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SSANGYONG REXTON 2004.04, Manual

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GENERAL INFORMATION

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GENERAL INFORMATION

GENERAL INFORMATION

1. HOW TO READ ELECTRICAL WIRING   
    DIAGRAM...............................................

3

Summary of Contents for REXTON 2004.04

Page 1: ...GENERAL INFORMATION 0000 00 GENERAL INFORMATION GENERAL INFORMATION 1 HOW TO READ ELECTRICAL WIRING DIAGRAM 3 ...

Page 2: ......

Page 3: ...al No1 Refer to Major Connector Position Section 2 D S201 Splice pack S101 S302 Refer to Major Splice Pack Position Section2 E Wiring Harness Color Refer to Wiring Harness Color Abbreviation F Internal circuit of component Relay Component Name and Terminal Number G Internal circuit of component Switch Component Name Terminal Number and Connecting Wiring Circuit H Lower horizontal line Ground line ...

Page 4: ... B Black Lg Light Green 6 HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on Female Terminal Male Connector ex Terminal Number 4 of C901 connection Power supply No Power supply condition 15 Battery Voltage B supply in Ignition Switch ON and ST IGN 1 15A Battery Voltage B supply in Ignition Switch ON IGN 2 15C Battery Voltage B supply in Ignition Switch ON and ACC 30 Batter...

Page 5: ...connector that connects various wiring harness 1 Part location number Part number according to locating section Part Numbe Location 1 Engine compartment 2 Instrument panel 3 Passenger compartment Tailgate 9 Underbody In the locating section the assignment for part number starts from left bottom and proceeds clockwise In the fuse and relay box or the instrument panel the part number is assigned fro...

Page 6: ...0 6 REXTON 2004 04 0000 00 GENERAL INFORMATION 9 ABBREVIATIONS ...

Page 7: ...0 7 GENERAL INFORMATION REXTON 2004 04 0000 00 ...

Page 8: ......

Page 9: ...TION OF CONNECTOR 8201 00 POSITION OF CONNECTORS AND GROUNDS CONNECTOR GROUND 8210 00 W H ENGINE ROOM 8210 02 W H MAIN 8210 03 W H FLOOR LH 8210 03 W H FLOOR LH 8210 06 W H DOOR LH RH 8210 08 W H RR DOOR 6810 00 W H AIR CON 8210 10 W H TAIL GATE 8210 09 W H ROOF 7410 00 W H SEAT 3 13 14 16 17 17 18 18 19 19 20 ...

Page 10: ......

Page 11: ...0 3 CONNECTOR GROUND REXTON 2004 04 8201 00 POSITION OF CONNECTOR 8201 00 POSITION OF CONNECTORS AND GROUNDS 1 POSITION OF CONNECTOR GROUND SPLICE PACK 2 COMPONENTS LOCATION ...

Page 12: ...0 4 REXTON 2004 04 8201 00 CONNECTOR GROUND 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 13: ...0 5 CONNECTOR GROUND REXTON 2004 04 8201 00 GROUND SPLICE PACK ...

Page 14: ...0 6 REXTON 2004 04 8201 00 CONNECTOR GROUND 4 SPLICE PACK S102 S103 S202 CAN S203 S205 S208 S101 1 2002 MODEL S204 S206 S207 ...

Page 15: ...0 7 CONNECTOR GROUND REXTON 2004 04 8201 00 S301 S207 S301 S205 S202 S203A S302 S201 S203 2 2003 MODEL XDi Only S206 S208 S204 ...

Page 16: ...0 8 REXTON 2004 04 8201 00 CONNECTOR GROUND S302 S301A ...

Page 17: ...0 9 CONNECTOR GROUND REXTON 2004 04 8201 00 C101 C115 C301 C905 5 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION C101 C115 ...

Page 18: ...0 10 REXTON 2004 04 8210 02 CONNECTOR GROUND CONTROL UNIT SW SWITCH ...

Page 19: ...0 11 CONNECTOR GROUND REXTON 2004 04 8201 00 MOTOR AIR BAG LAMP SENSOR ...

Page 20: ...0 12 REXTON 2004 04 8201 00 CONNECTOR GROUND COIL SOLENOID UNIT ...

Page 21: ...0 13 CONNECTOR GROUND REXTON 2004 04 8210 02 CONNECTOR 8210 02 W H ENGINE ROOM ...

Page 22: ...0 14 REXTON 2004 04 8210 01 CONNECTOR GROUND 8210 01 W H MAIN ...

Page 23: ...0 15 CONNECTOR GROUND REXTON 2004 04 8210 01 ...

Page 24: ...0 16 REXTON 2004 04 8210 03 CONNECTOR GROUND 8210 03 W H FLOOR LH ...

Page 25: ...0 17 CONNECTOR GROUND REXTON 2004 04 8210 06 8210 03 W H FLOOR RH 8210 06 W H DOOR LH RH ...

Page 26: ...0 18 REXTON 2004 04 6810 00 CONNECTOR GROUND 8210 08 W H RR DOOR 6810 00 W H AIR CON ...

Page 27: ...0 19 CONNECTOR GROUND REXTON 2004 04 8210 09 8210 10 W H TAIL GATE 8210 09 W H ROOF ...

Page 28: ...0 20 REXTON 2004 04 7410 00 CONNECTOR GROUND 7410 00 W H SEAT ...

Page 29: ...10 06 POWER DISTRIBUTION FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 8410 04 I P FUSE RELAY BOX ELECTRICITY DIVIDE 8210 02 POWER WIRING DIAGRAM DSL 8410 04 POWER WIRING DIAGRAM GSL 8410 06 POWER WIRING DIAGRAM XDi 2003 MODEL 3 7 10 14 18 ...

Page 30: ......

Page 31: ...0 3 POWER DISTRIBUTION REXTON 2004 04 8410 02 FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 1 2002 MODEL 2 REAR 3 FRONT DSL 1 FRONT 4 FRONT GSL ...

Page 32: ...0 4 REXTON 2004 04 8410 02 POWER DISTRIBUTION 5 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 6 CONNECTOR 2 2003 MODEL W XDi 1 FRONT 2 REAR ...

Page 33: ...0 5 POWER DISTRIBUTION REXTON 2004 04 8410 04 3 FRONT DSL 5 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 4 FRONT GSL 6 CONNECTOR ...

Page 34: ...0 6 REXTON 2004 04 8410 06 POWER DISTRIBUTION 7 FRONT TI 8 FRONT XDi 9 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 10 CONNECTOR ...

Page 35: ...0 7 POWER DISTRIBUTION REXTON 2004 04 8410 04 8410 04 I P FUSE RELAY BOX 1 2002 MODEL 1 FUSE BOX 2 POWER SUPPLY 3 RELAY ...

Page 36: ...0 8 REXTON 2004 04 8410 04 POWER DISTRIBUTION 2 2003 MODEL 1 FUSE BOX 2 POWER SUPPLY 1 FUSE BOX 2 POWER SUPPLY 3 TI ...

Page 37: ...0 9 POWER DISTRIBUTION REXTON 2004 04 8410 04 4 XDi 1 FUSE BOX 2 POWER SUPPLY 3 RELAY ...

Page 38: ...0 10 REXTON 2004 04 8410 02 POWER DISTRIBUTION ELECTRICITY DIVIDE 8210 02 POWER WIRING DIAGRAM DSL 1 2002 MODEL ...

Page 39: ...0 11 POWER DISTRIBUTION REXTON 2004 04 8410 02 ...

Page 40: ...0 12 REXTON 2004 04 8410 02 POWER DISTRIBUTION 2 2003 MODEL ...

Page 41: ...0 13 POWER DISTRIBUTION REXTON 2004 04 8410 02 ...

Page 42: ...0 14 REXTON 2004 04 8410 04 POWER DISTRIBUTION 8410 04 POWER WIRING DIAGRAM GSL 1 2002 MODEL ...

Page 43: ...0 15 POWER DISTRIBUTION REXTON 2004 04 8410 04 ...

Page 44: ...0 16 REXTON 2004 04 8410 04 POWER DISTRIBUTION 2 2003 MODEL ...

Page 45: ...0 17 POWER DISTRIBUTION REXTON 2004 04 8410 04 ...

Page 46: ...0 18 REXTON 2004 04 8410 06 POWER DISTRIBUTION 8410 06 POWER WIRING DIAGRAM XDi 2003 MODEL 1 ENG ROOM FUSE BOX 2 SB6 SB11 1 SB1 SB5 ...

Page 47: ...0 19 POWER DISTRIBUTION REXTON 2004 04 8410 06 4 Ef5 Ef9 3 Ef1 Ef4 ...

Page 48: ...0 20 REXTON 2004 04 8410 06 POWER DISTRIBUTION 5 Ef10 Ef14 6 Ef15 Ef20 ...

Page 49: ...0 21 POWER DISTRIBUTION REXTON 2004 04 8410 06 7 Ef21 Ef26 1 F1 F5 2 FUSE BOX ...

Page 50: ...0 22 REXTON 2004 04 8410 06 POWER DISTRIBUTION 2 F6 F15 3 F16 F21 ...

Page 51: ...0 23 POWER DISTRIBUTION REXTON 2004 04 8410 06 5 F29 F31 4 F22 F28 ...

Page 52: ......

Page 53: ...ELT TENSION R EDUCER CIRCUIT 2002 MODEL ONLY 7410 04 PASSENGER POWER SEAT CIRCUIT 8310 10 AUTO LIGHT CONTROL CIRCUIT 8711 02 STICS 2002 MODEL 8711 02 STICS 2003 MODEL 8711 02 STICS XDi 8511 05 POWER WINDOW CIRCUIT 7830 02 REAR GLASS WIPER WASHER CIRCUIT 8610 10 HORN CIRCUIT 7632 20 CIGAR LIGHTER CIRCUIT 8711 02 REKES CIRCUIT 2003 MODEL 7340 03 SUN ROOF CIRCUIT 8310 01 HEAD LAMP CIRCUIT 8310 01 HEA...

Page 54: ......

Page 55: ...0 3 CIRCUIT REXTON 2004 04 1461 01 1461 01 STARTING CHARGING 2 GASOLINE M T A T 2002 MODEL 1 DIESEL M T A T 2002 MODEL ...

Page 56: ...0 4 REXTON 2004 04 1461 01 CIRCUIT 4 GASOLINE M T A T 2003 MODEL W XDi 3 DIESEL M T A T 2003 MODEL W XDi ...

Page 57: ...0 5 CIRCUIT REXTON 2004 04 2820 01 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 58: ...0 6 REXTON 2004 04 2820 01 CIRCUIT 2820 11 PREHEATING UNIT CIRCUIT 2 2003 MODEL 1 2002 MODEL ...

Page 59: ...0 7 CIRCUIT REXTON 2004 04 1792 01 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 3 XDi ...

Page 60: ...0 8 REXTON 2004 04 1792 01 CIRCUIT 1 GENERAL 2002 MODEL 1792 01 2 EURO 2002 MODEL EGR EXHAUST GAS RECIRCULATION CONTROL CIRCUIT DSL ...

Page 61: ...0 9 CIRCUIT REXTON 2004 04 1491 01 3 HUBER EGR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 62: ...CU ELECTRONIC CONTROL UNIT E23 SPARK PLUG SENSOR CAM SHAFT POSITION MAP NTC CRANK SHAFT POSITION THROTTLE MOTOR AIR TEMP KNOCK CAM SHIFT ACTUATOR CIRCUIT 2002 MODEL 2 OVPR FUEL PUMP CANISTER PURGE VALVE O2 SENSOR PEDAL MODULE CIRCUIT 2002 MODEL 1 ...

Page 63: ...0 11 CIRCUIT REXTON 2004 04 1491 01 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION DIGITAL CLOCK ENG TEMP SENSOR IMMOBILIZER CIRCUIT 2002 MODEL 3 ...

Page 64: ...1 01 CIRCUIT 5 SPARK PLUG SENSOR CAM SHAFT POSITION MAP NTC CRANK SHAFT POSITION THROTTLE MOTOR AIR TEMP KNOCK CAM SHIFTACTUATORCIRCUIT2003MODEL 4 OVPR FUEL PUMP CANISTER PURGE VALVE O2 SENSOR PEDAL MODULE CIRCUIT 2003 MODEL ...

Page 65: ...0 13 CIRCUIT REXTON 2004 04 1491 01 6 DIGITAL CLOCK ENG TEMP SENSOR IMMOBILIZER CIRCUIT 2003 MODEL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 66: ...CU ELECTRONIC CONTROL UNIT E28 E32 SPARK PLUG SENSOR CAM SHAFT POSITION NTC CRANK SHAFT POSITION THROTTLE MOTOR SENSOR KNOCK CAM SHIFT ACTUATOR RESONANCEFLAPCIRCUIT 2002MODEL 2 OVPR FUEL PUMP CANISTER PURGE VALVE PEDAL MODULE CIRCUIT 2002 MODEL 1 ...

Page 67: ...0 15 CIRCUIT REXTON 2004 04 1491 01 4 O2 SENSOR 2002 MODEL DIGITAL CLOCK ENG TEMP SENSOR IMMOBILIZER CIRCUIT 2002 MODEL 3 ...

Page 68: ...0 16 REXTON 2004 04 1491 01 CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 69: ...04 04 1491 01 SPARK PLUG SENSOR CAM SHAFT POSITION NTC CRANK SHAFT POSITION THROTTLE MOTOR SENSOR KNOCK CAM SHIFT ACTUATOR RESONANCEFLAPCIRCUIT2003MODEL 6 OVPR FUEL PUMP CANISTER PURGE VALVE PEDAL MODULE CIRCUIT 2003 MODEL 5 ...

Page 70: ...0 18 REXTON 2004 04 1491 01 CIRCUIT O2SENSOR2003MODEL 8 DIGITAL CLOCK ENG TEMP SENSOR IMMOBILIZER CIRCUIT 2003 MODEL 7 ...

Page 71: ...0 19 CIRCUIT REXTON 2004 04 1491 01 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 72: ... 01 ECU XDi FUEL FILTER WARNING LAMP IMMOBILIZER SENSOR FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT KNOCK WATER PUMP FUEL TEMP 2 ENG MAIN RLY PEDAL MODULE HFM SENSOR VALVE TURBO CHANGER BOOSTER EGR VACUUM MODULE INLETMETERING VALVE 1 ...

Page 73: ...0 21 CIRCUIT REXTON 2004 04 8210 01 3 INJECTOR CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 74: ...0 22 REXTON 2004 04 8210 01 CIRCUIT 8211 01 DIAGNOSIS CIRCUIT 2 2003 MODEL 1 2002 MODEL ...

Page 75: ...0 23 CIRCUIT REXTON 2004 04 3110 01 3 XDi 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 76: ...0 24 REXTON 2004 04 3110 01 CIRCUIT 3110 01 TCU TRANSMISSION CONTROL UNIT 4 SPEED 2 GSL 2002 MODEL 1 DSL 2002 MODEL ...

Page 77: ...0 25 CIRCUIT REXTON 2004 04 3110 01 4 GSL 2003 MODEL 3 DSL 2003 MODEL ...

Page 78: ...0 26 REXTON 2004 04 3110 01 CIRCUIT 5 2004 MODEL DSL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 79: ...0 27 CIRCUIT REXTON 2004 04 3110 01 3110 01 TCU 5 SPEED 1 START MOTOR A T LEVER CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 80: ...0 28 REXTON 2004 04 3410 01 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 81: ...0 29 CIRCUIT REXTON 2004 04 3410 01 3410 01 TCCU TRANSFERCASE CONTROL UNIT 2 2003 MODEL 1 2002 MODEL ...

Page 82: ...0 30 REXTON 2004 04 3410 01 CIRCUIT 4 XDi 3 2004 MODEL ...

Page 83: ...0 31 CIRCUIT REXTON 2004 04 3232 34 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 84: ...0 32 REXTON 2004 04 3232 34 CIRCUIT 3232 34 TOD TORQUE ON DEMAND 2 2003 MODEL 1 2002 MODEL ...

Page 85: ...0 33 CIRCUIT REXTON 2004 04 4892 01 3 XDi 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 86: ...0 34 REXTON 2004 04 4892 01 CIRCUIT 4892 01 BRAKE SYSTEM 2 ABS TEVES 1 ABS ABS ABD 5 3 II ...

Page 87: ...0 35 CIRCUIT REXTON 2004 04 4892 01 3 ABS ESP TEVES 2 BRAKE PRESSURE SENSOR SWAS SENSOR CLUSTER ESP OFF SW 1 WHEEL SPEED SENSOR STOP LAMP SW DIAGNOSIS WARNING LAMP ...

Page 88: ...0 36 REXTON 2004 04 3110 01 CIRCUIT A CONNECTOR INFORMATION B CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 89: ...0 37 CIRCUIT REXTON 2004 04 8810 01 3110 01 A T SHIFT LOCK CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 90: ...0 38 REXTON 2004 04 8010 01 CIRCUIT 8810 01 AIR BAG SIDE AIR BAG CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 91: ...0 39 CIRCUIT REXTON 2004 04 8010 01 8010 01 CLUSTER 2 WARNING LAMP DEFOGGER CIRCUIT 2002 MODEL 1 POWER SUPPLY GROUND LAMP FUEL LOW WARNING 4H 4L CIRCUI 2002 MODEL ...

Page 92: ...0 40 REXTON 2004 04 8010 01 CIRCUIT POWER SUPPLY GROUND LAMP FUEL LOW WARNING 4H 4L CIRCUIT 2003 MODEL 3 4 WARNING LAMP DEFOGGER CIRCUIT 2003 MODEL ...

Page 93: ...0 41 CIRCUIT REXTON 2004 04 8010 01 3 XDi GAUGE SPEED RPM FUEL TEMP WARNING FUEL DR OPEN FUEL FILTER ABS ESP 1 WARNING BAT CHANGE OIL BRAKE EGR CHECK AIR BAG SSPS SEAT BELT TURNSIGNAL DEFOGGER 2 ...

Page 94: ...0 42 REXTON 2004 04 8010 01 CIRCUIT A CONNECTOR INFORMATION B CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 95: ...0 43 CIRCUIT REXTON 2004 04 8611 09 8010 01 MULTI METER CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 96: ...0 44 REXTON 2004 04 8611 09 CIRCUIT 8611 09 RAIN SENSING WIPER CIRCUIT 1 2002 MODEL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 97: ...0 45 CIRCUIT REXTON 2004 04 7410 04 2 XDi 2003 MODEL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 98: ...0 46 REXTON 2004 04 7410 32 CIRCUIT 7410 04 POWER SEAT CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 99: ...0 47 CIRCUIT REXTON 2004 04 8410 30 7410 32 FRT SEAT WARMER W O MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 100: ...0 48 REXTON 2004 04 8410 30 CIRCUIT 8410 30 POWER O SIDE MIRROR DEFOGGER SEAT WARMER CIRCUIT W MEMORY 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 101: ...0 49 CIRCUIT REXTON 2004 04 8410 30 8410 30 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION POWER O SIDE MIRROR DEFOGGER CIRCUIT W O MEMORY 1 2002 MODEL ...

Page 102: ...0 50 REXTON 2004 04 8710 01 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITIO 1 CONNECTOR INFORMATION 2 XDi ...

Page 103: ...0 51 CIRCUIT REXTON 2004 04 7410 00 8710 01 CENTRAL DOOR LOCKING SYSTEM 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 104: ...0 52 REXTON 2004 04 7410 04 CIRCUIT 7410 00 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION SEAT BELT TENSION REDUCER CIRCUIT 2002 MODEL ONLY ...

Page 105: ...0 53 CIRCUIT REXTON 2004 04 8310 10 7410 04 PASSENGER POWER SEAT CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 106: ...0 54 REXTON 2004 04 8310 10 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8310 10 AUTO LIGHT CONTROL CIRCUIT 1 2002 MODEL ...

Page 107: ...0 55 CIRCUIT REXTON 2004 04 8711 02 2 XDi 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 108: ...0 56 REXTON 2004 04 8711 02 CIRCUIT 8711 02 STICS 2002 MODEL FRT WIPER DR SWITCH LAMP ROOM MAP CIRCUIT 2 POWER SUPPLY GND CHIME BELL BUZZER WARNING LAMP PARKING BRAKE SEATBELT CIRCUIT 1 ...

Page 109: ...0 57 CIRCUIT REXTON 2004 04 8711 02 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION DR LOCK DEFOGGER POWER WINDOW CIRCUIT 3 ...

Page 110: ...0 58 REXTON 2004 04 8711 02 CIRCUIT POWER SUPPLY GND CHIME BELL BUZZER WARNING LAMP PARKING BRAKE SEATBELT CIRCUIT 2 FRT WIPER DR SWITCH LAMP ROOM MAP CIRCUIT 8711 02 STICS 2003 MODEL 1 ...

Page 111: ...0 59 CIRCUIT REXTON 2004 04 8711 02 3 DR LOCK DEFOGGER POWER WINDOW CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 112: ...0 60 REXTON 2004 04 8711 02 CIRCUIT 8711 02 STICS XDi POWER SUPPLY GND CHIME BELL BUZZER WARNING LAMP PARKING BRAKE SEATBELT CIRCUIT 1 2 FRT WIPER DR SWITCH LAMP ROOM MAP CIRCUIT ...

Page 113: ...0 61 CIRCUIT REXTON 2004 04 8511 05 3 DR LOCK DEFOGGER POWER WINDOW CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 114: ...0 62 REXTON 2004 04 7830 02 CIRCUIT 8511 05 POWER WINDOW CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 115: ...0 63 CIRCUIT REXTON 2004 04 7830 02 7830 02 REAR GLASS WIPER WASHER CIRCUIT 1 REAR GLASS WIPER WASHER W O FLIP UP GLASS 2 REAR GLASS DPS WIPER WASHER W FLIP UP GLASS ...

Page 116: ...0 64 REXTON 2004 04 8610 10 CIRCUIT 3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION REAR GLASS DPS WIPER WASHER W FLIP UP GLASS XDi ...

Page 117: ...0 65 CIRCUIT REXTON 2004 04 7632 20 8610 10 HORN CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 118: ...0 66 REXTON 2004 04 8711 02 CIRCUIT 7632 20 CIGAR LIGHTER CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 119: ...0 67 CIRCUIT REXTON 2004 04 7340 03 8711 02 REKES CIRCUIT 2003 MODEL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 120: ...0 68 REXTON 2004 04 8310 01 CIRCUIT 7340 03 SUN ROOF CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 121: ...0 69 CIRCUIT REXTON 2004 04 8310 01 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 8310 01 HEAD LAMP CIRCUIT ...

Page 122: ...0 70 REXTON 2004 04 8310 01 CIRCUIT 8310 01 HEAD LAMP LEVELING DEVICE CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 123: ...0 71 CIRCUIT REXTON 2004 04 8320 01 8310 01 DRL DAY TIME RUNNING LIGHT UNIT EU 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 124: ...0 72 REXTON 2004 04 8320 01 CIRCUIT 8320 01 TAIL LAMP CIRCUIT 1 2002 MODEL 2 2003 MODEL ...

Page 125: ...0 73 CIRCUIT REXTON 2004 04 8310 01 3 XDi 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 126: ...0 74 REXTON 2004 04 8310 01 CIRCUIT 8310 01 TURN SIGNAL HAZARD LAMP CIRCUIT 2 2003 MODEL 1 2002 MODEL ...

Page 127: ...0 75 CIRCUIT REXTON 2004 04 8310 23 3 XDi 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 128: ...0 76 REXTON 2004 04 8310 23 CIRCUIT 8310 23 FOG LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 1 2002 MODEL ...

Page 129: ...0 77 CIRCUIT REXTON 2004 04 8320 01 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 XDi ...

Page 130: ...0 78 REXTON 2004 04 7770 08 CIRCUIT 8320 01 STOP BACK UP LAMP CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 131: ...0 79 CIRCUIT REXTON 2004 04 7770 03 7770 08 INTERIOR LAMP CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 132: ...0 80 REXTON 2004 04 8910 02 CIRCUIT 7770 03 AUTO DIMMING ROOM MIRROR CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 133: ...0 81 CIRCUIT REXTON 2004 04 8931 01 8910 02 AUDIO DIGITAL CIOCK CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 134: ...0 82 REXTON 2004 04 8931 01 CIRCUIT 8931 01 AUDIO MULTI VISION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 1 HEAD UNIT 2CH EXT AMP REMOCON NAVI UNIT GPS ...

Page 135: ...0 83 CIRCUIT REXTON 2004 04 6810 18 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 HEAD UNIT TUNER UNIT VCD CHANGER ...

Page 136: ...0 84 REXTON 2004 04 6810 18 CIRCUIT 6810 18 AIR CON MANUAL DSL 2002 MODEL 1 ACTUATOR MODE AIR MIX BLOWER UNIT CIRCUIT 2 INTAKE MOTOR BLOWER MOTOR CIRCUIT ...

Page 137: ...0 85 CIRCUIT REXTON 2004 04 6810 18 6810 18 AIR CON MANUAL DSL 2004 MODEL 1 ACTUATOR MODE AIR MIX BLOWER UNIT CIRCUIT 2 INTAKE MOTOR BLOWER MOTOR CIRCUIT ...

Page 138: ...0 86 REXTON 2004 04 6810 18 CIRCUIT 6810 18 AIR CON MANUAL DSL XDi 1 ACTUATOR MODE AIR MIX BLOWER UNIT CIRCUIT 2 INTAKE MOTOR BLOWER MOTOR CIRCUIT ...

Page 139: ...0 87 CIRCUIT REXTON 2004 04 6810 18 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 140: ...0 88 REXTON 2004 04 6810 18 CIRCUIT 6810 18 FATC FULL AUTO TEMPERATURE CONTROL CIRCUIT DIESEL 1 AIR MIX ACTUCTOR SENSOR SUN AMBIENT INCAR WATER TEMP CIRCUIT 2 ACTURATOR MODE INTAKE CIRCUIT ...

Page 141: ...0 89 CIRCUIT REXTON 2004 04 6810 18 6810 18 FATC FULL AUTO TEMPERATURE CONTROL CIRCUIT GASOLINE XDi AIR MIX ACTUCTOR SENSOR SUN AMBIENT INCAR WATER TEMP CIRCUIT 1 2 ACTURATOR MODE INTAKE CIRCUIT ...

Page 142: ...0 90 REXTON 2004 04 7010 06 CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 143: ...0 91 CIRCUIT REXTON 2004 04 8790 01 7010 06 IMMOBILIZER DSL 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 144: ...0 92 REXTON 2004 04 4610 00 CIRCUIT 8790 01 PARKING AID CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 145: ...0 93 CIRCUIT REXTON 2004 04 6810 15 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 4610 00 TRAILER CONNECTOR CIRCUIT ...

Page 146: ...0 94 REXTON 2004 04 6910 01 CIRCUIT 6810 15 P T C HEATER POSITIVE TEMPERATURE COEFFICIENT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 147: ...0 95 CIRCUIT REXTON 2004 04 4620 12 6910 01 FFH FUEL FIRED HEATER 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 148: ...0 96 REXTON 2004 04 4620 12 CIRCUIT 4620 12 S S P S 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 149: ...RAL 0000 00 VEHICLE GENERAL VEHICLE GENERAL 1 VEHICLE SPECIFICATIONS 2 VEHICLE IDENTIFICATION 3 GUIDELINES FOR SERVICE WORK SAFETY 4 LIFTING POINTS 5 TIGHTENING TORQUE OF STANDARD BOLTS 6 CLEANNESS 3 8 10 17 18 19 ...

Page 150: ......

Page 151: ...01 3 VEHICLE GENERAL undefined 0000 00 0000 00 VEHICLE GENERAL GENERAL 1 VEHICLE SPECIFICATIONS 1 Vehicle Dimension ...

Page 152: ...01 4 undefined 0000 00 VEHICLE GENERAL 2 Specifications ...

Page 153: ...01 5 VEHICLE GENERAL undefined 0000 00 Specifications Cont d ...

Page 154: ...01 6 undefined 0000 00 VEHICLE GENERAL 3 Maintenance Major Components and Service Interval ...

Page 155: ... Please contact Ssangyong Dealer for approved alternative fluid In only case not available MB 229 1 or 229 3 API or ACEA oil may be accepted however it would rather recommend to shorten the change interval around 30 IDI Indirect Injection DI Direct Injection ...

Page 156: ...em 9 Engine Type S Check Digit 1 Model Year P Plant Code 122357 K Korea P Ssangyong Motor Company T Passenger car 4WD P Rexton O 5 door A Standard B Deluxe C Super deluxe 0 No seatbelts 1 3 point seatbelts 2 2 point seatbelt 9 3199cc In line 6 cylinders Gasoline E32 D 2874cc Il line 5 cylinders Diesel S All area except North America 1 2001 2 2002 3 2003 P Pyungtaek plant Production serial number 2...

Page 157: ...er block in exhaust manifold side 4 Manual Transmission Number The transmission label is affixed on the upper area of clutch housing 5 Automatic Transmission Number The transmisson label is affixed on the right area of transmission housing 6 Transfer Case Number The transfer case label is affixed on the transfer case housing ...

Page 158: ...aused by personal working method skill ways and service procedures and to allow prompt correct service works While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works However abo...

Page 159: ... contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of polar...

Page 160: ... from foreign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine Engine and accessories Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly assembly Main...

Page 161: ...een HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance dro...

Page 162: ...e and then support with chassis stand before service work 1 2 Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work 4 5 ...

Page 163: ...ase on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line bet...

Page 164: ...rcuited fuse If use electrical wire or steel wire other than fuse there can be damages on the various electrical systems If replaced with over capacity fuse there can be damages on the related electrical device and fire Every wire on the vehicle should be fastened securely not to be loosened with fixing clip If wires go through edges protect them with tape or other materials not to be damaged 1 2 ...

Page 165: ...necting device on the edge of front and rear of board on lift Be sure to use attachment during lifting to prevent the lift from contacting with body floor While lifting the vehicle widen the lift floor as far as possible to stabilize between vehicle front and rear When fixing the lift floor be careful not to contact with brake tube and fuel lines Safety jack and safety stand If lift up the vehicle...

Page 166: ...ral Observe standard tightening torque during bolt tightening works and can adjust torque to be proper within 15 if necessary Try not to over max allowable tightening torque if not required to do so 1 2 Determine extra proper tightening torque if tightens with washer or packing If tightens bolts on the below materials be sure to determine the proper torque 3 4 Aluminum alloy Tighten to 80 of above...

Page 167: ...ed due to foreign materials injector remains open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elemen...

Page 168: ...ling caps to perform the diagnosis for DI engine fuel system in DIAGNOSIS section in this manual At this point thoroughly clean the related area in engine compartment 5 Clean the engine compartment before starting service works Tool kit for high pressure line Tool kit for transfer line Sealing caps and torque wrench Carefully listen the symptoms and problems from customer Visually check the leaks ...

Page 169: ...ages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to specified tightening torque as well If not the injection point may be deviated from correct position and it may cause engine disorder Disconne...

Page 170: ...t value from scan tool after replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Check the installed components again and connect the negative battery cable Start the engine and check the operating status With Scan i check if there are current faults and erase the history faults 10 11 For details refer to DI10 Diagnosis...

Page 171: ...stem 2 SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due to poor lubrication...

Page 172: ......

Page 173: ...01 3 ENGINE ASSEMBLY undefined 0000 00 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 174: ...01 4 undefined 0000 00 ENGINE ASSEMBLY Fastener Tightening Specifications Cont d ...

Page 175: ...le Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel system Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly eart...

Page 176: ...02 4 undefined 0000 00 FUEL SYSTEM Temperature VS Resistance ...

Page 177: ...th that the surrounding air absorbs from the heated element MAF sensor is located between the air filter and the throttle valve Under high fuel demands the MAF sensor reads a high mass flow condition such as wide open throttle The ECM uses this information to enrich the mixture thus increasing the fuel injector on time to provide the correct amount of fuel When decelerating the mass flow decreases...

Page 178: ...s the air fuel ratio based on inputs from the ECT sensor and the MAF sensor The ECM stays in open loop until the following conditions are met The O2 has a varying voltage output showing that it is hot enough to operate properly The ECT sensor is above a specified temperature 22 5 C A specific amount of time has elapsed after starting the engine 4 Closed Loop The specific values for the above condi...

Page 179: ...sing the following methods Increasing the fuel injector pulse width Increasing the idle speed rpm Increasing the ignition dwell time 8 Fuel Cut Off Mode No fuel is delivered by the fuel injectors when the ignition is off This prevents dieseling or engine runon Also the fuel is not delivered if there are no reference pulses received from the CKP sensor This prevents flooding ...

Page 180: ......

Page 181: ......

Page 182: ...l Load or Over Mid Load 4 Intake Air Duct Cross Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air B Blow B...

Page 183: ...the crank chamber 12 through the oil separation chamber 11 airconditioner bracket 10 vent line 9 and restrictor 7 mounted to the cylinder head The circulated engine oil returns to the oil pan through the oil return pipe 13 at the bottom of oil separation chamber 11 The fresh air gets supplied to the crank chamber 12 through the HFM sensor 1 intake air duct 4 vent line 5 oil separation chamber 3 ch...

Page 184: ...ct Cross Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air C Blow By Gas D Vent Connection ...

Page 185: ...ened The air flows very rapidly through the vent line 5 s connection D and the intake air duct when full load at partial load Consequently most of the low by gases are supplied to the combustion chamber through the timing gear case cover 15 chain housing 17 oil separation chamber 3 vent line 5 throttle valve 6 and intake manifold 8 ...

Page 186: ...t 10 Connecting Rod Bearing 11 Crankshaft Bearing 12 Connecting Rod 13 Piston 14 Oil Spray Piston Crown Area 15 Non Return Valve Crankcase 16 Oil Supply To Chain Tensioner 17 Camshaft 18 Cam Bearing 19 Valve 20 Oil Gallery Supply Oil to Intake Tappet 21 Oil Gallery Supply Oil to Exhaust Tappet 22 Ball φ 8 mm 23 Camshaft Plug 24 Seal 25 Screw Plug 26 Oil Return Gallery Cylinder Head and Crankcase 2...

Page 187: ... of spark distribution Each cylinder is paired with the cylinder that is opposite it 2 3 or 1 4 The spark occurs simultaneously in the cylinder coming up on the compression stroke and in the cylinder coming up on the exhaust stroke The cylinder on the exhaust stroke requires very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylind...

Page 188: ...NO DATA ...

Page 189: ...08 3 ENGINE CONTROLS undefined 0000 00 1430 01 ENGINE CONTROLS GENERAL 1 ENGINE AND ECM PROBLEM CHECK REPORT 1 Vehicle and Customer Information 2 MIL Information 3 Problem Description ...

Page 190: ...08 4 undefined 0000 00 ENGINE CONTROLS 4 Condition When Problem Occurs ...

Page 191: ...08 5 ENGINE CONTROLS undefined 0000 00 2 SPECIFICATIONS 1 Engine Data Display Table Condition Warmed up idle P N or neutral ...

Page 192: ...08 6 undefined 0000 00 ENGINE CONTROLS 2 Fastener Tightening Specifications ...

Page 193: ...08 7 ENGINE CONTROLS undefined 0000 00 OVERVIEW AND OPERATION PROCESS 1 SCHEMATIC AND ROUTING DIAGRAMS 1 ECM Wiring Diagram 2 3L DOHC 1 of 7 MSE 3 53D ...

Page 194: ...08 8 undefined 0000 00 ENGINE CONTROLS 2 ECM Wiring Diagram 2 3L DOHC 2 of 7 MSE 3 53D ...

Page 195: ...08 9 ENGINE CONTROLS undefined 0000 00 3 ECM Wiring Diagram 2 3L DOHC 3 of 7 MSE 3 53D ...

Page 196: ...08 10 undefined 0000 00 ENGINE CONTROLS 4 ECM Wiring Diagram 2 3L DOHC 4 of 7 MSE 3 53D ...

Page 197: ...08 11 ENGINE CONTROLS undefined 0000 00 5 ECM Wiring Diagram 2 3L DOHC 5 of 7 MSE 3 53D ...

Page 198: ...08 12 undefined 0000 00 ENGINE CONTROLS 6 ECM Wiring Diagram 2 3L DOHC 6 of 7 MSE 3 53D ...

Page 199: ...08 13 ENGINE CONTROLS undefined 0000 00 7 ECM Wiring Diagram 2 3L DOHC 7 of 7 MSE 3 53D ...

Page 200: ...l side trim form passenger side Re er to Section 9G Interior trim Remove the four securing nuts for the Engine Control Module ECM from the mounting bracket 1 2 3 10 Nm 89 lb in Pull out the ECM from the bracket Disconnect the vehicle side coupling Installation should follow the removal procedure in the reverse order 4 5 6 ...

Page 201: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 202: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 203: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 204: ... When the desired speed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control sy...

Page 205: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 206: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 207: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 208: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 209: ...01 3 ENGINE ASSEMBLY undefined 0000 00 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 210: ...01 4 undefined 0000 00 ENGINE ASSEMBLY Fastener Tightening Specifications Cont d ...

Page 211: ... Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel system Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly earthe...

Page 212: ...02 4 REXTON 2004 12 0000 00 FUEL SYSTEM Temperature VS Resistance ...

Page 213: ... provide the correct amount of fuel When decelerating the mass flow decreases This mass flow change is sensed by the MAF sensor and read by the ECM which then decreases the fuel injector on time due to the low fuel demand conditions The O2 sensors are located in the exhaust pipe before catalytic converter The O2 sensors indicate to the ECM the amount of oxygen in the exhaust gas and the ECM change...

Page 214: ...ystem goes into closed loop operation In closed loop the ECM calculates the air fuel ratio fuel injector on time based on the signals from the O2 sensors This allows the air fuel ratio to stay very close to 14 7 to 1 Acceleration Mode The ECM responds to rapid changes in throttle position and airflow and provides extra fuel Deceleration Mode The ECM responds to changes in throttle position and air...

Page 215: ...NO DATA ...

Page 216: ...NO DATA ...

Page 217: ...05 3 LUBRICATION SYSTEM undefined 0000 00 1542 07 LUBRICATION SYSTEM GENERAL 1 ENGINE OIL SPECIFICATION 1 Drain Plug 25 Nm 18 lb ft 2 Oil Filter 3 Engine Oil Filler Cap 4 Dipstick Gauge Specifications ...

Page 218: ... Oil Gallery At Cylinder Head 16 Ball φ 15mm 17 Oil Restriction Inner φ 4mm 18 Oil Supply To Exhaust Camshaft 19 Oil Supply To Intake Camshaft 20 Oil Supply To Exhaust Camshaft Bearing 21 Oil Supply To Intake Camshaft Bearing 22 Oil Gallery Oil Supply to Exhaust Valve Tappet 23 Oil Gallery Oil Supply to Intake Valve Tappet 24 Camshaft Closing Cover 25 Ball φ 8 mm 26 Screw Plug 27 Camshaft Adjuster...

Page 219: ... spark distribution Each cylinder is paired with the cylinder that is opposite it 1 6 or 2 5 or 3 4 The spark occurs simultaneously in the cylinder coming upon the compression stroke and in the cylinder coming up on the exhaust stroke The cylinder on the exhaust stroke requires very little of the available energy tofire the spark plug The remaining energy is available to the spark plug in the cyli...

Page 220: ...NO DATA ...

Page 221: ...08 3 ENGINE CONTROLS undefined 0000 00 1430 01 ENGINE CONTROLS GENERAL 1 SPECIFICATIONS 1 Engine Data Display Table ...

Page 222: ...08 4 undefined 0000 00 ENGINE CONTROLS 2 Fastener Tightening Specifications ...

Page 223: ...08 5 ENGINE CONTROLS undefined 0000 00 OVERVIEW AND OPERATION PROCESS 1 SCHEMATIC AND ROUTING DIAGRAMS 1 ECM Wiring Diagram 3 2L DOHC 1 of 7 MSE 3 63D ...

Page 224: ...08 6 undefined 0000 00 ENGINE CONTROLS 2 ECM Wiring Diagram 3 2L DOHC 2 of 7 MSE 3 63D ...

Page 225: ...08 7 ENGINE CONTROLS undefined 0000 00 3 ECM Wiring Diagram 3 2L DOHC 3 of 7 MSE 3 63D ...

Page 226: ...08 8 undefined 0000 00 ENGINE CONTROLS 4 ECM Wiring Diagram 3 2L DOHC 4 of 7 MSE 3 63D ...

Page 227: ...08 9 ENGINE CONTROLS undefined 0000 00 5 ECM Wiring Diagram 3 2L DOHC 5 of 7 MSE 3 63D ...

Page 228: ...08 10 undefined 0000 00 ENGINE CONTROLS 6 ECM Wiring Diagram 3 2L DOHC 6 of 7 MSE 3 63D ...

Page 229: ...08 11 ENGINE CONTROLS undefined 0000 00 7 ECM Wiring Diagram 3 2L DOHC 7 of 7 MSE 3 63D ...

Page 230: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 231: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 232: ...09 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 233: ... When the desired speed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control sy...

Page 234: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 235: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 236: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 237: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 238: ... GENERAL 1 STRUCTURE OVERVIEW AND OPERATION PROCESS 1 ENGINE CONTROLS COMPONENTS 2 INTAKE SYSTEM COMPONENTS 3 EXHAUST SYSTEM COMPONENTS 4 LUBRICATION SYSTEM COMPONENTS 5 COOLING SYSTEM COMPONENTS 6 FUEL SYSTEM COMPONENTS 3 6 9 11 13 15 17 ...

Page 239: ......

Page 240: ...r Power steering pump pulley Idle pulley Water pump pulley Alternator 1 2 3 4 5 6 Cooling fan pulley Aut tensioner pulley Auto tensioner Poly groove belt Cam position sensor Drive plate M T DMF 7 8 9 10 11 12 Oil filter Vacuum pump Crank position sensor EGR valve Power steering pump EGR center pipe 13 14 15 16 17 18 Front view Rear view ...

Page 241: ...inder head cover Intake manifold Water outlet port Common rail Fuel pressure sensor 19 20 21 22 23 Fuel pipe Injector Fuel return line Oil filler cap Glow plug 24 25 26 27 28 Booster pressure sensor Oil separator Oil dipstic EGR center pipe 29 30 31 32 ...

Page 242: ... view Cylinder head Cylinder block pan Drain plug Turbocharger 33 34 35 36 37 EGR RH 3 pipe Oil separator Oil dipstic HP pump 38 39 40 41 Turbocharger vacuum modulator EGR valve vacuum modulator EGR valve Exhaust manifold 42 43 44 45 Right side view ...

Page 243: ...01 6 undefined 0000 00 ENGINE GENERAL OVERVIEW AND OPERATION PROCESS 1 ECU Related Components 1 ENGINE CONTROLS COMPONENTS ...

Page 244: ...01 7 ENGINE GENERAL undefined 0000 00 2 Engine And Sensors ...

Page 245: ...01 8 undefined 0000 00 ENGINE GENERAL 3 Electrical Components And Pre Heating System ...

Page 246: ...01 9 ENGINE GENERAL undefined 0000 00 2 INTAKE SYSTEM COMPONENTS ...

Page 247: ...01 10 undefined 0000 00 ENGINE GENERAL Intake Air Flow Chart ...

Page 248: ...01 11 ENGINE GENERAL undefined 0000 00 3 EXHAUST SYSTEM COMPONENTS ...

Page 249: ...01 12 undefined 0000 00 ENGINE GENERAL Exhaust Air Flow Chart ...

Page 250: ...01 13 ENGINE GENERAL undefined 0000 00 4 LUBRICATION SYSTEM COMPONENTS ...

Page 251: ...linder head side Ball φ 15 mm 1 2 3 4 5 7 9 10 11 12 13 14 15 16 Oil restriction inner φ 4 mm Oil supply to exhaust camshaft Oil supply to intake camshaft Oil supply to exhaust camshaft bearing Oil supply to intake camshaft bearing Oil gallery to exhaust valve tappet Oil gallery to intake valve tappet Oil gallery to chain tensioner Expansion plug Ball Valve tappet Oil gallery between oil pump and ...

Page 252: ...01 15 ENGINE GENERAL undefined 0000 00 5 COOLING SYSTEM COMPONENTS ...

Page 253: ...01 16 undefined 0000 00 ENGINE GENERAL Coolant Flow Chart ...

Page 254: ...01 17 ENGINE GENERAL undefined 0000 00 6 FUEL SYSTEM COMPONENTS ...

Page 255: ...ensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease...

Page 256: ...that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque 1 Coolant reservoir 2 FFH device 3 Brake fluid reservoir 4 Washer fluid reservoir 5 Common rail 6 Fuse box 7 Battery 8 Fuel filter 9 Power steering pump 10 Priming pump 11 EGR valve 12 Air cleaner assembly 13 Turbo charger 14 Oil dipstic...

Page 257: ...steering pump pulley 4 Idle pulley 5 Coolant pump pulley 6 Alternator 7 Viscos fan clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly grooved belt 11 Cam position sensor 12 Drive plate MT DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR to center pipe Front View Rear View ...

Page 258: ...er head cover 20 Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 PCV valve and oil separator 31 Oil dipstick 32 EGR LH 1 pipe ...

Page 259: ...ad 34 Cylinder block 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH 3 pipe 39 PCV valve and oil separator 40 Oil dipstick 41 High pressure pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Right Side View ...

Page 260: ...02 7 ENGINE ASSEMBLY undefined 1212 01 2 SPECIFICATIONS ...

Page 261: ...02 8 undefined 1212 01 ENGINE ASSEMBLY 3 ENGINE PERFORMANCE CURVE Output and Torque ...

Page 262: ...02 9 ENGINE ASSEMBLY undefined 1212 01 Oil Temperature Pressure and Boost Pressure ...

Page 263: ...02 10 undefined 1212 01 ENGINE ASSEMBLY 4 TIGHTENING TORQUE ...

Page 264: ...02 11 ENGINE ASSEMBLY undefined 1212 01 ...

Page 265: ...02 12 undefined 1212 01 ENGINE ASSEMBLY ...

Page 266: ...ere failure has been occurred in a vehicle the system safety mode is activated to protect the system It reduces the driving force restricts the engine speed rpm and stops engine operation Refer to Diagnosis section in this manual When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of th...

Page 267: ...uel After draining the water from fuel separator After replacing the fuel filter Priming Pump Conditions for Using Priming Pump Fuel Filter and Water Separator 1 Fuel filter 2 Water drain plug water separating operation every 10 000 km 3 Priming pump When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The wate...

Page 268: ...ets out from the port then turn the drain plug to B direction to tighten it 2 3 Be careful not to be injured by surrounding equipment during the working procedures Press the priming pump until it becomes rigid Start the engine and check the conditions 4 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to pe...

Page 269: ...osition sensor determines injection order and ECU detects driver s pedal position driver s demand through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to...

Page 270: ...ontrolled electronically by engine ECU Accordingly fuel system is completely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section Fuel route ...

Page 271: ...03 8 undefined 1881 01 ENGINE FUEL SYSTEM 3 Hydraulic Cycle in Fuel Line Transfer and High Pressure Line ...

Page 272: ...nt excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the con...

Page 273: ...re foreign materials in the fuel fuel system including pump components delivery valve and injector nozzles may be damaged Fuel filter purifies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line ...

Page 274: ...ure pump increases system pressure of fuel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a spe...

Page 275: ...ector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel returned by low pressure and fuel used for high pressure pump lubrication also return to fuel tank through return line 6 Fuel filter replacement Fuel filter ch...

Page 276: ...03 13 ENGINE FUEL SYSTEM undefined 1881 01 6 Electrical Wiring Diagram ...

Page 277: ...04 3 ENGINE INTAKE SYSTEM undefined 2313 01 OVERVIEW AND OPERATION PROCESS 1 COMPONENTS LOCATOR 2313 01 ENGINE INTAKE SYSTEM ...

Page 278: ...04 4 undefined 2313 01 ENGINE INTAKE SYSTEM 2 AIR FLOWS Work Flow of Intake System ...

Page 279: ...05 3 ENGINE EXHAUST SYSTEM undefined 0000 00 0000 00 ENGINE EXHAUST SYSTEM OVERVIEW AND OPERATION PROCESS 1 COMPONENTS LOCATOR ...

Page 280: ...05 4 undefined 0000 00 ENGINE EXHAUST SYSTEM 2 EXHAUST GAS FLOWS ...

Page 281: ...d operation as in stop and go traffic When most trips are less than 6 km Operating when outside temperatures remain below freezing and when most trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Oil Pressure Switch Operating temperature 40 140 Operating pressure 0 3 0 55 bar Permissible pressure 10 bar ...

Page 282: ...06 4 undefined 1533 01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1 COMPONENTS LOCATOR ...

Page 283: ...YSTEM undefined 1533 01 2 LUBRICATION SYSTEM LAYOUT Cylinder head Cylinder block Main oil gallery φ16 Hole to cylinder head φ9 Main bearing hole φ7 Chain and injection pump φ7 Return hole φ14 Chain nozzle φ1 HP pump bearing φ6 ...

Page 284: ...LUBRICATION SYSTEM 3 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head 1 2 ...

Page 285: ...06 7 ENGINE LUBRICATION SYSTEM undefined 1533 01 4 BLOW BY GAS REDUCTION DEVICE ...

Page 286: ...07 3 ENGINE COOLING SYSTEM undefined 1520 11 1520 11 ENGINE COOLING SYSTEM GENERAL 1 SPECIFICATIONS ...

Page 287: ...07 4 undefined 1520 11 ENGINE COOLING SYSTEM OVERVIEW AND OPEATION PROCESS 1 COMPONENTS LOCATOR FFH Fuel Fired Heater refer to FFH System in this manual ...

Page 288: ...520 11 2 COOLING FLOWS Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump PTC Engine Coolant Flows FFH Engine Coolant Flows ...

Page 289: ... inflows through the heater line rear section cylinder 4 and 5 of cylinder head However in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page It prevents cooling efficiency from decreasing due to coolant separation between cylinder 4 and 5 In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it...

Page 290: ...oir is a transparent plastic reservoir similar to the windshield washer reservoir The coolant reservoir is connected to the radiator by a hose and to the engine cooling system by another hose As the vehicle is driven the engine coolant heats and expands The portion of the engine coolant displaced by this expansion flows from the radiator and the engine into the coolant reservoir The air trapped in...

Page 291: ...08 3 ENGINE ELECTRIC SYSTEM undefined 2820 01 2820 01 ENGINE ELECTRIC SYSTEM GENERAL 1 SPECIFICATIONS ...

Page 292: ...08 4 undefined 2820 01 ENGINE ELECTRIC SYSTEM OVERVIEW AND OPERATION PROCESS 1 SENSORS IN ENGINE COMPARTMENT ...

Page 293: ...08 5 ENGINE ELECTRIC SYSTEM undefined 2820 01 2 PREHEATING SYSTEM COMPARTMENT ...

Page 294: ...08 6 undefined 2820 01 ENGINE ELECTRIC SYSTEM 3 ELECTRIC DEVICES IN ENGINE COMPARTMENT ...

Page 295: ...08 7 ENGINE ELECTRIC SYSTEM undefined 2820 01 4 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 296: ...08 8 undefined 2820 01 ENGINE ELECTRIC SYSTEM 5 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 297: ...09 3 ENGINE CONTROL SYSTEM undefined 1491 01 1491 01 ENGINE CONTROL SYSTEM OVERVIEW AND OPERATION PROCESS 1 ENGINE ECU AND OTHER COMPONENTS ...

Page 298: ...09 4 undefined 1491 01 ENGINE CONTROL SYSTEM TOP VIEW ...

Page 299: ...09 5 ENGINE CONTROL SYSTEM undefined 1491 01 SIDE VIEW ...

Page 300: ...e of turbulence is low If injection pressure is too high the nozzle s penetration will be excessive and part of the fuel will be sprayed directly onto the sides of the cylinder causing incomplete combustion So there occurs smoke and damages engine durability 2 Fuel Pressure Control Rail pressure is controlled by closed loop regulation of IMV A mapping system open loop determines the current which ...

Page 301: ...ng advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liable ...

Page 302: ...nt temperatures This correction allows the pilot injection timing to be adapted to the operating temperature of the engine A second correction is made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude During the starting phase the pilot injection timing is determined as a function o...

Page 303: ...flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order to...

Page 304: ...harged fuel Once the engine changes to normal operation the system uses the total fuel The main fuel is obtained by subtracting the pilot injection fuel from the total fuel A mapping determines the minimum fuel which can control an injector as a function of the rail pressure As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable...

Page 305: ...values The driver demand is then corrected according to the coolant temperature This correction is added to the driver demand 3 Idle Speed Controller The idle speed controller consists of 2 principal modules The first module determines the required idle speed according to The operating conditions of the engine coolant temperature gear engaged Any activation of the electrical consumers power steeri...

Page 306: ...s case and depending on the gravity of the fault the system activates Reduced fuel logic 1 Guarantees 75 of the performance without limiting the engine speed Reduced fuel logic 2 Guarantees 50 of the performance with the engine speed limited to 3 000 rpm Reduce fuel logic 3 Limits the engine speed to 2 000 rpm The system chooses the lowest of all these values A correction depending on the coolant ...

Page 307: ... the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The di...

Page 308: ...dow is used to establish the background noise level of the accelerometer signal for each cylinder This window must therefore be positioned at a moment when there cannot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the m...

Page 309: ...hich a fault is signaled is a percentage of the maximum possible value of the ratio Because of the severity of the recovery process engine shut down the etection must be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilo...

Page 310: ...sion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors I...

Page 311: ...to make the most optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depresse...

Page 312: ...mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning conditions 2 Trouble codes ...

Page 313: ...hen this switch is operating AUTO CRUISE lamp comes on The minimum speed for setting the cruise control system is 36 km h 22 37 mph Pay constant attention to the distance between the vehicles and the traffic conditions when using the cruise control system The cruise control system is a supplementary system which helps the driver to drive the vehicle at a desired speed without using the accelerator...

Page 314: ...ways or highways where there is no sudden change in the driving condition due to traffic lights pedestrian etc Use the cruise control system only when driving on motorways or highways Do not use the cruise control system where the road conditions are as follows When there is strong wind or cross wind Heavy traffic Slippery roads or steep decline ...

Page 315: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 316: ... When the desired speed is reached which should be within the above range push up the cruise control switch lever to ACCEL side upwards arrow or push down the switch lever to DECEL side downwards arrow Now the vehicle is cruised by this system with the set speed You don t need to use the accelerator pedal Refer to the following pages for details of operation 1 2 3 4 Never use the cruise control sy...

Page 317: ...and hold it When the desired speed is reached release the accelerator pedal and the switch lever 1 2 To increase the speed with the cruise control system while the system is not running follow the procedures below 3 Tap up while the cruise control system is running Push up the cruise control switch lever to ACCEL side for less than 0 5 second per one switching while the cruise control system is ru...

Page 318: ... over 36 km h 22 37 mph When the desired speed is reached release the switch lever But the cruise control system cannot maintain the cruise function at less than 34 km h 21 13 mph 1 2 3 To decrease the speed with the cruise control system while the system is not running follow the procedures below 3 Tap down while the cruise control system is running Push down the cruise control switch lever to DE...

Page 319: ...like below Pull the switch lever in the arrow direction shown in the illustration This RESUME function works only when the vehicle speed is more than 36 km h 22 37 mph without using the accelerator or brake pedal But the driver should know the previous set speed to react to the changed vehicle speed properly If the vehicle speed increases abruptly depress the brake pedal to adjust the vehicle spee...

Page 320: ...an open circuit 1 2 3 When the cruise control function is cancelled abnormally or intermittent problems occur stop the vehicle and turn off the ignition switch and remove the key to reset the system After a while turn on the ignition switch again to operate the cruise control system Do not move the shift lever to Neutral position while driving with the cruise control turned on Otherwise it may res...

Page 321: ...FUSES AND RELAYS 0000 00 FUSES AND RELAYS GENERAL 1 GENERAL INFORMATION OVERVIEW AND OPERATION PROCESS 1 COMPARTMENT 2 ELECTRIC COMPONENTS LOCATOR 3 6 12 ...

Page 322: ......

Page 323: ...bject to be damaged The volatile memory in electrical devices may be erased Store them with safe methods The harnesses that can be touched with a sharp edge or corner should be wrapped with insulating tape to prevent damaging Carefully handle the wiring harnesses not to damage them during servicing the electric components 2 3 If a fuse is blown be sure to eliminate the cause of problem before inst...

Page 324: ...k When disconnecting always hold the connector body other than the harness 7 8 9 Disconnect the connector while pressing down the locking tab if applicable 10 When checking the continuity or voltage the test probes of the circuit tester should be inserted from harness side rear of connector In case of sealed connector insert the test probe through the cavity in wiring rubber cap Be careful not to ...

Page 325: ...other metal components such as vehicle body Check if the continuity exists on the bolt and vehicle body in ground connection Check the wire arrangement Securely fasten the wiring harnesses not to contact to a sharp edge and hot elements exhaust manifold and pipes Keep the proper clearance between the wire harness and the moving components such as fan pulley and fan belt In case of the wiring harne...

Page 326: ... FUSES AND RELAYS OVERVIEW AND OPERATION PROCESS 1 COMPARTMENT 1 DI D27DT ENGINE EQUIPPED VEHICLE Fuse Box In Engine Compartment It is installed in the left side of engine compartment Name and Capacity Connector Arrangement ...

Page 327: ...01 7 FUSES AND RELAYS undefined 0000 00 Interior Fuse Box It is install at left side of the instrument panel Name and Capacity ...

Page 328: ...01 8 undefined 0000 00 FUSES AND RELAYS Interior Relay Box It is installed behind the lower instrument panel Relay Arrangement Relay Name ...

Page 329: ... 9 FUSES AND RELAYS undefined 0000 00 2 GASOLINE ENGINE EQUIPPED VEHICLE Fuse Box In Engine Compartment It is installed in the left side of engine compartment Connector Arrangement Fuse Name and Capacity ...

Page 330: ...01 10 undefined 0000 00 FUSES AND RELAYS Interior Fuse Box It is install at keft side of the instrument panel Name and Capacity Fuse ...

Page 331: ...01 11 FUSES AND RELAYS undefined 0000 00 Interior Relay Box It is installed behind the lower instrument panel Relay Name Relay Arrangement ...

Page 332: ...01 12 undefined 0000 00 FUSES AND RELAYS 2 ELECTRIC COMPONENTS LOCATOR ...

Page 333: ...02 3 STICS undefined 8710 01 8710 01 STICS GENERAL 1 SPECIFICATIONS 2 RATED LOAD ...

Page 334: ...ON is not included 150 ms target input Door lock switches tailgate lock switch IGN1 switch IGN2 switch door switches tailgate switch 80 ms target input 40 ms target input Inputs except 10 ms 80 ms and 150 ms target inputs 20 ms target input Wiper motor stop speed sensor The time described for each function doesn t include the time from switch input change to chattering process ...

Page 335: ...fined 8710 01 OVERVIEW AND OPERATION PROCESS 1 REMOTE KEYLESS ENTRY SYSTEM REKES 1 Function UNLOCK button 1 Unlocks all doors LOCK button 2 Locks all doors 1 2 Use a CR 2025 battery for replacement Battery Replacement ...

Page 336: ...the system starting will be impossible so never attempt to remove damage or modify it Do not drop or shock to the transponder in the key or it could be damaged When the transponder has damaged replace it with new one and register new code on engine control unit at our authorized service network Otherwise the engine cannot be started In any cases the immobilizer system can not be removed from the v...

Page 337: ...02 7 STICS undefined 8710 01 2 REKES STICS RKSTICS COMPONENTS LOCATOR 1 RK STICS 2 Interior fuse box 3 Buzzer 4 Outside mirror folding unit ...

Page 338: ...Wiper MIST and Washer Coupled Wiper The wiper MIST and washer coupled wiper output is ON when turning ON the washer switch for 0 2 0 59 seconds 1 The wiper MIST and washer coupled wiper output is ON when turning ON the washer switch for over 0 6 seconds 2 1 Wiper Control ...

Page 339: ...per relay ON request time is shorter than the remained ON time it is disregarded Speed sensitive INT intermittent wiper The wiper relay continues to output for remaining ON time even when the INT switch is turned off IGN 2 switch ON INT switch OFF resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON resume the intermittent time when turning ON The wiper relay continues to ou...

Page 340: ...revious vehicle speed value V vehicle speed for calculation V max Vnew Vold If the vehicle speed is over 150 km h the value is regarded as 150 km h Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 pulses sec 60 Km h x 60 sec 637 pulses 1 41 Km h VOLUME calculation Calculates the INT VOLUME as 5 grades VOLUME value has a hysteresis as below When the VOLUME va...

Page 341: ... The pause time is calculated by the vehicle speed and VOLUME value The changes of pause time is immediately applied If the elapsed time is greater than the current intermittent time the wiper relay turns on immediately If the pause time is below 1 0 second the wiper operates without pause However in continuous operation the wiper start to operate intermittently from when the pause time goes over ...

Page 342: ... WARNING Chime Bell Control The chime bell output is ON when opening the driver s door while the ignition key is inserted into ignition switch In above conditions the chime bell output is OFF when closing the driver s door or removing the ignition key from ignition switch This function is not available when the IGN 1 switch is ON ...

Page 343: ...ignition key is inserted into ignition switch and driver s door opens The door unlock relay output is ON when closing the door within T3 after turning ON the door lock switch while the ignition key is inserted into ignition switch and driver s door opens The unlock relay output is ON when any of unlock conditions are changed within T1 The unlock relay output will not be ON when removing the igniti...

Page 344: ... driver s door or passenger s door while the tail lamp relay turns ON and the ignition key is removed The buzzer output is OFF when any of above conditions are not met This function is not available when IGN 1 is ON This function is not available when the tail lamp relay output is OFF by the battery saver function ...

Page 345: ...oor and locking the door lock switch while the tail lamp relay output is ON and the ignition key is removed The door unlock relay output is OFF when closing both doors or turning off the tail lamp switch This function is not available when IGN 1 is ON This function is not available when the tail lamp automatically turns off ...

Page 346: ...p blinks when opening a door while the vehicle speed is over V1 10 km h The warning lamp goes off when closing the door in step 1 and step 2 The warning lamp comes on when the vehicle speed is below V1 in step 2 This function is not available when IGN 1 is OFF However the vehicle speed can be detected from 1 5 seconds after turning ON the IGN 1 switch ...

Page 347: ... warning lamp goes off and the chime bell stops when turning OFF the IGN 1 switch during the warning operation The chime bell stops and the seatbelt warning lamp stays on for the specified duration 6 seconds when fastening the seatbelt during the warning operation The seatbelt warning lamp comes on and the chime bell sounds when unfastening the seatbelt with IGN 1 switch ON ...

Page 348: ...e vehicle speed is below V1 The warning lamp blinks and the buzzer sounds when the vehicle speed is over 10 km h for 2 seconds with the warning lamp ON and when turning ON the parking brake switch while the vehicle is over 10 km h PARKING START WARNING The warning lamp comes on and the buzzer stops when the vehicle speed goes down below V1 in step 3 The warning lamp goes off and the buzzer stops w...

Page 349: ...nd the room lamp prolongs its operation time for T1 and decays for T2 when closing the door within T2 The room lamp output immediately stops when turning ON the IGN 1 switch while decaying operation The room lamp comes on for 30 seconds when receiving the unlock signal from remote control key while the door is closed The output prolongs 30 seconds when receiving the unlock signal from remote contr...

Page 350: ...ation stops when turning ON the IGN 1 switch or when receiving the lock signal from remote control key within 10 seconds This function is not available in the immobilizer equipped vehicle 9 Battery Saver The tail lamp relay output is OFF when removing the ignition key from the ignition switch and opening and then closing the door while the tail lamp is coming on The tail lamp relay output is OFF w...

Page 351: ...IGN 2 switch is ON with engine running The output is OFF when turning ON the rear defogger switch again during outputting The output is ON only for T3 when turning ON the rear defogger switch within T2 after completion of output This can be done only once The output is OFF when the IGN 2 switch is OFF or the ALT L terminal is below V1 ...

Page 352: ...osition The changes of locking position are disregarded when outputting the LOCK or UNLOCK by other functions The door lock unlock is not operating regardless of the door lock switch positions when connecting to battery If the LOCK UNLOCK conditions are generated along with IGN KEY REMINDER conditions outputs only when the ignition key is removed after 0 5 seconds In case of operation by the outsi...

Page 353: ...Unlock by REKES Remote Keyless Entry System The door lock relay output is ON for 0 5 seconds when receiving the remote control lock signal The door unlock relay output is ON for 0 5 seconds when receiving the remote control unlock signal ...

Page 354: ... is changed to UNLOCK from LOCK during the 5 outputs will not be regarded as FAILED If the door that was regarded as FAIL will be unlocked again only one LOCK output will be done If the door that was LOCK is changed to UNLOCK only one LOCK output will be done Do not try AUTO DOOR LOCK operation for the vehicle speed after the completion of auto door unlock operation The FAIL is erased when turning...

Page 355: ...in after manually locking in above UNLOCK condition IGN ON UNLOCK can be done regardless of the numbers of operation However the vehicle speed input can be detected from 1 5 seconds after turning ON the IGN 1 switch The impact sensor in unit moves to unlock all doors when taking an impact However the AUTO DOOR UNLOCK function may not be operated when the door has been damaged or the internal elect...

Page 356: ...ndow relay output is ON when turning on the IGN 1 switch The power window relay output is ON for T1 when turning off the IGN 1 switch The power window relay output is ON for T2 when opening the door within T1 The power window relay output is OFF when closing the door within T2 ...

Page 357: ...ows When pressing over two switches at a time only one signal can be sent according to the below priority Priority LOCK UNLOCK Data structure Definition of data Specifications of Receiver Operating requirements The ignition key should be removed Code registration requirement After connecting the B to external code save terminal applying battery voltage ...

Page 358: ...t is ON for T1 and the siren output is ON for T2 when registering the code Code output requirements When the customer and ID codes are correct and the rolling code is within operating range while the ignition switch is removed and the code saving device is turned off the code can be output after identifying the function code The function codes that can be output are LOCK and UNLOCK ...

Page 359: ...ing ON the theft warning selection switch from OFF during the warning output the warning operation output can be done by remained time Determination for ON OFF position of theft warning selection switch Can be determined only when the theft warning operating is in normal mode before receiving Tx LOCK signal Disregards the changes of theft warning selection switch in the armed mode or warning opera...

Page 360: ... normal mode However in these cases if closing the door and locking the door lock switch the siren outputs once and the hazard relay outputs twice and then activates armed mode When the door is opened the door unlock switch is ON or the ignition key is not inserted into ignition switch for 30 seconds after receiving T x UNLOCK signal outputs LOCK and then activates armed mode RELOCK operation The ...

Page 361: ...ening the door in armed mode When unlocking the door lock switch in armed mode When closing and then opening the door after completion of warning 27 seconds Warning operation The siren output is ON for T3 and the hazard relay output is ON for T3 with the interval of T2 ...

Page 362: ... undefined 8710 01 STICS Warning cancellation requirements When locking or unlocking by Tx When turning ON the door unlock switch Warning cancellation operation The siren and the hazard relay outputs are OFF ...

Page 363: ...switch are turned OFF The WAKE UP mode is activated immediately after any of above requirements is failed canceling the SLEEP mode The WAKE UP mode is activated immediately after inputting the KEYLESS signal canceling the SLEEP mode The above output conditions and ready conditions are cancelled after a certain period of waiting when some outputs room lamp key hole illumination tail lamp power wind...

Page 364: ...PPED VEHICLE Total 5 immobilizer key can be coded to ECU with Scan i Refer to the coding procedures in Troubleshooting section The immobilizer should be coded whenever replacing the immobilizer related components and ECU at the Ssangyong Authorized Service Operation ...

Page 365: ...02 35 STICS undefined 8710 01 5 RK STICS CIRCUIT DIAGRAM Tail Lamp and Switch ...

Page 366: ...02 36 undefined 8710 01 STICS Warning Lamps ...

Page 367: ...02 37 STICS undefined 8710 01 Wiper Door Switch Lamps Room Lamp Map Lamp Door Ajar Warning Lamp ...

Page 368: ...02 38 undefined 8710 01 STICS Door Lock Heated Wire ...

Page 369: ...02 39 STICS undefined 8710 01 Central Door Locking Device ...

Page 370: ...02 40 undefined 8710 01 STICS 6 IMMOBILIZER CIRCUIT DIAGRAM ...

Page 371: ...e active type to enhance the sensitiveness and stability Immobilizer RF IC It drives the coil antenna converts the received signals from the coil antenna to special code and delivers it to the immobilizer ECU Immobilizer Unit It analyzes the received signals from the immobilizer RF IC confirms the authorized transponder and delivers the result start or start inhibition to the engine ECU Engine ECU...

Page 372: ...02 42 undefined 8710 01 STICS SCHEMATIC DIAGRAM ...

Page 373: ...ine D29ST Conventional cluster that cannot communicate with CAN DI Engine D27DT Conventional appearance CAN communication function internal function New cluster with BLACK FACE appearance CAN communication Gasoline Engine G32D New cluster with BLACK FACE appearance CAN communication IDI Engine equipped vehicle CAN communication X DI Engine equipped vehicle CAN communication O BLACK FACE Cluster OV...

Page 374: ...03 4 undefined 8010 01 CLUSTER 1 BLACK FACE TYPE CLUSTER 1 DI GASOLINE ENGINE EQUIPPED VEHICLE ...

Page 375: ...dicator 9 4WD CHECK indicator 10 Defogger indicator 11 Low fuel level warning light 12 Fuel gauge 13 Temperature gauge 14 WINTER mode indicator A T 15 High beam indicator 16 Turn signal indicator right 17 Turn signal indicator left 18 ESP warning light 19 Tachometer 20 EBD waring light 21 SSPS warning light 22 Brake system warning light 23 ABS warning light 24 Aigbag warning light 25 Door open war...

Page 376: ...H indicator 10 4WD CHECK indicator 11 Glow indicator 12 Water separator warning light 13 Defogger indicator 14 Low fuel level warning light 15 Fuel gauge 16 Temperature gauge 17 WINTER mode indicator A T 18 High beam indicator 19 Turn signal indicator right 20 Turn signal indicator left 21 ESP warning light 22 Tachometer 23 EBD waring light 24 SSPS warning light 25 Brake system warning light 26 AB...

Page 377: ...03 7 CLUSTER undefined 8010 01 CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT ...

Page 378: ...ne CHECK indicator 9 4WD CHECK indicator 10 4WD LOW indicator 11 WINTER mode indicator A T 12 4WD HIGH indicator 13 Temperature gauge 14 Turn signal indicator left 15 High beam indicator 16 Turn signal indicator right 17 Brake system warning light 18 Tachometer 19 ESP warning light 20 EBD waring light 21 ABS warning light 22 Aigbag warning light 23 Fuel gauge 24 Low fuel level warning light 25 Wat...

Page 379: ...03 9 CLUSTER undefined 8010 01 CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT DI Engine Equipped Vehicle ...

Page 380: ...ht 7 Seatbelt reminder 8 4WD CHECK indicator 9 4WD LOW indicator 10 WINTER mode indicator A T 11 4WD HIGH indicator 12 Temperature gauge 13 Turn signal indicator left 14 High beam indicator 15 Turn signal indicator right 16 Brake system warning light 17 Tachometer 18 EBD waring light 19 ABS warning light 20 Aigbag warning light 21 Fuel gauge 22 Low fuel level warning light 23 Defogger indicator 24...

Page 381: ...03 11 CLUSTER undefined 8010 01 IDI Engine Equipped Vehicle without CAN Communication ...

Page 382: ...tance TRIP B will be indicated When the button is pressed once more total distance ODO will be indicated If pressing and holding the reset button for over 3 seconds in TRIP A or TRIP B mode the trip odometer resets to zero Odometer Trip Odometer The tachometer indicates engine speed in revolutions per minute Multiply 1 000 to the current number then it will be the current number of engine revoluti...

Page 383: ...el remaining in the fuel tank This gauge operates only when the ignition switch is in ON position F Full E Empty Engine Oil Pressure Warning Light This warning light comes on when the ignition is switched on and should go out after the engine is started Severe engine damage could result Do not run the engine with the engine oil pressure warning light illuminated If oil level is normal have the sys...

Page 384: ... and repaired immediately by the nearest Ssangyong Dealer or Ssangyong Authorized Service Operation Seat Belt Reminder The seat belt warning light comes on whenever the ignition switch is placed in the ON position unless the driver s seat belt is securely fastened Also the seat belt warning chime will sound for about 6 seconds when the ignition switch is in the ON position unless the driver s seat...

Page 385: ...IGH warning light come on or blink IDI Engine or 4WD CHECK warning light stays on have the 4WD system checked at Ssangyong Dealer or Ssangyong Authorized Service Operation 4WD LOW Indicator This indicator comes on when the 4WD LOW mode is selected by pushing 4L switch To shift 4L position completely stop the vehicle and always depress the clutch pedal for manual transmission or position the select...

Page 386: ...il the shift is completed After completion of shift the indicator stays on The indicator comes on without blinking when shifting from 2WD to 4WD HIGH Defogger Indicator The indicator comes on when the tailgate glass defogger is switched ON It goes out after specified time Door Open Warning Light This light comes on when a door or tailgate is either opened or not closed completely Driving with door...

Page 387: ...ked without delay by a Ssangyong Dealer or Ssangyong Authorized Service Operation Turn Signal Hazard Flasher Indicator When the turn signal switch is turned on this indicator flashes to indicate operation of the external turn signal Shorter flashes indicate the failure of a turn signal lamp bulb Both right and left lights flash when the hazard warning switch is turned on If a bulb is burned out re...

Page 388: ...ht comes on when the parking brake is applied with the ignition on and goes out when the parking brake is released If the parking brake is applied this warning light still remains on until the parking brake released Make sure the parking brake is fully released before driving If this warning light comes on even when the parking brake is completely released it may indicate that the brake fluid in t...

Page 389: ...ormal the warning light comes on and when the relative ABS system is also abnormal it comes on with ABS warning light If this warning light fails to go out or comes on have the system checked and repaired immediately by the nearest Ssangyong Dealer or Ssangyong Authorized Service Operation EBD Electronic Brake force Distribution When the brake pedal is applied it controls the braking pressure elec...

Page 390: ...ght illuminates while driving a malfunction of ABS is indicated In this case the brake system performs its regular function but without the anti locking capability Have the system checked by Ssangyong Dealer as soon as possible if this condition occurs If the brake system warning light and ABS warning light illuminate at the same time while driving it may indicate a failure in the base brake syste...

Page 391: ...thorized Service Operation SSPS Warning Light This warning light comes on when the SSPS system is defective When this warning light comes on the steerability becomes heavy If this light comes on have the SSPS system checked by Ssangyong Dealer or Ssangyong Authorized Service Operation SSPS In traditional constant power assist steering system the steerability gets lighter as vehicle speed rises and...

Page 392: ...w to drain the water from fuel filter on next page This warning light goes out when the draining is completed Drain the water from fuel filter immediately after the warning light comes on If you cannot do that by yourself visit nearest Ssangyong Dealer or Ssangyong Authorized Service Operation For the draining procedures please refer to How to drain the water from fuel filter on next page After dr...

Page 393: ...o be injured by surrounding equipment during the working procedures 1 Fuel filter 2 Drain plug 3 Priming pump Wait until a certain amount of fuel gets out from the port then turn the drain plug to counterclockwise direction to tighten it Engage the connector under the drain plug and press the priming pump until it becomes rigid Close the engine hood and start the engine 5 6 7 If the priming pump i...

Page 394: ...indicator lamp signals that the vehicle has a problem that requires attention Driving with the engine check indicator lamp on can damage the emissions control system and can affect the fuel economy and drivability or the vehicle Consult a Ssangyong Dealer or a Ssangyong Authorized Service Operation to repair the problem as soon as possible Rheostat Black Face type Press and hold the Trip odometer ...

Page 395: ... 8010 01 3 MULTI METER OPERATING PROCESS 1 SYSTEM LAYOUT 1 Barometer 2 Electronic compass 3 Speed sensing indicator 4 Relative altimeter 5 Altimeter 6 Adjustment switch 7 Down switch 8 Power switch 9 Up switch 10 Mode switch ...

Page 396: ...rent direction flashes Turn the vehicle over 1 complete circle within 128 seconds slowly then the calibration will be accomplished When the calibration is finished the vehicle s new direction will be indicated 1 2 3 If the compass continues to flash turn again slowly until it goes off Release Conditions for Turning Calibration When the adjustment switch is pressed over 0 6 second When the vehicle ...

Page 397: ...PEED SENSING INDICATOR The flashing interval of the road signs changes gradually according to the vehicle speed Flashing intervals by speed ranges 4 BAROMETER It indicates the current atmospheric pressure up to 600 hpa 1 100 hpa by 1 hpa ...

Page 398: ... however if less than 20 m it indicates as 0 m How to Calibrate the Altitude How to Erase the Calibrated Altitude Value Altitude Calibration Ranges Press the UP and DOWN switches simultaneously for more than 1 second then the calibrated altitude value will be erased and the current altitude will be indicated after showing 0000 for 2 seconds The difference between minimum value and maximum value is...

Page 399: ...ude after arrival To See the Destination s Altitude 1 Enter the altitude of the point where you know the altitude from the sea level 2 The indicated value on the destination is the altitude from the sea level Coming Out Order of the Road Signs If the vehicle stops the currently turned off area of the signs will remain as it is If the vehicle drives off again the next area from the turned off signs...

Page 400: ...8510 01 SWITCHES 1 COMPONENTS LOCATOR 1 Center Switches Audio remote control switch Defogger switch Front fog lamp switch 4WD switch Full Time 4WD switch Part Time Hazard warning switch ESP OFF switch OVERVIEW AND OPERATION PROCESS ...

Page 401: ...04 4 undefined 8510 01 SWITCH 2 Others Outside rearview mirror switch Tailgate window wiper washer switch ...

Page 402: ... the button to warm the seat and press it again to stop the operation Do not place anything sharp on the seat This may cause damages to the seat warmer When cleaning the seats do not use organic solvents such as benzene or thinner The seat surfaces may get deteriorated Do not operate when the engine is not running ...

Page 403: ...05 3 LAMP undefined 8310 01 1 SPECIFICATIONS 8310 01 LAMP GENERAL ...

Page 404: ...lamp Low beam Headlamp High beam Clearance lamp Turn signal lamp Fog lamp High mounted stop lamp Tail and stop lamp 1 2 3 4 5 6 7 Tail lamp Stop lamp Turn signal lamp Back up lamp Rear deflector License plate lamp 8 9 10 11 12 13 OVERVIEW AND OPERATION PROCESS ...

Page 405: ...06 3 WIPER undefined 7810 01 7810 01 WIPER AND WASHER 1 COMPONENTS LOCATOR Wiper blade Wiper motor and linkage Washer reservoir assembly 1 2 3 Wiper blade Wiper motor 4 5 OVERVIEW AND OPERATION PROCESS ...

Page 406: ...ner upper central windshield senses rain 2 System Diagram 3 Principle of Rain Sensor Rain sensing unit detects amount of rains through LED and photodiode When infrared rays emitted from LED are reflected against rains on the windshield surface photodiode detects the amount of rains Rain sensing unit has glass transmitting rate compensation circuit so it can detect rains constantly regardless of tr...

Page 407: ...iper operation time and wiper operation speed to LOW or HIGH automatically 1 OFF mode When wiper switch is in OFF position and ignition switch is in ON position rain sensor operates in OFF mode On this mode the wiper motor does not operate During OFF mode rain sensor monitors windshield conditions and then sets the wiper switch sensitivity stage So the sensor performance can be optimized when turn...

Page 408: ...tization characteristics that prevents repeating operation between AUTO INT and AUTO LO while accumulating rain 5 Automatic high speed AUTO HI mode operates when rains on windshield exceed critical value of AUTO LO and AUTO HI This critical value has magnetization characteristics that prevents repeating operation between AUTO LO and AUTO HI while accumulating rain 6 Washer mode Rain sensor monitor...

Page 409: ...able sensitivity performance Sensitivity of rain sensor can be set by increasing decreasing INT on wiper switch Sensitivity can be set from stage 1 to stage 5 according to actual system Each stage can be identified so that can satisfy every driver s desire on level of rains Adjustable ranges are from short delay time 1 5 sec to long delay time over 20 sec so that can meet very small amount of rain...

Page 410: ...re returning to operation position This one time operation happens every time when wiper switch is operated to increase the sensitivity by changing INT volume from lower state state 1 to higher stage However it does not happen when wiper switch is changed into lower sensitivity If ignition switch is turned ON when ignition switch is turned off and wiper switch is set to a certain sensitivity wiper...

Page 411: ...e CAM switch are connected during revolution again relay 2 on CONT turns off and then relay 1 turns on to rotate the motor clockwise It means by changing motor polarities between 2 and 4 with CAM switch the wiper operates 1 2 3 Parking mode operation Parking while operating clockwise If turns off wiper switch during wiper operation W and C points on the CAM switch are connected during revolution t...

Page 412: ...r does not operate 1 2 3 System operation description If turn on motor operation switch relay 1 on controller turns on to rotate the motor clockwise operation order 1 2 3 4 When W and C points on the CAM switch are connected during revolution relay 2 on controller turns off and relay 1 on controller turns on to rotate the motor clockwise It means by changing motor polarities between wiping ranges ...

Page 413: ... 2 times and then return to parking position Wiper motor output works same as the wiper operation mode 1 2 3 2 Limit switch ON OFF mode operation If turn on limit switch while wiper motor is operating under ignition switch on condition returns to parking position without delay to stop the motor Under limit switch on condition wiper motor output control will be stopped It is to control the wiper bl...

Page 414: ...07 11 RAIN SENSOR undefined 8610 11 4 Specifications 5 Circuit Diagram ...

Page 415: ...ght sensor unit on the instrument panel upper passenger detects surrounding brightness and then turns on or off position lamps and headlamps automatically if light switch is in AUTO mode even when the driver does not operate light switch If enters tunnel during day driving or gets dark due to fog rain or snow it also operates 2 Specifications 3 Input Output Diagram ...

Page 416: ...dlamp AUTO switch Turn on off the position lamp headlamp and switch Turn on the AUTO switch At this moment position lamps and headlamps come on automatically if brightness of light that reflected on the photodiode in the auto light sensor unit is the same as voltage that set by software in CPU If operate position lamp and headlamp switch manually again the lamps turn on off according to switch ope...

Page 417: ...01 3 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 3650 01 BTRA 4 AUTO TRANSMISSION GENERAL 1 SPECIFICATIONS 1 Model Part Numbers and Applications 2 Model Specifications ...

Page 418: ...01 4 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION 3 Clutch Pack Details 4 Model Part Numbers and Applications E23 Gasoline Engine ...

Page 419: ...01 5 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 E32 Gasoline Engine ...

Page 420: ...01 6 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION 662LA Diesel Engine ...

Page 421: ...01 7 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 422: ...e of throttle opening engine speed vehicle speed transmission fluid temperature gear selector position and mode selector inputs and in some applications a Kickdown Switch to control all shift feel and shift schedule aspects The TCM drives a single proportional solenoid multi plexed to three regulator valves to control all shift feel aspects The output pressure of this solenoid is con trolled as a ...

Page 423: ...ferred through the transmission in Neutral But the final drive is not locked by the parking pawl so thewheels are free to rotate D Overdrive range is used for all normal driving conditions 4th gear overdrive gear reduces the fuel consumption and the engine noise Engine braking is applied with reduced throttle First to second 1 2 first to third 1 3 second to third 2 3 second to fourth 2 4 third to ...

Page 424: ...cur to maximize fuel economy When POWER mode is se lected upshifts will occur to give maximum performance and the POWER mode indicator light is switched ON When WINTER mode is selected starting in second gear is facilitated the WINTER mode indicator light is switched ON and the POWER mode indicator light is switched OFF 3 Indicator Light The indicator light is located on the instrument panel Auto ...

Page 425: ...ins seven electromagnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn ON and OFF the two regulator valves that control the shift feel The seventh solenoid is the proportional or Variable Pressure Solenoid VPS which works with the two regu lator valves to control shift feel 1 Transmission Con...

Page 426: ...es the engine torque output adjusts the variable pressure solenoid ramp pressure then executes the shift The TCM continuously monitors every input and output circuit for short or open circuits and operating range When a failure or abnormal operation is detected the TCM records the condition code in the diagnostics memory and implements a Limp Home Mode LHM The actual limp home mode used depends up...

Page 427: ... shaft speed signal to the Engine Control Module ECM The information is then transferred to the TCM via the CAN Transmission Fluid Temperature The transmission fluid temperature sensor is a thermistor located in the solenoid wiring loom within the valve body of the transmission This sensor is a typical Negative Temperature Coefficient NTC resistor with low temperatures producing a high resistance ...

Page 428: ... throttle voltage is 0 2 V to 1 0 V Wide open throttle voltage is 3 V to 4 5 V These measurements are taken between pins 1 and 3 of the TPS connentor Maintaining good shift feel through the transmission life span is dependant on having an accurate measure of the engine throttle position To achieve this the TCU continu ously monitors the maximum and minimum throttle potentiometer voltages and if a ...

Page 429: ...smission case The gear position sensor is a multi function switch providing three functions Inhibit starting of the vehicle when the shift lever is in a position other than Park or Neutral Illuminate the reverse lamps when Reverse is se lected Indicate to the TCM which lever position has been selected by way of a varying resistance Readings for Resistance Shift Lever Positions Ω ...

Page 430: ...g harness or computer interface Battery voltage monitoring input The battery voltage monitoring input is connected to the positive side of the battery This signal is taken from the main supply to the TCM If the battery voltage at the TCM falls below 11 3 V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may ...

Page 431: ... sequencing S3 switches the clutch regulator valve OFF or ON S4 switches the front band regula tor valve OFF or ON S5 also provides the signal pressure for the converter clutch regulator valve Solenoid 5 S5 is a variable pressure solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pres sures ...

Page 432: ...01 18 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION Solenoid Operation during Gearshifts ...

Page 433: ...acent to each solenoid on the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power ON or OFF Normally open NO solenoid POWER ON Line 500 port is closed The output port is open to exhaust at the solenoid valve POWER OFF The exhaust port is closed The output port is open to line 500 ...

Page 434: ...urrent decreases output S5 pressure Decreasing current increases output S5 pressure Line 500 pressure approximately 440 to 560 kPa is the reference pressure for the VPS and the VPS output pressure is always below line 500 pressure When the VPS is at standby that is no gearshift is taking place the VPS current is set to 200 mA giving maximum output pressure Under steady state conditions the band an...

Page 435: ... stored faults runtime parameters are then available The stored trouble codes can also be cleared by scan tool The K line can be used for vehicle coding at the manufacturer s plant or in the workshop This allows for one TCM design to be used over different vehicle mod els The particular code is sent to the microprocessor via the K line and this results in the software selecting the correct shift a...

Page 436: ...ators OFF and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is completed by simultaneously switching the regulators OFF switching the shift valves and at the same time causing the VPS to return to stand by pressure The primary regulator ...

Page 437: ...01 23 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 1 HYDRAULIC CONTROL CIRCUIT ...

Page 438: ...nto the PRND fluid circuits 1 2 shift valve The 1 2 shift valve is a two position valve that must be switched to the 2 3 and 4 position in order to get any forward gear other than first gear It is used for all 1 2 and 2 1 gearshifts The switching of this valve is achieved by using S1 and or S2 During a 1 2 gearshift drive oil from the manual valve passes through to the second gear circuit During a...

Page 439: ...ieved by S1 which is located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve Exhausts the front band release B1R circuit thereby allowing the application of the front band B1 Connects the inner apply area of the front servo B1AI to the Band Apply Feed BAF circuit thus allowing greater apply forces to the front band Exhausts the Overrun Clutch OC circuit which allows the C4...

Page 440: ...shift Solenoid supply pressure regulator valve The solenoid supply pressure regulator valve supplies a constant pressure to all solenoids S1 to S7 Line pressure is used as the feeding oil to this regulator and the output is termed line 500 Line pressure control valve Line pressure is controlled by S6 which acts as the line pressure control valve When S6 pressure is applied to the end of the Primar...

Page 441: ...CAF pres sure of 2 25 times the S5 signal pressure when S3 is ON When S3 is OFF the output pressure is 2 25 times the line 500 pressure Band apply feed regulator valve The band apply feed regulator valve is a fixed ratio 1 4 1 valve It provides a regulated pressure to the front servo and controls the change rate of the front band B1 state to give the desired shift quality Second gear oil supplied ...

Page 442: ... following conditions are satisfied In P or N vehicle speed 3 km h In R vehicle speed 10 km h Engine speed 1600 rpm Throttle position 12 Under these conditions the TCM switches solenoids S1 and S2 to OFF The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston ...

Page 443: ...ft feel because all shifting pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slip page This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and S6 ...

Page 444: ...converter clutch The switching of this valve is governed by the signal pressure from S7 When the valve is in the OFF or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the ON or applied position r...

Page 445: ...t servo It permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the need to force the oil back from the front servo through the valve body and through the 3 4 shift valve The spring positions the valve to prevent oil entering the release area of the servo until the B1R circuit oil pressure reaches approximately 100 k...

Page 446: ...ption of the operation of the Power Train System is detailed below First gear is engaged by applying the C2 clutch and locking the 1 2 One Way Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3...

Page 447: ...01 33 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 ...

Page 448: ...of the damper and piston assembly en ables the torque converter to lock up under favorable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and vehicle speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted...

Page 449: ...verse sun gear This only occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 and Drive 3 to prevent objectionable free wheel coasting 3 Bands The transmission utilizes two bands the B1 band sometimes known as the 2 4 band and the B2 band sometimes known as the low reverse band The B1 band is a flexible band w...

Page 450: ...y The one way clutch is engaged only in Drive 1 This 3 4 OWC is located between the C4 and the C2 clutch assemblies This allows the C2 clutch to drive the forward sun gear in first second and third gears but unlocks in fourth gear and during overrun The B2 band is a solid band which is engaged by the rear servo piston B2 is activated in Park Reverse Neutral and Manual 1 When activated B2 prevents ...

Page 451: ...pound gear set 6 Parking mechanism When Park is selected the manual lever extends the park rod rearwards to engage the parking pawl The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a return spring holds the parking pawl clear of the output shaft preventing accidental engagement of Park ...

Page 452: ...s are listed below Power Flow Neutral and Park Power Flow Reverse Power Flow Manual 1 Power Flow Drive 1 Power Flow Drive 2 Power Flow Drive 3 Power Flow Drive 3 Lock Up Power Flow Drive 4 Overdrive Power Flow Drive 4 Lock Up The following table details the engaged elements versus the gear selected for all transmission selections ...

Page 453: ...01 39 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 1 PARK AND NEUTRAL ...

Page 454: ... ring gear Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pump pressure is applied to the Primary Regulator Valve PRV and to the solenoid supply pressure regulator valve The converter oil cooler and lubrication circuits are charged from the primary regulator valve The line 500 circuit is charged by th...

Page 455: ...01 41 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 2 REVERSE ...

Page 456: ...the same direction The internal ring being splined to the output shaft drives it in an anti clockwise or reverse direction Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched OFF Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear servo piston for B2 band ...

Page 457: ...01 43 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 3 MANUAL 1 ...

Page 458: ...lockwise The long pinion rotating about its axis drives the internal ring gear and the output shaft in a clockwise or forward direction The C4 clutch provides engine braking through the 3 4 OWC on overrun Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are switched ON The 1 2 2 3 and 3 4 shift valves are held in their first...

Page 459: ...01 45 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 4 DRIVE 1 ...

Page 460: ... the long pinion clockwise The 1 2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction There is no engine braking on overrun Control To maintain this arrangement in the steady state solenoids and valves are activated as follows Solenoids S1 and S2 are s...

Page 461: ...01 47 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 5 DRIVE 2 AND MANUAL 2 ...

Page 462: ...s and valves are activated as follows Solenoid S1 is switched OFF S2 is switched ON Drive line pressure oil from the manual valve en gages the C2 clutch When S1 switches OFF S1 oil pressure which is derived from line 500 pressure moves the 3 4 shift valve to the left At the same time S1 oil is directed to the 1 2 shift valve which moves the valve to the second gear position 2nd oil line pressure f...

Page 463: ...01 49 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 6 DRIVE 3 AND MANUAL 3 ...

Page 464: ...ar position by S1 S2 oil pressure 2nd oil line pressure from the 1 2 shift valve is directed to the band apply feed regulator valve and to the 2 3 shift valve The band apply feed regulator valve supplies 2nd oil regulated to line pressure multiplied by the valve ratio to the Band Apply Feed BAF circuit Band apply feed oil is directed to The outer apply area of the front servo The 1 2 shift valve t...

Page 465: ...01 51 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 ...

Page 466: ...01 52 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION 7 DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP ...

Page 467: ...erter clutch circuit activated by solenoid S7 When S7 is switched ON S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the convert...

Page 468: ...01 54 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION 8 DRIVE 4 OVERDRIVE ...

Page 469: ...by line 500 pressure on the small end of the valve With S2 switched OFF the 2 3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve The 1 2 shift valve is held in the fourth gear position by S2 oil pressure 2nd oil line pressure from the 1 2 shift valve is directed to the band apply feed regulator valve and to the 2 3 shift valve The band apply feed r...

Page 470: ...01 56 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION ...

Page 471: ...01 57 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 9 DRIVE 4 LOCK UP ...

Page 472: ...s switched ON S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position Regulated apply feed oil drived from drive oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch Converter clutch release oil is e...

Page 473: ...01 59 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 9 SCHEMATIC AND ROUTING DIAGRAMS TCM WIRING DIAGRAM gasoline engine 1 OF 2 ...

Page 474: ...01 60 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION TCM WIRING DIAGRAM GASOLINE ENGINE 2 OF 2 ...

Page 475: ...01 61 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 TCM WIRING DIAGRAM DIESEL ENGINE 1 OF 2 ...

Page 476: ...01 62 REXTON 2004 04 3650 01 BATRA 4 SPEED AUTO TRANSMISSION TCM WIRING DIAGRAM DIESEL ENGINE 2 OF 2 ...

Page 477: ...01 63 BATRA 4 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 CONNECTOR END VIEW ...

Page 478: ...02 3 DC 5 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 1 SPECIFICATIONS 3650 01 DC 5 SPEED AUTOMATIC TRANSMISSION GENERAL ...

Page 479: ...02 4 REXTON 2004 04 3650 01 DC 5 SPEED AUTO TRANSMISSION ...

Page 480: ...e hydraulically actuated multiple disc clutches and two mechanical one way clutches This electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting in relation to engine power This function improves shifting quality significantly And the driver can select S Standard mode or W Winter mode according to the driving conditions This automatic transmission...

Page 481: ...02 6 REXTON 2004 04 3650 01 DC 5 SPEED AUTO TRANSMISSION 2 CHARACTERISTICS ...

Page 482: ...converter 2 Oil pump 3 Input shaft 4 Disc brake B1 5 Disc clutch C1 6 Disc clutch C2 Disc brake B3 Disc clutch C3 Disc brake b2 Output shaft Parking lock gear Intermediate shaft 7 8 9 10 11 12 13 Freewheel F2 14 Center planetary gear set 15 Electric control unit valve body 16 Freewheel F1 17 Stator shaft 18 Converter lockup clutch ...

Page 483: ... A T equipped vehicle specifications 1 Gear ratio 1st gear 3 595 2nd gear 2 185 3rd gear 1 405 4th gear 1 000 5th gear 0 831 Axle ratio 3 31 Rev 1st gear 3 167 Rev 2nd gear 1 926 WINTER Mode Standard Mode 2 Allowable shifting point Upshift Downshift Lockup sleeping Unlock open FAST OFF Dynamic shift range 3 Pedal value Vehicle speed kph ...

Page 484: ...ns at 4th gear other than 4 4 shift when slowly releasing the accelerator pedal the transmission is shifted to 5th gear Dynamic shift range 5 When operating the accelerator pedal the 4 3 shift is completed by kick down signal after completion of 4 4 shift When promptly operating the accelerator pedal the 4 3 shift is done in shaded arae ...

Page 485: ...02 10 REXTON 2004 04 3650 01 DC 5 SPEED AUTO TRANSMISSION 5 POWER FLOW Sectional View Shifting elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun B1 C1 C2 B3C3 B2 ...

Page 486: ... B2 Planetary gear carrier Clockwise rotation with reduced speed Center ring gear Clockwise rotation Center sun gear Locked by B2 Rotation with reduced speed Output shaft Clockwise rotation Torque converter lockup clutch Engine speed Transmission input shaft 1st gear ratio 2nd gear ratio 16 A B C D E 3rd gear ratio F Mounting elements H Rear planetary gear set L Stator M Center planetary gear set ...

Page 487: ...r planetary gear set P Impeller T Turbine wheel V Front planetary gear set Input shaft Clockwise rotation Sun gear and planetary gear carrier Clockwise rotation by C1 activation Rear ring gear Clockwise rotation Rear sun gear Locked by F2 and B2 Planetary gear carrier Rotation with reduced speed Center ring gear Clockwise rotation Sun gear Locked by B2 Planetary gear carrier Rotation with reduced ...

Page 488: ... Rear planetary gear set Stator Center planetary gear set D H L M Impeller Turbine wheel Front planetary gear set P T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Center ring gear Clockwise rotation by clutch 2 activation direct connection Center sun gear Locked by B2 Planetary gear carrier Clockwise rotation with reduced speed Output shaft Clockwise rotation ...

Page 489: ...t ring gear Clockwise rotation Center ring gear and rear planetary gear carrier Clockwise rotation Front sun gear and planetary gear carrier Clockwise rotation direct connection Rear ring gear Clockwise rotation Rear sun gear Rotation by ring gear and planetary gear carrier direct connection Center ring gear Clockwise rotation by C3 activation Planetary gear carrier Clockwise rotation by center su...

Page 490: ...ockwise rotation Front sun gear Locked Planetary gear carrier Rotation with reduced speed Rear planetary gear carrier Clockwise rotation with reduced speed Center ring gear and rear planetary gear carrier Clockwise rotation by clutch C2 activation Rear sun gear Clockwise rotation because rear planetary gear carrier rotates faster than rear ring gear increasedspeed Center sun gear Clockwise rotatio...

Page 491: ...e wheel Front planetary gear set M P T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Front sun gear Locked by one way clutch F1 Front planetary gear carrier Clockwise rotation reduced speed Rear planetary gear ring gear Clockwise rotation Rear planetary gear carrier Locked by B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center ring gear Locke...

Page 492: ...Turbine wheel Front planetary gear set M P T V Input shaft Clockwise rotation Front ring gear Clockwise rotation Front planetary gear carrier Clockwise rotation by clutch C1 activation direct connection Rear ring gear Clockwise rotation Rear planetary gear carrier and center ring gear Locked by brake B3 Rear sun gear and center sun gear Counterclockwise rotation increased speed Center planetary ge...

Page 493: ...02 18 REXTON 2004 04 3650 01 DC 5 SPEED AUTO TRANSMISSION 6 CIRCUIT DIAGRAM 1 Starter Selector Lever CAN Communication ...

Page 494: ...02 19 DC 5 SPEED AUTO TRANSMISSION REXTON 2004 04 3650 01 2 Solenoid Oil Temperature Sensor RPM Sensor N2 N3 ...

Page 495: ...03 3 MANUAL TRANSMISSION REXTON 2004 04 3170 01 3170 01 MTMANUAL TRANSMISSION 1 SPECIFICATIONS 1 General Specifications 2 Tightening Torque GENERAL ...

Page 496: ...o prevents the break and wear 1 2 4WD 2WD Gasoline Features All gears use the helical type and high strength materials 1 The helical type gear prevents the axial gear missing and provides less noise The synchronizing devices are installed in 1 2 3 4 5 R gears To prevent the double engagement the independent interlock devices are installed 2 TSM54 52 transmission uses the inertia lock type key to m...

Page 497: ...03 5 MANUAL TRANSMISSION REXTON 2004 04 3170 01 2 SYSTEM COMPONENTS 1 Gear Combinations 2 Shift Fork and Rail Combinations ...

Page 498: ...03 6 REXTON 2004 04 3170 01 MANUAL TRANSMISSION 3 Sectional View ...

Page 499: ... R 32 Single synchro sleeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Needle bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 C...

Page 500: ...03 8 REXTON 2004 04 3170 01 MANUAL TRANSMISSION IDI Engine equipped vehicle 4WD ...

Page 501: ...2 Single synchro sleeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th ...

Page 502: ...03 10 REXTON 2004 04 3170 01 MANUAL TRANSMISSION IDI Engine equipped vehicle 2WD ...

Page 503: ...ro sleeve 33 Retainer ring 34 Adaptor dowel pin 35 Reverse idler shaft 36 Dowel pin 37 Bearing 38 Reverse idler gear 39 Reverse idler spacer 40 Reverse idler bracket 41 Retainer ring 42 Reverse lock nut 43 Transmission adaptor 44 Input shaft spacer 45 Counter spacer 46 Reverse needle bearing 47 Reverse gear 48 Reverse clutch gear 49 Reverse counter gear 50 Synchro hub 51 Counter 5th gear 52 5th ne...

Page 504: ...ackup lamp switch tightening torque 30 40 Nm Shift rail 3 4th Interlock bolt tightening torque 40 50 Nm 1 2 3 4 5 6 7 8 9 Shift lever 10 Interlock plate 11 Shift rail 1 2nd 12 Shift rug 1 2nd 13 Shift fork 3 4th 14 Input shaft 15 Counter shaft 16 Reverse idler assembly 17 Spring pin 6 x 25 18 Spring pin 6 x 25 Backup lamp switch Concentric slave cylinder adaptor Apply Loctite 243 Apply Loctite DRI...

Page 505: ...ck plate Reverse lock bolt Stopper plate Air vent tightening torque 30 40 Nm Lock washer TGS bushing Outer spring pin TGS pin Lock bolt tightening torque 17 26 Nm 1 2 3 4 5 6 7 8 9 10 Offset lever Offset lever bushing Rolling plunger Return spring Spring plug tightening torque 30 35 Nm Apply Long term grease MoS2 when installing the offset lever 11 12 13 14 15 A ...

Page 506: ...03 14 REXTON 2004 04 3170 01 MANUAL TRANSMISSION 6 Power Flows 1st gear Counter shaft 2nd gear ...

Page 507: ...03 15 MANUAL TRANSMISSION REXTON 2004 04 3170 01 7 Power Flows Cont d 3rd gear 4th gear ...

Page 508: ...03 16 REXTON 2004 04 3170 01 MANUAL TRANSMISSION 8 Power Flows Cont d 5th gear Reverse gear ...

Page 509: ...170 01 3 SHIFTING MECHANISM 1 Interlock System Interlock system prevents the gears from meshing over two sets 2 Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward ...

Page 510: ...ng Plunger To make the next shift easier the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected 1 Offset lever 2 Shift lever 3 Shift shaft 4 Rolling plunger rolling plunger return spring and ball ...

Page 511: ...Also it prevent the selected gear from getting out of its meshed position 1 Gear pump out locking device It prevents the shift lever is beyond the correct shift position while shifting 2 Guiding a control direction and preventing an over stroke 3 4 Backup Lamp Switch It is normal open type switch Its circuit is formed when the reverse gear is selected Sealant Loctite DRI LOC 200 Tightening torque ...

Page 512: ...2 shift added synchronizer inner cone and middle cone Single cone type Double cone type 1 2 shift 3 4 shift 5 R shift 1 2 shift 3 4 shift 5 R shift 1 Synchronizer sleeve 2 Synchronizer hub 3 Synchronizer ring 4 Synchronizer key 5 Synchronizer key locking ring 6 Synchronizer inner cone 7 Synchronizer middle cone Be careful not to mix up the 1 2 shift synchronizer sleeve with 3 4 or 5 R shift synchr...

Page 513: ...vehicle is rolling the transmission main shaft is turning and the clutch gear is spinning Even though the clutch is disengaged the clutch gear continues to spin until friction slows it down or stops it Thus when the driver shifts into another gear he is trying to mesh gears that may be moving at different speeds By using synchronizers the possibility of broken or damaged teeth is reduced and shift...

Page 514: ...everse gear with cut out area Needle bearing for 5th gear 3 4 7 End Play of Taper Roller Bearing 1 Taper roller bearing for input shaft 2 Taper roller bearing for counter shaft A End play A 0 85 2 28 mm B End play B 1 17 1 97 mm Use the following spacers to adjust the end play A or B between input shaft and counter shaft Specified range of end play 0 05 0 1 mm For input shaft 0 75 1 45 mm 15 space...

Page 515: ...n each shaft and gear assembly receives the axial force and this force acts as a resistance to rotating gears 9 Lubrication Transmission oil SAE 75W 90 Initial installation for taper roller bearing and needle roller bearing lubrication for shift rail MoS2 Grease Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm ...

Page 516: ...03 24 REXTON 2004 04 3170 01 MANUAL TRANSMISSION 1 Oil filler plug 2 Air vent Sealant on oil drain screw during installation Loctite DRI LOC 200 Tightening torque 40 50 Nm 4WD 2WD ...

Page 517: ...03 25 MANUAL TRANSMISSION REXTON 2004 04 3170 01 4 CIRCUIT DIAGRAM BACKUP LAMP ...

Page 518: ...04 3 CLUTCH REXTON 2004 04 0000 00 1 SPECIFICATIONS 2 TIGHTENING TORQUE 0000 00 CLUTCH GENERAL ...

Page 519: ... driven elements are held in contact by spring pressure This pressure is exerted by a diaphragm spring in the clutch pressure plate assembly 3 Operating Elements The clutch release system consists of the clutch pedal are clutch release cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by using release lever and re...

Page 520: ...04 5 CLUTCH REXTON 2004 04 0000 00 B Concentric slave cylinder pipe A Adaptor D Clutch assembly C Concentric slave cylinder 2 COMPONENTS AND LOCATIONS ...

Page 521: ...04 6 REXTON 2004 04 0000 00 CLUTCH CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY 1 Transmission housing 2 Clutch disc assembly 3 Clutch disc cover assembly 4 Bolt 5 Washer 6 Bolt ...

Page 522: ...CH COMPONENTS 1 Clutch pedal 2 Clutch master cylinder 3 Clutch hydraulic line 4 Clutch fluid chamber 5 Clutch fluid hose 6 Adaptor 7 Clutch housing 8 Concentric slave cylinder cover 9 Concentric slave cylinder 10 Clutch cover 11 Clutch disc ...

Page 523: ...05 3 PART TIME TRANSFER CASE REXTON 2004 04 3240 01 1 SPECIFICATIONS 3240 01 PART TIME TRANSFER CASE GENERAL ...

Page 524: ...n when selecting 4WD HIGH and 2 48 of reduction gear ratio when selecting 4WD LOW The silent chain in transfer case transfers the output power to front wheels Simple operation of switches on instrument panel allows to shift to 2H 4H and 4L easily while driving The warning lamp alarms the driver when the system is defective 2 OPERATION OVERVIEW AND OPERATION PROCESS ...

Page 525: ...ME TRANSFER CASE REXTON 2004 04 3240 01 3 SECTIONAL DIAGRAM Planetary gear set Oil pump Magnetic clutch Shift motor Front output shaft 4H 4L Shift fork Reduction shift fork Input shaft 2H 4H Shift fork lockup fork ...

Page 526: ...es the hall effect It generates 0V and 5V of square type digital wave according to the rotation of the wheel with teeth of transfer case rear output shaft The speed signal from rear propeller shaft is entered into control unit When the control unit determines that 4WD HIGH operation is available electric current flows into the clutch coil The coil magnetized by this electric current pull in the lo...

Page 527: ...N 2004 04 3240 01 4 SYSTEM LAYOUT 4WD switch Automatic transmission Input Output Indicators Input shaft Planetary gear set 2H 4H shift fork Front output shaft Shift motor Shift position Speed sensor 4L Oil pump Magnet clutch Drive gear ...

Page 528: ...riving For the shifting between 4WD HIGH and 4WD LOW stop the vehicle 1 2H 4H Change the 4WD switch in instrument panel from 2H to 4H This shift is available during driving 4WD HIGH indicator in meter cluster comes on When the system is defective 4WD CHECK warning lamp comes on 2 4H 2H Change the 4WD switch in instrument panel from 4H to 2H This shift is available during driving 4WD HIGH indicator...

Page 529: ...lutch pedal is depressed manual transmission or selector lever is selected to N position automatic transmission TCCU must recognize the clutch pedal signal or N signal Change the 4WD switch in instrument panel from 4H to 4L 4WD LOW warning lamp in meter cluster flickers during this process then goes out when the shift is completed 4WD CHECK warning lamp comes on when the system is defective 4WD LO...

Page 530: ...05 10 REXTON 2004 04 3240 01 PART TIME TRANSFER CASE 2 Transfer Case Block Diagram ...

Page 531: ...05 11 PART TIME TRANSFER CASE REXTON 2004 04 3240 01 ...

Page 532: ...itch position and the shift motor position code does not match when the IG power is turned ON the shift is controlled to move in the direction of the selector switch position The shift operation is controlled to move only toward selector switch position if the selector switch position is not met with shift motor position code when the ignition switch is turned to ON Function of indicating lamp dur...

Page 533: ...regardless of ignition power If there are not operating signals from position sensor the shifting failure due to timeout occurs This failure appears when the shifting time between 2H and 4H and between 4H and 4L is delayed over 5 seconds compared to normal shift Once the shifting time exceeds the specified time TCCU cannot properly supply the voltage to shift motor and is operated in compensation ...

Page 534: ...05 14 REXTON 2004 04 3240 01 PART TIME TRANSFER CASE 6 POWER FLOW POWER FLOW ...

Page 535: ...05 15 PART TIME TRANSFER CASE REXTON 2004 04 3240 01 1 2H MODE REAR WHEEL DRIVE Power Flow Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 536: ...05 16 REXTON 2004 04 3240 01 PART TIME TRANSFER CASE 2 4H MODE 4WD DRIVE HIGH SPEED Power Flow Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 537: ...05 17 PART TIME TRANSFER CASE REXTON 2004 04 3240 01 3 4L MODE 4WD DRIVE LOW SPEED Power Flow Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 538: ...05 18 REXTON 2004 04 3240 01 PART TIME TRANSFER CASE 7 CIRCUIT DIAGRAM DI 5 SPEED A T ...

Page 539: ...06 3 TOD REXTON 2004 04 3240 01 1 SPECIFICATIONS 3240 01 TORQUE ON DEMAND TOD GENERAL ...

Page 540: ...le and rear axle the TPS signals from engine and the operating signals from ABS control unit via CAN Based on these data TOD control unit controls the electro magnetic clutch to distribute the 3 97 44 56 of driving force to front wheels and rear wheels The conventional system uses FR driving theoretically the 100 of driving force is transferred to rear wheels on normal paved road When the system d...

Page 541: ...ain safe ground grab capacity against side winds and rain Distribution ratio 15 for front wheels and 85 for rear wheels 2 When turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capac...

Page 542: ...to apply maximum torque into front and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set Releasing the 4L Mode When selecting 4H mode 4L drive mode is released and 4H mode is resumed 4H switch Self return type 4L switch Push lock type 3 4WD Operation Overview To make the mode shift easier stop ...

Page 543: ...06 7 TOD REXTON 2004 04 3240 01 2 POWER FLOW System Layout 4WD Switch Instrument Panel Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output ...

Page 544: ...06 8 REXTON 2004 04 3240 01 TOD 4H Mode 4WD Drive High Speed Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 545: ...06 9 TOD REXTON 2004 04 3240 01 4L Mode 4WD Drive Low Speed Front Axle Front Wheel Transmission Rear Axle Rear Wheel ...

Page 546: ...06 10 REXTON 2004 04 3240 01 TOD 3 CIRCUIT DIAGRAM ...

Page 547: ...07 3 AXLE REXTON 2004 04 4120 01 1 SPECIFICATIONS 4120 01 AXLE GENERAL 2 REAR AXLE 1 FRONT AXLE ...

Page 548: ...08 3 PROPELLER SHAFT REXTON 2004 04 3310 01 3310 01 PROPELLER SHAFT GENERAL 1 SPECIFICATION ...

Page 549: ... rounded steel pipe to have the strong resisting force against the torsion and bending Both ends of propeller shaft are connected to the spider and the center of propeller shaft is connected to the spline to accommodate the changes of the height and length The rubber bushing that covers the intermediate bearing keeps the balance of rear propeller shaft and absorbs its vibration OVERVIEW AND OPERAT...

Page 550: ...01 2 COMPONENT LOCATOR Cross Sectional View Flange yoke Journal bearing cap Spider journal Slip yoke assembly Grease nipple Dust cap Oil seal 1 2 3 4 5 6 7 Split washer Slip tube shaft Tube Tube yoke Flange yoke Center bearing 8 9 10 11 12 13 ...

Page 551: ...08 6 REXTON 2004 04 3310 01 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLE Bolt Front propeller shaft Bolt Transfer case 1 2 3 4 Bolt Rear propeller shaft Bolt 5 6 7 ...

Page 552: ...09 3 STEERING SYSTEM REXTON 2004 04 4620 01 1 SPECIFICATIONS 4620 01 STEERING SYSTEM GENERAL ...

Page 553: ...09 4 REXTON 2004 04 4620 01 STEERING SYSTEM 2 TIGHTENING TORQUE ...

Page 554: ...r absorb the impact The steering column has the ignition switch and lock cylinder If removing the ignition key with the ignition switch in LOCK position the lock cylinder locks the steering wheel 1 Steering Wheel The vibration damper absorbs the vibration from vehicle to minimize it 2 Column and Shaft Assembly 3 Lower Shaft This minimizes the torque changes due to angular speed changes OVERVIEW AN...

Page 555: ...09 6 REXTON 2004 04 4620 01 STEERING SYSTEM 2 COMPONENT LOCATOR 1 System Layout Installation point A Steering components 1 ...

Page 556: ... REXTON 2004 04 4620 01 2 Sctional View of Steering Gear Box Tie rod end Tie rod Bellows Rack housing Feed tube Mounting bracket 1 2 3 4 5 6 Tie rod end Tie rod Cylinder tube Valve assembly ECPS solenoid valve 7 8 9 10 11 ...

Page 557: ...09 8 REXTON 2004 04 4620 01 STEERING SYSTEM 3 Steering Column Assembly 1 Steering wheel 2 Column shaft assembly 3 Lower shaft assembly 4 Steering gear assembly 5 ECPS solenoid valve ...

Page 558: ...10 3 SUSPENSION REXTON 2004 04 4411 01 1 SPECIFICATIONS 4411 01 SUSPENSION GENERAL 1 FRONT SUSPENSION SPECIFICATIONS ...

Page 559: ...10 4 REXTON 2004 04 4411 01 SUSPENSION 2 REAR SUSPENSION SPECIFICATIONS ...

Page 560: ...S by providing appropriate steerability to driver according to the changes of vehicle speed gives steering stability In other words the steering wheel gets lighter by adjusting steerability in stop or low speed and provides steering stability by adjusting steering wheel to become heavier in high speed SSPS system applied in Rexton is ECPS Electronic Control Power Steering Hydraulic Pressure Reacti...

Page 561: ...11 4 REXTON 2004 04 4620 01 ECPS 2 INPUT OUTPUT OF ECPS CONTROL UNIT ...

Page 562: ...action device by moving the spool valve according to the changes of solenoid valve Reaction device This device increases the steerability effect by binding the input shaft with supplied hydraulic pressure from PCV Solenoid valve This valve determines the valve spool position in PCV with the electric current supplied from ECPS control unit ...

Page 563: ...avy steerability with low current as the vehicle speed increases And it provides light steerability with high current as the vehicle speed decreases During parking and low speed driving 1 During parking and driving in low speed the control unit supplies approx 1 A of electric current to solenoid valve Then the spool located in PCV compresses the upper spring and elevates upward and the working pre...

Page 564: ... weak electric current to solenoid valve Then the spool located PCV moves from top to bottom and the working pressure A port from oil pump is applied to reaction plunger C port through B port As a result the pressing force from reaction plunger against input shaft is increased and the steerability becomes heavier ...

Page 565: ...11 8 REXTON 2004 04 4620 01 ECPS 5 CIRCUIT DIAGRAM ...

Page 566: ...ke mechanical type master cylinder booster pedal and supply lines pipes and hoses 2 Hydraulic Brake This system uses the leverage effect and Pascal s principle When depressing the brake pedal the pedal pressure is increased by booster and is delivered to master cylinder to generate hydraulic pressure The hydraulic pressure generated by the master cylinder is delivered to the brake caliper through ...

Page 567: ...ered to the rear wheels 5 Brake Booster The brake booster is a power assist device for brake system It relieves the pedal depressing force by using the pressure difference between the vacuum pressure generated by vacuum pump in intake manifold and the atmospheric pressure 1 Pressure distribution at working When depressing the brake pedal the push rod 1 in booster pushes the poppet 2 and valve plun...

Page 568: ...ns back to the original position by return spring 4 and the air valve 6 closes At this time the vacuum valve 9 opens and the pressure difference between chamber A and B in power cylinder is eliminated Accordingly the power piston 5 returns back to original position by the reaction of master cylinder 10 and the diaphragm return spring 8 ...

Page 569: ...YSTEM LAYOUT HYDRAULIC LINE With ABS Without ABS 1 Brake booster 2 Brake reservoir and master cylinder 3 ABS control unit 4 Front disc brake and caliper 5 Load conscious reducing valve LCRV 6 3 way connector 7 Rear drum disc and wheel cylinder caliper ...

Page 570: ...12 7 BRAKE SYSTEM REXTON 2004 04 4850 01 3 BRAKE SYSTEM COMPONENTS LOCATOR ...

Page 571: ...7 Master cylinder assembly 8 Brake reservoir assembly 9 Brake reservoir cap 10 Brake reservoir 11 Grommet seal 12 Master cylinder 13 Stop lamp switch 14 Pedal assembly 15 Pedal bracket assembly 16 Brake pedal pad 17 Brake pedal 18 Brake pedal spring 19 Rear brake hose 20 Clip 21 Front brake hose 22 Union bolt 23 Plane washer ...

Page 572: ...umber fastener for is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque values must be used when installing fasteners that require them If the above procedures are not followed parts or system damage could result Use only DOT 3 equivalent hydraulic brake fluid T...

Page 573: ...for opens or shorts do not ground or apply voltage to any circuit unless instructed to do so by the diagnostic procedure Test circuits only with a high impedance multi meter Never remove or apply power to any control module with the ignition switch in the ON position Always turn the ignition to the OFF position before removing or connecting battery cables fuses or connectors 3 General service prec...

Page 574: ...Stopping Distance The stopping distance depends on the vehicle weight and initial speed when braking starts This also applies for vehicle with ABS where ABS always tries to set an optimum brake force on each wheel As great forces are exerted between the tires and the carriageway when braking even with ABS the wheels may scream and rubber is left on the road With an ABS skid mark one may be able to...

Page 575: ...liding friction with the result that the stopping distance is increased This loss of friction is termed slip in specialist literature The brake slip is the difference between the vehicle speed and the wheel circumference speed If the wheel locks the slip is greatest that is 100 If the wheel is running freely and unbraked the slip is the lowest equal to 0 Slip can be calculated from the vehicle spe...

Page 576: ...teral force e g when driving round curves If we drive into a curve too fast and the tire requires 100 transmissibility as cornering force the tire cannot transmit any additional brake force In spite of the ABS the car is carried out of the curve The relationship between brake force B and cornering force S is shown very clearly in the Kamm circle If we put a vehicle wheel in this circle the relatio...

Page 577: ...ble range then begins in which no further modulation is possible The ABS controls the regulation of the brake pressure so that the brake force only becomes great enough for a sufficient proportion of cornering force to remain With ABS we remain in the Kamm circle as long as the car is driving sensibly We will leave driving physics with these statements and turn to the braking systems with and with...

Page 578: ...imple approximation Simplified ABS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previously determined reference speed In that case the control cycle is ...

Page 579: ...ydraulic modulator and HECU Hydraulic and Electronic Control Unit compared to existing ABS And the wheel speed sensor uses different method to detect wheel speed The basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking has not been changed ...

Page 580: ...13 11 ABS REXTON 2004 04 4892 01 1 SYSTEM FUSE The ABS TCS system fuse and SB2 is located at the fuse box in engine compartment 2 INDICATORS The ABS and TCS indicators are in instrument cluster ...

Page 581: ...13 12 REXTON 2004 04 4892 01 ABS 3 INPUT AND OUTPUT DIAGRAM OF ABS UNIT ...

Page 582: ...sensor method The front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 583: ...ating To prevent the rear wheels locking when braking HECU receives the signals from wheel speed sensors and brake signals to calculate the reduced braking speed and controls the brake pressure to rear wheels by operating the intake 2 channel valve to provide the optimal braking conditions ...

Page 584: ... outlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increases At this moment the outlet valve is closed This...

Page 585: ...ses again The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises Pressure Increases in the Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber...

Page 586: ...ribution In an unloading car condition the brake efficiency is comparable to the conventional system but for a fully loaden vehicle the efficiency of the EBD system is higher due to the better use of rear axle braking capability 2 The Benefits of EBD Elimination of conventional proportioning valve EBD utilizes the existing rear axle wheel speed sensor to monitor rear wheel slip Based on many varia...

Page 587: ...ting is critical during component service Disconnect the EBCM connector with the ignition OFF Do not hang the suspension components from the wheel speed sensor cables The cables may be damaged Do not use petroleum based fluids in the master cylinder Do not use any containers previously used for petroleum based fluids Petroleum causes swelling and distortion of the rubber components in the hydrauli...

Page 588: ...13 19 ABS REXTON 2004 04 4892 01 6 ELECTRIC CIRCUIT DIAGRAM 1 ABS Wheel Speed Sensor Stop Lamp Switch Diagnostic Connector Warning Lamp ABS ESP ...

Page 589: ...14 3 ESP REXTON 2004 04 4892 01 1 SPECIFICATIONSS 4892 01 ESP Electronic Stability Program SYSTEM GENERAL ...

Page 590: ...ring The yaw rate sensor lateral sensor and longitudinal sensor in the sensor cluster and the steering wheel angle sensor under the steering column detect the spin present at any wheels during over steering under steering or cornering The ESP ECU controls against over steering or under steering during cornering by controlling the vehicle stability using the input values from the sensors and applyi...

Page 591: ...14 5 ESP REXTON 2004 04 4892 01 2 COMPONENTS LOCATION ...

Page 592: ...14 6 REXTON 2004 04 4892 01 ESP 3 INPUT AND OUTPUT DIAGRAM OF ESP UNIT ...

Page 593: ...rake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function When various systems operate simultaneously under a certain situation there may be vehicle control problems due to internal malfunction of a system or simultaneous operations In order to compensate to this problem the ESP system sets the priority among systems The system operates in the o...

Page 594: ...s the tires can easily lose the traction and the vehicle tends to slip outward when the curve angle gets bigger and the speed increases The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs reversely against the vehicle cornering direction during understeering with the yaw rate sensor and the lateral sensor Then the ESP syste...

Page 595: ... tires lose traction and the vehicle speed increases The ESP system recognizes the directional angle with the steering wheel angle sensor and senses the slipping route that occurs towards the vehicle cornering direction during oversteering with the yaw rate sensor and the lateral sensor Then the ESP system applies the brake at the front outer wheel to compensate the yaw moment value In this way th...

Page 596: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 597: ...14 11 ESP REXTON 2004 04 4892 01 5 HYDRAULIC DIAGRAM OF ESP ...

Page 598: ...t panel flickers and beep comes on every 0 1 seconds The ESP operation shows that the vehicle stability is extremely unstable and it is used to warn the driver The ESP system is just a supplementary system for the vehicle motion and it cannot control the vehicle when it exceeds the physical limits Do not solely rely on the system but be advised to drive the vehicle safely When the ESP system activ...

Page 599: ...ON In this position the separation valve and the inlet valve are open normal open the electrically operated shuttle valve and the outlet valve are closed When the brake is applied under these conditions the brake fluid will be sent to each wheel via the separation valve and inlet valve 1 ...

Page 600: ...essure decreases just before the wheel speed drops and the wheels The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump operates to allow fast oil drainage ...

Page 601: ...d outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens ...

Page 602: ...The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Page 603: ...safety supplementary system that builds high braking force during initial braking according to pressure value of the brake pressure sensor and the pressure changes of the pressure sensor intervals When the system is designed to apply high braking force when brake pedal is depressed softly by an elderly or physically weak driver the vehicle will make abrupt stopping under normal braking situation d...

Page 604: ...14 18 REXTON 2004 04 4892 01 ESP ...

Page 605: ...ng on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the wheel starts...

Page 606: ...14 20 REXTON 2004 04 4892 01 ESP 7 ELECTRIC CIRCUIT DIAGRAM Wheel Speed Sensor Stop Lamp Switch Diagnostic Connector Warning Lamp ABS ESP ...

Page 607: ...14 21 ESP REXTON 2004 04 4892 01 Brake Pressure Sensor Steering Wheel Angle Sensor Sensor Cluster ESP OFF Switch ...

Page 608: ...01 3 AIR CONDITIONER REXTON 2004 04 6820 11 1 SPECIFICATIONS 6820 11 AIR CONDITIONER GENERAL ...

Page 609: ...isture from the atmosphere When installing refrigerant components to a vehicle do not remove the caps unseal until just before connecting the components Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system Only use the specified lubricant from a sealed container Immediately reseal containers of lubricant Without proper sealing lubricant will ...

Page 610: ...ventilated area to prevent suffocation Do not introduce compressed air to any refrigerant container or refrigerant component 3 Handling O Ring Even though O rings may look identical it is extremely important that only recommended service replacement air conditioning O rings be used or excessive leakage of the refrigerant may occur Always O ring and installation area should be kept clean Any foreig...

Page 611: ...d the polyalkalene glycol PAG compressor oil They will also affect the pressure temperature relationship reduce efficient operation and can possibly cause interior corrosion and abnormal wear of moving parts Observe the following practices to ensure chemical stability in the system Wipe away dirt or oil at and near any connection before opening that connection This will reduce the chance of dirt e...

Page 612: ...01 7 AIR CONDITIONER REXTON 2004 04 6820 11 1 OVERVIEW Cooling Fan Engine ECU Cooler Outlet Cooler Outlet Cooler Outlet Cooler Outlet Outlet Port Inlet Port OVERVIEW AND OPERATION PROCESS ...

Page 613: ...01 8 REXTON 2004 04 6820 11 AIR CONDITIONER Refrigerant Flows 2 AIR FLOWS ...

Page 614: ... Locator 1 Condenser 2 Receiver drier 3 Compressor 4 Air conditioner Heater Blower module 5 Defrost nozzle 6 Front air conditioner controller 7 Rear duct 8 Rear cooler assembly 9 Rear cooler duct 10 Suction rear pipe line 11 Liquid rear pipe line 12 Rear cooler controller ...

Page 615: ...her because the stator can pull the center piece tightly 3 V 5 Compressor General Vehicle using the V5 compressor may have differences between installations in the mounting brackets the drive system the pulleys the connections and the system capacities Basic overhaul procedures are similar between the compressors used on different vehicles When serving the compressor keep dirt and foreign material...

Page 616: ...The angle of the wobble plate is controlled by a force balance of seven pistons A slight elevation of the crankcase suction pressure differential creates total force on the piston resulting in a movement about the wobble plate pivot pin that reduces the plate angle The compressor has a unique lubrication system The crankcase suction bleed is routed through the rotating wobble plate for lubrication...

Page 617: ...nsferred to the cooler surface or the core which cools the air As the process of heat transfer from the air the evaporator core surface is taking place any moisture humidity in the air condenses on the outside surface of the evaporator core and is drained off as water 9 Pressure Relief Valve The compressor is equipped with a pressure relies valve which is placed in the system as a safety factor Un...

Page 618: ...ay Relay This relay controls the current to A C system and instantly delays the A C operation during starting the engine Mode control Turn on to operate the blower motor at four speeds Turn OFF to stop the blower Operates completely independently from both the mode control knob and temperature control knob Changes the fan speed in any mode and at any speed Blower control ...

Page 619: ...01 14 REXTON 2004 04 6820 11 AIR CONDITIONER 5 CIRCUIT DIAGRAM 1 Automatic Air Conditioner Air Mix Motor Sensors Sun Ambient Interior Coolant Temperature ...

Page 620: ...01 15 AIR CONDITIONER REXTON 2004 04 6820 11 Motor Mode Interior Ambient ...

Page 621: ...01 16 REXTON 2004 04 6820 11 AIR CONDITIONER 2 Manual Air Conditioner Power A C Compressor Motors Mode Interior Ambient Air Mix ...

Page 622: ...01 17 AIR CONDITIONER REXTON 2004 04 6820 11 Blower Motor Front Rear ...

Page 623: ...02 3 FATC REXTON 2004 04 6810 30 1 SPECIFICATIONS 6810 30 FULL AUTOMATIC TEMPERATURE CONTROL FATC GENERAL ...

Page 624: ...scent Display panel provides system operating information for the driver With the system in OFF mode the outside temperature is displayed continuously The driver may display the current temperature setting by selecting any mode except OFF or adjusting the temperature control Also it provides the convenience to the driver by indicating the ambient air temperature If it occurs the faulty in the FATC...

Page 625: ...02 5 FATC REXTON 2004 04 6810 30 2 FATC INPUT OUTPUT ROUTING DIAGRAM ...

Page 626: ... ON To enter the diagnostic mode perform the following procedure Turn the ignition switch ON Set the temperature control to 26 C 79 F Within 3 seconds push the AUTO and the OFF switches simultaneously more than three times Check the diagnostic trouble code DTC in the temperature indicator screen blinks If there are no diagnostic trouble code DTC set the screen will display 00 When the FATC control...

Page 627: ...conditioner not only performs self diagnosis but also has safety function against faults If there is open or short in the sensors or potentiometer of temperature door some specific value will be substitute Error Fault Safety Function Inside air Sensor Error 25 C will be substituted as temperature of inside of vehicle Ambient Temperature Sensor Error 25 C will be substituted as ambient temperature ...

Page 628: ... the mode door the I A door air mix door and blower motor etc 2 Airflow Control For setting at Full AUTO it is possible to control the blower motor operation both manually and automatically in order to adjust the airflow according to the set temperature 3 Manual Control When you push the blower switch you can control the blower motor manually and it increases or decreases each step by moving the s...

Page 629: ... to the cold air give a negative effect to the heating performance Therefore vent step is fixed 1st on blower AUTO step until the coolant sensor detects above 20 C and also the blower step increases gradually according to going up the coolant temperature When the coolant temperature goes up above 40 C the heating operation stops 6 Vent Rate Control By Cooling Operation When the air inside the reso...

Page 630: ...s 0 5 C increment in the set temperature digit by ambient temperature sensor When you push the AMB key it indicates the ambient temperature for 5 seconds and return back the set temperature If you push the AMB key again during indicating in 5 seconds it returns back The ambient temperature sensor is securing in the front of radiator and may be influenced easily to the heat of the engine compartmen...

Page 631: ...the vent inlet according to the vehicle speed in order to prevent the exhaust gas of the preceding vehicle from flowing inside with the vehicle stopping or driving at low speed The operation and control condition is following as When the vent inlet mode is AUTO and the A C ON When the vehicle keeps to drive at below 10 km h for 10 seconds and changes the REC mode at stop If 10 minutes passes after...

Page 632: ...recirculation air max blower speed air mix door close and for HI A C OFF floor vent mode ambient mode air mix door open 15 Wiper Calibration Control It is possible to generate the frost on the windshield in the rainy days At this time FATC controller allows the mode to change the AUTO defroster mode Operation Condition When the passenger operates the wiper on AUTO mode the system controls the wipe...

Page 633: ...mperature sensor and measure the resistance between the sensor connectors approximately 2 2 KW at 25 C Replace the inside air temperature sensor when the resistance value is excessive low or high Replace the inside air temperature sensor for outside the specified value and check the followings for within the specified value Turn the ignition ON Measure the voltage between A13 and A16 terminal of t...

Page 634: ...olant Temperature Sensor Coolant temperature sensor is a thermistor that decreases its resistance when temperature up and increases when temperature down It detects coolant temperature to operate the blower speed at low when the coolant temperature is less than 50 C 122 F If the coolant temperature sensor is open or short 100 C 212 F will be substitute Measure the resistance between the sensor con...

Page 635: ... followings Remove the sensor to place it under the sun light and measure the current between the connector terminals Place the sun sensor under the shadow place and measure the current between the connector terminals If the value is lower than the value under the sun light it s normal Turn the ignition ON Measure the voltage between A13 and B10 terminal of the AUTO temperature control connector S...

Page 636: ...inal to No 4 of the motor connector and connecting No 5 and No 7 to terminal sequentially using 12 V power When the vent inlet mode displayed in the AUTO temperature control is different from the actual mode check the followings Turn the ignition ON Measure the voltage between positive terminal and negative terminal of the Mtr Act AI connector Specified value 12 V Measure the voltage between P1 P2...

Page 637: ...eplace the Mtr Act AI Check the motor operation connecting the terminal to the Mtr Act mode and each terminal P1 P5 to terminal sequentially using 12 V power 1 2 3 4 5 6 9 Power Transistor Power transistor controls the blower airflow and it receives the airflow control signal from the AUTO temperature control in order to for blower motor to shift the speed without step by adding the current to the...

Page 638: ...ck the followings Turn the ignition ON Measure the voltage within P1 P2 terminals specified value 12 V and a b specified value 5 If the value is outside the specified value check the open or short circuit If the wiring is normal replace the Mtr Act Temp If the terminal connects to P1 and P2 of the Mtr Act Temp alternately the output by the each mode is following 1 2 3 4 5 AMD Mode Bc Resistance Co...

Page 639: ...03 3 HEATER REXTON 2004 04 6810 18 1 SPECIFICATIONS 6810 18 HEATER AND VENTILATION SYSTEM GENERAL ...

Page 640: ... inlet for further processing and distribution The heater core transfers the heat from the engine coolant to the inlet air The heater system consists of the heater hoses heater module blower motor and control system The control switch assembly installed on the instrument panel regulates the temperature amount and flow direction of the air 1 OVERVIEW OVERVIEW AND OPERATION PROCESS ...

Page 641: ...ct LH 4 Main defroster nozzle 5 Side defroster duct RH 6 Side defroster joint 7 Console front ventilation duct 8 A C controller 9 Console middle ventilation duct 10 Console foot duct 11 Console rear ventilation duct 12 Rear cooler duct 13 Rear cooler assembly 14 Rear cooler controller 2 COMPONENTS LOCATOR ...

Page 642: ...03 6 REXTON 2004 04 6810 18 HEATER 3 AIR FLOWS THROUGH VENTS MODE SWITCH OPERATIONS ...

Page 643: ...r source door motor Outside air intake and recirculation mode 3 Air Mix Door Motor Controls the outlet air temperature by opening an closing the damper Air Flows Location Function Controls the air outlet directions Vent Bi level Foot Foot Def or Def mode Location Located at the upper right side of blower housing Function Located at the bottom of heater housing Location Function ...

Page 644: ...03 8 REXTON 2004 04 6810 18 HEATER ...

Page 645: ...03 9 HEATER REXTON 2004 04 6810 18 5 CIRCUIT DIAGRAM Blower Motor ...

Page 646: ...04 3 FFH SYSTEM REXTON 2004 04 6910 03 6910 03 FFH SYSTEM GENERAL 1 SPECIFICATIONS ...

Page 647: ...mperature intake air temperature FFH system consists of independent fuel lines and fuel pump coolant circuit and coolant circulation pump electrical glow plug and exhaust system It also provides the diagnostic function FFH system cannot be operated or stopped by driver s intention The FFH system is automatically operated by the coolant temperature and the ambient temperature The FFH system operate...

Page 648: ...d bracket assembly 3 FFH No 1 bracket assembly 4 FFH No 2 bracket assembly 5 Silencer and pipe assembly 6 Fuel pump assembly 7 Fuel pump bracket assembly 8 Temperature sensor assembly 9 Intake hose 10 Fuel pipe No 1 11 Fuel pipe No 2 12 Pump outlet hose 13 FFH inlet outlet hose assembly ...

Page 649: ...04 6 REXTON 2004 04 6910 03 FFH SYSTEM Exploded View ...

Page 650: ... 14 Flame sensor 15 Bush for flame sensor graphite 16 Control and overheating sensor with cable 17 O ring 18 Surface sensor with cable 19 Controller connector 14 pin connector waterproof 20 Pressure spring for surface sensor 21 Pressure spring for control and overheating sensor 22 O ring 23 Coolant hose inlet 24 Coolant hose outlet 25 Tooth ring 2x 26 Cable harness cover 27 Rubber seal 28 O ring 2...

Page 651: ...fference when operating FFH FFH is operated again For example if the initial operating temperature was 4 C the ambient temperature at repeat operation should be below 1 C and the coolant temperature should be below 75 C Initial Repeat FFH Operations According to the Changes of Coolant Temperature Above graph shows the FFH control process while the FFH is operating The control element is coolant as...

Page 652: ...ure from radiation and direct contact Before working on the coolant circuit disconnect the negative battery cable and wait until all components have cooled down completely When installing the heater and the water pump note the direction of flow of the coolant circuit Fill the heater and water hoses with coolant before connecting to the coolant circuit When routing the coolant pipes observe a suffi...

Page 653: ...onnected to the water pump the fuel circulation pump and the ambient temperature sensor switch that provides important signals for the initial and repeat operations For diagnosis remove the FFH system connector and install the scan tool Currently the K Line that is connected to the diagnostic connector is not available ...

Page 654: ...er is overheated lack of water poorly vented cooling circuit the overheating sensor triggers the fuel supply is interrupted and the heater is switched off The heater is switched off if the lower or upper voltage limit is reached The fuel pump does not start when the glow plug is defect or electrical lead to the dosing pump is interrupted The fan motor speed is monitored continuously If the fan mot...

Page 655: ...04 12 REXTON 2004 04 6910 03 FFH SYSTEM 7 Characteristic Curve of Water Pump 12 V 8 Function Diagram ...

Page 656: ...04 13 FFH SYSTEM REXTON 2004 04 6910 03 9 Sectional Drawing according to the Temperatures ...

Page 657: ... rings are installed between jacket cover and two coolant hoses The coolant hoses should be connected to right side 1 Jacket 2 Jacket cover 3 Cable harness cover The Control and overheating sensor and cable harness make up one component 1 Control and overheating sensor 2 Pressure spring Check the control and overheating sensor with a digital multimeter If the resistance according to the changes of...

Page 658: ...ponent 1 Surface sensor 2 Pressure spring Check the surface sensor with a digital multimeter If the resistance of flame sensor is out of specified values the flame sensor is defective Specifiedl value 4 Controller The surface heater and cable harness make up one component 1 Controller 2 Jacket 3 Combustion chamber housing 4 Screw ...

Page 659: ...housing 7 Flame sensor 1 Glow plug 2 Combustion chamber with flame pipe 1 Jacket 2 Combustion chamber 3 Combustion chamber housing 4 Insulation washer 5 Seal combustion chamber combustion air fan 6 Seal combustion chamber heat exchanger 1 Flame sensor 2 Graphite bush 3 Bush ...

Page 660: ... sensor Check the surface sensor with a digital multimeter If the resistance of flame sensor is out of specified values the flame sensor is defective Specifiedl value 8 Combustion air fan 1 Combustion chamber 2 O ring 3 Rubber seal 4 Combustion air fan ...

Page 661: ...1 Combustion chamber 2 Heat exchanger 3 Jacket 4 O ring 5 Seal combustion chamber heat exchanger 1 Jacket 2 Heat exchanger 3 Combustion chamber with flame tube 4 Seal combustion chamber heat exchanger 5 O ring for heat exchanger 1 Heat exchanger 2 Jacket 3 Stopper 4 Groove bottom of heat exchanger ...

Page 662: ... the heating effect by increasing the temperature of flowing air into the passengers room This system needs higher electric power than conventional system due to it heats the ceramic in PTC with the electricity And the alternator capacity has been largely increased 12 V 75 A 90 A to 12 V 140 A Non operational Condition During engine cranking Too low battery voltage below 11 V During preheating pro...

Page 663: ...05 4 REXTON 2004 04 6810 21 PTC SYSTEM PTC operating relay Engine ECU PTC unit 2 COMPONENTS LOCATOR ...

Page 664: ...05 5 PTC SYSTEM REXTON 2004 04 6810 21 3 COMPONENTS CHARACTERISTICS OF PTC ...

Page 665: ...05 6 REXTON 2004 04 6810 21 PTC SYSTEM 4 CIRCUIT DIAGRAM ...

Page 666: ...ntal impact against a solid concrete wall at over 25 km h or near frontal impact within 30 degrees from the center of the vehicle at both corners The air bag can inflate when Underbody impact from the road surface impact against the curb at a very high speed dropping impact onto the road surface with a large angle The air bag does not inflate when Rollover side impact or rear impact The air bag se...

Page 667: ...e defective Have the air bag system checked immediately by Ssangyong Dealer or Ssangyong Authorized Service Operation The seat belt and air the bags are the most effective when you are sitting well back and upright in the seat A child restraint system must not be placed on the front seat The infant or child can be severely injured by an air bag inflation in case of an accident Do not carry your ch...

Page 668: ...itation continues When any repairs are needed for the steering wheel or when an accident occured without the air bag deployment have the air bag system checked by Ssangyong Dealer or Ssangyong Authorized Service Operation The windshield glass may be broken when the passenger s air bag is deployed The air bag deployment can cause abrasion on your hands and face 4 Airbag Module Discard Airbag module...

Page 669: ...13 mm 0 5 inch of the insulation from the end of the wires leading to the contact coil Use two additional wires each at least 10 meters 33 feet long to reach from the deployment battery to the airbag module Strip 13 mm 0 5 inch of the insulation from the ends of these two additional wires Twist the two wires together at one end Place the twisted ends of the two wires near the deployment battery Do...

Page 670: ...ing Observe following precaution if the airbag is deployed Deploy the airbags only in an evacuated area Service mechanics should be at least 10 meters 33 feet Do not connect the voltage source until after having completed all other preparations for the deployment of the airbags Allow a deployed airbag module or pretensioner to cool for at least 30 minutes before handling If the deployment fails di...

Page 671: ... also known as baking soda Therefore it is unlikely that sodium hydroxide will be present after deployment Wear gloves and eye protection during the disposal procedure After deployment the metal surfaces of the airbag module will be hot In order to avoid the risk of an injury or a fire do not place the deployed airbag module near any flammable objects and allow the airbag module to cool for 30 min...

Page 672: ... possibly cause a serious injury Only trained personnel at franchised SsangYong dealers and authorized SsangYong service dealerships may service the airbag system Never attempt to disassemble repair or reuse the following component Airbag modules Clock spring Sensing and diagnostic module Wiring harness When repairing SIR component follow the service notice Inspect any SIR part before it is instal...

Page 673: ...IR System SIR system consists of 6 Loop DAB PAB 2 SAB 2 PRET fully and the block diagram is as shown below On this diagram SDM sends the output signal to DAB PAB 2 SAB 2 PRET and receives the input of side impact from 2 SIS Side Impact Seasor Abbreviation ...

Page 674: ...ody structure and the airbag The airbag reaction is absorbed generally to the steering wheel or instrument panel The module cover must be considered in a viewpoint of protection between exterior internal units and cushion Also the module cover should be designed not to cause any personal injury for deployment 3 Inflator The inflator is a type of the direct gas generated device The inflator with in...

Page 675: ...f the steering wheel The passenger airbag module is installed in the instrument panel at passenger side The driver and passenger side airbag is inside each seat Do not disassemble the airbag module because unintentional deployment of the airbags resulting from any damage or interference of the module can cause injury ...

Page 676: ...te the AIRBAG indicator to alert the driver to any fault Power supply function Provide a reserve power source to deploy the airbags and pretensioners if an accident has disabled the normal power source 6 Acceleromenter sensor The accelerometer sensor electronically represents the acceleration or deceleration of the vehicle during a frontal impact In this electronic representation the electrical si...

Page 677: ...river airbag module and the horn switch Turning the steering wheel more than three and onequarter turns may damage the clock spring The contact coil should never be disassembled and must be replaced if the airbag have been deployed Turn the label of the clock spring clockwise to lock and turn the label of the clock spring counterclockwise approximately 2 9 0 2 turns to the neutral positions with t...

Page 678: ...operation of the AIRBAG indicator and sensing and diagnostic module SDM The SDM performs a turn on test when the ignition is turned ON The SDM flashes the AIRBAG indicator seven tomes by supplying an intermittent ground to the indicator lamp circuit After flashing seven times the AIRBAG indicator will turn off if no more malfunctions have been detected ...

Page 679: ...rting bars are located in following locations Driver airbag module connector Passenger airbag module connector Driver and passenger side airbag module connector SDM wiring harness connector Contact coil connector to airbag wiring harness The shorting bar is only a backup safety device Always disable the supplemental restraints system SRS before beginning any service procedure 12 Belt Pretensioner ...

Page 680: ...07 3 SEAT REXTON 2004 04 8510 31 1 SPECIFICATIONS 8510 31 SEAT GENERAL ...

Page 681: ...07 4 REXTON 2004 04 8510 31 SEAT 1 SEAT ARRANGEMNT OVERVIEW AND OPERATION PROCESS ...

Page 682: ...NO DATA ...

Page 683: ...NO DATA ...

Page 684: ...NO DATA ...

Page 685: ...11 3 BODY REPAIR REXTON 2004 04 5110 01 5110 01 BODY REPAIR GENERAL 1 VEHICLE DIMENSION ...

Page 686: ...11 4 REXTON 2004 04 5110 01 BODY REPAIR 2 SPECIFICATIONS ...

Page 687: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 688: ......

Page 689: ...0 3 ECU GASOLINE REXTON 2004 04 0000 00 0000 00 ECU GASOLINE DIAGNOSIS 1 ECU GASOLINE ...

Page 690: ...0 4 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 691: ...0 5 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 692: ...0 6 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 693: ...0 7 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 694: ...0 8 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 695: ...0 9 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 696: ...0 10 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 697: ...0 11 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 698: ...0 12 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 699: ...0 13 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 700: ...0 14 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 701: ...0 15 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 702: ...0 16 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 703: ...0 17 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 704: ...0 18 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 705: ...0 19 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 706: ...0 20 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 707: ...0 21 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 708: ...0 22 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 709: ...0 23 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 710: ...0 24 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 711: ...0 25 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 712: ...0 26 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 713: ...0 27 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 714: ...0 28 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 715: ...0 29 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 716: ...0 30 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 717: ...0 31 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 718: ...0 32 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 719: ...0 33 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 720: ...0 34 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 721: ...0 35 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 722: ...0 36 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 723: ...0 37 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 724: ...0 38 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 725: ...0 39 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 726: ...0 40 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 727: ...0 41 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 728: ...0 42 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 729: ...0 43 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 730: ...0 44 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 731: ...0 45 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 732: ...0 46 REXTON 2004 04 0000 00 ECU GASOLINE ...

Page 733: ...0 47 ECU GASOLINE REXTON 2004 04 0000 00 ...

Page 734: ......

Page 735: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 736: ......

Page 737: ...0 3 ECU DIESEL REXTON 2004 04 0000 00 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL ...

Page 738: ...0 4 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 739: ...0 5 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 740: ...0 6 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 741: ...0 7 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 742: ...0 8 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 743: ...0 9 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 744: ...0 10 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 745: ...0 11 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 746: ...0 12 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 747: ...0 13 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 748: ...0 14 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 749: ...0 15 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 750: ...0 16 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 751: ...0 17 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 752: ...0 18 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 753: ...0 19 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 754: ...0 20 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 755: ...0 21 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 756: ...0 22 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 757: ...0 23 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 758: ...0 24 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 759: ...0 25 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 760: ...0 26 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 761: ...0 27 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 762: ...0 28 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 763: ...0 29 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 764: ...0 30 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 765: ...0 31 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 766: ...0 32 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 767: ...0 33 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 768: ...0 34 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 769: ...0 35 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 770: ...0 36 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 771: ...0 37 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 772: ...0 38 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 773: ...0 39 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 774: ...0 40 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 775: ...0 41 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 776: ...0 42 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 777: ...0 43 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 778: ...0 44 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 779: ...0 45 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 780: ...0 46 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 781: ...0 47 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 782: ...0 48 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 783: ...0 49 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 784: ...0 50 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 785: ...0 51 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 786: ...0 52 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 787: ...0 53 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 788: ...0 54 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 789: ...0 55 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 790: ...0 56 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 791: ...0 57 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 792: ...0 58 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 793: ...0 59 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 794: ...0 60 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 795: ...0 61 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 796: ...0 62 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 797: ...0 63 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 798: ...0 64 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 799: ...0 65 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 800: ...0 66 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 801: ...0 67 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 802: ...0 68 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 803: ...0 69 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 804: ...0 70 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 805: ...0 71 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 806: ...0 72 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 807: ...0 73 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 808: ...0 74 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 809: ...0 75 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 810: ...0 76 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 811: ...0 77 ECU DIESEL REXTON 2004 04 0000 00 ...

Page 812: ...0 78 REXTON 2004 04 0000 00 ECU DIESEL ...

Page 813: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 814: ......

Page 815: ...0 3 BRAKE REXTON 2004 04 0000 00 0000 00 BRAKE DIAGNOSIS 1 BRAKE ...

Page 816: ...0 4 REXTON 2004 04 0000 00 BRAKE ...

Page 817: ...0 5 BRAKE REXTON 2004 04 0000 00 ...

Page 818: ...0 6 REXTON 2004 04 0000 00 BRAKE ...

Page 819: ...0 7 BRAKE REXTON 2004 04 0000 00 ...

Page 820: ...0 8 REXTON 2004 04 0000 00 BRAKE ...

Page 821: ...0 9 BRAKE REXTON 2004 04 0000 00 ...

Page 822: ...0 10 REXTON 2004 04 0000 00 BRAKE ...

Page 823: ...0 11 BRAKE REXTON 2004 04 0000 00 ...

Page 824: ...0 12 REXTON 2004 04 0000 00 BRAKE ...

Page 825: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 826: ......

Page 827: ...0 3 AIR BAG REXTON 2004 04 0000 00 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG ...

Page 828: ...0 4 REXTON 2004 04 0000 00 AIR BAG ...

Page 829: ...0 5 AIR BAG REXTON 2004 04 0000 00 ...

Page 830: ...0 6 REXTON 2004 04 0000 00 AIR BAG ...

Page 831: ...0 7 AIR BAG REXTON 2004 04 0000 00 ...

Page 832: ...0 8 REXTON 2004 04 0000 00 AIR BAG ...

Page 833: ...0 9 AIR BAG REXTON 2004 04 0000 00 ...

Page 834: ...0 10 REXTON 2004 04 0000 00 AIR BAG ...

Page 835: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 836: ......

Page 837: ...0 3 CCCS REXTON 2004 04 0000 00 0000 00 CCCS DIAGNOSIS 1 CCCS ...

Page 838: ...0 4 REXTON 2004 04 0000 00 CCCS ...

Page 839: ...0 5 CCCS REXTON 2004 04 0000 00 ...

Page 840: ...0 6 REXTON 2004 04 0000 00 CCCS ...

Page 841: ...0 7 CCCS REXTON 2004 04 0000 00 ...

Page 842: ...0 8 REXTON 2004 04 0000 00 CCCS ...

Page 843: ...0 9 CCCS REXTON 2004 04 0000 00 ...

Page 844: ...0 10 REXTON 2004 04 0000 00 CCCS ...

Page 845: ...0 11 CCCS REXTON 2004 04 0000 00 ...

Page 846: ...0 12 REXTON 2004 04 0000 00 CCCS ...

Page 847: ...0 13 CCCS REXTON 2004 04 0000 00 ...

Page 848: ...0 14 REXTON 2004 04 0000 00 CCCS ...

Page 849: ...0 15 CCCS REXTON 2004 04 0000 00 ...

Page 850: ...0 16 REXTON 2004 04 0000 00 CCCS ...

Page 851: ...0 17 CCCS REXTON 2004 04 0000 00 ...

Page 852: ...0 18 REXTON 2004 04 0000 00 CCCS ...

Page 853: ...0 19 CCCS REXTON 2004 04 0000 00 ...

Page 854: ...0 20 REXTON 2004 04 0000 00 CCCS ...

Page 855: ...0 21 CCCS REXTON 2004 04 0000 00 ...

Page 856: ...0 22 REXTON 2004 04 0000 00 CCCS ...

Page 857: ...0 23 CCCS REXTON 2004 04 0000 00 ...

Page 858: ...0 24 REXTON 2004 04 0000 00 CCCS ...

Page 859: ...0 25 CCCS REXTON 2004 04 0000 00 ...

Page 860: ...0 26 REXTON 2004 04 0000 00 CCCS ...

Page 861: ...0 27 CCCS REXTON 2004 04 0000 00 ...

Page 862: ......

Page 863: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 864: ......

Page 865: ...IAGNOSIS 1 SELF DIAGNOSIS 1 Starting Self Diagnosis Turn the ignition switch to ON position and press OFF switch for more than 5 seconds within 10 seconds Check LED segments on the vacuum fluorescent display VFD Press OFF switch more than 5 seconds ...

Page 866: ...he digit 2 is displayed implying step 2 on the display window and the trouble diagnosis for sensors is executed If no failure exists 20 is displayed If any failure exists the appropriate trouble code is displayed as below Trouble Code The symbol in front of step number 2 means a short circuit of the blinking sensor Short circuit in the ambient air temperature sensor ...

Page 867: ...EMP dial to the right to set in the trouble diagnosis step 3 Indication of Step 2 Starting self diagnosis Sensor failure code blinking 30 no failure Trouble Code 4 Set in Trouble Diagnosis Step 4 In this step check the position of actuator door check the fan speed and check the compressor operation Slightly turn the TEMP switch in step 3 until 41 is displayed on the display window When pressing DE...

Page 868: ...mbient air temperature Interior air temperature Intake air temperature Press Press Press 6 Set in Trouble Diagnosis Step 6 In this step the temperature can be compensated within the range of 3 C to 3 C in the control process according to the temperature to air conditioner controller The step 6 initiates when slightly rotating the fan speed switch other than TEMP switch in step 5 Step 6 Min tempera...

Page 869: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 870: ......

Page 871: ...0 3 FFH REXTON 2004 04 0000 00 0000 00 FFH DIAGNOSIS 1 FFH ...

Page 872: ...0 4 REXTON 2004 04 0000 00 FFH ...

Page 873: ...0 5 FFH REXTON 2004 04 0000 00 ...

Page 874: ...0 6 REXTON 2004 04 0000 00 FFH ...

Page 875: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 876: ......

Page 877: ...0 3 P TRUNK REXTON 2004 04 0000 00 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK ...

Page 878: ...0 4 REXTON 2004 04 0000 00 P TRUNK ...

Page 879: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 880: ......

Page 881: ...ted terminals in the ICM box 1 2 It rains but the system does not work in the AUTO position Symptom 2 Check whether the variable resistance knob on the multifunction wiper switch is set in FAST The FAST is the highest stage of the sensitivity and very sensitive to small amount of rain drops Therefore change the knob to the low sensitivity The wiper operates 3 or 4 times at high speed abruptly Symp...

Page 882: ...he wiper operates at high speed when grounding pin 1 and pin 2 The wiper responses are too fast or slow Symptom 6 Check whether the variable resistance knob on the wiper switch is set in FAST or SLOW Notify that the customer can select the sensitivity by selecting the variable resistance value And select a proper stage ...

Page 883: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 884: ......

Page 885: ...0 3 STICS REXTON 2004 04 0000 00 0000 00 STICS DIAGNOSIS 1 STICS ...

Page 886: ...0 4 REXTON 2004 04 0000 00 STICS ...

Page 887: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 888: ......

Page 889: ...0 3 TC REXTON 2004 04 0000 00 0000 00 TC DIAGNOSIS 1 TC ...

Page 890: ...0 4 REXTON 2004 04 0000 00 TC ...

Page 891: ...0 5 TC REXTON 2004 04 0000 00 ...

Page 892: ...0 6 REXTON 2004 04 0000 00 TC ...

Page 893: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 894: ......

Page 895: ...0 3 TCU REXTON 2004 04 0000 00 DIAGNOSIS 0000 00 TCU 1 TCU ...

Page 896: ...0 4 REXTON 2004 04 0000 00 TCU ...

Page 897: ...0 5 TCU REXTON 2004 04 0000 00 ...

Page 898: ...0 6 REXTON 2004 04 0000 00 TCU ...

Page 899: ...0 7 TCU REXTON 2004 04 0000 00 ...

Page 900: ...0 8 REXTON 2004 04 0000 00 TCU ...

Page 901: ...0 9 TCU REXTON 2004 04 0000 00 ...

Page 902: ...0 10 REXTON 2004 04 0000 00 TCU ...

Page 903: ...0 11 TCU REXTON 2004 04 0000 00 ...

Page 904: ...0 12 REXTON 2004 04 0000 00 TCU ...

Page 905: ...0 13 TCU REXTON 2004 04 0000 00 ...

Page 906: ...0 14 REXTON 2004 04 0000 00 TCU ...

Page 907: ...0 15 TCU REXTON 2004 04 0000 00 ...

Page 908: ...0 16 REXTON 2004 04 0000 00 TCU ...

Page 909: ...0 17 TCU REXTON 2004 04 0000 00 ...

Page 910: ...0 18 REXTON 2004 04 0000 00 TCU ...

Page 911: ...0 19 TCU REXTON 2004 04 0000 00 ...

Page 912: ......

Page 913: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 914: ......

Page 915: ...0 3 TGS LEVER REXTON 2004 04 0000 00 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER ...

Page 916: ...0 4 REXTON 2004 04 0000 00 TGS LEVER ...

Page 917: ...0 5 TGS LEVER REXTON 2004 04 0000 00 ...

Page 918: ...0 6 REXTON 2004 04 0000 00 TGS LEVER ...

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