission Assembly
- 3170-01 Gear Arrangement
- 3116-25 Neutral Switch
- 3116-29 Backup Lamp Switch
- REMOVAL AND INSTALLATION
- 3170-01 Troubleshooting
- 3170-01 Oil Check And Change
- 3170-01 Manual Transmission Assembly
- 3170-01 Overhaul Of Manual Transmission
TGS LEVER
- OVERVIEW AND OPERATION PROCESS
- 1. Introduction
- 2. Functions Of The Selector Lever
- 3. Mode Switch
- 4. Parking Lock System
- CONFIGURATION AND FUNCTIONS
- 3722-01 Selector Lever Control Unit
- REMOVAL AND INSTALLATION
- 3722-01 Shift Rod Postion Adjustment
- 3722-01 Tgs Lever
CLUTCH
- GENERAL
- 1. Clutch Specifications
- 2. Tightening Torque
- OVERVIEW AND OPERATION PROCESS
- 1. Function And Overview
- CONFIGURATION AND FUNCTION
- 3020-01 Clutch Master Cylinder
- 3020-04 Clutch Release Chamber
- 3030-04 Clutch Assembly
- 3030-01 Clutch Pedal
- REMOVAL AND INSTALLATION
- 3010-01 Clutch Trouble Diagnosis
- 3010-01 Clutch Inspection And Maintenance
- 3020-01 Clutch Air Bleeding
- 3010-01 Clutch Assembly
- 3010-01 Clutch Replacement
- 3171-14 Concentric Slave Cylinder
- 3020-01 Clutch Master Cylinder
- 3030-01 Clutch Pedal
- 3020-04 Clutch Chamber
PROPELLER SHAFT
- GENERAL INFORMATION
- 1. Specification
- 2. Tightening Torque
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- CONFIGURATION AND FUNCTION
- 1. Configuration
- 2. Component
- REMOVAL AND INSTALLATION
- 3310-00 Trouble Diagnosis
- 3310-01 Front Propeller Shaft (4wd)
- 3310-02 Rear Propeller Shaft
AXLE
- GENERAL
- 1. Specifications Of Axle
- OVERVIEW AND OPERATION PROCESS
- 1. Overview Of Axle
- CONFIGURATION AND FUNCTION
- 4120-01 Front Axle
- 4210-01 5-Link Type Rear Axle
- REMOVAL AND INSTALLATION
- 4120-01 Trouble Diagnosis
- 4120-01 Inspection Of Ring Gear Tooth Contact Pattern
- 4120-01 Front Axle Assembly
- 4120-01 Axle Shaft
- 4120-01 Axle Housing
- 4220-01 Rear Axle Shaft(Disc Brake Type)
- 4220-01 Rear Axle Housing
TRANSFER CASE
- GENERAL
- 1. Overview
- 2. Specifications
- OVERVIEW AND OPERATION PROCESS
- 1. Structure
- 2. System Layout And Operation
- 3. Locking Hub System
- 4. Power Flow
- CONFIGURATION AND FUNCTION
- 3240-01 Transfer Case
- 4116-01 Components Of Iwe (Integrated Wheel End)
- 8510-47 4wd Mode Switch
- 3410-01 Tccu(Transfer Case Control Unit)
- REMOVAL AND INSTALLATION
- 3240-01 Part Time Transfer Case General Diagnosis
- 4116-01 Vacuum Locking Hub Check
- 3240-01 Oil Level Check And Change
- 3410-01 Self-Diagnosis Test
- 3410-01 Tccu Diagnostic Trouble Code
- 3240-01 Part Time Transfer Case
- 3240-01 Transfer Case Motor
- 4116-01 Iwe(Integrated Wheel End)
- 4116-01 Locking Hub Actuator Assembly
- 3410-01 Tccu
SUSPENSION
- GENERAL
- 1. Specifications Of Suspension
- 2. Wheel Alignment
- CONFIGURATION AND FUNCTION
- 4411-01 Front Suspension (Double Wishbone)
- 4510-01 Rear Suspension(5-Link Type)
- REMOVAL AND INSTALLATION
- 4510-01 Trouble Diagnosis Of Rear Suspension
- 4410-01 Front Suspension-Upper Arm
- 4411-01 Front Suspension- Coil Spring & Shock Absorber Assembly
- 4420-01 Front Suspension-Stabilizer Bar
- 4410-01 Front Suspension-Lower Arm
- 4510-01 Rear Suspension(5 - Link Type)
BRAKE SYSTEM
- GENERAL INFORMATION
- 1. Specification
- 2. System Overview
- 3. Troubleshooting
- 4. Air Bleeding
- 5. Brake System Check
- 6. Components
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. System Layout
- 3. Parking Brake
- 4. Hydraulic Circuit
- 5. Circuit Diagram Of Stop Lamp
- CONFIGURATION AND FUNCTION
- 4850-01 Brake Master Cylinder Assembly

- 4850-02 Brake Booster Assembly
- 4803-01 Front Brake Caliper Assembly
- 4115-01 Front Brake Disc
- 4830-02 Brake Pad
- 4841-01 Rear Brake Caliper Assembly
- 4910-01 Parking Brake
- REMOVAL AND INSTALLATION
- 4850-09 Brake Booster Vacuum Hose
- 4850-01 Master Cylinder And Booster
- 4810-01 Brake Pedal
- 4810-08 Stop Lamp Switch
- 4830-01 Front Brake Caliper/Disc
- 4830-02 Front Brake Pad
- 4841-01 Rear Brake Caliper/Disc
- 4841-02 Rear Brake Pad
- 4910-01 Parking Brake Assembly
- 4841-15 Parking Brake Lining (Shoe)
ESP & ABS
- GENERAL
- 1. System General
- 2. Sectional Drawing
- 3. Specifications
- 4. Brake Operation And Noise
- 5. Esp System Related Precautions
- OVERVIEW AND OPERATION PROCESS
- 1. Overview Of Esp(Electronic Stabilityprogram) System
- 2. Components Of Esp
- 3. Principle Of Esp
- 4. Principle Of Bas(Brake Assist System)
- 5. Principle Arp(Active Roll-Over Protection)
- 6. Principle Of Hdc(Hill Descent Control)
- 7. Input And Output Diagram Of Esp System
- 8. Hydraulic Circuit Diagram Of Esp System
- 9.Hydraulic Pressure For Each Esp Operatingrange
- 10. Hydraulic Circuit Of Bas (Brake Assistsystem)
- 11. Components Of Abs System
- CONFIGURATION AND FUNCTION
- 4892-01 Hecu Of Esp
- 4892-01 Hecu Of Abs
- 4850-01 Pressure Sensor
- 4890-01 Sensor Cluster
- 8510-21 Swas(Steering Wheel Angle Sensor)
- 8510-56 Esp Off Switch
- 4890-01 Awss(Active Wheel Speed Sensor)
- 4892-00 Abs/Esp
- REMOVAL AND INSTALLATION
- 4892-01 How To Use Scan Tool
- 4892-01 Abs/Esp Trouble Diagnosis
- 4892-01 Cautions When Removing Front Wheel Speed Sensor-Esp
- 4892-01 Cautions When Removing Front Wheel Speed Abs
- 4892-01 Hecu-Esp
- 4892-01 Hecu-Abs
- 4890-01 Front Wheel Speed Sensor
- 4890-01 Rear Wheel Speed Sensor
- 4850-01pressure Sensor
- 4890-01 Sensor Cluster
STEERING
- GENERAL
- 1. Overview
- 2. Specifications
- OVERVIEW AND OPERATION
- 1. System Layout
- 2. Components
- REMOVAL AND INSTALLATION
- 4610-01 Trouble Diagnosis
- 4610-01 Inspections Of Power Steering System
- 4610-06 Steering Column Shaft
- 4610-07 Lower Shaft
- 4620-02 Steering Gear Box
- 4711-01 Power Steering Pump
- 4640-01 Power Steering Oil Pipe
WHEEL & TIRE
- GENERAL INFORMATION
- 1. Specifications
- 2. Trouble Diagnosis
- 3. Inspection
- 4. Components
- OVERVIEW AND OPERATING PROCESS
- 1. Overview
- 2. Abnormal Tire Symptom
- 3. Wheel Balance
- CONFIGURATION AND FUNCTION
- 4170-09 Configuration
- REMOVAL AND INSTALLATION
- 4170-09 Wheel And Tire
AIR CONDITIONER
- OVERVIEW AND OPERATION PROCESS
- 1. System Layout And Components
- 2. Ventilation System
- 3. Air Conditioner Module And Sensors
- 4. System Diagram
- CONFIGURATION AND FUNCTIONS
- 6810-20 Air Conditioner Controller Unit
- 0000-00 Sunsensor
- 6810-20 Incar Sensor Assembly
- 6810-20 Ambient Temperature Sensor
- 6820-24 Water Temperature Sensor
- 6810-06 Power Transistor
- 6810-02 Mode Door Actuator
- 6810-02 In/Ex - Air Door Actuator
- 6810-02 Air Mix Door Actuator
- 6810-24 Thermo Amp (Intake Sensor)
- 6810-00 Fatc (Full Auto Temp. Control) Circuit
- 6810-00 Air-Con (Manual) Circuit
- 6810-15 Ptc(Positive Temperature Coefficient)
- REMOVAL AND INSTALLATION
- 6810-20 Self Diagnosis (Only For Fatc A/C Controller)
- 6810-20 Ambient Temperature Sensor
- 6820-24 Water Temperature Sensor
- 6810-06 Power Transitor
- 6810-02 Mode Door Actuator
- 6810-02 In/Ex-Air Door Actuator
- 6810-02 Air Mix Door Actuator
- 6810-24 Thermo Amp(Intake Sensor)
- 6810-01 Air Conditoner Module Assembly
- 6810-20 A/C Controller Switch And Active Incar Sensor
- 6810-01 Air Duct Assembly
- 6820-01 Condenser Assembly
- 6820-19 Receiver Drier
- 6820-18 A/C Hose And Pipe
- 6910-20 Ambient Temperature Switch
- 6810-15 Ptc
AIR BAG
- GENERAL
- 1. Overview (Including Curtain Air Bags)
- OVERVIEW AND OPERATION PROCESS
- 1. Locations And Related Components
- 2. Air Bag System Operation Process
- 3. Air Bag Module And Related Components
- REMOVAL AND INSTALLATION
- 8810-03 Trouble
- 8810-03 Driver Air Bag
- 8810-06 Passenger Air Bag
- 8810-11 Curtain Air Bag
- 8810-12 Contact Coil
- 8810-01 Air Bag Unit(Sdm)
- 8810-16 Curtain Air Bag G Sensor
SEAT
- OVERVIEW AND OPERATION PROCESS
- 1. Composition Of Seat
- 2. Functions Of Seat
- 3. Components Of Seat Belt
- 4. Circuit Diagram
- REMOVAL AND INSTALLATION
- 7410-01 Seat Mounting Points
- 7410-01 Seat Assembly
- 7430-01 Seat Belt
SUNROOF
- OVERVIEW AND OPERATION PROCESS
- 1. Components And Locations
- 2. Operation And Function
- CONFIGURATION AND FUNCTION
- 7340-01 Components Of Sunroof
- REMOVAL AND INSTALLATION
- 7340-01 Resetting Of Sunroof Control Unit
- 7340-01 Trouble Diagnosis
- 7340-04 Glass Panel Assembly
- 7340-05 Bellows Cover
- 7340-12 Drain Channel
- 7340-05 Sun Shade Panel
- 7340-12 Sunroof Control Unit(Scu) And Motor
- 7340-12 Sunroof Drain Hose
- 7340-01 Sunroof Assembly
BODY INTERIOR
- OVERVIEW AND OPERATION PROCESS
- 1. Locations
- REMOVAL AND INSTALLATION
- 7610-01 Instrument Panel Assembly
- 7610-01 Instrument Panel Frame Assembly
- 7330-01 Center Console (Automatic Transmission)
- 7332-01 Center Console(Manual Transmission)
- 7770-01 Sunvisor
- 7730-12 Pillar And Rear Quarter Trim
- 7330-01 Headlining Assembly
- 7850-01 Outside Rearview Mirror
- 7770-01 Inside Rearview Mirror
BODY EXTERIOR
- OVERVIEW AND OPERATION PROCESS
- 1. Composition Of Body Exterior
- CONFIGURATION AND FUNCTION
- 7870-01 Front Bumper Fascia
- 7880-01 Rear Bumper Assembly
- 6110-01 Hood Panel Assembly
- 7930-01 Side Silmolding
- 6210-01 Front Door Assembly
- 7120-01 Front Window Regulator
- 6310-01 Rear Door Assembly
- 7120-01 Rear Window Regulator
- 6410-01 Tailgate Assembly
- REMOVAL AND INSTALLATION
- 7870-00 Front Bumper Assembly
- 7880-01 Rear Bumper Assembly
- 6110-01 Hood Panel Assembly
- 6110-06 Hood Latch Assembly
- 6110-04 Hood Insulator
- 7930-01 Side Sill Molding
- 7870-01 Fender Panel
- 7115-01 Front Door Trim(Driver Side)
- 6210-01 Front Door(Driver Side)
- 7120-01 Window Regulator(Passenger Side)
- 7215-01 Rear Door Trim
- 6310-01 Rear Door Assembly
- 6310-01 Rear Door Molding And Panel
- 7220-01 Rear Window Regulator
- 7321-01 Tailgate Trim
- 6410-01 Tailgate Assembly
- 7310-01 Tailgate Latch And Actuator
- 7840-01 Rear Quarter Glass
BODY REPAIR
- GENERAL INFORMATION
- 1. Dimensions
- 2. Jack-Up Points
- 3. Design Changes For Improving Nvh Performance
- CONFIGURATION AND FUNCTIONS
- 4110-01 Frame Dimensions
- 4110-01 Frame Body Mounting
- 5110-01 White Body
- 5110-01 Body Dimensions
- 5110-01 Body Gaps
- 6210-01 Door Components (Including Engine Hood)
- 4010-70 Components Of Body Panels




WIRING DIAGRAM

GENERAL INFORMATION
- GENERAL INFORMATION
- 1. Dimensions
- 2. Specifications
- 3. Vehicle Identification
- 4. Maintenance Interval
- 5. Recommended Fluids And Lubricants
- 6. Jack-Up Points
- 7. Pin Arrangement Of Diagnostic Connector
ELECTRIC DEVICE GENERAL INFORMATION
- 1. HOW TO READ ELECTRICAL WIRING DIAGRAM
CONNECTOR/GROUND
- WIRING HARNESS
- 0000-00 Wiring Harness, Components Location
POWER DISTRIBUTION
- FUSE/RELAY
- 8410-00 Engine Room Fuse / Relay Box
- 8410-00 I/P - Lh Fuse / Relay Box
- 8410-00 I/P - Rh Fuse / Relay Box
ELECTRICITY DIVIDE
- 8410-00 ENGINE ROOM FUSE / RELAY BOX CIRCUIT
- 8410-00 I/P - LH FUSE / RELAY BOX CIRCUIT
- 8410-00 I/P - RH FUSE / RELAY BOX CIRCUIT
- 8410-00 ICM RELAY BOX CIRCUIT
CIRCUIT
- 1461-00 STARTING / CHARGING
- 1413-00 GLOW CONTROL UNIT
- 1491-00 ECU (ENGINE CONTROL UNIT - D20DTR EU-V)
- 1490-00 ECU (ENGINE CONTROL UNIT - GSL G23)
- 8210-00 DIAGNOSIS CIRCUIT
- 3110-00 TCU (6-A/T)
- 3110-00 TCU (5-A/T)
- 3410-00 TCCU
- 4892-00 ABS/ESP
- 8810-00 AIR-BAG (CURTAIN AIR-BAG)
- 8010-00 CLUSTER
- 7410-00 POWER SEAT - DRIVER
- 7410-00 POWER SEAT - PASSENGER
- 8510-00 ELECTRIC OUTSIDE MIRROR
- 8510-00 FRT SEAT WARMER
- 8710-00 STICS
- 7830-00 RR WIPER CIRCUIT
- 8510-00 POWER WINDOW CIRCUIT
- 8610-00 HORN
- 8730-00 IMMOBILIZER CIRCUIT (D20DTR)
- 7632-00 CIGAR LIGHTER / POWER OUTLET CIRCUIT
- 7340-00 SUNROOF CIRCUIT
- 8310-00 HEAD LAMP CIRCUIT
- 8510-00 HLLD (HEAD LAMP LEVEL G DEVICE) CIRCUIT
- 8320-00 TAIL LAMP CIRCUIT
- 8410-00 TURN SIGNAL / HAZARD LAMP CIRCUIT
- 8210-00 TRAILER LAMP CIRCUIT
- 8310-00 FOG LAMP CIRCUIT
- 4810-00 STOP / BACK-UP LAMP CIRCUIT
- 7770-00 INTERIOR LAMP CIRCUIT
- 7770-00 AUTO DIMMING ROOM MIRROR CIRCUIT
- 8910-00 AUDIO / CLOCK CIRCUIT
- 8790-00 PARKING AID CIRCUIT
- 6810-00 PTC HEATER (POSITIVE TEMPERATURE COEFFICIENT)
- 6810-00 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT
- 6810-00 AIR-CON (MANUAL) CIRCUIT




OWNER’S MANUAL

SAFETY PRECAUTIONS
- Checks before starting a journey
- Safety instructions
- Starting the engine and driving off the vehicle
- Vehicle care
- Caring for your vehicle under 0°c (32°f)
- Precautions regarding unauthorized modification & alteration
IGNITION KEYREMOTE CONTROL KEY
- Remote control key* and ignition key
- Immobilizer system*
- Key functions
- Opening and closing the doors with ignition key
- Theft deterrent system
OPENING AND CLOSING
- Door opening lever, door lock/unlock knob
- Windows
- Sunroof*
- Tailgate
- Fuel filler door
- Engine hood
INTERIOR SWITCHES
- Interior switches
- Light switch
- Wiper and washer switch
- Rain sensing wiper*
- Cruise control switch*
- Remote control switches on steering wheel*
- Outside rearview mirror control switch
- Esp off switch*
- Trip and reset switch
- Hdc (hill descent control) switch*
- Heated glass switch
- Hazard warning flasher switch
- 4-wheel drive system and switch*
- Switches in overhead console
INSTRUMENT CLUSTER
- Instrument cluster
- Gauges and display window
- Warning lights and indicators
- Lcd display
TRANSMISSION AND BRAKE
- Shift lever in manual transmission (6-speed)
- Shift lever in manual transmission (5-speed)
- Gear selector lever in automatic transmission*
- Driving tips for automatic transmission
- Gear selector lever positions
- Winter (w) / standard (s) mode
- Safety mode (automatic transmission)
- Parking aid system*
- Brake system
- Parking brake operation
SEATS
- Driver’s seat (power seat)*
- Driver’s seat (manual seat)
- Passenger’s seat
- Rear seat
- Seat heating system*
- Warning and caution
SEAT BELT ANDAIR BAG
- Seat belt and air bag
- Seat belt
- How to fasten the three point seat belt
- How to fasten the 2-point rear center seat belt
- Child restraints* and pregnant woman
- Securing a child restrain system with “isofix” and “tether anchorage” system*
- Warnings for seat belt
- Air bag
- Airbag non-inflation conditions
- Warnings for air bag
VENTILATION, HEATING, AIR CONDITIONING AND AIR PURIFICATION SYSTEM
- Heater / air conditioner system
- Warnings and cautions
- Automatic heater / air conditioner*
- Manual heater / conditioner
- Defogging and defrosting
- Replacing conditioner filter
CONVENIENCE DEVICES
- Storage boxes and convenience device
- Tiltable steering wheel and horn
- Inside rearview mirror*
- Center console / front cup holder / ashtray holder
- Removable ashtray/storage box (front)
- Cigarette lighter/sunglasses box

- Card hcard holder / sun visors and vanity mirror lamp
- Glove box / digital clock
- Power outlet
- Handbag hook
- Rear armrest / assist grip and coat hook
- Room lamps
- Rear storage box
- Luggage and luggage anchor
- Luggage cover* and handbag hook
- Roof rack
- Rear defogger and antenna
- Bluetooth system*
- Audio system*
IN CASE OF EMERGENCY
- Starting the engine with jumper cables
- Ovm tools
- Warning triangle
- Cautions when a tire is flat
- Changing a flat tire*
- Removing the spare tire
- When the engine is overheating
- Water separator warning light and engine check warning light
- Towing a disabled vehicle
- Emergency towing
- Accident/fire/heavy snow
- Trailer towing
SERVICE AND MAINTENANCE
- Daily check list
- Locations in engine compartment
- Engine oil
- Engine coolant
- Air cleaner
- Power steering fluid
- Fuel filter (diesel engine)
- Drive belt (for gasoline) / brake pedal & clutch pedal
- Brake and clutch fluid (with m/t)
- Washer fluid
- Battery
- Fuse and relay box
- Tire
- Spare tire and winter tire
- Wiper blade replacement
- Do-it-yourself operation
- Emission control
- Emission reduction device
- Scheduled maintenance services (eu) - diesel engine
- Scheduled maintenance services (general) - diesel engine
- Scheduled maintenance services - gasoline engine
LAMP
- Bulb specifications and functional check
- Location of exterior lamps
- Interior lamps

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