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SSANGYONG RODIUS 2007.07, Manual

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SSANGYONG RODIUS 2007.07 Manual Download Page 257

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RODIUS 2007.07

3410-01

Ring, snap
Ring, snap
Ring, snap
Bearing
Hub, circular
Asm. -shaft, input
Plate, thrust
Gear, sun
Snap ring
Asm. -carrier (complete)
Hub reduction
Asm. -shaft, main
Clamp hose
Hose
Filter
Asm. -coil, electric
Asm. -cam/coil hsg.
Ring, snap
Armature
Hub, lockup
Spring, sleeve return
Collar, lockup
Sprocket, driving
Spring, return
Rail, shift
Fork, shift
Asm. -fork, shift
Cam, electric shift
Spring, torsion
Spacer
Shaft, shift
Ring, retaining
Asm. -case, transfer
Barb, breather

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Decal
Shaft, output
Deflector, dust
Magnet
Ring snap
Sprocket lower
Spacer
Chain
Ring retaining
Bearing
Bearing
Cover
Bendable clip
Bolt, Metric
Seal, oil
Washer
Nut, Metric
Flange, companion
Seal, oil
Spacer
Tone wheel (upper)
Nut, Metric

Clip, “J”

Bolt, hex head
Bracket, relay mounting
Locking clip
Connector
Bolt, hex head
Capscrew, hex head
Asm. -motor, electric
Seal, oil
Plug, pipe
Sealing Compound

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Summary of Contents for RODIUS 2007.07

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

Page 2: ......

Page 3: ...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 Gro...

Page 4: ...k 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 Batt...

Page 5: ...oint 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 assigne...

Page 6: ......

Page 7: ...CONNECTOR GROUND 8201 00 CONNECTOR GROUND WIRING 8201 00 WIRING HARNESS COMPONENTS LOCATION 3 ...

Page 8: ...0 2 undefined 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 undefined 8201 00 3 CONNECTOR GROUND SPLICE PACK INFORMATION CONNECTOR ...

Page 10: ...0 4 undefined 8201 00 CONNECTOR GROUND S202 S205 CAN S206 GND 4 SPLICE PACK S203 GND S204 ILL ...

Page 11: ...0 5 CONNECTOR GROUND undefined 8201 00 S301 EPB EAS CAN S207 5 GROUND ...

Page 12: ......

Page 13: ... 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 4 6 10 ...

Page 14: ......

Page 15: ...0 3 POWER DISTRIBUTION undefined 8410 02 FUSE RELAY 8410 02 ENGINE ROOM FUSE RELAY BOX 1 FRONT 2 REAR ...

Page 16: ...0 4 undefined 8410 05 POWER DISTRIBUTION 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 17: ...0 5 POWER DISTRIBUTION undefined 8410 05 ...

Page 18: ...0 6 undefined 8410 02 POWER DISTRIBUTION ELECTRICITY DIVIDE 8210 02 ENG ROOM FUSE BOX 1 SB1 SB5 2 SB6 SB11 ...

Page 19: ...0 7 POWER DISTRIBUTION undefined 8410 02 3 Ef1 Ef4 4 Ef5 Ef7 ...

Page 20: ...0 8 undefined 8410 02 POWER DISTRIBUTION 5 Ef8 Ef10 6 Ef11 Ef18 ...

Page 21: ...0 9 POWER DISTRIBUTION undefined 8410 02 8 Ef22 Ef26 7 Ef19 Ef21 ...

Page 22: ...0 10 undefined 8410 04 POWER DISTRIBUTION 8410 04 I P FUSE BOX 1 F1 F5 2 F6 F12 ...

Page 23: ...0 11 POWER DISTRIBUTION undefined 8410 04 3 F13 F16 4 F17 F24 ...

Page 24: ...0 12 undefined 8410 04 POWER DISTRIBUTION 6 F32 F36 5 F25 F31 ...

Page 25: ... PTC HEATER POSITIVE TEMPERATURE COEFFICIENT 6910 01 FFH FUEL FIRED HEATER 6810 30 FATC FULL AUTO TEMP CONTROL CIRCUIT 6810 30 AIR CON MANUAL 8810 01 AIR BAG 8010 01 CLUSTER 7630 02 CIGAR LIGHTER POWER OUTLET 8710 03 STICS 8510 03 POWER WINDOW CIRCUIT 4810 10 STOP BACK UP LAMP CIRCUIT 8510 00 HEAD LAMP LEVELING DEVICE CIRCUIT 8510 26 TURN SIGNAL HAZARD LAMP CIRCUIT 7 9 11 12 13 14 17 18 22 23 24 2...

Page 26: ......

Page 27: ...0 3 CIRCUIT undefined 1491 01 1491 01 ECU ENGINE CONTROL UNIT D27DT EU IV 1 ENG MAIN RELAY PEDAL MODULE HFM SENSOR VALVE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 28: ...fined 1491 01 CIRCUIT 2 FUEL FILTER WARNING LAMP IMMO SENSOR FUEL PRESSURE CAM SHAFT BOOSTER PRESSURE CRANK SHAFT COOLANT FUEL TEMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 29: ...0 5 CIRCUIT undefined 1491 01 3 INJECTOR CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 30: ...0 6 undefined 8210 01 CIRCUIT 8210 01 DIAGNOSIS CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 31: ...0 7 CIRCUIT undefined 3670 01 3670 01 TCU 5 SPEED 1 START MOTOR TGS LEVER CAN LINE 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 32: ...0 8 undefined 3670 01 CIRCUIT 2 SOLENOID OIL TEMP SENSOR SPEED SENSOR N2 N3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 33: ...0 9 CIRCUIT undefined 4891 01 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 34: ...0 10 undefined 4891 01 CIRCUIT 2 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION PRESSURE SENSOR S W A SENSOR SENSOR CLUSTER ESP OFF SW ...

Page 35: ...0 11 CIRCUIT undefined 4920 01 4920 01 EPB 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSI ...

Page 36: ...0 12 undefined 4480 01 CIRCUIT 4480 01 EAS 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 37: ...0 13 CIRCUIT undefined 8810 01 8810 01 AIR BAG 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 38: ...0 14 undefined 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 39: ...0 15 CIRCUIT undefined 8010 01 2 WARNING EAS EPB TGS LEVER AUTO PARK G 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 40: ... 16 undefined 8010 01 CIRCUIT 3 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION WARNING BAT CHANGE OIL BRAKE ENG CHCK AIR BAG IMMOM SEAT BELT TURN SIGNAL DEFOGGER DOOR OPEN ...

Page 41: ...0 17 CIRCUIT undefined 7630 02 7630 02 CIGAR LIGHTER POWER OUTLET 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSIT ...

Page 42: ...0 18 undefined 8710 03 CIRCUIT 8710 03 STICS 1 POWER WINDOW WARNING LAMP P BRAKE S BELT ILL KEY REMINDER SW 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 43: ...0 19 CIRCUIT undefined 8710 03 2 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION WIPER DOOR SW LAMP DOOR COURTESY G HANDLE DOOR OPEN WARNING LAMP ...

Page 44: ...0 20 undefined 8710 03 CIRCUIT 3 DOOR LOCK DEFOGGER 1 CONNECTOR INFORMATION ...

Page 45: ...0 21 CIRCUIT undefined 8710 03 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 46: ...0 22 undefined 8510 03 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 8510 03 POWER WINDOW CIRCUIT ...

Page 47: ...0 23 CIRCUIT undefined 4810 10 4810 10 STOP BACK UP LAMP CIRCUIT 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 48: ...0 24 undefined 8510 00 CIRCUIT 8510 00 HEAD LAMP LEVELING DEVICE CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 49: ...0 25 CIRCUIT undefined 8510 26 8510 26 TURN SIGNAL HAZARD LAMP CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 50: ...0 26 undefined 8910 01 CIRCUIT 1 CONNECTOR INFORMATION 8910 01 AUDIO MULTI VISION A V HEAD UNIT NAVI UNIT GPS RR VIEW CAMERA AUX JACK 1 ...

Page 51: ...0 27 CIRCUIT undefined 8910 01 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION ...

Page 52: ...0 28 undefined 8910 01 CIRCUIT 2 A V HEAD UNIT DSP AMP TUNER UNIT WOOFER AMP 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 53: ...0 29 CIRCUIT undefined 8910 01 8910 01 AUDIO 1 CONNECTOR INFORMATION 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSI ...

Page 54: ...0 30 undefined 6810 21 CIRCUIT 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION 6810 21 PTC HEATER POSITIVE TEMPERATURE COEFFICIENT ...

Page 55: ...0 31 CIRCUIT undefined 6910 01 6910 01 FFH FUEL FIRED HEATER 2 CONNECTORIDENTIFICATIONSYMBOL PINNUMBERPOSITION 1 CONNECTOR INFORMATION ...

Page 56: ...undefined 6810 30 CIRCUIT 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 57: ...0 33 CIRCUIT undefined 6810 30 2 FRT BLOWER ACTUATOR MODE INTAKE AQS SENSOR 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION ...

Page 58: ...0 34 undefined 6810 30 CIRCUIT 3 RR AIR CON BLOWER MODE ACTIATOR 1 CONNECTOR INFORMATION 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION ...

Page 59: ...0 35 CIRCUIT undefined 6810 30 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 60: ...0 36 undefined 6810 30 CIRCUIT 2 CONNECTOR IDENTIFICATION SYMBOL PIN NUMBER POSITION 1 CONNECTOR INFORMATION 2 BLOWER MOTOR FRT RR ...

Page 61: ...ENGINE INFORMATION 0000 00 ENGINE INFORMATION GENERAL 1 COMPONENT LOCATOR 2 DESCRIPTION AND OPERATION 4 7 ...

Page 62: ......

Page 63: ......

Page 64: ...01 4 RODIUS 2007 07 0000 00 ENGINE INFORMATION 0000 00 ENGINE GENERAL 1 COMPONENT LOCATOR 1 Front View ...

Page 65: ... Connecting rod 3 Resonance flap 14 Exhaust manifold 4 Cylinder head cover 15 Crankshaft 5 Exhaust camshaft 16 Engine mounting 6 Intake camshaft 17 Starter 7 Cylinder head 18 Crankcase 8 Spark plug connector 19 Oil pump sprocket 9 Valve tappet 20 Oil strainer 10 Injector 21 Oil pan 11 Exhaust valve 22 Drain plug Front View ...

Page 66: ... 07 0000 00 ENGINE INFORMATION 2 SIDE VIEW NO FUNCTION NO FUNCTION 23 Camshaft adjuster 27 Oil pump drive chain 24 Cooling fan and viscous clutch 28 Oil return pipe 25 Piston 29 Timing chain 26 Flywheel of drive plate ...

Page 67: ... They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts 2 On Engine Service Disconnect the negative battery cable before removing or installing any electrical unit or wh...

Page 68: ...02 3 ENGINE ASSEMBLY RODIUS 2007 07 0000 00 1113 01 ENGINE ASSEMBLY 1 SPECIFICATIONS 1 ENGINE SPECIFICATIONS ...

Page 69: ...02 4 RODIUS 2007 07 0000 00 ENGINE ASSEMBLY 2 PERFORMANCE CURVE ...

Page 70: ...02 5 ENGINE ASSEMBLY RODIUS 2007 07 0000 00 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 71: ...02 6 RODIUS 2007 07 0000 00 ENGINE ASSEMBLY ...

Page 72: ...02 7 ENGINE ASSEMBLY RODIUS 2007 07 0000 00 Name and Part Number A9917 0012B DW110 120 Holding Pin ...

Page 73: ...02 8 RODIUS 2007 07 0000 00 ENGINE ASSEMBLY 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 74: ...02 9 ENGINE ASSEMBLY RODIUS 2007 07 0000 00 4 FASTENER TIGHTENING SPECIFICATIONS CONT D ...

Page 75: ...cle Do Not Use Methanol Fuels containing methanol wood alcohol should not be used in vehicle This type of fuel can reduce vehicle performance and damage components of the fuel system Use of methanol may damage the fuel sys tem Vehicle Fueling from Drums or Storage Containers For safety reasons particularly when using noncommercial fueling systems fuel containers pumps and hoses must be properly ea...

Page 76: ...03 4 RODIUS 2007 07 0000 00 ENGINE FUEL SYSTEM temperature vs resistance ...

Page 77: ...NO DATA ...

Page 78: ...tion is discovered upon inspection of the front muffler and pipe assembly the complete assembly should be replace the complete assembly should be replaced The same procedure is applicable to the rear muffler assembly Heat shields for the front and rear muffler assembly and catalytic converter protect the vehicle and the environment from the high temperatures that the exhaust system develops 3 OVER...

Page 79: ...05 4 RODIUS 2007 07 0000 00 ENGINE EXHAUST SYSTEM 4 FASTENER TIGHTENING SPECIFICATIONS ...

Page 80: ...06 3 LUBRICATION SYSTEM RODIUS 2007 07 0000 00 9210 01 ENGINE LUBRICATION SYSTEM 1 OIL CIRCULATION ...

Page 81: ...ve tappet 7 Oil gallery at chain tensioner 24 Camshaft closing cover 8 Oil non return valve 25 Ball φ 8 mm 9 Chain tensioner 26 Screw plug 10 Vent chain tensioner 27 Camshaft adjuster 11 Front closing cover φ 17 mm 28 Front closing cover intake camshaft 12 Oil gallery perpendicular to the shaft 29 Front treaded bushing exhaust camshaft 13 Ball φ 6 mm 30 Valve tappet 14 Oil spray nozzle timing chai...

Page 82: ...07 3 COOLING SYSTEM RODIUS 2007 07 0000 00 2110 01 ENGINE COOLING SYSTEM 1 GENERAL SPECIFICATIONS ...

Page 83: ...07 4 RODIUS 2007 07 0000 00 COOLING SYSTEM 2 SPECIAL TOOLS AND EQUIPMENT ...

Page 84: ...07 5 COOLING SYSTEM RODIUS 2007 07 0000 00 3 FASTENER TIGHTENING SPECIFICATIONS ...

Page 85: ...ystem to operation The water pump draws the coolant from the radiator The coolant then circulates through water jackets in the engine block the intake manifold and the cylinder head When the coolant reaches the operating temperature of the thermostat the thermostat opens The coolant then goes back to the radiator where it cools This system directs some coolant through the hoses to the heat core Th...

Page 86: ...07 7 COOLING SYSTEM RODIUS 2007 07 0000 00 2 COMPONENT LOCATOR ...

Page 87: ... pieces Bolt M6 4 pieces Bolt M6 4 pieces Upper radiator insulator Lower radiator insulator Plate Clip 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Inlet hose Outlet hose 3 way hose Deaeration hose reserver tank Clamp Clamp Make up hose holder Reserver tank Bolt M6 2 piece Cooling fan Viscous clutch Bolt M6 1 piece Bolt M6 3 piece 15 16 17 18 19 20 21 22 23 24 25 26 27 ...

Page 88: ...08 3 ENGINE ELECTRIC DEVICES RODIUS 2007 07 0000 00 1452 01 ENGINE ELECTRIC DEVICES 1 GENERAL SPECIFICATIONS ...

Page 89: ...08 4 RODIUS 2007 07 0000 00 ENGINE ELECTRIC DEVICES 2 FASTENER TIGHTENING SPECIFICATIONS ...

Page 90: ...ate as the battery warms Charger Capacity A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more State of Charge A completely discharged battery requires more than twice as much charge as a onehalf charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the c...

Page 91: ...e exhaust stroke requires very little of the available energy to fire the spark plug The remaining energy is available to the spark plug in the cylinder on the compression stroke These systems use the EST signal from the ECM to control the EST The ECM uses the following information Engine load mass air flow sensor manifold air pressure sensor Engine coolant temperature Intake air temperature Crank...

Page 92: ...08 7 ENGINE ELECTRIC DEVICES RODIUS 2007 07 0000 00 4 STARTING AND CHARGING SYSTEM GASOLINE ENGINE CIRCUIT ...

Page 93: ...09 3 ENGINE CONTROL SYSTEM RODIUS 2007 07 0000 00 1522 16 ENGINE CONTROL SYSTEM 1 ENGINE DATA DISPLAY TABLE ...

Page 94: ...09 4 RODIUS 2007 07 0000 00 ENGINE CONTROL SYSTEM 2 FASTENER TIGHTENING SPECIFICATIONS 1 TEMPERATURE VS RESISTANCE ...

Page 95: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 ENGINE ASSEMBLY 2 ENGINE INTAKE SYSTEM 3 ENGINE LUBRICATION SYSTEM 4 ENGINE COOLING SYSTEM 3 8 9 10 ...

Page 96: ......

Page 97: ... ASSEMBLY Injector Puller Y99220072B Glow Plug Wrench Y99220132B Fuel Pipe Wrench Sealing Caps 665 995 5844 Valve Remover Installer Y99220082B Pulley Lock Wrench Y99220052B Engine Lock 602 589 00 40 00 Injector Copper Washer Puller Y99220022B 1 D20DT Engine 1 COMPONENTS AND SPECIAL TOOLS ...

Page 98: ...Glow Plug Wrench Y99220132B Fuel Pipe Wrench Sealing Caps 665 995 5844 Injector Copper Washer Puller Y99220022B Valve Remover Installer Y99220082B Pulley Lock Wrench Y99220052B HP Pump Lock Y99220102B Engine Lock 602 589 00 40 00 HP Pump Bearing Puller Y99220032B 2 D27DT Engine ...

Page 99: ... 07 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 100: ...0 6 RODIUS 2007 07 0000 00 SPECIAL SERVICE TOOLS Name and Part Number Application Y99220152B HLA remover Y99220142B Stem seal installer ...

Page 101: ...0 7 SPECIAL SERVICE TOOLS RODIUS 2007 07 0000 00 Name and Part Number Application Y99220122B Piston protrusion measuring jig Y99220172B Piston insertion jig ...

Page 102: ...0 8 RODIUS 2007 07 0000 00 SPECIAL SERVICE TOOLS Name and Part Number Application Y99220112B Intake manifold guide pin Installation of intake manifold 2 ENGINE INTAKE SYSTEM ...

Page 103: ...0 9 SPECIAL SERVICE TOOLS RODIUS 2007 07 0000 00 Name and Part Number Application 103 589 02 09 00 Engine filter cap 3 ENGINE LUBRICATION SYSTEM 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 104: ...0 10 RODIUS 2007 07 0000 00 SPECIAL SERVICE TOOLS 4 ENGINE COOLING SYSTEM 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 105: ... STRUCTURE AND COMPARISON 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 3 TIGHTENING TORQUE 4 MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT OERVIEW AND OPERATION PROCESS 1 ENGINE COMPARTMENT 2 SYSTEM IN ENGINE COMPARTMENT 3 9 12 15 24 28 ...

Page 106: ......

Page 107: ...0 3 ENGINE GENERAL RODIUS 2007 07 0000 00 0000 00 ENGINE GENERAL 1 STRUCTURE AND COMPARISON D27DTP POWER UP CDPF Engine Front View D27DTP POWER UP CDPF Engine Top View ...

Page 108: ...0 4 RODIUS 2007 07 0000 00 ENGINE GENERAL D27DTP POWER UP CDPF Engine Side View D27DTP POWER UP CDPF Engine Left Side View ...

Page 109: ...0 5 ENGINE GENERAL RODIUS 2007 07 0000 00 D27DT EU IV Engine Front View D27DT EU IV Engine Top View ...

Page 110: ...0 6 RODIUS 2007 07 0000 00 ENGINE GENERAL D27DT EU IV Engine Side View D27DT EU IV Engine Left Side View ...

Page 111: ...0 7 ENGINE GENERAL RODIUS 2007 07 0000 00 D27DT Engine General Front View D27DT Engine General Top View ...

Page 112: ...0 8 RODIUS 2007 07 0000 00 ENGINE GENERAL D27DT Engine General Side View D27DT Engine General Left Side View ...

Page 113: ...0 9 ENGINE GENERAL RODIUS 2007 07 0000 00 2 ENGINE SPECIFICATIONS AND PERFORMANCE CURVE 1 Specifications ...

Page 114: ... 2007 07 0000 00 ENGINE GENERAL 2 D27DTP Power Up Engine Performance Curve 1 Output and Torque vehicle with automatic transmission Oil Temperature Pressure and Boost Pressure vehicle with automatic transmission 2 ...

Page 115: ...0 11 ENGINE GENERAL RODIUS 2007 07 0000 00 3 D27DT Engine Performance Curve 1 Output and Torque 2 Oil Temperature Pressure and Boost Pressure ...

Page 116: ...0 12 RODIUS 2007 07 0000 00 ENGINE GENERAL 3 TIGHTENING TORQUE This table shows the tightening torques for removal mounting and disassembly reassemly of the engine ...

Page 117: ...0 13 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 118: ...0 14 RODIUS 2007 07 0000 00 ENGINE GENERAL ...

Page 119: ...07 0000 00 MAJOR CHANGES IN D27DTP POWER UP ENGINE COMPARED TO D27DT 4 The shape and size of D27DTP POWER UP are slightly different from those of D27DT engine but the basic configuration of two systems is almost same 1 Engine Assembly ...

Page 120: ...0 16 RODIUS 2007 07 0000 00 ENGINE GENERAL 2 Major Changes and Summary ...

Page 121: ...0 17 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 122: ...0 18 RODIUS 2007 07 0000 00 ENGINE GENERAL ...

Page 123: ...0 19 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 124: ...0 20 RODIUS 2007 07 0000 00 ENGINE GENERAL ...

Page 125: ...0 21 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 126: ...0 22 RODIUS 2007 07 0000 00 ENGINE GENERAL ...

Page 127: ...0 23 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 128: ...0 24 RODIUS 2007 07 0000 00 ENGINE GENERAL 1 ENGINE COMPARTMENT The major changes due to the newly adopted engine compared to D27DT engine are as follows ...

Page 129: ...0 25 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 130: ... compartment fuse box PTC relay box Battery Vacuum modulator for VGT turbo charger 1 2 3 4 5 6 7 8 9 10 11 12 13 FFH Assembly Only for vehicle with FFH Power steering oil tank Engine oil filler cap Fan shroud E EGR Valve High capacity PCV oil separator HFM sensor 6 0 VGT turbo charger Air cleaner housing 2Coolant surge tank ABS ESP HECU Including TPMS function optional Exhaust gas FRT Temp sensor ...

Page 131: ...0 27 ENGINE GENERAL RODIUS 2007 07 0000 00 Major Sensors and Components ...

Page 132: ...0 28 RODIUS 2007 07 0000 00 ENGINE GENERAL 2 SYSTEMS IN ENGINE COMPARTMENT 1 Engine Accessories Related to ECU ...

Page 133: ...0 29 ENGINE GENERAL RODIUS 2007 07 0000 00 ...

Page 134: ...0 30 RODIUS 2007 07 0000 00 ENGINE GENERAL 2 Preheat System ...

Page 135: ...0 31 ENGINE GENERAL RODIUS 2007 07 0000 00 3 Fuel System ...

Page 136: ...0 32 RODIUS 2007 07 0000 00 ENGINE GENERAL Fuel Supply System ...

Page 137: ...0 33 ENGINE GENERAL RODIUS 2007 07 0000 00 4 Lubrication System ...

Page 138: ...0 34 RODIUS 2007 07 0000 00 ENGINE GENERAL 5 Cooling System ...

Page 139: ...0 35 ENGINE GENERAL RODIUS 2007 07 0000 00 6 Intake System ...

Page 140: ...0 36 RODIUS 2007 07 0000 00 ENGINE GENERAL 7 Exhaust System ...

Page 141: ...currently 7 to the tip of the injector to increase the amount of fuel injection and to improve injection efficiency according to the increased engine power The existing C2I coding 16 digits is changed to C3I coding 20 digits to monitor fuel injection and follow the target value For the D27DT engine the injector MDP minumum current for the solenoid in the injector to lift the nozzle is leaned only ...

Page 142: ...d to the connection to the fuel pipe of the HP pump to prevent the fuel pulsation by the fuel supply and fuel cut according to the increase of injected fuel volume It is also installed on the connection of the high pressure fuel supply line of the HP pump D27DTP D27DT EU IV D27DT ...

Page 143: ...pump Common rail D27DT Fuel pipe Common rail Injector Fuel high pressure pipe HP pump Common rail The I D and O D of the fuel rail between HP pump and common rail are increased according to the increased amount of fuel injection Also the engine ECU HFM sensor and EGR system are changed to control the fuel injection volume and engine more precisely ...

Page 144: ...0 6 RODIUS 2007 07 0000 00 ENGINE FUEL SYSTEM 2 COMPONENTS OF FUEL SYSTEM ...

Page 145: ...0 7 ENGINE FUEL SYSTEM RODIUS 2007 07 0000 00 Fuel Flow of D27DTP Power Up Engine Fuel Supply System ...

Page 146: ...ine is equipped with the throttle body that has a flap to block the air coming to the engine when the engine is switched off Therefore the structure of the intake manifold has been changed Also the improved HFM sensor from HFM5 0 to HFM6 0 has been installed to control the intake air precisely so that the NOx in the exhaust gas can be decreased ...

Page 147: ...ECU vacuum modulator control has been deleted 2 EGR cooler Decreasing EGR gas NOx efficiently by cooling the EGR gas and let it flow to the intake pipe 3 VGT turbocharger Increase in capacity and performance compared to D27DTP D20DT engine The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed to increase the engine power For more details refer t...

Page 148: ...0 3 CDEF Catalytic Disel Particulate Filter RODIUS 2007 07 0000 00 1725 12 CDPF Catalytic Disel Particulate Filter 1 Specifications for engine with CDPF ...

Page 149: ... the amount of PM in the exhaust gas passed through the DOC Diesel Oxydation Catalyst is reduced The CDPF Catalyst Diesel Particulate Filter is an integrated filter including DOC Diesel Oxydation Catalyst and DPF Diesel Particulate Filter COMPARISON OF THROTTLE BODY FUNCTIONS BASED ON EXHAUST EMISSION REGULATION Regulated parts are carbon monoxide CO nitrogen oxide NOx particular matter PM and soo...

Page 150: ...0 5 CDEF Catalytic Disel Particulate Filter RODIUS 2007 07 0000 00 2 COMPONENTS Differential Pressure Sensor CDPF Assembly and Rear Exhaust Gas Temperatiure Sensor ...

Page 151: ... D27DT engine is as follows Engine ECU Fuel Common Rail and Fuel Rail Between Common Rail and Injector The I D and O D of fuel rail has changed from 2 4 mm 6 0 mm to 3 0 mm 6 35 mm Also the damping orifice is installed to prevent the fuel pulsation occured by fuel pressure The engine ECU has been revised since terminals have been added for front rear temperature sensors Its version is 3 2 but it i...

Page 152: ...0 7 CDEF Catalytic Disel Particulate Filter RODIUS 2007 07 0000 00 ...

Page 153: ... soot with high temperature exhaust gas over 600 C The rear exhaust gas temperature sensor monitors the temperature of DPF section If this temperature is below the regeneration temperature the ECU increases the post injection period to increase the fuel injection amount and consequently to increase the exhaust gas temperature Normally when the vehicle is driven for 600 1 200 km the enough amount o...

Page 154: ...on There are two fuel injection patterns pilot injection and main injection As the CDPF is installed the post injection pattern is added 3 Post Injection and Air Mass Control When the differential pressure sensor detects the pressure difference between the front and the rear side of CDPF the sensor sends signal indicating the soot is acumulated and the post injection is performed to raise the temp...

Page 155: ... Engines The throttle body is not installed in the D27DT engine general but is installed in the following engines 1 D27DT EU IV engine 2 D27DTP POWER UP engine 3 D27DTP POWER UP engine CDPF Both engines are equipeed with the throttle body but its appearance and the related control system are differ ...

Page 156: ...t is oxidized The ECU detects the temperature change with two temperature sensors The CO HC and partial particulate material are removed from the exhaust gas this procedures are the sames as the ones for the conventional DOC and no sensor is required After the exhaust gas is passed through the DOC and oxidized most of the harmful material is removed from the exhaust gas However to meet the environ...

Page 157: ...eached due to low speed even though CDPF regeneration is in process The CDPF regeneration process must be completed by driving for 15 20 minutes at a speed higher than 80 km h to solve this problem The engine CHECK lamp flashes when CDPF is over loaded therefore 4 above must be performed in this case 1 2 3 4 5 7 CDPF s Excessive Soot Accumulation P0432 When the vehicle is driven at a low speed 5 1...

Page 158: ...NO DATA ...

Page 159: ...WER UP engine the cooling system is equipped with E EGR cooler and the water pump which its capacity is improved according to the additional coolant line in the cylinder block For the D27DT engine the cooling system uses the fan clutch Cooling System for D27DTP POWER UP Engine ...

Page 160: ...0 4 RODIUS 2007 07 0000 00 ENGINE COOLING SYSTEM D27DT Engine D27DTP POWER UP D27DT EU IV Engine Comparison ...

Page 161: ...NO DATA ...

Page 162: ...NO DATA ...

Page 163: ...RTMENT 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 COMPONENTS LOCATOR ELECTRIC GENERAL ELECTRIC GENERAL ELECTRIC GENERAL 4 6 8 10 12 13 ...

Page 164: ......

Page 165: ......

Page 166: ...0 4 RODIUS 2007 07 0000 00 ELECTRIC GENERAL 0000 00 ELECTRIC GENERAL 1 LOCATIONS OF UNITS AND SENSORS IN PASSENGER COMPARTMENT ...

Page 167: ...0 5 ELECTRIC GENERAL RODIUS 2007 07 0000 00 ...

Page 168: ...0 6 RODIUS 2007 07 0000 00 ELECTRIC GENERAL 2 SWITCHES UNITS AND SENSORS IN ENGINE COMPARTMENT EXCEPT ENGINE RELATED SENSORS AND UNITS ...

Page 169: ... 2007 07 0000 00 Sub condenser Theft deterrent horn under the washer fluid reservoir PTC power supply relay PTC system equipped vehicle ABS ESP HECU under the battery Fuse and relay box in engine compartment Brake pressure sensor ...

Page 170: ... 0000 00 ELECTRIC GENERAL Window switches Outside rearview mirror adjusting and folding switch 4WD switch and rear washer wiper switch 3 SWITCHES IN PASSENGER COMPARTMENT Audio remote control switch on the steering wheel ...

Page 171: ...0 9 ELECTRIC GENERAL RODIUS 2007 07 0000 00 ...

Page 172: ...0 10 RODIUS 2007 07 0000 00 ELECTRIC GENERAL 4 SYSTEM LAYOUT BASED ON DVD SYSTEM EQUIPPED VEHICLE ...

Page 173: ...0 11 ELECTRIC GENERAL RODIUS 2007 07 0000 00 DVD changer Tuner DSP integrated amplifier Navigation unit Radio antenna amplifier Rearview camera ...

Page 174: ...0 12 RODIUS 2007 07 0000 00 ELECTRIC GENERAL 5 WIRING HARNESS ARRANGEMENT ...

Page 175: ...0 13 ELECTRIC GENERAL RODIUS 2007 07 0000 00 6 COMPONENTS LOCATOR ...

Page 176: ... 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 1 2 All switches except wiper motor A S parking terminal The vehicle speed calculating time is 1 0 seconds The elapsed time of 1 5 seconds after IGN 1 switch ON is not included 20 ms target input 2 Wiper motor A S parking terminal 100 ms...

Page 177: ...0 4 RODIUS 2007 07 8710 01 STICS 4 Input Signals Of Rk Stics ...

Page 178: ...vate automatic door unlock function when the vehicle collided over 15 km h of vehicle speed 1 COMPONENTS LOCATOR STICS ICM module Air bag ECU Sends the vehicle collision signals to STICS Theft deterrent horn Installed under the battery This horn works only for the theft deterrent function panic function and remote starting SCAN tool SCAN 100 is used for REKES key coding and trouble diagnosis REKES...

Page 179: ...6 RODIUS 2007 07 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 180: ...1 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 1 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 2 ...

Page 181: ...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 3 ...

Page 182: ...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 183: ...ion 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 t...

Page 184: ...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 requ...

Page 185: ...he 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 186: ...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 187: ...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 188: ... on the washer switch while the wiper relay is operating 1 If the wiper relay ON request time is shorter than the remained ON time it is disregarded 2 Speed sensitive INT intermittent wiper The wiper relay continues to output for remaining ON time even when the INT switch is turned off IGN 2 switch ON INT switch OFF resume the intermittent time when turning ON IGN 2 switch OFF INT switch ON resume...

Page 189: ...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 190: ...nlocked 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 tail...

Page 191: ... 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 192: ...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 spe...

Page 193: ...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 194: ... 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 c...

Page 195: ...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 lamp stays on If cl...

Page 196: ...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 Door coupled front room lamp switch ...

Page 197: ... 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 198: ...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 199: ...ng on the defogger switch again during its operation The output is ON only for 6 minutes T3 when turning ON the rear defogger switch 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...

Page 200: ... windshield heated glass and the tailgate and outside rearview mirror heated glass The heater relay in the ICM box controls the tailgate and outside rearview mirror heated glass and its fuse 15A is located in the engine compartment fuse box Defogger switch ...

Page 201: ...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 202: ...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 203: ... by Remote Control Key The door lock system outputs LOCK for 0 5 seconds T2 when receiving LOCK signal from the remote control key The door lock system outputs UNLOCK signal for 0 5 seconds T3 when receiving UNLOCK signal from the remote control key 1 2 ...

Page 204: ...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 205: ...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 controll...

Page 206: ...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 207: ...mote control that has the following additional functions Dual REKES two remote controller and REKES only can be coded by scan Tool 1 2 Door locking and theft deterrent armed mode Press door lock button to release 1 2 Door lock button Panic button Operates under the theft deterrent armed mode Theft deterrent horn Sounds approx 27 seconds Door unlock Unlocking all doors and tailgate ...

Page 208: ...RODIUS 2007 07 8710 01 Dual REKES Coding Connect the SCAN Tool the diagnostic connector as shown in the figure blow and perform the coding operation when replaced REKES transmitter and receiver Diagnosis connector ...

Page 209: ...0 36 RODIUS 2007 07 8710 01 STICS ...

Page 210: ...ey coding is finished successfully the below screen is displayed Press YES button to start the second REKES key coding 7 Turn off SCAN 100 and remove it from the diagnostic connector Check if the remote controllers are functioning properly If the remote controllers are not properly working perform the REKES coding process again 9 ...

Page 211: ...ivates 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 onc...

Page 212: ...econds 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 ON posit...

Page 213: ...y in armed mode The system sends the current vehicle conditions LOCK engine running when the PANIC warning is turned off by the remote control key 4 5 The theft deterrent warning is canceled when receiving PANIC signal from the remote control key during theft deterrent The theft deterrent warning output is ON when the theft deterrent conditions are established during PANIC warning PANIC output is ...

Page 214: ...US 2007 07 8710 01 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 215: ...instrument panel in this vehicle is different from conventional 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 Meter cluster Warning lamps and indicators ...

Page 216: ... Engine check warning light 9 Cruise control indicator 10 4WD CHECK warning light 11 4WD HIGH indicator 12 4WD LOW indicator 13 Brake warning light 14 Battery charge warning light 15 Seat belt reminder 16 Low fuel level warning light 17 Heated glass indicator 18 Door open warning light 19 High beam indicator 20 Engine oil pressure warning light 21 Air bag warning light 22 Water separator warning l...

Page 217: ......

Page 218: ...0 6 RODIUS 2007 07 8010 10 CLUSTER 3 WARNING INDICATOR PANEL ...

Page 219: ...0 7 CLUSTER RODIUS 2007 07 8010 10 ...

Page 220: ...nger 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 tachometer If there is a ...

Page 221: ...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 Check the allowable tolerance of the speedometer and operations of the trip odometer by using a tester Check if the speedometer pointer is shaking ...

Page 222: ...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 223: ...nce 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 C 2449 Ω 5 50 C 826 Ω 5 80 C 321 Ω 5 100 C 112 Ω 5 When the resistance value by coolant temperature is within the specified range check thermostat water pump radiator related coolant circuit for normal operation Also chec...

Page 224: ...P A TRIP B and ODOmeter Reset button 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 ...

Page 225: ...0 13 CLUSTER RODIUS 2007 07 8010 10 5 CIRCUIT DIAGRAM OF INDICATOR DISPLAY ...

Page 226: ...0 3 LAMP RODIUS 2007 07 8310 01 8310 01 LAMP 1 COMPONENTS OF EXTERIOR LAMPS ...

Page 227: ...0 4 RODIUS 2007 07 8310 01 LAMP 2 COMPONENTS OF INTERIOR LAMPS ...

Page 228: ...0 5 LAMP RODIUS 2007 07 8310 01 1 LOCATIONS OF EXTERIOR LAMPS 1 Front Lamps ...

Page 229: ...0 6 RODIUS 2007 07 8310 01 LAMP 2 Rear Lamps ...

Page 230: ......

Page 231: ... pressed in 2 Rear room lamp in second and third row seats one at both sides 12V 5W Rear room lamps are turned on and off when the switch 1 is pressed in and out Four rear room lamps are turned on when opening a rear door with this switch pressed in The rear room lamps are turned off when closing the door 3 Center console lamp one at back of center console 12V 5W Center console lamp is turned on w...

Page 232: ...nd off when opening and closing one of rear doors with the front room lamp switch pressed in 5 Glove box lamp one at center 12V 5W 6 Door courtesy lamp one at each door 12V 5W Door courtesy lamp is turned on when opening a door while the ignition switch is in ON position Rear third row set room lamp Rear second row set room lamp Front room lamp Glove box lamp Center console lamp ...

Page 233: ... 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 Adjustment of low beam No 1 adjustment hole Up and Down No 2 adjustment hole Left and Right Adjustment of high beam No 3 adjustment hole Up and Down No 4 adjustment hole Left and Right No 1 adjustment Direction A Up Direction B Dow...

Page 234: ...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 235: ...align the center lines of the vehicle and the screen 1 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 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 Unit mm Unit mm ...

Page 236: ...0 13 LAMP RODIUS 2007 07 8310 01 2 Fog Lamp Aiming Adjustment ...

Page 237: ...his switch 1 pressed in The front room lamps are dimmed out after closing the door Rear door coupled room lamp switch Rear room lamps A and luggage room lamp B are turned on when opening a rear door with this switch 2 pressed in The lamps are dimmed out after closing the door Rear and luggage room lamps are turned on only when the side room lamp coupled switch is pressed in 1 2 Door coupled room l...

Page 238: ...mits infrared rays through LED and then detects the amount of rain drops by receiving reflected rays against sensing section rain sensor mounting section on the windshield with photodiode Rain sensing unit Multifunction wiper switch AUTO and sensitivity control AUTO Wiper operates automatically by rain sensor FAST SLOW Auto delay Auto speed control A position that can control sensitivity against r...

Page 239: ...x Relay5 Wiper INT Low Relay6 Wiper High STICS 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 ...

Page 240: ...tting section of the rain sensor 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 Unit latch Rain sensor unit PCB assembly and emitter lens Emitter lens The LED e...

Page 241: ...0 6 RODIUS 2007 07 8610 11 RAIN SENSOR 3 OPERATION MODE OF RAIN SENSING WIPER SYSTEM ...

Page 242: ...ver that the wiper switch is in AUTO position When the wiper switch is turned to AUTO from OFF the wiper operates one cycle It always operates one cycle for the initial operation however the wiper does not operate afterwards to prevent the wiper blade wear if not raining when turning the wiper switch to AUTO from OFF However the wiper operates up to 5 minutes after rain stops If this function does...

Page 243: ...eck the sensor for coming off Check the rain sensor cover installation Check that the customer is familiar to how to control the wiper sensitivity 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 Check that the customer can select the sensitivity by selecting the va...

Page 244: ...0 9 RAIN SENSOR RODIUS 2007 07 8610 11 5 DIAGNOSIS PROCEDURES ...

Page 245: ...erminal 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 to the rain sensor to recognize whether it is actual rain or it is in rain sensing wiper operation mode No 2 terminal sends the wiper and washer operation information such as washer operation mode MIST mode or AUTO...

Page 246: ...0 3 WIPER WASHER SYSTEM RODIUS 2007 07 0000 00 7810 01 WIPER WASHER SYSTEM 1 SPECIFICATIONS OF WIPER ...

Page 247: ...0 4 RODIUS 2007 07 0000 00 WIPER WASHER SYSTEM Front wiper and washer assembly Rear wiper and washer assembly 1 SYSTEM LAYOUT OF WIPER AND WASHER ...

Page 248: ...0 5 WIPER WASHER SYSTEM RODIUS 2007 07 0000 00 2 COMPONENTS LOCATOR OF FRONT WIPER ASSEMBLY Wiper blade Wiper linkage Wiper motor ...

Page 249: ...0 6 RODIUS 2007 07 0000 00 WIPER WASHER SYSTEM 3 COMPONETS LOCATOR OF REAR WIPER ASSEMBLY Rear wiper assembly Rear wiper motor Wiper blade assembly ...

Page 250: ...0 7 WIPER WASHER SYSTEM RODIUS 2007 07 0000 00 4 CIRCUIT DIAGRAM OF WIPER WASHER ...

Page 251: ...0 3 TRANSFER CASE RODIUS 2007 07 3410 01 3410 01 PART TIME TRANSFER CASE 1 SPECIFICATIONS ...

Page 252: ...se achieves direct connection when selecting 4WD HIGH and 2 48 of reduction gear ratio when selecting 4WD LOW The silent chain in transfer case transfers the output power to front wheels Simple operation of switches on instrument panel allows to shift to 2H 4H and 4L easily while driving The warning lamp alarms the driver when the system is defective ...

Page 253: ...0 5 TRANSFER CASE RODIUS 2007 07 3410 01 2 OPERATION To make the mode shift easier stop the vehicle depress the brake pedal select the mode switch and move the selector lever with the sequence of N P N ...

Page 254: ...0 6 RODIUS 2007 07 3410 01 TRANSFER CASE 3 SYSTEM LAYOUT ...

Page 255: ...0 7 TRANSFER CASE RODIUS 2007 07 3410 01 4 SECTIONAL DIAGRAM ...

Page 256: ...0 8 RODIUS 2007 07 3410 01 TRANSFER CASE 5 EXPLODED VIEW ...

Page 257: ...t shift Ring retaining Asm case transfer Barb breather 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Decal Shaft output Deflector dust Magnet Ring snap Sprocket lower Spacer Chain Ring retaining Bearing Bearing Cover Bendable clip Bolt Metric Seal oil Washer Nut Metric Flange companion Seal oil Spacer Tone wheel upper Nut Metric Clip J Bolt hex head B...

Page 258: ...0 10 RODIUS 2007 07 3410 01 TRANSFER CASE 6 POWER FLOW ...

Page 259: ...0 11 TRANSFER CASE RODIUS 2007 07 3410 01 1 2H Mode Rear Wheel Drive Power Flow ...

Page 260: ...0 12 RODIUS 2007 07 3410 01 TRANSFER CASE Power Flow 2 4H Mode 4Wd Drive High Speed ...

Page 261: ...0 13 TRANSFER CASE RODIUS 2007 07 3410 01 Power Flow 3 4L Mode 4Wd Drive Low Speed ...

Page 262: ...0 14 RODIUS 2007 07 3410 01 TRANSFER CASE 7 TRANSFER CASE BLOCK DIAGRAM ...

Page 263: ...0 15 TRANSFER CASE RODIUS 2007 07 3410 01 ...

Page 264: ...pedal is depressed manual transmission or selector lever is selected to N position automatic transmission TCCU must recognize the clutch pedal signal or N signal Change the 4WD switch in instrument panel from 4H to 4L 4WD LOW warning lamp in meter cluster blinks during this process then remains when the shift is completed 4WD CHECK warning lamp comes on when the system is defective 4H 4L ...

Page 265: ...g driving For the shifting between 4WD HIGH and 4WD LOW stop the vehicle 2H 4H Change the 4WD switch in instrument panel from 2H to 4H This shift is available during driving 4WD HIGH indicator in meter cluster comes on When the system is defective 4WD CHECK warning lamp comes on Change the 4WD switch in instrument panel from 4H to 2H This shift is available during driving 4WD HIGH indicator in met...

Page 266: ...0 3 MANUAL TRANSMISSION RODIUS 2007 07 3170 01 3710 01 MANUAL TRANSMISSION 1 SPECIFICATIONS 1 General Specifications 2 Tightening Torque ...

Page 267: ... with current T5 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 ...

Page 268: ...engagement 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 mecha...

Page 269: ...0 6 RODIUS 2007 07 3170 01 MANUAL TRANSMISSION 2 CIRCUIT DIAGRAM BACKUP LAMP ...

Page 270: ...0 3 CLUTCH RODIUS 2007 07 3010 01 3010 01 CLUTCH 1 CLUTCH SPECIFICATIONS 2 TIGHTENING TORQUE ...

Page 271: ...and driven elements are held in contact 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...

Page 272: ...bly of clutch disc cover When reinstall the clutch assembly without the special zig Disc can be slip and worn easily Installation of special zig Identify the SAT clutch with adjusting equipment around the clutch cover Adapt the zig set 4 pieces between the clutch cover and diaphram spring around Refer to the picture 1 2 Diaphram Cover Zig for clutch removal and installation Adjusting equipmen t 1 ...

Page 273: ...ram spring around Refer to the picture 1 2 Diaphram Cover Zig for clutch removal and installation Adjusting equipment SST part number D9930 0010C Rexton applied SAC Self Adjusting Clutch system This clutch system also requires to replace both clutch cover and disc when the disc need to be replaced However for disc re usage special zig set is not necessary This is different point with SAT system ...

Page 274: ...ave cylinder cover 7 Hose 13 Switch 2 Concentric slave cylinder 8 Pipe 14 Bracket 3 Clutch cover 9 Clutch fluid chamber 15 Clutch pedal 4 Clutch disk 10 Clutch hydraulic line 16 Clutch pedal pad 5 Adaptor 11 Clutch pin B 6 Clutch master cylinder 12 Clutch housing ...

Page 275: ...0 3 AXLE SYSTEM RODIUS 2007 07 0000 00 4120 01 AXLE SYSTEM 1 FRONT AXLE SPECIFICATION 2 REAR AXLE SPECIFICATION ...

Page 276: ...0 3 TORQUE ON DEMAND RODIUS 2007 07 3240 01 3240 01 TOD TORQUE ON DEMAND 1 SPECIFICATIONS ...

Page 277: ...0 4 RODIUS 2007 07 3240 01 TORQUE ON DEMAND 1 TOD SYSTEM LAYOUT ...

Page 278: ...transferred to rear wheels on normal paved road When the system detects a slip in the rear wheels a proper percentage of driving force is transferred to front wheels TOD control unit receives the wheel speed signals from the speed sensors in propeller shaft of transfer case and engine output information from the engine control unit TOD control unit changes the pressure force of the electromagnetic...

Page 279: ...intained by controlling the ground grab capacity at high level Distribution ratio 30 for front wheels and 70 for rear wheels When climbing or starting off on the road with low friction rate In order to secure the maximum ground grab capacity and driving force during climbing or starting off on the roads such as unpaved snowy and icy road the system controls the driving force to distribute properly...

Page 280: ... to 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 an...

Page 281: ...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 Basic controls in EMC ...

Page 282: ...0 9 TORQUE ON DEMAND RODIUS 2007 07 3240 01 3 Signal Flow ...

Page 283: ...0 10 RODIUS 2007 07 3240 01 TORQUE ON DEMAND 4 Power Flow 1 4H Mode 4WD Drive High Speed ...

Page 284: ...0 11 TORQUE ON DEMAND RODIUS 2007 07 3240 01 2 4H Mode 4WD Drive Low Speed ...

Page 285: ...0 12 RODIUS 2007 07 3240 01 TORQUE ON DEMAND 3 OPERATION 1 System Layout ...

Page 286: ...f which 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 Relea...

Page 287: ...0 14 RODIUS 2007 07 3240 01 TORQUE ON DEMAND 4 CIRCUIT DIAGRAM ...

Page 288: ...ctured 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 and absorbs its vibration 2 S...

Page 289: ...1 Front Prepeller Shaft Assembly 2 Rear Prepeller Shaft Assembly Bolt Bolt CV joint Front propeller shaft assembly Universial joint Bolt was her nut Universial joint 1st rear propeller shaft Center bearing assembly CV joint 2nd rear propeller shaft Universial joint Bolt ...

Page 290: ...0 3 SUSPENSION SYSTEM RODIUS 2007 07 4111 01 4410 01 SUSPENSION SYSTEM 1 FRONT SUSPENSION SPECIFICATION ...

Page 291: ...0 4 RODIUS 2007 07 4111 01 SUSPENSION SYSTEM 2 REAR SUSPENSION SPECIFICATION ...

Page 292: ...0 5 SUSPENSION SYSTEM RODIUS 2007 07 4111 01 3 STRUCTURE OF SHOCK ABSORBER AND COIL SPRING 1 front coil spring Specification ...

Page 293: ...0 6 RODIUS 2007 07 4111 01 SUSPENSION SYSTEM 2 front shock absorber assembly Specification ...

Page 294: ...ION SYSTEM RODIUS 2007 07 4111 01 Marking Point 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 ...

Page 295: ...0 8 RODIUS 2007 07 4111 01 SUSPENSION SYSTEM 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 296: ...0 3 BRAKS SYSTEM RODIUS 2007 07 4830 01 4830 01 BRAKE SYSTEM 1 SPECIFICATION ...

Page 297: ...0 4 RODIUS 2007 07 4830 01 BRAKS SYSTEM 1 COMPONENTS OF BRAKE SYSTEM ...

Page 298: ...0 5 BRAKS SYSTEM RODIUS 2007 07 4830 01 ...

Page 299: ...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 300: ...acuum pump in intake manifold and the atmospheric pressure Pressure distribution at 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 from the poppet 2 And then the air val...

Page 301: ...essure sensors under master cylinder and these two sensor are used for BAS Brake Assist System system 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 Vehicle with ESP Vehicle with ABS Brake fluid reservoir tank Master cylinder Vehicle with ESP ...

Page 302: ...ICATIONS 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 303: ...e has the longitudinal sensor in the HECU 1 HECU Hydraulic Engine conrol unit 2 Pressure sensor 3 Wheel speed sensor 4 Sensor cluster Yaw rate lateral sensor longitudinal sensor 5 Steering wheel angle sensor 6 ESP off switch Electronic Stability Program Switch ESP Warning lamp ...

Page 304: ...0 5 ESP SYSTEM RODIUS 2007 07 4892 01 2 INPUT AND OUTPUT DIAGRAM ...

Page 305: ...nering by detecting the moment right before the spin and automatically limiting the engine output coupled with the ASR system Understeering is when the steering wheel is steered to a certain angle during driving and the front tires slip toward the reverse direction of the desired direction Generally vehicles are designed to have under steering The vehicle can return back to inside of cornering lin...

Page 306: ...stem includes the ABS EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions For example when the brakes are applied during cornering at the speed of 100 km h the ABS system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel And when yaw rate sensor detects the rate exceeding 4 Æ seconds the ES...

Page 307: ...apply the brake force to the corresponding wheel to compensate the yaw moment with the vehicle stability control function When various systems operate simultaneously under a certain situation there may be vehicle control problems due to internal malfunction of a system or simultaneous operations In order to compensate to this problem the ESP system sets the priority among systems The system operat...

Page 308: ...ntrols 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 309: ...rd 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 valu...

Page 310: ...sors 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 311: ...0 12 RODIUS 2007 07 4892 01 ESP SYSTEM 5 Comparison with ABS System ...

Page 312: ...0 13 ESP SYSTEM RODIUS 2007 07 4892 01 6 Hydraulic Circuit Diagram ...

Page 313: ...SP is operating Noise and vibration that driver senses when the ESP is operating When the ESP operates during 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 ...

Page 314: ...sition 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 315: ...pressure decreases just before the wheel speed drops and the wheels The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied Then the pump operates to allow fast oil drainage ...

Page 316: ...and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels By closing the valves the hydraulic pressure at the wheels will not be lost or supplied any more During ESP operation the separation valve closes and only the shuttle valve at the pump opens ...

Page 317: ...e The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed Then the pump is operated When ESP operates while the ABS is operating the pressure will be increased continuously until just before the corresponding wheel gets locked ...

Page 318: ...ding 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 star...

Page 319: ...0 20 RODIUS 2007 07 4892 01 ESP SYSTEM 4 ELECTRICAL CIRCUIT DIAGRAM Wheel Speed Sensor Stop Lamp Diagnosis Warnung Lamp ABS ESP ...

Page 320: ...0 21 ESP SYSTEM RODIUS 2007 07 4892 01 Brake Pressure Sensor ESP Sensor Sensor Cluster ESP OFF Switch ...

Page 321: ...0 3 ABS SYSTEM RODIUS 2007 07 4892 01 4892 01 ABS 1 SPECIAL TOOLS AND EQUIPMENT ...

Page 322: ...physics principles 1 The Stopping Distance The stopping distance depends on the vehicle weight and initial speed when braking starts This also applies for vehicle with ABS where ABS always tries to set an optimum brake force on each wheel As great forces are exerted between the tires and the carriageway when braking even with ABS the wheels may scream and rubber is left on the road With an ABS ski...

Page 323: ...ng friction with the result that the stopping distance is increased This loss of friction is termed slip in specialist literature Slip The brake slip is the difference between the vehicle speed and the wheel circumference speed If the wheel locks the slip is greatest that is 100 If the wheel is running freely and unbraked the slip is the lowest equal to 0 Slip can be calculated from the vehicle sp...

Page 324: ...nd 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 for this is based in physics and not in the Anti Lock System However as mentioned before ABS is not about the stopping distance but maneuverability and driving st...

Page 325: ... fast and the tire requires 100 transmissibility as cornering force the tire cannot transmit any additional brake force In spite of the ABS the car is carried out of the curve The relationship between brake force B and cornering force S is shown very clearly in the Kamm circle If we put a vehicle wheel in this circle the relationship becomes even clearer In this relationship as long as the acting ...

Page 326: ...ABS operating range The operating range starts just before the maximum brake force and ends in maximum for the unstable range then begins in which no further modulation is possible The ABS controls the regulation of the brake pressure so that the brake force only becomes great enough for a sufficient proportion of cornering force to remain With ABS we remain in the Kamm circle as long as the car i...

Page 327: ...BS control If during braking one wheel speed deviates from the reference speed the ABS control unit attempts to correct that wheel speed by modulating the brake pressure until it again matches the reference speed When all four wheels tend to lock all four wheels speeds suddenly deviate from the previously determined reference speed In that case the control cycle is initiated again in order to agai...

Page 328: ...l of the modulator such as to replace the HECU air will not enter the modulator and normal bleeding will be all that is needed If air enters the hydraulic modulator or if an unfilled modulator is installed use the brake bleeding program in the scan tool to bleed the modulator Manual bleeding of the hydraulic modulator is not possible 1 Service Precautions Brake Fluid may irritate eyes and skin In ...

Page 329: ...luid is not recommended Reduced brake performance or durability may result Avoid spilling brake fluid on any the vehicle s painted surfaces wiring cables or electrical connectors Brake fluid will damage paint and electrical connections If any fluid is spilled on the vehicle flush the area with water to lessen the damage ...

Page 330: ...grated hydraulic modulator and HECU Hydraulic and Electronic Control Unit compared to existing ABS And the wheel speed sensor uses different method to detect wheel speed The basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking has not been changed ...

Page 331: ...0 13 ABS SYSTEM RODIUS 2007 07 4892 01 1 System Fuse 2 Indicators The ABS TCS system fuse and SB2 is located at the fuse box in engine compartment The ABS and TCS indicators are in instrument cluster ...

Page 332: ...0 14 RODIUS 2007 07 4892 01 ABS SYSTEM 2 INPUT AND OUTPUT DIAGRAM ...

Page 333: ...he brake force distribution 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 ...

Page 334: ... TCS components are extremely 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 fl...

Page 335: ...0 17 ABS SYSTEM RODIUS 2007 07 4892 01 3 ELECTRICAL CIRCUIT ...

Page 336: ...sensor method The front wheels that are the primary circuit of the brake system is composed of two wheel speed sensors and two channel valves system with two inlet valves and two outlet valves The rear wheels that are the secondary circuit of the brake system is composed of two wheel speed sensors one inlet valve and one outlet valve This system is similar to the one from the previous model ...

Page 337: ...pen inlet valve At this moment the normally closed outlet valve is closed The speed of the wheel that hydraulic pressure is delivered reduces gradually As hydraulic pressure on each wheel increases the wheel tends to lock In order to prevent the wheel from locking the hydraulic valve modulator operates the inlet valve control solenoid to close the inlet valve and stop the hydraulic pressure increa...

Page 338: ...sent to the low pressure changer and the wheel speed increases again The ABS ECU operates the pump to circulate the oil in the low pressure chamber to the master cylinder This may make the driver to feel the brake pedal vibration and some noises 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 cham...

Page 339: ...ector has 47 pins and the number of valves in valve body is 6 when equipped with only ABS and 12 when equipped with ESP system 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 The cam bushing is installed between plungers and it draws and discharges the brake fluid ...

Page 340: ...ntrols the hydraulic 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 The electrical components are we...

Page 341: ...0 3 POWER STEERING SYSTEM RODIUS 2007 07 4610 00 4610 00 POWER STEERING SYSTEM 1 SPECIFICATION ...

Page 342: ...0 4 RODIUS 2007 07 4610 00 POWER STEERING SYSTEM 2 TIGHTENING TORQUE 3 SPECIAL TOOLS AND EQUIPMENT ...

Page 343: ...irects the oil from the power steering pump to one side of rack piston The integrated 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...

Page 344: ...0 6 RODIUS 2007 07 4610 00 POWER STEERING SYSTEM 1 COMPONENTS OF POWER STEERING ASSEMBLY ...

Page 345: ...alve The power cylinder has cylinder piston and 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 ...

Page 346: ...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 4 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 m...

Page 347: ...fication Wheel Size Aluminum type 6 5J x 16 Wheel nut tightening torque Aluminum wheel 13 16 kgf m Tire Type Radial tire Radial Tire Inflation pressure psi P225 65R16 35 psi Wheel alignment Toe in Front 0 4 mm Rear 0 4 0 08 5 mm 1 mm Camber Front 0 30 0 0 5 Rear 1 30 1 0 5 Caster 4 5 30 ...

Page 348: ...immy 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 according to the types of the tire b...

Page 349: ...e 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 350: ...0 6 RODIUS 2007 07 4710 09 WHEEL 4 The Relations Between Inflation Pressure and Tire 5 The Relations Between Load and Tire ...

Page 351: ... 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 low...

Page 352: ...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 mil...

Page 353: ...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 354: ...0 3 AIR CONDITIONING SYSTEM RODIUS 2007 07 6810 20 6910 20 AIR CONDITIONING SYSTEM 1 FFH SPECIFICATION ...

Page 355: ...0 4 RODIUS 2007 07 6810 20 AIR CONDITIONING SYSTEM 2 SYSTEM LAYOUT AND COMPONENTS Front air conditioner module assembly inside instrument panel ...

Page 356: ...0 5 AIR CONDITIONING SYSTEM RODIUS 2007 07 6810 20 Rear air conditioner module assembly bottom of rear left ...

Page 357: ...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 358: ...0 7 AIR CONDITIONING SYSTEM RODIUS 2007 07 6810 20 4 COMPONENTS AND LOCATIONS ...

Page 359: ...0 8 RODIUS 2007 07 6810 20 AIR CONDITIONING SYSTEM 1 VENTILATION SYSTEM COMPONENTS 1 Locations of Vents Front Ventilation Rear ventilation ...

Page 360: ...0 9 AIR CONDITIONING SYSTEM RODIUS 2007 07 6810 20 2 Ventilation Modes Bi level mode Defrost and floor mode Rear air conditioning mode Defrost mode Floor mode Vent mode ...

Page 361: ...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 362: ...M RODIUS 2007 07 6810 20 2 Rear Air Conditioner Module Wiring layout Components Roof air conditioner duct Blower motor Evaporator Air mixer door actuator Rear floor heater duct Mixer door Heater core Heater air conditioner pipes ...

Page 363: ...0 12 RODIUS 2007 07 6810 20 AIR CONDITIONING SYSTEM 3 AIR CONDITIONER AND HEATER PIPE LAYOUT ...

Page 364: ...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 365: ...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 366: ...re the resistance between terminal No 5 and 6 on the sensor connector standard approx 25 C 2 2 kΩ If the measured value is out of the specified range replace the AIH sensor If the measured values are within the specified range check as below Turn the ignition switch to ON position and measure the voltage to active incar sensor from the FATC controller connector standard approx 2 V at 25 C If the v...

Page 367: ... and measure the output voltage while the voltage is applied output voltage approx 0 8 3 4 V Check whether the output voltage is changed when blowing into the inlet of the sensor If there is a voltage change the sensor is in normal condition However if the voltage is not changed replace the humidity sensor In addition if the output voltage is extremely high or low even in the specified range repla...

Page 368: ...ce selection switch in AUTO mode However the indicator on the switch turned ON OFF In other 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 MOD...

Page 369: ...e 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 air source is automatically changed to the fresh air mode 2 If the AQS switch is pressed in the AQS function works ...

Page 370: ...eared 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 to recirculation mode in AUTO mode get into Manual mode first then press the air source selection switch 1 2 ...

Page 371: ...it for open If the measured value is within the specified range replace the FATC controller 1 2 3 4 5 6 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...

Page 372: ...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 373: ... FATC Front air conditioner power transistor Rear air conditioner power transistor 1 Inspection If the power transistor defect code DTC 6 is appeared check as below 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 circu...

Page 374: ...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 375: ...er 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 to each term...

Page 376: ...0 25 AIR CONDITIONING SYSTEM RODIUS 2007 07 6810 20 4 Air Door Actuator The air door actuator sets the intake door mode according to the control signals from FATC ...

Page 377: ...ge value is out of the specified value check the related circuits for open If the circuits are in normal condition replace the air door actuator assembly 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 air door actuator And connect the cable to each terminal P1 and P2 in turn to check the...

Page 378: ...NDITIONING SYSTEM RODIUS 2007 07 6810 20 5 Air Mix Door Actuator The air mix door actuator controls the discharging air temperature properly by closing opening the damper according to the control signals from FATC ...

Page 379: ...nal P1 and P2 approx 12 V and terminal a and b approx 5V 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 air mix door actuator assembly Connect the positive and negative cables of temporary power supply to the air mix door actuator And connect the cable to each terminal P1 and P2 in turn to check the motor o...

Page 380: ...pprox 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 approx 12 V If the voltage value cannot be measured check th...

Page 381: ...0 2 RODIUS 2007 07 8810 01 AIR BAG SYSTEM 8810 01 AIR BAG SYSTEM 1 AIRBAG OVERVIEW Passenger s airbag Airbag unit SDM Driver s airbag Front seat Driver s Passenger s Height adjuster Driver passenger ...

Page 382: ...0 3 AIR BAG SYSTEM RODIUS 2007 07 8810 01 Pretensioner Retractor ...

Page 383: ...0 4 RODIUS 2007 07 8810 01 AIR BAG SYSTEM 1 COMPONENTS OF DRIVER S AIRBAG MODULE ...

Page 384: ...0 5 AIR BAG SYSTEM RODIUS 2007 07 8810 01 2 COMPONENTS OF PASSENGER S AIRBAG MODULE ...

Page 385: ...he steering wheel The passenger airbag module is installed in the instrument panel at passenger side The driver and passenger side airbag is inside each seat 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 th...

Page 386: ...rs the system components continuously The SDM also records any faults which are discovered The SDM allows the fault codes to be retrieved with a scan tool and illuminates a warning lamp that alerts the driver to any faults 1 2 3 The SDM located on floor beneath the floor console assembly The SDM performs the following functions Impact decision processor function Determine the airbag deployment thr...

Page 387: ...to lock and turn the label of the clock spring counterclockwise approximately 2 9 0 2 turns to the neutral positions with the front wheels ahead Align the pointed marks 43 7 Accelometer Sensor The accelerometer sensor electronically represents the acceleration or deceleration of the vehicle during a frontal impact In this electronic representation the electrical signal is proportional to the accel...

Page 388: ...cuit When it is detected any problem it illuminates the airbag warning indicator to inform driver of the fault and stores the fault information 10 Airbag Warning Lamp The instrument cluster contains an airbag warning indicator bulb to verify the operation of the AIRBAG indicator and sensing and diagnostic module SDM The SDM performs a turn on test when the ignition is turned ON The SDM flashes the...

Page 389: ...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 390: ...face impact against the curb at a very high speed dropping impact onto the road surface with a large angle The air bag does not inflate when Rollover side impact or rear impact The air bag seldom inflates when 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 drainage or a p...

Page 391: ...0 2 RODIUS 2007 07 7410 01 SEAT Belt type buckle Front seat belt 7410 01 SEAT 1 SEAT OVERVIEW Fixed type buckle Front seat Driver s Passenger s ...

Page 392: ...0 3 SEAT RODIUS 2007 07 7410 01 Rear 1st seat Rear 2nd seat Rear 3rd seat Swivel seat Rear 1st seat Rear 1st seat Rear 2nd seat Rear 3rd seat ...

Page 393: ...7410 01 SEAT Back flat adjust lever Seat warmer switch Sliding adjust lever Seat control switch Sliding control 1 COMPONENTS OF SEAT Seat position control Seat height control Reclining control Back supporter Driver s seat ...

Page 394: ...0 5 SEAT RODIUS 2007 07 7410 01 Seat sliding adjust lever Seat swivel control lever Rear 3rd seat back folding adjust lever Back folding adjust lever Head rest ...

Page 395: ...0 6 RODIUS 2007 07 7410 01 SEAT Rear 1st row 3 point 2 point Rear 2nd row 3 point 2 point Rear 3rd row 3 point 2 point Front Seat Belt 3 point 2 COMPONENTS OF SEAT BELT 1 11 Passengers ...

Page 396: ...0 7 SEAT RODIUS 2007 07 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 397: ...0 8 RODIUS 2007 07 7410 01 SEAT 3 7 Passengers Front Seat Belt 3 point Rear 2nd row 3 point 2 point Rear 1st row 3 point ...

Page 398: ...0 9 SEAT RODIUS 2007 07 7410 01 3 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 399: ...0 10 RODIUS 2007 07 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 400: ...0 11 SEAT RODIUS 2007 07 7410 01 3 Layout 7 Passengers ...

Page 401: ...ont 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 Front 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 ...

Page 402: ...ear 2nd seat back folding while driving Rear 1st seat Move to the far end Center seat jumping Swiveled Rear 2nd seat Move to the far end Rear 3rd seat Fixed 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 ...

Page 403: ... parking 8 passengers with loading 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 404: ...ng 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 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 ...

Page 405: ...0 16 RODIUS 2007 07 7410 01 SEAT 5 Entry Way Rear 1st seat Folding center seat Rear 2nd seat Folding center seat Rear 3rd seat Fixed ...

Page 406: ...0 17 SEAT RODIUS 2007 07 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 407: ...OPERATION OF FRONT SEAT DRIVER S SEAT 1 Components Sliding motor Sliding rail Seat position front up down rail Seat warmer connector Seat position up down motor Seat position up down rail Seat position rear up down motor Reclining motor ...

Page 408: ...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 Seat position rear up down Rear side of seat moves up down controlled by seat position control switch ...

Page 409: ...0 RODIUS 2007 07 7410 01 SEAT Seat height up down Seat moves up down controlled by seat height control switch Reclining Seat back reclining controlled by seat reclining control switch Seat reclining motor ...

Page 410: ... and check if the power is supplied Refer to the wiring diagram 1 If the power supply has no problem remove the seat 2 Check the motor and wiring if damaged 3 Connect the battery to the seat connector 4 Control the seat switch and check the opration Electrical parts are not supplied by a part separately ...

Page 411: ... 4 Operation of center seat 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 When seating When jumping ...

Page 412: ...0 23 SEAT RODIUS 2007 07 7410 01 5 OPERATION OF REAR SEAT 1 Rear 1st seat swivel seat Seat back folding cable Sliding cable Seat back flat cable Jumping mechanism Swivel lever Sliding lever ...

Page 413: ...0 24 RODIUS 2007 07 7410 01 SEAT 2 Operation of rear seat Rear 1st and 2nd seat Seat sliding Front Rear ...

Page 414: ...DIUS 2007 07 7410 01 3 Seat back flat Rear 1st Rear 2nd 4 Seat back folding Fold the rear 1st or 2nd raw seat back to put something on or to utilize it as a table Rear 1st 2nd seat When to recline or to flat fully ...

Page 415: ...g Rear 1st seat Turn around seat as the swing lever is pulled 6 Rear 3rd seat Pull the lever behind back seat to fold the back seat Pull the lever under back seat to fold up the seat As the seat is folded disconnect hook and spread out the board ...

Page 416: ...0 3 SUNROOF RODIUS 2007 07 7340 01 7340 01 SUN ROOF 1 SUNROOF LAYOUT ...

Page 417: ...0 4 RODIUS 2007 07 7340 01 SUNROOF 2 COMPONENTS OF SUNROOF ...

Page 418: ...0 5 SUNROOF RODIUS 2007 07 7340 01 Drain hose Control switch Sun shade glass Control unit Sun roof motor 3 COMPONENTS AND LOCATIONS ...

Page 419: ...ilting Push the front side of the button when the glass is closed then mtor actuate 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 ...

Page 420: ...0 7 SUNROOF RODIUS 2007 07 7340 01 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 421: ...NO DATA ...

Page 422: ...06 3 BODY EXTERIOR RODIUS 2007 07 7115 01 7115 01 BODY EXTERIOR 1 COMPONENTS AND LOCATION OF EXTERIOR ...

Page 423: ...06 4 RODIUS 2007 07 7115 01 BODY EXTERIOR ...

Page 424: ...06 5 BODY EXTERIOR RODIUS 2007 07 7115 01 1 DOOR SYSTEM 1 LAYOUT FRONT DOOR ...

Page 425: ...06 6 RODIUS 2007 07 7115 01 BODY EXTERIOR ...

Page 426: ...06 7 BODY EXTERIOR RODIUS 2007 07 7115 01 2 LAYOUT REAR DOOR ...

Page 427: ...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 Window motor Regulator operating cable Guide rail ...

Page 428: ...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 Door latch Operating cable Inside handle Lock Unlock Inside door handle ...

Page 429: ... 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 Lock Unlock Inside door handle Inside handle Outside handle Key cylinder ...

Page 430: ...06 11 BODY EXTERIOR RODIUS 2007 07 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 431: ...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 432: ... 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 433: ...4 RODIUS 2007 07 7115 01 BODY EXTERIOR 2 TAILGATE 1 OPERATION TAILGATE Tailgate handle Actuator Key cylinder Door latch Connecting tailgate handle Connecting rod actuator handle Connecting rod key cylinder ...

Page 434: ...06 15 BODY EXTERIOR RODIUS 2007 07 7115 01 2 LAYOUT TAILGATE Washer nozzle Rear view camera Rear spoiler Wipre motor Key cylinder ...

Page 435: ...06 16 RODIUS 2007 07 7115 01 BODY EXTERIOR Shock absorber Door latch Door hinge Door striker ...

Page 436: ...06 17 BODY EXTERIOR RODIUS 2007 07 7115 01 3 LAYOUT COWL ASSY HOOD ...

Page 437: ...06 18 RODIUS 2007 07 7115 01 BODY EXTERIOR 4 LAYOUT FRONT BUMPER ...

Page 438: ...06 19 BODY EXTERIOR RODIUS 2007 07 7115 01 5 LAYOUT REAR BUMPER ...

Page 439: ...06 20 RODIUS 2007 07 7115 01 BODY EXTERIOR 6 KEY CYLINDER 1 COMPONENTS Door handle Front Key cylinder Key cylinder Tailgate Key cylinder Door handle Front Starting key cylinder key ...

Page 440: ...0 3 BODY REPAIR RODIUS 2007 07 5710 01 5710 01 BODY REPAIR 1 BODY DIMENSION unit mm ...

Page 441: ...0 4 RODIUS 2007 07 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 442: ...SPECIAL SERVICE TOOLS 0000 00 SPECIAL SERVICE TOOLS GENERAL 1 AIR BAG SYSTEM 3 ...

Page 443: ......

Page 444: ...0 3 SPECIAL SERVICE TOOLS RODIUS 2007 07 0000 00 1 SPECIAL TOOLS AND EQUIPMENT Name and Part Number 1 AIR BAG SYSTEM 0000 00 SPECIAL SERVICE TOOLS ...

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