CONTENT
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
CRUISE CONTROL SYSTEM -OVERVIEW AND OPERATION PROCESS
1. CRUISE CONTROL SWITCH
2. CIRCUIT DIAGRAM
3. HOW TO OPERATE CRUISE CONTROL SWITCH
4. CRUISE CONTROL SWITCH – REMOVAL AND INSTALLATION
ENGINE ASSEMBLY 1212-01/1312-01/1125-01/1130-01/1130-33/1130-13/ 1881-01/1114-01/1222-21/2313-01/1312-01
GENERAL
1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
2. SPECIFICATIONS AND PERFORMANCE CURVE
3. TIGHTENING TORQUE
CONFIGURATION AND FUNCTIONS
1. CYLINDER HEAD
2. CAMSHAFT ASSEMBLY
3. TIMING CHAIN ASSEMBLY
4. CYLINDER BLOCK
5. CRANKSHAFT ASSEMBLY
6. FLYWHEEL
7. PISTON AND CONNECTING ROD
8. HIGH PRESSURE PUMP(HPP)
REMOVAL AND INSTALLATION
1. GENERAL DIAGNOSIS
2. DIAGNOSTIC INFORMATION AND PROCEDURE
3. REMOVAL STEPS OF ENGINE ASSEMBLY
4. ENGINE ACCESSORIES
5. DISASSEMBLY AND REASSEMBLY OF ENGINE
6. ENGINE OVERHAUL
7. CYLINDER HEAD
8. INTAKE/EXHAUST
9. CAMSHAFT ASSEMBLY
10. TIMING CHAIN
11. CRANKSHAFT
12. PISTON AND CONNECTING ROD
13. DISASSEMBLY AND
14. 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
1. TRANSFER PUMP
2. INLET METERING VALVE(IMV)
3. HIGH PRESSURE PUMP
4. FUEL FILTER
5. PRIMING PUMP
6. HIGH PRESSURE ACCUMULATOR (COMMON RAIL)
7. FUEL PRESSURE SENSOR
8. FUEL TEMPERATURE SENSOR
9. INJECTOR
REMOVAL AND INSTALLATION
1. DRAINING THE WATER FROM FILTER
2. HIGH PRESSURE PUMP
3. FUEL FILTER
4. HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
5. INJECTOR
ENGINE INTAKE SYSTEM
GENERAL
1. ENGINE INTAKE SPECIFICATIONS
OVERVIEW AND OPERATION PROCESS
1. INTAKE SYSTEM LAYOUT
2. AIR FLOWS
CONFIGURATION AND FUNCTIONS
1. AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)
2. INTERCOOLER
3. INTAKE MANIFOLD ASSEMBLY
REMOVAL AND INSTALLATION
1. PRECAUTIONS WHEN INSTALLING INTAKE SYSTEM
2. AIR CLEANER ELEMENTREPLACEMENT
3. AIR CLEANER HOUSING
4. AIR FLOW SENSOR(HOT FILM AIR MASS SENSOR)
5. INTERCOOLER
6. INTAKE MANIFOLD
ENGINE EXHAUST SYSTEM 1913-01/1913-01/1792-01/2411-01/1913-01/1913-01/ 913-01/1913-01/1913-01/1913-01/2411-01/1792-01/ 1725-01/2411-01/
GENERAL
1. INSPECTION BEFORE DIAGNOSIS
OVERVIEW AND OPERATION PROCESS
1. EXHAUST SYSTEM LAYOUT
CONFIGURATION AND FUNCTIONS
1. TUBO CHARGER ASSEMBLY
2. VGT(VARIABLE GEOMETRY TUBOCHARGER)
3. EGR VALVE AND VACUUM MODULATOR
4. EXHAUST DEVICE AND MUFFLER
REMOVAL AND INSTALLATION
1. DIAGNOSIS AND MAINTENANCE For TURBO CHARGER SYSTEM
2. PATH OF TUBO CHARGER DEFECT
3. HOW TO DIAGNOSE
4. PATH OF EXHAUST DEVICE DEFECT
5. TUBO CHARGER ASSEMBLY
6. TUBO CHARGER CHECK FOR VGT
7. EGR VALVE
8. VACUUM MODULATOR ASSEMBLY
9. EXHAUST MANIFOLD
10 EXHAUST PIPE
LUBRICATION SYSTEM 1533-01/1543-01/1222-01/1222-09/1533-08/1533-01/ 1543-01/1533-01/1533-34/1125-10/1533-08
GENERAL
1. SPECIFICATIONS
2. OIL PRESSURE SWITCH
OVERVIEW AND OPERATION PROCESS
1. LAYOUT AND OVERVIEW
2. LUBRICATION DIAGRAM
CONFIGURATION AND FUNCTIONS
1. OIL PUMP
2. BLOW-BY GAS REDUCTION DEVICE
3. CYLINDER HEAD COVER
4. OIL SEPARATOR
5. OIL SPRAY NOZZLE
6. OIL PAN ASSEMBLY
REMOVAL AND INSTALLATION
1.TROUBLE DIAGNOSIS
2. ENGINE OIL CHANGE
3. ENINE OIL FILTER CHANGE
4. OIL FILTER AND COOLER
5. OIL DIPSTICK GUIDE TUBE
6. DISASSEMBLY OF OIL SPRAY NOZZLE
7. OIL PAN AND OIL PUMP
ENGINE COOLING SYSTEM 2112-01/1520-01/2130-13/1520-11/1431-07/1411-01/ 9210-05/2130-01/1333-15/1520-11/1333-14/1412-01
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
2112-01 RADIATOR
1520-01 WATER PUMP
2130-13 COOLANT RESERVOIR
1520-11 THERMOSTAT
1431-07 COOLANT TEMPERTURE SENSOR
1411-01 PREHEATING SYSTEM
REMOVAL AND INSTALLATION
1. TROUBLE DIAGNOSIS
2. COOLANT LEVEL CHECK
3. INSPECTION AND REPAIR
4. DRAINING AND ADDING OF COOLANT
5. COOLANT HOSE(INLET/OUTLET)
6. SHROUD AND COOLING FAN/CLUTCH
7. WATER PUMP ASSEMBLY
8. THERMOSTAT
9. WATER PUMP HOUSING
10. RADIATOR
11. REPLACEMENT OF FAN BELT
12. COOLANT RESERVOIR
13. PREHEATING
14. PREGLOW PLUG
ENGINE ELECTRICAL SYSTEM 1451-01/1451-51/1461-01
GENERAL
1. SPECIFICATIONS OF ENGINE ELECTRIC
OVERVIEW AND OPERATION PROCESS
1. COMPONENTS OF ELECTRIC IN ENGINE
2. COMPONENTS OF ELECTRIC DEVICES IN ENGINE
3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM
4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR
REMOVAL AND INSTALLATION
1. TROBULE DIAGNOSIS
2. ALTERNATOR
3. STARTER
ENGINE CONTROL SYSTEM 1491-01/2010/04/1431-07/1431-09/4890-02/4810-26
GENERAL
1. ENGINE ECU AND OTHER COMPONENTS
2. TOP VIEW
3. SIDE VIEW
OVERVIEW AND OPERATION PROCESS
1. ECU INPUTS/OUPTPUTS
2. STRUCTURE AND FUNCTION OF ECU
3. CONTROL FUNCTION OF ECU
4. FUEL PRESSURE CONTROL
5. FUEL INTECTION CONTROL
6. FUEL FLOW CONTROL
7. INDIVIDUAL INTECTOR CALIBRATION(C2I)
8. MINIMUM DRIVE PULSE(MDP) LEARNING
CONFIGURATION AND FUNCTIONS
1. ECU
2. ACCELERATOR PADAL SENSOR
3. COOLANT TEMPERATURE SENSOR
4. BOOST PRESSURE SENSOR
5. VEHICLE SPEED SENSOR
6. OTHER SWITCHES
REMOVAL AND INSTALLATION
1. ECU
ENGINE ASSEMBLY 1114-00
GENERAL
1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
2. SPECIFICATIONS AND PERFORMANCE CURVE
3. TIGHTENING TORQUE
4. MAJOR CHANGES IN D20DT (EURO IV) ENGINE (COMPARED TO D20DT)
REMOVAL AND INSTALLATION
1. D20DT (EURO IV) ENGINE ASSEMBLY
ENGINE FUEL SYSTEM 1881-09/1881-23/1881-08/1881-23
GENERAL
1. MAJOR CHANGES IN FUEL SYSTEM OF ENGINE
OVERVIEW AND OPERATION PROCESS
1. COMPONENTS OF FUEL SYSTEM
2. FUEL FLOW OF D20DT (EURO 4) ENGINE
CONFIGURATION AND FUNCTIONS
1. INJECTOR
2. COMMON RAIL & FUEL SUPPLY PIPE
REMOVAL AND INSTALLATION
1. INJECTOR CODING(C2I/C3I)
2. COMMON RAIL AND FUEL SUPPLY PIPE
ENGINE INTAKE SYSTEM 2321-01/1431-01
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW
2. INTAKE SYSTEM LAYOUT
CONFIGURATION AND FUNCTIONS
1. HFM (HOT FILM AIR MASS) SENSOR (VERSION 6.0)
2. THROTTLE BODY
REMOVAL AND INSTALLATION
1. HFM SENSOR
2. THROTTLE BODY
ENGINE EXHAUST SYSTEM 1792-01/2433-01
OVERVIEW AND OPERATION PROCESS
1. COMPONENTS
CONFIGURATION AND FUNCTIONS
1. E-EGR VALVE(ELECTRICEXHAUST GAS RECIRCULATION VALVE)
2. EGR COOLER
3. VACUUM MODULATOR FOR CONTROLLING VGT TURBOCHARGER ACTUATOR
REMOVAL AND INSTALLATION
1. E-EGR VALVE ASSEMBLY
2. VACUUM MODULATOR
LUBRICATION SYSTEM
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW OIL SEPARATORS
REMOVAL AND INSTALLATION
1. PCV OIL 5 SEPARATOR
ENGINE COOLING SYSTEM 2112-00/1520-00
COOLING SYSTEM
1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE WATER PUMP
2. OVERVIEW
ECU 2321-01/1715-65/1431-09
CONFIGURATION AND FUNCTIONS
1. ENGINE ECU – CDPF (EURO IV)
2. CONNECTOR PIN OF ENGINE ECU – CDPF (EURO IV)
1491-01 ECU (ENGINE CONTROL UNIT – D20DT EU IV)
REMOVAL AND INSTALLATION
1. ENGINE ECU – CDPF (EURO IV)
CDPF 1881-09/18823
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW
2. CDPF (EURO IV) SYSTEM CONTROL
3. SOOT FILTERING AND BURNING PROCEDURES
4. COMPONENTS OF CDPF SYSTEM
CONFIGURATION AND FUNCTIONS
1. FRONT EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
2. REAR EXHAUST GAS TEMPERATURE SENSOR
3. DIFFERENTIAL PRESSURE SENSOR – CDPF (EURO IV)
REMOVAL AND INSTALLATION
1. FRONT EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
2. REAR EXHAUST GAS TEMPERATURE SENSOR – CDPF (EURO IV)
3. DIFFERENTIAL PRESSURE SENSOR – CDPF (EURO IV)
4. CDPF ASSEMBLY – CDPF (EURO IV)
CRUISE CONTROL SYSTEM 8510-23
OVERVIEW AND OPERATION PROCESS
1. CRUISE CONTROL SWITCH
2. CIRCUIT DIAGRAM
3. HOW TO OPERATE CRUISE CONTROL SWITCH
REMOVAL AND INSTALLATION
1. CRUISE CONTROL SWITCH
ENGINE ASSEMBLY 1113-01/1532-00/1452-01/1130-07/1332-18/1221-01/1221-02/ 1332-01/1124-17/1130-07/1131-02/1124-16/1130-01/1130-11/ 1130-09/1311-31/1221-21/1211-32/1211-30/1532-19/1311-01/ 1311-04/1311-09/1311-05/1130-04/1130-20/1130-13/1130-21/ 1532-24/1532-00/1124-01/1211-02
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
1. ENGINE ASSEMBLY
2. ALTERNATOR
3. EINGINE MOUNT
4. POLY V-BELT
5. POLY V-BELT INSPECTION
6. TENSIONING DEVICE
7. TENSIONING DEVICE SHOCK ABSORBER
8. CYLINDER HEAD COVER
9. CYLINDER HEAD FRONT COVER
10. CYLINDER HEAD
11. TIMING GEAR CASE COVER
12. CRANKSHAFT SEALING REAR COVER
13. BELT PULLEY AND VIBRATION DAMPER
14. CRANKSHAFT FRONT RADIAL SEAL
15. CRANKSHAFT REAR RADIAL SEAL
16. CRANKSHAFT
17. ARRANGEMENT OF THE THRUST BEARING AND THE MAIN BEARING
18. FLYWHEEL/ DRIVE PLATE
19. CAMSHAFT ADJUSTER
20. CAMSHAFT
21. INSPECTION AND ADJUSTMENT OF CAMSHAFT TIMING POSITION
REMOVAL AND INSTALLATION
1. VALVE SPRING
2. VALVE STEM SEAL
3. CHAIN TENSIONER
4. TIMING CHAIN
5. TENSIONING RAIL
6. CYLINDER HEAD GUIDE RAIL
7. CRANKCASE GUIDE RAIL
8. CRANKSHAFT SPROCKET
9. PISTON
10. CONNECTING ROD
11. PISTON RING
12. OIL PAN
13. ENGINE OIL AND OIL FILTER ELEMENT
14. OIL PUMP
15. OIL PRESSURE RELIEF VALVE
16. OIL NON-RETURN VALVE
17. OIL DIPSTICK GUIDE TUBE
18. REPAIR OF CORE PLUGS IN CRANKCASE
19. CYLINDER BORE
20. CRANKCASE MATING SURFACE
21. CYLINDER HEAD MATING SURFACE
ENGINE INTAKE SYSTEM 1713-08/2312-01
GENERAL
1. SPECIFICATIONS
CONFIGURATION AND FUNCTIONS
1. RESONANCE FLAP
2. AIR CLEANER AND INTAKE AIR DUCT
REMOVAL AND INSTALLATION
1. AIR CLEANER AND INTAKE AIR DUCT
2. INTAKE MANIFOLD
ENGINE EXHAUST SYSTEM 2420-01
GENERAL
1. SPECIFICATION
OVERVIEW AND OPERATION PROCESS
1. DESCRIPTION AND OPERATION
REMOVAL AND INSTALLATION
1. EXHAUST LINE
ENGINE COOLING SYSTEM 2110-01/1522-18/1522-10/2110-00/2110-07
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
1. DTC FOR PWM ELECTRIC FAN
2. DIAGNOSTIC INFORMATION AND PROCEDURE
3. REPAIR INSTRUCTIONS ONVEHICLE SERVICE
4. WATER PUMP
5. THERMOSTAT AND THERMOSTAT HOUSING ASSEMBLY
6. PWM CONTROLLER UNIT
7. PWM ELECTRIC FAN AND SHROUD ASSEMBLY
ENGINE ELECTRIC DEVICES 1452-01/1462-01/2610-01/1440-01
GENERAL
1. DIAGNOSTIC INFORMATION AND PROCEDURE
OVERVIEW AND OPERATION PROCESS
1. DESCRIPTION AND OPERATION
REMOVAL AND INSTALLATION
1. GENERATOR REPAIR INSTRUCTIONS
2. STARTER REPAIR INSTRUCTIONS
3. BATTERY REPAIR INSTRUCTIONS
4. SPARK PLUG AND IGNITION COIL REPAIR INSTRUCTIONS
CRUISE CONTROL SYSTEM 8510-23
OVERVIEW AND OPERATION PROCESS
1. CRUISE CONTROL SWITCH
2. CIRCUIT DIAGRAM
3. HOW TO OPERATE CRUISE CONTROL SWITCH
REMOVAL AND INSTALLATION
1. CRUISE CONTROL SWITCH
ELECTRIC GENERAL 0000-00
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 8790-03
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
1. PARKING AID SENSOR
AUDIO SYSTEM 8930-01/8610-22/8620-22/8610-26
OVERVIEW AND INSTALLATION
1. AUDIO SYSTEM OVERVIEW
2. CIRCUIT DIAGRAM OF AUDIO SYSTEM
CONFIGURATION AND FUNCTION
1. COMBINATION ANTENNA
2. USB/AUX MODULE
REMOVAL AND INSTALLATION
1. AV HEAD UNIT
2. FRONT DOOR SPEAKER AND REAR DOOR SPEAKER
3. DOOR TWEETER SPEAKER
4. COMBINATION ANTENNA
5. USB/AUX MODULE
FUSE AND RELAY 1725-12/2412-42/2412-20/1715-65
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
1. CONFIGURATION OF PCB IN ICM BOX AND FUNCTION OF CONNECTOR
2. CIRCUIT DIAGRAM FOR FUSE & RELAY BOX IN ENGINE COMPARTMENT
3. CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON DRIVER SIDE
4. CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON PASSENGER SIDE
REMOVAL AND INSTALLATION
1. ICM BOX
STICS 8710-01
GENERAL
1. OVERVIEW
2. MAJOR CHANGES
3. SPECIFICATIONS
OVERVIEW AND OPEARATION PROCESS
1. OVERVIEW
2. FUNCTIONS AND SPECIFICATIONS
3. CIRCUIT DIAGRAM
REMOVAL AND INSTALLATION
1. REKES KEY CODING
2. DIAGNOSIS TROUBLE CODE AND HEIP TIPS
3. STICS
IMMOBILIZER SYSTEM 7010-06
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
1. IMMOBILIZER CODING PROCEDURE
2. IMMOBILIZER UNIT
CLUSTER 8010-01
GENERAL
1. DESCRIPTIONS OF INDICATOR DISPLAY
2. WARNING & INDICATOR PANEL
3. CLUSTER OPERATION PROCESS
4. CIRCUIT DIAGRAM
CONFIGURATION AND FUNCTIONS
1. COFIGURATION OF CLUSTER
REMOVAL AND INSTALLATION
2. METER CLUSTER
LAMP 8310-01/8310-10/8310-13/8320-01/8320-12/8320-16/ 8320-19/8610-01
OVERVEIW AND OPERATION PROCESS
1. LOCATIONS OF EXTERIOR LAMPS
2. INTERIOR LAMPS
3. LAMP OPERATION LOGIC
CONFIGURATION AND FUNCTIONS
1. FRONT LAMPS
2. REAR LAMP
3. INTERIOR LAMPS
REMOVAL AND INSTALLATION
1. HEAD LAMPS
2. FOG LIGHT
3. SIDE REPEATER
4. REAR COMBINATION LAMP
5. LICENSE PLATE LAMP
6. HIGH MOOUNTED STOP LAMP
7. REAR FOG LIGHT
8. INTERIOR LAMPS
SWITCH 8510-31/8510-52/7770-20/8510-05/8510-01/8510-21/ 8510-13/8610-06/8510-31/8510-52/7770-20/8510-05/ 8510-01/8510-21/8510-13/7632-16/7610-54/8610-08/
GENERAL
1. SWITCH ARRANGEMENT
CONFIGURATION AND FUNCTIONS
1. CENTER FASCIA & BEZEL SWITCH ASSEMBLY
2. OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
3. INTERIOR LAMP SWITCH
4. MAIN POWER WINDOW SWITCH
5. AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL
6. MULTIFUNCTION SWITCH
7. TAIL GATE OPEN SWITCH
8. DIGITAL CLOCK
9. HORN (INCLUDING THEFT WARNING HORN)
REMOVAL AND INSTALLATION
1. HAZARD & SWITCH ASSEMBLY
2. OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
3. OUTSIDE REARVIEW MIRROR FOLDING UNIT
4. OVERHEAD CONSOLE SWITCH
5. MAIN POWER WINDOW SWITCH
6. AUDIO REMOTE CONTROL SWITCH
7. MULTIFUNCTION SWITCH
8. TAIL GATE OPEN SWITCH
9. CIGARETTE LIGHTER
10. FRONT POWER OUTLET
11. REAR POWER OUTLET
12. DIGITAL CLOCK
13. HORN
WIPER & WASHER 7810-01/7830-01/7820-01/7820-22
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
1. CORRECTION OF FRONT WIPER
2. FRONT WIPER ASSEMBLY
3. REAR WIPER ASSEMBLY
4. WASHER FLUID RESERVOIR TANK
5. WASHER NOZZLE
RAIN SENSOR 8610-09
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
1. FUNCTIONS AND CHECKS OF RAIN SENSOR
2. DIAGNOSIS PROCEDURES
3. RAIN SENSOR
ION 4-SPEED 3410-01/2010-01/3640-01/3640-01/3640-01/3640-01/ 410-01/3640-01/3643-01/3640-01/3640-01/3642-18/ 3410-01/
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
1. TCU
2. ACCELERATOR PEDAL SENSOR
REMOVAL AND INSTALLATION
1. DIAGNOSTIC INFORMATION AND PROCEDURES
2. REBUILD WARNINGS
3. FRONT AND REAR BAND ADJUSTMENT
4. SYMPTOM DIAGNOSIS
5. TROUBLE CODE DIAGNOSIS
6. ION AUTOMATIC TRANSMISSION ASSEMBLY
7. VALVE BODY
8. DISASSEMBLY OF TRANSMISSION
9. ASSEMBLY OF TRANSMISSION
10. GEAR SHIFT CONTROL LEVER
11. TCU
STEERING 4610-01/4610-06/4610-07/4620-02/4711-01
GENERAL
1. OVERVIEW
2. SPECIFICATIONS
OVERVIEW AND OPERATION
1. SYSTEM LAYOUT
2. COMPONENTS
REMOVAL AND INSTALLATION
1. TROUBLE DIAGNOSIS
2. INSPECTIONS OF POWER STEERING SYSTEM
3. STEERING COLUMN SHAFT
4. LOWER SHAFT
5. STEERING GEAR BOX
6. STEERING GEAR PUMP
SPECIAL SERVICE TOOLS 0000-00
GENERAL
1. ION AUTO TRANSMISSION
2. SPECIAL TOOLS AND EQUIPMENT
DSI M78 6-SPEED A/T 3110-01/3650-01/3660-01/3680-01/3721-01/9210-01
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
1. TGS LEVER
2. DSI M78 6-SPEED A/T ASSEMBLY
3. VALVE BODY
4. TCU
5. INHIBITOR SWITCH
REMOVAL AND INSTALLATION
1. FLUID LEVEL INSPECTION
2. 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 3722-01
OVERVIEW AND OPERATION PROCESS
1. INTRODUCTION
2. FUNCTIONS OF THE SELECTOR LEVER
3. MODE SWITCH
4. PARKING LOCK SYSTEM
CONFIGURATION AND FUNCTIONS
1. SELECTOR LEVER CONTROL UNIT
REMOVAL AND INSTALLATION
1. SHIFT ROD POSTION ADJUSTMENT
2. TGS LEVER
MANUAL TRANSMISSION 3170-01/3660-01
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
1. MANUAL TRANSMISSION LOCATION
2. MANUAL TRANSMISSION SYSTEM COMPONENTS
3. SHIFTING MECHANISM
REMOVAL AND INSTALLATION
1. DIAGNOSTIC INFORMATION AND PROCEDURES
2. OIL CHECK/CHANGE OF MANUAL TRANSMISSION
3. MANUAL TRANSMISSION
4. MANUAL TRANSMISSION OVERHAUL
5. TRANSMISSION ADAPTER.
6. SHIM ADJUSTMENT
CLUTCH 3020-01/3020-04/3030-04/3030-01/3010-01/3010-01/ 3020-01/3010-01/3020-01/3030-01/3020-04/
GENERAL
1. CLUTCH SPECIFICATIONS
2. TIGHTENING TORQUE
OVERVIEW AND OPERATION PROCESS
1. FUNCTION AND OVERVIEW
CONFIGURATION AND FUNCTIONS
1. CLUTCH MASTER CYLINDER
2. CLUTCH RELEASE CHAMBER
3. CLUTCH ASSEMBLY
4. CLUTCH PEDAL
REMOVAL AND INSTALLATION
1. CLUTCH TROUBLE DIAGNOSIS
2. CLUTCH INSPECTION AND MAINTENANCE
3. CLUTCH AIR BLEEDING
4. CLUTCH ASSEMBLY
5. CLUTCH REPLACEMENT
6. CONCENTRIC SLAVE CTLINDER
7. CLUTCH MASTER CYLINDER
8. CLUTCH PEDAL
9. CLUTCH CHAMBER
AXLE 4120-01/4220-01
GENERAL
1. SPECIFICATIONS OF AXLE
OVERVIEW AND OPERATION PROCESS
1. OVERVIEW OF AXLE
CONFIGURATION AND FUNCTIONS
1. FRONT AXLE
2. 5-LINK TYPE REAR AXLE
REMOVAL AND INSTALLATION
1. TROUBLE DIAGNOSIS
2. INSPECTION OF RING GEAR TOOTH CONTACT PATTERN
3. FRONT AXLE ASSEMBLY
4. AXLE SHAFT
5. AXLE HOUSING
6. REAR AXLE SHAFT(DISC BRAKE TYPE)
7. REAR AXLE HOUSING
TRANSFER CASE 3240-01/4116-01/3410-01
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
1. TRANSFER CASE
2. COMPONENTS OF IWE (INTEGRATED WHEEL END)
3. TCCU(TRANSFER CASE CONTROL UNIT)
REMOVAL AND INSTALLATION
1. PART TIME TRANSFER CASE GENERAL DIAGNOSIS
2. VACUUM LOCKING HUB CHECK
3. OIL LEVEL CHECK AND CHANGE
4. SELF-DIAGNOSIS TEST
5. TCCU DIAGNOSTIC TROUBLE CODE
6. PART TIME TRANSFER CASE
7. TRANSFER CASE MOTOR
8. IWE (INTEGRATED WHEEL END)
9. LOCKING HUB ACTUATOR ASSEMBLY
10. TCCU
SUSPENSION 4510-01/4411-01/4420-01
GENERAL
1. SPECIFICATIONS OF SUSPENSION
2. WHEEL ALIGNMENT
CONFIGURATION AND FUNCTION
1. FRONT SUSPENSION
2. REAR SUSPENSION (5-LINK TYPE)
REMOVAL AND INSTALLATION
1. TROUBLE DIAGNOSIS OF REAR SUSPENSION
2. FRONT SUSPENSION-UPPER ARM
3. FRONT SUSPENSION- COIL SPRING & SHOCK ABSORBER ASSEMBLY
4. FRONT SUSPENSIONSTABILIZER BAR
5. FRONT SUSPENSIONLOWER ARM
6. REAR SUSPENSION (5 LINK TYPE)
ESP 4892-01/4850-01/4890-01/8510-21/8510-56
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
1. HECU OF ESP
2. HECU OF ABS
3. PRESSURE SENSOR
4. SENSOR CLUS
5. SWAS(STEERING WHEEL ANGLE SENSOR)
6. ESP OFF SWITCH
7. ASS(Active Wheel Speed Sensor)
REMOVAL AND INSTALLATION
1. ESP SYSTEM AIR BLEEDING
2. SENSOR CALIBRATION AND FORCED OPERATION OF ACTUATOR SENSOR VALUE
3. ABS/ESP TROUBLE DIAGNOSIS
4. CAUTIONS WHEN REMOVING FRONT WHEEL SPEED SENSOR-ESP
5. CAUTIONS WHEN REMOVING FRONT WHEEL SPEED ABS
6. HECU-ESP
7. HECU-ABS
8. FRONT WHEEL SPEED SENSOR
9. REAR WHEEL SPEED SENSOR
10. PRESSURE SENSOR
11. SENSOR CLUSTER
AIR BAG 8810-03/8810-06/8810-11/8810-12/8810-01/8810-16
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
1. TROUBLE
2. DRIVER AIR BAG
3. PASSENGER AIR BAG
4. CURTAIN AIR BAG
5. CONTACT COIL
6. AIR BAG(SDM)
7.CURTAIN AIR BAG G SENSOR
SEAT 7410-01/7410-01/7430-01
OVERVIEW AND OPERATION PROCESS
1. COMPOSITION OF SEAT
2. FUNCTIONS OF SEAT
3. COMPONENTS OF SEAT BELT
REMOVAL AND INSTALLATION
1. SEAT MOUNTING POINTS
2. SEAT ASSEMBLY
3. SEAT BELT
SUNROOF 7340-01/7340-04/7340-05/7340-12
OVERVIEW AND OPERATION PROCESS
1. COMPONENTS AND LOCATIONS
2. OPERATION AND FUNCTION
CONFIGURATION AND FUNCTION
1. COMPONENTS OF SUNROOF
REMOVAL AND INSTALLATION
1. RESETTING OF SUNROOF CONTROL UNIT
2. TROUBLE DIAGNOSIS
3. GLASS PANEL ASSEMBLY
4. BELLOWS COVER
5. DRAIN CHANNEL
6. SUN SHADE PANEL
7. SUNROOF CONTROL UNIT(SCU) AND MOTO
8. SUNROOF DRAIN HOSE
9. SUNROOF ASSEMBLY
BODY INTERIOR 7610-01/7330-01/7332-01/7770-01/7730-12/7850-01
OVERVIEW AND OPERATION PROCESS
1. LOCATIONS
REMOVAL AND INSTALLATION
1. INSTRUMENT PANEL ASSEMBLY
2. INSTRUMENT PANEL FRAME ASSEMBLY
3. CENTERCONSOLE (AUTOMATIC TRANSMISSION)
4. CENTER CONSOLE (MANUAL TRANSMISSION)
5. SUNVISOR
6. PILLAR
7. HEADLINING ASSEMBLY
8. OUTSIDE REARVIEW MIRROR
9. INSIDE REARVIEW MIRROR
BODY EXTERIOR 7870-00/7880-01/6110-01/7930-01/6210-01/7120-01/ 6310-01/7220-01/6410-01/7930-01/5720-04/7115-01/ 6210-01/7210-01/7215-01/7220-01/7321-01/6410-01/ 7310-01/7840-01
OVERVIEW AND OPERATION PROCESS
1. COMPOSITION OF BODY EXTERIOR
CONFIGURATION AND FUNCTION
1. COMPONENT OF FRONT BUMPER ASSEMBLY
2. COMPONENTS OF REAR BUMPER ASSEMBLY
3. COMPONENTS OF HOOD ASSEMBLY
4. COMPONENTS OF SIDE SILMOLDING
5. COMPONENTS OF FRONT DOOR ASSEMBLY
6. COMPONENTS OF FRONT WINDOW REGULATOR
7. COMPONENTS OF REAR DOOR ASSEMBLY
8. COMPONENTS OF REAR WINDOW REGULATOR
9. COMPONENTS OF TAILGATE ASSEMBLY
REMOVAL AND INSTALLATION
1. HOOD ASSEMBLY
2. SIDE SILMOLDING
3. FENDER PANEL ASSEMBLY
4. FRONT DOOR TRIM (DRIVER SIDE)
5. FRONT DOOR (DRIVER SIDE)
6. WINDOW REGULATOR (PASSENGER SIDE)
7. REAR DOOR TRIM
8. REAR DOOR ASSEMBLY
9. REAR DOOR MOLDING AND PANEL
10. REAR WINDOW REGULATOR
11. TAILGATE TRIM
12. TAILGATE ASSEMBLY
13. TAILGATE LATCH AND ACTUATOR
14. REAR QUARTER GLASS
15. FRONT BUMPER ASSEMBLY
16. REAR BUMPER ASSEMBLY
BODY REPAIR 4110-01/4110-01/5110-01/5110-01/5110-01/6210-01/ 4010-70/
GENERAL
1. DIMENSIONS
2. JACK-UP POINTS
3. DESIGN CHANGES FOR IMPROVING NVH PERFORMANCE
CONFIGURATION AND FUNCTIONS
1. FRAME DIMENSIONS
2. FRAME BODY MOUNTING
3. WHITE BODY
4. BODY DIMENSIONS
5. BODY GAPS
6. DOOR COMPONENTS(INCLUDING ENGINE HOOD)
7. COMPONENTS OF BODY PANELS
AIR CONDITIONER 6810-20/6820-24/6810-06/6810-02/6810-24/6910-01/6810-15
OVERVIEW AND OPERATION PROCESS
1. SYSTEM LAYOUT AND COMPONENTS
2. VENTILATION SYSTEM
3. AIR CONDITIONER MODULE AND SENSORS
4. SYSTEM DIAGRAM
CONFIGURATION AND FUNCTIONS
1. AIR CONDITIONER CONTROLLER UNIT
2. SUNSENSOR
3. ACTIVE INCAR / HUMIDITY SENSOR: AI SENSOR
4. AMBIENT TEMPERATURE SENSOR
5. WATER TEMPERATURE SENSOR
6. POWER TRANSISTOR
7. MODE DOOR ACTUATOR
8. IN/EX – AIR DOOR ACTUATOR
9. AIR MIX DOOR ACTUATOR
10. THERMO AMP (INTAKE SENSOR)
11. FFH (FUEL FIRED HEATER) SYSTEM
12. PTC(POSITIVE TEMPERATURE COEFFICIENT)
13. SELF DIAGNOSIS (ONLY FOR FATC A/C CONTROLLER)
14. TROUBLE DIAGNOSIS
15. AMBIENT TEMPERATURE SENSOR
16. WATER TEMPERATURE SENSOR
17. POWER TRANSITOR
18. MODE DOOR ACTUATOR
19. IN/EX-AIR DOOR ACTUATOR
20. AIR MIX DOOR ACTUATOR
21. THERMO AMP (INTAKE SENSOR)
22. AIR CONDITONER MODULE ASSEMBLY
23. A/C CONTROLLER SWITCH AND ACTIVE INCAR/HUMIDITY SENSOR
24. AIR DUCT ASSEMBLY
25. CONDENSER ASSEMBLY
26. RECEIVER DRYER ASSEMBLY
27. FUEL PUMP
28. AMBIENT TEMPERATURE SWITCH
29. FFH ASSEMBLY
30. PTC
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