SsangYong Rexton All Models Repair Service Manual
SsangYong Rexton All Models Repair Service Manual
Complete service repair manual with electrical wiring diagrams for SsangYong Rexton All Models, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.
SsangYong Rexton I, Rexton II, Rexton W All Models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 22,742 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
2001-2006 Rexton.......1
ENGINE.......1
CHASSIS.......588
2001-2011 Rexton I-II.......1894
ENGINE.......1894
ENGINE ASSEMBLY.......1894
STRUCTURE AND FUNCTION DESCRIPTIONS.......1895
ENGINE PERFORMANCE CURVE.......1900
GENERAL DIAGNOSIS.......1902
DIAGNOSTIC INFORMATION AND PROCEDURE.......1907
COMPRESSION PRESSURE TEST.......1908
CYLINDER PRESSURE LEAKAGE TEST.......1910
TIGHTENING TORQUE.......1911
REMOVAL AND INSTALLATION.......1914
Engine Assembly - Removal.......1915
DISASSEMBLY AND REASSEMBLY.......1924
Inspection Before Disassembly and.......1925
Accessories - Removal and Installation.......1926
Engine - Disassembly and Reassembly.......1940
ENGINE HOUSING.......1954
CYLINDER HEAD/CYLINDER BLOCK.......1955
CAMSHAFT ASSEMBLY.......1969
TIMING CHAIN ASSEMBLY.......1977
CYLINDER BLOCK.......1981
CRANKSHAFT.......1984
ARRANGEMENT OF THRUST WASHERS AND BEARINGS.......1985
TORSIONAL VIBRATION DAMPER.......1990
Crankshaft - Disassembly.......1991
PISTON AND CONNECTING ROD.......1994
PISTON RING.......1995
CYLINDER INNER DIAMETER AND PISTON SIZE.......1996
Piston - Reassembly.......1997
HIGH PRESSURE PUMP (HPP).......2001
HP Pump - Disassembly and Reassembly.......2002
INTAKE SYSTEM.......2007
AIR FLOWS.......2008
INTAKE SYSTEM LAYOUT.......2009
AIR CLEANER.......2010
AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR).......2013
INTERCOOLER.......2019
INTAKE MANIFOLD ASSEMBLY.......2021
EXHAUST SYSTEM.......2026
EXHAUST SYSTEM LAYOUT.......2027
EXHAUST GAS FLOWS.......2028
TURBO CHARGER ASSEMBLY.......2030
EGR VALVE AND VACUUM MODULATOR.......2051
EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM.......2052
EXHAUST SYSTEM AND MUFFLER.......2060
SYSTEM OVERVIEW Exhaust System.......2061
LUBRICATION SYSTEM.......2067
LUBRICATION SYSTEM LAYOUT.......2069
LUBRICATION DIAGRAM.......2070
SPECIFICATIONS.......2071
ENGINE OIL CHANGE.......2075
OIL PUMP.......2079
OIL SPRAY NOZZLE.......2081
OIL PAN ASSEMBLY.......2082
TROUBLE DIAGNOSIS.......2083
SPECIAL TOOLS AND EQUIPMENT.......2084
COOLING SYSTEM.......2085
ENGINE COOLING SYSTEM.......2087
SPECIFICATIONS.......2097
INSPECTION AND REPAIR.......2098
REMOVAL AND INSTALLATION.......2100
PREHEATING SYSTEM.......2113
OVERVIEW.......2114
PREHEATING SYSTEM DIAGRAM.......2115
FUEL SYSTEM.......2117
CAUTIONS FOR DI ENGINE.......2118
FUEL INJECTION SYSTEM.......2121
FUEL TRANSFER LINE.......2127
INLET METERING VALVE (IMV).......2129
HIGH FUEL PRESSURE LINE.......2132
INJECTOR.......2163
ENGINE CONTROL SYSTEM.......2177
SENSORS FOR DIAGNOSIS.......2178
TOP VIEW.......2179
SIDE VIEW.......2180
ENGINE CONTROL SYSTEM.......2181
FUEL PRESSURE CONTROL.......2187
FUEL INJECSTION CONTROL.......2188
FUEL FLOW CONTROL.......2189
INDIVIDUAL INJECTOR CALIBRATION (C2I).......2194
MINIMUM DRIVE PULSE (MDP) LEARNING.......2196
Accelerator Pedal Sensor.......2197
ELECTRIC DEVICES.......2202
SENSORS IN ENGINE COMPARTMENT.......2203
ELECTRIC DEVICES IN ENGINE COMPARTMENT.......2204
SPECIFICATIONS.......2205
CIRCUIT DIAGRAM OF PREHEATING SYSTEM.......2206
CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR.......2207
TROUBLE DIAGNOSIS.......2208
ALTERNATOR.......2210
STARTER.......2212
PREHEATING SYSTEM.......2214
PREHEATING TIME RELAY.......2216
GLOW PLUG.......2217
SPECIAL TOOLS AND EQUIPMENT.......2219
GENERAL INFORMATION.......2220
CLEANNESS.......2221
STRUCTURE.......2226
ENGINE CONTROLS.......2229
ENGINE AND SENSORS.......2230
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM.......2231
INTAKE SYSTEM.......2232
LUBRICATION SYSTEM.......2236
COOLING SYSTEM.......2237
FUEL SYSTEM.......2239
GENERAL SPECIFICATIONS.......2241
MAINTENANCE.......2244
VEHICLE IDENTIFICATION.......2246
HOW TO USE AND MAINTAIN WORKSHOP MANUAL.......2248
GUIDELINES FOR SERVICE WORK SAFETY.......2249
LIFTING POINTS.......2254
TIGHTENING TORQUE OF STANDARD BOLTS.......2255
SCAN-I OPERATING PROCEDURES.......2256
FUNCTION SELECTION.......2259
Sensor Data Check.......2260
Actuator Check.......2261
Trouble Code Clear.......2263
ECU Identification.......2265
Injector Coding (C2I).......2266
Leak Detection.......2268
Variant Coding.......2269
ECU Replace.......2271
TROUBLE DIAGNOSIS TABLE.......2276
INDEX OF DTC.......2277
TROUBLE DIAGNOSIS TABLE.......2280
INDEX OF DTC.......2323
TROUBLE DIAGNOSIS PROCEDURES.......2327
Cam Position Sensor (missing event).......2328
Too Small Clearance of Crank Angle.......2330
Barometric Sensor Malfunction.......2333
Battery Voltage Monitoring Signal.......2334
Booster Pressure Sensor Malfunction.......2336
Brake Pedal Switch Malfunction.......2342
High Wiring Resistance (Injector #1).......2344
Clutch Switch Malfunction.......2349
Coolant Temperature.......2350
Too Fast or Low Main Relay Operation.......2352
EGR Actuator Malfunction.......2353
Condenser Fan Driving Signal Fault.......2354
#1 Accelerometer Malfunction.......2356
Injector Bank 1 Malfunction.......2358
Cylinder Balancing Fault (Injector #1) =.......2362
Open Circuit (Injector #1).......2367
Fuel Temperature Sensor Malfunction.......2377
Glow Plug Malfunction (Driving Signal).......2378
Heater 1 Malfunction (Driving Signal).......2379
Rail Pressure Control Fault.......2381
IMV Operation Fault (Electrical Fault).......2387
Intake Air Temperature Sensor Fault.......2388
MDP Fault (Injector #1).......2389
Rail Pressure Fault (Too High).......2392
Accelerator Pedal Sensor Malfunction.......2394
Fuel Rail Pressure Sensor Malfunction.......2400
Main Relay Malfunction - Stuck.......2404
Vehicle Speed Fault.......2405
5V Supply Voltage 1 Fault.......2406
Turbo Charger Actuator Operation Fault.......2409
ECU Watchdog Fault.......2410
Accelerometer Learning Fault.......2415
EGR Valve Control Fault.......2416
VGT Operation Fault.......2417
TBD.......2419
No Crank Signal.......2420
High Torque Trim.......2421
Glow Plug Module Communication Fault.......2422
TCU Signal Fault.......2425
Air Conditioner Operating Circuit Fault.......2426
Excessive Water in Fuel Filter.......2427
Immobilizer Malfunction.......2428
FUEL SYSTEM DIAGNOSIS.......2429
OVERVIEW.......2430
FUEL PRESSURE SYSTEM.......2431
FUEL SYSTEM PRESSURE TEST.......2434
FUEL SYSTEM CHECK PROCESS.......2436
PRESSURE LEAKAGE TEST WITH SCAN-100.......2445
CHASSIS.......2447
FFH/PTC SYSTEM.......2447
FUEL FIRED HEATER (FFH) SYSTEM.......2448
SYSTEM LAYOUT.......2449
TROUBLE DIAGNOSIS.......2458
REMOVAL AND INSTALLATION.......2470
POSITIVE TEMPERATURE COEFFICIENT (PTC) SYSTEM.......2475
COMPONENTS.......2476
CIRCUIT DIAGRAM.......2477
REMOVAL AND INSTALLATION.......2478
HEATER & VENTILATION.......2480
GENERAL INFORMATION.......2481
MANUAL AIR CONDITIONER.......2482
AUTOMATIC AIR CONDITIONER.......2485
AIR FLOWS THROUGH VENTS (MODE SWITCH OPERATIONS).......2490
SPECIFICATIONS.......2491
AIR DISTRIBUTION.......2492
CIRCUIT DIAGRAM.......2494
TROUBLE DIAGNOSIS.......2495
BLOWER ELECTRICAL.......2497
MAINTENANCE AND REPAIR.......2502
AIR DUCT ASSEMBLY.......2503
REAR COOLER DUCT.......2504
HEATER AND BLOWER MODULE.......2505
A/C SYSTEM.......2508
DESCRIPTION AND OPERATION.......2509
TROUBLE DIAGNOSIS.......2519
CHECK AND REPLACEMENT.......2526
REMOVAL AND INSTALLATION.......2531
DISASSEMBLY AND REASSEMBLY.......2537
MANUAL AIR CONDITIONING SYSTEM.......2539
TROUBLE DIAGNOSIS.......2542
REMOVAL AND INSTALLATION.......2545
AUTOMATIC AIR CONDITIONER SYSTEM.......2546
SPECIFICATIONS.......2557
TROUBLE DIAGNOSIS.......2558
REMOVAL AND INSTALLATION.......2573
BODY.......2579
GENERAL INFORMATION.......2580
SPECIFICATIONS.......2581
WATERLEAK TEST.......2582
GENERAL REPAIR.......2584
TROUBLE DIAGNOSIS.......2586
SPECIAL TOOLS AND EQUIPMENT.......2589
BODY DIMENSIONS.......2590
FRAME.......2591
SIDE STRUCTURE COMPLETE.......2592
ENGINE COMPARTMENT.......2594
WINDSHIELD AND TAILGATE GLASS.......2595
TAILGATE.......2596
GAP CHART.......2597
UNDERCOATING.......2599
BODY MOUNTINGS.......2600
WIRING HARNESS (DI ENGINE EQUIPPED VEHICLE).......2601
VEHICLE INTERIOR.......2615
SEAT.......2616
REMOVAL AND INSTALLATION.......2622
DISASSEMBLY AND REASSEMBLY.......2626
SEAT BELT.......2632
REMOVAL AND INSTALLATION.......2633
CONVENIENT DEVICES.......2638
OTHER COMPONENTS.......2641
INTERIOR TRIM AND ROOF ASSEMBLY.......2647
INSTRUMENT ASSEMBLY.......2652
EXTERIOR.......2657
COMPONENTS LOCATOR.......2658
TAILGATE.......2659
FLIP-UP SYSTEM.......2660
HOOD.......2662
SUN ROOF AND ROOF RACK.......2663
MOLDING.......2664
REMOVAL AND INSTALLATION.......2665
AIRBAG SYSTEM.......2732
GENERAL DESCRIPTION AND OPERATION.......2733
CAUTIONS WITH THE AIR BAG.......2734
FUNCTION DESCRIPTION.......2738
FRONT AIR BAG.......2741
SIDE AIR BAG.......2744
DC 5-SPEED AUTOMATIC.......2772
GENERAL INFORMATION.......2773
CHARACTERISTICS.......2774
STRUCTURE.......2775
PERFORMANCE CURVE AND GENERAL CHARACTERISTICS.......2776
SPECIFICATIONS.......2777
POWER FLOW.......2779
FUNCTION AND DESCRIPTION.......2787
TORQUE CONVERTER.......2788
LOCKUP CLUTCH.......2790
PLANETARY GEAR SET.......2792
MULTIPLE-DISC CLUTCH.......2793
FREEWHEEL.......2794
SENSORS AND CONTROLS.......2795
OTHER FUNCTIONS.......2817
TROUBLE CODE AND DIAGNOSIS.......2822
HYDRAULIC SYSTEM.......2831
HYDRAULIC CIRCUIT.......2832
HYDRAULIC CIRCUIT WHEN STARTING ENGINE.......2837
STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE).......2843
REMOVAL AND INSTALLATION (DC 5-SPEED A/T).......2745
DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T).......2846
CLUTCH.......2852
GENERAL DESCRIPTION AND OPERATION.......2853
SPECIFICATIONS.......2854
DIAGNOSTIC INFORMATION AND PROCEDURES.......2855
CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY.......2856
CLUTCH COMPONENTS.......2857
CLUTCH MASTER CYLINDER.......2861
CLUTCH PEDAL.......2862
INSPECTION PROCEDURE.......2866
SPECIAL TOOLS AND EQUIPMENT.......2868
PART TIME - T/C.......2869
GENERAL INFORMATION.......2870
SECTIONAL DIAGRAM.......2873
TCCU.......2875
SYSTEM LAYOUT.......2876
SYSTEM OPERATION.......2877
POWER FLOW.......2882
4H MODE (4WD DRIVE - HIGH SPEED).......2884
4L MODE (4WD DRIVE - LOW SPEED).......2885
DIAGNOSTIC INFORMATION AND PROCEDURES.......2886
TROUBLE DIAGNOSIS TEST.......2887
SELF-DIAGNOSIS TEST.......2888
DIAGNOSTIC TROUBLE CODE.......2890
CIRCUIT DIAGRAM (DI & 5-SPEED A/T).......2892
MAINTENANCE AND REPAIR.......2893
REMOVAL AND INSTALLATION OF TRANSFER CASE.......2895
TOD.......2906
CROSS SECTIONAL DIAGRAM (TOD TRANSFER CASE).......2910
TCCU.......2914
SYSTEM OPERATION.......2917
ELECTRIC SHIFT SYSTEM OPERATION.......2919
TOD SYSTEM OPERATION.......2921
SHIFT OPERATION.......2922
POWER FLOW.......2924
TROUBLE DIAGNOSIS.......2927
CODING ON TOD CONTROL UNIT.......2930
DIAGNOSTIC TROUBLE CODE.......2931
REMOVAL AND INSTALLATION.......2934
FRONT AXLE.......2945
GENERAL INFORMATION.......2946
COMPONENT LOCATOR.......2947
REMOVAL AND INSTALLATION.......2949
DISASSEMBLY AND REASSEMBLY.......2960
REAR AXLE.......2974
GENERAL INFORMATION.......2975
COMPONENTS LOCATOR.......2976
REMOVAL AND INSTALLATION.......2978
DISASSEMBLY AND REASSEMBLY.......2990
PROPELLER SHAFT.......2999
GENERAL INFORMATION.......3000
COMPONENT LOCATOR.......3002
REMOVAL AND INSTALLATION.......3003
DISASSEMBLY AND REASSEMBLY.......3007
TROUBLE DIAGNOSIS.......3011
WHEEL & TIRE.......3013
DESCRIPTION AND OPERATION.......3014
REMOVAL AND INSTALLATION.......3020
MAINTENANCE AND REPLACEMENT.......3022
INSPECTION.......3027
STEERING COLUMN.......3033
GENERAL INFORMATION.......3034
SYSTEM LAYOUT.......3035
TIGHTENING TORQUE.......3036
REMOVAL AND INSTALLATION.......3037
DISASSEMBLY AND REASSEMBLY.......3045
TROUBLE DIAGNOSIS.......3046
SPECIAL TOOLS AND EQUIPMENT.......3047
ECPS.......3048
GENERAL INFORMATION.......3049
TROUBLE DIAGNOSIS.......3057
FLOW CHART FOR TROUBLE DIAGNOSIS.......3059
CIRCUIT DIAGRAM.......3061
REMOVAL AND INSTALLATION OF ECPS CONTROL UNIT.......3062
POWER STEERING.......3063
GENERAL INFORMATION.......3064
COMPONENT LOCATOR.......3066
REMOVAL.......3068
INSTALLATION.......3071
DISASSEMBLY AND REASSEMBLY.......3074
INSPECTION.......3079
TROUBLE DIAGNOSIS.......3081
GENERAL INSPECTION.......3082
AIR BLEEDING.......3090
SPECIAL TOOLS AND EQUIPMENT.......3091
FRONT SUSPENSION.......3092
GENERAL INFORMATION.......3093
SYSTEM LAYOUT.......3096
REMOVAL AND INSTALLATION.......3098
REAR SUSPENSION.......3114
GENERAL INFORMATION.......3115
SYSTEM LAYOUT.......3117
REMOVAL AND INSTALLATION.......3118
TROUBLE DIAGNOSIS.......3126
BRAKE SYSTEM.......3128
GENERAL INFORMATION.......3129
SYSTEM LAYOUT (HYDRAULIC LINE).......3131
INSPECTION.......3135
REMOVAL AND INSTALLATION.......3137
TROUBLE DIAGNOSIS.......3151
FRONT BRAKE.......3152
GENERAL INFORMATION.......3153
REMOVAL AND INSTALLATION.......3155
INSPECTION.......3159
TROUBLE DIAGNOSIS.......3163
SPECIAL TOOLS AND EQUIPMENT.......3164
REAR BRAKE.......3165
GENERAL INFORMATION.......3166
COMPONENTS LOCATOR.......3170
REMOVAL AND INSTALLATION.......3171
DISASSEMBLY AND REASSEMBLY.......3184
INSPECTION.......3186
TROUBLE DIAGNOSIS.......3188
SPECIAL TOOLS AND EQUIPMENT.......3189
PARKING BRAKE.......3191
GENERAL INFORMATION.......3192
COMPONENTS LOCATOR.......3194
REMOVAL AND INSTALLATION.......3195
INSPECTION.......3199
TROUBLE DIAGNOSIS.......3200
ABS.......3201
GENERAL.......3202
REPAIR INSTRUCTIONS.......3207
ELECTRIC CIRCUIT DIAGRAM.......3210
HYDRAULIC CIRCUIT DIAGRAM.......3211
COMPONENTS LOCATOR.......3218
REMOVAL AND INSTALLATION.......3219
SPECIAL TOOLS AND EQUIPMENT.......3225
ESP SYSTEM.......3226
GENERAL.......3227
COMPONENTS LOCATION.......3228
INPUT AND OUTPUT DIAGRAM OF ESP UNIT.......3230
ESP COMPONENTS.......3242
FUNCTION DESCRIPTION AND REMOVAL/INSTALLATION.......3246
TROUBLE DIAGNOSIS.......3262
ABS/ESP SENSOR VALUE.......3267
ABS/ESP FORCED OPERATION.......3268
ELECTRIC CIRCUIT DIAGRAM.......3273
ELECTRIC GENERAL .......3275
GENERAL INFORMATION.......3276
INSPECTION OF CABLES AND WIRES.......3278
FUSES AND RELAYS.......3279
IDI (D29ST) ENGINE EQUIPPED VEHICLE.......3282
GASOLINE ENGINE EQUIPPED VEHICLE.......3285
ELECTRIC COMPONENTS LOCATOR.......3288
ELECTRIC SYSTEM.......3289
IGNITION KEY AND REMOTE CONTROL KEY.......3290
REKES + STICS (RKSTICS).......3292
SPECIFICATIONS.......3293
CHATTERING OF INPUT SIGNALS.......3296
IGNITION KEY REMINDER.......3301
MARK LAMP LEFT ON WARNING.......3303
DOOR AJAR WARNING.......3305
SEATBELT WARNING TIMER.......3306
PARKING BRAKE WARNING.......3307
DECAYED ROOM LAMP TIMER.......3308
IGNITION KEY HOLE ILLUMINATION.......3309
REAR DEFOGGER TIMER.......3311
DOOR LOCK/UNLOCK CONTROL.......3312
TIME LAG POWER WINDOW CONTROL.......3316
REKES.......3317
THEFT WARNING.......3319
RK-STICS.......3323
IMMOBILIZER (FOR D27DT ENGINE EQUIPPED VEHICLE).......3329
CIRCUIT DIAGRAM.......3330
COMPONENTS.......3331
SCHEMATIC DIAGRAM.......3332
INSTRUMENT PANEL.......3333
CLUSTER.......3334
BLACK-FACE TYPE CLUSTER.......3336
DIRECT INJECTION DIESEL EQUIPPED VEHICLE (WITH CAN).......3337
CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT.......3338
CLEAR GLASS TYPE CLUSTER.......3339
CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT.......3340
INDIRECT INJECTION DIESEL EQUIPPED VEHICLE (WITHOUT CAN.......3341
MAINTENANCE AND REPAIR.......3343
METERS/INDICATORS/WARNING LIGHTS.......3350
MULTI-METER.......3361
ELECTRONIC COMPASS.......3362
SPEED SENSING INDICATOR / BAROMETR.......3363
ALTIMETER (ABSOLUTE ALTIMETER).......3365
RELATIVE ALTIMETER.......3366
SWITCHES.......3368
COMPONENTS LOCATOR.......3369
FUNCTION AND CIRCUIT OF SWITCHES.......3372
LEFT SWITCH PANEL.......3382
STEERING WHEEL REMOTE CONTROL SWITCH.......3385
SEAT WARMER SWITCH.......3387
MULTI-FUNCTION SWITCH.......3389
CONNECTOR PIN ARRANGEMENT.......3391
FUNCTION AND COMPOSITION OF SWITCHES.......3392
RAIN SENSING WIPER SYSTEM.......3398
AUTO LIGHT SYSTEM.......3406
SEAT MEMORY SWITCH.......3409
FUNCTION DESCRIPTION.......3411
WINDOW SWITCH.......3414
LAMPS.......3416
LAMP LOCATIONS.......3417
SPECIFICATIONS.......3418
MAINTENANCE AND ADJUSTMENT.......3419
MEASUREMENT OF HEADLAMP AIMING.......3421
TROUBLE DIAGNOSIS.......3422
EXTERIOR LAMPS.......3423
INTERIOR LAMPS.......3428
WIPER & WIPER MOTOR/HORN.......3432
COMPONENTS LOCATOR.......3433
INSPECTION.......3437
HORN.......3443
ELECTRONIC WIRING DIAGRAM.......3444
SECTION 1.......3444
HOW TO READ ELECTRICAL WIRING DIAGRAM.......3445
CIRCUIT IDENTIFICATION SYMBOL.......3447
HOW TO CHECK TERMINAL NUMBER OF CONNECTOR.......3450
PART LOCATION ACCORDING TO PART NUMBER.......3451
ELECTRIC SYMBOLS.......3452
ABBREVIATIONS.......3453
SECTION 2.......3457
POSITION OF CONNECTOR, GROUND & SPLICE PACK.......3458
CONNECTOR, GROUND & SPLICE PACK INFORMATION.......3459
COMPONENTS LOCATION.......3463
WIRING HARNESS, CONNECTOR & GROUND LOCATION.......3464
CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION.......3483
SECTION 3.......3491
POWER WIRING DIAGRAM (DSL).......3492
POWER WIRING DIAGRAM (GSL).......3508
POWER WIRING DIAGRAM (XDi, 2004 MODEL ~ ).......3524
SECTION 4.......3536
ENGINE ROOM FUSE & REALY BLOCK.......3537
I.P FUSE & RELAY BOX.......3545
SECTION 5.......3551
STARTING & CHARGING.......3556
PREHEATING UNIT CIRCUIT.......3562
EGR (EXHAUST GAS RECIRCULATION) CONTROL CIRCUIT (DSL).......3566
ECU (ELECTRONIC CONTROL UNIT) (E23).......3570
ECU (ELECTRONIC CONTROL UNIT) (E28, E32).......3578
ECU(XDi).......3590
DIAGNOSIS CIRCUIT.......3596
TCU (TRANSMISSION CONTROL UNIT) (4-SPEED).......3600
TCU (5-SPEED).......3606
TCCU (TRANSFERCASE CONTROL UNIT).......3610
TOD(TORQUE ON DEMAND).......3616
BRAKE SYSTEM.......3620
A/T SHIFT LOCK CIRCUIT.......3626
AIR BAG & SIDE AIR-BAG CIRCUIT.......3628
CLUSTER.......3630
MULTI METER CIRCUIT.......3638
RAIN SENSING WIPER CIRCUIT.......3640
POWER SEAT CIRCUIT.......3644
FRT SEAT WARMER(W/O MEMORY).......3646
POWER O/SIDE MIRROR, DEFOGGER SEAT WARMER CIRCUIT.......3648
POWER O/SIDE MIRROR, DEFOGGER CIRCUIT (W/O MEMORY).......3650
CENTRAL DOOR LOCKING SYSTEM.......3654
SEAT BELT, TENSION REDUCER CIRCUIT (2002 MODEL ONLY).......3656
PASSENGER POWER SEAT CIRCUIT.......3658
AUTO LIGHT CONTROL CIRCUIT.......3660
STICS.......3664
POWER WINDOW CIRCUIT.......3676
REAR GLASS WIPER & WASHER CIRCUIT.......3678
CIGAR LIGHTER CIRCUIT.......3682
REKES CIRCUIT (~ 2003 MODEL).......3684
SUN ROOF CIRCUIT.......3686
HEAD LAMP CIRCUIT.......3688
HEAD LAMP LEVELING DEVICE CIRCUIT.......3690
DRL (DAY TIME RUNNING LIGHT) UNIT (EU).......3692
TAIL LAMP CIRCUIT.......3694
TURN SIGNAL & HAZARD LAMP CIRCUIT.......3698
FOG LAMP CIRCUIT.......3702
STOP & BACK UP LAMP CIRCUIT.......3706
INTERIOR LAMP CIRCUIT.......3708
AUTO DIMMING ROOM MIRROR CIRCUIT.......3710
AUDIO, DIGITAL CIOCK CIRCUIT.......3712
AUDIO(MULTI VISION).......3714
AIR-CON (MANUAL, DSL).......3724
C__EPC_EY230EWD05045.pdf.......3732
FATC (FULL AUTO TEMPERATURE CONTROL) CIRCUIT.......3738
PARKING AID CIRCUIT.......3740
TRAILER CONNECTOR CIRCUIT.......3742
P.T.C HEATER(POSITIVE TEMPERATURE COEFFICIENT).......3744
F.F.H (FUEL FIRED HEATER).......3746
S.S.P.S.......3748
SUPPLEMENT REXTON 2 .......3750
GENERAL INFORMATION.......3750
DIMENSIONS.......3751
VEHICLE IDENTIFICATION.......3752
SPECIFICATIONS.......3753
RECOMMENDED FLUIDS AND LUBRICANTS.......3755
LIFTING POINTS.......3756
TIGHTENING TORQUE OF STANDARD BOLTS.......3757
FUSE & RELAY.......3758
FUSES AND RELAYS.......3759
RK STICS.......3774
RKSTICS (REKES+STICS).......3775
SEAT POSITION WITH.......3825
SPWM (Seat Position with Memory) UNIT.......3826
EASY ACCESS AND SEAT MEMORY SWITCH.......3842
VARIABLE SEAT WARMER SYSTEM.......3848
IMMOBILIZER SYSTEM.......3853
CLUSTER.......3862
INSTRUMENT CLUSTER.......3863
SWITCH / ELECTRIC PARTS.......3887
GENERAL INFORMATION.......3888
CENTER FASCIA & BEZEL SWITCH ASSEMBLY.......3890
4WD SWITCH.......3908
OUTSIDE REARVIEW MIRROR FOLDING AND.......3912
OVERHEAD CONSOLE SWITCH.......3920
POWER WINDOW MAIN SWITCH.......3928
PASSENGERS POWER WINDOW SWITCH.......3936
REAR DOOR POWER WINDOW SWITCH.......3938
DRIVERS POWER WINDOW MOTOR.......3941
REMOTE CONTROL SWITCHES ON STEERING WHEEL.......3949
MULTIFUNCTION SWITCH.......3954
CIGARETTE LIGHTER AND POWER OUTLET.......3963
HORN AND SIREN.......3966
RAIN SENSOR UNIT.......3969
PARKING AID SYSTEM.......3985
MULTI JACK STATION.......3996
AV SYSTEM.......4008
TUNER.......4017
DSP AMPLIFIER.......4020
DVD CHANGER.......4023
NAVIGATION UNIT.......4026
GPS ANTENNA.......4028
REMOVAL OF CENTER SPEAKER (DVD SYSTEM).......4030
REMOVAL OF WOOFER SPEAKER (DVD SYSTEM).......4031
DOOR SPEAKER (INCLUDING TWEETER SPEAKER).......4032
TV ANTENNA MODULE.......4034
RADIO ANTENNA MODULE.......4035
AUX TERMINAL (FOR VEHICLE WITH AV SYSTEM).......4036
LAMP.......4038
BULB SPECIFICATIONS.......4039
FRONT LAMPS.......4040
REAR LAMP.......4053
INTERIOR LAMPS.......4060
AWD (All Wheel Drive).......4069
AXLE.......4090
IOP (Integrated Oil Pan) Front Axle.......4091
INDEPENDENT SUSPENSION TYPE REAR AXLE.......4105
IWE LOCKING HUB SYSTEM.......4114
IRS SUSPENSION.......4130
SUSPENSION.......4131
IRS TYPE REAR SUSPENSION.......4132
TGS LEVER.......4144
TGS LEVER.......4145
AIR CONDITIONING SYSTEM.......4161
BODY.......4181
DIMENSIONS.......4182
CENTER CONSOLE.......4198
WIPER AND WASHER.......4201
FENDER PANEL.......4209
FRONT BUMPER ASSEMBLY.......4214
REAR BUMPER ASSEMBLY.......4218
HOOD ASSEMBLY.......4223
RADIATOR GRILLE.......4227
SEAT.......4228
SEAT BELT.......4231
ELECTRONIC WIRING DIAGRAM REXTON 2.......4233
SECTION 1.......4233
HOW TO READ ELECTRICAL WIRING DIAGRAM.......4234
CIRCUIT IDENTIFICATION SYMBOL.......4235
FUNCTION OF POWER SUPPLY LINE (NUMBER).......4236
WIRING HARNESS COLOR IDENTIFICATION.......4237
HOW TO CHECK TERMINAL NUMBER OF CONNECTOR.......4238
PART LOCATION ACCORDING TO PART NUMBER.......4239
ELECTRIC SYMBOLS.......4240
SECTION 2.......4241
WIRING HARNESS, COMPONENTS LOCATION.......4242
W/H ENGINE ROOM.......4282
W/H MAIN.......4284
W/H FLOOR.......4287
W/H ROOF.......4290
W/H DRIVER DOOR.......4291
W/H PASSENGER DOOR.......4292
W/H RR DOOR.......4293
W/H TAIL GATE.......4294
SECTION 3.......4295
ENGINE ROOM FUSE & RELAY BOX.......4296
I/P - FUSE BOX.......4299
I/P - RELAY BOX.......4301
SECTION 4.......4302
ENGINE ROOM FUSE & RELAY BOX CIRCUIT.......4303
I/P - FUSE BOX CIRCUIT.......4311
I/P - RELAY BOX CIRCUIT.......4318
SECTION 5.......4323
STARTING & CHARGING.......4326
PREHEATING CIRCUIT I - AQGS(D27DTP).......4328
PREHEATING CIRCUIT II (D27DT).......4330
ECU (ENGINE CONTROL UNIT - D27DTP).......4332
ECU (ENGINE CONTROL UNIT - D27DT).......4338
ECU (ENGINE CONTROL UNIT - GSL G32D).......4344
DIAGNOSIS CIRCUIT.......4350
TCU (5SPEED - A/T).......4352
TCCU.......4358
TOD.......4360
EAS.......4362
EPB.......4364
ABS/ESP.......4366
S.S.P.S.......4374
AIR-BAG (SIDE AIR-BAG).......4378
POWER SEAT - DRIVER (W/ MEMORY).......4380
POWER SEAT - PASSENGER.......4388
ELECTRIC OUTSIDE MIRROR & FOLDING (W/O MEMORY).......4390
FRT SEAT WARMER (W/ MEMORY).......4392
FRT SEAT WARMER (W/O MEMORY).......4394
RR SEAT WARMER.......4396
STICS.......4400
RR DPS WIPER & WASHER (W/ FLIP UP GLASS).......4430
RR STANDARD WIPER & WASHER.......4432
POWER WINDOW CIRCUIT.......4434
HORN.......4436
CIGAR LIGHTER & POWER OUTLET CIRCUIT.......4438
SUN ROOF CIRCUIT.......4440
HEAD LAMP & DRL (DAY TIME RUNNING LIGHT) UNIT CIRCUIT.......4442
HLLD (HEAD LAMP LEVELG DEVICE) CIRCUIT.......4444
TAIL LAMP CIRCUIT.......4446
TURN SIGNAL & HAZARD LAMP CIRCUIT.......4448
TRAILER LAMP CIRCUIT.......4450
FOG LAMP CIRCUIT.......4452
STOP & BACK-UP LAMP CIRCUIT.......4454
INTERIOR LAMP CIRCUIT.......4456
AUTO DIMMING ROOM MIRROR CIRCUIT.......4458
AUDIO.......4460
A/V SYSTEM.......4462
PARKING AID SYSTEM.......4472
PTC (POSITIVE TEMPERATURE COEFFICIENT) HEATER.......4476
FFH (FUEL FIRED HEATER).......4478
FATC (FULL AUTO TEMP. CONTROL) CIRCUIT.......4486
2002-2003 Rexton.......4496
INDEX OF VOL. 1.......4496
INDEX OF VOL. 2.......4502
0B - GENERAL INFORMATION.......4512
01 - ENGINE.......4526
1A - ENGINE GENERAL INFORMATION.......4526
1B1_1 - M162 ENGINE MECHANICAL.......4553
1B1_2 - M162 ENGINE MECHANICAL.......4583
1B1_3 - M162 ENGINE MECHANICAL.......4612
1B1_4 - M162 ENGINE MECHANICAL.......4640
1B2_1 - M161 ENGINE MECHANICAL.......4673
1B2_2 - M161 ENGINE MECHANICAL.......4712
1B2_3 - M161 ENGINE MECHANICAL.......4748
1B3_1 - DIESEL ENGINE MECHANICAL.......4781
1B3_2 - DIESEL ENGINE MECHANICAL.......4817
1B3_3 - DIESEL ENGINE MECHANICAL.......4837
1B3_4 - DIESEL ENGINE MECHANICAL.......4862
1B3_5 - DIESEL ENGINE MECHANICAL.......4888
1B3_6 - DIESEL ENGINE MECHANICAL.......4913
1D - ENGINE COOLING.......4946
1E - ENGINE ELECTRICAL.......4986
1F1 - M162 ENGINE CONTROLS.......5019
1F2_1 - M161 ENGINE CONTROLS.......5123
1F2_2 - M161 ENGINE CONTROLS.......5168
1F3_1 - DIESEL ENGINE CONTROLS.......5229
1F3_2 - DIESEL ENGINE CONTROLS.......5259
1G - ENGINE INTAKE & EXHAUST.......5300
02 - SUSPENSION.......5321
2C - FRONT SUSPENSION.......5321
2D - REAR SUSPENSION.......5341
2E - TIRES AND WHEELS.......5357
03 - DRIVELINE _AXLE.......5375
3A - FRONT AXLE.......5375
3C - PROPELLER SHAFT.......5405
3D - REAR AXLE.......5417
04 - BRAKES.......5440
4A - BRAKE SYSTEM.......5440
4B - FRONT BRAKE.......5465
4C - REAR BRAKE.......5479
4D - PARKING BRAKE.......5501
4E_1 - ABS SYSTEM AND TRACTION CONTROL SYSTEM.......5511
4E_2 - ABS SYSTEM AND TRACTION CONTROL SYSTEM.......5550
4E_3 - ABS SYSTEM AND TRACTION CONTROL SYSTEM.......5582
05 - TRANSMISSION (A-T & M-T).......5607
5A_1 - AUTOMATIC TRANSMISSION.......5607
5A_2 - AUTOMATIC TRANSMISSION.......5662
5A_3 - AUTOMATIC TRANSMISSION.......5726
5A_4 - AUTOMATIC TRANSMISSION.......5765
5B - MANUAL TRANSMISSION.......5825
5C - CLUTCH.......5874
5D1 - PART TIME - T_C.......5891
5D2_1 - TRANSFER CASE - TOD.......5934
5D2_2 - TRANSFER CASE - TOD.......5987
06 - STEERING.......6023
6A - POWER STEERING.......6023
6E - STEERING COLUMN.......6046
07 - HVAC (HEATING, VENTILATION & AIR CONDITIONING).......6062
07A - HEATING AND VENTILATION SYSTEM.......6062
07B - GENERAL HVAC (HEATING, VENTILATION AND AIR CONDITIONING) SYSTEM.......6080
07C - MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM.......6107
07D - AUTOMATIC CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM.......6116
08 - RESTRAINTS.......6150
8A - SEAT BELTS.......6150
8B - RESTRAINTS.......6159
09 - BODY & ACESSORIES.......6179
9A - GENERAL BODY.......6179
9B - BODY INTERIOR.......6188
9C - BODY EXTERIOR.......6209
9D - BODY ELECTRICAL.......6268
9E - BODYS MEASURING DIMENSION.......6355
2004.04 Edition.......6367
SERVICE MANUAL.......6367
WML_101.......6367
VEHICLE GENERAL.......6367
1. VEHICLE SPECIFICATIONS.......6369
2. VEHICLE IDENTIFICATION.......6374
3. GUIDELINES FOR SERVICE WORK SAFETY.......6376
4. LIFTING POINTS.......6383
5. TIGHTENING TORQUE OF STANDARD BOLTS.......6384
6. CLEANNESS.......6385
WML_201.......6391
ENGINE ASSEMBLY.......6391
GENERAL.......6391
1. SPECIFICATIONS.......6391
WML_202.......6393
FUEL SYSTEM.......6393
GENERAL.......6393
1. FUEL SYSTEM SPECIFICATION.......6393
CONFIGURATION AND PROCESS.......6395
1. FUEL SYSTEM.......6395
WML_204.......6400
EXHAUST SYSTEM.......6400
OVERVIEW AND OPERATION PROCESS.......6400
1. CRANKCASE VENTILATION SYSTEM.......6400
WML_205.......6404
LUBRICATION SYSTEM.......6404
OVERVIEW AND OPERATION PROCESS.......6404
1. OIL CIRCULATION.......6404
WML_206.......6405
ENGINE ELECTRICAL.......6405
OVERVIEW AND OPERATION PROCESS.......6405
1. IGNITION SYSTEM.......6405
WML_207.......6406
WML_208.......6407
ENGINE CONTROLS.......6407
GENERAL.......6407
1. ENGINE AND ECM PROBLEM CHECK REPORT.......6407
2. SPECIFICATIONS.......6409
OVERVIEW AND OPERATION PROCESS.......6411
1. SCHEMATIC AND ROUTING DIAGRAMS.......6411
WML_209.......6419
CRUISE CONTROL SYSTEM.......6419
OVERVIEW AND OPERATION PROCESS.......6419
1. CRUISE CONTROL SWITCH.......6419
2. CIRCUIT DIAGRAM.......6421
3. HOW TO OPERATE CRUISE CONTROL SWITCH.......6422
WML_301.......6427
ENGINE ASSEMBLY.......6427
GENERAL.......6427
1. SPECIFICATIONS.......6427
WML_302.......6429
FUEL SYSTEM.......6429
GENERAL.......6429
1. FUEL SYSTEM SPECIFICATION.......6429
OVERVIEW AND OPERATION PROCESS.......6431
1. FUEL SYSTEM.......6431
WML_303.......6433
WML_304.......6434
WML_305.......6435
LUBRICATION SYSTEM.......6435
GENERAL.......6435
1. ENGINE OIL SPECIFICATION.......6435
OVERVIEW AND OPERATION PROCESS.......6436
1. OIL CIRCULATION.......6436
WML_306.......6437
ENGINE ELECTRICAL.......6437
OVERVIEW AND OPERATIONPROCESS.......6437
1. IGNITION SYSTEM.......6437
WML_307.......6438
WML_308.......6439
ENGINE CONTROLS.......6439
GENERAL.......6439
1. SPECIFICATIONS.......6439
OVERVIEW AND OPERATION PROCESS.......6441
1. SCHEMATIC AND ROUTING DIAGRAMS.......6441
WML_309.......6448
CRUISE CONTROL SYSTEM.......6448
OVERVIEW AND OPERATION PROCESS.......6448
1. CRUISE CONTROL SWITCH.......6448
2. CIRCUIT DIAGRAM.......6450
3. HOW TO OPERATE CRUISE CONTROL SWITCH.......6451
WML_401.......6456
ENGINE GENERAL.......6456
GENERAL.......6458
1. STRUCTURE.......6458
OVERVIEW AND OPERATION PROCESS.......6461
1. ENGINE CONTROLS COMPONENTS.......6461
2. INTAKE SYSTEM COMPONENTS.......6464
3. EXHAUST SYSTEM COMPONENTS.......6466
4. LUBRICATION SYSTEM COMPONENTS.......6468
5. COOLING SYSTEM COMPONENTS.......6470
6. FUEL SYSTEM COMPONENTS.......6472
WML_402.......6474
ENGINE ASSEMBLY.......6474
GENERAL.......6474
1. D27DT ENGINE STRUCTURE.......6474
2. SPECIFICATIONS.......6478
3. ENGINE PERFORMANCE CURVE.......6479
4. TIGHTENING TORQUE.......6481
WML_403.......6484
ENGINE FUEL SYSTEM.......6484
GENERAL.......6484
1. CAUTIONS FOR DI ENGINE.......6484
OVERVIEW AND OPERATION PROCESS.......6487
1. FUEL INJECTION SYSTEM.......6487
WML_404.......6495
ENGINE INTAKE SYSTEM.......6495
OVERVIEW AND OPERATION PROCESS.......6495
1. COMPONENTS LOCATOR.......6495
2. AIR FLOWS.......6496
WML_405.......6497
ENGINE EXHAUST SYSTEM.......6497
OVERVIEW AND OPERATION PROCESS.......6497
1. COMPONENTS LOCATOR.......6497
2. EXHAUST GAS FLOWS.......6498
WML_406.......6499
ENGINE LUBRICATION SYSTEM.......6499
GENERAL.......6499
1. SPECIFICATIONS.......6499
OVERVIEW AND OPERATION PROCESS.......6500
1. COMPONENTS LOCATOR.......6500
2. LUBRICATION SYSTEM LAYOUT.......6501
3. LUBRICATION DIAGRAM.......6502
4. BLOW-BY GAS REDUCTION DEVICE.......6503
WML_407.......6504
ENGINE COOLING SYSTEM.......6504
GENERAL.......6504
1. SPECIFICATIONS.......6504
OVERVIEW AND OPEATION PROCESS.......6505
1. COMPONENTS LOCATOR.......6505
2. COOLING FLOWS.......6506
3. FUNCTION DESCRIPTION.......6507
WML_408.......6509
ENGINE ELECTRIC SYSTEM.......6509
GENERAL.......6509
1. SPECIFICATIONS.......6509
OVERVIEW AND OPERATION PROCESS.......6510
1. SENSORS IN ENGINE COMPARTMENT.......6510
2. PREHEATING SYSTEM COMPARTMENT.......6511
3. ELECTRIC DEVICES IN ENGINE COMPARTMENT.......6512
4. CIRCUIT DIAGRAM OF PREHEATING SYSTEM.......6513
5. CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR.......6514
WML_409.......6515
ENGINE CONTROL SYSTEM.......6515
OVERVIEW AND OPERATION PROCESS.......6515
1. ENGINE ECU AND OTHER COMPONENTS.......6515
2. FUEL PRESSURE CONTROL.......6518
3. FUEL INJECSTION CONTROL.......6519
4. FUEL FLOW CONTROL.......6521
5. INDIVIDUAL INJECTOR CALIBRATION (C2I).......6528
6. MINIMUM DRIVE PULSE (MDP) LEARNING.......6530
WML_410.......6531
CRUISE CONTROL SYSTEM.......6531
OVERVIEW AND OPERATION PROCESS.......6531
1. CRUISE CONTROL SWITCH.......6531
2. CIRCUIT DIAGRAM.......6533
3. HOW TO OPERATE CRUISE CONTROL SWITCH.......6534
WML_501.......6539
FUSES AND RELAYS.......6539
GENERAL.......6541
1. GENERAL INFORMATION.......6541
OVERVIEW AND OPERATION PROCESS.......6544
1. COMPARTMENT.......6544
2. ELECTRIC COMPONENTS LOCATOR.......6550
WML_502.......6551
STICS.......6551
GENERAL.......6551
1. SPECIFICATIONS.......6551
2. RATED LOAD.......6551
3. CHATTERING OF INPUT SIGNALS.......6552
OVERVIEW AND OPERATION PROCESS.......6553
1. REMOTE KEYLESS ENTRY SYSTEM (REKES).......6553
2. REKES + STICS (RKSTICS) COMPONENTS LOCATOR.......6555
3. REKES + STICS (RKSTICS) OPERATING PROCESS.......6556
4. IMMOBILIZER (FOR D27DT ENGINE EQUIPPED VEHICLE).......6582
5. RK-STICS CIRCUIT DIAGRAM.......6583
6. IMMOBILIZER CIRCUIT DIAGRAM.......6588
WML_503.......6591
CLUSTER.......6591
OVERVIE AND OPERATION PROCESS.......6591
1. APPEARANCE AND CIRCUIT DIAGRAM.......6591
2. METERS/INDICATORS/WARNING LIGHTS.......6600
3. MULTI-METER OPERATING PROCESS.......6613
WML_504.......6618
SWITCH.......6618
OVERVIEW AND OPERATION PROCESS.......6618
1. COMPONENTS LOCATOR.......6618
WML_505.......6621
LAMP.......6621
GENERAL.......6621
1. SPECIFICATIONS.......6621
OVERVIEW AND OPERATION PROCESS.......6622
1. LOCATIONS.......6622
WML_506.......6623
WIPER & WASHER.......6623
OVERVIEW AND OPERATION PROCESS.......6623
1. COMPONENTS LOCATOR.......6623
WML_507.......6624
RAIN SENSOR.......6624
OVERVIEW AND OPERATION PROCESS.......6624
1. OPERATION PROCESS.......6624
2. OPERATION MODE.......6625
3. OPERATIONAL CHARACTERISTICS OF RAIN SENSOR.......6627
4. REAR WIPER CONTROL SYSTEM.......6629
5. AUTO LIGHT SYSTEM.......6633
WML_601.......6635
BTRA 4 AUTO TRANSMISSION.......6635
GENERAL.......6635
1. SPECIFICATIONS.......6635
2. FASTENER TIGHTENING SPECIFICATIONS.......6639
OVERVIEW AND OPERATION PROCESS.......6640
1. DESCRIPTION AND OPERATION.......6640
2. OPERATORS INTERFACES.......6641
3. CONTROL SYSTEMS.......6643
4. ELECTRONIC CONTROL SYSTEM.......6643
5. COMMUNICATION SYSTEMS.......6653
6. HYDRAULIC CONTROL SYSTEM.......6654
7. POWER TRAIN SYSTEM.......6664
8. POWER FLOWS.......6670
9. SCHEMATIC AND ROUTING DIAGRAMS.......6691
WML_602.......6696
DC-5 SPEED AUTOMATIC TRANSMISSION.......6696
GENERAL.......6696
1. SPECIFICATIONS.......6696
OVERVIEW AND OPERATION PROCESS.......6698
1. OVERVIEW.......6698
2. CHARACTERISTICS.......6699
3. STRUCTURE.......6700
4. PERFORMANCE CURVE AND GENERAL CHARACTERISTICS.......6701
5. POWER FLOW.......6703
6. CIRCUIT DIAGRAM.......6711
WML_603.......6713
MTMANUAL TRANSMISSION.......6713
GENERAL.......6713
1. SPECIFICATIONS.......6713
OVERVIEW AND OPERATION PROCESS.......6714
1. OVERVIEW.......6714
2. SYSTEM COMPONENTS.......6715
3. SHIFTING MECHANISM.......6727
4. CIRCUIT DIAGRAM (BACKUP LAMP).......6735
WML_604.......6736
CLUTCH.......6736
GENERAL.......6736
1. SPECIFICATIONS.......6736
2. TIGHTENING TORQUE.......6736
OVERVIEW AND OPERATION PROCESS.......6737
1. OVERVIEW.......6737
2. COMPONENTS AND LOCATIONS.......6738
WML_605.......6741
PART TIME TRNASFER CASE.......6741
GENERAL.......6741
1. SPECIFICATIONS.......6741
OVERVIEW AND OPERATION PROCESS.......6742
1. OVERVIEW.......6742
2. OPERATION.......6742
3. SECTIONAL DIAGRAM.......6743
4. SYSTEM LAYOUT.......6745
5. SYSTEM OPERATION.......6746
6. POWER FLOW.......6752
7. CIRCUIT DIAGRAM (DI & 5-SPEED A/T).......6756
WML_606.......6757
TORQUE ON DEMAND(TOD).......6757
GENERAL.......6757
1. SPECIFICATIONS.......6757
OVERVIEW AND OPERATION PROCESS.......6758
1. OVERVIEW.......6758
2. POWER FLOW.......6761
3. CIRCUIT DIAGRAM.......6764
WML_607.......6765
AXLE.......6765
GENERAL.......6765
1. SPECIFICATIONS.......6765
WML_608.......6766
PROPELLER SHAFT.......6766
GENERAL.......6766
1. SPECIFICATION.......6766
OVERVIEW AND OPERATION PROCESS.......6767
1. OVERVIEW.......6767
2. COMPONENT LOCATOR.......6768
