SSANGYONG REXTON 2007.09 Manual Download Page 359 | Manualshive

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06-4

REXTON 2007.09

3240-01

TORQUE ON DEMAND

1. OVERVIEW

TOD system means the full time 4WD system and the registered trade mark of Borg Warner.
TOD is an abbreviation of Torque On Demand.

TOD (Torque On Demand) system, which is superior than existing Full Time 4WD, checks the
road surface and vehicle conditions via various sensors and, subsequently, according to the
situations and conditions, distributes the most optimal driving force to front wheels and rear
wheels by activating the electro-magnetic clutch located inside of TOD Transfer Case.

TOD receives the speed signals from speed sensors installed in front axle 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 detects a slip in the rear
wheels, a proper percentage of driving force is transferred to front wheels.

TOD control unit receives the wheel speed signals from the speed sensors in propeller shaft of
transfer case and engine output information from the engine control unit. TOD control unit
changes the pressure force of the electromagnetic clutch based on the analyzed data.

OVERVIEW AND OPERATION PROCESS

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Summary of Contents for REXTON 2007.09

Page 1: ...SIONS 2 SPECIFICATIONS 3 VEHICLE IDENTIFICATION 4 MAINTENANCE 5 RECOMMENDED FLUIDS AND LUBRICANTS 6 JACK UP POINTS DOTTED CIRCLES 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR 8 ELECTRIC COMPONENTS AND LAYOUT 9 TIGHTENING TORQUE OF STANDARD BOLTS 3 4 6 7 13 14 15 16 18 ...

Page 2: ......

Page 3: ...01 3 VEHICLE GENERAL undefined 0000 00 0000 00 VEHICLE GENERAL GENERAL 1 DIMENSIONS ...

Page 4: ...01 4 undefined 0000 00 VEHICLE GENERAL 2 SPECIFICATIONS Optional 2WD D27DTP Diesel 2 7 Power Up D27DT Diesel 2 7 G32D Gasoline ...

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

Page 6: ... area of cylinder block in exhaust manifold side Diesel Engine D27DTP D27DT The engine number is stamped on the lower area of cylinder block behind the Intake manifold 2 Chassis Number The chassis number is stamped on the frame behind the front right tire 3 Certification Label The certification label is located on the driver s door sill ...

Page 7: ...er severe condition Frequent stop and go traffic extended idling short driving distance below 6 km driving distance below 16 km when the outside temperature remains below freezing Driving in a hilly or mountainous terrain sandy or dusty area High load driving such as trailer towing Taxi patrol service or delivery service extended idling and excessive driving with low speed Shorten the service inte...

Page 8: ...d under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then change every 60 000 km 6 Change a...

Page 9: ...y inspected Examine threaded fasteners for looseness 7 If necessary rotate and balance wheels 8 After completion of off road operation the drive shaft boots should be inspected 9 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F...

Page 10: ... Inspect these items and their related parts If necessary correct clean replenish adjust or replace R Replace or change In order to secure engine long life and effective break in first oil factory filled would be recommended to drain with in 10 000 km 1 If vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition shorten the service interval 2...

Page 11: ...d under any of the following conditions In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hilly or moutainous terrain or When doing frequent trailer towing or Uses such as found in taxi police or delivery service 5 Inspect manual transmission fluid every 15 000 km Inspect the leak of fluid at any time occasionally then change every 60 000 km 6 Change a...

Page 12: ...f road operation the underbody of the vehicle should be throughly inspected Examine threaded fasteners for looseness 7 If necessary rotate and balance wheels 8 Inspect propeller shaft grease every 5 000 km or 3 months if the vehicle is mainly driven under severe condition In off road or dusty road or In heavy city traffic where the outside temperature regularly reaches 32 C 90 F or higher or In hi...

Page 13: ... LUBRICANTS Use only Ssangyong recommended fluids and lubricants Keep the specified levels when adding or replacing the fluids Do not mix any different types or brands of oils or fluids This may cause damages D27DTP Diesel 2 7 Power Up D27DT Diesel 2 7 G32D Gasoline ...

Page 14: ...01 14 undefined 0000 00 VEHICLE GENERAL IRS type 5 link type 6 JACK UP POINTS DOTTED CIRCLES ...

Page 15: ...ndefined 0000 00 7 PIN ARRANGEMENT OF DIAGNOSTIC CONNECTOR It is installed under the instrument panel and consists of 16 pins The REKES key coding should be performed with SCAN TOOLS Functions of Terminal Diagnostic connector ...

Page 16: ...01 16 undefined 0000 00 VEHICLE GENERAL 8 ELECTRIC COMPONENTS AND LAYOUT 1 Wiring Harness Arrangement ...

Page 17: ...01 17 VEHICLE GENERAL undefined 0000 00 2 Components Locator ...

Page 18: ...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 19: ...as during assembly to protect and lubricate the surfaces on initial operation Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure This is considered standard shop practice even if not specifically stated Whenever valve train components are removed for service they should be kept in order They should be installed in the same locations and with the ...

Page 20: ...sed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Any time the air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the en...

Page 21: ...01 5 ENGINE ASSEMBLY undefined 0000 00 2 G23D ENGINE ASSEMBLY Front View Rear View ...

Page 22: ...01 6 undefined 1113 01 ENGINE ASSEMBLY LH Side View RH Side View ...

Page 23: ...01 7 ENGINE ASSEMBLY undefined 0000 00 3 G23D ENGINE STRUCTURE Front View Side View ...

Page 24: ...ng Rod 6 Fuel Distributor 17 Crankshaft 7 Injector 18 Engine Mounting Bracket 8 Exhaust Camshaft 19 Starter 9 Intake Camshaft 20 Crankcase 10 Valve Tappet 21 Oil Pump Sprocket 11 Intake Valve 22 Oil Pan NO FUNCTION NO FUNCTION 23 Camshaft Adjuster 29 Oil Pump Drive Chain 24 Oil Filler Cap 30 Oil Strainer 25 Engine Hanger Bracket 31 Oil Pump 26 Cooling Fan and Viscous Clutch 32 Ring Gear and Flywhe...

Page 25: ...cation of the leak by the drippings on the paper Visually check around the suspected component Check around all the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solvent Clean the area well Dry the area Operate the vehicle for sev...

Page 26: ...urce the cause of the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired also Before attempting to repair a leak check for the following conditions and correct them as they may cause a leak Repairing the Leak Gaskets The fluid level pressure is too high The c...

Page 27: ...ompression pressure tester A9912 0012B 001 589 76 21 00 and install it into the spark plug hole Crank the engine approx eight revolutions by using the start motor Compare the measurements of compression pressure tester A9912 0012B 001 589 76 21 00 with the specifications Measure the compression pressure of the other cylinders in the same way If measured value is not within the specifications perfo...

Page 28: ...re LeakageTest Permissible Pressure Leakage At Whole Engine Max 25 At Valve and Cylinder Head Gasket Max 10 At Piston and Piston Ring Max 20 OT TDC 1 4 UT BDC 180 2 3 Cylinder Number Cylinder Number Cylinder Pressure Leakage Tester Bosch EFAW210A Sun CLT 228 ...

Page 29: ...ressure line and adjust the scale of tester Install the connecting hose to spark plug hole Position the piston of No 1 cylinder at TDC by rotating the crankshaft Connect the connecting hose to tester and measure the leakage volume after blowing up 5 bar of compressed air Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable Perform the p...

Page 30: ...01 14 undefined 0000 00 ENGINE ASSEMBLY 5 GENERAL DIAGNOSIS ...

Page 31: ...01 15 ENGINE ASSEMBLY undefined 1113 01 General Diagnosis Cont d ...

Page 32: ...01 16 undefined 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 33: ...01 17 ENGINE ASSEMBLY undefined 1113 01 General Diagnosis Cont d ...

Page 34: ...01 18 undefined 1113 01 ENGINE ASSEMBLY General Diagnosis Cont d ...

Page 35: ...01 19 ENGINE ASSEMBLY undefined 0000 00 6 SPECIFICATIONS 1 Engine Specifications MSE Engine Control Module 3 53D 4 Cylinder Version ...

Page 36: ...01 20 undefined 1113 01 ENGINE ASSEMBLY 2 Fastener Tightening Specifications ...

Page 37: ...01 21 ENGINE ASSEMBLY undefined 1113 01 Fastener Tightening Specifications Cont d ...

Page 38: ...01 22 undefined 1113 01 ENGINE ASSEMBLY 2 Performance Curve ...

Page 39: ...02 3 ENGINE INTAKE SYSTEM undefined 0000 00 0000 00 ENGINE INTAKE SYSTEM GENERAL 1 SPECIFICATIONS 1 Fastener Tightening Specifications ...

Page 40: ...03 3 ENGINE EXHAUST SYSTEM undefined 0000 00 2420 01 ENGINE EXHAUST SYSTEM GENERAL 1 SPECIFICATION 1 Fastener Tightening Specifications ...

Page 41: ...damage the catalytic converter Use of anything other than unleaded fuel will damage the catalyst in the catalytic converter 1 2 Catalytic Converter Structure The Catalytic converter of monolith type consists of 2 walled metal bodies which is made of Cordierite The principal element of converter consists of the materials like Alumina or oxidized Serume in order to apply to Ceramic Monolith Washer c...

Page 42: ...rmal range of temperature CO purification rate becomes the best near the temperature of 450 C and NOx does so near the temperature of 400 to 500 C Purification of Catalytic Converter Adhesion of soluble organic fraction SOF below 180 C Purification of soluble organic fraction SOF over 180 C Chemical reaction formula SOF HC O2 CO2 H2O 2CO O2 2CO2 2C2H6 7O2 4CO2 6H20 By catalytic action of two prima...

Page 43: ...actor are high EGR valve can decrease NOx 30 to 35 decrease by making temperature of combustion chamber fall by means of exhaust gas re circulation EGR valve is installed on the diesel engine of Musso Korando Istana and Rexton And micro switch is installed together to control EGR valve The setting method of micro switch is identical with the existing one ...

Page 44: ...04 3 ENGINE COOLING SYSTEM undefined 0000 00 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 45: ...04 4 undefined 0000 00 ENGINE COOLING SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 46: ...OPERATION PROCESS 1 COMPONENT LOCATOR 1 Reserver Tank 2 Deaeration Tube 3 Inlet Hose 4 Outlet Hose 5 3 way Hose 6 Clamp 7 Clamp 8 Bolt M6 2 piece 9 Radiator 10 Lower Radiator Insulator 11 Plate 12 Clip 13 Upper Radiator Insulator 14 Bracket 15 PWM Electric Fan ...

Page 47: ... correct coolant level The cooling system for this vehicle has no radiator cap or filler neck The coolant is added to the cooling system through the coolant reservoir 2 Radiator This vehicle has a lightweight tube and fin aluminum radiator Plastic tanks are mounted on the upper and the lower sides of the radiator core On vehicles equipped with automatic transaxles the transaxle fluid cooler lines ...

Page 48: ...ng of the thermostat permits enough engine coolant to enter the radiator to keep the engine within proper engine temperature operating limits The wax pellet in the thermostat is hermetically sealed in a metal case The wax element of the thermostat expands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the engine coolant temperature increases When th...

Page 49: ...ooling fan relay and a cooling fan motor relay The ECM will turn the cooling fans on at low speed when the coolant temperature reaches 95 C 203 F and at high speed when the coolant temperature reaches 105 C 221 F The ECM will change the cooling fans from high peed to low speed at 100 C 212 F and will turn the cooling fans off at 90 C 194 F A C On The ECM will turn the cooling fans on at low speed ...

Page 50: ...DULATION ELECTRIC FAN OPERATION 1 Function The PWM Pulse Width Modulation high capacity electric fan is installed instead of electric condenser fan to enhance the durability and controllability and reduce noise 2 Mounting Location PWM Fan shroud Electric fan PWM unit ...

Page 51: ...Modulation Unit It controls the time of the output voltage to control the fan motor speed independently Internal functions Motor power shutting off function when overcurrent is applied Adverse voltage prevention function Detection function for the motor lock Temperature detecting function The electric fan operates at FULL speed to cool down the PWM unit when the interior temperature of PWM unit is...

Page 52: ...or 4 seconds after engine starting abrupt acceleration and A C refrigerant pressure sensor detecting the followings A C compressor is turned off when the refrigerant pressure is below 2 0 kg cm2 and then is turned on when the refrigerant pressure is over 2 4 kg cm2 A C compressor is turned off when the refrigerant pressure is over 30 kg cm2 and then is turned on when the refrigerant pressure is be...

Page 53: ...05 3 ENGINE ELECTRICAL SYSTEM undefined 0000 00 0000 00 ENGINE ELECTRIC DEVICES GENERAL 1 DIAGNOSTIC INFORMATION AND PROCEDURE 1 Ignition System ...

Page 54: ...05 4 undefined 1452 01 ENGINE ELECTRICAL SYSTEM 2 Ignition System Cont d ...

Page 55: ...riods of time More power available in a lighter smaller case The battery has three major functions in the electrical system First the battery provides a source of energy for cranking the engine Second the battery acts as a voltage stabilizer for the electrical system Finally the battery can for a limited time provide energy when the electrical demand exceeds the output of the generator 2 Ratings A...

Page 56: ...p the battery cable terminals clean and tight or a loose battery hold down clamp Mechanical problems in the electrical system such as shorted or pinched wires 3 Charging Time Required The time required to charge a battery will vary depending upon the following factors Size of Battery A Completely discharged large heavy duty battery required more than twice the recharging time as a completely disch...

Page 57: ... may not have enough voltage to activate this circuitry even though the leads are connected properly making it appear that the battery will not accept charging current Therefore follow the specific charger manufacturer apos s instruction for by passing or overriding the circuitry so that the charger will turn on and charge a low voltage battery Continue to charge the battery until the charge curre...

Page 58: ...y Make sure it does not touch any other metal parts Clamp the other end of the same cable to the positive terminal on the discharged battery Never connect the other end to the negative terminal of the discharged battery 6 7 Do not attach the cable directly to the neg ative terminal of the discharged battery Doing so could cause sparks and possible battery explosion Clamp one end of the second cabl...

Page 59: ...l loads the on time may be 90 percent and the off time 10 percent 7 Charging System Generators use a new type of regulator that incorporates a diode trio A Delta stator a rectifier bridge and a rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan are used There is no test hole 8 Starter Wound field starter motors have pole pieces arranged a...

Page 60: ...ll the related wiring Diagnostic tables will aid in troubleshooting system faults When a fault is traced to a particular component refer to that component section of the service manual The starting system circuit consists of the battery the starter motor the ignition switch and all the related electrical wiring All of these components are connected electrically ...

Page 61: ...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 62: ...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 63: ...07 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 64: ... 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 65: ...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 66: ... 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 67: ...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 68: ...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 69: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 70: ......

Page 71: ......

Page 72: ...01 4 undefined 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 73: ...onnecting rod 3 Resonance flap 14 Exhaust manifold 4 Cylinder head cover 15 Crankshaft 5 Exhaust camshaft 16 Engine mounting 6 Intake camshaft 17 Starter 7 Cylinder head 18 Crankcase 8 Spark plug connector 19 Oil pump sprocket 9 Valve tappet 20 Oil strainer 10 Injector 21 Oil pan 11 Exhaust valve 22 Drain plug Front View ...

Page 74: ...d 0000 00 ENGINE INFORMATION 2 SIDE VIEW NO FUNCTION NO FUNCTION 23 Camshaft adjuster 27 Oil pump drive chain 24 Cooling fan and viscous clutch 28 Oil return pipe 25 Piston 29 Timing chain 26 Flywheel of drive plate ...

Page 75: ...ey should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or when ...

Page 76: ......

Page 77: ...02 3 ENGINE ASSEMBLY undefined 0000 00 1113 01 ENGINE ASSEMBLY GENERAL 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 78: ...02 4 undefined 0000 00 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 79: ...02 5 ENGINE ASSEMBLY undefined 0000 00 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 80: ...02 6 undefined 0000 00 ENGINE ASSEMBLY ...

Page 81: ...02 7 ENGINE ASSEMBLY undefined 0000 00 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 82: ...02 8 undefined 0000 00 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 83: ...02 9 ENGINE ASSEMBLY undefined 0000 00 1 Fastener Tightening Specifications Cont d ...

Page 84: ... of your vehicle 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 sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must b...

Page 85: ...03 4 undefined 0000 00 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 86: ...NO DATA ...

Page 87: ...ration is discovered upon inspection of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 OV...

Page 88: ...05 4 undefined 0000 00 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 89: ...06 3 LUBRICATION SYSTEM undefined 0000 00 9210 01 ENGINE LUBRICATION SYSTEM OVERVIEW AND OPERATION PROCESS 1 OIL CIRCULATION ...

Page 90: ...tappet 7 Oil gallery at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chain a...

Page 91: ...07 3 COOLING SYSTEM undefined 0000 00 2110 01 ENGINE COOLING SYSTEM GENERAL 1 GENERAL SPECIFICATIONS ...

Page 92: ...07 4 undefined 0000 00 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 93: ...07 5 COOLING SYSTEM undefined 0000 00 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 94: ...the cooling system to operation The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to the...

Page 95: ...07 7 COOLING SYSTEM undefined 0000 00 2 COMPONENT LOCATOR ...

Page 96: ...ieces Bolt M6 4 pieces Bolt M6 4 pieces Upper radiator insulator Lower radiator insulator Plate Clip 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Inlet hose Outlet hose 3 way hose Deaeration hose reserver tank Clamp Clamp Make up hose holder Reserver tank Bolt M6 2 piece Cooling fan Viscous clutch Bolt M6 1 piece Bolt M6 3 piece 15 16 17 18 19 20 21 22 23 24 25 26 27 ...

Page 97: ...08 3 ENGINE ELECTRIC DEVICES undefined 0000 00 1452 01 ENGINE ELECTRIC DEVICES GENERAL 1 GENERAL SPECIFICATIONS ...

Page 98: ...08 4 undefined 0000 00 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 99: ...her current rate as the battery warms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged ...

Page 100: ...xhaust stroke requires very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These systems use the EST signal from the ECM to control the EST The ECM uses the following information Engine load mass air flow sensor manifold air pressure sensor Engine coolant temperature Intake air temperature Cranksha...

Page 101: ...08 7 ENGINE ELECTRIC DEVICES undefined 0000 00 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 102: ...09 3 ENGINE CONTROL SYSTEM undefined 0000 00 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE GENERAL ...

Page 103: ...09 4 undefined 0000 00 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 104: ...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 105: ...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 106: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 107: ... 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 108: ...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 109: ... 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 110: ...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 111: ...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 112: ... STRUCTURE AND COMPARISON 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 3 TIGHTENING TORQUE 4 MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT OERVIEW AND OPERATION PROCESS 1 ENGINE COMPARTMENT 2 SYSTEM IN ENGINE COMPARTMENT 3 7 9 12 22 26 ...

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Page 114: ...01 3 ENGINE GENERAL undefined 0000 00 0000 00 ENGINE GENERAL GENERAL 1 STRUCTURE AND COMPARISON D27DT EU IV Engine Front View D27DT EU IV Engine Top View ...

Page 115: ...01 4 undefined 0000 00 ENGINE GENERAL D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Page 116: ...01 5 ENGINE GENERAL undefined 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Page 117: ...01 6 undefined 0000 00 ENGINE GENERAL D27DT Engine General Side View D27DT Engine General Left Side View ...

Page 118: ...01 7 ENGINE GENERAL undefined 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 119: ...01 8 undefined 0000 00 ENGINE GENERAL 2 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 120: ...01 9 ENGINE GENERAL undefined 0000 00 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Page 121: ...01 10 undefined 0000 00 ENGINE GENERAL ...

Page 122: ...01 11 ENGINE GENERAL undefined 0000 00 ...

Page 123: ... GENERAL MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT 4 The shape and size of D27DTP POWER UP are slightly different from those of D27DT engine but the basic configuration of two systems is almost same 1 Engine Assembly ...

Page 124: ...01 13 ENGINE GENERAL undefined 0000 00 2 Major Changes and Summary ...

Page 125: ...01 14 undefined 0000 00 ENGINE GENERAL ...

Page 126: ...01 15 ENGINE GENERAL undefined 0000 00 ...

Page 127: ...01 16 undefined 0000 00 ENGINE GENERAL ...

Page 128: ...01 17 ENGINE GENERAL undefined 0000 00 ...

Page 129: ...01 18 undefined 0000 00 ENGINE GENERAL ...

Page 130: ...01 19 ENGINE GENERAL undefined 0000 00 ...

Page 131: ...01 20 undefined 0000 00 ENGINE GENERAL ...

Page 132: ......

Page 133: ...01 22 undefined 0000 00 ENGINE GENERAL OVERVIEW AND OPERATION PROCESS 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Page 134: ...01 23 ENGINE GENERAL undefined 0000 00 ...

Page 135: ...ompartment fuse box PTC relay box Battery Vacuum modulator for VGT turbo charger 1 2 3 4 5 6 7 8 9 10 11 12 13 FFH Assembly Only for vehicle with FFH Power steering oil tank Engine oil filler cap Fan shroud E EGR Valve High capacity PCV oil separator HFM sensor 6 0 VGT turbo charger Air cleaner housing 2Coolant surge tank ABS ESP HECU Including TPMS function optional Exhaust gas FRT Temp sensor T3...

Page 136: ...01 25 ENGINE GENERAL undefined 0000 00 Major Sensors and Components ...

Page 137: ...01 26 undefined 0000 00 ENGINE GENERAL 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Page 138: ...01 27 ENGINE GENERAL undefined 0000 00 ...

Page 139: ...01 28 undefined 0000 00 ENGINE GENERAL 2 Preheat System ...

Page 140: ...01 29 ENGINE GENERAL undefined 0000 00 3 Fuel System ...

Page 141: ...01 30 undefined 0000 00 ENGINE GENERAL Fuel Supply System ...

Page 142: ...01 31 ENGINE GENERAL undefined 0000 00 4 Lubrication System ...

Page 143: ...01 32 undefined 0000 00 ENGINE GENERAL 5 Cooling System ...

Page 144: ...01 33 ENGINE GENERAL undefined 0000 00 6 Intake System ...

Page 145: ...01 34 undefined 0000 00 ENGINE GENERAL 7 Exhaust System ...

Page 146: ...les are added currently 7 to the tip of the injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle i...

Page 147: ...to the connection to the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume It is also installed on the connection of the high pressure fuel supply line of the HP pump D27DTP D27DT EU IV D27DT ...

Page 148: ...mp Common rail D27DT Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail The I D and O D of the fuel rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely ...

Page 149: ...02 6 undefined 0000 00 ENGINE FUEL SYSTEM 2 COMPONENTS OF FUEL SYSTEM ...

Page 150: ...02 7 ENGINE FUEL SYSTEM undefined 0000 00 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 151: ...P POWER UP engine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Page 152: ...on signal to ECU vacuum modulator control has been deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more de...

Page 153: ...05 3 CDPF Catalytic Disel Particulate Filter undefined 0000 00 1725 12 CDPF Catalytic Disel Particulate Filter GENERAL 1 Specifications for engine with CDPF ...

Page 154: ... again so that the amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter COMPARISON OF THROTTLE BODY FUNCTIONS BASED ON EXHAUST EMISSION REGULATION Regulated parts are carbon monoxide CO nitrogen oxide NOx particular mat...

Page 155: ...05 5 CDPF Catalytic Disel Particulate Filter undefined 0000 00 2 COMPONENTS Differential Pressure Sensor CDPF Assembly and Rear Exhaust Gas Temperatiure Sensor ...

Page 156: ...27DT engine is as follows Engine ECU Fuel Common Rail and Fuel Rail Between Common Rail and Injector The I D and O D of fuel rail has changed from 2 4 mm 6 0 mm to 3 0 mm 6 35 mm Also the damping orifice is installed to prevent the fuel pulsation occured by fuel pressure The engine ECU has been revised since terminals have been added for front rear temperature sensors Its version is 3 2 but it is ...

Page 157: ...05 7 CDPF Catalytic Disel Particulate Filter undefined 0000 00 ...

Page 158: ...oot with high temperature exhaust gas over 600 C The rear exhaust gas temperature sensor monitors the temperature of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Normally when the vehicle is driven for 600 1 200 km the enough amount of ...

Page 159: ... There are two fuel injection patterns pilot injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temper...

Page 160: ...ngines The throttle body is not installed in the D27DT engine general but is installed in the following engines 1 D27DT EU IV engine 2 D27DTP POWER UP engine 3 D27DTP POWER UP engine CDPF Both engines are equipeed with the throttle body but its appearance and the related control system are differ ...

Page 161: ...is oxidized The ECU detects the temperature change with two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environme...

Page 162: ...ched due to low speed even though CDPF regeneration is in process The CDPF regeneration process must be completed by driving for 15 20 minutes at a speed higher than 80 km h to solve this problem The engine CHECK lamp flashes when CDPF is over loaded therefore 4 above must be performed in this case 1 2 3 4 5 7 CDPF s Excessive Soot Accumulation P0432 When the vehicle is driven at a low speed 5 10 ...

Page 163: ...NO DATA ...

Page 164: ...OOLING SYSTEM FOR EACH ENGINE For the D27DTP POWER UP engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block For the D27DT engine the cooling system uses the fan clutch Cooling System for D27DTP POWER UP Engine ...

Page 165: ...07 4 undefined 0000 00 ENGINE COOLING SYSTEM D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 166: ...NO DATA ...

Page 167: ...NO DATA ...

Page 168: ...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 169: ...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 170: ...10 5 CRUISE CONTROL SYSTEM undefined 8510 23 2 CIRCUIT DIAGRAM 1 Configuration ...

Page 171: ... 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 172: ...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 173: ... 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 174: ...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 175: ...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 176: ...NO DATA ...

Page 177: ...Performance 2 Characteristics of Radio Wave Transmitting frequency 447 800 0 0125 MHz Channel width below 12 5 KHz Frequency bandwidth below 8 5 KHz Modulation method FSK Frequency Shift Keying Receiving distance Approx 10 15 m In case there are not obstacles around the system 1 2 3 4 5 ...

Page 178: ...02 4 undefined 0000 00 RKSTICS 3 Rated Load ...

Page 179: ...02 5 RKSTICS undefined 0000 00 4 Input Signals ...

Page 180: ... function does not include the vehicle speed calculating time 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal 1 2 3 6 Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 100 ms The time indicated in each function does not include chattering processing time fr...

Page 181: ...nspect the error for related devices 2 MAJOR CHANGES Integration of Auto Light Sensor and Rain Sensor The auto light sensor integrated rain sensor communicates with STICS Auto Washer Coupled Wiper When pressing the auto washer switch the washer fluid is sprayed on the windshield and the wiper sweeps off 4 times and then the washer fluid is sprayed and the wiper sweeps off 3 times again Communicati...

Page 182: ...02 8 undefined 0000 00 RKSTICS 3 FUNCTIONS Wiper and Washer Operations ...

Page 183: ... on for 0 1 to 0 59 seconds T2 with the ignition switch ON If the wiper parking terminal gets off the wiper relay is turned off 1 The wiper relay is turned on at 0 3 seconds T1 after from the time when the washer switch is turned on for more than 0 6 seconds T2 with the ignition switch ON The wiper relay gets on 3 times immediately after turning off the washer switch 2 ...

Page 184: ...S When the washer switch is turned on for more than 0 6 seconds during the wiper operation by AUTO switch the wiper operates three times When it is turned on for a certain period of time 0 1 to 0 59 seconds the wiper operates once 3 ...

Page 185: ...ned on with the ignition switch ON and the AUTO switch OFF the washer motor output gets ON for 1 second If the system recognizes the output signal the wiper relay output gets ON during 4 cycles and the washer motor output gets ON for 1 second Then the wiper relay output gets OFF after 3 cycles 1 ...

Page 186: ...put is overridden during the auto washer coupled wiper operation The auto washer switch input is overridden during the rain sensor coupled wiper or vehicle speed sensitive AUTO wiper operation When the AUTO switch input is received during the auto washer operation the auto washer operation stops and the auto INT operation is activated 2 3 4 5 ...

Page 187: ...02 13 RKSTICS undefined 0000 00 Rain Sensor Coupled Wiper and Auto Light Control If equipped with RKSTICS rain sensor it has following operation system System layout ...

Page 188: ...tion with rain sensor The wiper relay LOW is turned on and the wiper motor runs one cycle when changing the auto switch from OFF to ON position regardless of communication with rain sensor while the ignition key is in the ON position When the auto switch is turned to the ON position again from the OFF position the system drives the wiper motor through LOW relay one cycle only when the rain sensor ...

Page 189: ...detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode auto light sensor integrated type AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto speed control A position that can control sensitivity against rains in the windshield and transmits wiping demand signal accordingly ...

Page 190: ...he operation data is sent to the rain sensor even during the washer coupled wiper s operation 1 2 Rain Sensing Sensitivity Control The wiper LOW relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased while the ignition key is in the ON position the AUTO switch is in the ON position and the wiper motor is in Parked position However the wiper motor can be oper...

Page 191: ...sition and the AUTO switch is in ON position The wiper motor runs only when the rain sensor requires the wiper operation 1 When the parking terminal is fixed to HIGH with the ignition key and the AUTO switch in ON position the wiper system outputs the wiper operating signal for 2 seconds then continuously outputs the wiper parking signal The wiper motor runs only when the rain sensor requires the ...

Page 192: ...ng the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 1 The wiper relay LOW is turned on and the wiper motor runs one cycle when the volume sensitivity is changed to 3 from 4 during receiving the malfunction signal from the rain sensor while the ignition key is in ON position and the AUTO switch is in ON position 2 ...

Page 193: ...while the light switch is in AUTO position and the wiper switch is in AUTO position Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 2 3 Emitter lense The emitter lens located at bottom of ra...

Page 194: ...itioned to ON Intermittent interval at 0 km h 3 0 5 19 2 seconds 2 Vehicle speed calculation Input the vehicle speed It is calculated by the numbers of input pulses for one second 1 PULSE SEC 1 41 km h 60 km h x 60 sec 637 x 4 PULSE 3 VOLUME calculation The pause time of the vehicle speed sensitive AUTO wiper is calculated by the AUTO volume input voltage Each level has the hysteresis 4 Pause time...

Page 195: ...h OFF AUTO switch ON Resume the intermittent time when turning ON Controls when the wiper motor parking is defective 1 The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while the wiper relay is ON AUTO switch ON or Washer switch ON The output stops immediately after turning off the switch The output stops immediately after turning OFF the switch Pause time...

Page 196: ... interval of 0 3 seconds when opening the driver s door while the ignition key is in ignition switch When removing the ignition key or closing the driver s door during chime buzzer operation the buzzer stops This function is not available when the ignition switch is in ON position 1 2 3 Chime bell location bottom of audio unit right to the sensor cluster Sensor cluster Chime bell ...

Page 197: ...onds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds while the ignition key is in the ignition switch If the UNLOCK conditions are met the system outputs UNLOCK signal unconditionally However if the ignition key is removed after the door lock switch is changed from UNLOCK to LOCK the system does not output UNLOCK signal 1 2 3 1 Door LO...

Page 198: ...put the UNLOCK output stops immediately When the ignition key is inserted during the UNLOCK output the output continues for approx 5 seconds If the ignition switch is in the ON position or the ignition switch is removed the above steps are performed If the key is in the key cylinder the ignition key reminder function is activated This function does not work if the vehicle speed is over 10 km h 1 2...

Page 199: ...n and the ignition key is removed The buzzer output stops when turning off the tail lamp and closing the driver s door The system outputs UNLOCK signal for 5 seconds when the driver s and passenger s door lock switch is locked while the tail lamp is turned on and the driver s door is open This function is not available when the ignition key is in the ON position 1 2 3 4 ...

Page 200: ...ng light goes off when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h while the warning light is turned on The warning light blinks when a door is open while the vehicle speed is over 10 km h The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle speed goes below 10 km h under step 3 1 2 3 4 5 6 ...

Page 201: ...l stops when turning the ignition switch to the OFF position The chime bell stops and the seat belt warning light stays on for the specified period of time when fastening the seat belt during the warning operation The seat belt warning light comes on and the chime bell sounds for 6 seconds again when unfastening the seat belt during fastening operation while the ignition key is ON position 1 2 3 4...

Page 202: ...ed on while the vehicle speed is below 10 km h The warning light goes off when turning off the parking brake switch under step 2 The warning light blinks and the chime bell sounds for 0 6 seconds and stops for 0 3 seconds when the vehicle speed is over 10 km h for more than 2 seconds while the parking brake switch is turned on The warning light goes off and the chime buzzer stops when turning off ...

Page 203: ...02 29 RKSTICS undefined 0000 00 Vehicle with Hand Operated Type Parking Brake Vehicle with EPB Operates in EPB module with separate control logic ...

Page 204: ...for 30 seconds when receiving the unlock signal from the remote control key while the doors are closed The front room lamp and the center room lamp output period is extended by 30 seconds when receiving the unlock signal from the remote control key again during output The lamp stays on when unlocked by the remote control key When a door is opened during its extended period the lamp stays on If clo...

Page 205: ...s on when a rear door is opened The lamp always comes on while the switch is at the other position Door coupled switch Ignition Key Hole Illumination The ignition key hole illumination comes on when opening the driver s door or passenger s door when the ignition key is removed The ignition key hole illumination stays on for 10 seconds when closing the door after step 1 The output stops when the ig...

Page 206: ...02 32 undefined 0000 00 RKSTICS Opening Driver s or Passenger s Door Key hole illumination Wiring Circuit of STICS Related to Tail Lamp Auto Cut Battery Saver ...

Page 207: ...ff auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp The tail lamp relay is turned on when inserting the ignition key into the ignition switch The tail lamp relay is not turned off automatically auto cut when opening and closing the driver s door while the ignition is removed and the tail lamp is turned on 1 2 3 4 ...

Page 208: ...operating the defogger switch STICS controls the operating time only in IGN2 position Rear defogger switch Tailgate window and outside rearview mirror heated glass switch The tailgate window and outside rearview mirror heated glass is turned on for 12 minutes when pressing this switch Windshield heated glass switch The windshield heated glass is turned on for 12 minutes when pressing this switch ...

Page 209: ...tion switch is ON with engine running The output stops when turning on the front defogger heated glass switch again during its operation The output is ON only for 6 minutes when turning ON the front defogger heated glass switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the ignition switch is OFF 1 2 3 4 ...

Page 210: ...IGN 2 switch is ON with engine running The output is OFF when turning ON the rear defogger switch again during output The output is ON only for 6 minutes when turning ON the rear defogger switch within 10 minutes after completion of output for 12 minutes This can be done only once The output is OFF when the IGN 2 switch is OFF 1 2 3 4 ...

Page 211: ...o UNLOCK by the driver s or passenger s door key cylinder The door lock system outputs UNLOCK signal for 0 5 seconds when switching from UNLOCK to LOCK by the driver s or passenger s door key cylinder The alarm will not be activated when switched to UNLOCK by driver s or passenger s door key cylinder switch in theft deterrent mode It does not occur abnormal operation when reconnecting the battery ...

Page 212: ...Door Lock Switch The door lock system outputs LOCK UNLOCK signal for 0 5 seconds when operating the central door lock switch However if the door lock switch front doors is at LOCK position the system outputs UNLOCK signal and vice versa The LOCK or UNLOCK inputs from the central door lock switch in anti theft mode are ignored 1 2 ...

Page 213: ...oor LOCK UNLOCK by Remote Control Key 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 1 2 ...

Page 214: ...50 km h Nonetheless the central door lock function works properly When the system receives UNLOCK signal from a door switch it outputs LOCK signals 5 times If additional LOCK signal from another door switch is detected during the period the system outputs five LOCK signals 5 times for the door system outputs five LOCK signals 5 times for the door The door lock system outputs UNLOCK automatically i...

Page 215: ...ontinues on for remaining period The function is erased when turning OFF the IGN switch 1 2 3 4 The Unlock control by air bag signal prevails over any LOCK or UNLOCK control by other functions The LOCK UNLOCK request by other functions will be ignored after during the output of UNLOCK by the air bag However the door lock is controlled by other functions when the ignition switch is OFF LOCK or UNLO...

Page 216: ...g the remote control key lock signal armed mode during its extended operation period of 30 seconds 1 2 3 Definition of Terms DOOR OPEN and DOOR CLOSE DOOR OPEN Any of all door switches including hood and tailgate is in OPEN position DOOR CLOSE All door switches including hood and tailgate are in CLOSE position 1 The door lock unlock operation does not affect the engine hood DOOR LOCK Indicates tha...

Page 217: ...h the above three conditions met 2 The sleep mode is deactivated immediately if any of them is out of the specified conditions wake up mode Also the sleep mode is deactivated when receiving the UNLOCK signal from the remote control key 3 During the sleep mode the sleep mode is deactivated for 30 seconds when room lamp key hole illumination tail lamp or power window is operated or after the system ...

Page 218: ... the LOCK output can be done and then activates the armed ready mode without hazard warning flasher At this moment if the ignition key is in the ignition switch the door unlock switch is turned ON or the door lock switch is unlocked it cancels the armed mode and activates the normal mode However when closing and locking the opened door the hazard warning lamps flash twice 4 When the door is not op...

Page 219: ...rd warning flasher output is ON for 27 seconds with the interval of 1 second 5 Warning cancellation requirements 1 Cancels warning by using any signal from the remote control key LOCK UNLOCK PANIC during warning operation 2 Cancels warning after 27 seconds remaining period while the ignition key is turned to ON position 3 If the ignition switch is turned to ON position when the warning is activate...

Page 220: ...a battery the siren sounds and the emergency warning lamp blinks Same operations with warning in armed mode RELOCK Operation It the door is not opened or the ignition key is not inserted into the key cylinder within 30 seconds after unlocking the door with remote control key the system outputs LOCK signal and activates the armed mode ...

Page 221: ...ck briefly press If you press this button briefly all doors and the tail gate are unlocked and the theft deterrent mode is deactivated When the deterrent mode is deactivated hazard warning flashers blink once 2 Panic function press and hold If you are in your vehicle and feel threatened while the ignition key is inserted into the key switch you may activate the alarm to call attention If you press...

Page 222: ...OCK switch on remote control key less than 0 5 seconds The system outputs LOCK signal immediately after receiving the door lock message from the remote control key The system activates the theft deterrent mode when all doors are locked while they are fully closed the hazard warning lamps blink twice 1 2 ...

Page 223: ...for 0 5 seconds when receiving the door unlock message from the remote control key The hazard warning lamps blink once only when all the doors unlocked 1 2 3 Auto Door Lock in 30 Seconds after Pressing Door Unlock Button If no door is opened for 30 seconds after inputting remote door unlock the doors are automatically locked and the armed mode of anti theft system is activated again 1 ...

Page 224: ...02 50 undefined 0000 00 RKSTICS 4 CIRCUIT DIAGRAM OF STICS ...

Page 225: ...02 51 RKSTICS undefined 0000 00 Output Signals except STICS ...

Page 226: ...horized key to start the engine The transponder inside the key communicates with the immobilizer installed in the key box and the system permits the engine to start after confirming the encrypted coding from the engine ECU Refer to the information that follows for specific functions and their descriptions Immobilizer warning lamp Immobilizer unit Transponder for Diesel engine Transponder for gasol...

Page 227: ... If you press this button briefly all doors and the tail gate are unlocked and the theft deterrent mode is deactivated When the deterrent mode is deactivated hazard warning flashers blink once 2 Panic function press and hold If you are in your vehicle and feel threatened while the ignition key is inserted into the key switch you may activate the alarm to call attention If you press this button the...

Page 228: ...ending or receiving electromagnetic fields or waves When the key is close to any electronic or electric devices such as lightening equipment security keys or security cards When the key is close to a magnetic or metal object or a battery In the following cases a driver may be unable to start the vehicle with the immobilizer Transponder for DI engine Transponder for gasoline engine The transponder ...

Page 229: ...ssage to the immobilizer unit to verify whether the key is valid ENGINE CONTROL UNIT ECU Only when the two signals are identical it recognizes the key as the authorized one and transmits the positive message to the ECU The ECU enable the engine to be started Do not drop or shock to the transponder in the key as it may be damaged With a damaged transponder the engine cannot be started When you eras...

Page 230: ...04 3 CLUSTER undefined 0000 00 GENERAL 8010 01 CLUSTER 1 INDICATOR COLORS AND LED SPECIFICATIONS ...

Page 231: ...04 4 undefined 0000 00 CLUSTER 2 SIGNALS AND LIGHT ON RELATIONS FOR THE CAN COMMUNICATIONOF THE INSTRUMENT PANEL ...

Page 232: ...04 5 CLUSTER undefined 0000 00 ...

Page 233: ...ned 0000 00 CLUSTER OVERVIEW AND OPERATION PROCESS 1 OVERVIEW The instrument cluster uses the CAN communication The HDC warning lights green red are added since the HDC function has been introduced into ESP system ...

Page 234: ...04 7 CLUSTER undefined 0000 00 2 LOCATION AND CONFIGURATION ...

Page 235: ...light 17 Battery charge warning light 18 SSPS warning light 19 EAS level change indicator 20 EAS warning light 21 EPB warning light 22 Automatic parking brake setting indicator 23 Brake warning light 24 Seat belt reminder driver s seat 25 Air bag warning light 26 Door ajar warning light 27 Auto shift indicator 28 Odometer Trip odometer 29 TPMS warning light 30 Global warning 31 Low fuel level warn...

Page 236: ... light 12 Seat belt reminder 13 Air bag warning light 14 Door open warning light 15 Speedometer 16 Gear display Odometer 17 Right turn signal indicator 18 High beam indicator 19 Front fog lamp indicator 20 Winter mode indicator 21 Fuel level gauge 22 Coolant temperature gauge 23 Low fuel level warning light 24 4WD LOW indicator TOD Part time 25 4WD HIGH indicator Part time 26 4WD CHECK warning lig...

Page 237: ...04 10 undefined 0000 00 CLUSTER 4 CONFIGURATION Deluxe Version Standard Version ...

Page 238: ...e up test and start the engine Eliminate the hysteresis by tapping the tachometer Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive 1 2 3 For vehicle equipped with gasoline engine the indicator shows up to 7 000 rpm and 8 000 rpm The tolerance at 7 000 rpm is 100 Checking If the tachometer pointer vibrates stands at a certain range or sounds a...

Page 239: ...escribed However it is not similar simple work in field due to lack of measuring conditions such as test equipment and preciseness 1 Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester 2 Check if the speedometer gauge is shaking and the abnormal noise sounds 3 Eliminate the hysteresis by tapping the speedometer The allowable tolerance increases wh...

Page 240: ...hat this vehicle doesn t have a service hole for checking the fuel sender connector in the fuel tank The fuel sender and its connector can be checked and replaced only when the fuel tank is removed The power supply and resistance value should be measured at the connector in front of the fuel sender refer to wiring diagram When the power supply and output resistance are normal the float operation b...

Page 241: ...e and resistance value by indicating angle This table shows the tolerance and resistance value changes by fuel level in normal conditions Therefore the differences that can be occurred by the road conditions and fuel fluctuations are ignored ...

Page 242: ...n ohmmeter and replace if the resistance is out of specified range Resistance value by coolant temperature 20 C 2449Ω 5 50 C 826Ω 5 80 C 321Ω 5 100 C 12Ω 5 When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal operation Also check the wiring harnesses and connectors for proper connection D27DT engine E...

Page 243: ...04 16 undefined 0000 00 CLUSTER 6 WARNING INDICATOR PANEL ...

Page 244: ...04 17 CLUSTER undefined 0000 00 ...

Page 245: ...cle with A T Vehicle with M T 0 Zero setting when pressing and holding the RESET button in TRIP A B mode for less than 1 second briefly press for less than 1 second briefly press for less than 1 second briefly press ODO Display Range 0 999999 km Minimum unit 1 km TRIP A Display Range 0 0 999 9 km Minimum unit 0 1 km TRIP B Display Range 0 0 999 9 km Minimum unit 0 1 km ...

Page 246: ...uster the brightness can be adjusted in 6 steps each in day time mode and night time mode The tail lamp ON condition is used to determine whether it should be the day time mode or the night time mode Day Time tail lamp OFF Night Time tail lamp ON The brightness can be adjusted using TRIP switch as follows ...

Page 247: ... and red warning lamp The HDC switch is a push self return type switch when you press it once it starts to operate and when you press it again it stops the operation For its functions and operation logic refer to ABS ESP in Chassis section Basically the brake system s basic functions can work even when there are problems with the HDC system As given in the table above the HDC warning lamp comes on...

Page 248: ...less of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on The detailed operation procedures are as follows 1 The ESP warning lamp comes on when the ESP OFF switch is pressed for over 150 ms 2 The switch returns to normal position when the OFF switch is released 3 The ESP system will be cancelled after approximately 150 ms Based on the above...

Page 249: ...witch returns to normal position when the OFF switch is released 3 The ESP system will be resumed after approx 150 ms When turning the ignition switch off while the ESP system is activated the ESP system will be resumed when ignition switch is turned on again When the vehicle is controlled by ESP system during driving the ESPOFF switch does not operate The ESPOFF switch operates when it is pushed ...

Page 250: ...ines it as a ESPOFF switch malfunction When the ESPOFF switch is pushed the ESP system is resumed after 10 seconds However the ESP warning lamp comes on when the ESPOFF switch is pushed for over 150 ms and then goes out when the ESP system is resumed When the ESPOFF switch returns to normal position the ESP unit resets the ESPOFF switch for approx 3 5 seconds ...

Page 251: ...lamp operations when the ESP system is defective or ESP including TCS function is working When the driver presses the brake pedal during the ESP OFF mode the yaw control is performed to compensate the vehicle stability posture during ESP operation Be careful not to damage other parts when removing the instrument cluster ...

Page 252: ...erload frame Connector A 20 pins Connector B 20 pins 1 Door open 2 Oil pressure 3 Seat belt 4 Charge 5 Light 6 7 IGN Alternator 8 Signal ground 9 10 Battery 11 Parking brake signal output 12 Auto parking switch 13 Easy loading switch 14 Light 15 16 Turn signal lamp RH 17 High beam 18 Headlamp 19 Turn signal lamp LH 20 Parking brake signal input 1 Neutral switch input M T 2 Reverse switch input M T...

Page 253: ...04 26 undefined 0000 00 CLUSTER 2 Circuit Diagram Deluxe version Internal Electric Circuit This circuit diagram shows the parts controlled through the MICOM and the parts controlled by the switches ...

Page 254: ...04 27 CLUSTER undefined 0000 00 External electric circuit However if the fuel filter is filled with water the buzzer sounds for 6 seconds when the engine speed is over 400 rpm during engine starting ...

Page 255: ...05 3 SPWM undefined 0000 00 7410 32 SPWM Seat Position With Memory UNIT GENERAL 1 SPECIFICATIONS 1 Driver s Power Seat 2 Actuator ...

Page 256: ...05 4 undefined 0000 00 SPWM 3 Outside Rearview Mirror Manual Mode Normal 12V Position Sensor and Folding Switch Motor ...

Page 257: ...emory recall position switch ON twice When starting to recall the memory position switch ON once When pressing the position switch button twice consecutively three times When detecting a sensor error while recalling position switch ON three times No buzzer output for the easy access memory recall operations No buzzer output for the outside mirror position recall by the auto down operation when rev...

Page 258: ...iable seat warmer system controls the temperature in 5 levels Seat Warmer Unit Seat Warmer Switch It is located on the lower side of the center switch panel It is installed under the passenger s seat for vehicle equipped with SPWM unit It is installed under the driver s seat for vehicle without SPWM unit ...

Page 259: ...RISTICS The variable seat warmer system operates when the ignition is ON The unit heats the seat in each level according to the resistance based on each switch operation 1 Operation Characteristics 2 Temperature and sensor output value in each switch level ...

Page 260: ...shion and the seatback is heated by operating the switch and the temperature of the seat can be adjusted in five levels Seat wamer switch The temperature of the seat surface should be rised to over 20 C within 3 minutes while sitting on the seat driver s height 175 5 cm driver s weight 75 5 kg when operating the seat warmer switch ...

Page 261: ...06 6 undefined 0000 00 SEAT WARMER 4 CIRCUIT DIAGRAM The variable seat warmer unit is supplied the ignition power and the battery power without its own relay ...

Page 262: ...07 2 undefined 0000 00 SWITCH 8511 29 SWITCH OVERVIEW AND OPERATION PROCESS 1 OVERVIEW ...

Page 263: ...07 3 SWITCH undefined 0000 00 ...

Page 264: ...lly operate 4 times Then the fluid will be sprayed again and the wiper will automatically operate 3 times 1 Wiper function coupled auto washer 2 Integrated auto light sensor in rain sensor unit The rain sensor unit is installed on a proper location to detect the rain drops and the illumination intensity When the wiper is in operation in LO mode by the rain sensor the headlamps come on if the light...

Page 265: ...08 4 undefined 0000 00 WIPER 2 SYSTEM LAYOUT ...

Page 266: ...08 5 WIPER undefined 0000 00 Layout of Front Wiper ...

Page 267: ...08 6 undefined 0000 00 WIPER 3 CIRCUIT DIAGRAM 1 Front Wiper and Washer ...

Page 268: ...08 7 WIPER undefined 0000 00 2 Rear Wiper and Washer DPS STD ...

Page 269: ...sor Integrated Type A sensor that emits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode The auto light sensor is Integrated into the rain sensor Multifunction Wiper Switch AUTO and Sensitivity Control AUTO Wiper operates automatically by rain sensor FAST SLOW Auto ...

Page 270: ...IT 1 Internal Components Emitter lens The LED which is located at bottom emits the infrared rays and the lens guides the infrared rays to target point Auto light sensor Vertical Auto light sensor Horizon Enlarged auto light sensor section ...

Page 271: ...amount of rain drops and sends the operating signal to STICS and STICS drives the wiper directly At this moment STICS determines the wiper operation mode washer MIST AUTO then sends the information to the rain sensor Engine Compartment Fuse and Relay Box IP Lower Relay Box Front wiper lower relay ...

Page 272: ...uires the intermediate INT speed the headlamps are turned on automatically Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level For example the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level 1 2 ...

Page 273: ...ch requires the highest INT speed the headlamps are turned on automatically 2 Night detected wiping When the auto light control turns on the headlamps and the rain sensor detects the rain the wiper sensitivity is automatically increased by one level i e the AUTO wiper switch is at the 3rd level but the wiper operates at the 4th level ...

Page 274: ...ion When the wiper switch is turned to AUTO from OFF the wiper operates one cycle It always operates one cycle for the initial operation however the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF However the wiper operates up to 5 minutes after rain stops If this function does not occur check No 2 terminal on the rain...

Page 275: ...e cannot wipe the glass uniformly and clearly the irregular operations could be occurred And the wiper blade should be replaced with new one with same specifications 6 Self Diagnosis Poor Sensing Position the wiper switch to AUTO position and rotate the variable resistance knob from FAST toward SLOW by one step At this moment check if the wiper operates one cycle The wiper operates when the windsh...

Page 276: ...10 3 LAMP undefined 0000 00 8310 01 LAMP GENERAL 1 BULB SPECIFICATIONS ...

Page 277: ...11 3 MULTI JACK STATION undefined 0000 00 8611 41 MULTI JACK STATION GENERAL 1 HARDWARE SPECIFICATIONS ...

Page 278: ...eo jack which can be connected to an external audio device and the MP3 USB jack which can be connected to the USB flash drive for playing music through the speakers on vehicle 2 COMPONENTS For the vehicle with the AV system the device change and the file search in folders can be done by using AV monitor For the vehicle without monitor such operations can be done by using the multi jack station but...

Page 279: ...11 5 MULTI JACK STATION undefined 0000 00 3 ELECTRICAL PERFORMANCE AND CONFIGURATION 1 Electrical Performance 2 Configuration ...

Page 280: ...PUT SIGNALS Time Tolerance For the time in which the tolerance is not specified the tolerance is 10 For the time within 500 ms the tolerance is 100 ms The time specfied in each function does not include the lapse from the switch input to the chattering process time 1 2 ...

Page 281: ...11 7 MULTI JACK STATION undefined 0000 00 5 APPEARANCE Internal Appearance when Installed Apperance when Removed PCB and Internal Components ...

Page 282: ...11 8 undefined 0000 00 MULTI JACK STATION 6 CIRCUIT DIAGRAM Vehicle with MP3 Audio System Vehicle with A V System ...

Page 283: ...11 9 MULTI JACK STATION undefined 0000 00 A V Specification ...

Page 284: ...11 10 undefined 0000 00 MULTI JACK STATION 7 PANEL AND BUTTONS ...

Page 285: ...utput through the stereo jack File search and play through the USB flash drive 2 Multi Jack Station Specifications Identified by USB port For the vehicle with common audio system press the AUX button on upper side of the audio unit to enter the multi jack station mode The USB mode has the higher priority than the stereo jack mode ...

Page 286: ...m interval increases as the obstacle approaches This supplementary system is to secure the safety distance for parking Parking Aid Unit Detecting type Super sonic wave Detecting distance 25 cm 120 cm distance between sensor and obstacle Parking Aid Sensor Type Piezo ceramic element Calculates the distance between the sensor and the object by caculating the return time of the emitted the ultrasonic...

Page 287: ...absorb ultrasonic waves Obstacles lower than the bumper ex drain ditch or mud puddle Not defective but improperly working When the sensing portion is frozen operates normally after thawed When the sensing portion is covered by rain water drops snow or mud operates normally after cleaned When receiving other ultrasonic signals metal sound or air braking noises from heavy commercial vehicles When a ...

Page 288: ...acles When placing the gear selector lever to R position the designated unit PAS unit in the rear right quarter panel activates the parking aid sensors to measure the distance to obstacles If a sensor is malfunctioning the buzzer in PAS unit sounds to warn the driver Outside rearview mirro aiming down by 3 5 The locations of buzzer and folding unit may vary according to the model Buzzer Parking Ai...

Page 289: ...rt intervals and if within stage 3 the warning beep sounds continuously Detection range 25 cm from bumper may not be detected 20 cm from ground may not be detected 2 Troubleshooting of Sensor When the shift lever is in the R position with the ignition switch on the sensor is diagnosed once under normal condition the buzzer sounds once If found any failure due to open circuit to sensor or communica...

Page 290: ...12 7 PARKING AID SYSTEM undefined 0000 00 When sensor fails self diagnosis ...

Page 291: ...12 8 undefined 0000 00 PARKING AID SYSTEM 3 CIRCUIT DIAGRAM ...

Page 292: ...0 8611 26 WOOFER SPEAKER DVD SYSTEM Disconnect the negative battery cable and remove the passenger seat Disconnect the connector and four mounting nuts 10 mm to remove the subwoofer speaker Components Circuit Connector Sound volume lever ...

Page 293: ...nna is attached on the tailgate The integrated type antenna is not available AV System Radio CD Cassette MP3 TV and DVD system are available The USB type MP3 jack is installed as the standard specification If the navigation is installed the GPS antenna is attached on the rear section of the roof The speaker system consists of 1 center speaker 4 door speakers one in each door and 2 tweeter speaker ...

Page 294: ...13 5 AV SYSTEM REXTON 2007 09 0000 00 2 MAJOR COMPONENTS AND LOCATIONS OF AV SYSTEM 1 AV System ...

Page 295: ...13 6 REXTON 2007 09 0000 00 AV SYSTEM 2 Audio System ...

Page 296: ...01 3 DC 5 SPEED AUTO TRANSMISSION REXTON 2007 09 3650 01 1 SPECIFICATIONS 3650 01 DC 5 SPEED AUTOMATIC TRANSMISSION GENERAL ...

Page 297: ...01 4 REXTON 2007 09 3650 01 DC 5 SPEED AUTO TRANSMISSION ...

Page 298: ...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 299: ...01 6 REXTON 2007 09 3650 01 DC 5 SPEED AUTO TRANSMISSION 2 CHARACTERISTICS ...

Page 300: ...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 301: ... 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 302: ...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 303: ...01 10 REXTON 2007 09 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 304: ... 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 305: ...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 306: ... 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 307: ...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 308: ...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 309: ...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 310: ...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 311: ...01 18 REXTON 2007 09 3650 01 DC 5 SPEED AUTO TRANSMISSION 6 CIRCUIT DIAGRAM 1 Starter Selector Lever CAN Communication ...

Page 312: ...01 19 DC 5 SPEED AUTO TRANSMISSION REXTON 2007 09 3650 01 2 Solenoid Oil Temperature Sensor RPM Sensor N2 N3 ...

Page 313: ...NO DATA ...

Page 314: ...03 3 MANUAL TRANSMISSION REXTON 2007 09 3170 01 3170 01 MTMANUAL TRANSMISSION 1 SPECIFICATIONS 1 General Specifications 2 Tightening Torque GENERAL ...

Page 315: ...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 316: ...03 5 MANUAL TRANSMISSION REXTON 2007 09 3170 01 2 SYSTEM COMPONENTS 1 Gear Combinations 2 Shift Fork and Rail Combinations ...

Page 317: ...03 6 REXTON 2007 09 3170 01 MANUAL TRANSMISSION 3 Sectional View ...

Page 318: ... 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 319: ...03 8 REXTON 2007 09 3170 01 MANUAL TRANSMISSION IDI Engine equipped vehicle 4WD ...

Page 320: ...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 321: ...03 10 REXTON 2007 09 3170 01 MANUAL TRANSMISSION IDI Engine equipped vehicle 2WD ...

Page 322: ...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 323: ...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 324: ...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 325: ...03 14 REXTON 2007 09 3170 01 MANUAL TRANSMISSION 6 Power Flows 1st gear Counter shaft 2nd gear ...

Page 326: ...03 15 MANUAL TRANSMISSION REXTON 2007 09 3170 01 7 Power Flows Cont d 3rd gear 4th gear ...

Page 327: ...03 16 REXTON 2007 09 3170 01 MANUAL TRANSMISSION 8 Power Flows Cont d 5th gear Reverse gear ...

Page 328: ...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 329: ...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 330: ...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 331: ...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 332: ...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 333: ...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 334: ...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 335: ...03 24 REXTON 2007 09 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 336: ...03 25 MANUAL TRANSMISSION REXTON 2007 09 3170 01 4 CIRCUIT DIAGRAM BACKUP LAMP ...

Page 337: ...04 3 CLUTCH REXTON 2007 09 0000 00 1 SPECIFICATIONS 2 TIGHTENING TORQUE 0000 00 CLUTCH GENERAL ...

Page 338: ... 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 339: ...04 5 CLUTCH REXTON 2007 09 0000 00 B Concentric slave cylinder pipe A Adaptor D Clutch assembly C Concentric slave cylinder 2 COMPONENTS AND LOCATIONS ...

Page 340: ...04 6 REXTON 2007 09 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 341: ...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 342: ...05 3 PART TIME TRANSFER CASE REXTON 2007 09 3240 01 1 SPECIFICATIONS 3240 01 PART TIME TRANSFER CASE GENERAL ...

Page 343: ...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 344: ...ME TRANSFER CASE REXTON 2007 09 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 345: ...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 346: ...N 2007 09 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 347: ...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 348: ...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 349: ...05 10 REXTON 2007 09 3240 01 PART TIME TRANSFER CASE 2 Transfer Case Block Diagram ...

Page 350: ...05 11 PART TIME TRANSFER CASE REXTON 2007 09 3240 01 ...

Page 351: ...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 352: ...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 353: ...05 14 REXTON 2007 09 3240 01 PART TIME TRANSFER CASE 6 POWER FLOW POWER FLOW ...

Page 354: ...05 15 PART TIME TRANSFER CASE REXTON 2007 09 3240 01 1 2H MODE REAR WHEEL DRIVE Power Flow Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 355: ...05 16 REXTON 2007 09 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 356: ...05 17 PART TIME TRANSFER CASE REXTON 2007 09 3240 01 3 4L MODE 4WD DRIVE LOW SPEED Power Flow Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 357: ...05 18 REXTON 2007 09 3240 01 PART TIME TRANSFER CASE 7 CIRCUIT DIAGRAM DI 5 SPEED A T ...

Page 358: ...06 3 TORQUE ON DEMAND REXTON 2007 09 3240 01 1 SPECIFICATIONS 3240 01 TORQUE ON DEMAND TOD GENERAL ...

Page 359: ...ont axle 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 sy...

Page 360: ...d maintain 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 gra...

Page 361: ...ocked 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...

Page 362: ...06 7 TORQUE ON DEMAND REXTON 2007 09 3240 01 2 POWER FLOW System Layout 4WD Switch Instrument Panel Output Input Rear Speed Manetic Clutch Motor Front Speed Front Output ...

Page 363: ...06 8 REXTON 2007 09 3240 01 TORQUE ON DEMAND 4H Mode 4WD Drive High Speed Transmission Front Axle Front Wheel Rear Axle Rear Wheel ...

Page 364: ...06 9 TORQUE ON DEMAND REXTON 2007 09 3240 01 4L Mode 4WD Drive Low Speed Front Axle Front Wheel Transmission Rear Axle Rear Wheel ...

Page 365: ...06 10 REXTON 2007 09 3240 01 TORQUE ON DEMAND 3 CIRCUIT DIAGRAM ...

Page 366: ...07 3 ALL WHEEL DRIVE REXTON 2007 09 3260 01 3260 01 ALL WHEEL DRIVE GENERAL 1 SPECIFICATIONS ...

Page 367: ...els through the internal planetary gears without a control unit to operate AWD function It also doesn t have the TC Transfer Case shift motor and 4WD transfer switch Since it doesn t have a control unit such as TCCU Transfer Case Control Unit it delivers the driving force to the front and rear propeller shafts according to the gear ratio based on the gear combinations The distribution ratio of dri...

Page 368: ...07 5 ALL WHEEL DRIVE REXTON 2007 09 3260 01 2 LOCATION Distribution of Driving Force in AWD ...

Page 369: ...07 6 REXTON 2007 09 3260 01 ALL WHEEL DRIVE 3 STRUCTURE 1 Sectional View ...

Page 370: ...haft 4 Sprocket 5 Front sun gear 6 Differential carrier assembly 7 Thrust washer 8 Rear sun gear 9 Snap ring 10 Cover assembly 11 Oil seal 12 Rear output shaft assembly 13 Air breather 14 Front output shaft assembly 15 Oil seal 16 Retaining ring 17 Driven sprocket 18 Chain 19 Clip 20 Bolt 21 Plug ...

Page 371: ...07 8 REXTON 2007 09 3260 01 ALL WHEEL DRIVE 4 POWER FLOW Distribution of Front Output Torque Distribution of Rear Output Torque ...

Page 372: ... of turning radius while cornering the tight corner braking symptom occurs in part time transfer case However for the AWD this gap of turning radius is compensated by the differential so that the tight corner braking symptom will not occur The ESP also operates the wheel slip under control in order to keep the vehicle stable under severe conditions such as icy road ...

Page 373: ...e rear sun gear move toward the moving direction with the torque ratio of 40 60 The front wheels should rotate faster than the rear wheels while cornering including wheel slip since the front wheels turning radius is larger than the rear wheels At this moment the step pinion 19T 13T should rotate faster than the pinion 13T in relation to the carrier s movement This function is similar to the regul...

Page 374: ...NO DATA ...

Page 375: ...09 3 AXLE REXTON 2007 09 4210 01 1 SPECIFICATIONS 4120 01 AXLE GENERAL 2 REAR AXLE 1 FRONT AXLE ...

Page 376: ...COMPONENT LOCATOR 1 Axle tube assembly 2 Snap ring 3 Ball bearing 4 Oil seal 5 Protector 6 Oil seal 7 Inner shaft LH 8 Inner shaft RH 9 Bolt 10 Front axle bracket LH 11 Front axle bracket RH CONFIGURATION AND FUNCTIONS 4120 01 FRONT AXLE ...

Page 377: ...09 5 AXLE REXTON 2007 09 4120 01 2 Axle Shaft Drive Shaft 1 Drive shaft 2 Housing inboard 3 Boot outboard 4 Boot inboard 5 Shaft 6 Boot band 7 Boot band 8 Boot band 9 Boot band 10 Seal 11 Ball joint ...

Page 378: ...09 6 REXTON 2007 09 4220 01 AXLE 1 COMPONENTS LOCATOR 1 Axle shaft Tube 2 Stabilizer bar 3 Spring seat and spring 4 Upper arm 5 Shock absorber 6 Lateral rod 7 Flange 8 Axle housing 4220 01 REAR AXLE ...

Page 379: ... 2 CROSS SECTIONAL VIEW 1 Rear axle shaft assembly 2 Brake assembly parking brake 3 Oil seal inner 4 Bolt 5 Axle shaft tube 6 Coil spring seat lower 7 Carrier assembly 8 Input shaft Flange 9 Rod mounting bracket 10 Wheel speed sensor ...

Page 380: ...01 IOP INTEGRATED OIL PAN FRONT AXLE 4220 01 INDEPENDENT SUSPENSION TYPE REAR AXLE 4122 01 OIL CHANGE REMOVAL AND INSTALLATION 4220 01 TROUBLE DIAGNOSIS 4122 01 OIL CHANGE OF IOP INTEGRATED OIL PAN FRONT AXLE 4122 01 IOP INTEGRATED OIL PAN FRONT AXLE 4220 01 REAR AXLE 4220 01 REAR AXLE SHAFT 3 4 8 13 16 18 21 26 28 ...

Page 381: ......

Page 382: ...10 3 IOP IRDA AXLE REXTON 2007 09 4122 01 4122 01 IOP IRDA AXLE GENERAL 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 383: ...E Components Location CONFIGURATION AND FUNCTIONS 4122 01 IOP INTEGRATED OIL PAN FRONT AXLE 1 OVERVIEW The IOP front axle is integrated with the engine oil pan so that the engine mounting height is lowered and the engine vibration is reduced ...

Page 384: ...tional front axle it makes more space and decreases the engine height so that the vehicle s center point of gravity is lowered and driving safety is ensured while cornering Advantage 2 of IOP Front Axle 2 IOP front axle has a larger mass than conventional front axle due to integration of oil pan In terms of NVH Noise Vibration Harshness it increases the damping force against the engine vibration A...

Page 385: ...10 6 REXTON 2007 09 4122 01 IOP IRDA AXLE 3 POWER FLOW ...

Page 386: ...ange 17 Pinion flange washer 18 Pinion flange nut 19 Fill plug O ring 20 Fill plug 21 Output shaft seal 22 Drain plug 23 Drain plug O ring 24 Differential case bearing 25 Ring gear 26 Differential case 27 Differential case cross pin screw 28 Differential pinion gear thrust washer 29 Differential pinion gear 30 Differential gear thrust washer 31 Differential side gear 32 Differential pinion gear 33...

Page 387: ...10 8 REXTON 2007 09 4220 01 IOP IRDA AXLE 4220 01 INDEPENDENT SUSPENSION TYPE REAR 1 OVERVIEW The IRDA Independent Rear Drive Axle is adopted for the independent type suspension in this vehicle AXLE ...

Page 388: ...10 9 IOP IRDA AXLE REXTON 2007 09 4220 01 2 EXPLODED VIEW ...

Page 389: ...olt 16 Cover pan gasket 17 Dowel pin 18 Cover pan 19 Vent connector 20 Cover pan bolt 21 Dowel pin 22 Pinion spacer 23 Pinion head bearing assembly 24 Pinion shim 25 Pinion gear 26 Output shaft 27 Output shaft snap ring 28 Shaft seal assembly 29 Differential case side bearing snap ring 30 Differential bearing race 31 Drain plug 32 Drain plug washer 33 Filler plug 34 Filler plug washer 35 Pinion fl...

Page 390: ...10 11 IOP IRDA AXLE REXTON 2007 09 4220 01 Sectional Drawing ...

Page 391: ...10 12 REXTON 2007 09 4220 01 IOP IRDA AXLE 3 COMPONENTS LOCATION ...

Page 392: ... leakage drain the oil completely and then put the specified amount of oil 0 78 L by using a measuring container In case of oil leakage If water has entered inside the axle through the air breather when driving on puddle or water If abnormal noise from the axle is heard check the oil level Then if necessary check if any foreign material exists in axle 1 2 3 When the oil refill or change is require...

Page 393: ...ere conditions or the oil leakage perform the following procedures Oil measuring and filling tools SST No Y99410020C Oil level measuring container Oil filling tool Remove the drain plug and drain oil to the oil measuring container 1 After draining the oil completely check the oil conditions and foreign material in oil measuring container If the oil change is required measure the drained oil level ...

Page 394: ...k of the oil filling tool into the filler plug of IOP axle and refill new oil same specification with the drained oil as the same amount of the drained oil if there is no leakage 3 If there is leakage refill the specified oil approx 0 78 L Make sure thah the oil with specified specification is refilled Oil specification Shell Synthtic Fuel Efficient GL 75W 90 ...

Page 395: ...10 16 REXTON 2007 09 4220 01 IOP IRDA AXLE REMOVAL AND INSTALLATION 4220 01 TROUBLE DIAGNOSIS ...

Page 396: ...2007 09 4220 01 Inspection of Ring Gear Tooth Contact Pattern Normal contact Apply gear marking compound Prussian blue red lead on the ring gear teeth Rotate the ring gear and check the tooth contact pattern 1 Abnormal contact 2 ...

Page 397: ...8 REXTON 2007 09 4122 01 IOP IRDA AXLE 4122 01 OIL CHANGE OF IOP INTEGRATED OIL PAN FRONT AXLE The inner diameter of seals are different from each other Therefore be careful not to mix them when installing ...

Page 398: ...P front axle and remove the pressed seal using a long flat blade screwdriver 1 A large tool should be used to remove the seal in the axle housig Secure the adjuster in its location when removing or installing the seal Do not scratch inside the seal surface 2 Install new oil seal and adjust its level ...

Page 399: ... the special tool make sure the direction is correct When there is leakage in the left oil seal of the IOP axle the repair work can be performed on the vehicle with the left drive shaft removed When there is leakage in the right oil seal of the IOP axle the oil can be found around the IOP connector ...

Page 400: ... from IOP front axle and remove four bolts from transfer case front output shaft to remove the front propeller shaft 1 When removing the front propeller shaft push it from the front side IOP axle side to the rear side T C side so that the front side is separated first Remove the oil drain plug and drain the axle oil completely to the measuring container special tool 2 ...

Page 401: ... 3 Remove the tires and remove the split pin and mounting nut on the knuckle 5 Remove drive shafts LH RH from the axle using a special tool 4 Separate the upper arm and the upper seat of the knuckle Removal of Split Pin Removal of Mounting Nut ...

Page 402: ...007 09 4122 01 6 Unscrew four bolts at the right side of the oil pan and remove the connector assembly 7 Push out the intermediate shaft When removing the intermediate shaft make sure not to contact the differential case cross pin ...

Page 403: ...10 24 REXTON 2007 09 4122 01 IOP IRDA AXLE Removal of Intermediate Shaft 8 Unscrew the mounting bolts and remove the IOP front axle assembly Mounting Location ...

Page 404: ...10 25 IOP IRDA AXLE REXTON 2007 09 4122 01 Front Axle Layout ...

Page 405: ... tire Unscrew four mounting bolts at rear axle side and remove the rear propeller shaft 1 70 80 Nm Separate the air breather hose from the clamp 2 3 Unscrew the mounting bolts LH RH 6EA and remove the rear drive shaft Install the hydraulic jack under the axle housing to support it 4 ...

Page 406: ...everse order when installing 5 Remove the rear front axle mounting bolt and install the rear front axle mount bolt in the reverse order when intalling 6 Remove the rear axle by lowering the hydraulic jack 7 Unscrew three mounting bolts from the rear axle and remove the bracket screw three mounting in the reverse order when intalling 8 ...

Page 407: ...AR AXLE SHAFT Remove the tire Make the installation mark on the axle shaft and the axle flange and remove the mounting bolts LH RH 6EA 1 2 Stretch out the bent point in the axle shaft lock nut and remove the lock nut 3 Lower the axle shaft and pull it out ...

Page 408: ...11 3 PROPELLER SHAFT REXTON 2007 09 3310 01 3310 01 PROPELLER SHAFT GENERAL 1 SPECIFICATION ...

Page 409: ... 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 410: ...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 411: ...11 6 REXTON 2007 09 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 412: ...12 3 STEERING SYSTEM REXTON 2007 09 4620 01 1 SPECIFICATIONS 4620 01 STEERING SYSTEM GENERAL ...

Page 413: ...12 4 REXTON 2007 09 4620 01 STEERING SYSTEM 2 TIGHTENING TORQUE ...

Page 414: ...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 415: ...12 6 REXTON 2007 09 4620 01 STEERING SYSTEM 2 COMPONENT LOCATOR 1 System Layout Installation point A Steering components 1 ...

Page 416: ... REXTON 2007 09 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 417: ...12 8 REXTON 2007 09 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 418: ...13 3 SUSPENSION REXTON 2007 09 4411 01 1 SPECIFICATIONS 4411 01 SUSPENSION GENERAL 1 FRONT SUSPENSION SPECIFICATIONS ...

Page 419: ...13 4 REXTON 2007 09 4411 01 SUSPENSION 2 REAR SUSPENSION SPECIFICATIONS ...

Page 420: ...NO DATA ...

Page 421: ...ering SSPS SSPS 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 P...

Page 422: ...15 4 REXTON 2007 09 4620 01 ELECTRONIC CONTROL POWER STEERING 2 INPUT OUTPUT OF ECPS CONTROL UNIT ...

Page 423: ...supplied to reaction 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 424: ... It provides heavy 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 ...

Page 425: ... unit supplies 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 426: ...15 8 REXTON 2007 09 4620 01 ELECTRONIC CONTROL POWER STEERING 5 CIRCUIT DIAGRAM ...

Page 427: ...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 428: ...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 429: ...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 430: ...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 431: ...16 7 BRAKE SYSTEM REXTON 2007 09 4850 01 3 BRAKE SYSTEM COMPONENTS LOCATOR ...

Page 432: ...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 433: ... part number 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 ...

Page 434: ...esting 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 servi...

Page 435: ... 1 The 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 ...

Page 436: ...lower sliding 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 vehi...

Page 437: ...ting lateral 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 ...

Page 438: ...e unstable 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 a...

Page 439: ...ed by simple 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 cy...

Page 440: ...rated hydraulic 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 441: ...11 ANTI BRAKE SYSTEM REXTON 2007 09 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 442: ...17 12 REXTON 2007 09 4892 01 ANTI BRAKE SYSTEM 3 INPUT AND OUTPUT DIAGRAM OF ABS UNIT ...

Page 443: ...nnel 4 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 444: ...is Operating 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 445: ... closed 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 clos...

Page 446: ... increases 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 ...

Page 447: ...ke Distribution 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 man...

Page 448: ...er mounting 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 h...

Page 449: ...17 19 ANTI BRAKE SYSTEM REXTON 2007 09 4892 01 6 ELECTRIC CIRCUIT DIAGRAM 1 ABS W SPEED SENSOR STOP LAMP SW DIAGNOSIS HDC TPMS ABS ESP ...

Page 450: ...18 3 ELECTRONIC STABILITY PROGRAM REXTON 2007 09 4892 01 1 SPECIFICATIONSS 4892 01 ESP Electronic Stability Program SYSTEM GENERAL ...

Page 451: ...during cornering 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 sensor...

Page 452: ...18 5 ELECTRONIC STABILITY PROGRAM REXTON 2007 09 4892 01 2 COMPONENTS LOCATION ...

Page 453: ...18 6 REXTON 2007 09 4892 01 ELECTRONIC STABILITY PROGRAM 3 INPUT AND OUTPUT DIAGRAM OF ESP UNIT ...

Page 454: ... apply the brake 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 opera...

Page 455: ...orce increases 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 ...

Page 456: ...hen the rear 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...

Page 457: ...vehicle controls 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 458: ...18 11 ELECTRONIC STABILITY PROGRAM REXTON 2007 09 4892 01 5 HYDRAULIC DIAGRAM OF ESP ...

Page 459: ...he instrument 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 ...

Page 460: ...RAKING POSITION 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 461: ...essure The pressure 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 462: ...let valve and 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 463: ...sed pressure 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 464: ...system is a 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...

Page 465: ...18 18 REXTON 2007 09 4892 01 ELECTRONIC STABILITY PROGRAM ...

Page 466: ...king depending 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 ...

Page 467: ...18 20 REXTON 2007 09 4892 01 ELECTRONIC STABILITY PROGRAM 7 ELECTRIC CIRCUIT DIAGRAM Wheel Speed Sensor Stop Lamp Switch Diagnostic Connector Warning Lamp ABS ESP ...

Page 468: ...18 21 ELECTRONIC STABILITY PROGRAM REXTON 2007 09 4892 01 Brake Pressure Sensor Steering Wheel Angle Sensor Sensor Cluster ESP OFF Switch ...

Page 469: ...01 3 AIR CONDITIONER REXTON 2007 09 6820 11 1 SPECIFICATIONS 6820 11 AIR CONDITIONER GENERAL ...

Page 470: ...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 471: ...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 472: ...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 473: ...01 7 AIR CONDITIONER REXTON 2007 09 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 474: ...01 8 REXTON 2007 09 6820 11 AIR CONDITIONER 2 AIR FLOWS Refrigerant Flows ...

Page 475: ... 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 476: ...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 477: ...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 478: ...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 479: ...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 480: ...01 14 REXTON 2007 09 6820 11 AIR CONDITIONER 5 CIRCUIT DIAGRAM 1 Automatic Air Conditioner CONDENSOR FAN SENSOR D27DT GSL ...

Page 481: ...01 15 AIR CONDITIONER REXTON 2007 09 6820 11 CONDENSOR FAN SENSOR D27DTP ...

Page 482: ...01 16 REXTON 2007 09 6820 11 AIR CONDITIONER MOTOR MODE INTAKE BLOWER POWER TR ...

Page 483: ...01 17 AIR CONDITIONER REXTON 2007 09 6820 11 2 Manual Air Conditioner Power A C Compressor Motors Mode Interior Ambient Air Mix ...

Page 484: ...01 18 REXTON 2007 09 6820 11 AIR CONDITIONER Blower Motor Front Rear ...

Page 485: ...02 3 FULL AUTO TEMPERTURE CONTROL REXTON 2007 09 8511 14 8511 14 FULL AUTO TEMPERATURE CONTROL GENERAL 1 SPECIFICATIONS ...

Page 486: ...02 4 REXTON 2007 09 8511 14 FULL AUTO TEMPERTURE CONTROL OVERVIEW AND OPERATION PROCESS 1 FATC SYSTEM LAYOUT Configuration and Characteristic of A C Controller ...

Page 487: ...02 5 FULL AUTO TEMPERTURE CONTROL REXTON 2007 09 8511 14 A C System Related Devices ...

Page 488: ...ature switch in increment of 0 5 C When pressing the AMB button the display shows the ambient temperature and returns to the adjusted temperature The ambient temperature switch can be affected by the heat in the engine compartment since it is installed in front of the radiator Therefore the display can show the correct temperature when the vehicle is driven at over a certain speed approx 40 km h 2...

Page 489: ...t voltage of the blower motor simultaneously The blower motor can shift without step 3 Vent Rate Control By Heating Operation When the temperature of the engine coolant is low or it s difficult to obtain the desired hot air in winter the system controls to prevent the cold airflow from the outlet due to the cold air give a negative effect to the heating performance ...

Page 490: ... hot air 5 Defroster Calibration On the blower AUTO step when the passenger sets to Defroster Def the system increases the blower voltage by 2 V for some intervals comparing AUTO voltage But it is excluded the condition when the blower voltage is above 10 5 V Also the voltage increasing by defroster calibration is limited up to 10 5 V 3 Vent Inlet Control 1 Manual control When you push the I A con...

Page 491: ...ssing AQS switch When the AQS switch is pressed in the recirculation mode is maintained for 20 seconds regardless of the AQS sensor s input Then the AQS controls the intake mode according to the air polution However the signal of the AQS is overridden if the heater is controlling the fan Preheating of AQS when starting the engine For stabilization of the AQS sensor the signal from the AQS sensor i...

Page 492: ...ntrol you can select four type of the vent outlets When you push the Def switch it keeps to change to the defroster mode regardless of the sequence 2 AUTO Control 5 A C Control 1 Manual control When you pushed the A C switch ON or the Def switch ON A C starts to operate 2 AUTO control Basic Control A C ON has the priority for the initial operation ...

Page 493: ...s 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 wiper on the A C AUTO mode after sending the wiper signal and controlling the delay for 1 minutes 8 Dehumidifying Control 1 Basic functions To dehumidify the window glass before it will be fogged the defrost timing is assumed by the...

Page 494: ...02 12 REXTON 2007 09 8511 14 FULL AUTO TEMPERTURE CONTROL 3 CIRCUIT DIAGRAM FATC Full Auto Temperature Control ...

Page 495: ...03 3 FFH SYSTEM REXTON 2007 09 6910 03 6910 03 FFH SYSTEM GENERAL 1 SPECIFICATIONS ...

Page 496: ...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 497: ...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 498: ...03 6 REXTON 2007 09 6910 03 FFH SYSTEM Exploded View ...

Page 499: ... 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 500: ...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 501: ...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 502: ...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 503: ...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 504: ...03 12 REXTON 2007 09 6910 03 FFH SYSTEM 7 Characteristic Curve of Water Pump 12 V 8 Function Diagram ...

Page 505: ...03 13 FFH SYSTEM REXTON 2007 09 6910 03 9 Sectional Drawing according to the Temperatures ...

Page 506: ... 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 507: ...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 508: ...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 509: ... 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 510: ...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 511: ... 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 512: ...04 4 REXTON 2007 09 6810 21 PTC SYSTEM PTC operating relay Engine ECU PTC unit 2 COMPONENTS LOCATOR ...

Page 513: ...04 5 PTC SYSTEM REXTON 2007 09 6810 21 3 COMPONENTS CHARACTERISTICS OF PTC ...

Page 514: ...04 6 REXTON 2007 09 6810 21 PTC SYSTEM 4 CIRCUIT DIAGRAM ...

Page 515: ...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 516: ...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 517: ...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 518: ...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 519: ...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 520: ... 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 521: ... 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 522: ...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 523: ...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 524: ...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 525: ...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 526: ...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 527: ...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 528: ...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 529: ...06 3 SEAT REXTON 2007 09 8510 31 1 SPECIFICATIONS 8510 31 SEAT GENERAL ...

Page 530: ...06 4 REXTON 2007 09 8510 31 SEAT 1 SEAT ARRANGEMNT OVERVIEW AND OPERATION PROCESS ...

Page 531: ...NO DATA ...

Page 532: ...NO DATA ...

Page 533: ...NO DATA ...

Page 534: ...10 3 BODY REPAIR REXTON 2007 09 4012 01 4012 01 BODY DIMENSIONS GENERAL 1 DIMENSIONS Unit mm Option ...

Page 535: ...10 4 REXTON 2007 09 4012 01 BODY REPAIR IRS type 5 link type 2 JACK UP POINTS DOTTED CIRCLES ...

Page 536: ...10 5 BODY REPAIR REXTON 2007 09 4012 01 3 APPLIED THE ASPHALT TO THE BODY PANEL IMPROVED ANTI VIBRATION ...

Page 537: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 538: ......

Page 539: ...0 3 ECU GASOLINE REXTON 2007 09 0000 00 0000 00 ECU GASOLINE DIAGNOSIS 1 ECU GASOLINE ...

Page 540: ...0 4 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 541: ...0 5 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 542: ...0 6 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 543: ...0 7 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 544: ...0 8 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 545: ...0 9 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 546: ...0 10 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 547: ...0 11 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 548: ...0 12 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 549: ...0 13 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 550: ...0 14 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 551: ...0 15 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 552: ...0 16 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 553: ...0 17 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 554: ...0 18 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 555: ...0 19 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 556: ...0 20 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 557: ...0 21 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 558: ...0 22 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 559: ...0 23 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 560: ...0 24 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 561: ...0 25 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 562: ...0 26 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 563: ...0 27 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 564: ...0 28 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 565: ...0 29 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 566: ...0 30 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 567: ...0 31 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 568: ...0 32 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 569: ...0 33 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 570: ...0 34 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 571: ...0 35 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 572: ...0 36 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 573: ...0 37 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 574: ...0 38 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 575: ...0 39 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 576: ...0 40 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 577: ...0 41 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 578: ...0 42 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 579: ...0 43 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 580: ...0 44 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 581: ...0 45 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 582: ...0 46 REXTON 2007 09 0000 00 ECU GASOLINE ...

Page 583: ...0 47 ECU GASOLINE REXTON 2007 09 0000 00 ...

Page 584: ......

Page 585: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 586: ......

Page 587: ...0 3 ECU DIESEL REXTON 2007 09 0000 00 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL ...

Page 588: ...0 4 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 589: ...0 5 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 590: ...0 6 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 591: ...0 7 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 592: ...0 8 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 593: ...0 9 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 594: ...0 10 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 595: ...0 11 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 596: ...0 12 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 597: ...0 13 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 598: ...0 14 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 599: ...0 15 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 600: ...0 16 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 601: ...0 17 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 602: ...0 18 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 603: ...0 19 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 604: ...0 20 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 605: ...0 21 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 606: ...0 22 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 607: ...0 23 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 608: ...0 24 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 609: ...0 25 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 610: ...0 26 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 611: ...0 27 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 612: ...0 28 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 613: ...0 29 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 614: ...0 30 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 615: ...0 31 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 616: ...0 32 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 617: ...0 33 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 618: ...0 34 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 619: ...0 35 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 620: ...0 36 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 621: ...0 37 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 622: ...0 38 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 623: ...0 39 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 624: ...0 40 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 625: ...0 41 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 626: ...0 42 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 627: ...0 43 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 628: ...0 44 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 629: ...0 45 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 630: ...0 46 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 631: ...0 47 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 632: ...0 48 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 633: ...0 49 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 634: ...0 50 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 635: ...0 51 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 636: ...0 52 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 637: ...0 53 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 638: ...0 54 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 639: ...0 55 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 640: ...0 56 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 641: ...0 57 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 642: ...0 58 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 643: ...0 59 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 644: ...0 60 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 645: ...0 61 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 646: ...0 62 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 647: ...0 63 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 648: ...0 64 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 649: ...0 65 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 650: ...0 66 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 651: ...0 67 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 652: ...0 68 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 653: ...0 69 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 654: ...0 70 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 655: ...0 71 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 656: ...0 72 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 657: ...0 73 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 658: ...0 74 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 659: ...0 75 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 660: ...0 76 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 661: ...0 77 ECU DIESEL REXTON 2007 09 0000 00 ...

Page 662: ...0 78 REXTON 2007 09 0000 00 ECU DIESEL ...

Page 663: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 664: ......

Page 665: ...0 3 BRAKE REXTON 2007 09 0000 00 0000 00 BRAKE DIAGNOSIS 1 BRAKE ...

Page 666: ...0 4 REXTON 2007 09 0000 00 BRAKE ...

Page 667: ...0 5 BRAKE REXTON 2007 09 0000 00 ...

Page 668: ...0 6 REXTON 2007 09 0000 00 BRAKE ...

Page 669: ...0 7 BRAKE REXTON 2007 09 0000 00 ...

Page 670: ...0 8 REXTON 2007 09 0000 00 BRAKE ...

Page 671: ...0 9 BRAKE REXTON 2007 09 0000 00 ...

Page 672: ...0 10 REXTON 2007 09 0000 00 BRAKE ...

Page 673: ...0 11 BRAKE REXTON 2007 09 0000 00 ...

Page 674: ...0 12 REXTON 2007 09 0000 00 BRAKE ...

Page 675: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 676: ......

Page 677: ...0 3 AIR BAG REXTON 2007 09 0000 00 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG ...

Page 678: ...0 4 REXTON 2007 09 0000 00 AIR BAG ...

Page 679: ...0 5 AIR BAG REXTON 2007 09 0000 00 ...

Page 680: ...0 6 REXTON 2007 09 0000 00 AIR BAG ...

Page 681: ...0 7 AIR BAG REXTON 2007 09 0000 00 ...

Page 682: ...0 8 REXTON 2007 09 0000 00 AIR BAG ...

Page 683: ...0 9 AIR BAG REXTON 2007 09 0000 00 ...

Page 684: ...0 10 REXTON 2007 09 0000 00 AIR BAG ...

Page 685: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 686: ......

Page 687: ...0 3 CCCS REXTON 2007 09 0000 00 0000 00 CCCS DIAGNOSIS 1 CCCS ...

Page 688: ...0 4 REXTON 2007 09 0000 00 CCCS ...

Page 689: ...0 5 CCCS REXTON 2007 09 0000 00 ...

Page 690: ...0 6 REXTON 2007 09 0000 00 CCCS ...

Page 691: ...0 7 CCCS REXTON 2007 09 0000 00 ...

Page 692: ...0 8 REXTON 2007 09 0000 00 CCCS ...

Page 693: ...0 9 CCCS REXTON 2007 09 0000 00 ...

Page 694: ...0 10 REXTON 2007 09 0000 00 CCCS ...

Page 695: ...0 11 CCCS REXTON 2007 09 0000 00 ...

Page 696: ...0 12 REXTON 2007 09 0000 00 CCCS ...

Page 697: ...0 13 CCCS REXTON 2007 09 0000 00 ...

Page 698: ...0 14 REXTON 2007 09 0000 00 CCCS ...

Page 699: ...0 15 CCCS REXTON 2007 09 0000 00 ...

Page 700: ...0 16 REXTON 2007 09 0000 00 CCCS ...

Page 701: ...0 17 CCCS REXTON 2007 09 0000 00 ...

Page 702: ...0 18 REXTON 2007 09 0000 00 CCCS ...

Page 703: ...0 19 CCCS REXTON 2007 09 0000 00 ...

Page 704: ...0 20 REXTON 2007 09 0000 00 CCCS ...

Page 705: ...0 21 CCCS REXTON 2007 09 0000 00 ...

Page 706: ...0 22 REXTON 2007 09 0000 00 CCCS ...

Page 707: ...0 23 CCCS REXTON 2007 09 0000 00 ...

Page 708: ...0 24 REXTON 2007 09 0000 00 CCCS ...

Page 709: ...0 25 CCCS REXTON 2007 09 0000 00 ...

Page 710: ...0 26 REXTON 2007 09 0000 00 CCCS ...

Page 711: ...0 27 CCCS REXTON 2007 09 0000 00 ...

Page 712: ......

Page 713: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 714: ......

Page 715: ...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 716: ...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 717: ...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 718: ...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 719: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 720: ......

Page 721: ...0 3 FFH REXTON 2007 09 0000 00 0000 00 FFH DIAGNOSIS 1 FFH ...

Page 722: ...0 4 REXTON 2007 09 0000 00 FFH ...

Page 723: ...0 5 FFH REXTON 2007 09 0000 00 ...

Page 724: ...0 6 REXTON 2007 09 0000 00 FFH ...

Page 725: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 726: ......

Page 727: ...0 3 P TRUNK REXTON 2007 09 0000 00 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK ...

Page 728: ...0 4 REXTON 2007 09 0000 00 P TRUNK ...

Page 729: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 730: ......

Page 731: ...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 732: ...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 733: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 734: ......

Page 735: ...0 3 STICS REXTON 2007 09 0000 00 0000 00 STICS DIAGNOSIS 1 STICS ...

Page 736: ...0 4 REXTON 2007 09 0000 00 STICS ...

Page 737: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 738: ......

Page 739: ...0 3 TC REXTON 2007 09 0000 00 0000 00 TC DIAGNOSIS 1 TC ...

Page 740: ...0 4 REXTON 2007 09 0000 00 TC ...

Page 741: ...0 5 TC REXTON 2007 09 0000 00 ...

Page 742: ...0 6 REXTON 2007 09 0000 00 TC ...

Page 743: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 744: ......

Page 745: ...0 3 TCU REXTON 2007 09 0000 00 DIAGNOSIS 0000 00 TCU 1 TCU ...

Page 746: ...0 4 REXTON 2007 09 0000 00 TCU ...

Page 747: ...0 5 TCU REXTON 2007 09 0000 00 ...

Page 748: ...0 6 REXTON 2007 09 0000 00 TCU ...

Page 749: ...0 7 TCU REXTON 2007 09 0000 00 ...

Page 750: ...0 8 REXTON 2007 09 0000 00 TCU ...

Page 751: ...0 9 TCU REXTON 2007 09 0000 00 ...

Page 752: ...0 10 REXTON 2007 09 0000 00 TCU ...

Page 753: ...0 11 TCU REXTON 2007 09 0000 00 ...

Page 754: ...0 12 REXTON 2007 09 0000 00 TCU ...

Page 755: ...0 13 TCU REXTON 2007 09 0000 00 ...

Page 756: ...0 14 REXTON 2007 09 0000 00 TCU ...

Page 757: ...0 15 TCU REXTON 2007 09 0000 00 ...

Page 758: ...0 16 REXTON 2007 09 0000 00 TCU ...

Page 759: ...0 17 TCU REXTON 2007 09 0000 00 ...

Page 760: ...0 18 REXTON 2007 09 0000 00 TCU ...

Page 761: ...0 19 TCU REXTON 2007 09 0000 00 ...

Page 762: ......

Page 763: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 764: ......

Page 765: ...0 3 TGS LEVER REXTON 2007 09 0000 00 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER ...

Page 766: ...0 4 REXTON 2007 09 0000 00 TGS LEVER ...

Page 767: ...0 5 TGS LEVER REXTON 2007 09 0000 00 ...

Page 768: ...0 6 REXTON 2007 09 0000 00 TGS LEVER ...

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