SSANGYONG RODIUS 2004.09 Manual Download Page 407 | Manualshive

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01-13

DC 5-SPEED

RODIUS 2004.09

3650-01

2) 2nd Gear (2.408)

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 speed
Output shaft: Clockwise rotation

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Summary of Contents for RODIUS 2004.09

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

Page 2: ......

Page 3: ...al No1 Refer to Major Connector Position Section 2 D S201 Splice pack S201 S207 Refer to Major Splice Pack Position Section2 E Wiring Harness Color Refer to Wiring Harness Color Abbreviation F Internal circuit of component Relay Component Name and Terminal Number G Internal circuit of component Switch Component Name Terminal Number and Connecting Wiring Circuit H Lower horizontal line Ground line ...

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

Page 5: ...k Joint connector that connects various wiring harness 1 Part location number Part number according to locating section Part Numbe Location 1 Engine compartment 2 Instrument panel 3 Passenger compartment 4 Tailgate 9 Underbody In the locating section the assignment for part number startsfrom left bottom and proceeds clockwise In the fuse and relay box or the instrument panel the partnumber is assi...

Page 6: ......

Page 7: ... WIRING 8201 00 WIRING HARNESS COMPONENTS LOCATION CONNECTOR GROUND 8210 02 W H ENGINE ROOM 8210 01 W H MAIN 8210 03 W H FLOOR LH 8210 04 W H FLOOR RH 8210 06 W H DOOR LH RH 8210 07 W H RR DOOR 6810 11 W H FRT AIR CON 6811 07 W H RR AIR CON 8210 09 W H TAIL GATE 8210 08 W H ROOF 7421 60 W H SEAT 3 17 18 20 21 21 22 22 23 23 24 24 ...

Page 8: ...0 2 RODIUS 2004 09 0000 00 CONNECTOR GROUND WIRING HARNESS 8201 00 WIRING HARNESS COMPONENTS LOCATION 1 POSITION OF CONNECTOR GROUND SPLICE PACK 2 COMPONENTS LOCATION ...

Page 9: ...0 3 CONNECTOR GROUND RODIUS 2004 09 8201 00 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 10: ...0 4 RODIUS 2004 09 8201 00 CONNECTOR GROUND GROUND SPLICE PACK ...

Page 11: ...0 5 CONNECTOR GROUND RODIUS 2004 09 8201 00 4 CONNECTOR C101 C102 C103 C104 C105 ...

Page 12: ...0 6 RODIUS 2004 09 8201 00 CONNECTOR GROUND C106 C107 C108 C109 C109 C110 C109 ...

Page 13: ...0 7 CONNECTOR GROUND RODIUS 2004 09 8201 00 C115 C116 C113 C114 DSL ...

Page 14: ...0 8 RODIUS 2004 09 8201 00 CONNECTOR GROUND C201 C203 ...

Page 15: ...0 9 CONNECTOR GROUND RODIUS 2004 09 8201 00 C204 C205 C204 C204 ...

Page 16: ...0 10 RODIUS 2004 09 8201 00 CONNECTOR GROUND C210 C211A 13 PIN FATC C202 C212 C211 C211A 16 PIN MANUAL C211B ...

Page 17: ...0 11 CONNECTOR GROUND RODIUS 2004 09 8201 00 C213 C217 C219 C213 C218 ...

Page 18: ...0 12 RODIUS 2004 09 8201 00 CONNECTOR GROUND C221 C302 C303 C304 C301 C220 ...

Page 19: ...0 13 CONNECTOR GROUND RODIUS 2004 09 8201 00 C306 C351 C381 C305 C361 C371 ...

Page 20: ...0 14 RODIUS 2004 09 8201 00 CONNECTOR GROUND C402 C903 C401 C901 C902 ...

Page 21: ...0 15 CONNECTOR GROUND RODIUS 2004 09 8201 00 S201 S203 GND S205 CAN S206 GND 5 SPLICE PACK S202 S204 ILL ...

Page 22: ...0 16 RODIUS 2004 09 8201 00 CONNECTOR GROUND S207 ...

Page 23: ...0 17 CONNECTOR GROUND RODIUS 2004 09 8210 02 CONNECTOR 8210 02 W H ENGINE ROOM ...

Page 24: ...0 18 RODIUS 2004 09 8210 01 CONNECTOR GROUND 8210 01 W H MAIN ...

Page 25: ...0 19 CONNECTOR GROUND RODIUS 2004 09 8210 03 ...

Page 26: ...0 20 RODIUS 2004 09 8210 03 CONNECTOR GROUND 8210 03 W H FLOOR LH ...

Page 27: ...0 21 CONNECTOR GROUND RODIUS 2004 09 8210 04 8210 04 W H FLOOR RH 8210 06 W H DOOR LH RH ...

Page 28: ...0 22 RODIUS 2004 09 8210 07 CONNECTOR GROUND 8210 07 W H RR DOOR 6810 11 W H FRT AIR CON ...

Page 29: ...0 23 CONNECTOR GROUND RODIUS 2004 09 6811 07 6811 07 W H RR AIR CON 8210 09 W H TAIL GATE ...

Page 30: ...0 24 RODIUS 2004 09 8210 08 CONNECTOR GROUND 8210 08 W H ROOF 7421 60 W H SEAT ...

Page 31: ... DISTRIBUTION 8410 02 8410 05 POWER DISTRIBUTION FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 8410 05 I P FUSE ICM BOX IP RELAY BOX ELECTRICITY DIVIDE 8210 02 ENG ROOM FUSE BOX 8410 04 I P FUSE BOX 3 5 7 11 ...

Page 32: ......

Page 33: ...0 3 POWER DISTRIBUTION RODIUS 2004 09 8410 02 FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 1 FRONT 2 REAR 3 FUSE RELAY POSITION 1 XDi ENGINE ...

Page 34: ...0 4 RODIUS 2004 09 8410 02 POWER DISTRIBUTION 4 USAGE OF FUSE IN ENGINE ROOM FUSE BOX 5 ENGINE ROOM FUSE BOX CONNECTOR NUMBER 2 GSL G23 ENGINE ...

Page 35: ...0 5 POWER DISTRIBUTION RODIUS 2004 09 8410 05 8410 05 I P FUSE ICM BOX IP RELAY BOX 1 FUSE BOX 2 POWER SUPPLY 3 ICM BOX 4 ICM BOX POWER SUPPLY 1 C203 ...

Page 36: ...0 6 RODIUS 2004 09 8410 05 POWER DISTRIBUTION ...

Page 37: ...0 7 POWER DISTRIBUTION RODIUS 2004 09 8410 02 ELECTRICITY DIVIDE 8210 02 ENG ROOM FUSE BOX 1 SB1 SB5 2 SB6 SB11 ...

Page 38: ...0 8 RODIUS 2004 09 8410 02 POWER DISTRIBUTION 3 Ef1 Ef4 4 Ef5 Ef9 ...

Page 39: ...0 9 POWER DISTRIBUTION RODIUS 2004 09 8410 02 5 Ef10 Ef14 6 Ef15 Ef20 ...

Page 40: ...0 10 RODIUS 2004 09 8410 02 POWER DISTRIBUTION 7 Ef21 Ef26 ...

Page 41: ...0 11 POWER DISTRIBUTION RODIUS 2004 09 8410 04 8410 04 I P FUSE BOX 1 F1 F5 2 F6 F15 ...

Page 42: ...0 12 RODIUS 2004 09 8410 04 POWER DISTRIBUTION 3 F16 F21 4 F22 F27 ...

Page 43: ...0 13 POWER DISTRIBUTION RODIUS 2004 09 8410 04 5 F28 F32 ...

Page 44: ......

Page 45: ...10 03 STICS 8510 03 POWER WINDOW CIRCUIT 8710 03 CENTRAL DOOR LOCKING CIRCUIT 8510 12 RR WIPER WASHER CIRCUIT 8610 09 HORN 7630 02 CIGAR LIGHTER POWER OUTLET 7340 03 SUN ROOF CIRCUIT 8310 01 HEAD LAMP DRL DAY TIME RUNNING LIGHT UNIT CIRCUIT 8510 00 HEAD LAMP LEVELING DEVICE CIRCUIT 8320 01 TAIL LAMP CIRCUIT 8510 26 TURN SIGNAL HAZARD LAMP CIRCUIT 8510 24 FOG LAMP CIRCUIT 4810 10 STOP BACK UP LAMP ...

Page 46: ......

Page 47: ...0 3 CIRCUIT RODIUS 2004 09 1461 01 1461 01 STARTING CHARGING 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 48: ...0 4 RODIUS 2004 09 2820 01 CIRCUIT 2820 01 PREHEATING UNIT CIRCUIT DSL 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 49: ...control after monitoring the engine preheating after heating and glow plug diagnosis function the fault contents will be delivered to ECU Engine preheating post heating functions Preheating relay activation by ECU controls Senses engine temperature and controls the preheating post heating time Preheating warning light K LINE for information exchanges between preheating unit and ECU Transmits prehe...

Page 50: ...IRCUIT 1491 01 ECU ENGINE CONTROL UNIT DSL 1 ENG MAIN RELAY PEDAL MODULE HAN SENSORS VALVE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 TRUBO CHARGER BOOSTER EGR VACUUM MODULE INLETMETERING VALVE ...

Page 51: ... 09 1491 01 2 FUEL FILTER WARNING LAMP IMMOBILIZER SENSOR CIRCUIT FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT KNOCK COOLANT TEMP FUEL TEMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 52: ...0 8 RODIUS 2004 09 1491 01 CIRCUIT 3 INJECTOR CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 53: ...m speed Driving mode control If the vehicle runs normally fuel injection volume will be calculated by accelerator pedal travel and engine rpmand the drive map will be used to match the drivers inputs with optimum engine power C ECU INPUTS OUTPUTS D STRUCTURE AND FUNCTION OF ECU ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage levels an...

Page 54: ...0 10 RODIUS 2004 09 1491 01 CIRCUIT 1491 01 ECU E23 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION FUEL PUMP CANISTER PURGE VALVE O2 SENSOR PEDAL MODULE CIRCUIT ...

Page 55: ...S 2004 09 1491 01 2 SPARK PLUG SENSOR CAM SHAFT POSITION MAP NTC CRANK SHAFT POSITION THROTTLE MOTOR AIR TEMP KNOCK CAM SHIFT ACTUATOR CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 56: ...0 12 RODIUS 2004 09 1491 01 CIRCUIT 3 DIGITAL CLOCK ENG TEMP SENSOR IMMOBILIZER CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 57: ...0 13 CIRCUIT RODIUS 2004 09 1491 01 4 C E BOX ECU ICM ECU CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 58: ...0 14 RODIUS 2004 09 8210 01 CIRCUIT 8210 01 DIAGNOSIS CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 59: ...le Connect the No 3 terminal REKES coding and No 16 terminal battery on the diagnosis connector with a jumper cable Press any button on the remote control key shortly approx 0 5 sec When the coding is successful turn signal lamps blink once and warning horn sounds once If the coding has failed repeat 1 to 4 steps ...

Page 60: ...0 16 RODIUS 2004 09 3670 01 CIRCUIT 3670 01 TCU 5 SPEED 1 START MOTOR TGS LEVER CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 61: ...0 17 CIRCUIT RODIUS 2004 09 3670 01 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 62: ...is selected the Winter mode indicator in meter cluster comes on and the vehicle starts off with 2nd gear to achieve smooth starting on the icy or slippery road In winter mode the up shift becomes faster and the down shift becomes slower for improving fuel consumption The W mode is automatically changed to S mode in full throttle or kick down operation The vehicle can starts off with 2nd reverse ge...

Page 63: ...nt planetary carrier If the speed sensor is defective the transmission is operated in emergency driving mode Below table shows the detection of speed sensor H LOCKUP SOLENOID VALVE This valve activates and releases the lockup clutch by adjusting the current to solenoid valve according to engine throttle opening value and output shaft speed The lockup clutch operates in 3rd 4th and 5th gear with st...

Page 64: ...0 20 RODIUS 2004 09 3670 03 CIRCUIT 3670 03 TOD 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 65: ... aid in braking without counteracting the ABS System 4L strategy When the system is operating in 4L the TOD continues TOD operation provided that the propeller shaft speed is below 10 Hz When the speed increases above 10 Hz the EMC Duty Cycle is set to the maximum value 88 which applies the maximum available torque to the front axle B SHIFT REQUIREMENTS If 4H 4L switch position is not matched with...

Page 66: ...started it is completed 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 o...

Page 67: ...0 23 CIRCUIT RODIUS 2004 09 3670 03 ...

Page 68: ...0 24 RODIUS 2004 09 4891 01 CIRCUIT 4891 01 ABS ESP WHEEL SPEED SENSOR STOP LAMP SW DIAGNOSIS WARNING LAMP 1 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 69: ...0 25 CIRCUIT RODIUS 2004 09 4891 01 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 70: ...e ECU recognizes the attempt at full braking and transmits the signal calling for full brake pressure from the hydraulic booster An inexperienced elderly or physically weak driver may suffer from the accident by not fully pressing the brake pedal when hard braking is required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force fr...

Page 71: ...t least 1 4 seconds with 100 ms interval I ESP SYSTEM CANCELLATION USING THE ESP OFF SWITCH When the ESP switch at the center switch panel is pushed for over approximately 150 ms the ESP system will be cancelled and the vehicle will be driven regardless of the output values from the corresponding sensors Then the ESP warning lamp on the instrument panel comes on J RESUMING THE ESP SYSTEM BY USING ...

Page 72: ...0 28 RODIUS 2004 09 8810 01 CIRCUIT 8810 01 AIR BAG 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 73: ... inflation requirements Impact against narrow objects such as a telegraph pole or a tree The vehicle falls into a drainage or a puddle The front of the vehicle crashes into high impact point vehicle such as a truck Impact on the hood by falling stones The air bag warning lamp is on 2 SDM SENSING AND DIAGNOSTIC MODULE The airbag system consists of the module section driver passenger and side seat b...

Page 74: ...0 30 RODIUS 2004 09 8010 01 CIRCUIT 8010 01 CLUSTER 1 GAUGE SPEED RPM FUEL TEMP WARNING LAMP 4WD FUEL FILTER ABS ESP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 75: ... CIRCUIT RODIUS 2004 09 8010 01 2 WARNING BAT CHANGE OIL BRAKE ENG CHECK AIR BAG IMMOM SEAT BELT TURN SIGNAL DEFOGGER DOOR OPEN 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 76: ...there could be defectives in speedometer However these symptoms also could be appeared when the tire has uneven wear different tire inflation pressures or different tire specifications Perform the speedometer test regarding the tolerance as described However it is not similar simple work in field due to lack of measuring conditions such as test equipment and preciseness Check the allowable toleran...

Page 77: ...t changes by coolant temperature is as shown below Measurement of coolant temperature sensor resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range Resistance value by coolant temperature 20 2449W 5 50 826W 5 80 321W 5 100 112W 5 E TRIP ODOMETER TRIP A TRIP B AND ODOMETER This table shows the tolerance and resi...

Page 78: ...0 34 RODIUS 2004 09 8610 04 CIRCUIT 8610 04 MULTI METER 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 79: ...Move and select the information to be adjusted while briefly pressing the MODE button 0 5 seconds The selected information is blinking Changing sequence Adjust the information by using UP or DOWN button Press and hold the MODE button for more than 1 second to set the time and date A day of the week is automatically changed according to the adjusted date month and year An intercalary is automatical...

Page 80: ...d hold over 0 5 seconds continues to increase by 20 m with the interval of 0 2 seconds DOWN button Press briefly below 0 5 seconds decreases by 20 m Press and hold over 0 5 seconds continues to decrease by 20 m with the interval of 0 2 seconds How to erase the calibrated altitude value Press the UP and DOWN buttons simultaneously for more than 1 second to cancel the altitude calibration It can be ...

Page 81: ...or lever to R position This message appears when the parking aid sensor is defective All displaying bars are displayed when the distance between rear bumper and obstacle is over 120 cm The number of displaying bars is decreased and the alarm interval becomes faster as the obstacle approaches H BATTERY MODE The screen shows fully charged battery when the battery voltage is over 12 V It indicates th...

Page 82: ...0 38 RODIUS 2004 09 8610 11 CIRCUIT 8610 11 RAIN SENSING WIPER CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 83: ...nsor unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The sensing section on the windshield is located just above the center point between LED and photodiode The rain sensor has one connector with 4 pins and each pin has following function as shown in the circuit diagram However in this vehicle the terminal No 1 a...

Page 84: ... And the wiper also operates during raining up to 5 minutes after rain stops 3 WASHER COUPLED WIPER FUNCTION Check the washer coupled wiper operation by pressing the washer switch 4 IRREGULAR OPERATIONS ABRUPT OPERATIONS Check the sensor for coming off Check the rain sensor cover installation Check that the customer is familiar to how to control the wiper sensitivity Check that the customer can se...

Page 85: ...is in AUTO position Check the power to sensor Check the conditions of pin 3 Ground and pin 4 IGN Check the wiper relay for defective The wiper operates 3 or 4 times with high speed abruptly 3 Check whether the variable resistance knob on the wiper switch is set in FAST The FAST is the highest stage of sensitivity and very sensitive to small amount of rain drops Therefore change the knob to low sen...

Page 86: ...0 42 RODIUS 2004 09 7421 60 CIRCUIT 7421 60 DRIVER POWER SEAT CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 87: ...0 43 CIRCUIT RODIUS 2004 09 8510 52 8510 52 null ELECTRIC OUTSIDE MIRROR FOLDING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 88: ...0 44 RODIUS 2004 09 8610 17 CIRCUIT 8610 17 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION DEFFOGER FRT GLASS RR GLASS OUTSIDE MIRROR ...

Page 89: ...n turning on the defogger switch while the engine is running If the defogger switch is pressed again during the operation the operation stops If the defogger switch is pressed again within T2 10 minutes after completion of the first operation T1 the defogger system operates for 6 minutes just for once The defogger is not available when the ignition switch is in OFF position or the alternator is no...

Page 90: ...0 46 RODIUS 2004 09 8510 20 CIRCUIT 8510 20 FRT SEAT WARMER 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 91: ...0 47 CIRCUIT RODIUS 2004 09 8510 20 8510 20 AUTO LIGHT CORTROL CIRC 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 92: ...turns on and off the tail lamps and headlamps while the light switch is in AUTO position without light switch operations The system turns on and off the lamps when passing through the tunnel during day driving and getting dark due to fog rain or snow A Turning on conditions 2 INSPECTION Position the multifunction switch to AUTO position and cover the auto light sensor on the instrument panel passe...

Page 93: ...CIRCUIT RODIUS 2004 09 8710 03 8710 03 STICS 1 ESCORT PANIC POWER WINDOW WARNING LAMP PARKING BRAKE SEAT BELT ILL KEY REMINDER SW 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 94: ...0 50 RODIUS 2004 09 8710 03 CIRCUIT 2 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION WIPER DOOR SW LAMP DOOR COURTESY G HANDLE DOOR OPEN WARNING LAMP ...

Page 95: ...0 51 CIRCUIT RODIUS 2004 09 8710 03 3 DOOR LOCK DEFOGGER 1 CONNECTOR INFORMATION ...

Page 96: ...0 52 RODIUS 2004 09 8710 03 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 97: ...g section A TRANSMITTER CODING Remove the ignition key from key hole Connect the No 3 terminal REKES coding and No 16 terminal battery on the diagnosis connector with a jumper cable Press any button on the remote control key shortly approx 0 5 sec hen the coding is successful turn signal lamps blink once and warning horn sounds once If the coding has failed repeat 1 to 4 steps B CONNECTOR ARRANGEM...

Page 98: ... after IGN 1 switch ON is not included 20 ms target input Wiper motor A S parking terminal 100 ms target input switch All switches except wiper motor A S parking terminal Time tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 50 ms The time indicated in each function does not include chattering processing time from switch input changing point D...

Page 99: ...0 55 CIRCUIT RODIUS 2004 09 8710 03 E DIAGNOSIS ...

Page 100: ...0 56 RODIUS 2004 09 8510 03 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 8510 03 POWER WINDOW CIRCUIT ...

Page 101: ...ing the ignition key to OFF position However the power window relay stays on for 30 seconds T2 when the ignition key is turned to OFF position while the door is opened The power window relay is turned ON again for 30 seconds T2 just for once when opening the door during its extended operation period of 30 seconds T1 The power window relay is turned OFF when closing the door during its extended ope...

Page 102: ...0 58 RODIUS 2004 09 8710 03 CIRCUIT 8710 03 CENTRAL DOOR LOCKING CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 103: ...when receiving LOCK signal within 30 seconds T1 after receiving the first UNLOCK signal 4 AUTO DOOR LOCK The door lock system outputs LOCK when the vehicle speed stays over 50 km h However it doesn t output LOCK when all doors are locked or failed If any of doors is unlocked after outputting LOCK in step 1 outputs LOCK up to 5 times except step 1 with interval of one second If any of doors is unlo...

Page 104: ...0 60 RODIUS 2004 09 8510 12 CIRCUIT 8510 12 RR WIPER WASHER CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 105: ...0 61 CIRCUIT RODIUS 2004 09 8610 09 8610 09 HORN 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 106: ...0 62 RODIUS 2004 09 7630 02 CIRCUIT 7630 02 CIGAR LIGHTER POWER OUTLET 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 107: ...0 63 CIRCUIT RODIUS 2004 09 7340 03 7340 03 SUN ROOF CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 108: ...0 64 RODIUS 2004 09 8310 01 CIRCUIT 8310 01 HEAD LAMP DRL 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION HEAD LAMP DRL DAY TIME RUNNING LIGHT UNIT CIRCUIT ...

Page 109: ...0 65 CIRCUIT RODIUS 2004 09 8510 00 8510 00 HEAD LAMP LEVELING DEVICE CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 110: ...0 66 RODIUS 2004 09 8320 01 CIRCUIT 8320 01 TAIL LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 111: ...s turned on and the driver s door is opened This function is not available when the ignition key is in ON position 2 BATTERY SAVER TAIL LAMP AUTO CUT The tail lamp is turn on or off according to the operations of the multifunction tail lamp switch The tail lamp relay is turned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp ...

Page 112: ...0 68 RODIUS 2004 09 8510 26 CIRCUIT 8510 26 TURN SIGNAL HAZARD LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 113: ...n activates the armed ready mode without theft deterrent horn and hazard warning flasher At this moment if the ignition key is in the ignition switch the door unlock switch is turned ON or th door lock switch is unlocked after 0 6 seconds cancels the armed mode and activates the normal mode However in these cases if closing the door and locking the door lock switch the theft deterrent horn outputs...

Page 114: ...g 27 seconds D Warning operation The theft deterrent horn and hazard warning flasher output is ON for T3 27 seconds with the interval of T2 1 second E Warning cancellation requirements Cancels warning by using any signal from the remote control key LOCK UNLOCK START STOP PANIC CHECK during warning operation Cancels warning after 27 seconds remaining period while the ignition key is turned to ON po...

Page 115: ...0 71 CIRCUIT RODIUS 2004 09 8510 24 8510 24 FOG LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 116: ...0 72 RODIUS 2004 09 4810 10 CIRCUIT 4810 10 STOP BACK UP LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 117: ...0 73 CIRCUIT RODIUS 2004 09 8610 01 8610 01 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION INTERIOR LAMP ROOM G HENDLE DOOR COURTESY CIRCUIT ...

Page 118: ... by 30 seconds T3 when receiving the unlock signal from the remote control key again during output When a door is opened during its extended period the lamp stays on If closed operates as in step 2 The room lamp output stops immediately after receiving the lock signal from driver s door and passenger s door lock switch while the driver s door and passenger s door are closed B Rear room lamp The re...

Page 119: ...0 75 CIRCUIT RODIUS 2004 09 7770 07 7770 07 AUTO DIMMING ROOM MIRROR CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 120: ...0 76 RODIUS 2004 09 8910 01 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 8910 01 AUDIO MULTI VISION A V HEAD UNIT NAVI UNIT DVD CHANGER GPS RR VIEW CAMARA 1 ...

Page 121: ...0 77 CIRCUIT RODIUS 2004 09 8910 01 2 A V HEAD UNIT DSP AMP TUNER UNIT WOOFER AMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 122: ... play following discs DVD R DVD RAM DVD ROM DVD Audio CD G Mixed CD Date Active Audio Date VSD Multi section disc DVD with region code other than 3 or ALL Bulk CD R or CD RW that their quality cannot be secured may not be recognized Double layer DVD video disc When playing the double layer disc there occurs time lag between at the end of first layer and start of second layer causing broken display...

Page 123: ...nel rear end receives amplified signals from glass antenna and then transmits to tuner input 1 channel DVD Navigation CHINA Only Navigation unit in this vehicle transmits huge amount of data on the DVD CD directly to AV head unit without via tuner and AMP It has 3D view function for roads and buildings and supporting data GPS antenna to receive send vehicle position from to satellite is located be...

Page 124: ...dless of displays by head unit Auto mode Automatic operating mode When selecting R position while A V system is in use Ignition switch ON engine running The video mode in front A V system is changed to rearview monitoring mode However the audio mode stays on The video mode in front A V system resumes when shifting out from R position The audio and video mode in rear A V system are not changed When...

Page 125: ...0 81 CIRCUIT RODIUS 2004 09 8910 01 8910 01 AUDIO 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSI ...

Page 126: ...0 82 RODIUS 2004 09 8730 01 CIRCUIT 8730 01 PARKING AID CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 127: ...cure the safety distance for parking A Parking aid unit Detecting type Super sonic wave Detecting distance 25 120 cm distance between sensor and obstacle B Parking aid sensor Type Piezo ceramic element Frequency 40 KHz 2 KHz Detecting range 13 5 V Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 cm Min 60 at 50 5 cm 2 ALARM INTERVAL Alarm interval and display changes accor...

Page 128: ...unds for 3 seconds and the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions conditions for warning beep due to failure Sensor failure conditions conditions for warning beep due to failure Open in sending circuit Open in ...

Page 129: ...0 85 CIRCUIT RODIUS 2004 09 6810 21 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 6810 21 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT ...

Page 130: ...perating condition of PTC is controlled by two step Generally ECU control the power relay for PTC depending on the coolant temperature and ambient temperature sensor 1st step Initial PTC operating condition When coolant temperature 15 C PTC is operating ON When coolant temperature 15 C tow conditions decribed below must be satisfied 2nd step Coolant temperature 15 C When coolant temperature 65 C a...

Page 131: ...0 87 CIRCUIT RODIUS 2004 09 6910 01 6910 01 FFH FUEL FIRED HEATER 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 132: ...ng the fuel pump still fails to ignite the heater is switched off in fault mode The controller is locked after a certain number of failed starts If the flame does out by itself during operation firstly a new start is activated If the fuel pump fails to ignite within 90 seconds after fuel pumping has started again the heater is switched off If the heater is overheated lack of water poorly vented co...

Page 133: ...0 89 CIRCUIT RODIUS 2004 09 6910 01 ...

Page 134: ...0 90 RODIUS 2004 09 6910 01 CIRCUIT 4 GENERAL TROUBLE CAUSES AND REMEDIES ...

Page 135: ...RCUIT RODIUS 2004 09 6810 30 6810 30 FATC FULL AUTO TEMP CONTROL CIRCUIT 1 CONDENSOR FAN AIR MIX MOTOR SUN SENSOR WATER TEMP SENSOR 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 136: ...0 92 RODIUS 2004 09 6810 30 CIRCUIT 2 FRT BLOWER ACTUATOR MODE INTAKE AQS SENSOR 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 137: ...0 93 CIRCUIT RODIUS 2004 09 6810 30 3 RR AIR CON BLOWER MODE ACTIATOR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 138: ...0 94 RODIUS 2004 09 6810 30 CIRCUIT 6810 30 AIR CON MANUAL 1 POWER A C COMP MOTOR MODE INTAKE AIR MIX 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 139: ...0 95 CIRCUIT RODIUS 2004 09 6810 30 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 BLOWER MOTOR FRT RR ...

Page 140: ...e caused by disconnecting the interior temperature sensor humidity temperature sensor connector After displaying defect code operates again in AUTO mode For sun sensor the diagnosis for short circuit is only available When the switch circuit is opened the system recognize it as a night Phenomenon when air conditioner system is defective Initial automatic diagnosis If any sensor in the air conditio...

Page 141: ...troller E AIR QUALITY SYSTEM AQS AQS operation The AQS operates under air conditioner AUTO mode or when the AQS switch is pressed under manual mode It requires preheating time for seconds for operation and the module and sensor are integrated However it operates only when the DEF defroster switch on the air conditioner switch panel is not pressed in Components of AQS Air Quality System AQS changes...

Page 142: ...ndard approx 2 V at 25 C If the voltage value cannot be measured check the circuit for open If the measured value is within the specified range replace the FATC controller G SUN SENSOR It is installed on the upper left end of instrument panel It is using characteristics that the amount of current changes according to amount of light on the photosensitive surface Photo diode converts the changes in...

Page 143: ...irections according to FATC controller Under the FATC controller AUTO mode it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed Inspection If the intake door mode on FATC is different from the actual intake door mode check as below Turn the ignition switch to ON position Measure the voltage betw...

Page 144: ...t the cable to each terminal P1 and P2 in turn to check the motor operation and terminal output K AIR DOOR ACTUATOR The air door actuator sets the intake door mode according to the control signals from FATC Inspection If the intake door mode on FATC is different from the actual intake door mode check as below Turn the ignition switch to ON position Measure the voltage between terminal P1 and P2 ap...

Page 145: ...the voltage between terminal A12 and A11 on the FATC controller connector standard approx 12 V If the voltage value cannot be measured check the circuit for open If the measured value is within the specified range replace the FATC controller M VEHICLE SPEED CALIBRATION On the Ambient or the 1 3 Ambient and the blower AUTO the blower decreases the voltage with the vehicle speed 100 Km h such as 1 5...

Page 146: ......

Page 147: ... FUEL SYSTEM LAYOUT 9 FUEL SUPPLY SYSTEM 10 CLEANNESS 11 MAINTENANCE AND REPAIR 12 GUIDELINES FOR SERVICE WORK SAFETY 13 DURING SERVICE WORK FOR INSPECTION 14 DURING SERVICE WORK FOR ELECTRIC DEVICES 15 VEHICLE LIFTING PROCEDURES 16 OWNER INSPECTIONS AND SERVICES 17 STANDARD BOLTS SPECIFICATIONS 18 BASIC SPECIFICATION 19 VEHICLE IDENTIFICATION 20 HOW TO USE AND MAINTAIN WORKSHOP MANUAL 3 6 8 9 11 ...

Page 148: ......

Page 149: ...r compressor 3 Power steering pump pulley 4 Idle pulley 5 Water pump pulley 6 Alternator 7 Viscos clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly groove belt 11 Cam position sensor 12 Drive plate M T DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR center pipe Front view Rear view ...

Page 150: ...9 Cylinder head cover 20 Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 Oil separator 31 Oil dipstic 32 EGR center pipe ...

Page 151: ...der head 34 Cylinder block 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH pipe 39 Oil separator 40 Oil dipstic 41 HP pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Left side view Right side view ...

Page 152: ...E GENERAL 2 ENGINE CONTROLS LAYOUT 1 ECU Related Componets ECU Barometric Sensor Cam Position Sensor Fuel Filter Water Detection Sensor Accelerator Pedal Sensor HFM Sensor Intake Air Temperature Sensor Pre Heating Time Relay Main Relay ...

Page 153: ...US 2004 09 0000 00 Knock sensor 2 2 Engine And Sensors Injector Common rail Crankshaft position sensor HP pump Coolant temperature sensor HP pump Camshaft position sensor Glow plug Fuel pressure sensor Booster pressure sensor ...

Page 154: ...01 8 RODIUS 2004 09 0000 00 ENGINE GENERAL Glow plug Pre heating time relay 3 ELECTRICAL COMPONENTS AND PREHEATING SYSTEM Starter motor Alternator Battery Fuse box ...

Page 155: ...01 9 ENGINE GENERAL RODIUS 2004 09 0000 00 Air cleaner assembly HFM sensor Intake duct hose Intake manifold Intake outlet hose Turbocharger Intercooler Inlet hose 4 INTAKE SYSTEM LAYOUT ...

Page 156: ...01 10 RODIUS 2004 09 0000 00 ENGINE GENERAL Intake Air Flow Chart ...

Page 157: ...01 11 ENGINE GENERAL RODIUS 2004 09 0000 00 5 EXHAUST SYSTEM LAYOUT Muffler Exhaust manifold EGR valve Turbocharger Catalytic converter EGR pipe Vacuum modulator ...

Page 158: ...01 12 RODIUS 2004 09 0000 00 ENGINE GENERAL Exhaust Air Flow Chart ...

Page 159: ...ENGINE GENERAL RODIUS 2004 09 0000 00 6 LUBRICATION SYSTEM LAYOUT Cylinder head cover Oil dipstick Oil separator Engine oil filter housing Engine oil pump Oil pan Engine oil cooler Engine oil pressure switch ...

Page 160: ...01 14 RODIUS 2004 09 0000 00 ENGINE GENERAL Coolant reservoir Water pump Radiator assembly Cooling fan and fan clutch 7 COOLING SYSTEM LAYOUT ...

Page 161: ...01 15 ENGINE GENERAL RODIUS 2004 09 0000 00 Coolant Flow Chart ...

Page 162: ...01 16 RODIUS 2004 09 0000 00 ENGINE GENERAL Fuel return hose Fuel pressure pipe Common rail Fuel filter 8 FUEL SYSTEM LAYOUT Injector HP pump Priming pump ...

Page 163: ... through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant temperature s...

Page 164: ... open Even in this case the HP pump still operates to supply high pressurized fuel This increases the pressure to combustion chamber over 250 bar and may cause fatal damage to engine You can compare the thickness of injector nozzle hole and hair as shown in below figure left side The right side figure shows the clearance between internal operating elements The core elements of fuel system has very...

Page 165: ...ce on the wiring harnesses and connectors in engine compartment Perform the diagnosis proceee with SCAN 100 refer to DI10 DIAGNOSIS section in this manual Locate the fault If the cause is from fuel system from priming pump to injector including return line follow the step 1 through step 3 above If the problem is from HP pump fuel supply line or injector prepare the clean special tools and sealing ...

Page 166: ...d be tightened tospecified tightening torques during installation Over or under torques out of specified range may cause damages and leaks at connections Once installed the pipes have been deformed according to the force during installtion therefore they are not reusable The copper washer on injector should be replaced with new one The injector holder bolt should be tightened to specified tighteni...

Page 167: ...r replacing the high pressure pump 7 8 To supply the fuel to transfer line of HP pump press the priming pump until it becomes hard 9 Do not crank engine before having filled pump Check the installed components again and connect the negative battery cable Start the engine and check the operating status With SCAN 100 check if there are current faults and erase the history faults 10 11 For details re...

Page 168: ...in heater see fuel system System Supplement And Remedy Against Water In Fuel As mentioned above some gas stations supply fuel with excessive than specified water In the conventional IDI engine excessive water in the fuel only causes dropping engine power or engine hunting However fuel system in the DI engine consists of precise components so water in the fuel can cause malfunctions of HP pump due ...

Page 169: ...uid and lubricants Engine Oil and Oil Filter Change Always use above the API SH grade or recommended engine oil Engine Oil Viscosity Engine oil viscosity thickness has an effect on fuel economy and cold weather operation Lower viscosity engine oils can provide better fuel economy and cold weather performance however higher temperature weather conditions require higher viscosity engine oils for sat...

Page 170: ...heck the wire boot fit at the Distributor and at the spark plugs Replace the wires as needed Spark Plug Wire Replacement Brake System Service Check the disc brake pads or the drum brake linings Check the pad and the lining thickness carefully Tire and Wheel Inspection and Rotation Check the tires for abnormal wear or damage To equalize wear and obtain maximum tire life rotate the tires If irregula...

Page 171: ...ed by personal working method skill ways and service procedures and to allow prompt correct service works Note Notice While using this manual there are a lot of Note or Notice having below meaning Note means detailed description of supplementary information on work procedure or skill Notice means precautions on tool device or part damages or personal injuries that can occur during service works Ho...

Page 172: ...f contacted Painted surface of the body can be damaged if spilled over with oil or anti freeze Never go under vehicle if supported only with jack Never near the battery and fuel related system to flames that can cause fire like cigarette Never disconnect or connect battery terminal or other electrical equipment if ignition key is turned on While connecting the battery terminals be cautious of pola...

Page 173: ...reign materials While removing the engine do not position the jack and others under the oil pan or engine To secure the safety use only safety hook on the engine 1 2 3 4 5 Cautions before service works Engine has a lot of precise portions so tightening torque should be correct during disassembly assembly and removal installation and service work should be done in clean ways during disassembly asse...

Page 174: ...etween HP pump and injectors So be sure to cover removed fuel system components with cap and protect removed parts not to be contaminated with dirt Refer to cleanness in this manual while working on DI engine fuel system Electrical equipment Electrical equipment should be handled more carefully Currently the engine is equipped with a lot of electrical equipments so there can be engine performance ...

Page 175: ...hicle and then support with chassis stand before service work 1 2 Before service work be sure to disconnect battery negative terminal to prevent damages by bad wire and short 3 If service from interior of the vehicle use protection cover to prevent damage and contamination of seat and floor Brake fluid and anti freeze can damage painted surface of body So carefully handle them during service work ...

Page 176: ...rease on the driving and sliding surfaces before installing parts Use sealer or gasket to prevent leakage if necessary Damaged or not never reuse removed gasket Replace with new and cautious on installing directions Tighten every bolt and nut with specified torque When service work is completed check finally whether the work is performed properly or the problem is solved If work on the fuel line b...

Page 177: ...circuited fuse If use electrical wire or steel wire other than fuse there can be damages on the various electrical systems If replaced with over capacity fuse there can be damages on the related electrical device and fire Every wire on the vehicle should be fastened securely not to be loosened with fixing clip If wires go through edges protect them with tape or other materials not to be damaged 1 ...

Page 178: ...ment only at the points indicated Failure to use these precise positions may result in permanent vehicle body deformation Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle If any other hoist method is used take special care to avoid damaging the fuel tank the filter neck the exhaust system or ...

Page 179: ... device on the edge of front and rear of board on lift Be sure to use attachment during lifting to prevent the lift from contacting with body floor While lifting the vehicle widen the lift floor as far as possible to stabilize between vehicle front and rear When fixing the lift floor be careful not to contact with brake tube and fuel lines Safety jack and safety stand If lift up the vehicle with s...

Page 180: ...s These are signs that the system may be leaking or overheating Have the system inspected and repaired immediately Tires Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds This may mean a wheel needs to be balanced Also a pull right or left on a straight level road may show the need for a tire pressure adjustment or a wheel alignmen...

Page 181: ...The cold oil will not drain back to the pan fast enough to give a true oil level reading Check the coolant level in the coolant reservoir tank and add coolant if necessary Inspect the coolant Replace dirty or rusty coolant Engine Coolant Level and Condition Check the washer fluid level in the reservoir Add fluid if necessary Windshield Washer Fluid Level 3 At Least Twice A Month Tire And Wheel Ins...

Page 182: ...xle Boot And Seal Inspection Inspect the front and rear suspension and the steering system for damaged loose or missing parts signs of wear or lack of lubrication Inspect the power steering line and the hoses for proper hookup binding leaks cracks chafing etc Clean and inspect the drive axle boot and seals for damage tears or leakage Replace the seals if necessary Inspect the complete system inclu...

Page 183: ... the glove box and the console doors and any folding seat hardware Body Lubrication Service Underbody Flushing Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control At least every spring clean the underbody First loosen the sediment packed in closed areas of the vehicle Then flush the underbody with plain water Engine Cooling System Inspect the c...

Page 184: ...01 38 RODIUS 2004 09 0000 00 ENGINE GENERAL 17 STANDARD BOLTS SPECIFICATIONS ...

Page 185: ...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 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 1 2 3 4 Aluminum alloy Tighten to 80 of above torque table Plastics Tighten to 20 of...

Page 186: ...01 40 RODIUS 2004 09 0000 00 ENGINE GENERAL 18 BASIC SPECIFICATION 1 Vehicle Specifications Vehicle Dimension ...

Page 187: ...01 41 ENGINE GENERAL RODIUS 2004 09 0000 00 2 Specifications ...

Page 188: ...01 42 RODIUS 2004 09 0000 00 ENGINE GENERAL Specifications Cont D ...

Page 189: ...01 43 ENGINE GENERAL RODIUS 2004 09 0000 00 3 Maintenance Major Components and Service Interval ...

Page 190: ...Dealer for approved alternative fluid In only case not available MB 229 1 or 229 3 API or ACEA oil may be accepted however it would rather recommend to shorten the change interval around 30 Mixture of antifreeze to water demineralized 1 2 3 General region 50 50 Extremily coil region 60 40 ...

Page 191: ...01 45 ENGINE GENERAL RODIUS 2004 09 0000 00 1 Vehicle Identification Number Vin Vehicle identification number VIN is is on the right front axle upper frame 19 VEHICLE IDENTIFICATION ...

Page 192: ...certification label is affixed on the bottom of driver s side B pillar 2 Manufacturer S Plate 3 Engine Serial Number Diesel Engine D27DT Type Approval No Vehicle Identification No 1 2 The engine number is stamped on the lower area of cylinder block behind the compressor ...

Page 193: ...ower rear side of the alternator 4 Transmission Transfer Case Number Manual The transmission label is affixed on the upper area of clutch housing Automatic The transmisson label is affixed on the right area of transmission housing Transfer Case The transfer case label is affixed on the transfer case housing ...

Page 194: ... automotive term like part name on the manual is the same in parts catalog technical bulletin and drawings to avoid confusion among them Consists of Small Group Contents In small group included subjects and detailed subjects are described in General In the general summary of the small group assembly function and operational principle specifications structure and components diagnosis and circuit di...

Page 195: ...01 49 ENGINE GENERAL RODIUS 2004 09 0000 00 ...

Page 196: ......

Page 197: ......

Page 198: ...e 5 Common rail 12 Air cleaner assembly 6 Fuse box 13 Turbo charger 7 Battery 14 Oil dipstick 1114 01 ENGINE ASSEMBLY 1 MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT The advanced electronically controlled D27DT engine that has high pressure fuel system has been introduced to this vehicle It satisfies the strict emission regulation and provides improved output and maximum torque ...

Page 199: ...3 Power steering pump pulley 4 Idle pulley 5 Water pump pulley 6 Alternator 7 Viscos clutch 8 Auto tensioner pulley 9 Auto tensioner 10 Poly groove belt 11 Cam position sensor 12 Drive plate M T DMF 13 Oil filter 14 Vacuum pump 15 Crank position sensor 16 EGR valve 17 Power steering pump 18 EGR center pipe Front view Rear view ...

Page 200: ...19 Cylinder head cover 20 Intake manifold 21 Water outlet port 22 Common rail 23 Fuel pressure sensor 24 Fuel pipe 25 Injector 26 Fuel return line 27 Oil filler cap 28 Glow plug 29 Booster pressure sensor 30 Oil separator 31 Oil dipstic 32 EGR center pipe ...

Page 201: ...nder head 34 Cylinder block 35 Oil pan 36 Drain plug 37 Turbo charger 38 EGR RH pipe 39 Oil separator 40 Oil dipstic 41 HP pump 42 Turbo charger booster vacuum modulator 43 EGR valve vacuum modulator 44 EGR valve 45 Exhaust manifold Left side view Right side view ...

Page 202: ...02 7 ENGINE ASSEMBLY RODIUS 2004 09 1212 01 3 SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 203: ...02 8 RODIUS 2004 09 1212 01 ENGINE ASSEMBLY 2 Engine Performance Curve Output and Torque ...

Page 204: ...02 9 ENGINE ASSEMBLY RODIUS 2004 09 1212 01 Oil Temperature Pressure and Boost Pressure ...

Page 205: ...02 10 RODIUS 2004 09 1212 01 ENGINE ASSEMBLY 4 TIGHTENING TORQUE ...

Page 206: ...02 11 ENGINE ASSEMBLY RODIUS 2004 09 1212 01 ...

Page 207: ...02 12 RODIUS 2004 09 1212 01 ENGINE ASSEMBLY ...

Page 208: ...er to Diagnosis section in this manual 3 Water Separator Warning Light When the water level inside water separator in fuel filter exceeds a certain level approx 39 cc this warning light comes on and buzzer sounds Also the driving force of the vehicle decreases torque reduction If these conditions occur immediately drain the water from fuel filter For the draining procedures please refer to How to ...

Page 209: ...y 15 000km max Draining could be done at same time than oil change 1 2 Priming pump Water separator 3 4 When replaced the fuel filter or drained the water from fuel filter press the priming pump until it becomes rigid before starting the engine The water drain from fuel filter should be performed whenever changing the engine oil ...

Page 210: ...uel gets out from the port then turn the drain plug to B direction to tighten it 3 Press the priming pump until it becomes rigid 4 Start the engine and check the conditions 5 If the priming pump is not properly operated air may get into the fuel line It may cause starting problem or fuel system problem Make sure to perform the job in step 4 Be careful not to be injured by surrounding equipment dur...

Page 211: ...r Wait until a certain amount of fuel gets out from the port then turn the both drain plugs to B direction to tighten it 1 2 3 4 Be careful not to be injured by surrounding equipment during the working procedures Engage the connector under the drain plug and press the priming pump until it becomes rigid Start the engine and check the onditions Clear the fault code of ECU with SCAN Tools 4 5 6 If t...

Page 212: ...nd through electrical signal that is generated by variable resistance changes in accelerator pedal sensor Air flow hot film sensor detects intake air volume and sends the signals to ECU Especially the engine ECU controls the air fuel ratio by recognizing instant air volume changes from air flow sensor to decrease the emissions EGR valve control Furthermore ECU uses signals from coolant temperature...

Page 213: ... is completely different from injection pump type fuel supply system on the conventional Diesel engine The fuel injection system in common rail engine is composed of transfer pressure section that transfers fuel in low pressure high pressure section that transfers fuel in high pressure and ECU control section High pressure pipe Common rail Fuel pressure sensor Priming pump Fuel pump High pressure ...

Page 214: ...03 9 ENGINE FUEL SYSTEM RODIUS 2004 09 1881 01 3 HYDRAULIC CYCLE IN FUEL LINE TRANSFER AND HIGH PRESSURE LINE High pressure supply line Transfer pressure supply line Return line ...

Page 215: ...event excessive pressure building Also to supply fuel smoothly it has structure to prevent fuel from leaking in shocks slopes and corners and If fuel runs out during driving or air gets into fuel line after fuel filter replacement it may cause poor engine starting or damage to each component Therefore the hand priming pump is installed to bleed air from transfer line When the vehicle is under the ...

Page 216: ...fies fuel before it reaches to high pressure pump to help proper operations in high pressure pump And more it separates water from fuel to prevent water from getting into FIE system high pressure line 3 Fuel filter 4 Transfer Pump The transfer pump is included in the housing of the high pressure pump The transfer pump is the volumetric blade type pump To deliver the continuously required fuel volu...

Page 217: ...uel to approx 1 600 bar and this compressed fuel is transferred to high pressure accumulator common rail in tube through high pressure line 1 High pressure pump including IMV and limit valve It stores fuel transferred from high pressure pump and also stores actual high pressure of fuel Even though the injectors inject fuel from the rail the fuel pressure in the rail is maintained to a specific val...

Page 218: ...er No 2 and 4 cylinder 4 Injectors The fuel injection device is composed of electrical solenoid valve needle and nozzle and controlled by engine ECU The injector nozzle opens when solenoid valve is activated to directly inject the fuel into combustion chamber in engine When injector nozzle is open remaining fuel after injection returns to fuel tank through return line Pressure limit valve fuel ret...

Page 219: ...03 14 RODIUS 2004 09 1881 01 ENGINE FUEL SYSTEM 7 ECU Wiring Diagram ...

Page 220: ...lement Type Service Interval Initial cleaning 5 000 km Clean or change every 10 000 km as required However change every 30 000 km If the vehicle is operated under severe condition short distance driving extensive ldling or driving in dusty condition More frequent maintenance is required 2313 01 ENGINE INTAKE SYSTEM ...

Page 221: ...04 4 RODIUS 2004 09 2321 01 ENGINE INTAKE SYSTEM Air cleaner HFM Sensor Intercooler 1 ENGINE INTAKE COMPONENTS LOCATOR Intake Manifold ...

Page 222: ...04 5 ENGINE INTAKE SYSTEM RODIUS 2004 09 2321 01 2 AIR FLOWS 1 Work Flow of Intake System ...

Page 223: ... could create customer s complaint and by connecting the scanning device could display as the malfunction of the EGR valve s potentiometer As previously explained this car has a separate controller to control the HUBER EGR and in accordance with various input element the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through PWM control At this time ...

Page 224: ... is capable of making electronically controlled fuel injection In other word to reduce the amount of the fuel injection in no load rapid acceleration mode the IDI engine s HUBER EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative pressure to occur in the vacuum modulator to reduce the amount of fuel injection When DI engine basing inpu...

Page 225: ...05 5 ENGINE EXHAUST SYSTEM RODIUS 2004 09 1913 01 Muffler Exhaust Manifold EGR Valve Turbo Charger Catalytic Converter DOC EGR Pipe Vacuum Modulator 1 COMPONENTS LOCATOR OF EXHAUST SYSTEM ...

Page 226: ...05 6 RODIUS 2004 09 1913 01 ENGINE EXHAUST SYSTEM 2 EXHAUST GAS FLOWS ...

Page 227: ... are less than 6 km Operating when outside temperatures remain below freezing and whenmost trips are less than 16 km When operating in dusty sandy and salty areas In hilly or moutainous terrain When doing frequent trailer towing Operating temperature 40 140 C Operating pressure 0 3 0 55 bar Permissible pressure 10 bar Severe Condition Oil Pressure Switch 1533 01 ENGINE LUBRICATION SYSTEM ...

Page 228: ...06 4 RODIUS 2004 09 1533 01 ENGINE LUBRICATION SYSTEM 2 LUBRICATION SYSTEM LAYOUT Cylinder Head Cover Oil Dipstick Oil Separator Oil Filter Oil Pump Oil Pan Oil Cooler Oil Pressure Switch ...

Page 229: ...CATION SYSTEM RODIUS 2004 09 1533 01 Cylinder Head Cylinder Block Main oil gallery φ 16 Hole to cylinder head φ 9 Main bearing hole φ 7 Chain and injection pump φ 7 Return hole φ 14 Chain nozzle φ 1 HP pump bearing φ 6 ...

Page 230: ...INE LUBRICATION SYSTEM 3 LUBRICATION DIAGRAM Opening pressure of by pass valve in oil filter 3 0 4 bar To prevent instant oil shortage after stopping the engine the return check valve is installed in oil supply line of cylinder head ...

Page 231: ...07 3 ENGINE COOLING SYSTEM RODIUS 2004 09 2112 01 9210 05 ENGINE COOLING SYSTEM 1 ENGINE COOLING SPECIFICATIONS ...

Page 232: ...07 4 RODIUS 2004 09 2112 01 ENGINE COOLING SYSTEM Coolant Temperature Sensor Coolant Reservoir FFH Radiator Water Pump Cooling Fan 1 COMPONENTS ENGINE COOLING ...

Page 233: ...12 01 2 COOLING SYSTEM FLOW PTC Engine Coolant Flows FFH Engine Coolant Flows Cylinder block side Block 5 Oil cooler Heater Heater water pump inlet pipe Water pump Cylinder head side Cylinder head Coolant outlet port intake 1 Radiator Water pump ...

Page 234: ...h the heater line rear section cylinder 4 and 5 of cylinder head However in D27DT engine coolant inflows from cylinder block through oil cooler refer to coolant flows layout in previous page It prevents cooling efficiency from decreasing due to coolant separation between cylinder 4 and 5 In OM 600 engine the cooling fan is installed with water pump however in case of D27DT engine it is connected t...

Page 235: ...08 3 ENGINE ELECTRIC DEVICES RODIUS 2004 09 1451 01 1461 01 ENGINE ELECTRIC SYSTEM 1 SPECIFICATIONS OF ENGINE ELECTRIC ...

Page 236: ...INE ELECTRIC DEVICES Coolant temperature sensor Fuel temperature sensor Knock sensor Crankshaft position sensor Camshaft position sensor Fuel pressure sensor Booster pressure sensor Oil pressure switch 1 SENSORS IN ENGINE COMPARTMENT ...

Page 237: ...INE ELECTRIC DEVICES RODIUS 2004 09 1451 01 Alternator Glow plug Air conditioner compressor Starter 2 ELECTRIC DEVICES IN ENGINE COMPARTMENT Capacity PTC equipped vehicle 12V 140A FFH equipped vehicle 12V 115A ...

Page 238: ...08 6 RODIUS 2004 09 1451 01 ENGINE ELECTRIC DEVICES 3 CIRCUIT DIAGRAM OF PREHEATING SYSTEM ...

Page 239: ...08 7 ENGINE ELECTRIC DEVICES RODIUS 2004 09 1451 01 4 CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR ...

Page 240: ... 09 1491 01 HFM Sensor Intake Air Temperature Sensor Preheating Relay Main Relay 1491 01 EGINE CONTROL SYSTEM 1 ENGINE ECU AND OTHER COMPONENTS ECU Barometric Sensor Camshaft Position Sensor Fuel Filter Water Sensor Accelerator Pedal Sensor ...

Page 241: ...09 4 RODIUS 2004 09 1491 01 ENGINE CONTROL SYSTEM Fuel Pressure Sensor 2 TOP VIEW Booster Pressure Sensor Injectors 5 EA Glow Plugs 5 ...

Page 242: ...09 5 ENGINE CONTROL SYSTEM RODIUS 2004 09 1491 01 3 SIDE VIEW Coolant Temperature Sensor Knock sensors 2 Fuel Temperature Sensor Crankshaft Position Sensor Fuel Pressure Regulating Valve ...

Page 243: ...ankshaft position sensor camshaft position sensor Accelerator sensor Vehicle speed sensor Switch input signal IG brake clutch A C signal A C compressor Inputs Injector EGR system Fuel pressure regulating valve IMV Electrical fan control Low High speed A C compressor relay Glow plug relay Immobilizer Warning lights Water warning light glow plug indicator light engine warning light Preheater auxilia...

Page 244: ... range of ECU is normally 40 85 C and protected from factors like oil water and electromagnetism and there should be no mechanical shocks To control the fuel volume precisely under repeated injections high current should be applied instantly so there is injector drive circuit in the ECU to generate necessary current during injector drive stages Current control circuit divides current applying time...

Page 245: ...ncomplete combustion So there occurs smoke and damages engine durability Fuel pressure is corrected according to air temperature coolant temperature and atmospheric pressure and to take account of the added ignition time caused by cold running or by high altitude driving A special pressure demand is necessary in order to obtain the additional flow required during starts This demand is determined a...

Page 246: ...ming advance as a function of the atmospheric pressure and therefore the altitude A third correction is made according to the coolant temperature and the time which has passed since starting This correction allows the injection timing advance to be increased while the engine is warming up initial 30 seconds The purpose of this correction is to reduce the misfiring and instabilities which are liabl...

Page 247: ... is made according to the atmospheric pressure This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore the altitude The pilot injection timing is determined as a function of the engine speed and of the total flow The elements are Pilot injection timing control During the starting phase the pilot injection timing is determined as a functio...

Page 248: ...ot flow in order to prevent any loss of control of the vehicle during a sharp deceleration This value is then compared with the flow limit determined by the cruise control As soon as the injected fuel becomes lower than the flow limit determined by the cruise control the vehicle s speed falls below the value required by the driver The system therefore chooses the greater of these 2 values in order...

Page 249: ...ssure As soon as the main fuel falls below this value the fuel demand changes to 0 because in any case the injector is not capable of injecting the quantity demand Until the stating phase has finished the system uses the supercharged fuel Once the engine changes to normal operation the system uses the total fuel A switch makes it possible to change over from the supercharge fuel to the total fuel ...

Page 250: ...ines the maximum fuel which can be injected as a function of the driver demand and the rail pressure Since the flow is proportional to the injection time and to the square root of the injection pressure it is necessary to limit the flow according to the pressure in order to avoid extending the injection for too long into the engine cycle The system compares the driver demand with this limit and ch...

Page 251: ...smoke emissions to be reduced when driving at altitude The full load flow curve is determined according to the gear engaged and the engine speed It allows the maximum torque delivered by the engine to be limited A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are detected by the system In this case and depending on the gravity of ...

Page 252: ...re the altitude During starting the pilot flow is determined on the basis of the engine speed and the coolant temperature 6 Cylinder Balancing Strategy Balancing of the point to point flows The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2 successive injectors The instantaneous speeds on two successive injections are first calculated The ...

Page 253: ...annot be any combustion The second window is used to measure the intensity of the pilot combustion Its position is such that only the combustion noises produced by the pilot injection are measured It is therefore placed just before the main injection The accelerometer does not allow any evaluation of the quantity injected However the pulse value will be measured when the injector starts injection ...

Page 254: ...ust be extremely robust An increase in the ratio can be the consequence of various causes Pilot injection too strong Main combustion offset Fuel leak in the cylinder If the ratio becomes too high the strategy initially restricts the pilot injection flow and retards the main injection If the ratio remains high despite these interventions this shows that a real leak is present a fault is signaled an...

Page 255: ...ersion the loss of charge through the functional orifices the friction between moving parts and electromagnetic field level are different from one injector to the other So the difference of fuel delivery for the same pressure and the same pulse can reach 5 mg str from one injector to the other It is impossible to control efficiently the engine with such a dispersion between the different injectors...

Page 256: ...ost optimal fuel injection When replacing the injector C2I code on the top of new injector should be input into ECU because the ECU is remembering the injector s C2I value If C2I is not input engine power drops and occurs irregular combustion When ECU is replaced C2I code of every injector should be input If not cannot accelerate the vehicle even when the accelerator pedal is depressed C2I Number ...

Page 257: ...ed mininum drive pulse MDP Through MDP controls can correct pilot injections effectively Pilot injection volume is very small 1 2 mm str so precise control of the injector can be difficult if it gets old So there needs MDP learning to control the very small volume precisely through learning according to getting older injectors 1 Learning Conditions 2 Trouble Codes ...

Page 258: ......

Page 259: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 COMMON ENGINE 2 IDI ENGINE 3 DI ENGINE 4 GASOLINE ENGINE 3 6 8 12 ...

Page 260: ......

Page 261: ...L SERVICE TOOLS RODIUS 2004 09 0000 00 0000 00 SPECIAL SERVICE TOOLS 1 COMMON ENGINE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 262: ...0 4 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 263: ... 09 0000 00 Name and Part Number Application Y99220092B Compression pressure measuring adapter and gauge Y99220082B Supporting bar and lever Y99220162B Guide pin extractor Y99220112B Intake manifold guide pin 2 Special Tools and Equipment ...

Page 264: ...6 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS Name and Part Number Application Cylinder head hanger Y99220082B Supporting bar and lever Y99220162B Guide pin extractor Y99220112B Intake manifold guide pin ...

Page 265: ...0 7 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 266: ...0 8 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS 2 IDI ENGINE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 267: ...0 9 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 Name and Part Number Application Y99220152B HLA remover Y99220142B Stem seal installer ...

Page 268: ...0 10 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 269: ...0 11 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 Name and Part Number Application Y99220122B Piston protrusion measuring jig Y99220172B Piston insertion jig ...

Page 270: ...US 2004 09 0000 00 SPECIAL SERVICE TOOLS Special Tools and Equipment Application Y99220112B Intake manifold guide pin Installation of intake manifold 2 ENGINE INTAKE SPECIFICATIONS 1 Special Tools and Equipment ...

Page 271: ...0 13 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 3 DI ENGINE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 272: ...0 14 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS Name and Part Number Application 103 589 02 09 00 Engine filter cap 1 Special Tools and Equipment 3 ENGINE LUBRICATION SYSTEM ...

Page 273: ...0 15 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 274: ...0 16 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 275: ...0 17 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 4 ENGINE ELECTRICAL SYSTEM Name and Part Number Application Glow plug remover Removal of glow plug 1 Special Tools and Equipment ...

Page 276: ...0 18 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 277: ...0 19 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 4 GASOLINE ENGINE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 278: ...SENSORS IN PASSENGER COMPARTMENT 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT EXCEPT ENGINE RELATED SENSORS AND UNITS 3 SWITCHES IN PASSENGER COMPARTMENT 4 SYSTEM LAYOUT BASED ON DVD SYSTEM EQUIPPED VEHICLE 5 WIRING HARNESS ARRANGEMENT 6 ELECTRIC COMPONENTS LOCATOR 2 4 6 8 10 11 ...

Page 279: ...n unit and PAS unit STICS ICM module TV antenna amplifier Sensor cluster ESP Air bag unit SDM 0000 00 ELECTRIC GENERAL LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT 1 PAS unit Tuner Navigation unit DSP integrated amplifier Sun sensor Windshield heated glass unit ...

Page 280: ... 2004 09 0000 00 Sun roof unit and motor EngineECU AM FM radio amplifier TV antenna amplifier Steering wheel angular sensor Rain sensing unit and ECM Interior temperature and humidity sensor TCU and TCCU TCU TCCU Auto light sensor ...

Page 281: ... drier Horn Ambient temperature sensor FFH 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT EXCEPT ENGINE RELATED SENSORS AND UNITS FFH Fuel Fired Heater AQS Ambient temperature sensor Integrated type Air conditioner AQS sensor Ambient temperature sensor ...

Page 282: ...US 2004 09 0000 00 ABS ESP HECU under the battery Theft deterrent horn nder the washer fluid reservoir Brake pressuresensor Fuse and relay box in engine compartment PTC power supply relay PTC system equipped vehicle Sub condenser ...

Page 283: ... wiper switch Outside rearview mirror adjusting and folding switch Window switches Audio remote control switch on the steering wheel 3 SWITCHES IN PASSENGER COMPARTMENT Power button Mode button SEEK button Up SEEK button Down Mute button Volume button Up Volume button Down ...

Page 284: ...function switch and steering wheel angular sensor Passenger s window switch Sun roof switch Room lamp switch coupled operation with door Front room lamp switch Driver seat warmer switch Front fog lamp Front defogger switch Passenger seat warmer switch ESPOFF Outside rearview mirror and rear glass heated switch ...

Page 285: ... EQUIPPED VEHICLE Tweeter speaker Center speaker Audio remote control switches AV head unit Center speaker GPS antenna Front speaker RH Sub woofer amplifierintegrated type Center speaker Front speaker LH Front tweeter speaker LH Center speaker LH AV head unit Center speaker RH Front tweeter speaker RH DVD changer ...

Page 286: ...Rear tweeter speaker RH Tuner Navigation unit DSP integrated amplifier TV antenna amplifier RH Rear speaker RH Radio antenna amplifier Rearview camera Tuner Amplifier Navigation unit Rear speaker LH TV antenna amplifier LH Rear tweeter speaker LH Rear monitor ...

Page 287: ...01 10 RODIUS 2004 09 0000 00 ELECTRICAL SYSTEM 5 WIRING HARNESS ARRANGEMENT ...

Page 288: ...01 11 ELECTRICAL SYSTEM RODIUS 2004 09 0000 00 6 ELECTRIC COMPONENTS LOCATOR ...

Page 289: ......

Page 290: ...use and relay box is located in the engine compartment and the interior fuse box is located under the driver side instrument panel Especially ICM box an integrated circuit of relays is mounted along with STICS behind the driver side instrument panel Back of the fuse and relay box after removal 8410 05 FUSES RELAYS ...

Page 291: ...02 4 RODIUS 2004 09 8410 05 FUSES 1 Arrangement of Fuses and Relays 2 Descriptions of Fuses and Relays ...

Page 292: ...S RODIUS 2004 09 8410 05 2 INTERIOR FUSE COMPARTMENT The interior fuse box is located in the lower area of driver side instrument panel To check the fuses open the driver side door and remove the fuse box cover ...

Page 293: ...re installed on the integrated circuit with a safety circuit This system operates with small current by using transistor and minimizes the sparks that occur during operations connection disconnection of relays therefore its durability and wear resistance has been greatly increased compared to the conventional relays Relays in the ICM box cannot be replaced respectively so when the internal compone...

Page 294: ... ICM Box The figure shows the internal arrangement of ICM box when the cover is removed and then disassembled The relays cannot be disassembled and replaced respectively so the ICM box should be replaced as an assembly when any internal components are defective 1 Front view ...

Page 295: ...02 8 RODIUS 2004 09 8410 05 FUSES 2 Rear View ...

Page 296: ...02 9 FUSES RODIUS 2004 09 8410 05 4 WIRING HARNESS CONNECTOR GROUND LOCATION 1 W H Engine Room ...

Page 297: ...02 10 RODIUS 2004 09 8410 05 FUSES 2 W H Main ...

Page 298: ...02 11 FUSES RODIUS 2004 09 8410 05 3 W H Floor LH ...

Page 299: ...02 12 RODIUS 2004 09 8410 05 FUSES 4 W H Floor RH ...

Page 300: ...02 13 FUSES RODIUS 2004 09 8410 05 5 W H Air con 1 Front air con ...

Page 301: ...02 14 RODIUS 2004 09 8410 05 FUSES 2 Rear air con ...

Page 302: ...02 15 FUSES RODIUS 2004 09 8410 05 6 W H Door 1 Front Door 2 Rear Door 3 Tail Gate Door ...

Page 303: ...02 16 RODIUS 2004 09 8410 05 FUSES 7 W H Roof ...

Page 304: ...02 17 FUSES RODIUS 2004 09 8410 05 8 W H Seat Driver s Passenger s ...

Page 305: ...of 1 5 seconds after IGN 1 switch ON is not included 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 3 Time Tolerance If not indicated time tolerance will be 10 However if less than 500 ms time tolerance will be 50 ms The time indicated in each function does not include chattering processing time from switch ...

Page 306: ...03 4 RODIUS 2004 09 8710 01 STICS 4 RK STICS of input signals ...

Page 307: ...vehicle models Additional function of diagnosing through SCAN I has been added into new STICS The major difference in hardware wise is that receives automatic door unlock signal from airbag module through Gsensor in RK STICS unit when the vehicle has collided over 15 km h of vehicle speed 1 COMPONENTS LOCATOR ...

Page 308: ...6 RODIUS 2004 09 8710 01 STICS 2 DESCRIPTIONS Below table shows the major differences compared to the previous vehicle model before year 2004 For whole functions and details refer to corresponding section ...

Page 309: ...s T1 after turning ON the washer switch for 0 2 0 59 seconds T2 with the ignition key ON and it is turned off when the parking terminal is turned off The wiper relay is turned on 0 3 seconds T1 after turning ON the washer switch over 0 6 seconds T2 with the ignition key ON and it is turned on three times immediately after turning off the washer switch ...

Page 310: ... inputted while the wipers are operating in intermittent or AUTO mode the system stores the previous intermittent interval and operates the washer coupled wiper After then the wiper operation returns back to intermittent or AUTO mode with the stored operating interval ...

Page 311: ...er control logic compared to other models As shown in the system diagram the rain sensor unit does not control wiper directly The rain sensor unit sends infrared rays signal through LED and then receives it with photo diode and then sends the returned signal to STICS and the STICS controls the wipers directly For more details refer to rain sensing wiper section in this manual ...

Page 312: ...tion again from other positions the system drives the wiper relay LO to run the wiper motor one cycle only when the rain sensor detects the Rain Detected signal 1 2 Rain sensing sensitivity control The wiper relay is turned on and the wiper motor runs one cycle when the volume sensitivity is increased ex from 0 to 1 while the ignition key is in ON position the wiper switch is in AUTO position and ...

Page 313: ... grounded while the ignition key is in ON position and the wiper switch is in AUTO position 1 The wiper motor runs only when the rain sensor requires When the parking terminal is fixed to IGN HIGH the wiper system outputs the operating signal of current sensitivity for 2 seconds then continuously outputs the parking signal of current sensitivity 2 The wiper motor runs only when the rain sensor req...

Page 314: ...the malfunction signal 1 from the rain sensor while the ignition key is in ON position and the wiper switch is in AUTO position 1 The wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 3 from 4 during receiving the malfunction signal 2 from the rain sensor while the ignition key is in ON position and the wiper switch is in AUTO position 2 ...

Page 315: ...om 1 during receiving the malfunction signal 3 from the rain sensor while the ignition key is in ON position and the wiper switch is in AUTO position Also the wiper relay LO is turned on and the wiper motor runs one cycle when the wiper sensitivity is changed to 2 from 1 during receiving the ground fixed or IGN fixed signal from the rain sensor 3 ...

Page 316: ...ine with the INT switch positioned 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 pulses sec 60 km h x 60 sec 637 pulses 1 41 km h 3 VOLUME calculation Calculates the INT VOLUME with 5 grades as shown in the table in next page 4 Pause time calculation Pause time the duration ...

Page 317: ... wiper relay continues to output for remaining ON time even when the INT switch is turned off 2 IGN 2 switch ON INT switch OFF resume the intermittent time when turning ON 3 IGN 2 switch OFF INT switch ON resume the intermittent time when turning ON Controls when the wiper motor parking is defective The wiper relay continues to output when the parking terminal is fixed at the ground or IGN while t...

Page 318: ...does not work if the vehicle speed is over 3 km h The system outputs UNLOCK for 5 seconds T2 from 0 5 seconds after the driver s door is opened and the door lock switch is changed to LOCK while the ignition key is in ignition switch The system outputs UNLOCK for 5 seconds T2 when the door lock switch is changed to LOCK from UNLOCK and the driver s door is closed within 0 5 seconds T1 while the ign...

Page 319: ...unlocked but passenger s and rear doors are locked only the driver s door generates unlock signal when trying to lock the driver s door with the driver s door opened Above operations is regardless of key positions and have priority over the ignition key reminder function 2 When the door is closed during unlock output for 5 seconds under item 1 condition the unlock output stops All doors except tai...

Page 320: ... lamp is turned on 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 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 opened This function is not available when the ignition key is in ON position 1 2 3 4 ...

Page 321: ... when closing the door under step 1 The warning light blinks when the vehicle speed is over 10 km h V1 for more than 2 seconds while the warning light is turned on The warning light blinks when a door is opened while the vehicle speed is over 10 km h V1 while the warning light is turned off The warning light goes off when closing the door under step 3 The warning light comes on when the vehicle sp...

Page 322: ...display blinks for 6 seconds however the chime buzzer does not sound The seat belt warning light goes off and the chime buzzer in the ICM box stops when turning the ignition switch to OFF position The chime buzzer stops and the seat belt warning light stays on for the specified duration 6 seconds when fastening the seat belt during the warning operation The seat belt warning light comes on and the...

Page 323: ...n turning off the parking brake switch under step 2 The warning light blinks and the chime buzzer in the ICM box sounds for 2 85 seconds and stops for 1 5 seconds when the vehicle speed is over 10 km h V1 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 the parking brake switch under step 4 The warning light ...

Page 324: ... after turning on the ignition key during decaying operation The front room lamp comes on for 30 seconds T3 when receiving the unlock signal from the remote control key while the door is closed 1 2 3 4 The front room lamp output period is extended by 30 seconds T3 when receiving the unlock signal from the remote control key again during output When a door is opened during its extended period the l...

Page 325: ...gage room lamp The rear room lamp extends its lighting period by 5 seconds when closing the rear door The room lamp output stops immediately after turning the ignition key to ON position during the extended period The room lamp output stops immediately after receiving the lock signal from the rear door lock switch or the remote control key while the rear door is closed 1 2 3 4 ...

Page 326: ...n opening the driver s door or passenger s door while 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 ignition key is turned to ON position The output stops when receiving the lock signal from the remote control key under armed mode 1 2 3 4 ...

Page 327: ...ned off auto cut when opening and closing the driver s door after removing the ignition key without turning off the tail lamp Tail lamp relay is turned on when inserting the ignition key into ignition switch again after step 2 operation The tail lamp relay is turned off auto cut when opening and closing the driver s door while the ignition key is removed and the tail lamp is turned on 1 2 3 4 ...

Page 328: ...h within 10 minutes T2 after completion of output When turning on the defogger switch again within 10 minutes T2 after completion of initial 12 minutes T1 of output the output comes on for 6 minutes T3 again once only The output stops when the IGN 2 switch is turned to OFF position or the ALT is OFF 1 2 3 4 This vehicle has the windshield heated glass and the tailgate and outside rearview mirror h...

Page 329: ...itch to unlock position LOCK or UNLOCK by the door lock switch is ignored when outputting the LOCK or UNLOCK by other functions The door lock unlock system is not working regardless of the door lock switch positions when connecting the battery All door lock signals are UNLOCK for 0 5 seconds T4 just for once when receiving the LOCK signal within 0 5 seconds T3 after closing the driver s or passeng...

Page 330: ...tem outputs LOCK for 0 5 seconds T1 when pressing LOCK button on the central door lock switch The door lock system outputs UNLOCK for 0 5 seconds T2 when pressing UNLOCK button on the central door lock switch The LOCK or UNLOCK inputs from the central door lock switch in armed mode are ignored 1 2 3 ...

Page 331: ...signal for driver s door for 0 5 seconds T3 when receiving UNLOCK signal from the remote control key The door lock system outputs UNLOCK signal for all doors for 0 5 seconds T3 when receiving UNLOCK signa again within 30 seconds T1 after receiving the first UNLOCK signal second unlock step The second unlock step is canceled when receiving LOCK signal within 30 seconds T1 after receiving the first ...

Page 332: ...nlock only one LOCK output will be done If the door that was LOCK is changed to UNLOCK only one LOCK output will be done However if it maintains unlock after lock output the corresponding door will not be regarded as fail The door lock system outputs UNLOCK automatically if the LOCK output conditions are established by this function or the key is cycled IGN1 ONaOFF even when there is no Lock outpu...

Page 333: ... remaining period After input of the air bag collision signal the door lock system doesn t output UNLOCK even when turning the ignition key to ON position 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 control...

Page 334: ...n key to OFF position However the power window relay stays on for 90 seconds T2 when the ignition key is turned to OFF position while the door is opened The power window relay is turned ON again for 90 seconds T2 just for once when opening the door during its extended operation period of 90 seconds T1 The power window relay is turned OFF when closing the door during its extended operation period o...

Page 335: ...03 33 STICS RODIUS 2004 09 8710 01 13 REKES Remote Keyless Entry System 1 Transmitter PANIC function is added on the previous version of REKES ...

Page 336: ... during the registration Coding terminal OFF a ON applying battery voltage Press LOCK UNLOCK or PANIC switch on the transmitter Outputs hazard warning flasher for 0 5 seconds once and horn for 0 04 seconds once during registration Code output requirements The system outputs the function code when the CUSTOM and ID code are correct and the Rolling code is within operating range while the ignition k...

Page 337: ...tivates the armed ready mode without theft deterrent horn and 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 after 0 6 seconds cancels the armed mode and activates the normal mode However in these cases if closing the door and locking the door lock switch the theft deterrent horn outputs on...

Page 338: ... seconds 1 2 3 Warning operation The theft deterrent horn and hazard warning flasher output is ON for T3 27 seconds with the interval of T2 1second 1 Warning cancellation requirements Cancels warning by using any signal from the remote control key LOCK UNLOCK START STOP PANIC CHECK during warning operation Cancels warning after 27 seconds remaining period while the ignition key is turned to positi...

Page 339: ... canceled when receiving PANIC signal from the remote control key during theft deterrent 2 The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning PANIC output is OFF 3 The PANIC warning output is ON when receiving the PANIC signal from the remote control key in Armed Ready Armed Warning Completion Relock Ready mode maintaining the theft de...

Page 340: ...4 09 8710 01 STICS 16 Auto Light Function The lights automatically come on and off according to the ambient brightness when the multifunction light switch is in AUTO position while the ignition key is in ON position 1 ...

Page 341: ...nal type of instrument panel The meter cluster and indicator display are separated The meter cluster is located at the center of the dash panel and the indicator display is located in front of driver s seat Coolant temperature gauge RPM gage Speedometer Fuel level gauge Meter cluster Warning lamps and indicators 8010 01 CLUSTER WARNING INDICATOR PANEL ...

Page 342: ... signal indicator and hazard flasher 15 Door open warning light 5 Auto shift indicator for automatic transmission 16 High beam indicator 6 Right turn signal indicator and hazard flasher 17 Engine oil pressure warning light 7 4WD CHECK warning light 18 Air bag warning light 8 4WD LOW indicator 19 Water separator warning light 9 Engine check warning light 20 ABS warning light 10 Brake warning light ...

Page 343: ...everse driving Auto Shift Indicator for automatic transmission Brake Warning Light 4WD CHECK Warning Light 4WD LOW indicator This indicator shows the automatic transmission selector lever position When the selector lever is at D position while driving D indicator and currently selected gear indicator are coming on If you move the selector lever to left or right direction only the selected gear ind...

Page 344: ...ndshield heated glass control unit is installed on the bottom of driver side Instrument panel Whenever pressing the switch the windshield heated glass operates for 12 minutes and turns off if pressed again during its operation If the switch is pressed again it operates another 12 minute operation Tailgate Heated Glass Outside Rearview Mirror Heated Glass controlled by STICS The outside rearview mi...

Page 345: ...ontinuously while driving it means that there is malfunction in the system This light comes on when a door or tailgate is either opened or not closed completely If you drive over 10 km h of vehicle speed without closing the door the warning light blinks Low Fuel Level Warning Light This warning light indicates that the fuel will soon be exhausted The time it takes to turn on however varies accordi...

Page 346: ...800 rpm The red zone danger rpm range starts from 4 500 rpm 1 Connect the tachometer for tune up test and start the engine 2 Eliminate the hysteresis by tapping the tachometer 3 Compare the values on the tester and tachometer and replace the tachometer if the tolerance is excessive If the tachometer pointer vibrates stands at a certain range or sounds abnormal noise there could be defectives in ta...

Page 347: ...ferent tire inflation pressures or different tire specifications Perform the speedometer test regarding the tolerance as described 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 pointer is shak...

Page 348: ...nly 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 by fuel level may be defective if so replace the fuel sender Tolerance and resistance value by indicating angle This table shows the tolerance and resistance value c...

Page 349: ...ow Measurement of coolant temperature sensor resistance Measure the resistance between the terminal and the ground with an ohmmeter and replace if the resistance is out of specified range 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 ...

Page 350: ...IP A TRIP B and ODOmeter Press and hold over 1 sec Trip odometer TRIP A and TRIP B will be reset to 0 However only the corresponding driving range will be set to 0 Press shortly between 0 1 1 sec The mode changes in order as shown in the figure Reset button ...

Page 351: ...04 13 CLUSTER RODIUS 2004 09 8010 01 5 CIRCUIT DIAGRAM OF INDICATOR DISPLAY ...

Page 352: ... 8310 01 LAMP 1 COMPONENTS OF EXTERIOR LAMPS Side turn signal lamp Connector Bulb Lamp cover Fog lamp assembly Lamp cover Bulb Headlamp assembly Rear tail lamp assembly License plate lamp Tail lamp back up lamp High mounted stop lamp ...

Page 353: ... 4 RODIUS 2004 09 8310 01 LAMP 2 COMPONENTS OF INTERIOR LAMPS Door courtesy lamp Luggage room lamp Center console lamp assembly Interior room lamp assembly Front room lamp assembly Glove box lamp assembly ...

Page 354: ......

Page 355: ...05 6 RODIUS 2004 09 8310 01 LAMP 1 LOCATIONS OF EXTERIOR LAMPS 1 Front Lamps Side turn signal lamp one at each side 12V 5W ...

Page 356: ...05 7 LAMP RODIUS 2004 09 8310 01 2 Rear Lamps ...

Page 357: ... 8 RODIUS 2004 09 8310 01 LAMP 2 LOCATIONS OF INTERIOR LAMPS 1 Front room lamp one at both sides 12V 5W Front room lamp switch coupled operation with door Rear room lamp switch coupled operation with door ...

Page 358: ...05 9 LAMP RODIUS 2004 09 8310 01 ...

Page 359: ...used for a correct headlamp aiming Make sure to follow the operating instructions provided by the manufacturer If not available to use the beam setting device adjust the headlamp aiming with a screen Headlamp aiming requirements parking on a flat surface specified tire pressure one passenger driver 65 kg spare tire and OVM tools loaded unlade all other loads ...

Page 360: ...headlamp aiming by rotating the direction control levers Up Down Left Right in turn with a screwdriver When using a beam setting device Align the vehicle and beam setting device according to the operating instructions provided by the manufacturer Adjust the headlamp aiming by rotating the direction control levers Up Down Left Right in turn with a screwdriver 1 2 ...

Page 361: ... align the center lines of the vehicle and the screen 1 Unit mm Run the engine with approx 2 000 rpm and turn on the headlamp At this moment the focus of the headlamp should aim the A point 2 Unit mm If the focus deviates the A point adjust the headlamp aiming by rotating control levers Up Down Left Right in turn with a screwdriver 3 ...

Page 362: ...05 13 LAMP RODIUS 2004 09 8310 01 2 Fog Lamp Aiming Adjustment Fog lamp Fog lamp Down Up ...

Page 363: ...05 14 RODIUS 2004 09 8310 01 LAMP 4 INTERIOR LAMP OPERATION 1 Door Coupled Room Lamp Switch Operation ...

Page 364: ...h 8510 01 SWITCH Audio power button Mode button SEEK button Up SEEK button Down Mute button Volume button Up Volume button Down 4WD switch and rear washer wiper switch Outside rearview mirror control and folding switch Window switch 1 INTERIOR SWITCH COMPARTMENT ...

Page 365: ...function switch Window switch Sun roof switch Multi meter Front room lamp operation Front room lamp operation Center Switch Driver s seat warmer switch Rear fog lamp switch Front fog lamp switch Hazard warning flasher switch Defogger switch ESPOFF switch Passenger s seat warmer switch 1 2 3 4 5 6 7 ...

Page 366: ...07 3 WIPER RODIUS 2004 09 7810 01 7810 01 WIPER WASHER 1 SPECIFICATIONS OF WIPER SYSTEM ...

Page 367: ...UT OF WIPER AND WASHER Wiper blade assembly Washer nozzle and washer hose Washer motor and washer fluid reservoir Wiper motor and linkage assembly Wiper blade assembly Wiper motor and linkage assembly Wiper blade assembly Wiper blade assembly Washer nozzle and washer hose Washer motor and washer fluid reservoir ...

Page 368: ...07 5 WIPER RODIUS 2004 09 7810 01 2 COMPONENTS LOCATOR OF FRONT WIPER ASSEMBLY Wiper blade Wiper linkage Wiper motor ...

Page 369: ...07 6 RODIUS 2004 09 7810 01 WIPER Rear wiper motor 3 COMPONENTS LOCATOR OF REAR WIPER ASSEMBLY 4 CIRCUIT DIAGRAM OF WIPER WASHER Rear wiper assembly Wiper blade assembly ...

Page 370: ...h photodiode Rain sensing unit Multifunction wiper switch AUTO and sensitivity control The rain sensing unit detects the 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 STICS Relay5 Wiper INT Low Relay6 Wiper High ICM box The wiper...

Page 371: ...or unit emits infrared rays against the windshield and then detects the amount of rain drops by receiving reflected rays with photodiode The sensing section on the windshield is located just above the center point between LED and photodiode Components and functions of the rain sensor unit Rain sensor unit including cover Unit latch Rain sensor unit PCB assembly and emitter lens Emitter lens The LE...

Page 372: ...08 5 RAIN SENSOR UNIT RODIUS 2004 09 8610 11 3 OPERATION MODE OF RAIN SENSING WIPER SYSTEM ...

Page 373: ...he 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 3 If this function does not occur check No 2 terminal on the rain sensor ...

Page 374: ...r blade for wear If the wiper blade 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 ...

Page 375: ...08 8 RODIUS 2004 09 8610 11 RAIN SENSOR UNIT 5 DIAGNOSIS PROCEDURES ...

Page 376: ... terminal No 1 and No 2 are for communications between STICS and the rain sensor the No 1 terminal sends the detected value from the rain sensor to STICS then the STICS drives wiper motor No 2 terminal sends the wiper and washer operation information such as washer operation mode MIST mode or AUTO wiper position to the rain sensor to recognize whether it is actual rain or it is in rain sensing wip...

Page 377: ...th a specific interval and detects the reflected signals from obstacles while the gear selector lever is in R position The number of displaying bars is decreased and the alarm interval becomes faster 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 25 120 cm distance between sensor ...

Page 378: ...IUS 2004 09 0000 00 PAS Parking Aid Sensor Horizontal Min 20 at 110 5 cm Min 100 at 50 5 cm Vertical Min 20 at 110 5 cm Min 60 at 50 5 cm Type Piezo ceramic element Frequency 40 KHz 2 KHz Detecting range 13 5 V ...

Page 379: ...screen The video mode in front A V system is changed to rearview monitoring mode However the audio mode stays on The video mode in front A V system resumes when shifting out from R position The audio and video mode in rear A V system are not changed When selecting R position while A V system is in use When selecting R position while A V system is not in use Both monitors are automatically turned o...

Page 380: ...id system PAS and transmits the signals from sensors to multimeter and buzzer installed in tuner amplifier bracket Front monitor When moving the gear selector lever into R position while watching DVD or VCD the rearview appears on the front monitor ICM box When moving the gear selector lever into R position the alarm buzzer in ICM box sounds installed at bottom of STICS Rearview camera The rearvie...

Page 381: ...acles Rear left obstacles This unit controls the parking aid system One of 3 LEDs comes on when the corresponding parking aid sensor is defective and shows below message on multi meter PAS unit Tuner Amplifier with built in DSP Navigation unit Rear left sensor Rear center sensor Rear right sensor Right sensor Left sensor Parking aid buzzer Center sensor ...

Page 382: ... is in R position the sensor will be diagnosed once If found any failure due to open circuit to sensor or communication error warning buzzer sounds for 3 seconds and the data on failed sensor transmits to the instrument panel to light up the corresponding LED If normal the warning buzzer sounds only for 65 ms Whenever the power is applied the diagnosis mode is initiated Sensor failure conditions c...

Page 383: ...ns a short beep sounds when the gear selector lever is moved into R position with the ignition key ON If the system is in abnormal operating conditions a beep sounds for 3 seconds when the gear selector lever is moved into R position with the ignition key ON or engine running However it is also occurred when the obstacle is within 50 cm from the rear bumper 1 2 3 4 5 Note that the display does not...

Page 384: ... commercial vehicles When a high power radio is turned on Narrowed sensing area When the sensing portion is partially covered by snow or mud Surrounding temperature of sensor is too high approx over 80 C or too low approx below 30 C Not defective but may occur improper working When driving on the rough roads gravel road hill and grass When the bumper height is changed due to the heavy load When th...

Page 385: ...09 11 PAS RODIUS 2004 09 0000 00 4 PARKING AID SYSTEM CONTROL 1 Parking Aid Unit 2 Parking Aid Sensor ...

Page 386: ...system are not changed when selecting R position while A V system is in use The real distance is different from what you see in monitor because the camera uses wide angle lens Note that the display does not show everything in the rear area Keep the camera lens clean with a lens cleaner Operates only when the gear selector lever is in R position The rearview camera displays the rearview The rear mo...

Page 387: ... the ignition key ON or engine running the rearview appears on the monitors automatically regardless of displays by head unit When the rearview mode is activated the AV system doesn t work even though the buttons on the AV unit are pressed However the monitor angle can be adjusted when the AV system is changed to the rearview mode with the head unit turned off And the monitor angle and volume can ...

Page 388: ...s an operation signal for rearview camera If it receives reverse signal the rearview camera is turned on even though the AV unit is turned off The rearview camera consists of AV unit including monitor reverse signal battery voltage and rearview camera The AV unit receives the power from battery and if it receives the reverse signal supplies the power to rearview camera When the rearview camera ope...

Page 389: ...09 15 PAS RODIUS 2004 09 0000 00 7 CIRCUIT DIAGRAM ...

Page 390: ...nal item There are 6 speakers in basic and it can be 12 including tweeter if equipped with DVD system 6 CD changer and 8 DVD changer can be installed as an extra item DVD changer is available for the vehicle equipped with DVD head unit and can play audio CD video CD MP3 CD and DVD CD Followings are AV systems and will be described based on the vehicle equipped with DVD system 2 AV SYSTEM BY VEHICL...

Page 391: ...10 4 RODIUS 2004 09 8930 01 AV DVD head unit Navigation DVD changer ...

Page 392: ...10 5 AV RODIUS 2004 09 8930 01 3 SPECIFICATIONS OF AV HEAD UNIT ...

Page 393: ...10 6 RODIUS 2004 09 8930 01 AV 1 AVSYSTEM LAYOUT BASED ON DVD EQUIPPED SYSTEM Subwoofer with built in amplifier ...

Page 394: ...10 7 AV RODIUS 2004 09 8930 01 DVD changer ...

Page 395: ...10 8 RODIUS 2004 09 8930 01 AV 2 DVD SYSTEM SIGNALS AND DATA PROCESSING ...

Page 396: ...10 9 AV RODIUS 2004 09 8930 01 ...

Page 397: ...lly 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 provides tw...

Page 398: ...01 4 RODIUS 2004 09 3650 01 DC 5 SPEED 2 STRUCTURE Basic structure of DC 5 speed automatic transmission ...

Page 399: ...n DI Engine A T equipped vehicle specifications Gear ratio 1st gear 3 595 2nd gear 2 185 3rd gear 1 405 4th gear 1 000 5th gear 0 831 Rev 1st gear 3 167 Rev 2nd gear 1 926 Axle ratio 3 31 2 WINTER Mode Standard Mode 3 Allowable shifting point Upshift Downshift Lockup sleeping Unlock open FAST OFF Dynamic shift range ...

Page 400: ...ion remains at 4th gear other than 4 4 shift when slowly releasing the accelerator pedal the transmission is shifted to 5th gear 5 Dynamic shift range 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 401: ...01 7 DC 5 SPEED RODIUS 2004 09 3650 01 4 SPECIFICATIONS ...

Page 402: ...01 8 RODIUS 2004 09 3650 01 DC 5 SPEED ...

Page 403: ...01 9 DC 5 SPEED RODIUS 2004 09 3650 01 1 Friction Disc 2 Tightening Torque ...

Page 404: ...01 10 RODIUS 2004 09 3650 01 DC 5 SPEED 1 COMPONENTS OF AUTO TRANSMISSION DC 5 SPEED A T ...

Page 405: ...01 11 DC 5 SPEED RODIUS 2004 09 3650 01 2 POWER FLOW Sectional View Shifting elements 1 Selector program switch S mode 2 Selector program switch W mode 3 Overrun ...

Page 406: ...d B1 Planetary gear carrier Rotation with reduced speed Rear ring gear clockwise rotation Rear sun gear Locked by F2 and 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 3 Overrun ...

Page 407: ...r 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 speed Output shaft Clockwise rotation 3 Overrun ...

Page 408: ...ut 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 409: ...e 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 sun gear and ring gear direct connection Output shaft Clockwise rotation ...

Page 410: ...uced 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 increased speed Center sun gear Clockwise rotation with increased speed by C3 activation Center planetary gear carrier Clockwise rotation increased speed Output shaft Clockwise rotation increas...

Page 411: ...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 Locked by B3 Center planetary gear carrier Counterclockwise rotation reduced speed Output shaft Counterclockwise rotation 3 Overrun ...

Page 412: ...ar 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 gear carrier Counterclockwise rotation reduced speed Output shaft Counterclockwise rotation ...

Page 413: ...02 3 M T RODIUS 2004 09 3170 01 1 SPECIFICATIONS 1 General Specifications 2 Tightening Torque 3170 01 M T ...

Page 414: ... transmission and BTRA automatic transmission It provides maximum drivability by the optimized engine torque and gear ratio TSM54 52 transmission uses linkage type shift elements directly connected to the transmission It prevent the transmission from shifting to the reverse gear from 5th gear when shifting to reverse gear It also prevents the break and wear 1 2 4WD 2WD ...

Page 415: ...nt the independent interlock devices are installed 4 TSM54 52 transmission uses the inertia lock type key to make smooth gear engagement and to provide silent gear engagement The clutch release system is available to use CSC Concentric Slave Cylinder or Fork type according to the vehicle model New Rexton uses the fork type clutch release system The semi remote control type gear shift mechanism is ...

Page 416: ...03 3 CLUTCH RODIUS 2004 09 3010 01 3010 01 CLUTCH 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE ...

Page 417: ...by spring pressure This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly 3 Operating Elements The clutch control system consists of the clutch pedal clutch master cylinder concentric slave cylinder This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by using release lever and release fork...

Page 418: ...usting equipment Clutch replacement Replacement of cluch disc Replace the clutch cover assembly together Reinstallation of clutch disc cover Apply the zig set SST on the clutch cover set Engine removal and reinstallation Flywheel related job Checking the clutch assy When reinstall the clutch assembly without the special zig Disc can be slip and worn easily Installation of special zig Identify the ...

Page 419: ...lave cylinder cover 2 Concentric slave cylinder 3 Clutch cover 4 Clutch disk 5 Adaptor 6 Clutch master cylinder 7 Hose 8 Pipe 9 Clutch fluid chamber 10 Clutch hydraulic line 11 Clutch pin B 12 Clutch housing 13 Switch 14 Bracket 15 Clutch pedal 16 Clutch pedal pad ...

Page 420: ...04 3 AXLE SYSTEM RODIUS 2004 09 4120 01 4120 01 AXLE 1 FRONT AXLE SPECIFICATION 2 REAR AXLE SPECIFICATION ...

Page 421: ...05 3 TOD RODIUS 2004 09 3240 01 3240 01 TOD TORQUE ON DEMAND 1 SPECIFICATIONS ...

Page 422: ...05 4 RODIUS 2004 09 3240 01 TOD 1 TOD SYSTEM LAYOUT T M Transfer case TOD Front propeller shaft Sub frame Exaust pipe Rear propeller shaft ...

Page 423: ...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 r...

Page 424: ...ntain safe ground grab capacity against side winds and rain Distribution ratio 15 for front wheels and 85 for rear wheels When turning on the road with low friction rate During cornering on roads such as unpaved snowy icy and muddy ground grab capacity is increased by distributing required torque and at the same time comfortable steering operation is maintained by controlling the ground grab capac...

Page 425: ...engage HIGH LOW collar directly with input shaft for transmitting the driving force to front and rear propeller shafts When a driver selects 4WD LOW the TOD control unit controls the electro magnetic clutch and operates the shift motor to engage HIGH LOW collar with carrier The power from transmission is increased up to 2 48 1 by reduction ratio from planetary gear and then is sent to front and re...

Page 426: ... EMC consists of coil and housing TOD control unit controls EMC by controlling duty cycle according to the road and driving conditions These controls use the continuity time and amount of electric current to determine the torque to be transmitted to front wheels ...

Page 427: ...05 9 TOD RODIUS 2004 09 3240 01 3 Signal Flow ...

Page 428: ...05 10 RODIUS 2004 09 3240 01 TOD 4 Power Flow 1 4H Mode 4WD Drive High Speed ...

Page 429: ...05 11 TOD RODIUS 2004 09 3240 01 2 4H Mode 4WD Drive Low Speed ...

Page 430: ...05 12 RODIUS 2004 09 3240 01 TOD 3 OPERATION System Layout ...

Page 431: ...h gear ratio is 1 1 and 4L mode distributes power to front and rear wheels 50 50 of which gear ratio is 2 48 1 4L Mode When selecting 4L mode EMC is locked to apply maximum torque into front and rear propeller shafts when the wheel speed is more than 87Hz 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 t...

Page 432: ...05 14 RODIUS 2004 09 3240 01 TOD 4 CIRCUIT DIAGRAM ...

Page 433: ... reduction gear It is manufactured by a thin 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 a...

Page 434: ...07 3 SUSPENSION SYSTEM RODIUS 2004 09 4110 01 4410 10 SUSPENSION SYSTEM 1 FRONT SUSPENSION SPECIFICATION 2 REAR SUSPENSION SPECIFICATION ...

Page 435: ...07 4 RODIUS 2004 09 4110 01 SUSPENSION SYSTEM 3 STRUCTURE OF SHOCK ABSORBER AND COIL SPRING 1 front coil spring Specification ...

Page 436: ...07 5 SUSPENSION SYSTEM RODIUS 2004 09 4110 01 2 front shock absorber assembly Specification ...

Page 437: ... 2004 09 4110 01 SUSPENSION SYSTEM 3 rear shock absorber Keep the suitable distance when compressed and expanded Minimum length is 10 mm longer than the minimum length under compression Specification Marking Point ...

Page 438: ...07 7 SUSPENSION SYSTEM RODIUS 2004 09 4110 01 4 rear coil spring Steel for high tensional spring is adapted Maintain more than 20 mm of freeplay when compressed Spring seat applied Specification ...

Page 439: ...08 3 BRAKS SYSTEM RODIUS 2004 09 4830 01 4841 01 BRAKE SYSTEM 1 SPECIFICATION ...

Page 440: ...08 4 RODIUS 2004 09 4830 01 BRAKS SYSTEM 1 COMPONENTS OF BRAKE SYSTEM ...

Page 441: ...08 5 BRAKS SYSTEM RODIUS 2004 09 4830 01 ...

Page 442: ...parking brake 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 calip...

Page 443: ...acuum pump in intake manifold and the atmospheric pressure Pressure distribution at working Pressure distribution after working When depressing the brake pedal the push rod 1 in booster pushes the poppet 2 and valve plunger 3 The poppet 2 pushes the power piston seat 5 resulting in closing the vacuum valve 9 The chamber A and B in power cylinder are isolated and the valve plunger 3 is separated fr...

Page 444: ...as two pressure sensors under master cylinder and these two sensor are used for BAS Brake Assist System system Vehicle with ESP Vehicle with ABS Brake fluid reservoir tank Master cylinder Do not disassemble the brake oil pressure sensors These can not be reinstalled of disassembled After reinstall the reserver tank perform a air bleeding of brake system ...

Page 445: ...ONS OF ESP SYSTEM 1 Specifications Of Pressure Sensor 2 Specifications Of Sensor Cluster sensor cluster yaw rate sensor lateral acceleration sensor Longitudinal acceleration sensor 3 Specifications Of Wheel Speed Sensor 4 Specifications Of Steering Wheel Angle Sensor ...

Page 446: ...nsor 5 Steering wheel angle sensor 3 Wheel speed sensor 1 HECU Hydraulic Engine conrol unit 4 Sensor cluster Yaw rate lateral sensor longitudinal sensor 6 ESP off switch Electronic Stability Program Switch 2WD vehicle has the longitudinal sensor in the HECU ESP Warning lamp ...

Page 447: ...09 5 ESP RODIUS 2004 09 4892 01 2 INPUT AND OUTPUT DIAGRAM ...

Page 448: ...ions in dangerous situations and stabilizes the vehicle by wheel individual braking and engine control intervention with no need for actuating the brake This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to under steering or over steering during cornering The yaw rate sensor lateral sensor and longitudinal sensor in the sensor cluster an...

Page 449: ...cle cornering direction during understeering with the yaw rate sensor and the lateral sensor Then the ESP system applies the brake at the rear inner wheel to compensate the yaw moment value In this way the vehicle does not lose its driving direction and the driver can steer the vehicle as driver intends ESP controls during oversteering The ESP system recognizes the directional angle with the steer...

Page 450: ...ly 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 operates ...

Page 451: ...ols by ESP system under various situations such as when the brake pedal is pressed or not pressed during cornering and when the ABS is operating or when just the conventional brake is operating during braking It also includes the vehicle conditions when the TCS that is included in the ESP system is operating ...

Page 452: ...braking is required under emergency The HBA System increases the braking force under urgent situations to enhance the inputted braking force from the driver Based on the fact that some drivers depress the brake pedal too soft even under when hard braking is necessary the HECU system is a safety supplementary system that builds high braking force during initial braking according to pressure value o...

Page 453: ...s under the master cylinder When the ESP ECU system determines that emergency braking is present the pump operates the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered to the wheels via the inlet valves If the drive depress the brake pedal slowly the pressure change is not high In this case only the conventional brake system with booster is activated ...

Page 454: ...09 12 RODIUS 2004 09 4892 01 ESP 5 Comparison with ABS System ...

Page 455: ...09 13 ESP RODIUS 2004 09 4892 01 6 Hydraulic Circuit Diagram ...

Page 456: ...vehicle movement the ESP warning lamp on the 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...

Page 457: ...ion 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 ...

Page 458: ...ssure 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 459: ... 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 460: ...he 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 461: ...g on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing it operates the pump immediately to apply the brake pressure at the wheels Then the pressure in the pump increases until just before the corresponding wheel gets locked The motor still keeps rotating and the outlet valve and the separation valve are will stay closed When the wheel starts ...

Page 462: ...09 20 RODIUS 2004 09 4892 01 ESP 4 ELECTRICAL CIRCUIT DIAGRAM Wheel Speed Sensor Stop Lamp Diagnosis Warnung Lamp ABS ESP ...

Page 463: ...09 21 ESP RODIUS 2004 09 4892 01 Brake Pressure Sensor ESP Sensor Sensor Cluster ESP OFF Switch ...

Page 464: ...pers By the use of electronic computers the brakes rapidly alternate at a rate of 30 times per second from full pressure to full release 1 Driving Physics To give you a better understanding of the tasks and functions of ABS we will first look at the physics principles 1 The Stopping Distance The stopping distance depends on the vehicle weight and initial speed when braking starts This also applies...

Page 465: ... a dry road the brake force which can be obtained is considerably higher The brake force which can be obtained can be calculated from below formula Maximum brake force FBmax Vehicle Weight x Adhesion coefficientmh The braking process cannot be described sufficiently accurately with the brake forces calculated The values calculated only apply if the wheel is not locked In the case of a locking whee...

Page 466: ...without ABS the wheel locks on braking and therefore pushes a wedge before it This wedge of loose surface or freshly fallen snow means and increased resistance and as a result the stopping distance is shorter This reduction in stopping distance is not possible with a vehicle with ABS as the wheel does not lock On these surfaces the stopping distance with ABS is longer than without ABS The reason f...

Page 467: ...st 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 relationship becomes even clearer In this relationship as long as the acting for...

Page 468: ...le range then begins in which no further modulation is possible The ABS controls the egulation of the brake pressure so that the brake force only becomes great enough for a sufficient proportion of cornering force to remain With ABS we remain in the Kamm circle as long as the car is driving sensibly We will leave driving physics with these statements and turn to the braking systems with and withou...

Page 469: ...lating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previously determined reference speed In that case the control cycle is initiated again in order to again correct the wheel speed by modulating the brake pressure Selector low control This control is used for regulating the brake pressure for rear ...

Page 470: ...ble any component designated as nonserviceable The hydraulic modulator and the HECU can be seperated There is however no access to repair the each components 3 Bleeding system Replacement modulators are shipped already filled and bled In normal procedures requiring removal of the modulator such as to replace the HECU air will not enter the modulator and normal bleeding will be all that is needed I...

Page 471: ...alled out The correct torque values must be used when installing fasteners that require them If the above procedures are not followed parts or system damage could result Use only DOT 3 equivalent hydraulic brake fluid The use of DOT 5 silicone brake fluid is not recommended Reduced brake performance or durability may result Avoid spilling brake fluid on any the vehicle s painted surfaces wiring ca...

Page 472: ...f integrated 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 ABS HECU ABS EBD warning lamp ...

Page 473: ...10 12 RODIUS 2004 09 4892 01 ABS System Fuse The ABS TCS system fuse and SB2 is located at the fuse box in engine compartment Indicators The ABS and TCS indicators are in instrument cluster ...

Page 474: ...10 13 ABS RODIUS 2004 09 4892 01 2 INPUT AND OUTPUT DIAGRAM ...

Page 475: ...between the front and rear axles This is called Electronic Brake 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 a...

Page 476: ...remely sensitive to EMI eletromagnetic interference Proper 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 s...

Page 477: ...10 16 RODIUS 2004 09 4892 01 ABS 3 Electrical Circuit ...

Page 478: ...sor 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 479: ...et valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually No Hydraulic Pressure Circuit when ABS is Operating 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...

Page 480: ...eases 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 No Hydraulic Pressure Circuit when ABS is Operating As the wheel speed increases the inlet valve opens and the wheel s pressure increases due to the master cylinder pressure The oil in the low pressure chamber c...

Page 481: ... number of valves in valve body is 6 when equipped with only ABS and 12 when equipped with ESP system Motor Pump The motor is operated when ABS is activated The cam shaped output shaft of the motor enables the brake system to receive and supply the brake fluid during the motor operation Valve Body The cam bushing is installed between plungers and it draws and discharges the brake fluid ...

Page 482: ...c valves by supplying or cutting off the voltage to solenoid valves depending on the wheel speed and other information from wheel speed sensors The figure shown in left side is for ESP ECU There are two channels for front wheels and one channel for rear wheels Each channel has one inlet and one outlet valve therefore there are six solenoid valves ECU lower cover The electrical components are weak ...

Page 483: ...11 3 POWER STEERING SYSTEM RODIUS 2004 09 4610 00 4610 01 POWER STEERING 1 SPECIFICATION 2 TIGHTENING TORQUE ...

Page 484: ...ed rack piston converts the hydraulic pressure to linear movement The operating force of rack moves the wheels through tie rod tie rod end and steering knuckle Even though the hydraulic pressure cannot be generated a driver can steer the vehicle without power assist but it needs very high steering force In this case the operating force of steering wheel is conveyed to pinion and the movement of pi...

Page 485: ...11 5 POWER STEERING SYSTEM RODIUS 2004 09 4610 00 1 COMPONENTS OF POWER STEERING ASSEMBLY ...

Page 486: ...piston rod The control valve directs the oil to one end face of the piston to enhance the steering force The control valve controls the directions and operations of power cylinder Additionally the safety check valve is installed so that the system can be operated manually when the system is defective Tie rod end Gear box assembly Clamp mounting Tie rod end Tie rod Boot Bush mounting Boot Tie rod ...

Page 487: ...ates the excessive amount of discharging oil When the steering wheel is stationary or the oil circuit is blocked the pressure relief valve returns the over pressurized oil to the oil reservoir The oil reservoir sends the oil to the power steering pump and receives the oil from the power steering gear The oil level in the reservoir depends on the steering wheel positions therefore measure the oil l...

Page 488: ...12 3 WHEEL RODIUS 2004 09 0000 00 4170 09 WHEEL TIRE 1 SPECIFICATION ...

Page 489: ...himmy General Balance Precautions Remove all deposits of foreign material from the inside of the wheel Remove stones frim the gread in order to avoid operator injury during spin balancing Inspect the tire for any damage Balance the tire according to the equipment manufacturer s recommendations 2 Structure of Tubeless Tube The tire structure is different slightly ccording to the types of the tire b...

Page 490: ...re and endures applied load and shock to tire it should have a high anti fatigue characteristic Side Wall 4 It is provided to improve the comfortable driving by protecting carcass and cushion movement Bead 5 A steel wire winding the ending part of carcass code coated with rubber film and wrapped with nylon cord papers It fixes tire to a rim 3 Conventions for Radial Tire ...

Page 491: ...12 6 RODIUS 2004 09 0000 00 WHEEL 4 The Relations Between Inflation Pressure and Tire 5 The Relations Between Load and Tire ...

Page 492: ...g last deformation so the trembling wave appears in the tread portion The lower the tire pressure the severe the trembling wave appears during the high speed The condition of driving a vehicle fast on the road surface covered with water can cause tires to fail to rotate with a good contact on the surface so results in remaining them a float This is so called hydroplaning It causes brake failure lo...

Page 493: ... parallel rolling of the wheels The toe serves to offset the small deflections of the wheel support system which occur when the vehicle is rolling forward The specified toe angle is the setting which achieves degrees 0 of toe when the vehicle is moving Incorrect toe in or toe out will cause tire wear and reduced fuel economy As the individual steering and suspension components wear from vehicle mi...

Page 494: ...s positive and a forward tilt negative Caster influences directional control of the steering but does not affect tire wear Weak springs or overloading a vehicle will affect caster One wheel with more positive caster will pull toward the center of the car This condition will cause the car to move or lean toward the side with the least amount of positive caster Caster is measures in degrees and is n...

Page 495: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 MANUAL TRANSMISSION 2 DSI TRANSMISSION 3 MB TRANSMISSION 4 TRANSAXLE TRANSMISSION 5 AXLE 6 SUSPENTION 7 BRAKE 3 6 8 1 0 1 5 1 7 1 8 ...

Page 496: ......

Page 497: ...ERVICE TOOLS RODIUS 2004 09 0000 00 1 MANUAL TRANSMISSION 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 498: ...0 4 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 499: ...0 5 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 500: ...0 6 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS 2 DSI TRANSMISSION MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 501: ...0 7 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 502: ...0 8 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS 3 MB TRANSMISSION MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 503: ...0 9 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 504: ...0 10 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS 4 TRANSAXLE TRANSMISSION MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 505: ...0 11 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 506: ...0 12 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 507: ...0 13 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 508: ...0 14 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 509: ...0 15 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 5 AXLE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 510: ...0 16 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 511: ...0 17 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 6 SUSPENTION MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 512: ...0 18 RODIUS 2004 09 0000 00 SPECIAL SERVICE TOOLS 7 BRAKE MODEL M Musso Musso Sports I Istana K Korando CM Chairman R Rexton S Stavic Rodius Ky Kyron A Actyon Actyon sports W Chairman W ...

Page 513: ...01 3 AIR CONDITIONING SYSTEM RODIUS 2004 09 0000 00 6810 20 AIR CONDITIONING SYSTEM 1 FFH SPECIFICATION ...

Page 514: ...01 4 RODIUS 2004 09 0000 00 AIR CONDITIONING SYSTEM 2 SYSTEM LAYOUT AND COMPONENTS ...

Page 515: ...01 5 AIR CONDITIONING SYSTEM RODIUS 2004 09 0000 00 ...

Page 516: ...ion FFH System consists of independent fuel lines fuel pump coolant circuit coolant ciculation pump electrical glow plug and exhaust system by driver s intention because FFH system is automatically Operated according to the coolant temperature and the ambient temperature FFH system operates up to more than 2 minutes to burn the residual fuel inside the system when driver stop the engine during its...

Page 517: ...01 7 AIR CONDITIONING SYSTEM RODIUS 2004 09 0000 00 4 COMPONENTS AND LOCATIONS ...

Page 518: ...01 8 RODIUS 2004 09 0000 00 AIR CONDITIONING SYSTEM 1 VENTILATION SYSTEM COMPONENTS 1 Locations of Vents Air conditioned air flows Heater vent Heated air flows Front Ventilation Rear ventilation ...

Page 519: ...01 9 AIR CONDITIONING SYSTEM RODIUS 2004 09 0000 00 2 Ventilation Modes Vent mode Bi level mode Floor mode Defrost and floor mode Defrost mode Rear air conditioning mode ...

Page 520: ...ONDITIONING SYSTEM 2 AIR CONDITIONER MODULE WIRING AND LAYOUT 1 Front Air Conditioner Module Wiring layout Components Air source selection door actuator Air conditioner filter Evaporator Blower motor Blower high speed relay Heater core ...

Page 521: ...01 11 AIR CONDITIONING SYSTEM RODIUS 2004 09 0000 00 2 Rear Air Conditioner Module Wiring layout Components ...

Page 522: ...nd changes it into current and then sends the signal to FATC controller 1 Inspection Remove the sun sensor and measure the current between terminals under sunlight Measure the current again under shade It is in normal conditions if the measured value is less than the measured value under sunlight Turn the ignition switch to ON position Measure the voltage to the sun sensor from FATC connector appr...

Page 523: ...emperature sensor This sensor is a negative temperature coefficient NTC thermistor and detects the interior temperature with air coming from senor hole and then sends the voltage value according to the changed resistance to FATC controller Humidity sensor This sensor detects the interior humidity with humidity cell and then sends the voltage value according to the changed humidity to FATC controll...

Page 524: ...ue cannot be measured check the circuit for open If the measured value is within the specified range replace the FATC controller 1 2 3 4 Humidity sensor Apply 5 V to terminal No 1 and 3 on the humidity sensor connector Connect the positive probe of a tester on No 2 terminal and the negative probe on No 3 terminal and measure the output voltage while the voltage is applied output voltage approx 0 8...

Page 525: ...r words the air source cannot be changed to recirculation mode in AUTO mode by just pressing the switch To change the air source to recirculation mode in AUTO mode get into Manual mode first then press the air source selection switch Manual Mode To change the AQS mode to Manual mode from AUTO mode use the MODE switch or the fan speed control dial In Manual mode the AUTO symbol on the display is di...

Page 526: ...t pressed in 1 Self diagnosis and preheating process during initial operation of A C controller AUTO mode When the air conditioner controller is operated in AUTO mode during its initial operation the air source is changed to the recirculation mode and AQS LED comes on This is the self diagnosis and preheating process for AQS 1 After completing the above process the AQS LED is turned off and the ai...

Page 527: ...ed the AQS operates and converts the air source to recirculation mode automatically At this moment the recirculation mode indicator comes on in the display 1 2 If the polluted air is disappeared the air source is automatically changed to the fresh air mode and AQS LED stays on The air source is not changed when pressing the AQS and air source selection switch in AUTO mode To change the air source ...

Page 528: ...hin the specified range replace the FATC controller 1 2 3 4 5 6 Ambient temperature sensor Remove the sensor and measure the resistance between terminal No 5 and 6 on the sensor connector standard approx 25 C 2 2 kΩ In addition if the resistance is extremely high or low replace the sensor If the measured value is out of the specified range replace the ambient temperature sensor If the measured val...

Page 529: ...ature sensor and measure the resistance between terminals on the sensor connector standard approx 25 C 2 2 kΩ In addition if the resistance is extremely high or replace the sensor If the measured value is out of the specified range replace the duct temperature sensor If the measured value is within the specified range check as below Turn the ignition switch to ON position and measure the voltage t...

Page 530: ...m FATC If the power transistor defect code DTC 6 is appeared check as below 1 Inspection Turn the ignition switch to ON position Measure the voltage between terminals while changing the fan speed from stage 1 to stage 6 The specified voltage value in each stage 1 2 3 If the voltage is out of specified value check the circuit for open If the circuit is in normal condition replace the power transist...

Page 531: ...oses opens and adjusts the mode door for VENT FLOOR and DEF mode to change the air flow directions according to FATC controller Under the FATC controller AUTO mode it stays on DEF mode until the engine coolant temperature reaches at normal operating level and the mode is changed as below when the MODE switch is pressed ...

Page 532: ...to 12 V after selecting the mode it is normal If the voltage value is out of the specified value check the related circuits for open If the circuits are in normal condition replace the FATC If the voltage is within the specified value replace the mode door actuator assembly Connect the positive and negative cables of temporary power supply to the door mode actuator And connect the negative cable t...

Page 533: ...01 23 AIR CONDITIONING SYSTEM RODIUS 2004 09 6810 20 4 Air Door Actuator The air door actuator sets the intake door mode according to the control signals from FATC ...

Page 534: ... on the connector Check whether the output voltages ON approx 12 V off 0 V If the voltage value is out of the specified value replace the thermo AMP If the circuit is in normal condition check as below Turn the ignition switch to ON position and turn on the air conditioner by pressing the A C button And measure the voltage between terminal A12 and A11 on the FATC controller connector standard appr...

Page 535: ......

Page 536: ...03 3 AIR BAG SYSTEM RODIUS 2004 09 8810 03 1 COMPONENTS OF DRIVER S AIRBAG MODULE Airbag module Steering wheel Contact coil 8810 01 AIR BAG SYSTEM ...

Page 537: ...03 4 RODIUS 2004 09 8810 03 AIR BAG SYSTEM 2 COMPONENTS OF PASSENGER S AIRBAG MODULE Cushion Retainer Housing Inflator Bracket ...

Page 538: ... module can cause injury 3 Module Cover Housing It is a type of a container that includes the cushion and the inflator The module housing functions to deliver the reaction force between the body 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...

Page 539: ...agnostic trouble code when malfunction is detected Display airbag fault codes Display airbag fault codes and system status information when connected to a scan tool Self diagnosis function Illuminate 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...

Page 540: ...mpact and identifies whether the current condition is necessary for airbag deployment or not And then the controller sends the specified currents to the airbag ignition circuit as needed This device always monitors the airbag system in conduction with the diagnostic circuit When it is detected any problem it illuminates the airbag warning indicator to inform driver of the fault and stores the faul...

Page 541: ...g 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 The ...

Page 542: ...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 seldom inflates when Oblique impact rollover Weak impact in which the sensor is unable to detect under the inflation requirements Impact against narrow objects such as a telegraph pole or a tree The vehicle falls into a dra...

Page 543: ...NO DATA ...

Page 544: ...07 3 BODY EXTERIOR RODIUS 2004 09 7115 01 7115 03 Body Exterior 1 COMPONENTS AND LOCATION OF EXTERIOR Roof rack Hood Front bumper assembly Front door Rear door Rear view mirror ...

Page 545: ...07 4 RODIUS 2004 09 7115 01 BODY EXTERIOR Rear spoiler Rear view camera Tailgate Rear bumper assembly Sunroof assembly Wide ganish assembly ...

Page 546: ...DIUS 2004 09 7115 01 1 DOOR SYSTEM 1 LAYOUT FRONT DOOR B Outside door handle C Power window switch D Folding switch Adjustment switch Rear view mirrow A Inside door handle E Door courtesy lamp F Door striker contact switch ...

Page 547: ...07 6 RODIUS 2004 09 7115 01 BODY EXTERIOR Door connector Door hinge Check linkage Window regulator motor Door latch crank Rear view mirror folding unit ...

Page 548: ...ERIOR RODIUS 2004 09 7115 01 2 LAYOUT REAR DOOR Door hinge Door striker Contact switch Door check linkage Twitter speaker Power window switch Door latch crank Window regulator Motor Inside handle Door courtesy lamp ...

Page 549: ...perating Process Power window motor 1 which is controlled by the window switch draws up and down the window regulator 2 and operating cable The window glass move up and down with the window regulator Window regulator Guide rail Regulator operating cable Window motor ...

Page 550: ...7115 01 4 OPERATION DOOR LOCK UNLOCK 1 Front Door Connecting rod key cylinder Door key cylinder Outside door handle Lock Unlock cable Connecting rod outside handle Operating cable Inside handle Door latch Lock Unlock Inside door handle ...

Page 551: ...ide handle Outside handle Key cylinder Operation of lock button Operating cable Latch lock Unlock Operation of Inside handle Operating cable Latch open mode Operation of outside handle Connecting rod outside handle Latch open mode Insert key operation Connecting rod key cylinder Latch lock Unlock ...

Page 552: ...07 11 BODY EXTERIOR RODIUS 2004 09 7115 01 2 Rear Door Outside door handle Connecting rod Outside handle Rock Unlock cable Operating cable Inside handle CHILD SAFETY mode Lock Unlock Inside door handle ...

Page 553: ...DY EXTERIOR Operating Process Lock Unlock Inside door handle Inside handle CHILD SAFETY mode Lock button Operating cable Latch lock Unlock Operation of handle Operating cable Open mode Latch Safety FREE mode Latch Crank in operation ...

Page 554: ... Mirror adjustment When switch rear view mirror is operated two motors which of one moves up and down and the other one moves left and right are shifted to the direction the driver intended Refer to the picture below Folding Motor is operated to fold the rear view mirrow when switch is pushed ...

Page 555: ...US 2004 09 7115 01 BODY EXTERIOR 2 HOOD BUMPER TAILGATE 1 OPERATION TAILGATE Tailgate handle Connecting tailgate handle Actuator Connecting rod actuator handle Key cylinder Door latch Connecting rod key cylinder ...

Page 556: ...07 15 BODY EXTERIOR RODIUS 2004 09 7115 01 Washer nozzle Rear view camera Rear spoiler 2 LAYOUT TAILGATE Wipre motor Key cylinder ...

Page 557: ...07 16 RODIUS 2004 09 7115 01 BODY EXTERIOR Shock absorber Door hinge Door striker Door latch ...

Page 558: ...07 17 BODY EXTERIOR RODIUS 2004 09 7115 01 3 LAYOUT COWL ASSY HOOD ...

Page 559: ...07 18 RODIUS 2004 09 7115 01 BODY EXTERIOR 4 LAYOUT FRONT BUMPER ...

Page 560: ...07 19 BODY EXTERIOR RODIUS 2004 09 7115 01 5 LAYOUT REAR BUMPER ...

Page 561: ...07 20 RODIUS 2004 09 7115 01 BODY EXTERIOR 6 KEY CYLINDER 1 COMPONENTS Door handle Front Key cylinder Key cylinder Tailgate Starting key cylinder key Key cylinder Door handle Front ...

Page 562: ...08 3 BODY REPAIR RODIUS 2004 09 5710 01 5710 01 BODY REPAIR 1 BODY DIMENSION ...

Page 563: ...08 4 RODIUS 2004 09 5710 01 BODY REPAIR 2 BODY JACK POINT Be sure to lift the vehicle only on the deginated jack point otherwise the vehicle could be body damaged Rear Front ...

Page 564: ...0 3 SUNROOF RODIUS 2004 09 7340 01 7340 01 SUN ROOF 1 SUNROOF LAYOUT ...

Page 565: ...0 4 RODIUS 2004 09 7340 01 SUNROOF 2 COMPONENTS OF SUNROOF ...

Page 566: ...0 5 SUNROOF RODIUS 2004 09 7340 01 3 COMPONENTS AND LOCATIONS 1 Drain hose 2 Control switch 3 Sun shade glass 4 Control unit 5 Sun roof motor ...

Page 567: ...ctuate the operating cable to lift up the glass Push the rear side of the button to put down the glass Motor actuates the operating cable Mechanical equipment lifts up down the glass 2 Sliding push the rear side of the button to slide the door back Motor actuates the operating cable Mechanical equipment slides the glass back and forth ...

Page 568: ... SEAT 7410 01 SEAT 1 COMPONENTS OF SEAT Seat control switch Sliding control Seat position control Seat height control Reclining control Sliding adjust lever Seat warmer switch Back flat adjust lever Back supporter Driver s seat ...

Page 569: ...0 5 SEAT RODIUS 2004 09 7410 01 Rear 3rd seat back folding adjust lever Back folding adjust lever Head rest Seat sliding adjust lever Seat swivel control lever ...

Page 570: ...0 6 RODIUS 2004 09 7410 01 SEAT 2 COMPONENTS OF SEAT BELT 1 11 Passengers Front Seat Belt 3 point Rear 1st row 3 point 2 point Rear 2nd row 3 point 2 point Rear 3rd row 3 point 2 point ...

Page 571: ...0 7 SEAT RODIUS 2004 09 7410 01 2 9 Passengers Front Seat Belt 3 point Rear 1st row 3 point Rear 2nd row 3 point Rear 3rd row 3 point 2 point ...

Page 572: ...0 8 RODIUS 2004 09 7410 01 SEAT 3 7 Passengers Front Seat Belt 3 point Rear 1st row 3 point Rear 2nd row 3 point 2 point ...

Page 573: ...0 9 SEAT RODIUS 2004 09 7410 01 1 SEAT LAYOUT 1 Layout 11 Passengers Front seat Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed ...

Page 574: ...0 10 RODIUS 2004 09 7410 01 SEAT 2 Layout 9 Passengers Front seat Move 36 mm from the far end to the front Rear 1st seat Movable Rear 2nd seat Movable Rear 3rd seat Fixed ...

Page 575: ...0 11 SEAT RODIUS 2004 09 7410 01 3 Layout 7 Passengers ...

Page 576: ...ont seat Move 36 mm from the far end to the front Rear 1st seat Move to the far front Remove head rest Back full flat Rear 2nd seat Move to the far end Back semi full flat Rear 3rd seat Fixed Front seat Move to the far front Back semi full flat Rear 1st seat Move to the far end Rear 2nd seat Move to the far end Rear 3rd seat Fixed ...

Page 577: ...ile driving Rear 1st seat when swiveled Rear 1st seat Move to the far end Center seat jumping Swiveled Rear 2nd seat Move to the far end Back folding Rear 3rd seat Fixed Rear 1st seat Move to the far end Center seat jumping Swiveled Rear 2nd seat Move to the far end Rear 3rd seat Fixed ...

Page 578: ...nd seat back folding while parking Front seat Move to the far front Rear 1st seat Middle Center seat jumping Swiveled Rear 2nd seat Middle Back folding Rear 3rd seat Fixed Front seat Move 36 mm from the far end to the front Rear 1st seat Middle Rear 2nd seat Middle Rear 3rd seat Double folding ...

Page 579: ...ng Front seat Move to the far end Back folding Rear 1st seat Middle Back folding Rear 2nd seat Middle Back folding Rear 3rd seat Middle Back folding Front seat Move 36 mm from the far end to the front Rear 1st seat Move to the far end Rear 2nd seat Middle Rear 3rd seat Double folding ...

Page 580: ...0 16 RODIUS 2004 09 7410 01 SEAT 5 Entry Way Rear 1st seat Folding center seat Rear 2nd seat Folding center seat Rear 3rd seat Fixed ...

Page 581: ...0 17 SEAT RODIUS 2004 09 7410 01 6 Sliding of Rear 1st and 2nd Seat 4 rail 1 610mm for rear 1st and 2nd seat sliding Rail mounting Floor bolt type ...

Page 582: ...0 18 RODIUS 2004 09 7410 01 SEAT 2 OPERATION OF FRONT SEAT DRIVER S SEAT 1 Components ...

Page 583: ...ding Rear side of seat moves up down controlled by seat position control switch Sliding Seat moves from front to rear controllde by sliding control switch Seat position front up down Front side of seat moves up down controlled by seat position control switch ...

Page 584: ...0 20 RODIUS 2004 09 7410 01 SEAT Reclining Seat back reclining controlled by seat reclining control switch Sliding Seat moves from front to rear controllde by sliding control switch Seat reclining motor ...

Page 585: ... and check if the power is supplied Refer to the wiring diagram If the power supply has no problem remove the seat Check the motor and wiring if damaged Connect the battery to the seat connector Control the seat switch and check the opration 1 2 3 4 Electrical parts are not supplied by a part separately ...

Page 586: ... 4 Operation of center seat When seating When jumping Pull up the center seat when to jump Push down the center seat when to seat 5 Removal and installation of center seat jumping seat Unscrew 4 mounting nuts to remove the center seat ...

Page 587: ...0 23 SEAT RODIUS 2004 09 7410 01 3 OPERATION OF REAR SEAT 1 Rear 1st seat swivel seat Seat back folding cable Seat back flat cable Sliding cable Jumping mechanism Sliding lever Swivel lever ...

Page 588: ...0 24 RODIUS 2004 09 7410 01 SEAT Rear Front 2 Operation of rear seat Rear 1st and 2nd seat Seat sliding ...

Page 589: ...DIUS 2004 09 7410 01 4 Seat back folding Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table 3 Seat back flat When to recline or to flat fully Rear 1st Rear 2nd Rear 1st 2nd seat ...

Page 590: ...2004 09 7410 01 SEAT 6 Rear 3rd seat 5 Seat swing Rear 1st seat Turn around seat as the swing lever is pulled Pull the lever behind back seat to fold the back seat Pull the lever under back seat to fold up the seat ...

Page 591: ...0 27 SEAT RODIUS 2004 09 7410 01 As the seat is folded disconnect hook and spread out the board ...

Page 592: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 BODY INTERIOR 3 ...

Page 593: ......

Page 594: ...0 3 SPECIAL SERVICE TOOLS RODIUS 2004 09 0000 00 0000 00 SPECIAL SERVICE TOOLS 1 BODY INTERIOR Name and Part Number Scanner Wheel wrench 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 595: ......

Page 596: ...ECU GASOLINE 0000 00 ECU GASOLINE 1 ECU GASOLINE 3 ...

Page 597: ......

Page 598: ...0 3 ECU GASOLINE RODIUS 2004 09 0000 00 0000 00 ECU GASOLINE 1 ECU GASOLINE ...

Page 599: ...0 4 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 600: ...0 5 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 601: ...0 6 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 602: ...0 7 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 603: ...0 8 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 604: ...0 9 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 605: ...0 10 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 606: ...0 11 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 607: ...0 12 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 608: ...0 13 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 609: ...0 14 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 610: ...0 15 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 611: ...0 16 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 612: ...0 17 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 613: ...0 18 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 614: ...0 19 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 615: ...0 20 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 616: ...0 21 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 617: ...0 22 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 618: ...0 23 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 619: ...0 24 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 620: ...0 25 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 621: ...0 26 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 622: ...0 27 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 623: ...0 28 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 624: ...0 29 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 625: ...0 30 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 626: ...0 31 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 627: ...0 32 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 628: ...0 33 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 629: ...0 34 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 630: ...0 35 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 631: ...0 36 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 632: ...0 37 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 633: ...0 38 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 634: ...0 39 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 635: ...0 40 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 636: ...0 41 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 637: ...0 42 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 638: ...0 43 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 639: ...0 44 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 640: ...0 45 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 641: ...0 46 RODIUS 2004 09 0000 00 ECU GASOLINE ...

Page 642: ...0 47 ECU GASOLINE RODIUS 2004 09 0000 00 ...

Page 643: ......

Page 644: ...ECU DIESEL 0000 00 ECU DIESEL DIAGNOSIS 1 ECU DIESEL 3 ...

Page 645: ......

Page 646: ...0 3 ECU DIESEL RODIUS 2004 09 0000 00 0000 00 ECU DIESEL 1 ECU DIESEL ...

Page 647: ...0 4 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 648: ...0 5 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 649: ...0 6 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 650: ...0 7 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 651: ...0 8 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 652: ...0 9 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 653: ...0 10 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 654: ...0 11 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 655: ...0 12 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 656: ...0 13 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 657: ...0 14 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 658: ...0 15 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 659: ...0 16 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 660: ...0 17 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 661: ...0 18 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 662: ...0 19 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 663: ...0 20 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 664: ...0 21 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 665: ...0 22 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 666: ...0 23 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 667: ...0 24 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 668: ...0 25 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 669: ...0 26 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 670: ...0 27 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 671: ...0 28 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 672: ...0 29 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 673: ...0 30 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 674: ...0 31 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 675: ...0 32 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 676: ...0 33 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 677: ...0 34 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 678: ...0 35 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 679: ...0 36 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 680: ...0 37 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 681: ...0 38 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 682: ...0 39 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 683: ...0 40 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 684: ...0 41 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 685: ...0 42 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 686: ...0 43 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 687: ...0 44 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 688: ...0 45 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 689: ...0 46 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 690: ...0 47 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 691: ...0 48 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 692: ...0 49 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 693: ...0 50 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 694: ...0 51 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 695: ...0 52 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 696: ...0 53 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 697: ...0 54 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 698: ...0 55 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 699: ...0 56 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 700: ...0 57 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 701: ...0 58 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 702: ...0 59 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 703: ...0 60 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 704: ...0 61 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 705: ...0 62 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 706: ...0 63 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 707: ...0 64 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 708: ...0 65 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 709: ...0 66 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 710: ...0 67 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 711: ...0 68 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 712: ...0 69 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 713: ...0 70 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 714: ...0 71 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 715: ...0 72 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 716: ...0 73 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 717: ...0 74 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 718: ...0 75 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 719: ...0 76 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 720: ...0 77 ECU DIESEL RODIUS 2004 09 0000 00 ...

Page 721: ...0 78 RODIUS 2004 09 0000 00 ECU DIESEL ...

Page 722: ...BRAKE 0000 00 BRAKE DIAGNOSIS 1 BRAKE 3 ...

Page 723: ......

Page 724: ...0 3 BRAKE RODIUS 2004 09 0000 00 0000 00 BRAKE 1 BRAKE ...

Page 725: ...0 4 RODIUS 2004 09 0000 00 BRAKE ...

Page 726: ...0 5 BRAKE RODIUS 2004 09 0000 00 ...

Page 727: ...0 6 RODIUS 2004 09 0000 00 BRAKE ...

Page 728: ...0 7 BRAKE RODIUS 2004 09 0000 00 ...

Page 729: ...0 8 RODIUS 2004 09 0000 00 BRAKE ...

Page 730: ...0 9 BRAKE RODIUS 2004 09 0000 00 ...

Page 731: ...0 10 RODIUS 2004 09 0000 00 BRAKE ...

Page 732: ...0 11 BRAKE RODIUS 2004 09 0000 00 ...

Page 733: ...0 12 RODIUS 2004 09 0000 00 BRAKE ...

Page 734: ...AIR BAG 0000 00 AIR BAG DIAGNOSIS 1 AIR BAG 3 ...

Page 735: ......

Page 736: ...0 3 AIR BAG RODIUS 2004 09 0000 00 0000 00 AIR BAG 1 AIR BAG ...

Page 737: ...0 4 RODIUS 2004 09 0000 00 AIR BAG ...

Page 738: ...0 5 AIR BAG RODIUS 2004 09 0000 00 ...

Page 739: ...0 6 RODIUS 2004 09 0000 00 AIR BAG ...

Page 740: ...0 7 AIR BAG RODIUS 2004 09 0000 00 ...

Page 741: ...0 8 RODIUS 2004 09 0000 00 AIR BAG ...

Page 742: ...0 9 AIR BAG RODIUS 2004 09 0000 00 ...

Page 743: ...0 10 RODIUS 2004 09 0000 00 AIR BAG ...

Page 744: ...CCCS 0000 00 CCCS DIAGNOSIS 1 CCCS 3 ...

Page 745: ......

Page 746: ...0 3 CCCS RODIUS 2004 09 0000 00 0000 00 CCCS 1 CCCS ...

Page 747: ...0 4 RODIUS 2004 09 0000 00 CCCS ...

Page 748: ...0 5 CCCS RODIUS 2004 09 0000 00 ...

Page 749: ...0 6 RODIUS 2004 09 0000 00 CCCS ...

Page 750: ...0 7 CCCS RODIUS 2004 09 0000 00 ...

Page 751: ...0 8 RODIUS 2004 09 0000 00 CCCS ...

Page 752: ...0 9 CCCS RODIUS 2004 09 0000 00 ...

Page 753: ...0 10 RODIUS 2004 09 0000 00 CCCS ...

Page 754: ...0 11 CCCS RODIUS 2004 09 0000 00 ...

Page 755: ...0 12 RODIUS 2004 09 0000 00 CCCS ...

Page 756: ...0 13 CCCS RODIUS 2004 09 0000 00 ...

Page 757: ...0 14 RODIUS 2004 09 0000 00 CCCS ...

Page 758: ...0 15 CCCS RODIUS 2004 09 0000 00 ...

Page 759: ...0 16 RODIUS 2004 09 0000 00 CCCS ...

Page 760: ...0 17 CCCS RODIUS 2004 09 0000 00 ...

Page 761: ...0 18 RODIUS 2004 09 0000 00 CCCS ...

Page 762: ...0 19 CCCS RODIUS 2004 09 0000 00 ...

Page 763: ...0 20 RODIUS 2004 09 0000 00 CCCS ...

Page 764: ...0 21 CCCS RODIUS 2004 09 0000 00 ...

Page 765: ...0 22 RODIUS 2004 09 0000 00 CCCS ...

Page 766: ...0 23 CCCS RODIUS 2004 09 0000 00 ...

Page 767: ...0 24 RODIUS 2004 09 0000 00 CCCS ...

Page 768: ...0 25 CCCS RODIUS 2004 09 0000 00 ...

Page 769: ...0 26 RODIUS 2004 09 0000 00 CCCS ...

Page 770: ...0 27 CCCS RODIUS 2004 09 0000 00 ...

Page 771: ......

Page 772: ...FATC 0000 00 FATC DIAGNOSIS 1 SELF DIAGNOSIS 3 ...

Page 773: ......

Page 774: ...ATC 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 775: ...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 776: ...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 777: ...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 778: ...FFH 0000 00 FFH DIAGNOSIS 1 FFH 3 ...

Page 779: ......

Page 780: ...0 3 FFH RODIUS 2004 09 0000 00 0000 00 FFH 1 FFH ...

Page 781: ...0 4 RODIUS 2004 09 0000 00 FFH ...

Page 782: ...0 5 FFH RODIUS 2004 09 0000 00 ...

Page 783: ...0 6 RODIUS 2004 09 0000 00 FFH ...

Page 784: ...P TRUNK 0000 00 P TRUNK DIAGNOSIS 1 P TRUNK 3 ...

Page 785: ......

Page 786: ...0 3 P TRUNK RODIUS 2004 09 0000 00 0000 00 P TRUNK 1 P TRUNK ...

Page 787: ...0 4 RODIUS 2004 09 0000 00 P TRUNK ...

Page 788: ...RAIN SENSOR 0000 00 RAIN SENSOR DIAGNOSIS 1 TROUBLE SHOOTING 3 ...

Page 789: ......

Page 790: ...erminals 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 Symptom 3...

Page 791: ...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 792: ...STICS 0000 00 STICS DIAGNOSIS 1 STICS 3 ...

Page 793: ......

Page 794: ...0 3 STICS RODIUS 2004 09 0000 00 0000 00 STICS 1 STICS ...

Page 795: ...0 4 RODIUS 2004 09 0000 00 STICS ...

Page 796: ...TC 0000 00 TC DIAGNOSIS 1 TC 3 ...

Page 797: ......

Page 798: ...0 3 TC RODIUS 2004 09 0000 00 0000 00 TC 1 TC ...

Page 799: ...0 4 RODIUS 2004 09 0000 00 TC ...

Page 800: ...0 5 TC RODIUS 2004 09 0000 00 ...

Page 801: ...0 6 RODIUS 2004 09 0000 00 TC ...

Page 802: ...TCU 0000 00 TCU DIAGNOSIS 1 TCU 3 ...

Page 803: ......

Page 804: ...0 3 TCU RODIUS 2004 09 0000 00 0000 00 TCU 1 TCU ...

Page 805: ...0 4 RODIUS 2004 09 0000 00 TCU ...

Page 806: ...0 5 TCU RODIUS 2004 09 0000 00 ...

Page 807: ...0 6 RODIUS 2004 09 0000 00 TCU ...

Page 808: ...0 7 TCU RODIUS 2004 09 0000 00 ...

Page 809: ...0 8 RODIUS 2004 09 0000 00 TCU ...

Page 810: ...0 9 TCU RODIUS 2004 09 0000 00 ...

Page 811: ...0 10 RODIUS 2004 09 0000 00 TCU ...

Page 812: ...0 11 TCU RODIUS 2004 09 0000 00 ...

Page 813: ...0 12 RODIUS 2004 09 0000 00 TCU ...

Page 814: ...0 13 TCU RODIUS 2004 09 0000 00 ...

Page 815: ...0 14 RODIUS 2004 09 0000 00 TCU ...

Page 816: ...0 15 TCU RODIUS 2004 09 0000 00 ...

Page 817: ...0 16 RODIUS 2004 09 0000 00 TCU ...

Page 818: ...0 17 TCU RODIUS 2004 09 0000 00 ...

Page 819: ...0 18 RODIUS 2004 09 0000 00 TCU ...

Page 820: ...0 19 TCU RODIUS 2004 09 0000 00 ...

Page 821: ......

Page 822: ...TGS LEVER 0000 00 TGS LEVER DIAGNOSIS 1 TGS LEVER 3 ...

Page 823: ......

Page 824: ...0 3 TGS LEVER RODIUS 2004 09 0000 00 0000 00 TGS LEVER 1 TGS LEVER ...

Page 825: ...0 4 RODIUS 2004 09 0000 00 TGS LEVER ...

Page 826: ...0 5 TGS LEVER RODIUS 2004 09 0000 00 ...

Page 827: ...0 6 RODIUS 2004 09 0000 00 TGS LEVER ...

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