MANUAL DE SERVIÇO – SSANGYONG Actyon (G23D 2008)

CONTENT

GENERAL
– DIMENSIONS
– SPECIFICATIONS
– VEHICLE IDENTIFICATION
– MAINTENANCE INTERVAL
– RECOMMENDED FLUIDS AND LUBRICANTS
– JACK-UP POINTS (DOTTED CIRCLES)
– PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR
– ELECTRIC COMPONENTS AND LAYOUT
– STANDARD BOLTS SPECIFICATIONS

ENGINE GENERAL
– ENGINE ASSEMBLY LAYOUT
– ENGINE CONTROLS LAYOUT
– ELECTRICAL COMPONENTS AND PREHEATING SYSTEM
– INTAKE SYSTEM LAYOUT
– EXHAUST SYSTEM LAYOUT
– LUBRICATION SYSTEM LAYOUT
– COOLING SYSTEM LAYOUT
– FUEL SYSTEM LAYOUT
– FUEL SUPPLY SYSTEM
– CLEANNESS
– MAINTENANCE AND REPAIR
– GUIDELINES FOR SERVICE WORK SAFETY
– DURING SERVICE WORK FOR INSPECTION
– DURING SERVICE WORK FOR ELECTRIC DEVICES
– OWNER INSPECTIONS AND SERVICES
– STANDARD BOLTS SPECIFICATIONS

CRUISE CONTROL SYSTEM
– CRUISE CONTROL SWITCH
– CIRCUIT DIAGRAM
– HOW TO OPERATE CRUISE CONTROL SWITCH

ENGINE ASSEMBLY
– GENERAL
– MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
– SPECIFICATIONS AND PERFORMANCE CURVE
– 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
– CAUTIONS FOR DI ENGINE
– OVERVIEW AND OPERATION PROCESS
– ELECTRONIC CONTROL OF FUEL SYSTEM
– COMPOSITION OF FUEL SYSTEM
– HYDRAULIC CYCLE IN FUEL LINE (TRANSFER AND HIGH PRESSURE LINE)
– COMPONENTS OF LOW PRESSURE TRANSFER LINE
– COMPONENTS OF HIGH PRESSURE TRANSFER LINE
– 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
– ENGINE INTAKE SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
– INTAKE SYSTEM LAYOUT
– 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
– INSPECTION BEFORE DIAGNOSIS
– OVERVIEW AND OPERATION PROCESS
– 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
– SPECIFICATIONS
– OIL PRESSURE SWITCH
– OVERVIEW AND OPERATION PROCESS
– LAYOUT AND OVERVIEW
– 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
– ENGINE COOLING SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
– COMPONENTS OF ENGINE COOLING
– COOLING SYSTEM FLOW
– 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
– OVERVIEW FOR CDPF (EURO IV)
– CDPF (EURO IV) SYSTEM
– OVERVIEW AND OPERATION PROCESS
-. OVERVIEW
– CDPF (EURO IV) SYSTEM CONTROL
– SOOT FILTERING AND BURNING PROCEDURES
– 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
– CRUISE CONTROL SWITCH
– CIRCUIT DIAGRAM
– HOW TO OPERATE CRUISE CONTROL SWITCH
– REMOVAL AND INSTALLATION
– CRUISE CONTROL SWITCH

ENGINE ASSEMBLY
– GENERAL
–  DESCRIPTION AND OPERATION
– G23D ENGINE ASSEMBLY
– G23D ENGINE STRUCTURE
– DIAGNOSTIC INFORMATION AND PROCEDURE
– GENERAL DIAGNOSIS
– 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
– 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
– SPECIFICATION
– OVERVIEW AND OPERATION PROCESS
– DESCRIPTION AND OPERATION
– REMOVAL AND INSTALLATION
– EXHAUST LINE

ENGINE COOLING SYSTEM
– GENERAL
– GENERAL SPECIFICATIONS
– FASTENER TIGHTENING SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
– COMPONENT LOCATOR
– DESCRIPTION AND OPERATION
– 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
– DIAGNOSTIC INFORMATION AND PROCEDURE
– OVERVIEW AND OPERATION PROCESS
– 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
– LOCATIONS OF INTERIOR UNITS AND SENSORS
– LOCATION AND COMPARTMENT OF INTERIOR SWITCHES
– SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT
– ELECTRIC COMPONENTS AND LAYOUT
– DIAGNOSTIC CONNECTOR
– PAS

GENERAL
– COMPONENT SPECIFICATIONS
– CAUTIONS ON PARKING AID SYSTEM OVERVIEW AND OPERATION PROCESS
– SYSTEM OVERVIEW
– ALARM INTERVAL
– TROUBLESHOOTING OF SENSOR
– CIRCUIT DIAGRAM
– REMOVAL AND INSTALLATION
– PARKING AID SENSOR

AUDIO SYSTEM
– OVERVIEW AND INSTALLATION
– AUDIO SYSTEM OVERVIEW
– 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
– GENERAL INFORMATION
– OVERVIEW AND OPERATING PROCESS
– OVERVIEW
– FUSE & RELAY MOUNTING LOCATION
– CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE COMPARTMENT
– CAPACITY AND NAME OF INTERIOR FUSE AND RELAY
– 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
– OVERVIEW
– MAJOR CHANGES
– SPECIFICATIONS
– OVERVIEW AND OPEARATION PROCESS
– OVERVIEW
– FUNCTIONS AND SPECIFICATIONS
– CIRCUIT DIAGRAM
– REMOVAL AND INSTALLATION
– REKES KEY CODING
– DIAGNOSIS TROUBLE CODE AND HEIP TIPS
– STICS

IMMOBILIZER SYSTEM
– OVERVIEW AND OPERATION PROCESS
– OVERVIEW
– BASIC FUNCTIONS OF IMMOBILIZER KEY
– OTHER FUNCTIONS IN SYSTEM
– REKES OPERATION LOGIC
– CIRCUIT DIAGRAM
– REMOVAL AND INSTALLATION
– IMMOBILIZER CODING PROCEDURE
– IMMOBILIZER UNIT

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

LAMP
– OVERVEIW AND OPERATION PROCESS
– LOCATIONS OF EXTERIOR LAMPS
– INTERIOR LAMPS
– 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
– 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
– SYSTEM LAYOUT AND FUNCTION
– SYSTEM LAYOUT OF WIPER AND WASHER (WITH RAIN SENSOR)
-. WIPER & WASHER RELATED FUNCTION AND SPECIFICATION
– 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
– SYSTEM LAYOUT AND OVERVIEW
– RAIN SENSING OPERATION
– RAIN SENSOR RELATED CIRCUIT
– FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING WIPER
– OPERATION MODE OF RAIN SENSING WIPER SYSTEM
– REMOVAL AND INSTALLATION
– FUNCTIONS AND CHECKS OF RAIN SENSOR
– DIAGNOSIS PROCEDURES
– RAIN SENSOR

ION 4-SPEED
– GENERAL
– SPECIFICATIONS
– FASTENER TIGHTENING SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
– DESCRIPTION AND OPERATION OF AUTOMATIC TRANSMISSION
– APPEARANCE
– SHIFT PATTERN DIAGRAM
– OPERATORS INTERFACES
– CONTROL SYSTEMS
– ELECTRONIC CONTROL SYSTEM
– HYDRAULIC CONTROL SYSTEM
– 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
– OVERVIEW
– SPECIFICATIONS
– OVERVIEW AND OPERATION
– SYSTEM LAYOUT
– 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
– DSI M78 6-SPEED AUTOMATIC TRANSMISSION GENERAL
– STRUCTURE CHARACTERISTICS AND SPECIFICATIONS
– TIGHTENING TORQUE
– OVERVIEW AND OPERATION PROCESS
– GENERAL DESCRIPTION
– ADVANCED SIX SPEED FEATURES
– FUNCTION OF EACH MODE
– LIMP HOME MODE
– TRANSMISSION ELECTRONIC CONTROL SYSTEM
– CONFIGURATION OF CAN RELATED TO TCU
– 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
– WIRING DIAGRAM
– WIRE HARNESS CONNECTOR CHART
– UNIT CONNECTOR DESCRIPTION
– TROUBLE CODE EIAGNOSIS
– DIAGNOSTIC TROUBLE CODE LIST
– SYSTEM DIAGNOSIS
– MAINTENANCE OPERATIONS
– OIL TEST
– STALL TEST
– TRANSMISSION RESET PROCEDURE (REPLACEMENT TRANSMISSION)
– FLUID LEVEL INSPECTION
– TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE
– LUBRICATION
– TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE (NEW TRANSMISSION)

TGS LEVER
– OVERVIEW AND OPERATION PROCESS
– INTRODUCTION
– FUNCTIONS OF THE SELECTOR LEVER
– MODE SWITCH
–  PARKING LOCK SYSTEM
– CONFIGURATION AND FUNCTIONS
– SELECTOR LEVER CONTROL UNIT
– REMOVAL AND INSTALLATION
– SHIFT ROD POSTION ADJUSTMENT
– TGS LEVER

MANUAL TRANSMISSION
– GENERAL
– OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION
– SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION
– OVERVIEW AND OPERATION PROCESS
– 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
– CLUTCH SPECIFICATIONS
-. TIGHTENING TORQUE
– OVERVIEW AND OPERATION PROCESS
-. 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
-. SPECIFICATIONS OF AXLE
– OVERVIEW AND OPERATION PROCESS
– OVERVIEW OF AXLE
– CONFIGURATION AND FUNCTIONS
– FRONT AXLE
– 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
– OVERVIEW
– SPECIFICATIONS
– OVERVIEW AND OPERATION PROCESS
– STRUCTURE
-. SYSTEM LAYOUT AND OPERATION
– LOCKING HUB SYSTEM
– 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
– SPECIFICATIONS OF SUSPENSION
– 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
– SYSTEM GENERAL
-. SECTIONAL DRAWING
-. SPECIFICATIONS
– BRAKE OPERATION AND NOISE
– ESP SYSTEM RELATED PRECAUTIONS
– OVERVIEW AND OPERATION PROCESS
– OVERVIEW OF ESP(ELECTRONIC STABILITY PROGRAM) SYSTEM
– COMPONENTS OF ESP
– PRINCIPLE OF ESP
– PRINCIPLE OF BAS(BRAKE ASSIST SYSTEM)
– PRINCIPLE ARP(ACTIVE ROLL-OVER PROTECTION)
– PRINCIPLE OF HDC(HILL DESCENT CONTROL)
– INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM
– HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM
– HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE
– HYDRAULIC CIRCUIT OF BAS (BRAKE ASSIST SYSTEM)
– 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
– OVERVIEW (INCLUDING CURTAIN AIR BAGS)
– OVERVIEW AND OPERATION PROCESS
– LOCATION AND RELATED COMPONENTS
–  AIR BAG SYSTEM OPERATION PROCESS
– 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
– COMPOSITION OF SEAT
– FUNCTIONS OF SEAT
–  COMPONENTS OF SEAT BELT
– REMOVAL AND INSTALLATION
– SEAT MOUNTING POINTS
– SEAT ASSEMBLY
– SEAT BELT

SUNROOF
– OVERVIEW AND OPERATION PROCESS
– COMPONENTS AND LOCATIONS
–  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
–  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
– 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
– DIMENSIONS
– JACK-UP POINTS
–  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
– SYSTEM LAYOUT AND COMPONENTS
–  VENTILATION SYSTEM
–  AIR CONDITIONER MODULE AND SENSORS
–  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