SsangYong Actyon 2008 Service Repair Manual

SsangYong Actyon 2008 Service Repair Manual

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Índice

ACTYON 2008.07

GENERAL
1. DIMENSIONS
2. SPECIFICATIONS
3. VEHICLE IDENTIFICATION
4. MAINTENANCE INTERVAL
5. RECOMMENDED FLUIDS AND LUBRICANTS
6. JACK-UP POINTS (DOTTED CIRCLES)
7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR
8. ELECTRIC COMPONENTS AND LAYOUT
9. STANDARD BOLTS SPECIFICATIONS

ENGINE GENERAL
1. ENGINE ASSEMBLY LAYOUT
2. ENGINE CONTROLS LAYOUT
3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM
4. INTAKE SYSTEM LAYOUT
5. EXHAUST SYSTEM LAYOUT
6. LUBRICATION SYSTEM LAYOUT
7. COOLING SYSTEM LAYOUT
8. FUEL SYSTEM LAYOUT
9. FUEL SUPPLY SYSTEM
10. CLEANNESS
11. MAINTENANCE AND REPAIR
12. GUIDELINES FOR SERVICE WORK SAFETY
13. DURING SERVICE WORK FOR INSPECTION
14. DURING SERVICE WORK FOR ELECTRIC DEVICES
15. OWNER INSPECTIONS AND SERVICES
16. STANDARD BOLTS SPECIFICATIONS

CRUISE CONTROL SYSTEM
1. CRUISE CONTROL SWITCH
2. CIRCUIT DIAGRAM
3. HOW TO OPERATE CRUISE CONTROL SWITCH

ENGINE ASSEMBLY
– GENERAL
1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
2. SPECIFICATIONS AND PERFORMANCE CURVE
3. TIGHTENING TORQUE
CONFIGURATION AND FUNCTIONS
– CYLINDER HEAD
CAMSHAFT ASSEMBLY
TIMING CHAIN ASSEMBLY
CYLINDER BLOCK
CRANKSHAFT ASSEMBLY
FLYWHEEL
PISTON AND CONNECTING ROD
HIGH PRESSURE PUMP(HPP)
– REMOVAL AND INSTALLATION
GENERAL DIAGNOSIS
DIAGNOSTIC INFORMATION AND PROCEDURE
REMOVAL STEPS OF ENGINE ASSEMBLY
ENGINE ACCESSORIES
DISASSEMBLY AND REASSEMBLY OF ENGINE ASSEMBLY
ENGINE OVERHAUL
CYLINDER HEAD
INTAKE/EXHAUST
CAMSHAFT ASSEMBLY
TIMING CHAIN
CRANKSHAFT
PISTON AND CONNECTING ROD
DISASSEMBLY AND REASSEMBLY OF HIGH PRESSURE PUMP(HPP)

ENGINE FUEL SYSTEM
– GENERAL
1. CAUTIONS FOR DI ENGINE
– OVERVIEW AND OPERATION PROCESS
1. ELECTRONIC CONTROL OF FUEL SYSTEM
2. COMPOSITION OF FUEL SYSTEM
3. HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE)
4. COMPONENTS OF LOW PRESSURE TRANSFER LINE
5. COMPONENTS OF HIGH PRESSURE TRANSFER LINE
6. CIRCUIT DIAGRAM
– CONFIGURATION AND FUNCTIONS
TRANSFER PUMP
INLET METERING VALVE(IMV)
HIGH PRESSURE PUMP
FUEL FILTER
PRIMING PUMP
HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
FUEL PRESSURE SENSOR
FUEL TEMPERATURE SENSOR
INJECTOR

ENGINE INTAKE SYSTEM
– GENERAL
1. ENGINE INTAKE SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
1. INTAKE SYSTEM LAYOUT
2. AIR FLOWS
– CONFIGURATION AND FUNCTIONS
AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)
INTERCOOLER
INTAKE MANIFOLD ASSEMBLY
– REMOVAL AND INSTALLATION
PRECAUTIONS WHEN INSTALLING INTAKE SYSTEM
AIR CLEANER ELEMENTREPLACEMENT
AIR CLEANER HOUSING
AIR FLOW SENSOR(HOT FILM AIR MASS SENSOR)
INTERCOOLER
INTAKE MANIFOLD

ENGINE EXHAUST SYSTEM
– GENERAL
1. INSPECTION BEFORE DIAGNOSIS
– OVERVIEW AND OPERATION PROCESS
1. EXHAUST SYSTEM LAYOUT
– CONFIGURATION AND FUNCTIONS
TUBO CHARGER ASSEMBLY
1913-01 VGT(VARIABLE GEOMETRY TUBOCHARGER)
EGR VALVE AND VACUUM MODULATOR
EXHAUST DEVICE AND MUFFLER
– REMOVAL AND INSTALLATION
DIAGNOSIS AND MAINTENANCE For TURBO CHARGER SYSTEM
PATH OF TUBO CHARGER DEFECT
HOW TO DIAGNOSE
PATH OF EXHAUST DEVICE DEFECT
TUBO CHARGER ASSEMBLY
TUBO CHARGER CHECK FOR VGT
EGR VALVE
VACUUM MODULATOR ASSEMBLY
EXHAUST MANIFOLD
EXHAUST PIPE

LUBRICATION SYSTEM
– GENERAL
1. SPECIFICATIONS
2. OIL PRESSURE SWITCH
– OVERVIEW AND OPERATION PROCESS
1. LAYOUT AND OVERVIEW
2. LUBRICATION DIAGRAM
– CONFIGURATION AND FUNCTIONS
OIL PUMP
BLOW-BY GAS REDUCTION DEVICE
CYLINDER HEAD COVER
OIL SEPARATOR
OIL SPRAY NOZZLE
OIL PAN ASSEMBLY
– REMOVAL AND INSTALLATION
TROUBLE DIAGNOSIS
ENGINE OIL CHANGE
ENINE OIL FILTER CHANGE
OIL FILTER AND COOLER
OIL DIPSTICK GUIDE TUBE
DISASSEMBLY OF OIL SPRAY NOZZLE
OIL PAN AND OIL PUMP

ENGINE COOLING SYSTEM
– GENERAL
1. ENGINE COOLING SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
1. COMPONENTS OF ENGINE COOLING
2. COOLING SYSTEM FLOW
3. FUNCTION DESCRIPTION OF COOLING SYSTEM
– CONFIGURATION AND FUNCTIONS
RADIATOR
WATER PUMP
COOLANT RESERVOIR
THERMOSTAT
COOLANT TEMPERTURE SENSOR
PREHEATING SYSTEM
– REMOVAL AND INSTALLATION
TROUBLE DIAGNOSIS
COOLANT LEVEL CHECK
INSPECTION AND REPAIR
DRAINING AND ADDING OF COOLANT
COOLANT HOSE(INLET/OUTLET)
SHROUD AND COOLING FAN/CLUTCH
WATER PUMP ASSEMBLY
THERMOSTAT
WATER PUMP HOUSING
RADIATOR
REPLACEMENT OF FAN BELT
COOLANT RESERVOIR
PREHEATING
PREGLOW PLUG

ECU
– CONFIGURATION AND FUNCTIONS
ENGINE ECU – CDPF (EURO IV)
CONNECTOR PIN OF ENGINE ECU – CDPF (EURO IV)
ECU (ENGINE CONTROL UNIT – D20DT EU IV)
– REMOVAL AND INSTALLATION
ENGINE ECU – CDPF (EURO IV)

CDPF
– GENERAL INFORMATION
1. OVERVIEW FOR CDPF (EURO IV)
2. CDPF (EURO IV) SYSTEM
– OVERVIEW AND OPERATION PROCESS
1. OVERVIEW
2. CDPF (EURO IV) SYSTEM CONTROL
3. SOOT FILTERING AND BURNING PROCEDURES
4. COMPONENTS OF CDPF SYSTEM
– COMFIGURATION AND FUNCTIONS
FRONT EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
REAR EXHAUST GAS TEMPERATURE SENSOR
DIFFERENTIAL PRESSURE SENSOR – CDPF (EURO IV)
– REMOVAL AND INSTALLATION
FRONT EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
REAR EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
DIFFERENTIAL PRESSURE SENSOR – CDPF (EURO IV)
CDPF ASSEMBLY – CDPF (EURO IV)

CRUISE CONTROL SYSTEM
– OVERVIEW AND OPERATION PROCESS
1. CRUISE CONTROL SWITCH
2. CIRCUIT DIAGRAM
3. HOW TO OPERATE CRUISE CONTROL SWITCH
– REMOVAL AND INSTALLATION
CRUISE CONTROL SWITCH

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
CRANKCASE VENTILATION SYSTEM
OIL CIRCULATION
– REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
ALTERNATOR
EINGINE MOUNT
POLY V-BELT
POLY V-BELT INSPECTION
TENSIONING DEVICE
TENSIONING DEVICE SHOCK ABSORBER
CYLINDER HEAD COVER
CYLINDER HEAD FRONT COVER
CYLINDER HEAD
TIMING GEAR CASE COVER
CRANKSHAFT SEALING REAR COVER
BELT PULLEY AND VIBRATION DAMPER
CRANKSHAFT FRONT RADIAL SEAL
CRANKSHAFT REAR RADIAL SEAL
CRANKSHAFT
ARRANGEMENT OF THE THRUST BEARING AND THE MAIN BEARING
FLYWHEEL/ DRIVE PLATE
CAMSHAFT ADJUSTER
CAMSHAFT
INSPECTION AND ADJUSTMENT OF CAMSHAFT TIMING POSITION
– REMOVAL AND INSTALLATION
VALVE SPRING
VALVE STEM SEAL
CHAIN TENSIONER
TIMING CHAIN
TENSIONING RAIL
CYLINDER HEAD GUIDE RAIL
CRANKCASE GUIDE RAIL
CRANKSHAFT SPROCKET
PISTON
CONNECTING ROD
PISTON RING
OIL PAN
ENGINE OIL AND OIL FILTER ELEMENT
OIL PUMP
OIL PRESSURE RELIEF VALVE
OIL NON-RETURN VALVE
OIL DIPSTICK GUIDE TUBE
REPAIR OF CORE PLUGS IN CRANKCASE
CYLINDER BORE
CRANKCASE MATING SURFACE
CYLINDER HEAD MATING SURFACE

ENGINE INTAKE SYSTEM
– GENERAL
1. SPECIFICATIONS
– CONFIGURATION AND FUNCTIONS
RESONANCE FLAP
AIR CLEANER AND INTAKE AIR DUCT
– REMOVAL AND INSTALLATION
AIR CLEANER AND INTAKE AIR DUCT
INTAKE MANIFOLD

ENGINE EXHAUST SYSTEM
– GENERAL
1. SPECIFICATION
– OVERVIEW AND OPERATION PROCESS
1. DESCRIPTION AND OPERATION
– REMOVAL AND INSTALLATION
EXHAUST LINE

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
DTC FOR PWM ELECTRIC FAN
DIAGNOSTIC INFORMATION AND PROCEDURE
REPAIR INSTRUCTIONS ONVEHICLE SERVICE
WATER PUMP
THERMOSTAT AND THERMOSTAT HOUSING ASSEMBLY
PWM CONTROLLER UNIT
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
GENERATOR REPAIR INSTRUCTIONS
STARTER REPAIR INSTRUCTIONS
BATTERY REPAIR INSTRUCTIONS
SPARK PLUG AND IGNITION COIL REPAIR INSTRUCTIONS

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

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
PARKING AID SENSOR

AUDIO SYSTEM
– OVERVIEW AND INSTALLATION
1. AUDIO SYSTEM OVERVIEW
2. CIRCUIT DIAGRAM OF AUDIO SYSTEM
– CONFIGURATION AND FUNCTION
COMBINATION ANTENNA
USB/AUX MODULE
– REMOVAL AND INSTALLATION
AV HEAD UNIT
FRONT DOOR SPEAKER AND REAR DOOR SPEAKER
DOOR TWEETER SPEAKER
COMBINATION ANTENNA
USB/AUX MODULE

FUSE AND RELAY
– GENERAL INFORMATION
1. GENERAL INFORMATION
– OVERVIEW AND OPERATING PROCESS
1. OVERVIEW
2. FUSE & RELAY MOUNTING LOCATION
3. CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE COMPARTMENT
4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY
5. OPERATING PROCESS OF ICM BOX
– CONFIGURATION AND FUNCTIONS
CONFIGURATION OF PCB IN ICM BOX AND FUNCTION OF CONNECTOR
CIRCUIT DIAGRAM FOR FUSE & RELAY BOX IN ENGINE COMPARTMENT
CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON DRIVER SIDE
CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON PASSENGER SIDE
– REMOVAL AND INSTALLATION
ICM BOX

STICS
– GENERAL
1. OVERVIEW
2. MAJOR CHANGES
3. SPECIFICATIONS
– OVERVIEW AND OPEARATION PROCESS
1. OVERVIEW
2. FUNCTIONS AND SPECIFICATIONS
3. CIRCUIT DIAGRAM
– -REMOVAL AND INSTALLATION
REKES KEY CODING
DIAGNOSIS TROUBLE CODE AND HEIP TIPS
STICS

IMMOBILIZER SYSTEM
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW
2. BASIC FUNCTIONS OF IMMOBILIZER KEY
3. OTHER FUNCTIONS IN SYSTEM
4. REKES OPERATION LOGIC
5. CIRCUIT DIAGRAM
– REMOVAL AND INSTALLATION
IMMOBILIZER CODING PROCEDURE
IMMOBILIZER UNIT

CLUSTER
– GENERAL
1. DESCRIPTIONS OF INDICATOR DISPLAY
2. WARNING & INDICATOR PANEL
3. CLUSTER OPERATION PROCESS
4. CIRCUIT DIAGRAM
– CONFIGURATION AND FUNCTIONS
COFIGURATION OF CLUSTER
– REMOVAL AND INSTALLATION
METER CLUSTER

LAMP
– OVERVEIW AND OPERATION PROCESS
1. LOCATIONS OF EXTERIOR LAMPS
2. INTERIOR LAMPS
3. LAMP OPERATION LOGIC
– CONFIGURATION AND FUNCTIONS
FRONT LAMPS
REAR LAMP
INTERIOR LAMPS
– REMOVAL AND INSTALLATION
HEAD LAMPS
FOG LIGHT
SIDE REPEATER
REAR COMBINATION LAMP
LICENSE PLATE LAMP
HIGH MOOUNTED STOP LAMP
REAR FOG LIGHT
INTERIOR LAMPS

SWITCH
– GENERAL
1. SWITCH ARRANGEMENT
– CONFIGURATION AND FUNCTIONS
CENTER FASCIA & BEZEL SWITCH ASSEMBLY
OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
INTERIOR LAMP SWITCH
MAIN POWER WINDOW SWITCH
AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL
MULTIFUNCTION SWITCH
TAIL GATE OPEN SWITCH
DIGITAL CLOCK
HORN (INCLUDING THEFT WARNING HORN)
– REMOVAL AND INSTALLATION
HAZARD & SWITCH ASSEMBLY
OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
OUTSIDE REARVIEW MIRROR FOLDING UNIT
OVERHEAD CONSOLE SWITCH
MAIN POWER WINDOW SWITCH
AUDIO REMOTE CONTROL SWITCH
MULTIFUNCTION SWITCH
TAIL GATE OPEN SWITCH
CIGARETTE LIGHTER
FRONT POWER OUTLET
REAR POWER OUTLET
DIGITAL CLOCK
HORN

WIPER & WASHER
– OVERVIEW AND OPERATION PROCESS
1. SYSTEM LAYOUT AND FUNCTION
2. SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR)
3. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION
4. WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM
– REMOVAL AND INSTALLATION
CORRECTION OF FRONT WIPER
FRONT WIPER ASSEMBLY
REAR WIPER ASSEMBLY
WASHER FLUID RESERVOIR TANK
WASHER NOZZLE

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
FUNCTIONS AND CHECKS OF RAIN SENSOR
DIAGNOSIS PROCEDURES
RAIN SENSOR

ION 4-SPEED
– GENERAL
1. SPECIFICATIONS
2. FASTENER TIGHTENING SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
1. DESCRIPTION AND OPERATION OF AUTOMATIC TRANSMISSION
2. APPEARANCE
3. SHIFT PATTERN DIAGRAM
4. OPERATORS INTERFACES
5. CONTROL SYSTEMS
6. ELECTRONIC CONTROL SYSTEM
7. HYDRAULIC CONTROL SYSTEM
8. POWER FLOWS
– CONFIGURATION AND FUNCTIONS

TCU
ACCELERATOR PEDAL SENSOR
– REMOVAL AND INSTALLATION
DIAGNOSTIC INFORMATION AND PROCEDURES
REBUILD WARNINGS
FRONT AND REAR BAND ADJUSTMENT
SYMPTOM DIAGNOSIS
TROUBLE CODE DIAGNOSIS
ION AUTOMATIC TRANSMISSION ASSEMBLY
VALVE BODY
DISASSEMBLY OF TRANSMISSION
ASSEMBLY OF TRANSMISSION
3642-18 GEAR SHIFT CONTROL LEVER
TCU

STEERING
– GENERAL
1. OVERVIEW
2. SPECIFICATIONS
– OVERVIEW AND OPERATION
1. SYSTEM LAYOUT
2. COMPONENTS
– REMOVAL AND INSTALLATION
TROUBLE DIAGNOSIS
INSPECTIONS OF POWER STEERING SYSTEM
STEERING COLUMN SHAFT
LOWER SHAFT
STEERING GEAR BOX
STEERING GEAR PUMP

DSI M78 6-SPEED A/T
– GENERAL INFORMATION
1. DSI M78 6-SPEED AUTOMATIC TRANSMISSION GENERAL
2. STRUCTURE CHARACTERISTICS AND SPECIFICATIONS
3. TIGHTENING TORQUE
– OVERVIEW AND OPERATION PROCESS
1. GENERAL DESCRIPTION
2. ADVANCED SIX SPEED FEATURES
3. FUNCTION OF EACH MODE
4. LIMP HOME MODE
5. TRANSMISSION ELECTRONIC CONTROL SYSTEM
6. CONFIGURATION OF CAN RELATED TO TCU
7. POWER TRAIN
– CONFIGURATION AND FUNCTIONS
TGS LEVER
DSI M78 6-SPEED A/T ASSEMBLY
VALVE BODY
TCU
INHIBITOR SWITCH
– REMOVAL AND INSTALLATION
FLUID LEVEL INSPECTION
TRANSMISSION RESET PROCEDURE (REPLACEMENT TRANSMISSION)
– DIAGNOSIS AND TESTING
1. WIRING DIAGRAM
2. WIRE HARNESS CONNECTOR CHART
3. UNIT CONNECTOR DESCRIPTION
– TROUBLE CODE EIAGNOSIS
1. DIAGNOSTIC TROUBLE CODE LIST
2. SYSTEM DIAGNOSIS
– MAINTENANCE OPERATIONS
1. OIL TEST
2. STALL TEST
3. TRANSMISSION RESET PROCEDURE (REPLACEMENT TRANSMISSION)
4. FLUID LEVEL INSPECTION
5. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE
6. LUBRICATION
7. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE (NEW 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
SELECTOR LEVER CONTROL UNIT
– REMOVAL AND INSTALLATION
SHIFT ROD POSTION ADJUSTMENT
TGS LEVER

MANUAL TRANSMISSION
– GENERAL
1. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION
2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION
– OVERVIEW AND OPERATION PROCESS
1. MANUAL TRANSMISSION SYSTEM
– CONFIGURATION AND FUNCTIONS
MANUAL TRANSMISSION LOCATION
MANUAL TRANSMISSION SYSTEM COMPONENTS
SHIFTING MECHANISM
– REMOVAL AND INSTALLATION
DIAGNOSTIC INFORMATION AND PROCEDURES
OIL CHECK/CHANGE OF MANUAL TRANSMISSION
MANUAL TRANSMISSION
MANUAL TRANSMISSION OVERHAUL
TRANSMISSION ADAPTER
SHIM ADJUSTMENT

CLUTCH
– GENERAL
1. CLUTCH SPECIFICATIONS
2. TIGHTENING TORQUE
– OVERVIEW AND OPERATION PROCESS
1. FUNCTION AND OVERVIEW
– CONFIGURATION AND FUNCTIONS
CLUTCH MASTER CYLINDER
CLUTCH RELEASE CHAMBER
CLUTCH ASSEMBLY
CLUTCH PEDAL
– REMOVAL AND INSTALLATION
CLUTCH TROUBLE DIAGNOSIS
CLUTCH INSPECTION AND MAINTENANCE
CLUTCH AIR BLEEDING
CLUTCH ASSEMBLY
CLUTCH REPLACEMENT
CONCENTRIC SLAVE CTLINDER
CLUTCH MASTER CYLINDER
CLUTCH PEDAL
CLUTCH CHAMBER

AXLE
– GENERAL
1. SPECIFICATIONS OF AXLE
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW OF AXLE
– CONFIGURATION AND FUNCTIONS
FRONT AXLE
5-LINK TYPE REAR AXLE
– REMOVAL AND INSTALLATION
TROUBLE DIAGNOSIS
INSPECTION OF RING GEAR TOOTH CONTACT PATTERN
FRONT AXLE ASSEMBLY
AXLE SHAFT
AXLE HOUSING
REAR AXLE SHAFT(DISC BRAKE TYPE)
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
TRANSFER CASE
COMPONENTS OF IWE (INTEGRATED WHEEL END)
TCCU(TRANSFER CASE CONTROL UNIT)
– REMOVAL AND INSTALLATION
PART TIME TRANSFER CASE GENERAL DIAGNOSIS
VACUUM LOCKING HUB CHECK
OIL LEVEL CHECK AND CHANGE
SELF-DIAGNOSIS TEST
TCCU DIAGNOSTIC TROUBLE CODE
PART TIME TRANSFER CASE
TRANSFER CASE MOTOR
IWE (INTEGRATED WHEEL END)
LOCKING HUB ACTUATOR ASSEMBLY
TCCU

SUSPENSION
– GENERAL
1. SPECIFICATIONS OF SUSPENSION
2. WHEEL ALIGNMENT
– CONFIGURATION AND FUNCTION
FRONT SUSPENSION
REAR SUSPENSION (5-LINK TYPE)
– REMOVAL AND INSTALLATION
TROUBLE DIAGNOSIS OF REAR SUSPENSION
FRONT SUSPENSION-UPPER ARM
FRONT SUSPENSION- COIL SPRING & SHOCK ABSORBER ASSEMBLY
FRONT SUSPENSIONSTABILIZER BAR
FRONT SUSPENSIONLOWER ARM
REAR SUSPENSION (5 LINK TYPE)

ESP
– 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 STABILITY PROGRAM) 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 OPERATING RANGE
10. HYDRAULIC CIRCUIT OF BAS (BRAKE ASSIST SYSTEM)
11. COMPONENTS OF ABS SYSTEM
– CONFIGURATION AND FUNCTIONS
HECU OF ESP
HECU OF ABS
PRESSURE SENSOR
SENSOR CLUS
SWAS(STEERING WHEEL ANGLE SENSOR)
ESP OFF SWITCH
ASS(Active Wheel Speed Sensor)
– REMOVAL AND INSTALLATION
ESP SYSTEM AIR BLEEDING
SENSOR CALIBRATION AND FORCED OPERATION OF ACTUATOR SENSOR VALUE
ABS/ESP TROUBLE DIAGNOSIS
CAUTIONS WHEN REMOVING FRONT WHEEL SPEED SENSOR-ESP
CAUTIONS WHEN REMOVING FRONT WHEEL SPEED ABS
HECU-ESP
HECU-ABS
FRONT WHEEL SPEED SENSOR
REAR WHEEL SPEED SENSOR
PRESSURE SENSOR
SENSOR CLUSTER

AIR BAG
– GENERAL
1. OVERVIEW (INCLUDING CURTAIN AIR BAGS)
– OVERVIEW AND OPERATION PROCESS
1. LOCATION AND RELATED COMPONENTS
2. AIR BAG SYSTEM OPERATION PROCESS
3. AIR BAG MODULE AND RELATED COMPONENTS
– REMOVAL AND INSTALLATION
TROUBLE
DRIVER AIR BAG
PASSENGER AIR BAG
CURTAIN AIR BAG
CONTACT COIL
AIR BAG(SDM)
CURTAIN AIR BAG G SENSOR

SEAT
– OVERVIEW AND OPERATION PROCESS
1. COMPOSITION OF SEAT
2. FUNCTIONS OF SEAT
3. COMPONENTS OF SEAT BELT
– REMOVAL AND INSTALLATION
SEAT MOUNTING POINTS
SEAT ASSEMBLY
SEAT BELT

SUNROOF
– OVERVIEW AND OPERATION PROCESS
1. COMPONENTS AND LOCATIONS
2. OPERATION AND FUNCTION
– CONFIGURATION AND FUNCTION
COMPONENTS OF SUNROOF
– REMOVAL AND INSTALLATION
RESETTING OF SUNROOF CONTROL UNIT
TROUBLE DIAGNOSIS
GLASS PANEL ASSEMBLY
BELLOWS COVER
DRAIN CHANNEL
SUN SHADE PANEL
SUNROOF CONTROL UNIT(SCU) AND MOTO
SUNROOF DRAIN HOSE
SUNROOF ASSEMBLY

BODY INTERIOR
– OVERVIEW AND OPERATION PROCESS
1. LOCATIONS
– REMOVAL AND INSTALLATION
INSTRUMENT PANEL ASSEMBLY
INSTRUMENT PANEL FRAME ASSEMBLY
CENTERCONSOLE (AUTOMATIC TRANSMISSION)
CENTER CONSOLE (MANUAL TRANSMISSION)
SUNVISOR
PILLAR
HEADLINING ASSEMBLY
OUTSIDE REARVIEW
MIRROR
INSIDE REARVIEW MIRROR

BODY EXTERIOR
– OVERVIEW AND OPERATION PROCESS
1. COMPOSITION OF BODY EXTERIOR
– CONFIGURATION AND FUNCTION
COMPONENT OF FRONT BUMPER ASSEMBLY
COMPONENTS OF REAR BUMPER ASSEMBLY
COMPONENTS OF HOOD ASSEMBLY
COMPONENTS OF SIDE SILMOLDING
COMPONENTS OF FRONT DOOR ASSEMBLY
COMPONENTS OF FRONT WINDOW REGULATOR
COMPONENTS OF REAR DOOR ASSEMBLY
COMPONENTS OF REAR WINDOW REGULATOR
COMPONENTS OF TAILGATE ASSEMBLY 
– REMOVAL AND INSTALLATION
HOOD ASSEMBLY
SIDE SILMOLDING
FENDER PANEL ASSEMBLY
FRONT DOOR TRIM (DRIVER SIDE)
FRONT DOOR (DRIVER SIDE)
WINDOW REGULATOR (PASSENGER SIDE)
REAR DOOR TRIM
REAR DOOR ASSEMBLY
REAR DOOR MOLDING AND PANEL
REAR WINDOW REGULATOR
TAILGATE TRIM
TAILGATE ASSEMBLY
TAILGATE LATCH AND ACTUATOR
REAR QUARTER GLASS

BODY REPAIR
– GENERAL
1. DIMENSIONS
2. JACK-UP POINTS
3. DESIGN CHANGES FOR IMPROVING NVH PERFORMANCE
– CONFIGURATION AND FUNCTIONS
FRAME DIMENSIONS
FRAME BODY MOUNTING
WHITE BODY
BODY DIMENSIONS
BODY GAPS
DOOR COMPONENTS(INCLUDING ENGINE HOOD)
COMPONENTS OF BODY PANELS

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
AIR CONDITIONER CONTROLLER UNIT
SUNSENSOR
ACTIVE INCAR / HUMIDITY SENSOR: AI SENSOR
AMBIENT TEMPERATURE SENSOR
WATER TEMPERATURE SENSOR
POWER TRANSISTOR
MODE DOOR ACTUATOR
IN/EX – AIR DOOR ACTUATOR
AIR MIX DOOR ACTUATOR
THERMO AMP (INTAKE SENSOR)
FFH (FUEL FIRED HEATER) SYSTEM
PTC(POSITIVE TEMPERATURE COEFFICIENT)
SELF DIAGNOSIS (ONLY FOR FATC A/C CONTROLLER)
TROUBLE DIAGNOSIS
AMBIENT TEMPERATURE SENSOR
WATER TEMPERATURE SENSOR
POWER TRANSITOR
MODE DOOR ACTUATOR
IN/EX-AIR DOOR ACTUATOR
AIR MIX DOOR ACTUATOR
THERMO AMP (INTAKE SENSOR)
AIR CONDITONER MODULE ASSEMBLY
A/C CONTROLLER SWITCH AND ACTIVE INCAR/HUMIDITY SENSOR
AIR DUCT ASSEMBLY
CONDENSER ASSEMBL
RECEIVER DRYER ASSEMBLY
FUEL PUMP
AMBIENT TEMPERATURE SWITCH
FFH ASSEMBLY
PTC

ECU-GASOLINE

DIAGRAMS AND CONECTORS