Actyon Sports Q145 2008.07

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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. 1111-01 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 INTAKE MANIFOLD 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 ASSEMBLY
        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. 1543-01 TROUBLE DIAGNOSIS
        2. 9210-01 ENGINE OIL CHANGE
        3. 9210-01 ENGINE 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 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 GENERAL 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. ENGINE D20DT(EU4)

    1. ENGINE ASSEMBLY

      1. GENERAL
        1. 1. MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT
        2. 2. SPECIFICATIONS AND PERFORMANCE CURVE
        3. 3. TIGHTENING TORQUE
        4. 4. MAJOR CHANGES IN D20DT (EURO IV) ENGINE (COMPARED TO D20DT)
      2. REMOVAL AND INSTALLATION
        1. 1114-00 D20DT (EURO IV) ENGINE ASSEMBLY
    2. ENGINE FUEL SYSTEM

      1. GENERAL
        1. 1. MAJOR CHANGES IN FUEL SYSTEM OF ENGINE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS OF FUEL SYSTEM
        2. 2. FUEL FLOW OF D20DT (EURO 4) ENGINE
      3. CONFIGURATION AND FUNCTIONS
        1. 1881-09 INJECTOR
        2. 1881-23 COMMON RAIL £¦ FUEL SUPPLY PIPE
      4. REMOVAL AND INSTALLATION
        1. 1881-08 INJECTOR CODING(C2I/C3I)
        2. 1881-23 COMMON RAIL AND FUEL SUPPLY PIPE
    3. ENGINE INTAKE SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW
        2. 2. INTAKE SYSTEM LAYOUT
      2. CONFIGURATION AND FUNCTIONS
        1. 2321-01 HFM (HOT FILM AIR MASS) SENSOR (VERSION 6.0)
        2. 1431-01 THROTTLE BODY
      3. REMOVAL AND INSTALLATION
        1. 2321-01 HFM SENSOR
        2. 1431-01 THROTTLE BODY
    4. ENGINE EXHAUST SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. COMPONENTS
      2. CONFIGURATION AND FUNCTIONS
        1. 1792-01 E-EGR VALVE(ELECTRIC-EXHAUST GAS RECIRCULATION VALVE)
        2. 2433-01 EGR COOLER
        3. 1792-01 VACUUM MODULATOR FOR CONTROLLING VGT TURBOCHARGER ACTUATOR
      3. REMOVAL AND INSTALLATION
        1. 1792-01 E-EGR VALVE ASSEMBLY
        2. 1792-01 VACUUM MODULATOR
    5. ENGINE LUBRICATION SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW OIL SEPARATORS
      2. REMOVAL AND INSTALLATION
        1. 0000-00 PCV OIL SEPARATOR
    6. ENGINE COOLING SYSTEM

      1. COOLING SYSTEM
        1. 1. COMPARISON IN COOLING SYSTEM FOR EACH ENGINE
      2. WATER PUMP
        1. 1. OVERVIEW
    7. ENGINE ELECTRICAL SYSTEM

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW OF ENGINE ECU
        2. 2. D20DT (EURO4) ENGINE'S ECU CIRCUIT
      2. CONFIGURATION AND FUNCTIONS
        1. 1491-01 TERMINAL (PIN) ARRANGEMENT OF ECU
      3. REMOVAL AND INSTALLATION
        1. 1491-01 ENGINE ECU
    8. 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
  4. 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 COMPARTMENT
        4. 4. ELECTRIC COMPONENTS AND LAYOUT
    2. FUSE AND RELAY

      1. GENERAL INFORMATION
        1. 1. GENERAL INFORMATION
      2. OVERVIEW AND OPERATING PROCESS
        1. 1. OVERVIEW
        2. 2. FUSE & RELAY MOUNTING LOCATION
        3. 3. CAPACITY AND NAME OF FUSE AND RELAY IN ENGINE COMPARTMENT
        4. 4. CAPACITY AND NAME OF INTERIOR FUSE AND RELAY
        5. 5. OPERATING PROCESS OF ICM BOX
      3. CONFIGURATION AND FUNCTIONS
        1. 8210-01 CONFIGURATION OF PCB IN ICM BOX AND FUNCTION OF CONNECTOR
        2. 8410-02 CIRCUIT DIAGRAM FOR FUSE & RELAY BOX IN ENGINE COMPARTMENT
        3. 8410-04 CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON DRIVER SIDE
        4. 8402-06 CIRCUIT DIAGRAM FOR INTERIOR FUSE & RELAY BOX ON PASSENGER SIDE
      4. REMOVAL AND INSTALLATION
        1. 8210-01 ICM BOX
    3. STICS

      1. GENERAL
        1. 1. OVERVIEW
        2. 2. COMPARISON TO ACTYON (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 HELP TIPS
        3. 8710-01 STICS
    4. IMMO

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. OVERVIEW
        2. 2. BASIC FUNCTIONS OF IMMOBILIZER KEY (REKES FUNCTION)
        3. 3. OTHER FUNCTIONS IN SYSTEM
        4. 4. REKES OPERATION LOGIC
        5. 5. CIRCUIT DIAGRAM
      2. REMOVAL AND INSTALLATION
        1. 7010-06 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 EXTERIOR LAMPS AND SPECIFICATIONS
        2. 2. REAR COMBINATION LAMP
        3. 3. LAMP OPERATION LOGIC
      2. CONFIGURATION AND FUNCTIONS
        1. 8310-01 FRONT LAMPS
        2. 8610-01 INTERIOR LAMPS
      3. REMOVAL AND INSTALLATION
        1. 8310-01 HEAD LAMPS
        2. 8310-10 FOG LAMP
        3. 8320-01 REAR COMBINATION LAMP
        4. 8320-12 LICENSE PLATE LAMP
        5. 8610-01 INTERIOR LAMPS
    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. 8610-08 DIGITAL CLOCK
        8. 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. 7632-16 CIGARETTE LIGHTER
        9. 7610-54 POWER OUTLET
        10. 8610-08 DIGITAL CLOCK
        11. 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 (WITH RAIN SENSOR)
        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 FRONT WIPER ASSEMBLY
        3. 7820-01 WASHER FLUID RESERVOIR TANK
        4. 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 WIPER
        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. COMPONENTS AND FUNCTION
        2. 2. ALARM INTERVAL
        3. 3. 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 COMBINATION ANTENNA
        2. 8910-07 USB/AUX MODULE
      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 COMBINATION ANTENNA
        5. 8910-07 USB/AUX MODULE
  5. CHASSIS

    1. DSI M78 6-SPEED A/T

      1. GENERAL INFORMATION
        1. 1. DSI M78 6-SPEED AUTOMATIC TRANSMISSION GENERAL
        2. 2. STRUCTURE CHARACTERISTICS AND SPECIFICATIONS
        3. 3. TIGHTENING TORQUE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. GENERAL DESCRIPTION
        2. 2. ADVANCED SIX SPEED FEATURES
        3. 3. FUNCTION OF EACH MODE
        4. 4. LIMP HOME MODE
        5. 5. TRANSMISSION ELECTRONIC CONTROL SYSTEM
        6. 6. CONFIGURATION OF CAN RELATED TO TCU
        7. 7. POWER TRAIN
      3. CONFIGURATION AND FUNCTIONS
        1. 3721-01 TGS LEVER
        2. 3680-01 DSI M78 6-SPEED A/T ASSEMBLY
        3. 3680-01 VALVE BODY
        4. 3110-01 TCU
        5. 3650-01 INHIBITOR SWITCH
      4. REMOVAL AND INSTALLATION
        1. 9210-01 FLUID LEVEL INSPECTION
        2. 3650-01 TRANSMISSION RESET PROCEDURE (REPLACEMENT TRANSMISSION)
        3. 3650-01 DSI M78 6-SPEED A/T ASSEMBLY
        4. 3660-01 VALVE BODY
        5. 3110-01 TCU
        6. 3721-01 TGS LEVER
        7. 3650-01 INHIBITOR SWITCH
        8. 3110-01 TROUBLE CODE DIAGNOSIS
      5. DIAGNOSIS AND TESTING
        1. 1. WIRING DIAGRAM
        2. 2. WIRE HARNESS CONNECTOR CHART
        3. 3. UNIT CONNECTOR DESCRIPTION
      6. TROUBLE CODE EIAGNOSIS
        1. 1. DIAGNOSTIC TROUBLE CODE LIST
        2. 2. SYSTEM DIAGNOSIS
      7. MAINTENANCE OPERATIONS
        1. 1. OIL TEST
        2. 2. STALL TEST
        3. 3. TRANSMISSION RESET PROCEDURE (REPLACEMENT TRANSMISSION)
        4. 4. FLUID LEVEL INSPECTION
        5. 5. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE
        6. 6. LUBRICATION
        7. 7. TRANSMISSION COOLER AND HYDRAULIC LINE FLUSHING PROCEDURE (NEW TRANSMISSION)
    2. TGS LEVER

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. INTRODUCTION
        2. 2. FUNCTIONS OF THE SELECTOR LEVER
        3. 3. MODE SWITCH
        4. 4. PARKING LOCK SYSTEM
      2. CONFIGURATION AND FUNCTIONS
        1. 3722-01 SELECTOR LEVER CONTROL UNIT
      3. REMOVAL AND INSTALLATION
        1. 3722-01 SHIFT ROD POSTION ADJUSTMENT
        2. 3722-01 TGS LEVER
    3. M/T

      1. GENERAL
        1. 1. OVERVIEW AND CHARACTERISTICS OF MANUAL TRANSMISSION
        2. 2. SPECIFICATIONS AND TIGHTENING TORQUE OF MANUAL TRANSMISSION
      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
    4. 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
    5. 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
        2. 4210-01 5-LINK TYPE REAR AXLE
      4. REMOVAL AND INSTALLATION
        1. 4120-01 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
    6. 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
    7. SUSPENSION

      1. GENERAL
        1. 1. SPECIFICATIONS OF SUSPENSION
        2. 2. WHEEL ALIGNMENT
      2. CONFIGURATION AND FUNCTION
        1. 4411-01 FRONT SUSPENSION
        2. 4510-01 REAR SUSPENSION(5-LINK TYPE)
        3. 4990-01 LCRV
      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. 4990-01 DIAGNOSIS OF LCRV
        8. 4990-01 SETTING OF LCRV
        9. 4990-01 LCRV
    8. ABS

      1. GENERAL
        1. 1. SYSTEM GENERAL
        2. 2. SECTIONAL DRAWING
        3. 3. SPECIFICATIONS
        4. 4. BRAKE OPERATION AND NOISE
      2. OVERVIEW AND OPERATION PROCESS
        1. 1. LOAD CONSCIOUS REDUCING VALVE (LCRV)
        2. 2. COMPONENTS OF ABS SYSTEM
      3. CONFIGURATION AND FUNCTIONS
        1. 4892-01 HECU OF ABS
        2. 4850-01 PRESSURE SENSOR
        3. 4890-01 AWSS(Active Wheel Speed Sensor)
        4. 4990-01 DIAGNOSIS OF LCRV
        5. 4990-01 SETTING OF LCRV
      4. REMOVAL AND INSTALLATION
        1. 4890-01 ABS SYSTEM AIR BLEEDING
        2. 4890-01 SENSOR CALIBRATION AND FORCED OPERATION OF ACTUATOR SENSOR VALUE
        3. 4892-01 ABS/ESP TROUBLE DIAGNOSIS
        4. 4892-01 CAUTIONS WHEN REMOVING FRONT WHEEL SPEED ABS
        5. 4892-01 HECU-ABS
        6. 4890-01 FRONT WHEEL SPEED SENSOR
        7. 4890-01 REAR WHEEL SPEED SENSOR
        8. 4850-01 PRESSURE SENSOR
        9. 4990-01 LCRV
    9. POWER STEERING

      1. GENERAL
        1. 1. OVERVIEW
        2. 2. 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
  6. 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. GENERAL
        1. 1. SEAT COMPONENTS
      2. OVERVIEW AND OPERATION
        1. 1. COMPOSITION OF SEAT
        2. 2. FUNCTIONS OF SEAT
        3. 3. SEAT BELT CONFIGURATION
      3. REMOVAL AND INSTALLATION
        1. 7510-01 SEAT MOUNTING POINTS
        2. 7410-01 SEAT ASSEMBLY
        3. 7510-01 REAR SEAT
        4. 7430-01 MOUNTING POINTS OF SEAT BELT AND TIGHTENING TORQUE
    3. BODY INTERIOR

      1. OVERVIEW AND OPERATION PROCESS
        1. 1. LOCATIONS
        2. 2. REAR TRIM AND QUARTER TRIM/PILLAR CONFIGURATION
      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
    4. BODY EXTERIOR

      1. CONFIGURATION AND FUNCTIONS
        1. 7870-01 COMPONENT OF FRONT BUMPER ASSEMBLY
        2. 6110-01 COMPONENTS OF HOOD ASSEMBLY
        3. 7120-01 COMPONENTS OF FRONT WINDOW REGULATOR
        4. 7730-01 REAR TRIM/QUARTER TRIM/PILLAR CONFIGURATION
        5. 6410-01 TAILGATE ASSEMBLY
        6. 7880-01 REAR BUMPER ASSEMBLY CONFIGURATION
        7. 5110-01 DECK ASSEMBLY CONFIGURATION
        8. 5110-01 C- PILLAR GARNISH CONFIGURATION
      2. REMOVAL AND INSTALLATION
        1. 7870-00 FRONT BUMPER ASSEMBLY
        2. 6110-01 HOOD ASSEMBLY
        3. 5720-04 FENDER PANEL ASSEMBLY
        4. 7115-01 FRONT DOOR TRIM(DRIVER SIDE)
        5. 6210-01 FRONT DOOR(DRIVER SIDE)
        6. 7120-01 WINDOW REGULATOR(PASSENGER SIDE)
        7. 7730-01 REAR TRIM
        8. 6410-01 TAILGATE ASSEMBLY
        9. 5110-00 DECK TRIM
        10. 5110-00 DECK ASSEMBLY
        11. 5110-00 INSPECTION AND MAINTENANCE OF RUBBER INSULATOR AND DECK
        12. 5110-00 C- PILLAR GANISH
    5. BODY REPAIR

      1. GENERAL
        1. 1. DIMENSIONS
        2. 2. JACK UP POINTS (DOTTED PORTIONS)
        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 BODY DIMENSIONS
        4. 5110-01 MAJOR GAPS
    6. 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 AMBIENT TEMPERATURE SENSOR
        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 AMBIENT TEMPERATURE SENSOR
        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
  7. 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. 0000-00 WIRING HARNESS, COMPONENTS LOCATION
  3. POWER DISTRIBUTION

    1. FUSE/RELAY

      1. 8410-00 ENGINE ROOM FUSE / RELAY BOX
      2. 8410-00 I/P - LH FUSE / RELAY BOX
      3. 8410-00 I/P - RH FUSE / RELAY BOX
    2. ELECTRICITY DIVIDE

      1. 8410-00 ENGINE ROOM FUSE / RELAY BOX CIRCUIT
      2. 8410-00 I/P - LH FUSE / RELAY BOX CIRCUIT
      3. 8410-00 I/P - RH FUSE / RELAY BOX CIRCUIT
      4. 8410-00 ICM RELAY BOX CIRCUIT
  4. CIRCUIT

    1. ENGINE

      1. 1461-00 STARTING / CHARGING
      2. 2820-00 PREHEATING CIRCUIT
      3. 1491-00 ECU (ENGINE CONTROL UNIT - D20DT EU-IV)
      4. 1491-00 ECU (ENGINE CONTROL UNIT - D20DT)
      5. 8210-00 DIAGNOSIS CIRCUIT
    2. CHASSIS

      1. 3110-00 TCU (6-A/T)
      2. 3410-00 TCCU
      3. 4892-00 ABS
    3. ELECTRIC

      1. 8810-00 AIR-BAG
      2. 8010-00 CLUSTER
      3. 7410-00 POWER SEAT - DRIVER
      4. 7410-00 POWER SEAT - PASSENGER
      5. 8510-00 ELECTRIC OUTSIDE MIRROR
      6. 8510-00 SEAT WARMER
      7. 8710-00 STICS
      8. 8510-00 POWER WINDOW CIRCUIT
      9. 8610-00 HORN
      10. 7632-00 CIGAR LIGHTER / POWER OUTLET CIRCUIT
      11. 8310-00 HEAD LAMP / DRL (DAY TIME RUNNING LIGHT) UNIT CIRCUIT
      12. 8510-00 HLLD (HEAD LAMP LEVEL¡¯G DEVICE) CIRCUIT
      13. 8320-00 TAIL LAMP CIRCUIT
      14. 8410-00 TURN SIGNAL / HAZARD LAMP CIRCUIT
      15. 8310-00 FOG LAMP CIRCUIT
      16. 4810-00 STOP / BACK-UP LAMP CIRCUIT
      17. 7770-00 INTERIOR LAMP CIRCUIT
      18. 7770-00 AUTO DIMMING ROOM MIRROR CIRCUIT
      19. 8910-00 AUDIO / CLOCK CIRCUIT
      20. 8790-00 PARKING AID CIRCUIT
      21. 6810-00 PTC HEATER (POSITIVE TEMPERATURE COEFFICIENT)
      22. 6810-00 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT
      23. 6810-00 AIR-CON (MANUAL) CIRCUIT