Manual de Servicio Taller Wingle 5 Diesel

Preface
Warning: To avoid possible injury and/or damage to property, be sure to carefully observe the
following instructions:
This service manual, provided by Great Wall Motor Company Limited (Great Wall Motors), is
compiled for qualified professional technicians. If you try to carry out maintenance or repairs
without proper training, appropriate tools and equipment, you and others may be hurt. Even
the vehicle will be damaged or can not work normally.
Proper vehicle maintenance and repairs are very important for maintenance personnel safety
and motor vehicle's safety and reliability. Please use part with the same number or the one
specified by Great Wall Motors if you need to replace one part in the vehicle. Do not use any
replacement parts which are not approved by Great Wall Motors.
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The maintenance procedures recommended and described in this manual are effective
ways for maintenance and repairs. In some procedures, special tools may be needed.
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Therefore, if you want to use replacement parts, maintenance procedures or tools which are
not recommended or approved by the Great Wall Motors, be sure that there is no harm to
personal safety and safe operation of vehicles.
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The manual includes all kinds of "Warnings" and "Notes" which you must observe in order to
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reduce the risk of injuries in maintenance and repairs. Inappropripate maintenance or repairs
may damage the vehicle or bring potential safety hazard to the vehicle. However, these
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"Warnings" and "Notes" are not exhaustive. Great Wall Motors could not list all warnings on
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the potential dangers brought by violating these instructions.
The manual includes the repair procedures for vehicles equipped with airbags. Refer to the
Notes, and refer to Airbag Parts and Circuit Location Map before repair on or near the airbags
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and the circuit. Violation of these requirements will result in airbag deployment, injury or
unnecessary repairs on airbags.
In order to avoid airbag deployment and injuries, if airbags and other vehicle systems are
all in need of repair, it is recommended that airbags should be repaired first, and then other
systems.
Although we have tried our best to compile this manual, we could not ensure that all contents
inside are absolutely correct. As vehicle model updates continuously, we could not guarantee
that the latest information can be delivered to you correctly and timely. Users shall not put
forward unreasonable demands to Great Wall Motors because of the manual. We are not
responsible for the loss caused by using the manual. Due to our limited level of compiling, it
is inevitable to have defects and errors, please feel free to point out them.
The manual shall be explained by Great Wall Motor Company Limited.
Remark: This is a supplementary manual, applies only to Wingle 3/5 models after Year 2012.
For the information not contained in this manual, please refer to Wingle 3/5 service manual
before 2012.
Editor
May 2013 Editon 1
2014.01.09
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2014.01.09
GENERAL
VEHICLE PARAMETERS
ENGINE ACCESSORIES
CLUTCH
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TRANSMISSION
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TRANSFER CASE
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SUSPENSION SYSTEM AND AXLE
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BRAKE SYSTEM
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STEERING SYSTEM
ELECRICAL ACCESSORIES
HEATING, VENTILATION AND AIR-CONDITIONING
BODY AND INTERIOR/EXTERIOR DECORATION
CIRCUIT DIAGRAM
: Chapters of this symbol are not contained.
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2014.01.09
CONTENTS
GENERAL
General............................................................................................1-2
VEHICLE PARAMETERS
Vehicle Parameters. .....................................................................2-2
ENGINE ACCESSORIES
Exhaust System............................................................................4-2
CNG System...................................................................................4-4
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TRANSFER CASE
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Intelligent 4WD Transfer Case...................................................6-2
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Rear Axle Shaft Assembly..........................................................8-2
Tire Pressure Monitoring System.............................................8-7
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BRAKE SYSTEM
Rear Brake (Disc/Drum). .............................................................9-2
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Rear Parking Brake (Disc/Drum)...............................................9-10
ESP...................................................................................................9-18
STEERING SYSTEM
G Steering Column...........................................................................10-2
HEATING, VENTILATION AND AIR-CONDITIONING
Heating, Ventilation and Air-conditioning (Automatic Air-
conditioning)..................................................................................12-2
BODY AND INTERIOR/EXTERIOR DECORATION
Front Bumper (Type 2012)..........................................................13-2
Roll Cage. .......................................................................................13-4
Side Step.........................................................................................13-5
WIRING DIAGRAM
Wiring Diagram Instructions......................................................14-3
Wiring Diagram..............................................................................14-5
Vehicle Electrical Schematics....................................................14-44
Electrical appliance plug-in........................................................14-59
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General 1-1
GENERAL
General
How to use this manual...............................................................1-2
Repair procedures........................................................................1-2
Location..........................................................................................1-2
Schematics......................................................................................1-3
Repair procedures...........................................................................1-3
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Identification number position...................................................1-4
Vehicle identification number...........................................................1-4
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Engine number................................................................................1-4
Integrated repair instruction.......................................................1-5
Trouble shooting instruction on electrical equipment
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malfunction.....................................................................................1-8
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Before trouble shooting...................................................................1-8
Basic operation................................................................................1-8
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Five-step troubleshooting method ..........................................1-12
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Assembling and disassembling of the clip.............................1-13
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1-2 WINGLE Maintenance Manual
General
How to use this manual
In order to help you find the contents of this manual moreeasily, chapter name and main title are given
on the top of each page. In order to introduce maintenance items for you, index is given on the first
page of each chapter. Cautions for all repair operation related to this chapter are also given at the
beginning of each chapter. Please read these cautions first before starting repair operation. The trouble
diagnosis table of each system can help you diagnose system trouble and find out source of trouble.
The repair methods aimed at possible reasons are given in repair methods column, which can help you
get solutions as soon as possible.
Repair procedures
Most of repair operation can be started through referring to iconography. These iconographies help you
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identify parts and indicate their matching with each other.
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Location
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2
1. Rearview morror
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General 1-3
Schematics
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4±0.3
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3
2
N·m Specific torque
1. Tire pressure monitor sensor 4. Gasket

2. Valve cap 5. Tire pressure monitor transmitter
3. Locknut
Repair procedures
Operation title: what to do
2. Measuring radial clearance of intermediate shaft 5th

gear
(a) Mount spacer, needle bearing and reverse idler
gear on the intermediate shaft.
(b) Measure the radial clearance of reverse idler gear
with dial gauge.
Radial clearance: (0.009-0.32)mm
Specification Detailed instruction: how to do it
Iconography: what to do and where to do it
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Identification number position

Vehicle identification number
Vehicle identification number (VIN) is unique number
with 17 digits representing vehicle identification, and this
number is also engraved on the outer right side of the
frame right side member and VIN nameplate of upper
left instrument panel besides being present in vehicle
certificate.
B
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Engine number is engraved on the left side of the engine
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A cylinder body.
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General 1-5
Integrated repair instruction

1. Protect all the paint coating and seats with clean
cloth and polythene to prevent dust and scratches.
2. Concentrate yourself and be careful in working. After
lifting front and rear wheels, wedge the wheels not
lifted reliably. If two or more persons work together,
communicate with each other as much as possible.
Do not let the engine rotate unless workshop or
operational area is in perfect ventilation.
3. Before removing or disassembling parts, inspect
them carefully to isolate the parts needing repair.
Please observe all the safety instructions and
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preventive measures given in this manual and
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operate as correct steps.
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4. Mark all the parts taken down or put them on the
parts rack in order so as to reassemble them
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completely as original order.
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required.
6. Assemble parts as the regulations in maintenance

standard with correct tightening torque.
7. When tightening a group of bolts or nuts, start from
center bolt or diameter bolt, and finish them in two
or more steps in cross way.
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8. Parts no longer for use after service

(a) When reassembling parts, use new packing,
gasket, O seal ring and cotter pin.
(b) Parts no longer for use after service are marked
with “◆” symbol in part drawing.
9. Do not continue using old parts needing replacement
and it is required to change them.
10. Use parts and lubricants produced by original

factory. When continue using parts, inspect
them carefully and ensure there is no damage or
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deterioration and the parts are in perfect service
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status.
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the parts as required. When removing the parts,
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clean all of them with solvent.
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Locking sealant
12. Precoat parts
Precoat parts are bolts and nuts, and they are coated
with locking sealant in the factory.
(a) If precoat parts are tightened, loosened or moved
for a certain reason, coat them again with specified
sealant.
(b) Coating steps for precoat parts
1) Clean off the old sealant from the thread of this
part.
2) Blow them dry with compressed air.
3) Coat specified locking sealant on the part thread.
(c) Precoat parts are marked with “★” symbol in part
drawing.
13. Disassembling and assembling of vacuum hose
(a) To disconnect vacuum hose, hold the hose end and
pull it out by twisting. Do not hold the middle hose
Wrong Correct and pull forcibly, because this will damage the hose.
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General 1-7
(b) In order to facilitate reassembling the hose, add

labels in disconnecting to help recognize.
(c) Inspect carefully after finishing the work to ensure
the vacuum hose is connected correctly.
(d) When using vacuum gauge, do not connect the
hose to oversized joint compulsively. Adjust the joint
size gradually, and note that there will be leakage
once the hose is tensed.
14. Disassemble the hose clip

(a) Before removing the hose, check the clip position to
reset correctly.
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(b) Replace the deformed or dented clip.
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(c) When using the clip repeatedly, lock the clip at
dented position.
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(d) As to spring clip, gently pull the spring leaf to
tighten the spring clip as the arrow direction after
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assembling.
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15. Brake fluid and hydraulic element
(a) When applying fluid to the system, be extremely
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careful to prevent dust or contaminant entering into
system.
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(b) It is forbidden to mix fluid of different brands,
because they may not be solved with each other.
(c) Do not reusing emitted brake oil.
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(d) For brake oil may damage paint coat or resin
surface, be extremely careful not to let the brake oil
spatter on these surfaces, and immediately wash
with water or warm water if the brake oil spatters.
After disconnecting brake hose and brake pipe,
block the opening to ensure there is no loss with the
brake oil.
(e) Clean all the parts taken down with clean brake oil
and blow all the holes and passes with compressed
air.
(f) Avoid the parts taken down contacting with dust
and friction matters brought by the air.
(g) Before assembling parts, inspect and confirm they
are clean.
(h) Avoid smearing oil or grease on rubber parts or
pipelines, unless otherwise specified.
(i) When assembling, check each part is correctly
installed and in normal operation.
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Trouble shooting instruction on

electrical equipment malfunction
Before trouble shooting
(a) Check corresponding fuse/fuse in the relay box.
(b) Check charging status of the battery, whether the
battery is damaged, and clean, and tighten the
connector.
Note:
Wrong (a) Do not perform quick charge to the battery if the
battery ground cable is not cut, or the diode of
Wrong alternator will be damaged.
(b) Do not try to start the engine in the case of the
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battery ground cable being loosely connected, or
Correct the wiring will be seriously damaged.
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(c) Check the alternator belt tension
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Loosening the coiling Basic operation
1. Dismounting of harness joint
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Core of conductor
(a) When disconnecting the joint, squeeze both ends
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of the joint with hands at first to loosen the lock and
Terminal de- then press the lock claw to release the joint.
formation (b) When disconnecting the joint, do not pull the
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Gently pulling harness, directly hold the joint and disconnect it.
(c) Before connecting the joint, check it is deformed,
damaged and port lost.
(d) When connecting the joint, crack sound indicates
successful connection.
2. Inspection of harness joint
(a) Inspection for joint connected
Squeeze both ends of the joint to ensure the joint is
safely inserted and tightly locked.
(b) Inspection for joint disconnected
Terminal like male contact
Inspect by gently pulling the harness from the joint
back.Find the terminal not meshed or fallen off,
loosened clip or broken lead.
Visually check there is corrosion, metal chips,
impurities and water, bending, rust, overheating,
contamination or terminal deformed etc.
(c) Inspecting the terminal contact pressure:
Prepare a male contact matching the joint port, and
insert it into the socket, and then check they are in
good tension status in inserting and after complete
mesh.
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General 1-9
3. Repair method of harness joint terminal

(a) If there is dust on the terminal, clean the contact
Correct Wrong
with air gun or duster cloth.Do not wipe with tissue
paper, because this will damage galvanized coating.
(b) If the contact pressure is not normal, replace the
same class socket.
(c) Broken, deformed or eroded terminal should be
replaced.If the terminal is not locked in the housing,
the housing also needs replacing.
4. Dismounting of the harness

Wrong Wrong
(a) When dismounting the harness, check the wiring
and tightening of the harness before operating to
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reassemble the parts correctly.
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(b) It is absolutely forbidden to distort, extend or loosen
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the harness.
(c) D o n o t l e t t h e h a r n e s s c o n t a c t w i t h h i g h -
Wrong
temperature, rotating, vibrating or sharp-angled
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parts. Avoid contacting the panel edge, screw tip or
other similar articles.
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(d) When installing parts, do not mix the harness with
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the parts.
(e) Do not use the lead or harness whose insulating
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layer is cracked.If it is cracked, replace it or wind
the cracked part with electric adhesive tape.
(f) After installing the parts, ensure no lead is locked
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under the parts.
(g) If possible, insert the tester probe from lead side
(except waterproof connector).Use the probe with
gimlet-point.
Note:
piercing the lead insulating layer will result in poor
electrical connection or intermittent electrical
connection fault.
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Fig. 1 5. Check open circuit

ECU (a) For an open circuit in the wire harness in Fig. 1,
C OPEN B A perform a resistance check (Step b) or a voltage
Sensor
1 1 1 1 check (Step c).
2 2 2 2
(b) Check the resistance.

(1) Disconnect connectors A and C and measure
Fig. 2 the resistance between them.
Resistance: 1 Ω or less
Hint:
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ECU
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Measure the resistance while lightly shaking the wire
Sensor
1 1 1 harness vertically and horizontally.
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2 2 2 Fig. 2:
C B A
Between terminal 1 of connector A and terminal 1 of
connector C → 10 kΩ or higher
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Between terminal 2 of connector A and terminal 2 of
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connector C → Below 1 Ω
In this case, an open circuit exists between terminal
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Fig. 3 1 of connector A and terminal 1 of connector C.
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(2)Disconnect connector B and measure the
ECU resistance between the connectors.
Sensor Fig. 3:
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Between terminal 1 of connector B1 and terminal 1
1 1 1 1 of connector A → Below 1 Ω
2 2 2 2 Between terminal 1 of connector B2 and terminal 1
C B2 B1 A
of connector C → 10 kΩ or higher
In this case, an open circuit exists between terminal
1 of connector B2 and terminal 1 of connector C.
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General 1-11
Fig. 4 (c) Check the voltage.

(1) In a circuit in which voltage is applied to the
ECU connector terminal, an open circuit can be
5V checked by conducting a voltage check.
Sensor 0 V Fig. 4:
1 14 V 1 1
2 2 2 With each connector still connected, measure the
C B A voltage between the body ground and terminal 1 of
connector A at the ECU 5 V output terminal, terminal
1 of connector B and terminal 1 of connector C, in
that order.
(2)Example results:
5 V: Between terminal 1 of connector A and body
ground
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5 V: Between terminal 1 of connector B and body
ground
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0 V: Between terminal 1 of connector C and body
ground
If your results match the examples above, an open
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circuit exists in the wire harness between terminal 1
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of B and terminal 1 of C.
6. Check short circuit
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Fig. 5
(a) If the wire harness is ground shorted (Fig. 5), locate
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C
Short
B A
the section by conducting a resistance check with
the body ground (Below).
1 1 1
2 2 2
Fig. 6
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(1) Disconnect connectors A and C and measure
the resistance between terminals 1 and 2 of
ECU connector A and the body ground.
Sensor Resistance: 10 Ω or higher
1 1 1
2 2 2 Hint:
C B A Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
In the case of Fig. 6:
Between terminal 1 of connector A and body ground
→ Below 1 Ω
→ 10 kΩ or higher
In this case, a short circuit exists between terminal
1 of connector A and terminal 1 of connector C.
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Fig. 7 (2) Disconnect connector B and measure the

resistance between terminal 1 of connector
A and the body ground, and terminal 1 of
connector B2 and the body ground.
Sensor
Fig. 7:
→ 10 kΩ or higher
Between terminal 1 of connector B2 and body
ground → Below 1 Ω
In this case, a short circuit exists between terminal
1 of connector B2 and terminal 1 of connector C.
Five-step troubleshooting method
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1. Fault check
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Connect the power supply of all elements in faulted circuit to check the fault description of customers,
and pay attention to symptoms.Before confirming the fault position, do not dismount or test.
2. Principle analysis
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Check the circuit diagram to confirm the faulted circuit. Check all components along the current path
from power supply to ground connection and confirm the operating principle of this circuit in this way.
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If there is trouble with several circuits at the same time, the trouble is likely to be caused by fuse or
grounding.Recognize one or more reasons of the trouble based on the symptoms and understanding of
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the circuit operating principle.
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3. Isolate the trouble by circuit test
Test the circuit to check the diagnosis in step 2.Remember that clear and simple step is the key to elim-
inate trouble effectively. Test the circuit that is most likely to cause the trouble and start testing from the
points easy to approach.
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4. Troubleshooting
Once the fault is recognized, repair it immediately.In repairing, use correct tools and follow safe opera-
tional procedure.
5. Confirm normal operation of the circuit
Under all operating modes, connect all components in the loop that has been repaired, and confirm the
whole trouble has been eliminated.If the fault is the break of fuse, test all the circuits connected to this
fuse. Ensure that no new fault appears and the former trouble no longer occurs.
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General 1-13
Assembling and disassembling of the clip

The method to assemble and disassemble vehicle body parts is shown as the table below.
Remark: if this clip is damaged during operating, replace new clip.
Shape Disassembling/assembling
Jaw vice
Clip detacher
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Screwdriver
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Protect tape
Screwdriver
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Continued table:
Shape Disassembling/assembling
Disassembling assembling
Screwdriver
Pressing
Clip detacher
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Push out the king pin and remove it, and prize off the king pin
bush.
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Screwdriver Pressing
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Clip detacher
G Screw off the king pin and prize off the king pin bush.
Pressing
Screwdriver
Clip detacher
Small clip detacher
Prize out the king pin and remove the rivet, and then prize off the
king pin bush.
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Vehicle Parameters 2-1
VEHICLE PARAMETERS
Vehicle Parameters
Table of Vehicle Models. .............................................................2-2
Basic Parameters..........................................................................2-2
Dimensions....................................................................................2-3
Weight. ............................................................................................2-4
Engine. ............................................................................................2-5
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Transmission and Transfer Case..............................................2-6
Front Wheel Alignment (no load)..............................................2-7
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Wheels and Tires. .........................................................................2-7
Working Fluid Filling....................................................................2-8
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2-2 WINGLE Service Manual
Vehicle Parameters
Table of Vehicle Models
Description Vehicle model
WINGLE 5, GW4D20B engine, BOSCH CC1031PS4J CC1031PS6J CC1021PS4K
electronic fuel injection (EFI) system, WGT
turbocharger CC1031PA4J CC1031PA6J CC1031PA4K
CC1031PS4G CC1031PS5G CC1031PS6G
WINGLE 5, GW4D20 engine, Euro V emission CC1031PS7G CC1031PD4G CC1031PD5G
CC1031PD6G CC1031PD7G ---
WINGLE 5, 491QE engine (CNG) CC1021PA0E --- ---
Basic Parameters
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Front
Body and
Vehicle model Engine Transmission Drive type suspension
cargo-bed type
type
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Torsion-
CC1021PS4J 2WD
bar spring
Small double
Torsion-
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CC1031PS6J 4WD cabin
bar spring
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CC1031PS4K 6MT(ZM016B) 2WD Coil spring
GW4D20B
6MT(ZM016BF) Torsion-
CC1031PA4J 2WD
a
bar spring
Big double
Torsion-
CC1031PA6J 4WD cabin
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bar spring
CC1031PA4K 2WD Coil spring
CC1031PS4G 2WD
2WD(right-
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CC1031PS5G
rudder) Small double
CC1031PS6G 4WD cabin
4WD(right-
CC1031PS7G
6MT(ZM016B) rudder) Torsion-
GW4D20
CC1031PD4G 6MT(ZM016BF) 2WD bar spring
2WD(right-
CC1031PD5G
rudder)
Single cabin
CC1031PD6G 4WD
4WD(right-
CC1031PD7G
rudder)
Big double
CC1021PA0E 491QE(CNG) 5MT(ZM001B) 2WD Coil spring
cabin
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Dimensions
The limited-terms include the body and cargo-bed types (big/small double cabin, single cabin) as well
as the front suspension spring type (torsion-bar spring and coil spring).
Item Limitation Specifications
Big double cabin 5360/5390
Length
Small double cabin 5040/5060/5090
(mm)
Single cabin 5015
Overall
Width Torsion-bar spring 1800
dimension
(mm) Coil spring 1720
Height Torsion-bar spring 1730/1735
(mm) Coil spring 1675/1700
Big double cabin 3350
wheel base (mm)
Small double cabin/Single cabin 3050
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Front Torsion-bar spring 1515
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Tread
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Rear Torsion-bar spring 1525
Front suspension (mm) --- 745/765/795
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Rear suspension (mm) --- 1220/1245
Minimum ground Torsion-bar spring 194
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clearance (mm) Coil spring 178
Minimum turning Big double cabin 14.5
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diameter (m) Small double cabin/Single cabin 13.5
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Weight
Item Specifications (kg)
GW4D20 491QE(CNG)
Differentiating
2WD 4WD 2WD
conditions
Double cabin Single cabin Double cabin Single cabin Double cabin
Complete Vehicle 1680/1710/1720
1630 1835/1865 1735 1670
Kerb Mass 1750
Maximum
480/575 900 480/575 900 405
load weight
2485/2515/2525
Total mass 2680 2640/2670/2785 2785 2400
2555/2670
Front axle weight
925/930/945/950 925 1040/1045 1015 855
(no load)
Rear axle weight
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755/775/780/800 705 795/820 720 815
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(no load)
Front axle weight 1010/1015/1030
980 1130/1135/1110 1070 1020
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(full load) 1035
Rear axle weight 1475/1495/1500
1700 1510/1535/1725 1715 1380
(full load) 1520/1705
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Engine
Model GW4D20B GW4D20A

Inline, water-cooling, four-stroke,
Inline, water-cooling, four-stroke,
BOSCH, 16-valves, high-pressure
direct injection, 16-valve, high-
Type common-rail, turbocharged &
pressure common-rail, turbocharged &
intercooling, electrical EGR, WGT
intercooling, cooling EGR
turbocharger
Bore × Stroke (mm) 83.1×92 83.1×92
Total displacement (L) 1.996 1.996
Compress ratio 16.7:1 16.7:1
Idling stability speed (r/min)750±50 750±50
Rated power/
100/4000 110/4000
speed (kWr/min)
Maximum net power (kW) 105 102
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Maximum torque/
310/1800~2800 310/1800~2800
speed (N•m/rpm)
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Model 491QE(CNG)
4-cylinder inlined, water-cooling,
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four-stroke, top-mounted valve,
Type
sequential multi-point electronic fuel
injection petrol engine
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Bore × Stroke (mm) 91×86
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Total displacement (L) 2.237
Compress ratio 9.1:1
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Idling stability speed (r/min)750±50
Rated power/ 78/4600 (petrol edition)
speed (kWr/min) 68/4600 (CNG edition)
74.5 (petrol edition), 65 (CNG
Maximum net power (kW)
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edition)
Maximum torque/ 190/2400~2800 (petrol edition)
speed (N•m/rpm) 160/2400~2800 (CNG edition)
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Transmission and Transfer Case
Model ZM016B (2WD) ZM016BF (4WD)

Type Mechanical, 6 forward gears
Final drive ratio 4.1
I gear 4.179
II gear 2.330
III gear 1.436
Gear ratio IV gear 1.000
V gear 0.838
VI gear 0.696
R gear
4.22
(reverse)
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Transfer H gear (high)
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--- 1.00
case
speed ratio
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(electronic L gear (low) --- 2.48
4WD)
Transfer
--- --- 1.00
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case (TOD)
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Model ZM001B
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Type Mechanical, 5 forward gears
Final drive ratio 4.1
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I gear 4.452
II gear 2.398
III gear 1.414
Gear ratio
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IV gear 1.000
V gear 0.802
R gear
4.473
(reverse)
Transfer H gear (high) ---
case
speed ratio
(electronic L gear (low) ---
4WD)
Transfer
--- ---
case (TOD)
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Front Wheel Alignment (no load)

Front wheel
(′) --- 0′~4.66′(0mm~2mm)
toe-in
Front wheel
(°) --- 0°±30′, left-right deviation ≤30′
camber
Kingpin
inclination (°) --- 12°30′±30′, left-right deviation ≤30′
angle
Kingpin Torsion-bar spring 3°30′±30′, left-right deviation ≤30′
(°)
caster angle Torsion-bar spring 3°30′±35′, left-right deviation ≤45′
Maximum Torsion-bar spring 32° (inside)/28° (outside)
(°)
turning angle Torsion-bar spring 37°6′ (inside)/33°30′ (outside)
Wheels and Tires

Tire type ---
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Tubeless radial tire
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Torsion-bar spring 235/70R16 P235/70R16
Tire specification
Coil spring P215/75R15 215/75R15
Wheel Rim Torsion-bar spring 16×7J
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specification Coil spring 15×6J
Tire pressure --- 220kpa (front wheel)/250kpa (rear wheel)
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Working Fluid Filling

The limited-terms include the engine, transmission and drive type, etc.
Working fluid Limitation Volume

Fuel oil (L) 4D20B/4D20A Euro V/ 491QE 70L±3L
Vehicle gas 491QE(CNG) 80L
4D20B/4D20A Euro V 5.5L±0.2L
Engine lubricant (L)
491QE 4.2L
4D20B/4D20A Euro
Clutch fluid 150ml±30ml
V/491QE (CNG)
Manual transmission ZM016B/ZM016BF 2.7L±0.1L
oil (L) ZM001B 2.4L
Front drive axle (L) 4D20A Euro V/4D20B 1.8L±0.1L
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Front axle
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Electronically
4D20A Euro V/4D20B 0.19L±0.01L
controlled shift
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fork pad (L)
4D20B/491QE
Rear drive axle (L) 2.9L±0.1L
(CNG)/4D20A Euro V
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Power steering 4D20B/491QE(CNG) 778mL±32mL
fluid (L) 4D20A Euro V 1.0L±0.1L
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4D20B/491QE 480mL±50mL
Brake fluid (L)
4D20A Euro V 540mL±50mL
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Air-conditioning 4D20A Euro V/4D20B/491QE
480g±20g
refrigerant (g) (CNG)
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Primary
7.0L±0.5L
filling amount
4D20B
Secondary
1.0L±0.3L
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filling amount
Primary
6.5L±0.5L
filling amount
Coolant (L) 4D20A Euro V
Secondary
0.7L±0.3L
filling amount
Primary
6.5L±0.5L
filling amount
491QE(CNG)
Secondary
1.0L±0.3L
filling amount
Windshield washing 4D20B 1.2L±0.1L
liquid (L) 4D20A Euro V/491QE (CNG) 1.5L±0.2L
2014.01.09
Engine Accessories 4-1
ENGINE ACCESSORIES
Exhaust System
Schematics.....................................................................................4-2
Maintenance Guide.......................................................................4-3
CNG System
Introduction....................................................................................4-4
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Gas Cylinder....................................................................................4-5
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Filter................................................................................................4-5
Pressure Reducer Assembly. ..........................................................4-5
Change-over Switch and Cover Board.............................................4-6
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Exhaust System
Schematics
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4
3 5
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◆
3
◆ 6
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8
10
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11
N·m Specified torque 12

◆ Non-reusable parts
1. Catalytic connection pipe gasket 7. Differential pressure sensor

2. Oxygen catalytic mounting bracket
converter assembly 8. Differential pressure sensor pipe I
3. Catalytic converter gasket 9. Tri-hole rubber block
4. Exhaust temperature sensor 10. Particle filter assembly
5. Differential pressure sensor pipe II 11. Muffler cushion
6. Muffler intake and exhaust pipe 12. Muffler assembly
assembly
2014.01.09
Maintenance Guide
Note:
·
·Wait for 30 minutes after the engine has stopped before removing any exhaust system
component to prevent any personal injury caused by the high-temperature components.
·
·The gaskets at various component connectors are intended for sealing. They may be
deformed due to pressure after the first installation and thus deteriorate the sealing effect.
Therefore, these gaskets cannot be reused again.
·
·Install and adjust the exhaust pipe assembly, and make sure that the clearance between the
exhaust pipe assembly and each component on either side is no less than 15mm.
·
·Apply an adequate amount of washing liquid within the mounting hole of the tri-hole rubber
block, and the load on the installed rubber block must be even.
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CNG System
Introduction
Introduction of the CNG system
CNG is an acronym for “compressed natural gas”. The CNG system adds a set of dedicated CNG fuel
device system on the fuel vehicles, equipping the vehicle with two independent fuel supply systems,
one is the fuel oil and the other is the fuel gas.
System components
The main CNG system components include: gas cylinder, fuel gas ECU, nozzle rail, high-pressure
solenoid valve, pressure reducer assembly, pressure gauge, gas filter, fuel mode change-over switch
and filling port. The structural parameters and performance of each component are described in the
table below.
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Serial No. Item Structural parameters and performance description
Water capacity CNG2-G-325-80-2OB CNG steel cylinder, to store
1 Gas cylinder
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natural gas.
Achieves precise control of gas injection via collecting petrol
2 CNG ECU ECU data as well as sensor signals such as intake pressure and
temperature and throttle valve position when using the fuel gas.
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Pressure reducer Preheats the natural gas; converts the high-pressure fuel gas in
3
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assembly the gas cylinder into the gas required by the engine operation.
The high-pressure solenoid valve is a supporting component of the
High-pressure
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4 pressure reducer. Its role is to control the open/close of the high-
solenoid valve
pressure gas line.
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Indicates the existing amount of fuel in the cylinder and sends the
5 Pressure gauge
gas volume display signal to the change-over switch.
Achieves the switchover between the fuel gas and petrol as well
Fuel mode
6 as indicates the fuel usage according to instructions (displayed by
changeover switch
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indicator lamp).
7 Filling port Fills the natural gas fuel for the vehicle at the refueling stations.
8 Nozzle rail Channels the fuel gas into the engine cylinder for combustion.
High-pressure
9 Used for connection between various components.
pipeline
CNG system control

The vehicle employs a dual-ECU control of fuel gas ECU + petrol ECU.
The basic working principle for fuel gas ECU electronic control system:
·· Determine the natural gas injection timing and basic injection pulse width through the
measurements of the main ECU petrol injection timing and pulse width;
·· Correct the fuel gas injection pulse width according to the collected sensor signals such as intake
pressure, rail pressure, coolant temperature, and perform closed loop control;
·· Lastly, achieve the precise control of air-fuel ratio through the gas nozzle.
The CNG cannot be used as an engine fuel simultaneously when using the fuel oil. Conversely, the fuel
oil cannot be combusted when using the CNG.
2014.01.09
Maintenance Guide
Gas Cylinder
Inspection
1. Check that the cylinder assessment and certification
are valid
2. The cylinder surface should be free of defects such
as serious scratches, concaves or cracks
3. Check that all valves are well sealed and that they
can be opened and closed quickly and effectively
Replacement
1. Unscrew the gas cylinder valve nut
2. Disconnect the manual valve between the high-
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pressure gas pipe and the cylinder
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Filter
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Inspection
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1. Check that the connector is well fastened and does
not have any gas leakage. Apply the leak detection
liquid and observe for 10 seconds. Check that no
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bubble appears
2. The hose must be free of aging, oil dirt or cracks.
Check that the hose is reliably connected and does
not have friction with other components
Pressure Reducer Assembly

Inspection
1. Check that the connector is well fastened and the
hose surface is free of cracks
2. Check that it does not have friction with other
components
Replacement
Note:
The pipeline contains a small amount of fuel gas,
therefore the maintenance must be carried out in an
open and well-ventilated space without any sources
of fire.
1. Unplug the filter wire
2. Remove the joint clamp
2014.01.09
Change-over Switch and Cover Board

Replacement
1. Disconnect the change-over switch plug and the
harness terminal
2. Dismantle the switch and the lower cover board of
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the cover board assembly
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3. Dismantle the upper cover board
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4. The installation process is to the opposite that of the
dismantlement
2014.01.09
Transfer Case 6-1
TRANSFER CASE
Intelligent 4WD Transfer Case

Introduction....................................................................................6-2
Maintenance Specifications.......................................................6-3
Table of tightening torque values.....................................................6-3
Fault Diagnosis and Detection..................................................6-4
Diagnosis and fault code display.....................................................6-4
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Fault repair and detection procedure...............................................6-4
Diagnosis and fault code display.....................................................6-4
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Instructions on maintenance...........................................................6-6
Oil seal............................................................................................6-6
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Shifting motor. ................................................................................6-7
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Intelligent 4WD control module........................................................6-8
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Intelligent 4WD Transfer Case

Introduction
The intelligent 4WD transfer case (instant torque automatic full-time 4WD) is able to achieve the
required power according to the weather and road conditions. When driving under normal conditions,
the intelligent 4WD transfer case system functions as the rear-wheel drive. When the road condition
changes, however, the system will transfer the torque to the front wheels as necessary to provide
adequate traction.
Throttle pedal
Steering angle
signal
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Wheel speed
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sensor
RPM signal
Intelligent 4WD vehicle
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ABS/ESP
signal
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Indicates mounting Front axle clutch
position lock signal
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and send
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Intelligent 4WD
4WD torque
transfer case
output
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Front axle
clutch
2014.01.09
Transfer Case 6-3
Maintenance Specifications
Table of tightening torque values
Part name Torque (N•m)
Filler plug, drain plug 25±5
Motor mounting screw × 3 10±1
Motor bracket mounting screw 10±1
Front flange locknut 222±19
Rear flange locknut 318±13
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Fault Diagnosis and Detection

Diagnosis and fault code display
The diagnosis of the intelligent torque management system in the 47-80 two-speed intelligent 4WD
transfer case is the CAN-bus diagnosis.
When TMM detects the fault, the AWD indicator on the instrument panel will flash with a specific
frequency to show that a fault has occurred.
Fault repair and detection procedure
1) Determine the model of the vehicle with the fault, i.e. the type of intelligent torque distribution
system
2) Read the fault code with a diagnosis instrument to determine the cause of the fault
3) Confirm the symptoms of the fault with the intelligent 4WD system
4) Replace the faulty parts and confirm that the 4WD system is able to work properly,
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clear the fault codes history with a diagnosis instrument, reconnect the electric power supply, and
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5) Confirm that the system is working properly and that there isn’t any fault code.
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Diagnosis and fault code display
A diagnosis instrument must be used to read and clear all intelligent torque management system fault
codes; the fault codes are as follows:
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Note: Use the CAN BUS connector, upgrade the X431 system to 31.0, and select the procedures
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that correspond to the vehicle type.
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U0101 U0402 Automatic transmission signal error
U0101 U0402 Gear position signal error
U0140 U0431 Handbrake signal error
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U0140 U0431 Reverse gear signal failure
U0100 U0401 Clutch pedal position signal failure
U0100 U0401 Throttle pedal signal failure
U0100 U0401 Engine speed signal failure
U0100 U0401 Engine torque signal failure
Atmospheric temperature signal
U0100 U0401
failure
U0126 U0428 Steering wheel angle signal failure
U0100 U0401 Engine status failure
U0121 U0415 Left front wheel speed signal failure
U0121 U0415 Right front wheel speed signal failure
U0121 U0415 Left rear wheel speed signal failure
U0121 U0415 Right rear wheel speed signal failure
U0121 U0415 Brake system request failure
U0001 CAN-bus interruption
System voltage exceeds the normal
P3003
working range
P1773 P1771 Overheating protection
P1728 P1729 P1730 Solenoid clutch coil failure
Front axle clutch feedback signal
P1734
error
2014.01.09
Transfer Case 6-5
Cause of fault code failure:

U0100 Signal from the engine controller not received.
U0101 Signal from the automatic transmission not received.
U0121 Signal from the ABS/ESP controller not received.
U0126 Signal from the steering wheel angle controller not received.
U0140 Signal from the body controller not received.
U0401 Signal from the engine controller contains invalid data.
U0402 Signal from the automatic transmission contains invalid data.
U0415 ABS/ESP controller sends a signal.
U0428 Signal from the steering wheel angle controller contains invalid data.
U0431 Signal from the body controller contains invalid data.
P1728 Solenoid clutch coil is open-circuited.
P1729 Solenoid clutch coil is short-circuited to the power supply.
P1730 Solenoid clutch coil is short-circuited to the ground.
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P1734 Front axle clutch fault or line fault
P1771 Torque controller overload (excessive trackslip)
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P1773 Torque controller overload (excessive trackslip)
P3003 Vehicle electrical system failure
·
·CAN-bus is open-circuited.
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·
·CAN Hi is short-circuited to the ground or CAN Lo is short-circuited to
U0001
the power supply.
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·
·CAN Hi and CAN Lo are shorted
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2014.01.09
Maintenance Guide
Instructions on maintenance
·· The Borg Warner BW 47-80 series of intelligent 4WD
transfer case is only allowed to use the Mobil LT oil.
·· Under normal circumstances, regular filling or
changing of oil is not required throughout its service
life (maintenance-free).
·· In case of front or rear oil seal failure (leakage) and
a need for their replacement, replacement of the
oil seal is allowed only if proper lubricant has been
used.
Oil seal
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Replacement
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1. After the vehicle has cooled down, remove the
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intelligent 4WD transfer case from the chassis
2. Unscrew the oil drain plug to discharge the lubricant
within the intelligent 4WD transfer case. Refer to the
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diagram on the left for product nameplate information
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and oil level
Nameplate
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Borg Warner product
Oil drain plug Filler plug assembly model
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Assembly no
Assembly date(DD/MM/YY)
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3. After the oil has almost been drained, replace the
front and rear outlet oil seals according to the
information shown in the diagram on the left
Front outlet oil seal Things to note during press-fitting of the oil seal:
Align with surface Use appropriate tools to fit the oil seal, and avoid
O-ring
uneven installation or local im pact as fa r a s
Washer
Locknut
possible. Protect the seal lip against scratching.
Front flange
Prevent the oil seal from been scratched or peeled
during the fitting, and make sure it is pressed into
the depth shown in the diagram (distance between
the front oil seal and the end surface is 0±0.5 mm;
distance between the rear oil seal and the end
Rear flange surface is 2.0~3.0 mm).
Locknut
Washer
O-ring
Rear outlet
oil seal
2014.01.09
Transfer Case 6-7
4. After the oil seal is replaced, fasten the oil drain plug
and unscrew the filler plug to refill the lubricant with
a filling volume of 1.5±0.05 L.Fasten the filler plug
after the refilling is done
5. Please refer to “Maintenance Specifications” on
Page 6-3 for screwing down the fasteners.
Shifting motor
Replacement
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Motor mounting screw
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Motor bracket mounting screws
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diagram above to replace the gear-shifting motor
assembly
2. Please refer to the “Maintenance Specifications” on
Page 6-3 for screwing down the fasteners.
2014.01.09
Intelligent 4WD control module

Replacement
Note:
·
·Cut off the battery power supply and unplug
the connectors before removing the controller
module.
·
·The battery power supply must also be cut off
when installing the controller module. Install the
controller module and connect the plug-in with a
nut fastening torque of 11±1.N•m.
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Suspension System and Axle 8-1
Rear Axle Shaft Assembly

Schematics.....................................................................................8-2
Rear Axle Shaft Assembly. ..............................................................8-3
Tire Pressure Monitoring System
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Introduction....................................................................................8-7
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Location Diagram. ........................................................................8-8
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Schematics.....................................................................................8-9
Tire Pressure Monitor Sensor..........................................................8-9
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Tightening Torque. ..........................................................................8-10
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Technical Specifications..................................................................8-10
Electrical Schematics......................................................................8-11
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Rearview Mirror (TPMS Display). .....................................................8-12
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Special Tools. ................................................................................8-15
THA13 Setter...................................................................................8-15
Common System Abnormity............................................................8-16
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System Error Code..........................................................................8-16
Tire Pressure Monitor Sensor..........................................................8-17
Tire Pressure Monitor Receiver. ......................................................8-19
Tire Pressure Setter Operating Instructions.....................................8-20
2014.01.09

Schematics

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N·m Specified torque

ƹ Non-reusable parts
1. Rear axle 6. Oil seal compressing seat

2. Circlip 7. Parking brake assembly
3. Oil seal seat 8. Parking cable assembly
4. Bearing 9. Brake disc
5. Oil seal 10. Brake caliper assembly
2014.01.09
Maintenance Guide
Removal
1. Remove the wheels
2. Disconnect the handbrake cable and the frame joint,
and loosen the small bracket
3. Remove the brake caliper together with the brake
disc
4. Remove the rear axle shaft assembly from the rear
axle housing
(a) Connect the special tool and the axle shaft flange
surface with bolts.
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(b) Hold the special tool hammer and hit it repeatedly
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to remove the rear axle shaft.
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5. Remove the circlip from the axle shaft assembly
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Use a pair of circlip pliers to remove the circlip.
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2014.01.09
Parts inspection and maintenance
Extreme Extreme 1. Check the rear axle shaft and flange for wear,
2.0mm 0.2mm damage and run-out tolerance
Maximum offset of shaft: 2mm
Maximum offset of flange: 0.2mm
If the rear axle shaft or flange is already damaged or
worn, or the detected run-out value has exceeded the
tolerance, please replace the rear axle shaft.
2. Inspect the outer oil seal

(a) Check for any wear or damage, and pay special
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attention to the seal lip.
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(b) Replace it as necessary.
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3. Inspect the bearing and oil seal seat
Check for any wear or damage, and replace it as
necessary.
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4. Remove the bearing and oil seal seat
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(a) Move the brake and oil seal compressing seat to
the limiting position towards the flange, then move
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the outer oil seal to the limiting position of the oil
seal.
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(b) Place the hooks on the special tools in sequence
first until the hooks are holding the bearing (refer
to the diagram for the positions), and connect the
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hook and the hammer securely with bolts. Finally,
place it onto the retaining board with the axle shaft
spline facing down.
(c) Hold the special tool hammer and hit it downwards
repeatedly to remove the bearing and oil seal seat.
Note: Do not damage the oil seal.
5. Install a new outer oil seal
(a) Wash and clean the axle shaft.
(b) Apply an adequate amount of HP-R grease at the
oil seal lip.
Note: The lip should not contact the axle shaft when
installing the oil seal to avoid scratching the oil seal.
6. Replace new bearing and oil seal seat
(a) Heat the oil seal compressing seat to 100°C in the
22# engine oil.
Note: The end with larger chamfer should face the
axle shaft spline.Install the oil seal immediately after
it is taken out of the engine oil.
(b) Use a hydraulic machine to press the new bearing
and oil seal compressing seat.
2014.01.09
7. Install the circlip

Use a pair of circlip pliers to install the new circlip into
the axle shaft slot.
8. Check for any wear or damage on the inner oil seal

SST 9. Remove the inner oil seal
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Use the special tool to remove the inner oil seal.
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SST
(a) Apply an adequate amount of HP-R grease on the
oil seal lip.
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(b) Use the special tools to knock the new oil seal in.
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Installation
1. Install the axle shaft assembly into the axle housing
(a) Wipe the axle shaft and inner oil seal seat clean
with kerosene.
(b) Fit the axle shaft spline with the gear spline and
knock the axle shaft assembly into the axle housing
with a copper rod.
Note: Protect the inner and outer oil seal lips and
cable assembly during the assembly to align the
brake bolt with the rear axle flange bolt hole.
Tightening torque: 95-105N•m
2. Install the rear brake disc
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3. Install the brake caliper
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Tightening torque: 95-105N•m
4. Connect the parking cable
5. Install the wheels
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6. Deflate the brake system
2014.01.09
Tire Pressure Monitoring System

Introduction
The tire pressure monitoring system configured by WINGLE is made up of four tire pressure monitor
sensors (none on the spare tire), one tire pressure monitor receiver and one anti-glare rearview mirror.
When one or more tires are under-pressured or over-pressured, the data and alarm symbols will be
indicated on the anti-glare rearview mirror in graphical form and the alarm will be sounded to alert the
driver to step up on driving safety and vehicle reliability.
The tire pressure monitoring system (TPMS) is a new technology to improve active vehicle safety.The
system employs automotive electronics, sensor, wireless transmitter and receiver as well as many
other technologies.
TPMS can monitor the real-time tire pressure and can send alarms for unusual statuses like pressures
that are too low or too high and rapid gas leakage to notify the driver to take prompt actions and
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eliminate the potential risk of a tire puncture effectively. The system can also reduce fuel consumption
and prolong the tire’s service life, thereby improving vehicle safety and economic efficiency.
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Location Diagram
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3
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4
1. Rearview mirror (tire information 3. Front left seat

display) 4. Tire pressure monitor sensor
2. Tire pressure monitor receiver
2014.01.09
Schematics
Tire Pressure Monitor Sensor
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4±0.5
4 5
3
2
1. Tire pressure monitor sensor 4. Gasket

2. Valve cap 5. Tire pressure monitor transmitter
3. Locknut
2014.01.09
Tightening Torque
Name Status Torque (N•m) Quantity
Valve nut Lock the nut to the valve 3~5(4 recommended) 4×1
Technical Specifications
Technical parameters for tire pressure monitor sensor
Applicable valve mounting (11.5±0.2) mm (the mounting surface in contact with the seal ring being
hole diameter the plane)
Weight 40g (including valve components)
Frequency 433.92MHz±100kHz
Power -20dBm(EIRP)
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Working temperature -40°C~125°C
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Measurement scope 100kPa~900kPa
Pressure: 0°C~70°C ±10kPa
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Measurement accuracy
Others: ±25kPa Temperature: ±3°C
Technical parameters for tire pressure monitor receiver
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Nominal voltage 12V Working voltage: DC 9V~16V
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Working temperature -40°C~+85°C
Static current ≤3.5mA
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Modulation method FSK
Receiver sensitivity <-105dbm (coaxial cable input);
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Receiving frequency 433.92MHz±100kHz
Terminal plug/pull force Pull-out 100mm/min. >85N plug-in 20mm/min. <75N
2014.01.09
Electrical Schematics
TPMS Electrical Schematics
316 390 390
Diagnostic interface
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Sensor 1
Normal IGN IGN
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RF 1 4 1
Sensor 2
TPMS 3
777 LIN
3
Rearview mirror
Sensor 3
2
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2
GND GND
Sensor 4
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Tire pressure monitor receiver terminals and definitions
Pin Definition Maximum current

1 Normal source 150mA
2 Ground 1A
3 LIN 20mA
1 2 3 4 4 Ignition source 20mA
2014.01.09
Rearview Mirror (TPMS Display)

Appearance and function descriptions
Tire pressure display key Photosensitive diode

transparent cover
Drive radar display reserved

color display:
green (outer)/yellow (middle)/ Tire data loss alarm
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red (inner) symbol Amber
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Over-pressure/under-pressure alarm
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symbol Amber
Leakage alarm
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Tire pressure info symbol Amber
display
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Color: green/red Over-temperature alarm
symbol Amber
Vehicle signal
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display
Color: amber
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Temperature unit
symbol Amber
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Pressure unit
symbol Amber
Reverse radar info display reserved

Color display: green (outer)/yellow Data display
(middle)/red (inner) field Amber
Description of displays
1. Power-on display
When no data is received from the tire pressure host, the rearview mirror will display the tire pressure
and temperature values in turn: kPa
when the normal tire information is
received from the host, the tire pressure and temperature values will display in turns with a duration
of 1.5s; when an unusual information is received from the tire pressure host, the display will show
according to the following unusual tire information display description.
2. Tire NORMAL display
The four tire pressure values will be displayed in turn, and the corresponding tire status indicator will
flash. The tire pressure and temperature values will stop displaying after 30 seconds.
3. Tire UNUSUAL display
In case of tire abnormity, the rearview mirror will keep on displaying the abnormity information: the
pressure alarm symbol, temperature alarm symbol, fast leakage alarm symbol and signal loss alarm
symbol will be turned on and the corresponding data will be displayed (e.g. pressure abnormality, the
2014.01.09
pressure alarm symbol and the pressure values will continue displaying). In the case of abnormal
pressure, signal loss and abnormal temperature, the buzzer will sound five times (sound for 0.5s and
stop for 0.5s), and the corresponding tire pressure status indicator would turn red and flash. In case of
fast leakage, the buzzer will sound continuously for 15s, and at the same time, the corresponding tire
pressure status indicator would turn red and flash. Under normal conditions, the rearview mirror display
interface would shut down. If an alarm information is received from the host during this period, the
display interface will turn on automatically and continue to display the relevant alarm information until
everything is back to normal. The display interface will close automatically after the alarm has stopped
for 30 seconds.
4. LEARN mode display instructions
When a LEARN information is received from the tire pressure host, the rearview mirror will
automatically enter the LEARN interface: the four tire status indicators would turn green and flash at
the same time, and the word “SET” would be displayed at the bottom right of the vehicle symbol; press
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the rearview mirror key (about 0.5s) to feedback the received response information to the tire pressure
host, now the learning is successful; if this key is not pressed within 30s, the rearview mirror will
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automatically feedback the unreceived response information to the tire pressure host, now the learning
is unsuccessful.
5. Tire pressure sensor replacement learning display instructions
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When the rearview mirror receives the “replace tire pressure sensor” information from the tire pressure
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host, the corresponding tire status indicator will turn green color and flash at the same time, and the
word “SET” would be displayed at the bottom right of the vehicle symbol; press the rearview mirror key
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(about 0.5s) to feedback the received response information to the tire pressure host; if this key is not
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pressed within 30s, the rearview mirror will automatically feedback the unreceived response information
to the tire pressure host.
6. Tire rotation learning display instructions
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After the rearview mirror has received the “tire rotation” information from the tire pressure host (one
or more tires), the corresponding tire status indicator will turn green and flash at the same time, and
the word “SET” would be displayed at the bottom right of the vehicle symbol; press the rearview mirror
key (about 0.5s) to feedback the received response information to the tire pressure host, and the tire
replacement is successful; if this key is not pressed within 30s, the rearview mirror will automatically
feedback the unreceived response information to the tire pressure host, and the tire replacement is
unsuccessful.
Key function descriptions
1. Tire NORMAL display
30s after “IGN=ON”, the rearview mirror will turn off the tire pressure and temperature values display.
Press this key (about 0.5s) to turn on the tire pressure and temperature value displays again, and press
it again (about 0.5s) to turn them off. This allows you to view the current tire condition at any time.
2. Tire pressure and temperature value display unit setting
During IGN=ON, the tire pressure and temperature value display unit will default to the last display unit.
Press and hold the key (about 3s) to enter the tire pressure and temperature value unit setting. Enter
the tire pressure unit setting first, and the tire pressure unit will flash. At this time, each press of the
key would switch between the units (switching between the kPa, bar and psi displays in circulation).
If the key is not pressed within 3s, the system would regard the setting of the tire pressure unit as
having been completed and would display the last selected unit. The unit would stop flashing and the
system would enter the temperature unit setting. The temperature unit would flash, and each press
of the key would switch between the units ( switching between the °C and °F in circulation). If the key
2014.01.09
is not pressed within 3s, the system would regard the setting of the temperature unit as having been
completed and would display the last selected unit. The unit would stop flashing, and the system would
exit the unit setting mode and enter the normal display mode.
3. Relevant settings for rearview mirror under LEARN display mode
Description of diagnosis functions
1. IGN power cord failure diagnosis
(a) Over-voltage: >16V, error code on digital display: "E-1", tire display color: red.
(b) Under-voltage: <9V, error code on digital display: "E-2", tire display color: red.
Remarks:
Perform inspection throughout the process of IGN power cord diagnosis. An alarm will sound within 2s
after a fault occurs.
2. LIN power cord fault diagnosis
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(a) Short-circuited to the electric source; error code on digital display: "E-3", tire display color: red.
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(b) Short-circuited to the ground, error code on digital display: "E-4", tire display color: red.
Remarks:
a
LIN power cord diagnosis will be performed only when the LIN signal is not received. The diagnosis
response time is 250 ms~500 ms.
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3. Fault diagnosis when LIN information is not received
(a) When the system is first powered on, the digital display will indicate the error code E-5 if no LIN
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information is received after 800±200 ms.
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(b) If the system does not receive LIN information after 16s during operation under normal driving, the
digital display will indicate error code E-6.
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(c) When the codes in (a) and (b) above are displayed, the indicator of the four tires will turn red color
and flash for 0.5s at the same time (0.5s on and 0.5s off), the buzzer will sound five times (sound
for 0.5s and stop for 0.5s), the tire pressure warning symbol " " will be displayed, and the digital
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display will indicate the corresponding error code. When the fault has disappeared, the display will
return directly to the normal status.
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Special Tools
THA13 Setter
Introduction
The THA setter is a TPMS system tool designed and developed for the vehicle 4S shop. Tire pressure
sensor initialization, sensor replacement and tire rotation can be performed through the THA13 setter.
Quick and convenient repair and maintenance of the TPMS system can also be done at the 4S shop
through the THA13 setter.
Appearance and function schematics
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a
Indicator
Key
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a
Power switch
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Technical parameters
Working voltage DC 9V square battery

Working current <3mA
LF trigger distance 0.5m<L<1m
RF trigger distance 1.5m<L<3m
LF frequency 125kHz±2kHz
RF frequency 433.92MHz±100kHz
Note
During the operation, if the indicator dims after the power switch is turned on, or if all the
indicators flash when triggered, it means that the battery power is low. Please replace the
battery.
When the battery power is low, the trigger distance will shorten. Please get as close to the tire
valve position as possible. Please open the door when doing the setting, and press the ENTER
key to perform the setting inside the driver’s cab.
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Common System Abnormity
In case of tire abnormity, the rearview mirror will keep displaying the ABNORMAL information: the
pressure alarm symbol, temperature alarm symbol, fast leakage alarm symbol as well as signal loss
alarm symbol will be turned on and the corresponding data will be displayed(refer to “Tire ABNORMAL
display” on Page 8-12 for details).
When events such as unusual tire pressure and temperature and low tire pressure monitor sensor
power occur, the corresponding indicator lights on the rearview mirror would report the abnormity.
Checks on the tire pressure, temperature and sensor will be performed according to the specific
problem to eliminate the abnormities.
System Error Code
In case of a tire pressure monitoring system failure, check the TPMS data display area (refer to
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“Diagnosis function description” for details) on the rearview mirror for any error code. Refer to the
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“Electrical schematics” on Page 8-11 and carry out the troubleshooting according to the following error
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codes and causes:
Error code Description of cause
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E-1 IGN power cord over-voltage (>16V)
E-2 IGN power cord under-voltage (<9V)
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E-3 LIN power cord short-circuited to the electric source
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E-4 LIN power cord short-circuited to the ground
First power-on, no LIN information received after
E-5
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800±200ms
During the system operation under drive, no LIN
E-6
information received after 16s
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Maintenance Guide
Tire Pressure Monitor Sensor
Note:
·I· n o r d e r t o e n s u r e t h e r e l i a b i l i t y o f t h e
communication between the receiver and the
sensor as well as the tightness between the
sensor and the hub, please read this section
carefully.
Removal
1. Lift the vehicle
2. Remove the wheel assembly
3. Remove the tire bead from the wheel assembly
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4. Remove the valve cap and locknut (A) in sequence
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from the valve (B)
a
Note:
Place the removed valve locknut at a clean place and
take care to keep water and dust away.
A
B
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5. Remove the tire pressure monitor sensor from the
wheel
Note:
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Place the removed valve locknut at a clean place.
Installation
Prompts on assembly requirements:
·
·The valve is suitable for hubs with a valve
mounting hole of Φ11.5±0.2 mm.
·
·The outer diameter of the valve locknut is Φ14
mm and the length 19 mm.
1. Clear all dirt or debris from the ring sealing part
2. Unscrew the sensor valve locknut (A)
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3. Penetrate the valve end through the hub hole

Remarks:
The sensor surface should be parallel to the rim surface
as much as possible. After the installation, the sensor
arc surface should fit in with the hub’s arc surface and
should ensure a clearance of 0-3 mm with the front of
the hub.
4. Screw on the valve locknut (A) by hand and tighten

it with a tool
A Specified torque: 4±0.5.N•m
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6. Inflate the tire to the standard pressure and check
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the valve core and locknut for any air leakage using
soapy water
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7. Install the valve cap, and then the sensor installation
is complete
8. Adjust the tire’s dynamic balance and mount the tire
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Note:
Inspection and adjustment of the tire’s dynamic
balance must be performed after the sensor
transmitter has been installed.
9. Initialize the newly installed tire pressure monitor
sensor
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Tire Pressure Monitor Receiver

Replacement
Note:
Refer to the “Electrical troubleshooting instructions”
before carrying out the replacement.
1. Remove the front left seat (A)
2. Lift up the carpet under the seat appropriately until
the tire pressure monitor receiver (B) is exposed.
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3. Disconnect the tire pressure monitor receiver’s
A harness plug-in
4. Remove the two cross-recessed pan head tapping
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screws, and remove the tire pressure monitor
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receiver (A) from the mounting bracket (B)
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B
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5. T h e a s s e m b l y i s t h e o p p o s i t e t h a t o f t h e
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disassembly. Confirm that the tire pressure
monitoring system works properly after the
replacement is completed
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Tire Pressure Setter Operating Instructions

Replacing the tire pressure monitor sensor
This function can be used for the replacement of the
vehicle sensor.
1. Turn on the setter power switch and press the
sensor replacement key, and the relevant indicator
will light up
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2. Place the setter within 50 cm of the valve of the tire
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that needs a sensor replacement. Press the key
corresponding to the tire position, and the position
indicator will flash, the indicator light will stay
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on after receiving the sensor information. Please
trigger in sequence to light up the sensor position
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indicators if replacing multiple sensors at the same
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time.
Remarks: The diagram on the left is an example of the
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replacement of the front right wheel sensor.
3. Take the setter into the driver cab, turn the key to
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“ACC-ON” position and press the “ENTER” key
on the setter. The four tire position indicators will
display in turn
4. When the receiver installed below the seat receives

the setting information, the rearview mirror will
display “SET”, and the tire position indicator related
to the sensor replacement will light up
5. The operator is to press the key on the rearview
mirror within 30s for confirmation. The sensor
replacement is completed upon the confirmation
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Note:
· the operator fails to press the key on the
·If
rearview mirror within 30s for confirmation, this
operation will be invalidated, and the sensor
replacement cannot be completed. The operator
must repeat the above operations again.
·
·Please carry out the above operations after the
sensor has been installed. The 4S shop must
record the sensor ID code and the corresponding
information of the installation position during the
maintenance and installation.
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Initialize the tire pressure monitor sensor

This function can be used for users who install additional
sensors.
1. Turn on the setter power switch, and the initialization
indicator will lights up (by default, it will light up
automatically when powering on)
2. Place the setter near the front left wheel and press
the key representing the front left wheel within a
distance of 50 cm from the wheel valve. The front
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left wheel indicator will flash, and will stay on after
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receiving the information from the sensor
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t W3. Trigger the front right wheel, rear right wheel
and rear left wheel in sequence, and all the
a
corresponding position indicator lights will stay on
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upon after the triggering
G 4. When all four tire position indicators are lighted up,

take the setter into the driver cab turn the key to
“ACC-ON” position and press the “ENTER” key on
the setter. The four tire position indicator lights will
display in turn

display “SET”, and the four tire position indicators
will light up at the same time
mirror within 30s for confirmation. The sensor
initialization is completed upon the confirmation
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Note:
If the operator fails to press the key on the rearview
mirror within 30s for confirmation, this operation will
be invalidated, and the sensor replacement cannot
be completed. The operator must repeat the above
operations again.
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Tire rotation
After the tires have been used for a long time, this
function may be used to perform tire rotations.
1. Turn on the setter power supply and press the “Tire
Rotation” key. The corresponding indicator will light
up.
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2. Select the tires for mutual rotation and press the
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corresponding position keys in sequence. The tire
a
position indicator will light up. The diagram on the
left figure is an example of the rotation between the
front left wheel and the rear right wheel
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a 3. Take the setter into the driver cab and turn the key
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to “ACC-ON” position and press the “ENTER” key
on the setter. The four tire position indicators will
display in turn
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display “SET”, and the tire position indicators for
the tires involved in the rotation will light up
mirror within 30s for confirmation. The tire rotation
is completed after the confirmation
Note:
· the operator fails to press the key on the
·If
rearview mirror within 30s for confirmation, this
operation will be invalidated, and the sensor
replacement cannot be completed. The operator
must repeat the above operations again.
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·
·Please rotate the corresponding tires before
carrying out the above operations. Removal
of the sensor during the replacement is not
required. If more than two tires are involved
in the tire rotation, please repeat the above
operations several times. Only two tire rotations
may be performed for each operation.
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2014.01.09
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2014.01.09
Brake System 9-1
BRAKE SYSTEM
Rear Brake (Disc/Drum)

Schematics.....................................................................................9-2
Brake Pad........................................................................................9-3
Brake Disc.......................................................................................9-6
Brake Wheel Cylinder......................................................................9-7
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Brake Caliper...................................................................................9-9
Rear Parking Brake (Disc/Drum)
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Schematics.....................................................................................9-10
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Rear Parking Brake..........................................................................9-11
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ESP
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Introduction....................................................................................9-18
ESP 9 Hydraulic Regulator...............................................................9-18
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Note. ...............................................................................................9-19
ECU Interface Circuit.......................................................................9-22
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ECU Pin Assignment. ......................................................................9-22
Preliminary Check...........................................................................9-23
Fault diagnosis flowchart. ...............................................................9-25
Troubleshooting Without a Fault Code. ...........................................9-26
Maintenance of Occasional Faults...................................................9-26
Table of Fault Codes........................................................................9-28
Fault Code Analysis.........................................................................9-30
Instructions for Discharging............................................................9-35
ESP Hydraulic Control Unit..............................................................9-38
Steering Angle Sensor.....................................................................9-39
Combined Sensor............................................................................9-40
2014.01.09
Rear Brake (Disc/Drum)

Schematics
3
25-30 4 55 11 12
5 9 10
7
1 2
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17
25-30
22 8
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13
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18 15
13
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19
14
G
14
100
21
20 16
17
1. Rear parking brake assembly 12. Cylinder bore dust shield

2. Rear brake hose 13. Anti-noise shim composite
3. Guide pin 14. Anti-noise shim
4. Bleed screw hood 15. Inner brake pad
5. Bleed screw 16. Brake pad wear indicator panel
6. Brake hose fastening bolt 17. Brake pad circlip
7. Copper washer 18. Outer brake pad
8. Brake caliper 19. Brake caliper locking bolt
9. Piston 20. Pin pouch
10. Rectangular seal ring 21. Caliper bracket
11. Wire clamp 22. Positioning pin
2014.01.09
Brake System 9-3
Maintenance Guide
Brake Pad
Inspection
Remarks: If the rear wheel squeals during braking,
check the brake pad wear indicator panel. If there are
any traces of friction with the brake disc on the panel,
the brake pad should be replaced.
Measure the thickness of the brake pad liner

Standard thickness: 8.0.mm
Minimum thickness: 2.0.mm
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If the thickness is less than the minimum value or if there
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are traces of uneven wearing, the brake pad should be
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replaced.
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1. Remove the rear wheels
a
2. Check the thickness of the brake pad liner
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Measure the thickness of the brake pad liner (friction
material) from the peephole on the caliper. If its
thickness is beyond the specified range, the brake pad
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Peephole needs to be replaced.
Minimum thickness: 2.0 mm.
3. Lift the brake wheel cylinder

(a) Remove the positioning pin.
(b) Lift the brake wheel cylinder and hang it with a rope
to protect the brake hose.
Remarks: Do not remove the brake hose.
2014.01.09
4. Remove the following parts

(a) Two brake pads
(b) Two anti-noise shims
(c) Two anti-noise shim composites
(d) One brake pad liner wear indicator panel
(e) Two brake pad circlips
5. Measure the brake disc thickness

Refer to “Measure brake disc thickness” on Page 9-6
6. Measure the radial run-out of the brake disc
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Refer to “Measure radial run-out of brake disc” on Page
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9-6
7. Install the brake pad circlip
a
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8. Install the new brake pads
(a) Install a brake pad liner wear indicator panel on the
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inner brake pad.
(b) Install one anti-noise shim and one anti-noise shim
composite on each brake pad.
Remarks:
Apply disc brake oil on both sides of the anti-noise shim
(do not substitute with other types of oil).
(c) Install two brake pads with the wear indicator panel
on the lower pad (near the cylinder).
Remarks:
The brake pad and brake disc working surfaces must not
have grease or paint contamination.
2014.01.09
Brake System 9-5
9. Install the wheel cylinder

(a) Loosen the bleed screw and pump out a small
amount of brake fluid.
(b) Press in the piston with a hammer handle or similar
tools and tighten the bleed screw at the same time.
Tightening torque: 8~13 N•m
Remarks:
Only the brake pads on the same wheel can be replaced
each time so as to prevent the opposite piston from
popping out.
(c) Install and tighten the locating pin.
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Tightening torque: 25~30 N•m
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10. Install the rear wheels
Tightening torque: 135±15 N•m
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11. The replacement is completed. Fill with brake fluid
and bleed the air within the brake system
2014.01.09
Brake Disc
Measurement and replacement
1. Measure brake disc thickness
If the brake disc is scratched or worn, or when its
thickness is smaller than the minimum value, the brake
disc should be repaired or replaced.
2. Measure the radial run-out of the brake disc
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Remarks: Ensure the rear bearing has been correctly
adjusted before measuring.
a
Maximum radial run-out: 0.11.mm
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3. Replace the brake disc as necessary
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(a) Remove the bracket from the rear axle flange.
(b) Remove the rear brake disc and install a new brake
disc.
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(c) Install the bracket and tighten the brake caliper bolt
firmly.
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Brake System 9-7
Brake Wheel Cylinder

Removal
1. Remove the brake hose
Remove the brake hose. Drain the brake fluid into a
container.
2. Remove the wheel cylinder from the bracket

(a) Remove the positioning pin and the guide pin.
(b) Remove the caliper body.
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3. Remove the brake pads
(a) Two brake pads
a
(b) Two anti-noise shims
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(c) Two anti-noise shim composites
(d) One brake pad liner wear indicator panel
(e) Two brake pad circlips
G Dismantlement
1. Dismantle the piston from the caliper body
(a) Line the duster cloth or another soft cloth between
the piston and the caliper body.
(b) Dismantle the piston and cylinder bore dust shield
from the caliper body using compressed air.
Warning: Do not put your fingers in front of the
piston when using the compressed air.
2. Dismantle the piston seal ring from the caliper body

Use a screwdriver to remove the piston seal ring.
2014.01.09
Assembly
1. During the assembly, apply an adequate amount of
vacuum silicone grease on the guide pin, and apply
an adequate amount of rubber grease on the piston
and rectangular seal ring working surfaces
2. Install the piston seal ring and the piston in the

caliper body
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in the caliper body
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G 4. Install the pin pouch on the caliper bracket
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Brake System 9-9
Brake Caliper
Installation
1. Install the brake pad
2. Install the wheel cylinder
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(a) Install the brake wheel cylinder.
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(b) Install and tighten the positioning pin and the guide
a
pin.
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3. Connect the brake hose
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Connect the brake hose to the caliper body.
4. Fill the brake system with brake fluid and bleed the
air in the brake system
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5. Check for any brake fluid leakage
2014.01.09
Rear Parking Brake (Disc/Drum)

Schematics
1
3
ƹ8
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a
7 6
9
14
15 18
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16
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2
a
10
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17
11 13
G
12
ƹ Non-reusable parts
1. Spring rod 10. Pull-down spring

2. Parking brake cable 11. Gap-adjuster spring
3. Block 12. Gap-adjuster gear
4. Upper return spring 13. Gap-adjuster bolt head
5. Push plate return spring 14. Rear brake shoe
6. Push plate 15. Lever pin
7. Front brake shoe 16. Compression spring
8. Saddle washer 17. Compression spring seat
9. Brake shoe lever 18. Rear brake disc
2014.01.09
Brake System 9-11
Maintenance Guide
Rear Parking Brake
Disassembly
Remarks: When the parking brake force does not meet
the requirements, check the thickness of the brake shoe.
If the thickness of the brake shoe liner is smaller than
the minimum value, the brake shoe should be replaced.
1. Remove the rear wheels
2. Remove the rear brake caliper
3. Remove the rear brake disc
Remarks: If he brake disc is difficult to disassemble,
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remove the adjustable plug and insert the screwdriver
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into the hole on the rear brake backing plate. Relax the
a
brake shoe adjuster by turning the gap-adjuster gear.
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4. Remove the brake shoe compression spring, the
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spring seat and the spring rod
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G 5. Remove the lower tension spring and gap adjuster
Remove the tension spring with a caliper. Loosen the
gap adjuster and remove it.
6. Remove the two upper tension springs
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7. Remove the brake shoe

(a) Remove the brake shoe, backing plate and backing
plate return spring.
(b) Remove the handbrake cable from the parking
brake lever.
8. Remove the parking brake lever

Use a screwdriver to remove the parking brake lever
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2014.01.09
Brake System 9-13
Check and repair

1. Check the disassembled parts
Check the disassembled parts for any wear, rust or
damage.
2. Measure the inner diameter of the brake disc
Standard inner diameter: 210 mm
Maximum inner diameter: 212 mm
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3. Measure the thickness of the brake shoe
a
If the thickness of the brake shoe is smaller than the
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minimum value or there is uneven wearing, the brake
shoe should be replaced.
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Remarks: If any one brake shoe needs to be replaced,
a
all the rear brake shoes should be replaced to maintain
an even braking performance.
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4. Check if the contact between the brake shoe liner
and the brake disc is good.
If the contact between the brake shoe liner and the
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brake disc is poor, the brake shoe assembly should be
repaired or replaced with a brake shoe grinding device.
2014.01.09
Assembly
Remarks: Assemble the parts according to the direction
shown in the diagram;
Grease or paint contamination is strictly forbidden on the
brake drum and friction plate working surfaces. If there
are traces of contamination on the friction plate, polish it
with fine-grain sand paper. If the contaminated surface
is large, the brake shoe should be replaced, otherwise
it would lead to the serious consequence of insufficient
braking force.
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Left wheel Right wheel
Front of vehicle
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Front of vehicle
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1. Install the gap-adjuster assembly
Insert the spindle nose into the gap-adjuster gear and
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screw the screw rod into the gear
Remarks:
Left screw rod thread rotates to the left
Right screw rod thread rotates to the right
2. Apply an adequate amount of high-temperature

resistant grease on the following parts:
(a) The contact joint between the brake backing plate
and the brake shoe.
2014.01.09
Brake System 9-15
(b) Contact surface between the push plate and the

brake shoe as well as the contact surface between
the gap-adjuster assembly and the brake shoe.
3. Install the parking brake lever

Install the parking brake lever and use a new saddle
washer.
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4. Install the rear brake shoe
(a) Install the parking brake cable on the brake lever.
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G (b) Insert the end of the rear brake shoe into the

support pin on the brake backing plate.
Insert the compression spring rod into the brake
backing plate and the brake shoe assembly in
sequence. After that, insert the compression spring
as well as its seat, and rotate the spring seat with a
spring fork until it is in position.
5. Install the front brake shoe

Install the front brake shoe by inserting one end into the
positioning pin on the backing plate.
Insert the compression spring rod into the brake backing
plate and the brake shoe assembly in sequence. After
that, insert the compression spring as well as its seat,
and rotate the spring seat with a spring fork until it is in
position.
2014.01.09
6. Install the brake push plate

Insert the return spring into the push plate, and install
the push plate between the front and the rear brake shoe
assembly.
7 Install the lower tension spring

Install the lower tension spring between the front and the
rear brake shoes.
l l
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Push aside the brake shoe with a screwdriver and install
a
the gap adjuster.
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G 9. Install the two upper return springs
Install the stop into the supporting pin, and install
the upper return spring between the two brake shoe
assemblies.
10. Check the operation of the automatic adjuster

mechanism
(a) Pull the handbrake cable and release it. Check for
any rotation of the gap-adjuster gear. If the gear
cannot rotate, inspect the rear brake and identify
the problem.
2014.01.09
Brake System 9-17
(b) Adjust the gap adjuster to shorten its length as

much as possible.
(c) Install the rear brake disc.
11. Adjust the gap between the brake drum and the
brake shoe
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Push aside the adjuster hole plug on the brake drum
and insert the screwdriver into the hole. Rotate the gap-
a
adjuster gear to open the brake shoe until the brake disc
cannot be rotated by hand anymore. After that, rotate
the gear in the reverse direction by 3-5 teeth and rotate
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the brake disc by hand at the same time. Free rotation
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without the contact between the friction plate and the
brake disc would be the best. A slight feeling of friction
a
for the new brake shoes without run-in is allowed. When
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adjusting the gap, the left and right wheels must be
adjusted simultaneously. Install the hole plug after the
adjustment is done.
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12. Install the rear brake caliper
13. Install the rear wheel
2014.01.09
ESP
Introduction
WINGLE ESP employs the BOSCH ESP 9.0 system.
ESP 9 is made up of the hydraulic module with an electronic controller and various sensors:
·· ESP hydraulic regulator module with electronic controller
·· Wheel speed sensor
·· Steering wheel angle sensor
·· Yaw velocity and lateral acceleration sensor (combination sensor)
·· Communication with the engine management system
ESP 9 Hydraulic Regulator

The vehicle brake system employs the type II layout, as shown below. The ESP 9 hydraulic regulator
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consists of one motor, two reflux pumps, two accumulators, one pressure transducer and 12 solenoid valves.
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MC2 MC1
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U
HSV2 USV2 USV1 HSV1
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sRP2 sRP1
M
RLEV RREV FLEV FREV

RVR2 RVR1
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A2 A1
RLAV RRAV FLAV FRAV
RL RR FL FR
The English abbreviations shown in the diagram are explained below:

MC1 Brake master cylinder circuit 1 FLAV Front left wheel outlet valve
MC2 Brake master cylinder circuit 2 FREV Front right wheel inlet valve
M Motor FRAV Front right wheel outlet valve
RP1 Reflux pump 1 RLEV Rear left wheel inlet valve
RP2 Reflux pump 2 RLAV Rear left wheel outlet valve
A1 Accumulator 1 RREV Rear right wheel inlet valve
A2 Accumulator 2 RRAV Rear right wheel outlet valve
FL Front left wheel HSV1 High pressure valve 1
FR Front right wheel HSV2 High pressure valve 2
RL Rear left wheel USV1 Guide valve 1
RR Rear right wheel USV2 Guide valve 2
FLEV Front left wheel inlet valve P/U Pressure transducer
2014.01.09
Brake System 9-19
Note
The ESP is a component that involves safety. Therefore,
the following things to note for diagnosis must also
be obeyed during the repair and diagnosis in addition
to compliance with general safety and preventive
measures.
1. Repair and maintenance of the ESP system must be
performed by technicians who have been specially
trained and have mastered the relevant repair and
maintenance skills. Only original factory parts may
be used for replacement.
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2. Clear any existing faults in the basic brake system
first before diagnosing the ESP system, such as:
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·· Brake system noise
·· Brake pedal being too stiff
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·· The brake pedal or the vehicle vibrating during
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normal braking
·· Vehicle brake yawing
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·· Parking brake system failure
3. The ESP assembly (referring to the ESP electronic
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controller and hydraulic regulator assembly and
excluding brake hose, sensor and other attachments)
can only be replaced as a whole. Overhaul or partial
replacement/mutual exchange is not allowed.
BOSCH does not supply individual spare parts and
will not warrant the disassembled ESP assembly.
The company also assumes no responsibility for
the partial replacement/mutual exchange of the ESP
hydraulic regulator.
4. The two following situations indicate that the ESP
system has detected a failure:
·· The ignition switch is turned on, and the alarm
indicator light remains on after the system self-test is
completed.
·· The alarm indicator light remains on during driving.
The driver now can carry out normal braking, but should
reduce the braking force as much as possible to prevent
the wheels from locking. If the alarm indicator lights up,
drive the vehicle carefully to an authorized service shop
for overhaul so as to prevent more faults from occurring
as they may result in a traffic accident.
2014.01.09
5. Pay attention to the following points when plugging

the ESP and the sensor harness:
·· Turn off the ignition switch before unplugging the
ESP or the sensor harness.
·· Keep the connector dry and clean to prevent any
foreign matters from entering it.
·· The ESP harness’ connectors must be installed
properly in the horizontal and vertical directions in
order to avoid damaging the connectors.
6. Ensure the correct connection of the ESP brake
hoses. The ESP ECU cannot determine whether
the brake hose has been connected correctly or
not. Incorrect connection may result in serious
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accidents. The marks on the ESP assembly must be
complied with when connecting the brake hose:
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·· MC1: Connect the brake master cylinder hose 1;
·· MC2: Connect the brake master cylinder hose 2;
·· FL: Connect the brake hose of the front left brake
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wheel cylinder;
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·· FR: Connect the brake hose of the front right brake
wheel cylinder;
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·· RL: Connect the brake hose of the rear left brake
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wheel cylinder;
·· RR: Connect the brake hose of the rear right brake
wheel cylinder.
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7. The ESP may generate noises in the following
situations:
·· A short hum would be generated when the vehicle
accelerates to 40km/h. The sound comes from
the starting up of the reflux pump motor during
the dynamic ESP self-test. This is a normal
phenomenon.
·· When the vehicle accelerates to 30km/h and the
brake fluid within the accumulator reaches a certain
amount, the ESP reflux pump motor would start up
and generate a hum/
·· After the vehicle has been driven for 500 minutes
continuously, the ESP reflux pump motor will
be started up and cause the brake fluid in the
accumulator to reflow, which would generate a hum;
·· The ESP system would generate a sound when it
is working normally, which is reflected mainly in the
following aspects:
1) The sound of motor, solenoid valve and reflux
pump actions in the ESP hydraulic unit
2) A sound caused by vibration of the brake pedal
2014.01.09
Brake System 9-21
3) The sound of impact between the suspension

and the body caused by emergency braking or
intense driving
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2014.01.09
ECU Interface Circuit
Refer to “Wiring Diagram-ESP (4D20 Euro V)”
ECU Pin Assignment
2 12
1 13
14 24
25 26 38
37
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Pin Function Pin Function
1 Motor power terminal (positive) 20 CAN2 H
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2 Wheel speed sensor output (FR) 21 Undefined
3 Undefined 22 Undefined
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Wheel speed sensor
4 23 ESP shutdown indicator
signal terminal (FR)
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6 Undefined 25 Valve relay power terminal
7 Undefined 26 CAN1 H
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8 Wheel speed sensor signal terminal (FL) 27 Undefined
ECU power terminal
9 Undefined 28
(ignition power cord)
Wheel speed sensor
10 Undefined 29
signal terminal (RR)
11 Undefined 30 Brake light switch
Wheel speed sensor
12 ESP shutdown switch 31
power terminal (RL)
13 Motor ground terminal 32 Undefined
14 CAN1 L 33 CAN2 L
Wheel speed sensor
16 35 Undefined
power terminal (FR)
Wheel speed sensor
17 36 Undefined
power terminal (RR)
18 Wheel speed sensor signal terminal (RL) 37 Undefined
19 Wheel speed sensor power terminal (FL) 38 ECU ground terminal
2014.01.09
Brake System 9-23

Preliminary Check
Before diagnosing the ESP system, check the easily
accessible components that may have caused ESP
system failure first. Visual inspection and appearance
checks can quickly determine the fault, thereby
eliminating the need for further diagnosis.
1. Make sure that only the tires and hubs with
recommended sizes are installed on the vehicle. The
tread pattern and depth must be the same for coaxial
tires. For the detailed tire model, please refer to the
vehicle user manual.
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2. Check the ESP hydraulic regulator, brake hose and
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the connections for any leakages.
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3. Check the ESP system fuse and ensure that there is
no fuse is burnt and that the model is correct. The
ESP system has three fuses, which are:
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·· Pump motor fuse (40A)
·· Solenoid valve fuse (25A)
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·· Electronic controller fuse (5A)
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4. Check the battery voltage, and check if the battery
terminal are corroded or loose.
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·· The normal working voltage range of the ESP system
is 9.3V–16.8V.
5. Check whether the ESP ground wire grounding point
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is loose, and whether the grounding position has
been changed.
6. The ESP grounding wire must be well sealed to
prevent the water and moisture from penetrating
the ESP ECU connector through the pores in the
harness under the capillary (siphon) effect, thereby
causing it to fail.
Measures: Apply sealant on the exposed end of the
harness and use a heat shrink tubing.
Apply sealant on the exposed end of the
harness and use a heat shrink tubing.
Ignition coil/ignition cable/spark plug 7. Perform visual inspection and appearance check for
the following electrical components:
Gear ring ·· Whether the harness and connectors of the ESP
system components are properly connected, and
whether they have been pinched or cut.
Generator ·· Whether the harness wiring is too close to high-
Wheel speed sensor voltage or high-current devices such as high-voltage
or high-current components, generator and motor as
well as the stereo amplifier added after sales.
2014.01.09
Note:
The high-voltage or high-current devices may
cause the circuit to generate induced noises,
thereby interfering with the normal operation of
the circuit.
·· E S P c o m p o n e n t s a r e v e r y s e n s i t i v e t o
electromagnetic interference (EMI). If any intermittent
faults are suspected, check whether the anti-theft
devices, lights or mobile phones added after sales
are installed correctly.
8. The ESP is an active safety system. Its main role
is to maintain the vehicle’s maneuverability and
driving stability through the maximized use of
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ground adhesion. When the physical limit has
been exceeded or when driving at a high speed on
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slippery roads, however, the ESP system cannot
completely prevent the vehicle from skidding.
9. If the ESP noise is too loud, it may be caused by the
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following reasons:
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·· The fixing of the ESP assembly and bracket is loose.
·· The fixing of the ESP bracket and vehicle body is
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loose.
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·· The plastic washer onthe ESP bracket is missing or
damaged.
2014.01.09
Brake System 9-25
Fault diagnosis flowchart
1 The vehicle enters the repair shop
2 Analyze the customer’s problems
3 Read the fault codes
With fault code Proceed to Step 4
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Without fault code Proceed to Step 6
4 Record the fault code and clear the fault memory.
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Demonstrate and reproduce the fault: Accelerate the vehicle to 15km/h to simulate the fault
5
status and read the fault code
a t With fault code Active fault code. Proceed to Step 7
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Without fault code Historical fault code. Proceed to Step 8
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6 Repair without a fault code and proceed to Step 9
7 Troubleshoot according to the fault code and proceed to Step 9
8 Troubleshoot according to the fault symptom and proceed to Step 9
9 Confirm that the fault has been cleared.
10 Prevent the reoccurrence of the fault.
Finish
2014.01.09
Troubleshooting Without a Fault Code

If the braking system has a fault but the ESP system has not stored the fault code, such a fault will be
referred to as a fault without fault code. A fault without fault code is generally caused by a basic braking
system failure. For example:
·· Brake fluid leakage (which may cause soft braking, an exceedingly long brake pedal travel and
even brake failure in severe cases)
·· Use of poor-quality brake fluid (the use of poor-quality brake fluid may corrode the brake hose and
ESP hydraulic regulator module internal components and even brake failure in severe cases)
·· Brake hose contains air (which may cause soft braking and even brake failure)
·· Brake hose blockage (which may cause hard braking, and even brake failure)
·· Excessive wear of the brake disc (which may cause soft braking as well as an exceedingly long
brake pedal travel)
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·· Booster fault (which may cause soft or hard braking, an exceedingly long brake pedal travel and
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even brake failure in severe cases)
·· Brake hose connection error (which may cause a decline in ESP performance, unsteadiness
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and braking distance to be long, etc. Refer to the mark near the oil hole on the ESP hydraulic
regulator module for the proper installation method: MC1 represents the #1 master cylinder hose;
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MC2 represents the #2 master cylinder hose; FL represents the front left wheel cylinder hose; FR
represents the front right wheel cylinder hose; RL represents the rear left wheel cylinder hose; and
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RR represents the rear right wheel cylinder hose)
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Note:
No power supply or unusual power interruption for the ESP will cause the ABS and ESP alarm
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indicators to light up for a long time but has no sign of fault codes.
Troubleshooting suggestions:
Check the corresponding components in accordance with the fault, and troubleshoot according to the
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vehicle maintenance manual.
Maintenance of Occasional Faults

In an electronic system, problems of instantaneous poor contact may be found at the electrical circuit
and input/output signals, resulting in occasional faults. The cause of the fault would sometimes
disappear by itself, and so it is not easy to identify the problem. In case of an occasional fault, simulate
the fault in the following ways to check if it occurs again.
2014.01.09
Brake System 9-27
No. Possible cause Simulated fault Remarks

· the harness is broken because
·If
·
·Sway the ESP ECU connector of twisting or tight pulling,
gently up and down as well as left replace with new parts.
and right ·
·When the vehicle is driving, the
·
·Sway the ESP harness gently up wheel speed sensor harness
If the vibration is the
1 and down as well as left and right will result in a temporary open/
main cause
·
·Sway the sensor gently up and close circuit due to the vertical
down as well as left and right movement of the suspension
·
·Sway the other moving parts such system. Therefore, an actual
as the wheel bearings gently test drive must be carried out to
check the sensor harness.
·
·Heat the faulty parts with a blower
If the temperature is
2 ·
·Check for cold welding with cold
the main cause
sprays
·
·Turn on all electrical switches,
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If an exceedingly i n c l u d i n g t h o s e f o r t h e a i r -
3 high electrical load conditioner, headlights, speakers
is the main cause and wipers, etc. to operate the
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vehicle power supply at high load.
If the fault does not recur, diagnosis and maintenance must only be carried out only when the fault
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recurs next time. Generally, the occasional fault would evolve gradually into the recurring fault and will
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not disappear by itself.
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2014.01.09
Table of Fault Codes
DTC DTC(Hex) DTC Description

C190004 0x590004 ECU over-voltage
C190104 0x590104 ECU under-voltage
C100004 0x500004 ECU fault (hardware and controller fault)
C101008 0x501008 ECU fault (software error)
ABS/ESP control abnormity (an exceedingly long continuous actuation
C006B06 0x406B06
time, etc.)
Left front wheel speed sensor signal error. Out of range, missing, noise
C003108 0x403108
and interruption.
C003200 0x403200 Left front wheel speed sensor open circuit
C00A000 0x40A000 Left front wheel speed sensor is short-circuited to the ground
C00A100 0x40A100 Left front wheel speed sensor is short-circuited to the electric source
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Unidentified left front wheel speed sensor fault (the exact cause of fault
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C00A900 0x40A900
cannot be defined)
Right front wheel speed sensor signal error. Out of range, missing, noise
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C003408 0x403408
and interruption.
C003500 0x403500 Right front wheel speed sensor open circuit
C00A200 0x40A200 Right front wheel speed sensor is short-circuited to the ground
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C00A300 0x40A300 Right front wheel speed sensor is short-circuited to the electric source
Unidentified right front wheel speed sensor fault (the exact cause of fault
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C00AA00 0x40AA00
cannot be defined)
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Left rear wheel speed sensor signal error. Out of range, missing, noise and
C003708 0x403708
interruption.
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C003800 0x403800 Left rear wheel speed sensor open circuit
C00A400 0x40A400 Left rear wheel speed sensor is short-circuited to the ground
C00A500 0x40A500 Left rear wheel speed sensor is short-circuited to the electric source
Unidentified left rear wheel speed sensor fault (the exact cause of fault
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C00AB00 0x40AB00
cannot be defined)
Right rear wheel speed sensor signal error. Out of range, missing, noise
C003A08 0x403A08
and interruption.
C003B00 0x403B00 Right rear wheel speed sensor open circuit
C00A600 0x40A600 Right rear wheel speed sensor is short-circuited to the ground
C00A700 0x40A700 Right rear wheel speed sensor is short-circuited to the electric source
Unidentified right rear wheel speed sensor fault (the exact cause of fault
C00AC00 0x40AC00
cannot be defined)
Common wheel speed sensor fault (sensor mutual exchange, multiple and
C109904 0x509904
sensor faults, etc.)
C004460 0x404460 Pressure sensor fault (signal)
C004510 0x404510 Pressure sensor fault (circuit)
C004008 0x404008 Brake light switch reliability failure
U160108 0xD60108 Brake light switch CAN signal failure
C006108 0x406108 Lateral acceleration sensor signal error
C006208 0x406208 Longitudinal acceleration sensor signal error
C006308 0x406308 Yaw velocity sensor signal error
C019604 0x419604 Yaw velocity sensor fault
C00A800 0x40A800 Yaw velocity sensor not calibrated or calibration failure
U000500 0xC00500 CAN bus over-voltage
U000700 0xC00700 CAN bus under-voltage
C100104 0x500104 CAN bus hardware fault
2014.01.09
Brake System 9-29
Table of Fault Codes (Cont'd)
DTC DTC(Hex) DTC Description

U000104 0xC00104 CAN bus shutdown failure
U100104 0xD00104 External CAN bus error
U010004 0xC10004 EMS CAN telegram timeout
U010008 0xC10008 EMS data interrupt or signal failure
C106600 0x506600 SAS steering wheel angle sensor calibration error
C046008 0x446008 SAS steering wheel angle sensor fault (signal)
U012604 0xC12604 SAS steering wheel angle sensor CAN
U012608 0xC12608 SAS steering wheel angle sensor data interrupt or signal failure
U010104 0xC10104 TCU CAN telegram timeout
U010108 0xC10108 TCU data interrupt or signal failure
C001004 0x401004 Valve fault, front left inlet valve
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C001104 0x401104 Valve fault, front left outlet valve
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C001404 0x401404 Valve fault, front right inlet valve
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C001504 0x401504 Valve fault, front right outlet valve
C001804 0x401804 Valve fault, rear left outlet valve
C001904 0x401904 Valve fault, rear left outlet valve
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C001C04 0x401C04 Valve fault, rear right inlet valve
C001D04 0x401D04 Valve fault, rear right outlet valve
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C000104 0x400104 Valve fault, guide valve 1
C000204 0x400204 Valve fault, guide valve 2
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C000304 0x400304 Valve fault, high-pressure valve 1
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C000404 0x400404 Valve fault, high-pressure valve 2
C109504 0x509504 Valve relay fault
C002004 0x402004 Reflux pump fault
Common valve fault (overheating protection, signal failure and hardware
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C007208 0x407208
fault, etc.)
C104C04 0x504C04 ESP shutdown switch fault
C121208 0x521208 Configuration code error
U160208 0xD60208 Handbrake signal failure (CAN signal)
C100300 0x500300 Clutch switch fault
U160308 0xD60308 Clutch signal failure (CAN signal)
U160408 0xD60408 Reverse switch signal failure (CAN signal)
C108C08 0x508C08 Reverse switch signal level high/low (continuous)
U012308 0xC12308 Loss of communication with yaw velocity sensor
U051308 0xC51308 Invalid data received from the yaw velocity sensor
C006102 0x406102 Lateral acceleration sensor signal error
C006202 0x406202 Longitudinal acceleration sensor signal error
C006302 0x406302 Yaw velocity sensor signal error
U014008 0xC14008 BCM CAN communication timeout
U014004 0xC14004 BCM data interruption
U014608 0xC14608 CAN bus gateway timeout
U014604 0xC14604 CAN bus gateway data interruption
2014.01.09
Fault Code Analysis

1. C190004; C190104 ECU power supply failure
Possible causes
(a) Storage battery over-voltage or under-voltage;
(b) Poor grounding of the vehicle body.
Maintenance and diagnosis
(a) Measure the battery voltage and charge it as necessary (standard voltage: 9.3V~16.8V);
(b) Check the two ESP grounding points, including the ESP electronic controller grounding and reflux
pump motor grounding;
(c) Turn on all high-power electrical appliances and measure the ESP supply voltage. Power supply
shortage may occur under high electrical loads;
(d) Measure the voltage fluctuation generated during vehicle startup and high-power electrical
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appliance switch on/off. The potential electrical appliance fault may result in a substantial voltage
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fluctuation in the power supply circuit.
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2. C100004 ECU fault
Possible causes
(a) ECU damaged
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(a) Replace the ESP assembly and discharge the brake pipeline.
3. C006B06 Brake system abnormity (an exceedingly long ABS/ESP action time)
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Possible causes
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(a) Continuous intense driving or use of the brake for a long period of time;
(b) Inaccurate wheel speed sensor signal;
(c) Steering wheel angle sensor and yaw velocity sensor signal abnormity
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(a) Use a diagnostic device to read the wheel speed sensor data stream and observe whether the
wheel speed continues to be too high or to low;
(b) Drive the vehicle to carry out the “8” test, turn the steering wheel to the limit both to the left and the
right, and read the fault code again;
(c) If there are no steering wheel angle sensor or yaw velocity sensor related fault codes, check
whether the ESP mounting position is horizontal and firm. The ESP bracket cannot be used to
install other devices.
4. C003200; C00A000; C00A100; C003500; C00A200; C00A300; C003800; C00A400;
C00A500; C003B00; C00A600; C00A700 Wheel speed sensor circuit fault
Possible causes
(a) The wheel speed sensor cable is broken; the connector is loose or broken.
(b) The wheel speed sensor signal cable and power cord are connected in reverse.
(c) Signal cable is short-circuited to the ground.
(a) Check the wheel speed sensor harness for open circuit or short circuit;
(b) Check whether all connectors on the wheel speed sensor circuit are loose or broken;
(c) Check whether the heel speed sensor power cord and the signal cable are connected in reverse;
(d) Accelerate the vehicle to 40km/h to perform the dynamic ESP system self-test;
(e) If the faults still cannot be eliminated after the dynamic self-test, replace the wheel speed sensor.
5. C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08;
2014.01.09
Brake System 9-31
C00AC00; C109904 Wheel speed sensor signal failure

Possible causes
(a) Wheel speed sensor harness is bent and the connector is loose or broken;
(b) Wheel speed sensor signal cable is short-circuited to the electric source;
(c) Wheel speed sensor power cord is short-circuited to the ground;
(d) Gear ring is not installed or missing teeth, dirty gear ring with foreign matters, demagnetization
and eccentricity;
(e) The air gap between the sensor and the gear ring is too large;
(f) The wheel speed sensor is subjected to external magnetic field interference (wheel or axle have
not demagnetized);
(g) Wheel speed sensor fault;
(h) Gear ring tooth number error;
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(i) Non-standard tire dimension.
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(a) Check the wheel speed sensor harness for bending;
(b) Check whether the connector on the wheel speed sensor circuit is loose or broken;
(c) Check whether the wheel speed sensor harness is short-circuited to the electric source or the
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ground;
(d) Check whether the wheel speed sensor is fixed correctly;
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(e) Use a diagnostic device to read the wheel speed sensor data stream and observe whether each
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wheel speed and acceleration display is consistent and whether the vehicle speed display is
accurate;
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(f) If the wheel speed display is inconsistent, it is necessary to check the corresponding wheel speed
sensor signal gear ring for missing tooth, dirty, foreign matter, demagnetization and eccentricity;
(g) After any maintenance is done on the wheel speed sensor, accelerate the vehicle to over 40km/h
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and perform the dynamic ESP system self-test;
(h) If the faults still cannot be eliminated after the dynamic self-test, replace the wheel speed sensor.
6. C004460; C004510 Pressure transducer fault
Possible causes
(a) Brake light switch fault or the circuit failure;
(b) Pressure transducer fault.
Methods of maintenance and diagnosis
(a) Check whether the brake light switch and its circuit are in normal condition;
(b) Replace the ESP assembly and discharge the brake pipeline.
7. C004008; U160108 Brake light switch (BLS) fault
Possible causes
(a) Brake light switch open circuit or short circuit;
(b) Brake light switch is installed incorrectly;
(c) Brake light switch is damaged.
(a) Check the brake light switch and its harness;
(b) Replace the brake light switch.
8. C006108; C006208; C006308; C019604; C00A800 Yaw rate sensor fault
The yaw rate sensor includes three signals: lateral acceleration, longitudinal acceleration and yaw
velocity.
2014.01.09
Possible causes
(a) Yaw rate sensor mounting position is incorrect; (ensure that the sensor is level on the vehicle
body)
(b) Yaw rate sensor is not properly calibrated;
(c) Yaw rate sensor is damaged.
(a) Adjust the mounting position of the yaw rate sensor and check the mounting position for any
bending or wear;
(b) Re-calibrate the yaw rate sensor;
(c) Replace the yaw rate sensor.
9. U000500; U000700; C100104; U000104; U100104 CAN bus failure
Possible causes
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(a) Storage Battery over-voltage or under-voltage (standard voltage: 9.3V~16.8V);
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(b) CAN bus network failure;
(c) ECU is damaged.
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(a) Measure the storage batter voltage and charge it as necessary;
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(b) Troubleshoot the CAN bus and each bus node;
(c) Replace the ESP assembly and discharge the brake pipeline.
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10. C106600; C046008; U012604; U012608 Steering wheel angle sensor fault
a
Possible causes
(a) Steering angle sensor is not calibrated correctly;
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(b) Steering angle sensor circuit fault;
(c) Steering angle sensor connector is loose or broken;
(d) Steering angle sensor is damaged.
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(a) Cancel the steering angle sensor calibration and re-calibrate it;
(b) Check the steering angle sensor harness;
(c) Check and re-connect the steering angle sensor plug;
(d) Replace the steering angle sensor.
11. U012604; U012608; U010104; U010108; U014008; U014004; U014608;
U014604; U012308; U051308 CAN bus node failure
Possible causes
(a) CAN bus communication interrupt;
(b) Poor CAN bus node power supply;
(c) CAN bus node failure (disconnected from the CAN bus or ECU fault).
(a) Check whether the CAN bus communication is normal;
(b) Turn off the ignition switch, measure the resistance between each CAN bus node and the ESP
(CAN-H, CAN-L); (standard value: less than 5Ω)
(c) Check the resistance between the CAN-H and CAN-L bus from the connector of each CAN bus
node (keep the connector connected); (standard value: 60Ω)
(d) Check the power supply for each CAN bus node;
(e) Read the fault code of each CAN bus node and perform the inspection accordingly.
12. C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04;
2014.01.09
Brake System 9-33
C000104; C000204; C000304; C000404; C007208 Solenoid valve fault

Possible causes
(a) System overheating protection;
(b) ESP electronic controller is damaged.
(a) Cool down the vehicle for 10 minutes and read the fault codes;
(b) Replace the ESP assembly and discharge the brake pipeline.
13. C109504 Solenoid valve relay fault
Possible causes
(a) Poor power supply for the solenoid valve (under-voltage, damaged fuse or poor contact);
(b) Poor grounding of the ESP electronic controller;
(c) ESP Electronic controller is damaged.
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(a) Check the valve relay power supply, fuse and the supply voltage;
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(b) Measure the voltage drop between the ESP connector valve relay power supply pin and the
battery positive with a 21W test lamp (standard value: less than 0.2V);
(c) Measure the voltage drop between the ESP connector ESP ECU grounding pin and the body
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grounding point with a 21W test lamp (standard value: less than 0.2V);
(d) Accelerate the vehicle to over 40km/h and perform the dynamic ESP system self-test;
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(e) If the faults still cannot be eliminated after the dynamic self-test, replace the ESP assembly and
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discharge the brake pipeline.
14. C002004 Reflux pump motor fault
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Possible causes
(a) System overheating protection;
(b) Poor power supply for pump motor (under-voltage, damaged fuse or poor contact);
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(c) Poor grounding of the pump motor;
(d) Pump motor is damaged.
(a) Cool down the vehicle for 10 minutes and read the fault codes;
(b) Check the pump motor power supply circuit, fuse and supply voltage;
(c) Measure the voltage drop between the ESP connector pump motor power supply pin and the
battery positive with a 21W test lamp (standard value: less than 0.2V);
(d) Measure the voltage drop between the ESP connector pump motor grounding pin and the body
grounding point with a 21W test lamp (standard value: less than 0.2V);
(e) Accelerate the vehicle to over 40km/h and perform the dynamic ESP system self-test;
(f) If the faults still cannot be eliminated after the dynamic self-test, replace the ESP assembly and
discharge the brake pipeline.
15. CC104C04.ESP Shutdown switch fault
Possible causes
(a) ESP shutdown switch is pressed by other items;
(b) ESP Shutdown switch or its circuit is damaged.
(a) Activate the ESP function by closing and re-opening the ESP shutdown switch with hands;
(b) Check the ESP shutdown switch.
16. C121208.ESP Configuration information error
2014.01.09
Possible causes
(a) Configuration information is not written;
(b) Configuration information is incompatible.
(a) Write the correct configuration information with a diagnostic device.
17. U160208; C100300; U160308; U160408; C108C08 Handbrake/clutch/reverse signal abnormity
Possible causes
(a) Handbrake signal abnormity;
(b) Clutch switch fault;
(c) Clutch signal abnormity;
(d) Clutch signal cable open circuit or short circuit;
(e) Reverse signal abnormity;
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(f) Reverse signal cable open circuit or short circuit.
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(a) Check the handbrake cable;
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(b) Check the clutch switch;
(c) Check the clutch signal cable;
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(d) Check the reverse signal cable.
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2014.01.09
Brake System 9-35
Maintenance Guide
Instructions for Discharging
·· After replacing the brake system components (such as brake fluid, brake pipeline and hydraulic
unit) or when the brake pedal is too soft, carry out the discharging.
·· The hydraulic unit for replacement must be an ESP hydraulic regulator filled with hydraulic oil and
installed with an ECU.
·· During the discharging, ensure the brake system structural integrity and make sure that all the high-
press hydraulic units have been connected.
·· Pull up the parking brake before the discharging.
·· The brake fluid is corrosive. Wash thoroughly if it come into contact with the skin accidentally.
Discharging with an exhaust/filling unit (2.bar exhaust)
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Connect the exhaust/filling unit to the accumulator, ensure the brake fluid
is sufficient to open the switch, and set the pressure to 2 bar
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A
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Open the bleed screw at the cylinder until the air is discharged Sequence: RL, FL, FR, RR
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B
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Check the pedal travel
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C
If unsuccessful, repeat the discharging at each wheel
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D
E Check the brake fluid level and ensure that it is between the maximum and minimum values
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Combined manual pedal and 2 bar discharging
Connect the exhaust/filling unit to the reservoir, ensure that the brake fluid
is sufficient to open the switch, and set the pressure to 2 bar
A
Open the bleed screw at the cylinder until the air is discharged Sequence: RL, FL, FR, RR
B
Step on the pedal repeatedly

B1
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C
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If unsuccessful, repeat the discharging at each wheel
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D
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E Check the brake fluid level and ensure it is between the maximum and minimum values
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Brake System 9-37
Manual pedal discharging
Fill the reservoir (until the filter neck)

A
Repeat the following procedures to discharge the air in each cylinder Sequence: RL, FL, FR, RR
B
Open the bleed screw

C
Step on the pedal repeatedly
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D
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Close the bleed screw
E
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If unsuccessful, repeat the discharging
H
J Check the brake fluid level and ensure it is between the maximum and minimum values
Remarks:
·· Recommended exhaust sequence: RL, FL, FR and RR.
·· During the process of discharging, the brake fluid in the reservoir cannot be lower than the
minimum value.
2014.01.09
ESP Hydraulic Control Unit

Removal
1. Locate the ignition switch in the LOCK position and
disconnect the battery’s negative pole
2. Remove the harness from the ESP assembly
3. Step on the brake pedal all the way down and hold it
in place with the pedal support bracket
Prevent the brake fluid from flowing out after the brake
hose is removed from the brake master cylinder.
4. Remove the brake hose and block the thread hole
on the ESP assembly and the oil hole of brake hose
with a plug to prevent foreign matters from entering
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them.
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5. Remove the ESP from the fixing bracket.
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Installation
1. Install the ESP assembly onto the bracket
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2. Remove the plugs in the ESP thread hole and brake
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hose oil hole and connect the brake hose into them
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3. Fill the reservoir with brake fluid to the Max level and
discharge according to the prescribed method
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4. Write in the configuration information after replacing
the ESP assembly (if any)
5. Calibrate the steering wheel angle sensor and the
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yaw rate sensor after replacing the ESP assembly
2014.01.09
Brake System 9-39
Steering Angle Sensor

The steering angle sensor is located below the combined
switch and is mounted on the steering column together
with the combined switch.
Replacement
1. Place the front wheels in the frontal position
2. Disconnect the storage battery’s negative pole
3. Remove the driver airbag
Notes:
Before removing the airbag, confirm that the storage
battery’s negative pole has been disconnected for
more than 90s.
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4. Remove the steering wheel
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5. Remove the cover of the combined switch
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6. Remove the clock spring
7. Remove the combined switch and the steering angle
sensor assembly
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8. Dismantle the steering angle sensor and the
combined switch assembly
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(a) Disconnect the harness connector connected to the
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steering angle sensor.
(b) Remove the 5 bolts.
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(c) Remove the steering angle sensor.
FL
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Steering angle
requirement
9. The sequence of installation is the opposite that of
the replacement. Take note of the following items:
Note:
·
·After installing the steering angle sensor,
-5°﹤linear﹤5° calibrate it with the X-431 detector.
·
·When calibrating the steering angle sensor,
ensure the position of the steering wheel is
RL RR linear.
·
·The maximum allowable error is ± 5°.
·
·Incorrect calibration will generate a fault code in
the fault code memory. Re-ignition is required to
verify an incorrect calibration, and re-calibration
can only be performed after the next ignition
cycle.
·
·Center the clock spring when installing the clock
spring (see the descriptions on the clock spring’s
label for the centering method).
2014.01.09
Combined Sensor
The combined sensor is located below the handbrake
lever guard
Replacement
1. Disconnect the storage battery’s negative pole
2. Remove the handbrake lever guard
3. Remove the combined sensor
(a) Disconnect the harness connector connected to the
combined sensor.
(b) Remove the two bolts.
(c) Remove the combined sensor installation.
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4. The sequence of the installation is opposite that of
the replacement. Take note of to the following items:
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Note:
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·
·After installing the combined sensor, calibrate it
with the X-431 detector.
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·
·The steering wheel must be turned to the frontal
position when calibrating the combined sensor.
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·
·The tire pressure is correct.
·
·Under normal load.
·
·Additional interference such as the closing of the
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door or the engine hood is not allowed.
·
·Only the driver must sit in the car.
·
·The maximum inclination angle of the ground
must be within the allowable range (along both
aligning directions).
·
·Maximum allowable inclination angle: ± 0.57°
(±1%)
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2014.01.09
Steering System 10-1
STEERING SYSTEM
Steering Column
Schematics.....................................................................................10-2
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Steering Column
Schematics
4D20 Euro V model
30±5
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25±3
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3
25±3
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25±3
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4
1. Steering wheel cover assembly 3. Steering column assembly

2. Steering wheel body 4. Special eccentric nut assembly
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Heating, Ventilation and Air-conditioning 12-1
HEATING, VENTILATION AND AIR-

CONDITIONING
Heating, Ventilation and Air-conditioning (Automatic Air-
conditioning)
Introduction....................................................................................12-2
Function..........................................................................................12-2
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Principles of an Air-conditioning System.........................................12-2
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Air-conditioning Maintenance Key Points and Things to Note. ........12-4
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Location Diagram. ........................................................................12-8
Interior Air-conditioning Assembly..................................................12-8
Air-conditioning System..................................................................12-9
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System-related Parameters........................................................12-10
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Air–conditioning-related Parameters...............................................12-10
System Electrical Devices and Principles........................................12-11
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Air-conditioning Control Panel. .......................................................12-14
Maintenance Diagnosis and Detection....................................12-17
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General Fault Diagnosis. .................................................................12-17
Fault Diagnosis Using Manifold Pressure Gauge Assembly.............12-20
Air-conditioning Fault Self-diagnosis. .............................................12-26
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Pressure Switch (High, Medium and Low Tri-state Pressure Switch)
........................................................................................................12-27
Evaporator Temperature Sensor......................................................12-28
Interior Temperature Sensor............................................................12-29
Exterior Air Temperature Sensor......................................................12-30
Air-conditioning Controller Assembly..............................................12-31
Interior Temperature Sensor Replacement.......................................12-32
Evaporator Temperature Sensor......................................................12-33
Refrigerant Related Operations. ......................................................12-34
Refrigerant Filling............................................................................12-35
Check the Air Tightness. .................................................................12-36
2014.01.09
Heating, Ventilation and Air-conditioning

(Automatic Air-conditioning)
Introduction
Function
The automatic air-conditioning system used in WINGLE vehicles incorporates ventilation, heating and
air conditioning, and the front and rear windscreens are equipped with a defrosting function (optional)
at the same time. The system is an electronically controlled system, and the internal and external
circulation, blowing mode as well as the warm and cold temperature regulations are controlled by the
servo motor installed on the air-conditioning assembly in the vehicle.
The automatic air-conditioning system is installed with external temperature sensor and evaporator
temperature sensor; the internal temperature sensor installed on the control panel is equipped with an
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automatic temperature regulation function.
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Principles of an Air-conditioning System
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The air-conditioning system takes the heat away from the car by absorbing the heat of interior air into
the evaporator. The evaporator cools the air down with the refrigerant circulating in it. The expansion of
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the refrigerant in the evaporator makes the evaporator become very cold and absorb the heat from the
air inside the vehicle. When the heat is absorbed into the evaporator, the blower fan makes the air pass
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through the evaporator and blows the cooled air into the passenger compartment.
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Blower fan
Expansion valve
(controls the refrigerant feed rate for Evaporator (heat absorption)
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the evaporator)
Evaporator temperature sensor
Pressure relief valve

Air conditioning (A/ (Relief the air conditioner compressor
C) pressure switch pressure when the pressure is too high)
HP vapor
A/C condenser HP liquid

(heat radiation)
LP liquid
LP vapor
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Air-conditioning (A/C) pressure switch

·· When the refrigerant pressure is below 196 kPa or above 3140 kPa, the ECM will shut the
compressor relay down to protect the A/C compressor.
·· When the refrigerant pressure is above 1470 kPa, the A/C pressure transducer will adjust the
radiator fan to rotate at high speed.
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2014.01.09
Air-conditioning Maintenance Key

Points and Things to Note
Things to note regarding the refrigerant
1. Do not dispose the refrigerant in enclosed spaces or
near an open flame.
2. The boiling point of the refrigerant is about -30°C.
When handling the refrigerant, be sure to wear the
goggles and protective gloves. Direct contact of
the skin with the refrigerant will result in frostbite.
Always wear goggles.
3. If the liquid refrigerant is splashed into the eyes or
onto the skin, wash the affected part with plenty of
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cold water. Do not rub your eyes or skin. Coat the
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skin with Vaseline and go to the hospital for medical
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treatment immediately.
4. Do not heat up the refrigerant tank or place it near

an open flame.
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5. Be careful not to fall into the refrigerant tank or
subject it to physical impact, and to avoid the
release of refrigerant into the atmosphere.
6. In case of accidental system drainage, ventilate the
work site adequately before carrying out recovery
and repair.
7. Do not drain the refrigerant too fast when draining

the system, otherwise the oil from the A/C
compressor in the system will be sucked out.
8. Before replacing the A/C system components, be
sure to disconnect the storage battery’s negative
cable.
9. The compressor is a component that rotates at
high speed, and any minor impurity within the
air conditioning system will cause damage to the
compressor. Therefore, the entire air-conditioning
system needs to be washed clean. Do not allow
2014.01.09
moisture and dust to enter the system. Block the

pipe nozzle with a plug or cap immediately after the
pipeline is disassembled. Do not remove the plug or
cap before reconnecting the pipeline.
10. When the engine is running, do not open the high-
pressure valve for the manifold vacuum meter as
the backflow of high-pressure gas would cause
unnecessary harm.
11. When tightening or loosening any fitting, use
another wrench to fix its supporting component.
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Things to note regarding the О-ring

1. Use a new O-ring.
2. To avoid looseness of the O-ring and prevent
leakage of the refrigerant gas, do not wear gloves
nor use duster cloth during operation.
3. Apply compressor oil onto the O-ring to prevent
sticking before carrying out the installation.
4. Use a torque wrench to tighten the O-ring joint: too
much tightening would deform the O-ring and pipe
ends.
5. If the connection of the pipeline is interrupted
halfway, re-seal the pipe and components and block
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them with a plug or tape to prevent contaminants
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from entering them.
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thread and the joint visually. Replace the parts if
there is a problem.
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7. Install the O-ring into the pipe groove at an
appropriate angle.
G 8. Use the oil and grease specified in the manual to

lubricate the O-ring. Coat the top and side surface
of the O-ring with lubricant before the installation.
Apply compressor oil onto the O-ring and the pipe
groove.
9. After tightening the O-ring, wipe the excess oil at the

joints and other places with a clean cloth to prevent
contamination of the vehicle body or other parts.
10. In case of a suspected leakage, stop tightening the
connection, disconnect the joint and remove the
O-ring. Check the O-ring, thread and the connection.
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Routine maintenance of the air-conditioning system

Maintain the air-conditioning system regularly
to ensure its normal operation. The routine
maintenance of the air-conditioning system is as
follows:
1. Check and clean the air-conditioning condenser, and
make sure the heat sink is clean and that there is no
blockage between them. After driving in the rain or
on muddy roads, check the condenser fan for any
mud or rock. Clean promptly if any.
2. Check the refrigerant level in the cooling system.
Look through the observation hole on the air-
conditioning pipeline when the air-conditioning unit
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is running properly. There should be no air bubble in
the sight glass under normal circumstances.
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3. C h e c k t h e d r i v e b e l t . T h e b e l t b e t w e e n t h e
compressor and engine must be taut.
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4. Check the air-conditioning system for any unusual
noise and odor.
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5. Check whether the compressor inlet and outlet
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temperature is normal.
6. Check to see if the appearance of the cooling
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system hose is normal and whether all the joints are
securely connected.
7. Check if the cooling system pipeline is bumping
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against the other parts, and check all the joints for
any trace of oil leakage.
8. Check whether the cooling system circuit is securely
connected, and whether there is any disconnection.
9. Check whether the compressor fastening bolts are
reliably tightened, and whether there is breakage.
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Location Diagram
Interior Air-conditioning Assembly
3
2
1
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1. Heater assembly 5. Circulation control actuator

2. Heating/cooling control actuator 6. Blower assembly
3. Evaporator assembly 7. A/C controller assembly
4. Speed regulator module 8. Mode control actuator
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Air-conditioning System
2 3
1
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4
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G 6
1. Access valve (LP side) 5. Refrigerant tank

2. Evaporator assembly 6. Condenser
3. Access valve (HP side) 7. Tri-state pressure switch
4. A/C compressor 8. Sight glass
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System-related Parameters
Air–conditioning-related Parameters
No. Item Structure & parameters
1 Structure type Vapor compression cooling, water heating
Performance Air-conditioning refrigeration capacity: 4.5kW; blower air flow: 630m3/h;
2
parameters Air-conditioning heating capacity: 6.0kW
Air-conditioning controller assembly knob and button manipulation; position
damper and temperature damper servo motor drive, fresh air micro motor
drive that can be used for selection and adjustment of wind position mode,
3 Controls
heating/cooling mode, inner/outer air circulation mode as well as air speed
and temperature, etc. The control units are located on the central control
panel of the instrument panel and the HVAC
R134a refrigerant, filled according to the amount stated on the label on the
4 Refrigerant
vehicle
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5 Compressor Construction 120, BX13, 10B7
Parallel flow sub-cooling condenser close-packed structure, flat tube
6 Condenser
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thickness: 16mm; dry reservoir: Φ34mm
Interior Air-conditioning (HVAC): tri-box structure, of which the air outtake box
assembly is made up of a parallel flow evaporator, parallel flow heater, H-type
Interior Air-
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7 expansion valve and vent distribution box; the air intake box assembly is
conditioning
made up of a centrifugal blower, dust filter and air duct, and has the functions
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of cooling, heating, defrosting and new wind generation
Cooling pipe: combined rubber hose and aluminum tube structure for
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Cooling and compressor suction and exhaust pipe assembly; the other pipes are hard
8
heating pipes aluminum tubes.
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Heating pipe: molded rubber hose
Exterior temperature sensor (automatic), interior temperature sensor
9 Sensor
(automatic) and evaporator temperature sensor (manual, automatic)
10 Pressure switch High, medium and low tri-level pressure switches
2014.01.09
System Electrical Devices and Principles

Diagram of working principles of electrical devices
Ignition+
Battery+
Backlight GND
Electric heating relay
Interior circulation position drive
X17
X32
X21
X1
X2
Circulation actuator
P1
Reserved
M
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P2
X23
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Exterior circulation position drive
X20
30
87
X22
85
86
High-speed relay
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Blower relay
30 85
Cooling position drive
85
86
X18 X24
X13
Cooling/heating actuator
Sensor GND 1
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5
87
87 86
30
Feedback signal 2 M
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+
X30
3
Blower M
+5V
4
Speed regulator
B Defrost position drive
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A
module
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D
X12
Rear windscreen defroster

Head wind position drive
X18 X9
Sensor GND 1
5
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Rear defrost feedback
Mode actuator
X14
Rear defrost indicator

Feedback signal 2 M
X25 X4 X6
+5V 3
Defrost position drive
4
GND
OUT
Rear defrost drive

VCC
X15
SW
Rear defrost relay

Sensor GND(common GND with power supply)
X18
A/C output
X27
Reserved
Evaporation temperature sensor

X19
Working indicator brightness weakening signal

X10
Exterior temperature sensor

X28
Engine speed signal

Reserved
X29
Fuel heating signal

X31
Water temperature sensor

Reserved
X26
X16
Backlight power+
2014.01.09
Air-conditioning controller port and definition
32 17
16 1
Air-conditioning controller rear port
No. Port Signal Voltage Current Remarks
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1 X1 IG2 12V ﹤1A Ignition power supply
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2 X2 GND(KL.31) 0V ﹤1A Power GND
3 - --- --- --- ---
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4 X4 +5V 5V ﹤30mA Actuator reference power supply
5 X5 Temp Act. F/B 0V-5V ﹤5mA Temperature actuator position feedback
6 X6 Mode Act. F/B 0V-5V ﹤5mA Mode actuator position feedback
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7 X7 IG/INTAKE 0V/12V ﹤600mA Circulation actuator power supply
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8 X8 HOT 0V/12V ﹤600mA Temperature actuator heating position drive
9 X9 VENT 0V/12V ﹤600mA Mode actuator head wind position drive
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Working indicator brightness weakening
10 X10 Adjust 0V/12V ﹤2mA
signal (active high)
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11 --- --- --- --- ---
12 X12 TB 24V ﹤10mA Speed regulator module drive
13 X13 HS 0V/12V ﹤200mA High-speed relay (active low)
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14 X14 --- 0V/12V ﹤2mA Rear defrost feedback (active high)
15 X15 RDEF 0V/12V ﹤200mA Rear defrost drive (active high)
16 X16 Lamp+ 12V ﹤200mA Backlight power+
17 X17 IG2 12V ﹤1A Ignition power supply
18 X18 SGND 0V ﹤30mA Signal GND
19 X19 EVAP. Sensor 0V-5V ﹤5mA Evaporator temperature sensor
Circulation actuator exterior circulation
20 X20 FRE 0V ﹤600mA
position drive
Circulation actuator interior circulation
21 X21 REC 0V ﹤600mA
position drive
22 X22 PTC_CTRL 0V/12V ﹤200mA PTC drive (active low)
23 X23 PTC_F/B 0V/12V ﹤10mA PTC feedback signal
24 X24 COOL 0V/12V ﹤600mA Temperature actuator cooling position drive
25 X25 DEF 0V/12V ﹤600mA Mode actuator defrosting position drive
26 X26 W_sensor --- --- Water temperature sensor
27 X27 A/C Request 0V/12V ﹤200mA Compressor control signal (active high)
28 X28 AMB 0V-5V ﹤5mA Ambient temperature sensor
29 X29 E-speed_sin 0V/12V --- Engine speed signal
30 X30 TC 0V ﹤10mA Blower negative feedback signal
31 X31 fuel heating_sin 0V/12V --- Fuel heating signal
32 X32 Lamp- 0V ﹤200mA Backlight GND
2014.01.09
Air-conditioning controller port and pin definition

Cooling/heating and mode control motor
2 3 4 5 Pin definition
Pin No. Cooling/heating
Mode control motor
control motor
1 GND
2 TEMP F/B
3 +5V
4 5 Cold end Blowing side
1 5 4 Hot end Defrost
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Interior/exterior circulation control motor
P1
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Pin No. Pin definition
P1 P2 P1--->P2
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P1 P2 P2--->P1
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Speed regulator module
D C
Pin No. Pin definition

A Power supply GND
B Output terminal
C ---
D Control terminal
B A
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Air-conditioning Control Panel

Button and function descriptions
1 2 3
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9 8 7 6 5 4
1. Temperature knob
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2. Air flow knob 7. OFF button
3. Mode knob 8. AUTO button
4. Front defrost button 9. A/C button
5. Rear defrost button
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1. “AUTO” button
The air-conditioning system starts up when this button is pressed. The AUTO indicator turns on, and all
the equipment enter automatic operation.
2. “Defrost” button
The defrost indicator turns on when this button is pressed, the AUTO indicator turns off, and the air
conditioning system enters the defrost/demist mode. If the air-conditioning system is in the OFF mode,
the system will turn on and enter the front defrost mode.
When the ambient temperature is ≤-5°C, the system is in defrost mode, and the mode actuator turns
to the defrost position, with its air speed is at the maximum, temperature damper at its hottest, and
the compressor turned off for interior circulation. When the ambient temperature is higher than -5°C,
the system is under demist mode. The mode actuator turns to the defrost position, with its air speed at
the maximum, the original temperature damper position maintained, and the compressor turned on for
exterior circulation.
When the system is in the defrost mode, press this button or turn the mode knob to resume the mode
actuator into the mode before the defrost mode while maintaining the user adjustments made during
the defrost/demist mode.
3. “A/C” button
Press this button to command the compressor to start up or shut down. The A/C enters the manual
mode, the AUTO indicator is turned off and the A/C indicator is turned on when the A/C command is
enabled.
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If this button is pressed when the air-conditioning system is OFF, the air-conditioning system is turned
on, the compressor started up and enters the manual mode, the AUTO indicator is turned off, the
compressor indicator turns on, and the other equipment will return to the state before the system is
shut down.
When the compressor command is enabled (the working indicator turns on), it will shut the compressor
down if the evaporation temperature is below the frost protection temperature, and will start up the
compressor when the evaporation temperature is above the frost protection recovery temperature.
When the ambient temperature is below -5°C, the A/C shuts down, the indicator is turned off, and there
is no output when the A/C button is pressed.
4. “Circulation” button
Press this button to switch between the interior and exterior circulation. The circulation actuator enters
the manual mode, the AUTO indicator is turned off, and the status is displayed by the circulation
indicator at the same time with the indicator being turned on during interior circulation. When the air-
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conditioning system is shut down, it cannot be started by pressing this button, but the interior and
exterior circulation can be switched.
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5. "Rear Defrost” button
Press this button to start the rear defrosting. The Rear Defrost indicator is turned on and would turn
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off automatically after 10 minutes (controlled by rear defrost delay relay). When the rear defrosting is
already turned on, press this button to turn off the rear defrosting and its indicator.
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This button is unrelated to the air-conditioning system and will not affect the ON/OFF as well as AUTO
modes of the air-conditioning system.
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6. Mode knob
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Turn this knob to enter the circulation actuator into the manual mode. The AUTO indicator is turned
off. When the knob is turned clockwise, the mode actuator turns into the corresponding positions in
the sequence of head air, head and foot air, foot air and foot defrost, and the related indicator is turned
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on at the same time. When the knob is turned counterclockwise, the mode actuator turns into the
corresponding positions in the sequence of foot defrost, foot air, head and foot air and head air, and the
related indicator is turned on at the same time.
When the air-conditioning system is OFF, the AIR mode indicator light stays on. Turn this knob to adjust
the blowing mode without turning on the air-conditioning system.
7. “Air Speed” knob
When turning this knob, the blower enters the manual mode and the AUTO indicator is turned off. The
clockwise rotation increases the air speed; the counterclockwise rotation decreases the air speed, and
the corresponding indicator will light up at the same time.
When the air-conditioning system is OFF, turning this knob will start up the A/C system, and all the
equipment will return to the mode before the system is shut down.
8. “Temperature” knob
When the temperature knob is rotated clockwise by one step, the temperature setting increases by
2°C and the corresponding indicator lights up. The temperature setting will not increase after reaching
32°C (maximum heating). When the temperature knob is rotated counterclockwise by one step, the
temperature setting decreases by 2°C and the corresponding indicator will light up. The temperature
setting will not increase after reaching 18°C (maximum cooling).
The temperature damper has no manual mode and remains the automatic operation.
When the air-conditioning system is OFF, turning this knob will start up the A/C system, and all the
equipment will return to the mode before the system is shut down.
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9. “OFF” button
If the “OFF” button is pressed when the air-conditioning system is ON, the blower and compressor will
shut down, the AUTO indicator will be turned off, but the air mode, circulation mode and rear defrosting
will not be controlled by the OFF button. When the “OFF” button is pressed during the front defrosting,
the front defrosting indicator light remains on, and the mode damper remains at the front defrost
position with the setting mode shut down.
Pressing the “OFF” button during air-conditioning system shutdown is an invalid instruction.
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Maintenance Diagnosis and Detection

General Fault Diagnosis
The fault and cause analysis listed in the following table are used as reference for basic fault diagnosis.
During specific diagnosis, confirm the findings with instruments and equipment while troubleshooting
according to the faults, and refer to the air-conditioning self-diagnosis outcomes at the same time.
Fault Occurrence Analysis of possible causes

·· Fuse burned, compressor relay damaged
·· Pressure switch contact disconnected, short circuit or open circuit
·· Compressor electromagnetic clutch coil open circuit
·· Switch burned, main relay burned
Compressor is ·· Clutch slipping
not closed ·· Compressor belt is broken or too loose
·· Compressor fault
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·· Insufficient refrigerant, exceedingly low or high system pressure
·· Engine water temperature too high
·· Clutch voltage too low
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A/C system does
·· Compressor relay contact (normally open) bonding as well as
not perform
serious refrigerant leakage
the cooling Compressor is
·· Expansion valve stuck and cannot be closed (blocked by ice or dirt)
W
operation closed
·· Compressor inlet and outlet valve damaged
·· Reservoir filter blocked by dirt
t
·· Fuse burned
·· Blower motor brush damaged
a
·· Blower switch damaged
No air from the ·· Wiring connector disengaged or open circuit
re
blower ·· Speed regulator module damaged
·· High-speed blower has no air, high-speed relay damaged
Note: resistance during blower shutdown is approximately 0, open
circuit resistance is ∝
G
Compressor
··Evaporator core is blocked by ice, thermistor failure
operation
Intermittent ··Poor A/C switch contact, cooling fan damaged
is normal
cooling of the
cooling system Compressor
operation is ··Clutch slipping, clutch coil loose, clutch coil poorly grounded
not normal
·· Blower motor working normally: air supply duct damaged
·· Cooling fan not working normally:
Small air flow (1) Blower switch failure
(2) Low electric power
(3) Speed regulator module damaged
Compressor working normally
(1) Pressure at high- and low-pressure sides are too low
·· Expansion valve blockage
·· Expansion valve opening too small
Insufficient (2) Pressure at high- and low-pressure sides are too high
cooling ·· High-pressure pipeline failure, the pipe is blocked
·· Thermistor failure
Normal air flow ·· Expansion valve opening too large
·· Excessive compressor oil
·· Excessive refrigerant
·· Poor condenser radiation
Note: When the RPM reaches 2000r/min, the cooling fan is at the top
gear and the temperature is between 30°C~35°C, the system pressure
at low-pressure side should be at 147kPa~192kPa, and the system
pressure at the high-pressure side should be at 1373kPa~1668kPa
2014.01.09
Fault Occurrence Analysis of possible causes

Compressor works normally
(3) Pressure at high-pressure side too low
·· Low-pressure pipeline damaged
·· Low-pressure pipeline blocked
(4) Pressure at low-pressure side too low
·· Evaporator frosted
·· Expansion valve stuck
·· Low-pressure pipeline blocked
·· Thermal speed regulator resistor failure
(5) The pressure at the low-pressure side is normal or negative, and
there is water and ice blockage in the cooling system
(6) Negative pressure at the low-pressure side, exceedingly low
pressure at high-pressure side, cooling system blocked
(7) Low-pressure side pressure is too low, high-pressure side pressure
is too high
l
·· Condenser interior blockage
l
·· High-pressure pipeline blocked
Insufficient
Normal air flow (8) Low-pressure side pressure is too high, high-pressure side pressure
cooling
a
is too low
·· Compressor leakage
·· Compressor valve damaged
(9) Poor condenser radiation caused by small fan air flow
W
Compressor working abnormally
(1) Compressor interior fault
t
(2) Compressor belt is too loose or slipping
(3) Electromagnetic clutch fault
a
·· Low supply voltage
·· Interference between the stator and the rotor
re
·· Idling stability amplifier fault
·· Open circuit, joint detachment
·· Poor switch and relay operation
·· Short circuit, open circuit
G
·· Poor grounding
Other causes
·· Poor sealing
·· The belt is too loose or excessively worn
·· Compressor mounting bracket screw is loose
·· Compressor mounting bracket damaged
·· Compressor internal parts damaged
High cooling ·· Too little or no compressor oil
system Too high noise ·· Clutch slipping noise
noise ·· Clutch bearing lacks oil or is damaged
·· Blower motor bearing damaged
·· Blower bracket is broken or loose
·· Blower blade is broken or loose
·· Friction between the blower blade and other components
2014.01.09
Fault Phenomena Analysis of possible causes

·· Air-conditioning blower fault
·· Blower relay damaged
No heating or ·· Heating air duct blocked
insufficient heating ·· Cooling water pipe blocked
·· Cooling/heating air damper actuator damaged
·· Insufficient coolant
·· Burned fuse or poor switch contact
·· Blower fan burned
The blower does
·· Blower high-speed relay open circuit
not rotate
Heating ·· Speed regulator resistor damaged
system ·· Open circuit
Water leakage ·· Heating water pipe aging, joint unsecured
·· Fan speed regulator resistor damaged
Overheat
·· Cooling/heating air damper actuator damaged
l l
·· Mode cable damaged
·· Air damper is not in place
a
Insufficient hot ·· Air outlet blocked
defrosting air ·· Insufficient heating
·· Air duct installation is not well-fitted
·· Open circuit
t W
a
re
G
2014.01.09
Fault Diagnosis Using Manifold Pressure Gauge Assembly

Instructions:
·· The use of manifold pressure gauge assembly is a method to identify the faulty parts.
·· For the detailed method of use and related things to note about the manifold pressure gauge
assembly, refer to the instructions provided by the equipment manufacturer.
Read the manifold pressure gauge after the following test conditions are satisfied.
Test conditions:
·· When the switch is at the interior circulation position, the air inlet temperature is 30-35 °C.
·· The engine runs at a speed of 1500 rpm.
·· The blower speed control switch is located in the maximum air rate position.
·· The temperature control knob is at "coldest".
·· The air-conditioning switch is turned on.
l
·· The vehicle door is fully opened.
l
1. The cooling system under normal operation
03
04
05
15 2
a
W
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5
t
30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
a R134a
re
G
Instrument readings:
·· Low-pressure side: 0.15 to 0.25 MPa
·· High-pressure side: 1.37 to 1.57 MPa
2014.01.09
2.The cooling system contains moisture
Condition: Periodic cooling, and the cooling cannot be

achieved in the end
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8 3
0
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
l
Symptom Possible causes Diagnosis Rectifications
l
The moisture in the
The dryer is excessively ·· Replace the dryer
·· The pressure at low- cooling system is frozen
a
saturated, and the ·· Remove the moisture
pressure side is at the expansion valve
moisture in the cooling from the circulation by
switching between throttle orifice, which
system is frozen at the repeated emptying
the normal value and stops the circulation
expansion valve throttle ·· Fill with an
W
the vacuum value temporarily. However,
orifice, which stops the adequate amount
during the operation it will return to normal
refrigerant circulation. of new refrigerant
t
when it is melted.
a
3. Poor refrigerant circulation
re
Condition: The cooling system is not working effectively.
04 15 2
G
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

·· The pressure of the
high-pressure side
and low-pressure side The flow of the refrigerant
are both too low is clogged by the dust Reservoir clogging Replace the reservoir
·· The pipeline between in the reservoir
the condenser and
the cooling device
2014.01.09
4. No refrigerant circulation
Condition: The cooling system is not working.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
Symptom Possible causes Diagnosis
l l Rectifications
a
·· Check the
·· The low-pressure expansion valve
side shows vacuum, ·· Clear the dust within
·· The flow of refrigerant
W
and the high- the expansion valve
is clogged by the
pressure side shows by blowing air
moisture or dust within
t
very low pressure No refrigerant circulation ·· Replace the condenser
the cooling system
·· Frost or condensation ·· Empty and fill
·· The expansion valve
a
can be found on the with adequate
leakage obstructs the
reservoir/dryer or the new refrigerant
flow of refrigerant
pipes on both sides of ·· Expansion valve gas
re
the expansion valve leakage, replace the
expansion valve
2014.01.09
5. Refrigerant overfilling or poor condenser cooling effect
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
l l
a
·· Clean the condenser
·· The pressure at the ·· Overfilled refrigerant
·· Check the cooling
low-pressure side and ·· The excessive use of during the circulation
fan when the fan
high-pressure side the cooling system (excessive
W
motor is running
are both too high causes its inadequate refrigerant is filled)
·· If 1 and 2 are normal,
·· No bubble is observed performance ·· Poor condenser
t
check the refrigerant
through the sight glass ·· Poor condenser cooling effect
level and fill with an
even if the engine cooling effect (condenser fin of the
adequate amount
a
speed is decreased cooling fan is clogged)
of refrigerant
re
6. The cooling system contains air
G
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0
-76 08 -76 35 Remarks: Open the
-01 15
085 0
-01
35 cooling system and fill
MPa MPa
with refrigerant when the
vacuuming operation
is not performed.

·· The pressure at the
low-pressure side and
high-pressure side
·· Check whether the
are both too high
·· The cooling system compressor oil is
·· The low-pressure pipe
The system contains air contains air dirty or insufficient
is overheated and
·· Poor purification ·· Empty and fill with
cannot be touched
new refrigerant
·· Bubbles can be
observed through
the sight glass
2014.01.09
7. Expansion valve fault
Condition: Inadequate cooling.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01
35
MPa MPa
Symptom Possible causes Diagnosis
l l Rectifications
a
low-pressure side and ·· Excessive refrigerant
high-pressure side in the low-pressure
Check the
W
are both too high Expansion valve fault pipeline
expansion valve
·· Frost or condensation ·· Valve opening
t
is detected on the low- is too large
pressure pipelines
a
8. Poor compression of the compressor
re
Condition: Inadequate cooling.
G
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 - 01 35
MPa MPa

low-pressure side and
·· Compressor fault
high-pressure side
Leakage hin the ·· Leakage caused by Repair or replace
are both too high
compressor damaged valve or the compressor
·· The pressure at
broken moving parts
the high-pressure
side is too low
2014.01.09
9. Inadequate cooling
Condition: The cooling system is not working effectively.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01 35
MPa MPa
l
l
·· Check for leakage,
maintain the system
a
as necessary
·· The pressure at the ·· Fill with an
low-pressure side and adequate amount
W
high-pressure side of new refrigerant
are both too low ·· When connecting
·· Insufficient refrigerant
t
·· Bubbles can be Cooling system leakage the instrument,
·· Refrigerant leakage
observed through the indicated
a
the sight glass pressure reading
·· Inadequate cooling is approximately 0,
re
performance and a vacuum will be
generated after the
inspection and repair
of the leaking part.
2014.01.09
Air-conditioning Fault Self-diagnosis

Air-conditioning panel button descriptions
AUTO button
AUTO键 Air volume
风量指示灯 indicator Mode indicator
模式指示灯
l l
a
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温度旋扭 Temperature
Temperature 温度指示灯 OFF button
OFF按键 Defrost
除霜键 button
t
knob indicator
a
Self-test procedure
re
Press and hold the AUTO button and the DEFROST button for 3 seconds, and the system will enter the
fault self-test mode. At this time, the mode indicator is turned on, and the temperature indicator acts as
the fault number and the air flow indicator as the fault content. In the fault self-test mode, turning the
G
temperature knob changes the fault number. Pressing the OFF button or turning off the IG will exit the
fault self-test mode and return to the normal operation.
Fault display and countermeasures
Fault No. Fault Content Countermeasures
--- Normal ---
Ambient temperature sensor short Ambient temperature sensor default is
18
circuit 20°C
Ambient temperature sensor open Ambient temperature sensor default is
20
circuit 20°C
Evaporation temperature sensor Evaporation temperature sensor default
22
short circuit is -2°C
Evaporation temperature sensor Evaporation temperature sensor default
24
open circuit is -2°C
Interior temperature sensor default is
26 Interior temperature sensor fault
20°C
28 Blower fault Shutdown compressor output
30 Mode actuator fault Stop the mode actuator drive
32 Temperature actuator fault Stop the temperature actuator drive
2014.01.09
Pressure Switch (High, Medium and

Low Tri-state Pressure Switch)
Inspection
1. Connect the manifold vacuum meter to the HP
access valve
2. Remove the pressure switch harness connector.
l l
a
3. Use a multimeter to test the conductivity of the
4
pressure switch terminals 1 and 4
2 3
4. Observe and record the switch conductivity
W
1
LP side HP side and pressure value, and check whether they are
t
consistent with the data shown in the diagram
196 kPa 3140 kPa
a
OFF (Nonconductive) OFF (Nonconductive)
re
5. If the working condition does not satisfy the
regulations, replace the condenser outlet pipe with
G
the pressure switch assembly (refer to the air-
conditioning pipe section for the structural diagram
and replacement)
2014.01.09
Evaporator Temperature Sensor

Test
1. Remove the evaporator core and the evaporator
temperature sensor
2. Immerse the sensor in ice water and measure the
resistance between each terminal
3. Add hot water gradually into the ice water and check
the change in resistance value
4. Compare the resistance reading with the R/T
specification table. The resistance must be within
the specified range
5. If the resistance reading is beyond the specified
l l
range, replace the evaporator temperature sensor
Temp. Lower limit Standard Upper limit
a
(°C) (kΩ) (kΩ) (kΩ)
-10 6.123 6.278 6.433
-5 4.987 5.103 5.218
W
Resistance (kΩ)
7 0 4.088 4.174 4.26
5 3.358 3.436 3.513
t
6
5
10 2.775 2.845 2.914
a
4
15 2.306 2.368 2.431
3
20 1.927 1.983 2.038
re
2
25 1.619 1.668 1.718
1
30 1.366 1.41 1.455
-10 -5 0 5 10 15 20 25 30
G
Temperature (°C)
2014.01.09
Interior Temperature Sensor

Test
1. Remove the interior temperature sensor
2. Hold the interior temperature sensor by hand and
place it in the front of the central ventilation hole,
perform the test under different air-conditioning
modes
·· Adjust the system to (Max Cool) and measure the
resistance.
·· Adjust the system to (Max Hot) and measure the
resistance.
Interior temperature sensor
3. Compare the resistance reading between the
l
interior temperature sensor terminals 1 and 2 with
l
1 2 the specification value listed in the table below.
a
The resistance must be within the specified range
Standard resistance (kΩ) Temp. Lower limit Standard Upper limit

(°C) (kΩ) (kΩ) (kΩ)
W
6
5 0 6.019 6.27 6.52
t
4
5 4.833 5.024 5.215
10 3.908 4.05 4.192
a
3
15 3.17 3.285 3.399
2
20 2.6 2.68 2.76
re
1
25 2.134 2.2 2.266
0 30 1.726 1.816 1.87
0 5 10 15 20 25 30 35 40
Temperature (°C) 35 1.441 1.507 1.576
G
40 1.198 1.258 1.319
2014.01.09
Exterior Air Temperature Sensor

Test
1. Remove the exterior air temperature sensor
2. Immerse the sensor in ice water and measure the
resistance. Add hot water gradually into the ice
water and check the change in resistance value
3. Compare the resistance reading between the
exterior temperature sensor terminals 1 and 2 with
the specification value listed in the table below. The
resistance must be within the specified range
4. If the resistance value is beyond the specified range,
Exterior temperature sensor replace the exterior air temperature sensor
ll
Temp.
RMIX(kΩ) RMIN(kΩ) RMAX(kΩ)
(°C)
a
-20 14.46 15.13 15.82
-15 11.38 11.88 12.39
Standard resistance (kΩ) -10 9.021 9.391 9.771
W
16 -5 7.203 7.481 7.764
14
0 5.79 6 6.213
t
12
5 4.685 4.844 5.004
10
a
10 3.815 3.935 4.057
8
15 3.125 3.217 3.309
re
6
4 20 2.574 2.644 2.715
2 25 2.12 2.186 2.25
-40 -20 0 20 40 60
30 1.769 1.817 1.865
G
35 1.442 1.518 1.594
Temperature (°C)
40 1.21 1.274 1.338
2014.01.09
Maintenance Guide
Air-conditioning Controller Assembly
Replacement
1. Remove the central speaker control panel
l l
2. Dismantle the two cross-recessed pan head self-
tapping screws connected to the central speaker
a
control panel body and remove the air-conditioning
controller assembly
t W
a
re
3. Carry out the installation in the reverse order of the
disassembly. After the installation is completed,
perform the functional test to ensure normal
G
operation
4. Perform self-diagnosis to ensure that the system
has no faults
2014.01.09
Interior Temperature Sensor Replacement

1. Remove the central speaker control panel
2. Remove the interior temperature sensor

(a) Remove the signal transmission cable connected to
l
the interior temperature sensor.
l
(b) Remove the two bolts fixing the interior temperature
a
sensor, and remove the interior temperature sensor.
t W3. Carry out the installation in the reverse order of the

disassembly. After the installation is completed,
a
perform the functional test to ensure normal
re
operation
4. Perform the self-diagnosis to ensure that the system
has no faults
2014.01.09
Evaporator Temperature Sensor

Replacement
1. Remove the evaporator from the interior Air-
conditioning assembly
2. Carefully remove the temperature sensor from the
evaporator
53 3. Carry out the assembly in the reverse order of the

disassembly
l l
Note:
115
When re-installing the evaporator temperature
a
sensor, take note of the mounting position, and
install the sensor according to the required size
W
shown in the diagram on the left.
Unit: mm
a t
re
G
2014.01.09
Refrigerant Related Operations

Note:
·· Use only R-134a refrigerant to maintain the
equipment. During the actual operation, refer to
the manufacturer instructions and precautions
for the specific methods of use.
· case of an accidental discharge, the work site
·In
must be ventilated adequately before continuing
with the maintenance.
·· For further instructions on health and safety,
refer to the instructions supplied by the
refrigerant and lubricant manufacturers.
l l
Refrigerant recovery
a
A 1. As shown in the diagram, connect the R-134a
refrigerant recovery/circulation/filling equipment (A)
or other equipment with the same functions to the
W
high-voltage access interface (B) and low-voltage
access interface (C) according to the manufacturer’s
t
instructions.
C
a
re
B
2. After the recovery is completed, measure the
G
amount of compressor oil drained from the air-
conditioning (A/C) system. Ensure that the same
amount of new compressor oil has been filled into
the air-conditioning (A/C) system prior to the filling.
System vacuum pumping

Note: When the air-conditioning (A/C) system
is exposed to the atmosphere (for example,
during the installation and repair), use the R-134a
refrigerant recovery/circulation/filling equipment
for vacuum pumping. However, if the system has
been disassembled for several days, replace the
reservoir/desiccant and carry out the vacuum
pumping for several hours.
2014.01.09
A 1. Connect the R-134a refrigerant recovery/circulation/

filling equipment (A) to the high-voltage access
interface (B) and low-voltage access interface (C)
and carry out the vacuum pumping.
2. If the low pressure reached 760 mmHG or higher

when more than 20 minutes have passed, close the
high-pressure and low-pressure valves and shut
the vacuum pump down. If the low pressure cannot
l l
reach 760 mmHG, the system may be leaking. Carry
out system filling and check for any leakages.
Refrigerant Filling
a
W
1. As shown in the diagram, connect the R-134a
A
t
(A) to the high-voltage access interface (B) and
a
low-voltage access interface (C) according to the
re
manufacturer’s instructions
2. Carry out vacuum pumping for the system
C
G
B
3. Fill the system with the same amount of new

compressor oil with that which was drained during
the recovery. Use only the R-134a refrigerant
4. Fill the system with a specified amount of R-134a
refrigerant. Refer to the “System-related Parameters”
on Page 12-10 “System-related Parameters”for the
filling amount. Do not overfill the system, otherwise
the compressor will be damaged
5. Check for any refrigerant leakage
6. Check the system performance
2014.01.09
Check the Air Tightness

1. As shown in the diagram, connect the R-134a
A
(A) to the high-voltage access interface (B) and
low-voltage access interface (C) according to the
manufacturer’s instructions
2. Open the high-pressure valve and fill the specified

amount of refrigerant into the system, and close the
l
filler valve, disconnect the filling system fitting
l
and select the appropriate measuring device for the
a
refrigerant filling equipment.
Refrigerant capacity: Refer to the “System-related
Parameters” on Page 12-10 “System-related
W
Parameters”
t
3. Use a R-134a refrigerant leakage detector (with an
accuracy of 10g) to check for system leakage every
a
year or an even shorter period
re
4. If a leakage is discovered and it is necessary to
disassemble the system (repair or replacement of
hose and joint, etc.), recover all the refrigerant in the
system
G
5. The system must be pumped to vacuum after the
detection and repair of the leakage have been
completed
2014.01.09
Body and Interior/Exterior Decoration 13-1
BODY AND INTERIOR/EXTERIOR

DECORATION
Front Bumper (Type 2012)
Replacement. ..................................................................................13-2
Roll Cage
l l
a
Replacement. ..................................................................................13-4
Side Step
W
Replacement. ..................................................................................13-5
a t
re
G
2014.01.09
Front Bumper (Type 2012)

Maintenance Guide
Replacement
A B 1. Remove the radiator cover
(a) Remove the two bolts (A) and four expansion
A
buckles (B).
(b) Disengage the eight joint structures shown in the
diagram and remove the radiator cover.
Note:
Be careful not to damage the radiator cover. When
using the screwdriver and other tools, the front-end
l
must be covered with tape to avoid scratching the
l
vehicle body and the bumper.
a
2. Remove the bumper
B
A
(a) Remove the eight hex head screws from the upper
B and lower sides, the flat washer assembly (B) as
W
well as the two expansion buckles (A) for the left
t
and right sides of the front bumper.
a
re
G
A
(b) Pull the bumper and remove it carefully from the

hooks shown in the diagram (symmetrical between
the left and right sides).
(c) Disconnect the fog light plug and remove the
bumper.
2014.01.09
3. Assembly
Carry out the assembly procedure in the reverse order of
the disassembly, and take note of the following:
Note:
·
·Ensure that the front fog light plug is connected
correctly.
·
·Ensure that the front bumper is connected
securely to the hooks on each side.
·
·Check the joint structure for any damages or
breakages caused by high load. Replace with a
new clamp as necessary.
·
·Push the clamp and the hook until they are firmly
in place.
l l
a
t W
a
re
G
2014.01.09
Roll Cage
l l
a
t W
a
re
G
Maintenance Guide
Replacement
1. R emove all six bolts on the left and right sides
shown in the diagram, and remove the roll cage (A)
2. The assembly procedure is the opposite that of the
disassembly
2014.01.09
Side Step
Dotted side step
24
×6
A
B
D
C
l l
×6
a
9
W
Tubular side step
t
24
a
×6
re
G ×6
Maintenance Guide
Replacement
1. Remove the side step body
(a) Remove the six bolts from the bottom of the side
step body (D), and remove the side step body from
the bracket.
2014.01.09
2. Dismantle the side step Bracket 1 (A), Bracket 2 (B)

and Bracket 3 (C)
(a) Remove the six nuts connected to the suspended
outer panel, and dismantle the front, middle and
rear brackets.
3. Carry out the assembly procedure in the reverse
order of the disassembly, and tighten the bolts with
the specified torque shown in the assembly diagram
l l
a
t W
a
re
G
2014.01.09
Wiring Diagram 14-1
WIRING DIAGRAM
Wiring Diagram Instructions

Instructions For Use.....................................................................14-3
Wiring Diagram
4D20B-WGT LHD...........................................................................14-5
GW2.8TC 2012 type......................................................................14-11
l
4G69 2012 type..............................................................................14-17
l
2.8TDI-2 2012 type.........................................................................14-24
a
4D20B 2012 type............................................................................14-30
4D20 Euro-V....................................................................................14-36
491QE (CNG)..................................................................................14-43
W
Vehicle Electrical Schematics
t
Power Generation and Startup System (4D20 Euro V)........14-44
a
Engine Control System (4D20B-WGT).....................................14-45
Engine Control System (4D20 Euro V) 1..................................14-46
re
Engine Control System (4D20 Euro V) 2..................................14-47
Engine Control System (491QE-CNG)......................................14-48
Lighting and Signaling System (4D20 Euro V) 1...................14-49
G
Lighting and Signaling System (4D20 Euro V) 2...................14-50
Airbag (4D20 Euro V)....................................................................14-51
Central Control Lock (4D20 Euro V).........................................14-52
Combination Instrument System (4D20 Euro V)....................14-53
Cigarette Lighter/ Power Socket/ Instrument Panel Central
Lighting/ Electric Rearview Mirror/ Front Wiper/ Scrubber (4D20
Euro V).............................................................................................14-54
ESP (4D20 Euro V)........................................................................14-55
Radio/ Air-conditioning/ Defrosting (4D20 Euro V)...............14-56
Anti-theft/ Electric Seat Heating (4D20 Euro V).....................14-57
Intelligent 4WD/ Front Axle Electric Clutch Control (4D20 Euro
V).......................................................................................................14-58
2014.01.09
Electrical appliance plug-in

Generator/ Starter/ ECU (4D20 Euto-V)....................................14-59
ECU 491QE(CNG)..........................................................................14-61
Lighting/ Signal (4D20 Euto-V)...................................................14-62
Airbag/ Central control lock(4D20 Euto-V)..............................14-63
Combination instrument/ ESP/ Electical accessories(4D20
Euto-V).............................................................................................14-64
l l
Radio/ Air-conditioning/ Defrosting (4D20 Euro V)...............14-65
Anti-theft/ Electrical heating seat/ 4WD control(4D20 Euto-V) 14-
a
66
t W
a
re
G
2014.01.09
Wiring Diagram 14-3
Wiring Diagram Instructions

Instructions For Use
1. A dedicated connector symbol has been added in the harness connection relationship
schematics to represent the connection relationship of the harnesses. see Figure 1 below.
2. The harness relationship and the plug-in connection number diagram only reflects the
connection between the harnesses and the connector connection numbers. The specific
harness information is for reference only.
3. The cable number includes the wire number and the wire diameter, as shown in Figure 2. The
cable colors are represented by English letters.
The letters indicating the two colors on the dual-color wire is separated with a slash (/). The letter
before the (/) represents the cable color, and the letter after the (/) represents the color of the other thin
wire. For example: L/R represents the blue cable with red wires; Br/Gr represents the brown cable with
l
gray wires.
Refer to the table below for cable color indicating letters:
B --black Br—brown G---green Gr--gray
a l L---blue Lg--light green
W
Or--orange P---pink R---red V---violet W---white Y---yellow
a t Wire number
re
Jack end Plug end
Wire diameter
G
Figure 1 Figure 2
4. The plug-in pin number is subject to the cable and the insertion direction towards the sheath.
The pin hole number for female connector is numbered from the top left to the bottom right.
The pin hole number for male connector is numbered from the top right to the bottom left. See
Figure 3.
Female connector Male connector
Figure 3
2014.01.09
5. The male and female connectors are distinguished by their internal pin shapes. See Figure 4.
All connectors are indicated by an open end and are locked at the top.
When pulling out the connector, please pull the connector itself and not the wiring cable.
Note: Before pulling out the connector, you should check the type of the connector that you are
going to pull out first.
Female connector Male connector
Figure 4
l l
a
t W
a
re
G
2014.01.09
Wiring Diagram 14-5
Wiring Diagram
4D20B-WGT LHD
Relationship between harnesses and plug-in connection numbering diagram
Engine compartment wiring harness①
C03
C01
C02
C19
Main power supply fuse box
Engine Harness
Batttery
l l
Power supply harness
a
2#Fuse Box
W
C08
t
Airbag harness
C04
C05
C06
a
re
Instrument harness
G
1#Fuse Box Engine compartment
C13
C14
C11
C12
C10
C09
C18
wiring harness②
Gearbox harness assembly
Cabin harness
Right Front door harness
Left Front door harness

C16
C15
C07
C17
Roof harness
Left Rear door harness Right Rear door harness
Frame harness
2014.01.09
Harness Connectors
4D20B-WGT LHD 1
175 177 177 175

0.5 0.5 0.5 0.5
182 109 437B 438B 438B 437B 109 182
0.5 0.5 1.25 1.25 1.25 1.25 0.5 0.5
439A 440B 442B 443B 444B 444B 443B 442B 441B 440B 439A
l
441B
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
l
133 447B 446B 445B 445B 446B 447B 133
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
To engine harness A
a
To engine compartment A
t W
a
re
15B 354B 354B 15B
3.0 0.5 0.5 3.0
436B 214B 143 143 214B 436B
G
0.85 0.85 0.5 0.5 0.85 0.85
To engine harness B To engine compartment B
402E 448B 449B 450B 450B 449B 448B 402E

0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85
456B 457B 458B 458B 457B 456B

0.5 0.5 0.5 0.5 0.5 0.5
459B 460B 468B 468B 460B 459B
0.5 0.5 0.5 0.5 0.5 0.5
To engine harness C To engine compartment C
2014.01.09
Wiring Diagram 14-7
4D20B-WGT LHD 2
46C 32E 97B 97B 32E 46C

0.5 0.5 0.5 0.5 0.5 0.5
35B 34B 47B 359A 360B 67D 67D 360B 359A 47B 34B 35B
0.5 0.5 0.5 0.5 0.5 1.25 0.5 0.5 0.5 0.5
1.25 0.5
41D 42B 55A 126A 356A 358B 358B 356A 126A 55A 42B 41D
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
71B 72B 54A 350A 353B 354A 354A 353B 350A 54A 72B 71B
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
l l
To instrument and control console harness A To engine compartment A
a
W
215A 520B 521B 521B 520B 215A
t
0.5 1.25 1.25 1.25 1.25 0.5
3B 3B 3B 3B
7A 3.0 3.0 16A 522B 522B 16A 3.0 3.0 7A
1.25 0.5 0.5 0.5 0.5 1.25
a
252 3B 3B 13A 13A 3B 3B 252
1.25 3.0 3.0 0.5 0.5 3.0 3.0 1.25
re
To instrument and control console harness B To engine compartment B
400A
0.85
455B
0.5
37A
0.5
G 421A
0.5
465B
0.5
38A
0.5
464B
0.5
422A
0.5
A42
0.5
423A
0.5
511A
0.5
A39
0.5
423A
0.5
511A
0.5
A39
422A
0.5
A42
464B
0.5
421A
0.5
465B
0.5
38A
400A
0.85
455B
0.5
37A
0.5 0.5 0.5 0.5
167A 167A
0.5 0.5
To instrument and control console harness C To engine compartment C
252 67 82 82 67 252
1.25 0.5 0.5 0.5 0.5 1.25
909C 81A 80C 80C 81A 909C
1.25 0.5 0.5 0.5 0.5 1.25
To Roof harness To instrument and control console harness C
2014.01.09
4D20B-WGT LHD 3
904H 904H 402J 402J 554A 553A

0.5 0.5 0.85 0.85 0.5 0.5
162A 161A 160A 166A Without ABS 166A 160A 161A 162A
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
l
402J 554A 553A
l
553A 554A 402J
0.85 0.5 0.5
0.5 0.5 0.85
With ABS 166A 160A 161A 162A
162A 161A 160A 166A
a
0.85 0.85 0.85 0.85
0.85 0.85 0.85 0.85
To instrument and control console harness To engine compartment A
t W
a
re
G
To Gearbox harness To instrument and control console harness
To Cab harness To instrument and control console harness
106B 105B 286B

286B 105B 106B
0.5 0.5 0.5
0.5 0.5 0.5
252C 284A 283A 282B 281B
281B 282B 283A 284A 252C
0.5 0.5 0.5 0.85 0.85
0.85 0.85 0.5 0.5 0.5
To left front door harness A To instrument and control console harness A
2014.01.09
Wiring Diagram 14-9
4D20B-WGT LHD 4
909B 301B 303A 303A 301B 909B

1.25 1.25 0.5 0.5 1.25 1.25
150B 155A 153A 152A 152A 153A 155A 150B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
To instrument panel and

Front left door harness B conrtol console harness assembly B
l l
108B
0.5
107B
0.5
a 107B
0.5
108B
0.5
W
252E 284 283 282C 281C 281C 282C 283 284 252E
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
t
Front right door harness A To instrument panel and
a
conrtol console harness assembly A
re
G
Front right door harness B To instrument panel and
conrtol console harness assembly B
55B 54B 355B 466A 466A 355B 54B 55B

0.85 0.85 0.5 1.25 1.25 0.5 0.85 0.85
71B 61B 46B 67B 906G 914A 914A 906G 67B 46B 61B 71B
0.5 0.85 0.85 1.25 1.25 0.5 0.5 1.25 1.25 0.85 0.85 0.5
To frame harness A To cabin harness A
To frame harness B To cabin harness B
2014.01.09
4D20B-WGT LHD 4
281B 115B 115B 281B

0.85 0.5 0.5 0.85
282B 303B 906B 301B 116B 116B 301B 906B 303B 282B
0.85 0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5 0.85

To Rear left door harness
conrtol console harness assembly
281C
0.85
282C 303C 906E 302B
117B
0.5
118B
117B
0.5
118B
a
302B 906E 303Cll 281C
0.85
282C
W
0.85 0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5 0.85
t
To Rear right door harness
a
466A 71A 46A
re Without ABS 46A 71A
G
1.25 0.5 0.85 0.85 0.5
To cabin harness(White) To engine compartment harness(White)
563A 564A 46A 71A 71A 46A 564A 563A

0.5 0.5 0.85 0.5 0.5 0.85 0.5 0.5
562A 561A 466A 565A 560A 559A With ABS 559A 560A 565A 466A 561A 562A
0.5 0.5 1.25 0.5 0.5 0.5 0.5 0.5 0.5 1.25 0.5 0.5
To cabin harness(Green) To engine compartment harness(Green)
405 405B 405B 405

2.0 2.0 2.0 2.0
405D 405E 405E 405D

2.0 2.0 2.0 2.0
To engine harness D To engine compartment D
2014.01.09
Wiring Diagram 14-11
GW2.8TC 2012 type

C03
C01
C02
C19
Engine Harness
Batttery
l l
a
2#Fuse Box
W
C08
Airbag harness
C04
C05
C06
t
C18
a
re
Instrument harness
G
1#Fuse Box Engine compartment
C13
C14
C09
C11
C12
C10
wiring harness②
Cabin harness

C16
C15
C07
C17
Roof harness
Frame harness
2014.01.09
Harness Connectors
GW2.8TC 2012 type LHD 1
402E 411B 411A 402A

0.85 0.85 0.85 0.85
435B 436B 437B 438B 438A 437A 436A 435A
1.25 1.25 1.25 1.25 1.25 1.25 0.85 0.85
439B 440B 441B 442B 444B 444A 443A 442A 441A 440A 439A
443B 1.25
1.25 1.25 1.25 1.25 1.25 1.25
1.25 1.25 1.25 1.25 1.25
445B 446B 447B 447A 446A 445A
0.5 0.5 0.5
0.5 0.5 0.5
l l
To engine harness A To engine compartment harness A
a
W
15B 15A
3.0 3.0
t
354B 356B 356A 354A
0.5 0.5 0.5 0.5
a
To engine harness B To engine compartment harness B
re
19
G 408B 405B
2.0
2.0
2.0
407B 406B
2.0
405B 408B
2.0 2.0
406B 407B
2.0 2.0
To engine harness D To engine compartment harness D
448B 449B 450B 450A 449A 448A

0.5 0.5 0.5 0.5 0.5 0.5
456B 457B 458B 458A 457A 456A

0.5 0.5 0.5 0.5 0.5
0.5
459B 460B 460A 459A
0.5 0.5
0.5 0.5
To engine harness C To engine compartment harness C
2014.01.09
35A 34A 47A 359A 360A 67 356A 46A 32A 97A 97A 32A 46A 356A 67 360A 359A 47A 34A 35A
0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5
71A 72B 54E 350G 353B 354A 41A 42A 55E 126A 358B 358B 126A 55E 42A 41A 354A 353A 350G 54E 72B 71A
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
l
To engine compartment A
l
To instrument panel A
a
t W
a
215A 520B 521B 521B 520B 215B
0.5 1.25 1.25 1.25 1.25 0.5
3B 3B 3A 3C
7A 3.0 3.0 16A 522B 522B 16A 7C
re
3.0 3.0
1.25 0.5 0.5 0.5 0.5 1.25
252 3B 3B 13A 13B 3E 3G 252
1.25 3.0 3.0 0.5 0.5 3.0 3.0 252A
G To instrument panel B To engine compartment B
455B 465 464 511A 400B 421A 422A 423A 423A 422A 421A 400B 511A 464 465 455B
0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5
167 37A 38A 38A 37A 167
0.5 0.5 0.5 0.5
To instrument panel C To engine compartment C
2014.01.09
252 67 82 82A 67A 252A

1.25 0.5 0.5 0.5 0.5 1.25
909C 777 350F 81A 80C With 80 81A 350 777 909A
1.25 0.5 0.5 0.5 0.5 Rear defrosting 80A 0.5 0.5 0.5 1.25
252 67 82
82A 67A
1.25 0.5 0.5
Without 0.5 0.5
909C 777 350F 81A 80C
1.25 0.5 0.5 0.5 0.5
Rear defrosting 80 81A 350 777 909A
l
80A 0.5 0.5 0.5 1.25
l
Roof front harness assembly To instrument panel harness
a
t W
402A 554A 553A 904 904A 402A
0.85 0.5 0.5 0.5 0.5 0.5
166B 160C 161B 162B Without ABS 162B 161B 160C 166B
0.85 0.85 0.85 0.85
a
0.85 0.85 0.85 0.85
re
402A 554A 553A 553A 554A 402A
0.85 0.5 0.5 With ABS 0.5 0.5 0.5
166B 160C 161B 162B 162B 161B 160C 166B
G
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
To engine compartment harness To instrument panel harness
60B 61A 513A 514A 61A 60B

0.85 0.85 0.5 0.5 0.85 0.85
357 515B 516B 357A
0.5 0.5 0.5
2WD 0.5
908T 501 517 511 908
0.5 0.85 0.5 0.5 0.5
500B
2.0
514A 513A 61A 60B

60B 61A 513A 514A
0.5 0.5 0.85 0.85
0.85 0.85 0.5 0.5
516B 515B 357A
357 515B 516B 0.5 0.5
0.5 0.5 0.5 4WD 0.5
511 517 501A 908A 908A
908T 501 517 511 0.5 0.5 0.5 0.5 0.5
0.5 0.85 0.5 0.5
500B
500B
2.0
2.0
To gearbox harness To instrument panel harness
2014.01.09
118B 117B 282D 281D 54F 55F 61B 350F 355A 116B 115B 115B 116B 355A 350F 61B 55F 54F 281D 282D 117B 118B
0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5
67A 351A 352A 81 777 83A 84A 303 302C 301C 50C 50C 301C 302C 303 84A 83A 777 81 352A 351A 67A
1.25 0.5 0.5 81A 0.5 0.5 0.5 303A 1.25 1.25 0.5 0.5 1.25 1.25 303A 0.5 0.5 0.5 81A 0.5 0.5 1.25
To cabin harness To instrument panel harness
l l
a
106B 105B 286B 286A 105A 106A
0.5 0.5 0.5 0.5 0.85 0.85
252C 284B 283B 282B 281B 281A 282A 283A 284A 252B
W
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
t
Front left door harness A
a
re
55F 909B 301B 303A 303A 301A 909A 55F
0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
150B 155A 153A 152A 152A 153A 155A 150A
G
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Front left door harness B To instrument panel and

54F 907B 302B 303B 303A 302A 907A 54F

0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
155B 153B 152B 152A 153A 155A
0.5 0.5 0.5 0.5 0.5 0.5
Front right door harness B To instrument panel and

108B 107B 107A 108A

0.5 0.5 0.85 0.85
252E 284C 283C 282C 281C 281A 282A 283A 284A 252B
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5

Front right door harness A
2014.01.09
559A 914B 71A 355A 54A 55A 561A 561A 55A 54A 355A 71A 914A 559A
0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5
560A 901A 67A 46A 61A 466A 562A 562A 466A 61A 46A 67A 906G 560A
0.5 1.25 1.25 0.85 0.85 1.25 0.5 0.5 1.25 0.85 0.85 1.25 1.25 0.5
l
To cabin harness A To frame harness assembly A
a l
281B
0.85
t W 115B
0.5
115A
0.5
281A
0.85
a
282B 303B 906B 301B 116B
116A 301A 906A 303A 282A
0.85 0.5 1.25 1.25 0.5
0.5 1.25 1.25 0.5 0.85
re
To Rear left door harness To instrument panel and
281C
0.85
282C 303C
G 906E 302B
117B
0.5
118B
117A
0.5
281A
0.85
0.85 0.5 0.5 118A 302A 906A 303A 282A

1.25 1.25
0.5 1.25 1.25 0.5 0.85
To Rear right door harness To instrument panel and

288A 390A 465C 382A 380A 380A 382A 465C 390A 288A
0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5
To airbag harness (Yellow) To instrument panel (Yellow)
2014.01.09
4G69 2012 type

C01
C02

Engine Harness
Batttery
2#Fuse Box
l l
a
W
C07
C08
C05
C04
C06
t
Airbag harness
a
C03
re
Instrument harness
G C13
C14
C09
C11
C12
1#Fuse Box C10
Engine compartment
wiring harness②
Cabin harness

C18
C15
C16
C19
C17
Roof harness
Frame harness
2014.01.09
Harness Connectors
4G69 2012 type LHD 1
439 441 426 425 465

0.5 0.5 0.5 0.5 0.5
442 419 420 423 422
l
0.85 0.5 0.5 0.5 0.5
To engine compartment harness 2
a l
To engine harness 2
t W
a
re
455 464 400 400 464 455
0.5 0.85 0.5 0.5 0.85 0.5
402 358 437 456 456 437 358 402

1.5 0.5 0.5 0.5 0.5 0.5 0.5 2.0
211 403 212 453 453 212 403 211

0.5 0.5 0.5 0.5
G
0.5 0.5 0.5 0.5
356B 461 214 451 451 214 461 356B
0.5 0.5 1.0 0.5 0.5 1.25 0.5 0.5
To engine compartment harness 1 To engine harness 1
288A 390A 465C 382A 380A 380A 382A 465C 390A 288A
0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5
To airbag harness(Yellow) To instrument panel(Yellow)
2014.01.09
35A 34A 47A 67 356A 46A 32A 97A 97A 32A 46A 356A 67 359A 47A 34A 35A
0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5
l
l
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
To instrument panel harness A
a
To engine compartment harness A
t W
a
re
4 1
1 4 521B 520B 215B
215A 520B 521B 1.25 1.25 0.5
3A 3C
0.5 1.25 1.25 522B 16A 3.0 3.0 7C
3B 3B 10 0.5 5
7A 2.5 2.5 16A 522B 10 0.5 1.25
1.25 0.5 0.5 13B 3E 3G 252D
G
3B 3B 13A 0.5 3.0 3.0 1.25
252B
1.25 2.5 2.5 0.5
11 16 16 11
To instrument panel harness B To engine compartment harness B
423A 422A 421A 400B 511A 464 465 455B 455B 465 464 511A 400B 421A 422A 423A
0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5
38A 37A 167 441A 442A 439A 439A 442 441 167 37A 38A 420 419
0.5 0.5 167A 0.5 0.85 0.85 0.5 0.85 0.5 167A 0.5 0.5 0.5 0.5
To engine compartment harness C To instrument panel harness C
2014.01.09
71F 46B 563A 564A 46B 71F

0.5 0.85 0.5 0.5 0.85 0.5
466 Without ABS 562A 561A 466 565A 560A 559A
1.25 0.5 0.5 1.25 0.5 0.5 0.5
l l
a
71F 46B 564A 563A 563A 564A 46B 71F
0.5 0.85 0.5 0.5 0.5 0.5 0.85 0.5
559A 560A 565A 466 561A 562A
ABS 562A 561A 466 565A 560A 559A
0.5 0.5 0.5 1.25 0.5 0.5 0.5 0.5 1.25 0.5 0.5 0.5
To cabin harness
t W To engine compartment harness
a
re
G
402A 554A 553A 904 904A 402A
0.85 0.5 0.5 0.5 0.5 0.5
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
402A 554A 553A 553A 554A 402A

0.85 0.5 0.5
166B 160C 161B 162B ABS 0.5 0.5
162B 161B
0.5
160C 166B
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
To engine compartment harness To instrument panel harness
2014.01.09
9
60B 61A 513A 514A 514A 513A 61A 60B
0.85 0.85 0.5 0.5 0.5 0.85 0.85
0.5
357 439B 441B 442B 515B 516B 516B 515B 442B 441B 439B 357A
0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.75 0.5 0.5 0.5
501 402B 517 511 4WD 511 517 402B 501A 908A 908A
0.85 0.85 0.5 0.5 0.5 0.5 0.75 0.5 0.5 0.5
500B 500B
2.0 2.0
l l
a
61A 60B
60B 61A 513A 514A
0.85 0.85
0.85 0.85 0.5 0.5
W
357 439B 441B 442B 515B 516B 442 441 439 357A
0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.85 0.5 0.5
2WD
t
501 402B 517 511 402 908 908
0.75 0.5 0.5
0.85 0.85 0.5 0.5
a
500B
2.0
re
To transmission harness To instrument panel harness
118B
0.5
117B
0.5
G
282D
0.85
281D
0.85
54F
0.85
55F
0.85
61B
0.85
350F
0.5
355A
0.5
116B
0.5
115B
0.5
115B
0.5
116B
0.5
355A
0.5
350F
0.5
61B
0.85
55F
0.85
54F
0.85
281D
0.85
282D
0.85
117B
0.5
118B
0.5
1.25 0.5 0.5 81A 0.5 0.5 0.5 303A 1.25 1.25 0.5 0.5 1.25 1.25 303A 0.5 0.5 0.5 81A 0.5 0.5 1.25
286B 106B 105B 105B 106B 286B

0.5 0.5 0.5 0.5 0.5 0.5
252C 284A 283A 282B 281B 281B 282B 283A 284A 252C
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
To left front door harness A To instrument panel harness A
2014.01.09
55F 909B 301B 303A 303A 301A 909A 55F

0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
150B 155A 153A 152A 152A 153 155A 150A
0.5 0.5 0.5 0.5 0.5 153A 0.5 0.5
To left front door harness B To instrument panel harness B
l l
a
W
54F 907B 302B 303 303A 302A 907A 54F
t
0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
155B 153B 152B 152A 153A 155A
0.5 0.5 0.5 0.5 0.5 0.5
a
re
To right front door harness B To instrument panel harness B
G 252E 284
0.5 0.5
283
0.5
108B
0.5
282C
0.85
107B
0.5
281C
0.85
107B
0.5
281C
0.85
108B
0.5
282C
0.85
283
0.5
284 252E
0.5 0.5
To right front door harness A To instrument panel harness A
To frame harness A To cabin harness A
2014.01.09
914B 71A 355A 54A 55A

0.5 0.5 0.5 0.85 0.85
901A 67A 46A 61A 466A
1.25 1.25 0.85 0.85 1.25
561A
0.5
55A
0.85
54A
0.85
355A
0.5
71A
0.5
914A
0.5
559A
0.5
Without ABS
562A 466A 61A 46A 67A 906G 560A
0.5 1.25 0.85 0.85 1.25 1.25 0.5
559A 914B 71A 355A 54A 55A 561A

0.5 0.5 0.5 0.5 0.85 0.85 0.5
To frame harness A 560A 901A 67A 46A 61A 466A 562A
l
0.5 1.25 1.25 0.85 0.85 1.25 0.5
l
With ABS
To cabin harness A
a
t W 281 117 281
a
0.85 0.85 0.85 0.85
282 303A 906A 302A 118 118 302A 906A 303A 282
0.85 0.5 1.25 1.25 0.85 0.85 1.25 1.25 0.5 0.85
re
To right rear door harness To cabin harness
G 281
0.85
282
0.85
303A
0.5
906A 301A
1.25 1.25
115
0.85
116
0.85
115
0.85
116
0.85
301A 906A
1.25 1.25 0.5
281
0.85
303A 282
0.85
To left rear door harness To cabin harness
252 67 82 82A 67A 252A

1.25 0.5 0.5 With 0.5 0.5 1.25
909C 777 350F 81A 80C 80 81A 350 777 909A
1.25 0.5 0.5 0.5 0.5
rear defrosting 80A 0.5 0.5 0.5 1.25
252 67 82 82A 67A

1.25 0.5 0.5 Without 0.5 0.5
909C 777
0.5
350F 81A 80C rear defrosting 80 81A 350 777 909A
1.25 0.5 0.5 0.5 80A 0.5 0.5 0.5 1.25
To roof harness To instrument panel harness
2014.01.09
2.8TDI-2 2012 type

C03
C01
C02
Engine Harness
Batttery
l l
a
2#Fuse Box
W
C18
C08
C05
C04
C06
a t
re
Instrument harness
G
Engine compartment
C09
C14
1#Fuse Box
C13
wiring harness②
C12
C11
C10
Cabin harness
Right Front door

Left Front door harness harness
C16
C185
C07
C17
Roof harness
Frame harness
2014.01.09
Harness connectors
2.8TDI 2012 type 1
214A 430 450 223 24 26

1.25 0.5 0.5 1.0 0.5 0.5
446 448 449 23 38 36
0.5 0.5 0.5 0.5 0.5 0.5
447 438 431 27 11 25
0.5 0.5 0.5 0.5 0.5 0.5
445 437 429 18 7 5
0.5 0.5 0.5 0.5 0.5 0.5
To engine harness A
l l
a
t W
a
405B 15A 10 6
3.0 3.0 4.0 2.0
To engine harness B
re To engine compartment harness B
G
459 356A 410 4 353 19a
0.5 0.5 0.5 0.5 0.5 0.5
443 435 16A 354A
3 32 21 356
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
444 436 455A 369
8 40 355 41
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
905 460 402
910a 29 15
0.5 0.5 1.0
0.5 0.5 1.0
2014.01.09
2.8TDI 2012 type 2
46C 32E 97B

0.5 0.5 0.5
35B 34B 47B 359A 360B 67D
0.5 0.5 0.5 0.5 0.5 1.25
41D 42B 55A 356A
0.5 0.5 0.5 0.5
71B 72B 54A 350A 353B 354A
0.85 0.5 0.5 0.5 0.5 0.5
97A 32A 46A
0.5 0.5 0.5
ABS 67B 359A 47A 34A 35A
l
1.25 0.5 0.5 0.5 0.5
358B 55E 42A 41A
l
0.5 0.5 0.5 0.5
354A 350G 54E 72B 71A
46C 32E 97B 0.5 1.25 0.5 0.5 0.85
a
0.5 0.5 0.5
35B 34B 47B 359A 360B 67D
0.5 0.5 0.5 0.5 0.5 1.25
41D
0.5
42B
0.5
55A
0.5
356A
0.5
W
71B 72B 54A 353B 354A
0.85 0.5 0.5 0.5 0.5
t
Without ABS
a
To instrument panel harness A
re
215A
0.5
7A
1.25
252B
1.25
G
3B
2.5
3B
2.5
3B
2.5
3B
2.5
16A
0.5
13A
0.5
13B
0.5
16A
0.5
14A
0.5
3A
3.0
3E
3.0
3B
3.0
3G
3.0
215B
0.5
7C
1.25
252A
1.25
400A 421A 423A 423A 421A 400A

0.85 0.5 0.5 0.5 0.5 0.85
455B 465A 464B 463A 463A 464A 465A 455B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
469A 469A
0.5 0.5
167A 167A
0.5 0.5
To instrument panel harness C To engine compartment harness C
2014.01.09
2.8TDI 2012 type 3
82A 67B 252

252A 67A 82A
0.5 0.5 1.25
1.25 0.5 0.5
80C 81A 350 777 909C
909A 777 350 81A 80A
0.5 0.5 0.5 0.5 1.25
1.25 0.5 0.5 0.5 0.5
To instrument panel harness To roof harness
l l
402A
0.85
553A
0.5
554A
0.5
a 402G
0.85
W
166B 160C 161B 162B 355C 162A 161A 160A 166A
0.85 0.85 0.85 0.85 0.5 0.85 0.85 0.85 0.85
t
To engine compartment harness (White) To instrument panel harness (White)
a
re
G
357A
0.5
60B 61A
0.85 0.85
14B 908T 402B

0.5 0.5 0.85
To instrument panel harness To transmission harness
115B 116B 355A 350F 61B 55F 54F 281D 282D 117B 118B 118B 117B 282D 281D 54F 55F 61B 350F 355A 116B 115B
0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5
50C 301C 302C 303 84A 83A 777 81 352A 351A 67A 67A 351A 352A 81 777 83A 84A 303 302C 301C 50C
0.5 1.25 1.25 303A 0.5 0.5 0.5 81A 0.5 0.5 1.25 1.25 0.5 0.5 81A 0.5 0.5 0.5 303A 1.25 1.25 0.5
To instrument panel harness To cabin harness
2014.01.09
2.8TDI 2012 type 4
286A 105 106 106B 105B 286B

0.5 0.85 0.85 0.5 0.5 0.5
281A 282A 283A 284 252A 252C 284B 283B 282B 281B
0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85
To instrument panel harness A To left front door harness A
l l
303A 301A 909A 55F 55F
a
909B 301B 303A
W
0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
152A 153 155A 150A 150B 155A 153A 152A
0.5 153A 0.5 0.5 0.5 0.5 0.5 0.5
t
To instrument panel harness B To left front door harness B
a
re
G
107A 108A 108B 107B
0.85 0.85 0.5 0.5
281A 282A 283A 284A 252A 252E 284C 283C 282C 281C
0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85
To instrument panel harness A To right front door harness A
303A 302A 907A 54F 54F 907B 302B 303B

0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
152A 153A 155A 155B 153B 152B
0.5 0.5 0.5 0.5 0.5 0.5
To instrument panel harness B To right front door harness B
2014.01.09
2.8TDI 2012 type 5
914B 71A 355A 54A 55A

0.5 0.5 0.5 0.85 0.85
901A 67A 46A 61A 466A
561A 55A 54A 355A 71A 914A 559A 1.25 1.25 0.85 0.85 1.25
0.5 0.85 0.85 0.5 0.5 0.5 0.5
562A 466A 61A 46A 67A 906G 560A Without ABS
0.5 1.25 0.85 0.85 1.25 1.25 0.5
To frame harness A 559A 914B 71A 355A 54A 55A 561A
l
0.5 0.5 0.5 0.5 0.85 0.85 0.5
l
560A 901A 67A 46A 61A 466A 562A
0.5 1.25 1.25 0.85 0.85 1.25 0.5
ABS
a
To cabin harness A
t W
a
To cabin harness To right rear door harness
re
G To cabin harness To left rear door harness
71A 46A
0.5 0.85
563A 564A 46A 71A

0.5 0.5 0.85 0.5 White Without ABS
562A 561A 466A 565A 560A 559A
0.5 0.5 1.25 0.5 0.5 0.5
To engine compartment harness 71F 46B 564A 563A

0.5 0.85 0.5 0.5
(Green) 559A 560A 565A 561A 562A
0.5 0.5 0.5 0.5 0.5
Green ABS
To cabin harness
2014.01.09
4D20B 2012 type

C03
C01
C02
C19
Engine Harness
Batttery
l
2#Fuse Box
a l
W
C18
C08
Airbag Harness
C04
C05
C06
a t
re
Instrument harness
G C13
Engine compartment
C14
C11
C12
C10
C09
1#Fuse Box
wiring harness②
Cabin harness Right Front door

harness

C16
C15
C07
C17
Roof harness Right Rear door harness

Left Rear door harness
Frame harness
2014.01.09
Harness connectors
4D20B 2012 type 1
175 177 193 112 121 136 177 175

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
182 109 437B 438B 438B 437B 109 182
0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5
439B 440B 441B 442B 443B 444B 444B 443B 442B 441B 440B 439B
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
133 447B 446 445 445 446 447B 133
l
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
To engine harness A
a
l
t W
a
354B 15B
re
15B 354B 3.0
0.5
3.0 0.5
147 146 143 214B 436B
436B 214B
0.5 0.5 0.5 0.85 0.85
0.85 0.85
G
402E 448B 449B 450B 450B 449B 448B 402K

0.85 0.5 0.5 0.5 0.5 0.5 0.5 1.25
158 453 452 451
0.5 0.5 0.5 0.5
456B 457B 458B 171 458B 457B 456B
0.5 0.5 0.5 0.5 0.5 0.5 0.5
459B 460B 468B 132 108 460B 459B
0.5 0.5 0.5 0.5 0.5 0.5 0.5
2014.01.09
4D20B 2012 type 2
35A 34A 47A 359A 360A 67 356A 46A 32A 97A 97A 32A 46A 356A 67 360A 359A 47A 34A 35A
0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
To instrument panel harness A To engine compartment harness A
l l
520B 521B
a
W
215A
0.5 1.25 1.25 521B 520B 215B
3B 3B 1.25 1.25 0.5
7A 3.0 3.0 16A 522B 3A 3C
1.25 522B 16A 3.0 3.0 7C
0.5 0.5
t
0.5 0.5 1.25
252 3B 3B 13A
3.0 3.0 13B 3E 3G 252
1.25 0.5
0.5 3.0 3.0 252A
a
re
455B
0.5
465
0.5
464
0.5
G 511A
0.5
167
167A
400B
0.85
To instrument panel harness C

37A
0.5
421A
0.5
38A
0.5
422A
0.5
A42
0.5
423A
0.5
A39
0.5
423A
0.5
A39
0.5
422A
0.5
A42
0.5
421A
0.5
38A
0.5
To engine compartment harness C

400B
0.85
37A
0.5
511A
0.5
167
167A
464
0.5
465
0.5
455B
0.5
252 67 82 82A 67A 252A

1.25 0.5 0.5 With 0.5 0.5 1.25
909C 777 350F 81A 80C 80 81A 350 777 909A
1.25 0.5 0.5 0.5 0.5 rear defrosting 80A 0.5 0.5 0.5 1.25
252 67 82 82A 67A

1.25 0.5 0.5 Without 0.5 0.5
909C 777
0.5
350F 81A
0.5
80C
0.5
rear defrosting 80 81A 350 777 909A
1.25 0.5 80A 0.5 0.5 0.5 1.25
2014.01.09
4D20B 2012 type 3
402A 554A 553A 904 904A 402A

0.85 0.5 0.5 0.5 0.5 0.5
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
l l
402A 554A 553A 553A 554A 402A
0.85 0.5 0.5 0.5 0.5 0.5
With ABS
a
166B 160C 161B 162B 162B 161B 160C 166B
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
To instrument panel harness (White) To engine compartment harness (White)
t W
a
re
60B 61A 513A 514A 61A 60B
0.85 0.85 0.5 0.5 0.85 0.85
357 515B 516B 357A

0.5 0.5 0.5 0.5
908T 501
2WD
517 511 235
G
0.5 0.85 0.5 0.5 0.5
500B
2.0
60B 61A 513A 514A 514A 513A 61A 60B

0.85 0.85 0.5 0.5 0.5 0.5 0.85 0.85
357 515B 516B 516B 515B 357A

0.5 0.5 0.5 0.5 0.5 0.5
4WD
908T 501 517 511 511 517 501A 235A
0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5
500B 500B
2.0 2.0
118B 117B 282D 281D 54F 55F 61B 350F 355A 116B 115B 115B 116B 355A 350F 61B 55F 54F 281D 282D 117B 118B
0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5
1.25 0.5 0.5 81A 0.5 0.5 0.5 303A 1.25 1.25 0.5 0.5 1.25 1.25 303A 0.5 0.5 0.5 81A 0.5 0.5 1.25
2014.01.09
4D20B 2012 type 4
286B 106B 105B 105B 106B 286B

0.5 0.5 0.5 0.5 0.5 0.5
252C 284A 283A 282B 281B 281B 282B 283A 284A 252C
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
l l
55F 909B 301B 303A 303A 301B 909B 55F
0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
a
150B 155A 153A 152A 152A 153A 155A 150B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
t W
a
108B 107B 107B 108B
0.5 0.5 0.5 0.5
252E 284 283 282C 281C 281C 282C 283 284 252E
re
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
54F
0.5
G 54F
0.5
914B 71A 355A 54A 55A

0.5 0.5 0.5 0.85 0.85
901A 67A 46A 61A 466A
1.25 1.25 0.85 0.85 1.25
561A 55A 54A 355A 71A 914A 559A
0.5 0.85 0.85 0.5 0.5 0.5 0.5
562A
0.5
466A
1.25
61A
0.85
46A
0.85
67A
1.25
906G
1.25
560A
0.5
Without ABS
To frame harness A 914B 71A 355A 54A 55A 561A

559A
0.5 0.5 0.5 0.5 0.85 0.85 0.5
560A 901A 67A 46A 61A 466A 562A
0.5 1.25 1.25 0.85 0.85 1.25 0.5
ABS
To cabin harness A
2014.01.09
4D20B 2012 type 5
281 117 117 281

0.85 0.85 0.85 0.85
282 303A 906A 302A 118 118 302A 906A 303A 282
0.85 0.5 1.25 1.25 0.85 0.85 1.25 1.25 0.5 0.85
l l
a
281 115 115 281
0.85 0.85 0.85 0.85
W
282 303A 906A 301A 116 116 301A 906A 303A 282
0.85 0.5 1.25 1.25 0.85 0.85 1.25 1.25 0.5 0.85
t
a
re
G
71F 46B 563A 564A 46B 71F
0.5 0.85 0.5 0.5 0.85 0.5
Without ABS 562A 561A 565A 560A 559A
0.5 0.5 0.5 0.5 0.5
71F 46B 564A 563A 563A 564A 46B 71F

0.5 0.85 0.5 0.5 0.5 0.5 0.85 0.5
559A 560A 565A 561A 562A ABS 562A 561A 565A 560A 559A
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
To cabin harness To engine compartment harness
405 405B 405B 405

2.0 2.0 2.0 2.0
405D 405E 405E 405D

2.0 2.0 2.0 2.0
To engine harness D To engine compartment harness
2014.01.09
4D20 Euro-V
C03
C01
C02
C19
Engine Harness
Batttery
l
2#Fuse Box
a l
W
C08
Airbag Harness
C04
C05
t
C06
a
C22
re
Instrument harness
G C13
Engine compartment
C14
C11
C12
C10
C09
1#Fuse Box C18

wiring harness②
Cabin harness Right Front door

harness

C16
C15
C07
C17
Roof harness
Right Rear door harness

Left Rear door harness
Frame harness
2014.01.09
Harness connectors
4D20 Euro-V 1
01
175 177 136 121

112 193 193 112 121 136177 175
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.50.5 0.5
182 109 437B 438B 438B 437B 109 182
0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5
439B 440B 441B 442B 443B 444B 444B 443B 442B 441B 440B 439B
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
133 447B 446 445 445 446 447B 133
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
l
To engine harness A To engine compartment harness A
02
a l
t W
15B 454B 354B 354B 454B 15B
3.0 0.5 0.5 0.5 0.5 3.0
436B 214B 143 146 147 147 146 143 214B 436B
0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85
a
re
03
G 402E
0.85
451
0.5
456B
0.5
459B
448B
0.5
452
0.5
457B
0.5
460B
449B
0.5
453
0.5
458B
0.5
108
450B
0.5
158
0.5
171
0.5
132
450B
0.5
158
0.5
171
0.5
132
449B
0.5
453
0.5
458B
0.5
108
448B
0.5
452
0.5
457B
0.5
460B
402E
0.85
451
0.5
456B
0.5
459B
0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
04
97A 32A 46A 67 360A 47A 34A 35A 35A 34A 47A 359A 360A 67 358B 46A 32A 97A
0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 67A 0.5 0.5 0.5 0.5
126A 55E 42A 41A 354A 350G 54E 72B 71A 71A 72B 54E 350G 354A 41A 42A 55E 126A 356A
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
To engine compartment harness A To instrument panel harness A
2014.01.09
4D20 Euro-V 2
05
521B 520B 215B 215A 520B 521B

1.25 1.25 0.5 0.5 1.25 1.25
3A 3C 3B 3B
522B 16A 3.0 3.0 7C 7A 16A 522B
0.5 1.25 3.0 3.0 0.5 0.5
0.5 1.25
13B 3E 3G 252 252 3B 3B 13A
0.5 3.0 3.0 1.25 1.25 3.0 3.0 0.5
l
To engine compartment harness B To instrument panel harness B
l
06
a
A39B A42B
421A
0.5
38A
400B
0.85
t
37A 167
W 464
0.5
465
0.5
455B 465
0.5 0.5
464
0.5
511A
0.5
167
0.5
400B
0.85
37A
0.5
421A
0.5
38A
0.5
422A
0.5
A42
0.5
423A
0.5
A39
0.5
a
0.5 0.5 0.5 0.5 0.5
re
To engine compartment harness C To instrument panel harness C
07
G 252
1.25
909C
1.25
67
0.5
777 350F 81A
0.5 0.5 0.5
82
0.5
80C
0.5
82A
0.5
80
0.5
67A
0.5
81A
0.5
350
0.5
252A
1.25
777 909A
0.5 1.25
08
402A 402A
0.5 0.5
166B 160C 161B 162B 619 619 162B 161B 160C 166B
0.85 0.85 0.85 0.85 0.5 0.5 0.85 0.85 0.85 0.85
2014.01.09
4D20 Euro-V 3
09
60B 61A 522A 524A 524A 522A 61A 60B 61A 60B
0.85 0.85 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85
512B 516B 516B 512B
0.5 0.5 0.5 0.5
501B 908T A39E A42E A42C A39C 908T 501B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
500B 500B
2.0 2.0
With TOD Without TOD
l
l
10
a
W
115B 116B 355A 350B 61B 55F 54F 281D 282D 117B 118B 118B 117B 282D 281D 54F 55F 61B 350F 355A 116B 115B
t
0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.85 0.5 0.5 0.5 0.5
914 301C 302C 303 84 83 777 81 352A 351A 67A 67A 351A 352A 81 777 83A 84A 303 302C 301C 914
0.5 1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 0.5
a
re
To instrument panel harness To cabin harness
11
G
286B
0.5
252C 284A 283A
0.5 0.5 0.5
106B
0.5
282B
0.85
105B
0.5
281B
0.85
105
105A
281C
0.85
106
106A
282C 283C 284C
0.85 0.5 0.5
286A
0.5
252C
0.5

12
55F 909B 301B 303A 303A 301B 909B 55A

0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
150B 155A 153A 152A 152A 153A 155A 150B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
2014.01.09
4D20 Euro-V 4
13
108B 107B 107 108

0.5 0.5 107A 108A
252E 284 283 282C 281C 281C 282C 283C 284C 252C
0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 0.5
l
l
14
a
W
54F 907B 302B 303 303B 302B 907B 54A
t
0.5 1.25 1.25 0.5 0.5 1.25 1.25 0.5
155B 153B 152B 152B 153B 155B
0.5 0.5 0.5 0.5 0.5 0.5
a
re
15
561
562
G 55
466
54
61
355
46
71 914
67 906G 560
559 559 914
560 906G
71
67
355
46
54
61
55
466
561
562
To frame harness To cabin harness

16
281 115 115 281

0.85 0.85 0.85 0.85
282 303A 906A 301A 116 116 301A 906A 303A 282
0.85 0.5 1.25 1.25 0.85 0.85 1.25 1.25 0.5 0.85
2014.01.09
4D20 Euro-V 5
17
281 117 117 281

0.85 0.85 0.85 0.85
282 303A 906A 302A 118 118 302A 906A 303A 282
0.85 0.5 1.25 1.25 0.85 0.85 1.25 1.25 0.5 0.85
l
l
18
a
563A
0.5
562A
0.5
564A
0.5
561A
0.5
40C
0.5
t W
466
46B
0.85
560A
0.5
71F
0.5
559A
0.5
71F
0.5
559A
46B
0.85
560A
564A 563A
0.5 0.5
40C 561A 562A
a
0.5 0.5 0.5 0.5 0.5
re
To engine compartment harness To cabin harness
19
G D39A D42A
0.5 0.5
405 405B
2.0 2.0
405D 405E
D42A D39A
0.5 0.5
405B 405
2.0 2.0
405E 405D
2.0 2.0
2.0 2.0
To engine harness E To engine compartment harness E
20
662 661 155 903 903 155 661 662

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
663 666 667 663
0.5 0.5 0.5 0.5
To engine harness D To engine compartment harness D
2014.01.09
4D20 Euro-V 6
21
908S 350C 908G 56A 34B 908S 169A 160E 160E 169A 908S 34B 56A 908G 350C 908S
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
A39D A42D 72A 57A 35B 164A 165 170A 170A 165 164A 35B 57A 72A A42 A39
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
l l
To combination instrument To combination instrument and
swithes transition harness control panel harness
a
22
t W
a
288A 390A 465C 382A 380A 380A 382A 465C 390A 288A
0.5 0.5 0.5 0.5 0.75 0.75 0.5 0.5 0.5 0.5
To airbag harness(Yellow)
re To instrument panel harness
2014.01.09
491QE (CNG)
Based on the 491 engine model, the following harness connecting plug-in is suitable for model 491QE
(CNG).
97A 111 32E 46C 46A 32A 111 97A

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
67A 112 113 47A 34A 35A 35A 34A 47A 113 112 67B
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25
358A 356A 114 55A 42A 41D 41A 42A 55E 114 356A 358A
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
354A 353A 350B 54A 72A 71F 71A 72A 54E 350E 353A 354A
0.5 0.5 1.25 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 0.5
ll
97A 32E 46C 46A 32A 97A
0.5 0.5 0.5
a
0.5 0.5 0.5
67A 47A 34A 35A 35A 34A 47A 67B
0.85 0.5 0.5 0.5 With 0.5 0.5 0.5 1.25
358A 356A 126A 55A 42A 41D anti-theft 41A 42A 55E 126A 356A 358A
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
W
354A 353A 350B 54A 72A 71F 71A 72A 54E 350E 353A 354A
0.5 0.5 1.25 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 0.5
t
To instrument panel harness A To engine compartment harness A
a
re
521A 520A 138 215A
215A 138 520A 521A
1.25 1.25 3C 3B 0.5 0.5 3B 3A
0.5 0.5 1.25 1.25
522A 16A 2.5 2.5 137 7A
7C 137 2.5 2.5 16A 522A
G
0.5 0.5 0.5 1.25
3D 3E 1.25 0.5 3C 3D 0.5 0.5
13A 77 252B 252A 77 14A 13A
2.5 2.5 2.5 2.5
0.5 0.5 1.25 1.25 1.25 0.5 0.5
423 422 780 400 400A 780 422A 423A

0.5 0.5 0.5 0.5 1.25 0.5 0.5 0.5
511 464A 465B 455 455A 465 464A+464B 511A
0.5 0.5 0.5 0.5 0.5 0.5 0.5+0.5 0.5
440 438 38A 37A 37 38 438 440
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.85

439 442 441 554A 553A 167A+167B
167A 553 554 441 442 439A
0.5 0.85 0.5 0.5 0.5 0.5+0.5
0.5 0.5 0.5 0.5 0.85 0.5
To instrument panel harness C To engine compartment harness C
86 85 77 89
89 77 85 86 1.25 1.25 1.25 0.5
0.5 1.25 1.25 1.25 93 92 79 78
78 79 92 93 0.5 0.5 1.25 1.25
1.25 1.25 0.5 0.5
Fuel gas ECU adapter plug-in Fuel gas ECU adapter plug-in
2014.01.09
Vehicle Electrical Schematics

Power Generation and Startup System (4D20 Euro V)
ACC out
L4 output
L5 output
IG1 out
IG2 out
Central control pin 7

404 3 6 8 7 F6
Ignition switch
L1 output
L2 output
R R/L W Y W 10A
F6 output
Key
Remove the key
position Plug the key in
l
START
LOCK
l
ACC
ON
Switch
status
Lead-out
terminal 287 424 4 2 350
BT2 L/Or Br R R/L W
a
ACC
IG2
ST
12
BT1 W/Or
W
IG1
K1
908
t
K2
B
a
F1
re
5A
L4 L5 13
60A 60A W/G
Charging indicator
L2 L1
L3 100A
60A 60A
G
1R
Start relay J15
87 85 2 350 16
R W W/B
30 86
15 14
Battery R/L W/V
+B S L
Generator
12V
90Ah C B U>
E
Starter
900 900 908 900
2014.01.09
Engine Control System (4D20B-WGT)
14-45
2014.01.09
Independent relay From normal power supply
402 2 404 404 402 67 0 404 359 402 7 400 358 455 211 212 402 4 402 356 420 402 424 464 404 465 390 517
R R L/Or R/Gr W R Br/P Br/CY/Or Y/Br R R/G W/R W/Or W/Br R R/Br R/W R/Or L/Br B/W C/Or
l
R/Or
R/Or
R/Gr
R/Y
R/Or
l
Oil-water separator
F2 F29 F27
10A 10A 10A
Master relay
85 87
a
400 213
86 30 60A Y
F38 R
401 10A 65 R/W 464
Brake switch
System fault indicator

Compressor relay J11
30
Preheating indicator
86 85 87
EGR control sensor
R/W
OBD indicator
L11
Preheating relay
High-speed fan relay J17

R/B
904
Low-speed fan relay J10

30A W 1
Air quality sensor

85 87 87 85
Fuel heating relay J6
m 86 30
461 F37
85 87 405 403 214
20A t
Br/L Br/Or Y/R 86 30 30 86
86 30 87 85
66
Clutch switch
428 427 425

3 4 2 421 423 422
Compressor clutch coil

402 W/R W/L W/Gr
67 168 142 416 417 P/L
P/B P/G
Wiring Diagram
R/Gr R/L 1 5 6 2 4
467 466 418 H L
R/Y
Oil-water separator
L/Or Br/P Br/V

175 177 133 182 109 900 426
I_S_BRKMN Glow plug
463 Br/Y W/P
TACHOMETER OUT
R/B M
O_T_EGRNEG
O_T_EGRPOS
I_S_ACCMED
t
O_T_CTSIND
I_S_BRKRED
O_S_GLWLP
O_S_GLWLP
O_S_GLWLP
V_V_BAT+Ra
V_V_BAT+Rc
V_V_BAT+Rc
B_D_CANH1
V_V_5VEGR
O_S_MRLY
2 3 4
I_S_ACSW
1
I_S_WFLS
G_R_EGR
G_R_AMS
I_S_CONV
o_S_GLW
t
I_A_EGR
905
I_T_AMS
I_T_IATS
I_F_VSS
I_S_T15
FAN-H
B
FAN-L
a
Fuel heater and controller
K47 K01 K05 K03 K55 K78 K38 K90 K54K30 A04 A19 K23 A39 K39 K73 K77 K12 K20 K63 K46 K19 K43 K37 K75 A20 K91 K70 K71 K68 K62 K93 K92
Rotating speed
Vehicle speed
K29
K04 EDC16C39-5.H1
re
K02
K06
K10 K85 K28 K81 K67 K22 K60 K58 A60 A16 A47 A02 A31 A01 A46 A17 A33 A13 A14 A56 A08 A57 A35 A07 A54 A28 A53 A06 A52 A40 A37 A50 K66 K87 K44
I_A_FTS
G_R_FTS
V_V_5VAPP1
I_A_APP1
G_R_APP1
V_V_5VAPP2
I_A_APP2
G_R_APP2
O_T_MEU
O_P_JNJVH11
O_P_JNJVH11
O_P_JNJVH22
O_P_JNJVH22
O_P_JNJVH21
O_P_JNJVH21
O_P_JNJVH12
O_P_JNJVH12
L_F_CRSPOS
L_F_CRSNEQ
C_C_CRS
V_V_5VCAS
L_F_CAS
L_F_CAS
V_V_5VBPS
I_A_BPS
G_R_BPS
I_A_BTS
V_V_5VRAILPS
I_A_RAILPS
G_R_RAILPS
I_A_CTS
G_R_CTS
SRS DUAG REQ
SDATA
465 464 390
L/Br R/W B/W
108 132 429 430 431 432 433 434 65 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 456 457 458 459 460
A39 A42
G
0.5
G/Y G/L G/R G/Br G/B G/Or G/Gr G/V Or/R Or/W Or/L Or/P Or/Br Or/Y Or/Gr Or/G Or/V Or/C W L B L/R L/W L/Y L/Or L/Br L/P L/G L/V L/Gr L/B G/Y G/L Br/B 0.5
Br/G
2 4 3 1 6 5 3 2 1 9 16
1 2 2 1 3 4 1 2 3 2 1 1 2
u 2 1 2 1 2 1 2 1 2 1 u
u
t p& t u t 8
n n p 1
905 901
908
B B
B
Oil temperature sensor Electronic throttle pedal sensor High-pressure pump #1 fuel injector #2 fuel injector #3 fuel injector #4 fuel injector Crankshaft position sensor Phase sensor Boost pressure and temperature sensor Fuel rail pressure sensor Coolant temperature sensor Diagnostic plug
Engine Control System (4D20 Euro V) 1
2014.01.09
Anti-theft ECU 3-pin
Storage battery L1
ESP 30-pin
F37 output
Battery L4
From IG1
l l
404 402
R R/G
7 402 4
a
402 401 404 402 402 400
W R/G R
R/G W/B R/B R R/G R/G R
10A
67
R/Y
10A
F38
W
10A
903
65 1 400
Master relay
85 87 EGR controller 30 86 R
213
WINGLE Service Manual
Compressor sensor
Preheating relay
Oil-water separator switch

86 30 1 Y
Air quality sensor

m
VGT 85 87
Brake switch
461 401
2 6 1 5 3 t
Br/L R/B 86 30
VGT vacuum valve
177 177 133 182 109 87 85
G/W G/B Br/R G/W R/Y 405 4 2 3 174
Clutch switch L/Y Gr/B
F37 R 3 2
t
20A R R/Y G/R
403 214
402 168 123 142 417 418B 416 Br/B Y/R
511 463
EGRValue DCmotor,negative
EGRValue DCmotor,positive
R/G V/W G/W B/R V Br/W Br/Y
a
G/B R/B 193 112 121 136 66 67
Electromagnetic clutch
Glow plug
G/R Gr B L/W R/L R/Y
BoostActuator-out
Water in fuel -gnd

Water in fuel -sw
InterAirTemp-sig
I_S_BRKRED
V_V_BAT+Rb
V_V_BAT+Ra
V_V_BAT+Rc
VGTPos-Vref
V_V_5VEGR
EGRpos-gnd
VGTPos-gnd
2 3 4
I_S_BRKMN
1
O_S_ACRLY
EGRpos-sig
VGTPos-sig
O_S_MRLY
Clutch1-sig
Clutch2-sig
I_S_GLW
MAF-gnd
I_S_T15
MAF-sig
re
A45 A03 A05 A01 A18 A17 K91 K90 K65 K16 K20 K88 K69 K14 K62 A30 A32 K85 K48 K95 K58K71 K53 A19 A50 A55 A41 A36 A42 A51
CAN CAN CAN CAN CAN
DCM3.7GWM E5
A02 A04 A06 A24 A25 A26 A29 A13 A14 K42 K13 K34 K68 K66 K8 K44 K6 K23 K27 K26 K51 K75 K3 K25 K50 K74 K60 K36 K87 K40 K59 K47
G
G_G_BAT-1
G_G_BAT-2
G_G_BAT-3
Pedal1-sig
Pedal1-gnd
Pedal2-sig
Pedal2-gnd
BoostPress-sig
BoostTemp-sig
BoostPress-gnd
Delta P-sig
Delta P-gnd
T5Temp-sig
T5Temp-gnd
InjectionH11
InjectionL11
InjectionH22
InjectionL22
InjectionH33
InjectionL33
InjectionH44
InjectionL44
Crankshaft sensor positive

Crankshaft sensor neg
C_C_CRS
CAM-sig
CAM-gnd
BoostPressVref
Delta P-vref
CAM-Vref
Pedal11-5V
Pedal12-5V
429 430 431 432 433 434 451 452 454 453 661 662A 663A 666A 667 437B 438B 441B 442B 443B 444B 439B 440B 445 446 447 448 450 449
G/R L/Y L/B G/R G G/V W/V L/W P L/G Br W R G V Or/L R R/B L/Y L/R Gr/B Br/B B/Y W Y B R G B
181
2 4 3 1 6 5 1 3 2 125 174 102 149 126 151 103 104 188 187 137 138 114
B A C D 1 2 1 2 1 2 1 2 2 1 3 C A B
u P t
p & t n n
14-46
901 901 901 Electronic throttle pedal sensor Intake pressure sensor Differential pressure sensor CPF exhaust temperature sensor #1 fuel injector #3 fuel injector #4 fuel injector #2 fuel injector Crankshaft position sensor Camshaft position sensor
B B B
Engine Control System (4D20 Euro V) 2
14-47
Airbag ECU 9-pin

Tri-state pressure switch 4-pin
Tri-state pressure switch 1-pin
2014.01.09
Storage battery L2
F27 input
l
Battery L4
l
402
R/G
a
212 211 402 424
402 402 402 465 404 464 517
Y/Gr Y R/G Br
R R R L R R/W G/R
W 10A
F27
High-speed fan relay
Low-speed fan relay

Wiring Diagram
85 87 87 85
Flow valve EGR cooling
86 30 30 86 9 16
2 1 1 A42 464A
428 427 0.5 0.5
t
Br/G R
W/R W/G 50B 50S A39 465 517
390 0.5 0.5 0.5 0.5 W/Y
B B Br/B Br/W 0.85
3 4 1 2 8
1
a
426 171 158 50 436
InlerMetering Valve-out
H L 425
Cooling fan
W/R W/G Y/Gr R/L L/W

AirConDemand-sw
155
IntakeThottle-out
211
IntakeThottle-sig
ACpressure-sig
Y/Or M
R
O_T_FAN-H
re
C-CANH
C-CANL
FAN-L
A8 A58 A43 A37 K89 K12 K77 K86 A31 A48 A47
212
G
K28 K31 K30 K38 K19 K35 K9 K45 K10 K46 A23 A15 A33
Engine Block ACCEl1 positive
Engine Block ACCEl1 negative
FuleTemp-sig
FuleTemp-gnd
CoolantTemp-gnd
RailPressure-Vref
RailPressure-gnd
Shield
CoolantTemp-sig
RailPressure-sig
143
456 458 457 459 460
B G Br 108 132
W G/Y L/G
146 147 Y/W W/B
G/Y Br/W 186 184 159 157 156
2 1 3 2 1 2 1
u u u
n p t t
Knock sensor Fuel rail pressure sensor Coolant temperature sensor Oil temperature sensor
Engine Control System (491QE-CNG)
2014.01.09
C1
Petrol ECU
Instrument
Petrol injection Petrol injection Petrol injection Petrol injection Oxygen intake high Oxygen intake panel speed 58× low 58× high
signal 1 signal 2 signal 3 signal 3 signal signal output signal signal
l l
C17 Diagnosis interface
C4 C2
a
C3
+12V
Battery power supply
C18
U
5 GND
9
4
8
3 PCTXD
7
2 PCRXD
6
1
t°
P W Oxygen sensor P t°
U low signal
C16 C19
Switch
Hardware processing circuit
5 3 1 2 4 C20
ECU
Main fuse
fuse
10A
2A Battery negative pole
t
438 439 109 104 103 450 458
111 112 113 114
432 433 434 409 407
+12V ignition switch 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5
431
a
G/R L/R LW LY VB W
Battery negative pole

0.85 0.85 0.85 0.85 1.25 0.5 BrY PW G/L BrB
Batt
GB GrBr Gr GrR RG Cylinder pressure 137 138 77
0.5 0.5 1.25
+12V
G/Y Y/R
25 23 21 19 53 1 36 9 17 10 12 13 14 38 6 34 8 44 43 32 31 C0
Petrol injection Petrol injection Petrol injection Petrol injection Nozzle MCU Oxygen sensor Oxygen sensor Instrument panel 58x 58x Intake pressure
Download/diagnosis
request signal
SIL
Coolant temperature
Swtich
+CNG
Signal GND
Transmitter end
Receiver end
Beeper
input 1 input 2 input 3 input 4 power supply power supply high signal low signal speed input low output high output signal signal
(optional)
re
Natural gas ECU (IME)
Petrol injection Petrol injection Petrol injection Petrol injection CNG injection CNG injection CNG injection CNG injection IME main relay 58x 58x Reference Air rail Air rail Reference
output 1 output 2 output 3 output 4 output 1 output 2 output 3 output 4 output Ignition switch Nozzle GND Power supply GND low input high input GND temperature pressure +5V
26 24 22 20 27 28 56 55 17 40 54 30 2 29 52 16 15 30 33 5 46
50 63 49 64 78 79 86 85 77 400 906 92 89 93
1.25 906 906 906 906 906 445 447
0.85 1.25 1.25
G
0.85 0.85 0.85 1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5
B/Y RG 1.25 0.5 1.25 1.25 1.25
Y G/Br G/L Br/B W/G B/L YG C13 R B B B B B W Y B WG WR Y/B
C5 C6 C7 C8 C9 C10 C11 C12
+ - + - + - + - + - + - + - + - + -
C14
C15
U
P t°
Pressure reducer solenoid valve
+12V
14-48
+12V ignition switch Battery negative pole
Connect to petrol main relay output
Lighting and Signaling System (4D20 Euro V) 1
14-49
2014.01.09
storage battery L1
Connect to
IG1
Connect to storage battery L5

Position light output
7
W 53
3
l
G/Br
R/L
l
4 4 4 4 71
4
R R R R G/W
R F4
a
10A
Central control 8-pin

51
51 G/V 51
G/V
53 G/V
Left turning relay

F32 Y
Right turning relay

15A F33
10A
F30
15A
W F31
15A
Low beam relayJ7

F34 55 54
87 85
87 85
High beam relayJ8
G/R
G/Y
10A 30 86
30 B/R 30 86
Front fog light relayJ12
31 B/L
40 F14 56 53 54 57
R/L 71 15A G/Y Y G/R G/W
70
87 85 87 85 G/W 50
85 87 G Or/L
Wiring Diagram
30 86 30 86
Airbag alarm light

86 30
Position light relayJ9

Alarm light switch
45
33 35 L/Y
42 41
R 32
85 87 OFF
B/W B/Y
34 L/R
G R/G ON
86 30
52 55 54
t
72 71 G G/Y G/R
Rear fog light relayJ18
L/W G/W Position light indicator
Turning switch
3 2 1
FlasherJ5
Left
Front fog light switch
Right headlight
OFF
Left headlight
85 87 B
High beam indicator

Right
Front left position light Front left turning light E
86 30
re
47
Rear fog light switch
G/B Right turning light

Rear left position light Rear left turning light
OFF Logic control
OFF
circuit
ON ON 46 7 6 10 9
Rear right position light Left turning indicator
Light switch
G/V Position
light
G
Low
Front right position lamp Front right turning light
Front fog light indicator
Rear fog light indicator

beam
High
Front right fog light
beam
Rear left fog light

Rear right fog light
Front left fog light
Left license plate light Right turning light

Dimmer assembly Right license plate light Rear right turning light
GND Vcc
OUT
Right turning indicator
73 G/B
903 904 908 908 903 901 901 908 908 903 904 908 901 908 903 904 908 908
B B B B B B B B B B B B Instrument illumination light B B B B B B
Daytime running light control
2014.01.09
Daytime running
42
light relay
Right daytime running light
B
87
30
5A
41
B
4
R
l
Left daytime running light

85
86
a l
909
B
20W
High-mounted brake light
R/Y
901
R/Y
67
67
B
21W 21W
Brake switch W Right brake light
901
B
Left brake light
Lighting and Signaling System (4D20 Euro V) 2
Electric horn
Horn relayJ13
903 904
H
B
Br/B
30
87
96
10A
F35
B
95
4
R
97
85
86
Br/B
908
Connect to storage battery L1
B
Horn switch
a t
Door indicator
BAT
Central dome light
15A
F15
Br/B
909
R/L
B
re
80
3
Br/Gr
Connect to storage battery L5 Rear right door switch
906
Key hole illumination light
B
81
Br/B
80
Connect CD player A7-pin Rear left door switch
Front reading light
906
B
Front right door switch
906
B
G
Front left door switch
Br/L
Br/Y Br/R Br/L
82
82
906
B
84
83
61
G
Reverse radar 13-pin
G/Y
60
Vehicle speed sensor
21W
Left reverse light
901
B
10A
Reverse light switch
F5
IG1
61
W
7
901
B
14-50
21W
Right reverse light
Airbag (4D20 Euro V)
Engine A31-pin

F6 output
IG1
入
465 390 7 350 288
L B/W W W L/G
l l
Airbag alarm light
a
W
15A
t
380 382
DUAG REQ
R L/W
SDATA
a
AWL
CRASH OUT
IG
re
9 15 5 7
Airbag ECU 34
G
10 11 6 18 19
DAB HI
DAB LO
GND
PAB HI
PAB LO
384 385 386 387

L/R L/Y Y/R Y/B
Clock spring
388 389
Y/R Y/B
912
Driver airbag B Co-driver airbag
2014.01.09
Central Control Lock (4D20 Euro V)
Combination instrument 5-pin

From L5 output
Front right door switch
F6 output
Front left door switch
Position light output

Airbag ECU 34-pin
Right turning light
Ignition switch K1
Left turning light
l
Reading light
Electric doors and windows relay J1

a l
W
83 84 82 350 289 3 287 55 54 71 288 350 3
Br/Y Br/R Br/L W Y R/L L/Or G/Y G/R G/W L/G W R/L
Front left door switch detection
CRASH OUT
t
Vehicle speed lockout input
455
Front right door switch detection
R/W F16 85 87
Position light detection
20A
Reading light delay
86 30
a
Right turning light
280
Left turning light
L
Key detection
304
300 Y
Engine RPM
橙/G
Collision signal
re
IN4007〈300MA
F9 F10
IG BAT 30A 30A
Small light 18 12 11 16 7 8 2 17
signal input 72 IG power-off delay
15 3
Central door lock controller

301 L/W 302 Y
303 Y/W
G
Daytime running Lockout signal 284 L
light control 42 CLOSE OPEN 19
4
Lockout output
Status detection
Unlock signal
13 4 6 4 2 7 2 5 4 2
Front left door Rear left door Front right door Rear left door
window switch window switch window switch window switch
14 7 3 5 5 3 6 6 3 1 4 5 3 6
283 L/Y 305 306 307 308 309 310 311 312
R/G L/Y R/G L/Y R/G L/G R/B L/R
M
281 282
L/W Front left door lock latch L/R
M M M M M
Front right door lock latch Front left Rear left motor Front right Rear right motor
door motor door motor
M 909 906 907 906
B B B B
Rear left door lock latch
M
Rear right door lock latch
907
B
2014.01.09
2014.01.09
Tachometer
n
Water temperature gauge

t
Speedometer
v
Automatic cruise indicator reserved

Preheating indicator
Oil-water separator indicator
ESPOFF indicator
ESP indicator
ABS indicator
EDB indicator
Engine maintenance indicator
Engine system failure indicator
AWD indicator
36
524
G/V
Charging indicator
32
B
G
Anti-theft indicator
33
126 16
20
High beam
32
B/W V/W W
382
L/W
8
Airbag alarm light Left turning

19
55
G/Y
Defrost indicator
Right turning
252
R/Y
5
289
Y
30
54
G/R
re
Door lock
34
357
Br/Gr
A42
Br/Gr
a
Vehicle speed output CAN direction
35
A39
Br/B
22
t
46
G/V
B
914
40
Rear fog light
41
R/G
W
39
Front fog light Water temperature sensor
402
R/G
356
900
Br/Gr
t
10
F37 input
61
G
Fuel alarm light
15
Reverse light switch
a
Fuel gauge
Fuel sensor
B
24
355
901
Q
Q
l
16
Engine oil pressure indicator Engine oil pressure switch

354
Y/B
900
l Combination instrument
F6
10A
IG
350
7
W
W
13
IG1 in
Parking brake switch
352
Parking brake indicator

900
27
W/L
350
W
F6 output
B
Seatbelt indicator Seatbelt switch

351
906
W/G
12
BAT
464
R/W
7
F27 input
B
908
2
Brake vacuum detection switch
28
Brake failure indicator
900
360
G/W
73
G/B
21
Lighting input Position light indicator
B
908
71
G/W
31
Position light
Door indicator
11
81
80
Combination Instrument System (4D20 Euro V)

14-53 Wiring Diagram
Cigarette Lighter/ Power Socket/ Instrument Panel Central Lighting/

Electric Rearview Mirror/ Front Wiper/ Scrubber (4D20 Euro V)
Self-position light output
From IG2 out

From ACC out
8
71 6 8
Y
G/W W Y
F23
15A
160
G
l
F17 F22
l
20A 5A
5 8 2 10 19 20
a
90 150 MIST
Front wiper switch

R/L P
OFF
INT
1 2 4 5 6 7 8
W
中 LO
左 HI
右
t
L
Electric rearview mirror switch
上
下 160
a
中 G
169 170 164 160
Front scrubbing relay
左 5
R/W R/B Gr/G G
关闭
Intelligent wiper relay

Intermittent
右
Front power socket
re
上 165
Cigarette lighter
9
Glove box light
Ashtray light
Gr/W
下 87 85 I 15 53e
中
左
30 86 Lo Intermittent
R 右
167 circuit
Hi
G
上 Gr/B
下 31
161 162 53c
Gr/Y Gr/R
31b
151 152 153 154 155
Reset control
P/G P/Y P/B P/Br P/G
Front scrubbing
167 166
Gr/B Gr/L
160
167 Gr
Front scrubbing motor
Right reverse mirror
Vertical Horizontal
Gr/B
Vertical Horizontal
M M
Left reverse mirror
M
M
Front wiper motor
M M
910 909
903 903 904 904
B B
B B B B
170 Wiper high-speed control
169 Wiper low-speed control
162 Wiper high-speed motor signal
161 Wiper low-speed motor signal
2014.01.09
ESP (4D20 Euro V)
F6 output
Brake switch
Generator output
l l
a
L
H 350 67 350 2 2
W/R R/Y W R R
SAS steering DRS yaw
W
W angle sensor rate sensor
S/B2 ESP-OFF
40A 25A Switch
t
3 2
551 552 619
a
R/L R/G V
350 906 906
re
WSO-FR
563 564
PWR-M
PWR-V
R/W R/L
BLS
IG
14 26 33 20 30 28 1 25 2 23 12
G
ESP ECU(BOCH9.0)
29 17 4 16 18 31 8 19 38
WS RL
WP RL
WS FL
WP FL
WS RR
WP RR
WS FR
WP FR
Fuel pump motor
M
561 562 557 558 559 560 555 556
W/L W/B Y/B Y/R L/Y B/G Y/B L/W
FL FR RL RR
Control solenoid valve

13
Integrated ABS control module assembly
1 2 1 2 1 2 1 2
Rear right Front right Rear left Front left

906 913 913 913
B Wheel speed sensor B B B
2014.01.09
Radio/ Air-conditioning/ Defrosting (4D20 Euro V)
2014.01.09
From engine ECU 8-pin

From F6 output
From IG1 out
From IG2 out

From L1 out
From engine ECU 58-pin
Generator output
From ACC out
From F15 out
l l
a
71 6 80 7 350 71 8 4 71 211 212
G/W W Br/B W W G/W Y R G/W Y Y/Gr
2
F24
F18
10A
W F36 5A
L8
30A
20A
Tri-state pressure switch

15A
215 200
250 Br/B 1 4
R
Front left speaker
橙 HP 212
Rear left speaker
Blower relay J20

100
Y/Gr
L Or L MP
85 87 B424
LP
Cooling fan relay

86 30
H H 2 3 85 87
Defrost switch
202 201
208 86 30
105 106 108 107 Y W/R
Y/L
t
R/Y Br/W R/B R/W A424
Steering wheel key-controlled switch (optional) 207 208
a
B5 B6 A6 A4 A7 B4 B3 119 R F28 Y/R Y/L
251 902 A/C
10A
A1 Or/G B switch
Radio-CD player 206
Blower
A8 905
Y/W
A2 120 G M
252
re
B7 B8 C2 C1 B2 B1 VOL-UP DN CH-UP DN MODE R/Y
VCC SW M
115 116 118 117
L/Y Gr/B G R/G 905
Defrost OUT 203
Y
Evaporator
temperature
relay J19
Front right speaker
Speed control resistor controller

Rear right speaker
75Ω GND 204 205
G
L L
Signal feed line
Y/Gr Y 209 210

L/Y G/Y

Blower speed control switch
Gear position 4 6 5 3 2 1 t
Rear windscreen defroster
Defrost indicator
Left rearview mirror defrost
Right rearview mirror defrost

0
Front dome antenna

1
2
3
4
908 903 909 908 909 909 902 902 902 902
B B B B B B B B B B
14-56
Anti-theft/ Electric Seat Heating (4D20 Euro V)
From engine ECU
From engine ECU
F 27 input
L5 output
A31-pin
A19-pin
From ACC
465 400 3 464 71 6
L R R/L R/W G/W
l
W
10A
l
F19
20A
125
314
a
Gr/L R/G
Status indicator
t W 126
1 2 3 4 5 6
a
OFF
V/W
re
ON
7 3 4 1
Anti-theft ECU
assembly 2
G
Backlight
123 124
Y/R Y/B
316 315
R/W R/B
Driver seat heating resistance
Co-driver seat heating resistance
Key detection
903 908 908 908 908

B
B B B B
2014.01.09
Intelligent 4WD/ Front Axle Electric Clutch Control (4D20 Euro V)
Instrument 4-pin
From F6
L5 output
7
W
F3
l
15A
l
350
a
501
W R/G
501 516
R/G G/V 3 516 512 522
Electric clutch indicator

R/L G/V L/Y Y/W
Vehicle speed input from IP

4WD indicator
W
2WD/4WD selector switch
(AWD: low power level F13

/ 2H: suspended) 20
t
EMC
Cluech
a
4WD switch 512
Axle Dlsconnect Control Signal
10 1
L/Y
To electromagnetic clutch coil
AxleDlsconnect Feedback
AWD Control
re
A39 A42 524 501 500
AWD switch signal
2H circuit 357
504 Br/B Br/GrG/V R/G G
L/R Br/Gr
AWD indicator
(When in 2H, function indication)

CAN LO
CAN HI
6 1 7
G
(When in AWD, function indication) 71 IG
G/W 11 8 9 10 23 13 4 6 3 4WD front axle
8
9
(2H backlight indication) electric clutch controller
Small light
7
(AWD backlight indication) startup signal input Intelligent 4WD 3 2 5
12
520 521 522
GND B/Y Y Y/W
Clutch motor
Clutch switch
2014.01.09
Electrical appliance plug-in

Generator/ Starter/ ECU (4D20 Euto-V)
12A 6A 7A 3F
0.5 3.0 3.0 3.0
15
8A 3H 908F 287A
1.25 3.0 0.5 0.5
Ignition switch Connected to starter control
C A 3 1
1 2 1 50B 173E 4
2 156 157 1 137 114 138 662 663 661 2 A42 A39 3
108 132
l l
Connected to water Connected to Connected to oil Connected to Exhaust temperature
temperature transmitter camshaft sensor temperature transmitter (green) differential pressure sensor transmitter
a
6 2
175 177
2 147 146 1 163 160 454 183 2 187 188 1
47
182109 133
W
5 1
Connected to Connected to Connected to Connected to Connected to engine oil

knock sensor EGR intake pressure transducer crankshaft position sensor pressure transducer
t
3 1
a
1 2
155 173D 136 121 112 158 171 173C 50 402F 142 123
1 0.5 0.5 0.5 173B 176
4 3 2 1
3
re
Connected to flow valve
Connected to EGR cooler Connected to VGT Electronic throttle valve Oil-water separator alarm
(brown)
125 103 102 1 126 1 905B 427B
G
1 1
6.0 4.0
174 104 149 151 428A
2 2 2 2
6.0
Connected to #1 nozzle Connected to #2 nozzle Connected to #3 nozzle Connected to #4 nozzle Radiator fan
12D 400C 418B 416B 417B

12C 12B 12A 0.85 0.85 0.5 0.5
1 4
Connected to glow plug 4 Connected to glow plug 3 Connected to glow plug 2 Connected to glow plug 1 Air flowrate sensor
1 8
1 3 390B 908D 908E A39C 465
2 1 1 903 903C 2 0.5 0.5 0.5 0.5 0.5
0.5 0.5 A42C
159 184186 193 173A 464
511B 463A 0.5 0.5
3 0.5 0.5 4
9 16
Connected to Connected to
Clutch switch Diagnostic socket
rail pressure transducer vacuum valve
404
1 6 6.0
402G 168
432B 429B 431B 430B 434B 433B 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5
405
6.0
Electronic throttle pedal sensor Preheating relay
2014.01.09
2014.01.09
73 96
440A 442A 168 155 447A 193 171 175 177
l
436A 142
0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
l
439A 441A 416A 417A 450A 445 136 133 661 453 112 418A
0.5 0.5 72
0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
a
444A 438A 437A 143 147 146 454A 457A 446 456A 448A 451 663A 460A 132 449A 123
25 0.85 0.85 0.85 0.5 0.5 0.5 0.5 48
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
443A 666A 662A 459A
W 108 158 452 121 182 458A 109 667
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
01 05 10 12 15 20 24
ECU-A
a t
402B 901B 46 358B C42A C39A 356B 423A 403A 422A 211B 58
1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
re
33 455A 359B 425B 421A 426B 461B
0.5 0.5 0.5 0.5 0.5 0.5 45
402C 901C
1.25 1.25
235 429A 430A 431A 357B 432A 66B 465 67C 32
20
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
402D 901D 212A 433A 434A 463B 511C 400B 19
1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.85
G
ECU-B
14-60
ECU 491QE(CNG)
1 10 14 15 28
29 42 43 56
CNG system fuel gas ECU
l l
a
89 93 92 904 904 780 400
0.5 0.5 0.5 0.5 0.5 0.5 0.5
W
CNG rail pressure/temperature transmitter Connected to barometer plug-in
a t 908 780 77
re
0.5 0.5 0.5
904 77
0.5 0.5 138 137 464
0.5 0.5 0.5
Pressure reducer electromagnetic valve Gas displacement display switch
G400C
0.5
465C
0.5
Connected to anti-theft alarm host

903T
0.5
126A
0.5
125A
0.5
908 908
0.5 0.5
47
0.5
Front and rear fog

light switches
908
0.5
42
0.5
71
0.5
112
0.5
113
0.5
111
0.5
CNG system diagnostic interface

114 464
0.5
6 1
86 85 77 77 79 78
1.25 1.25 1.25 1.25 1.25 1.25
Natural gas nozzle
2014.01.09
Lighting/ Signal (4D20 Euto-V)
33B 904B 71E 3 1 3 1 3

1 8C 908Q
1.25 1.25 0.5 67B 909C 71D 908H 73A
2.0 2.0
904C 32B 904D 0.5 0.5 0.5 0.5 0.5
4 6
1.25 1.25 1.25
Right front combination light High-mounted brake light Instrument dimming Connected to the alarm light
1 2 1 3
65C 65B 1 2 55B 53C 54B
1 33C 903B 71D 3 0.85 1.25 0.85
1.25 1.25
1.25 1.25 0.5 903G 96
67A 66A 1.25 1.25 52A 50B 51B 71G 908V
4 903B 32C 903B 6 1.25 0.5 1.25 1.25 0.85 0.5 0.5
1.25 1.25 1.25
3 4 4 8
Left front combination light Brake light switch Left electric horn
l l Alarm switch
1 2
910C 71J
1
904F 96A
2
a 83 81B
W
55C 903K 0.5 0.5 1.25 1.25
0.5 0.5
906C
t
Left side turning light Cigarette lighter illumination light Right electric horn Connected to left front door light switch
a
re
1 2 1 2
97B
55B 903D 81B 80A 0.5 81C
0.5 0.5 0.5 0.5
Left turning light Roof light Electric horn Connected to left rear door light switch
G
1 2 1 3 6 1
84 81D
54C 904H 80 82B 909D 908K 908L 47B 908J 42B 71B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
906D
Connected to
Right side turning light Reading light Front and rear fog light switches (white)
right front door light switch
1 2
56A 57A 908S
54B 904D 82A 80E 0.5 0.5 0.5 81
0.5 0.5 0.5 0.5 908G 72A 34B 35B
0.5 0.5 0.5 0.5
Connected to
Right turning light Keyhole illumination light Combination switch (light)
right rear door light switch
71 908
0.5 0.5 41B 903F
904L 38B 33E 904M 37B 33D
0.5 0.5 0.5 71 38 37 908 0.5 0.5 0.5 1.25 1.25
0.5 0.5 0.5 0.5
Right headlight
Headlight adjusting switch Left headlight upward adjusting Left front fog light
upward adjusting
1 2
41E 904E
61B 60B
1.25 1.25 0.85 0.85
Right front fog light Reverse gear switch
2014.01.09
Airbag/ Central control lock(4D20 Euto-V)
288A 390A 465C 382A 380A

0.5 0.5 0.5 0.5 0.75 351 906F
6 5 4 3 2 1
Connected to airbag harness (yellow) Connected to seat belt detection switch
1 6
1 2 909B 305A 301B 306A 303B 282B 281B

1.25 1.25 1.25 1.25 0.5 0.85 0.85
306B 305B
909C 284A 283B
l
1.25 1.25
1.25 0.5 0.5
l
7 14
a
Connected to the glass lifter Electrical window switch for left front door Fastener
1 4
W
2 1 309A 302B 907B 310A 282 281
1.25 1.25 1.25 1.25 0.85 0.85
312B 311B
303B 283B 284B 907C
1.25 1.25
0.5 0.5 1.25
t
0.5
5 10
a
Glass lifter Electrical window switch for right front door Fastener
re
2 1
1 2 303B 282B 281B

0.5 0.85 0.85
308B 307B
311A 302B 906B 312A 909E 286B
1.25 1.25
1.25 1.25 1.25 1.25 0.5 0.5
G
6 3
Glass lifter Electrical window switch Fastener
1 2
1 2 303B 282 281

0.5 0.85 0.85
310B 309B
1.25 1.25 307A 301B 906B 308A
1.25 1.25 1.25 1.25
3 6
Connected to the glass lifter Electrical window switch for left rear door Fastener
1 10
71L 54D 304 281A 282A 287B 55D 82 286A
0.5 0.85 304A 1.25 1.25 0.5 0.85 82A 0.5
1
289A 350F 907D 280A 288 284 283 83B 84B
0.5 0.5 1.25 1.25 0.5 284A 283A 0.5 0.5
11 22
Central locking controller
2014.01.09
Combination instrument/ ESP/ Electical accessories(4D20 Euto-V)
1 10 20
908N 357A 289B 421B 351B 382B 252D 402B 81C 464C 350C 61C 354B 55C 32B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
73B 914 355B 352B 360B 54C 71F 16A 126B A42A A39A 524B 41B 46B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
21 40
Combination instrument A
1 2 A39F A39A A39C A39B

360A 903M 360A 0.5 0.5 0.5 0.5
0.5 352 A42F A42A A42C A42B
0.5 0.5 0.5 0.5 0.5 0.5
Vacuum alarm Brake fluid level Connected to parking brake switch Short-circuit connector
l l
LO 1 3
90B 90C 160B 162B 161B 1 2
169A 160E
1.25 1.25 0.5 0.85 0.85 0.85
0.5 167A 903E
166B
a
910B 910D 164A 165 170A 904C 0.5
0.5 0.85 0.85 0.5
1.25 1.25 0.5 0.5
HI 4 6
Cigarette lighter Power supply output Combined switch (wiper) Connected to wiper motor Scrubber
252A
0.5
909
0.5
55A
0.5
252A
0.5
t W 907D
0.5
54A
0.5
a
153 151B 154B 153B 152B 155B 909D 150B 151A 152B 153A 154A 155B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
re
Left Right
Electrical rearview mirror switch
electical rearview mirror electical rearview mirror
3 1 1 2 1 2
G
6 1 908S A39C A42C 555A 556A
0.5 0.5 0.5 557A 558A
908M 908M 619B 71C
350C 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
0.5
6 4
Connected to SAS
ESP seitch (black) ABS-FL sensor ABS-FR sensor
(steering angle sensor)
25 26 30 37 38
B39A 350 561 67 560 563
0.5
552 Br/B 0.85 0.5 0.5 0.5 0.5 913
2.5 2.5 1 564 3 350
B42A
0.5 558 562 559 556 564 906H 2 563 4
Br/G 0.5 0.5 0.5 0.5 0.5
551 913
557 555 619
4.0 4.0
0.5 0.5 0.5
1 2 12 13
Connected to yaw sensor
ESP-ECU
2014.01.09
Radio/ Air-conditioning/ Defrosting (4D20 Euro V)
1 4
1 2 207A 902E 71G 350C

252B 909B 0.5 0.5 0.5 0.5
105 106
1.25 1.25 206B 902F 902G 251B 252A
0.85 0.85
0.5 0.5 0.5 0.5 0.5
5 12
Woofer Defrost+ Defrost- Air-conditioning panel
1 3
1 2 205B 204B 203B
204 203 1.25 2.0
105A 106A 1 2 2.0
2.0 2.0
0.5 0.5 902B 202B
3 205 902C 4 2.0 0.5
1.25 0.85
4 6
Tweeter Speed control resistor Blower switch
l l
1 2 1 3 1 203A
2.0
107 108 208A 902D 207B
a
0.85 0.85 201A
0.5 0.5 0.5 2
3.0
Woofer Evaporator temperature controller Blower
W
208B
t
1
1 2 0.5
212A 208B 3 905B A424
115 116 2
0.5 0.5 2.0 2.0
0.85 0.85 211A
a
0.5 4
re
Woofer Tri-state pressure switch Connected to conderser fan
1 2
71E 119A
117 118 0.5 0.5 124
G
0.85 0.85 120A
0.5
Woofer Connected to CD wire controller Connected to air-conditioning clutch
7 1 7 1
115A 105A 107A 117A 80B 119A
0.5 0.5 0.5 0.5 1.25 0.5
116A 106A 108A 118A 908R 71E 100B 120A
0.5 0.5 0.5 0.5 1.25 0.5 1.25 0.5
8 2 8 2
CD A CD B
2014.01.09
Anti-theft/ Electrical heating seat/ 4WD control(4D20 Euto-V)
126B 903B 400D

0.5 0.5 0.5
125B 465
0.85 0.5
Connected to anti-theft alarm host
1 2
316A 315A 315A 316A
1.25 1.25 1.25 1.25
71N 908W 314B 907E
0.5 0.85 2.0 2.0
l
3 4
l
Connected to
Electrical seat heating switch
electrical seat harness
a
1 4 1 6
501C 521A 520A A39D A39E A39F C39A B39A D39A A39A 516A
1.25 1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
W
522A 512C 357B 907C A42D A42E A42F C42A B42A D42A A42A 910H 71H 501D
0.5 0.5 0.5 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
5 9 7 12
t
Front axle clutch controller Short-circuit connector Short-circuit connector Electical 4WD switch
a
1 5
re
903L 522A 16B
1.25 0.5 0.5 504B 350B 304A
520A 521A 350B 1.25 0.5 0.5
1.25 1.25 0.5
3 6
G
Electically controlled clutch Connected to magnetic coil Diode assembly
1 13
5 10
504A 911C 500C
522B 516A 512A A39A A42A 524A 1.25 1.25 1.25
0.5 0.5 0.5 0.5 0.5 0.5
501A
0.5
14 20 26
Connected to TOD assembly
2014.01.09

Manual de Servicio Taller Wingle 5 Diesel

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Manual de Servicio Taller Wingle 5 Diesel

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Preface

: Chapters of this symbol are not contained.

N·m Specific torque

1. Tire pressure monitor sensor 4. Gasket

2. Measuring radial clearance of intermediate shaft 5th

Identification number position

Integrated repair instruction

6. Assemble parts as the regulations in maintenance

8. Parts no longer for use after service

10. Use parts and lubricants produced by original

(b) In order to facilitate reassembling the hose, add

14. Disassemble the hose clip

Trouble shooting instruction on

3. Repair method of harness joint terminal

4. Dismounting of the harness

Fig. 1 5. Check open circuit

(b) Check the resistance.

Fig. 4 (c) Check the voltage.

Fig. 7 (2) Disconnect connector B and measure the

Five-step troubleshooting method

Assembling and disassembling of the clip

Small clip detacher

Model GW4D20B GW4D20A

Transmission and Transfer Case

Model ZM016B (2WD) ZM016BF (4WD)

Front Wheel Alignment (no load)

Wheels and Tires

Working Fluid Filling

Working fluid Limitation Volume

N·m Specified torque 12

1. Catalytic connection pipe gasket 7. Differential pressure sensor

CNG system control

Pressure Reducer Assembly

Change-over Switch and Cover Board

2. Dismantle the switch and the lower cover board of

Intelligent 4WD Transfer Case

Intelligent 4WD Transfer Case

Intelligent 4WD vehicle

Fault Diagnosis and Detection

Cause of fault code failure:

Intelligent 4WD control module

SUSPENSION SYSTEM AND AXLE

Rear Axle Shaft Assembly

Tire Pressure Monitoring System

Rear Axle Shaft Assembly

N·m Specified torque

1. Rear axle 6. Oil seal compressing seat

Parts inspection and maintenance

2. Inspect the outer oil seal

7. Install the circlip

8. Check for any wear or damage on the inner oil seal

2. Install the rear brake disc

Tire Pressure Monitoring System

1. Rearview mirror (tire information 3. Front left seat

N·m Specified torque

1. Tire pressure monitor sensor 4. Gasket

Technical parameters for tire pressure monitor receiver

316 390 390

Pin Definition Maximum current

Rearview Mirror (TPMS Display)

Tire pressure display key Photosensitive diode

Drive radar display reserved

Reverse radar info display reserved

Working voltage DC 9V square battery