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GREAT-WALL Florid (Xuanli) 2008-2013 ManualTaller PDF
GREAT-WALL Florid (Xuanli) 2008-2013 ManualTaller PDF
XUANLI 2008-2013
GWFLORID will build 1.3L (GW413EF, GW4G13) or 1.5L (GW4G15) gasoline engines, in which the
GW4G13 and GW4G15 engines will both incorporate the newest VVT technology which meets the Euro IV
emission standards. GWFLORID features McPherson technology on its chassis system. With an ultra light
body made from structural steel and high-intensity front and rear fender impact beams as well as a collision
impact absorption system, it is able to maintain the cab's integrity and safety to greater extent. We wrote this
maintenance manual in order to meet the demand of Great Wall after-sales service technicians. This manual
mainly introduces the areas of importance in regard to maintenance and care, and removal and installation of
each system's assembly and maintenance technical parameters.
To reduce the possibility of injury or property damage, read and follow the instructions carefully:
This manual is provided by the Great Wall Motor Co., Ltd, and is written for the technician use. Any
maintenance or repair without proper prior training and tools or devices may result in personal injury of the
person performing the maintenance or others in the vicinity. It is also possible that damage to the vehicle will
occur or will lead to mechanical failure during normal operation.
Correct vehicle maintenance and repair is essential for the safety of the person performing regular
maintenance as well as the vehicle itself. If there is any component that needs to be replaced, use a
component with the same serial number or a serial number specified by the Great Wall Motor Co., Ltd. Never
use any part that has not been authorized by the Great Wall Motor Co., Ltd.
Any maintenance procedure introduced in this manual is effective for maintenance and repair. Some of
these procedures need specially designed tools.
Therefore, before using any vehicle part following any maintenance procedure or working with a tool
that has not been authorized by the Great Wall Motor Co., Ltd, check to make sure that none of the above
will endanger the safety of the person performing the work or the correct operation of the vehicle.
This manual includes multiple "Warnings" and "Cautions," which should be strictly followed, so as to
reduce the possibility of injury during maintenance or repair. Improper maintenance or repair of the vehicle
may cause potential safety hazards. These "Warnings" and "Cautions" are not exhaustive. It is impossible for
the Great Wall Motor Co., Ltd, to warn against all the potential dangers caused by not properly following the
instructions.
Please read carefully the "Areas of Importance" before carrying out any maintenance or repair on the
airbag system's components or its surrounding electrical components. Action contrary to any of the "Areas of
Importance" may lead to the deployment of the airbag, resulting in injury or unnecessary repair of the airbag.
To avoid accidental deployment of the airbag and its resulting injury, we suggest repairing the airbag
system before other vehicle systems if the airbag and the other vehicle systems both need repairing.
We have received generous support and help from many professional technicians during the preparation
of this manual. We would like to express our heartfelt gratitude to all of them.
Although we have tried our best to write this manual well, we do not guarantee that the entire content
in this manual is absolutely correct. Users may not make any legal claim against the Great Wall Motor Co.,
Ltd. in regards to this manual. Any loss caused by using this manual is not our responsibility. Because of
the writer's limited experience, there are likely mistakes in this manual, therefore we welcome any user
comments, suggestions, and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.
Editor
May 2008
Overview
Hollow bolt
Q43082
Front hub bearing assembly
Vehicle Nameplate
Every vehicle has a vehicle nameplate, and this vehicle's
nameplate is located at the bottom of the right B-pillar.
Vehicle Nameplate
3. Disposable parts:
(a) Always use new parts to replace cotter pins, gaskets, O-
rings, and oil seals.
(b) Disposable parts will be marked with a " " in the
components schematics section.
4. Precoated components.
The precoated components include bolts and nuts which
have been coated with locking sealant in the factory.
(a) If the precoated part is tightened, loosened, or moved
for certain reason, it must be coated with prescriptive
sealant again.
(b) When reused, the original sealant should first be
cleaned and dried using compressed air. Afterwards,
use the required locking sealant to coat the bolts, nuts,
or threads.
(c) Precoated parts are marked with " " in the components
schematics section.
5. All rules regarding a bolt's tightening torque must be
seriously obeyed, and a torque wrench must be used.
2.��������������������������������������������������������
�������������������������������������������������������
Inspection procedures for related fuses or fuses in re-
Same current rating lay boxes. Inspect the battery for damage, the battery's
charging state, cleanness, and tightening with the
connectors.
Before changing a fuse, make sure to check if the fuse's cur-
rent rating meets the required standards. You must not use a
fuse with a current rate that is higher or lower than required
standards.
5. ���������������������������������������������������
Maintenance methods��������������������������������
for wire harness connector ter-
minals.
(a) Use an airgun or rag to clean the contact points if the
terminals become dusty. Do not use sandpaper to clean
it, as that could damage the electroplated layer.
(b) If the contact pressure seems unusual, change it to a
socket of the same type.
(c) Any terminal that has been damaged, deformed, or
Correct
corroded must be changed. If the terminal is not locked
Incorrect
to the case, then the case needs to be replaced too.
Vise
Clip extractor
Protection band
Screwdriver
Protection band
Screwdriver
Continued table
Shape Removal / Installation
Removal Installation
Screwdriver
Press
Clip extractor
Removal Installation
Screwdriver Press
Clip extractor
Removal Installation
Press
Screwdriver
Clip extractor
Overall Parameters
Cooling style and water temperature under water temperature under opening pressure of the
performance normal working condition normal working condition coolant compensation
parameters is 90-100oC, the opening is 80-90oC, the opening box's pressure limiting
pressure of the coolant pressure of the coolant valve is 108±14.7 kpa
compensation box's compensation box’s
pressure limiting valve is pressure limiting valve is
108±14.7 kpa 108±15 kpa
Starting style and Motor starting, starting performance complies with GB18297
performance requirements 8.1.2 and 8.1.3
Lubricating
Pressure and splash combination
method
Item Specifications
Model number GW413EF GW4G15 YC4W75-31
Single chip, dry type,
Single chip, dry type, diaphragm spring
diaphragm spring
Driven disc diameter: Clutch disc diameter: Driven disc diameter:
Clutch type
Clutch 200 mm 213 mm 212 mm
Separating stroke:
Maximum stroke: 9 mm, separating stroke: 7.5 mm
7.5 mm
Clutch hydraulic pressure
Clutch pedal total stroke: 116.5mm
control system
Transmission
037A CC0011A ZM007Q ZM007W
model number
Transmission type Mechanical 5-gear manual transmission
Main speed
3.944 4.3125 4.267 3.937
reduction ratio
1st gear 3.545 3.545 3.364 3.182
2nd gear 1.913 1.905 1.895 1.895
Tightening
Fastening piece name
No. Important fastening piece locations Quantity torque
and model number
(N·m)
1 Chassis
Left mount & left side member Hexagon bolt for flange face 1 112±10
1.01
Left mount & left mounting bracket Hexagon bolt for flange face 2 64±5
Left mounting bracket & transmission Hexagon bolt for flange face 3 64±5
1.02
Right mount & engine Hexagon nut for flange face 1 41±4
Right mount & engine Hexagon bolt for flange face 2 64±5
1.03
Right mount & vehicle body Hexagon bolt for flange face 2 64±5
Tightening
Fastening piece name
No. Important fastening piece locations Quantity torque
and model number
(N·m)
Right mount & vehicle body Hexagon bolt for flange face 1 64±5
1.04
Right mount & transmission Hexagon bolt for flange face 1 64±5
Right mount & transmission Hexagon bolt for flange face 2 64±5
1.05
Rear mount & rear mounting bracket Hexagon bolt for flange face 1 64±5
Hexagon bolt for flange face
1.06 Rear mount & subframe 1 64±5
(M10 × 1.25 × 70)
1.07 Rear mount & subframe Hexagon nut for flange face (M10 × 1.25) 2 64±5
Hexagon head bolt and flat washer
1.08 Fuel tank & rail 4 35±3
subassembly
Hexagon head bolt, spring washer and flat
1.09 Fuel filler pipe & vehicle body 1 47±3
washer subassembly
1.10 Accelerator pedal & vehicle body Hexagon nut for flange face 3 9±2
Hexagon head bolt and flat washer
1.11 Fuel filter bracket & tank 3 9±2
subassembly
Hexagon head bolt and flat washer
1.12 Fuel pump install panel & tank 8 4±1
subassembly
Fuel filler pipe assembly & vehicle Hexagon head bolt and spring washer
1.13 1 9±2
body subassembly
Hexagon head bolt and spring washer
1.14 Air filter bracket & vehicle body 2 9±2
subassembly
Hexagon head bolt and flat washer
1.15 Air filter & air filter bracket 3 9±2
subassembly
1.16 Exhaust pipe rear protection support Hexagon bolt for flange face 2 23±3
Between the front muffler and catalytic
1.17 Hexagon bolt for flange face 2 64±5
convertor
Connections between the front exhaust
1.18 pipe and catalytic convertor, front & Bolt (M10 × 1.25) 4 64±5
rear muffler flanges
Connections between the front exhaust
1.19 Air intake and exhaust nut components 2 64±5
pipe & engine exhaust manifold
Hexagon head bolt, spring washer and flat
1.20 Front, central, and rear heat shield 5 9±2
washer subassembly
1.21 Front heat shield Hexagon nut for flange face 1 9±2
Hexagon head bolt and flat washer
1.22 Fan with overflow tank assembly 3 9±2
subassembly
1.23 Clutch pedal & clutch master cylinder Nut (M8) 2 21±5
1.24 Clutch pedal & beam Hexagon bolt for flange face 1 23±3
Mounting bolts on the bracket connected
Hexagon head bolt and flat washer
1.25 the rigid pipe of the clutch master cylinder 1 9±2
subassembly
and hose
Connected the rigid pipe bracket of
1.26 Hexagon head bolt 3 23±3
clutch slave cylinders & bolts
Transmission control mechanism Hexagon head bolt and flat washer
1.27 4 20±2
assembly & floor subassembly
Transmission control cable assembly Hexagon head bolt and flat washer
1.28 1 9±2
bracket mounting bolt subassembly
Transmission control cable fixed plate Hexagon head bolt and flat washer
1.29 2 9±2
mounting bolt subassembly
Transmission control cable assembly
1.30 Hexagon nut for flange face 1 9±2
bracket & vehicle body
Tightening
Fastening piece name
No. Important fastening piece locations Quantity torque
and model number
(N·m)
1.31 Propeller shaft assembly Front drive shaft nut (M22 × 1.5) 2 240±20
Hexagon bolt for flange face and flat
1.32 Subframe & vehicle body (rear) 2 116±10
washer subassembly
Hexagon bolt for flange face and flat
1.33 Subframe & vehicle body (front) 2 70±5
washer subassembly
Hexagon head bolt and flat washer
1.34 Subframe strut bar & vehicle body 4 47±5
subassembly
1.35 Swing arm & steering knuckle Swing arm ball end nut (M12 × 1.25) 2 98±10
1.36 Swing arm & subframe Hexagon nut for flange face (M12 × 1.25) 2 \
Hexagon head bolt and flat washer
1.37 Swing arm & subframe 2 136±10
subassembly
Hexagon head bolt and flat washer
1.38 Swing arm & subframe 2 107±10
subassembly
1.39 Front shock absorber & vehicle body Hexagon nut for flange face (M8) 6 39±4
1.40 Front shock absorber & steering knuckle Hexagon bolt for flange face (M14 × 1.5) 4 \
1.41 Front shock absorber & steering knuckle Hexagon nut for flange face 4 132±10
Hexagon head bolt and flat washer
1.42 Front stablizer bar bracket & frame 4 23±3
subassembly
1.43 Hanger rod, swing arm & stablizer bar Type 2 non-metal insert lock nut 2 23±3
Hexagon head bolt and flat washer
1.44 Trailing arm spindle sleeve assembly 2 82±5
subassembly
1.45 Rear shock absorber support shaft Hexagon nut for flange face 2 49±5
1.46 Rear shock absorber components I type hexagon nut 4 64±5
1.47 Hub Wheel nut (M12 × 1.25) 16 103±10
Steering wheel & steering column
1.48 Hexagon nut for flange face 1 50±4
mounting nut
1.49 Steering column & beam mounting bolt Hexagon bolt for flange face 1 23±3
Hexagon head bolt and flat washer
1.50 Steering column & beam mounting bolt 2 23±3
subassembly
Steering pump adjustable bracket &
1.51 Hexagon bolt for flange face 3 39±4
engine mounting bolt
Powr steering pump & bracket mounting
1.52 Hexagon bolt for flange face 1 64±5
bolt
Steering pump mounting bracket
1.53 Hexagon bolt for flange face 2 35±3
&engine mounting bolt
Steering gear & subframe mounting Hexagon head bolt and flat washer
1.54 2 107±7
bolt subassembly (M12 × 1.25 × 80)
Steering gear & subframe mounting Hexagon head bolt and flat washer
1.55 2 107±7
bolt subassembly (M13 × 1.25 × 100)
Steering gear & steering knuckle
1.56 Hexagon castle thin-nut 2 50±10
mounting nut
Steering protection plate & subframe
1.57 Hexagon bolt for flange face 2 23±3
mounting bolt
Hexagon head bolt and spring washer
1.58 ABS sensor & steering knackle 2 9±2
subassembly
1.59 Rear brake & rear axle Bolt: for installing brake 8 50±5
1.60 Brake pedal & booster Nut 4 23±3
Tightening
Fastening piece name
No. Important fastening piece locations Quantity torque
and model number
(N·m)
ABS sensor front wire harness & front Hexagon head bolt and flat washer
1.61 2 23±3
shock absorber subassembly
Hexagon head bolt and flat washer
1.62 ABS & vehicle body 3 23±2
subassembly
Hexagon head bolt and spring washer
1.63 Parking brake cable & vehicle body 6 9±2
subassembly
Hexagon head bolt and spring washer
1.64 Parking brake cable & rear brake 2 9±2
subassembly
ABS sensor rear wire harness, vehicle Hexagon head bolt and spring washer
1.65 6 9±2
body & rear brake subassembly
Parking brake fixed cable braket & Hexagon head bolt and spring washer
1.66 1 9±2
vehicle body subassembly
ABS sensor front wire harness & vehicle Hexagon head bolt, spring washer and flat
1.67 2 9±2
body washer subassembly
Hexagon head bolt, spring washer and flat
1.68 Parking brake control mechanism 2 23±3
washer subassembly
Rear brake pipe connector & vehicle
1.69 Hexagon bolt for flange face 1 9±2
body
1.70 Seven-hole tube clamp & vehicle body Hexagon bolt for flange face 1 9±2
1.71 Brake pedal & vehicle body Hexagon bolt for flange face 1 23±3
1.72 Brake cable & rear axle Hexagon nut for flange face 2 9±2
1.73 All of the brake line connectors M10 16±2
1.74 All of the brake line connectors M12 16±2
2 Vehicle body
2.1 Connected seat belt Front seat belt upper mounting bolt (7/16) 2 42±5
2.2 Connected seat belt Seat belt lower mounting bolt (7/16) 4 38±5
2.3 Connected seat belt retractor Front seat belt retractor lower bolt (7/16) 2 38±5
2.4 Connected seat belt retractor Hexagon bolt for flange face 2 9±3
2.5 Connected seat belt Rear seat belt upper mounting bolt (7/16) 2 38±5
2.6 Connected seat belt retractor Rear seat belt retractor bolt (7/16) 2 38±5
Mounting bolts on the middle seat belt
2.7 Connected seat belt 1 38±5
(7/16)
2.8 Connected front seat belt mortise lock Front seat belt mortise lock bolt (7/16) 2 60±5
2.9 Connected rear seat belt lock Rear seat belt lock bolt (7/16) 2 38±5
3 Air conditioner
Hexagon bolt for flange face Q1841030FD
3.1 Compressor bracket & engine 4 64±5
(M10 × 1.25)
Hexagon bolt for flange face-oversize
3.2 Comperssor bracket & compressor 4 23±3
Q1860890FD
Hexagon head bolt and flat washer
3.3 Condensor fan mounting bolt 1 9±2
subassembly Q1400630 (Q402) F32
3.4 Condensor mounting bolt Hexagon bolt for flange face 2 23±3
Compressor suction hose & HVAC
3.5 Hexagon bolt for flange face Q1460640F32 1 9±2
refrigeration line port
Air conditioner hose, compressor, and
3.6 Hexagon bolt for flange face Q1840625F32 4 9±2
condenser coupling bolt
3.7 Expansion valve & HVAC refrigeration line port Hexagon bolt for flange face Q1840630F32 2 9±2
Imaginary
reference line
Engine Compartment
Mark Axis (X, Y, Z) Diameter (mm) Mark Axis (X, Y, Z) Diameter (mm)
A (115.2, 0.4, 701.5) Ф10 B (-461.2, -447.6, 627.7) Ф8
C (56.5, -520.3, 698.8) Ф11 D (-143.9, -645.9, 690.9) Ф8
E (-506.2, -45.0, 679.1) Ф9 F (-52.3, -681.0, 725.3) Ф10
G (-606.8, -464.3, 290.6) Ф8.5 H (-548.7, -403.6, 359.8) Ф8
J (-188.4, 467.5, 387.9) Ф13 K (-319.0, -425.0, 327.5) Ф14
Chassis
LH
side
Upper Lower
Front
Front
Unit: mm
Chassis (Continued)
Axis Axis
Ф
LH
side
Ф
Ф
Ф
Front
Unit: mm
Subframe
1195±1.5 ( Distance between the center points of both shaft's end surfaces )
1381±0.5 ( Distance between points P and Q )
Unit: mm
I Rear door lower hinge mounting via hole Φ15 J Rear door contact switch via hole (location Φ19
hole)
Windshield
Desorption hose II
Desorption hose I
Q1461025
Q67639 Q67639
Fuel filler pipe
assembly Air return hose
Q1461025
Q67639 Q67639
Fuel filler pipe assembly
Air return hose
Exhaust System
Components
Exhaust manifold
Gasket I
Exhaust pipe front joint
Front heat shield
Sealing
Air intake and exhaust ring
nut components
Bolt
Q1460612
Spring
Hexagon flange nut
Q1840816
Q1460612
Areas of Importance............................................................ 37
Troubleshooting................................................................... 37
Clutch Operational System.................................................. 38
Components...................................................................... 38
Clutch Master Cylinder Removal....................................... 38
Clutch Master Cylinder Installation.................................... 40
Clutch Pedal Removal....................................................... 40
Clutch Pedal Installation.................................................... 40
Clutch Pedal Examination and Adjustment....................... 41
Areas of Importance
1. Clutch Rigid Pipe Installation
Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is
clean, and that there is no foreign materials.
2. Clutch Hose Installation
Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
3. Coat grease on the U-joint of the pedal and the master cylinder.
4. Strictly adhere to the set torque guidelines when tightening the pipe fittings.
Rigid pipe and the master cylinder: M10 16±2 N·m
Clutch rigid pipe and hose: M10 16±2 N·m
5. While the clutch system is undergoing the exhausting process, make sure that all the air bubbles in
the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should be between
MIN and MAX.
Troubleshooting
The numbers in the table represent the order of the possible malfunction causes, so be sure to check each part in
turn. If necessary, replace the part.
Reservoir
Clutch discharge pipe
Return spring
Lock nut
Lock nut
Bleed screw
Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
Remark: Residual air in the clutch system has been
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Pedal height
Free play
Transmission
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7
Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets).
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or installation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dry place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.
Troubleshooting
Common problems Possible causes Solving methods
Difficult gear Not applying clutch Use correct driving methods
engagement Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ring Replace component
Positioning spring is too hard Replace component
Noise is too loud or Oil level is too low Fill oil to the specified level
abnormal Lubricant is of poor quality Replace the specified oil
Untimely oil changes Replace oil and damaged part
1
2
3
4
5 9
6 10
7 11
8 12
76 13
75 14
74 15
73 16
17
72 18
71 19
70 20
21
22
69 23
68 24
67 25
66 26
65
64
63
27
28
29
62 30
31
61 32
60 33
59
58
57
56
55 34
54 35
53 36
52 37
38
51 39
50 40
49 41
48 42
47 46
45
44
43
1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring
7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective
cover 12. Release fork spring 13. Bolt for flange face (3) 14. Release fork 15. Clutch housing 16. Release fork support nail 17. Ball
bearing 18. 2nd gear synchronizer ring 19. T oil seal 20. No. 1 gear sleeve 21. No. 1 Slider 22. 1st gear synchronizer ring 23. 1st gear
gear components 24. Needle bearing 25. Release bearing subassembly 26. Tapered roller bearing 27. Guide nozzle 28. 2nd gear gear
assembly 29. No. 1 gear hub 30. Spring expansion ring (2) 31. Bolt for flange face (6) 32. Straight pin 33. Odometer driver 34. T oil
seal 35. Tapered roller bearing 36. Adjusting shim (2) 37. Axle shaft gear (2) 38. Planetary gear (2) 39. Gasket (2) 40. Differential
case 41. Planetary gear shaft 42. Differential ring gear 43. Bolt for flange face (8) 44. Tapered roller bearing 45. Adjusting shim 46.
T oil seal 47. Shaft retainer 48. Retaining ring 49. Needle bearing 50. 3rd driven gear 51. Spacer 52. 4th driven gear 53. 5th driven
gear 54. Shaft retainers 55. Tapered roller bearing 56. Adjusting shim 57. Output shaft 58. 5th gear gear assembly 59. Shaft retainer
60. Retaining ring 61. Spring expansion ring (2) 62. Needle bearing 63. Input shaft 64. Adjusting shim 65. Ball bearing 66. 3rd gear
gear hub 67. 3rd gear Slider (3) 68. 3rd gear gear sleeve 69. 5th gear synchronizer ring 70. Steel ball 71. 5th gear thrust washer 72.
Needle bearing 73. 4th gear components 74. Retaining ring 75. 4th gear synchronizer ring 76. Transmission case
Clutch
Components
Release bearing
Cable bracket
Release fork
Bolts with
washer
×5
11.3
Cable bracket
Release fork support nail
29.4
Differential assembly
Clutch housing Magnetic body
Guide nozzle
Tapered roller
bearings
T oil seal
Output shaft assembly
Clutch housing
Shaft retainers
Elastic
cylindrical pin
Reverse gear
idler assembly
Reverse gear
idler shaft Output shaft assembly
Bolt for flange face
29.4
Gasket
Input shaft assembly
Transmission Case
Components
Clip
Clip
Clip
Adjusting shim
Position mechanism
assembly
36.8 39.2
Hexagon head plug
6. Remove the No. 1 gear shift fork shaft and the set
bolts.
8. Remove the No. 1 gear shift fork, No. 1 gear shift fork
shaft, and No. 1 guide block.
10. Remove the elastic cylindrical pin from the No. 3 guide
block.
12. Remove the set bolts from the No. 2 gear shift fork
shaft.
13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift
fork, and No. 2 guide block.
17. Remove the oil drain slot from the inside of the transmis-
sion case.
19. Remove the release fork and the release bearing from
the clutch housing.
20. Remove the set bolts of the release fork from the
clutch housing.
Retaining ring
Spring expansion
ring Shaft retainer
Retaining ring
Steel ball
Front ball bearing
5th gear thrust washer
7. Remove the steel balls from the 5th gear thrust washer
of the input shaft.
12. Remove the needle bearing from the 3rd gear of input
shaft.
Rear tapered
1st gear roller bearing
synchronizer ring
Shaft retainer
Needle bearing
Spacer
Retaining ring
Shaft retainer
Needle bearing
Output shaft
2nd gear gear subassembly
5. Remove the output shaft's 3rd driven gear and the 2nd
gear subassembly spacer.
Dust cover
T oil seal
38.0 Set bolt
Pressure spring
Manipulation lid
Shaft retainer
T oil seal
2. Remove the shaft retainer on the shift lever and the se-
lect lever.
8. Remove the shaft retainer on the shift shaft and the se-
lect lever.
Caution: Use a cord to fasten the shift lever in order to
Cord make the operation convenient.
9. Remove the shift shaft and the shift shaft dust cover.
11. Remove the shift shaft T oil seal from the manipulation
lid.
T oil seal
Clutch housing
Gasket
Planetary gear
Adjusting shim Differential ring gear
Gasket
T oil seal
Adjusting shim
Transmission case
Suspension System
Tightening torque
Tightening
Assembly locations for
Part Code torque Quantity Glue Grade
standard components
(N·m)
Q1861455TF2
(M14×1.5) + Q402 Subframe & vehicle body (rear) 145±15 2 Red glue 10.9
(d2=32 t=5) FD
Q1861275TF2
(M12×1.25) + Q402 Subframe & vehicle body (front) 120±10 2 Red glue 10.9
(d2=32) FD
Q1401020 (M10×1.25) FD Subframe strut bar mounting bolt 49±5 4 Red glue 10.9
2904011-S08 Swing arm & steering knuckle 98±10 2 Red glue
Front Q1401495 (t=4)
Swing arm & subframe (front) 180±10 2 Red glue 10.9
suspen- (M14×1.5) FD
sion Q1401280 (M12×1.25) FD Swing arm & subframe (rear) 120±10 2 Red glue 10.9
2904013-S08 Swing arm & subframe (rear) / 2
Front shock upper assembly loca-
2905011-S08 40±5 6
tion
Front shock lower assembly loca-
Q32014 (M14×1.5) FD 132±10 4 Red glue 10.9
tion
Front stabilizer bar mounting
Q1400830 (d2=13.5) 37±4 4 Red glue
bracket
Q32608 Front stabilizer bar hanger rod 16±2 4
Front Suspension
Components
Lightly hammer here 4. Remove the cotter pins and lock nuts of the steering tie
rod and the lower swing arm
Because the ball stud and steering knuckle act in conjunction
with the tapered bore, they can not yet be removed after re-
moving the nuts. Pound the steering knuckle arm (unfinished
surface) with a hammer. Positions are shown on the left.
Shake to loosen.
Caution:
1. To avoid separating the ball studs, do not pound the
tie rod and the lower swing arm with a hammer.
2. To avoid damaging the thread, do not hammer the
ball stud's head.
Front bumper
Dust cover
Front coil spring Erection support on the front coil spring
Front
Subframe
5. Subframe installation.
Installation follows the reverse removal steps.
Caution: Fix the position of the subframe with the
position pin, to avoid influencing the four wheels'
positioning. Location hole is shown on the left: a total
of two, one on the left and one on the right.
Shaft sleeve
Bushing Washer
(b) The sliding side of the hanger rod should face upward,
Correct Incorrect so as to make the operation more convenient.
Q1401495
Subframe
Q1401280
Q1401495
Q1401280
SST
3. Inspect the lower swing arm's large and small shaft sleeve
for signs of wear.
Clean the large and small shaft sleeve of the lower swing
arm with water, and inspect for damage, wear, cracks, and
similar flaws. Replace with new ones if needed.
(b) On the press, press out the lower swing arm's large
F
shaft sleeve with SST (Special Service Tools), and re-
place it with a new one.
SST
(c) Check that the mounting holes of the lower swing arm's
large shaft sleeve are Φ55-0.2
-0.3 , measure for inaccurate di-
SST
Sanding spots
F
(b) On the press, use SST (Special Service Tools) to press
out the lower swing arm's small shaft sleeve, and re-
SST place it with a new one.
(c) Check that the lower swing arm's small shaft sleeve's
mounting hole dimensions are Φ31+0.05
0 .
SST Caution: Measure for inaccurate dimensions, replace
the lower swing arm's weld assembly if inaccurate.
SST
Drive Shaft
Components
Front drive
shaft nut LH Front drive shaft
assembly LH Transmission assembly
Wheel assembly
Rear Suspension
Components
3. Compression spring.
Hold up the rear twist beam upwards with a lift, compressing
the rear coil spring and damper.
Wear marks
There are several tread wear marks (refer to location A in the
diagram shown on the left) inside of the tire's pattern groove.
These marks indicate that the tire has been worn to the point
of replacing.
Before the tire's usage limit, indicated by the remaining
A pattern's depth, reaches 1.6 mm (and its main pattern groove
bottom protrudes to the same level), for your safety, please
replace the tire.
When serious eccentric wear leads to the partial protrusion
of the cord fabric level, or outside objects damage the tire to
a depth that reaches the cord fabric level or steel band level,
stop using the tire.
Tire rotation
For equal wear or tear for the tires, please rotate the tire
positions timely. Swapping principle shown on the left.
Radial tires should be regularly switched, and add pressure
according to the regulations.
Front Rear Caution:
Due to structural reasons, radial tires usually quickly
receive most of its wear on the shoulders, especially
the front tires. Do a tire rotation per 8000-12000 km,
and the tire life can increase by 20%. This makes
regular tire rotation especially useful.
Deviation judging methods
"Deviation" means that, when no one is in control of the steering, the vehicle does not move in a straight line
while driving on a straight and leveled surface.
After solving,
If the problem is not yet
switch the tires again
solved, it means the "good
tire" is in fact not good
Deviation causes:
• Incorrect tire and front wheel alignment,
• Braking force is not even,
• Tire structure problems.
Tire production and manufacturing methods can also lead to vehicle deviation. For example, the arrangement of
the tires inner steel wire belt. A steel wire belt which is inside the radial tire deviating from the tires centerline
can create lateral force when the tires are rolling in a straight line. If one of the tire's diameter is larger than the
other, the tire will tend to roll to that side, this also creates lateral force (a tapering effect) leading to vehicle
deviation. When the front wheel alignment is found to be correct and in proper order, the above process is also
applicable in judging tire deviation. Rear tires cannot cause deviation.
Caution:
• The " " symbol on the tire bead of the spare tire in-
dicates the set position of the wear index (shown on
the left).
• The spare tire's maximum driven speed is 80 km/h,
and maximum distance 200 km per trip.
• Each vehicle is allowed to use only one spare tire.
• The spare tire is only used as a temporary backup.
Please go to a professional service station immediately
to get the initial tire repaired or replaced.
Wheel
General tire balancing procedures
Clean out the accumulated dirt and debris from the inside of the rim.
Warning:
The gravel on the tread must be eliminated to avoid flying out and injuring the operator when
undergoing rotational balancing. This is also a good way to acquire better balance. First thoroughly
inspect the tire's damaged condition, then according to the balancing device manufacture's
recommendations, carry out the balancing operation.
Off-vehicle balancing
Most off-vehicle balancers are more accurate and convenient than on-vehicle rotational balancers. They are
also able to perform dynamic (two sided) balancing. Although it does not correct drum brake and brake disc
imbalance like on-vehicle balancing, it achieves the same effect based on its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on equipment and tool manufacturer. Therefore, when performing
balancing operations, be sure to comply to each manufacturer's operating instructions.
Warning: Control the wheel rotation speed to make sure the speedometer stays within 55 km/h.
This restriction is necessary because when a driven wheel slides while the other one stays still, the
speedometer will display only half of the actual wheel speed. When a wheel is sliding, be extremely
careful, because sliding wheels can reach very high speeds. This may lead to the tire rubber peeling
or differential damage, which may cause serious personal injury, or damage to the vehicle.
[C] [D] Dynamic balance means that the weight distribution on the
2
two sides of the medium plane of the wheel is equal, so
during the rotation process, the tire assembly cannot create a
tendency for the medium plane of the wheel to shift from one
side to the other. If the wheel is dynamic and unbalanced, it
can create a shimmying effect. Shown in diagram 2.
1. Wheel shimmy important points [C]: Counterweight not yet added
2. Locations to add counterweight [D]: Counterweight added
3
3. Axis
1 Diagram 2
Wheel maintenance
Do not use welding, heating, or hammering to repair wheels. All damaged wheels must be replaced.
If the vehicle's wheel is twisted or deformed, sunken or depressed, having too much horizontal or radial hop,
leaking air from the welded parts, stretched out at the bolt holes , having flimsy nut bolt lock, or severely rusty,
the wheel must be replaced. When the wheel is hopping too much, it will lead to undesirable vibrations.
When replacing the tire, be sure that the load capacity, diameter, rim width, offset distance, and the installation
structure of it, are equal to the settings of original wheel. If the wheel dimensions are not appropriate, this will
influence the wheel and bearing's life, brake cooling effect, speedometer and odometer calibration, vehicle
ground clearance, as well as the clearance between the tire and the vehicle body, and the tire and vehicle chassis.
Wheel (steel wheel) removal
1. Remove the wheelhouse and loosen the nuts, 1-2 turns is
enough.
2. Hoist the vehicle.
3. Screw off the nuts and remove the wheel.
Nut tightening torque: 110±10 N·m
Caution: Heating methods absolutely must not be used
to loosen tightened wheels, otherwise the heat will
reduce its use life and damage the hub bearing.
Brake System
Rear brake
assembly RH
Rear brake Rear brake assembly LH
drum
(e) Make sure not to let the system valves block the air bleeding.
(f) When the brake fluid that flows out of the hose or connector has no bubbles, it means that the air
in the system has been exhausted. There is still air inside the system if the hose inserted into the
brake fluid is still bubbling when pressing down the pedal.
(g) Keep the free end of the hose immerged in the brake fluid to avoid air from flowing into the
system while opening the screw.
(h) While air bleeding, hammer the casting part of the vibrating brake device with a rubber hammer.
This is helpful for removing bubbles deep in the brake fluid.
(i) If air in the master cylinder is suspected, then perform air bleeding on the master cylinder first,
then the wheel cylinder or brake caliper.
(j) When releasing air from the tires, generally make sure to release air out of all the tires.
(k) To avoid the possibility of air reversely entering into the system, a bleeder hose that has a check
valve could be used.
(2) Pressure blow-off
Under the proper conditions, a pressure blow-off device can be used to release the air inside the brake system.
3. Air releasing sequence
(1) Master cylinder air bleeding
If the master cylinder does not have air bleed screws, perform the following steps:
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary.
(b) Slowly take off the front brake pipe connector until the brake fluid flows out from the end.
(c) Reconnect the brake pipe, but do not tighten it.
(d) Slowly step down and press on the brake pedal, check if the brake fluid flowing out of the connector
contains bubbles.
(e) Tighten the pipe fitting.
(f) Have the assistant loosen the pedal, wait for 15 s.
(g) Repeat the above steps until all the air is released.
(h) Take off the rear brake pipe connector, repeat the above steps.
(2) Wheel brake air releasing
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary. During the
entire air releasing period, check repeatedly and add promptly.
(b) Connect one end of the bleeder hose with the bleed screw and the other end immerged in the brake fluid.
(c) Have the assistant step on the pedal several times, raise the pedal gradually until it cannot be stepped on
any more, then forcibly press on the pedal once more.
(d) Loosen the bleed screw, check if there are any bubbles in the brake fluid flowing out. Meanwhile, slowly
lower the pedal.
(e) When the brake pedal is close to the stroke end or the out flowing brake fluid does not have any bubbles,
tighten the bleed screw.
(f) Have the assistant release the pedal and wait for 15 s.
(g) Repeat the above steps until there are no bubbles in the flowing brake fluid when the screw is loosened.
(h) Release the air for all the wheels in turn using the same method.
(i) After releasing the air from the entire system, switch the ignition to the on position.
(j) Inspect the stroke of the brake pedal and its reaction.
(k) Inspect the lighting condition of the brake warning lamp, and repeatedly perform maintenance or air
bleeding if necessary.
(l ) Add brake fluid to the reservoir until the specified fluid level, air bleeding is complete.
Brake Pedal
Components
Bushing
Brake pedal lever
Nut welding assembly
Brake pedal bracket
welding assembly
Limiting stopper
Center pin
Pedal pad
Pedal shaft
Cotter pin
Return spring
Areas of Importance
1. During removal, all components should be gently handled to avoid knocking, especially the junction
surface. All components should be placed in order to avoid losing or taking the wrong parts.
2. Keep all parts clean and free of dust, scuffs, rust, corrosion, oil build-up, or any other contaminants.
3. All rubbing surfaces in a relative motion must be coated with lubricant.
4. During installation, strictly adhere to the standard torque for installing nuts.
5. While installing the return spring, be careful to avoid operator injury from it bouncing back.
Troubleshooting
Symptoms Possible causes Eliminating methods
Brake pedal cannot return Return spring is broken Replace the spring
to the original position Return spring's fixed end comes off Check, secure in place
Feels slippery when Pedal pad is worn out Replace
stepping on the pedal Pedal pad comes off Reinstall
The plastic bushing is seriously worn out Replace
Stepping on the pedal
Spring broken Replace
produces abnormal noise
Spring's fixed end comes off Check, re-fix
Pedal shaft
Bushing
Q1460825
Q1420612
B
Q32006 Q1420616
A
C D
B
D Q1420612
Vacuum booster
Check valve
Check valve
seat
Pad
Fluid supply
sealing ring Lock nut
Areas of Importance
1. The vacuum booster with brake cylinder assembly is tightly connected with the brake pedal assembly on
the cowl panel using four nuts. It is also connected with the brake pedal push rod via an center pin and
lock pin. Thus before removal of the assembly, first loosen the rigid pipe fitting with an open-end wrench,
disconnect the lock pin and center pin using pliers, loosen the four nuts, and then proceed with the booster.
2. Tighten the lock nuts on brake master cylinder and vacuum booster according to the specified torque,
and coat with signal paint.
3. Dimensions between the rear housing head face and the adjusting fork hole center is adjusted to
standard before it leaves factory. Please do not adjust it again.
4. The vacuum booster valve rod on the vehicle must be in a free state.
5. The brake master cylinder's working agent is DOT4 brake fluid. It must not be mixed with any other
brake fluid.
Troubleshooting
Problems and symptoms Causes Eliminating methods
Master cylinder's oil reservoir is The master cylinder, slave cylinder, or hydraulic line Eliminate the areas with leaks (in general, it may be that
severely leaking is leaking. the pipe fitting's tightening torque is not enough, check
one by one and tighten as necessary)
1. Vacuum booster not sufficient 1. Under non-operating conditions, the vacuum booster 1. Replace the front and back gas seal and control valve
2. No boost when the engine is off leaks air. assembly.
3. May lead to unsteady engine idling 2. Front and rear housing connection are not sealed. 2. Replace the vacuum booster.
when severe 3. Booster's front and rear gas seal sealing failure. 3. Replace the vacuum check valve assembly.
4. Vacuum check valve leaks.
Brake pedal is heavy with no boost 1.Under non-operating conditions, the vacuum booster 1. Replace the front, back gas seal and booster diaphragm.
effect leaks air. 2. Replace the vacuum booster.
2. Booster diaphragm worn and damaged. 3. Replace the control valve assembly.
3. Control valve ring cup worn and damaged.
Spongy pedal when braking 1. There is air in the brake fluid. 1. Eliminate the air in the system.
2. Cylinder or slave cylinder leaks oil. 2. Inspect the cylinder and sub-pump cup and replace
3. There is brake line seepage. with new parts.
3. Inspect the pipeline and eliminate the seepage.
When continuously step on the brake Pump valve opening blockage. Brake fluid cleanliness is insufficient, please replace the
pedal, the pedal will gradually change brake fluid.
and expand till the highest extend.
Push rod: Stepping onto the pedal Removal of the vacuum booster
in order to pass the force
with brake cylinder assembly
1. Discharge the vacuum.
If there is vacuum inside of the booster, before removal, step
on the brake pedal 3-5 times, so as to discharge the vacuum.
Clean container
Lock pin
Return spring
Bolt
Elastic cylindrical
pin
Check valve Check valve seat 3. Remove the check valve assembly.
Pull out the check valve and valve seat from the vacuum
booster's front case as shown on the left.
Rod clevis
Split ring
Hydraulic modulator
Wheel cylinder
Vehicle speed
Wheel slippage
Wheel speed
Master cylinder
pressure
Wheel cylinder
brake pressure
ABS installation
ABS controller 1. Install the ABS controller assembly.
assembly (a) Use three hexagon bolts for flange face (Q1840825) to
ABS hydraulic pressure
fix the ABS bracket assembly onto the vehicle body.
pump shock pad (b) Fix the shock pad of the ABS hydraulic pump onto the
mounting holes of the ABS bracket assembly.
ABS mounting (c) Insert the mount pin of the ABS controller assembly
bracket assembly into the shock pad holes by simply inserting the two
anchor pins into the bracket.
v or v
0 0
t t
Output signal when the wheels are rotating: signal type is 0.44 V and 1.26 V square wave signal, duty cycle: 50: 50.
0
t
The X431 scanner possesses a waveform function. Wheel speed signal error (wheel speed sensor failure)
only appears when intermittent problems occure, such as high speed. When in use, some signal errors may
occasionally appear. Continue observing the waveform to make sure there is nothing abnormal.When driving
the vehicle on a flat and straight road, all four wheels' speed sensor waveform are extremely similar. One can
compare the two front wheels' with the two rear wheels' signal wave at the same time.
Mechanical causes:
Signal gear distortion, loosened hub bearings, smudges on the sensor surface, etc, all may lead to wheel speed
signal intermittency and inaccuracy. Failure examples:
V( Km/h)
60
30
Signal interrupt
As shown above, once the intermittent failures with the wheel's speed sensor signal are detected, the ABS
control unit records the sensor problems and lights up the warning lamp.
4. Wheel speed sensor velocity failure (ECU detects an excessive difference between the two wheels'
speed sensor signals).
Possible causes are the gear's wheel speed sensor gap is overly large, or the wheel speed sensor signal is
experiencing interference. For this, first determine which sensor is emitting the signal, and then use failure
three's maintenance methods.
Areas of Importance
1. Sometimes, in order to determine whether there is a common brake system problem or an ABS
problem, the ABS must be terminated by pulling out its ABSECU connector or fuse. At this time the
ABS/EBD loses function as well. On muddy, icy, or snowy roads, the vehicle may fishtail or slide, in
which cases one must be extremely careful to avoid hard braking.
2. The ABS malfunction rate is extremely low, when the brake system shows any problem (before the
warning lamp goes on), first eliminate the normal brake system problems, then consider the ABS mal-
functions.
3. When raining or on gravel, this adjusting process is longer than the standard process, because this
kind of road's unstable adhesion coefficient will lead to a difference between the sliding measurement
and calculation procedures, thus it is necessary to remind drivers to be especially careful when driving
under the circumstances mentioned above.
4. ABSECU Areas of Importance:
(a) The ABSECU is easily damaged from impacts or collisions, thus pay attention to ensure the ECU avoids
such incidents.
(b) High temperature environments can also easily damage the ECU, so when the vehicle undergoes hot paint
work, make sure to first take the ECU out of the vehicle.
(c) When the power switch is ON, do not disassemble the system's electrical elements and wire harness plugs,
in order to avoid damage to the ECU. If removal or installation must be carried out, be sure to disconnect
the ignition switch firstly. When welding components or circuits to the system, the wire harness plug
Copper washer
Wheel bolt
Disposable parts
SST
(c) Use dye penetrant to inspect the front hub flange for
cracks, which should be replaced if found.
(d) If one would like to continue using the front hub flange
assembly, first inspect the dimensions for the mounting
area of the bearing for inaccurate dimensions. If
oversized, replace.
Measurement range: Φ38+0.025 +0.009 mm
5. Press out the front hub bearing from inside of the steer-
ing knuckle.
On the press, withstand the bearing inner ring that was put
SST on with SST, and press out the entire front hub bearing.
Caution: The front hub bearing assembly is a disposable
part, which needs to be replaced with a new one.
SST
SST
30 ± 5
Q1840820
Caliper
Guide pin
Rubber grease
N·m : Specified torque
Disposable parts
(c) Install the inner and outer brake pad assembly with
inner muffler plate subassembly onto the caliper frame.
Inner brake pad assembly Make the inner brake pad assembly with inner muffler
plate subassembly and alarm plate rest close to the
Outer brake pad brake caliper's inner side.
assembly
Caution: For the inner and outer brake pad assembly,
Inner muffler
plate subassembly the working surface of the brake disc must not have
Alarm plate any grease, oil or paint pollution.
Guide pin dust cover 4. Install the guide pin and guide pin dust cover onto the
caliper frame.
Guide pin
(a) Install the guide pin dust cover onto the guide pin.
(b) Screw the guide pin into the caliper frame.
Caution: Do not damage the guide pin dust cover.
5. Install an inner and outer brake pad assembly and
inner and outer muffler plate subassembly.
Caliper frame Brake block yoke
spring plate
Rear Brake
Components
Dust cover
Bleed screw
Piston
Wheel cylinder
Bleed screw cap Ring cup
Rubber plug of the Piston spring
adjuster's observation port Ring cup
7.8-11.8 Washer
Return spring
Adjusting
paddle Brake leading shoe assembly
Adjusting
clearance Pin Rear brake drum
screw rod
Pressure spring
Pressure spring bar
Pressure spring cap
Lever
rotating Locking cap
shaft
Split ring
Brake lever
Side spring
Brake back plate assembly
Brake trailing Retainer spring
High temperature resistant shoe assembly
grease Brake shoe tension spring
Rubber grease
N·m : Specified torque
Disposable parts
Method two:
(a) Find two M6×40 (the thread is longer than 25 mm)
phillip screws, and screw them into the rear brake
drum's two threaded holes.
M6×40
(b) Use a screwdriver to tighten the phillip screw, and push
out the rear brake drum.
Caution: Alternately tighten the two screws.
(b) Take out the brake leading and trailing shoe assembly
from the brake back plate assembly, take down the
retainer spring, and remove the cable connector.
Remark: When taking out the brake leading and trailing
shoe assembly from the brake back plate assembly, screw
the adjusting clearance wheel thread completely into the
adjusting clearance screw rod, decrease the return spring's
tension on the brake leading and trailing shoe assembly.
(c) Use needle nose pliers to remove the brake shoe tension
spring, and take down the adjusting paddle.
(d) Use pliers to remove the return spring from the brake
leading and trailing shoe assembly, and separate the
brake leading and trailing shoe assembly.
Foreward Foreward
100
9±1
Right parking brake
Spring cable assembly
Rear brake drum Trailing arm spindle sleeve
with nylon bushing assembly
Rear hub unit
9±1
Rear brake assembly LH
Spring
78-98
100
Rear twist beam assembly
Disposable parts
Steering System
Troubleshooting................................................................... 135
Steering System Maintenance............................................ 137
Power Steering Fluid Instructions........................................ 141
Technical Requirements...................................................... 141
Troubleshooting
Fault
Malfunction Causes Troubleshooting
Symptoms
1. Too much clearance between the steering 1. Have the clearance adjusted by professionals,
gear and gear rack. and if it cannot be adjusted, replace the steer-
ing gear.
2. The inner and outer ball stud of the steering 2. After inspection, replace the ball stud if nec-
tie rod ball is worn out. essary.
3. Steering joint is worn out. 3. Replace the lower section of steering column.
Steering wheel
4. Steering propeller shaft and steering gear 4. Fasten the connection bolts in accordance
free play too
connection is loose. with the specified torque.
big / abnormal
5. Steering wheel and steering column connec- 5. Fasten the lock nut of the steering wheel.
noise
tor is loose. When the spline is damaged, make sure to re-
place the steering wheel or steering column.
6. Steering gear mounting bolt is loose. 6. Fasten the mounting bolts of the steering
gear.
7. The sliding spline of the lower propeller 7. Replace the lower section of steering column.
shaft is worn and loose.
1. Tire pressure insufficient. 1. Inflate according to the specified pressure.
2. Front wheel alignment angle incorrect. 2. Check and adjust the front wheel alignment
angle.
3. Clearance between the steering gear presses 3. Replace the steering gear or have profession-
too small. als adjust the clearance between the presses.
4. Steering column's spider bearing broken. 4. Replace the lower section of steering column.
5. Steering tie rod ball stud lacks oil or is dam- 5. Replace the lower section of the steering tie
aged. rod ball.
6. Front shock absorber's support bearing bro- 6. Replace the connecting components of the
ken. front shock absorber (refer to the front sus-
pension maintenance section).
7. Damaged lower swing arm ball end. 7. Replace the lower swing arm (refer to the
Hard steering front suspension maintenance section).
8. Damaged steering pump leads to insufficient 8. Replace the power steering pump.
output volume and output pressure.
9. Power steering pump belt slides. 9. Adjust the belt's tension.
10.Power steering gear internal leakage too 10. Replace the power steering gear.
much.
11. Power steering contains air bubbles and pro- 11.In place, repeatedly turn, exhaust the air
duces irregular noise. bubble, then after leaving it stationary for one
hour, replenish the power steering according
to the specific model number.
12. Power steering insufficient. 12.Fill the power steering (with specific model
number) until it reaches the PS fluid reser-
voir's specified scale mark.
Fault
Malfunction Causes Troubleshooting
Symptoms
1. Tire pressure insufficient. 1. Inflate according to the specified pressure.
2. Wheel counterweight falls off or other fac- 2. Recalibrate the wheel's dynamic balance.
tors cause extremely poor wheel balance.
3. Lower swing arm's rubber bushing is too old, 3. Replace the lower swing arm.
big difference between the left and right's
rigidity.
4. The front shock absorber's support bearing 4. Fill with grease of the specified model num-
and lower swing arm ball lacks sufficient lu- ber.
Poor steering
brications.
return
5. The four wheels' positional parameters incor- 5. Re-measure and adjust the four wheels' posi-
Straight
rect. tional parameters.
movement
6. Steering gear's gear rack meshing condition 6. Replace the steering gear.
stability poor
worsens and causes intense reverse resis-
tance.
7. Steering column bearing and spider bearing 7. Replace the steering column assembly.
damaged.
8. Power steering pump's oil supply insuffi- 8. Replace the power steering pump.
cient.
9. Inner portion of the steering gear's control 9. Replace the power steering gear.
valve performance degradation.
Steering wheel
PS fluid reservoir
Steering column
Upper trim cover 3. Remove the upper and lower trim cover of the combina-
tion switch.
3404202-S08
Q1840820 (d2=22) 6. Screw off the two flange bolts Q1840820 (d2=22) which
are in the upper part of steering column connected
to instrument brace reinforcement with a M13 socket
wrench in the counterclockwise direction, and screw
off one flange bolt Q1840850 which is in the lower
part of steering column connected to instrument brace
reinforcement with a M10 socket wrench in the counter-
clockwise direction. Follow the column's upper axes
Q1840850 and pull out the steering column assembly.
3412012-S08
2904013-S08
Ball stud
Example: 3. Connector
(a) Negative connector pin number
Arranged from upper left to lower right.
(b) Positive connector pin number
Arranged from upper right to lower left.
Double-colored wire: Primary color is Red, secondary color is Blue, marked as RBl.
0.5BrGr means Brown wire with a Gray fine wire, and sectional area is 0.5 mm2.
Areas of importance in circuit maintenance
1. Before operating any electronic devices, and when tools or maintenance devices may easily make
contact with an uncovered electronic terminal, please make sure to turn the ignition switch to the LOCK
position, and then disconnect the battery's negative cable to avoid injury or vehicle damage. When the
ignition switch is on the ON position, please do not disconnect the battery's connecting wire or take out
the power's fuse, regardless if the engine is running or not.Otherwise it would seriously damage the
ECU and related microelectronic devices such as sensors.
2. When changing the fuse, please make sure that the new fuse possesses the proper current rating,
and is not above or below this rating.
3. When repairing the wire harnesses of the airbag and pretensioner, only specified contact points,
plugs, and wires are allowed to be used.
4. Before repairing the wire harness, make sure to eliminate any factor that might cause damage,
for example, the edge of a vehicle body part is too sharp, or the used electronics are damaged or
corroded.
5. Shielded wire should not be repaired, it must be replaced entirely once it is damaged.
6. Unless it is specified during the test, please do not use an analog multimeter to test the ECU and
sensor, instead use a high-impedance digital multimeter (internal resistance should be ≥10 kΩ) or a
vehicle multimeter for inspection.
7. When inspecting the connector with a digital multimeter, take the waterproof rubber cover off the
connector, and tightly insert the test pen along the connecting terminal. Don't use too much force, as
to avoid cracking the connector.
Circuit inspection steps
The principle of troubleshooting is to confirm the "possible cause". Once the possible cause is confirmed, the
components that need to be inspected are limited to the components that are related to the possible cause. The
confirmed possible cause should be based on theory and be supported by facts, but not just by intuition. If
one tries to solve the problem but does not adopt the proper troubleshooting steps, it may make the problem
worse. Then the possible cause not only can't be confirmed, but also maintenance can't be performed properly.
Troubleshooting should adhere to the four steps below:
1. Observe the symptoms carefully, inspect if there is anything else abnormal, and record it.
2. While confirming the possible causes, study the circuit diagram carefully, and regard it as a whole
system in order to understand the circuit. Thorough knowledge of switches, relays, and other
electronic components is obligatory for proper analysis.
3. Inspect and eliminate the problems one by one until the cause is found.
4. After the malfunction is fixed, make sure to check if the inspected system is working properly, and also
check if the maintenance may have caused any new problems.
Fuse Box
Cab No.1 fuse box
Reserve
Lamplet
Reserve
Reverse lamp
Combination
Front wiper
brake lamp
CD player
Rearview
door lock
Cigarette
Reserve
Reserve
Reserve
Reserve
lighting
Interior
Charge
Airbag
central
lighter
mirror
meter
Reserve
B C
A
E F
D
H
Eilte
(Elite)
Connected dashboard's
wire harness E Connected dashboard's
wire harness H
G01 G03
G02
G04
G05 G06
G07
G08
G10
G09
Reverse sensor
ECU
Throttle
position sensor
ABS ECU
Camshaft
position sensor
Front wiper
Front motor
combination
lamp RH
Acceleration pedal
Diagnostic port
Glove box lighting Blower
Window regulator
switch
Window regulator
Door lock Door and window motor
Middle & low Middle & low
motor main switches
tone speaker tone speaker
Front door Rear door
Rear
combination
Rear lamp RH
combination lamp LH
Fog lamp
License plate lamp
Reverse sensor
probe
Oil pump motor
Reverse sensor ECU Parking brake switch
Rear wheel speed sensor RH
nozzle
nozzle
cylinder
nozzle
G Rear oxygen sensor Connected front washer motor
ba ene Connected reverse switch
Connected 2nd
Connected 1st
S tte rat
cylinder injection
injection nozzle
Connected 4th
ry or
Connected 3rd
ba tar po co
cylinder injection
Connected front wheel
cylinder injection
tte ter sit nn
speed sensor LH ry co ive ec Connected inlet Connected phase sensor
po nn t to temperature pressure Connected front wheel speed sensor RH
sit ec
iv t t sensor connected
e o electronic throttle
Connected
ignition coil Connected knock sensor
Connected engine speed sensor
Left ground Connected starter field coil
Right ground
Connected speed sensor
Front tweeter LH
Connected glove box lamp
Left combination switch (light)
Front tweeter LH
Rear window
regulator RH
Rear medium woofer RH
Rear window regulator LH Rear window
regulator switch RH
Rear wheel speed sensor RH
Ground point A
Capacitor Rear door lock motor RH
Rear door lock motor LH
Ground point B
Rear interior dome lamp
C01
C03
(Luxury) (Luxury)
(Elite) (Elite)
(Comfort) (Comfort)
Connector 2
C04
(Comfort) (Comfort)
(Elite) (Elite)
(Luxury) (Luxury)
C05
(Elite) (Elite)
Connected cab fuse box C-14 Connected dashboard
wire harness
C06
Connector 3
C06
(Elite) (Elite)
Connected cab fuse box D-16 Connected dashboard wire harness
C07
(Elite) (Elite)
Connected cab fuse box E-8 Connected dashboard wire harness
C08
Connector 4
C09
(Elite) (Elite)
(Comfort) (Comfort)
(Luxury) (Luxury)
Connected dashboard Connected engine
wire harness A compartment wire harness A
C10
(Luxury) (Luxury)
(Comfort) (Comfort)
Connector 5
C10
(Elite) (Elite)
Connected dashboard Connected engine compartment
wire harness B wire harness B
C11
C12
C13
(Elite) (Elite)
Connector 6
C13
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
(Elite) (Elite)
Connector 7
C15
(Comfort)/(Luxury) (Comfort)/(Luxury)
Connected dashboard Connected vehicle body
wire harness A wire harness A
C16
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
Connected dashboard Connected vehicle
wire harness B body wire harness B
C17
Connector 8
C18
(Elite) (Elite)
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
Connector 9
C20
(Elite) (Elite)
C21
(Elite) (Elite)
Connector 10
C21
Connector 11
C24
C25 C26
Theft
deterrent
ECU 6
Main relay
Pin
position
Shift
position
Ignition switch
ABS motor 40A
Starter relay
Generator
Starter
to engine ECU 51
to engine ECU 21
Airbag electric control module ABS electric control module
Airbag ECU housing hole location marks are signs showed on the housing
Connected brake
Airbag ECU (yellow) (Luxury, elite) lamp switch
Airbag ECU housing hole location marks are signs showed on the housing
Connected high
Airbag ECU (yellow) (Comfort) mounted brake lamp
To light brightness
regulator switch Connected central
control ECU #18
Connected coolant
temperature sensor
Fuel gauge
Tachometer
Brake fluid level switch
Speed sensor
Fuel sensor
Connected combination meter A Connected combination meter B Brake fluid level warning switch
Driver seat belt switch Connected parking brake switch Fuel pump, fuel sensor Speed sensor Coolant temperature sensor Engine speed sensor
Blower relay
To flasher relay
Defroster relay
Blower relay
Manually air
Off On
On Off
Defroster switch
Electric AC controller
Speed adjustive
Blower resistance
Mode damper actuator Cycle damper actuator Temperature regulation
damper actuator
Right outer electric rearview mirror Left outer electric rearviewmirror Front passenger seat Connected speed adjustive resistance, Connected rear Connected cycle damper Connected blower regulate Connected temperature regulation
defroster (Elite) defroster (Elite) belt switch blower (Comfort, luxury) window defroster actuator (Elite) module (Elite) damper actuator (Elite)
Electronic rearview mirror & CD system
Connected parking
lamp relay
Steering wheel
switch spiral coil
Fold switch
Reset Upper Left
Fold Left Off
Shift switch
Off Right
Foldable motor
Front tweeter LH Front tweeter RH
Vehicle Body Electronic System
Left mirror adjustment motor Front medium Rear medium Rear medium Front medium
woofer LH woofer LH woofer RH woofer RH
Sunroof switch
Front
Rear washer
Engine
Inlet temperature
pressure sensor
Connected
Connected generator
combination meter
Connected ABS
Connected airbag
Fuel pump relay
IG1 relay
Ignition coil
Ignition coil
Injection nozzle
Compressor clutch
Phase sensor
Canister control valve
Condenser fan
Rediator fan
Scanner
Coolant temperature sensor
Starter relay 86
AC pressure switch
Connected AC switch
Engine speed sensor
Rear oxygen sensor Front oxygen sensor Inlet pressure & tem. sensor Coolant temperature sensor Accelerator pedal module Electronic throttle AC temperature Knock sensor Engine speed sensor
sensor
1st cylinder injection 2nd cylinder injection 3rd cylinder injection 4th cylinder injection Connected oil Canister control
nozzle nozzle nozzle nozzle pressure switch valve
Connected accelerator pedal Front oxygen sensor Rear oxygen sensor Knock sensor Condenser fan motor Connected brake lamp switch
Jam protection window regulator control system Non jam protection window regulator control system
Terminal
Window relay
Off Off Off
Airbag signal
switch RH
switch RH
switch LH
Door lock is Rise Rise Rise Rise
switch RH
switch RH
switch LH
locked
Stationary Off Off Off Off Descend Descend Descend
state
Door lock is
on Descend Descend Descend Descend
Lock signal
Unlock
signal
Terminal
Location
Trunk motor
Front door lock LH Lock Front door jam Front door jam Rear door jam Rear door jam
Unlock protection motor LH protection motor RH protection motor LH protection motor RH
Front door lock
motor RH
Front door lamp switch RH
Front door lamp switch LH
Rear door lamp switch RH
Rear door lamp switch LH
Connected central door Window regulator mainly switch, central door lock mainly Window regulator mainly switch, central door lock Connected front passenger side Front window regulator switch RH (Elite) Connected front window regulator switch Connected front window regulator switch Connected rear window regulator switch
lock controller (white) control switch (comfort, luxury) mainly control switch (Elite) central door lock switch RH (comfort, luxury) RH (comfort, luxury) LH (Elite)
Connected front Connected front Connected rear Connected rear Connected rear Rear window regulator RH Front door lamp Front door lamp Rear door lamp Rear door lamp Front door lock motor LH Front door lock motor RH The key is inserted into the
window regulator LH window regulator RH window regulator LH window regulator RH window regulator LH switch LH switch RH switch LH switch RH detected switch
Connected rear window regulator LH Connected rear window regulator RH (Elite) Connected rear window Front window regulator LH Front window regulator RH Rear door lock motor LH Rear door lock motor RH Back door lamp ON Back door open switch Back door lock motor
(comfort, luxury) regulator RH (comfort, luxury)
Connected combination
meter A18
Connected central
control ECU #8
Connected central
control ECU #1
Connected central
control ECU #2
Connected central
control ECU #14
Flasher relay
ON signal lamp
Pin
taking
Headlight vertical switch
position
Off High Front parking Left turn
signal lamp
Lamp beam lamp RH
Front fog
lamp Off Low
beam
Rear fog
lamp Over- Rear parking Front turn
taking lamp LH signal lamp RH
Right headlight adjustment motor
High pitched Electric horn
Alarm switch
High beam indicator
Location
Left headlight
Front fog lamp LH
On
Rear fog lamp LH
Front fog lamp RH Front fog lamp LH Front combination lamp RH Front combination lamp LH Rear combination lamp LH Rear combination lamp RH Rear defroster & alarm switch Connected rear fog lamp RH Connected rear fog lamp LH Connected left headlight Connected right headlight Connected right license
vertical adjustment motor vertical adjustment motor plate lamp
Left outer electric rearview mirror Right outer electric rearview mirror Left combination switch (light) Horn switch High pitched horn Low pitched horn Connected left Connected light brightness Connected headlight vertical
(left turn signal lamp) (right turn signal lamp) license plate lamp regulator switch adjustment switch
Auxiliary system
To diagnostic port
To ECU 29#
To ECU 71#
Buzzer
Detector No. 2
Detector No. 3
Detector No. 4
Right reverse lamp
Left reverse lamp
Electrical Accessories
Reverse Sensor
Reverse sensor operation (ultrasonic wave distance-measurement)
Sound is a kind of wave. Sound frequency that can be heard by human beings range from 20 Hz to 20 KHz.
Those that exceed 20 KHz are called ultrasonic waves. Since an ultrasonic wave is also a kind of sound, its
velocity in the air also equals the sound velocity of 340 m/s. Part of the ultrasonic wave will rebound when it
encounters an obstacle. So the distance between the sound source and the obstacle can be calculated according
to the sonic speed and the time difference between the emission of sound and the receipt of sound.
Reverse sensor system composition
This system is composed of a reverse sensor head unit (ECU), four sensors (SENSOR) and an external buzzer.
Black (-)
Inductor L
Inductor CL Controller
Inductor CR
Inductor R
Plug
Definition Remark
number
1 GND Ground wire of the head unit's power supply
2 BUZZER - Buzzer ground wire
3 DATA Reserve display data wire
4 GND Reserve buzzer ground wire
5 L (SENSOR) Inductor signal wire (four inductors)
6 CL (SENSOR)
7 CR (SENSOR)
8 R (SENSOR)
9 GND Inductor ground wire (four inductors)
10 GND
11 GND
12 GND
13 GND
14 VCC Reserve display power wire
15 BUZZER + Buzzer power wire
16 + 12 V Head unit power wire
A Zone: When it is a long sounding alarm, the obstacle is within the distance of (0-40±4) cm.
B Zone: When the alarm frequency is an 8 Hz continuous sound, the obstacle is within the distance of
(40±4-90±4) cm.
C Zone: When the alarm frequency is a 4 Hz intermittent sound, the obstacle is within the distance of (90±4-
150±4) cm.
Areas of importance
1. When placed near a car equipped with the same system or a similar system (having been activated)
offered by other suppliers, though this system may receive interference, it can still operate normally.
2. When the relative rate of travel between the obstacle and the car is lower than 1 m/s, this system will
operate as normal. When reverse speed is accelerated, the sensing accuracy of the reverse system
may decrease. A low speed of 6 km/h is suggested.
3. When it is a long sounding alarm, please stop the car at once, because there may be an obstacle
within 40cm.
4. The inductor precision level is high. It will be very difficult to return it to normal after opening the inner
portion.
5. The reflected signal may not be received due to the location, angle, size, or material of the object.
Furthermore, the reflected signal in a complex environment may not be accurate.
System malfunction causes and solutions
1. A lack of power or a low supply voltage may lead to the abnormal operation of the reverse sensor
system. Under such circumstances, check whether the supply battery voltage is normal, or whether
the ignition switch connector and other connections are accurately placed.
2. If the power supply is on, irregular system operation may be caused by the incorrect position of the
socket. Under such circumstances, correctly re-place all the sockets.
3. A long sounding alarm from the buzzer may be caused by the inductor coming off, incorrect installa-
tion, damage to the inductor, or detecting the car or ground. Under such circumstances, please repair
or replace the sensor.
4. Incorrect indication of an obstacle's distance may be caused by abnormal battery voltage, inaccurate
socket positioning, or inductor connection damage. At this time, check whether the battery voltage
is normal, and whether the inductor connection is connected to the exhaust pipe and muffler. It is
suggested that the system be turned off and all the sockets be correctly placed.
Combination Meter
If something is wrong with the meter, check the relevant component and circuit according to the connector defi-
nition. If the failure still cannot be eliminated, check whether the instrument itself has malfunctioned in the fur-
ther steps. The following diagram shows the view of the meter connector and its number.
10 1
1 10
11 22
22 11
Controller plug front view
Controller socket front view
The door lamp signal and side window signal uses a triode transistor emitter open-drain output.
No connection
Power supply ON diagnostic (12 V)
Connected car key ON wire
Power supply negative pole
Trunk door motor
Ground
Trunk door switch
Power supply positive pole (12 V)
Door lamp indicator + 12 V
No connection
Door lamp signal 10 kΩ
Manual lock signal
Manual switch lock rocker switch
Manual unlock signal
Front left door diagnostic Driver side door switch
Front right door diagnostic
Front right door switch
1. Headlight
Connected to the positive wire of the vehicle's headlight, this wire will hold 12 V when the headlight is turned on.
2. Right turn signal lamp
Connected to the positive wire of the vehicle's right turn signal lamp, this wire will hold 12 V when the wire is in use.
3. Sunroof positive output (reserve)
Connected to one end of the wire package of the window lift relay, this wire will output 12 V when the key is
turned to the ON position. After the key is pulled out, the wire will maintain 12 V for 60 seconds.
4. Side window negative output
Connected to the negative trigger wire of the side window remote controller, this wire will output a negative
signal for 10 seconds after the door is remotely locked by the system.
5. Central door lock unlocking output
Connected to the unlock wire of the central remote controller actuator, this wire will output 12 V when
unlocking.
Power Windows
The GWFLORID electric power window actuator consist of a motor and module. Its functions include: jam
protection, centralized control rise, soft-stop, characterized by easy control, long life, etc.
The functions of electric power window actuator
1. Jam protection
Power windows have an jam protection function when manually or automatically rising after it has been
initialized. There is no limit on the amount of jam protections. When room temperature is 25±5 oC, wire
resistance 150 mΩ and 14.5 V working voltage, the jam protection force risen glass is less than 100 N. When the
window is manually or electrically rising, once it encounters a force greater than the jam protection force, the glass
will immediately stop rising and make the motor rotate in reverse. Reverse rotation distance is about 125 mm.
2. Centralized control rise
The central door lock controller provides four lifters with a low level signal. The power windows will close until
they are completely closed. This enables the two power window actuators to start separately, which can avoid
hitting peak currents if they start up at the same time. As long as the centralized controller's rising pin receives
the low level signal, the motor will close the window until it is completely closed.
3. Soft-stop
If the motor suffers from an impacting block when the window is rolled all the way up or all the way down, it
would shorten the power window actuator's use life. In order to avoid this, the soft-stop function must be used,
in which both manual and automatic rolling up and down should have this function.
(a) Soft close function:
When the window is about to get to the top, that is to say, when it's rising to the soft-stop point, the engine's
power will cut off to make the motor stop working, meanwhile the rising inertia will continue to roll the
window up to the top. The soft-stop point is about 2 mm under the top limiting position.
(b) When the window is about to lower to the bottom, that is to say, when it's lowering to the soft-stop point,
the engine's power will cut off to make it stop working, meanwhile the lowering inertia will continue to roll
the window down to the bottom. The soft-stop point is about 12 mm above the bottom limiting position.
(c) Zero position calibration: This position takes the top limiting position as the zero position. In order to
guarantee reliable and safer system operation while in use, the zero position will need constant calibration.
Manual calibration: When the window stops at the rising soft-stop position after rising for a period,
press the rise button so it will rise to the limiting position. Zero calibration is then complete.
Automatic calibration: After the motor runs forward and reverse more than 20 times, it will undergo
zero position calibration one time. That is to say, when it completely starts or stops operating, the motor will
be blocked one time. Currently, there is no soft close or start-up function. Zero position calibration is com-
pleted when the window is completely closed to the limiting position.
4. Motor locked protection
The control module will cut off the power supply to stop the motor from working within 250 ms of the locking.
5. Motor temperature protection
When the control module is powered on, the initial temperature of the motor is set at 40oC. There are two
temperature limits for the motor's thermal protection function. If the temperature of the coil exceeds the first
temperature limit (170oC), the motor will not respond to any new operation input, but it will still complete the present
operation. If the motor's temperature exceeds the first temperature limit during its operation, it will keep working until
the temperature of the motor coil reaches the second temperature limit (190oC), then the motor will not be limited by
the second temperature's threshold while reversing, so as to guarantee the safety of the users. Once the temperature of
the motor has lowered below the temperature limit, the motor will work normally.
6. Self-diagnostic protection function
So as to guarantee the system's reliability while improving the system's average non-failure time, self-diagnostic
protection measures are used: If the power supply voltage exceeds 16 V, the control module will close the auto-
rising function.
(a) Switch contact point adhesion:
If it is detected that the switch contact point adhesion has reached up to 10 m input instructions will no
longer be received. If later the switch contact is detected to be disconnected again, it's function will return
to normal.
(b) Relay contact point adhesion:
The power window actuator is controlled by two contact point relays.
After a shutoff command is sent to one of the relays, if the system detects that this relay is still on, then
the system will choose this relay contact point for adhesion. Thereupon, the system will send out another
command to make the other electric relay switch on as well, so as to guarantee the motor's power supply is
cut off. Before sending out any new input instructions, the software will first detect whether the adhesive
contact point of the relay has been released. If it has been released, then all the operations, including the
sleep pattern, will once again be executable. If the contact point is still adhered, then only operations
going in one direction have the possibility of execution (depending on which direction the relay contact is
adhered). Then soon afterwards, activate the contact point adhesion handling function again.
(c) Motor protection when the Hall element failed or magnetic ring damaged.
If the Hall element or magnetic ring has malfunctioned, the control module can not receive the Hall
element's signal. In this case, the control module will return to the state before basic initialization, which
means it can only rise about 45 mm at most, and it will not have the jam protection function. During
the process of a centralized control rise, re-initialization is prohibited. Once any switch is activated, the
window will stop moving.
Regulator components
Immobilizer System
Immobilizer system composition
This vehicle's engine immobilizer system consists of a theft deterrent ECU assembly, a theft deterrent coil as-
sembly, and two theft deterrent converter assemblies. The theft deterrent coil assembly is put on the head of
ignition lock cylinder, with the other end connected to the theft deterrent ECU assembly. The two theft deterrent
converter assemblies are separately installed inside the plastic handles of the two keys.
1. Position diagram
All the components of immobilizer system are assembled on the overall vehicle except for the theft deterrent
converter assemblies inside the keys. They achieve communication functions via the wire harness connections.
The following figure shows the position of each component in the overall vehicle.
LED
ON Battery - +
A4 A1
Ignition switch Ground Battery
A2
620 Ω
W wire
A8
LED Engine ECU
A3 R wire
A5
ANTA
B1
ANTB K wire Diagnostic
Coil B2 A7
GND
B3 scanner
not necessarily mean that engine start failure is due to a immobilizer system malfunction. The reasons for start-
ing engine failures are numerous, including factors like fuel, gas, fire, electricity, wires, etc. If the engine cannot
start, first check if the immobilizer system is working normally. This can be judged by looking at the flashing
theft deterrent indicator lamp which is located on the dashboard in front of the driver seat: Insert the key into the
lock cylinder and turn it to the "ON" position. If a legal key is used to start the engine, once the warning lamp is
connected to the ON end and the transponder is confirmed, the LED will remain unlit. Then when the ON end is
disconnected and the key is pulled out, the LED will shine for 0.25 s and darken for 4 s, as to act as a warning.
If an illegal key is used to start up the engine or there is something wrong with the system, the alarm indicator
lamp will shine for 0.25 s and darken for 4 s. If all is normal, then check the other parts of the engine. If abnor-
mal, first perform immobilizer system troubleshooting. A scanner can be used to judge if the immobilizer system
is working normally, but the precondition is that the scanner must be able to establish communication with the
theft deterrent controller.
1. If communication cannot be established, consider the following:
(a) Check whether the battery voltage is higher than 9 V
(b) Check whether the scanner plug is well contacted to the vehicle socket
(c) Use a multimeter to check whether the 7 pin of the OBD-II plug (diagnostic plug) is connected to the theft
deterrent controller's A7 pin
(d) Check whether the power supply of the theft deterrent controller is normal. (Use a multimeter to measure
whether the voltage of the theft deterrent controller's socket A1 pin and A2 pin is higher than 9 V)
(e) Then adopt the substitution method, which is to replace the theft deterrent controller to check if there is
anything wrong with the theft deterrent controller.
• If the failure is related to the theft deterrent controller, change it and initiate re-matching.
• If the failure has nothing to do with the theft deterrent controller, remove the electronic controller which
is connected to the alarm's K wire, such as the ABS controller, engine electrojet controller, airbag ECU
assembly, etc., as to ascertain if the present fault is caused by the wire harness connected with the theft
deterrent controller's K wire.
2. If communication can be established
Connect the scanner to the vehicle diagnostic port. Insert the key into the steering lock, and turn it to the "ON"
position, then select the scanner to check the immobilizer system's trouble code.
3. Security system troubleshooting
Investigate the problem and perform troubleshooting according to the trouble code on the scanner:
Trouble Code
Failure cause Troubleshooting methods
code significance
B1000 Theft deterrent Theft deterrent coil open 111 Check whether the theft deterrent coil's connecting plug and
controller circuit or short circuit. Theft the theft deterrent controller is well connected.
internal deterrent controller internal 222 Check whether the theft deterrent coil's wire harness plug is sliding
malfunction malfunction. or touching each other.
333 Remove the theft deterrent coil plug, and then use a
multimeter to check the resistance between the B1 and B2
pins. The normal resistance is about 5-30 Ω. If the resistance
is close to zero, that means the coil has been short circuited.
If the resistance is infinite, then it means the coil's circuit is
open. Measure the resistance between pins B1 and B3, and
B2 and B3, normally they are infinite. If the resistance gains
a certain value, then it means the coil is short circuited or
leaking electricity.
444 If there is nothing wrong with the coil, the next step is to
check the theft deterrent controller. Adopt the substitution
approach, replace it with a non-matched new theft deterrent
controller or an theft deterrent controller which has been
reset (please refer to the immobilizer system component
replacement). Insert the key into the ignition lock and turn it
to the "ON" position and read the trouble code. If there is no
9000 failure, it means the replaced controller has an internal
malfunction, and the new replaced controller must be re-
matched.
Trouble Code
Failure cause Troubleshooting methods
code significance
B3040 W wire failure, There is no response from 111 First check whether the two failures B043 and B0422
communication the electrojet controller after coexist. If so, first solve these two problems.
the theft deterrent controller 222 Check whether the 8-core plug of the theft deterrent
sends out communication controller is well connected. Check whether the wire harness
requests. connecting the A8 pin (N wire) of the 8-core plug and
electrojet is well connected, not short circuited, and has no
poor contact. Check whether the electrojet wire harness and
the connector is well connected.
333 Replace the alarm (please refer to the immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the alarm.
444 Replace the electrojet (please refer to immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the
electrojet.
B3042 W wire Short circuiting happens 111 Check whether the theft deterrent controller's 8-core plug
grounding between the W wire and the wire harness is touching each other.
ground 222 Check whether the wire harness which connects the 8-core
plug's A8 pin (W wire) and the electrojet is short circuited to
the ground.
333 Replace the alarm (please refer to immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the alarm
444 Replace the electrojet (please refer to immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the
electrojet.
B3043 W wire and Short circuiting happens 111 Check whether the theft deterrent controller's 8-core plug
power is short between the W wire (A8 wire harness is touching each other.
circuited pin) and the battery positive. 222 Check whether the wire harness which connects the 8-core
plug's A8 pin (W wire) and the electrojet battery positive has
short circuited
333 Replace the alarm (please refer to immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the alarm
444 Replace the electrojet (please refer to immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the
electrojet.
B3045 LED has a The wire harness (A3 111 Check whether the theft deterrent controller's 8-core plug
(vehicles short circuit or pin) connected to the theft wire harness is touching each other.
without open circuit, deterrent indicator (LED) 222 Check whether the wire harness which connects the 8-core
the theft LED operates has short circuited to the plug's A3 pin and the immobilizer indicator has short
deterrent abnormally ground. The wire harness circuited to the ground.
indicator (A3 pin) connected to 333 Check whether the wire harness which connects the 8-core
lamp will the immobilizer indicator plug's A3 pin and the immobilizer indicator has an open
show this (LED) has an open circuit. circuit.
trouble
code, but
it will
not affect
immobilizer
system
validation.)
Trouble Code
Failure cause Troubleshooting methods
code significance
B3048 The LED has The wire harness (A3 111 Check whether the theft deterrent controller's 8-core plug
a short circuit pin) connecting to the wire harness is touching each other.
or open circuit immobilizer indicator 222 Check whether the wire harness which connects the 8-core
to the power (LED) has short circuited to plug's A3 pin and the immobilizer indicator has short
supply the battery positive. circuited to the battery positive.
B3055 Transponder No transponder inside the 111 Check whether there is transponder in the key.
cannot key, transponder damage, 222 Check whether the theft deterrent coil is correct as specified
modulate and the theft deterrent coil in Article 1.
or without damage will lead to theft 333 Replace the transponder (please refer to immobilizer system
transponder deterrent controller receiver component replacement).
failure of the response
signal from the transponder.
B3056 No key The theft deterrent controller Re-learn the keys.
message is hasn't been matched or
stored in the has no key duplicate, thus
theft deterrent there is no transponder
controller identification code stored
inside the theft deterrent
controller
B3057 PIN is not The theft deterrent controller Set up the safety code and match the theft deterrent controller
recognized is new or has been reset. again.
by the theft
deterrent
controller
B3059 No request The theft deterrent 111 Check whether the theft deterrent controller's 8-core plug is
signal from controller doesn't receive well connected.
the electrojet the communication request 222 Check whether the wire harness connecting the A5 pin (R
controller is signal from the electrojet wire) of the 8-core plug and electrojet is well connected, is
received controller. not short circuited, and is not poorly connected.
333 Replace the alarm (please refer to immobilizer system
component replacement). Check whether the above failures
exists. If they do not, the fault most likely exists in the alarm.
444 Replace the electrojet (please refer to immobilizer system
component replacement). Check whether the above failures
exists. If not, the fault most likely exists in the electrojet.
B3060 Illegal key No transponder Use the scanner to carry out the "learning keys" function.
message is identification code stored in
received the theft deterrent controller.
B3061 The The transponder 111 Check whether the theft deterrent coil is correct as specified
communication can not establish in Article 1.
with the key is communication with the 222 Check whether the transponder is new or not matching.
interrupted theft deterrent controller, Rematch it if it is not matched;
the communication 333 If the transponder has been matched, make sure to check
is interrupted, or the whether the transponder has been changed, or the electrojet
communicating data is changed or reset
incorrect. The electrojet • If the transponder has been changed, then it cannot be used
key is not identical to the again, and must be replaced with a new one and then re-
transponder's. matched
• If the transponder hasn't been changed and only the
electrojet has been reset, then it only needs to matched again.
• If the transponder has not been changed but the electrojet
has been changed, make sure the replacing electrojet
is new or has been reset. If the substituted electrojet is
matched but not yet reset, then it must be replaced with a
new or reset one and then re-matched.
(b) Input the PIN code and the key matching instructions with the scanner
(c) If the PIN code is correct, after receiving the key matching instructions, transponder learning will be
complete
(d) Switch off the ignition switch
2. Check the key quantity:
Check the alarm's currently matched key quantity and matchable key quantity with the scanner.
3. Match the theft deterrent controller:
(a) Properly connect the engine ECU and the theft deterrent controller
(b) Input the PIN code and theft deterrent controller matching instructions with the scanner
(c) If the PIN code is correct, after receiving the theft deterrent controller matching instructions, matching will
be complete.
After theft deterrent controller matching is done, it needs to re-learn each key if the original key is still to be
used. If the original key will not be in use any more, then it needs to rematch the new key.
4. Match the engine ECU
(a) Properly connect the engine ECU and the theft deterrent controller.
(b) Input the PIN code and engine ECU matching instruction with the scanner.
(c) If the PIN code and instructions are correct, the matching process will be completed automatically.
5. PIN code scan-resisting strategy
From the matching process above, it's apparently that the PIN code is a security code for the matching process.
This code is passed to the vehicle owner in document format during the sales service. If it is lost accidentally,
the customer service staff can check the vehicle identification code stored in the theft deterrent controller with a
scanner, and then send it to the authorized staff in the factory to check the PIN code. In order to prevent someone
from illegally scanning the PIN code, it uses a forced time-delay method to prevent divulgence of information.
CD Player
CD player outside view
6 7 8
5 4 3
2 1
DVD Player
Head unit outside view
5 4 3
4 Microphone audio ground cable
5 Auxiliary left audio output
6 Auxiliary right audio output
2 1
7 Auxiliary audio ground cable
8 Power supply ground cable
Antenna
Navigator
Power amplifier
control
P.CONT
Green
Reverse shift switch
P.CONT
Pink
Reverse detect
REVERSE
Areas of Importance
1. When putting in a new compressor, adjust the new compressor's inner lubricant to make it the same
level as of the old compressor's.
2. When the air conditioner malfunctions, if the pipeline, condenser or evaporator is the source of the
damage leading to its replacement, just add model number RS20 professional lubricant 5-10 ml.
3. The compressor is a high speed operating component, the smallest impurity in the air conditioning
system can lead to the compressor's damage, therefore the entire air conditioning system must be
cleaned.
4. In order to avoid liquid damage to the compressor, pay careful attention when filling the refrigerant.
When the vehicle stopped, fill the liquid refrigerant from the high pressure side. When in operation, fill
the liquid refrigerant from the low pressure side.
5. When undergoing maintenance, pay attention that the amount of refrigerant being added is 510±10 g.
Observe through the check glass to determine if there is sufficient new refrigerant charge.
Technical Parameters
Item Parameter
Model Rotary vane compressor (JSS-96TV4-4)
Discharge capacity 96 ml/r
Number of vanes 5
Normal rotational speed range 800-7800 r/min
Max. speed 8400 r/min
Weight 4.744 kg (without clutch)
Compressor Low pressure side 50 kg/cm2, High pressure
Pressure resistance
side 75 kg/cm2
Leakage ≤14 g/year
Direction of rotation Clockwise (looking from the clutch)
Refrigerant R134a
Lubricant number RS20
Lubricant capacity 200±10 ml
Min. pull-in voltage 7.5 V (12 V)
Pulley style 4PK810
Weight 2.1 kg
Clutch Rated voltage 12 V (DC)
Power consumption ≤45W (20oC DC 12 V)
Static friction torque ≥40 N·m
Pulley diameter φ110 mm
Coil resistance (3.5±5%) Ω
Operating temperature On / Off (130±5)oC/(150±5)oC
Thermal protector
Rated voltage, current 16 V, 5 A
Troubleshooting
Failure Symptoms Cause analysis
Air con- Compressor Blown fuse, compressor relay damaged
ditioning does not work Pressure switch contact broken, short circuited, or open circuit
system fails Compressor electromagnetic clutch open circuit
to produce Switch burnt out
cold air Main relay burnt out
Clutch slips
Compressor belt broken or loose
Compressor failure
Insufficient coolant, system pressure below 0.196 MPa
System pressure exceeds 3.14 MPa
Engine water temperature is too high
Clutch voltage is below 7 V
Compressor Compressor relay often open contact bond, system coolant leaks severely,
pulling in system has no coolant
Blower does not work
Blower has no wind Blown fuse
Blower motor brush damaged
Blower switch damaged
Wiring connector detached or open circuit
Speed regulation module damaged
Blower has no wind at high speeds, high speed relay damaged
Note: Blower's non operational process has a resistance value of 0, with a
open circuit resistance value of
The cool- Compressor operates Cooling system has ice blockage
ing system normally Thermistor or thermometer bulb malfunction
sometimes Abnormal A/C switch contact
works, some- Condenser blower damaged
times not
Compressor operates Clutch slides, clutch coil loose, clutch coil bad connection
abnormally
Insufficient Low wind volume Blower fan normal: air pipe damaged
cooling Cooling fan operates abnormally:
(1) Blower switch abnormal
(2) Supply voltage low
(3) Speed regulation module damaged
Downloaded from www.Manualslib.com manuals search engine
Air Conditioning System 205
Troubleshooting (Continued)
Failure Symptoms Cause analysis
Insufficient Wind vol- Compressor operates normally
cooling ume normal (3) High pressure side pressure is too low
(a) Low pressure pipeline damaged
(b) Low pressure pipeline blocked
(4) Low pressure side pressure is too low
(a) Evaporator frost
(b) Expansion valve is blocked
(c) Low pressure pipeline not clear
(d) Thermal speed adjustive resistance failure
(5) Low pressure side's pressure sometimes normal, sometimes negative,
moisture in the cooling system, and ice blockage
(6) Low pressure side's negative pressure, high pressure side's pressure too
low, blockage in the cooling system
(7) Low pressure side pressure too low, high pressure side pressure too high
(a) Inner portion of the condenser is blocked
(b) High pressure pipeline blocked
(8) Low pressure side pressure too high, high pressure side pressure too low
(a) Compressor leaks
(b) Compressor valve damaged
(9) Low wind volume of the condenser blower can lead to poor heat dissipation
Compressor operates abnormally
(1) Compressor internal malfunction
(2) Compressor belt loose, slides
(3) Electromagnetic clutch malfunction
(a) Supply voltage low
(b) Interference between the stator and the rotor
(c) Idling stabilizing amplifier malfunction
(d) Circuit broken, connector detached
(e) Bad switch and relay operation
(f) Short, open circuit
(g) Bad ground
Other causes
Dysfunctional Carriage seal
Cooling Noise too loud Belt loose or overly worn
system is Compressor's mounting bracket set screw loose
too noisy Compressor's mounting bracket damaged
Compressor's internal components are damaged
Refrigerant too little or empty
Clutch slip noise
Clutch bearing lacks oil or is damaged
Blower motor bearing damaged
Blower bracket broken or loose
Blower vane broken or loose
Blower vane rubs against other components
Troubleshooting (Continued)
Failure Symptoms Cause analysis
Heating sys- No or insuffi- Air conditioner blower malfunction
tem cient heating Blower relay damaged
Hot air duct blockage
Cooling water pipe blockage
Temperature change throttle actuator damaged
Coolant insufficient
Blower does Fuse blown or ill switch contact
not work Blower motor burnt out
Blower's high speed relay broken
Speed adjustive resistance damaged
Open circuit
Water leakage Heater water pipe degradation, poor connection
Over heated Fan's speed adjustive resistance damaged
Temperature change throttle actuator damaged
Defroster’s hot Mode cable damaged
air insufficient Vent is not in place
Air outlet blockage
Insufficient heating
Air duct mounting
Open circuit
Expansion valve
Condenser
Pipeline
Accumulating
dehydrator
Air conditioner
Compressor
Condenser fan
Air conditioner switch Hazard warning switch + rear defroster switch Blower + night lighting + safety instruction
Compressor
Entire outline structure (shown on the left)
Compressor Removal
1. Hoist the vehicle with a jack.
2. Remove the bottom mudguard.
3. Remove the compressor.
Compressor Installation
Before installing, manually rotate the compressor several
circles, allowing each component in the relative motion to be
covered with lubricant.
Clearance between the compressor's auricular branch and
bracket should be less than 0.1 mm. If the clearance is too
big, fill the clearance with a washer.
1. Loosen the engine's adjusting bolt firstly, take down the
engine belt, and then change the compressor belt.
2. Fix the compressor bracket onto the engine body with
the bolts. The bracket must be fastened tightly with suf-
ficient intensity. Fix the compressor bracket onto the
engine with four M10 ×1.25 (Q1461030 FD) bolts and
a tightening torque of 45±5 N·m, and then install the
compressor onto the bracket with a tightening torque of
22±3 N·m.
3. Take off the suction and exhaust cap. Select the
Suction port (S-end) size Exhaust port (D-end) size suction duct and exhaust duct that matches the size
C-C B-B of the suction and exhaust port to connect with each
2:1 2:1 other (size of suction and exhaust port shown in the
diagram). Then tighten the coupling bolt.
Engine pulley
4. Put the 4PK850 type compressor belt onto the pulley,
and then adjust the bracket to make the belt reach the
specified tension. That is, if a force of 100-120 N is
Water pump pulley
Tensioner pulley used on the belt, deformation of the belt is 8-10 mm.
Steering
pump pulley
Electromagnetic Clutch
Clutch composition
Electromagnetic clutch consists of an armature, a solenoid,
and a pulley.
Areas of importance during clutch usage
Because the joint of the electromagnetic clutch
operates under high speeds, separation-joint marks on
the pulley and armature are completely normal, and do
not harm clutch usage.
The clutch's operating voltage must be consistent with
the specified voltage rating. Too high or too low will
affect its normal usage.
The clearance between the coil and the pulley is
very important. If too big, the effect of the magnetic
field reduces. If too small, the high speed pulley rubs
against the fixed coil, causing the clutch to burn.
The clearance between the armature and the pulley
is also very important. If too big, it leads to insufficient
clutch pull-in force. If too small, it may cause armature
damage.
Clutch removal
1. Seize the clutch's triangular piece and secure the
clutch's armature with a clamp. Then take down the
inner hexagon lock screws of the main shaft with an
inner hexagon spanner.
2. After removing the lock screws, manually grasp the
triangular piece and take out the armature, at the same
time remove the clamp spring with the circlip pliers.
Clutch Installation
1. Install the solenoid coil at the place pressing up against the head cover's end surface and pay atten-
tion to insert the dowel pin of the solenoid coil into the bottom hole of the head cover. Put the retaining
ring into the groove with circlip pliers, and press the solenoid coil's connecting wire onto the pressing
line plate on the head cover with a SST.
2. Put the compressor on a specially designed fixture or platform, with its head cover facing upwards.
Press the pulley into the head cover shaft, and put the pulley bearing's retaining ring into the groove
with circlip pliers.
3. Install the armature onto the main shaft's spline and seize the clutch's triangular piece with a clamp.
Then tighten the inner hexagon lock screws and washers with a torque wrench. Screw torque should
be between 150-180 N·m. After installation is done, make sure to check if the clutch's pulley and
armature are able to operate freely, and also check the clearance between the pulley and armature,
which should be 0.3-0.6 mm.
Low pressure
High pressure Vacuuming and Charging Refrigerant
Manifold gauge
Blue Initiate vacuum pumping by using the manifold pressure
Low pressure Red gauge connected to the air conditioner (compressor) pipeline
pipe
and vacuum pump. When the vacuum pumping starts, open
Quick coupler the manifold pressure gauge's high and low pressure valve,
High pressure pipe
and open the vacuum pump's end surface valve (if equipped),
Vacuum pump Quick coupler then press the "ON" button to start the vacuum pump, and let it
run for at least 20 minutes. When the manifold pressure gauge
shows -760 mmHg or lower, close the high and low pressure
valve, and press the switch to turn off the vacuum pump.
Charge refrigerant
After verifying the system's air tightness, connect the
refrigerant tank (or gas cylinder) and yellow air supply hose
Close head. Connect the yellow air supply hose's other head with
Air purge the injection port in the middle of the manifold pressure
Red gauge. Ensure the refrigerant tank and air supply hose's nut
Yellow is tightly connected, then open the refrigerant tank's valve.
At this time, the high and low pressure valve is closed. Use
a tip shaped screwdriver or similar instrument and press
Blue the valve core at the side port for 1-2 s, then expel the air
Refrigerant tank
between the air supply hose and manifold gauge.
Airbags
Areas of Importance
1. While performing maintenance on the SRS airbag, make sure to work in accordance with this
chapter's steps and notes.
2. Be sure to use the specified test apparatus and SST (Special Service Tools) which are mentioned in this
chapter.
3. While performing maintenance on the following mentioned components, if there is any problem with a
component, be sure to replace it with a new one.
• Airbag ECU assembly.
• Clock spring assembly.
• Driver side airbag assembly.
• Front passenger side airbag module.
• Driver side preload seat belt.
• Front passenger side preload seat belt.
• Airbag wire harness.
4. While performing maintenance, please disconnect the battery's negative terminal connector, and then
after waiting for 60 s, commence operation. Furthermore, wrap up the removed negative terminal with
insulating tape.
After the battery power is cut off, the capacitor in the airbag ECU will still maintain a set amount of electrical
energy. If used without waiting a sufficient amount of time, it may lead to serious injury and accidents due to
the airbag's faulty deployment.
5. When painting the vehicle, excessive heat may influence the components, in which case the SRS-ECU,
airbag module, clock spring, etc., should first be removed and set aside.
Use a diagnostic scanner to clear the trouble code after the SRS airbag is repaired, as to ensure the warning
lamp will continue to work normaly.
Diagnostic Scanner
Instrument Name Application
X-431 diagnostic scanner Check the system malfunction
of the SRS airbag system and
clear the ECU trouble code.
Troubleshooting
Basic processes of the malfunction diagnostic
There are two SRS-ECU malfunctions types classified by time: current malfunction and history malfunction.
The malfunction types categorized by property are: external malfunction and internal malfunction.
Current malfunction trouble codes and history malfunction trouble codes may exist at the same time. External
malfunction trouble codes can be eliminated with a diagnostic instrument, but the internal malfunction trouble
codes cannot be cleared unless the SRS-ECU is changed.
Caution: After installing a new SRS airbag system electronic control unit, the airbag system warning
lamp will remain on for 6-7 s when the ignition switch is set to the ON position. This indicates that
the SRS airbag is operating properly. At this point, the system does not need to be inspected and
repaired. Aside from this case however, the system should be diagnosed and repaired.
Malfunction judgment
1. Malfunction record (trouble code storage)
After the ECU performs the diagnostic test cycle in order to verify a malfunction, the SRS-ECU will store the
relevant code, the initial detection time, the final detection time, and the number of times it occurred in the
EEPROM.
The SRS-ECU can store 16 codes at most.
2. SRS-ECU approved trouble codes
Trouble Possible
No. Malfunction introduction Type code
code removal
(Front passenger side preload seat belt), connected to the
1 03H 01H Removable
power supply
(Driver side front row preload seat belt), connected to the
2 03H 02H Removable
power supply
(Driver side airbag assembly), connected to the power
3 03H 03H Removable
supply
(Front passenger side airbag assembly), connected to the
4 03H 04H Removable
power supply
5 (Front passenger side seat preload seat belt), grounded 02H 01H Removable
6 (Driver side front row preload seat belt), grounded 02H 02H Removable
7 (Driver side airbag assembly), grounded 02H 03H Removable
8 (Front passenger side airbag assembly), grounded 02H 04H Removable
(Front passenger side preload seat belt), resistance too
9 01H 01H Removable
high or open circuit
(Driver side front row preload seat belt), resistance too
10 01H 02H Removable
high or open circuit
(Driver side airbag assembly), resistance too high or open
11 01H 03H Removable
circuit
(Front passenger side airbag assembly), resistance too
12 01H 04H Removable
high or open circuit
(Front passenger side preload seat belt), resistance too
13 0CH 01H Removable
low or short circuit
(Driver side preload seat belt), resistance too low or short
14 0CH 02H Removable
circuit
(Driver side airbag assembly), resistance too low or short
15 0CH 03H Removable
circuit
(Front passenger side airbag assembly), resistance too
16 0CH 04H Removable
low or short circuit
Power supply voltage is out of range (high voltage or low
17 12H 42H Removable
voltage)
18 Power cord contact dysfunctional 11H 42H Removable
Warning lamp fault - connected to the power supply or
19 03H 40H Removable
bulb is short circuited
20 Warning lamp fault - grounded or open circuit in filament 02H 41H Removable
21 Configuration error 06H 44H Removable
Internal malfunction 0DH >80H Irremovable
22 Replace
airbag ECU
Trouble code transmission is completed the SRS-ECU outputs through the maintenance program's
serial data interface to the specified diagnostic instrument (X-431 diagnostic scanner).
3. Internal malfunction
The microcontroller can detect the following items not only when starting up detection, but also during the
diagnostic detection cycle.
(a) The ignition circuit triggers the transistor: The high-end transistor will be detected not only when starting up
detection but also during the diagnostic detection cycle. However, if a short circuit on the power supply causes
a malfunction, and the low-end transistor is opened while malfunctioned, the low-end transistor can only be
detected when starting up detection, as to avoid faulty execution.
(b) Ignition voltage is provided by a pressure increase converter.
(c) Acceleration sensor performs self-detection when starting up detection.
(d) Allowed offset range of the acceleration sensor during a diagnostic cycle.
(e) Microcontroller includes AD converter, ROM, RAM, etc.
(f) Security sensor status.
Caution: There is a short-circuiting bar inside the squib circuit connector. When the connector is not
connected, the short circuit happens between the squib circuit's terminal (+) and terminal (-), as to
avoid faulty deployment caused by static electricity. When the connector is bad and the short-circuiting
bar is connected, the fault symptom may not be eliminated.
4. Clear the trouble code
When the X-431 diagnostic instrument receives the "Clear the trouble code" order sent through the serial inter-
face, the trouble code inside the ECU will be cleared. However, if an internal trouble code is recorded or has a
collision record, it will not carry out this order.
(a) Malfunction status display.
When the working voltage is supplied to the SRS-ECU through a battery, the SRS-ECU will light the warning
lamp to inspect the light bulbs. During the initialization stage, the warning lamp will remain on for 6-7 s, and
in order to inform the driver that the system has a malfunction, the warning lamp will continue to remain on
after the working voltage is supplied. If the history trouble code’s quantity is less than 16, the warning lamp
will remain lit for 6-7 s after turning the ignition on and then turn off automatically. If the history trouble code’s
quantity is 16 and the current malfunction appears, it will be recorded and the first history malfunction record
will be automatically removed.
(b) Malfunction indicator.
When the system has malfunctioned, the warning lamp will be always on.
A displayed or history malfunction can only be reset by service personnel. A SRS-ECU internal malfunction or
malfunction’s "collision record" cannot be reset. In this situation, the SRS-ECU must be replaced.
(c) Microcontroller - independent warning lamp is lit.
The controller has a self-diagnosis function. If the inner controller malfunctions, the warning lamp will always
be on.
(d) If the airbag warning lamp is always on, please inspect it according to the following steps.
The first step of inspecting any of the malfunctions is to detect the malfunction’s position with a scanner. Then
carry out the inspection using the corresponding part’s inspection method. If the scanning result is an internal
malfunction or having to do with airbag execution, the SRS-ECU can be directly replaced.
Diagnostic procedures
While performing the first malfunction detection, it is suggested to wiggle the wire harness and plugs to check for
intermittent or poor contact. If there is, please check whether the plugs, terminals, and the wire harness are connected
properly and undamaged. If the above mentioned problems do not exist, please take the following steps.
Steps Inspection Operation
Detect other wire harness and instrument cluster indicator Set the ignition switch to the LOCK
lamps Yes position, and then proceed to the
• Set the ignition switch to the ON position next step
1
• Are other warning and indicator lamps on? Detect the instrument cluster's
No power supply system and the
grounded system (fuse)
Inspect the light bulbs Go to the next step
Warning:
Incorrect airbag system component operation will cause the
Yes
airbag and preload seat belt to opened accidentally, which
may cause serious injuries. Please read the airbag system
services warning before working on the airbag components
2
• Set the ignition switch to the LOCK position Replace the combination meter
• Disconnect the battery's negative cable and maintain for at
least 60 s
No
• Remove the combination meter
• Check whether the two corresponding pins of the airbag
warning lamp are conducting
Detect the wire harness connection between the ECU unit and Yes Go to the next step
the instrument cluster
Replace the wire harness
• Set the ignition switch to the LOCK position
3 • Disconnect the battery's negative cable
• Disconnect the instrument cluster plugs No
• Check whether the warning lamp's corresponding circuits
are conducting
Diagnostic procedures
When starting inspection, please first use the specially designed diagnostic instrument (X - 431 diagnostic scanner)
and the ECU to diagnose the communication and determine the causes of malfunction. If communication fails,
please perform the following inspections
Steps Inspection Operation
Examine the battery
• Check the battery voltage Yes Go to the next step
1
• Is the voltage higher than 9 V?
Battery power supply
Examine the charging/discharging system, and then go to step No is insufficient
5
Examine the conducting state of the wire harness between the
ECU unit and combination meter
• Set the ignition switch to the LOCK position Yes Go to the next step
• Disconnect the battery's negative terminal
• Open the dashboard base
2
• Disconnect the instrument cluster connectors
• Connect the battery's negative
• Set the ignition switch to the ON position Check the circuit, and then
No
• Check whether the corresponding connector terminal's go to step 5 after it is fixed
voltage is 12 V (power supply and meter connection)
• Set the ignition switch to the LOCK position Yes Go to the next step
• Check if the meter connector's corresponding terminal and
3 Repair or replace the wire
diagnostic interface's corresponding terminal are conducting
No harness.Then go to step 5
(diagnose the K wire's two ends)
Be sure to disconnect the battery's negative cable and
maintain for at least 1 min Yes Go to the next step
• Disconnect the ECU connector
4 • Disconnect the instrument cluster plugs
• Are the ECU connector terminal 25, 10, 46, and instrument Replace the wire harness,
No
cluster's connectors conducting? and then go to step 5
Remove the ECU to check whether the terminal is in good Yes Replace the ECU
5 condition. Is the short-circuiting bar broken? Reconnect the ECU connector,
No
and then go to the next step
4. Internal malfunction
Type SRS airbag system unit internal malfunction
code 0D
Trouble
code >80
Detecting Warning
conditions • This malfunction's diagnosis requires a trouble code not to be shown prior to inspection. Use a DTC
to perform inspection. Performing this malfunction detection might cause operator injury or system
damage due to incorrect operation. Therefore, before inspection, please properly prepare.
• SRS airbag system electronic control unit circuit internal malfunction
Possible
SRS airbag system unit internal malfunction
causes
Operation Replace the SRS airbag system unit. Refer to airbag system and SRS airbag system unit removal and installation
5. Power supply
Trouble The SRS airbag system electronic control unit's power supply voltage is out of the standard range
code 12
and 42
Detecting Warning
conditions • This malfunction's diagnosis requires that a trouble code not be shown prior to inspection. Use a
DTC to perform inspection. Performing this malfunction detection might cause operator injury or
system damage due to incorrect operation. Therefore, before inspection, please properly prepare.
• Voltage of the SRS airbag system unit's 5 and 6 connector pins is lower than 9 V
Diagnostic procedures
Steps Inspection Operation
Inspect the battery Yes Go to the next step
1 Measure the battery voltage Battery's voltage too low. Inspect
Is the voltage higher than 9 V? No
the charging/discharging system
Inspect the wire harness between the battery and the fuse box
Yes Go to the next step
Take out the fuse box making sure not to loosen the connector,
2 and set the ignition switch to the ON position
Inspect and repair
Is the fuse box's two corresponding terminal stub voltage higher No
the wire harness
than 9 V?
Diagnostic procedures
Steps Inspection Operation
Inspect the clock spring
Warning
If not handled properly, the airbag module may deploy Normal Go to the next step
and cause serious operator injury. Therefore, before
maintenance, please read the maintenance warnings
1 carefully. Replace the clock spring
See also airbag system maintenance warning See also airbag system and clock
Are the components relating to the clock spring work- Abnormal spring removal/installation
ing normally? (The relationship between each pin is
normal, no unnecessary short or open circuit, etc.).
Check whether the malfunction is on the driver side Replace the driver side
airbag module or other components airbag module
Replace with a good DAB module Yes See also airbag system and
Install the battery's negative cable driver side airbag module
2
Set the ignition switch to the "ON" position removal/installation
Is the trouble code still displayed? Or can it be cleared?
No Go to the next step
Diagnostic procedures
Steps Inspection Operation
Is the vehicle equipped with a front passenger side Yes Go to the next step
1
airbag module? No Line fault, inspect the wire harness
Check the front passenger side airbag module connec- [Current trouble code]
tor warning Go to the next step
• If not handled properly, the airbag module may deploy Normal [History trouble code]
and cause serious operator injury. Therefore, before Go to the next step
maintenance, please read the maintenance warnings
carefully.
See also airbag system maintenance warning
2 Set the ignition switch to the "LOCK" position
Loosen the battery's negative cable and wait for at least
1 min
Abnormal Replace the wire harness
Take the glove box off
Loosen the front passenger side airbag module connec-
tors
Is the front passenger side airbag module connector
normal?
Yes Go to the next step
Check whether the malfunction is on the front passen-
ger side airbag module or the other components
Replace the front passenger side
Connect a good module with the front passenger side
airbag module
3 airbag module connector's A and B terminal studs
No See also airbag system and front
Connect the battery's negative cable
passenger side airbag module re-
Set the ignition switch to the "ON" position
moval/installation
Is a trouble code displayed?
Inspect the wire harness between front passenger side [Current trouble code]
airbag module and SRS airbag system electronic con- Replace the SRS airbag system
trol unit unit
Set the ignition switch to the "LOCK" position See also SRS airbag system
Loosen the battery's negative cable and then wait for at Normal SRS airbag system unit removal/
least 1 min installation
Take the steering column housing off [History trouble code]
Loosen the clock spring connector Fault diagnosis complete
Loosen the driver side and front passenger side airbag
module connectors
4
Take out the dashboard base
Loosen all the SRS airbag system unit connectors
Inspect the circuit between the connector terminal stubs
of SRS airbag system electronic control unit and front
passenger side airbag module, and check if it has the Abnormal Replace related wire harness
following problems
• Ground
• Short connected with the power supply
• Open circuit
Is the related wire harness normal?
3. SRS-ECU
(a) Inspect whether the SRS-ECU housing and bracket are
sunken or depressed, cracked, deformed, etc.
(b) Inspect for broken connectors as well as deformed
terminals.
(c) Inspect the SRS-ECU bracket's installation status.
• Inspect whether the cover is sunken or depressed,
cracked, deformed, etc.
• Inspect for broken connectors as well as deformed
terminals and biting wire harnesses.
• Check whether the gas generator's housing is sunken or
depressed, cracked, deformed, etc.
• Inspect whether the arrow's direction is pointed towards
the front of the vehicle.
(d) Inspect the airbag module's installation status.
4. Inspect the driver side airbag module
5. Clock spring
(a) Inspect for broken connectors and protective tube and deformed terminals.
(b) Inspect for deformed housing.
6. Steering wheel, steering column, and lower shaft components
(a) Inspect the driver side airbag module's installation status.
(b) Inspect the steering wheel for abnormal noise, and whether the clearance is normal.
7. Inspect the wire harness connectors (dashboard wire harness).
8. Inspect whether the wire harnesses are firm. Check for damaged connectors, and deformed terminals.
Warning label
The driver side, clock spring, SRS-ECU, and front passenger side airbag, all have warning labels, with the
caution areas shown by an image. While maintenaning and using the SRS airbag, please work in accordance
with the label.Furthermore, when a label becomes damaged or dirty, please replace it with a new one.
3. Driver side airbag module installation sequence (after steering wheel installation is completed)
(a) Install the horn's wire harness.
(b) Install the airbag module executing equipment's (gas generator) wire harness.
(c) Place the airbag module onto the steering wheel's proper installation position (avoid heavy knocking while
placing).
(d) Tighten the airbag module mounting bolt.
(e) Connect the battery's negative (-) terminal.
(f) Inspection after installation.
Auxiliary airbag removal and installation
1. Auxiliary airbag removal
(a) Remove the glove box.
(b) Pull out the dashboard wire harness and the auxiliary airbag wire harness connectors.
(c) Remove the airbag mounting bolt.
(d) Remove the upper dashboard.
(e) Remove the auxiliary airbag's two mounting nuts.
(f) Press the buckle and remove the auxiliary airbag.
2. Installation sequence for the auxiliary airbag is reverse to the removal sequence.
Caution: Please do not place anything on the auxiliary airbag, as to avoid accidents while deploying
the airbag.
Operation essentials
1. Driver side airbag and steering wheel removal
Caution: The following operations should only be performed after the battery's negative (-) terminal
has been disconnected, and after the ignition switch key has been pulled out for 60 s.
(a) Remove the mounting screws from the two holes under the steering wheel bottom cap, and lightly pick up
the driver side airbag module.
(b) Pull out the deployed airbag module's wire harness and the horn line, and remove the airbag module.
Attention: Diagnose the airbag module's circuit with an electrical measuring instruments but do not
dismantle it. Face the bottom of the removed passenger side airbag upwards and store it in a clean
and dry place.
(c) Remove the steering wheel mounting bolt on the steering column.
Caution: Due to the over-tight occlusion of the spline and column, the steering wheel and steering
column may be hard to separate, in which case make sure not to use force to remove the steering
wheel. The correct method is to tighten the screw into the column just a bit, and then pull up the
steering wheel (because the steering wheel bottom is connected to the clock spring, if force is used to
remove it, it may damage it).
2. Clock spring removal
(a) After steering wheel removal is completed, remove the combination switch hood.
(b) Pull out the dashboard wire harness connectors under the clock spring.
(c) Take off the clock spring.
Caution: Store the removed clock spring in a clean and dry place.
3. Installation notes
(a) Inspection before installation, inspection of driver side airbag module.
(b) Inspect the new airbag or clock spring before installing them.
4. Driver side airbag module inspection
Inspect each of the following items. If any faults are found, replace with a new corresponding airbag module
part. Discard the old components after they have been deployed in the proper order.
(a) Whether the cover sunken or depressed, cracked, or deformed.
(b) Whether the wire harness has broken connectors and deformed terminals.
(c) Whether the gas generator's housing is sunken or depressed, cracked, or deformed.
(d) Airbag module installation status.
Caution: The specified measuring instrument cannot measure the airbag module (tube rupture) circuit
resistance. Test the resistance with a testing instrument. There is an electric current in the tube rup-
ture which may lead to accidental deployment due to static electricity and cause serious accidents.
5. Clock spring inspection
Inspect each of the following items. If any fault is found, replace with a new clock spring.
Airbag deployment
1 Warning: The following steps can prevent static
electricity trigged accidental deployment, so please
carefully follow them.
3
1. Park the vehicle on a flat surface.
2. Disconnect the battery's negative and positive
terminals, and remove the battery from the car.
2
Caution: Avoid wearing apparel which may generate
friction due to electricity. Disconnect the battery's
positive and negative terminals, and commence
operation after waiting 60 s.
3. Remove the airbag module according to the driver side
airbag's normal removal procedures.
8. Place three old tires with no hub on the tires which are
used to fix in place the driver side airbag module (shown
on the left).
Old tire with no hub
Wire harness used for
deployment
No
Disconnect the driver side airbag line and Yes Inspect whether the clock spring is
replace it with a 2 Ω resistor to see whether
airbag warning lamp is still on. conducting
No No
No
Disconnect the driver side seat belt pretensioner
wires and replace it with a 2 Ω resistor to see
whether airbag warning lamp is still on.
No
Disconnect the front passenger side seat belt
pretensioner wires and replace it with a 2 Ω
resistor to see whether airbag warning lamp is
still on.
No
Go to a professional maintenance station to
perform inspection
Vehicle Body
Gasket
mounting hole Front
door
Gasket
outside
handle
Mounting screw
Lock cylinder
Mounting screw
Door lock inside handle
Q2580820 + Q141F32
Mounting screw
Door lock inside handle
Q2580822
11. For rear door lock removal, please simply reverse the
installation steps.
Q2580820 + Q141F32
Q1460620 (Q402) F3
Q1840616F3
Connect the central door lock controller Trunk door outside handle assembly
Q1840616F3
Screw
Windshield installation
1. Install the trim strip and inner rearview mirror on the
windshield.
2. Coat the windshield frame and its edge with primer.
3. Use a glue gun to coat the windshield with glass
sealant, glass sealant height is 10±2 mm.
4. Use adhesive tape fix the windshield and the
windshield's outside sheet metal.
5. Remove the tape after the glass sealant has solidified
for 24 hours.
Dashboard
Components
Small glove
box assembly
Combination switch
cover assembly
Dashboard right
trim strip
Dashboard removal
Front ash tray assembly
1. Remove the auxiliary facia console.
Parking brake lever panel (a) Take down the front ash tray assembly
Auxiliary facia console (b) Take down the auxiliary facia console decorative carpet.
decorative carpet
(c) Remove one screw.
Screw
(d) Remove the parking brake lever panel.
(e) Remove the shift lever cap.
Buckle (f) Remove the auxiliary facia console assembly.
Auxiliary facia console
2. Remove the left & right trim strip assembly of the dash-
Dashboard right trim
strip assembly
board.
Right trim
strip
Glove box
assembly
Buckle
Combination
meter hood
Screw
Screw
Coin box
Buckle bottom
Bolt
Brace reinforcement assembly 19. Remove the dashboard bottom and brace reinforce-
ment assembly.
(a) Remove the two buckles.
Nut
(b) Remove the two screws.
Buckle (c) Remove the two nuts.
Buckle
Nut (d) Remove the dashboard lower framework assembly.
Screw
Dashboard lower framework assembly
20. For dashboard installation, please simply reverse the
removal steps.
Cooling Unit
Components
Electronic fan
with overflow
tank assembly
Radiator lower mount
Radiator examination
1. Check for impurities between the radiator pipes.
Mounting bolt 2. Check whether the radiator is broken, and repair it if
necessary.
3. Check whether the radiator core is corroded, broken,
or corroded, and change it if necessary.
4. Check whether the pipe is cracked or broken.
5. According to the device circuit, check the operation
conditions of the electronic fan and change it if neces-
sary.
Electronic fan operation conditions:
Direction of rotation Low rotational speed High rotational speed
(looking from the radiator) (r/min) (r/min)
Counterclockwise 1850±250 2250±250
6. Check the sealing conditions of the radiator filler cap:
Connect the diagnostic scanner of the radiator filler
cap, and pressurize until the scanner indicator stops. If
the indicator does not stop at the specified point within
10 s, replace the filler cap.
Caution: Opening pressure of pressure valve is
108±14.7 KPa.
Radiator installation
1. Install the electronic fan onto the radiator assembly
with three mounting bolts.
2. Install four radiator mounts onto the four radiator instal-
lation points.
3. Install the radiator and electronic fan assembly be-
tween the upper and lower radiator cross member.
4. Install the inlet and outlet pipes connecting the radiator
and engine.
5. Fill up the radiator with coolant.
6. Check whether leakage exists in the radiator assembly,
the hose, and the connection.
Front door
window LH
Front door Front door glass run LH 2. Remove the front door external weatherstrip.
window LH Lower the window and manually grasp the weatherstrip
Front door
Front door external window front firmly, then pull it up to remove.
weatherstrip LH guide rail LH 3. Remove the front door window assembly.
(a) Adjust the window to make the window bracket
mounting bolts level with door inner decoration board
mounting hole, and remove the two window bracket
mounting bolts.
(b) Pull the window upwards and then tilt it to remove.
Front door window rear 4. Remove the front door glass run.
guide rail LH Front door assembly LH
5. Remove the front door window guide rail assembly.
Window regulator
assembly
Front door lower hinge LH
Front door
assembly LH
Front door outside handle LH 2. Install the door outside handle with lock cylinder and
door lock.
(a) Install the lock cylinder on the door outside handle with
spring clasp.
(b) Install the door outside handle and lock cylinder with
two bolts with spring clasp.
Front door
inside (c) Install the door lock with three bolts.
handle LH (d) Connect the control lever to the door outside handle.
3. Install the door inner lock button.
Install the door inner lock button and connect the control
Front door lock assembly LH Front door assembly LH lever.
Front door
assembly LH
Front door
assembly LH
Rear door
window
regulator LH Rear door retainer LH
Rear door assembly LH
Rear door window LH Rear door glass run LH 2. Remove the rear door external weatherstrip.
Lower the window and manually grasp the weatherstrip
Rear door window rear firmly, then pull it up to remove.
guide rail LH
3. Remove the rear door window assembly.
(a) Pull the rear door regulator down in a position that en-
ables the rocker to turn freely, and then lower the win-
dow. Finally make the rocker slide out of the guide rail
Rear door below the window.
Rear door external window front
weatherstrip LH (b) Pull the window upwards and then tilt it to remove.
guide rail LH
Rear door window regulator LH
4. Remove the rear door glass run.
5. Remove the rear door window guide rail assembly.
Rear door window LH Rear door glass run LH 5. Install the guide rail and bolts on the rear door window
guide rail assembly.
Rear door window
rear guide rail LH 6. Install the rear door glass run.
7. Install the rear door window assembly.
Pull the regulator down in a position that enables the rocker
to turn freely, install the window into the door chamber, then
make the rocker of the regulator smoothly slide out of the
guide rail below the window.
Rear door window
front guide rail LH
Rear door assembly LH
Right side
Left side deco- decorative block
rative block
Trunk door
assembly
Trunk door left side air spring Trunk door air spring removal
1. Open the trunk door.
2. Remove the air spring mounting bolts from the trunk
door.
Front Bumper
Components
11 1
5
3
11
10
11
2
11
11
6 4
3
8
5
6
9 7
8
7. Disconnect the wire harness of the left & right fog lamps.
Front bumper plastic 8. Remove the bumper attachments.
support
Remove the front bumper plastic support and energy absorb-
ing block from the vehicle body respectively.
Rear Bumper
Components
1
4 3
5 1
2 6 10
3
8
7 11
1 12
18
1
11
13
13
14
13
13
17 16
15
1. Cross slot & concave hexagon head self-tapping screw and large 10. Front mounting bracket RH of the rear bumper
washer subassembly 11. Rear bumper trim panel buckle
2. Rear mounting bracket LH of the rear bumper 12. Rear bumper right trim panel
3. Rear bumper mounting bolt 13. Expansion button
4. Hexagon nut for flange face 14. Rear bumper body
5. Rubber cushion of the rear bumper central mounting bracket 15. Rear bumper plastic buffer anchor
6. Rear bumper central mounting bracket bolt 16. Rear bumper drawbar close lid
7. Central left mounting bracket of the rear bumper 17. Rear bumper left trim panel
8. Central right mounting bracket of the rear bumper 18. Front mounting bracket LH of the rear bumper
9. Rear mounting bracket RH of the rear bumper
Rear bumper
Rear mounting bracket Central left mounting 5. Pull the bumper out.
LH of the rear bumper bracket of the rear bumper Pull the rear bumper out of the left & right side bracket of
Rear bumper central
mounting bracket bolt
the rear bumper, and make the central part of the rear bum-
per slide out along the rear bumper central mounting bracket
bolt.
Cross slot & concave hexagon head self- 7. Remove the front bracket.
tapping screw and large washer subassembly Screw off the cross slot & concave hexagon head self-tap-
ping screw and large washer subassembly on the left & right
front mounting bracket of the rear bumper, and pull the left
& right front mounting bracket of rear bumper out.
Front mount-
ing bracket LH of
the rear bumper Rear bumper body
Installation
Areas of Importance: Different metals making direct
Engine hood Bolt contact will accelerate corrosion. Make sure to use the
lock latch release correct fastening piece to avoid premature corrosion.
mechanism
1. Install the cable onto the engine hood lock latch re-
lease mechanism assembly.
Cable 2. Install the engine hood lock latch release mechanism
assembly with the bolts.
3. Install the cable onto the engine hood lock latch re-
lease lever.
4. Install the engine hood release lever onto the dash-
board.
Seat Belt
Components
45±5 45±5
Seat belt lower mounting bolt
Seat belt lower mounting bolt
Guide ring mounting bolt
45±5 45±5
Body B-pillar Guide ring
sheet metal
Vertical adjuster
mounting bolt Woven band
Vertical adjuster
Retractor
Retractor lower
mounting bolt
Lower mounting
bolt
C-pillar
protector
Lower
mounting bolt
Seats
Components
Rear seat
Driver seat
Backrest regulating lever
Areas of Importance
1. Pay attention to safety in the process of removal, transportation, and installation, as to avoid
scratching or crushing injury caused by the seat.
2. Take note to protect the inner decorative components in the process of installation and transporta-
tion, as to avoid scratching the side panels.
3. After finishing installation, make sure to calibrate the tightening torque of mounting bolts.
Sunroof Assembly
Components
Sunroof panel
Sunroof window weatherstrip
Slider
Spacing tube Upper trim strip
Wind guard
End piece
Bolt
3.5
Troubleshooting
Fault classification Fault symptom Fault diagnosis Fault maintenance
Window panel Window panel (sunroof) Check if anything is blocking the guide rail Replace the sunroof guide rail assem-
motion failure cannot open, rise, or close for window panel movement. Check whether bly. Replace the motor.
from its initial position the mechanism moves smoothly or stiffly.
Check whether the mechanism is broken.
Check whether the guide rail is deformed.
Check whether the motor works normally.
The window panel can- Diagnosis: Check whether there are oddities Clean the objects and close the sun-
not close while half- impeding the window panel's movement . roof by force when the jam protection
opened or half-tilted Check whether the wind guard or rear roof function is started, then open it again
drip channel is arched or deformed. for operation. Replace the wind guard
and rear roof drip channel.
Sun visor push/pull Sun visor cannot open Check whether the guide rail for the sun visor Clean the oddities in the guide rail.
fault or close normally is blocked by oddities. Check whether the sun Change the sun visor. Change the sun
visor bracket is broken. visor bracket.
The sun visor cannot open Check whether the front part of sun visor Replace the sun visor. Replace the
and close completely arches. Check whether the sun visor lever has sun visor lever.
been broken off.
Sunroof leakage fault Sunroof leakage Check the clearance between the window Adjust and enlarge the window panel
panel and the car roof hatch. weatherstrip.
Check whether a build up of sand or dust ex- Clean the weatherstrip surface and
ists on the surface of window panel weather- car roof hatch.
strip.
Check the sealing conditions between the Replace the sunroof guide rail assem-
guide rail & front roof drip channel and rear bly.
roof drip channel.
Check whether the front roof drip channel Replace the sunroof guide rail assem-
and rear roof drip channel are broken. bly or rear roof drip channel.
Abnormal noise There is abnormal noise (1) Check the positioning of the closed win- (1) Adjust the window panel's position.
when closing the sunroof dow panel. (2) Place the wind deflector spring in
(2) Check whether the wind deflector spring is the right position .
in the right position. (3) Re-install the fixed spring.
(3) Check whether the rear roof drip channel's (4) Re-install the rubber block.
fixed spring has broken off.
(4) Check whether the wind deflector buffer
rubber block has broken off.
There is abnormal (1) Check whether the motor is working nor- (1) Replace the motor.
noise when the sun- mally. (2) Clean out any contamination.
roof is operating (2) Check whether oddities exist in the guide (3) Lubricate the components.
rail for mechanism movement . (4) Replace the components or the
(3) Check the grease's conditions on the mov- sunroof guide rail assembly.
ing components .
(4) Check whether the moving components
are broken.
Drive device
3. Check the condition of the circuit connection.
Sunroof
B assembly 4. Install the bolts.
Mounting bolt Tighten them successively from the left and right side to the
rear part of the sunroof drive device. Tightening torque for
all is 8 N·m.
5. Install the outlet pipe.
6. Insert the drive device plug.