Rodius A100 2004.09

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Service Manual

  1. ENGINE

    1. ENGINE GENERAL

      1. GENERAL
        1. 1. ENGINE ASSEMBLY LAYOUT
        2. 2. ENGINE CONTROLS LAYOUT
        3. 3. ELECTRICAL COMPONENTS AND PREHEATING SYSTEM
        4. 4. INTAKE SYSTEM LAYOUT
        5. 5. EXHAUST SYSTEM LAYOUT
        6. 6. LUBRICATION SYSTEM LAYOUT
        7. 7. COOLING SYSTEM LAYOUT
        8. 8. FUEL SYSTEM LAYOUT
        9. 9. FUEL SUPPLY SYSTEM
        10. 10. CLEANNESS
        11. 11. MAINTENANCE AND REPAIR
        12. 12. GUIDELINES FOR SERVICE WORK SAFETY
        13. 13. DURING SERVICE WORK FOR INSPECTION
        14. 14. DURING SERVICE WORK FOR ELECTRIC DEVICES
        15. 15. VEHICLE LIFTING PROCEDURES
        16. 16. OWNER INSPECTIONS AND SERVICES
        17. 17. STANDARD BOLTS SPECIFICATIONS
        18. 18. BASIC SPECIFICATION
        19. 19. VEHICLE IDENTIFICATION
        20. 20. HOW TO USE AND MAINTAIN WORKSHOP MANUAL
    2. ENGINE ASSEMBLY

      1. GENERAL
        1. 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
        2. 2. ENGINE STRUCTURES
        3. 3. SPECIFICATIONS AND PERFORMANCE CURVE
        4. 4. TIGHTENING TORQUE
      2. CONFIGURATION AND FUNCTIONS
        1. 1212-01 CYLINDER HEAD
        2. 1222-21 CAMSHAFT ASSEMBLY
        3. 1312-01 TIMING CHAIN ASSEMBLY
        4. 1125-01 CYLINDER BLOCK
        5. 1130-01 CRANKSHAFT
        6. 1130-18 FLYWHEEL
        7. 1130-33 PISTON AND CONNECTING ROD
        8. 1881-01 HIGH PRESSURE PUMP(HPP)
      3. REMOVAL AND INSTALLATION
        1. 1114-01 GENERAL DIAGNOSIS
        2. 1114-01 INSPECTION BEFORE ISASSEMBLY AND REASSEMBLY
        3. 1114-01 DIAGNOSTIC INFORMATION AND PROCEDURE
        4. 1114-01 ENGINE ASSEMBLY
        5. 1114-01 ENGINE ACCESSORIES
        6. 1114-01 ENGINE OVERHAUL
        7. 1212-01 CYLINDER HEAD-DISASSEMBLY AND REASSEMBLY
        8. 2313-01 INTAKE/EXHAUST VALVE
        9. 1222-21 CAMSHAFT
        10. 1312-01 TIMING CHAIN
        11. 1881-01 DISASSEMBLY AND REASSEMBLY OFHIGH PRESSURE PUMP(HPP)
        12. 1610-01 VACUUM PUMP
    3. ENGINE FUEL SYSTEM

      1. GENERAL
        1. 1. CAUTIONS FOR DI ENGINE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. ELECTRONIC CONTROL OF FUEL SYSTEM
        2. 2. COMPOSITION OF FUEL SYSTEM
        3. 3. HYDRAULIC CYCLE IN FUEL LINE(TRANSFER AND HIGH PRESSURE LINE)
        4. 4. COMPONENTS OF LOW PRESSURE TRANSFER LINE
        5. 5. COMPONENTS OF HIGH PRESSURE TRANSFER LINE
      3. CONFIGURATION AND FUNCTIONS
        1. 1881-01 TRANSFER PUMP
        2. 1881-01 INLET METERING VALVE(IMV)
        3. 1881-01 HIGH PRESSURE PUMP
        4. 2231-01 FUEL FILTER
        5. 2231-01 WATER SEPARATOR(GENERAL AREA ONLY)
        6. 2231-04 PRIMING PUMP
        7. 1881-23 HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
        8. 1881-23 FUEL PRESSURE SENSOR
        9. 1881-01 FUEL TEMPERATURE SENSOR
        10. 1881-09 INJECTOR
      4. REMOVAL AND INSTALLATION
        1. 2231-01 FUEL FILTER
        2. 1881-01 HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
        3. 1881-09 FUEL INJECTION
        4. 2210-01 FUEL TANK
    4. ENGINE INTAKE SYSTEM

      1. GENERAL
        1. 1. ENGINE INTAKE SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. ENGINE INTAKE COMPONENTS LOCATOR
        2. 2. AIR FLOWS
      3. CONFIGURATION AND FUNCTIONS
        1. 2321-01 AIR FLOW SENSOR(HOT FILM AIR MASS SENSOR)
        2. 2330-01 INTERCOOLER
        3. 1715-01 INTAKE MANIFOLD ASSEMBLY
      4. REMOVAL AND INSTALLATION
        1. 2313-01 TIGHTENING TORQUE OF INTAKYSTEM
        2. 2313-01 AIR CLEANER ELEMENT-REPLACEMENT
        3. 2330-06 AIR CLEANER HOUSING
        4. 2321-01 AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)
        5. 1333-15 INTERCOOLER ASSEMBLY
        6. 1715-01 INTAKE MANIFOLD
    5. ENGINE EXHAUST SYSTEM

      1. GENERAL
        1. 1.BEFORE DIAGNOSIS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS LOCATOR OF EXHAUST SYSTEM
        2. 2. EXHAUST GAS FLOWS
      3. CONFIGURATION AND FUNCTIONS
        1. 1913-01 TUBO CHARGER ASSEMBLY
        2. 1792-01 EGR VALVE AND VACUUM MODULATOR
        3. 2411-01 EXHAUST DEVICE AND MUFFLER
      4. REMOVAL AND INSTALLATION
        1. 1913-01 DIAGNOSIS AND MAINTENANCE TURBO CHARGER SYSTEM
        2. 1913-01 PATH OF TUBO CHARGER DEFECT
        3. 1913-01 HOW TO DIAGNOSE
        4. 1913-01 PATH OF EXHAUST DEVICE DEFECT
        5. 1913-01 TUBO CHARGER ASSEMBLY
        6. 1792-01 EGR VALVE AND PIPE
        7. 1792-01 VACCUM MODULATOR
        8. 2411-01 EXHAUST PIPE
    6. ENGINE LUBRICATION SYSTEM

      1. GENERAL
        1. 1. SPECIFICATIONS
        2. 2. LUBRICATION SYSTEM LAYOUT
        3. 3. LUBRICATION DIAGRAM
      2. CONFIGURATION AND FUNCTIONS
        1. 1533-01 OIL PUMP
        2. 1543-01 BLOW-BY GAS REDUCTION DEVICE
        3. 1222-01 CYLINDER HEAD COVER
        4. 1222-09 OIL SEPARATOR
        5. 1222-09 OIL SPRAY NOZZLE
        6. 1533-08 OIL PAN ASSEMBLY
      3. REMOVAL AND INSTALLATION
        1. 1543-00 TROUBLE DIAGNOSIS
        2. 9210-01 ENGINE OIL CHANGE
        3. 1543-01 OIL FILTER AND COOLER
        4. 1533-08 OIL PUMP
        5. 1533-34 OIL DIPSTICK GUIDE TUBE
        6. 1222-09 DISASSEMBLY OF OIL SPRAY NOZZLE
        7. 1533-08 OIL PAN
    7. ENGINE COOLING SYSTEM

      1. GENERAL
        1. 1. ENGINE COOLING SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS ENGINE COOLING
        2. 2. COOLING SYSTEM FLOW
        3. 3. FUNCTION DESCRIPTION OF COOLING SYSTEM
      3. CONFIGURATION AND FUNCTIONS
        1. 2112-01 RADIATOR
        2. 1520-01 WATER PUMP
        3. 2130-13 COOLANT RESERVOIR
        4. 1520-11 THERMOSTAT
        5. 1431-07 COOLANT TEMPERTURE SENSOR
        6. 0000-00 PREHEATING SYSTEM
      4. REMOVAL AND INSTALLATION
        1. 9210-05 TROUBLE DIAGNOSIS
        2. 9210-05 COOLANT LEVEL CHECK
        3. 9210-05 INSPECTION AND REPAIR
        4. 9210-05 DRAINING AND ADDING OF COOLANT
        5. 9210-05 COOLANT RESERVOIR
        6. 1520-01 WATER PUMP ASSEMBLY
        7. 1520-11 THERMOSTAT
        8. 1520-01 WATER PUMP HOUSING
        9. 2112-01 RADIATOR
        10. 1333-15 INTERCOOLER ASSEMBLY
        11. 1333-15 ELECTRIC FANS
        12. 1333-15 CONDENSER ASSEMBLY
        13. 1333-15 FAN SHROUD
        14. 1333-15 FAN CLUTCH
        15. 1333-15 FAN BELT
    8. ENGINE ELECTRIC DEVICES

      1. GENERAL
        1. 1.SPECIFICATIONS OF ENGINE ELECTRIC
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. SENSORS IN ENGINE COMPARTMENT
        2. 2. ELECTRIC DEVICES IN ENGINE COMPARTMENT
        3. 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM
        4. 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR
      3. CONFIGURATION AND FUNCTIONS
        1. 0000-00 PREHEATING SYSTEM
      4. REMOVAL AND INSTALLATION
        1. 1451-01 GENERAL TROUBLE DIAGNOSIS
        2. 1451-51 ALTERNATOR
        3. 1461-01 STARTER
        4. 0000-00 GLOW PLUG
    9. ENGINE CONTROL SYSTEM

      1. GENERAL
        1. 1. ENGINE ECU AND OTHER COMPONENTS
        2. 2. TOP VIEW
        3. 3. SIDE VIEW
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. ECU INPUTS/OUTPUTS
        2. 2. STRUCTURE AND FUNCTION OF ECU
        3. 3. CONTROL FUNCTION OF ECU
        4. 4. FUEL PRESSURE CONTROL
        5. 5. FUEL INJECTION CONTROL
        6. 6. FUEL FLOW CONTROL
        7. 7. INDIVIDUAL INJECTOR CALIBRATION (C2I)
        8. 8. MINIMUM DRIVE PULSE (MDP) LEARNING
      3. CONFIGURATION AND FUNCTIONS
        1. 1491-01 ECU
        2. 2010-04 ACCELERATOR PADAL SENSOR
        3. 1431-07 COOLANT TEMPERATURE SENSOR
        4. 1431-09 BOOST PRESSURE SENSOR
        5. 4890-02 VEHICLE SPEED SENSOR
        6. 4810-26 OTHER SWITCHES
      4. REMOVAL AND INSTALLATION
        1. 1491-01 ECU
    10. SPECIAL SERVICE TOOLS

      1. GENERAL
        1. 1. COMMON ENGINE
        2. 2. IDI ENGINE
        3. 3. DI ENGINE
        4. 4. GASOLINE ENGINE
        5. 1. ENGINE ASSEMBLY SYSTEM
        6. 2. ENGINE INTAKE SPECIFICATIONS
        7. 3. ENGINE LUBRICATION SYSTEM
        8. 4. ENGINE ELECTRICAL SYSTEM
  2. ELECTRIC

    1. ELECTRICAL SYSTEM

      1. ELECTRIC GENERAL
        1. 1. LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT
        2. 2. SWITCHES, UNITS AND SENSORS IN ENGINE COMPARTMENT(EXCEPT ENGINE RELATED SENSORS AND UNITS)
        3. 3. SWITCHES IN PASSENGER COMPARTMENT
        4. 4. SYSTEM LAYOUT (BASED ON DVD SYSTEM EQUIPPED
        5. 5. WIRING HARNESS ARRANGEMENT
        6. 6. ELECTRIC COMPONENTS LOCATOR
    2. FUSES & RELAYS

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. ENGINE COMPARTMENT FUSE AND RELAY BOX
        2. 2. INTERIOR FUSE COMPARTMENT
        3. 3. ICM(INTERGRATED CONTROL MODULE) BOX
        4. 4. WIRING HARNESS, CONNECTOR & GROUND
      2. CONFIGURATION AND FUNCTIONS
        1. 8410-05 ICM CONNECTOR ARRANGEMENT(BASED ON WIRING CONNECTORS)
        2. 8410-05 ICM BOX POWER SUPPLY CIRCUIT
      3. REMOVAL AND INSTALLATION
        1. 8410-05 ICM BOX
    3. STICS

      1. GENERAL
        1. 1. SPECIFICATIONS OF RK STICS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS LOCATOR
        2. 2. DESCRIPTIONS
        3. 3. FUNCTIONS OF RK STICS
      3. CONFIGURATION AND FUNCTIONS
        1. 8710-01 TRANSMITTER CODING
        2. 8710-01 STICS CONNECTOR ARRANGEMENT
      4. REMOVAL AND INSTALLATION
        1. 8710-01 DIAGNOSIS TROUBLE CODE AND HELP TIPS
        2. 8710-01 STICS
    4. CLUSTER

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. APPEARANCE OF METER CLUSTER AND INDICATOR DISPLAY
        2. 2. DESCRIPTIONS OF INDICATOR DISPLAY
        3. 3. WARNING & INDICATOR PANEL
        4. 4. FUNCTION DESCRIPTION AND INSPECTION OF METER
        5. 5. CIRCUIT DIAGRAM OF INDICATOR DISPLAY
      2. CONFIGURATION AND FUNCTIONS
        1. 8010-01 CLUSTER AND INDICATOR DISPLAY CONNECTORS ARRANGEMENT
        2. 8010-01 METER CLUSTER
        3. 8010-10 INDICATOR DISPLAY
    5. LAMP

      1. GENERAL
        1. 1. COMPONENTS OF EXTERIOR LAMPS
        2. 2. COMPONENTS OF INTERIOR LAMPS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. LOCATIONS OF EXTERIOR LAMPS
        2. 2. LOCATIONS OF INTERIOR LAMPS
        3. 3. EXTERIOR LAMP OPERATION
        4. 4. INTERIOR LAMP OPERATION
      3. REMOVAL AND INSTALLATION
        1. 8310-01 HEADLAMP
        2. 8310-01 REPLACEMENT OF HEADLAMP BULB
        3. 8310-07 FOG LAMP
        4. 8310-10 SIDE REPEATER
        5. 8320-10 HIGH MOUNTED STOP LAMP
        6. 8320-12 LICENSE PLATE LAMP
        7. 8320-07 TAIL LAMP(BACK-UP LAMP/REAR FOG LAMP)
        8. 8320-01 TAIL LAMP
        9. 7115-08 DOOR COURTESY LAMP
        10. 8610-07 GLOVE BOX LAMP
        11. 8610-08 LUGGAGE ROOM LAMP
        12. 8610-08 SIDE ROOM LAMP
        13. 8610-01 FRONT ROOM LAMP (OVERHEAD CONSOLE LAMP)
    6. SWITCH

      1. GENERAL
        1. 1. INTERIOR SWITCH COMPARTMENT
      2. CONFIGURATION AND FUNCTIONS
        1. 8510-01 CENTER SWITCH
        2. 8410-14 4WD SWITCH REAR WIPER/WASHER SWITCH
        3. 8510-42 SWITCH ON STEERING WHEEL
        4. 8510-03 SWITCH ON DOOR TRIM
        5. 8510-10 MULTIFUNCTION SWITCH
        6. 8510-60 AUTO LIGHT SENSOR
        7. 8610-04 MULTI-METER
      3. REMOVAL AND INSTALLATION
        1. 8510-01 CENTER SWITCHES
        2. 8410-14 4WD SWITCH, REAR WIPER/WASHER SWITCH
        3. 8510-42 SWITCH ON STEERING WHEEL
        4. 8610-09 HORN AND THEFT DETERRENT HORN
        5. 8510-03 OUTSIDE REARVIEW MIRROR SWITCH
        6. 8510-03 WINDOW SWITCH
        7. 8510-10 MULTIFUNCTION SWITCH ASSEMBLY
        8. 8610-04 MULTI-METER
    7. WIPER & WASHER SYSTEM

      1. GENERAL
        1. 1. SPECIFICATIONS OF WIPER
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM LAYOUT OF WIPER AND WASHER
        2. 2. COMPONENTS LOCATOR OF FRONT WIPER ASSEMBLY
        3. 3. COMPONENTS LOCATOR OF REAR WIPER ASSEMBLY
        4. 4. CIRCUIT DIAGRAM OF WIPER & WASHER
      3. REMOVAL AND INSTALLATION
        1. 7810-01 FRONT WIPER
        2. 7830-01 REAR WIPER
    8. RAIN SENSOR UNIT

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF RAIN SENSOR
        2. 2. RAIN SENSOR OPERATION
        3. 3. OPERATION MODE OF RAIN SENSING WIPER SYSTEM
        4. 4. FUNCTIONS OF RAIN SENSOR
        5. 5. DIAGNOSIS PROCEDURES
        6. 6. RAIN SENSOR RELATED CIRCUIT
      2. REMOVAL AND INSTALLATION
        1. 8610-11 TROUBLE SHOOTING
        2. 8610-11 RAIN SENSOR
    9. PAS

      1. GENERAL
        1. 1. COMPONENT SPECIFICATIONS OF PARKING AID SYSTEM
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF PARKING AID SYSTEM
        2. 2. COMPONENTS OF PARKING AID SYSTEM(PAS)
        3. 3. OPERATIONS OF PARKING AID SYSTEM(PAS)
        4. 4. PARKING AID SYSTEM CONTROL
        5. 5. OPERATIONS OF REARVIEW CAMERA
        6. 6. OPERATIONAL PRINCIPLE OF REARVIEW CAMERA
        7. 7. CIRCUIT DIAGRAM
      3. REMOVAL AND INSTALLATION
        1. 8790-04 PARKING AID SENSOR
        2. 8790-01 PARKING AID UNIT
        3. 0000-00 REARVIEW CAMERA
    10. AV

      1. GENERAL
        1. 1. AV HEAD UNIT OVERVIEW
        2. 2. AV SYSTEM BY VEHICLE MODEL
        3. 3. SPECIFICATIONS OF AV HEAD UNIT
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. AVSYSTEM LAYOUT (BASED ON DVD EQUIPPED SYSTEM)
        2. 2. DVD SYSTEM SIGNALS AND DATA PROCESSING
      3. CONFIGURATION AND FUNCTIONS
        1. 8930-01 AV HEAD UNIT(BASED ON DVD SYSTEM)
        2. 8930-08 TUNER/5.1 CHANNEL AMP WITH BUILT-IN DSP/
        3. 8930-12 REAR MONITOR(ROOF MONITOR)
      4. REMOVAL AND INSTALLATION
        1. 8930-01 AV HEAD UNIT(BASED ON DVD SYSTEM)
        2. 8930-08 TUNER
        3. 8930-14 AMPLIFIER WITH BUILT-IN DSP
        4. 8930-14 DVD NAVIGATION
        5. 8930-12 REAR MONITOR
        6. 8910-12 SPEAKER
        7. 8930-09 ANTENNA MODULE
  3. CHASSIS

    1. DC 5-SPEED

      1. GENERAL
        1. 1. OVERVIEW
        2. 2. STRUCTURE
        3. 3. PERFORMANCE CURVE AND GENERAL CHARACTERISTICS
        4. 4. SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF AUTO TRANSMISSION (DC 5-SPEED A/T)
        2. 2. POWER FLOW
      3. CONFIGURATION AND FUNCTIONS
        1. 3650-01 OPERATION OF SELECTOR LEVER MODE
        2. 3650-01 AUTOMATIC TRANSMISSION (DC 5-SPEED) ASSEMBLY
        3. 3660-01 VALVE BODY
        4. 0000-00 KICK-DOWN CONTROL
        5. 0000-00 REVERSE/PARKING(R/P) LOCK SYSTEM
        6. 3110-01 TCU (TRANSMISSION CONTROL UNIT)
        7. 3650-01 OIL LEVER CONTROL
      4. REMOVAL AND INSTALLATION
        1. 3650-01 OIL CHECK AND SPECIFICATION
        2. 3721-01 SHIFT ROD ADJUSTMENT
        3. 3110-01 DTC(DIAGNOSIS TROUBLE CODE) OF DC5AT
        4. 3650-01 TRANSMISSION ASSEMBLY
        5. 3721-01 SELECTOR LEVER ASSEMBLY
        6. 3660-01 VALVE BODY ASSEMBLY
        7. 3650-01 CONVERTER HOUSING AND TRANSMISSION HOUSING
    2. M/T

      1. GENERAL
        1. 1. SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. MANUAL TRANSMISSION OVERVIEW
      3. CONFIGURATION AND FUNCTIONS
        1. 3170-01 MANUAL TRANSMISSION SYSTEM COMPONENTS
        2. 3170-01 SHIFTING MECHANISM
      4. REMOVAL AND INSTALLATION
        1. 3170-01 EIAGNOSTIC INFORMATION PROCEDURES
        2. 3170-01 OIL CHECK/HANGE
        3. 3170-01 TRANSMISSION ASSEMBLY
        4. 3710-01 TRANSMISSION OVERHAUL
        5. 3660-01 TRANSMISSION ADAPTER AND BACKUP SWITCH
        6. 3170-01 SHIM ADJUSTMENT
    3. CLUTCH

      1. GENERAL
        1. 1. CLUTCH SPECIFICATIONS
        2. 2. TIGHTENING TORQUE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW
        2. 2. COMPONENTS
      3. CONFIGURATION AND FUNCTIONS
        1. 3010-01 CLUTCH ASSEMBLY
        2. 3020-01 CLUTCH FLUID RESERVOIR TANK(Common Usage with Brake Oil Reservoir Tanks)
        3. 3020-04 CLUTCH RELEASE CHAMBER
        4. 3030-01 CLUTCH PEDAL
      4. REMOVAL AND INSTALLATION
        1. 3020-01 CLUTCH AIR BLEEDING
        2. 3010-01 TROUBLE DIAGNOSIS
        3. 3010-01 CLUTCH ASSEMBLY
        4. 3171-14 CONCENTRIC SLAVE CYLINDER
        5. 3020-01 CLUTCH MASTER CYLINDER
        6. 0000-00 CLUTCH FLUID PIPE
        7. 3030-01 CLUTCH PEDAL
        8. 3010-01 INSPECTION
    4. AXLE SYSTEM

      1. GENERAL
        1. 1. FRONT AXLE SPECIFICATION
        2. 2. REAR AXLE SPECIFICATION
      2. CONFIGURATION AND FUNCTIONS
        1. 4120-01 FRONT AXLE ASSEMBLY
        2. 4220-01 REAR AXLE ASSEMBLY
      3. REMOVAL AND INSTALLATION
        1. 4120-01 AXLE SHAFT(DRIVER SHAFT)
        2. 4120-01 AXLE HOUSING OIL SEAL
        3. 4120-01 AXLE HOUSING ASSEMBLY
        4. 4220-01 REAR AXLE ASSEMBLY
        5. 4220-01 REAR AXLE SHAFT
        6. 4210-01 REAR AXLE HOUSING
        7. 4220-01 RADIAL SEALING AND O-RING
        8. 4220-01 REPLACEMENT OF RADIAL SEALING AND O-RING ON PROPELLER SHAFT FLANGE
    5. TOD

      1. GENERAL
        1. 1. SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. TOD SYSTEM LAYOUT
        2. 2. GENERAL DESCRIPTION
        3. 3. OPERATION
        4. 4. CIRCUIT DIAGRAM
      3. CONFIGURATION AND FUNCTIONS
        1. 3240-01 TOD ASSEMBLY
        2. 3410-01 TCCU(TRANSFERCASE CONTROL UNIT)
        3. 4116-01 SPEED SENSOR AND CLUTCH COIL
        4. 3252-43 SHIFT MOTOR CONNECTOR
      4. REMOVAL AND INSTALLATION
        1. 3410-01 TROUBLE DIAGNOSIS
        2. 3410-01 TCCU
        3. 3253-43 SHIFT MOTOR
        4. 4116-01 SPEED SENSOR
        5. 3240-01 TOD ASSEMBLY
        6. 3240-01 TOD DISASSEMBLY PROCEDURE
        7. 3240-01 TOD ASSEMBLY PROCEDURE
    6. PROPELLER SHAFT

      1. GENERAL
        1. 1. PROPELLER SHAFT GENERAL INFOROMATION
        2. 2. SPECIFICATION
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS AND LOCATION
      3. REMOVAL AND INSTALLATION
        1. 3310-01 TROUBLE DIAGNOSIS
        2. 3310-01 FRONT PROPELLER SHAFT(4WD)
        3. 3310-06 REAR PROPELLER SHAFT
        4. 3310-01 FRONT PROPELLER SHAFT AND REAR PROPELLER SHAFT(4WD)
        5. 3310-01 UNIVERSAL JOINT
    7. SUSPENSION SYSTEM

      1. GENERAL
        1. 1. FRONT SUSPENSION SPECIFICATION
        2. 2. REAR SUSPENSION SPECIFICATION
        3. 3. STRUCTURE OF SHOCK ABSORBER AND COIL SPRING
      2. CONFIGURATION AND FUNCTIONS
        1. 4110-01 FRONT SUSPENSION
        2. 4320-01 FRONT SUB FRAME
        3. 4510-01 REAR SUSPENSION
      3. REMOVAL AND INSTALLATION
        1. 4410-10 TROUBLE DIAGNOSIS
        2. 4410-20 FRONT SUSPENSION- UPPER ARM ASSEMBLY
        3. 4411-01 COIL FRONT SUSPENSION-SPRING & SHOCK ABSORBER ASSEMBLY
        4. 4420-01 FRONT SUSPENSION-STABILIZER BAR ASSEMBLY
        5. 4410-01 FRONT SUSPENSION- LOWER ARM ASSEMBLY
        6. 4115-01 FRONT SUSPENSION-KNUCKLE ASSEMBLY
        7. 4320-01 FRONT SUB FRAME
        8. 4521-03 REAR SUSPENSION - SHOCK ABSORBER ASSEMBLY
        9. 4521-01 REAR SUSPENSION-COIL SPRING
        10. 4331-11 REAR SUSPENSION-THRUST LINK
        11. 4331-06 REAR SUSPENSION-TENSION LINK
        12. 4331-07 REAR SUSPENSION- TRACK ROD
        13. 4331-01 REAR SUSPENSION-CAMBER LINK
        14. 4520-25 REAR SUSPENSION-STABILIZER BAR/ STABILIZER LINK
        15. 4510-10 REAR SUSPENSION-SPRING LINK
        16. 4221-01 REAR SUSPENSION-WHEEL CARRIER ASSEMBLY
    8. BRAKES SYSTEM

      1. GENERAL
        1. 1.SPECIFICATION
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF BRAKE SYSTEM
        2. 2. BRAKE SYSTEM OPERATION PROCESS
      3. CONFIGURATION AND FUNCTIONS
        1. 4830-01 FRONT BRAKE
        2. 4841-01 REAR BRAKE
        3. 4221-01 PARKING BRAKE
      4. REMOVAL AND INSTALLATION
        1. 4830-01 TROUBLE DIAGNOSIS
        2. 4830-01 AIR BLEEDING(WITH ABS)
        3. 4830-01 BRAKE PEDAL CHECK
        4. 4850-03 AFTER REPLACING MASTER CYLINDER
        5. 4850-03 AFTER REPLACING HYDRAULIC UNIT
        6. 4850-03 INSPECTIONS OF BRAKE COMPONENTS
        7. 0000-00 ADJUSTMENT OF PARKING BRAKE
        8. 4850-03 VACUUM HOSE BRAKE BOOSTER
        9. 4850-03 BRAKE FLUID RESERVOIR TANK
        10. 4850-03 MASTER CYLINDER( ESP EQUIPPED VEHICLE)
        11. 4850-03 BRAKE BOOSTER
        12. 4810-10 STOP LAMP SWITCH
        13. 3039-09 BRAKE PEDAL
        14. 4830-01 CALIPER/ BRAKE DISK
        15. 4830-01 FRONT BRAKE PAD
        16. 4841-01 REAR CALIPER/ BRAKE DISK
        17. 4841-02 BRAKE PAD
        18. 4910-01 PARKING BRAKE PEDAL ASSEMBLY
        19. 4221-20 PARKING BRAKE SHOE
    9. ESP

      1. GENERAL
        1. 1. SPECCIFICATIONS OF ESP SYSTEM
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS AND LOCATIONS
        2. 2. INPUT AND OUTPUT DIAGRAM
        3. 3. ESP SYSTEM DESCRIPTION
        4. 4. ELECTRICAL CIRCUIT DIAGRAM
      3. CONFIGURATION AND FUNCTIONS
        1. 4892-01 HECU(HYDRAULIC AND ELECTRONIC CONTROL UNIT
        2. 4890-01 WHEEL SPEED SENSOR
        3. 8510-21 SWAS(STEERING WHEEL ANGLE SENSOR)
        4. 4890-05 SENSOR CLUSTER
        5. 4850-01 PRESSURE SENSOR
        6. 8510-56 ESP OFF SWITCH
      4. REMOVAL AND INSTALLATION
        1. 4892-01 ABS/ESP TROUBLE DIAGNOSIS
        2. 4892-01 AIR BLEEDING
        3. 4892-01 HECU ASSEMBLY
        4. 8510-21 STEERING WHEEL SENSOR
        5. 4890-05 SENSOR CLUSTER
    10. ABS

      1. GENERAL
        1. 1. GENERAL INFORMATION
        2. 2. ON-VEHICLE SERVICE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS AND LOCATION
        2. 2. INPUT AND OUTPUT DIAGRAM
        3. 3. ABS SYSTEM DESCRIPTION
      3. CONFIGURATION AND FUNCTION
        1. 4892-01 ACTIVE WHEEL SPEED SENSOR
      4. REMOVAL AND INSTALLATION
        1. 4892-01 HECU ASSEMBLY
        2. 4892-01 FRONT WHEEL SPEED SENSOR
        3. 4892-01 REAR WHEEL SPEED SENSOR
        4. 4892-01 FRONT TOTH WHEEL
    11. POWER STEERING SYSTEM

      1. GENERAL
        1. 1. SPECIFICATION
        2. 2. TIGHTENING TORQUE
        3. 3. SPECIAL TOOLS AND EQUIPMENT
        4. 4. OVERVIEW
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF POWER STEERING ASSEMBLY
        2. 2. POWER STEERING GEAR BOX ASSEMBLY
        3. 3. POWER STEERING PUMP
        4. 4. OIL RESERVOIR
      3. REMOVAL AND INSTALLATION
        1. 4610-00 TROUBLE DIAGNOSIS
        2. 4610-00 GENERAL INSPECTIONS OF POWER STEERING
        3. 4610-00 AIR BLEEDING
        4. 4610-06 COLUMN SHAFT AND LOWER SHAFT
        5. 4620-02 STEERING GEAR BOX
        6. 4620-02 DISASSEMBLY AND REASSEMBLY OF STEERING GEAR BOX
        7. 4711-11 STEERING GEAR PUMP
        8. 4711-01 OIL PIPE
    12. WHEEL & TIRE

      1. GENERAL
        1. 1. SPECIFICATION
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW OF WHEEL & TIRE
        2. 2. TIRE¡¯S ABNORMAL PHENOMENA
        3. 3. WHEEL ALIGNMENT
      3. REMOVAL AND INSTALLATION
        1. 4170-09 TROUBLE DIAGNOSIS
        2. 4710-09 INSPECTIONS OF WHEEL £¦ TIRE
        3. 4710-09 TIRE
        4. 4710-09 SPARE TIRE
        5. 4710-09 MAINTENANCE AND REPLACEMENT
    13. SPECIAL SERVICE TOOLS

      1. GENERAL
        1. 1. MANUAL TRANSMISSION
        2. 2. DSI TRANSMISSION
        3. 3. MB TRANSMISSION
        4. 4. TRANSAXLE TRANSMISSION
        5. 5. AXLE
        6. 6. SUSPENTION
        7. 7. BRAKE
  4. BODY

    1. AIR CONDITIONING SYSTEM

      1. GENERAL
        1. 1. FFH SPECIFICATION
        2. 2. SYSTEM LAYOUT AND COMPONENTS
        3. 3. FFH GENERAL INFORMATION
        4. 4. COMPONENTS AND LOCATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. VENTILATION SYSTEM COMPONENTS
        2. 2. AIR CONDITIONER MODULE WIRING AND LAYOUT
        3. 3. SENSORS AND ACTUATORS
        4. 4. AIR QUALITY SYSTEM (AQS)
        5. 5.AIR CONDITIONER MODULE SENSORS AND ACTUATORS
      3. CONFIGURATION AND FUNCTIONS
        1. 6810-20 AIR CONDITIONER CONTROLLER (UNIT)
        2. 6910-01 F.F.H COMPONENTS AND FUNCTIONS
        3. 6810-15 PTC (POSITIVE TEMPERATURE COEFFICIENT) SYSTEM
      4. REMOVAL AND INSTALLATION OF AQS SENSOR
        1. 6910-01 F.F.H TROBULE DIAGNOSIS
        2. 6910-01 F.F.H ASSEMBLY
        3. 8510-64 AQS SENSOR
        4. 6820-24 SENSORS AND ACTUATORS
        5. 6810-20 AIR CONDITIONER CONTROLLER (UNIT)
        6. 6810-01 AIR DUCT ASSEMBLY
        7. 6810-01 AIR CONDITIONER MODULE ASSEMBLY
        8. 6820-16 RECEIVER DRYER AND CONDENSER
        9. 6820-02 COMPRESSOR ASSEMBLY
        10. 6820-01 SUB CONDENSER ASSEMBLY
        11. 1881-01 FUEL PUMP
        12. 8510-64 AMBIENT TEMPERATURE SWITCH
        13. 6910-01 F.F.H ASSEMBLY
        14. 6810-15 PTC
    2. AIR BAG SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF DRIVER'S AIRBAG MODULE
        2. 2. COMPONENTS OF PASSENGER'S AIRBAG MODULE
        3. 3. AIRBAG FUNCTION DESCRIPTION
        4. 4. INFLATION OF AIRBAG
      2. CONFIGURATION AND FUNCTIONS
        1. 8810-01 AIRBAG UNIT(SDM)
      3. REMOVAL AND INSTALLATION
        1. 8810-01 TROUBLE DIAGNOSIS
        2. 8810-03 AIRBAG MODULE(DRIVER¡®S AIRBAG)
        3. 8810-12 CONTACT COIL
        4. 8810-04 PASSENGER AIR BAG
        5. 8810-01 AIR BAG UNIT (SDM)
    3. BODY INTERIOR

      1. CONFIGURATION AND FUNCTIONS
        1. 7610-01 COMPONENT OF INTERIOR
      2. REMOVAL AND INSTALLATION
        1. 7630-01 CONSOLE BOX ASSEMBLY
        2. 7610-24 GLOVE BOX
        3. 7631-10 OVERHEAD CONSOLE
        4. 7610-20 ABOVE GLOVE BOX
        5. 7630-01 UNDER I/P CENTER PANEL
        6. 7730-10 REAR CUP HOLDER AND REAR CIGAR LIGHTER
        7. 5510-04 SUNVISOR
        8. 7421-07 TEA TABLE
        9. 7420-60 POWER SEAT SWITCH ASSEMBLY(DRIVER'S SEAT)
        10. 7420-07 BACK TABLE£¦ FOLDING LEVER (DRIVER'S SEAT)
        11. 7770-07 ECM ROOM MIRROR
        12. 8610-11 RAIN SENSING UNIT
        13. 7610-00 HAND GRIP
        14. 0000-00 FIRE EXTINGUISHER & OVM TOOL
        15. 7610-01 INSTRUMENT PANEL ASSEMBLY
    4. BODY EXTERIOR

      1. GENERAL
        1. 1. COMPONENTS AND LOCATION OF EXTERIOR
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. DOOR SYSTEM
        2. 2. HOOD / BUMPER & TAILGATE
        3. 3. LAYOUT - COWL ASSY / HOOD
        4. 4. LAYOUT - FRONT BUMPER
        5. 5. LAYOUT - REAR BUMPER
        6. 6. KEY CYLINDER
      3. REMOVAL AND INSTALLATION
        1. 7115-01 FRONT DOOR ASSEMBLY
        2. 7515-02 FRONT DOOR TRIM
        3. 7121-08 FRONT DOOR TRIM SEAL
        4. 7120-01 WINDOW REGULATOR ASSEMBLY
        5. 7120-02 WINDOW MOTOR (FRONT/REAR)
        6. 7110-01 DOOR LATCH & CRANK ASSEMBLY
        7. 7110-08 ADJUSTMENT OF FRONT/REAR LOCK STRIKER
        8. 7110-11 OUTSIDE DOOR HANDLE
        9. 8610-22 FRONT DOOR SPEAKER
        10. 7115-08 DOOR CURTESY LAMP
        11. 8516-46 POWER WINDOW SWITCH ASSEMBLY
    5. BODY REPAIR

      1. GENERAL
        1. 1. BODY DIMENSION
        2. 2. BODY JACK POINT
      2. CONFIGURATION AND FUNCTIONS
        1. 5710-01 ENGINE ROOM AND HOOD
        2. 5610-01 FLOOR PANEL ASSEMBLY
        3. 5210-01 SIDE PANEL £¦ REAR WHEEL HOUSE PANEL
        4. 5510-01 ROOF PANEL / TAILGATE / DOOR PANEL
        5. 5210-06 SIDE GARNISH
        6. 5110-01 WHITE BODY DIMESION
        7. 5610-01 FLOOR PANEL DIMENSION
        8. 4012-01 FRAME MOUNTING POINT
        9. 5110-01 BODY GAP £¦ ALLOWANCE
    6. SUNROOF

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. SUNROOF LAYOUT
        2. 2. COMPONENTS OF SUNROOF
        3. 3. COMPONENTS AND LOCATIONS
        4. 4. SUNROOF OPERATION
      2. REMOVAL AND INSTALLATION
        1. 7340-01 SUNROOF ASSEMBLY
        2. 7340-04 REPLACEMENT OF SUNROOF GLASS
    7. SEAT

      1. GENERAL
        1. 1. COMPONENTS OF SEAT
        2. 2. COMPONENTS OF SEAT BELT
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. SEAT LAYOUT
        2. 2. OPERATION OF FRONT SEAT(DRIVER'S SEAT)
        3. 3. OPERATION OF REAR SEAT
      3. REMOVAL AND INSTALLATION
        1. 7410-01 LOCATION OF SEAT MOUNTING BOLT
        2. 7540-01 SEAT RAIL
        3. 7430-01 SEAT BELT
    8. SPECIAL SERVICE TOOLS

      1. GENERAL
        1. 1. BODY INTERIOR
  5. DIAGNOSIS

    1. ECU-GASOLINE

      1. DIAGNOSIS
        1. 1. ECU-GASOLINE
    2. ECU-DIESEL

      1. DIAGNOSIS
        1. 1. ECU-DIESEL
    3. BRAKE

      1. DIAGNOSIS
        1. 1. BRAKE
    4. AIR-BAG

      1. DIAGNOSIS
        1. 1. AIR-BAG
    5. CCCS

      1. DIAGNOSIS
        1. 1. CCCS
    6. FATC

      1. DIAGNOSIS
        1. 1. FATC
    7. FFH

      1. DIAGNOSIS
        1. 1. FFH
    8. P/TRUNK

      1. DIAGNOSIS
        1. 1. P/TRUNK
    9. RAIN SENSOR

      1. DIAGNOSIS
        1. 1. RAIN SENSOR
    10. STICS

      1. DIAGNOSIS
        1. 1. STICS
    11. TC

      1. DIAGNOSIS
        1. 1. TC
    12. TCU

      1. DIAGNOSIS
        1. 1. TCU
    13. TGS LEVER

      1. DIAGNOSIS
        1. 1. TGS LEVER


Electrical Wiring Diagram

  1. GENERAL INFORMATION

    1. GENERAL INFORMATION

      1. 1. HOW TO READ ELECTRICAL WIRING DIAGRAM
  2. CONNECTOR/GROUND

    1. WIRING

      1. 8201-00 WIRING HARNESS, COMPONENTS LOCATION
    2. CONNECTOR/GROUND

      1. 8210-02 W/H ENGINE ROOM
      2. 8210-01 W/H MAIN
      3. 8210-03 W/H FLOOR (LH)
      4. 8210-04 W/H FLOOR (RH)
      5. 8210-06 W/H DOOR (LH/RH)
      6. 8210-07 W/H RR DOOR
      7. 6810-11 W/H FRT AIR-CON
      8. 6811-07 W/H RR AIR-CON
      9. 8210-09 W/H TAIL GATE
      10. 8210-08 W/H ROOF
      11. 7421-60 W/H SEAT
  3. POWER DISTRIBUTION

    1. FUSE/RELAY

      1. 8410-02 ENGINE ROOM FUSE £¦ RELAY BOX
      2. 8410-05 I.P FUSE £¦ ICM BOX (IP RELAY BOX)
    2. ELECTRICITY DIVIDE

      1. 8210-02 ENG ROOM FUSE BOX
      2. 8410-04 I.P FUSE BOX
  4. CIRCUIT

    1. ENGINE

      1. 1461-01 STARTING £¦ CHARGING
      2. 2820-01 PREHEATING UNIT CIRCUIT (DSL)
      3. 1491-01 ECU (ENGINE CONTROL UNIT - DSL)
      4. 1491-01 ECU (E23)
      5. 8210-01 DIAGNOSIS CIRCUIT
    2. CHASSIS

      1. 3670-01 TCU (5-SPEED)
      2. 3670-03 TOD
      3. 4891-01 ABS/ESP
    3. ELECTRIC

      1. 8810-01 AIR-BAG
      2. 8010-01 CLUSTER
      3. 8610-04 MULTI METER
      4. 8610-11 RAIN SENSING WIPER CIRCUIT
      5. 7421-60 DRIVER POWER SEAT CIRCUIT
      6. 8510-52 ELECTRIC OUTSIDE MIRROR & FOLDING CIRCUIT
      7. 8610-17 DEFFOGER (FRT GLASS, RR GLASS, OUTSIDE MIRROR)
      8. 8510-20 FRT SEAT WARMER
      9. 8510-20 AUTO LIGHT CORTROL CIRC
      10. 8710-03 STICS
      11. 8510-03 POWER WINDOW CIRCUIT
      12. 8710-03 CENTRAL DOOR LOCKING CIRCUIT
      13. 8510-12 RR WIPER £¦ WASHER CIRCUIT
      14. 8610-09 HORN
      15. 7630-02 CIGAR LIGHTER, POWER OUTLET
      16. 7340-03 SUN ROOF CIRCUIT
      17. 8310-01 HEAD LAMP £¦ DRL (DAY TIME RUNNING LIGHT) UNIT CIRCUIT
      18. 8510-00 HEAD LAMP LEVELING DEVICE CIRCUIT
      19. 8320-01 TAIL LAMP CIRCUIT
      20. 8510-26 TURN SIGNAL £¦ HAZARD LAMP CIRCUIT
      21. 8510-24 FOG LAMP CIRCUIT
      22. 4810-10 STOP £¦ BACK-UP LAMP CIRCUIT
      23. 8610-01 INTERIOR LAMP(ROOM, G/HENDLE, DOOR COURTESY) CIRCUIT
      24. 7770-07 AUTO DIMMING ROOM MIRROR CIRCUIT
      25. 8910-01 AUDIO (MULTI VISION)
      26. 8910-01 AUDIO
      27. 8730-01 PARKING AID CIRCUIT
      28. 6810-21 PTC HEATER (POSITIVE TEMPERATURE COEFFICIENT)
      29. 6910-01 FFH (FUEL FIRED HEATER)
      30. 6810-30 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT
      31. 6810-30 AIR-CON (MANUAL)