Actyon C100 2006.03

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Service Manual

  1. GENERAL

    1. GENERAL

      1. 1. DIMENSIONS
      2. 2. SPECIFICATIONS
      3. 3. VEHICLE IDENTIFICATION
      4. 4. MAINTENANCE INTERVAL
      5. 5. RECOMMENDED FLUIDS AND LUBRICANTS
      6. 6. JACK-UP POINTS
      7. 7. PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR
      8. 8. ELECTRIC COMPONENTS AND LAYOUT
      9. 9. STANDARD BOLTS SPECIFICATIONS
  2. 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. OWNER INSPECTIONS AND SERVICES
        16. 16. STANDARD BOLTS SPECIFICATIONS
    2. ENGINE ASSEMBLY

      1. GENERAL
        1. 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
        2. 2. SPECIFICATIONS AND PERFORMANCE CURVE
        3. 3. 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 ASSEMBLY
        6. 1130-33 FLYWHEEL
        7. 1130-13 PISTON AND CONNECTING ROD
        8. 1881-01 HIGH PRESSURE PUMP(HPP)
      3. REMOVAL AND INSTALLATION
        1. 1114-01 GENERAL DIAGMOSIS
        2. 1114-01 DIAGNOSTIC INFORMATION AND PROCEDURE
        3. 1114-01 REMOVAL STEPS OF ENGINE ASSEMBLY
        4. 1114-01 ENGINE ACCESSORIES
        5. 1114-01 DISASSEMBLY AND REASSEMBLY OF ENGINE ASSEMBLY
        6. 1114-01 ENGINE OVERHAUL
        7. 1222-21 CYLINDER HEAD
        8. 2313-01 INTAKE/EXHAUST
        9. 1130-01 CAMSHAFT ASSEMBLY
        10. 1312-01 TIMING CHAIN
        11. 1130-01 CRANKSHAFT
        12. 1130-13 PISTON AND CONNECTING ROD
        13. 1881-01 DISASSEMBLY AND REASSEMBLY OF HIGH PRESSURE PUMP(HPP)
    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
        6. 6. CIRCUIT DIAGRAM
      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. 2231-04 PRIMING PUMP
        6. 1881-23 HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
        7. 1881-23 FUEL PRESSURE SENSOR
        8. 1881-01 FUEL TEMPERATURE SENSOR
        9. 1881-09 INJECTOR
      4. REMOVAL AND INSTALLATION
        1. 2231-01 DRAINING THE WATER FROM FILTER
        2. 1881-01 HIGH PRESSURE PUMP
        3. 2231-01 FUEL FILTER
        4. 1881-23 HIGH PRESSURE ACCUMULATOR(COMMON RAIL)
        5. 1881-09 INJECTOR
    4. ENGINE INTAKE SYSTEM

      1. GENERAL
        1. 1. ENGINE INTAKE SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. INTAKE SYSTEM LAYOUT
        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 INTAKEMANIFOLD ASSEMBLY
      4. REMOVAL AND INSTALLATION
        1. 2313-01 PRECAUTIONS WHEN INSTALLING INTAKE SYSTEM
        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
        6. 1715-01 INTAKE MANIFOLD
    5. ENGINE EXHAUST SYSTEM

      1. GENERAL
        1. 1. INSPECTION BEFORE DIAGNOSIS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. EXHAUST SYSTEM LAYOUT
      3. CONFIGURATION AND FUNCTIONS
        1. 1913-01 TUBO CHARGER ASSEMBLY
        2. 1913-01 VGT(VARIABLE GEOMETRY TUBOCHARGER)
        3. 1792-01 EGR VALVE AND VACUUM MODULATOR
        4. 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. 1913-01 TUBO CHARGER CHECK FOR VGT
        7. 2411-01 EGR VALVE
        8. 1792-01 VACUUM MODULATOR
        9. 1725-01 EXHAUST MANIFOLD
        10. 2411-01 EXHAUST PIPE
    6. LUBRICATION SYSTEM

      1. GENERAL
        1. 1. SPECIFICATIONS
        2. 2. OIL PRESSURE SWITCH
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. LAYOUT AND OVERVIEW
        2. 2. LUBRICATION DIAGRAM
      3. 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
      4. REMOVAL AND INSTALLATION
        1. 1543-00 TROUBLE DIAGNOSIS
        2. 9210-01 ENGINE OIL CHANGE
        3. 9210-01 ENINE OIL FILTER CHANGE
        4. 1543-01 OIL FILTER AND COOLER
        5. 1533-34 OIL DIPSTICK GUIDE TUBE
        6. 1222-09 DISASSEMBLY OF OIL SPRAY NOZZLE
        7. 1533-08 OIL PAN AND OIL PUMP
    7. COOLING SYSTEM

      1. GENERAL
        1. 1. ENGINE COOLING SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF 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. 1411-01 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. 2130-01 COOLANT HOSE(INLET/OUTLET)
        6. 1333-15 SHROUD AND COOLING FAN/CLUTCH
        7. 1520-01 WATER PUMP ASSEMBLY
        8. 1520-11 THERMOSTAT
        9. 1520-01 WATER PUMP HOUSING
        10. 2112-01 RADIATOR
        11. 1333-14 REPLACEMENT OF FAN BELT
        12. 9210-05 COOLANT RESERVOIR
        13. 1412-01 REMOVAL AND INSTALLATION OF PREHEATING
        14. 1412-01 PREGLOW PLUG
    8. ENGINE ELECTRIC DEVICES

      1. GENERAL
        1. 1. SPECIFICATIONS OF ENGINE ELECTRIC
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF ELECTRIC IN ENGINE
        2. 2. COMPONENTS OF ELECTRIC DEVICES IN ENGINE
        3. 3. CIRCUIT DIAGRAM OF PREHEATING SYSTEM
        4. 4. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR
      3. REMOVAL AND INSTALLATION
        1. 1451-01 TROBULE DIAGNOSIS
        2. 1451-51 ALTERNATOR
        3. 1461-01 STARTER
    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/OUPTPUTS
        2. 2. STRUCTURE AND FUNCTION OF ECU
        3. 3. CONTROL FUNCTION OF ECU
        4. 4. FUEL PRESSURE CONTROL
        5. 5. FUEL INTECTION CONTROL
        6. 6. FUEL FLOW CONTROL
        7. 7. INDIVIDUAL INTECTOR 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. CRUISE CONTROL SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. CRUISE CONTROL SWITCH
        2. 2. CIRCUIT DIAGRAM
        3. 3. HOW TO OPERATE CRUISE CONTROL SWITCH
      2. REMOVAL AND INSTALLATION
        1. 8510-23 CRUISE CONTROL SWITCH
  3. ELECTRICAL

    1. ELECTRIC SYSTEM

      1. ELECTRIC GENERAL
        1. 1. LOCATIONS OF INTERIOR UNITS AND SENSORS
        2. 2. LOCATION AND COMPARTMENT OF INTERIOR SWITCHES
        3. 3. SWITCHES, UNITS AND SENSORS IN ENGINE
        4. 4. ELECTRIC COMPONENTS AND LAYOUT
        5. 5. DIAGNOSTIC CONNECTOR
    2. FUSES AND REALYS

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. LOCATION AND COMPARTMENT OF FUSE AND RELAY
        2. 2. DESIGNATION AND CAPACITY OF FUSES AND RELAY
        3. 3. POWER DISTRIBUTION
        4. 4. POWER DISTRIBUTION OF INTERIOR FUSE
      2. REMOVAL AND INSTALLATION
        1. 8410-02 CHECK FOR BATTERY DISCHARGE AND DARK CURRENT
        2. 8410-02 FUSES AND RELAYS IN ENGINE ROOM
    3. STICS

      1. GENERAL
        1. 1. OVERVIEW
        2. 2. MAJOR CHANGES
        3. 3. SPECIFICATIONS
      2. OVERVIEW AND OPEARATION PROCESS
        1. 1. OVERVIEW
        2. 2. FUNCTIONS AND SPECIFICATIONS
        3. 3. CIRCUIT DIAGRAM
      3. REMOVAL AND INSTALLATION
        1. 8710-01 REKES KEY CODING
        2. 8710-01 DIAGNOSIS TROUBLE CODE AND HEIP TIPS
        3. 8710-01 STICS
    4. IMMO

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW
        2. 2. BASIC FUNCTIONS OF IMMOBILIZER KEY
        3. 3. OTHER FUNCTIONS IN SYSTEM
        4. 4. REKES OPERATION LOGIC
        5. 5. CIRCUIT DIAGRAM
      2. REMOVAL AND INSTALLATION
        1. 7010-06 ACTYON IMMOBILIZER CODING PROCEDURE
        2. 7010-06 IMMOBILIZER UNIT
    5. CLUSTER

      1. GENERAL
        1. 1. DESCRIPTIONS OF INDICATOR DISPLAY
        2. 2. WARNING & INDICATOR PANEL
        3. 3. CLUSTER OPERATION PROCESS
        4. 4. CIRCUIT DIAGRAM
      2. CONFIGURATION AND FUNCTIONS
        1. 8010-01 COFIGURATION OF CLUSTER
      3. REMOVAL AND INSTALLATION
        1. 8010-01 CLUSTER
    6. LAMP

      1. OVERVEIW AND OPERATION PROCESS
        1. 1. LOCATIONS OF LAMPS AND SPECIFICATIONS
        2. 2. INTERIOR LAMPS
        3. 3. LAMP OPERATION LOGIC
      2. CONFIGURATION AND FUNCTIONS
        1. 8310-01 FRONT LAMPS
        2. 8320-01 REAR COMBINATION LAMP
        3. 8610-01 INTERIOR LAMPS
      3. REMOVAL AND INSTALLATION
        1. 8310-01 HEAD LAMP
        2. 8310-10 FOG LAMP
        3. 8310-13 SIDE REPEATER
        4. 8320-01 REAR COMBINATION LAMP
        5. 8320-12 LICENSE PLATE LAMP
        6. 8320-16 HIGH MOUNTED STOP LAMP
        7. 8320-19 REAR FOG LIGHT
        8. 8610-01 INTERIOR LAMP
    7. SWITCH

      1. GENERAL
        1. 1. SWITCH ARRANGEMENT
      2. CONFIGURATION AND FUNCTIONS
        1. 8510-31 CENTER FASCIA & BEZEL SWITCH ASSEMBLY
        2. 8510-52 OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
        3. 7770-20 INTERIOR LAMP SWITCH
        4. 8510-05 MAIN POWER WINDOW SWITCH
        5. 8510-01 AUDIO REMOTE CONTROL SWITCH ON STEERING WHEEL
        6. 8510-21 MULTIFUNCTION SWITCH
        7. 8510-13 TAIL GATE OPEN SWITCH
        8. 0000-00 DIGITAL CLOCK
        9. 8610-06 HORN (INCLUDING THEFT WARNING HORN)
      3. REMOVAL AND INSTALLATION
        1. 8510-31 HAZARD & SWITCH ASSEMBLY
        2. 8510-52 OUTSIDE REARVIEW MIRROR SWITCH BEZEL ASSEMBLY
        3. 8510-52 OUTSIDE REARVIEW MIRROR FOLDING UNIT
        4. 7770-20 OVERHEAD CONSOLE SWITCH
        5. 8510-05 MAIN POWER WINDOW SWITCH
        6. 8510-01 AUDIO REMOTE CONTROL SWITCH
        7. 8510-21 MULTIFUNCTION SWITCH
        8. 8510-13 TAIL GATE OPEN SWITCH
        9. 7632-16 CIGARETTE LIGHTER
        10. 7610-54 POWER OUTLET
        11. 7610-54 REAR POWER OUTLET
        12. 8610-08 DIGITAL CLOCK
        13. 8610-06 HORN
    8. WIPER & WASHER

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM LAYOUT AND FUNCTION
        2. 2. SYSTEM LAYOUT OF WIPER AND WASHER
        3. 3. WIPER AND WASHER RELATED FUNCTION AND SPECIFICATION
        4. 4. WIPER AND WASHER SYSTEM RELATED CIRCUIT DIAGRAM
      2. REMOVAL AND INSTALLATION
        1. 7810-01 CORRECTION OF FRONT WIPER
        2. 7810-01 OF FRONT WIPER ASSEMBLY
        3. 7830-01 REAR WIPER ASSEMBLY
        4. 7820-01 WASHER FLUID RESERVOIR TANK
        5. 7820-22 WASHER NOZZLE
    9. RAIN SENSOR

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM LAYOUT AND OVERVIEW
        2. 2. RAIN SENSING OPERATION
        3. 3. RAIN SENSOR RELATED CIRCUIT
        4. 4. FUNCTIONS AND SPECIFICATIONS OF RAIN SENSING
        5. 5. OPERATION MODE OF RAIN SENSING WIPER SYSTEM
      2. REMOVAL AND INSTALLATION
        1. 8610-09 FUNCTIONS AND CHECKS OF RAIN SENSOR
        2. 8610-09 DIAGNOSIS PROCEDURES
        3. 8610-09 RAIN SENSOR
    10. PAS

      1. GENERAL
        1. 1. COMPONENT SPECIFICATIONS
        2. 2. CAUTIONS ON PARKING AID SYSTEM
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM OVERVIEW
        2. 2. ALARM INTERVAL
        3. 3. TROUBLESHOOTING OF SENSOR
        4. 4. CIRCUIT DIAGRAM
      3. REMOVAL AND INSTALLATION
        1. 8790-03 PARKING AID SENSOR
    11. AUDIO SYSTEM

      1. OVERVIEW AND INSTALLATION
        1. 1. AUDIO SYSTEM OVERVIEW
        2. 2. CIRCUIT DIAGRAM OF AUDIO SYSTEM
      2. CONFIGURATION AND FUNCTION
        1. 8610-26 MICRO(ACTIVE) POLE ANTENNA
      3. REMOVAL AND INSTALLATION
        1. 8930-01 AV HEAD UNIT
        2. 8610-22 FRONT DOOR SPEAKER AND REAR DOOR SPEAKER
        3. 8620-22 DOOR TWEETER SPEAKER
        4. 8610-26 MICRO(ACTIVE) POLE ANTENNA
  4. CHASSIS

    1. ION 4-SPEED

      1. GENERAL
        1. 1. SPECIFICATIONS
        2. 2. FASTENER TIGHTENING SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. DESCRIPTION AND OPERATION OF AUTOMATIC TRANSMISSION
        2. 2. APPEARANCE
        3. 3. SHIFT PATTERN DIAGRAM
        4. 4. OPERATORS INTERFACES
        5. 5. CONTROL SYSTEMS
        6. 6. ELECTRONIC CONTROL SYSTEM
        7. 7. HYDRAULIC CONTROL SYSTEM
        8. 8. POWER FLOWS
      3. CONFIGURATION AND FUNCTIONS
        1. 3410-01 TCU
        2. 2010-01 ACCELERATOR PEDAL SENSOR
      4. REMOVAL AND INSTALLATION
        1. 3640-01 DIAGNOSTIC INFORMATION AND PROCEDURES
        2. 3640-01 REBUILD WARNINGS
        3. 3640-01 FRONT AND REAR BAND ADJUSTMENT
        4. 3640-01 SYMPTOM DIAGNOSIS
        5. 3410-01 TROUBLE CODE DIAGNOSIS
        6. 3640-01 ION AUTOMATIC TRANSMISSION ASSEMBLY
        7. 3643-01 VALVE BODY
        8. 3640-01 DISASSEMBLY OF TRANSMISSION
        9. 3640-01 ASSEMBLY OF TRANSMISSION
        10. 3642-18 GEAR SHIFT CONTROL LEVER
        11. 3410-01 TCU
    2. M/T

      1. GENERAL
        1. 1. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION
        2. 2. MANUAL TRANSMISSION OF SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. MANUAL TRANSMISSION SYSTEM
      3. CONFIGURATION AND FUNCTIONS
        1. 3170-01 MANUAL TRANSMISSION LOCATION
        2. 3170-01 MANUAL TRANSMISSION SYSTEM COMPONENTS
        3. 3170-01 SHIFTING MECHANISM
      4. REMOVAL AND INSTALLATION
        1. 3170-01 DIAGNOSTIC INFORMATION AND PROCEDURES
        2. 3170-01 OIL CHECK/CHANGE OF MANUAL TRANSMISSION
        3. 3170-01 MANUAL TRANSMISSION
        4. 3170-01 MANUAL TRANSMISSION OVERHAUL
        5. 3660-01 TRANSMISSION ADAPTER
        6. 3170-01 SHIM ADJUSTMENT
    3. CLUTCH

      1. GENERAL
        1. 1. CLUTCH SPECIFICATIONS
        2. 2. TIGHTENING TORQUE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. FUNCTION AND OVERVIEW
      3. CONFIGURATION AND FUNCTIONS
        1. 3020-01 CLUTCH MASTER CYLINDER
        2. 3020-04 CLUTCH RELEASE CHAMBER
        3. 3030-04 CLUTCH ASSEMBLY
        4. 3030-01 CLUTCH PEDAL
      4. REMOVAL AND INSTALLATION
        1. 3010-01 CLUTCH TROUBLE DIAGNOSIS
        2. 3010-01 CLUTCH INSPECTION AND MAINTENANCE
        3. 3020-01 CLUTCH AIR BLEEDING
        4. 3010-01 CLUTCH ASSEMBLY
        5. 3010-01 CLUTCH REPLACEMENT
        6. 3171-14 CONCENTRIC SLAVE CYLINDER
        7. 3020-01 CLUTCH MASTER CYLINDER
        8. 3030-01 CLUTCH PEDAL
        9. 3020-04 CLUTCH CHAMBER
    4. AXLE

      1. GENERAL
        1. 1. SPECIFICATIONS OF AXLE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW OF AXLE
      3. CONFIGURATION AND FUNCTIONS
        1. 4120-01 FRONT AXLE ASSEMBLY
        2. 4210-01 5-LINK TYPE REAR AXLE
      4. REMOVAL AND INSTALLATION
        1. 4220-01 TROUBLE DIAGNOSIS
        2. 4120-01 INSPECTION OF RING GEAR TOOTH CONTACT PATTERN
        3. 4120-01 FRONT AXLE ASSEMBLY
        4. 4120-01 AXLE SHAFT
        5. 4120-01 AXLE HOUSING
        6. 4220-01 REAR AXLE SHAFT(DISC BRAKE TYPE)
        7. 4220-01 REAR AXLE HOUSING
    5. TRANSFER CASE

      1. GENERAL
        1. 1. OVERVIEW
        2. 2. SPECIFICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. STRUCTURE
        2. 2. SYSTEM LAYOUT AND OPERATION
        3. 3. LOCKING HUB SYSTEM
        4. 4. POWER FLOW
      3. CONFIGURATION AND FUNCTION
        1. 3240-01 TRANSFER CASE
        2. 4116-01 COMPONENTS OF IWE (INTEGRATED WHEEL END)
        3. 3410-01 TCCU(TRANSFER CASE CONTROL UNIT)
      4. REMOVAL AND INSTALLATION
        1. 3240-01 PART TIME TRANSFER CASE GENERAL DIAGNOSIS
        2. 4116-01 VACUUM LOCKING HUB CHECK
        3. 3240-01 OIL LEVEL CHECK AND CHANGE
        4. 3410-01 SELF-DIAGNOSIS TEST
        5. 3410-01 TCCU DIAGNOSTIC TROUBLE CODE
        6. 3240-01 PART TIME TRANSFER CASE
        7. 3240-01 TRANSFER CASE MOTOR
        8. 4116-01 IWE (INTEGRATED WHEEL END)
        9. 4116-01 LOCKING HUB ACTUATOR ASSEMBLY
        10. 3410-01 TCCU
    6. SUSPENSION

      1. GENERAL
        1. 1. SPECIFICATIONS OF SUSPENSION
        2. 2. WHEEL ALIGNMENT
      2. CONFIGURATION AND FUNCTIONS
        1. 4411-01 FRONT SUSPENSION
        2. 4510-01 REAR SUSPENSION(5-LINK TYPE)
      3. REMOVAL AND INSTALLATION
        1. 4510-01 TROUBLE DIAGNOSIS OF REAR SUSPENSION
        2. 4410-01 FRONT SUSPENSION-UPPER ARM
        3. 4411-01 FRONT SUSPENSION- COIL SPRING SHOCK ABSORBER ASSEMBLY
        4. 4420-01 FRONT SUSPENSION-STABILIZER BAR
        5. 4410-01 FRONT SUSPENSION-LOWER ARM
        6. 4510-01 REAR SUSPENSION(5 - LINK TYPE)
    7. ESP

      1. GENERAL
        1. 1. SYSTEM GENERAL
        2. 2. SECTIONAL DRAWING
        3. 3. SPECIFICATIONS
        4. 4. BRAKE OPERATION AND NOISE
        5. 5. ESP SYSTEM RELATED PRECAUTIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW OF ESP(ELECTRONIC STABILITY
        2. 2. COMPONENTS OF ESP
        3. 3. PRINCIPLE OF ESP
        4. 4. PRINCIPLE OF BAS(BRAKE ASSIST SYSTEM)
        5. 5. PRINCIPLE ARP(ACTIVE ROLL-OVER PROTECTION)
        6. 6. PRINCIPLE OF HDC(HILL DESCENT CONTROL)
        7. 7. INPUT AND OUTPUT DIAGRAM OF ESP SYSTEM
        8. 8. HYDRAULIC CIRCUIT DIAGRAM OF ESP SYSTEM
        9. 9. HYDRAULIC PRESSURE FOR EACH ESP OPERATING RANGE
        10. 10. HYDRAULIC CIRCUIT OF BAS (BRAKE ASSIST SYSTEM)
        11. 11. COMPONENTS OF ABS SYSTEM
      3. CONFIGURATION AND FUNCTIONS
        1. 4892-01 HECU OF ESP
        2. 4892-01 HECU OF ABS
        3. 4850-01 PRESSURE SENSOR
        4. 4890-01 SENSOR CLUS
        5. 8510-21 SWAS(STEERING WHEEL ANGLE SENSOR)
        6. 8510-56 ESP OFF SWITCH
        7. 4890-01 ASS(Active Wheel Speed Sensor)
      4. REMOVAL AND INSTALLATION
        1. 4892-01 ESP SYSTEM AIR BLEEDING
        2. 4890-01 SENSOR CALIBRATION AND FORCED
        3. 4892-01 ABS/ESP TROUBLE DIAGNOSIS
        4. 4892-01 CAUTIONS WHEN REMOVING FRONT WHEEL SENSOR-ESP
        5. 4892-01 CAUTIONS WHEN REMOVING FRONT WHEEL ABS
        6. 4892-01 HECU-ESP
        7. 4892-01 HECU-ABS
        8. 4890-01 FRONT WHEEL SPEED SENSOR
        9. 4890-01 REAR WHEEL SPEED SENSOR
        10. 4850-01 PRESSURE SENSOR
        11. 4890-01 SENSOR CLUSTER
    8. POWER STEERING

      1. GENERAL
        1. 1. POWER STEERING SYSTEM OVERVIEW
        2. 2. POWER STEERING SPECIPICATIONS
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM LAYOUT
        2. 2. COMPONENTS
      3. REMOVAL AND INSTALLATION
        1. 4610-01 TROUBLE DIAGNOSIS
        2. 4610-01 INSPECTIONS OF POWER STEERING SYSTEM
        3. 4610-06 STEERING COLUMN SHAFT
        4. 4610-07 LOWER SHAFT
        5. 4620-02 STEERING GEAR BOX
        6. 4711-01 STEERING GEAR PUMP
  5. BODY

    1. AIR BAG

      1. GENERAL
        1. 1. OVERVIEW (INCLUDING CURTAIN AIR BAGS)
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. LOCATIONS AND RELATED COMPONENTS
        2. 2. AIR BAG SYSTEM OPERATION PROCESS
        3. 3. AIR BAG MODULE AND RELATED COMPONENTS
      3. REMOVAL AND INSTALLATION
        1. 8810-03 TROUBLE
        2. 8810-03 DRIVER AIR BAG
        3. 8810-06 PASSENGER AIR BAG
        4. 8810-11 CURTAIN AIR BAG
        5. 8810-12 CONTACT COIL
        6. 8810-01 AIR BAG UNIT(SDM)
        7. 8810-16 CURTAIN AIR BAG G SENSOR
    2. SEAT

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPOSITION OF SEAT
        2. 2. FUNCTIONS OF SEAT
        3. 3. COMPONENTS OF SEAT BELT
      2. REMOVAL AND INSTALLATION
        1. 7410-01 SEAT MOUNTING POINTS
        2. 7410-01 SEAT ASSEMBLY
        3. 7430-01 SEAT BELT
    3. SUNROOF

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS AND LOCATIONS
        2. 2. OPERATION AND FUNCTION
      2. CONFIGURATION AND FUNCTIONS
        1. 7340-01 COMPONENTS OF SUNROOF
      3. REMOVAL AND INSTALLATION
        1. 7340-01 RESETTING OF SUNROOF CONTROL UNIT
        2. 7340-01 TROUBLE DIAGNOSIS
        3. 7340-04 GLASS PANEL ASSEMBLY
        4. 7340-05 BELLOWS COVER
        5. 7340-12 DRAIN CHANNEL
        6. 7340-05 SUN SHADE PANEL
        7. 7340-12 SUNROOF CONTROL UNIT(SCU) AND MOTOR
        8. 7340-12 SUNROOF DRAIN HOSE
        9. 7340-01 SUNROOF ASSEMBLY
    4. BODY INTERIOR

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. LOCATIONS
      2. REMOVAL AND INSTALLATION
        1. 7610-01 INSTRUMENT PANEL ASSEMBLY
        2. 7610-01 INSTRUMENT PANEL FRAME ASSEMBLY
        3. 7330-01 CENTER CONSOLE (AUTOMATIC TRANSMISSION)
        4. 7332-01 CENTER CONSOLE(MANUAL TRANSMISSION)
        5. 7770-01 SUNVISOR
        6. 7730-12 PILLAR AND REAR QUARTER TRIM
        7. 7330-01 HEADLINING ASSEMBLY
        8. 7850-01 OUTSIDE REARVIEW MIRROR
        9. 7770-01 INSIDE REARVIEW MIRROR
    5. BODY EXTERIOR

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPOSITION OF BODY EXTERIOR
      2. CONFIGURATION AND FUNCTIONS
        1. 7870-00 COMPONENT OF FRONT BUMPER ASSEMBLY
        2. 7880-01 COMPONENTS OF REAR BUMPER ASSEMBLY
        3. 6110-01 COMPONENTS OF HOOD ASSEMBLY
        4. 7930-01 COMPONENTS OF SIDE SILMOLDING
        5. 6210-01 COMPONENTS OF FRONT DOOR ASSEMBLY
        6. 7120-01 COMPONENTS OF FRONT WINDOW REGULATOR
        7. 6310-01 COMPONENTS OF REAR DOOR ASSEMBLY
        8. 7220-01 COMPONENTS OF REAR WINDOW REGULATOR
        9. 6410-01 COMPONENTS OF TAILGATE ASSEMBLY
      3. REMOVAL AND INSTALLATION
        1. 7870-00 FRONT BUMPER ASSEMBLY
        2. 7880-01 REAR BUMPER ASSEMBLY
        3. 6110-01 HOOD ASSEMBLY
        4. 7930-01 SIDE SILMOLDING
        5. 5720-04 FENDER PANEL ASSEMBLY
        6. 7115-01 FRONT DOOR TRIM(DRIVER SIDE)
        7. 6210-01 FRONT DOOR(DRIVER SIDE)
        8. 7120-01 WINDOW REGULATOR(PASSENGER SIDE)
        9. 7215-01 REAR DOOR TRIM
        10. 6310-01 REAR DOOR ASSEMBLY
        11. 6310-01 REAR DOOR MOLDING AND PANEL
        12. 7220-01 REAR WINDOW REGULATOR
        13. 7321-01 TAILGATE TRIM
        14. 6410-01 TAILGATE ASSEMBLY
        15. 7310-01 TAILGATE LATCH AND ACTUATOR
        16. 7840-01 REAR QUARTER GLASS
    6. BODY REPAIR

      1. GENERAL
        1. 1. DIMENSIONS
        2. 2. JACK-UP POINTS
        3. 3. DESIGN CHANGES FOR IMPROVING NVH PERFORMANCE
      2. CONFIGURATION AND FUNCTIONS
        1. 4110-01 FRAME DIMENSIONS
        2. 4110-01 FRAME BODY MOUNTING
        3. 5110-01 WHITE BODY
        4. 5110-01 BODY DIMENSIONS
        5. 5110-01 BODY GAPS
        6. 6210-01 DOOR COMPONENTS (INCLUDING ENGINE HOOD)
        7. 4010-70 COMPONENTS OF BODY PANELS
    7. AIR CONDITIONER

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. SYSTEM LAYOUT AND COMPONENTS
        2. 2. VENTILATION SYSTEM
        3. 3. AIR CONDITIONER MODULE AND SENSORS
        4. 4. SYSTEM DIAGRAM
      2. CONFIGURATION AND FUNCTIONS
        1. 6810-20 AIR CONDITIONER CONTROLLER UNIT
        2. 0000-00 SUNSENSOR
        3. 6810-20 ACTIVE INCAR / HUMIDITY SENSOR: AIH SENSOR
        4. 6810-20 AQS (AIR QUALITY SYSTEM)
        5. 6820-24 WATER TEMPERATURE SENSOR
        6. 6810-06 POWER TRANSISTOR
        7. 6810-02 MODE DOOR ACTUATOR
        8. 6810-02 IN/EX - AIR DOOR ACTUATOR
        9. 6810-02 AIR MIX DOOR ACTUATOR
        10. 6810-24 THERMO AMP (INTAKE SENSOR)
        11. 6910-01 FFH (FUEL FIRED HEATER) SYSTEM
        12. 6810-15 PTC(POSITIVE TEMPERATURE COEFFICIENT)
      3. REMOVAL AND INSTALLATION
        1. 6810-20 SELF DIAGNOSIS (ONLY FOR FATC A/C CONTROLLER)
        2. 6910-01 TROUBLE DIAGNOSIS
        3. 6810-20 AQS
        4. 6820-24 WATER TEMPERATURE SENSOR
        5. 6810-06 POWER TRANSITOR
        6. 6810-02 MODE DOOR ACTUATOR
        7. 6810-02 IN/EX-AIR DOOR ACTUATOR
        8. 6810-02 AIR MIX DOOR ACTUATOR
        9. 6810-24 THERMO AMP(INTAKE SENSOR)
        10. 6810-01 AIR CONDITONER MODULE ASSEMBLY
        11. 6810-20 A/C CONTROLLER SWITCH AND ACTIVE INCAR/HUMIDITY SENSOR
        12. 6810-01 AIR DUCT ASSEMBLY
        13. 6820-01 CONDENSER ASSEMBLY
        14. 6820-16 RECEIVER DRYER ASSEMBLY
        15. 6810-01 FUEL PUMP
        16. 6810-20 AMBIENT TEMPERATURE SWITCH
        17. 6910-01 FFH ASSEMBLY
        18. 6810-15 PTC
  6. 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. 2. ELECTRICAL SYSTEM LAY-OUT
  2. CONNECTOR/GROUND

    1. WIRING

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

      1. 8210-00 W/H ENGINE ROOM
      2. 8210-02 W/H MAIN
      3. 8210-03 W/H FLOOR
      4. 8210-09 W/H ROOF
      5. 8210-10 W/H TAIL GATE
      6. 8210-06 W/H FRT DOOR
      7. 8210-08 W/H RR DOOR
  3. POWER DISTRIBUTION

    1. FUSE/RELAY

      1. 8410-02 ENGINE ROOM FUSE £¦ RELAY BOX
      2. 8410-04 I/P - LH FUSE £¦ RELAY BOX
      3. 8410-06 I/P - RH FUSE £¦ RELAY BOX
    2. ELECTRICITY DIVIDE

      1. 8210-02 ENGINE ROOM FUSE £¦ RELAY BOX CIRCUIT
      2. 8410-04 I/P - LH FUSE £¦ RELAY BOX CIRCUIT
      3. 8410-06 I/P - RH FUSE £¦ RELAY BOX CIRCUIT
  4. CIRCUIT

    1. ENGINE

      1. 1461-01 STARTING £¦ CHARGING
      2. 2820-01 PREHEATING CIRCUIT
      3. 1491-01 ECU (ENGINE CONTROL UNIT - D20DT)
      4. 1491-01 ECU (ENGINE CONTROL UNIT - GSL G32)
      5. 8210-01 DIAGNOSIS CIRCUIT
    2. CHASSIS

      1. 3110-01 TCU
      2. 3740-01 A/T SHIFT LOCK
      3. 3410-01 TCCU
      4. 4892-01 ABS/ESP
    3. ELECTRIC

      1. 8810-01 AIR-BAG (CURTAIN AIR-BAG)
      2. 8010-01 CLUSTER
      3. 7410-01 POWER SEAT - DRIVER
      4. 7410-02 POWER SEAT - PASSENGER
      5. 8510-52 ELECTRIC OUTSIDE MIRROR £¦ FOLDING
      6. 8510-48 SEAT WARMER
      7. 8710-02 STICS
      8. 7830-03 RR WIPER CIRCUIT
      9. 8510-05 POWER WINDOW CIRCUIT
      10. 8610-06 HORN
      11. 7632-16 CIGAR LIGHTER £¦ POWER OUTLET CIRCUIT
      12. 7340-03 SUN ROOF CIRCUIT
      13. 8310-01 HEAD LAMP & DRL (DAY TIME RUNNING LIGHT) UNIT CIRCUIT
      14. 8510-00 HLLD (HEAD LAMP LEVEL¡¯G DEVICE) CIRCUIT
      15. 8320-01 TAIL LAMP CIRCUIT
      16. 8410-01 TURN SIGNAL £¦ HAZARD LAMP CIRCUIT
      17. 8210-01 TRAILER LAMP CIRCUIT
      18. 8310-10 FOG LAMP CIRCUIT
      19. 4810-01 STOP £¦ BACK-UP LAMP CIRCUIT
      20. 7770-02 INTERIOR LAMP CIRCUIT
      21. 7770-10 AUTO DIMMING ROOM MIRROR CIRCUIT
      22. 8910-01 AUDIO £¦ CLOCK CIRCUIT
      23. 8790-01 PARKING AID CIRCUIT
      24. 6810-15 PTC HEATER (POSITIVE TEMPERATURE COEFFICIENT)
      25. 6910-01 FFH (FUEL FIRED HEATER)
      26. 6810-20 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT
      27. 6810-20 AIR-CON (MANUAL) CIRCUIT