SsangYong KORANDO C C200 2010.10 Workshop Manual

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SsangYong KORANDO C C200 2010.10 Workshop Manual
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Language: English
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KORANDO C C200 2010.10
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Service Manual
VEHICLE GENERAL
VEHICLE GENERAL
SPECIFICATIONS AND CHECK ITEMS
1. VEHICLE IDENTIFICATION
2. SPECIFICATIONS
3. OIL SPECIFICATIONS AND CAPACITY
ENGINE
D20DTF ENGINE INFORMATION
GENERAL INFORMATION
1. ENGINE LAYOUT
2. MAJOR COMPONENTS
DURING SERVICE WORK
1. GUIDELINES FOR SERVICE WORK SAFETY
2. JACK-UP POINTS
3. STANDARD BOLTS SPECIFICATIONS
SPECIAL TOOL
1. NEW SPECIAL 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 SYSTEM
2. VACUUM PUMP
3. ENGINE MOUNTINGS
4. INTAKE/EXHAUST SYSTEM
5. CYLINDER HEAD COVER AND OIL SEPARATOR
6. CYLINDER HEAD
7. CHAIN AND GEAR DRIVE SYSTEM
8. OIL PAN
9. MASS BALANCE UNIT (MBU)
10. FLYWHEEL AND DRIVE PLATE
11. PISTON/CRANKSHAFT/CYLINDER BLOCK
CONFIGURATION
1. BELT SYSTEM
2. VACUUM PUMP
3. ENGINE MOUNTINGS
4. INTAKE/EXHAUST MANIFOLD
5. OIL SEPARATOR
6. CYLINDER HEAD ASSEMBLY
7. CHAIN DRIVE SYSTEM
8. OIL PAN
9. MASS BALANCE UNIT (MBU)
10. DUAL MASS FLYWHEEL (DMF) AND DRIVE PLATE
11. PISTON/CONNECTING ROD/CRANKSHAFT/
REMOVAL AND INSTALLATION
1336-00 TIMING CASE (D20DTF)
1336-04 BELT TENSIONER ASSEMBLY
1336-25 IDLER PULLEY ASSEMBLY NO.1 (NO.2)
1130-00 CRANKSHAFT
1130-12 ISOLATION DAMPER ASSEMBLY
1610-00 VACUUM PUMP
1610-01 VACUUM PUMP ASSEMBLY
1990-00 ENGINE MOUNTING
1330-01 ENGINE MOUNTING INSULATOR (LH-MTG)
1990-02 ENGINE MOUNTING INSULATOR (RH-MTG)
1990-03 ENGINE MOUNTING INSULATOR (FRT-MTG)
1990-11 ENGINE MOUNTING INSULATOR (RR-MTG)
1225-00 CYLINDER HEAD COVER AND CAMSHAFT (D20DTF)
1225-01 CYLINDER HEAD COVER
1214-00 CYLINDER HEAD ASSEMBLY AND CYLINDER
1214-01 CYLINDER HEAD ASSEMBLY
0000-00 ENGINE ASSEMBLY (D20DTF)
1315-00 CHAIN DRIVE
1315-01 TIMING CHAIN ASSEMBLY (UPPER CHAIN-BUSH)
1533-08 OIL PAN ASSEMBLY
1533-08 OIL PAN ASSEMBLY
1130-00 CRANKSHAFT AND FLYWHEEL
1130-40 MASS BALANCE SHAFT UNIT (MBU)
1130-13 DUAL MASS FLYWHEEL (DMF) ASSEMBLY
1120-00 ENGINE OVERHOLE
ENGINE 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
2210-05 FUEL SENDER ASSEMBLY
1882-15 HIGH PRESSURE PIPE
2231-01 FUEL FILTER
1882-23 FUEL RAIL ASSEMBLY (COMMON RAIL)
1882-01 FUEL HP PUMP ASSEMBLY
REMOVAL AND INSTALLATION
0000-00 COMPONENT
2210-01 FUEL TANK ASSEMBLY
2210-05 FUEL SENDER
2231-01 FUEL FILTER ASSEMBLY
1882-01 FUEL HP PUMP
1882-23 FUEL RAIL ASSEMBLY
INTAKE SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. INSPECTION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. COMPONENT
3. INPUT/OUTPUT DEVICES
4. OPERATING PROCESS
5. WIRING DIAGRAM
CONFIGURATION AND FUNCTION
2313-01 AIR CLEAR ASSEMBLY
2330-01 INTERCOOLER
1719-01 INTAKE MANIFOLD
REMOVAL AND INSTALLATION
2313-01 COMPONENT
2313-01 AIR CLEAR
2330-01 INTERCOOLER
1719-01 INTAKE MANIFOLD ASSEMBLY
EXHAUST SYSTEM
GENERAL INFORMATION
1. TROUBLESHOOTING
2. CAUTIONS
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. COMPONENT
3. OPERATING PROCESS
CONFIGURATION AND FUNCTION
1729-01 EXHAUST MANIFOLD ASSEMBLY
2412-00 EXHAUST PIPE ASSEMBLY
REMOVAL AND INSTALLATION
1719-00 COMPONENT
1729-01 EXHAUST MANIFOLD
2412-01 EXHAUST SYSTEM
TURBOCHARGER
GENERAL INFORMATION
1. SPECIFICATION
2. INSPECTION
3. TROUBLESHOOTING
OVERVIEW AND OPERATING PROCESS
1. SYSTEM DESCRIPTION OF E-VGT
2. COMPONENT
3. INPUT/OUTPUT DEVICES
4. OPERATING PRINCIPLES
CONFIGURATION AND FUNCTION
1914-01 TURBOCHARGER ASSEMBLY
REMOVAL AND INSTALLATION
1914-00 COMPONENT
1914-00 TURBOCHARGER ASSEMBLY
LUBRICATION SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. MAINTENANCE
OVERVIEW AND OPERATING PROCESS
1. SYSTEM DESCRIPTION
2. OPERATING PROCESS
CONFIGURATION AND FUNCTION
9210-01 ENGINE OIL
1543-09 ENGINE OIL FILTER ELEMENT
1543-13 OIL COOLER ASSEMBLY
1533-01 OIL PUMP ASSEMBLY
1533-08 OIL PAN ASSEMBLY
1127-22 OIL INJECTION NOZZLE
REMOVAL AND INSTALLATION
1543-01 COMPONENT
1543-09 OIL FILTER ELEMENT AND ENGINE OIL CHANGE
1543-01 OIL FILTER ASSEMBLY
1543-13 OIL COOLER MODULE
1533-08 OIL PAN ASSEMBLY
1533-01 OIL PUMP ASSEMBLY
ENGINE COOLING SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. CHECK AND INSPECTION
3. CAUTIONS
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
CONFIGURATION AND FUNCTION
2112-01 RADIATOR ASSEMBLY
2112-02 FAN AND SHROUD ASSEMBLY
1520-11 THERMOSTAT ASSEMBLY
1520-01 WATER PUMP ASSEMBLY
2130-11 RESERVOIR ASSEMBLY
REMOVAL AND INSTALLATION
2112-00 COMPONENT
9210-06 REPLENISHMENT
2112-01 RADIATOR ASSEMBLY
2112-02 FAN AND SHROUD ASSEMBLY
1520-11 THERMOSTAT ASSEMBLY..
1520-01 WATER PUMP ASSEMBLY
1520-21 COOLANT OUTLET PORT ASSEMBLY
CHARGE SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. INSPECTION
OVERVIEW AND OPERATING PROCESS
1. SYSTEM DESCRIPTION
2. OPERATING PROCESS
3. CIRCUIT DIAGRAM
CONFIGURATION AND FUNCTION
1. ALTERNATOR
2. BATTERY
REMOVAL AND INSTALLATION
1453-00 COMPONENT
1453-01 ALTERNATOR
2610-01 BATTERY
2610-05 BATTERY GROUND CABLE
2610-05 BATTERY POWER CABLE
PRE-HEATING
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SYSTEM OPERATION
CONFIGURATION AND FUNCTION
1413-18 GLOW PLUG CONTROL UNIT
1413-01 GLOW PLUG
REMOVAL AND INSTALLATION
0000-00 COMPONENT
1413-01 GLOW PLUG
2. GLOW PLUG CONTROL UNIT
TROUBLESHOOTING
1. DTC (DIAGNOSTIC TROUBLE CODE)
STARTING SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. TROUBLESHOOTING
OVERVIEW AND OPERATING PROCESS
1. SYSTEM DESCRIPTION
2. OPERATING PROCESS
CONFIGURATION AND FUNCTION
1. OVERVIEW
2. MOUNTING LOCATIONS
REMOVAL AND INSTALLATION
1461-00 COMPONENT
1461-01 STARTER
CRUISE CONTROL
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. CONFIGURATION
3. HOW IT WORKS
REMOVAL AND INSTALLATION
8530-01 COMPONENT
8530-01 CRUSE CONTROL SWITCH ASSEMBLY
E-EGR SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. OPERATING PROCESS
CONFIGURATION AND FUNCTION
1793-12 EGR COOLER ASSEMBLY
REMOVAL AND INSTALLATION
1793-12 COMPONENT
1793-05 E-EGR PIPE
1793-12 E-EGR COOLER
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. OPERATING TEMPERATURE
7. ELECTRIC CIRCUIT DIAGRAM
CONFIGURATION AND FUNCTION
2412-01 CDPF ASSEMBLY
REMOVAL AND INSTALLATION
2412-00 COMPONENT
2412-01 CDPF ASSEMBLY
ENGINE CONTROL SYSTEM
GENERAL INFORMATION
1. ENGINE DATA LIST
OVERVIEW AND OPERATING PROCESS
1. MAJOR COMPONENT
2. SYSTEM OPERATION
CONFIGURATION AND FUNCTION
1491-01 ECU (D20DTF)
1882-09 INJECTOR (C3I)
2313-15 HFM (HOT FILM AIR-MASS METER)
1432-01 T-MAP (TEMPERATURE/MAP) SENSOR
1432-07 WATER 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 DIFFERENT PRESSURE SENSOR
1432-17 EXHAUST GAS TEMPERATURE SENSOR
1793-01 E-EGR VALVE
1719-16 ELECTRONIC THROTTLE BODY
1432-14 E-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 (APS)
1533-30 OIL LEVEL SWITCH
1882-21 INLET METERING VALVE (IMV)
1432-05 KNOCK SENSOR
REMOVAL AND INSTALLATION
1491-01 ECU (D20DTF)
1882-09 INJECTOR (C3I)
2313-15 HFM (HOT FILM AIR-MASS SENSOR)
1432-01 T-MAP (TEMPERATURE/MAP) SENSOR
1432-07 WATER 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 DIFFERENT PRESSURE SENSOR
1432-17 EXHAUST GAS TEMPERATURE SENSOR
1793-01 E-EGR VALVE ASSEMBLY
1719-16 ELECTRONIC THROTTLE BODY
1432-14 E-EGR BYPASS SOLENOID VALVE
1719-02 VARIABLE SWIRL ACTUATOR
1432-03 CAMSHAFT POSITION SENSOR
1127-35 CRANKSHAFT POSITION SENSOR
2010-01 ACCELERATOR PEDAL POSITION SENSOR
1553-30 OIL LEVEL SWITCH
1882-01 IMV (HP ASSEMBLY)
1432-05 KNOCK SENSOR
ELECTRICAL
ELECTRIC GENERAL INFORMATION
1. EXTERIOR LAMP SYSTEM LAYOUT
2. INTERIOR LAMP SYSTEM LAYOUT
3. SWITCH SYSTEM LAYOUT
4. SCHEMATIC DIAGRAM FOR WIRING & ELECTRICAL
5. CAN COMMUNICATION CONFIGURATION
FUSE AND RELAY
GENERAL INFORMATION
1. CAUTIONS WHEN WORKING ON ELECTRICAL UNITS
2. CHECKING CABLES AND WIRES
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SYSTEM LAYOUT
3. OPERATING PROCESS
COMPONENT
8410-02 FUSE BOX IN ENGINE COMPARTMENT
REMOVAL AND INSTALLATION
8410-02 FUSE BOX IN ENGINE COMPARTMENT
8410-08 ICM BOX
BCM
GENERAL INFORMATION
1. SPECIFICATION
2. FUNCTIONS
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW & FUNCTIONS
2. CODING FOR IMMOBILIZER/REMOTE CONTROLLER KEY
CONFIGURATION
8710-01 BCM
REMOVAL AND INSTALLATION
8710-01 BCM
7010-06 IMMOBILIZER ANTENNA
7010-06 BUZZER
DIAGNOSTIC GUIDE
INSTRUMENT CLUSTER
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SYSTEM LAYOUT
3. WARNING LAMPS AND INDICATORS
4. OPERATING PROCESS
5. SELF DIAGNOSIS
CONFIGURATION
8010-01 COMPONENT
8010-01 CIRCUIT DIAGRAM
REMOVAL AND INSTALLATION
8010-00 INSTRUMENT CLUSTER
SWITCH
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SWITCH CLUSTER ON DOOR TRIM
3. SWITCH CLUSTER ON INSTRUMENT PANEL
4. STEERING WHEEL SWITCH
5. SEAT WARMER SWITCH
6. OVERHEAD CONSOLE SWITCH
7. TAILGATE OPEN SWITCH
CONFIGURATION AND FUNCTION
8520-01 POWER WINDOW MAIN SWITCH
8520-05 OUTSIDE MIRROR SWITCH
8520-07 POWER WINDOW SUB SWITCH
6810-20 FATC SWITCH
8510-15 CENTER FASCIA SWITCH
8510-21 4WD SWITCH
8510-23 ESP OFF SWITCH
8510-25 REAR FOG LAMP SWITCH
8510-28 HEAD LAMP LEVELING SWITCH
7410-26 POWER SEAT SWITCH ASSEMBLY
8530-10 AUDIO REMOTE CONTROL SWITCH
8530-01 LIGHT SWITCH ASSEMBLY
8530-02 WIPER SWITCH ASSEMBLY
8530-03 CRUISE CONTROL SWITCH
8610-06 HORN SWITCH
8510-01 SEAT WARMER SWITCH ASSEMBLY
8520-10 REAR SEAT WARMER SWITCH
7770-20 OVERHEAD CONSOLE SWITCH
7310-00 TAILGATE OPEN SWITCH
REMOVAL AND INSTALLATION
8520-01 POWER WINDOW MAIN SWITCH
8520-05 OUTSIDE MIRROR SWITCH
8520-07 POWER WINDOW SUB SWITCH
6810-20 FATC SWITCH
8510-15 CENTER FASCIA SWITCH
8510-00 LOWER MAIN PANEL SWITCH
7410-26 POWER SEAT SWITCH
8530-10 AUDIO REMOTE CONTROL SWITCH
8530-01 LIGHT SWITCH ASSEMBLY
8530-02 WIPER SWITCH ASSEMBLY
8530-03 CRUISE CONTROLSWITCH
8510-01 SEAT WARMER SWITCHASSEMBLY
8520-10 REAR SEAT WARMER SWITCH ASSEMBLY
7770-20 OVERHEAD CONSOLE SWITCH
7310-00 TAILGATE OPEN SWITCH
LAMP
GENERAL INFORMATION
SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. EXTERIOR LAMPS
2. INTERIOR LAMPS
CONFIGURATION
8310-01 HEADLAMP
8610-09 AUTO LIGHT AND RAIN SENSOR MODULE
8310-08 FRONT FOG LAMP
8320-01 REAR COMBINATION LAMP
8320-10 HIGH MOUNTED STOP LAMP
8320-08 LICENSE PLATE LAMP
7850-01 SIDE REPEATER LAMP
7850-01 PUDDLE (APPROACH) LAMP
7700-03 FRONT ROOM LAMP
8610-06 CENTER ROOM LAMP
8610-06 LUGGAGE LAMP
8610-08 GLOVE BOX LAMP
7770-02 SUN VISOR LAMP
8610-02 DOOR COURTESY LAMP
REMOVAL AND INSTALLATION
8310-01 HEADLAMP
8310-10 FRONT FOG LAMP
8320-01 SIDE REPEATER LAMP
8320-01 PUDDLE LAMP
8320-01 REAR COMBINATION LAMP
0000-00 HIGH MOUNTED STOP LAMP
8320-01 LICENSE PLATE LAMP
7770-03 FRONT ROOM LAMP
7770-03 CENTER ROOM/LUGGAGE LAMPS
7770-03 DOOR COURTESY LAMP
7770-03 GLOVE BOX LAMP
7770-03 SUN VISOR LAMP
8610-09 AUTO LIGHT AND RAIN SENSOR MODULE
WIPER AND WASHER SYSTEM
GENERAL INFORMATION
1. WIPER CONTROL
2. CAUTIONS ON RAIN SENSOR
OVERVIEW AND OPERATING PROCESS
1. WIPER AND WASHER SYSTEM
2. RAIN SENSING SYSTEM
3. SYSTEM LAYOUT (INCLUDING RAIN SENSOR)
4. WIPER & WASHER OPERATION
COMPONENT
7810-00 FRONT WIPER
7820-00 WINDSHIELD WASHER
7830-00 REAR WIPER
8511-05 WIPER SWITCH
7810-03 WIPER MOTOR
7815-05 FRONT WIPER ARM AND BLADE
7820-01 WASHER FLUID RESERVOIR
8610-09 AUTO LIGHT AND RAIN SENSOR MODULE
7810-01 FRONT / REAR WIPER AND WASHER
REMOVAL AND INSTALLATION
7810-01 CORRECTION OF FRONT WIPER
8610-09 AUTO LIGHT AND RAIN SENSOR MODULE
7810-01 FRONT WIPER ASSEMBLY
7830-01 REAR WIPER ASSEMBLY
7820-01 RESERVOIR
7820-22 NOZZLE AHD HOSE
PAS (PARKING AID SYSTEM)
GENERAL INFORMATION
1. SPECIFICATION
2. CAUTIONS
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. CONFIGURATION
3. OPERATING PROCESS
4. ALARM FOR SELF DIAGNOSIS
COMPONENT
8790-01 PARKING AID UNIT
8790-03 PARKING AID SENSOR
8790-01 CIRCUIT DIAGRAM
REMOVAL AND INSTALLATION
8790-04 REAR PAS SENSOR
8790-01 PAS UNIT
AUDIO SYSTEM
GENERAL INFORMATION
8910-05 RDS (RADIO DATA SYSTEM) AUDIO
OVERVIEW AND OPERATING PROCESS
1. LOCATION OF CONTROLS
2. DISPLAY WINDOW
3. CONNECTORS (AUDIO REAR VIEW)
8530-10 STEERING WHEEL AUDIO
8910-10 USB PORT AND AUX JACK
8930-11 POLE ANTENNA
CHASSIS
CHASSIS GENERAL INFORMATION
MAJOR COMPONENTS
1. MOUNTING LOCATIONS (CHASSIS)
2. CHASSIS COMPONENT LAYOUT
3. SUB FRAME AND STEERING GEAR BOX LAYOUT
4. FRONT SUSPENSION COMPONENT LAYOUT
5. REAR SUSPENSION COMPONENT LAYOUT
6. BRAKE SYSTEM AND ESP SYSTEM LAYOUT
7. STEERING SYSTEM LAYOUT
DURING SERVICE WORK
1. GUIDELINES FOR SERVICE WORK SAFETY
2. JACK-UP POINTS.
3. STANDARD BOLTS SPECIFICATIONS
SPECIAL TOOLS AND EQUIPMENT
1. NEW SPECIAL TOOLS
2. NORMAL EQUIPMENTS
DSI 6 SPEED AUTO TRANSAXLE
GENERAL INFORMATION
1. GENERAL INFORMATION
2. SPECIFICATIONS
3. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. FEATURES
3. MODES AND FUNCTIONS
4. LIMP HOME MODE
5. TRANSAXLE ELECTRONICAL CONTROL SYSTEM
6. CAN NETWORK
7. POWER TRANSFER
CONFIGURATION AND FUNCTIONS
3722-01 TGS LEVER
3680-01 DSI 6-SPEED A/T ASSEMBLY
3680-01 VALVE BODY ASSEMBLY
3110-01 TCU
3680-01 INHIBITOR SWITCH
3110-01 CIRCUIT DIAGRAM
REMOVAL AND INSTALLATION
3680-01 FLUID LEVEL INSPECTION
3680-01 MAINTENANCE OPERATIONS
3680-01 A/T ASSEMBLY
3680-01 VALVE BODY ASSEMBLY
3680-00 TORQUE CONVERTER
3680-00 INHIBITOR SWITCH
3110-01 TCU
3722-01 TGS LEVER ASSEMBLY
3722-06 TGS CABLE
3110-01 DTC
6-SPEED M/T
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. POWER FLOWS
3. SHIFTING MECHANISM
CONFIGURATION AND FUNCTION
1. MOUNTING LOCATION
2. COMPONENT
REMOVAL AND INSTALLATION
3190-00 TROUBLESHOOTING
3190-01 OIL CHECK AND CHANGE
3710-04 TRANSMISSION CABLE ASSEMBLY
3190-01 M/T ASSEMBLY
3190-01 DISASSEMBLING OF M/T ASSEMBLY
3193-02 PRIMARY OUTPUT SHAFT ASSEMBLY
3194-02 SECONDARY OUTPUT SHAFT ASSEMBLY
3195-04 REVERSE IDLE GEAR ASSEMBLY
3195-09 DIFFERENTIAL CARRIER
3194-25 SHIFT RAIL
3190-01 ASSEMBLING OF M/T ASSEMBLY
CLUTCH
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SATIC
3. DUAL MASS FLYWHEEL (DMF)
CONFIGURATION
3010-01 CLUTCH ASSEMBLY
3020-01 CLUTCH MASTER CYLINDER
3020-06 CLUTCH RELEASE CHAMBER
3030-01 CLUTCH PEDAL
REMOVAL AND INSTALLATION
3010-00 TROUBLESHOOTING
3010-00 CIRCUIT DIAGRAM OF INTERLOCK SWITCH
3020-00 AIR BLEEDING
3010-00 INSPECTION AND MAINTENANCE
3010-01 CLUTCH DISC & COVER ASSEMBLY
3191-11 CONCENTRIC SLAVE CYLINDER
3020-01 CLUTCH MASTER CYLINDER & RELEASE CHAMBER
3030-01 CLUTCH PEDAL
PROPELLER SHAFT
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. COMPONENT
CONFIGURATION AND FUNCTION
1. CONFIGURATION
2. COMPONENTS DIAGRAM
REMOVAL AND INSTALLATION
3310-00 TROUBLESHOOTING
3310-01 PROPELLER SHAFT
DRIVE SHAFT AND AXLE
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. COMPONENT
2. TORQUE STEER
3. REAR AXLE
REMOVAL AND INSTALLATION
4110-01 TROUBLESHOOTING
4115-01 FRONT HUB AND KNUCKLE
4221-01 REAR HUB AND KNUCKLE (FOR 4WD)
4221-01 REAR HUB AND KNUCKLE (FOR 2WD)
4110-01 FRONT DRIVE SHAFT
4220-03 REAR DRIVE SHAFT (FOR 4WD)
4110-03 DRIVE SHAFT BOOT
4220-01 REAR AXLE (FOR 4WD)
4220-01 DIFFERENTIAL CARRIER
AWD
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SYSTEM LAYOUT
COMPONENT
3270-01 PTU (POWER TRANSFER UNIT)
3280-01 E-COUPLING
3280-17 E-COUPLING CONTROL UNIT
REMOVAL AND INSTALLATION
3270-01 PTU ASSEMBLY
3271-00 PTU ASSEMBLY
3270-00 CHANGING AND ADDING OIL
3280-01 E-COUPLING ASSEMBLY
3281-00 E-COUPLING ASSEMBLY
3280-17 E-COUPLING CONTROL UNIT
SUSPENSION SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
COMPONENT
1. SYSTEM LAYOUT
4410-00 FRONT SUSPENSION
4520-00 REAR SUSPENSION
REMOVAL AND INSTALLATION
4410-00 TROUBLESHOOTING
4410-01 FRONT SUSPENSION LOWER ARM
4411-01 DAMPER STRUT ASSEMBLY
4411-03 FRONT COIL SPRING
4420-01 FRONT STABILIZER BAR ASSEMBLY
4420-02 STABILIZER BAR MOUNTING BUSH
4520-00 REAR SUSPENSION ASSEMBLY
4520-01 REAR UPPER ARM
4520-13 REAR TRACK ROD
4520-03 REAR TRAILING ARM
4520-14 REAR STABILIZER BAR ASSEMBLY
4521-01 REAR COIL SPRING
4521-04 REAR SHOCK ABSORBER ASSEMBLY
4521-13 REAR LOWER ARM ASSEMBLY
BRAKE SYSTEM
GENERAL INFORMATION
1. SYSTEM OVERVIEW
2. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. SECTIONAL DIAGRAM
3. SYSTEM LAYOUT
4. CIRCUIT DIAGRAM OF STOP LAMP
CONFIGURATION AND FUNCTION
4850-01 MASTER CYLINDER AND BOOSTER
4830-01 FRONT BRAKE CALIPER/DISC
4841-01 REAR DISC BRAKE
4910-01 PARKING BRAKE
REMOVAL AND INSTALLATION
4850-00 TROUBLESHOOTING
4850-00 BRAKE OPERATION AND NOISE
4850-00 AIR BLEEDING
4810-01 BRAKE PEDAL CHECK
4850-03 BRAKE BOOSTER CHECK
4830-01 FRONT BRAKE CHECK
4210-54 REAR BRAKE CHECK
4910-01 PARKING BRAKE CHECK
4850-09 BRAKE BOOSTER VACUUM HOSE
4850-03 MASTER CYLINDER
4850-02 BRAKE BOOSTER
4810-01 BRAKE PEDAL
4810-09 STOP LAMP SWITCH
4830-01 FRONT BRAKE CALIPER/DISC
4830-02 FRONT BRAKE PAD CHANGE
4841-01 REAR BRAKE CALIPER/DISC
4841-02 REAR BRAKE PAD
4910-01 PARKING BRAKE CABLE
4840-01 PARKING BRAKE
ANTI-LOCK BRAKE SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. SYSTEM OVERVIEW
2. COMPONENT
3. ABS CONTROL LOGIC
4. WARNING LAMPS
5. SYSTEM OPERATION
6. HYDRAULIC CIRCUIT OF ABS
7. CIRCUIT DIAGRAM
CONFIGURATION
4892-01 HECU)
4890-01 ACTIVE WHEEL SPEED SENSOR
4890-09 G-SENSOR (ONLY FOR 4WD)
REMOVAL AND INSTALLATION
4825-00 AIR BLEEDING
4892-01 HECU)
4890-01 ACTIVE WHEEL SPEED SENSOR
4890-10 G-SENSOR)
ELECTRONIC STABILITY PROGRAM
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. COMPONENT
3. PRECAUTIONS
4. WARNING LAMPS
5. SYSTEM DESCRIPTION
6. HYDRAULIC CIRCUIT OF ESP
7. CIRCUIT DIAGRAM
CONFIGURATION
4892-01 HECU (HYDRAULIC ELECTRONIC CONTROL UNIT)
4890-10 SENSOR CLUSTER
8530-09 SWAS (STEERING WHEEL ANGLE SENSOR)
8510-23 ESP OFF SWITCH
4890-01 ACTIVE WHEEL SPEED SENSOR
REMOVAL AND INSTALLATION
4825-00 AIR BLEEDING
4892-01 HECU (HYDRAULIC ELECTRONIC CONTROL UNIT)
4890-10 SENSOR CLUSTER
4890-01 ACTIVE WHEEL SPEED SENSOR
8530-09 STEERING WHEEL SENSOR
8510-23 ESP OFF SWITCH
4850-01 MASTER CYLINDER AND BOOSTER
POWER STEERING SYSTEM
GENERAL INFORMATION
1. SPECIFICATION (HPS)
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. SYSTEM DESCRIPTION
2. SYSTEM LAYOUT
CONFIGURATION AND FUNCTION
1. COMPONENT
REMOVAL AND INSTALLATION
4610-00 TROUBLESHOOTING
4610-00 INSPECTION AND MAINTENANCE
4711-06 POWER STEERING PUMP
4711-01 POWER STEERING OIL RESERVOIR
4640-00 POWER STEERING OIL PIPE
4610-05 STEERING COLUMN AND LOWER SHAFT
4620-01 STEERING GEAR LINKAGE
WHEEL & TIRE
GENERAL INFORMATION
1. SPECIFICATION
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. ABNORMAL TIRE SYMPTOM
3. WHEEL BALANCE
CONFIGURATION AND FUNCTION
1. CONFIGURATION
2. EMERGENCY PUNCTURE REPAIR KIT
REMOVAL AND INSTALLATION
4170-00 TROUBLESHOOTING
4170-00 INSPECTION
4170-01 WHEEL AND TIRE
ELECTRIC POWER STEERING
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. OPERATIONS
CONFIGURATION AND FUNCTION
1. SYSTEM LAYOUT
2. COMPONENT
3. CIRCUIT DIAGRAM
REMOVAL AND INSTALLATION
4610-00 CAUTIONS
4610-04 STEERING COLUMN AND SHAFT
4620-01 STEERING GEAR BOX
4610-00 INITIALIZATION & DTC
SUB FRAME ASSEMBLY
GENERAL INFORMATION
1. SPECIFICATION
2. TIGHTENING TORQUE
OVERVIEW AND OPERATING PROCESS
4012-01 OVERVIEW OF FRONT SUB FRAME
4015-01 OVERVIEW OF REAR SUB FRAME
CONFIGURATION
4012-01 LAYOUT OF FRONT SUB FRAME
4015-01 LAYOUT OF REAR SUB FRAME
4012-00 COMPONENT
REMOVAL AND INSTALLATION
4012-01 FRONT SUB FRAME
4015-01 REAR SUB FRAME (4WD)
BODY
AIR CONDITIONING SYSTEM
GENERAL INFORMATION
1. SPECIFICATIONS
OVERVIEW AND OPERATING PROCESS
1. SYSTEM LAYOUT
2. HEATER AND A/C CONTROL
3. A/C COOLING CYCLE
4. A/C COOLING CIRCUIT
5. A/C CIRCUIT DIAGRAM
COMPONENTS
6810-01 A/C MODULE
6820-01 A/C HOSES AND PIPES
6830-01 AIR DISTRIBUTOR
6810-20 HEATER AND A/C CONTROL ASSEMBLY
6810-00 A/C MODULE
6810-15 PTC HEATER ASSEMBLY
REMOVAL AND INSTALLATION
6810-20 FATC SELF DIAGNOSIS
6810-20 HEATER AND A/C CONTROL ASSEMBLY
6810-01 A/C
6810-12 MODE ACTUATOR ASSEMBLY
6810-02 INTAKE ACTUATOR ASSEMBLY
6810-11 TEMPERATURE ACTUATOR ASSEMBLY
6810-11 WATER TEMPERATURE SENSOR
6810-24 INTAKE SENSOR
6810-06 RESISTOR
6810-05 BLOWER MOTOR ASSEMBLY
6810-03 AIR FILTER ASSEMBLY
6810-03 PTC HEATER
AIR BAG SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. MAJOR REPLACEMENT PARTS
3. OPERATING CONDITIONS
4. CAUTIONS FOR AIR BAG OPERATION
OVERVIEW AND OPERATING PROCESS
1. SYSTEM CONFIGURATION
2. OPERATING CONDITIONS
3. OPERATION
4. AIR BAG WARNING LAMP ON CONDITION
5. CIRCUIT DIAGRAM
COMPONENT
8620-13 DRIVER AIR BAG MODULE
8620-23 PASSENGER AIR BAG MODULE
8621-03 INFLATABLE CURTAIN AIR BAG MODULE
7400-13 SAB (SIDE AIR BAG)
7460-13 SEAT BELT PRETENSIONER
8627-03 FRONT IMPACT SENSOR ASSEMBLY
8627-03 SIDE AIR BAG SENSOR ASSEMBLY
8625-03 SDM UNIT ASSEMBLY
REMOVAL AND INSTALLATION
8620-13 DRIVER AIR BAG MODULE
8530-00 CONTACT COIL
8620-23 PASSENGER AIR BAG MODULE
8621-03 INFLATABLE CURTAIN AIR BAG MODULE
8627-03 FRONT IMPACT SENSOR ASSEMBLY
8627-03 SIDE AIR BAG SENSOR ASSEMBLY
8625-03 SDM UNIT ASSEMBLY
SEAT
GENERAL INFORMATION
1. SPECIFICATION
2. WARNINGS FOR POWER SEAT
3. CAUTIONS FOR POWER SEAT
COMPONENT
7400-13 FRONT SEAT
7500-13 REAR SEAT
7460-13 FRONT SEAT BELT
7560-13 REAR SEAT BELT
7510-08 CHILD RESTRAINT SYSTEM (ISO FIX)
REMOVAL AND INSTALLATION
7410-01 DRIVER SEAT ASSEMBLY
7410-01 PASSENGER SEAT ASSEMBLY
7510-01 REAR SEAT (LH, 6:4 PARTITION SEAT)
7510-02 REAR SEAT (RH, 6:4 PARTITION SEAT)
7430-00 SEAT BELT ASSEMBLY
SUNROOF SYSTEM
GENERAL INFORMATION
1. SPECIFICATION
2. CAUTIONS WHEN WORKING
OVERVIEW AND OPERATING PROCESS
1. SYSTEM LAYOUT
2. OPERATING PROCESS
3. SUNROOF OPEN WARNING
4. ZERO POINT SETTING
5. CIRCUIT DIAGRAM
CONFIGURATION
7340-00 COMPONENTS
7340-02 SCU (SUNROOF CONTROL UNIT)
7340-02 SUNROOF MOTOR
REMOVAL AND INSTALLATION
7340-00 TROUBLESHOOTING
7340-00 ACTIONS
7770-20 OVERHEAD CONSOLE SWITCH
7340-02 SCU (SUNROOF CONTROL UNIT)/MOTOR
7340-01 WIND DEFLECTOR
7340-01 DRAIN CHANNEL
7340-04 SUNROOF GLASS PANEL ASSEMBLY
7340-01 SUNROOF ASSEMBLY
7340-03 SUNROOF SUN SHADE
BODY INTERIOR
COMPONENT
7110-00 FRONT DOOR OPENING SYSTEM
7115-00 FRONT DOOR TRIM
7120-00 FRONT WINDOW LIFTER
7210-00 REAR DOOR OPENING SYSTEM
7215-00 REAR DOOR TRIM
7220-00 REAR WINDOW LIFTER
7321-00 TAILGATE TRIM
7330-00 HEAD LINING
7610-00 INSTRUMENT PANEL
7630-00 FRONT CONSOLE
7710-00 FLOOR CARPET
7730-00 PILLAR TRIM
7752-00 LUGGAGE PARTS
7770-00 SUN SHADE AND INSIDE MIRROR
7792-00 ANTI-VIBRATION PAD
REMOVAL AND INSTALLATION
7610-01 INSTRUMENT PANEL
7610-17 GLOVE BOX ASSEMBLY
7610-27 CLUSTER FASCIA PANEL ASSEMBLY
7610-09 SIDE FASCIA PANEL (LH) ASSEMBLY
7610-16 CENTER FASCIA PANEL ASSEMBLY
7610-10 SIDE FASCIA PANEL (RH) ASSEMBLY
7630-00 FRONT CONSOLE (AUTOMATIC TRANSMISSION)
7630-00 FRONT CONSOLE (MANUAL TRANSMISSION)
7730-12 DOOR SCUFF FRONT TRIM ASSEMBLY
7730-23 DOOR SCUFF REAR TRIM ASSEMBLY
7730-01 A-PILLAR TRIM ASSEMBLY
7730-03 B-PILLAR UPPER TRIM ASSEMBLY
7730-09 QUARTER UPPER TRIM ASSEMBLY
7770-01 SUN VISOR ASSEMBLY
7330-11 GRIP ASSEMBLY
7330-01 HEAD LINING ASSEMBLY
7115-00 FRONT DOOR TRIM
7215-01 REAR DOOR TRIM
7830-01 REAR END AND TAILGATE TRIM
BODY EXTERIOR
COMPONENT
5110-01 WHITE BODY
5120-00 BODY MOUNTING
5125-00 BODY FRAME
5210-00 SIDE AND REAR BODY
5510-00 ROOF PANEL
5610-00 FRONT FLOOR PANEL
5620-00 REAR FLOOR PANEL
5710-00 FRONT END PANEL
5720-00 FENDER AND APRON PANEL
5730-00 DASH PANEL AND COWL
6110-00 HOOD PANEL
6210-00 FRONT DOOR PANEL
6310-00 REAR DOOR PANEL
6410-00 TAILGATE PANEL
7090-00 FUEL FILLER DOOR LOCK
7121-00 FRONT WEATHERSTRIP
7221-00 REAR WEATHERSTRIP
7310-00 TAILGATE OPENING SYSTEM
7830-00 BACK WINDOW WIPER
7840-00 GLASS
7850-00 OUTSIDE REAR VIEW MIRROR
7870-00 FRONT BUMPER
7880-00 REAR BUMPER
7910-00 RADIATOR GRILLE
7930-00 SIDE BODY MOLDING
7940-00 ROOF AND REAR BODY MOLDINGS
7970-00 WHEEL HOUSE COVER
REMOVAL AND INSTALLATION
7870-00 FRONT BUMPER
7880-00 REAR BUMPER
6110-00 HOOD PANEL
6410-00 TAILGATE PANEL ASSEMBLY
7930-00 SIDE SEAL GARNISH ASSEMBLY
6210-00 FRONT DOOR PANEL
7120-00 FRONT WINDOW LIFTER
7110-01 FRONT DOOR LATCH AND CABLE ASSEMBLY
6310-00 REAR DOOR PANEL ASSEMBLY
7220-00 REAR WINDOW LIFTER
7210-01 REAR DOOR REAR LATCH AND CABLE ASSEMBLY
5720-00 FENDER PANEL
7910-00 RADIATOR GRILLE
7810-01 COWL GRILLE ASSEMBLY
7940-20 REAR SPOILER
7850-00 OUTSIDE REAR VIEW MIRROR
BODY REPAIR
GENERAL INFORMATION
1. MAJOR DIMENSION
2. LIFTING POINTS
3. SEALING APPLICATION POINTS
4. DEADENER APPLICATION POINTS
5. UNDER COATING
6. MAJOR WELDING POINTS
7. MAJOR BODY DIMENSIONS
8. GAP CHART


Electrical Wiring Diagram
GENERAL INFORMATION
GENERAL INFORMATION
1. MAJOR DIMENSION
2. VEHICLE IDENTIFICATION
3. EXTERIOR LAMP SYSTEM LAYOUT
4. INTERIOR LAMP SYSTEM LAYOUT
5. SWITCH SYSTEM LAYOUT
6. CAN COMMUNICATION CONFIGURATION
ELECTRIC DEVICE GENERAL INFORMATION
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
2. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
3. PART LOCATION ACCORDING TO CONNECTOR NUMBER
CONNECTOR/GROUND
WIRING HARNESS
8210-00 WIRING HARNESS, COMPONENTS LOCATION
8210-00 CONNECTOR, GROUND / SPLICE PACK
CONNECTOR/GROUND
8210-01 W/H MAIN
8212-01 W/H FLOOR(LH)
8212-02 W/H FLOOR(RH)
1413-02 W/H ENGINE MAIN
8211-01 W/H ENGINE EXTN
8213-09 W/H ROOF
8810-22 W/H AIR BAG
8810-23 W/H AIR BAG EXTN
8213-03 W/H DRIVER DOOR
8213-04 W/H PASSENGER DOOR
8213-06 W/H REAR DOOR
8213-10 W/H TAIL GATE
POWER DISTRIBUTION
FUSE
8210-00 ENGINE ROOM FUSE / RELAY BOX
8410-04 INDOOR FUSE BOX
8410-05 ICM RELAY BOX
CIRCUIT
ENGINE
1461-01 STARTING / CHARGING
2820-01 GLOW CONTROL UNIT
1491-01 ECU(D20DTF EU-V -ENGINE CONTROL UNIT)
6810-15 PTC HEATER
8210-01 DIAGNOSIS CONNECTOR
CHASSIS
3110-01 TCU(6-A/T)
3110-17 AWD COUPLING UNIT
4892-01 ABS/ESP
ELECTRICAL SYSTEM
8810-01 AIR BAG (DUAL/SIDE/CURTAIN) SYSTEM
8010-01 CLUSTER
4610-04 EPS
7410-02 POWER SEAT / FRT SEAT WARMER
8510-48 REAR SEAT WARMER
8620-01 BCM(BODY CONTROL MODULE)
8510-05 POWER WINDOW
8510-52 OUTSIDE MIRROR
7810-01 FRT(RR) WIPER / WASHER
8610-06 HORN
7632-16 CIGAR LIGHTER / POWER OUTLET
7840-01 DEFOGGER / DEICER
8710-03 DOOR LOCK CIRCUIT
7340-03 SUN ROOF
8310-01 HEAD LAMP
8310-01 HEAD LAMP LEVEL¡®G DEVICE(EXP)
8320-01 TAIL LAMP
8310-01 TURN SIGNAL LAMP / HAZARD LAMP
8210-03 TRAILER LAMP(EXP)
8310-10 FRT FOG LAMP(DOM)
8310-10 FRT / RR FOG LAMP(EXP)
4810-08 STOP LAMP
7770-02 INTERIOR / DOOR LAMP
8790-01 PARKING AID / BACK UP LAMP / ECM MIRROR
8930-03 AUDIO
8930-40 AUX / HANDSFREE MODULE
8930-01 AV SYSTEM(DOM)
6810-20 AIR CONDITIONER SYSTEM
2112-02 COOLING FAN SYSTEM
8210-01 CAN
8712-03 SKM(SMART KEY MODULE)(DOM)