LF630 Service Manual Guide

Service Manual
LIFAN 630
LIFAN INDUSTRY(GROUP) IMP&EXP CO.,LTD

Foreword
LF630 Service Manual on common treatment of troubles is to help you correctly use and maintain your love sedan.
This manual, with illustrative figures and easy-going words, thoroughly introduces the structure features, use
and maintenance of LF630 sedan, which will be a good guide for wide users and maintenance technicians.
Meanwhile, LF630 Spare Parts List will also be referred if necessary. For any questions and doubts, please do
not hesitate to contact the service stations of Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd.
The figures, notes, specifications etc contained in the manual will take effect as of the date of printing, which can
be modified and terminated at any moment by Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd. without any
notice in advance.
Any comment on anything improper in the manual shall be preferred, and no responsibility on anything improper
shall be undertaken by Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd.
Without a permit from Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd., any unit or individual shall not be
allowed
to duplicate, store, and distribute any part of the manual in any form or by any method.
Great appreciation for your support!
2013.6
Contents
PartⅠ General Introduction 4
PartⅡ Maintenance of Systems 15
ChapterⅠ UAES Electronic Injection System 15
Section Ⅰ Engine Control System 16
Section Ⅱ Trouble Diagnosis 45
Section Ⅲ Sensor Actuator 183
Chapter Ⅱ Delphi Electronic Injection System 214
Section Ⅰ Introduction 214
Section Ⅱ Principle of Controlling and Actuating Components 214
Section Ⅲ Steps for Trouble Diagnosis with DTC 225
Section Ⅳ Steps for Trouble Diagnosis Based on Engine Symptom 231
Section Ⅴ Security Items for System Diagnosis and Maintenance 245
Chapter Ⅲ Chassis System 247
Section Ⅰ Suspension and Axle 247
Section Ⅱ Hydraulic Power Steering System 259
Section Ⅲ Electric Power Steering System 272
Section Ⅳ Brake System 291
Section Ⅴ Fuel System 311
Section Ⅵ Engine Cooling System 313
Section Ⅶ Intake and Exhaust System 36
ChapterⅣ ABS 318
Section Ⅰ Function and Composition of ABS 318
Section Ⅱ Principle of ABS 319
Section Ⅲ Removal and Installation of ABS 322
Section Ⅳ Trouble Diagnosis and Troubleshooting 325
ChapterⅤ Electrical System 349
Section Ⅰ Instrument Cluster 354
Section Ⅱ Power Window 365
Section Ⅲ Power Sunroof（Optional） 370
Section Ⅳ BCM Central Lock, Burglar Alarm System 379
Section Ⅴ Electric Rear-view Mirror 392
Section Ⅵ Illumination System. 395

Section Ⅶ Wiper and Washer 406
Section Ⅷ Audio System 413
Section Ⅸ Reverse Radar System 418
Section Ⅹ Power Supply and Other Electrical System 424
Chapter Ⅵ Air Bag 471
Section Ⅰ Composition, Principle and Safety Rules for Maintenance 471
Section Ⅱ Diagnosis & Troubleshooting 476
Section Ⅲ Diagnosis of Vehicles after Collision 483
Section Ⅳ Removal and Installation 484
Section Ⅴ Scrapping Tips for Air Bag Module 487
ChapterⅦ A/C System 488
Section Ⅰ Introduction 488
Section Ⅱ System Layout 492
Section Ⅲ Component Maintenance 496
Section Ⅳ Fault Diagnosis 510
Section Ⅴ Precautions 519
ChapterⅧ Auxiliary Component System 520
Section Ⅰ Cable 520
Section Ⅱ Windshield 521
Section Ⅲ Safety Belt 524
Section Ⅳ Front Side Door 526
Section Ⅴ Rear side Door 528
Section Ⅵ Seat Assembly 530
Section Ⅶ Interior & Exterior trim 537
ChapterⅨ Vehicle Body Dimension 553

PartⅠ
General Introduction
ChapterⅠ Entire Vehicle Overview
LF630 sedans are devised to give expression to the human orientation with features of portable operation, comfortable
ride, spacious inner room, excellent power performance and economical efficiency. The high tech and low price endow them
with the stronger market competition.
一、Engine assembly
1. Either the engine of LF479Q2-B or LF479Q2 or LFB479Q is adopted, which is a double overhead camshaft
multi-point electronic injection engine with 16 valves.
二、Chassis：
1. The McPherson independent suspension is applied in the front suspension; and the dependent
trailing arm suspension is adopted by the rear suspension. It also enjoys the design of the elastic
elements and the shock absorber of the front and rear suspensions, director elements and stable
ones of the front sub-frame suspension.
2. Steering gear: The steering column employs the angular adjustable mode.
3. Operation system: Clutch pedal mechanism, hydraulic clutch operating device.
4. Both the front and rear brake gears are the vented disc brakes with reasonable load layout and the
Anti-Lock Brake System, namely ABS safety device. It is used to prevent sliding and dragging on the
road due to locked wheel when the vehicle brakes so as to improve the vehicle’s directional stability,
steering control ability and shorten the braking distance so that the braking will be more efficient
and safer. It greatly promotes the safety and reliability of the vehicle in various road conditions
and the reasonable distribution of the front and rear braking force.
5. 195/60R15 tires are used; the tire rim, 6J.
三、 Body:
1. An integral body is adopted which has passed the frontal impact test and qualified by the state
testing institutions. Exterior design is fashionable with excellent aerodynamic performance with
streamline figure.
2. The dash board, exterior trims and lighting equipments employ the novel craftworks and materials.
3. A/C system: It gives full expression to the ergonomic, after the filtration, offering clean and
fresh air evenly and noiselessly.
四、 Electric equipment
The electric equipment design of LF630 sedans absorbs all the electric options so as to meet
diversified customers’ needs.
1. Engine and electronic fan
The engine is equipped with a starter and a generator. Double electronic fans at two speed-adjusting
levels are arranged.
2. Power start, charging systems
The power start system mainly deals with the model and specs size confirmation of the engine, battery
and generator and voltage regulator, etc.
3. Ignition and electronic injection system
① Ignition switch: Only the mature products can be employed and the corresponding current is set to
satisfy the functional requirement.
② The engine is the mature product of the LF479Q2-B or LF479Q2 and the electronic injection system
adopts the electronic fuel injection system supplied by the UAES or the Delphi. The key components
of this type’s system include the controller：engine control unit；sensors: air inlet pressure
temperature sensor,throttle valve position sensor, knock sensor, oxygen sensor, camshaft position
sensor, crankshaft position sensor, coolant temperature sensor, weak acceleration sensor etc; the
actuators:canister control valve, fuel injector, ignition coil etc and other related components like
fuel rail, catalytic converter.
4. Warning signal
The design for the control of the circuit system has been devised correspondingly to satisfy the
requirement of the entire vehicle and the state legal regulations.
The warning signal devices are used to warn and hint signals to the surrounding environment, including
the horn, turn indicator, emergent lamp switch, reversing lamp and brake lamp and switches, front daytime
lights and rear fog lights and so on.
5. Instrument assembly
1) Instrument cluster: Instrument cluster of the electronic odometer. The instruments include the water
thermometer, engine tachometer, speed odometer and the fuel gauge.
2）Indicators include: The battery charge indicators, engineer oil pressure indicator, brake fluid
level indicator, engine malfunction detecting indicator, handbrake indicator, safety belt indicator,
fuel warning indicator, instrument lighting light, high beam indicator, turn (emergency) indicator,
ABS indicator, door ajar indicator. Reverse radar display, fuel flow sensor, engine oil pressure sensor,
vehicle speed sensor, door lamp switch, brake shoe sensor, safety belt contact switch, brake fluid
level sensor, parking brake (handbrake) switch etc.
6. Auxiliary electrical devices
(1) Front windshield wiper system: controlled by a combination switch handle. The wiper motor and the
connecting rod are collocated in front of the dash panel.
(2) CD player : Four speakers with adjustable high pitch function.
(3) Audio system
Single disc CD player on the dash board, six speakers, with radio reception, disc playing and time
display functions simultaneously. This novel CD player has a nice appearance.
(4) Cigarette lighter: one, installed for convenience, collocated according to the modeling necessity.
(5) Rear defrosting: The heating-type glass is employed for the rear window and controlled by the switch.
(6) Self-closing four-door window functions: four-door collocation, master control at driver side and
independent control for right doors and windows, the operating switch collocated on the door armrest.
(7) Central lock: for four doors, unified switch. Remote control, mature products selected according
to the body structure and modeling and adoption of the BCM centralized control.
(8) Electronic anti-theft device: Controlled collectively by the BCM so as to realize the function
of electronic anti-theft.
(9) A/C system: JSS-120 swinging-vane type compressor with delivery capacity 120ml/r and excellent
refrigerating effect, consisted of the condenser, evaporator, thermostat, sensor, pressure switch and
blower, etc.
7. Safe anti-theft device
(1) Air bag: The electric double air bags are located on the steering wheel and the dash board of the
co-driver room respectively.
(2) The ABS safety device of the Anti-Lock Brake System guarantees the safety and reliability of the
vehicle’s brake system.
(3) Anti-theft device (optional)
The anti-theft system is mainly controlled by the body controller BCM, connected to the engine ECU
by a communication link. When the ignition key is plugged in, if the signal detected is correct, the
ignition system will work normally; otherwise, the engine can not work. This is the anti-theft system
in common use.
8. Other electric devices:
The other electrical devices mainly include the harness, center control box, relay, fuse, connector,
switch, corresponding fixing bracket and the strapping components. Requirements of the use meet the
automobile standard of QC/T420-1999.Blown fuse indication.
ChapterⅡ Main Technical Parameters
一、Basic performance parameters
1. Complete vehicle basic parameter (Table 1)
2. Complete vehicle performance index (Table 2)
Table 1 Complete Vehicle Main Parameter

Item LF630-1.5 LF630-1.8
3 compartments, 4 doors, 5 seats
Type
and 2 covers
Front lateral engine, front-wheel
Drive model
drive
Length mm 4610
External
Width mm 1705
dimension
Height (idle load) mm 1495
Wheelbase mm 2605
Front track (idle load) mm 1470
Track
Rear track (idle load) mm 1460
Front overhang 1000
Rear overhang 1005
Approach angle (°) 18°
Trafficability Departure angle (°) 17°
characteristic Minimum ground clearance mm 150
Minimum turning diameter m 10.2
Luggage boot capability L 650
Curb weight kg 1150 1180
Axle load distribution
kg 710/440 720/460
（unloaded）(front/rear)
Gross weight kg 1555 1585
Mass Axle load distribution（full load）
kg 810/745 820/765
(front/rear)
Axle load distribution
percentage (full load) ﹪ 51/49
(front/rear)
Mass center height (no/full) mm 593
Table 2 Complete Vehicle Performance Parameter

Item LF630
Maximum vehicle speed Km/h 170 200
Acceleration
s ＜15.5
Performance performance ( 0-100km )
parameter Fuel consumption of L/100k
7.5/7.7/7.8 7.8
uniform speed traveling m
Maximum climbing ability (﹪) ≥30
Peopl
Number of passengers 5
e
二、Structure and Parameter of Main Assemblies
1.Main technical parameters of engine assembly (Table 4)
Table 4-1 Main Performance Parameter of LF479Q2 Engine
Item Unit Type、Parameter

Four-stroke、water cooling、16 valves、4 cylinder in line、
Model double overhead camshaft、multipoint electronic injection
Cylinder bore mm 78.7
Stroke mm 77
Total displacement L 1.498
Compression ratio 10：1
Lubricant capacity L 3.0～3.2
Fuel No. 93# unleaded gasoline（GB 17930）
Engine oil No. Not lower than SM grade（GB 11121）
Starting mode Electric start
Lubricating mode Pressure and splash combined type
Cooling mode Forced circulating water cooling
Rated rotation speed r/min 6000
Maximum power Kw 69
Rated torque N·m/rmp 128/（3500~4500）
Minimum fuel consumption g/kw.h ≤270

Minimum idle load stabilized
r/min 800±50
rotation speed (idle speed)
Intake valve clearance (cool) 0.15~0.20
Exhaust valve clearance (cool) 0.25~0.30
㎜
External With
610×580×588
dimension transmission
Table 4-2 Main Performance Parameter of LF479Q2-B Engine

Model double overhead camshaft 、 timing belt drive 、 variable
timing
Cylinder bore mm 78.7
Stroke mm 77
Fuel No. 93# unleaded gasoline
Engine oil No. Not lower than SM grade
Maximum power Kw 76
Rated torque N·m/rmp 133/(3500~4500)
Minimum idle load stabilized rotation

g/kw.h ≤255
speed (idle speed)
Intake valve clearance (cool) r/min 750±30
Exhaust valve clearance (cool) 0.15~0.20
0.25~0.30
speed (idle speed) mm
External without transmission 610×580×588
dimension With transmission 820×580×588
Table 4-3 Main Performance Parameter of LFB479Q Engine
Model double overhead camshaft、timing belt drive、variable timing
Cylinder bore mm 79
Stroke mm 91.5
Fuel No. 93# unleaded gasoline
Engine oil No. Not lower than SM grade
Maximum power Kw 98
Rated torque N·m/rmp 168（4200-4400r/min）

g/kw.h ≤260
speed (idle speed)
Intake valve clearance (cool) r/min 750±50
Low idle CO≤0.5%, HC≤100ppm
Emission limit at idle speed speed
High idle CO≤0.3%, HC≤100ppm
speed
Ignition advance angle (idle speed) 4±2º
Exhaust valve clearance (cool) 0.20～0.25
0.30～0.35
speed (idle speed) mm
External without transmission 640×750×644
dimension With transmission 988×750×644
2. Model and parameter of main assemblies of chassis (Table 5)
Table 5 Model and Parameter of Main Assemblies

Name Structure and parameter
Exhaust system Three-way catalytic converter (one section) and muffler (two sections)
Intake system Intake pipeline and air cleaner
Including fuel pump, fuel cleaner, pressure regulator, accelerator pedal, fuel
Fuel supply system
tank
Cooling system Ribbon-tubular radiator and electronic fan
Clutch pedal force ≤140N
Clutch pedal maximum play ≤100mm
Drive shaft Model Model
Front suspension MacPherson independent suspension
Suspension
Rear suspension Independent suspension with a torsion
Tire type Radial ply tire
Tire specification 195/60 R15
Rim specification 6J×15
Tire Tire pressure 230KPA
Steering gear
Rack and pinion steering
model
Pipe angle can be adjusted, steering wheel external
Steering device
diameter 375mm
Front wheel 0°30′±45′(idle load)
camber
Front wheel -2～2
Wheel alignment toe-in
Kingpin 11°15′±45′(idle load)
inclination angle
Kingpin caster 3º±30′ (idle load)
Structure model Hydraulic dual-pipe, with vacuum booster and ABS
Brake system Driving brake Disc brakes for both front and rear wheels
Parking brake Mechanical cable rear wheel rim brake
3. Vehicle body structure model and parameter (Table 6)
Table 6 Vehicle body and interior and exterior trim

Body model Frameless body, 3 compartments, 4 doors, 2 covers and 5 seats
Body-in-white All metal closed type structure
Vehicle
Door assembly Framed, 4 doors open in regular direction, card lock, with side bumper
body
Engine hood Open backward, bent arm hinge
Front and rear bumpers Injection molding
Interior trim Injection molding with surface texture
Dashboard Injection molding with surface texture
A, B and C pillars and Injection molding framework, knitted flocking surface
indoor shield
interior
and Front windshield: laminated glass,
Windshield
exterior Rear window: Toughened glass
trim Outside rearview mirror: Convex mirror in both left and right,
Rearview mirror manual/automatic adjustment
Inner rearview mirror: Anti dazzle
Front seat: independent seat, adjustable back and forth position, backrest
Seat angle, headrest and so on; rear seat with safe belt: dependent seat,
unadjusted
Structure model Compressive refrigeration, water heating
Adjusted with knob to control air flow direction, to control and adjust air flow
A/C Operation speed, temperature and air circulation; luxurious ones with electric
adjustment
Refrigerant Model R134a, filling 500g ± 50g
4. Structure and parameter of electrical system (Table 7)
Table 7 Structure and Parameter of Electrical System

Wire Single wire, negative pole grounded, direct current 12V
Generator Integral type, AC, built-in voltage regulator, specification 14V/80A
Start Motor solenoid-operated (with generator), power 1.2kw
Electronic fan Without speed regulation single fan
Battery Maintenance-free plumbic acid battery, capacity 60Ah
Front Headlamp(60/55W，white，2 lamps)，width lamp(5W、LED、white)，
combination lamp turning lamp(21W，amber，2 lamps，both combination switch)
12V、0.6W，amber，2 lamps
Daytime light Daytime light (12V,LED,white，2 lamps)
Front fog light Rear fog light(21W、LED、red，both combination switch)
Brake lamp(5W ，red，2 lamps，contact closure switch)，reversing
Rear combination
Ilumination and lamp (21W，white，2 lamps)，turning lamp(21W，amber，2 lamps，
lamp
signal both combination switch)，rear width lamp (5W，LED，red)
Rear license
5W, white, 2 lamps
plate lamp
High-mounted
LED, LED, red, 1 lamp
brake lamp
Inner combination
5W, white, 2 lights
roof light
Door lamp 6.2W, white, 4 lamps
Instrument cluster with electronic odometer, including LCD water
Instrument cluster
thermostat, fuel gauge, vehicle odometer, engine rotation speed
Including battery charge indicator, engine oil pressure indicator, fuel
warning indicator, brake fluid level indicator, engine fault indicator,
handbrake indicator, anti-theft indicator, safe belt indicator, electronic
Instrument airbag indicator, instrument illumination light, high beam indicator, fog
system light indicator, steering light (emergency lamp) indicator, ABS indicator,
Indicator
door ajar indicator.
Brake indicator, anti-theft indicator, safe belt indicator, electronic airbag
indicator, instrument illumination light, high beam indicator, fog light
indicator, steering light (emergency lamp) indicator, ABS indicator, door
ajar indicator.
Electric assistant Including CD (or DVD) player, cigar lighter, rear defroster, wiper and
system washer, remote door lock, anti-theft system, airbag, window regulator.
5. Lubricant, fuel, brake fluid, coolant, refrigerant and capacity
(1) Lubricant
Table 8 Lubricant
Lubricant No. Weight
Bearing and ball pin Lithium base grease 7022 0.34kg
(2) Fuel
Table 9 Fuel number and fuel tank capacity
Name Performance index
Fuel No. 93# or better unleaded gasoline for vehicle
Fuel tank capacity (L) 58L
(3) Brake fluid, coolant and refrigerant
Table 10 Brake fluid, coolant and refrigerant

Name No. Capacity or mass
Brake fluid DOT4 0.72L
Coolant Antifreeze G11 5.8 L
Refrigerant R134a 500g±50g
Windshield cleaning solvent NFC-60 2.2L
Powet steering fluid ESSO 220 0.84L
Chapter Ⅲ Maintenance Routine
LF630 Maintenance Plan can make the vehicle run stably, safely and economically and reduce
faults. Maintenance interval varies according to the odometer or time interval. Please refer to the plan. Those
items that have exceeded the deadline should also be maintained in the same interval. Rubber hoses (in cooling
and heating system, brake system and fuel system) should be specially maintained. In case of aging, cracking or
damage, replace the hose. Only professional technician can check the vehicle.
Basic maintenance items:
一、Body electrical equipment

1. Body interior and exterior illumination devices and electrical appliances check：instrument indicator、front
headlight、daytime light、rear fog light、front width lamp、rear width lamp、front turning light、rear turning
light、brake light、reversing light、license plate light、luggage illumination light、cigarette lighter、horn、
power glass lifter、power outside rearview mirror、ventilation system.
2. Airbag：inspect the appearance visually and check for damage.
3. Self-diagnosis：use the special diagnostic equipment of Lifan to read the fault information of each system in
storage.
二、Body exterior
1. Door arrester、fixed pin、door lock、engine hood、decklid hinge and lock catch：check their function and
lubricate.
2. Window：check the function, clean the guide,spread with special grease.
3. Windshield wiper/cleaning device：fill with cleaning solution, check the function and adjust the spray
nozzle as necessary.
三、Engine compartment
1. Inspect all parts visually and check them for damage and leakage.
2. Cooling system：check the antifreeze, fill with antifreeze fluid as necessary. Standard value：-25℃(Cold regions
-35℃)
3. Brake system：check the brake lines for leakage, check the brake fluid level and top up if necessary.
4. Replace brake fluid：replace every 2 years or 5000km.
5. Air filter：clean the filter core every 7500km and replace the core every 30000km.
6. Oil filter：replace filter core every 7500km.
7. Fuel filter：replace filter every 40000km.
8. Battery：check whether the connection of positive electrode and negative electrode is secure, observe the
electric eye.
四、Engine and vehicle underbody
1. Vehicle underbody：check the fuel pipe, brake pipe and bottom protective layer for damage, check the exhaust
pipe for leakage and determine whether it is fixed firmly.
2. Steering tie rod：check the gap，check whether the connection is firm and check the dust cover for wear.
3. Brake friction lining：check the thickness.
4. Parking brake device：check, adjust the length of cable when necessary.
5. Tyre (including spare tyre)：check the tyre for wear, check the tyre pressure.
6. Four-wheel alignment：check with wheel aligner.
7. Wheel retaining bolt：check according to torque requirement.
8. Headlamps light：check, adjust when necessary.
9. Test run：performance check.
Abbreviations in this manual
AC： Alternating current

ACC： Air conditioning clutch
ACMC： Air conditioning magnetic clutch
ACT： Air charge temperature
A/C： Air conditioning
ABDC： After bottom dead center
ABS： Anti-lock brake system
A/D： Aanalog/digit
A/F： Air/fuel ratio
AFS： Air flow meter (air flow sensor)
A-ELR： Automatic/emergency locking retractor (of safety belt)
ATDC： After top dead center

AAA： American Automobile Association
ATF： Automatic transmission fluid
ALR： Automatic locking retractor (of safety belt)
ASD： Automatic switching-over device
A/T： Automatic transmission
BATT： Battery
B＋： Battery positive pole
BBDC： Before bottom dead center
BOO： Brake on-off
BTDS： Before top dead center
CAB： ABS control unit with electromagnetic coil

CANP： Canister Purge exhaust valve
CMP Sensor： Camshaft position sensor (crankshaft turning angle sensor)

CO： Carbon monoxide
CKT： Circuit
12
CPP Switch： Clutch pedal position switch (clutch switch)
CPS： Crankshaft position sensor
CPU： Central processing unit
CVT： Continuously variable transmission
CRS： Child restraint system
CTS： Coolant temperature sensor
D
DC： Direct current
DLC： Digit link connector (series data link)

DOHC： Double overhead camshaft engine
DOJ： Double offset joint
DRL： Daytime running light
DTC： Diagnostic trouble code, diagnostic code
DS： Detonation sensor
E
ECA： Electronic control assembly
EBCM： Electronic control module (anti-lock brake module)
ECM： Engine control module
ECT ： Engine coolant temperature
ECT Sensor： Engine coolant temperature sensor
EFE Heater： Early fuel evaporation heater

EFI： Electronic fuel injection
EGR： Exhaust gas recirculation
EGRT Sensor： EGR temperature sensor
EMI： Electro magnetic interference
ELR： Emergency locking retractor
EPS： Electric power steering
EST： Electronic spark timing
EVAP： Evaporative system
EVAP Evaporative system canister
Canister：
F
FP： Fuel pump
13
FPC： Fuel pump control ECU
G
GEN： Engine
GND： Grounding
HC： Hydrocarbon
HO2S： Heated oxygen sensor
HUC： Hydraulic unit control with solenoid valve
IAC Valve： Idle air control valve

IAT Sensor： Intake air temperature sensor
ICM： Ignition Control Module
ICU： Integrated control unit, composed of four parts
IG： Ignition
In： Inch
ISC Actuator： Idle speed control actuator
L
L： Left
LH： Left hand
dLSPV： Load sensor proportion valve
Max： Maximum
MAF Sensor： Mass air flow sensor
MAP Sensor： Manifold absolute pressure sensor
MFI： Multipoint fuel injection
Min： Minimum
MIL： Malfunction indicator light, engine check light
M/T： Manual transmission
N： Neutral
14
Ne： Engine rotation speed, engine efficient power
NOx： Nitrogen oxides
OBD： On-board diagnostics
O/D： Over-speed driving
OHC： Overhead camshaft
P
P： Parking
PCM： Power control module
PCV： Positive crankcase vent
PDC： Power distribution control
PIM： Pressure of intake manifold
PNP： Park/neutral position
P/N： Park/neutral
P/S： Power steering
PSP Switch： Power steering pressure switch
PSW： Position of throttle wide-open
PWR： Power
R： Right
RAM： Random memorizer
RH： Right hand
15
Part II Maintenance of
Systems
Chapter I UAES Electronic Injection System
16
Section 1 Engine control system
Preparation
1. Special tool
S/N Tools Contour Drawing No. Description
Read engine
control system
1 Diagnostic
fault code and
scanner
data flow, etc.
2. Recommended Tools
S/N Tools Contour Drawing No. Description
For measuring
1 Digital multi-meter voltage and
resistance
2 Wiring set For testing circuits
17
Repair Data
1. Table of Technical Specifications
Intake VVT valve working voltage 11~14V
Intake VVT valve resistance 9.4~10.6Ω
Limit working voltage of intake temperature / pressure sensor 16V
Limit tolerant pressure of intake temperature / pressure sensor 500 kPa
Working voltage of intake air temperature/pressure sensor 4.5~5.5V
Working current of intake air temperature/pressure sensor 6.0~12.5mA
Resistance of intake air temperature sensor at 20°C 2.4~2.7kΩ
Intake air pressure test range 20~115kPa
Intake air temperature test range -40~130℃
Working voltage of canister control valve 8~16V
Minimum starting voltage of canister control valve 7V
Working temperature of canister control valve -30~120℃
Pressure difference between inlet and outlet that canister control 800mbar
valve can bear
Current under canister control valve rated voltage 0.5A
Frequency of control pulse of canister control valve 30Hz
Canister control valve impedance 22~30Ω
22~30Ω
Operating temperature of exhaust end of oxygen sensor 200~850℃
Working temperature at oxygen sensor mounting position ≤ 570℃
Working temperature at connecting position of oxygen sensor ≤ 250℃
cable and metal buckle
Storage temperature of oxygen sensor -40~100℃
Oxygen sensor heater resistance 7~11Ω
Working gap of crankshaft position sensor 0.25~1.75mm
Coil resistance of crankshaft position sensor 860Ω
Working temperature of crankshaft position sensor -40~150℃
Working voltage of coolant temperature sensor 5V
Limit working temperature of coolant temperature sensor 130℃
Response time of coolant temperature sensor temperature 17~27s
Coolant temperature sensor resistance 1.98kΩ
Effective sealing pressure of coolant temperature sensor 145kPa
Working temperature of camshaft position sensor -40~130℃
Working voltage of camshaft position sensor 4.5~5.5V
Peak voltage of camshaft position sensor 24V
Working gap of crankshaft position sensor 0.3~2mm
Low electric level output of crankshaft position sensor 0~700mV
18
High electric level output of crankshaft position sensor 3.2~5V
Working conditions of electric control throttle valve housing -40~150℃
Diameter of valve hole of electric control throttle valve housing 57mm
Maximum air flow when the throttle is fully open (standard 67g/s
atmospheric pressure)
Minimum by-pass air flow when the throttle is fully closed 1.7g/s
Opening range of throttle position sensor 7%-93% opening
Working voltage of throttle position sensor 5±0.1V
Throttle position sensor resistance 1.6~2.4kΩ
Knock sensor working temperature -40~130 ℃
Knock sensor capacitance 800~1600pF
Sensitivity to 5kHz signal of new sensor of knock sensor 26±8mV/g
Linearity of knock sensor resonance 15~39mV/g
Main resonance frequency of knock sensor >20kHz
Fuel pump output pressure >350kPa
Fuel pump output flow >10g/s
Fuel pump safety relief <900kPa
Fuel pump pressure keeping 24kPa
Fuel pump working voltage 8~14V
Fuel pump overpressure protection -13.5~26( <60s）
Fuel pump fuel-free operation <60s
Maximum operating current of fuel level sensor <130mA
Suited temperature of electric fuel pump working conditions -40~70℃
Operating voltage range of electric fuel pump 6~14.2V
Rated current of fuel sensor of electric fuel pump 1~80mA
Fuel pressure range of electric fuel pump 300~350kPa
Working temperature of fuel track -30~115℃
No return system set pressure of of fuel pressure regulator 350 kPa
Rated resistance of speed sensor at 20°C 860Ω
Clearance between speed sensor induction element and 0.7~1.2 mm
crankshaft pulley teeth
Rated resistance of fuel injector at 20°C 11~17Ω
2. Table of Tightening Torque Specifications

Item N•m
ECM fixing bolts 20
Fixing bolts of intake air temperature/pressure sensor 21~25
Fixing bolt of coolant temperature sensor 20
Fixing bolt of crankshaft position sensor 6~10
Fixing bolt of camshaft position sensor 6~10
19
Oxygen sensor 40~60
Knock sensor 15~25
Fixing bolt of VVT valve 6~10
Precautions
1. Whether the engine is running or not, as long as the ignition switch is turned on (ON), any
action that will cause disconnection of 12V electrical work device shall be prohibited. Once
this device is disconnected, high transient voltage will be generated due to self-inductance of
coil, which in turn can seriouly damage ECM and sensor.
2. When the engine is running, it is not allowed to pull out any sensor wire plug (connector).
Otherwise, there is artificial fault code (false code) in ECM, which will affect judgment and
troubleshooting of maintenance staff.
3. If it is required to dismantle earthing wire of battery, it is necessary to rotate ignition switch to
OFF position, and all electric load shall be turned off. After negative pole earthing wire is
dismantled for 60s, other electrical equipments can be maintained.
4. Parts of EFI system have high reliability. In case any fault occurs to the complete vehicle or
engine, first check related mechanical parts, system connector and wire harness, earth wire,
spark plug Overhigh voltage wire connector and so on.
5. Before installing, use sealant scraper or steel wire brush to remove sundries on mounting
surface and confirm sealing surface is smooth, without oil stain. Do not forget to remove
sealant in assembling hole, thread hole and on thread.
6. When installing elements like sensor or actuator, etc., tighten fixing bolts according to
specified value.
7. The sensor shall be handled with care in the course of installing and transporting to prevent
damage. Any impact and falling may damage its performance seriously.
8. Do not check system electrical signal by puncturing wire harness with fine needle.
9. When dismantling and replacing oxygen sensor, the sensor shall not contact water or other
liquid.
10. Fuel pump cannot run for a long time without gasoline. Neither can it run with gasoline in air.
11. Most of EFI parts cannot be repairable. After any part is damaged, replace it normally.
12. The system should use anti-interference spark plugs and high-voltage lines. The
non-impedance spark plugs and high-voltage lines will not only produce interference waves,
but also have a negative impact on ECM ignition coil drive-module.
13. Do not disassemble ECM.
14. Do not use test lamp to check electronic control system sensor and ECM control unit
20
(including connecting terminal).
15. Except special instructions in testing procedure, normally a pointer type multi-meter is not
used to check the resistance of electronic control system. High resistance digit multi-meter
(above 10MΩ) or special instrument of electronic control system shall be used.
16. On the vehicle equipped with electronic control system, it is forbidden to use earthing test fire
or wire removal striking fire to check the circuit.
17. When a vehicle equipped with electronic control engine is required to bridge power supply of
any other vehicle for starting, first turn off ignition switch and all electrical loads on electronic
control vehicle, then dismantle and install the jump leads.
18. When arc welding is made on the vehicle equipped with electronic control system, ECM
power supply shall be disconnected to protect ECM from damage caused by Overhigh voltage.
19. When repairing vehicle body near ECM or sensor, please be careful to protect these electronic
components from damage.
20. When dismantling wire joint of electronic control system, first turn off ignition switch (OFF)
and dismantle the battery negative earth wire. For checking electronic control system, you can
turn off ignition switch only (turn it to OFF).
21. Remember all power supply systems on electronic control vehicle are negative earth. When
installing battery, pay attention that positive and negative electrodes of the battery shall not be
reversed.
22. When installing or removing ECM, the operator should make himself earth. Otherwise,static
electricity on his boday can cause damage to ECM circuit.
23. Before dismantling any fuel line, first release fuel system pressure. When repairing fuel line
system, please keep away from open fire.
24. Poor contact may be caused by connector terminal corrosion, external dirt intruding into
terminal or contact pressure reduction between connector plug and socket. Disconnect and then
reconnect the connector can change this contact situation and normal contact may be restored.
Check if wire harness and connector are normal in fault diagnosis, in case the fault disappears
after being checked, it may be wiring or connector’s fault.
25. When washing or overhauling the engine on a rainy day, water shall be prevented from
splashing on ECM and other circuits.
26. Electronic control system faults are mainly wire harness and connector faults. Mainly wire
harness broken, connector poor contacted, connector terminal pulled out or not inserted
completely or accessory earthed.
27. It is unusual that wire harness is broken in the middle. Normally, it is broken at the connector.
21
Therefore, please check wire harness at the sensor and connector carefully.
28. Before connecting V30 diagnostic scanner, be sure to turn off the ignition switch (turn it to
OFF). After the completion of connecting the diagnostic scanner, turn on ignition switch (turn
it to ON).
29. In case any fault occurs to the system and remains unsolved, even if the diagnosis tester clears
its fault code, the fault code will still and always exist in operating the re-reading fault code
procedure until the very fault gets eliminated.
Electronic Control System Description

1 Overview
• The LF479Q2-B engine fitted on LIFAN 630 adopts the UAES ME788 electronic control
fuel injection system.
• Use control strategy based on the torque. Main purpose is to link a large number of
different control targets, utilize all kinds of sensors installed on different portions of an
engine to measure various working parameters of it and, as per the control programs preset
in computer, precisely control the fuel injection quantity by controling the fuel injectors,
so as to guarantee the optimum concentration of air mixture for the engine to operate
under any working conditions.
• The electronic control gasoline injection system utilizes the control programs preset in
ECM and other corresponding actuators to realize the functions, such as cranking
enrichment, warm-up enrichment, accelerating enrichment, and full-load enrichment,
decelerating dilution, forced idle fuel cutoff and automatic idle speed control, so as to
meet the engines' requirements for air mixture under special working conditions and
guarantee good fuel economy and emission performance of it, which in turn can improve
the operation performance of the vehicle.
• ECM also has several fault diagnosis modes, which can simplify troubleshooting process.
2. System function
Main functions of the system:
S/N Function S/N Function
1 System structure based on torque 7 Heating of catalytic converter
2 Emission control 8 Idling control
3 Improve gas mixture control function in static 9 Determine cylinder load capacity by intake air
and dynamic states temperature/pressure sensor
4 λ closed-loop control 10 Speed sensing by incremental system
5 Sequential fuel injection cylinder by cylinder 11 Troubleshooting
6 Ignition timing control 12 Limp home
3. System Function Introduction
22
(a). Starting control.
During starting, adopt a special calculation method to control the charging amount, fuel
injection and ignition timing. At the initial stage of this process, the air within the intake
manifold is still and the internal pressure of intake manifold is indicated as ambient pressure.
The throttle valve is closed and the idling regulator appoints a fixed parameter that established
according to the start-up temperature. The fuel injection amount changes with the engine
temperature to promote the film formation of intake manifold and cylinder wall, therefore, it is
necessary to enrich gas mixture before the engine reaches a certain speed. The ignition angle
will be adjusted constantly under the starting conditions. It changes with engine temperature,
intake temperature and rotation speed.
(b). Idling speed control
• Idling control function refers to the system will control the engine speed with the throttle
closed. The system controls the idling parameters so that actual speed will coincide with
the target idling-speed.
• The system uses idle air stepper motor to achieve high accuracy idling-speed control.
(c). Closed-loop control
The system adopts closed-loop control for engine fuel supply and idle speed; Advantages of
closed-loop control is to eliminate differences of system and related mechanical parts due to
manufacturing and wear during the course of operating, increase comprehensive consistency of
complete vehicle, and reduce emission.
(d). Knock control
The system detects characteristic vibration when knocking through the knock sensor installed
on proper engine position, and changes it into electronic signal, so as to input ECM for
processing. ECM uses special calculation method tocheck if knock occurs during the course of
each combustion cycle in each cylinder. Once knock is detected, knock closed-loop control is
triggered. When knock risk is eliminated, affected cylinder ignition will be advanced to preset
ignition advance angle gradually.
(e). Overvoltage control
When recharging system has fault which causes overvoltage, the system will enters protection
condition and limit engine rotation speed, to avoid damage of ECM.
(f).A/C compressor control
When air conditioner switch is turned on, the system will receive signal of air conditioner
request, and make preparation for adding load for air conditioner according to current engine
working condition, and then switch on air conditioner compressor. The system will control the
23
switching on or switching off of air conditioner according to the protection requirements of air
conditioner. In order to ensure power take-off and protect the engine, the system will cut off air
conditioner under some special conditions.
(g). Three-way Catalytic Converter.
The function of three-way catalyst is to convert harmful gas from engine combustion into
harmless gas and then discharge into the atmosphere.
Internal structure of three-way catalyst is designed to be cellular pipe. Palladium, rhodium and
platinum coatings on cellular pipe are used as catalytic reaction agent. Three-way catalyst may
make the engine lose 3%~ 5% power.
(h). Three-way catalyst overheating system protection function.
The system predicts engine exhaust temperature increase trend according to actual working
conditions of the engine, and adopts control method of air-fuel ratio in time to reduce engine
combustion temperature and protect three-way catalyst.
(i). Cooling fan control
• The vehicle is equipped with electric dual-speed engine cooling fan.
• Electric fan control function: ECM will determine whether or not to turn on each fan to
reduce the engine's internal power consumption based on high-low engine coolant
temperature and opening A/C conditions and so on.
(j). Self-diagnosis
• Self-diagnosis of system fault is an essential function of engine control system. When one
or several parts work abnormally, the system will remind the user of necessary check and
maintenance by lighting fault indicator. When a fault occurs, the system can adopt
emergent plan to control the engine so as to ensure the driver can drive it to service
station.
• When one sensor and actuator are detected to be abnormal, engine fault indicator lamp is
lit to remind the driver.
• When one sensor and actuator are detected to be abnormal, corresponding fault code will
be output.
• Read RAM data related to sensor and actuator in ECM by fault diagnosis tester. In
addition, in some case, the actuator can be driven forcedly.
4. Basic Principle
① Start control principle.
(a). After ignition switch is turned on, fuel pump runs for 2s and then stops.
(b). Engine begins to run. After ECM detects two effective 58X signals, fuel pump begins to run.
24
(c). In 0.8s after speed signal disappears (analog signal is subject to interference), fuel pump stops
running.
(d). Pre-injection:
Pre-inject only once during the course of normal starting (if fuel is absorbed by carbon deposit,
gas mixture becomes thinner and it is not easy to start).
(e). At the initial stage of starting:
The pressure in intake manifold is shown as atmospheric pressure. The throttle is closed. ECM
designates one fixed parameter according to starting temperature.
(f). During the course of starting:
Fuel injection amount changes with engine coolant temperature. Ignition angle is adjusted
continuously and changes with engine coolant temperature, intake air temperature and engine
speed.
(g). Starting process is over:
After engine speed exceeds 600r/min, working condition of starting is over.
② Fuel injection control principle.
(a). ECM controls the drive time and injection timing of fuel injectors to achieve the air mixture of
best air-fuel ratio for the engine under all kinds of working conditions.
(b). In fuel track, fuel pressure regulator keeps fuel injection pressure stable. Fuel injector injects
fuel into air duct of each cylinder. In each working circulation of engine (crankshaft rotates 2
circles), the cylinder injects fuel once (injection sequence is 1-3-4-2). This kind of injection
method is called sequence injection.
(c). When the engine runs in a cold or heavy-duty state, in order to maintain good engine
performance, ECM will apply open-loop control to provide richer gas mixture. While in
normal working state (with a small-and-medium load), ECM will apply closed-loop control
based on the feedback signal of oxygen sensor and to obtain the optimum air-fuel ratio and the
best purification efficiency of catalytic converter.
(d). Fuel-injection pulse width control.
25
Input signal ECM Control output
Air-fuel ratio correction
Closed-loop feedback correction
intake manifold Pressure
Air inflation temperature
Air inflation efficiency
Self-learning correction
Power supply voltage correction Calculate fuel injection amount Intake manifold pressure
Exhaust gas cycle

Accelerating and stronger
Decelerating and thinner
Fuel will be cut off during
deceleration.
Fuel injector parameters
Control Signal Description:

Correction item Contents
• Air-fuel ratio for starting
• Air-fuel ratio when the engine runs
• Air-fuel ratio at low coolant temperature of the engine
Air-fuel ratio includes • Air-fuel ratio at normal coolant temperature of the engine
• Theoretical air-fuel ratio
• Stronger air-fuel ratio
• Overheating protection air-fuel ratio
• Actual air-fuel ratio is controlled around theoretical value through feedback
Closed-loop feedback correction
signal of oxygen sensor.
Intake manifold pressure • Read directly through MAP installed on intake manifold
Self-learning • Correct slow change in the engine due to long time running
• When battery voltage changes, voltage correction can ensure correct fuel
Power voltage
injection amount.
• When ECM detects the intake manifold pressure and the degree of throttle
opening increases substantially, in order to avoid the instantaneous thinning
Accelerating and stronger
of air-fuel mixture of the engine, the fuel injection quantity will be increased
improve power.
• When ECM detects the intake manifold pressure and the degree of throttle
opening reduces substantially, in order to avoid the instantaneous thickening
Decelerating and thinner
of air-fuel mixture of the engine, the fuel injection quantity will be
decreased. to improve emission and driving performance
• When the system detects that the vehicle goes into decelerating state, it
controls fuel cut-off. to reduce emission and fuel consumption
Fuel cut-off during deceleration.
• When engine speed is higher than the set value, fuel is cut off.
• When ignition system has a fault, fuel is cut off.
Fuel injection parameters • Provide relation between the engine and fuel injection amount
(e). Engine gas mixture correction

• When the engine is at normal working temperature, partial load control is closed-loop fuel
control. Now, the system corrects fuel injection amount at real time by ECM according to
voltage signal of oxygen sensor feedback so that it can adjust gas mixture concentration
26
closed to theoretical air-fuel ratio to ensure conversion efficiency of harmful gas through
three-way catalytic converter reaches to optimal state, and a better fuel economy.
• When the engine is within normal working temperature range, open-loop fuel control is
used at full load. At the moment, to ensure the best power output of the engine, the system
will control fuel injected with a richer air-fuel ratio, and increase the ignition advance
angle moderately without engine knock. The system can control exhaust temperature
through exhaust temperature mathematical model established when calibrating to protect
the engine and three-way catalytic converter.
• The system determines full-load conditions of the engine according to signals provided by
throttle position sensor. Normally, when throttle opening reaches 80%~90%, the system
will consider that the engine is in full-load state. When the driver steps on accelerator
pedal, the system will increase fuel injection amount appropriately to ensure power
required by the engine when accelerating. Increased fuel injection amount is directly
proportional to throttle opening change rate. When accelerating, ECM first delays ignition
advance angle appropriately, then restore it gradually in order to avoid increased torque
from impacting drive system when the engine accelerates quickly.
• When working condition of accelerating is close to full load of the engine, the system will
disconnect vehicle air conditioner system temporarily to ensure power takeoff of the
engine when accelerating. No matter in any condition, when engine rotation speed exceeds
maximum speed set in system, the system will cut fuel supply to resist endless increase of
rotation speed, to protect engine and prevent "vehicle flying". When rotation speed returns
to maximum speed limit specified by the system, the system will immediately recover fuel
supply.
③ Ignition control principle
(a). Start:
• When the engine starts, one fixed ignition advance angle is used to ignite gas in the cylinder
and provide positive torque. After the engine speed increases to a certain degree, ECM
calculates ignition advance angle according to input signals.
(b). Ignition advance angle control.
ECM
Correction signal Control output
ECM
Coolant temperature correction
Intake air temperature correction
Calculate ignition advance angle Ignition advance angle
Idle speed correction
Main ignition angle
27
Decelerating and fuel cut-off
correction
Accelerating correction
Power enrichment correction
Air conditioner correction
(c). Main ignition advance angle:
After the engine reaches to normal value, usually, the main ignition angle when the throttle is
opened shall be the minimum ignition angle at the optimal torque point. When the throttle is
closed, ignition angle shall be decreased to obtain idle speed stability.
(d). Ignition advance angle correction:
• Acceleration correction: when the vehicle is accelerating, ECM detects knock signal,
correct ignition angle until no knock occurs. In addition, it is used to reduce engine speed
fluctuation caused by drive system knock.
• Power enrichment corrected: In the vicinity of engine-performance, to obtain a better
power and torque, the enriched air-fuel ratio can reach the thinnest one with the best
torque value,
• Decelerating and fuel cut-off correction: when exiting deceleration and fuel cut-off,
correct ignition advance angle to ensure stable transition.
• Air conditioner control correction: when the engine is idling, turn off air conditioner.
Correct ignition advance angle to ensure stable transition.
④ Idling-speed control principle
(a). Idle speed control
• According to idle speed conditions and engine load changing at idle speed, control throttle
bypass air amount to keep idle speed optimal. According to engine coolant temperature
and air conditioner load, ECM drives idling stepper motor to make the engine run at preset
target idle speed. In addition, if turn on or turn off the air conditioner when engine runs at
idle speed, idle air stepper motor will adjust bypass air volume according to engine
loading condition, to avoid unstable idle speed.
(b). Calculate target idle speed.
12-12
Input signal ECM Control output
Basic target idle speed
Voltage compensation
Vehicle speed compensation
Headlamps compensation Calculate target idle speed Target idle speed
Fan compensation
A/C compensation
Decelerating adjustment
28
• Voltage compensation:
• When the voltage is less than 12 V, the system will increase target idle speed automatically
to increase generated energy of the generator.
• A/C compensation:
• Stop and run idly, turn on air conditioner. In order to compensate power consumption of
the compressor, target idle speed will be increased by 150r/min.
• Headlight compensation:
• After the low-beam headlights are turned on to compensate for their power consumption,
the target idling-speed will be increased to 50r/min.
• Fan compensation: when coolant temperature is increasing, the fan is running. In order to
compensate power consumption of fan running, target idle speed will be increased
50r/min.
(c). Idle speed control parameters:
• Idle speed air amount control.
• Fuel injection amount control.
• Ignition timing control.
(d). Idle speed design control opportunity:
• Idle speed stability calibration.
• Accelerate working condition calibration.
• Decelerate working condition calibration.
Deceleration and fuel cut-off.
• Engine transient state transition working condition fuel supply calibration.
• Constant speed driving calibration.
• Mechanical and electrical load increasing / decreasing calibration.
(e). Decisive factors of target idle speed:
• When the engine water temperature is too low, the system will provide high target idle
speed to speed up warming-up process.
• When the additional loads (such as: the headlights, air conditioning, cooling fans and other
electrical loads) are turned on, the system will increase the idling speed to compensate for
the increased loads and to maintain the stability of idling-speed.
⑤ Knock control principle
(a). Knock sensor introduction:
• Knock sensor is a kind of vibration acceleration sensor, which is installed on engine block.
Generally it is installed between No. 2 and No. 3 cylinders, which are conducive to the
29
balance of engine knock. ECM determines if the engine has knock using vibration
frequency signal output by the sensor through filtering inside ECM. When knock signal is
detected, ECM corrects ignition angle until no knock occurs.
(b). Knock control conditions:
• The vehicle is provided with knock sensor.
• Engine speed is larger than 800r/min.
• MAP > 40kPa。
• MAP>40kPa.
(c). Knock control mode:
• Steady-State Control:
• When the engine is running normally, ECM collects and analyzes noise during the course
of engine combustion through knock sensor. After filtering, knock is detected. Once knock
strength exceeds the limit, the system will retard ignition advance angle of the cylinder
that has knock to eliminate the knock.
• Transient control:
• In sudden acceleration or dramatical change in the engine speed, knocking easily occurs.
After predicting the possibility of knock, the system will defer the ignition advance angle
automatically to avoid excessive (violent) knock.
• Quick-delay of ignition advance angle:
• After detecting the knock, the system will delay the ignition advance angle quickly in
accordance with different engine speed, and restore the ignition advance angle 2~3
seconds later.
• Adaptability adjustment of ignition angle:
• Due to manufacturing deviation and wear caused by long term usage (belt, toothed pulley
and cam affecting phase angle relation), the engine have differences or changes. If the
system and engine are used initially or after ECM is charged, the engine may have knock.
The system will record it. After a period of running-in, the system will generate ignition
adjustment correction value (self-learning value) automatically. When the engine runs to
the same working conditions, the system will adjust ignition advance angle automatically.
Strong knock is forbidden. Adaptive learning of the system is continuously updated during
the course of running.
⑥ Canister solenoid control principle.
(a). It is used to control washing air flow of the canister. Based on engine load, engine coolant
temperature, engine speed and a series of signals, duration and frequency (duty cycle) of the
30
electrical pulse to be sent through comprehensive calculation, ECM will control canister
solenoid. Excessively-accumulated fuel vapor in the canister can cause gasoline leak, resulting
in environmental pollution. Therefore, the purpose of canister control valve is to open at the
right time to allow excessive fuel vapor in the canister to mix with air before entering into
intake manifold to participate in combustion.
(b). Canister will not work in the following conditions:
• Within a period of time after engine cold start.
• Engine coolant e temperature is too low.
• Engine in idle speed stage.
• Engine in high load stage
• System important sensor faults.
31
Components Layout
32
Engine Control System--Engine Control System
1 Electronic Control Module (ECM) 8 Electronic Control throttle valve housing
2 Camshaft position sensor 9 Rear oxygen sensor
3 Intake air temperature/pressure sensor 10 Coolant temperature sensor
4 Fuel injector 11 Crankshaft position sensor
5 Canister control valve 12 Front oxygen sensor
6 Fuel pump 13 Knock sensor
7 Intake VVT valve 14 Ignition coil
△ Hint:
Various sensors and actuators are described in the table below:
S/N Parts Qty. Function
Optimize control system to be appropriate for
1 Electronic Control Module (ECM) 1 working conditions of the engine according to
signals provided by the sensor
It provides the crank camshaft position
information for ECM, that is to say, to
2 Camshaft position sensor 1
distinguish the top dead center of compression
stroke and exhaust stroke of the crankshaft.
Check engine intake air temperature, air intake
3 Intake air temperature/pressure sensor 1
and determine compression TDC.
4 Fuel Injector 4 Inject fuel according to ECM signals
Control emission according to ECM digit pulse
5 Canister control valve 1
square wave
6 Fuel pump 1 Deliver fuel
Control engine oil flow into camshaft position
7 Intake VVT valve 1
actuator.
1
8 Electronic Control throttle valve housing Control air intake volume.
1
9 Rear oxygen sensor 1 Check oxygen concentration in exhaust gas
10 Coolant temperature sensor 1 Check engine coolant temperature
Check engine crankshaft rotation position and
11 Crankshaft position sensor 1
speed
12 Front oxygen sensor 1 Check oxygen concentration in exhaust gas
13 Knock sensor 1 Check if the engine has knock
14 Ignition coil 4 Ignition of air-fuel mixture.
33
ECM Power Supply, Ground Connection, Data Line
Driver
compartment Engine compartment central
central control box control box
Cooling fan control
34
Oxygen sensor
ECM ignition system
Fuel pump and fuel injector
Battery power supply Main relay contro Main relay power supply
ECM equipment control
Circuit Diagram
ECM Equipment Control
Intermediate voltage
WT control valve CPV control A/C request signal
Steering switch signal switch signal
35
High pressure switch
ECM Power Supply, Air-conditioning
Medium pressure switch
Ground Connection, Data Pressure Switch
Line Low pressure switch
PAS switch
Intake WT
Canister control valve
valve
A/C System
PWR, GND, SIG
ECM Sensor
Accelerator pedal position sensor Intake air temperature/pressure sensor
Camshaft position sensor
KS
36
CMPS signal APS signal APS signal IATS signal IMAPS signal high-voltage
CPS low-voltageCPS high-voltage KS KS level
CTS signal TB Motor- TB Motor+ TPS signal TPS signal level level high-volta high-voltage
ge level level
Water temperature sensor Electronically-controlled Crankshaft position sensor Knock sensor
throttle valve housing
ECM Ignition System
Ignition coil control
Ignition coil control
Ignition coil control Ignition coil control
ECM power supply, ground,
data line
37
No. 1 cylinder spark plug No. 2 cylinder spark plug No. 3 cylinder spark plug No. 4 cylinder
spark plug
Cooling Fan Control
Engine compartment
central control box
38
data line
Electronic fan
A/C
FC (high speed) FC (low speed)
compressor Compressor
control
Fuel Pump and Fuel Injector
ECM power supply, Engine compartment
ground, data line central control box
39
Fuel pump control
Injector control
Injector control Injector control Injector control
Fuel pump
No. 2
No. 4
No. 1 cylinder No. 3
cylinder
cylinder injector cylinder
injector
injector injector
Oxygen Sensor
Front oxygen sensor Rear oxygen sensor
40
data line
Signal Heating Signal Heatin
g
Terminal Definition
E01 to the engine ECM
Terminal
Terminal No. Color Function Color Function
No.
1 V No. 2 cylinder ignition coil control 42 Bl IATS signal
2 G No. 3 cylinder ignition coil control 43
3 B Ignition ground 44 BlR Main relay power supply
4 Br No. 4 cylinder ignition coil control 45 BlR Main relay power supply
5 RB No. 1 cylinder ignition coil control 46 WG CPV control
6 YR No. 2 cylinder injector control 47 GY No. 4 cylinder injector control
7 PY No. 3 cylinder injector control 48 YW VVT control
8 WB Engine speed output 49 - -
9 GB Engine coolant temperature output 50 WB Low speed fan control
10 P Fuel consumption output 51 B Electronic ground
11 WY SVS lamp 52
R
12 Battery power supply 53 B Electronic ground
R
BW
13 IG1 PWR 54 WP TPS signal
BW
Y
14 Main relay control 55 Gr Rear HO2S signal
Y
15 PG CPS low level signal 56 - -
16 RG APS signal 57
17 BBl Sensor ground 58 GW Brake switch state signal input
18 OY Front HO2S signal 59 VW Vehicle speed signal input
19 LgB KS low electric-level signal 60 BlY Headlamp load
20 Lg KS high electric-level signal 61 B Power ground
21 GGr Brake light switch state signal input 62 - -
22 - 63 BlR Main relay power supply
23 - 64 P TB Motor (-)
24 - 65 P TB Motor (-)
25 - 66 RG TB Motor (+)
26 BR Front HO2S heating 67 RG TB Motor (+)
27 OB No. 1 cylinder injector control 68 WR High speed fan control
28 GR Rear HO2S heating 69 WBl Fuel pump control
29 - - 70 WY A/C compressor control
30 - - 71 PG Diagnosis communication
31 PW MIL lamp 72 - -
5V DC
32 RB 73 - -
5V DC
5V DC
33 OBl 74 BW Clutch switch state signal input
5V DC
34 Br CPS high level signal 75 VR A/C switch signal
35 WB Sensor ground 76 GV A/C intermediate voltage switch signal
36 VB Sensor ground 77 BlG Power steering switch signal
37 PB MAPS signal 78 V Sensor ground
38 BlG TPS signal 79 LgW CMPS signal
39 Br CTS signal 80 B Power ground
40 Gr APS signal 81 - -
41 - -
41
E02 to accelerator pedal sensor E04 to A/C pressure switch
Terminal Color Function Terminal Color Function

No. No.
1 Gr 5v power supply 2 1 B Grounding
2 WB 5v power supply 1 2 GrY A/C switch status
3 RG Sensor ground 3 GV A/C intermediate voltage switch
4 VB Sensor signal 4 VR A/C request
5 OBl Sensor ground
6 RB Sensor signal
E03 to camshaft sensor E05 to generator regulator

No. No.
1 RB Sensor power 1 R Battery power supply
2 LgW CMPS signal 2 BlW IG1 PWR
3 VB Sensor ground 3 WR Charge indicator
E07 to A/C electromagnetic switch E06 to oil pressure alarm

No. No.
1 YW A/C compressor (+) 1 YB Oil pressure switch state signal
E08 to ignition coil A E12 to front oxygen sensor

No. No.
1 RB Primary ignition coil (-) 1 BlR HO2S heating( +）
2 BlR Primary ignition coil (+) 2 BR HO2S heating( -）
3 B Secondary ignition coil ground 3 OY HO2S signal
4 VB HO2S ground
E09 to ignition coil B
E13 to rear oxygen sensor
Terminal Color Function

No. Terminal Color Function
1 V Primary ignition coil (-) No.
2 BlR Primary ignition coil (+) 1 BlR HO2S heating( +）
3 B Secondary ignition coil ground 2 GR HO2S heating( -）
3 Gr HO2S signal
E10 to ignition coil C 4 VB HO2S ground
E14 to crankshaft position sensor

No.
42
1 G Primary ignition coil (-) Terminal Color Function
2 BlR Primary ignition coil (+) No.
3 B Secondary ignition coil ground 1 B Grounding
2 Br CPS( +）
3 PG CPS( -）
E11 to ignition coil D
E15 to vehicle-speed sensor

1 Br Primary ignition coil (-) No.
2 BlR Primary ignition coil (+) 1 WBl Vehicle signal
3 B Secondary ignition coil ground 2 B Grounding
3 BlR Sensor power
E16 to reversing lamp switch

E21 to knock sensor

1 GR Reverse light (+) No.
2 GBl Reverse light switch (+) 1 LgB KS( -）
2 Lg KS( +）
E17 to water temperature sensor E22 to intake VVT valve

Terminal Color Function No.
No.
1 BlR VVT valve power supply
1 BBl Sensor ground
2 YW VVT valve ground
2 - -
3 Br CTS signal
E23 to injector D
E18 to power steering switch

Terminal Color Function No.
No. 1 GY Injector ground
1 BlG Power steering signal 2 BlR Injector power supply
E19 to electronically controlled throttle valve housing

E24 to canister solenoid

No. No.
1 P Motor (-) 1 WG Canister solenoid ground
2 BlG TPS signal 2 BlR Canister solenoid power supply
3 WP TPS signal
4 RG Motor (+)
5 V Sensor ground
6 RB Sensor power
43
EU1 to central control box of engine compartment
Terminal Color Function Terminal No. Color Function

No.
1 RW A/C compressor power supply
2 WR Fan speed-regulating relay control
3 WB Fan low-speed relay control
4 WBI Pump relay control
5 Y Main relay control
6 WY A/C compressor relay control
7 BIR Main relay power supply
8 BIY Headlamp load
9 BL Fan control relay
10 R ECU power supply
E20 to starter E27 to intake temperature / pressure sensor

No.
Terminal Color Function 1 PB MAPS signal
No. 2 OBl Sensor power
1 BY Starter (+) 3 Bl IATS signal
4 BBl Sensor ground
E25 to injector C
E28 to injector A

1 PY Injector ground No.
2 BlR Injector power supply 1 OB Injector ground
2 BlR Injector power supply
E26 to injector B

No.
1 YR Injector ground
2 BlR Injector power supply
EI1 to Dashboard harness
Terminal
Color Function Terminal No. Color Function
No.
Immobilizer ECU communication Immobilizer ECU electronic injection
1 pw 12 V
request communication
2 G Brake switch state signal 13 GW Brake switch
3 GB Engine malfunction indicator light 14 WV Fuel sensor
4 VG Engine charging indicator 15 WR EPS controller
5 BW Oil pressure switch 16 NL -
-
6 BR PWM coolant temperature output 17 -VB
- Rear oxygen sensor
7 Vacant 18 NL- -
8 GW SVS indicator lamp 19 G - Rear oxygen sensor
9 WY Rotation signal 20 BO - Fuel pump relay
10 Gr Rear oxygen sensor 21 -NL -
44
11 NL 22 OG Vehicle speed sensor
EI2 to Dashboard harness
Terminal
Color Function Terminal No. Color Function
No.
1 P/B Reversing lamp power supply 6 -B/W -Engine power-supply
2 G/Br Reversing switch 7 NL
3 NL 8 -Br Ignition switch power supply
4 RY Clutch switch 9 -r/B -TCU CAN-L
5 BL/R Rear oxygen sensor 10 -r/B -TCU CAN-H
45
Basic check
△ Hint:
If the DTC isn't determined during inspection of DTC, all possible circuits must be considered as
possible fault cause to analyze and eliminate fault. In most cases, basic check for the engine in the
following table will be made to find fault location quickly and efficiently.
Steps Inspection Item Recommended Action
Check the battery voltage YES Go to step 2
1 • The battery voltage shall be ≥9.6V.
NO Charge or replace the battery.
Inspect if the result is normal
Check if the engine starts YES Go to step 3
2 • Engine starting
NO Go to step 6
Check air filter YES Go to step 4
• Take out air filter
3 • Check if air filter is polluted or oily
NO Clean or replace air filter
excessively visually.
Check idle speed YES Go to step 5
• Engine starting
4 Refer to Chapter 12
• Let the engine in idling state. NO
Table of Fault Symptoms
Check ignition timing YES Go to step 6
• Use timing lamp or ignition timing
tester to check ignition timing. NO
Inspect Fuel Pressure YES Go to step 7
• Check fuel pressure with fuel pressure
gauge. NO
Inspection of sparks
Basic check is over
• Dismantle spark plugs one by one. YES
7
• Test spark plug.
NO Replace spark plug
46
Section 2 Fault diagnosis
Diagnosis System Description
1. System overview
The engine EFI diagnosis system refers to on-board (OBD) system for emission control. It can
identify possible faults and store fault code into electronic control unit memory.
2. Information storage
(a). After a fault occurs and the system confirms it, each fault is stored in electronic control module
(ECM) as a separate fault code.
(b).Store fault information and engine state parameters when the fault occurs, including load value,
engine speed, fuel pressure and correction, vehicle speed, coolant temperature, etc.
3. Information reading
(b). Diagnosis interface:

16-pin interface, located below the left lower of
dashboard.
(c).Diagnosis interface description:
Terminal code Function description Inspection of data

4 Grounding (-) Resistance : about 1Ω or less
7 Diagnostic K-line Pulse Signal
8 IG1 PWR Ground voltage 9~14V
9 EPS diagnosis communication Pulse Signal
12 SRS diagnosis communication Pulse Signal
16 Battery positive terminal (+). Pulse Signal
47
4. Malfunction indicator light
(a). Location and symbol
Instrument panel contains 2 fault indicators:
system malfunction indicator lamp "SVS" (A),
the other is OBD malfunction indicator lamp
MIL(B). Both are controlled by ECM
calibration.
The difference is that OBD MIL is mandatory
by national laws and regulations. When it is lit,
it means there is a fault in electronic control
system that deteriorates emission of complete
vehicle. SVS light means there are other faults
in electronic control system. During the course
of normal running for the engine, when a fault
occurs, both lights are lit according to
respective rule.
5. Lighting type of malfunction indicator light

△ Hint:
• Before starting vehicle, turn key to ON position and hold for 2s, and observe whether indicator
lamp self-inspect. Start the vehicle at least 5s after turning off ignition switch.
• The SVS and MIL lamps installed on the dashboard are to Hint the user whether the fault is
related to the electronic control system. Their illumination will be controlled by ECM internal
calibration data.
(a). When the system has no fault

• Rotate ignition switch to ON, and MIL is always lit, SVS goes out after self check.
• After starting, MIL lamp and SVS go out;
• After flameout, rotate ignition switch to OFF, and then MIL and SVS go out.
(b). When the system has a fault.

• Rotate ignition switch to ON, and MIL is always lit, SVS goes out and then is lit after self
check.
• After starting, if MIL in fault classes is defined to be lighting mode, MIL goes out and is
lit after MIL lighting condition is met; if SVS in fault classes is defined to be lighting
mode, SVS is continuously lit after SVS lighting condition is met.
• After flameout, rotate ignition switch to OFF, and all go out after AFTERRUN process
(the longest time is 90s).
6. Classification of faults occurred in engine electronic control system
(a). Light OBD malfunction indicator lamp. When OBD malfunction indicator lam of OBD lights
48
up, according relevant requirements of nation law, the user must immediately go to service
station authorized by LIFAN and let the professional technicians to deal with it.
(b). Light SVS malfunction indicator lamp. This fault can't affect the emission, but it can indicate
that electric control system has abnormal working condition, and the user needs to go to
service station authorized by LIFAN for inspection.
△ Hint:
The two faults require the user to go to the service station authorized by LIFAN to have
themchecked with the diagnostic tester or the special equipment with the equivalent function.
49
Fault Diagnosis Procedure
Ask users for time, symptom, situation, condition, occurrence reason,

troubleshooting condition and moved part.
Visual checking: Check the system for missing part; Check the connectors
and harnesses of circuits for looseness; Check the wires and hoses for
connection errors; Check the parts and sensors for clear damages.
Basic check: perform the basic idle check and ignition timing check; check
the fuel pressure; check the battery, etc.
Search and draw fault code
Verify fault code: 1. if the code fault exists; 2. if the fault has been
eliminated while the fault code displays uncleared.
Read Not read

out out
Use fault symptom simulated test to verify fault
Use fault code to
determine fault part
When the code is normal but the fault still exists,
diagnose the fault according to the "fault
diagnosis table" and "common fault judgment
method"
Treatment as per single
fault code trouble
shooting method
Check and repair as per the detected fault causes.
Verify if the fault is excluded
50
Fault Diagnosis Analysis
△ Hint:
• Electronic control engine has common faults: difficult to start, flameout after starting, unstable
idling, idle speed too high, driving poor, accelerating poor, backfire blasting, shaking gasp,
smoking and high fuel consumption. Fault reasons are very complicated. So it is very
important to analyze faults carefully.
1. Analyzing and determining whether there is a fault in the engine
To determine whether there is a fault in the engine, the general methods include:
• When the engine cannot start or cannot run normally after starting, or the engine runs with
exhaust pipe blasting, has exhaust pipe backfire and obvious knock, it means the engine
has a fault.
• Whether engine malfunction indicator light (CHECKENGINE）of engine electronic
control system is lit. If this light is lit, it means engine electronic control system has a
fault;
• If the engine performance changes a lot in a short time, it means the engine has a fault. For
example, the engine power decreases obviously and fuel consumption increases obviously.
• Engine performance changes a little, the following method can be used to test it: when the
engine runs under various working conditions, check if exhaust pipe and intake pipe have
abnormal noise; check if the engine has obvious shaking or metal knock, and engine speed
changing.
Note:
• Step on the pedal slowly to increase engine speed gradually and check the above-mentioned
phenomenon exists.
• If it exists, it means the engine may have a fault. It is necessary to make tests repeatedly and
provide a basis to determine faults correctly.
• Step on accelerator pedal suddenly; check if the above-mentioned phenomenon exists and
engine speed increases correctly. If any abnormal condition occurs or engine speed increase is
slow, it means the engine has a fault.
• In both cases, if the engine has no abnormal phenomenon, release accelerator pedal and check
engine running at idle speed: check if idle speed is too high, unstable, and if the engine shakes
seriously.
△ Hint:
After the completion of the above operation, if no abnormal phenomenon has been detected, it is an
indication that the engine works normally. If you want to carefully inspect dynamic performance,
51
economy and emission condition of engine, it is necessary to use inspection line or special detector
to inspect and diagnose fault.
2. Analyzing and determining type of fault
When there is a trouble in the electronically controlled engine, firstly observe the condition of
the engine electronic control system's self-diagnostic fault indicator"CHECKENGINE (check
the engine)". If the light is lit during the course of running the engine, it means electronic
control engine has a fault that can be monitored by fault self-diagnosis system. The fault
normally relates to electronic control system. Now fault code stored in the computer can be
called out. Then find out the fault reason according to fault code. If the engine really has a fault
and engine "malfunction indicator light" ―CHECKENGINE( Check the engine）‖on dashboard
is not lit when the engine runs, it means the engine fault is not identified by electronic control
unit self-diagnosis system. Now, according to traditional engine and fault phenomenon, you
analyze possible fault reasons based on a principle from external to internal and from simple to
complicated. In this case, do not dismantle electronic control system at random. Only when the
fault is in electronic control system, it is necessary to check electronic control system.
Otherwise, check other parts.
3. Analyzing and determining the exact location of the fault
To reduce the workload of troubleshooting, after abnormal engine reaction occurs, you can use
the method for subtracting 1/2, that is, narrowing the objects of suspicion to the range of 1/2. To
achieve that end, first of all, it is necessary to determine that the fault is in the oil ways or in the
circuits. Most of engine faults arise from fuel line or electrical circuit. Therefore, when the
engine has a fault, you can reduce work amount by 1/2 if you are sure that the fault arises from
fuel line or electrical circuit. Therefore, the following procedure shall be observed:
(a). Determine if fuel line or electrical circuit has a fault.
Since it is simple and easy to diagnose electrical circuit fault, first, check electrical circuit and
start from making spark-over test on cylinders. If no high voltage spark is found or spark is
weak, it means the ignition system has a fault. If it is still normal after the above inspections
being checked and spark for each cylinder and electrical circuit are normal as well, then the
fault may probably arise from fuel line.
(b). Determine if individual cylinder or all cylinders work abnormally.
If the engine works abnormally, individual cylinder or all cylinders work abnormally. If
individual cylinder does not work or works abnormally, it is necessary to analyze and check
individual cylinder. If each cylinder of the engine works normally and any fault is not
obviously displayed, it is necessary to check and analyze each cylinder of the engine to reduce
52
work amount by 1/2. The following procedures shall be observed: start the engine and run idly.
After the temperature is normal, make fire cutoff test of distributing live line for each cylinder
discontinuously to check running conditions of the engine. If discontinuous fire cutoff and
refiring tests are made on single cylinder, the engine runs normally. It means this cylinder
works abnormally. So it is necessary to analyze and check this cylinder. If discontinuous fire
cutoff and refiring tests are made on all cylinders, the engine runs normally. It means working
conditions of all cylinders are the same. It is necessary to check all cylinders that are abnormal.
Fault Code Reading

1. Description
(a). So-called "fault code" refers to "vehicle computer self diagnosis fault code". When the vehicle
computer makes performance test for each part before starting and during the course of driving,
it finds a fault and then stores the information in the computer by means of fault code. For
example, when water temperature sensor circuit is open, the computer will detects that water
temperature sensor interface signal changes suddenly or deviates from normal value. Now, the
computer will record this state. So, "reading fault code" means reading fault code information
in vehicle computer and explains it correctly.
In this way, maintenance staff can differentiate these items easily.
(b). Contents of fault code. Normally, fault code of the instrument indicates fault position and fault
character. For example, "P0107" fault code, "intake air pressure sensor" is fault location; "low
voltage or open circuit" is fault character. For some vehicles, fault characters defined in fault
code are detailed, including short to ground, short to power supply, open circuit, poor contact,
signal too high, signal too low, rapid change and slow change.
Note:
• Through reading fault code, possible reasons and locations for most of faults can be
determined correctly. Sometimes, wrong judgment is made, which gives rise to misleading.
• In fact, fault code is only a conclusion, which does not give detailed reason of the fault. In
order to determine fault location, it is necessary to make further analysis and check according
to the engine fault symptom.
• Self diagnosis system cannot display all sensor faults. When ECM detects sensor signal, it only
receives abnormal signal beyond the range (sensor) to determine whether the sensor has a fault
or not. Normally, after reading fault code, check corresponding sensor, wire connector and
wire to find out and eliminate fault points of open circuit and short circuit. But, if the sensor
sensitivity reduces due to some reason (although it is within the range set by ECM, it responds
slowly. Output characteristic deviates), self diagnosis system cannot detect it.
53
• Although the engine really has a fault, self diagnosis system outputs normal code without any
fault. Now, it is necessary to analyze and determine the engine fault symptom, and then check
the sensor to find out and make troubleshooting of the sensor. For example, when the engine
runs unstably at idle speed and with unbalancing engine running and the system does not
output any fault code, first check air flow sensor or intake manifold pressure sensor because
these two sensors have direct effect on basic fuel injection amount. Although no corresponding
fault code is displayed, it is necessary to check them.
• Self diagnosis system may display wrong fault code. This is caused by working condition
signal error. For example, fault code displays "water temperature sensor short circuit or open
circuit" fault; but engine fault symptom: whenever the engine is cold or hot, it is difficult to
start, with backfire and unstable idling. The engine speed cannot be increased all the time.
Obviously, these faults are not close to water temperature sensor (check water temperature
sensor, and no fault is found).
• It is suggested to compare fault code with actual fault symptom of the engine to get an
appropriate judgment. Do not regard fault code as only one basis.
• Improper maintenance will cause wrong fault code. For example, during the course of running,
if one sensor plug is pulled out for testing at random, ECM will record one fault code of the
sensor.
• If old fault code is not cleared completely due to improper operation after repairing EFI engine,
the remaining old fault code is still displayed again, which leads to confusion of maintenance
staff.
• Before reading fault code, first execute "fault code clearing" operation.
• When the system has a fault, diagnosis tester is used to clear the fault code. If the system fault
is eliminated, the fault code will still appear when executing fault code operation again until
the fault is eliminated.
2. Reading procedure
△ Hint:
Fault LIFAN 630 engine electric control system is read by special diagnostic scanner provided by
LIFAN. If fault is read by diagnostic scanner not provided by LIFAN, the result is unreliable. The
diagnostic scanner used for reading and removing the following DTC is a LIFAN special V30
diagnostic scanner.
54
(a). Connect Lifan V30 diagnostic scanner to
the diagnostic connector.
(b). Turn on the diagnostic scanner, and enter into

Series selection
"Chongqing Lifan diagnosis system".
LIFAN Other
Dedicated s
Chongqing Lifan
System Help About Power

configurat off
ion
(c). Select the diagnostic program V5.0

Choose the version of
diagnosis program version, and then click "OK".
Demo
OK
Cance
l
Software of this version can test the engine, transmission,
ABS, airbag and anti-theft system of Lifan models.
Service help info not found.
Please choose a version, and then click "OK" to start

diagnosis.
55
(d). Select and enter "Power Train".
Chongqing Lifan LIFAN
Dedicated\Chongqing Lifan\V5.0\
Power system Previous
page
Anti-lock braking system
Airbag system Next
page
Immobilizer
Instrument system Print
Vehicle body system
A/C system Return
Electrical power steering system
(e). Select and enter "Engine System (UMC

Power system LIFAN Dedicated\Chongqing
Lifan\V5.0\Power system\Engine
Engine system (DELPHI)
ME788)".
Previous
Engine system (SUN-TECK) page
Automatic clutch system (ACS) Next

Engine system (DELPHI MT20U2/CNG) page
Continuously Variable Transmission Print

system (CVT)
Engine system (DELPHI VVT ETC)
Engine system (UMC Return
M797)
(f). Select and enter "Read DTC".

UMC EMS LIFAN Dedicated\Chongqing
Lifan\V5.0\Power system
Read fault code Previous
page
Clear fault code
Read data stream
Next
Version information page
Motion test Print
Return
56
(g). Read the engine EFI DTC information.
Fault code list
Fault code Description

Engine coolant temperature sensor
circuit is too high
Previou Next Help Print Return

s page page
DTC Clearing
1. Description
(a). "Clearing fault code" means clearing fault code information in vehicle computer.
(b). The DTC can be cleared only after the vehicle fault has been troubleshot.
(c). After the completion of erasing the DTC, the tester will perform the operation of reading the
DTC once automatically. If the tester can still read a DTC, it is an indication that there is still a
certain fault which has not been eliminated.
(d). Using the function of 'Clear DTC’ to remove some DTCs which can be directly removed from
ECM fault memory after repair.
Note:
Some DTC may light MIL in OBD system, it is necessary to start several times according to
corresponding calibration mode to clear it automatically.
2. Clearing procedure
△ Hint:
The usual methods for removing DTC include: using nstrument, disconnecting the battery negative
cable and disconnecting the master fuse of electronic control system.
DTC of LIFAN 630 model is cleared by special V30 diagnostic scanner.
(a). Connect the LIFAN V30 diagnostic scanner to the diagnostic interface of diagnostic scanner.
(b). Turn on the diagnosis tester, and enter into "Chongqing Lifan diagnosis system".
(c). Select the diagnostic program V5.0 version, and then click "OK".
(e). Select and enter "Engine System (UMC ME788)".
57
(f). Click "Clear DTC" to clear off DTC.
Read fault code Previou
Clear fault code s page
Read data stream Next

Motion test Print
Return
(g). Select "Confirm" to clear fault code.

Information
△ Hint:
Do you want to clear all the fault
codes. OK
If the DTC cannot be removed, it is an indication
Cancel
that the fault has not been troubleshooted. You
should remove the fault based on the DTC before
trying to remove the DTC again.
Read Data Flow

1. Description
The so-called data flow refers to the electrical signals sent out by the auto computer in a
continuous manner based on various operating parameters and work status of a certain system.
There are many data flows. Common data flow in engine system as follows:
• Ignition Advance Angle
• Throttle Position
• Number of steps of idling-speed control motor
• Intake manifold pressure
• Coolant temperature
• Inlet air temperature
• Intake manifold Pressure
58
• Atmospheric Pressure
• Fuel injection start angle
• Battery voltage and soon
Note:
Reading the data table displayed on the diagnostic tester, you can check data values, including
switches, sensors, actuators and other parts, without removing any part. First read data table so as to
shorten diagnosis time.
2. Reading procedure
(a). Connect the LIFAN V30 diagnostic scanner to the diagnostic interface of diagnostic scanner.
(b). Turn on the diagnosis tester, and enter into "Chongqing Lifan diagnosis system".
(c). Select the diagnostic program V5.0 version, and then click "OK".
(e). Select and enter "Engine System (UMC ME788)".
(f). Click "Reading data flow".


Motion test Print
Return
59
(g). Click and select the content to be read.
Data stream list
Battery voltage Previou

Engine speed s page
Target idle (without Next

compensation)
Target idle (with page
compensation)
Vehicle speed Print
Car acceleration
Engine coolant temperature sensor
Return
voltage
Engine coolant temperature
Intake air temperature sensor Cancel
voltage
Inlet air temperature
(h). Select the normal mode.

Please select mode
Common mode Self-study mode
Comparison mode
OK Cancel
(i). Read the data.

Data stream
Enable data stream

memory playback
Name Current Unit
value
Battery voltage
Engine speed
Target idle (without
compensation)
Target idle (with
compensation)
Vehicle speed
Previou Next Wavefo Playbac

s page page rm k Return
Help Print Channe Record
l
60
Motion Test
1. Description
Action testing is a type of self-learning process of the components. It does not require any part
removal. It can perform testing on the components (including relays and actuators) and learn
other special operations.
2. Test procedures
(a). Connect Lifan V30 diagnostic scanner to the diagnostic connector.
(b). Rotate ignition switch to "ON" position.
(c). Turn on the diagnosis tester, and enter into "Chongqing Lifan" diagnosis system.
(d). Select V5.0 diagnosis procedure version, and click "OK".
(e). Select and enter "Power Train"
(f). Select and enter "Engine System (UMC ME788)".
(g). Click "Action Testing".

Motion test
Print
Return
(h). When using the action testing function to check the engine components, if you find any
abnormal phenomenon, be sure to check and repair the relevant harnesses or components.
(i). After repair, clear DTC.
(j). Start the engine and use the V30 diagnostic tester to verify whether the fault has been
eliminated.
(k). Disconnect the connection between the V30 diagnostic tester and the diagnostic interface.
3. Test items
S/N Name Test mode Description

Engine fault indicator Test if engine malfunction
1 ON/OFF
lamp (MIL). indicator light works normally
61
Starting the engine, test whether
0~255
2 Canister control valve canister solenoid is working
0~255
properly.
Test if fuel pump relay works
3 Fuel pump relay ON/OFF
normally
Test whether low-speed fan is
4 Cooling fan relay #1 ON/OFF
working properly.
Test whether high-speed fan is
5 Cooling fan relay #2 ON/OFF
working properly.
Test if air conditioner relay works
6 A/C clutch ON/OFF
normally
Service Vehicle Soon Test whether the SVS indicator
7 ON/OFF
(SVS). lamp is working properly.
Start the engine to perform
8 Forbidden fuel injection ON/OFF
injector control.
Start the engine to input
0~255 numerical value. Turn off ignition
9 Idle speed control
0~255 switch and restore the original
settings
62
Problem Symptoms Table
△ Hint:
The causes of EFI engine failure phenomenon are various and complex. The common potential
locations of the corresponding faults are listed in the following table. Following the described
locations to troubleshoot one by one can allow most problems to be solved.
Symptom Suspected Area Recommended Action
1. Power supply (ECM power supply Check the battery voltage and make
The diagnosis tester circuit is poor) troubleshooting for power supply circuit
cannot communicate with 2. The circuit between ECM and
Make troubleshooting for the circuit
ECM diagnosis tester (open circuit)
3.ECM (damaged) Replace
1. Intake air system (air leakage) Check and eliminate system leakage
Check fuel pressure and eliminate fuel system
2. Fuel pressure (too low)
fault
3. Air filter (clogging) Clean and eliminate clogging
4. Coolant temperature sensor
Inspection and replacement
(damaged)
The engine cannot be 5. Electronically controlled throttle
started valve housing (damaged)
6. Injector (oil leakage) Replace fuel injector
7. Ignition timing (Incorrect) Adjust ignition timing
8. Connection from the ignition lock to
ECM (open-circuit)
9. Cylinder compression pressure (too Check cylinder pressure and eliminate
low) mechanical fault of the engine
1. Intake air system (air leakage) Check and eliminate system leakage
2. Fuel pressure (too low)
fault
3. Air filter (clogging) Clean and eliminate clogging
4. Coolant temperature sensor
(damaged)
It is difficult to start a
5. Electronically controlled throttle Replace
cold engine and the
valve housing (damaged)
vehicle is shaking
6. Injector (oil leakage) Replace fuel injector
7. Ignition timing (Incorrect) Adjust ignition timing

8. Connection from the ignition lock to
ECM (open-circuit)
1. Ignition system (fault) Check and eliminate ignition system fault
-
2.Air-fuel ratio (incorrect)
-
Idle speed is not stable 3. Idle air stepper motor (poor) Repair or replace
5. Front and rear oxygen sensors
Re-connect them properly.
(reversal).
Idle speed is too high 1.Intake air system (vacuum leakage) Check and eliminate system leakage
63
Symptom Suspected Area Recommended Action
2. Electronically controlled throttle
Replace
3.ECM (damaged) Replace
2. Air-fuel ratio (incorrect) -
3. Fuel supply system (fault)
Poor acceleration and fault
performance 4. Cylinder compression pressure (too Check cylinder pressure and eliminate
5. Exhaust system (blocked) Clean and eliminate clogging
6. ECM (damaged) Replace
-
1.Air-fuel ratio (incorrect)
-
2. Fuel supply system (fault)
fault
Accelerated reaction is
slow and unbalanced

1. Electronically controlled throttle
Replace
The engine will flame out 2. Fuel injector (damaged) Replace fuel injector
when starting 3. Ignition system (fault) Check and eliminate ignition system fault
4. Load signal (poor) -
2. Air-fuel ratio (incorrect) -
Engine will flame out 3. Intake air system (fault) Check and eliminate intake air system fault
when it runs at idle speed 4. Cylinder compression pressure (too Check cylinder pressure and eliminate
in cold state Check and eliminate emission control system
5. Discharge control system (fault)
fault
64
Fault Code (DTC) List
Note:
In check mode, if a certain DTC is displayed, it is necessary to check electrical system associated to
the code listed in the following table.
Fault code
Fault code description Suspected Area
(DTC)
• Valve timing
• VVT solenoid valve
• Solenoid valve filter element
P000A The intake VVT responds slowly.
• VVT actuator assembly
• ECM
• ECM
• Intake VVT valve
VVT intake control valve circuit is • Intake VVT valve wire harness
P0010
open-circuited. • ECM
• ECM
• Valve timing
• VVT solenoid valve
When starting, the intake VVT valve is not at • Solenoid valve filter element
P0012
the default position. • VVT actuator assembly
• ECM
• ECM
• Timing chain tensioner
• Timing chain
• Crankshaft sprocket
Unreasonable relative position of camshaft and
P0016 • Exhaust sprocket
crankshaft installation
• VVT actuator
• ECM
• ECM
• Front oxygen sensor
Failed heating control circuit of upstream • Front oxygen sensor wire harness
P0030
oxygen sensor • ECM
• ECM
Voltage below level of heating control circuit • Front oxygen sensor wire harness
P0031
of upstream oxygen sensor • ECM
• ECM
Overhigh voltage of heating control circuit of • Front oxygen sensor wire harness
P0032
upstream oxygen sensor • ECM
• ECM
• Rear oxygen sensor
Failed heating control circuit of downstream • Rear oxygen sensor wire harness
P0036
oxygen sensor • ECM
• ECM
Voltage below level of heating control circuit • Rear oxygen sensor wire harness
P0037
of downstream oxygen sensor • ECM
• ECM
• Rear oxygen sensor wire harness
Overhigh voltage of heating control circuit of
P0038 • ECM
downstream oxygen sensor
• ECM
• Front oxygen sensor wire harness
Unreasonable heated internal resistance of
P0053 • ECM
upstream oxygen sensor
• ECM
65
• Rear oxygen sensor wire harness
Unreasonable heated internal resistance of
P0054 • ECM
downstream oxygen sensor
• ECM
• Intake air temperature/pressure sensor
• Intake air temperature/pressure sensor wire
P0105 No fluctuation of intake pressure sensor signal harness
• ECM
• ECM
Unreasonable intake pressure sensor
P0106 harness
/atmospheric pressure sensor
• ECM
• ECM
Intake pressure sensor short-circuited to
P0107 harness
ground
• ECM
• ECM
Intake pressure sensor short-circuited to power
P0108 harness
supply
• ECM
• ECM
Voltage below level of intake temperature
P0112 harness
sensor signal circuit
• ECM
• ECM
Overhigh voltage of intake temperature sensor
P011313 harness
signal circuit
• ECM
• ECM
• Coolant temperature sensor
Voltage below level of engine coolant • Coolant temperature sensor wire harness
P0117
temperature sensor circuit • ECM
• ECM
• Coolant temperature sensor
Overhigh voltage of engine coolant • Coolant temperature sensor wire harness
P0118
temperature sensor circuit • ECM
• ECM
Unreasonable electronic throttle position
P0121 • Electronic Control throttle valve housing
sensor 1 signal
• Electronic Control throttle valve housing
• Electronically controlled throttle valve
Voltage below level of signal circuit of
P0122 housing wire harness
electronic throttle position sensor 1
• ECM
• ECM
Overhigh voltage of signal circuit of electronic
P0123 housing wire harness
throttle position sensor 1
• ECM
• ECM
P0130 Unreasonable upstream oxygen sensor signal • Front oxygen sensor
P0131 Low voltage of upstream oxygen sensor signal
• ECM
• ECM
P0132 Overhigh voltage of upstream oxygen sensor • Front oxygen sensor
66
signal circuit • Front oxygen sensor wire harness
• ECM
• ECM
P0133 Upstream oxygen sensor aging • Front oxygen sensor
P0134 Upstream oxygen sensor circuit signal failure
• ECM
• ECM
Unreasonable downstream oxygen sensor
P0136 • Front oxygen sensor
signal
Low voltage of downstream oxygen sensor • Rear oxygen sensor wire harness
P0137
signal • ECM
• ECM
Overhigh voltage of downstream oxygen • Rear oxygen sensor wire harness
P0138
sensor signal circuit • ECM
• ECM
Downstream oxygen sensor circuit signal • Rear oxygen sensor wire harness
P0140
failure • ECM
• ECM
housing wire harness
harness
Unreasonable self-learning of end of line test
P0170 • Oxygen sensor
of air-fuel ratio closed-loop control
• Oxygen sensor wire harness
• Intake air system hardware
• Fuel system pressure
• Fuel injector hardware
• ECM
• ECM
housing wire harness
harness
Over-thin self-learning of end of line test of
P0171 • Oxygen sensor
air-fuel ratio closed-loop control
• Oxygen sensor wire harness
• Intake air system hardware
• Fuel system pressure
• Fuel injector hardware
• ECM
• ECM
• Fuel injector leaks or is blocked
• Manifold pressure sensor
• Water temperature sensor
• Ignition system
• Fuel pressure
• Exhaust system gas leakage
Over-thick self-learning of end of line test of
P0172 • Oxygen sensor wire harness circuit is open or
air-fuel ratio closed-loop control
short
• Oxygen sensor
• Oxygen sensor heater
• Relay and wire harness
• ECM
• ECM
67
• No. 1 cylinder fuel injector
No. 1 cylinder's injector control open-circuited • Fuel injector wire harness
P0201
circuit • ECM
• ECM
P0202
circuit • ECM
• ECM
P0203
circuit • ECM
• ECM
P0204
circuit • ECM
• ECM
Unreasonable electronic throttle position
P0221 • Throttle position sensor (TAPS)
sensor 2 signal
• Throttle position sensor (TAPS)
Voltage below levelof signal circuit of • Throttle position sensor wire harness
P0222
electronic throttle position sensor 2 • ECM
• ECM
• Throttle position sensor (TAPS)
Overhigh voltage of signal circuit of electronic • Throttle position sensor wire harness
P0223
throttle position sensor 2 • ECM
• ECM
No. 1 cylinder's injector control circuit • Fuel injector wire harness
P0261
short-circuited to ground • ECM
• ECM
P0262
short-circuited to power supply • ECM
• ECM
P0264
• ECM
• Fuel injector wire harness
No. 2 cylinder's injector control circuit
P0265 • ECM
short-circuited to power supply
• ECM
• Three-cylinder fuel injector
No. 3 cylinder's injector control circuit • ECM
P0267
P0268
• Four-cylinder fuel injector
P0270
No. 4 cylinder's injector control circuit
P0271 • ECM
short-circuited to power supply
• ECM
• Engine harness
P0300 Several cylinders misfiring
• Injector
68
• Ignition System
• Fuel pressure
• Working voltage of intake air
temperature/pressure sensor
• Valve mechanism timing
• Valve clearance
• Cylinder head
• Vent valve pipe
• Air Intake system
• Vacuum hose
• ECM
• ECM
P0301 No. 1 cylinder misfiring • Same as DTC300
Unreasonable signal of missing teeth of
P0321 • Crankshaft position sensor
crankshaft TDC (top dead center)
• Crankshaft position sensor wire harness
P0322 Speed sensor signal fault • Crankshaft position sensor
• Crankshaft position sensor wire harness
• Knock sensor
Voltage below level of knock sensor signal • Knock sensor wire harness
P0327
circuit • ECM
• ECM
• Knock sensor
Overhigh voltage of knock sensor signal • Knock sensor wire harness
P0328
circuit • ECM
• ECM
• Camshaft position sensor
• Camshaft position sensor wire harness
P0340 Improper phase sensor mounting position
• ECM
• ECM
• Camshaft position sensor wire harness
P0341 Unreasonable phase sensor signal
• ECM
• ECM
Phase sensor signal circuit short-circuited to • Camshaft position sensor wire harness
P0342
ground • ECM
• ECM
Phase sensor signal circuit short-circuited to • Camshaft position sensor wire harness
P0343
power supply • ECM
• ECM
• Three-way catalytic converter.
Aging of oxygen storage capacity of three-way • Front oxygen sensor
P0420
catalytic converter (emissions overrun) • Rear oxygen sensor
• Exhaust leakage
• Canister control valve wire harness
Canister solenoid's control circuit • Canister control valve
P0444
open-circuited • ECM
• ECM
Voltage below levelof canister solenoid's • Canister control valve
P0458
control circuit • ECM
• ECM
Overhigh voltage of canister solenoid's control
P0459 • Canister control valve
circuit
• ECM
69
• ECM
P0501 Vehicle speed sensor signal fault • Vehicle speed sensor
• ETC throttle valve housing assembly
P0506 Speed of idle control less than target value housing wire harness
• ECM
• ECM
• ETC throttle valve housing assembly
P0507 Speed of idle control more than target value housing wire harness
• ECM
• ECM
• Battery
• Engine wire harness
P0560 Unreasonable battery voltage signal
• ECM
• ECM
• Battery
• Engine wire harness
P0562 Low battery voltage
• ECM
• ECM
• Battery
P0563 Overhigh battery voltage • ECM
• ECM
• Brake switch signal line
Brake switch signal circuit failed or
P0571 • ECM
correlation not synchronized
• ECM
• ECM
P0602 Electronic control unit (ECU) coding fault
• ECM
• ECM
P0604 ECU RAM fault
• ECM
• ECM
P0605 ECU ROM fault
• ECM
Electronic throttle safety monitoring function
P0606 • ECM
failed
• ECM
• Fuel pump relay
Voltage below level of oil pump relay control • Oil pump relay wire harness
P0628
circuit • ECM
• ECM
• Fuel pump relay
Overhigh voltage of oil pump relay control • Oil pump relay wire harness
P0629
circuit • ECM
• ECM
• A/C compressor relay
Voltage below level of A/C compressor relay • A/C compressor relay wire harness
P0646
• ECM
• A/C compressor relay
Overhigh voltage of A/C compressor relay • A/C compressor relay wire harness
P0647
• ECM
• Instrument
P0650 MIL lamp driver circuit failed
• CAN bus wire harness
• Cooling fan relay (low speed)
Voltage below level of cooling fan relay • Cooling fan relay (low speed) wire harness
P0691
control circuit (low speed) • ECM
• ECM
• Cooling fan relay (low speed)
Overhigh voltage of cooling fan relay control
P0692 • Cooling fan relay (low speed) wire harness
circuit (low speed)
• ECM
70
• ECM
• Cooling fan relay (high speed)
Voltage below level of cooling fan relay • Cooling fan relay (high speed) wire harness
P0693
control circuit (high speed) • ECM
• ECM
• Cooling fan relay (high speed)
Over Overhigh voltage of cooling fan relay • Cooling fan relay (high speed) wire harness
P0694
control circuit (high speed) • ECM
• ECM
MIL indicator lamp line

P0700 MIL external request failed
• ECM
• ECM
• Clutch switch signal line
P0704 Unreasonable clutch pedal switch signal • ECM
• ECM
• Electronic throttle line
Torque limit of electronic throttle safety
P1336 • ECM
monitoring
• ECM
Overrun of deviation between the actual • Electronic throttle line
P1545 position and target position of electronic • ECM
throttle • ECM
Excessive resistance of electronic throttle
P1558 • ECM
opening
• ECM
P1559 Electronic throttle self-learning process failed • ECM
• ECM
System voltage do not meet electronic throttle
P1564 • ECM
self-learning conditions
• ECM
Electronic throttle lower limit position
P1565 • ECM
initialized self-learning failed
• ECM
Excessive resistance of electronic throttle
P1568 • ECM
return
• ECM
Electronic throttle self-learning conditions are
P1579 • ECM
dissatisfied
• ECM
Electronic throttle gain-adjustment
P1604 • ECM
self-learning failed
• ECM
• Ignition key
• Ignition key excitation coil
Error of Secret Key and SECMrity Code not
P1610 • ECM
programming
• ECM
• Chip immobilizer module
• Ignition key
P1611 Error of SECMrity Code receiving • ECM
• ECM
• Chip anti-theft module
• Ignition key
P1613 IMMO Code request failed • ECM
• ECM
• Chip anti-theft module
Anti-theft certification communication error or • ECM
P1626
burglar alarm do not respond • ECM
71
• Burglar alarm
• ECM
P1631 Anti-theft certification failed
• ECM
• SVS indicator lamp line
P1651 SVS lamp drive-circuit failed • ECM
• ECM
VVT intake control valve circuit • Intake VVT valve wire harness
P2088
• ECM
VVT intake control valve circuit • Intake VVT valve wire harness
P2089
• ECM
• ECM
P2106 Electronic throttle drive-circuit failed
• ECM
• Sensor
Signal voltage below level of electronic • Sensor wire harness
P2122
accelerator pedal position sensor 1 • ECM
• ECM
• Sensor
High signal voltage of electronic accelerator • Sensor wire harness
P2123
pedal position sensor 1 • ECM
• ECM
• Sensor
Signal voltage below level of electronic • Sensor wire harness
P2127
• ECM
• Sensor
Overhigh signal voltage of electronic • Sensor wire harness
P2128
• ECM
Unreasonable electronic accelerator pedal
P2138 • Sensor
position sensor signal
• Fuel injector
Air-fuel ratio closed-loop control self-learning
• Canister
P2177 value exceeding upper limit (medium load
• Intake Air Temperature/Pressure Sensor
area)
• Fuel injector
Air-fuel ratio closed-loop control self-learning
• Canister
P2178 value exceeding lower limit (medium load
• Intake Air Temperature/Pressure Sensor
area)
• Fuel injector
Air-fuel ratio closed-loop control self-learning • Canister
P2187
value exceeding upper limit (low load area) • Intake Air Temperature/Pressure Sensor
• Fuel injector
Air-fuel ratio closed-loop control self-learning • Canister
P2188
value exceeding lower limit (low load area) • Intake Air Temperature/Pressure Sensor
P2195 Upstream oxygen sensor aging
• ECM
• ECM
P2196 Upstream oxygen sensor aging
• ECM
• ECM
72
Engine Control System - Fault Diagnosis
The Diagnosis Tester Cannot Communicate with ECM

Steps Diagnosis YES NO
Check engine data
• Rotate the ignition switch to OFF.
• Connect diagnosis tester to fault diagnosis connector (16-pin) on
the bottom left of dashboard.
Intermittent fault
1 • Rotate ignition switch to ON, and turn on the diagnosis tester- To Step 2
exists
use the latest software version.
• Read engine data displayed on the diagnosis tester.
• Check if the diagnosis tester can enter into ECM module to read
data flow
Inspection of data of other modules
• Read the airbag or ABS data displayed by the diagnostic tester.
2 • Read the data displayed by the diagnostic tester. To Step 4 To Step 3
• Check whether the diagnostic tester can enter the airbag or ABS
module to read the data flow.
Check ECM diagnosis communication circuit
• Disconnect ECM connector E01.
• Check whether the circuit between the Terminal 7 of diagnostic
interface I22 and the Terminal 71 of ECM connector has good
continuity with the digital multimeter.
Resistance: ＜2Ω
3 • Measure the continuity between 7# terminal of diagnosis To Step 5 To Step 6
interface I22and the ground with a multimeter.
Resistance: ＞1MΩ
• Rotate the ignition switch to ON, and measure the voltage of the
Terminal 7 of diagnostic interface I22 with the digital
multimeter.
Voltage: 0V
• Inspect if the result is normal
Check ECM power supply and earthing
4 • Disconnect ECM connector E01. To Step 5 To Step 6
• Check if ECM power supply works normally
• Check whether ECM grounding wire is short-circuited.
Replace ECM.
• Replace ECM. (Refer to Chapter 12 Electronic Control Unit) Recheck
5 • Read engine data displayed on the diagnosis tester. To Step 6 according to the
• Confirm whether V30 diagnostic scanner and ECM have normal sequence
communication.
Eliminate detected fault and test if the fault is eliminated.
6
Diagnosis is over.
73
The Engine Cannot be Started
Check the engine fault indicator and DTC.
• Rotate the ignition switch to position OFF. Refer to fault
• Connect diagnosis tester to fault diagnosis connector (16-pin) on the code list and
bottom left of dashboard. execute fault
1 To Step 2
• Rotate ignition switch to ON, and turn on the diagnosis tester- use the code
latest software version. diagnosis
• Read engine fault code. procedure.
• Check if fault code exists.
Check ignition system
• Remove the pen-type ignition coil, and remove the spark plug.
• Connect spark plug to ignition coil, and contact spark plug negative
2 To Step 4 To Step 3
electrode contacts cylinder block.
• Start the engine to test if ignition system is normal.
• When the engine runs, check if blue white spark comes from each spark
plug.
Check mechanical fault of ignition system
• Check the resistance of ignition coil, and clean the connector terminals.
Reference resistance：≥ 4 kΩ
3 • Inspect whether there is carbon, carbon sign deposited on spark plug, To Step 4 To Step 15
and whether ceramic insulation section has cracks or electricity leakage,
whether clearance is normal, whether positive and negative poles are
burned. And then clean the spark plug.
• Check if above-mentioned condition is normal.
Inspect crankshaft position sensor.
• With the diagnostic tester, read the data flows of the engine crankshaft
position sensor displayed by the diagnostic tester.
• When starting the engine, check if data flow reaches to specified value
Hint:
If the LIFAN V30 diagnostic scanner fails to read out the data flow of
crankshaft sensor due to the problem of software version, please refer to
Chapter 12 crankshaft position sensor.
Check the throttle
5 • Step on accelerator pedal slightly and start the engine. To Step 6 To Step 15
• Check if the engine starts.
Check coolant temperature sensor and intake air
• Check if intake air temperature/pressure sensor is installed correctly.
• Dismantle intake air temperature/pressure sensor.
• Check if gaging hole is blocked and the resistance between terminals
6 conform to the standard. To Step 7 To Step 15
• Check if temperature sensor is dirty.
• Ignition switch: ON, read the data flows of the engine intake
temperature / pressure sensor and coolant temperature sensor displayed
by the diagnostic tester.
• Inspection of circuits of fuel system
7 • Ignition switch: ON To Step 8 To Step 16
• Check whether the fuel pump relay and the fuel pump can work.
Check fuel system pressure \
8 • Check if fuel system pressure is normal? (See Chapter 13 Fuel System - To Step 15
fuel System, Onboard Inspection"). To Step 9
Check fuel system supply
9 • Check if inlet pipe leaks or is blocked? To Step 16 To Step 10
• Check the fuel filter for clogging.
10 Check fuel injector To Step 11 To Step 15
74
• Pull out fuel injector connector.
• Dismantle fixing bolt of fuel distribution pipe and pull out fuel
distribution pipe and fuel injector together.
• Apply the battery 12 V voltage on the fuel injector directly.
• Check if each fuel injector can inject fuel that conforms to standard flow
and atomize it uniformly.
• If it is not qualified, clean fuel injector, recheck if working condition of
fuel injector is normal?
Hint:
When checking the injector's injection state, if the injection shape is
columnar instead of tapered, or if the quantity of fuel injected by each
injector of the four cylinders under the same conditions is different
significantly(>5ml), replace the injector. Check fuel injector nozzle has
colloids. If it has, it is immersed in cleaning agent and washed. Otherwise,
fuel injection amount is insufficient or the acceleration is poor.
Note:
When testing the fuel system,
• Place a "Be careful: inflammable" mark in working area.
• Be sure to work at the ventilated area equipped with a carbon dioxide
fire extinguisher.
• It is forbidden to smoke when fuel system is used. Working area shall
keep away from open fire and spark.
• Place discharged fuel in a explosion proof contain.
Check cylinder pressure
• Perform cylinder compression pressure tests.
• Each cylinder reference pressure: 1.2MPa
• Each cylinder reference limit value: 1.0MPa
• Each cylinder phase-difference reference limit value: 0.1MPa
• Check whether all is normal.
Check engine valve timing
12 • Check if engine timing gear mark is aligned and damaged, if the belt is To Step 13 To Step 15
loose or has "jumping over teeth"?
Check mechanical part of the engine
• Dismantle and eliminate the fault inside the engine, clean carbon deposit
or dismantle engine cylinder head.
13 • Check valve and intake manifold carbon deposit. For example: clearance To Step 14 To Step 15
between piston ring and cylinder block is big and untight, cylinder pad
has air leakage; valve guide pipe is loose; valve is not tightly closed,
valve has carbon deposit.
Replace ECM. Recheck
• Replace ECM. (Refer to Chapter 12 Electronic Control Unit) according
14 • Check engine data flow and confirm engine fault does not exist. Check To Step 15
if the system is normal? Eliminate detected fault and test if the fault is to the
eliminated? Diagnosis is over. sequence
15
75
It is Difficult to Start a Cold Engine and the Vehicle is Shaking
Check engine malfunction indicator light and fault code
• Rotate the ignition switch to OFF. Refer to fault
1 To Step 2
• Check if fault code exists?
2
Inspect the battery. To Step 3 To Step 16
• When starting the engine, check if the battery voltage is ≥9.6 V?
3
Check the starter To Step 16 To Step 4
• Check starter or starter circuit has a fault?
Inspect crankshaft position sensor.
• With the diagnostic tester, read data flows of the engine crankshaft
position sensor displayed by the diagnostic tester.
4 • When starting the engine, check if data flow reaches to specified value To Step 5 To Step 16
Tip: If the LIFAN V30 diagnostic scanner fails to read out the data flow of
the crankshaft sensor due to the problem of software version, please refer
to Chapter 12 Crankshaft Position Sensor.
• Check if gaging hole is blocked and the resistance between terminals \ \
5 conforms to the standard. To Step 6 To Step 16
• Ignition switch: ON, read data flows of the engine intake temperature /
pressure sensor and coolant temperature sensor displayed by the
diagnostic tester.
Check intake air system
• Inspect whether joints of intake pipe, bushing, vacuum hose and fuel
evaporation system are damaged.
• Check if air filter element is clogged.
Check the throttle
7 • Step on accelerator pedal slightly and start the engine. To Step 16 To Step 8
• Check if the engine starts?
Inspection of idle-speed stepping motor
• Rotate ignition switch to "ON" position, and inspect whether idle air
stepper motor is telescopic.
• Rotate ignition switch to "OFF" position, and inspect whether idle air
stepper motor takes action. If normal, the opening should be maximum
value.
Check fuel system pressure
9 • Check if fuel system pressure is normal? (See Chapter 13 Fuel System - To Step 11 To Step 10
Fuel System, Onboard Inspection").
10 • Check if inlet pipe leaks or is blocked? To Step 11 To Step 16
Check fuel injector
11 distribution pipe and fuel injector together. To Step 12 To Step 16
76
fuel injector is normal?
Hint:
injector of the four cylinders under the same conditions is different
Note:
• Be sure to work at ventilated area equipped with a carbon dioxide fire
extinguisher.
13 • Check if engine timing gear mark is aligned and damaged, check if the To Step 14 To Step 16
belt is loose or has "jumping over teeth".
• Check valve and intake manifold carbon deposit. For example: clearance
Replace ECM.
• Replace ECM. (Refer to Chapter 12 Electronic Control Unit)
if the system is normal? Eliminate detected fault and test if the fault is
eliminated? Diagnosis is over.
16
Idle Speed Unstable

1 To Step 2
• Check if fault code exists?
Visual check and external check
• Start the engine and observe engine running conditions and shaking
degree.
• Observe engine tachometer pointer swing and the speed at the time of
flameout.
• Observe if the engine flames out at normal idle speed or at loading idle
77
speed. (turn on air conditioner, lights, put into gears and turn steering
wheel, etc.)
• Check if external parts of the engine are abnormal. Check if vacuum
pipe is loose or damaged. Check if the connector is loose.
• Check if the engine has fuel, water, gas and electricity leakage.
• Check the exhaust pipe for chug (an indication of poor burning), black
smoke, fresh gasoline smell and other abnormal phenomena.
• Check if the above-mentioned conditions are normal.
Inspection of electronic control throttle valve housing
• Check if the throttle has oil stain and carbon deposit, is smooth, if inlet
duct around the throttle has oil stain and carbon deposit, and if stepper
motor has carbon deposit.
• Start the engine and make it idle.
• When the diagnostic tester controls the idle air stepper motor extending
and rotating, the engine speed will change synchronously.
stepper motor takes action.
• Remove the pen-type ignition coil, and remove the spark plug.
plug.
• Check if the above-mentioned condition is normal.
Check fuel injector
• Apply the battery 12 V voltage on fuel injector directly.
fuel injector is normal.
Hint:
6 columnar instead of tapered, or if the quantity of fuel injected by each To Step 7 To Step 16
injector of four cylinders under the same conditions is different
fuel injection amount is insufficient or the acceleration is poor. Note: when
testing fuel system:
fire extinguisher.
7
Check fuel system pressure To Step 9 To Step 8
• Check if fuel system pressure is normal. (See Chapter 13 Fuel System -
78
fuel System, Onboard Inspection").
8 • Check if inlet pipe leaks or is blocked. To Step 9 To Step 16
Check intake/exhaust system
• Check if engine intake air system leaks.
• Check if intake air pipe connection is loose, cracked or deformed, or
sealing is aged.
• Check if intake air pipe has air leakage when the engine is running.
• Check the positive crankshaft ventilation valve (PCV) hoses for leak,
and check whether the PCV opens excessively.
• Check if evaporation emission control system vacuum pipe leaks.
• Check if three-way catalytic converter is blocked.
• Check if throttle body seal leaks.
• Check if intake manifold seal gasket leaks.
10 conform to the standard. To Step 11 To Step 16
temperature/pressure sensor and coolant temperature sensor displayed
Check oxygen sensor
• Check if pre/rear oxygen sensor is installed correctly.
111 • When the engine runs idly, check the diagnosis tester data flow. After To Step 12 To Step 16
coolant temperature reaches normal temperature of activated closed-loop
control, check if oxygen sensor works normally.
loose or has "jumping over teeth".
Replace ECM.
if the system is normal. Eliminate detected fault and test if the fault is
eliminated. Diagnosis is over.
16
79
Idle speed Overhigh
1 To Step 2
degree
• Observe engine tachometer pointer swing and speed at the time of
flameout.
2 To Step 10
wheel, etc.) To Step 3
• Check if engine intake air system leaks.
3 • Check if intake air pipe has air leakage when the engine is running. To Step 4 To Step 10
• Check if intake air pipe connection is loose, cracked or deformed, or
sealing is aged.
Check related accessories
• Check if canister control valve vacuum hose is connected reliably or
damaged.
4 • Check if crankcase forced vent vacuum pipe is installed reliably or To Step 5 To Step 10
damaged.
• Check if brake system vacuum boosting pipe is installed reliably or
damaged.
• Check if the throttle has oil stain and carbon deposit, is smooth, if inlet
duct around the throttle has oil stain and carbon deposit, and if stepper
motor has carbon deposit.
• When the diagnostic tester controls the idle air stepper motor extending
and rotating, the engine speed will change synchronously.
80
7 • Check if fuel system pressure is normal. (See Chapter 13 Fuel System - To Step 8 To Step 10
Check fuel injector
• Apply the battery 12 V voltage on fuel injector directly.
Hint:
Note:
fire extinguisher.
• Place discharged fuel in an explosion proof contain.
Replace ECM.
10
81
Poor Acceleration and Performance
1 To Step 2
• Rotate ignition switch to ON, and turn on the diagnosis tester-, use the code
degree.
flameout.
wheel, etc.)
Check throttle position
• Check the diagnosis tester and check the throttle is normal.
• Check if throttle opening change is normal when stepping on accelerator
pedal.
• Check fuel filter for clogging.
Check fuel injector
• Apply battery 12 V voltage on fuel injector directly.
7 • Check if each fuel injector can inject fuel that conforms to standard flow To Step 8 To Step 14
Hint:
82
Note:
fire extinguisher.
• Remove pen-type ignition coil, and removespark plug.
plug.
11 • Check if engine timing gear mark is aligned and damaged, if the belt To Step 12 To Step 14
is loose or has "jumping over teeth".
• Dismantle and eliminate the fault inside the engine, clean carbon
deposit or dismantle engine cylinder head.
• Check valve and intake manifold carbon deposit. For example:
clearance between piston ring and cylinder block is big and untight,
cylinder pad has air leakage; valve guide pipe is loose; valve is not tightly
closed, valve has carbon deposit.
Replace ECM.
14
83
Accelerated Reaction is Slow and Unbalanced
1 To Step 2
• Inspect whether joints of intake pipe, bushing, vacuum hose and fuel
evaporation system are damaged.
• Check if air filter element is clogged.
3
Check idle speed To Step 4 To Step 14
• Check if idle running of the engine is normal.
• Ignition switch: ON, read the data flows of engine intake
• With the diagnostic tester, check whether the throttle position will
5 change normally. To Step 6 To Step 14
pedal.
Check fuel injector
Hint:
Note:
fire extinguisher.
84
fuel System, Onboard Inspection").
Inspect the exhaust system.
9 • Check if exhaust system and three-way catalyst are normal. To Step 14 To Step 10
• Check if exhaust pipe is blocked.
Replace ECM.
14
85
The Engine Flames out When Starts
1 To Step 2
degree.
flameout.
2 • Observe if the engine flames out at normal idle speed or at loading idle To Step 3 To Step 14
wheel, etc.)
• Check if external parts of the engine are abnormal. Check vacuum pipe
is loose or damaged; check if the connector is loose.
• Check if the throttle has oil stain and carbon deposit, if it is smooth, if
inlet duct around the throttle has oil stain and carbon deposit, and if
stepper motor has carbon deposit.
• When diagnostic tester controls idle air stepper motor extending and
rotating, the engine speed will change synchronously.
• Check diagnosis tester and check the throttle is normal.
pedal.
• Rotate ignition switch to OFF.
• Remove pen-type ignition coil, and remove spark plug.
plug.
Check fuel injector
7 • Pull out fuel injector connector. To Step 8 To Step 14
86
Hint:
Note:
fire extinguisher.
• Place discharged fuel in an explosion proof contain.
Replace ECM.
14
87
Engine Flames out When It Runs at Idle Speed in Cold State
Check engine malfunction indicator light and fault code Refer to
fault code
• Connect diagnosis tester to fault diagnosis connector (16-pin) on the bottom
list and
left of dashboard.
1 execute To Step 2
• Rotate ignition switch to ON, and turn on the diagnosis tester- use the latest
fault code
software version.
diagnosis
• Read engine fault code.
procedure.
• Start the engine and observe engine running conditions and shaking degree.
flameout.
wheel, etc.)
• Check if external parts of the engine are abnormal. Check vacuum pipe is
loose or damaged; check if the connector is loose.
• Check if the throttle has oil stain and carbon deposit, is smooth, if inlet duct
around the throttle has oil stain and carbon deposit, and if stepper motor has
carbon deposit.
• When the diagnostic tester controls the idle air stepper motor extending and
rotating, the engine speed will change synchronously.
Check coolant temperature sensor
• Check if the resistance between coolant temperature sensor terminals
conforms to the standard.
4 • Check if coolant temperature sensor is dirty. To Step 5 To Step 13
• Rotate ignition switch to ON, read diagnosis tester coolant temperature
sensor data flow.
• Check if data flow is normal.
Inspection of intake temperature sensor
• Check if the resistance between intake air temperature sensor terminals
conforms to the standard.
5 • Check if intake air temperature sensor is dirty. To Step 6 To Step 13
• Rotate the ignition switch to ON, and read the data flows of the intake
temperature sensor displayed by the diagnostic tester.
• Check if data flow is normal.
Check fuel injector
• Dismantle fixing bolt of fuel distribution pipe and pull out fuel distribution
pipe and fuel injector together.
6 • Check if each fuel injector can inject fuel that conforms to standard flow To Step 7 To Step 13
• If it is not qualified, clean fuel injector, recheck if working condition of fuel
injector is normal.
Hint:
When checking the injector's injection state, if the injection shape is columnar
88
instead of tapered, or if the quantity of fuel injected by each injector of the
four cylinders under the same conditions is different significantly(>5ml),
replace the injector. Check fuel injector nozzle has colloids. If it has, it is
immersed in cleaning agent and washed. Otherwise, fuel injection amount is
insufficient or the acceleration is poor.
Note:
• Be sure to work at the ventilated area equipped with a carbon dioxide fire
extinguisher.
• It is forbidden to smoke when fuel system is used. Working area shall keep
away from open fire and spark.
7 • Check if fuel system pressure is normal. (See Chapter 13 Fuel System - fuel To Step 8 To Step 13
System, Onboard Inspection").
• Dismantle and eliminate the fault inside the engine, clean carbon deposit or
dismantle engine cylinder head.
between piston ring and cylinder block is big and untight, cylinder pad has
air leakage; valve guide pipe is loose; valve is not tightly closed, valve has
carbon deposit.
Replace ECM.
12 • Check engine data flow and confirm engine fault does not exist. Check if To Step 13
the system is normal. Eliminate detected fault and test if the fault is
13
89
P000A - Slow response of intake VVT
P0012 - Intake VVT is not at the default location when it starts.
Circuit Diagram
Intake VVT valve
WT valve control
Main relay control
box
central control
compartment
Engine
Description of intake VVT valve
1. The intake camshaft position (CMP) actuator is connected to the intake camshaft and operated
by hydraulic pressure. The hydraulic pressure is provided by oil pump in order to change the
angle of intake camshaft relative to crankshaft position (CKP).
2. The intake VVT solenoid valve is powered by main relay, and ECM is grounded with the pulse
width control signal. Thereby, the oil flow of engine to actuator of the camshaft position is
controlled.
3. The engine oil pressure will drive a safety slide valve inside camshaft position actuator
mechanism fixed at the front of the camshaft to move. When safety slide valve moving, engine
oil will be led into camshaft position actuator to make camshaft rotate.
4. The intake camshaft position actuator can allow the cam working angle to change
50 °maximally.
90
Diagnostic Steps
Note:
Before carrying out this diagnosis steps, you should observe the data list on the fault diagnosis
tester and analyze the accuracy of the data to help quick troubleshooting.
1. Primary check
(a). Before executing the following procedures, ensure ECM grounding is good.
(b). Before executing electronic diagnosis and test, refer to circuit diagram and component
information.
(c). Before measuring, first check if connector terminal is broken, loose or corrosive, ensure the
terminal contact is good.
91
2. Read DTC on the diagnosis tester
(a). Connect fault diagnosis tester to a datalink

connector.
(b). Rotate the ignition switch to ON.
(c). Press the fault diagnosis tester power button.
(d). Select from the following menu items: Power
Train/Engine System (UMC ME788) / Read
DTC.
(e). Read DTC codes.
Check whether the displayed DTC are the DTC except P000A and P0012.
Yes ＞ Go to the DTC list.
No ＞ Go to Step 3.
92
3. Inspect resistance of intake VVT valve
(a). Disconnect the connector E22 of intake VVT

solenoid valve harness.
(b). Measure the resistance between Terminal 1 and
Terminal 2 of intake VVT solenoid valve with
the digital multimeter.
Standard resistance: 9.4 ~ 10.6Ω (20°C_
Check if the test result is normal.

Yes ＞ Go to Step 4.
No ＞ Replace the intake VVT solenoid valve.
Note:
To avoid explosion, fire or other danger, don't connect the two cables together directly in the
process of testing.
93
4. Inspect action of VVT valve.
(a). Connect the battery positive cable to Terminal 1 of

the intake VVT solenoid valve, and the battery
negative cable to Terminal 2 of the intake VVT
solenoid valve.
(b). Check the valve core for movement.

Yes ＞ Go to 11--Engine Mechanical System-- Fault Diagnosis.
5. Use fault diagnosis tester to confirm if fault code is stored again
(a). Use a diagnosis tester to execute DTC confirmation procedure.

(b). Execute reading sensor data flow procedure. Confirm no DTC exists and data is normal.
94
P0010 - VVT intake control valve circuit is open-circuited.
P2088 - Intake VVT intake solenoid valve circuit short-circuited to ground
P2099 - Intake VVT intake solenoid valve circuit short-circuited to power
supply
Circuit Diagram
Intake VVT valve
VVT valve control
Main relay control
control box
central
compartment
Engine
Description of intake VVT valve

1. The intake VVT solenoid valve controls the internal ground of the solenoid valve through the
Terminal 48 of ECM harness connector E01.
2. There is a feedback circuit inside ECM. The engine ECM determines whether control circuit is
open-circuited, short-circuited to ground or short-circuited to voltage through monitoring the
feedback signal.
3. If the engine ECM detects the voltage of the control circuit within predefined range when the
control circuit is disconnected by commands, this DTC will occur.
95
Diagnostic Steps
1. Primary check
information.
2. Read DTC on diagnosis tester

connector.
Train / Engine System (UMC ME788) / Read
DTC.
Check whether the displayed DTC are P0010, P2088 and/or P2099.
No ＞ Go to fault code (DTC) list.
3. Inspection of voltage of power supply of intake VVT solenoid valve
96
(a). Rotate the ignition switch to the "OFF" position;
(b). Disconnect the connector E22 of intake VVT
solenoid valve wire harness.
(c). Rotate ignition switch to "ON" position.
(d). Measure the voltage between the Terminal 1 of
E22 connector and ground with the digital
multimeter.
Voltage: 11~14V
4. Inspection of control circuits and connectors of VVT solenoid valve

(b). Disconnect the connector E22 of intake VVT
(c). Disconnect ECM connector E21.
(d). Measure the resistance between Terminal 2 of the
intake VVT solenoid valve connector E22 and
the Terminal 48 of ECM connector E01 with the
digital multimeter.
电阻：≤ 2Ω
Resistance: ≤2Ω
(e). Measure the resistance between Terminal 2 of
intake VVT solenoid valve connector E22 and
ground with the digital multimeter.
Resistance: ＞1MΩ
97
(f). Rotate ignition switch to ON position. Measure
the voltage between Terminal 2 of intake VVT
solenoid valve connector E22 and ground with
digital multimeter.
Voltage: 0 V
Note:
At the moment, E01 and E22 connectors must be in
the disconnection position.
No ＞ Repair or replace the corresponding harness and connector.
5. Inspection of power circuits of intake VVT solenoid valve
(a). Rotate the ignition switch to the OFF position.

Disconnect Normal
(b). Open the central control box of engine
compartment.
(c). Check if fuse FS04 is in good condition.
(d). Pull out relay RL02, and apply the battery voltage
between terminals 1 and 2 of RL02. Check for the
continuity between terminals 3 and 5 of RL02
with digital millimeter.
No ＞ Replace the fuse or relay.
6. Inspection of connection between intake VVT solenoid valve and main relay
98
(a). Disconnect connector E22 of intake VVT
solenoid valve.
(b). Disconnect the connector EU1.
(c). Measure the resistance between Terminal 1 of
E22 and Terminal 7 of EU1 with digital
multimeter.
Resistance: ≤2Ω
(d). Use a digital multimeter to check the resistance
between No.1 terminal of E22 and grounding.
Resistance: ＞1MΩ

No ＞ Repair or replace faulty wire harness.
7. Inspect resistance of intake VVT valve
(a). Disconnect the connector E22 of the intake VVT

Terminal 2 of E22 of intake VVT solenoid valve
with the digital multimeter.
Resistance: 9.4 ~ 10.6 Ω (20 °C)

8. Replace ECM
(a). Replace ECM.

(b). Use a diagnosis tester to execute DTC confirmation procedure.
99
(c). Execute reading sensor data flow procedure. Confirm no DTC exists and data is normal.
100
P0105 - No fluctuation of intake pressure sensor signal
P0106 - Unreasonable intake pressure sensor/atmospheric pressure sensor
P0107 - Intake air pressure sensor short-circuited to ground
P0108 - Intake air pressure sensor short-circuited to power supply
Circuit Diagram
IATS signal
Intake Air Temperature/Pressure Sensor

MAPS signal
Intake air pressure sensor description
1. The intake pressure sensor (MAPS) is a type of sensor for indirect measurement of engine
intake volume. Its function is to detect engine working condition through measuring intake
pressure between throttle valve and intake manifold, and to convert the pressure signal into
electric signal to input the engine ECM so that ECM can calculate and determine fuel injection
time and ignition timing.
2. Sensor circuit consists of: 5V reference voltage circuit, low reference voltage circuit, sensor
101
signal circuit.
3. ECM provides a 5V reference voltage to Terminal 2 of sensor harness connector E27
throughTerminal 33 of ECM harness connector E01. Meanwhile, it also provides a low
reference voltage circuit to Terminal 4 of sensor E27 through Terminal 17 of E01.
4. The sensor is also used to determine atmospheric pressure, and this occurs when the ignition
switch is turned on while the engine is shut off. As long as the engine runs with throttle fully
open, atmospheric pressure readings will also be updated.
5. ECM monitors sensor signal to determine whether the voltage exceeds normal range.
Diagnostic Steps
△ Hint:
Intake air temperature/pressure sensor consists of intake air pressure sensor and intake air
temperature sensor.
1. Primary check
information.
102
connector.
(c). Start the engine and run for a period of time.
(d). Press power supply key of fault diagnosis tester.
(e). Select from the following menu items: Power
DTC.
(f). Read fault diagnosis code.
Check whether the displayed DTC are P0105, P0106, P0107 and/or P0108.
3. Check intake air pressure sensor power supply voltage

(b). Disconnect intake air temperature/pressure
sensor connector E27.
(d). Measure the voltage between 2# terminal of wire
harness connector E27 and the ground with a
digital multimeter.
Voltage: 4.5~5.5V
4. Inspection of reference power line of intake pressure sensor
103
(a). Turnignition switch to "OFF" position;
(b). Disconnect intake air temperature/pressure sensor
connector E27.
(d). Measure the resistance between the Terminal 2 of
the connector E27 of the intake
temperature/pressure sensor and the Terminal 33
of E01 with the digital multimeter.
Resistance: ≤2Ω
(e). Measure the resistance between the Terminal 2 of
connector E27 of intake temperature/ pressure
sensor and ground with the digital multimeter.
Resistance: ＞1MΩ

No ＞ Repair or replace wire harness or connector.
5. Inspection of low reference voltage line of intake pressure sensor
(a). Rotate ignition switch to "OFF" position;

connector E27.
(d). Measure the resistance between Terminal 4 of
sensor and Terminal 17 of E01 with digital
multimeter.
Resistance: ≤2Ω
104
No ＞ Repair or replace wire harness or connector. If the harness is normal, Replace ECM.
6. Check intake air pressure sensor signal wire
(a). Rotate ignition switch to OFF position.

connector E27.
(d). Measure resistance between Terminal 1 of
multimeter.
Resistance: ≤2Ω
sensor and ground with digital multimeter.
Resistance: ＞1MΩ
(f). Rotate ignition switch to OFF position.

(g). Measure the resistance between Terminal 1 of
sensor and ground with digital multimeter.
Voltage: 0V

7. Check intake air pressure sensor
105
connector.
(b). Rotate ignition switch to "ON" position, press
power supply key of fault diagnosis tester.
(c). Select the following menu items: Power Train /
Engine System (UMC M788) / Read Data Flow /
Actual Intake Manifold Pressure Sensor Voltage &
Actual Intake Manifold Pressure.
Standard value: 101kPa (specific value is related to
air pressure at the moment)

No ＞ Repair or replace intake air temperature/pressure sensor.
8. Replace ECM
(a). Replace ECM.

106
P0112 - Voltage below level of intake air temperature sensor signal circuit
P0113 - Overhigh voltage of intake air temperature sensor signal circuit
Circuit Diagram
IATS signal

MAPS signal
Intake air temperature sensor description

1. The intake air temperature sensor (IATS) undertakes to detect intake air temperature and
convert intake air temperature signal into electric signal which will then be transmitted to
engine control module (ECM), so that ECM could correct time for fuel injection and ignition
to make the engine working in the best condition.
2. Intake air temperature sensor adopts thermistor with negative temperature coefficient (NTC)
its resistance value decreases with temperature increasing. ECM provides a 5V reference
voltage to Terminal 2 of intake temperature/pressure sensor harness connector E27 through
Terminal 33 of E01. Meanwhile, it also provides a low reference voltage circuit to Terminal 4
of intake temperature/pressure sensor E27 through Terminal 17 of E01. When intake air
temperature/pressure sensor is in cold state, thermistor resistance value used to measure the
temperature is high. When air temperature increases, resistance value decreases. When
resistance value is high, ECM will detect that signal circuit voltage is high. With resistance
value decreasing, ECM detects that intake air temperature signal circuit voltage decreases.
Diagnostic Steps
1. Check if intake air temperature is normal
107
connector.
Intake Temperature Sensor Voltage & Intake
Temperature.
Temperature: it is the same as actual intake air
temperature

Yes ＞ Check transient fault.
No ＞ if the reading is -40°C, go to step 2. If the reading is 130 °C or above, go to Step 3.
2. Check signal wire circuit open circuit and short to power supply

connector E27 of intake temperature/pressure
multimeter.
Resistance: ≤2Ω
(e). Rotate ignition switch to "ON" position
(f). Measure the voltage between Terminal 3 of
Voltage: 0V
108
3. Check signal wire circuit is short to ground

(b). Disconnect ECM connector E01.
(c). Disconnect intake air temperature/pressure sensor
connector E27.
Resistance: ＞1MΩ
No ＞ Repair or replace intake temperature sensor wire harness.
4. Check intake air temperature sensor earth circuit
(a). Rotate the ignition switch to OFF position.

connector E27.
sensor and the Terminal 17 of E01 with digital
multimeter.
Resistance: ≤2Ω
109
5. Check intake air temperature/pressure sensor
(a). Rotate ignition switch to OFF position.

(c). Use a digital multimeter to measure the resistance
between Terminal 3 and Terminal 4 of intake air
pressure/temperature sensor.
Resistance:2.5 kΩ ± 5%( 20°C）
No ＞ Replace intake air temperature/pressure sensor.
6. Replace ECM
(a). Replace ECM.

110
P0117 - Voltage below level of engine coolant temperature sensor circuit
P0118 - Overhigh voltage of engine coolant temperature sensor circuit
Circuit Diagram
Coolant temperature sensor
ECT signal
Engine coolant temperature sensor description
1. Coolant temperature sensor (ECT) function is to transfer engine coolant temperature signal
into electrical signal and then sends it to engine ECM so that ECM corrects fuel injection time
and ignition time to ensure the engine is in optimal working state.
2. Coolant temperature sensor adopts thermistor with negative temperature coefficient (NTC). Its
resistance value decreases with the temperature increasing.
3. ECM provides a 5V reference voltage to the Terminal 3 of ECT sensor harness connector E15
through the Terminal 39 of ECM harness connector E01. Meanwhile, it also provides a low
reference voltage circuit to the Terminal 1 of ECT sensor connector E15 through the Terminal
17 of E01.
4. ECM will always record the length of time the ignition switched off. When starting, if the
ignition switched off time reaches the pre-set time, the engine control module will compare the
111
engine coolant temperature and intake air temperature in order to determine whether the
difference between the two is in normal working range.
Diagnostic Steps
1. Inspect and check whether coolant temperature value is normal

connector.
Engine Coolant temperature Sensor Voltage &
Engine Coolant Temperature.
Temperature: it is the same as actual coolant
temperature

Yes ＞ Check transient fault.
No ＞ If the data read out is -40°C, go to step 2. If the data read out is 130 °C or above, go to Step
3.
2. Check signal wire circuit is open and is short to power supply
(a). Rotate the ignition switch to "OFF" position;

(b). Disconnect coolant temperature sensor connector
E15.
between No.3 terminal of coolant temperature
sensor connector E15 and No.39 terminal of E01.
Resistance: ≤2Ω
112
(f).Measure the voltage 3# terminal of between
coolant temperature sensor connector E15 and the
ground with a digital multimeter.
Voltage: 0V

3. Check engine coolant temperature sensor signal wire is short to ground

E15.
coolant temperature sensor connector E15 and
ground with digital multimeter.
Resistance: ＞1MΩ
4. Check engine coolant temperature sensor earth circuit

E15.
coolant temperature sensor connector E15 and the
Terminal 17 of E01 as well as the resistance
between Terminal 1 of coolant temperature sensor
113
connector E15 ground with digital multimeter.
Resistance: ≤2Ω
5. Check engine coolant temperature sensor
(a). Disconnect engine coolant temperature sensor

connector E15.
Terminal 3 of coolant temperature sensor
connector E15 with digital multimeter.
Resistance:1.98 kΩ ±10%( 20°C）
(For details, see coolant temperature sensor
temperature and resistance relation)
No ＞ Repair or replace the coolant temperature sensor.
6. Replace ECM
(a). Replace ECM.

114
P0121 - Unreasonable signal of electronic throttle position sensor 1
P0122 - Voltage below level of signal circuit of electronic throttle position
sensor 1
P0123 - Overhigh voltage of signal circuit of electronic throttle position
sensor 1
P0221 - Unreasonable signal of electronic throttle position sensor 2
P0222 - Voltage below level of signal circuit of electronic throttle position
sensor 2
P0223 - Overhigh voltage of signal circuit of electronic throttle position
sensor 2
Circuit Diagram
TB Motor-
Electronically-controlled throttle valve housing
TB Motor+
TPS signal
TPS signal
115
Throttle position sensor description
1. Throttle position sensor (TPS) is applied to change the throttle opening (engine load) size into
electric signal and input it into engine ECU, to determine air-fuel ratio.
2. The actual throttle position will be compared with the determined according to the engine load.
The engine control module (ECM) determines the engine load based on the signal of intake
manifold absolute pressure sensor (MAPS). With a further comparison, you can determine
whether the sensor is failed and set the corresponding DTC.
Diagnostic Steps
1. Primary check
information.

connector.
DTC.
Check whether the displayed DTC are P0121, P0122, P0123, P0221, P0222 and/or P0223.
116
3. Check throttle position sensor power supply circuit
(a). Disconnect connector E19.

(c). Measure the voltage between 6# terminal of
connector E19 and the ground with a digital
multimeter.
Voltage: 5V
(d). Rotate ignition switch to "OFF" position.

connector E19 and ground with digital multimeter.
Resistance: ＞1MΩ

4. Check throttle position sensor earth circuit
(a). Disconnect the throttle position sensor connector

E19.
(b). Measure the resistance between Terminal 5 of
electric control throttle housing connector E19 and
Resistance: ≤2Ω
117
(c). Rotate the ignition switch to the ON position.
(d). Measure the voltage between Terminal 5 of
electric control throttle housing connector E19 and
Voltage: 0V

5. Check throttle position sensor
(a). Disconnect electric control throttle housing

connector E19.
Terminal 6 of electric control throttle housing with
digital multimeter.
Resistance: 1.6~2.4kΩ
(c). Rotate throttle valve slowly from one end to the
other, use a digital multimeter to detect the
resistance between Terminal 2 and Terminal 6 of
connector E19, and its resistance will feature a
linear variation with changes of throttle valve
openness. The resistance change between 2# and
5# terminals is opposite.
No ＞ Replace the electric control throttle housing.
6. Inspection of electric control throttle valve housing harness and connectors
118
(b). Disconnect the electric control throttle valve
housing connector E19.
electric control throttle valve housing connector
E19 and Terminal 38 of E01 with the digital
multimeter.
Resistance: ≤2Ω
E19 and Terminal 38 of E01 with digital
multimeter.
Resistance: ≤2Ω
(f). Measure the resistance between Terminal 5 of

multimeter.
Resistance: ≤2Ω
(g). Measure the voltage between Terminal 2 of

E19 and ground with digital multimeter.
Voltage: 0V
119
(h). Measure the resistance between Terminal 2 of
Resistance: ＞1MΩ
(i). Measure the resistance between Terminal 3 of

multimeter.
Resistance: ≤2Ω
(j). Measure the resistance between Terminal 3 of

Resistance: ＞1MΩ
(k). Measure the voltage between Terminal 3 of

Voltage: 0V

7. Use a diagnosis tester to read data flow
120
connector.
(c). Select from the following menu items: Power
Train / Engine System (UMC M788) / Read Data
Flow / Throttle Potentiometer 1 Voltage & Throttle
Potentiometer 2 Voltage.
Throttle potentiometer 1 voltage: 1V
Throttle potentiometer 2 voltage: 4V
(d). Start the engine and make it idle. Change the
electrical load or the position of accelerator pedal.
The throttle potentiometer voltage should change
in a linear manner. The change of potentiometer 1
is just the reversal of that of potentiometer 2.
Yes ＞ Go to 12--Engine Mechanical System--Engine Assembly, Troubleshooting.
8. Replace ECM
(a). Replace ECM.

121
P0030 - Upstream oxygen sensor heating control circuit failed
P0031 - Voltage below level of upstream oxygen sensor heating control
circuit
P0032 - Overhigh voltage of upstream oxygen sensor heating control
circuit
P0053 - Unreasonable internal heating resistance of upstream oxygen
sensor
Circuit Diagram
Main relay control
box
central
compartment
Engine
control
Front oxygen sensor

Signal
Heating
Description of upstream oxygen sensor

1. The upstream heated oxygen sensor is
122
used for fuel control.
Sensor 2. The sensor compares oxygen content
voltage/m
in ambient air with the oxygen
V
content in exhaust flow.
3. Each heated oxygen sensor has an
internal heating element for sensor
Theoretical heating.
Air fuel ratio
Dense air-fuel Thin
4. ECM controls heating control circuit
ratio
of heating type oxygen sensor. This
makes the system enter into the
closed-loop control mode earlier, so
that ECM can calculate Air-fuel ratio
earlier.
5. ECM commands heater control module switched on or off, so that heated oxygen sensor works
within specified working temperature range. Engine control module detects temperature by
Measure heater current. The working voltage of heating coil of front oxygen sensor is provided
by main relay controlled by ECM, that is, when turning the ignition switch to ON position, the
voltage of Terminal 1 of sensor of harness connector E12 is equal to the battery voltage. ECM
controls the working time of heater through No.26 terminal of ECM wire harness connector
E01.
Diagnostic Steps
1. Primary check
information.
123
connector.
DTC.
124
3. Check front oxygen sensor heater resistance value
(a). Disconnect front oxygen sensor connector E12.

Terminal 2 of front oxygen sensor with digital
multimeter.
Resistance: 7 ~ 11 Ω

No ＞ Peplace front oxygen sensor.
4. Check the voltage between front oxygen sensor terminal and the ground

(c). Measure the voltage betweenTerminal 1 of front
oxygen sensor E12 and grounding with digital
millimeter.
Voltage: 11~14V

5. Check front oxygen sensor heater power supply circuit

compartment.
(d). Pull out the relay RL02, and apply the battery
voltage between Terminals 1 and 2 of RL02.
125
Check for the continuity between tTerminals 3 and
Disconnect Normal
5 of RL02 with digital millimeter.
126
6. Check connection between front oxygen sensor and main relay

(b). Disconnect connector EU1.
(c). Measure the resistance between Terminal 1 of E12
and Terminal 7 of EU1 with digital multimeter.
Resistance: ≤2Ω

Resistance: ＞1MΩ

127
7. Check connection between front oxygen sensor and ECM

and Terminal 26 of E01 with digital multimeter.
Resistance: ≤2Ω

Resistance: ＞1MΩ

128

129
P0036 - Downstream oxygen sensor heating control circuit failed
P0037 - Voltage below level of downstream oxygen sensor heating control
circuit
P0038 - Overhigh voltage of downstream oxygen sensor heating control
circuit
P0054 - Unreasonable internal heating resistance of downstream oxygen
sensor
Circuit Diagram
130
Main relay control
central control box
compartment
Engine
Rear oxygen sensor

Signal
ng
Heati
Description of downstream oxygen sensor

1. The post-catalytic heated oxygen sensor (HO2S) is used for monitoring three-way catalytic
converter working status.
2. The sensor compares the oxygen content in ambient air with the oxygen content in exhaust
flow.
3. Each heated oxygen sensor has an internal heating element for sensor heating.
4. ECM controls heated oxygen sensor's heating control circuit. This makes the system enter into
the closed-loop control mode earlier, so that ECM can calculate Air-fuel ratio earlier.
5. ECM commands heater control module switched on or off, so that heated oxygen sensor works
within specified working temperature range. Engine control module detects the temperature by
Measure heater current. The working voltage of heating coil of rear oxygen sensor is supplied
by main relay controlled by ECM, that is, when the ignition switch is turned to ON position,
the battery voltage will be applied to No.1 terminal of rear oxygen sensor connector E13. ECM
controls the working time of heater through No.28 terminal of ECM wire harness connector
131
E01.
Diagnostic Steps
1. Primary check
information.
132

connector.
DTC.
(e)Read DTC codes.
133
3. Check rear oxygen sensor heater resistance value
(a). Disconnect rear oxygen sensor connector E13.

Terminal 2 of rear oxygen sensor with digital
multimeter.
Resistance: 7 ~ 11 Ω

NO ＞ Replace rear oxygen sensor.
4. Check the voltage between rear oxygen sensor terminal and ground

(c). Use a digital multimeter to check voltage between
No.1 terminal of rear oxygen sensor E13 and
grounding.
Voltage: 11~14V

5. Check rear oxygen sensor heater power supply circuit

compartment.
(d). Pull out relay RL02, and apply the battery
voltage between Terminals 1 and 2 of RL02. Check for
134
the continuity between Terminals 3 and 5 of RL02 with
Disconnect Normal
digital millimeter.

135
6. Check connection between rear oxygen sensor and main relay

Resistance: ≤2Ω
(d). Measure the resistance between Terminal 1 of E13

and ground with a digital multimeter.
Resistance: ＞1MΩ

136
7. Check connection between rear oxygen sensor and ECM

Resistance: ≤2Ω

and ground with digital multimeter.
Resistance: ＞1MΩ

137

138
P0130 - Unreasonable front oxygen sensor signal
P0131 - Low voltage of front oxygen sensor signal
P0132 - Overhigh voltage of front oxygen sensor signal
P0133 - Front oxygen sensor ageing
P0134 - Front oxygen sensor signal circuit failed
Circuit Diagram
139
Main relay control
box
central
compartment
Engine
control
Front oxygen sensor

Signal
ng
Heati
Description of front oxygen sensor

1. Oxygen sensor's senses ceramic oxygen ion concentration inside and outside difference and
sends it out as a voltage signal.
2. When the temperature of the sensing ceramic tube reaches 350°C, it owns the characteristics of
solid electrolyte. The oxygen ions can pass through ceramic tube freely because of its special
textures. It is also this texture that the concentration difference can be changed into potential
difference and then forms electrical signal output.
3. When the air-fuel mixture is richer, the difference of oxygen ion concentration inside and
outside ceramic tube is larger and the potential difference is higher, resulting in a large amount
of oxygen ions moving from inside to outside, so that the output voltage is higher (nearly 800
to 1000mV).
4. When the mixed gas is relatively thin, the oxygen ion concentration difference inside and
outside the ceramic tube will be lower and the potential difference will be relatively low so that
only a little of oxygen ions will move from inside to outside, resulting in a lower output
140
voltage ( near 100mV）.
Diagnostic Steps

connector.
DTC.
Check whether the displayed DTC are P0130, P0131, P0132, P0133, P0134, P2195 and/or P2196.
No ＞ Go to fault code list.
2. Check front oxygen sensor wire harness and connector
(a). Disconnect the oxygen sensor connector E12.

connector E12 and the Terminal 18 of E01 with
digital multimeter.
Resistance: ≤2Ω
141
connector E12 and Terminal 36 of E01 with digital
multimeter.
电阻：≤ 2Ω
Resistance: ≤2Ω

142
3. Check front oxygen sensor signal circuit

(c). Measure the voltage between 3# terminal of E12
Voltage: 0.35~0.45V
(d). Rotate ignition switch to "OFF" position.

(e). Measure the resistance between 3# terminal of
Resistance: ＞1MΩ

143
4. Check front oxygen sensor earth circuit

(c).Measure the voltage between 4# terminal of E12
Voltage: 0V
(d). Rotate the ignition switch to ON position.

Resistance: ≤2Ω

144
5. Check front oxygen sensor

connector.
(c). Select the following menu items: Power Train/
Oxygen Sensor Voltage 1 (sensor 1).
(d). Make the engine run at 2500r/min about 2min.
Make oxygen sensor be in working state to reach
the temperature of 400°C and above. And then,
connect digital multimeter between Terminal 3 and
Terminal 4 of oxygen sensor connector. The
normal voltage should be as follows: When
turning on ignition switch, the voltage should be
about 0.45V. When starting the engine and
supplying it with rich air-fuel mixture (pressing
the accelerator pedal to its extreme position), the
signal voltage should be about 0.9V. When
supplying the engine with thin air-fuel mixture,
the signal voltage should be about 0.1V.
Otherwise, the oxygen sensor would be failed and
be sure to replace it.
No ＞ Replace front oxygen sensor.

145
P0136 - Unreasonable rear oxygen sensor signal
P0137 - Low voltage of rear oxygen sensor signal
P0138 - Overhigh voltage of rear oxygen sensor signal
P0140 - Rear oxygen sensor signal circuit failed
P2270 - Rear oxygen sensor ageing
P2271 - Rear oxygen sensor ageing
Circuit Diagram
146
Main relay control
control box
compartment central
Engine
Rear oxygen sensor

Signal
ng
Heati
Description of rear oxygen sensor

1. After the vehicle starts, control module works under open-loop mode, i.e., signal voltage of
heating type oxygen sensor is ignored when calculating air-fuel ratio. The control module
provides approximately 450mV reference voltage to heated oxygen sensor.
2. The heated oxygen sensor will be heated to generate a voltage of 00.1V when the engine
running. Once the control module detects heated oxygen sensor voltage exceeds threshold
voltage, it will immediately enter into closed-loop mode.
3. Control module determines Air-fuel ratio by using the received heated oxygen sensor voltage
signal. If heated type oxygen sensor voltage is increased to above reference voltage (tend to 1
V), the mixture is too thick. If heated oxygen sensor voltage decreases to below reference
voltage (tend to 0mV), it indicates that the air fuel mixture is too lean.
147
Diagnostic Steps

connector.
Train/Engine System (UMC ME788)/Read DTC.
Check whether the displayed DTC are P0136, P0137, P0138, P0140, P2270 and/or P2271.
148
2. Check rear oxygen sensor wire harness and connector
(a). Disconnect the oxygen sensor connector E13.

(b). Disconnect rear oxygen sensor connector E01.
multimeter.
Resistance: ≤2Ω
multimeter.
Resistance: ≤2Ω

149
3. Check rear oxygen sensor signal circuit

(c). Measure the voltage between 3# terminal of E13
电压：0.35~0.45V
Voltage: 0.35~0.45V
Resistance: ＞1MΩ

150
4. Check rear oxygen sensor earth circuit

(b). Measure the voltage between Terminal 4 of E13
Voltage: 0V

Resistance: ≤2Ω

151
5. Check rear oxygen sensor

connector.
(c). Select the following menu items: Power
Train/Engine System (UMC M787)/Read Data
Flow/Oxygen Sensor Voltage 1 (sensor 2).
(d). Make the engine run at 2500r/min about 2min.

Make oxygen sensor be in working state to reach
the temperature of 400°C and above. And then,
connect the digital multimeter between Terminal 3
and Terminal 4 of oxygen sensor connector. The
normal voltage should be as follows: When turning
on the ignition switch, the voltage should be about
0.45V. When starting the engine and supplying it
with rich air-fuel mixture (pressing the accelerator
pedal to its extreme position), the signal voltage
should be about 1V. When supplying the engine
with thin air-fuel mixture, the signal voltage should
be about 0V. Otherwise, the oxygen sensor would
be failed and be sure to replace it.
NO ＞ Replace rear oxygen sensor.
152
153
P0201 - No. 1 cylinder's injector control circuit open-circuited
P0261 - No. 1 cylinder's injector control circuit short-circuited to ground
P0262 - No. 1 cylinder's injector control circuit short-circuited to power
supply
supply
supply
P0271- No. 4 cylinder's injector control circuit short-circuited to power
supply
Fuel injector description
1. The fuel injector operating voltage is provided by ECM-controlled main relay and the battery
voltage is delivered to Terminal 2 of each fuel injector connector through Terminal 5 of main
relay. ECM controls fuel injectors of No.1 cylinder, No.2 cylinder, No.3 cylinder and No. 4
cylinder through 27, 6, 7 and 47# terminals, respectively.
2. ECM monitors the state of each injector drive circuit. If ECM detects incorrect voltage
corresponding to drive circuit command state, it will set a fault diagnosis code for injector
control circuit fault.
Note:
154
Before carrying out this diagnosis steps, you should observe the data list on fault diagnosis tester
and analyze the accuracy of data to help quick troubleshooting.
155
Circuit Diagram
156
Engine compartment central control box
157
Main relay control box
Injector control Injector control Injector control Injector control
No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder
injector injector injector injector
Diagnostic Steps
1. Primary check
information.
Note:
Here takes No.1 cylinder fuel injector for example. The principle also applies to No.2 cylinder, No.3
cylinder and No. 4 cylinder fuel injectors.
158

connector.
Whether the DTCs are P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268,
P0271, P0272?
159
3. Measure resistance value of fuel injector assembly
(a). Disconnect the No.1 cylinder's injector harness

connector E28.
(b). Measure resistance value between two terminals of
fuel injector with a digital multimeter.
Reference resistance value: 11~17Ω

No ＞ Replace fuel injector assembly.
160
4. Check fuel injector power supply voltage

(b). Disconnect No.1 cylinder's injector harness
connector E28.
(d). Use a digital multimeter to measure the voltage
between Terminal 2 of Cylinder 1 injector
connector E28 and ground.
Voltage: battery voltage
161
5. Check fuel injector power supply circuit

Disconnect Normal (b). Open the central control box of engine
compartment.
voltage between Terminals 1 and 2 of RL02. Check
for the continuity between Terminals 3 and 5 of
RL02 with digital millimeter.
162
6. Check connection between fuel injector and main relay
(a). Disconnect injector harness connector E28.

Resistance: ≤2Ω

between No.2 terminal of E28 and ground.
电阻：＞ 1MΩ
Resistance: ＞1MΩ

163
7. Check fuel injector control circuit

(b). Disconnect Cylinder 1 injector connector E28 and
ECM connector E01.
(c). Use a digital multimeter to measure the resistance
between Terminal 1 of connector E28 and
Terminal 27 of connector E01.
Resistance: ≤2Ω
(d). Measure the resistance between Terminal 1 of the
Resistance: ＞1MΩ
(d). Rotate the ignition switch to ON position.

(e). Measure the voltage between Terminal 1 of
Voltage: 0V

8. Replace ECM
(a). Replace ECM.

(c). Execute reading sensor data flow procedure.
(d). Confirm no DTC exists and data is normal.
164
165
P0300 - Several cylinders misfiring
P0301 - No. 1 cylinder misfiring
Ignition coil description
1. Each ignition coil corresponds to one cylinder. Under the control of computer ECM, recharge
the preliminary coil for accumulating magnetic energy, and secondary coil winding will sense
high voltage, to make the spark plug connected to coil jump spark, which can control output
voltage energy from ignition coil of each cylinder to spark plug.
2. Ignition coil is connected with engine control part on the vehicle so as to control ignition time,
pause time and spark progress. The ignition function can be completed with the current flow to
the primary coil within ignition system. The switch will be controlled by the electronic spark
timing signal from pulse code modulation. When the electronic spark timing signal falls to or
below a specific critical voltage level, the primary current will be cut off to make the
electricity rotate from the primary winding to secondary winding. The electricity generated in
secondary winding will be directly transmitted to the spark plug.
166
Engine compartment central control box
Main relay control
Ignition coil control Ignition coil control Ignition coil control Ignition coil control
167
No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder
spark plug spark plug spark plug spark plug
circuit Diagram
Diagnostic Steps
1. Primary check
information.
Note:
Here takes the ignition coil of No. 1 cylinder for example. The principle also applies to ignition coil
of No.2, 3, and 4 cylinders, respectively.
168

connector.
Check whether the displayed DTC are P0300, P0301, P0302, P0303 and/or P0304.
169
3. Check ignition coil
(a). Disconnect the connector E08.

Terminal 2 of ignition coil E08 with digital
multimeter.
Resistance: 0.5±0.05Ω

No ＞ Replace ignition coil.
170
4. Check ignition coil power supply circuit

(b). Rotate ignition switch to "OFF" position.

171
5. Check ignition coil wire harness and connector

(a). Disconnect ignition coil connector E08.
(d). Measure points the resistance between Terminal 1
of connector E08 and Terminal 5 of E01 with
digital multimeter.
Resistance: ≤2Ω
Resistance: ≤2Ω
(f). Measure the resistance between Terminal 1of

Resistance: ＞1MΩ
(g). Rotate the ignition switch to ON position.

Voltage: 0V

172

173
P0321 - Unreasonable crankshaft TDC missing teeth signal
P0322 - Speed sensor signal fault
Circuit Diagram
level
low-voltage
CPS
Crankshaft position sensor

level
high-voltage
CPS
174
Crankshaft position sensor description
1. The crankshaft position sensor (CPS). signal tells ECM about current crankshaft speed and
position. The crank position sensor generates an alternating voltage with different amplitude
and frequency. The frequency depends on crankshaft rotation speed, and output AC voltage
depends on crankshaft position sensor. There is one fixing 58X variable reluctance rotor on
crankshaft position sensor and crankshaft to cooperate working.
2. ECM can calculate ignition timing, fuel injection timing and knock ignition control according
to input signal of crankshaft position sensor and camshaft position sensor. Crankshaft position
sensor is also used to detect misfire and tachometer display.
Diagnostic Steps
1. Primary check
information.
175

connector.
Check whether the displayed DTC are P0321 and/or P0322.

176
3. Check crankshaft position sensor
(a). Disconnect the connector E14 of crankshaft

position sensor.
(b). Measure the resistance between 2# and 3#
terminals of crankshaft position sensor with digital
multimeter.
Standard resistance:860Ω（20°C）
No ＞ Replace crankshaft position sensor.
177
4. Check crankshaft position sensor wire harness and connector

(c). Disconnect crankshaft position sensor connector
E14.
Resistance: ≤2Ω
(e). Measure the resistance between Terminal 1 of E14
Resistance: ≤2Ω
(f). Measure the resistance between Terminal 2 of E14

Resistance: ＞1MΩ
(g). Measure the resistance between Terminal 2 of E14

Resistance: ＞1MΩ
178
(h). Measure the resistance between Terminal 3 of E14
Resistance: ＞1MΩ
(i). Rotate ignition switch to "ON" position.

(j). Measure the voltage betweenTerminal 2 of E14
Voltage: 0V
(k). Measure the voltage between Terminal 3 of E14

Voltage: 0V

179
5. Replace ECM
(a). Replace ECM.

180
P0327 - Voltage below level of knock sensor signal circuit
P0328 - Overhigh voltage of knock sensor signal circuit
level
high-voltage
KS
Knock sensor
level
age
low-volt
KS
Knock sensor description
1. Knock sensor is a kind of vibration acceleration sensor, which is installed on engine cylinder
block.
2. Sensing element of sensor is a piezoelectric element. Engine cylinder block vibration is
transferred to piezoelectric crystal through weight block in sensor. Because piezoelectric
crystal bears pressure generated by weight block vibration, the voltage is generated on both
pole faces to convert vibration signal into AC voltage signal output.
3. Its purpose is to detect the engine for knock, and output voltage signal to ECM to determine
the working condition of the engine.
Diagnostic Steps
1. Primary check
information.
181
connector.

3. Check knock sensor
(a). Disconnect the knock sensor connector E21.

(b). Measure the resistance between 1# and 2# pins of
knock sensor with a digital multimeter.
Resistance: ＞1MΩ

No ＞ Replace knock sensor.
182
4. Check knock sensor wire harness and connector

(c). Disconnect the knock sensor connector E21.
Resistance: ≤2Ω
(e). Measure the resistance between Terminal 1 of E21
Resistance: ≤2Ω
(f). Measure the resistance between Terminal 2 of E21

Resistance: ＞1MΩ
(g) Measure the resistance between Terminal 1 of E21

Resistance: ＞1MΩ
183
(h). Measure the resistance between Terminal 2 of E21
Resistance: ＞1MΩ

(j). Measure the voltage between Terminal 1 of E21
Voltage: 0V
(k). Measure the voltage between Terminal 2 of E21

Voltage: 0V

5. Replace ECM
(a). Replace ECM.

184
P0340- Improper mounting position of phase sensor
P0341- Unreasonable phase sensor signal
P0342- Phase sensor signal circuit short-circuited to ground
P0343- Phase sensor signal circuit short-circuited to power supply
Circuit Diagram
Camshaft position sensor

CMPS signal
185
Descriptions of the camshaft position sensor
Camshaft position sensor (CMPS) is also called as cylinder identification sensor, and its function is
to collect the position signal of gas distribution camshaft and input it to ECM in order to determine
the piston is at the TDC position of compression (or exhaust) stroke and ultimately determine when
to inject fuel into the cylinder.
Diagnostic Steps
1. Primary check
information.
186

connector.
187
3. Inspect power supply voltage of camshaft position sensor.

(c). Measure the voltage between Terminal 1 and
Terminal 3 of the connector E03 with digital
multimeter.
Voltage: 5V

188
4 Check camshaft position sensor grounding circuit.

(b). Measure the resistance between Terminal 3 of the
camshaft position sensor connector E03 and
Resistance: ≤2Ω

189
5. Inspection of camshaft position sensor signal circuit
(a). Disconnect the camshaft position sensor connector

E03.
电压：4.5~5.5V
Voltage: 4.5~5.5V
190
6 Check camshaft position sensor wire harness and connectors.

(b). Disconnect camshaft position sensor connector
E03.
Terminal 32 of E01 with digital multimeter.
Resistance: ≤2Ω
Resistance: ≤2Ω
(f). Measure the resistance between Terminal 3 of the

Resistance: ≤2Ω
(g). Measure the resistance between Terminal 1 of

Resistance: ＞1MΩ
191
Resistance: ＞1MΩ

(j). Measure the voltage between Terminal 3 of
Voltage: 0V
(k). Measure the voltage between Terminal 2 of

Voltage: 0V
(l). Measure the voltage between Terminal 1 of

Voltage: 0V

7. Replace camshaft position sensor
(a). Replace the camshaft position sensor.

192
193
P0444 - Canister solenoid control open-circuited circuit
P0458 - Voltage below level of canister solenoid control circuit
P0459 - Overhigh voltage of canister solenoid control circuit
Circuit Diagram
Canister control valve
Main relay
control
control
CPV
compartment
control box
Engine
central
Canister control valve description

The canister solenoid, which is controlled by ECM, controls the quantity of fuel vapor entering into
the engine inlet pipe from canister in manner of duty cycle.
Diagnostic Steps
1. Primary check
information.
194

connector.
Check whether the displayed DTC are P0444, P0458 and/or P0459.
195
3. Check canister control valve power supply voltage
(a). Disconnect the canister solenoid connector E24.

(c). Measure the voltage between Terminal 1 of the

196
4. Check canister control valve power supply circuit

Disconnect Normal
compartment.
voltage between Terminals 1 and 2 of RL02.
Check for the continuity between Terminals 3 and
5 of RL02 with digital millimeter.
No ＞ Replace fuse or relay of corresponding specifications.
197
5. Check connection between canister control valve and main relay

(b). Disconnect the connector EU1.
Resistance: ≤2Ω

Resistance: ＞1MΩ

198
6. Check canister control valve control circuit

(b). Disconnect the canister solenoid connector E24.
multimeter.
Resistance: ≤2Ω
Resistance: ＞1MΩ
(f). Rotate the ignition switch to ON position.

Voltage: 0V

7. Check canister control valve
199
(b). Measure the resistance between 1# and 2#
terminals of canister control valve with a digital
multimeter.
Resistance: 22 ~ 30 Ω (20 °C)

No ＞ Replace canister control valve.
8. Replace ECM
(a). Replace ECM.

200
P0691 - Voltage below level of cooling fan relay control circuit (low
speed)
P0692 - Overhigh voltage of cooling fan relay control circuit (low speed)
P0693 - Voltage below level of cooling fan relay control circuit (high
speed)
P0694 - Overhigh voltage of cooling fan relay control circuit (high-speed)
201
Engine
compartment
central control
box
202
Electronic fan
Circuit Diagram
Main relay control FC (high speed) FC (low speed)

Diagnostic Steps
1. Primary check
information.
2. Check cooling fan control power supply voltage

(d). Use a digital multimeter to check the voltage
Voltage: 11~14V
(e). Measure the voltage between 68# terminal of E01
电压：11~14V
Voltage: 11~14V

3. Check cooling fan control power supply circuit
203
(b). Open the central control box of engine compartment.
(c). Take out fuse FS04.
Note:
It is required to a special fuse detacher to dismantle the fuse. Do not pull it out manually because it
is easy to damage fuse.
(d). Check whether the main relay fuse FS04 is blown.
Disconnect Normal
(e). Check relay RL02, RL05, RL06 and RL07.

Standard value:
The multimeter is
Specified
Condition connected with
value
terminal
Normal State 85-86 Continuity
Normal State 30-87a Continuity
Normal State 30-87 No continuity

Apply the voltage 30-87 Continuity
between terminal
85 and 86 30-87a No continuity

No ＞ Replace fuse or relay of corresponding specifications.
204
4. Check cooling fan control circuit wire harness and connector

(d). Disconnect connector E01.
(e). Measure the resistance between Terminal 2 of connector EU1 and Terminal 68 of E01 as well
as between Terminal 3 of EU1 and Terminal 50 of E01 with digital multimeter.
Resistance: ≤2Ω
(f). Use a digital multimeter to measure the resistance
between Terminal 50 of E01 and ground.
Resistance: ＞1MΩ
(g). Usedigital multimeter to measure the resistance

between Terminal 68 of E01 and ground.
Resistance: ＞1MΩ
(h). Measure the voltage between 68# terminal of E01

Voltage: 0V
205
(i). Measure the voltage between 50# terminal of E01
and ground with a digital multimeter.
Voltage: 0V

5. Replace ECM
(a). Replace ECM.

206
P0562 - Bttery voltage below level
P0563 - Bttery voltage overhigh
207
Driver
compartment
central control Engine compartment central
box control box
208
Battery power supply Main relay control
Main relay power
supply
Circuit Diagram
Diagnostic Steps
1. Primary check
information.
2. Check ECM power supply voltage

(d). Measure the voltage between 12# terminal of E01
Voltage: 11~14V
(e). Measure the voltage between 14# terminal of E01
Voltage: 11~14V

Yes＞ Go to Step 4.
No＞ Go to Step 3.
3. Check ECM power circuit fuse and relay

209
(b). Open the central control box in driving compartment.
(c). Take out fuse FS03.
(d). Open the central control box in engine compartment.
(e). Take out fuse FS04.
Note:
is easy to damage the fuse.
(f). Check whether fuse FS03 or FS04 is blown.

Disconnect Normal
(g). Check relay RL02.

Standard value:
The multimeter is
Specified
Condition connected with
value
terminal
Apply power
supply voltage
3-5 Continuity
between terminal 1
and 2

No ＞ Replace corresponding specification fuse or relay.
4. Check ECM power supply circuit wire harness and connector
210
(a). Disconnect the connector EU1.
(b). Disconnect the connector E01.
connector EU1 and the Terminal 44 of E01 with
digital multimeter.
Resistance: ≤2Ω
5. Inspect battery.
(a). Check battery voltage.

Voltage: 11~14V

No ＞ Charge or replace the battery.
6. Check battery terminal
(a). Check if battery terminal is loose or corrosive.

OK: the battery terminal is not loose or corrosive

No ＞ Repair or replace the battery terminal.
7. Check engine wire harness earth point
(a). Check harness electronic ground G03, and power ground G04.
211
OK: earthing point is not loose and body connection is good.

No ＞ Repair or replace earthing terminal.
8. Replace ECM
(a). Replace ECM.

P0628 - Voltage below level of oil pump relay control circuit

P0629 - Overhigh voltage of oil pump relay control circuit
Circuit Diagram
Main relay control
Fuel pump control
Fuel pump
box
central control
compartment
Engine
Description of electric fuel pump
212
1. The purpose of electric fuel pump is to supply the injectors with fuel with pressure higher than
the pressure of intake manifold. The electric fuel pump consists of fuel pump, bracket,
fuel-level sensor and fuel pressure regulator.
2. The electric fuel pump of the LF479Q2 -B engine is a type of single-stage electric fuel pump,
which is controlled by ECM through fuel pump relay to work. A check valve is designed at the
outlet of fuel pump. When the engine stops running, the residual fuel in pipe will not return to
tank in order to ensure re-starting performance.
Note:
• Old fuel pump can't be tried in dry condition: when fuel pump is dismantled, it still has
residual gasoline inside pump housing. If switching on for test on this condition, once electric
brush has bad connection with commutator and creates spark, it will cause explosion due to the
combustion of gasoline inside fuel pump housing. The consequence is very serious.
• Don't perform the drying test on the new fuel pump, either. Because the fuel pump motor in
pump housing is sealed, once being energized, the heat generated in drying test can not be
distributed. The overheated armature can burn out motor. Therefore, to perform the test, dip
the fuel pump in gasoline.
Diagnostic Steps
1. Primary check
information.
213
connector.
DTC.

3. Check fuel pump control circuit voltage

(d).Measure the voltage between 69# terminal of
ECM connector E01 and ground with digital
multimeter.

4. Check fuel pump control circuit fuse and relay

(b). 打开发动机舱中央控制盒。
214
(b). Open the central control box of engine compartment.
(c). Take out main relay fuse FS04 (25A).
Note:
is easy to damage the fuse.
(d). Check whether the intermediate fuse of main relay

Disconnect Normal fuse FS04 (25A) is blown.
(e). Check main relay RL02 and fuel pump relay

RL03.
Standard value:
The multimeter is
Specified
Condition connected with a
value
terminal

Apply power
supply voltage
3-5 Continuity
between terminal 1
and 2
No ＞ Replace fuse and relay of corresponding specifications.
5. Check fuel pump control circuit
215
(c). Disconnect connector EU1.
E01 and Terminal 4 of EU1 with digital
multimeter.
Resistance: ≤2Ω

E01 and ground with a digital multimeter.
Resistance: ＞1MΩ
(f). Use a digital multimeter to check the voltage

Voltage: 0V

6. Replace ECM
(a). Replace ECM.

216
P2122 - Signal voltage below level of electronic accelerator pedal position
sensor 1
P2123 - Overhigh signal voltage of electronic accelerator pedal position
sensor 1
P2127 - Signal voltage below level of electronic accelerator pedal position
sensor 2
P2128 - Overhigh signal voltage of electronic accelerator pedal position
sensor 2
P2138 - Unreasonable electronic accelerator pedal position sensor signal
Circuit Diagram
APS 信号
APS signal
Accelerator pedal position sensor

APS 信号
APS signal
Description of electronic accelerator pedal position sensor

The electronic accelerator pedal position sensor is a type of sliding potentiometer. When pressing
217
accelerator pedal, the sensor will feed voltage signal back to ECM so that it can adjust throttle
opening through voltage signal. The sensor signal voltage is proportional to throttle opening within
the range of 0~5V.
Diagnostic Steps
1. Primary check
information.
(d). If it is good connection, move the connector and harness to observe the sensor signal voltage.
If there is a trouble, the voltage displayed on diagnostic tester will change.

connector.
DTC.
Check whether the displayed DTC are P2122, P2123, P2127, P2128 and/or P2138.
218
3. Inspection of power circuit of accelerator pedal position sensor

(b). Disconnect the connector E02 of accelerator pedal
position sensor.
(d). Measure the voltage between Terminal 6 and
Terminal 2 of connector E02 of accelerator pedal
position sensor with digital multimeter.
Voltage: 5V
(e). Measure the voltage between Terminal 5 and

Terminal 4 of connector E02 of accelerator pedal
position sensor with digital multimeter.
Voltage: 5V

4. Inspection of grounding circuit of accelerator pedal position sensor

(b). Disconnect the connector E02 of accelerator pedal
position sensor.
connector E02 of accelerator pedal position sensor
Resistance: ≤2Ω
219
Resistance：≤ 2Ω

(f). Measure the voltage between Terminal 2 of
Voltage: 0V

Voltage: 0V

5. Inspection of signal circuit of accelerator pedal position sensor

(b). Disconnect connector E02 of accelerator pedal
position sensor.
Resistance: ＞1MΩ
220
Resistance: ＞1MΩ

221
6. Inspection of harness and connector of accelerator pedal position sensor
(a). Disconnect connector E02 of accelerator pedal position sensor.

(c). With digital multimeter, measure the resistance between Terminal 6 of connector E02 of
accelerator position sensor and Terminal 32 of ECM connector E01, between Terminal 1 of
E02 and Terminal 40 of E01, between Terminal 2 of E02 and Terminal 35 of E01, between
Terminal 5 of E02 and Terminal 33 of E01, between Terminal 3 of E02 and Terminal 16 of E01,
between Terminal 4 of E02 and Terminal 36 of E01, between Terminal 6 of E02 and ground,
between Terminal 1 of E02 and ground, between Terminal 2 of E02 and ground, between
Terminal 5 of E02 and ground, between Terminal 3 of E02 and ground, as well as between
Terminal 4of E02 and ground, respectively.
The multimeter is connected with a terminal Resistance

Terminal 6 of E02 and Terminal 32 of E01 ≤ 2Ω
Terminal 6 of E02 and ground ＞ 1MΩ
Terminal 2 of E02 and ground ≤ 2Ω
Terminal 4 of E02 and ground ≤ 2Ω

222
7. Inspection of accelerator pedal position sensor

connector.
(c). Select the following menu items: Power Train/
Pedal Position Sensor 1 Voltage 1 & Pedal
Position Sensor 2 Voltage.
(d). Press the accelerator pedal slowly, so that the
accelerator pedal position sensor voltage should
change slowly.
Accelerator pedal position from rest to full stroke:
Accelerator Pedal Position Sensor 1 Voltage ：
1V~4V
Accelerator Pedal Position Sensor 2 Voltage ：
0V~2V
223
No ＞ Replace the accelerator pedal position sensor assembly.
8. Replace ECM
(a). Replace ECM.

224
Section 3 Sensor actuator
Electronic Control Unit (ECM)
1. Parts drawing
2. ECM installation position

3. Working principle
ECM is the core of engine electronic control
system. It is an engine electronic control centre
with an interface of sensor signal input and
actuator drive circuit which takes microprocessor
as a core. It receives and treats the engine state
signals input by various sensors and sends
control signals to actuators so that the engine can
run according to predefined procedures to enable
the engine to be in the optimum working state in
order to ensure good power, economy and
emissions.
4. Replace
(a). .Rotate the ignition switch to OFF position.
(b). Disconnect battery negative cable.
Note:
When disconnecting and re-connecting negative
cable of battery, please turn off ignition switch and
all illumination switches first. And loosen the
fastening nut of the battery negative terminal. Don't
pry up the cable terminal when performing such
225
operation.
(c). Disassemble cover component. (Refer to
Chapter 5 Disassemble Cover Component)
226
(d). Disconnect ECM connector.
Note:
After disconnecting the connector, make sure the
connector does not contact dirt, water and other
impurities.
(e). Dismantle 4 fastening bolts of ECM.

(f).Take down ECM.
Note: After dismantling ECM, do not immerse it
in water. When dismantling ECM, handle it with
care.
(g). Install ECM.

Torque: 20N•m
Note:
When installing, electrostatic protection shall be
made.
227
(h). Connect ECM connector.
(i). Install cover component (Refer to Chapter 5

Disassemble Cover Component).
(j). Connect the battery negative cable.
228
1. Parts drawing and terminal

(a). Intake air temperature/pressure sensor diagram
(b). Intake temperature/pressure sensor terminal.
(Refer to Chapter 12 Definitions of Terminals)
2. Mounting position for intake air temperature /

pressure sensor
The intake manifold absolute pressure sensor is
composed of a piece of silicon chip. A piece of
pressure diaphragm is etched on silicon chip. Four
piezo resistances are on pressure diaphragm and
they, as a strain element, form a Wheatstone
bridge. Besides this pressure diaphragm, a signal
processing circuit is also integrated on this silicon
chip. The silicon chip together with a metal shell
make up a spatial reference. The air absolute
pressure in this spatial reference approaches to zero
and it becomes a MEMS. The active side of silicon
chip is under a pressure approaching to zero and its
reverse side is under intake manifold absolute
pressure that is introduced by a connecting pipe
and needs to be measured.
The thickness of silicon chip is only few microns (μm), therefore, the changes of intake manifold
absolute pressure can cause mechanical transformation of silicon chip, then the four piezo
resistances transform and the resistance value changes too. Voltage signals which are linear to
pressure are formed after the circuit processing through signal processing circuit of silicon chip.
229
Intake temperature sensing element is the resistance of a negative temperature coefficient (NTC).
The resistance will change with intake temperature. This sensor inputs a voltage showing intake
temperature change to controller.
4. Possible faults and reasons
(a). Fault phenomenon: Misfiring, poor idle, increased fuel consumption and emissions and so
on.
(b). General fault reason:
• Abnormal high voltageo or large reverse current occurs in the process of use.
• Vacuum components can be damaged in the process of maintenance.
5. Check it on the vehicle

(a). Start the engine and make it run to reach its
normal working temperature.
(b). Rotate the ignition switch to OFF position.
(c).Connect diagnosis tester to fault diagnosis
connector (16-pin) on the bottom left of dashboard.
(d).Rotate ignition switch to ON, and turn on the
diagnosis tester- use the latest software version.
(e). Select "reading data flow" menu item.
Items
displayed
Normal
by the Check conditions (range)
value
diagnosis
tester
Inlet air
- 20℃
temperature: - 20℃
ON Inlet air
Ignition temperature: 0℃
switch: 0℃
ON Inlet air
Inlet air
• or start temperature: 20℃
temperature
the 20℃
engine Inlet air
and make temperature: 40℃
it run. 40℃
Inlet air
80℃
temperature: 80℃
Items
displayed Normal
Inspection conditions
by the value
diagnosis
230
tester
Inlet air
temperature: 3.2~3.8V
Data Flow 0℃
Use data flow RAM playback Inlet air
Name Current Value Unit temperature: 2.3~2.9V
Intake air
Intake air temperature Ignition 20℃
Sensor voltage of intake air temperature temperature
switch: ON Inlet air
sensor voltage
40℃
Inlet air
Page up Page down Wave form Play back
Return
Help Print Bypass Record 80℃
(f).If the result does not comply with relevant
provisions, check intake manifold pressure,
temperature sensor, wire harness or ECM.
6. Inspection and replacement
(b). Open engine hood.
(c). Disconnect battery negative cable.
Note:
When disconnecting and re-connecting negative cable
of battery, please turn off ignition switch and all
illumination switches first. And loosen the fastening nut
of battery negative terminal. Don't pry up the cable
terminal when performing such operation.
(d). Lift the vehicle to a certain height
(e). Disconnect intake air temperature/pressure
sensor connector.
(f).Remove the fixed bolt of the intake
temperature/pressure sensor, and remove the intake
temperature/pressure sensor.
Note:
After dismantling, clean mounting surface and sensor
to make sure no oil stains and contaminants.
(g). Check the resistance of intake
temperature/pressure sensor. Switch digital
multimeter to resistance function, and connect two
probes to Terminal 3 and 4 of sensor, respectively.
231
Analogous method can be used during
measurement, that is, to supply air towards the
sensor with electric blower (Hint: don’t be too
closed to it), observe the changes of sensor
resistance, and at the moment, the resistance shall
drop off.
(h). If the measured resistance is inconsistent with
specified value, replace intake
temperature/pressure sensor.
(i). Install intake temperature/pressure sensor, and
tighten its fixed bolt.
Torque: 21~25N•m
Note:
Install it by pressing method. Do not use any impact
tool (like a hammer) to knock sensor into mounting
hole.
(j). Connect intake air temperature / pressure sensor
connector.
(k). Connect cable to battery negative terminal.
232
Coolant Temperature Sensor
1. Parts drawing
2. Coolant temperature sensor installation position
The coolant temperature sensor is installed on engine body or cylinder head, touching coolant,
which is used to detect the temperature of engine circulating coolant and transmit the measured
result to electronic control unit in order to correct the quantity of fuel injection and ignition
timing. The water-temperature sensor is usually made of thermostat which is very sensitive to
temperature change. In general, the thermostat uses the NTC resistance. The lower water
temperature is, the larger thermostat resistance is. According to such signal, electronic control
unit can enable the quantity of fuel injection to increase so as to enrich air-fuel mixture.
(a). Fault phenomenon: engine fuel consumption and exhaust pollution is increasing, it is
difficult to start a cold engine or the engine cannot start, engine flames out intermittently and
idle speed is unstable.
233
• Poor contact of circuits inside coolant temperature sensor can cause no sensor signal or
abnormal sensor signal.
• Thermal element of coolant temperature sensor is aged, which leads to abnormal signal.
(c). Connect diagnosis tester to fault diagnosis
(d). Rotate ignition switch to ON, and turn on the

Items displayed
Check conditions Normal
by the diagnosis
(range) value
tester
Data Flow Engine coolant
Engine Idling Speed 80℃ ~100℃
Use data flow RAM playback temperature
Name Current Value Unit
Intake air temperature
Engine coolant temperature
(f).If the result does not conform to specification,
check coolant temperature sensor, wire harness or
Page up Page down Wave form Play back ECM.
Return
Help Print Bypass Record
234
6. Inspection and replacement
Note:
illumination switches first. And loosen the fastening
nut of battery negative terminal. Don't pry up cable
(d). Discharge engine coolant. (See Chapter 15
Cooling System--Coolant, Drain)
(e). Disconnect coolant temperature sensor
connector.
(f).Dismantle coolant temperature sensor.
Note:
Clean mounting surface after dismantling. Clean up the
mounting hole threads after removal. Clean up the
mounting threads after the sensor is dismantled. When
removing or installing it, be careful not to let the tool
touch the linker (the resin part).
(g). Dip temperature probe of ECT sensor in hot

water, and then measure the resistance between
Terminal 1 and Terminal 3 of ECT sensor with
digital multimeter.
(h). If the check result doesn't meet requirement,
replace ECT sensor.
Measuring conditions Standard resistance(kΩ)
0℃ 5.1~6.5
20℃ 2.1~2.7
40℃ 0.9~1.3
80℃ 0.26~0.36
Note:
If checking ECT sensor in the water, do not let water
go into terminal. After checking, wipe off the sensor.
235
(i). Install ECT sensor and tighten it to specified
torque.
Torque: 20 N.m
(j). Install ECT sensor connector.
(k). Refill the engine with recommended coolant.
(l). Check coolant for leak.
(m). Connect cable to battery negative terminal.
236
Crankshaft Position Sensor
1. Parts drawing
2. Crankshaft position sensor installation position
The system uses magnetic inductive speed sensor which generates the AC current and voltage
signal through rotating to cut the lines of magnetic force. ECM uses such AC signal and reform
it to convert such signal into the digital signal which engine ECM can identify for controlling
the systems of the engine. The flywheel ring gear is installed together with the signal wheel.
The signal wheel uses the type of 58X teeth and provides rotating speed, corner and top dead
center (TDC). for ECM. The continuous notch position is just the TDC of No.1 cylinder.
(a). Fault phenomenon: the engine cannot start or it flames out after starting.
• Sensor connector or internal circuit is in poor contact state or open, which leads to weak
sensor signal or no signal output.
• Sensor induction coil is short or grounding, which leads to weak sensor signal or no signal
237
output.
• Sensor is loose or the clearance is improper, which leads to weak sensor signal or no signal
output.
5. Overhaul and replace
Note:
cable of battery, please turn off ignition switch and all
illumination switches first. And loosen fastening nut
of battery negative terminal. Don't pry up cable
(d). Disconnect crankshaft position sensor
connector.
(e). Remove crankshaft position sensor.
Note:
After dismantling, clean mounting surface to ensure
no oil stain.
(f).Check crankshaft position sensor.
(g). Adjust digital multimeter to resistance scale,
2 meter probes are connected respectively to
No.2 and No.3 terminal of sensor, and check
resistance between 2 terminals.
Standard resistance:860Ω
(h). If check resistance value doesn't meet
requirement, replace sensor.
(i). Install position sensor.
(j). Install crankshaft position sensor with the bolt.
Torque: 6~10N•m
Note:
tool (like a hammer) to knock the sensor into
mounting hole.
238
(k). Mount crankshaft position sensor connector.
(l). Connect cable to battery negative terminal.
239
Camshaft Position Sensor
1. Parts drawing
2. Mounting position for camshaft position sensor

This sensor is coupled with pulse plate and used in
distributorless system to provide crankshaft
camshaft position information to ECM. Namely, it
distinguishes crankshaft compression TDC and
exhaust TDC. This sensor consists of a Hall sensor
(HS) and a steel rotor. The Hall sensor is fixed,
while the rotor is arranged on a camshaft. The rotor
is a cylindrical steel blade with the range of 180°,
and when the blade covers up the Hall sensor, there
will be no output signal; otherwise, there will be
output signal. If closed together, the two
semi-circles of camshaft are equivalent to two
whole circles of crankshaft, by which the
crankshaft compression TDC can be distinguished
from exhaust TDC.
(a). Fault phenomenon: Excessive emissions, increased fuel consumption, or other.
(b). General cause of fault: Man-made fault.
240
Note:
cable of battery, please turn off ignition switch and all
illumination switches first. And loosen fastening nut
(d). Disconnect camshaft position sensor
connector.
(e). Remove the camshaft position sensor.
Note:
After dismantling, clean mounting surface to ensure
no oil stain.
(f).Check camshaft position sensor.
(g). Switch digital multimeter to resistance
function, and connect the two probes to Terminal
1 and Terminal 3 of sensor respectively, and then
measure the resistance between two terminals.
Standard resistance:
(h). If the check resistance value doesn't meet
(i). Install camshaft position sensor.
(j). Install camshaft position sensor with bolts.
Torque: 6~10N•m
Note:
tool (like a hammer). to knock sensor into mounting
hole.
(k). Mount camshaft position sensor connector.
(l). Connect cable to the battery negative terminal.
241
Oxygen Sensor
1. Parts drawing
2. Mounting position of oxygen sensor

Oxygen sensor has a sensing element, which is a porous ceramic tube, the outer wall surrounded by
engine exhaust and inside connecting to atmosphere. Sensing ceramic pipe wall is a solid electrolyte
that contains electric heating pipes. The function of oxygen sensor is realized through changing
concentration difference of oxygen ions inside and outside the sensing ceramic tube into voltage
signal output. When the temperature of sensing ceramic tube reaches to 350°C, it owns
characteristics of solid electrolyte. The oxygen ions can pass through the ceramic tube freely
because of its special textures. It is also this texture that the concentration difference can be changed
into potential difference and then forms electrical signal output. If the air mixture is too thick. The
more the density difference of oxonium ion is in and out ceramic pipe, the bigger the potential
difference is. Plenty of oxonium ions move out from inside to outside of the pipe, and output
voltage is also high (near 800-1000mV). If the mixed gas is thinner, the density difference of
oxonium ions in and out ceramic pipe is low and potential difference is low. Only small amount of
242
oxonium moves out from inside of pipe and output voltage is low (near 100mV).

(a). Fault phenomenon: engine fuel consumption and exhaust pollution increasing, idle speed
unstable, misfire, shaking etc.
• Lead poisoning, for use of leaded gasoline. At high temperature, the lead will attach onto
the surface of oxygen sensor so that the oxygen cannot produce normal signals.
• Deposited carbon. If the carbon deposits onto the surface of oxygen sensor platinum, the
oxygen sensor will not produce normal voltage signals.
• Internal circuit of oxygen sensor is poor contact or open circuit so that no signal voltage is
output.
• Due to damage to the ceramic components of oxygen sensor, the oxygen sensor cannot
produce normal voltage signals.
• The resistance wire of the heater of oxygen sensor is blown or the circuit is open-circuited
so that the oxygen sensor cannot reach its normal working temperature quickly.
5. Check it on vehicle
Data Flow
Use data flow RAM playback
Name Current Value Unit (c).Connect diagnosis tester to fault diagnosis
Oxygen sensor voltage Group 1 (Sensor 1)
Oxygen sensor voltage Group 1 (Sensor 2)

connector (16-pin). on bottom left of dashboard.
(d).Rotate ignition switch to ON, and turn on

Return
Help Print Bypass Record (e). Select "reading data flow" menu item.
Items displayed
Inspection
by the diagnosis Normal value
conditions
tester
Group 1, oxygen
sensor voltage Engine running 0.1~0.85V
(sensor 1, sensor 2)
(f).If the voltage does not comply with relevant
provisions, check sensor, wire harness and ECM.
243
(b). Open t engine hood.
Note:
illumination switches first. And loosen the fastening nut
(d). Remove the connectors of front and rear
oxygen sensors.
Note:
Exhaust pipe is hot, operate after exhaust pipe is cooled
completely.
(e). Remove front and rear oxygen sensors.
(f).Check front and rear oxygen sensors.
(g). Adjust a digital multimeter to resistance scale,
2 meter probes are connected respectively to No.2
and No.3 terminal of sensor, and check the
resistance between 2 terminals.
Standard resistance: 7~11Ω (20℃ )
△ Hint:
Measuring methods of front/rear oxygen sensors are the
same.
(h). If the check resistance value doesn't meet
(i). Install front and rear oxygen sensors.
Note:
Before installing, apply a layer of antirust oil on threads
to prevent corrosion.
(j). Connect the cable to battery negative terminal.
244
Knock Sensor
1. Parts drawing
2. Knock sensor installation position
Knock sensor is a kind of vibration acceleration sensor, which is installed on engine cylinder
block. Sensing element of sensor is a piezoelectric element. Engine cylinder block vibration is
transferred to piezoelectric crystal through weight block in the sensor. Because piezoelectric
crystal bears pressure generated by weight block vibration, the voltage is generated on both
pole faces to convert vibration signal into AC voltage signal output. Vibration signal frequency
caused by engine knock is higher than normal vibration signal frequency of the engine.
Therefore, ECM can differentiate knock signal and non-knock signal after knock sensor signal
processing.
(a). Fault phenomenon: bad acceleration.
(b). Common fault reasons: various liquids such as engine oil, coolant, brake fluid and water
come into contact with sensor for a long time, corrosive sensor.
245
Data Flow
Use data flow RAM playback (b). Rotate the ignition switch to ON position.
Knock sensor signal
(c). Connect diagnosis tester to fault diagnosis
connector (16-pin). on the bottom left of
dashboard.
Return
(d). Select "reading data flow" menu items.
(e). At the moment, the knock sensor should
produce 0~1V voltage signal output.
(f).If there is no voltage signal output, replace knock
sensor.

(b). Open the engine hood.
(c). Disconnect the battery negative cable.
(d). Remove intake manifold. (See Chapter 11
Engine Mechanical System--Intake Manifold,
Replacement)
(e). Disconnect the knock sensor connector.
(f).Remove fixed bolt and knock sensor.
Note:
Clean mounting surface after dismantling. After
dismantling, do not contact various liquids, such as
engine oil, coolant, brake fluid etc. The sensor will be
subject to corrosion due to long-term exposure to
these fluids.
246
(g). Check the knock sensor. Switch the digital
multimeter to the resistance function and check
whether the resistance between two terminals is
infinite.
(h). If the check result doesn't meet requirement,
replace knock sensor.
(i). Install the knock sensor and tighten its fixed bolt.
Torque: 15~25N• m
Note:
Make sure knock sensor direction is right. Install it by
pressing method. Do not use any impact tool (like a
hammer). to knock the sensor into mounting hole.
Metal face of the sensor shall be very close to
cylinder block. When installing, any type of washer is
not allowed. When laying the sensor signal cable,
signal cables shall not have resonance to avoid
breaking.
(j). Connect the knock sensor connector.
(k). Install intake manifold. (See Chapter 11
Replacement)
247
Electronic Control Throttle Valve Housing
1. Parts drawing
2. Mounting position of electric control throttle valve

housing
The throttle opening of electronic throttle body assembly should be determined by ECM. And it
will calculate required engine output power of vehicle at this moment and under this condition
based on throttle pedal control input signals controlled by driver and other sensor input signals,
and thus control fuel supply (injection) of the engine and correct control parameters in
accordance with feedback signals, so as to ensure the best control condition of engine. The
electronic throttle body is newly provided with drive motor, gear drive mechanism, as well as
throttle position sensor with better function and higher reliability.
(a). Fault phenomenon: high idle speed, idle at idle speed and so on.
(b). General cause of fault: Due to deposits of dust, fuel vapor or other, the by-pass air way is
clogged, resulting in abnormal idle adjustment of stepping motor.
248
dashboard.
(d).Rotate ignition switch to ON, and turn on the

Items
displayed
Check conditions Normal
by the
Data Flow (range) conditions
Use data flow RAM playback
diagnosis
tester
Degree of throttle opening Idling
7%
position
• Ignition It’s increased
Throttle switch: ON The throttle proportionally to
opening • Engine opens the opening
Page up Page down Wave form Play back doesn't run gradually. angle of the
Return throttle.
Fully open 93%
(f).If the signal value is inconsistent with the specified
value or there is no signal output, check the electric
control throttle valve hosing, harness and ECM.
(b). Open the engine hood.
(d). Remove the intake manifold assembly. (See
Chapter 11 Engine Mechanical System--Intake
Manifold, Replacement)
(e). Remove the electric control throttle valve
housing assembly.
249
(f).Check the resistance of electric control throttle
valve housing. Measure the resistance between
Terminal 2 and Terminal 6 of connector on the side
of component of throttle valve housing.
Connection of digital
Specified conditions
multimeter
Resistance value:
The throttle opens gradually from
the idling position up until it opens
Terminal 2 and Terminal 6
fully. The resistance changes
steadily and proportionally with
the throttle opening angle.
(g). If the resistance is beyond the standard range
or the resistance changes unsteadily, replace
throttle valve housing.
(h). Check the stepping motor of electric control
throttle valve. Connect the battery positive and
negative cables to Terminal 4 and Terminal 1 of
electric control throttle valve housing, respectively,
make sure that the stepping motor should rotate.
Otherwise, replace electric control throttle valve
housing.
(i). Install electric control throttle valve housing
assembly.
(j). Install intake manifold assembly. (See Chapter 11
Replacement)
(k). Connect battery cathode cable.
250
Intake VVT valve
1. Parts drawing
2. Mounting position of intake VVT

The working power supply of intake VVT
solenoid valve is provided by main relay. ECM
controls grounding through
pulse-width-modulated signal. Thereby,
controlling the engine oil flow to camshaft
position actuator. The oil pressure actuates a
safety sliding valve, which is inside camshaft
position actuator mechanism fixed in front of
camshaft to operate. When safety sliding valve
operates, the oil will be led into camshaft position
actuator to make camshaft rotate.
(a). Fault phenomenon: engine idle speed
unstable, poor acceleration. It is impossible to
drive the vehicle normally.
(b). General cause of fault: The oil way has not
been cleaned thoroughly.
251
(a). Start engine and make it run to reach its
(c). Open engine hood.
(d). Disconnect battery negative cable.
(e). Disconnect the VVT solenoid valve
connector.
(f).Measure the resistance between two terminals of

VVT solenoid valve with digital multimeter.
Standard resistance:9.4~10.6Ω( 20°C）
(g). If the measured resistance is inconsistent
with standard value, replace VVT solenoid valve.

(a). Rotate the ignition switch to OFF.
(d). Disconnect the VVT solenoid valve
connector.
(e). Remove the VVT solenoid valve.
(f).Check the VVT solenoid valve filter for clogging
or damage. If there is, replace the filter.
252
(g). Connect the battery positive cable to
Terminal 1 of the VVT solenoid valve, and
connect the battery negative cable to Terminal 2
of the VVT solenoid valve.
Note:
To avoid explosion, fire or other danger, don't connect
two cables together directly in the process of testing.
(h). Check the valve core for operation. If it
doesn't work, replace the VVT solenoid valve.
(i). Install the VVT solenoid valve and tighten it.
Torque: 6~10N• m
(j). Connect the VVT solenoid valve connector.
(k). Connect battery cathode cable.
253
Canister Control Valve
1. Parts drawing
2. Mounting position of canister solenoid

The canister solenoid contains a solenoid valve
mechanism. The opening of solenoid valve is
controlled by digital pulse square waves sent by
ECM. The opening of canister solenoid varies
with engine working conditions. When the
engine is loaded heavily and the engine is idling,
the canister solenoid will not be put into
operation in order to ensure engine output power.
(a). Fault phenomenon: function failure,
excessive accumulation of gasoline vapor in
canister, resulting in gasoline leak and
environment pollution.
(b). General cause of fault: Foreign objects enter
into the valve, resulting in rust, corrosion, poor
sealing and so on.
254
dashboard.
(d).Rotate ignition switch to ON, and turn on
(e). Touch the canister solenoid of evaporative
emission control system (EVAP) with your hand.
(f).Use the "Action Testing" function of diagnostic
tester; test the operation of canister solenoid.
(g). Canister solenoid shall have slight vibration.
Motion Test Only Use in LF\Chongqin Lifan\ V5.0\Power Train\Engine System
If the canister solenoid has no slight vibration,
Engine fault indicator(MIL) Page up
Canister solenoid
Fuel pump relay
check solenoid valve, harness and ECM.
Page down
Cooling fan relay #1
Print
A/C clutch
Service Vehicle Soon (SVS) Indicator.
Return
Forbidden fuel injection
Idling speed control

(d). Remove intake manifold.
(e). Disconnect the connector of canister
solenoid.
(f).Loosen the clamp of air inlet of the canister
solenoid and disconnect the connection of hose
(to the canister).
Note:
For a vehicle with a long mileage, when
255
disconnecting a hose, first twist the hose to confirm it
has been loose.
(g). Loosen the clamp of air outlet of canister
(connected to the lower intake manifold of
throttle housing).
(h). Remove canister solenoid.
(i). Check canister solenoid.
(j). Use battery power supply to switch on canister
solenoid. When switching on or off canister
solenoid, a "tick" sound should be produced. At
this moment, blow air into air inlet (to canister).
If there is air flowing from air outlet (to intake
manifold), it indicates that canister solenoid has
good working condition. Otherwise, replace
solenoid valve.
(k).If solenoid valve is not energized, it shall keep
closed and air cannot go through it.
(l). Check the resistance of the canister solenoid.
Switch digital multimeter to the resistance
function, connect the two probes to Terminal 1
and Terminal 2 of solenoid valve, respectively,
and then measure the resistance between two
terminals.
Standard resistance: 22~30Ω(20℃ )
(m). If the resistance is inconsistent with specified
value, replace solenoid valve.
(n). Connect the clamp of air outlet of canister
(connect to the lower intake manifold of throttle
housing).
(o). Connect the clamp of air inlet of canister
(connect to canister).
256
(p). Connect the connector of canister solenoid.
(q). Install intake manifold.
257
Injector
1. Parts drawing and terminal
2. Mounting position of injector

The nozzle structure is a ball valve device of
electromagnetic switch. The coil leads to two
poles through the engine wire harness to connect
with ECM and power.After the coil is breakover
to system under control of ECM, it will generate
magnetic force to overcome spring force, fuel
pressure and manifold vacuum suction. When the
valve core is sucked up, the fuel will pass
through the valve seat hole and spray out of pilot
hole to intake valve in mist status. After the
power is off, the magnetic force will disappear,
under spring force and fuel pressure, the nozzle
will be closed.
(a). Fault phenomenon: poor idling and
acceleration, it is difficult to start.
(b). General cause of fault: lack of maintenance,
resulting in the colloid accumulation inside the
injector and failure.
258
(a). After warming up the engine, make it run at
idle speed.
(b). Touch the injector with a spin tool
(screwdriver). or stethoscope (touch-rod type).
(c). When the engine operating, you can hear
rhythmic "rattling" sounds from the injectors -
These are the fuel injection sounds of injectors
under action of electric pulses.
(d). If the working sound of injector of each
cylinder is clear and uniform, it is an indication
that each injector is working properly. If the
working sound of injector of a cylinder is very
small, it indicates that the injector of cylinder is
not working properly. It is possible that its needle
valve is seized up, be sure to perform further
examination on it. If you hear no working sound
of the injector of a cylinder injector, it is clear
that the injector in cylinder is not working, be
sure to check the injector and its control circuit.
Note:
cable of battery, please turn off ignition switch and
all illumination switches first. And loosen the
fastening nut of battery negative terminal. Don't pry
up the cable terminal when performing such
operation.
(d). Dismantle fuel rail assembly.
(e). Remove the injector.
(f).Check fuel injector.
259
(g). Adjust a digital multimeter to resistance
scale, 2 meter probes are connected respectively
to No.2 and No.3 terminal of sensor, and check
the resistance between 2 terminals.
Standard resistance:11~17Ω(20℃ )
(h). If the resistance value doesn't meet
requirement, replace fuel injector.
260
Ignition Coil
1. Parts drawing
2. Mounting position of ignition coil

The ignition coil is mainly composed of a
primary coil, a secondary coil and an iron core.
In ignition system, the ignition coil is used to
change a low voltage into a high voltage to
enable the spark plugs to generate sparks. Each
ignition coil corresponds to only one cylinder.
Under control of ECM, charge primary coil to
save magnetic energy, the secondary coil
winding will sense high voltage, so as to make
the spark plug connected to coil spark over and
at the same time, orderly control the output high
voltage energy from ignition coil of each
cylinder to spark plug.
(a). Fault phenomenon: engine idle speed
unstable, intermittent flameout, the engine
cannot start.
• Ignition coil winding is short circuit, open circuit or grounding. As a result, ignition coil
generates Voltage below level or does not generate voltage, which leads to insufficient
261
ignition energy or misfire.
• Insulation material of ignition coil is ageing which make the insulation performance bad.
Ignition system has weak spark or doesn't ignite due to electricity leakage of ignition coil.
(d). Remove the fixing bolts of high-voltage
ignition coil, and then remove the high-voltage
ignition coil.
(e). Check the surface of high-voltage ignition
coil for crack or damage. If there is, replace the
ignition coil.
(f).Switch the digital multimeter to resistance
function, and measure the resistance between
Terminal 1 and Terminal 2 of high-voltage
ignition coil. Standard resistance: 0.5±0.05Ω
(g). If the check resistance doesn't meet
requirement, replace ignition coil.
(h). Install the ignition coil and tighten its fixed
bolts.
(i). Connect battery cathode cable.
262
Fuel Pump
1. Parts drawing
2. Mounting position of fuel pump

The electric fuel pump consists of a DC motor, a
vane pump and an end-cover (integrated with a
check valve, a pressure relief valve and
anti-electromagnetic interference components). and
so on. Both the pump and the motor are installed
on the shaft and sealed inside the same housing.
Gasoline is filled around the pump and motor
inside the housing and is used for cooling and
lubricating. The battery powers the electric fuel
pump through fuel pump relay. Only when the
engine starts and operates, the relay can allow
electric fuel pump circuit to have good continuity.
When the engine stops running due to any
accident, the fuel pump will stop operating
automatically.
4. Possible faults
(a). Fault phenomenon: noisy operation, poor
acceleration, unable to start (difficult to start), etc.
(b). General cause of fault: due to use of poor fuel.
263
(d) Rotate ignition switch to ON, and turn on the
(e). Use the "Action Testing" function of

Motion Test Only Use in LF\Chongqin Lifan\ V5.0\Power Train\Engine System
Engine fault indicator(MIL)

diagnostic tester, and perform the action testing on
Page up
Canister solenoid
Fuel pump relay Page down
"Fuel Pump Relay".
Print (f).The fuel pump relay should operate, and the fuel
A/C clutch
Service Vehicle Soon (SVS) Indicator.
Return pump should produce a slight pumping sound. If
Forbidden fuel injection
Idling speed control
there is on operation of fuel pump relay or no
pumping of fuel pump, make sure to check the fuel
pump, harness and ECM.

(a). Rotate the ignition switch to OFF.
(c). Disconnect the negative cable of battery.
(d). Disconnect fuel pump connector.
(e). Remove fuel pump. (See Chapter 13 Fuel
System-Fuel Pump, Replacement)
(f).Check the fuel pump. Put the fuel pump into a

container with fuel, and connect the fuel pump to
the battery with wires.
264
Note:
Separate the battery from the container with a wooden
plate to prevent fire from igniting the fuel.
(g). Make sure that the fuel pump can pump fuel
normally. If not, replace the fuel pump.
(h). Install the fuel pump. (See Chapter 13 Fuel
System-Fuel Pump, Replacement)
(i). Connect fuel pump connector.
(j). Connect the negative cable of battery.
Chapter II Delphi Electronic Injection System

Section Ⅰ Overview
Ⅰ. Basic Principle of Electronic Injection System of LIFAN Motors
This system is an electronic control multi-port sequential fuel injection system. The electronic
control unit (ECU) of the engine utilizes all kinds of sensors installed on different portions of the
engine to measure all kinds of working parameters of the engine and, as per the preset control
programs in ECU, controls the fuel injectors so as to control fuel injection quantity pricisely which
in turn garentees the air mixture of the best concentration under all kinds of working conditions of
the engine. In addition, the electronic control gasoline injection system utilizes the control programs
preset in ECU and other corresponding actuators to realize the functions, such as cranking
enrichment, warm-up enrichment, accelerating enrichment, and full-load enrichment, decelerating
dilution, forced idle fuel cutoff, and automatic idle speed control, so as to meet the engines'
requirements for air mixture under special working conditions, whereby good fuel economy and
emission performance of the engine can be guaranteed, and the operation performance of the
vehicle can be improved.
Ⅱ. Basic Composition of Electronic Control System
The electronic control system of LIFAN Motors is composed of the following three parts:
(1) Sensors – The sensors convert all kinds of non-electric physical values of the engine into
electric values and provide all kinds of information to the sub-control unit. The sensors for the
electronic control unit of the engine include: ①Intake pressure and temperature sensor;
②Throttle position sensor (TAPS); ③Coolant temperature sensor; ④ Heated oxygen sensors
(Upstream and downstream oxygen sensors, of which the Chinese Stage-III models are only
equipped with upstream oxygen sensor and the Chinese Stage-III + EOBD and Chinese
265
Stage-IV models are equipped with both upstream and downstream oxygen sensors); ⑤Knock
sensor; ⑥Crankshaft position sensor; ⑦ Weak acceleration sensor (The simplified Chinese
Stage-III models are not equipped with weak acceleration sensor and the Chinese Stage-III +
EOBD and Chinese Stage-IV models are equipped with weak acceleration sensor).
(2) The electronic control unit of controller is the brain of the entire electronic control system and
is referred to as ECU for short. It analyzes and processes all kinds of information provided by
the sensors and issues the conclusion obtained to the actuators by means of commands so that
the engine is running under optimized status.
(3) The actuators fulfill the commands issued by the electronic control unit. The actuators are the
hands and feet of electronic control system. The actuators for electronic control system include:
①Figure Fuel pump; ②Fuel Injector; ③Ignition coil; ④ Idling actuator with stepper motor;
⑤Canister control valve.
266
Section Ⅱ Principles of Control Unit and Actuators
1. Intake pressure and temperature sensor (Figure 1-1)

Pin 1 Intake pressure signal
Pin 2 5V power +
Pin 3 Intake temperature signal
Pin 4 5V power -
Fig. 1-1
(1) Application: It measures 0.1~0.2bar intake manifold absolute pressure and the intake airflow
temperature to provide load information to the engine.
(2) Composition and principle: This sensor is composed of intake manifold absolute pressure
sensor and intake temperature sensor and is installed on pressure stabilizer box.
(3) Intake pressure sensor: It’s composed of a silicon chip. A diaphragm is etched on the silicon
chip. Four piezo resistances are on the pressure diaphragm and they, as a strain element, form a
Wheatstone bridge. Besides this pressure diaphragm, a signal processing circuit is also
integrated on the silicon chip. The silicon chip together with a metal shell make up a spatial
reference. The air absolute pressure in this spatial reference approaches to zero and it becomes
a MEMS. The active side of silicon chip is under a pressure approaching to zero and its reverse
side is under the intake manifold absolute pressure that is introduced by a connecting pipe and
needs to be measured. The thickness of silicon chip is only few microns (μm), therefore, the
changes of intake manifold absolute pressure can cause mechanical transformation of silicon
chip, then the four piezo resistances transform and the resistance value changes. Voltage
signals that are linear to pressure are formed after the circuit processing through the signal
processing circuit of silicon chip.
(4) Intake temperature sensor: The sensing unit is a negative temperature coefficient (NTC)
resistor. Similar to coolant temperature sensor, its resistance is reduced following the
increasing of intake temperature. The engine ECU monitors the variation of intake temperature
by means of an internal comparison circuit.
(5) Connecting circuit (Figure 1-2)
267
No.2 5V power positive
Intake pressure
No.2 5V power negative
Inlet air temperature
Intake Air Temperature and Pressure Sensor
Fig. 1-2
(6) Fault diagnosis: Follow-up electronic device of intake air pressure sensor can determine faults,
such as open circuit, short circuit of intake air pressure sensor, and sensor damage. When ECU
detects that output signal of the sensor exceeds other signals except output characteristic curve,
ECU estimates that the sensor has a fault. For example: when intake air pressure is higher than
upper limit of intake air pressure or lower than lower limit of intake air pressure, ECU
estimates that the sensor has a fault (when starting, intake air pressure is lower than lower limit,
but ECU can estimate working conditions of starting). At the same time, engine malfunction
indicator light is lit. Run in fault mode.
2. Diagram of throttle position sensor (Figure 1-3)
Exterior of throttle position sensor

Pins: 1 Voltage input 2. Signal grounding 3 Signal
output
Fig. 1-3
(1) Application: This sensor is functioned to provide rotating angle information of throttle to
ECU. Based on this information, ECU can obtain the engine load information, working
condition information (such as start, idling, reverse towing, partial load, and full load), and
acceleration and deceleration information. This sensor adopts three-wire type and ECU detects
the opening extent of throttle by monitoring the voltage variation.
268
(2) Composition and principles: The sensor is an angle sensor with linear output. It consists of
two arc sliding contact resistances and two sliding contact arms. The revolving shaft of the
sliding contact arm is connected on the same axis of the throttle spindle. Apply 5V power
supply voltage US on both ends of sliding contact resistance. When the throttle is rotating,
sliding contact arm also rotates. At the same time, it moves on sliding contact resistance, and
uses contact potential UP as output voltage for outgoing. Therefore, in fact, it is a rotation
angle potentiometer. ECU adopts Up/Us actually to avoid the sensor value fluctuation caused
by engine voltage fluctuation.
(3) Connecting circuit: The circuit diagram of throttle position sensor is shown below (Figure
1-4).
Throttle position sensor (TAPS)
Throttle position sensor circuit diagram
Fig. 1-4
(4) Fault diagnosis: ECU monitors whether the rotation angle of throttle is beyond the upper limit
or lower limit of the output signal. If the output signal is beyond the upper limit or lower limit,
ECU judges the fault of throttle position sensor, the engine runs under fault mode, and the
engine fault indicator lights up (The impact and internal contamination of the sensor will easily
lead to engine fault).
(5) Installation: The tightening torque for mounting screws is 1.5N.m~2.5N.m.
3. Coolant temperature sensor (Fig.1-5)
269
Diagram of coolant temperature sensor
Pins: This sensor totally has three pins, which can be interchanged.
a. Coolant temperature signal pin of electronic injection system. The resistance
is approximate 2.45KΩ at 20℃.
b. Coolant temperature pin of instrument. The resistance is approximate 0.05KΩ
at 80℃.
c. Signal GND
Fig. 1-5
(1) Application: This sensor is functioned to provide coolant temperature information. It provides
the coolant temperature sensor to the engine ECU for control of ignition timing and fuel
injection pulse width at start, idling, and normal start.
(2) Composition and Principle: This sensor is one negative temperature coefficient (NTC)
thermistor, of which the resistance reduces following the increasing of coolant temperature in a
non-linear mode. Thermal resistance with negative temperature coefficient is installed in a
copper heat conduction sleeve. By means of one voltage division circuit, ECU converts the
resistance change of thermistor to one varying voltage and provides to ECU and thus monitors
the change of water temperature (internal structure of ECU).
Coolant temperature sensor
Fig. 1-6
(4) Fault diagnosis: When the coolant temperature is beyond creditable upper limit or creditable
lower limit, the fault flag bit is set, the engine fault indicator lights up, the engine runs under
fault mode, ECU controls the ignition and fuel injection as per the coolant temperature preset
under engine coolant temperature fault mode, and at the same time the fan starts high speed
running.
(5) Installation tip: The tightening torque is 15 ±2N·m
270
4. Diagram of knock sensor
Knock Sensor
(1) Application: This sensor is functioned to provide the engine knock information to ECU for
knock control.
(2) Composition and principles: Knock sensor is a kind of vibration acceleration sensor, which is
installed on engine cylinder block. Sensing element of the sensor is a piezoelectric element.
Engine cylinder block vibration is transferred to piezoelectric crystal through weight block in
the sensor. Because piezoelectric crystal bears pressure generated by weight block vibration,
the voltage is generated on both pole faces to convert vibration signal into AC voltage signal
output. Vibration signal frequency caused by engine knock is higher than normal vibration
signal frequency of the engine. Therefore, ECU filters knock sensor signals and differentiate
knock signal and non-knock signal. When engine load, speed and coolant temperature exceed
respective threshold value and no knock sensor fault information record is made, knock sensor
signal is used for knock closed-loop control. When knock closde-loop control is activated,
knock sensor signal is input into ECU, then amplified, filtered and integral. When integral
value exceeds threshold value within a certain crankshaft rotation angle, ECU considers there
is a knock. Then it reduces ignition advance angle. If a knock appears again in the next cycle,
ignition advance angle will be reduced; if no knock appears in the following cycles, then
ignition advance angle is restored to normal value gradually.
271
Pin 1: High signal
Pin 2: Low signal
Knock sensor Schematic diagram of

harness end seal fitted
with knock sensor
Knock sensor circuit diagram
Fig. 1-7
(4) Fault diagnosis: ECU to monitor various sensors, actuator, amplifier circuit and detection
circuit. In event of any of the following conditions, namely fault of knock sensor, fault of
knock control data processing circuit, suspicious cylinder judgment signal, and set of fault flag
bit of knock sensor, the knock closed-loop control is deactivated and the ignition advance
angle stored within ECU is reduced by one safe angle. When the error frequency is reduced to
below preset value, the fault flag bit will be reset.
(5) Installation Tip: installed to tightening torque 20±5N·m。
5. Oxygen sensor (Figure1-8)
Oxygen sensor
Pin 4 Low level output signal
Pin 3 High level output signal
Pin 2 Negative pole of heating unit
Pin 1 Positive pole of heating unit
Fig. 1-8
(1) Application: This sensor is functioned to provide the information whether the oxygen is
272
surplus after the fuel injected into the engine cylinder is combusted completely within air
sucked. ECU utilizes this information for quantitive fuel closed-loop control so that three main
toxic substances within the engine emission, namely hydrocarbon (HC), carbon oxide (CO),
and nitric oxide (NOX), can be converted and purified to the maximum extent within the
three-way catalytic converter.
(2) Composition and principles: Oxygen sensor has a sensing element, which is a porous
ceramic tube, the outer wall surrounded by the engine exhaust and inside connecting to
atmosphere. The sensing ceramic tube wall is a solid electrolyte and is embedded with electric
heating tube to heat the ceramic body to 300℃ so that the ceramic body starts working.
Namely, it embodies the characteristic of solid electrolyte. The oxygen ions can pass through
the ceramic tube freely because of its special textures. It is also this texture that the
concentration difference can be changed into potential difference and then forms electrical
signal output. If the air mixture is too thick, the more the density difference of the oxonium ion
is in and out ceramic pipe, the bigger the potential difference is. Plenty of oxonium ions move
out from inside to outside of the pipe, and the output voltage is also high if the mixed gas is
thinner, the density difference of oxonium ions in and out ceramic pipe is low and potential
difference is low. Only small amount of oxonium moves out from inside of pipe and output
voltage is low. The oxygen sensor working voltage fluctuates between 0.1-0.9V, changing 5-8
times every 10 seconds. If the oxygen sensor's frequency is lower than such frequency value, it
is an indication that the sensor gets ageing and needs to be replaced, the sensor cannot be
repaired.
(3) Connecting circuit: Refer to oxygen sensor circuit diagram (Figure 1-9).
273
Main relay
Fig. 1-9
(4) Fault diagnosis: ECU monitors various sensors, actuator, amplifier circuit and detection
circuit. In event of any of the following conditions, namely suspicious battery voltage,
suspicious intake manifold absolute pressure signal, suspicious engine coolant temperature
signal, and fault of fuel injector driver, the fault flag bit of oxygen sensor is set, the fuel
quantitive closed-loop control is deactivated, and the basic fuel injection time stored within
ECU is adopted for fuel quantification.
(5) Installation Tip: The tightening torque for oxygen sensor is 50~60 N·m. After the
replacement of oxygen sensor, apply one film of anti-rusting oil onto the oxygen sensor, in
order to prevent the failure of disassembly due to rusting.
6. Electronic control unit (ECU) (Figure 1-6)
(1) Application: ECU is the core of engine electronic control system. The sensors provide all
kinds of electronic control signals to ECU and ECU controls, after internal calculations, the
actions of series of actuators, including fuel injectors and ignition coil, to control the working
of the engine.
(2) Composition: Shielded casing and printed circuit board. The circuit board integrates many
electronic control units for control of electronic injection system.
(3) Installation: It's fixed by screws beneath the dashboard glovebox. The engine ECU is a
twin-interface ECU.
(4) Definitions of pins for LF479Q2 engine ECU (Refer to Table 1-1 and Figure 1-10)
274
Table 1-1
Number Number Number

Definition Definition Definition
of pin of pin of pin
J1-01 Ignition switch J1-02 Unused J1-03 Vehicle speed
Oxygen sensor signal
J1-04 Pin 2 5V power + J1-05 Pin 1 5V power - J1-06
low
J1-07 Unused J1-08 Unused J1-09 Unused
High signal of
J1-10 Unused J1-11 Serial data J1-12
crankshaft 58th tooth
J1-13 Unused J1-14 CAN line - J1-15 CAN line +
J1-16 Unused J1-17 Battery power 1 J1-18 Battery power 2
J1-19 Unused J1-20 Pin 1 5V power + J1-21 Pin 2 5V power -
J1-22 Unused J1-23 Unused J1-24 Throttle Position
J1-25 Unused J1-26 Unused J1-27 Inlet air temperature
Low signal of crankshaft
J1-28 J1-29 Fault service (SVS) lamp J1-30 Unused
58th tooth
Engine fault diagnostic Idling phase B output
J1-31 J1-32 Ignition coil A J1-33
lamp +
J1-34 Idling phase A output - J1-35 Acceleration signal J1-36 Power steering signal
Rear oxygen senor signal
J1-37 Unused J1-38 J1-39 A/C request (+)
high
J1-40 Unused J1-41 Unused J1-42 Intake pressure
J1-43 Coolant temperature J1-44 Unused J1-45 Tachometer
A/C compressor clutch
J1-46 Pump relay control J1-47 relay control and oil pump J1-48 Unused
relay control
J1-49 Unused J1-50 High speed fan relay control J1-51 Unused
Idling phase A output
J1-52 Ignition coil B J1-53 Idling phase A output - J1-54
+
No. 1 cylinder fuel
J1-55 J1-56 No. 3 cylinder fuel injector J1-57
injector
J1-58 Main relay J1-59 Unused J1-60 Unued
Front oxygen sensor Front oxygen senor signal Canister solenoid
J1-61 J1-62 J1-63
heating control high valve control
Rear oxygen sensor
J1-64 J1-65 Unused J1-66 Unused
heating control
Low speed fan relay
J1-67 J1-68 Unused J1-69 Knock signal
control
No. 2 cylinder fuel
J1-70 J1-71 No. 4 cylinder fuel injector J1-72 Unused
injector
J1-73 System grounding wire
275
Illustration of connector pins
Fig. 1-10
7. Electric fuel pump (Figure 1-11)
Fig. 1-11
(1) Application: It’s functioned to deliver the fuel at certain pressure and flow to the engine from
the fuel tank. The temperature and voltage are of high influence on fuel pump.
(2) Composition and Principle: The electric fuel pump is composed of DC motor, vane pump,
and end caps (which integrate check valve, relief valve, and anti-electromagnetic interference
unit), in which the pump and the motor are installed coaxially and are enclosed within the
same housing. Gasoline is filled around the pump and motor inside the housing and is used for
cooling and lubricating. The battery powers electric fuel pump through fuel pump relay. Only
when the engine starts and operates, the relay can allow electric fuel pump circuit to have good
continuity. When the engine stops running due to any accident, the fuel pump will stop
operating automatically. The maximum output pressure of the electric fuel pump depends on
the relief valve. As this system is a return-free system, the fuel pump assembly is fitted with
fuel pressure regulator, which regulates the fuel pressure of fuel pump at 380kPa to meet the
working requirements of the system.
Caution: The fuel temperature is of great influence on the performance of the fuel pump. Under
long-term running at high temperature, the pumping pressure of the fuel pump is reduced sharply
276
when the fuel temperature is above certain temperature. Therefore, if the hot engine can’t be started,
please carefully check for the poor working performance of fuel pump at high temperature.
Fuel
pump fuse
Battery
power
Pump relay control

Ignition
switch output
Fuel pump relay
Fig. 1-12
8. Electromagnetic fuel injector (Figure 1-13)
Diagram of electromagnetic fuel injector
Fig. 1-13
(1) Application: As per the command of ECU, the fuel injector injects the fuel within the
specified period to supply the fuel to the engine and atomize the fuel.
(2) Composition and principles: ECU sends electric pulse to fuel injector coil to form magnetic
field force. When magnetic force increases to overcome resultant force from return spring
pressure, needle valve gravity and friction, needle valve starts to lift and injection process
begins. Maximum lift of needle valve does not exceed 0.1mm. When injection pulse stops,
return spring pressure shuts off the needle valve again.
277
Main relay
1-cylinder 2-cylinder 3-cylinder 4-cylinder
Fuel injector group
Circuit diagram of electromagnetic fuel injector
Fig. 1-14
Installation Tip: Make sure to use corresponding connector for specific fuel injector and never mix
any connectors. To ease the installation, it’s recommended to apply silicone-free clean engine oil
onto the surfaces of the upper O-ring for connecting with fuel distribution pipe. Attention, do not let
engine oil pollute the inside of fuel injector and injection hole. Install the fuel injector into the fuel
injector seat along the direction perpendicular to the fuel injector seat and fix the fuel injector onto
the fuel injector seat with clamps.
Note: If the long-parked vehicle can not be normally started due to gasoline bonding in the fuel
injector, please carefully check whether the injector is bonded.
(4) Fault Diagnosis: The electronic injection system does not implement fault diagnosis on the
fuel injector itself, however it implements on the fuel injector driver. When the fuel injector
driver is short circuited or overloaded to battery voltage, short circuited to ground, or open
circuited, the fault flag bit will be reset. In such case, if the oxygen sensor closed-loop control
and its self-learning pre-control are deactivated, the last self-learning data apply. The fault flag
bit will be reset after the fault is resolved.
9. Idling actuator stepper motor (Figure 1-15)
278
Pin:
Pin 1 To ECU pin 19
Pin 2 To ECU pin 20
Pin 3 To ECU pin 35
Pin 4 To ECU pin 36
Idling actuator stepper motor
The pin 1 and pine 2 share one coil and pin 3 and pin 4
share one coil. The resistance shall be same for two coil
groups. Therefore, at the time of checking, please confirm
whether the resistances of coils are within the standard
range.
Fig. 1-15
(1) Function: The idling actuator with stepper motor provides a bypass intake passage as well.
When the throttle is closed, the air enters into the engine through this bypass passage. ECU can
adjust the section area of this bypass passage through a stepper motor to adjust intake amount
into engine and adjust the fuel injection amount depending on intake amount. While the engine
is running, ECU controls the action of stepper motor depending on different working
conditions of the engine to change working status of the engine.
(2) Composition and principles: The stepper motor is a micro motor. It consists of many steel
stators and one rotor. Each steel stator is winded by one coil; the rotor is a permanent magnet.
The permanent magnet core is a nut. All stator coils shall be always energized. If current
direction of a certain coil is changed, the rotor will turn an angle. When each stator coil
changes current direction in a suitable order, a rotary field is formed to make the rotor made of
permanent magnet rotate in a definite direction.
Idling control unit
Fig. 1-16
279
(4) Fault diagnosis: ECU can monitor the short-circuit or open-circuit of two coils of idling
stepper motor and, upon detection of such fault, light up the engine fault indicator and run the
engine under fault mode. Sometimes the engine runs abnormally even no change of step
number of stepper motor is detected by diagnostic scanner. In such case, check the change of
intake pressure to verify whether the piston of stepper motor is acting.
10. Ignition Coil (Fig. 1-17)
Fig. 1-17
(1) Function: The ignition coil converts the low voltage of primary winding to high voltage of
secondary winding and generates spark via discharge of spark plug to ignite the fuel-air
mixture within the cylinder.
(2) Independent ignition (grouped ignition): The vehicle totally has one such ignition coil.
Depending on the signals of crankshaft position sensor and camshaft position sensor, the
engine ECU controls the ground of these three ignition coils respectively to control the ignition
of the engine.
(3) Composition and principle: Ignition coil consists of primary winding, secondary winding and
iron core，housing, etc. When the battery voltage is applied onto the primary winding, the
primary winding is charged. Once ECU cuts off the circuit of primary winding, the charging is
stopped and at the same time high voltage is inducted in the secondary winding.
(4) Parts circuit (Figure 1-18)
Ignition switch
Coil A
Shielded
line
Coil B
Ignition coil
Fig. 1-18
280
(5) Fault Diagnosis: ECU has no function to conduct the fault diagnosis on the ignition coil.
Therefore, there is no DTC when the ignition coil is faulty. Only the checking of ignition coil
resistance can determine the normal working of ignition coil. Under normal condition, the
heating value of ignition coil is high during working. However, the over-high temperature of
ignition coil will lead to increased resistance of ignition coil and engine faults such as unstable
running and automatic flameout.
Primary winding: 0.47Ω;
Secondary winding: 8Ω
11. Canister control valve (Figure 1-19)
Fig. 1-19
(1) Application: It’s functioned to control the cleaning airflow rate of canister. The canister
control valve is controlled by ECU via duration and frequency of electric pulse (namely duty
ratio) based on engine load. The excessive accumulation of gasoline vapor within active
canister will lead to external leakage of gasoline and environment contamination. Therefore,
the canister electromagnetic valve is functioned to open electro magnetic valve when
appropriate so that the excessive gasoline vapor will enter into the intake pipe for combustion.
(2) Composition and principle: The canister control valve is composed of electromagnetic coil,
armature, and valve. Canister inlet port has a filter. On one hand, air flow through the canister
control valve is related to ECU to the canister control valve output electrical pulse duty cycle
on the other hand, it is related to the pressure difference between the canister inlet port and
outlet port. When there is no electrical pulse, the canister control valve is closed. According to
the signals provided by various engine sensors, ECU can control the energized time of the
carbon canister solenoid and indirectly control the size of the cleaning air flow.
(3) Fault diagnosis: ECU has no function to conduct the fault diagnosis on canister control valve,
but has fault diagnosis function on driver of canister control valve. In event of short-circuit to
281
battery voltage, overload, short-circuit to ground, or open circuit of the driver of canister
control valve, the basic self-learning of fuel metering closed-loop control and the self-learning
of idling intake demand will be deactivated. In such case, the current self-learning data still
apply. When the canister electromagnetic valve is faulty, the common phenomena of the engine
are unstable or over-high idling.
(4) Parts circuit (Figure 1-20)
Canister solenoid valve control From main relay output
Fig. 1-20
282
Section Ⅲ Procedure of Fault Diagnosis by DTC
Ⅰ. LIFAN self-made engine (LF479Q2)

1. Throttle position sensor (See Table 1-4)
Table 1-4
DTC (DTC) Location or type of fault

P0122 Throttle /pedal position sensor / switch A circuit input low
P0123 Throttle /pedal position sensor / switch A circuit input high
Checking Subsequent
S/N Operation procedure
result procedure
1 Rotate the ignition switch to ―ON‖ Next
Unplug the connector of throttle position sensor from the harness and YES Next
2 use a multimeter to measure whether the voltage between pin (1) and
pin (2) thereon is approximate 5V. NO 5
Use a multimeter to measure whether the resistance between pin (1) YES Next
3 and pin (2) of the sensor is within 1.6~2.4k.
NO Replace the sensor.
Move the throttle position sensor slowly from one end to another end. YES Replace the sensor.
At the same time, use a multimeter to check for open-circuit or
4
short-circuit or jumping resistance between pin (1) (-) and pin (3) (+) NO Replace ECU.
of the throttle position sensor.
Connect an adapter between ECU and harness and use a multimeter
to check for presence of open-circuit or short-circuit between pins Repair or replace
5 YES
J1-20, J1-05, and J1-24 of ECU and pins (1), (2), and (3) of sensor harness
connector respectively.
2. Knock sensor (Refer to Table 1-5)

Table 1-5

P0325 Fault of knock sensor 1 circuit
Checking Subsequent
result procedure
1 Turn off the ignition switch to stop the engine. Next
Unplug the connector of knock sensor from the harness and use a YES Next
multimeter to measure whether the resistance between pin (1) and pin
2
(2) of knock sensor is more than 1MΩ. Replace with new
NO
sensor.
Use a small hammer to lightly hammer the vicinity of the knock YES Next
3 sensor and use a multimeter to measure for presence of AC output
signal between pin (1) and pin (2) of sensor. NO Replace the sensor.
4 Turn on the ignition switch, but do not start the engine. Next
Connect an adapter between ECU and wire harness and use a Repair or replace
5 YES
multimeter to measure for presence of short-circuit or open-circuit wire harness
283
between pins J1-05 and J1-69 of ECU and pins 1 and 2 of sensor
connector respectively. NO Replace ECU.
3. Intake manifold absolute pressure and temperature sensor (Refer to Table 1-6)
Table 1-6

P0107 Low input of intake manifold absolute pressure/atmospheric pressure circuit
P0108 High input of intake manifold absolute pressure/atmospheric pressure circuit
Checking Subsequent
result procedure
Unplug the connector of intake manifold absolute pressure and intake YES 4
temperature sensor from the harness and use a multimeter to measure
2
whether the voltage between pin (2) and pin (4) of the connector is
NO Next
approximate 5V.
Connect an adapter between ECU and harness and use a multimeter Repair or replace the
YES
to check for presence of open-circuit or short-circuit between pins harness
3
J1-21, J1-42, and J1-04 of ECU and pins (4), (1), and (2) of sensor
connector respectively. NO Next
Shift to neutral gear, start the engine, and idle the engine. Depress the YES Replace ECU.
throttle to almost full open. In such case, use a multimeter the
5 measure via adapter whether the voltage between pins (1) and (4) of Replace ECU.
sensor, namely between pin J1-42 and pin J1-21 of ECU gradually NO Replace sensor.
rises to approximate 4V.
4. Oxygen sensor (Refer to Table 1-7)

Table 1-7

P0131 Oxygen sensor short-circuit to ground fault (upstream oxygen sensor)
P0132 Oxygen sensor short-circuit to power supply fault (upstream oxygen sensor)
P0133 Oxygen sensor response time fault (upstream oxygen sensor)
P0134 Oxygen sensor open-circuit fault (upstream oxygen sensor)
P0135 Oxygen sensor heating fault (upstream oxygen sensor)
P1167 Oxygen sensor DFCO over-rich fault (upstream oxygen sensor)
P1171 Oxygen sensor PE under-thin fault (upstream oxygen sensor)
P0137 Oxygen sensor short-circuit to ground fault (downstream oxygen sensor)
Oxygen sensor short-circuit to power supply fault (downstream oxygen
P0138
sensor)
P0140 Oxygen sensor open-circuit fault (downstream oxygen sensor)
284
P0141 Oxygen sensor heating fault (downstream oxygen sensor)
Checking Subsequent
result procedure
Unplug the oxygen sensor connector from the harness and use a YES Next
2 multimeter to measure for presence of approximate 12V battery
voltage between pin (1) (+) and pin (2) (-) of connector. NO 4
Use a multimeter to measure whether the resistance between pin (1) YES Replace ECU.
3
and pin (2) of the oxygen sensor is within 6~25. NO Next, replace sensor.
Check whether the fuse within heating circuit of oxygen sensor is YES Replace Fuse
4
burnt. NO Next
Use a multimeter to measure for presence of open-circuit or Repair or replace
YES
short-circuit between pin (1) of oxygen sensor connector and pin wire harness
5 J1-02 of main relay and between pin (2) of sensor connector and pin
J1-61 (upstream oxygen sensor)/pin J1-64 (downstream oxygen NO Next
sensor) of ECU.
Plug the oxygen sensor connector to the harness, shift to neutral gear,
6 start the engine, and idle the engine, till the coolant temperature Next
reaches normal value.
Unplug the oxygen sensor connector from the harness and use a YES Next
7 multimeter to measure for presence of 0.1~0.9V voltage output
between pin (4) (+) and pin (3) (-) of sensor. NO Replace the sensor.
Connect an adapter between ECU and harness and use a multimeter Repair or replace
YES
to check for presence of open-circuit or short-circuit between pins wire harness
8 J1-06 and J1-62 (upstream oxygen sensor)/J1-38 (downstream
oxygen sensor) of ECU and pins (3) and (4) of sensor connector NO Replace ECU.
respectively.
285
5. Intake temperature sensor part of intake manifold absolute pressure and intake
temperature sensor (Refer to Table 1-8)
Table 1-8

P0112 Intake air temperature circuit input low
P0113 Intake air temperature circuit input high
Checking Subsequent
result procedure
Unplug the connector of intake manifold absolute pressure and intake YES Next
temperature sensor from the harness and use a multimeter to measure
2
whether the voltage between pin (4) and pin (3) of the connector is NO To item 4
approximate 5V.
Use a multimeter to measure whether the resistance between pin (4) YES Replace ECU.
3 and pin (3) of sensor corresponds to the temperature (Refer to relevant
parts in this Repair Maintenance). NO Replace the sensor.
YES
multimeter to check for presence of open-circuit or short-circuit wire harness
4
between pins J1-20, J1-05, and J1-24 of ECU and pins (4), (2), and (3)
of sensor connector respectively. NO Replace ECU
286
6. Coolant temperature sensor (Refer to Table 1-9)
Table 1-9

P0117 Engine coolant temperature circuit input low
P0118 Engine coolant temperature circuit input high
Checking Subsequent
result procedure
1 Rotate the ignition switch to ―ON‖. Next
Unplug the connector of coolant temperature sensor from the harness YES Next
2 and use a multimeter to measure whether the voltage between pin (c)
(+) and pin (a) (-) of connector is approximate 5V. NO To item 4
Use a multimeter to measure whether the resistance between pin (c) YES Replace ECU.
3 and pin (a) of sensor corresponds to the temperature (Refer to relevant
parts in this Repair Maintenance). NO Replace sensor.
Connect an adapter between ECU and harness and use a multimeter to Repair or replace
YES
check for presence of open-circuit or short-circuit between pins J1-05 harness
4
and J1-43 of ECU and pins (c) and (a) of sensor connector
respectively. NO Replace ECU.
287
7. Nozzle (Refer to Table1-10)
Table 1-10

P0201 1st cylinder injector nozzle fault
P0202 2nd cylinder injector nozzle fault
P0203 3rd cylinder injector nozzle fault
P0204 4th cylinder injector nozzle fault
Checking Subsequent
result procedure
1 Turn off the ignition switch to stop the engine. Next
Unplug all electromagnetic fuel injector connectors from wire
2 harness in turn and use two pins of multimeter to connect between Next
pin (1) (+) of the connector and the engine ground.
YES Repeat 2
Rotate the ignition switch to ―ON‖ Observe whether the multimeter
3 indicates the battery voltage reading of approximate 12V for All yes
approximate 1s at the moment that the ignition switch is turned on. To item 6
NO Next
Use a multimeter to measure for presence of open-circuit or Repair or replace wire

YES
4 short-circuit between pin J1-02 of main relay output terminal and pin harness
(1) of various electromagnetic fuel injector connectors respectively. NO Next
Repair or replace wire
5 Repair or replace fuel pump relay and main relay and their circuits. YES
harness
Connect an adapter between ECU wire harnesses and use a
multimeter to measure for open-circuit or short-circuit between pins
6 J1-55, J1-70, J1-56, and J1-71 of ECU and pin (2) of various NO Next
electromagnetic fuel injector connectors on wire harness
respectively.
YES Repeat 7
Use a multimeter to measure for presence of 12~16Ω resistance All yes Next
7 between pin (1) and (2) of electromagnetic fuel injectors respectively
Replace
at 20℃.
NO electromagnetic fuel
injector.
Re-plug connectors of all electromagnetic fuel injectors, shift to YES Repeat 8
neutral gear, start the engine, and idle the engine. In turn unplug the
8 connectors of all electromagnetic fuel injectors from the harness.
Whenever one connector is unplugged, observe whether the engine NO Replace ECU.
vibration becomes worse thereof.
288
8. Canister control valve driver (Refer to Table 1-11)
Table 1-11

P0443 Fault of canister control valve
Checking Subsequent
result procedure
Start the engine and idle, till the engine coolant temperature reaches
1 Next
normal value.
Unplug the canister control valve connector from wire harness and use a YES Next
2 multimeter to measure for presence of approximate 12V battery voltage 5 (Check the live
between two pins of the connector. NO
wire)
Re-plug the canister control valve connector into wire harness, increase YES Next
3 the engine speed to 1,500r/min, and touch the canister control valve 7 (Check the
body for presence of slight vibration and impact. NO
grounding wire)
YES Replace ECU.
Use a multimeter to measure whether the resistance between pin (1) and
4 Replace canister
pin (2) of the canister control valve is within 22~30. NO
control valve.
Use a multimeter to measure for presence of open-circuit or Repair or replace

YES
5 short-circuit between pin J1-02 of main relay and pin (1) of canister wire harness
control valve. NO Next
6 Repair or replace main relay and its circuits.
Stop the engine, connect an adapter between ECU and wire harness, and Repair or replace
YES
use a multimeter to measure for presence of open-circuit or short-circuit wireharness
7
between pin J1-63 of ECU and pin (2) of canister control valve
connector. NO Replace ECU
289
9. Fault indicator (Refer to Table 1-12)
Table 1-12

P0650 OBD fault lamp
Checking Subsequent
result procedure
Disassemble the instrument panel, unplug the fault indicator bulb, and YES Next
2 use a multimeter to measure for presence of approximate 12V battery 5 (Check the live
voltage on the fault indicator holder. NO
wire)
Use a multimeter to check the intactness of the instrument panel fault YES Next
3
indicator bulb. NO Replace Bulb
Connect an adapter between ECU and harness and use a multimeter to Repair or replace
YES
4 measure for open-circuit or circuit-circuit between pin J1-63 of ECU harness
and input connector of fault indicator. NO Replace ECU
YES Replace Fuse
5 Check whether the fuse within heating circuit of oxygen sensor is burnt.
Repair or replace
Use a multimeter to measure for presence of open-circuit or short-circuit YES
6 wireharness
between pin 87 of main relay and the pin (1) of fault indicator holder.
NO Next
7 Repair or replace main relay and its circuits.
290
10. Coil 1 and coil 2 driver of stepper motor (Refer to Table 1-13)
Table 1-13
Checking Subsequent
result procedure
Unplug the connector of idling actuator stepper motor from wire YES Next
harness and use a multimeter to measure whether the resistance
2 Replace idling
between tpin 1 and pin 2 and between pin 3 and pin 4 of idling NO
actuator stepper motor is within 40~80Ω. actuator.
Use a multimeter to measure whether the resistance between pin 1 and YES Next
3 pin 2 and between pin 3 and pin 4 of idling actuator stepper motor is
infinite. Replace idling
NO
actuator
Use a multimeter to measure the presence of approximate 12V batter Replace idling
YES
4 voltage between the pin 1 and pin 2 and between pin 3 and pin 4 of actuator
idling actuator stepper motor.
NO Next
YES
multimeter to measure for presence of open-circuit or short-circuit wireharness
5
between pins J1-34, J1-33, J1-53, and J1-54 of ECU and the pins 1, 2,
3, 4 of idling actuator stepper motor connector respectively. NO Replace ECU
291
Section Ⅳ Procedure of Fault Diagnosis by Engine Symptoms
Before the start of fault diagnosis procedure by engine symptoms, firstly conduct the initial
checking:
1. Ensure that there is no abnormality in ECU and fault indicator (This time can be omitted for
the models without fault indicator).
2. Use a fault diagnostic scanner or flashing lamp to ensure that there is no record of fault
information.
3. Use a fault diagnostic scanner to check the hot idling data of electronic control system and
ensure that the data are within normal range.
4. Ensure that the fault symptom complained by the owner exists and find out the accurate
location of symptom.
Next, check the appearance:
1. Check the wire harness grounding location for cleanliness and firmness.
2. Check the vacuum pipeline for presence of rupture and kinking and check for correct
connections
3. Check for presence of pipeline blockage and check whether the intake pipeline is flattened or
damaged.
4. Check whether the sealing surface between throttle body and intake manifold is intact.
5. Check the high voltage wires of ignition system for presence of rupture and aging and for
correct arrangements.
6. Check the wires for correct connections and check the connectors for presence of looseness or
poor contact.
Important Tip:
Upon detection of any of above symptoms, repair in response to the fault symptoms, or it will
impair the subsequent fault diagnosis and repair.
Diagnosis Tips:
1. Confirm that the engine has no fault record.
2. Ensure that the complained fault symptoms exist.
3. No abnormal symptom is detected after checking as per above procedure.
4. During the checking and repair, do not neglect the system influences such as vehicle
maintenance status, cylinder pressure, mechanical ignition timing, and fuel status.
5. Replace ECU and conduct test.
In such case, if the fault symptoms can be solved, the fault location is ECU. If the fault symptoms
292
still exist, replace with old ECU and repeat the procedure for checking and repair.
293
Ⅰ. LF479Q2 engine
1. In event of no rotation or slow rotation of engine at the time of start, conduct the fault
diagnosis and troubleshooting as per Table 1-51.
Table 1-51
Checking Subsequent
result procedure
Use a multimeter to measure for presence of approximate YES Next
1 10~2.5V voltage between two wiring poles of battery.
Repair or replace the
NO
battery
Next, shift the ignition switch to position ―ON‖. Use a YES Next
2 multimeter to measure for presence of an approximate
10~12.5V battery voltage at the positive wiring pole of battery. Repair the wiring pole or
NO
replace wires
Next, maintain the ignition switch at position START and use a YES Next
multimeter to measure for presence of above 8V voltage at the
3 Repair or replace ignitions
wiring pole of the ignition switch that is connected to the NO
positive pole of starter motor. witch
YES Next
Maintain the ignition switch at position START and use a
4 multimeter to measure for presence of above 8V voltage at the
positive wiring post of the starter motor. NO Repair wiring pole or
replace wires
Repair or replace starter
Use a multimeter to measure the starter motor for presence of YES
5 motor
open-circuit or short-circuit.
NO Next
Check the engine for presence of blockage due to poor YES Troubleshooting
6
lubrication. NO Next
Replace with appropriate
If the fault only occurs in winter, check for presence of YES
oil
7 over-high resistance of starter motor due to improper selection
of engine oil and gearbox oil. Repair or replace timing
NO
belt
294
2. If the engine can rotate but can’t start successfully at the time of start, conduct the fault
diagnosis and troubleshooting as per Table 1-52.
Table 1-52
Checking Subsequent
result procedure
Rotate the ignition switch to ―ON‖ Use a fault diagnostic scanner YES Solve the faults indicated.
1
to check for presence of fault information record. NO Next
Unplug the spark plug, place the electrode of spark plug 5~10mm YES 8
2 reach from the engine block, use the starter motor to drive the
engine, and check for presence of blue-white high voltage spark. NO Next
YES Next
Check whether the resistance of the high voltage wires is normal
3 (approximate 16k/m. This value can’t be too low, or it indicates
that this circuit is faulty) NO Repair or replace high
voltage wires
Check various ignition coils for presence of damage and YES Replace
4
cracking. NO Next
YES Replace
5 Check ignition coils for presence of looseness or damage.
NO Next
YES Next
6 Check whether the ignition coils are normal.
NO Replace
Check whether the connectors of the high voltage coils are YES Next
7
properly connected. NO Connect the connectors.
YES Next
Place the ignition switch to position ―ON‖ and check whether the
8 Check and repair fuel
fuel pump relay and fuel pump can work for 3s. NO
pump circuit.
Connect the fuel pressure gauge value. Short circuits pin J1-46 YES Next
9 with pin J1-73 of fuel pump relay to run fuel pump and check
whether the fuel pressure is at approximate 300kPa. NO 13
Unplug the fuel distribution pipes and fuel injectors, unplug the YES 12
connectors of fuel injectors from the harness in turn, charge
10
directly 12V voltage to fuel injectors from the battery, and check NO Next
the fuel injectors for presence of fuel injection.
After the cleaning of fuel injectors, re-check the fuel injectors for YES Next
11
presence of fuel injection. NO Replace fuel injector
YES Replace fuel
12 Check the fuel for presence of deterioration or water content.
NO 18
YES Next
13 Check whether the fuel pressure is less than 300kPa.
NO 17
Close the fuel gauge valve. Turn on the ignition switch again to YES Next
14 run the fuel pump for 3s and check for establishment of fuel
pressure. NO 16
Repair or replace fuel inlet

15 Check the fuel inlet pipe for presence of leakage or blockage. YES
pipe.
295
NO Replace fuel pump
Repair or replace fuel
YES
return pipe.
16 Check the fuel return pipe for presence of blockage or bending.
Replace fuel pressure
NO
regulator
Connect an adapter between ECU and wire harness, check the pin YES Next
J1-73 of ECU for presence of voltage, and check the positive
17 Repair or replace wire
power wire to the above-mentioned ECU pin and the grounding NO
wires to the pins J1-01, J1-17, and J1-18 of ECU for normality. harness
YES Repair
18 Check the parts of intake system for presence of air leakage.
NO Next
Check the intake manifold absolute pressure and temperature YES Repair or replace
19
sensor for presence of blockage. NO Next
YES Next
20 Check the coolant temperature sensor for normality.
NO Repair or replace
Check for start failure due to excessive gap between piston and YES Eliminate mechanical fault
21 cylinder and air leakage of cylinder arising from mechanical
issues. NO Replace ECU
3. Difficult start of hot engine

Table 1-53
Checking Subsequent
result procedure
1
Connect the fuel pressure gauge valve (of which the connecting YES Next
points depend on the actual vehicle model). Short circuits pin
2
J1-46 with pin J1-73 of the fuel pump relay to run the fuel pump NO 9
and check whether the fuel pressure is at approximate 300kPa.
Disconnect the connecting fuel pipes, turn off the ignition switch, YES Next
3 and, after one hour, observe whether the pressure of the fuel Repair the leakage of fuel
system is maintained within 150~200kPa. NO
system
Connect the connecting fuel pipes, block the fuel return pipe with
fuel return blocker, and at the same time close the fuel pressure YES Replace the fuel pressure
4 gauge valve. Turn off the ignition switch, and, after one hour, regulator (built-in)
observe whether the pressure of the fuel system is maintained
within 150~200kPa. NO Next
Replace the fuel injectors
YES
5 Check the fuel injectors and fuel pipes for presence of fuel and fuel pipes
leakage. NO Next
Check the coolant
Unplug the coolant temperature sensor connector and start the YES
6 temperature and circuit
engine. Observe whether the engine can start successfully.
NO Next
Connect an adapter between ECU and harness, check pin J1-73 of Repair or replace wire
7 YES
ECU for presence of voltage, and check the positive power wire harness
296
to the above-mentioned ECU pin and the grounding wires to pins
J1-01, J1-17, and J1-18 of ECU for normality. NO Next
Replace the fuel, conduct the hot start again, and observe whether YES End
8
the engine can start successfully. NO Replace ECU
Check the fuel pipes for presence of blockage or bending and YES Next
9
check the fuel pump pressure regulator for normal working. NO Repair or replace
YES Next
Use a multimeter to measure for presence of battery voltage
10 Repair or replace the fuel
between two ends of fuel pump connector. NO
pump relay and wires
Use a multimeter to measure whether the resistance of fuel pump YES Next
11
is correct. NO Replace fuel pump
YES Replace fuel pump
12 Check the fuel pump for presence of blockage.
Replace ECU
297
4. The rotation speed is normal, but the engine start is always difficult.
Table 1-54
Checking Subsequent
result procedure
1
YES Next
2 Check the air cleaner for presence of blockage.
NO Replace
YES Next
After the successful start, check whether the intake manifold
3 Solve the air leakage fault
pressure during idling is within 35~65kPa. NO
of intake system.
Depress the throttle lightly and observe for easier start of the Replace and check the
4 YES
engine. throttle and idling passage
Connect the fuel pressure gauge value. Short circuits pin 30 with NO Next
5 pin 87 of the fuel pump relay to run the fuel pump and check
whether the fuel pressure is at approximate 300kPa. YES 9
Use a special connector to supply 12V voltage directly from the NO 8

6 battery to the fuel injectors and check the fuel injectors for
normal working. YES Next
After cleaning the fuel injectors, check the fuel injectors for NO Next
7
normal working again. YES Replace fuel injector
Replace the fuel and check the fuel for presence of deterioration NO Replace fuel
8
or water content. YES 14
NO Next
YES 13
Close the fuel gauge valve. Turn on the ignition switch again to NO Next
pressure. YES 12
Replace the fuel pressure

Open the fuel gauge valve, clamp the fuel return pipe with fuel YES
regulator
11 return blocker to block the fuel return, and check for rapid
establishment of fuel pressure. Repair or replace fuel
NO
injectors or fuel pipes.
YES
12 Check the fuel inlet pipe for presence of leakage or blockage. pipe
YES
return pipe
NO
regulator
Before the engine coolant temperature drops to 35°C, unplug the YES Next
14 idling actuator connector from the harness and observe whether Repair or replace the
the engine speed drops. NO
idling actuator.
Rotate the ignition switch to ―ON‖ Check the following pins of YES Next
15 ECU for presence of normal voltage: Approximate 12V battery
voltage at pin J1-12 (crankshaft position sensor) and 0V at vacant NO Check wire harness and
298
pin and pin J1-54 (idling stepper motor A+). connector
Idle the engine. After the coolant temperature reaches normal YES Next
16 value, short circuit the pin 51 of ECU to ground and check Adjust the ignition
whether the ignition advance angle is the 6.75°crankshaft angle. NO
advance angle.
Check whether the cylinder compression pressure of the engine is YES Next
17
normal. NO Troubleshooting
18
sensor for presence of blockage. NO Next
YES Replace ECU
NO Repair or replace
299
5. Difficult start of cold engine
Table 1-55
Checking Subsequent
result procedure
Rotate the ignition switch to ―ON‖ Use a fault diagnostic scanner YES Solve faults indicated
1
Use a multimeter to check the coolant temperature sensor for YES Next
2
normality. (The resistance shall be within XX~XX) NO Replace sensor
Next, turn on the ignition switch, connect an adapter between YES Next
ECU and harness, and check the following pins of ECU for
3 normal voltage: Approximate 12V battery voltage at pin J1-12 Check wire harness and
(crankshaft position sensor) and 0 at vacant pin and pin J1-54 NO
connector
(Idling stepper motor A+).
YES Next
4 Next, check the air cleaner for blockage.
NO Replace
YES Next
After the successful start, check whether the intake manifold
pressure during idling is within 35~65kPa. NO
of intake system
Check the throttle and
Depress the throttle lightly and observe for easier start of the YES
6 idling passage
engine.
NO Next
Before the engine coolant temperature drops to 35°C, unplug the YES Next
7 idling actuator connector from the harness and observe whether Repair or replace the
the engine speed drops. NO
idling actuator
Connect the fuel pressure gauge valve (of which the connecting YES Next
points depend on the actual vehicle model). Directly ground pin
8 86 of fuel pump relay. Turn on the ignition switch to run fuel
pump relay and fuel pump and check whether the fuel pressure is NO 12
within 250~300kPa.
Use a special connector to supply 12V voltage directly from the YES 11
normal working. NO Next
After cleaning the fuel injectors, check the fuel injectors for YES Next
10
normal working again. NO Replace fuel injector
YES Replace fuel
NO 17
YES Next
NO 16
pressure. NO 15

regulator
establishment of fuel pressure. Repair or replace the fuel
NO
injectors or fuel pipes
300
YES
15 Check if inlet pipe leaks or is blocked. inlet pipe
YES
return pipe.
NO
regulator
YES Next
17 Check whether the cylinder pressure of engine is normal.
NO Troubleshooting
YES Repair
18 Check if engine intake air system leaks
NO
Next
19
sensor for presence of blockage. NO Replace ECU
301
6. Unstable idling at all times
Table 1-56
Checking Subsequent
result procedure
Rotate the ignition switch to ―ON‖ Use a fault diagnostic scanner YES Solve the faults indicated
1
Repair or replace the
Check the idling actuator and stepper motor idling actuator for YES
2 idling actuator
presence of blockage.
NO Next
Turn on the ignition switch, connect an adapter between ECU and Check wire harness and
YES
harness, and check the pins J1-27 and J1-43 of ECU (Output connector
signal terminals of intake temperature sensor and coolant
3
temperature sensor), the pins J1-54, J1-33, J1-53, and J1-34 of
ECU (for output signal terminals of stepper motor), and pins NO Next
J1-54 and J1-53 of ECU for normal voltages.
Idle the engine, cut off the cylinders in turn and observe the YES 8
4
engine speed for presence of drop and fluctuation. NO Next
YES Next
Check the fuel injectors of all cylinders for normal working
5 Check the fuel injectors
status. NO
and wire harness
Check the high voltage wires of all cylinders for normal YES Next
6
resistance. NO Replace
YES Replace
7 Check the ignition coil for presence of damage or cracking.
NO Next
YES Next
8 Check the spark plug for normal working.
Connect the fuel pressure gauge value. Short circuit pin J1-46 YES Next
9 with pin J1-73 of the fuel pump relay to run the fuel pump and
check whether the fuel pressure is at approximate 380kPa. NO 13
normal working. NO
Next
11
YES Replace fuel
NO 18
YES Next
NO 17
pressure. NO 16
Open the fuel gauge valve, clamp the fuel return pipe with fuel Replace fuel pressure
15 YES
return blocker to block the fuel return, and check for rapid regulator
302
NO
YES
16 Check the fuel inlet pipe for presence of leakage or blockage. return pipe.
YES
return pipe.
NO
regulator
Check the sensing port of intake manifold pressure and intake YES Clean
18
temperature sensor for presence of blockage. NO Next
Idle the engine. After the coolant temperature reaches the YES Next
19 temperature for activation of closed-loop control, observe the Check the oxygen sensors
oxygen sensors for normal working. NO
and harnesses.
YES Solve the leakage.
20 Check if engine intake air system leaks.
NO Next
YES Next
21 Check whether the cylinder pressure of engine is normal.
NO Troubleshooting
303
7. Unstable idling during warm-up
Table 1-57
Checking Subsequent
result procedure
1
YES Next
NO Replace
YES Next
Idle the engine and, during the warm-up, check whether the
intake manifold pressure is within 35~65kPa. NO
of intake system
Stop the engine, turn on the ignition switch, connect an adapter YES Next
between ECU and harness, and check pins J1-27 and J1-35 of
4
ECU (Output signal terminals of intake temperature sensor and NO Do check and repair
coolant temperature sensor).
At completion of warm-up, unplug the connector of idling YES Next

5
actuator and observe for change of engine speed. NO Replace idling actuator
YES Next
NO Replace
304
8. Unstable idling after warm-up
Table 1-58
Checking Subsequent
result procedure
1 to check whether there is fault information record for the fault
solved. NO Next
Rotate the ignition switch to ―ON‖ Connect an adapter between YES Next
ECU and wire harness and check pin J1-42 (output of intake
manifold absolute pressure sensor), pin J1-27 (output of intake
2 temperature sensor), pin J1-43 (output of coolant temperature Repair or replace wire
sensor), pins J1-62, J1-06, and J1-38 (output of oxygen sensors), NO
harness
and pins J1-54, J1-33, J1-53, and J1-34 (output to idling actuator)
of ECU for normal voltages.
YES Next
3 Stop the engine and check the air cleaner for blockage.
NO Replace
YES Next
Check whether the intake manifold pressuring during idling is
within 35~65kPa. NO
of intake system.
Connect the fuel pressure gauge value. Short circuit pin 30 with YES Next
5 pin 87 of fuel pump relay to run the fuel pump and check whether
the fuel pressure is at approximate 380kPa. NO 9
After cleaning the fuel injectors, check the fuel injectors for YES Replace
7
YES Replace fuel
NO 14
YES Next
NO 13
pressure. NO 12

regulator
establishment of fuel pressure. Repair or replace the fuel
NO
injectors or fuel pipes
YES
12 Check the fuel inlet pipe for presence of leakage or blockage. inlet pipe
YES
return pipe
NO
regulator
15 Unplug the coolant temperature sensor and observe the engine for YES Replace the coolant
305
normal working. temperature sensor
NO Next
Check whether the cylinder compression pressure of the engine is YES Next
16
normal. NO Troubleshooting
Check the high voltage wires of all cylinders for normal YES Next
17
resistance. NO Replace
YES Replace
18 Check the ignition coils for presence of damage or cracking.
NO Next
YES Replace ECU
19 Check the spark plug for normal working.
306
9. Unstable idling or flameout under loaded condition (such as air conditioner)
Table 1-59
Checking Subsequent
result procedure
1
to check for presence of fault information record. NO Next step
Turn on the A/C switch, connect an adapter between ECU and YES Next step
2 harness, and measure the pins J1-09 and J1-39 of ECU (A/C Check and repair the A/C
switch) for presence of signal input. NO
circuit
Check whether the pressure of A/C system, the electromagnetic YES Next step
3
clutch of compressor, and A/C pump are normal. NO Repair or replace
Rotate the ignition switch to ―ON‖ Check pins 19, 20, 35, and 36 YES Next step
4
of ECU (output to idling actuator) for normal voltage. NO Check the control circuit
Repair and replace
Disassemble the stepper motor and check the stepper motor for YES
5 stepper motor.
blockage or unstable running.
NO Next step
Start the engine, turn on the A/C, and use a fault diagnostic YES Replace ECU
scanner to check the idling actuator for normal working by means
6
of the step number of the stepper motor. (The normal step number NO Replace idling actuator.
is provided separately)
307
10. Unstable periodicity (The self-learning must be conducted again after cutoff of ECU)
Table 1-60
Checking Subsequent
result procedure
Shift the ignition switch to position ―ON‖ and use a fault Y Solve the faults indicated
1 diagnostic scanner to check for presence of fault information
record. N Next
Y Next
N Replace
Y Next
Idle the engine and check whether the intake pressure is within
3 Check and repair intake
35~65kPa. N
and air leakage.
Idle the engine, cut off cylinders in turn and observe the engine Y 7
4
speed for presence of drop and fluctuation. N Next
Rotate the ignition switch to ―ON‖ Connect an adapter between Y Next
ECU and harness and check the pin J1-42 (output of intake
manifold absolute pressure sensor), pin J1-27 (output of intake
temperature sensor), pin J1-43 (output of coolant temperature
5 Repair or replace wire
sensor), pins J1-62, J1-06, and J1-38 (output of oxygen sensors), N
pin J1-01 of ECU (ignition switch), and pins J1-54, J1-33, J1-53, harness
and J1-34 (output to idling actuator) of ECU for normal
voltages.
Y Next
Idle the engine. After the coolant temperature reaches normal
6 Adjust the ignition
value, check for normal ignition advance angle. N
advance angle
Check the sensing port of intake manifold pressure and intake Y Clean
7
temperature sensor for presence of blockage. N Next
Y Replace fuel
N Next
Y 下Next
Use a special connector to supply 12V voltage directly from the
9 battery to the fuel injectors and check fuel injectors for normal Check and repair fuel
working. N injectors and
corresponding harness.
Y Next
10 Check high voltage wires of all cylinders for normal resistance.
N Replace
Y Replace
11 Check the ignition coils for presence of damage or cracking.
N Next
Y Replace ECU
12 12 Check the spark plug for normal working.
N Replace spark plug
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11. Over-high idling
Table 1-61
Checking Subsequent
result procedure
Rotate the ignition switch to ―ON‖ Use a fault diagnostic YES Solve the faults indicated.
1
scanner to check for presence of fault information record. NO Next
Adjustment or
Check the connecting cable of throttle pedal for blockage or YES
2 replacement
over-tightness.
NO Next
Check the canister control valve, fuel pressure regulator, Adjustment or

YES
3 crankcase forced ventilation vacuum pipe, and vacuum booster replacement
hose of brake system for reliable installation or damage. NO Next
Idle the engine, shift to neutral gear, depress the brake pedal, and YES Next
4
observe for over-high idling speed. NO 6
Repair or replace vacuum
YES
5 Clamp the vacuum booster hose and observe for normal idling. booster.
NO Next
Replace PVC valve, clamp the crankcase forced ventilation YES Replace the PVC valve.
6
vacuum pipe, and observe whether the idling becomes normal. NO Next
Replace canister control
Clamp the canister control valve hose and observe whether the YES
7 valve.
idling becomes normal.
NO Next
YES Repair or replace
8 Check the idling actuator for inflexibility and blockage.
NO Next
Repair or replace and check other portions of intake pipe for YES Repair or replace
9 presence of leakage. NO Next
YES Next
10 Check the seal rings of fuel injectors for intactness.
NO Replace seal rings.
Check the intake manifold absolute pressure and temperature YES Replace ECU
11
sensor for intactness. NO Replace sensor.
309
12. Speed rise failure or flameout at time of acceleration
Table 1-62
Checking
S/N Operation procedure Subsequent procedure
result
Rotate the ignition switch to ―ON‖ Use a fault diagnostic YES Solve the faults indicated.
1
scanner to check for presence of fault information record. NO Next
YES Next
NO Replace
YES Next
3 Idle the engine and check for normal idling speed. Next, check and repair with
NO reference to the idling fault
diagnosis procedure.
Idle the engine and check whether the intake pressure is YES Next
4
within 35~65kPa. NO Do check and repair.
YES Next
使Idle the engine. After the coolant temperature reaches
5 Adjust the ignition advance
normal value, check for normal ignition advance angle. NO
angle.
Connect the fuel pressure gauge value. Short circuit the pin YES Next
J1-46 with pin J1-73 of the fuel pump relay to run the fuel
6
pump and check whether the fuel pressure is at approximate NO 10
300kPa.
Use a special connector to supply 12V voltage directly from YES 9
7 the battery to the fuel injectors and check the fuel injectors for
8
YES
9 Check the fuel for presence of deterioration or water content. Replace fuel
NO 15
YES Next
NO 14
Close the fuel gauge valve. Turn on the ignition switch again YES Next
11 to run the fuel pump for 3s and check for establishment of
fuel pressure. NO 13

Open the fuel gauge valve, clamp the fuel return pipe with YES
regulator
12 fuel return blocker to block the fuel return, and check for
rapid establishment of fuel pressure. Repair or replace fuel injectors
NO
or fuel pipes.
YES
13 Check the fuel inlet pipe for presence of leakage or blockage. pipe.
Repair or replace fuel return
Check the fuel return pipe for presence of blockage or YES
14 pipe.
bending.
NO Replace fuel pressure
310
regulator
Rotate the ignition switch to ―ON‖ Connect an adapter YES Next
between ECU and harness, and check pin J1-24 of ECU
15 (Output signal terminals of throttle position sensor), pin J1-05
of ECU (grounding terminal), and pin J1-20 of ECU (for NO Repair or replace the harness
4.5~5V sensor power supply) for normal voltages.
Check the ignition coil, distributor, high voltage wires, and YES Replace ECU.
16
spark plug for normal working. NO Repair or replace related parts
311
13. Slow response at time of acceleration
Table 1-63
Checking Subsequent
result procedure
Solve the faults
Rotate the ignition switch to ―ON‖ Use a fault diagnostic scanner YES
1 indicated
to check for presence of fault information record.
NO Next
YES Next
2 Stop the engine and check the air cleaner for blockage.
NO Replace
YES Next
3 Idle the engine and check for normal idling speed. Check and repair with
NO reference to idling fault
diagnosis procedure.
Idle the engine and check whether the intake pressure is within YES Next
4
35~65kPa. NO Do check and repair.
Turn on the ignition switch, connect an adapter between ECU and YES Next
wire harness, and check pin J1-24 of ECU (Output signal
5 terminals of throttle position sensor), pin J1-05 of ECU Repair or replace wire
(grounding terminal), and pin J1-20 of ECU (for 4.5~5V sensor NO
harness
power supply) for normal voltages.
YES Next
6 Adjust ignition advance
value, check for normal ignition advance angle. NO
angle.
check whether the fuel pressure is at approximate 250 to 300kPa. NO 11
9
YES Replace fuel
NO 16
YES Next
NO 15
pressure. NO 14
Replace pressure
regulator.
NO
YES
14 Check the fuel inlet pipe for presence of leakage or blockage. inlet pipe
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YES
return pipe
Replace pressure
NO
regulator.
YES Replace or clean
16 Check the exhaust system for presence of blockage.
NO Replace ECU.
313
14. Poor performance or weakness at time of acceleration
Table 1-64
Checking Subsequent
result procedure
Check for presence of faults such as clutch skid, low tire pressure, YES Repair
1 braking stagnation, incorrect tire size, and incorrect alignment of
wheels. NO Next
YES Next
2 Check whether the throttle can fully open.
NO Replace or repair throttle.
3
YES Next
4 Adjust ignition advance
value, check for normal ignition advance angle. NO
angle.
Rotate the ignition switch to ―ON‖ Connect an adapter between YES Next
ECU and harness and check pin J1-42 (output of intake manifold
absolute pressure sensor), pin J1-27 (output of intake temperature
5 sensor), pin J1-43 (output of coolant temperature sensor), pins Repair or replace wire
J1-62, J1-06, and J1-38 (output of oxygen sensors), pin J1-01 of NO
harness
ECU (ignition switch), and pins J1-54, J1-33, J1-53, and J1-34
(output to idling actuator) of ECU for normal voltages.
Idle the engine and check whether the intake pressure is within YES Next
6
35~65kpa. NO Do check and repair.
check whether the fuel pressure is at approximate 300kPa. NO 11
9
YES Replace fuel
NO 16
YES Next
NO 15
pressure. NO 14
Replace pressure
regulator.
NO
YES
14 Check the fuel inlet pipe for presence of leakage or blockage. pipe.
314
YES
return pipe.
Replace pressure
NO
regulator.
Check whether the data of intake manifold absolute pressure and YES Next
16
intake temperature sensor are normal. NO Replace sensor.
Check the spark plugs, high voltage wires, distributor, and YES Next
17
ignition coils for normal working. NO Replace or adjust
YES Check the A/C system.
18 Check whether it’s caused by A/C system.
NO Replace ECU
315
15. Fault of A/C system.
Table 1-65
Checking Subsequent
result procedure
Check the system for sufficient refrigerant and check A/C belt, YES Next
1
A/C clutch and pressure switch for normal working. NO Troubleshooting
Idle the engine and turn on A/C switch. Use a fault diagnostic YES Solve the faults indicated.
2
scanner to check A/C thermistor for presence of fault. NO Next
Turn on the A/C switch, connect an adapter between ECU and YES Next
3 wire harness, and measure pins J1-09 and J1-39 of ECU (A/C
switch) for presence of signal input. NO Check Harness
Replace bulb or repair

If this vehicle adopts low level control, check whether A/C is still YES
4 harness.
working after A/C is turned off.
NO Next
Check the pin J1-47 of ECU (for connecting to the grounding Repair A/C relay and
YES
5 terminal of A/C relay actuating coil) for presence of low level harness
output. NO Replace ECU
316
16. Cylinder misfire
Table 1-66
Checking Subsequent
result procedure
YES Next
Start the engine, idle the engine, and listen for presence of air
1 Find out the air leakage
leakage sound at intake pipe. NO
location and repair.
Stop the engine and visually check the exhaust pipe, three-way YES Next
2
catalytic converter, and muffler for normal working. NO Repair or replace
Disassemble the wire connectors of all ignition coils one by one YES 5
3 and observe for presence of instant engine speed drop due to
disconnection of cylinders. NO Next
YES Next
Check whether each fuel injector has working sound during
4 Check the fuel injectors and
idling. NO
related circuits.
YES Next
Disassemble the ignition metal wire from the spark plug, install
5 this metal wire into a good spark plug, ground the end of spark Check the ignition coils,
plug, turn to the engine, and check for presence of normal spark. NO power transistors, and their
circuits.
YES Next
Move away the spark plug and check the inside for presence of
6 Repair or replace with spark
dirt. NO
plug of standard type.
YES Next
Check the compressor pressure: The standard pressure is
1275kPa/300rpm; Check the piston, piston
7 ring, intake valve, intake
Minimum is 981kPa/300rpm; NO
valve seat, and cylinder top
The difference between cylinders: 98kPa/300rpm
gasket.
Install all parts disassembled, relieve the fuel pressure to 0, YES Next
8 install the fuel pressure gauge, and check the normal fuel Check by fuel pressure
pressure. NO
checking method.
Check the ignition time: The ignition time is 15°±5°BTDC YES Next
9
The target idling speed is M/T: 800 ±50rpm. NO Conduct basic checking.
Start the engine and warm up to the normal working
temperature. Use a voltmeter to measure the voltage between
YES Next
pin J1-62 (high signal of upstream oxygen sensor) or pin J1-06
(low signal of upstream oxygen sensor) of ECU and the ground.
10 Measure the voltage under 2,000rpm engine speed. The
variations at 0V~0.3V and 0.6V~1.0V shall be no less than 5
times within 10s, with the maximum voltage in excess of 0.6V Replace with new upstream
NO
for at least one time and the minimum voltage less than 0.3V for oxygen sensor.
at least one time. The voltage measured shall not exceed 1V.
YES Replace ECU
Use a fault diagnostic scanner to check the intake sensor signal: Check the connectors of
11 intake temperature sensor
2.0~6.0gm/sec (during idling); 7.0~20.0gm/sec (at 2,500rpm). NO
circuit for presence of
rusting or looseness.
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Section Ⅴ Safety Precautions for Repair of System
1. Safety precautions for diagnosis and repair of gasoline injection electronic control system
(1) Disassembly and installation requirements of control unit:
① Disassemble the control unit before the electric welding or powder coating;
② While disassembling or installing the control unit, make sure to place the ignition switch
to position OFF to prevent damage;
③ During the running of engine or working of electric system, do not disassemble the power
wires from the battery;
④ Do not start the engine by high current of charger;
⑤ Pay attention that the ambient temperature around the control unit can't exceed 80°C.
(2) Cleanliness requirements:
① Before operating the fuel supply system and fuel injection system, carefully abide by the
following requirements;
② Place all parts disassembled in a clean location and cover properly and do not use cloth
with loose fibers.
(3) It’s allowed to unplug or insert all kinds of harnesses and harness of fault diagnostic scanner
only after the ignition switch is turned off.
While measuring the voltage or grounding of electronic control system, ensure the correct
wiring.
Disconnecting the power wires from the battery or unplugging the control unit connector from
the harness will lead to loss of related diagnosis and self-learning information stored.
(4) Cautions in repair fuel supply system;
① While disassembling or installing the fuel pump on the full or partially full tank, pay
attention to;
318
② Before the start of operations, install a device capable of absorbing all leaked gasoline in
the vicinity of the fuel tank opening;
③ Avoid the direct contact between skin and gasoline;
④ Before loosening any connection, thoroughly clean the connection and its surrounding
area;
⑤ To prevent the spray of fuel from the loosened connection, place a rag in the vicinity of the
connection;
⑥ If the disconnected part is not to be repaired immediately, cover or seal carefully;
⑦ The parts shall be unpacked only immediate before the installation. Do not use any
unpacked parts;
⑧ While installing the fuel injectors, pay attention not to damage the O-rings. To ease the
assembly, apply a small amount of lubricating oil onto the O-rings.
After the system is opened, do not use the compressed air or move the vehicle whenever
possible.
2. Safety Measures
To prevent the personal injuries and the damage of fuel injection and ignition device, please pay
attention to:
If the engine is running or under start speed, do not contact or unplug the ignition harness. If the
engine is driven by the starter motor and is not started itself (such as the checking of compression
pressure), unplug the harness connector from the Hall sensor (distributor).
319
Chapter II Chassis System
Section I Suspension and Axle
I. Overview
1. Front axle and front suspension, Fig. 2-1.
Fig. 2-1
1. Hexagon flange nut (36 N·m) 2. Front shock absorber upper pressure plate
3. Left front shock absorber assembly 4. Hexagon flange bolt (240 N·m)
5. Hexagon flange nut 4 (240 N·m) 6. Front stabilizer bar connecting rod assembly
7. Hexagon bolt with flat washer (horizontal: 180 N·m; vertical: 210 N·m)
8. Cotter pin 9. Hexagon flange slotted nut (100 N·m)
10. Left front lower arm assembly 11. Sub-frame rubber plug
12. Sub-frame assembly 13. Hexagon bolt with flat washer (210 N·m)
14. Hexagon flange nut (75 N·m) 15. Front stabilizer rod rubber mount
16. Front stabilizer rod hoop 17. Hexagon bolt with taper washer (23 N·m)
18. Front stabilizer rod assembly 19. Hexagon flange nut
20. Right front lower arm assembly 21. Right front shock absorber assembly
22. Hexagon flange nut (75 N·m)
They can receive larger traction under the same conditions. As the main indicator for automobile
performance, the dynamic power should be strengthened by all means thus to determine the drive axle.
Generally, autos are driven by rear axles because 2/3 weight of the entire vehicle is burdened by the
rear axle which thus can receive better traction. When the sedan, special for passenger use, is fully
320
loaded, the front axle together with the engine, transmission, driver and co-driver will weight more than
the passengers on the rear axle. The fat person always sits at the co-driver seat and loads more on the
front axle. Therefore, more traction will be achieved by the front axle rather than the rear one.
When the vehicle is driven by the front axle, the increasing weight on the front axle will gain more
steering resistance, thus the steering response is stronger and operation becomes easier. The engine is
laterally placed, convenient for front axle drive and simplifying the main reducer, reducing the cost and
achieving an easy maintenance. Therefore, the front axle of LF630 sedan is the steering drive axle,
namely functioning as both a steering axle and a drive axle. It is composed of steering knuckle,
sub-frame assembly, left and right front lower arms assembly and their suspensions. It is used to:
(1) Bear all force and torque, such as weight, payload, traction, brake force, inertia force, centrifugal
force, lateral force and fatigue stress under alternating impact, etc.
(2) Reduce the impact from vibration, and advance the riding comfort and driving stability.
(3) Realize the steering.
(4) Transfer the engine torque to the left and right wheels after the torque is increased through
deceleration and then transform it to the forward traction.
The front suspension of LF630 sedan is a McPherson independent suspension. Refer to Fig. 2-1 for its
structure.
It consists of coil spring, integrated asymmetric bidirectional canister-type shock absorber, stabilizer bar
and triangle lower arm. The offset coil spring is connected with the canister shock absorber, thus to form
the spring bracket of the suspension. The top of the bracket is flexibly connected with the vehicle body.
The limit stop is installed in the shock absorber and the thrust ball bearing is fixed on the boss ring over
the shock absorber. The front suspension kingpin center, center lines of the shock absorber and coil
spring are not overlapped, and form a negative offset distance of kingpin distance, namely the kingpin
inclination angle is larger than that of the piston rod. Such a design enjoys the following features:
(1) Avoiding the lateral misalignment of the steering wheel during the distortion of the strut type
independent suspension, and reducing the wear and tear of the steering wheel.
(2) While a flexible distortion happens to the suspension, the location parameters of the steering wheels
will complement each other although that of the kingpin change, and then improve the stability of the
vehicle.
(3) Compact structure. The shock absorber, coil spring and steering kingpin are integrated, which
produces a small dimension and less space and is helpful for the location of the vehicle with a front-built
engine and front drive.
(4) There will be less change in the location of the front wheel during the usage period. Thus please do
not adjust the inclination and caster angle of the kingpin.
(5) The non-payload is lighter, which helps to decrease the impact load on the suspension and improve
the driving smoothness of the vehicle.
(6) The left and right wheels are independently hinged, which assists the wheels to contact the road
surface better, reduces the vehicle vibration due to uneven road surface and enhances the comfort and
driving stability.
2. Rear suspension. Refer to Fig. 2-2.
321
Fig. 2-2
1. Left rear shock absorber assembly 2. Hexagon flange nut (75N·m)
3. Hexagon flange bolt (75N·m) 4. Hexagon flange bolt (85N·m)
5. Right rear shock absorber assembly 6. Hexagon flange nut
7. Hexagon flange bolt (75N·m) 8. Hexagon flange bolt
9. Hexagon flange bolt 10. Big washer
11. Hexagon flange nut 12. Rear axle welding components (120N·m)
13. Rear stabilizer rod components 14. Left rear axle rubber bushing assembly
15. Right rear axle rubber bushing assembly
The rear axle of the suspension is a trailing axle, functioning as:
(1) Bearing all force and torque, such as weight, payload, traction, brake force, inertia force, centrifugal
force, lateral force and fatigue stress under alternating impact, etc.
(2) Reducing vibration and impact, and improving the vehicle comfort and driving stability.
The rear axle assembly of LF630 sedan is shown in Fig. 2-2.
The rear axle assembly is composed of rear axle welding component 12, left rear shock absorber 1,
right rear shock absorber 5, rear stabilizer bar component 13 and left rear axle bushing 14 and right rear
axle bushing 15.
The rear suspension is a trailing arm suspension with a torsion bar. The main axis of the body is directly
connected with the body and then with the suspension system; then the component is installed on the
body. And the spring and shock absorber are installed near the vehicle axis. The supporting arm moves
around the axis of the center line of the vehicle body, namely parallel to the vehicle axle which moves up
and down, parallel to the vehicle body and no camber angle. The most prominent advantage lies in the
large space between the left and right wheels together with no camber angle of the body, and a sunken
rear wheel of the swing arm suspension to balance the vehicle body.
3. Specifications of wheel alignment parameters
322
If the wheels enjoy good geometric alignment, the fuel economic efficiency and tire service life will be
improved.
(1) Kingpin caster angle: It refers to the angle between the highest point of the wheel steering center and
the vertical direction in the view at the side of the vehicle, as shown in Fig. 2-3. The caster angle is
positive (+), while the front rake angle is negative. The retroversion of the kingpin will influence the
control on the direction of the steering mechanism, but not on the wear and tear of the wheels. In case of
a larger positive kingpin caster angle of a wheel than that of other wheels, this wheel will drive towards
the center line of the vehicle and the vehicle will move forwards towards the side with a smaller positive
kingpin caster angle.
Fig. 2-3
(2) (2) Wheel camber angle: Extroversion is viewed from the front of the vehicle. It refers to the angle of
the wheel off the vertical direction as shown in Fig. 2-4. If the top point of the angle is towards outside,
the camber angle is positive (+); while towards inside, it is negative (-). Extroversion will not only
influence the control on the direction, but also the wear and tear of the wheels. An excessive
extroversion will result in a worn wheel and cause the vehicle to move towards the largest camber angle
or to one side.
Fig. 2-4
(3) Toe-in of wheel: It refers to that the weel moves inward off the geometric center line/thrust line. The
negative toe-in means that the wheel moves outward, as shown in Fig. 2-5.
323
Fig. 2-5
The toe-in is designed to ensure a parallel roll of the wheels. The toe-in can also complement the little
excursion of the wheel supporting system during driving forwards. Only with a proper toe-in can the
wheels run in parallel on the road surface.
(4) Thrust angle: The front wheels direct or steer the vehicle while the rear wheels control the same rut.
The rut is related with the thrust angle which is the angle between the rut of the rear wheels and the
center line of the vehicle body (as shown in Fig. 2-6).
Fig. 2-6
(5) Wheel alignment parameters standard, Table 2-1.
Table 2-1
Item Unit Parameter

0°30′±45′
Front wheel camber angle (°)
（idle load）
Front wheel toe-in mm -2～2
Wheel Alignment 11°15′±45′

Kingpin inclination angle (°)
（idle load）
3º±30′
Kingpin caster angle (°)
（idle load）
324
II. Fault Elimination Table, Table 2-2.
Table 2-2
Fault Possible Cause Action
Incorrect vehicle height (high or low Check if the load is abnormal, if the ring spring is
front or rear) sunken or is not standard spring.
Worn or broken steering gear or
Check the steering system.
Leaning to one connecting rod.
side Brake system. Check the brake.
Incorrect wheel alignment. Adjust the wheel alignment.
Worn front wheel bearing. Check the front wheel bearing. See this chapter.
Wheel and tire. Wheel transposition or replacement.
Incorrect vehicle height (high or low front Check if the load is abnormal, if the ring spring is
or rear). sunken or is not standard spring.
Unaligned
Steering gear or connecting rod. Check the steering system.
steering wheel
Suspension lower support arm ball joint. Carry out the test of ball joint in this chapter.
Incorrect rear caster angle. Check the rear caster angle.
Incorrect track
Damaged rear suspension. Check the rear suspension.
Front or rear balance connecting rod, Check or install new suspension components if
connector or bush. necessary.
Front suspension lower support arm Check or install new suspension components if
Uncomfortable bush. necessary.
riding Check or install new suspension components if
Rear suspension arm bush.
necessary.
Front bracket with spring. Check the front bracket with spring.
Rear shock absorber. Check the shock absorber.
Worn front wheel bearing. Check the wheel bearing.
Too large noise Suspension lower support arm ball joint. Carry out the test of ball joint in this chapter.
Damaged suspension. Check the suspension.
Improper worn Incorrect tire pressure. Adjust the tire pressure.

tire Incorrect wheel alignment. Adjust the wheel alignment.
Damaged or worn front wheel bearing Check the front wheel bearing.
Check the tire. Balance the tire or install a new one
Wheel and tire.
Vibration if necessary.
Abnormal steering system operation. Check the steering system.
三、Maintenance
325
(一) Wheel alignment adjustment
1. Front wheel camber adjustment
The front wheel toe-in is adjusted as shown in Fig. 2-7. Raise the vehicle, and dismantle the support
from the vehicle. Fix the support on the bench clamp and gouge holes on the side panel. The
extroversion can be adjusted by the bolt hole between the file support and steering knuckle.
Fig. 2-7
1. Camber angle 2. File upper bolt hole 3. File lower bolt hole
2. Front wheel toe-in adjustment, Fig.2-8
Fig.2-8
1. Locking hexagon nut 2. Steering tie rod shaft 3. Seal clamp
Details as below:
(1) Dismantle the small boot clamp on the steering stabilizer bar.
(2) Adjust the steering wheel to the front center position.
(3) As shown in Fig. 2-8, release the hexagon bolt, and revolve the steering stabilizer bar for a proper
toe-in angle.
(4) Confirm that each steering stabilizer bar revolves for the same turns.
(5) Tighten the locking nut.
(6) Install the boot clamp.
Replacement of parts and components assembly
1. Replacement of front brake wheel hub assembly
326
(1) Disassembly of front brake wheel hub assembly
1) Raise and properly support the vehicle and dismantle the wheel assembly.
2) As per Fig. 2-9, disconnect the wheel speed sensor connector, and remove the sensor from the
bracket.
Fig. 2-9
3) Remove the brake caliper bracket and brake caliper, and then secure the brake caliper on the vehicle
body to avoid bend or even damage of brake pipeline due to the weight of brake caliper, and then
dismantle the brake disk.
4) Remove the nuts of drive shaft.
5) As shown in Fig. 2-10, connect the removal tools of hub center shaft to the separating drive shaft on
the wheel bearing/wheel hub and the wheel bearing by 3 wheel nuts.
Fig. 2-10
6) According to Fig. 2-11, remove the wheel bearing.
Fig. 2-11
(2) Installation of front brake wheel hub assembly
To install, reverse the removal procedure. When installing front wheel speed sensor, please ensure that
the connector clip is well matched.
2. Replacement of front stabilizer bar
327
(1) Disassembly of front stabilizer bar. Disconnect the related connections. Lower the whole front
sub-frame according to Fig. 2-12.
Fig. 2-12
Remove the front stabilizer bar as shown in Fig. 2-13.
Fig. 2-13
(2) Installation: Install the front stabilizer, reverse the removal procedure.
3. Replacement of steering knuckle.
The steering knuckle is replaced together with the brake gear assembly according to related sections
about brake gear.
4. Replacement of lower arm assembly
(1) Disassembly of the lower arm assembly
1) Revolve the steering wheel to move the relevant front wheel to the minimum side position.
2) According to Fig. 2-14, dismantle the cotter pin and slotted nut from the ball head bolt, and knock the
steering knuckle to remove the ball pin of the lower arm from the steering knuckle.
328
Fig. 2-14
3) Dismantle the 2 bolts and nuts, and remove the front lower arm assembly according to Fig. 2-15.
Please do not rotate the locking nut because any rotation will cause damage to it.
.
Fig. 2-15
4) Check the lower arm assembly

① Before installing nuts, shake the ball pin bolt for over 5 times as described in Fig. 2-16.
② Use a torque wrench to rotate the nuts at a speed of a turn for each 2-4s, and record the tightening
torque reading at the fifth turn. Tightening torque: 1.5N.m～5N.m.
Fig. 2-16
329
Fig. 2-17
○
3 Install the front suspension lower arm onto the steering knuckle by nuts. Tightening torque: 100 N·m.
Follow Fig. 2-18.
Fig. 2-18
○
4 Install the cotter pin. Note: In case that the hole of cotter pin is not correctly aligned, please further
tighten the nut according to the hole of cotter pin.
○
5 Fully tighten the front suspension lower arm assembly. Secure the lower arm by 2 bolts as shown in
Fig. 2-17.
5. Replacement of shock absorber
(1) Disassembly of front shock absorber assembly.

1) Dismantle the front wheel.
2) Disconnect the brake hose. Remove the bolt, brake hose and ABS vehicle speed sensor harness
clip from the shock absorber bracket (of vehicle with ABS) according to Fig. 2-19.
330
Fig. 2-19
3) Dismantle the front shock absorber with coil spring.
① Remove the nuts connecting the connecting rod of front stabilizer bar and the front shock
absorber. Then dismantle the shock absorber from the steering knuckle after removing the 2 nuts
and bolts connecting the front shock absorber assembly and the steering knuckle, as shown in Fig.
2-20.
Mounting nuts
Fig. 2-20
② Dismantle the front shock absorber with coil spring, and then the 3 nuts on the suspension bracket
according to Fig. 2-21.
Fig. 2-21
(2) Installation of front shock absorber assembly.
To install, reverse the removal procedure.
(3) Disassembly of the rear shock absorber assembly
331
1) Dismantle the rear wheel.
2) Dismantle the left and right rear shock absorber assembly according to Fig. 2-22.
Fig. 2-22
① Raise the rear axle frame by a jack.
② Dismantle the thickened flange nut connecting the rear shock absorber from the rear
sub-frame assembly.
③ Dismantle a bolt and 2 nuts connecting the rear shock absorber assembly and the vehicle body.
④ Dismantle the rear shock absorber from the vehicle body.
(4) Installation of rear shock absorber assembly

(5) Inspection of shock absorber assembly.

Check if there is abnormal resistance or noise when pressing or pulling the push rod of shock
absorber. In case of any abnormal situation, please replace the shock absorber with a new one.
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SectionⅡ Hydraulic Power Steering System
The steering system is a special mechanism to change or maintain the driving direction of a vehicle.
It is used to change the direction at a proper time according to the requirement of the driver during
driving, and cooperate with the driving system to keep the vehicle moving stably in case that the vehicle
moves off the driving direction due to the accidental impact from the road surface. It is one of the
important systems to keep safe driving. Therefore, check and maintenance of the steering system in
time is an effective measure to ensure safe driving and fewer accidents.
The steering wheel of LF630 sedan is composed of steering wheel 1, steering column 2, power
steering pump 5, oil tank 4, steering gear 3, etc. Follow Fig. 2-23.
Fig. 2-23
1. Return line bracket 2. Hex bolt with flat washer
3. Return line clamp 4. Return line bracket B
5. Steering oil pump intake pipe 6. A-type worm-driven tube hoop
7. A-type worm-driven tube hoop 8. Power steering oil can assembly
9. Hex bolt with flat washer (75N·m) 10. Power steering oil can clip
11. Power steering oil can bracket 12. Power steering oil pump assembly
13. Steering return line assembly 14. Steering gear intake pipe assembly
15. Hexagon flange bolt (75N·m) 16. Oil pipeline bracket A component
17. Cotter pin 18. Hex slotted thin nut (75N·m)
19. Steering gear and tie-rod assembly 20. Hexagon flange bolt (75N·m)
21. Acoustic hood on the steering gear 22. Collar of acoustic hood on the steering gear
23. Steering column dustproof cap components 24. Steering column and adjustment mechanism assembly
25. Steering wheel assembly
一、Fault Diagnosis of Steering System

1. Note for inspection
(1) Take extra care while replacing the components. Incorrect operation may affect the performance of
the steering system and lead to driving accident.
(2) Notes for SRS system. This vehicle is equipped with SRS, like driver air bag and front passenger air
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bag. If failing to repair the air bag in correct order, the unexpected deployment of air bag during the
maintenance may lead to serious accident. Read the notes for supplement restraint system before
maintenance (including removal or installation, and check or replacement of components).
二、Fault Elimination Table

With the help of Fault Elimination Table (as shown in Table 2-3), it is more convenient to discover the
fault. The Table indicates the frequent faults. Eliminate all faults according to measures provided in this
Table. Check each component in sequence. Repair or renew these components if necessary.
Table 2-3
Fault Possible Cause Actions
Incorrect tire size or pressure. Check the tire size and adjust the tire pressure.
Over loaded or uneven loaded. Adjust the load.
Replace the steering gear or tie-rod end with a new one if

Loose or worn tie-rod or its end
necessary.
Loose or broken bolts of the

Lock the bolt or install a new one.
When the steering steering gear
wheel is fixed and in
Loose or worn suspension ball Replace the suspension ball joint assembly with a new
straight forward
joint. one.
direction, the vehicle
moves between two Loose bolts between the steering
Lock the bolts of pinion shaft.
sides. column shaft universal joint and
Lock the steering column shaft universal joint.
the pinion shaft.
Loose or broken steering column

Install a new steering column shaft universal joint.
shaft universal joint.
Improperly adjusted toe. Adjust it if necessary.
Loose or broken rear suspension. Lock or install new rear suspension components.
Incorrect tire pressure. Adjust the tire pressure.
Incorrect tire size or different

Install new tires if necessary.
tire/tread types.
Over loaded or uneven loaded. Adjust the load.
Improperly toe adjustment. Adjust it if necessary.

The vehicle leans to
one side when running Broken front suspension
Install new front suspension components if necessary.
on smooth road components.
surface.
Broken rear suspension
Install new rear suspension components if necessary.
components.
In case of a vehicle speed below 50 km/h (30mph), turn the

Unbalanced action of steering transmission to NEUTRAL, and turn the ignition switch to
gear valve. position I (engine OFF-sliding). In case that the vehicle
does not lean to one side when stopping, install a new
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steering gear.
In case that the vehicle does not move when stopping,
interchange the front wheel assembly
In case that the vehicle does not lean to the other side,
exchange the front and rear wheels at the same side.
In case the vehicle leans in the same direction, check the
front suspension components and adjust the toe.
Check if the front/rear brake is
Adjust it if necessary.
normal.
Check if the rear suspension
components are bent and if the
front/rear suspension ring spring
is broken or sunken.
Check if the rear suspension
components or bolts are loose or
Lock all bolts.
worn.
Steering gear input shaft
Install a new universal joint if necessary.
connector.
Feedback (whine or Loose/worn tie-rod. Install a new steering gear if necessary.
knock sound of the Loose or broken steering gear
Lock or install new fixing bolts if necessary.
steering gear)-the bolts.
steering wheel feels Loose bolts and the steering
Lock bolts.
rough when driving on column shaft and universal joint.
the rough road. Loose suspension boot, bolts or
Lock or install new bolts or ball joints if necessary.
ball joints.
Bad steering column shaft. Install new steering column if necessary.
After steering, the Incorrect tire pressure. Adjust the tire pressure.
steering wheel will not Incorrect tire size or type. Install new tires if necessary.
go back to the central
Unaligned steering column or the
position without the
protecting hood rubs the steering Align the steering column.
assistance of the
wheel.
driver. Besides, it may
feel obstructed or Blocked steering column universal
Install a new universal joint.
unsmooth when the joint.
driver turns the
The sealed pad of the soleplate of
steering wheel to the Install a new sealed pad if necessary.
steering column shaft may be torn
central position.
After steering, the Blocked or broken tie-rod. Install a new steering gear if necessary.
steering wheel will not Broken or worn front suspension
go back to the central Install new front suspension components if necessary.
components.
position without the
Incorrect toe adjustment. Adjust it if necessary.
assistance of the
driver. Besides, it may Blocked column bearing. Install a new steering column.
feel obstructed or
Contaminated steering oil. Wash the power steering system.
unsmooth when the
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driver turns the
steering wheel to the
central position.
Insufficient power steering pump
Refill the oil if necessary and check if there is oil breakage.
oil.
Incorrect tension of the accessory
Check the tension of the accessory drive belt.
drive belt.
Leakage in the hose or outer
Repair or install a new hose or cooler if necessary.
cooler.
Steering feels heavy Incorrect engine idle speed. Refer to the air discharge of power system.
when steering and Loose or distorted power steering
Install a new power steering pump belt pulley.
parking at the road pump belt pulley.
side Power steering pump flow or Check the pump flow and pressure. Refer to the pump flow
pressure out of specification. and pressure test in this chapter.
Obstructed hose or cooler
Clean the hose or cooler or install a new one if necessary.
pipeline.
Check if there are foreign materials or contamination in the
Contaminated steering shaft.
system. Wash the power steering system.
Air in steering oil. Discharge the air in the system.
Excessively filled system. Correct the fluid level height.
Oil leakage Find out the suspicious component and repair it if

Leakage in components.
necessary.
The accessory drive

belt utters a long
shriek (especially
Check if the tension of the
while the steering
accessory drive belt is correct or if Install a new accessory drive belt if necessary.
wheel turns to the end
the belt skids.
and parking the
vehicle at the original
position)
Chatter from the Loose or broken accessory drive
Install a new accessory drive belt.
steering pump belt.
Insufficient oil and possible Refill the oil to the specified height.
Noise from power leakage. Discharge the air in the system.
steering pump Check if there is a leakage. Repair it if necessary.

Power steering pump.
Install a new power steering pump if necessary.
Oil at a temperature below 54°C

Swish noise (130°F) flow into the bypass valve Normal.
of the housing of pump valve.
With air in the oil and leakage in
Purify the air in the system.
the system.
Sob noise
Check O-ring oil seal of one-way
Install a new power steering pump if necessary.
valve cap.
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Too much oil. Correct the fluid level height if necessary.
Leakage in power
Lost, loose or broken filler cap or
steering pump or fuel Install a new filler cap or O-ring seal if necessary.
lost O-ring seal.
tank
Loose or broken hose connector. Install a new hose connector if necessary.
Leakage in shaft seal:

Broken oil seal.
Broken rotor shaft, e.g. groove or Install a new power steering pump.
bruise.
Leakage in power Worn bush or sleeve of shaft.
steering pump or fuel Inlet tube. Install a new power steering pump.
tank Perforated housing. Install a new power steering pump.
Loose nuts of outlet pipe
Lock it if necessary.
connector or plug valve.
Broken connector, nuts or plug of
Install a new power steering pump.
outlet pipe.
Refill the oil if necessary and check if the system has a
Power steering oil (insufficient).
leakage.
Universal joint (worn). Replace it if necessary.

Abnormal noise
Power steering vane pump
Check and replace it if necessary.
(faulty).
Steering gear (faulty). Replace it if necessary.
Tire (improper inflation). Adjust the tire pressure.
Front wheel alignment (incorrect). Align the wheels.

Insufficient return
Steering column (bent). Align it and replace it if necessary.
Steering gear (malfunction). Replace it if necessary.
Steering knuckle (worn). Replace it if necessary.
Suspension arm ball joint (worn). Replace it if necessary.
Intermediate shaft, and slip

Over large clearance Replace it if necessary.
joint/yoke (worn).
Front wheel bearing (worn). Replace it if necessary.
Tire (improper inflation). Adjust the tire pressure.
Refill the oil if necessary and check if there is a leakage in

Power steering oil (little).
the system.
Front wheel alignment (incorrect) Align the wheels.

Heavy steering
Steering knuckle (worn). Replace it if necessary.
Suspension arm ball joint (worn). Replace it if necessary.
Steering column (bent). Check and replace it if necessary.
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Power steering vane pump
Replace it if necessary.
(malfunction).
三、Maintenance
1. Check the free play of steering wheel
The methods for checking the free play of steering wheel are as follows:
(1) Make sure that the road wheels are in the straight ahead position.
(2) Gently turn the steering wheel, and check its free play. As shown in Fig. 2-24, the free play of
steering wheel ≤ 20°.
Fig. 2-24
2. Steering wheel and column as shown in Fig. 2-25.
Fig. 2-25
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3. Removal and installation of steering wheel and column assembly
Note:
① Follow the notes for the maintenance of steering pump.
② Disconnect the negative terminal of the battery.
③ Make sure that the front wheels are in the straight ahead position.
(1) Removal
1) Remove the horn button assembly.
Note: Disconnect the connector of air bag in case that the ignition switch is at position “ON”.
2) Loosen the two bolts with socket wrench or screwdriver until the bolt head is locked into the bolt
housing, as shown in Fig. 2-26.
Fig. 2-26
3) Push out the horn button assembly from the steering wheel, as shown in Fig. 2-27.
Fig. 2-27
4) Use a screwdriver to release the locked part of the air bag connector and then remove the air bag
connector.
Note: Do not drag the air bag harness when removing the horn button assembly; make the upper
surface upward when placing the assembly; do not disassemble the horn button assembly.
5) Disconnect the connector.
6) Remove the fixing nut of the steering wheel, as shown in Fig. 2-28.
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Locking nut of steering wheel
Fig. 2-28
7) Mark the matching place on the steering wheel assembly and the main shaft assembly.
8) Use a special tool to remove the steering wheel assembly.
9) Remove the lower cap of the steering column. Remove the three bolts, the upper & lower caps of the
steering column, as shown in Fig. 2-29.
Remove the 3 bolts and dismantle
the upper and lower covers of
the steering column
Fig. 2-29
10) Locate the ignition switch at position ACC, and dismantle the coil spring assembly. Note: The
combination switch is connected to the installation plate by a metal clip and 2 plastic clips. Firstly prize
the metal clip from the installation hole by a screwdriver and then remove the 2 plastic clips. See
structure drawing in Fig. 2-30.
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Firstly prize the metal clip
Then remove the 2 plastic clips
Fig. 2-30
11) Remove the left combination switch (headlamp dimmer switch assembly), as shown in Fig. 2-31.
Coil spring
Left combination switch Right combination switch
Fig. 2-31
12) Remove the right combination switch (wiper switch assembly).
13) Remove the dustproof cap of the steering column.
14) Disconnect No. 2 steering intermediate shaft assembly, as shown in Fig. 2-32.
Fig. 2-32
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① Mark the matching place on the slip yoke and intermediate shaft.
② Loosen the bolt A and B, and then disconnect the intermediate shaft.
15) Remove the steering column assembly, as shown in Fig. 2-33.
Fig. 2-33
① Disconnect the connector and harness clip from the steering column assembly.
② Remove the 3 bolts and the steering column assembly.
16) Remove No. 2 steering intermediate shaft assembly.
① Mark the matching place on the main shaft and intermediate shaft, as shown in Fig. 2-34.
② Remove the bolt and intermediate shaft.
Fig. 2-34
17) Dismantle the switch support from the steering column, as shown in Fig. 2-35.
Fig. 2-35
① Use a center punch to make center marks on the two conical bolts.
② Drill the two bolts by a 3-4mm drill.
③ Remove 2 bolts and switch support assembly on the steering column by a screwdriver.
18) Remove the steering column upper clip board.
19) Remove the ignition switch lock core assembly as shown in Fig. 2-36.
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Fig. 2-36
① Turn the ignition switch to position ACC.
② Press down the lock by a screwdriver and pull out the lock core.
20) Dismantle the unlocked warning switch assembly.

① Disconnect the unlocked warning switch from the ignition switch assembly.
② Dismantle the unlocked warning switch assembly.

21) Remove the ignition switch assembly. Remove the 2 bolts and also the ignition switch assembly
from the steering column bracket.
(2) Installation
1) To install the ignition switch assembly and the unlocked warning switch assembly, reverse the
removal procedure.
2) Install the ignition switch lock core assembly.
① Make sure that the ignition switch is at position ACC.
② Install the ignition switch lock core assembly.
3) Check the action of steering lock.
① Check the steering locking mechanism for its lock with the key out.
② Check the steering locking mechanism for its activeness with the key in position ACC.
4) Install the switch support on the steering column.
(1) Adopt two new conical bolts for the temporary installation of the switch support assembly and the
clip on the steering column.
(2) Screw up the two conical bolts till their nut heads disconnect.
5) Install No. 2 steering intermediate shaft assembly.
① Align the matching mark on the intermediate shaft and main shaft.
② Install the intermediate shaft with bolt. Tightening torque: 36N·m.
6) Install the steering column assembly.
① Install the steering column assembly with three bolts. Tightening torque: 21N·m.
② Connect the connector to the harness clip.
7) Connect No. 2 steering intermediate shaft assembly.
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① Align the matching mark on the intermediate shaft and slip yoke.
② Install the bolt B and screw down bolt A. Tightening torque: 28N·m.
8) Install the cover board of the steering column hole.
9) Install wiper switch. Install the wiper switch assembly and connector.
10) Install the headlamp dimmer switch assembly. Install the headlamp dimmer switch assembly and
connector.
11) Make the front wheel in the straight ahead position.

12) Install the clock spring when the key is at position ACC.
13) Check the inter-locking of the key.
14) Install the upper cap of the steering column. Install the upper & lower caps of the steering column
with three bolts.
15) Align the clock spring.

① Make sure the ignition switch at position OFF.
② Make sure the negative terminal of the battery is disconnected. Note: Operate 90s later.
③ Rotate the cable disc counterclockwise with hand till it can not be rotated any more.
④ Rotate the cable disc clockwise about 2.5 circles, and align the mark.
Note: The cable disc can be turned around the center about 2.5 circles.
16) Install the steering wheel assembly.
① Align the matching mark on the steering wheel assembly and steering main shaft assembly.
② Install the steering wheel with fastening nut. Tightening torque: 50N·m.
③ Connect the connector.
17) Check the horn button assembly.

18) Install the horn button assembly.
Note:
① Do not use the air bag components removed from another vehicle. Renew as required.
A Make sure that the horn button assembly is installed with specified tightening torque.
B When dropped or crack, depress or other defects detected on the housing or connector, replace a
new horn button assembly.
C Make sure that the wire is not interfered and clipped by other components when install the horn
button assembly.
② Connect the air bag connector.
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③ Install the horn button after clipping the bolt groove to the bolt cap.
④ Install two srew bolts with torque socket wrench. Tightening torque: 8.8N·m.
19) Align the steering wheel.

4. Inspection for the power steering device
(1) Check the oil level for the power steering gear
① Park the vehicle in a flat place, and turn the steering wheel for several times without moving the
vehicle after starting the engine, in order to increase the oil temperature (to 50-60℃).
② Start the engine and turn the steering wheel from lock to lock several times.
③ No air bubble, flocculent deposits in the oil.
④ Stop the engine and check the fluid level for any change. Discharge air if the level change exceeds
5mm.
5. Replacement of power steering fluid
Removal and inspection are required if fault occurs in the power steering device. At the same time,
replace the power steering fluid. Replace the fluid in time as well if it goes bad. The steps are as below:
(1) Raise the front wheel with a jack or hoist the complete vehicle with a lifter.
(2) Disconnect the return hose from the steering fluid reservoir. Connect a plastic tube with the return
hose, and collect the fluid with proper container. Avoid splashing the fluid to the vehicle body and
components, or wipe up immediately.
(3) With idle operation of the engine, repeatedly turn the steering wheel from lock to lock, to discharge
the fluid; intermittently start the engine several times, to confirm that it has been totally discharged.
(4) Connect the return hose, and fix with clip.
(5) Fill the reservoir with the specified oil, neither higher than the maximum level, nor lower than the
minimum level.
Oil：ESSO 220，Filling amount for reference：0.84L。
(6) With idle operation of the engine, repeatedly turn the steering wheel from lock to lock, to discharge
the air for the steering system.
(7) Check the oil level again. Fill the reservoir with the specified oil if necessary, in order to make the oil
reach the maximum level.
6. Air discharging of the power steering system
(1) Raise the front wheel by a jack.

(2) Intermittently start the engine for several times, and meanwhile turn the steering wheel from lock to
lock for 5 to 8 times to raise the oil temperature, and then make the steering wheel in the straight
ahead position and note the fluid level in the reservoir.
(3) Note the fluid level in the reservoir again in 3 to 5 minutes later after the engine misfires, and
compare the level with that in (2). If the gap is below 5mm and there is no bubble or emulsification
345
in the fluid, the air inside the system has been discharged completely. Otherwise, repeat step (4)
and step (5) until the air is discharged completely.
(4) Check the fluid level. Fill the fluid reservoir with oil to the regulated level as necessary.
Note：
① During discharging air, the fluid should be higher than the minimum level of the reservoir. Otherwise,
fill more fluid.
② The air will be micronized and dissolved in the fluid if it is discharged with the engine on. Therefore,
discharge the air while starting the engine.
③ The fast increasing fluid level after the engine stops indicates an incomplete air discharging.
④ An incomplete air discharging in the system will cause a vibration noise from the pump and abnormal
sound from the flow control valve which may affect the service life of the pump and other components.
7. Oil pressure checking (see Fig. 2-37)
reservoir
Fig. 2-37
(1) Disconnect the oil pump from the high pressure hose, and install the special tool.
(2) Discharge the air and turn the steering wheel for several times to raise the fluid temperature to
50-60℃.
(3) Start the engine and keep it rotating at a speed of 1000±100r/min.
(4) Close the cut-off valve of the pressure gauge completely and check if the safety pressure of the oil
pump is within the standard value. Standard value: 8MPa.
(5) Replace the oil pump in case of a deflection from the standard value.
(6) Open the cut-off valve of the pressure gauge completely and check if the oil pressure is within the
standard value without load.
Standard value: 0.2-0.7MPa.
(7) Any deflection from the standard value can be considered to be caused by a poor fuel line or steering
gear. Repair it and measure the pressure again.
(8) Check if the oil pressure is within the standard value in a state of turning the steering wheel from lock
to lock. Standard value: 7.9MPa.
(9) In case of an oil pressure lower than the standard value, remove and install the steering gear; in case
of a higher one, replace the oil pump.
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(10) Tighten the high pressure hose with specified tightening torque after removing the special tool.
Tightening torque: 55±5N·m.
(11) Air discharging
8. Inspection of the power steering gear: see Fig. 2-38.
Fig. 2-38
1. Lower steering shaft 2. Bolt
3. Acoustic hood on the steering gear 4. Oil pipeline connector of steering gear
5. Bolt 6. Steering gear assembly
7. Sub-frame
(1) Removal
① Discharge steering fluid.
② Dismantle the high pressure oil outlet pipe connected to the steering oil pump, screw off the hollow
bolt, and remove the hose bracket connected to the engine.
③ Disconnect the steering gear from the steering lower shaft.
④ Dismantle the connectors between steering gear and the return oil pipeline, and remove the front
sub-frame and steering assembly from the vehicle body.
⑤ Dismantle the steering gear assembly from the front sub-frame.
(2) Inspection of the power steering gear

Note：The internal components of the steering gear can not be disassembled, but replaced or returned
for repair by the producer.
1) Inspection of the shaking resistance of the steering tie-rod

① Shake the steering tie-rod forcibly for 10 times.
② Put one end of the steering tie-rod downwards, measure the shaking resistance by a spring scale
and compare it with the standard value.
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Standard value: 1.5-4.9N·m.
③ In case of a value above the standard one, replace the steering tie-rod.
④ In case of a value below the standard one, check if the ball joint is loose or creak can be heard. If
shaking smoothly, it is all right; if any looseness detected or abnormal sound heard, replace the
steering tie-rod.
2) Inspection of steering tie-rod ball joint end and dustproof cap
① Press the dustproof cap forcibly by finger and check if there is any crack or damage on the dustproof
cap.
② In case of any crack or damage detected on the dustproof cap, replace the steering tie-rod outer joint;
however, if caused by maintenance, only replace the dustproof cap.
3) Installation of power steering gear
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Section Ⅲ EPS system
The steering system is the special mechanism used by the vehicle to change or maintain the
driving direction of the vehicle. Function: It's functioned to change the driving direction as
appropriate as per the driver’s operation needs during the driving of the vehicle and work with
driving system to jointly maintain the stable driving of the vehicle in event of accidental deviated
driving direction due to occasional impact from the road. The steering system is one of the
important systems maintaining the driving safety of the vehicle. Therefore, the timely checking and
maintenance of the steering system is the effective measure to guarantee the driving safety of the
vehicle and reduce the traffic accidents.
LF630 car power steering system mainly consists of steering wheel, steering column, steering
gear and EPS steering mechanism, etc,as shown in figure 2-84.
Fig. 2-84
1. Hexagon flange bolt (75N·m); 2. Split pin; 3. Hexagon thin slotted nut (75N·m); 4.Steering
gear and steering pull rod assembly; 5. Hexagon flange bolt (75N·m); 6. Steering gear upper
acoustic enclosure; 7. Steering gear upper acoustic enclosure clamp; 8. Steering column dust cover
component; 9. Steering column and adjustment mechanism assembly; 10. Steering wheel assembly
Ⅰ. Fault diagnosis of electric power steering system
1. Precautions for checking and repair
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(1) Make sure to operate carefully and correctly during the replacement of parts. The incorrect
operation and replacement will probably impair the performance of the steering system and
probably lead to driving accidents.
(2) Precautions for airbag (SRS) system. This vehicle is fitted with airbags (SRS), such as the
driver airbag and front passenger airbag. The repair in violation of the correct procedure will
probably lead to accidental deployment of airbag during the repair and probably lead to serious
accidents. Before the repair (including the disassembly or installation, checking or replacement
of parts), make sure to read the precautions of supplemental restraint system.
(3) Avoid impacting the electronic parts, such as ECU and motor. The parts ever fallen or subject
to serious impact shall be replaced with new ones.
(4) Do not expose any electronic parts in high temperature or humid environment.
(5) Do not touch the terminals of connector, in order to prevent deformation or fault due to
electrostatic.
Avoid impacting the steering column or steering gear assembly, especially the motor and torque
sensor. The parts ever fallen or subject to serious impact shall be replaced with new ones.
(6) While moving the steering column or steering gear assembly, do not lift the harness.
(7) While disconnecting or reconnecting the connector: Make sure to place the ignition switch to
position OFF.
2. Electric and circuit wiring diagrams of electric power steering
Shielded line
Torque sensor
Battery Ignition
switch
To "A"
Instrument
ECU03 control
unit
Diagnostic
scanner
OBD diagnosis
port Diagnostic
terminal
350
Electrical connection diagram
C’ C Motor
+
ECU03Controller
B’ B Power
A’ A Body signal
D’
D Torque sensor
Wiring diagram of electric power steering ECU harness

3. Exterior diagram of connectors
Plug A (175967-2)
Plug B (7123-4125-50） Plug C (7123-4129-90）
Plug D’ (6098-2206) Plug D (6098-2208)
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No. Location Purpose Color
A Body harness Signal plug Black
B Body harness Power plug Red
C Motor Motor plug Blue
D’ Body harness Sensor socket White
D Torque sensor Sensor plug White
4. Terminal definitions
Definition of ECU03 control unit interface
Definition of terminal
Terminal Signal description
applications
Open-circuit gate (optional), low output after the current is
A1 Idling booster signal
beyond certain range.
A2 EPS indicator Open-circuit gate
A3 CANH
Fault diagnostic switch Ground to access the diagnosis. The EPS indicator flashes the
A4
DTC.
A5 Neutral
A6 Vehicle signal 0～300Hz 8～16V square wave
A7 Neutral
A8 Neutral
A9 Neutral
A10 Ignition ―ON‖ signal 6～16VDC
A11 CANL
A12 Engine rotation speed signal 0～300Hz 8～16V square wave
A13 Neutral
A14 Sensor power 5V about 5V
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A15 K-LINE OBD7 pin, diagnosis by diagnostic scanner
A16 Sensor auxiliary circuit Approximate 2.5V when the steering wheel is standstill.
A17 Sensor grounding wire
A18 Neutral
A19 Sensor main circuit Approximate 2.5V when the steering wheel is standstill.
A20 Sensor power 12V about 12V
B1 Power 10～16VDC
B2 Ground
C1 Motor + 5~7V when the steering wheel is standstill.

C2 Motor - 5~7V when the steering wheel is standstill.
Pin definitions of sensor socket D’ (6098-2206)
Definition of terminal Input and

Terminal Signal description Color
applications output
D1 Sensor power 12V This pin is vacant for sensor with contacts.
D2 Sensor power 5V about 5V
D3 Neutral
Sensor auxiliary circuit Approximate 2.5V when the steering wheel
D4
is standstill.
D5 Neutral
Sensor main circuit Approximate 2.5V when the steering wheel
D6
is standstill.
D7 Sensor grounding wire 0V
D8 Neutral
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5.Fault Diagnosis
(1) Diagnosis flowchart
Faults?
YES
Park the vehicle NO

safely and stop
the engine.
YES
Connect the NO Properly connect NO

diagnostic scanner. the diagnosis
terminals.
YES YES
Select the corresponding NO Check the indicator circuit.

vehicle model and read out Flashing DTC
the DTC. at ignition.
YES
Read the DTC and look

up the DTC Table.
Check the related

circuits as per the DTC.
Fault NO Maintenance
elimination?
YES
Restore use.
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(2) Table of DTC
For instance: When the DTC21 is set
DTC21 DTC21 DTC21

Multi-function
al indicator
(“EPS”).
indicator ON
Time
(second)
DTC Diagnosis
Diagnosis
Numb “EPS” indicator flashing waveform diagram description
er This DTC is
Normal displayed when no
other DTC appears.
Torque sensor
Vehicle signal
Conduct the fault

Engine rotation speed diagnosis as per
signal corresponding
DTC in “DTC
flowchart”.
Motor
Controller
(3) Display of DTC

1) Connect the diagnosis terminal A4 and negative pole (namely grounding) of power supply
(battery) with service cable.
2) Park the vehicle in a safe place, block the left and right wheels (tires) with wood wedges, and
apply parking brake.
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3) Start the engine (The DTC ―22‖ is displayed when the engine is not started)
6. Diagnosis by diagnostic scanner
Find out the diagnostic interface on the vehicle, which is generally beneath the instrument. Connect
the diagnostic scanner, select the corresponding vehicle model, find out the EPS diagnostic item,
and select ―read DTC‖. The current DTC and its definition description will be displayed on the
screen.
List of DTC
DTC Fault code description Suspected Area

Open-circuit or short-circuit of torque
11 Abnormal sensor
sensor main circuit
High output difference between main
13 Abnormal sensor circuit and auxiliary circuit of torque
sensor
Over-high or under-low power
14 Abnormal sensor
voltage of torque sensor
Open-circuit or short-circuit of sensor
15 Abnormal sensor
auxiliary circuit
Power fault of torque sensor without
16 Abnormal sensor
contacts
Poor harness or connector or
21 Abnormal vehicle speed
abnormal vehicle speed
22 Abnormal engine speed not-started engine or unavailable
engine signal
24 Abnormal vehicle speed
abnormal vehicle speed
41 Abnormal motor Open-circuit or short-circuit of motor
High actual motor current beyond the
42 Abnormal motor
calculated target current
43 Abnormal motor Over-high motor current
Low actual motor current beyond
45 Abnormal motor
calculated target current
52 Abnormal relay Out-of-control of relay
53 Abnormal battery Low power supply
54 Abnormal battery Low power supply
55 Abnormal control unit Internal fault of control unit
Ⅱ. Table of Fault Phenomena

The Table of Fault Phenomena helps find out the fault causes and lists the faults easily occurred in
the vehicle at ordinary times, which can be solved as per the measures listed therein. When
necessary, repair or replace these parts. The troubleshooting of steering system is shown in Table
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2-3.
Table 2-6
Condition Possible reasons Measures

Check the tire size and adjust tire
Incorrect size or pressure of tires
pressure
Overload or uneven loading of vehicle Adjust the load
Loose or worn tie rod or tie rod end. Replace with new steering gear or tie
rod end as necessary.
Loose or damaged steering gear bolts. Tighten or install new bolts.
Loose or worn suspension ball joint.
When the vehicle is
Replace with new suspension ball joint
traveling linearly with fixed
assembly.
steering wheel, the vehicle
wobbles between two sides. Loose bolts from steering column universal Tighten the pinion shaft bolts.
joint to pinion shaft. Tighten the steering column universal
joint.
Loose or worn steering column universal joint. Replace with new steering column
universal joint.
Improper adjustment of toe-in. Adjust as necessary.
Loose or worn rear suspension. Tighten or replace with new rear
suspension parts.
Incorrect tire pressure Adjust the tire pressure.
Incorrect tire size or different tire/tread
Replace with new tires as necessary.
pattern.
Overload or uneven loading of vehicle Adjust the load
Improper adjustment of toe-in. Adjust as necessary.
Damage of front suspension parts. Install new front suspension parts as
necessary.
The vehicle deviates
Damage of rear suspension parts. Install new rear suspension parts as
towards one side while
necessary.
traveling on a level road.
Check the front/rear braking operations for
Adjust as necessary.
normal working.
Check the rear suspension parts for presence
Install new rear suspension parts as
of bending and check the front/rear suspension
necessary.
coil springs for damage or deflection.
Check the rear suspension parts or rear Install new rear suspension parts as
suspension bolts for presence of looseness or necessary.
wear. Tighten all bolts.
Replace with new universal joint as
Steering gear input shaft connector.
necessary.
Feedback (Whine or
knocking sound of steering Replace with new steering gear as
Loose/worn tie rod.
gear). – While the vehicle is necessary.
driving on a rough road, a Tighten or install new fastening bolts
rough feeling can be felt on Loose or damaged steering gear bolts.
as necessary.
the steering wheel.
Loose bolts from steering column to universal Tighten bolts.
joint.
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Loose suspension bushing, bolts, or ball joint. Tighten or install new bolts or ball
joint as necessary.
Poor status of steering column. Replace with new steering column as
necessary.
There is no return of Incorrect tire pressure Adjust the tire pressure.

steering wheel without the Incorrect tire size or incorrect tire pattern.
assistance of the driver after
Replace with new tires as necessary.
th steering. In addition,
there is probably a Non-aligned steering column or friction Align the steering column.
stagnation or hindered between cover and steering wheel.
feeling when the steering
wheel is rotated to the Stagnation of steering column universal joint. Replace with new universal joint.
central position by the Probable tear of steering column baseplate Replace with new baseplate sealing
driver. sealing gasket. gasket as necessary.
There is no return of Replace with new steering gear as
Stagnation or damage of tie rod.
steering wheel without the necessary.
assistance of the driver after
the steering. In addition, Install new suspension parts as
Damaged or worn front suspension parts.
there is probably a necessary.
stagnation or hindered Incorrect toe-in adjustment. Adjust as necessary.
feeling when the steering
wheel is rotated to the
central position by the Stagnation of steering column bearings. Replace with new steering column.
driver.
Steering knuckle (wear) Replace as necessary
Abnormal noise Steering gear (fault) Replace as necessary
Steering motor (noise) Replace
Tire (improper air pressure) Adjust the tire pressure.
Front wheel alignment (Incorrect) Adjust the wheel alignment.
Insufficient return
Steering column (bend) Correct or replace as necessary.
Steering gear (fault) Replace as necessary
Steering knuckle (wear) Replace as necessary
Suspension arm ball joint (wear) Replace as necessary
Excessive play Intermediate shaft and slide joint yoke (wear) Replace as necessary
Front wheel bearings (wear). Replace as necessary
Steering gear (fault). Replace as necessary
Tire (improper air pressure) Adjust the tire pressure.
Front wheel alignment (Incorrect) Adjust the wheel alignment.
Steering knuckle (wear). Replace as necessary
Suspension arm ball joint (wear). Replace as necessary
Steering column (bend). Check and replace as necessary.
Hard Steering
Steering gear (fault) Replace as necessary
Damaged control unit Replace
Improper connection or poor contact of
Connect the connectors.
connector
Steering wheel (wrong installation) Correctly mount the steering wheel
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Poor performance of torque sensor Replace
Engine speed sensor fault. Replace
Poor performance of motor Replace as necessary
Burnout of main fuse and circuit fuse Replace
Fault of steering ECU Replace
Controller (the engine signal does not match
Occasional failure of Replace
with the controller)
electric power steering
Failure of control unit Replace
Ⅲ. Maintenance Work
1. Checking of steering wheel free travel
The method to check the steering wheel free travel is as below.
(1) Park the vehicle and face the tires straight forward.
(2) Lightly rotate the steering wheel and check the steering wheel free travel. As shown in Figure
2-24, the maximum travel of the steering wheel is 20°.
Fig. 2-24
2. The steering wheel and steering column are shown in Figure 2-25.
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Plastic clamp
Steering column dust
cover component Steering wheel
assembly
Steering gear upper

acoustic enclosure clamp Plastic clamp
Steering column
assembly
Steering gear upper

acoustic enclosure
Fig. 2-85
3. Disassembly/installation of steering wheel, combinations witch, and ignition switch
(Caution: Disconnect the negative terminal of battery and ensure that the front wheels face
straight forward.)
Dismounting
(1) Disassembly of steering wheel
1) Dismantle the horn button assembly.
Caution: If the airbag connector is disconnected when the ignition switch is at position
ON
2) Use a socket wrench or screwdriver to loosen two screws, till the screw heads are clamped
within the screw housing, as shown in Figure 2-26.
Fig. 2-26
3) Pull out the horn button assembly from the steering wheel, as shown in Figure 2-27.
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Fig. 2-27
4) Use a screwdriver to loosen the locked part of airbag connector and disassemble the airbag
connector.
Caution: When disassembling the horn button assembly, do not pull the airbag harness.
While placing the horn button assembly, ensure to face its top surface upward. Do not
break down the horn button assembly.
5) Disconnect the connector.
6) Disassemble the fastening nuts of steering wheel, as shown in Figure 2-28.
Steering wheel lock nut
Fig. 2-28
7) Add fitting marks on the steering wheel assembly and main shaft assembly.
8) Use special tools to disassemble the steering wheel assembly.
Disassembly of combination switch
1) Remove Steering Wheel Assembly
2) Disassemble the lower cap of steering column. Disassemble 3 screws and the upper and
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lower caps of the steering column, as shown in Fig. 2-29.
Disassemble 3
screws and the upper
and lower caps of the
steering column.
Fig. 2-29
3) Place the ignition switch to position ACC and disassemble the coil spring assembly.
Caution: The combination switch is connected with the mounting plate by 1 metal clamp
and 2 plastic clamps. Firstly use a screwdriver to pry out the metal clamp through the
mounting hole and then disassemble 2 plastic clamps. The structure is shown in Figure
2-30.
Firstly pry out the metal

Then disassemble 2
clamp.
plastic clamps.
Fig. 2-30
4) Disassemble the left combination switch (headlamp dimmer switch assembly) as shown in
Fig. 2-31.
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Spiral spring
Left combination
Right combination
switch switch
Fig. 2-31
5) Disassemble the right combination switch (wiper switch assembly)
Disassembly of ignition switch assembly
1) Disassemble the steering wheel and combination switch assembly
2) Disassemble the steering column dust cover.
3) Disconnect the 2# steering intermediate shaft assembly, as shown in Figure 2-32.
Fig. 2-32
① Add fitting marks on the slide yoke and intermediate shaft.
② Loosen the bolts A and B and then disconnect the intermediate shaft.
6) Disassemble the steering column assembly, as shown in Figure 2-33.
Fig. 2-33
① Disconnect the connectors and harness clamps from the steering column assembly.
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② Disassemble 3 bolts and steering column assembly.
7) Disassemble the switch bracket from the steering column, as shown in Figure 2-35.
Fig. 2-35
① Use a center punch to add center marks on two tapered bolts.
② Use a 3~4mm drill bit to drill into two bolts.
③ Use a screwdriver to disassemble 2 bolts and switch bracket assembly from the
steering column.
8) Disassemble the steering column clamping plate.
9) Disassemble the ignition switch lock cylinder assembly, as shown in Figure 2-36.
Fig. 2-36
① Rotate the ignition switch to position ACC.
② Use a screwdriver to push down the stop lock and pull out the lock cylinder assembly.
10) Disassemble unlock warning switch assembly.
① Disconnect unlock warning switch from the ignition switch assembly.
② Disassemble unlock warning switch assembly.
11) Disassemble the ignition switch assembly. Disassemble 2 screws and disassemble the
ignition switch assembly from the steering column bracket.
Installation
1) Install the ignition switch assembly and unlock warning switch assembly as per reverse order
of disassembly.
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2) Install the ignition switch lock cylinder assembly.
① Ensure to place the ignition switch to position ACC.
② Install the ignition switch lock cylinder assembly.
3) Check the function of steering lock.
① Check whether the steering lock mechanism is locked after the key is withdrawn.
② Check whether the steering lock mechanism is unlocked after the key is inserted and
rotated to position ACC.
4) Install the steering column upper switch bracket.
① Use two new tapered bolts to temporarily install the steering column upper switch bracket
assembly and steering column upper clamp.
② Tighten two tapered bolts, till their nut heads break.
5) Install the 2# steering intermediate shaft assembly.
① Align the fitting marks on the intermediate shaft and main shaft.
② Use bolts to install the intermediate shaft. Tightening torque: 36N·m.
6) Install the steering column assembly.
① Use 3 bolts to install the steering column assembly. Tightening torque: 21N·m.
② Connect the connectors and harness clamps.
7) Connect the 2# steering intermediate shaft assembly.
① Align the fitting marks on the intermediate shaft and slide yoke.
② Install the bolts B and tighten the bolts A. Tightening torque: 28N·m.
8) Install the steering column opening cover plate.
9) Install the wiper switch. Install the wiper switch assembly and connect the connectors.
10) Install the headlamp dimmer switch assembly. Install the headlamp dimmer switch assembly
and connect the connectors.
11) Face the front wheels straight forward.
12) Place the key to position ACC and install the clock spring.
13) Check the interlocking function of the key.
14) Install the steering column upper cap. Use 3 screws to install the upper and lower caps of the
steering column.
15) Align clock spring
① Check that the ignition switch is placed at position OFF.
② Check whether the negative terminal of the battery is disconnected. Caution: Conduct the
operations only after the terminal is disconnected for 90s.
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③ Use hands to rotate cable reel counter-clockwise, till it’s difficult for further rotation.
④ Rotate cable reel clockwise for approximate 2.5 turns and align the marks.
Note: The cable reel can rotate in both leftward and rightward directions around the center for
2.5 turns.
16) Mount the steering wheel assembly
① Align the fitting marks of steering wheel assembly and steering shaft assembly.
② Use the fastening nuts to install the steering wheel. Tightening torque: 50N·m.
③ Connect the connectors.
17) Check horn button assembly.
18) Install horn button assembly.
Note:
① Do not use any airbag parts disassembled from other vehicle. Make sure to use new parts
during replacement.
A. Ensure that the horn button assembly is installed to the specified torque.
B. If the horn button assembly ever drops onto the ground or there is defects such as
cracking and pit on the housing or connector, replace with new assembly.
C. While installing the horn button assembly, guard the wires against interference with
other parts and against being clamped.
② Connect the airbag connector.
③ Ensure that the surrounding grooves of the screws are clamping the screw caps before the
installation of horn button.
④ Use a torque socket wrench to install 2 Torx screws. Tightening torque: 8.8N·m
19) Align the steering wheel.
4. Disassembly of motor assembly
1) Disassemble steering wheel and combination switch assembly
2) Disassemble steering column assembly.
3) Disassemble steering column dust cover.
4) Disconnect 2# steering intermediate shaft assembly, as shown in Figure 2-32.
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Fig. 2-32
① Add fitting marks on the slide yoke and intermediate shaft.
② Loosen bolts A and B and then disconnect the intermediate shaft.
5) Disassemble the steering column assembly, as shown in Figure 2-33.
Fig. 2-33
① Disconnect the connectors and wire harness clamps from the steering column
assembly.
② Disassemble 3 bolts and steering column assembly.
6) Disassemble the switch bracket from the steering column, as shown in Figure 2-35.
Fig. 2-35
① Use a center punch to add center marks on two tapered bolts.
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② Use a 3~4mm drill bit to drill into two bolts.
③ Use a screwdriver to disassemble 2 bolts and switch bracket assembly from the
steering column.
7) Disassemble the fastening bolts of steering motor and take out the steering motor
assembly.
Fig. 2-86
5. Checking and repair of power steering gear: The structural diagram is shown in Figure 2-37.
Fig. 2-87
1. Lower steering shaft assembly 2. Bolt 3. Steering gear upper acoustic enclosure 4. Bolt 5.
Steering gear assembly 6. Subframe
(1) Disassemble the steering gear
① Disconnect the steering gear and lower steering shaft assembly and lower the subframe
assembly and steering gear assembly from the body.
② Disassemble the steering gear assembly from the front subframe.
(2) Checking and repair of power steering gear
Caution: The steering gear can’t be broken down internally and shall be replaced by the
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manufacturer or returned to the manufacturer for repair.
1) Checking of steering tie rod swing resistance
① Swing the steering tie rod for 10 times with a high force.
② Face one end of steering tie rod downward, use a spring scale to measure swing resistance,
and compare against the standard value.
Standard value: 1.5~4.9N.m.
③ If the measurement is beyond the standard value, replace the steering tie rod.
④ If the measurement is less than standard value, check the ball joint for presence of
looseness and creaking feeling. If the swing is smooth, it can be judged that the ball joint
can be used further. Upon detection of looseness or noise, replace the steering tie rod.
2) Checking of steering tie rod ball socket and dust cap.
① Use fingers to press the dust cap with high force and check the dust cap for presence of
cracking or damage.
② Upon detection of cracking or damage on the dust cap, replace the external connector of
the steering tie rod. If the dust cap is damaged during the maintenance, it’s acceptable to
only replace the dust cap.
3) Installation of power steering gear (as per reverse order of disassembly)
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Section IV Brake System
The brake system is used to transform the force on the brake pedal from the driver to braking force
of all wheels. Then the hydraulic system will distribute the braking force to each wheel. The vacuum
brake booster is used to decrease the force from the pedal and increase the hydraulic pressure. The
parking brake operates by rear wheels and controls the operation manually.
LF630 sedan has two brake systems, namely driving brake system and parking brake system. The
driving brake system is an engine vacuum booster ABS hydraulic brake system. And the parking brake
is to control the rear brake by cable system which utilizes the self-adjusting ratchet and pawl structure.
The ABS is controlled by the hydraulic control unit (HCU) in the hydraulic system, and only works when
the vehicle speed sensor detects that the wheels are locked.
一、Fault Diagnosis
The fault elimination of brake system is shown in Table 2-4. The figures in the Table refer to the
sequence of possible faults. Check all components and parts in sequence. Replace related parts if
necessary.
Table 2-4
Alignment angle of wheels Check the alignment angle of wheels.
Brake pad Check and install a new component if necessary.

Braking deviation or
brake drifts Brake disc Check and install a new component if necessary.
Brake caliper Check and install a new component if necessary.
Brake fluid level sensor Refer to WDS.

Red brake warning
lamp is lighted Parking brake control device Release and adjust the parking brake.
continuously Excessively worn brake pad Check and install a new component if necessary.

Vibration during
brake action
Brake disc Check and install a new component if necessary.
With air in system Discharge the air in system.
Braking master pump Check the braking master pump.

Rapidly sunken
Pedal Brake disc Check and install a new component if necessary.

Slowly sunken pedal
Brake master pump Check the brake master pump.
With air in system Discharge the air in system.

Low-position or soft
pedal
Brake booster Check the booster components.
Locked pedal when Brake pad Check and install a new component if necessary.
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gently stepping down Brake disc Check and install a new component if necessary.
the pedal
Brake booster Check the booster components.
Insufficiently lubricated sliding

Lubricate it if necessary.
part

Too long/unstable
brake pedal travel Brake disc Check and install a new component if necessary.
Wheel bearing Check the wheel bearing or install a new one.
Brake pedal Check and repair the brake pedal.
Brake booster Check and repair booster components.
Brake caliper Check and install new components if necessary.
Electronic stability control

Brake daggles
system Refer to WDS.
(if equipped)
Electronic stability control

system Refer to WDS.
(if equipped)
Slow or incomplete
Carry out test of brake master pump components in
return of the pedal Brake master pump
this chapter.
二、Inspection of Brake system, Table 2-4.

(一) Air discharging of brake fluid
Please purify the air if repairing the brake system or considering air in the brake pipeline.
Note：Do not splash the brake fluid on the paint, otherwise clean it immediately.
l．Refill brake fluid into the reservoir (as shown in Fig. 2-39)
Brake fluid:DOT4, filling amount: 0.72L.
图 2-39
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2．Discharge the air in the brake master pump
Note: Discharge the air in the brake master pump if it has been dismantled or the reservoir is empty.
1) Disconnect the oil pipeline connector from the brake master pump.
2) Slowly step down the pedal and maintain without movement, as shown in Fig. 2-40.
Fig. 2-40
3) Block up the hole from outside by fingers, and release the brake pedal as Fig. 2-41.
图 2-41
4) Repeat step 2) and 3) for 3 or 4 times.
3. Air discharging of brake oil pipe (Fig. 2-42)
Fig. 2-42
1) Connect the plastic pipe to the brake caliper and slave cylinder.
2) Step down the pedal for times and then keep it stepped down, and then screw off the air discharging
bolt.
3) Screw down the air discharging bolt immediately when the brake fluid flows out, and release the brake
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pedal.
4) Repeat step 2) and 3) until all air in brake fluid flow out.
5) Repeat the above steps to exhaust air from each brake slave cylinder. Tightening torque: 8.0N·m.
4. Check the oil level in the reservoir
Check the oil level. Refill brake fluid if necessary. Brake fluid: DOT4
(二) Inspection of brake pedal

1. Check the pedal height as shown in Fig. 2-43. Height above floor: 136mm-146mm.
Fig. 2-43
2. Adjust the pedal height.
1) Remove the central console cover.
2) Dismantle the connector from the brake lamp switch.
3) Release the brake lamp switch locking nut and dismantle the brake lamp switch.
4) Release the locking nut of U connector.
5) Rotate the push rod of pedal, and adjust the pedal height.
6) Screw down the locking nut of the push rod. Tightening torque: 26N·m.
7) Install the brake lamp switch.
8) Insert the connector of brake lamp switch.
9) Push down the brake pedal for 5-15mm, and then turn the brake lamp switch until the lamp goes out.
Then lock the nut.
10) After installation, step down the brake pedal for 5-15 mm, and then check if the lamp is lighted (it
should be lighted).
3. Check the free play of the pedal

1) Stop the engine, step down the pedal repeatedly until there is no vacuum in booster.
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2) Step down the pedal until resistance is felt. Measure the distance shown in Fig. 2-44. Free play of
pedal: 1-6mm. In case of clearance out of specifications, check the clearance of the brake lamp switch.
In case of an incorrect clearance, diagnose the brake system. Brake lamp clearance: 0.5-2.4mm.
Pedal free play
Fig. 2-44
4. Check the braking distance. Fig. 2-45.
Loosen the push rod of the parking brake. When the engine runs, step down the pedal. Measure the
braking distance as shown in Fig. 2-45. Step down the pedal by a force of 140N. The braking distance
should be over 55mm above the floor. In case of a distance out of specifications, diagnose the brake
system.
Fig. 2-45
5. Removal and installation. See Fig. 2-46.
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Brake lamp switch
Brake pedal shaft
Brake pedal bush
Fig. 2-46
(1) Removal
1) Remove the components of instrument cluster.
2) Disconnect the U connector of the push rod of brake master pump. Dismantle the clip and push rod
pin, and disconnect the brake master pump from the brake pedal.
3) Remove the brake pedal support.
① Remove the bolts from the brake pedal support. See Fig. 2-47.
Fig. 2-47
② Disconnect the connector of the brake lamp.
③ Remove 4 nuts and the brake pedal support. See Fig. 2-48.
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Fig. 2-48
4) Remove the brake pedal assembly.
① Remove the bolts and nuts from the brake pedal support.
② Remove the brake pedal and 2 bushes.
5) Remove the brake lamp components.
① Release the brake lamp switch and locking nuts.
② Remove the brake lamp switch from the brake pedal support.
6）Remove the pad of brake pedal from the brake pedal.
(2) Installation
1) Install the brake pedal pad on the pedal.
2) Install the brake lamp components on the brake pedal.
3) Install the brake pedal.
① Smear lithium base glycol grease on the head face and side on the 2 new bushes.
② Install the brake pedal and 2 bushes onto the brake pedal support by bolts and nuts. Tightening
torque: 37N·m.
4) Install the brake pedal support.
① Install the brake pedal support by 4 nuts. Tightening torque: 13N·m.
② Connect the connector of brake lamp switch.
③ Encase the bolts into the brake pedal support. Tightening torque: 20N·m.
5) Connect the U connector of push rod of the brake master pump.
① Smear lithium base glycol grease on the push rod pin.
② Connect the clip of push rod pin to the push rod of brake master pump.
6) Install the instrument cluster components.
7) Check and adjust the height of the brake pedal.
8) Check the free play of the brake pedal.
9) Check the braking distance of the brake pedal. After assembly, check and adjust the height, free play
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and braking distance of the brake pedal.
(三) Inspection of brake master pump and vacuum booster

On-vehicle inspection
1. Inspect the vacuum booster
1) Check the air tightness. See Fig. 2-49.
Fig. 2-49
① Start the engine and then stop it after 1-2 min, and slowly step down the pedal for several times. Note:
It proves good air tightness in case that the pedal drops greatly at the first trample rises gradually after
the second or third trample.
② When the engine is running, step down the brake pedal and then stop the engine. Note: It proves
good air tightness if the braking distance has no change at 30s after the pedal is stepped down.
2) Operation Inspection.
① When the ignition switch is at position OFF, step down the pedal for times, and then check if the
braking distance is changed.
② Step down the pedal and start the engine. Note: The operation is normal if the pedal drops slightly.
2. Check the vacuum one-way valve.
1) Glide the clip and disconnect the vacuum pipe.
2) Remove the vacuum one-way valve.
3) Check if the way from the booster to engine is ventilated.
4) Replace the vacuum one-way valve in case of a fault.
3. Check if there is brake fluid leakage outside the brake master pump.
4. After the engine stops, step down the pedal for times and keep brake force. Check if the pedal falls
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and if there is pressure leakage inside the brake master pump. Replace the brake master pump in case
of a fault.
(四) Inspection of driving brake

1. Inspection of the front brake gear
(1) Removal
1) Remove the front wheel.
2) Discharge the brake fluid. Note: Do not splash the brake fluid on the paint, otherwise clean it
immediately.
3) Remove the front disc brake caliper.
① Remove the connector bolts and washer from the front disc brake caliper, and then disconnect the
hose. See Fig. 2-50.
Fig. 2-50
②Remove the 2 bolts after securing the sliding pin of the slave cylinder of front disc brake. See Fig.
2-51.
Fig. 2-51
4) Remove the front brake pad suite.
① Remove the 2 brake pads with silencer pads.
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② Remove No.1 and No. 2 silencer pads from each brake pad.
5) Remove the front brake pad holding piece. Remove the 2 lining pads from the support of the brake
master pump.
6) Remove the sliding pin of the slave cylinder of front disc brake. Remove the sliding pin from the
support of the disc brake master pump.
7) Remove the dustproof cover of the front disc sliding pin. Remove the 2 dustproof cover from the
support of the slave cylinder of front disc brake. See Fig. 2-52.
Disc brake wheel cylinder support
Fig. 2-52
8) Remove the support of slave cylinder of left front disc brake. Take off the support after removing the 2
bolts.
9) Remove the dustproof cover of the brake slave cylinder. Remove the fixing ring and dustproof cover
by a screwdriver. See Fig. 2-53.
Fig. 2-53
Note: Do not splash the brake fluid.
10) Remove the air discharging bolt of the front disc brake gear.
11) Remove the piston in the slave cylinder of front brake.
① Place a cloth or equivalent between the slave cylinder and piston.
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② Blow out the piston from the slave cylinder by compressed air. See Fig. 2-54. Note: Do not put your
hand before the piston when blowing the compressed air.
Fig. 2-54
12) Remove the oil seal of piston. Take out the oil seal from the brake slave cylinder by a screwdriver.
See Fig. 2-55.
Fig. 2-55
(2) Inspection
1) Inspect eh brake slave cylinder and piston. Check if the piston is rusty or scratched.
2) Check the lining thickness of the brake pad. Measure the thickness by a ruler. See Fig. 2-56.
Standard thickness: 11.0mm; min thickness: 2.0mm.
Fig. 2-56
3) Check the sheet steel of the front brake wear indicator. Make sure that the sheet steel is sufficiently
flexible and free of rust, dirt and other foreign material, and has no crack or wear.
4) Check the thickness of the brake disc. Measure the thickness of the brake disc by a micrometer
caliper. Standard: 25.0mm; min: 23.0mm.
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5) Take off the front brake disc.
① Mark on the brake disc and wheel hub.
② Take off the brake disc.
6) Install brake disc. Note: Install it through the part with min thickness.
7) Check the brake disc swaying.
① Temporarily tighten the brake disc. Tightening torque: 103N·m.
② Measure the swaying of brake disc at 10mm away from the outer edge of brake disc by a dial
indicator. See Fig. 2-57. Max: 0.05mm.
Fig. 2-57
③ In case that the swaying of brake disc reaches or exceeds the limit, check the axial clearance of the
bearing and the swaying of wheel hub. If both bearing and hub are normal, adjust the swaying of brake
disc.
(3) Installation
1) Temporarily screw down the air discharging bolt on the front brake slave cylinder.
2) Install the oil seal of piston.
① Smear the lithium base glycol grease on the new oil seal of the piston.
② Insert the new oil seal into the brake slave cylinder.
3) Install brake piston.
① Smear the lithium base glycol grease on the brake piston.
② Install the piston into the front disc brake slave cylinder.
Note: Do not forcibly spin the piston into the brake slave cylinder.
4) Install the dustproof cover of brake slave cylinder.
① Smear the lithium base glycol grease on the dustproof cover of the new brake slave cylinder, and
install it into the brake pump. Note: Install the dustproof cover into the groove between the slave cylinder
and piston.
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② Install the retaining ring by a screwdriver. Note: Do not damage the dustproof cover of the slave
cylinder.
5) Install the support of left front brake slave cylinder. Tighten the support by 2 bolts. Tightening torque:
88N·m.
6) Install the dustproof boot of the front disc brake bush.
① Smear the lithium base glycol grease on the surface of 2 new dustproof covers.
② Install the 2 dustproof covers into the support of front disc brake slave cylinder.
7) Install the sliding pin of the front disc brake slave cylinder.
① Smear the lithium base glycol grease on the sliding part of the 2 sliding pins and the surface of oil
seal.
② Install the 2 sliding pins into the support of the front disc brake slave cylinder.
8) Install the components of brake pad.
Note: The silencer pad must be replaced at the same time while the wear brake pad is replaced.
① Smear grease for disc brake on the two sides of each silencer pad. See Fig. 2-58.
Fig. 2-58
② Install silencer pad on each brake pad.
③ The wear indicator is upwards. Install the inside brake pad, and then the outside.
Note: The friction surface between the brake pad and the brake disc should be free of engine oil or
grease.
9) Install the front disc brake slave cylinder.
① Install the front disc brake slave cylinder by 2 bolts. See Fig. 2-59. Tightening torque: 34N·m.
Fig.2-59
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② Install the new washer and hose by joint bolt. Tightening torque: 30N·m. Note: Secure the hose tightly
in the locking hole of the brake slave cylinder.
10) Discharge the air in the brake slave cylinder.
11) Discharge the air in the brake pipeline.
12) Check if there is brake fluid leakage.
13) Install the front wheel. Tightening torque: 103N·m.
2. Inspection of rear brake gear
Disassembly Diagram of rear brake gear components.
Fig. 2-60
(1) Disassembly
1) Remove the rear wheel.
2) Discharge the brake fluid.
Note: Do not splash the brake fluid on the paint, otherwise wash it immediately.
3) Dismantle the slave cylinder of the rear disc brake.
① Remove the joint bolt and washer from the slave cylinder of the rear disc brake, and then disconnect
the hose. See Fig. 2-61.
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Fig. 2-61
② Dismantle the 2 bolts after securing the sliding pin of the slave cylinder of the rear disc brake. See Fig.
2-62.
Fig. 2-62
4) Dismantle the rear brake pad suite.
① Dismantle the brake pad with 2 silencer pads.
② Dismantle No. 1 and No. 2 silence pad from each brake pad.
5) Dismantle the rear brake pad holding piece. Remove the 2 friction pads from the support of the brake
master pump.
6) Remove the sliding pin of the slave cylinder of the rear disc brake. Remove the sliding pin from the
support of the disc brake master pump.
7) Dismantle the dustproof cover of the rear brake sliding pin. Remove the 2 dustproof covers from the
support of the rear disc brake slave cylinder. See Fig. 2-63.
Disc brake wheel cylinder support
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Fig. 2-63
8) Dismantle the left rear disc brake slave cylinder support. Remove the 2 bolts and then take off the
support.
9) Dismantle the dustproof cover of the brake slave cylinder. Remove the fixing ring and dustproof cover
by a screwdriver. See Fig. 2-64
Fig. 2-64
10) Dismantle the air discharging bolt of the rear disc brake gear.
11) Dismantle the piston of the rear brake slave cylinder.
① Place a cloth or equivalent between the slave cylinder and piston.
②Blow out the piston from the brake slave cylinder by compressed air. See Fig. 2-65
Fig. 2-65
Note: Do not put your hand before the piston when blowing the compressed air. Do not splash the brake
fluid.
12) Remove the oil seal of piston. Take out the oil seal from the slave cylinder. See Fig. 2-66.
Fig. 2-66
(2) Inspection
1) Check the slave cylinder and piston. Check if the piston is rusty or scratched.
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2) Check the thickness of the lining of brake pad. Measure the thickness by a ruler. See Fig. 2-67.
Standard: 10.0mm; min: 2.0mm.
Fig. 2-67
3) Check the sheet steel of the front brake wear indicator. Make sure that the sheet steel is enough
flexible and free of rust, dirt and other foreign material, and has no crack or wear.
4) Check the thickness of the brake disc. Measure the thickness of the brake disc by a micrometer screw.
Standard: 9.0mm; 9.0mm, min:7.5mm

5) Take off the rear brake disc.
① Mark on the brake disc and wheel hub.
② Take off the brake disc.
6) Install brake disc. Note: Install it through the part with min thickness.
7) Check the brake disc swaying.
① Temporarily tighten the brake disc. Tightening torque: 103N·m.
② Measure the swaying of brake disc at 10mm away from the outer edge of brake disc by a dial
indicator. See Fig. 2-68. Max: 0.05mm.
Fig. 2-68
③ In case that the swaying of brake disc reaches or exceeds the limit, check the axial clearance of the
bearing and the swaying of wheel hub. If both bearing and hub are normal, adjust the swaying of brake
disc.
(3) Installation
1) Temporarily screw down the air discharging bolt on the rear brake slave cylinder.
2) Install the oil seal of piston.
① Smear the lithium base glycol grease on the new oil seal of the piston.
② Insert the new oil seal into the brake slave cylinder.
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3) Install brake piston.
① Smear the lithium base glycol grease on the brake piston.
② Install the piston into the front disc brake slave cylinder. Note: Do not forcibly spin the piston into the
brake slave cylinder.
4) Install the dustproof cover of brake slave cylinder.
① Smear the lithium base glycol grease on the dustproof cover of the new brake slave cylinder, and
install it into the brake pump. Note: Install the dustproof cover into the groove between the slave cylinder
and piston.
② Install the retaining ring by a screwdriver. Note: Do not damage the dustproof cover of the slave
cylinder.
5) Install the support of left rear brake slave cylinder. Tighten the support by 2 bolts. Tightening torque:
88N·m.
6) Install the dustproof cover of the rear disc brake bush.
① Smear the lithium base glycol grease on the surface of 2 new dustproof covers.
② Install the 2 dustproof covers into the support of front disc brake slave cylinder.
7) Install the sliding pin of the rear disc brake slave cylinder.
① Smear the lithium base glycol grease on the sliding part of the 2 sliding pins and the surface of oil
seal.
② Install the 2 sliding pins into the support of the front disc brake slave cylinder.
8) Install the rear brake pad holding piece. Remove the 2 holding pieces from the rear disc brake slave
cylinder support.
9) Install the components of brake pad. Note: The silencer pad must be replaced at the same time while
the wear brake pad is replaced.
① Smear grease for disc brake on the two sides of each silencer pad. See Fig. 2-69.
Fig. 2-69
② Install silencer pad on each brake pad.
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③ The wear indicator is upwards. Install the inside brake pad, and then the outside.
Note: The friction surface between the brake pad and the brake disc should be free of engine oil or
grease.
10) Install the rear disc brake slave cylinder.
① Install the rear disc brake slave cylinder by 2 bolts. See Fig. 2-70. Tightening torque: 34N·m.
Fig. 2-70
② Install the new washer and hose by joint bolt. Tightening torque: 30N·m. Note: Secure the hose tightly
in the locking hole of the brake slave cylinder.
11) Fill brake fluid into the reservoir.
12) Discharge the air in the brake slave cylinder.
13) Discharge the air in the brake pipeline.
14) Check the brake fluid level in reservoir.
15) Check if there is brake fluid leakage.
16) Install the rear wheel. Tightening torque:120N·

m。
(五) Inspection of parking brake system
Parking system as shown in Fig. 2-71
Fig. 2-71
1. Parking brake control lever assembly
2. Front and rear cables support
3. Parking brake cable
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1. Fault elimination
Table 2-5
Fault Possible Cause Action
1. Parking brake cable 1. Check the parking cable and adjustment
Inactive parking brake
2. Parking brake control 2. Check the parking brake control
Unreleased parking 1. Parking brake cable 2. Check the parking cable
brake 2. Parking brake control 2. Check the parking brake control
1) Parking brake rod play (maladjusted) Adjust it
2) Parking brake cable (blocked) Adjust it
3) Parking brake shoe clearance

Blocked brake Adjust it
(maladjusted)
4) Parking brake lining (cracked or distorted) Replace it if necessary
5) Pull-back or tensioned spring (broken) Replace it
Table 2-5 indicates the possible causes for faults. The figure indicates the sequence of the possible
faults. Inspect all components in order and replace them if necessary.

(1) Remove the rear wheel.
(2) Adjust the brake shoe clearance.
(3) Install the rear wheel. Tightening torque: 120N·m.
(4) Check the parking brake rod play. Hold the rod and count the number of clicks. Parking brake rod
play: 6-9 clicks under 200N force.
(5) Adjust the parking brake rod play. See Fig.2-72.
Fig. 2-72
1) Remove the glove box cover.
2) Rotate the No. 1 adjustment nut cable until the pulling rod play is normal.
3) Install the glove box cover.
3. Accessories of parking brake rod
Disassembly of parts and components as shown in Fig. 2-73
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Fig. 2-73
(1) Removal
1) Remove the trim strip of the instrument cluster and air conditioning control panel as shown in Fig.
2-74.
Fig. 2-74
1. Trim strip of the instrument cluster
2. Air conditioning control panel
3. Bolt
4. Hand brake cover
5. Auxiliary fascia console sundries box
2) Remove the two bolts of the fixed fascia console and auxiliary fascia console beneath the position of
the air conditioning control panel.
3) Remove bolt 3 (both left and right).

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4) Dismantle the floor brake cover.
5) Open the auxiliary fascia console sundries box cover, and dismantle the two bolts at the bottom.
6) Remove the lead of No. 1 adjustment nut.
7) Remove the accessories of the parking brake rod as shown in Fig. 2-75.
Fig. 2-75
① Dismantle the connector of the parking brake rod switch.
② Take off the parking brake rod after removing the 2 bolts.
8) Dismantle the parking brake switch components. Remove the bolts and parking brake switch
components.
(2) Installation
1) Install the parking brake switch components.
2) Install the parking brake switch components by bolts.
① Install the parking brake cable onto the rod and install the lead of No. 1 adjustment nut.
② Tighten the parking brake rod by 2 bolts. Tightening torque: 13N·m.
③ Connect the connector of parking brake switch.
4) Dismantle the floor brake cover.
5) Remove and replace bolt 3 (both left and right).
6) Install the two bolts of the fixed fascia console and auxiliary fascia console beneath the air
conditioning control panel.
7) Install the trim strip of the instrument cluster and air conditioning control panel.
8) Check the parking brake rod play.
9) Adjust the parking brake rod play.
4. Accessories of parking brake rod
Disassembly of parts and components (as shown in Fig. 2-76)
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Fig. 2-76
(1) Removal
Remove the No. 2 parking brake cable components by the same way with the right side.
1) Remove the trim strip of the instrument cluster and air conditioning control panel.
2) Remove the two bolts of the fixed fascia console and auxiliary fascia console beneath the position of
the air conditioning control panel.
3) Remove and replace the bolt 3 (both left and right)
4) Remove the floor brake cover.
6) Remove the No. 1 adjustment nut lead.
7) Remove the accessories of the parking brake rod as shown in Fig. 2-76.
① Dismantle the connector of the parking brake rod switch.
② Take off the parking brake rod after removing the 2 bolts.
8) Dismantle the parking brake switch components. Remove the bolts and parking brake switch
components.
9) Dismantle the components of the front exhaust pipe.
10) Dismantle the No. 2 front floor heat-insulating pad. Remove the 2 bolts and take off the front floor
hear-insulating pad.
11) Disassemble the No. 3 parking brake cable components.
① Remove the No. 3 parking brake cable from the vehicle body after removing the 4 bolts.
② Remove the cable components after disconnecting the components of No. 3 parking brake cable from
the parking brake balancer.
12) Remove the rear wheel.
13) Remove the accessories of the brake disc.
14) Remove the front brake shoe.
15) Remove the left rear self-adjusting rod.

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16) Remove the rear brake shoe.
17) Remove the components of No. 3 parking brake cable. Disconnect the components of No. 3 parking
brake cable from the soleplate after removing the bolts, as shown in Fig. 2-77.
Fig. 2-77
(2) Installation
1) Install components of No. 3 parking brake cable, as shown in Fig. 2-78.
Fig. 2-78
① Connect the components of No. 3 parking brake cable to the balancer.
② Tighten the No. 3 parking brake cable by 4 bolts. Tightening torque: 5.4N·m.
2) Install the components of No. 3 parking brake cable. Tighten the components of No. 3 parking brake
cable to the soleplate by bolts. Tightening torque: 7.8N·m.
3) Smear the heat-resistant grease.
4) Install the brake shoe.
5) Install the pull-back spring of brake shoe.
6) Install the self-adjusting rod of LR brake.
7) Install the front brake shoe.
8) Inspect the installation of brake disc.
9) Install the accessories of brake disc.
10) Adjust the brake shoe clearance.

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11) Install the rear wheel. Tightening torque: 120N·m.
12) Temporarily tighten the adjustment nut lead.
13) Install the No. 2 front floor heat-insulating pad. Tighten the No. 2 front floor heat-insulating pad by 2
bolts. Tightening torque: 5.5N·m.
14) Install the components of the front exhaust pipe.
15) Install the front floor rod by 2 bolts.
16) Check the parking brake rod play.
17) Adjust the parking brake rod play.
18) Check if there is air leakage.
19) Install the accessories of auxiliary fascia console sundries box.
20) Install floor shift lever components.
21) Install the auxiliary fascia console.
22) Install the accessories of the auxiliary fascia console.
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SectionⅤ Fuel System
I. Removal and Installation

1. Operation before removal
① Suck the fuel
② Avoid fuel flowing to the floor
③ Remove the secondary muffler
2. Operation after installation
① Fill fuel
② Confirm if there is fuel leakage
③ Install the secondary muffler
3 .Removal procedures as shown in Fig. 2-79
Fig. 2-79
1. Components of hose connecting fuel tank and canister 2. Components of fuel tank return pipe
3. Components of fuel tank/filter hose 4. Steel band type flexible ring clamps
5. Fuel filter 6. Fuel pump assembly
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7. Oil pump seal 8. Fuel tank assembly
9. Components of right fixing strap of fuel tank 10. Hex bolt with flat washer (40N·m)
11. B-type worm-driven hoop 12. Oil return hose
13. Components of left fixing strap of fuel tank 14. Air return tube mount B
15. Upper components of filler tube 16. Air return tube mount A
17. Snap spring under the oil filler shield 18. Oil filler shield
19. Snap spring above the oil filler shield 20. Components of oil filler cap
21. B-type worm-driven hoop 22. Lower section of filler tube
23. Filler tube lower shield
4. Notes for fuel tank removal
(1) Raise the vehicle by a lifter. Assistant support should be provided when supporting/raising the fuel
tank by a jack to avoid the fuel tank turning over.
(2) Do not attempt to repair a certain section of the rubber tube, but replace the entire tube instead.
(3) Cover the accessory and block the hole when the fuel system works to avoid dust and other dirties
entering the fuel system from open pipeline or entries.
(4) Take care to keep all components of fuel system clean.
Note:
(1) Reinstall the 4 M10 fixing bolts used for fuel tank, and tighten them by a tightening torque of 40N·m.
(2) Tighten all the clips and replace them if necessary.
(3) Check and conform all hoses are not circled or damaged during removal and installation.
(4) Open the ignition switch for 2s, and then close it for 10s. Then open it again and check if there is oil
leakage.
二、Electric Fuel Pump

1. Replacement of fuel filter
Removal of fuel filter
(1) Release the pressure of fuel system.
(2) Discharge the extra fuel into a suitable container.
(3) Dismantle the oil pipelines at the two sides of the fuel filter. Fig. 2-80 shows a fuel filter after removal.
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2. Installation of fuel filter
(1) Remove the shield of the new fuel filter.
(2) Connect the fuel hoses at the two ends of the fuel filter.
(3) Screw down the cap of oil filling pipe of the fuel tank.
(4) Reconnect the battery negative pole cable.
(5) Open the ignition switch for 2s, and then close it for 10s. Then open it again and check if there is fuel
leakage.
Note:
After the high pressure pipe is connected, pull it in negative direction and check if it has been connected
and if there is an about 3mm clearance.
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SectionⅥ Engine Cooling System
Warning:
Do not open the cover of radiator or loose the bolt for drainage when the engine runs or the radiator
is too hot, to avoid serious hurt caused by the boiling coolant and steam. Besides, the engine and
cooling system may also be damaged. Stop the engine and wait till it is cool. Otherwise, extra care
should be taken when you open the cover. Place a thick cloth on the cover, and rotate it
counterclockwise slowly and repeat this operation until the pressure is discharged. When you ensure
there is no pressure, press down the radiator cover by the cloth and then open it.
一、Maintenance Standards Details
Maintenance standards value refers to the standard valve opening pressure of the radiator cover:
74-103kpa. Limit: 64kpa.
二、Coolant
The coolant is antifreezer G11 with 8.5 L capacity.
三、On-vehicle Maintenance as Shown in Fig. 2-81.
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Fig. 2-81
1. Hex bolt with flat washer 2. Upper installation support 3. Upper installation bush 4. Radiator
assembly 5. Lower installation bush 6. Steel band spring clamp 7. Steel band spring clamp
8. Radiator water inlet pipe 9. Hexagon flange nut 10. Radiator water outlet pipe 11. Electric
fan with a fan cowl 12. Fuel tank assembly with overflow pipe 13. Hex bolt with flat washer
14. Hex bolt with flat washer
1. Inspection of the valve opening pressure of the radiator cover
Standard: 74-103kPa
Limit: 64kPa
2. Inspection of coolant
(1) Check if the coolant level is between “F” and “L”;
(2) Check if the coolant is mixed with engine oil.
3. Replacement of coolant
(1) Dismantle the bolt for drainage and radiator cover in order. Discharge the coolant in the radiator,
warm air blower and engine;
(2) Dismantle the drain valve of the cylinder body, and discharge the coolant in the water-cooled jacket;
(3) Dismantle the coolant reservoir and discharge the coolant;
(4) After the coolant is discharged, fill water from the radiator cover and clean the coolant pipeline;
(5) Screw down the drain valve of the cylinder body by a specified tightening torque: 40±5N·m.
(6) Confirm that the drain bolt of radiator has been screwed down;
(7) Install coolant reservoir;
(8) Fill the coolant to the radiator opening, and fill coolant into the reservoir to level “F”;
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Coolant: antifreezer G11. Total capacity: 8.5L
(9) Install the radiator cover;
(10) Start the engine and warm it up till the thermostat is opened;
(11) Stop the engine after it runs at a high speed for several times;
(12) When the engine is cool, remove the radiator cover, and then fill the coolant to the water filler of the
radiator. The coolant in reservoir should also reach level “F”.
四、Water Pump
1. Removal and installation
(1) Clean the foreign materials on the gasket by a scraper or a wire brush.
(2) Operation after installation and before removal:
① Discharge and filling of coolant. Smear sealant smoothly. It is not needed at some place.
② Removal and installation of timing belt cover.
(3) Install the water pump when the sealant is still damp.
Notes for installation:
2. Installation of water pump
五、Water Inlet and Outlet Hose

1. Operation after installation and before removal
(1) Discharge and filling of coolant (refer to related details in this chapter).
(2) Removal and installation of engine cover (refer to related details in this chapter).
(3) Removal and installation of lower housing plate.
(4) Removal and installation of battery and the bracket. To disassemble according to Fig. 2-81.
2. Notes for removal
(1) Disconnect the water inlet pipe and outlet pipe. Make alignment marks on the inlet and outlet pipes of
the radiator.
(2) Removal of water inlet pipe. Remove the installation bolt of the pressurizer tank resonator and
stagger the pressurizer tank resonator.
3. Notes for installation
(1) Firstly moisten the outer and inside installation surface of O ring, and then insert them.
(2) Installation of thermostat assembly (refer to details about engine)
1) Clean the foreign material on the gasket by a scraper or a wire brush.
2) Smear the specified sealant evenly. Sealant and sealing is not need at some place.
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3) Install the thermostat when the sealant is still damp (within 15 min).
(3) Connection of radiator water outlet and inlet pipes
1) Insert the water outlet and inlet pipes into the connectors or projected part of the drain pipe connector.
2) Install according to the alignment mark on the water inlet pipe and clamp.
六、Radiator
Removal and installation of radiator
(1) Operation before removal
Discharge the coolant
1) Remove the bolt for drainage and the cover of radiator in order, and then discharge the coolant in the
radiator, warm air blower and engine;
2) Dismantle the drain valve of the cylinder body, and discharge the coolant in the water-cooled jacket;
3) Dismantle the coolant reservoir and discharge the coolant;
4) After the coolant is discharged, fill water from the radiator cover and clean the coolant pipeline;
5) Remove the lower housing plate;
6) Remove the air cleaner;
7) Remove the battery and bracket.
(2) Operation after removal:
1) Smear the specified sealant on the screw thread of the drain valve on the cylinder body.
Sealant: Clear out the old sealant before using the new one LT5699. Tightening torque: 40±5N·m
2) Confirm that the bolt for drainage of the radiator cover has been screwed down;
3) Install the coolant reservoir;
4) Fill the coolant to the radiator opening, and fill coolant into the reservoir to level “F”;
Coolant：Antifreeze G11，Total capacity：8.5L

5) Install the radiator cover;
6) Start the engine and warm it up till the thermostat is opened;
7) Stop the engine after it runs at a high speed for several times;
8) When the engine is cool, remove the radiator cover, and then fill the coolant to the water filler of the
radiator. The coolant in reservoir should also reach level “F”.
9) ATF supplement and inspection;
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10) Install the lower housing plate;
11) Install battery and bracket;
12) Install the air cleaner.
(3) Removal steps (Fig. 2-82)
Removal and installation of electronic fan assembly
Removal of water inlet and outlet pipes of radiator. Firstly make alignment marks on the inlet and outlet
pipes and clamps of radiator.
Notes for installation:
Installation of radiator outlet pipe. Insert the hose into the radiator and the projected part of the engine
according to the alignment mark on the pipe clamp of the radiator.
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Section Ⅶ Intake and Exhaust System
一、Air Filter Assembly
Removal and installation (Fig. 2-82 shows the air filter assembly of LF630 engine).
Note: The filter core is made from waste paper and resin. Notes for operation:
① Do not inflict severe collision and load after assembly and removal.
② The core should be well cooperated with the housing below the air cleaner during assembly.
Fig. 2-82
1. Snap button 2. Hexagon flange nut 3. Air filter intake pipe assembly
4. Air filter assembly 4-1. Air filter upper cover components 4-2. Air filter core components
4-3. Air filter fixed spring 4-4. Air filter lower cover components 5. Hexagon bolt with flat washer
6. Engine intake hose assembly 6-1. Engine intake hose 6-2. B-type worm-driven hoop
6-3. Positive crankcase ventilation line 7. Hexagon bolt with taper elastic washer
8. Cavity resonator assembly 9. Hexagon flange nut
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二、Removal and Installation of Exhaust Pipe and Muffler
1. Removal and installation, (Fig. 2-83 shows the exhaust system of the LF630 engine).
Fig. 2-83
1. Small gasket 2. Hexagon flange bolt 3. Pre-purifier assembly 4. Hexagon bolt with taper elastic washer
5. Ball sealed pad 6. Rear muffler rubber suspension block 7. Front muffler rubber suspension block
8. Front muffler with purifier 9. Hexagon flange bolt 10. All-metal hexagon flange locknut
11. Hexagon flange nut 12. Dash panel lower heat shield of exhaust pipe 13. Front floor lower heat shield of
exhaust pipe 14. Lower heat shield of exhaust pipe fuel tank
15. Rear muffler assembly 16. Heat shield damping pad 17. Right rear girder lower heat shield of exhaust pipe 18.
Compressed spring bolt 19. Compressed spring
1. Warning
Too hot engine and exhaust system may cause severe hurt. Stop the engine until the engine and
exhaust system are cool. And then remove the exhaust system.
2. Inspection
Start the engine and check if there is leakage in the components of the exhaust system assemblies. In
case of a leakage, repair or replace it as necessary.
Check all components or assemblies. In case of open weld or damage, replace it if necessary.
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ChapterⅤ ABS
SectionⅠ Function and Composition of ABS
一、Function of ABS
① To improve stability of the vehicle;
② To ensure steering performance of the vehicle;
③ To guarantee shortest braking distance.
二、ABS Composition (in Fig. 3-1)

The ABS of LF630 sedan is composed of electronic control unit, hydraulic control unit, sensor and motor.
Motor
Fig. 3-1
1. Electronic control unit (ECU)
Electronic control unit is actually a microprocessor, which calculates the speed of the 4 wheels and
speed increase and decrease according to the signal from the sensor so as to determine the slide
situation and drive the solenoid valve and motor to increase, decrease and maintain the pressure and so
on.
2. Hydraulic control unit (HCU)
Hydraulic control unit is composed of two hydraulic circuits and solenoid valve, which calculates and
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determines slide situation to decide the ABS operation according to the signal from the sensor, and then
controls the program to start the solenoid valve and motor to increase, decrease and maintain the
pressure and so on.
3. Sensing
The sensing sends the signal from the gear rotation detection to ECU.
4. Motor
The motor rotates according to the signal of ECU. And the bearing transfers the rotation into straight
reciprocating motion to cycle the brake fluid.
SectionⅡ Principle of ABS
一、Control Principle of ABS

Fig. 3-2 shows the control principle of ABS.
Fig. 3-2
二、Operating Mode of ABS

1. Operating condition of regular brake (Table 3-1 and Fig. 3-3).
Table 3-1
Solenoid valve Electricity Solenoid valve condition
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Normally opened
Off Open
valve
Normally closed
Off Closed
valve
Table 3-3
The pressure of master pump will be transmitted to wheel slave cylinder through normally opened
valve to apply the brake. If no further braking is needed, the driver can reduce the pressure to the brake
pedal, which allows the brake fluid return to master pump for pressure decrease.
2. ABS operation (pressure decrease) condition (Table 3-2 and Fig. 3-4).
Table 3-2
Normally opened valve On Closed
Normally closed valve On Open
Fig. 3-4
If a vehicle is equipped with ABS and the braking pressure is too large, the friction coefficient will be
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decreased and the wheel speed will be decreased much quickly than the vehicle body. Finally the wheel
will be locked, which makes ECU send HCU a signal of pressure decrease to wheel. In order to
decrease the pressure of wheel slave cylinder, the normally opened valve will close and the normally
closed valve will open. Then the brake oil from wheel slave cylinder will return to low pressure
accumulator (LPA) temporarily, and return to master pump with the oil pump started by the motor. High
pressure accumulator (HPA) between LPA and master pump will decrease the high pressure pulse
produced by oil pump with the help of metering jet fluid resistance.
3. ABS operation (maintaining) condition (Table 3-3 and Fig. 3-5).

Table 3-3
Normally opened valve On Closed
Normally closed valve Off Closed
Fig. 3-5
The pressure of wheel slave cylinder is maintained by the closed normally opened valve and normally
closed valve, when proper pressure is applied to the salve cylinder through increase or decrease of
pressure.
4. ABS operation (pressure increase) condition (Table 3-4 and Fig. 3-6).
Table 3-4
Normally opened valve Off Open
Normally closed valve Off Closed
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Fig. 3-6
When the pressure is decreased, if too much brake fluid is discharged or friction coefficient is
increased, the pressure to every wheel should be increased. ECU will send HCU a signal of pressure
increase to wheel. In order to increase the pressure of wheel slave cylinder, the normally opened valve
will open and the normally closed valve will close. In case of pressure decrease, the brake fluid in LPA
will flow out under the pressure increase condition with rotation of motor and then into wheel slave
cylinders through the master pump and the normally opened valve. HPA between LPA and master pump
will decrease the high pressure pulse produced by oil pump with the help of metering jet fluid resistance.
Concerning operations described in item 2-4 above, ABS will work until the vehicle has been
completely stopped according to locking condition, so as to guarantee the safety and steering
performance.
三、EBD Control Mode (Fig. 3-7)
Fig. 3-7
EBD is to guarantee the operation stability. Rear wheel will be stopped after front wheel. As front brake
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does more work than rear brake, the rear wheel will stop first if it receives equal pressure. In order to
prevent it, the equipment, pressure reducing valve (P-Valve), to decrease the pressure of rear wheel is
needed. A special P-Valve is not necessary for the vehicle with ABS, as ABS can control the rear wheel
braking pressure with supplementary procedures and improve the operation stability.
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Section III Removal and Installation of ABS
一、Spare Parts Supply Condition

1. Difference between dry HECU and wet HECU (Fig. 3-8)
Dry Wet
Fig. 3-8
The biggest difference between dry HECU and wet HECU is the second circuit (between normally
closed valve and master pump) of dry HECU does not exhaust. As a result, only regular exhaust and
filling will be necessary for brake system after replacement in case of wet HECU; regular exhaust and
filling and that to the second circuit will be necessary for brake system after replacement in case of dry
HECU. Besides, there is a seal bolt for wet HECU and protection film for dry HECU.
2. Notes
If the bolt on wet HECU is off (e.g. during transportation), regular exhaust and filling for brake
system is necessary for first circuit, but not necessary for the second circuit.
二、Notes on Removal and Installation

1. Notes on HECU installation
(1) Remove the protection film on HECU, and confirm pipelines of master pump and wheel slave
cylinder before operation (master pump: MCP and MCS; wheel slave cylinder: FR, FL, RR and RL).
(2) Make sure the brake pipe is tightened and torque is 14N·m with a special tool, torque wrench or
other equipments.
(3) No foreign material is allowed in HECU holes and brake pipes, as shown in Fig. 3-9.
411
Fig. 3-9
2. Notes on HECU bracket assembly
(1) As installation error may occur for the frictional resistance of buffer pad when tightening (3) bolts,
lubricant not affecting physical property of buffer pad is preferred.
(2) For easy operation, (3) bolts can be inserted into the buffer pad on bracket and then to HECU.
(3) Make sure the tightening torque of (3) bolts is 20N·m with a special tool, torque wrench, as shown in
Fig. 3-10.
Fig. 3-10
3. Notes on HECU and bracket assembly installation
(1) Install brake pipe and bracket part to HECU and then install HECU to vehicle body with bolt special
for vehicle body fastness.
(2) Make sure the tightening torque of bolt special for vehicle body fastness is 23N·m with a special tool
or torque wrench.
(3) Make sure again the pipelines of master pump and wheel slave cylinder are installed correctly
(master pump: MCP and MCS; wheel slave cylinder: FR, FL, RR and RL).
(4) Tighten the loose brake pipe with a specified torque (140N·m) by a special tool or torque wrench.
412
4. Other notes
(1) Use diagnostic instrument to find out fault reason before repair.
(2) Wrap off spare part only before installation.
(3) Use original part only.
(4) Pay attention to cleanliness. Only use cloth except tweed.
(5) Clean the surface with cleanser without mineral oil before removal.
(6) Do not use compressed air or move the vehicle when system is opened.
(7) Block the hydraulic pressure outlets with plugs as soon as possible after removal of ABS assembly.
(8) Remove other parts hindering operation.
(9) Use DOT#4 brake fluid.
(10) Soak the seal component with brake fluid, not with engine oil or brake unguent.
(11) Check for leakage of connectors of all hydraulic pipes.
5. Replacement of HECU
(1) Remove connecting piece of pin 25 and wire harness of HECU in engine compartment when engine
stops, as shown in Fig. 3-11.
Fig. 3-11
(2) Remove the 6 M10×1 nuts of brake pipe of HECU with wrench 10 in a counterclockwise (clockwise
when installing) direction. Tightening torque of brake pipe is 14N·m.
(3) Remove the 3 bolts or nuts on bracket with wrench13 in a counterclockwise (clockwise when
installing) direction. Tightening torque of bolts or nuts for bracket fastness is 23N·m.
(4) Remove the 3 M6 bolts in HECU with 5mm hexagonal wrench in a counterclockwise direction after
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removal of products, as shown in Fig. 3-12
Fig. 3-12
（5）Remove the 6 bolts on wet HECU with 6mm hexagonal wrench in a counterclockwise direction, as
in Fig. 3-13.
Fig. 3-13
（6）Assemble the wet HECU and bracket with a 5mm tool (hexagonal wrench) by tightening the 3
inserted nuts M6 in clockwise direction, as shown in Fig. 3-14.
Fig. 3-14
（7）To install spare HECU, reverse the removal procedures of item (1) - (3) above.
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Section IV Fault Diagnosis and Troubleshooting
一、Fault Detection Procedure (Fig. 3-15)
Fig. 3-15
二、Notes on Fault Diagnosis (Table 3-5)

As ABS is controlled by the electronic hydraulic pressure, the phenomena in the following table are
normal under normal working condition of ABS, not faults.
Table 3-5
Phenomenon Description
System self-check Sometimes there will be sound like collision from the engine compartment after
sound engine is started. It is normal because it is caused by the ABS self-check.
1. Motor sound in ABS hydraulic unit;
2. Sound with brake pedal vibration;
ABS working sound 3. Suspension impact sound caused by braking or screak caused by friction
between wheel and ground when ABS works.
Note: Wheel may screak when ABS is working normally.
ABS works, but the Sometimes the braking distance of the vehicle with ABS will be longer than that of
braking distance is the vehicle without ABS on snow or sandstone road. The driver should be more
long. careful when driving on these roads.
三、Key Points on Maintenance of Dynamic Faults

Instantaneous poor contact may occur in the electronic control system, electrical circuit and signal input
and output areas, which may cause occasional dynamic fault or DTC during ECU self-check. If fault
cause continues, the abnormal part can be detected with reference to DTC table. As sometimes fault
cause vanishes itself, it is difficult to figure out the real cause.
415
In such a situation, faults can be simulated to check if the fault occurs again.
1. When vibration may be the main reason:
(1) Shake the connector lightly in all directions;
(2) Shake the harness lightly in all directions;
(3) Shake the sensor lightly in all directions;
(4) Shake the other moving parts (like wheel bearing) lightly.
Note: If the harness is twisted off or fractured for tight pull, it must be replaced with new parts. Especially
when vehicle is moving, the sensor will move up and down, which may cause instantaneous open/short
circuit. As a result, sensor signal check must be carried out when vehicle is moving.
2. When overheating or supercooling may be the main reason:
Heat the possibly faulted part with a blower; check for cold welding phenomenon with a cold spray.
3. When overlarge contact resistance of power supply circuit may be the main reason:
Open all electrical switches, including the headlight and rear defrosting lamp. If fault does not show
again, it can only be diagnosed and repaired when it comes out next time. Generally the occasional
dynamic fault will only get worse, not better.
四、ABS Fault Diagnosis and Troubleshooting

1. Check ABS warning lamp
Check if ABS warning lamp is turned on in the following ways
(1) Turn the vehicle key to connect the circuit, and then ABS warning lamp is turned on and then turned
off after 3 seconds.
(2) Fault exists if not the same with the situation in (1); check the DTC and refer to DTC Check Table.
(3) Refer to No DTC Fault Table if the warning lamp can not be turned on.
2. Regular Fault Table (Table 3-6).
Table 3-6
Warning lamp
Location Reason Structure
ABS
Brake pipe installation

Wheel locked, braking deviation
error Vehicle
Vehicle harness Off
Oil leakage of brake harness
ABS and EBD abnormal start
gear
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Wire installation error Unable to brake
Exhaust fault ABS performance decreased
Motor Motor fault ABS unable to start On Motor

ECU power cord fault ABS and EBD unable to start
Control valve power

ABS and EBD unable to start
cord fault
On ECU
ECU
ECU poor grounding ABS and EBD unable to start
ECU fault ABS and EBD unable to start
Motor power cord fault ABS unable to start On
Wheel
Sensor open/short One fault: ABS unable to start On speed
circuit sensor
Two faults: ABS/EBD unable to start On

Wheel speed
sensor Gear ring fault
Sensor disturbance One fault: ABS wrong start On
fault
Air gap fault Two faults: ABS and EBD unable to start On
3. DTC read and deletion without fault diagnostic instrument

（1）Purpose and condition of DTC read without diagnostic instrument
If no diagnostic instrument is available, ABS fault condition can be indicated and DTC can be read
through ABS warning lamp, so as to confirm and eliminate the fault. If the DTC is a 2 digital code, refer to
the number in the bracket of DTC Table in Section 24.
The use conditions are:
1) Speed is less than 2 km/h;
2) Not connected to fault diagnostic instrument;
3) Wire L (pin 7 in the internal diagnosis interface) is always grounded during diagnosis.
Besides, restore ECU mode of ABS to normal mode (diagnosis mode before) after DTC read.
Method: after diagnosis, disconnect wire L from ground, turn the key to off-power condition, and connect
again.
（2）Method of DTC read without fault diagnostic instrument

Read in the following steps if meeting the conditions of DTC read without fault diagnostic instrument.
The procedures in Fig. 3-16 are:
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Fig. 3-16
1) Ground wire L and turn the vehicle key to connect the circuit;
2) ABS warning lamp is turned on and then turned off after 3 seconds, which indicates the start of
diagnosis;
3) ABS warning lamp is turned off for 3 seconds, which indicates the DTC display stage;
4) DTC read;
5) ABS warning lamp is turned off for 3 seconds, which indicates the next DTC display or circular display
stage;
6) New DTC display and read, or circular display of previous DTC.
The meaning of marks in Fig. 3-16 is listed in Table 3-7.
Table 3-7
Symbol Symbol description Duration
T1 Symbol of diagnosis start; warning lamp flickers 3.0s
T2 Interval of different DTC 3.0s
T3 Warning lamp flash interval in case of DTC 0.5s
Interval of different digital place of a DTC (the ten’s place
T4 is displayed before the interval and the unit’s place is 1.5s
after the interval)
Take the procedure illustrated in Fig. 3-16 for example. In the display area of the first DTC, as
warning lamp blinks twice (each on and off is T3, 0.5 second) before T4 (1.5 seconds before warning
lamp is turned on), the first mark (ten’s place) of the 2 digital code is 2; as warning lamp blinks once after
T4 (1.5 seconds after warning lamp is turned off), the second mark of the 2 digital code (unit’s place) is 1;
418
as then warning lamp is turned off for 3 seconds (T2), the display of the first DTC is finished, and the
DTC is 21. Detailed description of the fault can be found in the DTC Table of Section 2.4. It is the same
with DTC 22.
（3）Deletion of DTC without fault diagnostic instrument

After DTC read and fault elimination according to DTC Table, previous DTC should be deleted
before next DTC check. The conditions of DTC deletion are the same with that of DTC read, as shown in
Fig. 3-17.
Fig. 3-17
Procedures in the figure are:
1) Step on the brake pedal, ground wire L and then turn the vehicle key to connect the circuit;
2) ABS warning lamp is turned on, and then is turned off after 3 seconds;
3) Release the brake pedal within 1 second after ABS warning light is turned off;
4) Release the pedal for about 1 second, and then press it again for about 1 second. Repeat this
procedure for 5 times; warning lamp is not turned off during this process;
5) ABS warning lamp is turned on, and then turned off after 3 seconds; DTC is deleted in this process.
After DTC deletion, restore ECU mode of ABS to normal mode. Operation process is the same with
that of DTC diagnosis. If no DTC is in ECU of ABS, ground wire L and turn the key to connect the circuit;
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the ABS warning lamp will flash in a way illustrated in Fig. 3-18, and meanings of symbols are the same
with that above.
Fig. 3-18
4. DTC Table
(1) DTC content is in Table 3-8.
(2) See Table3-9, Table 3-10, Table 3-11, Table 3-12, Table 3-13, Table 3-14 and Table 3-15 for DTC
Table.
Table 3-8
DTC Content DTC Content
Left front sensor open/short
C1 200 C1 206 Left rear sensor open/short circuit
circuit
Left front sensor or gear ring Left rear sensor or gear ring
C1 201 C1 207
disturbance disturbance
C1 202 Left front sensor air gap error C1 208 Left rear sensor air gap error
Right front sensor open/short Right rear sensor open/short
C1 203 C1 209
circuit circuit
Right front sensor or gear ring Right rear sensor or gear ring
C1 204 C1 210
disturbance disturbance
C1 205 Right front sensor air gap error C1 211 Right rear sensor air gap error
Too high battery voltage (17V Fault in solenoid valve fuse or
C1 101 C2 112
above) relay
Too low battery voltage (9.4V
C1 102 C2 402 Fault in motor fuse or motor
below)
Fault in ECU internal circuit or
C1 604
solenoid valve coil
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Table 3-9
C1 200 C1 203
DTC C1 206 C1 209 Note: If faults corresponding to more than 2 DTC can be
confirmed, delete the DTC (that can be deleted), drive the
vehicle at a speed of over 40 km/h, confirm the fault
Sensor open/short circuit: fault due to sensor
corresponding to this DTC again and refer to the recorded
Cause battery positive or negative pole short circuit
DTC (and confirm the same DTC).
or open circuit
Elimination
procedure
421
Elimination
procedure
422
Table 3-10
C1 202 C1 205 Note: ① Air gap is the gap between gear ring and sensor;
DTC
C1 208 C1 211 ② If faults corresponding to more than 2 DTC can be
Air gap error: no signal because of air gap too
Cause large or sensor short circuit (resistance is 0),
DTC (and confirm the same DTC).
or gear ring is not properly installed.
Elimination procedure
※. Air gap adjustment method
☞ Not to adjust the type of air gap, but to set automatically according to the tolerance of relevant part. As a
result, confirm the part with abnormal air gap and replace or adjust to specified air gap (by burnishing the
mounting surface contact area of sensor); a thin washer should be placed on the mounting surface of sensor
to adjust to specified air gap.
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Table 3-11
Note: ① Foreign materials, like engine oil and scrap iron in
gear may cause asymmetrical sensor signal;
② Air gap means the gap between gear ring and sensor;
③ If faults corresponding to more than 2 DTC can be
C1 201 C1 204
DTC confirmed, delete the DTC (that can be deleted), drive the
C1 207 C1 210
DTC (and confirm the same fault code).
Gear ring or sensor disturbance:

Cause
If nonstandard gear ring is installed
Elimination
procedure
424
Table 3-12
DTC C1 101 C1 102 Note: If faults corresponding to more than 2 DTC can be
Battery voltage abnormal: corresponding to this DTC again and refer to the recorded
Cause
Occurring when voltage too high or too low DTC (and confirm the same fault code).
Elimination
procedure
425
Table 3-13
DTC C2402 Note: If faults corresponding to more than 2 DTC can be

Cause Motor fuse/motor fault
Elimination
procedure
426
Table 3-14
DTC C2112 Note: If faults corresponding to more than 2 DTC can be

Valve fuse and relay faults: vehicle at a speed of over 40 km/h, confirm the fault
a) Main replay or fuse disconnection corresponding to this DTC again and refer to the recorded
Cause
b) Main relay short circuit
Elimination
peocedure
427
Table 3-15
DTC C1 604 Note: If faults corresponding to more than 2 DTC can be

Cause ECU internal circuit and valve coil faults
Elimination
procedure
5. No DTC Fault Table is in Table 3-16, Table 3-17, Table 3-18, Table 3-19 and Table 3-20.
428
Table 3-16
Fault Start the engine, but ABS warning lamp can not be turned on
① Fuse is blew out ② Bulb of ABS warning lamp is broken

Cause
③ Circuit is open ④ Warning lamp controller is broken
Elimination
procedure
429
Table 3-17
Fault Start the engine, but ABS warning lamp is always on
① Controller of ABS warning lamp is broken

Cause ② Return circuit of warning lamp controller is open
③ ECU is broken
Elimination
procedure
430
Table 3-18
Fault ABS works abnormally
① Sensor is damaged ② Sensor is not properly installed

③ Foreign material adheres to sensor ④ Wire harness of sensor is broken
Cause
⑤ Gear ring is broken ⑥ Wheel axle is broken
⑦ HCU of ABS is broken ⑧ ECU of ABS is broken
Elimination
procedure
431
Table 3-19
Fault Brake pedal play is too long
① Parking brake is not properly adjusted ② Brake fluid leaks

Cause ③ Friction plate of brake is severely worn ④ Normally closed valve can not be closed tightly
⑤ Air is in the system
Elimination
procedure
432
Table 3-20
Fault No fault code output (unable to communicate with fault diagnostic instrument)
① Fault diagnostic instrument is broken ② Fuse is blew out

Cause
③ Diagnosis wire is broken or connector is loose ④ ECU is broken
Elimination
procedure
433
五、Exhaust and Filling
1. Regular operation procedures (Fig. 3-19).
Fig. 3-19
Regular operation procedures of exhaust and filling:
A. Move vacuum device and brake oil filling device;
B. Start after connection of vacuum, brake oil filling devices and SDL;
C. Drive normally closed solenoid valve and use the first vacuum;
D. Excessive leak experiment;
E. Minim leak experiment after first vacuum separation;
F. Use the second vacuum and drive motor;
G. Reduce brake oil pressure after filling and pressure increase maintenance of brake oil, stop normally
closed solenoid valve and motor and adjust brake oil level;
H. Disconnect the connection of vacuum equipment and brake fluid filling equipment;
I. Cover the oil can lid/disconnect SDL;
J. Step into next step.
2. Equipment check
(1) The lower the vacuum degree, the better. Confirm that the oil gun should supply max l vacuum of
1mmHg.
(2) Check whether vacuum is formed in the bleed screw of hydraulic equipment (drum brake or caliper)
of rear wheel within the specified time. (Should below 5 ~ 10 mmHg after vacuum connection for 20 ~ 25
seconds.)
(3) Check whether working voltage to HECU is 10 ~ 12V as specified.
(4) Check cycle time (C/T) and if solenoid valve working time is in compliance with specification.
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1) C/T is below 90: keep solenoid valve working;
2) C/T is between 90 ~ 180 seconds: repeat the process of solenoid valve working for 2 seconds and
then stopping for 2 seconds;
3) C/T is above 180 seconds: set total working time of solenoid valve below 90 seconds.
3. Notes on exhaust and oil filling

(1) When filling brake oil, if not to maintain the filling pressure for a certain period, the oil level of the oil
can will fall after finish of filling. As a result, additional brake oil or filling pressure for a certain period is
necessary.
(2) Usually the marked time of regular operation is the cycle time.
(3) As the inside of spare HECU is wet, exhaust mode operation is not necessary (exhaust mode
operation is defined in item 5 (6)); exhaust can be carried out to all wheels directly (in order to meet
performance and pedal sentience, exhaust mode operation is preferred).
(4) HECU voltage of 10 ~ 12V is preferred during exhaust mode operation. As battery on vehicle is
used when using diagnostic instruments, there should be no problem. (If exhaust mode operation is
repeated with high voltage, ECU coil may be damaged.)
4. Exhaust fault confirm methods (Table 3-21)
Table 3-21
D Leak experiment
iffere
ECU operation Remark
nce Excessive leak Minim leak
Type
Case 1 Normal O.K O.K Case 1
Case 2 Normal O.K N.G Case 2
Case 3 Normal N.G N.G Case 3
Case 4 No O.K O.K Case 4
Case 5 No O.K N.G Case 5
Case 6 No N.G N.G Case 6
Case 1: Condition after normal operation.
Case 2: Bad connection condition of brake gear (HECU hole/brake pipe/brake hose); rework is
necessary.
Case 3: Similar to Case 2; but severe leak may make rework unable to be carried out.
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Case 4: Exhaust fault of HECU internal circuit; spongy pedal or enlargement of pedal play may occur
after one ABS operation. Rework is necessary.
Case 5: Synthetic fault of Case 2 and Case 4; rework is necessary.
Case 6: Similar to Case 5; but severe leak may make rework unable to be carried out.
5. Measures for exhaust and filling faults (dry inside of brake system).
(1) Fault confirmation. Confirm all connections from the master pump to wheel slave cylinder: HECU
hole, brake connection, brake hose connection, bleed screw of caliper and drum brake, etc.
(2) Reassemble according to specification for leak prevention after fault confirmation.
(3) Connect the reassembled equipment to connecting piece of pin 25 of ECU or connect diagnostic
instrument to wire K (pin 7). Special wire should be applied when connecting to connecting piece;
vehicle circuit should be connected or started when connecting to wire K (pin 7). The oil can of the
master pump should be connected to uninterruptible brake oil supply equipment, or there should be
always brake oil in the oil can.
(4) Diagnose HECU with the reassembled equipment and diagnostic instrument to check whether there
is still a DTC. DTC should be deleted first if it exists. (If fault of item (1) is not confirmed, fault
confirmation is also necessary.) If DTC can not be deleted, refer to “DTC Check Table” in Section 24 (If
there is fault in HU, motor and ECU, exhaust and filling in HECU can not be operated).
(5) After stepping on the brake pedal, open the bleed screw on the caliper or drum brake to exhaust the
inside air. This operation should be carried out for all wheels before that the brake fluid exhausted
through the bleed screw contains no air and the brake pedal is hard enough. When using the
reassembled equipment that can form vacuum or is filled with brake fluid, refer to item (10).
(6) Operate the exhaust mode with the reassembled equipment or diagnostic instrument and step on the
brake pedal, if there is no reaction force, repeat stepping on and releasing the pedal until the exhaust
mode is finished. (Exhaust mode: repeat the process of start and stop of normally closed solenoid valve
with interval of 2 seconds for 1 minute, and keep motor working. The repeat of stepping on and releasing
of pedal should be carried out on the normally closed solenoid valve while motor is operating.)
(7) Rework of operation of item ⑤ (exhaust) should be carried out for all wheels.
(8) Measure the play of brake pedal; if not in compliance with specification, repeat the processes in item
⑥ (exhaust mode) and item ⑤ (exhaust). If the brake pedal play still does not comply with specification
after over 10 repeats of exhaust mode and exhaust operation, replace with spare HECU (wet) and then
restart the operation.
(9) Connect the reassembled equipment and diagnostic instrument to HECU to recheck whether there is
still a DTC. If yes, delete the DTC, and then disconnect the reassembled equipment or diagnostic
instrument.
(10) When using other reassembled equipments (that can produce vacuum or is filled with liquid), the
methods are as follows.
1) Operate in process as described in item (1) - (4) above;
2) The inside of brake system will form vacuum after the vacuum pump works for about 60s.
3) Exhaust mode in item ⑥ above should be conducted 10 seconds before vacuum separation.
4) Do not repeat stepping on and releasing the pedal.
5) Fill brake fluid for over 20 seconds during vacuum separation (7bar/100Psi above).
6) End brake fluid filling and exhaust mode.
7) Operate in process described in item ⑧ - ⑨.
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6. Measures for faults in inspection and ABS operation experiment (wet inside of brake system).
(1) Connect reassembled equipment or diagnostic instrument. The following conditions should be met:
1) Special wire should be applied when connecting to pin 25 connecting piece of ECU.
2) When connecting to wire K (pin 7), the circuit of vehicle should be connected or the vehicle should be
started.
3) Oil tank of the master pump should be connected to uninterruptible brake oil supply equipment, or
there should be always brake oil in oil can.
(2) Diagnose HECU with reassembled equipment and diagnostic instrument to check if there is still a
DTC.
1) DTC should be deleted first if it exists.
2) If DTC can not be deleted, refer to “DTC Check Table” in Section 24 (If there is fault in HU, motor and
ECU, exhaust and filling in HECU can not be operated).
(3) After stepping on brake pedal, open the bleed screw on the caliper or drum brake to exhaust the air
inside.
This operation should be carried out for all wheels before that the brake fluid exhausted through the
bleed screw contains no air and brake pedal is hard enough.
(4) Operate the exhaust mode with the reassembled equipment or diagnostic instrument and step on
brake pedal, if there is no reaction force, repeat stepping on and releasing the pedal until exhaust mode
is finished.
(5) Rework of operation of item (3) (exhaust) should be carried out for all wheels.
(6) Measure the play of brake pedal; if not in compliance with specification, repeat the processes in item
(4) (exhaust mode) and item (3) (exhaust). If the brake pedal play still does not comply with specification
after over 10 repeats of exhaust mode and exhaust operation, replace with spare HECU (wet) and then
restart the operation.
(7) Connect the reassembled equipment and diagnostic instrument to HECU to recheck whether there is
still a DTC. If there is still a DTC, disconnect the reassembled equipment or diagnostic instrument.
437
Appendix I:
Fault Cases and Mistaken Repair Cases
HECU mistaken repair cases:
1. HECU replacement concerning ABS working sound
Case of HECU replacement for misjudging sounds of solenoid valve and motor as fault when ABS is
working
It is normal that there is noise during brake pressure decrease or increase when ABS is working. The
volume of noise varies according to different pressures to all wheels. It is not a fault, which should be
explained to clients.
When ECU diagnoses whether motor is working at the vehicle speed of 10 km/h for the first time after
start, a sensitive client may hear noise, which is also a normal ABS working condition.
2. HECU replacement concerning EBD working sound
Case of HECU replacement for misjudging “click” sound from rear wheel as fault when braking.
ABS can work as EBD. When rear wheel is blocked before front wheel, ABS will reduce the brake
pressure of rear wheel, which may cause noise. It is normal.
3. HECU replacement concerning braking deviation
Case of HECU replacement concerning the phenomenon that vehicle drifts to one side when braking
ABS is an auxiliary brake equipment to calculate the speeds of all wheels by ECU and maintain the best
brake force and operation stability. When a fault occurs to HECU, ECU will turn on the warning lamp
after diagnosis. As a result, if braking deviation occurs while ABS warning lamp is not turned on, other
hydraulic brake equipments should be checked.
Braking deviation may occur when ABS is working if brake hose is mistakenly assembled.
4. Case of replacement concerning that ABS works during low speed (below 40 km/h) brake
Case of HECU and sensor replacement concerning that ABS works during every low speed brake.
ABS may work during low speed braking according to road condition and brake pressure. If ABS works
every time, check whether the air gap of sensors of all wheels is too large, whether the ring gear is
disturbed and damaged.

Air gap adjustment method: After confirmation of part with abnormal air gap, replace or burnish the
mounting surface (contact area) of sensor and adjust to the specified air gap; when disturbance occurs,
a thin washer should be placed on the surface of sensor and then adjust to specified air gap.
438
Appendix II:
ABS Common Sense
1. If braking distance will be shorter after installing ABS?
According to experimental statistics, the braking distance will be shorter (about 5% ~ 20%) on most
roads; but it can be longer on some special roads (like snow, non-asphalt and uneven roads), but with
stable steering.
2. What are the main purposes of ABS?
The main purpose of ABS is to prevent block. The functions are as follows:
(1) To stabilize the vehicle when braking
(2) To control the direction of the vehicle during braking to avoid collision
(3) To maintain the best brake pressure regardless of the skill of driver
3. Why ABS warning lamp is turned on?
After the vehicle is started, warning lamp will be turned off if no fault is detected by the self-diagnosis of
ECU of ABS. If warning lamp is turned on or can not be turned off when vehicle is running, the ABS is
abnormal and ABS check in appointed service factory is necessary. When warning lamp is turned on
and ABS is abnormal, the brake system still has the basic braking ability.
4. Will no accident happen if ABS is installed?
ABS is an equipment to improve driving safety, not to avoid accident caused by driving mistake or traffic
condition. As a result, do not depend too much on ABS. Please always drive safely.
5. Is it caused by ABS that the vehicle drifts to one side when running on a slippery road?
This is because the friction coefficients of the left and right wheels are different. ABS can stabilize the
vehicle in this situation, but the driver should also control the steering wheel to avoid accident.
6. The vehicle will drift before braking when turning on a slippery road. Does ABS work if to brake now?
Definitely ABS will work effectively and may stabilize the vehicle according to the speed, but the position
of vehicle can only be adjusted slightly even ABS works because the outward force is too large for the
inertia. Usually there are two kinds of forces during turning: one is needed when running and braking; the
other is needed when turning and stabilizing. Actually running, braking and turning of the vehicle are
coordinated by the two kinds of forces above; and they are in inverse proportion to each other. As a
result, the brake force will increase while the turning and stabilizing force will decrease if to brake when
turning. The two kinds of forces can be adjusted to the best on the vehicle with ABS; but they can not be
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adjusted on the vehicle without ABS, which will weaken its steering performance and stability.
If the two kinds of forces are too small (For example, the vehicle will leave the running route as the
speed is too high when drifting), the force to adjust the vehicle is too small, the ABS effect is not obvious.
In a word, deceleration in advance and safe turning is the best solution.
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Appendix III: ABS Interior Hydraulic Pressure Flow Diagram
Fig. 3-20
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Appendix IV: MGH-25 ABS ECU Connector Pin Layout
Fig. 3-21
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Appendix V: Electric Circuit Diagram
Fig. 3-22
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ChapterⅤ Electrical System
General rules Troubleshooting
I. Appearance inspection before repair

1. Check for relevant fuses and relays.
2. Check for possible damage, charging state, surface cleanness and harness connector tightening of
battery;
Notes:
(1) When the battery has a loose earth connection, do not attempt to start up the engine, or the
connection will be seriously damaged.
(2) If the earth connection is not disconnected, quick charge is forbidden, otherwise damage will bring to
diodes of AC generator.
3. Check for belt tightness of AC generator;
II. Operating condition of harness connector

1. Clean and tight connector terminal.
2. All connectors equipped with pushing separated latch fitting (A). (Fig. 4-1)
Fig. 4-1
3. Some connectors have clips for fixing the connector onto the vehicle body or other assembly, noted
that the clips secure through reverse buckling.
4. Some connectors are equipped with double self-locking, which must be unlocked before removing the
connector from its mount (A).
5. To separate connectors, pulling the harness should be avoided, instead, grab the connector (for the
ones with self-locking, unlocking is required) to remove it from the mount (A). (Fig. 4-2)
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Fig. 4-2
6. As for the ones with protective plastic or rubber sleeve, install the sleeve while removing. (Fig. 4-3)
Fig. 4-3
7. Before connecting connectors, make sure the terminal (B) locates at its origin, free from bending or
other distortion; regarding some multihole connectors, make sure the socket is filled with grease
(waterproof interface excluded). (Fig. 4-4)
Fig. 4-4
三、Before repair
1. Check for tightness of retainer (A) and rubber seal (B). (Fig. 4-5)
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Fig. 4-5
2. Insert the connector directly, to ensure reliable locking.

3. Secure the lead at designated mounting position with the help of the binding belt for each lead.
4. Remove the wire clip with care, be aware not to damage its latch fitting (A). (Fig. 4-6)
Fig. 4-6
5. Slide the pliers down to the bottom of the wire clip, through the hole at a certain angle, and then seize
up the expansion piece, so as to loose the wire clip. (Fig. 4-7)
Fig. 4-7
6. After fixing the wire clip, make sure that it does not interfere with other movable components.
7. Keep the harness away from exhaust pipes and other heating components, edge components, and
screws or bolt mounting positions.
8. Locate the gum cover right into the groove of corresponding mounting hole, and be aware not to
distort the gum cover (B). (Fig. 4-8)
Fig. 4-8
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9. Use of lead or connector with cracking insulation is forbidden, in case of cracking, do replace it with a
new one or wrap the cracking with electrical adhesive tape to ensure a good insulation.
10. After installing each part, make sure that no lead is caught below the part.
11. When using electrical instrument for equipment testing, follow the guidance of this manual.
12. Make the probe of tester cut in from the lead side (waterproof interface excluded). (Fig. 4-9)
Fig. 4-9
13. Apply the probe with conical tip. (Fig. 4-10)
Fig. 4-10
Note: Perforating the lead insulation should be avoided, since the perforation will lead to poor electrical
connection or intermittent electrical connection fault.
14. When testing the connector terminal of any control module or unit, insert the acuminate probe gently
into the connector from the lead side till get to the terminal face of lead. (Fig. 4-11)
Fig. 4-11
15. Some interfaces have back filled with grease, make refill when necessary, if the grease is
contaminated, change it. Refer to Fig. 4-12.
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Fig. 4-12
四、Troubleshooting and steps
1. Fault verification
Switch on all components of faulty circuit to verify the fault, and pay attention to symptoms. Before locate
the fault, do not start dismantling or testing.
2. Analysis based on principles
Refer to the schematic diagram to determine the faulty circuit. Start from the power supply, and check
each component along the current path, till the earth, to figure out the operating principle of circuit. If
there is more than one faulty circuit at the same time, then fuse or earth is likely cause. Figure out one
cause or more of the fault, basing on symptoms and understanding to the operating principle of circuit.
3. Insulate the malfunction during circuit testing, to check up the diagnosis made in step 2. Mind that
organized and concise steps are critical for troubleshooting, i.e. first test the most probably faulty point
by way of the approachable points.
4. Trouble handling
Repair at once when the fault is identified. Use the right tools in accordance with safe operation steps.
5. Confirmation of normal operation
Switch on all components along the repaired loop under all operating modes to make sure that all faults
are eliminated. If the fault is a blown fuse, then testing of all circuits connected by the fuse is required.
Make sure no new fault arises, and the original fault does not occur again.
五、Troubleshooting with DTC

1. Vehicle entry
① Make registration
② Clean the car
③ Make a record of current environment
2. Trouble record and analysis
Make an inquiry on trouble details, like the status and environment when the trouble occurs.
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3. Symptom verification and DTC inspection
① Check the battery voltage during engine flameout
② Check the harness, connector, and fuse
③ Run the engine at normal operating conditions, verify symptoms and conditions, make DTC
inspection according to the DTC attached.
4. Use of DTC or trouble symptom table
Work out investigational procedures and scope of systems and components concerned with the help of
DTC or trouble symptom table based on DTC data or symptoms.
5. Electrical check
Locate and figure out further causes of trouble in this way.
6. Repair
Repair damaged systems and components.
7. Validation test
Make sure if the fault is eliminated under identical environment or conditions.
8. Maintenance record
Record and file off for treatment.
六、Fuse check and replacement
A type (blade) Fig. 4-13
Fig. 4-13
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B type blade Fig. 4-14
Fig. 4-14
C type blade Fig. 4-15
Fig. 4-15
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SectionⅠ Instrument Cluster
一、Overview
Fig. 4-16
1. Engine tachometer 2. Engine OBD indication
3. Engine coolant overheated indication 4. Oil pressure insufficient indication
5. Charging warning 6. Subtotal odometer adjusting rod
7. Engine coolant temperature indication 8. Subtotal odometer
9. Accumulated odometer 10. Door ajar and reverse radar indication
11.Fuel indication 12. Clock adjusting rod
13. 120km/h speed warning 14. Brake fluid warning
15. Seat belt reminder 16. Insufficient fuel warning
17. Speedometer 18. ABS fault warning
19. Parking brake on-position indication 20. BCM fault warning
21.Air bag fault warning 22. Left turn signal light indication
23.Master lighting switch indicator 24. Headlight low beam indication
25.Headlight high beam indication 26. Clock
27.Rear fog light 28.Right turn signal light indication
29.Shift indication 30. Luggage boot ajar indication
31.Rear defroster indication 32.Fault warning indication excluding engine OBD
The instrument cluster as shown in Fig. 4-16 falls into electromechanical equipment, locating right ahead
of the driver, above the steering column, composed of installation parts, electrical connections and so on.
All circuits of the instrument cluster combine to form a single harness, which is connected by interfaces
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at the back of cluster housing. All instruments and indicators are under good protection behind a
transparent plastic sheet, obviously seen in front of gauge cover. Behind the transparent plastic sheet
are protective cover and panel of instrument cluster. The light screen is integrated into the protective
cover, to keep the instrument face unaffected from ambient illumination and reflection, so as to ease the
dazzle. The instrument cluster panel and dial enjoy multi-layer structures. In the panel close to the center,
there are two big round opening, through which, two master instruments (tachometer and speedometer)
can be seen; on the centers of the two master instruments, there are LCD displays, each display has two
isometric square panes, through which, two minor instruments (fuel gauge and engine coolant
temperature gauge) can be seen; there is a display under the two minor instruments, through which
mileage can be read. Vocal warning is also integrated into the instrument cluster. Dark coloring of the
panel facilitates to recognize that the face and instrument dial face consist of multiple layers with surface
layer or covering layer. The surface layer is semitransparent of dark color, which can prevent the
vagueness of cluster component encapsuled with unlighted indicators, while the semitransparent feature
makes indicators and icons visible when lighted. Graphs, graduations, and figures are also
semitransparent, lighted from the back; while the white instrument pointer is lighted from the inside.
Below the plastic sheet of instrument cluster along the central position is a little plastic button switch for
odometer and mileometer, which protrudes over the sheet surface through the special hole penetrating
the sheet. By utilizing integrated circuit and PCI data bus, partial information from the network of
instruments and indicators are controlled by the instrument cluster, and some information is directly input
from corresponding instrument and indicator for function.
Table 4—1
Engine coolant
Insufficient fuel Battery charging Oil pressure insufficient Brake system fault
overheated
warning warning indication warning
indication
Parking brake Engine OBD ABS fault warning Seat belt reminder
on-position indication indication indication
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Rear defroster Turning light Turning light Hazard warning light Headlight high
indication indication, L indication, R indication beam indication
Fault warning
Headlight low beam Master lighting
Rear fog light indication indication excluding
indication switch indicator
engine OBD
……
120 km/h speed Luggage boot ajar Reverse radar range

Door ajar indication ……
warning indication display indication
The instrument cluster is lit to have necessary visibility by adjustable LED from the back. Each
indicator of instrument cluster is lit by special LED. All LED are wholly welded to the circuit board at the
back of the cluster housing. The instrument cluster is connected to the electrical system of the complete
vehicle with connecting circuits, which are integrated into the vehicle harness and go along different
paths, secured in varied ways.
二、Placement
As shown in Fig. 4-17 and Fig. 4-18
Fig. 4-17
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Front seat belt lock
图 4-18
三、Terminal end voltage

1. As shown in Fig. 4-19
Fig. 4-19
2. For terminal description, refer to Table 4-2
Table 4-2
Testing
Wire color Terminal description Test condition Standard value
terminal
Ignition switch ON, indicator lit → Less than

A1—body Y/W SRS air bag fault signal
unlit 1V→10～14V
Parking brake indication 10～14V→less

A3—body Y/B Braking indicator unlit → lit
signal than 1V
Ignition switch ON, indicator lit → Less than

A4—body W/G ABS brake indication signal
unlit 1V→10～14V
Driver’s seat belt status Ignition switch ON, driver’s seat 10 ～ 14 V → less
A6—body Y/U
signal belt buckle open → in than 1V
A7—body R/Y BCM fault warning signal BCM Malfunction indicator light Less than
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unlit → lit 1V→10～14V
A9—body B Instrument cluster grounding Always Less than 1Ω
A10—body W/B LIA BA9 signal input Reverse radar in operation LIA signal
Less than
A12—body V/W Braking fault indication signal Braking indicator unlit → lit
1V→10～14V
Front door open, close status Less than

A13—body S Door open lit → door close unlit
indication, L 1V→10～14V
Front door open, close status Less than

A14—body S/B Door open lit → door close unlit
indication, R 1V→10～14V
Rear door open, close status Less than
A15—body S/G Door open lit → door close unlit
indication, L 1V→10～14V
Rear door open, close status Less than
A16—body S/Y Door open lit → door close unlit
indication, R 1V→10～14V
Testing
terminal
Less than
A17—body R Lamplet power signal Lamplet switch OFF→ON
1V→10～14V
Less than
A18—body G/Y Battery power B+ Always
1V→10～14V
A19—body V/B Engine power IG1 Always Less than 1Ω
A20—body V/B Engine power IG1 Always Less than 1Ω
Ignition switch ON, turn the

A21—body O/G Speed signal (input) Less than 1Ω
driving wheel slowly
Pulse signal
A22—body W/B Engine rotation speed signal Engine runs
generated
A23—body W/U Fuel indication signal Always Less than 1Ω
Engine coolant temperature Engine runs, coolant temperature Pulse signal

A24—body N
signal rises generated
Ignition switch ACC, low beam Less than
B3—body R/B Low beam indication signal
Ignition switch ACC, high beam Less than
B4—body P/G High beam indication signal
Daytime light indication Ignition switch ON, daytime light Less than
B5—body Y/W
signal unlit → lit 1V→10～14V
Less than
B6—body G/R Lamplet power signal Lamplet switch OFF→ON
1V→10～14V
Generator charging indicator Engine runs, charging indicator Less than
B8—body V/G
signal unlit → lit 1V→10～14V
Oil pressure warning lamp lit → Less than
B9—body B/W Oil pressure signal
unlit 1V→10～14V
B10—body G/B Engine fault signal Ignition switch ON, indicator lit → Less than
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unlit 1V→10～14V
Ignition switch ON, rear fog light Less than

B11—body Lg/W Rear fog light power signal
Luggage boot ajar warning Less than
B12—body S/V Luggage boot opens → closes
indication signal 1V→10～14V
Less than
B13—body N/W Rear defroster indication Rear defroster indicator unlit → lit
1V→10～14V
SVS engine fault warning Less than
B14—body G SVS indicator lit → unlit
excluding engine OBD 1V→10～14V
Ignition switch ON, turning signal Less than
B19—body R/Y Turning signal, L
light, L OFF→ON 1V→10～14V
Ignition switch ON, turning signal Less than
B20—body N/Y Turning signal, R
light, R OFF→ON 1V→10～14V
Less than
B21—body G Self-locking output signal Unlock → lock
1V→10～14V
四、Trouble Symptom Table 4-3
Table 4-3
Symptom Cause Symptom Cause
1 Faulty fuse
1 1 Faulty speed sensor
2 Faulty wiring and 2 Speedometer
Instrument cluster 2 Faulty wiring and connector
connector fault
does not work 3 Faulty instrument cluster
3 Faulty instrument cluster
1 Faulty engine or ECM
1 Faulty fuel level sensor
3 2 Faulty wiring and 4 Fuel gauge
2 Faulty wiring and connector
Tachometer fault connector fault
1 Faulty coolant temperature
6 Reverse radar 2 Faulty BCM controller
5 sensor
alarm buzzer 3 Faulty reverse radar probe
Water thermometer 2 Faulty wiring and
does not work 4 Faulty reversing switch
fault connector
properly 5 Faulty key unlocking alarm switch
1 Faulty door lamp switch of
7 four doors 1 Faulty door lamp switch of four
8 Door ajar
Seat belt reminder 2 Faulty air bag ECU doors
buzzer does not
buzzer does not 3 Faulty wiring and 2 Faulty wiring and connector
work properly
work properly connector 3 Faulty instrument cluster
五、Circuit check pof instrument cluster

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1. Instrument cluster doesn’t work
(1) Check steps
1) Check the power (60A) fuse of driver’s cabin (located on the distribution box inside the engine room).
If it is in a normal condition, go to step 2), if not, change the fuse of instrument.
2) Check the live (10A) fuse of instrument cluster (located on the fuse box of instrument desk). If it is in a
normal condition, go to step 3), if not, change the fuse of instrument.
3) Check the ignition (5A) fuse of instrument cluster (located on the fuse box of instrument desk). If it is in
a normal condition, go to step 4), if not, change the fuse of instrument.
4) Check the instrument cluster.
① Remove the instrument cluster, ignition switch on-position, check the voltage between connector
terminals A18, A19 and A20 of instrument cluster and the body, normally around 10～14V.
② Check the resistance between connector terminal A9 and the body, normally less than 1Ω. If it is in a
normal condition, replace the instrument cluster, if not, repair or change the wire and connector.
(2) Check the circuit as shown in Fig. 4-20.
2. Speedometer fault
(1) Check steps
1) Check the power input end of speed sensor.
Ignition switch ON-position, check the voltage between 1-T2 and the body, normally around 10～14V.
If it is in a normal condition, go to step 2), if not, repair or change the fuse, wire and connector.
2) Check the ground end of speed sensor as shown in Fig. 4-20.

Connector A
Fig. 4-20
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Check the resistance between 2-T2 and the body, normally less than 1Ω. If it is in a normal condition, go
to step 3), if not, repair or change the wire and connector.

Shift lever N-position, lift front wheels with lifter, ignition switch ON-position, check the voltage
between harness terminals A21 and A9 of instrument cluster when wheels turn slowly, normally, pulsed
voltage peaking around 5～14V generated.
If it is in a normal condition, replace the instrument cluster, if not, repair or change the wire and
connector as well as the speed sensor.

Connector A
Fig. 4-21
3. Tachometer fault
(1) Check steps
1) Check rotation speed signal output of engine ECM.
Check the voltage between connector terminals A22 and A9 of instrument cluster when engine runs,
normally, pulsed voltage peaking around 5V generated.
If it is in a normal condition, replace the instrument cluster, if not, repair or change the wire, connector or
electronic injection system.
2) Check the circuit as shown in Fig. 4-22.
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Connector A
Fig. 4-22
4. Fuel gauge fault
(1) Check steps
1) Check the resistance of fuel level sensor.
Disconnect fuel pump harness connector F11, check the resistance between connector terminals 2-F11
and 3-F11 of fuel level sensor when the floater of fuel level sensor is between E and F. Resistance
corresponding to floater position F is around 1～5Ω, while resistance corresponding to floater position E
is around 112～116Ω.
If it is in a normal condition, go to step 2), if not, change the fuel level sensor (located on fuel pump).
2) Check the wiring and connector between instrument cluster and fuel pump.
① Disconnect the instrument cluster harness connector, fuel pump harness connector F11 remains
disconnected.
② Measure the impedance between A23 and 3-F11, normally less than 1Ω.
③ Measure the impedance between harness terminal A9 and the body ground, normally less than 1Ω.
④ Measure the impedance between instrument cluster terminal A23 and the body, normally more than
100KΩ.
⑤ Measure the impedance between instrument cluster terminal A9 and the body, normally more than
100KΩ.
connector.
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Connector A
Fig.4-23
5. Water thermometer fault
(1) Check steps
1) Check the coolant temperature sensor.
Disconnect the harness connector of engine coolant temperature sensor when the coolant temperature
is at 90℃, the resistance between the signal wire terminal of coolant temperature sensor and the body
should be around 75～98Ω.
If it is in a normal condition, go to step 2), if not, change the coolant temperature sensor.
2) Check the wiring and connector between the instrument cluster and the coolant temperature sensor.
① Disconnect the harness connector of instrument cluster, the harness connector of engine coolant
temperature sensor remains disconnected.
② Check the impedance between the harness terminal of instrument cluster foot A24 and engine ECM
harness foot 65, normally less than 1Ω.
③ Measure the impedance between the instrument cluster foot A24 and the body, normally more than
100KΩ.
connector.
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Connector A
Fig.4-24
6. Door lamp alarm buzzer does not work properly
(1) Check steps
1) Check left front door lamp switch
Open → close left front door, check the on off state between the instrument cluster A13 and the body,
normally should be from on (and resistance less than 1Ω) → off (resistance more than 100 KΩ).
If it is in a normal condition, go to step 2), if not, change left front door lamp switch.
2) Check right front door lamp switch.
Open → close right front door, check the on off state between the instrument cluster A14 and the body,
If it is in a normal condition, go to step 3), if not, change right front door lamp switch.
3) Check left rear door lamp switch
If it is in a normal condition, go to step 4), if not, change left rear door lamp switch.
4) Check right rear door lamp switch
If it is in a normal condition, go to step 5), if not, change right rear door lamp switch.
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5) Check luggage boot lamp switch
Open → close luggage hood, check the on off state between the instrument cluster B12 and the body,
If it is in a normal condition, forward to the next step, if not, change luggage boot lamp switch.
(2) Check the circuit as shown in Fig. 4-25
Fig. 4-25
7. Driver’s seat belt reminder buzzer does not work properly, as shown in Table 4-4.
Table 4-4
Symptom Cause
Driver’s seat belt reminder
2 Faulty air bag ECU
buzzer does not work
properly
4 Faulty seat belt buckle switch
六、System component check

1. Check the speedometer as shown in Fig. 4-26.
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Digital multimeter
Fig. 4-26
A: Speed sensor maintenance wire socket

B: Speed sensor
C: Speed sensor signal serial port
D: Speed sensor power serial port
E: Speed sensor ground serial port
(1) Prepare maintenance wire and numeral multimeter;
(2) Lift the front of vehicle, reliable support required;
(3) Ignition switch ON-position, shift lever neutral-position;
(4) Turn the wheel, check with multimeter if the voltage is within 0-5V or exceeding the range, if no signal
is detected, change the speed sensor, if the condition is normal, go to step (5);
(5) Observe the speedometer, if the pointer does not work properly, change the instrument cluster.
2. Check the output status of speed signal
(1) Prepare maintenance wire and numeral multimeter;
(2) Lift the front of vehicle, reliable support required;
(3) Ignition switch ON-position, shift lever neutral-position;
(4) Drive the car at 10km/h, and check the voltage between connector terminals 10-C7 and 1-C7 of
instrument cluster, normally around 5～14V with a vibration frequency of 14 times/s, if the response is
abnormal, change the instrument cluster or speed sensor.
Note: Do check the output signal with ignition switch ON-position and harness connector connected.
3. Check the tachometer
Start the engine at DC 13.5V±0.5V, ambient temperature 25℃±5℃, externally connect with trouble
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diagnostic instrument to measure the rotation speed, the value measured should correspond to the
instrument display within a permissible range, as shown in the table below.
Tachometer permissible range (see Table 4-5)
Tavle 4-5
Value
measured Instrument display (rpm)
(rpm)
1000 900～1100
3000 2800～3200
5000 4800～5200
4. Check the fuel gauge
(1) Disconnect the harness connector of fuel level sensor, turn the ignition switch ON-position, check the
pointer of fuel gauge, normally at position E;
(2) Connect the connector terminals 2-F11 and 3-F11 at the side of fuel level sensor wire, ignition switch
ON-position, check the pointer of fuel gauge, normally at position F;
5. Check the fuel level warning lamp, disconnect the harness connector of fuel level sensor, turn the
ignition switch ON-position, normally the pointer of fuel gauge should be at position E, fuel level warning
lamp lit.
6. Check the water thermometer
(1) Disconnect the harness connector of coolant temperature sensor, turn the ignition switch ON-position,
check the pointer of water thermometer, normally at position C;
(2) Connect the connector terminal at the side of coolant temperature sensor wire to the body, and check
the pointer of water thermometer, normally at position H;
7. Check the seat belt reminder warning lamp
(1) Turn the ignition switch ON-position, driver’s seat belt buckle open, check the seat belt reminder
warning lamp, normally lit;
(2) Turn the ignition switch ON-position, driver’s seat belt buckle in, check the seat belt reminder
warning lamp, normally unlit;
(3) Disconnect the buckle switch connector, and connect the connector terminal at the side of buckle
switch wire to the body. Turn the ignition switch ON-position, driver’s seat belt buckle in, check the seat
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belt reminder warning lamp, normally lit;
8. Check the oil pressure warning lamp
Disconnect the harness connector of oil pressure warning lamp, ignition switch ON-position, connect the
connector terminal at the side of oil pressure warning lamp switch wire and the body, normally, the
warning lamp should be lit.
9. Check the oil pressure warning lamp switch
Disconnect the harness connector of oil pressure warning lamp, and check the conductivity between the
terminal of oil pressure warning lamp switch and the body. When the engine shuts down, the wiring
between terminal and body should be conducted; when the engine runs, the wiring between terminal and
body should be not conducted.
10. Check the door lamp alarm buzzer
Check the working condition: Ignition switch at ON (IG1) position, if one of the four doors is unclosed, it
will buzz, till one condition is eliminated, buzz stops.
11. Check the brake warning lamp
(1) Check the parking brake warning lamp: Disconnect the parking brake switch
Connect the connector terminal at the side of parking brake switch wire and the body with harness
connector, ignition switch ON-position, check the parking brake warning lamp, normally lit;
(2) Check the brake fluid level warning lamp: Disconnect the connector of brake fluid level warning lamp,
short-connect the connector terminal at the side of parking brake switch wire, ignition switch ON-position,
check the brake fluid level warning lamp, normally lit.
12. Check the brake fluid level warning switch: Remove the fluid reservoir lid and the cleaner, disconnect
the harness connector of brake fluid level warning switch, and check the conductivity between the
terminals of brake fluid level warning switch, normally not conducted while floater is rising. Suck out the
brake fluid in reservoir, and check the conductivity between the terminals of brake fluid level warning
switch, normally conducted while the floater is descending.
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Section II Power Window
一、Overview
System operation: Operate the switch on door trim panel to make the window ascend or descend,
as shown in Fig. 4-27 and Fig. 4-28. The driver can operate switches of all windows by operating the
main switch on front door trim panel at driver’s side; the safety switch of power window locates on front
door trim panel at driver’s side, the driver can inactivate the switches of all windows through key A. Only
when the ignition switch locates at ON position, can the power window system work.
(1) Inching up
EX: Lift the window glass controller for ≥300ms, corresponding window glass will rise, and then release
the switch, rise stops.
LX/DX: Lift the window glass controller switch, corresponding window glass will rise, and then release
the switch, rise stops.
(2) Inching down
EX/LX/DX: Press the window glass controller for ≥300ms, corresponding window glass will descend, and
then release the switch, descending stops.
⑶Automatic up
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EX: Lift the window glass controller for ≤300ms, corresponding window glass will rise, the window lifter
will power off till the glass reaches the top. If the detection signal is lost, then the window lifter will work
for 8 seconds at one time and stop to protect the motor. If another rise or descending operation is
ordered during the rise, then the rise stops, and the window lifter will power off till the glass reaches the
top.
If something is caught by rising window glass, the rise immediately stops and the glass starts
descending automatically, during the descending, all operations are useless, and the window lifter will
power off till the glass touches the bottom.
⑷Automatic down:
EX/LX/DX: Press the window glass controller for ≤300ms, corresponding window glass will descend,
the window lifter will power off till the glass touches the bottom. If the detection signal is lost, then the
window lifter will work for 8 seconds at one time and stop to protect the motor. If another rise or
descending operation is ordered during the descending, then the descending stops, and the window
lifter will power off till the glass touches the bottom.
Certain functions of power window system depend on the control of its electronic module, which is
integrated into the switch components of left front door glass frame riser as well as the BCM body
controller.
System components as follows:
(1) Power window switch
(2) Power window motor
(3) BCM body controller
The latest technology, technique and material are applied to the power window system, for example, to
ensure good waterproof performance, hermetic design is adopted together with waterproof and
breathable film (the motor is easy to have differential pressure compared to the outside when
temperature rises during motor running, then the weakest point of sealing is likely to break up, therefore,
the motor needs an apparatus which can breathe to balance the pressure difference, so as to relieve the
impact on the weakest point of sealing, and the breathable film is the right one, because it can not only
balance the pressure difference by gas, but also can prevent liquid water from entering the motor, to
perfectly meet hermetic requirements); regarding overheat protection, polymer PTC overcurrent
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protector is used to promptly and effectively protect the motor from burning resulting from external fault
(such as a switch fault); considering acoustic treatment, special design is adopted on the rotating shaft of
super shock absorption and fine abrasion resistance to prevent the metallic impact and rubbing noise
from occurring during high speed rotation; with respect to power ground, interface is directly connected
without lead wire, so faults like poor contact of the wire are avoided; the structure of bipolar DC with
permanent magnetism is applied to have bilateral rotation, overheat protection device equipped inside,
independent from external electrical protection; when the motor powers on, under the effect of magnetic
force, the motor rotates, and decelerates through a big turbine reducer to generate low speed high
pulling torque at output gear, when the motor is jammed or an electrical fault occurs, the overheat
protection device can cut off the power immediately, to protect the motor. To protect the motor from
probable overheat damage resulting from continual rise or descending operation of power window,
automatic protection of circuit is available, and after a stop of five minutes, the circuit will recover
automatically.
二、Placement (See Fig. 4-29)
Fig. 4-29
A: Balustrade panel switch of left front door B: Motor of left front door glass frame riser
C: Bracket of left front door glass frame riser D: Balustrade panel switch of right front door
E: Motor of right front door glass frame riser F: Bracket of right front door glass frame riser
G: Balustrade panel switch of left rear door H: Bracket of left rear door glass frame riser
I: Motor of left rear door glass frame riser J: Balustrade panel switch of right rear door
K: Bracket of right rear door glass frame riser L: Motor of right rear door glass frame riser
1. Switch of left front door glass frame riser (See Fig. 4-30 and Fig. 4-31)
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Fig. 4-30 Fig. 4-31
2. Definitions of balustrade panel switches of right front, left rear and right rear doors (See Fig. 4-32 and
Fig. 4-33)
1.Glass up 5.Child lock(safety switch)

2.NC 6.Ground
3.NC 7.Glass down
4.NC 8.Blacklight power
Fig. 4-32 Fig.4-33
3. Definitions of glass frame riser (See Fig. 4-34 and Fig. 4-35)
Fig. 4-34 Fig.4-35
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4. Switch of left front glass frame riser (Fig. 4-36 and Table 4-6)
Fig. 4-36
Table 4-6
Testing
terminal
P/B Left rear door glass frame Ignition ON-position, 4～5V →Less than
1—body
riser motor up rise-stop glass 1V
P Left rear door glass frame Ignition ON-position, 4～5V →Less than
2—body
riser motor down descend-stop glass 1V
G Press safety switch,

3—body Safety switch 10～14V
always
6—body W/R Live power input B+ Always 10～14V
N/B Left front door glass Ignition ON-position, 4～5V →Less than
7—body
frame riser motor up rise-stop glass 1V
N Left front door glass Ignition ON-position, 4～5V →Less than

8—body
frame riser motor down descend-stop glass 1V
Y/B Right rear door glass Ignition ON-position, 4～5V →Less than
9—body
frame riser motor up rise-stop glass 1V
Y Right rear door glass Ignition ON-position, 4～5V →Less than

10—body
frame riser motor down descend-stop glass 1V
12—body B Electrical ground Always Less than 1Ω
R Lamplet on, backlight Pulse signal

14—body Backlight power
dim-bright generated
U/G Right front glass frame Ignition ON-position, 4～5V →Less than
15—body
riser motor up rise-stop glass 1V
U/Y Right front glass frame Ignition ON-position, 4～5V →Less than
16—body
riser motor down descend-stop glass 1V
5. Power window circuit (Fig. 4-37)
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Table 4-37
6. Power window fault symptom table (Table 4-7)
Table 4-7
Symptom Cause
1. Faulty BCM controller
All power windows do not work 2. Faulty glass frame riser power fuse
3. Faulty wiring
1. Faulty glass frame riser switch of corresponding door
One power window does not work 2. Faulty glass frame riser motor
3. Faulty wiring
1. Faulty safety switch of left front door glass frame riser
Window locking system does not
switches
work
2. Faulty wiring
三、Component check
1. Check balustrade panel switch of left front door. For the check of left front door glass frame riser
switch, refer to the table above. As for the rest doors: check the conductivity between terminals of glass
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frame riser switch connector.
(1) Check if glass frame riser switch is normal
Press the safety switch on balustrade panel switch of left front door, and locate the switch of left front
door glass frame riser switch at UP, normally terminal 3 and terminal 12 conducted, terminal 7 and
terminal 12 conducted; locate the switch at DOWN, normally terminal 3 and terminal 12 conducted,
terminal 8 and terminal 12 conducted. Check the rest riser buttons as per steps aforesaid. If the
conductivity is not qualified, then change corresponding glass frame riser switch.
(2) Check if safety switch is normal
If only press the safety switch on balustrade panel switch of left front door, normally terminal 3 and
terminal 12 conducted; if the safety switch on balustrade panel switch of left front door is not pressed,
normally terminal 3 and terminal 12 not conducted. If the conductivity is not qualified, then change
corresponding glass frame riser switch.
(3) Check if the backlight of balustrade panel switch of left front door is normal
Connect terminal 14 (10～14V) to power, terminal 12 grounded, observe if the backlight is lit, lit means
qualified, while unlit unqualified.
2. Check glass frame riser motor
Connect battery positive to terminal 5 of glass frame riser motor, negative to terminal 4, glass rises.
Connect battery positive to terminal 4 of glass frame riser motor, negative to terminal 5, glass descends.
Section Ⅲ Electric Sunroof (Optional)
Ⅰ. Overview:
The electric sunroof of the 630 is of built-in type, in which the torque generated by the sunroof
motor transmits to the flexible shaft through gears to drive the slide of sunroof glass. The forward or
reverse rotation of sunroof motor determines the forward or backward slide, namely the opening or
closing, of the sunroof glass. In addition, it’s fitted with electronic control system to realize the
opening, closing, and stop functions as well as comfort, ventilation, privacy, and safety. The overall
thin thickness of sunroof guarantees larger interior space and the light alloy material adopted by the
sunroof takes the deformation resistance into sufficient consideration. Of course, the modular
design guarantees the easy disassembly and maintenance. As a whole, it’s an electric sunroof with
humanized design and relatively advanced technology.
Ⅱ. Basic structure of electric sunroof
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The basic structure of this electric sunroof is shown in Figure 7-46. It’s mainly composed of
sunroof motor, bumper bar, water channel, slide rail, crossbeam, flexible shaft, and glass.
11
2
3
4 12
13
5
8 7 6
14
15
10
9 16
17
2
Figure 7-46 Structure of Electric Sunroof

1 – Roof framework and cover plate assembly; 2 – Front ceiling lamp mounting bracket
component; 3 – Sunroof reinforcement plate mounting bracket (3); 4 – Sunroof reinforcement plate
mounting bracket (2); 5 – Sunroof reinforcement plate mounting bracket (1); 6 – Hexagon head bolt
and conical spring washer subassembly; 7 – Sunroof body connecting bracket subassembly; 8 –
Ceiling; 9 – Front ceiling lamp and sunroof switch assembly; 10 – Rear ceiling lamp; 11 - Sunroof
glass assembly; 12 – Hexagon flange lock nut; 13 – Sunroof glass guard plate assembly; 14 –
Sunroof sunvisor; 15 – Water drainage hose; 16 – Sunroof control module; 17 - Sunroof motor;
Ⅲ. Functions of sunroof:
1. It can effectively keep the interior air ventilation for the passengers to enjoy the fresh air freely.
2. It can increase the beauty of the vehicle and promote the grade of the vehicle.
3. The use of sunroof can achieve energy-saving.
4. It can provide the support for interior trims and provide appropriate surfaces for exterior trims.
5. The sunroof embodies the anti-pinch function. If the sunroof encounters a resistance of above
100N during the closing, the sunroof motor rotates reversely to slide the sunroof to the limit
position and then conducts the closing movement, till the resistance disappears.
6. Self-closing function. When the vehicle key is rotated to position OFF, if the sunroof is not at
closed position, the sunroof will close automatically after 10s.
Ⅳ. Operation instructions for control switches of electric sunroof:
1. Sliding operation:
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Touch the hidden "SLIDE OPEN / TILT UP" button (at "SLIDE OPEN" side of the switch)
gently (less than 0.3 seconds), the sunroof will automatically slide open to its hidden maximum
position or the position for complete closing. While the sunroof is automatically sliding and if it
has not reached its hidden maximum position or the position for complete closing, the sunroof
will stop sliding when any key is pressed. as shown in Fig. 7-47.
DOO DO O
R R
S LID S LID
O PE E O PEN E
N
O FF O FF
T ILT TI LT
UP UP
a b
Figure 7-47 Slide operations of electric sunroof

a. Open b. Close
Long press the hidden "SLIDE OPEN / CLOSE" button (more than 0.3 seconds), the sunroof
will slide hidden or slide closed, and if the button is released, the sunroof will stop sliding.
2. Tild up operation:
Press the built-in button CLOSE/TILT UP (―TILT UP‖ side of switch) (for less than 0.3s) to
automatically tilt up the sunroof to the maximum position or move the sunroof to fully close
position. During the automatic tilting-up of the sunroof, if any sunroof operation button is
pressed again before the sunroof is tilted up to the maximum position or moved to the fully
close position, the sunroof will stop movement, as shown in Fig. 7-48.
DO OR
S LI
O PE D E
N
O FF
T IL
UP T
Figure 7-48 Tilting operations of electric sunroof

Long press ―TILT UP / CLOSE" button (more than 0.3 seconds), and the sunroof will tilt up or
close. Release the button and the sunroof will stop moving.
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Ⅴ. Maintenance of electric sunroof:
The periodical and good maintenances can use the electric sunroof more safely and effectively
and prolong the service life of sunroof to the maximum extent:
1. After being used for one period, the slide rails and gaps of the sunroof will generally be
deposited with some sands and the non-periodical cleaning will wear various parts of the
sunroof. Frequently clean the surrounding area of the slide rails, prevent the deposit of sands,
and prolong the service life of sunroof sealing strips. Generally at interval of 2~3 months, wrap
the surrounding area of sealing strips and slide rails with wet cotton cloth and insert a
screwdriver with the tip dipped with cleaning water to clean the sealing strips and slide rails.
Wipe clean the slide rails and apply a small amount of lubricating grease to prolong the service
life of sealing strips and slide rails of sunroof.
2. Before opening the sunroof, observe the roof of the vehicle for presence of obstacle that may
obstruct the movement of sunroof glass.
3. The largest concern for the use of sunroof is the water leakage and the correct use and
maintenance of the sunroof can effectively prevent water leakage. Before the approach of rain
season, besides the cleaning of the sands from the slide rails and the gaps of sealing strips,
apply a small amount of plastic protective agent or talcum powder onto the plastic parts such
as sealing strips.
4. After the snow or car wash in winter, the sunroof glass and the sealing strips may be frozen. In
such case, the forcible opening of sunroof will easily damage the sunroof motor and sealing
strips. The correct method is to, after the snow or car wash, open the sunroof and wipe dry the
residual water from the edges or wait for the interior temperature to raise and ensure the
unfreezing before opening the sunroof. In addition, it’s prohibited to open the sunroof during
raining. After the rain, drive the vehicle till the water is basically blown dry (approximate
10min) and then open the sunroof or directly use a dry cloth to wipe dry the water between the
glass and frame. It can prevent the water leakage arising thereof.
5. It’s better not to fully open the sunroof while driving on a extremely rough road, or it will
probably lead to deformation of related parts or even the damage of motor due to excessive
vibration between sunroof and slide rails.
6. While using the electric sunroof, make sure to pay special attention to the use of control
switches, as most sunroof faults are caused by improper use.
7. The sunroof glass is designed with heat insulation and ultraviolet-proof functions. Please clean
with soft cloth and detergent and do not clean with viscous detergent. Periodically use engine
oil or lubricant to clean the mechanical unit of the sunroof, generally at least once every two
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months.
8. It's prohibited for the children to use the sunroof as a ―toy"" and open and close the sunroof
repeatedly at will, or there is a danger of being pinched in addition to the power consumption
and easy damage of motor.
9. It’s absolutely prohibited to contact the sunroof sealing strip with oil stain, in order to prevent
impairing the sealing performance of sunroof due to aging.
10. While repairing the sunroof drain pipe portion, it’s prohibited to use oil (grease) for easing the
installation of drain pipe. Once the drain pipe comes into contact with the grease, there is a
danger of cracking.
11. If the inside or drain opening of drain pipe is blocked, the water can’t be drained timely, which
will lead to leakage. If the inside or drain opening of drain pipe is blocked, the deposited water will
overflow into the vehicle from the surrounding area of the sunroof and the connector of drain pipe.
If the left rear lower drain opening is blocked, the deposited water will overflow into the trunk from
the drain pipe and connector of drain opening. Therefore, at ordinary times, frequently check the
drain pipe and drain opening of the sunroof and timely remove the small leaves, grass clippings, and
small sundries flown therein, in order to prevent blocking the drain opening. Upon detection of
blockage of drain pipeline, in addition to the timely repair by the service station, fully open the
sunroof and use an elastic wire to dredge downward through the drain holes at four corners of water
collecting channel. Alternatively, use compressed air to blow away the blocking material towards
the drain holes.
12. Certain maintenances shall be conducted each year. Before the approach of sunlight exposure
period, apply same plastic protective agent. Before the approach of winter, conduct necessary
lubrications for the sunroof parts.
13. In any case, the power failure of sunroof will lead to the function disorder of sunroof. Firstly
re-initialize the sunroof before reuse.
14. After the sunroof is being used for a period, there is certain looseness between the glass
assembly and framework of the sunroof during the slide. The failure for timely maintenance
will lead to certain change in longitudinal and lateral positions of the glass assembly. Under
worse condition, it will impair the sealing performance of the sunroof and even the failure of
full closing or opening of sunroof due to incorrect position of glass, which will seriously
impair the safety and sealing performance of the complete vehicle. To prevent the occurrence
of similar problems, it’s necessary to conduct periodical adjustment and maintenance for the
sunroof glass assembly. During the periodical maintenance of the complete vehicle or in event
of similar problems, check 4 mounting bolts of the glass and tighten forcibly. Use the sunroof
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only after the trial run meets the requirements.
15. In event of any other problem, please contact the LIFAN’s authorized service station, in order
to prevent losses.
Ⅵ. Checking and repair of electric sunroof:
Some parts of the electric sunroof can only be repaired by professional repair personnel with special
tools and repair equipment. Upon detection of abnormality during use of electric sunroof, please
check and repair as per the methods listed in the table below.
1. Check the working status of the electric sunroof motor. Provided that the mechanical
mechanisms of the sunroof are completely normal, firstly connect the positive pole of battery
with terminal 3 of electric sunroof motor and connect the negative pole with terminal 1 and
then reverse the positive and negative poles to observe whether the sunroof can open or close.
The sunroof shall open or close without any abnormal noise. If the sunroof fails to open or
close, replace the electric sunroof motor.
2. Check the conductivity of electric sunroof limit switch. If disqualified, replace the electric
sunroof motor.
3. Check the conductivity of electric sunroof motor grounding circuit. If disqualified, replace the
electric sunroof motor.
4. Check the working status of electric sunroof motor circuit breaker. Fully open the electric
sunroof, press the button OPEN of electric sunroof switch, and check for presence of noise at
the electric sunroof motor circuit breaker within 10~90s. Fully close the electric sunroof, press
the button CLOSE of electric sunroof switch, and check whether the electric sunroof closes
completely within 20s. If the working status fails to meet the requirement, replace electric
sunroof motor.
2 1
6 5 4 3
Figure 7-49 Motor terminals.

Ⅶ. Disassembly and installation of electric sunroof:
In event of slide fault of the sunroof, if the sunroof is at position zero (closed), disassemble the
sunroof glass assembly from the roof for checking and repair. If the sunroof is not at position zero
(closed), it’s necessary to disassemble the entire sunroof from the roof for checking and repair.
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1. Disassembly and installation of sunroof glass assembly
Disassemble 3 screws from left and right sides of the sunroof glass assembly, as shown in
Figure 7-50. Hold the sunroof glass assembly and take out from the outside of the vehicle.
Install as per the reverse order of the disassembly at the time of installation. Ensure that the
sunroof movement mechanism is at position zero (closed), hold the sunroof glass within the
vehicle, adjust the sunroof glass assembly to an appropriate height within the roof opening, and
tighten the screws on the left and right sides.
Figure 7-50 Disassemble Sunroof Glass Assembly

2. Disassembly and installation of sunroof
(1) Unplug the doorsill trim panel and take out the side panel rubber strip. As shown in figure
7-51.
Front
前后
Rear
Figure 7-51 Disassemble doorsill trim panel

(2) Disassemble the left and right side trim panels and pull out the C-pillar upper trim panel.
As shown in figure 7-52
(3) Pull out A-pillar upper trim panel as shown in figure 7-52
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a b
Figure 7-52 Fixing bracket and hook

a. A-pillar upper trim panel b. C-pillar upper trim panel
(4) Pull out B-pillar upper and lower trim panel as shown in figure 7-53.
Figure 7-53 Disassembe B-pillar’s upper and lower guard plates

A – B-pillar upper guard plate B – B-pillar lower guard plate
(5) Disassemble the front and rear three safety armrests. As shown in figure 7-54.
Figure 7-54 Disassemble safety armrests
(6) Take out the rear interior lamp cover, screw off two connecting screws, disconnect the rear
interior lamp connector, and take out the rear interior lamp. As shown in figure 7-55.
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Figure 7-55 Disassemble rear interior lamp
(7) Screw off 2 connecting bolts and take out rear interior lamp bracket.
(8) Open the cover of glasses box, screw off 2 connecting bolts, disconnect the front ceiling
lamp connector and sunroof switch connector, and take out the front interior lamp and
sunroof switch assembly. Shown in Figure 7-56 and Figure 7-57.
SLIDE
DOOR OPEN
OFF TILT
UP
DOOR SLIDE
OPEN
OFF TILT
UP
Figure 7-56 Glasses box Figure 7-57 Disassemble front

ceiling lamp assembly
(9) Remove the left and right sunvisors and pull out the sunvisor fastening hooks and
fastening brackets. As shown in figure 7-58.
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a
Figure 7-58 Fixing bracket and hook Figure 7-59 Disassemble ceiling
clamps
a – Fastening bracket b – Hook
(10) Pry out 3 plastic clamps on the rear of the ceiling and take out the ceiling. As shown in
figure 7-59.
(11) Disconnect the connections between 4 drain pipes and water channels.
(12) Disconnect the cables of sunroof control unit.
(13) Screw off the connecting bolts and fastening nuts of sunroof and roof as per the
sequence shown in Figure 7-60 and take out the sunroof assembly.
Install as per reverse order of disassembly at the time of installation. While installing the drain pipes,
ensure that the drain pipes are not squeezed or kinked.
3. System initialization
After the repair, turn on the ignition switch and press and hold the button ―SLIDE OPEN‖ to
complete one working cycle of sunroof and complete system initialization.
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2 2
2 2
3 3
3 3
1
4 3
3
Figure 7-59 Disassemble sunroof assembly

1-M6*10 bolt 2、4-M5*16 bolt 3-M6*16 bolt 5-M6 nut
Ⅷ. Table of fault troubleshooting for electric sunroof:
Abnormal
Possible cause Troubleshooting
status
Clean the slide rails, wipe clean, and apply a
1. Dust deposit on slide rails
small amount of lubricating grease.
The slightly deformed one can be appropriately
2. Deformation of mounting plate slide plate
adjusted by tools and the seriously deformed one
subassembly
must be replaced.
3. Serious wear of cam Replace with new cam.
4. Breakage of limit plate due to long service

Replace with new limit plate.
time
Wipe the cam slot and apply the lubricating
Open/close 5. Stagnation of slide arm
grease or grind the edges of slide arm.
failure of
sunroof 6. Incorrect wire arrangement of sunroof motor Re-connect the wires correctly.
7. Open-circuit of sunroof motor Connect the circuit.
8. Deteriorated performance of motor after

Replace with new motor.
several years due to wear of motor
9. Falloff of mounting plate T-slot nut Bond with sealant.
10. Improper connection between plug and

Re-install the plug and socket within connector.
socket within the connector
11. Unclean plug within connector. Use a clean cloth to wipe clean the contacts.
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12. Open-circuit of control circuit board Reconnect the wiring.
13. Poor engagement between motor output gear

Readjust and install
and flexible shaft
Adjust to an appropriate position and repeat the
14. Clamping of spring within slide rail
cycles for several times.
1. Over-large sunroof glass Replace the glass.
2. Backward installation position of sunroof Disassemble and re-install the sunroof glass. At
glass due to loose screws after long-term the time of installation, move the sunroof glass as
service forward as possible and tighten the screws.
3. Interference between limit plate chamfer and
Slightly grind the limit plate.
Tilting failure limit pin B
of sunroof
4. Reduced elasticity of spring Replace with new parts.
5. After long service time, the left and right

springs are not within corresponding slots of
the slide rails due to over-high play of Repair the positions of springs.
movement mechanism during lowering of
sunroof.
Frequently check the water channels of sunroof
1. Internal blockage of drain pipe or blockage of
Water and timely remove any small leaves, grass
drain pipe opening.
permeation or clippings, and small sundries flown therein.
leakage
2. Rupture of pressure bars Replace with new glass assembly.
1. During the opening or closing, the edges of

the sunroof always have friction with the
Use a wet rag dipped with washing water to wipe
sunroof frame. As the contact surfaces are
clean and apply a small amount of lubricating
subject to frequent rains and winds, the dusts
grease.
and sands deposited become more or the
lubrication is insufficient.
Noise and Disassemble for cleaning and apply a small
high vibration 2. Impurities within cam slot
amount of lubricating grease.
of sunroof
3. Obvious interference between springs and Adjust the left and right mounting plate slide
slide rails during opening of sunroof plate subassemblies.
4. Friction between bumper rod and roof Grind the bumper rod or repair body.
5. Friction between sunroof pressure bars and Readjust the front and rear positions of sunroof
roof opening glass.
Failure of
sunroof
Poor contact of circuit. Check and re-connect the circuits.
control circuit
board buttons
1. Shortage of lubricating grease on movement Wipe the movement mechanisms and apply the
mechanisms such as elastic rollers. lubricating grease.
Slow and
hindered Stop the running of motor, till its temperature
2. Overheating of motor
movements of drops, and then proceed working.
sunroof
3. Excessive movement resistance of flexible Apply a small amount of lubricating grease into
shaft the slide rails.
Falloff of Repair the fallen sealing strips or replace with
Frequent friction between sealing strips and roof
sealing strips new glass assembly.
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Ageing of Frequently use talcum powder to prevent aging or
Long service life or deteriorated environment
sealing strips replace with new glass assembly.
The sunroof
opens before
Falloff of cam roller shaft Replace the cam subassembly
reaching
position zero.
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SectionⅣ BCM Central Lock, Burglar Alarm System
一、Overview
The central lock system is part of BCM (body control module), jointly used with burglar alarm system,
mainly responsible for the control of four door-lock motors, remote keyless entry and inner lighting
control, inactive car start after entering burglar alarm, car locating and so forth. Refer to use’s manual to
find more, its control principle as shown in figure.
Fig. 4-38
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Fig. 4-39
The control logic of central lock conforms to Q/LFQ J07.009-2008 Logic Technology Specifications on
LF630 Sedan Central Control Lock/Burglar Alarm System.
Alarm setting condition: Ignition switch disconnected, ignition key pulled out, four doors and luggage
boot well closed.
Remote control condition: Remote control operation is useless when ignition key is in ignition lock.
1. Locking operation
Under door unlocking status, locking operation can be realized through many ways, and different ways
bring about varied results.
(1) Automatic locking upon driving
When the car drives to 20km/h, automatic locking of four doors will act simultaneously, during one
driving circle (car does not stop and ignition switch is closed) when the speed reduces to less than
20km/h and then up to 20km/h again, locking operation will not be implemented again no matter whether
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door unlocking is performed or not.
(2) Locking through dashboard
Operate the keyswitch for locking on dashboard, locking of four doors will act simultaneously.
(3) Locking through remote control
Press the locking key on remote controller (prompt operation), locking of four doors will act
simultaneously, the steering light flashes for once and annunciator sounds for once.
(4) Locking through inserting door lock key
Insert door lock key into door lockhole, turn it counterclockwise, locking of four doors will act
simultaneously.
(5) Locking by door locking button
Door locking button may display the status of door lock, i.e. red mark outward means unlocking; red
mark inward means locking. Move the door locking button inside the car, only the corresponding door
will lock, and the rest doors will not lock.
(6) Logical flow of door locking operation
As shown in Fig. 4-40.
Fig.4-40
2. Unlocking operation
Under door locking status, unlocking operation can be realized through many ways, and different ways
bring about varied results.
(1) Unlocking through dashboard
The unlocking switch on dashboard only implements door unlocking, two-time unlocking available.
First-time unlocking is for driver’s door, while second-time unlocking is for the rest three doors.
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(2) Unlocking through key
Insert door lock key into door lockhole, turn it clockwise, locking of four doors will act simultaneously.
(3) Unlocking by ignition key
After car stops, ignition key returns from “ON” to “ACC”, locking of four doors will act simultaneously.
(4) Unlocking by air bag
During a collision, simultaneous to the triggering of ignition of air bag, air bag SDM sends out unlocking
signal, independent unlocking of four doors will act simultaneously, the steering light sends out danger
warning (ignition lock closes).
(5) Unlocking through remote control
Press the unlocking key on remote controller, independent unlocking of four doors will act
simultaneously, the steering light flashes for twice and annunciator sounds for twice.
(6) Logical flow of door unlocking operation
Note 1: When the key is inserted into ignition lock, it’s useless to press the locking key and unlocking
key of remote controller
Fig. 4-41
3. Alarm setting
Alarm setting condition: Ignition switch connected, ignition key pulled out, four doors and luggage boot
closed.
(1) Alarm setting by remote locking control
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1) When alarm setting condition is met, press the locking key on remote controller (prompt operation),
locking of four doors will act simultaneously, the steering light flashes for once and annunciator sounds
for once; burglar indicator flashes, together with system fuel cut-off, and brake to indicate state of alert;
2) If the alarm setting condition with four doors and luggage boot closed is not qualified, the steering light
flashes for ten seconds to indicate door close; after ten seconds, the burglar indicator flashes, together
with system fuel cut-off and brake to indicate state of alert.
(2) Alarm setting by two-time remote unlocking control
① When alarm setting condition is met, press the unlocking key on remote controller, unlocking of four
doors will act simultaneously, the steering light flashes for twice and annunciator sounds for twice,
burglar indicator goes out, and fuel supply recovers.
② If any of the doors is not opened within 30 seconds, the four doors lock, burglar indicator flashes,
together with fuel cut-off and brake to indicate state of alert.
(3) Logical flow of alarm setting
Fig. 4-42
4. Disarming
Under alarm setting condition is met, unauthorized entry or burglar behavior will be detected and the car
immobilized, only upon correct disarming by authorized person, can the car recover.
(1) Disarming operation through unlocking key of remote controller
Press the unlocking key of remote controller, unlocking of four doors will act simultaneously, when the
system is at alert state, the steering light flashes for twice, annunciator sounds for twice; burglar indicator
489
stops flashing, fuel supply recovers upon disarming.
If the car is at disarming state, unlocking of four doors will act simultaneously.
(2) Logical flow of disarming operation
Fig. 4-43
5. Locking indication
If the car is unlocked with alarm setting when it is not used, the system will determine the situation and
offer an indication.
(1) Locking alarm setting indication
1) When the ignition switch is connected, ignition key is pulled out, four doors and luggage boot are
closed, if the locking key of remote controller is pressed for alarm setting within ten seconds, alarm
setting will be implemented.
2) If the locking key of remote controller is not pressed for alarm setting within ten seconds, the steering
light flashes for three times and annunciator sounds for three times for locking indication with alarm
setting implemented.
(2) Logical flow of locking alarm setting indication
Fig. 4-44
490
6. Car locating
When there are too many cars at a parking lot, it’s difficult to find your car in time, and car locating is
furnished for your convenience.
(1) Operation
When the car is at alert state, press the unlocking key of remote controller for ≥2S, a car locating
indication will occur, with the steering light flashing and annunciator sounding for 15 seconds and
stopping afterward.
Within the 15S, if any key on the remote controller is pressed, the car locating is ended.
If the unlocking key is pressed for ＜2S, the car will still be at alert state.
(2) Logical flow of car locating operation
Fig. 4-45
7. Open the luggage boot through electrical operation (EX)
(1) Press the luggage boot key on remote controller when it is not alerted
When it is not alerted, the luggage boot opening key on central console is available for luggage hood
springing up, the luggage boot indicator on instrument cluster (No. 31 in Fig. 49) is lit, the luggage hood
can be opened by hand, to close, press the hood by hand, the luggage boot indicator on instrument
cluster (No. 31 in Fig. 49) goes out, do make sure the luggage hood is locked. If the luggage hood is not
closed within 60 seconds, the steering light will flash to give an indication
(2) To open the luggage boot during alert state
491
1) It’s useless to press the luggage boot key on remote controller when the ignition key is inserted into
ignition lock, only when the key is pulled out, can such remote operation be implemented.
2) During alert state, it is necessary to disarm first, then press the luggage boot key on remote controller,
the luggage hood springs up, the luggage boot indicator on instrument cluster is lit, the luggage hood
can be opened by hand, to close, press the hood by hand, the luggage boot indicator on instrument
cluster goes out, do make sure the luggage hood is locked. If the luggage hood is not closed within 60
seconds, the steering light will flash to give an indication.
二、Placement (As shown in Fig. 4-46)
Fig. 4-46
A: Body control module B: Unlocking alarm switch
C: Burglar alarm security system D: Central control actuator of right front door
E: Door lamp switch F: Central control actuator of right rear door
G: Central control actuator of left rear door H: Door lamp switch
I: Central control actuator of left front door J: Switch component of left front door glass frame riser
三、Lock end
1. For pin definition of central door lock of body control module (BCM), refer to Fig. 4-47, Table 4-8, Fig.
4-48, Table 4-9, Fig. 4-49, and Table 4-10.
Fig. 4-47
492
Table 4-8
Terminal
Testing terminal Wire color Test condition Standard value
description
(3-1)－body GRB Central lock power Always Less than 1Ω
Locking of left front

(3-2)－body YR Always Less than 1Ω
door lock
Unlocking of left
(3-3)－body WBL Always Less than 1Ω
front door lock
(3-4)－body B Grounding Always Less than 1Ω
(3-5)－body NC
(3-6)－body NC
(3-7)－body NC
(3-8)－body NC
(3-11)－body NC Always Less than 1Ω
(3-12)－body VG Headlight relay Always Less than 1Ω
When pressing the unlocking 10～14V

or locking key on remote
(3-13)－body GW Anti-theft alarm horn controller (refer to the user’s
guide to find more),
intermittent
(3-14)－body BRV Trunk lock Always Less than 1Ω
(3-15)－body G Width lamp power Always Less than 1Ω
(3-16)－body GR Width lamp power Always Less than 1Ω
(3-17)－body RY Left turning light Always Less than 1Ω
(3-18)－body BRY Right turning light Always Less than 1Ω
Locking of the rest Always Less than 1Ω

(3-19)－body BRG
three doors
Unlocking of the rest Always Less than 1Ω

(3-20)－body BrW
three doors
Right rear glass Always Less than 1Ω

(3-21)－body YR
motor down
Right rear glass Always Less than 1Ω

(3-22)－body BBL
motor up
(3-23)－body WR Glass lifter power 始终 Less than 1Ω
493
(3-24)－body GB Glass lifter power Always Less than 1Ω
Left rear glass motor Always Less than 1Ω

(3-25)－body GY
up
(3-26)－body NC Less than 1Ω
(3-27)－body B Power-- Always Less than 1Ω
Right front glass Always Less than 1Ω

(3-28)－body BG
motor down
Right front glass Always Less than 1Ω

(3-29)－body BY
motor up
(3-30)－body NC
(3-31)－body NC
(3-32)－body WR Glass lifter power Always Less than 1Ω
(3-32)－body WR Glass lifter power Always Less than 1Ω
Left front glass Always Less than 1Ω

(3-33)－body O
motor down
Left front glass Always Less than 1Ω

(3-34)－body Gr
motor up
(3-35)－body RG Turning light power Always Less than 1Ω
Fig. 4-48
Table 4-9
Testing Terminal
Wire color Test condition Standard value
terminal description
Extended
(1-1)－body B/R illumination control See instructions Less than 1Ω
output of inner light
(1-2)－body Y/G Keyhole illumination See instructions Less than 1Ω
494
control output
Roof window
(1-3)－body GW See instructions
signal
Fuel relay control Before engine start → After engine Less than 1V→10～
(1-4)－body V/G
line + start 14V
Key inserting
(1-5)－body BW See instructions Less than 1Ω
signal
Anti-theft
(1-6)－body GB See instructions Less than 1Ω
indicator
(1-7)－body BLG Start signal See instructions Less than 1Ω
Reversing switch
(1-8)－body GBL See instructions Less than 1Ω
signal
(1-9)－body NC
(1-10)－body GBL Controller power See instructions Less than 1Ω
(1-11)－body BRB Left front door up See instructions Less than 1Ω
Left front door

(1-12)－body BR See instructions Less than 1Ω
down
Right front door

(1-13)－body BLG See instructions Less than 1Ω
up
Right front door

(1-14)－body BLY See instructions Less than 1Ω
down
(1-15)－body PB Left right door up See instructions Less than 1Ω
Left right door

(1-16)－body P See instructions Less than 1Ω
down
(1-17)－body YB Right rear door up See instructions Less than 1Ω
Right rear door

(1-18)－body Y See instructions Less than 1Ω
down
Diagnostic
(1-19)－body WB See instructions Less than 1Ω
interface
(1-20)－body BY Locking by key See instructions Less than 1Ω
Airbal collision
(1-21)－body YG See instructions Less than 1Ω
signal input
(1-22)－body WY Unlocking by key See instructions Less than 1Ω
(1-23)－body See instructions Less than 1Ω
(1-24)－body B Controller power - See instructions Less than 1Ω
495
Fig. 4-49
Table 4－10
Testing terminal Wire color Terminal description Test condition Standard value
Unlocking of central control Active
(2-1)－body BLW Less than 1Ω
switch
Locking of central control Active
(2-2)－body GBL Less than 1Ω
switch
(2-3)－body G Speed signal input Active Less than 1Ω
(2-4)－body PW Width lamp switch signal Active Less than 1Ω
(2-5)－body PB Headlight switch signal Active Less than 1Ω
(2-6)－body PY Automatic headlight switch Active Less than 1Ω
(2-7)－body BR Hazard lamp switch signal Active Less than 1Ω
(2-8)－body BRR Left turning light signal Active Less than 1Ω
(2-9)－body BRB Right turning light signal Active Less than 1Ω
(2-10)－body GRV Trunk door switch Active Less than 1Ω
(2-11)－body GR Left front door switch Active Less than 1Ω
(2-12)－body GRBL Right front door switch Active Less than 1Ω
(2-13)－body GRG Left rear door switch Active Less than 1Ω
(2-14)－body GRY Right rear door switch Active Less than 1Ω
(2-15)－body VG photoelectric signal Active Less than 1Ω
(2-16)－body NC
(2-17)－body W Receiving antenna Active Less than 1Ω
(2-18)－body RY Reversing distance data Active Less than 1Ω
(2-19)－body BG Active Less than 1Ω

Left front door lock state
496
switch
(2-20)－body B Ultrasonic probe power- Active Less than 1Ω
(2-21)－body G Ultrasonic power + Active Less than 1Ω
(2-22)－body Y Ultrasonic probe 1 Active Less than 1Ω
(2-23)－body RW Ultrasonic probe 2 Active Less than 1Ω
(2-24)－body YR Ultrasonic probe 3 Active Less than 1Ω
四、Circuit check (Fig. 4-50)
Fig. 4-50
五、Burglar alarm
During alert state, if the key is inserted into ignition lock, ignition switch short-connected, four doors and
backdoor open, then the fuel control output is inactivated, the annunciator sounds continuously and
steering light flashes; after 20 seconds, the annunciator stops, only flash continues; after another 10
seconds, flash stops; alarm can only be stopped by pressing unlocking key, after which, the ignition
switch recovers its control over oil passage.
For central lock trouble symptoms of body control module, refer to Table 4-11.
Table 4－11
Door lock Door lock 1 Faulty air conditioning
1 Faulty power supply fuse
control locking/unlocking controller
2 Faulty body control module
system does fault (apply central 2 Faulty body control module
3 Faulty wiring
not work control switch and 3 Faulty wiring
497
key) 4 Faulty door key
locking/unlocking switch
1 Faulty body control module
Only one door
1 Faulty door lock motor All four door locks 2 Faulty switch control device
lock does not
2 Faulty wiring do not work 3 Faulty door lock motor
work
4 Faulty wiring
1 Faulty door lamp switch
2 Faulty key locking and unlocking Locking by mistake
switch of door (key at ignition 1 Faulty fastener
Remote
3 Faulty body control module (receiving) switch, automatic 2 Faulty body control module
control fails
4 Weak battery or faulty remote locking available at 3 Faulty wiring
controller (sending) stop)
5 Faulty wiring
六、Component check
1. Basic check
(1) When locking the door at driver’s side using key, all doors should be locked; when unlocking the door
at driver’s side using key, all doors should be unlocked.
(2) Security check：

① If the burglar alarm system is still not activated, and the unlocking key on the remote controller is
pressed, then only unlocking will be implemented.
② If the burglar alarm system is activated, upon unlocking by remote control, then the steering signal
lamp flashes for twice and annunciator sounds for twice, burglar alarm indicator goes out.
③ If the burglar alarm system is activated, and no door is opened after unlocking by remote control,
then alert state will recover together with automatic locking, the steering light does not flash and
annunciator does not sound.
2. Check of left front door central lock actuator as shown in Fig. 4-51
Left front door central lock actuator
Fig. 4-51
(1) Check the conductivity of locking/unlocking switch of left front door central lock actuator:
498
When the locking/unlocking switch of left front door central lock actuator is at locking position, actuator
terminals 2 and 4 should be conducted; when it is at middle position, actuator terminals 2 and 4 should
be not conducted, terminals 2 and 3 not conducted either; when it is at unlocking position, actuator
terminals 2 and 3 should be conducted. If the conductivity is unqualified, change the locking/unlocking
switch.
(2) Check the working status for locking/unlocking of left front door central lock actuator motor
Connect battery positive to terminal 5 of left front door central lock actuator, negative to terminal 6, the
control lever of left front door central lock actuator will locate to locking position. Contrarily, the control
lever of actuator will locate to unlocking position. If the condition aforesaid is not met, change the
locking/unlocking of left front door central lock actuator motor.
4. Check the central lock actuator for right front door, left rear door and right rear door as shown in
Fig. 4-52.
Central lock actuator for right front door, left rear door and right rear door
Fig. 4-52
Connect battery positive to terminal 1 of the central lock actuator, negative to terminal 2, the control
lever of central lock actuator will locate to locking position. Contrarily, the control lever of central lock
actuator will locate to unlocking position. If the condition aforesaid is not met, change the central lock
actuator.
4. Check the cause for incapability of remote keyless entry system

Check steps
(1) Control check
1) Basic check
① Within a range of 1m, press the key on remote controller for around 1s and check if all door locks are
unlocked or locked, at the moment, the key is not inserted into the ignition lock cylinder and all doors are
locked.
499
② Press the key on remote controller for three times and check if the LED on the controller flashes for
three times as well; if press the key and hold on, the LED should light constantly. Note: If press the key
for more than three times and the LED still does not light up, a dead battery might be the case.
2) Automatic locking check

① When the car is at burglar alarm state, press the unlocking key on remote controller, if no door is
opened within 30 seconds upon unlocking, automatic locking of all doors will be implemented, burglar
alarm be activated again, steering light not flash, and annunciator not sound.
② Under the condition above, if any door is opened within 30 seconds upon unlocking, automatic
locking of all doors will not be implemented.
3) Security check
① When the key is inserted into the ignition lock cylinder and the locking or unlocking key on remote
controller is pressed, no door lock will be locked or unlocked.
② If an unregistered remote controlled is applied for operation, then the door lock should not be locked
or unlocked; when an registered remote controller is applied, the door lock should be available for
locking and unlocking.
4) When the key is not inserted into the ignition lock cylinder, and the door is open or ajar, close the door
by remote control, the door lock will be locked with a warning generated.
5) Steering signal lamp flash check
① Press the locking key on remote controller: Burglar alarm is alerted (burglar indicator flashes and fuel
cuts off), locking implemented; if it is qualified for alarm setting, the steering light flashes for once and
annunciator sounds for once; if alarm setting condition is not met, the steering light flashes for ten
seconds, annunciator does not sound, door closing indicated, the flash will stop upon closing the door.
② Press the unlocking key on remote controller: Disarm during burglar alarm, unlocking of four doors
will be implemented, the steering light flashes for twice and annunciator sounds for twice; if not under
burglar alarm, only unlocking will be implemented.
③ If press for unlocking by remote control under burglar alarm and no door is opened within 30 seconds,
automatic locking will be implemented with burglar alarm alerted, without flashing of steering light or
sounding of annunciator.
④ Lock setting indication: Ignition switch disconnected, ignition key pulled out, all doors closed, if
500
locking is not implemented within 10 seconds, then the steering light flashes for three times and
annunciator sounds for three times for locking indication.
⑤ Car locating: Press the locking key on remote controller for more than 2 seconds, car locating will be
implemented; the steering light flashes for 15 seconds, annunciator sounds for every 0.2s with a 0.6
intermission, stops after 15 seconds. If any key is pressed within the 15 seconds, car locating will be
ended together with corresponding action.
⑥ Burglar alarm: During alert state, if the key is inserted into ignition lock, ignition switch
short-connected, doors and backdoor open, then the fuel control output is inactivated, the annunciator
sounds continuously and steering light flashes; after 20 seconds, the annunciator stops, only flash
continues; after another 10 seconds, flash stops; alarm can only be stopped by pressing unlocking key,
after which, the ignition switch recovers its control over oil passage.
⑦ Damaged bulb indication: If main light bulb is damaged, the flash frequency of steering light will be
doubled.
⑧ Press the luggage boot key on remote controller (EX): Under alert state, first disarm and then unlock
the luggage boot. If unlocking is not implemented within 60 seconds and luggage boot is not closed, the
steering light flashes to indicate probable wrong opening. The flash stops upon unlocking or closing of
luggage boot.
If it is qualified for the conditions aforesaid, then the system is in a normal state; if not, proceed to the
next step.
(2) Remote controller battery check
Upon pressing the remote controller switch three times, the LED of remote controller should light for
three times.
If it is the case, proceed to the next step; if not, insufficient battery capacity is indicated, change a battery
with designated specification.
(3) Back inner light check
Turn the back inner light switch to position ON, check if the light is lit.
Turn the back inner light switch too position DOOR, check if the light is lit.
If it is in a normal state, proceed to the next step; if not, repair or change the back inner light.
(4) Control range check of remote controller
At 1m away from the driver’s door, press the switch of a new or normal remote controller of a same car
501
model, check if the system is in a normal state.
Hint: The back inner light at position DOOR, press the remote controller switch, the back inner light will
flash again and again.
If it is the case, change the remote controller. If not, proceed to the next step.
(5) Check of ignition switch unlocking alarm switch
During the ignition switch is inserted with key, and the key is then pulled, check the conductivity between
terminals 2 and 1 of the switch, normally from conducted → not conducted.
If it is the case, proceed to the next step; if not, change the ignition switch unlocking alarm switch.
(6) Body controller check
Ignition switch open, pull out the fuel relay and check the conductivity from the fuel control line of body
controller to fuel relay, as well as the voltage between terminal pin BCM (1-4) of fuel control line of body
controller and the body, normally around 10～14V.
If it is in normal condition, proceed to the next step; if not, change the body controller.
(7) Check of automatic window closing of four doors by remote control
Disconnect interface BCM3 of body controller, and check the voltage between central lock power pin
BCM (3-1), steering light power pin BCM (3-35), glass frame riser power pins BCM (3-23) and BCM
(3-32) of body controller terminal, and the body respectively, normally around 10～12V. Check the
resistance between body controller terminals BCM (3-4), BCM (3-9), BCM (3-10) and BCM (3-27), and
the body respectively, normally less than 1Ω. Check the conductivity between body controller terminals
BCM (3-33) and BCM (3-34), and the left front door glass frame riser motor. Check the conductivity
between glass frame riser motors of right front, left rear and right rear doors, and their corresponding
terminal in BCM. If it is normal, proceed to the next step; if not, repair or change the glass frame riser
motor.
502
SectionⅤ Electric exterior rear-view mirror
一、Overview
Fig. 4-53
①Electric exterior rear-view mirror ②Sealing gasket ③Electrical interface
By operating the electric switcher on the dashboard at the left side of the driver’s seat, the left and right
electric rear-view mirrors can be ordered for turning to left, right or up and down, with adjustable angle
over 7 degrees. During car stop, the driver can fold up the side mirror, to protect it from possible damage,
with adjustable angle over 85 degrees. When the side mirror is bumped from the back, the mirror cover
will turn outwardly to protect the mirror, maximally to 105 degrees. If the mirror is smashed, little pieces
of glass will remain in mirror cradle, to ensure good security.
Consist of the following:
(1) Left and right electric exterior rear-view mirrors
(2) Electric exterior rear-view mirror switch component
二、Placement
1. As shown in figure 4-54
Fig. 4-54
A：Left electric exterior rear-view mirror B：Electric exterior rear-view mirror switch C：Right
electric exterior rear-view mirror
2. Exploded view Fig. 4-55
503
Fig. 4-55
1：Electric exterior rear-view mirror 2：Mirror cover 3：Bracket 4：Commutator 5：Mirror
extension unit 6：Mirror 7：Base 8：Mounting bolt 9：Seating wahser
三、Terminal voltage
1. For electric exterior rear-view mirror switch, refer to Fig. 4-56 and Fig. 4-57.
Width lamp
Electric rear-view mirror switch
Fig. 4-56
Fig. 4-57
504
Ignition switch ACC, select left electric rear-view mirror for left and right adjustment
Left: 2-3 conducted, resistance less than 1Ω, 5-1 conducted, resistance less than 1Ω
Right: 5-3 conducted, resistance less than 1Ω, 2-1 conducted, resistance less than 1Ω
Ignition switch ACC, select left electric rear-view mirror for up and down adjustment
Up: 6-3 conducted, resistance less than 1Ω, 1-2 conducted, resistance less than 1Ω
Down: 2-3 conducted, resistance less than 1Ω, 1-6 conducted, resistance less than 1Ω
Ignition switch ACC, select right electric rear-view mirror for left and right adjustment
Left: 3-2 conducted, resistance less than 1Ω, 1-10 conducted, resistance less than 1Ω
Right: 3-10 conducted, resistance less than 1Ω, 1-2 conducted, resistance less than 1Ω
Ignition switch ACC, select right electric rear-view mirror for up and down adjustment
Up: 9-3 conducted, resistance less than 1Ω, 1-2 conducted, resistance less than 1Ω
Down: 2-3 conducted, resistance less than 1Ω, 1-9 conducted, resistance less than 1Ω
2. Electric exterior rear-view motor

(1) Ignition switch ACC, select electric rear-view mirror switch for left and right adjustment
5 (+) 1 (-) Motor turns left
5 (-) 1 (+) Motor turns right
(2) Ignition switch ACC, select electric rear-view mirror switch for up and down adjustment
4 (-) 5 (+) Motor turns down
4 (+) 5 (-) Motor turns up
四、Trouble Symptom Table 4-12

Table 4-12
1. Faulty fuse
1. Faulty side mirror switch
2. Faulty side mirror switch Side mirror does not work
Side mirror does not work 2. Faulty side mirror motor
3. Faulty side mirror motor properly
3. Faulty wiring
4. Faulty wiring
五、Component check
1. Switch check, check items as mentioned before, if the conductivity is unqualified, change the side
mirror switch.
505
2. Mirror check, check items as mentioned before, if corresponding requirement is not met, change the
side mirror motor, wire connector of side mirror motor ③.
六、Burglar indicator
Check if the burglar indicator is at fault:
Fig. 4-58
As shown in Fig. 4-58, pin 2 grounded, pin 1 connected to (10～14V) power, burglar indicator should be
lit.
If it is normal, forward to other fault check and repair; if not, change the burglar indicator.
七、Backlight regulating switch

Check if the backlight regulating switch is at fault:
As shown in Fig. 4-58, pin 3 grounded, pin 2 connected to (10～14V) power, pin 1 randomly connected
to a switch with backlight, adjust the backlight regulating switch manually, there should be change in
brightness.
If it is normal, forward to other fault check and repair; if not, change the backlight regulating switch.
Fig. 4－59
506
Section Ⅵ Illumination System
一、Overview
The illumination system is to offer lighting for night driving, consists of outer lights of headlight, backup
light, license plate lamp, fog light etc, and inner ones of dashboard light, inner light, luggage boot lamp,
door lamp, various backlights etc. Each light is installed at required position, equipped with control switch,
wire, fuse protector and so forth, to make up the illumination system, which also enjoys signal indication,
comes out with light signals to warn the driver of another car and the foot passenger, to ensure safe
driving, including signals for steering, brake, danger warning, outline marker etc. The components as
shown in Table 4-13
Table 4-13
Name Model Technical parameter
Low beam of front

H1 12V55W
combination lamp
High beam of front
H4 12V60W
combination lamp
Position lamp of front
W5W 12V 5W
combination lamp
Steering light of front
PY21W 12V21W
combination lamp
Side turn signal light WY5W 12V5W
Daytime light LED 12V

Position lamp of rear
LED 12V1W
combination lamp
Brake lamp of rear
P21 12V 5W
combination lamp
Backup light of rear
P21W 12V21W
combination lamp
Turning light of rear
PY21W 12V21W
combination lamp
Rear fog light of rear
LED 12V3W
combination lamp
License plate lamp W5W 12V5W
High-mounted brake lamp LED 12V0.5W
Rear roof light (Q)-12V5W 12V5W
Luggage boot lamp W5W 12V5W
Door lamp LED 12V0.24W
507
Note: Do not use bulbs without specifications indicated in the table below, or the car lamps will be
damaged. Do not touch the halogen lamp or get it contacted by oily surface, or the bulb’s life will be
shortened.
二、Placement
1. Headlight assembly (Fig. 4-60)
Turning light bulb
Fig. 4－60
1.1 Front combination lamp interface (Fig. 4-61)
Turning light
turning light
Fig. 4-61
508
1.2 Headlight checking circuit (Fig. 4-62)
Fig. 4-62
2. Rear combination lamp (Fig. 4-63, Fig. 4-64 and Fig. 4-65)
Fig. 4-63
509
Turning light
Fig. 4-64
Fig. 4-65
3. Daytime light (Fig.4-66 and Fig.4-67)
A044428
Fig.4－66 Fig. 4－67

510
4. Side turn signal light (Fig. 4-68)
Fig. 4-68
5. High-mounted brake lamp (Fig. 4-69)
Fig.4-69
6. Rear roof light (Fig. 4-70 and Fig. 4-71)
Fig. 4-70 Fig.4-71
7. Luggage boot lamp (Fig. 4-72 and Fig. 4-73)
Fig.4-72 Fig.4-73
511
三、Check and repair
1. Disassemble and assemble left and right of front combination lamp in the same steps, disassembling
steps are contrary to assembling steps.
(1) Remove radiator grille
(2) Remove left front fender inner panel
(3) Remove right front fender inner panel
(4) Remove front bumper
(5) Remove left headlight
Remove the three screws to pull out the left front combination lamp assembly as per the direction shown
in the Fig., disconnect the bracket at the side of the car, and disconnect each electrical connector lug of
lamp socket, as shown in Fig. 4-74.
A044428
Fig. 4-74
(6) Remove low beam bulb of left headlight

As shown in Fig. 4-75, take off the square shape sealing cover, remove the clamp spring, then low beam
bulb of left headlight is removable.
Fig.4－75
512
(7) Remove high beam bulb of left headlight as shown in Fig. 4-76, take off the sealing cover and clamp
spring, then the bulb is removable.
Fig.4-76
(8) Remove turning light of left headlight as shown in Fig. 4-77.
Fig. 4-77
2. Focusing adjustment of front combination lamp

(1) Car preparation: Ensure the part around front combination lamp is not damaged or distorted, fuel
tank filled. Make sure unladen mass of complete vehicle: Fill coolant to designated level; charge the tire
to proper pressure, put spare wheel, jack, and tool kit to original position, and empty the luggage boot, a
man of common weight (75kg) seated at driver’s seat.
(2) Focusing preparation: Park the car at a dark place, to observe the boundary between brightness and
darkness of the light. The boundary is quite obvious, below which the light of front combination lamp is
visible, while above which the light is invisible. The car midline is angulated at 90 degrees to the wall, a
distance of 3m between the car and wall available. Park the car on a level ground, several jounces
operated to stabilitate the chassis. A thick white paper (2m×4m) is furnished as screen, on the central of
which a vertical line is drawn (V-line), as shown in Fig. 4-78, set the screen (erect the screen on the
ground, to align the V-line to car midline). As shown in Fig. 4-79, base lines are drawn on the screen (H
line, left V line, right V line). The base lines differ from low beam as well as high beam check: Line out
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the center mark of front combination lamp bulb on the screen, H line (height of front combination lamp) is
drawn a horizontal across the screen to traverse the center mark, left V line and right V line (center
marks of left combination lamp and right combination lamp respectively) are drawn two verticals to cut H
line at their respective center mark.
Fig. 4－78 Fig.4-79
(3) Check: When checking one side of front combination lamp, cover the other side or disconnect the
electrical connector plug to prevent the unchecked front combination lamp interfere the focusing check.
Note: Do not cover the front combination lamp for more than 3 minutes, because the glass block of front
combination is made of synthetic resin, which is vulnerable to overheating. Start the engine, to exceed
1500 rpm.
As shown in Fig. 4-80 and Fig. 4-81, turn on the front combination lamp to make the boundary within
designated area.
Fig.4-80 Fig.4-81
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(4) Vertical focusing adjustment: Turn screw A for focusing adjustment using a screwdriver, to focus the
light within designated range, when turning the screw A clockwise, the focusing light moves upward,
contrarily, downward;
Horizontal focusing adjustment: Turn screw B for focusing adjustment using a screwdriver, to focus the
light within designated range, when turning the screw B clockwise, the focusing light moves upward,
contrarily, downward. As shown in Fig. 4-82.
Fig.4-82
(5) Low beam adjustment: As shown in the Fig., vertically move the screw for focusing adjustment to
adjust the focusing of low beam, when turning the screw clockwise, the focusing light moves upward,
contrarily, downward. As shown in Fig. 4-83.
Fig. 4-83
3. Check left combination switch (light control) as shown in Fig. 4-84 and Fig. 4-85.
Fig. 4-84
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Table1 Logical function of lighting combination switch
Corresponding pin
Load Light
current position
Rear fog light On
Fog light Off
Width light
Headlight
High beam flashes
High beam
High beam Off
Left turning light
Turning light Off
Right turning light
Fig. 4-85
(1) Check the conductivity of control switch of rear fog lights

When the light control switch is at OFF, terminals should be not conducted with each other, when the
switch is at rear fog light position, terminals 1 and 2, 6,7,17 should be conducted.
(2) Check the conductivity of dipswitch of headlight: When the dipswitch is at overtaking flash position,
terminals 7 and 15, 16 should be conducted, when the dipswitch is at front headlight position, terminals 6
and 4, and terminals 4 and 3 should be conducted, when the dipswitch is at high beam position,
terminals 7 and 15 should be conducted.
(3) Check the conductivity of signal switch of turning light: When the signal switch is at turn right position,
terminals 10 and 11, and terminals 12 and 13 should be conducted, when the signal switch is at neutral
position, terminals should be not conducted with each other, when the signal switch is at turn left position,
terminals 9 and 10, and terminals 13 and 14 should be conducted.
(4) Check the conductivity of front fog light switch: When the switch is at OFF, terminals 1 and 2, 4
should be not conducted, when the switch is at ON, terminals 1 and 2, 4 should be conducted.
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4. Daytime light relay check （Fig,4-86）
Fig.4-86
The relay falls into a normally open one. Check the daytime light relay, the resistance between
terminals 1 and 2 should be around 60～90Ω, while terminals 3 ,4 and 5 should be not conducted; apply
the battery voltage between terminals 1 and 2 of the relay, terminals 3 and 4 should be conducted.
5. Check emergency alarm switch (electrical air conditioning) as shown in Fig. 4-87
Fig.4－87
(1) Check the conductivity of emergency light switch: The emergency light switch (electrical air
conditioning controller) is installed onto the real vehicle, and then pressed, if the switch flashes, it is
normally, if not, change the switch.
(2) Check the luminated light for emergency light switch: Connect the battery positive to terminal B5 of
emergency switch, negative to terminal B15, and the luminated light should be lightened.
6. Check the rear roof light: When the switch is at OFF, terminals should be not conducted with each
other, when the switch is at DOOR, terminals 2 and 3 should be conducted, when the switch is at ON,
terminals 2 and 1 should be conducted, as shown in Fig. 4-88.
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Fig. 4-88
7. Check the flash signal control

(1) The flash signal is controlled by BCM body controller, as required in the table, check the voltage as
well as conductivity between terminals of flash wire connector. If the check results can not meet the
requirements in the table, check corresponding circuit. To find more, refer to Fig. 4-89 and Table 4-14.
Fig. 4-89
Table 4-14
Testing terminal Wire color Test condition Standard value
(2-7)―body B/R Press the emergency light switch, always Less than 1Ω
(2-8)―body N/R Left combination switch at turn left, always Less than 1Ω
(2-9)―body N/B Left combination switch at turn right, always Less than 1Ω
(3-17)―body R/Y Left combination switch at turn left, always 10～14V
(3-18)―body N/Y Left combination switch at turn right, always 10～14V
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(3-35)―body R/G Turning light constant power input 10～14V
8. Check the operation status of inner light delay system

(1) Main components: Ignition key ring indicator, rear roof light.
(2) The ignition key is pulled out.
(3) When the roof light switch is at “DOOR”, upon unlocking by remote control or opening of any door,
the roof light is lightened. If no door is opened within 30 seconds after unlocking by remote control, the
light goes out; (open the door) 8 seconds after close the door, linear weakening occurs to the brightness,
the light gradually goes out within another 5 seconds; press the locking key on remote controller after the
door is closed, the roof light goes out immediately.
(4) Open the left front door when the ignition key is pulled out, the key ring indicator will lighten for 30
seconds, if the left front door is closed within the 30 seconds, the key ring indicator will go out 15
seconds after the closing; when the key is inserted into the ignition lock, the indicator goes out
immediately; when the key is pulled out, the indicator lightens and goes out after 15 seconds.
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Section Ⅶ Wiper and Washer
一、Overview
The wiper system is composed of wiper blade arm, connecting rod mechanism, blade and wiper
motor. It enjoys one-step wiping, intermittent wiping, slow-speed wiping and high-speed wiping. The
washer system is composed of pump, detergent pot, filler and nozzle. Both the wiper and washer
systems attempt to provide a convenient, safe and reliable means to ensure the view of the windshield.
All components of this system transform the electricity generated by the circuit system to mechanical
movement of the wiper blade, so as to wipe the water drops on the outer windshield and also to
movement of the washer system, so as to spray the detergent in the detergent pot onto the concerned
area. The combination of these two systems can wipe the rain drop, snow, insects, mud water or other
tiny materials on the outer windshield, so as to offer a way to the driver to keep a clear view even under a
severe driving environment. The driver can use the combination switch at the right side of the steering
column under the steering wheel to start all the functions of the wiper and washer system. The wiper
system allows the driver to choose different modes, like high/low speed continuous wiping and
intermittent wiping. Push the right combination switch control lever forwards and then release it to select
the defogging mode of the wiper system and carry out a complete wiper operation. Pull it upwards to
start the washer system which then sprays the detergent to the windshield by the nozzle as shown in Fig.
4-90.
Fig. 4－90
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二、Layout Diagram of Wiper and Washer System
1. Layout diagram of wiper and washer system 4-91 and 4-92
Fig. 4-91
Fig. 4-92
1. Rocker arm cap pattern 2. Hexagon nut with taper spring gasket
3. Right rocker arm with blade 4. Left rocker arm with blade
5. Installing bolt of wiper motor and bracket assembly 6. Wiper motor and bracket assembly
2. Layout of main wiper blade Fig. 4-93
Fig. 4-93
Blade stop position: a=50-70mm b=40-60mm

Blade wiping angle: right blade =92°±3° left blade =82°±3°
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3. Layout of washer nozzle Fig. 4-94 and Fig. 4-95
Fig. 4-94
Fig. 4-95
Spraying position adjustment: a=485mm b=675mm c=450mm d=330mm e=530mm f=500mm
g=210mm h=245mm
Spraying position adjustment area: a 60×60 square area
Use the special tool (a thin probe) for nozzle
Adjustment scope: ±10°
4. Sketch map of wiper motor as shown in Fig. 4-96
Fig. 4-96
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三、Circuit Maintenance of Wiper and Washer System
1. Map of harness end interface. See Fig. 4-97, 4-98 and 4-99 and Table 4-15, 4-16 and 4-17.
Fig. 4-97
Table 4-15
Testing Standard
Wire color Terminal description Test condition
terminal value
Ignition switch ON; the right

High-speed power output of combination switch is at
1-body B/U 10～14V
wiper motor high-speed wiping position,
always
Low-speed power output of combination switch is at
2-body Y/U 10～14V
wiper motor low-speed wiping position,
always
3-body G/B Power output of wiper motor combination switch is at 10～14V
washing position, always
8-body B Right combination ground signal Always 小于1Ω

Return control of right Right combination switch is at
10- body Y/G 小于1Ω
combination switch OFF or INT, always
Power input of right combination
11-body R/B Ignition switch ON, always 10～14V
switch
Fig. 4－98
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Table 4-16
Testing
terminal
Low-speed input of wiper Motor runs at low

1 Y/U 1 (+) 5 (-), always
motor speed
Ignition switch is at ACC,
2 U Power input of wiper motor 10～14V
always
Return signal of wiper Motor returns to the end,
3 Y/G ＜1Ω
motor always
High-speed input of wiper Motor runs at high
4 B/U 4 (+) 5 (-), always
motor speed
5 B Motor ground signal Always ＜1Ω
Fig. 4－99
Table 4－17
Testing
terminal
Ignition switch is at ON; right

Power input of washer
1－body G/B combination switch is at 10～14V
motor
washing position, always
Washer motor
2－body B Always ＜1Ω
grounding
2. Check circuit as shown in Fig. 4-100
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Fig. 4-100
四、Fault Table of Wiper and Washer System (as shown in Table 4-18)
Table 4-18
Fault Cause Fault Cause
1 Fault in accessory relay
1 Fault in wiper combination switch
2 Fault in wiper fuse
Inactive wiper and Inactive wiper at LO or assembly
3 Fault in wiper combination
washer HI 2 Fault in wiper motor
switch assembly
3 Fault in wiring
4 Fault in wiring
1 Fault in wiper combination 1 Fault in wiper combination switch
switch assembly assembly
Inactive wiper at INT Inactive washer motor
2 Fault in wiper motor 2 Fault in washer motor
3 Fault in wiring 3 Fault in wiring
Inactive wiper while 1 Fault in wiper combination
wiper combination switch assembly 1 Fault in washing hose
No detergent spraying
switch assemble at 2 Fault in wiper motor 2 Fault in nozzle
MIST 3 Fault in wiring
While the wiper
Inactive or wrong combination switch
1 Fault in wiper combination
positioned wiper assembly is at OFF, the
switch assembly The crank of wiper motor is not at
while right blade moves
2 Fault in wiper motor the resetting position
combination switch downwards, but then
3 Fault in wiring
is at OFF upwards a little and
stops at last.
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五、Inspection of Wiper and Washer System Components
1. Check the wiper combination switch assembly

(1) Check the conductivity between terminals of the wiper switch as shown in Fig. 4-101
Fig. 4-101
① Check the conductivity between terminals of wiper connector of the wiper combination switch
assembly. When the wiper is at MIST, the terminal 2 and terminal 11 should be conducted. When at OFF,
terminal 2 and terminal 10 should be conducted; when at INT, terminal 2 and terminal 10 should be
conducted as well as terminal 2 and terminal 11; when at LO, terminal 2 and terminal 11 should be
conducted; when at HI, terminal 11 and terminal 1 should be conducted.
② Check the conductivity between terminals of washer connector of the wiper combination switch
assembly. When the washer is at OFF, the terminals should be not conducted; at ON, terminal 3 and
terminal 11 should be conducted.
(2) Check the operation of wiper position of the wiper combination switch assembly
Locate the wiper combination switch assembly at OFF, connect the battery positive pole with terminal 11
of the wiper switch connector, and connect the negative pole with the terminal 8. Connect the test probe
of the positive pole of voltmeter with the terminal 3 of right combination switch connector; and test probe
of negative pole with terminal 8; locate the right combination switch at OFF→ON→OFF of washing
position; check the voltage between terminal 3 and 8 of the wiper switch connector which should be less
than 1V→10～14V→less than 1V.
2. Check wiper motor

(1) Low-speed operation: Connect the battery positive pole with the terminal 1 of wiper motor connector;
negative pole with terminal 5. The motor should run at low speed. See F7 for wiper motor connector.
(2) High-speed operation: Connect the battery positive pole with the terminal 4 of wiper motor connector;
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negative pole with terminal 5. The motor should run at high speed. See F7 for wiper motor connector.
(3) Automatic stop: Connect the battery positive pole with the terminal 1 of wiper motor connector;
negative pole with terminal 5. When the motor runs at low speed, disconnect terminal 1 to make the
wiper motor stop at any position except the automatic stop position. Shortly connect terminal 1 and 3,
and connect the positive pole with the terminal 2, and then restart the motor and run it at low speed. The
motor should stop at the automatic stop position. See F7 for wiper motor connector.
Check the motor of spraying cleaner
Firstly install the motor and water pump onto the water tank of the spraying cleaner, and then fill water.
Connect the battery positive pole with the terminal 1 of motor of spraying cleaner, and negative pole with
terminal 2. The water should be sprayed from the water tank. See W1 for motor connector of the
spraying cleaner.
Note:
As shown in Fig. 4-102, before installing the wiper arm, firstly clean the pivot area to avoid the
possibility of a loose arm.
Fig. 4-102
4. Check the washer nozzle

Blow air to the direction of washer spraying and confirm the airflow only pass in a single way, rather than
in a reverse direction. See Fig. 4-103.
Fig. 4-103
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Section Ⅷ Audio System
一、Overview
This system combines digital video and various devices to decorate your car to be a tiny music
theater and satisfy you with CD music, USB interface, AM/FM radio. It is composed of: (1) antenna
amplifier, (2) AM/FM printed antenna, (3) CD assembly, (4) speaker and (5) USB interface.
Fig. 4-104
Operating principle: This system is to provide entertainment programs and information by receiving,
modulating and amplifying the AM/FM radio signal at commercial frequency from the local radio station.
Through the printed antenna, the electromagnetic signals from the radio station will then form weak
current modulation signal and then transfer to the radio by the antenna amplifier and cable. Then the
radio will modulate and amplify the weak signals received to stronger current signal, and then transfer it
to the speaker which will then transform the strong signal to air vibration to revert the signal to sound.
The user can select the audio system of other models to supply equipments with sound and video like
cassette, CD or VCD. No matter what type you choose, the components of the audio system will amplify
and adjust the audio signal within the car to cater for all people in the car.
The audio system resists the radio frequency interference and electromagnetic wave interference by the
inner circuit. Outer measures:
(1) Grounded antenna amplifier housing
(2) Grounded radio housing
(3) Grounded engine and vehicle body
(4) Resistor type spark plug
(5) Radio anti-noise secondary ignition coil
二、Definitions of Interfaces of Audio System
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Fig. 4-105
Table 4-19
Testing
Wire color Identifaction of the pins Test condition Standard
terminal
Steering wheel control (-)

A1－body W/G - -
(reserved)
Steering wheel control (+)
A2－body Y/W - -
(reserved)
Power input while ignition switch at
A4－body Y Ignition switch at ACC, always 10～14V
ACC
Backlight signal input of audio Combination switch at width
A5－body R 10～14V
system light position
＜1Ω
A6－body G/N Reverse signal input Always
Normal power input of audio

A7－body W/Y Always 10～14V
system
＜1Ω
A8－body B Audio system grounding Always
B1－body V Right rear speaker drive output (+) Audio system in process -
B2－body V/B Right rear speaker drive output (-) Audio system in process -
B3－body Gr Right front speaker drive output (+) Audio system in process -
B4－body Gr/B Right front speaker drive output (-) Audio system in process -
B5－body W Left front speaker drive output (+) Audio system in process -
B6－body W/B Left front speaker drive output (-) Audio system in process -
B7－body N Left rear speaker drive output (+) Audio system in process -
B8－body N/B Left rear speaker drive output (-) Audio system in process -
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Radio assembly of audio system: Fig. 4-106
Fig. 4-106
(Definition of harness terminal of speaker) Refer to Fig. 4-107 and Table 4-20
2 1 1 2 2 1
P10 P9 R21 R20 T6 T5
Fig. 4-107
Table 4-20
Standard
Testing terminal Wire color Terminal description Test condition
value
1-body — Speaker drive input Audio system in process —
2-body — Speaker drive input Audio system in process —
三、Fault Table of Audio System
Table 4－21
Press down
1. Fault in audio system power Audio system night 1. Fault in audio system illumination
power switch,
circuit illumination system circuit
audio system
2. Fault in CD player assembly can not work 2. Fault in CD player assembly
does not work
1. Fault in speaker circuit
Poor tonal quality in all 1. Fault in speaker circuit
No speaker voice 2. Fault in audio system power
modes (volume is too 2. Fault in audio system power circuit
in all modes circuit
low) 3. Fault in CD player assembly
3. Fault in CD player assembly
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Can not put in CD or
Can not receive 1. Fault in CD disk
1. Fault in antenna circuit CD can not come out
radiobroadcast 2. Fault in audio system power circuit
2. Fault in CD player assembly immediately after
(poor reception) 3. Fault in CD player assembly
putting it in
1. Fault in CD disk
Although has 1. Fault in CD disk
2. Fault in audio system power Can not take out
powered on, CD 2. Fault in audio system power circuit
circuit CD/VCD
still can not work 3. Fault in CD player assembly
3. Fault in CD disk
1. Fault in CD disk
Poor tonal quality 1. Fault in CD disk Intermittent voice
2. Improper installation of CD player
when playing CD 2. Fault in CD player assembly when playing CD
assembly
1. Fault in audio system power
Touching panel circuit
switch does not 2. Fault in CD player assembly
work 3. Fault in wiring harness
connecting circuit
四、Audio system component check
Fig.4-108
1. Press down power switch, can not start audio system:
According to the circuit diagram Fig. 4-108, ① check the environment of CAB, for possible features
causing electrical short-circuit, and keep CAB dry and ventilative; ② Test the voltage between audio
system assembly connector terminal A7 and vehicle body, the voltage shall be 10-14V. ③ Test the
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resistance between audio system assembly connector terminal A8 and vehicle body, the resistance shall
be less than 1Ω. ④ Turn ignition switch to ACC, and test the voltage between audio system assembly
connector terminal A4 and vehicle body, the voltage shall be 10~14V. If all above is normal, check and
replace audio system assembly; if not, repair or replace wiring and connector.
2. Audio system night illumination system can not work:
Turn the light control gears of light combination switch assembly to lamplet or fog light, test voltage
between audio system assembly connector terminal A5 and vehicle body according to the circuit
diagram Fig. 4-108, the voltage shall be 10~14V. If the voltage is normal, check and replace CD player
assembly; if not, repair and replace wiring and connector.
3. No speaker voice in all modes:

Check according to the circuit diagram Fig. 4-108, detailed steps as follows:
(1) Check display device
Turn ignition switch to ACC, make audio system in ON position, the display device is lightened. If all
above is normal, proceed to next step; if not, proceed to 5th step.
(2) Adjust volume controller and adjust sound balance
Operate audio system volume control knob and adjust sound balance to identify which speaker is silent.
If one specific speaker is silent, proceed to next step; if all the speakers are silent, check and replace
audio system.
(3) Check speaker
Disconnect speaker connector, test the resistance between speaker terminals, the resistance shall be
2~9Ω. If it is normal, proceed to the next step; if not, replace speaker.
(4) Check connector between audio system and speaker
If it is normal, proceed to the next step; if not, repair or replace wiring and connector.
(5) Check CD player assembly
① Test the voltage between audio system assembly connector terminal A7 and vehicle body, the
voltage shall be 10~14V.
② Test the voltage between audio system assembly connector terminal A8 and vehicle body, the
voltage shall be less than 1Ω.
③ Turn ignition switch to ACC, test the voltage between audio system assembly connector terminal A4
and vehicle body, the voltage shall be 10~14V.
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If all above is normal, check and replace CD player assembly; if not, repair or replace wiring and
connector.
4. Can not put in CD or CD comes out immediately after putting in, can not play CD disk
Check according to circuit diagram Fig. 4-108, detailed steps as follows:
(1) Make sure the CD disk is normal, and has no deformation, crack, flaw, burr or other defects.
If it is normal, proceed to the next step; if not, fault of CD disk exists.
(2) Check if CD is put in with wrong side. If it is normal, proceed to the next step; if not, put in the CD disk
correctly.
(3) Replace the fault CD with a normal CD, check whether the same fault appears again.
If it is normal, fault of CD disk exists; if not, proceed to the next step.
(4) Check whether radio automatic search works normally.
If it is normal, repair or replace CD player assembly; if not, proceed to 6th step.
(5) Check whether CAB temperature and humidity change severely.
If they do change severely, the cause of condensing is temperature and humidity change (rest for a while
before use); if not, check and replace CD player assembly.
② Test the resistance between audio system assembly connector A8 and vehicle body, the resistance
shall be less than 1Ω.
and vehicle body, the voltage shall be 10~14V.
If it is normal, repair or replace CD player assembly; if not, repair or replace wiring or connector.
5. Can not take out CD disk
Check according to circuit diagram Fig. 4-108, detailed steps as follows:
(1) Check whether radio automatic search works normally:
If it works normally, repair or replace CD player assembly; if not, proceed to 5th step.
(2) Press down CD player of audio system assembly, press eject or close switch for 2s or even longer,
and check whether CD disk comes out.
If it is normal, proceed to the next step; if not, repair or replace CD player assembly.
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(3) Check whether the sound is Intermittent when driving on road of poor condition
If it is normal, proceed to the next step; if not, fault of CD disk exists.
(4) Check the installation of CD player assembly
If it is normal, fault of CD disk exists; if not, proceed to the next step.
① Check the voltage between audio system assembly connector terminal A7 and vehicle body, the
② Check the resistance between audio system assembly connector terminal A8 and vehicle body, the
resistance shall be less than 1Ω.
③ Turn ignition switch to ACC, check the voltage between audio system assembly connector terminal
A4 and vehicle body, the voltage shall be 10~14V.
If it is normal, repair or replace CD player assembly; if not, repair or replace wiring or connector.
6. Poor tonal quality only when playing CD (volume is too low)
Check the installation of CD player assembly. If it is normal, fault of CD disk exists; if not, check and
repair CD player assembly.
7. Can not receive radiobroadcast (poor reception)
(1) Check whether radio automatic search works normally.
If it works normally, repair or replace CD player assembly; if not, proceed to the next step.
(2) Check whether any jamming equipment is working (e.g. wiper, air conditioner blower, glass frame
riser).
If any jamming equipment is working, the influence is from the jamming equipment; if not, proceed to the
next step.
(3) Make noise check for printed antenna.
Turn ignition switch to ACC, start radio and select AM mode, check whether the speaker noise is caused
by putting screwdriver on the antenna. If it is normal, repair or replace CD player assembly; if not,
proceed to the next step.
(4) Check audio system antenna assembly.
Disassemble the aerial plug of audio system assembly, after connect radio connector, turn ignition
switch to ACC, start radio and select AM mode. Check whether speaker noise is caused by putting metal
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matters like fine flat blade screwdriver or tenuous wire on the antenna base of radio assembly. If it is
normal, proceed to the next step; if not, repair or replace CD player assembly
8. Touching panel switch does not work
(1) Check touching panel for stains; if stains exist, clean the surface stains; if not, proceed to the next
step.
(2) Check whether touch switch works well. If it works well, proceed to the next step; if not repair or
replace CD player assembly.
(3) Check multimedia player assembly.
② Test the voltage between audio system assembly connector terminal A8 and vehicle body, the
voltage shall be less than 1Ω.
and vehicle body, the voltage shall be 10~14V. If it is normal, proceed to the next step; if not, repair or
replace wiring and connector.
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Section Ⅸ Reverse Radar System
一、Overview
Vehicle reverse radar system is a kind of vehicle monitoring system imitating bat detection
principles. By installing several ultrasonic radar probes, receive and send signals, and send feedback
information to controller. According to signal reentrant time, controller can calculate the distance to the
tested barrier, and trigger different sound and indicator warning according to different distances to
remind driver for the distance between the barrier and vehicle, and increase backup convenience and
safety.
1. The warning mode applied by this reverse radar system is instrument cluster display screen LCD, as
shown in Fig. 4-109.
Fig. 4-109
2. Radar detection range: see Fig. 4-110.
Fig. 4-110
The reverse radar distance in LCD applies segment display and is controlled by instrument cluster,
specific distance detection and display as follows:
a. When detection distance S is greater than 1.5m, no light in all 3 sections: (No warning);
b. When detection distance S greater than 1m and equal or less than 1.5m, light in outermost layer:
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(warning: time interval of 1s);
c. When detection distance S is greater than 0.5m and equal and less than 1m, light in 2 outer layers:
(warning: time interval of 0.5s);
d. When detection distance S is less than 0.5m, light in all 3 layers: (warning: constant
warning).
3. System components:
(1) Reverse radar (2) Reverse probe (3) Reverse indicator (on automatic panel)
二、Reverse radar system terminal: See Fig. 4-111 and Table 4-22.
Fig. 4-111
Table 4-22
Testing terminal Wire color Terminal description Test condition Standard value
Turn ignition switch to
10～14V
BCM (1-8) - body G/N Input reverse signal ON, take reverse gear,
10~14V
always
Input reverse LIN signal to Pulse signal
BCM (1-19) - body W/B Data transmission
instrument generated
Output BCM fault warning to When reverse radar
BCM (2-18) - body R/Y 10~14V
instrument cluster indicator warns barriers
Ultrasonic probe power
BCM (2-20) - body B Always Less than 1Ω
negative
Ultrasonic probe power
BCM (2-21) - body G Always 10~14V
positive
When probe works
Pulse signal
BCM (2-22) - body Y Ultrasonic probe 1 signal wire after BCM sends out
generated
starting signal
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When probe works
Pulse signal
BCM (2-23) - body R/W Ultrasonic probe 2 signal wire after BCM sends out
generated
starting signal
When probe works
Pulse signal
BCM (2-24) - body Y/R Ultrasonic probe 3 signal wire after BCM sends out
generated
starting signal
Check circuit as shown in Fig. 4-112
Fig.4-112
三、Reverse radar system notes

The system is the driving auxiliary equipment; the use of rearview mirror is indispensable. Driver shall be
at his/her own risk for accident caused by overspeed reverse and his/her negligence.
1. Testing function of sensor can not work normally in the following conditions
(1) Sensor covered by earth or snow (back to normal, after cleaning foreign matters with water)
(2) Sensor covered by hand
(3) For low external temperature, sensor fault caused by sensor freezing
2. Sensor detection range will change in the following conditions
(1) Sensor covered by earth or snow (back to normal, after cleaning foreign matters with water)
(2) Vehicle in insolation or low temperature condition
3. Detecting mistake might appear in the following conditions
(1) Driving on uneven road, gravel road or grass
(2) Influenced by sound made by other auto horns, motorcycle engine, air braking system of oversize
538
vehicles or influenced by sound wave of other vehicles with probes
(3) Vehicle with water stain made in rain
(4) Relatively great inclination of vehicle
(5) Sensor covered by earth or snow
(6) Vehicle with drawbar
(7) Another vehicle with probe is approaching
(8) Driving to higher or square curb
4. Sensor can not detect because of the shape or features of barriers
(1) Wirelike objects, e.g. wire or rope
(2) Objects can absorb sound wave greatly, e.g. cotton, snow accumulation, etc.
(3) Objects with sharp edge
(4) Object is too low
(5) Object is too high or the upper part of object is bulging
(6) Sensor is hit or knocked heavily
(7) Vehicle is close to stairs too much, system can not correctly detect the distance between bottom stair
and the vehicle rear, causing damage on rear mudguard (Fig. 4-113).
Fig. 4-113
(8) As shown in Fig. 4-114, when driving approaching the wall, warning mistake is caused by inaccurate
distance detecting
Fig. 4-114
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四、Self-diagnosis and troubleshooting
1. Prior examination
1) Position ignition switch to ON, position shift lever to reverse, make parking brake to guarantee vehicle
safety, check reverse radar system
(2) Switch on reverse indicator switch
(3) Move a cylinder object with 60mm diameter around the sensor, measure the sensor detection range
(4) When detecting a barrier, check indicator and the warning condition of buzzer
A. When detection distance S is greater than 1.5m, no light in 3 sections.
B. When detection distance S is greater than 1m, and equal or less than 1.5m, light in outermost layer.
(Warning: time interval of 1s)
C. When detection distance S is greater than 0.5m, and equal or less than 1m, light in outer 2 layers.
(Warning: time interval of 0.5s)
D. When detection distance S is less than 0.5m, light in all 3 layers. (Warning: constant warning)
Test height: 528 + -10MM
2. Self-checking function check
(1) Check self-checking function of LCD indicator and buzzer: about 0.4s after turning ignition switch to
ON, positioning shift lever to reverse gear, check indicator and buzzer operation, the operation time shall
be 0.8±0.2s, now system is in normal testing operation.
(2) If the LCD indicator is not on or buzzer does not make sound as stipulated, wiring might be in
disconnection.
3. Fault table, Table 4-23.

Table 4-23
Buzzer does not
Totally can not work 1.Fault in power circuit 1. Fault in buzzer drive circuit
work (can
(can not self-check) 2.Fault in reverse radar 2. Fault in reverse radar
self-check)
Sometimes LCD Open circuit or 1. Fault in sensor or sensor
1.Fault in indicator drive circuit
indicator does not freezing indicated influenced by external environment
2.Fault in reverse radar
work (can self-check) in self-checking 2. Fault in sensor circuit
When in reverse gear, 1.Fault in reverse gear switch
Volume of buzzer is 1. Fault in buzzer drive circuit
system does not work circuit
too low 2. Fault in reverse radar
(can self-check) 2.Fault in reverse radar
540
五、Troubleshooting
1. Totally do not work
(1) Check circuit as shown in Fig. 4-115
Fig. 4-115
(2) Check step
1) Disconnect reverse radar probe wire harness connector, check the impedance of foot 3 in the
previous figure and vehicle body, the impedance shall be less than 1Ω.
2) Turn ignition switch to ON, take reverse gear, check the voltage of foot 1 in the previous figure and
vehicle body, the voltage shall be 10-14V. If it is normal, replace reverse radar; if not, proceed to the next
step.
2. Buzzer does not work, check whether it is damaged.
(1) Check circuit as shown in Fig. 4-115
(2) Check step
1) Check whether output signal exists
① Disconnect instrument cluster connector.
② After starting engine, take reverse gear, check whether square signal output exists in BCM (1-19)
with oscillograph. If it is normal, proceed to the next step; if not, check whether BCM controller and probe
are damaged.
2) Check wire harness or connector
541
① Disconnect BCM vehicle body controller connector
② Disconnect instrument cluster connector
③ Check the impedance of BCM vehicle controller sleeve BCM (1-19) and instrument cluster A10, the
impedance shall be less than 1Ω.
If it is normal, proceed to the next step; if not, repair or replace wiring and connector.
3) Check for instrument cluster buzzer does not work
① Turn ignition switch to ON, open one of the four vehicle doors, buzzer shall give off a sound.
② If vehicle speed signal is sent to instrument and wire harness is normal, replace instrument cluster.
If it is normal, continue other troubleshooting; if not, replace instrument cluster.
3. When in reverse gear, system does not work
(1) Check circuit: see Fig. 4-115
(2) Check step
1) Check reverse radar
① Turn ignition switch to ON, put shift lever from non-reverse gear to reverse gear.
② Test the voltage between BCM (1-8) and vehicle body, the voltage should be over 8V.
If it is normal, check reverse radar probe and BCM controller; if not, proceed to the next step.
2) Check reverse switch
① Disconnect reverse switch wire harness connector.
② Gear to reverse gear and measure the resistance between BCM (1-8) and IG2, if the resistance is
more than 100KΩ while the resistance between reversing switch interface harness and BCM is less than
1Ω, then the reversing switch is broken, replacement required.
If it is normal, proceed to the next step; if not, replace reverse switch.
3) Check wire harness or connector
Check whether the wire from wire harness of reverse switch interface to BCM is in good connection.
If it is normal, continue other troubleshooting; if not, repair or replace wiring and connector.
542
Section Ⅹ Power Supply and Other Electrical System
1、Overview
This section covers battery, power distribution network, rear defrost system, electric horn system and
electronic clock.
2、Battery
Fig. 4-116
Note：
①: If an auxiliary battery and a jumper cable are required for engine starting, please apply the battery of
12V.
②: After connecting battery cable, make sure the cable is fastened to the battery tightly to ensure a good
contact.
How to use battery
①: Battery surface (especially the top) shall always keep dry and clean. If the surfaces are wet or
electrolyzed, battery will make electric discharge.
②: Shall remove the negative cable for long time not using intention.
Note: Do not make electrolyte contact with skin, eye, textile or painted surface. After contacting, wash
with water for 15min and seek for medical assistance.
③: Sulphation of battery. If battery is not used for a long time and the proportion of electrolyte is less
than 1.1, sole battery pole plate sulphation caused by complete electric discharge will happen.
Compared with normal battery, although sulphation battery has higher voltage in early stage of charging,
the electric current is not stable.
To protect battery, the battery shall be maintained in good charging state. Note: For battery
maintenance, operate according to notes on the battery.
543
3、Power switch system
1. If the fuse is blown, renew it after clearing the related fault causes.
2. Employ the fuse with the designated specifications, no fuse exceeding the given specifications can be
accepted.
3. Don’t install the fuse obliquely, ensure it to install correctly in the fuse box.
Relay mainly includes: normally open, normally closed and the mixed type.
四、The rear defrosting system includes: rear window glass heating net, rear window
defroster relay, rear window defroster switch: in combination with the emergency
light switch, inner integration on the air conditioner controller (for electrical air
conditioning)
1. Fault table, Table 4-24.
Table 4-24
Fault Cause
1. Fault in rear defrosting relay

2. Fault in rear defrosting fuse
Deficiency of rear defrosting system
3. Fault in rear defrosting switch
4. Fault in wiring
2. Check the rear defrosting switch (for electrical air conditioning), shown in Fig. 4-117.
Fig. 4-117
When the defrosting switch is positioned at ON, the terminal 15 and 12 shall be connected; while at OFF,
shall not be connected. If the continuity is out of the specification, renew the defrosting switch.
Check the luminous indicator light of rear defrosting switch (for electrical air conditioning). Connect
the battery positive with the terminal 3 on the air conditioning HVAC assembly end connector, while the
544
negative with the terminal 9, when the rear defrosting switch luminous indicator shall be lit. If the process
is out of the specification, renew the defrosting switch.
五、Electric horn system composition

The horn system is started by the horn switch hidden under the ornamental cap of the central air bag
module in the steering wheel. Press the air bag module ornamental cap and the horn relay can be
started, which will lead the necessary electricity to the horn.
1. Check circuit as shown in Fig. 4-118
Fig. 4-118
545
2. Fault table, Table 4-25
Table 4-25
Fault Cause
1. Fuse blown
2. Deficiency of horn relay
3. Deficiency of horn switch
Deficiency of the two horns
4. Deficiency of horn
5. Fault in clock spring
6. Fault in wiring
1. Deficiency of horn
Deficiency of one horn
2. Fault in wiring
1. Deficiency of horn relay

2. Deficiency of horn switch
Horn keeps chirping
3. Fault in clock spring
4. Fault in wiring
546
Section ⅩⅠ Wireness diagram
Part 1 Relay/fuse location view
1. I/P control box relay and fuse view 4-119
No.1 center control box
Fig.4-119
2.Engine compartment relay and fuse location view4-120
Fig .4-120
3. I/P control box relay and fuse description 4-121
547
Fig.121
548
4. Engine compartment relay and fuse description 4-122
Fig. 122
549
5. I/P control box principle 4-123
Fig.4-123
550
6. Engine compartment relay &fuse principle 4-124
Fig.4-124
551
Part 2 Harness location and connector figure.
1.Body harness and spare parts location view 4-125(a).the body ground points and wireness
connector location view 4-125(b)
B1-the connector of the LF door lamp switch; B2-the connector of thr electronic fuel pump; B3-the
connector of the RR speed sensor wireness;B4-the connector of the RR door lamp switch;B5-the
connector of the RF door lamp switch;B6-the connector of the LR door lamp switch;
B7-the connector of left liscense lamp; B8-the connector of right liscense lamp;B9-the conector of
the anti-theft alarm;B10-the connector of the rear left ASSY. Lamp;B11-the connector of the
lagguage switch;B12-the connector of the rear right ASSY. Lamp;B13-the connector of the noise
filter;B14-the connector of the left rear speaker.
B15-the connector of the right rear speaker,B16-the connector of the high mount brake
lamp;BA-the connector of the engine compartment harness;BG-the connector of the left rear door
wireness;RE/WJ/BD1/BD2/BD3-the connector of the Instrument harness.G25/G26/G27/G31-the
gound point of the body harness;BH1-the connector of the reverse radar harness;BH2-the connector
of the rear defroster;LH1-the connector of the left body harness;LH2-the negative pole of the
defroster;L1/L2-the connector of the reverse radar sensor;R1-the connector of the dome
lamp;W1-the connector of the CD player;
552
Fig. 4-125（a）
Fig.4-125(b)
2.the roof harness and spare parts location view 4-126
R1- the connector of the dome lamp；

RE-the connect the Instrument harness;
Fig 4-126
3.Door harness and spare parts location view4-127(a),the ground point and wireness connector
location view.4-127(b)
553
D1-the connector of the LF glass regular motor;D2-the connector of the left power rearview
mirror;D3-the connector the the left teween, D4-the connector of the LF speaker;D5-the connector
of the LF glass switch;D6-the connector of the LF door lamp ;D7-the connector of the LF door lock
motor;D11-the connector of the RF glass regular motor;D12-the connector of the right power
rearview mirror;D13-the connector of the right teween;D15-the connector of the RF glass
switch;D16-the connector of the right door lamp;D17-the connector of the right door lamp;D22- the
connector of the LR glass switch;D23-the connector of the LR door lamp;D24-the connector of the
LR door lock motor;D31-the connector of the RR glass switch;D32-the connector of the RR glass
switch;D33-the connector of the RR door lamp;D34-the connector of the RR door lock
motor;DH1/DH2/DH3/DH-the connector for the Instrument harness,DG-the connector for the Body
harness.
Fig4-127(a)
554
Fig.4-127(b)
4.Engine compartment harness and spare parts location view4-128(a),Ground point and connector
lacation view.4-128(b)
555
U1-the connector of the brake fluid level switch;U2-the connector of the wiper motor;U3-the
connector of the ABS;U4-the connector of the A/C H/L pressure switch;U5-the connector of the
right turn lamp;U6-the connector of the right axle adjustment switch; U7-the connector of the right
headlamp;U8-the connector of the right daytime lamp;U9-the connector of the washer
motor;U10-the connector of the RF speed sensor;U11-the connector of the left turn lamp;U12- the
connector of the LF speed sensor;U13-the connector of the left daytime lamp;U14-the connector of
the freezing fan;U15-the connector of the radiator fan;U16-the connector of the left axle adjustment
switch;U17-the connector of the left turn lamp;U18/U19-the connector of the horn(louder);U20/21-
the connector of the horn(lower)U22-the connector of the weak accelerate sensor;UA-the
connector for the left bosy harness;UB1/UB2-the connector for the Instrument
harness;G03/G11/G12/G13-the Ground point of the body.
Fig.4-128(a)
556
Fig.4-128(b)
5.Instrument harness and spare parts lacation view4-129(a)&1-129(b),ground point and connector
laction view,4-129(c)&4-129(d)
I1-the connector of the light sensor,I2-the connector of the instrument cluster A ;I3-the connector of
the instrument cluster B;I4-the connector of the antenna power;I10-the connector of the brake
557
switch;I11-the connector of the rear oxygen sensor;I19-the connector of the RFdoor lamp
switch;I23-the connector of the power rearview mirror switch;I25-the connector of the background
adjustment switch;I26-the connect of DLC;IG-the connector for the HAVC harness,IE-the
connector for the roof harness;IB1/IB2-the connector for the engine compartment harness;IH3-the
connector for the RF door harness;IH4-the connector for the RR door harness;G21/G23-the ground
point;BM1-the connector for BCM.
Fig.4-129(a)
I5/I6-the connector of the CD system;I7-the connector of the BCM antenna;I8-the connector of the
cigratte lighter;I9-the connector of the ashtry illumination;I12-the connector Ignition switch;I13-the
connector of the key insert switch;I14-the connector of the brake switch;I15-the coonector of the
wiper switch;I16-the connector of the key inllumination;I17-the connector of the spring
coiling;I20-the connector of the capacitance ASSY.I21-the connector of the brake switch; I1A、I1B、
I1C 、 I1E-the connector with the I/P control box;IA1/IA2-the connector with the engine
harness;ID1/ID2-the connector with the left body harness;IH1/IH2-the connector with the left front
door harness;IF-the connector with the SRS harness;BM2/BM3-the connector of the BCM
Fig.4-129(b)
558
Fig.4-129(c)
Fig.4-129(d)
5.SRS harness and spare parts location view4-130(a),Air bag/reverse radar/rear dome lamp/rear
559
defroster harness and the ground point’s connector location view.4-130(b).
SF-the connector with the instrument harness；S1-the connector of the SRS modual；S2-the
connector of the spring coiling；S3-the connector of the driver safty belt buckle switch;S4-the
connector of the airbag ECU；G22-the ground point.
Fig.4-130(a)
560
Fig.4-130(b)
7.the HAVC ground point and connector location view 4-131
Fig.4-131
Part 3 Wireness diagram
1.the principle of the code
（1）the code for the harness assembly between with the adapter
The base of the connector’s code is the harness，we indentified the 3 nummbers or 2
nummbers for the connector of the harness and the harness’,for example：When there are many
connectors of the engine compartment harness with the body harness,the codes are
UA1/UA2……,On the other side, the codes of the body harness’ connectors are
BA1/BA2…….The 1st code indentified the connector that belongs to the harness，we use the
first letter of the English name’s abbreviation what indentified the harness,the later two
number are same, which indicated the relationship of the connectors between with the couple
harnesses.If there is one connector,the number of behind we can ignore it,its code are two
561
numbers,such as UA/BA.
The number of the connector
The code of the harness The code of the connector of the harness
Fig.4-132
We identified the code from the connector between the two harnesses，its harness’ code and
the connector’s code like below, 4-26
4-26
Main harness The other harness Main harness The other harness
The The The

The code The The code
The name of code of name code of
The connector’s name of the connector’s of the
the harness the of the the
connector name connector
harness harness harness
The connector
The connector of the
A of the engine B
body harness
assembly
The connector
The connector of the of the
B C
instrument harness instrument
The engine The harness
compartment U chasis C
harness harness The connector
The connector of the of the engine
C E
engine assembly compartment
harness
The connector
E of the body F
chasis
harness
The connector
A A
The engine assembly The instrument
instrument I engine E harness
harness The connector of the harness The connector
engine compartment B of the chasis B
harness harness
562
The connector
The connector of the of the engine
C C
chasis harness compartment
harness
The connector
D of the body B
body harness
The harness
roof R The connector
The connector of the harness of the
E E
roof harness instrument
harness
The connector
F of the door B
SRS harness
harness
The connector
The connector of the air
G of the rear trunk C
condition harness
harness
The
The connector
The connector of the floor F
H of the body E
door harness harness
harness

J
antenna

engine compartment A
harness
The connector
B of the floor B
roof harness
harness
The connector
D of the rear trunk C
instrument harness
The body The harness
B
harness door D The connector
The connector of the harness
E of the body G
floor harness
harness
The connector
F H
chasis harness instrument
harness
The connector of the The The connector

G L C
door harness rear of the floor
563
trunk harness
harness
The connector
H of the body H
rear trunk harness
harness
The connector
The
The antenna The connector of the of the
W J A/C A G
harness instrument harness instrument
harness
harness
The SRS The connector of the

S F
harness instrument harness
(2)The code of the spare parts with the connector

The base of the connector’s code is based on the harness，we indentified the 2 nummbers for
the connector of the harness and the spare parts,for example: When there are many connectors of
the engine compartment harness with the body harness,the codes are U1/U2……. The 1st code
indentified the connector that belongs to the harness，we use the first letter of the English name’s
abbreviation what indentified the harness,the later number indentidied the index nummber,such as
the 4-26.
The code of the harness The number of the connector
Fig.4-133
(3)The code’s principle of the relay/fuse
a:the code’s principle of the center control box
the code of the center control box identified by 1,2,2…N.the I/P control box named 1,the
engine compartment fuse and relay box named 2,If there are other control box name as the rule.
b: The code’s principle of the relay/fuse
The connector’s code is base on the center control box，we identified the code of the relay or
fuse which there are 2 nummbers，for instance;there are so many relays and fuses in the I/P center
control box, named 1A/1B……；the first Arabic numerals indicated the relay who belongs to
center control box,the second Arabic numerals indicated the connector’s code, all of the code
identification ,please refer the figure 4-134.
564
The number of the center control box The number of the connector
Fig.
C;The code’s principle of the relay and fuse with the harness
The code of the harness The number of the connector
The number of the center control box

Fig.
(4)The principle of the ground points

We identified three numners for the ground points,the 1st number G is the ground point
code,the later two number are the SN,for instance,G21 means the first ground point in the room
from front to behind,the principle such as figure 4-27.
Fig.4-27
engine
engine assembly room the other
comparment/chasis
G01~G09 G11~G19 G21~G29 G31~G39
2 the wireness’ color and code

The wirness’ color and code should obey the 4-28.
Fig.4-28
blac whit gree yello brow viole orang
the wireness' color k e red n w n blue gray t e pink
code B W R G Y Br Bl Gr V O P
3 symbol
565
566
Fig.4-132
567
Fig.4-133
568
Fig.4-134
569
Fig.4-135
570
Fig.4-136
571
Fig.4-137
572
Fig.4-138
573
Fig.4-139
574
Fig.4-140
575
Fig.4-141
576
Fig.4-142
577
Fig.4-143
578
Fig.4-144
579
Fig.4-145
580
Fig.4-146
581
fig.4-147
582
Fig.4-148
583
Fig.4-149
584
Fig.4-150
585
Fig.4-151
586
Fig.4-152
587
Fig.4-153
588
Fig.4-154
589
Chapter V Air Bag
Section I Composition, Principle and Safety Rules for Maintenance
I. Composition & layout of air bag system

LF630 adopts electronic double-air-bag system, with air bag in the central ornamental cap of
steering wheel and in the dash board in front of the passenger respectively. The whole air bag system is
mainly composed of driver air bag module (DAB), front passenger air bag module (PAB), air bag clock
spring (SRS CS), air bag electronic control unit (SRS ECU), safety belt pre-tensioners for driver side and
front passenger side (deluxe scheme), air bag harness, warning label, and so on. Air bag system layout
for LF630 is illustrated in Fig. 5-1.
1. Air bag ECU (Electronic Control Unit)

The air bag ECU assembly is installed at the central axis of the vehicle, under the central control
panel, as shown in Fig. 5-1.
Fig. 5-1
The air bag ECU can keep in operation for over 100ms under the circumstances that the battery
590
voltage drops too low or the power supply disconnects because of collision. Two models of the air bag
are involved in the LF630: the two circuits and four circuits which must work simultaneously with the front
pre-tensioned safety belt.
2. Driver air bag module

The un-removable driver air bag module, containing gas generator, bag, ornamental cap and a series of
auxiliary components, is installed in the central ornamental cap of the steering wheel, as shown in Fig.
5-2.
Fig.5-2
The main functions of the driver air bag module: Under normal usage, the driver air bag module
shall receive ignition signal from SRS ECU (Supplement Restraint System Electronic Control Unit) after
certain collision and then spark the gas generator and produce abundant air rapidly for the deployment
of air bag. With all of these, the driver can be protected.
3. Air bag clock spring

Driver air bag module, whose communication with ECU is carried out through air bag clock spring, is
installed on the steering wheel and turns simultaneously with the steering wheel. The clock spring,
comprising of swirly cable, turnplate, housing, harness and auxiliary components etc., is installed on the
combination switch, as shown in Fig. 5-3.。
591
Fig. 5-3
The working principle of air bag clock spring: The installation housing of the clock spring is fixed on
the steering column, and the upper part of the clock spring turn plate is inserted into the steering wheel,
and the swirly cable is installed between the turnplate and installation housing. When the steering wheel
turns left or right, the clock spring turnplate will turn simultaneously with the steering wheel, turning the
output end of the cable and stretching or tightening the swirly cable. For this reason, the harness is
prevented from being wound upon the steering column. Beyond that, the continuity of the harness and
the connection of the electronic signal are assured. Thus, the harness of the clock spring is also the
bridge for supplying electricity from the vehicle body to the related functional components of steering
wheel.
4. Front passenger air bag module

The front passenger air bag module, comprising of gas generator, bag and a series of auxiliary
components, etc, is installed above the sundries box of dash board, as shown in Fig. 5-4.
592
Fig.5-4
The main function of front passenger air bag module: Under normal usage, the front passenger air
bag module shall receive ignition signal from SRS ECU (Supplement Restraint System Electronic
Control Unit) after certain collision and then spark the gas generator and produce abundant air rapidly for
the deployment of air bag. With all of these, the passenger can be protected.。
5. Air bag harness
Air bag harness is used to connect the air bag ECU, clock spring and dash board harness, as
shown in Fig. 5-5.
Fig. 5-5
6. SRS warning lamp

SRS warning lamp can be observed in the instrument cluster, as shown in Fig. 5-6.
593
Fig.5-6
When the self-diagnostic circuit of air bag ECU assembly detects fault, the SRS warning lamp shall
be illuminated so as to inform the driver of the malfunction of air bag system. Under normal
circumstances, the illumination of the warning lamp will last for 5s before run out when the ignition switch
has been turned to the position ON. However, in the special conditions, such as the circuit contact
malfunctions, intermittent faults, if the faults recorded by the air bag ECU are over 8 times, the warning
lamp will be lighted. Generally speaking, the driver should check the car in the service station in time
once the SRS warning lamp shows the abnormal signal.
When the self-diagnostic circuit of air bag ECU assembly detects fault, the SRS warning lamp shall
be illuminated so as to inform the driver of the malfunction of air bag system. Under normal
circumstances, the illumination of the warning lamp will last for 5s before run out when the ignition switch
has been turned to the position ON.

二、Working principle of air bag system
When frontal collision accident occurs, the collision sensor shall produce signal for the collision, and
the air bag ECU shall detect and analyze the collision signal to determine the necessity for ignition
requirement. If necessary, the ignition impulse shall be sent out immediately, the ignition pipe in each air
bag module will be ignited, and then the gas generating material in each of the air bag module shall be
ignited by the ignition pipe. Therefore, abundant gas generated in extremely short time shall inflate the
air bag suddenly, forcedly open the ornamental cap, and the fully inflated air bag will be formed. By this
way, the impact upon the driver and passenger arising from the collision accident shall be absorbed, and
the injury of the driver and the passenger shall be avoided or lessened.
594
三、Safety rules for air bag maintenance
During the maintenance of air bag system, unexpected deployment may occur if correct operation
procedure is not carried out, which shall lead to serious accident. Beyond that, the air bag may fail to
deploy if the maintenance operation is incorrect. Therefore, please carefully read the following notes and
take correct operation procedure.
1. Inspection, installation and maintenance shall be carried out by professionals.
2. Inspecting lamp, common voltmeter and ohmmeter shall not be used during inspection, and special
voltmeter and ohmmeter (minimal 10kΩ/V) shall be used for measuring voltage and resistance.
3. Read out the flash DTC (Diagnostic Trouble Code) before removing the battery ground line when clear
off air bag system fault.
4. Remove the negative ground line of the battery before carrying out specific maintenance. Then wait
for over 3min and perform maintenance operation, or the air bag may be unexpectedly deployed. The
negative electrode removed shall be wrapped with insulating tape for insulation.
Note: Wait for over 3min before carrying out any operation after disconnecting the battery, or the
unexpected deployment of air bag may result in serious accident!
5. After slight collision, check driver air bag module and air bag ECU assembly even if the air bag has
not been deployed.
6. Remove air bag ECU assembly before maintenance if the sensor can be vibrated during the
maintenance.
7. Forbid to reuse the air bag system components removed from other vehicles. Renew if necessary.
8. Disassembling and repairing for repeated usage or other reasons of driver and front passenger air bag
modules and air bag ECU assembly are not allowed.
9. If accidentally dropped, vibrated or knocked, driver air bag module, front passenger air bag modules
and air bag ECU assembly shall be renewed. If crack, impress or other damages are discovered on the
housing, support or interface, also renew these components.
10. Direct contact with hot air or flame of driver air bag module, front passenger air bag module and air
bag ECU assembly is unallowable.
11. Remove such components as air bag ECU, air bag module, clock spring, and so on, during
spray-painting operation, or these components may be affected due to the high temperature (above
595
93℃).
12. The air bag ECU interface, interfaces for the connection between air bag ECU assembly and clock
spring, clock spring and driver air bag module, as well as front passenger air bag module and air bag
ECU assembly, are all provided with protection mechanism for the unexpected development of air bag.
Operate as per the maintenance requirements to avoid the unexpected deployment of air bag and the
damage of components.
13. Pay attention to the warning label on the component of the air bag system and the relative positions
inside the vehicle. Follow the operation requirements specified on the label.
14. During the maintenance of the air bag system, the air bag module must be immediately installed after
being taken out from the transportation device. Return the module to the transportation device if the
installation is terminated. It is not allowed to place the module unattended. Keep the deploying side of
the air bag upwards when storing the removed air bag module.
15. Electrical inspection shall be carried out first after finishing the maintenance of the air bag system.
Connect the air bag with the circuit only after ensuring the electrical system is all right.
16. Nobody is allowed to stay in the vehicle when connecting the air bag system with the power supply.
Do not connect with the power supply before well fixing the air bag ECU.
17. Check the operation of SRS warning lamp after finishing the maintenance of the air bag system.
18. Refer to the Instruction Manual for the service-life of the air bag. Renew the air bag and label when it
is out of its service-life.
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Section II Diagnosis & Fault Clearing
LF630 air bag system can carry out self-diagnosis, and the basic diagnostic procedure is as follows:
一、Self-diagnosis of SRS warning lamp circuit

1. Turn the ignition switch to position ACC or ON, and check SRS warning lamp for illumination.
2. The system is ok if the warning lamp keeps light for about 5s and then dark for over 5s.
3. The continuous illumination of the warning lamp indicates that single fault or multiple faults have been
detected, then read out DTC and clear off the faults as per part II in this section.
4. If SRS warning lamp illuminates sometimes after connected with the ignition switch for 5s, or SRS
warning lamp illuminates again even the ignition switch has been turned to position LOCK, check SRS
warning lamp circuit for short circuit as per Section 2.5.
二、Read out fault

Read out the fault by special hand-held diagnostic instrument
(1) Connect to the fault diagnostic interface of the vehicle.
(2) Read out the fault as per the indication shown in the diagnostic instrument, as shown in DTC Table
5-1
DTC Table 5-1

Bosch
DTC Description Lifan DTC DTC in
EEPROM
Electronic Control Unit (ECU) Internal Fault Tbd 9000
Configuration Fault Tbd 9001
Driver Airbag Resistance High Tbd 8026
Driver Airbag Resistance Low Tbd 8022
Driver Airbag Short to GND or Cross Coupling Tbd 8024
Driver Airbag Short to Battery Tbd 8025
Passenger Airbag Resistance High Tbd 8017
Passenger Airbag Resistance Low Tbd 8016
Passenger Airbag Short to GND or Cross Coupling Tbd 8018
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Passenger Airbag Short to Battery Tbd 8019
Driver Belt Pretensioner Resistance High Tbd 8065
Driver Belt Pretensioner Resistance Low Tbd 8064
Driver Belt Pretensioner Short to GND or Cross Coupling Tbd 8066
Driver Belt Pretensioner Short to Battery Tbd 8067
Passenger Belt Pretensioner Resistance High Tbd 8058
Passenger Belt Pretensioner Resistance Low Tbd 8057

Passenger Belt Pretensioner Short to GND or Cross
Tbd 8059
Coupling
Passenger Belt Pretensioner Short to Battery Tbd 8060
Battery Voltage High Tbd 9328
Battery Voltage Low Tbd 9327
Driver Buckle Switch Circuit Fault Tbd 8097
System Warning Lamp Short to GND or Open Tbd 8671
System Warning Lamp Short to Battery Tbd 8673
Driver Buckle Switch Warning Lamp Circuit Fault Tbd 8595
三、Fault checking and repairing (as shown in Table 5-2)
Table 5-2
S/N Possible Faults Areas Fault Clearing Methods

1. Preparation before checking;
2. Check the earth wire, if normal, go to the step 3; if loose or
Ground wire Earth wire
1 disconnected, repair it;
deficient Harness
3. Check the harness, if normal, the parts with faults have been
recovered; if not, repair or renew the harness.
2 Voltage too high Battery 2. Check the battery voltage, if normal, the parts with faults have been
recovered; if too low, charge or renew the battery.
2. Check the driver air bag circuit, if normal, go to the step 3; if not, go
Driver air bag to 5;
module 3. Check the air bag ECU, if normal, go to 4; if not, renew the air bag
DAB
3 Clock spring ECU;
inexistence
Harness 4. Check the driver air bag module, if normal, the parts with faults have
Air bag ECU been recovered; if not, renew the driver air bag module;
5. Check the clock spring, if normal, go to 6; if not, renew the clock
spring;
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6. Check the harness between the air bag ECU and clock spring, if
normal, the parts with faults have been recovered; if not, repair or
renew the harness.
2. Check the front passenger air bag circuit, if normal, go to 3; if not,
Front repair or renew the harness or interface between the air bag ECU and
passenger air front passenger air bag module;
4 PAB inexistence bag module 3. Check the air bag ECU, if normal, go to 4; if not, renew the air bag
Harness ECU;
Air bag ECU 4. Check the front passenger air bag module, if normal, the parts with
faults have been recovered; if not, renew the front passenger air bag
module.
2. Check driver safety belt pre-tensioner, if normal, go to 3; if not, repair
1. Driver safety
or renew the harness or interface between air bag ECU and driver
belt
LPSB safety belt pre-tensioner module;
5 pre-tensioner
inexistence 3. Check air bag ECU, if normal, go to 4; if not, renew the air bag ECU;
2. Harness
4. Check the driver safety belt pre-tensioner, if normal, the parts with
3. Air bag ECU
faults have been recovered; if not, renew the driver safety belt
pre-tensioner.
1. Front 2. Check front passenger safety belt pre-tensioner circuit, if normal, go
passenger to 3; if not, repair or renew the harness or interface between air bag
RPSB safety belt ECU and front passenger safety belt pre-tensioner module;
6
inexistence pre-tensioner 3. Check the air bag ECU, if normal, go to 4; if not, renew air bag ECU;
2. Harness 4. Check front passenger safety belt pre-tensioner, if normal, the parts
3. Air bag ECU with faults have been recovered; if not, renew the front passenger
safety belt pre-tensioner.
Simultaneous
Related
7 over 2 faults Diagnose and clear the fault one by one according to the flash DTC.
components
shown
4、Air bag circuit (as shown in Fig. 5-7 and Table 5-3)
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Fig. 5-7
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Table 5-3 Names of Air Bag ECU Pins and Terminals
No. Name
A1 K line, diagnostic interface 12 feet
A3 Safety belt reminder buzz output
A5 Collision output to BCM
A7
Driver safety belt switch
A8
A12 Power line
A14 Driver’s safety belt reminder warning lamp
A15-
Driver air bag module
A16+
A17+
Front passenger air bag module
A18-
A19-
Driver safety belt pre-tensioner
A20+
A21+
Passenger side safety belt pre-tensioner
A22-
A23 GND
A24 To air bag indicator
2. Preparation before checking

Before maintenance, carefully read the section 1.3 about the safety rules for air bag maintenance. In
addition, following preparation work shall be carried out.
(1) Remove the negative ground wire from the battery and wait for at least 3min.
(2) Remove the driver and front passenger air bag modules, keep the air bag module upwards when
storing the module (See the removal methods in Section IV).
(3) Disconnect the interface of the driver and front passenger air bag modules, air bag ECU interface, as
shown in Fig. 5-8.
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Fig. 5-8
3. Check for too low or too high voltage
(1) Connect the negative ground wire on the battery, turn on the ignition switch at the position of ON.
(2) Measure the PW voltage at the end of the air bag harness.
(3) Normal voltage: 10~14V.
4. Check for harness and interface

(1) Exam the connection of the air bag harness. Check if the resistance is below 1Ω.
(2) Check whether the other harnesses and the corresponding terminals are connected.
(3) Check all the leads of the harness for damage.
(4) Check the interface of the harness for damage.
5. Check for air bag ECU

(1) Connect the air bag ECU with the air bag harness. See Fig. 5-8.
(2) Connect the negative ground wire to the battery, and wait for at least 3min.
(3) Turn the ignition switch to the position of ACC or ON and wait for at least 20s.
(4) Eliminate the flash DTC by the diagnostic instrument and read out the flash DTC.
6. Check for the driver air bag module

(1) Turn the ignition switch to position LOCK.
(3) Connect the driver air bag module. See Fig. 5-9.
Fig. 5-9
(4) Connect the negative ground wire on the battery and wait for at least 3min.
7. Check for driver air bag circuit
(1) Measure the resistance between the DA+ and DA- at one side of the clock spring. Normal resistance
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shall be above 1MΩ.
(2) Measure the resistance between the DA+ at one side of the clock spring and DA+ at one side of the
air bag ECU. Normal resistance shall be within 1MΩ.
(3) Measure the resistance between DA- at one side of the clock spring and DA- at one side of the air
bag ECU. Normal resistance shall be within 1MΩ.
8. Check for front passenger air bag module
(3) Connect the interface of the front passenger air bag module.
9. Check for front passenger air bag circuit
(1) Measure the resistance between the PA+ and PA- at one side of the air bag ECU. Normal resistance
shall be above 1MΩ.
(2) Measure the resistance between the PA+ at one side of the air bag ECU and PA+ at one side of the
front passenger air bag module. Normal resistance shall be within 1MΩ.
(3) Measure the resistance between the PA- at one side of the air bag ECU and PA- at one side of the
front passenger air bag module. Normal resistance shall be within 1MΩ.
10. Check for driver safety belt pre-tensioner
(3) Connect the interface on the driver safety belt pre-tensioner. See Fig. 5-10.
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Fig. 5-10
11. Check for driver safety belt pre-tensioner
(1) Measure the resistance between the RLP+ and RLP- at one side of the air bag ECU. Normal
resistance shall be above 1MΩ.
(2) Measure the resistance between the RLP+ at one side of the air bag ECU and RLP+ at one side of
the driver safety belt pre-tensioner. Normal resistance shall be within 1Ω.
(3) Measure the resistance between the RLP- at one side of the air bag ECU and RLP- at one side of the
driver safety belt pre-tensioner. Normal resistance shall be within 1Ω.
12. Check for front passenger safety belt pre-tensioner
(3) Connect the interface on the front passenger safety belt pre-tensioner. See Fig. 5-10.
13. Check for front passenger safety belt pre-tensioner circuit
(1) Measure the resistance between the RRP+ and RRP- at one side of the air bag ECU. Normal
resistance shall be above 1MΩ.
(2) Measure the resistance between the RRP+ at one side of the air bag ECU and RRP+ at one side of
the front passenger safety belt pre-tensioner. Normal resistance shall be within 1Ω.
(3) Measure the resistance between the RRP- at one side of the air bag ECU and RRP- at one side of
the front passenger safety belt pre-tensioner. Normal resistance shall be within 1Ω.
14. Check for clock spring
(1) Unplug the interface between the air bag ECU and the clock spring. See Fig. 5-10.
(2) Measure the resistance at one side of the air bag ECU. Normal resistance shall be above 1Ω.
(3) Measure the resistance between the A+ at one side of the clock spring and A+ at one side of the air
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bag ECU. Normal resistance shall be within 1Ω.
(4) Measure the resistance between the A- at one side of the clock spring and A- at one side of the air
bag ECU. Normal resistance shall be within 1Ω.
四、Check for SRS warning lamp circuit fault

In the normal conditions, when the ignition switch turns from the position LOCK to ACC or ON, the
SRS warning lamp shall keep lighting for 5s, and then go out automatically; if there is any faults in the air
bag system, the SRS warning lamp will keep lighting and never go out. Read out the flash DTC
according to the normal process.
Provided that the lamp keeps lighting when the ignition switch is at the position of LOCK, or keeps
dark when the switch is at the position of ACC or ON, there must be malfunctions in the SRS warning
lamp circuit. With reference to the air bag system wiring diagram (see Fig. 5-7), check the circuit as per
the following process.
1. Check for constant illumination when ignition switch at LOCK

(3) Unplug the air bag ECU interface.
(4) Connect the ground wire to the battery negative pole and wait for at least 3min.
(5) Check whether the SRS warning lamp goes out or not. If it goes out, the air bag ECU shall be
renewed; if not, check the SRS warning lamp circuit.
2. Check for SRS warning lamp circuit

Before checking the SRS warning lamp circuit, exam the fuse of the engine ECU; if the fuse has been
burned out, it shall be renewed; if it works normally, go to the following checking process.
(1) Preparation before checking.
(3) Turn the ignition switch to position ACC or ON.
(4) Measure the voltage between the LA pin of the air bag ECU and the vehicle body.
(5) Normal voltage: 0~4V. If the voltage is abnormal, check the SRS warning lamp or repair the SRS
warning lamp circuit. If normal, go to the following process.
(7) Connect the air bag ECU interface. See Fig. 5-11.
605
Fig.5-11
(9) Turn the ignition switch to position ACC or ON.
(10) Observe whether the SRS warning lamp is lighted or not; if lighted, the malfunctions have been
cleared; if not, check the LA terminal of the air bag ECU. If normal, the air bag ECU shall be renewed.
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Section III Diagnosis of Vehicles after Collision
Check and maintain the vehicles after collision even without the deployment of air bag. Refer to Section
IV for related methods of removal and installation.
一、Diagnosis, with the deployment of air bag

1. In the case that the air bag of the vehicle has been deployed after a collision, carry out a system fault
diagnosis according to the methods in Section II. Renew the following Components.
(1) Air bag ECU.
(2) Driver air bag module.
(3) Front passenger air bag module.
(4) Driver safety belt pre-tesioner module.
(5) Front passenger safety belt pre-tensioner module.
Note: The old air bag ECU, driver air bag module, front passenger air bag module, driver safety belt
pre-tensioner module and front passenger safety belt pre-tensioner module removed are required to be
recovered.
2. Check the following components. Renew as required.

(1) Clock spring. Check the interface and harness of the clock spring for damage and the circuit
performance of the clock spring as per 2.3.10. Renew as required.
(2) Steering wheel, steering column and steering lower shaft components. Check the steering wheel,
steering column and steering lower shaft components for distortion and anything abnormal. Repair or
replace if necessary.
(3) Harness. Check the harness of the air bag for firmness, the harness and interface for damage, and
the terminal for distortion. Renew as required.
二、Diagnosis, without the deployment of air bag

In the case that the air bag of the vehicle has not been deployed after a collision of low speed, carry out
a system fault diagnosis according to the methods in Section II and check the following components.
1. Air bag ECU. Check the air bag ECU box and bracket for depression, crack and distortion, the
interface for damage and the terminal for distortion. Check the air bag ECU for normal installation.
607
Renew if necessary.
2. Driver air bag module. Check the ornamental cap for depression, crack and distortion, the harness
and interface for damage and the terminal for distortion. Also check the gas generator housing for
depression, crack and distortion, the pushbutton switch contact piece of the steering wheel horn for
distortion. Check the module for normal installation. Renew if necessary.
3. Front passenger air bag module. Check the ornamental cap for depression, crack and distortion, the
harness and interface for damage and the terminal for distortion. Also check the gas generator housing
for depression, crack and distortion. Check the module for normal installation. Renew if necessary.
4. Driver safety belt pre-tensioner. Check the pre-tensioner for depression, crack and distortion, the
harness and interface for damage and the terminal for distortion. Check the pre-tensioner for normal
installation. Renew if necessary.
5. Front passenger safety belt pre-tensioner. Check the front passenger safety belt pre-tensioner for
depression, crack and distortion, the harness and interface for damage and the terminal for distortion.
Check the pre-tensioner for normal installation. Renew if necessary.
6. Clock spring. Check the interface and harness of the clock spring for damage and the circuit
performance of the clock spring as per 2.3.14. Renew as required.
7. Harness. Check the air bag harness for firmness, the harness and interface for damage and the
terminal for distortion. Renew if necessary.
Note: Replace the entire air bag components if they are soaked by water.
8. Press the SST switch and deploy the air bag. With the LED lamp of the SST switch on, the air bag
deploys simultaneously.
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Section IV Removal and Installation
During the process of repair for LF630 air bag system, removal and installation of driver air bag
module, front passenger air bag module, air bag clock spring, air bag ECU and air bag harness may be
involved. Some removal processes and notes are introduced as follows.
Note: Make the following preparations before removal and installation:
1. Locate the ignition switch in position ON, and encrypt the air bag SRS ECU with diagnostic
instrument.
2. Locate the ignition switch in position LOCK.
3. Remove the negative ground wire from the battery and wait for at least 3min.
一、Removal and installation of air bag ECU assembly
Note: Forbid to open the housing of air bag ECU assembly unless absolutely necessary. The integrated
circuit may be damaged in the case of contacting with its terminal.
1. Tips for removal of air bag ECU assembly
(1) Unplug the interface. Note: Unplug the interface under the state of installation for ECU assembly.
(2) Remove the screws with wrench and take off the air bag ECU assembly.
2. Tips for installation of air bag ECU assembly
(1) Install the air bag ECU assembly with wrench in the correct direction. Note: Make sure the tightening
torque is 8 N·m.
(2) Connect the interface.
3. Check after installation
After installation, check the air bag ECU assembly for its tightness.
二、Notes for removal, installation and maintenance of driver air bag module (DAB)
1. Removal process and notes
609
(1) Locate the ignition switch in position LOCK.
(2) Disconnect the battery negative cable for more than 3min.
(3) Remove the two hexagon flange bolts at the left and right sides of steering wheel hub.
(4) Pull the driver air bag module from the steering wheel, and disconnect the interface of clock spring
with the terminal of gas generator.
Note: The black spring plate should be picked up with a minitype flat tip screwdriver.
(5) Disconnect the interface of horn wire, and take out the air bag module. Removal is finished.
Note: Take care not to haul the air bag harness when removing the driver air bag module and keep the
ornamental cap upwards when storing the module. Disassembling the driver air bag module is not
allowed. Do not knock the air bag module. If knocked, install a new one. Forbid exposing the module
under the temperature over 90°C, and contact with lubricants, lubricant grease as well as water. Seal the
old module removed in a sealing bag, and return it to LIFAN Passenger Car Co., Ltd.
2. Installation process and notes

(1) Install a new driver air bag module, and plug the interface between the clock spring and gas
generator.
Note: Engage the black interface buckle in the gas generator. Then plug the horn wire interface.
(2) Place the whole module in the steering wheel, adjust the position of the air bag module and ensure
the equality of the gap at the four corners. And then screw two hexagon bolts into the corresponding
position using hexagon socket wrench at the torque of 8 N·m.
(3) Check the middle of steering wheel. After installation, gently revolve the steering wheel to left and
right, making sure that no noise or something abnormal exists.
3. Note for maintenance
For the driver air bag module of the LF630, there is no need for maintenance of any part except repairing
and changing the horn. If trouble occurs, install a new one.
Note: Make sure that new component is installed by the professionals at the designated service center.
三、Notes for removal, installation and maintenance of front passenger air bag
module (PAB)
610
(2) Disconnect the negative cable of the battery for more than 3min.
(3) Remove the trim strip of the sundries box door in the sundries box of dash board, unscrew the bolts
connecting front passenger air bag module with tubular beam by the wrench.
Note: When handling the air bag interface, take care not to damage the air bag harness.
(4) When dismantling the sundries box of dash board, gently uplift the dash board, and pick up the
interface in the air generator terminal of front passenger air bag with a mini-type straight screwdriver.
(5) Remove the front passenger air bag module. Dismantle the nuts fixing the front passenger air bag
module and dash board with a wrench, draw out the ropes tied on the front passenger air bag from the
gap, take out the front passenger air bag module from the top of the dash board. Seal the old front
passenger air bag module removed in a sealing bag, and return it to Chongqing LIFAN Industry(Group)
Imp.&Exp.Co.,Ltd.
Note: Forbid to disassemble the front passenger air bag module.
2. Installation process and notes

(1) Install a new front passenger air bag module. Place the module mount rightly into the corresponding
bolts on the dash board. And tighten the three flange locknuts with the wrench at the torque of 8 N·m.
(2) Unscrew the bolts on the draw cord ring, then put the draw cord on the dash board into the draw cord
ring of the air bag module, screw the bolts at the torque of 8N·m.
(3) After installing the dash board at the corresponding position in the car, plug the interface of air bag
harness into the corresponding air generator terminal of front passenger air bag module.
(4) Fix the dash board on the car.
(5) At this moment, the installing hole at the bottom of the air bag module shall directly face the installing
hole at the tubular beam. Fix them with the bolt.
(6) Install the sundries box.
(7) After installation, watch the surface of dash board for its levelness. Check the clearance also.
Reinstall and adjust if unqualified.
Note: The installation and adjustment of the module must be operated by professionals to avoid danger!
3. Notes for maintenance

For the driver air bag module of this model, there is no need of maintenance for front passenger air bag
611
module. Install a new one when trouble occurs.
Note: Make sure that new component is installed by the professionals at the designated service center!
四、Notes for removal, installation and maintenance of clock spring
(1) Make sure that the road wheels are in the straight ahead position.
(3) Disconnect the negative cable of battery for more than 3min.
(4) Dismantle the driver air bag module. Remove the M12 nuts fixing steering wheel with Φ19 socket,
and take down the steering wheel gently.
(5) Remove the screws on the cover of combination switch with cross screwdriver, and then take down
the cover of combination switch gently.
(6) Unplug the interface connected in the input jack of clock spring.
(7) Remove the clock spring from the steering column, and pay attention to the two buckles fastening the
clock spring on the steering column. Seal the old clock spring removed in a sealing bag, and return it to
Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd.
2. The installation process and notes

Install a new air bag clock spring. Do not remove the lock piece before installing the steering wheel.
(1) Locate the clock spring to the steering column shaft.
(2) Press the clock spring downward with proper pressure, making the two plastic buckles and a metal
buckle engage in the corresponding mount of the steering column.
Note: Uneven force shall be avoided when engaging the two plastic buckles! If the buckles are broken, a
new clock spring is needed.
(3) Check whether the buckles of the clock spring are engaged in the corresponding position.
(4) Install the covers at the front and back of combination switch for the steering wheel, and tighten the 2
installation screws.
(5) Make sure that the road wheels are in the straight ahead position (refer to the installation instruction
of clock spring) and install the steering wheel. Then align the steering wheel with the mark on the main
shaft of steering column, and tighten the installation nuts of steering wheel. Adjust the direction if the
612
steering wheel is new, and then unplug the lock piece of clock spring.
Note: Callback for the lock piece of clock spring is needed!
(6) Connect the battery negative pole and turn the ignition switch to the position ON.
3. Notes for maintenance

For the air bag clock spring of LF630, no maintenance and calibration is needed!
613
Section V Scrapping Tips for Air Bag Module
When scrapping the air bag module, remove the air bag module first. If scrapping the vehicle
equipped with air bag system, or the air bag module, the air bag module should always be deployed as
the following operation procedure. If something abnormal appears in the process of deployment, contact
the service center of LIFAN Passenger Car Co., Ltd. When lacking in the conditions of scrapping, please
deliver the module to related departments for disposal.
1. When deploying the air bag, loud noise will be heard. Therefore, the air bag should be deployed in an
outside open area with no nuisance to others.
2. When deploying the air bag, the operation shall be carried out by the professionals.
3. After the air bag is deployed, the air bag module will become very hot. Thus, do not touch it until at
least 30min later after the deployment.
4. When handling the deployed air bag module, put on gloves and safety glasses. After finishing the
operation, wash hands cleanly.
5. Forbid to water the deployed air bag module.
6. After the deployment of air bag module, the gas generator will be with a high temperature, and should
be handled after being cooled for more than 30min.
7. Put on gloves and safety glasses to remove the deployed air bag module.
8. Put the air bag into a plastic bag, fasten the mouth of the bag, and then dispose as scrap. See Fig.
5-12.
Fig. 5-12
9. After operation, do not forget to wash hands.
614
Note: Environmental protection treatment for
the scrapped air bag module is needed.
615
Chapter VI A/C System
Section I Introduction
This series of sedan has a full air conditioning system with functions of refrigeration, heating and
ventilation. The air conditioner can be used to reduce the temperature of the vehicle in summer, heating
and defrost the windscreen in winter. The air conditioning system is fully functional and easy to operate
with the compact conformation.
一、Principle of compressor refrigeration of air conditioner

The refrigeration system consists of compressor, evaporator, condenser, expansion valve, blower
and control mechanism, etc., see Figure 6-1:
Fig. 6-1
1. condenser 2. Pressure switch 3. Blower
4. Evaporator 5. Expansion valve 6. Compressor
See the principle of compressor refrigeration of vehicle in the illustration. Driven by the engine, the
compressor extracts the gaseous refrigerant from the evaporator and presses into the condenser. The
high pressure gaseous refrigerant makes liquefaction and heat exchange (release heat) in condenser.
Heat will be taken away by the air out of the vehicle. After the throttling action of expansion valve, high
pressure liquid refrigerant can reduce its pressure; low pressure liquid refrigerant makes gasification and
616
heat exchange (absorb heat) in evaporator. The cooled air near the evaporator is blown into the vehicle
by the blower. Gaseous refrigerant is extracted by the compressor again and pumped into the condenser.
Refrigerant repeats the closed circulation and discharges heat from the inside to the outside of the
vehicle and makes the temperature inside the vehicle reduce to a comfortable temperature. See Figure
6-2:
Fig.6-2
二、Principle of heating system
Water heating is applied for the heating system, with the coolant of engine as the heat source.
Heating system mainly consists of heat exchanger, coolant pipeline, blower, air duct, air vent, and
control mechanism, etc. The housing of warm air heating set and the housing of evaporator are
combined together, using the same blower and air duct with refrigeration system. See Figure 6-3:
617
图 6-3
1. Air duct 2. Coolant pipeline 3. Blower 4. Heat exchanger
When engine works, heated by the high temperature of the engine cylinder, the coolant is pumped
into the heat exchanger through water pipe by the water pump of the cooling system. Air from blower can
take the heat given off by the coolant into the vehicle or the windscreen to raise the temperature in the
vehicle or defrost. After the cooling process in the heat exchanger, coolant is pumped back by water
pump. Repeating the circulation can make warm air heating. See Figure 6-4:
Fig. 6-4
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三、Air conditioning control system
Air conditioning system includes power control circuit, compressor clutch control circuit and safety
protection control circuit and data communication circuit. It mainly consists of air conditioning switch, air
conditioning controller (electrical air conditioning system), coolant temperature sensor, pressure switch,
solenoid valve and temperature controller, etc. Air conditioning control system is to guarantee the
effective work of air conditioning system under any circumstances, and guarantee the safe operation of
the air conditioning system and the engine.
1. 1. Refrigeration temperature control

It mainly consists of evaporator temperature sensor, A/C controller and relevant circuits, etc. When
the temperature of evaporator changes, the resistance of sensor changes accordingly, making A/C
controller receive the relevant voltage signal of the temperature. Amplified by the amplifying circuit, the
signal is to control the work of electromagnetic clutch relay: when connecting electromagnetic clutch
relay, compressor electromagnetic clutch connects, compressor starts to work, and the temperature will
decrease; when disconnecting the electromagnetic clutch relay, compressor electromagnetic clutch
disconnects, compressor stops working, and the temperature will increase. By controlling compressor,
air conditioning control system maintains the refrigeration temperature in the set range.
2. To reduce the engine load under certain circumstances, electronic fuel injection engine also controls
the compressor: when engine starts, drives off, suddenly accelerates and overspeeds, the air
conditioner compressor stops working.
3. Security protection control

Security protection control mainly guarantees the normal operation of the system. Monitoring the
system pressure and temperature by the pressure switch installed on the high-pressure hard pipe can
realize the security protection control. Functions of security protection control as follows:
(1) Low pressure protection: for pressure below 0.196±0.02 MPa, pressure switch (between 1-A4 and
3-A4) switches off, the power of compressor clutch is cut off, and compressor stops working;
(2) Over pressure protection: for pressure over 3.14±0.2 MPa, pressure switch (between 1-A4 and 3-A4)
switches off, the power of compressor clutch is cut off, and compressor stops working;
(3) Control high pressure: for pressure over or equal to 1.77±0.1 MPa, pressure switch (between 2-A4
and 4-A4) switches on, a trigger signal is sent to engine ECM to make the electronic fan work at high
speed;
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(4) Low temperature protection: for temperature below 2℃ sensed by evaporator temperature sensor,
the power of compressor clutch is cut off, and compressor stops working;
(5) High temperature protection: for temperature over 110.25℃ sensed by coolant temperature sensor,
apply overheat protection for compressor; the power of compressor clutch is cut off, and compressor
stops working.
4. Engine cooling system (electronic fan) control. Engine cooling system control consists of coolant
temperature sensor, engine ECM, 1#, 2#, 3# electronic fan control relay, cooling fan, cooling fan
regulation resistance, condensation fan and relevant circuits. Depending on relevant temperature
sensors and switching signals, engine ECM controls the on off state of relevant fan control relay circuits,
as follows:
(1) For coolant temperature of 93℃~96℃, engine ECM electrifies 1# relay and 3# relay; the 2 electronic
fans are connected in parallel and work at low speed simultaneously.
(2) For coolant temperature of 98℃~100℃, engine ECM electrifies 2# relay; cooling fan works at high
speed.
(3) For coolant temperature reaching 110℃, instrument cluster lightens the warning lamp.
(4) For air conditioner switch closing, electronic fan works at low speed no matter coolant temperature is
high or low.
(5) For the pressure of air conditioning refrigeration system over or equal to 1.77±0.1MPa, electronic fan
works at high speed.
(6) For abnormal coolant temperature signals (broken coolant temperature sensor), engine ECM will
judge the engine runs with heavy load, electronic fan works at high speed.
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Section II System Layout
Heating and air conditioning electronic control system layout 1 (Figure 6-5)
Fig. 6-5
8 8
Fig. 6-6
① Sunlight sensor ② Instrument cluster ③ Air conditioning control module
④ Engine ECU ⑤ Air conditioning controller ⑥ Room temperature sensor ⑦ Junction box assembly ⑧USB
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Electrical air conditioning controller, as shown in Figure 6-7
Fig. 6-7
1. “A/C” switch, Cool/warm wind regulation knob 2. Rear window defrosting button 3. Face blowing mode button 4. Face
and foot blowing mode button 5.Foot blowing mode button 6. Front window defrosting button and foot blowing mode
button 7.Front window defrosting button 8. Internal and external recycling modes option button and air regulation knob
Fig. 6-8
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Exploded view of air conditioner parts as shown in Figure 6-9.
Fig. 6-9
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Exploded view of air conditioner parts as shown in Figure 6-10.
Fig.6-10
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Section III Component Maintenance
一、. Performance parameter of LF630 electrical air conditioning system
Table 6-1
Compressor Model WXH-086
Type Parallel flow

Condenser
Specification L×W×D mm 590×370×16mm
assembly
Heat transfer capacity ≥4.5m/s frontal velocity
Type Cascading style
Specification
Evaporator 38×250×258
D×H×W mm
core
Intake air flow rate (m³/h) 450, refrigerating capacity
Refrigerating capacity
≥4.1Kw
Type Cascading style

HVAC assembly
Specification
27×220×180
Radiator core D×H×W mm
For 6L/h flow rate, 350 m³/h air flow rate, heating
Heating capacity
capacity ≥4.24.1kW
th
Air flow regulation 4 gear
Air flow regulation Refrigerating face blowing ≥450m³/h
Maximum air flow Heating foot blowing ≥300 m³/h
R134a
Refrigerant
Type 500g±50g
Injection quantity PAG56

Lubricant
Type 120ml
Air conditioning Injection quantity Compressor 1800 revolutions, ≥4.0K
system Maximum refrigerating capacity 18℃～32℃
二、Inspection of air conditioner compressor belt

New belt is that used on the engine for not more than 5 min. Used belt is that used on the engine for
more than 5 min. Install the drive belt and check whether the belt is well contacted with the belt groove
(Figure 6-11).
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Check whether the belt slides in the belt groove by hand.
Fig. 6-11
三、Inspection of air filter
1. Remove sundries box as shown in Figure 6-12. For detail, please refer to the removal method of
sundries box.
Fig. 6-12
2. Take out the filter as shown in Figure 6-13.
Fig. 6-13
3. Take out filter element upwards, and check the ventilation property. Change the filter element for bad
ventilation property, as shown in Figure 6-14.
Fig. 6-14
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四、Inspection for evaporator housing
1. Disassemble air duct
(1) Disassemble upper air duct of the housing
① Remove the cover board of dashboard (please refer to the disassemble method of dashboard)
② Disassemble guard staples of the two sides of the air duct, as shown in Figure 6-15.
Fig. 6-15
(2) Disassemble lower air duct of the housing
① Move seat backwards
② Pull away the carpet, disassemble left and right upper air ducts, and then take out all the air ducts.
Disconnect the upper air duct on the left floor. According to the position indicated by the arrowhead,
move the upper air duct on the left floor sideways to loosen it, as shown in Figure 6-16.
Fig. 6-16
Disconnect the upper air duct on the right floor. According to the position indicated by the arrowhead,
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move the upper air duct on the right floor sideways to loosen it, as shown in Figure 6-17.
Fig. 6-17
2. Disassemble housing
(1) Discharge coolant from the system.
(2) Disconnect air conditioner pipeline assembly (as shown in Figure 6-18).
Fig. 6-18
Clamp the two ends of M16’s pipe with 24mm and 27mm open end wrenches; clamp the two ends of
M8’s pipe with 17mm and 19mm open end wrenches; then disassemble nuts and disconnect air
conditioner pipeline assembly.
(3) Remove clamp from air conditioner pipeline assembly.
Disassemble the hoop of heater inlet and outlet pipes from the heater unit (as shown in Figure 6-19).
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Fig. 6-19
(4) Remove the lower shield of dashboard (please refer to the disassemble method of dashboard)
(5) Disassemble the air duct and wire harness from the top and the bottom of air conditioner housing.
(6) Disassemble steering wheel and steering column (please refer to the disassemble methods of
steering wheel and steering column)
(7) Disassemble the lower shield of dashboard and air conditioning controller (please refer to the
disassemble methods of the lower shield of dashboard and air conditioning controller)
(8) Loosen the screw connected to the hollow beam mounting.
(9) Disassemble the hollow beam (please refer to the disassemble method of hollow beam)
(10) Disassemble 3 nuts in Figure 6-20.
Fig. 6-20
(11) Disassemble nuts in Figure 6-21.
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Fig. 6-21
(12) Disassemble bolts and nuts in the following figure, then the air conditioner housing can be taken out.
See Figure 6-22.
Fig.6-22
(13) Disassemble evaporator unit assembly.
1) Disassemble the inlet and outlet cover board of evaporator
2) Take off 2 inlet and outlet pipes and their retaining clamps as well as expansion valves
3) Disassemble the right pipe plate of evaporator
4) Evaporator can be taken out
5) Disassemble 2 O-shape rings from evaporator core (Figure 6-23)
Fig. 6-23
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(14) Disassemble heater unit.
1) Disassemble the inlet and outlet cover board of heater and lower air outlet of the CAB, as shown in
Figure 6-24.
Fig. 6-24
2) Disassemble 2 bolts of the retaining clamp of heater core inlet and outlet pipes, take off the retaining
clamp.
(15) Disassemble cooler connection, and disconnect the joint.
(16) Disassemble fan resistor. Disassemble 2 screws and blower resistor,
(17) Disassemble blower assembly with fan resistor. Disassemble 3 screws and blower assembly with
motor, as shown in Figure 6-25.
Fig. 6-25
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(18) Disassemble evaporator temperature sensor.
1) Take out the evaporator, as shown in Figure 6-26.
2) Disassemble the evaporator temperature sensor from the plunger piston of the evaporator right
housing.
Fig. 6-26
3. Installation notes
(1) Install the evaporator assembly
1) Coat the 2 new O-shape rings and the interface of expansion valve surface with sufficient compressor
oil; compressor oil: PAG56
2) Install 2 new O-shape rings to evaporator assembly.
(2) Install 2 inlet and outlet pipes, retaining clamp and expansion valve; install 2 hex bolts with 5.0mm
hex wrench
Tightening torque: 3.5 N·m
五、Inspection of compressor assembly

1. Removal and Installation
Before compressor removal, refrigerant should be emptied first. After the removal and installation of
compressor, fill refrigerant into the compressor, and check the tensity of compressor driving belt.
(1) Disassemble air conditioner pipeline。
For keeping foreign matters like dust away from entering, the disassembled pipeline and pipe joint of
evaporator should be sealed with plunger piston. All the hoses should be sealed completely, or
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compressor lubricants and receiver-drier will absorb vapor.
(2) Removal of compressor driving belt
Loosen the retaining bolt of steering pump (for specific details, please refer to the removal of steering
pump), loosen the adjusting bolt, and remove the driving belt.
(3) Removal of compressor
For this operation, be cautious for compressor lubricants splash, key points for installation
Check:
Action test of electromagnetic clutch
Connect battery positive to the connector clip of electromagnetic clutch directly, negative to the body of
compressor. If the electromagnetic clutch is normal, you will hear a rattle. If the belt pulley does not
touch the armature (no rattle), fault exists, Figure 6-27.
Fig. 6-27
2. Disassembly and Assembly:
Disassemble self-locking nut according to disassembly essentials as shown in Figure 6-28
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Fig. 6-28
1. Compressor overheating protection switch; 2. Self-locking nut; 3. Washer; 4. Armature head;
5. Snap ring; 6. Rotor; 7. Snap ring; 8. Clutch coil;
Assembly essentials for clutch coil: see Figure 6-20 and Figure 6-30
Fig. 6-29
Fig. 6-30
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When installing clutch coil to compressor housing, aim the compressor housing pin hole to the clutch coil
lug boss.
Assembly of snap ring; see Figure 6-31.
Fig. 6-31
Note: install snap ring with its conical surface towards outside.
In the installation of self-locking nut, special tools are applied to fasten the electromagnetic clutch.
Then screw the nut with the same method of disassembly. Adjust the clearance of clutch according to
Figure 6-32.
Fig. 6-32
Check whether the deviation of electromagnetic clutch clearance is within standard value. If it is not
within standard value, adjust with washer. Standard value: 0.3-0.5mm. Check compressor overheating
protection switch, as shown in Figure 6-33.
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Fig. 6-33
Put the metal part of engine overheating protection switch into engine oil, heat with gas stove until
reaching standard temperature, check whether switch terminals are on, as shown in Figure 6-34.
Fig. 6-34
Compressor overheating protection switch
On: Lower than 105℃
Off: Higher than 130℃ (in OFF mode, the lowest temperature is 125℃)
Note: When heating, temperature should not exceed necessary temperature.
六、Inspection for condenser assembly

1. On-vehicle check
(1) Check condenser assembly
1) Check whether the condenser thermal sink surface is dirty. If it is dirty, brush it with banister brush. Do
not wash with water-cannon in order to avoid possible damage to the thermal sink. Note: Do not damage
condenser assembly thermal sink.
2) For bend of condenser thermal sink, make it straight with screwdriver or pliers.
(2) Check the leak of condenser refrigerant
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1) Check gas leak at pipeline joint with halide leak detector.
2) If gas leak exists at the joint, check tightening torque of the joint.
2. Disassembly and assembly from vehicle
(1) For details of water tank removal, please refer to the removal of water tank.
(2) Disconnect 2 pipelines connecting condenser, remove 2 screws from the upper part of condenser,
and take out condenser.
(3) Coat sufficient compressor oil to the interfaces of cover and O-shape ring. Compressor oil: PAG56
(4) Install the cover and filter to condenser assembly with 10mm hex wrench tightening torque: 12N·m
(5) Install the condenser assembly.
(6) Install air conditioner pipeline assembly
1) Open the upper pipeline plug of the pipeline, connect every parts of condenser assembly;
2) Install a new O-ring seal at pipeline joint and coat sufficient compressor oil on the joint; compressor oil:
PAG56
3) Apply bolts to connect air conditioner pipeline assembly and the condenser assembly; note: tighten
according to torque requirement.
4) Inject refrigerant. Specified quantity: 500g
5) Engine warm up
6) Check the existence of refrigerant leak
七、Replacement of air conditioner amplifier assembly

1. Disassembly
(1) Disassemble auxiliary dashboard assembly
(2) Disassemble air conditioner amplifier assembly
1) Disconnect the connector
2) Remove air conditioner amplifier assembly
2. Installation
八、Removal and repair of refrigeration pipeline

1. Common faults for refrigeration pipeline, insufficient refrigeration or no refrigeration caused by
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stoppage or leak of refrigeration pipeline.
(1) Weak refrigerant flow or complete blockage caused by pipe bending or deformation.
(2) Leak caused by damage or loose of pipe joint.
2. Disassembly of refrigeration system
Cautions for pipeline disassembly:
(1) When loosening, two wrenches should be applied to avoid damaging pipe fittings. Figure 6-35.
Fig. 6-35
(2) For disassembled pipes, pipe joints should be sealed with plugs or cloth to avoid pollution in the
pipes.
3. Main content of the inspection of refrigeration system pipeline:
(1) Check possible loose and leak of pipeline joints, tighten the joint for existing loose; if leak still exists
after tightening with specified torque, it is a must to check the damage of O-ring seal and pipes.
(2) Check possible sag, bend deformation, rupture of pipeline or damage on pipe joint thread, etc. If any
of the problems aforesaid exists, replace the pipe.
(3) Check whether the pipeline is dirty. If the pipeline is dirty, wash it with pure alcohol. Install it after
complete drying.
Note: Do not clean pipes by applying compressed air.
Pipeline installation of refrigerating system
Two wrenches should be applied to install the pipeline of refrigerating system, tightening with specified
tightening torque. Loose tightening can not make pipeline sealed completely. Over tight tightening will
break pipe joint thread easily.
Cautions for installation:
(1) Suitable O-ring seal should be applied. Be cautious of not dropping or damaging the O-ring seal;
(2) For installation, coat the O-ring seal with some compressor oil;
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(3) Before connection, coat some compressor oil on pipe joint;
(4) After pipe installation, it is necessary to check the correctness of pipeline layout, whether the
pipelines will collide with other parts. After completing the installation, check the existence of leak,
vacuumize pipes, inject refrigerant and check the performance of air conditioning system.
Note:
(1) When disassembling pipeline, be cautious that both butt joints should be sealed. The seal material
applied should resist the corrosion of R134a to prevent foreign matters and water entering pipes.
(2) For pipeline installation, restore all the buckles and pipe straps to the original positions, as shown in
Figure 6-36.
Fig.6-36
九、Removal and repair of condenser fan (Figure 6-37)
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Retaining bolt
Fig.6-37
1. Remove the connecting pipe of swelling water kettle and water tank.
2. After removing the 2 retaining bolts in the figure, the fan assembly can be removed.
3. Install in the reverse order
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Section IV Fault Diagnosis
一、Fault diagnosis of system

（一）Direct observation check
1. For checking faults like stop working or abnormal working of air conditioning system, some apparent
symptoms will appear by applying direct observation check. Direct observation check (of looking,
touching and listening) can diagnose faults accurately and easily, and quickly eliminate faults.
(1) Carefully observe the existence of damage of pipelines, crack or oil stain on the surface of condenser
and evaporator. If oil stain exists on condenser, evaporator or their respective pipelines, apply soap
bubble leak detection. Key leak inspection areas include:
① Every joint of pipeline and every joint of valve;
② Joint between hoses;
③ Compressor oil seal, front and rear cover board, sealant pad, etc.
④ Scratch and deformation on the surfaces of condenser and evaporator;
(2) Observe the inspection window. Observing the inspection window of pipeline can check refrigerant.
Before observation, start engine and turn on air conditioning system, and make engine work for 5 min at
fast idle speed (1500~2000r/min). Then circulation condition of refrigerant can be viewed through the
inspection window:
① For normal circulation with one air bubble occasionally, refrigerant is in normal condition.
② For clarity and no bubble viewed, full refrigerant and no refrigerant can both be possible. If the air
outlet is cold, the refrigerant is in normal condition; if not, probably no refrigerant remains.
③ For relatively more bubbles, refrigerant is insufficient.
(3) Check electric circuits. Check whether disconnection of relevant circuits exists.
2. Check fault by touching with hands
(1) Check the high-pressure end of air conditioner refrigerating system. Switch on the air conditioner;
make refrigerating compressor work for 10~20min, touch pipelines and parts of the high-pressure end of
air conditioning system. From compressor outlet → condenser → expansion valve inlet, normally,
temperature felt by touching should change from hot to warm. If certain part in the middle of the process
is especially hot, the heat emission of the part is in poor condition; if the parts are cold, faults like
blockage, no refrigerant, compressor stopping working or working in poor condition or so forth might
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exist.
(2) Check the low-pressure end of air conditioner refrigerating system. Switch on the air conditioner;
make refrigerating compressor work for 10~20min, touch pipelines and parts of the low-pressure end of
air conditioning system. From condenser to compressor inlet, normally, temperature felt by touching
should change from cool to cold. If it is not cold or frost appears, the refrigerating system is in abnormal
condition.
(3) Check temperature difference at compressor outlet. Switch on the air conditioner; make refrigerating
compressor work for 10~20min, touch the two ends of compressor inlet and outlet. Obvious temperature
difference should exist between the high-pressure end and the low-pressure end of compressor. If
temperature difference is not obvious or no temperature difference exists, probably no refrigerant exists
or refrigerant is extremely insufficient.
(4) Check circuits. Check whether the wire connector is in good connection. No connector of air
conditioning system circuits should be loose or hot. If some connector is loose or the surface
temperature of connector felt by touching is relatively high (hot), the inside of connector is in poor contact,
which makes air conditioning system stop working or work in abnormal condition.
3. Check fault by listening
Listen carefully for abnormal noises of compressor and whether compressor is working normally to
identify whether no refrigeration or poor refrigeration of air conditioning system is caused by faults of
compressor or compressor control circuit.
4. Common Faults and Elimination Methods
(1) Air conditioning system is not refrigerating, both compressor and blower stop working.
1) Control circuit fuse protector is blown—after finding out causes, replace with fuse protector of the
same specification.
2) Disconnection of control line or earth wire—check whether each terminal or earth strap connection is
loose or disconnected, reconnect them firmly.
3) Damage of blower relay—Check whether blower relay coil is damaged and check the intactness of
contact terminal. If damage exists, repair or replace it.
4) Damage of electromagnetic clutch coil—check whether electric current exists in clutch coil. If no
electric current exists, repair or replace it.
5) Damage of electronic temperature controller—check whether thermal resistor temperature sensor is
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damaged, and check whether thermal resistor characteristics are normal, then check the amplifying part.
If fault of temperature controller exists, repair or replace it.
6) Fault of pressure switch—inject 300KPa (G) refrigerant into refrigerating system. If refrigerating
system starts to work again, low-pressure switch is in normal condition; if not, fault of low-pressure
switch exists. Short connect the pressure switch. If the system starts to work, fault of the pressure switch
exists. Short-circuit method can also be applied to check high-pressure switch. Repair or replace
pressure switches with faults.
7) Blower stops working—check whether blower circuit is in normal condition, whether fan blades are
blocked and whether blower motor is damaged.
(2) Insufficient refrigerating capacity
1) Too little refrigerant—both high pressure and low pressure are relatively lower. Make leak detection,
repair and inject refrigerant again till pressure is back to normal;
2) Excessive refrigerant—both high pressure and low pressure are relatively higher and pressure meter
dithers severely. Get cooling medium back, re-vacuumize and inject refrigerant with definite quantity;
3) Moisture exists in system—after air conditioner working for a period, low pressure becomes vacuum,
frost and ice plug appear on expansion valve, outlet air is not cold. Stop air conditioner and restart it later.
After air conditioner works normally for a short time, above faults appear again. Inleak of damp air or
moisture in refrigerant or refrigerant oil is too much. Replace drier and extend vacuumizing time, fill in dry
cooling medium and lubricants again;
4) Dirty matters exist in system—low pressure side appears to be in vacuum, pressure of high pressure
side is on the lower side, moisture condensation and frost appear on front and rear pipelines of
expansion valve and outlet air is not cold. If the condition is not improved after power off, the fault is dirty
matter blockage. Replace parts blocked by dirty matters;
Compressor is damaged, inleakage exists—low pressure is over high while high pressure over low,
sometime accompanying abnormal knocking. Change the compressor.
5) Compressor drive belt is too loose—compressor rotation speed is too slow, outlet air is not cold, noise
of belt skidding can be heard. Strain the drive belt or replace it.
6) Compressor clutch skidding—compressor can not work normally. Disassemble the clutch, repair or
replace it;
7) Little heat releasing air flow of condenser—both high pressure and low pressure are too high. Check
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whether blower is working normally and whether wind speed switch is in normal condition;
8) Condenser fins are blocked by dust—high pressure is too high, together with poor heat eliminating
effect. Clean dust on the condenser;
9) Evaporator fins are blocked by dust—air output decreases. Clean the dust by blowing with nitrogen
and compressed air;
10) Evaporator air cleaner is blocked by dust or foreign matters—air output decreases. Clean or replace
the air cleaner;
11) Too big jaw opening of expansion valve—both high pressure and low pressure are too high,
excessive refrigerant flows through evaporator and can not evaporate completely. Replace expansion
valve;
12) Leakage of expansion valve power head—both high pressure and low pressure are on the lower
side. Replace expansion valve;
13) Improper adjustment of thermostat—frequent starting, influencing air conditioning effect. Replace or
re-adjust the thermostat;
14) Too much lubricant in system—both high pressure and low pressure are on the higher side, clouding
stripes appear in sightglass. Expel redundant lubricant.
15) Fresh air door of air conditioner is not closed completely—a lot of high temperature air enters vehicle
from the outside. Close the fresh air door completely;
16) HVAC cool & warm air door is not closed completely—air is heated. Close the cool & warm air door
completely;
17) Air supply pipeline is blocked—air output is little, noises increase. Eliminate blockage in the pipeline.
3. Intermittent temperature decreasing of air conditioner
The main reasons are system ice plug, faults of temperature controller and relay and compressor clutch
skidding and poor contact of coils, etc.:
1) Faults of controller and relay, compressor clutch skidding and poor contact of coils, etc.
2) Unfirm contact of compressor clutch coil, poor ground connection and loose connection—clutch
separates too early when working. Fasten the joint.
3) Abnormal temperature controller—severe frost appears on evaporator surface, no cool air vented.
Replace the temperature controller.
4. Noise of air conditioner is too loud
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1) Noises of blower, compressor, drive belt and part collision, etc.
2) Noise of expansion valve operation.
5. Insufficient warm air of air conditioner
1) Damage of blower motor—check the blower motor, repair or replace it;
2) Air leakage of heater—replace sealant pad;
3) Abnormal jaw opening of cool & warm air door—check the working mode of the cool & warm air door;
4) Dust deposit or deformation of heater fins, and poor ventilation—clean or replace the heater;
5) The hot-water pipe of heater is blocked by scale deposit—replace the heater;
6) Insufficient engine cooling water—check whether leakage exists in cooling system, repair it and
replenish cooling water;
7) Failure of engine thermostat—replace the thermostat;
8) Air exists in the heater core barrel—expel air in the pipe.
（二）Fault diagnosis table of air conditioning system

Table 6-2
Phenomenon & state Cause analysis Measure
1. Air leaks into the system. Re-vacuumize and reinject refrigerant.
2. Excessive refrigerant refill. Expel redundant refrigerant.
Expel redundant lubricant or replace with new

3. Excessive lubricant
Both high pressure and lubricant.
lower pressure are high Wash and clean dust on the condenser
4. Poor heat eliminating effect.
surface or replace with a new condenser.
5. Abnormal common cooling fan of Inspect the condenser or replace with a new
condenser and water tank one.
1. Insufficient refrigerant. Replenish refrigerant.

Both high pressure and
2. Leakage of refrigerant exists. Make leak detection, replace leaking parts.
low pressure are low
3. O-shape ring is damaged. Replace the O-shape ring.
1. Jaw opening of expansion valve is too Adjust the jaw opening of expansion valve, or
big, or expansion valve is damaged. replace with a new expansion valve.
High pressure is normal,
low pressure high 2. Excessive refrigerant refill. Expel redundant refrigerant.
3. Fault of compressor exists. Replace the compressor.
1. Insufficient refrigerant. Replenish refrigerant.
High pressure is normal, 2. Ice plug of expansion valve exists. Replace with a new drier-receiver.
low pressure low 3. Dust exists on evaporator surface or Clean the evaporator surface or replace with a
blockage exists in the evaporator. new one.
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Inspect the compressor or replace with a new
1. Compressor efficiency decreases.
High pressure is low, low one.
pressure high Adjust jaw opening of expansion valve or

2. Air duct is blocked.
replace with a new expansion valve.
1. Stop the machine, low pressure

Replace with a new drier-receiver.
High pressure is low, low increases quickly—system ice plug.
pressure negative 2. Stop the machine, low pressure

Clean the system.
increases slowly—system ice plug.
1. Inlet air cleaner is blocked. Replace with a new inlet air cleaner core.
2. Air duct is blocked. Clean air duct.

Normal
3. Evaporator surface dust Clean the evaporator surface.
voltage
Insufficient Inspect the blower motor, or replace with a
4. Blower motor works stagnantly.
air output new one.
1. Vehicle power supply voltage is

Insufficient unstable. Inspection.
voltage
2. Fault of power grounding exists
High pressure can not

Clutch or belt is skidding. Inspect or replace the clutch or the belt.
reach a certain value
Replace it or check the correctness of the
1. Poor evaporator temperature sensor.
sensing head position.
2. Evaporator temperature sensor wire

Inspection.
harness and insert are in poor condition.
Evaporator is frozen
3. Excessive refrigerant. Expel some of the refrigerant.
4. Air capacity passing through evaporator

Check whether blower speed is normal.
is insufficient.
5. Failure of expansion valve. Replace it.
（三）Check of refrigerant
1. Check refrigerant quantity, observing through the observing glass window on the air conditioner pipe
Note: If refrigerant is sufficient and ambient temperature is higher than normal, viewing air bubbles
through the observing glass window can be identified to be in normal condition.
Test condition:
① Engine speed: 1500r/min;
② Blower speed control speed: HI “high”;
③ Air conditioner switch: on;；
④ Temperature control panel: MAX COLD “maximum refrigeration”;
⑤ Fully open the vehicle door.
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（四）Refrigerant injection, as shown in Figure 6-38.
Fig. 6-38
1. Expel refrigerant from refrigerating system.
① Switch on air conditioner.
② When engine runs at 1000r/min, make air conditioner compressor work 5~6min, circulate refrigerant
and collect residual oil of all parts to the compressor.
③ Engine misfiring.
④ Expel refrigerant
Note: For refrigerant expelling, press down the one-way valve, and expel slowly to avoid taking
compressor oil out.
2. Inject refrigerant
① Vacuumize with vacuum pump.
② Add in HFC-134a (R134a). Standard: 500g±50g.
3. Engine warming up.
4. Check the leakage of refrigerant. Check the leakage of refrigerant with gas leak detector.
二、Fault diagnosis flow

Poor refrigerating effect, see Figure 6-39
Abnormal ATC see Figure 6-40
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Poor heating effect see Figure 6-41
Fig. 6-39
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Fig. 6-39(Continued)
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Fig. 6-40
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Fig. 6-41
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Fig. 6-41(Continued)
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Section V Precautions of Air Conditioning System
一、Apply pure R-134a refrigerant

(1) Must apply authentic R-134a cooling medium with qualified standard of component, moisture content,
foreign matters and foul gas. 13.6kg canned cooling medium is recommend for service station;
(2) Refrigerant charge must comply with the provision of complete vehicle factory, both excess and lack
will reduce the refrigerating effect.
(3) Before injecting refrigerant, completely check whether every pipe O-ring seal is in good condition and
whether leakage of every part exists;
(4) Before compressor starts working, can inject from the low pressure side and high pressure side
simultaneously; after compressor starts working, can only inject from the low pressure side slowly;
Figure 6-42.
Fig. 6-42
(5) After filling in R-134a cooling medium, apply electronic leak detector for leakage inspection.
二、Add lubricant correctly

1. Must apply lubricant with type and brand stipulated by compressor manufacturer. Do not mix lubricant
of different types and brands, or compressor will be damaged;
2. The injection quantity should full comply with the stipulation. Lubricant has bad influence on heat
transmission, excessive lubricant will reduce the air conditioning effect greatly; generally, it is not
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necessary to add lubricant, for that has been injected by compressor manufacturer; properly add
lubricant when replacing parts: condenser 20ml; drier-receiver 30ml; evaporator 30ml; pipeline 10ml/m.
3. Lubricant has great water absorption power, thus it is necessary to reduce the time of contacting air as
much as possible;
4. Before injection, quality of lubricant in pipelines should be checked first. If lubricant is black or carbon
granule precipitation exists, clean and blow the entire air conditioning system completely, and replace all
the lubricant; Note: Water, corrosive agents or combustible & explosive agents are forbidden to clean air
conditioning system. Cleaning agents of R-141b and methane are recommended.
5. Lubricant should be injected from compressor exhaust vent before vacuumizing.
三、Sufficient vacuumizing time and vacuum degree

1. Vacuumize for over 20min with strong power vacuum pump;
2. Maintain the system absolute pressure below 1000Pa;
3. Before refrigerant injection, should maintain pressure for over 5min and make air tightness
examination; if the examination result is qualified, continue vacuumizing for 5min.
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Chapter VII Auxiliary Component System
Section I Cable
一、Inner control handle and cable assembly of engine hood

During the installation, the inner control handle and cable assembly of the engine hood penetrate
the part 1 first and then part 2, connect with the part 4 along part 3 and finally install the inner control
handle and dash board. Make sure that the cable keeps along the harness after going through the part 2.
There is a front wheel housing cover stem on part 2. The cable will come through the cover stem and be
fixed on part 3 by a buckle as shown in Fig. 7-1.
Fig. 7-1
1. Dash panel 2. Housing plate of left front wheel
3. Header crossbar assembly of water tank 4. Locking device assembly of engine hood
二、Inner control handle and cable assembly of fuel tank

During the installation, the inner control handle is fixed on the part 1 with the bolt first; next the cable
penetrates the back of part 1, goes through the holes on the part 2, 3, 4, 7, 6 in order to circle to the other
side of the metal sheet, and finally the end of pin shaft will be installed on the part 8. The direction of the
cable must keep along the harness after running through the back of the part 1. When fixing the end of
pin shaft, put the pin shaft alignment sleeve on the part 8 first and then install the end of pin shaft on the
pin shaft alignment sleeve on the other side of the part 8, as shown in Fig. 7-2.
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Fig. 7-2
1. Left front seats beam 2. Middle section of left door sill inner plate
3. Rear section of left door sill inner plate 4. Left rear wheel housing inner plate 5. Left C pillar inner panel
6. Left junction panel of luggage compartment front reinforced beam 7. Filler lock bracket
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Section II Windshield
一、Introduction:
The windshield is installed by the one-component Polyurethane sealant. As for its renewing, what is
essential is to use the adhesive which can offer the surface cementing strength, and adopt the
appropriate process.
Note:
① When using the base coat and glass sealant produced by other manufacturers, their Instruction
Manual must be referred. The adhesive performance of the glass sealant will be impacted due to the
misusing or neglect in the following operations. Therefore, please read carefully the instruction and
trademark provided by the glass sealant manufacturer before operating, and abide by the process and
the notes during the whole operation.
② The scuffed or damaged surface of the coating must be recoated, or the corrosion will expand.
Tools needed in this process:
1. Awl 2. Piano wire 3. Brushes used for primer coating (2) 4. Cutting tool
5. Rubber adhesive disc 6. Sealant gun (used for sealant filling) 7. Putty knife (used for finishing
the adhesive parts)
二、Front windshield
1. Front windshield removal
(1) Clear the inner and outer surfaces and surrounding parts of the glass.
(2) Remove the wiper arm.
(3) Remove the coping side sealing strip.
(4) Cover the car body around the glass with the adhesive tape to protect the car body.
(5) Remove (or cut off) the sealing strip around the windshield so that the brim of the windshield can be
revealed.
(6) Drill a hole with the awl to penetrate the adhesive and make the piano wire run through it.
(7) Decompose the adhesive around the glass with the piano wire and pay attention to the two fixed
points on the front windshield.
Note: The piano wire shall be as close to the glass as possible so as to protect the car body.
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(8) Finish the adhesive for the vehicle body connection parts with the knife to make sure that the
thickness of each part is 1-2mm.
Note: Clear the grease for the vehicle body connection parts with the alcohol or similar stuffs before
finishing the body with the cutting tool.
(9) Eliminate the old sealing strip and adhesive before renewing the glass.
2. Front windshield installation:
(1) Clean the vehicle body (or windshield brim) needed to adhere and connect to the windshield with the
cleaning agent. (Dry at least for 10 minutes.)
(2) Completely clean the old strip, the paint and the surface with the metal. If the paint and the surface
with the metal are completely exposed, never coat the primer on the adhesive remained on the body.
Note:
① The correct operation and drying time shall be practiced as per the Instruction Manual of the
primer manufacturer.
② Don’t touch the body and old adhesive surfaces to adhere and connect with the glass.
(3) Install the new strip on the glass. For convenience, heat the strip at the temperature of 35℃ one and
a half hours.
(4) Clean the glass surface to adhere and connect to the body with the clean cloth. If the cleaning agent
has been used, dry at least 10 minutes.
(5) Coat the glass surface to adhere and connect to the body with the enough primer at the thickness of
15mm with new brushes.
Note:
①The correct operation and drying time shall be practiced as per the Instruction Manual of the
manufacturer.
② Don’t touch the primer coating surface.
(6) Attach the windshield tent on the front windshield and coat it the adhesive.
Note:
① Start from the hemline of the glass.
② Don’t ruin the primer.
③ After coating, press the glass on the body as soon as possible.
④ After coating, use the rubber adhesive disc to install and convey the glass.
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⑤ Complete the step 6 and 7 within 10 minutes to guarantee the agglutinate strength.
⑥The correct operation and drying time shall be practiced as per the Instruction Manual of the
manufacturer.
⑦ Don’t touch the body to agglutinate with the glass and the old adhesive surface.
(7) Hold the rubber adhesive disc, press the glass on the body and clap the glass surface and
surrounding areas of the strip so as to glue the glass on the body completely.
Note: Don’t damage the glass surface or body.
(8) Install the coping side sealing strip.
(9) After the solidifying of the adhesive, check whether the window leaks or not through splashing water
in the hose on it. If the window leaks, dry the glass and fill the leaking position with the adhesive. After
filling, if it keeps leaking, remove the glass and reinstall as per above steps.
Note:
① Don’t use the high-pressure water.
② When drying, don’t let the adhesive coating parts expose directly to the compressed air. Don’t
use the infrared ray bulb and the similar stuffs to dry.
③ Before the adhesive complete solidifying, the sudden closing the car door may result in glass
looseness or falling off. Therefore, before the adhesive part completely adheres to the door, open or
close the door in a correct way.
④ If the strip does not completely glue, press it with the adhesive tape until all the adhesive parts
installed closely.
⑤ Every adhesive has its own solidifying time. Do not forget to refer to the Instruction Manual of the
manufacturer, check the solidifying time of the adhesive used and observe the necessary measures
taken before the complete adherence of the adhesive parts.
⑥ Before complete adherence of the adhesive parts, forbid to drive so as to guarantee the complete
and full solidifying.
(10) Install the windshield wiper.
三、Rear windshield
1. Rear windshield removal:
(1) Clear the inner and outer surfaces and surrounding parts of the glass.
(2) Disconnect the interface connected to the rear windshield.
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Note: When disconnecting the interface, don’t pull the cable wire but loosen the lock card of the interface
first, and then hold the interface and loosen the interface.
(3) Remove the coping side sealing strip.
(4) Cover the body around the glass with the adhesive tape so as to protect the body.
(5) Remove (or cut off) the sealing strip around the rear windshield until the brim of the rear windshield is
revealed.
(6) Drill a hole with the awl to penetrate the adhesive and make the piano wire run through it.
(7) Decompose the adhesive around the glass with the piano wire and pay attention to the two fixed
points on the rear windshield. The fixed points are 176mm away from the glass brim.
Note: The piano wire shall be as close to the glass as possible so as to protect the car body.
(8) Finish the adhesive for the vehicle body connection parts with the knife to make sure that the
thickness of each part is 1-2mm.
Note: Clear the grease for the vehicle body connection parts with the alcohol or similar stuffs before
finishing the body with the cutting tool.
(9) Eliminate the old sealing strip and adhesive before renewing the glass.
2. Rear windshield installation:
(1) Clean the vehicle body (or windshield brim) needed to adhere and connect to the windshield with the
cleaning agent. (Dry at least for 10 minutes.)
(2) Completely clean the old strip, the paint and the surface with the metal. If the paint and the surface
with the metal are completely exposed, never coat the primer on the adhesive remained on the body.
Note:
① The correct operation and drying time shall be practiced as per the Instruction Manual of the
primer manufacturer.
② Don’t touch the boy and old adhesive surfaces to adhere and connect with the glass.
(3) Install the new strip on the glass. For convenience, heat the strip at the temperature of 35℃ one and
a half hours.
(4) Clean the glass surface to adhere and connect to the body with the clean cloth. If the cleaning agent
has been used, dry at least for 10 minutes.
(5) Coat the glass surface to adhere and connect to the body with the enough primer at the thickness of
15mm with new brushes.
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Note:
①The correct operation and drying time shall be practiced as per the Instruction Manual of the
manufacturer.
② Don’t touch the primer coating surface.
(6) Coat the rear windshield with the adhesive.
Note:
① Start from the hemline of the glass.
② Don’t ruin the primer.
③ After coating, press the glass on the body as soon as possible.
④ After coating, use the rubber adhesive disc to install and convey the glass.
⑤ Complete the step 6 and 7 within 10 minutes to guarantee the agglutinate strength.
⑥The correct operation and drying time shall be practiced as per the Instruction Manual of the
manufacturer.
(7) Hold the rubber adhesive disc, press the glass on the body and clap the glass surface and
surrounding areas of the strip so as to glue the glass on the body completely.
Note: Don’t damage the glass surface or body.
(8) Install the coping side sealing strip.
(9) After the solidifying of the adhesive, check whether the window leaks or not through splashing water
in the hose on it. If the window leaks, dry the glass and fill the leaking position with the adhesive. After
filling, if it keeps leaking, remove the glass and reinstall as per above steps.
Note:
① Don’t use the high-pressure water.
② When drying, don’t let the adhesive coating parts expose directly to the compressed air. Don’t
use the infrared ray bulb and the similar stuffs to dry.
③ Before the adhesive complete solidifying, the sudden closing the car door may result in glass
looseness or falling off. Therefore, before the adhesive part completely adheres to the door, open or
close the door in a correct way. The correct operation and drying time must conform to the Instrument
Manual of the manufacturer. Don’t touch the surface of the primer coating surface.
④ If the strip does not completely glue, press it with the adhesive tape until all the adhesive parts
installed closely.
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⑤ Every adhesive has its own solidifying time. Do not forget to refer to the Instruction Manual of the
manufacturer, check the solidifying time of the adhesive used and observe the necessary measures
taken before the complete adherence of the adhesive parts.
⑥ Before complete adherence of the adhesive parts, forbid to drive so as to guarantee the complete
and full solidifying.
(10) Install all the interfaces connecting to the rear windshield
Section III Safety Belt

Note:
(1) The fasteners removed must be reinstalled in the original position. If any fasteners need renewing,
the ones with the same part No. are required. However, if there is no such fastener with the same part
No., the ones with the same dimension and intensity (or higher intensity) are acceptable. The
non-recyclable fasteners and the ones need locking by the screw thread, shall be eliminated from the car.
If reinstalling fasteners with designated tightening torques, fasten them to the given torques. Violating
the requirement above may cause the damage of the components or the system.
(2) The safety belt and its auxiliary components may influence the key components and the system.
Therefore, carefully checking and renewing with the components from the original manufacturer are
necessary.
(3) If it is necessary to renew the safety belt, renew the buckle lock and belt together, to ensure the
inosculation between the lock tongue and the buckle lock.
一、Front seat safety belt
Fig. 7-3
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a. Bolt tightening torque: 45N·m
1. Upper fixing bolt 2. Lower fixing bolt 3. Tensioning retractor
1. Removal: As shown in Fig. 7-3
(1) Disconnect the cathode cable from the battery.
(2) Deactivate the air bag system.
(3) Remove the B pillar guard panel assembly.
(4) Remove the safety belt assembly from the vehicle body.
2. Installation: The process of installation is opposite with that of removal; however, the following points
must be taken into consideration:
(1) The bolt for fixing the safety belt ring shall be the British system fine screw thread (7/16-20UNF). The
screw thread with different dimension or metric screw thread will be never acceptable.
(2) Make sure that screw the fixing bolt to the designated torque, refer to the Fig. above.
(3) Tightening torque (a): 45N·m
二．Rear seat safety belt:

1. Removal, as shown in Fig. 7-4.
Fig. 7-4
a. Fastener torque 45N·m
(1) Disconnect the cathode cable from the battery
(2) Deactivate the air bag system.
(3) Remove the rear seat side back.
(4) Remove the rack board guard panel assembly.
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(5) Remove the fixing bolt of the rear safety belt retractor.
(6) Remove the rear seat cushion.
(7) Remove the fixing bolt at the lower end of the s
(8) Remove the rear safety belt assembly from the body.
2. Installation: The order of the installation is opposite with that of the removal.
三、Notes for safety belt maintenance:

Read the following notes before repairing and renewing the safety belt:
1. The safety belt shall connect normally to the retractor and buckle lock.
2. Don’t let the sharp and destructive stuffs approach to the safety belt.
3. Avoid bending or damaging any parts of the buckle lock or lock plate.
4. Don’t blanch or dye the belt (only the cleanout with the mild soap and warm water is acceptable).
5. Hold the pre-tightening screw to avoid the floss when installing the safety belt.
6. Don’t try to repair the retractor or the retractor cap; renew the deficient assembly with the new one.
7. Keep the belt dry and clean.
8. Renew the deficient components if necessary.
9. Renew the belt cut off or damaged by other ways.
10. Don’t fill the hole of the ornamental panel, gone through by the safety belt, with any stuffs.
Section IV Front Side Door

一、Decomposition Diagram. See Fig. 7-5:
Fig. 7-5
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1. Right front safety belt retractor 2. Safety belt head guard cap
3. Hexangular flange bolt (a) 4. Hexangular flange bolt (b)
5. Hexangular flange bolt (c) 6. Hexangular flange bolt (d)
7. Safety belt altitude controller assembly 8. Left front safety belt retractor
9. Rear seat safety belt retractor assembly 10. Hexangular flange bolt (e)
11. Rear seat double connection lock buckle assembly 12. Rear seat lock buckle and waist belt assembly
二、Front side door glass, as shown in Fig. 7-5:

1. Removal:
(1) Remove the front side door glass frame riser switch assembly.
(2) Remove the front side door guard panel.
(3) Remove the front side door sealing film.
(4) Connect the glass frame riser switch, lower the glass to the reasonable position (reveal the two
installing holes of the glass).
(5) Dismantle the bolts for glass installation.
(6) Dismantle the glass of the front door.
2. Installation: install the glass of the door as per the opposite process, and pay attention to the following
notes:
(1) Check whether the top of the glass and the sliding channel contact evenly or not, and the
up-and-down movement is stable or not during the installation.
(2) Adhere the door sealing film firmly with the adhesive.
三、Glass frame riser:

1. Removal
(1) Remove the front side door glass referring to the front side door glass removal process.
(2) Disconnect the motor harness of the electric glass frame riser.
(3) Remove the bolt of the glass frame riser, and take out the glass frame riser.
2. Exam:
1) Check whether the components for movement and rotation of the glass frame riser need lubricating or
not.
2) Check whether the trolley is frayed or damaged.
3. Installation:
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Install the front window glass frame riser as per the reverse order.
Note: During the installation of the glass, check whether the top of the glass and the sliding channel
contact evenly or not, and the up-and-down movement is stable or not.
四、Front side door lock:

1. Removal:
(1) Remove the front side door glass frame riser switch assembly.
(2) Remove the front side door ornamental guard panel.
(3) Remove the front side door sealing film.
(4) Remove the front side door inner handle and door lock assembly after disconnect the joints of every
controlling rod.
(5) Remove the door handle.
2. Installation: Installing as per the reverse order, and pay attention to the following points:
① Install and adjust the locking ring. Move the locking ring up and down so as to make its axis nearly line
with the door lock groove, and screw the bolt tightly.
Note: The locking ring shall be placed in a horizontal position and moved up and down, and don’t adjust
the door lock.
② Make the door keep contact with the body when closed.
Note: Inject the oil or grease lubricant into the joint of the locking ring regularly.
五、Front side door assembly:

1. Removal:
(1) Remove the front fender.
(2) Disconnect the door harness. Remove the door limiter. Use the jack and underlay a piece of wood
between the jack and the door plate to support the door plate. Unscrew the hinge bolt so as to remove
the door assembly.
2. Installation: install the front side door as per the reverse order. Pay attention to the following points:
(1) Coat the hinge installing surface with the sealant and the rotation components with grease lubricant.
(2) The induration of the strip will lead to the leakage. In such conditions, renew the strip.
(3) Adjust the position of the door locking ring according to “door lock installation”, so as to locate the
door correctly.
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(4) Keep the door contact with the body when closed.
(5) Check the door gap through opening and closing the door after installation. When the gap exists,
adjust the door.
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Section V Rear Side Door
一. Decomposition Diagram. See Fig. 7-6:
Fig. 7-6
1. Right rear side window assembly 2. Right rear side door angle window assembly
3. Right rear side door angle window glass seal 4. Right rear side door window glass sealing strip
5. Right rear side window glass supporting bracket treadle bar
6. Right rear side window glass supporting bracket assembly
7. Right rear window glass frame riser assembly 8. Right rear side door sealing strip
9. Right rear side door top hinge assembly 10. Right rear side door bottom hinge assembly
11. Right rear side door limiter assembly 12. Right rear side door frame sealing strip
13. Right rear side door outside handle assembly 14. Right side door inner handle assembly
15. Right rear side door lock 16. Side door locking ring
二. Rear side door glass

1. Removal:
(1) Remove the rear side door glass frame riser switch assembly.
(2) Remove the rear side door ornamental guard panel.
(3) Remove the rear side door sealing film.
(4) Remove the rear door movable guide rail and the triangle window glass to avoid the damage.
(5) Dismantle the rear door glass.
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2. Installation: install the glass of the door as per the opposite process, and pay attention to the following
notes:
(1) Check whether the top of the glass and the sliding channel contact evenly or not, and the
up-and-down movement is stable or not during the installation.
(2) Adhere the door sealing film firmly with the adhesive.
三. Glass frame riser:

1. Removal:
1) Remove the rear side door glass referring to the rear side door glass removal process.
2) Disconnect the motor harness of the electric glass frame riser.
3) Remove the bolt of the glass frame riser, and take out the glass frame riser.
2. Exam:
1) Check whether the components for movement and rotation of the glass frame riser need lubricating or
not.
2) Check whether the trolley is frayed or damaged.
3. Installation: Install the front window glass frame riser as per the reverse order.
Note: During the installation of the glass, check whether the top of the glass and the sliding channel
contact evenly or not, and the up-and-down movement is stable or not.
四. Rear side door lock:

1. Removal:
(1) Remove the rear side door glass frame riser switch assembly.
(2) Remove the rear side door ornamental guard panel.
(3) Remove the rear side door sealing film.
(4) Remove the movable guide rail of the rear side door and the triangle window glass to avoid damage.
(5) Remove the front side door inner handle, rear door lock assembly in order after disconnecting the
joints of every controlling rod. (The rear door outside handle is removed at last.)
2. Installation: Installing as per the reverse order, and pay attention to the following points:
① Install and adjust the locking ring. Move the locking ring up and down so as to make its axis nearly line
with the door lock groove, and screw the bolt tightly.
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Note: The locking ring shall be placed in a horizontal position and moved up and down, and don’t adjust
the door lock.
② Make the door keep contact with the body when closed.
Note: Inject the oil or grease lubricant into the joint of the locking ring regularly.
五. Rear side door assembly:

1. Removal:
(1) Disconnect the door harness.
(2) Remove the door limiter.
(3) Use the jack and underlay a piece of wood between the jack and the door plate to support the door
plate.
(4) Unscrew the hinge bolt so as to remove the door assembly. (When removing the rear door top and
bottom hinges, unscrew the bolts.)
2. Installation: install the rear side door as per the reverse order.
(1) Coat the hinge installing surface with the sealant and the rotation components with grease lubricant.
(2) The induration of the sealing strip will lead to the leakage. In such conditions, renew the strip.
(3) Adjust the position of the door locking ring according to “door lock installation”, so as to locate the
door correctly.
(4) Keep the door contact with the boy when closed.
(5) Check the door gap through opening and closing the door after installation. When the gap exists,
adjust the door.
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Section VI Seat Assembly
一、Structure of the driver seat assembly:

The assembly structure as shown in Fig. 7-7.
Fig. 7-7
Fix the bolt at the torque of 20.4N·m
二、Components and maintenance of the driver seat:

Note: The process of installation and that of removal are reverse. Therefore, only the extra steps for the
installation will be referred.
1. Removal
(1) Remove the driver seat lower guard panel
① Remove one bolt;
② Remove the driver seat lower guard panel.
(2) Remove the right front foot cap of the driver seat.
(3) Remove the right rear foot cap of the driver seat.
(4) Remove the front two bolts of the driver seat.
(5) Remove the rear two bolts of the driver seat and the whole assembly.
2. Installation
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Installing as per the reverse order, and pay attention to the following points:
(1) Remove the glass frame riser switch assembly of the rear side door.
三、Structure of the front passenger seat assembly:

1. The assembly structure as shown in Fig. 7-8：
Fig. 7-8
Note:
The process of installation and that of removal are reverse. Therefore, only the extra steps of the
1. Removal
(1) Remove the front passenger seat lower guard panel
a. Remove one bolt
b. Remove the left front foot cap of the front passenger seat.
(2) Remove the left rear foot cap of the front passenger seat.
(3) Remove the two bolts of the front passenger seat front slide rail.
(4) Remove the rear two bolts of the front passenger seat and the whole assembly.
Torque: 35N·
m
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2. Installation
Installing as per the reverse order, and pay attention to the following points:
Fix the bolt at the torque of 35N·

m
四. Components and maintenance of the rear seat assembly

1. The assembly structure as shown in Fig. 7-9:
Fig.7-9
2. Removal
Note:
The process of installation and that of removal are reverse. Therefore, only the extra steps of the
(1) Remove the head restraint.
(2) Seat cushion assembly, pull upwardly the two bulging parts in the front of the seat cushion and
remove them, as shown in Fig. 7-10.
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Fig. 7-10
Note: The pad bracket is easy to be deformed. In order to avoid the deforming, make sure the hands
beside the two pothooks as shown in the Fig.
(3) Remove the left rear seat back assembly, as shown in Fig. 7-11.
Fig.7-11
① Open the front part of the rear seat back cover.
② Incline the seat back assembly.
③ Remove the two bolts and the seat back.
(4) Remove the right rear seat side back assembly, as shown in Fig. 7-12.
Fig. 7-12
① Open the front part of the rear seat back cover.
③ Remove the two bolts and the seat back.
(5) Remove the left rear seat side back assembly, bolts and the seat back assembly, as shown in Fig.
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7-13.
Fig. 7-13
① Remove the bottom fixing bolts on the left side back of the rear seat.
② Pull out the left side back and the Fig. 7-13 may be referred.
(6) Remove the rear seat right side back assembly, bolts and side seat back.
① Remove the bottom fixing bolts on the rear seat right side back.
② Pull out the right side back.
(7) Remove the left hinge of the rear seat back, bolts and hinge.
(8) Remove the right hinge of the rear seat back, bolts and hinge.
(9) Remove the central hinge of the rear seat back, as shown in Fig. 7-14.
.
Fig. 7-14
① Remove the two bolts and hinge.
② Take out of the hinge.
(10) Remove the armrest assembly.
① Pick up the armrest hinge cover with the screwdriver. Note: Encase the sharp part of the screwdriver
before working.
② Remove the bolts and the armrest.
(11) Install the central hinge of the rear seat back with two bolts at the torque of 20.4N·m.
(12) Install the left hinge of the rear seat back with bolts at the torque of 18.1N·m.
(13) Install the side back hinge of the rear seat with bolts at the torque of 18.1N·m.
(14) Install the left rear side seat side back assembly with bolts at the torque of 7.8N·m.
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Note: Hang the pothook on the upper side of the side back on the body first when installing.
(15) Install the right rear seat side back assembly with bolts at the toque of 7.8N·m.
Note: Hang the pothook on the upper side of the side back on the body first when installing.
(16) Install the left rear seat back assembly with two bolts at the torque of 18.1N·m.
(17) Install the right rear seat back assembly with two bolts at the torque of 18.1N·m.
(18) Install the rear seat cushion assembly, as shown in Fig. 7-15.
Fig. 7-15
① Hang a pothook on the body firmly (rear side).
② Put the seat frame carrier on the two pothooks (front side).
Note: Confirm the fastness of the seat.
五、Components and maintenance of the rear seat assembly

1. Structure of the components as shown in Fig. 7-16:
Fig.7-16
676
2. Removal
(1) Remove the rear seat back pad assembly
① Lift the unlocking button to unlock the back pad and push over the back pad, as shown in Fig. 7-17.
Fig. 7-17
③ Remove the two side bracket flange bolts connecting to the body at the left and right side.
Note: Removing the bolts first is acceptable.
(2) Remove the left side back of the left rear seat.
① Remove the bolts.
② Hold the side back assembly upwardly along the direction of the arrowhead so as to separate the
armrest pothook with the body, as shown in Fig. 7-18.
Fig. 7-18
Note: If the pothook is damaged during the removal, renew the side back assembly.
(3) Remove the right side back assembly in accordance with the process of the left side back, mentioned
above.
(4) Remove the rear seat cushion assembly, referring to the Fig. 7-10.
677
Pull upwardly the two bulging parts in the front of the seat cushion and remove them.
Note: The pad bracket is easy to be deformed. In order to avoid the deforming, make sure the hands
beside the two pothooks as shown in the figure.
3. Installation process:
(1) Install the rear seat cushion, referring to Fig. 7-15.
① Push the cushion backwardly to make the back pad pin the cushion.
② Put the frame pothook of the seat on the two buckle seat assemblies (front side).
Note: Confirm the fastness of the seat cushion.
(2) Install the left armrest assembly.
① Reverse to the removal steps, press the armrest along the direction shown in Fig. 7-19 so as to fix the
othook on the body.
Fig.7-19
② Install the hinge with bolts at the torque of 9.8N·m.
(3) Installing the right rear seat side back assembly shall conform to the steps of left armrest installation.
Torque: 9.8N·m
(4) Install the rear seat back pad assembly, as shown in Fig. 7-20.
Fig. 7-20
Use a side hinge flange bolt at the left side as well as the right side to install it. After installation, the rear
678
back pad can be turned.
Torque: 22.1N·m
Note: Check whether the side connecting plate is firm with the back pad or not
before installation. (If loose, screw it at the torque of 22.1N·m)
679
Section VII Inside & Outside Decorations
一、Roof
1. Roof (standard scheme) removal:
As shown in Fig. 7-21, first remove the A, B, C pillars, dismantle the roof light, sun visor and the inner
rearview mirror, remove 8 with the buckle clamp, and dismantle 6 with the sleeve, take out of 7
buttressing the roof and then the roof can be removed. Meanwhile, 1, 2, 3 will be adhered on the roof
metal sheet.
Fig.7-21
1. Roof rear heat-insulating pad 2. Roof middle heat-insulating pad
3. Roof front heat-insulating pad 4. Roof guard panel front heat-insulating pad
5. Roof guard panel 6. Installing bolt
7. Roof armrest 8. Roof fixing buckle
二、Rack board, as shown in Fig. 7-22
Fig. 7-22
1. Rack board upper guard panel left audio cover 2. Rack board upper guard panel right audio cover
3. Audio cover installing buckle 4. Guard panel installing buckle
680
5. Rack board felt pad 6. Rack board upper guard panel
7. Rear seat ornament board
Removal of the rack board: First, remove the C pillar and high-mounted brake lamp; second, turn over
the rear seats and take out of the safety belt from 4 and remove 6, 7 and 5 successively. 1 and 2 are
fixed on 6 through 3 and 4.
(Note: The rear sun visor device is added at 4 in the luxury scheme so the buckle is installed on the
lower place of the rear sun visor device. When removing the 4 for fixing 7, uplift 7 directly and the buckle
here can be taken out; 1 and 2 are welded on 7; four small pads replace 5 in certain standard scheme.)
三、Front side door
1. Removal of the front side door, as shown in Fig. 7-23:
Fig. 7-23
1. Plastic square nut 2. Small audio cover buckle on door superior angle
3. Small audio cover on left front side door superior angle
4. Small audio cover on right front side door superior angle
5. Left front side door guard panel assembly 6. Right front side door guard panel assembly
7. Fixing compound bolts 8. Door handle seat installing bolt cover stem
9. Front side door armrest seat bolt 10. Left front side door armrest seat
11. Right front side door armrest seat 12. Left front side door sealing felt pad assembly
13. Right front side door sealing felt pad assembly 14. Front door guard panel fixing buckle
15. Bolt caulking calking
681
Remove 3 and 4, unscrew 15 and 9 with the cross-tip screwdriver, open 8 and unscrew 7 as well. Take
out of 5 and 6 from 10 and 11, and unfix the harness. Pull out 5 and 6 to observe whether 14 remains on
the metal sheet, if it does, take it with the buckle clamp and return it to the 5 and 6. If it is necessary to
remove 12 and 13, dismantle the door handle and armrest seat installing bracket first, and tear out 12
and 13, if it is necessary to return them, glue recoating is required. If 1 needs renewing, dismantle it with
the flat blade screwdriver.
四、Rear side door guard panel

1. Installation of rear side door
① Glue the door horn mouth cap to the lower side round mouth at the position as shown in the figure.
② Glue the rear side door sealing felt pad assembly on the door inner metal sheet and after confirming
that its hole position directly faces with that of the metal sheet, press them tightly.
③ Install the armrest seat installing bracket.
④ Confirm the non-installation of the inner handle installing bolts, install seven door plate fixing buckles
on the door plate bracket. Put the upper body buckle seat into the place between the door plate and the
glass first. As shown in Fig. 7-24: then lead the buckle to aim at the installing hole of the buckle and
press the buckle in; after this, the door guard panel is installed on the door inner plate.
Fig. 7-24
682
⑤ Install the inner handle cover stem after the installation of the bolts.
⑥ After installing the harness on the corresponding armrest seat of the door plate, fix the rear side of the
armrest seat in the installing hole of the door plate first and then press the snap spring at the front side
into the installing hole of the door plate. Firm the armrest seat with the armrest seat bolts.
五、Rear wall
1. Removal of rear wall, as shown in Fig. 7-25:
Fig. 7-25
The luggage boot hood can be removed after dismantling the 11 fixing buckles. The luggage carpet is on
the top of the inner luggage boot. Uncovering the carpet, the caudal cover board and spare tire cover
board can be revealed, all of which are not fixed by the fasteners. The left and right protective covers
and the rear skirt plate is firmed by the plastic buckles so they can be dismantled after removing the
buckles. The cover boards for check and maintenance are clipped on the left and right protective covers
respectively.
683
(Note: The rear skirt plate has its own buckle corner so don’t damage the corner when removing.)
Removal of rear wall air opening, as shown in Fig. 7-26.：
Fig. 7-26
The four buckle corners of the air opening will be unveiled after the other components of the rear wall are
removed. Support the buckle corners with hands or tools to push them outward and the rear wall air
opening will be dismantled.
六、Side wall
1. Assembly of side wall, as shown in Fig. 7-27
Fig. 7-27
684
(1) The front and rear linings of the ventral shield are fixed on the body through 4 places (A in the Fig.)
and 3 places (B in the Fig.) respectively. During the installation, fix the buckles in the buckle holes
directly and then install the roof. After that, the A, B, C pillar guard panels can be installed.
(2) Fix the buckle on the buckle installing bracket (Total: 2) of the A pillar upper guard panel. First put the
front small buckle foot into the corresponding installing holes on the dash board, the two buckles into the
buckle holes of the A pillar metal sheet so that the A pillar upper guard panel can be fixed.
(3) Firm the inner felt pad of the C pillar upper guard panel and five fixing buckles on the C pillar upper
guard panel. First put the rear side small buckle foot into the metal sheet hole of the C pillar and five
buckles into the buckle hole of the C pillar metal sheet so that the C pillar upper guard panel can be
firmed.
(4) Make the small buckle foot on the lower part of the B pillar upper guard panel into the metal sheet
hole of the B pillar and press the buckle on the upper side into the corresponding round holes of the B
pillar so that the B pillar can be fixed, as shown in Fig. 7-28.
Fig. 7-28
(5) Install the two fixing buckles into the buckle bracket of the B pillar lower guard panel and the column
at the upper side of the B pillar lower guard panel into the B pillar upper guard panel holes, and put the
buckle foot in the appropriate position (as shown in the following figure). Two fixing buckles shall be
installed in the buckle holes.
(6) Make the snap spring fixed on the A pillar lower guard panel clip the brim of the metal sheet and
press ahead. Install the buckles on the bolt from the inner side and press the A pillar lower guard panel
inward tightly.
(7) Install the front and rear door sill guard panel, press the end of the door sealing strip under the door
sill guard panel and put the small column connecting to the B pillar lower guard panel into the
corresponding round hole on the B pillar lower guard panel, and place the buckles (3 buckles see D; 2
685
buckles see C.) under it into the corresponding installing holes of the body, and the small buckle foot
connecting to the B pillar lower guard panel, in position. See Fig. 7-29:
Fig. 7-29
Note: The buckles at the lower side of the door sill guard panel shall aim at the metal sheet buckle holes
precisely, or the buckles will be bent. The door sill guard panel will match with the thread clip below.
七、Heat-insulating pad
1. Installation of heat-insulating pad of front wall
(1) First install five buckles on the buckle installing holes of the heat-insulating pad of front wall, open the
upper mouth of the pad and hang it on the beam under the windshield (see Fig. 7-30), and after gluing its
surface with the dash panel, place the five buckles into the corresponding bolts on the dash panel.
Fig. 7-30
(2) Install two buckles on the each side respectively.
Engine room heat-insulating layer, see Fig. 7-31.
686
Fig. 7-31
Engine room heat-insulating layer installation: Joint the engine room heat-insulating layer with the front
side of the dash panel; after the installation of the other components of the dash panel, the layer can be
fixed. The installation of the auxiliary fascia console heat-insulating layer, see Fig. 7-32: Joint the
auxiliary fascia console heat-insulating layer on the central passage cover board; if matched well, they
can be fixed by two fixing buckles, as shown in the above figure.
Fig.7-32
八、Carpet
Installation of the carpet, as shown in Fig. 7-33:
a. Clean the surface of the floor.
b. Put the carpet in, stretch out the inner control handle first. Glue the front right fibula of the carpet first
and the left one second.
c. Install the buckles.
d. Install at the two square holes at rear side of the carpet.
687
Fig. 7-33
九、Fascia console frame (Fig. 7-34, Fig. 7-35)
Fig. 7-34
688
Fig. 7-35
1. Hexangular flange bolt 2. Screw 3. Hexangular flange bolt 4. Hexangular flange bolt
5. Hexangular flange nut 6. Screw 7. Plastic buckle 8. Snap spring nut
9. Hexangular flange nut
十、Main instrument desk, as shown in Fig. 7-36
689
Fig. 7-36
1. Sunshine sensor cover stem 2. Optical sensor cover stem

3. Instrument panel upper guard panel 4. Front passenger air bag cover board
5. Instrument cluster face shield 6. Screw
7. Middle vent small assembly 8. Left vent small assembly
9. Right vent small assembly 10. Instrument panel trim strip fastening buckle
11. Instrument panel left trim strip 12. Instrument panel right trim strip
13. Instrument panel lower guard panel 14. Left small sundries box
15. Steering wheel lower guard panel 16. Sundries case
17. Pneumatic pullback spring 18. Self-tapping screw
1. Detailed installation notes
(1) Right sundries box
After pneumatic pullback spring and sundries box are fastened, insert the pneumatic pullback spring
hole into the buckle corner (as shown in the circle of Fig. 7-37).
690
Fig.7-37
Then insert lower part of sundries box as shown in Fig. 7-38
Fig. 7-38
2. Connect fascia console upper guard panel with vehicle body
As shown in Fig. 7-39, seen from back side, there are 5 buckles attaching to vehicle body in front part of
instrument panel.
Fig. 7-39
The 5 buckles on upper guard panel of fascia console must be inserted into the lower part of beam under
windshield
There are 5 buckles and 4 screws on upper and down guard panels of fascia console as connecting
equipments. The 4 screws and A type spring nut are fastened to the lower part of the left and right A/C
vent and the middle of CD and A/C panel. The 4 screws are shown in Fig. 7-40 and Fig. 7-41.
691
Fig. 7-40
Fig.7-41
Seen from back side, 5 buckles and 4 screws are needed to connect the upper and lower guard panels
十一、Auxiliary fascia console (Fig. 7-42)
692
Fig. 7-42
1. Middle and lower face shield assembly 1-1. Middle and lower face shield 1-2. Decorative frame 1-3. Leather sheath of
shift lever 1-4. Plastic buckle
2. Handbrake cover board components 2-1. Handbrake cover board 2-2. Handbrake cover board rubber pad
3. auxiliary fascia console assembly 3-1. auxiliary fascia console 3-2. Outer panel of front cup salver cover 3-3. Inner
panel of front cup salver cover 3-4. Turning panel spring of front cup salver cover 3-5. Buffer pad of front cup salver cover
3-6. . Front cup salver clapboard
3-7. Rubber pad of sundries box on auxiliary fascia console 3-8. Cover board of auxiliary fascia console
4. Front ashtray assembly 5. Rear ashtray assembly 5-1. Outer panel of rear ashtray assembly 5-2. Rear ashtray 5-3.
Rear ashtray body 6. Sundries box assembly on auxiliary fascia console 6-1.Switch locking tab 7. Auxiliary fascia
console lower insulation
1. Removal
1) Remove trim strip of instrument panel and A/C control panel.
2) Remove the two screws fastening instrument panel and auxiliary fascia console under the A/C control
panel.
693
3) Remove and replace screw 3 (2 screws in left and right)
4) Remove floor type handbrake cover board.
5) Open sundries case cover of auxiliary fascia console and remove the two bolts in the bottom.
6) Remove auxiliary fascia console assembly.
十二. Front bumper components replacement (Fig. 7-43)
Fig. 7-43
1. Cross slot recessed hexangular head self-tapping screw 2. Rubber head bolt 3. Plastic buckle 6. Mark
5.Front grille 6. Front grille trim strip 7. Front bumper 8. Cross slot hexangular head self-tapping screw 9. Left/right
trim strip of daytime lights 10.Lower grille 11.Licence retaining plate 12.Sealing strip components of front grille 13.
Cover board of towing hook
1. Remove the sealing strip components of front grille

694
Remove the 11 mounting buckles of the sealing strip components of front grille
Note: Wrap the screwdriver tip with adhesive tape before use.
2. Remove bumper assembly
①Remove the mounting buckle of front grille and two rubber head bolts.
② Disconnect the 3 jack catches and remove grille with a screwdriver.
Note: Wrap the screwdriver tip with adhesive tape before use.
③Remove mudguard of left front wheel
(a) Remove 2 screws.
(b) Remove mudguard of left front wheel.
Notes:
It is not necessary to completely remove the mudguard of left front wheel; the bumper can be removed in
Step 4 if it is partly removed.
④Remove mudguard of right front wheel. Notes: the same with Step 2.
⑤Remove the other 2 screws connecting front bumper and engine mudguard.
⑥Remove front bumper.
(a)Put protecting tape on the fender.
(b)Remove the 2 self-tapping screws connecting the left and right corners of front bumper and the
fender.
(c)Disconnect the 4 jack catches at left and right and the bumper with a screwdriver.
Notes: Wrap the screwdriver tip with adhesive tape before use.
(d)Disconnect the interfaces of the two daytime lights(optional); Remoce bumper assembly.
⑦Remove the left daytime light assembly.
Remove screw and fog light.
⑧Remove the right daytime light assembly
Remove screw and fog light.
⑨System with clearance sonar: Remove sonar retainer and sonar with screwdriver.
⑩Remove left connection bracket of front bumper.
⑪Remove right connection bracket of front bumper.
Notes: the same with Step 7.
695
⑫Remove front bumper.
(a)Remove the screws on trim strip of front grille with screwdriver and disconnect all the buckles.
(b)Disconnect the buckles of front grille and bumper with screwdriver, remove the front grille.
(c) Remove the screws of L/R daytime lights and L/R trim strips with screwdriver, and disconnect the
buckle.
Remove 4 nuts, 4 bolts and front bumper framework.
⑬13. Install left connection bracket of front bumper.
⑭Install right connection bracket of front bumper.
3. To install, reverse the removal steps.
十三. Rear bumper components (Fig. 7-44)
Fig.7-44
1. Luggage boot right protective cover component 2. Plastic buckle 3. Luggage boot left protective cover component 4.
Rear skirt plate guard panel 5. Luggage boot carpet 6. Rear bumper right connection bracket 7. Rear bumper right fixing
metal sheet 8. Rear bumper block 9. Right rear small mudguard 10. Plastic buckle 11. Rear bumper left connection
bracket 12. Rear bumper left fixing metal sheet 13. Left rear small mudguard 14. Plastic buckle 15. Leaf spring nut
696
16. Hex bolt with cone washer 17. Cross slot hexangular head self-tapping screw and plastic buckle
1. Remove rear wall pedal
① Remove 3 buckles.
② Disconnect the 8 jack catches and rear skirt plate with screwdriver. Notes: Wrap the screwdriver tip
with adhesive tape before use.
2. Remove rubber strips of luggage boot.
3. Remove floor felt pad in luggage boot.
4. Remove left felt pad in luggage boot.
Remove 4 buckles and left felt pad in luggage boot with buckle detacher. Notes: Wrap the screwdriver
tip with adhesive tape before use.
5. Remove right felt pad in luggage boot. Notes: the same with Step 3
6. Remove left rear combination headlamp.
① Remove the 3 nuts fastening the combination headlamp with spanner.
② Disconnect interfaces of combination lamp.
③ Remove the combination headlamp. Notes: Do not scratch vehicle body paint and anticorrosion paint
in the vehicle.
7. Remove right rear combination headlamp. Notes: the same with Step 5.
8. Remove the screws and plastic buckles fastening the rear bumper and body metal sheet. Notes: Wrap
the screwdriver tip with adhesive tape before use.
9. Remove left rear small mudguard
① Remove 2 screws and left rear small mudguard.
② Remove BL234 snap button and matching washer Q40208. Notes: Turn the sub-button with a
cross-tip screwdriver in counter-clockwise direction.
10. Remove right rear small mudguard. Notes: the same with Step 7.
11. Remove rear bumper
① Remove the 2 self-tapping screws in the left side of rear bumper with Phillips screwdriver.
② Remove the 2 self-tapping screws in the right side of rear bumper with Phillips screwdriver.
③ Remove the 2 bolts in the left side of rear bumper.
④ Remove the 2 bolts in the right side of rear bumper.
697
⑤ Remove the 2 BL1409 snap buttons in the bottom of rear bumper.
⑥ Put protecting tape under the side wall plate.
⑦ Disconnect the rear bumper and left and right connection brackets. Notes: Disconnect the 4 jack
catches in the left and right with screwdriver.
⑧ After disconnecting rear bumper and left and right connecting pieces of rear wall, remove rear bumper.
Notes: Pull backwards lightly the rear bumper with holding its two sides by hands and shake lightly from
side to side to disconnect rear bumper from the jack catches of left and right connecting pieces of rear
wall of rear bumper.
⑨ System with radar probe: Disconnect interfaces of probe wire.
⑩ Disconnect the harness interfaces of L/R rear fog lights.
⑪System with radar probe: Remove the probe.
⑫Remove left connection bracket of rear bumper.
⑬Remove the right connection bracket of rear bumper.
⑭Remove the L/R fog light assembly with screwdriver.
⑮To install, reverse the removal steps.
698
Chapter VIII Vehicle Body Dimension
M detail P detail p detail
699
i
l
g
B I
M6 H
A F b L
c
D
K
a
J
E d
18
发动机纵梁安装孔
Engine grider mounting hole 副车架安装孔
Sub-frame mounting hole
G 处详图
detail G I I处详图
I detail H HH detail
处详图 g g处详图
g detail
700
Dimensio
Dimension
Measuring Measuring n
S/N parameter Remark S/N Remark
point point parameter
(mm)
(mm)
1 A-a 690 17 I-K 1223.6
2 A-B 835.2 18 I-L 1146.4
3 A-C 685.2 19 L-l 1490.6
4 B-b 1365 20 M-m 1126.5
5 C-c 1136.6 21 M-N 834.7
6 C-b 1256.4 22 M-O 1024.9
7 C-d 1147.4 23 N-O 374.8
8 C-E 952.8 24 P-p 1066.6
9 C-F 706 25 Q-q 1028
10 D-d 911.5 26 R-r 1524.9
11 D-E 888 27 S-s 1398
12 D-F 507.9 28 T-t 1097
13 E-F 848.8 29 β-β 1506.7
14 G-H 1437.9 30 δ-δ 1550.2
15 I-i 1130.4 31 P-β 1608.7
16 I-J 1255.2 32 G-g 1056.4
Hole usage description：

S/N Remark S/N Remark
A, a Engine radiator assembly mounting V, v Front floor weld positioning hole
hole
B, b Fender mounting hole W, w Front floor weld positioning hole
C, c Front shock absorber assembly X, x Rubber cover stem mounting hole

mounting hole
D, d Y, y Rear shock absorber assembly
Sub-frame assembly mounting hole
mounting hole
E, e Engine girder mounting hole Z, z Rear towing eye hook
F Four-way proportional valve

mounting hole
J Door sill technical hole
701
K Front door limiter mounting hole
L Fender mounting hole
N Rear door limiter mounting hole
O Door sill technical hole
Q, q Rear panel weld positioning hole
R, r Rear bumper connecting piece

mounting hole
S, s Tail lamp mounting hole
T, t Tail lamp mounting hole
U, u Engine radiator assembly mounting

hole
702
Unit:m
703
Front and rear shock absorbers and front and rear sub-frames mounting holes
coordinate:
Hole name X（mm） Y（mm） Z（mm）
Sub-frame
56.9 -455.6 113.0
mounting hole 1
Sub-frame
56.9 455.6 113.0
mounting hole 2
Front shock
absorber mounting -39.7 -568.3 621.4
hole 1
Front shock
absorber mounting 59.3 -625.5 619.2
hole 2
Front shock
hole 3
Front shock
absorber mounting -39.7 568.3 621.4
hole 4
Front shock
absorber mounting 59.3 625.5 619.2
hole 5
Front shock
hole 6
Rear axle mounting
2196.5 -616 0
hole 1
Rear axle mounting
2196.5 -512 0
hole 2
Rear axle mounting
2196.5 616 0
hole 3
Rear axle mounting
2196.5 512 0
hole 4
Rear shock
absorber mounting 2442 -537.1 280.5
hole 1
Rear shock
hole 2
Rear shock
absorber mounting 2576 -491.9 275.9
hole 3
Rear shock 2442 537.1 280.5
704
absorber mounting
hole 4
Rear shock
hole 5
Rear shock
absorber mounting 2576 491.9 275.9
hole 6
Vehicle body coordinates origin: X0 is in the center of front axle; Y0 is in the bilateral symmetry center;
and Z0 is in the upper surface of middle floor.
705

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Service Manual

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PartⅡ Maintenance of Systems 15

ChapterⅠ UAES Electronic Injection System 15

Section Ⅰ Engine Control System 16

Section Ⅱ Trouble Diagnosis 45

Section Ⅲ Sensor Actuator 183

Chapter Ⅱ Delphi Electronic Injection System 214

Section Ⅰ Introduction 214

Section Ⅱ Principle of Controlling and Actuating Components 214

Section Ⅲ Steps for Trouble Diagnosis with DTC 225

Section Ⅳ Steps for Trouble Diagnosis Based on Engine Symptom 231

Section Ⅴ Security Items for System Diagnosis and Maintenance 245

Chapter Ⅲ Chassis System 247

Section Ⅰ Suspension and Axle 247

Section Ⅱ Hydraulic Power Steering System 259

Section Ⅲ Electric Power Steering System 272

Section Ⅳ Brake System 291

Section Ⅴ Fuel System 311

Section Ⅵ Engine Cooling System 313

Section Ⅶ Intake and Exhaust System 36

ChapterⅣ ABS 318

Section Ⅰ Function and Composition of ABS 318

Section Ⅱ Principle of ABS 319

Section Ⅲ Removal and Installation of ABS 322

Section Ⅳ Trouble Diagnosis and Troubleshooting 325

ChapterⅤ Electrical System 349

Section Ⅰ Instrument Cluster 354

Section Ⅱ Power Window 365

Section Ⅲ Power Sunroof（Optional） 370

Section Ⅳ BCM Central Lock, Burglar Alarm System 379

Section Ⅴ Electric Rear-view Mirror 392

Section Ⅵ Illumination System. 395

Section Ⅷ Audio System 413

Section Ⅸ Reverse Radar System 418

Section Ⅹ Power Supply and Other Electrical System 424

Chapter Ⅵ Air Bag 471

Section Ⅰ Composition, Principle and Safety Rules for Maintenance 471

Section Ⅱ Diagnosis & Troubleshooting 476

Section Ⅲ Diagnosis of Vehicles after Collision 483

Section Ⅳ Removal and Installation 484

Section Ⅴ Scrapping Tips for Air Bag Module 487

ChapterⅦ A/C System 488

Section Ⅰ Introduction 488

Section Ⅱ System Layout 492

Section Ⅲ Component Maintenance 496

Section Ⅳ Fault Diagnosis 510

Section Ⅴ Precautions 519

ChapterⅧ Auxiliary Component System 520

Section Ⅰ Cable 520

Section Ⅱ Windshield 521

Section Ⅲ Safety Belt 524

Section Ⅳ Front Side Door 526

Section Ⅴ Rear side Door 528

Section Ⅵ Seat Assembly 530

Section Ⅶ Interior & Exterior trim 537

ChapterⅨ Vehicle Body Dimension 553

Table 1 Complete Vehicle Main Parameter

Table 2 Complete Vehicle Performance Parameter

Table 4-1 Main Performance Parameter of LF479Q2 Engine

Item Unit Type、Parameter