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2019 CHANA P201 Workshop Manual – Complete Factory Service & Repair Manual PDF
$39.95 Original price was: $39.95.$24.95Current price is: $24.95.
The complete 2019 CHANA P201 Workshop Manual covering all systems, engines (D20T, 4K22T, JE4D25), transmissions, chassis, brakes, electrical, and body repairs. 3,386 pages of detailed service procedures, specifications, and diagnostics in PDF format.
SKU: CHANA-P201-WSM-2019-HD
Category: Automotive Service & Repair Manuals
Tags: CHANA P201 PDF manual, CHANA P201 workshop manual, P201 2019 service repair manual, P201 diesel engine repair manual
Vendor: DrivetrainDocs
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Description
File Details
- Manual Type: Workshop Manual / Service Repair Manual
- Brand: CHANA
- Model: P201
- Year: 2019
- Edition: January 2020 Edition
- Language: English
- Page Count: 3,386 pages
- File Format: PDF
- Engines Covered: D20T (1.91L Diesel), 4K22T (2.378L Gasoline), JE4D25 (2.499L Diesel)
Chapters Covered
- Group 1 – Overview: Service Information, Identification Codes, Traction and Lifting, Maintenance Interval, Noise Vibration and Harshness
- Group 2 – Chassis: Suspension System (General Information, Front Suspension, Rear Suspension, Wheel and Tire, Mounting System), Driveline System (2WD General Information, 4WD General Information, Drive Shaft, Propeller Shaft, Transfer, Rear Axle Final Drive, Front Axle), Brake System (General Information, Rear Disc Brake, Front Disc Brake, Parking Brake and Operation, Hydraulic Brake Control, Power Brake, Anti-lock Brake System, Rear Drum Brake), Steering System (General Information, Power Steering System, Steering Gear, Steering Column)
- Group 3 – Powertrain: Engine (Diesel) covering Mechanical System, Lubrication System, Cooling System, Intake System, Exhaust System, Fuel System, Starting System, Charging System, Emission Control System, Engine Immobilizer System, Cruise System, Electronic Control System; Manual Transmission/Clutch covering General Information, Clutch, Manual Transmission, Manual Transmission External Control; Engine (4K22T) covering Mechanical System, Lubrication System, Cooling System, Intake System, Exhaust System, Fuel System, Ignition System, Starting System, Charging System, Emission Control System, Engine Immobilizer System, Cruise System, Electronic Control System; Automatic Transmission covering General Information, DTC Diagnosis, Removal and Installation, External Control; Engine System (JE4D25) covering Mechanical System, Lubrication System, Cooling System, Intake System, Exhaust System, Fuel System, Starting System, Charging System, Emission Control System, Engine Immobilizer System, Cruise System, Electronic Control System
- Group 4 – Electrical: Heating Ventilation and Air Conditioning; Supplemental Restraint System; Body Electrical covering Instrument Panel and Panel Illumination, Instrument Cluster, Horn, Cigarette Lighter/Accessory Power Supply, Information and Entertainment System, Lighting System, Wiper and Washer, Power Rearview Mirror, Central Door Lock, Power Window, Defroster, Parking Assist System, Body Control System, PEPS System, Tire Pressure Monitoring System, On-board Network System
- Group 5 – Body: Body and Accessories covering Front and Rear Windshields, Door, Seat, Seat Belt, Inner Rearview Mirror, Instrument Panel and Console, Bumper, Handles Locks and Latches, Interior Trim Panel and Ornamentation, Exterior Trim, Cargo Compartment; Body Repairs covering Accident Vehicle Maintenance Operation, Technical Data, Body Front, Body Center, Body Rear
The 2019 CHANA P201 Workshop Manual is a comprehensive technical resource spanning 3,386 pages across five major groups. It provides detailed descriptions for accomplishing service and repair work on the P201 vehicle, covering three distinct engine platforms: the D20T 1.91L diesel, the 4K22T 2.378L gasoline, and the JE4D25 2.499L diesel. Each engine section includes mechanical system procedures, lubrication and cooling system service, fuel and intake system diagnostics, exhaust system repair, starting and charging system testing, emission control, and complete electronic control system troubleshooting with DTC diagnosis. The chassis group delivers full suspension, driveline, brake, and steering system coverage with torque specifications, symptom charts, and step-by-step removal and installation procedures. The electrical group encompasses HVAC, supplemental restraint system, and all body electrical subsystems including lighting, wipers, power windows, central locking, PEPS, tire pressure monitoring, and on-board network diagnostics. The body group provides collision repair guidance with body measurement and structural repair data. This manual is structured with specifications, description and operation, general inspection, symptom diagnosis and testing, DTC diagnosis and testing, removal and installation, and disassembly and assembly sections for each system, making it suitable for professional technicians and experienced DIY mechanics working on the CHANA P201.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2019 CHANA P201 Workshop Manual – Complete Factory Service & Repair Manual PDF” are as follows:
+1.1 Service Informationp. 5
+Overviewp. 7
+Description and Operationp. 7
About This Manualp. 7
Health and Safety Precautionsp. 8
Standard Workshop Practicep. 18
Solvents, Sealants and Adhesivesp. 20
Road or Roller Testp. 20
+Identification Codesp. 23
+Description and Operationp. 23
Vehicle Identification Number (VIN)p. 23
Name Platep. 24
+Traction and Liftingp. 25
+Description and Operationp. 25
Tractionp. 25
Jackingp. 25
Liftingp. 26
+Maintenance Intervalp. 27
+Description and Operationp. 27
Maintenance Itemsp. 27
+Noise, Vibration and Harshnessp. 37
+Description and Operationp. 37
Meaning of NVH in Automotive Engineeringp. 37
Noise Type in Automotive Engineeringp. 37
Vibration Process Engineeringp. 38
Noise and Vibration on Vehiclep. 39
Noise and Vibration Caused By Intake and Exhaust Systemsp. 40
Vehicle Bodyp. 41
+Symptom Diagnosis and Testingp. 43
Inspection and Verificationp. 43
Noise Diagnostic Procedurep. 43
+2.1 Suspension Systemp. 49
+Suspension System – General Informationp. 53
+Specificationsp. 53
General Specificationsp. 53
+Description and Operationp. 54
System Overviewp. 54
+General Inspectionp. 56
Front Shock Absorber Inspectionp. 56
Rear Shock Absorber Inspectionp. 56
Worktable Testp. 56
Wheel Bearing Inspectionp. 57
Tie Rod Ball Joint Inspectionp. 58
Ball Pin Inspectionp. 58
Suspension Inspectionp. 58
Vehicle Inspectionp. 59
Lifting Vehicle for Inspectionp. 59
Road Testp. 59
Suspension Device Inspectionp. 60
Vehicle Inspectionp. 60
Lifting Vehicle for Inspectionp. 60
Road Testp. 60
Front Wheel Toe-in Inspection and Adjustment Procedurep. 61
Pitch Angle and Kingpin Caster Angle Inspection and Adjustment Procedurep. 62
+Symptom Diagnosis and Testingp. 63
Inspection and Verificationp. 63
Symptom Chartp. 64
+Front Suspensionp. 87
+Specificationsp. 87
Torque Specificationsp. 87
+Description and Operationp. 88
System Overviewp. 88
Components Location Viewp. 89
Symptom Diagnosis and Testingp. 90
+Removal and Installationp. 91
Front Suspension Upper Swing Arm Assemblyp. 91
Front Suspension Lower Swing Arm Assemblyp. 93
Front Strut Assemblyp. 95
Front Connecting Rod Assemblyp. 96
Front Stabilizer Barp. 97
Front Steering Knucklep. 99
Front Wheel Hub Bearing Assemblyp. 102
+Rear Suspensionp. 105
+Specificationsp. 105
Torque Specificationsp. 105
+Description and Operationp. 106
System Overviewp. 106
Components Location Viewp. 106
Symptom Diagnosis and Testingp. 107
+Removal and Installationp. 108
Rear Axle Assemblyp. 108
Rear Leaf Spring Assemblyp. 112
Rear Shock Absorber Assemblyp. 114
+Wheel and Tirep. 115
Specificationsp. 115
+Description and Operationp. 116
Components Descriptionp. 116
+General Inspectionp. 118
Removal/Installation and Charging of Tirep. 118
Symptom Diagnosis and Testingp. 123
+Removal and Installationp. 126
Wheel and Tirep. 126
+Mounting Systemp. 127
Specificationsp. 127
+Description and Operationp. 128
System Overviewp. 128
Symptom Diagnosis and Testingp. 143
+Removal and Installationp. 145
Left Mounting Module – (D20T)p. 145
Left Mounting Module – (4K22T)p. 146
Left Mounting Module – (JE4D25)p. 148
Right Mounting Module – (D20T)p. 149
Right Mounting Module – (4K22T)p. 150
Right Mounting Module – (JE4D25)p. 151
Rear Mounting Module (D20T Manual 2WD)p. 152
Rear Mounting Module (D20T Manual 4WD)p. 154
Rear Mounting Module (JE4D25 Manual 2WD)p. 156
Rear Mounting Module (JE4D25 Manual 4WD)p. 158
Rear Mounting Module (4K22T Manual 2WD)p. 160
Rear Mounting Module (4K22T Manual 4WD)p. 162
Rear Mounting Module (4K22T Automatic 2WD)p. 164
Rear Mounting Module (4K22T Automatic 4WD)p. 166
+2.2 Driveline Systemp. 169
+Driveline System (2WD) – General Informationp. 173
+Description and Operationp. 173
System Overviewp. 173
+General Inspectionp. 174
Axle Shaft Inspectionp. 174
Axle Shaft Oil Seal Inspectionp. 174
Axle Shaft Bearing Inspectionp. 174
Final Drive and Differential Assembly Inspectionp. 174
+Symptom Diagnosis and Testingp. 180
Inspection and Verificationp. 180
Symptom Chartp. 181
+Driveline System (4WD) – General Informationp. 189
+Specificationsp. 189
Torque Specificationsp. 189
+Description and Operationp. 190
System Overviewp. 190
+General Inspectionp. 191
Drive Shaft Inspectionp. 191
Axle Shaft Inspectionp. 191
+Symptom Diagnosis and Testingp. 194
Inspection and Verificationp. 194
Symptom Chartp. 195
Diagnosis Procedure for Drive Shaft Noisep. 197
Diagnosis Procedure for Dull Metallic Sound Occurs When Re- accelerating After Neutral Coastingp. 199
Diagnosis Procedure for Vehicle Shudders or Vibrates When Acceleratingp. 200
Diagnosis Procedure for Drive Shaft Falling-offp. 202
Diagnosis Procedure for Whole Vehicle Shimmy at Low Speedp. 204
+Drive Shaftp. 207
+Specificationsp. 207
Material Specificationsp. 207
Torque Specificationsp. 207
+Description and Operationp. 208
System Overviewp. 208
Symptom Diagnosis and Testingp. 209
+Removal and Installationp. 210
Drive Shaftp. 210
Axle Shaftp. 212
+Propeller Shaftp. 215
Specificationsp. 215
+Description and Operationp. 216
System Overviewp. 216
Components Exploded Viewp. 217
Symptom Diagnosis and Testingp. 218
+Removal and Installationp. 219
Propeller Shaftp. 219
Propeller Intermediate Shaftp. 221
+Transferp. 223
+Specificationsp. 223
General Specificationsp. 223
+Description and Operationp. 224
System Overviewp. 224
4WD High Speed Indicatorp. 224
+Symptom Diagnosis and Testingp. 225
Inspection and Verificationp. 225
Symptom Chartp. 226
+General Inspectionp. 227
Transfer Oil Replacementp. 227
+Removal and Installationp. 228
Transferp. 228
Shift Motor Sub-assemblyp. 230
4WD Switch Assemblyp. 232
+Disassembly and Assemblyp. 233
Transfer Assemblyp. 233
Replacement of Input Shaft Oil Sealp. 247
Replacement of Front Input Shaft Oil Sealp. 248
Replacement of Rear Input Shaft Oil Sealp. 249
+Rear Axle Final Drivep. 251
+Specificationsp. 251
General Specificationsp. 251
+Description and Operationp. 252
System Overviewp. 252
Symptom Chartp. 253
Symptom Diagnosis and Testingp. 254
+Removal and Installationp. 255
Rear Axle Final Drivep. 255
+Front Axlep. 257
+Specificationsp. 257
General Specificationsp. 257
+Description and Operationp. 258
Components Exploded Viewp. 258
+Removal and Installationp. 260
Front Axle Assemblyp. 260
+2.3 Brake Systemp. 265
+Brake System – General Informationp. 271
+Specificationsp. 271
Material Specificationsp. 271
+Description and Operationp. 272
System Overviewp. 272
+General Inspectionp. 275
Road Testp. 275
Hydraulic Leakage Inspectionp. 275
Substandard or Polluted Brake Fluidp. 276
Brake Fluid Level Inspectionp. 276
Brake Pedal Free Height Adjustmentp. 276
Brake Lamp Switch Adjustmentp. 277
Pedal Free Travel Inspectionp. 277
Brake Master Cylinder Inspectionp. 278
Parking Brake Inspection and Adjustmentp. 278
Brake Hose and Fluid Pipe Inspectionp. 278
Vacuum Booster Inspectionp. 278
Brake System Bleedingp. 279
ABS/ESP Hydraulic Unit Bleedingp. 280
Front Brake Disc Runout and Thickness Inspectionp. 281
Brake Pad Inspectionp. 281
Brake Drum Inspectionp. 282
Brake Shoe Inspectionp. 282
Wheel Cylinder Inspectionp. 283
Brake Shoe Clearance Adjustmentp. 283
Rear Drum Brake Shoe Adjustmentp. 283
+Symptom Diagnosis and Testingp. 284
Inspection and Verificationp. 284
Symptom Chartp. 285
Diagnosis Procedure for Uneven Braking – Deviationp. 291
Diagnosis Procedure for Shaking/Vibration When Brakingp. 295
Diagnosis Procedure for Quick Down of Brake Pedalp. 297
Diagnosis Procedure for Brake Pedal Low or Feeling Spongyp. 299
Diagnosis Procedure for Brake Locking with Pedal Depressed Slightlyp. 301
Diagnosis Procedure for Brake Pedal Slow Down When Depressing and Holding Pedalp. 303
Diagnosis Procedure for Brake Dragp. 305
+Rear Disc Brakep. 307
+Specificationsp. 307
Material Specificationsp. 307
Rear Disc Brake Specificationsp. 307
Torque Specificationsp. 307
+Description and Operationp. 308
System Overviewp. 308
Components Descriptionp. 309
Components Location Viewp. 310
+Removal and Installationp. 311
Brake Padp. 311
Brake Caliperp. 314
Brake Discp. 316
+Front Disc Brakep. 317
+Specificationsp. 317
Material Specificationsp. 317
Front Disc Brake Specificationsp. 317
Torque Specificationsp. 317
+Description and Operationp. 318
System Overviewp. 318
Components Descriptionp. 319
Components Location Viewp. 320
+Removal and Installationp. 321
Brake Padp. 321
Brake Caliperp. 324
Brake Discp. 325
+Parking Brake and Operationp. 327
+Specificationsp. 327
Parking Brake Specificationsp. 327
Torque Specificationsp. 327
+Description and Operationp. 328
System Overviewp. 328
+General Inspectionp. 329
Parking Brake Lever Inspectionp. 329
Parking Brake Cable Adjustmentp. 329
+Symptom Diagnosis and Testingp. 330
Inspection and Verificationp. 330
Symptom Chartp. 331
Diagnosis Procedure for Parking Brake Not Functioning (Failure)/ Poor Parking Brake Forcep. 333
Diagnosis Procedure for Parking Brake Not Releasing (Dragging)p. 335
Diagnosis Procedure for Parking Brake Indicator Constant ONp. 337
+Removal and Installationp. 339
Parking Brake Control Mechanism Assemblyp. 339
Parking Brake Cablep. 341
Parking Brake Warning Lamp Switchp. 345
EPB Switchp. 346
Electronic Parking Brake Actuatorp. 347
+Hydraulic Brake Controlp. 349
+Specificationsp. 349
Material Specificationsp. 349
Torque Specificationsp. 349
+Description and Operationp. 350
System Overviewp. 350
Components Descriptionp. 350
+Removal and Installationp. 352
Brake Fluid Reservoirp. 352
Brake Master Cylinderp. 354
Brake Pedalp. 356
Brake Lamp Switch Assemblyp. 358
+Power Brakep. 359
+Specificationsp. 359
Torque Specificationsp. 359
+Description and Operationp. 360
System Overviewp. 360
Components Location Viewp. 360
+Removal and Installationp. 361
Brake Boosterp. 361
+Anti-lock Brake Systemp. 365
+Specificationsp. 365
Material Specificationsp. 365
Torque Specificationsp. 365
+Description and Operationp. 366
System Overviewp. 366
+General Inspectionp. 367
Inspection and Verificationp. 367
+Symptom Diagnosis and Testingp. 368
Intermittent Malfunction Diagnosis Procedurep. 368
Diagnosis Procedure for ABS Warning Lamp Not ONp. 370
Diagnosis Procedure for ABS Warning Lamp Constant ONp. 372
+DTC Diagnosis and Testingp. 374
Control Module Terminal Listp. 374
Diagnosis Procedure for Disabled Communication Between Diagnostic Tool and Vehiclep. 376
DTC Listp. 376
DTC Diagnosis Procedure Indexp. 378
C1101p. 380
C1101p. 381
C1103, C1604p. 383
C1200, C1203, C1206, C1209p. 385
C1202, C1201, C1205, C1204, C1208, C1207, C1211, C1210p. 388
C2112, C2227, C2380p. 392
C1260, C1261, C1264p. 394
C1542p. 396
C1520p. 399
C1503p. 403
U0100, U0126, U0140, C160Ep. 405
+Removal and Installationp. 408
ABS/ESP Actuator Assemblyp. 408
Front Wheel Sensor Assemblyp. 411
Rear Wheel Sensor Assemblyp. 413
Steering Angle Sensorp. 414
+Rear Drum Brakep. 415
+Specificationsp. 415
Material Specificationsp. 415
Rear Drum Brake Specificationsp. 415
Torque Specificationsp. 415
+Description and Operationp. 416
System Overviewp. 416
Components Descriptionp. 416
Components Location Viewp. 417
+Removal and Installationp. 418
Brake Drump. 418
Brake Shoep. 419
Brake Wheel Cylinderp. 427
Brake Platep. 429
+2.4 Steering Systemp. 431
+Steering System – General Informationp. 433
+Specificationsp. 433
General Specificationsp. 433
+Description and Operationp. 434
System Overviewp. 434
Components Descriptionp. 434
Components Location Viewp. 435
+General Inspectionp. 436
Dust Boot Inspectionp. 436
Steering Gear Inspectionp. 436
Add Power Steering Fluidp. 436
Steering System Bleedingp. 437
+Symptom Diagnosis and Testingp. 438
Inspection and Verificationp. 438
Symptom Chartp. 439
+Power Steering Systemp. 445
+Specificationsp. 445
Torque Specificationsp. 445
+Description and Operationp. 446
System Overviewp. 446
Components Location Viewp. 447
+Removal and Installationp. 448
Steering Oil Pump Assembly – (D20T)p. 448
Steering Oil Pump Assembly – (4K22T)p. 450
Steering Oil Pump Assembly – (JE4D25)p. 452
Power Steering Gear Assemblyp. 454
Steering Fluid Reservoir Assembly – (D20T)p. 455
Steering Fluid Reservoir Assembly – (JE4D25) (4K22T)p. 456
+Steering Gearp. 457
+Specificationsp. 457
Torque Specificationsp. 457
+Description and Operationp. 458
System Overviewp. 458
Components Location Viewp. 459
+Removal and Installationp. 460
Tie Rod Ball Jointp. 460
Steering Gear Dust Bootp. 462
+Steering Columnp. 463
+Specificationsp. 463
Torque Specificationsp. 463
+Description and Operationp. 464
System Overviewp. 464
+Removal and Installationp. 465
Steering Wheelp. 465
Steering Upper Shaft Assemblyp. 468
Steering Lower Shaft Assemblyp. 472
+3.1 Engine (Diesel)p. 477
+Engine System – General Informationp. 487
Overviewp. 487
+Mechanical Systemp. 489
+Specificationsp. 489
General Specificationsp. 489
Torque Specificationsp. 490
Engine Oil Application Component and Area Chartp. 491
+Description and Operationp. 492
Components Exploded Viewp. 492
+General Inspectionp. 499
Accessory Drive Belt Inspectionp. 499
Accessory Drive Belt Tension Adjustmentp. 500
+Symptom Diagnosis and Testingp. 501
Inspection and Verificationp. 501
Symptom Chartp. 502
Diagnosis Procedure for Abnormal Noise in Lower Part of Enginep. 507
Diagnosis Procedure for Drive Belt Noisep. 508
Diagnosis Procedure for Abnormal Exhaust (Blue Smoke)p. 510
Diagnosis Procedure for Abnormal Exhaust (Black Smoke)p. 512
Diagnosis Procedure for Noise from Connecting Rod and Connecting Rod Bearingp. 514
Diagnosis Procedure for Noise from Piston and Piston Pinp. 516
Diagnosis Procedure for Valve Train Noisep. 518
Diagnosis Procedure for Engine Not Start – Crankshaft Not Turnp. 521
+Removal and Installationp. 523
Accessory Drive Beltp. 523
Cylinder Head Coverp. 525
Timing Chainp. 527
Engine Assemblyp. 533
+Disassembly and Assemblyp. 540
Camshaft and Lifterp. 540
Crankshaft and Cylinder Blockp. 543
Valve and Cylinder Headp. 546
Piston, Piston Ring, Connecting Rod and Cylinderp. 553
+Lubrication Systemp. 559
+Specificationsp. 559
Component Specificationsp. 559
Torque Specificationsp. 559
General Specificationsp. 559
+Description and Operationp. 560
System Overviewp. 560
Components Descriptionp. 561
Components Exploded Viewp. 563
+General Inspectionp. 564
Oil Pressure Inspectionp. 564
Oil Level Inspectionp. 564
Engine Oil Replacementp. 565
Oil Filter Replacementp. 565
+Symptom Diagnosis and Testingp. 567
Inspection and Verificationp. 567
Symptom Chartp. 568
Diagnosis Procedure for Oil Pressure Warning Lamp Constant ONp. 570
Diagnosis Procedure for Oil Pressure Warning Lamp Not ONp. 572
Diagnosis Procedure for Abnormal Oil Consumptionp. 574
+Removal and Installationp. 575
Oil Module Assemblyp. 575
Oil Panp. 578
Oil Pumpp. 580
+Cooling Systemp. 583
+Specificationsp. 583
Component Specificationsp. 583
General Specificationsp. 583
Torque Specificationsp. 583
Material Specificationsp. 584
+Description and Operationp. 585
System Overviewp. 585
Components Descriptionp. 586
Components Exploded View for Cooling Systemp. 587
+General Inspectionp. 590
Coolant Level Inspectionp. 590
Coolant Leakage Inspectionp. 590
Coolant Draining and Fillingp. 591
Cooling Fan Inspectionp. 592
+Symptom Diagnosis and Testingp. 593
Inspection and Verificationp. 593
Symptom Chartp. 594
Diagnosis Procedure for Cooling Fan Not Running at Low Speedp. 599
Diagnosis Procedure for Cooling Fan Not Running at High Speedp. 604
Diagnosis Procedure for Cooling Fan Constantly Running at High Speedp. 609
Diagnosis Procedure for Cooling Fan Constantly Running at Low Speedp. 611
+Removal and Installationp. 613
Coolant Reservoirp. 613
Thermostatp. 614
Cooling Fanp. 616
Radiatorp. 618
Water Pump Assemblyp. 621
+Intake Systemp. 623
+Specificationsp. 623
Torque Specificationsp. 623
+Description and Operationp. 624
System Overviewp. 624
Components Descriptionp. 624
Intake Components Exploded Viewp. 626
+Symptom Diagnosis and Testingp. 628
Inspection and Verificationp. 628
Symptom Chartp. 629
Diagnosis Procedure for Intake Air Leakagep. 630
+Removal and Installationp. 631
Air Filter Elementp. 631
Air Filterp. 633
Air Filter Outlet Pipe Assemblyp. 635
Intercooler Outlet Pipe Assemblyp. 637
Intercooler Intake Pipe Assemblyp. 638
Intercooler Assemblyp. 639
Throttle Assemblyp. 641
Intake Manifoldp. 642
+Exhaust Systemp. 645
+Specificationsp. 645
Torque Specificationsp. 645
+Description and Operationp. 646
Components Exploded Viewp. 646
+Symptom Diagnosis and Testingp. 649
Inspection and Verificationp. 649
Symptom Chartp. 650
Diagnosis Procedure for Exhaust System Blockagep. 652
+Removal and Installationp. 654
Exhaust Manifold Assemblyp. 654
Oxidation Catalytic Converter Assemblyp. 656
Diesel Particles Catcher Assemblyp. 658
Front Muffler Assemblyp. 660
Boosterp. 661
+Fuel Systemp. 665
+Specificationsp. 665
Component Specificationsp. 665
Fuel Specificationsp. 665
Torque Specificationsp. 665
+Description and Operationp. 666
System Overviewp. 666
Components Descriptionp. 666
Components Exploded Viewp. 668
+General Inspectionp. 670
Fuel System Bleedingp. 670
Fuel System Drainingp. 670
Fuel Filter Inspectionp. 671
+Symptom Diagnosis and Testingp. 672
Inspection and Verificationp. 672
Symptom Chartp. 673
Diagnosis Procedure for High Pressure Fuel Pump Faultp. 675
+Removal and Installationp. 678
Manual Fuel Pumpp. 681
Fuel Tank Assemblyp. 683
Fuel Suction Platep. 685
High Pressure Fuel Pipe Componentp. 686
High Pressure Fuel Railp. 688
Fuel Injectorp. 691
+Starting Systemp. 693
+Specificationsp. 693
Component Specificationsp. 693
Torque Specificationsp. 693
+Description and Operationp. 694
System Overviewp. 694
Starting Procedurep. 694
Components Descriptionp. 694
Components Location Viewp. 696
+General Inspectionp. 697
Magnetic Switch Testp. 697
Pinion Return Testp. 697
Test without Loadp. 698
+Symptom Diagnosis and Testingp. 699
Inspection and Verificationp. 699
Symptom Chartp. 700
Diagnosis Procedure for Starting Motor Faultp. 702
Diagnosis Procedure for Starting Motor Fails to Stopp. 705
Diagnosis Procedure for Starting Motor Slow Runp. 706
Diagnosis Procedure for Preheating Indicator Constant ONp. 708
Diagnosis Procedure for Preheating Indicator Not ONp. 711
+Removal and Installationp. 715
Starting Motorp. 715
ENGINE START STOP Switchp. 716
+Charging Systemp. 719
+Specificationsp. 719
Component Specificationsp. 719
+Description and Operationp. 720
System Overviewp. 720
Components Descriptionp. 720
Components Exploded Viewp. 722
+General Inspectionp. 723
Battery Inspectionp. 723
Battery Chargingp. 723
Battery Parasitic Current Testp. 724
Alternator Testp. 725
Alternator Belt Tension Inspectionp. 725
+Symptom Diagnosis and Testingp. 726
Inspection and Verificationp. 726
Symptom Chartp. 727
Diagnosis Procedure for Insufficient Battery Chargingp. 728
Diagnosis Procedure for Battery Overchargingp. 730
Diagnosis Procedure for Charging Indicator Constant ONp. 731
Diagnosis Procedure for Charging Indicator Not Come ONp. 732
Diagnosis Procedure for Alternator Noisep. 734
+Removal and Installationp. 735
Batteryp. 735
Alternatorp. 736
+Emission Control Systemp. 739
+Specificationsp. 739
Torque Specificationsp. 739
+Description and Operationp. 740
System Overviewp. 740
Components Descriptionp. 740
Components Exploded Viewp. 742
+General Inspectionp. 743
EGR Vacuum Switching Valve Inspectionp. 743
Electronic Control EGR Valve Inspectionp. 743
Exhaust Gas Recirculation Cooler Inspectionp. 744
+Symptom Diagnosis and Testingp. 745
Inspection and Verificationp. 745
Symptom Chartp. 746
Diagnosis Procedure for EGR Vacuum Switching Valve Faultp. 747
+Removal and Installationp. 749
EGR Coolerp. 749
Electronic Control EGR Valvep. 751
+Engine Immobilizer Systemp. 753
+Description and Operationp. 753
System Overviewp. 753
General Inspectionp. 754
+Symptom Diagnosis and Testingp. 755
Inspection and Verificationp. 755
Symptom Chartp. 756
+Cruise Systemp. 757
+Description and Operationp. 757
System Overviewp. 757
+General Inspectionp. 758
Inspection and Verificationp. 758
+Removal and Installationp. 759
Engine Control Modulep. 759
+Electronic Control Systemp. 761
+Description and Operationp. 761
Components Descriptionp. 761
+General Inspectionp. 763
DTC Read Procedurep. 763
Data Flow Read Procedurep. 763
Active Test Procedurep. 763
+Symptom Diagnosis and Testingp. 764
Inspection and Verificationp. 764
Intermittent Malfunction Diagnosis Procedurep. 765
Symptom Chartp. 768
Diagnosis Procedure for Engine Not Startp. 772
Diagnosis Procedure for Engine Start Problemp. 776
Diagnosis Procedure for Unstable Engine Operation, Rough Idlingp. 779
Diagnosis Procedure for Poor Engine Acceleration Performancep. 782
+DTC Diagnosis and Testingp. 785
ECU Wiring Harness Connector Terminal Listp. 785
DTC Listp. 788
DTC Diagnosis Procedure Indexp. 795
DTC P068A00, P068B00p. 803
DTC P048013, P069212, P04804B, P069111p. 806
DTC P0480F1, P0694FE, P0480F0, P0693FCp. 812
DTC P268713, P26874B, P268712, P268711p. 819
DTC P064513, P06454B, P0647F0, P064611p. 825
DTC P0100F4, P0100F5, P010011, P0100F3, P0100F1, P010329, P010312, P010211, P011317, P011216p. 831
DTC P064D2F, P003004, P064D00, P015A00, P003009, P003012, P003011, P003029, P223C19, P223C18, P2622F0, P223C29, P2622F1, P2622F2, P223C2F, P2622F3, P219564, P219664p. 836
DTC P226409, P226900p. 842
DTC P040313, P0404F0, P0404F2, P04019C, P04029B, P213A13, P213A92, P213A4B, P214212, P213D12, P214111, P213C11, P213A01, P213A19, P213AA2, P042F73, P042E72, P0404F5, P0404F7, P040612, P040511p. 846
DTC P00E313, P00E34B, P00E312, P00E311p. 851
DTC P210001, P2100F3, P210015, P210014, P262012, P262011, P262013p. 855
DTC P0251F1, P025292, P025112, P025111p. 861
DTC P020113, P020313, P020413, P020213, P062DF0, P062EF0, P026212, P026812, P027112, P026512, P026111, P026711, P027011, P026411p. 865
DTC P018312, P018211p. 872
DTC P012312, P022312, P012211, P022211, P213564p. 876
DTC P2452F0, P2452F2, P245212, P245211p. 880
DTC P042812, P042711p. 884
DTC P244D12, P244C11p. 888
DTC P007312, P007211p. 892
DTC P019185, P019184, P019312, P019211p. 896
DTC P011627, P011812, P011711p. 900
DTC P033629, P261937, P034A30, P261738, P261836, P034A31, P033531p. 904
DTC P034129, P034031p. 908
DTC P034001p. 912
DTC P024212, P024111p. 915
DTC P009812, P009711p. 919
DTC P070401p. 923
DTC P229964p. 928
DTC U0415F0, U0415F1, U041581, U012187, U0415F2, U00D287, U0140F0, U0073F0, U1192F0, U113B02, P215A08p. 932
DTC P100600, P0607F0, P062FF0, P062FF1, P062F44, P100800, P021900, P062FF2, P060BF0, P060B00, P060BA1, P060CF0, P060CF1, P060CF2, P060CF3, P060CF4, P060CF5, P060CF6, P060C13, P060CF7, P060CF8, P060CF9, P060CFA, P060CFB, P101200, P101300, P101400, P10…p. 937
DTC P064312, P064317, P064111, P064216p. 941
DTC P065317, P065317, P065111, P065216p. 942
DTC P069912, P069917, P069711, P069816p. 943
DTC P062BF0, P062BF1, P062BF2, P062BF3p. 944
+Removal and Installationp. 945
Engine Control Modulep. 945
Oxygen Sensorp. 946
DPF Differential Pressure Sensorp. 947
DPF Upstream Temperature Sensorp. 948
DOC Upstream Temperature Sensorp. 949
Air Flow Meterp. 950
Air Intake Pressure/Temperature Sensorp. 951
Camshaft Position Sensorp. 952
Glow Plugp. 953
Fuel Rail Pressure Sensorp. 954
Accelerator Pedal Assemblyp. 955
+3.2 Manual Transmission/Clutchp. 957
+Manual Transmission/Clutch – General Informationp. 961
+Specificationsp. 961
Material Specificationsp. 961
General Specificationsp. 961
+General Inspectionp. 962
Clutch Pedal Assembly and Pipe Inspectionp. 962
Clutch Wheel Cylinder Inspectionp. 962
Clutch Driven Disc Assembly Inspectionp. 962
Clutch Cover Assembly Inspectionp. 962
Clutch System Bleedingp. 963
+Symptom Diagnosis and Testingp. 964
Inspection and Verificationp. 964
Symptom Chartp. 964
Diagnosis Procedure for Clutch Slippagep. 969
Diagnosis Procedure for Clutch Clickety-clack or Shudderp. 972
Diagnosis Procedure for Clutch Dragp. 974
Diagnosis Procedure for Clutch Pedal Pulsationp. 976
Diagnosis Procedure for Clutch Vibrationp. 978
Diagnosis Procedure for Difficult Gear Shiftingp. 981
Diagnosis Procedure for Excessive Noisep. 983
Diagnosis Procedure for Oil Leakagep. 985
Diagnosis Procedure for Abnormal Noises During Drivingp. 987
+Clutchp. 989
+Specificationsp. 989
General Specificationsp. 989
Torque Specificationsp. 989
+Description and Operationp. 990
System Overviewp. 990
Components Location Viewp. 990
Symptom Diagnosis and Testingp. 993
+Removal and Installationp. 994
Clutch Cover Assembly and Driven Disc Assemblyp. 994
Release Bearing Sub-assemblyp. 996
Clutch Pedal and Clutch Master Cylinder Assemblyp. 998
Clutch Wheel Cylinderp. 1001
Clutch Switchp. 1002
+Manual Transmissionp. 1003
+Specificationsp. 1003
General Specificationsp. 1003
Torque Specificationsp. 1003
+Description and Operationp. 1005
System Overviewp. 1005
Transmission Structure Diagramp. 1006
Front Case, Clutch Housing and Accessory Exploded Viewp. 1007
Input Shaft and Output Shaft Sets Exploded Viewp. 1008
Intermediate Shaft Set Exploded Viewp. 1010
Reverse Idler Gear Shaft Set Exploded Viewp. 1011
Intermediate Plate Set and Gearshift Set Exploded Viewp. 1012
Gear Select & Shift Set (2WD) Exploded Viewp. 1013
Rear Case and Accessory Exploded Viewp. 1014
General Inspectionp. 1015
Symptom Diagnosis and Testingp. 1016
+Removal and Installationp. 1017
Neutral Switch Assemblyp. 1017
Reverse Switch Assemblyp. 1019
Manual Transmissionp. 1020
+Disassembly and Assemblyp. 1026
Manual Transmissionp. 1026
Input Shaftp. 1060
Output Shaftp. 1062
Intermediate Shaftp. 1066
+Manual Transmission External Controlp. 1075
+Specificationsp. 1075
General Specificationsp. 1075
Torque Specificationsp. 1075
+Description and Operationp. 1076
Components Location Viewp. 1076
General Inspectionp. 1077
+Symptom Diagnosis and Testingp. 1078
Inspection and Verificationp. 1078
Symptom Chartp. 1079
+Removal and Installationp. 1080
Manual Transmission Shift Leverp. 1080
Gearshift Control Assemblyp. 1081
+3.3 Engine – (4K22T)p. 1085
+Engine System – General Informationp. 1095
Overviewp. 1095
+Mechanical Systemp. 1097
+Specificationsp. 1097
General Specificationsp. 1097
Component Specificationsp. 1098
Torque Specificationsp. 1099
+Description and Operationp. 1101
Components Location Viewp. 1101
Components Exploded Viewp. 1103
+General Inspectionp. 1108
Accessory Drive Belt Inspectionp. 1108
Accessory Drive Belt Adjustmentp. 1109
Valve Clearance Inspectionp. 1110
+Symptom Diagnosis and Testingp. 1112
Inspection and Verificationp. 1112
Symptom Chartp. 1113
Diagnosis Procedure for Abnormal Noise in Lower Part of Enginep. 1118
Diagnosis Procedure for Accessory Drive Belt Noisep. 1120
Diagnosis Procedure for Abnormal Exhaust (White Smoke)p. 1121
Diagnosis Procedure for Abnormal Exhaust (Blue Smoke)p. 1123
Diagnosis Procedure for Abnormal Exhaust (Black Smoke)p. 1124
Diagnosis Procedure for Noise from Connecting Rod and Connecting Rod Bearingp. 1126
Diagnosis Procedure for Noise from Piston and Piston Pinp. 1127
Diagnosis Procedure for Valve Train Noisep. 1128
Diagnosis Procedure for Engine Not Start – Crankshaft Not Turnp. 1130
+Removal and Installationp. 1132
Accessory Drive Beltp. 1132
Timing Beltp. 1135
Rocker Coverp. 1148
Engine Assemblyp. 1150
+Disassembly and Assemblyp. 1155
Camshaft and Lifterp. 1155
Valve and Cylinder Headp. 1160
Piston and Connecting Rodp. 1166
Crankshaft and Cylinder Blockp. 1178
+Lubrication Systemp. 1193
+Specificationsp. 1193
General Specificationsp. 1193
Component Specificationsp. 1193
Torque Specificationsp. 1193
+Description and Operationp. 1194
Components Location Viewp. 1194
+General Inspectionp. 1195
Oil Pressure Inspectionp. 1195
Oil Level Inspectionp. 1195
Engine Oil Replacementp. 1196
Oil Filter Replacementp. 1196
+Symptom Diagnosis and Testingp. 1198
Inspection and Verificationp. 1198
Symptom Chartp. 1199
Diagnosis Procedure for Oil Pressure Warning Lamp Constant ONp. 1201
Diagnosis Procedure for Oil Pressure Warning Lamp Not ONp. 1204
Diagnosis Procedure for Excessive Oil Consumptionp. 1205
+Removal and Installationp. 1207
Oil Panp. 1207
Oil Pressure Switchp. 1210
Oil Pumpp. 1211
+Cooling Systemp. 1215
+Specificationsp. 1215
Component Specificationsp. 1215
General Specificationsp. 1215
Torque Specificationsp. 1215
+Description and Operationp. 1216
System Overviewp. 1216
Components Descriptionp. 1217
Components Exploded Viewp. 1219
+General Inspectionp. 1222
Coolant Level Inspectionp. 1222
Coolant Draining and Fillingp. 1222
Coolant Temperature Sensor Inspectionp. 1224
Cooling Fan Inspectionp. 1224
+Symptom Diagnosis and Testingp. 1225
Inspection and Verificationp. 1225
Symptom Chartp. 1226
Diagnosis Procedure for Cooling Fan Not Running at Low Speedp. 1231
Diagnosis Procedure for Cooling Fan Not Running at High Speedp. 1237
Diagnosis Procedure for Cooling Fan Constantly Running at High Speedp. 1243
Diagnosis Procedure for Cooling Fan Constantly Running at Low Speedp. 1246
+Removal and Installationp. 1249
Coolant Reservoirp. 1249
Cooling Fan Assemblyp. 1250
Radiatorp. 1251
Coolant Temperature Sensorp. 1254
Electronic Thermostatp. 1256
Water Pump Assemblyp. 1258
+Intake Systemp. 1261
+Specificationsp. 1261
Torque Specificationsp. 1261
+Description and Operationp. 1262
Components Descriptionp. 1262
Intake Components Exploded Viewp. 1263
+Symptom Diagnosis and Testingp. 1266
Inspection and Verificationp. 1266
Symptom Chartp. 1267
Diagnosis Procedure for Intake Air Leakagep. 1268
+Removal and Installationp. 1270
Air Filter Elementp. 1270
Air Filter Assemblyp. 1272
Intercoolerp. 1273
Throttlep. 1275
Intake Relief Valvep. 1276
Intake Manifoldp. 1277
+Exhaust Systemp. 1281
+Specificationsp. 1281
Torque Specificationsp. 1281
+Description and Operationp. 1282
Components Descriptionp. 1282
Components Exploded Viewp. 1284
+Symptom Diagnosis and Testingp. 1288
Inspection and Verificationp. 1288
Symptom Chartp. 1289
Diagnosis Procedure for Exhaust System Blockagep. 1291
+Removal and Installationp. 1293
Exhaust Manifoldp. 1293
Boosterp. 1296
Three-way Catalytic Converter with Accessory Assemblyp. 1302
Three-way Catalytic Converterp. 1304
Particles Catcherp. 1305
High Temperature Sensorp. 1307
Differential Pressure Sensorp. 1308
Mufflerp. 1309
+Fuel Systemp. 1311
+Specificationsp. 1311
General Specificationsp. 1311
Torque Specificationsp. 1311
+Description and Operationp. 1312
Components Descriptionp. 1312
Components Exploded Viewp. 1314
+General Inspectionp. 1317
Fuel System Pressure Dischargep. 1317
Fuel Pressure Inspectionp. 1317
Fuel Pump Inspectionp. 1317
Fuel Injector Inspectionp. 1318
+Symptom Diagnosis and Testingp. 1319
Inspection and Verificationp. 1319
Symptom Chartp. 1320
Diagnosis Procedure for Fuel Pump Faultp. 1321
Diagnosis Procedure for Heavy Fuel Smellp. 1325
+Removal and Installationp. 1327
Fuel Filterp. 1327
Fuel Injectorp. 1328
Fuel Tank (EURO V)p. 1330
Fuel Tank (EURO VI)p. 1333
Fuel Pump (EURO V)p. 1336
Fuel Pump (EURO VI)p. 1338
+Ignition Systemp. 1341
+Specificationsp. 1341
Component Specificationsp. 1341
General Specificationsp. 1341
Torque Specificationsp. 1341
+Description and Operationp. 1342
System Overviewp. 1342
Components Descriptionp. 1342
Components Location Viewp. 1343
+General Inspectionp. 1344
Ignition Spark Testp. 1344
Spark Plug Inspectionp. 1344
Ignition Coil Testp. 1345
+Symptom Diagnosis and Testingp. 1346
Inspection and Verificationp. 1346
Symptom Chartp. 1347
Diagnosis Procedure for Spark Plug Not Flash Overp. 1348
Diagnosis Procedure for Insufficient Engine Powerp. 1355
+Removal and Installationp. 1362
Ignition Coilp. 1362
Spark Plugp. 1363
+Starting Systemp. 1365
+Specificationsp. 1365
Component Specificationsp. 1365
General Specificationsp. 1365
+Description and Operationp. 1366
System Overviewp. 1366
Components Descriptionp. 1366
Components Exploded Viewp. 1367
+General Inspectionp. 1368
Magnetic Switch Testp. 1368
Pinion Return Testp. 1368
Test without Loadp. 1368
+Symptom Diagnosis and Testingp. 1370
Inspection and Verificationp. 1370
Symptom Chartp. 1371
Diagnosis Procedure for Starting Motor Faultp. 1372
Diagnosis Procedure for Starting Motor Fails to Stopp. 1381
Diagnosis Procedure for Starting Motor Slow Runp. 1383
+Removal and Installationp. 1385
Starting Motorp. 1385
ENGINE START STOP Switchp. 1386
+Charging Systemp. 1389
+Specificationsp. 1389
Component Specificationsp. 1389
+Description and Operationp. 1390
System Overviewp. 1390
Components Descriptionp. 1390
Components Exploded Viewp. 1392
+General Inspectionp. 1394
Battery Inspectionp. 1394
Battery Chargingp. 1394
Battery Parasitic Current Testp. 1395
Alternator Testp. 1395
+Symptom Diagnosis and Testingp. 1397
Inspection and Verificationp. 1397
Symptom Chartp. 1398
Diagnosis Procedure for Insufficient Battery Chargingp. 1399
Diagnosis Procedure for Battery Overchargingp. 1401
Diagnosis Procedure for Alternator Noisep. 1402
Diagnosis Procedure for Charging Indicator Constant ONp. 1403
Diagnosis Procedure for Charging Indicator Not Come ONp. 1405
+Removal and Installationp. 1407
Batteryp. 1407
Alternator Assemblyp. 1409
+Emission Control Systemp. 1413
+Specificationsp. 1413
General Specificationsp. 1413
Torque Specificationsp. 1413
+Description and Operationp. 1414
System Overviewp. 1414
Components Descriptionp. 1414
Components Location Viewp. 1416
Components Exploded Viewp. 1418
Components Exploded Viewp. 1419
+General Inspectionp. 1420
PCV Valve Inspectionp. 1420
Carbon Canister Solenoid Valve Inspectionp. 1420
Oxygen Sensor Heater Inspectionp. 1420
+Removal and Installationp. 1421
PCV Valvep. 1421
Carbon Canister Solenoid Valvep. 1422
Front Oxygen Sensorp. 1423
Rear Oxygen Sensorp. 1424
Fuel Tank Pressure Sensorp. 1425
Carbon Canister (EURO V)p. 1426
Carbon Canister (EURO VI)p. 1427
+Engine Immobilizer Systemp. 1429
+Description and Operationp. 1429
System Overviewp. 1429
+Symptom Diagnosis and Testingp. 1430
Inspection and Verificationp. 1430
Symptom Chartp. 1431
+Cruise Systemp. 1433
+Description and Operationp. 1433
System Overviewp. 1433
Steering Wheel Buttonp. 1433
Use of Cruise Functionp. 1433
+Removal and Installationp. 1435
Constant Cruise Switchp. 1435
+Electronic Control Systemp. 1437
+Specificationsp. 1437
Component Specificationsp. 1437
Torque Specificationsp. 1437
+Description and Operationp. 1438
System Overviewp. 1438
Components Descriptionp. 1438
+General Inspectionp. 1441
DTC Read Procedurep. 1441
Data Flow Read Procedurep. 1441
Actuation Component Test Procedurep. 1441
+Symptom Diagnosis and Testingp. 1442
Inspection and Verificationp. 1442
Intermittent Malfunction Diagnosis Procedurep. 1443
Symptom Chartp. 1446
Diagnosis Procedure for Engine Not Startp. 1450
Diagnosis Procedure for Engine Start Problemp. 1454
Diagnosis Procedure for Unstable Engine Operation, Rough Idlingp. 1457
Diagnosis Procedure for Poor Engine Acceleration Performancep. 1460
+DTC Diagnosis and Testingp. 1463
ECU Wiring Harness Connector Terminal Listp. 1463
DTC Listp. 1467
DTC Diagnosis Procedure Indexp. 1472
DTC P0012, P0016, P0026, P0075, P0076, P0077, P1340, P1341p. 1479
DTC P0015, P0017, P0027, P0366, P0078, P0079, P0080p. 1484
DTC P0031, P0032, P0130, P0131, P0132, P0133, P0134, P014C, P014D, P1167, P1171p. 1489
DTC P0037, P0038, P0136, P0137, P0138, P2A01p. 1493
DTC P0033, P0034, P0035p. 1497
DTC P0068, P0122, P0123, P0222, P0223, P2119, P2135, P1516, P2101, P0641, P0651p. 1501
DTC P0112, P0113, P0237, P0238p. 1506
DTC P0097, P0098, P0107, P0108p. 1510
DTC P0117, P0118p. 1514
DTC P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271p. 1518
DTC P0324, P0325p. 1522
DTC P0335, P0336p. 1526
DTC P0335, P0336p. 1530
DTC P0340, P0341p. 1534
DTC P0340, P0341p. 1538
DTC P0351, P0352, P0353, P0354, P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310p. 1542
DTC P2564, P2565, P0234, P0299, P1234p. 1548
DTC P0458, P0459p. 1553
DTC P0598, P0599p. 1557
DTC P2122, P2123, P2127, P2128, P2138p. 1561
DTC P0557, P0558p. 1565
DTC P1556, P1559, P258C, P258Dp. 1569
DTC P0564, P0565, P0566, P0567, P0568, P0569, P056C, P0570, P1570, P1580, P1581p. 1574
DTC P0601, P0602, P0606, P060A, P060B, P060C, P060D, P1601, P1605, P160Ap. 1577
DTC P0480p. 1579
DTC P0481p. 1585
DTC P0230p. 1591
DTC P0831, P0832p. 1596
DTC P3336, P3337, P3338, P3339p. 1600
DTC P0646, P0647p. 1601
DTC P0616, P0617, P26E5, P26E6, P1515p. 1605
DTC P0685, P0687p. 1613
DTC P0562, P0563p. 1617
DTC P2104, P2105, P2106, P2110p. 1620
DTC P0504, P0571p. 1627
DTC P0630p. 1632
DTC P0171, P0172, P2187, P2188p. 1633
DTC P0420p. 1635
DTC P0300p. 1637
DTC P1336p. 1642
DTC P0700p. 1643
DTC U0001, U0073, U0101, U0121, U0126, U0146, U0151p. 1648
+Removal and Installationp. 1656
Engine Control Unitp. 1656
Air Intake Pressure/Temperature Sensorp. 1657
Intake Camshaft Position Sensorp. 1658
Exhaust Camshaft Position Sensorp. 1659
Intake OCV valvep. 1660
Exhaust OCV valvep. 1661
Crankshaft Position Sensorp. 1662
Knock Sensorp. 1663
Accelerator Pedal Assemblyp. 1664
+3.4 Automatic Transmissionp. 1667
+Automatic Transmissionp. 1669
+Specificationsp. 1669
General Specificationsp. 1669
Torque Specificationsp. 1669
+General Inspectionp. 1670
Oil Leakage Position Inspectionp. 1670
Transmission Programmingp. 1674
Transmission Adjustmentp. 1674
Automatic Transmission Oil Replacementp. 1676
Automatic Transmission Oil Level Inspectionp. 1677
+DTC Diagnosis and Testingp. 1678
DTC Listp. 1678
DTC Diagnosis Procedure Indexp. 1681
DTC P0602p. 1685
DTC P0634p. 1686
DTC P0658, P0659, P1915p. 1688
DTC P0560p. 1689
DTC P0562, P0563p. 1691
DTC P0741p. 1693
DTC P0716, P0717, P0722, P0723p. 1695
DTC P0742p. 1697
DTC P0751, P0752, P0756p. 1699
DTC P0776, P0777, P0796, P0797, P2714, P2715, P2723, P2724p. 1701
DTC P0601, P0603, P0604, P062F, P0667, P0668, P0669, P06AC, P06AD, P06AE, P0711, P0712, P0713, P0842, P0843, P0872, P0873, P0877, P0878, P0961, P0962, P0963, P0965, P0966, P0967, P0969, P0970, P0971, P0973, P0974, P0976, P0977, P0989, P0990, P182E, P…p. 1703
DTC U0073, U0100, U0102, U0103, U0121p. 1707
+Removal and Installationp. 1709
Oil Panp. 1709
Hydraulic Torque Converterp. 1711
Filterp. 1713
Electronic Control Elementp. 1715
AWD Output Shaft O-ringp. 1720
Gearshift Shaft Seal Ringp. 1721
Hydraulic Torque Converter Oil Sealp. 1724
Rear Drive Transmission Connecting Housingp. 1726
Automatic Transmissionp. 1728
+Automatic Transmission External Controlp. 1733
+Description and Operationp. 1733
Components Exploded Viewp. 1733
+General Inspectionp. 1734
Gearshift Control Cable Adjustmentp. 1734
+Removal and Installationp. 1735
Gearshift Control Assemblyp. 1735
Gearshift Control Cablep. 1737
+3.5 Engine System – (JE4D25)p. 1741
+Engine System – General Informationp. 1751
Overviewp. 1751
+Mechanical Systemp. 1753
+Specificationsp. 1753
General Specificationsp. 1753
Component Specificationsp. 1754
Torque Specificationsp. 1755
+Description and Operationp. 1757
Components Location Viewp. 1757
Components Exploded Viewp. 1759
+General Inspectionp. 1765
V-ribbed Belt Inspectionp. 1765
+Symptom Diagnosis and Testingp. 1766
Inspection and Verificationp. 1766
Symptom Chartp. 1767
Diagnosis Procedure for Abnormal Noise in Lower Part of Enginep. 1772
Diagnosis Procedure for V-ribbed Belt Noisep. 1774
Diagnosis Procedure for Abnormal Exhaust (White Smoke)p. 1776
Diagnosis Procedure for Abnormal Exhaust (Blue Smoke)p. 1778
Diagnosis Procedure for Abnormal Exhaust (Black Smoke)p. 1780
Diagnosis Procedure for Noise from Connecting Rod and Connecting Rod Bearingp. 1782
Diagnosis Procedure for Noise from Piston and Piston Pinp. 1783
Diagnosis Procedure for Valve Train Noisep. 1785
Diagnosis Procedure for Engine Not Start – Crankshaft Not Turnp. 1787
+Removal and Installationp. 1789
V-ribbed Beltp. 1789
Automatic Tension Pulleyp. 1790
Timing Beltp. 1792
Engine Assemblyp. 1805
+Disassembly and Assemblyp. 1814
Cylinder Head Cover and Camshaftp. 1814
Valve and Cylinder Headp. 1826
Piston and Connecting Rodp. 1834
Crankshaft and Cylinder Blockp. 1842
+Lubrication Systemp. 1857
+Specificationsp. 1857
Component Specificationsp. 1857
General Specificationsp. 1857
Torque Specificationsp. 1857
+Description and Operationp. 1858
System Overviewp. 1858
Components Descriptionp. 1859
+General Inspectionp. 1860
Oil Pressure Inspectionp. 1860
Oil Level Inspectionp. 1860
Engine Oil Replacementp. 1861
Oil Filter Replacementp. 1861
+Symptom Diagnosis and Testingp. 1863
Inspection and Verificationp. 1863
Symptom Chartp. 1864
Diagnosis Procedure for Oil Pressure Warning Lamp Constant ONp. 1866
Diagnosis Procedure for Oil Pressure Warning Lamp Not ONp. 1868
Diagnosis Procedure for Too Large Oil Consumptionp. 1869
+Removal and Installationp. 1871
Oil Panp. 1871
Oil Pumpp. 1873
Oil Pressure Sensorp. 1875
Oil Coolerp. 1876
Oil Suction Pipep. 1878
Relief Valvep. 1879
Oil Level Gauge Guidep. 1880
+Cooling Systemp. 1883
+Specificationsp. 1883
Component Specificationsp. 1883
General Specificationsp. 1883
Torque Specificationsp. 1883
+Description and Operationp. 1884
System Overviewp. 1884
Components Descriptionp. 1884
Components Exploded View for Cooling Systemp. 1886
+General Inspectionp. 1890
Coolant Level Inspectionp. 1890
Coolant Leakage Inspectionp. 1890
Coolant Draining and Fillingp. 1891
Cooling Fan Inspectionp. 1891
+Symptom Diagnosis and Testingp. 1893
Inspection and Verificationp. 1893
Symptom Chartp. 1894
Diagnosis Procedure for Cooling Fan Not Running at Low Speedp. 1898
Diagnosis Procedure for Cooling Fan Not Running at High Speedp. 1902
Diagnosis Procedure for Cooling Fan Constantly Running at High Speedp. 1906
Diagnosis Procedure for Cooling Fan Constantly Running at Low Speedp. 1908
+Removal and Installationp. 1910
Coolant Reservoirp. 1910
Cooling Fanp. 1911
Radiatorp. 1912
Thermostatp. 1915
Coolant Temperature Sensorp. 1917
Water Pumpp. 1918
+Intake Systemp. 1923
+Specificationsp. 1923
Torque Specificationsp. 1923
+Description and Operationp. 1924
Components Descriptionp. 1924
Intake Components Exploded Viewp. 1925
+Symptom Diagnosis and Testingp. 1929
Inspection and Verificationp. 1929
Symptom Chartp. 1930
Diagnosis Procedure for Intake Air Leakagep. 1930
+Removal and Installationp. 1932
Air Filter (EURO V)p. 1932
Air Filter (EURO VI)p. 1934
Air Filter Element (EURO V)p. 1936
Air Filter Element (EURO VI)p. 1938
Intercooler Assemblyp. 1940
Electronic Throttlep. 1942
Intake Connecting Pipep. 1944
+Exhaust Systemp. 1947
+Specificationsp. 1947
Torque Specificationsp. 1947
+Description and Operationp. 1948
Components Exploded Viewp. 1948
+Symptom Diagnosis and Testingp. 1953
Inspection and Verificationp. 1953
Symptom Chartp. 1954
Diagnosis Procedure for Exhaust System Blockagep. 1956
+Removal and Installationp. 1958
Exhaust Manifoldp. 1958
Boosterp. 1961
Oxidation Catalytic Converterp. 1966
Upstream Exhaust Temperature Sensorp. 1968
Diesel Particles Catcherp. 1969
Exhaust Temperature Sensor (DPF)p. 1971
Differential Pressure Sensorp. 1972
Muffler Inlet Pipep. 1973
Selective Catalytic Reductorp. 1974
Front Muffler (EURO V)p. 1976
Muffler (EURO VI)p. 1978
Urea Tankp. 1980
+Fuel Systemp. 1983
+Specificationsp. 1983
Torque Specificationsp. 1983
+Description and Operationp. 1984
System Overviewp. 1984
Components Descriptionp. 1984
Components Exploded Viewp. 1986
+General Inspectionp. 1990
Fuel System Bleedingp. 1990
Fuel System Drainingp. 1990
Fuel Filter Replacementp. 1991
+Symptom Diagnosis and Testingp. 1992
Inspection and Verificationp. 1992
Symptom Chartp. 1993
Diagnosis Procedure for High Pressure Fuel Pump Faultp. 1994
+Removal and Installationp. 1998
Fuel Filter Assemblyp. 1998
Fuel Tank Assemblyp. 2000
Fuel Suction Platep. 2002
Fuel Railp. 2003
Fuel Injectorp. 2006
Glow Plug Control Unitp. 2009
Glow Plugp. 2010
Fuel Injection Pumpp. 2012
+Starting Systemp. 2017
+Specificationsp. 2017
Component Specificationsp. 2017
General Specificationsp. 2017
Torque Specificationsp. 2017
+Description and Operationp. 2018
System Overviewp. 2018
Starting Procedurep. 2018
Components Descriptionp. 2019
Components Location Viewp. 2020
+General Inspectionp. 2021
Magnetic Switch Testp. 2021
Pinion Return Testp. 2021
Test without Loadp. 2021
+Symptom Diagnosis and Testingp. 2023
Inspection and Verificationp. 2023
Symptom Chartp. 2024
Diagnosis Procedure for Starting Motor Faultp. 2026
Diagnosis Procedure for Starting Motor Fails to Stopp. 2030
Diagnosis Procedure for Starting Motor Slow Runp. 2032
Diagnosis Procedure for Preheating Indicator Not ONp. 2034
Diagnosis Procedure for Preheating Indicator Constant ONp. 2038
+Removal and Installationp. 2040
Starting Motorp. 2040
ENGINE START STOP Switchp. 2041
+Charging Systemp. 2043
+Specificationsp. 2043
Component Specificationsp. 2043
+Description and Operationp. 2044
System Overviewp. 2044
Components Descriptionp. 2044
Components Exploded Viewp. 2046
+General Inspectionp. 2048
Battery Inspectionp. 2048
Battery Chargingp. 2048
Battery Parasitic Current Testp. 2049
Alternator Testp. 2049
V-ribbed Tension Inspectionp. 2050
+Symptom Diagnosis and Testingp. 2051
Inspection and Verificationp. 2051
Symptom Chartp. 2052
Diagnosis Procedure for Insufficient Battery Chargingp. 2053
Diagnosis Procedure for Battery Overchargingp. 2055
Diagnosis Procedure for Charging Indicator Constant ONp. 2056
Diagnosis Procedure for Charging Indicator Not Come ONp. 2057
Diagnosis Procedure for Alternator Noisep. 2059
+Removal and Installationp. 2060
Batteryp. 2060
Alternator Assemblyp. 2062
+Emission Control Systemp. 2065
+Specificationsp. 2065
Torque Specificationsp. 2065
+Description and Operationp. 2066
System Overviewp. 2066
Components Descriptionp. 2066
Components Location Viewp. 2068
Components Exploded Viewp. 2069
+General Inspectionp. 2071
Vacuum Switch Inspectionp. 2071
+Symptom Diagnosis and Testingp. 2072
Inspection and Verificationp. 2072
Symptom Chartp. 2073
Diagnosis Procedure for EGR Vacuum Switch Faultp. 2074
+Removal and Installationp. 2076
Crankcase Ventilation Valvep. 2076
Vacuum Switchp. 2077
Oxygen Sensorp. 2078
EGR Coolerp. 2079
+Engine Immobilizer Systemp. 2083
+Description and Operationp. 2083
System Overviewp. 2083
+Symptom Diagnosis and Testingp. 2084
Inspection and Verificationp. 2084
Symptom Chartp. 2085
+Cruise Systemp. 2087
+Description and Operationp. 2087
System Overviewp. 2087
Steering Wheel Buttonp. 2087
Use of Cruise Functionp. 2087
+Removal and Installationp. 2089
Constant Cruise Switchp. 2089
+Electronic Control Systemp. 2091
+Specificationsp. 2091
Torque Specificationsp. 2091
+Description and Operationp. 2092
System Overviewp. 2092
System Diagramp. 2092
Components Descriptionp. 2094
+General Inspectionp. 2096
DTC Read Procedurep. 2096
Data Flow Read Procedurep. 2096
Actuation Component Test Procedurep. 2096
+Symptom Diagnosis and Testingp. 2097
Inspection and Verificationp. 2097
Intermittent Malfunction Diagnosis Procedurep. 2098
Symptom Chartp. 2101
Diagnosis Procedure for Engine Not Startp. 2106
Diagnosis Procedure for Engine Start Problemp. 2110
Diagnosis Procedure for Unstable Engine Operation, Rough Idlingp. 2113
Diagnosis Procedure for Poor Engine Acceleration Performancep. 2116
+DTC Diagnosis and Testingp. 2119
ECU Wiring Harness Connector Terminal List (EURO V)p. 2119
ECU Wiring Harness Connector Terminal List (EURO VI)p. 2124
DTC Listp. 2130
DTC Diagnosis Procedure Indexp. 2149
DTC P0645-13, P0645-F0, P0645-F0, P0645-F1, P0647-12, P0646-F1, P0647-F0, P0646-11, U0424-00, U0466-29p. 2167
DTC P00E3-13, P00E3-12, P00E3-11, P245A-13p. 2173
DTC P0403-13, P0404-F0, P0404-F1, P0404-F2, P0404-F3, P0401- 9C, P0402-9B, P213A-13, P213A-92, P2142-12, P213D-12, P2141-11, P213C-11, P213A-01, P213A-A2, P042F-73, P042E-72, P0404-F5, P0404-F6, P0409-85, P0409-84, P0404-F7, P0404-F8, P0403-74, P0406…p. 2179
DTC P0073-12, P0072-11p. 2186
DTC P0341-29, P0340-31p. 2190
DTC P0336-29, P2619-37, P034A-30, P2617-38, P2618-36, P034A- 31, P0335-31p. 2194
DTC P0201-13, P0203-13, P0204-13, P0202-13, P062D-F0, P062E- F0, P0262-12, P0268-12, P0271-12, P0265-12, P0261-11, P0267-11, P0270-11, P0264-11, P020A-F0, P020C-F0, P020D-F0, P020B-F0, P020A-F1, P020C-F1, P020D-F1, P020D-F1, P020B-F1, P0301-00, P0303…p. 2199
DTC P0251-F0, P0251-F1, P0251-12, P0251-11, P0254-12, P0253-11p. 2208
DTC P0194-1F, P0190-85, P0190-84, P0191-85, P0191-84, P0193-12, P0192-11p. 2214
DTC P0123-12, P0223-12, P0122-11, P0222-11, P2135-64p. 2219
DTC P007A-85, P007A-84, P0098-12, P0097-11p. 2224
DTC P2100-19, P2108-F0, P2108-F1, P2108-F2, P2112-92, P2112-85, P2111-84, P2100-13, P2100-1D, P2100-F0, P2100-12, P2100-F1, P2100-11, P2100-F2, P2100-92, P2100-A2, P2112-73, P2111-72, P2108-F3, P2108-F4, P2101-12, P2101-92, P2108-84, P2108-85, P212A-…p. 2229
DTC P0425-64, P0425-85, P0425-84, P0428-12, P0427-11p. 2235
DTC P200C-64, P200C-85, P200C-84, P200C-12, P200C-11p. 2240
DTC P064D-2F, P0030-04, P064D-00, P015A-00, P0030-09, P0030- 12, P0030-11, P0030-29, P223C-19, P223C-18, P223C-29, P223C-F1, P223C-2F, P223C-F3, P014D-F0, P2195-64, P014D-64, P014C-F2, P2196-64, P014C-64, P0130-12, P0130-11, P0130-02, P064D-29p. 2245
DTC P0615-F1, P04804N, P0615-4B, P0615-12, P0615-11, P26E4-12, P26E4-11, P0615-13, P060C-05p. 2251
DTC P0381-13, P0381-12, P0381-11, P064C-41, P064C-F1, P064C- F2, P064C-07, P0380-F4, P0380-12, P0380-11, P0380-13, P0671-07, P0673-07, P0674-07, P0672-07, P0671-01, P0673-01, P0674-01, P0672-01, P0672-01, P0380-14, P064C-F3, P064C-09p. 2256
DTC P0115-85, P0115-84, P0116-26, P0116-27, P0118-12, P0117-11, P0655-13, P0655-12, P0655-11p. 2262
DTC P0579-29, P1680-13, P1682-12, P1683-11, P0577-85, P0576-84, P0575-01, P0578-F1p. 2267
DTC P0480-13, P0692-12, P0691-11p. 2272
DTC P226A-13, P226A-12, P226A-11, P2264-09, P2269-00p. 2277
DTC P062B-F0, P062B-F1, P062B-F2, P062B-F3p. 2282
DTC P2452-76, P2452-F0, P242F-00, P244B-00, P244A-00, P244A- F0, P226D-09, P2002-00, P246C-00, P2459-F0, P24A2-F0, P2458-00, P2463-F3, P2463-84, P2463-85, P2463-F0, P2463-F1, P2463-F2, P244B-85, P2452-14, P2452-F1, P2452-64, P2452-F3, P2452-13, P2452…p. 2284
DTC U0415-F1, U1400-29, U0415-81, U0121-87, U1402-29, U0073- F0, U0030-16, U01B7-86p. 2290
DTC P0100-01, P0100-F4, P0100-F5, P0100-11, P0100-F3, P0100-F1, P0103-29, P0103-12, P0102-11, P0113-37, P0112-36, P0100-85, P0100-84, P0113-17, P0112-16, P00AB-1Cp. 2296
DTC P0704-01p. 2301
DTC P0340-01p. 2309
DTC P068A-00, P068B-00p. 2313
DTC P2299-64, P0571-29, P0504-62, P0703-29p. 2317
DTC P0069-64, P023D-17, P023D-16, P0235-17, P0235-16, P2263- 84, P2263-85, P2263-F0, P2263-F1, P2263-F2, P2263-F3, P2263-F4, P2263-F5, P2263-7Cp. 2326
DTC P060B-F0, P060B-00, P060B-A1, P060-F0, P060C-F1, P060C- F2, P060C-F3, P060C-F4, P060C-F5, P060C-F6, P060C-13, P060C- F7, P060C-F8, P060C-F9, P060C-FA, P060C-FB, P1012-00, P1013- 00, P1014-00, P1015-00, P1016-00, P1017-00, P1018-00, P1019-00, P109…p. 2330
+Removal and Installationp. 2335
Engine Control Unitp. 2335
Air Flow Meterp. 2336
Air Intake Pressure/Temperature Sensorp. 2337
Camshaft Position Sensorp. 2337
Boost Temperature Sensorp. 2338
Crankshaft Position Sensorp. 2338
Accelerator Pedal Assemblyp. 2339
+4.1 Heating, Ventilation and Air Conditioningp. 2343
+Heating, Ventilation and Air Conditioningp. 2345
+Specificationsp. 2345
Material Specificationsp. 2345
+Description and Operationp. 2346
System Overviewp. 2346
Components Descriptionp. 2347
Function Position for A/C Control Panelp. 2348
Function Button Description for A/C Control Panelp. 2349
A/C System Operationp. 2351
Vehicle Inside Ventilation Diagramp. 2352
Refrigeration System Operationp. 2353
A/C System Component Viewp. 2354
HAVC Components Location Viewp. 2355
+General Inspectionp. 2356
A/C Repair Precautionsp. 2356
Refrigeration System Testp. 2356
"Quick Inspection" Procedure for Insufficient A/C Coolingp. 2357
Refrigeration System Leakage Testp. 2357
Evaporator Core Testp. 2357
Compressor Shaft Seal Testp. 2358
A/C Refrigerant Recycling/ Draining and Fillingp. 2358
+Symptom Diagnosis and Testingp. 2361
Inspection and Verificationp. 2361
Symptom Chartp. 2362
Diagnosis Procedure for Insufficient A/C Refrigerantp. 2364
Diagnosis Procedure for Insufficient A/C Heatingp. 2369
Diagnosis Procedure for Blower Faultp. 2371
Diagnosis Procedure for A/C Compressor Clutch Faultp. 2376
+DTC Diagnosis and Testingp. 2381
DTC Listp. 2381
DTC Diagnosis Procedure Indexp. 2382
DTC B14A017, B14A116p. 2383
DTC U120088, U120187, U120287, U120387, U120587, U120687, U120787, U120887p. 2386
DTC B1400p. 2388
DTC B1401p. 2391
DTC B1402p. 2394
DTC B1403p. 2397
DTC B1404p. 2400
DTC B1405p. 2403
DTC B1406p. 2405
DTC B1407p. 2408
+Removal and Installationp. 2411
Compressorp. 2411
Condenserp. 2413
A/C Pressure Switchp. 2415
Expansion Valvep. 2416
A/C Pipep. 2418
Front A/C Control Panelp. 2421
Blower Motorp. 2422
Mode Damper Actuator Assemblyp. 2423
Speed Control Module Assemblyp. 2425
Cool and Warm Damper Actuator Assemblyp. 2426
Inside and Outside Circulation Actuator Assemblyp. 2427
Ion Generator Assemblyp. 2429
HVAC Assemblyp. 2430
Evaporator Core Assemblyp. 2432
Heater Core Assemblyp. 2436
Sunshine Strength Sensor Assemblyp. 2438
Front Room Temperature Sensor Assemblyp. 2439
Outside Temperature Sensor Assemblyp. 2440
A/C Filterp. 2441
+4.2 Supplemental Restraint Systemp. 2443
+Supplemental Restraint Systemp. 2445
+Specificationsp. 2445
General Specificationsp. 2445
+Description and Operationp. 2446
System Overviewp. 2446
Components Descriptionp. 2447
Components Location Viewp. 2450
+Symptom Diagnosis and Testingp. 2451
Inspection and Verificationp. 2451
Symptom Chartp. 2452
Diagnosis Procedure for Airbag Warning Lamp Constant ONp. 2453
+DTC Diagnosis and Testingp. 2457
Airbag Control Unit (ACU) Terminal Listp. 2457
DTC Listp. 2458
DTC Diagnosis Procedure Indexp. 2462
DTC B1B1055, B1B102B, B1B1013, B1B1011, B1B1012, B1B101Ap. 2467
DTC B1B111A, B1B1112, B1B1111, B1B1113, B1B112B, B1B1155p. 2471
DTC B1B121A, B1B1212, B1B1211, B1B1213, B1B122B, B1B1255p. 2475
DTC B1B131A, B1B1312, B1B1311, B1B1313, B1B132B, B1B1355p. 2479
DTC B1B141A, B1B1412, B1B1411, B1B1413, B1B142B, B1B1455p. 2483
DTC B1B151A, B1B1512, B1B1511, B1B1513, B1B152B, B1B1555p. 2487
DTC B1B161A, B1B1612, B1B1611, B1B1613, B1B162B, B1B1655p. 2491
DTC B1B171A, B1B1712, B1B1711, B1B1713, B1B172B, B1B1755p. 2495
DTC B1B0112, B1B0113, B1B0181, B1B012B, B1B0196, B1B0155, B1B0111p. 2499
DTC B1B0212, B1B0213, B1B0281, B1B022B, B1B0296, B1B0255, B1B0211p. 2503
DTC B1B0312, B1B0313, B1B0381, B1B032B, B1B0396, B1B0355, B1B0311p. 2507
DTC B1B0412, B1B0413, B1B0481, B1B042B, B1B0496, B1B0455, B1B0411p. 2511
DTC B1B0049, B1B4100, B1B4200, B1B4300, B1B4400p. 2515
DTC B1B2012p. 2516
DTC B1B2112p. 2519
DTC B1B4516, B1B4617p. 2522
DTC U000188, U158687, U158487, U158587, U158887, U158787p. 2524
+Removal and Installationp. 2526
Driver Frontal Airbagp. 2526
Rotary Connectorp. 2527
Side Airbagp. 2529
Front Passenger Frontal Airbagp. 2530
Side Curtain Shield Airbagp. 2531
Airbag Control Unitp. 2533
Side Collision Sensorp. 2534
Frontal Collision Sensorp. 2535
+4.3 Body Electricalp. 2537
+Instrument Panel and Panel Illuminationp. 2549
+Specificationsp. 2549
General Specificationsp. 2549
+Description and Operationp. 2550
System Overviewp. 2550
+Symptom Diagnosis and Testingp. 2551
Inspection and Verificationp. 2551
Symptom Chartp. 2552
Diagnosis Procedure for Inoperative Front Control Panel Illumination with Position Lamp ONp. 2555
Diagnosis Procedure for Inoperative Left Front Window Switch Illumination with Position Lamp ONp. 2557
Diagnosis Procedure for Inoperative Power Rearview Mirror Switch Illumination with Position Lamp ONp. 2559
Diagnosis Procedure for Inoperative ENGINE START STOP Switch Illumination with Position Lamp ON (with PEPS)p. 2561
Diagnosis Procedure for Inoperative Cigarette Lighter Illumination with Position Lamp ONp. 2562
Diagnosis Procedure for Inoperative Steering Wheel Button Switch Illumination with Position Lamp ON (with PEPS)p. 2564
+Instrument Clusterp. 2565
+Specificationsp. 2565
General Specificationsp. 2565
+Description and Operationp. 2566
System Overviewp. 2566
Instrument Cluster Indicatorp. 2567
Components Location Viewp. 2569
+Symptom Diagnosis and Testingp. 2570
Inspection and Verificationp. 2570
Symptom Chartp. 2571
Diagnosis Procedure for Inoperative Oil Pressure Indicator with Ignition Switch "ON"p. 2574
Diagnosis Procedure for Inoperative Battery Charging Indicator with Ignition Switch "ON"p. 2576
Diagnosis Procedure for Inoperative Seat Belt Indicator with Ignition Switch "ON"p. 2578
Diagnosis Procedure for Inoperative Anti-theft System Indicatorp. 2580
Diagnosis Procedure for Inoperative Parking Brake Indicator with Parking Brake Lever Pulled Upp. 2581
Diagnosis Procedure for Abnormal Fuel Level Indicationp. 2583
+Removal and Installationp. 2585
Instrument Clusterp. 2585
+Hornp. 2587
+Specificationsp. 2587
Torque Specificationsp. 2587
+Description and Operationp. 2588
System Overviewp. 2588
Components Location Viewp. 2588
+Symptom Diagnosis and Testingp. 2590
Inspection and Verificationp. 2590
Symptom Chartp. 2591
Diagnosis Procedure for Horn Constantly Workingp. 2592
Diagnosis Procedure for Horn Not Soundingp. 2594
+Removal and Installationp. 2599
Hornp. 2599
+Cigarette Lighter/Accessory Power Supplyp. 2601
+Specificationsp. 2601
General Specificationsp. 2601
+Description and Operationp. 2602
System Overviewp. 2602
Components Location Viewp. 2603
+Symptom Diagnosis and Testingp. 2606
Symptom Diagnosis and Testingp. 2606
Symptom Chartp. 2607
Diagnosis Procedure for Cigarette Lighter Faultp. 2608
Diagnosis Procedure for Rear USB Interface Faultp. 2610
+Removal and Installationp. 2612
Cigarette Lighterp. 2612
Front USB External Interfacep. 2614
Rear USB External Interfacep. 2615
+Information and Entertainment Systemp. 2617
+Specificationsp. 2617
Torque Specificationsp. 2617
+Description and Operationp. 2618
System Overviewp. 2618
Components Descriptionp. 2618
Components Location Viewp. 2619
+Symptom Diagnosis and Testingp. 2620
General Equipmentp. 2620
Symptom Chartp. 2621
Diagnosis Procedure for On-board Information and Entertainment Terminal Fault after ACC Power-onp. 2622
+Removal and Installationp. 2624
On-board Information and Entertainment Terminalp. 2624
Displayp. 2625
Front Speakerp. 2627
Rear Speakerp. 2628
Tweeterp. 2629
Radio Antennap. 2630
Central Switch Installation Box Assemblyp. 2632
+Lighting Systemp. 2635
+Description and Operationp. 2635
System Overviewp. 2635
Components Location Viewp. 2636
+General Inspectionp. 2640
Test for Lighting Combination Switchp. 2640
+Symptom Diagnosis and Testingp. 2644
Inspection and Verificationp. 2644
Symptom Chartp. 2645
Diagnosis Procedure for Brake Lamp Failurep. 2649
Diagnosis Procedure for Single Brake Lamp Faultp. 2656
Diagnosis Procedure for Brake Lamp Remaining Onp. 2658
Diagnosis Procedure for Turn Lamp Failurep. 2661
Diagnosis Procedure for One or More Turn Lamps Failurep. 2665
Diagnosis Procedure for One or More Turn Lamps Remaining ONp. 2667
Diagnosis Procedure for Hazard Warning Lamp Failurep. 2668
Diagnosis Procedure for Position Lamp Failurep. 2671
Diagnosis Procedure for Position Lamp Remaining Onp. 2676
Diagnosis Procedure for Front Fog Lamp Failurep. 2678
Diagnosis Procedure for Front Fog Lamp Remaining Onp. 2684
Diagnosis Procedure for Rear Fog Lamp Failurep. 2686
Diagnosis Procedure for Rear Fog Lamp Remaining Onp. 2692
Diagnosis Procedure for Backup Lamp Failurep. 2694
Diagnosis Procedure for Backup Lamp Remaining ONp. 2700
Diagnosis Procedure for Low Beam Lamp Failurep. 2702
Diagnosis Procedure for One Side Low Beam Lamp Faultp. 2709
Diagnosis Procedure for High Beam Lamp Failurep. 2711
Diagnosis Procedure for One Side High Beam Lamp Faultp. 2716
Diagnosis Procedure for Overtaking Lamp Failurep. 2718
Diagnosis Procedure for License Plate Lamp Failurep. 2725
Diagnosis Procedure for Daytime Running Lamp Failurep. 2727
Diagnosis Procedure for Single Daytime Running Lamp Failurep. 2731
Diagnosis Procedure for Front Dome Lamp Failurep. 2733
+Removal and Installationp. 2735
Lighting Combination Switchp. 2735
Hazard Warning Lamp Switchp. 2736
Headlampp. 2737
Side Turn Lampp. 2738
High Mounted Stop Lampp. 2739
License Plate Lampp. 2740
Rear Combination Lampp. 2741
Front Dome Lampp. 2742
Rear Dome Lampp. 2743
Front Fog Lampp. 2744
+Wiper and Washerp. 2745
+Description and Operationp. 2745
System Overviewp. 2745
Components Location Viewp. 2746
+General Inspectionp. 2748
Wiper Combination Switch Testp. 2748
Wiper Abnormal Sound Treatmentp. 2748
+Symptom Diagnosis and Testingp. 2749
Inspection and Verificationp. 2749
Symptom Chartp. 2750
Diagnosis Procedure for Front Windshield Wiper Failurep. 2753
Diagnosis Procedure for Front Windshield Wiper Constantly Runningp. 2758
Diagnosis Procedure for Inoperative Wiper in LO Levelp. 2760
Diagnosis Procedure for Inoperative Wiper in HI Levelp. 2763
Diagnosis Procedure for Inoperative Wiper in INT Levelp. 2766
Diagnosis Procedure for Poor Wiping Effectp. 2768
Diagnosis Procedure for Shaking Wiper During Operationp. 2770
Diagnosis Procedure for Abnormal Sound During Wipingp. 2772
Diagnosis Procedure for Front Wiper cannot Return to Initial Positionp. 2774
Diagnosis Procedure for Poor Water Injection Effect on Windshieldp. 2776
Diagnosis Procedure for Inoperative Washerp. 2777
+Removal and Installationp. 2780
Wiper Motor and Linkagep. 2780
Washer Equipmentp. 2784
Wiper Combination Switchp. 2786
+Power Rearview Mirrorp. 2787
+Description and Operationp. 2787
System Overviewp. 2787
Components Location Viewp. 2788
+Symptom Diagnosis and Testingp. 2790
Inspection and Verificationp. 2790
Symptom Chartp. 2791
Diagnosis Procedure for All Power Rearview Mirrors Failing to Operatep. 2792
Diagnosis Procedure for Single Power Rearview Mirror Failing to Operatep. 2795
+Removal and Installationp. 2798
Power Rearview Mirrorp. 2798
Power Rearview Mirror Switchp. 2800
+Central Door Lockp. 2801
+Description and Operationp. 2801
System Overviewp. 2801
Components Location Viewp. 2802
+Symptom Diagnosis and Testingp. 2803
Inspection and Verificationp. 2803
Symptom Chartp. 2804
Diagnosis Procedure for Central Lock Faultp. 2806
Diagnosis Procedure of Driver Side Door Lock Faultp. 2810
Diagnosis Procedure for Passenger Side Door Lock Faultp. 2813
Diagnosis Procedure for Central Lock is Normal but Remote Controller Faultp. 2815
Diagnosis Procedure for Door Cannot be Locked by Mechanical Keyp. 2817
Diagnosis Procedure for Door Cannot be Unlocked by Mechanical Keyp. 2819
+Removal and Installationp. 2821
Front Door Lock Latch Assemblyp. 2821
Rear Door Lock Latch Assemblyp. 2821
+Power Windowp. 2823
+Specificationsp. 2823
General Specificationsp. 2823
+Description and Operationp. 2824
System Overviewp. 2824
Components Location Viewp. 2825
+General Inspectionp. 2828
Window Initializationp. 2828
+Symptom Diagnosis and Testingp. 2829
Inspection and Verificationp. 2829
Symptom Chartp. 2830
Diagnosis Procedure for All Power Windows Failing to Operatep. 2832
Diagnosis Procedure for Driver Side Power Window Failurep. 2837
Diagnosis Procedure for Passenger Side Power Window Failurep. 2841
+Removal and Installationp. 2846
Driver Side Power Window Switchp. 2846
Passenger Side Power Window Switchp. 2848
Front Door Glass Regulator Assemblyp. 2850
Rear Door Glass Regulator Assemblyp. 2852
+Defrosterp. 2855
+Description and Operationp. 2855
System Overviewp. 2855
+Symptom Diagnosis and Testingp. 2856
Inspection and Verificationp. 2856
Symptom Chartp. 2857
Diagnosis Procedure for Rear Windshield Defroster Failurep. 2858
Diagnosis Procedure for Rearview Mirror Defroster Failurep. 2864
Diagnosis Procedure for Defroster System cannot Cut Off Automaticallyp. 2867
+Parking Assist Systemp. 2871
+Description and Operationp. 2871
System Overviewp. 2871
Components Descriptionp. 2873
Terminal Listp. 2874
+Symptom Diagnosis and Testingp. 2875
Inspection and Verificationp. 2875
Symptom Chartp. 2876
Diagnosis Procedure for Buzzer Not Sound When Obstacle Occurs During Reversingp. 2878
Diagnosis Procedure for Buzzer Sounds When No Obstacle Occurs During Reversingp. 2882
+Removal and Installationp. 2884
Reversing Radar Modulep. 2884
Rear Reversing Radar Sensorp. 2886
+Body Control Systemp. 2887
Specificationsp. 2887
+Description and Operationp. 2888
Components Location Viewp. 2888
+DTC Diagnosis and Testingp. 2889
Body Controller (Not Equipped with PEPS) Terminal Definitionp. 2889
DTC Listp. 2892
DTC Diagnosis Procedure Indexp. 2895
DTC B12000, B12010, B12011, B12100, B12110, B12120, B12121, B12122, B12200, B12201, B12202, B12300, B12301, B12302, B12303, B12304, B12305, B12306, B12308p. 2900
DTC B12310, B12320, B12330, B12340, B18720, B18730, B18740, B18750, B18760, B18770, B18780, B18790, B18800, B18810, B18820, B18830, B18840, B18850, B18860, B18870p. 2903
DTC B15200, B18200p. 2907
DTC B15302, B18302p. 2908
DTC B15303p. 2911
DTC B15304p. 2913
DTC B15305, B18303p. 2915
DTC B15306p. 2918
DTC B15308, B18301p. 2920
DTC B18000, B18001p. 2923
DTC B18010, B18011p. 2924
DTC B18110, B18111, B18112, B18113, B18114, B18115, B18116, B18117p. 2926
DTC B18400p. 2933
DTC B18500, B18501p. 2935
DTC B18710, B18711p. 2938
DTC B18718, B18719p. 2941
DTC B187112, B187113p. 2944
DTC B187114, B187115p. 2947
DTC B187116, B187117p. 2950
DTC B187124, B187125p. 2953
DTC B190000, B190100, B190200, B190300, B190400, B190500, B190600p. 2956
DTC U007388, U008087, U008387, U008487, U008687, U008887, U009387,U009187p. 2960
DTC U020487p. 2963
DTC U019987p. 2966
+Removal and Installationp. 2968
Body Controller Assemblyp. 2968
+PEPS Systemp. 2969
+Description and Operationp. 2969
System Overviewp. 2969
Components Location Viewp. 2970
+Symptom Diagnosis and Testingp. 2971
Inspection and Verificationp. 2971
Symptom Chartp. 2972
+DTC Diagnosis and Testingp. 2973
IBCM Control Module Terminal Listp. 2973
DTC Listp. 2977
DTC Diagnosis Procedure Indexp. 2982
DTC B100212p. 2987
DTC B100312, B100313p. 2990
DTC B100412, B100413p. 2992
DTC B100612, B100613, B101412, B101413p. 2994
DTC B100712, B100713p. 2996
DTC B100812p. 2998
DTC B100912, B100913p. 3001
DTC B100A12, B100A13p. 3003
DTC B100B12, B100B13p. 3005
DTC B101612, B101613p. 3007
DTC B102012p. 3009
DTC B102112, B102111p. 3011
DTC B102212, B102211p. 3013
DTC B102311, B102313p. 3015
DTC B102411, B102412, B102413p. 3017
DTC B102811, B102812, B102813, B106B23p. 3020
DTC B102B12, B102B13, B106429, B102911, B102912p. 3021
DTC B102A11, B102A13p. 3024
DTC B102C11, B102C12, B102C13p. 3027
DTC B102F11, B102F12, B102F13p. 3030
DTC B103111, B103112, B103113, B103118p. 3031
DTC B103211, B103212, B103213, B103218p. 3034
DTC B103311, B103312, B103313, B103318p. 3037
DTC B103512p. 3042
DTC B103613, B103612p. 3045
DTC B103813p. 3047
DTC B103912, B103913, B103918p. 3049
DTC B103A11, B103A12, B103A13p. 3050
DTC B104311, B104312, B104313p. 3053
DTC B103B11, B103B12p. 3054
DTC B103C11, B103C12, B103C13p. 3057
DTC B104011, B104012, B104013p. 3060
DTC B105414p. 3061
DTC B105514p. 3064
DTC B105314p. 3064
DTC B105823p. 3065
DTC B105A29p. 3068
DTC B106023, B106029, B106123, B106129, B106211p. 3072
DTC B106311p. 3075
DTC B106523p. 3077
DTC B106623p. 3079
DTC B106723p. 3081
DTC B106F00p. 3083
DTC B107102, B107202, B107302, B107402p. 3085
DTC B107993, B107A93, B107B93, B107C93p. 3086
DTC B107502, B107602p. 3087
DTC B108862p. 3088
DTC U100988, U100A87, U100B87, U100E87, U100F87, U101087, U101287, U101387, U101487p. 3091
DTC U100281, U100287, U100381, U100387p. 3093
DTC U101883, U101A87, U101B86p. 3096
DTC U101B86, U101B85, U101B44p. 3097
DTC U101C00p. 3098
+Removal and Installationp. 3101
PEPS Controllerp. 3101
Interior Central Antennap. 3102
Left Rear Door Antennap. 3103
+Tire Pressure Monitoring Systemp. 3105
+Description and Operationp. 3105
System Overviewp. 3105
Components Exploded Viewp. 3107
+Symptom Diagnosis and Testingp. 3108
Diagnosis Procedure for Tire Pressure Monitoring Faultp. 3108
+Removal and Installationp. 3111
Radio Frequency Receiver Assemblyp. 3111
Tire Pressure Sensor Assemblyp. 3112
+On-board Network Systemp. 3113
+Description and Operationp. 3113
CAN Bus Integrity Inspectionp. 3115
Components Location Viewp. 3116
+Symptom Diagnosis and Testingp. 3117
Inspection and Verificationp. 3117
Symptom Chartp. 3118
Diagnosis Procedure for Disabled P CAN Communication Between Diagnostic Tool and ECUp. 3122
Diagnosis Procedure for Disabled B CAN Communication Between Diagnostic Tool and BCMp. 3126
+DTC Diagnosis and Testingp. 3130
Control Module Terminal Listp. 3130
DTC Listp. 3131
DTC Diagnosis Procedure Indexp. 3132
DTC B250044, B250045, B250046p. 3133
DTC U140016, U140017p. 3137
DTC U001088p. 3140
DTC U001288p. 3143
DTC U001988p. 3146
DTC U001388p. 3149
DTC U140087p. 3152
DTC U140187p. 3154
DTC U010087, U013187, U042087, U110A87p. 3156
DTC U015587, U014087, U142187, U016487, U042387, U042487, U016187, U010487, U042787, U015887, U042187, U012687p. 3158
+Removal and Installationp. 3160
Gateway Controller Assemblyp. 3160
+5.1 Body and Accessoriesp. 3163
+Front and Rear Windshieldsp. 3167
+Specificationsp. 3167
General Specificationsp. 3167
+Description and Operationp. 3168
System Overviewp. 3168
+Removal and Installationp. 3169
Front Windshieldp. 3169
Rear Windshield (with Defroster)p. 3178
+Doorp. 3185
+Specificationsp. 3185
Torque Specificationsp. 3185
+Description and Operationp. 3187
System Overviewp. 3187
+Removal and Installationp. 3188
Front Door Interior Trim Panelp. 3188
Rear Door Interior Trim Panelp. 3192
Front Door Glassp. 3195
Rear Door Glassp. 3197
Front Door Rear Lower Slot Assemblyp. 3200
Rear Door Rear Lower Slot Assemblyp. 3201
Front Door Glass Runp. 3202
Rear Door Glass Runp. 3203
Front Door Glass Regulator Assemblyp. 3204
Rear Door Glass Regulator Assemblyp. 3205
Front Doorp. 3206
Rear Doorp. 3209
Engine Compartment Coverp. 3212
+Seatp. 3215
+Specificationsp. 3215
Torque Specificationsp. 3215
+Description and Operationp. 3216
Components Location Viewp. 3216
+Removal and Installationp. 3217
Front Seat Assemblyp. 3217
Rear Seat Assemblyp. 3219
+Seat Beltp. 3223
+Specificationsp. 3223
Torque Specificationsp. 3223
+Description and Operationp. 3224
System Overviewp. 3224
+Removal and Installationp. 3225
Front Seat Beltp. 3225
Rear Seat Beltp. 3228
+Inner Rearview Mirrorp. 3231
+Description and Operationp. 3231
System Overviewp. 3231
Components Location Viewp. 3231
+Removal and Installationp. 3232
Inner Rearview Mirrorp. 3232
+Instrument Panel and Consolep. 3233
+Specificationsp. 3233
Torque Specificationsp. 3233
+Removal and Installationp. 3234
Auxiliary Fascia Console Assemblyp. 3234
Instrument Panelp. 3238
Steering Support Assemblyp. 3247
+Bumperp. 3253
+Specificationsp. 3253
Torque Specificationsp. 3253
+Removal and Installationp. 3254
Front Bumperp. 3254
Front Grillep. 3258
Rear Bumperp. 3261
+Handles, Locks and Latchesp. 3265
+Specificationsp. 3265
Torque Specificationsp. 3265
+Removal and Installationp. 3266
Front Hood Lock Assemblyp. 3266
Steering Lock Assemblyp. 3267
Front Door Outside Handle Assemblyp. 3268
Front Door Lock Assemblyp. 3271
Front Door Lock Pinp. 3273
Rear Door Outside Handle Assemblyp. 3274
Rear Door Lock Assemblyp. 3277
Rear Door Lock Pinp. 3279
Front Door Inside Handle Assemblyp. 3280
Rear Door Inside Handle Assemblyp. 3281
Cargo Box Door Lock Outside Handlep. 3282
Cargo Compartment Door Lock Assemblyp. 3285
Cargo Compartment Door Lock Ringp. 3287
+Interior Trim Panel and Ornamentationp. 3289
+Removal and Installationp. 3289
Front Doorsill Trim Panelp. 3289
Rear Doorsill Trim Panelp. 3290
A Pillar Lower Interior Trim Panelp. 3291
A Pillar Upper Interior Trim Panelp. 3292
B Pillar Lower Interior Trim Panelp. 3294
B Pillar Upper Interior Trim Panelp. 3296
C Pillar Lower Interior Trim Panelp. 3298
C Pillar Upper Interior Trim Panelp. 3299
Rear Quarter Interior Trim Panelp. 3301
Sun Visorp. 3303
Roof Liningp. 3305
+Exterior Trimp. 3309
+Removal and Installationp. 3309
Front Fenderp. 3309
Front Mud Guardp. 3312
Rear Mud Guardp. 3313
Mud Guardp. 3314
Front Wheel Housing Lining Platep. 3315
Rear Wheel Housing Lining Platep. 3317
Roof Rackp. 3319
Side Footrest Assemblyp. 3320
+Cargo Compartmentp. 3321
+Specificationsp. 3321
Torque Specificationsp. 3321
+Removal and Installationp. 3322
Cargo Compartment Guardrailp. 3322
Cargo Compartment Doorp. 3323
Cargo Compartmentp. 3326
+5.2 Body Repairsp. 3329
+Accident Vehicle Maintenance Operationp. 3333
+General Maintenance Specificationp. 3333
Vehicle Protectionp. 3333
Safety Measuresp. 3333
+Notes for Operations on Body Structural Steel Platep. 3335
Bending Deformation of Structural Steel Plates Must Be Replacedp. 3335
Door Impact Beam Cannot Be Repaired Alonep. 3335
+Maintenance Sequence of Accident Vehiclesp. 3336
Preparations for Removalp. 3336
Removalp. 3336
Installation Preparationp. 3337
Installationp. 3338
Anti-rust Treatment (Before Painting)p. 3339
Anti-rust Treatment (After Painting)p. 3339
Anti-rust Treatment by Paintingp. 3339
+Notes for Operation of Related Systemsp. 3340
Protect Adjacent Parts of Body Steel Platep. 3340
Electronic Control Unitp. 3340
Batteryp. 3340
Notes for Fuel Tank and Fuel Hosep. 3340
A/Cp. 3340
Airbagp. 3341
+Technical Datap. 3343
+Body Clearance Offset Sizep. 3343
Body-Frontp. 3343
Body-Rearp. 3344
Symbol Meaningp. 3345
+Body Reference Sizep. 3346
Engine Compartment Reference Sizep. 3346
Floor Bottom Reference Sizep. 3347
Middle Reference Sizep. 3348
Middle Reference Sizep. 3349
Rear Reference Sizep. 3350
+Body – Frontp. 3351
+Replacement of Front Impact Beam Assemblyp. 3351
Removal of Original Partsp. 3351
Preparation of New Componentsp. 3352
Installation of Componentsp. 3352
+Replacement of Front Upper Component Assemblyp. 3353
Removal of Original Partsp. 3353
Preparation of New Componentsp. 3353
Installation of Componentsp. 3354
+Replacement of Front Hub Set Welding Assemblyp. 3355
Removal of Original Partsp. 3355
Preparation of New Componentsp. 3356
Weldingp. 3356
+Replacement of Headlamp Bracket Assembly (Left)p. 3357
Removal of Original Partsp. 3357
Preparation of New Componentsp. 3358
Weldingp. 3358
+Body – Centerp. 3359
+Replacement of A Pillar Quarter Outer Panelp. 3359
Removal of Original Partsp. 3360
Preparation of New Componentsp. 3362
Weldingp. 3363
+Replacement of A Pillar Inner Panel Assembly (Left)p. 3366
Removal of Original Partsp. 3366
Preparation of New Componentsp. 3367
Weldingp. 3368
+Replacement of B Pillar Stiffener Assembly (Left)p. 3369
Removal of Original Partsp. 3369
Preparation of New Componentsp. 3370
Weldingp. 3371
+Replacement of Roof Panel Welding Assemblyp. 3372
Removal of Original Partsp. 3372
Preparation of New Componentsp. 3373
Weldingp. 3373
+Replacement of Front Floor Welding Assemblyp. 3375
Removal of Original Partsp. 3375
Preparation of New Componentsp. 3376
Weldingp. 3376
+Body – Rearp. 3379
+Replacement of Rear Quarter Sheet Metal Assemblyp. 3379
Removal of Original Partsp. 3380
Preparation of New Componentsp. 3380
Weldingp. 3381
+Replacement of Rear Floor Side Beam Welding Assembly (Left)p. 3382
Removal of Original Partsp. 3382
Preparation of New Componentsp. 3384
Weldingp. 3385
Vehicle Systems Covered in Depth
The 2019 CHANA P201 Workshop Manual provides extensive coverage of every major vehicle system. The diesel engine sections for both D20T and JE4D25 platforms include timing chain and timing belt procedures, cylinder head and valve service, piston and connecting rod specifications, crankshaft and cylinder block disassembly, fuel injection pump diagnostics, high pressure fuel rail service, fuel injector testing, glow plug systems, and complete electronic control system DTC diagnosis with wiring harness connector terminal lists. The 4K22T gasoline engine section covers dual VVT system operation, timing belt replacement, valve clearance inspection, ignition system testing, spark plug service, and multi-point fuel injection diagnosis. Transmission coverage includes detailed manual transmission disassembly and assembly with synchronizer and gearshift component inspection, clutch system bleeding and component replacement, and automatic transmission DTC diagnosis with electronic control element service. Chassis coverage extends to front and rear suspension component replacement, wheel alignment specifications, driveline system inspection for both 2WD and 4WD configurations, transfer case disassembly, propeller shaft and drive shaft service, rear axle final drive adjustment, and complete brake system service including ABS/ESP actuator assembly, wheel speed sensors, and brake bleeding procedures. Steering system coverage includes power steering pump service, steering gear replacement, and steering column component removal.
Diagnostic and Repair Capability
This 2019 CHANA P201 Workshop Manual equips technicians with the diagnostic procedures needed to identify and resolve complex vehicle faults. The manual includes comprehensive DTC lists for engine control systems, automatic transmission, anti-lock brake system, supplemental restraint system, body control module, PEPS system, and on-board network, each with detailed diagnosis procedures, terminal lists, and circuit testing instructions. Symptom charts guide systematic troubleshooting for issues ranging from engine performance problems and transmission shift quality complaints to electrical accessory failures and suspension noise diagnosis. The manual provides torque specifications for critical fasteners throughout the vehicle, fluid capacities and specifications for engine oil, coolant, transmission fluid, brake fluid, and refrigerant, and component wear limits and adjustment values for engine mechanical components, brake discs and pads, and suspension parts. Removal and installation procedures are supported by illustrations showing component locations and fastener sequences, while disassembly and assembly sections detail internal component inspection and measurement requirements. Whether diagnosing an engine misfire, repairing a suspension fault, servicing the brake system, or troubleshooting an electrical issue, this manual provides the procedures and data required to complete the work correctly.
IMAGES PREVIEW
Why This Manual Matters
Having the correct service information is essential for maintaining vehicle reliability and safety. The 2019 CHANA P201 Workshop Manual provides the exact procedures and specifications that CHANA specifies for this vehicle, helping technicians avoid guesswork and reducing the risk of improper repairs. Torque values, fluid capacities, and adjustment specifications are presented for each system, ensuring that components are installed and adjusted to factory requirements. Diagnostic procedures include circuit testing steps with expected voltage and resistance values, allowing systematic fault isolation rather than parts replacement by trial and error. For independent workshops and experienced owners performing their own maintenance, this manual delivers the same technical depth found in professional service information, covering everything from routine maintenance intervals to complete engine overhaul and transmission disassembly.
Instant PDF Delivery
The 2019 CHANA P201 Workshop Manual is delivered as a PDF file that can be accessed immediately after purchase. No shipping or waiting is required. The file can be viewed on any device with PDF reading capability, including desktop computers, laptops, tablets, and smartphones. Pages can be printed for use in the workshop, allowing technicians to reference procedures and specifications at the vehicle without risking damage to electronic devices. The PDF format preserves the original layout, illustrations, and tables, ensuring that all diagrams and specification charts remain clear and readable. Whether used for a single repair or as a long-term reference for maintaining a CHANA P201, this manual provides convenient, searchable access to the complete service and repair information in one organized document.
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