Content

Service manual

General information

• Dimensions
• Specifications
• Vehicle identification
• Maintenance interval
• Recommended fluids and lubricants
• Jack-up points
• Pin arrangement of diagnostic connector

Electric device general

• How to read electrical wiring

Wiring harness

• Wiring harness, components location

Power distribution

• Fuse / relay
• Electricity divide

Circuit

• Engine
• Starting / charging
• Glow control unit
• ECU (engine control unit - D20DTR EU-V)
• ECU (engine control unit-GSLG23)
• Diagnosis circuit
• Chassis
• TCU (6-A/T)
• TCU (5-A/T)
• TCCU
• ABS / ESP
• Electric
• Air-bag (curtain air-bag)
• Cluster
• Power seat - driver
• Power seat - passenger
• Electric outside mirror
• FRT seat warmer
• STICS
• RR wiper circuit
• Power window circuit
• Horn
• Immobilizer circuit (D20DTR)
• Cigar lighter / powfr outlet circuit
• Sunroof circuit
• Head lamp circuit
• HLLD (head lamp level'g device) circuit
• Tail lamp circuit
• Turn signal / hazard lamp circuit
• Trailer lamp circuit
• Fog lamp circuit
• Top / back-up lamp circuit
• Interior lamp circuit
• Auto dimming room mirror circut
• Audio / clock circuit
• Parking aid circuit
• PTC heater (positive temperature coefficient)
• FATC (full auto temp. Control) circuit
• Air-con (manual) circuit

Engine general

• Engine layout
• Major components
• Engine compartment layout
• Caution when servicing the engine
• Standard bolts specifications
• Tightening torque
• Coding and initialization

D20DTR engine assembly

• General information
• Specification
• Tightening torque
• Check and inspection
• Guidelines on engine service
• Overview and operating process
• Belt layout
• Vacuum pump
• Engine mounting
• Intake / exhaust manifold
• Cylinder head cover and oil separator
• Cylinder head
• Chain and gear drive system
• Oil pan
• Dual mass flywheel and drive plate
• Piston / crankshaft / cylinder block

Fuel system

• General information
• Specification
• Maintenance and inspection
• Cautions for di engine
• Overview and operating process
• Overview
• System layout and operation

Intake system

• General information
• Specification
• Inspection
• Overview and operating process
• Overview
• Component
• Input / output of intake system
• Operating process

Engine exhaust system

• General information
• Troubleshooting
• Cautions
• Overview and operating process
• Overview
• Layout
• Operating process

Turbocharger

• General information
• Specification
• Inspection
• Troubleshooting
• Overview and operating process
• System description of E-VGT (electric-variable geometry turbine)
• Components
• Input / output devices
• Operating principles

Lubrication system

• General information
• Specification
• Maintenance
• Overview and operating process
• System description
• Functions of lubrication

Cooling system

• General information
• Specification
• Inspection
• Cautions
• Overview and operating process
• System description

Charging system

• General information
• Specification
• Inspection
• Overview and operating process
• System description
• Operating process
• Circuit diagram

D20DTR pre-heating

• General information
• Specification
• Overview and operating process
• Overview
• System operation

Starting system

• General information
• Specification
• Troubleshooting
• Overview and operating process
• System description
• Operating process

Cruise control system

• Overview and operation process
• Cruise control switch
• How to operate cruise control switch

E-EGR system

• General information
• Specification
• Overview and operating process
• System description
• Operating process

CDPF system

• General information
• Specification
• Cautions
• Overview and operating process
• Overview
• Component
• Input / output devices
• Post-injection and air mass control
• Operating process
• Electric circuit diagram

Engine control

• General information
• Engine data list
• Overview and operatinf process
• Major components
• System operation

Engine assembly

• General
• Description and operation
• G23d engine assembly
• G23d engine structure
• Diagnostic information and procedure
• General diagnos

Fuel system

• General
• Fuel system specification
• Overview and operationprocess
• Fuel system

Engine intake system

• General
• Specifications

Engine exhaust system

• General
• Specification
• Overview and operation process
• Description and operation

Lubrication system

• Overview and operation process
• Oil circulation

Engine cooling system

• General
• General specifications
• Fastener tightening specifications
• Overview and operation process
• Component locator
• Description and operation
• PWM (pulse width modulation) electric fan operation

Engine electric devices

• General
• Diagnostic information and procedure
• Overview and operation process
• description and operation

Cruise control system

• Overview and operation process
• Cruise control switch
• How to operate cruise control switch

Engine control system

• General
• Engine data display table

Electric general

• General
• Locations of interior units and sensors
• Location and compartment of interior switches
• Switches, units and sensors in engine compartment
• Electric components and layout
• Diagnostic connector

Fuse and relay

• General information
• Cautions when working on electrical units
• Overview and operating process
• Overview
• Fuse and relay mounting locatio

STICS

• General
• Overview
• Specifications
• Overview and operation process
• Overview
• Functions and specifications
• Circuit diagram

Immobilizer system

• Overview and operation process
• Overview
• Basic functions of immobilizer key(rekes function)
• Other functions in system
• Rekes operation logic
• Circuit diagram

Cluster

• General
• Specifications
• Overview and operating process
• Descriptions of indicator display
• Configuration
• Warning lights and indicators
• Self-diagnosis check
• Buzzer output spec
• Circuit diagram

Lamp

• General
• Specifications

Switch

• General
• Switch arrangement

Wiper and washer

• Overview and operation process
• System layout and function
• Configuration (including rain sensor)
• Wiper and washer related function and specification
• Wiper and washer system related circuit diagram

Rain sensor

• Overview and operation process
• System layout and overview
• Rain sensing operation
• Rain sensor related circuit
• Functions and specifications of rain sensing wiper
• Operation mode of rain sensing wiper system

PAS

• General
• Component specifications
• Cautions on parking aid system
• Overview and operation process
• System overview
• Alarm interval
• Troubleshooting of sensor
• Circuit diagram

Audio system

• Overview and installation
• Audio system overview

MB 5 auto transmission

• General information
• Specifications
• Tightening torque
• Overview and operation process
• Overview
• Power flow
• Circuit diagram

DSI 6 A/T

• General
• Features and specifications
• Tightening torque
• Shift pattern diagram
• Overview and operating process
• Overview
• Features
• Mode descriptions
• Limp home mode
• Electronic control system
• Power flow

Manual transmission (5 M/T)

• General
• Overview and characteristics of manualtransmission
• Specifications and tightening torque ofmanual transmission
• Overview and operation process
• Manual transmission system

Manual transmission (6 M/T)

• General information
• Specification
• Special service tools
• Tightening torque
• Overview and operating process
• Overview
• Power flow
• Shifting mechanism

TGS lever

• Overview and operation process
• Introduction
• Functions of the selector lever
• Mode switch
• Parking lock system

Clutch

• General
• Clutch specifications
• Tightening torque
• Overview and operation process
• Function and overview

Propeller shaft

• General information
• Specification
• Tightening torque
• Overview and operating process
• Overview

Axle

• General
• Specifications of axle
• Overview and operation process
• Overview of axle

Transfer case

• General
• Overview
• Specifications
• Overview and operation process
• Structure
• System layout and operation
• Locking hub system
• Power flow

Suspension

• General
• Specifications of suspension
• Wheel alignment

Brake system

• General information
• Specification
• System overview
• Troubleshooting
• Air bleeding
• Brake system check
• Components
• Overview and operating process
• Overview
• System layout
• Parking brake
• Hydraulic circuit
• Circuit diagram of stop lamp

ESP and ABS

• General
• Sectional drawing
• Specifications
• Brake operation and noise
• ESP system related precautions
• Overview and operation process
• Overview of ESP(electronic stabilityprogram) system
• Components of ESP
• Principle of ESP
• Principle of BAS(brake assist system)
• Principle ARP(active roll-over protection)
• Principle of HDC(hill descent control)
• Input and output diagram of ESP system
• Hydraulic circuit diagram of ESP system
• Hydraulic pressure for each ESP operatingrange
• Hydraulic circuit of BAS (brake assistsystem)
• Components of ABS system

Steering

• General
• Overview
• Specifications
• Overview and operation
• System layout
• Components

Wheel and tire

• General information
• Specifications
• Trouble diagnosis
• Inspection
• Components
• Overview and operating process
• Overview
• Abnormal tire symptom
• Wheel balance

Air conditioner

• Overview and operation process
• System layout and components
• Ventilation system
• Air conditioner module and sensors
• System diagram

Air bag

• General
• Overview (including curtain air bags)
• Overview and operation process
• Locations and related components
• Air bag system operation process
• Air bag module and related components

Seat

• Overview and operation process
• Composition of seat
• Functions of seat
• Components of seat belt
• Circuit diagram

Sunroof

• Overview and operation process
• Components and locations
• Operation and function

Body interior

• Overview and operation process
• Locations

Body exterior

• Overview and operation process
• Composition of body exterior

Body repair

• General information
• Dimensions
• Jack-up points
• Design changes for improving nvh performance