Ssangyong Actyon Sports - Workshop Manual

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SSANGYONG ACTYON SPORTS - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING

- English Workshop Manual and Wiring Diagram to vehicles Ssangyong Actyon Sports.

CONTENTS:

WORKSHOP MANUAL

GENERAL 
- GENERAL INFORMATION 
- 1. Dimensions 
- 2. Specifications 
- 3. Vehicle Identification 
- 4. Maintenance Interval 
- 5. Recommended Fluids And Lubricants 
- 6. Jack-Up Points 
- 7. Pin Arrangement Of Diagnostic Connector 
- 8. Electric Components And Layout 
- 9. Standard Bolts Specifications 
GLOSSARY 
- OVERVIEW AND OPERATING PROCESS 
- 1. Glossary 
ENGINE GENERAL 
- GENERAL INFORMATION 
- 1. Engine Layout 
- 2. Major Components 
- 3. Engine Compartment Layout 
- 4. Caution When Servicing The Engine 
- 5. Standard Bolts Specifications 
- 6. Tightening Torque 
- 7. Coding And Initialization 
- SPECIAL SERVICE TOOLS 
- 1. Special Service Tools 
- 2. Normal Equipments 
ENGINE ASSEMBLY 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Tightening Torque 
- 3. Check And Inspection 
- 4. Guidelines On Engine Service 
- OVERVIEW AND OPERATING PROCESS 
- 1. Belt Layout 
- 2. Vacuum Pump 
- 3. Engine Mounting 
- 4. Intake/Exhaust Manifold 
- 5. Cylinder Head Cover And Oil Separator 
- 6. Cylinder Head 
- 7. Chain And Gear Drive System 
- 8. Oil Pan 
- 9. Dual Mass Flywheel (Dmf) & Drive Plate 
- 10. Piston/Crankshaft/Cylinder Block 
- CONFIGURATION 
- 1115-00 Engine Assembly (D20dtr) 
- 1120-01 Short Block (D20dtr) 
- 1127-00 Cylinder Block (D20dtr) 
- 1130-00 Crankshaft And Flywheel 
- 1214-00 Cylinder Head And Gasket Kit(D20dtr) 
- 1225-00 Cylinder Head Cover And Camshaft(D20dtr) 
- 1315-00 Chain Drive (D20dtr) 
- 1336-00timing Case (D20dtr) 
- 1350-01 Belt 
- 1610-00 Vacuum Pump (D20dtr) 
- 1990-00 Engine Mounting 
- REMOVAL AND INSTALLATION 
- 1336-00 Belt 
- 1610-01 Vacuum Pump Assembly 
- 1130-12 Isolation Damper Assembly 
- 1990-00 Engine Mounting Insulator 
- 1225-01 Cylinder Head Cover 
- 1214-01 Cylinder Head Assembly 
- 1130-13 Dual Mass Flywheel (Dmf) Assembly 
- 1115-01 Engine Assembly 
- 1127-01 Engine Overhaul 
FUEL SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Maintenance And Inspection 
- 3. Cautions For Di Engine 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. System Layout And Operation 
- CONFIGURATION 
- 2210-01 Fuel Tank Assembly 
- 2210-06 Fuel Sender Assembly 
- 1882-15 Fuel Pipe Assembly 
- 1882-23 Fuel Rail Assembly (Common Rail) 
- 1882-01 High Pressure Pump Assembly 
- 2231-01 Fuel Filter Assembly

- REMOVAL AND INSTALLATION 
- 2210-01 Fuel Tank Assembly 
- 2210-06 Fuel Sender Assembly 
- 1882-01 High Pressure Pump Assembly 
- 1882-23 Fuel Rail Assembly 
- 2231-01 Fuel Filter Assembly 
- 2231-13 Fuel Filter Element 
INTAKE SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Inspection 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Component 
- 3. Input/Output Of Intake System 
- 4. Operating Process 
- CONFIGURATION AND FUNCTION 
- 2313-01 Configuration And Function 
- 2330-01 Intercooler 
- 1719-40 Intake Manifold 
- REMOVAL AND INSTALLATION 
- 2313-04 Air Cleaner Element 
- 2330-01 Intercooler 
- 1719-01 Intake Manifold Assembly 
ENGINE EXHAUST SYSTEM 
- GENERAL INFORMATION 
- 1. Troubleshooting 
- 2. Cautions 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Layout 
- 3. Operating Process 
- CONFIGURATION AND FUNCTION 
- 1729-01 Exhaust Manifold Assembly 
- 2412-00 Exhaust Pipe Assembly 
- REMOVAL AND INSTALLATION 
- 1729-01 Exhaust Manifold 
- 2412-01 Exhaust Front Pipe Assembly 
- 2412-03 Muffler Assembly 
- 2412-10 Exhaust Tail Pipe Assembly 
TURBOCHARGER 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Inspection 
- 3. Troubleshooting 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description Of E-Vgt (Electric-Variable Geometry Turbine) 
- 2. Components 
- 3. Input/Output Devices 
- 4. Operating Principles 
- CONFIGURATION AND FUNCTION 
- 1914-01 Turbocharger Assembly 
- REMOVAL AND INSTALLATION 
- 1914-01 Turbocharger Assembly 
LUBRICATION SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Maintenance 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description 
- 2. Functions Of Lubrication 
- CONFIGURATION AND FUNCTION 
- 9210-01 Engine Oil 
- 1543-01 Oil Filter Module 
- 1543-13 Oil Cooler Assembly 
- 1543-09 Engine Oil Filter Element 
- 1533-30 Oil Pressure Switch 
- 1533-01 Oil Pump Assembly 
- 1533-08 Oil Pan Assembly 
- 1127-22 Oil Injection Nozzle 
- REMOVAL AND INSTALLATION 
- 1543-09 Engine Oil Filter Element And Engine Oil Change 
- 1543-01 Oil Filter And Cooler Module 
- 1543-13 Oil Cooler Assembly 
- 1533-30 Oil Pressure Switch 
- 1533-08 Oil Pan Assembly 
COOLING SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Inspection 
- 3. Cautions 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description 
- CONFIGURATION AND FUNCTION 
- 2112-01 Radiator Assembly 
- 2112-02 Pwm Electric Fan 
- 1520-11 Thermostat Assembly 
- 1520-01 Water Pump Assembly 
- 2130-07 Reservoir Assembly 
- 9210-05 Replenishment 
- 9210-05 Air Bleeding 
- REMOVAL AND INSTALLATION 
- 2112-01 Radiator Assembly 
- 2112-02 Pwm Electric Fan 
- 1520-11 Thermostat Assembly 
- 1520-01 Water Pump Assembly 
- 1520-21 Coolant Outlet Port 
CHARGING SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Inspection 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description 
- 2. Operating Process 
- 3. Circuit Diagram 
- CONFIGURATION AND FUNCTION 
- 1451-01 Alternator Assembly

- 2610-01 Battery 
- REMOVAL AND INSTALLATION 
- 1543-09 Alternator Assembly And Pulley 
- 2610-01 Battery 
- 2610-05 Battery Positive Cable Assembly 
D20DTR PRE-HEATING 
- GENERAL INFORMATION 
- 1. Specification 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. System Operation 
- CONFIGURATION AND FUNCTION 
- 1413-01 Glow Plug 
- 1413-18 Glow Plug Control Unit 
- REMOVAL AND INSTALLATION 
- 1413-01 Glow Plug 
- 1413-18 Glow Plug Control Unit 
STARTING SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Troubleshooting 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description 
- 2. Operating Process 
- CONFIGURATION AND FUNCTION 
- 1461-01 Start Motor 
- REMOVAL AND INSTALLATION 
- 1461-01 Start Motor 
CRUISE CONTROL SYSTEM 
- OVERVIEW AND OPERATION PROCESS 
- 1. Cruise Control Switch 
- 2. How To Operate Cruise Control Switch 
- REMOVAL AND INSTALLATION 
- 8510-23 Cruise Control Switch 
E-EGR SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- OVERVIEW AND OPERATING PROCESS 
- 1. System Description 
- 2. Operating Process 
- CONFIGURATION AND FUNCTION 
- 1793-12 E-Egr Cooler Assembly And Bypass Valve 
- REMOVAL AND INSTALLATION 
- 1793-12 E-Egr Cooler Assembly 
CDPF SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Cautions 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Component 
- 3. Input/Output Devices 
- 4. Post-Injection And Air Mass Control 
- 5. Operating Process 
- 6. Electric Circuit Diagram 
- CONFIGURATION AND FUNCTION 
- 2412-00 Cdpf 
- REMOVAL ANC INSTALLATION 
- 2412-02 Cdpf Assembly 
ENGINE CONTROL 
- GENERAL INFORMATION 
- 1. Engine Data List 
- OVERVIEW AND OPERATINF PROCESS 
- 1. Major Components 
- 2. System Operation 
- CONFIGURATION AND FUNCTION 
- 1491-01 Ecu 
- 1882-09 Injector (C3i) 
- 2330-08 Hfm (Hot Film Air Mass Sensor) 
- 1432-01 T-Map (Temperature-Manifold Air Pressure) Sensor 
- 1432-07 Coolant Temperature Sensor 
- 1882-23 Fuel Rail Pressure Sensor 
- 1882-01 Fuel Temperature Sensor 
- 2231-01 Water Sensor In Fuel Filter 
- 1432-08 Wide Band Oxygen Sensor 
- 1432-04 Differential Pressure Sensor 
- 1432-17 Egt (Exhaust Gas Temperature) Sensor 
- 1793-01 E-Egr (Electric-Exhaust Gas Recirculation) Valve 
- 1719-16 Electronic Throttle Body 
- 1432-14 Egr Bypass Solenoid Valve 
- 1719-02 Variable Swirl Actuator 
- 1914-01 E-Vgt Control Actuator 
- 1432-03 Camshaft Position Sensor 
- 1127-35 Crankshaft Position Sensor 
- 2010-01 Accelerator Pedal Position Sensor 
- 1882-21 Inlet Metering Valve (Imv) 
- 1432-05 Knock Sensor 
- REMOVAL AND INSTALLATION 
- 1491-01 Ecu (D20dtr) 
- 1882-09 Injector 
- 2330-08 Hfm (Hot Film Air-Mass) Sensor 
- 1432-01 T-Map (Temperature-Manifold Air Pressure) Sensor 
- 1432-07 Coolant Temperature Sensor 
- 1432-08 Wide Band Oxygen Sensor 
- 1432-04 Differential Pressure Sensor 
- 1432-17 Egt (Exhaust Gas Temperature) Sensor 
- 1793-01 E-Egr (Electric-Exhaust Gas Recirculation) Valve Assembly 
- 1719-16 Electric Throttle Body 
- 1432-14 E-Egr Bypass Solenoid Valve 
- 1729-02 Variable Swirl Actuator 
- 1432-03 Camshaft Position Sensor 
- 1127-35 Crankshaft Position Sensor 
- 2010-01 Accelerator Pedal Position Module 
- 1882-01 Imv (Inlet Metering Valve) 
- 1432-05 Knock Sensor 
ENGINE ASSEMBLY 
- GENERAL 
- 1. Description And Operation 
- 2. G23d Engine Assembly 
- 3. G23d Engine Structure 
- 4. Diagnostic Information And Procedure 
- 5. General Diagnosis 
- 6. Specifications 
- CONFIGURATION AND FUNCTIONS 
- 1113-01 Crankcase Ventilation System 
- 1532-00 Oil Circulation 
- REMOVAL AND INSTALLATION 
- 1113-01 Engine Assembly 
- 1452-01 Alternator 
- 1113-01 Engine Mount 
- 1130-07 Poly V-Belt 
- 1130-07 Poly V-Belt Inspection 
- 1332-18 Tensioning Device 
- 1332-18 Tensioning Device Shock Absorber 
- 1221-01 Cylinder Head Cover 
- 1221-02 Cylinder Head Front Cover 
- 1221-02 Cylinder Head 
- 1332-01 Timing Gear Case Cover 
- 1124-17 Crankshaft Sealing Rear Cover 
- 1130-07 Belt Pulley And Vibration Damper 
- 1131-02 Crankshaft Front Radial Seal 
- 1124-16 Crankshaft Rear Radial Seal 
- 1130-01 Crankshaft 
- 1130-11 Arrangement Of The Thrust Bearing And The Main Bearing 
- 1130-09 Flywheel/ Drive Plate 
- 1311-31 Camshaft Adjuster 
- 1221-21 Camshaft 
- 1221-21 Inspection And Adjustment Of Camshaft Timing Position 
- 1211-32 Valve Spring 
- 1211-30 Valve Stem Seal 
- 1532-19 Chain Tensioner 
- 1311-01 Timing Chain 
- 1311-04 Tensioning Rail 
- 1311-09 Cylinder Head Guide Rail 
- 1311-05 Crankcase Guide Rail 
- 1130-04 Crankshaft Sprocket 
- 1130-20 Piston 
- 1130-13 Connecting Rod 
- 1130-21 Piston Ring 
- 1532-24 Oil Pan 
- 1532-00 Engine Oil And Oil Filter Element 
- 1532-00 Oil Pump 
- 1532-00 Oil Pressure Relief Valv 
- 1532-00 Oil Non-Return Valve 
- 1532-00 Oil Dipstick Guide Tube 
- 1311-31 Repair Of Core Plugs In Crankcase 
- 1124-01 Cylinder Bore 
- 1311-31 Crankcase Mating Surface 
- 1211-02 Cylinder Head Mating Surface 
ENGINE FUEL SYSTEM 
- GENERAL 
- 1. Fuel System Specification 
- OVERVIEW AND OPERATIONPROCESS 
- 1. Fuel System 
- CONFIGURATION AND FUNCTIONS 
- 2211-06 Fuel Pump 
- 2241-20 Fuel Injector 
- 1623-06 Purge Control Valve 
- 2241-01 Fuel Rail 
- 2241-08 Fuel Pressure Regulator 
- REMOVAL AND INSTALLION 
- 2241-08 Discharging The Pressure In Fuel System 
- 2210-06fuel Pump Assembly 
- 2221-01 Fuel Filter 
- 2210-01 Fuel Tank Assembly 
- 2241-08 Fuel Pressure Regulator 
- 2241-20 Fuel Rail And Injectors 
- 1623-06 Purge Control Valve 
- 2221-09 Canister 
ENGINE INTAKE SYSTEM 
- GENERAL 
- 1. Specifications 
- CONFIGURATION AND FUNCTIONS 
- 2312-01 Air Cleaner And Intake Air Duct 
- REMOVAL AND INSTALLATION 
- 2312-01 Air Cleaner And Intake Air Duct 
- 1713-03 Intake Manifold 
ENGINE EXHAUST SYSTEM 
- GENERAL 
- 1. Specification 
- OVERVIEW AND OPERATION PROCESS 
- 1. Description And Operation 
- REMOVAL AND INSTALLATION 
- 2420-01 Exhaust Line 
LUBRICATION SYSTEM 
- OVERVIEW AND OPERATION PROCESS 
- 1. Oil Circulation 
- CONFIGURATION AND FUNCTIONS 
- 1531-24 Oil Pan 
- REMOVAL AND INSTALLION 
- 1541-03 Engine Oil And Oil Filter Element 
- 1531-01 Oil Pump 
- 1531-07 Oil Pressure Relief Valve 
- 1311-00 Oil Non-Return Valve 
- 1531-31 Oil Dipstick Guide Tube 
ENGINE COOLING SYSTEM 
- GENERAL 
- 1. General Specifications 
- 2. Fastener Tightening Specifications 
- OVERVIEW AND OPERATION PROCESS 
- 1. Component Locator 
- 2. Description And Operation 
- 3. Pwm (Pulse Width Modulation) Electric Fan Operation 
- REMOVAL AND INSTALLATION 
- 2110-01 Dtc For Pwm Electric Fan 
- 2110-01 Diagnostic Information And Procedure 
- 2110-01 Repair Instructions On-Vehicle Service 
- 1522-18 Water Pump 
- 1522-10 Thermostat And Thermostat Housing Assembly 
- 2110-00 Pwm Controller Unit 
- 2110-07 Pwm Electric Fan And Shroud Assembly 
ENGINE ELECTRIC DEVICES 
- GENERAL 
- 1. Diagnostic Information And Procedure 
- OVERVIEW AND OPERATION PROCESS 
- 1. Description And Operation 
- REMOVAL AND INSTALLATION 
- 1452-01 Generator Repair Instructions 
- 1462-01 Starter Repair Instructions 
- 2610-01 Battery Repair Instructions 
- 1440-01 Spark Plug And Ignition Coil Repair Instructions 
CRUISE CONTROL SYSTEM 
- OVERVIEW AND OPERATION PROCESS 
- 1. Cruise Control Switch 
- 2. How To Operate Cruise Control Switch 
- REMOVAL AND INSTALLATION 
- 8510-23 Cruise Control Switch 
ENGINE CONTROL SYSTEM 
- GENERAL 
- 1. Engine Data Display Table 
- 2. Fastener Tightening Specifications 
- CONFIGURATION AND FUNCTIONS 
- 1490-01 Engine Control Module 
- 1521-26 Engine Coolant Temperature Sensor 
- 1311-25 Camshaft Actuator 
- 2010-01 Accelerator Pedal Module 
- 1712-06 Knock Sensor 
- 1430-01 Crankshaft Position Sensor 
- 1311-25 Camshaft Position Sensor 
- 8510-23 Cruise Control Switch 
- REMOVAL AND INSTALLATION 
- 1490-01 Engine Control Module 
- 1712-06 Knock Sensor 
- 1430-01 Crankshaft Position Sensor 
- 1311-25 Camshaft Position Sensor 
- 1490-01 Strategy-Based Diagnostics 
- 1491-01 System Diagnosis 
ELECTRIC GENERAL 
- GENERAL 
- 1. Locations Of Interior Units And Sensors 
- 2. Location And Compartment Of Interior Switches 
- 3. Switches, Units And Sensors In Engine Compartment 
- 4. Electric Components And Layout 
- 5. Diagnostic Connector 
FUSE AND RELAY 
- GENERAL INFORMATION 
- 1. Cautions When Working On Electrical Units 
- 2. General Information 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Fuse & Relay Mounting Location 
- CONFIGURATION AND FUNCTIONS 
- 8410-02 Engine Room Fuse / Relay Box 
- 8410-02 Engine Room Fuse / Relay Box Circuit 
- 8410-04 Capacity And Name Of Interior Fuse And Relay 
- 8410-04 I/P - Lh Fuse / Relay Box Circuit 
- 8410-06 Interior Fuse And Relay Box On The Passenger Side 
- 8410-06 I/P - Rh Fuse / Relay Box Circuit 
- 8410-08 Operating Process Of Icm Box 
- 8410-08 Icm Relay Box Circuit 
- REMOVAL AND INSTALLATION 
- 8410-08 Icm Box 
STICS 
- GENERAL 
- 1. Overview 
- 2. Specifications 
- OVERVIEW AND OPERATION PROCESS 
- 1. Overview 
- 2. Functions And Specifications 
- 3. Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 8710-01 Rekes Key Coding 
- 8710-01 Diagnosis Trouble Code And Help Tips 
- 8710-01 Stics 
IMMOBILIZER SYSTEM 
- OVERVIEW AND OPERATION PROCESS 
- 1. Overview 
- 2. Basic Functions Of Immobilizer Key(Rekes Function) 
- 3. Other Functions In System 
- 4. Rekes Operation Logic 
- 5. Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 7010-06 Replacing Electric Head Of Key 
- 7010-06 Rekes Key Coding 
- 7010-06 Immobilizer Unit 
CLUSTER 
- GENERAL 
- 1. Specifications 
- OVERVIEW AND OPERATING PROCESS 
- 1. Descriptions Of Indicator Display 
- 2. Configuration 
- 3. Warning Lights And Indicators 
- 4. Self-Diagnosis Check 
- 5. Buzzer Output Spec 
- 6. Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 8210-01 Cluster 
LAMP 
- GENERAL 
- 1. Specifications 
- CONFIGURATION AND FUNCTIONS 
- 8310-01 Front Lamps 
- 8320-01 Rear Lamps 
- 8610-01 Interior Lamps 
- REMOVAL AND INSTALLATION 
- 8310-01 Headlamps 
- 8310-10 Fog Lamp / Drl 
- 8310-13 Side Repeater 
- 8320-01 Rear Combination Lamp 
- 8320-12 License Plate Lamp 
- 8320-16 High Moounted Stop Lamp 
- 8320-19 Rear Fog Lamp 
- 8610-01 Interior Lamps 
- 8310-01 How To Adjust Angle Of Headlamp And Fog Lamp 
SWITCH 
- GENERAL 
- 1. Switch Arrangement 
- CONFIGURATION AND FUNCTIONS 
- 8510-31 Center Fascia & Bezel Switch Assembly 
- 8510-52 Outside Rearview Mirror Switch Bezel Assembly 
- 7770-20 Interior Lamp Switch 
- 8510-05 Main Power Window Switch 
- 8510-01 Audio Remote Control Switch On Steering Wheel 
- 8510-21 Multifunction Switch1 
- 8510-13 Tail Gate Open Switch 
- 8610-08 Digital Clock 
- 8610-06 Horn (Including Theft Deterrent Horn) 
- REMOVAL AND INSTALLATION 
- 8510-31 Hazard & Switch Assembly 
- 8510-52 Outside Rearview Mirror Switch Bezel Assembly 
- 8510-52 Outside Rearview Mirror Folding Unit 
- 7770-20 Overhead Console Switch 
- 8510-05 Main Power Window Switch 
- 8510-01 Audio Remote Control Switch 
- 8510-21 Multifunction Switch 
- 8510-13 Tailgate Open Switch 
- 7632-16 Cigarette Lighter 
- 7610-54 Power Outlet 
- 7610-54 Rear Power Outlet 
- 8610-08 Digital Clock 
- 8610-06 Horn (Including Theft Deterrent Horn) 
WIPER & WASHER 
- OVERVIEW AND OPERATION PROCESS 
- 1. System Layout And Function 
- 2. Configuration (Including Rain Sensor) 
- 3. Wiper & Washer Related Function And Specification 
- 4. Wiper And Washer System Related Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 7810-01 How To Correct Angle Of Front Wiper Arm 
- 7810-01 Front Wiper Assembly 
- 7830-01 Rear Wiper Assembly 
- 7820-01 Reservoir Tank 
- 7820-22 Nozzle And Hose 
RAIN SENSOR 
- OVERVIEW AND OPERATION PROCESS 
- 1. System Layout And Overview 
- 2. Rain Sensing Operation 
- 3. Rain Sensor Related Circuit 
- 4. Functions And Specifications Of Rain Sensing Wiper 
- 5. Operation Mode Of Rain Sensing Wiper System 
- REMOVAL AND INSTALLATION 
- 8610-09 Functions And Checks Of Rain Sensor 
- 8610-09 Diagnosis Procedures 
- 8610-09 Rain Sensor 
PAS 
- GENERAL 
- 1. Component Specifications 
- 2. Cautions On Parking Aid System 
- OVERVIEW AND OPERATION PROCESS 
- 1. System Overview 
- 2. Alarm Interval 
- 3. Troubleshooting Of Sensor 
- 4. Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 87902-03 Parking Aid Sensor 
AUDIO SYSTEM 
- OVERVIEW AND INSTALLATION 
- 1. Audio System Overview 
- CONFIGURATION AND FUNCTIONS 
- 4610-00 Audio Control Switch On Steering Wheel 
- 8610-26 Radio Antenna 
- 8910-07 Usb/Aux Module 
- REMOVAL AND INSTALLATION 
- 4610-01 Audio Control Switch 
- 8930-01 Audio Assembly 
- 8610-22 Front Door Speaker And Rear Door Speaker 
- 8620-22 Door Tweeter Speaker 
- 8910-07 Usb/Aux Module 
- 8610-26 Micro-Pole Antenna 
MB 5 AUTO TRANSMISSION 
- GENERAL INFORMATION 
- 1. Specifications 
- 2. Tightening Torque 
- OVERVIEW AND OPERATION PROCESS 
- 1. Overview 
- 2. Power Flow 
- 3. Circuit Diagram 
- CONFIGURATION AND FUNCTION 
- 3650-01 Mb 5-Speed Assembly 
- 3660-01 Valve Body 
- 3721-01 Tgs Lever 
- 3110-01 Tcu (Transmission Control Unit) 
- REMOVAL AND INSTALLATION 
- 3650-01 Oil Check And Specification 
- 3110-01 Tcu 
- 3650-01 Transmission Assembly (Mb 5-Speed) 
- 3721-01 Tgs Lever 
- 3650-01 Disassembly And Reassembly (Dc 5-Speed A/T) 
- 3650-01 Valve Body Assembly 
- 3660-01 Valve Body Overhaul 
- 3110-01 Dtc (Diagnosis Trouble Code) Of Mb5at 
- 3721-01 Dtc For Selector Lever 
DSI 6 A/T 
- GENERAL 
- 1. General Information 
- 2. Features And Specifications 
- 3. Tightening Torque 
- 4. Shift Pattern Diagram 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Features 
- 3. Mode Descriptions

- 4. Limp Home Mode 
- 5. Electronic Control System 
- 6. Power Flow 
- CONFIGURATION AND FUNCTION 
- 3722-01 Tgs Lever 
- 3680-01 Dsi M78 6-Speed A/T Assembly 
- 3683-01 Valve Body 
- 3110-01 Tcu 
- 3682-18 Inhibitor Switch 
- REMOVAL AND INSTALLATION 
- 9210-02 Fluid Level Inspection 
- 3680-01 A/T Assembly 
- 3683-01 Valve Body Assembly 
- 3110-01 Tcu 
- 3722-01 Tgs Lever 
- 3682-18 Inhibitor Switch 
- 3110-01 Trouble Diagnosis Code 
- DIAGNOSIS AND TESTING 
- 1. Wiring Diagram 
- 2. Wire Harness Connector Chart 
- 3. Unit Connector Description 
- TROUBLE CODE DIAGNOSIS 
- 1. Diagnostic Trouble Code List 
- 2. System Diagnosis 
MANUAL TRANSMISSION (5 M/T) 
- GENERAL 
- 1. Overview And Characteristics Of Manualtransmission 
- 2. Specifications And Tightening Torque Ofmanual Transmission 
- OVERVIEW AND OPERATION PROCESS 
- 1. Manual Transmission System 
- CONFIGURATION AND FUNCTIONS 
- 3170-01 Manual Transmission Location 
- 3170-01 Manual Transmission System Components 
- 3170-01 Shifting Mechanism 
- REMOVAL AND INSTALLATION 
- 3170-01 Diagnostic Information And Procedure 
- 3170-01 Oil Check/Change Of Manual Transmission 
- 3170-01 Manual Transmission 
- 3170-01 Manual Transmission Overhaul 
- 3660-01 Transmission Adapter 
- 3170-01 Shim Adjustment 
MANUAL TRANSMISSION (6 M/T) 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Special Service Tools 
- 3. Tightening Torque 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Power Flow 
- 3. Shifting Mechanism 
- CONFIGURATION AND FUNCTION 
- 3170-01 Mounting Location 
- 3170-01 Manual Transmission Assembly 
- 3170-01 Gear Arrangement 
- 3116-25 Neutral Switch 
- 3116-29 Backup Lamp Switch 
- REMOVAL AND INSTALLATION 
- 3170-01 Troubleshooting 
- 3170-01 Oil Check And Change 
- 3170-01 Manual Transmission Assembly 
- 3170-01 Overhaul Of Manual Transmission 
TGS LEVER 
- OVERVIEW AND OPERATION PROCESS 
- 1. Introduction 
- 2. Functions Of The Selector Lever 
- 3. Mode Switch 
- 4. Parking Lock System 
- CONFIGURATION AND FUNCTIONS 
- 3722-01 Selector Lever Control Unit 
- REMOVAL AND INSTALLATION 
- 3722-01 Shift Rod Postion Adjustment 
- 3722-01 Tgs Lever 
CLUTCH 
- GENERAL 
- 1. Clutch Specifications 
- 2. Tightening Torque 
- OVERVIEW AND OPERATION PROCESS 
- 1. Function And Overview 
- CONFIGURATION AND FUNCTION 
- 3020-01 Clutch Master Cylinder 
- 3020-04 Clutch Release Chamber 
- 3030-04 Clutch Assembly 
- 3030-01 Clutch Pedal 
- REMOVAL AND INSTALLATION 
- 3010-01 Clutch Trouble Diagnosis 
- 3010-01 Clutch Inspection And Maintenance 
- 3020-01 Clutch Air Bleeding 
- 3010-01 Clutch Assembly 
- 3010-01 Clutch Replacement 
- 3171-14 Concentric Slave Cylinder 
- 3020-01 Clutch Master Cylinder 
- 3030-01 Clutch Pedal 
- 3020-04 Clutch Chamber 
PROPELLER SHAFT 
- GENERAL INFORMATION 
- 1. Specification 
- 2. Tightening Torque 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- CONFIGURATION AND FUNCTION 
- 1. Configuration 
- 2. Component 
- REMOVAL AND INSTALLATION 
- 3310-00 Trouble Diagnosis 
- 3310-01 Front Propeller Shaft (4wd) 
- 3310-02 Rear Propeller Shaft 
AXLE 
- GENERAL 
- 1. Specifications Of Axle 
- OVERVIEW AND OPERATION PROCESS 
- 1. Overview Of Axle 
- CONFIGURATION AND FUNCTION 
- 4120-01 Front Axle 
- 4210-01 5-Link Type Rear Axle 
- REMOVAL AND INSTALLATION 
- 4120-01 Trouble Diagnosis 
- 4120-01 Inspection Of Ring Gear Tooth Contact Pattern 
- 4120-01 Front Axle Assembly 
- 4120-01 Axle Shaft 
- 4120-01 Axle Housing 
- 4220-01 Rear Axle Shaft(Disc Brake Type) 
- 4220-01 Rear Axle Housing 
TRANSFER CASE 
- GENERAL 
- 1. Overview 
- 2. Specifications 
- OVERVIEW AND OPERATION PROCESS 
- 1. Structure 
- 2. System Layout And Operation 
- 3. Locking Hub System 
- 4. Power Flow 
- CONFIGURATION AND FUNCTION 
- 3240-01 Transfer Case 
- 4116-01 Components Of Iwe (Integrated Wheel End) 
- 8510-47 4wd Mode Switch 
- 3410-01 Tccu(Transfer Case Control Unit) 
- REMOVAL AND INSTALLATION 
- 3240-01 Part Time Transfer Case General Diagnosis 
- 4116-01 Vacuum Locking Hub Check 
- 3240-01 Oil Level Check And Change 
- 3410-01 Self-Diagnosis Test 
- 3410-01 Tccu Diagnostic Trouble Code 
- 3240-01 Part Time Transfer Case 
- 3240-01 Transfer Case Motor 
- 4116-01 Iwe(Integrated Wheel End) 
- 4116-01 Locking Hub Actuator Assembly 
- 3410-01 Tccu 
SUSPENSION 
- GENERAL 
- 1. Specifications Of Suspension 
- 2. Wheel Alignment 
- CONFIGURATION AND FUNCTION 
- 4411-01 Front Suspension (Double Wishbone) 
- 4510-01 Rear Suspension(5-Link Type) 
- REMOVAL AND INSTALLATION 
- 4510-01 Trouble Diagnosis Of Rear Suspension 
- 4410-01 Front Suspension-Upper Arm 
- 4411-01 Front Suspension- Coil Spring & Shock Absorber Assembly 
- 4420-01 Front Suspension-Stabilizer Bar 
- 4410-01 Front Suspension-Lower Arm 
- 4510-01 Rear Suspension(5 - Link Type) 
BRAKE SYSTEM 
- GENERAL INFORMATION 
- 1. Specification 
- 2. System Overview 
- 3. Troubleshooting 
- 4. Air Bleeding 
- 5. Brake System Check 
- 6. Components 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. System Layout 
- 3. Parking Brake 
- 4. Hydraulic Circuit 
- 5. Circuit Diagram Of Stop Lamp 
- CONFIGURATION AND FUNCTION 
- 4850-01 Brake Master Cylinder Assembly 
- 4850-02 Brake Booster Assembly 
- 4803-01 Front Brake Caliper Assembly 
- 4115-01 Front Brake Disc 
- 4830-02 Brake Pad 
- 4841-01 Rear Brake Caliper Assembly 
- 4910-01 Parking Brake 
- REMOVAL AND INSTALLATION 
- 4850-09 Brake Booster Vacuum Hose 
- 4850-01 Master Cylinder And Booster 
- 4810-01 Brake Pedal 
- 4810-08 Stop Lamp Switch 
- 4830-01 Front Brake Caliper/Disc 
- 4830-02 Front Brake Pad 
- 4841-01 Rear Brake Caliper/Disc 
- 4841-02 Rear Brake Pad 
- 4910-01 Parking Brake Assembly 
- 4841-15 Parking Brake Lining (Shoe) 
ESP & ABS 
- GENERAL 
- 1. System General 
- 2. Sectional Drawing 
- 3. Specifications 
- 4. Brake Operation And Noise 
- 5. Esp System Related Precautions 
- OVERVIEW AND OPERATION PROCESS 
- 1. Overview Of Esp(Electronic Stabilityprogram) System 
- 2. Components Of Esp 
- 3. Principle Of Esp 
- 4. Principle Of Bas(Brake Assist System) 
- 5. Principle Arp(Active Roll-Over Protection) 
- 6. Principle Of Hdc(Hill Descent Control) 
- 7. Input And Output Diagram Of Esp System 
- 8. Hydraulic Circuit Diagram Of Esp System 
- 9.Hydraulic Pressure For Each Esp Operatingrange 
- 10. Hydraulic Circuit Of Bas (Brake Assistsystem) 
- 11. Components Of Abs System 
- CONFIGURATION AND FUNCTION 
- 4892-01 Hecu Of Esp 
- 4892-01 Hecu Of Abs 
- 4850-01 Pressure Sensor 
- 4890-01 Sensor Cluster 
- 8510-21 Swas(Steering Wheel Angle Sensor) 
- 8510-56 Esp Off Switch 
- 4890-01 Awss(Active Wheel Speed Sensor) 
- 4892-00 Abs/Esp 
- REMOVAL AND INSTALLATION 
- 4892-01 How To Use Scan Tool 
- 4892-01 Abs/Esp Trouble Diagnosis 
- 4892-01 Cautions When Removing Front Wheel Speed Sensor-Esp 
- 4892-01 Cautions When Removing Front Wheel Speed Abs 
- 4892-01 Hecu-Esp 
- 4892-01 Hecu-Abs 
- 4890-01 Front Wheel Speed Sensor 
- 4890-01 Rear Wheel Speed Sensor 
- 4850-01pressure Sensor 
- 4890-01 Sensor Cluster 
STEERING 
- GENERAL 
- 1. Overview 
- 2. Specifications 
- OVERVIEW AND OPERATION 
- 1. System Layout 
- 2. Components 
- REMOVAL AND INSTALLATION 
- 4610-01 Trouble Diagnosis 
- 4610-01 Inspections Of Power Steering System 
- 4610-06 Steering Column Shaft 
- 4610-07 Lower Shaft 
- 4620-02 Steering Gear Box 
- 4711-01 Power Steering Pump 
- 4640-01 Power Steering Oil Pipe 
WHEEL & TIRE 
- GENERAL INFORMATION 
- 1. Specifications 
- 2. Trouble Diagnosis 
- 3. Inspection 
- 4. Components 
- OVERVIEW AND OPERATING PROCESS 
- 1. Overview 
- 2. Abnormal Tire Symptom 
- 3. Wheel Balance 
- CONFIGURATION AND FUNCTION 
- 4170-09 Configuration 
- REMOVAL AND INSTALLATION 
- 4170-09 Wheel And Tire 
AIR CONDITIONER 
- OVERVIEW AND OPERATION PROCESS 
- 1. System Layout And Components 
- 2. Ventilation System 
- 3. Air Conditioner Module And Sensors 
- 4. System Diagram 
- CONFIGURATION AND FUNCTIONS 
- 6810-20 Air Conditioner Controller Unit 
- 0000-00 Sunsensor 
- 6810-20 Incar Sensor Assembly 
- 6810-20 Ambient Temperature Sensor 
- 6820-24 Water Temperature Sensor 
- 6810-06 Power Transistor 
- 6810-02 Mode Door Actuator 
- 6810-02 In/Ex - Air Door Actuator 
- 6810-02 Air Mix Door Actuator 
- 6810-24 Thermo Amp (Intake Sensor) 
- 6810-00 Fatc (Full Auto Temp. Control) Circuit 
- 6810-00 Air-Con (Manual) Circuit 
- 6810-15 Ptc(Positive Temperature Coefficient) 
- REMOVAL AND INSTALLATION 
- 6810-20 Self Diagnosis (Only For Fatc A/C Controller) 
- 6810-20 Ambient Temperature Sensor 
- 6820-24 Water Temperature Sensor 
- 6810-06 Power Transitor 
- 6810-02 Mode Door Actuator 
- 6810-02 In/Ex-Air Door Actuator 
- 6810-02 Air Mix Door Actuator 
- 6810-24 Thermo Amp(Intake Sensor) 
- 6810-01 Air Conditoner Module Assembly 
- 6810-20 A/C Controller Switch And Active Incar Sensor 
- 6810-01 Air Duct Assembly 
- 6820-01 Condenser Assembly 
- 6820-19 Receiver Drier 
- 6820-18 A/C Hose And Pipe 
- 6910-20 Ambient Temperature Switch 
- 6810-15 Ptc 
AIR BAG 
- GENERAL 
- 1. Overview (Including Curtain Air Bags) 
- OVERVIEW AND OPERATION PROCESS 
- 1. Locations And Related Components 
- 2. Air Bag System Operation Process 
- 3. Air Bag Module And Related Components 
- REMOVAL AND INSTALLATION 
- 8810-03 Trouble 
- 8810-03 Driver Air Bag 
- 8810-06 Passenger Air Bag 
- 8810-11 Curtain Air Bag 
- 8810-12 Contact Coil 
- 8810-01 Air Bag Unit(Sdm) 
- 8810-16 Curtain Air Bag G Sensor 
SEAT 
- OVERVIEW AND OPERATION PROCESS 
- 1. Composition Of Seat 
- 2. Functions Of Seat 
- 3. Components Of Seat Belt 
- 4. Circuit Diagram 
- REMOVAL AND INSTALLATION 
- 7410-01 Seat Mounting Points 
- 7410-01 Seat Assembly 
- 7430-01 Seat Belt 
SUNROOF 
- OVERVIEW AND OPERATION PROCESS 
- 1. Components And Locations 
- 2. Operation And Function 
- CONFIGURATION AND FUNCTION 
- 7340-01 Components Of Sunroof 
- REMOVAL AND INSTALLATION 
- 7340-01 Resetting Of Sunroof Control Unit 
- 7340-01 Trouble Diagnosis 
- 7340-04 Glass Panel Assembly 
- 7340-05 Bellows Cover 
- 7340-12 Drain Channel 
- 7340-05 Sun Shade Panel 
- 7340-12 Sunroof Control Unit(Scu) And Motor 
- 7340-12 Sunroof Drain Hose 
- 7340-01 Sunroof Assembly 
BODY INTERIOR 
- OVERVIEW AND OPERATION PROCESS 
- 1. Locations 
- REMOVAL AND INSTALLATION 
- 7610-01 Instrument Panel Assembly 
- 7610-01 Instrument Panel Frame Assembly 
- 7330-01 Center Console (Automatic Transmission) 
- 7332-01 Center Console(Manual Transmission) 
- 7770-01 Sunvisor 
- 7730-12 Pillar And Rear Quarter Trim 
- 7330-01 Headlining Assembly 
- 7850-01 Outside Rearview Mirror 
- 7770-01 Inside Rearview Mirror 
BODY EXTERIOR 
- OVERVIEW AND OPERATION PROCESS 
- 1. Composition Of Body Exterior 
- CONFIGURATION AND FUNCTION 
- 7870-01 Front Bumper Fascia 
- 7880-01 Rear Bumper Assembly 
- 6110-01 Hood Panel Assembly 
- 7930-01 Side Silmolding 
- 6210-01 Front Door Assembly 
- 7120-01 Front Window Regulator 
- 6310-01 Rear Door Assembly 
- 7120-01 Rear Window Regulator 
- 6410-01 Tailgate Assembly 
- REMOVAL AND INSTALLATION 
- 7870-00 Front Bumper Assembly 
- 7880-01 Rear Bumper Assembly 
- 6110-01 Hood Panel Assembly 
- 6110-06 Hood Latch Assembly 
- 6110-04 Hood Insulator 
- 7930-01 Side Sill Molding 
- 7870-01 Fender Panel 
- 7115-01 Front Door Trim(Driver Side) 
- 6210-01 Front Door(Driver Side) 
- 7120-01 Window Regulator(Passenger Side) 
- 7215-01 Rear Door Trim 
- 6310-01 Rear Door Assembly 
- 6310-01 Rear Door Molding And Panel 
- 7220-01 Rear Window Regulator 
- 7321-01 Tailgate Trim 
- 6410-01 Tailgate Assembly 
- 7310-01 Tailgate Latch And Actuator 
- 7840-01 Rear Quarter Glass 
BODY REPAIR 
- GENERAL INFORMATION 
- 1. Dimensions 
- 2. Jack-Up Points 
- 3. Design Changes For Improving Nvh Performance 
- CONFIGURATION AND FUNCTIONS 
- 4110-01 Frame Dimensions 
- 4110-01 Frame Body Mounting 
- 5110-01 White Body 
- 5110-01 Body Dimensions 
- 5110-01 Body Gaps 
- 6210-01 Door Components (Including Engine Hood) 
- 4010-70 Components Of Body Panels

WIRING DIAGRAM

GENERAL INFORMATION 
- GENERAL INFORMATION 
- 1. Dimensions 
- 2. Specifications 
- 3. Vehicle Identification 
- 4. Maintenance Interval 
- 5. Recommended Fluids And Lubricants 
- 6. Jack-Up Points 
- 7. Pin Arrangement Of Diagnostic Connector 
ELECTRIC DEVICE GENERAL INFORMATION 
- 1. HOW TO READ ELECTRICAL WIRING DIAGRAM 
CONNECTOR/GROUND 
- WIRING HARNESS 
- 0000-00 Wiring Harness, Components Location 
POWER DISTRIBUTION 
- FUSE/RELAY 
- 8410-00 Engine Room Fuse / Relay Box 
- 8410-00 I/P - Lh Fuse / Relay Box 
- 8410-00 I/P - Rh Fuse / Relay Box 
ELECTRICITY DIVIDE

- 8410-00 ENGINE ROOM FUSE / RELAY BOX CIRCUIT 
- 8410-00 I/P - LH FUSE / RELAY BOX CIRCUIT 
- 8410-00 I/P - RH FUSE / RELAY BOX CIRCUIT 
- 8410-00 ICM RELAY BOX CIRCUIT 
CIRCUIT 
- 1461-00 STARTING / CHARGING 
- 1413-00 GLOW CONTROL UNIT 
- 1491-00 ECU (ENGINE CONTROL UNIT - D20DTR EU-V) 
- 1490-00 ECU (ENGINE CONTROL UNIT - GSL G23) 
- 8210-00 DIAGNOSIS CIRCUIT 
- 3110-00 TCU (6-A/T) 
- 3110-00 TCU (5-A/T) 
- 3410-00 TCCU 
- 4892-00 ABS/ESP 
- 8810-00 AIR-BAG (CURTAIN AIR-BAG) 
- 8010-00 CLUSTER 
- 7410-00 POWER SEAT - DRIVER 
- 7410-00 POWER SEAT - PASSENGER 
- 8510-00 ELECTRIC OUTSIDE MIRROR 
- 8510-00 FRT SEAT WARMER 
- 8710-00 STICS 
- 7830-00 RR WIPER CIRCUIT 
- 8510-00 POWER WINDOW CIRCUIT 
- 8610-00 HORN 
- 8730-00 IMMOBILIZER CIRCUIT (D20DTR) 
- 7632-00 CIGAR LIGHTER / POWER OUTLET CIRCUIT 
- 7340-00 SUNROOF CIRCUIT 
- 8310-00 HEAD LAMP CIRCUIT 
- 8510-00 HLLD (HEAD LAMP LEVEL G DEVICE) CIRCUIT 
- 8320-00 TAIL LAMP CIRCUIT 
- 8410-00 TURN SIGNAL / HAZARD LAMP CIRCUIT 
- 8210-00 TRAILER LAMP CIRCUIT 
- 8310-00 FOG LAMP CIRCUIT 
- 4810-00 STOP / BACK-UP LAMP CIRCUIT 
- 7770-00 INTERIOR LAMP CIRCUIT 
- 7770-00 AUTO DIMMING ROOM MIRROR CIRCUIT 
- 8910-00 AUDIO / CLOCK CIRCUIT 
- 8790-00 PARKING AID CIRCUIT 
- 6810-00 PTC HEATER (POSITIVE TEMPERATURE COEFFICIENT) 
- 6810-00 FATC (FULL AUTO TEMP. CONTROL) CIRCUIT 
- 6810-00 AIR-CON (MANUAL) CIRCUIT

Ssangyong Actyon Sports - Workshop Manual - Wiring Diagram

inicio - index

coche - car

moto

4x4

quad - buggy

cami?n - truck

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