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BYD AUTO Technical Monthly
The BYD AUTO Technical Monthly is dedicated to providing better technical services and supports for BYD service centers and/ or service shops. This monthly contains „TECHNOLOGY NOTICE‟ „TROUBLESHOOTING‟ AND „SPARE PARTS‟. It can help distributors, service centers and/or service shops settle technical problems and order spare parts rightly. All people should understand it clearly.
If any comments or suggestions about monthly, you can contact BYD AUTO by following ways: 1. Mailbox:BYDAUTOSERVICE@BYD.COM; 2. Tel: +86-755-89888888 ext.64555; 3. Service Engineers for your market.
BYD AUTO CO. LTD., 2012-8-31
All rights reserved by BYD AUTO
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..................................13 All rights reserved by BYD AUTO 3 / 23 ................................................ 13 Distinguish—Spare parts of F0 2012 Model Type ...................................7 TROUBLESHOOTING................................................ 11 Troubleshooting— False Over-heating in F3 AT....................... abnormal sound determination ...................................................4 Judging handbook of shock absorber abnormal noise-For all vehicles of BYD ..................................BYD AUTO Technical Monthly CATALOG TECHNOLOGY NOTICE ........................................................11 SPARE PARTS ........................................................................................................ 4 BYD vehicles‟ shock absorber oil leakage.......
therefore. 2. LTD. Connecting rod surface microcrack All rights reserved by BYD AUTO 4 / 23 . which can store a certain amount of oil forming oil film on the surface. LTD. which does not affect the use of shock absorber. wet friction is made between connecting rod and oil seal. and prolong service life. in order to protect oil seal and prevent abnormal sound caused by dry friction. thus wetting rod. Shock absorber oil seepage is a kind of normal phenomenon. Purpose and applicable range： For uniform shock absorber oil leakage. oil seepage oil is allowed..BYD AUTO Technical Monthly TECHNOLOGY NOTICE BYD vehicles’ shock absorber oil leakage.. overall improve the use of shock absorber performance. abnormal sound determination 1. and 4S shop fault parts‟ inspection in warranty. micro cracks exist on the shock absorber connecting rod surface (below). In order to achieve the function of the shock absorber and use requirements.. abnormal sound fault determination and acceptance in warranty. the technology notice is hereby formulated. This notice is suitable for the hydraulic shock absorber produced be BYD automobile co. This notice is suitable for BYD auto co. Shock absorber oil leakage fault determination 1) Attention i.
hence define it as oil seepage. see illustrations below: Seal cage Oil seepage. The oil pollution stain leaking from oil cylinder seal does reach even over the spring tray place (reach or over 50 mm if no spring tray). There‟s no obvious failure occurs on shock absorber. because the rain. hence define it as oil leakage. but no oil droplets and no lots of sludge formatted. please pay special attention to judge whether water stain or not. see illustrations below: Oil seal to spring tray Oil leakage. replace 50 mm Oil leakage. and oil pollution exists on the surface. And the oil pollution stain leaking from oil cylinder seal doesn‟t reach the spring tray place (not reach 50 mm if no spring tray). replace Seal cage Spring tray All rights reserved by BYD AUTO 5 / 23 . snow and ice melt or after washing the car would affect your test results. not 50 mm replace 50 mm Bottom mounting bracket ii. not Spring replace tray Oil seepage. 2) Shock absorber oil leakage appearance determination method: i.BYD AUTO Technical Monthly ii. During the oil leakage criterion of shock absorber.
the bolt with the moment requirements need to be fastened. define it as oil leakage. The scope from the oil cylinder seal to the spring tray (50 mm from the seal downward if no spring tray). or contact between the spiral spring bracket ring with the first working ring car while the car is derived on the concave road with holes. replace see illustrations below: iv. bolt between the upper part and lower part of shock absorber and etc all will lead to vehicles‟ abnormal noise during driving. the oscillating arm next ball head. peak-shaped oil drip trace can‟t be existed. may have collision sound. such as a looseness. 4) Check the connecting bracket assembly of front shock absorber: Check the connecting bracket assembly if there‟s the "click. All welding and static sealing parts located on the edge of oil cylinder seal are not allowed to appear oil leakage. check the tires using condition and keep the tire pressure standard. 3. click" or other noise while the vehicle is steering.BYD AUTO Technical Monthly iii. otherwise. All rights reserved by BYD AUTO 6 / 23 . shock absorber abnormal sound fault determination method 1) Check the tire pressure: Automobile suspension overall damping performance would be reduced if the tire pressure is too high. otherwise they must be replaced. 2) Check shock absorber connecting joints: Looseness of transverse stabilizer bar rod & ball head assembly. then replace shock absorber spiral spring. bolt between the horizontal stabilizer bar rod & ball head assembly and the former damping connection parts. Note: Regard rear shock absorber of series 3 auto models as no spring tray ones to determine. replace Oil leakage. 50 mm Oil leakage. 3) Check shock absorber spiral spring: If there‟s gap between the shock absorber spiral spring with the upper and lower spring seat.
click" sound. while shaking the connecting bracket assembly top of shock absorber. hold the wheel and Ball head of swing arm loosen then rock it. Possible causes of Checking methods solution abnormal sound No previous collision. If their torque is Fasten nuts and bolts the chassis loosen lower than the standard or there is no torque. if the shock absorber upper part sends out "click. it means that nuts and bolts loosen Bolts on the front/rear axle Abnormal noise generates loosen. damage. deformation. Judging handbook of shock absorber abnormal noise-For all vehicles of BYD Abnormal noise of shock absorber-judgment of the vehicle: before judging.BYD AUTO Technical Monthly Replace the upper connecting bracket. NO. check if the ball replace the swing or friction noise head of front swing arm has arm loosened or there is friction noise All bushings assembly and Check all the rubber parts if replace the damaged other rubber parts damaged they have damaged or parts or loosened loosened 1 2 3 4 5 All rights reserved by BYD AUTO 7 / 23 . driving abnormal when shaking the car body Fastening torque sound. check all the related chassis parts and find the source. check if caused by the friction of there is fit clearance and friction Increase the gasket wheel trim cover and the side between the trim board and the of tires side of tires Fasten the nuts and bolts to check if their torque has Fastening nuts and bolts on decreased. No abnormal noise when shaking the car body perpendicularly. Lift the car. The By sight replace the damaged appearance of the wheels and spare parts hubs is normal. Tire pressure is too high or Check if the tire pressure is Adjust tire pressure too low normal Abnormal sound “kaka” Press the trim board. metal impact sound transversely.
hub bearing with abnormal noise Continuous abnormal noise when steering. steering gear with noise BYD AUTO Technical Monthly 1. Steering in situ with abnormal noise after stopping Check if the heat insulation sheet has deformed and related with brake disc Clear metal clicking noise appears in low-speed driving and backing a car.6 Ball pins of stabilizer bar and steering link loosen or damage Stabilizer bar bushings creak Steering with sudden abnormal noise. and check if there is still abnormal noise 7 Fasten the steering connecting bolts. parts shake the ball pin and check the ball head Press the engine hood heavily Replace rubber bushings Shake the car body when it is in Replace hub stationary state bearings Steering in situ in stationary state No abnormal noise with cold start.remove the connecting nuts. “Tweets” generates after 10 minutes driving. its abnormal noise is similar to that of chassis torque loosen Adjust the clearance between heat insulation sheet and brake disc Coat lubricating oil and then tighten the torque Polish the brake disc Normal sound 8 Braking with abnormal noise 9 The fuel in the tank vibrates 11 12 13 14 Metal clicking noise generates Coat glue on the rivet because of the loosening of Check the rivet joint of fuel tank joint tank rivet Connecting bolts of shock Tighten the nuts absorber and steering Tighten it and check (bolts) knuckle loose Connecting bolts of shock Tighten it and check Tighten the nuts absorber and car body loose fault mounting place of helical Check the spring if it is mounted Adjust the spring spring on the spring seat or side frame Steering Shake the steering knuckle Replace knuckle with abnormal noise when driving with abnormal steering knuckle noise (F6 only) 8 / 23 All rights reserved by BYD AUTO . No abnormal noise when pressing the car in vertical stationary state Harsh noise Full up the tank. Other treatment if the bearings loosen Steering abnormal noise Heat insulation sheet with abnormal noise Main pin of brake loosens.whether the steering wheel vibrates when controlling it replace relative spare 2.
Noise Type Phenomenon Description Judging Method We can hear the sound in normal circumstance when the vehicle is driving on gentle slope at a low speed. Continuous clear sound “Dong…Dong” may be abnormal noise of the shock absorber. It‟s normal. Abnormal noise still exists after 5-8 minutes‟ driving. The Sound is similar to that of the friction 9 / 23 All rights reserved by BYD AUTO . Running-on and collision of helical spring. buffer block and dust cover damage BYD AUTO Technical Monthly Check the bolts of two sides of Tighten the nuts frame Remove the absorber. Sound “chichichi…” We can hear the sound in Sound normal circumstance when the “dongdongdong…” vehicle is driving on gentle slope at a low speed. conclusion The sound similar to that of airflow is caused by the air working inside the shock absorber. We can hear the sound in Sound “sisisi…” normal circumstance when the vehicle is driving on large slope at a low speed. tighten the nuts according to the standard torque 17 18 Front (left or lower right) car body with abnormal noise when steering in stationary state Improper torque of tighten nuts of shock absorber causes abnormal noise Test the torque according to the requirement with a wrench Abnormal noise of shock absorber-judgment of the vehicle: eliminate all the failures above. Check if the springs Replace the helical spring collide obviously Normal sound caused by rapid flow of fluid inside the shock absorber. investigate the abnormal noise of shock absorber as following chart.15 16 Stabilizer bar. rear side frame with abnormal noise Supporting cushion. buffer block buffer block and dust cover has and dust cover damaged Check if the connecting bolts of steering gear loose Adjust bolts of steering gear Reassemble it. cushion.(not impact sound) Abnormal We can hear the sound in noise in Sound ”jijiji…” normal circumstance when the driving vehicle is driving on gentle slope at a low speed. and Replace supporting check if the supporting cushion.
Creak Dust cover with abnormal noise Scrape forms because of the friction between the plastic dust cover and the wall of oil reservoir BYD AUTO Technical Monthly between metal and We can hear the sound when the rubber. especially day. Springs collide with abnormal noise Helical spring collide Replace helical springs. Check all the vehicle is driving on large slope at rubber-metal hinged part a low speed. it means collides with the oil reservoir bad tolerance of the car body and rear torque beam. Press the rear of the car reservoir. especially in cold on the chassis. If the friction places are change as the angle does. If friction places and observe if the dust cover are the same. Metal crash won‟t exist except the shock absorber is destructively damaged. Check if the springs collide (little More than 1. such as bar layering bushings. Remove the dust cover and observe it after it rotates at an angle if obvious noise forms by the friction of the dust Keep the car stationary on level cover and the wall of oil ground. sudden brake.5 parallel possibility) circles means that the vehicle overloaded heavily All rights reserved by BYD AUTO 10 / 23 . it means that we need to replace the dust cover. more seriously so long as the the position of stabilizer vehicle knocks down.
no problems found. it is not real over-heating. Using BYD Diagnostic (ED300/ED400) to read the data when the malfunction appeared shows that it‟s normal.BYD AUTO Technical Monthly TROUBLESHOOTING Troubleshooting— False Over-heating in F3 AT Malfunction Description: Dashboard water temperature gauge goes up abruptly. and up to the alert zone finally. we analyzed and found that it‟s the poor ground wire that finally leads the dashboard water temperature gauge in disorder. Then check the water temperature sensor it‟s OK too. Maintenance Process: All rights reserved by BYD AUTO 11 / 23 . At last. Malfunction Analysis: Checking the whole cooling system.
Applicable Model: F3 AT All rights reserved by BYD AUTO 12 / 23 .BYD AUTO Technical Monthly 1 Please kindly confirm that there is no additional electronics in this vehicle. 3 Check the dashboard ground wiring. But the simplest way to solve this malfunction is connecting a new ground wiring between Engine and Car Body. 5 Replace the wire harness of dashboard. 2 Please check the ground wiring between power train (Engine & Transmission) and Body. 4 Replace the dashboard.
BYD AUTO Technical Monthly SPARE PARTS Distinguish—Spare parts of F0 2012 Model Type No 1 2 SAP 10136857-00 10782063-00 Part Name TRANSMISSION ASSY TRANSMISSION ASSY Suitable Model Former Model 2012 Model No neutral gear switch Former Model Add neutral gear switch 2012 Model No 1 2 SAP 10124735-00 10739854-00 Part Name BRAKE CLUTCH PEDAL ASSY BRAKE CLUTCH PEDAL ASSY Suitable Model Former Model 2012 Model No clutch switch Former Model Add clutch switch 2012 Model All rights reserved by BYD AUTO 13 / 23 .
SMART KEY SYSTEM 2012 Model All rights reserved by BYD AUTO 14 / 23 . SMART KEY SYSTEM Suitable Model 2012 Model 2012 Model CONTROLLER ASSY..BACK DOOR LOCK ASSY...BYD AUTO Technical Monthly No 1 2 SAP 10150232-00 10756202-00 Part Name LOCK ASSY..BACK DOOR Suitable Model Former Model 2012 Model No induction switch Former Model Add induction switch 2012 Model No 1 2 SAP 10209168-00 10763200-00 Part Name START BUTTON CONTROLLER ASSY.
INNER DETECTING ANTENNA ASSY OUTER DETECTING ANTENNA ASSY OUTER JIGGLE SWITCH ASSY REMOTE KEY CARD ELECTRONIC KEY KEY HIGH-FREQUENCY RECEIVER MODULE ELECTRIC STEERING COMULN LOCK ASSY.BYD AUTO Technical Monthly No 1 2 SAP 10007906-00 10763201-00 Part Name CENTRAL CONTROL MODULE WITH TELECONTROL BODY CONTROL MODULE ASSY Suitable Model Former Model 2012 Model Former Model 2012 Model No 1 2 3 4 5 6 7 8 SAP 10274341-00 10209162-00 10763398-00 10763399-00 10834835-00 10303138-00 10295381-00 10031059-00 Part Name CENTRAL DETECTING ANTENNA ASSY. INNER DETECTING ANTENNA ASSY All rights reserved by BYD AUTO 15 / 23 . Suitable Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model 2012 Model CENTRAL DETECTING ANTENNA ASSY.
OUTER JIGGLE SWITCH ASSY REMOTE KEY CARD ELECTRONIC KEY KEY HIGH-FREQUENCY RECEIVER MODULE ELECTRIC STEERING COMULN LOCK ASSY. All rights reserved by BYD AUTO 16 / 23 . OUTER DETECTING ANTENNA ASS Location: Left front door assy.BYD AUTO Technical Monthly Location: Left front door assy.
BYD AUTO Technical Monthly No 1 2 SAP 10762066-00 10762063-00 Part Name REAR LOGO ASSY MOUNTING SEAT. LED Suitable Model Former Model 2012 Model Former Model 2012 Model All rights reserved by BYD AUTO 17 / 23 . LED REAR LOGO ASSY MOUNTING SEAT. LED Suitable Model 2012 Model 2012 Model Suitable Type: G-I & GL-I Suitable Type: GLX-I No 1 2 SAP 10238197-00 10776088-00 Part Name REAR LOGO REAR LOGO ASSY.
COMBINATION SWITCH LOWER GUARD BOARD ASSY.BYD AUTO Technical Monthly No 1 2 SAP 10402937-00 10782864-00 Part Name LOWER SHIELD ASSY..WHEEL WHEEL HUB CAP ASSY Suitable Model Former Model 2012 Model Former Model 2012 Model All rights reserved by BYD AUTO 18 / 23 . COMBINATION SWITCH Suitable Model Former Model 2012 Model Suit for Mechanical Ignition Key Former Model Suit for Start Button 2012 Model No 1 2 SAP 10314599-00 10782064-00 Part Name DECORATING COVER..
INSTRUMENT PANEL Suitable Model Former Model 2012 Model No vent Former Model New design vent 2012 Model All rights reserved by BYD AUTO 19 / 23 . MIDDLE COVER BOARD ASSY.INSTRUMENT PANEL UPPER SHIELD ASSY.INSTRUMENT PANEL Suitable Model Former Model 2012 Model Former Model 2012 Model No 1 2 SAP 10143862-00 10725182-00 Part Name CENTRAL CONTROL PANEL ASSY.BYD AUTO Technical Monthly No 1 2 SAP 10143840-00 10070157-00 Part Name UPPER SHIELD ASSY...
BYD AUTO Technical Monthly No 1 2 SAP 10048003-00 10772865-00 Part Name DRIVER SEAT ASSY DRIVER SEAT ASSY Suitable Model Former Model 2012 Model No bracket and key bag Former Model Add bracket and key bag 2012 Model No 1 2 SAP 10048004-00 10772866-00 Part Name PASSENGER SEAT ASSY PASSENGER SEAT ASSY Suitable Model Former Model 2012 Model No bracket and key bag Former Model Add bracket and key bag 2012 Model All rights reserved by BYD AUTO 20 / 23 .
BACK DOOR Former Model (WITHOUT ELECTRICALLY HEATED WIRE AND WIPER HOLE) BACK DOOR GLASS 2012 Model No mounting hole for LED LOGO Former Model Mounting hole for LED LOGO 2012 Model No 1 SAP 10249839-00 2 10774236-00 Part Name GLASS.No 1 SAP 10249838-00 2 10774237-00 BYD AUTO Technical Monthly Part Name Suitable Model GLASS.BACK DOOR(WITH ELECTRICALLY HEATED WIRE AND WIPER HOLE) BACK DOOR GLASS Suitable Model Former Model 2012 Model No mounting hole for LED LOGO Former Model Mounting hole for LED LOGO 2012 Model All rights reserved by BYD AUTO 21 / 23 .
L FRONT DOOR ASSY. with SRS and ABS 2012 Model All rights reserved by BYD AUTO 22 / 23 ..BYD AUTO Technical Monthly No 1 2 SAP 10141832-00 10851763-00 Part Name FRONT DOOR ASSY.L Suitable Model Former Model 2012 Model No mounting hole for micro switch Former Model Mounting hole for micro switch 2012 Model No 1 2 SAP 10782012-00 10782013-00 Part Name SPEEDOMETER AND INSTRUMENT PANEL JUNCTION BOX ASSY COMBINATION INSTRUMENT ASSY Suitable Model 2012 Model/G-I 2012Model/GLX-I Add key indicator. without SRS and ABS Former Model Add key indicator..
L REAR BACK DOOR WIRE. L Suitable Model 2012 Model/UAES 2012 Model 2012 Model/G-I 2012 Model/GL-I 2012 Model/GLX-I 2012 Model G-I/GL-I 2012 Model/GLX-I 2012 Model/G-I 2012 Model/GL-I 2012 Model/GLX-I 2012 Model/GLX-I 2012 Model G-I/GL-I All rights reserved by BYD AUTO 23 / 23 . ENGINE CABIN REAR BACK DOOR WIRE.BYD AUTO Technical Monthly No 1 2 3 4 5 6 7 8 9 10 11 12 SAP 10781782-00 10781788-00 10782893-00 10782895-00 10782894-00 10781783-00 10781779-00 10781781-00 10781784-00 10781780-00 10775870-00 10775874-00 Part Name ENGINE WIRE FRONT DOOR WIRE. ENGINE CABIN WIRING HARNESS. ENGINE CABIN WIRING HARNESS. L INSTRUMENT PANEL WIRE INSTRUMENT PANEL WIRE INSTRUMENT PANEL WIRIE FLOOR WIRE FLOOR WIRE WIRING HARNESS.
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