Troubleshooting (Rexton)

International A/S & Parts
Quality Problem & Trouble Shooting Team
Jan.18,2002
Subject Check the free stroke of brake pedal and adjust

Models Rexton
Phenomenon
The brake pad is worn out fast abnormally
Main cause
The free stroke of the brake pedal is not adjusted
Work procedure
Fig. 1.
1. In engine stop, remove the vacuum pressure by pushing
the pedal 2 or 3 times.
2. Check the free stroke to feel hardness by pushing the pedal
- Specification of free stroke : 2 to 3 mm
3. If no free stroke, loosen the nut(fig. 2-1), and then ②
adjust the pedal rod by turning the rod(fig. 2-2)
to anti-clock wise 1 or 1.5 turns.
①
Fig. 2
Improvement history :
Jan.18,2002
Subject Atmosphere temp mode of FATC

Models Rexton
Atmosphere temp view

When to push "AMB" button, the word OUSIDE and atmosphere temp for 5 seconds display
on the LCD.
Temp display function

The AMB temp sensor is installed on the fornt of airconditioner cooling fan.
The sensor sense almost the same atmosphere temp in driving, but in idling, the sensing value
is not correct due to engine room temp or groung heat, so the indicated temp is a little different
to real temperature even though the compensation circuit is operated.
AA. In driving over 10Km/h

- Display the temp converted to registor from temp sensor.
BB. In driving below 10Km/h

To protect the perceived temp to display too high compared with real temp, if the present temp
is higher than the temp in driving over 10Km/h, display the temp value up 0.05℃ per a minute.
CC. In idling
This mode display the same condition as in driving below 10Km/h.
But if IG key turns OFF to ON, this unit compares the compensated temp to the memory temp
before IG off, then display the more correct value.
Self diagnosis
AA. If diagnose the FATC, only display the perceived temp in being erased the compensated temp.
So the display temp is a little different to real atmosphere temp.
But if the vehicle drives over 10Km/h, this condition returns to normal function.
BB. Identify the sensors

- the register decrease following temp increase, and increase to temp decrease.
: the standard value is about 2.2㏀ at 25℃.
ceived temp in being erased the compensated temp.
Jan.18,2002
Subject Atmosphere temp mode of FATC

Models Rexton
Phenomenon
CC. How to self diagnosis

1) Set to 26℃ with temp switch.
2) Push the OFF switch 3 times in 3 seconds in pushing AMB switch.
3) The damage code blinks on the temp indicator.
Damage code Description Compensation value

0 Normal
1 Internal sensor damage apply 25℃
2 Atmosphere sensor damage apply 25℃
3 Engine temp sensor damage apply 50℃
4 Air mix door damage
5 Sun sensor damage sunshane 0
6 Power Tr damage
7 High speed blower relay damage
Jan.18,2002
Subject The warning lamp of door open indicate in driving

Models Rexton
Phenomenon
This lamp on the cluster indicates in driving, even though all door are closed.
In this time, the map lamp also turns on.
Main cause
The brown wire which is of door switch is short to body.
The main short point is located on 100mm from map lamp terminal.
Work procedure
Map맵lamp
램프
Blac Short point
k
Brown
Brown
Floor
B+
Stics B8
Door
switch
Jan.18,2002
Subject Special chareteristics of some electric goods

Models Rexton
Phenomenon
Customer misunderstands some electric parts malfunction.
Main items
1. Outside mirror
- Condition : When to operate the outside mirror by switch, Strainge noise sounds,
or the motor still operates even though the mirror function stop.
- Main cause : Whenever the mirror position is changed, this noise happens to identify
the position. - This phenomenon occurs only in first operation.
2. Atmosphere temp display of FATC

- Condition : In idling, when to display the atmosphere temp by pushing "AMP", the temp is
not real outside temp, and the atmosphere temp sensor does not operate.
- Main cause : this sensor functions only in driving, and the temp in idling means the temp
captured just before idling.
: this is to protect miscommunication due to engine room temperature.
3. Sunroof malfunction
- Condition : In case of battery discharge or replacement of it, the close button does not operate.
- Cause : This is due to the memory erase, so if set the position again, operate normally.
- work procedure of memory set

: Operate the "CLOSE" button more for 5 seconds.
If in sliding position, repeat the function like CLOSE , OPEN , CLOSE.
Jan.18,2002
Subject How to rework the rear door glass

Models Rexton
Phenomenon
Notice the easy and safety way to dismantle and install the rear door glass.
Main cause
Work procedure
AA. Take out the rear door trim panel and vinyl seal.
- the glass should be in full down mode ②
BB. Dismantle the door belt outside weather-strip(①) ①
CC. Dismantle the door trim front garnish(②)
DD. Finally take out the door glass(③)
③
Caution) when to assemble the door glass run rubber, ③
be careful not to make any wave.
Jan.18,2002
Subject Not avaiable to unlock the driver's door

Models Rexton
Phenomenon
AA. When to operate the unlock switch, the passenger door safty knob is unlocked,
but it is locked automatically .
BB. Not available to unlock with remocon or key.
Main cause
AA. The inside handle lever and safty lock lever are jammed each other.
BB. In case of that both front door inside handles operates in the same time, the lock system
is operated repeat, then locked immediately.
Work procedure
If pushing the driver's safety lock to lock knob way strongly, the safety lock system
is unlocked.
Safety lock knob
Unlock switch
Jan.18,2002
Subject ABS warning lamp ON in driving

Models Rexton
Phenomenon
In engine starting, the ABS warning lamp is indicated. Check water ingress
Main cause
AA. Water ingress into the modulator connector.
BB. The body earth terminal is fixed incorrect.
Work procedure
AA. IG key off

BB. Check the water ingress into the connector after dismentle the modulator.
CC. If find out any water ingress,
- Erase the water and sludge.
- Spray WD40 to erase dirty completely.
- Dry this connector around for 10 mins.
Caution) when to connect both connector and modulator, confirm the connecting force.
DD. To check the earth terminal condition,
- Dismantle the reservoir tank.
- If the cupper wire is appeared, wrap up it with silicon.
- In case of that only the wire plastic cover and earth terminal are appeared,
disconnect the terminal and fix it in correct direction, and touch the silicon on the terminal.
Look at Wrap up
the wire silicon
cupper
Before After
rrect direction, and touch the silicon on the terminal.
Jan.18,2002
Subject Noise from the seat belt D ring

Models Rexton
Phenomenon
Un driving, any abnormal noise sounds from the D ring area of the seat belt.
Main cause
Due to friction between adjuster lever and holdering. Adjuster
Grease (fig.1)
touch popint
Anker plate
Work procedure
AA. After loosening the anker plate cover and fixing bolt,
seperate the anker plate.
BB. Touch the grease into the adjusting lever like Fig.1.
CC. Assemble the anker plate.
Warning) be careful not to come out the grease outside.
Jan.18,2002
Subject Intermitant illuminating of the brake warning lamp

Models Rexton
Phenomenon
The brake warning lamp turns on even though the brake oil level is normal.
Main cause
In case of Rexton model, the worning indicate position
is designed a little higher than general models.
So even though the oil level is normal, the warning lamp
might be illuminated.
MAX
MAX
Warning lamp
touch point
MIN Warning lamp

MIN touch point
Rexton Musso
Work procedure
AA. At first, check the concerned parts like oil leakage, and pad worn out, if necessary
do some necessary rework.
BB. If everything is correct, refill the brake oil up to maximum.
CC. Finally explain the rexton characteristics to customer.
Improvement history
Jan.18,2002
Subject Unbalance of the vehicle height, right and left

Models Rexton
Phenomenon
The diference between left and right height is around 10 to 15mm.
Main cause
This is due to the biased clearence of the front and rear spring.
On the specification, the diferent spring clearence between left and right in standard load is
is around 5%, this means 18mm for front, 14mm for rear.
Work procedure
1. Replace bothe spring front and rear.
2. If necessary, insert a sim 5mm to the front.
- The position is on the upper bracket bolt.
Note) B and C mean the arrangement position when to dismentle and to assemble.
5mm sim insert

position
Upper bracket
and bolt
Jan.18,2002
Subject Noise in the room

Models Rexton
Phenomenon
1, Noise from windshield glass.
2. Sound from rear of the cluster in driving. Windshield glass
Main cause
Fender
Friction area
Work procedure
1. Check
AA. Windshield noise : After dismentle the rubber molding from the noise, clarify it.
If not sound any noise, interferenced between rubber molding and body panel.
BB. Check whether to frict or not both cawol cover and fender panel.
2. Rework
AA. Replace the rubber molding with new one
- To make easy install the molding, warm it.
장 Before
착 사 양 After
개 선 사 양
전면유리glass
Windshield 전면유리
Windshield glass
P/No.: 79121-08002
BB. Make a gap between cawol cover and fender panel.
Jan.28,2002
Subject Replacement procedure for the Front suspension shock absorber

Models Rexton
Description
Replacement procedure of the Front Shock Absorber are as follows
Work procedure
1. Structure
1. Shock absorber 9. Shock absorber collar

2. Coil spring 10. Washer
3. Dust cover 11. Nut
4. Bumper stopper 12. Lower bracket
5. Spring Sheet (One piece with s/absorber)
6. Upper Bracket 13. Bracket yoke
7. Lower bush
8. Upper bush
2. Replacement procedure
1) Install the Shock absorber and Spring assembly
to Spring jack(Special Tool : 162 589 01 36 00).
[Note]
- Upper bracket is installed to the 2nd column of the spring,
Lower bracket is installed to the 7th column of the spring.
- Spring is exactly installed to the prominence of upper
and lower bracket inside.
2) Compress the spring with Jack.
3) Remove the Nut(17mm) and Washer / Upper bush.

[ Caution]
When you remove the nut, hold the shock absorber.
4) Remove the Upper bracket and Spring sheet.
5) Remove the Lower bush and Bumper stopper.
6) Remove the Shock absorber.
7) Install the new Shock absorber.
8) Install the Bumper stopper, Lower bush, Spring sheet, Upper bracket, Bush and washer, one by one.
9) Tighten the Nut as the upper part of Shock absorber hold with 8mm spanner due to protect the Shock
absorber collar's rotating.
[Note]
- Distance(ⓐ) from Nut to collar of Shock absorber is 23mm~24mm.
- Tightening specification : 25 ~ 40Nm
[Caution]
- One of bolts which are upper bracket and lower bracket yoke© are in the straight line.
If it does not stand in a low, Spring and Shock absorber are not installed.
10) Loosen the spring with Jack. At this time, upper bracket bolt and lower bracket yoke must be in the
straight line.
11) The lower and upper end side of Spring is exactly installed to spring sheet of Lower bracket and
Upper bracket. And loosen the spring and remove the shock absorber & spring from the Spring Jack
Jan.28,2002
Subject Precautions when the Room lamp is replaced

Models Rexton
Description
When the Room lamp is replaced, using of the different kind screw is cause of roof panel damage
Work procedure
1. Precautions when the room lamp is replaced
* When you rework the Center room lamp and Rear room lamp, only specified screw is used.
* If you do not use the specified screw, the Roof panel is damaged.
(The Roof panel is holed or protruded)
2. Room lamp Screw specification
Specified screw Different kind screw
Screw name Round head screw Round and plate head screw
Length 12mm 12mm ~

Spiral
Pitch 3.2mm or 4.2mm -
Pitch Length
Picture
스크류 끝단 Screw Name (Round head)

Jan.28,2002
Subject Removal and Installation procedure of Head lamp and Bulb

Models Rexton
Description
Removal and Installation procedure of Head lamp and Bulb
Work procedure
1. Removal procedure
1) Remove the Radiator grille.
2) Remove the mounting bolt ① of Head lamp(6mm × 2ea).
3) Remove the Wheel house liner front cover (②) which is installed
in Wheel cover. And remove the mounting bolt(③) of Head lamp ②
(6mm × 1ea).
4) Remove the Head lamp
①
※ Head lamp Replacement ③

- Low lamp and position lamp : It can be replaced without removing
the Head lamp. It can be replaced only when the Liner front cover(②) is removed.
{ When you install the Head Lamp housing cover, ▲ mark must be toward the upward direction.}
- High Lamp Bulb : It can be only replaced when the Head lamp is removed.
2. Installation procedure
1) Installation should follow the removal procedure in the reverse order.
2) After Head lamp installation, Adjust the aiming.
※ When the head lamp install, tighten the Nut which is in below as push the Head lamp upward
direction. And then, tighten the Nut which is in above.
※ Check the gap and clearance between head lamp and body panel.
Jan.28,2002
Subject Coding procedure for TOD T/CCU

Models Rexton
Description
TOD T/CCU(Transfer case control unit) of Musso & Korando is applied to Rexton also.
Therefore, when you replace it you must code it with Scan-tool.
TOD Transfer case controller coding procedure is as follows
Work procedure
1. Coding procedure
- Vehicle coding : Select the 'Musso' (Rexton is not in the data)
- Engine coding : Select the 'GAS' (TOD is applied to only gasoline 3.2 vehicle.)
- Transmission coding : Select the Manual or Automatic transmission following

the vehicle's option
- Axle Ratio Coding : Select the 3.73 @ M/T or 4.55 @ A/T following the vehicle's option
- Tire Coding : Select the P235 or P255 following the vehicle's option.
2. Remark
- New TOD T/CCU applied target date : Jul. 01, 2002
Jan.28,2002
Subject Information for Head Rest storage position

Models Rexton
Description
When you fold the 3rd seat, Head rest storage position is as follows
Work procedure
1. Head rest storage position
- After fold the seat, put the Head rest into the bend which is left and right side of 3rd seat
(Refer to the below picture)
2. Applied date
- It is applied from initial vehicle.
3. Remark :
- When the customer comes to your workshop, explain about this.
Jan.28,2002
Subject Trouble shooting for Heater pipe interference noise

Models Rexton
Phenomenon
- Noise comes from the Instrument Panel center when the vehicle is
- It is a squeak noise.
Main cause
- Clearance between Heater Pipe and Heater pipe housing.
Work procedure
- Open the engine room.
- Insert the plastic band to the between heater pipe and sponge pad.
- If the clearance exist, Insert the additional plastic band.
- Check the clearance between Heater Pipe and Heater Pipe housing.
- If the clearance not exist, cut the outside part of the inserted plastic band
Inserted Plastic Band

International A/S Team
Quality Problem & Trouble Shooting
Jan.28,2002
Subject Removal and Installation procedure of Sunroof sunshade

Models Rexton
Description
Removal and Installation procedure of Sunroof sunshade
Work procedure
1) Remove the sunroof glass.
2) Remove the mounting bolt(2ea) for Drain channel.

And remove the Drain channel as push the hook of Support drain channel.
Hook
3) Close the Sun shade panel.

4) Pull out the Slide block which is in the Sunshade from the Guide rail using the screwdriver('-')
(4point)
Slide Block
5) Remove the Sun shade panel.
1) Put the Sunshade on the Guide rail.
2) Insert the Slide block to the Guide rail using the screwdriver('-').
3) Insert the Drain channel to inside of Roof.
4) Insert the Support drain channel to the Drain channel.

(First, insert the rear hook and then push the front hook)
5) Tighten the Bolt ( 2ea, 1.2Nm)
6) Check the function of Sun shade.

(Operating status, Noise, Interference, variation)
7) Install the Glass

Jan.28,2002
Subject Information for Sunroof switch and setting of glass position

Models Rexton
Description
The function of Sun roof switch and Setting of sun roof glass position are as follows
Work procedure
1. Function of the Control switch
1) To open and close the sun roof, this switch is used.
2) When the glass is closed, if you push the open switch for below 0.5second the Sunroof is
opened. → One touch open
3) When the glass is closed, if you push the open switch for over 0.5 second the Sunroof can
be opened by manual.
4) When the glass is opened, if you push the close switch the Sunroof can be closed by manual.
5) When the glass is closed, if you push the close switch the Sunroof is tilted up.
6) When the glass is tilted up, if you push the open switch the Sunroof is tilted down.
2. Setting the Sunroof glass position
1) Cases that requires glass position setting : When the Battery is discharged, When the
memory of control unit is erased by electrical shock or etc.
2) Setting the position(Zero position)

- Tilt-up the glass and Push the close switch(for above 5 seconds) until the mechanical
sound (rattling sound) is heard
3) When the glass is not close

- Push the close switch for above 5 seconds and then, the Glass will be closed slowly.
{ Repeat the 2 ~ 3 times this procedure}
Jan.28,2002
Subject Trouble shooting for locked 2nd seat

Models Rexton
Phenomenon
When you fold the rear seat (2nd seat), the locking of Latch is not released.
Main cause
The interference between the 2nd seat latch and the Rear floor mat.
Work procedure
- After fold the 2nd seat, Cut the Floor mat like picture below.
Cutting 30mm
Remark
- Reclining : Only fold the Rear seat backs using the adjustment lever.
- Folding : Fold the Rear seat forward with pushing the adjustment lever
- To fold the rear seat, the Rear seat is reclined and then rear seat back must be locked.
The rear seat back can be locked by pushing the rear seat back.
- If the rear seat back is not locked, the rear seat is interfered with the Console box cover
handle. Therefore the rear seat back can be damaged.
Jan.28,2002
Subject Disassemble procedure for Multi Meter & Center Facia Panel
Models Rexton
Description
The Removal and assemble procedure for Multi Meter & Center Facia Panel are as follows
Work procedure
Multi Meter
a) Remove the Multi Meter cover

To easy removing, Raise the multi meter to upward as push
the left and right side of multi meter.
b) Remove the screw (2ea)
c) Remove the Multi Meter.
d) Remove the Center Facia Lower Cover.
To easy removing, grip the under portion of Center Facia
and Pull it (Refer to the Picture ⓓ)
e) Remove the Center Facia upper Panel.
(It is mounted with screw 3ea and pin)
Center Facia Upper Panel
Center Facia Lower Panel
( Picture ⓓ )
※ The parts which can be replaced when the Center Facia Lower Panel is removed
- Audio and Video head unit, Air con control panel, Chime-bell, 'G'-sensor
※ The parts which can be replaced when the Center Facia Upper Panel is removed
- Switches, Clock, Center Air Vent Louver
- Installation should follow the removal procedure in the reverse order.
Jan.28,2002
Subject Specification of Wheel Alignment

Models Rexton
Description
The Specification of wheel Alignment is as follows
Work procedure
1. First check point before adjusting the wheel alignment.
- Tire pressure and wear of tire
- Clearance of front/rear Hub
- Level status of vehicle ( Oil leak of Shock absorber … )
2. Specification of front wheel alignment

- Toe-in : 2.0 ± 2mm
- Camber : 0.0 ± 0.5˚ (Variation must be within 0.5˚)
- Caster : 2.75 ± 0.5˚ (Variation must be within 0.5˚)
- King Pin : 10.5 ± 0.5˚
Note) When the Unit is conversion degrees into minutes, the above data is as follows
- Toe-in : 2.0 ± 2mm
- Camber : 0.0 ± 30´ (Variation must be within 30´)
- Caster : 2˚45´ ± 30´ (Variation must be within 30´)
- King Pin : 10˚30´ ± 30´
3. Procedure for wheel alignment adjusting

1) Cam bolt value increasing
- Front bolt : When turn it toward outside of vehicle, camber is increased 0.05˚
and caster is increased 0.2˚ for one scale.
- Rear bolt : When turn it toward outside of vehicle, camber is decreased 0.11˚
and caster is increased 0.2˚ for one scale.
2) For more detail information, refer to the attached table.
3) Adjust the toe-in after adjustment of camber and caster.
4. When the cam bolt turns, turn it slowly.
※ The Alignment table is attached.

Specification of Wheel Alignment
Camber (deg) 0.0 ±0.5。 (LH/RH Variation must be within 0.5˚)
Caster (deg) 2.75±0.5。 (LH/RH Variation must be within 0.5˚)
Toe-in (mm) 2.0 ± 2
King pin (deg) 10.5 ±0.5。
Front Wheel Alignment adjustment Table Direction of vehicle's outside
Rear
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6
Front
CAMBER 0.46 0.31 0.17 0.04 -0.08 -0.19 -0.3 -0.41 -0.52 -0.65 -0.77 -0.91 -1.07
6 CASTER 0.4 0.64 0.85 1.04 1.22 1.39 1.55 1.72 1.88 2.07 2.26 2.47 2.71
CAMBER 0.53 0.37 0.23 0.11 -0.02 -0.13 -0.24 -0.35 -0.46 -0.58 -0.71 -0.85 -1.01
5 CASTER 0.64 0.88 1.09 1.28 1.47 1.63 1.8 1.96 2.08 2.32 2.51 2.72 2.96
CAMBER 0.59 0.43 0.29 0.17 0.04 -0.07 -0.18 -0.29 -0.4 -0.53 -0.65 -0.79 -0.95
4 CASTER 0.85 1.09 1.3 1.49 1.7 1.85 2.01 2.18 2.34 2.53 2.72 2.93 3.17
CAMBER 0.64 0.48 0.34 0.22 0.09 -0.02 -0.13 -0.24 -0.35 -0.48 -0.6 -0.74 -0.9
3 CASTER 1.05 1.28 1.5 1.71 1.87 2.04 2.21 2.37 2.54 2.73 2.92 3.13 3.36
CAMBER 0.69 0.54 0.4 0.27 0.14 0.03 -0.08 -0.19 -0.3 -0.42 -0.55 -0.69 -0.85
2 CASTER 1.24 1.47 1.69 1.91 2.06 2.23 2.4 2.56 2.73 2.92 3.11 3.32 3.56
CAMBER 0.74 0.58 0.44 0.31 0.19 0.08 -0.03 -0.14 -0.25 -0.38 -0.51 -0.65 -0.81
1 CASTER 1.41 1.64 1.85 2.04 2.23 2.4 2.57 2.73 2.89 3.08 3.27 3.49 3.73
CAMBER 0.79 0.63 0.51 0.36 0.23 0.12 0 -0.1 -0.21 -0.34 -0.46 -0.61 -0.76
0 CASTER 1.57 1.81 2.03 2.21 2.4 2.57 2.75 2.9 3.06 3.25 3.44 3.66 3.89
Direction of vehicle's
CAMBER 0.83 0.67 0.53 0.4 0.28 0.17 0.06 -0.06 -0.17 -0.29 -0.42 -0.56 -0.72
-1 CASTER 1.72 1.95 2.17 2.36 2.55 2.71 2.88 3.05 3.21 3.4 3.59 3.81 4.04
CAMBER 0.88 0.72 0.58 0.45 0.32 0.21 0.1 -0.01 -0.12 -0.25 -0.38 -0.52 -0.68
-2 CASTER 1.89 2.12 2.34 2.53 2.73 2.88 3.05 3.22 3.31 3.57 3.76 3.98 4.22
outside
CAMBER 0.93 0.77 0.63 0.5 0.37 0.26 0.15 0.04 -0.07 -0.2 -0.33 -0.47 -0.63
-3 CASTER 2.07 2.32 2.53 2.72 2.91 3.08 3.24 3.41 3.58 3.77 3.96 4.17 4.41
CAMBER 0.98 0.82 0.68 0.55 0.42 0.31 0.2 0.09 -0.02 -0.15 -0.28 -0.42 -0.58
-4 CASTER 2.27 2.51 2.72 2.91 3.11 3.27 3.44 3.61 3.77 3.96 4.15 4.37 4.61
CAMBER 1.04 0.88 0.73 0.61 0.48 0.38 0.26 0.14 0.03 -0.1 -0.22 -0.37 -0.53
-5 CASTER 2.49 2.73 2.94 3.13 3.32 3.49 3.56 3.82 3.99 4.18 4.37 4.59 4.83
CAMBER 1.1 0.94 0.8 0.67 0.54 0.43 0.32 0.2 0.09 -0.04 -0.16 -0.31 -0.47
-6 CASTER 2.73 2.95 3.18 3.37 3.56 3.73 3.9 4.07 4.23 4.42 4.61 4.83 5.07
※ Example of Wheel alignment adjusting
When the Camber is 0.29˚ and Caster is 1.3˚,
1. Turn the front Cam Bolt to "-" direction (toward outside) 4 click CAMBER is changed to 0.51˚ and CASTER is changed to 2.03˚.
2. And turn the rear Cam Bolt to "+" direction(toward outside) 4 click, CAMBER is changed to 0˚ and CASTER is changed 2.75˚.
Jan.28,2002
Subject Information about parts replacement (Quarter trim)

Models Rexton
Description
When the quarter trim is removed, the replaceable parts are as follows
Work procedure
1) Remove the rear door scuff trim.
2) Tail gate trans verse trim (5 seater) or
floor accessory tray (8 seater)
3) Remove the third row seat
4) Loose the seat belt fixing bolt which fixes the seat belt lower side
of 2nd and 3rd row seat and remove the quarter lower trim (①).
5) Remove the quarter upper trim (②).
※ The replaceable parts when the Center Facia Lower Panel is removed
- Left side : Power AMP unit, TV tuner unit, CD changer
- Right side : Automatic radio antenna
※ The replaceable parts when the Center Facia Upper Panel is removed
- Left side : Quarter front glass, TV antenna module, Seat belt assembly of 2nd and 3rd row seat
- Right side : Quarter front glass, TV antenna module, Seat belt assembly of 2nd and 3rd
row seat, Rear cooler assembly
- Installation should follow the removal procedure in the reverse order.
Jan.28,2002
Subject Removal and Installation procedure of Sunroof

Models Rexton
Description
Removal and Installation procedure of Sunroof are as follows
Work procedure
1) When the sunroof glass is closed, press the close switch.
And then, Glass is tilted.
1)
2) Pull the side inner cover and remove it.
2)
3) Remove the glass fixing bolt.
(left - 3ea, right-3ea)
3)
4) Pull the sunroof glass to upward and remove it
4)
1) When the glass is opened, put the glass on the cover panel inside (Picture 1)-1)
(Check the bolt mounting point at inside of vehicle)
Note) The SSANGYONG characters which are marked on the sunroof glass must be
toward the rear direction.
1) 1)-1
2) tighten the fixing bolt temporarily (6ea).
3) Close the sunroof glass slowly by using the switch.

(Glass must be operated well)
4) Adjust the height and gap of glass.

And tighten the fixing bolt(5Nm)
5) Check the operating status using the switch.
6) Close the sunroof and press the close switch.

And then the sunroof glass will be tilted.
7) Assemble the side cover(left and right)
Notice) 1. After the side cover assembling, check the assembly status.
If it is not assembled correctly or have eccentricity
the sunroof will be deformed when the sunroof is operated.
2. Check the noise and operating status as you operate the sunroof.
Jan.28,2002
Subject Removal and Installation procedure of Sunroof Motor & Control unit
Models Rexton
Description
Removal and Installation procedure of Sunroof Motor & Control unit are as follows
Work procedure
1) Close the sunroof. (Sunroof must be in normal close position)
Note) Normal close position : Stop point when the sun roof is closed from rear to front
2) Remove the Room lamp, Sun visor, Head lining and several trim parts.
3) Cut the Tie lap of control unit.
4) Remove bolts (3ea).
5) Remove the control unit from the front beam

(Push the control unit from the front beam by hand)
1) The glass panel must be in close position.
(Normal close position)
2) Check the normal close position of the Motor.

Note) Normal close position : Position which the motor is stopped, before assemble the motor,
when the relay and motor are connected and power is supplied.
3) Assemble the motor.

Note) Motor is assembled to the Locating bracket bolt hole and Front beam, driver tube cables
are inserted.
4) Tighten bolts(3ea).
Note) Tightening specification : 3Nm
5) Insert the Control unit hook to Front beam.
6) Tightening the control unit with Tie lap.
7) Check the operating status of sun roof.
8) assemble the Room lamp, Sun visor, Head lining and several trim parts.

Troubleshooting (Rexton)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Troubleshooting (Rexton)

Uploaded by

Copyright:

Available Formats

International A/S & Parts

Quality Problem & Trouble Shooting Team

Subject Check the free stroke of brake pedal and adjust

Subject Atmosphere temp mode of FATC

Atmosphere temp view

Temp display function

AA. In driving over 10Km/h

BB. In driving below 10Km/h

BB. Identify the sensors

Subject Atmosphere temp mode of FATC

CC. How to self diagnosis

Damage code Description Compensation value

Subject The warning lamp of door open indicate in driving

Subject Special chareteristics of some electric goods

2. Atmosphere temp display of FATC

- work procedure of memory set

Subject How to rework the rear door glass

Subject Not avaiable to unlock the driver's door

Subject ABS warning lamp ON in driving

AA. IG key off

Subject Noise from the seat belt D ring

Subject Intermitant illuminating of the brake warning lamp

MIN Warning lamp

Subject Unbalance of the vehicle height, right and left

5mm sim insert

Subject Noise in the room

BB. Make a gap between cawol cover and fender panel.

Subject Replacement procedure for the Front suspension shock absorber

1. Shock absorber 9. Shock absorber collar

2) Compress the spring with Jack.

3) Remove the Nut(17mm) and Washer / Upper bush.

4) Remove the Upper bracket and Spring sheet.

5) Remove the Lower bush and Bumper stopper.

6) Remove the Shock absorber.

7) Install the new Shock absorber.

Subject Precautions when the Room lamp is replaced

2. Room lamp Screw specification

Specified screw Different kind screw

Length 12mm 12mm ~

스크류 끝단 Screw Name (Round head)

Subject Removal and Installation procedure of Head lamp and Bulb

2) Remove the mounting bolt ① of Head lamp(6mm × 2ea).

※ Head lamp Replacement ③

2) After Head lamp installation, Adjust the aiming.

Subject Coding procedure for TOD T/CCU

- Vehicle coding : Select the 'Musso' (Rexton is not in the data)

- Transmission coding : Select the Manual or Automatic transmission following

Subject Information for Head Rest storage position

Subject Trouble shooting for Heater pipe interference noise

Inserted Plastic Band

Subject Removal and Installation procedure of Sunroof sunshade

2) Remove the mounting bolt(2ea) for Drain channel.

3) Close the Sun shade panel.

3) Insert the Drain channel to inside of Roof.

4) Insert the Support drain channel to the Drain channel.

5) Tighten the Bolt ( 2ea, 1.2Nm)

6) Check the function of Sun shade.

7) Install the Glass

Subject Information for Sunroof switch and setting of glass position

2. Setting the Sunroof glass position

2) Setting the position(Zero position)

3) When the glass is not close

Subject Trouble shooting for locked 2nd seat