2005 Sail (SGM7165, SGM7165 Series)

Service Manual

The service manual has provided information on diagnostic, repair procedures, adjustment and
specification about Sail SGM 7165 (SL, SE,SEAT) and SGM7166 (SL, SE, SXAT).

Titles in the service manual without A or B is adaptable to both SGM7165 and SGM7166 series.While
those marked with A is only adaptable to SGM7165 series, and marked with B is only adaptable to
SGM7166 series.

ASCs of Shanghai General Motors will be able to provide to owners of SGM7165 and SGM7166 with
better services after they have the servicemen understand the manual as well as the service bulletins
released by SGM.

When the manual refers to products, part number or special tools with registered marks, we strongly
recommend you purchase such products, parts and special tools through Shanghai General Motors.

2004 Shanghai General Motors
Copyright Reserved.
Information is due at October, 2004.

Without prior written approval by Shgnahai general Motors, no part of the manual may be copied, stored in
searching system at any means or medias (including but not limited to electronic, mechanical, photocopy
or record).This also applies to all texts, illustrations and tables.

Error reporting and recommendations
If you find any error in the manual or you have any recommendations, we will appreciate if you will tell us.

You may give us your recommendations or report errors you find through mail or fax. The following are the
contact information:

SGM Aftersales Engineering
3999 Longdong Avenue
Pudong New Area, Shanghai, PRC
Zip Code:201201
Fax:(021)58583264

Please give us the following information.

Your name
Name of the ASC
Phone and fax of the ASC
Model year and model of the vehicle
VIN of your vehicle
Description of what you concern
other necessary information (such as sample or page number)
Any applicable electric info part identification number

SGM will reply your questions in the following ways:
Transfer your concern to relevant service engineer;
Consult service engineer to reply you;
Provide you with solutions within 10 working days

Welcome owners of SGM7165 and SGM7166 to feedback your concerns to Customer Support
Centers of SGM.Tel: (800) 820-2020 or (021) 50554580.

Foreword ........................................... -1 5.4Parking Brake ............................. 5-83
Cautions and Notices ...........................-3 5.5 Anti-lock brake system (if equipped)
0. General Information .................. 0-1 ......................................................... 5-95

0.1General Information.......................0-3
6. Engine....................................... 6-1
0.2Maintenance and Lubrication ......0-15 6.1 Engine Mechanical....................... 6-5
0.3 Vibration Diagnosis and Correction 6.2 Engine Cooling System............ 6-149
..........................................................0-21 6.3Engine Electrical ....................... 6-183
1. Heating, Ventilation and Air 6.4 Engine Controls ....................... 6-201
Conditioning System................. 1-1 6.5 Engine Exhaust........................ 6-379

1.1.1 Specifications.............................1-3 7. Clutch and transmission ........... 7-1
1.1.2Schematic and Wiring Diagram ..1-4 7.1 Manual transmission .................... 7-3
1.1.3Component Locator ....................1-4 7.2 Automatic transmission (if equipped)
1.1.4Diagnostic Information and ......................................................... 7-75
Procedures .......................................1-15 8. Body and Attachments.............. 8-1
1.1.5Repair guidance .......................1-31 8.1Lighting System ............................ 8-9
1.1.6Description and Operation........1-89 8.2Wiper/Washer System ................ 8-71
1.1.7Special tools .............................1-98 8.3 Exterior Trim .............................. 8-99
2. Steering System........................ 2-1 8.4 Water Leakage......................... 8-135
2.1Power Steering System .................2-3 8.5Air/Wind Noise .......................... 8-143
2.2Steering wheel and Steering Column 8.6Squeaks and Rattle................... 8-147
..........................................................2-47 8.7Stationary Windows .................. 8-149
3. Suspension system................... 3-1 8.8Body Front End ......................... 8-189
3.1Wheel alignment............................3-3 8.9Door .......................................... 8-189
3.2Front suspension ......................... 3-11 8.10Horn ........................................ 8-273
3.3 Rear suspension.........................3-43 8.11Body Rear End........................ 8-283
3.4 Tyres and wheels........................3-71 8.12 Underbody ............................. 8-333
4. Driveline/ shaft .......................... 4-1 8.13Painting/Coating...................... 8-339
8.14Collision repair ........................ 8-347
4.1.1Specification ...............................4-3
8.15 Instrument Panel, Gauges, and
4.1.2Visual Identification.....................4-4
Console.......................................... 8-351
4.1.3Diagnostic Information and
8.16Seats....................................... 8-413
Procedure ...........................................4-5
8.17 Interior Trim............................ 8-459
4.1.4Repair Guidance.........................4-6
8.18Plastic Panel Information and Repair
4.1.5Description & Operation ...........4-14
....................................................... 8-503
4.1.6Special Tools.............................4-15
8.19 Entertainment......................... 8-537
5. Brake ........................................ 5-1
8.20Wiring System......................... 8-567
5.1Hydraulic brake..............................5-3
8.21Data Link Communications ..... 8-695
5.2Disc brake....................................5-49
8.22Central controlled keyless entry
5.3Shoe-type brake ..........................5-67 system............................................ 8-703

8.23BRoof (if equipped).............. 8-713
9. Safeguard Device ..................... 9-1
9.1Safety Belt ..................................... 9-3
9.2 Safety Guard Air Bag system ..... 9-23

Foreword

Foreword table of contents 1

Cautions and Notices
Cautions and Notices ................................................. -3 Caution on the special purpose tools for the safety air bag
system ............................................................................. 6
Definitions of Cautions, Notices and Notes .................... -3
Caution on the lifting of the vehicle.................................. 6
Definition of Caution ........................................................ 3
Caution on the dismantling of the windows of the vehicle6
Definition of Notice .......................................................... 3
Caution on the fixing of the windows of the vehicle......... 6
Definition of Note............................................................. 3
Caution on the testing of the operation area ................... 6
Caution on the treatment of the antilock brake system ... 3
Notices for the air in the power steering system.............. 7
Caution on the bracing cable of the gear selector in the
driving mechanism of the transmission ........................... 3 Notices regarding the anti rust materials ......................... 7
Caution on the explosive gas generated by the battery .. 3 Notices regarding rectification of the driving belt............. 7
Caution on the disconnection of the battery .................... 4 Notices regarding the tightening of the fasteners of the
components ..................................................................... 7
Caution on the dust of the brake ..................................... 4
Notices regarding the malfunction diagnosis device ....... 7
Caution on the irritation of the braking liquids ................. 4
Notices regarding the refitting of the exhaustion. ............ 7
Caution on the replacement of the pipe of the brake ...... 4
Notices regarding the engine exhaust. ............................ 7
Caution on the intake of R-134a...................................... 4
Notices specific to the fasteners...................................... 8
Caution on the fan for the powered cooling liquids ......... 4
Special cautions specific to the fuel pressure.................. 8
Caution on the fast dropping function of the windows..... 4
Notices specific to the fasteners of the fuel box yoke...... 8
Caution on the fuel and evaporation discharge pipe ....... 4
Note specific to the treatment of the parts sensitive to the
Caution on the leakage of the fuel gauge........................ 5
electrostatic discharge..................................................... 8
Caution on the joint of the fuel pipe................................. 5
Note specific to the treatment of the idle air control valve.
Caution on the storage of the fuel; .................................. 5
....................................................................................... -8
Caution on gasoline/vapours of the gasoline .................. 5
Note specific to the closing of the ignition switch when the
Caution on the halide lamp.............................................. 5 battery is to be disconnected........................................... 8
Caution on the dismantling of the lower O-ring seal........ 5 Note specific to untwisted or bent installation of the hose.
Caution on the moving parts and hot surfaces. ............... 5 ....................................................................................... -8
Caution on the dismantling of the cover of the radiator... 5 Special cautions specific to the nylon fuel pipe. .............. 8
Caution on the pressure relief of the fuel; ....................... 5 Notices specific to the description of system II OBD (on
Caution on the applicable road test................................. 6 board diagnosis) .............................................................. 8
Caution on the safety protection goggles and compressed Remarks on the control module of the power system and
air..................................................................................... 6 electrostatic discharge..................................................... 9
Caution on the fuel and safety protection goggles .......... 6 Notices specific to the silicone contamination of the
Caution on the safety air bag system .............................. 6 heated oxygen sensor ..................................................... 9
Caution on the scrapping of the safety air bag system ... 6 Special cautions specific to the simplex oil overflow ....... 9
Caution on the transportation and storage of the safety air Note specific to the test probe ......................................... 9
bag system ...................................................................... 6 Note specific to the application of the appropriate power
steering oil ....................................................................... 9

2 table of contents Foreword

Blank

Foreword Cautions and Notices 3

Cautions and Notices
Definitions of Cautions, Notices and Notes Damage to the fasteners, frequently used tools
or special purpose tools.
The diagnosis and service guidance in this service Leakage of the cooling liquids, lubrication oils or
manual includes the information on cautions, notices other main machine liquids;
and notes, which are designed to assist the technicians
to carry out the normal operation in the diagnosis and Definition of Note
service of the vehicles. Failure to operate in abidance
by the recommended method, some procedures may Note stresses the necessity of a certain diagnosis or
be dangerous. Cautions, notices and notes are service procedure. The purposes of the statement of
prepared to prevent the occurrence of any danger (but the Note are in the following:
not all the dangers are predictable). Identification of the procedure;
The information about the cautions, notices and notes Provide the additional information for the
are put in the prominent positions in the service performance of the procedure;
manual. The said information is to prevent the Provide the internal cause for the operation in
following: accordance with the recommended procedure;
Serious injury to the technician himself Provide the information helpful to the
Damage to the vehicle performance of the procedure more effectively;
Unnecessary service of the vehicle Provide the technicians with the past
Unnecessary replacement of the parts experiences and information, facilitating the
easier performance of the procedure;
Improper service or replacement of the
components of the vehicle. Caution on the treatment of the antilock
Caution and Note appearing in the normal information brake system
are cited from various service categories.
Caution: It is impossible to maintain individually some
Definition of Caution components in the antilock brake system
(ABS).Attempt to dismantle or detach some
Caution requests you to adopt the necessary action or components of the system will cause injury to the
not to adopt any prohibited action. In case Caution is people and/or improper operation of the system. Only
neglected, the following will be caused: those components with the approved procedure for the
Serious injury to the technician himself dismantling and installation can be maintained.
Serious injury to other technicians in the working Caution on the bracing cable of the gear
area
selector in the driving mechanism of the
In case the vehicle is not properly repaired, the
driver of the said vehicle will be seriously
transmission
injured. Caution: The bracing cable of the gear selector in the
and/or passengers driving mechanism of the transmission consists of two
Definition of Notice sections. Don't detach the two metal hooks after the
initial connection. The detachment of the two metal
Notice requires the special attention to be paid to the hooks will be detrimental to the integrity of the
necessary or prohibiting measures. In case Notice is connection of the two metal hooks. When the driving
neglected, the following will be caused: mechanism of the transmission is to be maintained, the
Damage to the vehicle bracing cable is to be dismantled at the lever of the
gear selector in the driving mechanism of the
Unnecessary service of the vehicle transmission and bracket of the bracing cable of the
Unnecessary replacement of the parts gear selector in the driving mechanism of the
The operation or performance of the maintained transmission. If it is necessary to replace any one
system or component is abnormal. section of the bracing cable, both sections must be
replaced. Loss of integrity of the two metal hooks will
Damage to any system or component cause the gear shifting of the driving mechanism of the
depending on the normal operation of the transmission out of the control, resulting in injury to the
service system or part. people.
The operation or performance of any system or
part depending on the normal operation of the
Caution on the explosive gas generated
service system or component is abnormal. by the battery

4 Cautions and Notices Foreword

Caution: Explosive gas may be generated by the In case it is in contact with the skin, it is to be
battery. The battery contains the corrosive acid. The washed with soap and water.
strength of the current generated by the battery is In case it is swallowed, see the doctor
sufficient to cause burns. Therefore, the following immediately.
guidelines must be abided by to reduce the dangers of
injury to the people performing operation near the Caution on the replacement of the pipe of
battery. the brake
Do wear the protective goggles.
Caution: Do replace the pipe of the brake with the
The human body is to be prevented from double walls steel pipe of the brake. It is not
bending over the battery as far as possible. recommended to use the pipeline of any other type.
Do not place the battery near the open fire or Otherwise, it will cause the malfunction of t he brake
sparks. system. The replacement pipe of the brake is to be
Prevent the acid liquid I the battery from being in arranged and fixed carefully. Do use the correct
contact with the eye or skin. fastener to replace the pipe of the brake in the original
position. The improper arrangement and fixing of the
- Flush it thoroughly with the water In case of pipe of the brake will damage the pipe of the brake and
being in contact with it, flush with water brake system, causing injury to the people.
thoroughly. Seek the medical assistance.
Caution on the intake of R-134a.
Caution on the disconnection of the
battery Caution: Avoid the intake of the vapour or fog of the
lubrication oil or coolant R-134a in the air conditioning
Caution: Before the service of any electric part, the system. Contact with them will irritate the eye, nose
igniting key must be in the position of OFF or LOCK, and throat. The operation should be carried out in an
with all the electric loads to be OFF, except it is area with good ventilation. Use the service equipment
otherwise specified in the operational procedure. If the validated under SAE J 2210 (R-134a recycling
tool or setup is easy to be in contact with the exposed equipment) to eliminate R-134a from the air
electric terminal, the cable for the negative pole is to be conditioning system. In case any accidental leakage
disconnected. Violation of the safety notice will cause occurred in the system, the working area must be
injury to the people and/or damage to the vehicle or ventilated before the service is to be continued.
components. Information related to the health and safety is to be
obtained from the coolant and lubrication oil producers.
Caution on the dust of the brake
Caution on the fan for the powered
Caution: The following operations are to be avoided in
the service of the braking parts of the wheels:
cooling liquids
Do not grind the frictional lining of the brake. Caution: The electric fan under the hood of engine will
Do not grind the frictional lining of the brake with start and cause injury to the people even when the
the sand paper. engine is idle. The hands, cloth and tools should be far
away from any electric fan under the hood of the
Do not clean the braking parts of the wheels engine.
with the dry brush or compressed air.
The braking parts in some models or fitted additionally
Caution on the fast dropping function of
after the sales may contain certain asbestos fibres, the windows
possibly mixed in the dust. Intake of the dust containing
asbestos will cause serious injury to the people. Please Caution: When the operation is carried out inside the
clean any dust on the parts of the brake with the wet door of the cabin, the switch of the powered window is
cloth. There is the equipment for this kind of cleaning to be turned on intermittently. In the operation, the fast
operation available in the market. The wet cleaning dropping function enables the window to drop very fast
may prevent the fibres from mixing in the air. with no stop, causing the injury to the people.

Caution on the irritation of the braking Caution on the fuel and evaporation
liquids discharge pipe

Caution: The braking liquids are irritating to the eye and Caution: The following should be abided by to reduce
skin. Once being in contact, the following measures are the danger of fire or injury to the people:
to be taken: In the process of the installation, replace all the
In case it is in contact with the eye, thorough nylon fuel pipes that are cracked, scratched or
cleaning is to be done with the flushing of water. damaged. It is prohibited to attempt the service
of the nylon fuel pipe.

Foreword Cautions and Notices 5

In the installation of the new fuel pipe, it is not exploded into broken glass. Avoid any injury to the
permitted to strike the clamp of the bundle of the people:
fuel pipes directly with the hammer. Damaged Before replacement of the lamp, the light is to
nylon pipe will lead to the leakage of the fuel. be turned off and lamp to cool down.
When operation is carried out with the blast The switch of the light is to be maintained off
burner near the nylon steam pipe, cover the until the replacement of the lamp is finished.
steam pipe with the wet towel. Do not permit the
vehile to stay for more than one hour at the When making replacement of the halide lamp,
temperature above 115F or for a long time at the the protective goggles must be worn.
temperature above 90F. The lamp is to be taken by holding the lamp
Before the connection of the joint of the fuel holder. Avoid contact with the glass.
pipe, do apply a few drips of clean engine oil at The lamp is to be prevented from attached with
the ends of the external pipe. Thus, it is to dirt or moisture.
ensure the correct re-connection and prevent Correct treatment of the used lamps
the leakage of fuel that might happen (in the
normal operation, the O-ring in the joint of the The halide lamp is to be put away from the
internal pipe will expand. If no lubrication is children.
applied, it will not be possible to reconnect Caution on the dismantling of the lower O-
correctly.
ring seal
Caution on the leakage of the fuel gauge
Caution: Examine the lower (small) O-ring seal of the
Caution: A piece of cotton towel is to be wrapped respective oil atomizer. It is not to remain on the lower
around the fuel pressure joint, to prevent the fire or manifold, to reduce the danger of fire or injury to the
injury to the people. The towel will absorb the fuel people.
leaked when the fuel pressure gauge is connected. If O-ring seal is not to be dismantled together with the
After the fuel pressure gauge is connected, the towel is oil atomizer, when the oil atomizer is to be replaced
to be put into an appropriate container. with the new O-ring, it will be impossible to put correctly
Caution on the joint of the fuel pipe into the atomizer holder. Any improper placement will
cause the leakage of oil.
Caution: Before the connection of the joint of the fuel
pipe, do apply a few drips of clean engine oil to prevent
Caution on the moving parts and hot
the fire or injury to the people. surfaces.
Thus, it is to ensure the correct reconnection and Caution: During the operation of the engine, it is to
prevent the leakage of fuel that might occur. avoid the contact with the moving parts and hot
In the normal operation, the O-ring seal in the joint of surfaces, to prevent the injury to the people.
the internal pipe will expand. If no lubrication is applied,
it will not be possible to make the correct reconnection.
Caution on the dismantling of the cover of
the radiator
Caution on the storage of the fuel;
Caution: It is not permitted to dismantle the cover of the
Caution: It is not permitted to put the fuel into the open radiator or lid of the auxiliary water tank before the
container. It is not permitted to store the fuel in the open engine is cooled down to prevent any burn.If the engine
container. Otherwise, fire or explosion will happen. and radiator have not been cooled down, open the
Caution on gasoline/vapours of the cover of the radiator and lid of the auxiliary water tank,
the cooling system shall discharge the very hot high
gasoline pressure liquids and vapors.
Caution: The gasoline or vapour of gasoline is highly Caution on the pressure relief of the fuel;
inflammable. If they is any fire source, it will burn. It is
not permitted to use the open container to receive or Caution: Before the service of the components of the
store gasoline or some types of oil. Otherwise, it will fuel system, he pressure of the fuel system is to be
cause fire or explosion. There shall be dry chemical fire relieved, to prevent the fire and injury to the people.
extinguisher (grade B) at the side. After the relief of the pressure in the system, there will
Caution on the halide lamp be a few quantity of fuel overflowed in the service of the
fuel piping or joint. In order to avoid any injury to the
Caution: There is pressure from the gas in the halide people, the joint of the fuel piping and adjuster shall be
lamp. Any improper treatment will cause the lamp to be covered with the cotton towel before the disconnection.
Thus the leaked fuel is to be adsorbed. After the

6 Cautions and Notices Foreword

disconnection, the towel is to be put into an appropriate Make sure the opening of the air bag is not
container. towards you.
Caution on the applicable road test When the non spread air filling module is to be stored,
make sure the opening of the air bag is not oriented to
Caution: The vehicle is to be tested on the road in the the surface on which the air bag is placed. When the
safe conditions with the traffic statutes to be abided by. steering column is stored, the opening of the air bag is
It is not permitted to attempt the operation hazardous to not permitted to be oriented downward and the steering
the control of the vehicle. Violation of the safety notice column should not be vertical. There should be
described above will cause the serious injury to the sufficient room around the safety air bag, to prevent the
people. accidental spreading. Otherwise, it will cause the injury
to the people.
Caution on the safety protection goggles
and compressed air. Caution on the special purpose tools for
the safety air bag system
Caution: When the compressed air is to be used, the
safety protection goggles are to be worn to prevent the Caution: In order to prevent the air bag from spreading
injury to the eyes. when the defective of the safety air bag system is being
eliminated, only the equipment stipulated and method
Caution on the fuel and safety protection designated in this manual are to be used. If the
goggles stipulated special purpose equipment is not used, it will
cause the spreading of the safety air bag, injury to
Caution: In the treatment of fuel, the safety protection oneself, others or unnecessary service of the safety air
goggles must be worn to prevent the fuel from bag.
splashing into the eye.
Caution on the lifting of the vehicle
Caution on the safety air bag system
Caution: In order to prevent the damage to the vehicle,
Caution: This vehicle is equipped with the safety air serious injury to the people or even death accident, the
bag system. Violation of the correct procedure for the vehicle is to be supported with the jack on the side
operation will cause the following: where the parts are to be dismantled when the main
Spreading of the safety air bag components are to be dismantled from the vehicle and
Injury to the people the vehicle is supported by the lifting device.

Service of the unnecessary air filling protective Caution on the dismantling of the
system attached; windows of the vehicle
The Safety rules of the air bag in the Safety air bag
system must be abided by. Caution: When any type of the glass is processed, the
approved safety protection goggles and gloves are to
Caution on the scrapping of the safety air be used to prevent the injury to the people.
bag system Caution on the fixing of the windows of
Caution: In order to prevent the safety air bag from the vehicle
accidental spreading, causing injury to the people, it is
not permitted to treat the non spread air filled module Caution: When the static windows are to be replaced, If
as the ordinary rejects. The non spread air filling device the ethyl carbamate adhesive assembly is not used,
module contains some materials. If the sealed the fixing ability of the windows will be reduced. In that
container is damaged during the scrapping process, it case the passenger without taking any protective
will cause the serious disease or injury to the people. measure will be popped out of the vehicle and injured.
For the spread air filling system, it may be treated as Caution on the testing of the operation
the ordinary rejects.
area
Caution on the transportation and storage
Caution: When the specific test required is being
of the safety air bag system performed in the working area, one or more guidelines
Caution: When the non spread air filling module is will be applicable:
transported: When the automobile is lifted with the jack while
It is not permitted to handle by means of the the test requires to rotate the driving wheels, the
wire or connector on the air filling device following safety notice is to be abided by:
module. - When one driving wheel is rotated with the
other being idle, the speed shall not be

Foreword Cautions and Notices 7

more than 56 kilometers /hour. Under those Notices regarding the tightening of the
conditions, as the tachometer indicates only
half of the actual speed, the said restriction
fasteners of the components
is essential. Too fast rotation of the wheel Notice: The serial number of the replacement part must
will cause injury to the people. be correct. Those parts with the necessity to use t he
- If all the driving wheels rotate as the same screw lock up glue, lubrication oil, anti rust agent or
speed, the speed should not be more than sealant should be indicated distinctly in the service
112 kilometers per hour. Too fast rotation of procedure. Some replacement parts are coated. Unless
the wheel will cause injury to the people. it is specified individually, it is not permitted to apply
- All the personnel should be far away from those coatings on the components. The said coatings
the rotary parts and counterbalance will affect the final torque, so to affect the operation of
locations, to avoid the injury to the people. the components. In the installation of the components,
the stipulated value of the correct torque is to be used
- When the engine is running for a long time to prevent any damage.
in the working area, the operation must be
very careful to prevent the engine or Notices regarding the malfunction
transmission from being overheated. diagnosis device
When the test requires the vehicle to be lifted
and run after the wheels and braked disc are Notice: It is not permitted to use the malfunction
dismantled, the following safety notice is to be diagnosis device that might indicate the erroneous
abided by: data. The defectives of the malfunction diagnosis
device should be reported o the manufacturer.
- The suspension is to be supported at the Application of the defective malfunction diagnosis
height for the normal driving. device will cause the erroneous diagnosis and
- It is not permitted to use the brake after the unnecessary replacement of the parts.
braked disc is removed.
Notices regarding the refitting of the
- When the driving axle is rotating, it is not
permitted to engage the transmission in the
exhaustion.
Idle gear position. Notice: The refitting of the following system will affect
- Turn off the igniting switch for the the control of the exhaustion of the vehicle, with the
components of the power train to stop possibility to turn on the malfunction indicator (MIL),
rotation. engine examination indicator or engine immediate
service indicator.
Notices for the air in the power steering
Engine
system
Transmission
Notice: In case the power steering system has been Exhaust system
maintained, if the air were not released from the
steering system, he reading of the liquid level will not Fuel system
be accurate. The air in the oil will cause the liquid pump The replacement tyre not in compliance with the tyre
to generate the gas corrosion noise and it will cause performance condition installed originally will also affect
the damage to the liquid pump if running for a long the control of the exhaust of the vehicle. May lead to
time. the malfunction indicator light, examine the engine or
maintain the engine indicator light as soon as possible
Notices regarding the anti rust materials for starting and being lighted.
Notice: The inner face of some metal lining is applied The service caused by the refitting of those systems or
with anti rust agent, to provide the protection against installation of the tyres with the tyre performance
the rust. When the lining is maintained or new lining condition being incorrect is not covered by the warranty
installed in the locations where the anti rust material is of the manufacturer. It will cause the vehicle not to pass
damaged, the anti rust agent is to be applied to prevent the required examination of the exhaust/service test.
the damage caused by the rust corrosion.
Notices regarding the engine exhaust.
Notices regarding rectification of the
Notice: The refitting of the engine or its parts will affect
driving belt. the exhaust control of the vehicle. It may cause the
Notice: Do not rectify the driving belt. Rectification of malfunction indicating light, examine the engine or
the driving belt will cause the breakage of the texture of immediate service of the engine indictor to be lighted. It
the belt. Violation of the said recommendation will will cause the vehicle not to pass the required
cause damage to the driving belt. examination of the exhaust/service test.

8 Cautions and Notices Foreword

Notices specific to the fasteners Avoid the following operations unless it is
specially required by the diagnostic procedure.
Notice: Use the correct fasteners in the correct - Bridge connection of the joint or part or
positions The part number of the replacement fastener grounding
must be correct. Those fasteners requiring the use of
the screw lock up glue, lubrication oil, anti corrosion - Connect the probe of the test equipment to
proof agent or sealant or fasteners requiring the the part or joint. When the probe is to be
replacement parts should be indicated distinctly in the tested, first the grounding line is to be
service procedure. It is not permitted to use paint, connected.
lubricant or corrosion proof agent on the fasteners or Before opening the protective case of the part, it
connecting surface of the fasteners unless specified is to be grounded first. It is not permitted to put
otherwise. The said coatings will affect the torque and the solid state parts on the metal operational
binding force of the fasteners and damage the bench, television set, radio or the top of other
fasteners. In the installation of the fasteners, do use the electric equipment.
correct tightening sequence and torque, to prevent the
damage to the parts and systems.
Note specific to the treatment of the idle
air control valve.
Special cautions specific to the fuel
pressure Notice: If the idle speed air control valve is being used,
it is not permitted to push pull the pivot of the idle speed
Notice: The fuel pressure is not permitted to exceed the air control valve. The force required to shift the pivot will
stipulated value. Otherwise, the fuel pressure regulator damage the threads on the worm drive. Additionally,
or manometer of the fuel will be damaged. the idle speed air control valve is not permitted to be
immersed in any liquid cleaner or solvent. Otherwise, it
Notices specific to the fasteners of the will be damaged.
fuel box yoke
Note specific to the closing of the ignition
Notice: Tighten gradually and alternatively the yoke switch when the battery is to be
fasteners until the stipulated torque is reached. If the
yoke fastener failed to be tightened to the stipulated
disconnected.
torque, the bottom of the fuel box will be curved Notice: The ignition switch must be off when the cable
upward. In this way, the fuel meter will indicate the of the battery, charger of the battery or the jumper cable
availability of fuel even if there is no fuel in the fuel tank. is to be connected or disconnected. Otherwise, it will
damage the control module of the power system or
other electric parts.
Note specific to the treatment of the parts
sensitive to the electrostatic discharge Note specific to untwisted or bent
installation of the hose
Notice: The electrostatic discharge (ESD) will damage
a lot of solid state electric parts. The parts easily Notice: When the inlet or outlet hose is installed, no
affected by the electrostatic discharge are not all kink is permitted. It is not permitted to bend or kind the
indicated with the symbol of electrostatic discharge. All inlet or outlet hose for the convenience of installation.
the electric parts are to be treated carefully. Abide by Violation of the said procedures will cause damage to
the following safety notice, to prevent the damage by the parts.
the electrostatic discharge:
Special cautions specific to the nylon fuel
Before the service of any electric part, first touch
the metal grounding point to discharge the
pipe.
electrostatic electricity from the body, especially Notice: It is not permitted to attempt the straightening of
after sliding on the seat. the kink nylon fuel pipe. Any kink nylon oil inlet pipe or
Never touch the exposed terminal. The terminal return pipe is to be replaced, to prevent the vehicle
may be connected with the circuit easily affected from being damaged.
by the electrostatic discharge.
Notices specific to the description of
When the joint is to be maintained, the tools are
not permitted to be in contact with the exposed
system II OBD (on board diagnosis)
terminal. Notice: The symbol of OBD II is used on the electric
It is not permitted to dismantle any part from the circuit diagram to remind the technicians that the said
protective case unless such operation is electric circuit is mainly used for the correct operation
requested. of the control circuit for OBD II exhaust. Any electric
circuit for malfunction and causing the lighting of the

Foreword Cautions and Notices 9

malfunction indicating light or causing the damage of eliminated first, before the replacement of the oxygen
the part relating to the exhaust is the OBD II circuit. sensor.
Remarks on the control module of the Special cautions specific to the simplex oil
power system and electrostatic discharge overflow
Notice: It is not permitted to touch the pin of the joint or Notice: In order to prevent the simplex oil overflow and
welded parts on the circuit board, to prevent the the possible damage of the engine, the fuel is to be
electrostatic discharge from damaging the control released before the procedure of testing the coil of the
module of the power system. fuel atomizer is carried out.
Notices specific to the silicone Note specific to the test probe
contamination of the heated oxygen Notice: It is not permitted to insert the probe into any
sensor joint or terminal of the fuser box. The diameter of the
probe will cause most of the terminals to be distorted.
Notice: The cause of the contamination of the oxygen After the distortion of the terminal, poor contact will
sensor is the incorrect use of the hardening sealant at occur, causing the malfunction of the system. Do use
room temperature (not safe to the oxygen sensor) or the plug test adapter J35616 -A or plain wire probe joint
excessive cooling liquid in the engine or consumption unit J42675 to detect the terminal from the front. Avoid
of machine oil. Dismantle the oxygen sensor and the use of the clip or other substitutes. Otherwise, it will
inspect the part of the sensor in the current of exhaust cause damage to the terminal and error of
and examine if there is any contaminant. If measurement.
contaminated, there will be a layer of white powder on
the sensor exposed to the exhaust current. The silicone Note specific to the application of the
contamination will cause the voltage of the signal HO2 appropriate power steering oil
(indicating the concentration of the exhaust to be too
dense) to be too high but not true. The control module Notice: Do use the appropriate power steering oil when
will reduce the quantity of oil supplied to the engine, the oil is replenished or replaced completely. The use
causing the serious worsening of the driving of any inappropriate oil will cause the damage to the
performance. The source for the contamination is to be hose and sealant and leakage of oil.

10 Cautions and Notices Foreword

Blank

General Information table of contents 0-1

0

General Information

0.1General Information ..............................0-3 0.3 Vibration Diagnosis and Correction ... 0-21
0.1.1 Special Tools Ordering Information ................. 0-3 0.3.1 Specification .................................................. 0-21
0.1.2 Diagnostic Work Sheets .................................. 0-3 0.3.1.1 Tire and Radial Wheel Runout Specifications 0-21

0.1.3 Vehicle Identification Number.......................... 0-3 0.3.2 Diagnostic Information and Procedures ........ 0-21
0.3.2.1 Diagnostic Information and Procedures ......... 0-21
0.1.4 Tire Placard ..................................................... 0-5
0.3.2.2 Tire and Wheel Check .................................... 0-22
0.1.5 Service Parts Identification Label.................... 0-5
0.3.2.3 Road Test ....................................................... 0-22
0.1.6 RPO Code List ................................................ 0-6 0.3.2.4 Types of Vibration........................................... 0-25
0.1.7 Key Coding...................................................... 0-7 0.3.2.5 Vibration that produces noise ......................... 0-25
0.1.8 Lifting and Jacking the Vehicle........................ 0-9 0.3.2.6 Matching Frequency to Component RPM ...... 0-26
0.1.9 Diagnostic Strategy ....................................... 0-12 0.3.2.7 Steering and Suspension Assembly Vibrations .....
0.2Maintenance and Lubrication ..............0-15 .................................................................................. 0-27
0.3.2.8 Brake Rotor/Drum Imbalance ......................... 0-27
0.2.1 Specifications ................................................ 0-15
0.3.2.9 Front Wheel Drive Vibrations.......................... 0-27
0.2.1.1 Fuel Capacity (Approximation) ....................... 0-15
0.3.2.10 Tire and Wheel Vibration .............................. 0-29
0.2.1.2 Recommended Oil and lubricants .................. 0-16
0.3.3 Repair Instructions ........................................ 0-35
0.2.1.3 Tire Inflation Pressure Specifications ............. 0-16
0.3.3.1 Balancing Tires and Wheels........................... 0-35
0.2.2 Maintenance Schedule.................................. 0-17
0.3.4 Description and Operation ............................ 0-39
0.2.2.1 Normal Vehicle Use........................................ 0-17
0.3.4.1Basic terminology: ........................................... 0-39
0.2.2.2 Regular Service Description........................... 0-18
0.3.4.2Electronic Vibration Analyzer (EVA) ................ 0-49
0.2.2.3 Owner Checks and Services .......................... 0-18
0.3.5 Special tools and devices.............................. 0-53

0-2 table of contents General Information

Blank

General
General Information General Information 0-3

0.1General Information
0.1.1 Special Tools Ordering
Information
The special tools shown in this service manual are
available through SPX Kent-Moore.The special tools of
the codes started with KM are CORSA series.They are
only suggested.

0.1.2 Diagnostic Work Sheets
The GM diagnostic worksheet has been designed to
improve communications between the service
customer and the technician.The diagnostic worksheet
can provide the technician with more information than
the conventional repair order, since it is filled out by the
service customer.GM service bulletin 58-01-01 has
information on how to order this diagnostic worksheet. 001002

0.1.3 Vehicle Identification Number This vehicle contains a second VIN plate.

The VIN plate is the legal identifier of the vehicle.

001003

001001
Legend:
(1) Seats
The VIN plate (1) is located on the upper left corner of
the instrument panel and can be seen through the (2) Gross Vehicle Weight
windshield from the outside of the vehicle. (3) Model
(4) Engine Model
(5) Engine Displacement
(6) Date of Production
(7) No. (VIN Number)

0-4 General Information General Information

The second VIN plate is located on the radiator
support.

001004

Vehicle Identification Number (VIN) System
Location Definition Character Description
Global Manufacture China
1-3 LSG
Identification

4-5 Vehicle Line and Series SJ 1.6 L Engine

5 4-Door Sedan
6 Body Style
8 5-Door station wagon

Seat Belt and Driver & Passenger Seat Air Bag
7 Restraint System 2
System

4-cylinder multiple fuel injection 1.6L (Optional Code
8 Engine types N
L01)

9 Verification figure - Verification figure

10 Model Year 3 2005

Shanghai GM Dongyue Automobile Co., Ltd.
11 Plant Location Y
(Yangtai)

12-17 Plant Code - -

General Information General Information 0-5

0.1.4 Tire Placard 0.1.5 Service Parts Identification Label
The tire placard is located on the lower part of the left The Service Parts Identification Label is attached on
front door. the vehicle in order to assist service and parts persons
1 2 3 to make identifications.
Original Parts and Options on the vehicle

Tire Loading Information Label
Number of Occupants Load Capacity
Front Rear Tota LBS KG

The maximum load weight is equal to the load capacity
Model:
Inflation Pressure
Tire size Speed level (only effective to cold tire) Service Parts ID Removal of the label
is prohibited
Front tire

Rear tire

Refer to the Owner’s Manual for details
Gross Vehicle Front Gross Axle Rear Gross Axle
Date Weight Rating Weight Rating Weight Rating

10 9 8 7 6 5 4
001005
001013

Legend:
(1) Total Occupant Seating
(2) Vehicle Type Number Legend:
(3) Maximum Vehicle Capacity Weight (1) Vehicle identification number
(4) Rated Loading, Rear Axle (2) Engineering Model Number (Vehicle Division,
(5) Tire Pressure, Front & Rear Vehicle Line and Body Style)
(6) Rated Loading, Front Axle (3) Interior Trim and Decor Level
(7) Tire Speed Level, Front & Rear (4) Vehicle Option Content (RPO code)
(8) Rated Gross Vehicle Weight
(9) Rated Tire Dimension
(10) Vehicle Identification Number

0-6 General Information General Information

0.1.6 RPO Code List RPO Description
C49 Defogger, RR Window, Electric
The following table provides the description of the
Regular Production Option (RPO) codes that are C60 Air Conditioner, Manual
available on the vehicle.The vehicle's RPO list is
C72 Reading Lamp, Rear
printed on the Service Parts Identification Label.
CF5 Power Sunroof
D07 Instrument Console
RPO Description
D08 Paint, High Gloss Finish
12U Metallic Bright Silver
D27 Roller Blind, Trunk
16U Bright White
D32 Vanity Mirror, Right Sunshade
24U Space Blue
D41 Outside Mirror, Black
49U Jasper Green
D67 Glove Box with Door, I/P Compartment
60U Bright Metallic
D6R Instrument Cluster, Silver Grey
64I Interior Trim, Beige
D72 Outside Door Handle, Black
70U Maple-Leaf Red
D75 Outside Door Handle, Concolorous
8HU Suspension Parts, Rear Left
(Door) Handle, L/Gate R/CMPT,
9HU Suspension Parts, Rear Right D91
Concolorous
A01 Shaded Windshield
D98 Body Decals
A32 Power Window, FRT DR
Outside Mirror, Foldable, LH Manual, RH
DNB
A33 Power Window, RR DR Electric, Concolorous

A51 Front Bucket Seat DR8 Outside Mirror, Manual, Concolorous

A90 Power Door Lock, L/Gate E22 Pull Handle, Roof, Rear Seat

AG4 Height Adjuster, Driver Seat FE2 Suspension System

Split Headrest, Leather Covered, FRT FQ7 Drive Ratio 4.05 Drive Axle
AJ5
Seat
FX1 Drive Ratio 3.94 Drive Axle
AJ8 Rear Seat, Foldable
Hydraulic Brake System, Front Disc, Rear
JM4
AK3 Split Headrest, Cloth Covered, FRT Seat Drum, FRT & RR Anti-lock Brake

AK5 Dual Air bag JVA Brake System, Anti-lock Brake Disabled

Three-Point Safety Belt, RR Seat, Central K12 Air Filter
AK9
Lap-Strap
K60 100AMP Generator
AQ4 Rear Seat
L01 1.6 L Engine
AR3 Split Headrest, Cloth Covered, Rear Seat
M79 5 Gear Manual Transmission
AU0 Door Lock, Remote Control
ML4 4 Gear Auto Transmission
AU3 Central Door Locking System, Four-Door
3-Spoke Steering Wheel, Leather
N34
Split Headrest, Leather Covered, Rear Wrapped
AY7
Seat
N40 Power steering
B52 Door Sill, Black
N45 3-Spoke Steering Wheel, Plastic Wrapped
B86 Molding, Outside Door, Concolorous
N51 Manual Steering
Three-Point Safety Belt, RR Seat, Central
AK9 NT3 Euro III Emission System
Lap-Strap
NV1 Oil Pan Guard
BC0 Instrument Panel, Dual Color
P08 Trim Cover, Steel Rim
BNN Trunk Stowage
PY4 14*5.5 Aluminum Rim
C1X Central Console, Titanium Silver
PY8 14*5.5 Steel Rim
C25 Rear Windscreen Wiper

General Information General Information 0-7

RPO Description 0.1.7 Key Coding
QIC 165/70R13-79T Tire
Key Identification and Usage
QUS 185/60HR14 Tire
A single key is used to unlock and lock all of the locks
T2F ABS Module 5.4 on the vehicle.The key identification is obtained from
T39 Turn Lamp, Aux. the four-character key code located on the key tag. The
four character key code should be recorded by the
Door Trim Panel, Inner, Coarse Cloth owner and the dealer. The mechanical key code can be
T6G
Covered determined through the use of a code cross-reference
T79 Rear Fog Lamp list which is available to the owner from the key cutting
equipment suppliers.
T84 Headlamp
Cutting Keys:
T8B Pull Handle, Roof, Front Seat
After the mechanical key code has been determined
T96 Front Fog Lamp
from the code list, perform the following steps:
Door Trim Panel, Inner, Punched Leather 1. Cut a blank key to the proper level (1) of each of
T9N
Covered
the tumbler positions (2).
TD8 Radio/Cassette Player 2. Inspect the key operation in the lock cylinder.
TK0 46L Plastic Fuel Tank Replace Lock Cylinders
TL6 Radiator Grille, Black New lock cylinder cores are available from the service
TN6 55AH Battery parts warehouses without tumblers and springs.The
tumblers and springs are also available and must be
TS6 High Mounted Brake Lamp
assembled into the lock cylinder according to the key
Engine Parts Package, Electronic code.Other components are also available.
U0R
Injection, Generation 2
Lock Cylinder Tumbler Operation
U16 Engine Tachometer
All tumblers are shaped alike with the exception of slot
U68 Driver Information Center position on them. As the key is inserted into the lock
U76 Antenna Windshield, Radio cylinder, it will set every tumbler slot to the same level
as inner surface of cylinder bore, allowing the cylinder
U95 2-Channel Speaker to turn inside the bore.
UAK CD/Radio Lock Cylinder Coding
Component Assembly, Engine W/Direct Note: If ignition cylinder does not work, it must be
UOR
Ignition System, Generation II replaced with the new ignition cylinder.
V35 Bumper FRT & RR, Body Color Steps described as below:
UC5 6-Channel Speaker, Deluxe 1. Place the key directly over the illustrated key;
UW4 4-Channel Speaker 2. Starting with Position 1, find and record the
lowest level (Tumbler number);
V36 Wheelhouse, Concolorous
3. Repeat Step 2 for Positions 2-10;
V44 Bumper FRT & RR, Dual Color
4. Insert a spring into the cylinder core for each
V54 Roof Luggage Rack tumbler;
V9I SL Vehicle Type 5. Starting with Position 1, insert tumbler into
W5Z Seat, Punched Leather Covered proper slot in coded order;

W6G Seat, Coarse Cloth Covered
6. Repeat Step 2 for Positions 5-10;Be careful to
put cylinder core in place without damaging the
W8X Radio Wiring Harness tumblers.
XM0 SXAT Vehicle Type Note: Except the different amount of tumblers, use the
XN5 Trunk Lamp
same way to code other cylinders.

Y7E SE Vehicle Type

0-8 General Information General Information

001501

Legend:
(1) Key
(2) Tumbler
(3) Spring
(4) Key Cylinder

General Information General Information 0-9

0.1.8 Lifting and Jacking the Vehicle Automotive Lift and
Floor Jack Contact Points
Caution: To avoid any vehicle damage, serious
personal injury or death when major components are
removed from the vehicle and the vehicle is supported
by a hoist, support the vehicle with jack stands at the
opposite end from which the components are being
removed.
Caution: To avoid any vehicle damage, serious
personal injury or death, always use the jack stands to
support the vehicle when lifting the vehicle with a jack.
Notice: Perform the following steps before beginning
any vehicle lifting or jacking procedure:
Remove or secure all of the vehicle's contents in
order to avoid any shifting or any movement that
may occur during the vehicle lifting or jacking
procedure.
The lifting equipment or the jacking equipment
weight rating must meet or exceed the weight of
the vehicle and any vehicle contents.
The lifting equipment or the jacking equipment
weight rating must meet the operational
standards of the lifting equipment or jacking
equipment's manufacturer.
Perform the vehicle lifting or jacking procedure
on a clean, hard, dry, level surface.
Perform the vehicle lifting or jacking procedure
only at the identified lift points.Do not allow the
lifting equipment or jacking equipment to contact 001006

any other vehicle components.
Failure to perform the previous steps could result in
Legend:
damage to the lifting equipment or jacking equipment,
the vehicle, and/or the vehicle contents. (1) Front Floor-Jacking Location
(2) Front Suspension-Contact Lift Location
(3) Front Frame-Contact Lift Location
(4) Rear Frame-Contact Lift Location
(5) Rear Suspension-Contact Lift Location
(6) Rear Floor-Jacking Location

0-10 General Information General Information

Vehicle Lifting-Frame Contact Lifter Vehicle Lifting-Suspension Contact Lifter
Front Lift Pads When lifting the vehicle with a suspension-contact lifter,
When lifting the vehicle with a frame-contact lifter, place place the front post lift points at the lower control arms
the front lift pads at the front pinch-weld flanges. (1).Lift the rear of the vehicle with the rear post lift point
only under the rear wheels.

001007
001009

Rear Lift Pads
Vehicle Jacking
When lifting the vehicle with a frame-contact lifter, place
the rear lift pads at the rear pinch-weld flanges. Under the Front Frame
When lifting the front of the vehicle with a floor jack,
place the floor jack lift pad at the center of the front
frame.

001008

001010

General Information General Information 0-11

Under the Center of the Rear Suspension Supporting the Vehicle with Jack
Lift the rear of the vehicle by placing the floor jack lift Note: Place the jack only under strong and stable
pad at the center of the rear suspension. vehicle structures.

001011

0-12 General Information General Information

0.1.9 Diagnostic Strategy
The goal of diagnostic strategy is to provide guidance diagnostic boxes is numbered, you are not required to
when you create a plan of action for each specific complete every box in order to diagnose a customer
diagnosis situation.Following similar plan for each concern successfully.The last step of your diagnostic
diagnostic situation, you will achieve maximum process should be, Repair and Verify the Fix.Refer to
efficiency when you diagnose and repair the following chart for the correct strategy based
vehicles.Although each of the strategy based diagnostics.

Verify the customer concern

Perform preliminary check,
visual check

Perform regular diagnostic
system check

Review the bulletins

Symptoms No published
Stored DTCs without the Intermittent
DTC
symptom condition
follow the follow the analyze and
published
published Symptom develop a
DTC table to Diagnosis table diagnostic plan see Diagnostic
make repairs to determine or request for Details
the symptom. technical
assistance

The vehicle operation complies with the design
Check identical vehicle
Customer Misunderstanding of System:
explain to the customer, or refer to the
Owner’s Manual or Service Manual
Request for technical assistance on the
product concern

No
Find the root cause of the concern Re-check
Yes
Repair and verify the fix

001012

Legend:
(1) Verify the customer concern: The first part of the system.System checks verify the proper
this step is to obtain as much information as operation of the system.This will lead the
possible from the customer.Are there after- technician in an organized approach to
market accessories on the vehicle ? When does diagnostics.
the condition occur? Where does the condition (4) Check bulletins and other service information:
occur? How long does the condition last? How Use newsletters.
often does the condition occur? In order to verify
the concern, the technician should be familiar (5.1) Stored DTCs: Follow the designated DTC table
with the normal operation of the system and exactly in order to make an effective repair.
refer to the owner or service manual for any (5.2) Symptom has no DTC: select the symptom from
information needed. the symptom tables.Follow the diagnostic steps
(2) Preliminary Checks: Conduct a thorough visual or suggestions in order to complete the repair,
inspection. Review the service history.Detect or refer to the applicable components/system
unusual sounds or odors.Gather diagnostic check.
trouble code information in order to achieve an (5.3) No published diagnostics: Analyze the
effective repair. concern.Develop a plan for the diagnostics.The
(3) Perform regular diagnostic system checks: one service manual schematics will help you to see
or more DTCs may not support the conditions in system power, ground, input and output

General Information General Information 0-13

circuits.You can also identify splices and other manual.The Tech 1 and Tech 2 scan tools, and
areas where multiple circuits are tied the J39200 (Fluke 87) have data capturing
together.Look at component location to see if capabilities that can assist in detection of
component, splices or harness exposed to intermittence.
extreme temperature, moisture, road salt or (5.5) Vehicle operation as designed: The condition
other corrosive. Utilize the wiring diagrams, described by the customer exists when the
system description and operation, and system vehicle is found to operate normally.It indicates
circuit description. that the condition may be normal. Verify against
(5.4) Intermittent condition: an intermittent condition another like vehicle that is operating under the
is one that does not occur continuously and will same conditions described by the customer.
occur when certain conditions are Explain your findings and the operation of that
met.Generally, intermittent conditions are system to the customer.
caused by faulty electrical connections and (6) Re-examine the concern: If a technician can not
wiring, malfunctioning components, successfully find the concern, a re-evaluation is
electromagnetic/radio frequency interference, necessary.Re-verify the concern.The concern
and after-market equipment.Combine technician could be an intermittent or normal.
knowledge with efficient use of the available
service information.Evaluate the symptoms and (7) Repair and verify Fix: after isolating the cause,
conditions described by the customer.Use a make the repairs and validate for proper
check sheet or other method in order to identify operation.Verify that the symptom has been
the component.Follow the suggestions for corrected, which may involve road testing of the
intermittent diagnosis found in the service vehicle.

0-14 General Information General Information

Blank

General Information Maintenance and Lubrication 0-15

0.2Maintenance and Lubrication
0.2.1 Specifications

0.2.1.1 Fuel Capacity (Approximation)
Application Specification
Engine oil

Filter replacement 3.5 L

Do not replace filter 3.25 L

Engine Cooling System 5.8 L

Transmission

Auto 6.0 L

Manual 1.6 L

Brake fluid 0.45 L

Power steering fluid 0.9 L

Fuel tank 46 L

Windscreen cleaning agent 2.6 L

A/C system refrigerant 0.68 kg

0-16 Maintenance and Lubrication General Information

0.2.1.2 Recommended Oil and lubricants
Usage Fluid/lubricants
Transmission

Auto DEXRON III Auto Transmission Oil

Manual CASTROL MTF0063 or SAE 75 W/85-APILGL4

Engine Coolant DEX-COOL Coolant

The Society of Automotive Engineers certified SAE5W30
Engine oil
If you are in an area where the temperature falls below -29 ℃ , use the
Society of Automotive Engineers certified SAE 0W30

Engine hood Multi-purpose lubricant

Door hinge Lubricating Grease, No.: 09309859

Brake fluid DOT 4 Brake fluid

Power steering system DEXRON III Auto Transmission Oil

Key cylinder Paraffin or graphite

0.2.1.3 Tire Inflation Pressure Specifications
Application Specification (Full load)
Tire (185/60 R14-82H)

Front tire 210 kpa.

Rear tire 250 kpa.

General Information Maintenance and Lubrication 0-17

0.2.2 Maintenance Schedule Inspect the A/C, and replace the air filter in the
passenger compartment as required.
0.2.2.1 Normal Vehicle Use Inspect the underbody and clean.
Lubricate the door hinge, the engine hood
The following schedule is used for the vehicle that
release mechanism, the lock cylinder.
meets the following conditions:
Road test the vehicle after the services
Carry passengers and cargo within
recommended limits.These limits are listed on 30,000km
the tire placard which is located on the driver's Repeat the required performances at 15,000
door. km.
Vehicles that are driven on reasonable road Inspect the brake drum.
surfaces within legal driving limits.
Inspect the steering system.
Use the recommended fuel and oil.
Replace the brake fluid.
Maintenance Schedule Intervals Replace the fuel filter
The repair and inspection contents shown in this Replace the spark plug
schedule up to 15,000 km (or one year) should be
45,000km
performed.The services shown in this schedule should
be repaired and inspected after 15,000km (or one year) Repeat the required performances at 15,000
at an interval of 15,000km (or one year).The services km.
shown in this schedule up to 200,000km (or 5 years) Replace the brake shoe.
should be performed after 200,000km (or 5 years) at
the same intervals.If the vehicle is not used frequently, 60,000km
the repair and inspection should be performed Repeat the required performances at 30,000
annually. km.
Maintenance Schedule 75,000km
15,000 km Repeat the required performances at 15,000
km.
Road test the vehicle before the services
90,000 km
Inspect the engine emission.
Repeat the required performances at 30,000
Replace the air filter.
km.
Replace the engine oil filter and the engine oil.
Replace the brake hose and the brake shoe
Clean the positive crankcase ventilation of the
engine. Replace the drive axle

Inspect the engine cooling system hose and Replace the transmission fluid
lines. Replace the parking brake cable
Inspect the engine coolant level. 105,000 km
Inspect the brake wears. Repeat the required performances at 15,000
Inspect the brake hose and lines. km.

Inspect the electrical system, signal and lighting 120,000 km
device for the possible conditions. Repeat the required performances at 30,000
Replace the wiper blade. km.
Inspect the windshield washer fluid level. 135,000 km
Inspect the headlamp aim Repeat the required performances at 45,000
km.
Inspect the transmission lubricant
150,000 km
Inspect the power steering system lubricant
Repeat the required performances at 30,000
Inspect the absorber for leaks
km.
Inspect the power steering system lubricant
165,000 km
Inspect the absorber for leaks
Repeat the required performances at 45,000
Inspect the tires km.
Inspect the engine drive belt. 180,000 km

0-18 Maintenance and Lubrication General Information

Repeat the required performances at 90,000 Inspect the transmission axle fluid level.If necessary,
km. add the fluid.
200,000 km Door Hinge Lubrication Care
Drain, flush and refill cooling system. First clean the deposits inside and around the hinge
Inspect radiator and heater hoses pin, then fill appropriate designated grease on the
hinge pin.
Clean radiator, condenser, pressure cap and
journalPerform a pressure test of the cooling At least once a year
system and pressure cap Key Cylinder Care
Repeat the required performances at 15,000 Use the recommended lubricants to lubricate the key
km. cylinder.
0.2.2.2 Regular Service Description Body Lubrication and Care

For time and/or mileage intervals of scheduled Lubricate all the following locations:
maintenance items, refer to Maintenance Schedule. - Body hood, safety lever and drive rod pivot
For information on the proper fluids and lubricants to - Fuel tank door
use, refer to Fluid and Lubricant Recommendations. - Rear compartment hinge
0.2.2.3 Owner Checks and Services - Rear compartment pin and lock
The following information covers the inspections and - Seat hardware
services required in order to retain the safety, Underbody flush
dependability, and emission control performance of the
At least every spring, use plain water to flush the
vehicle.
underbody in order to remove any corrosive materials
Immediately complete all of the necessary repairs.Fill from the underbody.
the vehicle with the recommended fluids or lubricants.
Regular Maintenance Checks
Before usage
At least twice a year, perform the following checks and
Inspect the engine oil level repairs.
Inspect the fuel level Steering mechanism, suspension and front drive axle
Inspect the brake fluid level boot seal checks
Inspect the power steering system fluid level Inspect front suspension and rear suspension
Inspect the windshield washer fluid level system.

Inspect the tire inflation Inspect the steering system for damage,
looseness or part loss, frayed or insufficient
Under the condition of vehicle speed less than lubrication.If necessary, repair the vehicle.
30km/h, try the steering and the braking.
Inspect the power steering system lines and
If any problems found, always resume the vehicle to hoses for proper hookup, binding, leaks, cracks,
normal before the vehicle use. chafing, etc.If necessary, repair the vehicle.
At least once half a year Clean and inspect the drive axle boot seals for
Restraint System Checks damage, tears, or leakage.If necessary, repair
the vehicle.
Ensure the safety belt indicator and all the safety belt
system operative normally.Inspect the safety belt Exhaust system checks
system parts for any looseness or damage.Repair the Inspect the entire system.If necessary, repair the
loose or damaged safety belt system parts.Repair any vehicle.
torn or frayed safety belts. Engine Cooling System Checks
Wiper Blade Checks
Inspect the hoses.Replace the hoses if the hoses are
Inspect the wiper blades for wear or cracking. cracked, swollen, or deteriorated.
Weather-strip Lubrication Inspect all the lines, connectors and clamps.If
Silicone grease on weather strips is helpful to make necessary, repair the components.
weather strips last longer, seal better, and not stick or Throttle linkage checks
squeak.Apply silicone grease on weather strips with a Notice: Do not lubricate the accelerator cables.
clean cloth.
Inspect the following contents, and replace if
Transmission Axle (Manual, Auto) Checks
necessary:

General Information Maintenance and Lubrication 0-19

Parts lost
Interference of linkage or cable conduit to critical Brake system checks
components such as fuel lines, brake pipes or
Notice: A low brake fluid level can indicate disc brake
harness leads.
pads are severely worn.
Clearance of throttle system moving parts
Inspect the entire system.
throughout travel from other stationary
components. Inspect the brake lines and hose.
Damaged Parts If necessary, repair the components.

0-20 Maintenance and Lubrication General Information

Blank

General Information Vibration Diagnosis and Correction 0-21

0.3 Vibration Diagnosis and Correction
0.3.1 Specification Test-drive the vehicle with customer, compare and
explain the conditions before the customer.
Sometimes the vibration can be duplicated at a given
0.3.1.1 Tire and Radial Wheel Runout speed.Other vibrations may not be as evident and may
require further troubleshooting by performing a road
Specifications test with the customer in the vehicle in order to
determine the specific vibration complaints.
Application Specification
Ask the following questions when attempting to identify
Aluminum Wheel a vibration complaint:
Lateral 0.762mm At what speed is the vibration the worst?
Radial 0.762mm Do you feel the vibration? If so, where is the
vibration?
Steel Wheel
Do you hear the vibration? If so, what does the
Lateral 1.143mm noise sound like?

Radial 1.015mm Does the engine or the vehicle load affect the
vibration?
Wheel Assembly (Radial and Lateral)
Does the vibration occur in more than one gear
Off vehicle 1.27mm range?
When did the vibration first appear?
On vehicle 1.52mm
The answers to these questions will help in duplicating
Wheel Stud 0.25mm and diagnosing the vibration.
Wheel hub 0.130mm If you suspect that the vibration is normal, compare the
vibration with a vehicle that is equipped in the same
way, including the following factors:

0.3.2 Diagnostic Information and Body Style
Engine option
Procedures
Engine drive accessories
0.3.2.1 Diagnostic Information and Transmission type
Procedures Tire size
Suspension type
This section describes the techniques and procedures
for correcting the following types of vibrations: Drive axle ratio
Tire and Wheel Waddle Removal Method
Launch shudder You must understand a few basic concepts before
Exhaust groan attempting to diagnose a vibration.As in any diagnostic
process, you must perform the following steps:
Engine ignition frequency
Gather the information
Drive System Vibrations
Read the information
Problem Identification
Make your correction based on the results
Note: DO NOT attempt to repair a normal condition, or
Road test the vehicle and inspect the vehicle in a
the customer will probably be convinced that the
manner which systematically eliminates different
vehicle has a problem.Customer satisfaction becomes
components.This process supplements the information
extremely difficult after this point.
which you have received from the customer concerning
The first step in diagnosing a vibration concern is to the complaint.Focus on the non-eliminated part in order
identify the exact vibration that concerns the customer. to speed up the repair work, and improve the efficiency.

0-22 Vibration Diagnosis and Correction General Information

0.3.2.2 Tire and Wheel Check
Inspect tire and wheel assembly for the following
The tires on all new production models have a tire conditions:
performance criteria (TPC) rating number molded on
the sidewall.The TPC rating will appear as a 4-digit Abnormal wear, such as concave, flat spots and
number preceded by the letters TPCSPEC on the tire tire bead and tire edge wears
wall near the tire size.A replacement tire should have Proper inflation pressure
the same TPC rating. Bulges in the sidewalls
Rim flange is bent
By inspecting these characteristics of the tire and
wheel assemblies, you may discover the cause of the
vibration.The inspection will also provide assurance
that the vehicle is safe for road testing.

0.3.2.3 Road Test
Road test's purpose
Note: DO NOT attempt to repair a normal condition, or
the customer will probably be convinced that the
vehicle has a problem.Customer satisfaction becomes
extremely difficult after this point.
The purpose of road testing is to duplicate the
vibration.Most importantly, road testing will determine
304008
whether the vibration is related to the engine speed or
to the vehicle speed.
In order to complete a quick and accurate road test,
install an engine tachometer (such as a scan tool) and
the Electronic Vibration Analyzer (EVA) in the
vehicle.Place the EVA vibration sensor in a location
where the customer's concern can be felt.
Determining the component group
After you have related a vibration to either the engine
speed or to the vehicle speed, break the vibration down
further in order to fit into one of the following groups of
rotating components:
Engine, clutch disc, transmission flywheel and
transmission torque converter
Transmission output shaft, propeller shaft, rear
axle differential pinion
003001
Tire, wheel, wheel hub, brake drum and brake
rotor
These three groups represent the major areas that can
produce vibration complaints.The components in each
Tire Wear group are related to each other because the
components are either bolted or splined together.This
Legend: means that each group of components rotates at the
(1) Hard steering/under inflation exact same speed.

(2) Improper alignment/insufficient rotation These component groups can be broken down further
in order to identify the exact component responsible for
(3) Improper alignment/unequal tire inflation the disturbance.Focus on the testing in order to find the
(4) Heavy acceleration/over inflation cause and avoid the unnecessary replacement of parts.
(5) Wear Indicator

Refer to Tire and Wheel Check Depending on the symptoms or the frequency. Observe the following readings where the disturbance occurs: Vehicle speed. 2.At this standstill. This test will be used to determine all the vibration conditions. Operate the vehicle at original engine speed. unless the disturbance occurs with the vehicle at a stand still. 1. On a smooth. This test will be used to determine all the vibration. lower gear. level road. slowly accelerate up to highway speed. Shift the vehicle into neutral and coast down through the vibration range. Caution: Refer to Road Test Caution in Cautions and Notices. Decelerate and safely downshift to the next vehicle at a stand still. level vibration conditions. On a smooth. conditions. inspect the tires Transmission flywheel and wheels. Observe whether the vibration is present in NEUTRAL gear.Additional tests may be necessary in order to determine the exact cause of the vibration. km/h Engine Speed (rev/min) Frequency Neutral coast-down test Caution: Refer to Road Test Caution in Cautions and Notices. related to the engine speed or the vehicle speed. level road. unless the disturbance road.General Information Vibration Diagnosis and Correction 0-23 Perform a road test for all vibration complaints unless If the vibration still occurs in NEUTRAL gear. point. 1. . unless the disturbance occurs with the 2. acclerate to the speed Slow acceleration test at which the concern vibration occurs. 2. the The following road test procedures are the most repair will concentrate on one of the following informative and the most used: components: Slow acceleration test Tire and wheel assembly Neutral coast-down test Torque converter output shaft Downshift test Rear axle differential pinion Neutral run-up test Rear drive axle or rear driven shaft Brake torque test Downshift test Steering input test Caution: Refer to Road Test Caution in Cautions and Standing start acceleration test Notices. This road test can be used to identify the conditions 3. then the the disturbance occurs only with the vehicle at a vibration is definitely sensitive to vehicle speed. These road tests will help to pinpoint the 1. This test will be used to determine all the vibration Observe the engine speed. occurs with the vehicle at a stand still. Verify the vibration that meets customer complaint. 3. Torque converter Note: Before performing any road test.Perform all of the tests on a smooth. the following components have been eliminated as a cause of the vibration: Types of road test procedures Engine Caution: Refer to Road Test Caution in Cautions and Notices.

tire speed related This test is designed to identify engine-related amplitude would remain the same. a powertrain mount or to the speed of the vehicle. With the vehicle at the vibration speed. a vibration may also be sensitive to Steering input test torque or engine load. 1.Use this test when through slow sweeping turns. Caution: Refer to Road Test Caution in Cautions and Neutral run-up test Notices. in order to confirm the results. Depress the brake pedal. vibrations that were not uncovered with the Neutral Standing start acceleration test Run-up test. and in NEUTRAL gear. and apply the braking. allowing front wheels the gear. With the vehicle at a full stop and remaining at 2. appear when the angle increases. Apply parking brake.0-24 Vibration Diagnosis and Correction General Information If the vibration returns at the same engine RPM. following: 6. Other possible causes of launch shudder include the 5. or as direction and then in the other direction. away from the ground. 2.The third order.These bearings and other suspension components contribute vibrations can be most difficult to diagnose. place the vehicle in REVERSE following conditions are the most possible causes of gear and repeat Steps 5 and 6. grinding.Putting a load on the CV joint may increase the vibration Brake torque test amplitude. vibrations that match the customer's description. remove the foot from the brake pedal. If the vibration gets worse or if the vibration goes not apply when the complaint is related to vehicle away. a follow-up to the downshift test. the vibration: Additional Test Engine driven accessories One or more of the following tests maybe necessary for Engine some unique vibrations. Place the transmission lever in DRIVE position. which are the customer Transmission flywheel concerns and are either torque/load sensitive in addition to vehicle speed or engine rpm sensitive. CV joint condition systems may where the vibration occurs.In some cases.On front weel drive and four wheel 2. 4. If necessary. and roaring. Standing start acceleration test In some cases. additional testing. inspect the following components as speed only (appearing at the same vehicle speed possible causes of the vibration: regardless of the engine speed). first in one the customer has a concern with vibration at idle. Torque converter Steering input test Repeat this test in lower gears. This test is designed to identify vibrations which are 1. 1. Slowly increase the engine speed while looking A worn or damaged drive axle CV joint for disturbances that match the customer's A rubber pad ground-out through the engine or description.The system method can usually be such as growl. transmission mounts 7. Start the engine and allow it to idle. and require to the vibration. Caution: Refer to Road Test Caution in Cautions and Notices. used to find out the conditions. Wheel bearing Caution: Refer to Road Test Caution in Cautions and Notices.This test will The purpose of this test is to duplicate a vibration called probably not apply to vibrations which are related only launch shudder. drive related to the speed of the engine. the 8. especially a vibration relating to noise. Wheel hub 1. rods and mounts . an exhaust ground-out may also be the cause of the vibration. The CV joint angle increases when the vehicle concern.This test also works for vibrations that are sensitive to engine load or to torque. Caution: Refer to Road Test Caution in Cautions and Notices. depending upon the symptoms. Accelerate to 48~64 km/h while looking for 3. Slowly increase the engine speed while looking Tire tread for disturbances that match the customer's 3. Observe the engine speed and the frequency A condition to exhaust pipe suspension hanger where the vibration occurs. as well as being related to a This test is intended to determine how much the wheel specific engine speed or vehicle speed.This test probably does 2. is turning. Observe the engine speed and the frequency drive vehicles. Lift the front of vehicle.

in your feet through the floor. Buzzing vibration The surge frequency is slightly higher.Customers may Rumbling refer to a shake in one of the following terms: Humming Shimmy Boom may be accompanied by a perceptible vibration.3. Boom through the steering wheel. or in the seat.If the EVA is not available.3. or a bass drum. Shake is sometimes felt in the steering wheel.5 Vibration that produces noise Boom Boom is a low frequency interior noise of 20-60 Hz.The best description is the feeling from Roaring an out-of-round or unbalanced tire. Jounce Vibration that can be felt: The vibration frequency of jounce is slightly higher than shake. observe how the Engine vibration feels or sounds.You may feel it in your hands .Vibration of surge is similar to the feeling you get Vibration that produces noise: from a electric shaver.Use the EVA in order to measure the Suspension ball joint frequency. Whine A/C Compressor Vibration that can be felt with shake: Engine Shimmy This is the highest vibration frequency that you can feel. somewhat higher than boomThe noise is Hop similar to a bumble bee or blowing air across the top of In most cases. Vibration Surge .The noise is similar to the noise of a bowling ball rolling down an alley.Customers may say the vibration creates numbness in their hands or feet.2. Roughness of jounce is . Swing Tremble Moaning or Droning Wobble Moan or drone is a sustained tone at a low frequency of 60-120 Hz.Shimmy sometimes may produce the feeling of acupuncture.4 Types of Vibration Wheel Brake rotor The next step after road testing the vehicle is to identify the frequency of the duplicated and abnormal Tie rod end vibration. A customer may use the following words to describe boom: 003002 Droning Growling Shake is a low frequency vibration. Groan for possible condition causes: . usually 25-50 Hz. 0. Tingle vibration Hz. Yell Exhaust system .2. deep thunder.Examples of similar noises include the the following components: sound of a blowing air across the top of a carbonated Tire . shake is caused by damage or wear to a soda bottle. Sometimes the customers complain of a pressure in their ears. Moaning or the console. .General Information Vibration Diagnosis and Correction 0-25 0.Most of the vibrations belong to one of the following categories. typically 5-20 Hz. usually 50-100 .Inspect the following components . the seat. Shake similar to the feeling you get from holding a jigsaw.

Repair the strongest vibration frequency calculations on a suspected vibration first. hour (km/h). number of cylinders.Axle Ratio is not At this point in the diagnosis. . or 3 (1st. Droning then press enter.The reading is then compared to 9.As long as you operate Press the arrow UP or DOWN key to adjust the vehicle at a constant speed. the rotational speed of the tires.3. press 9 to go to the bottom of the list. press 1 to go to the top of howling the list. are displayed in descending order beginning The EVA program is designed to perform targeted with line 2.This speed is measured in rotations. Resonance 3. 25.00 in).0-26 Vibration Diagnosis and Correction General Information water bottle. identified: vehicle speed and engine rpm are factored into a TIRE 1. Use the EVA to determine the speed at which describe moan or drone: the vibration occurs.Press average (avg) key to in cycles per second. Select the incremental step you want to Vehicle vibration is usually related to the component increase/decrease vehicle speed. then RPM. which is also measured instantaneous.One to three sources of vibration are source.6 Matching Frequency to 5.The amplitudes of the vibrations detected Calculating Tire Rotation with the EVA. 4. From the EVA main menu. As the test is run. toggle.2. or cycles per second. through the following analysis: 6. aspect 500 Hz range. screen to match the actual engine RPM.Similar sounds include mosquitoes.Hint: when Howl browsing the tire size or axle ratio list. Enter the driveshaft configuration (skip Step 5 if vehicle is front wheel drive).30-1. 0. Data is displayed as average or the frequency of the vibration. either an engine speed method or a vehicle speed View the frequency ranges applicable for method.00) from the Axle Ratio selection screen.00-9.The sound is similar to the sound of the wind list. turbine engines. Enter the vehicle tire size information with one Moan or drone may be accompanied by a perceptible of three options: buzzing vibration.00- gears or gear noise.50) and rim diameter (10. 7.Whine is usually related to the meshing ratio (0. 8. The vibration has been determined as unusual. the tires will operate at the on-screen RPM on the active data a constant speed.The tire size. determine screen. frequency. Whine is a prolonged. The vehicle speed is choosed in kilometres per The vibration has been duplicated. the vehicle speed must be The vibration has been assigned a frequency manually adjusted to match the actual vehicle from the Electronic Vibration Analyzer (EVA) or speed: identified based on its feel or its sound. select Vehicle Speed. the vibration has gone applicable if front wheel drive (FWD) is selected.Calculate the speed of these components using press enter.A customer may use the following words to 1. Exhaust system Database__Select the tire type and tire size from each selection screen. and vacuum cleaners. select Auto Mode. the vehicle speed. then press enter.(2. press enter to go to the are sensitive to engine speed. active data screen or exit to go back one If the vibration is sensitive to vehicle speed. Humming 2. Enter the vehicle speed at which the vibration is The vibration is related to the engine speed or felt.Use the engine to diagnose the vibrations that the speed selected. refer to the Axle Ratio Component RPM screen or table below. Enter the axle ratio. amplitude and the suspected vehicle system producing the vibration. press Howl is a noise at mid-range frequency of 120-300 a number key to go to a related point in the Hz. press 4 or 5 to go to the middle of Whine the list. 2. 2nd. axle ratio. for example. RPS at 5 mph __ Refer to the Tire/Speed Inspect the following system: table below for the Hertz value at 8 km/h for Powertrain mount that tire size. high-pitched sound in the 300- Enter the tire width (100-500 mm). or 3rd order tire/ calculation that determines the predominant vibration wheel system concern).

Replacement in Tires and Wheels. vehicle speed. record or playback. the vehicle.9 Front Wheel Drive Vibrations The front wheel propeller shaft has the following 0. which is over 21 g may have the potential to cause or The mass of front wheel propeller shaft is light. Note: Inspect the static balance of the rotor/drum Steering and suspension assembly vibrations are the only.2. 0:1.Refer frequencies). inspect the dynamic balance of the new brake rotor/drum. The vehicle speed (V) is measured in mph or Caution: Refer to Stall Test Caution in Cautions and km/h for display.4 Inspect the balance of the new rotor/drum. sensitive to vehicle speed.3 Replace the rotor/drum that is causing the Type Usage vehicle imbalance. 1. Use the proper lifter to support the vehicle. Reinstall the wheel.2 Perform the vibration test for each rotor/ RPM drum. S 185/60R14 ALS (China) 1. any brake rotor or drum imbalance Front wheel propeller shaft has a CV joint. 0:2-0:9. first level of testing for low-frequency vibrations that are 3. During record or playback the event and frame steps: numbers are displayed. Information. If the vibration has been eliminated. speed 6. 11.If an event is not selected. Tread Vehicle 8km/h Tire size 6. lower rate of speed than rear wheel propeller vehicle method.2. Measure the diameter and the width of the rotor/ drum. 10.General Information Vibration Diagnosis and Correction 0-27 Propeller Shaft 1 or 2 (Propeller shaft Inspect the brake rotor/drum imbalance (on- problem) vehicle). If the vibration still exists. perform the following 13.Press the down or up key to Notices. replace the shake. seat. Inspect for static imbalance. Before mounting the brake rotor/drum onto the Tie rod end vehicle. 14.3. Amplitude of the signal is displayed in number of 6. 5.1 Remove a pair of brake rotor/drum at a Tire/Speed time 6. An identification letter symbol displays during inspecting for the vibration. shaft. 0:0. There is not a set tolerance for brake rotor and bake drum. perform the G forces (G) following steps: 6.Inspect the rotor and the drum Front wheel propeller shaft turn or spin at a for imbalance using either the on-vehicle or the off.8 Brake Rotor/Drum Imbalance characteristics: Front wheel propeller shaft is short.During 5.Ignore the dynamic imbalance reading.2 Resume to the complaint speed and run from 0 to 9. and turn an angle.However.1 Replace the brake rotor/drum.7 Steering and Suspension 2. 4. Overlap (overlap of Tire 3 and Prop 1 1. Suspension ball joint Tire Wheel and engine 0.2. to Lifting and Jacking the Vehicle in General Unknown (vibration source is unknown). Remove the wheel assembly.Refer to Wheel or B (B is displayed). for example.The symptoms of a steering/ suspension first-order vibration are a shimmy or a 4. manually adjust this figure to match actual 3. If the rotor/drum shows imbalance. . 0. contribute to a vibration.Inspect the following parts for wears or damage: 5.3. Data is received through input A (A is displayed) 2. record or playback the frame number cycles 5. Run the vehicle at the complaint speed while 12.Press key 4 to toggle.This is usually felt in the steering wheel or in the rotor/drum. a question mark (?) appears.3. Mount the rotor/drum on a balancer in the same Assembly Vibrations manner as a wheel.07 Inspect the brake rotor/drum (off-vehicle).

The worn joint creates three disturbances per The angles are already excessive before revolution of the axle shaft. measure the similar noise.The tires and the bearings can make a damaged inner joints. worn or damaged inner tri-pot During fast acceleration. measure the moderate to heavy acceleration from a standing spring height in order to determine the required start. drive the vehicle in a straight line and perform Do not measure the body height. In order to lower the suspension. third-order raised by the high torque of the vehicle powertrain. forth motion in the vehicle during acceleration. Road test the vehicle. condition if one of the following conditions are present. the inner tri. The joints are worn. On the springs The driver does not operate the clutch pedal On the SPID label in the vehicle correctly. Although worn or damaged inner tri-pot joints can Launch shudder cause launch shudder. If you detect no obvious problem. Each vehicle line has multiple spring options with On the vehicle with manual transmission.Launch shudder may also be a rocking back-and.The assembly moves in and out freely in suspension may also produce the following conditions: order to compensate for drive axle length changes during suspension travel. launch different spring rates. the Suspension section in Service Manual. growling noise that increases with the 2. noise.Tri-pot or tri-potal joints have three the over adjustment of front trim or suspension spring trunnions (or a trilobal spider assembly) that fit into a height. The universal joint angle is excessive. tire vibrations. Visually inspect the drive axles for worn or vehicle speed. springs to install. The inner universally jointed shaft angle is Third-Order Tire-Related Vibrations excessive. Front-wheel-drive (FWD) hub and bearing assemblies 1. third-order tire-related Because the inner tri-pot joint is usually the cause of vibrations will result. can make a low. occur if the following conditions are present: pod angles increases and can cause a launch shudder The joint becomes worn or damaged.For methods of measurement refer to rear wheel drive. and the damaged or misaligned engine race or a cup. If the spring height is out-of-specification.You can find the list of available springs in the parts catalog. then the left- metal variations could lead to mis-diagnosis of the hand wheel bearing generally is causing the .0-28 Vibration Diagnosis and Correction General Information Although front wheel drive runs more smoothly than problem cause. launch shudder can be order to insure correct body levels and proper caused by the following conditions: suspension performance. the front suspension height is joints may also cause vehicle speed-related. adding sandbags until Launch shudder is a shaking sensation that is felt in the you eliminate the disturbance. Inner tripod universal joint is worn or damaged. at the same rate as the wheel.Because the axle shaft turns acceleration. and need to be diagnosed and eliminated: 4. place Launch shudder sandbags under the following locations in order Three vibrations related to the tire to lower the suspension: Under the hood or over the strut towers.If the noise measurements are not used because potential sheet level increases during a right-hand turn. Growling noise Caution: Refer to Road Test Cautions in Cautions and Clicking noise or shudder during turns Notices. Launch shudder 5. similar noise.The tires and the bearings can make a 3. launch shudder.You can achieve approximately shudder can be caused by the following conditions: 10 mm of suspension height change by dropping down Clutch disc performance is poor one spring code. the disturbance is typically related to Growling (Wheel Bearing) Noise third-order tire rotation frequency. Identify the type of disturbance. Note: Always replace the springs in matching sets in On front-wheel-drive vehicles.You can locate the spring codes in the following areas: Clutch operating mechanism has not been adjusted well. The joint has excessive free-play or lash.Body height several turning maneuvers side-to-side. trim or spring height in order to determine if the In order to differentiate between tire noise and bearing suspension is causing an excessive joint angle. Tri-pot joints are so named because of their design Excessive inner tripod joint angle is usually caused by characteristics. the following conditions may occur.Third-order tire-related disturbances can When the front suspension height rises. steering wheel and/or the front of the vehicle during 6.

depending on because an added load is applied to the bearing with the speed of the complaint and the size of the the fault. or on the dial indicator is decreased. produce noise. the runout problem is due to one of the following: . On the vehicle and the wheel hubs should be systematically tested.2. the noise level increases when turning The range of the human ear begins at 20 Hz. the vibration is NOT related to the tire and the vehicle.For because an added load is applied to the bearing with this reason.As the amount of runout decreases.The tires. Hub flange runout .Proceed to Wheel Hub/Axle Flange rear tire and wheel assemblies. according to the symptoms.10 Tire and Wheel Vibration runout and imbalance may result. usually in the off-vehicle measurement differs significantly from the steering wheel or the seat. The chance of water. because the runout of joint a tire/wheel assembly will directly affect the amount of A worn or damaged outboard CV joint imbalance and radial force variation. but this is a procedures. vehicle will indicate if any further problems exist.The exception is when the tires Clicking Noise or Shudder During Turns display an irregular tread pattern or flat spots. the vehicle. remount the tire. first-order tire vibrations rarely the fault.The distance from the edge of the smoothly. the faster the tire will bearing and not the tires is the cause of the rotate at any given speed. usually a symptom caused by one of the following conditions: Tire Runout Measurement A worn or damaged outer constant-velocity (CV) Correct the runout problem first.This frequency will disturbance. carefully inspect the tire for an destroy the joint. rest upon the ground. disturbance.If the The vibration will feel like a shake. dirt.If the beads are not seated properly.Measuring the tire/ Vibration wheel runout off the vehicle is the easier method for the The following are symptoms of first-order vibrations following reasons: caused by tire and wheel assemblies: A dial indicator can be more easily mounted in The vibration is always related to the speed of the correct location.Otherwise excessive 0. look for a decrease.General Information Vibration Diagnosis and Correction 0-29 problem.The CV joint will no longer function uneven bead seat.The opposite is true for a left-hand turn. damaged boot on the outer CV joint. Runout.This causes a growling or a slapping A clicking noise or a shudder during vehicle turns is noise.These flat spots will affect the . imbalance and force variation also During a visual inspection of the drive axle. general rule that may serve to initially isolate a Measuring Tire Runout problem to the front or the rear of the vehicle. causing the disturbance. ring to the concentric rim locating ring should be equal around the entire circumference. flat spots may develop at the point where the tires speeds of 856 km/h (535 mph).3.The opposite is true for a left-hand turn.You can correct radial and lateral runout at the same time.If a tire. and Wheel Stud (Stud Circle) Runout This may not always hold true. Tire and wheel vibrations that are felt in the steering wheel are most likely related to the Stud circle runout front tire and wheel assemblies. or slush getting If the vibration is affected by the speed of the engine.The smaller the tire. snow. If a vehicle sits in one place for an extended period of The customer may complain of a waddle at low time.If a The frequency on the EVA will correspond to the bearing and not the tires is the cause of the first-order of tire rotation. the noise level increases when turning usually be in the 10-20 Hz range. On the vehicle Make an initial on-car visual inspection prior to First-Order Tire and Wheel Assembly performing the off-car runout tests. the wheels. the brake rotors.Two methods are Tire and wheel assembly vibrations are the next level of available for measuring runout of the tire/wheel testing for low-frequency vibrations that are sensitive to assemblies: vehicle speed.A damaged boot can allow water and other contaminants such as dust Note: Before measuring or attempting to correct and dirt to compromise lubrication and prematurely excessive runout. on-vehicle measurement. Tire and wheel vibrations that are felt in the A mounting problem between the wheel and the seat or the floor are most likely related to the vehicle. if the vibration is eliminated by placing the transmission Once you have measured and corrected the runout off in Neutral. a quick examination of runout on the wheel assemblies.

003004 5. Radial Tire Runout For radial runout.Before you take any runout Lateral Tire Runout measurements.You may also use the engine at a slow speed in order to drive the wheels. . Rotate the assembly one more complete revolution and note the total amount of runout indicated.Visually inspect the amount of runout from the front or the rear.27 mm (0.Locate the tire/wheel assembly on the center pilot hole.The maximum allowable assembly radial and lateral runout is 1.52 mm 003003 (0. wrap the outer circumference with tape. In order to get an initial indication of how much runout exists. 1. 3. Load the indicator and slowly rotate the assembly one complete revolution. 2.Mount each assembly on a spin-type wheel balancer. Remove the tire/wheel assemblies one at a time.060 inch) when measured on the vehicle.Use either of the following dial indicator sets with roller contact point J 23672 when applying this procedure: J 23672 J 8001 with a clamp-on base J 7872 with a magnetic base 1. spin each tire and wheel on the vehicle by hand.050 inch) when measured off the vehicle and 1. 2.0-30 Vibration Diagnosis and Correction General Information runout readings. Ignore any jumps or dips due to sidewall splices. the figure. Lift the vehicle on a hoist or support the vehicle with jackstands.This allows for a smooth reading from the dial indicator. For lateral runout place the dial indicator in a smooth area on the tire sidewall as close to the Measure the tire/wheel assembly runout as shown in tread as possible. Mark the location of each tire/wheel assembly in relation to the wheel studs and to their position on the vehicle for future reference. 3. Set the indicator to zero on the low spot.Refer to Lifting and Jacking the Vehicle in General Information. eliminate these flat spots by driving the vehicle long enough to warm up the tires. 4.

Mark the new location of the runout high point on the tire.General Information Vibration Diagnosis and Correction 0-31 Vectoring runout problem. Mount the tire/wheel assembly on a tire machine and break down the bead. the wheel.Do not dismount the tire from the wheel at this time. Mount the assembly on the tire balancer and remeasure the runout.This runout problem.Refer to Balancing Tires and Wheels. Place a mark (2) on the tire sidewall at the location of the valve stem (5). 003005 003006 If the runout is excessive.This mark is the 12 Wheel Runout Measurement o'clock position.Then. 4. If runout is now within tolerance.Always refer to the location of Lateral Wheel Runout the high spot (3) in relation to its clock position on the wheel. 3. no further steps are necessary. 2. the wheel is the major contributor to the .Balance and mount the tire on the vehicle. 003007 If the clock location of the high spot remained at or near the clock location of the original high spot (7). called match-mounting or vectoring. determine if 180 degrees (6 hours) from the original high the runout problem exists in the tire. correct the problem. procedure. the tire is the major contributor to the combination of both.Next. 5.Rotate the tire an additional 90 tire/wheel assembly runout in order to verify that the degrees (3 hours) in both the clockwise and the runout is within tolerance. uses the following steps: If the high spot is in between the two extremes. or a spot.You may need to lubricate the bead in order to easily rotate the tire on the wheel. 1. remeasure the to the runout. Reinflate the tire and seat the bead properly. counterclockwise directions. mark the location of the high If the high spot (7) is now at or near a position spot (3) and the low spot on the tire. Rotate the tire 180 degrees on the rim so that the valve stem reference mark (8) is now at the 6 o'clock position in relation to the valve stem (6) itself.Proceed to Wheel Runout Measurement.Replace the tire. then both the tire and the wheel are contributing Note: After replacing a tire or a wheel. 6.

Ignore any 1. the runout problem is due to one of the following: Stud circle runout Hub flange runout A mounting problem between the wheel and the vehicle.Measure wheel runout using the same procedure as tire runout.DO NOT assume that a new wheel is automatically good. Dismount the tire from the wheel. chips.762 mm Lateral runout1. replace the tire. jumps or dips due to paint drips.015 mm Lateral runout1. or welds.0-32 Vibration Diagnosis and Correction General Information Radial Wheel Runout Lateral Wheel Runout (Tire Removed) 003008 003010 Complete the following steps if you cannot bring runout You can measure rim runout more accurately on the within tolerance by match-mounting: inside bead area of the wheel.If you notice a large difference in runout measurements between on-vehicle testing and off-vehicle testing. and the tire/wheel assembly runout cannot be reduced to an acceptable level by using the match-mounting technique. as shown. replace the wheel. . If the runout of the wheel is beyond the tolerance.reference the letter code with the parts catalog.If the runout of the wheel is within tolerance.Cross.143 mm Aluminum Wheels Radial runout. 2. refer to the wheel code that is stamped next to the valve stem.When replacing a wheel.The tolerances for wheel runout are as follows: Radial Wheel Runout (Tire Removed) Steel Wheels Radial runout1.143 mm Note: Always measure the runout of new wheels. 003009 Note: Always remeasure the tire/wheel assembly runout after you replace the tire. Measure the radial wheel runout and the lateral Measure both the inboard flange and outboard flange wheel runout.

higher are possible but rarely occur. or tolerances provided are only guidelines.The best way contacts the road.order. spindle once per each revolution of the tire and wheel Wheel Hub/Axle Flange Runout assembly.The tire and wheel assemblies have to eliminate lateral force variation is to ensure that the some variation due to splices in the tire plies. If you suspect force variation as a factor in tire and wheel assembly vibration complaints.Lateral force variation is based on the same concept as radial force variation.A snaky belt 003011 inside the tire may be the cause of lateral force. thus causing a first-order tire/wheel vibration. but not during off-vehicle testing.However.First-order and second-order flange runout if you are performing an on. . inspect the wheel hub/axle second-order vibration.Third.vehicle test tire/wheel vibrations are the most common as a result procedure.The of radial force variation.Always reduce runout to as little as possible in order to attain optimum results under all conditions. some sensitive vehicles may still be affected. the spots cause a When lateral runout occurs. variation is excessive.These stiff spots in the tire can The vehicle will wobble or waddle at slow speeds of deflect the tire and wheel assembly upward as the 840 km/h (525 mph) when lateral force variation is assembly contacts the road. some tire and wheel assemblies exhibit vibration-causing force variation even though they are within runout and balance tolerances. fourth-order. excessive.Ensure that the tire and wheel assembly runout is at an absolute minimum.These instances are becoming increasingly rare due to tighter tolerances and higher standards in manufacturing.This condition is usually related to the first- If the tire has only one stiff spot.These lateral runout of the tire and wheel assemblies is at an splices do not cause a problem unless the force absolute minimum. the spot will deflect the order of tire and wheel rotation. Radial Force Variation 003012 Lateral force variation tends to deflect the vehicle to the side. stiffness of a tire sidewall as the tire rotates and A lateral force variation condition is rare. substitute one or more known good tire and wheel assemblies.If Lateral Force Variation runout measurements are within tolerance but are marginal.If the tire has two stiff spots.Test the vehicle with substitute tires before installing Radial force variation refers to the difference in the replacement tires.This is the most effective way to minimize the possibility of force variation as a factor in tire and wheel assembly vibrations.General Information Vibration Diagnosis and Correction 0-33 The listed tolerances should serve only as a guideline. or laterally.

Rotate the hub again and check the total amount of runout. 3. Zero the dial indicator on the lowest stud. Specification Runout tolerance:0.254 mm . 4. or the rotor outside of the wheel studs. 2. Set the indicator to zero on the low spot. Rotate the hub again and check the total amount of runout. Turn the hub to register on each of the studs. the axle flange. Specification (Guideline) 1.0-34 Vibration Diagnosis and Correction General Information Wheel Stud Runout Use the wheel stud runout procedure whenever the following conditions occur: The off-vehicle radial runout differs significantly from the on-vehicle radial runout Earlier attempts to correct the tire and wheel vibration condition have been unsuccessful 003013 1.127 mm wheel mounting studs. Rotate the hub in order to find the low spot. Position the dial indicator in order to contact the Runout tolerance:0. 2. 003014 4. Position the dial indicator on the machined surface of the hub. 3.

recently calibrated off-car two plane dynamic balancer. 2. Add an 85 g (3 oz) test weight to the wheel at any location. Inspect the balancer readings. 3. 7.Observe the readings. or can become inaccurate as a result of abuse. 1.Back cone mounting is recommended. the weight should be called for on the flange of the wheel opposite the last weight. the balancer should call for 85 g (3 oz) of weight. Use coated weights on aluminum wheels.3.3. Balance a tire and wheel assembly that is within radial and lateral tolerances to ZERO. In the dynamic mode only. Tire Balancer Calibration Test Note: Calibrate the tire balancer according to the manufacturer's recommendations. 4. Specification Variation:7 gorless 8. Spin the tire and wheel assembly again. With the assembly unbalanced to 85 g (3 oz). 6. Wear eye protection.39 mm (1/4 ounce) on either rim flange.The center pilot hole is the primary locator. 5. 90 degrees apart.The balancer calibration should be inspected according to the manufacturer's requirements. Index the tire and wheel assembly at four separate locations on the balancer shaft. 180 degrees opposite the test weight. Spin the balancer without a wheel or any of the adapters on the shaft.3. In the static and dynamic modes. or use the following procedure.1 Balancing Tires and Wheels Caution: Failure to adhere to the following precautions before tire balancing can result in personal injury or damage to components: Clean away any dirt or deposits from the inside of the wheels.General Information Vibration Diagnosis and Correction 0-35 0. Note: Use a known good. Remove any stones from the tread.If any assembly calls for more than 7. Inspect the balancer readings. Tire and wheel balancers can drift out of calibration without warning. remove all balance weights and re- balance.3 Repair Instructions 0. .Use the finest balance mode available in order to perform a perfect balance of the assembly. cycle the balancer five times.

Use the correct coated weights on aluminum wheels. Evaluate the vehicle at the complaint speed and note if the vibration has been corrected. affects the distribution of weight on each side of the tire/ wheel centerline. Carefully follow the wheel balancer manufacturer's instructions for proper mounting techniques for different types of wheels. or two-plane balance. especially those incorporating universal lug patterns. Specification Variation:7 g or less Tire Balancing Guidelines Static and dynamic balance are the two kinds of tire/ wheel balance: Static balance. Most off-vehicle balancers can check both types of balance simultaneously. Retest the tire and wheel assemblies for excessive runout after correction and installation.0-36 Vibration Diagnosis and Correction General Information 9. 10.Vibration induced by static imbalance will cause a vertical. Cycle the balancer with the assembly at each location. affects the distribution of weights around the wheel circumference. consider these possibilities: - On-vehicle imbalance - Radial or lateral force variation . or bouncing. motion of the tire. Balance all four tires as close to ZERO as possible. Inspect the balancer readings. Dynamic balance. also called single plane balance. Aftermarket wheels. are potential sources of runout and mounting problems. 003016 If the vibration is still present.As little as 1421 g may induce a vibration in some vehicles. 003015 Dynamic imbalance results in a side-to-side motion of the tire. or shimmy. As a general rule. most vehicles are more sensitive to static imbalance than to dynamic imbalance. or is reduced but still unacceptable.

The two types of approved wheel weights are type MC(1) and type AW(2). place the clip-on balance weights on the inboard rim flange (2) and the outboard rim flange (1) at the positions specified by the tire balancer. place the weight on the inboard (2) flange if the weight is 28 grams (1 ounce) or less.The contour of the rim flange will determine which type of wheel weight should be used.The weight should follow the contour of the rim flange. 003017 Note: Special polyester-coated clip-on balance weights must be used on factory aluminum wheels. split the total weight required between the inboard rim flange (2) and the outboard rim flange (1).Type P(3) wheel weights are for use on steel wheels and can not be used on aluminum wheels. 003018 .If more than 28 grams (1 ounce) is required to balance the wheel.When using the static balancing method.General Information Vibration Diagnosis and Correction 0-37 Wheel Weight Usage Two methods for balancing wheels are the dynamic balancing method and the static balancing method.When using the dynamic balancing method.Use a plastic-tipped hammer when installing polyester- coated wheel weights in order to avoid damaging the polyester coating.Polyester- coated wheel weights reduce the potential for corrosion and damage to aluminum wheels.

Apply the wheel weight to the wheel. Ensure that there is sufficient clearance between the wheel weights and the brake components.2) may also be used on aluminum wheels. 8.Use the following procedure in order to install adhesive wheel weights.Wipe the area again with a mixture of half isopropyl alcohol and half water in order to remove any remaining residue.Do not touch the adhesive tape. wipe the area with a general purpose cleaner. 1. Determine where the wheel weight is to be placed on the wheel. 7.0-38 Vibration Diagnosis and Correction General Information Adhesive wheel weights (1. 003019 6.Press into place with hand pressure. 2. Remove the protective covering in order to expose the adhesive tape on the wheel weight. . 3. Using a clean cloth or paper towel. Warm the adhesive backing on the wheel weight to room temperature. 5. Dry the area with hot air until the wheel surface is warm to the touch. Secure the wheel weight to the wheel with a 90Newton (21 lb) force applied with a roller. 4.

1. back and speed. is less. Pull down on the edge of the stick and release Note: DO NOT attempt to repair a normal condition. demonstrate the vibration theory: Rotating components will vibrate with excessive imbalance or runout.In other words. extreme of travel. A rotating component For example. just because the seat vibrates does not mean the source of the vibration is in the seat. Clamp the yardstick to the edge of a table.1Basic terminology: 2. A vibrating component operates at a consistent rate . Inspect and test the components for conditions most vehicle vibrations: that cause vibration. Clamp a yardstick to the edge of a table.When the rate/speed is determined. and back to the midpoint vibration diagnosis: where the cycle begins again. then back past the midpoint.A vibration concern will occur when the firing impulses of the engine are not properly isolated from the passenger compartment. or amplitude.4. Relate the frequency to the rotational speed of a Vibration component that is operating at the same rate or Vibration is the repetitive motion of an object.The following are the common components also found a specific amount of motion. The object's properties of conducting or frequency.The vehicle has a problem. relate the vibration to a component that operates at an equal rate/speed in order to pinpoint the source.During vibration diagnosis.3. The physical properties of objects The cycle occurs over and over again at the same rate.4 Description and Operation 1.General Information Vibration Diagnosis and Correction 0-39 0.3.the path on which the vibration travels through the vehicle The responder . Measure the repetitive motion and assign a The stick vibrates at a much faster frequency:30 cycles value to the measurement in cycles per second per second . forth. or while observing the movement of the stick. Vibrations consist of the following three elements: The source the cause of the vibration 003020 The transfer path . the measure would be 10 cycles x component causes most customer vibration 60seconds = 600 cycles per minute (cpm).The following conditions cause 3. or cycles per minute.the component where the vibration is felt .Measure the rate of vibration in question. the better.Redo the experiment as follows: The seat cushion 1. Frame leaving approximately 25 cm (10 in) hanging over the edge of the table.The total travel. performing the following steps will help The engine combustion process firing impulses.Thereafter it is difficult to satisfy cycle begins at midpoint. 2. or amplitude.In this case. continues through the lowest the customers. or up and down. the amount of allowable imbalance or runout should be considered a tolerance and not a specification. the less imbalance or runout. 0. the customer will probably be convinced that the The motion of the stick occurs in repetitive cycles. leaving approximately 50 cm (20 in) hanging over the edge of the table.Vibrations also tend to transmit through the body structure to other components.Therefore. approximately 10 cycles per mechanical energy second. through The following are the two primary components of the upper extreme of travel. Dashboard 2.We have complaints. in that vibrate: the total travel of the yardstick from the very top to the Steering Wheel very bottom.If we measure the frequency to reflect the number of complete cycles that the yardstick made in The repetitive up/down or back/forth movement of a one minute. Pull down on the edge of the stick and release Vibration diagnosis involves the following steps: while observing the movement of the stick.

The most direct and effective repair would be to properly balance the tire. but adding the frame. acting as a large speaker. which the customer reports as exhaust. .Adding a brace to the steering column exhaust system and correct the grounded condition at may keep the steering wheel from vibrating.The source of the vibration is the system into the steering column.From the gathered panel vibrates.The responder is the frame.0-40 Vibration Diagnosis and Correction General Information 003021 003022 In the preceding figure. the source of the vibration is Vibration can also produce noise. a brace is not a practical solution.The responder is the engine firing impulses traveling through the steering wheel. decide which element makes the most produces noise. the unbalanced tire.Eliminating any one of these three elements exhaust hanger.The transfer path is a grounded or bound-up vibrating.This would eliminate the transfer path.The floor will usually correct the condition.The transfer path is the route the consider a vehicle that has an exhaust pipe which is vibrations travels through the vehicle's suspension grounded to the frame.The best repair would be to align the sense to repair.As an example. which information.

General Information Vibration Diagnosis and Correction 0-41 Cycle 003023 Legend (1) 1st Cycle (3) 3rd Cycle (2) 2nd Cycle (4) Time Vibration Cycles in Powertrain Components 003024 Legend (1) Spindle (2) Pinion Nose The word cycle comes from the same root as the word circle:both begin and end at the same point. All vibrations consist of repetitive cycles. .

second. frequency is expressed in cycles per occurs during a given period of time.With a vibration. . Multiply the Hertz by 60 to get the event is a cycle.0-42 Vibration Diagnosis and Correction General Information Frequency 003025 Legend (1) Amplitude (3) Time in Seconds (2) Reference (4) 1 second Frequency is defined as the rate at which an event second. and the period of time is one the cycles. Thus. or Hertz (Hz). or revolutions per minute (RPM).

Forced Vibration Forced vibration is when an object is vibrating continuously as a result of an outside force. Used in vibration diagnostics. or the displacement. A severe disturbance would have a high amplitude.In the yardstick example.General Information Vibration Diagnosis and Correction 0-43 Amplitude 003026 Legend (1) Large (2) Small (3) Zero-to-Peak Amplitude (4) Peak-to-Peak Amplitude Amplitude is the maximum value of a periodically varying quantity. Amplitude is measured by the amount of actual movement. the yardstick continued to vibrate even after the end was released. the amplitude increases. we are referring it to the magnitude of the disturbance. consider the vibration caused by an out-of-balance wheel at 80 km/h (50 mph) as opposed to 40 km/h (25 mph).As the speed increases. . For example. a minor disturbance would have a low amplitude. Free Vibration Free vibration is the continued vibration in the absence of any outside force.

The nut hangs vertically due to frequency and the amplitude will increase. amplitude will increase. once for each revolution of the tire. or the centrifugal force. Hold the string.As the vehicle speed A spinning object with an imbalance generates a increases. tire. Centrifugal force is trying to make the nut fly outward.As the tire gravity.The string represents the tire/ wheel/suspension assembly.Performing the following steps will unbalanced tire in the steering wheel. Tie a nut to a string.An unbalanced .0-44 Vibration Diagnosis and Correction General Information Centrifugal Force Due to Imbalance 003027 Legend (1) Location of Imbalance tire follows the same example. the seat. revolves.This disturbance will be repetitive (Hz) and the 1.The nut is the imbalance in the along with the spindle. the imbalance. Spin the string. 3. both the 2. you can feel the disturbing force of the centrifugal force. will alternately lift the tire up and force the tire downward.At higher speeds. and the help to demonstrate centrifugal force: floor. causing the pull you feel on your hand.The nut represents the (2) Centrifugal Force Acting on Spindle imbalance in the tire.

This natural frequency is the result frequency.The intersecting point is called the resonance.Eventually.The suspension's natural the frequency. frequency is the same at all vehicle speeds. the lower the natural the 1015 Hz range.Conversely.This is why some vibration complaints (5) Problem Speed occur only at specific vehicle speeds or engine RPM. The amplitude of a vibration will be greatest at the point of resonance.This causes the suspension to vibrate. the disturbance created by the tire increases in frequency.Generally. guitar strings.Bells. the frequency of the unbalanced tire will intersect with the natural frequency of the suspension. and tuning (1) Frequency-cps forks are all examples of objects that tend to vibrate at specific frequencies when excited by an external force. All objects have natural frequencies. (2) Suspension Frequency (3) Unbalanced Excitation Suspension systems.General Information Vibration Diagnosis and Correction 0-45 Natural or Resonant Frequency Resonance km/h mph 003029 003028 The natural frequency is the frequency at which an Legend object tends to vibrate.The natural the higher the natural frequency.As the tire speed increases along with the vehicle speed. . have a tendency to vibrate at certain (4) Point of Resonance frequencies. The stiffness and the natural frequency of a material have a relationship.The opposite is also frequency of a typical automotive front suspension is in true.While the vibration may be felt above and below the problem speed. and even engines within the mounts. the greater the mass. the vibration may be felt the most at the point of resonance.The softer a material. the lower of the suspension design. the stiffer the material.

The automotive shock absorber is a good example. .0-46 Vibration Diagnosis and Correction General Information Damping 003030 Legend (1) Low Damping (2) High Damping Damping is the ability of an object or material to dissipate or absorb vibration.The function of the shock absorber is to absorb or dampen the oscillations of the suspension system.

or subtracting from. each other's vehicles.A beating vibration condition will increase in disturbances can correct the condition.This beating vibration beating. . eliminating either one of the amplitude.General Information Vibration Diagnosis and Correction 0-47 Beating (Phasing) 10 Hz 8 Hz 003031 Two separate disturbances that are relatively close intensity or amplitude in a repetitive fashion as the together in frequency will lead to a condition called vehicle travels at a steady speed.Beating occurs when two vibrating can produce the familiar droning noise heard in some forces are adding to. or phasing.In many cases.

at minimum.This is called not equal a second-order vibration. a tire with one high spot would create a disturbance once for every revolution of the tire.Two first-order vibrations may force. 003033 An oval-shaped tire with two high spots would create a disturbance. 003032 For example.0-48 Vibration Diagnosis and Correction General Information Order Order refers to how many times an event occurs during one revolution of a rotating component. an unbalanced component will always create a add or subtract from the overall amplitude of the first-order vibration. but that is all.Two first-order vibrations do disturbance twice for every revolution. .Due to centrifugal second-order vibration. This is called first-order vibration.

Verify that the software cartridge is correctly inserted at the bottom of the unit. 4. 003036 A magnet holds the sensor to ferrous surfaces. such as the and the vibration sensor can be mounted virtually surface of the steering column.The sensor is directionally sensitive.General Information Vibration Diagnosis and Correction 0-49 0.This hand.4. 3.Therefore. proper vibration readings. place the sensor as flat as possible with the side marked UP facing upward.The vibration sensor. Plug the power cord into a 12-volt power feed in order to turn the EVA on. or putty or a hook and loop fastener in order to hold the the accelerometer.You can place the sensor held device is similar to a scan tool.The sensor should remain plugged into the unit at all times.Place the UP side of the sensor in the exact position every time for consistent results when repeating the tests or making a comparison.3. Push the connector into the input until the connector clicks and locks in place. anywhere on the vehicle where a vibration is felt. press the release button and gently pull the connector straight out. Note: Do not twist the connector.A standard 12-volt anywhere on the vehicle where vibrations are felt Use power feed supplies the power. Vibrations are typically felt in an up-and-down direction. Line up the connector so that the release button is at the bottom. sensor in place on non-ferrous surfaces. 2. is at the end of a 6 m (20 ft) cord. Connect the vibration sensor cord into either input A or B.2Electronic Vibration Analyzer (EVA) EVA Sensor Placement 003034 003035 J 38792 Electronic Vibration Analyzer (EVA) is Proper EVA sensor placement is critical in order to take specifically designed to diagnose vibrations. EVA Basic Hookup 1. 5. To disconnect the sensor. .

or when EXIT is pressed. This letter indicates which input is the tag number for the wanted snapshot. the screen will display AVG.Most tests use the averaging mode. the actual strength. Use the freeze function in order to freeze the display at any point in the sequence during playback. P followed by the tag number. Averaging/Non-averaging modes The EVA normally operates in an averaging mode that averages multiple vibration samples over a period of time.Pressing EXIT or the FREEZE button again deactivates the freeze function.During averaging Record/Playback mode.Data is recorded as Up to 3 dominant vibration frequencies are displayed snapshots of vibration information. order to indicate which frame of the snapshot is being displayed.At the right side of the screen.The EVA retains stored data for .Each snapshot on the EVA's liquid crystal screen.The averaging mode minimizes the effects of a sudden vibration that is not related to the problem . or Press the RECORD button in order to record a amplitude.The freeze function is useful when conducting an acceleration/deceleration test in which the significant amount of vibration registers only for a very short time. the snapshot data displays the letter to switch between the two inputs. and during acceleration/ The EVA offers the following main display features.The screen will display R? in order to request a tag number between 09. which locks the display of data. Note: Verify that the letter on the display matches the Then the screen displays the letter F followed by 09 in correct sensor input.On the left is the consists of 10 different frames.Once the activated.The non-averaging mode is used when measuring a vibration that exists for only a short period of time. all deceleration tests. These tag numbers are the Frequencies can be displayed in revolutions per minute individual frames of the snapshot recording. representation of the vibration's relative strength. Pressing the PLAYBACK button plays back the Next to the frequency data on the top line of the screen recorded data. keypad. Record/Playback The displayed vibration information can be recorded for later playback.The display returns to the active screen when the recording or playback of a snapshot is finished. of which are described below: Pressing the AVG button switches between the Freeze averaging and non-averaging modes.New data (RPM) or in Hertz (Hz).The screen shows P? in order to request is the letter A or B.Press the A/B button on the keypad in order number is entered. followed by a bar graph be recorded.Switch between the two will replace the existing data when a number is chosen readings by pressing the RPM/Hz button on the that has already been used in order to tag a snapshot. snapshot.The display is more instantaneous and 003037 not averaged over a period of time.0-50 Vibration Diagnosis and Correction General Information EVA Display approximately 70 hours after the unit has been unplugged from a power source. The EVA is more sensitive to vibrations in the non- averaging mode.You can view individual frames in a forward or backward sequence using the up and down arrow keys. is shown in acceleration force (G's). Averaging/Non-averaging modes Strobe Balancing Freeze Pressing the FREEZE button on the keypad activates the freeze function.Up to 10snapshots can frequency reading.The display shows FRZ at the top.

The timing light clips on to the trigger wire. Press the up arrow key on the EVA keypad. . Plug the sensor into either input A or B.The EVA is now ready to begin the strobe balance procedure. 7. 5. Press the number2 on the keypad 3times in order to begin calibration: The EVA can strobe balance a rotating component.Do NOT repeat this calibration under normal use.Press YES in 4.The phase shift calibration is performed at the factory. 8. The low and high ranges prevent other vibrations from interfering with the The ANY KEY TO CONTINUE message operation of the strobe light.Pressing a key will triggers the strobe light at the same frequency as the cancel the calibration process. Lay the sensor on a flat stationary surface with the UP side facing upward. which is until the message ANY KEY TO used with an inductive pick-up light strobe.The EVA is now ready to begin the strobe balance procedure.The vibration/strobe frequency must fall within the selected range.The message BURNING will appear. should appear. vibration. Sensor calibration 1. The display will return to the active mode when calibration is complete. Phase shift calibration 1. does not provide the strobe function. 003038 3. 6. 3. EVA Calibration The EVA features the following two built-in calibration procedures: Sensor calibration Phase shift calibration Calibrate a replaced or an added sensor in order to function properly with the EVA unit. After the display initializes. Press any key in order to return to the active order to select a range. Plug the EVA into a 12-volt power supply. the next range. 2. Press any key in order to commence calibration: Calibration will take approximately 20seconds. Press the down arrow key on the EVA keypad.The EVA will ask a series of The BURNING CENTER FREQUENCIES questions in order to determine the correct filter LOW=39 HIGH=48 message will appear. followed by a request to turn the sensor over. 003037 2. Turn the sensor over. range:full. select the proper input. The message BURNING PHASE SHIFT Pressing the STROBE button starts the strobe CONSTANTS will appear for one minute. or high.Input B minutes.The EVA CONTINUE appears. low.The The display will flash numbers for 56 vibration sensor must be attached to input A. Press the number2 three times on the keypad. Use the full range as a last resort only. balancing function.General Information Vibration Diagnosis and Correction 0-51 Strobe Balancing 4. Plug the EVA into a 12-volt power supply.A Do not press any key trigger wire is located on the top of the EVA.Press NO in order to go on to mode.

the word AVG individual frames of a snapshot during a freeze in the appears at the top of the display. the record mode. ENTER:Once the EVA is in the record mode and you FREEZ:Locks the display on the data at that moment have selected a snapshot tag number. EXIT:Returns the screen to the active display when the PLAYBACK:Places the EVA in the playback mode in EVA is in the freeze mode.When in the averaging mode. key operates in the active display or during playback. playback mode. or the strobe mode. the order to view vibration information that was previously playback mode.This order to start recording. RECORD:Places the EVA in the record mode. A/B:Switches the display between the A input and the B input.Pressing the EXIT key will return the key screen to the active display.0-52 Vibration Diagnosis and Correction General Information Keypad Reference recorded. :The numbered keys are used in order to select one of 10snapshot tag numbers (09) when recording or AVG:Switches the display between the non-averaging playing back information. and Hz.Pressing the FREEZE key again or pressing STROBE:Places the EVA in the strobe mode for the EXIT key unlocks the display.You must use Input A when strobe balancing. press ENTER in and displays the word FRZ at the top of the screen. driveshaft balancing and diagnosis.Pressing the UP arrow moves forward one frame and pressing the DOWN arrow moves RPM/HZ:Switches the frequency display between RPM backward one frame.Pressing the EXIT key will return the key screen to the active display. in the strobe balancing mode.Pressing the EXIT key will return the screen to YES or NO:Used in order to select a filter range when the active display. mode and the averaging mode.The non-averaging mode is more sensitive to sudden vibration :The arrow keys are used in order to move through the variations. \ .

General Information Vibration Diagnosis and Correction 0-53 0.5 Special tools and devices Legend Tool Number/Name J -38792 Electronic Vibration Analyzer (EVA) J38792 J -7872 Magnetic Base Dial Indicator Set J7872 J -8001 Dial Indicator Set J-8001 .3.

0-54 Vibration Diagnosis and Correction General Information Blank .

..1......5..33 Replacement of Fresh Air Door .....Driver 1....................1.....................5.. 1-38 1.........................2 Inspection of HVAC blower control system.Direct mount) ........1..................1 Correction of Odor........1....1...... 1-43 1..................... 1..........1...........1.6 Replacement of compressor Pressure Relief Valve (V5-Directly-mounted) .......1.......1......................................... 1-74 1. 1-4 ..1.6.. 1-5 1...1......5......22 Replacement of Passenger Cabin Air Filter ....... 1-15 1...1..........3.5...........1 HVAC System Component Locator .........................4...32 Replacement of Heat Distribution Duct .. 1-91 1..........6 The blower motor only runs at high speed ..... 1-31 1...............1-3 1.5... 1-27 1......5The blower motor would not run at any speed 1-17 1...............4 Inspection of HVAC air supply system ........1 Specifications ..1......5..........23 Replacment of Controller Assembly ... Ventilation and Air Conditioning 1.. 1-29 1. 1-31\ 1.. 1-15 1....................4 Odor Desceiption...6......... 1-19 1.................6....1................... 1-85 Cold Air Blast from the Floor . 1-91 1...... 1-4 1...4 Replacement of Compressor Control Valve ...... ... 1-3 1...1 Fasteners Tightening Torque...5.....................6....................... 1-91 1..5........5..6..5..................12 Description of Blower Motor ..30 Replacement of A/C and Defrosting Air Door 1..3...............25 Replacement of Air Distribution Duct .. 1-89 1..4......... 1-61 1..........1..........5..........1...............10 Replacement of Compressor Hose .................4.............4.. 1-51 1......1.....................1......................... 1-31 1.9 System Performance Test ............1..................4Diagnostic Information and Procedures .5....5..1..........4..... 1-30 1................................1...................... 1-31 1..1..5..................................1.......................4 Replacement of Compressor Control Valve 1...............1.... 1-49 1.........1.......5...... 1.............. 1-54 1................. 1-92 1........1.5......................6.Front Passenger Side ......... 1-17 Replacement of Body Pressure Relief Valve...3 Inspection of HVAC compressor control system ...........1..4............2..5. 1-16 Side ....5.............1...1.....4.. 1-53 1...............5.. 1-4 1........ Ventilation and Air Conditioning System 1.........1............1.......... 1-20 ...3 Replacement of Compressor Assembly ....... 1-48 1...4...11 A/C System Diagnosis .. 1-68 1....1. 1-52 1.......Heating.........25 Replacement of Air Distribution Duct ........1..............24 Replacement of Mixing Air Nozzle Case ......... 1-37 1. 1-81 1.....7The blower motor cannot be turned off ........................1..11 Replacement of Expansion Valve ...... 1-3 1............5.....1Functional Check........1 Description of A/C System..................... 1-16 1....10 Maintaining Chemical Stability..................... 1-39 ........1.............. 1...........21 Replacement of Heater Hose ....1.28 Replacement of Drainage Hose .... 1-13 1. 1-93 1-40 1............ 1-18 1.....................1.........3.....1.................. 1-73 ......1...5 Refrigerant R-134a .....2 Description of Air Distribution System ...1.1......5.......5.......1 Wiring diagram of air conditioning system..12 Condenser Replacement...1 Heating......6..8 Inspection of Refrigerating System ...3 Refrigeration System Description ................ 1-93 ............5Repair guidance ...............1...... .....1.... 1-89 1......4.......6Description and Operation ... 1-33 1............8 Replacement of O-ring Seals ..............................3Component Locator................ 1-90 1.. Ventilation and Air Conditioning System table of contents 1-1 1 Heating...........1..............6 Handling Procedure of Refrigerant R-134a ...........1.........13 Replacement of Condenser Seals......................1..................5..........4..31 Replacement of Fresh Air Door Actuator. 1.16 Odor Diagnosis..20 Replacement of Evaporator Core in A/C box 1-64 1..........1...........................1......1..12Insufficient Defrosting ....... 1-83 1...18 Replacement of A/C box.............1..1.................. 1-78 1...... ........... 1-92 Assembly (V5 .....1......5..................2Refrigerant Recovery and Recharging ........11 Description of Passenger Compartment Air Filter 1.............7 Handling Method of Compressor Oil ...19 Replacement of Heater Core in A/C box .. 1-41 1..........5.......... 1-21 1.........1..................1.13Insufficient Heating...........2Schematic and Wiring Diagram.... 1-3 1... 1-16 1.1... 1-94 ........ 1-80 1........4..............1....1....................................2 Refrigerant and refrigerant oil.5.........5........... 1-23 Rocker .. 1-70 1........29 Replacement of Heat Distribution Box Rocker ..... 1-93 1....1...........................1..............6.....5.........................1.6.........1.........9 The handling of A/C Compressor ..1........... 1-46 System .8 Handling Method of Refrigerant Tubes and Fittings 1.....7 Compressor Leak Testing (V5 Directly-mounted)................... 1-26 1.........5..........4..................................1...........1.1...6............. 1-79 1........... 1-73 1.......14 Noise Diagnosis ........ 1-56 1..... 1-4 Replacement of Blower Motor and Blower Fan.. 1-55 1.....15 Replacement of Liquid Container ...5.....1................3HVAC Connector Views.14 Replacement of Condenser Fan.1...............6........9 Replacement of Evaporator Pipe (Liquid Pipe) ...........10 Leak Testing ...6.... 1-76 1....1.4....4.... 1-92 1..16 Blower Motor Resistor Replacement..1. 1-82 1...1..2 HVAC Component Views.....................1..5..........4....1............

..................................24 HVAC Blower Controls Circuit Description . 1-95 ............1........6.........1.. 1..... 1.......6............... 1-95 1.........1............... 1-94 1.............................................6...............................1..25 HVAC Compressor Controls Circuit Description.......1...............6..19 Compressor Description ..1...1............ 1-96 1....22 Controller Assembly Description ..................... 1-95 1...............21 A/C Refrigerating Pressure Switch Description .....6................6........6.........15 Evaporator Description....................18 Heater Core Desceiption .... 1-94 1. Ventilation and Air Conditioning System 1...........6...1-2 table of contents Heating.. 1-97 1...............14 Description of Expansion Valve .............1.. 1-96 1..........1............ 1-95 ................. 1-96 1.....6...... 1-95 1..... 1-94 ..23 O-ring Seal/Plain Washer Desceription ................1......6.............................20 High Pressure Relief Valve (HPRV) Description ........................6.............. 1.......16 Condenser Description ...........1.13 Description of Blower Motor Resistor .............1............... 1-94 1..........6.....17 Liquid Container Description .......... .......1.........1..... 1-98 ...........6........7Special tools ........

5 N m Blower motor bolts 2.0-4.1 Heating.0 N m Blower motor resistor bolts 2.5 N m Screw on the housing of strainer 3.1 Specifications 1.1.0 N m Screws on the plate of air inlet grill 1.5-2.1.0 N m Bolts of fresh air door actuator 2. Ventilation and Air Conditioning System Specification 1-3 Specific 1.1.2 Refrigerant and refrigerant oil Specification and capacity Specification Capacity GM Part Number PAG synthetic refrigeration lubricant 220 ml.0-4.1.0-1.0-6.1 Fasteners Tightening Torque Application Specification Bolts on the liquid container bracket 4.680 kg 12345922 Mineral base 525 viscosity mineral oil (lubricant for O-rings and - 12301108 accessories) . Ventilation and Air Conditioning System ation 1.0 N m Air duct screw 1.0-3.0 N m Compressor hose assembly to compressor bolt 33 N m Compressor hose assembly to condenser bolt 16 N m Bolt on the front of compressor 30-40 N m Bolt on the back of compressor 30-40 N m Compressor pressure relief valve 6-10 N m Drive belt tensioner bolt 22-30 N m Collar nuts of liquid pipe lines connected to condenser 16 N m Bolts on the liquid pipelines of expansion valve 16 N m Refrigerant pressure switch 11-14 N m Compressor hose at the evaporator hose assembly 36 N m Bolts on the upper bracket of condenser assembly 4-6 N m Fan of condenser assembly 2N m Oil screw plug of compressor 15-20 N m Bolts on the rocker arm of air conditioner case 2. 12345923 R-134a refrigerant of air conditioning system 0. Heating.5 N m 1.1.

add 60ml.3. If there is a sudden loss of engine oil caused by mass leakage the amount of refrigerant added to the replaced component (as of refrigerant. - Connector End Views Blower motor resistor Inside IP. and the right side of the heater-air HVAC conditioner module. Addition of refrigerant oil omponen ocator Components replaced Oil to be added Note: If refrigerant oil leaks from air conditioning system in the process of recovery or part replacement. If the refrigerant oil that has been discharged is more than 30ml. add the same amount of it.3Component Locator 1. A/C compressor If the refrigerant oil that has been discharged is less than 30ml. - Connector End Views Blower motor LR of IP.1. 1-4 Schematic and wiring diagram. a result of mass leakage) should be 90ml more than the required volume.2.1 HVAC System Component Locator Name Location Component Views Connector End Views A/C Compressor A part of A/C compressor.21.1. Condenser assembly 30 ml. connecting to the Wiring Systems relay underside of the cross member Component Views - . located at LR of HVAC Clutch Coil the front side of engine. Add refrigerant oil as specified.1. and on top of the heater-air HVAC conditioner module - Connector End Views Temperature actuator On the left side of heater module - - Fuse box Left side of IP Wiring Systems Component Views - A/C Controller Center of IP HVAC Component Views - Rear window defogger On rear window grid line - - Rear window defogger Behind IP chamber. Ventilation and Air chematic nd wiring agram. component locator Heating. The evaporator 90 ml.1.2Schematic and Wiring Diagram 1.2.1 Wiring diagram of air conditioning system Refer to 8.20. 1. 1. Reservoir of the container The amount discharged plus 30ml. replenishment of it should be made.

Heating.2 HVAC Component Views Locator Condenser Assembly Component Views 103001 Legend (1) Front bumper assembly (3) Condenser assembly (with the fan and the (2) Front lower cross member reservoir) . Ventilation and Air Conditioning System Component Locator 1-5 Compon ent 1.1.3.

Ventilation and Air Conditioning System Compressor Assembly Component Views 103002 Legend (1) Engine (2) Compressor Assembly .1-6 Component Locator Heating.

Heating. Ventilation and Air Conditioning System Component Locator 1-7 HVAC Component Views (except for compressor) 103003 Legend (1) Condenser assembly (3) The A/C ducts (2) Heating. Ventilation and Air Conditioning Subassemblies .

without power (2) The fixing of compressor hose .1-8 Component Locator Heating.with power steering system steering system . Ventilation and Air Conditioning System Compressor Hose Component Views 103004 Legend (1) The fixing of compressor hose .

Ventilation and Air Conditioning System Component Locator 1-9 Component views of the air distribution duct and the air port 103205 Legend (1) Instrument Panel (3) Air distribution duct (2) Air conditioner case .Heating.

Ventilation and Air Conditioning System Component view of HVAC control assembly (at the center of instrument panel) 103206 Legend (1) Instrument Panel (2) The Controller of HVAC system .1-10 Component Locator Heating.

and the HVAC housing on firewall of the front boarding 103007 Legend (1) Firewall assembly (3) Strainer screen and its housing (2) A/C chamber assembly. the screen housing.Heating. A/C compressor controller . Ventilation and Air Conditioning System Component Locator 1-11 Component view of the HVAC strainer screen.

1-12 Component Locator Heating. Ventilation and Air Conditioning System Component view of compressor assembly 103008 Legend (1) Nut (8) Screw plug for addition/discharge of engine oil (2) Armature (9) Bolt (3) Gasket (10) Gasket (4) Clutch (11) Pressure Relief Valve (5) Coil and housing assembly (12) Control valve (6) Key (13) Gasket (7) Compressor (14) The fittings .

3.1.Heating.3HVAC Connector Views Blower motor A/C Compressor Clutch Coil 103011 103009 Pin Wire Color Function Pin Wire Color Function A Green Power supply Supplying power to B BRN Ground A Bluish brown clutch coil B Light brown Ground Pressure switch Blower motor resistor 103212 103010 Pin Wire Color Function Pin Wire Color Function A Reddish brown Medium pressure 1 WHT High speed High pressure and low B Black and white pressure 2 Blue Motor C BRN Medium pressure 3 YEL Low speed High pressure and low 4 Red Medium to low speed D black and yellow pressure 5 - - 6 PPL Medium to high speed . Ventilation and Air Conditioning System Component Locator 1-13 1.

Ventilation and Air Conditioning System Temperature sensitive resistor Air door actuator for fresh air 3 2 1 7 6 5 4 103213 103200 Pin Wire Color Function Pin Wire Color Function A Black and red Power supply 1 BLK Power supply B BRN Ground 2 - - C black and yellow Signal output 3 - - 4 Red and blue Corotation 5 WHT Reverse rotation 6 - - 7 - - .1-14 Component Locator Heating.

also engaged. closure of recycle valve.4. Therefore. The following conditions indicate the electric audible reduction of air noises. To the inspection of 2. and sometimes involve wrong temperature. Heating. A/C control head (mode selector) works before further diagnoses.1Functional Check speed. Set temperature regulator to the COLD (blue) To the inspection of 2 position. there should be an 1.1. - When the blower is at HIGH (high When blast volume controller is at OFF speed) operating state. When internal circulation mode is changed generally speaking. Verify that the compressor clutch is - The blade is running. When there is air coming out of a specified air systems to transfer messages to the driver. Place the ignition switch in the ON (turn on) position. also prevent future diagnostic mistake and Primary inspection: unnecessary replacement of any component. because of the malfunction. A/C control head is very reliable and. When the control mode of blast volume is at Verify the existence of following conditions: any position other than OFF. will not be the cause of any to external circulation mode. While listening to the blower motor. but conditioning system. information about how HVAC system operates and how each system interacts with the air conditioning Conduct the following functional tests to the air Controller. motor of A/C system operates at a proper speed. Is the blower motor turned on and the speed changing? 1. 2. can the A/C control system compressor be turned on and off normally? Use MODE controller on the A/C control head to select To the inspection of every mode. When the position of the temperature knob Most malfunctions can be traced back to improper has been changed. check for any change in wiring and connection. components. too. This will not only save diagnosis time. Air conditioning Controller uses signals from other 2. use fan speed 1 - Go to Step 2 HVAC blower control controller on A/C control head to turn the velocity system of blower from low to high.4Diagnostic Information and Procedures n and Procedure s 1. port. the blower motor will not run at any the blade should keep their current position. the blower - The roller is spinning. . Switch on the air conditioner.1. wiring is working normally. Inspect all outlets of the instrument board. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-15 Diagnostic Informatio 1. and its connection on 4 - System OK Is the operation of temperature regulator normal? the A/C control head and the A/C box. so as to test the airflow pattern of them. - Go to Step 3 HVAC compressor When A/C system is being used. Numerical Steps Measures Yes No values 1. But it is an exception when air conditioner has been turned on. 3 - Go to Step 4 HVAC air supply Is the air flow of each mode coming from the right system outlet? Turn temperature regulator from the maximum cold Inspect the blue cable (blue) to the maximum heat (red). the roller and position. first review general well.

Set the mode selector to Switch on the power supply of FACE (blowing to the face). The cooling fan of the engine may be running. A/C control head and the A/C box. The air cables and their connection on the conditioning compressor will run A/C control head and the A/C box. beside the windshield.3 Inspection of HVAC compressor control system operated by circuits. increasing speed.1-16 Diagnostic Information and Procedures Heating. the front defroster cables and their connection on the and the vent hole beside the A/C control head and the HVAC vehicle window. 1. The air assembly. 3. .1. the A/C control head at Air flow comes from the air medium speed. Switch on the air conditioner. The blower motor only works at high speed. 2 the I. Change to DEFROST mode on A/ Air flow comes from the air port Inspect the gray and the brown C control head. Set the A/C control head to the BI.1. The blower runs at medium Refer to Inspection of Power Train 2. and the HVAC subassemblies. cables and their connection on the blowing to the foot) position. increases. Start the engine.1. Turn temperature regulator to The idling speed of the engine 1 the blue area. The air flow cools down. II. III. Slide the recycle button on the A/C Internal air will be recycled through Inspect the green cables and their 6 control head. 5. the The blower motor would not from OFF (turned off) position to blower motor operates at an work at any speed. Set the A/C control head to the Airflow comes from the vent hole Inspect the gray and the brown DEFOG position. Ventilation and Air Conditioning 1.2 Inspection of HVAC blower control system Steps Measures Normal result Abnormal result Place the ignition switch in the ON 1 - - (turn on) position.4. the compressor.4. Refer to Diagnostic Information and Procedures in Engine Control System. 4. outlets on the panel and the connection on the A/C control head boarding.4. control system These diagnoses are included in the diagnoses of HVAC compressor control system and the engine 1. On-Board Diagnostic System. on the boarding. 2 automatically in this setting unless the outside temperature is below 4 °C. Airflow comes from the vent hole Inspect the gray and the brown 3 LEVEL (blowing to the face and on the boarding. 4 conditioning compressor will run automatically in this setting unless the outside temperature is below 4 °C. Turn the switch of blower motor Beginning from OFF position. Set the fan control switch on speed. IIII positions. port on instrument board.4 Inspection of HVAC air supply system Steps Measures Normal result Abnormal result 1.

5The blower motor would not run at any speed Numerical Steps Measures Yes No values Inspect fuse F20 in the fuse box. Replace the blower 9 - Go to Step 10 Is it working correctly? motor resistor. Is the strand working correctly? Inspect relay K6. 8 - Go to Step 9 Repair the strand. Is the fuse closed? Inspect fuse F15. Motor switch Inspect the harness between the blower motor switch Repair the 2 S24 and the blower motor resistor M10.4.4. 4 - Go to Step 5 Replace the relay. Is the fuse closed? Inspect the strand between relay K6 and the blower 3 switch S24. Is the strand working correctly? Inspect the blower motor resistor M10. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-17 1. Is it working correctly? Inspect the blower motor resistor M10. 7 - Go to Step 8 Replace the relay. Replace the blower 5 - Go to Step 6 Is the blower switch S24 working correctly? switch. Replace the blower 3 Is it working correctly? - System OK motor. Is the relay working correctly? Inspect the strand of relay K7. - Go to Step 3 harness. Is the relay working correctly? Inspect the blower switch S24. 2 - Go to Step 3 Replace fuse F15. Inspect blower motor Replace the blower 6 - Go to Step 7 Is the blower motor working correctly? motor. Resistor M10 . - Go to Step 4 Repair the strand.6 The blower motor only runs at high speed Numerical Steps Measures Yes No values Inspect the blower motor switch S24. Is it working correctly? 1. 1 - Go to Step 2 Replace fuse F20. 10 - System OK Repair the strand. Inspect the strand of blower motor resistor.Heating. Replace the 1 Is it working correctly? - Go to Step 2 blower.1.1. Inspect relay K7.

Is the test lamp lit up? Repair any short circuit in the following circuits: 1. Disconnect the heater-A/C control connector C1. Disconnect the blower motor resistor. Use a test lamp to conduct a backside exploration between the harness connector and the grounding of the 1 - Go to Step 2 Go to Step 5 blower motor resistor. IIIII . Continue to connect the test lamp to the same terminal that lights it up. 2. Refer to relevant To the sections of Instrument Board. Turn the blower switch to the OFF position. II . HVAC blower Is the repair complete? control system Replace the blower motor resistor.4. 2 - Go to Step 3 Go to Step 4 2. Ventilation and Air Conditioning 1. I . III .1-18 Diagnostic Information and Procedures Heating.Refer to Blower Motor To the Resistor Replacement.Harness connector terminal C (Circuit 73) of the control system blower motor resistor 5. 5.1.Harness connector terminal D (Circuit 72) of the inspection of 3 - - blower motor resistor HVAC blower 4. IIII . Turn the ignition switch to the RUN position. 3.7The blower motor cannot be turned off Numerical Steps Measures Yes No values 1. 4.Harness connector terminal A (Circuit 63) of the blower motor resistor To the 3. I-B (Circuit 60) II-A (Circuit 63) III-D (Circuit 72) III-C (Circuit 73) Does the test lamp light in every test? 1.Harness connector terminal B (Circuit 60) of the blower motor resistor 2. inspection of 5 - - Is the repair complete? HVAC blower control system . Cluster Gauge and Auxiliary inspection of 4 - - Instrument Board.Harness connector terminal F (Circuit 52) of the blower motor resistor Is the repair completed and the system newly inspected? Replace the HVAC control assembly. Set the A/C control head to the outside loop position.

Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-19 1.Refer to Refrigerant Recovery and Recharging.Heating. 2. Is there any leakage? Are the high side and low side pressures between 5 kPa System OK Go to Step 6 the specified values? Repair any leaks. conditioner? 1.8 Inspection of Refrigerating System Numerical Steps Measures Yes No values Does the performance test of A/C system require Go to System 1 further diagnosis of the filling of refrigerant in air - Go to Step 2 Performance Test. 6 - Go to Step 7 - Is the repair complete? Drain and recharge the A/C system. To A/C system 7 kPa System OK Are the high side and low side pressures equal to diagnosis the specified value? . Turn off the ignition unit. Inspect system for any leakage.4.5 kg of R-134a.1. To A/C system 2 kPa Go to Step 3 Are the high side and low side pressures equal to diagnosis the specified value? Are the high side and low side pressures equal to 3 kPa System OK Go to Step 4 the specified value? 1. Add 0. Refer to Leak 4 - Go to Step 6 Go to Step 5 Testing. Connect A/C measuring instrument. 2.

11. Open the vehicle windows.78 * A/C compressor is turned off due to excessive high side pressure.1. and stabilize ambient temperature should be at least 16C. Turn off the engine and compare the readings 5. .98 38 0. the speed of the engine at 2000 RPM.24 2000 13 2. Ventilation and Air Conditioning 1.02 70 21 0. Run the A/C system until the airflow at the air inside of the vehicle.18 2000 9 1.29 2000 16 2. pressure side. Close the vehicle doors and windows.1-20 Diagnostic Information and Procedures Heating.96 38 0. refer to A/C System Diagnosis.76 32 0. Open the engine hood and install a pressure 13.23 2000 11 2. 3 minutes). authorities. speed.20 2000 9 1.17 2000 8 1.9 System Performance Test 9. outlet reaches the lowest temperature (in about 3. table.75 27 0.78 80 21 0. 7. 15.22 2000 11 1. Use a wet-and-dry working state should not exceed the grade bulb thermometer or consult the local weather shown in the table.The position and turn on the engine.72 27 0.17 2000 8 1.18 40 27 0. Under normal conditions.12 30 32 0.27 2000 14 2.20 2000 11 1.91 38 0. 10. ambient temperature when performing the test.75 32 0.18 2000 8 1. A/C Performance Table Air temperature Maximum Maximum Relative Ambient Engine Speed at the center of pressure at the pressure at the humidity (%) temperatureC rpm the largest air low side MPa high side MPa outletC 24 38 0.76 32 0.4. 2.17 2000 6 1.27 50 27 0. and set the velocity of the blower to high refer to Refrigerating System Inspection. Exhaust waste gas in the engine.24 2000 14 2. 8. Park the vehicle inside or in the shade.77 27 0. If any reading is lower than the limit in the table. mode. Record air temperature at the air outlet and the gauge on the high pressure side and the low pressure of the high side and the low side. Record the ambient temperature outside the with the upper limit data in A/C performance vehicle. Record the relative humidity. and ventilate the 12.17 2000 8 1.17 2000 8 1. then turn the temperature regulator to the coldest and turn on the air conditioner. If any reading exceeds the limit in the table.23 2000 12 1. Open the air outlet diffuser of the air conditioner. Set the driving axle of the transmission to PARK 1. Place a thermometer at the center of the A/C air Note: Take care to record the relative humidity and the outlet. A/C system in 6. 14. Set the A/C control head to the outside loop 16.33 60 21 0. 4.20 2000 10 1.81 90 21 0.

towel can create a leak path across an O-ring. the existence of a leakage should be suspected. which can be confirmed by the measured detect the leakage of refrigerant. signal of high frequency. a refrigerant leak test should be conducted to the system.Heating. Lack of lubricant on the O-rings Ensure the instrument has been calibrated according to Dirt/debris across the O-ring its instructions. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-21 1. It has three settings: R-12 R-134a Severe leakage (complete leakage) 104003 The most common leakage occurs at refrigerating accessories or the connection.10 Leak Testing Caution: Don't operate the detector in an inflammable environment. The components Pipelines Fittings Halogen Leak Detector Tools required 104002 J39400-A Halogen Leak Detector J39183-CR134A Manifold measuring apparatus Before commencing the test. Ensure the detector has been correctly Even the smallest piece of lint from cotton gloves or a set to the type of the refrigerating system to be tested. Once a leakage is suspected.4. J39400-A is a static pressure on the pressure gauge.1. A reading packaged unit working with a DC of 12 volt. If the system is found to be insufficiently charged. The leakage may be caused by the following reasons: 104001 Improper torque Damaged O-rings Use Severe Leakage setting to distinguish any mass leakage detected in the other two settings. for its sensor works at high temperature. make sure the J39500-5023 kg Refillable recovery tank refrigerating system has been sufficiently charged for Halogen leak detector is a most effective tool used to the leak test. or whenever any repair work affecting the following components has been performed. It may cause personnel injuries or equipment damage. . and when between 413 and 689 kPa will be suitable for the leak R-12 or R-134a is detected. it will generate an audible test.

rate. according to instructions The evaporator inlet and outlet provided. and the opening of the air intake should not be chocked. R-134a does not contain chlorine. Shut the blower fan off. Wait for 10 minutes. The container intake and outlet For a discharged system. If the detector sends out a warning. it indicates a J 28428-E High Intensity Black Light leak has been found. Only use an injection rate of 1/4 ounce of tracer Note: Halogen leak detector is sensitive to the following dye.Even if a leak point has been detected. all of performed according to the following instructions: the above areas should be tested to ensure no more 1.The use of any other products will to a solid alarm. GM P/N 1050436. you can add tracer dye to a replaced component or use ACR4 to The condenser intake and outlet add it. the leak may Thorough detection in circling pattern should be take up to 7 days in order to become visible. Besides. performed at every joint at a speed of one to two inches Note: per second. Larger amounts may compromise the items: reliability of the A/C system.The balance knob should be adjusted compromise the reliability of the system and frequently in order to maintain the 1-2 clicks per second cause premature failures to the compressor. J 41436 Tracer Dye Injector 5. an engine degreaser of the GM Company. maintain it for more than 15 seconds. R-134a may leak from a electronic leak detector will depend on the scanning smaller path. and the tip of the detector should be J 41447 can only be used on vehicles with R- maintained as close as possible to the surface being 134a. Windshield washing solution After addition of tracer dye. Ensure that service valve and the equipment. Insert the leak detector into the blower position. Other connections Liquid Leak Detectors and Pressure Testing All brazed and welded areas The effectiveness of liquid/form leak detectors is very Areas that show signs of damage limited. This is because the visibility of the current Hose connection refrigerant system is very limited. and liquid/foam leak The compressor rear head detectors are not sensitive enough.The following items can be tested with this Dye Injection procedure: You can inject charged systems with tracer dye Pressure switch by using J 41436. exceed 1/4 inch. Ventilation and Air Conditioning The successful use of this leak detector or any other method for the leak detection. or an Solvents and cleaning agents equivalent of it should be used to remove any Binding agents remaining tracer dye on the surface of the Clean all surfaces to prevent false warning. as ingestion of liquids will damage prevent any mistake in diagnosis. Its distance from the surface should not 134a. The housing joints The evaporator core Note: Always follow the refrigerant system around in a One of the most difficult leaks to find is a leak in the continuous path so that you do not miss any potential evaporator core.1-22 Diagnostic Information and Procedures Heating.Depending upon the rate of the leak. R-134a tracer dye requires Maintenance time. Fluorescent Leak Detector 2.A testing to the evaporator core can be leak areas. The method of tracer dye should be used in conjunction Calibration with an electronic leak detector. for it can find out the smaller leaks that an electronic leak detector cannot Operation find out alone. Only R-134a refrigerant is different from the R-12 refrigerant used in the past. respects. A leak is indicated when the Only J 41447 is recommended for use in the R- audible tone goes from a steady 1-2 clicks per second 134a system. Switch the blower fan to the high gear and leaks exist in the whole system. Remove the blower fan. as its molecule is smaller than that of R- frequency. which instructions of the manufacturer in the following can be easily detected by an electronic leak detector. the detector. or vehicles changing from R-12 to R- inspected. J 41447 Tracer Dye 4. Tools required 3. It will also depend on compliance with 12. so as to the surfaces are dry. and it may require other .

Turn the ignition switch to the OFF position. These symptom diagnostic procedures a leak. and replace it if it has been damaged.5 kg of R-134a. V5 compressor will keep on running. A control valve is located on the in System Performance Test. 1. Inspect the airflow of condenser assembly for V5 Compressor any restriction. Inspect the surface of the evaporator core with mechanism.Is there any leakage? Are the high side and low side pressures within the specified range? 207-345 4 System OK Go to Step 5 kilopascal Repair any leaks. under-cooling.1. can be used to prevent any unnecessary replacement of A/C system components. and repair it if necessary.11 A/C System Diagnosis Inspect the driving belt. Wait 1-2 minutes.Refer to Refrigerant Recovery and Recharging. it indicates a leak Inspect the electric connection of the clutch coil.Heating. This control valve is system is OK. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-23 6. Probe the area in front of the pulley.4. Blow the rear and the front of the compressor Primary inspection: clutch/pullry with compressed air used in Inspect the fuse of A/C system. The ambient temperature should be at least 16C. process is different from those of systems with fixed therefore no oil can be seen. even when these is displacement. detector sends out a warning. This diagnostic with R-134a the lubricant is water-soluble. 1. - Go to Step 5 Go to Step 4 Refer to Leak Testing. and replace it if factories for at least 15 seconds. Refrigerating system Inspect the airflow of the system for any V5 compressor is a compressor with variable restriction. 5 - Go to Step 6 - Is the repair complete? Drain and recharge the A/C system. In systems the whole system will not cycle. has been found. necessary. 345 kPa Go to Step 7 Go to Step 3 Are the high side and low side pressures equal to the specified value? Add 0. V5 compressor meets the requirement of If the outgoing air temperature of the A/C system and air conditioning through stroking other than through the pressure of the compressor are equal to the values cycling the clutch. it indicates the A/C back cover of the compressor. Inspect the operation of A/C system blower. and an electric torch for any refrigerant. 2 2. 2. Connect A/C measuring instrument. and clean it as necessary. The aim of symptom diagnostic program is to examine Inspect the operation of electric cooling fan. and the following components for any problem caused by repair it if necessary. Compressor shaft seal 1. 6 345 kPa System OK Go to Step 7 Are the high side and low side pressures higher than the specified value? . displacement. used to fulfill the following function: sense the low side pressure and actuate the stroke of the compressor The filling up of refrigerant Step Action Value Yes No Did you turn to this step from the A/C System Performance Test? Go to System 1 - Go to Step 2 Performance Test. 3 Inspect A/C system for any leakage.If the replace it if necessary. and 3.

17 - System OK Go to Step 19 3. 18 - System OK - Is the repair complete? 1. Test the system for any leakage. Run A/C system for 5 minutes or longer. Ventilation and Air Conditioning The filling up of refrigerant(Cont’ d) Step Action Value Yes No 1. reinstall or replace A/C pipelines. Refer to Compressor Replacement. - Go to Step 9 Go to Step 16 Is the noise coming from the compressor or the driving belt? Inspect the belt for any skidding. Set the temperature to full cold. Is any fluid resistance present? 1. Record pressures on both high pressure and low pressure sides when the electric cooling fan is on. Go to Step 12 - Go to Step 14 Is it in contact with other components? 13 If necessary. 3. 2.Refer to Leak Testing. Inspect the outgoing air temperature at the air outlet. 2.Refer to Refrigerant Recovery and Recharging. Set the blower motor speed to the high speed. Is the clutch engaged? Examine the noise coming out from the compressor or the A/C driving 8 belt area. Turn on the A/C system. Recover the refrigerant. 2. See A/C Refrigerating Pressure Switch 20 Instruction. 13 - System OK Go to Step 16 Is the repair complete? Is the noise coming from the A/C compressor? Go to Step 14 - Go to Step 16 15 Replace the A/C compressor. so as to find out any restricted position. - System OK Go to Step 14 Is the repair complete? Listen to the A/C compressor for any noise. Go to Step 9 - Go to Step 11 Is the noise caused by the skidding belt? 10 Replace the driving belt of accessories. Go to Step 11 - Go to Step 14 Is the noise coming from the A/C compressor? 12 Inspect A/C pipelines for any contact with other components. Go to Step 15 - System OK Is the noise still present? 16 Inspect pipelines at the high pressure side for any restriction. 7 - Go to Step 8 Go to Step 15 4. Visually inspect the channels/pipelines for any frosting point. Let the engine run at idling speed. 5. Refer to System Performance Test. Set the A/C control head to the FACE mode. Are the low side and high side pressures within the specified range of the pressure switch? . Is the outgoing air temperature within the specified range? Repair the fluid resistance in pipelines of the high pressure side. or use physical Go to Step 16 methods to inspect the channels/pipelines for any difference in - Go to Step 17 18 temperature. Find out any restriction to the high side pressure and the low Go to Step 19 - Go to Step 30 side pressure. See Replacement of Driving 10 Belt of Accessories in Engine Mechanical System. 3.1-24 Diagnostic Information and Procedures Heating.

Drain and recharge the A/C system. 2. Go to Step 31 207 kPa - 5. 4. 29 - System OK - 3. 24 - System OK - Is the repair complete? Inspect the A/C system for excessive filling of refrigerant. Set the temperature to full cold. Run the engine at a speed of 2000 RPM. 4. Go to System 26 Drain and recharge the A/C system. Test. 2. 1. Go to System Go to Step 27 Is there any leakage present in A/C system? - Performance 28 Test. repair the cooling fan. Are the high side and low side pressures equal to the specified value? . Go to Step 30 207 kPa Go to Step 36 Are the high side and low side pressures equal to the specified 31 value? 1. Close the vehicle doors and windows. 3. Go to Step 21 - Go to Step 23 Is the fan running? 22 Inspect the airflow of the condenser for any restriction. Is the repair complete? With the engine running.Heating. Set the blower motor to the high speed. 21 6. If necessary. Recover the refrigerant. Go to Step 25 - Go to Step 27 Is the A/C system overfilled? 26 Recover the refrigerant.Refer to Refrigerant Recovery - System OK Performance and Recharging.Refer to Refrigerant Recovery and Recharging. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-25 The filling up of refrigerant(Cont’ d) Step Action Value Yes No 1. Set the A/C control head to the FACE mode.Refer to Refrigerant Recovery and Recharging. From outside loop to air conditioning. Go to Step 20 - Go to Step 25 5. Turn on the A/C system. 23 - System OK - Is the repair complete? Eliminate the restriction. Touch the liquid pipelines between the condenser and the expansion valve. Set the temperature control assembly to full cold. 2. Let the engine run at idling speed for 5 minutes. Go to System Go to Step 22 Is the airflow restricted? - Performance 24 Test. Go to System Go to Step 28 Is there any leakage present in A/C system? - Performance 29 Test. connect a pressure gauge for the high pressure side and the low pressure side.Refer to Leak Testing. Repair the leak of A/C system. Set the blower motor speed to the high speed.Refer to Refrigerant Recovery and Recharging. Is the repair complete? Inspect the air in A/C system. 3. Are the liquid pipelines cool? Inspect the cooling fan. cycle the mode once every 32 20 seconds and for 3 minutes. Leak test the A/C system.

Refer to Compressor Replacement.Refer to Refrigerant Recovery Go to System 42 and Recharging. - System OK Performance Is the repair complete? Test 1. Is the repair complete? 1. Ventilation and Air Conditioning The filling up of refrigerant(Cont’ d) Step Action Value Yes No Check for the following conditions: 1. 33 3.800 Go to Step 35 When the rotate speed of the engine is between the shown values. The induction pipe of the compressor becomes warm.5 kg R-134a refrigerant to the system. 172-241 Go to Step 36 Go to Step 40 Is the low side pressure within specified value? kPa 37 Add 0. Shortage of heat. Recover the refrigerant. Repair any leaks. Drain and recharge the A/C system. 6. Connect measuring apparatus to the high pressure and the low pressure sides. Set the A/C control head to the FACE mode. Go to Step 34 With the compressor clutch disengaged.Refer to Refrigerant Recovery and Recharging. 2. 2. Run the engine at a speed of 2000 RPM. 3. 172-241 System 40 Go to Step 41 kPa Performanc 5. Repair any loose instrument panel pad that blocks an outlet. Refer to Insufficient Heating. Go to Step 38 - System OK Is there any leakage? 39 1. 2. Pressures on the low side and high side pressure gauge increase slowly.4. . Go to Step 37 - Go to Step 40 Does the cooling performance improve? 38 Perform leak testing. Is the repair complete? Drain and recharge the A/C system. Remove any foreign objects. Is the low side pressure within the shown value? 1. Refer to Leak Testing. Refer to Compressor Control Valve - - 42 Assembly Replacement (V5 . Close the vehicle doors and windows.Direct Mount). Go to Step 33 RPM 40 does the pressure on the low side increase rapidly? Inspect the pressure on the low pressure side. The blast pipe is very hot. can the driver (not the - Go to Step 35 33 pulley) of the compressor clutch be rotated manually and freely? Inspect the pressure on the low pressure side. Go to Step 41 2. defroster is blocked. Set the blower motor speed to low speed. e Test. 33 - System OK - Is the repair complete? Turn off the engine.000-2. 7.1-26 Diagnostic Information and Procedures Heating. Are the listed conditions present ? Replace the A/C compressor.Refer to Refrigerant 39 - System OK - Recovery and Recharging.1.12Insufficient Defrosting Condition Action The injection nozzle of the Inspect the air outlet of the defroster. Replace the control valve. Set the temperature control to full cold. Go to 4. Turn on the A/C system. Go to Step 32 - Go to Step 34 2.

Inspect airflow at the outlet of the heater. - Go to Step 3 Go to Step 7 5. Inspect the driving belt tensioning force of the coolant pump. 2. Inspect the level of engine coolant.1.Heating. 2. Inspect airflow at the outlet of the defroster. Repair as necessary. Set the temperature control to full heat. Is it the airflow from the heater outlet is very small or no airflow is present? Inspect the outlet of the defroster or the vent hole for any airflow. 3. When the blower speed is turned to HI (high speed) then slows down as the switch is turned to LO (low speed). Inspect hoses of the radiator and the heater for any leakage or 1 - Go to Step 2 - kinking. does the blower motor speed drop to each of the corresponding speed grades? 1. Check for any obstruction at the opening of the blower intake and forced ventilator of the system.13Insufficient Heating Step Action Value Yes No 1. When the blower speed is turned to 4 (high speed) then slows down as the switch is turned to 1 (low speed). Set the mode to DEFROST. 3. Is the action complete? Set the blower speed from the following position to: OFF to 1 1-2 2-3 7 3-4 - Go to Step 8 Go to Step 16 Then return to OFF.4. 4 - Go to Step 5 Go to Step 15 Is it the airflow from the outlet of defroster is very small or no airflow is present? Set the blower speed from the following position to: OFF to 1 1-2 2-3 5 3-4 - Go to Step 6 Go to Step 16 Then return to OFF. 6 - Go to Step 7 - 2. Make inspection to find out whether the radiator cap is normal. Is the action complete? 1. 2. Ventilation and Air Conditioning SystemDiagnostic Information and Procedures 1-27 1. 3 Is it the airflow from the outlet of defroster or the vent hole is very - Go to Step 4 Go to Step 14 small or no airflow is present? 1. Set the mode to HEAT. 4. 2 4. Set the blower motor speed to the high speed. Turn the ignition switch to ON. does the blower motor speed drop to each of the corresponding speed grades? .

Go to Step 13 -{}-. 4. Inspect the correct position of the heater hose. Start the engine. Go to Step 20 Is the thermostat installed correctly? 21 Inspect the mode throttle controller and the cable. If the operation of the valve is - Go to Step 12 19 abnormal. Set the blower motor speed to 4 (high speed).13Insufficient Heating(Cont’ d) Step Action Value Yes No 1. Inspect the ambient air temperature with a thermometer. refer to HVAC Blower Control System Go to Step 16 Inspection. Touch the heater hose at the opening of the air intake and air Go to Step 10 - Go to Step 11 outlet. Start the engine. - Go to Step 9 17 54 °C @-18°C 59 °C @-4 °C 64 °C @10 °C Is the temperature at the outlet of the heater within the specified value? Is the air door actuator in normal operation? Go to Step 9 - Go to Step 18 10 1.4. Repair as necessary. - - 24 Is the action complete? 1. Go to Step 11 3. 13 Is the heater hose at the air inlet hot and the heater hose at the air outlet warm? 1. Repair as necessary. Is the position of the heater hose reversed? 1. 3. replace it. Go to Step 14 - - Is the action complete? 24 1. The shortest engine warm-up time is 20 minutes. Touch the heater hose at the opening of air intake and air outlet. 3. Disconnect the heater hoses at the heater core. Set the temperature control to full heat. Inspect the coolant valve. Drive the vehicle at 48 kilometer per hour. Is the heater hose at the opening of air inlet hot and the heater hose at the opening of air outlet warm? Inspect to see if the thermostat is installed correctly.Is the action complete? Repair or replace the throttle cables. 2. Go to Step 18 - - Is the action complete? 24 . Go to Step 15 2. Go to Step 12 4. Inspect the exhaust temperature at the heater outlet and the Go to Step 8 ambient temperature. Drain and refill the cooling system.1. 2. 2.1-28 Diagnostic Information and Procedures Heating. Inspect to see whether the heater outlet has been blocked. Inspect the following positions of the vehicle for any leakage of cold air. 3. Rinse the heater core. Instrument Panel Go to Step 17 - - Heater case 24 Front vent 2. - - 24 Is the action complete? Inspect the blower motor. Ventilation and Air Conditioning 1. Set the temperature regulator to full heat. - Go to Step 22 24 5. 2.

- Go to Step 6 Go to Step 5 Is excessive vibration present? 1. Close the vehicle doors and windows. Set the temperature control to full cold. so as to determine under what condition the noise is present. 1 - Go to Step 2 - Is the action complete? 1.4. Refer to Functional Test. Go to Step 21 - - Is the action complete? 24 Replace the heater core. 10 Was any foreign object found? 1. Go to Step 22 - - Is the action complete? 24 Check for any obstruction between the blower air inlet of the system Go to Step 23 and the opening of the forced ventilator. or grating sound? Does the sound weaken as the blower slows down? Listen to the sound of the blower again. 2. and under what condition the noise is absent. 2 6.4. trembling. 3. 24 - System OK - Is the action complete? 1. Is the blower giving out a persistent whining. 5. - - 24 Is the action complete? Perform functional test.13Insufficient Heating(Cont’ d) guidance Step Action Value Yes No Reinstall the heater hose at the correct position. Inspect the blower fan for presence of the following conditions: Wear spots Cracked blades Broken wheel hub Go to Step 6 - Go to Step 12 Loose fan holder 11 Misaligned fan 2. Inspect the bellows for any wear spot. ticking. Check for the presence of foreign objects at the opening of the Go to Step 5 - Go to Step 6 blower intake. Go to Step 19 - - Is the action complete? 24 Reinstall the thermostat. Ventilation and Air Conditioning System Repair guidance 1-29 Repair 1. 2. Was wearing found? . Sit inside the vehicle. modes and temperature controls. 3 Does the blower give out intermittent prolonged squealing/shrilling - Go to Step 4 Go to Step 7 sounds only at the startup and/or occasionally? Touch the bellows to inspect the vibration of the blower and the fan at 4 each blower speed. Heating.1.1. Set the blower motor speed to the high speed. Turn the ignition switch to ON. Remove the blower from the bellows. Go to Step 20 - - Is the action complete? 24 Replace the thermostat.14 Noise Diagnosis Step Action Value Yes No Inspect the electric connection and the grounding of the blower. 4. Cycle through all positions of the blower speeds. Set the mode to FACE. - Go to Step 4 Go to Step 3 7.

the air intake valve should The air inlet valve is only partly be properly closed in all modes. Remove any foreign object from the blower assembly. Check the heating system for any obstruction or any foreign objects between the blower fan and the air door. Refer to Functional Test.1. Go to Step 16 - - 2. Go to Step 14 - - 3. Check the seal of the heater and/or defroster intake. . Check the seal of air door. 17 - System OK - Is the action complete? Cold Air Blast from the Floor Problem Measures Except when the A/C system is in air conditioning mode. HEAT and DEFROSTER modes. Go to Step 8 Is the blower noise only present in the HEAT and/or DEFROST - Go to Step 9 14 mode? Listen to the sound of the blower again. Go to Step 9 Is the blower noise only present in the HEAT and/or DEFROST - Go to Step 16 15 mode? 1. Go to Step 13 - - 3. Go to Step 15 2. open.4. 2. Check the seal of the vent hole intake. 17 Is the action complete? 1. 17 Is the action complete? 1.14 Noise Diagnosis(Cont’ d) Step Action Value Yes No 1. Go to Step 11 - . Check the ducts for obstructions or foreign materials. Inspect all temperature positions from full heat to full cold under Go to Step 7 - Go to Step 8 the FACE. Repair as necessary. 2. Check all door seals. Go to Step 10 - - 2. Repair as necessary. The seals on side doors are 1. 17 Is the action complete? Perform functional test. 2. 2. Repair as necessary. Repair as necessary.- Is the action complete? 17 Replace the blower motor and the fan. Check the ducts for obstructions or foreign materials. Ventilation and Air Conditioning System 1. damaged or absent. 13 Is excessive blower noise only present in the FACE mode? Listen to the sound of the blower again. Repair as necessary.Is the action complete? 17 Repair the blower fan and/or the bellows as necessay. - - 17 Is the action complete? 1. Repair or replace faulty seals as necessary. Go to Step 12 - - Is the action complete? 17 1. Set the blower motor speed to 4 (high speed). Repair as necessary.1-30 Repair guidance Heating.

Recovery. Reconnect the A/C compressor clutch coil and to prevent the odor from returning. Note: Wear safety goggles and emulsion gloves when ventilate the work area before continuing performing the following steps. Replace HVAC box. and throat. Residules in the housing of the heater/evaporator or moulds growing on the 9. Musty Smell Obstruction in the duct of evaporator Clean the evaporator drain. Spray the area using short bursts.5Repair guidance 1.This odor is usually temporary.Refer to Installation check its operation. Instruction provided with the part. Ventilation and Air Conditioning System Repair guidance 1-31 1.Spray the interia of the pipeline with changing directions. Lay the engine aside for 3-5 minutes. of A/C system as it is started. should be worn and a clean cloth wrapped around 7. Recycling and Recharging (ACR4) Besides. Water leak (body) Find out and repair the leaking position. and turn the temperature control knob to the maximum heat and maintain J 41810 Pure Guard 2 it for 10 minutes.In order to remove R-134a from the A/C interfere the blower motor. If the odor is still present. J 39500-B Air Conditioning Refrigerant 3. run the blower motor at high speed in System the recirculation mode. Replace HVAC box. Choose a position on the A/C pipeline between Caution: Avoid breathing the A/C Refrigerant 134 a (R- the blower motor and the evaporator core and in 134a) and the lubricant vapor or the mist. J-41810-100A Positive flow control valve 4. the requirements of SAE J 2210 (R-134a recycling equipment). and connections when doing work that contents of the can over a 2-3 minute includes opening the refrigerant system.5.Heating. it may be necessary to clean the evaporator core with suitable cleaning agent. Recharging 2. Turn on the engine to dry the evaporator core. The heater core is leaking. Refrigerant Oil The heater core is leaking.Additional health and safety information may be 6. 1. this odor will disappear. Remove all residues that have been sucked into 1.5. evaporator.Exposure the downstream of the blower motor fan.Work in a well- 5. or any system.1. Turn off the engine. nose.Install a delayed blower control module in order 12. use service equipment that is certified to meet operating part of the system. Smell 1. Start the engine and run the fan at high speed will remove odors from the air conditioning for 15-20 minutes to dry it. Keep the blower motor run at high speed and obtained from the refrigerant and lubricant insert the drawtube of deodorizer GM P/N manufacturers.1. odors may come out 8. goggles and gloves drawtube has been reached. service. The musty odor is caused by microbial growth in the evaporator core. Coolant Smell The heater core pipes or hoses are leaking. Disconnect the clutch coil. gasket mixture. Drill a hole of 1/8 inch at a position that will not ventilated area.1.As climate changes. Seal the 1/8-inch hole with body sealant or RTV is available through GMSPO. Under tropical climatic conditions. may irritate the eyes. 12370470 into the hole until the mark on the Caution: For personal protection.If an accidental system discharge occurs. evaporator core will also create such odors.1.4. A single application of deodorizer GM P/N 12370470 11. A repair kit 10. system.1 Correction of Odor period.16 Odor Diagnosis Problem Possible causes Corrective measure There may be musty odor under certain climatic or operational conditions. This will shut down Tools required the operationof the A/C compressor clutch. Musty or mouldy evaporator core Clean the evaporator.2Refrigerant Recovery and the forced ventilation device from outside air.Dispense the fittings.If R-134a comes in contact with any part of the body severe . valves.

If any never be mixed.An automatic multipass filtering cycle will result in poor system performance or component be used for the exhausting process. These filtering failure. in the recovery process. Refer to Addition of Refrigerant Oil in Sepcifiections.1-32 Repair guidance Heating. the same amount of refrigerant Notice: R-12 refrigerant and R-134a refrigerant must oil should be added in the recharging process. R-134a A/C system and only 525 viscosity mineral oil Addition of refrigerant oil on fitting threads and O-rings. the are mixed. even in the smallest of amounts. cycles ensure a constant supply of clean and dry Notice: To avoid system damage use only R-134a refrigerant exists for the A/C system charging. prompt medical help should be obtained. compressor failure is likely to occur.If the refrigerants component replacement or accidental loss. Ventilation and Air Conditioning System frostbite and personal injury can result. compressor failure and/or If refrigerant oil of the A/C system has been discharged fitting seizure may result. please call 86- Refrigerant Oil (PAG) for internal circulation through the 10-6496-5588 then switch to 0305 or 0306. dedicated tools when servicing the A/C system.The recovery procedure uses one in this vehicle. .If lubricants other than those specified are used.Refer to refrigerant oil should be added.The use of any other refrigerant may filtering cycle. as reduction of the refrigerant has been caused by they are incompatible with each other. Notice: Use only Polyalkylene Glycol Synthetic For ACR4 technical assistance in China. The J 39500-B removes the Refrigerant-134 a from the Notice: R-134a is the only approved refrigerant for use vehicle's A/C system. Initial Installation Manual provided with J39500-B.The exposed the manufacturer instructions included with the service area should be flushed immediately with cold water and equipment before servicing.

5.1. 6. the air filter housing assembly and the suction hose. Loosen the drive belt.3 Replacement of Compressor Assembly Removal procedures 1. Remove the air intake hose. 4. 105001 5. Drain the A/C system. Install a dust cover on the compressor and the hose immediately. Remove the refrigerant hose assembly from the compressor (1).Heating. 2. Remove the drive belt. 105002 . Ventilation and Air Conditioning System Repair guidance 1-33 1. 3.

Remove wire connector from the compressor clutch. Remove the front bracket of the compressor. 105003 8. 105005 . Ventilation and Air Conditioning System 7. 105004 9. Remove the reat bracket of the compressor.1-34 Repair guidance Heating.

Remove the compressor oil screw plug assembly. Record the volume of compressor oil. Pour new compressor oil into a clean container. and the volume being charged should equal to the amount of oil that has been drained from the oil compressor. Ventilation and Air Conditioning System Repair guidance 1-35 10. Screw on the oil screw plug. 105007 . and let the compressor oil flow into the container.Heating. Make records. 105006 Installation procedures 1. Charge the new compressor. Tighten Tighten the oil screw plug to 15-20N m.

5. Connect refrigerant hose to the compressor. 105005 4. 105004 3. Tighten Tighten the bolts to 30-40 N m. Ventilation and Air Conditioning System 2. Use bolts to install the compressor onto the rear bracket. Apply mineral oil on the new sealing member. Tighten Tighten the bolts from compressor hose assembly to the compressor to 33 N m. Tighten Tighten the bolts to 30-40 N m.1-36 Repair guidance Heating. Connect wire connector to the compressor clutch. 105008 . Use bolts to install the compressor onto the front bracket. 6.

Tighten Tighten the bolts of the tensioner to 22-30 N m. 9. Remove the seal. and tighten the bolts of drive belt tensioner. 8. 105009 1. 2. Ventilation and Air Conditioning System Repair guidance 1-37 7. Install drive belt. Install air intake hose and air filter housing.1.4 Replacement of Compressor Control Valve Removal procedures 1. 3. Pull the control valve out of the compressor housing.Heating. Drain and recharge the A/C system. 105010 .5. Drain the A/C system.

5. Ventilation and Air Conditioning System Installation procedures 1. 2.1. 2. Use O-ring to seal the control valve.4 Replacement of Compressor Control Valve Assembly (V5 . Install the compressor onto the fixture. Remove the compressor control valve retaining ring with an internal snap ring plier. Install the control valve into the compressor housing. 105010 1.1-38 Repair guidance Heating. 105011 . Drain and recharge the A/C system. 3. Remove the compressor control valve from the compressor.Direct mount) Removal procedures 1. 3.

105011 1. Install compressor control valve retaining ring with an internal snap ring piler. Ventilation and Air Conditioning System Repair guidance 1-39 Installation procedures 1. release the pressure in the A/C system. Remove HPRV form the rear side of the compressor. Coat the O-ring with clean 525 viscosity refrigerant oil. it indicates HPRV is working.5.1. 4. Before disassembly. Removal procedures 1. Push the compressor control valve into the compressor with thumb pressure.Heating. 3.6 Replacement of compressor Pressure Relief Valve (V5-Directly- mounted) Notice: If there is no label on 1. and make sure the retaining ring has been properly fixed to the annual recess. Remove the compressor from the fixture. 2. 105012 . 2. Drain the A/C system.

Recover the refrigerant. Rotate the shaft several times. Remove the J 39893.7 Compressor Leak Testing (V5 Directly-mounted) Tools required J 39893 J 39500-B J 39400-A 1. With the compressor in a horizontal position. install the J 39893 on the rear head of the compressor. 8. Tighten Tighten the bolts connecting to the compressor housing to 6-10 N m. 11.5. 4. check for leaks at the following locations: Pressure Relief Valve Rear head switch Front head seals 105014 Rear head seals Through bolt head gaskets Compressor shaft seal 7. Disconnect the hoses from the J 39893. Ventilation and Air Conditioning System Installation procedures 1. 9. Screw the HPRV onto the compressor housing. 3. Recheck for leaks following any repair. 3.1-40 Repair guidance Heating. With the sealing washers in place. 6. Seal the new O-ring with mineral oil. Perform the measures necessary to correct any external leaks found. 5. 2. rotate by hand the compressor shaft in the operating direction. 2. Using the J 39400-A. Drain and recharge the A/C system. 10.1. Connect the gage charging lines and the J 39500-B. . Pressurize the suction and the high-side of the compressor with R-134a refrigerant. 105013 1.

discard the O-ring and the covering cap. For banjo-style fittings: carefully slide the new O- ring seal (1) onto the A/C refrigerant hose until seated. carefully clean the sealing surfaces of the A/C refrigerant hose and the A/C refrigerant component. Disconnect the A/C refrigerant hose and the A/C refrigerant component. Note: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seals to enter the refrigerant system. 3. 5.Refer to Refrigerant Recovery and Recharging. or tape the hose and the refrigerant component to prevent pollution. 4. 3. Note: Cap or tape the open A/C refrigerant hose and the A/C refrigerant component immediately.5. 105016 . For banjo-style fittings: carefully slide the new O- ring seal (1) onto the A/C refrigerant hose until seated. 105015 Installation procedures 1. Remove the cap or tape from the A/C refrigerant hose and the A/C refrigerant component. Remove air filter and air-duct assembly.Heating. 5. Recover the refrigerant.1. Lightly coat the new O-ring seals (1) with mineral base 525 viscosity refrigerant oil. Using a lint-free clean. For compression-style fittings: use spare wrench to lock the A/C refrigerant pipeline (of smaller size) connector (2).8 Replacement of O-ring Seals Removal procedures 1. 2. Ventilation and Air Conditioning System Repair guidance 1-41 1. For banjo-styel fittings: remove the clamping bolts/nuts retaining the A/C refrigerant hose to the A/C refrigerant pipeline. 4. then loosen the A/C refrigerant hose (of larger size) connector (2). 2. dry cloth.

then tighten to specification. Ventilation and Air Conditioning System 6. 7. Check the A/C refrigerant hose(s) to the A/C component(s) joints for leaks. For compression-style fittings: use a spare wrench to lock the A/C refrigerant pipeline (of smaller size) connector (2). install the bolt retaining the A/C refrigerant hose to the A/C refrigerant component. 8. 9.1-42 Repair guidance Heating. 105017 10. Install air filter and air-duct assembly. Install the A/C refrigerant hose to the A/C refrigerant component.Refer to Leak Testing. Allow a light coating of the refrigerant oil to remain on the A/C refrigerant hose in the area indicated (2) only. Evacuate and charge the refrigerant system. For banjo-style fittings. 12. Lightly coat the new O-ring seals (1) with mineral base 525 viscosity refrigerant oil. 11. 105015 .Refer to Refrigerant Recovery and Recharging. 13. then retighten the A/ C refrigerant hose (of larger size) connector (2).

105019 .Heating. Drain the A/C system.9 Replacement of Evaporator Pipe (Liquid Pipe) Removal procedures 1. Disconnect the evaporator intake pipe with the expansion valve and the condenser. Ventilation and Air Conditioning System Repair guidance 1-43 1.5. 105018 2.1.

Disconnect the evaporator outlet pipe with the condenser. Connect the evaporator outlet pipe with the condenser. 105020 Installation procedures 1. 105020 . Tighten Tighten the nut of liquid pipe connector to 16 N m.1-44 Repair guidance Heating. Ventilation and Air Conditioning System 3.

105019 3. Ventilation and Air Conditioning System Repair guidance 1-45 2. 105018 . Tighten Tighten the bolt of liquid pipe at the expansion valve to 16 N m.Heating. Drain and recharge the A/C system. Connect the evaporator intake pipe with the condenser.

Ventilation and Air Conditioning System 1. 105022 . Remove the compressor hose nut from the condenser.5. Recover the refrigerant. 3. 105021 4. Disconnect cables at the negative pole of the battery.1. Disconnect the evaporater pipe and the compressor hose.1-46 Repair guidance Heating.10 Replacement of Compressor Hose Removal procedures 1. 2.

105022 2. Install the compressor hose to the condenser. Refer to Leak Testing. Tighten Tighten the compressor hose connector at the evaporator hose assembly to 36 N m. Ventilation and Air Conditioning System Repair guidance 1-47 Installation procedures 1. Connect the evaporater pipe and the compressor hose. 105021 . 4.Tighten the compressor hose nut. Refer to Refrigerant Recovery and Recharging. Inspect system for any leakage. Connect cables at the negative pole of the battery.Heating. Evacuate and recharge the system with refrigerant. 3. 5. Tighten Tighten the bolts retaining the compressor hose assembly to the condenser to 16 N m.

Evacuate and recharge the system with refrigerant. Ventilation and Air Conditioning System 1. Tighten Tighten the pipelines to 4-6 N m. Recover the refrigerant. Install A/C pipelines connected to the expansion valve. 4. 3.1-48 Repair guidance Heating. 3. Remove A/C pipelines connected to the expansion valve. 2. 2. Remove the expansion valve. 105023 . Install the O-ring seal. Install the expansion valve. Tighten Tighten bolts of the expansion valve to 4-6 N m.11 Replacement of Expansion Valve Removal procedure 1.1. 105023 Installation procedures 1. Remove the O-ring seal.5. 4.

105022 3.1. Remove the nuts of liquid pipelines from the condenser. Remove the compressor hose bolt from the condenser.5.12 Condenser Replacement Removal procedures 1. Drain the A/C system. 4. 5. 2. Remove the condenser.Heating. Remove the upper bracket of the condenser. Ventilation and Air Conditioning System Repair guidance 1-49 1. 105021 .

105022 . Evacuate and recharge the A/C system. Screw the compressor hose bolt onto the condenser. Tighten Tighten the bolts retaining the compressor hose assembly to the condenser to 16 N m.1-50 Repair guidance Heating. 105021 4. 3. Ventilation and Air Conditioning System Installation procedures 1. Screw on the bolts of condenser upper bracket. 2. 5. Tighten Tighten the nuts of the condenser hose connector to 16 N m. Tighten Tighten the bolts of the condenser upper bracket to 4-6 N m. Install the condenser. Screw on the liquid pipeline nuts on the condenser.

13 Replacement of Condenser Seals Removal procedures 1. refer to Condenser Replacement. 2. Remove the upper and lower seals.5. Remove the condenser.1.Heating. Install the upper and lower seals. Ventilation and Air Conditioning System Repair guidance 1-51 1. 2. 105024 Installation procedures 1. refer to Condenser Replacement. Install the condenser. 105024 .

105025 Installation procedures 1.1. 105025 . 2. 2. Disconnect the fan. the protective case and the motor. refer to Condenser Replacement. Ventilation and Air Conditioning System 1.14 Replacement of Condenser Fan Removal procedures 1. Install the fan. the protective case and the motor. Tighten Tighten the bolts of condenser fan to 2 N m.1-52 Repair guidance Heating.5. Install the condenser. refer to Condenser Replacement. Remove the condenser.

Tighten the pressure switch to 11-14 N m. refer to Condenser Replacement. Install the condenser. Remove the container bolt and the pressure switch.15 Replacement of Liquid Container Removal procedures 1. refer to Condenser Replacement. Remove the condenser. 2. 105026 .Heating. 105026 Installation procedures 1.1. 2. Tighten Tighten the container bolts to 4-6 N m. Ventilation and Air Conditioning System Repair guidance 1-53 1. Install the container bolt and the pressure switch.5.

5. 105027 Installation procedures 1. Disconnect the electric connector of the blower motor resistor. Connect the connection between the blower motor and the blower motor resistor. Connect cables at the negative pole of the battery. 5. 4.1. Install air filter and its housing. 3.16 Blower Motor Resistor Replacement. Refer to Replacement of A/C box. Remove the resistor. Tighten Tighten the resistor bolts to 2 N m. Connect the electric connector of the blower motor resistor. 3. 2. Remove air filter and its housing.5. Ventilation and Air Conditioning System 1. 4. 2.1-54 Repair guidance Heating. Install the resistor. Disconnect cables at the negative pole of the battery. refer to Replacement of A/C box. Disconnect the connection between the blower motor and the blower motor resistor. Removal procedures 1. 105027 .

Connect cables at the negative pole of the battery. Replace the blower motor and the fan. 3. 105028 Installation procedures 1. Tighten Tighten the blower motor bolts to 2 N m. Connect the blower motor electrical connectors. 2. 2. Install the blower motor. Ventilation and Air Conditioning System Repair guidance 1-55 Replacement of Blower Motor and Blower Fan. Removal procedures 1. Disconnect the blower motor electrical connectors. Remove the blower motor. 105028 .Heating. 3. 4. Disconnect cables at the negative pole of the battery.

1. remove the coolant pot by unscrewing the bolt shown in the figure. Loosen the clamp. 2. 6.1-56 Repair guidance Heating.18 Replacement of A/C box Removal procedures 1. 105030 . Open the engine hood.5. Ventilation and Air Conditioning System 1. 5. release the engine cooling system pressure. If necessary. Uncap the engine coolant pot. 105029 4. 3. Remove the heater intake/outlet hose. then screw on the cap. Place a container under the hose.

12. 13. Ventilation and Air Conditioning System Repair guidance 1-57 7. 105034 . 105023 10. Evacuate the A/C system. Disconnect the connection between the blower motor and the blower motor resistor. Remove the A/C duct. Remove the air filter from its housing. Unscrew bolts on the housing. 8. Remove the housing. Unscrew bolts of the expansion valve. Cover the expansion valve and the refrigerant hose with a dust cover. 105031 Note: Cover foot area to prevent the coolant dropping down to the carpet. 9.Heating. Remove air distribution duct 14. 11.

16. 2. Tighten Tighten the bolts to 2. Cluster Gauge and Auxiliary Instrument Board.Refer to Replacement of Instrument Board in Instrument Board.0-4. 105036 . Ventilation and Air Conditioning System 15. replace the heater seal.1-58 Repair guidance Heating. If necessary. Install the A/C box onto the front boarding.0 N m. Remove the A/C box. 105035 Installation procedures 1. Remove the instrument panel.

Install the clamping collars onto the heater hose. Ventilation and Air Conditioning System Repair guidance 1-59 3. 105031 6. Connect the air distribution duct with the connector. Connect the heater intake/outlet hose. 105039 .5 N m. 7.Heating.0 N m. Tighten Tighten the bolts to 2.0-4. Assemble the air filter and install it to its housing. Tighten Tighten the bolts to 3-3. 105037 5. 4. Screw on the bolts to retain the heater intake/ outlet and the expansion valve.

12. Install coolant pot. Ventilation and Air Conditioning System 8. 11. Remove the transport cover on the expansion valve and the refrigerant pipeline. Charge the engine cooling system to "COLD".1-60 Repair guidance Heating. 105040 9. Tighten Tighten the bolt of liquid pipe at the expansion valve to 16 N m. Evacuate and recharge the A/C system. 10. 105023 . Install the refrigerant pipeline. Seal the new O-ring with mineral oil.

Remove the A/C box. Remove the supporting rack. refer to Replacement of A/ C box. 105042 . Ventilation and Air Conditioning System Repair guidance 1-61 1. Remove the side cover. Remove all seals of the A/C box. 3. 105041 4.1.Heating.5. 2.19 Replacement of Heater Core in A/C box Removal procedures 1.

Install the heater core. Remove the heater core. 105043 Installation procedures 1. 105043 .1-62 Repair guidance Heating. Ventilation and Air Conditioning System 5.

105042 3. refer to Replacement of A/C box. Tighten Tighten the bolts to 2. Ventilation and Air Conditioning System Repair guidance 1-63 2. Tighten Tighten the bolts to 2.0 N m.0-4. Install the A/C box. 4. 5.Heating.0 N m. 105041 . Install all seals of the A/C box.0-4. Install the side cover. Install the supporting rack.

1-64 Repair guidance Heating.5. The same with Removal procedures in Replacement of Heater Core in A/C box. 2. Ventilation and Air Conditioning System 1.20 Replacement of Evaporator Core in A/C box Removal procedures 1. Remove the upper part of the A/C box.1. Remove the upper seal. 105244 3. 105245 .

Remove the evaporator core. 105046 5. Ventilation and Air Conditioning System Repair guidance 1-65 4. Remove the thermistor.Heating. 105047 .

105047 2. Ventilation and Air Conditioning System Installation procedures 1. Install the evaporator core.1-66 Repair guidance Heating. 105046 . Install the thermistor.

Heating. 5. 105245 4. Install the upper seal. Ventilation and Air Conditioning System Repair guidance 1-67 3. Install the upper part of the A/C box. The same with Installation Procedures in Replacement of Heater Core in A/C box. 105244 .

5.1-68 Repair guidance Heating. 3.21 Replacement of Heater Hose Removal procedures 1. 2. 105029 4. 105030 . 6.5. Use a clamping collar to clamp the coolant hose. Remove the bolts of coolant pot. Ventilation and Air Conditioning System 1. Tighten the coolant pot cap.1. Unscrew the cap of coolant pot (middle arrow) and depressurize the cooling system. Place a collecting pot under the hose to collect spilling coolant. Loosen the clamping collar and remove the refrigerant hose connecting to the heater core from the connection socket.

Insert the refrigerant hose into the inlet/outlet metal tube of the heater core. 4. 105039 3. 5. 105073 . Add refrigerant as required. 2.Heating. Clamp the hose with a clamping collar. Close the coolant pot. Ventilation and Air Conditioning System Repair guidance 1-69 Installation procedures 1. Install the coolant pot.

105049 . Remove the windshield wiper arm assembly.1.22 Replacement of Passenger Cabin Air Filter Removal procedures 1.5. 105048 3. Disconnect earth lead from the battery. Pry open the air intake grille at the center of it and remove the two halfs of it one after another from the air compression room. Refer to Replacement of Wiper Arm Assembly in Windshield Wiper/Washer System. 2.1-70 Repair guidance Heating. Pull away the engine hood sealing members (2) from the front boarding. Remove bolt (1) in the air intake grille plate. Ventilation and Air Conditioning System 1.

Ventilation and Air Conditioning System Repair guidance 1-71 4. Remove plastic nut (1) from the shift driving shaft of the two wipers. and pull down the dasher (2). 105050 5. 105051 .Heating. On vehicles with clean air filters. loosen the fixing clip of the filter and remove the filter from the filter case.

Tighten Tighten the bolts to 1.0-1. Install the two halfs of the air intake grille board and beginning from outside use Philips screws (1) to tighten them. 5. 2. Connect the engine connecting seal (2) to the front boarding. Ventilation and Air Conditioning System Installation procedures 1.5 N m. 105049 . Install expansion nut (3) to fasten the air intake grille board. 105050 4. and screw the plastic nut (1) onto the shift driving shaft.1-72 Repair guidance Heating. Push the dasher (2) under the edge of the windshield. 3. Insert the filter into the filter case and lock the fixing clip. Unscrew the bolt retaining the clean air filter case in the air compression room.

105052 .5. Gauge and Console. Ventilation and Air Conditioning System Repair guidance 1-73 6. 7.5. Through this gap pry the nozzle case out of the slewing cam. Refer to Replacement of Wiper Arm Assembly in Windshield Wiper/Washer System. Install the windshield wiper arm assembly.1. Use a plastic wedge to turn the mixing air nozzle case backwards to the stopper so that a gap as wide as 1.24 Replacement of Mixing Air Nozzle Case Notice: All mixing air nozzle cases are identical and interchangeable. Connect earth lead to the battery.5 cm can be seen on the upside edge.23 Replacment of Controller Assembly Refer to Replacement of A/C Controller . Removal procedures 1.Heating. 105080 1. 1. then pull it out upwards and backwards.1.Central Control Board in Instrument Panel.

Turn the mixing air nozzle.1. Remove fuse box bolts (2) from the instrument panel and place it the driver's legroom.5. Separate the mixing air nozzle from the air distribution duct and remove it from the instrument panel. Ventilation and Air Conditioning System Installation procedures 1. 3. 2.25 Replacement of Air Distribution Duct . 4. Disconnect earth lead from the battery and remove the cover of the fuse box.Driver Side Removal procedures 1.1-74 Repair guidance Heating. According the profile of the nozzle case. 105053 1. Remove bolts (1) from the mixing air nozzle housing. lead the mixing air nozzle case into the housing until it is seated with a "click" sound. 105254 . 5.

Disconnect the air distribution duct from the port of air distributor housing (3). 105058 Installation procedures 1. 2. Tighten Tighten air duct bolts to 1. Install the mixing air nozzle. Connect earth lead to the battery.5 N m. 6.5-2. 3.5 N m. Use bolts to tighten fuse box to the instrument panel (5). To facilitate the installation.5-2. . Pull air distribution duct (1) through the opening of the mixing air nozzle housing (4). Ventilation and Air Conditioning System Repair guidance 1-75 6. 7. 105254 5. Connect the mixing air nozzle housing to the air distribution duct and use bolts to tighten it onto the instrument panel (6). Tighten Tighten the bolts to 1. Install air distribution duct into the groove of the shear plate that passes through the opening of the mixing air nozzle housing and is located at the port of the air distributor housing. the hose can be bended with the shear plate at "Service groove". 4.Heating. and pass it through the groove of the shear plate outside the instrument panel.

1. loosen it from the air distribution duct. Ventilation and Air Conditioning System 1. Remove the mixing air nozzle. then remove it from the instrument panel. Cluster Gauge and Auxiliary Instrument Panel. 815206 3. Remove the bolts (1) of mixing air nozzle housing from the instrument panel. Refer to Replacement of Glove Box in Instrument Panel. 2. Remove glove box from the instrument panel.25 Replacement of Air Distribution Duct .Front Passenger Side Removal procedures 1.5. 105256 .1-76 Repair guidance Heating.

Install the grove box. Ventilation and Air Conditioning System Repair guidance 1-77 4. 4. 2. lead the mixing air nozzle case into the housing until it is seated with a "click" sound. Connect the mixing air nozzle housing to the air distribution duct and use bolts to tighten it onto the instrument panel (1). 3. According the profile of the nozzle case.Heating.5-2. Remove the air distribution duct from connecting devices in the air room. 105256 . 105057 Installation procedures 1. Tighten Tighten the bolt retaining the air duct to the instrument panel to 1.5 N m. Put the air distribution duct through the opening on the instrument panel used by the grove box. then insert it into the port of air distributor housing.

Ventilation and Air Conditioning System Replacement of Body Pressure Relief Valve Removal procedures 1.1-78 Repair guidance Heating. 105061 . 105060 Installation procedures 1. 2. Unbolt body pressure relief valve. Remove inner air door. 2. Install inner air door. Connect body pressure relief valve.

Remove drainage hose (outside the A/C box). 105063 . Remove drainage hose (1). Set the carpet aside. Remove the A/C box.5. 5. refer to Replacement of A/ C box.1. 105062 4. 2. Ventilation and Air Conditioning System Repair guidance 1-79 1.Heating. 3. Remove drainage hose (inside the A/C box).28 Replacement of Drainage Hose Removal procedures 1.

the position indicated by the arrow can be coated with soap. 105064 1. 3. 4. Ventilation and Air Conditioning System Installation procedures 1.29 Replacement of Heat Distribution Box Rocker Removal procedures 1. Connect the opening to the hose of the A/C box. Thread the nozzle part through the front boarding and insert it into the engine room. Lay the carpet again. 105065 . refer to Replacement of A/ C box.5. Disconnect the rocker from the distribution box.1-80 Repair guidance Heating. Remove the A/C box. To facilitate installation. 3.1. 2. Remove assembling bolts and sealing members. 2.

2. Ventilation and Air Conditioning System Repair guidance 1-81 Installation procedures 1. refer to Replacement of A/ C box.Heating. Tighten Tighten the rocker bolts to 2.0 N m. Remove the A/C box. 105065 1. refer to Replacement of A/C Box.0-4. Install the A/C box. 105066 . Connect the rocker and the distribution box. Disconnect the rocker from the air door.1.30 Replacement of A/C and Defrosting Air Door Rocker Removal procedures 1. 2. Install assembling bolts and sealing members. 3.5.

Ventilation and Air Conditioning System Installation procedures 1. 3. refer to Replacement of A/ C box. 4. 105066 1. Remove assembling bolts. Install the A/C box. Remove the actuator. Disconnect the actuator harness connector.5. 2.31 Replacement of Fresh Air Door Actuator Removal procedures 1. 5. Remove actuator control rod. Remove the A/C box.1. Connect the rocker and the air door. refer to Replacement of A/C Box. 2.1-82 Repair guidance Heating. 105200 .

Connect the actuator harness connector.Heating. Refer to Replacement of A/C box. 2.1. Install the A/C box. Refer to Replacement of Heat Distribution Box Rocker 105068 . Use bolts to install the actuator. 3.0-4.32 Replacement of Heat Distribution Duct Removal procedures 1.Refer to Replacement of Heater Core in A/C Box 3. 105200 1.0 N m. 2. Remove the heater core. Ventilation and Air Conditioning System Repair guidance 1-83 Installation procedures 1. Install actuator control rod. Remove the A/C box. refer to Replacement of A/C Box. 4. Tighten Tighten the bolts to 2.5. Remove the rocker.

Disconnect the air door.1-84 Repair guidance Heating. 105069 Installation procedures 1. Connect the air door. Ventilation and Air Conditioning System 4. 105069 .

5.Heating. Remove the A/C box. 2. refer to Replacement of A/C Box Heater Core. 105070 . Ventilation and Air Conditioning System Repair guidance 1-85 2. 4.33 Replacement of Fresh Air Door Removal procedures 1. 3.1. Disconnect the heater and the evaporator box. 105068 1. Install the A/C box. Refer to Replacement of Heat Distribution Box Rocker Arm. Install heater core. Install the rocker. refer to Replacement of A/ C box. refer to Replacement of A/C Box.

Remove the air door. 105272 . Ventilation and Air Conditioning System Desc riptio 3. n and Oper ation 105071 4. 1-86 Description and Operation Heating. Remove the fresh air door rocker.

105272 2. Ventilation and Air Conditioning System Description and Operation 1-87 Installation procedures 1. Install the fresh air door rocker. Install the air door. 105071 .Heating.

Connect the heater and the evaporator box. Ventilation and Air Conditioning System 3. 4. 105070 . refer to Replacement of A/C Box.1-88 Description and Operation Heating. Install the A/C box.

occupants Forced ventilation The valve maintains a bleed from the crankcase to suction.Air moisture condenses on the wobble-plate.This control valve is located in the rear head of the compressor.This routing permits lubrication of the evaporator core fins. Through the evaporator core crankcase to the suction plenum. Low air temperature Air Conditioning The refrigerant in the system flows from the high pressure side to the low pressure side of the expansion Air conditioning system has a V5 compressor. . Air conditioning system is not running. any of the following condition is present.The rotation acts as an oil removes the moisture from the vehicle. air coming from evaporator will pass through According to the service condition of the engine.The rerouted oil can lubricate the through the heater core.A gravity feed through a drain hole wobble-plate bearing. Windshield defrosting No crankcase-suction pressure differential Side Window Defogging exists.6. refer The wobble-plate angle to the service manual and the manufacturer instruction provided with the repair equipment.This action separator. mode. The air from the passenger Low idle speed compartment is usually cooler than the outside air. Before performing the repair. vehicle in the following manners: The following actions occur when the A/C capacity The blower motor inhales outside air through the demand is lower and the suction pressure reaches the A/C bellows.6Description and Operation 1. The engine is turned off. Air will travel along the following path in the bellows: The valve closes off a passage from the 1. Into the passenger compartment the wobble plate. and senses the Notice: The refrigerating system of this vehicle uses R- suction pressure of the compressor. compressor will be shut down: you can turn to RECIRC (recycle) mode. Before repairing the system.You can start up the air conditioning or wobble plate.A slight increase of the crankcase- suction pressure differential changes the total force on If the ambient temperature is above 3C. During most operating conditions. crankcase-suction bleed and rerouted to the From the evaporator. Ventilation and Air Conditioning System Description and Operation 1-89 1. then warmed up by the engine coolant.1 Description of A/C System The basic compressor mechanism is a variable angle wobble-plate with five axially oriented cylinders. outside air enters the The compressor has maximum displacement. the air crankcase-suction bleed is routed through the rotating temperature drops.This change affects the movement around refrigeration system will chill the evaporator to almost the wobble-plate pivot pin and reduces the angle of the freezing. ensure correct repair The crankcase suction pressure differential controls the equipment will be used. crankcase.1. the the pistons. The compressor has a unique lubrication system.1.If the system is in heating compressor mechanism.The As the air passes through the evaporator. Through the heater core A force balance on the five pistons controls the angle of 3.Some of the oil is removed from the dehumidifies the air. a refrigerant incompitable with R-12 refrigerant. so that most Wide-open throttle of the air coming into the blower motor is from the passenger compartment. 2. 134a. when heater core. Operation of Heating-Ventilation-Air A bellows actuated control valve determines the Conditioning System compressor displacement. V5 (orifice) tube when the following conditions exist: compressor can satisfy the vehicle's air conditioning requirement without recycle on any condition. otherwise the system will be following: severely damaged. defrosting function. The compressor displacement The A/C system provides the following features: The following actions occur when the A/C capacity demand is high: Cooled or dehumidified air for the comfort of the The suction pressure is above the control point. control point: The forward movement of the vehicle forces in The valve bleeds discharge gas into the outside air.Heating. some or all of the air may pass crankcase. the If the maximum air conditioning function is required.

106001 106003 DEFOG FACE (Blowing-to-the-face mode) Air flows through outlets on the floor. Ventilation and Air Conditioning System The refrigerant continues to flow until the pressure is equalized.1-90 Description and Operation Heating.This action may cause a faint sound of liquid flowing (hissing) for 30 to 60 seconds.The sound is a normal condition. Air flows through the HVAC system as described for each of the following modes: OFF Slight exhaust from all air outlets 106004 Maximum Recirculated air flows through the instrument panel outlets. Air flows through the instrument panel outlets. Outside air flows through the instrument panel outlets. BI-LEVEL (mixed) NORM A/C Air flows through outlets on the floor and outlets on the instrument panel. outlets on the instrument panel and the defrost outlet. heated and outside air through the air ducts.6. . 1. Various positions on the control cause the mode valves to mix and direct cooled.1.2 Description of Air Distribution System A stay wire is used to control the air flowing through the system.

medium used in the A/C system to absort. Polyalkylene Glycol Synthetic Refrigerant Oil (PAG). Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings.Work in a well.6. Use only Polyalkylene Most air flows through outlets of the defroster.If an accidental system discharge occurs.1. compressor failure and/or fitting seizure may result. transmit and Refrigerants in A/C system have the following release heat. the lubricants and maintaining equipment they Releases heat . Absorbs heat and liquefied gas.4 Odor Desceiption obstructions such as leaves. and throat.In order to remove R-134a from the A/C may irritate the eyes. Ventilation and Air Conditioning System Description and Operation 1-91 use are different.1. uncombustible.Additional health and safety information may be ventilate the work area before continuing obtained from the refrigerant and lubricant service. The PAG refrigerant of the GM Company has a slight blue colour.e. This oil can absorb moisture (capable of water absorption).3 Refrigeration System Description 1. Carries heat Although R-134a A/C system is similar to the R-12 system. Inspect the following air passages for 1. colourless.Heating. use service equipment that is certified to meet ventilated area. obtained from the refrigerant and lubricant Similar to the function of engine coolant.e. i. Side window demister Odor in A/C system can be cleared away with Goodwrench A/C deodorizer. Notice: R-134a refrigerant is uncompatible with R-12 refrigerant in A/C system. This vehicle uses refrigerant -134a (R. passenger compartment.6. 1.6. i. This odor may be caused by residues The A/C ducts in the heater and evaporator subassemblies.Additional health and safety information may be manufacturers. nose. the requirements of SAE J 2210 (R-134a recycling ventilate the work area before continuing equipment). functions: 134a).Exposure Caution: Avoid breathing the A/C Refrigerant 134 a (R- may irritate the eyes. which primarily comes The heater duct out from A/C system when it is started under hot and humid condition.If an accidental system discharge occurs.Work in a well- system. R-134a contains a special kind of lubricant. 134a) and the lubricant vapor or the mist. Obstructions in these ducts and outlets will block the free output of air. a nontoxic. refrigerant oil deposition. The PAG refrigerant of GM Company has a slight blue colour.Using other lubricants will cause failure of the compressor or the fittings. Using R-12 in a system with R-134 will cause compressor failure. service. clear. nose.Exposure ventilated area.If A system of ducts and outlets directs air to the lubricants other than those specified are used.5 Refrigerant R-134a Caution: Avoid breathing the A/C Refrigerant 134 a (R- 134a) and the lubricant vapor or the mist.1. or it may The vent ducts be caused by a mouldy evaporator core. Polyalkylene Glycol Synthetic Refrigerant Oil 106002 (PAG). This oil can absorb moisture (absorbing moisture from atmosphere) and should be DEFROST strored in an airtight container. dirt or other objects: The defroster duct Some vehicles may have odor. R- 134a refrigerant contains a special kind of lubricating oil. use service equipment that is certified to meet equipment). and throat.In order to remove R-134a from the A/C the requirements of SAE J 2210 (R-134a recycling system. therefore it should be stored in an airtight container. or A/C system performance degradation. refrigerant is a manufacturers. Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only Air ducts and air outlets 525 viscosity mineral oil on fitting threads and O-rings.

a distance of 63. This will prevent any of the following items from entering the line: All R-134a disposable containers (coated with blue color) are shipped with a heavy metal - Moisture screw cap.1.8 Handling Method of Refrigerant - The valves Tubes and Fittings - The onnections Ensure none of the following conditions exists in Work in a well-ventilated area. use a piece of clean cloth to wrap the following positions: - The tube fittings 1.Don't inhale the metal tubes. Before commencing any repair operation that Inspect the flexible hose lines regularly. clear and colourless liquefied gas. Don't reuse refrigerant oil taken out from the A/C system.5 mm (2. drain all of refrigerant R-134a. this screw cap should be replaced to continue to protect the valve and the safety plug. connections on the O-ring fittings.6. the system capability caused by obstruction in Don't perform welding or evaporating cleaning pipelines. Cap the container immediately handling procedures should be followed to prevent any after using it. please complete the following less that 4 times the diameter of the hose. Compressor oil in an open or unsealed container will please wear grooves.5 in) of the exhaust - Have medical inspection immediately. - Addition of refrigerant oil Once you open a refrigerant line to the - Drain the refrigerating system.6.6. the local laws and regulations. has to open the pipelines or components of a Replace the flexible hose line with new hose if refrigerant system.7 Handling Method of Compressor Refrigerant -134a is a nontoxic. Oil Extract and use authorized compressor oil from closed and sealed container. Whenever you open the refrigerant system. uninflammable. - Refill the refrigerating system. the 1. Ventilation and Air Conditioning System These vehicles use refrigerant -134a (R-134a). refer to Handling Method of one of the following conditions exist: Refrigerant Pipelines and Fittings and How to Maintain Chemical Stability. manifold. 1. Always extract and use authorized personal injury: compressor oil from closed and sealed container. operations near vehicles equipped with A/C - Dents tubes or components. operations: Do not allow the flexible hose line to come within - Flush the exposed area with water. - Leaks Instructions should be strictly followed when - Brittleness performing the following repair works: - Deterioration - Recovery and recirculation of Disconnecting any fitting in the refrigerating refrigerant system. After the container has been used. so as to reduce pollution as much as possible. atmosphere.6 Handling Procedure of Refrigerant conveyor system and the container should be clean R-134a and dry. Don't open the refrigerant of this vehicle.1-92 Description and Operation Heating.1. - Kinks If any part of your body comes into contact with Do not bend the flexible hose line to a radius of R-134a. oil container until the maintenance procedure requires Whenever you use R-134a. the following special to use the refrigerant oil. When adding refrigerant oil. Refrigerant oil does not contain water. but will readily Refrigerant -134a (R-134a) is used in the A/C system absorb moisture from the air. Back-up the opposing fitting with a wrench in order to prevent distortion of the following areas: - The connecting lines - The components .1. Dispose of wasted oil according Whenever you open the refrigerating system.This screw cap is used to protect the - Dirt valve of the container and the safety plug from Use the proper wrenches when you make any damage. cap or tape the line immediately. absorb moisture. so as to prevent any damage to refrigerant gas.

Replacement interval of air filter is 12 months or 20. Keep PAG synthetic refrigerant oil off the fitting Do not leave the A/C system open any longer threads. moisture or particulate contamination formed in the the windshield. Before opening the package. When there is oil in the cylinder. Ventilation and Air Conditioning System Special tools 1-93 Tighten all of the tubing connections to the Before disconnecting any refrigerant connecting specified torque. these filters may need regular replacement.000 The efficiency of A/C system will decrease. connect rotation will cause damage to the valve and adverse the snap coupling of the A/C system effect to its durability. If the compressor is impacted or turned upside prevent moisture in the air from condensing into down. system. This will down.1. properly exhaust the system and base 525 viscosity refrigerant oil. so as to reduce moisture entering the Do not wipe the threads with a cloth.11 Description of Passenger Compartment Air Filter Chemical stability of the A/C system is critical to the efficient operation and the service life of it. PAG synthetic oil. This will reduce the dust and moisture entering the system. device. Heating.6. According to driving conditions. sudden After removing the maintenance shield. ensure the Don't bump or drop the compressor. maintenance eqipment as quickly as possible. on threads may cause future disassembly Before recharging an A/C system that has been difficulties. ensure the The use of polyalkylene glycol synthetic conveyor system and the container is clean and refrigerant oil (PAG) is forbidden.Flush threads of fitting with mineral opened. These filters are used to filtrate: refrigerating system will have the following results: Fresh air coming into the vehicle The stability of R-134a and PAG synthetic Besides filtrating dirt particles from the air. so as to circulate the oil in the cylinder. or the manifold measuring leak. 1. When adding PAG lubricant.Do not wipe threads with a cloth. - Deformed joint parts Ensure the following items are clean and tidy: - Refrigerant leakage - Tools used for the maintenance - An inoperative A/C system - Surrounding area of the maintenance Ensure that the O-rings and the seats are in operation perfect condition. kilometer. the compressor clutch should be rotated beads on the components. change. units Install new O-rings that you have lubricated with - Replacement parts the mineral base 525 viscosity refrigerant oil. wipe off dust and/or oil. tools following conditions: Cap. Use the following practice to maintain the chemical stability of the refrigerating system: .6.10 Maintaining Chemical Stability 1. air filters are lubricant will change. Abnormal corrosion and/or wearing will occur on internal components of the A/C system.9 The handling of A/C Compressor been made. plug up or tape both ends of open-type - Joints too loose connecting devices. tidy.6. This will reduce Speci al Too much or too little torque may result in the the possibility of particulate contaimination. or turn it upside components are at room temperature. also used to reduce unpleasant air coming into the The symmetry of pressure/temperature will vehicle.Do not use perform vacuum test. Service parts are dehydrated and sealed prior to shipping.Long term contact of PAG synthetic oil than necessary.Leave the components in their hermetic package until preparation for use has 1. The filter is located in the filter housing assembly under Air. manually for 5-6 times.1.1. - The hoses and fittings of ACR4 A burr or a piece of dirt may cause a refrigerant machine.

the following pipeline.6. Before air enters passenger compartment. Each speed is decided by the blower motor resistor.16 Condenser Description Condenser is used to receive high pressure and high temperature refrigerant vapor from the A/C compressor. the following evaporator will cool and dry the air. The refrigerant vaporizes. thus making the refrigerant flowing toward evaporator become low-pressure liquid.1. the following mostly water vapor. It forms restriction to the high-pressure liquid refrigerant in the liquid pipelines. The refrigerant flows through the evaporator in The blower motor runs faster.1. 106005 . the form of low-pressure. The blower motor runs at the lowest speed. the When the blower switch is at position 1. and the cooling fins can transmit heat away from high-pressure and high- temperature refrigerant vapor.6. 4. 2. and flow away in the form of water. it absorbs heat from The blower uses only one resistor. controller. operations occur: 5.1.13 Description of Blower Motor The expansion valve changes position from the big to Resistor the small according to the following conditions: The following components are used together to set the Lower limit of A/C pressure blower speed: Upper limit of A/C pressure The blower resistor The blower switch 1.15 Evaporator Description The blower resistor consists of 3 resistors located in the same housing. low-temperature and When the blower switch is at position 3. Condensor is composed of aluminium pipes and cooling fins. A squirrel cage type fan The blower runs at different speeds. The low-pressure.1. The refrigerant flows through the evaporator When the blower switch is at position 2. The cooling fins will condense high pressure and high temperature refrigerant vapor into high pressure but moderate temperature liquid.6.6. 1. A permanent magnet type motor The blower motor runs at the highest speed. The blower uses two resistors. As the heat is transferred from air to the evaporator core. while the blower 1.1-94 Special tools Heating. the following operations occur: The blower consists of the following components: None of the resistors is used. moisture in the air (humidity) will condense on the surface of the evaporator core.1.14 Description of Expansion Valve motor resistor is controlled by the blower motor speed Expansion is located at the opening of the evaporator. operations occur: 3. 1. The blower motor runs faster. The following operations occur: situations will happen in the evaporator: The blower circuit uses all of the 3 resistors. As the refrigerant vaporize.6. the air flowing through the evaporator. 1.12 Description of Blower Motor When the blower switch is at position 4. Ventilation and Air Conditioning System 1. low-temperature liquid/ evaporating refrigerant enters the evaporator.

Heating.To prevent prolong time. and when inner pressure of the A/C flowing through the heater core.1.6.1.18 Heater Core Desceiption replenish refrigerant that has been removed. When leaks are present for the following reasons. when the pressure core.This liquid container is used to store refrigerant and oil coming from the evaporator.1. The more distance the temperature control knob is turned clockwise. Before repairing the open the alternating circuit of the A/C system. 106006 1. Correct any condition that will cause this valve open. When the engine runs. and 1. any damage to the system.20 High Pressure Relief Valve container cannot be used but should be replaced. heater core or the heater hose.6.The compressor pulley rotates 2. Heater core is the main component of heating system. This operation causes the air flow through the heater core. Heater core is located at the interior of the heater and 1.19 Compressor Description The compressor for the air conditioning system is belt- Legend driven by the engine crankshaft and through the A/C 1. Sensor is applied in order to energize the clutch coil. the temperature valve will prevent airfroms from passing through passages in the heater core. When the temperature control knob is turned to FULL HOT position. the temperature valve begins to guide the air toward the heater core. engine coolant will be pumped into the heater core from Switch Description the engine. (HPRV) Description Perforation Damaged sealing positions The compressor is equipped with a relief valve that plays a safety role in the system. replacement of heater hose should be recorded. until an electromagnetic clutch coil is energized.21 A/C Refrigerating Pressure evaporator subassembly.1.1. No heat transfer happens. The pressure switch will continuously monitor the pressure of A/C system to realize the following Temperature control knob is connect with the functions: temperature valve. Entrance compressor clutch. Under certain Damaged threads on fasteners conditions.6.When voltage 3. this valve is designed to open automatically at approximately 3140 Kpa.6. Export freely. the temperature valve When the pressure exceeds 2940 Kpa. When air is heated in this way. the air exhausted will be warmed up. the refrigerant on the discharge side may Outside air has entered the system in the exceed the designed operating pressure. a clutch plate and hub is drawn toward the pulley. the pressure switch will specific intake and outlet pipe. outlet pipe. The heater core cooling fins are used to A/C refrigerating pressure switch is installed in the transfer the heat from the engine coolant to the air liquid container. The following operations take place: . This operation will make all airflows pass through the heater core. Ventilation and Air Conditioning System Special tools 1-95 1.6. When the temperature control knob is turned away from FULL COLD position. without turning the compressor shaft.17 Liquid Container Description All airflows from the evaporator bypass the heater core. When temperature control knob is turned to FULL COLD position.The magnetic force locks the clutch plate and pulley together as one The sealed accumulator is connected to the evaporator unit in order to drive the compressor shaft. The heater core has system is too high or too low. the 1. switch will cling to the air intake leading toward the heater off A/C clutch. the more air will be guided by the temperature valve to flow through the heater core.

23 O-ring Seal/Plain Washer Desceription Whenever a joint or a connection is torn apart. Before installation. the faster the Rear window defogger speed. Mode Control Using improper service parts and maintenance steps may cause leakage.22 Controller Assembly Description To start A/C system. Replace any damaged part. missed or misused will cause a loss of ducts near the floor. DEFOG: Air is permitted to flow through the floor ducts. When pressing this button again.24 HVAC Blower Controls Circuit window outlets.1. Pressing the Kpa. The right knob uses 4 settings to control the direction of airflow. The left knob changes the temperature of air flowing into the system. Description DEFROST: Most of the air is directed through the defroster and side window outlets. O-ring seals are used to seal refrigerant pipelines.1. outside air that has been filtered will come into the vehicle. cooling An O-ring seal consists of the following components: and ventilation in the vehicle.6. Recirculation and outside air button When pressing this button.Pressing Rear and the A/C system controller through the blower motor Window Defrosting button will start the rear window resistor. the defroster and the side window outlets. turn the knob to the An aluminum tube end with an O-ring position.6.This cap contains a specially designed O-ring or gasket which provides a leak-free seal. The air conditioning compressor will run automatically in this setting unless the outside temperature is below 4C.1-96 Special tools Heating. Fan Control knob A nut of free spiral and with outside screw The knob in the middle controls the selection of fan threads speed. press Temperature Control button. and the side 1.Turn it toward blue area for cooler air. Turn this knob toward red area for Coat the O-ring seal and the plain washer with warmer air. reconnect the A/C clutch. The system works best if An aluminum fitting with outside screw threads you keep your windows closed while using it. In the setting of medium to low speed (Gear I. an authorized new A/C O-ring seal or plain washer for replacement should be installed. you can control the heating. A/C (Air Conditioning) switch 1. . and the rest flows through refrigerant. air in the vehicle will be circulated. To turn the fan off. Service sealing caps FACE: Used to import air and direct it through The primary seal for the service ports is the sealing outlets on the instrument panel. cap. make sure the plain washer or the Temperature Control knob O-ring seal is in good condition. With this system. switch off defogger. The rear window defogger uses a warming grid to Voltage to the blower motor is supplied by the heater remove fog from the rear window. Ventilation and Air Conditioning System When the pressure exceeds 177 Kpa. and welded to an aluminum tube. 106007 Some vehicles use plain washers and O-rings to seal refrigerant system. 1. Plain washers are used on cylinder block fittings of refrigerant components. Blower motor is a motor with variable speed. Indicator on the button will light up and the the A/C clutch. when the pressure returns to 186 system will operate for about ten minutes.A sealing cap BI-LEVEL (mixed): Most of the air flows through that is too loose. The higher the voltage applied to the motor. authorized refrigerant oil.1. the front defroster.6. button again will stop the defroster.

Even when there is following functions: still a voltage signal on the PCM that comes from the To engage for A/C and defroster operation heater and the A/C controller. The relay energizes. the following blower motor resistor. the collapsing magnetic field of the A/C compressor clutch coil.The clutch allows the compressor to perform the compressor clutch will disengage. Ventilation and Air Conditioning System Special tools 1-97 II and III). not use internal blower motor resistors. the voltage will be depressed by the internal Under normal operating conditions. Circuit Description If PCM determines to reduce the load of the engine. The compressor for the air conditioning system is belt. The A/C CLU diode provides a path for the high The voltage signal tells the PCM that A/C compressor current that results from voltage spikes generated from operation is requested.6. and the clutch. 1. The compressor runs. so that it can run 2. 4. 3. .Voltage spikes occur every time the coil de- energizes. PCM will driven by the engine through the A/C compressor disconnect the A/C compressor controller. the blower motor do the A/C compressor controller. A/C Compressor Clutch is engaged.25 HVAC Compressor Controls 5. such as when the throttle is fully opened. Voltage is supplied to the A/C compressor clutch through the relay fuse. Each internal resistor will also actions occur: have a heat restrictor connected with it in series.1. Voltage will be supplied to the blower motor directly. The PCM supplies a ground to the relay coil of setting of high speed (Gear IV).Heating. To disengage when A/C is not needed The A/C compressor clutch diode is used to provide a To disengage when the engine load must be connection between terminals of the A/C compressor reduced clutch. at maximum speed. power supply will still be cut off. In the 1.

1. Recycling and J 28428-E Recharging (ACR4 ) High Intensity Black System Light J39500-B J28428-E J 41810 Pure Gaurd 2 J 38185 Hose Clamps Pliers J41810 J38185 .7Special tools Tool Number/ Graphics Description Tool Number/ Graphics Description J 39183-C R134A The manifold gauge set J 39200 Digital Multimeter J39183-C J39200 J 39400-A Halogen Leak Detector J 34142-B Passive Test Lamp J39400-A J34142-B J 39500-B Air Conditioning Refrigerant Recovery.1-98 Special tools Heating. Ventilation and Air Conditioning System 1.

Ventilation and Air Conditioning System Special tools 1-99 Tool Number/ Tool Number/ Graphics Graphics Description Description J 41810-100A J 6742-03 Positive Flow Control Microthermometer Valve J41810-100A J6742-03 J 39500-50 J 34614 50 Pound Rechargeable Shaft Seal Protector Recovery Tank J39500-50 J34614 J 41436 J 39893 Tracer Dye Injector Pressure Test Adapter J41436 J39893 J 41447 J 42136 R-134A Tracer Dye A/C System Lip Seal 24-1/4 Ounce per bottle Disassembly Tool J41447 J42136 .Heating.

Ventilation and Air Conditioning System Tool Number/ Tool Number/ Graphics Graphics Description Description J 36411 Valve Core J 9553-01 Disassembly/Installation O-ring Seal Remover Tool J36411 J9553-01 J 5403 J 33011 Spring Callipers O-ring Seal Installer J5403 J33011 J 6083 Spring Callipers J6083 J 8092 Infiltrator Handle J8092 .1-100 Special tools Heating.

... 2-8 2........................1.....................5 Replacement of steering column assembly... 2-47 Looseness of Steering Column ..1.......................2..........4.....5..... 2-4 2..................2................. 2-51 ..........4............ 2-64 2....4 Replacement of Power Steering Pump ..4..........2-11 2.4...........................................3........1...17 Swish Sound in Steeringt Pump .3.... 2-7 Members .......1..........1....11 Replacement of Corrugated Cover of Steering 2......1......2...............2 Explanation of Power Steering Pump ......2.......5 Explanation and Operation...1............2-11 2...............................7 Steering column is loose ............2..4 Specifications of steering liquid.... 2-13 2..................6 Inspection of steering shaft.......3....2............5...... 2-48 2....................1 Inspection/Adjustment of Straight Ahead Position...... 2-44 2............. 2..... 2-3 2....3 Diagnostic message and procedure..............2......13 Staggering or Instability of Steering Gear ...1 Locking System Cannot Be Unlocked ...........2.....4.....9 Replacemenet of Steering Knuckle Tie Rod.......................Exploded Wheel ........1.1 Safety Regulations for Power Steering System 2.............2..... 2-10 2..... 2-61 2......1...12 Replacement of Power Steering Gear ....1 Steering Wheel and Steering Column ........7 It Is More and More Difficult to Turn the Steering 2....3...........3.............................1 Specifications . 2-12 2... 2-68 Tank..5 Specifications of Hydraulic Steering Unit..4........1...3 Key Cannot Be Drawn out at Closed or Locked Position..................6 Flushing Power Steering System .............5 Replacement of Power Steering Liquid Reserve Column ................................2.1..............6 Special Tools ..........1 Power Steering Gear ..2.1.1..1...10 Replacemenet of Steering Knuckle Tie Rod......5 Leakage in Power Steering Gear and Power Steering Pump..... 2-16 2....9 Fluctation/Runout of Steering Wheel in the Course of Steering ...3...................2...... 2-15 2............ 2-47 2.....1............2 Identification of Appearance..6 Special Tools .5.....1 Explanation of Steering Wheel and Steering 2.......5................................18 Whining Sound in Steering Pump..................3...................... 2-3 2.... 2-50 2........4......1.....1..................................1.................... 2-25 2.......16 Clattering or Knocking Sounds in Steering Pump 2...3 Explanation of Power Steering Gear ...3................. 2-19 2...................... 2-14 2........................ 2-24 2..............Exploded View ....2..........1 Specifications .......4..........4 Repair guidance ......... 2-47 2.................2-11 2..11 Difficult Wteering in Both Directions ........ 2-8 2....1.......3... 2-50 2........ 2-48 2....2Steering wheel and Steering Column ....... 2-15 2.......... 2............5 Greating locking force.....3.....3 Discharge of Power Steering System..1..... 2-69 2..................3.....1...................3...................................................4 Diagnosis of Steering Gear .........5 Explanation and Operation. 2-29 2.1......8 Inspection of Steering Liquid Pressure .... 2-9 2....14 Wandering When the Brake Is Applied......4 Recommendation about Replacement of Sealing 2............ 2-8 2............................2....1. 2-44 2.......Power Steering ...3............2.. 2-12 2......... 2-53 2.......................2...........................4....................... 2-13 2......2 Replacement of Steering Wheel .. 2-12 2...3.1.3............1..4 Repair Instructions .1..............1....... 2-4 2.... 2-20 2......................3...2................10 Rebouncd of Steering Wheel................3 Diagnostic Message and Procedure .....1.1.........3..............15 Blistering..1.......4......1.4.........................1Power Steering System....2 Tightening toruqe of connectors ....1......... 2-52 2.1 Testing of power steering system ..13 Seal of Steering Gear .....12 Clearance between Steering Equipment Is Too Large ..2 Locking System Cannot Be Locked..........1 Replacement of the core of ignition switch lockî.... 2-68 2..... 2-44 2.....1.........7 Replacement of Hydraulic Pipelines. 2-3 Gear .......2 Hissing Sound in Steering System .......................................................1................................ 2-41 locking agent ...............1.........................................3.........2......3.2 Identification of Appearance.... 2-7 2...8 Steering wheel is loose.2............. lubricant and 2...........3................................5.3 Replacement of Ball Bearing at the Upper End of Steering Shaft .........3.......Steering System table of contents 2-1 2 Steering System 2......... 2-50 2... 2-5 ............3....1...........2.......4..... 2-18 2..........4 Greater locking force is needed between closed and locked positions ..................1...... 2-52 2.... 2-14 ....4.1...................... 2-50 2..2-3 2.2............................ 2-17 2....................1....... 2-50 2..................................... 2-7 2.. 2-46 2......3..........6 Over Rebound of Steering Wheel or over 2........1Tithtening Torque of Fasteners ......4.1.............1Tithtening Torque of Fasteners .....1........3.............................1.......... 2-45 2... 2-27 2.......4 Replacement of Upper Steering Shaft ...... 2-44 2....................1........2 Filling/deflation of hydraulic system.............4......1.... 2-50 2..........3 General specifications .........2........ Emulsifying or Low Level of Power Steering Liquid........... 2-21 ...............1..........8 Difficult Homing of Steering Wheel ...1....1........ 2-5 2..4......................on the Vehicle.. 2-28 2.2..................4.......1......... 2-51 2.......1..... 2-10 View....4....2 Clattering Noise in Steering System.. 2-3 2.. 2-57 ....................... 2-51 2...................1.1.1.........1.....3......................2...3........................

2-2 Steering System Blank .

1.1.3 General Specifications Applications Specifications Decompression pressure of steering pump 5.1.28megapascal .51-6. Steering system 2-3 2.1.1Power Steering System Ste 2.1.2 Tightening Toruqe of Connectors Applications Specifications Connector between oil suction hose of power steering system 2-3N m and power steering pump Connector between oil suction hose of power steering system 2-3N m and liquid reserve tank of power steering system Connector between high-pressure hose of power steering 20-35N m system and power steering pump Connector between high-pressure hose of power steering 20-35N m system and oil inlet hard tube of power steering gear Connector between oil inlet hard tube of power steering gear 20-35N m and power steering gear iteself Connector between oil outlet hard tube of power steering gear 20-35N m and power steering gear itself Connector between oil outlet hard tube of power steering gear 2-3N m and oil return hose of power steering system Connector between oil return hose of power steering system 2-3N m and liquid reserve tank of power steering system 2.1 Specifications 2.1Tithtening Torque of Fasteners Applications Specifications Assembling nut of power steering gear 20-26N m Clamp nut for steering knuckle tie rod and steering rack 63-77N m Clamp nut for the end of steering knuckle tie rod and steering 40-48N m knuckle Holddown bolt of power steering pump 22-28N m Binding bolt for the bracket of liquid reserve tank and the car 7-8N m body Binding bolt for clamping collar and the bracket of liquid 2-3N m reserve tank 2.1.1.

1.5 Specifications of Hydraulic Steering Unit Applications Specifications Manufacturer: Delphi Brazil Com.1.2-4 Steering system 2. Lubricant and Locking Agent Specifications Applications GM part number DEXRON III 油液 Steering liquid (1 litre) 12378494(4L) 12378495(4L) Silicon grease (1 ounce) Slip joints and plastic seal rings of all temperature 12345579 (100 gram) Locking glue Screwed joints (10 ml.1. Overall gear ratio 15.4 Specifications of Steering Liquid. 12378495 (DEXRON III) Volume of steering liquid 1 litre - When steering wheel 5510-6280 kilopascal turned to limiting position Pressure of steering liquid - At test point of central 200-500 kilopascal position .1.) 90542117 2.7:1 Part number of steering liquid 12378494.

1.Pinion and Rack 201001 Legend (1) Joint assembly of steering knuckle tie rod (8) Clamping collar for corrugated cover of steering (2) Mounting ring gear case (3) Dust cap (9) Locknut (4) Locknut (10) Assembly of steering knuckle tie rod with inner buttonhead (5) Jam nut (11) Stopper (6) Clamping collar for corrugated cover of steering knuckle tie rod (12) Check ring (7) Corrugated cover (13) Gasket (14) Seal ring .Exploded View Output at the End .2 Identification of Appearance 2.Steering system 2-5 2.2.1 Power Steering Gear .1.

2-6 Steering system (15) Bearing (24) Corrugated cover (16) Nut (25) Clamping collar for corrugated cover of steering (17) Shroud gear case (18) Locknut (26) Assembly of steering knuckle tie rod with inner buttonhead (19) Dust cap (27) Stopper (20) Check ring (28) Breather pipe (21) End of steering knuckle tie rod (29) Fuel pipe clamp (22) Jam nut (30) Hydraulic piping (23) Clamping collar for corrugated cover of steering knuckle tie rod (31) Hydraulic piping (32) Thrust seal ring .

Is the customer still complaining? . 2.1. - Front suspension. 2 Is the liquid level of power steering system too - To step 3 To step 4 low? Add steering liquid to the power steering system. The joint between steering column and steering Looseness or noisiness of wheel bearing. repair or replace any hose and hard tube. If necessary. Compare the noise level with that of anothre car 1 in normal operation. During diagnosis the following systems should be paid - Steering knuckle tie rod. If 7 - To step 8 The system is OK necessary. The following components should be inspected Inpsect the liquid level of power steering for looseness or damages: system. - To step 1 The system is OK Is the customer still complaining? Is the hissing sound coming from the interior of 4 - To step 5 To step 7 the car? The hissing sound is propably entering the passenger cabin via an opening in the frontside of the panel. pressure and uneven wearing. Tyres should be inspected for improper - Imbalance of tyres. - Out of roundness of tyres. Inspect the steering column and the 5 - To step 6 To step 7 boot of front enclosure.1.3. gear should be inspected for looseness or wear.3. Inspect the power steering pump 8 and the power steering gear. - To step 1 The system is OK Is the customer still complaining? Make sure the hoses and hard tubes of the power steering system are properly arranged (not touching the frontside of the panel).3 Diagnostic message and procedure 2. repair - To step 1 The system is OK or replace any component.1. attention to: Tyres should be inspected for the following Suspension system. - To step 2 The system is OK Is the hissing sound abnormally loud? Inpsect the liquid level of power steering system.1 Testing of power steering system - Rear suspension. 3 See Filling and Discharge of Hydraulic System. Are the steering column and the boot of front enclosure damaged or improperly installed? Repair or replace the seal of the steering 6 column.2 Hissing Sound in Steering System Numerical Steps Measures Yes No values Definition:Significant hissing sound can be heard during operation of engine and rotation of steering wheel. Is the customer still complaining? Determine the source of the noise with a stethoscope. Inspect power steering system for any leakage. conditions: Tyres and wheels. - Blending of tyres. - Steering gear.Steering system 2-7 2. Road test should be conducted before diagnosis.

2. Overflow . One end or both ends of the steering nuckle tie rod are loose. See Replacement of Power Steering Gear and Replacement of Steering Column Assembly.2-8 Steering system 2. Make sure pipelines in power steering system are properly arranged. The following steps need to be completed when 6. 5. Tighten the nut of steering gear to the required torque. Heavy steering. repair or replace any end of the steering nuckle tie rod. leakage. Determine the exact leaking position.4 Diagnosis of Steering Gear 4. 5. the repair work should be conducted according to the following Inspection Procedures procedures.3.1. some noises might be heard when steering in place. 6. positions of the system. Positions with dripping oily liquid are not always leaking Inspect hydraulic system for any leakage. Dry any suspicious region. Inspect the following components: Hose connection Hissing noise O-ring Under normal conditions.1. Inspect liquid reserve tank of power steering damage.1. Inspect steering pump for any under pressure. and fix it. steering pump.1 Clean the position of leakage before inspecting power steering system for any external disassembly. method to determine any position of penetrating When rapidly turning the steering wheel. add steering liquid. Inspect power steering system for any of the Tithtening Torque of Fasteners.5 Leakage in Power Steering Gear Note: The steering wheel should not be turned to and and Power Steering Pump hold at the extreme position for a long time. 1. The power steering pump will be damaged in this way. If necessary. system for any excess of steering liquid. Use the following Inspect power steering system for any air. 5.5 Ask your assistant to turn the steering wheel left and right to the limiting position Visible oily liquid appears on steering gear or for several times. 6. If necessary. If necessary.and car or when the engine is cool. The following signs indicate possible leakage of power steering system. See Replacement of Hydraulic Pipeline. repair or replace the steering universal joint assembly. 5.6 Operate according to Diagnosis Rumbling noise can be heard when parking the Procedures for Power Steering Gear.3Inpsect the liquid level of steering liquid Inspect liquid level to make sure it is not too low. See Replacemenet of the End of Steering Knuckle Tie Rod. Inspect internal pressure for any leakage. reserve tank. Steering universal joint assembly is loose.4 Tighten the bolt to the required torque. 2.2 Clattering Noise in Steering System Status Measures Pipelines of power steering system are worn.3. 5. 5. determine the exact position of leakage Power steering is lost when parking. See Tithtening Torque of Fasteners.4 Start the engine. 5. 6.3.3 Inspect the sealing surface for any 2. a larger force leakage: will be needed for an instant. The steering gear is loose.1 Turn off the engine.2 Replace the leaking seal.2 Dry the whole power steering system. 6. following conditions: Aerification of power steering liquid. If necessary. See 3.

Hydraulic System. it is irrelevant to the direction of steering.Power Steering. See Replacement of Bearing of Front Drive Shaft in Front Suspension. 4. See Replacemenet of the End of Steering Knuckle Tie Rod. Loose joint between steering column and steering gearSee Replacement of steering gear Steering Column.6 Deflation of power steering system. See Filling and Deflaction of Power Steering Gear. Inspect sealing surface. See Replacement of Power Steering Gear. Replace lip seals. complete the following steps: Torque arm 1. Drive shaft of the steering pump 2. seal. replace the steering gear. Inspect the connection of power steering system following componenets: for any leakage around it. Replace wheel hubs. See Replacement of system. If leakage is found at the end of the housing and oil injection is found when steering wheel is If leakage is still found after the drive shaft has been turned left to the extreme position. See Replacement of Bearing of Front Drive Shaft in Front Suspension. 3. Loose bracket of steering gear 1. If leakage is found on any side of the driver and If severe pitting is found on a drive shaft. See Replacement If slight corrosion is found on the contact zone of a lip of Power Steering Gear. Deflation of power steering system. Filling and Deflation of Hydraulic System.3. use crocus cloth to clean the surface of the drive shaft. See Filling/Deflation of Hydraulic System. Clean sealing surface thoroughly. See Replacement of Power Steering Gear. Tighten holddown bolts of power steering gear to the required torque. Inspect power steering system for any leakage.Steering system 2-9 6.6 Over Rebound of Steering Wheel or over Looseness of Steering Column Problems Measures There is air in power steering system 1. 2. If leakage is found between any of the following If leakage is found on any of the above components. Lip seals are used to seal drive shaft. replace the steering universal joint assembly between steering column and steering gear. 3. See Replacemenet of the End of Steering Knuckle Tie Rod. replace the drive shaft. Recommendation about the Replacement of 6. Inspect the end of steering knuckle tie rod. Loose end of steering knuckle tie rod 1. 2. Seals of this type are used on the 1. See Leakage in Power Steering Gear and Power Steering Pump 2. 2.5 Add steering liquid to the power steering power steering gear. See Tithtening Torque of Fasteners. Steering gear Seal . 2. 2. . Loose joint between steering column and 1. Input shaft 2. Inspect the bracket of steering gear. replace power steering gear. Replace the end of steering knuckle tie rod. components. Lip seals need Diagnosis Procedures of Power Steering Gear special treatment. See Sealing Members. See Steering Gear.1. replace it. Replace wheel bearings. Worn wheel bearing 1. See Replacement of Steering Column. If necessary. replace the cleaned with crocus cloth.

Inspect the bracket of steering column.1. Improper tyre pressure Charge the tyre to the required air pressure. The torque of pinch bolt of the steering Tighten the pinch bolt of steering universal joint assembly to the required torque.2-10 Steering system 2. See Replacement of Power Steering Gear. align the front wheel. See Wheel Alignment. universal joint assembly is too great. 2. Inspect the alignment of steering column. The liquid level of power steering liquid is Add power steering liquid into the power steering liquid reserve tank. repair the bracket of steering column. See Replacement of Power Steering Gear. If necessary. Improper front wheel alignment 1. adjust the alignment of steering column. Binding steering gear valve Replace steering gear.7 It Is More and More Difficult to Turn the Steering Wheel Problems Measures Severe internal leakage See Leakage in Power Steering Gear and Power Steering Pump The valve spool of power steering gear is Replace the steering gear with a new one. Deflation of Hydraulic System. See Replacement of Lower Globe Joint in Front Suspension. 2. 5. Inspect the bearing of steering column. See specifications in Tyre and Wheel. See Wheel Alignmentî. If necessary. See Replacement of Steering Column Assembly. replace the globe joint. 2. replace the steering column bearing. Inspect front wheel alignment.8 Difficult Homing of Steering Wheel Problems Measures Binding globe joint 1. Loose steering gear Tighten the holddown bolt of steering gear to the required torque. If necessary. See Replacement of Lower Globe Joint in Front Suspension. If necessary. See Replacement of Ball Bearing at the Upper End of Steering Shaft. If necessary. See Replacement of Power Steering binding/damaged Gear. 4. 3. See Replacement of Steering Column Assembly.3. Binding steering column 1. 2.1. See Replacement of Steering Column Assembly. See Filling/ too low.3. . 6. Inspect the globe joint.

Tighten holddown bolts of power steering gear to the required torque. binding/damaged The liquid level of power steering liquid is Add power steering liquid into the power steering system. .1.10 Rebouncd of Steering Wheel Problems Measures There is air in power steering system 1.11 Difficult Wteering in Both Directions Problems Measures Severe internal leakage See Leakage in Power Steering Gear and Power Steering Pump The valve spool of steering gear is See Replacement of Power Steering Gear.3. See Filling/Deflation of Hydraulic System. Inspect the steering universal joint assembly between steering column and steering gear steering gear. 3. Inspect the bracket of steering gear. Hydraulic System. See Replacement of Power Steering Gear. too low. See Filling/Deflation of Hydraulic System.Steering system 2-11 2. Deflate power steering system. See Filling/Deflation of Hydraulic System. Loose joint between steering column and 1. 2. See Leakage in Power Steering Gear and Power Steering Pump 2. See Tithtening Torque of Fasteners. 2. 2. Deflate power steering system. Replace the end of steering knuckle tie rod. See Replacement of Wheel Hub in Front Suspension. Loose bracket of steering gear 1. See Filling/Deflation of too low. Inspect the end of steering knuckle tie rod. Replace wheel bearings. See Replacement of Bearing of Front Drive Shaft in Front Suspension. replace the steering universal joint assembly between steering column and steering gear. 2. Inspect power steering system for any leakage. 2. Add power steering liquid into the power steering system. See Replacemenet of the End of Steering Knuckle Tie Rod. See Replacement of Power Steering Gear.3. See Replacement of Power Steering Gear.9 Fluctation/Runout of Steering Wheel in the Course of Steering Problems Measures The liquid level of power steering liquid is If necessary. See Filling/ Deflation of Hydraulic System. Replace wheel hubs.1. 2. See Flushing Power Steering System. add power steering liquid. See Replacemenet of the End of Steering Knuckle Tie Rod. Loose end of steering knuckle tie rod 1. Binding steering gear valve 1. If the symptom 2. Worn wheel bearing 1.1.3. Flush power Steering System. If necessary. 4.

2.2-12 Steering system 2. See Replacement of Shock Strut. Loose steering knuckle tie rod 1. See Replacement of Power Steering Gear. See Replacement of Shock Strut Assembly in Front Suspension. 2. Loose steering gear Tighten holddown bolts of power steering gear to the required torque. See Replacement of Stabilizer Bar in Front Suspension. align the front wheel. Repair the broken/loose spring. Loose control arm 1. repair tyres. Shock Strut Components and/or Spring in Front Suspension. See Wheel Alignment.14 Wandering When the Brake Is Applied Problems Measures Uneven/improper caster See Wheel Alignment.13 Staggering or Instability of Steering Gear Problems Measures Improper front wheel alignment 1. Replace any component and/or tighten fasteners to the required torque. 4. Inspect front wheel alignment. Warped brake disc If necessary. Worn wheel bearing Replace the hub and bearing assembly. Loose stabilizer bar Inspect the following components: Holddown bolts Tighten holddown bolts to the required torque. 2.1. If necessary. replace the brake disc. If necessary.3. See Replacement of Power Steering Gear. Inspect broken/loose spring. 2. Uneven wearing/improper alignment of 1. See Wheel Alignment. replace the steering universal joint assembly between steering column and steering gear.1. See Wheel Alignment. See Replacement of Control Arm in Front Suspension. Improper rear wheel alignment See RearSsuspension. 2. steering gear 2. If necessary. See Replacement of Brake Disc. See Replacement of Control Arm in Front Suspension. replace steering knuckle tie rod. See Replacement of Power Steering Gear. 2.1. See Replacement of Tyres in Tyres and wheels.3.12 Clearance between Steering Equipment Is Too Large Problems Measures Loose/worn steering universal joint 1.Irregular or Early tyres Wearing. adjust the alignment. 2. 2. 3. Inspect shock strut for any sign of wearing. See Diagnosis ofTtyres . Inspect the steering universal joint assembly between steering column and assembly between steering column and steering gear for improper torque. Inspect alignment. See Replacement of Shock Strut Assembly in Front Suspension. Inspect steering knuckle tie rod. See Replacemenet of Steering Knuckle Tie Rod. See Replacemenet of Steering Knuckle Tie Rod. If necessary. replace any tyre. See Replacement of Bearing of Front Drive Shaftî in Front Suspension. replace shock strut. Worn shock strut 1. Broken/loose spring 1. . If necessary. If necessary. Inspect control arm. See Replacement of Shock Strut. If necessary. Shock Strut Components and/or Spring in Front Suspension.3.

Steering liquid is blistering. There is internal leakage in the steering Inspect power steering pump for any leakage.3. If necessary.3.16 Clattering or Knocking Sounds in Steering Pump Problems Measures High-pressure hoses of power steering Inspect high-pressure hoses of power steering system to make sure they are in gear are worn. repair the spring. See Replacement of Power Steering Pump.15 Blistering. replace the steering universal joint.Steering system 2-13 2. See Leakage in Power Steering pump. Loose end of steering knuckle tie rod Inspect the end of steering knuckle tie rod. 1. 2. See Replacement of Shock Strut. Dismount power steering pump. See Replacement of Hydraulic Pipelines. Proper installation. Shock Strut Components and/or Spring in Front Suspension. See Replacement of Brake Tongs. 3. repair the brake tongs of any wheel. See Replacemenet of the End of Steering Knuckle Tie Rod. Gear and Power Steering Pump. Liquid level is normal. Replace wheel hubs.1. See Replacement of Hydraulic Pipelines. If necessary. See Replacement of Steering Column Assembly. Inspect the housing for any crack. The steering universal joint is loose. See Replacement of Shock Strut. 2. See Replacement of power steering pumpî. See Replacemenet of the End of Steering Knuckle Tie Rod. Deflate power steering system. The following conditions exist in power 1. Worn wheel bearing 1. Loose steering gear Inspect power steering gear for any improper installation. See Replacement of Brake Tongs. 2. 2. replace the steering pump. 2. See Filling/discharge of Hydraulic System. Replace the end of steering knuckle tie rod. See Replacement of Steering Column Assembly. steering liquid: 2. Emulsifying or Low Level of Power Steering Liquid Problems Measures There is air in power steering liquid. 2. If necessary. Inspect brake tongs of wheels.14 Wandering When the Brake Is Applied (Cont’ d) Broken/loose spring 1. See Tithtening Torque of Fasteners. See Replacement of Wheel Hub in Front Suspension.1. Proper clearance. 1.1. Inspect the soft plug for any crack. Inspect power steering system for any leakage. accordance with the following conditions. If necessary. 2. Inspect the spring. Leaking brake tongs of wheels 1. See Replacement of Power Steering Gear. Shock Strut Components and/or Spring in Front Suspension. See Leakage in Power Steering Gear and Power Steering Pump 2. Replace wheel bearings. See Replacement of Bearing of Front Drive Shaftî in Front Suspension. Inspect the steering universal joint.3. . 1. Tighten mounting nuts of power steering gear to the required torque. 4.

The pump bushing is scratched. See Filling/Discharge of too low. Hydraulic System. The dogs and blades are scratched.1. 2. If necessary.17 Swish Sound in Steeringt Pump Problems Measures The control valve is damaged. replace the steering pump. Replace the steering pump.18 Whining Sound in Steering Pump Problems Measures The liquid level of power steering liquid is 1.1. . See Leakage in Power Steering Gear and Power Steering Pump. Inspect power steering system for any leakage.2-14 Steering system 2.3. See Replacement of Power Steering Pump. add power steering liquid. See Replacement of Power Steering Pump. 3.3. See Replacement of Power Steering Pump. See Filling/Discharge of Hydraulic System. If necessary. If necessary. Inpsect the liquid level of power steering system. 2. replace the steering pump.

see Replacement of Steering Wheel.1 Inspection/Adjustment of Straight Ahead Position Tools required KM-551-A Detector J-830901 puller Note: After any operation (dismounting and installation or disassembly or assembly) on steering gear or steering column assembly. 201002 Adjustment If there is a deviation of 10 from the center of steering wheel . use J-830901 to dismount the steering wheel from steering shaft. the spoke of steering wheel should be level and the bolt of lower clamping flange should be flatly on top.Steering system 2-15 2. Note: When the steering wheel is at the straightahead position. Straightahead position will be obtained through inspection of dimension "1"=435 ± 2mm. insert it into the spline of steering shaft.4.1.4 Repair Instructions 2. 201003 . then with center alignment. Measurement Please use special tool KM-551-A that is built for the measurement of clearance between steering knuckle tie rod and the left mounting shoulder of steering housing.1. always inspect the straightahead position of steering gears.

When working temperature is about 80 ℃ . Measurement 1. The cover of liquid reserve tank should be screwed down completely. 12378495(1L) There is a power steering liquid level indicator mounted on the cover of steering liquid reserve tank. Start the engine and immediately add steering liquid to the lower mark of Min (2) . Turn the steering wheel left and right slowly to 45 degree for two or three times.2-16 Steering system 2.1. When inpsecting the level of steering liquid. . the 201004 measuring scale on the cover of liquid reserve tank should be used. Using unsuitable steering liquid will damage flexible conduits and sealing members and cause leakage of steering liquid. Turn of the engine and inspect liquid level. 2. steering liquid should be at minimum (2) position. Firstly. GM part numbers for steering liquid: 12378494(4L). Correct the level of steering liquid in reserve tank for two times. Steering liquid that has been discharged should not be reused. Amount of steering liquid that should be added: 1 litre. When the engine is cooled down to about 20 ℃ . add steering liquid to the Max (1) position.4. steering liquid is at the maximum (1) position. See Specifications of Steering Liquids. then turn it to the limit position twice. Lubricants and Locking Agents for the specifications of Steering liquid. Note: The steering liquid pump should not be operated when there is no steering liquid. with the engine unoperated.2 Filling/deflation of hydraulic system Notice: Suitable steering liquid should be used when adding or completely replacing steering liquid. Marks on the power steering liquid level indicator are used to indicate the level of steering liquid.

Deflate power steering system. Turn the steering wheel left and right to the limit position. 10.4. Ensure the front wheel can be turned freely. See Replacement of Hydraulic Pipeline. 3.Steering system 2-17 2. 5. Add power steering liquid into the power steering system. Notice: When flushing power steering system. 8. the steering wheel should not be turned to and held at the limit position. 7.1. Place the oil return hose into a large container that can hold steering liquid being discharged. 3. See Flushing Power Steering Systemî. Reconnect oil return hose in power steering system. See Filling/ Deflation of Hydraulic System. 2. If power steering liquid has been polluted. Raise the forepart of the vehicle above the ground. . See Filling/Deflation of Hydraulic System. flush the power steering system. Disassemble oil return hose from power steering liquid reserve tank. 9. 6. Please refer to Replacement of Hydraulic Pipeline. Ensure all of old steering liquid in the power steering system has been removed.1 Start the engine. Turn ignition switch to the OFF position.3 Discharge of Power Steering System 1. and cause damage to power steering pump and/or steering gear.2 Let the engine run at idle speed. 4. Complete the following procedures: 3. Turning the steering wheel to the limit position and holding it there will bring the system under overpressure and overheat.

Tightening Tighten the power steering pump to 22-28N m. Install driving belt of accessories. 3.1. Disassemble driving belt of accessories. Place a drip pan under it. Remove high-pressure hoses and intake lines from power steering pump. Comply with safety regulations. See Replacement of Hydraulic Pipeline. 3.2-18 Steering system 2. Let steering liquid flow out. See Replacement of Driving belt of Accessories in Techanical System of Engine. Remove power steering pump from the front engine support (as indicated by arrow in the diagram. See Replacement of Driving Belt of Accessories in Techanical System of Engine. 201005 .4. 201005 Installation Procedures 1. Reconnect high-pressure hoses and intake lines onto the power steering pump. Place power steering pump onto the bracket.4 Replacement of Power Steering Pump Disassembly Procedures 1. 2. 2.

Steering system 2-19 2. 201006 . Remove liquid reserve tank from the bracket. 3. 2.1. 2. Fill/deflat hydraulic system. Comply with safety regulations. See Filling/Deflation of Hydraulic Systemî. 3. Loosen two hose couplers (as indicated by arrow in the diagram) and remove the hose. Inspect hydraulic system for any leakage. Connect two hoses and tighten the hose clamping collar. Place a drip pan under it.5 Replacement of Power Steering Liquid Reserve Tank Disassembly Procedures 1.4. Put liquid reserve tank into the bracket and tighten the clamping bolts. Loosen clamping bolt (1) on the braket. 201006 Installation Procedures Tools required KM-354 Pressure Gage 1. Note: Let residual steering liquid flow out.

7. Place a drip pan under it. Notice: When flushing power steering system. Comply with safety regulations. Siphon power steering liquid from its reserve tank. See Filling/ Deflation of Hydraulic System. it will be impossible in most cases to determine immediately whether the hydraulic steering engine or the power steering pump should be inspected for any malfunctions. Remove oil return hose from power steering liquid reserve tank. the steering wheel should not be turned to and held at the limit position. See Replacement of Hydraulic Pipeline.4. connect pressure gage KM-354-B with the oil outlet and high pressure hose of the oil pump. fill up power steering pump with dedicated steering liquid DEXRON III. Insert the nose of oil return hose of power steering system into power steering liquid reserve tank. Raise and support the vehicle above the ground untill front wheels can rotate freely. 5. Using unsuitable steering liquid will damage flexible conduits and sealing members and cause leakage of steering liquid.2-20 Steering system Measurement Pressure of Steering Liquid.1. For this sake. at the same time ask an assistant to add power steering liquid into the reserve tank. 8. 201007 2. 3. Continue to discharge all of the oild steering liquid from the power steering system. Start the engine and run it at idle speed. Power steering pump should not be run without steering liquid. Through liquid reserve tank. Place the oil return hose of power steering system into a large container that can hold steering liquid being discharged. and cause damage to power steering pump and/or steering gear. .6 Flushing Power Steering System Notice: Suitable power steering liquid should be used when adding or completely replacing steering liquid. 2. 4. Then run the engine at idle speed and fill it up immediately with dedicated steering liquid DEXRON III. If power steering system breaks down. Note: Let steering liquid flow out. 1. Turn the steering wheel left and right to the limit position. Turning the steering wheel to the limit position and holding it there will bring the system under overpressure and overheat. 6.

Inspect power steering system for any leakage. Add power steering liquid into the reserve tank. 11.Steering system 2-21 9. 10. Comply with safety regulations. After installation. deflat and fill up hydraulic system. 15. 13. steering liquid will flow out. See Filling/Deflation of Hydraulic Systemî.4. Important: Power steering liquid that has been discharged should not be reused. of those hoses. Regularly replace plastic buckles. Connect the oil return hose of power steering system with power steering liquid reserve tank.9 litre new power steering liquid to flush the power steering system. Inspect power steering liquid that has been discharged untill all of it has been removed. See Replacement of Hydraulic Pipeline. ensure there is no bending or torsion in the oil circuit. A drip pan should be placed under it. Oilout hard tube When removing hard tubes and hoses. See Filling/Deflation of Hydraulic Systemî. Turn off the engine.1. When the engine is operating and executing steering. 12. gaskets. Use approximately 0. High-pressure hose 3.7 Replacement of Hydraulic Pipelines 1. During installation. 2. 16. 14. and avoid any contact with high-temperature or rotating parts. Remove the choke plug on the power steering pump. etc. Oil suction hose 4. Oil return hose 5. Oil inlet hard tube 2. Deflate power steering system. 201008 check for any leakage. .

Press oil inlet hard tube onto its fastener. Loose the special bolt of steering gear. Remove high-pressure hose from its fastener. Remove brake booster and brake master cylinder. Replacement of High-pressure Hose (2) Disassembly Procedures 1. Tightening Tighten the union bolt to 20-35N m. Insert the special nut into the steering gear. 2. See Replacement of Brake Master Cylinderî in Hydraulic Brake. Remove tube connector from high-pressure hose. Remove oil inlet hard tube from its fastener. Installation Procedures 1. 2. Tighten the union bolt of oil inlet hard tube. 201009 . use the new O-ring and Tightening Tighten the nut to 20-35 N m . Remove oil inlet hard tube and high-pressure hose union on the hydraulic pump.2-22 Steering system Replacement of Oil Inlet Hard Tube (1) Disassembly Procedures 1.

Screw on hydraulic pump and the union nut of oil inlet hard tube. power steering pump and steering liquid reserve tank. Insert oil return hose into the fastener. Loosen the hose clamping collar connecting hoses and remove oilout hard tube. Loose the special bolt of steering gear. hydraulic pump and oil inlet hard tube to N m . Remove oil return hose from its fastener. See Replacement of Brake Master Cylinder in Hydraulic Brake. 201009 Replacement of Oil Suction Hose (3) Disassembly Procedures 1. Remove oil suction hose from its fastener. Installation Procedures 1. Installation Procedures 1. Loosen the hose clamping collars of oilout hard tube and the power steering liquid reserve tank.Steering system 2-23 Installation Procedures 1. Tightening Tighten the bolt of clamping collar to 2-3N m. 2. Replacement of Oilout Hard Tube (5) Disassembly Procedures 1. Tightening Tighten the union nut between hydraulic lines. use hose clamping collar to connect oil return hose with oilout hard tube and power steering liquid reserve tank. Insert oil suction hose into the fastener. Remove brake booster and brake master cylinder. tighten the hose clamping collars between oil suction hose. Replacement of Oil Return Hose (4) Disassembly Procedures 1. Insert high-pressure hose into its fastener and tighten it. Loosen the hose clamping collars of power steering pump and power steering liquid reserve tank. .

when stop valve is opened the pressure indicated on the pressure gage is only a few kpa. With steering wheel at central position. Note: After the steering wheel has been turned to a limit position. 2. Tighten the hose clamping collar of oil return hose and oilout hard tube. the slight pressure difference between them is insignificant. 2.51-6. Measurement 1. Turn the steering wheel to the left or right limit position. 3. Tightening Tighten the bolt to 20-35N m . and read out the exacte maximum pressure of 5. fill up steering liquid before inspecting its pressure.8 Inspection of Steering Liquid Pressure Tools required KM-354-B Pressure Gage Note: If there is any leakage of steering liquid. turn on the stop valve. it should not be held at that position for more than 10 seconds.4. When the steering wheel is turned to the left or right limit position. Connect steering liquid pressure gage KM-354-B with high-pressure hose of steering liquid loop. turn off the stop valve. and . Then let the steering wheel return 201011 the central position.51-6. When the steering wheel is turned to left and right. the pressure will increase and reach maximum value of 5. Insert a special bolt between oilout hard tube and steering gear and tighten it.2-24 Steering system Installation Procedures 1. 4. 201010 2.28 megapascal.28 megapascal when the steering wheel is turned to the limit position.1.

2.Steering system 2-25 read out the maximum pressure of 5. 2.9 Replacemenet of Steering Knuckle Tie Rod Disassembly Procedures Tools required J-810902 Removal fork 1. Remove the two clamping collars from the corrugated cover. Remove the assembly of steering knuckle tie rod with inner buttonhead from the steering rack (as indicated by arrow in the diagram).4. and take out the corrugated cover. steering pump still runs at maximum pressure. When reading out a pressure from the pressure gage.51-6. 201012 3. 4. Remove the clamp nut at the end of the steering knuckle tie rod above steering knuckle. Remove the end of steering knuckle tie rod from the steering knuckle tie rod.1. 5.28 megapascal. the duration that the stop valve is turned off should not be too long (at most 10 seconds). Note: When the stop valve is turned off. Use J-810902 to press out the end of steering knuckle tie rod. Compare the two maximum pressure values. 201013 .

201013 . and use a new clamping collar and S-9407235 to tighten it on the steering gear and the steering knuckle tie rod. 201012 3. 4. See Wheel Alignment.2-26 Steering system Installation Procedures Tools required S-9407235 Nipper 1. Adjust the gather. Install corrugated cover. Install the end of steering knuckle tie rod onto the steering knuckle. Tightening Tighten the bolt to 70N m . Tighten the bolt between the assembly of steering knuckle tie rod with inner buttonhead (as indicated by arrow in the diagram) and steering racks. 2.

Steering system 2-27 2. The visible length of steering knuckle tie rod 2=158 6 mm. 201014 Installation Procedures Pay attention to the length of insertion. See Gather in Wheel Alignment. 1. remove the end of steering knuckle tie rod.1. Remove the clamp nut at the end of the steering knuckle tie rod (1) on the steering knuckle. Install the end of steering knuckle tie rod onto the steering knuckle.10 Replacemenet of Steering Knuckle Tie Rod Disassembly Procedures Tools required J-810902 Removal fork 1. Adjust the gather. Use J-810902 to press out the steering knuckle tie rod. It is not necessary to remove the corrugated cover.Use new clamp nut. 201015 . 2. Loosen the locknut.4. Tightening Tighten the nut to 40-48N m . 3.

Install corrugated cover. 2.2-28 Steering system 2. 201016 Installation Procedures Tools required S-9407235 Nipper 1.4. Remove the end of steering knuckle tie rod. 201016 .on the Vehicle Disassembly Procedures 1. and use a new clamping collar and S-9407235 to tighten it on the steering gear and the steering knuckle tie rod. Loose the clamping collar and remove the corrugated cover (as indicated by arrow in the diagram). See Replacemenet of the End of Steering Knuckle Tie Rod.11 Replacement of Corrugated Cover of Steering Gear .1.

Dismount refrigerant recovery tank and set it aside.Steering system 2-29 2. 201017 4. 5. Ventilation and Air Conditioning Systemî.4. Remove cacuum hose from brake booster. See Recovery and Refilling of Regrigerant in Heating.12 Replacement of Power Steering Gear Disassembly Procedures Tools required J-810902 Removal fork 1. Keep brake system turned off. Remove the bolt of brake fluid compensation tank (as indicated by arrow in the diagram). 2. 201018 . 6. Remove brake master cylinder from brake booster and put it aside with brake fluid compensation tank. Release the air conditioner. 3.1.

2-30 Steering system 7. so as to free the upper end of steering knuckle from steering column. 9. Loosen the two bolts on the lower steering knuckle (as indicated by arrow in the diagram). 11. Remove mounting spring from pedal shaft. Remove fixing clip from shifting fork and remove the pin of shifting fork. Take out the steering knuckle assembly. 201019 8. 201022 201021 . Push the lower end of steering knuckle toward steering gear and push it to the bottom. 201020 10.

Steering system 2-31 12. 201024 . and remove the support. 15. Remove brake booster from the engine cabin. Loosen shifting lever and press it out of the ball socket. Raise the engine. 201023 14. 13. Loosen hexagon nuts on the assembly of brake pedal support.

Remove the suspension of left front engine from the longitudinal side sill of body framework. Remove universal joint from shifting lever. Remove the assembly of guide bar from the mounting bracket of transmission gear. 201026 20. (As indicated by arrow in the diagram)。 18. 19. press the catch springs of the hollow pin together and remove it. Loosen the clip bolt of transmission sliding bar. 201025 17.2-32 Steering system 16. 201027 . Disassemble transmission support bracket. Remove the assembly of bolt and spring clip from the bearing of guide bar. Press transmission sliding bar out of the knurled bolt.

Remove the connectors of oil inlet hard tube and oilout hard tube from steering gear. Remove refrigerant line of air conditioner from expansion valve and press it out from the separator. Lower the engine.Steering system 2-33 21. 22. 24. 201009 25. 201012 . Block out the mouth of refrigerant pipelines. 201028 23. Remove the two ends of steering knuckle tie rod from the steering knuckle and press it out with J- 810902.

2-34 Steering system 26. Incline the steering gear to the left. (As indicated by arrow in the diagram)。 201030 . 29. 28. On the right side draw steering knuckle tie rod through the notch of the wheel into engine cabin. Push steering gear left as much as possible so as to push it into the notch of the wheel. Press the steering gear out of front enclosure until it can be pushed to the left end. and take it out from below the vehicle. (As indicated by arrow in the diagram)。 201029 27.

Steering system 2-35 Installation Procedures Tools required S-9409203 used to inspect the mounted position of steering mechanism 1. Lead the right steering knuckle tie rod into the notch of right wheel. (As indicated by arrow in the diagram)。 201032 . Insert steering gear into the notch of partition board. Incline steering gear top left as much as possible from the bottom (right) of vehicle and push it into the notch of the wheel. 4. Place steering gear on the mounting position and pretighten the bracket of steering gear. 2. 201031 3.

Connect the refrigerant line of air conditioner with expansion valve and tighten it. Install the two ends of steering knuckle tie rod onto the steering knuckle (1). Use S-9409203 to determine the mounting position of steering gear (as indicated by Arrow I) and tighten it. Tightening Tighten the steering gear with the front enclosure to 20-26N m 201033 6. Tightening Tighten the refrigerant line with expansion valve to 16 N m 201034 7. Tightening Tighten the end of steering knuckle tie rod with steering knuckle to 40-48 N m .2-36 Steering system 5. 201035 .

Raise the engin. 201036 11. 201037 . Insert brake booster into the bracket of brake pedal. 201009 9. (As indicated by arrow in the diagram)。 10. Install a sealing member on the contact surface between brake booster and front enclosure. Tightening Tighten the connector to 20-35N m . Tightening Tighten the bolt of left front engine suspension and the longitudinal side sill of body frame to 65 N m。 Tighten transmission bracket and snubber beneath body frame to 60 N m .Steering system 2-37 8. Tighten the connector between high-pressure hose and oil return hose and steering gear.

Lower the engine. 15. Install brake booster onto the bracket of brake pedal (as indicated by arrow in diagram). Lead the knurled bolt of guide bar into transmission connecting bar. Do not tighten the clamping collar of transmission connecting bar.2-38 Steering system 12. Press in clamp pin with spring (as indicated by arrow in diagram) untill both sides of spring clip ard locked. 201026 13. 201038 14. Install outside connecting bar of transmission. Tightening Tighten brake booster and pedal supporter to 22 N m. 201023 .

201019 . Place the lower end of steering knuckle on steering gear and push it to the bottom. Connect steering knuckle with steering column and put it to the mounting position. 201020 18. Tightening Tighten steering knuckle and steering gear or steering column to 20-26N m. Place the fork of brake booster on the brake pedal. 19. Tighten the bolts on steering knuckle (as indicated by arrow in the diagram).Steering system 2-39 16. 201022 17. Insert the pin of shifting fork (as indicated by arrow in the diagram) and tighten it.

Inspect the hydraulic system for any leakage. 201040 . See Gather in Wheel Alignment. See Filling/Deflation of Hydraulic System. 22. Tighten the bolts on refrigerant recovery tank. Install brake master cylinder and brake fluid compensation tank. Tightening Tighten brake master cylinder and brake booster to 22N m . Inspect gather.2-40 Steering system 20. 201039 21. Insert vacuum tube into brake booster. 201018 23. Tighten the bolt of clutch dragline bracket (as indicated by arrow in the diagram) and connect clutch dragline. Adjustment Inspect steering liquid level.

Loosen the connector tightening oil inlet and oilout hardtube and the oil pipe of power steering oil cylinder (as indicated by arrow in diagram) and steering gear. 2.13 Seal of Steering Gear . Be careful when handling sealing members and sealing surface.Power Steering Disassembly Procedures 1. 201041 Note: The two hard tubes should have no contact with corrugated cover. Ensure absolute cleanness. Tightening Tighten oilin and oilout hard tubes and oil lines of power steering oil cylinder and steering gear to 20-35 N m .Steering system 2-41 2. When removing pipelines from steering gear. nor should it be blended.1. brake booster should be removed from partition board and set aside.4. 201009 .

nor should it be blended. The two hard tubes should have no contact with corrugated cover. 201009 . Ensure absolute cleanness. Loosen the connector tightening the two hard tubes and tighten oil lines of power steering oil cylinder (as indicated by arrow in diagram) and steering gear.2-42 Steering system 3. Be careful when making the seal. Tighten oilin and oilout hard tubes and the steering gear (as indicated by arrow in diagram). Note: If there is leakage in any pipeline. 201041 Installation Procedures Tools required S-9407235 Nipper 1. the whole pipeline should be replaced. Tightening Tighten oilin and oilout hard tubes and the steering gear (as indicated by arrow in diagram) to 20-35 N m .

On Vehicle.Steering system 2-43 2. Use special nipper S-9407235 to nip the clamping collar of each corrugated cover. Replace the two corrugated cover on steering gear (as indicated by arrow in diagram) (with steering gear removed). 3. 201016 . See Replacement of Corrugated Cover of Steering Gear .

Flow control throttle orifice is a part of the high- pressure hose connector. control arm. Integral 2.5. besides inspecting the The motion of steering wheel will have the following alignment of chassis (inspection of chassis alignment effect: should always be conducted under all circumstances). Dog . When inserting a bolt. The rotary control valve is used to make the steering liquid flow toward the side of rack piston. Collar of steering pump 4. The motion of steering wheel is transfered to the following components should also be visually pinion. otherwise End plate changes in material behavior thus caused will have negative impact on operation safety of the The small opening at the side of the steering pump vehicle.1. Rack piston transforms hydraulic pressure into linear force. Regularly Thrust plate replace locknuts. After an accident takes place. earthing lead should be Blades disconnected and the negative terminal of The opening at the back of the steering pump housing battery should be covered.1. 1. tooth. such as spring hanger. its whole travelling circle. steering column flow control valve is used to limit the pressure of should be locked at Straight Ahead position so steering pump. stabilizer bar. as to avoid any damage to contact devices and the steering wheel during reinstallation.2 Explanation of Power Steering rack piston has the following functions: Pump 1.1. Steering knucke turns the wheels. 4. Linear force is transferred to internal and Drive shaft external steering knuckle tie rods and the Housing of steering pump steering knuckle. and the external thread Dog of them should be cleaned up. steering column. Chassis and all related components. housing includes the following components: When handling steering system (steering gear.1. control valve. The teeth of pinion engage with the teeth of corrected by turning the steering wheel through rack. Linear force makes the rack move from side to provide hydraulic pressure to the sytem. includes the following components: The internal threads of a bolt using locking glue Collar of steering pump should be rethreading. This is the motion of rack. locking glue should be used. do not reuse steering liquid that has Gear been discharged. Only authorized dedicated steering liquid should 2.5. consists of the following components: 3. ). steering system should also be 3.3 Explanation of Power Steering be used. High-pressure hose connector steering knuckle tie rod. etc. Steering system with pinion and rack has a rotary bridge. Besides.1 Safety Regulations for Power Thrust plate Steering System Flow control valve Rotor If there is any electrical danger of short circuit during operation.2-44 Steering system 2. steering knuckle. Steering pump side. The motion of pinion is transferred through gear Steering system and steering connecting rod.5 Explanation and Operation 2. Rotor Please do not conduct any heat treatment to the Blades components of steering system. Pressure relief valve in the When removing steering wheel. Integral rack piston is connected with the rack. inspected for any blending or cracks: 2.5. Power steering pump is a blade type pump used to 2. and other fasteners. Flow control valve steering mechanism should be held at Straight Spring Ahead position during disassembly and installation.

sealing need greater steering force. If slight corrosion is found on the contact It is recommended to seal drive shaft with lip seal at the zone of a lip seal. sealing surface completely cleaned. use crocus cloth to clean the surface following position: of the drive shaft. If there is no hydraulic member should be replaced after inspection and boosting force. Gear shaft of power steering pump . On the steering gear 2. the system will If any leakage is found at the following position. the system will maintain manual control.Steering system 2-45 If there is no hydraulic boosting force.5.4 Recommendation about Gear shaft of power steering pump Replacement of Sealing Members Only when severe pitting is found should the shaft be replaced. Only when a leakage still exists after On the steering gear the first cleaning up should the steering gear or steering pump be replaced.1.

2-46 Steering system 2.6 Special Tools Tool identification/ Graphics description Tool identification/ Graphics description KM354-B Pressure gage Used to inspect oil pressure of power J-830901 steering gear Puller Used to remove steering wheel KM-354-B J-830901 J-810902 Pulling fork Used to press the steering knuckle tie rod of steering knuckle J-810902 S-9409203 Detector Used to inspect the mounted position of steering mechanism S-9409203 S-9407235 Niper Used to tighten retaining clip of corrugated cover S-9407235 KM-551-A Detector Used to inspect the straightahead position of power steering gear KM-551-A .1.

2.Steering system Steering wheel and steering column 2-47 2.1 Specifications 2.2.1.1Tithtening Torque of Fasteners Applications Specifications Nut of steering wheel and steering shaft 15-25N m Bracket of steering column and lower supporting point of 20-26N m steering column Clamping bolt of steering shaft collar 20-26N m Clamping bolt of steering gear collar 20-26N m Separating die block and steering column bracket 20-26N m .2Steering wheel and Steering Column 2.

2.2-48 Steering wheel and steering column Steering system 2.2.2.2 Identification of Appearance 2.1 Steering Wheel and Steering Column .Exploded View 203001 Legend (1) Housing of ignition switch (12) Nut (2) Outer cover of ignition switch (13) Lock washer (3) Locking core of ignition switch (14) Steering wheel (4) Binding clip of ignition lock (15) Coil of safety air bag (if equipped) (5) Safety bolt (16) Thrust spring (6) Contact member (17) Spacer (7) Bolt (18) Contact spring (8) Upper half of signal switch cover cap (19) Signal switch (9) Windscreen wiper switch (20) Housing of signal switch (10) Contact spring (21) Lower half of signal switch cover cap (11) Horn button (22) Guide bearing .

Steering system Steering wheel and steering column 2-49 (23) Upper steering shaft (30) Guide bearing (24) Positioning plug (31) Gasket (25) M8 bolt (32) Bolt (26) E-ring (33) Steering column (27) Gasket (34) Bolt (28) Nut (35) Positioning plug (29) Gasket .

2. If required. If required.2.3 Key Cannot Be Drawn out at Closed or Locked Position Problems Measures Setup of the core of ignition switch lock is incorrect. . Inspect this component.3. 2. See Replacement of the Steering column Core Ignition Switch Lock or Replacement of Steering Column Assembly. replace it. replace the core of the lock.2.2. replace the core of the lock. If required. ignition switch lock.2. adjust core of the lock. replace ignition switch. If required.1 Locking System Cannot Be Unlocked Problems Measures The core of the lock may have been damaged. 2. Core of the lock If required.3 Diagnostic Message and Procedure 2. The core of the lock has been damaged. See Replacement of the Core of Ignition Switch Lock.2 Locking System Cannot Be Locked Problems Measures The following components may have been damaged: Inspect this component.2. replace ignition switch.2-50 Steering wheel and steering column Steering system 2. See Replacement of the Core of Ignition Switch Lock. replace the component.3. See Replacement of the Core of Ignition Switch Lock. See Replacement of the Core of Ignition Switch Lock. If required. replace the component. If necessary. replace the component. Inspect ignition switch.3.5 Greating locking force Problems Measures The following components may have been damaged: core of Inspect the component. If required.3.3. If necessary.2. 2. Ignition switch is worn or damaged.4 Greater locking force is needed between closed and locked positions Problems Measures The core of the lock is worn or damaged. See Replacement of the Core of Ignition Switch Lock.

a clearance can be felt. See Replacement of Steering Wheel. See Replacement of Steering Column Assembly. . Inspect the installation of steering wheel. The steering wheel has been damaged.2. See damaged. Inspect the supporting assembly of steering column. The supporting assembly of steering column is loose or 1.6 Inspection of steering shaft When turning the steering wheel.Steering system Steering wheel and steering column 2-51 2.3. See Replacement of Steering Wheel. 1. Replacement of Steering Column Assembly. But it is There is a clattering sound when the steering recommended to replace the steering shaft. Inspect to see whether the plastic pin of steering shaft If the pin of steering shaft has been broken by the slight is broken. Retighten the holddown nut of steering wheel. Replace the steering wheel. 2.2. Inspect steering wheel.8 Steering wheel is loose Problems Measures The holddown nut of steering wheel is loose. See Replacement of Power Steering Gear. See ithtening Torque of Fastenersî. Inspect steering counter shaft. 2. 2.7 Steering column is loose Problems Measures The holddown bolt of steering column is loose. Repair or replace the supporting assembly of steering column. Tighten the holddown bolt of steering column to the required torque. 1. The following are the symptoms of such bumping but other components are not severly condition: damaged. 2. the vehicle can still safely steer. Steering counter shaft is worn or damaged. See Replacement of Steering Wheel.3. See Replacement of Steering Wheel.3. 2.2. shaft slightly bumping from the side. See Replacement of Power Steering Gearî Replace steering counter shaft.

Disassembly procedures 1. 2.2. 203002 Installation procedures 1. move the core seat from position (1) to position (2) until a "clickî indicating it has reached designated position is heard. see Replacement of Panel.1 Replacement of the core of ignition switch lockî. Align the lobe of the core of ignition switch lock with the groove in the core seat. A Click sound indicates it has reached its designated position. 203003 .2-52 Steering wheel and steering column Steering system 2. 2. Insert the needlepoint into the unlocking hole.2. then insert the core into the core seat. Disassemble the plastic jacket of steering column. By pushing the travelling block toward the direction of arrow in the diagram.4 Repair guidance 2. then draw out the core of ignition switch lock from the lockseat.4.

2. see Replacement of Airbag Device . Caution: When handling safety airbag. Notice: When removing steering wheel.On the Driver Side in Safety Airbag System. Airbag Safety Regulations should be followed. 203005 . use KM-551-A. 203004 2.Steering system Steering wheel and steering column 2-53 2.2 Replacement of Steering Wheel Disassembly Procedures Tools required S-9409202 Detector KM-551-A Detector J830901 puller 1. for vehicles with power steering. lock steering column at straightahead position so as to ensure installation hereafter will not damage the coil of safety airbag. Remove the unit of safety airbag. Remove bolt (1) tightening the coil of safety airbag.4. Insert S-9409202 to fix steering mechanism at straightahead position.

Notice: Do not cause damage to safety airbag coil. Blend the lockplate (2) of nut (1) and loose the connection with steering column. 203009 5.2-54 Steering wheel and steering column Steering system 3. Use steering wheel puller J 830901 to pull the steering wheel out of the spline of steering shaft. 203006 4. 203008 . Disassemble the harness connector of the horn from the groove of steering wheel.

Remove the coil of safety airbag from the spline of steering shaft. Notice: Before installation ensure the coil of safety airbag is at the central position. Ensure the coil of safety airbag is at central position: turn the footstep (3) of safety airbag coil (1) counterclockwise toward the left until greater resistance can be clearly felt. Disconnect the harness connector of safety airbag coil at the bracket of steering column. 203007 Installation procedures 1. 203010 2. Put the harness of horn and the harness of safety airbag into the opening of steering wheel.5 turns toward the right until the arrow mark (1) is aligned.Steering system Steering wheel and steering column 2-55 6. 203011 . then rotate it 2. Screw on the bolt tigntening the safety airbag coil and the steering wheel.

Fasten steering wheel (1) and safety airbag coil (2) on the steering column. Tightening Tighten the bolt of steering wheel and steering column to 25 N m . 203007 . Install the unit of safety airbag. The anchor pin of switch housing must fit the guiding device of the safety airbag coil. 203012 5.On the Driver Side in Safety Airbag System. 203013 6. 4. 7. Tighten the nut of steering wheel.2-56 Steering wheel and steering column Steering system 3. Install the lockplate. Connect the safety airbag unit with the harness connector of the horn. and insert it into the bracket of steering column. screw on the bolt for steering wheel and steering column. Connect the harness connector of the horn and tighten it into the groove of steering wheel. see Replacement of Airbag Device . and knik the lockplate to lock up.

Loosen signal switch (1). Remove steering column assembly. 203015 .Steering system Steering wheel and steering column 2-57 2. see Replacement of Steering Column Assembly. 2.2. 203014 3.3 Replacement of Ball Bearing at the Upper End of Steering Shaft Disassembly procedures Tools required KM-108 Disassembly/installation rove iron 1. Remove spacer (1) from steering shaft (2).4.

203017 6.2-58 Steering wheel and steering column Steering system 4. Use electric screwdriver 1411 available at the market and ± 5mm drilling bit to drill a hole of 15 mm in depth on the safety bolt. Fix steering shaft on the vice. 203016 5. Drive the screwdriver into the hole and take out the safety bolt. Drive the screwdriver into the hole and take out the safety bolt. 203018 . Remove upper housing and top end ball bearing assembly from steering column. Punch at the center of two safety bolt connecting the steering column and the ignition switch housing. Punch at the center of 4 saffety bolts on steering column. Use electric screwdriver 1411 available at the market and 5mm drilling bit to drill a hole of 15 mm in depth on the safety bolt.

Use KM-108 to remove top end ball bearing from steering column.Steering system Steering wheel and steering column 2-59 7. 203019 Installation procedures Tools required KM-108 Disassembly/installation rove iron 1. Use KM-108 to press top end ball bearing into the housing. 203020 .

203018 3. 5. Install steering column assembly. see Replacement of Steering Column Assembly. Place the upper housing and top end ball bearing assembly on steering column and connect them with a bolt. Tightening Use new safety bolt. Use bolt (1) to connect signal switch with steering shaft. 203014 .2-60 Steering wheel and steering column Steering system 2. 203015 4. tighten until the hexagon head is broken. Install spacer (1) into steering column(2).

Steering system Steering wheel and steering column 2-61 2. Remove signal switch (left) and wiper switch (right) from their switch housing. Keep steering mechanism at straightahead position. Loosen the bolt on upper cover cap of signal switch. do not hammer the steering wheel. 203021 2. Note: When installing or removing steering wheel. Loosen the clamping bolt of steering shaft collar between upper and lower steering shafts (as indicated by arrow in diagram).4. Use J 830901 to remove steering wheel from steering column.4 Replacement of Upper Steering Shaft Disassembly Procedures Tools required J830901 puller 1.2. 203022 .

Note: The lower guide bearing of steering shaft is a rubber bearing. Take out the upper steering shaft from below the steering column. 203023 4. 6. Use steering shaft to carefully remove lower guide bearing. Use electric screwdriver 1411 available at the market and 5mm drilling bit to drill a hole on the safety bolt. Loosen hexagon bolt tightening steering column on its bracket. Punch at the center of safety bolt (right arrow in figure II).2-62 Steering wheel and steering column Steering system 3. 5. Steering lock should not be at the locking position 0. 203024 . Remove steering column. Loosen the bolt with movable die block that is tightening steering column under the panel. Drive the screwdriver into the hole and take out the safety bolt.

Insert signal switch and wiper switch. Insert lower guide tube into rubber bearing. Tightening Tighten the nut of steering wheel and steering shaft to 15-25 N m . 5. Install steering wheel onto the steering shaft. Insert the new steering shaft into the steering column. 2. Press rubber bearing to the bottom.Steering system Steering wheel and steering column 2-63 Installation Procedures 1. Insert the steering shaft collar and tighten it 203022 (arrow). The head of hexagon safety bolt is nipped off. 4. Tighten the clamping bolt of steering gear collar to 20-26N m . Tighten signal switch cover cap Tightening Tighten the clamping bolt of steering shaft collar to 20-26N m . see Inspection/adjustment of Straightahead Position. 3. Use a new locknut on the left side. Tighten the bracket of steering column and the lower support point of steering column to 20-26 N m. Tightening Tighten the separating die block and the bracket of steering column to 20-26 N m . Insert the harness connector of steering lock and ignition lock into contact member. Use bolts to connect the separating die block of steering column with the bracket of steering column and the lower support point of steering column with the column bracket. Inspect the straightahead position of steering mechanism. .

Use steering shaft to carefully remove lower guide bearing from steering column.2. 5. see Replacement of Steering Wheel. Drive the screwdriver into the hole and take out the safety bolt. Lower guide bearing is a needle bearing in rubber guide sleeve. See Replacement of Ball Bearing at the Upper End of Steering Shaft. Note: Ignition lock should not be at the locking position ì0î. Remove safety airbag unit and the steering wheel with it.5 Replacement of steering column assembly Caution: When handling safety airbag. Disassembly procedures 1. Loosen the clamping bolt of steering shaft collar (as indicated by arrow in diagram). Replace the steering column. Airbag Safety Regulations should be followed. Loosen hexagon bolt tightening steering column on its bracket. . 2. 203023 7.2-64 Steering wheel and steering column Steering system 2.4. Remove the upper steering shaft housing with the upper guide bearing. Take out the upper steering shaft fro steering column. 6. 4. Use electric screwdriver 1411 available at the market and mm drilling bit to drill a hole on the safety bolt. Punch at the center of safety bolt (on the right side). Loosen the separating die block under the panel. 8. Remove steering column. 203022 3.

203027 . (arrow). Note: Pay attention to the guide lug in the housing (arrow). Insert upper steering shaft housing together with upper steering shaft ball bearing into the steering column and tighten it. Use 4 safety bolts to tighten the upper steering shaft housing and the steering column. See Replacement of Ball Bearing at the Upper End of Steering Shaft.Steering system Steering wheel and steering column 2-65 Installation procedures 1. 203026 2. Tighten the bolts untill their heads are nipped off.

Insert the new steering shaft into the steering column. 203022 . Install steering column. 203023 7. Note: Steering and ignition lock should not be at the locking position ì0î. Press lower guide bearing into steering column and press it to the bottom. Insert steering shaft into steering shaft collar and tighten it. Hexagon heads are nipped off. 6.2-66 Steering wheel and steering column Steering system 3. Tighten safety bolts. Screw on hexagon bolts that tighten steering column. 4. 203028 5. Use bolts to tighten the housing of ignition lock and the upper steering shaft housing.

Tighten the bracket of steering column and the lower support point of steering column to 20-26 N m. Install steering wheel with safety airbag and the safety airbag unit. Inspect the straightahead position of steering mechanism. Tighten the clamping bolt of steering gear collar to 20-26N m . 9. . see Inspection/Adjustment of Straight Ahead Position in Power Steering System. see operation procedures in relevant sections. Tightening Tighten the clamping bolt of steering shaft collar to 20-26N m . Tighten the separating die block and the bracket of steering column to 20-26N m . 203029 Tighten the nut of steering wheel and steering shaft to 15-25 N m . Tighten the right side safety bolts untill their heads are nipped off. Tighten the separating die block under the panel.Steering system Steering wheel and steering column 2-67 8. 10.

2. 2.5.2-68 Steering wheel and steering column Steering system 2. steering column will contract to reduce the probability of injuring the driver. Use specified screw threads. Steering column falls off. The following components on steering column will fulfill functions described below: 1.1 Explanation of Steering Wheel and Steering Column Components of steering column are to fulfill functions other than steering. The steering wheel extractor that has been used is not the one recommended. The end of steering shaft has experienced severe bumping. Multifunction Multifunction control rod controls the following components: - Traffic beam of front headlight - Windscreen wiper and cleaner Disassembly and reinstallation of steering column is simple. 4. .5 Explanation and Operation 2. Plastic will retain the rigidity of steering column and it is likely to be nipped off or become loose under the following conditions: 1. Steering column Steering column absorbs energy. bolts and nuts to ensure energy absorption function. Ignition switch and steering lock on steering column Ignition and steering can be locked to prevent vehicles with ignition switch and steering lock mounted on steering column be stolen. Care should be taken when handling steering column after it has been removed from the vehicle. An object is reclining on the steering column. 3. 2. 3.2. When central collision occurs.

Steering system Steering wheel and steering column 2-69 2.2.6 Special Tools Tool identification/ Graphics description J-830901 Puller (used to remove steering wheel) J-830901 S-9409202 Detector(used to inspect the straight ahead position of manual steering gear) S-9409202 KM-551-A Detector (used to inspect the straightahead position of power steering gear) KM-551-A KM-108 (Disassembly/ Installation Rove Iron 86) KM-108 .

2-70 Steering wheel and steering column Steering system Blank .

............4 Explanation and operation ............3............................3...... 3.............. 3..................4.............1Replacement of front drive shaft bearing . 3-71 3........3.3........................................12 Replacement of the bush of tie bar bracket..................................3.....2 Replacement of steering knuckle .........1 Specifications ....3.................1..........................12 Replacement of stabilizer bar . 3-15 3.3..............5Instruction of tyres ....2........... 3-3 3...........4...............4Replacement of shock absorbing strut .....3......3..........4........2........3.....4......4.. 3-72 3.........2Replacement of steel wheel cap...........1..4................................2.........3...............3.................2Front suspension.....2Replacement of back axle assembly..................................... 3-80 3....4........1..4...........2... 3-22 ..3.....3.3 Gather ......9 Replacement of lower globe joint .........5Replacement of shock absorbing strut with steering knuckle .....4................3............4.2Correction of departure/wandering of radialply tyre 3... 3-81 3...4....2 Inspection of wheel alignment............................. 3-75 3..3-11 3..... 3-80 3....4.............. 3-23 3..1........................1..11Explanation on the repair of steel wheel. 3-71 3...........10 Replacement of stabilizer bar ............. 3-37 3................ 3-49 3... 3-12 3...4....1 Exploded view ......................irregular or early wearing 3-72 3..........................4.............2........... 3-82 3......2................1............8Lubrication of wheel bolts ..........................................4..4..........4Direction for use of tyre chain..........2 Tithtening Torque of Fasteners................3................ 3-71 3............. 3-44 3... 3-44 3............3....2....4. 3-3 3..4...2..... 3-57 3............ 3-32 3..........5Special tools ...1.......Suspension system table of contents 3-1 3 Suspension system 3....................2............................ 3-61 3.......................1 Specifications .... 3-36 3............1 Alignment of steering wheel at central position .. 3-79 3......... 3-40 3...........2...4 Special tools . .........4 Replacement of bush of rear axle ..3Inflation instruction of tyres.........3.............. 3-6 3..............1....5 Special tools .......1 Specifications ....3 Repair guidance .1General information..... 3-65 3..4... 3-70 3................ 3-4 ......... 3-83 3..2.................3 Repair guidance .. 3-83 3........3......... 3-70 ..5Replacement of wheel .........2.........3. 3-80 3...3Replacement of back axle (welded assembly) 3-52 3........1 Camber.....4......3... 3-11 3..........................3............1..........2............1.......4........... 3-82 3.... 3-74 3........2......3.......3.......3 Rear suspension .....4............3.11 Replacement of tie bar ................3..........4..............4............. 3-73 3.............................11Replacement of shock absorber / buffer block .................... 3-59 3.......3..............................2Repair instruction of tyres...4..................1Setting angle (with no load)..... 3-68 3..6Adjustment of clearance between wheel bearings .............. 3-55 3............7 Position exchange of tyres ..........3........................ 3-59 3.......................4..2............3.4........ 3-4 3.......... 3-28 3.... 3-43 3.................... 3-38 3.......4........... 3-22 3........8 Replacement of lower control arm bush.............3-3 .....9Replacement of rear spring.....3 Repair guidance .............3.........10Replacement of rear spring isolation block....................4. its 3........4.....2.....1 Diagnosis of tyres .......2..........................4................4. 3-84 ......... 3-80 3....3...1General information ...... 3-74 components and/or springs .....................................3..3....3............2................... 3-78 3...... 3........... 3-82 3............8 Explanation of tyres with P metric size ................ 3-82 3..3...3.3.........7 Replacement of lower control arm......2..................5Replacement of wheel hub assembly......................1General information ...3..1..........................10 Explanaiton of tyre replacement ........3..........6 Replacement of shock absorbing strut.....3..2Identification of appearance ........4...........3 Repair of pores on aluminum/steel wheel ................. 3-74 3......4......3.3-43 3................4.......................3.... 3-71 3..3 Repair guidance .................2........4.......8 Replacement of wheel shaft ..........6Repair instruction of sedan tyre..............3Replacement of wheel hub...7Explanation of all-weather tyre .........1........1Wheel alignment ..3..................1 Exploded view ......... 3-49 3....2................ 3-80 3...........4..... 3-66 3. 3-6 3.........2... 3-70 3.......................4 Explanation and operation ......... 3-64 3.. 3-3 3................12 Explanation of aluminum wheel.3................... 3-25 3.3...7Replacement of rear wheel bearing/oil seal ...9Explanation of tyre notification.4......... 3-12 3.2.......... 3-33 3....3... 3-34 3................4.......4..4 Surface dressing of aluminum wheel.......... 3-81 3.. 3-79 3.......3..................3...2 Visual Identification ........... 3-3 3...................4..................3.......... 3-74 3.....................2..6 Replacement of tyre ....4 Tyres and wheels.......................4..2 Diagnostic messages and procedures ..2Caster..1Replacement of aluminum wheel cap. 3-77 3...1 Specifications of tyres and wheels . 3-15 3....1 Specifications . 3-49 3....3.3....

3-2 table of contents Suspension system Blank .

1 Specifications 3.50 . 2.2.1Wheel alignment Sus 3.1 Camber Camber is unadjustable. its inspection value is: -0. process and with no load There should be a maximum tolerance of 1°between the left and the right wheels. of shock absorbing strut for related operations.distance between the peak of rear (body) Measure camber angle on a test board. Install shock absorbing strut.33 ± 0.2 Inspection of wheel alignment Note: Before inspecting wheel alignment. Measurement Rh . See * Gather 1) -0. Remove shock absorbing strut.distance between the peak of front (body) wheel cap and the ground.10 3.1.8+0.05mm * Gather 1) 2) -0. 301008 . *Total quality (with no load on the seat) 4.40 toward X or Y direction. Front wheel alignment Specifications Adjustment Camber -0.1. - Free play between globe joint and steering knuckle tie rod. Caster 1.30To +0. Camber2) -1. See camber. Move steeing knuckle from central position Total gather -0.50 In the course of repair. - Calibrate tyres under maximum load. Installation Note: Install front wheel. See Replacement of Wheel.17 replacement of shock absorbing strut for related operations. caster and gather for related operations.1Setting angle (with no load) 3. See specifications of tyre and wheel for authorized pressure.50 1. 3.1. Suspension system Wheel alignment 3-3 3. first inspect: - Status of tyres. No adjustment can be the steering knuckle be tightened. Fuel tank should be half full. See replacement Maximum difference between Rv and Rh is 10mm.1mm 2:φ 12. - Status of outer felloe of the wheel. wheel cap and the ground.85 ± 0.50 ± 0. Rv .1. 1) Positive value = gather.1. a camber angle of 0°50' will be obtained.40To +0. made in maintenance process. negative value = toe-out Note: Only after adjusting the camber angle of wheels 2) Predetermined values have been set in can the connecting bolt of shock absorbing strut and production process.27 ± 0. camber angle can be adjusted by changing the size of connecting hole.50 1:0.27 ± Specifications of vehicle in production 0. Enlarge lower fastening hole (see Figure Rear wheel alignment Specifications 301008).

3 Gather Gather should be in the following range: -0. insert knuckle. 302016 3.85° ± 0.For this end. tighten the bolt to 90 N m. Compress the carriage spring for several times and inspect the change of camber angle. and change 45 °To 60° . its inspection value is: 1. .3-4 Wheel alignment Suspension system Adjustment 1. 2. 6. Lower the vehivle slowly. pull the front wheel . Every time the bolt is screwed off.2Caster Caster is unadjustable. Loosen the bolt (1) of shock absorbing strut and steering knuckle. 301001 Use a steering wheel limiter available in the market to set the steering wheel at straightahead position.2.5 °. the camber angle will graphics). Raise the vehicle at the foreside.2.33° ± 0. Set reference dimension at straightahead position 4. outward and set it at the maximum camber angle (see indication of arrow in Figure 301009 Measurement ).1. it must be replaced.17° 3.1. 7. After the normal value has been reached. relevant wheels should be unrestricted. change in the negative direction. At the peak of the wheel. To clamp shock absorbing strut and steering 1=404 ± 3mm (435 ± 2mm) 1). 301009 3. tighten the bolt to measuring tool KM-551-A or KM-551-1 together with KM-551-21) inbetween the fastening shoulder (2) of left 10 N m。 steering housing and the seat of right dust cap (see the 5.

Subscript 1): for vehicles with power steering.tightening torque 50N m. 301003 Adjustment Retighten the lock nut . dimension (1) between the should of dust cap and the lock nut should be retained (see graphics) 174 ± 6mm (163 ± 6mm) 1). then the steering wheel should be reverted to straightahead position . If deviation between the position of steering wheel and the central position of steering wheel is greater than ± 5°. Remove distortion caused by folded dust cap and replace the clamping collar. Adjustment Remove clamping collar (1) from folded hood. 301002 Nominal value . and the bolt of lower clamping flange of steering shaft should be level.Adjust total gather by adjusting one by one the gathers on the left side and the right side. Loosen locknut (2). Subscript 1): for vehicles with hydraulic power steering. Adjust gather value by turning steering knuckle tie rod.see alignment of central position of steering wheel (for vehicles with safety airbag) .Suspension system Wheel alignment 3-5 Note: The steering wheel should be at the central position ± 5°.when adjusting and inspecting gather value. .

301004 2.1. 3.1 Alignment of steering wheel at central position Caution: When handling safety airbag system.3 Repair guidance 3.1. airbag sefety regulations should be followed. Wait one minute before starting operation until condenser discharge is completed. Remove signal control board. Disassembly procedures 1. 815020 .3. The right graphic representation is a signal control board with steering wheel removed.3-6 Wheel alignment Suspension system 3. 4. Disconnect the earth wire of battery and cover the negative pole. Loosen binding bolt (1) and (2).

7. see inspection/adjustment of straightahead position. Set the steering wheel at straightahead position (6). 8. Set safety airbag unit aside. Loosen the two bolts (1) on the coil of safety airbag. Remove upper bolt (3) of safety airbag unit from the rear side of steering wheel. with the side with gasket upward. 6.Suspension system Wheel alignment 3-7 5. Bend the locking plate of steering wheel clamp nut and remove the clamp nut. Turn the steering wheel rightwards from straightahead position (1) to 90°(2). 9. Then remove the second upper bolt (4) of safety airbag unit from the rear side of steering wheel. 12. Carefully lift safety airbag unit and draw down harness connector from the safety airbag unit (arrow). 13. Set steering mechanims at straightahead position. Remove safety airbag unit from steering wheel. 203005 . Turn the steering wheel backward to 180°(5). 301006 11. 301005 10.

Remove the coil of safety airbag from steering shaft. Use steering wheel puller J 830901 to pull the steering wheel out of the spline of steering shaft. 17. 203007 Installation procedures Determine the central position of the coil of safety airbag. then turn backwards about two and a half turns until it is aligned with arrow (1). Notice: Don't cause damage to safety airbag coil.3-8 Wheel alignment Suspension system 14. Note: Don't turn too much. 203010 . Pull out harness connector (arrow in diagram) of the safety airbag from the bracket of steering column. Remove harness connector of the horn from the groove of steering wheel. otherwise the spring of contact devices will be damaged. Turn bearer (3) of the coil of safety airbag (2) leftwards until greater resistance can be clearly felt. 15. 203008 16.

301007 3. 203012 5. 203006 . 7. Lock the clamping nut of steering wheel with a locking plate. Alignment of locking plate(2). The anchor pin of signal switch(3) must fit the guiding device of the safety airbag coil. 2. Screw on the bolt tigntening the safety airbag coil and the steering wheel. Put steering wheel (1) together with safety airbag coil (2) onto the steering shaft. Press steering wheel into steering shaft with the opposite force of spring force. Connect harness connector of the horn and the coil of safety airbag and insert it into the groove. Tightening Tighten steering wheel and steering shaft to 25 N m. 6. see inspection/adjustment of straightahead position. Note: Ensure steering mechanims are at straightahead position. 4. Put harness connector of the horn and the safety airbag through the opening of steering wheel.Suspension system Wheel alignment 3-9 1.

Tightening Tighten safety airbag unit to the steering wheel until 8 N m. 11. 203007 . and install safety airbag unit onto the steering wheel.3-10 Wheel alignment Suspension system 8. Install signal control board. 301006 9. Connect the safety airbag unit with harness connector of the horn. Connect earth wire of the battery. 10. Connect harness connector with safety airbag unit. and integrate it with the bracket on steering column.

Loosen capstan nut. and use the cotter pin to fasten it. 2.2. Tighten to 50 N M and turn 90 °to 105°. Pretighten to 100 N M.Suspension system Front suspension 3-11 3. .1 Specifications Applications Metric system Drive shaft and front hub 1) Brake backing plate and steering knuckle 4N M Brake tongs and steering knuckle 95 N M Brake disc and wheel hub 4N M Wheel speed sensor and steering knuckle (for vehicles with ABS) 8N M Front shock absorbing strut and steering knuckle 2) Lower globe joint and steering knuckle 30 N M Lower control arm and body 60 N M End of steering knuckle tie rod and steering knuckle 45 N M Clamping collar of stabilizer bar and tie bar 20 N M Front shock absorbing strut and the dome of it 30 N M Bracket of shock absorbing strut and piston rod of shock absorber 60 N M Tie bar and tie bar bracket 90 N M Tie bar and lower globe joint and lower control arm 3) Tie bar bracket and front cross rail 4) Every time a binding bolt subjected to yield limit is loosened in the process of screw fastening. loosen it and return to the next hole. Then tighten to 20 N M and turn 90°. 1.2Front suspension 3. If the hole of cotter pin can not align with the capstan nut. 4. Then tighten to 90 N M and turn 45° to 60°. Then tighten to 90 N M and turn 30° to 45°. it should be replaced. 3. Pretighten to 50 N M.

2 Visual Identification 3.2.3-12 Front suspension Suspension system 3.2.1 Exploded view Front hub. front drive shaft bearing 302001 Legend (1) Steering knuckle (7) Capstan nut (2) Bolt (8) Gasket (3) Shackles for springs (9) Wheel hub (4) Brake disc (10) Bearing (5) Cotter pin (11) Brake backing plate (6) Bolt .2.

Suspension system Front suspension 3-13 Assembly of front shock absorber 302002 Legend (1) Gasket (8) Thrust collar (2) lock nut (9) Vibration isolation block (3) Lock nut (10) Spring (4) Stopper (11) Shock absorbing strut (5) Footstep of shock absorbing strut (12) Buffer block (6) Spacer (13) Dust cap (7) Spring seat with bearing .

control arm and tie bar 302003 Legend (1) Bracket of tie bar (10) Control arm (2) Stabilizer bar (11) Globe joint (3) Gasket (12) Nut (4) Tie bar (13) Bush of control arm (5) Upper clamping collar (14) Bolt (6) Vibration isolation block (15) Lock nut (7) Bolt (16) Bush of tie bar bracket (8) Lower clamping collar (17) Bolt (9) Nut (18) Lock nut .3-14 Front suspension Suspension system Stabilizer bar.

Use the wheel hub as reference to make alignment. Remove the bolt with cotter pin from the capstan nut. Overhang the brake tongs in the arch of the wheel.810300 Support wrench J-810902 puller 1. 5. 302005 .2. Use a bolt to connect J-810300 (1) with the wheel hub.Suspension system Front suspension 3-15 3. 7. Remove the capstan nut. 302004 6.2.3 Repair guidance 3.3. 4.1Replacement of front drive shaft bearing Disassembly procedures Tools required KM-466-A Puller/installer J . 2. Use it as a support to loosen bolts on the wheel. Remove the bolt connecting brake tongs and steering knuckle (shown by arrow). Note: Keep hydraulic brake system turned off. 3.

3-16 Front suspension Suspension system 8. Use J-810902 (1) to press the end out of the steering knuckle. Remove check bolt (1) connecting brake disc and wheel hub. (for vehicles with ABS). 302008 . Remove bolt(1) connecting steering knuckle and shock absorbing strut. 14. Remove brake disc. 302007 13. Remove the nut on the end of steering knuckle tie rod (as shown by arrow). 15. Remove the bolt connecting wheel speed sensor and steering knuckle (shown by arrow). 302006 11. Remove globe joint. 12. 9. Remove the bolt connecting globe joint and steering knuckle (upper arrow). 10.

Note: Overhang drive shaft to protect the connector. 302011 18.Suspension system Front suspension 3-17 16. If necessary. Remove the whole steering knuckle from the drive shaft (Figure I). then remove brake backing plate. Use a check ring snipper to remove bearing collar from steering knuckle. Loosen bolt(1).use wheel hub removal tool available in the market to press steering knuckle out of the driving shaft (Figure I). 19. 302012 . 302009 17. Use hydraulic press and KM-466-5(2) to press the bearing out of wheel hub.

22. Use KM-466-1 (1) to remove inner bearing ring from front wheel hub. Clean up the groove of check ring in steering knuckle to ensure proper alignment.3-18 Front suspension Suspension system 20. Note: Don't reuse damaged bearing. KM-466-4 (3) and KM-466-5 (2) to press the bearing out of steering knuckle. 302013 . Use KM-466-2 (4). 302010 21.

Insert inner check ring into the steering knuckle. 7. Use special lubricant to slightly lubricate the inner bearing surface of steering knuckle. Apply locking agent on the new bolt connecting brake backing plate with steering knuckle. Use KM-466-5 (1) to press wheel hub into the bearing. 302015 . Place KM-466-3 (2) under the inner ring center of the bearing (otherwise the bearing will be damaged). The locking lobe should face downwards. 3.Suspension system Front suspension 3-19 Installation procedures Tools required KM-466-A Puller/installer J . 6. Tightening Tighten the bolt to 4 N m. Use KM-466-4 (2) and KM-466-5 (3) to press the bearing into steering knuckle so that it is on the check ring. and tighten the bolt. 302014 5. 4. Pull lobe should face downwards (installation position). (Installation position) 2.810300 Support wrench 1. Insert outer check ring into the steering knuckle.

Don't tighten the nut at this moment. 17. 11. Install the new nut. Install check bolt to connect brake disc and 302017 wheel hub. Tightening Tighten the bolt for brake disc and wheel hub to 4 N M. 13. From rear to front (viewed from the front of the vehicle) insert bolt (1) to connect globe joint and steering knuckle. 15. Use transmission oil to lubricate the spline of driving shaft. 10. Install the connector(2) of steering knuckle tie rod onto the steering knuckle. Insert driving shaft into front wheel hub. 302016 12. 14. Tightening Tighten the new locknut to 30 N M. Install the new locknut. From rear to front (driving direction) insert new bolt (1) to connect steering knuckle and shock absorbing strut. Install new capstan nut and gasket. . Tightening Tighten the new nut to 50 N M. then tighten it to 90N M then turn45°+15°. Install the new nut.3-20 Front suspension Suspension system 8. 9. 16. Tightening Tighten the new nut to 35 N M.

Suspension system Front suspension 3-21 18. then loosen capstan nut once again. Tightening Tighten the bolt for brake tongs and steering knuckle to 95 N M. 21. 19. 302018 20. Use the new bolt and new nut to connect wheel speed sensor and steering knuckle. Tightening Tighten the nut for wheel speed sensor and steering knuckle to 8 N M. 302020 . Tightening Pretighten the nut for driving shaft and front wheel hub to 100 N M. 23. Install bolt(3) to connect brake tongs and steering knuckle. Apply locking agent on the new bolt. loosen it and turn to the next hole position. and use the cotter pin to fasten it. (for vehicles with ABS). If the hole of cotter pin can not align with the capstan nut. Install corresponding wheels and pay attention to the related position of wheel hubs. Then tighten to 20 N M and turn 90 _90. Tighten capstan nut and insert it into cotter pin. 302019 22. Insert driving shaft into front wheel hub. Use J-810300 to support the wheel hub from reverse direction.

The inner ring of bearing can remain in the oil hub. See replacement of front drive shaft bearing.3Replacement of wheel hub 1.3. 302021 3.3-22 Front suspension Suspension system 3.2.2 Replacement of steering knuckle 1. See replacement of front drive shaft bearing. 302022 .3.2.

Disassemble the wheel. See replacement of wheels in tyres and wheels.Suspension system Front suspension 3-23 3. For right spring hanger: loosen connector clip of the bracket and remove the bolt of harness guider on the arch cap of spring hanger. (for vehicles with ABS). 1. Disconnect wheel speed sensor. The vehicle cannot be raised by a vehicle lifting device of the suspension contacting type. Remove nut (1) on shock absorbing strut. Remove shock absorbing strut. See hoisting and lifting of vehicle in general information.2. 4.3. 6. 302024 . 3.4Replacement of shock absorbing strut Disassembly procedures Note: The vehicle can only be raised with a vehicle lifting device of the carriage contacting type. Raise the vehicle and support it. 2. 302022 5. Remove bolt (1).

302022 . Tightening Tighten the upper nut to 30 N M. Tightening Pretighten the nut to 50 N M. Install the wheel. 5. 3. and clamp the connector clip into the bracket. 6. From rear to front (viewing from travelling direction) install new bolt (1) and new lock nut connecting the shock absorbing strut and the steering knuckle. Install new locknut M8(1) and the gasket. Install shock absorbing strut.3-24 Front suspension Suspension system Installation procedures 1. Lower the vehicle.For right front shock absorbing strut: fasten the harness guider to the arch cap of spring hanger. (for vehicles with ABS). then tighten to 90 N M and rotate 45°+15°. Connect wheel speed sensor. 302024 4. 2. See replacement of wheels in tyres and wheels.

Disassemble the wheel. Press the globe joint together with the control arm out of steering knuckle. 3. Remove the harness clip of wheel speed sensor from the bracket of shock absorbing strut (shown by upper arrow). 8.5Replacement of shock absorbing strut with steering knuckle Disassembly procedures Note: The vehicle can only be raised by a vehicle lifting device of the carriage contacting type. 5. Remove the bolt of brake tongs. See hoisting and lifting of vehicle in general information. 302025 7. See replacement of front drive shaft bearing. (for vehicles with ABS).2. (for vehicles with ABS). Remove the end of steering knuckle tie rod and the globe joint. 302026 . 2. 1. 6.3. The vehicle cannot be raised with a vehicle lifting device of the suspension contacting type.Suspension system Front suspension 3-25 3. 9. Place a bar at the position of the bolt connecting the bracket and the tie bar of control arm (as shown in the figure). Raise the vehicle and support it. Remove the bolt connecting wheel speed sensor and the bracket (shown by lower arrow). See replacement of wheels in tyres and wheels. 4. Remove the capstan nut on drive shaft of the wheel.

If necessary. 2. Install new locknut (as shown by arrow).3-26 Front suspension Suspension system 10. See replacement of shock absorbing strut assembly. Remove the assembly of shock absorbing strut and the steering knuckle from drive shaft (as shown if Figure I). Ensure that the fitting surface of wheel hub and wheel bearing is cleared of any dust. Install shock absorbing strut with steering knuckle. 302009 Installation procedures 1. Remove upper nut of shock absorbing strut.use wheel hub removal tool available in the market to press the assembly out of the driving shaft (Figure II). 302027 3. 302028 . but don't tighten it. 11.

14. Tighten the nut of globe joint to 30 N M. Tightening Tighten wheel speed sensor with steering knuckle to 8 N M. Insert the bolt of globe joint from rear to front. 5. then tighten it. 8. Use the new bolt (as shown by arrow) to install brake tongs onto steering knuckle. Tightening Pretighten to 30 N M. Insert wheel driving shaft into front wheel hub. 9. Install the wheel. See replacement of wheels in tyres and wheels. 11. See replacement of wheel drive shaft . 18. (for vehicles with ABS). 12. Ensure the arrangement of wires is correct (Figure I). 17. Tightening Tighten the bolt to 95 N M. 302031 . Install wheel drive shaft. Install wheel speed sensor to the steering knuckle (Figure II). 302029 10. 16. 15. Use the new locknut to tighten it. (for vehicles with ABS). Lower the vehicle. 302030 13. See replacement of front drive shaft bearing. Clamp the harness of wheel speed sensor with the bracket of shock absorbing strut. Use transmission lubricant to lubricate the spline of wheel hub. Tighten the capstan nut. Install upper nut of shock absorbing strut. Install shock absorbing strut.Suspension system Front suspension 3-27 4. 7. Use the new casptan nut and gasket and loosely install them on the wheel hub. 6. Connect steering knuckle tie (1) and globe joint (2) with steering knuckle. Don't tighten them at this time. Tightening Tighten the nut of steering knuckle tie rod to 40- 48 N M.

2.3-28 Front suspension Suspension system 3. 302032 3. 302033 . Loosen the spring compressor so that the claws are between the top and the bottom of the spring (as shown by arrow).3.6 Replacement of shock absorbing strut.2. 4. Install a pair of claws agreeing with diameter of the spring onto spring compressor J-810301-B. its components and/or springs Disassembly procedures Tools required J-810301-B Spring compressor KM-808 Special wrench 1. Compress the spring until it is separated from the upper and lower spring seats. then fix it on a table vice. If assembly fixture cannot be fixed on the work bench.

Suspension system Front suspension 3-29 5. 9. 8. 7. 302034 10. The ratchet wrench should be Vertical with KM-808 (as shown by the figure). Use KM-808 to remove the locknut. Remove the bracket of shock absorbing strut with limiter and gasket from piston connecting bar. 6. Remove spring compressor with spring and dust cap. 302035 . Remove upper spring seat with shock absorbing strut. 11. (1) Buffer block (2) Dust cap (3) Vibration isolation block (4) Footstep of shock absorbing strut (5) Upper spring seat with bearing and limiter. Remove buffer block. If the old shock absorbing strut has to be replaced. dismount the shock absorber. then remove the harness bracket of wheel speed sensor from the old shock absorber and install it onto the new shock absorber. Inspection: Inspect the following components according to the degree of damage and wearing.

302037 . 4. One circle on upper part of the spring and one and a half circle on lower part of the spring should be retained (as shown by arrow). If the old spring has to be replaced. loosen the spring. Install the new shock absorber into the assembly fixture. Insert the new spring into spring compressor J- 810301-B.3-30 Front suspension Suspension system Installation procedures Tools required J-810301-B Spring compressor KM-808 Special wrench KM-610 Torque wrench 1. 3. Compress the spring until the distance between the two claws is ≤ 120mm. then take the old spring out of spring compressor J-810301-B. 302036 2.

302038 6. Install buffer block. 302040 . Install upper spring seat with shock absorbing block. Ensure the offset of tightening position between the punched hole and the lower spring hanger is 180° (as shown by arrow). 7. and pull piston rod to the bottom. 302039 8. Place the spring onto spring seat. Note: The end of spring should be at the limiting hole (as shown by arrow).Suspension system Front suspension 3-31 5. Confirm the position of buffer block limiter (1).

Remove lower control arm. 302041 3.2.3. 10.7 Replacement of lower control arm Disassembly procedures 1. Remove bolt (2) and the nut connecting tie bar and globe joint with control arm. Use the new locknut to tighten them. 11. Install spacer. Note: Torque wrench KM-610 should be vertical with KM-808. 302042 . 3. bearing and positioner. Remove blot (1) and the nut connecting control arm with the body 2. Tightening Tighten to 60 N M. Use special wrench KM-610 and torque wrench KM-610 to tighten the new lock nut.3-32 Front suspension Suspension system 9.

Install globe joint and tie bar onto the control arm. 5. 302043 3.Suspension system Front suspension 3-33 Installation procedures 1.8 Replacement of lower control arm bush Disassembly procedures Tools required KM-547-1 Puller/installer 1. Install new bolt (2) and new locknut to connect globe joint and tie bar with control arm. 2.3. Use hydraulic press KM-547-1 and a suitable hard tube (2) to press the bush.2. 3. Tightening Tighten the nut to 90 N M then turn 30 ° +15°. 4. from front to rear. 302044 . From front to rear insert bolt (1) to connect control arm with the body. out of the control arm. Tightening Tighten the nut to 60 N M. Install a new nut to connect control arm with the body. Push control arm to nearly level position ( α is about ± 80°).

2. 302045 3. Remove lower globe joint.9 Replacement of lower globe joint Note: Before replacing lower globe joint. adjust the front cross rail. Disassembly procedures 1. inspect front cross rail. Don't try to repair lower globe joint. Remove the bolt connecting lower globe joint with control arm. The two side of the rubber globe of the bush should be popping out uniformly. 2.3-34 Front suspension Suspension system Installation procedures Tools required KM-547-1 Puller/installer 1. apply some soap bath on the new bush. Use KM-547-1 (1) and a suitable hard tube (3) to press the bush into control arm. The three lobes (2) with rubber curling should point to the rear (viewing from the front of the vehicle). If necessary. Before installation. 302046 . Remove the nut connecting lower globe joint with steering knuckle (shown by arrow). 3.2.3.

Insert lower globe joint into the steering knuckle. 4. Use a new bolt and a new locknut (as shown by arrow in Figure 1) to install lower globe joint onto control arm. Tighten the nut from below the control arm. 302047 3. Tightening Tighten to 90 N M then turn 30 ° +15°. Tightening Tighten to 30 N M.Suspension system Front suspension 3-35 Installation procedures 1. 302046 . 5. 2. Use a new nut to tighten it. Insert the bolt in driving direction (as shown by arrow).

10 Replacement of stabilizer bar Disassembly procedures 1.2.3-36 Front suspension Suspension system 3. Apply lubricating oil on the rubber bracket. Important: 1. 2. 2. Keep a distance between the center of clamping collar and the inner bolt. The distance 1 = 121mm. 302049 . Use new locknuts and clamping collars to tighten stabilizer bar with the left and right tie bars.3. Remove stabilizer bar. 302048 Installation procedures 1. 2. Replace the rubber seat that has been worn out or damaged. Remove the bolts (1) on clamping collars of the left and right tie bars.

globe joinnt and tie bar. 3. Install stabilizer bar.11 Replacement of tie bar Disassembly procedures 1. 2. 302050 Installation procedures 1.Suspension system Front suspension 3-37 3. See replacement of stabilizer bar. See replacement of stabilizer bar. Tightening Tighten the locknut (2) to 90 N M. 5. 4. Use new bolts and new locknuts (as shown by arrow) to connect the tie bar with control arm and globe joint. Install the gasket onto the tie bar.2. 4. 3. 302047 . Insert the tie bar into the bracket bush (4). 2. Tightening Tighten the nut to 90 N M then turn 30° +15°. Install the new locknut (2). Remove gasket (5) from the tie bar. Remove the nut (2) of front cross rail (1). Remove the bolts and nuts connecting stabilizer bar with the tie bar. Remove the tie bar (6).3. 5. Remove the bolt connecting control arm.

Remove the bracket.2.12 Replacement of the bush of tie bar bracket Disassembly procedures Tools required KM-547-4 Puller/installer 1. 302051 . Tightening Tighten the nut to 90 N M. Remove the bolt of enging hood fronm the bracket. 5. 4. Tightening Tighten the bolt to 50 N M then turn 90° +15°. 302050 Installation procedures Tools required KM-547-4 Puller/installer 1. Use KM-547-4 and a suitable hard tube to press the bush out of the bracket. 2. Tighten the bolt connecting engine hood with the bracket. 4. 3. Loosen the front nut (2) of tie bar (3). 2. 3. Remove the bolt connecting tie bar bracket (1) with front cross rail. Install gasket (5) and the bracket with bush onto the tie bar.3-38 Front suspension Suspension system 3. Tighten new locknut (2) connecting tie bar with the bracket. Tighten the new bolt connecting the bracket with the front cross rail.3.

Ensure the curling of the bush is facing forward (the front of vehicle). apply some soap bath on the new bush. 7.Suspension system Front suspension 3-39 5. Before installation. 302052 . Use KM-547-4 and a suitable hard tube to press the bush into the bracket. Ensure the curling will protrude from the bush after installation. 6.

Drive buffer bush of control range: 3 .2.3-40 Front suspension Suspension system 3.4 Special tools Tool identification/ Tool identification/ Graphics Graphics description description J-810902 J830901 Disassembly fork - Puller is used to end puller of Dismoun steering Steering knuckle tie wheel rod J-810902 J-830901 KM-547-A KM-610 Puller/installer used to remove and install Toruqe wrench 1/2 .130N M arm and buffer block of tie rod KM-547 KM-610 S-9409202 KM-466-A Detector used to Puller/installer inspect the Used to remove straightahead position Drive shaft from front of manual steering wheel hub gear S-9409202 KM-466 J-810300 KM-551-A Detector Suppert wrench Used to inspect the Used to support straightahead position wheel hub reversely of power steering When mounting gear wheel hub KM-551-A J-810300 .

Suspension system Front suspension 3-41 Tool identification/ Graphics description KM-808 Special wrench used to loosen And tighten the nut of piston rod of shock absorber KM-808 J-810301-B Spring compressor used to disassemble and assemble the shock absorbing strut of suspension J-810301-B .

3-42 Front suspension Suspension system Blank .

1 Specifications 3.3.1Tithtening Torque of Fasteners Applications Torque Nuts of back axle and body 50 N M+45°+15° Capstan nuts of wheel hub and axle .1.1.bearing clearance 25 N M Bolts of axle and back plate 50 N M+30°+15° Botls and nuts of stabilizer bar and back axle 60 N M+60°+15° Bolts of shock absorber and back axle 60 -70N M Nuts of shock absorber and body 18 -20N M Bolts of all brake hard tubes 16 N M Brake hard tubes and brake hoses 16 N M Nuts of wheel 110 N M .3 Rear suspension 3.Suspension system Rear suspension 3-43 3.

3.3.2.3-44 Rear suspension Suspension system 3.2Identification of appearance 3.1 Exploded view Back axle 303001 Legend (1) Shock absorber (3) Buffer bush of back axle (2) Back axle (4) Rear spring .

Suspension system Rear suspension 3-45 Rear suspension 303002 Legend (1) Dustproof sleeve of shock absorber (4) Back axle (2) Rear spring (5) Stabilizer bar (3) Shock absorber .

wheel and axle. oil seal 303003 Legend (1) Nut (6) Outer wheel bearing (2) Wheel and axle (7) Gasket (3) Oil seal (8) Cotter pin (4) Inner wheel bearing (9) Capstan nut (5) Wheel hub (10) Back axle cup . wheel hub.3-46 Rear suspension Suspension system Wheel bearing.

Suspension system Rear suspension 3-47 Rear spring. isolation block 303004 Legend (1) Isolation block (2) Rear spring .

3-48 Rear suspension Suspension system Shock absorber. nonconductor 303005 Legend (1) lid (6) Gasket (2) Nut (7) Dust cap (3) Positioner (8) Hollow buffer (4) Isolation block (9) Shock absorber (5) Buffer block . buffer block.

dustproof sleeve and buffer block should be replaced in pair.3. the position of wheel hub should be marked as reference for installation. If operation of rear axle on either side is presented. and block out brake hose. Note: Alignment of rear suspension is unadjustable.3. Disconnect brake hose. If necessary.1General information When disassembling wheels. Wheel nuts should be tighten to 110 N M.3.3 Repair guidance 3. 3.Suspension system Rear suspension 3-49 3.3. At the time of installation. 303006 . all contact surfaces should be clean and without any burr.3.2Replacement of back axle assembly Disassembly procedures 1. rear shock absorber. Rear spring. please inspect the wheel journal or the frame of axle (welded body) for any damage. Note: All operations should be conducted by workers according to the health. the other side is the same. When any value is beyond the tolerance range. When installing axles. remove the positioner of rear brake hose. safety and environmental laws and regulations of the local government. new bolts should be used. please replace the damaged component.

(for vehicles with ABS).3-50 Rear suspension Suspension system 2. and remove the back axle. Place lifting jack at the central position of back axle and jack up slightly. 303007 3. See replacement of rear spring. 303008 6. (Two persons) 303009 . Remove rear spring. Disconnect the connector of ABS sensor. Lower the lifting jack and back axle slowly. 4. Loosen and remove fasteners of back axle and the body plate. Disconnect parking brake cable with disengaging rod. isolation block and rear shock absorber. replacement of rear spring isolation block and replacement of shock absorber/buffer block. 5. 7.

303010 7. Place back axle on the lifting jack. 6. Jack up the lifting jack until back axle can be installed. (for vehicles with ABS). Install the spring and the spring isolation block. Install fasteners of back axle and the body. 3. (Two persons) 2. 4. See replacement of rear spring and replacement of rear spring isolation block. Connect ABS sensor.Suspension system Rear suspension 3-51 Installation procedures 1. Connect brake hard tubes and brake hoses. Don't tighten at this time. Install shock absorber. no entwisting or distorting is permitted. Notice: When installing a brake hose. Install fixing circlip of the brake hose. See replacement of shock absorber / buffer block. 303011 . 5.

Insert hand brake cable into the guide block. Use protection tool to mount rear axle onto the vice. Tighten the nut connecting back axle and the body plate. 303008 3.3-52 Rear suspension Suspension system 8. Install the wheel and tighten wheel nut. Park the vehicle over service pit or on service rack.4 parking brake for the adjustment of hand brake cable. 303012 . Apply a load of 70 kilogram on each of the two front seats.3Replacement of back axle (welded assembly) Disassembly procedures 1.3. use a punch. Note: See 5. Connect the cable with hand brake bar. Tightening Tighten the nut for back axle and body plate to 50 N M+45°+15° . Loosen the nut of stabilizer bar. 10. 9. and remove stabilizer bar and rubber shock isolator in the direction shown by the arrow.3. If necessary. Tightening Tighten the wheel nut to 110 N M.

Inspection: Use protection tool to mount the new axle onto the vice. and inspect it for any burr. but don't remove it. 5. During installation. clean the contact surface with wheel shaft. Loosen the bolt connecting hard tube of the brake and the brake itself.Suspension system Rear suspension 3-53 2. 3. 303014 . 303013 Installation procedures 1. Remove the clamping collar(1) of ABS sensor. (for vehicles with ABS). don't cause any damage to the profile of rear axle. 4. Remove the clamp of brake tube on rear axle. Loosen and remove wheel shaft and brake hard tube and wheel hub.

Install stabilizer bar with rubber isolator. Tightening Tighten the bolt of brake hard tube to 16 N M.3-54 Rear suspension Suspension system 2. and wheel hub with brake hard tube. 7. 303016 6. New bolts should be used. 303015 3. 4. Install clamping collar of brake hard tube. 5. (for vehicles with ABS). Tighten the bolt connecting brake hard tube with brake backing plate. Use new bolts and nuts. Tightening Tighten botls and nuts of stabilizer bar and back axle to 60 N M+60°+15°. Install the harness of ABS sensor. Assemble wheel shaft with brake backing plate. 303017 . Insert brake hard tube into the clamping collar (as shown by arrow). Install the guide block of brake cable into rear axle.

5. 4. 3. loosen the tightened part on left side and remove the nut. Place a hydraulic jack under the center of rear axle. Loosen and remove ABS sensor. 2. as shown in the figure. 303018 6.3. Remove the bush from rear axle (direction as shown by arrow). Remove the brake hard tube from floor of the body.3. use a screwdriver to remove it. If necessary. Remove tightened part on the right side. 303019 . (for vehicles with ABS). put a tool into the body plate to prevent movement of rear axle. a punch and a copper tube can be used. Slightly lower rear axle.Suspension system Rear suspension 3-55 3.4 Replacement of bush of rear axle Disassembly procedures 1.

303020 3. 2. 303018 . Ensure there is no lubricant.3-56 Rear suspension Suspension system Installation procedures 1. Before installation. Clean installation surface. apply some soap bath on the new bush. Install the bush (direction as shown by the figure).

3. Raise the vehicle and remove rear wheels. Install rear axle. see replacement of rear axle assembly. 2. If necessary. Remove wheel hub assembly including its gaskets. 303022 . 3. Remove the cotter ping locking wheel shaft and remove the bolt. Remove dust cap from wheel hub assembly. use a screwdriver to adjust the rear axle so that the binding bolt can be inserted more easily. 4.Suspension system Rear suspension 3-57 4.3. 303021 3.5Replacement of wheel hub assembly Disassembly procedures 1.

Fill the freakle area between the two bearings and the wheel hub with grease. Install the wheel hub and the wheel. At the same time apply some grease on the wheel shaft surface connecting the bearing and the oil seal contact surface. and apply some grease on the hole cover of oil seal assembly. Install the inner ring of inner bearing assembly into the wheel hub. Use KM-508-1 to press oil seal assembly into the wheel hub and tighten it. Lock adjusting device. 303023 3. Clean wheel shaft and insepct it for any damage or wear. 2. 303024 . 5. Use KM-266-5 to press in the positioner of inner and outer bearings. 4.3-58 Rear suspension Suspension system Installation procedures Tools required KM-266-5 Puller/installer KM-508-1 Puller/installer 1.

2. 3. Remove the inner ring of inner bearing. Use a bar to take oil seal out of the wheel hub and replace it.3.Suspension system Rear suspension 3-59 3.3.05mm.3. Replace inner bearing.3. 2.3.6Adjustment of clearance between wheel bearings 1. Tighgten capstan nut to 25 N M (rated value) and rotate the wheel hub. Then tighten the cotter pin. 303026 . 303025 3. Disassembly procedures Tools required KM-266-A Puller/installer KM-466-2 Puller/installer 1.03mm. the pretension of bearing is 0. and when axle force is (100 ± 15). The following operations are for the replacement of wheel bearing only. and the clearance is 0. Loosen or retighten the nut until the groove of capstan nut is aligned with the hole of cotter pin.5 except for the following additional operations. 3. When the cotter pin is tightened the wheel hub should be able to rotate freely in both direction without any binding.3.7Replacement of rear wheel bearing/oil seal Note: It's the same as 3.

Clean wheel hub assembly. Replace the outer bearing of wheel hub. 303028 . 303027 5. Use KM-266-3.3-60 Rear suspension Suspension system 4. KM-266-1 and KM-466-2 to press outer ring out of wheel hub assembly. Use KM-266-2. 6. KM-266-3 and KM-466-2 to press outer ring out of wheel hub assembly.

Remove cotter pin and the nut. 3.3. 303029 3.Suspension system Rear suspension 3-61 Installation procedures Tools required KM-266-A Puller/installer 1. 303022 . Use KM-266-5 to press the outer ring of inner bearing into wheel hub.8 Replacement of wheel shaft Disassembly procedures 1. Remove wheel hub assembly with brake backing plate. 4. Install wheel hub assembly.3. Remove dust cap from wheel hub assembly. Press in the outer ring and the oil seal of outer bearing. Install inner ring into wheel hub assembly. See replacement of wheel hub assembly. 2. 3. 2.

Loosen the nut of wheel shaft and remove wheel shaft and brake backing plate. 303030 6.3-62 Rear suspension Suspension system 4. Clean up the contact surface of brake backing plate or wheel shaft and inspect for any damage. wearing or burr. Loosen the nut of shock absorber. 303031 . Use lifting jack to support rear axle at a position on the rear axle near shock absorber. 5.

4. 303032 2. 5. Use new bolts to install wheel shaft and brake backing plate. See adjustment of wheel bearing. Tightening Tighten the nut of wheel shaft to 50N M+30°+15°. See replacement of wheel hub assembly. Install wheel hub assembly.Suspension system Rear suspension 3-63 Installation procedures 1. Lower the lifting jack. Adjust the clearance between wheel bearings. 6. Install the rear wheel. 3. Raise the lifting jack and install shock absorber. 303033 .

4. and remove the bolt of shock absorber and the shock absorber itself.3.3. Lower the lifting jack slowly. Disassembly procedures 1. 2. Lower the lifting jack and place it under the left control arm. Slightly jack up.3-64 Rear suspension Suspension system 3. 5. disconnect brake hoses with brake hard tubes . If necessary. Remove the bolt of shock absorber and the shock absorber itself. 303033 3. Place a hydraulic jack under the right control arm of rear axle and slightly jack up the rear axle. First remove right spring and isolation block. 6. 303034 .9Replacement of rear spring. Remove non-conductor. then remove left spring and isolation block.

Tightening Tighten the bolt of shock absorber and rear axle to 60-70N M. Install shock absorbers. 2. See replacement of rear spring. Remove rear spring. Operation on the left side is the same (pay attention to the installation position of the spring. first the left one then the right one.10Replacement of rear spring isolation block. 5. 3. 303036 . Remove isolation block (as shown by arrow).3.Suspension system Rear suspension 3-65 Installation procedures 1. Place a lifting jack under the right control arm of rear axle and slightly jack up the rear axle. then slightly raise the lifting jack. 303035 3. and ensure the end of coil spring faces toward the plate of body). Take the lifting jack out. Install right spring and isolator. 2.3. 4. Disassembly procedures 1.

Open the door of baggage compartment. 4. See replacement of rear spring. Remove the nut of shock absorber cap. Install rear spring.3-66 Rear suspension Suspension system Installation procedures 1.11Replacement of shock absorber / buffer block Note: Shock absorbers should be installed or removed in series. 2.3. When operation on only one side is described. If necessary. Install isolation block (as shown by arrow). Remove shock absorber. Raise the vehicle and remove the bolt. 5. 3. the other side is the same. Disassembly procedures 1. replace buffer block. 303036 3.3. 2. Remove buffer block and the positioner. 303037 .

303038 2.Suspension system Rear suspension 3-67 Installation procedures 1. Install the lower bolt connecting rear axle and shock absorber. Install buffer block. Lower the vehicle. the positioner and their nuts. When installing shock absorber. 303039 . 3. the piston rod should be aligned with the the hole of shock absorber in the body. and tighten the nut of shock absorber. Tightening Tighten the nut of shock absorber to 18-20 N M. and thread the end of shock absorber bar through a hole in the bottom board of the vehicle. Tightening Tighten the bolt of shock absorber and rear axle to 60-70N M.

If necessary. Install top cover. remove the wheel on another side. 4. 3. 303040 3. Remove the fastener of stabilizer bar on rear axle. 2.3-68 Rear suspension Suspension system 4. 303041 . Disassemble rear wheel on one side.3. a punch can be used. Remove stabilizer bar.3.12 Replacement of stabilizer bar Disassembly procedures 1.

Suspension system Rear suspension 3-69 Installation procedures 1. 303042 . Install the rear wheel. 3. Tightening Tighten the fastener of stabilizer bar to 60N M+60°+15°. apply some grease on the stabilizer bar. 4. Use new fastener to tighten stabilizer bar. 2. For the convinence of installation. Install stabilizer bar and the isolator.

a twistable axle bracket and a stabilizer bar. Twistable axle bracket helps the suspension to maintain quasi- independence.1General information Rear suspension uses a spring with variable rigidity. Alignment of rear wheel is unadjustable.3.4. 3.3.3-70 Rear suspension Suspension system 3.5 Special tools Tool identification/ Graphics description KM 266-A Puller/installer KM-266-A KM 466-A Puller/installer KM-466-A KM 508-AI Puller/installer KM508-A .3.4 Explanation and operation 3.

4.2 Tithtening Torque of Fasteners Conversion: 6.1 Specifications Common grades of speed 3.1.4 Tyres and wheels 3.9 kilopascal = 1 pound per square inch Applications Specifications Nuts of wheel 110 N M Load 68 69 70 71 72 73 74 75 index Maximu m load 315 325 335 345 355 365 375 387 (kilogram ) Load 76 77 78 79 80 81 82 83 index Maximum load 400 412 425 437 450 462 475 487 (kilogram) Load 84 85 86 87 88 89 90 91 index Maximu m load 500 515 530 545 560 580 600 615 (kilogram ) .4.1.1 Specifications of tyres and wheels Speed Maximum speed (kilometer per symbols hour) S 180 Conversion table of charge pressure (kilopascal to pounds per square inch) T 190 Pounds U 200 Kilopa per Pounds per square H 210 Kilopascal scal square inch inch V 240 140 20 215 31 Z More than 240 145 21 220 32 155 22 230 33 Inflation pressure of tyres 160 23 235 34 165 24 240 35 Applications Specifications (fully loaded) 170 25 250 36 Tyres (185/60 R14-82H) 180 26 275 40 Fore wheels 210 kilopascal 185 27 310 45 Rear tyres 250 kilopascal 190 28 345 50 200 29 380 55 205 30 415 60 3.4.Suspension system Tyres and wheels 3-71 3.

Schedule maintenance has been suspended. Inspect 304001 the wearing of rear wheel tyre. Uneven wearing on the tread of any tyre.3-72 Tyres and wheels Suspension system 3.4. Inspect the wearing of front wheel tyre. If any one the following conditions is detected. 304003 Inspection procedures 1. Improper wheel alignment may cause irregularity of tyres and early wearing.2. 2. Uneven wearing between left tyre and right Irregularity in rotation will cause irregular or tyre.4. 304002 Driving habit may also cause irregular or early wearing to tyres.1 Diagnosis of tyres .2 Diagnostic messages and procedures 3. and feather edge appears on the pattern of wheel ribs or one side of the tread. . Wearing condition appears on the tread pattern. wheel alignment should be conducted: Uneven wearing between front wheel tyres on the left side and the right side. Uneven wearing on tire tread. early wearing to tyres. rotate the tyre: Improper inflation pressure will cause irregularity or early wearing to tyres.irregular or early wearing There are many reasons for irregularity or early wearing of wheels . If any of the following conditions exists. 3.

Is the vehicle still wandering toward one side? 6 Change the parameter of caster. Drive forward and backward on a - To step 2 is OK smooth road surface. Exchange the position of right front wheel assembly with the position of right rear wheel assembly. The system 13 - To step 14 Is the vehicle still wandering towards one side? is OK Is the vehicle wandering leftwards? The system 14 - To step 11 is OK . Conduct road test to the vehicle. Is the vehicle departing or wandering toward one side? 1. Inspect the tyre. Has - To step 11 is OK the wandering been eliminated? Conduct road test to the vehicle. Is the vehicle still wandering towards one side? Continue to reduce right caster until the wandering is eliminated. Conduct road test to the vehicle. camber. rear tyre.4. Conduct road test to the vehicle. etc. Is the vehicle wandering leftwards? - To step 8 To step 9 Adjust wheel alignment to the required standard. - To step 4 To step 5 Is the vehicle wandering toward another direction? Inspect the orientational parameters of the front wheel caster. 9 - To step 13 - Is the adjustment completed? 1. See setting angle (fore wheel) in wheel alignment. See setting angle 7 - To step 13 - (fore wheel) in wheel alignment.2. 4 gather. The system 2 - To step 3 2. 2. Adjust tyre pressure to the required level. Is the adjustment completed? Set left caster to the upper limit. Inspect the brake for any binding condition. The system 1 3. - To step 6 To step 7 Is the locator value within the prescribed limit? 1. Conduct road test to the vehicle. 8 - To step 13 - Is the adjustment completed? Set right caster to the upper limit. 1.Suspension system Tyres and wheels 3-73 3. and right caster one degree smaller. Exchange the position of left front wheel assembly with the position of left rear wheel assembly. Exchange the position of front left and front right wheel assemblies. 2. and left caster one degree smaller. Replace left 5 - To step 10 rear tyre. is OK Is the vehicle still wandering toward one side? Inspect to see whether the vehicle is wandering toward another 3 direction.2Correction of departure/wandering of radialply tyre Numerical Steps Measures Yes No values Definition:Departure or wandering towards one side of a vehicle when driving straight forward. Replace right 10 - To step 6 2. Has the wandering - To step 12 is OK been eliminated? Continue to reduce the trim of left kingpin until the wandering is The system 12 eliminated. Caster The system 11 at cross direction should not exceed 2 degrees. 3. Caster at cross direction should not exceed 2 degrees.

3. 6. Clean up this area with an ordinary cleaner such as 3M#08984 or a similar device.3-74 Tyres and wheels Suspension system 3. Determine leaking area according to the following procedures: Charge the tyre to 275 kilopascal. . 3.4. Immerge the tyre and wheel into water.4. 7. Use screwdriver to remove wheel cap.3. 3. Remove the tyre from the wheel. Manually press the wheel cap into the wheel. 4. 5.3. Raise and properly support the vehicle. Installation procedures 1.4. 9.3 Repair guidance 3. See replacement of tyres and replacement of wheels in this chapter.4. See hoisting and lifting of vehicle in general information.2Replacement of steel wheel cap Disassembly procedures 1. 2. Installation procedures 1. Use screwdriver to remove wheel cap.3 Repair of pores on aluminum/steel wheel Repair procedures 1. 8. Sanding the inner side of the leaking area with sand paper of 80 granularity. Apply a layer of binding sealant (GM partnumber 1052366) as thick as 1/8 inch to the leaking area. Remove tyre and wheel assembly. Ensure the anchor pin of wheel cap is aligned with the small hole in the wheel.3. Dry for 12 hours. Manually press the wheel cap into the wheel.1Replacement of aluminum wheel cap Disassembly procedures 1. Mark leaking area. Ensure the gap of steel wire (on the wheel cap) is aligned with the air valve of tyre.

These products have been proven to be up to the durability requirement after repair. 12. Install tyre and wheel assembly. When dressing an aluminum wheel. An improperly used weight may cause surface degradation.4. then deflate. Once this protective transparent coating is damaged. it is not recommended to machine the wheel or use any scavenging agent of chemical coating. Lower the vehicle. don't stand on the tyre when inflating it. If the pressure of 275 kilopascal fails to put the bead in place. 3. 13. 16. the bead may fall off. Over inflation will cause the bead to break away and cause severe injury to personnel. exposure of the wheel toward alkali cleaner and/or anti-icing salt used on roads will cause further degradation to its surface. Adjust tyre pressure to the required level. Frequently cleaning the white side piece and the tyre with tyre brush soaked with excessive silicon carbide at automatic carwash will also damage this coating. See replacement of tyres and replacement of wheels . Series 1: Dupont products Series 2: PPG products Series 3: Spies Hecker . cleaning and recoating method of aluminum wheel hubs subject to the above conditions has been described in detail in repair procedures. 10. a kind of plastic media should be sprayed on the wheel surface so as to eliminate the transparant coating or the paint. For reasons of durability after repair. See balance of tyre and wheel in general Information. See the table of tyre inflation pressure in this chapter. Install the tyre onto the wheel. Pressurize to 275 kilopascal. The inflation pressure of any tyre whose bead has not yet been in place should exceed 275 kilopascal. 11. 15.3. relubricate the bead and recharge. When bead undercut has exceeded safety limit. These products are the only paint series meeting GM Standard 4350M-A336.Suspension system Tyres and wheels 3-75 Caution: To prevent any injury to personnel. Coat eliminating. Inspect for any leakage. Balance tyre and wheel assembly. 14. Materials needed Three different kinds of paint series can be used for the dressing of aluminum wheels.4 Surface dressing of aluminum wheel The surface of aluminum wheel with original equipment has a layer of transparent and/or primary color protective coating.

6. . Don't mix materials of prescribed series with products of other manufacturers. Cover the wheel and the tyre. Failing to comply with these preventive measures may result in irritation to the lungs and allergic respiratory reaction. Clean up all of the installing surface of the wheel and remove any corrosive or excess spray-paint or dust. it is recommended to use Corsican SILVER WAEQ9283 for pure aluminum appearance. 4. Install the wheel onto the vehicle. Record the weight of each balancer for use in reinstallation. Refer to and comply with the paint formulation and technics provided by the paint manufacturer. 9. it is not recommended to machine the aluminum wheel or use any scavenging agent of chemical coating. Products listed in this manual have been proved to be up to the requirement of durability after repair. The selection and validation of color should be referred to the color manual provided by paint manufacturer. Repair procedures Caution: When painting any component consisting of two parts. 7. 3. 5. 1. Note: Refer to and comply with the formulation and technics of each paint series provided by the manufacturer. Take off the balancer. and Sparkle SILVER WA9967 for extremely shining appearance. Remove the wheel from the vehicle. Spray the wheel with plastic media to remove the old paint or the transparent coating. please comply with the preventive measures provided by paint manufacturer. Take off the covering of wheel and tyre. Install the painted new balance at the marked position of the tyre. Keep the tyre installed on the wheel. Use wax or grease remover to remove the excess grease and/or dust on the wheel. 10. All of the four wheels and hubs should be dressed to ensure uniformity of color. See replacement of Wheel.3-76 Tyres and wheels Suspension system Selection of color If the wheel to be painted previously uses aluminum with transparent coating. to prevent any injury to personnel. See replacement of Wheel. 11. Mark the position of balancer on the tyre. These products are the only paint series meeting GM Standard 4350M-A336. Note: For reasons of durability. The products listed are regarded as one series. 12. 8. 2.

Penetrating oil will not work when removing a tight wheel. removal of the wheel may be very difficult.Suspension system Tyres and wheels 3-77 3. Remove wheel nut and the wheel. See 304004 hoisting and lifting of vehicle in general information. 3. Note: Don't use excess force when removing a wheel or a tyre. Heating must not be used to loosen a tight wheel. improper contact between metals on the installation surface will cause the wheel nut to become loose.4. Lay the backside of the wheel that has not been dressed on a soft and clean surface. It is recommended to tap the sidewall of the tyre lightly with your hand or a rubber club. thus resulting in accident with injuries. Turn off the engine. Tighten all wheel nuts on the wheel. 2. Caution: If there is penetrating oil on the vertical surface between the wheel and the brake disc or brake drum. 5. Lower the vehicle to the ground. Raise the vehicle. such as blowing with a hammer. thus resulting in a loss of control of the vehicle and possible injuries of personnel. Installation procedures Tools required J 39544-KIT Wheel nut torque limiter Caution: When installing the wheel. Move the vehicle for a few feet in the direction of driving and backing. Follow the following procedure to safely remove the wheel: 1. This will cause the wheel to fall off in the course of driving. 4. . so as to prevent bending of the wheel or the brake disc or the brake drum. use a scraper or a wire brush to remove any cumulative corrosive substance on installation surface of the wheel and installation surface of the brakd drum or brakd disc.3. Energically and rapidly tread the brake pedal to loosen the wheel. then unscrew each nut for two turns. Rock the vehicle left and right as heavily as possible so as to loosen the wheels.5Replacement of wheel Disassembly procedures Because of corrosion or the tight coupling between the location hole at wheel center and the wheel hub or the brake disc. Wheel nuts should be tightened in turn to the right torque. During installation of the wheel. Aluminum wheels should never stand vertically. It will reduce the service life of wheels. the wheel will become loose in the course of driving and the vehicle will go out of control. bolts or hur and bearing assemblies. Gear lever can also be shifted from driving (D) gear to reverse (R) gear.

Suspension system Tyres and wheels 3-78 To prevent bending of the wheel or the brake disc or the brake drum.6 Replacement of tyre Use tyre changer to install or remove tyres. nuts or installation surface of a wheel. 3. Install rear wheel and inflate it to 275 kilopascal. Use a wire brush or a piece of crude steel wool to remove the following substance from the seat of felloe and bead: Lubricant Old rubber Lightly rusty spot Caution: To prevent any injury to personnel. If the pressure of 275 kilopascal fails to put the bead into place. then deflate. . 304005 Over inflation will cause the bead to break away and cause severe injury to personnel. wheel nuts should be tightened in turn to the right torque. Use J 39544-KIT to tighten wheel nuts. Note: Do not use lubricants containing silicon to lubricate the tyre bead of felloe. When bead undercut has exceeded safety limit. Before installing or removing a tyre. relubricate the bead and recharge. Excessive tightening torque on the wheel nut of a steel wheel will damage the mounting hole of the wheel and result in the emergence of cracks. Don't replace tyres with hand tools or tyre lever.4. J 39544-KIT cannot be used to remove wheel nuts. Lubricating liquids and penetrating liquids should not be used on the surface of the bolts. because thses tools may damage tyre beads or felloes. The inflation pressure of any tyre whose bead has not yet been in place should exceed 275 kilopascal. Ensure the mounting ring of the tyre is around the two sides of wheel rim flange. don't stand on the tyre when inflating it. putting the bead into place. the bead may fall off. Install inner valve and inflate the tyre to the required pressure provided in tyre inflation specifications of general information. clean up the bead area and use a mixture of 50% lubricant and 50% water to throughly lubricate this area. Lubricants will increase the actual torque of a nut.3. Follow instructions of the manufacturer.

Besides regular exchange. will be worn at a faster rate. and thus make it difficult to meet tightening requirements. Then set tyre pressure.Suspension system Tyres and wheels 3-79 3. so as to balance their wearing. Note: After position exchange wheel nuts should be inspected to ensure proper tightening torque. This will change the coefficient of friction in the connection of bolts. especially at the front end. The shoulder area of a radialply tyre. 304007 .4. 304006 3. Therefore four-wheel position exchange will be required to solve this problem.3.8Lubrication of wheel bolts Note: After being installed and removed for several times. wheel bolts will lose a significant amount of the lubricant applied on them in factory.3.7 Position exchange of tyres The position of tyres should be exchanged regulary. please apply bearing oil on its conical surface. Before installing a dry wheel bolt. the positions of tyres should also be changd whenever uneven wearing is found on any tires.4. A radialply tyre at non-driving position will have irregular wearing and thus increase tyre noise.

4. Some of Good reaction to steering them are identified as 1100 series PL tyre chain.4. See the table of provided by tyre chain manufacturers. and repaired from the inside. If a tyre carefully calculated to provide the following properties: chain is to be used. the driver should pay attention Improper air pressure will impact driving condition.4.4. 3. recommended use of tyre Recommended pressures for all models of vehicles are chains is also provided in this user manual. gate to prevent entry of dust and water. comply with the Always purchase tyre chains suitable for the following conditions: tyres needing to use them.3Inflation instruction of tyres Because of the limited clearance between the tyre and body of some behicles. Drive the vehicle for less than one mile.2Repair instruction of tyres Unequal tyre pressure on the same shaft will Various kinds of materials and techniques can be used have the following effects: in the repair of tyres. most vehicles at present are Comfortable riding required to use tyre chains at grade S of SAE.4. The tyre should be cold tyre. These tyre chains are designed to limit the fly-apart action of Maximum tread wear wheels when they are rotating.4. Improved tyer life Manufacturers of tyre chains decide that each kind of Resistance of damage tyres should have specific tyre chain dimensions so as Inspect tyre pressure monthly or before driving of long to ensure proper match during installation. Tyres should never repaired from - Lowered steering performance outside. position of tyre The following factors will have significant effect on the Pressures under recommended values will service life of tyres: cause the following effects: Proper tyre pressure - Tyre noise at steering Wheel alignment - Rigid steering Driving techniques - Rapid and uneven wearing at the edge of tread The following driving habits will increase the wearing of tyres: - Wearing and breaking of felloe Steering heavily - Broken tyre cord Accelerating too fast - High temperature of tyre Braking heavily - Lowered steering performance - Increased fuel comsumption - Soft driving 3. Tyres should always removed from the wheel.4. If a tyre chain is too loose because of improper Park the vehicle for three or more hours. - Deviation in torsional interaction inspected for any damage.4Direction for use of tyre chain 3.1General information - Rigid driving - Wear of tyre or damage of carcass When inflated to recommended pressure. to the following requirements: Pressures exceeding recommended values will cause the following effects: . Always follow the installation instructions Set tyre pressure to the required level. size. For optimum efficiency. These instructions are available from tyre - Deviation in steering manufacturers. wheels and tyres installed in factory will work well when the load is - Rapid wearing of wheel track at the centeral close to or has reached full load. When using tyre chains. distance.4. Tyre manufacturers have - Uneven braking published detailed instructions on how and when to repair tyres.3-80 Tyres and wheels Suspension system 3. tyre inflation pressure in this chapter.4. Using tyre chain will have negative impact on the Install a valve cap or an extended device on the air steering performance of a vehicle. don't use rubber regulator to tighten the looseness or clearance of it.4 Explanation and operation 3.

4. If only one tyre is needed to be replaced. Load index specifies the loading capacity with different size or structure will severely impair the when tyres are inflated with maximum air injection following driving conditions: amount. Speed symbol is usually a letter between P Riding and Z. The bigger the value. there is a built-in tyre tread wear indicator in the tyre. While different tyres may have different tread designs. Speed symbol specifies the speed capacity of Steering the tyre. diagonal tyre full pressure. Any other tyres and 115. Load index When selecting a tyre for replacement. When this indicator is seen in two or more adjacent tread grooves at three different positions. load range and structure of the new tyre is Load index is usually a numerical value between 75 consistent with that of the original one. For the convinence of measurement.Suspension system Tyres and wheels 3-81 Adjust vehicle speed according to road Scaling of odometer or distance recorder conditions Clearance between the vehicle and the ground Avoid hurried steering Clearance between tyre and body and chassis Prevent locking the wheel brake This limitation is not applicable for the spare tyre This user manual has also published other specific provided on the vehicle. This will ensure the size.6 mm (or less) has been left. tyre size. cut open or worn to the extend that cord threads or cord All tyres are stamped with a specification number of fabrics can be seen from outside. Velocity level is only applicable for tyres with the same vehicle. with lower velocity level than the original one should not Caution: Different kinds of tyres should not be used on be used. Replacement of tyres is necessary in any of the following conditions: The tyre is worn to the extend that a tyre tread of only 1. condition that the steering performance of the vehicle Now repair instructions are printed on the side piece of has been severely compromised and the vehicle may most tyres following the tyre size. and when the tread is 1. This specification number confirms that the Slight depression on sidewall is normal. one with the Speed symbol same PTC number should be choosen. tyres with smaller size or Generally each tyre size has a specific TPC number.4. the tyre should be replaced. 304008 The tread or the sidewall is broken. such as radialply tyre. Traction force Puncturing. Repair instruction go out of control and cause severe injuries to includes the following two parts: personnel. a mixture of tyres made by different manufacturers but having the same TPC specification numbers can be used. it will no tyre is up to the following performance standards: impair the steering performance. information. unless under an emergent the value of its velocity level.6Repair instruction of sedan tyre Rolling resistance Note: When replacing tyres. swelling or broken. the greater the loading capacity.6mm (or less) it can be seen between the grooves of tyre tread. In the past the letter as speed symbol is a part .4.5Instruction of tyres treads. New tyres on the same shaft should be installed in pair. the new one should be mated up with the old one that has more tyre 3. Noise Steering 3. Tyres under inflation will unable to reach and diagonal lacing tyre. cutting-open or other damage to a Durability tyre is unrepairable for reasons of their size and Size positions.4. or cord threads or cord fabric can be seen. Tyre Performance Code (TPC) on the sidewall near The tyre is lumping up.

Tyre size (including emergency tyre) Now on the optional steering tyres used on some of the Cold inflation pressure (including emergency vehicles. diameter Most P metric tyre size do not have corresponding tyre Damage to the vehicle caused by changes in size described with letters and numerical values. load range and structure) with the described in this Repair Instruction of Tyres is available original tyre the vehicle uses. the greater not completely the same with FR78-15.radial (Section Width) 304008 B . and the maximum with adjacent vehicle parts large load being 283 kilopascal.temporary tire Speed Symbol Section Width (mm) Rim Diameter (inch) Aspect Ratio Construction Type (Section Height) R . Used as tyres for Section Height snowy weather. be replaced by a tyre of other size. Tyre companies can provide alphabet numbers closest to the P metric size for their tyre products. with the maximum Tyres damaged by changes in the clearance standard load being 242 kilopascal. should be consulted with. The load of tyres of Unstable steering caused by changes in tyre most sedans is standard load. 3.9 kPa.4.4.bias-belted D . wheel fasteners and Most vehicles use tyres with P metric size. If a P metric tyre has to from the tyre company. The bigger the letter. rolling resistance.3-82 Tyres and wheels Suspension system of the tyre size. the size and load capacity of P205/75R15 is still use this method. On the sidewall of placard provides the following information: these tyres. The the use of compound materials. these tyres have an average tractive quality better than that of non-all-weather radialply 304009 tyres used before. The metric unit of inflation is kilopascal (kPa). 3. a "M+S" is printed after the tyre size . and air retaining ability. Tyre information is available on this tag. the the speed capacity.10Explanaiton of tyre replacement 3. "MS" is also marked after tyre sizes and TPC tyre) specification numbers. Therefore.4.4. 1 psi equals to 6. Other properties have also been improved.7Explanation of all-weather tyre pressure in this chapter. such as tractive quality on wet road surface.8 Explanation of tyres with P metric Notice: Use of non-GM original wheel will result in: size Damage to wheel bearing.car tire T. A table of loads and speeds tyre being replaced should have the same TPC number corresponding to the load indexes and speed symbols (the same size. now some tyres at level V and level Z instance.4.9Explanation of tyre notification Tire Type Load Index P . TPC specification numbers also have a suffix of "MS" printed on the sidewall. Tyres with P the wheel metric size have two load ranges. The information tag of tyre is on the back of the driver These are realized through improved tread designs and door. See conversion table of inflation 3.4. tread life.Diagonal (bias) Most vehicles are equiped with radialply tyre with steel Section Width belts as standard configuration. the tyre dealer See tables in general speed levels of this chapter.4.4. Maximum car load Besides. Tyre pressure is provided in kPa and pounds per square inch (psi). For ground clearance .

.4.4. Remove and install the tyre on outer bead seat. the should not be repair by inserting an inner tube. plastic or Teflon®coating to protect the appearance of a wheel from any damage.Suspension system Tyres and wheels 3-83 Inaccuracy in odometer and distance recorder 3. some equipment still needs improvement. the cooling of brake. Even with these tools. equipment may also damage the apperance of a Steel wheel is identified by the two or three alphabetic wheel. The wheel nut cannot be tightened. codes printed on the felloe near valve stem. on the aluminum wheel and the flaking of the The bolt hole on the wheel is too long. If a scaling of odometer/distance recorder. wheel offset and installation configuration with the original one. diameter. Run out of the wheel is too great.11Explanation on the repair of steel Note: The wheel used for replacement should have the wheel same load capacity. The stripper of bottom flange on some unacceptable vibration. the ground leakage is detected on a steel wheel. Leakage of wheel or tyre life of wheel and bearing. transparent finish from the wheel. A wheel should be replaced under the following conditions: 3. Welding. A The wheel is severely rusty. Aluminum Most manufacturers of wheel replacing equipment wheels have codes.4. Notice: Do not scratch or damage the transparent finish of the aluminum wheel with tyre replacing equipment. There is air leakage at the welding seam of the Scratches on the transparent finish will cause corrosion wheel. replace it with a clearance and the clearance of tyre to body and new wheel up to the quality standard of the original chassis.12 Explanation of aluminum wheel The wheel is bending or depressed. heating or shot blasting should not be used Improper size or kind of wheels will impair the service for the repair of wheels. rim width.4. part numbers and the ID of provide adapter kit for aluminum wheels and tools with manufacturer casted on their back. device without a platform to place the wheel will cause damage to the appearance of the wheel when it is A run out of the wheel that is to great will produce clamped. one.

3-84 Tyres and wheels Suspension system 3. J 39544-CSE J39544 .4. J 39544-14. J 39544-13.5Special tools Tool labels and Graphics descriptions J 39544 General purpose torsional connector of wheel nut (used with air pressure impact wrench not exceeding 250 pound feet)Including: J 39544- 12.

...........................1.........1 Replacement of Front Wheel Drive Shaft ...................4 Sway or Vibration during Acceleration..........5......1....1........ 4-4 4.......1 Clicks while steering......2Visual Identification ...........................1..............1 Fastener Tightening Specifications....Driveline/ shaft table of contents 4-1 4 Driveline/ shaft 4............... 4-15 ...........1...1.............3 Deep metal friction noise heard during steering acceleration ..5Description & Operation ......2........ 4-14 acceleration ...........3......4..........1.. 4-3 4.....................1.....3Diagnostic Information and Procedure........1Specification .................1 Front Wheel Drive Shaft .....2 Deep metal friction noise heard during coast 4......................3..........1.........1............... 4-5 4............. 4-6 4.. 4-5 4.......4Repair Guidance ........... 4-10 4........................ 4-3 4...6Special Tools ................1....1............ 4-5 4.......... 4-14 4...... 4-5 4............. 4-5 .......2 Replacement of CV joint and protective housing...............1 Front Wheel Driveline Disassembled View..........1..........1.....3..........3...... 4........ 4-4 4......... 4-6 4............1 Front Wheel Drive Shaft.................1.........................1............4-3 4.....4..............................

4-2 table of contents Driveline/ shaft Blank .

1. Driveline/ shaft Specification 4-3 Driveline/ 4.1 Fastener Tightening Specifications Application Specification Front wheel drive shaft nut 160 N m Lower ball joint nut 30 N m Front wheel drive shaft retaining clamp 25 N m .1Specification 4.1.1.1 Front Wheel Drive Shaft shaft 4.

1.4-4 Visual Identification Driveline/ shaft 4.2.2Visual Identification 4.ring (9) Protective housing mounting retainer (20) VL outer race flange (10) Front wheel drive shaft (21) Dust shield (11) Protective housing mounting retainer (22) Connection ring .1 Front Wheel Driveline Disassembled View 402001 Legend (1) ABS bearing ring (for vehicles with ABS) (12) Front wheel drive shaft inner protective housing (2) RF outer race flange (13) Protective housing mounting retainer (3) RF housing (14) Cover (4) RF inner race flange (15) Lock ring (5) Ball (16) VL inner race flange (6) Flexible race (17) Ball (7) Protective housing mounting retainer (18) VL case (8) Front wheel drive shaft outer protective housing (19) O.1.

3.1. outside universal joint wearing or damage.2 Deep metal friction noise heard during coast acceleration 4.Driveline/ shaft Diagnostic information and procedure 4-5 4.1. . there maybe clicks heard during steering.3.1.3Diagnostic Information and Procedure 4.1. inspect if the front wheel situation: driveline CV joint housing exists crack or damage. inspect the following if there is clicks heard. Refer to Vibration Diagnosis and Correction in General Information for sway and vibration. 4.3 Deep metal friction noise heard If the front wheel drive shaft CV joint is worn or during steering acceleration damaged. sealing breakage or damage.3. If clicks are heard during steering.1.3.4 Sway or Vibration during Worn or damaged front wheel driveline CV joint or front Acceleration wheel driveline 3-pin type universal joint may result in deep metal friction noise during coast acceleration.1 Clicks while steering 4.

1. do not move the vehicle or load on the wheel bearing. 3. 2. insert a short bar in the wheel hub at certain fastening in susbstitution of the front wheel drive shaft.Slot-type nut may be partly fastened to the front wheel drive shaft end to protect the threads.4Repair Guidance 4.Refer to Replacement of Lower Ball Jointî in ì Front Suspension.4-6 Repair Guidance Driveline/ shaft 4. Remove the front wheel drive shaft from the front wheel hub with hand or press it out of the hub with puller.Otherwise the wheel bearing may be damaged. the front wheel drive shaft must be replaced as a whole.Insert screwdriver head or flat-bladed tool into brake caliper or brake disc so as to prevent the brake disc from rotating.Refer to Replacement of the wheels in Tire & Wheel.1 Replacement of Front Wheel Drive Shaft Removal Procedure Required tools KM-460 front wheel drive shaft remover KM-468-B long handle spnner KM-902 remover KM-313 shaft remover If CV joint is found with fault after driving for 80000- 10000 km. 404001 5. 404002 .If the vehicle must be moved.4. Remove the wheel.1. 4. Remove front wheel drive shaft slot-type nut. Note: Prevent the sealing (protective housing) from contacting other parts so as to avoid damage to the sealing (protective housing). Remove front wheel drive shaft slot-type nut pin. Take out the lower ball joint from the steering knuckle. Caution: After take out the front wheel drive shaft from the wheel hub.1.

Driveline/ shaft Repair Guidance 4-7 6. Right: remove the front wheel drive shaft from the transmission with KM-460-2A or KM-313 and KM-902 (short). 404003 Left: remove the front wheel drive shaft from the transmission with KM-460-2B or KM-313 and KM-902 (long). Note: Cover the fluid hole to avoid oil leakage. 404004 . Remove the front wheel drive shaft from the transmission.

Confirm the fixing ring has seated into the short shaft (arrow) slot at the transmission side of CV joint.4-8 Repair Guidance Driveline/ shaft Installation Procedure Required tools KM-468-B long handle spnner Note: Prevent the sealing (protective housing) from contacting other parts so as to avoid damage to the sealing (protective housing). 404006 . Press the front wheel drive shaft into transmission case and strike it slightly so that the CV joint seats and the fixing ring is in place. 1. 404005 2.

Connect the lower ball joint with the steering knuckle.Driveline/ shaft Repair Guidance 4-9 Note: Pull the outer part of the universal joint to verify the front wheel drive shaft is in place (arrow in the illustration figure). Install the hub washer and new front wheel drive shaft slot-type nut.Meanwhile. Refer to Replacement of the wheels in Tire & Wheel for installation of the wheels. then fix with the pin. then loose the nut and fasten to 20 N m+90°. 7. 8. loose the wheel hub nut untill the hole of the pin levels with the channel of the nut. Pre-tighten the wheel hub nut with KM-468(1) to 130 N m. 3. Install the front wheel drive shaft to the wheel hub. do not fasten. 5.Insert screwdriver head or flat-bladed tool into brake caliper or brake disc so as to prevent the brake disc from rotating. 302046 6. 404008 . Note: If necessary. prevent the brake disc from rotating. Fastening Fasten the lower ball joint nut to 30 N m. Install the bolts and nuts.Refer to Replacement of Lower Ball Joint in Front Suspension. 404007 4. Lower the vehicle. lubricate the slot manually with transmission oil.

2. fill to the maximum position if necessary. Inspect the wheel positioning.2 Replacement of CV joint and protective housing Removal Procedure 1. Inspect the transmission fluid level. Remove the fixing caliper from the dust shield housing.4.1. Put aside the dust. 404010 .4-10 Repair Guidance Driveline/ shaft 9.shield. Refer to wheel positioning inspection in Wheel Positioning. 10. clean the lubrication grease (arrow) on the locking ring. Minimum level: lower end at the observation hole at the rear of the differential housing (left along the driving direction) ( refer to illustration figure). 404009 4.

Inspect if there is wearing on inner flange.Driveline/ shaft Repair Guidance 4-11 3. 404011 5. outer flange and balls.Replace the worn front wheel drive shaft CV joint. 6. Remove the front wheel drive shaft CV joint. 4. Reaplce the front wheel drive shaft after it has been ussed for 80000 to 100000 km. fix the front wheel drive shaft with protective retainers into the panel. 7. Take out the dust-shield from the front wheel drive shaft. then slightly strike the CV joint with plastic hammer. 404012 . open the locking ring with ring caliper. Clean the front wheel drive shaft CV joint thouorghly.

404013 2.4-12 Repair Guidance Driveline/ shaft Installation Procedure Required tools S-9407235 Screwdriver MKM 804 Locker MKM 611 Torque spanner 1. 3.Match the CV joint into the spline of the front wheel drive shaft and press it with plastic hammer until the fixing ring (arrow in the illustration figure) is in place. Add special lubrication grease into the CV joint. Add the remained lubrication grease into the protective housing. 404014 . Slip the new fixing caliper and dust-shield upward to the concave of the front wheel drive shaft (arrow in the illustration figure).

Install the fixing retainer.Use special maintenance tool MKM-804 for correct installation.804. 404015 5. Fastening Fasten the front wheel drive shaft retaining clamp to 25 N m 7. 404017 . Put the new protective housing onto the should of the universal joint shaft.Manually fasten the fixing retainer with MKM. The fixing retainer of the CV joint at the transmission side is made up of stainless steel.Fasten the fixing retainer of the CV joint at the transmission side with S. Pre-install the fixing retainer of the protective housing according to regular methods. 404016 6. Note: Do not fold its drapes after installation of the protective housing. Fasten the fixing retainer with MKM-804 and torque spanner MKM-611.Refer to Replacement of Front Wheel Drive Shaft. Install the Front Wheel Drive Shaft.9407235(1).Driveline/ shaft Repair Guidance 4-13 4.

Front The protective housing (sealing) may prevent wheel drive shaft uses cylinder clip to interlock the lubrication grease from being damaged by with the transmission.1 Front Wheel Drive Shaft Note: Prevent the protective housing (sealing) from being damaged by sharp tools or the surrounding sharp The front wheel drive shaft is flexible assembly. Make the front wheel drive shaft VL insertion- There is a helix spline at the shaft end (to engage with type universal joint be able to conduct angular the steering joint/ wheel hub). .Front wheel drive shaft VL insert.5Description & Operation 4. edges. Housing Front wheel drive shaft RF fixed-type universal joint is flexible.1. Front wheel drive shaft VL insertion-type universal joint Function of the protective housing is as follows: adopts the cross-type universal joint design. however. type universal joint can move from inside to outside. joint and RF fixed-type universal joint.4-14 Description & Operation Driveline/ shaft 4. Protect the inner components of the front wheel Universal joint structure is suitable for the following drive shaft RF fixed-type universal joint and VL types of vehicles: insertion-type universal joint.5.But its strength can not bear the Protective housing (sealing) and retainer following conditions: Front wheel drive shaft RF fixed-type universal joint rough operation protective housing (sealing) is made of TPE. movement. front wheel drive shaft The leakage may also result in noise of the front wheel front wheel drive shaft connecting the VL drive shaft and finally the failure of the inner insertion-type universal joint and RF fixed-type components.Fixing retainer at the inner universal universal joint (inner universal joint) joint side is made of chromed iron. front wheel drive shaft RF fixed-type universal and also result in lubrication grease leaking from the joint (outer universal joint) front wheel drive shaft VL insertion-type universal joint and RF fixed-type universal joint. TPE exists good performance under normal conditions and working situation. it can not move from inside to front wheel drive shaft outside. Retainers may provide leakage proof connection Front wheel drive shaft VL insertion-type universal joint between the front wheel VL insertion-type universal is completely flexible. Fixing retainer at the outer universal joint side is made front wheel drive shaft VL insert-type of stainless steel. Front wheel drive shaft has outer spline. the following conditions: front wheel drive shaft RF fixed-type universal harmful atmospheric conditions (extreme joint (outer universal joint) temperature or ozone) Front wheel drive shaft RF fixed-type universal joint foreign matter (such as dust of water) uses ball case type design. The front wheel drive shaft is made up of the following Any damage to the sealing or retainer may result in components: leakage. universal joint. edges of components in vehicle). tight match of extrusion.1.Front wheel drive shaft RF fixed-type universal joint damage by sharp objects (such as sharp tool or protective housing (sealing) is made of CR. which may result in water leaking into front front wheel drive shaft VL insert-type universal wheel drive shaft VL insertion-type universal joint and joint (inner universal joint) RF fixed-type universal joint. Make the front wheel drive shaft RF fixed-type It can also avoid shaft end gap between wheel hub and universal joint be able to conduct angular front wheel drive shaft.Helix spline can ensure and axial movement.

driving head range 10- 60N m MKM-611 .1.6Special Tools Number & Name of Illustration the Tools Number & Name of Illustration the Tools MKM804 Lock plier to fasten the housing at the side of wheel bearing to lock KM-460 onto the body Fork type remover to remove the front wheel drive shaft from side of MKM-804 the transmission KM-460 KM-313 shaft remover to remove the front wheel drive shaft from side of KM-902 the transmission Remover (long and short)to remove the front wheel drive shaft KM-313 KM-902 KM-468-B Long handle spanner to fasten the wheel hub nut S-9407235 Plier to fasten the housing onto the body KM-468 S-9407235 MKM-611 Torque spanner 3/8".Driveline/ shaft Special Tools 4-15 4.

4-16 Special Tools Driveline/ shaft Blank .

1 Specification ......2.. 5....5.......3................ 5-49 Disassembled View (vehicles without ABS) ................................... 5-8 5.1.2.2 Brake disc lateral runout check .....2....3..........1.............................1 Brake system specifications ...3 Brake System Test .12 Discharge air from the hydraulic brake system..........................2........... 5-5 5....... 5-46 . 5-26 5............1..3. 5-18 5...... 5-3 5.........2.........1 Disc Braking System Description ..........Front..3..............1..4 Rear Brake Replacement ....2.................3 Match the lining and brake drum .7 Replacement of Brake Drum .................14 Rinsing of the Hydraulic Brake System ................2....1.......5..........2........13 Discharge air from the hydraulic brake system ....2.6 Brake Wheel brake cylinder Overhaul . 5... 5-52 5...1 Component Specifications ................3....3 Replacement of the brake master cylinder 5......6 Description & Operation ...1.1Hydraulic brake ......... 5-49 5................1............ 5-25 5...16 Replacement of vacuum booster hose.1....................... 5-20 5........................3 Visual Identification .2..............................2 Fastener Tightening Specifications..4 Description & Operation ...............3.............................................5..........3..........3...2..1. 5-78 5... 5-50 performance .........1 Brake Lining Inspection .5.................................2 Brake Master Cylinder and Reservoir Disassembled View (ABS vehicles) ......without ABS ...1....1. 5-23 5.... 5-4 5.............3.3Shoe-type brake ....................................5.. 5-52 5.1.....................5 Special Tools ......4........... 5-31 5...........................4.........3.6...........1..2 Fastener Tightening Specifications................................ 5-50 5.2..........1....... 5-3 5.............. 5-35 5............5 Repair Guidance ....1 Add to the brake master cylinder reservoir..6 Replacement of the brake pedal ....... 5-68 5...3......1 Brake master cylinder Description..2 Replacement of the brake pad ...........6.5.......... 5-49 5.....1.3...........2 Outside elements that may influence the brake 5......1.............1....2.................. 5-67 5.1...........3 Brake Master Cylinder and Reservoir 5......... 5-16 5.....................5 Brake Caliper Overhaul .....1....2Disc brake..........................1.4....1.1. 5-52 5... 5-21 5..15 Replacement of vacuum booster........4 Description to the Brake Alarming System ........ 5-9 5......6.............2.......................2 Add to the brake master cylinder reservoir..............3........5 Brake Fluid Leakage ..5......3.. 5-67 5.......................................2 Description to the Ratio Valve (without ABS) ....... 5-46 5...2.. 5-22 5........ 5-46 5...................... 5-8 5....1 Component Specifications .. ..... 5-46 5........2..... 5-8 5.....1 Hydraulic Brake Diagnostic System Check .................................... 5-8 5..............1....6.11 Replacement of the brake hose -rear (drum)..........2 Brake Lining Replacement .2..1.........................................6 Replacement of the brake caliper bracket ... 5-9 5............. 5-72 5........ 5-48 5.............7 Special Tools .. 5-3 5... 5-66 5.5.........2 Schematic and Wiring Diagrams.......... 5-13 5.4 Description & Operation ...4 Replacement of the brake master cylinder 5...... 5-67 5.... 5-10 5...1..... 5-64 reservoir.... 5-50 5.............. 5..1......5....6.........1 Hydraulic Brake System Disassembled View...1......2........... 5-46 5..3 Repair Guidance ....1............................3............ 5-45 5..1 Brake System Wiring Diagram ......3........... 5-43 5.............Brake table of contents 5-1 5 Brake 5.. 5-68 5............................1 Brake Pad Check......5 Description to the Braking System Failure 5...... 5-6 5....3....3. 5-7 5.............1.......................8 Brake Drum Surface Finishing............4......3......3 Description to the Vacuum Brake Booster.........1.........1........1 Check the Brake Disc Thickness Runout .......... 5-76 5....5..................2.............9 Brake hose inspection ........with 5.......... 5-7 5................. 5-55 5...3..5-3 5.....................2 Diagnostic Information and Procedure...........5.4 Travel of the brake pedal.........1 Shoe-type Braking System Description .with ABS............................1.3...10 Replacement of the Brake Hose... 5-60 5................2...1......1.2 Fastener Tightening Specifications......................................................2......3.... 5-5 5... 5-55 5...................5 Brake Wheel brake cylinder Replacement ......5......1.............. 5-64 5...1...........................1.2... 5-68 ...... 5-6 5...1........... 5-71 with ABS. ...1..1Specification ..3...........5.........1........................7 Replacement of Brake Disc ..2 Brake Disc Surface Finishing ............ 5-10 5....................2..... 5-4 Indicator Circuit...........3...2............................... 5-39 5..7 Replacement of ratio valve (without ABS)..17 Replacement of the Brake Lamp Switch ......5 Brake Master Cylinder Replacement..............3...4....... 5-61 5................5. 5-80 5.......8 Replacement of Brake Pipeline ..... 5-80 5..4......1...2...............5...5. 5-49 5......2.... 5-64 reservoir.............3Match the pad and brake disc............... 5-46 5.............2.......1..4.................... 5-58 ABS ......4 Replacement of the Brake Caliper.................................4 Diagnostic Information and Procedures ...............1......2..........1Specification ..1.....1....1. 5-74 without ABS...........without ABS..... 5-77 5......................5..........2.............. 5-67 5........2 Repair Guidance ...

....... 5-96 5... 5-119 5........3 Specific Information of the Electronic System 5-99 5.................. 5-80 5...............5..4........4....................5............12 DTC C0045................................ 5-97 5........ 5-131 5..............4.....3 Park Brake Right Cable Replacement/ Adjustment 5.......5................4.......................1Replace the ABS control unit.....4..........4 Fuse Jump Rated Current ...5......... 5-115 .....................4........ 5-143 System .....4....5 Replace the rear wheel speed sensor .9 DTC list. 5-93 5...........................11 DTC C0040....16 DTC C0080/ C0085 ... 5-140 5..... 5-138 5... 5-114 5.....5.........1Specification ..................4.............2.......................5... 5-113 ......1 Anti-lock brake system Operation.........5...............5... 5-84 5..........................18 DTC C0110...............................................................5.........4......5.................... 5-98 5.......2 Pin arrangement control unit wire connector......... 5-99 5...........5.............4.....5.................5.....................4......5-2 table of contents Brake 5....5....................3..............2 EBD System .........1 Overview .. 5-98 5.........................................8 Scan tool data definition ..................5... 5-83 5..4 Special Tools ...........................10 DTC C0035..................................................... 5-99 .......... 5-95 5..5.....4. 5-88 5.5...........5.........5.........2 Repair Guidance ...........2 Brake Drum Surface Finishing......5..................................3......5..........5..............6......2.................13 DTC C0050.................2 Park Brake Left Cable Replacement/ Adjustment ..5.. 5-91 5.5.. 5-140 System ...................... 5-126 5........... 5-140 5............... 5-103 5.............5.15 DTC C0070/ C0075 ...23 DTC C0550.................... 5-133 5...........................4.. 5-105 5....................................3 Component Location .........1 Specification ..........................4Parking Brake ...........................5..4................Anti-lock Braking 5.............. K50 Component View ......20 DTC C0141 .............. 5-99 5..1....4........7 Scan tool data list .2.4..........4...5..... 5-95 5....4 Park Brake Balancer Replacement .. 5................................C0156....2 Schemes and Wiring Diagram.4..............4...................24 DTC C0800.....................4..5.........5 Repair Guidance .......6......11 DTC C0040......5.......5..6 Description & Operation ..................... 5-116 5......................... 5-95 5.4.5.....................22 DTC C0245..5-111 5..5........ 5-84 5.................1 Tightener Tightening Specifications............ 5-120 5............4........6 Diagnostic System Check........ 5-95 5........7 Special Tools .......5...............4....5 Anti-lock brake system (if equipped)...............1Anti-lock brake system wiring diagram ...........5.....4..... 5-131 5..................19 DTC C0121.......4..............4............... 5-125 5...5...2 Replace the ABS Hydraulic Module ..1 Park brake lever and park brake alarm lamp 5... 5-107 5. 5-81 5. 5-118 5....3.........2 Safety measures ............ 5-117 5....3 Replace the ABS Hydraulic Module Bracket 5-135 5.. 5-122 5..........5...5..25 No Communication with EBCM ...4.5...5..... 5-129 5......5 Diagnostic Starting Point.................... 5-136 5..........................4 Replace the front wheel speed sensor .......................5..5.......................... 5-101 5.........4.......... 5-98 5.......5......17 DTC C0090/ C0095 ..............3. 5-104 5....3............14 DTC C0060/ C0065 .............Anti-lock Braking 5...5................................5....... 5-95 5...............2.....4....5....5...........4.......5.21 DTC C0161...........5................ 5-107 5...................... 5-109 switch replacement.....2....................... 5-95 5............4 Diagnostic Information and Procedure .......1 Component Location ..................4.................................................. 5-83 5...5..4.................

rotate the bolt tightly from 30.1.1.1 Specification 5.45 degree 50 N m Brake disc locking bolt 4N m .1.1Hydraulic brake 5.1. Brake Brake Hydraulic brake 5-3 5.1 Brake system specifications Application Specification servo brake booster dimensions 8 inches Brake master cylinder diameter 20.64 mm 1st piston travel 17mm 2nd piston travel 15mm Caliper diameter 48mm brake disc diameter 236mm brake disc thickness 20 mm brake pad thickness 16 mm wheel brake cylinder diameter 19.2 Fastener Tightening Specifications Application Specification Brake pipe nut 16 N m Brake master cylinder liquid tank installation nut 3N m caliper discharging valve and wheel cylinder discharging valve 6N m brake hose caliper bolts 40 N m Front caliper speed sensor installation bolt (applicable to ABS vehicles) 8N m Rear brake drum vehicle speed sensor installation bolt (applicable to ABS 4N m vehicles) Anti-lock brake system regulator bracket installation bolt (applicable to ABS 20 N m vehicles) Anti-lock brake system regulator installation nut (applicable to ABS vehicles) 10 N m Pedal bracket installation nut 22 N m Brake pedal pushing bar nut 18 N m Brake pedal bracket installation bolt 20 N m Booster vacuum pipe connection nut 18 N m Caliper bracket installation bolt 95 N m Rear brake installation bolt.05 mm brake drum diameter 200 mm brake plate width 28 mm 5.1.

2. . Refer to 8.5-4 Hydraulic brake Brake 5.8 for brake switch wiring diagram.1 Brake System Wiring Diagram Refer to 8.2 Schematic and Wiring Diagrams 5.1.20.1.5 for brake fluid sensor and park brake switch wiring diagram.2.20.2.

1.3 Visual Identification 5.1 Hydraulic Brake System Disassembled View 501001 Legend (1) Disc brake (4) Parking brake (2) Brake oil pipe (5) Drum brake (3) Brake master cylinder .3.1.Brake Hydraulic brake 5-5 5.

3.1.3.5-6 Hydraulic brake Brake 5.3 Brake Master Cylinder and Reservoir Disassembled View Reservoir Disassembled View (ABS vehicles) (vehicles without ABS) 501236 501202 Legend Legend (1) Reservoir cover (1) Reservoir cover (2) Reservoir (2) Reservoir (3) Sealing pad (3) Sealing pad (4) Brake master cylinder (4) Brake master cylinder .1.2 Brake Master Cylinder and 5.

the brake clicks. When the brake pedal is Front brake and rear brake works unevenly. The vehicle may stop with not too much braking force. Brake pedal must be stepped forcefully or hard to Brake pedal does not brake. Brake pedal is too soft (too near the floor) 3 Brake pedal stops against the pressure. 1 level in the reservoir. malfunction indicator malfunction indicator does not light. 4 original position.Brake Hydraulic brake 5-7 5.1 Hydraulic Brake Diagnostic System Check step action Normal Result(s) Abnormal result(s) * Inspect the brake fluid Brake fluid level is normal. brake braking. the steering wheel and pedal Brake produces noises. *To verify the correct test result. Press the brake pedal all The brake pedal moves Brake pedal moves unsteadily (hard or unsteady) the way down. malfunction indicator is off when the engine is started. Release the brake pedal. Ensure that the lights when the engine is When the engine is started. is stepped down slightly.1. tremble. Brake pedal returns to the Brake pedal fails to return to the original position. malfunction indicator lights. Brake system Start the engine. does not vibrate After the brake pedal is released. Turn off ignition Brake system When the engine is started. The front and rear brake works at the same time. 5 (tremble). Brake fluid level is too low. Refer to the relevant diagnostic table for the results of operation. The vehicle runs out during braking. . stepped down. The vehicle will not run out during brake. After the brake pedal is released. the brake does not click. stepped down. brake system switch. 2 released. The brake operates When the brake pedal is stepped down. the steadily and normally steering wheel and pedal trembles. Hydraulic brake system When the brake is When the brake is stepped down. compare the result with that of the operating vehicle/ system of the same type.4.4 Diagnostic Information and Procedures 5. there is delay in test. if possible. effect takes on The brake operates roughly when the brake pedal immediately. brake system parking brake is started.1. without jam or lock. Not much noise heard when the brake operates. steadily towards the floor.

Try to avoid locking of braks and slippery of the tires. Under different speed. Engine idle.Refer to Discharge air in the Contact with different road surface by tire with different hydraulic braking system.1. it is necessary to balance the braking system so as to avoid locking of the wheels.4. re-install or replace the elements If the road humps up and weight of the vehicle runs when necessary.If there is leakage. inspect the torque of the Fasteners or replace level the oil pipe and hose. oily and slippery Inspect if there is leakge from the housing of covered with loose mud the caliper and wheel cylinder.1. this may also do negative effect to the test. the Test the brake system on roads under the following brake alarm indicator will light to show there is conditions: leakage in the system.Travel of the pedal refers to the distance the Different tire thread and figure pedal moves from the fully released position to the Vehicle load floor. locked brakes and slippery tire cannot reflect the braking effect. . this may also negatively effect the test result.Conduct the following visual inspection to verify much.4 Travel of the brake pedal influence the brake performance If the travel of the brake pedal is too low. use point brake and emergent brake to test braking effect of different braking pedal force.The the minor reasons for too long travel of the brake pedal: following conditions may adversely affect braking Friction pad is heavily worn performance: Hydraulic system leakage Different tire inflation Measure the travel of the brake pedal regularly and Different tire size frequently.5 Brake Fluid Leakage maximum load requires more braking force than other wheels.3 Brake System Test slight drop of fluid level in the reservoir.If necessary.2 Outside elements that may 5.4.5-8 Hydraulic brake Brake 5. there If the wheels are not properly positioned. shift the transmission to Neutral.For vehicles with uneven load.Discharge air in the system Tire until all air is discharged. aside.There may be inside or dry outside leakage in the hydraulic system. it is usually the result of air in the system.4. especially may be leakage in the hydraulic braking when the camber and master pin inclination is too system. The following are some of adhesion force may result in different braking.1. Except under extreme high decelleration speed. feeling of the brake pedal is hard.If the fluid level in the reservoir is abnormally low. Inspect if there is damage to the connection element of the brakes.If the Wheel positioning pedal drops slowly while the brake force is kept. the wheel with 5.Normal friction disc worn may result in 5. Inspect the fluid level of the brake master cylinder. Step down the brake pedal and hold the braking force. the vehicle may run out during braking.During emergency braking. Heavy duty vehicle may require larger braking force. clean Inspect if there is leakage at the connection of adequately smooth brake pipe and brake hose.If the road is uneven and the wheel pumps. re-install or wet replace the elements connecting the brakes. if there is leakage.If there is leakage.4.1. Do not test brake under the following roads since the tires cannot adhere to the road surface evenly. therefore.Braking distance for emergency braking resulting in wheel rotation is shorter than that when wheels are locked.

Re-tighten the cover and film. Do not over-fill the reservoir to exceed the maximum filling level.Brake Hydraulic brake 5-9 5. sensor of fluid level in the reservoir will alarm in time. 501003 . That is.Otherwise. 2. fluid of the braking system may over flow to the exhaustion components of the engine. the reservoir is free of maintenance.5 Repair Guidance 5. may result in fire and hurt of human bodies. under normal conditions.1 Add to the brake master cylinder reservoir. Brake master cylinder reservoir and brake master cylinder are connected with brake hoses.with ABS Caution: Do not over-fill the brake fluid reservoir.1.Brake master cylinder reservoir should keep with enough brake fluid. clean the surrounding areas to avoid dust from entering. Before open the fluid reservoir. 501002 1. 4. Open the cover and remove the film.5.The fluid reservoir is at the left of the vehicle under the hood.1.Brake fluid is explosive and if contacting the engine exhaustion components. 3.When the brake fluid level is too low.

Remove the fluid level sensor connector. under normal conditions.3 Replacement of the brake master cylinder reservoir.without ABS Caution: Do not over-fill the brake fluid reservoir. 5. Re-tighten the cover and film. 3.Drain off fluid in the pilot bushing. clean the surrounding areas to avoid dust from entering. the least remained.5-10 Hydraulic brake Brake 5. the better.Brake fluid is explosive and if contacting the engine exhaustion components. 501004 . Drain off the brake fluid in the brake fluid reservoir with commercial siphon pipe.When the brake fluid level is too low.2 Add to the brake master cylinder reservoir. Before open the fluid reservoir. sensor of fluid level in the reservoir will alarm in time.with ABS Removal Procedure 1.Brake master cylinder reservoir should keep with enough brake fluid. Open the cover and remove the film. Do not over-fill the reservoir to exceed the 501200 maximum filling level. Remove the brake rfluid reservoir cover. fluid of the braking system may over flow to the exhaustion components of the engine. 4.Otherwise. 2. the reservoir is free of maintenance.5. may result in fire and hurt of human bodies.1. That is. 2.5. 3. The fluid reservoir is at the left of the vehicle under the hood.1. 1.

9. 501003 6. Inspect if the fluid reservoir has crack or deformation.If necessary. 501007 . Ply off the sealing ring to fluid conveying pipe in the brake master cylinder. Note: Pay attention to the over flow brake fluid. Clean the fluid reservoir with compressed air with no lubrication agent. replace the fluid reservoir. 8. Dry the fluid reservoir with compressed air with no lubrication agent. Uncover the waterproof panel sealing.Brake Hydraulic brake 5-11 4. loose the brake fluid reservoir nut (as shown by the arrow). Separate the brake master cylinder and conveying pipe. 7. 501005 5.

501007 2. Install brake fluid reservoir with new hexagon nuts. Apply brake master cylinder adhesive agent on the new sealing ring. 501008 . Tightening Tighten the brake fluid reservoir nut to 3 N m. insert the brake master cylinder and install the fluid conveying pipe.5-12 Hydraulic brake Brake Installation Procedure 1.

Connect the fluid level sensor connector. 501200 . 3. the least remained. the better. Remove the brake rfluid reservoir cover. Drain off the brake fluid in the brake fluid reservoir with commercial siphon pipe.without ABS Removal Procedure 1. 2. Install water drainage collector and body cover. 501003 5. Remove the fluid level sensor connector.4 Replacement of the brake master cylinder reservoir.1.Refer to Discharge air in the hydraulic braking system.Drain off fluid in the pilot bushing. 5.Brake Hydraulic brake 5-13 3. 4. Inspect if there is leakage in the brake system exhaustion.5.

Remove the sealing ring from the brake master cylinder. 501007 . 6.If necessary. Clean the fluid reservoir with compressed air with no lubrication agent.5-14 Hydraulic brake Brake 4. replace the fluid reservoir. Inspect if the fluid reservoir has crack or deformation. 7. 8. 501201 5. Incline the brake fluid reservoir and pull it upward to take it out. Dry the fluid reservoir with compressed air with no lubrication agent.

Inspect if there is leakage in the brake system exhaustion. 3. 501201 . Connect the fluid level sensor connector. Apply brake master cylinder adhesive agent on the new sealing ring.Refer to Discharge air in the hydraulic braking system. 501007 2. insert the brake master cylinder. Insert and install the brake fluid reservoir to the brake master cylinder. Install the outer cover of the brake fluid reservoir.Brake Hydraulic brake 5-15 Installation Procedure 1. 4.

Note: Pay attention to the over flow brake fluid. Remove the brake master cylinder fixing nut.1. 4. 501005 3.5.Refer to Replacement of Brake master cylinder Fluid Reservoir. 2.5-16 Hydraulic brake Brake 5. 501009 . Remove brake master cylinder. Disconnect the brake pipelines and the master pump. Remove the brake master cylinder fluid reservoir.5 Brake Master Cylinder Replacement Removal Procedure 1.

Refer to Filling of Brake master cylinder Fluid Reservoir. Install brake master cylinder. 2. Install the brake master cylinder fluid reservoir. 501009 3.Refer to Discharge air in the hydraulic braking system. 501008 . Install brake master cylinder nut. Discharge air in the exhaustion brake system.Brake Hydraulic brake 5-17 Installation Procedure 1. Tightening Tighten brake booster installation nut to 22 N m. refer to Replacement of Brake master cylinder Fluid Reservoir. Connect the brake pipeline and brake master cylinder. 4. 6. 5. Fill in the brake fluid into brake master cylinder fluid reservoir. Tightening Tighten the brake pipeline nut to 16 N m.

Remove the pedal and spring. 201022 3.6 Replacement of the brake pedal Removal Procedure 1. 2. 501011 .5.Loose the hexagon nut of the pedal shaft. clutch pedal and clutch cable.1. Disengage the brake pedal spring. 5. Remove the fixing clips from the fork and pull the fork off.5-18 Hydraulic brake Brake 5. Remove the fixing spring from the pedal shaft. Remove the pedal shaft and pull it from the left. 4.

7. 501012 6. Tightening Tighten the clutch bracket to the isolation panel to 20 N m. Replace the pedal rubber housing. During replacement.Brake Hydraulic brake 5-19 Installation Procedure 1.Adjust if necessary. 2. Fix the pedal shaft so that pusher bar connects with the brake pedal. 5. 3.Install the pusher pin and fixing caliper. Tightening Tighten the pedal to pedal bracket to 18 N m. 201022 . Install washer (3) and hexagon nut (4). Lubricate the pedal shaft (1) with special lubrication grease.Insert the brake pedal spring. Install the pedal and spring (7) to relevant position and insert the pedal shaft to the pedal bracket.Install clutch pedal spring and clutch cable. replace the brake pedal with assembly (2) with pedal bushing. Install clutch bracket and Tighten. 4.

Lower the vehicle. Remove the ratio valve. 3. pressure switch = 3Mpa). 3. 2. Loose the fluid reservoir outer cover.5-20 Hydraulic brake Brake 5.Block the brake fluid reservoir with cover similar to brake fluid reservoir. 501014 . Refer to Discharge air in the hydraulic braking system.3/3) (grades= 0.7 Replacement of ratio valve (without ABS) Removal Procedure Note: Do not rinse the ratio valve in any washing liquid. fill the brake fluid to the Maximum position. Remove the brake hard pipe connector with supporting spanner. Tightening Tighten the ratio valve nut to 16 N m. Install the ratio valve and Tighten the brake hard pipe connector to the ratio valve with hands. 2. 4. Replace two ratio valves at one time.1. Raise and adequately support the vehicle. Installation Procedure 1.3. Connect the brake hard pipe connector to the ratio valve with support spanner. 501014 5. Clean away dust and foreign matter on the brake pipeline and ratio valve.5. Discharge air in the brake.The inner components have been lubricated with special lubrication grease. 1.Use ratio valve with the same pressure grades and pressure switch (0. 4.

Do not Tighten the screw too much.1.Be sure to use the correct Fasteners when replacing the brake at the original position. Choose the correct pipeline sizes as well as the locking ring and formation cone bar. . 7. 9. or 501016 the pipe may be pushed out. 14. Obtain pipelines and steel connector nut of adequate size. 1.5. 13. otherwise the brake system may result in failure. 6. Insert the Tightening nut into tool bar.Use bending equipment in the workshop so as not to deform the brake intersection. Insert lock ring into the tool bar. Install the connector to the pipeline before start use of the flaring tool. After contact with the formation cone bar. Cut to the proper length. Clamp the flaring tool. 11. or the flare size may be too large. Put the clamp nut onto the brake pipe and insert into the correct lock ring. 12.Extend the pipeline out of the lock ring about 19mm. Notice: Do not use single bladed flaring tool. Wiper out the traces of lubrication oil at the brake 501015 pipeline and flaring tool.Be sure to use double-bladed flaring tool so that its strength is enough to support the system pressure.Unreasonable arrangement and installation may damage the brake pipe and result in brake system failure. Tighten the Tightening screw with spanner to the end.To determine the correct length. 10. Camber the inside and outside diameter with camber tools. Maintain the position of the center shaft and press on Tightening screws until the screw contacts formation central shaft and be able to move it. 4.Use of the single-bladed flaring tool may damage the system.Brake Hydraulic brake 5-21 5. 8. turn backward the Tightening screw one entire cycle.It is recommended not to use any of the other types.Place and keep the brake pipe carefully. measure the length of the old pipelines and plus 3mm. Insert adequate formation cone bar into tool bar.Choose outer diameter pipe satisfying the specified sizes. 3. Tighten.8 Replacement of Brake Pipeline Tools Required J 29803-A ISO (ISO) flaring tool Caution: Be sure to use double wall steel brake pipes to replace the old one. 5.brake pipe end must contact with the cone bar surface. 2.

1. 17. Remove the Tightening nut and locking ring. Inspect if the hose has the following situations: damage in road accident broken worn housing leakage pores wiring and assembled correctly Conduct adequate inspection requires lighting and mirrors.9 Brake hose inspection Inspect the flexible hydraulic brake hose at least twice a year. . 2. If the brake hose is found with any failure. Exit the Tightening nut from the tool. Bend the pipeline so that it matches with the old pipelines. 501017 5.5-22 Hydraulic brake Brake 15. replace the brake hose.Keep 19 mm away from moving or vibrating components.5.The hydraulic brake hose shall pass the hydraulic pressure in the steel brake hard pipe to brake caliper and brake disc.1. 16.Now the flare may be used.

501018 7. 3. or the hoses may be damaged. Notice: Do not have the components suspended on flexible hoses. Block the brake fluid reservoir with cover similar to brake fluid reservoir. Remove the hose (5) from the bracket. 4.Air in brake system may result in brake failure or casualty accident. Remove the front wheel. Raise and adequately support the vehicle. Clean away dust and foreign matter on the brake hose and connectors. 6. 1.Refer to Replacement of the wheel. 5. fill the brake fluid to the Maximum position.10 Replacement of the Brake Hose- Front Removal Procedure Caution: Do not move the vehicle before steady brake pedal travel is obtained. Loose the fluid reservoir outer cover.5.Do not bend brake hard pipe or bracket.1. Remove the fixing clip (1) from the hose mounting bracket. 8.Brake Hydraulic brake 5-23 5. 2. Remove the following items from the caliper (2): Brake hose bolt stem (4) hose (5) two washers (3) Discard the two washers 501019 . Use support spanner on the hose connector to remove the brake hard pipeline from the brake hose.

There shall be no distortion on the hose.Refer to Discharge air in the hydraulic braking system. 501018 8. Discharge air in the brake. Fix the hose connector with the support spanner. remove the hose and correct. Install the following part onto caliper (2) Brake hose bolt stem (4) hose (5) two new washers (3) Use the two new washers (according to relevant sequence) and refer to the illustration figures. Tighten the brake hard pipe to the brake hose with fingers. Do not bend the bracket or the pipeline.Inspect the operation of hoses at the uttermost right side and left side. 9. Install the front wheel. Lower the vehicle. 2. . Lubricate the bolt stem and thread with brake fluid. 4. Ensure there is no contact between the hose and suspension system.If there is contact between the hose and suspension. Tightly connect the brake hose onto the brake hard pipe.5-24 Hydraulic brake Brake Installation Procedure 1. 10. 5.Refer to Replacement of the wheel. Install the fixing discs to the hose connectors of the bracket. 6. 501019 3. 7. Tightening Tighten the brake hard pipeline connector nut to 16N m. Install the brake hose to the bracket. Tightening Tighten the brake hose caliper bolt stem to 40 N m.

1. Tighten the brake hard pipe to the brake hose with fingers. 1.Air in brake system may result in brake failure or casualty accident. Tightening Tighten the brake hard pipeline connector nut to 16 N m. 2. Do not bend the bracket or the pipeline. Remove the caliper from the brake hose from the bracket. .There shall be no distortion on the hose. 4. 5. Notice: There shall be no crimp on the brake hose anywhere to prevent the components from loss of brake fluid. 2. Clean away dust and foreign matter on the brake hose and connectors. Tighten the brake hose onto the brake hard pipelines. Remove the hoses from the bracket. Lower the vehicle. Install the brake hose to the bracket.11 Replacement of the brake hose - rear (drum) Removal Procedure Caution: Do not move the vehicle before steady brake pedal travel is obtained. 4.Brake Hydraulic brake 5-25 5. 5. Use support spanner on the hose connector to remove the brake hard pipeline from the brake hose. 3. Do not bend the bracket or the pipeline. 7.Do not bend brake hard pipe or bracket. 501021 6. Loosen the hose connector with the support spanner. 303006 Installation Procedure 1. Raise and adequately support the vehicle. Install the fixing discs to the hose connectors of the bracket.5. 3. Discharge air in the brake.Refer to Discharge air in the hydraulic braking system.

discharge air in this wheel caliper. which may result in casualty accident. 1. stop the discharging procedure. perform the procedure to the four brakes to discharge any air in them . do not put the foot on the brake pedal unless otherwise specified.Air in brake system may result in brake failure or casualty accident.Otherwise.If the brake hose or hard pipe at one wheel breaks. .with ABS Caution: Do not move the vehicle before steady brake pedal travel is obtained. rinse the parts with oil so as to reduce the damage degree.Have the engine running at least 10 seconds while observe the light yellow anti- lock braking system alarm indicator. discharge only the brake system related with the broken pipeline or hose. return the front and rear discharging pump to the maximum position. 2.If brake fluid is sprayed onto the vehicles.If there is not scan tool available. but the important thing is to strictly adhere to the following procedures. Caution: Do not over-fill the brake fluid reservoir. Caution: Use only clean OPEL DOT 4 brake fluid in enclosed reservoir. Put away your foot on the brake pedal. cable or electrical connectors. If air enters due to low brake fluid level or breaking of the brake hard pipe. the entire discharging procedure must be performed. The purpose of discharging air in the hydraulic braking system is to discharge air in the system. Start the engine. Notice: If any brake part is serviced or replaced and air enters into the brake system.Do not use brake fluid in open containers that maybe contaminated by water.If incorrect or contaminated hydraulic fluid is used.1. 3.Brake fluid is explosive and if contacting the engine exhaustion components. Note: During the entire procedure.5-26 Hydraulic brake Brake 5.Use scan tool to diagnose if ABS fails. If the light yellow ABS alarm indicator lights and hold for more than 10 seconds.If the brake hard pipe or hose breaks at the connection of the brake master cylinder and brakes. fluid of the braking system may over flow to the exhaustion components of the engine. components may be damaged or brake performance may lose. may result in fire and hurt of human bodies.5.12 Discharge air from the hydraulic brake system. Notice: Avoid spraying of brake fluid on paint. wire.Brake fluid may damage the paint and electrical connection. Notice: Before discharging air in the brake.The first choice is to perform reset procedure with the scan tool. choose the second procedure.

Repeat the above 4 steps.Brake Hydraulic brake 5-27 4. Wait for 30 seconds. Pressure discharging 1. Remove the brake fluid reservoir cover. 5. 6. Inspect and fill brake fluid reservoir to specified level if necessary. Connect the brake discharging equipment with the brake fluid reservoir with connector (1). then turns off continuously. Discharge air in the entire brake system. If the light yellow ABS indicator lights for about 3 seconds. 501022 3. 5. Charge pressure to the brake system. 501023 . Note: Wipe away the over flow brake fluid. then inspect the entire hydraulic brake system to ensure no leakage of brake fluid. turn off ignition.Repair if there is leakage. 2. 4.

25. 9. When there is no air in the brake fluid. Raise and adequately support the vehicle. 19. 23. 501025 17. Tightening Tighten the ABS regulator brake connector to 6N m。 8. close the ABS regulator brake pipe connector. 501024 11. Turn off ignition switch.5-28 Hydraulic brake Brake 6. If the brake pedal feels soft and its travel exceeds the specified value. 24. do not drive the vehicle. repeat step 6 and 7. Start the engine and have the engine running for at least 10 seconds. Start the engine and inspect the brake pedal. When there is no air bubble in the brake fluid. Open the discharging valve slowly.Pay attention to the pressure remained in the brake fluid reservoir. Remove the brake discharging equipment. Note: Ensure there is no leakage in the discharging valve. Inspect and fill brake fluid reservoir to specified level if necessary. right front caliper and left front caliper until no air bubbles occur. Remove the transparent discharging hose from the discharging valve. Install the transparent plastic discharging hose to the right rear brake exhaustion valve. 10.Brake fluid flows out. Install the brake fluid reservoir cover. 12. go to step 25. Immerse the other end of the hose in clean vessel with clean brake fluid. Tighten the brake drum discharging valve to 6N m. Slowly open one of the ABS brake pipe connector so that the brake fluid flows out. Repeat the above 6 steps (10-15) for left rear brake. 15. 18. 22. 20. If the brake pedal feels firm and its travel is within the specified value. 7. For the remained ABS regulator brake pipe connectors. 14. .to Step 26. 16. close the discharging valve. Remove the transparent discharging hose from the discharging valve. 21. Inspect the feeling of brake pedal and its travel. Lower the vehicle. 13.

. Slowly open one of the ABS brake pipe connector so as to fill the brake fluid.Go on with Step 26. go to Step 27. 10. give enough time for the brake system to cool down. repeat the discharging procedure from Step 1. Step down the brake pedal to 75% of the entire travel and hold. 6. When there is no air in the brake fluid. Tightening Tighten the ABS regulator brake connector to 16 N m。 5.Go to Step 1. 1. 2. Step down the brake pedal to 75% of the entire travel and hold. Caution: Do not move the vehicle before steady brake pedal is obtained.If the brake fluid level has dropped to the bottom of the brake master cylinder reservoir. 8.Test brake for several times at middle speed to ensure the brake system functions properly. 7. Brake system manual discharging procedure. repeat step 2 and 4. If the brake pedal feels soft. 4. Note: Ensure the brake master cylinder brake fluid level is not at its bottom.Otherwise. Road test the vehicle. Note: Wipe away the over flow brake fluid. 9. Open the discharging valve. For the remained ABS regulator brake pipe connectors. Inspect and fill brake fluid reservoir to specified level if necessary.Inspect and fill the brake master cylinder reservoir according to the volume of discharged brake fluid. Inspect and fill brake fluid reservoir to specified level if necessary.Between each brake. do not drive the vehicle. Raise and adequately support the vehicle. Immerse the other end of the transparent plastic hose in clean vessel with clean brake fluid. 11. 27.Brake Hydraulic brake 5-29 If the brake pedal feels firm and steady. 3. close the ABS regulator brake pipe connector. 26. human casualty may result. then repeat the brake system pressure discharging procedure. Install the transparent plastic discharging hose to the right rear exhaustion valve. Confirm the unacceptable soft feeling of brake pedal and its travel are not caused by improper adjustment of the brake disc plate or other mechanical failures. Note: An assistant is required to step the brake pedal during opening and closing of the discharging valves.

then turn off the engine. 15. right front caliper and left front caliper until no air bubbles occur. Lower the vehicle. If the pedal feels firm and steady and its travel is within the specification.Otherwise. Inspect the brake fluid level in the reservoir. Release the brake pedal.Pay attention to the feeling and travel. Repeat step 9 ñ13 until there is no air bubble in the brake fluid. Remove the transparent discharging hose from the discharging valve. Close the discharging valve. 26. Road test the vehicle. 24. 22. repeat the manual discharging procedure and start from Step 1.Fill in brake fluid to the correct level in the reservoir when necessary. Note: Ensure there is no leakage in the discharging valve. 19. Turn the ignition switch to RUN position. 25. 21.5-30 Hydraulic brake Brake 12. If the pedal feels firm and steady and its travel is within the specification. Repeat the above step 8-16 for left rear brake. perform road test to the vehicle.Test brake for several times at middle speed to ensure the brake system functions properly. Tighten the discharging valve to 6 N m. If the brake pedal feels soft or its travel exceeds the specifications at the beginning or after the engine is started. 14. 23.Test brake for several times at middle speed to ensure the brake system functions properly.Step the brake pedal with medium force and hold. Install the brake fluid reservoir cover. 17.Inspect the travel of the pedal again while the engine is running. 16. start the engine. 18. 13. 20. human casualty may result. Remove the brake fluid reservoir cover. Caution: Step down the brake pedal before move the vehicle. .

may result in fire and hurt of human bodies. Notice: Before discharging air in the brake. cable or electrical connectors. Notice: If any brake part is serviced or replaced and air enters into the brake system. components may be damaged or brake performance may lose.5.If brake fluid is sprayed onto the vehicles.13 Discharge air from the hydraulic brake system .If the brake hard pipe or hose breaks at the connection of the brake master cylinder and brakes. perform the procedure to the four brakes to discharge any air in themIf the brake hose or hard pipe at one wheel breaks.Be sure to follow the following procedures.1. discharge only the brake system related with the broken pipeline or hose. return the front and rear discharging pump to the maximum position.Brake fluid is explosive and if contacting the engine exhaustion components. Caution: Do not over-fill the brake fluid reservoir. Notice: Avoid spraying of brake fluid on paint. If air enters due to low brake fluid level or breaking of the brake hard pipe.without ABS Caution: Do not move the vehicle before steady brake pedal travel is obtained. The purpose of discharging air in the hydraulic braking system is to discharge air in the system.Otherwise. Caution: Use only clean OPEL DOT 4 brake fluid in enclosed reservoir.Do not use brake fluid in open containers that maybe contaminated by water. fluid of the braking system may over flow to the exhaustion components of the engine. . wire. rinse the parts with oil so as to reduce the damage degree. discharge air in this wheel caliper.Brake fluid may damage the paint and electrical connection. which may result in casualty accident.If incorrect or contaminated hydraulic fluid is used. the entire discharging procedure must be performed.Air in brake system may result in brake failure or casualty accident.Brake Hydraulic brake 5-31 5.

7. 501023 . Charge pressure to the brake system. Note: Wipe away the over flow brake fluid. 501022 3. Connect the brake discharging equipment with the brake fluid reservoir with connector (1). 2. Raise and adequately support the vehicle. Install the transparent plastic discharging hose to the right rear brake exhaustion valve. Wait for 30 seconds. 5. Remove the brake fluid reservoir cover.Repair if there is leakage. 4.5-32 Hydraulic brake Brake Pressure discharging 1. 6. Inspect and fill brake fluid reservoir to specified level if necessary. then inspect the entire hydraulic brake system to ensure no leakage of brake fluid.

Start the engine and inspect the brake pedal.Otherwise. If the brake pedal feels soft and its travel exceeds the specified value.Brake Hydraulic brake 5-33 8. Confirm the unacceptable soft feeling of brake pedal and its travel are not caused by improper adjustment of the brake disc plate or other mechanical failures. go to Step 24. 19. Install the brake fluid reservoir cover. 17. Turn off ignition switch. When there is no air bubble in the brake fluid. 13. Open the discharging valve slowly. 15. Tighten the brake drum discharging valve to 6 N m. do not drive the vehicle. Note: Ensure there is no leakage in the discharging valve. Lower the vehicle. If the brake pedal feels soft. Inspect and fill brake fluid reservoir to specified level if necessary.to Step 23. Brake fluid flows out. 11. Repeat the above 6 steps (7-12) for left rear brake. Road test the vehicle. 20. 501025 14. If the brake pedal feels firm and its travel is within the specified value. Caution: Do not move the vehicle before steady brake pedal is obtained. 18.Go to Step 1. 22. then repeat the brake system pressure discharging procedure. . human casualty may result. Immerse the other end of the hose in clean vessel with clean brake fluid.Go on with Step 23. go to step 22. Start the engine and have the engine running for at least 10 seconds. 21. 16. give enough time for the brake system to cool down. do not drive the vehicle.Pay attention to the pressure remained in the brake fluid reservoir. 12. close the discharging valve. right front caliper and left front caliper until no air bubbles occur. Inspect the feeling of brake pedal and its travel. If the brake pedal feels firm and steady.Test the brake for several tims at medimu speed (without ABS) to ensure the brake system functions properly. 24. Remove the transparent discharging hose from the discharging valve. 23. 9. Remove the transparent discharging hose from the discharging valve.Between each brake. 10. Remove the brake discharging equipment.

then turn off the engine. 10. If the pedal feels firm and steady and its travel is within the specification. Note: An assistant is required to step the brake pedal during opening and closing of the discharging valves. Install the brake fluid reservoir cover.Fill in brake fluid to the correct level in the reservoir when necessary. Lower the vehicle. Tighten the discharging valve to 6 N m. 13. Inspect and fill brake fluid reservoir to specified level if necessary. perform road test to the vehicle. 8.Inspect the travel of the pedal again while the engine is running. Open the discharging valve. right front caliper and left front caliper until no air bubbles occur. Repeat step 4 ñ8 until there is no air bubble in the brake fluid. 17. Remove the brake fluid reservoir cover. 1. Install the transparent plastic discharging hose to the right rear exhaustion valve. Note: Ensure there is no leakage in the discharging valve. Close the discharging valve.Pay attention to the feeling and travel. Remove the transparent discharging hose from the discharging valve. 14. Note: Ensure the brake master cylinder brake fluid level is not at its bottom.If the brake fluid level has dropped to the bottom of the brake master cylinder reservoir. Note: Wipe away the over flow brake fluid. Step down the brake pedal to 75% of the entire travel and hold. 19. 7.Step the brake pedal with medium force and hold. 2. Immerse the other end of the transparent plastic hose in clean vessel with clean brake fluid.Test brake for several times at middle . Raise and adequately support the vehicle.Inspect and fill the brake master cylinder reservoir according to the volume of discharged brake fluid. Repeat the above step 3-11 for left rear brake. 4. 15. 11. 16. 12.5-34 Hydraulic brake Brake Brake system manual discharging procedure. 5. start the engine. 18. Inspect the brake fluid level in the reservoir. 9. If the pedal feels firm and steady and its travel is within the specification. Release the brake pedal. 3. repeat the discharging procedure from Step 1. Turn the ignition switch to RUN position. 6.

which may result in casualty accident. Notice: Pressure discharging equipment may be used to rinse the system. Remove the brake fluid reservoir cover.If incorrect or contaminated hydraulic fluid is used.Brake fluid is explosive and if contacting the engine exhaustion components. repeat the manual discharging procedure and start from Step 1. 20. Fill the brake fluid reservoir with clean brake fluid. 2.Otherwise. Caution: Do not over-fill the brake fluid reservoir. fluid of the braking system may over flow to the exhaustion components of the engine.There must be rubber film between air supply and brake fluid to prevent air. components may be damaged or brake performance may lose. 21. 4.(P/N93730597). may result in fire and hurt of human bodies. Road test the vehicle.Test brake for several times at middle speed to ensure the brake system functions properly.5. If the brake pedal feels soft or its travel exceeds the specifications at the beginning or after the engine is started. 1. moisture and other pollutants entering the hydraulic system. 5. . 3. Clean the brake fluid reservoir cover and its adjacent area.Brake Hydraulic brake 5-35 speed to ensure the brake system functions properly.1.14 Rinsing of the Hydraulic Brake System Pressure rinsing Caution: Use only clean OPEL DOT 4 brake fluid in enclosed reservoir. human casualty may result.Do not use brake fluid in open containers that maybe contaminated by water.Otherwise. Caution: Step down the brake pedal before move the vehicle. Discharge any brake fluid remained.

Rinse the brake in line with the following sequence: right rear left rear right front left front 9. Raise and adequately support the vehicle. If necessary. 17. 18. 16.5-36 Hydraulic brake Brake 5. 6. Charge pressure to the brake system. Install the transparent plastic discharging hose to the right rear brake drum exhaustion valve. Discharge air in the entire brake system. 7. brake master cylinder rubber part brake caliper and brake drum sealing. Connect the brake discharging equipment with the brake fluid reservoir with connector (1). 13. Tightening Tighten the discharging valve to 6 N m. 15. Inspect the brake fluid level in the reservoir. .Fill in brake fluid to the correct level in the reservoir when necessary. Immerse the other end of the hose in clean vessel with clean brake fluid. Lower the vehicle. 8. 11. Install the brake fluid reservoir cover. Remove the discharging connector. Close the discharging valve when clean brake fluid flows. 10. 14.Refer to Discharge air in the hydraulic braking system. Open the discharging valve slowly so that brake 501022 fluid flows. 12. replace all the following rubber parts: brake hose assembly.

Discharge any brake fluid remained in the brake fluid reservoir. 11. Tightening Tighten the front caliper discharging valve to 6N m. 3. 10. Raise and adequately support the vehicle. Close the discharging valve when clean brake fluid flows.Refer to Discharge air in the hydraulic braking system. Clean the brake fluid reservoir cover and its adjacent area. Install the transparent plastic discharging hose to the right rear brake drum exhaustion valve. 12. Install the brake fluid reservoir cover. 13. 9. Use clean OPEL DOT 4(P/N93730597) brake fluid to fill the reservoir to adequate level. 2. Immerse the other end of the hose in clean vessel with clean brake fluid.Fill in brake fluid to the correct level in the reservoir when necessary. 5. brake master cylinder rubber part brake caliper and brake drum sealing. 16. Install the brake fluid reservoir cover. Discharge air in the entire brake system. Remove the brake fluid reservoir cover. If necessary. 6. Rinse the brake in line with the following sequence: right rear left rear right front left front 8.Brake Hydraulic brake 5-37 Manual rinsing Note: Absorb the brake fluid with suitable vessel and / or cloth to prevent it from contacting any paint surface. 4. Open the discharging valve slowly so that brake fluid flows out. . 1. 15. Lower the vehicle. 14. replace all the following rubber parts: brake hose assembly. 7. Inspect the brake fluid level in the reservoir.

3. Install MKM-558 brake tester to read pressure. 5. The test lasts for about 5 minutes. Install KM-325 brake pedal tensioner between the driver's seat and the brake pedal. If the established pressure drops. 7. the obtained pressure shall keep without any change.5-38 Hydraulic brake Brake Inspect if there is leakage Tools Required MKM-558 brake tester KM-325 brake pedal tensioner 1. 2. inspect to see if there is leakage in the brake system. Activate the brake pedal repeatedly to obtain pressure of 20 bar. 501027 4. If there is no leakage in the brake system. 6. Connect the test pipeline with brake caliper and brake drum.Discharge air in the exhaustion brake system. 501026 .

15 Replacement of vacuum booster Removal Procedure Note: It is not necessary to remove the brake hose from the brake master cylinder or regulator. or the brake switch may be damaged. 3.The booster can only be removed when the pushing bar and brake pedal is disconnected. 501028 2. 4.5. 1. 501029 . keep the brake pedal in stationary condition.Brake Hydraulic brake 5-39 5.1. Remove the foot panel cover. Remove vacuum hose from the brake booster. Push forward slightly. Rotate the brake lamp switch and remove it. Note: Disconnect pushing bar from the brake pedal. remove the brake master cylinder mounting nuts and the pump from the booster.

9. 501032 . 501030 6. Remove the booster and bracket as a whole. Remove the pusher lock and pusher from the booster. Remove the bracket and washer from the booster. Remove the connecting nut between booster bracket and front bottom fender. Remove the pedal and spring. Remove the booster pusher spring clamp.5-40 Hydraulic brake Brake 5. 501031 7. 10. 8.

2. 201036 . Install booster bracket and nut. Install the booster. Install the pusher to the booster. Tightening Tighten the nut to 22 N m.Brake Hydraulic brake 5-41 Installation Procedure 1. Adjustment Adjust the position of the pushing lever so that the distance between the booster surface to the center of pushing lever hole (A) is 141. 5. connect it with the front bottom fender.5mm. Install the washer. lock it. Install the connecting nut between the bracket and front bottom fender. 501033 3. 4. Tightening Tighten the nut to 20N m.

8. 7. 501028 . Install the booster pushing lever and pedal and the spring clamp together. 9. 11. 501030 10.5-42 Hydraulic brake Brake 6. Tightening Tighten the nut to 22 N m. Install the pedal spring. Install floor cover. Install the brake master cylinder onto vacuum booster and tighten the nut. Install the brake lamp switch. Install vacuum hose to the vacuum booster.

Brake Hydraulic brake 5-43 5. Remove vacuum hose from the brake booster.1.16 Replacement of vacuum booster hose Removal Procedure 1. 501029 2. Disconnect the vacuum hose from the inlet manifold.5. 501035 .

Connect the vacuum hose to the vacuum brake booster. 501035 2. 501029 .5-44 Hydraulic brake Brake Installation Procedure 1. Connect the vacuum hose to the inlet manifold.

Connect the electrical connectors. 501030 Installation Procedure 1. Install the instrument panel isolator. 3. Adjust the brake lamp switch. Disconnect the electrical connectors.5. 2. 501030 . Remove the brake lamp switch from the brake pedal bracket. Remove the instrument panel isolator.17 Replacement of the Brake Lamp Switch Removal Procedure 1.Brake Hydraulic brake 5-45 5.1. Install the brake lamp switch to the brake pedal bracket. 4. 3. 2.

brake master cylinder cover film caliper housing 5. on brake components.1. Refer to Rinsing of the Do not use compressed air with lubrication oil Hydraulic Brake System. ABS indicator turns off.1. The following conditions may result in boiling away of brake fluid: 2. discharge all or part 5. the following parts will swell: Check in Anti-lock braking System.There is used in diagonal diffluent braking system. rubber parts The brake master cylinder has integrated standard may be damaged.5 Description to the Braking System If aging takes place. Lubricate the rubber parts with silicon-based The brake master cylinder is made of Aluminum.The brake master cylinder is also equipped with fluid level When any of the hydraulic components is sensor.1. the indicator operates electrical connection.Otherwise. 5. ABS indicator lights.Dry the Brake system malfunction indicator in the instrument components with compressed air without lubrication cluster turns on under the following conditions: grease.Vehicles with ABS are equipped with EBD removed or disconnected. rubber parts Discharge air in the exhaustion brake system.1 Brake master cylinder Description Fill the brake system with new brake fluid. When any of the hydraulic components is removed or disconnected. Refer to Hydraulic Brake.Replace all rubber parts in the system.2 Description to the Ratio Valve (without ABS) 5. Discharge air in the hydraulic braking system. 5. Refer to may be damaged. yellow anti-lock indicator.Under normal conditions. while vehicles without ABS are equipped with The detailed torque value is for drying ratio valve to provide better front and rear brake Fasteners without lubrication grease.3 Description to the Vacuum Brake of the air in the brake system. brake fluid not correct 3.6.In the system. including hoses and useless hydraulic components. Refer to Filling of Brake master cylinder Fluid Reservoir. prevent the alcohol from entering the Ignition ON. Replace all components in the service box Service and operation on clean platform used for repairing the booster.Brake fluid may damage the paint and cluster. Service and operate on clean platform without mineral oils.It is lubrication grease for easy assembly.If the indicator turns on during rubber parts in brake hydraulic system aging driving.4 Description to the Brake Alarming Note: Do not rinse the ratio valve in any washing System liquid. When the engine starts.1.1. discharge all or part (electronic braking distribution) system (refer to ABS for of the air in the brake system. .6.The inner components have been lubricated with If the vehicle is equipped with ABS.6. rinse the parts with oil so as to reduce the damage degree. trouble exists. 1.If brake fluid is sprayed onto the according to the following specifications: vehicles.Refer to ABS Diagnostic System If the rubber part ages. Note: Rinse the brake system. balance under emergency braking. silicon-based lubrication grease in the service front and rear brake at diagonal are activated by initial box. level piston and other pair of brakes are activated by the second level of piston. without mineral oils. when the ignition is at ON position. the brake fluid contains mineral oil or water Operation of the ABS indicator is an important part in dianosis to ABS system. the ABS indicator lights.6. details). Rinse all the components with alcohol.1. Before start the engine. remove all useful hydraulic Failure Indicator Circuit components. Disc Brake. Do not use compressed air with lubrication oil on brake components.Otherwise. The ratio valve is at rear brake connection The anti-lock indicator is within the instrument pipelines. ABS system uses special lubrication grease.6. double brake master cylinder function.5-46 Hydraulic brake Brake 5. After the engine starts.6 Description & Operation system. Booster The specified torque value applies to dry non- Note: lubricated Fasteners.

Electronic brake control module provide ground for the instrument panel. the brake fluid level sensor will be off.The instrument panel grounds through the sensor and circuit. When ignition is ON and the park brake works. Brake fluid level too low in the brake master cylinder.Brake system malfunction indicator lights on. the indicator lights on to check if it works normal.Brake Hydraulic brake 5-47 park brake comes into effect. . When brake fluid level is too low in the brake master cylinder.

5-48 Hydraulic brake Brake 5.7 Special Tools Number & Name of Illustration the Tools MKM-558 Brake tester MKM-558 KM-325 brake pedal tensioner KM-325 J29803-A Brake pilot hose tool package J29803-A TECH 2 Scan tool TECH2 .1.

2.1Specification 5.Brake Disc brake 5-49 5.1.2.1.1 mm maximum scratch 0.01 mm Maximum lateral runout 0.4 mm brake pad thickness 16 mm Minimum brake pad thickness 7 mm 5.1 Component Specifications Application Specification Caliper piston diameter 48 mm brake disc diameter 236 mm Brake disc scraper thickness (refer to the notes) 16 mm Minimum thickness of the brake disc 17 mm Fabrication thickness of the brake disc 18 mm brake disc thickness (new) 20 mm Thickness deviation 0.2 Fastener Tightening Specifications Application Specification caliper locator pin 30 N m caliper bracket bolt 95 N m brake hose bolt connecting the caliper 40 N m exhaustion valve 6N m front brake disc bolt 4N m cover plate 4N m ABS front sensor bolt (for vehicles with ABS) 8N m .2Disc brake 5.03 mm Maximum lateral runout (assembling) 0.2.

5.1mm. finish the surface or replace 2.3 Brake disc geometric tolerance The following brake disc surface tolerance shall be under strict control during manufacturing: flatness parallel lateral runout Keep strict brake surface geometrical tolerance may prevent unevenness or vibration. remove the the reading is more than 0. satisfies the specifications.2. Rotate the wheel for one cycle. Refer loose. that is. mark the position of Removal Procedure brake disc on the hub (1 or 2 bolt away) to improve the Tools Required over lateral runout of brake disc.05mm. 7.Inspect each measured value at the brake rim with the same interval. the brake disc if necessary.2. obtain more 8.2.Be sure to have the dial gauge contact the brake disc surface 10mm away from the outer rim.2. 5. Install the tire and wheel assembly according to 5. . which may result in braking trembling.5-50 Disc brake Brake 5. Remove the wheel. Zero the dial gauge.For brake disc with thickness variance more than 0.Otherwise. check J8001 dial gauge if the lateral runout of the hub is too much or too 1.2.If the lateral runout cannot be corrected after marking the brake disc. fabricate or replace the braking disc. 6. 0.If the reading is more than condition.2. Clean the brake disc surface. knuckle. larger lateral runout may occur. Install and Tighten the wheel nut to fix the brake the marks at the wheel and hub. maintain the position of the caliper to obtain replace the braking disc. Remove the nut fixing the brake disc. 2.Refer to Replacement of the Installation Procedure wheels in Tire & Wheel.1mm. adjust or wheel.If the Tools Required are not available. Fix the J8001 dial gauge on the sterring 3.01mm. Refer to disc. 3. 1. trembling of pedal and/ or front vibration may occur during braking.Fabricate or replace the brake disc that fail to comply with the above specifications.1 Check the Brake Disc Thickness Runout Measure the thickness of the brake disc at four or more points to check the thickness runout of the brake disc.If the lateral runout Information.If unable to check while disassembling. 4. use J42450-A wheel hub cleaner to clear away rust or foreign matter on the brake disc 502001 connection surface as well as on the flange.2 Brake disc lateral runout check Notice: While removing the brake disc from the wheel bearing flange. Lower the vehicle.Check the runout accurate general runout readings under actual braking shown in dial gauge. Under certain circumstances. Check the lateral vibration of the wheel. Replacement of the wheels in Tire & Wheel. Take marks on the wheel and hub. accurate readings. the hub must be replaced.2 Diagnostic Information and Procedure 5.If the lateral runout of the hub is more than to Raise and Lift the Vehicle in General 0.2. Raise and adequately support the vehicle.

Brake disc may have scores under normal use.Brake Disc brake 5-51 New brake disc satisfing the above specification will get good re-finished surface. .Slight scratch on the brake surface with depth less than 0.Refer to Brake Disc Surface Finishing.4mm will not impact the brake performance. Control the brake disc surface will eliminate the following concerns: brake pedal feels hard brake performance decline drastically delay abnormal performance Control the brake disc surface coarseness can prolong the life of the brake pad.

Inspect the thickness of the pad: 7mm. replace with original GM brake pad or equivalent to maintain the balance of front and rear brake performance.3. replace it when it is worn to less than 0. Refer to Raise and Lift the Vehicle in General Information.3. 5. Push the piston into the caliper cylinder so as to separate the pad and brake disc. Remove the caliper fixing spring. 5.5 mm away from the rivot head.Meanwhile. Mark the position of the wheel in relation with the hub.2.These are the position where maximum wearing occurs. 502002 . 7. 8. replace the brake pad. Fill the brake fluid to the maximum position.5-52 Disc brake Brake 5. Check the brake pad whenever remove the wheel (wheel rotation and so on).3 Repair Guidance 5. 2.Some of the brake pad has a heat-isolation layer with the pad film. Check the thickness of the inner brake pad to ensure it is not worn too early. 1. Raise and adequately support the vehicle. Check the two ends of the caliper and the two ends of the outer pad.If the brake pad is rivoted. Install the two wheel nut and fix the brake pad. When the brake pad is worn and its thickness is less than 7 mm.Refer to Replacement of the wheels in Wire & Wheel.Brake components for replacement from GM are carefully selected to provide adequate balance under braking and control under various conditions. Remove the wheel.2. 4.Observe the inside brake pad through the check hole at the top of the caliper.2.2 Replacement of the brake pad Removal Procedure For all vehicles manufactured by GM.1 Brake Pad Check Check the brake pad every 15000 km.Do not confuse the heat isolation film with the inside and outside brake pad. replace all the disc brake pad. the braking performance of the vehicle may be changed. 6. 3.If the material nature of the front and rear brake pad is different from the replacement components recommended by GM.

Remove the caliper location pin. 502003 10. Remove the brake pad from the caliper. 502004 .Brake Disc brake 5-53 9.

Install the brake pad onto the caliper. Install the caliper location pin.Use industrial alcohol. Notice: Inner and outer brake pad must be new or parallel ones. 502003 .Do not damage the piston or caliper housing.Otherwise. Tightening Tighten the caliper pin to 30 N m.Use C-type clamp to fix the piston while install new brake pad.5-54 Disc brake Brake Installation Procedure Note: Wiper the outer surface of the caliper housing clean prior to installation of new brake pad. 502004 3. 1. which may result in damage of brake pad. Press the piston to the bottom of the caliper cylinder.Place a piece of metal sheet or wooden plate in front of the piston surface. Lubricate the caliper locator pin and two housing with silicon-based lubrication grease. over-heating of the brake may occur. brake disc or caliper. 2.

6. 3. 5. Refer to Match the pad and brake disc. 9. 1. Notice: If only brake pad is removed. Refer to Raise and Lift the Vehicle in General Information.3. human casualty may result.3Match the pad and brake disc. 4. Block the brake caliper case and the brake 502005 pipeline so as to prevent the brake fluid front leakage or being contaminated.3.4 Replacement of the Brake Caliper Removal Procedure Caution: Caution: Do not move the vehicle before steady brake pedal travel is obtained. Match the new brake surface after the surface is finished or new brake disc is replaced. Fill the brake fluid to the maximum position. 7. Install the caliper fixing spring. Match the pad and brake disc. Step forcefully the brake pedal three times so that the brake pad is in place.Do not over heat the brake. Lower the vehicle. . Brake 20 times when the vehicle speed is at 48km/h and match the new braking surface. the new brake pad has to be matched.Refer to Replacement of the wheels in Wire & Wheel. Mark the position of the wheel in relation with the hub. do not disconnect the oil inlet pipe connector. 5.2. Raise and adequately support the vehicle. 8. 7. 502002 5. Remove the wheel bolt Tightening the brake disc to the wheel hub. Keep the marks in wheel and hub correlate. 2. Install the two wheel nut and fix the brake pad to the wheel hub.2. After the brake pad is replaced. 5.Refer to Replacement of the wheels in Wire & Wheel.Brake Disc brake 5-55 4. 6. Step the brake pedal with force above average. 10. Install the wheel assembly.Otherwise. Remove the wheel. Remove the front brake hose and pay attention to the sealing ring.

11.Use new parts including the bushing to install the caliper. Inspect the caliper pin to see if there is corrosion or damage. replace the location pin housing.Refer to Brake Caliper Overhaul.5-56 Disc brake Brake 8. replace the piston housing. Inspect if the location pin has the following situation: cut tearing aging If there is damage. Remove the caliper fixing spring.Or the hose may be damaged. Inspect if the location pin has the following situation: cut tearing aging If there is damage. 502002 9. Remove the caliper housing from the brake disc and caliper bracket. Remove the caliper location pin.Once corrosion is found. 12. 10. do not try to wear it out. Notice: Do not hang the caliper with flexible hose. 13. . Refer to Replacement of the brake 502003 caliper bracket.

8. step the brake pedal with force of 238N after discharging. Lubricate the two location pin on the caliper bracket.Brake Disc brake 5-57 Installation Procedure 1. discharge air in the caliper. Tightening Tighten the caliper pin to 30 N m. 6. Lower the vehicle. Lubricate the caliper location pin. Remove the wheel bolt Tightening the brake disc to the wheel hub. . Inspect if there is leakage of brake fluid in the hydraulic braking system. 9. 5.Use silicon- based lubrication oil. If necessary. 3. Tightening Tighten the brake hose bolt to 40 N m. 2. 4. 11. Refer to Discharge air in the hydraulic braking system.Refer to Brake Fluid Leakage.Refer to Replacement 502005 of the wheels in Wire & Wheel.Use silicon-based lubrication oil.Do not lubricate the bolt and thread. if the connector is removed. Install the caliper location pin.Be sure to fix the bushing. Note: Replace the copper washer. Install the wheel assembly. 10. 7. Install the caliper housing to the brake disc and caliper bracket. Install brake hose bolt.

Notice: Use clean coth in the caliper housing while removing the piston. Inspect if the piston has the following situations: score scratch corrosion wearing or damage to the chromed layer Replace the piston if one of the above condition is found. replace the caliper assembly. which may result in serious human casualty. try to grasp or protect the piston.2.Do not score the case cylinder.5-58 Disc brake Brake 5. 4. 3.3. Notice: Do not remove the sealing with metal tools.Remove with small wooden tool or plastic tools. Remove the piston sealing ring from the caliper housing slot. pay attention not to put your finger in front of the caliper piston. Refer to Brake Caliper Replacement. even if there is pad. 502008 .If the piston drops. 1.Tighten the caliper.Push the piston from the cylinder with suitable force.The piston may fly out forcefully.Or. Remove brake caliper housing.Inject compressed air into the caliper hole with compressed air gun. Notice: If there is damage to the piston. Caution: Blow in compressed air.5 Brake Caliper Overhaul Removal Procedure Remove brake caliper. 502007 2. Remove the piston.The piston will drop out of the housing. caliper housing or sealing slot may be damaged. damage may also occur.

Use filtered compressed air without lubrication oil. replace the caliper. Blow dry all passage and discharging valve in the caliper housing.Replace the corrosive location pin. Polish the slight corrosion with fine sand cloth. 502010 Installation Procedure 1. 502011 . 10. 11. Place the caliper housing onto the caliper case flaring position. Tightening Tighten the discharging valve to 6 N m. 15.If the sealing slot is damaged. Inspect if the location pin has the following situation: cut tearing aging 502009 9. Remove the discharging cover and valve from the caliper housing. If corrosion in the sealing slot and surrounding area cannot be removed with fine sand cloth. Inspect the caliper pin to see if there is corrosion or damage. Check if the caliper housing and sealing slot has the following conditions: score scratch corrosion wearing 6. 8.Do not try to wear the corrosive objects. 7. 12. 2. replace the caliper housing. 14.Brake Disc brake 5-59 5. Rinse all components with clean industrial alcohol. Install the discharging valve and valve head onto the caliper housing. 13. Inspect if there is score or blur on caliper cylinder sealing slot. replace the damaged housing. Dry all parts with filtered compressed air without lubrication grease.

Remove the following components from the bracket. 2. Install the piston and housing onto caliper bushing. Housing bolt bushing 5. Tightening Tighten the caliper bracket bolt to 95 N m. Install the lubricated housing onto the piston. 3. Installation Procedure 1. 4. Check if the bracket is broken. 2.6 Replacement of the brake caliper bracket Removal Procedure Note: Do not remove the brake hose from the caliper. Install the following components into the caliper bracket.Support or hang the caliper. 502012 5.Refer to Brake Caliper Replacement. Do not hang the caliper at brake hose. Use bracket bolt to install the caliper bracket.2. . Remove the caliper bracket. 7.Refer to Brake Caliper Replacement.3. Lubricate the following components with silicon- based lubrication grease.5-60 Disc brake Brake 3. Caution: Replace with new Fasteners when the Fasteners are loosened or removed. Install the new lubricated piston sealing into caliper cylinder bushing slot.Push the brake caliper piston to the bottom of the bushing. 6. If there is broken.Or. 502013 6. Housing bolt bushing 3. Install the caliper. replace the bracket. 5. Note: New brake caliper bolt has already thread sealing agent applied. Remove the caliper bracket bolt. Lubricate the piston with clean brake fluid.Ensure there is no piston sealing ring distortion. 1. Remove brake caliper. 4. the vehicle may be out of control and may result in human casualty.

Refer to Brake Caliper Replacement. Install the caliper. Remove brake caliper. 502015 . 7. 5. Raise and adequately support the vehicle.2.Refer to Replacement of the brake caliper bracket. if it is less than 17mm.Brake Disc brake 5-61 4. Inspect the thickness of the brake rotor. Replace. Inspect the thickness of the brake rotor with MKM. 5. Refer to Raise and Lift the Vehicle in General Information.Refer to Replacement of the wheels in Tire & Wheel. Remove the caliper bracket. 4. 502014 6.Refer to Brake Caliper Replacement. Clean the contacting surface between braking disc and hub bearing flange. 3.7 Replacement of Brake Disc Removal Procedure Tools Required MKM-230-A Brake Disc Measuring Gauge 1. Remove the brake fixing bolt and brake disc.3.230- A. 2. Remove the wheel.

Refer to Replacement of the wheels in Tire & Wheel. corrosion or score deeper than the braking surface of the brake disc . 502015 5. 5. Tightening Tighten the bolt to 4 N m.5-62 Disc brake Brake Installation Procedure 1.Refer to Brake Caliper Replacement. 3.3. 4. Refer to Replacement of the brake caliper bracket. Assemble the brake disc bolt.8 Brake Disc Surface Finishing Tools Required J42450A Hub rinsing tool set J41013 Rola flange re-finishing tool package Note: Do not try to finish the brake disc surface to correct the following conditions: brake noise (rumbling/ squealing) early wearing of brake pad surface corrosion on the brake disc surface brake disc dis-colored Only when one or more of the following conditions occur.2. Install the caliper.4 mm) Brake runout resulting from the following causes: . 6. Brake disc thickness deviation exceeding 0. Install the caliper bracket. 2. Install the wheel assembly. it is necessary to finish the brake disc surface. Serious score on the brake disc surface (deeper than 0.01mm . Install the brake disc. Lower the vehicle.

Use J 41033 or equivalent to clear away rust on brake disc flange thoroughly.Rather. so not finish its surface. 5. 6. Finish the surface of the brake disc. use 120 moly- alumina and non-directional brake disc finisher (if available) to obtain a non-directional brake surface. Note: If best surface accuracy can not be reached. Use J42450-A to clear the wheel bearing and vehicle bearing hub. 4. brake runout or brake disc damage may occur. Clean the brake surface with industrial alcohol or adequate other cleaning agent. brake disc lateral runout may increase and vibration may occur during braking. Measure the thinnest point of the brake disc with dial gauge. Notice: If the wheel nut is improperly Tightened. 3. 1.Brake Disc brake 5-63 Notice: Whenever the brake disc is removed from the wheel bearing flange. brake performance may deteriorate. use J42450-A hub cleaning kit to clear away any corrosion or foreign matter on the matching surface of brake disc and flange.To avoid expensive service cost to the brakes. After machining the brake disc.Refer to the operation description provided by the brake machine tool manufacturer.If the value is less than the minimum value allowed for the brake disc. be sure to Tighten the wheel nut evenly to specified torque. . replace the brake disc.Otherwise. 2.

4mm.The All brake disc is cast with minimum thickness sizes on caliper slips towards the center of the vehicle.Do not use brake disc not outer section of the caliper acting on the back of the satisfying specifications after surface finishing.The accessories can eliminate tool vibration so as to improve surface finishing accuracy. moves outward and caliper moves from inside to connector outside may compensate the wearing of the pad.4.2 Brake Disc Surface Finishing the caliper onto the bracket with two bolts (2). Do not use compressed air with lubrication oil to the brakes. the following tools from inner and outer pads on the brake disc. Conduct service on clean operation console. The specified torque value applies to dry non.Piston and accessories must be under good conditions.The size is the minimum worn size rather caliper is an integrated one. Whenever the hydraulic components are removed. forces the caliper slipping at the assembling bolt. do not finish the brake disc during braking.2.Sealing ring (9) and slot will make the piston subtract a little.Install 5. Caliper (1) of the vehicle has one single bushing. . the pressure may cause the pad to use new brake disc to replace the old one.With the Accurately control the brake disc tolerance to ensure establishment of pressure in the pipeline.1 Disc Braking System Description Note: Replace all components used to serve the caliper on the service tool package. covering the outer surface of the brake disc. 502016 lubricated Fasteners.2.4 Description & Operation 5. rubber parts may be damaged.Finish the surface only under the following (10) bottom and piston bushing bottom.Observe service the pipeline relieves when the brake pedal is procedures recommended by the manufacturers.Use only tools recommended by the equipment manufacturer to replace. which may reduce the towing force During brake disc surface finishing.Ensure cleanness of the connector with no cracks.Be sure outer pad (5). discharge any air in the entire braking system.With tool frame the wearing of the pad.Use vibration absorber while finishing the brake surfaces. Lubricate all rubber parts with clean brake fluid for easy assembly. Pressure During regular maintenance of the brakes.bushing bottom.The force may stop the vehicle.Use service devices accordingly. if the worn of the fluid at the rear of the caliper piston increases out disc is replaced.4.Fabricate the from the pad on the brake disc surface increases brake disc with precise equipment. Brake runout Pressure acts on the piston. slippery may cause the than the finishing size.Or. and the area absorber increases. pressure the normal operation of the brake disc. which will do negative effect to the brake performance.The pressure shall act evenly on piston surface.Blunt or worn tools may result in uneven finishing of the surfaces. released. which Score deeper than 0. which forces the pad against the brake disc inner surface.2. brake fluid flows from the master pump into the rear of the piston.Then. tool package Always use sharp tools.Pressure from conditions: the piston passes onto the inner pad (5).Pressure in regularly to process equipment. Braking pad can only be replaced for each shaft ( front shaft or rear shaft).Since the its surface.5-64 Disc brake Brake 5.

use vehicle- carried brake machine to obtain the best effect and to eliminate troubles relating to the brake runout.Observe the specifications and procedures recommended by the equipment manufacturers. .Brake Disc brake 5-65 While finishing the brake disc surface.

2.5 Special Tools Number & Name of Illustration the Tools MKM-230-A Brake disc measuring gauge MKM-230-A J8001 grad indicator kit J8001 J42450A Hub rinsing tool set J42450 J41013 Rola flange re-finishing tool package J41013 .5-66 Disc brake Brake 5.

2 Fastener Tightening Specifications Application Value rear brake back plate bolt 50N m + 30°.3.5 mm 5.1 mm Brake lining thickness (to the rivet) 0.1Specification 5.1 Component Specifications Application Specification wheel brake cylinder piston diameter 19.1.3.1.05 mm brake drum width 28 mm Brake drum diameter (new) 200 mm Finished brake drum diameter 201 mm Maximum allowed runout 0.3.Brake Shoe-type brake 5-67 5.45° wheel brake cylinder bolt 9N M brake pipe bolt connecting the wheel brake cylinder 16 N M exhaustion valve 6N M ABS rear wheel sensor bolt (for vehicles with ABS) 4N M rear absorber bolt 65 N M .3Shoe-type brake 5.

when it is worn to less than 0.Meanwhile.5 mm away from the rivot head.5-68 Shoe-type brake Brake 5.If front or rear brake linings different from the SGM original ones are used. Remove the wheel. Raise and support the vehicle. 2. Inspect the brake lining while removing the wheel (wheel rotation and so on) Remove the rubber plug at the observation hole for the brake lining Inspect the thickness of the brake lining. .2. Refer to Raise and Lift the Vehicle in General Information. Mark the position of the wheel in relation with the hub.2 Brake Lining Replacement Removal Procedure Tools Required KM-346 remover It is recommended that all vehicles use SGM original replacement brake lining materials (or equivalent product) to maintain the front and rear brake performance balance.3. 3. replace the lining. replace the lining of the rear axle brake drum. 1.If the brake lining if fixed with rivot.2 Repair Guidance 5.3.2.Refer to Replacement of the wheels in Tire & Wheel.3.SGM original brake components for replacement are carefully selected to provide brake balance within the braking distance and the entire travel control. replace it. brake balance of the vehicle may be changed. 2 mm Whenever the thickness of the brake lining is less than 2mm.1 Brake Lining Inspection Brake Lining Inspection Inspect the brake lining every 15000 km. Install the rubber plug of the observation hole 5.

5. 503001 8.Refer to Brake Drum Replacement. 11.Brake Shoe-type brake 5-69 4. 7. 503002 . Remove the brake drum. Use pliers to remove the return spring and spring bracket. Use spring pliers to remove the return spring. spring and the fixing pin. Use KM-346 to remove the compressed spring chip. Remove the brake lining. Be sure to replace all brake lining at the same shaft. 10. Remove the adjustment lever. 9. 6. Remove the park brake cable from the cable channel.

503004 . 2. Use noise-reduction soft cloth at the contact area of the lining (refer to arrow in the figure). 503003 3. Connect the brake cable and the brake driven shoe lining park lever. Clean the brake back plate surface.5-70 Shoe-type brake Brake Installation Procedure 1.

Refer to Brake Drum Replacement. match the new brake surface. Install the wheel. Lower the vehicle. Install the brake drum. 14. Ensure correct position of the park cable (refer to arrow in the illustration figure). Align the previous marks on the wheel and drum. 17. Note: Ensure correct installation of the small washer to the brake lining.Refer to Filling of Brake master cylinder Fluid Reservoir. Adjust the brake lining gap. 16. Install the adjustment bracket spring. compressed spring and thin spring chip. Install small ring washer to the new brake lining (refer to arrow in the illustration figure).Refer to Replacement of the 503006 wheels in Tire & Wheel. Step down the brake pedal with medium or strong force.3 Match the lining and brake drum After replacement of the brake lining. braking failure or damage to the brake lining may occur. Brake for 10 -15 times to adjust the brake so as to ensure the correct gap.Refer to Match the lining and brake drum. Install slip bar regulator between the two brake lining. 11. Install the lower returning spring and brake shoe. otherwise. 7. Match the new braking surface after finishing the surface or new drum is replaced.Brake Shoe-type brake 5-71 4. 5. Install the brake driven shoe lining with fixing pin. Brake 20 times when the vehicle speed is at 48km/h and match the new braking surface. 8. Install the adjustment bracket with spring to the rotational pin.Refer to Wheel Bearing Adjustment in Rear Suspension. 19. 13. Match the lining and drum.Do not over-heat the brake. Adjust the wheel bearing gap. 5. 6. Use spring pliers to install the upper returning spring. Notice: Step down the brake pedal forcefully to adjust the brake lining gap automatically. 12. . 503005 9. 15. Fill with clean brake fluid to adequate level. 18.2.3. 10.

6.5-72 Shoe-type brake Brake Notice: Avoid emergency braking within 200km after new braking lining is replaced.3. Raise and adequately support the vehicle. Remove the brake hard pipe at the rear shaft. Remove park brake cable from the brake. 5.Or human casualty accident may occur. 503007 . 5. 3. Fill brake fluid into the reservoir to the MAX level 2. Refer to Replacement of the wheels in Tire & Wheel.4 Rear Brake Replacement Removal Procedure Caution: Do not move the vehicle before steady brake pedal is obtained.Refer to Brake Drum Replacement. Remove the wheel. 1. 4.2. 7. Refer to Replacement of park brake left and right cable. Mark the position of the wheel in relation with the drum. Remove the brake drum. Refer to Raise and Lift the Vehicle in General Information.

Clean and inspect the shaft surface. 503008 Installation Procedure Tools Required KM-470-B Angular torque measuring gauge 1. Tightening Tighten the brake pipe bolt to 16 N m. Note: Do not use the old bolt in the rear brake. Remove the four bolts at the rear brake. (vehicles with ABS) . (vehicles with ABS) 9. Install the brake pipe bolt onto the rear brake wheel brake cylinder. Remove the rear absorber bottom bolt. Remove ABS rear sensor. Tightening 503032 Tighten the bolt to 65 N m. 7. Tightening Tighten the bolt to 50 N m + 30°-45°. Install the rear absorber bolt. Use new bolt to install rear brake for rear brake back plate and rear shaft. Install the brake drum. 10. 6. 3. 11. Install park brake cable. 5.Brake Shoe-type brake 5-73 8. Install ABS rear sensor at the rear brake (refer to the following steps).Refer to Brake Drum Replacement. Remove the rear brake. 2. 4.

Fill with clean brake fluid to adequate level.2. 12.Refer to Discharge air in the hydraulic braking system.3. Refer to Replacement of the wheels in Tire & Wheel. Push the sensor to the end and Tighten with screws. Fill the brake fluid to the maximum position. . Rotate the lever clockwise for 30 degree to adjust. 5. Move the dust-shield to the brake drum. 9. discharge air in the brake.Refer to Filling of Brake master cylinder Fluid Reservoir. Install the wheel. 8. If necessary. step the brake pedal with force of 503010 238N after discharging. Lower the vehicle. Tightening Tighten the sensor bolt to 4 N m. 2. 13. If the inlet connector components are removed. 3. 10.Refer to Brake Fluid Leakage.5-74 Shoe-type brake Brake Install and adjust sensors (ABS vehicles) Install the sensor and Tighten the screws with fingers.Refer to Brake Drum Replacement. 11. Inspect if there is leakage of brake fluid in the hydraulic braking system. 4.5 Brake Wheel brake cylinder Replacement Removal Procedure 1. Remove vehicle shaft lock pin and nut. Remove the brake drum.

Install the brake drum. 503001 6. Brake for 10 -15 times to adjust the brake so as to ensure the correct gap. Use spring pliers to remove the upper returning spring. Install the wheel. . Remove the wheel brake cylinder.Refer to Discharge air in the hydraulic braking system. 7. 3. 4. Discharge air in the exhaustion brake system and inspect. 2. Tightening Tighten the discharging valve to 6 m. 7. 9.Refer to Replacement of the wheels in Tire & Wheel. Remove wheel brake cylinder bolt. Refer to Wheel Bearing Gap in Rear Suspension. Install the discharging valve to the wheel brake cylinder. Adjust the wheel bearing gap. 6. Tightening Tighten the sub-pump bolt to 9 N m. 9. 5. 8.Refer to Brake Drum Replacement. Install the brake pipe to the wheel brake cylinder. 503001 Installation Procedure 1. 8. Adjust the brake lining gap.Brake Shoe-type brake 5-75 5. Tightening Tighten the brake pipe bolt to 16 N m. Install the wheel brake cylinder to the brake back plate. Install the upper spring. Remove the discharging valve. Remove the wheel brake cylinder brake pipe.

10. Clear away all components with clean industrial alcohol. 15.Otherwise the cylinder or sealing channel may be damaged. 14. score scratch corrosion wearing 6.Refer to Brake Wheel brake cylinder Replacement.If the sealing slot is damaged. replace the damaged housing. Remove discharging valve cover and discharging valve from the wheel sum-pump. replace the wheel 503011 brake cylinder case and piston. Inspect if the sealing slot in the wheel sum-pump has scratch or blur. 4. Remove the wheel brake cylinder housing. replace the wheel sum-pump. Use a fine sand cloth to sand away slight corrosion. 5.2. Dry all parts with filtered compressed air without lubrication grease. 8.The piston will extend from the piston housing. Inspect if the housing has the following situations: cut broken aging 12. 13. 7. Remove the piston sealing ring from the wheel brake cylinder slot. replace the wheel sum-pump.5-76 Shoe-type brake Brake 5.3. Remove the brake wheel brake cylinder. If any one of the above occurs. 11. Remove the wheel brake cylinder piston. Inspect if there is the following condition on wheel brake cylinder cylinder and sealing channel.Blow compressed air into wheel brake cylinder inlet. 2. score scratch corrosion wearing 9. If the corrosion around the sealing slot cannot be sand away. do not use other liquid. . Inspect if there is the following condition on wheel brake cylinder cylinder and piston. Clean all parts with alcohol.6 Brake Wheel brake cylinder Overhaul Removal Procedure 1. 3. Notice: Do not remove the sealing with metal tools. 16.

3. Install the wheel brake cylinder. Remove the inner bearing and sealing ring in the brake drum. 5. 3. 7. 7. 5. remove the park brake cable on compensation fork.7 Replacement of Brake Drum Removal Procedure 1.Refer to Brake 503011 Wheel brake cylinder Replacement.Be sure there is no distortion in the piston sealing. Dry all pipelines in caliper case and discharging valve.Press the park lever of the brake with screwdriver so that it contacts the brake lining back plate. Remove the wheel. Lubricate the piston with clean brake fluid. Installation Procedure 1. Push the piston to the end of the pump diameter. 2. Tightening Tighten the discharging valve to 6 N m. Place the wheel sum-pump housing in the wheel brake cylinder case flaring hole. 2. Install the discharging valve and discharging valve cover onto the wheel brake cylinder. .Brake Shoe-type brake 5-77 17. Remove outer bearing of the brake drum. 503012 8. 5. Remove wheel bolt and nut pin. Install a new lubricated piston sealing ring in the wheel sum-pump slot. Install piston and housing in wheel brake cylinder. 6. Notice: If necessary.3.2. Refer to Raise and Lift the Vehicle in General Information.Use filtered compressed air without lubrication oil. Remove brake drum dust-shield cover. Remove the brake drum. 4. Install the lubricated housing onto the piston. 4. 6. Clear the metal contacting surface between the brake bolt and brake drum bearing. Refer to Replacement of the wheels in Tire & Wheel. Raise and adequately support the vehicle.

bearing and rust or foreign matter on the contact surface of brake drum bolt. Adjust the brake lining gap. 6.Refer to Brake Drum Replacement. 2. Clean the wheel bearing and brake drum inner layer.3. 2. Lower the vehicle. Adjust the wheel bearing gap. Remove the rear brake drum.8 Brake Drum Surface Finishing Tools Required J21177 Brake drum to brake shoe gap gauge KM-508-1 Installer Note: Do not finish the brake drum surface to correct the following conditions. 5. Install the wheel. 4. Brake for 10 -15 times to adjust the brake so as to ensure the correct gap. brake noise (rumbling/ squealing) early wearing of brake pad Notice: Whenever the brake drum is separated with the wheel bearing and brake drum bolt.2. use hub clean tool to clean the brake drum. 1.Refer to Wheel Bearing Adjustment in Rear Suspension. Remove the bearing sealing ring and brake drum bearing.5-78 Shoe-type brake Brake Installation Procedure 1.Refer to Replacement of the wheels in Tire & Wheel. .Other brake noise and runout may increase. 3. 503009 5. Install brake drum bearing and new sealing ring. 3.

. Finish the surface of the brake drum. use 120 moly- alumina and non-directional brake drum finisher (if available) to obtain a non-directional brake surface. replace the brake drum.To avoid expensive service cost to the brakes. Use KM-508-1 to install inner bearing and stick the sealing ring onto rear brake drum.If the diameter of the brake drum exceeds 201 mm. do not finish the brake drum surface. 5. be sure to Tighten the wheel nut evenly to specified torque. braking may be hard.Brake Shoe-type brake 5-79 4. 7. After machining the brake drum. Use J21177 to measure the brake drum inner diameter. 6. Note: If the best brake drum process surface can not obtain. 303024 Notice: If the wheel nut is improperly Tightened. brake runout or brake drum damage may occur. 8. Clean the brake surface with industrial alcohol or adequate other cleaning agent.Rather.

The size is the minimum worn size rather than the finishing size. Meanwhile.The force may stop the Do not use compressed air with lubrication oil vehicle. if the worn The specified torque value applies to dry non.Use vibration absorber while finishing the brake surfaces.Upper returning spring will damaged.Pressure of the fluid at the rear of the wheel brake cylinder increases during Description braking. surface. During brake drum surface finishing. control the tolerance of the drum accurately.3. which will do negative effect to the brake performance.5-80 Shoe-type brake Brake 5. To make the drum brake system operates normally. brake drum that fails to satisfy the above specifications shall not be used. replace the lining of the rear axle 5.2 Brake Drum Surface Finishing brake drum.The pressure will force Replace all components used to serve the shoe. do not finish the brake drum lubricated Tighteners. During regular maintenance of the brakes. discharge any air in the entire braking system.Lining gap regulating lever moves outward.Pressure in the pipeline relieves when the on brake components.After finishing.The pressure shall act evenly on piston bottom Note: and piston bushing bottom. extract the brake lining and piston.Rubber parts may be brake pedal is released.Finish the brake drum surface only under the Conduct service on clean operation console.Observe service procedures recommended by the manufacturers. cylinder.Use only alternative cutting tools recommended by the equipment manufacturers.3. out drum is replaced.1 Shoe-type Braking System brake onto rear axle bracket. pressure from the pad on the brake drum for easy assembly.3.With the establishment of pressure in the Lubricate all rubber parts with clean brake fluid pipeline.Service the mechanical process equipment regularly. which compensates Whenever the hydraulic components are automatically the wearing of the lining. following conditions: Brake runout All brake drum is cast with minimum thickness sizes on its surface.Use four installation bolt to install the rear . removed.Always use new drum to replace the old one. the lining to be against the brake drum inner type brake in the service tool package.The accessories can eliminate tool vibration so as to finish the surface 503013 better.Blunt or worn tools may result in uneven finishing of the surfaces. surface. surface increases accordingly.Process the brake drum with only precise equipment.4 Description & Operation 5.3.3. the following tools and accessories must be under good conditions.Ensure cleanness of the connector with no The rear brake in the vehicle has a wheel brake cracks. connector tool frame absorber tool Always use sharp tools.Pressure acting the piston passes to the two braking lining.

3.4 Special Tools Number & Name of Illustration the Tools KM-346 Remover KM-346 KM-470-B Angular torque measuring gauge KM-470B MKM-508-A Installer KM-508-A J 21177 Brake drum to brake shoe gap gauge clearance gauge J21177 .Brake Shoe-type brake 5-81 5.

5-82 Shoe-type brake Brake Blank .

1 Specification 5.1.1 Tightener Tightening Specifications Application Specification park brake lever installation bolt 24 N m park brake switch installation bolt 3N m .Brake Parking brake 5-83 5.4Parking Brake 5.4.4.

2 Repair Guidance 5. 504001 2.2.4. Remove cable (1) from the cable channel (2) 504002 . Raise and adequately support the vehicle rear axle.4.5-84 Parking brake Brake 5.1 Park brake lever and park brake alarm lamp switch replacement Removal Procedure 1.

504005 . Remove housing (2) from the pulling slip bar (3). 8. Remove left front seat. Loose the switch installation screw (2) and remove the switch (3). Remove the retainer (1) from the connector (2). Fold the carpet to access the park brake lever installation bolt. 7. 4. 9. refer to Front Seat Replacement. Remove the electrical connectors from park brake switch (3). Remove housing (3) from the pulling slip bar (4).Brake Parking brake 5-85 3. Pull out the park brake lever from body floor. 12. Remove connector (2) from cable (5) and pulling slip bar (4). 504004 10. 11. 504003 6. 5. Loose the installation bolt (1).

Connect the electrical connector and switch (3). Tightening Tighten the brake switch screw to 3 N m.Tighten bolt (1). 5. Tightening Tighten brake lever installation bolt to 24 N m. 4. Install brake switch (3) to lever (1).5-86 Parking brake Brake Installation Procedure 1. Tighten the switch screw(2). 504005 3. Place the carpet at adequate position. inspect the operation of switch 2. Install housing (2) to the pulling slip bar (3). 2. Install the park brake lever (4) to the body floor. 504004 .

Install the connector (2) to slip bar (4) and cable (5) through the body floor cable channel (6). 9. 504002 . 7.Brake Parking brake 5-87 6. Press cable (1) into the cable channel (2). Refer to Replacement of park brake left and right cable. Adjust park Brake. Insert retainer (1) into connector (2). 504003 8.

504006 4. Pull out rubber protective ring (2) (5) from balancer (3).2.4.5-88 Parking brake Brake 5. Measure the thread length of the short cable (1) near the balancer. 2. 504003 . Remove cable (5) from the connector (2). Remove short cable (1) from the balancer (3).2 Park Brake Left Cable Replacement/ Adjustment Removal Procedure 1. 3.

504007 . Install brake shoe lining (4) to brake back plate (1). Remove brake assembly from the rear axle. 10. 8. refer to Brake Drum Replacement. 7. Pull out cable (3) from the brake back plate (1). Remove cable (3) from the brake shoe lining (4). Install the cable retainer (2) to the brake back plate (1). 3. Remove brake shoe lining (4). 2. refer to Brake Lining Replacement. Remove the cable retainer (2) from the brake back plate (1). Install cable (3) to the brake shoe lining (4) through brake back plate. 504007 Installation Procedure 1. Pull out cable (4) from the balancer (3). refer to Brake Lining Replacement.Brake Parking brake 5-89 5. 504006 6. 9.

5-90 Parking brake Brake 4. Install long cable (5) to the connector (2). 9. 5. 504003 7. Insert rubber protective ring (5) into cable (4).Insert retainer (1) into connector (2). Adjust short cable (1) thread to the previously measured length. Connect short cable (1) and balancer(3). 504006 . Install rubber protective ring (2) (5) onto balancer (3). Adjustment 8. refer to Brake Drum Replacement. Install the brake assembly onto the rear axle. 504006 6.

Measure the thread length of the short cable (1) near the balancer. Remove the cable retainer (2) from the brake back plate (1). Remove brake shoe lining (4) from brake back plate (1). 2. refer to Brake Lining Replacement. refer to Brake Drum Replacement.4. Remove brake assembly from the rear axle.Brake Parking brake 5-91 5. Pull out rubber protective ring (2). Remove cable (3) from the brake shoe lining (4). Pull out cable (3) from the brake back plate (1). 7. 504006 4. 3.2. 5. Remove short cable (1) from the balancer (3). 504006 .3 Park Brake Right Cable Replacement/ Adjustment Removal Procedure 1. 6.

Install the brake assembly onto the rear axle. 7. Adjust short cable (1) thread to the previously measured length. Install the cable retainer (2) to the brake back plate (1). 4.5-92 Parking brake Brake Installation Procedure 1. Install cable (3) to the brake shoe lining (4) through brake back plate. 504007 5. Adjustment 6. Install brake shoe lining (4) to brake back plate (1).Install short cable (1) to the balancer (3). 2. refer to Brake Drum Replacement. refer to Brake Lining Replacement. 504006 . 3. Install rubber protective ring (2) to the balancer (3). Insert rubber protective ring (2) into cable (1).

2. 504008 . Remove short cable (1) from the balancer (3). 3.4 Park Brake Balancer Replacement Removal Procedure 1. 504006 5.2. Take out nut (1) from the balancer (2). Remove long cable (4) from the balancer (3).4.Brake Parking brake 5-93 5. 4. Measure the thread length of the short cable (1). Remove rubber protective ring (2) (5) from balancer (3).

Install rubber protective ring (2) to the balancer (3). Install new nut (1) to the balancer (2). Adjust short cable (1) thread to the previously measured length. 504008 2. 504006 .5-94 Parking brake Brake Installation Procedure 1. Install long cable (4) to the balancer (3).Install rubber protective ring (5) to the balancer (4). Connect short cable (1) and balancer(3). 4. 5. 3.

1Specification 5. 5.5.1 Tightener Tightening Specifications Application Specification Brake hard pipe fitting nut 16 N m caliper discharging valve and wheel brake cylinder discharging valve 6N m brake hose caliper bolts 40 N m Front caliper speed sensor installation bolt 8N m rear brake drum speed sensor installation bolt 4N m ABS module bracket installation bolt 20 N m ABS module installation nut 10 N m 5.Brake Anti-lock brake system (if equipped) 5-95 5.5 Anti-lock brake system (if equipped) 5.2 Schemes and Wiring Diagram 5.18.1Anti-lock brake system wiring diagram Refer to 8.2.1.20.5.5.3 Component Location .5.2.5.

right front P 19 sensor.1 Component Location 505001 Component section Location E14 lamp. passenger compartment .engine B3J within instrument panel instrument B3J instrument panel K31 control unit.SIR C4H right under the console.speed.anti-theft control module B3H Under steering column cover plate S1 switch. passenger compartment G1 battery E2J Engine compartment G2 AC alternator D2H in Engine H1 radio C3H between the bracket and instrument panel H2 signal horn B1H on the cross member H7 charging indicator B3J within instrument panel H30 signal device. left front A2G Wheel suspension system.anti-lock at ABS module B2H braking system K 57 control unit.5. tail U4 hydraulic integration assembly.5-96 Anti-lock brake system (if equipped) Brake 5.ignition module C2H in air inlet system K117 Control unit. left front P 18 sensor.lamps B3H within instrument panel P 17 sensor.speed. right rear S8 switch - brake lamp B3H above brake pedal X13 diagnostic interface B3H fuse box.speed. side K61 control unit.speed.central lock controller F3H behind molding. right rear F6G Wheel suspension system.ignition switch C3H Steering column cover plate S2 switch assembly. right front F2G Wheel suspension system. foot space.passenger compartment CD4K sunshade panel F1-F28 fuses B3H fuse box. left rear A6G Wheel suspension system. left rear P 20 sensor.3.

speed. right rear 11 X13 diagnostic interface 2 P 20 sensor.speed.speed. left rear 21 H26 Alarming lamp.Brake Anti-lock brake system (if equipped) 5-97 5. right rear 14 S8 switch - brake lamp 3 P 18 sensor. right front 16 ground 6 P 17 sensor. left rear 19 ground 9 P 19 sensor.speed.2 Pin arrangement control unit wire connector.speed. left front 17 system voltage (pin 30) 7 P 17 sensor. K50 Component View 505003 pin Legend pin Legend 1 P 20 sensor.speed. right front 15 Switch system voltage (pin15) 5 P 18 sensor.5. left front 18 system voltage (pin 30) 8 P 19 sensor.3.speed.anti-lock braking system .speed.

1 Overview When temperature reaches above 80°C(176°F) (such as during painting operation). xenon lamps) Each of the electronic system consists of its functional sets. Tighten the released or removed wirings and connecting channels to the previous positions. sensor. which may damage the control unit. it is recommended that automatic fuses Never start the engine with battery used during trouble shooting. disconnected. Use original aftersales parts (cable clip. such as Notice: switch. such as engine control system. the To avoid damage to the control unit. - electronic control throttle Firstly. never use test lamp or DM to measure the battery and vehicle electronic systems.5. wire harness.3 Caution: Vehicle diagnostic principles: Never serve the following pipelines/ systems: The major purpose of the vehicle diagnostic principle is - shielding wire/ axial cable (such as ABS sensor the identify and remove trouble in the vehicle as soon harness) as possible.This also adapts to welding set. danger of human hurt may occur.4 Diagnostic Information and Procedure 5. there may be life danger. Diagnosis Notice: Caution: Use only diagnostic tester to test the SIR. which are related with each other. automatically. otherwise. the fan may turn on wiring harness carefully. date and time).5. there may be danger of hurt. Disconnect the ground and battery will result in 5. operation to the vehicles. Disconnect the grounding cable of battery when there coolant temperature sensor circuit is such a functional is danger of short. turning on ignition. or.For example. disconnect avoid accident. . SIR and ABS system. wiring channel bracket and so on). circuit. never coolant temperature sensor circuit is made up of connect/ disconnect the control unit or other sensor. wiring harness.circuit. Too high voltage in the circuit may damage the If the harness plug pin must jump to avoid short- control unit. - High voltage cables (ignition system. failure of functions.5.Thus the following principles are developed - SIR for technicians to find the trouble causes directly.5-98 Anti-lock brake system (if equipped) Brake 5.4. be sure the wire harness be able to find out troublesome electronic system.To Before charging or quick charging.Loose the locking devices of the When the engine is running. re-program the memories that are Do not come into contact with high voltage easily lost and decode the record devices. control unit and control unit electrical part wiring harness connectors while software. each diagnostic step shall After finishing service. Use only voltage tester with high resistance. wire and so on. each functional set consists of several parts. vehicle has the following electronic systems.4. retainer. and is correctly connected and the battery grounds then diagnose related functional set. xenon Do not pull the cables while disconnecting the lamps).After the battery is re- Caution: connected.Error in circuit connection may result in the troublesome parts and repair. diagnosis to the following electronic system in Sail.For example. components (such as ignition system. remove the Diagnostic Information and Procedures refer to control unit. Never disconnect the battery from the vehicle circuit system when the engine is running. the SIR.2 Safety measures loss of certain memory functions in these Overview electronic systems (such as power window regulator. Never start the vehicle with battery quick Notice: charger. Wire harness Anti-lock brake system 5. and finally find out well. According to the structure.

DTC or DTC text will Use Diagnostic system check may identify correctly the not change. stop and steering operation. Refer to relevant 2 - Go to Step 3 Any current DTC displayed? DTC table . Command the system to identify the control DTC status: module You may read unfarmiliar Unknown DTC rather than capacity of the control module to communicate the farmiliar Current. through serial data circuit This shows that the diagnostic software or control unit identify the stored DTC and the status.0 30 consuming.0 10 Diagnostic aids 1. Ignition ON. automatic fuses may be used to the scan tool. 2.Under this circumstances. Perform road test according to guidance in the Note: When the rated current of the fuses is similar. system diagnostic procedure and position of the procedure. 2. Select Data List Mode.5.Diagnostic system Sometimes.5. Test the vehicle with quick test function of circuited to voltage). it is the starting point for troubleshooting of ABS system.Anti-lock Electronic System Braking System DTC nature Refer to Diagnostic System Check. short.5 5 steps. Diagnostic System Check.6 Diagnostic System Check.5.Otherwise. historical (and intermittent) info.4.3 Specific Information of the 5. it can guide the serviceman to carry out logical 0. 6. perform ABS braking on road with low friction (such as gravel road). while shoot troubles with fuse jump (ground. 5.Brake Anti-lock brake system (if equipped) 5-99 5.4. 3.4 Fuse Jump Rated Current lock Braking System Diagnostic system check is a systematic way to identify wire measuring gauge fuse jump rated current troubles in ABS system. therefore.While shooting troubles in ABS counts in unit of mm2 counts in unit of A system.Anti-lock braking System to start system diagnosis. Is the scan tool receiving data from EBCM? Read the display.Anti-lock Braking System Step Action Value Yes No 1.75 7. If the trouble cannot occur again. replace the fuses. Clear the DTC after all troubles in the system are removed. Perform the following tests. 1 - Go to Step 2 Go to Step 6 3. The special trouble mentioned above can not be eliminated with the scan tool.5 Diagnostic Starting Point.5. Install the scan tool.4. 0.0 30 1. important diagnostic data may loss. table.5 15 Service the ABS/EBD system according to the following steps. 2.5 25 which can result in difficulty in diagnosis and time- 4.Anti- 5.5 1. the scan tool may display non-familiar check will provide the following information: DTC status or description.4. has errors that the scan tool can not interperate or assess. Carry out normal acceleration.

Anti-lock Braking System (Cont’ d) Step Action Value Yes No 1.5-100 Anti-lock brake system (if equipped) Brake Diagnostic System Check. Turn ignition to LOCK position. left rear solenoid test solenoid test Command the solenoid to turn on and off. Is the measured voltage within the specified value? 1. Disconnect electronic braking control module (EBCM) harness connector. 6 11-14V Go to step 7 Communication 4. 10 - System OK - Is the trouble corrected? Repair open circuit or high resistance between terminal 11 11 of the EBCM harness connector and terminal 12 of DLC. Go to No 3. Turn ignition to LOCK position for 10 seconds. . Is the resistance value equals to the specified value? Repair open circuit trouble in the harness circuit. Go to Braking 2. 2. 2 ohm Go to Step 10 Go to Step 11 Is the resistance value less than the specified value? Replace the ABS assembly. Ignition ON. Turn ignition On and observe the ABS/EBD indicator. Use DVM to measure the resistance between the 7 ground and terminal 16. right front solenoid test solenoid test Command the solenoid to turn on and off. - Go to Step 5 Go to Step 4 Is the indicator on for 4 seconds and then off? Observe ABS indicator. 2. 17 and 18 of the EBCM harness connector. Go to ABS Go to ABS 4 Is the ABS indicator ON continuously? - indicator always indicator ON Inoperative 1. 12 - Go to DTC list - Is there any DTC set? Scan tool output control Scan tool output Additional menu Description control option automatic air to bleed hydraulic pressure in anti-lock braking system discharging - left front solenoid test solenoid test Command the solenoid to turn on and off. - Go to Step 1 - Is the trouble corrected? Perform road test described in Diagnosis Procedure. Use DVM to measure the voltage between the ground with EBCM and terminal 15. 19 of the EBCM harness 0 ohm Go to Step 9 Go to Step 8 connector. Turn ignition to LOCK position. Turn ignition to LOCK position for 10 seconds. right rear solenoid test solenoid test Command the solenoid to turn on and off. Alarm Indicator 5 - Go to Step 12 Is the indicator on for 4 seconds and then off? Inoperative in Hydraulic Brake 1. 8 - System OK - Is the trouble corrected? Use DVM to measure the resistance between terminal 11 of 9 the EBCM harness connector and terminal 12 of DLC. 3 2. Turn ignition On and observe the ABS indicator.

kph 0 towing control system data Anti-lock brake system data left rear wheel speed mph. engine OFF. use Typical data are obtained from normal vehicles driving EBCM scan tool data list as the amendament to under conditions specified in line 1 in Scan Tool Data diagnostic procedures.Scan tool data list The published DTC procedure and symptoms fail to solve the customer's problems.Data DTC procedure and symptoms diagnostic List column refers to the position of the parameter in procedures indicated in the system check fail to scan tool menu options.Parameters in the list is in alphabetic order. Scan tool parameter data list display unit typical data Ignition ON. vehicle stationary Anti-lock brake system data battery voltage V B+ towing control system data Anti-lock brake system data brake lamp switch apply / release apply towing control system data Anti-lock brake system data left front wheel speed mph. Compare the values obtained from the from ABS Diagnosis Starting Pointî. EBCM scan tool data list contains all parameters or.Use EBCM scan troublesome vehicles with the typical data. kph 0 towing control system data Anti-lock brake system data left front drum valve command active/ inactive inactive towing control system data Anti-lock brake system data left front drum valve feedback active/ inactive inactive towing control system data Anti-lock brake system data left front hold valve command active/ inactive inactive towing control system data Anti-lock brake system data left front hold valve feedback active/ inactive inactive towing control system data Anti-lock brake system data left rear drum valve command active/ inactive inactive towing control system data .Brake Anti-lock brake system (if equipped) 5-101 5. related with ABS system to be used in the scan tool.5. According to requirements of the diagnostic table. Identification number menu is displayed on main screen of the EBCM.4. solve the customer's problems. you may tool data list only when the following conditions are find where the trouble is. met.Start all diagnostic procedures List.

5-102 Anti-lock brake system (if equipped) Brake Scan tool parameter data list display unit typical data Anti-lock brake system data left rear drum valve feedback active/ inactive inactive towing control system data Anti-lock brake system data left rear hold valve command active/ inactive inactive towing control system data Anti-lock brake system data left rear hold valve feedback active/ inactive inactive towing control system data Anti-lock brake system data pump motor relay ON/ OFF OFF towing control system data Anti-lock brake system data right front wheel speed mph. kph 0 towing control system data Anti-lock brake system data right front drum valve command active/ inactive inactive towing control system data Anti-lock brake system data right front drum valve feedback active/ inactive inactive towing control system data Anti-lock brake system data right front hold valve command active/ inactive inactive towing control system data Anti-lock brake system data right front hold valve feedback active/ inactive inactive towing control system data Anti-lock brake system data right rear drum valve command active/ inactive inactive towing control system data Anti-lock brake system data right rear drum valve feedback active/ inactive inactive towing control system data Anti-lock brake system data right rear hold valve command active/ inactive inactive towing control system data . kph 0 towing control system data Anti-lock brake system data right rear wheel speed mph.

5.scan tool display alphabetic order. status of the left front drum valve. right front wheel speed brake lamp switch scan tool displays 0-255km/h(0-158m/h)- scan tool Scan tool display applied or released. battery voltage pump motor relay Scan tool display 0-30V. right rear hold valve command left front hold valve feedback Scan tool display active or inactive.scan tool display Scan tool display active or inactive.scan tool display actual status of the right front hold valve. right front hold valve command left front drum valve feedback Scan tool display active or inactive. actual status of the left front hold valve.8 Scan tool data definition left rear hold valve command Scan tool display active or inactive. actual status of the left front drum valve.scan tool display actual status of the right front drum valve.scan tool display Scan tool display active or inactive. circuit.scan tool display displays actual speed of the right front wheel.scan tool display Scan tool display active or inactive. displays actual speed of the left front wheel.Brake Anti-lock brake system (if equipped) 5-103 Scan tool parameter data list display unit typical data Anti-lock brake system data right rear hold valve feedback active/ inactive inactive towing control system data towing control system switch valve 1 towing control system data active/ inactive inactive status towing control system switch valve 2 towing control system data active/ inactive inactive status towing control system closing valve 1 towing control system data active/ inactive inactive status towing control system closing valve 2 towing control system data active/ inactive inactive status Anti-lock brake system data valve relay status ON/ OFF OFF towing control system data 5. .scan tool display scan tool displays 0-255km/h(0-158m/h)- scan tool status of the right front drum valve.scan tool display Scan tool display active or inactive. right rear wheel speed left front wheel speed scan tool displays 0-255km/h(0-158m/h)- scan tool scan tool displays 0-255km/h(0-158m/h)- scan tool displays actual speed of the right rear wheel. status of the brake switch.scan tool display status of the right front hold valve. right front hold valve feedback left front hold valve command Scan tool display active or inactive. status of the left front hold valve.scan tool display status of the right front hold valve.scan tool display the module battery positive voltage circuit and ground command status of the pump motor.scan tool display Data display function includes ABS and Towing Control status of the left front hold valve. actual status of the left front hold valve.The list is in Scan tool display active or inactive.4. right front drum valve command left rear wheel speed Scan tool display active or inactive. right front drum valve feedback left front drum valve command Scan tool display active or inactive. The following are brief descriptions to all ABS and Towing Control System left rear hold valve feedback data parameters displayed in scan tool. System data parameter list. displays actual speed of the left rear wheel.Measure the voltage between Scan tool display ON or OFF.

valve relay status Scan tool display active or inactive. towing control system closing valve 2 status Scan tool display active or inactive.scan tool display command status of the towing control system switch Scan tool display active or inactive.4.scan tool display the valve 2. command status of the display valve relay.scan tool display command status of the towing control system switch Scan tool display ON or OFF .scan tool display actual status of the right front hold valve.5-104 Anti-lock brake system (if equipped) Brake right rear hold valve feedback towing control system closing valve 1 status Scan tool display active or inactive.scan tool display Scan tool display active or inactive. command status of the towing control system closing towing control system switch valve 2 status valve 2. command status of the towing control system closing towing control system switch valve 1 status valve 1.5. 5.scan tool display valve 1.9 DTC list DTC Diagnostic Procedure Module DTC C0035 Electronic braking control C0035 module (EBCM) DTC C0040 Electronic braking control C0040 module (EBCM) DTC C0045 Electronic braking control C0045 module (EBCM) DTC C0050 Electronic braking control C0050 module (EBCM) DTC C0060/ C0065 Electronic braking control C0060/C0065 module (EBCM) DTC C0070/ C0075 Electronic braking control C0070/C0075 module (EBCM) DTC C0080/ C0085 Electronic braking control C0080/C0085 module (EBCM) DTC C0090/ C0095 Electronic braking control C0090/C0095 module (EBCM) DTC C0110 Electronic braking control C0110 module (EBCM) DTC C0121 Electronic braking control C0121 module (EBCM) DTC C0141/ C0156 Electronic braking control C0141-C0156 module (EBCM) DTC C0161 Electronic braking control C0161 module (EBCM) DTC C0245 Electronic braking control C0245 module (EBCM) DTC C0550 Electronic braking control C0550 module (EBCM) DTC C0800 Electronic braking control C0800 module (EBCM) .

speed sensor harness at the body bottom and perform tooth ring trouble. Disconnect the left front wheel speed sensor connector. 3 - system OK - Is the trouble corrected? 1.Even if the error may be cleared away with scan or voltage short circuit. disturbance.5. 1 . Measure the resistance between the terminals of the 0.The generated voltage depends on air if the parts are replaced. The step test if there is voltage short circuit in ON. 10. such as one of the speed is different from that of the other three. Important: If wrong wheel speed sensor signal has been entered into EBCM.tooth in the gear will produce Inspect the wiring and connectors pulse.10 DTC C0035 Diagnostic aids Ensure correct and firm wiring of the sped sensor. Turn ignition to LOCK position. 2 3. Each tooth. Switch the DVM to AC mv dial. Conditions for DTC to set Monitor wheel speed with scan tool during road Trouble or disconnection of the wheel speed test.Observe if there is abnormality in wheel speed sensor. wiring. The step test if there is ground short circuit in wiring. wet the connector trouble. 1. 2. the ABS alarm indicator keeps ON. contact trouble of the tool. even wheel speed.Otherwise. 5 - system OK - Is the trouble corrected? . signal fluctuates. monitor wheel speed with scan tool. This step checks if there is trouble in wheel Actions to take when DTC sets speed sensor. DTC C0035. to step 3 to step 2 Is there physical damage? 1. Is the measured resistance value within the specified range of about 25°C(77°F)? Replace the wheel speed sensor. connectors. Left Front Wheel Speed Sensor Circuit Trouble Step Action Value Yes No Inspect the wheel speed sensor. the trouble will still occur.To turn it off.EBCM uses the pulse frequency to determine the thoroughly. ABS alarm lamp will turn The procedure checks the wheel speed sensor. road test.1V to step 6 to step 5 the wheel speed sensor. accelerate the vehicle speed to 12km/h. Raise the vehicle with jack. EBD activates. slowly rotate the front left 4 wheel to measure the voltage between the terminals of >0. ground ON.so as circuit description to avoid pseudo signal resulting from electrical Gear rotor generates voltage pulse through sensor. wheel speed sensor installation error Test description sensor signal error The following number refers to the number of wheel speed sensor signal noise procedures in the diagnostic table. 2. The step test if there is open circuit or high resistance in wiring. Is the output within the specified range? Replace the speed sensor or gear rotor. Refer to EBD failure matrix.gap. Disable ABS operation and ABS alarm indicator turns 6. displayed in the scan tool.4. gap between the sensor and gear rotor and the wheel speed. error diagnosis may result.Brake Anti-lock brake system (if equipped) 5-105 5.5-3kohm to step 4 to step 3 sensor with DVM. the method can not identify intermittent trouble. 8.If wire trouble.

Are voltage values of the terminals less than the specified value? Repair voltage short circuit of the related circuits. Measure the resistance between EBCM harness connector terminal 6 and wheel speed sensor harness connector terminal. 2. 2. Measure the resistance between EBCM harness 10 5ohm to step 11 to step 12 connector terminal 7 and wheel speed sensor harness connector terminal. 6 3. Measure the resistance at terminal 7 of the electronic ∞ to step 9 to step 10 braking control module (EBCM) harness connector.3V to step 7 to step 8 4. For other terminals of the wheel speed sensor. Turn ignition to LOCK position. Any of the two resistance values less than the specified value? Repair ground short circuit of the related circuits. Left Front Wheel Speed Sensor Circuit Trouble (Cont’ d) Step Action Value Yes No 1. 0. 2. Any of the two resistance values higher than the specified value? Repair open circuit or high resistance in related circuits if 11 necessary. Ignition ON. 9 - system OK - Is the trouble corrected? 1. Connect the DVM between ground and one of the terminals of the wheel speed sensor connector. Disconnect electronic braking control module (EBCM) harness.3. - system OK - Is the trouble corrected? Replace the ABS assembly.5-106 Anti-lock brake system (if equipped) Brake DTC C0035. repeat step 1. 8 3. 12 - system OK - Is the trouble corrected? . Measure the resistance at terminal 6 of the electronic braking control module (EBCM) harness connector. 7 - system OK - Is the trouble corrected? 1.

Disable ABS operation and ABS alarm indicator turns 6. speed sensor harness at the body bottom and perform tooth ring trouble.5-3kohm to step 4 to step 3 sensor with DVM.4. the method can not identify intermittent trouble. wiring. signal fluctuates. slowly rotate the front right 4 wheel to measure the voltage between the terminals of >0. 2 3. error diagnosis may result. The step test if there is ground short circuit in wiring. ABS alarm lamp will turn The procedure checks the wheel speed sensor.1V to step 6 to step 5 the wheel speed sensor. gap between the sensor and gear rotor and the wheel speed. Conditions for DTC to set Monitor wheel speed with scan tool during road Trouble or disconnection of the wheel speed test. wet the connector trouble. 8. road test. The step test if there is open circuit or high resistance in wiring.Observe if there is abnormality in wheel speed sensor. Turn ignition to LOCK position. such as one of the speed is different from that of the other three. ground ON.To turn it off. displayed in the scan tool. 2. EBCM uses the pulse frequency to determine thoroughly. 3 - system OK - Is the trouble corrected? 1. Measure the resistance between the terminals of the 0. The step test if there is voltage short circuit in ON.gap. the ABS alarm indicator keeps ON. monitor wheel speed with scan tool. EBD activates.The generated voltage depends on air if the parts are replaced. the trouble will still occur. 1. even the wheel speed. Switch the DVM to AC mv dial. wheel speed sensor installation error Test description sensor signal error The following number refers to the number of wheel speed sensor signal noise procedures in the diagnostic table. Raise the vehicle with jack. Is the resistance value within the specified range of about 25°C(77°F)? Replace the wheel speed sensor. contact trouble of the tool. Right Front Wheel Speed Sensor Circuit Trouble Step Action Value Yes No Inspect the wheel speed sensor. DTC C0040.Brake Anti-lock brake system (if equipped) 5-107 5. Refer to EBD failure matrix. 1 - to step 3 to step 2 Is there physical damage? 1. Is the output within the specified range? Replace the speed sensor or gear rotor.tooth in the gear will produce Inspect the wiring and connectors pulse.Each tooth. sensor.so as circuit description to avoid pseudo signal resulting from electrical Gear rotor generates voltage pulse through disturbance.Otherwise. accelerate the vehicle speed to 12km/h. connectors.11 DTC C0040 Diagnostic aids Ensure correct and firm wiring of the sped sensor. Disconnect the right front wheel speed sensor connector. This step checks if there is trouble in wheel Actions to take when DTC sets speed sensor. 2.5. 10.Even if the error may be cleared away with scan or voltage short circuit.If wire trouble. 5 - system OK - Is the trouble corrected? . Important: If wrong wheel speed sensor signal has been entered into EBCM.

9 - system OK - Is the trouble corrected? 1. Connect the DVM between ground and one of the terminals of the wheel speed sensor connector. 0. Measure the resistance between EBCM harness connector terminal 3 and wheel speed sensor harness connector terminal. 2. - system OK - Is the trouble corrected? Replace the ABS assembly.5-108 Anti-lock brake system (if equipped) Brake DTC C0040. repeat step 1. Right Front Wheel Speed Sensor Circuit Trouble (Cont’ d) Step Action Value Yes No 1.3V to step 7 to step 8 4. 6 3. Are voltage values of the terminals less than the specified value? Repair voltage short circuit of the related circuits.3. Measure the resistance at terminal 3 of the electronic braking control module (EBCM) harness connector. Any of the two resistance values less than the specified value? Repair ground short circuit of the related circuits. 2. Ignition ON. 8 3. 12 - system OK - Is the trouble corrected? . Disconnect electronic braking control module (EBCM) harness. Measure the resistance at terminal 5 of the electronic to step 9 to step 10 braking control module (EBCM) harness connector. Turn ignition to LOCK position. Measure the resistance between EBCM harness 10 5ohm to step 11 to step 12 connector terminal 5 and wheel speed sensor harness connector terminal. For other terminals of the wheel speed sensor. Any of the two resistance values higher than the specified value? Repair open circuit or high resistance in related circuits if 11 necessary. 2. 7 - system OK - Is the trouble corrected? 1.

even wheel speed.The generated voltage depends on air gap if the parts are replaced. sensor. 8.12 DTC C0045 Diagnostic aids Ensure correct and firm wiring of the sp