Workshop Manual T60

T60/T70 㔪‫ؤ‬ᢁ߂
T60/T70 Service
Workbook
orkbook
2018 Year
Contents
Overview ......................................................................................................... 1-1
Precautions .......................................................................................................................... 1-1
Battery Disconnection ........................................................................................................................................ 1-1
Cooling Fan........................................................................................................................................................ 1-1
Moving Parts and Hot Surfaces ......................................................................................................................... 1-1
Radiator Cover Removal.................................................................................................................................... 1-1
Fuel Pressure Relief .......................................................................................................................................... 1-1
Vehicle Lifting..................................................................................................................................................... 1-1
Window Removal ............................................................................................................................................... 1-1
Drive Belt Repair................................................................................................................................................ 1-1
Fasteners ........................................................................................................................................................... 1-1
Power Steering Fluid.......................................................................................................................................... 1-1
General ........................................................................................................... 2-1

General ................................................................................................................................ 2-1
Specification....................................................................................................................................................... 2-1
Front/Rear Ventilated Disc Brake ...................................................................................................................... 2-2
Technical Parameters ........................................................................................................................................ 2-3
Fuel, Lubricant, Fluid ....................................................................................................................................... 2-10
Service and Maintenance................................................................................................... 2-11
Engine Mechanical System ............................................................................. 3-1

Specification......................................................................................................................... 3-1
Torque................................................................................................................................................................ 3-5
Layout .................................................................................................................................. 3-7
Troubleshooting ................................................................................................................. 3-12
Special Tool ....................................................................................................................... 3-17
Repair Guidance ................................................................................................................ 3-20

Replacement of Front-end Accessory Drive Belt ............................................................................................. 3-20
Replacement of Timing Belt............................................................................................................................. 3-20
Replacement of Timing Pulley Chamber and Shock Pad ................................................................................ 3-26
Replacement of Gear Chamber Casing........................................................................................................... 3-29
Individual Replacement of Front Oil Seal......................................................................................................... 3-31
Replacement of Crankshaft Front Oil Seal ...................................................................................................... 3-32
Replacement of Oil Pump ................................................................................................................................ 3-33
Replacement of Vacuum Pump ....................................................................................................................... 3-34
Replacement of Camshaft Oil Seal.................................................................................................................. 3-37
Replacement of Upper cylinder Head and Gasket........................................................................................... 3-39
Contents
Replacement of Camshaft................................................................................................................................ 3-44
Replacement of Cylinder Head and Gasket ..................................................................................................... 3-47
Replacement of Flywheel Ring Gear Components (Including the Dual-mass Flywheel) ................................. 3-53
Troubleshooting Method for Dual-mass Flywheel: ........................................................................................... 3-54
Replacement of Crankshaft Rear Oil Seal ....................................................................................................... 3-55
Replacement of Crankshaft.............................................................................................................................. 3-57
Replacement of Front Main Bearing................................................................................................................. 3-64
Replacement of Cylinder Sleeve and its Adjusting Pad ................................................................................... 3-65
Replacement of Piston and Connecting Rods.................................................................................................. 3-67
Replacement of Oil Filter.................................................................................................................................. 3-69
Engine Oil Drain ............................................................................................................................................... 3-70
Removal & Installation of Injection Pump Bracket............................................................................................ 3-70
Replacement of Engine Assembly ................................................................................................................... 3-71
Turbocharger Removal/Installation .................................................................................................................. 3-73
Removal/reinstallation of Turbocharger (European Stage V)........................................................................... 3-75
Electronic Throttle Removal/Installation ........................................................................................................... 3-75
Replacement of Glow Plug Controller .............................................................................................................. 3-76
Precautions for Installing Flywheel onto the Short-stroke Engine Maintenance .............................................. 3-76
Timing Failure Judgment.................................................................................................................................. 3-77
Engine Cooling System................................................................................... 4-1

Specification.......................................................................................................................... 4-1
Torque ................................................................................................................................................................ 4-1
Layout ................................................................................................................................... 4-2
Troubleshooting .................................................................................................................... 4-7
Repair Guidance ................................................................................................................... 4-8

Replacement of Thermostat ............................................................................................................................... 4-8
Replacement of Water Pump ............................................................................................................................. 4-8
Replacement of EGR Cooler (China Stage IV Standard)................................................................................... 4-9
Replacement of EGR Cooler (China Stage V Standard).................................................................................. 4-12
Replacement of Coolant................................................................................................................................... 4-13
Replacement of Expansion Tank Cap.............................................................................................................. 4-14
Replacement of Cooling Module ...................................................................................................................... 4-15
Replacement of Radiator.................................................................................................................................. 4-18
Replacement of Cooling Fan............................................................................................................................ 4-19
Engine Electrical System ................................................................................ 5-1

Specification.......................................................................................................................... 5-1
Torque ................................................................................................................................................................ 5-1
Contents
Layout .................................................................................................................................. 5-2
Troubleshooting ................................................................................................................... 5-4
Repair Guidance .................................................................................................................. 5-5

Replacement of Battery ..................................................................................................................................... 5-5
Replacement of Starter Motor............................................................................................................................ 5-5
Replacement of Alternator ................................................................................................................................. 5-6
Description and Operation ................................................................................................... 5-8

Battery................................................................................................................................................................ 5-8
Battery Usage and Maintenance .......................................................................................... 5-8

Safe Operation................................................................................................................................................... 5-8
Battery Maintenance Requirements:.................................................................................................................. 5-9
Battery Recharging .......................................................................................................................................... 5-11
Battery Failure Judgment................................................................................................................................. 5-13
Engine Controls............................................................................................... 6-1

Specification......................................................................................................................... 6-1
Torque................................................................................................................................................................ 6-5
Layout .................................................................................................................................. 6-6
Repair Guidance .................................................................................................................. 6-8

Replacement of Engine Harness ....................................................................................................................... 6-8
Replacement of Engine Coolant Temperature Sensor ...................................................................................... 6-9
Replacement of Oil Pressure Alarm Switch ....................................................................................................... 6-9
Replacement of Speed Sensor ........................................................................................................................ 6-10
Replacement of Camshaft Position Sensor ..................................................................................................... 6-10
Replacement of Common Rail ......................................................................................................................... 6-11
Replacement of Engine Control Module (ECM)............................................................................................... 6-11
Replacement of Glow Plug .............................................................................................................................. 6-13
Replacement of Accelerator Pedal Assembly.................................................................................................. 6-14
Fuel System .................................................................................................... 7-1

Specification......................................................................................................................... 7-1
Torque................................................................................................................................................................ 7-1
Layout .................................................................................................................................. 7-2
Repair Guidance .................................................................................................................. 7-6

Fuel System Fuel Pumping................................................................................................................................ 7-6
Replacement of Fuel Filter Element................................................................................................................... 7-6
Replacement of Fuel Tank Assembly ................................................................................................................ 7-7
Contents
Replacement of Fuel Pump Level Sensor Float................................................................................................. 7-8
Replacement of Fuel Pump Level Sensor.......................................................................................................... 7-9
Replacement of Injector ................................................................................................................................... 7-10
Replacement of High-pressure Fuel Pump ...................................................................................................... 7-12
Engine Fuel System 20L4E............................................................................. 8-1

Specification.......................................................................................................................... 8-1
Torque ................................................................................................................................................................ 8-1
Layout ................................................................................................................................... 8-2
Diagnostic Information and Procedures................................................................................ 8-5
Service Guide ....................................................................................................................... 8-6

Replacement of Fuel Tank Assembly................................................................................................................. 8-6
Replacement of Fuel Pump Level Sensor Float................................................................................................. 8-7
Replacement of Fuel Pump Level Sensor.......................................................................................................... 8-9
Description and Operation 9
Intake and Exhaust System ............................................................................ 9-1

Specification.......................................................................................................................... 9-1
Torque ................................................................................................................................................................ 9-1
Layout ................................................................................................................................... 9-2

Replacement of Mass Air Flow Meter ................................................................................................................ 9-4
Replacement of Air Filter Intake Passage Assembly ......................................................................................... 9-4
Replacement of Air Filter Assembly ................................................................................................................... 9-5
Replacement of Catalyst Assembly (China IV) .................................................................................................. 9-5
Replacement of Catalyst Assembly (China V) ................................................................................................... 9-6
Replacement of Muffler Assembly...................................................................................................................... 9-6
Catalyst .............................................................................................................................................................. 9-7
Engine Intake/Exhaust System 20L4E.......................................................... 10-1

Specification........................................................................................................................ 10-1
Torque .............................................................................................................................................................. 10-1
Layout ................................................................................................................................. 10-2

Replacement of Air Flow Meter ........................................................................................................................ 10-4
Replacement of Air Filter Intake Passage Assembly ....................................................................................... 10-4
Replacement of Air Filter Assembly ................................................................................................................. 10-5
Replacement of Air Filter Exhaust Passage Assembly .................................................................................... 10-5
Replacement of Front Catalytic Converter Assembly....................................................................................... 10-6
Replacement of Exhaust Pipe Assembly Bracket ............................................................................................ 10-7
Contents
Replacement of Rear Catalytic Converter Assembly ....................................................................................... 10-8
Replacement of Muffler Assembly ................................................................................................................... 10-9
Description and Operation ............................................................................................... 10-10

Catalyst .......................................................................................................................................................... 10-10
Air Intake System........................................................................................................................................... 10-12
Exhaust System ............................................................................................................................................. 10-12
5MT ............................................................................................................... 11-1

Technical Parameters ........................................................................................................ 11-1
Torque.............................................................................................................................................................. 11-1
Precautions ........................................................................................................................ 11-2

Precautions for Transmission Removal/Installation ......................................................................................... 11-2
Troubleshooting ................................................................................................................. 11-2
Layout ................................................................................................................................ 11-4
Repair Guidance .............................................................................................................. 11-14

Transmission Assembly Removal.................................................................................................................. 11-14
Replacement of Input Shaft Subassembly..................................................................................................... 11-22
Output Shaft Subassembly Removal ............................................................................................................. 11-25
Component Test Before Output Shaft Installation ......................................................................................... 11-27
Output Shaft Subassembly Installation .......................................................................................................... 11-29
Intermediate Shaft Subassembly Removal.................................................................................................... 11-34
Intermediate Shaft Subassembly Installation................................................................................................. 11-34
Rear body subassembly Removal ................................................................................................................. 11-35
Component Test before Rear Body Subassembly Installation ...................................................................... 11-36
Rear body subassembly Installation .............................................................................................................. 11-37
Front Cover Component Removal ................................................................................................................. 11-38
Front Cover Component Installation .............................................................................................................. 11-38
Transmission Assembly Installation ............................................................................................................... 11-38
Removal/Installation of Transmission Assembly............................................................................................ 11-51
Tool .................................................................................................................................. 11-53
6AT................................................................................................................ 12-1
Specification....................................................................................................................... 12-1
Torque.............................................................................................................................................................. 12-1
Layout ................................................................................................................................ 12-3
Service ............................................................................................................................... 12-9
Repair Guidance .............................................................................................................. 12-10

Transmission Drain & Oil Pan Removal......................................................................................................... 12-10
Contents
Oil Pan Installation ......................................................................................................................................... 12-11
Removal/Installation of Transmission Fluid Filler Rubber Plug ...................................................................... 12-12
Transmission Fluid Level Adjustment............................................................................................................. 12-13
Transmission Fluid Level Check .................................................................................................................... 12-14
Hydraulic Torque Converter Removal ............................................................................................................ 12-15
Hydraulic Torque Converter Installation ......................................................................................................... 12-17
Oil Filter Edge Seal Removal ......................................................................................................................... 12-18
Oil Filter Bush Seal Installation ...................................................................................................................... 12-19
Electric Component Removal......................................................................................................................... 12-20
Precautions for Electro Static Discharge (ESD) ............................................................................................. 12-23
Electric Component Installation...................................................................................................................... 12-23
Gear Selector and Seal Removal................................................................................................................... 12-26
Gear Selector Shaft and Seal Installation ...................................................................................................... 12-27
AWD Output Shaft O-ring Removal/Installation ............................................................................................. 12-28
Shift Connector Adjustment............................................................................................................................ 12-29
Transmission Adjustment ............................................................................................................................... 12-31
Automatic Transmission Assembly Removal/Installation ............................................................................... 12-34
Special Tool ...................................................................................................................... 12-36
DYMOS 6MT................................................................................................. 13-1

Technical Parameters ......................................................................................................... 13-1
Service Standard.............................................................................................................................................. 13-1
Snap Ring and Gasket for Adjustment ............................................................................................................. 13-2
Tightening Torque ............................................................................................................................................ 13-4
Layout ................................................................................................................................. 13-6
Repair Guidance ................................................................................................................. 13-7

Removal/Installation of Transmission Assembly .............................................................................................. 13-7
Replacement of Manual Transmission ............................................................................................................. 13-9
Installation of Subparts (Bush & Bearing & Flange) ....................................................................................... 13-42
Special Tool ...................................................................................................................... 13-44
SAGW 6MT ................................................................................................... 14-1

Overview ............................................................................................................................. 14-1
Overview and Characteristic of Transmission Assembly ................................................................................. 14-1
Transmission Assembly Specifications ............................................................................................................ 14-5
Transmission Assembly Structure Detail .......................................................................... 14-10

Transmission Assembly Exploded View......................................................................................................... 14-10
Power Flow Chart........................................................................................................................................... 14-16
Expanded Product Identification..................................................................................................................... 14-23
Contents
Repair Guidance .............................................................................................................. 14-26
Removal/Installation of Transmission Assembly............................................................................................ 14-26
Transmission Removal .................................................................................................................................. 14-28
Check before Transmission Installation ......................................................................................................... 14-37
Transmission Installation ............................................................................................................................... 14-38
Special Tool ..................................................................................................................... 14-50
SC25M(B)5 Transmission ............................................................................. 15-1

Overview ............................................................................................................................ 15-1
Overview and Characteristics of Transmission Assembly ............................................................................... 15-1
Parameters ...................................................................................................................................................... 15-3
Torque.............................................................................................................................................................. 15-4
Cementing Agent ............................................................................................................................................. 15-5
Disposable Parts.............................................................................................................................................. 15-6
System Structure Diagram............................................................................................................................... 15-7
Transmission Assembly Exploded View .......................................................................................................... 15-9
Power Flow Chart .......................................................................................................................................... 15-17
Expanded Product Identification .................................................................................................................... 15-23
Others ............................................................................................................................................................ 15-26
Common Troubleshooting.............................................................................................................................. 15-27
Repair Guides .................................................................................................................. 15-29

Removal/Installation of Manual Transmission ............................................................................................... 15-29
Check Before Assembly................................................................................................................................. 15-37
Special Tools.................................................................................................................... 15-49
Clutch ............................................................................................................ 16-1

Specification....................................................................................................................... 16-1
Layout ................................................................................................................................ 16-2
Diagnostic Information and Procedures ............................................................................. 16-3
Repair Guidance ................................................................................................................ 16-5

Replacement of Clutch Cover/Clutch Disc....................................................................................................... 16-5
Replacement of Clutch Main Pump ................................................................................................................. 16-5
Replacement of Clutch Pedal .......................................................................................................................... 16-6
Replacement of Clutch Pedal Position Sensor ................................................................................................ 16-6
Replacement of Clutch CSC Bleed Connector .............................................................................................. 16-10
Air Exhaust of Hydraulic Clutch ..................................................................................................................... 16-10
Steering System ............................................................................................ 17-1

Contents
Specification........................................................................................................................ 17-1
Torque .............................................................................................................................................................. 17-1
Layout ................................................................................................................................. 17-2
Repair Guidance ................................................................................................................. 17-4

Drain of Power Steering Hydraulic System ...................................................................................................... 17-4
Replacement of Steering Column Assembly.................................................................................................... 17-4
Replacement of Steering Intermediate Shaft ................................................................................................... 17-5
Replacement of Power Steering Gear Assembly and Steering Intermediate Shaft Extension ........................ 17-5
Replacement of Steering Gear Outer Rod ....................................................................................................... 17-7
Replacement of Steering Gear Dust Shield ..................................................................................................... 17-8
Replacement of Power Steering Pump (VM2.8 Engine) .................................................................................. 17-8
Replacement of Power Steering Pump (Mitsubishi 2.4 Engine)....................................................................... 17-9
Steering Pipeline ............................................................................................................................................ 17-10
Special Tool ...................................................................................................................... 17-11
Description and Operation ................................................................................................ 17-11

Steering Column............................................................................................................................................. 17-11
Power Steering Gear...................................................................................................................................... 17-11
Power Steering Fluid Reservoir...................................................................................................................... 17-12
Power Steering Fluid Flow ............................................................................................................................. 17-12
Steering Wheel.............................................................................................. 18-1

Torque .............................................................................................................................................................. 18-1
Layout ................................................................................................................................. 18-2

Repair Guidance ................................................................................................................. 18-3
Replacement of Steering Wheel....................................................................................................................... 18-3
Front Suspension .......................................................................................... 19-1

Specification........................................................................................................................ 19-1
Torque .............................................................................................................................................................. 19-1
Layout ................................................................................................................................. 19-2
Repair Guidance ................................................................................................................. 19-8

Four-Wheel Alignment...................................................................................................................................... 19-8
Front Wheel Alignment..................................................................................................................................... 19-8
Replacement of Front Suspension Upper Swing Arm Assembly ..................................................................... 19-9
Replacement of Front Lower Swing Arm Assembly ......................................................................................... 19-9
Lower Swing Arm Bumper Block.................................................................................................................... 19-11
Replacement of Front Lower Swing Arm Bushing.......................................................................................... 19-11
Contents
Replacement of Front Horizontal Stabilizer Bar............................................................................................. 19-12
Replacement of Front Shock Absorber Assembly ......................................................................................... 19-13
Replacement of Front Shock Absorber Assembly Component...................................................................... 19-13
Replacement of Front Steering Knuckle ........................................................................................................ 19-14
Special Tool ..................................................................................................................... 19-15
Rear Suspension........................................................................................... 20-1

Specification....................................................................................................................... 20-1
Torque.............................................................................................................................................................. 20-1
Layout ................................................................................................................................ 20-2
Repair Guidance ................................................................................................................ 20-6

Replacement of Rear Shock Absorber ............................................................................................................ 20-6
Replacement of Rear Leaf Spring.................................................................................................................... 20-6
Special Tool ....................................................................................................................... 20-8
Description and Operation ................................................................................................. 20-8
Tires and Wheels .......................................................................................... 21-1

Specification....................................................................................................................... 21-1
Torque.............................................................................................................................................................. 21-1
Tire Parameters ............................................................................................................................................... 21-1
Layout ................................................................................................................................ 21-2

Repair Guidance ................................................................................................................ 21-5
Replacement of Wheels................................................................................................................................... 21-5
Replacement of Spare Tire .............................................................................................................................. 21-6
Brake System ................................................................................................ 22-1

Specification....................................................................................................................... 22-1
Technical Parameters ...................................................................................................................................... 22-1
Torque.............................................................................................................................................................. 22-3
Layout ................................................................................................................................ 22-4
Repair Guidance .............................................................................................................. 22-11

Brake Disc Check .......................................................................................................................................... 22-11
Brake System Drain ....................................................................................................................................... 22-12
Contents
Adjustment of Parking Brake Handle Assembly............................................................................................. 22-13
Replacement of Front and Rear Brake Linings .............................................................................................. 22-15
Replacement of Front and Rear Brake Calipers ............................................................................................ 22-16
Replacement of Front Brake Disc .................................................................................................................. 22-16
Replacement of Rear Brake Disc/Brake Drum............................................................................................... 22-17
Replacement of Rear Parking Brake Shoe .................................................................................................... 22-18
Replacement of Rear Drum Brake ................................................................................................................. 22-19
Replacement of Brake Master Cylinder and Brake Fluid Reservoir ............................................................... 22-20
Replacement of Vacuum Booster Assembly .................................................................................................. 22-20
Replacement of ABS/ESP Regulator ............................................................................................................. 22-21
Replacement of Brake Pedal Assembly ......................................................................................................... 22-23
Replacement of Brake Pedal Position Sensor ............................................................................................... 22-24
Removal & installation of Yaw Angle Sensor/G-sensor ................................................................................. 22-24
Replacement of Brake Pipeline ...................................................................................................................... 22-25
Replacement of Parking Brake Cable ............................................................................................................ 22-25
Replacement of Parking Brake Handle .......................................................................................................... 22-26

Brake System ................................................................................................................................................. 22-27
Vacuum Booster Assembly ............................................................................................................................ 22-28
Brake Master Cylinder Assembly ................................................................................................................... 22-29
Front Brake..................................................................................................................................................... 22-30
Rear Brake ..................................................................................................................................................... 22-31
ABS System ................................................................................................................................................... 22-37
ESP System ................................................................................................................................................... 22-38
Wheel Speed Sensor ..................................................................................................................................... 22-39
G Sensor ........................................................................................................................................................ 22-39
Stroke Position Sensor................................................................................................................................... 22-39
Yaw Speed Sensor......................................................................................................................................... 22-39
Steering Angle Sensor ................................................................................................................................... 22-39
EBD System ................................................................................................................................................... 22-39
TCS System ................................................................................................................................................... 22-39
VDC System................................................................................................................................................... 22-39
EBA ................................................................................................................................................................ 22-39
RMI................................................................................................................................................................. 22-39
HHC................................................................................................................................................................ 22-39
HDC................................................................................................................................................................ 22-40
Transfer Case ............................................................................................... 23-1

Specification........................................................................................................................ 23-1
Torque .............................................................................................................................................................. 23-1
Layout ................................................................................................................................. 23-2
Troubleshooting .................................................................................................................. 23-5

General Inspection Process ............................................................................................................................. 23-5
Contents
Specific Inspection Process ............................................................................................................................. 23-5
Gear/Sprocket Tooth Check ............................................................................................................................ 23-5
Spline Tooth Check.......................................................................................................................................... 23-6
4-3 Service/Replacement................................................................................................................................. 23-6
Gear/Sprocket Tooth Service........................................................................................................................... 23-6
Repair Guidance .............................................................................................................. 23-10

Replacement of Transfer Case Assembly ..................................................................................................... 23-10
TCCU Replacement....................................................................................................................................... 23-12
Transfer Case Removal ................................................................................................................................. 23-12
Removal of Transfer Case Electric Shift Component .................................................................................... 23-13
Rear Housing Removal.................................................................................................................................. 23-14
4WD Shift Component Removal .................................................................................................................... 23-15
Chain Drive System Removal ........................................................................................................................ 23-15
Rear Output Shaft/Pump Subassembly Removal.......................................................................................... 23-16
Deceleration Shift Component Removal........................................................................................................ 23-16
Front Output Shaft Subassembly Removal.................................................................................................... 23-17
Shift Cam Mechanism Removal..................................................................................................................... 23-17
Removal of Front Housing/Output Shaft/Planet Mechanism Subassembly................................................... 23-18
Transfer Case Installation .............................................................................................................................. 23-19
Installation of Front Transfer Case Housing Subassembly............................................................................ 23-19
Installation of Front Housing/Input Shaft Subassembly/Planet Mechanism................................................... 23-21
Front Output Shaft Installation ....................................................................................................................... 23-22
Electric Shift Cam Installation ........................................................................................................................ 23-23
Deceleration Shift Component Installation..................................................................................................... 23-24
Output Shaft/Pump Subassembly Installation................................................................................................ 23-24
Chain Drive System Installation ..................................................................................................................... 23-25
Installation of 4WD Shift Component/Shift Lock Mechanism......................................................................... 23-25
Installation of Rear Transfer Case Housing Subassembly ............................................................................ 23-26
Installation of Transfer Case Housing Subassembly ..................................................................................... 23-27
Shift Motor Subassembly Installation............................................................................................................. 23-28
Rear Flange Component Installation & Lubricant Refill ................................................................................. 23-29
Installation of Transfer Case Transitional Housing (with AT)......................................................................... 23-30
Special Tool ..................................................................................................................... 23-31

Internal Structure of Transfer Case................................................................................................................ 23-32
Description of Transfer Case Function .......................................................................................................... 23-33
Transfer Case Power Flow ............................................................................................................................ 23-33
2H Power Flow Chart..................................................................................................................................... 23-34
4H Power Flow Chart..................................................................................................................................... 23-36
4L Power Flow Chart ..................................................................................................................................... 23-38
Propeller Shaft .............................................................................................. 24-1

Contents
Specification........................................................................................................................ 24-1
Torque .............................................................................................................................................................. 24-1
Layout ................................................................................................................................. 24-2
Repair Guidance ................................................................................................................. 24-6

Replacement of Front Drive Shaft Assembly (4WD) ........................................................................................ 24-6
Replacement of Constant-velocity Universal Joint and its Dust Shield ............................................................ 24-7
Replacement of Tripod Universal Joint and its Dust Shield ............................................................................. 24-8
Replacement of Propeller Shaft ....................................................................................................................... 24-9
Replacement of Cross Shaft .......................................................................................................................... 24-10
Replacement of Intermediate Support of Propeller Shaft............................................................................... 24-11
Front Axle and Rear Axle .............................................................................. 25-1

Specification........................................................................................................................ 25-1
Torque .............................................................................................................................................................. 25-1
Layout ................................................................................................................................. 25-2
Repair Guidance ................................................................................................................. 25-6

Replacement of Front Axle Assembly .............................................................................................................. 25-6
Replacement of Rear Axle Assembly............................................................................................................... 25-7
Refill & Drain of Front Axle Lubricant ............................................................................................................... 25-8
Replacement of Front Axle Drive Gear Flange and Drive Gear Oil Seal ......................................................... 25-8
Replacement of Front Axle Rim Oil Seal and Needle Bearing ....................................................................... 25-10
Replacement of Front Axle Half-shaft Clutch Assembly................................................................................. 25-11
Replacement of Front Axle Output Shaft........................................................................................................ 25-12
Replacement of Front Axle Bracket................................................................................................................ 25-13
Replacement of Front Axle Final Drive Assembly .......................................................................................... 25-13
Refill & Drain of Rear Axle Lubricant.............................................................................................................. 25-20
Replacement of Rear Axle Drive Gear Flange and Drive Gear Oil Seal ........................................................ 25-21
Replacement of Rear Axle Half Shaft Assembly ............................................................................................ 25-22
Replacement of Rear Axle Final Drive Assembly........................................................................................... 25-24
Rear Axle Final Drive Assembly..................................................................................................................... 25-25
Special Tool ...................................................................................................................... 25-33

Front Axle and Rear Axle ............................................................................................................................... 25-35
Front Axle Half Shaft Clutch (optional) ........................................................................................................... 25-35
Front and rear axle speed ratio ...................................................................................................................... 25-35
Eaton Differential Lock ................................................................................................................................... 25-36
Exteriors ........................................................................................................ 26-1

Contents
Torque.............................................................................................................................................................. 26-1
Layout ................................................................................................................................ 26-2
Repair Guidance ................................................................................................................ 26-4

Replacement of Front Grille ............................................................................................................................. 26-4
Replacement of Windshield Plate .................................................................................................................... 26-4
Replacement of Front Wheelhouse Liner ........................................................................................................ 26-5
Replacement of Rear Wheelhouse Liner ......................................................................................................... 26-5
Replacement of Front Mudguard ..................................................................................................................... 26-6
Replacement of Rear Mudguard...................................................................................................................... 26-6
Replacement of Side Fixed Courtesy .............................................................................................................. 26-7
Replacement of Cargo Compartment .............................................................................................................. 26-7
Replacement of Roof Rack .............................................................................................................................. 26-8
Replacement of Cargo Compartment Trim ...................................................................................................... 26-8
Driver Compartment Interiors and Switches.................................................. 27-1

Specification....................................................................................................................... 27-1
Torque.............................................................................................................................................................. 27-1
Layout ................................................................................................................................ 27-2
Repair Guidance ................................................................................................................ 27-7

Replacement of Front Door Interior Trim Panel ............................................................................................... 27-7
Replacement of Rear Door Interior Trim Panel................................................................................................ 27-7
Replacement of Courtesy Trim Panel .............................................................................................................. 27-7
Replacement of Driver Compartment Roof Interior Assembly ......................................................................... 27-8
Replacement of A-pillar Upper Trim Panel ...................................................................................................... 27-8
Replacement of A-pillar Lower Trim Panel ...................................................................................................... 27-9
Replacement of B-pillar Trim Panels ............................................................................................................... 27-9
Replacement of C-pillar Trim Panels ............................................................................................................. 27-10
Replacement of Front Passenger and Driver Roof Handles.......................................................................... 27-11
Replacement of Pillar Handle ........................................................................................................................ 27-11
Replacement of Rear Trim Panel and Upper & Lower Guard Plates of Rear Seat Belts .............................. 27-11
Replacement of Footrest Assembly ............................................................................................................... 27-11
Replacement of Glove Box Assembly............................................................................................................ 27-12
Replacement of Instrument Panel Side End Cover Assembly....................................................................... 27-12
Replacement of Driver Side Lower Guard Plate Assembly ........................................................................... 27-13
Replacement of Central Control Panel Assembly of Instrument Panel.......................................................... 27-13
Replacement of Instrument Cluster Shroud Assembly .................................................................................. 27-14
Replacement of Instrument Panel Side Air Outlet Panel Assembly............................................................... 27-14
Replacement of Instrument Panel Loudspeaker Grille .................................................................................. 27-15
Replacement of Radio Lower Storage Bo...................................................................................................... 27-15
Replacement of Glove Box Side Trim Panel Assembly ................................................................................. 27-16
Replacement of Front Passenger Airbag Cover Plate ................................................................................... 27-16
Contents
Replacement of Upper and Lower Steering Column Shrouds ....................................................................... 27-17
Replacement of Instrument Cluster................................................................................................................ 27-17
Replacement of Instrument Panel Body......................................................................................................... 27-18
Replacement of Instrument Panel Beam........................................................................................................ 27-19
Replacement of Auxiliary Fascia Console...................................................................................................... 27-20
Replacement of Auxiliary Fascia Console Cup Holder................................................................................... 27-21
Replacement of Auxiliary Fascia Console Molding ........................................................................................ 27-21
Replacement of Ashtray Assembly ................................................................................................................ 27-22
Replacement of Shift Lever Guard Plate Assembly ....................................................................................... 27-22
Replacement of Rear Panel Assembly of the Auxiliary Fascia Console ........................................................ 27-23
Replacement of Front Handbrake Cover Plate .............................................................................................. 27-23
Replacement of Left & Right Forward Extending Plate Assembly of the Auxiliary Fascia Console ............... 27-23
Replacement of Combination Switch Assembly............................................................................................. 27-24
Replacement of Dimmer Switch Assembly .................................................................................................... 27-24
Replacement of Start-stop Switch .................................................................................................................. 27-25
Replacement of Entertainment Control Switch............................................................................................... 27-25
Replacement of Hazard Warning Lamp Switch Assembly ............................................................................. 27-26
Replacement of Drive Conversion Switch Assembly ..................................................................................... 27-26
Replacement of Driver Side Window Regulator Switch Assembly................................................................. 27-26
Replacement of Central Control Switch Block Assembly ............................................................................... 27-27
Replacement of Rearview Mirror Regulating Switch ...................................................................................... 27-27
Seats ............................................................................................................. 28-1

Torque .............................................................................................................................................................. 28-1
Layout ................................................................................................................................. 28-2

Repair Guidance ................................................................................................................. 28-3
Replacement of Driver Seat and Front Passenger Seat .................................................................................. 28-3
Replacement of Rear Seats ............................................................................................................................. 28-4
Seat Belt........................................................................................................ 29-1

Torque .............................................................................................................................................................. 29-1
Repair Guidance ................................................................................................................. 29-2

Precautions for handling expanded pretightening seat belt or lap belt pretensioner........................................ 29-2
Precautions for handling unexpanded pretightening seat belt or lap belt pretensioner.................................... 29-2
Replacement of Driver/Front Passenger Seat Belt (Without Lap Belt Pretensioner) ....................................... 29-2
Replacement of Driver/Front Passenger Seat Belt (With Lap Belt Pretensioner) ............................................ 29-3
Replacement of Height Regulator .................................................................................................................... 29-5
Replacement of Lap Belt Pretensioner (If Any) ................................................................................................ 29-5
Contents
Replacement of Rear Seat Belt ....................................................................................................................... 29-6
Replacement of Front/Rear Seat Belt Buckle .................................................................................................. 29-7
Special Tool ....................................................................................................................... 29-7

Seat Belt Check/Test ....................................................................................................................................... 29-8
Rear Body ..................................................................................................... 30-1

Torque.............................................................................................................................................................. 30-1
Layout ................................................................................................................................ 30-2
Repair Guidance ................................................................................................................ 30-4

Rear Panel Replacement................................................................................................................................. 30-4
Rear Bumper Assembly Replacement............................................................................................................. 30-5
Entertainment System ................................................................................... 31-1

Layout ................................................................................................................................ 31-1
Repair Guidance ................................................................................................................ 31-2

Replacement of Radio+MP3 ............................................................................................................................ 31-2
Replacement of MP5 display ........................................................................................................................... 31-2
Replacement of Radio+MP5+Mirrorlink ........................................................................................................... 31-3
Replacement of Printed Antenna Amplifier ...................................................................................................... 31-3
Replacement of Front Loudspeaker................................................................................................................. 31-4
Replacement of Rear Loudspeaker ................................................................................................................. 31-4
Replacement of Front Loudspeaker (Treble) ................................................................................................... 31-5
Front Body..................................................................................................... 32-1

Torque.............................................................................................................................................................. 32-1
Layout ................................................................................................................................ 32-2
Repair Guidance ................................................................................................................ 32-5

Replacement of Engine Hood .......................................................................................................................... 32-5
Replacement of Fender ................................................................................................................................... 32-5
Replacement of Front Bumper Assembly ........................................................................................................ 32-6
Frame ............................................................................................................ 33-1

Contents
Torque .............................................................................................................................................................. 33-1
Layout ................................................................................................................................. 33-2
Repair Guidance ............................................................................................................... 33-14

Mount Installation ........................................................................................................................................... 33-14
Upper Soft Gasket Identification..................................................................................................................... 33-14
Lower Soft Gasket Identification..................................................................................................................... 33-15
Limit Sleeve Identification............................................................................................................................... 33-15
Stationary Windows ...................................................................................... 34-1

Layout ................................................................................................................................. 34-1
Repair Guidance ................................................................................................................. 34-3

Replacement of Front Door Glass.................................................................................................................... 34-3
Replacement of Rear Door Glass .................................................................................................................... 34-3
Replacement of Windshield.............................................................................................................................. 34-4
Replacement of Rear Window.......................................................................................................................... 34-5
Door .............................................................................................................. 35-1

Torque .............................................................................................................................................................. 35-1
Layout ................................................................................................................................. 35-2
Repair Guidance ................................................................................................................. 35-7

Replacement of Front Door/Hinge.................................................................................................................... 35-7
Replacement of Rear Door/Hinge .................................................................................................................... 35-8
Replacement of Front Door Lock Assembly..................................................................................................... 35-9
Replacement of Front Door Lock Catch ......................................................................................................... 35-10
Replacement of Rear Door Lock Assembly ................................................................................................... 35-10
Replacement of Rear Door Lock Catch Assembly ......................................................................................... 35-11
Replacement of Rear Panel Lock Assembly .................................................................................................. 35-12
Replacement of Rear Panel Lock Catch Assembly........................................................................................ 35-12
Replacement of Engine Hood Lock Assembly ............................................................................................... 35-13
Replacement of Front/Rear Door Outer Handle............................................................................................. 35-13
Replacement of Front/Rear Door Inner Handle.............................................................................................. 35-14
Replacement of Rear Panel Outer Handle Assembly .................................................................................... 35-14
Replacement of Exterior Mirror ...................................................................................................................... 35-15
Replacement of Front Door Glass Regulator Assembly................................................................................. 35-16
Replacement of Rear Door Glass Regulator Assembly ................................................................................. 35-17
Replacement of Fuel Filler Flap Assembly..................................................................................................... 35-18
Supplemental Inflatable Restraint (SIR)........................................................ 36-1

Contents
Specification....................................................................................................................... 36-1
Torque.............................................................................................................................................................. 36-1
Layout ................................................................................................................................ 36-2
Repair Guidance ................................................................................................................ 36-5

Replacement of Airbag Control Module ........................................................................................................... 36-5
Replacement of Airbag Front Impact Sensor................................................................................................... 36-5
Replacement of Airbag Side Impact Sensor .................................................................................................... 36-6
Replacement of Driver Airbag Assembly ......................................................................................................... 36-6
Replacement of Instrument Panel (front passenger) Airbag Assembly ........................................................... 36-7
Replacement of Curtain Airbag Assembly ....................................................................................................... 36-7
Body Control System .................................................................................... 37-1

Layout ................................................................................................................................ 37-1
Repair Guidance ................................................................................................................ 37-4

Replacement of Body Control Module ............................................................................................................. 37-4
Replacement of Trailer Module........................................................................................................................ 37-4
Replacement of Gateway................................................................................................................................. 37-5
Replacement of LDWS Control Module ........................................................................................................... 37-6
Replacement of Rain/Solar Sensor.................................................................................................................. 37-7

Function Description ........................................................................................................................................ 37-8
Instrument Warning Lamp................................................................................................................................ 37-8
PEPS and Immobilizer System ..................................................................... 38-1

PEPS-ECU Parameters ................................................................................................................................... 38-1
RKE Parameters .............................................................................................................................................. 38-1
Parameters of Door Handle Antenna............................................................................................................... 38-2
Parameters of Low-Frequency Antenna inside the Vehicle ............................................................................. 38-2
Layout ................................................................................................................................ 38-3
Repair Guidance ................................................................................................................ 38-4

Replacement of Low-Frequency Antenna (Instrument Panel) inside the Vehicle ............................................ 38-4
Replacement of Low-Frequency Antenna (Auxiliary Fascia Console) inside the Vehicle................................ 38-4
Replacement of PEPS Controller ECU ............................................................................................................ 38-5
Replacement of Clock Spring Assembly and Clock Spring Returning Ring .................................................... 38-5
Replacement of Immobilizer Base Station ....................................................................................................... 38-6
Replacement of Remote Control Receiving Module ........................................................................................ 38-7
Contents
PEPS and Immobilizer System ..................................................................... 39-1
Layout ................................................................................................................................. 39-1
Repair Guidance ................................................................................................................. 39-3

Replacement of Cigar Lighter........................................................................................................................... 39-3
Replacement of Power Outlet .......................................................................................................................... 39-3
Replacement of On-board Inverter................................................................................................................... 39-4
Parking Assist System .................................................................................. 40-1

Layout ................................................................................................................................. 40-1
Repair Guidance ................................................................................................................. 40-4

Replacement of Blind Spot Monitoring Control Module.................................................................................... 40-4
Replacement of Front Bumper Radar Sensor and its Bracket ......................................................................... 40-4
Replacement of Rear Bumper Radar Sensor and its Bracket.......................................................................... 40-5
Replacement of Radar Buzzer ......................................................................................................................... 40-7
Replacement of Front Camera ......................................................................................................................... 40-7
Replacement of Rear Camera.......................................................................................................................... 40-8
Tire Pressure Monitoring............................................................................... 41-1

Layout ................................................................................................................................. 41-1
Repair Guidance ................................................................................................................. 41-2

Tire Pressure Monitoring Control Module Replacement .................................................................................. 41-2
Operating instructions for hand-held TPMS match tool ...................................................... 41-2

Brief introduction to hand-held TPMS match tool............................................................................................. 41-2
General............................................................................................................................................................. 41-2
Packaging......................................................................................................................................................... 41-2
Appearance ...................................................................................................................................................... 41-2
Schematic......................................................................................................................................................... 41-2
Keyboard .......................................................................................................................................................... 41-3
Hand-held TPMS match tool configuration files ............................................................................................... 41-4
Hand-held TPMS match tool: match mode ...................................................................................................... 41-5
Air-conditioning ............................................................................................. 42-1

Specification........................................................................................................................ 42-1
Parameters....................................................................................................................................................... 42-1
Torque .............................................................................................................................................................. 42-1
Layout ................................................................................................................................. 42-2
Troubleshooting Information and Procedure....................................................................... 42-4

Contents
Repair Guidance ................................................................................................................ 42-6
Coolant Drain and Refill ................................................................................................................................... 42-6
Replacement of Receiver-drier to Front Expansion Valve Pipeline Assembly................................................. 42-7
Replacement of Compressor Intake Pipe ........................................................................................................ 42-8
Replacement of Compressor Exhaust Pipe ..................................................................................................... 42-8
Replacement of Condenser Outlet Pipe Assembly.......................................................................................... 42-9
Replacement of Front Heater Water Inlet Pipe Assembly ............................................................................. 42-10
Replacement of Front Heater Water Outlet Pipe Assembly........................................................................... 42-11
Replacement of Front A/C Assembly............................................................................................................. 42-12
Replacement of Mode Motor, Cooler & Heater Motor and Fresh Air Damper Motor ..................................... 42-13
Replacement of A/C Filter Element Cover Plate............................................................................................ 42-13
Replacement of A/C Filter.............................................................................................................................. 42-14
Replacement of Front Expansion Valve......................................................................................................... 42-14
Replacement of Evaporator Core Components ............................................................................................. 42-15
Replacement of Heater Core and Accessories.............................................................................................. 42-15
Replacement of Blower Assembly ................................................................................................................. 42-16
Replacement of Speed Regulating Module ................................................................................................... 42-17
Replacement of Evaporator Temperature Sensor ......................................................................................... 42-17
Replacement of Automatic A/C Suction Pipe................................................................................................. 42-18
Replacement of Front Floor Air Duct ............................................................................................................. 42-18
Replacement of Front A/C Control Panel....................................................................................................... 42-19
Replacement of Condenser ........................................................................................................................... 42-19
Replacement of Intercooler Assembly ........................................................................................................... 42-20
Replacement of Expansion Tank Assembly .................................................................................................. 42-21
Replacement of Engine Exhaust Pipe Assembly........................................................................................... 42-22
Replacement of Hose between Engine and Expansion Tank........................................................................ 42-22
Replacement of Intercooler Intake and Exhaust Hoses................................................................................. 42-23
Replacement of Radiator Water Inlet and Outlet Pipes ................................................................................. 42-24
Replacement of Transmission Oil Cooling Pipe Assembly ............................................................................ 42-24

Overview ........................................................................................................................................................ 42-26
Operating Principle ........................................................................................................................................ 42-26
Introduction of Parts Function ........................................................................................................................ 42-27
Lighting System............................................................................................. 43-1

Layout ................................................................................................................................ 43-1
Repair Guidance ................................................................................................................ 43-2

Replacement of Front Roof Reading Lamp ..................................................................................................... 43-2
Replacement of Rear Roof Reading Lamp ...................................................................................................... 43-2
Replacement of Headlamp Assembly.............................................................................................................. 43-3
Replacement of Front Fog Lamp ..................................................................................................................... 43-3
Replacement of Headlamp Leveling ECU ....................................................................................................... 43-4
Replacement of Front Height Sensor and Bracket .......................................................................................... 43-4
Contents
Replacement of Rear Height Sensor and Bracket ........................................................................................... 43-5
Replacement of Rear Combination Lamp ........................................................................................................ 43-6
Replacement of License Lamp......................................................................................................................... 43-7
Replacement of Reflex Reflector...................................................................................................................... 43-8
Replacement of High Mounted Stop Lamp ...................................................................................................... 43-8
Wiper/Washer System .................................................................................. 44-1

Torque .............................................................................................................................................................. 44-1
Layout ................................................................................................................................. 44-2
Repair Guidance ................................................................................................................. 44-4

Replacement of Wiper Blade............................................................................................................................ 44-4
Replacement of Wiper Arm Assembly.............................................................................................................. 44-4
Replacement of Wiper Linkage Mechanism Assembly (with Motor) ................................................................ 44-5
Replacement of Wiper Motor............................................................................................................................ 44-6
Replacement of Washer Reservoir Cover Assembly ....................................................................................... 44-6
Replacement of Washer Reservoir Assembly.................................................................................................. 44-7
Replacement of Washer Pump ........................................................................................................................ 44-7
Description and Operation .................................................................................................. 44-8
Horn .............................................................................................................. 45-1

Layout ................................................................................................................................. 45-1
Repair Guidance ................................................................................................................. 45-2

Horn Replacement ........................................................................................................................................... 45-2
SK81 controller instruction of GRADE-X....................................................... 46-1

EMS （Engine Management System） VM FGT/VGT ....................................................... 46-1
Configuration .................................................................................................................................................... 46-1
Special Function............................................................................................................................................... 46-3
BCM .................................................................................................................................. 46-31
PEPS ................................................................................................................................ 46-36
IMMO matching method of replacing PEPS and EMS at the same time .......................... 46-42
IMMO matching method of replacing BCM and EMS at the same time............................ 46-43
TBOX ................................................................................................................................ 46-46
TCU................................................................................................................................... 46-48
Contents
ABS/ESP.......................................................................................................................... 46-49
SAS .................................................................................................................................. 46-50
SRS.................................................................................................................................. 46-51
TPMS ............................................................................................................................... 46-52
IPK ................................................................................................................................... 46-53
AFS .................................................................................................................................. 46-55
GAW................................................................................................................................. 46-57
LDW ................................................................................................................................. 46-58
HVAC ............................................................................................................................... 46-60
TCCU ............................................................................................................................... 46-61
LSM .................................................................................................................................. 46-62
BSD.................................................................................................................................. 46-63
FICM-Color Radio ............................................................................................................ 46-64
FICM ................................................................................................................................ 46-65
Electrical System........................................................................................... 47-1

Fuse ................................................................................................................................... 47-1
Auxiliary Fuse Box (Engine Compartment)...................................................................................................... 47-1
Master Fuse Box (Passenger Compartment) .................................................................................................. 47-4
Layout of Complete Vehicle Harness............................................................................................................... 47-7
Layout of Grounding Points ............................................................................................................................. 47-9
Connector...................................................................................................... 48-1
Circuit Diagram.............................................................................................. 49-1

Abbreviations ..................................................................................................................... 49-1
Wire Color Codes ............................................................................................................... 49-2
Harness Codes .................................................................................................................. 49-3
Configuration Codes .......................................................................................................... 49-4
How to Use Circuit Diagram ............................................................................................... 49-7

Power Mode Description.................................................................................................................................. 49-7
Wire Properties ................................................................................................................................................ 49-7
Contents
Connectors ....................................................................................................................................................... 49-8
Grounding Point ............................................................................................................................................... 49-8
Twisted Pairs.................................................................................................................................................... 49-8
Shielded Wires ................................................................................................................................................. 49-9
Harness Configuration Codes ........................................................................................................................ 49-10
Circuit Diagram ................................................................................................................. 49-11

Starting&Charging System ............................................................................................................................. 49-11
Starting&Charging System ............................................................................................................................. 49-12
Power Distribution System ............................................................................................................................. 49-13
Engine Management System ......................................................................................................................... 49-26
Cooling Fan System ....................................................................................................................................... 49-32
Cooling Fan System ....................................................................................................................................... 49-33
Brake Control System .................................................................................................................................... 49-34
Brake Control System .................................................................................................................................... 49-35
Exterior Lighting System(LHD)....................................................................................................................... 49-36
Exterior Lighting System(RHD) ...................................................................................................................... 49-44
Contents
Transmission Control System ........................................................................................................................ 49-51
Wiper & Wash System ................................................................................................................................... 49-54
Body Control System ..................................................................................................................................... 49-55
Entry & Security System(LHD)....................................................................................................................... 49-58
Entry & Security System(LHD)....................................................................................................................... 49-59
Entry & Security System(RHD) ...................................................................................................................... 49-60
Entry & Security System(RHD) ...................................................................................................................... 49-61
Passive Entry & Passive Start System .......................................................................................................... 49-62
Interior Lighting System ................................................................................................................................. 49-65
Mirror System(LHD) ....................................................................................................................................... 49-66
Mirror System(RHD) ...................................................................................................................................... 49-67
Infotainment System ...................................................................................................................................... 49-68
Protection System.......................................................................................................................................... 49-74
Parking Distance Control System .................................................................................................................. 49-77
Information System ........................................................................................................................................ 49-78
CAN Bus System ........................................................................................................................................... 49-79
CAN Bus System ........................................................................................................................................... 49-80
CAN Bus System ........................................................................................................................................... 49-81
CAN Bus System ........................................................................................................................................... 49-82
CAN Bus System ........................................................................................................................................... 49-83
Auxiliary Device ............................................................................................................................................. 49-84
Auxiliary Device ............................................................................................................................................. 49-85
Power Window System .................................................................................................................................. 49-86
HVAC System ................................................................................................................................................ 49-87
HVAC System ................................................................................................................................................ 49-88
HVAC System ................................................................................................................................................ 49-89
Advanced Driver Assistance System ............................................................................................................. 49-90
Advanced Driver Assistance System ............................................................................................................. 49-91
Grounding(LHD)............................................................................................................................................. 49-92
Grounding(LHD)............................................................................................................................................. 49-93
Grounding(LHD)............................................................................................................................................. 49-94
Grounding(LHD)............................................................................................................................................. 49-95
Grounding(LHD)............................................................................................................................................. 49-96
Grounding(LHD)............................................................................................................................................. 49-97
Contents
Grounding(LHD) ............................................................................................................................................. 49-98
Grounding(LHD) ............................................................................................................................................. 49-99
Grounding(LHD) ........................................................................................................................................... 49-100
Grounding(LHD) ........................................................................................................................................... 49-101
Grounding(LHD) ........................................................................................................................................... 49-102
Grounding(LHD) ........................................................................................................................................... 49-103
Grounding(LHD) ........................................................................................................................................... 49-104
Grounding(LHD) ........................................................................................................................................... 49-105
Grounding(LHD) ........................................................................................................................................... 49-106
Grounding(LHD) ........................................................................................................................................... 49-107
Grounding(LHD) ........................................................................................................................................... 49-108
Grounding(LHD) ........................................................................................................................................... 49-109
Grounding(LHD) ........................................................................................................................................... 49-110
Grounding(LHD) ........................................................................................................................................... 49-111
Grounding(RHD) .......................................................................................................................................... 49-112
Grounding(RHD) .......................................................................................................................................... 49-113
Grounding(RHD) .......................................................................................................................................... 49-114
Grounding(RHD) .......................................................................................................................................... 49-115
Grounding(RHD) .......................................................................................................................................... 49-116
Grounding(RHD) .......................................................................................................................................... 49-117
Grounding(RHD) .......................................................................................................................................... 49-118
Grounding(RHD) .......................................................................................................................................... 49-119
Grounding(RHD) .......................................................................................................................................... 49-120
Grounding(RHD) .......................................................................................................................................... 49-121
Grounding(RHD) .......................................................................................................................................... 49-122
Grounding(RHD) .......................................................................................................................................... 49-123
Grounding(RHD) .......................................................................................................................................... 49-124
Grounding(RHD) .......................................................................................................................................... 49-125
Grounding(RHD) .......................................................................................................................................... 49-126
Grounding(RHD) .......................................................................................................................................... 49-127
Grounding(RHD) .......................................................................................................................................... 49-128
Grounding(RHD) .......................................................................................................................................... 49-129
Grounding(RHD) .......................................................................................................................................... 49-130
Grounding(RHD) .......................................................................................................................................... 49-131
Enging Management System(4G69) ............................................................................................................ 49-132
Engine Management System(NLE2.0T)....................................................................................................... 49-137
Overview
Overview
Precautions
Battery Disconnection Window Removal
Before servicing any electrical component, ensure the To avoid injury, wear certified goggles and gloves when
ignition key is in "OFF" or "LOCK" position and all machining any type of glass.
electrical loads are turned "OFF", unless otherwise stated
Drive Belt Repair
in the operating procedure. If the exposed live terminals
Do not repair the drive belt. Repairing of the drive belt
can be accessed easily by any tool or device, be sure to
could cause belt texture breakage. Violation of this
disconnect the negative battery cable. Violation of these
advice will cause damages to the drive belt.
safety instructions could cause personal injury and/or
damage to the vehicle or its components. Fasteners
Cooling Fan Use correct fasteners in correct positions. Fastener
replacement must have correct part number. Fasteners
The fan under the engine hood may start and cause
requiring thread locker, lubricating oil, corrosion inhibitor
injury even when the engine is not running. Be careful to
or sealant and fasteners requiring the replacement shall
keep your hands, clothes and tool away from the fan.
be specified in the service procedures. Unless otherwise
Moving Parts and Hot Surfaces stated, do not apply paint, lubricating oil or corrosion
To avoid injury, do not come into contact with moving inhibitor to the fasteners or the junction surface. These
parts and hot surfaces while the engine is running. coating will affect the torque and connection force of the
fastener and cause damages to fastener. Follow correct
Radiator Cover Removal tightening sequence and torque for fastener installation.
To avoid scalding, do not remove the radiator cap or
auxiliary water tank cap while the engine is hot. Power Steering Fluid
Otherwise the boiling high-pressure fluid and steam will Use proper power steering fluid when refilling or
be flown out of the cooling system. completely replacing the fluid. Use of improper fluid could
cause damage to hoses or seals and fluid leakage.
Fuel Pressure Relief
Before servicing any component of the fuel system, be
sure to relieve pressure in the system to avoid fire hazard
and injury. Servicing fuel pipe or joint can cause spilling of
a small amount of fuel. To prevent personal injury, cover
the adjuster and fuel pipe joints with cotton towels before
disconnection so as to absorb leaked fuel. After
disconnecting the fuel pipe, place the towels in a proper
container.
Vehicle Lifting
Before removing any main component from one end of
the vehicle, or using a hook to support the vehicle, use a
jack standard to support the other end. This can avoid
vehicle damage, serious personal injury and even death.
1-1
Overview
1-2
General
General
General
Main Vehicle Dimension Parameters

SC28R150Q5 diesel engine vehicles
Product Model SK8C-9100 SK8C-9120 SK8C-B120 SK8C-B320 SK8C-B130 SK8C-B330
Driving type 4X2, 4X4, Front-engine 4WD

Front-engine
Rear-drive
Length of outline 5395 5365 5680

dimension, mm
Width of outline 1900
dimension, mm
Height of outline 1809, 1845
dimension, mm
Length of cargo bar 2330 1485 1800
board, mm
Width of cargo bar 1510
board, mm
Height of cargo bar 530
board, mm
Wheel base, mm 3155 3470
Front/Rear 942/1298 942/1268 942/1268

suspension, mm
Front wheel track, mm 1580
Rear wheel track, mm 1580
Minimum turning 12.6 13.7

circle diameter, m
2-1
General
Product Model SK8C-9109 SK8C-9309 SK8C-9129 SK8C-9329
Driving type 4X2, Front-engine Rear-drive chassis 4X4, Front-engine 4WD chassis
Length of outline 5230

dimension, mm
Width of outline 1890
dimension, mm
Height of outline 1809, 1845
dimension, mm
Length of cargo bar NA
board, mm
Width of cargo bar NA
board, mm
Height of cargo bar NA
board, mm
Wheel base, mm 3155
Front/Rear 942/1133
suspension, mm
Front wheel track, 1580
mm
Rear wheel track, 1580
mm
Minimum turning 12.6
circle diameter, m
2-2
General
SC20M163Q5A diesel engine vehicles
Product SK8C-B100 SK8C-B300 SK8C-B120 SK8C-B320 SK8C-B120 SK8C-B320

Model
Driving type 4X2, Front-engine Rear-drive 4X4, Front-engine 4WD chassis
chassis
Length of 5365
outline
dimension,
mm
Width of 1900
outline
dimension,
mm
Height of 1809, 1845
outline
dimension,
mm
Length of 1485
cargo bar
board, mm
Width of 1510
cargo bar
board, mm
Height of 530
cargo bar
board, mm
Wheel base, 3155
mm
Front/Rear 942/1268
suspension,
mm
Front wheel 1580
track, mm
Rear wheel 1580
track, mm
Minimum 12.6
turning circle
diameter, m
2-3
General
Complete Vehicle Mass Parameters
Product SK8C-9100 SK8C-9120 SK8C-B120 SK8C-B320 SK8C-B130 SK8C-B330

Model
Total Mass, 2850 3050 2950, 3050 2950, 3050 2900 2900
kg
Curb weight, 1760 1850 1950, 2000 1980, 2060 2020 2050
kg
Axle load 1020/740 1110/740 1130/820 1150/830 1300/1600 1290/1610
(Front/rear 1160/840 1200/860
axle load
under curb
weight), kg
Number of 2 2 5 5 5 5
Seats
Product Model SK8C-9109 SK8C-9309 SK8C-9129 SK8C-9329
Total Mass, kg 2850 3050
Curb weight, kg 1590 1620 1680 1710
Axle load (Front/ 1020/570 1040/580 1110/570 1130/580

rear axle load
under curb weight),
kg
Number of Seats 2 2 2 2
SC20M163Q5A diesel engine vehicles
Product SK8C-B100 SK8C-B300 SK8C-B120 SK8C-B320 SK8C-B120 SK8C-B320

Model
Total Mass, 3000 3000 3050 3050 2900 2900
kg
Curb weight, 1890 1920 1980 2010 2050 2080
kg
Axle load 1080/810 1090/830 1150/830 1170/840 1190/860 1210/870
(Front/rear
axle load
under curb
weight), kg
Number of 5
Seats
2-4
General
Main Engine Parameters
Engine Model SC28R150Q5 SC20M163Q5A
Type In-cylinder direct injection diesel In-cylinder direct injection diesel

engine with turbocharger and engine with turbocharger and
intercooler intercooler
Displacement, L 2.776 1.996
Number of Cylinder 4 4
Cylinder Bore, mm 94 83
Stroke, mm 100 92
Volume Compression Ratio 17( ± 0.2) : 1 15.9:1
Maximum net power, KW 109.3 118.5
Engine speed at rated power, rev/ 3400 4000

min
Maximum torque, Nm 360 375
Engine speed at maximum torque, 1600 ～ 2800 1500 ～ 2400

rev/min
Idle speed, rev/min 750 ± 20 750 ± 25
Fuel Type and Grade Diesel, conform to Euro V or higher， Diesel, conform to Euro V or higher，
and thediesel with sulfur content less and the
than 15 ppm diesel with sulfur content less than 15
ppm
Fuel tank capacity, L 75 75
Maximum design speed, km/hour 170 170
Emission level reached when the Euro V Euro V

complete vehicle leaving factory
2-5
General
Chassis Technical Parameters
Item Parameters
Front Suspension Structure Double wishbone independent suspension
Rear Suspension Structure Vertical type spring non-independent suspension
Form specifications of steel plate spring Five leaf spring
Requirements for steel wheel dynamic balance Both sides of the remaining dynamic imbalance is less than:
10 grams(main tire ) / 15 grams(spare tire)
Dynamic Balance of Aluminum Wheels Both sides of the remaining dynamic imbalance is less than: 8
grams
Rational range of brake pedal free stroke within 10 mm
Rational use range of brake friction pair Friction material thickness is greater than 2 mm
2-6
General
Recommended Fluids
Item Grade Capacity
Engine(SC28R150Q5) CJ-4 5W-40 7(high chassis)

lubricating oil, L 6.5(low chassis)
Engine(SC20M163Q5A) SAE 5W-30 ACEA C3 4.7

lubricating oil, L
Engine coolant, L D-35(-35 ℃ ) 13
5th speed manual Fuchs MTF SAE 75W-90 GL-4, Total 2.4( ± 0.1)
transmission(Aisin) oil, L TRANSMISSION SYN FE 75W-90 API
SC36M(B)6B 6th speed GL-4 (Note:Drain all the fluid in the 2.5( ± 0.1)
manual transmission(SAGW) transmission during maintenance)
oil, L
SC48M(B)6B 6th speed Fuchs MTF SAE 75W-85, Castrol 3.3( ± 0.1)
manual transmission(SAGW) BOT581, Shell MTF GJ, SK MTF 75W-85
oil, L 201005
6th speed manual Fuchs MTF SAE 75W-85, Castrol 2.4

transmission(DYMOS) oil, L BOT581, Shell MTF GJ, SK MTF 75W-85
201005
Automatic transmission oil, L Fuchs MTF SAE 75W-85, Castrol 10.2

BOT581, Shell MTF GJ, SK MTF 75W-85
201005
Brake fluid, L petro-Canada Dexron VI 0.75
Power steering fluid, L Laike 901-4 DOT 4 1.15
Washer fluid, L ATF-DEXRON Ⅲ 3.8
Air conditioning refrigerant, g General low freezing point detergent 580 ± 30

R134a
Front axle lubricant, L TOTAL GL-5 80W-90 0.9
Rear axle lubricant, L TOTAL GL-5 80W-90 3
Transfer case lubricant, L ATF-DEXRON Ⅲ 1.5
2-7
General
Wheels and Tires
Item Parameters
Wheel Specification 15x6.5J 16x7J
Tire specification 215/70R15LT 215/70R15C 245/70R16
Tire pressure of front 300kPa/3.0bar/43.5psi 300kPa/3.0bar/43.5psi 220kPa/2.2bar/32psi

wheel(cold condition)
Tire pressure of rear 450kPa/4.5bar/65psi 375kPa/3.75bar/54psi 280kPa/2.8bar/41psi
Spare wheel 215/70R15LT 215/70R15C 245/70R16
specification
Tire pressure of spare 450kPa/4.5bar/65psi 375kPa/3.75bar/54psi 280kPa/2.8bar/41psi
Item Parameters
Wheel Specification 17x7J 19x7.5J
Tire specification 245/65R17 255/55R19
Tire pressure of front wheel(cold 250kPa/2.5bar/36psi 220kPa/2.2bar/32psi

condition)
Tire pressure of rear wheel(cold 250kPa/2.5bar/36psi 270kPa/2.7bar/39psi
condition)
Spare wheel specification 245/65R17 245/65R17
Tire pressure of spare wheel(cold 250kPa/2.5bar/36psi 290kPa/2.9bar/42psi

condition)
2-8
General
Wheel Alignment Parameters
Item Parameters
Front wheels Toe-in angle 0 ± 0.15°

Total toe-in ≤ 0.15°
Camber angle 0 ± 0.5°
Difference value between left and right ≤ 0.5°
Kingpin caster 3.6 ± 0.5°
Difference value between left and right ≤ 0.5°
Rear wheels Toe-in angle 0°± 0.25°
Camber angle 0°± 0.5°
Thrust Angle 0°± 0.25°
2-9
General
2-10
Engine Mechanical System
Specification
Technical Parameters
Engine model SC28R136.2Q4 SC28R150Q5
Type 16-valve, in-cylinder direct 16-valve, in-cylinder direct injection,

injection, high-pressure common highpressure common rail and
rail and supercharged intercooling supercharged inter-cooling
Cylinder bore 94 .006 ± 0.009mm 94 .006 ± 0.009mm

Stroke 100 mm 100 mm
Displacement 2776 cc 2776 cc
Power and torque 100KW/3200 rpm 110KW/3400 rpm

350 Nm/1700~2500 rpm 360 Nm/1800~2600 rpm
Injection sequence (the 1st cylinder is 1 - 3 - 4 - 2 (the 1st cylinder is on 1 - 3 - 4 - 2 (the 1st cylinder is on the timing
on the timing drive belt side) the timing drive belt side) drive belt side)
Compression ratio 17( ± 0.2) : 1 17( ± 0.2) : 1

Maximum explosion pressure between 15 bar 15 bar
two cylinders
Idle speed 750 ± 20 rpm 750 ± 20 rpm

Maximum speed 4000rpm 4000rpm
Emission standard China IV standard China V standard
Cylinder Head
Thickness of cylinder head gasket: - 1 hole 1.34 mm
- 2 holes 1.44 mm
- 3 holes 1.54 mm
The maximum impermissible 0.1mm

unevenness of cylinder head bottom
plane
Cylinder head height 94.95~95.05mm
Deflection of valve on the cylinder - Air inlet -0.15 ± 0.15 mm

head - Air outlet -0.15 ± 0.15 mm
Outer diameter of hydraulic tappet 11.988 ~12.00 mm
Valve
Valve cone angle - Air inlet 45° 25’~ 45° 35’
- Air outlet 45° 25’ ~45° 35’
Valve stem diameter - Air inlet 5.952 ~ 5.97 mm
- Air outlet 5.942~5.96 mm
Clearance between valve stem and - Air inlet 0.442 ~0.56 mm

valve guide - Air outlet 0.452 ~0.57 mm
Valve retainer diameter - Air inlet 32.30 ~32.50 mm

- Air outlet 30.80 ~31.00 mm
Valve Guide
Valve guide inner diameter 6.00 ~6.012 mm
3-1
Valve guide mounting height - Air inlet 14.5~15.0 mm

- Air outlet 16.5~17.0 mm
Valve Spring
Free height 45.26 mm
Mounting height 38.0 mm
Camshaft
Intake valve Open at 15°in front of the top dead center
Close at 64° behind the lower rear dead center

Exhaust valve Open at 66°in front of the lower rear dead center
Close at 32° behind the top dead center

Axial clearance 0.10~0.55 mm
Clearance between journal and 0.03~0.08 mm

bearing
Journal diameter 39.25~39.27 mm
Connecting Rod
Inner diameter of connecting rod 32.035~32.050 mm
sleeve 32.035
Inner diameter of connecting rod big 53.994~54.014 mm

end 53.994
Piston
Clearance between piston and inner 0.068 ~0.104 mm
wall of cylinder bore
Piston protrusion 0.46~0.609 mm

Install 1.34 mm thick cylinder head gasket (1 hole)
0.61~0.709 mm
Install 1.44 mm thick cylinder head gasket (2 holes)
0.71 - 0.81 mm
Install 1.54 mm thick cylinder head gasket (3 holes)
Piston diameter (measure at the 93.911~93.929 mm

position 10mm above the piston skirt)
Clearance Between the Piston Ring Grooves

The 1st gas ring 0.103 ~0.157 mm
The 2nd gas ring 0.055 ~0.1 mm
Oil ring 0.045 ~0.09 mm
Opening Clearance after Piston Ring Installation
The 1st gas ring 0.30 ~0.50 mm
The 2nd gas ring 0.50 ~ 0.75 mm
Oil ring 0.25 ~ 0.50 mm
Piston pin diameter 31.992 ~ 31.996 mm
3-2
Crankshaft
Crankshaft axial clearance 0.08 ~0.28 mm
Thickness of axial clearance thrust 2.31 ~2.36 mm

washer
Front-end journal diameter 62.985 ~63.005 mm
Clearance between front-end journal 0.04 ~0.089 mm

and bearing
Intermediate journal diameter 63.00 ~63.02 mm
Clearance between intermediate 0.048 ~0.091 mm

journal and bearing
Rear-end journal diameter 89.98 ~90.00 mm
Clearance between rear-end journal 0.045 ~0.08 mm

and bearing
Allowable out-of-tolerance value of 0.25 mm

main bearing dimension
Connecting rod journal 53.935 ~53.955 mm
Clearance between connecting rod 0.020 ~ 0.079 mm

journal and bearing
Allowable out-of-tolerance value of 0.25 mm

connecting rod bearing
Cylinder Block
Cylinder liner protrusion 0.01 ~0.05 mm
Adjusting gasket of cylinder liner 0.15、 0.17、 0.20、 0.23、 0.25 mm

protrusion
Cylinder liner inner diameter 94.006 ± 0.009 mm
Fuel System
Injection system Direct injection and electronically controlled common rail
High-pressure pump Bosch CP1H
ECM Bosch EDC17C53
Fuel injector Bosch CR12.2
Glow Plug
Type/model In-cylinder heating
Voltage 11 V
Lubrication System
Oil pump Rotary
Axial clearance of outer rotor 0.060~0.160 mm
Axial clearance of inner rotor 0.060 ~0.160 mm
Radial clearance between outer rotor 0.130 ~0.240 mm

and pump body
3-3
Clearance between rotor and drive 0.90~ 1.50 mm

gear
Opening pressure of fuel pressure 7 bar

regulating valve
Spring free length of fuel pressure 46.8 mm

regulating valve
Minimum fuel pressure (warming up) 3.5 bar (3000 rpm)
1 bar (750 rpm at idle speed)
Cooling System
Turning-on temperature of thermostat 83°C ± 2°C
Pressure setting of pressure cover 1.1 bar
Vacuum System
Minimum vacuum degree at idle speed 700 mmHg
Engine Lubricating Oil

Specification CJ-4 5W-40 （China V standard）
CI-4 5W-40 （China IV standard）
Volume (new engine) 7L （high chassis）
6.5L （low chassis）
Coolant
Antifreeze specification Non-methanol product; ethylene glycol product
Use antifreeze certified by MAXUS only
Solution concentration 50% antifreeze, 50% water
Capacity 12.6L
Sealant/Thread Locking Agent

Loctite adhesive 680 or 11264 Bowl plug
Loctite adhesive 510 Turbocharger oil return pipe transition connector
Molykote 111 or vaseline O-ring (rear crankshaft bearing, rear bearing seat)
Polymer 400 or vaseline Cylinder liner O-ring
Loctite adhesive 567 or Tonsan 1567F Coolant temperature sensor
Screw plug
Loctite adhesive 271 or Tonsan 1262 Engine support stud
Teflon grease Vacuum pump check valve
Loctite adhesive 567 or Tonsan 1567F Oil pressure warning switch
Molycote P - 1500 lubricating grease or Fuel injector

vaseline
Loctite adhesive 5900 or Tonsan 1591 Rear crankshaft bearing seat
Gear chamber casing
3-4
Torque
Application Torque Value (N.m)
Intake pipe bolt M6 11
Accessory bracket mounting bolt M10 45
Upper cylinder head bolt Refer to Cylinder Head
Camshaft position sensor bolt M6 11
Camshaft timing pulley fastening bolt 108
Hexagonal screw plug of camshaft timing hole 17
Filler cap connecting pipe Metal connecting pipe: 80; engineering plastic connecting
pipe: 45~50N.m
Clutch bolt M8 36
Connecting rod bolt Refer to Crankcase
Oil deflector bolt M8 33
Gear chamber casing bolt, 12 × 8mm 12
Main bearing seat bolt 44
Crankshaft drive gear bolt (oil pump/vacuum pump) 11
Speed sensor bolt 11
Fan bearing housing bolts M10*45 or M10*40 first 26-32Nm ； loose then 55-68Nm ；
M10*100 55-68Nm
Crankshaft timing pulley bolt Rotation angle method: 150N.m + 90°(reference torque
275N.m)
Use the bolt once only. And do not re-tighten after its
rotation angle is tightened
Crankshaft shock absorber/pulley bolt 33
Cylinder head bolt Refer to Cylinder Head
EGR valve mounting bolt 11
EGR cooler mounting bolt M8 33
EGR cooler mounting bolt M10 45
EGR exhaust pipe to EGR valve clamp bolt 33
Lug bolt 33
Flywheel dust board 25
Exhaust pipe nut 36
Exhaust pipe heat shield bolt 25
Accessory idler bolt (left-hand thread) 45
Accessory tension pulley 45
Flywheel bolt Refer to Flywheel
Nut on the high-pressure oil pipe injector end 25
Nut on the high-pressure oil pipe common rail end 28
3-5
High-pressure oil pump timing pulley nut 88
High-pressure oil pump retaining nut 25
Injector clamp bolt 33
Common rail retaining bolt 25
Bolt fixing the oil cooler to engine block 50
Oil filter Tighten it manually and tighten further 3/4 circle
Piston cooling nozzle bolt 11
Oil pump bolt 11
Suction pipe bolt 33
Crankshaft speed signal disc bolt 15
Oil pan bolt 15
Oil pan drain plug 80
Thermostat body bolt 25
Timing belt idler bolt (left-hand thread) 57
Timing belt tension pulley retaining nut 28
Timing pulley chamber bolt 5 × M6 11
Timing pulley chamber bolt 3 × M10 45
Front-end timing protective cover bolt 17 × M5 6
Dust board bracket 45
Turbocharger bracket bolt 33
Turbocharger oil inlet joint M10 × 1 24
Turbocharger oil return pipe bolt 11
Turbocharger oil return pipe connecting pipe nut 33
Nut fastening turbocharger to exhaust pipe 33
Vacuum pump check valve 57
Vacuum pump bolt 11
Water pump body nut 25
Coolant temperature sensor 18
Engine oil pressure alarm switch 12
Engine cover bolt 9±1
Note：Rotate the left-hand thread clockwise to loosen the nut.
3-6
Layout
Exploded View of Cylinder Head, Intake & exhaust System and Fuel System
1 2
4
9
3 6 7
8 11 10
12
13
14
31
30
29 28
27
26
25
24 18
23
17
16 18
22
21
19
20
1 Low-pressure fuel pipeline 9 Dipstick

2 High-pressure oil pipe (common rail to oil 10 Dipstick tube
injector) 11 Camshaft bulkhead
3 Common-rail pipe component 12 Intake temperature/pressure sensor
4 Fuel injector 13 Upper cylinder head
5 Common-rail oil inlet pipe component 14 Upper cylinder head gasket
6 Filler cap 15 Cylinder head
7 Oil-gas separator 16 Cylinder head gasket
8 Camshaft position sensor 17 Intake connecting pipe
3-7
18 Glow plug 25 Engine lug

19 Vacuum connecting pipe 26 Exhaust pipe gasket
20 Turbocharger oil return pipe 27 Exhaust pipe
21 Turbocharger oil inlet pipe 28 Exhaust pipe heat shield
22 Turbocharger component 29 Camshaft oil seal
23 Thermostat 30 Camshaft collar
24 Valve actuator 31 Camshaft
3-8
Exploded View of Engine Block and Cylinder Power Assembly
1 Cylinder liner 11 Assembling components of rear-end bearing

seat
2 Oil filter
12 Crankshaft speed sensor
3 Water pump
13 Flywheel dust board bracket
4 Oil Cooler
14 Crankshaft speed signal disc
5 Piston ring
15 Connecting rod bearing shell
6 Piston pin
16 Intermediate bearing seat component
7 Piston
17 Flywheel
8 Circlip for hole
18 Starter ring
9 Connecting rod sleeve
19 Rear crankshaft oil seal component
10 Fractured connecting rod
3-9
20 Annular thin block on the rear end of crankshaft 27 Crankshaft

21 O-ring 28 Vacuum pump
22 Oil pressure switch 29 Crankshaft pulley/shock absorber
23 Oil pan gasket 30 Oil pump drive gear
24 Oil pan 31 Oil pump
25 Oil suction pipe welding component 32 Block
26 Front-end main bearing shell 33 Flywheel casing
3-10
Exploded View of Front-end Timing and Accessory Assembly
8
9
5 7
6
4
2
3
12
3 11 10
13
20
15
16
13 1
14 17
19
18 17
18
1 Gear chamber casing 11 High-pressure oil pump timing pulley

2 Front-end timing protective cover 12 Timing tension pulley
3 Timing idler 13 Front crankshaft oil seal
4 Timing drive belt 14 Timing pulley chamber shock pad
5 Exhaust camshaft timing pulley 15 Injection pump
6 Intake camshaft timing pulley 16 Injection pump bracket
7 Timing pulley chamber 17 Front-end accessory drive belt
8 Timing pulley chamber sleeve 18 Front-end accessory drive idler
9 Timing pulley chamber shock pad 19 Front-end accessory drive tension pulley
10 Timing pulley chamber gasket 20 Power steering pump
3-11
Troubleshooting
Failure Possible Causes Measures
Hard engine start or start failure Starting circuit loose or corroded Clean and tighten circuit connectors
Starter motor and electric appliance Check/replace defective parts

system failure
The preheater is operated improperly Take correct preheating steps

(when necessary)
Intake system blocked Check whether the intake system

pipeline is unobstructed
Insufficient fuel in the fuel tank Fill the tank with appropriate amount of
fuel
Air mixed in the fuel system Exhaust the air
Incorrect specification of fuel or engine Use the fuel or engine oil specified in
oil this manual. Fill a temporary fuel tank
with high-quality fuel and verify its
quality by driving
Sudden engine flameout Fuel contamination Replace the original fuel with clean
and qualified fuel
Air mixed in the fuel system Fuel system bleeds
High-pressure oil pipe leaks Check leakage, and tighten/replace

relevant parts if necessary
Fuel pipeline or filter blocked Check the pipeline and filter element.
Clean the coarse filter and screen and
replace the fuel filter if necessary
Incorrect injection or valve timing Check DTCs. Check the timing system
and retime when necessary
Fuel delivery pump fails Repair or replace the fuel delivery

pump
3-12
Engine underpower Vehicle overloaded Reduce vehicle load to the allowable

range
Fuel supply system blocked Check the fuel supply resistance.

Clean the coarse filter and screen and
replace the fuel filter if necessary
Poor fuel quality Verify the fuel quality with a temporary

fuel tank filled with qualified diesel
High-pressure fuel pipe or joint leaks Check leakage. Tighten/replace the

joint or high-pressure fuel pipe if
necessary
Air mixed in the fuel system Fuel system bleeds and check the fuel
inlet pipe for leakage
Intake or exhaust system blocked Check the resistance for intake or

exhaust system and the air filter.
Replace if necessary
Incorrect injection or valve timing Check DTCs
Turbocharger damaged Check the boost pressure. Replace

the turbocharger if the pressure is low
Injection hole of fuel injector blocked, Check, clean or replace the fuel
leading to a poor atomizing effect injector
Excessively high ambient temperature In high-altitude areas or at excessively

or operating in high-altitude areas high ambient temperature, the engine
power will decrease. Reduce load
properly during use
Check whether the engine MIL goes Check DTCs

on
High oil level Check the engine oil level, and adjust
it to specified range
High fuel consumption Fuel leaks Check the pipeline sealing of fuel
system. Tighten the pipeline if it is
loose
Poor fuel quality Use the recommended fuel
Additional load caused by auxiliary Check the auxiliary device and vehicle
device failure parts (refer to the provisions specified
by the manufacturer)
Resistance for the intake system Check the filter element of air filter,
increases and replace if necessary
Check whether the MIL goes on Check DTCs
3-13
Engine overheating Coolant insufficient Check coolant for leakage. Add

coolant to fully exhaust the air
Radiator pressure cover failure Check the function of radiator cover
Engine overload Reduce engine load for operation
Too much dust on the radiator Check the radiator and clean if
necessary
Cooling fan shroud damaged or Check the fan shroud, and repair or
separated from the fan replace if necessary
Fan drive belt damaged or loose Verify the drive belt and tension pulley
Water pump failure Overhaul the water pump
Air or gas mixed in the cooling system Check the coolant pipeline for leakage
and looseness
Coolant temperature sensor or Check the sensor and thermometer

thermometer damaged
Thermostat failure Replace the thermostat
High oil pressure Pressure gauge failing to work Check the function of pressure gauge
Low engine running temperature Refer to "Low coolant temperature"
High engine oil viscosity due to Check the oil and replace with
incorrect specification qualified oil if necessary
Bypass valve stuck near OFF position Check/replace the bypass valve
Low oil pressure Low oil level Adjust the oil level
Low engine oil viscosity due to Check the oil and replace with
incorrect specification qualified oil if necessary
Engine oil pipeline joint loose or oil Check engine oil for leakage
duct bulkhead coming off
Oil diluted by water Find out the reason for dilution, and
replace the oil
Oil pressure regulating valve failure Check/replace the pressure regulating

valve
Oil pressure gauge failure Check the oil pressure gauge
Oil filter blocked Check/replace the oil filter
Engine shaft and bearing shell parts Replace the worn shaft or bearing
worn shell
Exhaust pipe smokes Engine overload Use low deceleration gear
Air mixed in the fuel system Exhaust the air and check the oil
suction part for leakage
Intake system blocked Check the intake system for blockage
Turbocharger failure Replace the turbocharger
Fuel injector failure Check DTCs/replace parts
Check whether the engine MIL goes Check DTCs

on
3-14
Low engine coolant temperature Radiator shutter stuck at the maximum Check the shutter, and replace if
opening necessary
Temperature sensor failure Check/verify the sensor
Thermometer failure Verify the thermometer, and replace if

necessary
Thermostat damaged Replace the thermostat
Loud engine noise The drive belt makes noise Check the drive belt system
Intake and exhaust leakage Check/repair the leakage
The turbocharger makes noise Check whether there is friction

between the impeller and housing
Engine oil low level Check/refill oil
Drive gear makes noise Check/replace defective parts
Severe engine vibration Engine frame loose or damaged Check/replace the engine frame
Fan damaged or accessory failure Check/replace defective parts
Crankshaft torsional vibration Check/replace defective parts

absorber failure
Drive system components worn and Check/replace the components

unbalanced according to the specification given by
the manufacturer
Moving parts loose or damaged Check/replace defective parts
Alternator does not work or Battery connector loose or corroded Clean/tighten the battery connector
undercharges
Engine belt slips Check/replace the belt and tension
pulley
Instrument or indicator lamp failure Check/replace the instrument or

indicator lamp
Engine wire loose or damaged Repair the wire
Alternator failure Replace the alternator
Engine running unsteadily at idle Air mixed in the fuel system Exhaust the air from the fuel system,
speed, hunting and check the oil suction part for
leakage
Coolant contamination Fuel return overflow valve failure Check/replace the fuel return overflow
valve
Fuel supply system blocked Clean the coarse filter and screen, and
check fuel pipe resistance
Injector nozzle blocked or failure Check/replace the injector nozzle
Incorrect injecting timing of injection Check DTCs, and retime if necessary

pump
Oil contamination Engine oil is mixed with coolant due to Check/replace defective parts
engine internal parts leakage
Too much oil deposits Check the replacement interval of

engine oil and its filter
Engine oil is mixed with fuel, and Check whether long idle running time
engine runs in the undercooling of engine causes engine running
condition below normal temperature
3-15
Fuel system leakage Air mixed in the fuel system Bleed the fuel system, and check the
fuel suction pipe for leakage
Engine knock Poor fuel quality Fill a temporary fuel tank with high-
quality fuel and verify its quality by
driving
Engine overload Prove whether the engine exceeds the

designed load with a low gear
Incorrect timing Check/adjust the timing
Fuel injector failure Remove the fuel injector. Check and

repair it
Fuel or engine oil leaks from exhaust Intake pipe blocked Check/replace the component of air
pipe filter element
Fuel injector needle valve stuck Find out and replace the failed fuel
injector
Turbocharger oil return pipe blocked Check/dredge the oil pipeline
Turbocharger seal ring leaks oil Check/replace the turbocharger
Engine keeps running at idle speed for Change the operating habit
a long time
Crankcase leaks too much air Breather pipe of crankcase ventilation Check whether the ventilation device
device blocked and breather pipe are blocked
Turbocharger seal leaks air Check the turbocharger sealing device
Valve guide of cylinder head Check/replace defective parts

excessively worn
Piston ring damaged or worn Check the piston ring and cylinder
sleeve
Vacuum connecting pipe leaks Check the vacuum connecting pipe for
leakage, exclude leakage sources
Glow plug failure Temperature rises slowly Check/replace defective parts
Failing to operate Check whether the harness is

powered on. Check/replace defective
parts
Negative pressure of vacuum pump is Vane excessively worn Check/replace the vacuum pump
low
Pipeline leaks Check/replace the defective pipe
Vacuum regulator failure Loud noise Check/replace defective parts
No pressure Check/replace the vacuum pipeline
Failing to operate Check whether it is powered on.

Check/replace defective parts if
necessary
Diagnosis of excessive belt wear The belt squeaks Belt slips or worn or stretched. Check/
replace the belt and tension pulley
Squeal or harsh noise Check the belt surface for foreign

objects
Continuous hiss or rattle Check the tension pulley and

accessory for bearing failure
3-16
Special Tool Name Illustration
Name Illustration
Crankshaft front oil seal
installer
C00017002
Clutch locator
C00016994
Flywheel timing pin
C00017003
Rear oil seal installer
C00016995
Cylinder sleeve retainer
Intake valve camshaft C00017004

timing pin
C00016996
Injection pump pulley
remover
C00017007
Exhaust valve camshaft
timing pin
C00016997
Fuel pump pulley
remover
C00017008
Camshaft oil seal
installer
C00016999
Cylinder sleeve
measurement tool
C00017009
3-17
Name Illustration Name Illustration
Crankshaft bearing pin

Flange retainer
remover
C00017010 C00017017
Cylinder sleeve Oil pressure relief valve

remover remover
C00017011 C00017018
Piston cooling nozzle

High-pressure pump
removal & installation
pulley timing tool
device
C00017012 C00017019
Crankshaft front
Camshaft bearing guide
bearing removal &
pin
installation device
C00017013 C00017021
Valve oil seal removal &

Flywheel mounting pin
installation toolkit
C00017014 C00017029
Camshaft gear locking

Tension pulley regulator
tool
C00017015 C00017030
3-18
Name Illustration
Oil filter
C00017031
Oil pan sealing position

separator
C00017032
Oil seal puller
C00017033
Mounting tool for

camshaft bearing seat
hole bulkhead
C00089858
3-19
Replacement of Timing Belt

Repair Guidance
Replacement of Front-end Accessory Drive Required tools:C00016996、 C00016997、
Belt
C00017003、C00017015、C00017016、C00017030。
Removal
1 Loosen the screw, rotate the tension pulley Removal
clockwise as shown in the figure, and remove
the front-end accessory drive belt. 1 Remove the front-end accessory drive belt (refer
to Replacement of Front-end Accessory Drive
Belt).
2 Remove the screw and the front-end accessory
drive belt tension pulley.
ES020035
Installation
1 Installation is the reverse of removal.
ES020035
3 Remove 4 M8 screws and the crankshaft shock

absorber.
Note：Before removing the crankshaft shock
absorber (4x10 mm), turn the engine to the timing
mounting position with a turning gear to avoid
bolts from being loosened when the crankshaft
timing pulley bolt is used for turning engine
during engine timing adjustment.
ES020035
CS113003
3-20
4 Remove 17 M5 screws and the front-end timing 6 Remove the dustproof bulkhead, and install
protective cover, and check gaskets and the flywheel timing pin C00017003. Ensure the
protective cover for sealant. flywheel is accurately located.
Note：The screws are pre-coated with glue.
C00017003
CS113222
CS113004
7 Remove hexagonal screw plugs (2 × M6); insert
intake camshaft timing pin C00016996 and
5 Rotate the engine crankshaft clockwise, remove
exhaust camshaft timing pin C00016997.
the dustproof bulkhead, and then install the
flywheel timing pin. At this time, the crankshaft Note：If timing pins cannot be inserted, remove
timing pulley shall be at 90 ° behind the top the flywheel timing pin, rotate the crankshaft
dead center of 1st cylinder. clockwise for 360 °, and insert the flywheel
timing pin. Then insert the camshaft timing pin.
C00016996
90
C00016997
CS113006
CS113007
3-21
8 Loosen the camshaft timing pulley retaining Installation

bolts(2 × M12). 1 Tighten the camshaft timing pulley with new
Note：Prevent the pulley from rotating with tool bolts. Tighten bolts manually, and then loosen
C00017015. DO NOT depend on the timing drive them for 1/16 circle (ensure the pulley can rotate
belt only. freely).
Torque for the timing tension pulley retaining nut: 28N.m
Torque for the timing idler bolt: 57N.m
C00017012 Note：The idler bolt is a reverse-thread bolt and

shall be tightened anticlockwise.
1/
16
CS113008
9 Loosen the nut (M10) on the belt tension pulley

retaining bolt, and rotate the tension pulley
anticlockwise to the lowest point with the tool
C00017030.
CS113010
10 Remove and scrap the timing drive belt.
Note：Without professional guidance, it is 2 Rotate the fuel pump timing pulley to align timing
prohibited to rotate the crankshaft after removing marks, as shown in the right figure.
the timing drive belt. Otherwise valves, pistons 3 Check whether the flywheel and camshaft timing
and other components may be damaged. pin still exists.
Note：If there is a need to replace the timing drive
belt, the idler and tension pulley must be
replaced meanwhile.
C00017030
CS113011
CS113009
3-22
4 Install a new timing drive belt: 5 Remove the temporary support tool from the
crankshaft timing pulley.
a.Install the crankshaft timing pulley firstly, and
temporarily install a proper support tool to fit the belt
with the timing pulley. Keep the belt tight, and then
install the belt around the following parts in turn:
b.Fuel pump timing pulley (do not damage the fuel

pump timing).
c.Idler.
d.Intake camshaft timing pulley.
e.Exhaust camshaft timing pulley.
f.Idler.
CS113012
6 Keep rotating the tension pulley clockwise with

tool C00017030 until there is 1mm overlap
between the upper pointer of tension pulley and
the spring (as shown in the figure). Tighten the
tension pulley retaining nut to the torque 28N.m.
C00017030
CS113012
1mm
g.Water pump pulley.
h.Timing drive belt tension pulley.
Note：DO NOT pry the belt onto the pulley with a

CS113013
crowbar; press it by fingers only.
7 To tighten the camshaft timing pulley bolt, it is

required to install tool C00017016 according to
e d
c the following steps:
f
—Rotate the adjustment handle of tool C00017016
anticlockwise to completely buckle the teeth on the timing
b pulley (the pulley shall be able to rotate flexibly at this
time).
g —Place the tool on the middle of camshaft timing pulley.

h
—Observe through the hole (elliptical hole). Keep
rotating the handle clockwise until two sliding teeth are
a
CS113005 completely embedded into the timing pulley teeth slot (as
shown in the figure).
3-23
9 Check the valve timing and belt tension as below

—Make a temporary mark on the timing drive belt.
C00017016
—Keep rotating the crankshaft clockwise until the mark
on the timing drive belt returns to its starting position (that
is, the belt rotates for a circle).
Note：If the upper cover of mounting cylinder has

been removed, rotate the crankshaft after 30min.
CS113014
—Tighten two retaining bolts to 108 N.m.
—Remove tool C00017016.
108 Nm
CS113017
108 Nm
—Continue rotating the crankshaft clockwise until
flywheel timing pin C00017003 can be installed.
CS113015 C00017003
8 Remove timing pins C00016996, C00016997

and C00017003.
CS113018
— Check whether camshaft timing pins C00016996 and

C00016997 can be inserted.
Note：The crankshaft may be further rotated for

360°.
CS113016 —If timing pins cannot be inserted, repeat the steps for
belt installation.
3-24
C00016996
C00016997
CS113019 CS113020
—Check the tensioning position of timing drive belt 12 Install the crankshaft shock absorber/pulley, and
tension pulley, and readjust it when necessary. tighten 4 screws (M8X16) to the torque of
33N.m.
—If the position is correct, remove all the three timing Note：It is compulsively required to use the bolts
pins and install the sealing bulkhead. (M8x16) with specified length, otherwise the
timing system may get damaged easily.
1mm
CS113223
CS113021
10 Check the sealing condition around the front-end
timing protective cover outer lip, and repair it
when necessary. During repair, remove the
original sealant and clean the surface. Then
apply Tonsan 1590 onto it. Leave it stand still for
a period of time. Do not install until silica gel is
solidified.
11 Install a new gasket and install a protective
cover. Apply thread locking glue onto the bolt
and tighten it to the torque of 6 N.m.
3-25
13 Install the front-end accessory drive belt tension Replacement of Timing Pulley Chamber and
pulley and screw M10. Tightening torque: 45 Shock Pad
N.m. Required tools:C00016996, C00016997, C00017003,
C00017015, C00017030 and C00017016 (tools
C00016996 and C00017002 are required for the
removal of gear chamber casing）
Removal
1 Remove the timing drive belt (refer to
Replacement of Timing Drive Belt).
2 Remove the timing drive belt tension pulley.
CS113022
14 Install the front-end accessory drive belt (refer to

Replacement of Front-end Accessory Drive
Belt), and ensure the belt is in the middle of all
pulleys.
CS113031
3 Remove two camshaft timing pulleys. Scrap the

camshaft timing pulley bolt.
CS113052
3-26
4 Remove the screw M12 and idler. Installation
Note：Left-hand thread. 1 Install the timing pulley chamber shock pad.

2 Apply a small amount of Tonsan 1591 silicone
rubber sealant (diameter: 3mm~6mm) onto the
positions shown in the figure on the gear
chamber casing seal gasket for waterproof
sealing.
CS113033
5 Remove screws (5 × M6 and 3 × M10) and the

timing pulley chamber. Remove the timing pulley
chamber shock pad.
CS113315
Note：Check the gaskets, sealing parts, etc. for
damage, and replace when necessary.
5 M6
3 M10 d
f
e
ES020033
CS113027
a. Idler hole shock pad
b. Sleeve
c. Shock pad
d. Timing pulley chamber shock pad
e. Timing pulley chamber
f. Central gasket of timing pulley chamber
3-27
3 Apply Tonsan 1591 silicone rubber sealant

5 Install the idler, and tighten the bolts to 57 N.m.
(diameter: 2mm~5mm) onto the upper cylinder
head according to the track shown in the figure.
CS113238
CS113316
Note：Left-hand thread
4 Install the timing pulley chamber, and tighten the 6 Install the timing drive belt tension pulley, and
following bolts to the specified torques: tighten bolts manually.
5 x M6 – 11 Nm
3 x M10 – 45 Nm
5 8mm
3 13mm
CS113031
7 Install 2 camshaft timing pulleys with new bolts

(keep pulley mounting faces consistent with that
CS113224 during removal). Tighten bolts manually, and
then loosen them for 1/16 circle.
Note：Apply Loctite adhesive 222 onto the 8
retaining bolts.
3-28
8 Install a new timing drive belt (refer to Timing Replacement of Gear Chamber Casing
Drive Belt). Required tools:C00017010 and C00017032
Removal
Note：Take care not to deform the gear chamber
1/ casing.
16
1 Remove the timing pulley chamber and its shock
pad (refer to Replacement of Timing Pulley
Chamber and Its Shock Pad).
2 Remove the crankshaft drive belt and its
mounting screws M16.
Note：For left-hand thread, do not remove the
crankshaft front oil seal until the gear chamber
casing is removed.
CS113010
C00017010
CS113035
3 Remove 12 M6 bolts fixing the gear chamber

casing.
CS113036
3-29
4 Separate the gear chamber casing sealed by 3 Protect the oil seal mounting cover with tool
silica gel from engine block with the sealant C00017002, and tighten the bolt to 12 N.m.
separation tool C00017032 (keep the sealing
split position of the tool lubricated).
C00017032
CS113040
CS113037 4 Install the crankshaft timing pulley with a new

bolt (left-hand thread). Tightening requirement:
5 Remove the gear chamber casing. 150 N.m +90°(reference torque: 275 N.m).
1
C00016994
1 275Nm
CS113041
CS113038
Note：Use the bolt once only. And do not retighten
Note：Position of locating pin ① . after its rotation angle is tightened.
Installation
1 Remove the original sealant from the engine

block, and clean the mating face.
2 Apply Tonsan 1591 (3~6mm wide and
continuous) onto the casing.
Note：Install the gear chamber casing within
10min after the sealant is applied.
3-30
Individual Replacement of Front Oil Seal Installation

Removal 1 Clean the crankshaft nose and front cover
1 Remove the front-end accessory drive (FEAD) sealing area throughly.
and timing belt. 2 Wind thin industrial adhesive tape around the
2 Remove the crankshaft drive gear (21mm). crankshaft nose to avoid keyways from
damaging sealing parts.
LDV118
CS113300
CS113302
Note：Left-hand thread
3 Install a new oil seal onto the adhesive tape
3 Make a mark on the belt, and carefully drill a hole
carefully.
on the oil seal. Install a proper screw, and pry the
oil seal out by virtue of this screw.
CS113303
CS113301 Note：Do not lubricate the sealing lip. Make sure
the oil seal lip is free of any damage during
Note：Make sure that the hole is not drilled so
installation. The arrow marked on the oil seal
deep that it damages the gear behind it.
must be consistent with the crankshaft rotation
direction.
3-31
Replacement of Crankshaft Front Oil Seal Installation

Removal 1 When pressing a new crankshaft front oil seal
1 Remove the gear chamber casing (refer to into the gear chamber casing, support the
Replacement of Gear Chamber Casing). position for installing the oil seal on the casing
onto the sleeve of tool C00017002, and press
2 Support the casing onto the sleeve of tool
the oil seal into the casing in place with tool
C00017002. Then carefully remove and scrap C00017002.
the oil seal.
3 Clean the contact position between the
crankshaft and oil seal, and check it for wear,
damage, etc.
C00017002
C00017002
CS113043
Note：To avoid oil leakage, do not lubricate the

C00017002
sealing lip or the corresponding journal position
CS113042 on the crankshaft. Hold the outer ring of oil seal
only when removing the oil seal. Mounting depth
of front oil seal: 23.8 ± 0.5mm away from the
engine block mounting plane. Flatness between
the oil seal and engine block mounting face:
0.25mm. Knock the locating pin onto the front
end of engine block. Protrusion height of locating
pin: 4 ± 0.5mm.
3-32
Replacement of Oil Pump Installation

Removal 1 Install the oil pump, and tighten 3 M6 hexagonal
1 Remove the gear chamber casing, etc. (refer to screws to the torque of 11N.m.
Replacement of Gear Chamber Casing).
2 Remove 4 M6 hexagonal screws and the drive
gear.
11Nm
CS113046
Note：Lubricate pump components before

installation.
CS113044
2 Check the axial clearance of inner rotor.
3 Remove 3 M6 hexagonal screws and the oil
pump.
0.06-0.16mm
CS113047
CS113045 3 Slightly lubricate the tooth surface of oil pump

drive gear with multi-function lubricating grease.
Install the gear, and tighten the retaining screw to
11N.m.
3-33
4 Install the gear chamber casing, etc. (refer to Replacement of Vacuum Pump
Replacement of Gear Chamber Casing). Required tools: C00017032, C00016996, C00016997,
C00017002, C00017003, C00017015, C00017016 and
C00017030 (Hazet tool).
11 Nm
Removal
1 Remove the gear chamber casing, etc. (refer to
Replacement of Gear Chamber Casing).
2 Remove 4 M6 hexagonal screws and the oil
pump drive gear.
CS113048 c
b
CS113056
a. Oil pump drive gear
b. Drive gear of oil pump and vacuum pump
c. Drive gear of vacuum pump
3 Remove 3 M6 hexagonal screws and the

vacuum pump.
CS113049
3-34
Check Installation
1 Check the axial clearance of outer rotor. Note：
—Install the inner rotor and outer rotor of oil pump with
the sides marked with circles facing the open side of oil
pump housing
—The circle marks on oil pump inner and outer rotors

shall be on the same plane. There is no special
0.06-0.16mm
requirement for the alignment angle of two circles.
Circle mark of oil pump outer rotor

Circle mark of oil pump inner rotor
Oil pump housing
CS113108
2 Check rotors and the clearance between rotors.
0.13-0.24mm
CS113111
1 Check whether the oil inlet hole of vacuum pump

(indicated by the arrow) is clean.
CS113109
CS113050
3-35
2 Install the vacuum pump, and tighten screws to 6 Install the gear chamber casing, etc. (refer to
11 N.m. Replacement of Gear Chamber Casing).
11 Nm
11Nm
CS113051 CS113048
3 Slightly lubricate the tooth surface of oil pump

and vacuum pump drive gears with multifunction
lubricating grease.
4 Install the oil pump drive gear, and tighten
screws to the torque of 11 N.m.
Note：After assembly, apply an appropriate
amount of vaseline to the meshing position
between vacuum pump/oil pump and oil pump
drive gear. Rotate the oil pump manually to
ensure the gear can rotate flexibly. Measure the
backlash as required: The meshing normal
clearance between the vacuum pump and oil
pump drive gear shall be 0.13-0.25mm, and the
meshing normal clearance between oil pump
drive gear and oil pump gear shall be 0.08-
0.33mm.
5 Place a new front oil seal into the gear chamber
casing.
3-36
Replacement of Camshaft Oil Seal 5 Install screws and pry out the camshaft oil seal.
Required tools: C00016996, C00016997, C00016999,
C00017003 ,C00017015, C00017016, C00017033 and
C00017030.
Removal
1 Remove the front-end accessory drive belt (refer
Belt).
2 Remove and scrap the timing drive belt (refer to
3 Remove and scrap two retaining bolts of
camshaft timing pulley. Remove the camshaft CS113053
timing pulley.
CS113052
4 Punch two holes on the camshaft oil seal with

punching tool C00017033 (the hole size shall fit
for M4 X 38 mm self-tapping screw).
CS113053
Note：DO NOT punch any hole on the upper

cylinder head, which may damage the cylinder
head.
3-37
Check 6 Install the front-end accessory drive belt (refer to

Clean the oil seal mounting position and check it for Replacement of Front-end Accessory Drive
damage. Clean the contact position between the Belt).
camshaft and oil seal, and check it for wear, damage,
etc.
1/
Installation 16
1 Slightly lubricate the oil seal sealing lip with

engine lubricating oil.
2 Place the oil seal on the plastic sleeve of tool
C00016997 till the sleeve shoulder. Install the oil
seal and oil seal cover in place medially.
CS113010
C00016999
CS113054
3 Install the camshaft timing pulley, fasten it with

new bolts, and then tighten bolts manually; then
loosen them for 1/16 circle.
4 Install a new timing drive belt (refer to
5 Install the front-end timing protective cover (refer
to Replacement of Timing Pulley Chamber).
3-38
Replacement of Upper cylinder Head and 4 Disconnect the fuel return pipe from the fuel
Gasket injector and high-pressure fuel pump. (Loosen it
Required tools: C00016996, C00016997, C00017003, by stretching the connector clamp inwards).
C00017015, C00017013, C00017016 and C00017030. 5 Disconnect the high-pressure fuel pipe from the
fuel injector as well as high-pressure fuel pump
from common rail.
Removal
6 Remove the fuel injector (refer to Replacement
Note：Cover all joints to prevent dust from of Fuel Injector).
entering.
1 Remove the timing pulley chamber, etc. (refer to

Replacement of Timing Pulley Chamber).
2 Disconnect the following connections:
– Camshaft position sensor ①，
– Intake temperature/pressure sensor ②。
– Fuel pressure sensor ③，
– Fuel injector connector ④。
CS113058
3
7 Remove the common rail and screws (1 × M8
and 2 × M12).
2
4
CS113072
3 Disconnect the intake elbow from intake pipe。
CS113059
Note：Do not remove end connecting parts from

the common-rail component. These parts have
been pre-tightened to the specific torque and
been subject to the pressure test during
manufacture.
8 Disconnect the breather pipe and remove the
oilgas separator. Scrap the O-ring.
CS113057
3-39
9 Remove the fuel filler cap connecting pipe and 14 Remove the valve actuator from exhaust side (②
scrap the seal washer. shown in the lower right figure).
3
3
CS113060 CS113229
Note：It is of great importance to remove the Note：The sequence of valve actuator installation
upper cylinder head correctly. Remove the upper is the same with that of removal.
cylinder head as follows: 15 Remove and scrap the upper cylinder
10 Remove two bolts (M8) from the upper cylinder headgasket.
head, and install two guide pins C00017013. Clean the junction surface between upper cylinder head
11 Remove the rest bolts of upper cylinder head. and cylinder head.
The maximum unevenness of upper cylinder head is

0.1mm.
C00017013
C00017013
C00017013
CS113061
12 Lift the upper cylinder head ① carefully to move

it away from the cylinder head. CS113064
Note：Remove and save the orifice plug ③ if
loose.
13 Cover the cylinder head intake port with a
bulkhead to prevent foreign objects from
entering.
3-40
Installation 10 Install all the rest retaining bolts and tighten them
manually.
1 Lubricate the valve actuator with clean engine
lubricating oil before installation (avoid the timing
drive pulley, relevant pulleys and belt pulleys
from being stained with engine oil).
2 Check whether flywheel timing pin C00017003 is C00017013
kept in place (which means the crankshaft is at
90° behind the top dead center of 1st cylinder).
CS113064
C00017003
C00016996
C00016997
CS113063
3 Re-install the guide pin C00017013 (if removed).

4 Make sure the top surface of cylinder head is
clean. Then install a new upper cylinder head
gasket (dry).
CS113065
5 Re-install the valve actuator into its original
position. Note：Replace any damaged bolt of upper
Note：Apply vaseline between the valve actuator cylinder head with a new one. New bolts shall be
and valve stem end. When installing the upper pre-lubricated. Before installation, lubricate old
cover, keep the valve actuator center aligned. bolts reused. Install two bolts in the positions
diagonal to the guide pin. Tighten bolts manually.
6 Clean the junction surface of upper cylinder
head. 11 Tightening sequence of upper cylinder head
bolts:
7 Ensure two orifice plugs are located correctly.
8 Lower the upper cylinder head carefully to the —Tighten all bolts according to the sequence shown in
position above guide pin C00017013. Ensure the the figure
valve actuator is not interfered during installation.
The first time: Tighten No.1~16 upper cylinder bolts to
9 Remove the guide pin C00017013. 7N.m.
The second time: Tighten No.1~16 upper cylinder bolts

to 25N.m.
The third time: Tighten No.1~5 upper cylinder bolts to

33N.m.
Note：When installing fuel system parts, make

sure they are completely clean.
3-41
12
15 14 13
16
5 4 3 2
1
6
7 8 9 10 11
CS113236 CS113067
12 Install the fuel common rail, and install its 16 Install the high-pressure fuel pipe between the
retaining bolts without clamping stagnation. high-pressure fuel pump and fuel common rail,
13 Check two tapered ends of high-pressure fuel and tighten nuts manually.
pipe for damage/distortion, and replace the pipe
when necessary.
14 Install the fuel injector (refer to Replacement of
Fuel Injector).
Note：Install the fuel injector with a new copper
washer and a new O-ring (lubricating seal ring).
CS113068
17 Tighten fuel injector clamp bolts. Tightening

torque: 32 N.m.
18 Tighten the fuel common rail bolts to the torque
of 25 N.m.
CS113066
15 Install the high-pressure fuel pipe (between fuel

rail and nozzle) and tighten nuts manually.
32 Nm
CS113069
3-42
19 Tighten the high-pressure fuel pipe. 21 Reconnect:

—Tighten the nut at the high-pressure fuel pipe common —Camshaft position sensor ①，
rail end to 28 N.m;
—Intake temperature/pressure sensor ②，
— Tighten the nut at the high-pressure fuel pipe injector
end to 25N.m. —Fuel pressure sensor ③，
—Fuel injector connector ④。
2
4
1
CS113070
CS113072
20 Install the fuel return pipe to the fuel injector.
22 Re-install the oil-gas separator.

Apply a small amount of Tonsan 1243 thread tightening
sealant onto the retaining bolt, and tighten the bolt to the
torque of 5 ± 1N.m. Make a tightening mark with a paint
marker after tightening. Use new O-ring. Connect the
breather pipe.
CS113071
Note：After the fuel return pipe is reconnected to

fuel common rail and injector, slightly pull the
pipe to check whether it is connected firmly. In
case of any junction pulled apart, replace the
connecting clamp.
CS113060
3-43
23 Re-install the filler cap connecting pipe. Replacement of Camshaft

Re-install the filler cap connecting pipe. Apply an Required tools: C00016996, C00016997, C00016999,
appropriate amount of Tonsan 1567 anaerobic pipe C00017003, C00017015, C00017013, C00017016,
thread sealant onto the thread of filler cap. Use new C00017033 and C00017030.
Oring. Tightening torques: 80 N.m for metal connecting
pipe; 45-50N.m for engineering plastic connecting pipe. Removal
Note：After installation, the bulkhead of camshaft
access hole shall be stuffed. However, it is not
recommended to stuff the bulkhead in this step.
1 Remove the upper cylinder head, etc. (refer to

Replacement of Upper Cylinder Head and
Gasket).
2 If the exhaust camshaft is removed, please
remove the camshaft position sensor together
(M6 hexagonal screw), and scrap the O-ring.
3 Remove the camshaft bulkhead. Clean the area
around the bulkhead hole firstly to prevent dust
from entering. Then drill a small hole in the
CS113073 center of bulkhead to pry it out. If you want to
install a new bulkhead, clean the bulkhead hole
24 Install the intake elbow. firstly, and then press the new bulkhead with a
proper-size sleeve in place.
25 Install the timing pulley chamber, etc. (refer to
Replacement of Timing Pulley Chamber/Shock 4 Remove the camshaft timing pin (if installed).
Pad).
CS113075
CS113057
5 Remove the camshaft oil seal as per the
following steps:
3-44
CS113076 CS113078
Note：DO NOT punch any hole on the upper Note：If two camshafts are removed meanwhile,
cylinder head, which may damage the cylinder identify them according to the timing pin
head. positions as shown in the figure. (The timing pin
of intake camshaft ① is on the front end).
—Punch two holes on the camshaft oil seal with
punching tool C00017033
—The hole shall fit for M4 x 38 mm Check

Check the camshaft journal, cam working face and
—self-tapping screw. sealing face for wear, pitting, etc. If the cam working face
—Install the screw and pull out the oil seal. is suspected for wear, compare and measure the
dimensions of this camshaft working face with a new
6 Remove the camshaft collar.
camshaft. Check the surface of upper cylinder head
7 Pull out the camshaft carefully. bearing for wear, scratch, etc.
CS113077
Note：DO NOT damage the bearing seat surface in

the upper cylinder head.
8 Identify camshafts.
3-45
Installation
1 Lubricate the camshaft.
Note：To install a new camshaft, lubricate its
journal with engine lubricating oil.
2 Install the camshaft carefully. Ensure it is C00016999
inserted centrally to protect bearing from being
damaged.
3 Install the camshaft collar. Before installation,
check the collar for damage, and replace it when
necessary.
4 Measure the camshaft axial clearance. The axial
clearance shall be between 0.10 and 0.55 mm. CS113054
7 Rotate the camshaft, and then install timing pins

C00016996 and C00016997.
C00016997
C00016996
CS113079
5 Install the camshaft oil seal:

CS113080
—Slightly lubricate the oil seal sealing lip with engine
lubricating oil.
8 The removed camshaft position sensor shall be
—Place the oil seal on the sleeve of tool C00016999 till equipped with a new O-ring in case of
the sleeve shoulder. reinstallation.
9 Re-install the upper cylinder head (refer to
—Press the oil seal and oil seal cover centrally into place Replacement of Upper Cylinder Head).
with tool C00016999.
6 Install a new camshaft plastic bulkhead onto the

access hole on the rear end of upper cylinder
head.
3-46
Replacement of Cylinder Head and Gasket 6 Remove the exhaust pipe heat shield.
C00017004, C00017009, C00017015, C00017013 and
C00017030.
Removal
1 Remove the upper cylinder head and gasket,
etc. (refer to Replacement of Upper Cylinder
Head).
2 Disconnect the glow plug connector ① and
coolant temperature sensor connector ② .
3 Remove EGR cooler and the inlet pipe of
freshwater pump. CS113083
4 Remove the coolant hose.
7 Remove the oil inlet pipe and oil return pipe of
turbocharger. Scrap the flange gasket.
8 Disconnect the intake pipe and exhaust pipe of
turbocharger.
1
2
CS113081
5 Remove the thermostat housing and 3 M8

screws and scrap the gasket.
CS113084
9 Remove the exhaust pipe and 9 M10 screws.

Before scrapping the exhaust pipe gasket,
record its correct installation method.
CS113082
CS113085
3-47
10 Remove the valve actuator: 13 Remove and scrap the cylinder head gasket.
① Hydraulic tappet Record the number of holes for identifying the
thickness before scrap.
② Spring clip
③ Rocker arm
2
3
1
CS113088
14 Install cylinder sleeve clamping tool C00017004

CS113086 to prevent the cylinder sleeve from being lifted
due to the crankshaft rotation, so as to damage
Note：Number the removed valve actuator the cylinder sleeve sealing.
correspondingly to make sure its original
position can be found out during re-installation.
Place the tappet vertically to prevent oil from
overflow. It is recommended to immerse it in
engine lubricating oil. C00017004
11 Remove and scrap cylinder head bolts (18 X

M10).
Note：If the engine operates just now, cool it down
first, and then remove cylinder head bolts.
Loosen outer bolts and then middle bolts.
12 Remove the cylinder head and place it on the
wooden block (take care not to contact valves
and the protruding positions of the injector). CS113089
CS113087
3-48
Check
1 Clean the mating face between upper cylinder
head, cylinder head and engine block.
2 Check components and inner bore of hydraulic
tappet for wear and damage. Before overhaul,
check the cylinder head for deformation as per
the following steps:
Check the cylinder head for deformation:
a.Remove the glow plug.
b.Clear deposit from the cylinder head surface with a

non-steel scraper. CS113115
c.Check the cylinder head for deformation with a ruler
Measure the valve deflection. Valve deflection
and plug gauge on multiple planes.
Intake valve: 1.08 - 1.34 mm
The maximum allowable unevenness is 0.1 mm.
Exhaust valve: 0.99 - 1.25 mm
Note：Machining operation on the cylinder head
shall be avoided. If the deflection of any valve is lower than the specified
value, install a new valve and remeasure its deflection.
Re-machine the valve seat ring if necessary.
To re-install the cylinder head:
—Install a new oil seal ring to the valve stem.
—Valve parts to be installed must be installed to their

original positions.
—Lubricate the valve stem before installation.
CS113113
CS113114
3-49
Installation sleeve) to record the dial indicator reading (that is, the
Note：Lubricate the moving parts with clean piston protrusion).
engine lubricating oil before installation (avoid
the timing drive pulley, relevant pulleys and belt —Repeat the aforesaid steps to measure protrusions of
pulleys from contacting engine oil). the other three pistons.
1 Cylinder head gasket identification —Calculate the average protrusion of all the four pistons,
and select a proper gasket according to the following
If the cylinder sleeve or piston is not replaced, install a
steps.
cylinder head gasket with the same thickness as before
(identify according to the number of holes). If new piston
and cylinder sleeve are installed, select a proper gasket
according to the table below after measuring the piston
protrusion.
Piston Gasket Number of

Protrusion Thickness Holes
0.460-0.609 1.34 1
0.610-0.709 1.44 2
0.710-0.810 1.54 3
CS113090
2 Rotate the crankshaft clockwise for 90°, and

reinstall the flywheel timing pin C00017003.
3 Remove the cylinder sleeve retaining tool
C00017004.
4 Clean the mating face, and install the selected
new cylinder head gasket (dry).
5 Re-install the upper cylinder head (refer to
Replacement of Upper Cylinder Head).
CS113088
The protrusion shall be checked as per the 90

following steps:
—Remove the flywheel timing pin C00017003

C00017003
temporarily.
—Vertically install the tool C00017009 equipped with a

proper dial indicator to the position above the piston pin
axis, 5mm away from the 1st cylinder piston edge.
CS113091
—Rotate the crankshaft till the accurate position of top
dead center is reached. Zero set the dial indicator. 6 Install the cylinder head with new bolts. Tighten
the bolts as per the following steps:
—Keep the dial indicator zero setting, and move its
contact to the top surface of engine block (not cylinder Step 1: Tighten No.3, No.2, No.1, No.10, No.9, No.8,
No.7, No.6, No.5, No.4, No.11, No.12, No.13, No.14,
3-50
No.15, No.16, No.17 and No.18 bolts to 30 N.m in 9 Install the exhaust manifold gasket correctly.
sequence as shown in the figure. Re-pull the bolts to
ensure all of them are tightened to 30 N.m.
Step 2: Rotate No.10, No.9, No.8, No.7, No.6, No.5,

No.4, No.3, No.2 and No.1 bolts for 75° in sequence,
and rotate No.11, No.12, No.13, No.14, No.15, No.16,
No.17 and No.18 bolts on both sides for 50° in
sequence.
Step 3: Rotate No.10, No.9, No.8, No.7, No.6, No.5,

No.4, No.3, No.2 and No.1 bolts for 75° in sequence
again, and rotate No.11, No.12, No.13, No.14, No.15,
No.16, No.17 and No.18 bolts on both sides for 75° in
CS113092
sequence again.
Note：New cylinder head bolts must be used. New 10 Install the exhaust pipe and tighten nuts
bolts shall be pre-lubricated. according to the two steps shown as below:
Apply an appropriate amount of Tonsan 1767
7 Install the upper cylinder head (refer to
silver-based high temperature anti-seizure agent
Replacement of Upper Cylinder Head)
onto one end of exhaust pipe stud, align the
coated end with the corresponding position on
ᥦ⇨ջ
the cylinder head, and then install the exhaust
pipe gasket; apply an appropriate amount of
11 12 13 14
Tonsan 1767 silver-based high temperature
1 9 3 7 5 antiseizure agent onto the other end of the stud,
ᅮ
亲 install the exhaust pipe and then tighten the
ᯊ
㋏
䕂 exhaust pipe nuts in turn.
䕧
㒳
ッ
ߎ Step 1: Tighten the nuts to 36 N.m in the sequence
ッ
10 2 8 4 6 shown in the figure.
15 16 17 18 Step 2: Re-tighten the nuts to the same torque (36 N.m)

䖯⇨ջ
in the same sequence.
CS113241
8 Connect glow plug ① to coolant temperature

sensor ② .
7 3 2 6
9 5 1 4 8
1
2
CS113227
11 Install oil inlet pipe and oil return pipe of

turbocharger.
CS113081
3-51
a.Install a copper washer onto turbocharger oil inlet joint, 12 Re-install the thermostat housing with a new
then screw it into the engine block, and tighten to the gasket. Tighten bolts to 25 N.m.
torque of 54 ± 3N.m.
b.Install a copper washer onto turbocharger oil inlet hinge

bolt, then cover it to the oil inlet pipe. Install another
copper washer, and then screw into the turbocharger
oil inlet, do not tighten it temporarily.
c.Screw the other end of turbocharger oil inlet pipe into

the oil inlet joint of the engine block. After ensuring the
turbocharger oil inlet pipe is free of interference through
adjustment, tighten oil inlet pipe nuts and hinge bolts.
Tighten oil inlet pipe nuts to the torque of 33 ± 2N.m,
and tighten hinge bolts to the torque of 25 ± 2N.m.
CS113082
d.Put the turbocharger oil return rubber hose into the
turbocharger oil return elbow joint and the hose clamp. 13 Re-install the heat shield.
Then cover the weld component of turbocharger oil 14 Re-install the coolant pipeline.
return pipe into the turbocharger oil return pipe gasket. 15 Re-install EGR pipeline.
Screw the bolt in, but do not tighten it temporarily. 16 Re-install the timing pulley chamber, etc. (refer to
Replacement of Timing Pulley Chamber/Shock
e.Cover the other end of weld component of
Pad).
turbocharger oil return pipe into the turbocharger oil
return rubber hose. Tighten the bolt and hose clamp to
the torque of 11 ± 2N.m and 2 ～ 2.5N.m respectively.
CS113083
CS113230
Note：Apply Loctite adhesive 510 onto the

turbocharger oil inlet pipe and oil return pipe
joint.
3-52
Replacement of Flywheel Ring Gear method) for 75°； if bolt length is 44mm， and tighten
Components (Including the Dual-mass them to the torque of 50 Nm in the sequence shown in
Flywheel) the figure， Loosen the bolts for 90°, re-tighten them to
Required tools: C00016994 and C00017014. 40Nm, then keep tightening (by the rotation angle
method) for 90°.
For DMF bolts if bolt length is 54mm，and tighten them to

Removal
the torque of 50 Nm in the sequence shown in the
1 Remove the clutch (refer to Replacement of figure， Loosen the bolts for 90°, re-tighten them to
Clutch).
25Nm, then keep tightening (by the rotation angle
2 Remove two diagonal bolts, and then install method) for 90°； if bolt length is 48mm， and tighten
guide pin C00017014 to support the flywheel.
them to the torque of 50 Nm in the sequence shown in
Warning: The flywheel is heavy. Please make sure the figure， Loosen the bolts for 90°, re-tighten them to
the flywheel is supported adequately when 40Nm, then keep tightening (by the rotation angle
removing it. method) for 90°.
3 Remove and scrap 8 flywheel bolts (M10), and For TRAY-FLEXIBILITY bolts if bolt length is 41mm，and
remove the flywheel. tighten them to the torque of 50 Nm in the sequence
shown in the figure，Loosen the bolts for 90°, re-tighten
them to 25Nm, then keep tightening (by the rotation
angle method) for 75°； if bolt length is 35mm， and
tighten them to the torque of 50 Nm in the sequence
shown in the figure，Loosen the bolts for 90°, re-tighten
them to 40Nm, then keep tightening (by the rotation
angle method) for 90°.
C00017014
Note：Tighten 1 bolt each time and tighten the
bolts in turn.
Note：Flywheel bolts (the same bolt can be used
for 1 time at most).
CS113093
Repeat in the sequence shown in the figure to tighten all
the rest bolts.
Installation
1
1 Clean the mating face between the flywheel and 50Nm
8 3
crankshaft. Check whether the locating pin is
installed properly.
5
Protrusion height of locating pin: 7.6 ± 0.5mm (for a 6
single-mass flywheel).
7
12.5 ± 0.5mm (for a dual-mass flywheel) 4
2
25Nm 60
2 Install flywheel bolts according to the next steps.
75
For SMF bolts if bolt length is 50mm，and tighten them to 90
CS113094
the torque of 50 Nm in the sequence shown in the
figure， Loosen the bolts for 90°, re-tighten them to Note：Tighten 1 bolt each time.
25Nm, then keep tightening (by the rotation angle
3-53
3 Install the clutch, and align it with tool Troubleshooting Method for Dual-mass
C00016994. Tighten clutch cover bolts first 8- Flywheel:
10N.m,then to the torque of 32-38 N.m in turn.
Dual-mass flywheel testing must be performed under the
Note：When assembling the clutch driven disc condition that the transmission is removed. The testing
component, the side marked with TRANS SIDE or mainly involves appearance and performance.
T/M side shall face outwards with the back
against the flywheel. Appearance inspection:
Appearance inspection refers to the visual inspection for

the general visible external parts. Appearance inspection
generally comprises of friction surfaces (heat, cracks,
etc.), starter ring wear and external dirts (such as
grease).
1. In the following cases, the dual-mass flywheel may not

be replaced:
Grease inside the transmission: A small amount of

C00016994
grease overflows between the primary and secondary
surfaces. The grease is thrown to the inner wall of
CS113095 transmission and concentrates inside due to the effect of
centrifugal force.
Note：Protrusion height of clutch locating pin: 7.6
± 0.5mm. Clutch heat: The clutch heat may not necessarily cause
the damage of dual-mass flywheel. When necessary,
carry out a test to make judgment.
2. In the following cases, the dual-mass flywheel is

recommended to replace:
Grease inside the transmission: The grease overflows

from the dual-mass flywheel. A large amount of grease
concentrates near the starter gear ring or inside the
transmission.
Clutch heat: Heat occurs on the mounting face

connected to the crankshaft; there are cracks on the
secondary flywheel, especially cracks on the connecting
face between the flywheel and clutch.
3. Damage of pressure plate locating pin, especially the

looseness, damage or missing of locating pin
Performance testing:
Torque testing for dual-mass flywheel:
Slightly apply a torque of 10N.m for secondary flywheel

when the flywheel is in "0" position (the position of
secondary flywheel relative to the primary flywheel at
idling). The relative gear ring of secondary flywheel can
be rotated for a 6-teeth angle to the maximum degree.
3-54
Improve the torsional torque to increase torsional angle. Replacement of Crankshaft Rear Oil Seal
Then the torsion shall increase smoothly. Meanwhile, Required tools ：
due to the reactive force of spring set, the forces and
angles in positive and negative directions shall be C00016994、 C00016995、C00017014、 C00017037
symmetrical. If the torsional rotation is unsymmetrical or
there is clamping and discontinuous resistance during Removal
torsional rotation or the corresponding knocking noise 1 Remove the clutch (refer to Replacement of
can be heard, this dual-mass flywheel shall be replaced. Clutch).
Common state of the dual-mass flywheel and possible 2 Remove the flywheel and scrap flywheel bolts
(refer to Replacement of Flywheel).
causes
3 Remove the oil ring metal frame ① and annular
1. The dual-mass flywheel is hot: thin block ② on the rear end of crankshaft. Scrap
O-rings of oil ring metal frame ① and annular
The main cause may be the clutch heat. The dual-mass
thin block ② on the rear end of crankshaft.
flywheel is not the part which produces heat and causes
failure. The secondary flywheel heat does not necessarily
mean that the dual-mass flywheel must be replaced.
3
1
For the hot dual-mass flywheel, it is recommended to
replace in case of the following conditions:
—Heat occurs at the punch radius of inner tooth disc
—Heat occurs at the pressure plate locating pin
— Cracks appear
2
2. The starter gear ring must be replaced if damaged
CS113096
3. Grease trace
The grease inside the dual-mass flywheel is thrown to 4 Gradually move tool C00017033 near the rear
external of parts through centripetal force, which is mainly end of crankshaft to pry the oil seal out of the
bearing seat.
appears between primary and secondary flywheels. A
small amount of grease overflow is acceptable, which will Note：DO NOT damage the crankshaft thrust plate
not lead to part failure. or bearing seat.
Due to production technology, a small amount of grease

may appear on the crankshaft mounting face, which will
not lead to part failure in general condition.
In case of grease overflow as below, the dual-mass

flywheel shall be replaced:
Grease overflows and concentrates near the starter gear

ring, showing this flywheel is damaged.
3-55
Installation seal (the distance between the rear bearing seat

end face and the crankshaft rear oil seal end
face) is 1.4 ± 0.15 mm.
Note：The new oil seal has included a new oil seal
Install a new O-ring onto the annular thin block on the
metal frame. DO NOT remove the oil seal from the
rear end of crankshaft. Place the annular thin block
metal frame before installation.
on the rear end of crankshaft into the rear-end
Note： The sealing lip is pre-lubricated. bearing seat thrust plate, and align the small locating
1 Clean the oil seal mounting position and pin hole on the crankshaft rear-end annular thin
crankshaft thrust plate. Then lubricate the block with the crankshaft locating pin. Then press
crankshaft thrust plate with engine lubricating oil. the edges of oil seal metal frame vertically into the
2 Install the crankshaft rear oil seal onto the guide rear main bearing seat hole by applying even force
pin. Ensure the locating hole on the rear oil seal onto the metal frame to make the plane of metal
is installed into the crankshaft locating pin (1). frame flush with or higher than the plane of rear
main bearing seat. During the whole press fitting of
oil seal, do not damage the main lip of oil seal.
1.4±0.15
Crankshaft rear
oil seal
Rear bearing
seat component
CS113099
3 Install tool C00016995 onto the guide pin. Then

press the oil seal components into the main CS113319
bearing seat hole on the rear end of crankshaft
with two old bolts to make the plane of oil seal 5 Install a new O-ring onto the annular thin block
metal frame flush with or a little lower than the on the rear end of crankshaft, and fix it with RTV
plane of rear main bearing seat. silicon rubber D18 (M) to avoid it from falling
down. Place the annular thin block on the rear
end of crankshaft into the rear-end bearing seat
thrust plate, and align the small locating pin hole
on the crankshaft rear-end annular thin block
with the crankshaft locating pin (1).
C00016995 6 Then press the edges of oil seal metal frame

vertically into the rear main bearing seat hole by
applying even force onto the metal frame to
make the plane of metal frame flush with or
higher than the plane of rear main bearing seat.
During the whole press fitting of oil seal, do not
damage the main lip of oil seal.
7 Install the flywheel (refer to Replacement of
CS113100 Flywheel). Remove the guide pin.
8 Install the clutch (refer to Replacement of
4 Try to remove the oil seal metal frame vertically Clutch).
with care. Ensure the press-fitting depth of oil
3-56
Replacement of Crankshaft
C00016997, C00017002, C00017003, C00017004,
1 C00017015, C00017013, C00017014, C00017016 and
C00017030.
Optional tools: C00017011, VM 1054, VM 1059, VM

1060, VM 1069 and VM 1073.
Removal
CS113098 1 Remove the cylinder head, etc. (refer to

Replacement of Cylinder Head).
2 Remove the flywheel (refer to Replacement of
Flywheel Housing).
3 Remove the flywheel dust board and 5 M10
screws.
4 Remove the rear oil seal and the annular thin
block on the rear end of crankshaft.
CS113101
5 Pull out the rear bearing seat with two bolts, as

shown in the figure.
CS113102
3-57
6 Remove the oil pump, vacuum pump drive gear 10 Remove the oil suction pipe and 2 M8 screws.
and 4 M6 screws. Scrap the O-ring.
7 Remove the flywheel dust board bracket and 4

M10 hexagonal screws.
CS113105
11 Remove the speed sensor and scrap its O-ring.

CS113103
12 Remove the cooling nozzle retaining bolts (4 M6
hexagonal screws), and pull the nozzle out with
8 Remove the oil pan and 21 M6 screws.
tool VM 1060. Scrap the O-ring.
9 Scrap the oil pan gasket and clean the mating
face.
CS113106
Note：Remove the piston cooling nozzle with
CS113104 special care, because the damaged nozzle will
lead to severe engine damage.
CS113107
3-58
13 Remove the piston and connecting rod

components as per the following sequence:
Note：Remove the piston cooling nozzle firstly
when removing the piston and connecting rod.
—Clear the carbon deposit on the top of each cylinder.
— Make proper marks on each pair of connecting rod

and connecting rod cap.
Note：Do not make marks by punching but by

paint or similar method. Number each component
(1 - 4) temporarily for identification during
installation. ES020003
14 After removing the oil baffle, put dipstick tube

and dipstick tube bracket away. Scrap the Oring.
2 2
ES020002
—Remove the connecting rod bearing cover, and push

ES020001
the piston/connecting rod component out.
Note：The connecting rod and connecting rod 15 Pull out the crankshaft bearing seat locking pin
bearing cover are provided with "cracking" with tool VM 1054.
mating face. DO NOT place any object on these
surfaces and avoid any object from falling onto
the surface; place the connecting rod and
connecting rod bearing cover laterally. DO NOT
knock the "cracking" mating face for removal.
—Re-install each connecting rod bearing cover onto its

connecting rod body (assemble it correctly), and tighten
bolts to 10 N.m.
Note：Re-install the piston/connecting rod

components into the engine block with new
connecting rod bolts.
ES020004
—Unless replacement, otherwise leave all connecting
rod bearing shells in their original positions.
16 Remove the oil pressure regulating valve with
tool C00017017.
3-59
—Make a mark on each crankshaft bearing seat

temporarily to make sure the crankshaft bearing seat
position and mounting face keep consistent with that
before removal.
C00017017
ES020005
17 Protect the crankshaft front bearing with a

sleeve.
ES020008
—Check whether there are corresponding marks on two

semicircles of each crankshaft bearing seat. If not, make
marks on them.
—Remove M6 hexagonal screw of each crankshaft

bearing seat in turn.
Sleeve
20 Remove the crankshaft.
Warning: The crankshaft is heavy.
ES020006 Note：Take care not to damage the crankshaft

journal. Remove the bearing from the bearing
18 Keep sliding the crankshaft backwards carefully seat.
until there is a large clearance between the
crankshaft bearing seat and the crank arm.
ES020009
ES020007
19 Crankshaft bearing seat:
3-60
Check Installation
Note：Lubricate moving parts with clean engine
lubricating oil before installation (avoid the
timing drive pulley, relevant timing pulleys and
belt pulleys from contacting engine oil).
Note：Keep clean during assembly, and avoid
dust from entering the oil duct.
1 2 3 4
1 Lubricate the mounting position of crankshaft
bearing seat in the engine block.
Note：
After bearing shells are installed into bearing seat, check
whether the oil hole on the bearing seat upper blade is
CS113117
unblocked.
Note：
The upper shell is provided with oil groove, while the
Be careful to avoid damaging the journal. lower shell is not. Do not make any mistake.
—Check whether all oil lines are clean. During maintenance and matching, mark the
intermediate bearing seat components with
—Check the followings for wear, scratch or overheat:
corresponding colors according to the grouping rules
—Crankshaft journal shown in the table below after measuring the inner
diameter dimension of intermediate bearing seat:
—Crankshaft thrust plate
—Journal of connecting rod
—Front-end journal Grouping Inner diameter grouping Mark

number color
—Bearing shells (three pairs of crankshaft bearing shells
1 Φ 66.670 ～Φ 66.679 Brown
are located inside the crankshaft bearing seat; front
bearing shells are on the engine block). Check whether 2 Φ 66.680 ～Φ 66.690 Green
these bearing shells are repairable, and remove/install

them if necessary. Crankshaft intermediate bearing shells are grouped as
follows:
Check whether these bearing shells are repairable, and
remove/install them if necessary.
Bearing shell identification: No.1 front bearing shell is Grouping Inner diameter grouping Mark
narrow and not equipped with locating projecting tongue, number color
but upper shell is provided with oil groove. No.2, 3 and 4 1 1.812 ～ 1.820 Brown
crankshaft bearing shells are wide. The upper shell is 2 Green
1.818 ～ 1.826
provided with oil groove, while the lower one is not.
Besides, they are equipped with locating projecting
Intermediate bearing seat and crankshaft intermediate
tongues used for location on the bearing seat.
bearing shell shall be paired by the grouping number and
shall not be mixed.
The mark color on the bearing shell and that on the

intermediate bearing seat shall keep consistent.
3-61
Check and confirm the locating lip on each bearing shell —Align the locating pin holes of three bearing seats with
is in the seam allowance of intermediate bearing seat. the corresponding holes on the engine block.
2 Assemble crankshaft components according to Note：Push the crankshaft into place carefully
the following steps. See the annex for details: without affecting alignment.
—Cover tool VM 1069 (if any) onto the crankshaft front —Remove tool VM 1069 (if used).
journal, and lubricate the journal with engine lubricating
oil.
—Install the crankshaft into the engine block.
—Install bearing shells into three intermediate bearing

seats (upper and lower shells are different: the upper
shell is provided with oil groove, while the lower one is
not. Do not make any mistake.
CS113120
—Install locating pins in place to fix the intermediate

bearing seats with the end of locating pin threads facing
the oil pan.
CS113118
—Install bearing seats according to relevant marks and

correct directions (gaps on the bearing seat shall
uniformly point to the front end of diesel engine). C00017017
—Tighten bearing seat bolts to 44 N.m.
CS113121
3 Install rear-end main bearing components:

— Install a new O-ring onto the rear-end bearing seat.
Note：When installing the rear-end main bearing,

apply Loctite adhesive 5699 or other-brand
silicone sealant (or equivalent) onto the mating
face between the rear-end main bearing seat and
engine block as shown in the figure. 1. O-ring 2.
CS113119 Silicone sealant
3-62
7 Install the locating pin of crankshaft bearing seat

with the end of thread facing the oil pan. Install
the oil baffle into its original position, and fix the
dipstick tube bracket and oil suction pipe (with
new O-rings). Tighten bolts to 32 N.m.
1 2
CS113122
—Locate the rear-end main bearing seat component with

two alignment bolts, and press it hard into place.
CS113125
8 If the oil pressure regulating valve has been

removed, install a new O-ring onto the valve
seat, and lubricate the seal ring with engine
lubricating oil. Press the oil pressure regulating
valve components into place (with tool
C00017018, if any).
CS113123
4 Install the flywheel dust board, and tighten C00017018

retaining bolts to 25 N.m.
5 Install the crankshaft rear oil seal, etc. (refer to
Replacement of Crankshaft Rear Oil Seal).
6 Install the flywheel (refer to Replacement of
Flywheel).
CS113126
9 Install the oil pan on the mating face between

engine block and oil pan with a new gasket.
Tighten all oil pan bolts to 15N.m in turn, and
loosen them for 90 ° in turn. Then re-tighten
25 Nm them to 15N.m.
CS113124
3-63
Replacement of Front Main Bearing

Removal
1 Remove the crankshaft, etc. (refer to
Replacement of Crankshaft).
2 Remove the old bearing with tool C00017021.
15 Nm
CS113127
C00017021
Note：When it is required to remove/install the oil
pan drain plug to remove/install the oil tank,
tighten the drain plug to the torque of 80 ± 3N.m.
10 Install a flywheel dust board bracket below the oil
pan, and tighten retaining bolts to 45 N.m. CS113130
Installation
1 Install the correct bearing shell into the engine
block crankshaft holes with tool C00017021.
45 Nm
C00017021
CS113128
11 Install the speed sensor.
CS113131
2 Select "brown" bearing shell for the engine block

marked with "H"; select "green" bearing shell for
the engine block marked with "L". The selected
bearing shell must have the consistent color.
Install correct bearing shell into the crankshaft
hole on the front end of engine block with a
special tool. After that, the front-end bearing hole
cylinder diameter shall be 0.02 and roundness
CS113129 shall be 0.017. Then check whether the front-end
main bearing shell' press-in depth is projecting
the engine block front-end surface for 0-0.3mm.
3-64
Note： Replacement of Cylinder Sleeve and its

Adjusting Pad
Assemble the front-end main bearing shell as per the
Removal
areas shown in the figure, and leave at least 2/3 space of
main oil duct hole. Otherwise it is required to press out, 1 Remove the crankshaft, etc. (refer to
Replacement of Crankshaft).
remove and re-assemble the bearing shell.If this engine
model is equipped with a flywheel dust board and without 2 Remove the piston and connecting rod (refer to
Replacement of Piston and Connecting Rod).
a flywheel housing, it is required to knock the locating pin
into the rear-end of engine block with a special tool 3 Pull out the cylinder sleeve, etc. with tool
C00017011.
(protrusion height: 5 ± 0.5mm). Install crankshaft
components into the engine block. 4 Remove and scrap green and black O-rings.
Remove the cylinder sleeve adjusting pad
Install the crankshaft into place carefully without affecting carefully.
alignment.
Note：When installing the bearing, the oil hole on

the bearing shell must be aligned with that on the C00017011
engine block.
C00017011
CS113132
H
CS113240
a
b
CS113116
a. Cylinder sleeve adjusting pad
b. Black O-rings (2pcs)
c. Green O-ring (1pc)
3-65
Installation
1 Determine the thickness of required cylinder
sleeve adjusting pad:
—Install the cylinder sleeve into engine block (without the
adjusting pad or O-ring). Apply pressure downwards, and
rotate the cylinder sleeve leftward and rightward for 45°
for several times.
CS113135
—Select an adjusting pad (there are 5 options), and

adjust the cylinder sleeve protrusion to the specified
range.
Cylinder sleeve protrusion: 0.01~0.05
Note：Only one adjusting pad can be used.

CS113133
—Install the selected clean adjusting pad onto the
cylinder sleeve.
—Place a dial indicator on the engine block and zero it as
shown. —Install a new O-ring as follows:
Note：Read all readings on the high-pressure oil 1） Install black O-rings to two grooves at the top of
pump side. cylinder sleeve (coolant seal rings).
2） Install the green O-ring to the groove at the bottom of

cylinder sleeve (lubricating oil seal ring).
3） Lubricate the position below the cylinder sleeve

assembling position in the engine block (lubricate O-
rings with a small amount of vaseline, while
lubricating oil is disallowed).
—Install the cylinder sleeve carefully, and ensure the

adjusting pad is installed properly. Fix the cylinder sleeve
with fixator C00017004.
CS113134 —Measure the cylinder sleeve protrusion (operate in the

same way as before). Protrusion shall be 0.01~0.05.
—Move the indicator until its contact is placed on the Note：There must be a 6h interval between
cylinder sleeve. At this time, the reading on the dial cylinder sleeve installation and engine start. If
indicator is the distance between the cylinder sleeve and you do not complete the engine reassembly after
the engine block. installing the cylinder sleeve, keep pressing the
cylinder sleeve for at least 12h.
3-66
Replacement of Piston and Connecting Rods Installation

Removal Note：The connecting rods are provided in a set (4
pcs). Select substitute parts with the weight of
1 Remove the components of piston and
the same group during connecting rod
connecting rod (refer to Replacement of
replacement. See color marks on the rod body for
Crankshaft). Clean the components of piston
and connecting rod. weight grouping marks.
—Check the piston for scratch, wear, etc. 1 If there is a need to re-install the old piston, clear
carbon deposit on piston head, piston skirt and
—Check whether all piston rings can rotate freely in their ring groove. Ensure the oil holes in the oil ring
grooves. groove are clean.
2 Install a new piston/piston ring centrally to the
—Check the piston pin for wear.
position 15mm away from the cylinder sleeve
Pay attention to marks to guarantee proper installation. top. The measure the ring opening clearance, as
shown in the figure. Refer to Technical
A The arrow on the piston head shall point to the front Parameters for correct opening clearance.
end. 3 If the opening clearance exceeds the dimension
range given, replace the piston ring or cylinder
B The identification marks on the connecting rod and
sleeve.
connecting rod bearing cover shall be on the same
side.
C The flange on the connecting rod bearing cover shall

be reverse with the arrow on the piston top surface
and point to the rear end.
2 Remove circlips from both sides of piston pin,

remove the piston pin, and separate the piston
and connecting rod.
CS113137
A
4 The identification mark (TOP) on the three rings

2 must face upwards. The three rings are identified
2
by color marks: the first ring is marked with
B
yellow; the second ring and oil ring are marked
with green. The color mark is on the side of ring.
C
CS113136
3-67
Note：Make sure not to damage the connecting

rod big end or crankshaft journal.
The second ring opening
120 120
CS113138 The first ring opening The third ring opening

Piston ring opening
5 If the piston has been separated from connecting CS113242

rod, re-assemble them as illustrated.
Note：If there is a need to re-install the old piston, —Install the corresponding connecting rod bearing cover,
clear carbon deposit on piston head, piston skirt and align identification numbers.
and ring groove. If re-installing the original piston
ring, make direction marks when removing the —Install new bolts, and tighten them gradually as per the
piston ring from the piston. Install the piston ring following 3 steps.
groove according to the original direction during
recovery. Piston ring opening shall stagger for Note：New bolts shall be pre-lubricated.
120° in circumference. Step 1 - 10°
Step 2 - 30°
Step 3 - 40°
A Note：After Step 3, check the tightening torque of

all bolts with a torque wrench (set as 88 N.m).
Note：The piston cooling nozzle should be
2 2
installed after the piston and connecting rods are
B
installed. Install O-ring onto the piston cooling
nozzle. Install the nozzle (with tool VM 1060, if
any) and tighten it to 11 N.m.
C Note：Install the piston cooling nozzle with
CS113136 special care, as the damage of nozzle will lead to
severe engine damage.
Install each component of piston and connecting rod as
Note：Apply Tonsan 1243 sealant onto the piston
below:
cooling nozzle bolts.
Note：If the piston is not replaced, make sure it is
re-assembled into its original cylinder.
—Place piston ring opening position as illustrated, and

press the piston ring with a proper clamping tool.
—Install the piston carefully to make the arrow on the

piston top point to the engine front end.
3-68
Replacement of Oil Filter

Removal
1 Drain oil and clean the area around the oil filter.
2 Fix the oil filter onto the modularized oil cooler
through thread directly. Loosen it with tool
C00017031, and then rotate the oil filter with
hands anticlockwise to remove the oil filter.
CS113140
CS113141
Installation
—Clean the mating face.
—The O-ring of oil cooler shall face the engine block.

Apply a small amount of oil onto O-ring. Screw the oil
cooler pipe joint towards the flywheel end, and then
tighten it to the torque of 50N.m. Then make a tightening
mark on it with a paint marker.
—Lubricate the seal ring.
—Install the oil filter. Lubricate the filter cylinder with

appropriate clean CD － 40 engine oil, and tighten the
filter cylinder to the torque of 20 ± 2N.m. Do not tighten it
excessively.
—Carry out recheck after the road test.
3-69
Engine Oil Drain Removal & Installation of Injection Pump

Bracket
1 There is an oil pan drain plug (M14x1.5) in the
Removal
lower front of the engine. Prepare an oil drum
(with capacity ＞ 10L) in the corresponding Note：During the removal of A/C alternator
position, and screw off the drain plug (80N.m) to bracket, the fasteners which must be removed
drain oil.。 and installed include the engine front support
bolt and stud of high-pressure oil pump.
2 Scrap the used drain plug seal ring.
3 After the oil is drained completely, install a new 1 Remove/install the front-end accessory drive belt
sealing washer onto the drain plug, and tighten it (refer to Removal & Installation of Front-end
to the specified torque (80N.m). Accessory Drive Belt).
2 Remove/install the timing drive belt (refer to
Removal & installation of Timing Drive Belt).
3 Remove/install the high-pressure oil pump (refer
to Removal & installation of High-pressure Oil
Pump).
4 Remove/install the A/C compressor, tighten bolts
to the torque of 25 ± 2N.m, and then make a
tightening mark with a paint marker.
5 Remove/install the alternator, tighten nuts to the
torque of 25 ± 2N.m, and then make a tightening
mark with a paint marker.
CS113239
CS113118
6 Remove/install the A/C alternator bracket.

7 Knock the A/C alternator bracket locating sleeve
into the engine block (the sleeve shall be 5 ±
0.5mm higher than the mounting face). Then
install the bracket (tightening torque: 45 ± 3N.m).
3-70
Replacement of Engine Assembly

Removal
1 Open the engine hood. Disconnect (refer to
Replacement of Battery) and remove the battery.
2 Remove the engine hood, disconnect the power
steering pump pipeline, and collect steering fluid
with a container.
3 Drain the coolant in the radiator, and collect the
coolant with a container (refer to Replacement of
Coolant).
CS113119
ES020022
4 Remove the intake grille.

5 Remove the intercooler (refer to Replacement of
Intercooler).
6 Remove the cooling module assembly from the
complete vehicle (refer to Replacement of
Cooling Module).
7 For an AT model, disconnect the transmission
cable. For a MT model, remove the center
console (refer to Removal of Center Console),
and then remove the shift lever.
8 Remove the catalytic converter assembly (refer
to Replacement of Catalytic Converter
Assembly).
9 Disconnect pipes and harnesses connected to
the engine.
3-71
ES020023 ES020024
10 Lift the complete vehicle to a certain height with

13 Lift out the engine assembly from the engine
a lifter, and disconnect the transmission rear
compartment with a proper lifting arm.
mount.
11 Lower the lifter to a certain height, and support
the engine assembly with an universal carrier.
ES020025
CS113234
Installation
12 Unscrew the nuts securing engine mount and
transmission to the engine. Place a proper
wooden or plastic block between the engine rear
end and firewall to prevent the engine from
damaging the firewall.
3-72
Turbocharger Removal/Installation 2 Remove and discard 4 turbocharger elbow

retaining nuts and turbine outlet gasket.
Removal
1 After removing the exhaust elbow heat shield,
disconnect the intake pipe, exhaust pipe,
turbocharger oil inlet and outlet pipes, etc (No
exhaust elbow heat shield for Euro IV engine).
ES020037
ES020036
ES020046
3 Remove and discard 4 turbocharger retaining

nuts, and separate the exhaust manifold from the
turbocharger.
ES020045
Note：Be sure to separate the turbocharger

exhaust elbow from the turbocharger as per the
following operating procedures.
ES020038
3-73
Installation
2 Turbocharger Installation.
a. Screw the turbocharger retaining studs into the
mating face between the exhaust pipe and
turbocharger, and check if the studs are fully
screwed in after tightening.
b. Install the turbocharger gasket, and the circular

flange of turbocharger gasket conforms to the
illustrated direction (toward the manifold flange).
ES020041
c. Install turbocharger components. Tighten the
turbocharger self-locking nuts to 33N.m in the
diagonal sequence.
ES020047
ES020040
Note： If the turbocharger retaining nut shown in

Figure 1 is adopted, be sure to install it properly,
with the end of 2 flat planes (pointed by the
arrow) on the nut facing upward.
3 Install the exhaust elbow.
a. Screw the exhaust elbow retaining studs into the
turbocharger exhaust end, and check if the studs
are fully screwed in after tightening.
b. Install the exhaust outlet flange gasket.
c. Install the exhaust elbow, and the tightening

torque of exhaust elbow retaining nuts is 45N.m.
d. Screw the studs into the triangle flange at the

other end of the exhaust elbow, and check if the
studs are fully screwed in after tightening.
e. Install the exhaust elbow heat shield (Euro V).
3-74
Removal/reinstallation of Turbocharger Electronic Throttle Removal/Installation

(European Stage V) Removal
Removal
1 Disconnect the negative battery cable.
1 Remove the turbocharger inlet and outlet pipes. 2 Raise the vehicle to a proper height.
2 Remove the turbocharger heat shield. 3 Loosen the hoop, and disconnect the intercooler
3 Remove the turbocharger bracket. hose from the engine assembly.
4 Remove the whole turbocharger (turbocharger 4 Disconnect the harness connected to the
and turbocharger controller) and exhaust elbow. throttle.
5 Remove the exhaust elbow from the 5 Loosen 4 bolts fixing the throttle body. Remove
turbocharger. the electronic throttle assembly.
Note：The turbocharger shall be replaced as a Note：Before the removal, it is required to mark
whole. the original mounting position of the throttle
(since the mounting screw hole is a square, but
the angle between the throttle shaft and
horizontal position shall be limited to ± 20°).
7XUERFKDUJHU
+HDWVKLHOG ([KDXVWHOERZ
7XUERFKDUJHUEUDFNHW
CS113337
ES020042
Installation
1 Install exhaust pipe onto the turbocharger.
2 Install the combination of turbocharger
Installation
andexhaust elbow onto the exhaust pipe.
3 Install the turbocharger bracket.
2 Assemble according to the positions marked
4 Install the turbocharger heat shield.
before the removal.
Other installation requirements are consistent with China
3 With the gasket installed, screw the electronic
stage IV standard for engine turbocharger installation.
throttle into the air inlet pipe component. The
Refer to China Stage IV Standard for Engine tightening torque is 11N.m.
Turbocharger Installation.
3-75
Replacement of Glow Plug Controller Precautions for Installing Flywheel onto the
Removal Short-stroke Engine Maintenance
1 Disconnect the battery ground terminal.

一、 Short-stroke Engine Maintenance
Component Status
2 Disconnect the harness connected to the glow The short-stroke timing has been adjusted, and the
plug controller.
camshaft timing is locked by the cam timing pin. The
flywheel timing cannot be locked by the flywheel timing
pin because the flywheel is not installed.
二、 Flywheel Mounting Steps after the Short-

stroke Engine Maintenance Component is
Unpacked
1 Remove the press plate bolts and press plate of
crankshaft rear oil seal (only applicable to the
transport of short-stroke engine).
2 Install 2 guide pins (C00017014), and then install
flywheel ring gear assembling components.
3 Install and pre-tighten flywheel bolts (8pcs).
ES020043
3 With a socket wrench, remove the nut fixing the

glow plug controller to the body.
C00017014
CS113093
4 Adjust flywheel timing. Install the flywheel timing

pin C00017003. If it cannot be inserted, slightly
ES020044 rotate the crankshaft clockwise or anticlockwise
(within 5° crankshaft rotation angle range).
5 Knock the straight pin into the flywheel ring gear
assembling component with a tool (the
Installation protrusion of the pin shall be 7.25-7.35 mm).
1 Installation is the reverse of removal, the
Note：The sphere of flywheel straight pin shall
tightening torque of glow plug controller nut is: 5
face outwards
± 1N.m.
3-76
6 Tighten flywheel bolts as specified. Refer to Timing Failure Judgment

Replacement of Flywheel Ring Gear
Required tools: C00016996、 C00016997、
Component.
C00017003、 C00017015
Note：Hang attached 2 plugs and 2 gaskets of
cam timing pin hole on the cylinder head. 1 Remove the flywheel as well as bulkheads and
screw plugs of intake and exhaust camshaft
Note：Screw plugs are disposable. Therefore it is
locating pins.。
prohibited to use removed screw plugs.
2 Rotate the crankshaft shock absorber
clockwisewith tool C00017015.
1.4±0.15
Crankshaft rear
oil seal
C00017003 Rear bearing

seat component
CS113222
CS113319
C00017015
CS113318
3-77
3 Locate with flywheel timing pin C00017003,

intake camshaft timing pin C00016996 and
exhaust camshaft timing pin C00016997 in turn.
C00017003
CS113222
C00016996
C00016997
CS113007
4 If accurate location still cannot be realized after

clockwise rotating the crankshaft shock absorber
for 2 circles, the timing will be judged as failed.
3-78
Engine Mechanical System SC20M163Q5A
Specification
Torque
Tightening Torque for Fasteners
Item Name Torque, N.m
Bolt - Vacuum Pump Parts 10 ± 1 N.m

Bolt - Crankshaft Shock Absorber 18 N.m ＋ 40°
Bolt - Steering Pump 33 ± 3 N.m
Bolt - Camshaft Timing Pulley 31 ± 1 N.m
Bolt - Timing Tension Pulley 25 ± 1 N.m
Bolt - Crankshaft Timing Pulley 135 N.m+120°
Bolt - High-pressure Fuel Pump Timing Pulley 30 ± 1 N.m
Bolt - Timing Idler I 40 ± 1 N.m
Bolt - Timing Idler II 50 ± 1 N.m
Bolt - Timing Idler III 40 ± 1 N.m
Bolt - Engine Belt Tension Pulley 50 ± 1 N.m
Bolt - Belt Idler 50 ± 1 N.m
Bolt - Camshaft Timing Pulley Intermediate Flange 65 N.m ± 90°
Nut - High-pressure Fuel Pump Timing Pulley Intermediate 80 ± 1 N.m
Flange
Bolt - A/C Compressor Bracket 35 ± 3 N.m

Bolt - Accessory Bracket 35 ± 3 N.m
Bolt - Steering Pump Bracket 25 ± 2 N.m
Cold Start Glow Plug 13 ± 2 N.m
Bolt - Camshaft 11 ± 1 N.m
Bolt - Camshaft Position Sensor Bracket 11 ± 1 N.m
Bolt - Valve Chamber Cover 11 ± 1 N.m
Bolt - Fuel Injector Clamp 33 ± 3 N.m
Bolt - Water-Air Intercooler Bracket 45 ± 3 N.m
Bolt - Timing Cover (Lower) 8 ± 1 N.m
Bolt - Timing Pulley Chamber 11 ± 1 N.m
Bolt - Camshaft Frame 11 ± 1 N.m
2-1
Bolt - Cylinder Head Step 1: 45 ± 2 N.m

Step 2: 75 ± 5 N.m
Step 3: Tighten by 100°
Step 1: 30 ± 2 N.m
Bolt - Connecting Rod
Step 2: 90 ± 5°
Bolt - Crankshaft Signal Plate 11 ± 1 N.m
Bolt - Front Crankshaft Oil Seal Assembly 11 ± 1 N.m
Bolt - Rear Crankshaft Oil Seal Assembly 11 ± 1 N.m
Piston Cooling Nozzle 27 ± 3 N.m
Bolt - Flywheel Assembly 80 N.m+140°
Bolt - Flex Plate 80 N.m+140°
Bolt - Balance Shaft 45 N.m+105°
Bolt - Balance Shaft Idler 60 ± 4 N.m
Bolt - Flywheel Housing to Cylinder Block 80 ± 3 N.m
Bolt - Flywheel Housing to Frame 43 ± 2 N.m
Oil Drain Plug 25 ± 2 N.m
Bolt - Oil Pump (Long) 22 ± 2 N.m
Bolt - Oil Pump (Short) 9 ± 1 N.m
Bolt - Oil Filter Cooling Module 25 ± 2 N.m
Bolt - Lower Engine Block Frame (M8) 22 ± 2 N.m
Bolt - Lower Engine Block Frame (M6) 10 ± 1 N.m
Bolt - Oil Pan 11 ± 1 N.m
Bolt - Oil Pump Suction Pipe 9 ± 1 N.m
oil filter 20 ± 2 N.m
2-2
Engine Model/No.
රਧ: SC 20 M 150 ⌘1 Q 6 ⌘2
1
2
3
4
5
6
S02013183
1: Emission stage
2: Automotive engine
3: Power (HP)
4: Serial code
5: Total displacement
6: Manufacturer (SDEC)
Note 1: When the displacement and power of the engines are the same, but other characteristics such as speed and torque
are different, and they must be distinguished in the models, it is allowed to distinguish the models with "1, 2,..." following the
power.
Note 2: When the technical route needs to be distinguished in the same emission stage, it is allowed to add the
supplementary symbol A/B/C... following the emission code; when further subdivision is required, it is allowed to add 1, 2...
following the supplementary symbol to distinguish.
2-3
Parameters
Basic parameters
Model SC20M163Q5A
Bore 83 mm
Stroke 92mm
Displacement 1.996 L
Injection Sequence 1-3-4-2
Compression ratio 15.9：1
Idle Speed rpm 700 ± 50
Cylinder Head
Cylinder Head Gasket
Type A - 1.45 mm
Thickness (Optional
Type B - 1.55 mm
According to Actual
Piston Protrusion) Type C - 1.65 mm
Cylinder Head Gasket Piston Protrusion

Selection Rules Select type A when the thickness is 0.56-0.66 mm (without mark hole)
Select type B when the thickness is 0.66-0.76 mm (with 1 mark hole)
Select type C when the thickness is 0.76-0.86 mm (with 2 mark holes)
Flatness Requirements
for Cylinder Head ≤ 0.075 mm
Surface
Cylinder Head Height 101 ± 0.08 mm
Deflection of the Valve
on the Cylinder Head 0.65 ± 0.2 mm
Outer Diameter of
12 mm
Hydraulic Tappet
Valve
Valve Conical Surface
Angle 45°
Valve Stem Diameter 6 mm

Clearance between
Intake: 0.025-0.052 mm;
Valve Stem and Valve
Guide
Exhaust: 0.035-0.062 mm;
Valve Cap Diameter Intake: 27.5 mm

Exhaust: 25.6 mm
Valve Guide
Inner Diameter of Valve
Guide Φ 6H7(0，﹢ 0.012)
Valve Guide Mounting

Height (from the valve oil 14. 6 ± 0.2 mm
seal mounting surface)
Valve Spring
Free height 49.7 mm
Mounting Height 34 mm
Camshaft
2-4
Crank Angles Intake Valve Open: 26° before top dead center
Corresponding to Intake
Valve Open and Closed Intake Valve Closed: 60° after bottom dead center
Crank Angles Exhaust Valve Open: 26° before bottom dead center
Corresponding to
Exhaust Valve Open and
Exhaust Valve Closed: 32° after top dead center
Closed
Axial Gap 0.07-0.12 mm
Journal Bearing
0.04-0.073 mm
Clearance
Journal Diameter 22mm
Connecting Rod
Inner Diameter of
30.028-30.038 mm
Connecting Rod Sleeve
Inner Diameter of
56.6-56.017 mm
Connecting Rod Big End
Axial Gap 0.35 - 0.63 mm
Connecting Rod Weight Group Weight, kg
B 0.820-0.824
C 0.825-0.829
D 0.830-0.834
E 0.835-0.839
F 0.840-0.844
G 0.845-0.849
Balance shaft size

Balance shaft journal
31.994-32 mm
diameter
Piston
Piston Clearance in Bore
0.043-0.076 mm
Hole
Piston Protrusion 0.56-0.86 mm
Piston Diameter
(measure the width of
82.938-82.956 mm
the piston 16 mm above
the piston skirt)
Piston Ring-to-Groove Clearance
Top Compression Ring 0.12-0.165 mm
2nd Compression Ring 0.06-0.105 mm
Oil Ring 0.03-0.07 mm
2-5
Piston ring opening clearance

Top Compression Ring 0.2-0.3 mm
2nd Compression Ring 0.4-0.65 mm
Oil ring 0.25-0.5 mm
Piston pin diameter 29.994-30 mm
Crankshaft axial gap
Axial Gap Thrust Washer
0.1-0.29 mm
Thickness
Main Journal Size 2(-0.06,-0.02)mm
Main Bearing Shell Thickness 58 （-0.017,0） mm
(Optional According to Black: 1.984-1.987 mm
Bearing Shell Selection Table) Green: 1.988-1.991 mm
Blue: 1.992-1.995 mm
Connecting Rod Journal Size 53(-0.017,0)mm
Connecting Rod Bearing Shell
Black: 1.784-1.788 mm
Thickness
Green: 1.789-1.793 mm
(Optional According to
Blue: 1.794-1.798 mm
Bearing Shell Selection Table)
Cylinder Block
Cylinder Bore Inner Diameter 83(0,0.014)mm
Glow Plug
Model/Type GLP2 HS
Voltage Preheating Start 1.9 s: 11 V
Stable Preheating: 4.4 V
Lubrication System
Oil Pump Two-stage Variable Oil Pump
Pressure High Pressure: 4 ± 0.2 bar
Low Pressure: 2 ± 0.2 bar
Displacement 17cc/rev
Gear Ratio 1.115
Vacuum System
The Minimum Vacuum at Idle
Speed ≥ 800mbar
2-6
Cylinder Block
12.6
A 67.6
118
B
S02010028
Items Standard Value (mm)

Cylinder Block Top Surface Deformation 0.05
Standard Value: 83-83.014
Cylinder Bore Inner Diameter
Wear Limit: 0.01
Out-of-round (difference between X and Y direction) 0.008
Taper (difference between A and C) 0.01
62-62.0085
Main Bearing Bore Diameter
62.0085-62.017
2-7
Layout
Accessory Pulley System
5
8
S02010021
1 Compressor Belt 5 Engine Belt Tension Pulley

2 Belt Idler Assembly 6 Accessory Belt
3 Timing Pulley Chamber Cover 7 Crankshaft Shock Absorber
4 Steering Pump 8 Timing Cover (Lower)
2-8
Cylinder Head
4
3
14
15 5
13
6
7
12 11
8
10
S02010022
1 Valve Chamber Cover Parts 9 Cylinder Head Assembly

2 Roller Rocker (Qty.: 16) 10 Valve (Qty.: 16)
3 Hydraulic Tappet (Qty.: 16) 11 Valve Spring (Qty.: 16)
4 Camshaft Position Sensor Bracket 12 Intake Camshaft
5 Camshaft Frame Parts 13 Exhaust Camshaft
6 Valve Cotter (Qty.: 32) 14 Camshaft Cover (Qty.: 5)
7 Valve Spring Upper Seat (Qty.: 16) 15 Camshaft Oil Seal
8 Valve Stem Oil Seal (Qty.: 16)
2-9
Crankshaft Connecting Rod
1
2
4
13
12 8
10
11
S02010023
1 Top Piston Ring (Qty.: 4) 8 Crankshaft Assembly

2 Second Piston Ring (Qty.: 4) 9 Main Bearing Shell (Qty.: 10)
3 Oil Ring (Qty.: 4) 10 Main Bearing Cap (Qty.: 5)
4 Piston Pin Retainer (Qty.: 8) 11 Crankshaft Thrust Bearing (Qty.: 2)
5 Piston Pin (Qty.: 4) 12 Flywheel
6 Connecting Rod Assembly (Qty.: 4) 13 Piston (Qty.: 4)
7 Connecting Rod Bearing Shell (Qty.: 8)
2-10
Timing Belt Pulley System
4
3
10
8
9
S02010024
1 Timing Drive Belt 6 Timing Idler I

2 Timing Tension Pulley 7 High-pressure Oil Pump Timing Pulley
3 Camshaft Timing Pulley 8 Timing Idler II
4 Timing Pulley Chamber 9 Crankshaft Timing Pulley
5 Timing Cover (Upper) 10 Timing Idler III
2-11
Engine Block
1
2
19
3
17
18
16 4
15
14
13
6
12
11
10
7
S02010025
1 Cylinder Head Gasket 10 Flywheel Housing

2 Front Engine Bracket 11 Exhaust Side Balance Shaft Gear
3 Front Crankshaft Oil Seal Seat 12 Balance Shaft
4 Front Crankshaft Oil Seal 13 Rear Crankshaft Oil Seal Seat
5 Right Front Engine Mount 14 Rear Crankshaft Oil Seal
6 Lower Engine Block Frame 15 Balance Shaft Idler Assembly
7 Oil Pump Assembly 16 Balance Shaft Needle Bearing
8 Oil Pump Suction Pipe Assembly 17 Left Front Engine Mount
9 Oil Pan Assembly Parts 18 Engine Block
2-12
19 Oil Filter Cooling Module Assembly 20 Intake Side Balance Shaft Gear
2-13
Vacuum Unit
3
5
1
2
S02010026
1 Vacuum Pump/On-off Solenoid Valve Hose 6 Solenoid Valve/High-pressure Turbine End

Bypass Valve Hose
2 Vacuum Control Solenoid Valve
7 Solenoid Valve/Low-pressure Turbine End Bypass
3 Vacuum Pump/Solenoid Valve Hose
Valve Hose
4 Vacuum Control Valve
8 Vacuum Pump Parts
5 Solenoid Valve/High-pressure Pressure End
Bypass Valve Hose
2-14
Under normal circumstances, the higher the speed is, the

Diagnostic Information and Procedures
louder the abnormal mechanical sound will be. At high
Diagnosis and Troubleshooting of Abnormal speeds, however, various kinds of sounds mingle together,
Engine Sound some abnormal sounds are not easy to distinguish,
therefore the speed for diagnosis depends on the condition
1 Large fit clearance
of the abnormal sound. For example, in the case of valve
Fit clearance is an important indicator of automobile
and piston knocking cylinder sound, it is noticeable at idle
assembly quality. When the lubrication, temperature, load
or low speeds. If the main bearing, connecting rod bearing
and speed are constant, the abnormal sound will become
and piston pin sounds are serious, they can also be heard
more obvious with the increase of the fit clearance. The
at idle and low speeds. In short, the diagnosis of abnormal
abnormal sound such as knocks generated from the piston
sound shall be carried out at the speed when the sound is
and the cylinder wall and clashes from the connecting rod
most obvious and at low speeds as much as possible to
bearing and the bearing journal may be caused by
reduce unnecessary noise and loss.
excessive clearance due to natural wear of some moving
parts of the engine. 7 Temperature
Some abnormal sounds are related to the engine
2 Insufficient lubrication
temperature, while some are not the case. In the diagnosis
Lubricating is an important condition for the normal
of abnormal mechanical sound, special attention shall be
operation of the engine. Lubrication, cooling, cleaning,
paid to the working condition of the accessories with high
sealing and rust prevention can be achieved by the
coefficient of thermal expansion in hot engine state, for
lubrication system. When the fit clearance, temperature,
example the piston knocking cylinder sound which
load and speed are constant, the thickness of the lubricant
becomes more obvious during engine cold start while
film is affected by the pressure of the lubrication system
weakens or disappears as the temperature rises.
and the quality of the lubricant, so good lubricant film
Therefore, the diagnosis of cylinder knocking sound shall
benefits from good lubricant and suitable pressure. The
be carried out at low engine temperatures. However, the
thicker the lubricant film is, the smaller the mechanical
temperature has little effect on the abnormal sound
impact will be, as a result, the abnormal sound is less likely
generated by the accessories with small coefficient of
to occur. If the lubricant film is too thin, resulting in
thermal expansion. For example, the abnormal sounds of
increased wear, abnormal sound will occur and be obvious
the crankshaft main bearing, connecting rod bearing and
and clear.
valve have no special requirements for the diagnostic
3 Deformation and damage to individual parts temperature. The temperature is also one of the main
Abnormal sound due to deformation or damage to a part. factors affecting the abnormal combustion sound.
For example, knocks caused by bent connecting rod, and 8 Load
abnormal sound caused by broken valve spring and
Many abnormal sounds are related to the engine load,
cracked crankshaft.
such as the crankshaft main bearing sound, connecting
4 Abnormal combustion rod bearing sound, piston knocking cylinder sound and
Metal knocking sound caused by premature roughness cylinder air leak sound, which increase with the increase of
due to premature oil injection of diesel engine. the load and weaken with the decrease of the load.
5 Improper assembly, adjustment or repair 9 Cylinder position
Inaccurate fit clearance between parts due to improper Some abnormal sounds are related to the cylinder position.
assembly, adjustment or repair. For example, the For piston knocking cylinder sound and connecting rod
abnormal sound caused by tightly assembled piston pin. bearing sound, twice a working cycle (abnormal sound
disappears when cutout occurs in a single cylinder); for
6 Speed valve train sound, once a working cycle; for piston pin
sound, connecting rod bearing sound, etc., once a
2-15
revolution of crankshaft; for valve sound, valve seat ring

sound, etc., once two revolutions of crankshaft.
Diagnostic methods of abnormal sound

Common abnormal engine sounds are mainly in the crank
train and the valve train. There are two diagnostic methods
of abnormal engine sounds: artificial auscultation and
instrument-aided diagnosis.
1 Artificial auscultation
The technician reproduces the abnormal sound by
changing the engine working condition and other means to
find out the characteristics and laws of the abnormal
sounds and understand the engine running condition and
the failure symptom when the abnormal sound occurs, so
as to determine the abnormal sound part, which is by far
the most common and the dominant method.
In the process of using artificial auscultation to diagnose

abnormal sounds in the engine, a screwdriver is often
used. Although the traditional method is simple and
effective, it has obvious shortcomings: a) The screwdriver
is limited in length and cannot be bent, as a result, multiple
parts cannot be touched and diagnosed due to limited
vehicle space. b) In the course of diagnosis, one ear of the
technician must be put close to the abnormal sound part,
which means it is impossible for him/her to watch the
screwdriver, for the sake of safety, a variety of rotating
parts are kept untouchable. c) When checking with a
screwdriver, one ear can hear the sound from the
screwdriver while the other ear is hearing strong
background noise, which reduces the accuracy of the
determination.
2 Instrument-aided diagnosis
Due to the low accuracy of artificial auscultation, some
instruments and equipment are often used to assist in the
auscultation and analysis. The commonly used
instruments mainly include the stethoscope, noise limiter,
vibration analyzer, etc.
2-16
Symptom Table
Symptoms Possible Causes Measures

Look for the evidence of oil leakage on the
parts. If the oil leakage is not noticeable, a UV
Oil leakage in engine or vehicle
leak detector can be used to locate the
accessory parts relating to lubrication
leakage part. Refer to “UV Test”
system
Replace with a new sealing gasket or a part
when necessary.
Lack of engine oil
Check if there is any oil film on the surface of
Oil cooler internal or external leakage coolant in the auxiliary radiator, and install a
new oil cooler or oil cooler gasket.
Leakage in front and rear crankshaft oil
Replace with a new oil seal.
seals
Confirm the type of the last used oil and
Oil that does not meet the standard
compare it with the standard oil required;
(standard brand) is used
replace the oil when necessary.
Failure of crankcase ventilation system
- Blocked vent pipe. This results in high
pressure in the crankcase, causing the
engine oil to enter the combustion
Check the crankcase ventilation system for
chamber.
normal operation; repair it when necessary.
- Failure of oil separator on the cylinder
head; the oil enters the combustion
chamber through the crankcase vent
pipe and the intake manifold.
High oil consumption
Check and maintain, and replace with a new
Leakage in turbocharger and seal ring turbocharger when necessary. Refer to
“Turbocharger Replacement”
Remove the cylinder head. Check the cylinder
Damaged or warped joint surface of head gasket for deformation or ablation; check
cylinder head, cylinder block and the flatness of the joint surface of cylinder head
cylinder head gasket and cylinder block. Refer to “Cylinder Head
Deformation” .
Worn piston ring or inner wall of Check the piston ring or inner wall of cylinder
cylinder bore bore; replace with a new one when necessary.
Worn valve oil seal, causing oil to enter
Replace with a new valve oil seal.
the combustion chamber
Replace with a new cooling system part when
Leakage in cooling system parts
necessary.
Replace with a new EGR cooler when
Leakage in EGR cooler
necessary.
Leakage in oil cooler Replace with a new oil cooler when necessary.
Excessive coolant
Check the cylinder head gasket for
consumption Damaged or warped joint surface of
deformation or ablation; check the flatness of
cylinder head, cylinder block and
the joint surface of cylinder head and cylinder
cylinder head gasket
block.
Cracks on engine parts such as
Find out the damaged engine part, and replace
cylinder block and cylinder head water
it with a new one.
jackets
2-17
No fuel Check the fuel tank.

Water in the fuel system Drain the water from the fuel system.
Blocked fuel filter Replace with a new fuel filter.
Bleed the fuel system. Check the fuel system
Engine cranks but does not Air in the fuel pipe
for leakage.
start
Blocked engine intake pipe and air filter Check the intake system.
Check the glow plug and replace it with a new
Glow plug failure
one when necessary.
Engine management system Check the engine management system.
High-pressure fuel pump or fuel Check the high-pressure fuel pump or the fuel
injector failure injector for normal operation.
Engine cranks but does not Incorrect valve timing Check and adjust the valve timing system.
start Check the timing drive belt and replace it with a
Broken timing drive belt
new one when necessary.
Blocked exhaust pipe Check the exhaust system.
Fuel system Check the fuel system parts.
Engine intake system Check the intake system.
Low power output/high oil Blocked exhaust system Check the exhaust system.
consumption/unsteady engine Engine management system Check the engine management system.
running
Turbocharger Check the turbocharger.
High-pressure fuel pump or fuel Check the high-pressure fuel pump or the fuel
injector failure injector.
Low power output/high oil
Incorrect valve timing and damaged Check and adjust the valve timing. Replace
consumption/unsteady engine
timing chain or timing sprocket with a new part when necessary.
running
Vehicle accessories such as front
Check the vehicle accessories for damage/
Noise in running wheel parts and support mountsLoose
looseness.
or damaged parts
Find out the standard brand of the fuel added
Incorrect fuel
last time.
Check the fuel system for water or other
Water in fuel or contaminated fuel
Noise in running, misfire/ impurities.
backfire High-pressure fuel pump or fuel Check the high-pressure fuel pump or the fuel
injector failure injector.
Incorrect valve timing and abnormally Check and adjust the valve timing. Replace
worn timing chain or timing sprocket with a new part when necessary.
Engine parts
- Piston
- Piston ring
Noise in running/worn or Check the engine parts for wear or damage.
damaged engine moving parts - Connecting rod big-end bearing, Replace with a new part when necessary.
crankshaft main bearing shell or thrust
bearing
- Bent or damaged connecting rod
2-18
Worn valve rocker Replace the valve rocker.

Broken valve spring Replace the valve spring.
Check the cam lobe of the engine.
Worn engine cam lobe Replace the camshaft and valve lash adjuster
when necessary.
Upper engine noise, regardless Check the components below, and repair or
of engine speed replace them when necessary.
Worn valve guide or valve stem
Valve.
Valve guide.
Stuck valve Check the components below, and repair or

Carbon deposits on the valve stem or replace them when necessary.
the valve seat may cause the valve to Valve.
get stuck in the open position Valve guide.
Worn accessory drive component -
Abnormal conditions, such as severe
Check the accessory drive system, and repair
crack, swell or partial absence of the
or replace it when necessary.
accessory drive belt and/or system part
misalignment occur
Loose or damaged flywheel Repair or replace the flywheel.
Damaged oil pan touching oil pump
screen - A damaged oil pan may result Check the oil pan.
Lower engine noise, regardless in wrong location of the oil pump Check the oil pump screen.
of engine speed screen, preventing the oil from flowing Repair or replace when necessary.
to the oil pump properly
Loose, damaged or blocked oil pump Check the oil pump screen, and repair or
screen replace it when necessary.
Large clearance between piston and Check the piston and cylinder bore and repair it
cylinder when necessary.
Large clearance between piston pin Check the piston, piston pin and connecting
and pin bore rod.
2-19
3 Fix the vacuum pump components to the camshaft

Service Guide
frame, install 4 bolts, tighten them to 10 ± 1 N.m,
Vacuum Pump Replacement and check the torque.
Removal Note: When assembling the vacuum pump, if the

vacuum pump convexity is not aligned with the
1 Remove the front catalytic converter. Refer to
camshaft concavity, do not hit the vacuum pump
“Front catalytic Converter Replacement” .
housing by using a copper rod to make it fall into
2 Remove 4 bolts fixing the vacuum pump to the the camshaft concavity, in order to avoid damage
camshaft frame. to the vacuum pump convexity and camshaft
3 Remove the vacuum pump (1). concavity and loose camshaft thrust ring.
4 Install the front catalytic converter. Refer to“Front

Catalytic Converter Replacement” .
S02013226
4 Remove the vacuum pump sealing gasket.

Note: Discard the used sealing gasket.
S02013227
Installation
1 Replace with a new sealing gasket.
2 Install the vacuum pump on the camshaft frame.
Note: If the vacuum pump does not lean against
the rear end of the cylinder head when assembling
the vacuum pump, it indicates that there is a
clearance. At this time, do not force to tighten the
bolts to avoid displacement of the camshaft thrust
ring.
2-20
Crankshaft Shock Absorber Replacement Accessory Belt Replacement

Removal Removal
1 Remove the lower engine guard plate. 1 Remove the lower engine guard plate.
2 Remove the accessory belt. Refer to “Accessory 2 Rotate the engine belt tension pulley (1)
Belt Replacement” . counterclockwise with a large-torque wrench until
3 Remove 4 bolts fixing the crankshaft shock the accessory belt (2) can fall off from the engine
absorber to the crankshaft timing pulley. belt tension pulley.
4 Remove the crankshaft shock absorber (1). 3 Remove the accessory belt (2).
1
1
S02013229 S02013230
Installation Installation
1 Fix the crankshaft shock absorber to the 1 Rotate the engine belt tension pulley
crankshaft timing pulley, install 4 bolts, tighten counterclockwise with a large-torque wrench until
them to 18 N.m for Step 1, further tighten them to the accessory belt can be mounted on the engine
belt tension pulley.
40° for Step 2, and check the torque.
Warning: Do not bend the accessory belt when
2 Install the accessory belt. Refer to “Accessory
Belt Replacement” . installing, and there shall be no oil, water and other
impurities on the accessory belt, So as not to affect
3 Install the lower engine guard plate.
the service life of the belt.
Note: When installing the accessory belt, the font
reading direction on the belt shall be consistent
with the running direction of the crankshaft shock
absorber, otherwise the accessory belt will be
damaged.
Note: When installing the accessory belt, make
sure that the belt is oriented the same as it is
removed.
2-21
Idler Bracket Replacement Timing Drive Belt Replacement

Removal Removal
1 Raise the vehicle. 1 Remove the cooling fan assembly. Refer to
2 Remove the accessory belt. Refer to “Accessory “Cooling Fan Assembly Replacement” .
Belt Replacement” . 2 Remove the timing pulley chamber cover. Refer to
3 Remove the intercooler. “Timing Pulley Chamber Cover Replacement” .
4 Remove 6 bolts on the idler bracket. 3 Align with the timing gear mark, and install the
special tools C00189125, C00189138 and
5 Remove the idler bracket (1).
C00189137.
Note: For ease of installation, make the timing
mark before removal.
1
S02013415
Installation
S02013233
1 Install the idler bracket.
2 Install the idler bracket bolts, tighten them to 30 ± 4 Fix the timing tension pulley (1) with tools, and
3 N.m, and check the torque. remove 1 bolt fixing the timing tension pulley to the
3 Install the intercooler. engine block.
4 Install the steering pump oil inlet/outlet pipe. Note: Unscrew the timing tension pulley retaining
5 Install the accessory belt. Refer to “Accessory bolt, but do not screw it out.
Belt Replacement” .
6 Lower the vehicle.
S02013234
5 Remove the timing drive belt (1).
2-22
tighten 3 retaining bolts of the camshaft pulley to

31 ± 1 N.m.
5 Install the timing pulley chamber cover. Refer to
1
“Timing Pulley Chamber Cover Replacement” .
6 Install the cooling fan assembly. Refer to“Cooling
Fan Assembly Replacement” .
S02013235
Installation
1 Ensure to align with the timing mark of the timing
gear, and install the timing drive belt.
Warning: Do not bend the timing drive belt when
installing, and there shall be no oil, water and other
impurities on the timing drive belt. So as not to
affect the service life of the timing drive belt.
Note: When installing the timing drive belt, the font
reading direction on it shall be consistent with the
running direction of the crankshaft shock
absorber, otherwise the timing drive belt will be
damaged.
Note: When installing the timing drive belt, make
sure that the timing drive belt is oriented the same
as it is removed.
2 Tighten 1 bolt fixing the timing tension pulley to the
engine block to 25 ± 1 N.m, and check the torque.
Note: Check the tension of the timing drive belt.
3 Remove the special tools C00189125, C00189138
and C00189137.
4 Carry out the timing inspection, walk around the
vehicle for 4 circles after completing the timing
system assembly, and install C00189138 and
C00189125 again. At this time, the crankshaft
pulley locating tooling pin C00189125 may not
insert into the locating hole due to deviation,
therefore it is required to unscrew 3 bolts of the
camshaft pulley, and rotate the crankshaft to
enable the crankshaft pulley locating pin
C00189125 to be inserted into the locating hole.
Then it is required to check if the timing tensioner
pointer is within the notch range. If there is large
deviation, it is required to readjust the timing
tensioner; after the tensioner is adjusted in place,
2-23
Camshaft Timing Pulley Replacement Timing Tension Pulley Replacement

Removal Removal
1 Remove the timing drive belt. Refer to “Timing 1 Remove the timing drive belt. Refer to “Timing
Drive Belt Replacement” . Drive Belt Replacement” .
2 Fix the special tool C00189138 (1) to the camshaft 2 Return the timing tension pulley, and install the
intermediate flange. timing tension pulley locating pin.
3 Remove 1 bolt fixing the timing tension pulley to
the block.
4 Remove the timing tension pulley (1).
1
S02013236
3 Remove 3 bolts fixing the camshaft timing pulley to

the camshaft timing pulley intermediate flange.
S02013238
4 Remove the camshaft timing pulley (1).
Installation
1 Return the timing tension pulley, and install the
1 timing tension pulley tooling.
2 Tighten 1 bolt fixing the timing tension pulley (1) to
the engine block to 25 ± 1 N.m, and check the
torque.
3 Install the timing drive belt. Refer to “Timing Drive
S02013237
Installation
1 Fix the camshaft timing pulley to the camshaft
timing pulley intermediate flange, install 3 bolts,
tighten them to 31 ± 1 N.m, and check the torque.
2 Remove the special tool C00189138.
3 Install the timing drive belt. Refer to“Timing Drive
2-24
Crankshaft Timing Pulley Replacement High-pressure Fuel Pump Timing Pulley

Removal Replacement
Removal
1 Remove the timing drive belt. Refer to “Timing
Drive Belt Replacement” . 1 Remove the timing drive belt. Refer to “Timing
Drive Belt Replacement” .
2 Remove the starter. Refer to “Starter
Replacement” . 2 Fix the special tool C00189137 (1) to the gear
3 Install the special tool C00189130. transition plate.
4 Remove the crankshaft timing pulley bolts. 3 Remove 3 bolts fixing the high-pressure fuel pump
timing pulley to the gear transition plate.
5 Remove the crankshaft timing pulley (1).
4 Remove the high-pressure fuel pump timing pulley
(2).
1
2
1
S02013241
Installation S02013242
1 Fix the crankshaft timing pulley to the crankshaft, Installation
install 1 bolt, and tighten it to 135 N.m + 120°.
1 Install 3 bolts fixing the high-pressure fuel pump
2 Remove the special tool C00189130. timing pulley to the gear transition plate, and
Note: The bolt can only be used for three times. manually tighten them.
3 Install the starter. Refer to“Starter Replacement” 2 Tighten 3 bolts on the high-pressure fuel pump
. timing pulley to 30 ± 1 N.m, and check the torque.
4 Install the timing drive belt. Refer to“Timing Drive 3 Remove the special tool C00189137.
Belt Replacement” . 4 Install the timing drive belt. Refer to“Timing Drive
2-25
Timing Idler Replacement Engine Belt Tension Pulley Replacement

Removal Removal
1 Remove the timing drive belt. Refer to “Timing 1 Remove the accessory belt. Refer to “Accessory
Drive Belt Replacement” . Belt Replacement” .
2 Remove 3 bolts fixing the timing idler to the block. 2 Remove 1 bolt fixing the engine belt tension pulley
3 Remove the timing idler I (1), timing idler II (2) and to the block.
timing idler III (3). 3 Remove the engine belt tension pulley (1).
2
1
1
31
S02013244 S02013245
1 Fix the timing idlers to the engine block, tighten the 1 Tighten 1 bolt fixing the engine belt tension pulley
timing idlers I and II to 40 ± 1 N.m, and check the to the engine block to 50 ± 1 N.m, and check the
torque. torque.
2 Tighten the timing idler II to 50 ± 1 N.m, and check 2 Install the accessory belt. Refer to “Accessory
the torque. Belt Replacement” .
2-26
Belt Idler Assembly Replacement Camshaft Timing Pulley Intermediate Flange

Removal Replacement
Removal
1 Remove the accessory belt. Refer to “Accessory
Belt Replacement” . 1 Remove the camshaft timing pulley. Refer to
2 Remove 1 bolt fixing the belt idler assembly to the “Camshaft Timing Pulley Replacement” .
block. 2 Fix the special tool C00189138 to the camshaft
3 Remove 2 belt idler assembly (1). timing pulley intermediate flange (1).
3 Install the special tool C00189130 to the camshaft
timing pulley intermediate flange with 3 bolts of the
camshaft timing pulley.
4 Fix and hold the special tool C00189139 manually,
and remove 1 bolt fixing the camshaft timing pulley
intermediate flange to the intake camshaft.
5 Remove the camshaft timing pulley intermediate
1
flange (1).
1
1
S02013246
Installation
1 Tighten 1 bolt fixing the belt idler assembly to the
engine block to 50 ± 1 N.m, and check the torque.
S02013247
Installation
1 Fix the camshaft timing pulley intermediate flange
with special tool C00189139.
2 Fix the camshaft timing pulley intermediate flange
to the intake camshaft, install 1 bolt, tighten it to 65
N.m + 9°, and check the torque.
3 Install the camshaft timing pulley. Refer to
“Camshaft Timing Pulley Replacement” .
2-27
Water-Air Intercooler Bracket Replacement 5 Disconnect the low-pressure EGR temperature

Removal sensor harness connector.
1 Disconnect the fuel injector assembly harness

connector.
2 Remove the harness.
S02013254
6 Disconnect the low-pressure EGR harness

connector.
S02013251
3 Disconnect the harness connector from the water

temperature sensor (1).
S02013255
7 Remove the engine harness.

8 Remove 4 clips connecting the fuel injector oil
S02013252 return pipe and the fuel injector assembly.
9 Remove the fuel injector oil return pipe (1).
4 Disconnect the turbocharger control valve harness
connector.
S02013256
S02013253
2-28
10 Remove 1 bolt fixing the oil dipstick (1) to the 4 Install the high-pressure fuel rail. Refer to “High-
water-air intercooler bracket. pressure Fuel Rail Replacement” .
5 Install the water-air intercooler. Refer to “Water-
Air Intercooler Replacement” .
6 Fix the dipstick components to the water-air
intercooler bracket, install 1 bolt, tighten it to 11 ±
1 N.m, and check the torque.
7 Fix the fuel injector oil return pipe to the fuel
injector assembly and install 4 clips.
8 Connect the low-pressure EGR harness
1
connector.
9 Connect the low-pressure EGR temperature
sensor harness connector.
S02013257
10 Connect the turbocharger control valve harness
11 Remove the water-air intercooler. Refer to connector.
“Water-Air Intercooler Replacement” . 11 Connect the water temperature sensor harness
12 Remove the high-pressure fuel rail. Refer to connector.
“High-pressure Fuel Rail Replacement” . 12 Connect the fuel injector assembly harness
13 Remove the thermostat outlet tube. Refer to connector.
“Thermostat Outlet Tube Replacement” .
14 Remove the vacuum control solenoid valve
bracket. Refer to“Vacuum Control Solenoid Valve
Bracket Replacement” .
15 Remove 4 bolts fixing the water-air intercooler
bracket to the cylinder head.
16 Remove the water-air intercooler bracket (1).
S02013258
Installation
1 Fix the water-air intercooler bracket to the cylinder
head, install 4 bolts, tighten them to 45 ± 3 N.m,
and check the torque.
2 Install the vacuum control solenoid valve bracket.
Refer to “Vacuum Control Solenoid Valve Bracket
Replacement” .
3 Install the thermostat water outlet tube. Refer to
2-29
High-pressure Fuel Pump Timing Pulley Solenoid Valve/Bypass Valve Hose (Twin
Intermediate Flange Replacement charger)
Removal Removal
1 Remove the high-pressure fuel pump timing 1 Disconnect the two ends of the solenoid valve/low-
pulley. Refer to“High-pressure Fuel Pump Timing pressure turbine end bypass valve hose, and
Pulley Replacement” . remove the solenoid valve/low-pressure turbine
end bypass valve hose (1).
2 Fix and hold the high-pressure fuel pump timing
pulley intermediate flange manually with special 2 Disconnect the two ends of the solenoid valve/
tool C00189140, and remove 1 nut fixing the high-pressure turbine end bypass valve hose and
intermediate flange to the high-pressure fuel the retaining clips, and remove the solenoid valve/
pump. low-pressure turbine end bypass valve hose (2).
3 Remove the high-pressure fuel pump timing pulley 3 Disconnect the two ends of the solenoid valve/
intermediate flange (1). high-pressure pressure end bypass valve hose
and the retaining clips, and remove the solenoid
valve/high-pressure pressure end bypass valve
hose (3).
1
3
1
S02013260
Installation
1 Fix the high-pressure fuel pump timing pulley S02013261
intermediate flange to the high-pressure fuel pump Installation
with special tool C00189140, install 1 nut, tighten it
to 80 ± 1 N.m, and check the torque. 1 Connect the two ends of the solenoid valve/high-
pressure pressure end bypass valve hose and the
2 Install the high-pressure fuel pump timing pulley.
retaining clips.
Refer to “High-pressure Fuel Pump Timing Pulley
2 Connect the two ends of the solenoid valve/high-
Replacement” .
pressure turbine end bypass valve hose and the
retaining clips.
3 Connect the two ends of the solenoid valve/low-
pressure turbine end bypass valve hose.
2-30
A/C Compressor Bracket Replacement (Twin Right Front Engine Mount Bracket
charger) Replacement
Removal Removal
1 Remove the A/C compressor. Refer to “A/C 1 Remove the heat shield bolts.
Compressor Replacement” . 2 Remove the heat shield (1).
2 Remove 4 bolts fixing the A/C compressor bracket 3 Remove 2 bolts fixing the engine mount bracket to
to the engine block. the body.
3 Remove the A/C compressor bracket (1).
S02013417
S02013263
4 Remove 4 bolts fixing the right front engine mount
Installation bracket (1) to the block.
5 Remove the right front engine mount bracket (1).
1 Fix the A/C compressor bracket to the engine
block, install 4 bolts, tighten them to 35 ± 3 N.m,
2 Install the A/C compressor. Refer to “A/C
Compressor Replacement” .
1
S02013264
Installation
1 Tighten 4 bolts fixing the front right engine mount
bracket to the engine block to 110 ± 10 N.m, and
check the torque.
2 Tighten 2 bolts fixing the front right engine mount
bracket to the body to 110 ± 10 N.m, and check
the torque.
3 Install the heat shield.
4 Install the heat shield bolts, tighten them to 22 ± 2
N.m, and check the torque.
2-31
Left Front Engine Mount Bracket Replacement Accessory Bracket Replacement

Removal Removal
1 Remove the bolts fixing the engine mount to the 1 Remove the alternator. Refer to “Alternator
body. Replacement” .
2 Remove the small circulation pipe. Refer to
“Small Circulation Pipe Replacement” .
3 Remove the timing pulley chamber. Refer to
“Timing Pulley Chamber Replacement” .
4 Remove 3 bolts fixing the steering pump bracket
to the cylinder head.
5 Remove the steering pump bracket (1).
1
S02013418
2 Remove 4 bolts fixing the left front engine mount
bracket (1) to the block.
3 Remove the left front engine mount bracket (1).
S02013266
6 Remove the intake manifold. Refer to “Intake

Manifold Replacement” .
7 Remove 5 bolts fixing the accessory bracket to the
engine block.
1
8 Remove the accessory bracket (1).
S02013265
Installation
1 Tighten 4 bolts fixing the front left engine mount 1
bracket to the engine block to 110 ± 10 N.m, and
check the torque.
2 Tighten the bolts fixing the engine mount bracket
to the body to 110 ±10 N.m, and check the torque.
S02013267
Installation
1 Fix the accessory bracket to the engine block,
install 5 bolts, tighten them to 35 ± 3 N.m, and
check the torque.
2 Install the intake manifold. Refer to “Intake
2-32
3 Fix the steering pump bracket to the cylinder head, Cold Start Glow Plug Replacement
install 3 bolts, tighten them to 25 ± 2 N.m, and Removal
check the torque.
1 Remove the water-air intercooler. Refer to
4 Install the timing pulley chamber. Refer to“Timing
“Water-Air Intercooler Replacement” .
Pulley Chamber Replacement” .
2 Remove the electronic throttle. Refer to
5 Install the small circulation pipe. Refer to “Small
“Electronic Throttle Replacement” .
Circulation Pipe Replacement” .
3 Disconnect the cold start glow plug harness
6 Install the alternator. Refer to “Alternator
connector, and remove it.
Replacement” .
S02013268
4 Remove the cold start glow plug.
S02013269
Installation
1 Install the cold start glow plug, tighten it to 13 ± 2
2 Connect the cold start glow plug harness
connector.
3 Install the electronic throttle. Refer to “Electronic
Throttle Replacement” .
2-33
Cold Start Glow Plug Harness Replacement Roller Rocker, Hydraulic Tappet Replacement
Removal Removal
1 Disconnect the cold start glow plug harness 1 Remove the intake and exhaust camshafts. Refer
connector. to“Intake and Exhaust Camshafts Replacement”
.
2 Remove the roller rocker and the hydraulic tappet
(1).
S02013270
1
2 Remove the water-air intercooler. Refer to
“Water-Air Intercooler Replacement” .
S02013272
“Electronic Throttle Replacement” . 3 Remove the connecting tab (3) fixing the roller
4 Disconnect the cold start glow plug harness rocker (1) to the hydraulic tappet (2).
connector.
5 Remove the cold start glow plug harness (1).
1
2
S02013273
S02013271
Installation
1 Install the cold start glow plug harness.
4 Connect the cold start glow plug harness
connector.
2-34
4 Separate the roller rocker from the hydraulic Intake and Exhaust Camshafts Replacement
tappet. Removal
Installation
1 Remove the vacuum pump. Refer to “Vacuum
1 Fix the roller rocker (1) to the hydraulic tappet (2) Pump Replacement” .
with the connecting tab (3).
2 Remove the thermostat outlet tube. Refer to
3 Remove the camshaft position sensor. Refer to
1
“Camshaft Position Sensor Replacement” .
2
4 Remove the fuel injector assembly. Refer to“Fuel
Injector Assembly Replacement” .
5 Remove the water-air intercooler bracket. Refer to
“Water-Air Intercooler Bracket Replacement” .
flange. Refer to “Camshaft Timing Pulley
3 Intermediate Flange Replacement” .
7 Remove 12 bolts fixing the valve chamber cover to
S02013273
the camshaft frame.
2 Install the roller rocker and the hydraulic tappet (1) Note: Do not damage the sealing gasket on the
to the camshaft frame. valve chamber cover when removing the valve
chamber cover. Replace it if damaged.
8 Remove the valve chamber cover (1).
1
S02013272
3 Install the intake and exhaust camshafts. Refer to

“Intake and Exhaust Camshafts Replacement” . S02013274
9 Remove 2 bolts fixing the camshaft position

sensor bracket to the camshaft frame.
2-35
10 Remove the camshaft position sensor bracket (1). 14 Remove the camshaft cover.
9 17 13 5
1 1
3 11 19 15 7
4 12 20 16 8
2 10 18 14 6
S02013275 S02013278
11 Confirm the markers before removing the 15 Remove the exhaust camshaft (1) and intake
camshaft cover for the ease of installation. camshaft (2) from the camshaft frame (3).
Ｈ５－１ 1
3
S02013276 S02013279
12 Confirm the direction of the camshaft cover before Installation

removing the camshaft cover for the ease of 1 Install the exhaust camshaft (1) and intake
installation. camshaft (2) on the camshaft frame (3).
Note: Lubricate the camshafts with the original
engine oil before installation.
1
3
S02013277
13 Remove 20 bolts fixing the camshaft cover to the

camshaft frame in the sequence shown. S02013279
Note: Do not screw the bolt out at once when
removing it.
2-36
2 Ensure that the two gear marks are aligned when 4 Use the camshaft timing tooling C00189124 (1) to
installing the intake and exhaust camshafts. set two camshaft positions at the top dead center
of one cylinder piston.
S02013280
S02013282
3 Fix the camshaft cover to the camshaft frame,
install 20 bolts in the sequence shown, tighten 5 Fix the camshaft position sensor bracket to the
them to 11 ± 1 N.m, and check the torque. camshaft frame, install 2 bolts, tighten them to 11
Note: Ensure that the marks on the camshaft ± 1 N.m, and check the torque.
covers are installed correctly. 6 Fix the valve chamber cover components to the
camshaft frame, install 12 bolts, tighten them to 11
Note: Lubricate the camshaft covers with the
± 1 N.m, and check the torque.
original engine oil before installation.
7 Install the camshaft timing pulley intermediate
Intermediate Flange Replacement” .
12 4
8 Install the water-air intercooler bracket. Refer to
8 16
20 “Water-Air Intercooler Bracket Replacement” .
18 10 2 6 14 9 Install the fuel injector assembly. Refer to “Fuel
10 Install the camshaft position sensor. Refer to
17 “Camshaft Position Sensor Replacement” .
9 5 13
1
19 11 3 7
15
S02013281 12 Install the vacuum pump. Refer to“Vacuum Pump
Replacement” .
2-37
Valve Chamber Cover Replacement 4 Disconnect the low-pressure EGR temperature

Removal sensor harness connector.

connector, and remove the harness.
S02013254
5 Disconnect the low-pressure EGR harness

S02013251 connector.
2 Disconnect the harness connector of the water

S02013255
6 Remove the engine harness.

S02013252 7 Remove the clips connecting the fuel injector oil
return pipe and the fuel injector assembly.
3 Disconnect the turbocharger control valve harness
connector. 8 Remove the fuel injector oil return pipe (1).
S02013253 S02013256
9 Remove the high-pressure fuel rail. Refer to

“High-pressure Fuel Rail Replacement” .
2-38
10 Remove 1 bolt fixing the oil dipstick (1) to the 18 Remove the fuel injector assembly (2).
water-air intercooler.
2 2 2 2
1 1
1
S02013283
S02013257
11 Remove the water-air intercooler. Refer to the camshaft frame.
“Water-Air Intercooler Replacement” . 20 Remove the valve chamber cover (1).
Note: Discard the used sealing gasket, replace it
“Thermostat Outlet Tube Replacement” . with a new one, and ensure it is installed correctly.
bracket. Refer to“Vacuum Control Solenoid Valve
Bracket Replacement” . 1
14 Remove 4 bolts fixing the water-air intercooler
bracket to the cylinder head.
15 Remove the water-air intercooler bracket (1).
S02013274
Installation
1 Fix the valve chamber cover components to the
S02013258 2 Fix the fuel injector assembly and the fuel injector
pressing plate to the cylinder, install 2 bolts,
16 Remove 2 bolts fixing the fuel injector pressure
plate to the cylinder head assembly.
3 Fix the water-air intercooler bracket to the cylinder
17 Remove the fuel injector pressure plate (1).
head, install 4 bolts, tighten them to 45 ± 3 N.m,
4 Install the vacuum control solenoid valve bracket.
Refer to “Vacuum Control Solenoid Valve Bracket
Replacement” .
2-39
6 Install the water-air intercooler. Refer to “Water- Camshaft Oil Seal Replacement
Air Intercooler Replacement” . Removal
7 Fix the dipstick components to the water-air
1 Remove the vacuum pump. Refer to “Vacuum
intercooler, install 1 bolt, tighten it to 11 ± 1 N.m,
Pump Replacement” .
8 Install the high-pressure fuel rail. Refer to “High-
pressure Fuel Rail Replacement” .
3 Remove the camshaft position sensor. Refer to
9 Fix the fuel injector oil return pipe to the fuel
injector assembly with the clips. “Camshaft Position Sensor Replacement” .
10 Connect the low-pressure EGR harness 4 Remove the fuel injector assembly. Refer to“Fuel
connector. Injector Assembly Replacement” .
5 Remove the water-air intercooler bracket. Refer to
11 Connect the low-pressure EGR temperature
sensor harness connector. “Water-Air Intercooler Bracket Replacement” .
12 Connect the turbocharger control valve harness
connector. flange. Refer to “Camshaft Timing Pulley
13 Connect the water temperature sensor harness
connector.
the camshaft frame.
14 Connect the fuel injector assembly harness
8 Remove the valve chamber cover (1).
connector.
Note: Do not damage the sealing gasket on the
valve chamber cover when removing the valve
chamber cover. Replace it if damaged.
S02013274
9 Remove the camshaft oil seal (1) from the

camshaft frame (2).
2-40
Note: Care must be taken not to damage other 6 Install the camshaft position sensor. Refer to
components when removing the camshaft oil seal. “Camshaft Position Sensor Replacement” .
2
8 Install the vacuum pump. Refer to“Vacuum Pump
Replacement” .
S02013284
Installation
1 Use the guider of special tool C00189132 to install
the seal ring (2) to the camshaft frame (3), and use
the pressure head of C00189132 (1) to press it
into the seal ring (2).
Note: Install a new camshaft oil seal.
Note: Apply the appointed grease to the oil seal lip
before installing the camshaft oil seal.
Note: Slowly and evenly push it in when installing.
2 3
1
S02013285
2 Fix the valve chamber cover components to the

3 Install the camshaft timing pulley intermediate
4 Install the water-air intercooler bracket. Refer to
“Water-Air Intercooler Bracket Replacement” .
5 Install the fuel injector assembly. Refer to “Fuel
2-41
Timing Pulley Chamber Cover Replacement Timing Pulley Chamber Replacement

Removal Removal
1 Remove the belt idler assembly. Refer to “Belt 1 Remove the timing drive belt. Refer to “Timing
Idler Assembly Replacement” . Drive Belt Replacement” .
2 Remove the crankshaft shock absorber. Refer to 2 Remove the camshaft timing pulley. Refer to
“Crankshaft Shock Absorber Replacement” . “Camshaft Timing Pulley Replacement” .
3 Remove 2 bolts fixing the timing cover (lower) to 3 Remove the timing tension pulley. Refer to
the timing pulley chamber cover. “Timing Tension Pulley Replacement” .
4 Remove the timing cover (lower) (1). 4 Remove the timing idler. Refer to “Timing Idler
Replacement” .
5 Remove 8 bolts fixing the timing pulley chamber to
the engine block.
6 Remove the timing cover (upper) (1).
7 Remove the timing pulley chamber (2).
1
1
2
S02013286
5 Remove the retaining clips fixing the timing pulley

chamber cover to the timing pulley chamber.
6 Remove the timing pulley chamber cover (1).
S02013289
Installation
1 Fix the timing pulley chamber and the timing cover
(upper) to the engine block, install 8 bolts, tighten
1
them to 11 ± 1 N.m, and check the torque.
2 Install the timing idler. Refer to “Timing Idler
Replacement” .
3 Install the timing tension pulley. Refer to “Timing
Tension Pulley Replacement” .
4 Install the camshaft timing pulley. Refer to
S02013287
“Camshaft Timing Pulley Replacement” .
Installation 5 Install the timing drive belt. Refer to “Timing Drive
1 Fix the timing pulley chamber cover to the timing Belt Replacement” .
pulley chamber with the clips.
2 Fix the timing cover (lower) to the timing pulley
chamber cover, install 2 bolts, tighten them to 8 ±
3 Install the crankshaft shock absorber. Refer to
“Crankshaft Shock Absorber Replacement” .
4 Install the belt idler assembly. Refer to “Belt Idler
Assembly Replacement” .
2-42
Cylinder Head Assembly Replacement

Removal
1 Remove the intake and exhaust camshafts. Refer
to“Intake and Exhaust Camshafts Replacement” 4
2 6 10 8
.
2 Remove the turbocharger assembly. Refer to
“Turbocharger Assembly Replacement” .
3 Remove the intake manifold. Refer to “Intake
4 Remove the exhaust manifold. Refer to “Exhaust 1 5 9 7 3
S02013294
5 Remove and discard 8 bolts fixing the camshaft
frame components to the cylinder block in the
sequence shown. 9 Remove the cylinder head gasket.
6 Remove the camshaft frame. Note: Never reuse the cylinder head gasket. It must
be replaced.
Disassembly
1 Remove the valve cotter (1), valve upper valve
2 6 8 4 spring retainer (2) and valve spring (3) in
sequence.
1
2
3
3 7 5 1
S02013293
7 Remove 10 bolts fixing the cylinder head

assembly to the engine block in the sequence
shown.
8 Remove the cylinder head assembly. S02013297
Note: Do not screw the bolt out at once when
removing it. 2 Use tools to remove 16 valve stem oil seals (2).
Note: Never reuse the bolts. Note: Never reuse the valve stem oil seal. It must
be replaced.
Note: Lift the cylinder head in a groove between
the cylinder head and the block with a screwdriver,
if it is difficult to remove.
Note: Be careful not to damage the mounting plane
of the cylinder head and the cylinder block.
2-43
Assembly
1 Clean the contact surface of the cylinder head and
the cylinder block.
S02013298
3 Remove the exhaust valve (1) and the intake valve

(2) from the cylinder head (3).
S02013301
Note: Mark the location of each valve to prevent
confusion with other valves.
2 Install the exhaust valve on the cylinder head,
tighten it to 25 ± 2 N.m, and check the torque.
3 Use special tool C00189123 (1) to install new
1
valve stem oil seal (2) on the cylinder head.
Note: Lubricate the valve stem oil seal with the
3
original engine oil before installation.
Note: Check if the valve stem oil seal is in place as
2
1
S02013299
4 Remove the exhaust valve (1) of the cylinder head

(2).
S02013303
4 Clean the intake and exhaust valves.

5 Install the intake and exhaust valves on the
cylinder head.
11
Note: Apply clean engine oil to the valve stem.
2
Note: If the original valve is to be installed, ensure
S02013300 that the valve is installed in the same position as
when it is removed.
2-44
6 Install the valve cotter, valve spring upper seat and A. If the protrusion is 0.56-0.66 mm, select the cylinder
valve spring on the valve stem successively. head gasket without mark hole in the first group (cylinder
Note: After the valve is installed, tap the top of the head gasket thicknes s:1.45 mm);
valve stem with a plastic hammer to ensure that
B. If the protrusion is 0.66-0.76 mm, select the cylinder
the valve is installed properly.
head gasket with one mark hole in the second group
Installation (cylinder head gasket thickness:1.55 mm)
1 Clean the contact surface of the cylinder block and
the cylinder head. C. If the protrusion is 0.76-0.86 mm, select the cylinder
head gasket with two mark holes in the third group
(cylinder head gasket thickness: 1.65 mm)
The cylinder head gasket grouping mark hole is as shown

in the figure.
S02013302
2 Use tools to measure the piston protrusion.

Note: The cylinder head gasket should be selected
based on the following measurements.
S02013377
4 Install a new cylinder head gasket on the engine

block.
Note: Install the cylinder head gasket on the top
surface of the engine block, and ensure the
cylinder head gasket locating pin sleeve is inserted
into the locating pin sleeve on the top surface of
the engine block.
5 In order to prevent reverse installation, the cylinder
head gasket marking content shall be displayed
upwards during assembly, as shown in the figure
S02013307 below.
3 Measure the protrusion of four pistons before

assembly. Respectively select each point at the
front and rear ends on the top piston surface of
each cylinder, to average the protrusion at the two
points of each cylinder, then select the cylinder
head gasket based on the largest one of four
averages, and the selection rules are as follows:
2-45
Note: After the sealant is applied, it shall be

assembled within 5 min.
Note: The sealant shall be applied evenly.
S02013387
S02013309
8 Install the camshaft frame (1) on the cylinder head.

Note: Check the locating pin for correct installation
during the installation of the camshaft frame.
S02013295
6 Fix the cylinder head on the engine block, install 1

10 new bolts in the sequence shown in the figure,
tighten them to 45 ± 2 N.m for Step 1; tighten
them to 75 ± 5 N.m for Step 2 (re-tighten); rotate
by 100 ° for Step 3; rotate by 70° for Step 4;
rotate by 50° for Step 5, and check the torque.
S02013310
9 Tighten 8 bolts installed in the sequence shown to

11 ± 2 N.m, and check the torque.
9 5 1 3 7 Note: Check if the locating pin is installed correctly
when installing the camshaft frame.
10 6 2 4 8
S02013308
7 Clean the camshaft frame and apply sealant along

the line.
2-46
Piston Connecting Rod Assembly

Replacement
Removal
7 3 1 5 1 Remove the engine assembly. Refer to “Engine
2 Remove the flywheel assembly. Refer to
“Flywheel Assembly Replacement” .
3 Remove the cylinder head assembly. Refer to
“Cylinder Head Assembly Replacement” .
6 2 4 8
4 Remove the lower engine block frame. Refer to
“Lower Engine Block Frame Replacement” .
S02013311
5 Remove the rear crankshaft oil seal assembly.
Refer to “Rear Crankshaft Oil Seal
10 Install the exhaust manifold. Refer to “Exhaust Replacement” .
6 Remove the front crankshaft oil seal assembly.
11 Install the intake manifold. Refer to “Intake Refer to “Front Crankshaft Oil Seal
Manifold Replacement” . Replacement” .
12 Install the turbocharger assembly. Refer to 7 Remove the oil pump assembly. Refer to “Front
“Turbocharger Assembly Replacement” . Crankshaft Oil Seal Replacement” .
13 Install the intake and exhaust camshafts. Refer to 8 Remove and discard 8 bolts fixing the connecting
“Intake and Exhaust Camshafts Replacement” . rod bearing shell to the connecting rod.
9 Remove the connecting rod bearing shell (1).
Note: Remember the corresponding mark for each
connecting rod bearing shell to avoid mixing the
connecting rod caps.
S02013315
10 Remove the piston connecting rod assembly.
2-47
S02013316 S02013319
Disassembly Assembly
1 Remove the top compression ring (1), the second 1 Assemble the piston, the connecting rod and the
compression ring (2) and the oil ring (3) in piston pin successively.
sequence. 2 Fix the piston pin to the piston, and install the
piston pin retainer..
Note: Apply a small amount of engine oil when
installing the piston pin.
1
Note: Insert the piston pin into the piston pin
2
bushing and through the connecting rod small-end
hole until it reaches the first piston pin retainer.
3 Note: Install the second piston pin retainer with the
retainer opening facing the 7 o’ clock position;
After the piston pin retainer is installed, rotate the
retainer with the circlip plier to check if it is
corrected installed into the piston retainer groove,
S02013317 and make marks with a marker after it is confirmed
correct.
2 Remove the piston pin retainer (2) fixing the piston 3 Use a piston ring mounting plier to install the top
pin (1) to the piston. compression ring, the second compression ring
and the oil ring.
Note: Be careful not to expand the piston ring too
1 much during installation, and ensure it is properly
installed into the piston ring groove.
4 Separate the three piston rings as shown in the
figure.
2
Note: All piston ring notches must be staggered by
120 °,and the oil ring opening shall be staggered
with the piston pin hole by 90°.
S02013318
3 Disassemble the piston pin (1), connecting rod (2)

and the piston (3) in sequence.
2-48

12
0°
0°
S02013321
12
S02013320
5 Clamp the piston ring with the piston installer, 2 According the mark on the connecting rod bearing
place the piston connecting rod on the top end of shell, the corresponding weight grouping and
the cylinder sleeve opening, and push the piston connecting rod seat hole grouping is used to
connecting rod into the cylinder sleeve with a select the correct connecting rod bearing.
wooden rod. Weight grouping: Letters B-G
Note: Apply the genuine oil to the piston before
installation. Connecting Rod Seat Hole Grouping: numbers 1 and 2
Note: The arrow mark on the top of the piston shall

point to the front end of the engine when
assembling.
Note: The orientation of the connecting rod
forward mark (the small emboss on the connecting
F1
rod cap) shall be consistent with that of the piston
forward arrow.
F1
F1
Note: For the same engine, it shall be equipped

with a connecting rod of the same weight
grouping.
Installation
S02013322
1 Select the correct connecting rod bearing from the
corresponding connecting rod journal groupings
3 For the replacement of a new connecting rod, it is
as per the mark on the crankshaft.
required to select the correct connecting rod
Connecting Rod Journal Grouping: numbers 1 and 2 assembly by reading the weight grouping mark on
the connecting rod bearing shell.
4 Selection of connecting rod bearing thickness.
Black: 1.784-1.788 mm
Green: 1.789-1.793 mm
Blue: 1.794-1.798 mm
2-49
12 Fit the cylinder head assembly. Refer to “Cylinder

Head Assembly Replacement” .
Connect-
ing rod 13 Install the flywheel assembly. Refer to “Flywheel
seat hole
grouping 14 Install the engine assembly. Refer to “Engine
A B Assembly Replacement” .
Connecting
Rod
Journal
Grouping
1 Black Green
2 Green Blue
Note: The upper and lower connecting rod

bearings are of the same color.
5 Install the connecting rod bearing.
Note: The bearing locating lip shall be stuck in the
bearing seat locating groove.
6 Fix the connecting rod bearing shell to the
connecting rod, install 8 new bolts, manually
tighten them to 30 ± 2 N.m for Step 1, further
tighten them to 90 ± 5° for Step 2, and check the
torque.
Note: Apply new engine oil on the inner wall of the
crankshaft connecting rod journal and the upper
and lower connecting rod bearings.
Note: The connecting rod cap is relative to the
shell groove on the connecting rod, and check if
the connecting rod cap and the outside of the
connecting rod have the same number mark.
After the tightening is completed, check the joints
on both sides of the connecting rod with hands to
ensure that there is no step-like sense of touch.
7 Use a dial gauge to measure the axial gap of the

connecting rod, the allowable range of which shall
refer to the engine parameters.
8 Install the oil pump assembly. Refer to “Front
Crankshaft Oil Seal Replacement” .
9 Install the front crankshaft oil seal assembly. Refer
to “Front Crankshaft Oil Seal Replacement” .
10 Install the rear crankshaft oil seal assembly. Refer
to “Rear Crankshaft Oil Seal Replacement” .
11 Install the lower engine block frame. Refer to
“Lower Engine Block Frame Replacement” .
2-50
Crankshaft Signal Plate Replacement Crankshaft Assembly Replacement

Removal Removal
1 Remove the crankshaft. Refer to “Crankshaft 1 Remove the piston connecting rod assembly.
Replacement” . Refer to “Piston Connecting Rod Assembly
2 Remove 3 bolts fixing the crankshaft signal plate Replacement” .
to the crankshaft assembly. 2 Remove and discard 10 bolts fixing the main
3 Remove the crankshaft signal plate (1). bearing cap on the engine block.
3 Remove the main bearing cap (1).
Note: Do not screw the bolt out at once.
1
1 1 1 1 1
S02013334
1 Install the crankshaft signal plate.
4 Remove the crankshaft assembly (1) from the
2 Install 3 bolts fixing the crankshaft signal plate to
engine block (2).
the crankshaft assembly, tighten them to 11 ± 1
N.m, and check the torque. Note: Lift the crankshaft up in parallel to avoid
3 Install the crankshaft. Refer to “Crankshaft bumps.
Replacement” .
S02013326
5 Remove the crankshaft main bearing shell from

the engine block.
2-51
AABBB
S02013329 S02013388
6 Remove the crankshaft main bearing shell from

the main bearing cap.

S02013331
S02013330 3 Selection of main bearing shell thickness.

Black: 1.984-1.987 mm
Installation
Green: 1.988-1.991 mm
1 Clean and check the crankshaft.
2 Select the main bearing shell of correct color Blue: 1.992-1.995 mm
according to the mark shown. The cylinder block
Note: The upper and lower main bearing shells are
mark corresponds to the engine block crankshaft
of the same color.
hole grouping, and the crankshaft-side mark
corresponds to the main journal grouping.
Engine Block Crankshaft Hole Grouping: Letters A and B
Block
Main Journal Grouping: numbers 1 and 2
Crank-
shaft Hole
Grouping A B
Main
Journal
Grouping
1 Black Green
2 Green Blue
2-52
4 Install the crankshaft main bearing shell on the Front Crankshaft Oil Seal Seat and Oil Seal
engine block. Replacement
Note: The crankshaft main bearing shell group Removal
shall correspond to the main bearing bore 1 Remove the engine belt tension pulley. Refer to
diameter and the main journal diameter. “Engine Belt Tension Pulley Replacement” .
Note: Never apply oil to the main bearing shell 2 Remove the timing drive belt. Refer to “Timing
mounting surface on the engine block or the Drive Belt Replacement” .
external surface of the main bearing shell. 3 Remove the crankshaft timing pulley. Refer to
Note: After the lower main bearing shell is installed “Crankshaft Timing Pulley Replacement” .
on the main bearing cap, apply new oil to the 4 Remove 8 bolts fixing the front crankshaft oil seal
mating surface of the lower main bearing shell and seat to the engine block.
the crankshaft. 5 Remove the front crankshaft oil seal seat and oil
5 Install the crankshaft assembly on the engine seal (1).
block.
Note: Apply a small amount of oil to the main shaft
1
bearing before installation. And install the
crankshaft assembly parallelly/vertically.
6 Fix the main bearing cap on the engine block,
install 10 new bolts in the sequence shown in the
figure, tighten them to 40 N.m for Step 1; tighten
them to 60 N.m for Step 2; rotate by 120° for Step
3, and check the torque.
Note: Install the bolts in the numbering sequence
with the arrow on the main bearing cap facing the
front of the engine. S02013336
Note: Apply a small amount of engine oil to the 6 If necessary, remove the oil seal from the front
main bearing cap bolt threads and the root of the crankshaft oil seal seat and discard it.
flange face before assembling. Installation
Note: Never use a bolt for more than twice. 1 Use special tool C00189243 (1) to install a new oil
seal to the front crankshaft oil seal seat.
7 3 1 5 9
8 4 2 6 10
S02013332
S02013378
7 Install the piston connecting rod assembly. Refer
to “Piston Connecting Rod Assembly 2 Use special tool C00189136 to fix the front
Replacement” . crankshaft oil seal seat and oil seal to the engine
block.
3 Install 8 front crankshaft oil seal assembly bolts,
2-53
Note: Apply sealant to the front crankshaft oil seal Rear Crankshaft Oil Seal Seat and Oil Seal
seat, and assemble it within 5 min. Failure to follow Replacement
the instruction may cause oil leakage. Do not add Removal
more than a specified amount of sealant.
1 Remove the flywheel housing. Refer to “Flywheel
4 Install the crankshaft timing pulley. Refer to Housing Replacement” .
“Crankshaft Timing Pulley Replacement” .
2 Remove 9 bolts fixing the rear crankshaft oil seal
5 Install the timing drive belt. Refer to“Timing Drive seat and oil seal to the engine block.
3 Remove the rear crankshaft oil seal seat and oil
6 Install the engine belt tension pulley. Refer to seal (1).
“Engine Belt Tension Pulley Replacement” .
S02013337
4 If necessary, remove the oil seal from the rear

crankshaft oil seal seat and discard it.
Installation
1 Use special tool C00189126 (1) to install a new oil
seal to the rear crankshaft oil seal seat.
S02013379
2 Use special tool C00189129 to fix the rear

crankshaft oil seal seat and oil seal to the engine
block.
3 Install 9 bolts, tighten them to 11 ± 1 N.m, and
check the torque.
Note: Apply sealant to the rear crankshaft oil seal
seat, and assemble it within 5 min. Failure to follow
2-54
the instruction may cause oil leakage. Do not add Piston Cooling Nozzle Replacement
more than a specified amount of sealant. Removal
4 Install the flywheel housing. Refer to “Flywheel 1 Remove the crankshaft assembly. Refer to
Housing Replacement” . “Crankshaft Assembly Replacement” .
2 Remove 4 nuts fixing the piston cooling nozzle to
the engine block.
3 Remove the piston cooling nozzle (1).
S02013338
Installation
1 Install 4 nuts fixing the piston cooling nozzle to the
engine block, tighten them to 27 ± 3 N.m, and
check the torque.
2 Install the crankshaft assembly. Refer to
“Crankshaft Assembly Replacement” .
2-55
Flywheel Assembly Replacement Note: Use new flywheel bolts.

Removal
1 Remove the transmission assembly.
Replacement” .
3 Use the special tool C00189130 (1) fix the
flywheel assembly.
S02013340
1
2 Install the special tool C00189130.
3 Install 8 flywheel assembly bolts in the sequence
shown in the figure, tighten them to 80 N.m for
Step 1, rotate by 140 ° for Step 2, and check the
torque.
S02013390
4 Remove and discard 8 bolts fixing the flywheel

assembly to the crankshaft assembly. 1
5 Remove the flywheel assembly (1). 6
7
Note: Discard the bolts.
4
3
8
5
2
S02013341

5 Install the starter. Refer to“Starter Replacement”
1 .
6 Fit the transmission assembly.
S02013339

Installation
1 Align the flywheel assembly locating pin, fix the
flywheel assembly to the crankshaft, and tighten
the bolts by hand.
2-56
Balance Shaft Replacement

Removal
1 Remove the piston connecting rod assembly. C00189127
Refer to "Piston Connecting Rod Assembly
Replacement".
2 Remove and discard the rear balance shaft cover
(1).
S02013419
5 Remove the bolt (1) on the balance shaft and bolt

1 (2) on the balance shaft idler.
1
S02013342
1
3 Remove and discard the front balance shaft cover
(1) and balance shaft idler gear cover (2).
1
S02013345
7 Remove the crankshaft assembly. Refer to

1 "Crankshaft Assembly Replacement".
8 Remove and discard the balance shaft idler (1),

2 1 and remove the balance shaft (2) and balance
shaft gear (3).
S02013343
4 Fix the special tool C00189127 to the crankshaft

and the engine block.
1
S02013348
2-57
9 Remove the balance shaft needle bearing (1). 6 Fix the special tool C00189127 to the crankshaft
and the engine block.
C00189127
1 1
S02013349
S02013419
Installation
7 After completing the crankshaft positioning
1 Lubricate and install the balance shaft needle
(ensure that the crankshaft is fully locked and not
bearing.
swaying) and the bearing shell fit clearance
2 Install the balance shaft and gear on the engine calibration, install the new idler between the
block. crankshaft gear and the balance shaft gear,
manually fine-tune it to mesh with each other, the
3 Rotate the balance shaft to allow the special tool
coating surface must be engaged with the
C00189135 locating pin align with two locating
crankshaft gear and the balance shaft gear, it is
holes of the balance shaft.
better to have the uncoated surface visible.
4 Fix the special tool C00189135 (1) to the engine
Note: A new balance shaft idler must be used.
block (2), install and tighten the bolts.
8 Install the weight on the pressure bar of the
Note: The correct mounting position of the balance
assembly fixture, and the middle hole is the fixed
shaft is only guaranteed when and only when the
position of the positioning pin (that is, the marked
two locating pins align with the two holes of the point in the figure below).
special tool C00189135, as shown in the figure
below.
S02013420
S02013353
9 Install the balance shaft idler bolt, tighten it to 60 ±
4 Nm, and check the torque.
5 Install the crankshaft assembly on the engine
block. Refer to "Crankshaft Assembly 10 Install the balance shaft bolt, tighten it to 45 Nm ＋
Replacement". 105°, and check the torque.
2-58
11 Remove the special tools C00189127 and 16 Install the balance shaft idler gear cover with the
C00189135. special tool C00189300-01, and the front/rear
balance shaft cover with the special tool
12 Install the special tools C00189094 Backlash
C00189300-02.
Measuring Fixture and C00189092 Dial Indicator
to the periphery of the balance shaft tightening
bolt, to measure the clearance.
C00189092
S02013431
C00189094
S02013421
13 Twist the blades of the measuring fixture slightly

with both hands, to the extent that it does not drive
the gear to rotate, and the difference between the
maximum value and the minimum value displayed
on the dial indicator is the total backlash of the
gear combination.
14 After assembling, turn the crankshaft 1 turn,

measure the idler backlash in at least 3 positions.
After manually rotating the crankshaft gear for
several turns, the backlash requirement is ≤
0.12mm without coating. S02013432
15 Apply sealant evenly on the balance shaft cover 17 Install the piston connecting rod assembly. Refer
and the balance shaft idler gear cover, the width of to "Piston Connecting Rod Assembly
the sealant line is ≥ 2.5mm, and the starting Replacement".
position of the sealant line is 1.5mm, as shown in
the figure.
M
P
S02013430
2-59
Flex Plate Replacement

Removal
1 Remove the transmission assembly.
2 Remove the starter. Refer to “Starter 6 1
Replacement” . 4 7
3 Install the special tool C00189130. 3
8
2 3
1 S02013381

.
6 Fit the transmission assembly.
S02013390
4 Remove 8 bolts (1) fixing the flex plate to the

crankshaft assembly.
5 Remove the flex plate (2) and the flange (3).
Note: And discard the used bolts.
S02013380

Installation
1 When installing the flange and the flex plate, first
screw the bolts with hands.
Note: Use new bolts.
2 Install the special tool C00189130.
3 Install 8 bolts of the flex plate in the sequence
shown in the figure, tighten them to 70 N.m for
Step 1, rotate by 90° for Step 2, and check the
torque.
2-60
Engine Oil Draining and Refilling

Drain
1 Raise and support the vehicle.
2 Put an oil collector under the oil pan drain bolt.
3 Remove the oil pan drain bolt, and drain the 1
engine oil.
S02013357

Refill
1 Remove the oil filler cap (1), and refill the engine
oil.
Note: Renew the oil filter element before refilling
S02013356
new engine oil.
4 Install the oil pan drain plug on the oil pan, tighten
it to 25 ± 2 N.m, check the torque, and replace the
drain plug and the seal ring if necessary.
1
S02013358
2 Check the engine oil level.

S02013356 Note: Do not refill oil if the oil level is between the
MIN and MAX marks. Refill oil immediately if the oil
5 Use the special tool C00189128 to replace the oil
level reaches the MIN mark. The oil level must not
filter (1),25 ± 2 N.m. exceed the MAX mark.
Note: When draining the oil, use water-proof (oil-
proof) cloth to fully cover the mount, preventing
the oil contaminants from dropping onto the
mount.
2-61
Oil Pump Assembly Replacement

Removal
1 Remove the oil pan. Refer to “Oil Pan
Replacement”
2 If necessary, remove the lower engine block
frame. Refer to “Lower Engine Block Frame
Replacement” .
MAX 3 Remove the oil suction pipe and the harness.
4 Remove 3 bolts fixing the oil pump assembly to
the engine block.
MIN
S02013359 5 Remove the oil pump assembly (1).
3 Cap the oil filler and rotate to tighten it.
S02013314
Installation
1 Install the oil pump drive belt on the oil pump.
2 Fix the oil pump assembly (3) to the engine block,
install 3 bolts, tighten the bolt (2) to 22 ± 2 N.m,
tighten the bolt (1) to 9 ± 1 N.m, and check the
torque.
1
1
S02013324
3 Install the oil suction pipe and the harness.

4 If necessary, install the lower engine block frame.
Refer to “Lower Engine Block Frame
Replacement” .
2-62
Install the oil pan. Refer to “Oil Pan Replacement” Oil Filter Cooling Module Assembly
Replacement
Removal
1 Remove the connecting clamp (2) of the oil filter
cooling module assembly inlet pipe (1).
2 Remove the oil filter cooling module assembly inlet
pipe (1).
3 Remove the connecting clamp (4) of the oil filter
cooling module assembly outlet pipe (3).
4 Remove the oil filter cooling module assembly
outlet pipe (3).
4
2
1
S02013361
5 Remove 1 bolt fixing the oil filter cooling module

(1) to the engine block.
1
S02013362
6 Remove 3 bolts fixing the oil filter cooling module

to the cylinder block.
2-63
7 Remove the oil filter cooling module (1). Oil Pump Belt Replacement
Removal
1 If necessary, remove the oil pump, refer to “Oil
2 Remove the front crankshaft oil seal seat and the
oil seal. Refer to “Front Crankshaft Oil Seal Seat
and Oil Seal Replacement” .
3 Remove the oil pump belt (1).
S02013363
1
Installation
1 Fix oil filter cooling module to the cylinder block,
install 4 retaining bolts, tighten them to 25±2 N.m,
2 Connect the inlet and outlet hoses of the oil filter
cooling module.
S02013366
Installation
1 Install the oil pump belt.
2 Install the front crankshaft oil seal seat and the oil
seal. Refer to“Front Crankshaft Oil Seal Seat and
Oil Seal Replacement” .
3 If necessary, install the oil pump, refer to “Oil
2-64
Lower Engine Block Frame Replacement Note: Apply sealant to the lower engine block
Removal frame, and assemble it within 5 min. Failure to
follow the instruction may cause oil leakage. Do
1 Remove the crankshaft shock absorber. Refer to
not add more than a specified amount of sealant.
2 Remove the A/C compressor bracket. Refer to
“A/C Compressor Bracket Replacement” .
3 Remove 1 bolt fixing the small circulation pipe to
the lower engine block frame.
S02013367
2 Fix the lower engine block frame to the engine

block, install 19 bolts in the sequence shown in the
figure, tighten 2 engine rear-end M8X65 bolts to
S02013360 22 ± 2 N.m, tighten the other 17 bolts to 10 ± 1
4 Remove the flywheel housing. Refer to “Flywheel
Housing Replacement” . 17 19 18
5 Remove the oil pump oil suction pipe assembly. 13 16
Refer to “Oil Pump Oil Suction Pipe Assembly
11
Replacement” . 10
9
6 Remove 19 bolts fixing the lower engine block 6
frame to the engine block in the sequence shown. 3
2
Note: Do not damage the contact surface of the 1
4
lower engine block frame and the engine block 5
8
when prying the lower engine block frame.
12 7
S02013368 15 14
17 19 18
13 16 3 Install the oil pump suction pipe assembly. Refer to
11 “Oil Pump Oil Suction Pipe Assembly
10 Replacement” .
9
6 4 Install the flywheel housing. Refer to “Flywheel
3
2 Housing Replacement” .
1 5 Tighten 1 bolt fixing the small circulation pipe to
4
5 the lower engine block frame to 10 ± 1 N.m, and
8
7 check the torque.
12
6 Install the A/C compressor bracket. Refer to “A/C
S02013368 15 14
Compressor Bracket Replacement” .
Installation
1 Apply sealant to the lower engine block frame.
2-65
Oil Pan Assembly Parts Replacement Note: Apply the sealant of 2.5 ± 0.5mm in diameter
Removal to the junction surface of the oil pan along the line
as shown in the figure.
1 Drain the engine oil.
Note: Assemble the oil pan with the lower block
2 Remove the lower engine guard plate.
frame within 5min after the sealant is applied, and
3 Remove 20 bolts fixing the oil pan assembly parts tighten them within 30min.
to the lower engine block frame.
7 3 4 8
11 12
15 16
19 20
17 18
13 14
9 10
5 1 2 6 S02013224
S02013369
3 Tighten the bolts clockwise in the sequence shown
4 Cut the sealant between the oil pan and the lower
to 11 ± 1 N.m, and check the torque.
engine block frame with a flat chisel, and pry the
oil pan open.
14 18 17 13
Note: Do not damage the contact surface of the
10 9
lower engine block frame and the oil pan when
prying the oil pan.
6 5
2 1
4 3
8 7
12 11
S02013225 16 20 19 15

5 Refill the engine oil.
S02013370
5 Remove and discard the oil pan.

Installation
1 Install new oil pan.
2 Apply the sealant at the new junction of the oil
pan.
Note: Clean the junction surface of the lower block
frame and the oil pan, and ensure that all junction
surfaces are free of oil, paint, ink marks, iron
filings or cleaning residues.
2-66
Oil Cooler Inlet Hose Assembly Replacement Oil Cooler Outlet Hose Assembly Replacement
Removal Removal
1 Remove the clamps on both ends of the oil cooler 1 Remove the clamps on both ends of the oil cooler
inlet hose assembly. outlet hose assembly.
2 Remove the oil cooler inlet hose assembly (1). 2 Remove the oil cooler outlet hose assembly (1).
1
S02013222 S02013223
1 Fix the oil cooler inlet hose assembly to the oil 1 Fix the oil cooler outlet hose assembly to the block
cooler and the small circulation pipe, and install thermostat and the oil cooler, and install clamps
clamps on both ends. on both ends.
2-67
Oil Pump Oil Suction Pipe Assembly Camshaft Check

Replacement
Camshaft Bearing Journal Diameter
Removal
1 Measure the camshaft bearing journal diameter.
1 Remove the oil pan assembly parts. Refer to “Oil
Pan Assembly Parts Replacement” Measure the diameter with a micrometer at 90° interval to
2 Remove 2 bolts fixing the oil pump oil suction pipe determine if the bearing journal is out of round.
assembly to the lower engine block frame.
Measure at two different points of the bearing journal to
3 Remove the oil pump oil suction pipe assembly determine for taper.
(1).
Note: Discard the used oil pump oil suction pipe Replace with a new camshaft if the measured value
assembly seal ring. exceeds the specified range.
S02013365 S02013188
Installation
Camshaft Journal Clearance
1 Tighten 2 bolts fixing the oil pump oil suction pipe
assembly (1) to the lower engine block frame to 9 1 Install a plastic line clearance gauge with certain
± 1 N.m, and check the torque. width on the bearing cap.
Note: Use a new oil pump oil suction pipe Insert the camshaft not applying lubricant into the cylinder
assembly seal ring. head.
Install the plastic line clearance gauge on the bearing

journal that the width is equivalent to that of the bearing
cap.
1
Note: The camshaft must meet the limit
specification of the parts used.
Note: No oil and dust on the bearing cap and the
bearing journal.
S02013365
2 Install the oil pan assembly parts. Refer to “Oil

Pan Assembly Parts” .
2-68
Camshaft Axial Clearance
1 Measure the axial clearance with the dial indicator.

Slide the camshaft. Read and record the maximum and the
minimum on the dial indicator.
The bearing end clearance is equal to the difference of the

maximum and the minimum value.
Note: Ensure that the camshaft meets the limit

specification of the part used.
S02013189
2 Install the camshaft bearing cap, and tighten the

mounting bolts of the bearing cap according to the
specified tightening torque.
3 Remove the camshaft bearing cap.
Note: Do not hit the bearing cap.
4 Read the measured value with the plastic line
clearance gauge.
Compare the width of the plastic line clearance gauge with
its scale. S02013191
The read value is the bearing clearance. 2 Replace with a new component if the measured
value does not meet the specification.
Camshaft Surface Check
1 Check the active area of the camshaft cam for

pitting corrosion or damage. The pitting corrosion
out of the active area is acceptable.
45º
S02013190
S02013192
2-69
Camshaft Cam Lift Crankshaft and Bearing Shell Check
1 Measure the cam lift. Main Crankshaft Journal Diameter

Measure the cam at two directions with the micrometer. 1 Measure the main crankshaft journal diameter.
The difference between the two measured values is the Measure the diameter with a micrometer at 90° interval to
cam lift. determine if the bearing journal is out of round.
Measure at two different points of the bearing journal to

determine for taper.
2
S02013193
1
S02013194
2 Replace with a new crankshaft if the measured

value exceeds the specified range.
Crankshaft Axial Gap
1 Measure the axial end clearance
S02013195
Install the dial indicator as shown in the figure.
Move the crankshaft with the screwdriver, measure the

crankshaft axial jump clearance that is equal to the
difference of the maximum dial reading and the minimum.
Replace with a new thrust gasket when necessary, and

correct the bearing end clearance.
2-70
Main Crankshaft Bearing Shell Check Crankshaft Connecting Rod Journal Diameter
Measurement
1 Check the main crankshaft bearing shell for the
defects below. 1 Measure the diameter with a micrometer at 90°
a Top groove friction - fatigue failure. interval to determine if the bearing journal is out of
round.
b Polished spot - improper installation. 2 Measure at two different points of the bearing
journal to determine for taper.
c Engine oil with dust.
d Scratch - Dirty oil.
e Exposed steel backing - insufficient oil lubrication.
f Ends friction - Bearing journal damaged.
g Either end friction - Tapered bearing journal or loose

crankshaft shell.
2
1
S02013218
3 Replace with a new crankshaft if the measured

value exceeds the specified range.
Select a correct connecting rod bearing shell according
to the measurement result.
a b Crank Pin Center Diameter Measurement
1 Measure the diameter of crankshaft crank pin

center.
c d e
f g
S02013220
S02013216
Select a correct main crankshaft bearing shell
according to the measurement result.
2-71
Cylinder Block Check Cylinder Block Deformation

Cylinder Bore Taper 1 As shown in the figure, measure the cylinder block
contact surface with the thickness gauge and the
1 Measure the cylinder journal with the inside ruler for deformation.
micrometer.
Measure the cylinder journal at three different heights as
shown in the figure with the inside micrometer, and check
for out-of-roundness or taper.
Note: Install the main bearing cap or the cylinder

skirt rack, and tighten it to the specified tightening
torque; but, do not install the main bearing shell.
S02013214
2 If the measured value does not meet the

specification, polish the contact surface within the
allowed range; or otherwise, replace with a new
cylinder block.
Main Bearing Hole Measurement
1 Measure the main bearing.
A
B
C
C
10
S02013196
S02013217
2 If the measured value does not meet the limit
specification of the part used, replace with a new Select a correct bearing shell according to the
cylinder block when necessary. measurement result.
2-72
Piston and Connecting Rod Check Piston Diameter

Piston Check 1 Measure the piston diameter with the micrometer,
as shown in the figure.
1 Perform the appearance inspection.
Note: Mark the piston, and ensure that the piston is
Clean the piston skirt, piston pin pushing bore, piston ring
arranged correctly.
groove and piston top, and check for friction or crack.
Note: Do not clean the piston with corrosive

cleaning fluid or wire brush.
S02013200
2 If the value does not meet the specification,

replace with a new piston.
S02013197
Piston and Connecting Rod Assembly
2 If there is any friction evidence on the piston skirt, Clearance
check the connecting rod for twist or beading.
1 Directly insert the thickness gauge between the
Piston Pin Bore Diameter piston and the connecting rod, as shown in the
figure, and measure the clearance.
1 Measure the piston pin bore diameter.
Measure the bore diameter at two directions.
If the value does not meet the specification, replace with a

new piston and piston pin.
Note: The piston shall be matched with the piston

pin. Do not mix the parts.
S02013199
S02013198
2-73
Piston Ring Opening Clearance Piston Ring Groove End Clearance
1 Remove the piston ring, push it with a piston 1 Directly insert the thickness gauge into the piston
without ring to 30mm in the cylinder bore. ring groove, as shown in the figure, and measure
the groove end clearance.
Note: Do not mix the piston rings, and install them
in their original places. Note: Make the piston ring stand out of the piston
groove. In order to calculate the piston ring
clearance, directly insert the thickness gauge into
the piston groove.
30
S02013201
2 Measure the piston ring opening clearance with

the thickness gauge. S02013203
Piston Pin Diameter
1 Measure the piston pin diameter at two directs, as

Note: The piston pin shall be used matching with
the piston. Do not mix them when checking.
S02013202
S02013204
If the value does not meet the specification, replace

with a new piston and piston pin.
Connecting Rod Big End Hole Diameter
1 Measure the connecting rod bearing shell hole

diameter at two directions. The difference is the
connecting rod hole diameter roundness. Ensure
that the roundness and the bore diameter of the
2-74
connecting rod bearing shell are within the Connecting Rod End Hole Center Diameter
specification range. Measurement
1 Measure the diameter of the connecting rod end

hole center.
15°
S02013205
15°
Measurement points
Connecting Rod Small-end Hole Diameter

S02013219
1 Measure the connecting rod small-end hole
diameter, as shown in the figure. 2 Select a correct connecting rod bearing shell
according to the measurement result.
S02013206
S02013207
2 Replace with a new connecting rod if the

measured value does not meet the specification.
2-75
Valve Train Check

Valve Seat Check
Valve Stem Diameter
1 As shown in the figure, measure the valve seat
1 Measure the valve stem with the micrometer, as width with the valve seat width gauge.
S02013210
S02013208
2 Correct the valve seat ring if the measured value
2 Replace with a new valve if the measured value does not meet the specification.
does not meet the specification.
Valve Check
1 Check the valve for the following damage

evidences, and replace with a new valve when
necessary.
Whether the valve angle is within the correct range.
Whether there is any abnormal abrasion on the valve

contact surface.
Whether the valve edge width is within the normal range.
S02013209
2-76
Flywheel Check Cylinder Head Check

Flywheel Check 1 As shown in the figure, measure the cylinder head
contact surface with the thickness gauge and the
1 Check the flywheel for the following damage ruler for deformation.
evidences, and replace with a new flywheel when
necessary. Note: First, confirm that there is no gasket
residues, oil and coolant on the cylinder head
Cracking
contact surface. Make sure the cylinder head
Flywheel ring gear worn surface is clean and tidy before test.
Flywheel ring gear notched or cracked
S02013213
If the measured value does not meet the specification,

S02013211
polish the contact surface within the allowed range.
Flywheel Clutch Surface Check
1 Check the flywheel for the following problems:

Friction burn mark
Notching
Crack
Replace with a new flywheel when necessary.
S02013212
2-77
Exhaust Manifold Cleaning and Check Engine Replacement

Removal
1 Check the cylinder head flange connecting to the
exhaust manifold for obvious exhaust leakage. 1 Disconnect the negative battery cable.
2 Check the exhaust manifold for cracks, the 2 Recover the A/C system. Recover and refill the
cylinder head gasket surface for damage or other refrigerant.
damages that are not suitable for continued use.
3 Drain the engine oil. Refer to“Engine Oil Draining
3 As shown in the figure, measure the exhaust and Refilling” .
manifold end with the thickness gauge and the
4 Discharge the coolant. Refer to “Cooling System
ruler, and check it for deformation.
Draining and Refilling” .
S02013215
GS030156
5 Remove the air filter outlet pipe. Refer to Air Filter

Air Outlet Pipe Replacement” .
6 Remove the water-air intercooler degassing pipe.
Refer to “Water-Air Intercooler Degassing
Replacement” .
7 Remove the engine degassing pipe. Refer to
“Engine Degassing Pipe Replacement” .
8 Disconnect the radiator water inlet/outlet pipe.
9 Disconnect the low-temperature radiator water
inlet/outlet pipe.
10 Disconnect the brake booster vacuum pipe from
the vacuum pump.
11 Disconnect the heater water inlet hose the water
outlet hose.
12 Disconnect the expansion tank compensating
pipe.
13 Remove the front catalytic converter assembly.
Refer to “Front Catalytic Converter Assembly
Replacement” .
14 Disconnect the low-pressure EGR assembly
intake pipe from the engine. Refer to “Low-
pressure EGR Assembly Intake Pipe
Replacement” .
15 Disconnect the A/C compressor and the
condenser hose from the A/C compressor.
2-78
16 Remove the engine radiator. Refer to “Radiator Installation

Replacement” .
1 Install the engine.
17 Disconnect all the pipes and harnesses from the
2 Install the left/right engine mount bolts, tighten
engine.
18 Remove the drive shaft. Refer to “Drive Shaft 3 Install 10 bolts connecting the engine and the
Replacement” .
transmission, tighten them to 50 ± 5 N.m, and
19 Remove the rear transmission mount bracket. check the torque.
Refer to “Rear Transmission Mount Bracket
4 Install the rear transmission mount bracket. Refer
Replacement” .
to “Rear Transmission Mount Bracket
20 Lower the lift to an appropriate height, and use a Replacement” .
common bracket to support the transmission
5 Install the drive shaft. Refer to “Drive Shaft
assembly.
Replacement” .
21 Remove 10 bolts (1) between the engine mount,
6 Install all the pipes and harnesses connecting the
transmission and the engine.
engine.
Note: Place a proper wooden block or plastic
7 Install the radiator. Refer to “Radiator
between the rear end of the engine and the dash
Replacement” .
panel, to avoid compression damage to the dash
8 Disconnect the A/C compressor and the
panel by the engine.
condenser hose from the A/C compressor.
9 Remove the air filter outlet pipe. Refer to Air Filter
Air Outlet Pipe Replacement” .
10 Connect the low-pressure EGR assembly intake
pipe to the engine. Refer to “Low-pressure EGR
1 Assembly Intake Pipe Replacement” .
1
1 11 Remove the front catalytic converter assembly.
1
1 Replacement” .
1
12 Connect the expansion tank compensating pipe.
13 Connect the heater water inlet hose and the water
outlet hose.
S02013416
14 Connect the low-temperature radiator water inlet/
22 Remove the left/right engine mount bolts. outlet pipe.
15 Connect the radiator water inlet/outlet pipe.
16 Install the engine degassing pipe. Refer to
“Engine Degassing Pipe Replacement” .
17 Install the water-air intercooler degassing pipe.
Refer to “Water-Air Intercooler Degassing
Replacement” .
18 Refill the power steering hydraulic system.
19 Refill the coolant. Refer to “Cooling System
Draining and Refilling” .
20 Refill the engine oil. Refer to “Engine Oil Draining
and Refilling” .
S02013418
21 Connect the negative battery cable.
23 Lift out the engine assembly from the engine
compartment with a proper lifting arm.
2-79
cars use metal chains instead of belts. Since the broken

Description and Operation
toothed timing belt can cause severe damage to the
Accessory Belt System internal engine valves, manufacturers generally specify the
The accessory belt system includes accessory belt, idler, replacement period of the timing belt.
tension pulley, crankshaft shock absorber, timing drive belt, Timing belts are rubber parts. As the engine working time
timing idler, timing tension pulley, camshaft timing pulley, increases, the timing belt and its accessories such as
high-pressure fuel pump, steering pump, vacuum pump, timing belt tension pulley, timing belt tensioner and water
alternator, compressor and other components. pump, wear or age. Therefore, for engines equipped with
As an important part of the engine valve train, the timing timing belts, manufacturers will have strict requirements on
belt connected with the crankshaft is used to ensure the the regular replacement of timing belts and accessories
accurate time of intake and exhaust under a certain within the specified period. The replacement period varies
transmission ratio. The use of a belt rather than a gear for with the structure of the engine. Generally, the parts should
transmission is due to such advantages of it as low noise, be replaced when the vehicle travels to 60,000 to 100,000
small variation and ease of compensation. However, it is kilometers. The specific replacement period should be
obvious that the service life of a belt is shorter than a metal subject to the maintenance manual.
gear, so the belt shall be replaced regularly.
The timing belt functions as a link, the upper and lower

parts of which are connected with the timing pulley on the
engine cylinder head and the crankshaft timing pulley
respectively. The timing pulley is connected with the
camshaft with a cam contacting the small rocker which
produces pressure through the power from the timing belt,
functioning as a jack, jacking the intake valve to let the
atomized gasoline enter the cylinder block and the exhaust
valve to bleed the cylinder block. Once the camshaft
concavity (note: not convexity) touches the small rocker,
the intake and exhaust valves will close, thus compression
ratio generates, the distributor ignites, internal combustion
starts and power is generated.
The timing belt is a consumable part, once it breaks, the

camshaft will of course not operate in the right direction. At
this time, it is very likely that the valve will collide with the
piston, causing serious damage. Therefore, the timing belt
must be replaced based on the mileage or time specified
by the manufacturer.
During the operation of the engine, four processes of

intake, compression, explosion and exhaust carries out
continuously in the cylinder, and the timing of each step
matches the motion state and position of the piston to
make the intake, exhaust and the rise and fall of the piston
coordinate with each other. The timing belt acts as a
“bridge” in the engine, driven by the crankshaft,
transferring power to the corresponding parts. In order to
ensure the stability of the timing system, a lot of premium
2-80
Valve Train The intake valve is generally made of alloy steel (chrome
The engine valve train (internal combustion engine valve steel, nickel-chromium steel) and the exhaust valve is
train) is to open and close the intake and exhaust valves of made of heat-resistant alloy (silicon chrome steel).
each cylinder according to the requirements of the working Sometimes, in order to save heat-resistant alloys, the
cycle and ignition sequence in each cylinder of the engine, exhaust valve head is made of heat-resistant alloy while
so that the fresh combustible mixture (gasoline engine) or the stem is made of chrome steel, and then the two parts
the air (diesel engine) can enter the cylinder in time, and are welded together.
the exhaust gas can be discharged from the cylinder in The valve head may be flat, spherical, horn-type, etc. The
time [1]. In the compression and power strokes, the valve is engine uses the flat head. The flat valve head is of simple
closed to ensure the seal of the combustion chamber. structure, manufacturing convenience, small heat
All kinds of valve trains can be divided into two parts: valve absorption area and low mass, which can be used for both
group and valve transmission group. The valve group intake and exhaust valves. The spherical valve head
includes valves and associated components, the applies to the exhaust valve and is of high strength, low
composition of which is substantially independent of the exhaust resistance and good exhaust gas elimination
form of valve train. effect, however its heating area is large, mass and inertia
are large and the processing is complicated. The horn-type
The valve transmission group includes all parts from the valve head is of a certain streamlined shape, which can
timing gear to the parts that drive the valves to act, the reduce the intake resistance, however its heating area is
composition of which varies with the form of valve train. It large, thus it only applies to the intake valve.
serves to drive the valves to open and close at regular
intervals. In order to reduce the intake resistance and improve the
cylinder intake efficiency, most engine intake valves are
Valve Group larger than the exhaust valves. The used intake and
The valve group includes valves, valve guides, valve seats exhaust valves are also different in color. The valve stem is
and valve springs. Some intake valves are also equipped cylindrical and continuously reciprocates in the valve guide,
with a valve rotating mechanism. The valve group shall and its surface must be subject to heat treatment and
ensure valve-to-cylinder sealing, and the requirements on polishing. The shape of the valve stem end depends on the
the valve group are as follows: fixing mode of the valve spring. Commonly, a two-half
The valve head is tightly attached to the valve seat; locking plate is used to fix the spring seat. The end of the
valve stem has a ring groove for installing the locking plate,
The valve moves up and down well in the valve guide. some of which are fixed by locking pins, and there is a hole
The end faces of the valve spring are perpendicular to the on the end for mounting the locking pin.
centerline of the valve stem to ensure that the valve head is 2 Valve Guide
not deflected on the valve seat.
The valve guide is used to guide the valve in a straight line,
The valve spring force is sufficient to overcome the inertial to make the valve and valve seat fit correctly. In addition,
force of the valve movement, so that the valve can be the valve guide serves as a thermal conductor between the
opened and closed at a constant speed. valve stem and the cylinder block.
1 Valve The valve guide works at a high temperature of about

500K, and the valve stem moves in it. It is easy to wear as
The valve consists of the valve head and the stem. The
it is only lubricated by the oil splashed by the valve train.
temperature of the valve head is very high (intake valve:
Therefore, most of the valve guides are made of gray cast
570~670; exhaust valve: 1,050~1,200), and it also
iron and nodular cast iron.
withstands the gas pressure, the valve spring force and the
inertia force of the transmission components. Since the The outer cylindrical surface of the valve guide is machined
lubrication and cooling conditions are poor, the valve must and pressed into the cylinder head. In order to prevent the
be of certain strength, stiffness, heat and wear resistance. valve guide from loosening during use, it is secured with a
2-81
snap ring in some engines. There is a clearance of one spring is broken. In addition, it also can reduce the
0.05~0.12mm between the valve stem and the valve height of the valve spring. When two valve springs are
guide, so that the valve stem can move freely in the guide. installed, the spiral direction of the spring coils shall be
opposite. This prevents the broken spring coil from sticking
3 Valve Seat
into the other spring coil.
The valve seat can be directly bored on the cylinder head
(top-mounted valve) or the cylinder block (side-mounted Valve Transmission Group
valve). It also can be made of better materials and then 1 Camshaft
embedded on the cylinder head or the block. Together with The camshaft is the key component of the valve train,
the valve head, they seal the cylinder and receive the heat which controls the valve timing of the valve. In some
from the valve. engines, it is also used to drive the oil pump, gasoline
The intake valve is of low temperature and can be directly pump and distributor.
bored, while the exhaust valve is of high temperature but The camshaft mainly consists of intake and exhaust cams,
poor lubrication and is easy to wear, so the inlaid type is a support shaft, a timing gear shaft, a gasoline pump
commonly used. The disadvantage of the inlaid type is that eccentric cam, an oil pump and a distributor drive gear.
the thermal conductivity is poor, the processing precision is
high, and it is easy to fall off, so the directly-bored type is During the operation of the engine, in order to reduce the
better. For the cylinder head made of aluminum alloy, the deformation of the camshaft to avoid malfunction of the
intake and exhaust valves are inlaid because the valve train, the camshaft commonly uses full support.
aluminum alloy is soft.
The camshaft is generally forged from high-quality steel or
4 Valve Spring cast from alloy cast iron or nodular cast iron. The working
surfaces of the cam and the journal are generally finely
The valve spring serves to overcome the inertial force of
ground after heat treatment to improve the abrasive
the valve and the transmission components during the
resistance.
valve closing process, so as to prevent the inertia between
the transmission parts from generating a clearance, and 2 Valve Tappet
ensure timely seating of the valve and close contact
The tappet serves to transmit the thrust of the cam to the
between the valve and the seat, so as to prevent the valve
push rod (or valve stem) and to withstand the lateral force
from jumping when the engine vibrates, deteriorating the
applied during the rotation of the camshaft. In the side-
sealing effect.
mounted valve train, the tappet is generally made into a
Most of the valve springs are cylindrical spiral springs mushroom shape, and an adjusting screw is arranged on
made of high carbon manganese steel cold drawn steel the top of the tappet to adjust the valve clearance. The
wire which is subject to heat treatment after processing tappet of the top-mounted valve train is generally made
and the surface of which to grinding, polishing and shot into a cylinder shape to reduce the weight. The roller tappet
blast. The surface is galvanized to avoid rusting. as shown has the advantage of reducing the lateral force
on the tappet caused by friction. Such tappet is complex in
One end of the valve spring is supported on the cylinder structure and heavy in weight. Generally, it is used on large
head or the cylinder block, and the other end is pressed bore diesel engines. The tappet is commonly made of
against the spring seat at the valve stem end, and the nickel-chromium alloy cast iron or chilled alloy cast iron.
spring seat is fixed to the end of the valve stem by a locking The friction surface should be finely ground after heat
plate. The variable-pitch cylindrical spring can be used to treatment.
prevent the spring from resonating. In most of the high-
speed engines, a valve with two valve springs (inner and
outer) installed concentrically is used. This can improve the
operational reliability of the valve spring, that is, not only
can prevent resonance, but also can keep operating when
2-82
Crank Train Lubrication System

The crank train is the main part in the engine. It serves to The term "Lubrication System" refers to a series of grease
convert the reciprocation of the piston into the rotation of supply, grease drain and accessory devices that supply
the crankshaft and at the same time transform the force lubricant to the lubrication parts. The lubrication system
acting on the piston into the torque output by the crankshaft includes a circulation lubrication system, a centralized
to drive the vehicle wheels. The crank train consists of a lubrication system, a spray lubrication system, an oil
piston group, a connecting rod group, a crankshaft and immersion and splash lubrication system, and a total-loss
flywheel group and the like. oil and grease lubrication system.
The crank train serves to provide a combustion place and The design of the lubrication system depends on the
converts the expansion pressure of the post-combustion characteristics and service conditions of various
gas acting on the top of the piston into the torque of the mechanical equipment. It always consists of several main
crankshaft rotation, to output power continuously. components such as hydraulic pump, fuel tank, filter,
cooling device, heating device, sealing device, buffer
(1) Convert the gas pressure into the crankshaft torque.
device, safety device and alarm.
(2) Convert the reciprocation of the piston into the rotation
The lubrication system serves to deliver a quantitative
of the crankshaft.
amount of clean lubricant to the surface of the parts that
(3) Convert the force from combustion acting on the top of move relative to each other to achieve liquid friction,
the piston into the crankshaft torque, to output mechanical reduce frictional resistance and mitigate wear of the parts.
energy to the working machine. In addition, it can clean and cool the surface of the parts.
The lubrication system usually consists of lubricating oil
The crank train consists of a block group, a piston
passage, oil pump, oil filter and some valves.
connecting rod group and a crankshaft flywheel group.
After the fuel enters the engine and burns, the internal
(1) Block group: cylinder block, cylinder head gasket,
energy of the fuel is successfully converted to make the
cylinder head, crankcase, cylinder sleeve and oil pan.
engine run. However, not all the power is used to drive the
(2) Piston connecting rod group: piston, piston ring, piston engine, as the friction between the parts in the engine
pin and connecting rod. consumes the power generated by the engine and
converts it into thermal energy. In order to reduce friction to
(3) Crankshaft flywheel group: crankshaft, flywheel, protect the engine, a lubrication system is required to
torsional shock absorber and balance shaft. lubricate the engine.
The block is the skeleton of the engine and the foundation
of the mechanisms and systems of the engine. All the main
parts and accessories of the engine are installed inside
and outside the block, bearing various loads. Therefore,
the block must have sufficient strength and stiffness.
2-83
Special Tool
SN. Tool name Illustration
SN. Tool name Illustration
C00189129
Rear Oil Seal
6
Bracket Assembly
Tooling
C00189123
1 Valve oil seal
tooling
C00189129
C00189123
C00189130
7
Flywheel Lock
C00189124
2 Camshaft timing
tooling
C00189130
C00189124
C00189131
8 Clutch Pressure
Plate Orientation
C00189125
Crankshaft Front-
3
end Timing Lock-
up Tooling C00189131
C00189125
C00189132
9 Camshaft Oil Seal
Installer
C00189126
4 Rear Oil Seal
Tooling
C00189132
C00189126
C00189133
10 Mainshaft Bearing
Remover
C00189128
5
Oil Filter Socket
C00189133
C00189128
2-84
SN. Tool name Illustration SN. Tool name Illustration
C00189140
C00189135
Fuel Pump
11 Balance Shaft 16
Transition Plate
Timing Tooling
Locating Tooling
C00189135 C00189140
C00189136 C00189243
12 Front Oil Seal 17 Front Oil Seal
Bracket Tooling Tooling
C00189136 C00189243
C00189137 C00189291
High-pressure Crankshaft Rear-
13 18
Pump Pulley end Locating
Locating Rod Tooling
C00189137 C00189291
C00189138 C00189316
14 Timing Wheel 19 Fuel Injector
Locating Pin Remover
C00189138 C00189316
C00189139
Camshaft C00189087
15 20
Intermediate Oxygen Sensor
Flange Installer Socket
C00189139
C00189087
2-85
2-86
Engine Cooling System
Specification
Antifreeze specification 50/50 ethylene glycol-water mixture
Radiator component Heat dissipation capacity 1: ≥ 51 kw

Intercooler component Heat dissipation capacity 2: 13.3kw
Relief valve of expansion tank cover When the air flow is 10cm3/min:
The relief valve opening pressure is 120~150KPa;
The vacuum valve opening pressure is 7~10KPa
Opening temperature of thermostat 83°C ± 2°C

Full opening temperature of thermostat 94°C ± 2°C
Pressure setting of pressure cover 1.1 Pa
Note: Heat dissipation capacity 1: under the condition of air flow = 4,615kg/h, water flow =4895kg/h and △ T=60 ℃
Heat dissipation capacity 2: under the condition of cold air side flow=0.85kg/s, pressurized air side flow=0.126kg/s
and △ T=125 ℃
Torque
Radiator to body bolts 20 ± 3

Hoop - radiator bottom hose 5 ± 0.5
Water pump body nut 32
Thermostat body bolt 25
4-1
Layout
Layout of Condenser/Cooling Fan
1
2
17 3
15
16
8
9 7
7
18
4
10
5
6
11
12
13
14
CS110007
1 Engine cooling module assembly 10 Main fan (30A)

2 Air-conditioning condenser assembly 11 Auxiliary fan (30A)
3 Intercooler assembly 12 Nut - engine cooling module mounting nut
4 Radiator 13 Large washer level-A
5 Radiator bottom rubber strip 14 Bolt - engine cooling module mounting bolt
6 Radiator bottom sealing strip 15 Upper radiator beam assembly
7 Radiator top sealing strip 16 Screw - upper radiator beam assembly
8 Radiator upper mounting bracket 17 Bolt - radiator to bo
9 Radiator upper rubber strip 18 Upper radiator beam mounting bracket assembly
4-2
Layout of Coolant Pipeline and Metal Parts
16 17
15
13 18
6
4
14 2 5
19 3 1
20
7
21 8
13
4
10
13
9
11
12
22
10
13
CS110008
1 Expansion tank 10 Hoop

2 Expansion tank cover 11 Radiator to expansion tank hose bracket
3 Bolt 12 Bolt
4 Hoop 13 Hoop
5 Radiator to water pump hose 14 Radiator top hose
6 Pipe clamp 15 Hoop
7 Expansion tank to water pump hose bracket 16 Engine to radiator hose
8 Bolt 17 Hoop
9 Radiator to expansion tank hose 18 Pipe clamp
4-3
19 Bolt 21 Pipe clamp
20 Hose support 22 Radiator bottom hose
4-4
Layout of EGR Cooler Components (China Stage IV Standard)
9
10 7
8
11
9 14
8
9
7
13
12
2
6
1
9
4 5
CS110009
1 EGR valve 8 EGR flange gasket

2 EGR valve gasket 9 Hose clamp
3 Bolt 10 EGR cooler water inlet pipe
4 EGR pipe V-clamp gasket 11 EGR cooler block
5 EGR pipe V-clamp 12 EGR cooler water outlet pipe
6 EGR exhaust pipe 13 Bolt
7 Bolt 14 EGR cooler
4-5
Layout of EGR Cooler Components (China Stage V Standard)
4 5 9
6
3 7
1
10
CS110010
1 Hexagonal flange bolt (M8 × 85) 6 EGR flange gaskets (4)

2 Hose clamp (4) 7 Hexagonal flange bolts (2-M8 × 50)
3 EGR water inlet pipe 8 EGR module
4 Hexagonal flange bolts (8-M8 × 20) 9 EGR water outlet pipe

5 EGR exhaust pipe 10 EGR intake pipe
4-6
Troubleshooting
Engine overheating Coolant insufficient Refill the coolant
Radiator pressure cover failure Replace
Engine overload Reduce engine load for operation
Too much dust on the radiator Wash
Cooling fan shroud damaged or Repair or replace

separated from the fan
Fan drive belt damaged or loose Repair or replace
Water pump failure Replace
Air or gas mixed in the cooling system For partial leakage, add sealant or
sealing parts to block the leaking
position; for severe leakage, replace
the cylinder block
Coolant temperature sensor or Replace

thermometer damaged
Thermostat failure Replace
Engine coolant temperature low Too much cold air flowing through the Replace the fan clutch
radiator
Radiator shutter stuck at the maximum Replace

opening
Temperature sensor failure Replace
Thermometer failure Replace
Thermostat damaged Replace
Turbocharger makes abnormal noise The engine vibrates and the load on Make a judgment by checking the
(European stage V standard) the turbocharger is excessively large, engine exhaust manifold, turbocharger
so that the turbocharger leaks and turbine and exhaust tailpipe for
makes noise exhaust gas traces or checking the
engine intake manifold and
turbocharger compressor for leakage
with soap water
Turbocharger push rod gets stuck SREA gets stuck Replace the turbocharger
(European stage V standard)
Nozzle gets stuck Replace the turbocharger
4-7
Repair Guidance Replacement of Water Pump
Replacement of Thermostat Required tools: C00016996, C00016997, C00017003,

C00017015, C00017016 and C00017030.
Removal
1 Remove the thermostat component bypass
hose. Removal
1 Remove the front-end accessory drive belt (refer
Belt).
2 Remove and scrap the timing drive belt (refer to
3 Remove the timing pulley chamber (refer to

Replacement of Timing Pulley Chamber and Its
Shock Pad).
4 Check gaskets, sealing parts, etc. for damage,

and replace if necessary.
5 Remove accessory parts/pipeline/hoses, etc.

CS113144 (when necessary) to install the water pump.
2 Unscrew 3 M8 bolts and thermostat components,

and scrap gaskets. This work includes the following steps:
—Remove the exhaust pipe heat shield.
—Remove the EGR pipe from the exhaust pipe rear end.
—Remove the top hose and bypass hose from the

thermostat housing.
—Remove the thermostat housing.
—Remove the intake pipe from the turbocharger.
—Remove oil inlet pipe and oil return pipe from the
turbocharger.
CS113145 —Remove the exhaust pipe.
Installation —Remove the hose, etc. to separate the coolant pipeline

from the water pump.

Note：Do not leave out any gasket. Tightening
torque for bolts: 25 ± 2N.m.
4-8
6 Unscrew nuts and remove the water pump.

Replacement of EGR Cooler (China Stage IV
Standard)
Removal
1 Remove the EGR cooler water inlet pipe.
CS113146
Note：Scrap O-rings.
Installation
CS113147
1 Installation is the reverse of removal. Pay
attention to the following precautions: 2 Remove the EGR cooler water outlet pipe.
—When installing a new water pump, please install the
pipelines, hoses, etc. of the old water pump onto the new
water pump.
—Use new O-rings.
—Install and tighten water pump studs, then check

whether the threads are screwed in completely. Install the
water pump inlet gasket and water inlet pipe component
onto water pump component with the gasket protrusion
facing the water inlet pipe, and tighten them to the torque
of 7 ± 2N.m. Install water pump components. Tighten
retaining nuts of water pump components to the torque of
CS113148
25 ± 2N.m.
3 Remove the EGR exhaust pipe, tighten bolts (2 x
—Apply Tonsan 1243 sealant onto the studs.
M8), and scrap gaskets.
CS113149
4-9
4 Loosen the bolt (M10) fastening the EGR cooler Installation

to cylinder head. 1 Install the intake connecting pipe and
respectively tighten bolts (4 x M6) and bracket
bolts (2 x M10) to the torques of 11N.m and
33N.m.
CS113150
5 Remove exhaust heat shield bolts (3 x M8).

Remove the EGR cooler from the exhaust CS113152
manifold, unscrew bolts (2 x M8), and scrap
gaskets. 2 Pre-install the EGR cooler.
CS113151 CS113153
Note：After the EGR cooler is separated from the Note：Do not tighten bolts (M10) temporarily to
exhaust manifold, unscrew the bolts connected facilitate subsequent installation.
to the cylinder head to remove the EGR cooler.
4-10
3 Install the EGR cooler to the exhaust manifold. Note：After the above steps, tighten bolts (M10)
Do not leave out any flange gaskets. Tighten fastening the EGR cooler to cylinder head to
bolts (M8) to the torque of 33N.m. thetorque of 45N.m. Tighten the exhaust heat
shield (3 × M8) to the torque of 25N.m.
CS113151
4 Install the EGR exhaust pipe to the EGR valve.

Torque: 45N.m.
CS113154
5 Connect the EGR exhaust pipe to the EGR

cooler. Do not leave out any gaskets. Torque:
33N.m.
CS113149
4-11
3 Loosen 4 bolts on the EGR intake pipe and

Replacement of EGR Cooler (China Stage V
exhaust pipe, and remove the EGR exhaust
Standard) pipe.
Removal
1 Loosen the hose clamp. Then remove the
retaining brackets from EGR water inlet/outlet
pipes and EGR cooler water inlet/outlet pipes.
CS113340
4 Loosen the bolts on the EGR cooler bracket, and

remove EGR module from the engine block.
CS113338
2 Loosen 8 bolts on the EGR intake pipe and

exhaust pipe, and remove the EGR intake pipe.
CS113341
Note：During removal, avoid the collision between

the EGR module and intake pipe.
CS113339
4-12
Installation
Replacement of Coolant
1 Install the EGR water inlet pipe and the joint, and
Drain
connect the water inlet pipe to the engine block.
Warning: During pressure relief of the cooling
2 Install the EGR cooling module.
system, cover the expansion tank cap with a piece of
3 Install the exhaust pipe. thick cloth.
4 Connect the water inlet pipe to EGR cooler.
1 Open the engine hood.
5 Install the EGR intake pipe. 2 Slowly rotate the coolant expansion cover for
Precautions for installation: 2~3 circles to release the pressure of cooling
system.。
1.The junction surface of flange shall be sealed with
3 Raise the vehicle with a lift.
gaskets. Do not miss any parts.
2.When re-installing the EGR system, remove residual

gaskets from the flange face with a blade and abrasive
cloth, and clean the flange face. Install new gaskets,
otherwise sealing performance would be affected.
3.The bolts on the EGR cooler must be tightened after all

bolts are installed.
4.The tightening torques for M8/M10 bolt of EGR system

are 33N.m and 45N.m respectively.
CS113155
4 Loosen the radiator bottom hose from the vehicle

bottom, and drain coolant into a proper
container.
CS113228
4-13
Refill
Replacement of Expansion Tank Cap
1 Re-install the radiator bottom hose. Lower the
High-pressure opening: 120-150KPa, Lowpressure
vehicle after no leakage is found during check.
opening: 7-10KPa
2 Open the expansion tank cap, and refill coolant
until its level reaches the required scale. Check
3 Tighten the expansion tank cap. 1 Visually check the engine and the cooling
system for any signs of coolant leakage.
2 Check the hose for any rupture and distortion
trace and check the safety of pipeline
connection.
CS113155
CS113156
3 Open the expansion tank cap.
Warning: In case of cooling system overheat, do

not open the expansion tank cap to avoid scald
due to steam overflow.
4 Select the correct pressure cap connector and
install the expansion tank cap onto the
connector.
5 Connect the pressure hose to the connector.
6 Fix the pressure testing tool. Connect the

pressure hose onto this testing tool.
4-14
7 Pressurize the expansion tank cap to the

Replacement of Cooling Module
specified pressure slowly and check for leakage.
Removal
1 Open the engine hood and drain the cooling
system. (refer to Replacement of Coolant)
2 Unscrew bolts, and remove the A/C grille from
the beam mounting bracket.
CS113155
Installation
CS113157
3 Remove the headlamp from the beam mounting

bracket.
CS113158
4-15
4 Unscrew the bolts connecting the vacuum 6 Loosen the pipeline and harness connected to
regulator to the upper radiator beam assembly to the Engine cooling module.
separate these two components.
CS113161
CS113159
7 Separate the bottom rubber strips of engine
5 Remove the harness, etc. installed on the cooling module assembly from the front
radiator beam, and loosen the bolts connecting anticollision beam bracket.
the cooling module to the upper beam assembly.
Then remove the upper radiator beam assembly
and upper radiator beam mounting bracket
assembly.
CS113162
CS113160
4-16
8 Remove the engine cooling module assembly hoops to the joints at both ends of radiator top
from the complete vehicle. hose, then tighten to 5 ± 0.5N.m.
CS113164
CS113163
5 Respectively install 2 steel-belt elastic hoops to
both ends of the hose between radiator and
water tank with a nipper plier, and connect both
Installation ends of the hose respectively to the radiator top
and expansion tank as shown in the figure
connect them in place, and then fix the 2
1 Install the bottom rubber strips of engine cooling steelbelt elastic hoops to the joints at both ends
module assembly onto the front anti-collision with the nipper plier.
beam bracket.
6 Respectively install 2 steel-belt elastic hoops to
2 Pre-tighten 2 hexagonal flange bolts to fix the both ends of the hose between water tank and
engine cooling module assembly onto the body water pump with a nipper plier, and connect both
beam assembly; tighten 2 hexagonal flange bolts ends of the hose respectively to the expansion
to 20 ± 3N.m. tank and engine as shown in the figure; connect
3 Respectively install 2 type-A worm drive hose them in place, and then fix the 2 steel-belt elastic
hoops to both ends of the radiator top hose, and hoops to the joints at both ends with the nipper
connect both ends of radiator top hose plier.
respectively to the radiator top and engine as 7 Respectively install 2 steel-belt elastic hoops to
shown in the figure; connect them in place, and the joint between the hose (engine to water tank)
then tighten with 8# sleeve to 5 ± 0.5N.m. and expansion tank and the joint between the
4 Respectively install 2 type-A worm drive hose hose (engine to water tank) and engine with a
hoops to both ends of the radiator bottom hose, nipper plier. Then connect both ends of the hose
and connect both ends of radiator bottom hose (engine to water tank) to the expansion tank and
respectively to the radiator bottom and engine as engine respectively as shown in the figure;
shown in the figure; connect them in place, and connect them in place, and then fix the 2
respectively move the 2 type-A worm drive hose
4-17
steelbelt elastic hoops to the joints at both ends

Replacement of Radiator
with the nipper plier.
Removal
1 Open the engine hood and drain the coolant
from the cooling system (refer to Replacement of
Coolant).
2 Remove the upper radiator beam assembly.
3 Remove the engine cooling module (refer to

Replacement of Cooling Module).
4 Loosen the connecting bolts from radiator.
5 Remove the A/C condenser and intercooler.
CS113165
8 Install the upper radiator beam assembly and the

upper radiator beam mounting bracket assembly.
CS113167
Installation
CS113166
4-18
Replacement of Cooling Fan Installation

1 Install the main/auxiliary fan to the radiator, then
Removal
tighten to the torque of 7 ± 1N.m.
Warning: Before removing the fan, disconnect the
2 Install the upper radiator beam assembly.
negative battery cable to prevent the injury due to
3 Connect the battery negative.
fan motor startup.
1 Open the engine hood, and remove the battery

negative.
2 Remove the upper radiator beam assembly.
3 Remove the engine cooling module (refer to

Replacement of Cooling Module).
CS113168
4 Remove the bolts fastening the fan to the

radiator, and remove the main/auxiliary fan from
the radiator.
CS113169
Note：Do not remove the fan from the fan motor,

because the assembly is tested and adjusted for
dynamic balance when manufactured. And
reassembly can not meet the same balancing
requirement.
4-19
4-20
Engine Cooling System SC20M163Q5A
Specification
Fastener Specifications
Bolt - Water Pump Inlet Pipe to Engine Block 10 ± 1 N.m
Bolt - Water Pump Inlet Pipe to Air Compressor
22 ± 2 N.m
Bracket
Bolt - Water Pump Assembly 25 ± 2 N.m
Bolt - Small Circulation Pipe 10 ± 1 N.m
Bolt - Cylinder Block Thermostat 10 ± 1 N.m
Bolt - Cylinder Head Thermostat 22 ± 2 N.m
Exhaust Valve 25 ± 2 N.m
Bolt - Expansion Tank 5 ± 0.5 N.m
Bolt - Engine Cooling Fan 9 ± 1 N.m
Parameter Specifications
Item Name Parameters

Thermostat Operating Temperature (cylinder block)
Initial Activation 65°C
Fully Open 75°C
Fully Open Lift >6 mm
Thermostat Operating Temperature (cylinder head)
Initial Activation 90°C
Fully Open 100°C
Fully Open Lift >8 mm
3-1
Layout
Cooling System
1
7
4
2
3
6
4
6
8
S02040002
Cylinder Head Thermostat Hose

1 5 Water Pump Inlet Pipe
Assembly
2 Cylinder Head Thermostat Assembly 6 Cylinder Block Thermostat
3 Small Circulation Pipe 7 Thermostat Water Outlet Tube
4 Water Pump Assembly
3-2
Check and Confirmation

1 Identify the problems, and carry out the
corresponding check and road tests.
2 Check the appearance for obvious mechanical or
electrical damages.
3 Solve the found problems before carrying out the
next check.
4 If the causes can't be identified visually, identify
the symptoms first, and then carry out the check
according to Symptom Table.
3-3
Symptom Table
? Insufficient coolant ? Refill the coolant as appropriate.
? Faulty water temperature sensor or ? Check the circuit, or replace the faulty water
High engine coolant tem-
circuit temperature sensor
perature
? Water pump leakage, loosen or fallen ? Replace the water pump.
blade, or poor operation
? Faulty water temperature sensor or ? Check the circuit, or replace the faulty sensor
Low engine coolant tem- circuit
perature ? Electronic fan always rotating ? Check the circuit, fuse, solenoid valve and
fan motor, and replace the faulty components.
? Filter element or pipe is damaged, ? Replace the damaged filter element or intake
foreign matters get into the pipe, and replace the turbocharger assembly.
turbocharger, which directly damages
the impeller or shaft
? Engine oil is too dirty or deteriorated ? Replace with engine oil complying with the
after a long period, which leads to poor standard, and replace the turbocharger
lubrication and stuck turbocharger assembly.
bearing
Abnormal turbocharger ? Engine oil pressure is too low, which ? Eliminate the low oil pressure, and replace the
operation sound leads to late turbocharger oil supply, turbocharger assembly.
and poor bearing lubrication
? Turbocharger impeller is damaged ? Replace the turbocharger assembly.
and has friction with housing
? There is periodic abnormal sound ? Replace the turbocharger assembly.
while rotating the turbocharger impeller,
and the bearing clearance and
excessive wear can be detected while
shaking the turbocharger impeller
3-4

Service Guide
Water Pump Assembly Replacement
Removal
1 Remove the accessory belt. Refer to “Accessory
2 If necessary, remove the turbocharger assembly.
Refer to“Turbocharger Assembly Replacement”.
3 If necessary, remove the low-temperature EGR
assembly. Refer to “Low-temperature EGR
4 Remove the water pump inlet pipe. Refer to
“Water Pump Inlet Pipe Replacement” .
5 Remove the low-pressure EGR cooler water inlet
hose. Refer to “Low-pressure EGR Cooler Water
Inlet Hose Replacement” .
6 Remove 4 bolts fixing the water pump assembly to
the engine block.
7 Remove the water pump assembly (1).
S02043032
Installation
1 Fix the water pump assembly to the engine block,
check the torque.
2 For the installation of the low-pressure EGR cooler
water inlet hose, refer to “Low-pressure EGR
Chiller Water Inlet Hose Replacement” .
3 For the installation of the water pump inlet pipe,
refer to “Water Pump Inlet Pipe Replacement” .
4 If necessary, for the installation of the low-
temperature EGR assembly, refer to “Low-
temperature EGR Assembly Replacement” .
5 If necessary, for the installation of the turbocharger
assembly, refer to “Turbocharger Assembly
Replacement” .
3-5
Cylinder Head Thermostat Hose Assembly Cylinder Head Thermostat Assembly

Replacement Replacement
Removal Removal
1 Remove the intercooler intake pipe when 1 Remove the water temperature sensor. Refer to
necessary. Refer to “Intercooler Intake Pipe “Water Temperature Sensor Replacement” .
Replacement” . 2 Remove the clamp (1) fixing the cylinder head
2 Remove the clamp fixing the cylinder head thermostat hose assembly to the cylinder head
thermostat hose assembly (1) to the cylinder head thermostat, and release the cylinder head
thermostat. thermostat hose assembly (2).
3 Remove the clamp (3) fixing the low-pressure
EGR cooler water inlet pipe assembly to the
cylinder head thermostat, and release the low-
pressure EGR cooler water inlet pipe assembly
(4).
1
2
1
S02043033
4 3
3 Remove the clamp fixing the cylinder head
thermostat hose assembly to the thermostat water
outlet tube.
4 Remove the cylinder head thermostat hose S02043036
assembly (1).
4 Remove 2 bolts fixing the cylinder head thermostat
to the cylinder head.
5 Remove the cylinder head thermostat (1).
S02043034
Installation
1 Fix the cylinder head thermostat hose assembly to S02043037
the thermostat water outlet tube, and install the
clamp. Installation
2 Fix the cylinder head thermostat hose assembly to 1 Fix the cylinder head thermostat to the cylinder
the cylinder head thermostat, and install the head, install 2 bolts, tighten them to 22 ± 2 N.m,
clamp. and check the torque.
3 Install the intercooler intake pipe when necessary.
Refer to “Intercooler Intake Pipe Replacement”.
3-6
2 Fix the cylinder head thermostat hose assembly Cylinder Block Thermostat Assembly
and the low-pressure EGR cooler water inlet pipe Replacement
assembly to the thermostat, and install the clamp. Removal
3 Install the water temperature sensor. Refer to
1 Remove the high-pressure EGR assembly. Refer
“Water Temperature Sensor Replacement” .
to “High-pressure EGR Assembly Replacement”
.
2 Remove the clamp fixing the hose assembly to the
cylinder block thermostat.
3 Release the cylinder block thermostat hose
assembly (1).
4 Release the oil cooler water inlet hose assembly
(2).
5 Release the high-pressure EGR cooler water inlet
hose assembly (3).
2
S02043038
6 Remove 4 bolts fixing the cylinder block

thermostat to the engine block.
7 Remove the cylinder block thermostat (1).
S02043039
Installation
1 Fix the cylinder block thermostat to the engine
block, install 4 bolts, tighten them to 10 ± 1 N.m,
3-7
2 Fix the oil cooler water inlet hose assembly to the Water Pump Inlet Pipe Replacement
cylinder block thermostat, and install the clamp. Removal
3 Fix the high-pressure EGR cooler water inlet hose
1 If necessary, remove the turbocharger assembly.
assembly to the cylinder block thermostat, and
Refer to “Turbocharger Assembly Replacement”
install the clamp.
.
4 Fix the cylinder block thermostat hose assembly to
2 If necessary, remove the low-pressure EGR
the cylinder block thermostat, and install the
clamp. assembly. Refer to “Low-pressure EGR
5 Install the high-pressure EGR assembly. Refer to
3 Remove the bolts fixing the water pump inlet pipe
“High-pressure EGR Assembly Replacement” .
to the engine block.
4 Remove the water pump inlet pipe (1), and discard
the seal ring.
S02043044
1
S02043045
Installation
1 Install new water pump inlet pipe seal ring.
2 Insert the water pump inlet pipe into the water
pump assembly.
3 Fix the water pump inlet pipe to the engine block,
tighten the bolts to 22 ± 2 N.m, and check the
torque.
4 Fix the water pump inlet pipe to the lower engine
block frame, tighten the bolts to 10 ± 1 N.m, and
check the torque.
3-8
5 If necessary, remove the low-pressure EGR Exhaust Valve Replacement

assembly. Refer to “Low-pressure EGR Removal
1 Remove the cylinder head thermostat assembly.
6 If necessary, install the turbocharger assembly.
Refer to “Cylinder Head Thermostat Assembly
Refer to“Turbocharger Assembly Replacement”.
Replacement” .
2 Remove the exhaust pipe (1).
S02043040
Installation
1 Install the exhaust valve, tighten it to 25 ± 2 N.m,
2 Install the cylinder head thermostat assembly.
Refer to “Cylinder Head Thermostat Assembly
Replacement” .
3-9
Thermostat Water Outlet Tube Replacement Small Circulation Pipe Replacement

Removal Removal
1 Drain the coolant. 1 Drain the coolant.
2 Remove the engine degassing pipe. Refer to 2 Remove the clamp (1) connecting the small
“Engine Degassing Pipe Replacement” . circulation pipe to the hose, and release the hose.
3 Remove the bolts (1) fixing the thermostat water 3 Remove 1 bolt (2) fixing the small circulation pipe
outlet tube to the water-air intercooler bracket. to the lower block frame.
4 Remove the clamps (2) on the two ends of
thermostat water outlet tube, and release the
hose.
5 Remove the thermostat water outlet tube (3).
1
3
2
S02043042
1
2 4 Remove the clamps (1) connecting the high-
1
pressure EGR cooler water outlet hose assembly
and the oil cooler water outlet hose assembly to
S02043041 the small circulation pipe.
5 Remove 1 bolt (2) fixing the small circulation pipe
Installation to the alternator bracket.
1 Install the thermostat water outlet tube. 6 Remove the small circulation pipe (3).
2 Install 3 thermostat water outlet tube retaining
bolts, tighten them to 22 ± 2 N.m, and check the
torque.
3 Install the clamps on the two ends of thermostat
water outlet tube.
4 Install the engine degassing pipe. Refer to 1
1
“Engine Degassing Pipe Replacement” . 2
5 Refill and drain the coolant.
3
S02043043
Installation
1 Connect the high-pressure EGR cooler water
outlet hose assembly and the oil cooler water
outlet hose assembly to the small circulation pipe,
and install the clamps.
2 Tighten 1 bolt fixing the small circulation pipe to
the alternator bracket to 10±1 N.m, and check the
torque.
3-10
3 Connect the small circulation pipe to the hose, and Intercooler Coolant Draining and Refilling
install the clamps. Drain
4 Tighten 1 retaining bolt fixing the small circulation
1 Remove the front grille cover plate.
pipe to the lower engine block frame to 10±1 N.m,
and check the torque. 2 Remove the front bottom lower guard plate..
5 Refill and drain the coolant. 3 Secure a proper container to collect the coolant.
4 Disconnect the radiator water outlet pipe from the
radiator.
5 Drain the engine coolant.
Refill
1 Connect the radiator water outlet pipe to the
radiator.
2 Prepare the coolant of specified concentration.
3 Remove the clamp, and disconnect the water-air
intercooler pipe (1).
4 Remove the expansion tank cap (2).
2
1
S02043051
5 Refill the coolant to the water tank opening

position.
6 Start the vehicle, and step down the accelerator
pedal to rotate the water pump.
Prompt: Longer time is required due to low air
temperature in the winter.
7 The fluid level of the expansion tank will go down,
therefore it is required to refill the fluid to the
position about 10 mm above the MIN line and the
fluid level will not go down any more.
3-11
Low-temperature Radiator Replacement

Removal
1 Drain the intercooler coolant. Refer to“Intercooler
Coolant Draining and Refilling” .
MIN 2 Remove the front grille assembly.
3 Disconnect the low-temperature radiator water
inlet/outlet pipe from the low-temperature radiator..
4 Remove 2 low-temperature radiator bolts (1).
5 Remove the low-temperature radiator (2).
S02043052
8 Screw the expansion tank cap to the dead center,

and install the water pipe and the clamp. 1
Note: Do not unscrew the cap on the engine water-
air intercooler during the whole refilling process. 1
9 Check the cooling system for leakage.
2
10 Install the front bottom lower guard plate..
11 Install the front grille cover plate.
S02043053
Installation
1 Install the low-temperature radiator.
2 Install 2 low-temperature radiator bolts, tighten
them to 5 ± 0.5 N.m, and check the torque.
3 Connect the low-temperature radiator water inlet/
outlet pipe.
4 Install the front grille assembly.
5 Refill the intercooler coolant. Refer to “Intercooler
Coolant Draining and Refilling” .
3-12
Liquid-gas Separator Replacement Cooling System Draining and Refilling

Removal Drain
1 Drain the intercooler coolant. Refer to“Intercooler 1 Remove the expansion tank cap.
Coolant Draining and Refilling” . Warning: The spilled vapour or coolant may cause
2 Disconnect the water pipe from the liquid-gas damage such as burns, therefore it is not allowed
separator. to open the expansion tank cap when the cooling
3 Remove the liquid-gas separator bolt (1). system is hot.
4 Remove the liquid-gas separator (2). 2 Secure a proper container to collect the coolant.
3 Raise the vehicle.
1 4 Remove the lower condenser guard plate.

5 Open from the vehicle bottom direction, loosen the
radiator bottom hose, and drain the coolant to an
appropriate container.
6 Drain the engine cooling system.
2
Refill
1 1 Install the radiator bottom hose.

2 Install the lower condenser guard plate.
S02043054 4 Prepare the coolant of specified concentration.
Installation 5 Open the expansion tank cap. Refill coolant to the
expansion tank until the coolant level reaches the
1 Install the liquid-gas separator.
neck of the expansion tank and keeps still.
2 Install the liquid-gas separator bolts, tighten them
6 Ensure that the A/C is turned off.
to 5 ± 0.5 N.m, and check the torque.
7 Start the vehicle, depress the accelerator pedal to
3 Connect the water pipe to the liquid-gas separator.
run the engine until the cooling fan operates,then
4 Refill the intercooler coolant. Refer to “Intercooler run the engine at idle speed until the cooling fan
Coolant Draining and Refilling” . stops.
8 Turn off the engine and cool it down for 30
minutes.
9 Check the cooling system for leakage. Check
whether the coolant level is between MIN and
MAX. If not, open the expansion tank cap and top
up the tank with coolant or drain it to be between
MIN and MAX as required.
3-13
Expansion Tank Replacement Electric Water Pump Replacement

Removal Removal
1 Drain the water-air intercooler coolant. 1 Disconnect the negative battery cable.
2 Remove the bonnet. 2 Drain the intercooler coolant.
3 Disconnect the water-air intercooler degassing 3 Remove the battery bracket.
pipe and liquid-air separator degassing pipe. 4 Disconnect the electrical connector of the electric
4 Remove the expansion tank bolts (1). water pump.
5 Remove the expansion tank (2). 5 Remove the electric water pump bolts (1).
6 Remove the electric water pump (2).
1
2
2
S02093045
1 Fit the expansion tank. Installation

2 Install the expansion tank bolts, tighten them to 5 1 Install the electric water pump.
± 0.5 N.m, and check the torque. 2 Install and tighten the electric water pump bolts.
3 Connect the water-air intercooler degassing pipe 3 Connect the electrical connector of the electric
and liquid-air separator degassing pipe. water pump.
4 Install the bonnet. 4 Install the battery bracket.
5 Refill the water-air intercooler coolant. 5 Refill the intercooler coolant.
3-14
Cooling System
The internal combustion engine will produce a large
amount of heat during operation. If the heat can't be
dissipated timely, the serious damages of engine, such as
invalid lubricating oil, piston scraping, crankshaft and
bearing burnt, will be caused due to the excessive
temperature. Uneven engine dissipation will also damage
some components due to the excessive temperature.
Therefore, the engine shall have a good cooling system to
dissipate the excess heat.
The excessive heat dissipation of cooling system will lead

to low operating temperature of engine and high viscosity
of engine oil, which is not beneficial to the lubrication of
engine moving components, and will cause the poor
lubrication in some locations needed to be lubricated,
increasing the whole running resistance of engine. The
excessive heat dissipation will also reduce the fuel
economy of engine.
The poor heat dissipation of cooling system will lead to

excessive operating temperature of engine and
overheated engine oil, which will destroy the formation of
oil film on the surface of moving components, is not
beneficial to the lubrication of engine moving components,
and will cause delayed heat dissipation, excessive
expansion and stuck of some engine parts, piston
scraping, bearing burnt and other serious damages.
Good cooling system can reasonably adjust and control

the operating temperature of engine, so as to obtain ideal
power output and good fuel economy.
3-15
3-16
Engine Electrical System
Specification
Torque
Mounting screw of starter motor 22 ± 2

Bolt - battery lock block 22 ± 2
5-1
Layout
Starting and Charging Devices Layout
1 Alternator 2 Starter motor
5-2
Battery Layout
ES020000
1 Battery
5-3
Troubleshooting
Hard engine start or start failure Starting circuit loose or corroded Clean and tighten circuit connectors
The preheater is operated improperly Take correct preheating steps

(when necessary)
Intake system blocked Check whether the intake system

pipeline is unobstructed
Insufficient fuel in the fuel tank Fill the tank with appropriate amount of
fuel
Starter motor and electric appliance Consult an authorized repairer for

system failure DTC query
Air mixed in the fuel system Exhaust the air
Starter motor does not operate Battery undercharged Charge or

normally replace the battery
Alternator does not work or Battery connector loose or corroded Clean/tighten the battery connector
undercharges
Engine belt slips Check/replace the belt and tension
pulley
Instrument or indicator lamp failure Check/replace the instrument or

indicator lamp
Engine wire loose or damaged Repair the wire
Alternator failure Replace the alternator
5-4
Repair Guidance Replacement of Starter Motor
Replacement of Battery Removal
Removal 1 Disconnect the battery ground terminal.
1 Disconnect the negative battery cable. 2 Remove 2 bolts fastening the heat shield of
starter motor to the rear engine mount bracket.
2 Disconnect the positive battery cable.
3 Remove the heat shield of starter motor.
3 Remove 1 bolt fixing the battery lock block.
4 Unscrew nuts and disconnect the control binding
4 Remove the battery lock block. post of alternator from battery harness.
ES020011
2 2
CS843005
5 Remove the battery assembly. 5 Unscrew the nuts, and disconnect the battery
harness from the starter motor solenoid coil.
6 Unscrew 3 bolts fixing the starter motor and

remove the starter motor.
3 4
ES020012 3
Installation
CS843006
5-5
Installation
Replacement of Alternator
1 Locate the starter motor. Then install and tighten Removal
bolts. Tightening torque: 36 ± 2N.m. 1 Disconnect the battery ground terminal.
2 Fix the battery harness to the positive pole of 2 Remove the accessory drive belt (6PK).
starter motor and tighten nuts. Tightening torque:
12 ± 3N.m. 3 Remove harness and connectors from the rear
end of alternator.
3 Fix the battery harness to the control binding
post of starter motor and tighten nuts. Tightening
torque: 6 ± 1N.m.
4 Install and tighten 2 bolts fixing the heat shield of
starter motor. Tightening torque: 18 ± 2N.m.
5 Connect the battery ground terminal.
Note：ECU power supply is common-grounded

with the starter motor. The wire between the
starter motor grounding and battery grounding
shall not exceed 3m in length. The starter motor
is connected to battery power supply through the
starter relay. Engine starting must be controlled
by the replay. CS863053
CS113243
4 Unscrew 3 bolts fixing the A/C compressor to the

engine, and remove the compressor.
CS113249
5 Loosen 2 mounting bolts (M8X110) and nuts

(M8) from the alternator.
5-6
6 Remove the alternator. 3 Locate the A/C compressor and install retaining
bolts (refer to Replacement of A/C compressor).
CS863053
CS113245
CS863053
CS113247
Installation
4 Recover and correctly tension the accessory
drive belt (6PK).
1 Place the alternator in the corresponding
position of A/C alternator bracket, and
respectively pass the mounting holes with 2 bolts
(M8X110) and 2 nuts (M8) to fix the alternator.
Tightening torque: 33N.m
Note：The bolt shall be installed with the thread
side facing the front end of engine.
CS863053
CS113248
CS863053
CS113246
2 Remove the harness connector sleeve on the

rear end of alternator. Connect the complete
vehicle electrical harness and confirm it is
connected firmly.
5-7
Description and Operation Battery Usage and Maintenance

Battery Safe Operation
Battery provides electric energy to start the vehicle and 1 Electric energy
adjusts the imbalance between alternator output and
When the positive and negative terminals of a battery is
load. When the engine does not work or runs at a low
short-circuited by a metal conductor (such as a metal
speed, the battery supplies power for electric appliances;
tool, metal wire or metal part) accidentally, that is, the
when the power of electric appliances is higher than the
battery is short-circuited externally, an electric arc will be
alternator output power, the battery and alternator will
produced, leading to terminal melting and splash of
supply power in parallel; when the power of electric
melted lead alloy. In severe cases, a lot of heat will be
appliances is lower than the alternator output power, the
produced, leading to combustion.
alternator will supply power for the battery and electric
appliances. Preventative measures: When assembling the battery
with a metal tool or troubleshoot a battery with a metal
Warning: Battery may produce explosive gases. Battery
wire, avoid the direct shortcircuit between the battery
contains corrosive acid. Battery supplies the electrical
positive and negative terminals.
current high enough to cause burns. Therefore, in order
to reduce the risk of injury, be sure to follow the rules Protective measures: Wear protective glasses and
below when operating near the battery: gloves.
Be sure to wear protective glasses and try to avoid the Emergency measures: In case of a fire, immediately
battery from tilting. disconnect the external short-circuit metal conductor with
an adjustable wrench or another tool from the battery. Do
Do not place the battery near open fire or sparks.
not contact with hands. Then extinguish the fire with
Protect skin and eyes from contacting battery electrolyte. extinguishing material.
If skin or eyes contact the electrolyte, flush immediately
2 Sulfuric acid
and take medical measures.
If the battery housing is broken due to drop or overcharge
Follow each step of the jump start procedure in order. of the battery, sulfuric acid may flow or splash from the
Treat both the booster and the discharged battery with broken position.
care when using a jumper cable. Preventative measures: Handle with care; keep upright;
recharge the battery as per specified procedures.
Protective measures: Wear protective glasses and

acidproof clothes.。
Emergency measures: When skin contacts sulfuric acid,

immediately flush skin surface with plenty of water and
take off the contaminated clothes; when eyes contact
sulfuric acid, immediately keep flushing eyes with clean
water for at least 10min; when sulfuric acid splashes into
the oral cavity accidentally, drink plenty of water or milk
immediately. See a doctor for treatment if necessary.
3 Exhaust gases
During charging and discharging, a battery will exhaust

the mixture of oxygen and hydrogen from its exhaust
vent. If the concentration of hydrogen in the
5-8
enviroN.mentexceeds 4%, an explosion would occur Battery Maintenance Requirements:

when the gas mixture contacts open fire, sparks or
1 Battery warehousing management
excessive heat.
Check incoming goods for damage. Battery case surface
Preventative measures: Charge in a well-ventilated or the juncture between positive and negative poles shall
place. Smoking is prohibited to prevent sparks and open be free of acid liquid overflow, cracks, bumps or dirts.
fire. Sequence for connecting battery harness: Connect
the positive cable and then the negative; Sequence for Check the status indicator (electric eye) of the battery.
disconnecting battery harness: Disconnect the negative Battery power indicator:
cable and then the positive. Green: The battery has enough power to start the
Protective measures: Wear protective glasses and vehicle normally.
acidproof clothes. Black: Low battery. The battery shall be recharged.
Emergency measures: When a large amount of sulfuric White: The battery is scrapped and shall be replaced.
acid splashes due to the battery burst, the operator shall
flush the positions with splashed sulfuric acid with water The length of forklift's fork handle had better be
immediately; immediately send the operator ablated by consistent with the width of pallet, so as to prevent the
sulfuric acid to hospital for treatment when necessary. battery damage.
Batteries shall be placed on a flat bracket in a centralized

way. Batteries can be stacked if isolation plates made of
paper or foam are provided (maximum stacking layers:
4); stacking is not allowed when there is no isolation
plate.
Obey the "first in, first out" principle.
DO NOT store batteries in a hot place. It is preferably to

store batteries in a ventilated dry room at 5 ～ 40 ℃ .
2 Battery installation
When carrying the battery, do not tilt it to an angle over

40°.
After installing to a complete vehicle, the battery shall not

tilt by more than 3° compared with the horizontal level.
It is prohibited to invert or laterally place a battery.
Check the electric eye and confirm it is green before

installation.
Check whether there are screws or nuts in the pallet for

transporting the battery, if any ,clean them to prevent the
battery from suffering secondary damage.
It is prohibited to install a battery with a black electric eye

into a vehicle (at the time of warehousing inspection, if a
battery's electric eye is black but the production batch or
date of the battery is recent (within 3 months), this battery
may be defective).
5-9
It is also prohibited to install a battery with leakage to a Check the status of battery electric eye once every three
vehicle. months
Do not knock or twist battery terminals during installation. The green electric eye indicates that the battery is
normal;
3 Battery circuit connection during assembly
The black electric eye indicates low battery and it must
Sequence for connecting battery circuit: Connect the
be recharged.
positive cable and then the negative.
For vehicles with battery circuit connected, check the
Sequence for disconnecting battery circuit: Disconnect
electric eye monthly. Recharge the battery with a black
the negative cable and then the positive.
electric eye.
4 Assembling process
For vehicles warehoused for one year above, if its battery
When assembling a battery, ensure all electrical has never been recharged as per the aforesaid
accessories are turned off. requirements, the battery must be replaced and
In different assembling areas, try to close doors, engine scrapped.
hood and trunk lid to prevent unnecessary electric energy
7 Battery maintenance requirements for agents
loss. and dealers
Ensure all on-board electrical systems are turned off Remove the negative battery cables from inventory
during a break, lunch or shift turnover or after work. vehicles and exhibition vehicles which have been parked
for 7 days above.
Check and assess vehicles for current leakage
periodically. The battery shall be installed firmly; battery case surface
or the juncture between positive and negative poles shall
When the vehicle is off-line, check and ensure its battery
be free of acid liquid overflow, cracks, bumps or dirts.
electric eye displays green. In case of undercharge,
immediately recharge the battery. Check the status indicator (electric eye) of the battery.
Battery power indicator:
5 Repair area
Green: The battery has enough power to start the vehicle
Develop the habit of saving battery power (except for
normally.
vehicle adjustment or maintenance, ensure
airconditioning, lamps, radio and ignition system are Black: Low battery. The battery shall be recharged.
turned off and doors and trunk lid are closed).
White: The battery is scrapped and shall be replaced.
Ensure all electrical systems are turned off during a break
or lunch or after work. Check the status of battery electric eye once every three
During "overhaul", disconnect the battery circuit. months
After repair, check and ensure the battery electric eye The green electric eye indicates that the battery is
displays green. normal;
In case of low battery (the battery electric eye displays The black electric eye indicates low battery and it must
black), analyze and judge the causes for the battery be recharged.
failure, and recharge the battery in accordance with Batteries of warehousing vehicles must be recharged
recharging procedures. every 6 months.
6 Battery maintenance of inventory vehicle For vehicles with battery circuit connected, check the
For the vehicle storing for 7 days above, disconnect its electric eye monthly. Recharge the battery with a black
negative battery cable. electric eye.
5-10
The battery of a vehicle warehoused for one year above Battery Recharging
(i.e. the battery has never been recharged) must be
1 Battery recharging
replaced and scrapped.
When the vehicle is not started, prolonged use of
During vehicle sales, check and ensure the battery onboard electrical appliances and other abnormal uses,
electric eye displays green. It is prohibited to directly electric leakage and long-time vehicle lay-off, or vehicle
deliver a vehicle powered by another vehicle's battery to alternator charging fault may cause charging failure, low
the customer. battery and black electric eye, even failure of vehicle
start. The battery needs to be recharged by external
power supply.
1） Battery appearance check before recharging:
A battery with a cracked case or acid leakage shall not be

recharged. Check the causes and replace the battery.
A battery with broken terminals shall not be recharged.

Check the causes and replace the battery.
A battery with a white electric eye shall not be recharged.

Replace the battery directly.
Before recharging, clean battery terminals and remove

the oxide coating on the surface.
2） Precautions for charging:
Wear safety goggles.
Keep the space well-ventilated and charge at normal

temperature.
No smoking and source of flame during charging.
For wiring after charging, connect the positive cable first;

for disconnection before charging, disconnect the
negative cable first.
3） Battery recharging:
Ensure the battery terminals are clean and the charging

circuit is properly connected.
Connect the positive pole of the charger to the battery

positive; so does for the negative pole. Do not charge a
battery through a series circuit (24V).
It is recommended to charge a battery with the power

supply with a constant voltage: 14.4V ± 0.2V (the
maximum limit is 16.0V. If the voltage exceeds this limit,
the fluid in battery will be electrolyzed largely, leading to
level decline, white electric eye and battery scrap) and 1/
5-11
10 of current limiting rated capacity until the charging some cases, but it will not affect the use). When the
current ≤ 0.5A and the electric eye turns green. charger cannot limit the charging voltage within 16V, the
voltage of charging battery terminals must be manually
If charging with constant voltage cannot be realized,
monitored hourly. Otherwise the battery will lose
conduct constant-current charging as per the following
electrolyte due to overvoltage charging, thereby causing
rules:
service life reduction even battery failure.
(a) Select the charging current which is 1/8 ～ 1/10 of the
(b) Relations between recharging time and battery
rated capacity. At the end of charging, the voltage shall
voltage (for reference)
reach but not exceed 16V (if final voltage is less than
16V, the electric eye may still be black after charging in
Battery 12.55- 12.45- 12.35- 12.20- 12.05- 11.95- 11.80- 11.65- 11.50- 11.30- Below
Voltage 12.45V 12.35V 12.20V 12.05V 11.95V 11.80V 11.65V 11.50V 11.30V 11.00V 11.00V
Rechar 2h 3h 4h 5h 6h 7h 8h 9h 10h 12h 14h
ging
Time
(c) After recharging, check the color of battery electric charging current after the battery temperature drops to
eye. If the electric eye displays green, it is shown that the room temperature.
battery has been charged fully. If the electric eye displays
During recharging, check the state of electric eye hourly.
black, check whether the charging wire has been
If the electric eye displays green, it is shown that the
connected firmly, whether the connectors are clean and
battery has been charged fully, and stop charging.
whether the charging voltage reaches 16V. Keep the
battery stand still for 24h. Then measure its voltage, and The voltage of a battery charged just now may be higher
continue recharging by reference to the relations than 13V, which is void power. Keep the battery still for
between recharging time and battery voltage. several days or discharge it for several times, its void
power will disappear.
(d) If the electric eye displays white, there may be
bubbles in it. Slightly shake the battery to remove It is recommended to apply grease to the terminals to
bubbles. If it still white after shaking (showing the prevent electric corrosion after recharging the battery and
electrolyte has lost), replace the battery. passing the tests.
For the battery with voltage lower than 11.0V, it may not
be charged at the beginning of recharging. In case of low
battery, the proportion of sulfuric acid in the battery has
been close to that of pure water, thus the internal
resistance of the battery is very high. At this time,
decrease charging current or replace the charger with a
new one with higher power or charge the battery with
another battery in series. As the battery is being charged,
the sulfuric acid inside the battery will increase, and the
charging current will return to normal gradually.
During charging, if acid is sprayed from the battery gas

vent, immediately stop charging and conduct
troubleshooting.
During charging, when the battery temperature is higher

than 45 ℃ , stop charging, and continue with half of
5-12
Battery Failure Judgment

1 Visual Check
Check Items Causes Measures Remarks

Damage 1、 Battery case damage Replace with a new
one
2、 Improper installation
Burning 1、 Looseness or poor contact of terminal wire Replace with a new
connectors one
Battery
2、 External shortcircuit
case
Burst 1、 Internal shortcircuit Replace with a new
one
2、 Electrolyte level low, producing sparks inside
the battery
3、 Gas vent blockage
Deformation 1、 Overcharge Replace with a new
one
2、 Charge with an excessive current
3、 Gas vent blockage
Acid leakage 1、 The plastic case is damaged due to impact Replace with a new
one
2、 The battery is inverted or tilts excessively
3、 Poor thermal sealing
Terminal erosion 1、 External shortcircuit Repair or replace with
a new one
2、 Poor contact
3、 Poor welding
2 Voltage check
(1)Visual check of electric eye state

The battery is equipped with a built-in densimeter. And there is a color display point in the top of densimeter. In case
of a battery failure or vehicle start problem due to unknown reason, visually check the state of electric eye, then you can
know the current state of charge and measures to be taken. (Note: The electric eye can only display the state of unit cell.
Thus it is necessary to make a comprehensive judgment in combination with open-circuit voltage, etc. in some cases.)
Color Green Black Bright color (white)

State of Charge More than 65% Lower than 65% Electrolyte level low
Measures Use normally Recharge the battery Replace the battery
(2)Check of battery open-circuit voltage
Check Items Causes Measures Remarks

Voltage 12.5V above, the electric Normal Use normally
eye displays green
Between 12.4 and 11V, the Undercharge Recharge the
electric eye displays black battery
Around 10.5V or below 1、 Overdischarge (the electric eye Recharge the
displays black) battery
2、 Shortcircuit (the electric eye displays Replace with a new
green in most cases) one
3、Break circuit (the electric eye displays Replace with a new
green in most cases) one
5-13
3 Causes for General Battery Failures
Type Symptoms Causes Measures Remarks

Underc 1. Charging voltage is lower 1. The set value of vehicle voltage 1. Adjust the vehicle's
harge than 12V regulator is too low electrical configuration
2. The vehicle is hard to 2. Electrical load of the vehicle is more 2. Adjust the charging
start and lamps are dim than the charging amount voltage to the range of
3. The result of the tester is 3. Driving at idle speed or at night 14V~14.5V (the charging
in the yellow or red area 4. Electrical overload voltage for two batteries in
series shall be between
5. The vehicle is started for multiple times
and drives for a short distance or drives 28V~29.0V)
at idle speed 3. Battery recharging
6. Engine drive belt loose or circuit fault
7. Battery terminal connectors or
harnesses are corroded
Overch 1. Battery case deforms 1. The set value of vehicle voltage 1. Adjust the charging
arge 2. Acid mist overflows from regulator is high voltage (refer to the
the case surface 2. Recharging time is long aforesaid requirements)
3. Lead powder on the plate 3. Charging voltage exceeds 16V during 2. Replace the battery
is easy to fall off recharging with a new one
4. The battery electric eye
displays white
Overdis 1. The voltage is lower than 1. Vehicle charging circuit fault 1. Adjust electric
charge 11.0V 2. Vehicle shortcircuit appliances
2. The battery electric eye 3. Electrical load is not turned off when 2. Recharge the battery
displays black the vehicle is not used 3. Replace the battery in
3. The surface of battery 4. Vehicle is parked with the negative severe cases
internal plate turns white battery cable connected for a long time
Shortcir 1. The voltage is around 1. Internal manufacture fault of the Replace the battery with a
cuit 10.5V and the battery battery new one
electric eye displays green 2. Plate growth shortcircuit caused by
2. Self-discharge capacity is excessive use, overcharge or high
great temperature during use
Break 1. Voltage is unstable Internal manufacture fault of the battery Replace the battery with a
circuit 2. Voltage is 0V during new one
discharging
3. The battery cannot be
recharged or electrolyte
rises during recharging
Reverse 1. Voltage value is negative Positive and negative poles are Replace the battery with a
charging 2. The colors of positive and connected incorrectly during discharging new one
negative plates are opposite
Battery Battery bursts with acid The flammable oxygen-hydrogen mixed Replace the battery with a
bursts splashed gas inside the battery is ignited due to new one
sparks or excessive heat
1. Poor welding or shortcircuit inside the
battery causes sparks
2. Electrolyte level is low, producing
sparks inside the battery
3. The battery is overcharged
4. Gas vent is blocked
5-14
Engine Electrical System SC20M163Q5A

Specification
Name Torque (N.m)
Bolt - Engine 22-28 N.m
Bolt - Starter 40-50 N.m
Nut - Battery Harness Connector Starter 12.5-14.5 N.m
Nut - Battery Harness Connector Alternator 12.5-14.5 N.m
Bolt - Harness Bracket to Alternator 8-10 N.m
Nut - Engine Harness Connector Starter 5.5-7.5 N.m
Bolt - Battery Block Bolt 20-24 N.m
5-1
Starter Motor Replacement

Service Guide
Removal
Alternator Replacement 1 Disconnect the negative battery cable.
Removal
2 Remove the lower engine guard plate.
3 Remove the battery harness connector starter
2 Remove the drive belt. Refer to “Drive Belt nut (1).
Replacement” .
4 Remove the engine harness connector starter
3 Disconnect the harness connector of the nut (2).
alternator.
5 Remove 3 starter bolts (3).
4 Remove the harness bracket bolt (1) from the
alternator. 6 Remove the starter (4).
5 Remove the engine harness connector alternator

nut (2).
6 Remove 2 retaining bolts (3) of the alternator. 3

1
7 Remove the alternator (4).
3
4
3
S02053028
1
Installation
3
1 Fix the starter to the engine.
4 2 2 Install 3 starter bolts, tighten them to 40-50 N.m
S02053010 and check the torque.
3 Install the battery harness starter nuts, tighten

Installation
them to 11-15 N.m and check the torque.
1 Install the alternator.
4 Install the engine harness nuts, tighten them to
2 Install 2 alternator retaining bolts, tighten them to 5.5-7.5 N.m and check the torque.
22-28 N.m and check the torque.
3 Install the alternator harness bracket bolts,
tighten them to 8-10 N.m and check the torque. 6 Connect the negative battery cable.
4 Install the engine harness connector alternator

nuts, tighten them to 12.5-14.5 N.m and check
the torque.
5 Connect the harness connector of the engine.
6 Install the drive belt. Refer to “Drive Belt

Replacement” .
5-2
Battery Replacement
Removal
2 Disconnect the positive battery cable.
3 Remove 2 battery block bolts (1).
4 Remove the battery block (2).
5 Remove the battery (3).
1 1
2
S02053029
Installation
1 Fix the battery to the tray.
2 Install the battery block and the block bolts，
tighten them to 20-24 N.m and check the torque.
3 Connect the positive battery cable.
5-3
alternator output power, the alternator will supply power

for the battery and electric appliances.
Engine Electrical Component Description
Caution: Batteries produce explosive gases. Batteries
and Operation
contain corrosive acid. Batteries supply levels of electrical
Overview
current high enough to cause burns.
The starting system of the vehicle includes a 12V starter
motor which drives the engine to start combustion When working around a battery, in order to reduce the
process and converts electric energy into mechanical risk of personal injury, observe the following guidelines:
energy. The electrical system of the vehicle must be able Always wear safety goggles and avoid the battery tilt
to provide sufficient energy to ensure the starter motor whenever possible.
can rotate the crankshaft. The charging system consists
of the battery, alternator and related electrical elements. Do not place the battery near the open flame or spark.
The alternator obtains mechanical energy from the
Prevent the battery electrolyte from coming into contact
crankshaft during engine running and converts it into
with the skin and eyes.
electric energy for the operation of electrical elements
and battery charging. A charging indicator is fitted on the When the skin or eye is contacted with the electrolyte,
instrument pack. It will be illuminated when the alternator you should rinse it with water immediately and take
has no output voltage or when the voltage is lower than medical measures.
the battery voltage.
Follow each step of the jump starting procedure in order.
Starter Motor
Treat both the booster and the discharged batteries
The starter motor is located at the left rear side of the carefully when using the jumper cables.
engine, and it is fixed with 3 bolts. The mechanical
energy of the pinion drives the flywheel, the transmission
ratio of them enlarges the torque so as to provide
sufficient torque.
Alternator
Alternator is located at the left front side of the engine,
and it is fixed on the bracket with 2 bolts. The drive pulley
is connected to the tail end of the rotor, which is driven by
the drive belt of the crankshaft. The belt tension is
maintained by the frictional restriction tension pulley. The
instrument pack is used together with a charging
indicator, and this indicator will illuminate when the output
of the alternator is zero or low.
Battery
The function of the battery is to provide electric energy for
vehicle starting and adjust the imbalance status between
alternator output and load. When the engine does not
work or runs at a low speed, the battery supplies power
for electric appliances; when the power of electric
appliances is higher than the alternator output power, the
battery and alternator will supply power in parallel; when
the power of electric appliances is lower than the
5-4
Engine Controls
Engine Controls
Specification
Component Name Connector Status Technical Parameters (static)
Mass air flow sensor 1#-12V;

2#-0V ground wire;
3#-5V intake temperature signal;
4#-5V flow sensor signal
1 2 3 4
1#2#-17.82K Ω
2#3#-9.27M Ω
1#3#-9.3K Ω
2#4#-9.26K Ω
1#4#-9.30M Ω
3#4#-0 Ω
Intake temperature/ 1#-OV ground wire;
pressure sensor 2#-1.0~4.8V pressure sensor signal;
3#-5V pressure sensor power supply;
4#-5V pressure sensor signal
1 2 3 4
1#2#-1.6K Ω
2#4#-3.2K Ω
1#3#-4K Ω
3#4#-2.4K Ω
1#4#-1.6K Ω
2#3#-5.6K Ω
Crankshaft position sensor 0.9K Ω
1 2
Camshaft position sensor 1#-0V ground;

2#-0~4.5V position sensor signal;
3#-5V position sensor power supply;
1#3#-261K Ω
1 2 3
2#3#-3.9K Ω
1#2#-0K Ω
6-1
Engine Controls
Coolant temperature 1#-signal wire; 2#-ground

sensor -40 ℃ /45.313K Ω ;
-30 ℃ /26.114K Ω ;
-20 ℃ /15.462K Ω ;
1 2 -10 ℃ /9.397K Ω ;
0 ℃ /5.896K Ω ;
10 ℃ /3.792K Ω ;
20 ℃ /2.500K Ω ;
30 ℃ /1.707K Ω ;
40 ℃ /1.175K Ω ;
50 ℃ /0.834K Ω ;
60 ℃ /0.596K Ω ;
70 ℃ /0.435K Ω ;
80 ℃ /0.323K Ω ;
90 ℃ /0.243K Ω ;
100 ℃ /0.186K Ω
Accelerator pedal position 1#-5V power supply;
sensor 2#-5V power supply;
3#-0V ground;
4#-0.25~3.85V; signal output;
5#-0V ground;
1 2 3 4 5 6
6#-0.377~1.92V signal output
Common-rail pressure 1#-ground;

sensor 2#-sensor signal;
3#-power supply, resistance: 24.32K Ω
1#2#-0K Ω
1 2 3
2#3#-6K Ω
1#3#-18.8K Ω
High-pressure fuel pump 3.5 Ω
1 2
Brake lamp switch 1#-12V;

2#-12V;
3#-0V;
4#-12V
2 1
4 3
6-2
Engine Controls
Clutch pedal switch 1#-signal wire;

2#-0V
1 2
Fuel injector 0.5 Ω
1 2
Fuel heater 1Ω
B A
Glow plug （1.2~1.5）Ω
Glow plug (Euro V) 0.7 Ω
Cooling fan （1.0~1.5）Ω ; 2#-unused
C B A
6-3
Engine Controls
Electronic throttle vacuum （15~20）Ω

regulator
1 2
EGR vacuum regulating （15~20）Ω

valve
1 2
Ambient temperature 1#- 0V ground;

sensor (Euro V) 2#- 5V power supply;
1 2 -40 ℃ /329.583K Ω ;
-30 ℃ /175.513K Ω ;
-20 ℃ /99.030K Ω ;
-10 ℃ /56.100K Ω ;
0 ℃ /32.970K Ω ;
10 ℃ /20.020K Ω ;
20 ℃ /12.520K Ω ;
30 ℃ /8.047K Ω ;
40 ℃ /5.310K Ω ;
50 ℃ /3.588K Ω ;
60 ℃ /2.477K Ω ;
70 ℃ /1.744K Ω ;
Glow plug 11V (operating voltage)
6-4
Engine Controls
Sensor-cirumstance tmp -40 ℃ /309.578-349.589K Ω ;

-35 ℃ /224.993-253.562K Ω ;
-30 ℃ /165.210-185.816K Ω ;
1 2 -25 ℃ /122.499-137.501K Ω ;
-20 ℃ /93.430-104.630K Ω ;
-15 ℃ /10.071-78.289K Ω ;
-10 ℃ /53.057-59.143K Ω ;
-5 ℃ /40.547-45.093K Ω ;
0 ℃ /31.258-34.682K Ω ;
5 ℃ /24.290-26.890K Ω ;
10 ℃ /19.026-21.014K Ω ;
15 ℃ /15.005-16.535K Ω ;
20 ℃ /11.927-13.113K Ω ;
25 ℃ /9.538-10.462K Ω ;
30 ℃ /7.685-8.409K Ω ;
35 ℃ /6.231-6.803K Ω ;
40 ℃ /5.083-5.537K Ω ;
45 ℃ /4.172-4.534K Ω ;
50 ℃ /3.443-3.733K Ω ;
55 ℃ /2.857-3.091K Ω ;
60 ℃ /2.383-2.571K Ω ;
65 ℃ /1.997-2.151K Ω ;
70 ℃ /1.682-1.806K Ω ;
Torque
Nuts - ECM & fuse box bracket assembly to body 8±1

Bolts - ECM & fuse box bracket assembly to battery bracket 22 ± 3
Bolts - ECM & fuse box bracket assembly 10 ± 1
6-5
Engine Controls
Layout
Engine Fuel Control System Layout
13
12 5
4 2
3
6
11
7
1
8 9 10
1 Speed sensor connector 8 Injection pump

2 Camshaft position sensor connector 9 Coolant temperature sensor connector
3 Fuel injector 10 Intake temperature/pressure sensor connector
4 Wiring harness bracket 11 Common-rail pressure sensor connector
5 Harness assembly 12 Starting motor, EGR, TVA signal circuit interface
6 ECM connector 13 Preheat power supply
7 Glow plug connector
6-6
Engine Controls
Engine Control System Layout
1 1 1 1 2 3 4
11
5
10
8 7 6
1 3 5
2 4 R
1 Fuel injector 7 Coolant temperature sensor

2 Glow plug 8 Common-rail component
3 Speed sensor 9 Instrument panel
4 Camshaft position sensor 10 Fuel pump component
5 Vacuum regulator 11 Preheater relay
6 EGR valve component 12 Engine control module
6-7
Engine Controls
Repair Guidance 5 Remove the engine harness.
Replacement of Engine Harness

Removal
1 Remove clamps and ties from the engine
harness bracket.
2 Remove M8 bolts fixing the engine harness
bracket at the flywheel side.
CS113172
Installation

Note：Fix the loose harnesses (if any) during
installation. Stick the wire with adhesive tape if it
CS113170
is exposed in the joint.
3 Remove M8 bolts fixing the engine harness

bracket at the timing pulley chamber side.
CS113171
4 Disconnect the connector between the engine

harness and sensor.
Note：During removal of the speed sensor,
common-rail pressure sensor, coolant
temperature sensor, intake temperature/pressure
sensor connector, glow plug and fuel injector
connectors, pay attention to the bayonets to
avoid breaking connectors.
6-8
Engine Controls
Replacement of Engine Coolant Temperature Replacement of Oil Pressure Alarm Switch

Sensor
Removal
Removal 1 Disconnect the oil pressure alarm switch
1 Remove the coolant temperature sensor connector.
connector (refer to Replacement of Harness - 2 Unscrew the oil pressure alarm switch with a
Removal).
3 24mm wrench.
2 The coolant temperature sensor is located on the
side of cylinder head, near the air inlet. Remove
the coolant temperature sensor with an extended
sleeve (19mm).
CS113174
Installation
CS113173 1 Apply an appropriate amount of PTFE sealant
onto the threads of new oil pressure alarm
switch, and tighten to the torque of 12N.m.
Installation
1 Apply Tonsan 1567 sealant onto the threads of
new coolant temperature sensor, and tighten to
the torque of 18N.m.
2 Connect the harness connector.
6-9
Engine Controls
Replacement of Speed Sensor Replacement of Camshaft Position Sensor

Refer to Replacement of Crankshaft. Refer to Replacement of Camshaft Position Sensor in the
Replacement of Upper Cylinder Head/Gasket.
CS113175
CS113176
6-10
Engine Controls
Replacement of Common Rail Replacement of Engine Control Module

Refer to Replacement of Upper Cylinder Head/Gasket. (ECM)
Removal
1 Open the engine hood and disconnect the
positive and negative battery cables.
CS113177
CS113178
2 Loosen two nuts between the battery and battery

bracket, and remove the battery.
3 Loosen relevant connector interfaces.
CS113179
4 Unscrew 2 bolts and 2 nuts fixing ECM & fuse

box bracket assembly.
6-11
Engine Controls
5 Unscrew 4 bolts fixing ECM assembly onto ECM Installation

& fuse box bracket assembly. 1 Tighten 4 hexagonal flange bolts installed in the
corresponding positions on the engine control
module assembly and fuse box bracket
assembly to the torque of 10 ± 1N.m.
CS113180
6 Remove the engine control module assembly.

CS113182
2 Install the ECM & fuse box bracket assembly to

the corresponding positions on bracket A -
battery and body in white assembly.
3 Tighten 2 hexagonal flange bolts fixing the ECM
& fuse box bracket assembly to the torque of 22
± 3N.m.
4 Tighten 2 hexagonal flange nuts fixing the ECM
& fuse box bracket assembly to the torque of 8 ±
1N.m.
5 Install the battery (refer to Replacement of
CS113181 Battery).
CS113180
6-12
Engine Controls
Note：Any glow plug suffering from mechanical

Replacement of Glow Plug
shock must be reported as a damaged part even
Removal it has normal heating function and passes
1 The glow plug is located at air intake side of the dimension and appearance inspections. Any
cylinder head. Pull out the harness connector glow plug with a bending head shall also be
and then loosen the glow plug to remove it. reported as a damaged part and cannot be used
sequentially.
CS113345
Installation
1 During installation, the engine must be in cold
state.
2 Check whether the glow plug dimension is
matched with the dimension of cylinder head
glow plug hole before installation.
3 During installation, ensure the glow plug threads
and cylinder head are free of engine oil and other
contaminants, and keep mounting tools clean.
4 During installation, protect the glow plug body
from all kinds of mechanical impacts.
5 Do not tighten the glow plug until the glow plug
threads are screwed completely in the cylinder
head.
6 Select the maximum tightening torque according
to thread dimensions. Tightening torque: 14N.m.
7 Avoid the installed glow plug from being
mechanically impacted by other installations.
8 Connect the harness connector.
Note：During maintenance, avoid all the
Note：mechanical impacts for the glow plug, such
as falloff, knock, etc. Mechanical impacts would
cause microcracks inside the glow plug, which
cannot be judged from appearance and would
affect the service life of glow plug.
6-13
Engine Controls
Replacement of Accelerator Pedal Assembly

Removal
1 Unscrew the nuts fastening the accelerator pedal
assembly to the dash panel.
ES020010
2 Remove the accelerator pedal assembly.
Installation
6-14
Engine Control System SC20M163Q5A
Specification

Bolt - Camshaft Position Sensor 10 ± 1 N.m
Water Temperature Sensor 23 ± 2 N.m
Bolt - Low-pressure EGR Differential Pressure Sensor 10 ± 1 N.m
High-pressure EGR Temperature Sensor 45 ± 2 N.m
Low-pressure EGR Temperature Sensor 45 ± 2 N.m
Bolt - MAP Sensor 11 ± 1 N.m
Intercooler Rear Intake Air Temperature Sensor 23 ± 2 N.m
Bolt - Crankshaft Speed Sensor 10 ± 1 N.m
Turbocharger Front Exhaust Temperature Sensor 45 ± 2 N.m
Oil Pressure Switch 15 ± 2 N.m
Bolt - Vacuum Switching Valve 10 ± 1 N.m
Bolt - Vacuum Control Valve 7 ± 1 N.m
Bolt - Turbocharger Heat Shield 30 ± 3 N.m
Bolt - Turbocharger Upper Bracket to Intercooler
25 ± 2 N.m
Bracket
Bolt - Turbocharger Upper Bracket to Turbocharger 35 ± 2 N.m
Bolt - Turbocharger Lower Bracket to EGR Cooler 35 ± 2 N.m
Bolt - Turbocharger Lower Bracket to Turbocharger 43 ± 3 N.m
Bolt - Turbocharger Oil Return Pipe to Turbocharger 10 ± 2 N.m
Bolt - Turbocharger Oil Return Pipe to Cylinder Block 10 ± 2 N.m
Bolt - Turbocharger Oil Inlet Pipe to Turbocharger 30 ± 2 N.m
Bolt - Turbocharger Oil Inlet Pipe to Cylinder Block 35 ± 2 N.m
Bolt - Turbocharger Assembly 55 ± 3 N.m
Nut - Turbocharger Assembly 70 ± 3 N.m
Bolt - Vacuum Control Solenoid Valve Bracket 25 ± 1 N.m
Bolt - Engine Control Module 9 ± 1 N.m
Bolt - Glow Plug Controller 9 ± 1 N.m
Bolt - Mass Air Flow Sensor 2.5 ± 0.5 N.m
Nut - Accelerator Pedal 9 ± 1 N.m
4-1
4-2
Layout
Engine Electronic Control
1 3
S02020004
1 Intercooler Rear Temperature Sensor 4 Crankshaft Speed Sensor

2 Camshaft Position Sensor 5 Low-pressure EGR Temperature Sensor
Turbocharger Front Exhaust Tempera-
3 6 Differential Pressure Sensor
ture Sensor
4-3
2 3
7
6
S02020005
Electronic Vacuum Switching Valve (Two-

1 Intake Manifold Pressure Sensor 5
stage Turbocharging)
2 Water Temperature Sensor 6 High-pressure EGR Temperature Sensor
3 Electronic Vacuum Switching Valve 7 Oil Pressure Switch
Electronic Vacuum Control Valve (Two-
4
stage Turbocharging)
4-4
Turbocharging System (Two-stage Turbocharging)
2
1
S02020006
1 Turbocharger Oil Inlet Pipe 4 Turbocharger Heat Shield

Turbocharger Water Outlet Pipe Assem-
2 Two-stage Turbocharger Assembly 5
bly
Turbocharger Water Inlet Pipe Assem-
3 6 Turbocharger Oil Return Pipe
bly
4-5
Turbocharging System (Single-stage Turbocharging)
S02020007
1 Turbocharger Oil Inlet Pipe 3 Turbocharger Heat Shield

2 Turbocharger Assembly 4 Turbocharger Oil Return Pipe
4-6
When carrying out failure diagnosis for electronic control

system, the failure shall be analyzed by using the grasped
Check and Confirmation professional knowledge and experiences, to identify the
possible causes, and the direction and location that are
1 Identify the problems, and carry out the given priority during check, to access the target, so as to
prevent the unnecessary check for failure-free items, and
2 Check the appearance for obvious mechanical or the missing check for check-related items. In addition, due
electrical damages.
to the factors in design, manufacturing, use environment
3 Solve the found problems before carrying out the and other aspects, certain failures of some vehicles are
next check.
common in some part or assembly, the maintenance
4 If the causes can't be identified visually, identify personnel shall give priority to these components and
assembly for check according to their experiences, which
will also eliminate the failures.
Appearance Checklist
Principle of "first up, and then down; first external, and
Mechanical Electrical then internal"
? Sensor ? Fuse With the more and more application of electronic control
? Actuator ? Wiring system in engine, the quantity of automotive parts and
? Electrical Connection
wiring harnesses is more and more, especially in the
? Engine Control Module
(ECU) engine chamber, there is little spare space. Sometimes, for
some check, many surrounding parts shall be
Basic Principles for Electronic Control Failure disassembled. Therefore, grasping this principle is quite
Diagnosis beneficial to save labor and time.
The general principles for electronic control system failure
Principle of "first preparation, and then use; code first"
diagnosis are summarized as follows: first simple, and then
complex; first easy, and then difficult; first thinking, and When diagnosing electronic control system, the
then action; first familiar, and then unknown; first up, and performance of electronic control elements and the
then down; first external, and then internal; first conditions of circuits shall be determined according to the
preparation, and then use; code first. accuracy voltage or resistance and other parameters. If the
is no such data, and no conditions for failure diagnosis by
Principle of "first simple, and then complex; first easy, replacing parts, the failure diagnosis will not be carried out.
and then difficult" The principle of "first preparation, and then use" requests
The structure of engine electronic control system and the that the maintenance materials shall be prepared prior to
causes of its failures are quite complex. In order to avoid the failure diagnosis for references in the future. When
detours in the failure diagnosis process, the simple check diagnosing the electronic control system, the DTC shall be
shall be carried out first by using sample tools, and by the retrieved first, and the diagnosis shall be carried according
ways of seeing, smelling, hearing and touching. If no failure to the indication of DTC. After eliminating the failures
is diagnosed during the simple check, and the instruments indicated in DTCs, if there is still failure in engine, or there
and equipment shall be used for failure diagnosis, the no DTC output at beginning, the other possible failure parts
items that use simple instruments and equipment, and of engine shall be checked.
those that are easy for check shall be given priority, and
Basic Procedures for Electronic Control
then disassembly is required for the check of more difficult
Failure Diagnosis
items by using more complex instruments and equipment.
After the failures of electronic control system of electric
Principle of "first thinking, and then action; first familiar, control machine are found, the failure diagnosis shall be
and then unknown" carried out according to the following basic procedures.
Investigation of insider
4-7
It is very necessary to learn about the time, location, repair. After determining the repair is qualified via the test,
phenomena, conditions before and after failures, recent the DTCs shall be cleared.
overhaul, etc. from insiders. Although some insiders'
Electronic Control Intermittent Failure
description is not clear enough, careful analysis of the
Diagnosis
information provided by insiders will be more or less helpful
for rapid failure diagnosis. Intermittent failure refers to the failures that exist
sometimes and disappear automatically sometimes under
External Check the effect of external factors (temperature, moisture and
The purpose of external check is to eliminate the causes of vibration). It is difficult to diagnose such failures because
general failure, and avoid detours; the main contents of they do not have obvious symptoms, or the symptoms are
external check include: check whether the exhaust pipes not stable which may appear sometimes and disappear in
are damaged, connected improperly and blocked; check another time, the conditions and environment in which the
whether the connecting nodes of various wiring harnesses failures occur stated by the client generally shall be
are connected reliably; check the engine for obvious oil simulated, to reproduce the failures, so as to find out the
leakage, gas leakage or external damages; and listen to causes according to the failure symptoms.
whether the engine sound is abnormal.
Vibration
Retrieval of DTCs For the failures caused by poor circuit connection of
If the "MIL" goes on, that is, there is a current failure, the electronic control system or infirm installation of elements,
DTCs shall be retrieved according to the specified the vibration during vehicle running will make the failure
procedures, and a check shall be carried out for relevant symptoms appear sometimes and disappear in another
sensors or actuating elements and their circuits according time. In case of such failures, keep the engine running at
to the indications of DTCs. In the use of vehicle, if the idle. Shake the wiring harnesses or harness connectors in
failures appear sometimes and disappear in another time, horizontal and vertical directions, tap the components
and there are DTCs, but the DTCs at this time may be the containing sensors, to observe whether the failures of
current failures, and also may be converted in to historical engine will reoccur, if yes, it indicates that there are failures
failures. At this time, the causes are difficult to be checked, in the electronic control system at the harnesses shaken or
and the failures shall be checked as intermittent ones. In parts tapped. Notes: don't tap the relay hardly, otherwise it
the use of vehicle, if the failure symptoms are obvious, but may be disconnected; while the sensor is subject to
the "MIL" is off, and the retrieved DTCs are empty or there vibration test, a multimeter may be used to measure its
are no DTCs consistent with the failure symptoms, the output signals for abnormal changes, so as to determine
failures shall be checked as those without DTCs. whether the sensor has failures.
Detection Heating
Only after detection, can the failure locations be finally If failures only occur when the engine is warm, the
determined and the causes be found. The detection suspected faulty electronic control element may be heated
includes many contents, such as: signal detection, data with an electric blower, if the failures reoccur, it indicates
detection, pressure detection, actuator action detection, that the element have problems. Note: the elements in
etc.. The involved detectors are also more complex, which ECU can't be directly heated, and the temperature shall not
shall be properly selected and used. exceed 60 ℃ .
Test Water Spray
After the exact causes of failures are determined and If failures only occur in rainy days, after car wash or in high
repaired, a test must be carried out, to confirm that whether humidity environment, the vehicle may be sprayed with
the failures are eliminated, and check the effects after water to reproduce the failures, so as to analyze and
determine the causes according to the failure symptoms.
Note: water shall not be directly sprayed on the elements of
4-8
electronic control system, but shall be sprayed on the front which deviate from the true values at this time, which may
of engine radiator, to indirectly change the temperature cause adverse impact on the working performance of
around engine. engine. A comprehensive analysis and judgment shall be
made according to the failure symptoms of engine. If
All Electrical Appliances On
possible, the special diagnostic instruments shall be used
If the failures are suspected to be caused by excessive to read the relevant data blocks, analyze the waveforms,
electrical load, all the electrical appliances may be turned and then carry out targeted testing for the sensor, so as to
on to check whether the failures will reoccur. find out the failures and eliminate them.
Road Test If the "MIL" goes on, that is, there is a current failure, the
Some failures only occur under specific driving conditions, DTCs shall be retrieved according to the specified
which must be reproduced by road test method. In general, procedures, and a check shall be carried out for relevant
intermittent failures will not appear for a long time. sensors or actuating elements and their circuits according
Therefore, during failure diagnosis, preparations shall be to the indications of DTCs. In the use of vehicle, if the
made in advance, for example: turn on the scan tool to the failures appear sometimes and disappear in another time,
window for DTC reading; if you want to see the data flow and there are DTCs, but the DTCs at this time may be the
state while the failures reoccur, turn to the data flow current failures, and also may be converted in to historical
window (several targeted data flows may be selected), and failures. At this time, the causes are difficult to be checked,
make good preparations for retention, so as to diagnose and the failures shall be checked as intermittent ones.
the failures and store them, once they reoccur.
Diagnosis without DTC

The failures without DTCs refer to that the vehicle has
obvious failure symptoms, but "MIL" is off, or there are no
corresponding DTCs when reading DTCs. Self-diagnosis
system can only monitor the circuits of electronic control
system, which means: first, if the failures do not belong to
circuits, there are generally no DTCs; second, if the failures
do not belong to the circuits of electronic control system
(starting system and charging system), the DTCs will not
be stored. Therefore, the failures without DTCs are often
independent of electronic control system. At this time,
troubleshooting shall be carried out according to the
diagnosis steps for failures not belonging to electric control
machine. Please keep in mind that don't check the ECUs,
actuating elements, sensors and circuits of electronic
control systems without aim at this time. Otherwise, not
only working in vain, but also causing damage to the
electronic control elements in case of a slight
carelessness.
In addition, self-diagnosis system can only monitor the

range of signals, but can't detect the changes of the
electrical characteristics of sensor. That is, if the electrical
characteristics of sensor signals are changed for some
reasons, but they are still within the monitoring scope of the
self-diagnosis system, the DTCs will not be generated
either. However, ECU has read the sensor signal values
4-9
Symptom Table
? The air filter element is too dirty, and ? Replace the air filter element, or remove the
the intake pipe is blocked by foreign foreign matters; tighten the pipeline connection
Reduced boosting effect matters or has air leakage or replace the damaged components.
of turbocharger ? The turbocharger impeller is loose or ? Remove the foreign matters, or replace the
damaged, or there are foreign matters damaged components.
stuck in the turbocharger
Sudden run-down of turbo- after a long period, which leads to poor standard, and replace the turbocharger
charger lubrication and stuck turbocharger assembly.
bearing
? Turbocharger exhaust bypass valve ? Eliminate the failures of turbocharger
is faulty, which leads to the long-term exhaust bypass valve components, and
high-load operation of turbocharger or replace the turbocharger assembly.
the damage of bearing
after a long period, which leads to poor standard, and replace the turbocharger
lubrication and stuck turbocharger assembly.
bearing
Abnormal turbocharger ? Engine oil pressure is too low, which ? Eliminate the low oil pressure, and replace
operation sound leads to late turbocharger oil supply, the turbocharger assembly.
and poor bearing lubrication
? Turbocharger impeller is damaged ? Replace the turbocharger assembly.
and has friction with housing
? There is periodic abnormal sound ? Replace the turbocharger assembly.
while rotating the turbocharger
impeller, and the bearing clearance
and excessive wear can be detected
while shaking the turbocharger impeller
4-10
Water Temperature Sensor Replacement

Service Guide
Removal
Camshaft Position Sensor Replacement Warning: Coolant is toxic. It is fatal to eat it by
Removal mistake, and the immediate medical help is
required.
2 Disconnect the harness connector of camshaft Warning: There will be steam when the coolant is
position sensor. hot, and the inhalation of steam shall be avoided.
3 Remove 1 bolt fixing the camshaft position sensor 1 Discharge the coolant.
to the valve chamber cover.
4 Remove the camshaft position sensor (1).
3 Disconnect the harness connector of water
temperature sensor.
4 Remove the water temperature sensor (1).
S02023041
Installation
1 Fix the camshaft position sensor to the valve S02023042
chamber cover, install 1 bolt, tighten it to 10 ± 1 Installation
1 Fix the water temperature sensor to the
2 Connect the harness connector of camshaft
thermostat, tighten it to 23 ± 2 N.m and check the
position sensor.
torque.
2 Connect the water temperature sensor harness
connector.
4 Refill the coolant.
4-11
Low-pressure EGR Differential Pressure High-pressure EGR Temperature Sensor

Sensor Replacement Replacement
Removal Removal
1 Disconnect the negative battery cable. 1 Disconnect the negative battery cable.
2 Loosen the clamps, and disconnect the pipes of 2 Remove the starter. Refer to “Starter
low-pressure EGR differential pressure sensor (1). Replacement” .
3 Disconnect the harness connector of low-pressure 3 Disconnect the harness connector of high-
EGR differential pressure sensor (2). pressure EGR temperature sensor.
4 Remove 1 bolt (3) fixing the low-pressure EGR 4 Remove the high-pressure EGR temperature
differential pressure sensor to the cylinder head. sensor (1).
5 Remove the low-pressure EGR differential
pressure sensor (4).
3
2
4
1
S02023044
S02023043 Installation
1 Fix the high-pressure EGR temperature sensor to
Installation the EGR assembly, tighten it to 45 ± 2 N.m, and
1 Fix the low-pressure EGR differential pressure check the torque.
sensor to the cylinder head, install 1 bolt, tighten it 2 Connect the harness connector of high-pressure
to 10 ± 1 N.m, and check the torque. EGR temperature sensor.
2 Connect the harness connector of low-pressure 3 Install the starter. Refer to“Starter Replacement”
EGR differential pressure sensor. .
3 Connect the pipes of low-pressure EGR 4 Connect the negative battery cable.
differential pressure sensor, and install the
retaining clamps.
4-12
Low-pressure EGR Temperature Sensor MAP Sensor Replacement

Replacement Removal
Removal
2 Remove the intercooler. Refer to “Intercooler
2 Disconnect the low-pressure EGR temperature Replacement” .
sensor harness connector. 3 Disconnect the harness connector of intake air
3 Remove the low-pressure EGR temperature temperature sensor (1).
sensor (1). 4 Remove 1 bolt (2) fixing the intake air temperature
sensor to the intake manifold.
5 Remove the intake manifold pressure sensor (3).
1
S02023045 3
Installation
S02023046
1 Fix the low-pressure EGR temperature sensor to
the low-pressure EGR assembly, tighten it to 45 ± Installation
1 Fix the intake manifold pressure sensor to the
2 Connect the low-pressure EGR temperature intake manifold, install 1 bolt, tighten it to 11 ± 1
sensor harness connector. N.m, and check the torque.
2 Install the intercooler. Refer to “Intercooler
Replacement” .
4-13
Intercooler Rear Intake Air Temperature Crankshaft Speed Sensor Replacement

Sensor Replacement Removal
Removal
1 Remove the A/C compressor bracket when
1 Disconnect the negative battery cable. necessary. Refer to “A/C Compressor Bracket
2 Disconnect the harness connector of intercooler Replacement” .
rear intake air temperature sensor. 2 Disconnect the harness connector of crankshaft
3 Remove the intercooler rear intake air temperature speed sensor.
sensor (1). 3 Remove 1 bolt fixing the crankshaft speed sensor
to the cylinder block.
4 Remove the crankshaft speed sensor (1).
1
S02023047
Installation
S02023048
1 Fix the intercooler rear intake air temperature
sensor to the intercooler exhaust pipe, tighten it to Installation
1 Fix the crankshaft speed sensor to the cylinder
2 Connect the negative battery cable. block, install 1 bolt, tighten it to 10 ± 1 N.m, and
check the torque.
2 Connect the harness connector of crankshaft
speed sensor.
3 Install the A/C compressor bracket when
necessary. Refer to “A/C Compressor
Replacement” .
4-14
Turbocharger Front Exhaust Temperature Oil Pressure Switch Replacement

Sensor Replacement Removal
Removal
1 Disconnect the negative battery cable. 2 Disconnect the harness connector of oil pressure
2 Remove the intercooler intake pipe when switch, and remove the oil pressure switch (1).
necessary.
3 Remove the turbocharger front exhaust
1
1
S02023050
Installation
S02023049 1 Install the oil pressure switch, tighten it to 15 ± 2

Installation
2 Connect the harness connector of oil pressure
1 Install the turbocharger front temperature sensor, switch.
tighten it to 45 ± 2 N.m, and check the torque. 3 Connect the negative battery cable.
2 Connect the harness connector of turbocharger
front exhaust temperature sensor.
3 Install the intercooler intake pipe when necessary.
4-15
Electronic Vacuum Switching Valve Electronic Vacuum Control Valve

Replacement Replacement (Two-stage Turbocharging)
Removal Removal
1 Disconnect the harness connector of electronic 1 Disconnect the harness connector of the
vacuum switching valve (1). electronic vacuum control valve.
2 Disconnect the connecting pipes of electronic 2 Disconnect the electronic vacuum control valve
vacuum switching valve. connecting pipe.
3 Remove 2 screws (2) fixing the electronic vacuum 3 Remove 4 screws (1) fixing the electronic vacuum
switching valve to the bracket. control valve to the bracket.
4 Remove the electronic vacuum switching valve 4 Remove the electronic vacuum control valve (3)
(3). from the bracket (2).
1
2
2 1
1
3
1 3 2
S02023051 S02023099
1 Fix the electronic vacuum valve to the bracket, 1 Fix 2 electronic vacuum control valves to the
install 2 bolts, tighten them to 10 ± 1 N.m, and bracket, install 4 bolts, tighten them to 7 ± 1 N.m,
check the torque. and check the torque.
2 Connect the harness connector, and connect the 2 Connect the harness connector, and connect the
connecting pipes of electronic vacuum switching connecting pipes of electronic vacuum switching
valve. valve.
3 Connect the negative battery cable. 3 Connect the negative battery cable.
4-16
Preheating Engine Harness Replacement Engine Harness Replacement

Removal Removal
1 Remove the water-air intercooler, refer to 1 Disconnect the harness connector of differential
“Water-Air Intercooler Replacement” . pressure sensor.
2 Disconnect the preheating engine harness
connector.
S02023054
2 Disconnect the low-pressure EGR temperature

S02023052
sensor harness connector.
3 Disconnect 4 harness connectors connecting the
preheating engine harness to the glow plug.
4 Remove the preheating engine harness.
S02023055
3 Disconnect the harness connector of intercooler

rear temperature sensor.
S02023053
Installation
1 Install the preheating engine harness on the
engine, and connect 4 harness connectors to the
glow plug.
2 Connect the preheating engine harness connector.
3 Install the water-air intercooler, refer to “Water-
S02023056
4 Disconnect the harness connector of high-

pressure EGR temperature sensor.
4-17
S02023057 S02023060
5 Disconnect the harness connector of oil pressure 8 Disconnect the harness connector of intake
switch. manifold pressure sensor.
S02023058 S02023061
6 Disconnect the harness connector of water 9 Disconnect the harness connector of camshaft
temperature sensor. position sensor.
10 Remove the engine harness clips, and remove the
engine harness assembly.
Installation
1 Fix the engine harnesses to various harness
brackets.
2 Connect various engine harness connectors in
turn.
S02023059
7 Disconnect the harness connector of vacuum

control valve.
4-18
Turbocharger Heat Shield Replacement Turbocharger Upper Bracket Replacement

Removal (Two-stage Turbocharging)
Removal
1 Remove the bolts fixing the turbocharger heat
shield to the turbocharger. 1 Remove 2 bolts (1) fixing the turbocharger bracket
2 Remove the turbocharger heat shield (1); to the intercooler bracket.
2 Remove 1 bolt (2) fixing the turbocharger bracket
to the turbocharger.
3 Remove the turbocharger bracket (3).
3
1 2
S02023062
Installation
1 Install the turbocharger heat shield. S02023063
2 Fix the turbocharger heat shield bolts to the
Installation
turbocharger, tighten them to 30 ± 3 N.m, and
check the torque. 1 Install the turbocharger upper bracket.
2 Fix the turbocharger bracket to the intercooler
bracket, install 2 bolts, tighten them to 25 ± 2 N.m,
3 Fix the turbocharger bracket to the turbocharger,
install 1 bolt, tighten it to 35 ± 2 N.m, and check
the torque.
4-19
Turbocharger Lower Bracket Replacement Turbocharger Replacement (Two-stage

(Two-stage Turbocharging) Turbocharging)
Removal Removal
1 Remove 2 bolts (1) fixing the turbocharger bracket 1 Remove the intercooler intake hose. Refer to
to the low-pressure EGR assembly bracket. “Intercooler Intake Hose Replacement” .
2 Remove 1 bolt (2) fixing the turbocharger bracket 2 Remove the air filter element inlet pipe. Refer to
to the turbocharger. “Air Filter Element Inlet Pipe Replacement” .
3 Remove the turbocharger bracket (3). 3 Remove the turbocharger water outlet pipe. Refer
to “Turbocharger Water Outlet Pipe
Replacement” .
4 Remove the turbocharger heat shield. Refer to
“Turbocharger Heat Shield Replacement” .
2
3 6 Disconnect the harness connector of turbocharger
control valve.
S02023064
Installation
1 Install the turbocharger lower bracket.
2 Fix the turbocharger bracket to the EGR cooler,
install 2 bolt, tighten them to 35 ± 2 N.m, and
check the torque.
3 Fix the turbocharger bracket to the turbocharger,
install 1 bolt, tighten it to 43 ± 3 N.m, and check S02023066
the torque.
7 Remove 1 through-hole bolt fixing the
turbocharger oil inlet pipe to the cylinder block.
S02023067
8 Remove 1 bolt (1) fixing the turbocharger

assembly to the lower bracket.
9 Remove 1 bolt (2) fixing the turbocharger oil return
pipe to the cylinder block.
4-20
S02023068 S02023071
10 Remove 2 bolts fixing the low-pressure EGR 15 Remove 2 bolts fixing the turbocharger oil return
exhaust pipe to the turbocharger, and remove the pipe to the turbocharger.
gaskets.
S02023072
S02023069
16 Remove 2 bolts fixing the turbocharger oil return
11 Remove 2 nuts (1) and 1 hexagon bolt (2) fixing pipe to the turbocharger.
the turbocharger to the exhaust manifold. 17 Remove the turbocharger oil return pipe (1).
12 Remove 1 bolt (3) fixing the turbocharger to the
upper bracket.
13 Remove the turbocharger assembly.
3
2
S02023073
1
Installation
S02023070 1 1 Fix the turbocharger oil return pipe assembly and
its gasket to the turbocharger, install 4 bolts,
14 Remove 2 through-hole bolts fixing the
turbocharger oil inlet pipe to the turbocharger. tighten them to 10 ± 2 N.m, and check the torque.
Remove the turbocharger oil inlet pipe.
4-21
2 Fix the turbocharger oil inlet pipe assembly and Turbocharger Replacement (Single-stage
gasket to the turbocharger, and install 2 through- Turbocharging)
hole bolts. Tighten them to 30 ± 2 N.m, and check Removal
the torque.
1 Remove the intercooler intake hose. Refer to
3 Fix the turbocharger assembly and gasket to the
“Intercooler Intake Hose Replacement” .
exhaust manifold, install 2 nuts (1) and 1 bolt (2).
Tighten the nut (1) to 70 ± 3 N.m, and check the 2 Remove the air filter element inlet pipe. Refer to
torque. Tighten the nut (2) to 55 ± 3 N.m, and “Air Filter Element Inlet Pipe Replacement” .
check the torque. 3 Remove the turbocharger water inlet pipe. Refer to
Note: Check the gasket. If any damage, replace it. “Turbocharger Water Inlet Pipe Replacement” .
4 Remove the turbocharger water outlet pipe. Refer
to “Turbocharger Water Outlet Pipe
Replacement” .
6 Disconnect the harness connector of turbocharger
control valve.
S02023074
4 Fix the turbocharger oil return pipe assembly to

the cylinder block, install 1 bolt, tighten it to 10 ± 2
5 Fix the turbocharger oil inlet pipe assembly to the
cylinder block, install 2 bolts, tighten them to 35 ±
S02023075
6 Fix the low-pressure EGR exhaust pipe and its
gasket to the turbocharger. 7 Remove 3 bolts fixing the turbocharger heat shield
7 Install the turbocharger upper and lower bracket to the turbocharger.
bolts. 8 Remove the turbocharger heat shield (1);
8 Install the water pipe and its clamp.
9 Turbocharger Heat Shield 1
10 Install the front catalytic converter. Refer to “Front

catalytic Converter Replacement” .
11 Install the turbocharger water outlet pipe. Refer to
“Turbocharger Water Outlet Pipe Replacement”.
12 Install the turbocharger water inlet pipe. Refer to
“Turbocharger Water Inlet Pipe Replacement” .
13 Install the air filter element inlet pipe. Refer to“Air
Filter Element Inlet Pipe Replacement” .
14 Install the intercooler intake hose. Refer to S02023076
9 Remove 1 bolt (1) fixing the turbocharger to the
upper bracket.
4-22
10 Remove 1 through-hole bolt (2) fixing the

turbocharger oil inlet pipe to the turbocharger.
1
2
S02023080

S02023077
pipe to the turbocharger, and remove the
11 Remove 1 bolt fixing the turbocharger oil return turbocharger oil return pipe (1).
pipe to the cylinder block, and remove the
turbocharger oil return pipe (1).
S02023081
Installation
S02023078
1 Fix the turbocharger oil return pipe assembly and
12 Remove 1 bolt fixing the turbocharger to the its gasket to the turbocharger, install 2 bolts,
exhaust manifold. tighten them to 11 ± 1 N.m, and check the torque.
2 Fix the turbocharger assembly and gasket to the
exhaust manifold, install 2 nuts and 1 bolt. Tighten
the nuts to 70 ± 3 N.m. Tighten the bolt to 55 ± 3
Note: Check the gasket. If any damage, replace it.
S02023079
13 Remove 2 nuts fixing the turbocharger to the

exhaust manifold, and remove the turbocharger.
4-23
Turbocharger Oil Inlet Pipe Replacement

(Single-stage Turbocharging)
Removal
1 Remove the turbocharger (Single-stage

Turbocharging). Refer to “Turbocharger
Replacement (Single-stage Turbocharging)” .
2 Remove 1 through-hole bolt fixing the
turbocharger oil inlet pipe to the cylinder block,
and remove the turbocharger oil inlet pipe (1).
S02023074
3 Fix the turbocharger oil return pipe assembly to 1

the cylinder block.
4 Install the turbocharger assembly on the upper
bracket.
5 Fix the turbocharger oil inlet pipe assembly to the
turbocharger, install 1 through-hole bolt, tighten it
6 Fix the turbocharger heat shield to the
turbocharger, install 3 bolts, tighten them to 30 ± 2 S02023082
7 Connect the harness connector of turbocharger Installation
control valve. 1 Fix the turbocharger oil inlet pipe to the cylinder
8 Install the front catalytic converter. Refer to “Front block, install 1 through-hole bolt, tighten it to 35 ±
Catalytic Converter Replacement” . 2 N.m, and check the torque.
9 Install the turbocharger water outlet pipe. Refer to 2 Install the turbocharger assembly. Refer to
“Turbocharger Water Outlet Pipe Replacement”. “Turbocharger Replacement (Single-stage
10 Install the turbocharger water inlet pipe. Refer to Turbocharging)” .
“Turbocharger Water Inlet Pipe Replacement” .
11 Install the air filter element inlet pipe. Refer to“Air
Filter Element Inlet Pipe Replacement” .
12 Install the intercooler intake hose. Refer to
4-24
Turbocharger Oil Return Pipe Replacement Turbocharger Oil Inlet Pipe Replacement
(Single-stage Turbocharging) (Two-stage Turbocharging)
Removal Removal
1 Remove the turbocharger (Single-stage 1 Remove the turbocharger (Two-stage
Turbocharging). Refer to “Turbocharger Turbocharging). Refer to “Turbocharger
Replacement (Single-stage Turbocharging)” . Replacement (Two-stage Turbocharging)” .
2 Remove 2 bolts fixing the turbocharger oil return 2 Remove 2 through-hole bolts fixing the
pipe to the turbocharger, and remove the turbocharger oil inlet pipe to the turbocharger.
turbocharger oil return pipe (1). Remove the turbocharger oil inlet pipe.
S02023081 S02023071
1 Fix the turbocharger oil return pipe assembly and 1 Fix the turbocharger oil inlet pipe assembly and
its gasket to the turbocharger, install 2 bolts, gasket to the turbocharger, and install 2 through-
tighten them to 10 ± 1 N.m, and check the torque. hole bolts. Tighten them to 30 ± 2 N.m, and check
2 Install the turbocharger (Single-stage the torque.
Turbocharging). Refer to “Turbocharger 2 Install the turbocharger (Two-stage
Replacement (Single-stage Turbocharging)” . Turbocharging). Refer to “Turbocharger
Replacement (Two-stage Turbocharging)” .
4-25
Turbocharger Oil Return Pipe Replacement Turbocharger Water Inlet Pipe Replacement
(Two-stage Turbocharging) (Two-stage Turbocharging)
Removal Removal
1 Remove the turbocharger (Two-stage 1 Loosen the water inlet hose clamp to release the
Turbocharging). Refer to “Turbocharger water inlet hose (1). Remove 1 bolt fixing the
Replacement (Two-stage Turbocharging)” . turbocharger water inlet pipe to the turbocharger,
and remove the turbocharger water inlet pipe (2).
pipe to the turbocharger.
S02023083
3 Remove 2 bolts fixing the turbocharger oil return 1 Fix the turbocharger water inlet pipe to the
pipe to the turbocharger. turbocharger, install 1 retaining bolt, tighten it to 10
4 Remove the turbocharger oil return pipe (1).
2 Connect the water inlet hose, and install the
clamp.
S02023073
Installation
1 Fix the turbocharger oil return pipe assembly and
its gasket to the turbocharger, install 4 bolts,
2 Install the turbocharger (Two-stage
Turbocharging). Refer to “Turbocharger
Replacement (Two-stage Turbocharging)” .
4-26
Turbocharger Water Outlet Pipe Replacement Vacuum Control Solenoid Valve Bracket
(Two-stage Turbocharging) Replacement
Removal Removal
1 Remove 1 bolt (1) fixing the turbocharger water 1 Remove the vacuum control valve. Refer to
outlet pipe to the turbocharger. “Vacuum Control Valve Replacement” .
2 Release the pipe clip (2). Remove the 2 Remove 4 bolts fixing the vacuum control solenoid
turbocharger water outlet pipe (3). valve bracket to the water-air intercooler bracket.
bracket (1).
2
1
1
S02023084
Installation
S02013259
1 Fix the turbocharger water outlet pipe to the
turbocharger, install 1 retaining bolt, tighten it to 10 Installation
± 1 N.m, and check the torque. 1 Fix the vacuum control solenoid valve bracket to
2 Fix the vacuum tube clip. the water-air intercooler bracket, install 4 bolts,
2 Install the vacuum control valve. Refer to
“Vacuum Control Valve Replacement” .
4-27
Glow Plug Controller Replacement Engine Control Module Replacement

Removal Removal
2 Disconnect the glow plug controller connector. 2 Disconnect the harness from the engine control
3 Remove the glow plug controller bolts (1). module bracket.
4 Remove the glow plug controller (2). 3 Disconnect the connector from the engine control
module.
Note: When disconnecting the engine control
module connector, avoid shaking the connector all
1 round; avoid applying force on one side only;
avoid damaging the connector structure.
2
4 Remove the engine control module bracket bolts
(1).
5 Remove the engine control module and its bracket
(2).
S02023120 1
Installation
1 Install the glow plug controller.
2 Install the glow plug controller bolts, tighten them 1
2
3 Connect the glow plug controller connector.
S02023109
6 Remove 4 engine control module bolts (1) and

nuts (2).
7 Disconnect the engine control module (3) from the
bracket (4).
1 1
2
2
S02023110
4-28
Installation Mass Air Flow Sensor Replacement

Removal
1 Fix the engine control module to the battery
bracket, install 4 bolts, tighten them to 9 ± 1 N.m, 1 Disconnect the negative battery cable.
and check the torque. 2 Disconnect the electrical connector of the mass air
2 Connect the engine control module connector. flow sensor.
3 Fit the expansion tank. 3 Remove 2 MAF sensor bolts (2).
4 Connect the negative battery cable. 4 Remove the MAF sensor (1).
5 Program and set the engine control module.
GS030165
Installation
1 Install the mass air flow Sensor.
2 Install 2 MAF sensor bolts, tighten them to 2.5 ±
0.5 N.m, and check the torque.
3 Connect the electrical connector of the mass air
flow sensor.
4-29
Accelerator Pedal Replacement

Removal
2 Remove the driver kick panel assembly.
3 Disconnect the electrical connector of the
accelerator pedal.
4 Remove 3 accelerator pedal nuts (2).
5 Remove the accelerator pedal (1) from the dash
panel (3).
DS060009
Installation
1 Fit the accelerator pedal.
2 Install 3 accelerator pedal nuts, tighten them to 9
3 Connect the electrical connector of the accelerator
pedal.
4-30
Crankshaft Speed Sensor

Water Temperature Sensor
S02023086
The function of crankshaft speed sensor is to locate the

S02023085
crankshaft, that is, the rotation angle of crankshaft. It
Water temperature sensor is a thermistor sensor with the usually works with the camshaft position sensor to
temperature resistance as a part of 5V voltage division determine the basic ignition time.
circuit, and the two ends of temperature sensor are
Crankshaft speed sensor is one of the most important
connected with the voltage bearing circuit. When the
sensors in the control system. Functions: detection of
temperature resistance of temperature sensor is changed
engine speed, also known as engine speed sensor;
with the temperature of coolant, the voltage of voltage
detection of piston top dead center (TDC) position, also
bearing circuit will change, which will be input to the
known as TDC sensor, including the detection of the top
analog-digital conversion circuit of ECU interface circuit.
dead center signals of various cylinders which are used for
The characteristic curve of the relationship between
ignition control, and the detection of the top dead center
voltage and temperature is stored in the ECU of engine's
signals of the first cylinder used to control the fuel injection
management system. Thus, the ECU can determine the
in sequence.
temperature of coolant according to the input voltage
signals, correct the fuel injection amount, accurately control
the fuel injection amount, time and idle speed. The coolant
temperature sensor is installed on the cylinder head water
outlet pipe.
4-31
Camshaft Position Sensor Intake Manifold Pressure Sensor
S02023087 S02023088
Camshaft position sensor is installed on the cam chamber Intake manifold pressure sensor is used to detect the
seat, which consists of camshaft position sensor and cam. absolute pressure of the intake manifold behind the
ECU shall calculate the engine speed and determine the throttle. It detects the changes of the absolute pressure in
piston stroke position in the cylinder according to the actual the manifold according to the engine speed and load, and
information of operating speed and load, so as to control then converts them into signal voltages and sends them to
the injector's opening time, fuel injection amount, time and the engine control unit (ECU), and the ECU will control the
idle speed. basic fuel injection amount according to this signal voltage.
Camshaft position sensor is also known as cylinder

identification sensor. The functions of camshaft position
sensor are to collect the position signals of air distribution
camshaft, and input ECU, to make it easy for ECU to
identify the compression top dead center of cylinder 1, so
as to carry out the sequential fuel injection control and
knock control.
4-32
Low-pressure EGR Differential Pressure Intercooler Rear Intake Air Temperature

Sensor Sensor
S02023089 S02023090
Differential pressure sensor is a sensor designed to Intercooler intake temperature sensor is a negative
accurately control the "regeneration" triggering time. temperature coefficient thermistor. When the temperature
Differential pressure sensor sends the differential pressure increases, the resistance value will decrease; and when
signals to ECU by measuring the pressure difference the temperature decreases, the resistance value will
between the front and rear channels of the collector, and increase. With the changes of the circuit resistance, the
the ECU will determine the accumulation of the particles in voltage changes, generating different voltage signals, to
the collector, so as to determine the "regeneration" complete the automatic operation of control system. When
triggering time and additional fuel injection amount. ECU the vehicle is in cold state, the signals of intake
may also increase the exhaust gas temperature by temperature sensor are basically the same as those of
controlling the opening of EGR valve and electronic engine water temperature sensor. When the vehicle is in
throttle. hot state, its signal voltage is about 2~3 times of water
temperature sensor. The low-pressure intercooler intake
temperature sensor converts the air intake amount and
pressure information into electrical signals, and input them
to ECU for calculation, so as to determine the fuel injection
advance angle, fuel injection time and amount.
4-33
High-pressure EGR Temperature Sensor Turbocharger Front Exhaust Temperature

Sensor
S02023091
S02023093
EGR temperature sensor detects the temperature of the
exhaust gas recycled in EGR system, ensures the normal Turbocharger front exhaust temperature sensor detects
operation of system, and reduces the content of NOx and the exhaust temperature, and provides it to ECU as the
S compounds as well as other harmful gas in the exhaust. reference for calculating the air density.
Low-pressure EGR Temperature Sensor Oil Pressure Switch
S02023092 S02023094
EGR temperature sensor detects the temperature of the
exhaust gas recycled in EGR system, ensures the normal For oil pressure switch, when the pressure within the
operation of system, and reduces the content of NOx and system is higher or lower than the rated safety pressure,
S compounds as well as other harmful gas in the exhaust. the disc in the inductor will move instantaneously, which
will push the switch connector on or off by connecting the
guide rod; when the pressure is decreased or increased to
the rated recovery value, the disc will be reset
instantaneously, and the switch will be reset automatically.
In brief, when the measured pressure exceeds the rated
value, the free ends of elastic elements will shift, which will
push the switch elements directly or by comparison, to
change the on-off state of switch elements, so as to control
the measured pressure.
4-34
Glow Plug the dynamic performance and plateau adaptability

of engine.
Glow plug is located on the side of cylinder head, which is
2 The application two-stage turbocharger extremely
used to help the engine start-up and improve the efficiency. broadens the range of turbocharging system,
The glow plug and its indicating lamp are controlled by enables the diesel engine to meet the
engine's electronic control unit. requirements of high power, high torque and low
oil consumption.
The glow plug preheats the combustion chamber to help
3 The application of turbocharger may adjust the
with cold start-up. During the preheating, the engine's exhaust pressure in exhaust manifold and the
electronic control unit receives the engine temperature turbocharging pressure in intake pipe, to realize
signals from coolant temperature sensor, and determines EGR, and meet the exhaust requirements.
the preheating time according to the signals. The lower the 4 The application of low-pressure turbocharger with
temperature is, the longer the preheating time is. Under the small inertness in two-stage turbocharging system
temperature of - 20°C or lower, the longest preheating may effectively solve the system acceleration lag.
time is 8 s. Above 80°C, no preheating stage.
Once the engine is started, the glow plug enters the post-
heating stage. The post-heating stage helps to improve the
idle and reduce the hydrocarbon emissions through the
efficient combustion after starting. The post-heating stage
is effective only when the engine speed is lower than 2,500
RPM. Beyond this speed, the post-heating stage will be
interrupted to extend the service life of glow plug. Under
the temperature of - 20°C or lower, the longest post-
heating time is 30 s.
Turbocharging System (Two-stage

Turbocharging)
If the turbocharging system of this engine is a two-stage
adjustable turbocharging system, the two turbochargers
shall be arranged in series. The two-stage adjustable
turbocharging system consists of high-pressure
turbocharger, low-pressure turbocharger, exhaust flow
distribution valve and exhaust bypass valve. High pressure
turbocharger is a small turbocharger, and the low-pressure
turbocharger is a large turbocharger. If the turbocharging
ratio is higher, the turbocharged air shall be cooled during
air compression. The turbocharging system with high-
pressure turbine bypass valve is mainly used in
commercial vehicle. In order to meet the transient
characteristics, the required turbocharging pressure and
other requirements, this turbocharging system can be used
in passenger vehicle with a slight improvement.
Advantages
1 The application of two-stage turbocharging system

may obtain higher intake pressure, and improve
4-35
Operating principle exhaust amount at the turbine end, LP TC only plays the
When the engine is running at a low speed of about 750 - role of air circulation.
1500 rpm, HP TC operates. Due to the small amount of the
To converter From air cleaner

（到催化转化器） LP （来自空气滤清器）
turbocharger
（LP增压器）
WGV
VGT HP
turbocharger CBV
（HP增压器）
TBV
From exhaust manifold

（来自排气歧管） To intercooler（到中冷器）
S02022001
4-36
When the engine is running at a medium-high speed of

about 1500 -3000 rpm, both HP and LP TC operate, but
HP TC is the main force.

turbocharger
（LP增压器）
WGV
VGT HP
turbocharger CBV
（HP增压器）
TBV

S02022002
4-37
When the engine is running at a high speed of about 3000- (only the compression amount is lower); LP TC is the main
4000 rpm, HP TC is bypassed, but still compresses the air force.

turbocharger
（LP增压器）
WGV
VGT HP
turbocharger CBV
（HP增压器）
TBV

S02022003
4-38
Turbocharging System (Single-stage

Turbocharging)
Function
Improve the intake amount of engine, and increase the
power and torque of engine.
Principle
Drive the turbine using the exhaust gas from engine, so as
to push the compressor to compress the fresh air, and
improve the density of the air entering cylinder.
⏗䖤 ু㕟䖤
ࡦᧈ≊㇗
ᶛ㠠グ┚ಞ
ᶛ㠠ᧈ≊㇗ ࡦ䘑≊㇗
S02023095
4-39
4-40
Fuel System
Fuel System
Specification
Torque
Bolt - fuel tank strap to body 40 ± 3

Bolt -front engine mount to frame plane 60 ± 5
Bolt -front engine mount bracket to engine 65 ± 8
Nut -front engine mount to front engine mount bracket 110 ± 10
Bolt - rear mount pad assembly to cross member 60 ± 5
Bolt - rear mount bracket to transmission 60 ± 5
Bolt - rear engine mount to transfer case 60 ± 5
Bolt - rear mount bracket to transmission 60 ± 5
Nut - rear mount pad assembly to rear mount bracket 60 ± 5
Bolt - fixing fuel filler pipe to frame 5±1
Bolt - fixing fuel filler pipe to frame 5±1
Bolt - fuel filter bracket to body 40 ± 4
Bolt - fuel filter to frame 40 ± 3
7-1
Fuel System
Layout
Fuel Supply System Layout
24
21 25
4 8
3
6 20
5 10
22
3
11 32
2 14
12 26
13
1
23
9
7
28
8 31
32
27
30
29
15 31
16 19
17
18
CS110003
1 Common rail pipe 9 Bolt - common rail inlet pipe

2 High-pressure fuel pipe (Cylinder 1) 10 Fuel injector
3 High-pressure fuel pipe (Cylinder 2, 3) 11 Fuel injector pressure plate bolt
4 High-pressure fuel pipe (Cylinder 4) 12 Fuel injector pressure plate
5 Bolt - common rail pipe 13 Fuel injector pressure plate block
6 Stud - common rail pipe 14 O-ring - fuel injector
7 Common rail inlet pipe 15 High-pressure fuel pump
8 Clamp 16 High-pressure fuel pump timing pulley
7-2
Fuel System
17 Nut - high-pressure fuel pump timing pulley 25 Bolt - fuel return manifold
18 Stud - High-pressure fuel pump 26 Block - fuel return manifold
19 Nut - High-pressure fuel pump 27 Engine oil inlet pipe assembly
20 Fuel return manifold assembly 28 Engine oil inlet pipe joint
21 Fuel injector return pipe 29 Engine oil inlet pipe
22 Fuel return pipe transition joint 30 Bolt - engine oil inlet pipe
23 Fuel pump return pipe 31 Hoop
24 Bolt - fuel return manifold 32 Hose clamp
7-3
Fuel System
Fuel System Layout
15 14
13
16 11
12
10
3
4
8
2
9 6
1
7
ES020026
1 Fuel filler cap assembly 9 Front fuel tank strap

2 Bolt - fuel filler pipe to body 10 Fuel tank assembly
3 Fuel filler pipe 11 Fuel level sensor assembly
4 Fuel filler connection clamp 12 Fuel level sensor
5 Fuel filler connection clamp 13 Level sensor seal ring
6 Bolt - fuel filler pipe to body 14 Level sensor screw ring
7 Bolt - fuel tank strap to body cross member 15 Fuel tank fuel return hose
8 Rear fuel tank strap 16 Fuel tank fuel inlet hose
7-4
Fuel System
Powertrain Installation/Removal
5
7
7
6
5
1 2
4
9 11 11
11
8
13
12 13 12
12
13
10 8 8 8
10 10
10
4WD 2WD(5MT) 2WD(6MT) 2WD(6AT)
ES020029
1 Left front engine mount bracket 8 Rear engine mount

2 Right front engine mount bracket 9 Bolt - rear engine mount to transfer case
3 Left front engine mount 10 Nut - rear mount pad assembly to cross member
4 Right front engine mount 11 Nut - rear mount pad assembly to rear mount
bracket
5 Bolt -front engine mount bracket to engine
12 Bolt - rear mount bracket to transmission
6 Bolt -front engine mount bracket to frame plane
13 Rear engine mount bracket
7 Nut -front engine mount to front engine mount
bracket
7-5
Fuel System
Repair Guidance Replacement of Fuel Filter Element
Fuel System Fuel Pumping 1 Wipe the outer surface of fuel filter.
Warning: Wear suitable gloves to protect your Note：Observe if it is absolutely clean, and ensure
hands from contacting diesel. that there will be no dust entering into the fuel
system. Take precautions to prevent the fuel
1 Connect a suitable pipe to the exhaust valve 1, dropping on the electrical equipment below.
and place the other end of the pipe into a 2 Disconnect the electrical connector from the filter
suitable container. base.
2 Rotate the exhaust valve for 1 cycle to open it. 3 Place a suitable oil pan under the filter. Screw off
3 Press the hand pump ③ on the filter for about 50 the fuel filter element counterclockwise with a
times, until several stable and consecutive fuel suitable tool.
flows appear.
4 Close the exhaust valve, and remove the pipe.
5 Press the hand pump for another 10 times.
6 Check whether the engine can start without fuel

leakage.
ES020031
Installation
ES020030 1 Unscrew the oil-water separator sensor from the

filter base,and install it on the replacement part.
2 Lubricate the O-ring on the filter with diesel, then
tighten the fuel filter element to fuel heater by
hand to 20-25N.m.
Note：If the intermediate screwed joint tightening

the fuel heater has been loosened during the
removal of fuel filter, check the torque of the joint
before installing new filter element.
3 Connect the electrical connector to the oil-water
separator sensor.
4 Pump fuel to the fuel filter (refer to "Fuel System

Pumping").
5 Start the engine and check if there is fuel

leakage.
7-6
Fuel System
Installation
Replacement of Fuel Tank Assembly
1 Connect the harness of the fuel pump.
Removal
2 Install the front and rear straps to the fixed
1 Push the button of the fuel filler cap on driver
position of fuel tank, and secure them to body
side to open it. Place the vehicle on the lifting
with bolts and nuts.
platform and lift it to a certain height.
2 Remove the fuel filler cap, release 5 bolts of fuel The torque is 40 ± 3N.m.
filler pipe, cut the ribbon, then remove the fuel
3 Connect the hoop and quick connector of the
filler pipe bracket and guard plate.
fuel tank and fuel filler rubber pipe.
4 Connect the clamp of the connector between fuel

filler pipe and fuel tank pipe.
5 Lower the vehicle to the ground.
ES020020
3 Remove the front and rear straps, the clamps

(fuel filler pipe, fuel filler exhaust pipe - fuel tank)
can be seen after fuel tank lowers down 70mm,
then remove the clamps.
ES020021
Note：It is recommended to heat the joint of fuel

filler pipe and fuel tank with hot towel for 3-4 min
before removing them.
4 Remove the bolts and nuts securing the front
and rear straps of fuel tank to the body.
5 Disconnect the harness of the fuel pump.
7-7
Fuel System
Replacement of Fuel Pump Level Sensor

Float
1 Remove the fuel tank assembly (refer to
Replacement of Fuel Tank Assembly).
2 Disconnect the fuel supply pipe between fuel
tank and filter and the fuel return pipe between
filter and fuel tank from the fuel pump.
DS070006
5 Check whether the slot of sensor frame is

broken, if yes, replace the level sensor.
DS070005
3 Loosen the loop coil securing fuel pump and

remove the fuel pump.
DS070008
Installation
1 Insert the float pole to the slot A and slot B of the
sensor frame.
B
DS070014
4 Hold the float pole with one hand, insert the

flatbladed screwdriver in the gap between
sensor frame and float pole with the other
hand,then pick out the float pole.
A
DS070009
7-8
Fuel System
2 Press the float pole into slot by left and right Replacement of Fuel Pump Level Sensor
thumbs, try to avoid other part of the pole under
Removal
pressure to prevent it from deformation.
1 Slightly press the spring leaf of harness terminal
with the flat-bladed screwdriver,and pull the rear
end of harness to remove two harness terminals
of the level sensor.
DS070010
3 The standard state of the pressed float pole is as

illustrated. Check whether the slot of sensor
frame is broken again, if yes, replace the level DS070012
sensor.
2 Press the tab of the level sensor with flat-bladed
screwdriver, then remove the level sensor by
hand.
Note：DO NOT damage the fuel tank.
DS070011
4 Rotate the float pole with hand in the full range of

stroke to confirm that the pole can rotate
normally and encounter no obvious resistance DS070013
during the rotation.
Installation
1 Get a new level sensor and insert in the slot of
fuel tank, then press in place with hand.
Note：The tab of level sensor should bounce and
lock appropriately.
2 Connect 2 harness terminals of the level sensor.
7-9
Fuel System
4 The pressure plate of fuel injector must be

Replacement of Injector
removed before removing No.1, 2 or 3 fuel
Required tool:C00017007 injector. Remove the pressure plate bolt (10 mm)
before pressure plate.
Removal
1 Remove the electrical connector from the fuel
injector.
CS113188
5 Remove the fuel injector.

CS113186
—Use the column of central screw installer C00017007,
2 Disconnect the fuel return pipe. make sure it is embedded above the fuel injector
correctly.
3 The high-pressure fuel pipe must be removed
before removing No.2, 3, or 4 fuel injector. Clean —Install the tool connector, washer and nut (30 mm).
the high-pressure fuel pipe (17mm) before
removing. Cover all joints to prevent dust. —Tighten the nut and unplug the fuel injector.
C00017007
CS113187 CS113189
7-10
Fuel System
6 Scrap the O-ring and copper washer. 3 Install the fuel injector as shown on the right:
—Put the fuel injector into the hole of cylinder head,

install the pressure plate, then install bolts without
resistance.
1 —Install new high-pressure fuel pipe,and tighten nuts on

both ends by hand.
—Put the fuel injector into the hole of cylinder head,

2 install the pressure plate, then install bolts without
3
resistance.
—Install new high-pressure fuel pipe,and tighten nuts on

both ends by hand.
CS113190
Check
Do not clean the nozzle area with the steel brush. Wipe it
with clean cloth. Clean the hole of fuel injector in the
cylinder head before reinstallation to ensure the O-ring
and copper washer are sealed correctly.
Note：Prevent the fragment from dropping into

combustion chamber.
Installation
CS113191
Note：Each fuel injector has an error correction
code. If it is replaced, new error correction code
must be read into ECU to realize fuel volume —Tighten the fuel injector pressure plate bolts to 32N.m.
correction.
—Tighten the high-pressure fuel pipe joint to 28N.m.
1 Install new O-ring on the fuel injector.
Note：Fuel injector copper washer is provided
with fuel injector.
2 Apply grease on the fuel injector body and Oring. 32 Nm
CS113192
4 Connect the fuel return pipe. Then slightly pull it

to check whether it is secure. Replace the clamp
if any joint has been pulled out.
7-11
Fuel System
5 Connect the electrical connector.

Replacement of High-pressure Fuel Pump
Required tools：VM 192, C00016997, C00017003,
C00017008, C00017012, C00017016 and C00017030.
Removal
1 Operate according to step 1-2 in "Replacement
of Timing Pulley Chamber/Shock Pad".
2 Disconnect the fuel pump:
—Electrical harness connector ①
—Fuel return pipe ②
—Fuel inlet pipe ③

CS113193
—Common rail fuel inlet pipe ④
Cover all fuel joints to prevent dust, etc.
3 Tighten the high-pressure fuel pump timing

pulley nut (21mm) with the tool C00017012, then
loosen the nut for 2-3 circles.
4
1
2
CS113201
4 Put the tool C00017008 into the timing pulley of

high-pressure fuel pump, rotate it clockwise to
7-12
Fuel System
secure it in place. Tighten the central screws 8 Remove 3 high-pressure fuel pump retaining
until the pulley and shaft separate. nuts (13mm), then remove the high-pressure fuel
pump.
C00017008
H 2587
CS113195
CS113197
5 Remove the tool C00017008.
Installation
1 Please re-install the components to the new
pump (including woodruff key if not installed) if it
is necessary to install high-pressure fuel pump.
2 When installing the high-pressure fuel pump, pay
attention to the woodruff key, and tighten the nut
to 25N.m.。
Note：Apply Tonsan 1234 sealant on the stud.
CS113196
6 Loosen the nuts of timing drive belt tension

pulley; remove and scrap the belt.
Note：DO NOT rotate the crankshaft when

removing timing drive belt, unless clear
instructions are given. Otherwise, valve, piston
and other components will be damaged.
7 Remove the high-pressure fuel pump timing
pulley, then pull out the woodruff key carefully.
CS113198
7-13
Fuel System
3 Do not miss the woodruff key. Install the 8 Start the engine, and check if there is fuel
highpressure fuel pump timing pulley, and tighten leakage.
the nut to 88N.m.
33
11
VM 1055
88 Nm 22
44
CS113194
CS113199
4 Rotate the high-pressure fuel pump timing pulley

to align the timing marks.
CS113200
5 Install the following components to the high

pressure fuel pump:
—High-pressure fuel pipe ④
—Fuel inlet pipe ③
—Fuel return pipe ②
—Electrical harness connector ①
6 Install new timing drive belt and other parts

according to steps 6-14 in "Replacement of
Timing Pulley Chamber/Shock Pad".
7 Pump fuel into the fuel system.
7-14
Engine Fuel System 20L4E
Specification
Torque
Application Torque (Nm)
Bolt - Fuel Tank Strap to Body 45 ± 5

Bolt - Fuel Tank Strap to Body 40 ± 3
Bolt - fixing fuel filler pipe 5 ± 0.5
Nut - Rear Mount Pad Assembly and Crossmember 110 ± 10
Nut - Rear Mount Pad Assembly and Rear Mount Bracket 110 ± 10
Nut - Front Engine Mount and Front Engine Mount Brac 110 ± 10
Bolt - Rear Engine Mount to Transfer Case 60 ± 5
Bolt - Rear Mount Bracket and Transmission 60 ± 5
Bolt - Front Engine Mount Bracket and Engine 60 ± 5
Bolt - Front Engine Mount Bracket and Engine 110 ± 10
Bolt - Front Engine Mount to Frame Plane 60 ± 5
8-1
Layout
Layout
12
9
6
10
11 12
9
4 5
2
3
7
6
10 11
1 8 1 17
5
2
23
22 18
27
28 33
13
14 19
30
29
15 33
24
13 32 16
31 25
26
20
21
ES020054 20
1 Canister to Engine Desorption Pipe 9 Pipe Clamp - Fuel Pipe to Frame

2 Filter to Engine Fuel Supply Pipe 10 Pipe Clamp - Fuel Pipe to Floor
3 Filter to Engine Fuel Supply Pipe 11 Pipe Clamp - Fuel Pipe and Longitudinal Beam
4 Canister to Engine Desorption Pipe 12 Pipe Clamp - Engine Fuel Inlet Pipe to Engine
Desorption Pipe
5 Filter to Engine Fuel Supply Pipe
13 Bolt - fixing fuel filler pipe
6 Canister to Engine Desorption Pipe
14 Fuel Filler Cap Assembly
7 Pipe Clamp - Fuel Pipe and Longitudinal Beam
15 Fuel Filler Pipe Assembly
8 Pipe Clamp - Fuel Pipe and Longitudinal Beam
8-2
16 Canister Assembly 25 Canister Breather Pipe
17 Fuel Tank Assembly 26 Rear Fuel Tank Strap
18 Fuel Filter 27 Threaded Ring - Level Sensor
19 Fuel Pump Assembly 28 Level Sensor Seal Ring
20 Bolt - Fuel Tank Strap to Body 29 Fuel Pump Level Sensor Float
21 Front Fuel Tank Strap 30 Fuel Pump Level Sensor Unit
22 Fuel Tank to Filter Fuel Supply Pipe 31 Hoop - Connecting Pipe between Fuel Filler Pipe
and Canister
23 Filter to Fuel Tank Fuel Return Pipe
32 Hoop - Fuel Filler Pipe and Fuel Tank
24 Canister Desorption Pipe
33 Hoop - Fuel Filler Pipe and Fuel Tank
8-3
Layout
11 10
13
12
11
13
3 2
11
8 8
8
9
9
6
6
5
7 5
5
7 7
4WD 2WD
ES020055
1 Front Left Engine Mount Bracket 8 Bolt - Rear Engine Mount to Transfer Case
2 Front Right Engine Mount Bracket 9 Nut - Rear Mount Pad Assembly and Rear
Mount Bracket
3 Front Left Engine Mount
10 Nut - Front Engine Mount and Front Engine
4 Front Right Engine Mount
Mount Bracket
5 Rear Engine Mount
11 Bolt - Front Engine Mount Bracket and Engine
6 Rear Engine Mount Bracket
12 Bolt - Front Engine Mount Bracket and Engine
7 Nut - Rear Mount Pad Assembly and
13 Bolt - Front Engine Mount to Frame Plane
Crossmember
8-4
Symptoms Check and Troubleshooting
Fuel level sensor failure Check the sliding resistor of fuel level sensor for contamination, corrosion or poor contact;
replace the fuel sensor components
The swing arm of the fuel float is deformed, failed and damaged during the transportation
and installation; replace the fuel
Too much noise in the fuel Check the strainer for blockage; clean the strainer
pump
Check the fuel pump for wear and check whether its service life expires; replace with
Fuel pump assembly does Check the power connector of the fuel pump for looseness or poor contact; use a
not supply oil multimeter to check whether the
Check the carbon brush/commutator of the fuel pump for excessive wear or failure;
replace the fuel pump assembly
The negative and positive cables of the fuel pump are fractured; replace the negative and
positive cables of the fuel
Fuel pump leaks Check the clamp at the joint of fuel pump pipe for looseness or existence of gap causing
the fuel to leak into the fuel tank, and check whether the pipe
Broken connecting pipes of the fuel pump assembly caused the leak of fuel pump; replace
the rubber pipe and/or the corrugated pipe.
8-5
Service Guide
Note：Place a piece of absorbent cloth around the
joint of high-pressure fuel pump low-pressure
fuel pipe and underfloor fuel pipeline to collect
the overflowing fuel. Disconnect the negative
battery cable and keep the fuel pipe connector
disconnected for 5 seconds before installing or
removing any fuel system, to release the fuel
pressure for the next repair work.
Warning：Fuel vapor is highly flammable and can
be explosive and toxic in narrow spaces. Fire
extinguishers, such as foam, carbon dioxide, gas DS070002
or powder fire extinguishers, must be located in
4 Loosen hoop A and quick joint B connecting the
the vicinity while operating or draining fuel.
fuel tank and the rubber fuel filler pipe
Warning：Fuel leak is unavoidable in this
operation. Ensure that necessary measures have
been taken to prevent fires and explosion.
Replacement of Fuel Tank Assembly B
Removal
1 Place the vehicle on the lifting platform and lift it
to a certain height.
A
2 Disconnect the quick joint between the fuel filter
and the fuel supply pipe (filter to engine) and the
quick joint between the desorption pipe (canister
to engine) and the canister desorption pipe.
Note：Place a container at the joint to collect the
DS070003
spilled fluid.
5 Remove the bolts and nuts fixing the front and
rear fuel tank straps to the body.
DS070001
3 Loosen the clamp of the connector between the DS070004

fuel filler pipe and the fuel tank pipe.
8-6
6 Disconnect the connecting harness of the fuel Replacement of Fuel Pump Level Sensor
pump. Float
1 Remove the fuel tank assembly (Refer to
Replacement of Fuel Tank Assembly).
Installation
2 Disconnect the fuel supply pipe (fuel tank to
1 Connect the connecting harness of the fuel filter) and the fuel return pipe (filter to fuel tank)
pump. from the fuel pump.
2 Install the front and rear straps to the fixed
positions on the fuel tank, secure them to the
body with bolts and nuts, and tighten the bolts
and nuts to 40 ± 5N.m.
3 Connect the hoop and the quick joint connecting
the fuel tank and the rubber fuel filler pipe.
4 Connect the clamp of the connector between the
fuel filler pipe and the fuel tank pipe.
5 Connect the quick joint between the fuel filter
and the fuel supply pipe (filter to engine) and the
quick joint between the desorption pipe (canister
to engine) and the canister desorption pipe.
DS070005
3 Loosen the threaded ring securing the fuel pump

and remove the fuel pump.
DS070014
4 Hold the float rod with one hand, insert the flat-
bladed screwdriver in the gap between the
sensor frame and the float rod with the other
hand, then pry-out the float rod forcibly.
8-7
parts of the rod during the press-in process for

protecting it from deformation.
DS070006
5 Check whether the slot of sensor frame is

broken; if yes, replace the level sensor. DS070010
3 The standard state of the pressed float rod is as

shown in the picture. Check whether the slot of
sensor frame is broken again; if yes, replace the
level sensor.
DS070008
Installation
1 Insert the float rod to slot A and slot B of the
sensor frame. DS070011
4 Rotate the float rod by hand in the full range of

stroke to confirm that the rod can rotate normally,
B without any obvious resistance during the
rotation.
DS070009
2 Press the float rod into the slot by left and right
thumbs; try to avoid applying force to the other
8-8
Replacement of Fuel Pump Level Sensor

Removal
1 Press the leaf spring of harness terminal gently The operating principle of the fuel pump is: after
with the flat-bladed screwdriver, and pull the rear energized, the permanent magnet motor will drive the
end of the harness to remove two harness pump to rotate, through which the fuel will be sucked in
terminals of the level sensor. from the inlet, flow through the inside of the electric fuel
pump and then be pressed out of the outlet, to provide
fuel for the fuel system.
The fuel pump is located on the oil pan of the fuel tank
which is provided with an oil sump formed by local
subsidence. When it operates, the fuel pump sucks oil
from the oil sump, and the oil outlet is connected with the
external oil supply pipeline via the oil-conveying pipe by
passing through the fuel tank cap.
The method to judge whether the electric fuel pump is

good or broken:
DS070012 1 Before the fuel pump breaks down, there will be

much more noises than normal, so it is easy to
2 Press the tab of the level sensor with the flat-
make the judgment through the sound.
bladed screwdriver, then remove the sensor by
hand. 2 Check if the armature winding resistance of the
electric fuel pump is within 10-20 Ω . If the value
Note：DO NOT damage the fuel tank.
is too high or too low, the armature winding of
electric fuel pump may suffer a short circuit, poor
contact of brush or winding open circuit failure.
3 Check the oil-conveying capacity of the electric

fuel pump: remove the oil outlet pipe of the
electric fuel pump, supply a voltage of over 11.5V
to the binding post of the pump, collect the fuel at
the outlet with a measuring cup; no less than 0.6
L fuel should be conveyed within 30 seconds,
otherwise the safety valve of the pump may have
failures.
The electric fuel pump is not repairable; once it is

determined to be damaged, the pump must be replaced.
DS070013
Switch off the main power during the removal and the
installation of the electric fuel pump.
Installation
1 Take a new level sensor, insert it into the slot of The service life (how many kilometers or how many
the fuel tank, and press it in place by hand. years) of the fuel pump is often asked by the vehicle
Note：The tab of the level sensor should bounce owners. In fact, there's no specified service life or
and lock appropriately. maintenance mileage for a fuel pump, for its service life
2 Connect 2 harness terminals of the level sensor. depends on various factors such as the quality of fuel, the
8-9
habit of refueling and the condition of vehicle failures.

The owners shall pay attention to the following:
1 High level fuel impurities will generally shorten

the service life of the fuel pump, thus, try to
refuel the vehicle with good-quality fuel. But
remember, higher RON does not mean better
fuel quality!
2 The fuel filter (gasoline) shall be inspected and
maintained regularly and the oil lines shall be
cleaned regularly.
8-10
Engine Fuel System SC20M163Q5A
Specification

Bolt - High-pressure Fuel Pump 33 ± 3 N.m
Nut - High-pressure Fuel Pump Timing Pulley
80 ± 1 N.m
Intermediate Flange
Bolt - High-pressure Fuel Pump Timing Pulley 30 ± 1 N.m
Nut - High-pressure Fuel Pipe to High-pressure
35 ± 3 N.m
Fuel Pump
Bolt - Fuel Injector Clamp 33 ± 3 N.m
High Pressure Fuel Pipe 27 ± 3 N.m
Nut - High-pressure Fuel Pipe to High-pressure
27 ± 3 N.m
Fuel Rail
Bolt - Fuel Filler Pipe 23 ± 2 N.m
Bolt - Fuel Filter 23 ± 2 N.m
Clamp - Urea Nozzle 4.6 ± 0.5 N.m
Bolt - Urea Filler Pipe Fixing 1.2 ± 0.2 N.m
Bolt - Urea Pipe Fixing Clamp 9 ± 1 N.m
Nut - Urea Pump Protective Housing 2 ± 0.5 N.m
Bolt - Urea Tank 40 ± 0.5 N.m
Bolt - Injection Control Module 9 ± 1 N.m
Bolt - Fuel Tank 40 ± 5 N.m
Bolt - Fuel Filter Assembly 22 ± 2 N.m
Parameters
Fuel System
Injection system High-pressure Common Rail Direct Diesel Injection System
High-pressure Pump CP4H1/BOSCH
ECM MD1CS089
Fuel Injector CRI2-20/BOSCH
5-1
Layout
Fuel System
2
6
8
7
3 5
11
12
10
S02030002
1 Fuel Injector Fuel Return Pipe 7 Cylinder 2 High-pressure Fuel Pipe

2 Fuel Injector Clamp (Qty.: 2) 8 Cylinder 1 High-pressure Fuel Pipe
3 Fuel Injector Assembly (Qty.: 4) 9 Fuel Return Manifold Assembly
4 Cylinder 4 High-pressure Fuel Pipe 10 High-pressure Fuel Pump
5 Cylinder 3 High-pressure Fuel Pipe 11 High Pressure Fuel Rail
High-pressure Fuel Pipe - High-pres-
6 12 Water-air Intercooler Bracket
sure Fuel Pump to Fuel Rail
5-2
Check and Confirmation

1 Identify the problems, and carry out the
2 Check the appearance for obvious mechanical or
electrical damages.
3 Solve the found problems before carrying out the
next check.
4 If the causes can't be identified visually, identify
5-3
Symptom Table
? Excessive bending of fuel ? Replace the damaged component, and
hose, crack and damage of reasonably arrange and install the fuel
fuel pipe and components, pipe.
and fuel leakage at the
connection can cause low fuel
Low fuel pressure pressure
? Fuel filter dirty and blocked ? Replace the fuel pump fuel injector.
? Fuel pump injector failure ? Replace the fuel pump fuel injector.
? High-pressure fuel pump ? Replace the high-pressure fuel pump
assembly failure assembly.
? Direct fuel leakage ? Check or replace the damaged
component.
? Water temperature sensor ? Replace the water temperature sensor.
failure, and fuel injection
correction deviation
? Accelerator pedal position ? Replace the accelerator pedal position
High engine fuel con- sensor failure sensor.
sumption ? High fuel system pressure ? Replace the high-pressure fuel pump/
fuel rail.
? Intake pressure temperature ? Replace the intake pressure
sensor failure, and fuel temperature sensor.
injection correction deviation
? Fuel injector leakage, and ? Clean or replace the fuel injector.
poor atomization
5-4
Service Guide
High-pressure Fuel Pump Replacement

Removal
Warning: Ensure that the fuel pressure has been
reduced to zero, and fuel is at room temperature.
Warning: Perform the cleaning procedures before 1
maintaining the fuel injection system parts.
1 Remove the crankshaft shock absorber. Refer to 2

S02033017
2 Remove the belt idler assembly. Refer to “Belt
Idler Assembly Replacement” . 7 Remove the timing cover. Refer to “Timing Cover
3 Remove the high-pressure EGR assembly. Refer Replacement” .
. 8 Remove the timing drive belt, refer to “Timing
Drive Belt Replacement” .
4 Disconnect the high-pressure fuel pump harness
9 Remove the high-pressure fuel pump timing pulley
connector.
intermediate flange, refer to “High-pressure Fuel
Pump Timing Pulley Intermediate Flange
Replacement” .
10 Remove 3 bolts fixing the high-pressure fuel pump
to the accessory bracket.
11 Remove the high-pressure fuel pump (1).
S02033016
5 Disconnect the fuel return manifold assembly (1).

6 Remove the hollow nut (2) fixing the high-pressure
fuel pipe to the high-pressure fuel pump.
Warning: Completely clean the connection before
S02033026
loosening the high-pressure fuel pipe nut.
Warning: Ensure that all fuel pipe openings have Installation
been sealed by hole plugs. 1 Fix the high-pressure fuel pump to the accessory
2 Install the high-pressure fuel pump timing pulley

intermediate flange, refer to “High-pressure Fuel
Pump Timing Pulley Intermediate Flange
Replacement” .
5-5
4 Install the timing cover. Refer to “Timing Cover High-pressure Fuel Rail Replacement
Replacement” . Removal
5 Fix the high-pressure fuel pipe to the high- Warning: Ensure that the fuel pressure has been
pressure fuel pump, install hollow nuts, tighten reduced to zero, and fuel is at room temperature.
Note: Perform the cleaning procedures before
6 Connect the fuel return manifold assembly.
7 Connect the high-pressure fuel pump harness
connector. 1 Disconnect the high-pressure fuel rail temperature
8 Install the high-pressure EGR assembly. Refer to sensor harness connector (1), the high-
temperature fuel rail pressure sensor harness
“High-pressure EGR Assembly Replacement” .
connector (2).
9 Install the belt idler assembly. Refer to “Belt Idler
1
2
S02033028
2 Disconnect the fuel return manifold assembly.
S02033029
3 Remove the hollow nut fixing the Cylinder 1-4

high-pressure fuel pipes to the high-pressure fuel
rail.
Note: Ensure that all fuel pipe openings have been
sealed by hole plugs.
Note: Completely clean the connection before
loosening the high-pressure fuel pipe nut.
4 Remove the high-pressure fuel pipes (1), (2), (3)
and (4).
5-6
Fuel Injector Return Pipe Replacement

Removal
1 2 3 maintaining the fuel injection system parts.
4
1 If equipped, remove the vacuum switching valve
and control valve.
2 Disconnect the fuel injector return pipe and the
manifold.
S02033030
5 Remove 1 hollow nut (1) fixing the high-pressure

fuel pipe to the high-pressure fuel rail.
6 Remove 2 bolts (2) fixing the high-pressure fuel
rail to the water-air intercooler bracket.
7 Remove the high-pressure fuel rail (3).
S02033032
1
3 Loosen the clips fixing the fuel injector return pipe
to the fuel injector.
4 Remove the fuel injector return pipe (1).
2 2
3
S02033031
Installation
1 Install the high-pressure fuel rail.
2 Fix the high-pressure fuel rail to the water-air
1
intercooler bracket, install 2 bolts, tighten them to
3 Fix the high-pressure fuel pipe to the high- S02033033
pressure fuel rail, install 1 hollow nut, tighten it to
Installation
4 Fix the Cylinder 1-4 high-pressure fuel pipes to the 1 Connect the fuel injector return pipe and the return
high-pressure fuel rail, install 4 hollow nuts, tighten manifold.
them to 27 ± 3 N.m, and check the torque. 2 Fix the fuel injector return pipe to the fuel injector,
5 Connect the fuel return manifold assembly. and install the clips.
6 Connect the high-pressure fuel rail temperature Note: Check if the lock washer is pressed in place.
sensor harness connector and the high-pressure 3 If equipped, install the vacuum switching valve and
fuel rail pressure sensor harness connector. control valve.
5-7
Fuel Injector Assembly Replacement 3 Install the cylinder high-pressure fuel pipe. Refer
Removal to “Cylinder High-pressure Fuel Pipe
Note: Ensure that the fuel pressure has been Replacement” .
reduced to zero, and fuel is at room temperature. 4 Install the fuel injector return pipe. Refer to “Fuel
Injector Return Pipe Replacement” .
5 Connect the fuel injector assembly harness
connector.
Note: Plug all fuel pipes with plugs immediately 6 Connect the negative battery cable.
after they are disconnected.

connector.
3 Remove the fuel injector return pipe. Refer to
“Fuel Injector Return Pipe Replacement” .
4 Remove the cylinder high-pressure fuel pipe.
Refer to “Cylinder High-pressure Fuel Pipe
Replacement” .
5 Remove 2 bolts fixing the fuel injector clamp to the
cylinder head.
6 Remove the fuel injector clamp (1) and the fuel
injector (2) with the special tool C00189316.
Note: If required, the long slide hammer of other
special tools may be used.
1
2
1
2
S02033036
Installation
Note: As the fuel injector is manufactured
precisely, when operating on these parts, it must
be under extreme cleaning condition, and provide
a hole plug for any hole or pipe.
1 Check and ensure that the seal ring of the fuel

injector assembly is not detached or damaged.
2 Fix the fuel injector and the fuel injector clamp to
the cylinder head, install 2 bolts, tighten them to 33
5-8
Cylinder High-pressure Fuel Pipe High-pressure Fuel Pump to Fuel Rail High-
Replacement pressure Fuel Pipe Replacement
Removal Removal
Warning: Ensure that the fuel pressure has been Warning: Ensure that the fuel pressure has been
reduced to zero, and fuel is at room temperature. reduced to zero, and fuel is at room temperature.
Note: Perform the cleaning procedures before Note: Perform the cleaning procedures before
maintaining the fuel injection system parts. maintaining the fuel injection system parts.
Note: Plug all fuel pipes with plugs immediately Note: Plug all fuel pipes with plugs immediately
after they are disconnected. after they are disconnected.
1 Remove the fuel injector harness. 1 Remove the nut (1) fixing the high-pressure fuel
2 Remove the cylinder high-pressure fuel pipe pipe to the high-pressure fuel rail.
hollow nut.
3 Remove and discard the Cylinder 1 high-pressure
fuel pipe (4), Cylinder 2 high-pressure fuel pipe
(3), Cylinder 3 high-pressure fuel pipe (2) and 1
Cylinder 4 high-pressure fuel pipe (1).
1 2 3
4
S02033037
2 Remove the hollow nut (1) fixing the high-pressure

fuel pipe to the high-pressure fuel pump.
3 Remove 1 bolt (2) fixing the high-pressure fuel
pipe to the water-air intercooler bracket.
S02033030
4 Remove and discard the high-pressure fuel pipe
Installation (3).
1 Install a new high-pressure fuel pipe.
2 Fix the Cylinder 1 high-pressure fuel pipe, Cylinder
2 high-pressure fuel pipe, Cylinder 3 high-
pressure fuel pipe and Cylinder 4 high-pressure
fuel pipe to the high-pressure fuel rail, install the 3 2
hollow nuts retaining the cylinder high-pressure
fuel pipes, tighten them to 27 ± 3 N.m, and check
the torque.
3 Install the fuel injector harness.
1
S02033038
Installation
1 Install a new high-pressure fuel pipe.
2 Fix the high-pressure fuel pipe to the high-
pressure fuel pump, install hollow nuts, tighten
5-9
3 Fix the high-pressure fuel pipe to the water-air Fuel Return Manifold Assembly Replacement
intercooler bracket, install 1 bolt, tighten it to 11 ± Removal
4 Fix the high-pressure fuel pipe to the high- maintaining the fuel injection system parts.
pressure fuel rail, install the nut, tighten it to 27 ±
3 N.m, and check the torque. 1 Loosen the fuel return manifold assembly quick
coupling (1).
2 Remove the clip (2) fixing the fuel return manifold
to the bracket.
3 Remove the fuel return manifold assembly (3).
1
2
2 3
1
S02033039
Installation
1 Install the fuel return manifold assembly.
2 Connect the fuel return manifold assembly quick
coupling.
3 Install the clip fixing the fuel return manifold to the
bracket.
4 Connect the fuel injector return pipe.
5-10
Fuel Filter Assembly Replacement Fuel Filter Element Replacement

Removal Removal
1 Raise the vehicle. 1 Raise the vehicle.
2 Disconnect the fuel pipe from the fuel filter 2 Remove the fuel filter cylinder body (1) from the
assembly. fuel filter integrated sensor assembly (4).
3 Remove the fuel filter assembly bolt (1). 3 Remove the seal ring (2) and fuel filter element (3)
4 Remove the fuel filter assembly (2). from the fuel filter cylinder body.
2
3
1 1
S02033073 S02033059
1 Install the fuel filter assembly. 1 Install a new seal ring to the cylinder body.
2 Install the fuel filter assembly bolt, tighten it to 22 2 Install a new fuel filter element.
± 2 N.m, and check the torque. Note: The fuel filter element and seal ring shall be
3 Connect the fuel pipe to the fuel filter assembly. replaced together.
4 Lower the vehicle. 3 Install the fuel filter cylinder body to the fuel filter
integrated sensor assembly.
Lower the vehicle.
5-11
Safety Precautions
Cautions Before Fuel System Operation
Fuel system
1 Disconnect the negative battery cable before
The engine uses the high-pressure common rail. High-
checking and maintaining the fuel system.
pressure common rail EFI refers to a fuel supply method in
2 Release the pressure of the fuel pipe before
which the injection pressure generation and the injection
removing the fuel pipe; put the discharged diesel
process are completely separated from each other in a
in a suitable container when removing.
closed loop system composed of a high-pressure fuel
3 Fuel is flammable. When operating the fuel
pump, a pressure sensor and an electronic control unit
system, keep cigarettes, open fires, indicator
(ECU). lights, arcing equipment and switches away from
the workplace, and provide the ventilation
It delivers the high-pressure fuel to the common rail via the
equipment in the workplace to avoid personal
high-pressure fuel pump to achieve the precise control by injury or death.
the fuel pressure in the common rail, so that the high-
4 The high-pressure fuel pipe and the fuel rail of the
pressure fuel pipe pressure is independent of the engine fuel pump contain high-pressure fuel. In order to
speed, greatly reducing the degree to which the diesel avoid personal injury, do not loosen any fuel pipe
engine fuel supply pressure varies with the engine speed. joint when the engine is running.
5 Keep fuel away from rubber or leather parts.
The common rail technology refers to a fuel supply method
in which the injection pressure generation and the injection 6 Manufacture diesel injection equipment according
to the extremely precision tolerance and
process are completely separated from each other in a
clearance. Therefore, the cleaning work
closed loop system composed of a high-pressure fuel
environment is very important when operating the
pump, a pressure sensor and an ECU. It delivers the high- fuel system. Seal all openings with special covers.
pressure fuel to the common rail via the high-pressure fuel
7 Check and confirm no dirt or impurities around the
pump to achieve the precise control by the fuel pressure in fuel pipe joint before disconnecting the fuel system
the common rail, so that the high-pressure fuel pipe pipe; if yes, clean it up because dirt or impurities
pressure is independent of the engine speed, greatly may damage the fuel system or the engine.
reducing the degree to which the diesel engine fuel supply 8 Do not allow the cleanser to contact with rubber or
pressure varies with the engine speed. Therefore, the plastic parts, which may damage the tightness of
defects of the conventional diesel engine are reduced. the fuel system.
ECU is used to control the fuel injection amount of the fuel 9 Do not excessively bend or twist the fuel system
injector, which depends on the opening time of the fuel rail fuel pipe.
(common rail) pressure and the solenoid valve. 10 Ensure no damage to the fuel pipe joints before
connecting the fuel system pipes; if damaged or
The fuel injection device uses the engine control module as cracked, replace the fuel pipe assembly; ensure
the control center to accurately control the fuel injection no dirt on the fuel pipe connection surface.
amount and time using the engine working parameters 11 Wear eye protection equipment when working on
provided by the sensors installed on the engine according or near the fuel-related parts. Failure to follow the
to the control procedures set in the computer through the instructions may cause personal injury.
control of the fuel injector, so that the engine can obtain the 12 Put all parts removed from the vehicle on the
best concentration of mixed gas under the working cotton-free and non-velvet materials.
conditions, which can realize start-up rich, warm-up rich, 13 Active metals such as zinc and copper
acceleration rich, full-load rich, and deceleration lean, manganese are easily dissolved in the diesel,
forced fuel cut-off and automatic idle speed control, etc. As coking occurs in the fuel injector due to high
temperature, blocking the orifice causing the
a result, the engine can obtain good fuel economy and
power reduction as a result of fuel amount decline.
emission, and the vehicle's performance is also improved.
Therefore, there shall be no active metal materials
5-12
such as zinc, copper and manganese in the high-

pressure common rail fuel system fuel passage.
14 Keep the fuel system clean, without impurities
such as rust and welding slag; or otherwise, the
fuel circuit may be blocked, the engine may be
automatically turned off, and in severe cases, the
expensive common rail system components may
be damaged.
Cautions in Fuel System Operation
1 Wear fuel-resistant gloves and goggles to

minimize your skin contact with fuel.
2 It is forbidden to have open fires, sparks and
electrical equipment that are prone to sparks in the
workplace.
3 In order to avoid wear the fuel pipe, be careful
when installing to keep sufficient distance from all
moving or hot parts, and do not excessively bend
the pipe.
5-13
Special Tool
SN. Tool Number/ Illustration

Description
C00189316
1 Fuel Injector
Remover
C00189316
5-14
Intake and Exhaust System
Specification
Torque
Self-tapping screw - mass air flow sensor to air filter 2.5 ± 0.5
assembly
Nut - intake pipe of air filter to body 5±1

Bolt - air filter assembly 9±1
Oxygen sensor 50 ± 5
Clamp - catalyst to supercharger 10 ± 1
Clamp - catalyst assembly Pre-tighten 2 bolts to 12 ± 3N.m and tighten again to 25 ±
3N.m respectively
Bolt - pressure pipeline to the retaining bracket of 9±1

differential pressure pipeline
Bolt - pressure sensor to sensor bracket 9±1

Screw - air filter upper cover to lower cover 1.5 ± 0.5
9-1
Layout
Exhaust System Layout
4
6
ES020028
1 Catalyst assembly (China IV) 4 Clamp - catalyst to supercharger

2 Catalyst assembly (China V) 5 Clamp - catalyst assembly
3 Exhaust muffler assembly 6 Oxygen sensor (China V)
9-2
Intake System Layout
ES020027
1 Air filter intake pipe assembly 3 Mass air flow meter

2 Air filter assembly 4 Air filter to turbocharger pipeline assembly
9-3
Replacement of Mass Air Flow Meter Replacement of Air Filter Intake Passage
Assembly
Removal
1 Unscrew 2 screws from the mass air flow meter Removal
(1). 1 Take down the fender.
2 Remove the mass air flow meter from the air
filter (2).
ES020014
2 Unscrew the bolt securing the air filter intake

ES020013
passage assembly.
Installation
attention to the following precautions:
—Tighten the screws securing mass air flow meter to air
filter assembly to 2.5 ± 0.5N.m.
ES020015
Installation
9-4
Replacement of Air Filter Assembly Replacement of Catalyst Assembly (China IV)

Removal Removal
1 Remove the air filter intake pipe. (Refer to 1 Loosen the clamp connecting catalyst assembly
Removal of Air Filter Intake Pipe). and engine supercharger.
2 Loosen the clamp of air filter exhaust pipe. 2 Loosen the clamp connecting catalyst assembly
and muffler.
ES020016
ES020017
3 Separate the air filter and mass air flow meter
(Refer to Replacement of Mass Air Flow Meter). 3 Take down the catalyst assembly.
4 Remove 3 bolts securing the air filter to the body.
Installation
Installation 1 Installation is the reverse of removal. Pay
attention to the torques of all clamps.
—Tighten the bolt securing the air filter to body to 9 ±
1N.m.
Note：Removal of air filter element only requires

loosening a row of screws on air filter assembly
upper cover.
9-5
Replacement of Catalyst Assembly (China V) Replacement of Muffler Assembly

Removal Removal
1 Pull out the temperature sensor harness 1 Remove the catalyst assembly (Refer to
connector from the front catalyst assembly. Replacement of Catalyst Assembly).
2 Pull out the oxygen sensor harness connector 2 Take down the master muffler assembly.
from the front catalyst assembly.
3 Pull out the harness connected to the differential

pressure sensor.
4 Loosen the clamp connecting catalyst assembly

and engine supercharger.
5 Loosen the clamp connecting catalyst assembly

and muffler.
6 Take down the catalyst assembly.
ES020019
Installation
ES020018
Installation
9-6
Catalyst
The catalyst converter is equipped with a catalytic
"partition brick", which can significantly reduce the
emissions of diesel engine.
It is obvious why installing a catalyst converter is

important. The toxic gas emitted from the exhaust system
of diesel engine shall not be released into the
atmosphere until its toxicity is reduced and converted. As
shown above, the catalyst converts nitrogen oxides
(NOX), carbon monoxide (CO) and hydrocarbons (HC)
into less harmful nitrogen (N2), carbon dioxide (CO2) and
water (H2O). If the catalyst converter fails, the vehicle will
not pass any emission inspection, including annual
inspection.
N2 CO2
H 2O
NO x
CO
HC
The catalyst converter is not widely known due to its

expensive price. Its "partition brick" is mainly designed
into a ceramic honeycomb structure with platinum,
palladium and other valuable metal catalytic materials
coated on the surface. It is more likely to be damaged
due to misuse compared with muffler (equipped with
baffle to reduce exhaust noise). Catalyst converter may
get failure for many reasons ranging from improper
operation to incorrect air-fuel ratio.
Due to its special design and material, the catalyst

converter is easy to be damaged if not properly handled.
Please handle with care to avoid collision; dropping or
collision will cause damage to or dislocation of the
"partition brick".
9-7
Catalyst converter may have the following problems during operation:
Problems Possible Causes
Click sounds can be heard during use Improper handling

"Partition brick" fractured
"Partition brick" melted
Entry of foreign object/turbocharger failure
Power consumption "Partition brick" blocked
Noise "Partition brick" fractured
High emission No conversion
There are many factors that possibly cause catalyst failure in operation, such as:
·Long-time misfire of engine
·Incorrect air-fuel ratio
·Fuel additive
·Improper fuel, such as biodiesel, gasoline, etc
·Carbon deposit
—Excessive engine oil consumption
—Intake air flow blocked
—Excessive fuel oil supply
Note：The catalyst acts efficiently only at high temperature, therefore, it will be installed close to the
engine to get high temperature from the heat radiated by the engine.
9-8
Engine Intake/Exhaust System 20L4E
Specification
Torque
Application Torque Value (Nm)
Bolt - Air Filter Assembly 9±1

Nut - Air Filter Inlet Pipe to Body 5±1
Bolt - Air Filter Outlet Pipe Bracket 40 ± 3
Nut - Turbocharger and Exhaust Pipe 45 ± 5
Nut - Muffler Assembly 45 ± 5
Nut - Exhaust System Heat Shield 9±1
Bolt - Front Exhaust Pipe Assembly Bracket to Engine 22 ± 2
Assembly
Bolt - Front Exhaust Pipe Assembly Bracket to Engine 45 ± 5

Assembly
10-1
Layout
Layout
4
4
13
1
5
11
8
12
7
12 3
10
ES020048
1 Air Filter Assembly 8 Air Flow Sensor

2 Air Filter Intake Passage Assembly 9 Nut - Air Filter Inlet Pipe to Body
3 Air Filter Element 10 Bolt - Air Filter Assembly
4 Bolt - Air Filter Outlet Pipe Bracket 11 Bracket - Air Filter Outlet Pipe
5 Upper Air Filter 12 Self-tapping Screw - Air Flow Sensor to Air Filter
Assembly
6 Air Filter Outlet Pipe Assembly
13 Air Filter Outlet Pipe Shock Pad
7 Crankcase Vent Pipe
10-2
Layout
4
5
6
1
12
7
8
14
15 9 2
13
3
16 10
19 11
19
20 17
18
19
ES020049
1 Seal Ring - Catalytic Converter to Turbocharger 11 Gasket - Catalytic Converter Assembly

2 Oxygen Sensor 12 Clamp - Catalytic Converter Assembly
3 Strip - Front Oxygen Sensor 13 Rear Catalytic Converter Assembly
4 Nut - Turbocharger and Exhaust Pipe 14 Rubber Lug - Frame to Exhaust System Hot End
5 Exhaust System Heat Shield 15 Oxygen Sensor
6 Nut - Exhaust System Heat Shield 16 Nut - Muffler Assembly
7 Bolt - Front Exhaust Pipe Assembly Bracket to 17 Gasket - Catalytic Converter Assembly and
Engine Assembly Muffler Assembly
8 Bolt - Front Exhaust Pipe Assembly Bracket to 18 Exhaust Muffler Assembly
Engine Assembly
19 Rubber Lug - Frame to Exhaust System Primary
9 Front Catalytic Converter Assembly Muffler
10 Rubber Lug - Frame to Exhaust System Hot End 20 Rubber Lug - Frame to Exhaust System Primary
Muffler
10-3
Replacement of Air Flow Meter Replacement of Air Filter Intake Passage

Removal Assembly
1 Remove 2 screws on the air flow meter 2. Removal
2 Remove the air flow meter from the air filter. 1 Remove the fender.
GS030166
GS030165
2 Remove the nut securing the air filter intake

passage assembly.
Installation
GS030167
Installation
- Torque of air filter inlet pipe to body nut: 5 ± 1N.m
10-4
Replacement of Air Filter Assembly Replacement of Air Filter Exhaust Passage

Removal Assembly
1 Remove the air filter inlet pipe (Refer to Removal Removal

of Air Filter Inlet Pipe). 1 Remove 2 clamps connecting the air filter outlet
2 Loosen the clamp of air filter outlet pipe. pipe assembly (1) respectively to the air filter (2)
and engine assembly, and disconnect the
breather pipe (4) from the engine assembly to
separate the air filter outlet pipe assembly from
the air flow meter and engine assembly.
GS030168
3 Disconnect the air filter from the air flow meter

(Refer to Replacement of Air Flow Meter).
GS030169
4 Remove 3 bolts fixing the air filter to the body.
2 Remove the air filter outlet pipe assembly from
the bracket.
Installation
- Tighten the bolts fixing the air filter to the body to 9 ±
1Nm.
GS030170
Installation
- Torque of air filter outlet pipe bracket bolt: 40 ± 3N.m
10-5
3 Remove 2 bolts (4) fixing the front catalytic

Replacement of Front Catalytic Converter converter assembly (1) to the engine bracket.
Assembly
Removal
1 Remove the turbocharger heat shield (Refer to
Removal of Turbocharger Heat Shield).
GS030173
4 Remove 3 nuts (3) fixing the front catalytic

converter assembly (1) to the engine
GS030171 turbocharger, and discard the gasket (2).
2 Remove the front oxygen sensor.
GS030174
GS030172 5 Loosen the clamp connecting the front catalytic

converter assembly and the rear catalytic
converter assembly, and discard the gasket.
GS030175
10-6
6 Remove the catalytic converter assembly from

Replacement of Exhaust Pipe Assembly
the exhaust pipe rubber hook.
Bracket
Removal
1 Remove the catalytic converter assembly from
the engine (Refer to Removal and Installation of
Catalytic Converter Assembly).
2 Remove 2 bolts fixing the front exhaust pipe
assembly bracket to the engine assembly.
GS030176
Installation
- Tighten the nut fixing the catalytic converter assembly to
the engine turbocharger to 45 ± 5N.m
GS030177
- Tighten the bolt fixing the front catalytic converter
assembly to the engine bracket to 45 ± 5N.m
- Tighten the catalytic converter clamp to 8 ± 0.3Nm Installation

- Tighten the bolts fixing the front exhaust pipe assembly
bracket to the engine assembly to 22 ± 2N.m (Bolt 1)
and to 45 ± 5N.m (Bolt 2).
10-7
3 Loosen 2 nuts connecting the rear catalytic

Replacement of Rear Catalytic Converter converter assembly to the front muffler
Assembly assembly, and discard the gasket.
Removal
1 Loosen the clamp connecting the front catalytic
converter assembly and the rear catalytic
ES020052
4 Remove the rear catalytic converter assembly

from the rubber hook.
ES020050
2 Remove the rear oxygen sensor from the rear

catalytic converter assembly. Installation
- Tighten the catalytic converter clamp to 8 ± 0.3Nm
- Tighten the muffler assembly nut to 45 ± 5N.m
ES020051
10-8
Replacement of Muffler Assembly

Removal
1 Loosen 2 nuts connecting the rear catalytic
converter assembly to the muffler assembly, and
discard the gasket.
ES020052
2 Remove the front muffler assembly from the

rubber hook.
ES020053
Installation
- Tighten the catalytic converter clamp to 8 ± 0.3Nm
- Tighten the muffler assembly nut to 45 ± 5N.m
10-9
collision will cause damage to or dislocation of the"

partition brick".
Catalyst
The catalytic converter is equipped with a catalytic
"partition brick" which can significantly reduce the amount
of pollution produced by a diesel engine.
The importance of installing a catalytic converter is

obvious. Toxic gases emitted from the exhaust system of
diesel engine shall not be released into the atmosphere
until its toxicity is converted and reduced. As shown
above, the catalyst converts nitrogen oxides (NOx),
carbon monoxide (CO) and hydrocarbons (HC) into less
harmful nitrogen (N?), carbon dioxide (CO?) and water
(H?O). If the catalytic converter fails, the vehicle will not
pass any emission inspection, including MOT test
(Ministry of Transport, or simply MOT).
N2 CO2
H 2O
NO x
CO
HC
The catalytic converter is not widely known due to its

expensive cost. The "partition brick" is basically of a
ceramic honeycomb structure with catalytic materials
such as platinum, palladium and other valuable metals
coated on the surface. It is more likely to be damaged
due to misuse compared with the muffler (equipped with
baffle to reduce exhaust noise). A catalytic converter may
get failure for many reasons ranging from improper
operation to incorrect air-fuel ratio.
Due to its special design and material, the catalytic

converter is easy to be damaged if not properly handled.
Please handle it with care to avoid collision; dropping or
10-10
The catalytic converter may have the following problems during the operation:
Problem Possible Causes
Click sounds can be heard during use Improper handling

"Partition brick" fractured
"Partition brick" melted
Entry of foreign object/turbocharger failure
Power consumption Restriction
Noise "Partition brick" fractured
High emission No conversion
Many factors may cause catalyst failure during the operation, such as:
·Long-time misfire of engine
·Incorrect air-fuel ratio
·Fuel additive
·Improper fuel, such as biodiesel, gasoline, etc
·Carbon deposit
– Excessive engine oil consumption
– Intake air flow blocked
– Excessive fuel supply
Note：The catalyst acts efficiently only at high temperature, therefore, it is installed close to the engine to
get high temperature from the heat radiated by the engine.
10-11
Air Intake System Exhaust System

The parts assembly acting to guide the air or air mixture The parts assembly acting to guide burnt gases away
into the engine cylinder is called an engine air intake from the cylinder is called an engine exhaust system.
system.
The exhaust system is composed of a series of steel
The air intake system is composed of air flow sensor, air structure components (catalytic converter assembly and
filter, turbocharger and various breather pipelines. Air exhaust muffler assembly). The catalytic converter is
flowing through the air filter enters the turbocharger via basically of a ceramic honeycomb structure with catalytic
the pipeline, producing high-temperature high-pressure materials such as platinum, palladium and other precious
gases which will be pressed into the intercooler and then metals coated on the surface. Its function is to convert
enter the intake pipe via the pipeline. The air filter NOx, CO and HC into less harmful N?, CO? and H?O.
composed of upper/lower sealing elements, filter The catalyst acts efficiently only at high temperature,
element, side intake dust covers, etc. provides clean air therefore, it is installed close to the engine to get high
for the engine. temperature from the heat radiated by the engine. There
are baffles and sound-absorbing devices installed in the
·Air filter: a device for clearing away particulate impurities
exhaust muffler, through which the energy of exhaust
in the air. It consists of a filter element and a housing. The
gases will be decreased owing to the friction against
essential requirements for an air filter is to be of high
sound-absorbing materials such as fiberglass, steel fiber,
filtration efficiency, low flow resistance and the capacity to
etc. and meantime, exhaust vibration and exhaust noises
operate continuously for a long time, without
will be effectively reduced The exhaust gases passed
maintenance.
through the catalytic converter and the exhaust muffler
are discharged into the atmosphere via the exhaust tail
pipe.
·Muffler: a device that blocks the transmission of sound

but allows the air to pass through. It is an important
measure to eliminate aerodynamic noise.
·Catalytic converter: the most important external

purification apparatus in the exhaust system of the
vehicle. It can convert harmful gases such as CO, HC
and NOx in the vehicle exhaust into harmless CO2, H2O
and N2 through oxidation-reduction reactions.
10-12
Engine Intake and Exhaust System SC20M163Q5A
Engine Intake and Exhaust System

SC20M163Q5A
Specification
Torque

Bolt - Intake Manifold 25 ± 2 N.m
Nut - Exhaust Manifold 35 ± 3 N.m
Bolt - Exhaust Manifold Heat Shield 30 ± 3 N.m
Bolt - Throttle 10 ± 1 N.m
Nut - Exhaust Manifold 35 ± 3 N.m
Bolt - Water-Air Intercooler 22 ± 2 N.m
Bolt – High-pressure EGR Exhaust Pipe 22 ± 2 N.m
Bolt - High-pressure EGR Assembly Intake Pipe to

22 ± 2 N.m
EGR
Bolt- High-pressure EGR Assembly Intake Pipe to

30 ± 2 N.m
Exhaust Manifold
Bolt - High-pressure EGR Module 22 ± 2 N.m
Bolt – Low-pressure EGR Exhaust Pipe to EGR 10 ± 1 N.m
Bolt - Low-pressure EGR Module 22 ± 2 N.m
Bolt- Low-pressure EGR Exhaust Pipe to Turbocharger 22 ± 2 N.m
Bolt – Low-pressure EGR Assembly Bracket 25 ± 2 N.m
Bolt – Low-pressure EGR Differential Pressure Sen-

10 ± 1 N.m
sor Intake Pipe Bracket
Bolt – Low-pressure EGR Cooler Water Inlet Pipe

10 ± 1 N.m
Bracket
Bolt - Mass Air Flow Sensor 1.5 N.m
Bolt - Air Filter 8-10 N.m
Bolt - Front Catalytic Converter Assembly Bracket 40-50 N.m
Bolt - Front Catalytic Converter to Rear Catalytic Con-

40-50 N.m
verter
Bolt - Rear Catalytic Converter to Front Exhaust Pipe

40-50 N.m
Assembly
Bolt - Front Exhaust Pipe to Front Muffler 40-50 N.m
Bolt - Front Muffler to Rear Muffler 40-50 N.m
6-1

Bolt - Urea Pump Protective Housing 4.5-5.5 N.m
Bolt - Front and Rear Urea Tank Straps 35-45 N.m
Bolt - Urea Tank Bracket 60-70 N.m
Clamp - Urea Nozzle 9-11 N.m
6-2
Layout
Intake/Exhaust System
7
6
S02060001
1 Engine Intake Elbow (Intercooler 5 Exhaust Manifold Heat Shield

Exhaust Hose)
2 Water-Air Intercooler 6 Intake Manifold
3 Intercooler Intake Hose 7 Electronic Throttle
4 Exhaust Manifold
6-3
EGR System
7
6
S02060002
1 High-pressure EGR Assembly Exhaust 5 Low-pressure EGR Assembly

Pipe
2 High-pressure EGR Assembly 6 Low-pressure EGR Differential Pressure
Sensor Intake Pipe
3 Low-pressure EGR Assembly Exhaust 7 Low-pressure EGR Differential Pressure
Pipe Sensor Exhaust Pipe
4 8 High-pressure EGR Assembly Intake
Low-pressure EGR Assembly Bracket
Pipe
6-4
Intake System Layout
5
3
S02060010
1 Air Filter Intake Passage Assembly

2 Air Filter
3 Mass Air Flow Sensor
4 Air Filter Outlet Pipe
5 Crankcase Ventilation Hose
6-5
Exhaust Layout
3
7
S02060011
1 Rear Catalytic Converter Assembly

2 Catalytic Converter Bracket
3 Front Catalytic Converter Assembly
4 Oxygen Sensor
5 Temperature Sensor
6 Nitrogen Sensor
7 Differential Pressure Sensor
8 Differential Pressure Sensor Pipeline
9 Temperature Sensor
6-6
5
4
3
S02060012
1 Rear Muffler Assembly

2 Front Muffler Assembly
3 Front Exhaust Pipe Assembly
4 Nitrogen Sensor
5 PM Sensor
6-7
Urea System Layout
5
8
4
7
3
6
9
10
S02060013
1 Urea Filler Cap

2 Urea Filler Pipe
3 Rear Urea Tank Strap
4 Urea Tank
5 Front Urea Tank Strap
6 Protective Housing
7 Urea Supply Pipe
8 Urea Nozzle Cooling Water Pipe
9 Urea Nozzle Clamp
10 Urea Nozzle
6-8
Urea and Fuel Filler Port Layout
1
2
S02060014
1 Fuel Filler Port

2 Urea Filler Port
6-9
Symptom Table

? Connecting bolts loose ? Tighten the loose bolts.
? Exhaust pipe gasket damaged and ? Check and replace the exhaust pipe
leak; exhaust pipe damaged and leak gasket; replace the exhaust pipe.
Large exhaust pipe noise
? Exhaust pipe gasket damaged or ? Replace the exhaust pipe gasket or
exhaust pipe connection loose; exhaust tighten the connection; replace the
pipe damaged damaged component.
? Insufficient fuel ? Refuel.
? Exhaust pipe is blocked by foreign ? Remove the foreign material.

material, resulting in large exhaust
resistance
Weak exhaust of exhaust pipe
? Large clearance between the piston ? Check the piston ring, piston and
ring, the piston and the cylinder, cylinder.
causing the oil enters the combustion
chamber and burns, blocking the
catalyst.
6-10
Electronic Throttle Replacement

Service Guide
Removal
Intercooler Exhaust Hose Replacement 1 Remove the intercooler exhaust hose. Refer to
Removal “Intercooler Exhaust Hose Replacement” .
1 Loosen the retaining clamps on both ends of the 2 Disconnect the harness connector of the
intercooler exhaust hose, and disconnect the electronic throttle.
intercooler exhaust hose from the intercooler and
electronic throttle.
2 Remove the intercooler exhaust hose.
S02063023
3 Remove 4 bolts fixing the electronic throttle to the

intake manifold.
S02063022
4 Remove the electronic throttle (1).
Installation
1 Install the intercooler exhaust hose, and install the
retaining clamps on both ends.
S02063024
Installation
1 Fix the electronic throttle to the intake manifold,
check the torque.
2 Connect the harness connector of the electronic
throttle.
3 Install the intercooler exhaust hose. Refer to
“Intercooler Exhaust Hose Replacement” .
6-11
Intake Manifold Replacement

Removal
2 Remove the engine assembly. Refer to “Engine
“Electronic Throttle Replacement” .
.
5 Remove the intake manifold pressure sensor. S02063027
Refer to “Intake Manifold Pressure Sensor
Replacement” . 2 Fix the intake manifold to the cylinder head, install
6 Disconnect the intake control valve harness 9 bolts, tighten them to 25±2 N.m in the sequence
shown, and check the torque.
connector.
7 3 1 5 8
6 4 9
2
S02063028
S02063025
3 Connect the intake manifold control valve harness
7 Remove 9 bolts fixing the intake manifold to the
connector.
cylinder head, and remove the intake manifold (1).
4 Install the intake manifold pressure sensor. Refer
to “Intake Manifold Pressure Sensor
Replacement” .
1
6 Install the high-pressure EGR cooler assembly.
Refer to “High-pressure EGR Cooler Assembly
Replacement” .
7 Install the engine assembly. Refer to “Engine
S02063026
Installation
1 Install the intake manifold rubber ring.
Note: Check the intake manifold seal ring, and
replace it if damaged.
6-12
Water-Air Intercooler Replacement 2 Connect the water-air intercooler water pipe, and
Removal install the pipe clamp.
3 Connect the intercooler exhaust hose, and install
1 Remove the intercooler rear intake air temperature
the retaining clamps.
sensor. Refer to “Intercooler Rear Intake Air
4 Connect the intercooler intake hose, and install the
Temperature Sensor Replacement” .
retaining clamps.
2 Loosen the retaining clamps on both ends of the
5 Install the intercooler rear intake air temperature
intercooler intake hose, and disconnect the
intercooler intake hose from the intercooler. sensor. Refer to “Intercooler Rear Intake Air
3 Loosen the retaining clamps on both ends of the
intercooler exhaust hose, and disconnect the
intercooler exhaust hose from the intercooler.
S02063030
4 Loosen the retaining clamps of the intercooler

water pipe, and disconnect the intercooler water
pipe from the intercooler.
5 Remove 4 bolts fixing the water-air intercooler to

the intercooler bracket, and remove the water-air
intercooler (1).
S02063032
Installation
1 Fix the water-air intercooler to the intercooler
6-13
Intercooler Intake Hose Replacement Exhaust Manifold Heat Shield Replacement

Removal Removal
1 Do not disconnect the hose, and only remove 4 1 Remove the turbocharger assembly. Refer to
retaining bolts for the water-air intercooler, and “Turbocharger Assembly Replacement” .
move the water-air intercooler.
2 Remove 4 bolts fixing the exhaust manifold heat
2 Loosen the retaining clamps on both ends of the shield to the exhaust manifold, and remove the
intercooler intake hose, and disconnect the exhaust manifold heat shield (1).
intercooler intake hose from the intercooler and
the turbocharger assembly.
3 Remove the intercooler intake hose (1). 1
1
2
1
S02063034
Installation
S02063001 1 Fix the exhaust manifold heat shield to the

exhaust manifold, install 4 bolts, tighten them to 30
Installation ± 3 N.m, and check the torque.
1 Install the intercooler intake hose, and install the 2 Install the turbocharger assembly. Refer to
retaining clamps on both ends. “Turbocharger Assembly Replacement” .
2 Fix the water-air intercooler, install 4 retaining
bolts for the water-air intercooler, tighten them to
6-14
Exhaust Manifold Replacement Note: Check the exhaust manifold missing

Removal identification, as shown below.

2 Remove the exhaust manifold heat shield. Refer to
“Exhaust Manifold Heat Shield Replacement” .
3 Remove the turbocharger front exhaust
S02063037
1
2 Fix the exhaust manifold to the cylinder head,
install 8 nuts, tighten them to 35 ± 3 N.m in the
sequence shown, and check the torque.
6 2 3 7
S02063035
4 Remove 8 bolts fixing the exhaust manifold to the

cylinder head.
5 Remove the exhaust manifold (1) and the exhaust
manifold gasket. 8 4 1 5
S02063038
3 Install the turbocharger front exhaust temperature

sensor on the exhaust manifold, tighten it to 20 ±
4 Install the exhaust manifold heat shield. Refer to
“Exhaust Manifold Heat Shield Replacement” .
5 Install the turbocharger assembly. Refer to
S02063036 “Turbocharger Assembly Replacement” .
Installation
1 Install the exhaust manifold gasket.
Note: Check the exhaust manifold gasket, and
replace it if damaged.
6-15
High-pressure EGR Assembly Replacement

Removal
2 Drain the coolant.
Replacement” .
4 Remove the high-pressure EGR temperature
sensor. Refer to “High-pressure EGR
5 Disconnect the vacuum pipe and the harness
connector. S02063041
8 Remove the high-pressure EGR assembly

exhaust pipe. Refer to “High-pressure EGR
Assembly Exhaust Pipe Replacement” .
9 Remove the oil filter cooling module assembly.
Refer to “Oil Filter Cooling Module Assembly
Replacement” .
10 Remove 2 bolts fixing the high-pressure EGR
intake pipe to the high-pressure EGR assembly.
11 Move the high-pressure EGR assembly intake
pipe.
S02063039
6 Loosen the clamps, and disconnect the water

pipe.
1
S02063042

assembly to the cylinder block.
S02063040
7 Loosen the clamps, and disconnect the water inlet

pipe.
6-16
13 Remove the high-pressure EGR assembly (1). Low-pressure EGR Assembly and Its Bracket
Replacement
Removal
2 Drain the coolant.
Replacement” .
4 Disconnect the low-pressure EGR temperature
sensor harness connector and the low-pressure
1 EGR assembly harness connector.
S02063043
Installation
1 Fix the high-pressure EGR assembly to the
cylinder block, install 3 bolts, tighten them to 30 ±
2 Fix the high-pressure EGR intake pipe to the high-
pressure EGR assembly, install the gasket and 2
bolts, tighten them to 22 ± 2 N.m, and check the
torque.
3 Install the high-pressure EGR exhaust pipe。
Refer to “High-pressure EGR Assembly Exhaust S02063044
Pipe Replacement” .
5 Remove the differential pressure sensor intake
4 Install the oil filter cooling module. Refer to “Oil pipe (1).
Filter Cooling Module Assembly Replacement” .
6 Remove 2 bolts (2) fixing the low-pressure EGR
5 Connect the high-pressure EGR assembly water assembly exhaust pipe to the EGR assembly, and
inlet/outlet pipe and clamps. remove the low-pressure EGR assembly exhaust
6 Install the high-pressure EGR control valve pipe (3).
vacuum pipe, and connect the high-pressure EGR
assembly harness connector.
7 Install the high-pressure EGR temperature sensor.
Refer to “High-pressure EGR Temperature 3
Sensor Replacement” .
2
.
1
10 Connect the negative battery cable. 2
S02063045
7 Remove 1 bolt (1) fixing the turbocharger oil return

pipe assembly to the cylinder block.
8 If equipped, remove 2 retaining bolts (2) fixing the
low-pressure EGR assembly bracket to the
turbocharger.
6-17
9 Loosen the clamp (3), and disconnect the EGR 6 Connect the low-pressure EGR temperature
assembly water pipe. sensor harness connector. Connect the low-
pressure EGR assembly harness connector.
Replacement” .
3
2
1
S02063046
10 Remove 3 bolts fixing the low-pressure EGR

assembly and its bracket to the cylinder block.
11 Remove the low-pressure EGR assembly (1) and
its bracket (2).
S02063047
Installation
1 Fix the low-pressure EGR assembly and its
bracket to the cylinder block, install 3 bolts, tighten
2 Connect the low-pressure EGR assembly pipe.
3 If equipped, fix the low-pressure EGR assembly
bracket to the turbocharger bracket, install 2 bolts,
4 Fix the turbocharger oil return pipe assembly to
the cylinder block, install 1 bolt, tighten it to 10 ± 1
5 Fix the low-pressure EGR assembly exhaust pipe
and its gasket to the low-pressure EGR assembly,
check the torque.
6-18
Low-pressure EGR Differential Pressure

Sensor Intake Pipe Replacement
Removal
2 Remove the bolts fixing the low-pressure EGR
1
differential pressure sensor intake pipe to the low-
pressure EGR exhaust pipe.
S02063050
Installation
1 Install the low-pressure EGR differential pressure
sensor intake pipe and 2 bolts to the cylinder
block, tighten them to 10 ± 1 N.m, and check the
torque.
2 Connect the low-pressure EGR differential
pressure sensor intake pipe and the differential
S02063048 pressure sensor, and install the retaining clamps.
3 Install the low-pressure EGR differential pressure
3 Remove the bolt (1) fixing the low-pressure EGR
sensor intake pipe to the low-pressure EGR
differential pressure sensor intake pipe to the low-
exhaust pipe.
pressure EGR exhaust pipe.
4 Install the turbocharger assembly. Refer to
4 Loosen the clamp (2), and disconnect the low-
pressure EGR differential pressure sensor intake “Turbocharger Assembly Replacement” .
pipe from the differential pressure sensor.
S02063049
5 Remove the bolts fixing the low-pressure EGR

differential pressure sensor intake pipe to the
cylinder block.
6 Remove the low-pressure EGR differential
pressure sensor intake pipe (1).
6-19
Low-pressure EGR Assembly Exhaust Pipe High-pressure EGR Cooler Water Outlet Hose
Replacement Assembly Replacement
Removal Removal
1 Remove 2 bolts fixing the low-pressure EGR 1 Drain the coolant.
exhaust pipe to the turbocharger, and remove the 2 Loosen the retaining clamps on both ends of the
low-pressure EGR exhaust pipe gasket. high-pressure EGR cooler water outlet hose
assembly, and remove the high-pressure EGR
cooler water outlet hose assembly (1).
S02063051
2 Remove the differential pressure sensor intake

S02063053
pipe (1).
3 Remove 2 bolts (2) fixing the low-pressure EGR Installation
exhaust pipe to the low-pressure EGR assembly. 1 Connect the high-pressure EGR cooler water
4 Remove the low-pressure EGR exhaust pipe (3) outlet hose assembly, and install the retaining
and its gasket. clamps on both ends.
2 Refill and drain the coolant.
?
1
2
S02063052
Installation
(3) and its gasket to the low-pressure EGR
assembly, install 2 bolts, tighten them to 10 ± 1
N.m.
2 Install the differential pressure sensor intake pipe,
tighten it to 10 ± 1 N.m, and check the torque.
and its gasket to the turbocharger, install 2 bolts,
6-20
High-pressure EGR Cooler Water Inlet Hose 2 Install the high-pressure EGR assembly. Refer to
Assembly Replacement “High-pressure EGR Assembly Replacement” .
Removal 3 Install the oil filter cooling module. Refer to “Oil
1 Remove the high-pressure EGR cooler. Refer to
“High-pressure EGR Cooler Replacement” . 4 Connect the high-pressure EGR cooler water inlet
hose assembly (1) to the high-pressure EGR
2 Loosen the retaining clamps of the high-pressure
assembly. Install the high-pressure EGR cooler
EGR cooler water inlet hose assembly, and
water inlet hose assembly, and install the retaining
remove the high-pressure EGR cooler water inlet
clamps.
hose assembly (1).
5 Install the high-pressure EGR cooler. Refer to
“High-pressure EGR Cooler Replacement” .
S02063054
3 Remove the oil filter cooling module. Refer to “Oil

.
5 Loosen the retaining clamps of the high-pressure
EGR cooler water inlet hose assembly, and
remove the high-pressure EGR cooler water inlet
hose assembly.
S02063055
Installation
1 Connect the high-pressure EGR cooler water inlet
hose assembly and the block thermostat,and
install the retaining clamps.
6-21
High-pressure EGR Assembly Exhaust Pipe High-pressure EGR Assembly Intake Pipe
Removal Removal
1 Remove 4 bolts fixing the high-pressure EGR 1 Remove the starter. Refer to “Starter
exhaust pipe to the high-pressure EGR assembly Replacement” .
and the throttle.
2 Remove the high-pressure EGR assembly assembly intake pipe to the exhaust manifold.
exhaust pipe (1).
3 Detach the high-pressure EGR assembly intake
pipe (1).
1
S02063056
1 Fix the high-pressure EGR assembly exhaust pipe 4 Remove 2 bolts fixing the high-pressure EGR
to the intake manifold and the high-pressure EGR assembly intake pipe to the high-pressure EGR
assembly, install 4 bolts, tighten them to 22 ± 2 assembly.
N.m, and check the torque. 5 Remove the high-pressure EGR assembly intake
pipe (1).
S02063058
Installation
1 Fix the high-pressure EGR assembly intake pipe
to the exhaust manifold, tighten to 30± 2 N.m, and
check the torque.
2 Fix the high-pressure EGR intake pipe to the high-
pressure EGR assembly, tighten to 22 ± 2 N.m
check the torque.
6-22
3 Install the starter. Refer to“Starter Replacement” Low-pressure EGR Cooler Water Inlet Hose
. Assembly Replacement
Removal
1 Remove the air filter element outlet pipe. Refer to
“Air Filter Element Outlet Pipe Replacement” .
2 Loosen the clamps of the low-pressure EGR
cooler water inlet hose assembly, and remove the
low-pressure EGR cooler water inlet hose
assembly.
S02063059
3 Remove 1 bolt fixing the low-pressure EGR cooler

water inlet hose assembly to water pump
assembly.
S02063060
4 Loosen the clamps of the low-pressure EGR

cooler water inlet hose assembly, and remove the
low-pressure EGR cooler water inlet hose
assembly (1).
6-23
Mass Air Flow Sensor Replacement

Removal
1 Remove 2 bolts for the mass air flow sensor.
2 Disconnect the electrical connector of the mass air
1 flow sensor.
3 Remove the mass air flow Sensor from the air
filter.
S02063061 1
Installation
1 Connect the low-pressure EGR cooler water inlet 2
hose to the low-pressure EGR assembly, and
install the retaining clamps.
2 Connect the low-pressure EGR cooler water inlet
hose to the thermostat, and install the retaining
clamps.
GS030165
3 Install the low-pressure EGR cooler water inlet
Installation
hose bracket retaining bolts, tighten them to 10 ±
1 N.m, and check the torque. 1 Install the mass air flow sensor.
4 Install the air filter element outlet pipe. Refer to 2 Connect the electrical connector of the mass air
“Air Filter Element Outlet Pipe Replacement” . flow sensor.
3 Install 2 bolts for the mass air flow sensor, tighten
them to 1.5 N.m, and check the torque.
6-24
Air Filter Inlet Pipe Replacement Air Filter Assembly Replacement

Removal Removal
1 Remove the fender. 1 Remove the air filter inlet pipe. Refer to “Air Filter
GS030166 Inlet Pipe Replacement” .
2 Loosen the clamp for the air filter outlet pipe.
3 Disconnect the electrical connector of the mass air
flow sensor.
4 Remove 3 bolts (2) fixing the air filter to the body.
5 Remove the air filter.
GS030166
2 Remove 2 retaining nuts (2) for the air filter inlet
pipe.
3 Remove the air filter inlet pipe (1).
GS030168
Installation
1 Install the air filter.
2 Install 3 retaining bolts for the air filter, tighten
them to 8-10 N.m, and check the torque.
flow sensor.
4 Install the clamp for the air filter outlet pipe.
5 Install the air filter inlet pipe. Refer to “Air Filter
GS030167 Inlet Pipe Replacement” .
Installation
1 Install the air filter inlet pipe.
2 Install 2 retaining bolts for the air filter inlet pipe,
tighten them to 5 N.m, and check the torque.
3 Install the fender.
6-25
Air Filter Outlet Pipe Assembly Replacement Air Filter Element Replacement
Removal Removal
1 Remove the bonnet assembly. 1 Disconnect the clamp for the air filter outlet pipe.
2 Disconnect 2 clamps (1) for the air filter outlet pipe 2 Disconnect the electrical connector of the mass air
assembly. flow sensor.
3 Remove the air filter outlet pipe assembly (2). 3 Remove 4 bolts for the air filter upper cover (1).
4 Remove the air filter upper cover (2).
1 1 1
1
1
S02063063
5 Remove the air filter element.
1 Install the air filter outlet pipe assembly.
Note: To protect the air filter from deformation, it is
2 Install 2 clamps for the air filter outlet pipe
assembly. required to remove the foreign objects on the air
filter housing during the replacement of air filter
3 Install the bonnet assembly.
element in the after-sales maintenance. Meanwhile,
it is also recommended to check the mass air flow
sensor for foreign objects and remove them in
time.
Installation
1 Install the air filter element.
2 Install the air filter upper cover, and tighten 4 bolts
for the air filter upper cover.
flow sensor.
4 Install the clamp for the air filter outlet pipe.
6-26
Front Catalytic Converter Assembly Rear Catalytic Converter Assembly

Removal Removal
1 Remove the front compartment cover. 1 Raise the vehicle.
2 Remove the windshield gutter channel. 2 Remove 2 bolts (1) connecting the front catalytic
3 Remove the intake clamp (1) and discard the converter assembly and the rear catalytic
gasket. converter assembly, and discard the gasket.
4 Disconnect the sensor connecting to the front 3 Remove 2 Bolts (2) connecting the rear catalytic
catalytic converter assembly. converter assembly to the front exhaust pipe
assembly, and discard the gasket.
5 Remove 2 bolts (2) connecting the low-pressure
EGR assembly intake pipe, and discard the 4 Remove the rear catalytic converter assembly
gasket. from the rubber hook (3).
6 Remove 2 bolts (3) connecting to the rear catalytic

7 Remove 2 bolts (4) for the front catalytic converter 1
assembly bracket. 3
1
8 Remove the front catalytic converter assembly (5).
2
1
5
2
S02063067
4 Installation
1 1 Install the catalytic converter assembly on the
3
rubber hook.
3 2
2 2 Install the new gasket, and 2 bolts connecting
S02063066 the rear catalytic converter assembly to the front
exhaust pipe assembly, tighten them to 40-50
Installation
1 Install the front catalytic converter assembly.
3 3 Install the new gasket and 2 bolts connecting the
2 Install the new gasket and 2 bolts for the front front catalytic converter assembly and rear
catalytic converter assembly bracket, tighten them catalytic converter assembly, tighten them to 40-
to 40-50 N.m, and check the torque. 50 N.m, and check the torque.
3 Install the new gasket and 2 nuts connecting the 4 4 Lower the vehicle.
rear catalytic converter assembly, tighten them to
40-50 N.m, and check the torque.
4 Install the new gasket and tighten 2 bolts
connecting the low-pressure EGR assembly intake
pipe.
5 Install the sensor connecting to the front catalytic
converter assembly.
6 Install the intake clamp.
7 Install the windshield gutter channel.
8 Install the front compartment cover.
6-27
Front Exhaust Pipe Assembly Replacement Front Muffler Replacement

Removal Removal
2 Disconnect the connector of the sensor. 2 Remove the front exhaust pipe assembly. Refer to
3 Disconnect the electrical connector of the exhaust “Front Exhaust Pipe Assembly Replacement” .
valve. 3 Remove 2 nuts (1) connecting the front muffler
4 Remove 2 nuts (1) connecting the rear catalytic assembly to the rear muffler assembly, and
converter assembly to the front exhaust pipe discard the gasket.
assembly, and discard the gasket. 4 Remove 3 rubber lugs (2) of the front muffler
5 Remove 2 nuts (2) connecting the front exhaust assembly.
pipe assembly to the front muffler assembly, and 5 Remove the front muffler assembly (3).
discard the gasket
6 Remove the front exhaust pipe assembly (3).
2
2
1
3 1
2
1
1
3 2
2
S02063140
Installation
S02063139
1 Install the front muffler assembly rubber lugs and
Installation the front muffler assembly.
1 Install the catalytic converter assembly on the 2 Install the new gasket, and 2 bolts connecting the
rubber hook. front muffler assembly to the rear muffler
2 Install the new gasket, and 2 bolts connecting the assembly, tighten them to 40-50 N.m, and check
front exhaust pipe assembly to the front muffler the torque.
assembly, tighten them to 40-50 N.m, and check 3 Lower the vehicle.
the torque.
3 Install the new gasket, and 2 bolts connecting the
rear catalytic converter assembly to the front
exhaust pipe assembly, tighten them to 40-50
4 3 Lower the vehicle.
6-28
Rear Muffler Assembly Replacement Urea Pump Protective Housing Replacement

Removal Removal
2 Remove the spare tyre. 2 Remove 6 bolts (1) of the urea pump protective
3 Remove 2 nuts (1) connecting the front muffler housing.
assembly to the rear muffler assembly, and 3 Remove the urea pump protective housing (2).
discard the gasket.
4 Remove 2 rubber lugs (2) of the rear muffler 2
assembly.
5 Remove the rear muffler assembly (3).
2 1
2 1
1 1
1
3 S02063142
1
1 Installation
1 Install the urea pump protective housing.
S02063141 2 Install 4 bolts of the urea pump protective housing,
tighten them to 4.5-5.5 N.m, and check the torque.
Installation
1 Install the rear muffler assembly rubber lugs and
the rear muffler assembly.
2 Install the new gasket, and 2 bolts connecting the
front muffler assembly to the rear muffler
assembly, tighten them to 40-50 N.m, and check
the torque.
3 Mount the spare tyre.
6-29
Urea Tank Replacement Installation

Removal 1 Raise the urea tank and urea tank bracket
1 Raise the vehicle. together with a suitable support.
2 Remove the urea pump protective housing. Refer 2 Install the urea tank and urea tank bracket to the
frame, install 8 bolts, tighten them to 60-70 N.m,
to “Urea Pump Protective Housing
Replacement” .
3 Disconnect the electrical connector of the urea 3 Install 2 bolts for the front/rear urea tank straps,
tank. install 2 bolts, tighten them to 35-45 N.m, and
check the torque.
4 Disconnect the urea tank from the urea filler pipe.
4 Connect the electrical connector of the urea tank.
Refer to “Urea Filler Pipe Replacement” .
5 Disconnect the urea tank from the urea supply 5 Connect the urea filler pipe to the urea tank. Refer
pipe. to “Urea Filler Pipe Replacement” .
6 Remove 2 bolts (1) of the front and rear urea tank 6 Connect the urea supply pipe to the urea tank.
straps. 7 Install the urea pump protective housing. Refer to
“Urea Pump Protective Housing Replacement” .
1 1
S02063143
7 Move the urea tank to make a room for removing
the bracket bolts.
8 Support the urea tank and front/rear straps with a
bracket.
9 Remove 8 bolts (1) of the front and rear urea tank
straps.
10 Remove the urea tank and front/rear straps (2,3).
2
1
S02063144
6-30
Urea Filler Pipe Replacement

Removal
1 Unscrew the urea filler cap counterclockwise.
2 Remove 3 bolts (1) connecting the urea filler port
to the body.
1
S02063147
S02063145
3 Remove the fuel tank assembly. Refer to “Fuel
Tank Assembly Replacement” .
1
4 Remove the nut fixing the urea filler pipe to the
body.
5 Loosen the connection with the urea tank, and
remove the urea filler pipe. S02063148
6 Remove the urea filler pipe (1).
Installation
1 Install the bolt fixing the urea filler pipe to the fuel
tank.
2 Connect the urea filler pipe to the urea tank.
3 Install the fuel tank assembly. Refer to “Fuel Tank
4 Install the nut fixing the urea filler pipe to the body
and tighten it.
5 Install the bolts connecting the urea filler port to
the body and tighten it.
6 Install the urea filler cap.
S02063146
6-31
Urea Supply Pipe Replacement

Removal
2 Remove the urea pump protective housing. Refer
to “Urea Pump Protective Housing
Replacement” .
3 Disconnect the electrical connector of the urea 2
tank. 1
4 Disconnect the clip connecting the urea supply
pipe to the urea tank.
S02063081
Installation
1 Install the urea supply pipe, and install the clip
connecting the urea supply pipe to the engine and
the urea nozzle.
2 Install the windshield gutter channel.
3 Install the front compartment cover.
5 Install the clip connecting the urea supply pipe to
the body.
S02063149
6 Install the clip connecting the urea supply pipe to
5 Disconnect the clip connecting the urea supply the urea tank.
pipe to the body. 7 Install the electrical connector of the urea tank.
8 Install the urea pump protective housing. Refer to
“Urea Pump Protective Housing Replacement” .
S02063150

7 Remove the front compartment cover.
8 Remove the windshield gutter channel.
9 Disconnect the clip connecting the urea supply
pipe to the engine.
10 Disconnect the urea supply pipe from the urea
nozzle, and remove the urea supply pipe.
6-32
Urea Nozzle Replacement Urea Nozzle Cooling Water Pipe Replacement

Removal Removal
1 Disconnect the negative battery cable. 1 Remove the front compartment cover.
2 Remove the front compartment cover. 2 Remove the windshield gutter channel.
3 Remove the windshield gutter channel. 3 Disconnect the urea nozzle from the cooling water
4 Disconnect the harness connector of the urea pipe.
nozzle.
5 Disconnect the urea nozzle from the urea supply
pipe.
6 Disconnect the urea nozzle from the cooling water
pipe.
7 Remove the clamp (1) fixing the urea nozzle to the
catalytic converter assembly.
8 Remove the urea nozzle (2).
S02063082
4 Disconnect the cooling water pipe from the
intercooler.
2
1
S02063081
Installation
1 Install the urea nozzle.
2 Install the clamp fixing the urea nozzle to the
catalytic converter assembly, and tighten it to 9-11
N.m.
S02063083
3 Connect the urea nozzle to the cooling water pipe.
Installation
4 Connect the urea nozzle to the urea supply pipe.
5 Install the harness connector of the urea nozzle. 1 Connect the cooling water pipe to the intercooler.
6 Install the windshield gutter channel. 2 Connect the cooling water pipe to the urea nozzle.
7 Install the front compartment cover. 3 Install the windshield gutter channel.
8 Connect the negative battery cable. 4 Install the front compartment cover.
6-33
Urea Injection Control Unit Replacement Oxygen Sensor Replacement

Removal Removal
2 Raise the vehicle. 2 Remove the bonnet.
3 Disconnect the electrical connector of the urea 3 Disconnect the electrical connector of the oxygen
injection control unit. sensor.
4 Remove the bolt (1) fixing the urea injection 4 Remove the oxygen sensor (1) with the special
control unit. tool C00189087.
5 Remove the urea injection control unit (2).
2 1
S02063179
Installation 1 Install the oxygen sensor with the special tool
1 Install the urea injection control unit. C00189087.
2 Install the bolt fixing the urea injection control unit. 2 Connect the electrical connector of the oxygen
sensor.
3 Connect the electrical connector of the urea
injection control unit. 3 Install the bonnet.
4 Lower the vehicle. 4 Connect the negative battery cable.
6-34
Temperature Sensor Replacement Nitrogen Sensor Replacement

Removal Removal
2 Remove the bonnet. 2 Remove the bonnet.
3 Disconnect the electrical connector of the 3 Remove the expansion tank fastener, and remove
temperature sensor. the expansion tank.
4 Remove the temperature sensor (1). 4 Disconnect the electrical connector of the nitrogen
sensor and harness clips.
5 Disconnect the nitrogen sensor from the front
catalytic converter.
6 Remove the bolt (1) for the nitrogen sensor.
7 Remove the nitrogen sensor (2).
1
S02063180
1
Installation
1 Install the temperature sensor.
2 Connect the electrical connector of the
temperature sensor.
S02063181
3 Install the bonnet.
Installation
1 Install the nitrogen sensor.
2 Install the bolt for the nitrogen sensor and tighten
it.
3 Connect the electrical connector of the nitrogen
sensor and harness clips.
4 Connect the nitrogen sensor to the front catalytic
converter.
5 Install the expansion tank to its original position.
6 Install the bonnet.
6-35
Pressure Sensor Replacement Pressure Sensor Pipeline Replacement

Removal Removal
2 Disconnect the electrical connector of the 2 Disconnect it from the pressure sensor.
pressure sensor. 3 Remove the bolt (1) fixing the pressure sensor
3 Disconnect the pressure sensor pipeline. pipeline.
4 Remove the bolt (1) fixing the pressure sensor. 4 Remove the front pressure sensor pipeline (2) and
5 Remove the pressure sensor (2). rear pressure sensor pipeline (3).
3
1
1
S02063182 S02063183
1 Install the pressure sensor. 1 Install the front pressure sensor pipeline and rear
pressure sensor pipeline.
2 Install the bolt for the pressure sensor and tighten
it. 2 Install the bolt fixing the pressure sensor pipeline
and tighten it.
3 Connect the pressure sensor pipeline.
3 Connect the pressure sensor pipeline to the
4 Connect the electrical connector of the pressure pressure sensor.
sensor.
6-36
Temperature Sensor Replacement Temperature Sensor Replacement

Removal Removal
3 Disconnect the electrical connector of the 3 Disconnect the electrical connector of the
temperature sensor. temperature sensor.
4 Remove the temperature sensor (1).
S02063185
S02063184 4 Remove the harness clips.
Installation 5 Remove the temperature sensor (1).

Installation
1 Install the temperature sensor.
2 Connect the electrical connector of the 1 Install the temperature sensor.
temperature sensor. 2 Connect the electrical connector of the
3 Lower the vehicle. temperature sensor.
4 Connect the negative battery cable. 3 Install the harness clips.

6-37
Nitrogen Sensor Replacement PM Sensor Replacement

Removal Removal
3 Disconnect the electrical connector of the nitrogen 3 Disconnect the electrical connector of the PM
sensor. sensor.
4 Disconnect the nitrogen sensor from the exhaust 4 Disconnect the PM sensor from the exhaust pipe.
pipe. 5 Remove 2 bolts (1) for the PM sensor.
5 Remove 2 bolts (1) for the nitrogen sensor. 6 Remove the PM sensor (2).
6 Remove the nitrogen sensor (2).
1
2
S02063187
Installation 1 Install the PM sensor.
1 Install the nitrogen sensor. 2 Install the bolts for the PM sensor, tighten them to
2 Install the bolts for the nitrogen sensor, tighten
them to 9 ± 1 N.m, and check the torque. 3 Connect the electrical connector of the PM sensor.
3 Connect the electrical connector of the nitrogen 4 Install the PM sensor to the exhaust pipe.
sensor. 5 Lower the vehicle.
4 Install the nitrogen sensor to the exhaust pipe. 6 Connect the negative battery cable.
6-38
achieving OBD monitoring of SCR components. The

ceramic sensing unit of the sensor utilizes the technology
Intake/Exhaust System with two ion chambers to measure the NOx concentration
The intake system is mainly used to provide the engine in the exhaust gas.
with sufficient clean air to the cylinder under different
DOC+DPF
working conditions. The intake mode adopted by the
DOC (diesel oxidation catalyst) produces harmless CO2
vehicle is exhaust turbocharging. The air enters the air filter
and H2O through the oxidation process of CO and HC;
assembly in the engine compartment and is filtered by the
DPF (diesel particulate filter) collects PM (particulate
air filter element. During this process, impurities in the air
matter) and regenerates to reduce HC and CO emissions.
are filtered by the filter element and remain on the surface
However, there are limits for reducing exhaust emissions
at the air intake side of the filter element. After being
of each system, so two systems will be used.
filtered, the air passes through the intake pipe and is
boosted by the turbocharger, and the turbocharged air has Urea Tank
a temperature increase, after being cooled down tin the The tank is used to store industrial urea, it mainly consists
intercooler, it passes through the intake pipe, and then of a urea filler cap, a urea filler pipe, a urea tank, an internal
enters the cylinder through the intake valve. urea pump, and a protective plate. The internal urea pump
The intake system mainly includes: is an electronic intelligent pump. Under the control of the
engine ECM, urea is supplied to the injector nozzle for
? Air Filter Assembly injection.
? Intake Manifold Pressure Sensor
Internal urea pump (with temperature/mass/level sensor/
? Air Intake Duct
heater)
? Air Intercooler
? Intake Manifold The internal urea pump delivers the urea solution
The exhaust system is mainly used to discharge the according to the CAN command sent by the engine ECM.
burned exhaust gas in the cylinder block as much as The internal urea pump has a built-in heating device that
possible. When the exhaust gas is discharged from the allows the system to work at an external temperature
exhaust pipe, a small part enters the intake pipe through below -40°C (the urea freezes at -11°C). The internal
the EGR valve, and enters the cylinder through the intake urea pump integrates a self-diagnostic program, and sends
pipe to burn again, thus reducing emission pollution; most OBD information via the CAN communication interface. It
of the exhaust gas enters the catalyst through the reports the status of its operation to the system. The
turbocharger (drives the turbocharger) for catalytic internal urea pump works on a 12V power supply.
conversion to reduce emission pollution, and is discharged
Urea Nozzle
through the silencer.
The urea nozzle is made of stainless steel and the injector
EGR System tube is welded to the injector nozzle body.
EGR system has a full name of: Exhaust Gas Re-
circulation. It is controlled by the EGR valve, draws exhaust
gas (mainly containing CO2) from the exhaust manifold or
the exhaust pipe, which is delivered to the intake system
after being cooled down by the EGR cooler, and enters the
cylinder with fresh air for burning to reduce the combustion
pressure, thus reducing NOx emission;
NOX Sensor
NOx sensor is used to control the urea injection volume of
the SCR system, thereby reducing NOx emissions and
6-39
Operating Principle of High-pressure EGR 3 Under the steady-state conditions, high-pressure

System EGR is closed and low-pressure EGR is opened,
which can meet the normal EGR rate demand;
1 High-pressure EGR draws air from the exhaust under transient high-load conditions, the intake
manifold; the exhaust gas has a high temperature flow increases greatly, which requires high-
(up to 750°C) after being delivered to the throttle. pressure EGR to open, in order to provide EGR
2 Low-pressure EGR draws air from the DPF rear rate compensation, reduce combustion
exhaust pipe; the exhaust gas has a low temperature, and ensure that emission meets the
temperature (300-400°C), and is delivered to the regulatory requirements.
turbocharger.
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S02062001
1 High-pressure EGR Assembly Gas Flow

2 High-pressure EGR Valve
1 High-pressure EGR: Exhaust Manifold → High-
3 High-pressure EGR Cooler pressure EGR Assembly Intake Pipe → High-
4 Bypass pressure EGR Assembly → High-pressure EGR
5 Low-pressure EGR Assembly Assembly Exhaust Pipe → Intake Manifold
6 Low-pressure EGR Valve 2 Low-pressure EGR: Exhaust Manifold →
7 Low-pressure EGR Cooler Turbocharger → After-treatment System → Low-
pressure EGR Assembly Intake Pipe → Low-
8 Exhaust Control Valve pressure EGR Assembly → Low-pressure EGR
Assembly Exhaust Pipe → Turbocharger →
Intercooler → Throttle → Intake Manifold
6-40
5MT
5MT
Torque
Bolt - seal plate to body 20 ± 2

Nut - transmission shift lever to body 20 ± 2
Bolt - transmission to engine 50 ± 5
11-1
5MT
Precautions Troubleshooting
Precautions for Transmission Removal/
Installation
For transmission removal, all parts shall be handled with Type
care, impact shall be avoided, especially for the mating Hard Clutch not applied Use proper driving
face; and all parts shall be arranged orderly so that no gear Clutch not techniques
part is missing or taken by mistake. engage thoroughly Check/replace
ment Replace
disengaged
In addition to the above, the following aspects shall be Severe Replace
observed during installation: synchronizer ring wear
Hard locating spring
1 Clean all parts before installation (except
Loud or Low oil level Refill oil to specified
bearing, rubber parts and gasket).
abnorma Inferior lubricant level
2 Do not reuse any oil seal, shaft collar, spring pin. l noise Failure to change oil Change with specified
timely oil
3 Apply lubricant to all friction surfaces and grease
Improper gear axial Change oil and replace
to the lip of all oil seals.
position and clearance damaged parts
4 When installing the bearing, do not use any Bearing damage Check/adjust
rolling element to transfer stress. Tooth with burr or Replace
5 When installing the lip type oil seal, do not tilt. damage by impact Repair or replace
gears
6 When installing the synchronizer component, the
opening of the spring packing ring on the two Oil leak/ Excessive oil, high oil Keep oil level at
sides shall be stagger. penetrati level specified location
on Missing or loose bolts Reinstall, tighten to
7 When the transmission is in normal position, all Air plug failure specified torque
locations shall be no grease leak. Seal damage Replace
8 The opening of the spring pin shall be consistent Replace
with the motion direction of the fork shaft. Synchro Excessive shift force Replace
nizer Clutch not applied Use proper driving
9 The adhesive of the mating face shall be around
damage Damaged synchronizer techniques
the inner diameter, and the adhesive of the bolt
spring packing ring Replace
hole shall be continuous.
Propeller shaft Check/adjust
improperly installed
Gear Control mechanism Check/adjust
disenga failure Reinstall
gement Locating spring or steel Replace
ball not installed Replace
Locating spring failure Replace
Gear sleeve fork slot
severely worn
Shift fork severely worn
Bearing/ Low oil level Inferior Check/adjust
gear lubricant Reinstall
burnt Failure to change oil Replace
timely, dirty oil Replace
Mix of different oils or Replace
use of additive
11-2
5MT

Type
Hard Synchronizer spring Replace
gear failure Replace
disenga Synchronizer ring slot Replace
gement worn Replace
Synchronizer ring stuck Replace
on conical surface
Shift fork/shift fork
shaft deformed
Shift fork severely worn
11-3
5MT
Layout
Transmission Assembly Layout
32 14
15 31
12
10 11
16
17
18 30
19
20
6
24 7
3 4
1 2 13
25
28
29
27
5 26
8
9
23
21 22 33
ES030000
11-4
5MT
No. Description Remarks ( ○ means it No. Description Remarks ( ○ means it

can be reused after can be reused after
removal, while ※ means removal, while ※ means
it cannot) it cannot)
1 Clutch housing ○ 18 Long wire clip ○
2 Cylindrical pin ○ 19 Magnet ○
3 Front cover Detachable 20 Hollow locating pin ※

component
4 Input shaft bearing ○ 21 Flange bolt ※
stop ring
5 Intermediate shaft ○ 22 CSC valve body ○
front bearing stop assembly
ring
6 Transmission ○ 23 Hexagon bolt (with ※
housing washer)
7 Bowl plug ※ 24 Lining ※
8 Hexagon plug ○ 25 Bolt (with washer) ※
9 Seal ring ※ 26 Bolt (with washer) ○
10 Shift shaft ○ 27 Output shaft bearing ○

baffle
11 Shift block ○ 28 Bolt (with washer) ○
12 Flange screw ※ 29 Bolt (with washer) ※
13 Rear body Detachable 30 Hexagon bolt (with ※

subassembly washer)
14 Shift lever ○ 31 Shift lever housing ○
subassembly component
15 Position mechanism ○ 32 Air plug assembly ※
component
16 Position mechanism ○ 33 Fuel pipe plug ○
component
17 Reverse gear switch ○
assembly
11-5
5MT
Input Shaft Subassembly Layout
4 5
1 2
ES030001
No. Description Whether can be No. Description Whether can be

Reused after Removal Reused after Removal
1 Input shaft collar No 4 Input shaft needle bearing Yes
2 Input shaft bearing Yes 5 4th gear synchronizer ring Yes
3 Input shaft component Yes
11-6
5MT
Output Shaft Subassembly Layout
9 22
8 21
20
7 19
18
6 17
5
3
2
4
16
13 14
1
12
15
11
10 13
27
26
25
24
23
ES030002
11-7
5MT
No. Description Remarks ( ○ means No. Description Remarks (○ means it

it can be reused after can be reused after
removal, while ※ removal, while ※
means it cannot) means it cannot)
1 Shaft collar for hub 2 ※ 15 Gear sleeve component ○

for hub 1
2 Gear sleeve ○ 16 1st gear synchronizer ○

component for hub 2 ring component
3 Packing ring for ○ 17 Shaft collar for hub 1 ※

synchronizer 2
4 Slider 2 ○ 18 1st gear needle spacer ○

5 3rd gear synchronizer ○ 19 1st gear needle bearing ○
ring
6 3rd gear needle ○ 20 1st gear component ○

bearing
7 3rd gear component ○ 21 1st gear thrust washer ○

8 Output shaft ○ 22 Output shaft bearing ○
9 Pin ○ 23 Output shaft bearing ○
stop ring
10 2nd gear component ○ 24 Output shaft 5th gear ○

11 2nd gear needle ○ 25 Spacer bush ○
bearing
12 2nd gear synchronizer ○ 26 Output shaft rear bearing ○

ring component
13 Slider 1 ○ 27 Output shaft rear shaft ※

collar
14 Compressed spring ○
11-8
5MT
Intermediate Shaft Layout
ES030003

1 Intermediate shaft front ※ 3 Intermediate shaft ○

shaft collar
2 Intermediate shaft front ○ 4 Intermediate shaft rear ○

bearing bearing
11-9
5MT
Rear Body Subassembly Layout
13
12 8
11 5
6
9
4 2
1
10
ES030004
1 Hexagon bolt with gasket 8 Position mechanism component L

2 Oil groove 9 T-shaped oil seal
3 R gear limit mechanism component 10 Oil nozzle
4 Rear body component 11 Rear body dust shield
5 Locating spring plug 12 Linear bearing
6 Elastic cylindrical pin 13 Plug
7 Position mechanism component H
11-10
5MT
Front Cover Layout
ES030005
No. Description Whether can be No. Description Whether can be

Reused after Reused after Removal
Removal
1 Front cover Yes 2 Oil seal No
11-11
5MT
Intermediate Plate Component Control Layout
12
13
21 15
8 17
9
10
14
16 18
19
1 10
2
11
22
7
1 20 4
5 6
3
ES030006

1 Shift fork locating bolt ※ 12 Shaft of shift fork 2 ○

2 Shift fork 2 ○ 13 Shaft of shift fork 1 ○
3 Shift fork 1 ○ 14 Elastic cylindrical pin ※
4 R gear shift rocker arm ○ 15 Shift fork 3 component ○
bracket
5 E-collar ※ 16 Shaft of shift fork 3 ○

6 R gear shift rocker arm ○ 17 Interlocking guide pillar ○
7 R gear shift fork ○ 18 Short interlocking pin ○
8 Locating spring plug ※ 19 R gear shift fork shaft ○
9 Fork shaft locating spring ○ 20 Bolt (with washer) ○
10 Steel ball ○ 21 Clamping washer ※
11 Intermediate plate ○ 22 Rgear locating spring ○
11-12
5MT
Reverse Gear Idler Layout
10
9
8
6
5
4
3
2
1
14
13
12
11
ES030168

1 Intermediate shaft 5th gear ○ 8 Gear sleeve 3 ○

needle bearing
2 Intermediate shaft 5th gear ○ 9 5th gear linkage gear ○

3 Slider for synchronizer 3 ○ 10 Intermediate shaft rear ※
shaft collar
4 Packing ring for synchronizer ○ 11 Reverse gear idler ○

3 component
5 Spring for synchronizer 3 ○ 12 Reverse gear idler shaft ○

6 Shaft collar ※ 13 5th gear thrust washer ○
7 5th gear synchronizer ring ○ 14 Pin ○
11-13
5MT
3 With a copper hammer, tap the clutch housing to

Repair Guidance
remove it.
Transmission Assembly Removal
Housing Removal
1 Remove the hexagon plug (drain plug) and seal
ring, drain the lubricant and prepare a container
to collect it.
ES030009
4 Remove the cover bolt, tap the cover to remove

it.
ES030007
2 Remove 9 hexagon bolts with gasket connecting

the clutch housing and transmission housing.
ES030010
5 Remove the left/right position mechanism

components.
ES030008
ES030011
11-14
5MT
6 Remove the flange bolt. 9 Remove the bolt connecting the front cover and
transmission housing, tap the front cover with a
copper hammer to remove it.
ES030012
7 Remove the bolt connecting the rear body and ES030015

transmission housing, tap the rear body
subassembly with a copper hammer to remove 10 Remove the stop ring of the input shaft bearing
it. and intermediate shaft front bearing.
Remove the stop ring of the input shaft bearing and
intermediate shaft front bearing with a plier.
ES030013
8 Remove the shift lever and shift block from the

rear body subassembly. ES030016
ES030014
11-15
5MT
11 With a copper hammer, tap the transmission Gear Control Parts Removal
housing to remove it.
1 Fix the intermediate plate component on the
vise.
ES030017
ES030018
2 Remove the locating spring plug.
ES030019
3 Remove the locating spring and steel ball with

the magnet.
ES030020
11-16
5MT
4 Remove the flange bolts of shift fork 1 and 2. 7 Take out the short interlocking pin and
interlocking guide pillar with the magnet.
ES030021
ES030024
5 With the screwdriver and copper hammer as
shown, tap the collar of fork shaft 2 to remove it. 8 Remove the shaft of shift fork 1 and shift fork 1.
ES030022 ES030025
6 Remove the shaft of shift fork 2 and shift fork 2. 9 Remove the collar of fork shaft 3.
ES030023 ES030026
11-17
5MT
10 Remove the elastic cylindrical pin with the push 13 Remove the shift fork shaft of the reverse gear.
rod.
ES030030
ES030027
14 Take out the steel ball and locating spring.
11 Remove the shaft of shift fork 3 and shift fork 3.
ES030031
ES030028
15 Remove the rocker arm component of the
12 Remove the short interlocking pin and locating reverse gear.
steel ball with the magnet.
ES030032
ES030029
11-18
5MT
16 Remove the bolt of the rocker arm bracket of the Working Parts Removal
reverse gear and remove the bracket.
1 Remove the odometer shaft collar.
ES030033
ES030034
2 Remove the drive gear and steel ball of the

odometer.
ES030035
3 Remove the odometer shaft collar.
ES030036
11-19
5MT
4 Remove the rear shaft collar of the output shaft. 7 Remove the 5th linkage gear of the intermediate
shaft.
Remove the 5th gear linkage gear of the intermediate
shaft with tool C00089864.
ES030037
5 Remove the rear bearing of the output shaft.

Remove the rear bearing of the output shaft with tool ES030040
C00089863.
8 Remove the 5th gear synchronizer ring, gear
component and needle bearing of the
intermediate shaft 5th gear.
ES030038
6 Remove the spacer bush.

ES030041
ES030039
11-20
5MT
9 Remove the thrust washer and pin of the 5th 12 With a copper hammer, tap the rear bearing of
gear. the intermediate shaft to remove it.
ES030042 ES030045
10 Remove the baffle bolt of the output shaft 13 Remove the intermediate shaft.
bearing to remove the bearing baffle.
ES030046
ES030043
14 Remove the input shaft.
11 Remove the shaft of the reverse gear idler and
reverse gear idler.
ES030047
ES030044
11-21
5MT
15 Remove the bearing stop ring of the output shaft.

Replacement of Input Shaft Subassembly
With a plier, remove the bearing stop ring of the output
Removal
shaft.
1 Remove the 4th gear synchronizer ring and input
shaft needle bearing.
ES030048
ES030050
16 Simply tap the intermediate plate to remove the
output shaft string.
2 Remove the input shaft collar.
Remove the input shaft collar with a plier.
ES030049
ES030051
11-22
5MT
3 Remove the input shaft bearing. Installation

Remove the input shaft bearing with the hydraulic press. 1 Install the input shaft bearing.
Install the input shaft bearing with the hydraulic press.
ES030052
ES030053
2 Select suitable input shaft collar.

The input shaft collar selected shall help to achieve the
minimum axial clearance.
ES030054
11-23
5MT
3 Install the input shaft collar.

（b） With a feeler gauge, measure the axial clearance
Install the input shaft collar with the plier. (standard value: 1.2) between the 4th gear synchronizer
ring and the linkage gear.
ES030055
ES030057
4 Install the 4th gear synchronizer ring.
（a）Apply gear oil to the conical surface of linkage gear 4 5 Check the synchronizer ring.
before installing the synchronizer ring of the 4th gear. Turn the ring and push it to check brake action.
ES030056 ES030058
11-24
5MT
6 Install the input shaft needle bearing.

Output Shaft Subassembly Removal
Apply gear oil to the cavity of the input shaft component
before installing the input shaft needle bearing. 1 Remove the output shaft 5th gear, output shaft
bearing, 1st gear thrust washer and 1st gear
component with the hydraulic press.
ES030059
ES030060
2 Remove the synchronizer ring, needle bearing

and needle spacer bush of the 1st gear.
ES030061
11-25
5MT
3 Remove the shaft collar of hub 1. 6 Remove the shaft collar of hub 2.
Remove the shaft collar of hub 1 with the screwdriver. Remove the shaft collar of hub 2 with the plier.
ES030062 ES030065
4 Remove the synchronizer component of the 1st/ 7 Remove the synchronizer component of the 3rd/
2nd gears, synchronizer ring, gear component 4th gears, synchronizer ring, gear component
and needle bearing of the 2nd gear with the and needle bearing of the 3rd gear with the
hydraulic press. hydraulic press.
ES030063 ES030066
5 Remove the synchronizer component of the 1st/ 8 Remove the synchronizer component of the 3rd/
2nd gears. 4th gears.
ES030064 ES030067
11-26
5MT
3 Measure the gap between shift fork 1 and gear

Component Test Before Output Shaft
sleeve 1.
Installation
With a vernier caliper, measure the slot size of shift fork 1
1 Measure the axial clearance between the (reference value: 5.28mm) and the boss size of gear
synchronizer ring and the gear. sleeve 1 (reference value: 5mm).
With a feeler gauge, measure the axial clearance
between the gear ring and the linkage gear.
Gear Reference value
1st gear 1.2
2nd gear 1.2
3rd gear 1.2
ES030070
4 Measure the gap between shift fork 2 and gear

sleeve 2.
With a vernier caliper, measure the pawl size of shift fork
2 (reference value: 10mm) and the slot of gear sleeve 2.
ES030068
2 Check the synchronizer ring.
Turn the ring and push it to check brake action.
ES030071
ES030069
11-27
5MT
5 Test the output shaft.

（c） With a micrometer, check the axial runout of the
（a） With a micrometer, measure the outer diameter of shaft (reference value: below 0.015mm).
the output shaft for each gear wheel.
A 37.992
B 46.992
C 38.987
A B C
ES030074
（d） With a inner bore gauge, measure the inner bore

diameter of each gear wheel.
1st gear 46.0275

ES030072 2nd gear 53.0275
3rd gear 44.0275

（b）With a micrometer, measure the flange thickness of
the output shaft (reference value: 5.0mm).
ES030075
ES030073
11-28
5MT
2 Install the synchronizer of the 3rd/4th gears.

Output Shaft Subassembly Installation
packing ring of synchronizer 2 on gear sleeve 2.
1 Install the synchronizer of the 1st/2nd gears.
（a） Install 3 springs first, then press the spring with a
screwdriver or other thin tools to install slider 1 (3) in
sequence;
a b
ES030078
Note：the synchronizer of the 3rd/4th gears has a

specified direction, which is determined by the
size of a, b shown in the figure. For installation,
ES030076
the opening direction of the two packing rings
shall be stagger.
（b） Install gear sleeve 1.
3 Install the 3rd gear component and synchronizer
of the 3rd/4th gears into the output shaft.
（a） Apply gear oil to the shaft and 3rd gear needle
bearing.
（b） Position the synchronizer ring on the 3rd gear

component, and align the notch of the synchronizer ring
a
b with the slider.
（c） Install the needle bearing into the 3rd gear

component.
ES030077
Note：The synchronizer of the 1st/2nd gears has a

specified direction, which is determined by the
size of a, b shown in the figure.
ES030079
11-29
5MT
4 Install the 3rd gear component and synchronizer 7 Measure the axial clearance of the 3rd gear
of the 3rd/4th gears with the hydraulic press. component.
Measure the axial clearance of the 3rd gear component
with a feeler gauge.
Reference value: 0.175mm.
ES030080
5 Select suitable shaft collar.

The shaft collar selected shall help to achieve the
minimum axial clearance. ES030083
8 Install the 2nd gear component and synchronizer

of the 1st/2nd gears.
（a） Apply gear oil to the 2nd gear needle bearing.
（b） Position the synchronizer ring on the 2nd gear, and

align the 3 pawls of the middle ring with the slot of the
linkage gear.
ES030081
6 Install the shaft collar.

Install the shaft collar with the plier.
ES030084
ES030082
11-30
5MT

（c） Install the 2nd gear needle bearing and 2nd gear.
ES030085
（d） Install the synchronizer of the 1st/2nd gears with a ES030087

hydraulic press.
Install the shaft collar with a screwdriver.
ES030086
Note：The synchronizer of the 1st/2nd gears has a

ES030088
specified direction.
11-31
5MT
11 Measure the axial clearance of the 2nd gear 13 Install the 1st gear thrust washer.
component.
Install the pin and 1st gear thrust washer into the output
Measure the axial clearance of the 2nd gear component shaft.
ES030091
Note：After the 1st gear thrust washer is installed,

ES030089 the pin shall be completely embedded into the
thrust washer.
12 Install the 1st gear component.
14 Install the output shaft bearing.
Install the 1st gear needle spacer bush, needle bearing,
Install the output shaft bearing with the hydraulic press.
synchronizer ring component and gear component of the
1st gear in the sequence shown.
ES030092
ES030090 Note：
Note：The 3 pawls of the middle synchronizer ring ·For the output bearing, the side with the stop ring
of the 1st gear are aligned with the slot of the groove shall face rearward.
linkage gear.
·During installation, press the 1st gear thrust washer with
a screwdriver to prevent it from dropping, which can
affect bearing pressing.
11-32
5MT
15 Measure the axial clearance of the 1st gear 17 Measure the radial clearance of each gear
component. wheel.
Measure the axial clearance of the 1st gear component Measure the radial clearance of each gear wheel with a
with a feeler gauge. micrometer.
1st gear 0.0465
2nd gear 0.0415
3rd gear 0.0415
ES030093
16 Install the output shaft 5th gear.

Install the output shaft 5th gear with a hydraulic press.
ES030095
ES030094
11-33
5MT
Intermediate Shaft Subassembly Removal Intermediate Shaft Subassembly Installation
1 Remove the intermediate shaft front shaft collar. 1 Perform a spot check for each part before
installation.
Remove the intermediate shaft front shaft collar with the
plier. Inspect the rear bearing of the intermediate shaft and the
diameter of the intermediate shaft 5th gear.
Inspection location Reference value (mm)
A 34.0075
B 29.992
A B
ES030096
2 Remove the intermediate shaft front bearing.

Remove the intermediate shaft front bearing with a
hydraulic press.
ES030098
2 Install the intermediate shaft front bearing.

Install the intermediate shaft front bearing in the
sequence shown with a hydraulic press.
ES030097
ES030099
Note：During installation, the side with groove of

the bearing shall be downward.
11-34
5MT

Rear body subassembly Removal
minimum axial clearance. 1 Remove the locating spring plug.
ES030102
ES030100
2 Remove the elastic cylindrical pin and R gear
4 Install the shaft collar. limit mechanism component.
Install the shaft collar with the plier.
ES030103
ES030101
3 Remove the oil nozzle.
ES030104
11-35
5MT
4 Remove the rear body oil seal.

Component Test before Rear Body
Subassembly Installation
1 Turn the interlocking block to check its flexibility.
ES030105
ES030106
11-36
5MT
3 Install the R gear limit mechanism component.

Rear body subassembly Installation
（a） Install the R gear limit mechanism component into
1 Install the rear body oil seal with the tool the limit hole.
C00089867-2.
ES030109
ES030107
（b） Install the elastic cylindrical pin.
2 Install the oil nozzle.
ES030110
ES030108
4 Install the locating spring plug.
ES030111
11-37
5MT
Front Cover Component Removal Transmission Assembly Installation
1 Remove the T-shaped oil seal. 1 Secure the intermediate plate.

Secure the intermediate plate to the vise.
ES030112
Note：Do not reuse the oil seal. ES030114
2 Install the output shaft.

Front Cover Component Installation Install the output shaft into the intermediate plate.
1 Install the T-shaped oil seal.

Install the T-shaped oil seal with the tool C00089869.
ES030115
ES030113
Note：Apply grease to the outside of the oil seal

before installation.
11-38
5MT
3 Install the output shaft bearing stop ring. 6 Select suitable shaft collar.
ES030116
4 Install the spacer bush.

Install the spacer bush into the output shaft. ES030119

Install the shaft collar with a screwdriver.
ES030117
5 Install the output shaft rear bearing.

Install the output shaft rear bearing with the hydraulic ES030120
press.
ES030118
11-39
5MT
8 Install the input shaft. 10 Install the intermediate shaft rear bearing.
Turn the input shaft into the output shaft, and align the Install the intermediate shaft rear bearing with the
slot of the synchronizer ring with the slider. hydraulic press.
ES030121 ES030123
9 Select suitable shaft collar. Note：The rear bearing of the intermediate shaft is
equipped with a bearing stop ring.
11 Install the reverse gear idler and reverse gear
idler shaft.
Install the reverse gear idler and reverse gear idler shaft
on the intermediate plate.
ES030122
ES030124
Note：The reverse gear idler with the shift fork

groove shall face backward, and the reverse gear
idler shaft is inserted from the back.
11-40
5MT
12 Install the baffle of the output shaft rear bearing. 14 Install the 5th gear of the intermediate shaft.
Install and tighten the bolt with a torque socket wrench. （a） Install gear sleeve 3.
Tightening torque: 12.6 ～ 23.4N.m. （b） Install the slider of synchronizer 3, synchronizer
packing ring, synchronizer spring and shaft collar.
ES030125
ES030127
13 Install the 5th gear thrust washer.
（c） Install the 5th gear needle bearing, 5th gear
Install the pin into the pin hole of the intermediate shaft,
component and 5th gear synchronizer ring of the
and install the 5th gear thrust washer.
intermediate shaft on the intermediate shaft.
ES030126
ES030128
Note：The 5th gear thrust washer has a specified
direction.
11-41
5MT
15 Install the 5th gear linkage gear. 17 Select suitable shaft collar.
Install the linkage gear of the 5th gear with the hydraulic The shaft collar selected shall help to achieve the
press. minimum axial clearance.
ES030129 ES030131
16 Measure the axial clearance of the 5th gear. 18 Install the shaft collar.
Measure the axial clearance of the 3rd gear component Install the shaft collar with a screwdriver.
ES030132
ES030130
11-42
5MT
19 Install the bracket of the R gear shift rocker arm. 21 Install the R gear shift rocker arm and R gear
shift fork connected on the location shown.
Install and tighten the bolt with a torque socket wrench.
Tightening torque: 12.6 ～ 23.4N.m.
ES030135
ES030133 22 Install the steel ball and R gear locating spring.

Install the steel ball and R gear locating spring into the R
20 Connect the R gear shift rocker arm and R gear gear shift rocker arm.
shift fork.
Install the E-collar to connect the R gear shift rocker arm
and R gear shift fork with a screwdriver.
ES030136
ES030134
11-43
5MT
23 Install the shift fork shaft of the R gear. 25 Install the component of shift fork 3 and the shaft
of shift fork 3.
With the tip of the shift fork shaft of the R gear forward,
install it on the intermediate plate and R gear rocker arm Install the component of shift fork 3 on gear sleeve 3, and
bracket. install the shaft of shift fork 3 and insert it into the fork
shaft hole of the component of shift fork 3.
ES030137
ES030139
24 Install the steel ball and interlocking guide pillar.
26 Install the clamping collar.
（a） Install the steel ball into the R gear shift rocker arm.
Install two clamping collars with a screwdriver to the
（b） Install the interlocking guide pillar into the location shown on the shaft of the R gear shift fork and
intermediate plate, and embed the steel ball into the hole
shift fork 3 respectively.
of the R gear shift fork shaft.
ES030140
ES030138
11-44
5MT
27 Install the interlocking guide pillar. 29 Install the interlocking guide pillar.
Install the interlocking guide pillar into the intermediate Install the interlocking guide pillar into the intermediate
plate. plate.
ES030141 ES030143
28 Install the shaft of shift fork 1 and shift fork 1. 30 Install the shaft of shift fork 2 and shift fork 2.
Install the shaft collar with a screwdriver. Pass the shaft of shift fork 2 through the intermediate
plate and the fork shaft holes of shift fork 1 and 2.
Apply grease to the shaft pin hole of shift fork 1, and
install the short interlocking pin, then insert the shaft of
shift fork 1 into shift fork 1 through the intermediate plate.
ES030144
Note：The shaft of shift fork 2 has a specified

ES030142 direction.
Note：
·The shaft of shift fork 1 has a specified direction.
·During installation, the short interlocking pin shall not

drop.
11-45
5MT
31 Secure the component of shift fork 3. 33 Fix shift fork 1 and 2.

With the special installer for the elastic cylindrical pin, Install and tighten the bolt with a torque socket wrench.
install the elastic cylindrical pin to fix the component and
fork shaft of shift fork 3.
ES030147
ES030145
34 Install the steel ball, locating spring and locating

32 Install the clamping collar.
spring plug.
Install two shaft collars to the location shown on the shaft
Install the steel ball, locating spring and locating spring
of shift fork 1 and 2 respectively with a screwdriver.
plug.
（a） Install the steel ball and locating spring.
ES030146
ES030148
11-46
5MT
（b） Install and tighten the plug with a torque socket 37 Install the odometer shaft collar.
wrench.
ES030152
38 Install the magnet. Install the magnet on the

ES030149 location shown.
35 Install the odometer shaft collar.
ES030153
ES030150
36 Install the steel ball and drive gear of the

odometer.
ES030151
11-47
5MT
39 Apply silica gel 1596 to the mating face between 41 Install the bearing stop ring. Install the stop ring
the transmission housing and the intermediate of the input shaft bearing and intermediate shaft
plate. front bearing with a plier.
Remove the oil stain, etc on the mating face, then apply
silicone rubber with a diameter of appr. 1.2mm to the
mating face.
ES030156
42 Install the shift shaft and shift block.
ES030154
Note：Eliminate any inclusion on the surface

before the application; and install the
transmission housing within 10min after the
application.
40 Install the transmission housing.
Install the transmission housing on the intermediate plate
component installed.
ES030157
43 Apply silica gel 1596 to the mating face between

the rear body subassembly and the transmission
housing. Remove the oil stain, etc on the mating
face, then apply silicone rubber with a diameter
of appr. 1.2mm to the mating face.
ES030155
ES030158
11-48
5MT
Note：Eliminate any inclusion on the surface 46 Install the position mechanism component.
before the application; and install the
transmission housing within 10min after the
application.
44 Install the rear body subassembly on the
transmission housing.
ES030161
47 Install the shift cover on the rear body

subassembly and tighten the bolt.
ES030159
45 Install the flange bolt, fix the shift block to the

shift shaft.
ES030162
48 Install the reverse gear switch.

ES030160
ES030163
11-49
5MT
49 Apply silica gel 1596 to the mating face between 51 Install the clutch housing on the transmission
the front cover and the transmission housing. housing, and tighten the bolt.
Remove the oil stain, etc on the mating face, then apply
silicone rubber with a diameter of appr. 1.2mm to the
mating face.
ES030166
Note：Tightening torque: 15.5 ～ 20.6N.m.
ES030164 52 Install the seal ring of gasket and hexagon plug.
Note：Eliminate any inclusion on the surface

before the application; and install the front cover
within 10min after the application.
50 Install the front cover.
Install and tighten 8 bolts with a torque socket wrench.
ES030167
ES030165
Note：Tighten the bolt in the diagonal sequence.
11-50
5MT
6 Rotate the shift knob counterclockwise to lift the

Removal/Installation of Transmission
shift knob and dust shield assembly.
Assembly
Removal
1 Apply the hand brake, hold it in N gear and place
the ignition switch in OFF position.
3 Lift the vehicle from the lifting machine. Remove
the catalytic converter assembly (refer to
Removal of Catalytic Converter Assembly).
4 Release the drain plug to drain the transmission
fluid, and keep the fluid in a proper container.
5 Remove the center console.
ES040122
7 Remove the seal gasket and seal plate of the

shift mechanism.
1 3 5
2 4 R
ES040130
Note：Please remove the dust shield of the shift

lever in the vertical direction; horizontal removal
tends to damage the leather sheath frame due to
force effect. ES040123
8 Disconnect the CSC bleed connector. Remove

with the connector upward, so that brake fluid
leak can be avoided.
ES040121
ES040124
11-51
5MT
9 Drain the brake fluid to a proper container. 13 Remove 4 bolts fixing the propeller shaft to the
10 Disconnect the reverse lamp harness, and transmission, disconnect the propeller shaft, and
remove the cable from the housing harness clip. move the propeller shaft properly so that it will
not interfere with the operation.
ES040125
ES040128
11 Unscrew 2 bolts of the intermediate support
assembly of the propeller shaft to remove the 14 Support the bottom of the transmission with a
intermediate support assembly. suitable bracket.
15 Remove 4 bolts connecting the rear mount
bracket to the transmission.
ES040126
12 Remove 4 bolts fixing the propeller shaft to the ES040129

rear axle.
16 Remove 4 bolts connecting the transmission
mount beam and the body, and remove the
transmission mount beam.
17 Remove 11 bolts securing the transmission to
the engine.
ES040127
11-52
5MT
18 Release the transmission from 2 locating pins,

Tool
and carefully put the bracket down to remove the
transmission assembly.
Description
Installation
—Slightly lubricate the input shaft spline.
1 Copper hammer
—Before installing the bolt, never hang the transmission
on the input shaft.
—After installing the propeller shaft, refill the specified oil

of 2.4 ± 0.1 L through the oil filler plug aperture. Remove
the oil level plug to drain the excess oil. Reinstall the plug.
—Connect the transmission gear cable, and check if all

gears are correct.
2 Plier
—The transmission mount uses self-locking nuts that
allow for one time use only, so new nut shall be used after
any removal, otherwise, the performance of the fastener
cannot be guaranteed.
3 Magnet
C00089862
4 Punch for
removal
11-53
5MT

Description
C00089863
Tool for output
5
shaft rear
bearing
C00089864
Tool for
6 intermediate
shaft 5th gear
linkage gear
C00089869
7 Tool for input
shaft oil seal
C00089867-2
8 Tool for rear
housing oil seal
C00089877
assemble jig of
9 flange-
companion and
dust-cover
11-54
6AT
6AT
Specification
Model 6L50
Hydraulic torque converter 240mm (with lock- up clutch control)
Engine input power 235 kw
Max. input torque of diesel engine 550 N.m
Max. load of transmission 650 N.m
Speed ratio Gear 1. 4.065 Gear 2. 2.371 Gear 3. 1.551

Gear 4. 1.157 Gear 5. 0.853 Gear 6. 0.674
Mode Default, sport, cruise, manual
Lubricant petro-Canada DEXRON VI
Weight 90Kg (wet weight)
Torque
Application Torque (N.m)
Bolt - cable bracket assembly 20 ± 2

Nut - transmission rocker arm 33 ± 3
Bolt - transmission shift lever assembly 20 ± 2
Nut - transmission shift lever assembly 20 ± 2
Bolt - shift cable assembly 9±1
Bolt - engine to transmission 55 ± 5
Bolt - flexible plate to hydraulic torque converter 55 ± 5
Bolt - flexible plate to engine First 50N.m, release 90°, then 25N.m + 75°
12-1
6AT
2WD 4WD
ES050135
12-2
6AT
Layout
Layout
ES050155
12-3
6AT
Layout
1
1
2
10
12
13
4
3
11
8
6
5
ES050000
1 RWD AT/4WD AT 7 Transmission oil pan gasket

2 Hydraulic torque converter assembly 8 Transmission fluid filter component
3 Electric component 9 Transmission oil pan component
4 O-ring component 10 Seal plug for transmission oil filter
5 Drain plug component for transmission fluid 11 Transmission bolt
renew 12 Shift control component
6 Transmission oil pan tightening bolt 13 Transmission O-ring
Note：Electric component = hydraulic valve assembly + 2 gaskets + control & support gasket + electric
plug sleeve + speed sensor + internal mode switch + bolt
12-4
6AT
Transmission/Electric Component Diagnosis
Transmission/electric component diagnosis
Test and service instructions Test and service instructions
Clear DTC and road test 30 miles
NO
Return the vehicle DTC appears again?
YES
Refer to test suggestions
ES050136
12-5
6AT
Oil Leak
Oil Leak
Check if there are NO Is the transmission

other faulty parts? fluid leaked?
YES
Clean the possible leaking

area with a piece of rag
Drive 15-20min to make the oil

temperature normal. Do not drive at
a high speed, or the oil will disperse,
and the leaking point cannot be identified.
Park at the clean place

and shut down the engine
Identify the leaking point
NO
Can the leakage be repaired Contact us
with after-sales parts?
YES
Service
ES050154
Note：Do not use active detergent like brake cleaner, etc to remove the leaking fluid, this may damage the
rubber gasket, gasket and shaft bush.
12-6
6AT
Location of 2WD Seal
6
2
12
1 3
7 13
11
10
14
8
4A
4B
5 9
ES050144
1 Electric plug sleeve 7 Seal plug for lubricant filler hole
2 Hole for pressure test 8 Output shaft seal
3 Junction between main transmission body and front 9 Oil pan gasket
housing
10 Seal for torque converter installation
4A Transmission to oil cooler
11 Oil level plug of oil pan
4B Oil cooler to transmission
12 External control of ASM park pawl
5 Shift shaft seal
13 Park pawl guide shaft
6 Breather pipe
14 Adjuster extension
12-7
6AT
Location of 4WD Seal
6
14 2
12
1 3
7 13
11
10
4A
4B
5 9
ES050145
1 Electric plug sleeve 7 Seal plug for lubricant filler hole
2 Hole for pressure test 8 Output shaft seal
3 Junction between main transmission body and front 9 Oil pan gasket
housing
10 Seal for torque converter installation
4A Transmission to oil cooler
11 Oil level plug of oil pan
4B Oil cooler to transmission
12 External control of ASM park pawl
5 Shift shaft seal
13 Park pawl guide shaft
6 Breather pipe
14 Transfer case seal
12-8
6AT
Service Frequency of Maintenance
Suggestions for towing: ·100,000Km is recommended.

Ensure the drive wheel is towed (below 50Km/h), the Characteristics of transmission fluid:
towing distance is below 50Km. Make sure the vehicle is
in N gear.
Item Specification
Type petro-Canada
DEXRON VI
Total capacity ~ 10.2 L
Oil pan removal 6.5-7L
Wet weight of transmission ~ 90 kg
ES050001
The label of the transmission is on the main transmission

body, the specific information is as follows.
Transmission label
ES050002
12-9
6AT
Repair Guidance 7 If the O-ring (gasket) is deformed, and the drain

plug is used, replace the drain plug.
Transmission Drain & Oil Pan Removal
1 Park on the lifting machine.

·Maintain the shift lever in P gear.
·Place the ignition switch in OFF position.
2 Lift the vehicle, and ensure there is an

appropriate space for removing the transmission
oil pan.
3 If the transmission is equipped with the guard
plate, remove and keep the bolt and gasket.
4 Place a container under the transmission for oil
collection. ES050007
Note：The ATF may burst out when the drain plug
is released, please ensure a container is placed 8 Remove the drain plug to drain the transmission
under the oil pan. fluid until the fluid changes from line to drop.
9 Release 17 bolts of the oil pan with a normal
hexagon wrench (M10).
ES050005
5 Wait the temperature of the transmission fluid to ES050008

reach the ambient temperature.
6 Slowly release and remove the drain plug of the
transmission.
ES050009
ES050006
12-10
6AT
10 Remove the oil pan and its gasket.

Oil Pan Installation
1 The sealing surface of the oil pan shall be clean

and free from any metal debris, etc.
2 Install the oil pan and gasket with two positioning
devices.
ES050010
Note：
· Check the surface of the oil pan gasket for obvious

deformation or fracture.
ES050012
· Seal of the oil pan gasket is achieved by deformation
under compression, it can be reused. 3 When removing the magnetic absorptive piece,
metal debris may occur.
· Check the two protrusions on the gasket, locate the
gasket and oil pan. If the oil pan gasket is damaged, do 4 Install the above parts properly, and tighten 17
bolts to a torque of.
not reuse.
5 8-10N.m in the sequence below.
5 4 1 9 17
7
13 14
11 12
16 15
8 6 2 3 10
ES050011
ES050013
11 Check the oil pan gasket for fracture, bubble due
to overheating and delamination of the rubber 6 For transmission fluid refill, please refer to
and underlayer metal, etc. procedures for transmission fluid refill.
12 If the above situations, even leak occurs, use
new parts for reinstallation.
12-11
6AT
9 Install the top plug (J1).

Removal/Installation of Transmission Fluid
Filler Rubber Plug
1 Lift the vehicle to facilitate the operation.

2 Before removal, clear the surrounding (J) of the
fluid filler pipe.
Top plug J1
Rubber plug J2
ES050016
Lubricating
oil filler J
ES050014
3 Place the screwdriver under the top plug (J1).

4 Lift the top plug (1).
5 Clamp the rubber plug (J2) with a plier.
6 Pull out the rubber plug (2).
ES050015
7 Discard the filler plug (J) removed, and do not

reuse it.
Note：When the top plug (J1) is lifted, the
diameter of the rubber plug (J2) diminishes, so it
is easy to remove the whole rubber plug.
8 Insert a new filler plug into the main transmission
body.
12-12
6AT
Note：Use petro-Canada DEXRON VI fluid only,

Transmission Fluid Level Adjustment
use of other fluids may cause damage to the
Note：Lift the vehicle and remove the guard plate. transmission.
1 For removal of the fluid filler plug, please refer to 4 Remove fluid refill tool.
the Removal and Installation of Fluid Filler Plug 5 For installation and refill of the filler pipe, please
document. refer to the Installation and Removal of
Transmission Fluid Pipe document.
7 For fluid level check, please refer to
Transmission Fluid Level Check.
ES050017
2 Eliminate fluid residue in all pipes with a

compressed air tool. Use a machine to connect
the fluid filler hole.
ES050018
Note：Use the following parameters to give an

approximate estimation of the fluid volume to be
refilled.
—Oil pan removal, 6.5-7L
—Hydraulic torque converter removal, 1L
—Transmission cooler oil line, 0.4L
3 Refill fluid until it overflows the filler hole.
12-13
6AT
7 Remove and replace the drain plug (F).

Transmission Fluid Level Check
1 Read the transmission fluid temperature (TFT)

with the testing tool.
2 Start and idle the engine.
3 Fully depress the brake pedal, shift gears and
stay in each gear for more than 3s, finally return
to P gear.
100 120 140
F
2 3
80 160
60 180
1 4 40 200
20 220
0 240
0 5
ES050023
P
R
8 Observe the following instructions:
N
· When the temperature rises, the transmission fluid
D
SD starts to come out, the fluid changes from stable liquid
M1...M4 flow to drops.
ES050020 · The TFT is increasingly high, observe its state at a

temperature of 30°-50°.
4 Idle the engine for at least 1mim.
· If the TFT is above 50°, but the fluid is still not drops,
Note：If the vehicle is provided with the manual fluid failure may occur, refill transmission fluid and
mode, no need to upshift to M5 and M6 gears, repeat the above steps.
because the clutch of these two gears is identical
with that of the M2 and M3 gears. ·The identification standard is as follows:
5 Lift the vehicle with a lifting machine, maintain
Upper limit: when the fluid becomes drops at 30°C
the P gear and idle the engine.
(+/- 2°C)
6 Place a container under the transmission for oil
collection, and slowly release the drain plug (F). Normal volume: when the fluid becomes drops at 40°
Note：During fluid level check, the engine shall be C (+/- 2°C)
in a stable idling. If the engine does not work,
Lower limit: when the fluid becomes drops at 50°C(+/
when refilling according to the above methods,
- 2°C)
the fluid volume is below the normal value, this
can lead to premature wear or failure of the parts. 9 Replace the drain plug and tighten it with a
torque of 25N.m.
Note：For fluid check and refill, the TFT shall be
30°-50°. 10 Check the surrounding of the drain plug, and
check for fluid leak. Other locations required a
check for possible leaks, please refer to the Oil
Leak Location document.
11 Install the guard plate under the transmission.
12 Lower the lifting machine and vehicle.
12-14
6AT
Note：
Hydraulic Torque Converter Removal
Check the color of the fluid.
1 Drain transmission fluid. Please refer to
The fluid shall be red or dark brown. Transmission Fluid Drain and Oil Pan Removal.
2 Remove the transmission from the vehicle.
If the fluid appears to be dull black or black, and has a
pungent burning odor, the fluid is contaminated or
becomes invalid due to overheating.
1
ES050024
Note：Keep the transmission level to avoid

release of the hydraulic torque converter.
3 Secure the transmission on the turning support.
ES050025
12-15
6AT
4 Pull out and remove the hydraulic torque 7 Install it into the input shaft.
converter (B).
B ES050028
ES050026
Note：When removing the hydraulic torque

converter, the transmission fluid will come out.
Be sure to prepare an oil pan under the
transmission.
5 Remove the O-ring (D) of the input shaft with a
screwdriver and discard it.
6 Replace the O-ring (D) and soak it with
transmission fluid.
ES050027
12-16
6AT
Hydraulic Torque Converter Installation 3 Check the distance between the surface of the
transmission housing and the hydraulic torque
Note：Please make sure that the O-ring (D) is not
converter with a gauge or check if the hydraulic
damaged and locates in the ring groove. torque converter is properly installed with the
retaining plate for transportation (if the hydraulic
torque converter is properly installed, it will not
interfere with the retaining plate when turning).
ES050029
1 Push the hydraulic torque converter along the

input shaft, turn it manually until it completely ES050030
enters into the housing.
Note：The distance (a) shall be at least 13mm.
ES050030
ES050031
2 Axial installation shall be made.
12-17
6AT
Oil Filter Edge Seal Removal Acceptable:
1 Drain transmission fluid, please refer to Oil Drain

and Oil Pan Removal.
2 Manually remove and discard the oil filter.
Directly pull out the oil filter, do not bend or twist
the pipe of the filter.
ES050156
·Remove the bush with a screwdriver or plier.
·Replace the bush, and do not reuse it.
·Install a new bush (refer to procedures for bush

installation)
ES050032
3 If the edge of the entire bush is higher than the

pump, the seal is invalid.
Note：A good bush shall be smooth and fit with
the oil circuit.
Unacceptable:
ES050033
12-18
6AT
Oil Filter Bush Seal Installation

Note：Ensure the bush is properly installed,
please refer to Oil Filter and Bush Removal.
1 If the pump seal is correct and intact, please

directly refer to section 6 of the document.
2 Before using a new bush, please ensure the
edge of the mounting hole is free from any
rubber debris that affects the sealing.
3 Bush with transmission fluid is allowed.
4 Install the bush with seal installer C00089880.
ES050037
6 When installing the filter component (H), ensure

it is perpendicular with the pump.
ES050035
5 Uniformly press the bush.

ES050038
C00089880
ES050036
12-19
6AT
7 Ensure the filter is correctly installed, then the

Electric Component Removal
position of the filter can press the bush and
guarantee the seal function. 1 Drain transmission fluid, please refer to Oil Drain
2 Remove the oil filter, please refer to Oil Filter and
Seal Removal.
ES050039
ES050041
Note：Caution：The seal position of the bush is

very crucial, it shall be smooth, fit and free of
deformation.
3 Remove the harness connector, rotate the
handle, and disconnect the connector plug with
the guide of the guide groove.
ES050040
ES050042
Note：Do not touch the connector pin.

4 Unlock the slide lock (1) of the sleeve of the
electric locking connector.
12-20
6AT
5 Remove the sleeve (2) of the electric connector. Precaution：Do not touch the connector pin and
welding component on the circuit board.
Edge seal O-ring
1
SCALE : FULL
2
ES050043
ES050046
Note：Pull out the sleeve of the connector axially,
do not turn/twist it. Note：
6 Remove 6 bolts in the sequence shown only. Check the sealing surface:
Bolt - 6 – M5 × 73 – 10N.m .·O-ring (X2)
·Edge seal (X1)
8 Reinstall the sleeve (2).

3 2 6
4 1 5
ES050044
7 Remove the electric control module.

ES050047
Note：For sleeve installation, a position notch for

correct installation is provided, please align and
insert it into the notch.
ES050045
12-21
6AT
9 Lock the anti-release lock (1). 12 Remove the seal component (5) from the main
transmission body.
ES050048
5
ES050050
Note：If the sleeve is improperly installed, the
anti-release lock cannot lock. Note：Discard the seal component, and do not
10 Remove the seal component (3) from the valve reuse it.
component. IMPORTANT： When the shaft of the gear selector
11 Remove the seal component (4) from the valve shall be removed or replaced, remove the electric
component. component.
4
ES050049
Note：Discard the seal component, and do not

reuse it.
12-22
6AT
Precautions for Electro Static Discharge Electric Component Installation

(ESD) Precaution：For electro static discharge, please
The electric component is quite susceptible to the static refer to Precautions for Electro Static Discharge
(including TCU, sensor, etc), and the static warning sign (ESD).
will be provided during the service.
1 Check the oil inlet of the electric component.
E ‐ Electro
S ‐ Static
D ‐ Discharge
When the operator touches any electric component, the

static will discharge directly;
When replacing any electric component, pay particular

attention to the electro static discharge (ESD), and failure
to follow the general security specifications
will cause damage to other electric components of the

vehicle; ES050051
To avoid electric component damage due to static, 2 Check the oil outlet of the oil pump.
please follow the following instructions:
For replacement, do not open the original package in

advance, remove the part from the original package only
when installation can be done immediately. Do not
directly touch the pin of the connector, touch the outer
package of the electric component only, if the electric
component must be removed, please put it back into the
original package as soon as possible (quick operation is
required).
Protective articles necessary for the operator:
Antistatic shoes, gloves.

ES050052
TEHCM
ES050137
12-23
6AT
3 Check the middle oil passage hole. 7 Remove the connector sleeve (1), please refer to
Electric Component Removal.
ES050053
ES050056
Note：The hole shall be clean, smooth and free
from residues. 8 Use the two holes of the main transmission body
to ensure correct installation of the control valve
4 Install a new seal component (3).
component.
ES050057
ES050054
ES050058
Note：When installing a new electric component,
do not forget to remove the spring of the shift
ES050055 mechanism from the former component,and a
H10 wrench shall be used, the torque is 12N.m.
12-24
6AT
9 Install bolt 1-6 in the sequence shown, ensure 15 Clear the DTCs due to rewriting or replacement.
the control valve component is on the 16 Perform a road test and execute a self-learning
transmission, 6 bolts – M5 × 73 – torque: for the transmission.
10N.m.
Note：Do not touch the connector pin.
3 2 6
4 1 5
ES050059
Note：Remember to tighten the bolts in the

sequence shown.
10 Reinstall the sleeve (1) of the electric connector,
axially insert the sleeve to connect the
connector, do not rotate the sleeve and ensure it
is properly installed. For correct installation, the
distance between the outer surface of the sleeve
and the surface of the transmission shall be 14-
16mm. If the sleeve is properly installed, the
slide lock (2) can lock.
14 - 16 mm
2
ES050060
11 Reinstall the oil filter and oil pan, please refer to

Oil Filter/Oil Pan Installation.
12 Connect the vehicle harness, please refer to
Electric Component Removal.
13 Rewrite the transmission data.
14 Clear the TCU cache, input the VIN of the TCU
with the scan tool.
12-25
6AT
9 Remove the spring pin (L1) of the shift lever

Gear Selector and Seal Removal
shaft, discard the spring pin removed, and do not
1 Lift the vehicle and drain transmission fluid, reuse it.
please refer to Oil Drain and Oil Pan Removal. Note：The two spring pins have a different size,
2 Remove the oil filter, please refer to Oil Filter and Remove L2 first, then L1.
Seal Removal. 10 Remove the shift shaft (L3) as illustrated, do not
3 Remove the electric control valve, please refer to reuse the shift shaft with any wear or
Electric Component Removal. deformation.
4 Remove the lever of the gear selector from the
gear selector shaft of the transmission.
L1
L2
L3
ES050067
ES050061
5 Install C00089882 (1) into the gear selector

shaft, and turn it to the end, then rotate the bolt
to remove the seal ring with a tool.
C00089882(1)
ES050062
6 Discard the gasket, and do not reuse it.

7 Remove the lever of the gear selector from the
gear selector shaft of the transmission.
8 Remove the spring pin (L2) of the shift lever
shaft, discard the spring pin removed, and do not
reuse it.
12-26
6AT
4 Install the spring pin (L1) of the shift shaft with a

Gear Selector Shaft and Seal Installation
hammer.
1 Select an appropriate new seal ring, and ensure
the shaft hole and the mounting surface of the
seal ring are free from any residue.
2 Install a new seal ring (L4) with C00089882 (2),
and ensure it is completely pressed into the
corresponding location with a uniform force.
L1
C00089882(2)
ES050070
L4
5 Align the pin hole of the stop shaft with that of the
shift shaft, and install a new spring pin (L2) with a
hammer.
ES050068
3 Install a new shift shaft (L3) and stop lever. L2
L3
ES050071
Note：The two sides of the spring pin shall have a

same length.
ES050069
L1 L2
ES050072
12-27
6AT
5 Install it on the output shaft.

AWD Output Shaft O-ring Removal/
Installation
1 Drain transmission fluid, please refer to Oil Drain

2 Remove the transmission, please refer to
Transmission Removal.
3 Pry and remove the O-ring (M) with a
screwdriver.
ES050075
M
ES050073
Note：Discard the ring, and do not reuse it.

4 Apply transmission fluid to the new ring.
ES050074
12-28
6AT
4 Insert tool C00045013 into the shift arm to fix the

Shift Connector Adjustment
shift arm, for this operation, the transmission is in
Note：Lift the vehicle with the lifting machine, the N gear.
remove the lower guard plate of the automatic
transmission, and maintain the shift lever in N
gear.
1 Remove the shift cable.
C00045013
ES050139
5 Clamp the shift cable into the slot of the shift

mechanism, rotate 90 ° to clamp the shift cable
and connect the cable connector with the pin
ES050076 shaft. For the process, the shift mechanism shall
be in the N gear.
2 Confirm that the shift lever and transmission
gear selector are in the N gear.
Confirm that the position of the gear selector is
unchanged for the fastening process.
3 Push out the adjuster of the shift cable laterally.
ES050140
ES050138
Note：Push out the adjuster of the shift cable to

adjust the length of the cable.
12-29
6AT
6 Install the shift cable and body. latch, then the shift cable locks, remove the
installer of the shift cable.
ES050141
ES050143
Note：The arrow of the shift cable is forward.
9 Confirm that the shift lever corresponds to the
7 Install the shift cable into the shift cable bracket. instrument indication displayed on the vehicle.
Push up with great effort, and a "snap" indicates
10 Lower the lifting machine.
correct installation.
ES050142
8 Adjust the latch of the shift cable to align it with

the shaft pin axis of the rocker arm, install the
latch into the rocker arm shaft, and push the
12-30
6AT
Procedures for transmission adaptive control:

Transmission Adjustment
Frequent upshift, coast, downshift and slowdown are
Description
more favorable to the quick self-learning of the
After transmission rewriting, mechanical part or electric
transmission than constant driving at a single mode.
component replacement, a self-learning is required for
the transmission (actually control valve). During driving before the self-learning, if frequent
downshift for some gears occurs, especially when more
The electric component will keep learning the than one gear downshifts at a time, a jerk will appear, this
accumulative operation of the transmission and will substantially reduce drive comfort.
optimizing the quality of the shift, power output and fuel
economy. The procedures listed below are basic driving principles
which can be used to optimize the shift performance and
If the data is rewritten or the electric component and
improve comfort, avoiding more customer complaints
transmission are replaced, the learn value will be
due to the quality of shift.
removed. The user can feel change of the quality of the
transmission shift The scan tool can be used to monitor the state of the
transmission (position of the throttle and accelerator
Before the transmission acquires enough learning pedal, TFT, gear engagement,etc) during self-learning.
values.
The self-learning shall be carried out after the TFT is
The following procedures for transmission adaptive
above 25 ℃ .
control is a guide document for shortening the duration of
self-learning and reducing difficulty in operation, in the Note：Each process shall be performed
period after program update or part replacement, repeatedly to ensure there are enough input value
customers' questions about change of the shift quality for calculation of the basic effective value during
shall be solved as soon as possible through constant self-learning. Therefore, each procedure of the
operation is very important, including the
learning of the working conditions for different gears in
process of gear shift and gear maintenance.
different driving enviroN.ments.
Note：that security shall be guaranteed for self-

learning, the operation shall comply with
applicable laws and regulations and shall be
done in the site that will not affect the traffic.
12-31
6AT
Shift for steady downshift: will drop slowly until the vehicle downshifts to the 1st
N-R：depress the brake for at least 5 times. gear, then slightly depress the brake pedal to stop.
N-DS: depress the brake for at least 5 times (do not stop The adaptive operation of the future upshift and downshift
in D gear). shall follow the same way: when the accelerator pedal is
released, the vehicle speed drops slowly until the vehicle
N-D: depress the brake for at least 5 times.
slows down, then slightly depress the brake to stop the
D-R and R-D follow the sequence: release the brake for vehicle, this helps to accumulate data during selflearning.
at least 5 times (shift every two seconds during
downshift).
Upshift in warm-up state and downshift by

coasting (throttle off or accelerator pedal
released)
Maintain the accelerator pedal (appr. 30%-50%), ensure
upshift (1-6). After the vehicle upshifts to the 6th gear
(with the accelerator pedal released), the vehicle speed
will drop slowly until the vehicle downshifts to the 1st
gear, then slightly depress the brake pedal to stop.
Steady shift for warm-up process/after warm-up

process:
N-R: depress the brake pedal.
N-DS: depress the brake (do not stop in D gear).
N-D: depress the brake, N-D gear, release the brake, do

not depress the accelerator pedal.D-R 和 R-D
D-R and R-D follow the sequence: release the brake

(shift every two seconds during low-speed shift).
Upshift for warm-up process:

1-6 gear:
Maintain the accelerator pedal (appr. 30%-50%), ensure

steady upshift (1-2, 2-3, 3-4, 4-5, 5-6).
Downshift by coasting (with the accelerator pedal

released):
After the vehicle upshifts to the 6th gear (approximately),
with the accelerator pedal released, the vehicle speed
12-32
6AT
Downshift controlled by accelerator pedal: Low-speed shift at normal oil temperature:

Use the following shift methods to depress the Same with warm-up process (see above)
accelerator pedal gradually and perform the self-learning
Upshift at normal oil temperature:
for downshift.
1-6 gear:
Two different ways of gear operation:
Shift between 1-2/2-3/3-4/4-5 and 5-6, slightly depress
1 At medium speed, depress the throttle pedal with
the accelerator pedal to upshift (10-20%).
moderate acceleration;
2 At low speed, quickly depress the accelerator 1-6 gear:
pedal.
Shift between 1-2/2-3 and 3-4, moderately depress the
At medium speed, moderately depress the accelerator
accelerator pedal to upshift (30-40%).
pedal:
1-5 gear:
Shift between 6-5/5-4/4-3/3-2 and 2-1 (shift when engine
speed reaches 2000-4000rpm) Perform 1-2, 2-3 and 3-4, moderately depress the
accelerator pedal to upshift (50-60%).
At low speed, quickly depress the accelerator pedal:
1-4 gear:
Shift between 6-5/5-4/4-3/3-2 and 2-1 (shift when engine
speed reaches 2000-4000rpm) Perform 1-2, 2-3 and 3-4, quickly depress the accelerator
pedal to upshift (100%).
Reminder：Downshift by coasting.
6-1 gear:
Whenever an upshift cycle is finished, perform a steady

downshift (the vehicle decelerates slowly and stops
finally), and depress the brake pedal only in the final low
speed stage.
IMPORTANT：
Before replacing the transmission, hydraulic torque
converter or electric component, contact and authorize
the PPT.
12-33
6AT

Automatic Transmission Assembly Removal/
assembly of the propeller shaft to remove the
Installation intermediate support assembly.
Removal
2 Lift the vehicle on the lifting machine. Remove
3 Release the drain plug, remove the transmission
oil pan, drain the transmission fluid and keep the
fluid in a proper container.
4 Disconnect the cable of the shift lever from the
transmission (refer to Replacement of
Transmission Cable).
5 Disconnect the connector of the transmission
harness assembly, and remove the cable. ES050148
8 Remove 4 bolts fixing the propeller shaft to the

rear axle.
ES050146
6 Release the bolt connecting the rear assembly of

the transmission cooler pipe and transmission, ES050149
and disconnect the rear assembly of the
transmission cooler pipe. 9 Remove 4 bolts fixing the propeller shaft to the
transmission, disconnect the propeller shaft, and
move the propeller shaft properly so that it will
ES050147
ES050150
12-34
6AT
10 Support the bottom of the transmission with a 14 Remove 10 bolts securing the transmission to
suitable bracket (no direct contact). the engine.
Note：The oil pan shall not be under direct stress.

ES050153

and ensure the torque converter is still
ES050151 connected to the transmission.
16 Carefully put the bracket down to remove the
Note：If a 4WD transmission is used, release the
transmission assembly.
bolt of the rear mount bracket on the transfer
case. Note：When removing the automatic transmission
assembly, do not drop the hydraulic torque
converter.
13 Rotate the flange of the transmission output
Installation：
shaft clockwise, remove the baffle of the flywheel
housing from the engine, and align the flexible 1 Installation is the reverse of removal. Pay
plate with the bolt of the automatic attention to the following precautions:
transmission,then remove 6 bolts fixing the
—Clean the junction of the engine and transmission.
flexible plate and torque converter.
—Lubricate the socket of the torque converter.

through the oil filler plug aperture. Remove the oil level
plug to drain the excess oil. Reinstall the plug.

allow for one time use only, so new nut shall be used after
ES050152
12-35
6AT
Special Tool
SN. Tool Number Tool Name Illustration Remark
1 C00089880 Oil seal installer
C00089880
Use for removal
C00089882
Installer/Remover
2 C00089882
for shift shaft oil seal
Use for installation
C00089882
12-36
DYMOS 6MT
DYMOS 6MT
Service Standard
Item Standard value (mm)
Main drive pinion bearing axial clearance (snap ring) 0 ~ 0.06L
Main drive pinion bearing axial clearance (spacer ring) 0 ~ 0.05L
Dropeller shaft axial clearance (snap ring) 0 ~ 0.06L
Intermediate shaft ball bearing axial clearance (snap ring) 0 ~ 0.15L
13-1
DYMOS 6MT
Snap Ring and Gasket for Adjustment
Item Thickness (mm)
Spacer ring 0.81

(for main drive pinion bearing axial clearance)
0.84
0.87
0.90
0.93
0.96
0.99
1.02
1.05
1.08
1.11
1.14
1.17
1.20
Snap ring 1.49

(for main drive pinion bearing axial clearance)
1.52
1.55
1.58
1.61
1.64
1.67
1.70
1.73
1.76
Snap ring 1.39

(for intermediate shaft ball bearing axial clearance)
1.46
1.53
1.60
13-2
DYMOS 6MT
Item Thickness (mm)
Snap ring 1.47

(for propeller shaft axial clearance)
1 50
1.53
1.56
1.59
1.62
1.65
1.68
1.71
1.74
13-3
DYMOS 6MT
Tightening Torque
Application Torque (N.m)
Oil deflector bolt 7.8 ~ 9.8
Rear bearing seat bolt 19.6 ~ 26.5
Main shaft gear lock nut (4WD) 245.2 ~ 264.8
Flange lock nut (2WD) 156.9 ~ 186.3
Intermediate shaft R gear lock nut 156.9 ~ 186.3
Shift assembly bolt 14.7 ~ 21.6
Front transmission housing bolt 42.2 ~ 53.9
Front bearing seat bolt 19.6 ~ 24.5
Oil bleeding bolt 58.8 ~ 78.5
Oil filling bolt 58.8 ~ 78.5
Lock plate bolt 14.7 ~ 21.6
Guide bolt 14.7 ~ 21.6
Seal plug 53.9 ~ 67.7
CSC assembly bolt 9.8 ~ 11.8
Reverse shift fork hinge bolt 53.9 ~ 67.7
Reverse indicator switch 39.2 ~ 58.8
Flange clip bolt (4WD) 19.6 ~ 26.5
Bolt - shift lever 22 ± 2

Bolt - seal plate to body 20 ± 2
Nut - transmission shift lever to body 20 ± 2
Bolt - transmission to engine 50 ± 5
Warning：Always follow the specified torque. Violation of the specified torque will lead to breakage or
looseness due to high/low torque. Any of the above situations can cause serious personal injury or
death to the occupant.
13-4
DYMOS 6MT
Lubricant
Item Designated lubricant Volume
Transmission gear oi MTF SAE 75W-85 2.4L
Transmission input shaft spline CASMOLY L9508 0.2g
Front bearing seat oil seal Lithium grease As required
Front transmission housing oil seal Lithium grease 0.2g
Control lever oil seal Lithium grease As required
13-5
DYMOS 6MT
Layout
Layout
ES090014
13-6
DYMOS 6MT

Repair Guidance
Assembly
Removal
5 Remove the center console. ES040122

shift mechanism.
5

ES040120

lever in the vertical direction; horizontal removal ES040123
force effect. 8 Disconnect the CSC bleed connector. Remove
ES040121
ES040124
13-7
DYMOS 6MT
ES040125
ES040128
ES040126

rear axle.
case.
the engine.
ES040127
13-8
DYMOS 6MT

Replacement of Manual Transmission
transmission assembly. Removal
1 Remove 2 guide pins (B), and remove the shift
control assembly.
Installation

TGS pin
on the input shaft.
B
A
of 2.4 L through the oil filler plug aperture. Remove the oil
level plug to drain the excess oil. Reinstall the plug.

gears are correct. ES090001
—The transmission mount uses self-locking nuts that 2 Remove the spring pin (B), and remove the lever
allow for one time use only, so new nut shall be used after (A).
A
B
ES090002
13-9
DYMOS 6MT
3 Remove the drain plug (A) to drain the 6 Release 8 bolts to remove the front bearing seat
transmission fluid. component (A).
A A
ES090003 ES090006
4 Destroy the 2 locking points (C), remove the lock 7 Remove the gasket (A) and oil seal (B) from the
nut (C) from the main shaft assembly, and front bearing seat component.
remove the flange tray (A) and O-ring (B).
A, B
A
B
C
ES090007
ES090004
Note：Do not reuse the oil seal.
Note：The O-ring (B) cannot be reused.
8 Remove the snap ring (A) with a special plier
5 Disassemble the starter (B) and 3 bolts to from the main shaft.
remove the C.S.C (A).
ES090008
ES090005
13-10
DYMOS 6MT
9 Disassemble the reverse indicator switch (A). 12 Remove the plug (A), and remove the guide
spring (B) and the push rod roller (C) of the oil
pump plunger.
C
B
A A
ES090009
Note：倒车指示灯开关不可重复使用。 ES090012
10 Do not reuse the reverse indicator switch.

13 Remove the guide bolt (A).
ES090010
ES090013
Note：Do not reuse the hinge bolt.
14 Remove the lock plate bolt (A).
11 Remove the conical ball bearing component (A).
ES090014
ES090011
15 Release 12 bolts retaining the front transmission

housing.
13-11
DYMOS 6MT
16 Remove the front transmission housing (A) with 19 Remove the rear transmission housing (A) with a
a rubber hammer. rubber hammer.
ES090015 ES090018
17 Remove the main shaft oil seal (A) and control Warning：Take care not to drop and damage the
shaft oil seal from the front transmission housing. main drive shaft component.
20 Remove the oil deflector (A) from the
transmission housing.
B
A
ES090016
18 Remove the magnet (A) and reverse idler gasket ES090019

(B).
21 Remove the R gear shift lug (A).
B
A
B
ES090017
ES090020
Note：Do not reuse the fork gasket (B).
13-12
DYMOS 6MT
22 Remove the R gear shift lug (A). 25 Remove the control shaft component (A).
ES090021 ES090024
23 Remove the E-ring (A) from the control shaft. 26 Release 2 bolts to remove the shift assembly (A)
of the 5th/6th gears.
ES090022
ES090025
Note：Do not reuse the E-ring.
24 Remove the spring pin (B) from the control shaft, 27 Remove the fork locating pins of the 3rd/4th
and then remove the plug rod (A). gears.
B A
ES090023 ES090026
Warning：When removing the spring pin (B), Warning：When removing the spring pin (A),
damage to the gear by the spring pin (B) shall be damage to the gear by the spring pin (A) shall be
avoided. avoided.
13-13
DYMOS 6MT
28 Remove the shift lever (A) of the 3rd/4th gears 31 Remove the fork (B)/(C) of the 1st/2nd gears and
and the shift lug (B) of the 5th/6th gears with a 3rd/4th gears.
rubber hammer.
B
B C
A
A
B
ES090029
ES090027
32 Destroy the 2 locking points (B), and remove the
29 Remove the fork (A) locating pin of the 1st/2nd lock nut (A) from the intermediate shaft.
gears.
ES090030
ES090028
33 Use the puller (A) to pull the reverse gear (B),
Warning：When removing the spring pin (A), and pull out the ball bearing (F), reverse gear
damage to the gear by the spring pin (A) shall be synchronizer hub sleeve (E), synchronizer ring
avoided. (C) and reverse gear (D).
30 Remove the shift lever (A) of the 1st/2nd gears
with a rubber hammer.
ES090031
13-14
DYMOS 6MT
34 Remove the reverse gear needle bearing (A). 38 Remove the reverse gear (A) of the intermediate
shaft.
35 Remove the reverse idler (B).
ES090035
ES090032
39 Remove the 6th gear (A) of the intermediate

36 Pull out the main shaft 6th gear (B) and reverse shaft.
gear sleeve (C) with the puller (A).
ES090036
ES090033
37 Remove the main shaft gasket (A). 40 Remove the synchronizer ring (B) and the 6th
gear needle bearing (A) of the intermediate
shaft.
ES090034
ES090037
13-15
DYMOS 6MT
41 Remove the shift fork (B) and synchronizer gear 44 Remove the 6th gear needle bearing (A) of the
sleeve (A) of the 5th/6th gears. intermediate shaft.
ES090038 ES090041
42 Remove 3 synchronizer sliders (A). 45 Remove 8 bolts with a box spanner to remove
the and bearing seat (A).
ES090039
ES090042
43 With the puller (A), pull out the main shaft 5th
gear (B), and remove the 6th gear sleeve (C) of Note：Do not reuse the bolt.
the intermediate shaft, hub (D) of the 5th/6th
46 Remove the snap ring (C) between the main
gears, outer synchronizer ring (E)/synchronizer
shaft (A) and the middle panel (B) with a plier.
cone (F)/inner synchronizer ring (G) of the 5th
gear and 5th gear.
ES090043
ES090040
13-16
DYMOS 6MT
47 Remove the snap ring (C) between the 50 Disconnect the main drive shaft component (A)
intermediate shaft (A) and the middle panel (B) and main shaft component (B).
with a plier.
ES090047
ES090044
51 Remove the needle bearing (B) from the drive
48 Release 2 bolts to remove the oil deflector (A). gear (A).
ES090045 ES090048
49 Disconnect the main shaft (A), intermediate shaft 52 Remove the snap ring (A) of the front ball
(B) and middle panel (C) with a rubber hammer. bearing.
B
ES090046 ES090049
13-17
DYMOS 6MT
53 Remove the ball bearing (A) with the pressing 56 Remove the synchronizer gear sleeve (A) of the
machine. 3rd/4th gears.
ES090050 ES090053
54 Remove the synchronizer ring (A) from the main 57 Press the 3rd gear (C) with the pressing
shaft assembly. machine, and remove the synchronizer ring
assembly (B) of the 3rd/4th gears and 3rd gear
(C) in sequence.
ES090051
55 Remove the snap ring (A) of the hub sleeve ES090054

assembly of the 3rd/4th gears.
58 Remove the needle bearing (A).
ES090052
ES090055
13-18
DYMOS 6MT
59 Press the 2nd gear with the pressing machine, 62 Remove the 1st gear sleeve (A).
then remove the 5th gear, ball bearing, 1st gear,
needle bearing, 1st gear synchronizer assembly,
1st gear sleeve, synchronizer hub sleeve
assembly of the 1st/2nd gears, 2nd gear
synchronizer assembly and 2nd gear.
ES090059
63 Remove the 1st gear (A).
ES090056
60 Remove the 5th gear (A).
ES090060
64 Remove the needle bearing (A).
ES090057
61 Remove the ball bearing (A).
ES090061
ES090058
13-19
DYMOS 6MT
65 Remove the synchronizer ring assembly (A) of 68 Remove the hub (A) of the 1st/2nd gears.
the 1st gear.
ES090065
ES090062
69 Remove the synchronizer ring assembly (A) of
66 Remove the synchronizer gear sleeve (A) of the the 2nd gear.
1st/2nd gears.
ES090066
ES090063
70 Remove the 2nd gear (A).
67 Remove 3 spring synchronizer sliders (A).
ES090067
ES090064
13-20
DYMOS 6MT
71 Remove the needle bearing (A). 74 With the gear puller (A), remove the roller
bearing (C), bearing shim and sleeve (B) of the
5th gear.
ES090068
72 Remove the snap ring (A) of the front roller ES090071

bearing from the intermediate shaft assembly.
75 Remove the inner ring (A) of the roller bearing
(base plate) with C00044499.
ES090069
73 Remove the front roller bearing (A) with the ES090072

pressing machine.
ES090070
13-21
DYMOS 6MT
Installation 4 Install the synchronizer hub (A) of the 1st/2nd

gears.
1 Assemble the needle bearing (A).
ES090076
ES090073
Warning：When assembling the hub assembly,
2 Install the 2nd gear (A). the surface with 3 oil grooves (E) shall be up.
ES090074 ES090077
3 Install the synchronizer ring (A) of the 2nd gear. Warning：Carefully align the groove between the
synchronizer ring (B) and the hub (C). After the
press operation, check the rotation state of the
synchronizer ring (D).
ES090075
13-22
DYMOS 6MT
5 Install the synchronizer hub (A) of the 1st/2nd 8 Install the needle bearing (A).
gears.
ES090081
ES090078
9 Install the synchronizer ring assembly (A) of the
Warning：Install the synchronizer gear sleeve (B) 1st gear.
with the gear upward.
6 Install 3 sliders (A).
A
A
ES090082
ES090079 10 Install the 1st gear (A).
7 Place C00089875 on the sleeve (A) of the 1st

gear, and press the sleeve (A) of the 1st gear
with a pressing machine or hammer.
A
ES090083
ES090080
13-23
DYMOS 6MT
11 Place C00089875 on the ball bearing (A), and 14 Install the synchronizer ring assembly (A) of the
press the ball bearing (A) with a pressing 3rd gear.
machine or hammer.
ES090087
ES090084
15 Place C00089875 on the synchronizer hub (A) of
12 Invert the main shaft, and install the needle the 3rd/4th gears, and press the synchronizer
bearing (A) of the 3rd gear. hub (A) of the 3rd/4th gears with a pressing
machine or hammer.
ES090085
ES090088
13 Install the 3rd gear (A).
Warning：When assembling the hub, the surface
with 3 oil grooves (E) shall be up.
ES090086
ES090089
13-24
DYMOS 6MT
Warning：Carefully align the groove of the 18 Install the synchronizer assembly snap ring (A)
synchronizer ring (D) and hub (C). After the press of the 3rd/4th gears [gap: 0 ~ 0.06L]
operation, check the rotation state of the
synchronizer ring.
16 Install the synchronizer gear sleeve (A) of the
3rd/4th gears.
ES090092
Warning：Confirm that the snap ring is new.
ES090090 Name Thickness (mm)
Warning：Install the synchronizer gear sleeve (B) Snap ring 1.47

with this surface upward. 1.50
17 Install the synchronizer slider (A) of the 3rd/4th 1.53
gears on 3 positions.
1.56
1.59
1.62
1.65
1.68
1.71
1.74
19 Install the synchronizer ring (A).
ES090091
ES090093
13-25
DYMOS 6MT
20 Install the needle bearing (A). Warning：Confirm that the snap ring is new.
Name Thickness (mm)
Snap ring 1.49
1.52
1.55
1.58
1.61
1.64
1.67
1.70
ES090094
1.73
21 Place C00089875 on the ball bearing (A), and 1.76
position the ball bearing (A) on the gear
assembly (B), then press it with the pressing
23 Assemble the main shaft assembly (A) and (B).
machine or hammer.
ES090097
ES090095
24 Place C00089875 on the inner ring (A) of the ball

22 Install the snap ring (A) of the front ball bearing
bearing, and press the inner ring (A) of the ball
[gap (mm): 0 ~ 0.06L].
bearing into the intermediate shaft with a
pressing machine or hammer.
ES090096
ES090098
13-26
DYMOS 6MT
25 Position the rear ball bearing (A) and rear 27 Install the snap ring (A) of the front ball bearing
bearing shim, and press the sleeve of the 5th [gap (mm): 0 ~ 0.15L].
gear in place with a pressing machine or
hammer.
ES090101
Warning：Confirm that the snap ring is new.

ES090099
26 Place C00089875 on the front ball bearing (A), Name Thickness (mm)
and press the front ball bearing (A) with a
pressing machine or hammer. Snap ring 1.39
1 46
1.53
1.60
28 Position the main shaft (A) on C00044497.
ES090100
ES090102
13-27
DYMOS 6MT
29 Assemble the intermediate shaft (A) into an 32 Install the snap ring (C) between the
assembly of main shaft/intermediate shaft with intermediate shaft (A) and the middle panel (B).
C00044497.
ES090106
ES090103
33 Install C00044499 between the 4th gear
30 Install the middle panel (A). synchronizer ring (A) of the main shaft and the
main drive gear (B).
ES090104
ES090107
31 Assemble the snap ring (C) between the main
shaft (A) and the middle panel (B) with a plier. Warning：Ensure the synchronizer protective
plate is properly installed, because the 4th gear
may be damaged during press operation.
ES090105
13-28
DYMOS 6MT
34 Install 8 bolts (B) with a hexagon wrench to 36 Place C00089875 (B) on the 5th gear sleeve (A)
secure the bearing seat (A) of the intermediate shaft, and press the 5th gear
sleeve (A) with the pressing machine or hammer.
[tightening torque: 2.0 ~ 2.7 kgf.m
19.6 ~ 26.5 N.m]
B
A-1
C
A
ES090110
Warning：When installing the gear sleeve (A),

ES090108
check if the 5th gear sleeve (A 1) is aligned with
the hole of the main shaft (C).
Note：Do not reuse the bolt.
37 Install the needle bearing (A).
35 Place C00089875 (B) on the 5th gear (A) of the
main shaft, and press the 5th gear (A) of the
main shaft with the pressing machine or
hammer.
QT
ES090111
& 38 Install the 5th gear (A) of the intermediate shaft.

ES090109
Warning：Install the 5th gear of the main shaft

with the direction point (C) upward or inner big
chamfer (D) downward.
ES090112
13-29
DYMOS 6MT
39 Install the synchronizer ring assembly (A) of the Warning：Carefully align the groove of the
5th gear. synchronizer ring (D) and hub (C). After the press
operation, check the rotation state of the
synchronizer ring.
41 Install the shift fork (B) and synchronizer gear
sleeve (A) of the 5th/6th gears.
ES090113
40 Place C00089875 (B) on the synchronize hub(A)

of the 5th/6th gears, and press the synchronize
hub (A) of the 5th/6th gears with a pressing ES090116
machine or hammer.
Warning：Install the synchronizer gear sleeve (C)
with this surface upward.
42 Place C00089875 (B) on the 6th gear sleeve (A)
of the intermediate shaft, and press the 6th gear
sleeve of the intermediate shaft with a pressing
machine or hammer.
ES090114
Warning：Assemble the hub with 3 oil grooves (D)

upward. A-1
ES090117
Warning：When installing the gear sleeve (A),

align the 6th gear sleeve (A-1) with the hole of the
main shaft (C).
ES090115
13-30
DYMOS 6MT
43 Install the 6th gear synchronizer ring (A) of the 46 Install the main shaft gasket (A).
intermediate shaft.
ES090121
ES090118
Warning：The raised part (B) shall be down.
44 Install the needle bearing (A). 47 Place C00089875 (B) on the 6th gear (A) of the
main shaft, and press the 6th gear (A) of the
main shaft with a pressing machine or hammer.
%
#
QT
ES090119
&
45 Install the 6th gear (A) of the intermediate shaft. ES090122
Warning：Install the 6th gear of the main shaft

with the direction point (C) upward or the inner
big chamfer (D) downward.
ES090120
13-31
DYMOS 6MT
48 Place C00089875 (B) on the reverse gear sleeve 51 Install the synchronizer ring (A) of the reverse
(A), and press the reverse gear sleeve (A) with a gear.
pressing machine or hammer.
ES090126
ES090123
52 Install the synchronizer hub (A) and synchronizer
49 Install the needle bearing (A) of the reverse gear. gear sleeve (B) of the reverse gear.
53 Install 3 sliders (C) and snap ring (D).
ES090124
ES090127
50 Install the reverse gear (A) of the main shaft.
54 Install the synchronizer hub sleeve assembly (A)
of the reverse gear.
ES090125
ES090128
13-32
DYMOS 6MT
Warning：The inner synchronizer ring (B) shall 57 Install the lock nut (A) of the intermediate shaft,
match with the inner side of the hub (C). and lock the 2 points at (B).
55 Install the reverse gear (A) of the intermediate [Tightening torque:16.0 ~ 19.0 kgf.m
shaft.
156.9 ~ 186.3 N.m]
$
QT
ES090129
ES090131
Warning：Install the reverse gear of the
intermediate shaft with the direction point (B) 58 Remove C00044498 between the 4th gear
upward or the inner big chamfer (C) downward. synchronizer ring (A) of the main shaft and the
56 Place C00089875 on the ball bearing (A), and main drive shaft (B).
press the ball bearing (A) with a pressing
machine or hammer.
ES090132
ES090130
13-33
DYMOS 6MT
59 Install the shift fork (C) and (D) of the 1st/2nd 61 Install the locating pin of the shift fork (A) and (B)
and 3rd/4th gears, and install the shift lever (A) of the 3rd/4th gears and 1st/2nd gears.
of the 3rd/4th gears and the shift lug (B) of the
5th/6th gears with a rubber hammer.
C A,B
B
A
C D
A B ES090135
Warning：Location of spring pin (A, B): the axial

ES090133
clearance between the spring pin and the fork rail
60 Install the shift lever (A) of the 1st/2nd gears with (C) shall be within ± 15°.
a rubber hammer. 62 Install the shift assembly of the 5th/6th gear with
the mounting bolt (2EA).
[Tightening torque: 1.5 ~ 2.2 kgf.m ； 14.7 ~ 21.6 N.m]
A
ES090134
Note：When installing the shift lever (A) of the 1st/

2nd gears, the lever shall match with the shift lug ES090136
(B) groove of the 5th/6th gears.
13-34
DYMOS 6MT
63 Install the shaft assembly (A) with a rubber Warning：Do not damage the E-ring during
hammer. installation, and do not reuse the E-ring.
66 Install 2 bolts to secure the oil deflector (A).
ES090137
64 Install the plug rod (A) to the control shaft with

the spring pin (B). ES090140
67 Install the shift lug (A) of the reverse gear.

A
C B
ES090138
Warning：Location of spring pin (B): the axial

ES090141
clearance between the spring pin and the control
shaft (C) shall be within 90 ± 15°. 68 Install the fork (A) of the reverse shaft.
65 Install the E-ring (A) through the control shaft.
B
ES090142
Note：Do not reuse the 2 fork gaskets (B).
ES090139
13-35
DYMOS 6MT
69 Install the oil deflector (A) on the rear 71 Install the gear assembly (A) to the rear
transmission housing. transmission housing.
ES090143 ES090145
70 Apply sealant (A) to the sealing surface of the 72 Install the magnet (A) and reverse idler gasket
rear transmission housing. (B).
A
B
ES090144 ES090146
Note：The section with sealant applied is 73 Apply sealant (A) to the sealing surface of the
0.8~.1.0mm, and the sealant shall be continuous middle panel.
[standard sealant: LOCTITE 5060].
ES090147
Note：The section with sealant applied is
13-36
DYMOS 6MT
Note：0.8~.1.0mm, and the sealant shall be 77 Install the interlock bolt (A).
continuous [standard sealant: LOCTITE 5060]. [Tightening torque: 1.5 ~ 2.2 kgf.m; 14.7 ~ 21.5 N.m]
74 Install the oil seal of the shift shaft to the front
transmission housing with C00089870-2, and
respectively install the 4WD and 2WD rear
housing oil seal to the front transmission housing A
with C00089878-1/C00089878-2.
ES090150
Note：Check the bolt size before assembly.

78 Install the guide bolt (A).
ES090148 [Tightening torque: 1.5 ~ 2.2 kgf.m; 14 7 ~ 21 5N m]
Note：If the inner lip of the oil seal assembled has

no grease, apply lithium grease of 0.2g to the
inner lip of oil seal. Do not reuse the oil seal.
A
75 Assemble the front transmission housing
assembly (A).
76 Tighten 12 bolts to the specified torque.
ES090151
A
Note：Check the bolt shape before assembly
ES090149
13-37
DYMOS 6MT
79 Install the guide spring (B) and rolling support 81 Install 2 hinge bolts (A) on the two sides of each
(C), and install the oil plug (A) on the rear front housing.
transmission housing. [Tightening torque: 5.5 ~ 6.9 kgf.m; 53.9 ~ 67.6 N.m]
[Tightening torque: 5.5 ~ 6.9 kgf.m; 53.9 ~ 67.6 N.m]
C
B
A
ES090154
ES090152
Note：Do not reuse the hinge bolt.
80 Install the conical ball bearing assembly (A). 82 Install the reverse indicator switch (A).
[Tightening torque: 3.0 ~ 4.2 kgf.m; 29.4 ~ 41.1 N.m] [Tightening torque: 4.0 ~ 6.0 kgf.m; 39.2 ~ 58.8 N.m]
ES090153 ES090155
Note：Do not reuse the reverse indicator.
13-38
DYMOS 6MT
83 Install the snap ring (A) on the main shaft Note：Do not reuse the bolt.
assembly.
86 Position the dial gauge (A) on the main shaft and
adjust to 0.
87 Pull the main shaft (B) forward to measure the
axial clearance.
ES090156
A
84 Install the shim (A) on the front bearing seat, and
install the oil seal (B) with C00089873.
ES090159
88 If the axial clearance does not meet the standard

value (0 - 0.06L), select a suitable gasket
according to the table below before
remeasurement.
Item Thickness (mm)
Gasket 0.81
0.84
0.87
ES090157
0.90
85 Temporarily assemble the front bearing seat (A). 0.93

[Tightening torque: 2.0 ~ 2.5 kgf.m; 19.6 ~ 24.5 N.m] 0.96
0.99
1.02
1.05
1.08
1.11
1.14
1.17
1.20
ES090158
13-39
DYMOS 6MT
89 If the axial clearance meets the specified value, 91 Install the bush (B) and 3 bolts to secure the
apply sealant (A) to the left of the front bearing C.S.C. (A).
seat assembly. [Tightening torque: 1.0 ~ 1.2 kgf.m; 9.8 ~ 11.8 N.m]
ES090160
ES090162
Note：The mating surface with sealant shall be
clean; the section with sealant applied is 92 Install the removable flange (A) and O-ring (B).
0.8~.1.0mm, and the sealant shall be continuous 93 Install the lock nut (C) on the main shaft
[standard sealant: LOCTITE 5060] assembly, and lock the two parts on point (D).
90 Install 8 bolts to secure front bearing retainer (A). [Tightening torque: 16.0 ~ 19.0 kgf.m
156.8 ~ 186.2 N.m]
A, B
D
C
A
B
C
A
ES090161
ES090163
13-40
DYMOS 6MT
94 Install the drain plug (A). 96 Install the shift control assembly (A) and 2 guide
pins (B).
TGS pin
B
A
A
B
A ES090166
ES090164
Note：Do not reuse the gasket (B).

95 Install the lever (A) and spring pin (B).
B C
A
B
ES090165
Warning：Location of spring pin (B): the

clearances of them are opposite, and the axial
clearance between the spring pin and the shaft
(C) shall be within ± 15°.
13-41
DYMOS 6MT
Warning：After the metal bush is assembled, each

Installation of Subparts (Bush & Bearing &
bush locks two points on the housing.
Flange)
Location and shape of the locking point.
1 Assemble the bush (A) to the housing (6
locations) with C00089874.
ES090189
ES090187
Opposite lock (180°)
The end of the locking point is away from the inner ring of
the bush.
The bush shall be intact after locking.

A
2 Assemble the linear ball bearing (A) to the

housing (2 locations) with C00089879.
ES090188
ES090190
13-42
DYMOS 6MT
3 Assemble the needle bearing (A) to the front

transmission housing with C00089872.
ES090191
13-43
DYMOS 6MT
Special Tool
SN. Tool number Tool name Illustration Remark
Remove the
1 C00044496 Oil seal installer transmission from the
vehicle before use
C00044496
Support tool for

installing the main
2 C00044497
shaft and
intermediate shaft
C00044497
Synchronizer
3 C00044498
protective plate
C00044498
4 C00044499 Shaft sleeve remover
C00044499
5 C00089876 Tool
C00089876
13-44
DYMOS 6MT
6 C00089875 Gear installer
C00089875
7 C00089873 Front oil seal installer
C00089873
8 C00089870-2 Shift oil seal installer
C00089870-2
9 C00089874 Bush installer
C00089874
Needle bearing
10 C00089879
installer
C00089879
13-45
DYMOS 6MT
11 C00087972 Bearing installer
C00089872
Applicable for 4WD

Rear housing oil seal transmission, and
12 C00089878-1
installer can be used on
complete vehicle
C00089878-1
Applicable for 2WD

Rear housing oil seal transmission, and
13 C00089878-2 can be used on
installer
complete vehicle
C00089878-2
14 C00089862 Push rod
C00089862
13-46
SAGW 6MT
SAGW 6MT
Overview
Overview and Characteristic of Transmission Assembly
SC36M(B)6B transmission includes 6 drive gears and 1 reverse gear. The drive gear and reverse gear are normally
engaged gears with synchronizers, the transmission housing is an aluminum alloy die casting, which can match the 2WD
(SC36M6B) and 4WD (SC36MB6B) formed parts, and the operation mode is direct operation.
SC36MB6B Transmission Outline View
ES040000
14-1
SAGW 6MT
SC36M6B Transmission Outline View
ES040119
Power transfer is realized by a series of normally engaged spiral gears which are installed on the 1st shaft, 2nd shaft,
intermediate shaft and reverse gear shaft. The free gear on the 2nd shaft, intermediate shaft and reverse gear shaft is
supported by the needle bearing, the 1st shaft and 2nd shaft on the transmission housing are supported by the bearing,
and the intermediate shaft on the transmission housing is supported by the cylindrical bearing.
The synchromesh operation of the transmission is achieved by the synchronizer; the synchronizer of the 5th/6th/R gears
is equipped with the single synchronizing ring, the synchronizer of the 3rd/4th gear is equipped with the double-cone
synchronizing ring and that of the 1st/2nd gear is equipped with the tri-cone synchronizing ring. Gear shift/selection of the
transmission is done by 4 shift fork shafts and 1 shaft of the main shift fork:
·The shaft of the main shift fork realizes gear selection and gear shift by selecting and toggling the other 3 shift fork
shafts.
·The other 3 shift fork shafts toggle the shift fork to engage the gear by the fork head on the shaft.
·Gear shift/selection control outside the transmission is realized by the external control assembly.
14-2
SAGW 6MT
SC36M (B) 6B Transmission Structure Diagram
2
3
4
5
ES040002
1 Seal plug 4 Lock nut
2 Locating pin 5 Bolt M8X40
3 Output shaft 6 Rear housing
14-3
SAGW 6MT
SC36MB6B Transmission Outline View
ES040003
1 Flange 4 Dust shield

2 Flange lock bolt 5 Bolt M8X32
3 Output shaft
14-4
SAGW 6MT
Transmission Assembly Specifications

Transmission Technical Parameters
Schematic Item Technical Parameters
Model SC36MB6B SC36M6B
Drive type 4WD 2WD
Input torque/center distance 360N.m/82mm
Weight 59Kg 58Kg
Gear 6 drive gears
R 1 3 5
1 reverse gear
2 4 6
Shift mode mechanical/manual, direct operation
Gear Normally engaged spiral gear
Drive ratio 1st gear 4.340
2nd gear 2.264
3rd gear 1.504
4th gear 1.152
5th gear 1
6th gear 0.72
R gear 3.870
14-5
SAGW 6MT
Gear axial clearance
1st gear 0.1 ～ 0.36 mm

2nd gear 0.1 ～ 0.31 mm
3rd gear 0.105 ～ 0.365 mm
4th gear 0.15 ～ 0.32 mm
6th gear 0.15 ～ 0.32 mm
R gear 0.1 ～ 0.32 mm
Reverse gear idler 0.1 ～ 0.3 mm
Reverse gear idler 1.96 ～ 2.11mm (accumulate at an
increment of 0.05mm)
Thickness of 1st/2nd gear hub circlip 1.93 ～ 2.08mm (accumulate at an



14-6
SAGW 6MT
Plane sealant grade Tonsan 1598
Transmission fluid 2.5 ± 0.1L
14-7
SAGW 6MT
Thread Tightening Torque
SN. Part Thread specification Use Torque (N.m)
1 Hexagon bolt M6X25 M6 Secure CSC 10 ± 3

2 Bolt M8X40 M8 Clutch housing and 25 ± 3
bearing box
Bearing box and rear
housing
3 Oil level hole bolt M16X1.5 Plug oil filling port 40 ± 3

4 Bolt M8X45 M8 Secure intermediate plate 25 ± 3
5 Drain plug M18X1.5 Plug drain hole 45 ± 5
6 Bolt M8X32 M8 Secure shaft 1/2, 25 ± 3
intermediate shaft bearing
7 R gear shaft bolt M8 Secure R gear shaft 25 ± 3

8 Interlocking plate bolt M8X1 Secure interlocking plate 25 ± 3
9 Flange lock bolt (2WD) M24X1.5 Secure flange 200 ± 10
10 Lock bolt M20X1.5 Fix intermediate shaft 180 ± 5
bearing
11 Shift fork pin shaft M16X1.5 Support shift fork 40 ± 3

12 Stop bolt M30X1.5 Position limit spring 25 ± 3
13 Reverse lamp switch M14X1.5 Transmit reverse signal 27 ± 2.5
assembly
14 Lock nut (4WD) M38X1.5 Axial locking 280~360
15 Bolt M8X15 (4WD) M8 Retain wire clip 15 ± 3

16 Bolt M6X18 M6 Fix oil groove 5±1
17 Bolt - shift lever 22 ± 2
18 Bolt - seal plate to body 20 ± 2
19 Nut - transmission shift lever to body 20 ± 2
20 Bolt - transmission to engine 50 ± 5
14-8
SAGW 6MT
List of Disposable Parts
SN. Part Name Quantity/unit
1 Flat washer φ 6 3
2 Reverse shaft seal cover 1
3 Aluminum gasket 16 1
4 Oil seal Φ 35X52X6.8 1
6 Shaft 1 bearing circlip Φ 33 1
10 Screw M6X18 8
11 Gear selection/shift shaft oil seal 1
12 Screw M6X18 4
13 Oil seal Φ 52X68X8 1
14 5th/6th gear synchronizer circlip Φ 29.2 1
20 1st/2nd gear synchronizer circlip Φ 47.7 1
24 3rd/4th gear synchronizer circlip Φ 42.5 1
30 Snap pin Φ 6X30 3
32 Connecting pin lock washer 2
33 Rubber bush 2
14-9
SAGW 6MT
Transmission Assembly Structure Detail

Transmission Assembly Exploded View
Peripheral Transmission Accessory Diagram
ES040004
14-10
SAGW 6MT
Gear Shift/Selection Mechanism & Housing
ES040005
14-11
SAGW 6MT
Gear Drive Mechanism
ES040006
SN. Name Quantity
1 Hexagon bolt M6X25 3
2 Flat washer φ 6 3
3 CSC assembly 1
4 CSC oil pipe bush 1
5 Bolt M8X40 26
14-12
SAGW 6MT
SN. Name Quantity
6 Bolt M8X32 10
7 Shift fork pin shaft 6
8 Drain plug 1
10 Oil level hole bolt 1
12 Locating pin 2
13 R gear shaft bolt 1
14 Locating pin of R gear shift fork shaft 1
15 Flange 1
16 Dust shield 1
17 Flange lock bolt 1
18 Reverse lamp switch assembly 1
19 Control assembly 1
20 Locating pin of shift fork shaft 3
21 Elastic pin Φ 5X25 1
22 Elastic pin Φ 3X25 1
23 Rubber bush 2
24 Support pin 1
25 Connecting pin bush 2
26 Connecting pin lock washer 2
27 Locating pin of gear selector/N gear 1
28 Locating pin of shifter 1
29 Stop bolt 1
30 Limit spring 1
31 Limit pin component 1
32 Ventilation pipe assembly 1
33 Clutch housing 1
35 Hollow pin 2
36 Oil sump 1
37 Oil groove 1
38 Hexagon bolt M6X15 1
39 1st/2nd gear shift fork 1
14-13
SAGW 6MT
SN. Name Quantity
41 1st/2nd gear shift fork shaft 1
42 R gear shift fork shaft 1
43 5th/6th/R gear shift fork component 2
44 Fork head of R gear shaft 1
45 Gear selection/shift shaft component 1
46 Magnetic steel 1
47 Intermediate plate 1
48 Locating pin bush of intermediate plate 2
49 Bolt M8X45 3
50 Bearing Φ 27X44X23 1
51 Bearing 4
53 Gear selection/shift shaft oil seal 1
54 Limit bush 1
55 Rear housing 1
56 Shift fork shaft bush 6
57 Interlocking plate bolt 2
58 Interlocking plate 1
59 Interlocking plate gasket 2
62 Bearing box 1
63 3rd/4th gear shift fork compone 1
64 Shift fork leg 8
65 Fork head of 3rd/4th gear shaft 1
66 3rd/4th gear shift fork shaft 1
67 5th/6th gear shift fork shaft 1
68 Fork head of 5th/6th gear shaft 1
71 Shaft 1 1
72 5th gear engaging tooth 1
75 5th/6th gear synchronizer assembly 1
14-14
SAGW 6MT
SN. Name Quantity
76 6th driven gear component 1
77 Needle bearing Φ 33X38X36 1
78 Shaft 2 1
80 2nd driven gear component 1
81 1st/2nd gear synchronizer assembly 1
83 1st driven gear (precision forging) 1
85 Bush 1
86 Needle bearing Φ 53X58X42.8 1
87 Reverse driven gear (precision forging) 1
88 Reverse gear synchronizer assembly 1
90 Lock bolt 1
91 Bearing Φ 35X72X18.2 1
92 Normally engaged gear of intermediate shaft 1
93 6th drive gear 1
94 3rd drive gear component 1
97 3rd/4th gear synchronizer assembly 1
98 4th drive gear component 1
100 Intermediate shaft 1
101 Reverse gear shaft bracket 1
102 Reverse gear shaft 1
104 Reverse gear idler 1
14-15
SAGW 6MT
Power Flow Chart

1st Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040007
1 Input shaft 8 Normally engaged gear

2 5th/6th gear synchronizer assembly 9 6th gear
3 3rd gear 10 3rd/4th gear synchronizer assembly
4 4th gear 11 2nd gear
5 1st/2nd gear synchronizer assembly 12 R gear
6 1st gear 13 Output shaft
7 Reverse gear synchronizer assembly
14-16
SAGW 6MT
2nd Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040008

14-17
SAGW 6MT
3rd Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040009

14-18
SAGW 6MT
4th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040010

14-19
SAGW 6MT
5th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040011

14-20
SAGW 6MT
6th Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040012

4 4th g 11 2nd gear
14-21
SAGW 6MT
Reverse Gear
1 2 3 4 5 6 7
8 9 10 11 12 13
ES040013

14-22
SAGW 6MT
Expanded Product Identification

SC36M6B&SC36MB6B Identification Table
SN. Part Name Schematic Quan tity Comparing with SC36M6B
1 Wire clip 1 Add-on special part
2 Bolt M8X15 1 Add-on special part, torque: 25 ± 3N.m
3 Bush 1 Add-on special part
4 Lock nut 1 Add-on special part, torque: 280- 360N.m,

replace flange lock bolt, cancel flange and
flange dust shield
14-23
SAGW 6MT
SN. Part Name Schematic Quan tity Comparing with SC36M6B
5 Locating pin 2 Add-on special part
6 Rear housing 1 Special part, replace SC36M6B rear

housing
7 Seal plug 1 Add-on special part
8 Bolt M8X40 4 Torque: 25 ± 3N.m, replace 4 bolts (M8*32)

used by SC36M6B
14-24
SAGW 6MT
Installation Location Diagram
77
11 55
22 88
33 44
ES040014
14-25
SAGW 6MT

Repair Guidance
Assembly
Removal
5 Remove the center console. ES040122

shift mechanism.
5

ES040120

lever in the vertical direction; horizontal removal ES040123
force effect. 8 Disconnect the CSC bleed connector. Remove
ES040121
ES040124
14-26
SAGW 6MT
ES040125
ES040128
ES040126

rear axle.
case.
the engine.
ES040127
14-27
SAGW 6MT

Transmission Removal
transmission assembly. 1 Remove the transmission fluid drain plug with
the socket (24mm), and drain the fluid
thoroughly. Place the transmission removed
Installation vertically on the workbench.

on the input shaft.

of 2.5 ± 0.1 L through the oil filler plug aperture. Remove
the oil level plug to drain the excess oil. Reinstall the plug.

gears are correct.
ES040015
allow for one time use only, so new nut shall be used after 2 Remove the connecting pin lock washer, and
any removal, otherwise, the performance of the fastener remove the connecting pin.
ES040016
14-28
SAGW 6MT
3 Remove the elastic pins ( φ 5 × 25 and φ 3 × 5 Remove the flange.

25) with punch C00089862, and remove the
control assembly.
ES040020
ES040017 6 Release and remove the reverse lamp switch

assembly with the socket (19mm).
Note：Take care not to lose the elastic pins ( φ 5
× 25 and φ 3 × 25).
ES040021
ES040018 7 Remove the locating pin of the shifter.
4 Release and remove the flange lock bolt with the

socket (30mm).
ES040022
ES040019
14-29
SAGW 6MT
8 Remove 2 locating pins of the shift fork shaft. 11 Release and remove 4 bolts (M8X32) and 13
studs (M8X40) with the socket (13mm).
ES040023
ES040026
9 Release and remove the stop bolt with the
hexagon wobbler (12mm), and remove the limit 12 Remove the locating pin of the housing with a
spring and limit pin component. punch.
ES040024 ES040027
10 Release and remove 2 pin shafts of the shift fork 13 Tap with a nylon hammer to remove the rear
with the hexagon wobbler (12mm). housing component.
ES040025 ES040028
14-30
SAGW 6MT
14 Remove the magnetic steel. 17 Remove the snap pin ( Φ 6X25) with a punch.
ES040029 ES040032
15 Remove the gear selection/shift shaft 18 Remove the shift fork shaft of the 1st/2nd gear
component. and shift fork.
ES040030 ES040033
16 Remove the R gear shift fork shaft component Note：Take care not to lose the shift fork leg.
and R gear shift fork component.
ES040031
Note：Take care not to lose the shift fork leg.
14-31
SAGW 6MT
22 Remove the 1st/2nd gear synchronizer assembly

19 Remove the bearing φ 40X90X23, R gear
synchronizer assembly, reverse driven gear and 2nd driven gear component.
component, bush, needle bearing φ53X58X42.8
and 1st driven gear component with a puller.
ES040036
ES040034 23 Remove the needle bearing Φ 53X58X37.
20 Remove the needle bearing Φ 48X54X40.1.
ES040037
ES040035 24 Release and remove the hexagon bolt M6 × 18

and oil groove with the socket 10mm.
21 Remove the 1st/2nd gear synchronizer circlip
with a plier.
ES040038
ES040131
Note：Take care not to lose or mix the circlips.
14-32
SAGW 6MT
25 Release and remove 2 clamp bolts with the 28 Remove the intermediate plate component.
hexagon wobbler (T40).
ES040042
ES040039
29 Release and remove 4 pin shafts of the shift fork
26 Remove the interlocking plate and its gasket. with the hexagon wobbler (12mm).
ES040040 ES040043
27 Release and remove 3 bolts (M8X45) with the 30 Remove 2 locating pins of the shift fork shaft.
socket (13mm).
ES040044
ES040041
14-33
SAGW 6MT
31 Place the assembly horizontally on the 33 Release and remove 3 hexagon bolts (M6X25)
workbench, and release and remove 6 bolts with the socket (10mm), and remove the CSC
(M8X32) with the socket (13mm). assembly and CSC oil pipe bush.
ES040045 ES040047
32 Remove the shift fork shaft component of the 34 Release and remove the bolt (M8X40) with the
3rd/4th gear, 5th/6th gear, shift fork component socket (13mm), remove the breather pipe, and
of the 3rd/4th gear, 5th/6th gear and the disconnect the clutch housing and bearing box.
component of shaft 2, intermediate shaft and
shaft 1 from the bearing box.
ES040048
ES040046 Note：Take care not to damage the breather pipe

during removal.
Note：
·After shafting removal, take care not to lose the

engaging gear.
·Handle the needle bearing with great care, and do not

lose the needle.
·Take care not to lose the shift fork leg.
ES040049
14-34
SAGW 6MT
35 Remove the bearing of shaft 1 with a puller. 38 Remove the 5th/6th gear synchronizer assembly.
ES040050 ES040053
Note：Take care not to lose or mix the circlips. 39 Remove the 6th driven gear and needle bearing
36 Remove the bearing of shaft 1 with a puller. Φ 33X38X36。
ES040054
ES040051
40 Release and remove the lock bolt with the

37 Remove the 5th/6th gear synchronizer circlips
hexagon wobbler (12mm).
with a plier.
ES040055
ES040052
14-35
SAGW 6MT
41 Remove the bearing Φ 35X72X17 and the 44 Remove the 3rd/4th gear synchronizer circlip
normally engaged gear of the intermediate shaft with a plier.
with a puller.
ES040059
ES040056
42 Remove the 6th drive gear with a puller. 45 Remove the 4th drive gear and 3rd/4th gear
synchronizer a puller.
ES040057
ES040060
43 Remove the 3rd drive gear component and
needle bearing Φ 42X47X34. 46 Remove the needle bearing Φ 45X50X36.8.
ES040058 ES040061
14-36
SAGW 6MT
6 Check the gear surface of the gear set for wear.

Check before Transmission Installation
7 Check the gear set for excessive wear, crack
1 Clean all components disassembled with and damage.
solvents, and dry them with compressed air. 8 Check all synchronizer assemblies:
Check the component for crack, wear and
damage. 1） Hub and gear sleeve engagement.
1） Clutch housing, bearing box, rear housing and 2） Wear of the inner conical surface of the
control assembly. synchronizer ring.
2） 5th gear engaging gear.
2 Check the support location of the shaft and

bearing on the clutch housing, bearing box and
rear housing for wear, and replace it when
necessary.
3 Check the surface condition of the following
components:
1） Input shaft.
2） Output shaft and each gear.
3） Intermediate shaft.
ES040062
4 Reverse gear idler shaft and reverse gear idler.
Note：Replace components with severe wear, do 9 Measure the gap between the synchronizer ring
not rub parts treated by precision machining. and the transmission gear:
5 Check the following components for wear: 1） 1st/2nd gear synchronizer ring: 1.1 ～ 1.7mm.
1） Control assembly. 2） 3rd/4th gear synchronizer ring: 1.1 ～ 1.7mm.
2） Gear shift fork and shift fork bush. 3） 5th/6th gear synchronizer ring: 1 ～ 1.4mm.
3）Shift fork component of the 1st/2nd gear, 3rd/4th 4） R gear synchronizer ring: 1 ～ 1.4mm.
gear, 5th/6th/R gear.
Note：If the gap is small, renew the synchronizer
4） Gear synchronizer assembly. ring, otherwise, damage may occur, which will
lead to missing gear or damaged gear.
5） Interlocking plate.
10 Check the engaging gear for each gear and the
Check the following components for excessive wear: gear tooth of the synchronizer gear sleeve for
wear.
1） Bearing Φ 35X85X23 (ball bearing).
2） Bearing Φ 57X77X17 (cylindrical bearing).
3） Needle bearing of the output shaft gear.
5） Bearing Φ 27X44X23 (cylindrical bearing).
7） Needle bearing of the intermediate shaft gear.
8） Reverse gear idler needle bearing.
14-37
SAGW 6MT
11 Check the engagement state of the synchronizer

Transmission Installation
gear sleeve and the engaging gear for each
gear. 1 Install the needle bearing.
ES040063 ES040064
2 Install the 4th drive gear and 3rd/4th gear

synchronizer ring component.
ES040065
Note：
·The inner ring of the synchronizer ring has no any

conical surface.
·The middle ring clamp leg of the synchronizer ring is

fixed into the groove of the 4th gear engaging gear.
14-38
SAGW 6MT
3 Install the synchronizer assembly of the 3rd/4th 5 Install the 3rd/4th gear synchronizer circlip with a
gears with tool C00089865. plier.
ES040066 ES040068
Note：
6 Install the needle bearing Φ 42X47X34 and 3rd
·The outer conical ring clamp leg of the synchronizer ring drive gear component.
is aligned with the synchronizer hub groove.
·The high boss of the synchronizer hub is upward.
4 Install the synchronizer ring component of the

3rd/4th gears.
ES040069
Note：The middle ring clamp leg of the

synchronizer ring is aligned with the groove of
the 3rd gear engaging gear.
ES040067 7 Install the 6th drive gear with tool C00051496.
Note：The outer conical ring clamp leg of the

synchronizer ring is aligned with the
synchronizer hub groove.
ES040070
14-39
SAGW 6MT
Note：The high boss of the 6th gear is upward. 10 Install and tighten the lock bolt with the hexagon
wobbler (12mm).
8 Install the normally engaged gear of the
intermediate shaft with tool C00051496.
ES040073
ES040071
11 Install the needle bearing ( Φ 33X38X36) and 6th
Note：The high boss of the normally engaged gear driven gear component.
is downward.
9 Install the bearing ( Φ 35X72X18.2) with tool

C00051496.
ES040074
12 Install the 5th/6th gear ring.

ES040072
ES040075
14-40
SAGW 6MT
13 Install the synchronizer assembly of the 5th/6th 16 Install the bearing circlip of shaft 1 with a plier.
gears with tool C00051496.
ES040079
ES040076
17 Assemble the clutch housing and bearing box,
14 Install the 5th/6th gear synchronizer circlip with a and install and tighten 13 bolts (M8X40) with the
plier. socket (13mm), and install the breather pipe
assembly.
ES040077
ES040080
15 Install the bearing ( Φ 35X85X23) with tool
C00051495.
ES040081
ES040078
14-41
SAGW 6MT
18 Assemble the component of shaft 1, 5th gear 20 Install the shift fork component/shift fork shaft
engaging gear, 5th/6th gear ring, bearing ( Φ component of the 3rd/4th gear and 5th/6th gear
23X38X20) and the component of shaft 2. with tool C00089868.
ES040082 ES040084
19 Assemble shaft 1, 2 and intermediate shaft, and Note：The fork head leg is fixed into the shift fork
install the shafting component into the groove.
intermediate plate. 21 Install the bearing box component into the
shafting.
ES040083
ES040085
Note：The thread hole of the bearing press plate is

aligned with the through-hole of the bearing box.
14-42
SAGW 6MT
22 Install and tighten 6 bolts (M8X32) with the 25 Install 2 locating pins of the shift fork shaft.
socket (13mm).
ES040089
ES040086
26 Install the oil groove, and use the socket (10mm)
23 Install the CSC assembly and CSC oil pipe bush; to install and tighten the hexagon bolt (M6 × 18).
install and tighten 3 hexagon bolts (M6X25) with
the socket (10mm).
ES040090
ES040087 27 Install the interlocking plate gasket and

interlocking plate, then install and tighten 2
24 Install and tighten 4 pin shafts of the shift fork clamp bolts with the hexagon wobbler (T40).
with the hexagon wobbler (12mm).
ES040091
ES040088
14-43
SAGW 6MT
30 Install the 1st/2nd gear synchronizer ring

component into shaft 2 with tool C00089865.
ES040092
28 Install and tighten 3 bolts (M8X45) with the

socket (13mm). ES040095
Note：The outer ring clamp leg of the

31 Install the synchronizer circlip of the 1st/2nd
gears.
ES040093
29 Install the needle bearing ( Φ 48X54X40.1), 2nd

driven gear component and 1st/2nd gear
synchronizer ring component.
ES040096
32 Install the needle bearing Φ 48X54X40.1 and 1st

driven gear component.
ES040094
Note：The middle ring clamp leg of the

synchronizer ring is fixed into the groove of the
engaging gear.
ES040097
14-44
SAGW 6MT
33 Install the reverse gear sleeve with tool Note：The outer ring clamp leg of the
C00089865. synchronizer ring is aligned with the
36 Install the shift fork and shift fork shaft of the 1st/
2nd gears with tool C00081493, and install the
snap pin ( Φ 6X25).
ES040098
34 Install the needle bearing ( Φ 53X58X42.8) and

reverse driven gear component.
ES040101
Note：Install the shift fork leg into the

synchronizer hub groove of the 1st/2nd gears.
37 Install the shift fork and shift fork shaft of the
reverse gear.
ES040099
35 Install the reverse gear synchronizer ring, and

install the synchronizer assembly of the reverse
gear with tool C00089865.
ES040102
Note：Install the shift fork leg into the

synchronizer hub groove of the 1st/2nd gears.
38 Install the gear selection/shift shaft. Press the
3rd/4th gear shift fork shaft into the 3rd
gear.Then the gear selection/shift shaft shall
ES040100
14-45
SAGW 6MT
locate in the shaft slot of the 3rd/4th gear shift 40 The boss of the reverse gear idler shall face the
fork. input shaft.
ES040103 ES040133
Note：When installing the gear selection/shift 41 For the input shaft, output shaft and intermediate
shaft, remove the locating pin of the gear shaft, do not install any bearing boss that does
selector/N gear from the rear housing assembly, not match exactly into the corresponding
and do not reuse the locating pin. housing.
39 For the shaft at the mating face between the

intermediate shaft and the rear housing, the big
end faces the input shaft, and the small end
faces the rear housing, apply grease and install it
into the rear housing.
small
direction
ES040134
42 Install the magnetic steel.
ES040132
ES040104
14-46
SAGW 6MT
43 With tool C00017013, install it into the flange tray 46 Install and tighten 4 bolts (M8X32) with the
of the bearing φ 40 × 90 × 23, then install into socket (13mm).
the rear housing assembly.
ES040108
ES040105
47 Install and tighten 2 pin shafts of the shift fork
Note：Before installing rear housing assembly,
with the hexagon wobbler (12mm).
please remove the locating pins of the D/N gears
from the outside of the rear housing.
44 Install 2 locating pins of the housing.
ES040109
48 Install 2 locating pins.

ES040106
45 Install and tighten 13 bolts (M8X40) with the
socket (13mm).
ES040110
ES040107
14-47
SAGW 6MT
49 Install the limit pin component and limit spring, 52 Install the flange, then install and tighten the
then install and tighten the stop bolt with the flange lock bolt with the socket (30mm).
hexagon wobbler (12mm).
ES040114
ES040111
53 Install the control connecting rod with tool
50 Install the locating pin of the shifter. C00051493, and install the elastic pins φ 5 × 25
and φ 3 × 25.
ES040112
ES040115
51 Install and tighten the reverse lamp switch
assembly with the socket (19mm). 54 Install the support arm of the control.
ES040113 ES040116
14-48
SAGW 6MT
55 Install the connecting pin and it lock washer.
ES040117
56 Install and tighten the washer and transmission

drain plug with the socket (24mm).
ES040118
14-49
SAGW 6MT
Special Tool
SN. Drawing Number Description Illustration Remark
1 C00051495 Bearing tooling of shaft 1 Assemble bearing

Φ 35X85X23,
assemble bush
reverse gear synchronizer
assembly
C00051495
2 C00051496 Installer for cone bearing Assemble 5th/6th gear
outer circle synchronizer assembly, 6th
drive gear, normally
engaged gear of the
intermediate shaft, bearing
Φ 35X72X18.2
C00051496
3 C00089866 Bearing installer Assemble bearing
Φ 27X44X23;
Assemble bearing
Φ 57X77X17;
bearing
Φ 50X78X17
C00089866
4 C00089865 Synchronizer socket tool Assemble 3rd/4th gear
synchronizer assembly,
1st/2nd gear synchronizer
assembly,
bush and reverse gear
synchronizer assembly
C00089865
5 C00089869 Tool for input shaft oil seal
C00089869
14-50
SAGW 6MT
6 C00086867-1 Oil seal installer
C00086867-1
7 C00089870-1 Tool for shift shaft oil seal
C00089870-1
8 C00089868 Assembly tooling Assemble the shafting, shift
fork, shift fork shaft, and
finally install the bearing
box and clutch housing
assembly
C00089868
9 C00017013 Camshaft bearing guide pin Install the guide rod into the
thread hole of the bearing
press plate, which will
function as a guide unit
when the rear housing
closes
C00017013
10 C00089871 Limit bush installer Install limit bush
C00089871
14-51
SAGW 6MT
11 C00089944 Lock nut remover/installer Install input shaft lock

shafting to prevent it from
turning
C00089944
12 C00051493 Elastic pin installer
C00051493
13 C00089862 Push rod
C00089862
14-52
SC25M(B)5 Transmission
Overview
Overview and Characteristics of Transmission Assembly
SC25M(B)5 Transmission System Structure Diagram
ES350001
15-1
ES350002
Characteristics
1 All gears are helical gears and made of high strength materials.
·Helical gears can prevent axial gear failure and reduce the noise
2 Use indirect control mechanism for gearshift operation.

3 To improve the gearshift performance, apply a tri-cone synchronizer composed of 3 synchronizer rings to the
1st gear, and a double-cone synchronizer composed of 3 synchronizer rings to the 2nd gear.
4 The synchronous devices are installed on 1st/2nd, 3rd/4th and 5th/R gears. Independent control cover
assembly is designed with the function of compound engagement prevention.
15-2
Parameters
Items Specification
Type SC25M5 SC25MB5
Drive Type 2WD 4WD
Length (mm) 664 694
Distance Between Axles (mm) 76
Input Torque (Nm) 210
Transmission Control Type Indirect Control
Weight (kg) - excluding transmission fluid 43
Transmission Ratio / Gear 1st Gear 4.331

Teeth (input gear: main
gear) 2nd Gear 2.316
3rd Gear 1.417
4th Gear 1.000
5th Gear 0.865
R Gear 3.957
Transmission Fluid Specification LAIKE MTF SAE 75W/85
Capacity (L) 2.2 ± 0.1L

Replacement Period 10,000 km for first maintenance, and every 80,000 km for
subsequent maintenance (Refill or replace when
necessary)
15-3
Torque
Items Specified Torque (Nm)
Bolt M6*18 10.2~13.8
Hexagon bolt component M10*1.25*18 35~44
Hexagon bolt component M10*1.25*38 35~44
Release bearing bolt M6*1*18 10.2~13.8
Hexagon bolt M8*20 22~29
Locking nut (2nd shaft) 180~220
Locking nut (intermediate shaft) 140~160
Reverse lamp switch assembly 26~35
Reverse gear shaft fastening bolt 22~29
Hexagonal bolt M6*16 8~13
Oil drain plug assembly 30~40
Oil filler plug 30~40
Reverse gear shaft stop bolt 22~29
Breather plug assembly 22~29
Bolt M8*22 22~29
Bolt M8*32 22~29
Locking nut 160~180
15-4
Cementing Agent
Items Special Sealants, Cementing Agents and Lubricants
Junction surface of clutch housing and bearing box Tonsan 1596F, gray
Junction surface of bearing box and rear housing Tonsan 1596F, gray
Junction surface of control cover and bearing box Tonsan 1596F, gray
1st shaft oil seal CENTOPLEX3# lithium grease
Output shaft oil seal CENTOPLEX3# lithium grease
Gear selection/shift shaft oil seal CENTOPLEX3# lithium grease
Reverse gear stop bolt Tonsan 1243B
Reverse gear fastening bolt Tonsan 1243B
Input shaft press plate bolt M6*18 Tonsan 1243B
Locking nut (2nd shaft) Tonsan 1243B
Locking nut (intermediate shaft) Tonsan 1243B
Locking nut Tonsan 1243B
Release bearing bolt M6*1*18 Tonsan 1243B
15-5
Disposable Parts
SN. Part Name Quantityset Type
1 1st shaft oil seal 1 2WD / 4WD
2 Input shaft ball bearing circlip 1 2WD / 4WD
3 3rd/4th gear synchronizer circlip 2.40 1set 2WD / 4WD
8 5th gear needle bearing circlip 1 2WD / 4WD
9 Circlip 1.46 1set 2WD / 4WD
10 Circlip1.53 1set 2WD / 4WD
15 Normally engaged driven gear circlip 2.35 1set 2WD / 4WD
20 Output shaft oil seal 1 2WD
21 Washer 1 2WD / 4WD
22 Aluminum washer 14 1 2WD / 4WD
23 Propeller shaft oil seal 1 4WD
15-6
System Structure Diagram

GearTrain
1 2 3 4 5 6
7 8 9
ES350003
1 3rd Gear 6 Output Shaft

2 2nd Gear 7 Input Shaft
3 1st Gear 8 Intermediate Shaft
4 Reverse Gear 9 Reverse Idler Gear
5 5th Gear
15-7
Shift Fork and Shift Fork Shaft Assembly
ES350004
1 5th/R Gear Shift Fork 4 1st/2nd Gear Shift Fork Component

2 5th/R Gear Shift Fork Shaft 5 5th/R Gear Taper
3 3rd/4th Gear Shift Fork Component
15-8
Transmission Assembly Exploded View

Peripheral Transmission Accessory Diagram
12
12
13
15
16 11
17 89
1
10 9
2
5
97
3 6
95
4
7
8
ES350005
15-9
Gear Selection/Shift Mechanism and Housing
22
95
23 24
27
28
19 20 94
29
21
30
31
32
93
33
34
ES350006
15-10
Gear Drive Mechanism
46
72
45 51 71
70
59
69 81
73
68
51 58 66
67 74
44
92
57
43
65 75
42
64
41 91
55 63 76
40 35
54 62
39 77
50 83
38 56
49 25 90 78 82
37 26
18 79 84
37
14 53 61 85
48
52 80 86
36 47 60
88
87
ES350007
SN. Name Quantity
1 Locking nut 1
2 Flange 1
3 Reverse gear stop bolt 1
4 Oil filler plug 1
5 Washer 2
15-11
SN. Name Quantity
6 Breather plug assembly 1
7 Wire clip 2
8 Hexagon bolt M10*1.25*18 1
9 Release bearing bolt M6*1*18 3
10 Hydraulic release bearing assembly 1
11 Gear selection cable bracket 1
12 Bolt M8*22 4
13 Shift cable bracket 1
14 3rd/4th gear synchronizer slider 3
15 Reverse gear shaft fastening bolt 1
16 Aluminum washer 8 1
17 Oil drain plug assembly 1
18 3rd/4th/R gear synchronizer gear ring 3
19 Bolt M8*32 3
20 Control cover assembly 1
21 Gear selection/shift shaft bushing 1
22 Hexagon bolt M6*16 3
23 Output shaft dust cover 1
24 Hexagon bolt M10*1.25*38 19
25 1st/2nd gear synchronizer slider assembly 3
26 1st/2nd gear synchronizer ring component 1
27 2WD rear housing component 1
28 Spring pin 4
29 Bearing box 1
30 5th/R gear shift fork 1
31 5th/R gear shift fork shaft 1
32 5th/R gear taper 1
33 1st/2nd gear shift fork component 1
34 3th/4th gear shift fork component 1
35 1st/2nd gear synchronizer ring component 1
36 Reverse gear shaft 1
37 Reverse idler gear needle bearing 2
38 Reverse idler gear 1
39 Reverse idler gear washer 1
40 Reverse idler gear circlip 1
15-12
SN. Name Quantity
41 Input shaft ball bearing circlip 1
42 Input shaft ball bearing Φ 90*40*23 1
43 Input shaft bearing press plate 1
44 Bolt M6*18 4
45 Input shaft component 1
46 Needle bearing φ 28*20*20 1
47 3rd/4th gear synchronizer circlip 1
48 3rd/4th gear synchronizer assembly 1
49 3rd driven gear assembly 1
50 3rd gear needle bearing 1
51 Output shaft (2WD) 1
52 1st/2nd gear needle bearing 2
53 2nd driven gear assembly 1
54 1st/2nd gear synchronizer assembly 1
55 1st gear bushing 1
56 5th/R gear synchronizer slider 3
57 1st driven gear assembly 1
58 Double inner ring ball bearing component 1
59 Reverse gear bushing 1
60 Reverse gear needle bearing 1
61 Reverse driven gear assembly 1
62 5th/R gear synchronizer assembly 1
63 Locking nut (2nd shaft) 1
64 5th gear needle bearing 1
65 5th driven gear assembly 1
66 5th gear semi-circle thrust washer 2
67 5th gear semi-circle thrust washer retaining ring 1
68 Output shaft rear bearing φ 72* φ 28*18 1
69 Circlip 1
70 Steel bushing 1
71 Intermediate shaft press plate 1
72 Hexagon bolt M8*20 8
73 Locking nut (intermediate shaft) 1
74 Intermediate shaft rear bearing φ 25* φ 62*17 1
75 5th driving gear 1
15-13
SN. Name Quantity
76 Intermediate shaft spacer bushing 1
77 Reverse driving gear 1
78 Intermediate shaft spacer ring 1
79 Adjusting gasket 1
80 Cone roller bearing Φ 62* Φ 30*17.25 1
81 Intermediate shaft 1
82 3rd driving gear circlip 1
83 3rd driving gear 1
84 Normally engaged driven gear 1
85 Normally engaged driven gear circlip 1
86 Cone roller bearing Φ 52* Φ 25*19.25 1
87 Clutch housing 1
88 1st shaft oil seal 1
89 Hydraulic release bearing bleeder connector 1
90 5th gear synchronizer ring 1
91 5th gear needle bearing circlip 1
92 Steel ball 4.762 1
93 Spring pin 5*22 2
94 Locating pin B6*10 2
95 Output shaft oil seal 1
96 Reverse lamp switch assembly 1
97 Aluminum washer 14 1
15-14
Synchronizer Assembly Exploded View
ES350008
1 Synchronizer Slider 3 Synchronizer Gear Sleeve

2 Synchronizer Gear Hub
15-15
Double-/Three-cone Ring Assembly Exploded View
ES350009
1 Synchronizer Inner Cone Ring 3 Synchronizer Outer Cone Ring

2 Synchronizer Intermediate Ring
15-16
Power Flow Chart

1st Gear
1 2 3 4
5 6 7 8 9 10 11
ES350010
1 Input Shaft 7 2nd Gear

2 3rd/4th Gear Synchronizer 8 1st Gear
3 1st/2nd Gear Synchronizer 9 Reverse Gear
4 5th/R Gear Synchronizer 10 5th Gear
5 Normally Engaged Gear 11 Output Shaft
6 3rd Gear
15-17
2nd Gear
1 2 3 4
5 6 7 8 9 10 11
ES350011

6 3rd Gear
15-18
3rd Gear
1 2 3 4
5 6 7 8 9 10 11
ES350012

6 3rd Gear
15-19
4th Gear
1 2 3 4
5 6 7 8 9 10 11
ES350013

6 3rd Gear
15-20
5th Gear
1 2 3 4
5 6 7 8 9 10 11
ES350014

6 3rd Gear
15-21
Reverse Gear
1 2 3 4
5 6 7 8 9 10 11
ES350015

6 3rd Gear
15-22
Expanded Product Identification

SC25M5 & SC25MB5 Comparison Table
SN. Part Name Part Schematic Quantity Compared to SC25M5
1 Output shaft (4WD) 1 Special part, replace SC25M5 output

shaft
2 4WD rear housing 1 Special part, replace SC25M5 rear

housing
3 Propeller shaft oil seal 1 Special part, replace SC25M5 output

shaft oil seal
4 Oil seal bushing 1 Special part, replace SC25M5 steel

bushing
15-23
SN. Part Name Part Schematic Quantity Compared to SC25M5
5 Circlip 1 Same as SC25M5, but with different

installation location
6 Wire clip 1 1 more than SC25M5
7 Hexagon bolt 1 1 more than SC25M5

M10*1.25*18
15-24
Installation Location Diagram
1
6
5
7
ES350016
15-25
Guide Plate
Others
" 王 "-shaped groove of gear selection/shift cam controls
Self-locking System the gearshift stroke.
Gear Selection/Shift Cam and Gear Selection/Shift
Rocker Arm Setting Sleeve
1 Determine the gearshift position through the fit

between gear selection/shift cam and gear
selection/shift rocker arm setting sleeve.
2 The groove of gear selection/shift cam provides
a resistance to prevent gear jump.
ES350019
Gear selection/shift
rocker arm setting Reverse Lamp Switch
sleeve
Reverse lamp switch is a normally on switch, and the
reverse lamp switch circuit is formed when the reverse
gear is selected.
Gear selection/shift cam
ES350017
Synchronizer Anti-jump Mechanism
Prevent the shift lever from jumping out of the correct

gear position during the gearshift operation
Gear hub spline Gear sleeve spline
ES350020
Note：The specified torque for installation is 26-

35N.m.
Transmission engaging gear spline

ES350018
15-26
Common Troubleshooting
Symptoms Reasons Measures
Gearshift Failure (the shift Control cover assembly Replace the control cover assembly
lever is movable)
Shift fork, shift fork shaft and Remove the assembly, check and replace the
synchronizer damage damaged components
Difficult to Shift Gear or Improper transmission fluid or low Refill the transmission fluid reservoir or replace
Gearshift Failure fluid level with the specified transmission fluid
Control cover assembly and shift fork Remove the control cover or assembly, check
shaft seized and replace the damaged components
Synchronizer or gear seized Remove the assembly, check the synchronizer

and gear and replace the damaged components
Gear Collision During Bearing fault Check or replace each bearing

Gearshift
Synchronizer damage Check or replace the synchronizer components
Transmission housing location error Locate the housing and boring
Gear damage Check or replace the gears
Runout Synchronizer damage or excessive Check or replace the synchronizer components

wear
Control cover assembly damage Check or replace the control cover assembly
Circlip damage Check or replace the circlip
Excessive axial clearance of Re-adjust the thickness of intermediate shaft

intermediate shaft gasket
Shift fork shaft wear or damage Check the wear or damage, and replace any
worn or damaged components
Transmission Locked in Shift fork, gear shift taper, control Remove the assembly, check the wear or
Certain Gear cover assembly and shift fork shaft damage, and replace the damaged components
Synchronizer wear or damage Check the worn or damaged components,

replace when necessary
Gear wear or damage Check the worn or damaged gears, replace

when necessary
Transmission Noise Improper transmission fluid or low Refill the transmission fluid reservoir, or drain
fluid level the fluid and add proper transmission fluid
Bolt or other attached components Tighten as specified

looseness
Noise found in transmission bearing Check the bearing, bearing roller or

components for wear or damage, replace when
necessary
Noise found in gear Check or replace the components
15-27
Symptoms Reasons Measures
Transmission Fluid Leak Transmission Fluid Leak Clean all exposed surfaces and check for
leakage
Breather plug blockage Clean or replace the breather plug
Excessive transmission fluid Check the fluid level
Bolt in the seal surface is loose Tighten as specified
Improper sealant used Clean the exposed surface and re-apply the
sealant
Oil seal wear or damage Replace the oil seal
15-28
3 Unscrew 3 connecting bolts M8*32 with the

Repair Guides socket (13mm), and remove the control cover
Removal/Installation of Manual Transmission assembly.
Removal
1 Remove the transmission fluid drain plug
(square, 14mm) and drain the fluid thoroughly.
Place the transmission removed vertically on the
workbench.
ES350023
Note：Take care not to lose the locating pin B6*10
4 Remove the reverse lamp switch assembly with

the socket (21mm).
ES350021
2 Remove the reverse lamp stop bolt with the

socket (13mm).
ES350024
Note：Take care not to damage the reverse lamp

switch wire.
ES350022
15-29
5 Unscrew the reverse gear fastening bolts with 7 Unscrew 2 hexagon bolt components M10 with
the hex socket head (6mm) and remove the the socket (14mm), and remove the wire clips.
aluminum washer 8.
ES350027
ES350025
8 Unscrew the locking nuts with the socket
6 Unscrew 4 hexagon bolt components M8*22 (14mm).
from the rear housing with the socket (13mm),
and remove the gear shift cable bracket and gear
selection cable bracket.
ES350028
9 Tap with a nylon hammer to remove the flange.

ES350026
ES350029
15-30
10 Unscrew 3 hexagon bolts M6*16 with the socket 13 Remove the steel sleeve from the output shaft
(10mm), and remove the output shaft dust cover. with a puller, take out the circlip with a plier and
remove the output shaft rear bearing φ 72* φ
28*18 with the puller.
ES350030
11 Support the bottom of the transmission with a ES350033

suitable bracket.
14 Remove the 5th gear semi-circle thrust washer
retaining ring, 5th gear semi-circle thrust washer,
steel ball 4.762, 5th driven gear assembly and
5th gear needle bearing from the output shaft in
sequence.
ES350031
12 Release and remove the intermediate shaft

locking nuts with the socket (30mm), and remove
the intermediate shaft rear bearing Φ25*Φ62*17
with a puller. ES350034
Note：Take care not to damage the 5th driving

gear
ES350032
15-31
15 Remove the 5th driving gear with a puller, and and finally remove the reverse gear needle
take out the reverse idler gear shaft assembly bearing.
and 5th gear synchronizer ring.
ES350037
ES350035
Note：Take care not to damage the reverse driving
Note：Take care not to damage the 5th driving gear
gear
18 Remove the reverse driving gear and
16 Remove the 5th/R gear shift fork spring pin 5*22 intermediate shaft spacer bushing with the puller.
with a punch.
ES350038
ES350036
17 Remove the 5th gear needle bearing circlip with

a plier; release and remove the locking nut (2nd
shaft) with the socket (40mm), then remove the
reverse driven gear assembly, 3rd/4th/R gear
synchronizergear ring, 5th/R gear synchronizer
assembly and 5th/R gear shift fork with a puller;
15-32
19 Release and remove 8 hexagon bolts M8*20 21 Place the transmission across the workbench,
with the socket (12mm), and remove the release and remove 7 hexagon bolt components
intermediate shaft press plate. M10 with the socket (14mm).
ES350039 ES350041
20 Release the transmission from 2 locating pins, 22 Remove the release bearing bleeder connector,
and carefully put the bracket down to remove the release and remove the release bearing bolts
transmission assembly. M6*18 with the hexagon socket head (6mm),
and remove the release bearing assembly.
ES350040
ES350042
Note：Use the stop circlip plier to remove the
circlip, so as to avoid the circlip from deformation 23 Place the transmission perpendicularly on the
workbench, release and remove 2 hexagon bolt
components M10 with the socket (14mm); then
15-33
tap with a nylon hammer to remove the bearing 26 Remove the input shaft assembly, output shaft
box.。 assembly and intermediate shaft assembly.
ES350043 ES350046
24 Remove the spring pin 5*22 with a punch, and Note：Do not lose the ring spring after shafting
remove the 5th/R gear shift fork shaft, 5th/R gear removal; handle the needle bearing with great
taper, 1st/2nd gear shift fork components and care, and do not lose the needle
3rd/4th gear shift fork components.
27 Remove the input shaft ball bearing circlip with
the plier, and remove the ball bearing with the
puller.
ES350044
25 Release and remove the bolts M6*18 with the

socket (8mm), and remove the input shaft ES350047
bearing press plate.
Note：Take care not to lose or mix the circlips
ES350045
15-34
28 Remove the tapered bearings on both sides of gear with the puller at one time, and take out the
the intermediate shaft with a puller. needle bearing.
ES350048 ES350050
Note：Prevent the bearing from damage during 31 Release the 1st/2nd gear, synchronizer
removal assembly, double inner ring bearing and reverse
gear bushing with a press.
29 Remove the 3rd/4th gear synchronizer circlip.
ES350051
ES350049
32 Remove the reverse gear bushing.
Note：Take care not to lose or mix the circlips
30 Remove the 3rd/4th gear synchronizer
assembly, synchronizer ring, ring spring and 3rd
ES350052
15-35
33 Remove the double inner ring bearing 36 Remove the 2nd gear synchronizer ring, 2nd
components. gear and needle bearing.
ES350053 ES350056
34 Remove the 1st gear, 1st gear synchronizer ring Note：Do not mix the 2nd gear synchronizer ring
component and needle bearing. with that of the 1st gear
ES350054
Note：1st gear is placed with synchronizer ring in

pair
35 Remove the 1st gear bushing and 1st/2nd gear

synchronizer assembly.
ES350055
15-36
5 Check the following components for wear:

Check Before Assembly
（1） Control cover assembly
1 Clean all components disassembled with
solvents, and dry them with the compressed air. （2） Each gear shift fork and shift fork bushing
Check the components for crack, wear and
damage. （3） Shift fork components and shift fork shaft tapers of
1st/2nd gear, 3rd/4th gear, 5th/R gear
（1） Clutch housing, bearing box, rear housing and
control cover assembly. （4） Gear synchronizer assembly
（2） Adjusting gasket. （5） Intermediate shaft press plate
2 Check the support locations of the shafts and Check the following components for excessive wear:
bearings on the clutch housing, bearing box and
rear housing for wear, and replace when （1） Input shaft ball bearing (ball bearing)
necessary.
（2）Double inner ring bearing components(ball bearing)
3 Check the surface condition of the following
components: （3） Needle bearing of each output shaft gear
（1） Input shaft
（4） Rear output shaft bearing (ball bearing)
（2） Output shaft and each gear
（5） Intermediate shaft tapered roller bearing (cone
（3）Intermediate shaft bearing)
4 Reverse idler gear shaft and reverse idler gear. （6） Rear intermediate shaft bearing (ball bearing)
Note：Replace components with excessive wear, （7） Needle bearing of each intermediate shaft gear
do not rub parts treated by precision machining
（8） Reverse idler gear needle bearing
6 Check the gear surface of the gear set for wear.
ES350057
15-37
7 Check the gear set for excessive wear, crack Note：If the clearance is small, replace with a new
and damage. synchronizer ring, otherwise damage may occur,
Check the status of each synchronizer assembly which will lead to missing gear or damaged gear
9 Check the engaging gear of each gear and the
（1） Hub and gear sleeve engagement gear tooth of synchronizer gear sleeve for wear.
（2） Wear of the inner conical surface of synchronizer 10 Check the engagement of the synchronizer gear
ring sleeve and the engaging gear of each gear.
ES350060
ES350058
8 Measure the clearance between the

synchronizer ring and the transmission gear
（1） 1st gear synchronizer ring：0.7~1.55mm
（2） 2nd gear synchronizer ring：1~1.3mm
（3） 3rd gear synchronizer ring：1~1.55mm
（4） 4th gear synchronizer ring：1~1.55mm
（5） 5th gear synchronizer ring：1~1.55mm
（6） R gear synchronizer ring：1~1.55mm
ES350059
15-38
3 Insert 3 synchronizer sliders between the 1st/

Installation
2nd synchronizer hub and gear sleeve.
1 Install the 2nd gear needle bearing.
ES350063
ES350061
4 Install the 1st/2nd gear synchronizer assembly.
2 Install the 2nd gear and synchronizer ring
component in order.
ES350064
ES350062 Note：The outer conical ring pin of the

Note：The inner ring of the 2nd gear synchronizer synchronizer hub groove
ring has no conical surface; the inner ring pin of 5 Install the 1st synchronizer gear ring into the 1st/
the synchronizer ring is inserted into the 2nd 2nd synchronizer gear hub。
engaging gear groove
ES350065
15-39
Note：The inner ring of the 2nd gear synchronizer 8 Install the double inner ball bearing components.
ring has the conical surface; The outer conical
ring pin of the synchronizer ring is aligned with
the synchronizer hub groove
6 Install the 1st gear bushing, and install the 1st
gear needle bearing in place。
ES350068
9 Install the reverse gear bushing.
ES350066
7 Install the 1st driven gear assembly
ES350069
10 Invert the output shaft, and install the 3rd gear

needle bearing.
ES350067
Note：The inner ring pin of the synchronizer ring

is aligned with the 1st engaging gear groove
ES350070
15-40
11 Install the 3rd gear assembly. 14 Install the 3rd/4th gear synchronizer assembly.
ES350071 ES350074
12 Install the 3rd gear synchronizer ring. Note： The synchronizer ring pin is aligned with
the synchronizer hub groove; the high boss of
synchronizer hub faces the 3rd gear
15 Install the 3rd/4th gear synchronizer circlip.
ES350072
13 Insert 3 synchronizer sliders between the 3rd/4th

synchronizer hub and gear sleeve.
ES350075
Note：Adjust the axial clearance between the

collar and the gear hub to 0-0.05mm with a feeler
gauge
ES350073
15-41
16 Install the input shaft ball bearing. with it, and place the assembly vertically on the
workbench.
ES350076
ES350079
17 Install the input shaft ball bearing circlip.
20 Assemble the intermediate shaft with the 1st and
2nd shafts, and install the assembly into the
clutch housing.
ES350077
18 Install the intermediate shaft tapered bearing.

ES350080
21 Install the input shaft bearing press plate, then

install and tighten 4 bolts M6*18 with the socket
(8mm).
ES350078
19 Install the input shaft together with the 4th gear

synchronizer ring, insert the needle bearing into
the input shaft hole, assemble the output shaft
ES350081
15-42
Note：Apply the thread sealant Tonsan 1243B to 24 Install 2 hexagon bolt components M10 with the
the bolt threads socket (14mm), invert the transmission and
install 7 hexagon bolt components M10.
22 Install the 1st/2nd and 3rd/4th gear shift fork
components into the 1st/2nd and 3rd/4th
synchronizer gear sleeves respectively, place
the 5th/R gear taper between the 1st/2nd and
3rd/4th gear shift fork component brackets, then
install to the 5th/R gear shift fork shaft from top to
bottom; install the spring pin 5*22 into the
reverse gear taper, and check the 2 spring pins
on the clutch housing for any miss.
ES350084
ES350082
Note：The notch of spring pin shall face the axial

direction of shift fork shaft
23 Apply the plane sealant Tonsan 1956F to the
junction surface between bearing box and clutch ES350105
housing, and install the bearing box.
25 Install the release bearing assembly, tighten 3
release bearing bolts with the hexagon socket
head (6mm), and install the release bearing
bleeder connector in place.
ES350083
Note：The plane sealant shall be applied evenly

without any discontinuousness; always keep the
plane sealant intact during mould closing ES350085
Note：The release bearing bleeder connector

faces the bearing box
15-43
26 Lift the output shaft, install the double inner ball 28 Install the intermediate shaft press plate, and
bearing circlip, and install the intermediate shaft tighten 8 hexagon bolts M8 with the socket
cone bearing outer ring in place. (12mm).
ES350086 ES350088
27 Measure the distance between the intermediate 29 Install the reverse gear needle bearing, reverse
shaft cone bearing outer ring surface and the driven gear and reverse driving gear
bearing box surface with a depth gauge, select successively.
the adjusting gasket based on the measurement
and install it in place.
ES350089
ES350087 Note：The mark groove in reverse driving gear

faces the bearing box
Note：The thickness of selected gasket shall be
0.05-0.1mm thicker than the measurement;
ensure the cone bearing outer ring is installed in
place before measurement
15-44
30 Install the reverse idler gear shaft assembly. 32 Install the locking nut (2nd shaft) with the socket
(40mm); and install the 5th gear needle bearing
circlip with a plier.
ES350090
Note：The plane of reverse idler gear shaft faces ES350092

the adjacent spring pin
33 Press-fit the intermediate shaft spacer bushing,
31 Install the reverse gear synchronizer ring,
5th driving gear and rear intermediate shaft
reverse gear synchronizer assembly and 5th/R
bearing Φ 25* Φ 62*17 successively, and install
gear shift fork successively, and install the spring
the intermediate shaft locking nut with the socket
pins 5*22 into relevant holes in the 5th/R gear
(30mm).
shift fork.
ES350093
ES350091
34 Install the 5th gear synchronizer ring, 5th gear
Note：Three synchronizer ring pins are aligned
needle bearing, 5th driven gear assembly, steel
with the synchronizer hub grooves; the large ball 4.762, 5th gear semi-circle thrust washer
boss of synchronizer hub faces the reverse gear;
and the notch of spring pin shall face the axial
direction of shift fork shaft
15-45
and 5th gear semi-circle thrust washer retaining Note：Adjust the axial clearance between the
ring on the output shaft successively. collar and the gear hub to 0-0.07mm with a feeler
gauge.
36 Apply the plane sealant Tonsan1596F to the
junction surface between the rear housing and
the bearing box, then install the rear housing.
ES350094
Note：Select the 5th gear semi-circle thrust

washer with a feeler guage, and adjust the axial
clearance of the 5th gear to 015-0.35mm
ES350096
35 Press-fit the rear output shaft bearing φ 72* φ
28*18, install the circlip with a plier and press-fit Note：The plane sealant shall be applied evenly
the steel sleeve. without any discontinuousness; always keep the
plane sealant intact during mould closing
37 Install 11 hexagon bolt components M10 with the
socket (14mm), 2 of which shall be installed with
wire clips.
ES350095
ES350097
ES350106
15-46
40 Install the gear selection/shift cable brackets,

secure with 2 hexagon bolt components M8*22
respectively, and tighten with the socket (13mm).
ES350107
Note：Apply the thread sealant Tonsan 1243B to

the bolt threads
38 Install the output shaft dust cover, and install 3 ES350100
hexagon bolts M6*16 with the socket (10mm).
41 Install the control cover assembly, and install 3
connecting bolts M8*32 with the socket (13mm).
ES350098
Note：Apply the thread sealant Tonsan 1243B to ES350101

the bolt threads
Note：Do not miss the locating pin; ensure each
39 Tap with a nylon hammer to install the flange and shift fork is in Neutral position
tighten the locking nuts with the socket (14mm).
ES350099
15-47
42 Install the reverse gear stop bolt with the socket 44 Install the reverse gear fastening bolts and
(13mm). aluminum washer8 with the hexagon socket
head (6mm).
ES350102
ES350104
43 Install the reverse lamp switch assembly with the
socket (21mm).
ES350103
Note：Take care not to damage the reverse lamp

switch wire
15-48
Clutch
Clutch
Specification
Bolt - clutch pedal 25 ± 3

Nut - clutch pedal 25 ± 3
Bolt - clutch disc 35 ± 3
16-1
Clutch
Layout
5
6
DS110005
1 Transmission assembly 4 Clutch hose/tube subassembly

2 Clutch cover 5 Clutch master cylinder assembly
3 Clutch disc 6 Clutch pedal assembly
16-2
Clutch
When the clutch pedal is fully Linkage mechanism is loosened Repair or replace the loosened linkage
depressed, the shift lever cannot mechanism when necessary
shift to/out of R gear freely
Clutch disc is damaged Replace damaged clutch disc
Shift fork shaft is installed improperly Remove the shift fork shaft and reinstall it
properly. Apply a small amount of wheel
bearing grease on the shift fork end at
the release bearing
Clutch disc hub is stuck in the input shaft Repair or replace the clutch disc hub
spline
Clutch disc warps or bends Replace warped or bent clutch disc
Clutch slip Driver operates the car improperly Correct the driver's operation when
necessary
Clutch disc is immersed with oil Eliminate the failure at oil leakage point
and install new clutch disc
The friction surface of clutch disc is worn Replace worn clutch disc with a new one
or torn
Clutch cover or flywheel warps Replace warped clutch cover or flywheel
Diaphragm spring is weak Replace the diaphragm spring
Clutch disc is not in place Start the engine 30-40 times. Do not
overheat the engine
Clutch disc is overheated Cool down the clutch disc
Clutch jitters Friction surface is burned or worn caused Eliminate the failure at oil leakage point
by oil on it and install new clutch disc
Input shaft spline is worn Replace worn input shaft
Clutch cover or flywheel warps Replace warped clutch cover or flywheel
Burned or smeared resin appears on Grind away the burned or smeared resin
clutch cover or flywheel on surface. Replace any burned parts or
parts with hot cracks.
Clutch clicks Contraction spring is weak Eliminate the failure of oil leakagesource
and replace clutch disc.
Oil exists in bumper block of clutch disc Eliminate the failure of oil leakage source
and replace clutch disc
Shock absorption spring of clutch disc is Replace clutch disc

damaged.
Clutch makes noises during Driver operates the car incorrectly Correct the driver's operation when
engagement necessary
Check if the release lever is installed Remove and reinstall the release lever
improperly properly
The return spring of connecting rod Replace the weak return spring of
degrades connecting rod
16-3
Clutch
Pedal stays on the floor without Connecting rod is stuck Grease and move the clamped
recovery connecting rod
Clutch cover spring is weak Replace clutch cover
16-4
Clutch
Replacement of Clutch Main Pump

Repair Guidance
Replacement of Clutch Cover/Clutch Disc Removal
Removal 1 Disconnect the negative battery cable. (Refer to

Battery section for precautions)
1 Remove the transmission. (See Replacement of
Manual Transmission Assembly)
2 Support clutch disc with a proper tool, then
screw out fastening bolts successively.
3 Remove the clutch cover and clutch disc.
DS110001
2 Drain the brake fluid reservoir.

Note：Caution: If brake fluid splashes on the
painting surface, flush the affected area with cold
DS110004 water immediately.
3 Disconnect the spring clamp, remove the oil
Installation
supply hose from clutch main pump and cover
1 Install the clutch cover and clutch disc, and align two ends tightly to prevent dust.
clutch disc with proper tool.
4 Disconnect the clutch high-pressure tube from
2 Install the clutch, and align it with tool main pump.
C00016994. Tighten clutch cover bolts first 8-
5 Screw out 2 bolts and remove the clutch main
10N.m,then to the torque of 32-38 N.m in turn.
pump from dash panel.
Note：Check the thickness of clutch disc. Replace
Installation
the disc when it exceeds or approaches the
wearing limit. Clutch cover must be replaced 1 Installation is the reverse of removal.
when it is fallen off accidentally. Clutch disc and Tightening torque of main pump mounting bolt: 22 -
clutch cover and bolts must be replaced at the 28N.m
same time.Clutch bolts must be used once.
2 Exhaust the air. Refer to Air Exhaust of Hydraulic
Clutch.
3 Refill the brake fluid to the position marked with
MAX of the fluid reservoir and connect the
negative battery cable.
16-5
Clutch
Replacement of Clutch Pedal Replacement of Clutch Pedal Position

Removal Sensor
1 Remove the clutch main pump. (Refer to

Removal
Replacement of Clutch Main Pump) 1 Remove the harness of clutch pedal position
sensor.
DS110002
DS110006
2 Remove fastening bolts from the clutch pedal.
3 Remove the clutch pedal. 2 Remove fastening bolts of clutch pedal position
sensor.
Note：After clutch switch or pedal is replaced, it is
3 Remove the clutch pedal position sensor.
required to perform initial "learning":
Note：After the switch of clutch pedal position
1 Completely depress the clutch pedal; sensor or clutch pedal is replaced, it is required
2 Pull the push rod of clutch switch to the highest to perform initial "learning":
point;
The clutch switch will not work properly until initial
3 Release the clutch pedal, and the pedal will "learning" is completed.
press the clutch switch to proper operating gear;
The clutch switch will not work properly until initial Installation
"learning" is completed. 1 Put the cylindrical bracket rod on the clutch
pedal in the middle of U-shaped structure of the
Installation sensor (as shown in Figure A below).
Tightening torque of clutch pedal mounting bolts: 22 -
28N.m
B
A
DS110008
2 Align the locating pin on the sensor with the
locating hole in the clutch pedal bracket (as
shown in Figure B above).
3 Tighten the bolt to 2.5 ± 0.5N.m.
16-6
Clutch
Component Clutch pedal sensor

Name
Connector
Status
Pin A Pin C
Pin B
DS110009
Technical A#:5V
Parameters C#: grounding
(static)
A#B#：3 ± 0.6K Ω

Monitor the position of clutch pedal, convert the position
into voltage signal and send to the control module.
Learning method for clutch pedal sensor: install

diagnostic software CVDS of the latest version
1.7.3.40964 and above.
After data has been refreshed, enter into EMS Special

Function- Clutch Pedal Self-learning to perform learning
of clutch pedal sensor:
Note：This function only applies to 6MT vehicles

equipped with clutch pedal position sensor.
When replacing with a new EMS or clutch pedal
or clutch pedal position sensor, it is aways
necessary to utilize Special Function- Clutch
Pedal Self-learning in the diagnostic software to
learn position information of clutch pedal
position sensor in EMS. Before learning, user can
enter into data flow, and view data flow -
selflearning state of clutch pedal position.
16-7
Clutch
EMS-EU4 special function-Clutch Pedal self learning
EMS-EU5 special function-Clutch Pedal self learning
Go to the special function-Clutch Pedal self learning,

according to the interface prompt operation. After
learning, turn off ignition switch at least 60 seconds.
You also can open CVDS, then go to the datalist to check

datalist-Status of Clutch pedal self-learning.
16-8
Clutch
(1).Learning successful as follow;
(2).If learning failure, learn again;
(3).If continuous learning failure, check the hardware

installation.
16-9
Clutch
Replacement of Clutch CSC Bleed Connector Air Exhaust of Hydraulic Clutch

Removal 1 Exhaust air entering into the hydraulic system
1 Disconnect the negative battery cable. (Refer to when pipelines are disconnected for repair.
Battery section for precautions) During air exhaust, the brake fluid in clutch fluid
reservoir must be kept in MIN or a slightly higher
2 Drain the brake fluid reservoir.
position.
3 Disconnect the clutch high-pressure tube from
main pump.
4 Disconnect CSC bleed connector from
transmission.
5 Take out the hose/tube assembly from each
clamp.
Installation
Tighten the hose/tube assembly connectors to 14 -
18N.m
2 Exhaust the air. Refer to Air Exhaust of Hydraulic

Clutch. DS110003
2 Connect ethylene plastic hose to the air exhaust
MAX of the fluid reservoir and connect the
plug of the clutch sub-pump. Insert the other end
negative battery cable.
of ethylene plastic hose into a glass container
half filled with brake fluid.
3 Slowly depress the clutch pedal.
4 While depressing the clutch pedal, rotate the
knob at the upper part of bleed connector by
hand until the fluid flows out, tighten the knob
and release the clutch pedal.
5 Repeat Step 3 and 4 until no bubble exists in the
fluid.
MAX in the fluid reservoir. Note: Brake fluid may
damage electrical connector and painting
surface. Use cotton cloth, proper container and
fender cover to prevent brake fluid from
contacting these areas.
Note：It is prohibited to refill the fluid drained
from the system back into fluid reservoir of
clutch main pump. Because:
1 Air may mix in the fluid

2 The fluid may be contaminated
3 The fluid may contain too much water
16-10
Steering System
Steering System
Specification
Torque
Nut/bolt - steering column bracket to body 22 ± 2

Bolt - intermediate shaft to extension shaft 30 ± 3
Bolt - steering column to intermediate shaft 22 ± 2
Bolt - steering intermediate shaft extension to steering gear 22 ± 2
Nut - dust shield of steering intermediate shaft to body dash 9±1
panel
Nut - steering gear outer rod to steering knuckle 90 ± 5

Locking nut of steering gear 53~72
Nut/bolt - frame to steering gear 250 ± 20

Bolt - frame to steering gear 100 ± 5
Bolt - steering pump to engine 25 ± 3
Bolt/nut - steering pipeline to body 9±1
Steering pipeline to steering gear 32 ± 2
Steering pipeline to steering pump 32 ± 2
17-1
Steering System
Layout
Power Steering System Layout (RHD)
10
5
3 6
7
2
ES070001
1 Steering reservoir 6 Power steering pump

2 Steering oil return pipe 7 Power steering gear
3 Steering cooling pipe 8 Steering intermediate shaft
4 Steering high-pressure pipe assembly 9 Steering intermediate shaft extension
5 Steering pump oil suction hose 10 Steering column
17-2
Steering System
Steering Gear Assembly Exploded View (RHD)
7 6
1
4 6
3
9
2
8
2
3
4
ES070003
1 Steering gear body 6 Bolt - steering gear to frame

2 Dust shield assembly 7 Nut - steering gear outer rod to steering knuckle
3 Lock nut 8 Nut - steering gear to frame
4 Outer rod 9 Shim - steering gear to frame
5 Locating bolt
17-3
Steering System
Repair Guidance
Drain of Power Steering Hydraulic System Replacement of Steering Column Assembly
Removal
1 Clean the area around the filler port of the power
steering oil tank and oil level indicator surface. 1 Remove the steering wheel. Refer to Removal/
2 Unscrew the cover from the power steering oil Installation of Steering Wheel for details.
tank and refill the steering oil to the level 2 Remove the upper and lower steering column
between the min and max scale. shroud. Refer to Replacement of Upper and
Note：Operate with care to prevent oil or other Lower Steering Column Shroud for details.
liquid from entering into and polluting the engine. 3 Fix the clock spring with adhesive tape or
equivalent, remove the clock spring and steering
3 Start up the engine and operate it for 10 seconds
angle sensor. Refer to Replacement of Clock
at idle speed, then shut down.
Spring for details.
4 Fill the oil tank with power steering oil to
4 Remove the combination switch. Refer to
indicated level.
Replacement of Combination Switch for details.
5 Start up the engine, operate it for 2 minutes and
5 Remove the ignition switch. Refer to
turn it fully to the left and right locking points,
Replacement of Ignition Switch for details.
then shut it down.
6 Unscrew the top clamping bolt connecting the
Note：DO NOT place the steering gear at the
steering column and the steering intermediate
locking points for more than 10 seconds. shaft.
6 Refill the oil tank with power steering oil to 7 Unscrew and remove the nuts and bolts securing
indicated level. the steering column bracket to the body.
7 Start up the engine, operate it for 2 minutes and
turn it fully to the left and right locking points,
then shut it down.
Note：DO NOT place the steering gear at the
locking points for more than 10 seconds.
8 Check the steering oil tank, if it discharges air
bubbles, just wait until no bubbles are 7
discharged, then refill the steering oil to the level
between the min and the max scale.
9 Install the oil filler cap of the power steering oil
tank.
6
ES070004
Installation
Where:
—The tightening torque of the bolt/nut - steering column

bracket to body is 22 ± 2N.m.
—The tightening torque of the bolt - steering column to

intermediate shaft is 22 ± 2N.m.
17-4
Steering System
Replacement of Steering Intermediate Shaft Replacement of Power Steering Gear

Removal Assembly and Steering Intermediate Shaft
Extension
1 Remove the bolt connecting the steering column
Removal
and the steering intermediate shaft. (Tightening
torque: 22 ± 2N.m) 1 Remove the bolt connecting the steering
intermediate shaft and the steering extension
2 Remove the bolt connecting the steering
shaft from the side of the wheel.
intermediate shaft and the steering extension
shaft from one side of the wheel. (Tightening
torque: 30 ± 3N.m)
3 Remove the nut connecting the dust shield of
steering intermediate shaft and body dash panel.
(Tightening torque: 9 ± 1N.m)
ES070006
2
2 Remove the nut connecting the steering gear tie
rod and the steering knuckle. Use ball head
puller C00017036 if necessary.
ES070005 3 Remove the bolt, nut and shim.
4 Disconnect the steering pipeline from the
steering gear.
Installation 5 Take out the steering gear and the intermediate

shaft extension assembly. For 4WD vehicles, the
1 Installation is the reverse of removal. distance between the steering gear and the front
axle housing is short; please move the steering
gear downward firstly to take it out.
6 Separate the steering gear and the steering
intermediate shaft extension. (Remove the
steering gear first before removing the steering
intermediate shaft extension)
17-5
Steering System
Installation 7 Connect the steering pipeline to the engine gear:

1 Install the bolt connecting the steering gear and first connect the lower pipe joint and then the
the steering intermediate shaft extension and upper one with the same tightening torque of
tighten to 22 ± 2N.m. 32 ± 2N.m.
2 Pass the steering intermediate shaft extension
through the hole in the frame, and align the
steering gear to corresponding mounting hole. 7
ES070010
8 Install the nut connecting the steering gear tie

rod and the steering knuckle, and tighten to
ES070008
90 ± 5N.m.
3 Pass the locating bolt through the steering gear 9 Install the bolt securing the steering intermediate
and frame. shaft to the steering intermediate shaft extension
from the side of the wheel, and then tighten to
30 ± 3N.m.
5
ES070009 R
ES070023
·The difference between the locating bolt and common
bolt: the locating bolt is indicated by the arrow.
4 Pass the common bolt through the steering gear

and the frame, face to the shim and nut, but do
not tighten it.
5 Install the bolt and tighten to 100 ± 5N.m.
6 Tighten the nut mentioned in Step 3 and 4 to 250
± 20N.m.
17-6
Steering System
Replacement of Steering Gear Outer Rod Installation

Removal 1 Tighten the steering tie rod to the position
1 Lift the vehicle from the lifting platform. marked on the inner rod thread, with the steering
tie rod ball joint upward. Never tighten the
2 Remove the wheels. Refer to Wheels locking nut of tie rod.
Replacement for details.
2 Connect the steering tie rod ball joint to the
3 Remove the nut fixing the tie rod ball head with steering knuckle, install new nut and tighten to
the steering knuckle, detach the ball head with
90 ± 5N.m.
the tool C00017036.
3 Install the wheels.
4 Align four wheels.
5 Tighten the locking nut to 53-72N.m.
C00017036
ES070012
4 Release the locking nut of the steering tie rod.

5 Mark the relative position of the outer rod on the
inner rod thread, and screw off the steering tie
rod from power steering gear.
ES070013
17-7
Steering System
Replacement of Steering Gear Dust Shield Replacement of Power Steering Pump

Removal (VM2.8 Engine)
Removal
1 Remove the steering gear outer rod. Refer to
Replacement of Outer Rod for details. 1 Remove the drive belt.
2 Loosen 2 clamps of the steering gear sleeve and 2 Disconnect the steering high-pressure oil pipe
discard them. bracket from the steering pump.
ES070014 ES070015
3 Take off the steering gear sleeve. 3 Remove the bolts connecting the steering gear
to the engine.
Installation
1 Clean the mating face of the dust shield on the
steering gear.
2 Apply silicone oil around the mating face of the
dust shield and the steering gear.
3 Install the dust shield and rotate it manually 3
turns and above.
4 Install a new clamp and tighten it.
5 Install the steering gear outer rod. Refer to Outer
Rod Installation for details.
6 Align four wheels. ES070016
4 Release the steering high-pressure oil pipe and

steering oil suction hose from the steering pump,
then take out the steering pump.
17-8
Steering System
Installation Replacement of Power Steering Pump

(Mitsubishi 2.4 Engine)
1 Connect the steering high-pressure oil pipe
bracket and the steering pump with the bolt, and Removal
tighten to 9 ± 1N.m. 1 Remove the drive belt.
2 Install 3 bolts connecting the steering pump to 2 Disconnect the steering pump from steering high
engine, and tighten to 25 ± 3N.m. and low pressure oil pipe brackets.
3 Connect the steering pump and the steering oil
suction hose with a clamp.
4 Connect the steering pump and the steering
high-pressure oil pipe assembly, and tighten to
32 ± 2N.m.
5 Install the drive belt.
ES070017
3 Remove 3 bolts connecting the steering gear

and the engine.
ES070018
4 Release the steering high and low pressure oil

pipes and steering oil suction hose from the
steering pump, then take out the steering pump.
17-9
Steering System
Installation Steering Pipeline

1 Connect the steering high/low pressure oil pipes The tightening torque of the bolt/nut - steering pipeline to
and the steering pump with bolts, and tighten to body is 9 ± 1N.m.。
9 ± 1N.m.
RHD (VM2.8 Engine)
2 Install 3 bolts connecting the steering pump to
engine, and tighten to 25 ± 3N.m.
3 Connect the steering pump and the steering oil
suction hose with a clamp.
4 Connect the steering pump and the steering
high/low pressure fuel pipe assembly, and
tighten to 32 ± 2N.m.
5 Install the drive belt.
ES070020
RHD (Mitsubishi 2.4 Engine)
ES070022
17-10
Steering System
Special Tool Description and Operation

Steering Column
The steering column is a foldaway mechanism which
Tool Number and Illustration takes into account the movement of the engine and
Description
steering system components in the event of a serious
vehicle crash. The upper steering column can slide away
from the driver, while the lower is flexible. The steering
column is fitted on a one-piece cast aluminum bracket
C00017036
which is connected to the vehicle body and the
Ball head puller
instrument panel beam. Both the height and the tilt of the
steering wheel are adjustable in each plane within a
C00017036
certain range. To make the tilt adjustment easy, at each
adjustment endpoint, there is a balance spring and a limit
pad. And there is a double-wall seal retainer between the
steering column and the dash panel. The steering wheel
is composed of a center wheel hub and frame casting
together with the soft polyurethane molded onto the
casting. The center wheel hub has spline slots with a
mark which is aligned with the corresponding mark on
the steering column. The horn switch, the control switch
and the cruise control switch are assembled on the
steering wheel. All of the switches are connected with the
rotary coupler connector through connecting wires. An
airbag located at the center of the steering wheel and
below the plastic cover is provided for protecting the face
and upper body of the driver.
Power Steering Gear

The power steering gear is fitted in an appropriate
position under the rear beam of the front subframe. Since
the mounting point of the power steering gear and the
suspension pivot are determined by the precisely
machined rigid front subframe, it is possible to maintain
the relative designed geometric dimensions between the
steering pinion and rack mechanism and the suspension
at any time. The power steering gear is fixed by four
bolts, two of which go through the press plate (casting)
tightening the power steering gear pipe, while the other
two go through the fixture that is at one end of conversion
valve unit and integrated with the power steering gear
pipe. The steering column is fixed to the power steering
gear by a "Double-D-type" mechanism with bolts and
nuts. Total transmission ratio of pinion and rack is 16.1:1
and the rubber bellows hood covers the moving area of
the steering pinion and rack. One end of the steering tie
rod is fitted on the threaded steering gear and fixed with
17-11
Steering System
locking nuts, which can be used to adjust alignment of

the steering system. The other end of the steering tie rod
is entirely fixed with locking nuts to the steering arm
stretching out from the front wheel hub.
Power Steering Fluid Reservoir

The power steering fluid reservoir consists of the body, lid
and filter assembly. On the lid, there is a fluid level gauge
of steering fluid reservoir integrated with the lid and an O-
ring preventing fluid leakage. There is also a venthole in
the lid allowing the change of fluid level of steering fluid
reservoir during operation. The filter assembly is fitted at
the bottom of the steering fluid reservoir. The filter is
made of fine stainless steel wire mesh molded in the filter
bracket. The filter detracts particles in the steering fluid
reservoir before the steering fluid enters into the fluid
supply pipeline. The filter is a maintenance-free
component. The basic function of the steering fluid
reservoir is to maintain a certain amount of surplus
steering fluid in the hydraulic system to allow the
expansion and contraction of the steering fluid at different
temperatures. Ensure that the fluid supply pipe is always
covered by the steering fluid under all operating
conditions. Any air in the hydraulic system will be
discharged from the liquid inside the steering fluid
reservoir.
Power Steering Fluid Flow

Power steering works with the steering mechanism. The
hydraulic pressure running the power steering system is
generated by a spiral vane pump which is driven by the
belt on the crankshaft pulley. The amount and pressure
of the power steering fluid are adjusted by the flow control
valve in the power steering fluid pump. The fluid pressure
from the power steering fluid pump is transferred to the
conversion valve via the steering pinion, the control valve
controls the fluid pressure and changes the fluid flow
direction. The fluid is directed to the corresponding side
of the power cylinder, generating steering pinion and rack
propelling forces. The hydraulic fluid returns from the
power cylinder through a circular channel of the fluid
return pipe. Before the power fluid returns to the steering
fluid reservoir, in this circular channel the power steering
fluid cools. The steering fluid reservoir is where the power
steering fluid is allowed to be stored.
17-12
Steering Wheel
Steering Wheel
Torque
Application Torque value (N.m)
Nut - steering wheel assembly 35 ± 3
18-1
Steering Wheel
Layout
Steering Wheel Layout
ES120000
1 Steering wheel
18-2
Steering Wheel
Repair Guidance
Replacement of Steering Wheel
Removal
1 Disconnect the battery (negative first).
2 Remove the driver airbag module assembly or
the steering wheel trim cover assembly (Refer to
Removal of Driver Airbag Module Assembly).
3 Disconnect the electrical connector of steering
wheel switch
4 Screw out the nuts of steering wheel assembly
and remove the steering wheel assembly.
5 Remove the steering wheel.
Installation
Note：When installing the steering wheel, ensure
the steering column is matched with the
rectangular key slot of the steering wheel.
18-3
Steering Wheel
18-4
Front Suspension
Front Suspension
Specification
Torque
Bolt - upper swing arm ball head assembly to upper swing arm welding 35 ± 3
assembly
Bolt - lower swing arm ball head assembly to lower swing arm welding 125 ± 10
assembly
Bolt/nut - front suspension lower swing arm assembly to frame 240 ± 10

Bolt/nut - front suspension upper swing arm assembly to frame 140 ± 20
Nut - brake hose to upper swing arm 16 ± 3
Bolt - lower swing arm ball head assembly to lower swing arm welding 125 ± 10
assembly
Bolt/nut - front shock absorber strut to lower swing arm welding 180 ± 10
assembly
Nut - front suspension lower swing arm ball head assembly to steering 150 ± 10
knuckle
Nut - front suspension upper swing arm ball head assembly to steering 100 ± 10
knuckle
Nut - front stabilizer bar link to lower swing arm 65 ± 5

Nut - front stabilizer bar to stabilizer bar link 50 ± 5
Nut - steering gear tie rod to steering knuckle 90 ± 5
Nut - front hub 350 ± 15
Nut - top of front shock absorber to frame 65 ± 5
Nut - front shock absorber locking nut 70 ± 5
Bumper block of high chassis - frame 95 ± 9
Bolt - bumper block of low chassis to frame 50 ± 8
Nut - front hub 350 ± 15
19-1
Front Suspension
Layout
Front Suspension Layout
2
8 9 4 7
ES060000
1 Front suspension upper swing arm assembly 6 Bumper block

2 Front suspension lower swing arm assembly 7 Brake corner assembly
3 Front suspension stabilizer bar 8 Steering gear
4 Front suspension stabilizer bar link 9 Drive shaft (4WD)
5 Front shock absorber strut and spring assembly
19-2
Front Suspension
Front Upper/Lower Swing Arm Exploded View
1
6
2
4 6 5
ES060001
1 Front suspension upper swing arm assembly 4 Front suspension lower swing arm ball head
assembly
2 Front suspension upper swing arm ball head
assembly 5 Front suspension lower swing arm bushing
3 Front suspension lower swing arm assembly 6 Front suspension upper swing arm bushing
19-3
Front Suspension
Front Horizontal Stabilizer Bar Exploded View
4
1
2
3
ES060002
1 Front suspension stabilizer bar 3 Front suspension stabilizer bar clamping bracket
2 Front suspension stabilizer bar link 4 Stabilizer bar bushing
19-4
Front Suspension
Front Shock Absorber Strut and Spring Assembly Exploded View
1
2
11 4
6
7
8
10
9
ES060003
1 Lock nut 6 Lower vibration isolator

2 Upper gasket 7 Lower gasket
3 Upper vibration isolator 8 Lower washer
4 Front shock absorber upper spring seat 9 Front shock absorber strut dust shield
5 Rubber gasket of front shock absorber upper 10 Front shock absorber strut subassembly
spring seat 11 Coil spring
19-5
Front Suspension
Front Steering Knuckle Exploded View (4WD)
3
1 2
ES060004
1 Brake disc 5 Brake disc mudguard

2 Front hub 6 Brake corner
3 Collar 7 Brake caliper
4 Front hub bearing
19-6
Front Suspension
Front Steering Knuckle Exploded View (2WD)
5
4 8
3
1 2
ES060005
1 Brake disc 6 ABS gear ring

2 Front hub 7 Mudguard
3 Collar 8 Brake corner
4 Front hub bearing 9 Brake caliper
5 Spindle
19-7
Front Suspension
Repair Guidance
Four-Wheel Alignment Front Wheel Alignment
Check
1 Unscrew 4 lower swing arm nuts as well as left
1 Ensure that the correct vehicle data has been and right steering gear adjusting nuts.
entered into the equipment.
2 Check if the steering tie rod ball joint, front lower
swing arm ball joint and wheel bearing are worn
or run properly. Replace or repair if necessary.
3 Check the tire pressure.
4 Lift the vehicle from the lifting platform. Ensure
that vehicle weight is on the support. Ensure that
the size of the mounting clamp for wheels has
been calibrated correctly and fixed safely to the
vehicle.
5 Ensure that the camera device is fixed and
aligned properly.
6 Conduct the alignment of the wheels according ES060007
to instruction of equipment manufacturer.
7 Ensure that the steering wheel is in middle 2 Adjust the angle of lower swing arm adjusting
position. bolt and the length of steering gear tie rod to
make four-wheel alignment parameters fall in the
Four-Wheel Alignment Parameters target range (adjust according to indication of
four-wheel aligner system).
Item Four-wheel Four-wheel
Alignment Alignment
Parameter Parameter
(Unilateral (Bilateral Sum/
Nominal Value Difference)
and Tolerance)
Front wheel 0 ± 0.5° Difference

camber between left and
right ≤ 0.5°
Front wheel 3.6 ± 0.5° Difference
kingpin caster between left and
right ≤ 0.5°
Front wheel toe 0 ± 0.15° Total front toe ≤
0.15°
ES060006
Rear wheel toe ± 0.25° -
Rear wheel ± 0.5° - 3 Tighten the lower swing arm nut to 240 ± 20N.m;
camber and tighten the steering locking nut to
Rear shaft - 53~72N.m.
0 ± 0.25°
thrust angle 4 After adjustment, turn the steering wheel leftward
and rightward to a fully locked position and
check whether wheels interfere suspension
components.
19-8
Front Suspension
Replacement of Front Suspension Upper Replacement of Front Lower Swing Arm

Swing Arm Assembly Assembly
Removal
1 Lift the vehicle.
2 Remove the wheels. Refer to Wheels Removal
for details.
3 Detach the wheel speed sensor and brake hose
installed on the upper swing arm.
4 Remove the nuts connecting front suspension
upper swing arm to brake corner. Use ball head
puller C00017036 if necessary. 6
5 Detach the bolts and nuts on the left/right for

connecting front upper swing arm to frame. 8 9 3 4
5
ES060008
6 Remove front suspension upper swing arm Removal
assembly.
1 Lift the vehicle.
7 To replace the ball head assembly, unscrew the
bolt connecting ball head to upper swing arm 2 Remove the wheels. Refer to Wheels Removal
for details.
(torque: 35 ± 3N.m), take out the bolt, then
control arm ball head can be removed. 3 Unscrew the lower nuts of stabilizer bar link.
Installation 4 Unscrew the nut fastening the steering gear tie
rod to the steering angle. If necessary, use the
1 Fix the upper swing arm to the frame. ball head puller C00017036.
2 Tighten the left/right bolts and nuts on the frame 5 Remove the nut connecting lower swing arm and
to 140 ± 10N.m. brake corner. Use ball head puller C00017036 if
3 Tighten the nut connecting upper swing arm to necessary.
brake corner to 100 ± 10N.m. Steps 6-7 are only for 4WD models
4 Install the wheel speed sensor and brake hose
connected to the upper swing arm. Tighten the 6 Remove the nuts at propeller shaft wheel end,
nut connecting brake hose to upper swing arm to refer to Removal of Propeller Shaft Assembly for
16 ± 3N.m. details. Use a jack to support the steering angle.
5 Install wheels. Refer to Removal/Installation of 7 Remove the upper swing arm assembly. Refer to
Wheels for details. Removal of Upper swing Arm Assembly for
details.
8 Remove the bolts and nuts on the left/right for
connecting lower swing arm to frame.
9 Remove the nut at the bottom of shock absorber,
and use a jack to support front lower swing arm
(to the height where lower swing arm can be
removed).
Note：Avoid damages to wheel speed harness
and brake pipeline. It is required to support the
swing arm and steering angle to avoid injury from
falling objects.
10 Remove the lower swing arm.
11 To replace the ball head assembly, unscrew the
bolt connecting ball head to lower swing arm
(torque: 125 ± 10N.m), take out the bolt, then the
control arm ball head can be removed.
19-9
Front Suspension
Installation When installing the hub nut, note that:

2WD:
· The mating surface with a "JPS" mark of the locking
1 Install the bolt and nut connecting shock washer shall face the mounting surface of nut.
absorber assembly to lower swing arm
assembly, but do not tighten them. (Tightening ·Pre-tightening torque: 100 ± 10N.m.
torque: 180 ± 10N.m)
·Rotate the hub for 10 circles back and force. Install the
2 Install the nut connecting lower swing arm
assembly to steering knuckle, but do not tighten hub bearing in place and tighten to: 350 ± 15N.m.
it. (Tightening torque: 150 ± 10N.m) · Vertically knock down the lock nut of front hub into the
3 Tighten left/right bolt and nut connecting lower groove of drive shaft or spindle to prevent the nut from
swing arm assembly to frame to 240 ± 20N.m. loosening.
4 Tighten the lower nut of stabilizer bar link to 65 ±
5N.m.
5 Tighten the nut connecting the steering gear tie
rod to the steering angle to 90 ± 5N.m.
6 Tighten the bolts/nuts mentioned in Step 1 and 2.
8 Check four-wheel alignment parameters.
4WD:
1 Install left/right bolt and nut connecting upper

swing arm assembly to frame and tighten to
140 ± 10N.m.
2 Install left/right bolt and nut connecting lower ES060018
swing arm assembly to frame and tighten to
240 ± 20N.m. 6 Install the nut connecting upper swing arm
3 Install the bolt and nut connecting shock assembly to steering knuckle and tighten to
absorber assembly to lower swing arm assembly 100 ± 10N.m.
and tighten to 180 ± 10N.m. 7 Tighten successively the nuts mentioned in Step
4 Install the nut connecting lower swing arm 4 to 5.
assembly to steering knuckle, but do not tighten 8 Tighten the lower nut of stabilizer bar link to 65 ±
it. (Tightening torque: 150 ± 10N.m) 5N.m.
5 Install a new drive shaft nut, but do not tighten it 9 Tighten the nut connecting the steering gear tie
(tightening torque: 350 ± 15N.m). Refer to rod to the steering angle to 90 ± 5N.m.
Installation of Drive Shaft for details. When 10 Install the wheels.
installing the steering knuckle, rotate it outside to
a certain angle to allow the half shaft to insert 11 Check four-wheel alignment parameters.
into steering knuckle hole.
19-10
Front Suspension
Lower Swing Arm Bumper Block Replacement of Front Lower Swing Arm
Install the bumper block to front frame. The lower swing Bushing
arm bumper block of high chassis is shown below. The Removal
special tool for removal and installation of bumper block 1 Use special tool C00089916 to press out the
is C00089915. The tightening torque of bumper block is lower swing arm bushing. It must be pressed out
95 ± 9N.m. vertically to prevent sleeve deformation.
ES060028
ES060009
Installation
The lower swing arm bumper block of low chassis is
shown below. The tightening torque of bolt is 50 ± 8N.m. 1 Check the sleeve for deformation. If any, replace
the lower swing arm assembly; press vertically
the bushing into sleeve, with the press-in force
controlled within 12 ～ 40KN. If beyond the range,
replace the lower swing arm assembly.
ES060010
19-11
Front Suspension
Replacement of Front Horizontal Stabilizer Incorrect Picture

Bar
Removal
1 Detach the lower fastening nut of the stabilizer
bar link.
2 Unscrew the nut fixing the stabilizer bar to the
stabilizer bar link.
3 Unscrew the stabilizer bar bracket bolt, remove
the stabilizer bar, stabilizer bar clamping bracket
and stabilizer bar bushing.
Installation
ES060032
1 Install the stabilizer bar, stabilizer bar clamping
bracket and stabilizer bar bushing.
2 Tighten the nut connecting stabilizer bar to
· Do not put the bracket on two lugs at the lower of
stabilizer bar link to 50 ± 5N.m.
bushing. The two lugs shall be placed outside the
3 Tighten the bolt connecting stabilizer bar
bracket.
clamping bracket to frame to 35 ± 3N.m.
4 Tighten the nut connecting stabilizer bar link to
lower swing arm to 65 ± 5N.m.
ES060011
· The white mark on horizontal stabilizer bar shall be

flush with the bushing.
Correct Picture
ES060012
19-12
Front Suspension
Replacement of Front Shock Absorber Replacement of Front Shock Absorber

Assembly Assembly Component
Removal Removal
1 Remove the wheels. Refer to Removal/ 1 Remove the front shock absorber assembly.
Installation of Wheels for details. Refer to Removal of Front Shock Absorber
2 Unscrew the nut fastening the steering gear tie Assembly for details.
rod to brake corner. Use ball head puller 2 Fix the spring compressor C00017035-1 and
C00017036 if necessary. C00017035-2 to front shock absorber spring.
3 Remove the front upper swing arm assembly.
Refer to Removal of Upper Swing Arm Assembly
for details. Jack the front lower swing arm with a
jack.
4 Remove the drive shaft nut, detach the drive
shaft and steering angle (for 4WD model).
5 Remove the bolt fixing the upper part of shock
absorber to frame.
6 Remove the bolt fixing shock absorber to lower
swing arm.
7 Remove the front shock absorber assembly.
ES060013
Installation
3 Unscrew the nut on the top of front shock
1 Install the nut connecting front shock absorber absorber and discard it.
assembly to frame, but do not tighten it.
(Tightening torque: 65 ± 5N.m)
2 Install the bolt connecting front shock absorber
3
assembly to lower swing arm and tighten to
180 ± 10N.m. Then tighten the nut mentioned in
Step 1. 5
4
3 Tilt the steering knuckle outside to a certain
angle to allow the half shaft to insert into the
steering angle hole. Install the drive shaft nut
(tightening torque: 350 ± 15N.m). Refer to 6
Installation of Drive Shaft for details.
4 Install the upper swing arm assembly. Refer to
Removal/Installation of Upper Swing Arm
ES060014
Assembly for details.
5 Install the nut connecting the steering gear tie Warning：Make sure the spring compressor has
rod to the brake corner and tighten to 90 ± 5N.m. compressed the spring and removed the bearing
6 Install the wheels. pressure from shock absorber before removing
7 Check four-wheel alignment. self-locking nut on the top of front shock
absorber strut.
Note：Ensure that the black coating of the spring
is not damaged.
4 Remove the upper gasket, upper vibration
isolator, front shock absorber upper spring seat,
front shock absorber upper spring seat rubber
19-13
Front Suspension
gasket, lower vibration isolator, lower gasket and Replacement of Front Steering Knuckle
lower washer. Removal
5 Remove the coil spring of front shock absorber.
1 Remove the brake caliper and brake disc. Refer
6 Remove the dust shield and lower washer of to Replacement of Front Brake Disc and Brake
front shock absorber. Caliper Assembly for details.
7 Release the pressure of coil spring, loosen 2 Disconnect the brake corner from upper swing
adapter from spring compressor and remove the arm/lower swing arm, the propeller shaft from
coil spring. brake corner and the wheel speed sensor, then
remove the brake corner assembly.
3 Press out the spindle (for 2WD model).
Installation
1 Check the front shock absorber strut, upper/
lower vibration isolators, washers, front shock
absorber upper spring seat and front shock
absorber dust shield for signs of crack, aging
and damage.
3
2 Clean the front shock absorber strut and 6
1 4 5
washers.
3 Successively install washer, dust shield, washer,
lower gasket and lower vibration isolator to front
shock absorber assembly.
4 Install the coil spring of front shock absorber to
front shock absorber strut. ES060016
5 Locate the spring compressor to the front shock
absorber, use spring compressor C00017035-1 4 Press out the hub.
and C00017035-2 to compress the spring. 5 Take out the circlip.
6 Ensure correct relative installation position, 6 Press out the front hub bearing.
install the upper vibration isolator of front shock
absorber, rubber gasket of upper spring seat and
upper spring seat of front shock absorber to front
shock absorber shaft.
7 Install the upper washer of front shock absorber
and new nuts and tighten to 70 ± 5N.m.
8 Release the elasticity of spring, loosen the
adapter of spring compressor and take off the
spring compressor.
9 Clean the junction between front shock
absorber/spring assembly and the body.
10 Install the front shock absorber assembly.
ES060017
Note：When pressing out the bearing, take care to

avoid producing burr on the inner cavity hole
surface of steering knuckle.
19-14
Front Suspension
Installation
Special Tool
1 Check and confirm there is no damages and
impact traces on components, and no damages
and impurities on machined component surface.
Tool Number and Illustration
2 Press the hub bearing into steering knuckle. Description
Make sure the outer ring of bearing contacts
closely with inner hole shaft shoulder of steering
knuckle. Press-in force shall not exceed 60KN.
3 Put the circlip into the slot of steering knuckle
C00017036
inner hole with a caliper, and take care not to Ball head puller
damage the bearing seal ring.
4 By aligning to front hub bearing inner ring end
C00017036
face, press the front hub into front hub inner ring
to make front hub shaft shoulder contact closely
with the end face of front hub bearing inner ring.
5 Press in the spindle. (2WD model) C00017035-1
6 Successively connect the brake corner to lower MacPherson spring
swing arm, propeller shaft to brake corner, brake damper removal and
corner to upper swing arm and wheel speed installation tool 1
sensor. Refer to Installation of Lower Swing Arm, C00017035-1
Upper Swing Arm and Propeller Shaft.
C00017035-2
MacPherson spring
damper removal and
installation tool 2
C00017035-2
C00089915
Lower swing arm
bumper block removal
and installation tool
C00089915
C00089916
Lower arm bushing
remover
C00089916
19-15
Front Suspension
simultaneously during the turning of front wheels, plus

the rigidity of the two arms is large, so the roll when
Vehicle suspension mainly consists of three basic parts: turning is small, the tire contact area is large, the ground
elastic element, shock absorber and guiding mechanism. gripping performance is superior and uneven wear of tire
is mitigated. In addition, multiple parameters such as
Elastic element: realize the elastic connection between
camber angle, caster angle and toe-in can be adjusted
frame (or body) and axle (or wheel). It is used to bear and
during the four-wheel alignment of vehicles with double
transfer vertical load and to mitigate the impact due to
wishbone suspension system.
uneven road, emergency braking, acceleration and
turning. Front shock absorber: The device that changes the
disturbing force of the vibration source or the
Shock absorber: used to reduce the vibration produced
transmission characteristic of the system to reduce the
by impacted elastic system.
vibration.
Guiding mechanism: used to make wheels (especially
Coil spring: The coil spring is the buffer element. When
steering wheel) move relative to body along a certain
the impact of the road on the wheels is transmitted to the
movement track.
coil spring, the spring deforms to absorb kinetic energy of
The above-mentioned three parts are capable of the wheels and transfer it to potential energy of the coil
transferring force meanwhile. spring, thus mitigating the impact of the ground on the
body.
In most cars and buses, to prevent body from too much
transverse tilt during turning, auxiliary elastic element Front horizontal stabilizer bar: When the body rolls, the
horizontal stabilizer bar is equipped in the suspension to two sides of suspension deform inconsistently, then the
improve stiffness under side tilt as well as the operational horizontal stabilizer bar will act like a lever to make the
stability and driving smoothness. deformations of the springs on two sides nearly
consistent so as to mitigate the roll and vibration of the
Double wishbone type suspension consists of front upper
body and the stability of driving.
swing arm assembly (guiding mechanism), front lower
swing arm assembly (guiding mechanism), coil spring
(elastic element), shock absorber assembly and stabilizer
bar. When front wheels are turning, the upper and lower
cross arms can absorb cross force borne by tires at the
same time, which, with high stiffness, leads to small side
tilt angle during turning, large contact area between tire
and ground, excellent grip performance and little uneven
wear of tire. Additionally, the double wishbone type
suspension has more adjustable parameters during
fourwheel alignment for adjusting the wheel camber,
wheel kingpin caster and toe-in.
Operation Principle of Double Wishbone Suspension

System
The double wishbone suspension consists of the front

upper swing arm assembly (guide mechanism), the front
lower swing arm assembly (guide mechanism), the coil
spring (elastic component), the shock absorber assembly
and the stabilizer bar. The two (upper and lower) arms
can absorb the lateral force borne by the tires
19-16
Rear Suspension
Rear Suspension
Specification
Torque
Nut - rear shock absorber to frame 75 ± 7

Nut - rear shock absorber to lower bracket 110 ± 10
Bolt - front spring ear bolt shield of leaf spring to frame 22 ± 2
Bolt/nut - front spring ear of rear leaf spring 190 ± 10
Nut - U-bolt 120 ± 10
Nut - rear leaf spring shackle 110 ± 10
Bolt - rear bumper block of low chassis to frame 45 ± 5
20-1
Rear Suspension
Layout
Rear Suspension Layout (High Chassis)
1
5
ES060019
1 Rear shock absorber 4 Rear brake

2 Leaf spring 5 Bumper block of rear leaf spring
3 Rear axle
20-2
Rear Suspension
Rear Suspension Layout (Low Chassis)
6
4
5
3
1
ES060020
1 Rear shock absorber 4 Rear brake

2 Leaf spring 5 Parking brake cable
3 Rear axle 6 Bumper block of rear leaf spring
20-3
Rear Suspension
Rear Suspension Exploded View (High Chassis)
2
13 11
7
12
10
5
4
4
6
3 9
3
8
ES060021
1 Rear leaf spring assembly 8 Nut - U-bolt

2 Front spring ear bushing 9 Lower bracket assembly of leaf spring
3 Rear spring ear bushing 10 Rear suspension shock absorber
4 Rear shackle bushing 11 Front spring ear bolt shield
5 Shackle 12 Bumper block
6 Shackle cover plate 13 End gasket
7 U-bolt
20-4
Rear Suspension
Rear Suspension Exploded View (Low Chassis)
2
13
7
12
14
11
5
4
4
3
10
3
8
ES060022
1 Rear leaf spring assembly 8 Nut - U-bolt

2 Front spring ear bushing 9 Upper cover plate of rear leaf spring
3 Rear spring ear bushing 10 Lower bracket assembly of leaf spring
4 Rear shackle bushing 11 Rear suspension shock absorber
5 Shackle 12 Front spring ear bolt shield
6 Shackle cover plate 13 Bumper block
7 U-bolt 14 End gasket
20-5
Rear Suspension
Repair Guidance
Replacement of Rear Shock Absorber Replacement of Rear Leaf Spring
Removal Removal
1 Lift the vehicle to a certain height, and remove 1 Place the vehicle on the lifting platform and lift it
the wheels (Refer to Replacement of Wheels). to a certain height.
2 Unscrew and remove 2 bolts connecting rear 2 Use a jack to support rear axle housing to
shock absorber to frame and rear axle. prevent rear axle from moving downward.
3 Remove the rear shock absorber assembly. 3 Remove the shock absorber. Refer to Removal/
4 Check the shock absorber. Hold one end, check Installation of Shock Absorber for details.
whether there is resistance when the shock 4 Unscrew U-bolt connecting leaf spring and rear
absorber extends and compresses quickly. If not, axle, take down the upper cover plate of rear leaf
the shock absorber has deteriorated and needs spring and the lower bracket assembly of leaf
to be replaced. spring.
5 Remove the front spring ear bolt shield, and
release the bolt connecting the front spring ear of
Installation rear leaf spring and frame.
1 Install the bolt connecting the rear shock 6 Remove nuts connecting the rear spring ear of
absorber and frame and tighten to 75 ± 7N.m; leaf spring with shackle as well as shackle with
tighten the bolts connecting rear shock absorber frame. Remove the shackle, shackle cover plate,
rear spring ear bushing of leaf spring and rear
and rear axle to 110 ± 10N.m.
shackle bushing.
2 Install wheels. Refer to Replacement of Wheels
7 Lower the jack to take out the rear leaf spring
for details.
assembly.
8 Check the front spring ear bushing of leaf spring
for aging and abrasion. Use special tool
C00089917 to force out the front spring ear
bushing of rear leaf spring if necessary.
20-6
Rear Suspension
Installation 8 Install the bumper block to frame and tighten the

bolt to 45 ± 5N.m (for low chassis).
1 Use special tool to press fit the front spring ear
bushing of leaf spring. 9 Install the front spring ear shield bolt and tighten
to 22 ± 2N.m.
2 Install the shackle bushing into frame hole.
10 Install the rear shock absorber assembly. Refer
3 Adjust the height of the jack appropriately and
to Removal/Installation of Rear Shock Absorber
install the leaf spring assembly. Pay attention to
direction during installation. Specific differences
are illustrated below, where arrow points to the
front.
ES060023
4 Install and pre-tighten the connecting bolt and

nut of front spring ear of leaf spring. (Tightening
4
7 9
1
6
6
6
6
6 6
2 2
10
5 5 5 5
ES060024
5 Install and pre-tighten the rear leaf spring

shackle, shackle cover plate and nut. (Tightening
6 Install and pre-tighten U-bolt connecting rear leaf
spring and rear axle, shackle cover plate (low
chassis), lower bracket assembly of bumper
block (high chassis) and nut. (Nut tightening
7 Re-tighten above-mentioned fasteners.
20-7
Rear Suspension
Special Tool Description and Operation

Rear suspension consists of leaf spring and
shockabsorber, wherein the leaf spring is provided with
Tool Number and Illustration the function of both elastic element and guiding
Description
mechanism.
T60 rear leaf spring is the full-flight leaf spring, the

C00089917 stiffness of which varies slowly with load to offer higher
Front spring ear bearing capability of suspension while perfectly taking
bushing removal and comfort into consideration. To better meet the demands
installation tool
of various customers, comfortable and bearing-type
C00089917 suspensions can be created by changing the stiffness of
leaf spring. In addition, note that comfortable and
bearing-type suspensions are the same in appearance
and shall be distinguished by the part number on the
upper surface of leaf spring.
20-8
Tires and Wheels
Tires and Wheels
Specification
Torque
Nut - wheel to hub 125 ± 13
Tire Parameters
Wheel dimension 15x6.5J 16x7J 17x7J
Tire dimension 215/70R15LT 215/70R15C 245/70R16 245/65R17
Tire Front 300kPa/3.0bar/ 300kPa/3.0bar/ 220kPa/2.2bar/32psi 250kPa/2.5bar/36psi

pressure wheel 43.5psi 43.5psi
(cold)
Rear 375kPa/3.75bar/54psi 375kPa/3.75bar/54psi 280kPa/2.8bar/41psi 250kPa/2.5bar/36psi
wheel
Spare tire dimension 215/70R15LT 215/70R15C 245/70R16 245/65R17
Spare tire pressure 375kPa/3.75bar/54psi 375kPa/3.75bar/54psi 280kPa/2.8bar/41psi 250kPa/2.5bar/36psi

(cold)
21-1
Tires and Wheels
Layout
Tire Exploded View (Aluminum Wheel)
3
5
ES060025
1 Tire 4 Valve
2 Rim 5 Wheel nut
3 Wheel trim cover
21-2
Tires and Wheels
Tire Exploded View (Steel Wheel)
ES060026
1 Tire 4 Valve
2 Rim 5 Wheel nut
3 Wheel trim cover
21-3
Tires and Wheels
Spare Tire Device Layout
ES060027
1 Spare tire 3 Guide sleeve of spare tire device

2 Spare tire device
21-4
Tires and Wheels
Repair Guidance
Replacement of Wheels
Warning：DO NOT lubricate the rim and tire with
10°Max
lubricating oil containing silicone oil. Clean the
tire bead before removal of tire. Lubricate the 1
2
area completely using 50% lubricating oil and
50% water before installation.
Warning：Use a tire changer to remove tires and
avoid using manual tools or tire lever alone to
replace tires, otherwise wheel disk or rim may be
damaged.
Removal
1 Place the vehicle on the lifting platform and lift it ES060029
2 Remove the wheel trim cover with a screwdriver. ·During the installation of alloy wheel, the tire with mark
1 of φ 10 red dot shall be installed on the same side
3 Remove 5 wheel bolts with a socket wrench.
with the steel wheel with mark 2 of φ 10 red dot (if
4 Remove the wheel.
marked) at 0 angle. The tire assembly is required to be
Note：Avoid placing the hub panel towards the within 10 degrees after installation.
ground to prevent scratches.
5 Take down the wheel balance block and record
the location and mass of each balance block for
re-installation. (if applicable) 10°Max
6 Loosen the valve cap and release the air. 1

2
Remove the tire and pull out the wheel valve or
tire pressure monitoring sensor.
Installation
Note：Brush away the deposited corrosion on the
mounting surfaces of wheel, brake drum and
brake disc with scraping tool or steel wire before
ES060030
installation of wheels. During the installation,
improper mating of metal mounting surface and
3 Inflate the tire until the wheel disk is in place.
metal will cause the looseness of wheel bolts.
Ensure the locating ring outside the tire bead is
The wheel may thus fall off in driving, resulting in around the wheel rim flange on both sides. This
vehicle out of control and even personal injury. method can ensure the correct position of tire
bead.
1 Install the wheel valve assembly and ensure it is
fully matched and sealed with the rim. 4 Check the air tightness of the valve with soap
water or reinstall it.
2 Install the tire with the tire changer and align the
tire to the matching marks on the wheel. Note：DO NOT damage the tire when installing
accessories, especially the tire bead.
·During the installation of steel wheel, the tire with mark
1 of φ 10 red dot shall be installed on the same side 5 After each wheel is assembled, carry out the
with the steel wheel with mark 2 of φ 8 white dot (if balance test to the tire with a tire dynamic
balancer.
marked) at 0 angle. The tire assembly is required to be
within 10 degrees after installation.
21-5
Tires and Wheels
6 Pay attention to the followings when installing Replacement of Spare Tire

the balance block: Removal
1） After installation of the steel wheel assembly, the 1 Loosen the spare tire device and take off the
allowable unilateral residual unbalance is 10 grams or wheel.
less for the main tire, and 15 grams or less for the
2 Remove the bolt fixing the spare tire device to
spare tire. The maximum weight of the balance block the frame. (Tightening torque: 22 ± 2N.m)
is 60 grams on the outer side and no more than 180
3 Remove the guide sleeve of spare tire device.
grams on both sides.
2） After installation of the alloy wheel assembly, the

allowable unilateral residual unbalance is 8 grams or Installation
less. The maximum weight of the balance block is 80 1 Installation is the reverse of removal.
grams unilaterally and no more than 160 grams on
both sides.
7 After the wheel dynamic balance test, determine

the mass of the balance block and install it on the
wheel.
8 Install the wheel trim cover.
9 Install the wheel and tighten the wheel nut in
sequence with the socket wrench to the torque:
125 ± 13N.m.
Warning：The penetrating oil on the vertical
surface between the wheel,the brake disc and
brake drum will cause wheel looseness in driving,
thereby resulting in injury accidents due to
vehicle out of control. DO NOT heat to loosen the
wheel fastened tightly, which will shorten the
service life of the wheel, wheel bolt, hub and
bearing assembly. The wheel nuts must be
tightened to the correct torque in proper
sequence to prevent distortion of the wheel,
brake disc and brake drum.
21-6
Tires and Wheels

Tire specification
The following mark is located on the tire side and its

meaning is as follows:
Tire section width
P 245 / 50 R 16 95S
Tire section height
Tire type
P - Passenger-car
T - Temporary Aspect ratio Load index
(section height)/δsection widthε
55
50 Speed symbol
Tire section width 40 Configuration Rim diameter
(mm) R - Radial (inch)
235 B - Bias-belted 16
245 D - Diagonal (bias) 17
275
ES060036
21-7
Tires and Wheels
21-8
Brake System
Brake System
Specification
Model Low chassis
·Front Disc brake
·Rear Drum brake
Brake caliper piston diameter:
·Front 2 × 45mm
Brake disc diameter:
·Front 281mm
·Rear 295mm
Minimum thickness of front brake disc
·New (nominal dimension) 27mm
·Service limit 25mm
Maximum rear brake drum bore diameter
·Service limit 297.5mm
Minimum thickness of brake pad material
·Front brake lining (with a self-adhesive gasket) 8 8 mm (friction lining material is 2mm left only)
·Rear brake shoe (with a self-adhesive gasket) The friction lining material is 2mm left only
Parking brake: The manually operating mechanical-type, the cable

transfers power on the rear disc middle-drum parking brake
Antilock brake system Standard ABS
Electronic stability program Optional ESP
Brake pipeline type X-shape pipeline layout
Brake master cylinder Series-type dual-chamber independent master cylinder
Vacuum booster Dual-diaphragm vacuum booster
22-1
Brake System
Model High chassis
·Front Disc brake
·Rear Disc brake
Brake caliper piston diameter:
·Front 2 × 45mm
·Rear 1 × 43mm
Brake disc diameter:
·Front 300mm
·Rear 324mm
Minimum thickness of front brake disc
·Service limit 25mm
Minimum thickness of rear brake disc/maximum bore diameter
·New (nominal dimension) 18mm 210mm
·Service limit 16mm 211mm
Minimum thickness of brake pad material
·Front brake lining (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear brake lining (with a self-adhesive gasket) 8 mm (friction lining material is 2mm left only)
·Rear brake shoe (with a self-adhesive gasket) The friction lining material is 2mm left only
Parking brake: The manually operating mechanical-type, the cable

transfers power on the rear disc middle-drum parking brake
Antilock brake system Standard ABS
Electronic stability program Optional ESP
Brake pipeline type X-shape pipeline layout
Brake master cylinder Series-type dual-chamber independent master cylinder
Vacuum booster Dual-diaphragm vacuum booster
22-2
Brake System
Torque
Sunk screw - brake disc to hub 8±2

Brake drain screw 9~13
Front brake caliper hinge pin bolt 30~35
Rear brake caliper hinge pin bolt 50~60
Bolt - front brake caliper to brake corner 200 ± 20

Bolt - rear brake caliper to brake corner 130 ± 10
Bolt - brake hose to brake caliper 35 ± 3
Brake tube to rear drum brake wheel cylinder 15 ± 2
Nut - brake master cylinder assembly to vacuum booster 18~20
Nut - vacuum booster to engine compartment 20 ± 2

Bolt - ABS/ESP regulator bracket to body 22 ± 2
Nut - brake pedal to engine compartment 20 ± 2
Brake tube to brake master cylinder 15 ± 2
Brake pipeline to ABS/ESP regulator 15 ± 2
Bolt - cable to rear leaf spring 22 ± 2
Bolt - cable to frame 10 ± 1
Bolt - cable to body 20 ± 2
Bolt - parking brake handle to body 22 ± 2
22-3
Brake System
Layout
Brake System Layout
13
12
6
10
7
8 1
3 11
4
ES110000
1 Vacuum booster assembly 8 Front brake tube

2 Brake pedal assembly 9 Front brake hose
3 ABS/ESP 10 Rear brake tube (front segment)
4 Front brake corner assembly 11 Rear brake tube (middle segment)
5 Rear brake assembly 12 Rear brake tube (rear segment)
6 Parking brake handle 13 Rear brake hose
7 Parking brake cable
22-4
Brake System
Exploded View of Vacuum Booster Assembly
5
7
ES110001
1 Vacuum booster pad 5 Reservoir alarm switch

2 Vacuum booster 6 Brake fluid reservoir cover
3 Vacuum tube 7 Filter
4 Master cylinder and fluid reservoir 8 Vacuum booster to the brake master cylinder
assembly O-ring
22-5
Brake System
Exploded View of Parking Brake
3 8
1
2
4 9
7 5
ES110002
1 Parking baseplate 6 Parking push board

2 Brake shoe 7 Brake pressure spring
3 Upper return spring 8 Shoe limiting pin and spring
4 Lower return spring 9 Observation hole plug
5 Clearance adjusting mechanism
22-6
Brake System
Exploded View of Drum Brake
4 7
6 9
8
5
5 1
3 2
ES110003
1 Rear brake baseplate 6 Clearance adjusting mechanism assembly

2 Brake shoe 7 Bleed nut
3 Return spring 8 Adjusting hole/observation hole plug
4 Wheel cylinder assembly 9 Bleed screw
5 Shoe limiting pin and spring
22-7
Brake System
Exploded View of Front and Rear Brake Calipers
3
5
ES110004
1 Brake block assembly 5 Guide pin bush

2 Brake block snap ring 6 Bleed screw
3 Locating pin 7 Bleed nut
4 Guide pin
22-8
Brake System
L Z
2 2
ES110005
1 Parking brake cable 3 Park brake switch

2 Parking brake handle 4 Brake cable lever assembly
22-9
Brake System
ES110006
1 Brake pedal position sensor 3 Brake pedal footpad

2 Brake pedal
22-10
Brake System
head onto the position 10mm away from the

Repair Guidance
brake disc edge.
Brake Disc Check
Removal
to a certain height. Then remove wheels (refer to
Replacement of Wheels).
2 Remove the bolt fixing the caliper to the steering
knuckle. Remove the brake caliper assembly
and hold it with a bracket.
Note：Do not hang the brake caliper on the hose.
3 Clear slight rust spots, scratches and grooves on
the operating surface of brake disc with an
abrasive paper. In case of severe wear signs, ES110007
scratches or cracks on the operating surface,
7 Zero set the dial indicator and rotate wheels for a
conduct turning to the brake disc or replace it
circle. Then measure the brake disc runout,
with a new one.
which shall not exceed 0.1mm （front brake
4 Measure the brake disc thickness of more than 8 disc）/0.19mm（rear brake disc）； . The brake
testing points on the circumference of contact drum bore runout shall not exceed 0.1mm. If the
center between the brake disc and friction lining runout exceeds the limit, the brake pedal will
with an outer-diameter dial indicator. The vibrate and shake during braking.
minimum thickness of brake disc shall not be
8 If the brake disc runout exceeds the limit:
lower than the value specified in Technical
Parameters, and the thickness change on the 1）Remove the sunk screw fixing the brake disc onto the
same-radius circumference shall not exceed hub, and then remove the brake disc.
0.025mm. If exceeds, the brake disc must be
replaced. 2） Keep the brake disc to hub flange clean.
5 Measure the brake disc inner diameter of more
3） Install the front brake disc onto the front hub. Then
than 4 testing points on the circumference of
install the sunk screw and tighten it to 8 ± 2N.m.
contact center between the brake disc and drum
friction lining with an outer-diameter dial 4） Check the brake disc runout according to the
indicator. The maximum bore diameter of brake
aforesaid steps.
disc shall not exceed the value specified in
Technical Parameters. If exceeds, the brake disc 5） If the runout still exceeds the limit, replace the front
must be replaced. brake disc.
Note：Brake discs must be replaced in pairs,
9 Install the brake caliper onto the brake corner.
unless the mileage does not reach 1,500km after
Then install the sunk screw and tighten it to
this brake disc is replaced.
8 ± 2N.m.
6 Fix the dial indicator onto the steering knuckle as
illustrated below. Fix the dial indicator measuring
11 Depress the brake pedal for several times to
adjust the brake block.
22-11
Brake System
Brake System Drain 5 Remove the bleed nut from the rear right brake
The following steps show the drain method of the overall caliper (for left-hand drive model), and install the
system. When the main or auxiliary line becomes an hose onto the exhaust screw. Insert the free end
of hose into the container filled with new brake
independent line, operate the line which shall be drained.
fluid.
Only when the brake tube is disconnected with the brake
hose and there is little oil loss, the hydraulic system can
be drained partially.
Warning：Protect eyes and skin from contacting

the brake fluid.
Note：DO NOT reuse the brake fluid drained from
the brake system.
Drain:
1 Fill the brake fluid reservoir to the MAX marking

position.
Note：Ensure new brake fluid level is between the
ES110009
MIN and MAX during the whole drainage.
2 Lift the vehicle from the lifting platform. 6 Apply braking onto the brake pedal for several
3 Start the engine. Do not conduct air clearance times, and then apply stable pressure onto it.
operation with the engine shut down, which may 7 Loosen the bleed screw to separate the brake
damage the vacuum booster. fluid from air. Leave the brake pedal to return
4 Exhaust the brake master cylinder assembly. without any external force.
8 Depress the brake pedal to the maximum stroke
steadily, and leave it to return without any
2 external force. Repeat this operations for several
times until the brake fluid containing no bubble
flows into the container. Then fix the brake pedal
to the maximum stroke position, tighten the drain
1
screw to 9-13N.m, and loosen the brake pedal.
9 Remove the hose from the drain screw, and
install the bleed nut.
10 Repeat the drain procedures for the rest 3
brakecalipers according to the sequence below:
For left-hand-drive model: rear right, rear left, front right
ES110008
and front left
·Connect the brake tube.
For right-hand-drive model: rear left, rear right, front left
·Depress the brake pedal slowly and hold. and front right
·Loosen the brake tube joint 1. Warning：The incorrect drain sequence may
severely weaken the braking efficiency.
·Re-tighten the brake tube joint, and leave the brake
pedal to return slowly. 11 Shut down the engine.
·Repeat the aforesaid steps until there is no air
13 Fill the brake fluid reservoir to the MAX marking
exhausted when the brake tube joint 1 is loosened.
line.
·Repeat the aforesaid steps to exhaust air from the 14 Apply braking and check for leakage.
brake tube joint 2.
22-12
Brake System
15 Test the vehicle on road. When the braking Adjustment of Parking Brake Handle
works, check whether the free stroke of brake Assembly
pedal is within 10mm. If the brake pedal feels
Before adjusting the parking brake cable, adjust the
soft, do not drive the vehicle. Confirm whether
parking brake clearance adjusting mechanism first.
the unacceptable brake pedal foot feeling and
stroke is not caused by the dislocation of brake
1 Clamp wheels and release the parking brake
friction lining or other mechanical faults. Then
handle (push it to the bottom).
repeat the brake system exhaust process.
Besides, if the aforesaid exhaust process does 2 Keep lifting the vehicle from the lifting platform
not achieve the ideal effect due to the severe until wheels leave the ground.
brake fluid loss, drain the ABS/ESP regulator. 3 Then apply a force within 200N to pull up the
This operation is conducted through the scan parking brake handle by 6~7 teeth generally, and
tool. Refer to Instructions for SAIC Commercial the rear wheels will be locked. After the brake
Vehicle Scan Tool for details. pedal is completely released, rear wheels can
rotate freely. Otherwise it is required to adjust the
clearance between the parking brake shoe and
brake drum and then adjust the length of parking
brake cable.
4 The brake cable lever assembly can be seen
after the rear cover plate of auxiliary fascia
console is removed.
ES110010
5 Loosen the adjusting nut on the brake cable

lever. The exposing length of screw shall not be
less than 15mm.
22-13
Brake System
after the parking brake handle is pulled for 6~7

teeth with a force within 200N.
10 Move the parking brake handle up and down
completely.
11 Loosen the parking brake handle and ensure the
rear brake disc can rotate without obstruction.
12 Rotate the ignition key to ON position.
13 Pull up the parking brake handle for 6~7 teeth.
Then the parking brake indicator lamp will go on
15 and both rear brake discs will be locked; loosen
the parking brake handle. Then the parking
brake indicator lamp will go out and rear brake
ES110011 discs can rotate freely. Re-adjust if the
adjustment result is nonconforming.
Note：The vehicle must be supported on a safe
14 Turn off the ignition key.
device.
15 Install the rear cover plate of auxiliary fascia
6 Remove rear wheels.
console.
7 Adjustment of the clearance between brake
16 Install rear wheels.
shoes of rear wheels:
1） Keep rotating the parking brake clearance adjusting
ratchet with a flat screwdriver or equivalent to expand
the brake shoe outwards until the rear brake disc is
slightly hindered when rotating. (The clearance
adjusting mechanism will be pushed outwards for
0.125mm after adjustment by every tooth)
2） Loosen the clearance adjusting ratchet for 5~7 teeth.
3） Ensure the rear brake disc can rotate freely without

obstruction.
Adjustment of the clearance between brake shoes of rear

wheels (for drum brake)
Note：The clearance between the brake shoe of

drum brake and brake disc can be adjusted
automatically.
1） Keep depressing and loosening the brake pedal

repeatedly until the automatic adjuster makes no
click sound.
2） Loosen the brake pedal. Ensure the rear brake disc

can rotate freely without obstruction.
8 Move the parking brake handle back and forth for

5 times to set the rear brake shoes and hand
brake cable.
9 Tighten the adjusting nut on the brake cable
lever. It is required that rear wheels are locked
22-14
Brake System
Replacement of Front and Rear Brake Installation

Linings
1 Clean the brake caliper housing and front brake
Removal caliper bracket.
The front and rear disc-type brakes are equipped with a 2 Check the brake caliper and sealing condition for
wear indicator respectively as illustrated. When the damage.
brakes make noise due to the wear is lower than the 3 Fix the brake shoe onto the bracket with a snap
specification, the friction lining shall be replaced. The ring, and close the caliper body. Tighten the
thickness of friction lining shall not be lower than the guide pin bolts: tighten the front brake caliper to
value specified in Technical Parameters. 30~35N.m; tighten the rear brake caliper to
50~60N.m.
4 Depress the brake pedal for several times to
install the brake pad.
5 Prompt: The stroke of brake pedal may be longer
than usual for the first time of braking.
6 Install wheels. Refer to Replacement of Wheels.
7 Lower the vehicle to ground.
ES110012
Warning：The brake shoes of front wheels or rear

wheels must be replaced meanwhile, otherwise
the braking efficiency will be weakened.

Warning：The vehicle must be supported on a
safe device.
2 Remove wheels.
3 Loosen the guide pin, rotate the caliper body to a
certain angle, and remove the snap ring and
brake shoe from the bracket.
ES110013
22-15
Brake System
Replacement of Front and Rear Brake Replacement of Front Brake Disc

Calipers Removal
Removal
1 Ensure the parking brake is completely
1 Lift the vehicle from the lifting platform. loosened.
Warning：Do not operate under a vehicle 2 Place the vehicle on the lifting platform and lift it
supported by a jack only. The vehicle must be to a certain height.
supported on a safe device. Warning：Do not operate under a vehicle
2 Remove the wheels. Refer to Wheels Removal supported by a jack only. The vehicle must be
for details. supported on a safe device.
3 Place a container under the vehicle to collect 3 Remove the wheels. Refer to Replacement of
spilled oil. Wheels for details.
4 Loosen the bolt fixing the brake hose to brake 4 Remove the bolt fixing the steering knuckle to
cylinder. the front brake caliper.
Note：Before disconnecting or removing the Note：Do not hang the brake caliper on the brake
brake pipeline, ensure the middle area and hose.
connecting joints around the junction surface are
5 Remove the sunk screw fixing the brake disc to
clean. Block the opened connection to prevent the front hub.
contaminant from entering.
5 Loosen the bolt fixing the brake caliper to the
brake corner, and remove the brake caliper.
Installation
1 Fix the brake calipers onto the brake corners.
Tighten the front brake caliper to 200 ± 20N.m;
tighten the rear brake caliper to 130 ± 10N.m.
2 Tighten the bolt connecting the brake hose to
brake caliper to 35 ± 3N.m.
3 Drain the brake system. Refer to Brake System
ES110016
Drain for details.
4 Install the wheels. 6 Remove the front brake disc assembly.
Installation
1 Ensure the junction surface between the front
brake disc and front hub is clean.
2 Install the brake disc onto the hub. Then install
the sunk screw and tighten it to 8 ± 2N.m.
3 Check the brake disc runout. Refer to Brake Disc
Check for details.
4 Install the brake disc. Refer to Replacement of
Brake Caliper Assembly for details.
22-16
Brake System
Replacement of Rear Brake Disc/Brake Drum Installation

Removal 1 Ensure the junction surface between the rear
1 Ensure the brake is completely loosened. brake disc and rear hub is clean.
2 Place the vehicle on the lifting platform and lift it 2 Install the brake disc onto the hub. Then install
to a certain height. the sunk screw and tighten it to 8 ± 2N.m.
3 Check the brake disc runout. Refer to Brake Disc
Warning：Do not operate under a vehicle
Check for details.
supported by a jack only. The vehicle must be
supported on a safe device. 4 Install the brake disc. Refer to Replacement of
Brake Caliper Assembly for details.
3 Remove the wheels. Refer to Replacement of
Wheels for details.
6 Check the parking brake. Adjust the parking
4 Remove the bolt fixing the steering knuckle to
brake if necessary. Refer to Adjustment of
the rear brake caliper.
Parking Brake Handle Assembly for details.
Note：Do not hang the brake caliper on the brake
hose.
5 Remove the sunk screw fixing the brake disc to
the rear hub.
ES110018
6 Remove the rear brake disc assembly.
22-17
Brake System
Replacement of Rear Parking Brake Shoe Installation

Removal 1 Clean the rear brake disc guard plate and brake
1 Remove the rear brake disc. Refer to disc, and check whether the brake drum is worn
Replacement of Brake Disc for details. uniformly.
2 Check the parking brake shoe. Replace the 2 Check the state of spring in the parking brake,
parking brake shoe in any of the following cases: and replace it if necessary.
3 Assemble rear brake shoe components.
1） The thickness of parking brake lining friction lining
material is less than 2mm.
2） The brake friction lining fractures.
3） The brake friction lining is contaminated by engine oil

or oil fluid.
3 Loosen the brake shoe limiting pin and spring,

and loosen the rear brake shoe assembly from
the rear brake disc guard plate.
ES110021
4 Fix brake shoe components onto the brake disc

guard plate with limiting pin and spring.
5 Fix the brake cable onto the brake shoe.
6 Install the brake disc.
7 Adjust the parking brake.
ES110019
4 Remove the brake shoe components. Pay

attention to their mounting positions.
22-18
Brake System
Replacement of Rear Drum Brake

Removal Installation
1 Remove wheels. 1 Install the rear wheel cylinder assembly onto the
2 Remove the brake drum. baseplate, and tighten it to 7-11N.m.
3 Remove the regulating lever spring. 2 Connect the brake tube to the rear brake wheel
cylinder, and tighten it to 15 ± 2N.m.
4 Remove the regulating lever.
3 Install the brake shoe. Do not damage the wheel
5 Remove the brake shoe retaining pin and spring.
cylinder dust cover during installation.
6 Remove the lower spring from the brake shoe.
7 Remove the regulator assembly and upper
spring from the brake shoe. 6 1
8 Remove the brake shoe assembly from the

3
baseplate.
9 Remove the parking lever from the brake shoe.
8
10 Place a container under the vehicle to collect 7
spilled oil, and disconnect the brake tube from
the wheel cylinder assembly. 4
11 Remove the wheel cylinder assembly from the

baseplate.
5
ES110022
4 Install the parking lever onto the brake shoe with

pull rod pin, pull rod washer and locating retainer
(it is recommended to use new parts).
5 Install the lower spring to the brake shoe.
6 Apply some lubricating grease onto the contact
position between the regulator assembly threads
and brake shoe. Install the regulator assembly
(including the upper spring) onto the brake shoe.
7 Fix the regulating lever to the brake shoe with a
new regulating ring, and install the regulating
lever spring.。
8 Install the brake shoe retaining pin and spring.
9 Install the brake disc.
10 Exhaust the brake system if the wheel cylinder
was disconnected from brake pipeline before.
12 Adjust the parking brake cable assembly.
22-19
Brake System
Replacement of Brake Master Cylinder and Replacement of Vacuum Booster Assembly

Brake Fluid Reservoir Removal
Removal
1 Remove the windshield cover plate and
1 Place a piece of cloth under the brake fluid windshield gutter channel. Refer to Replacement
reservoir to absorb the spilled oil. of Baffle for details.
2 Pull out the level sensor connector. 2 Pull out the vacuum tube from the booster.
3 Disconnect the brake tube connected to the 3 Pull out the level sensor connector.
master cylinder and the pipeline connected to 4 Disconnect the brake tube from the brake master
the clutch master cylinder. cylinder.
Note：Before disconnection, ensure the middle
area and connecting joints around the junction
are clean. Block the opened connection to
prevent contaminant from entering.
5 Remove the hinge pin and cotter pin fixing the
vacuum resistance push rod to the brake pedal.
6 Remove 4 nuts fixing the booster and brake
pedal to the engine compartment.
7 Pull out and scrap the booster pad.
8 Remove 2 nuts and washers fixing the master
3
cylinder to the vacuum booster, and scrap the
ES110023 nuts. Then separate the vacuum booster from
the master cylinder.
4 Remove 2 nuts and washers fixing the master
cylinder to the vacuum booster, and scrap the
nuts. Then remove the brake master cylinder
and brake fluid reservoir assembly.
Installation 7
8
1 Install an O-ring to the master cylinder.
2 Install the brake master cylinder and brake fluid
reservoir assembly onto the vacuum booster, ES110044
and fix them with new nuts. Tightening torque:
18-20N.m.
3 Clean the brake tube joint.
4 Connect the brake tube and clutch tube onto the
brake master cylinder, and tighten them to 15 ±
2N.m.
5 Install the level sensor.
6 Fill the specified brake fluid to the specified scale
range.
7 Exhaust the brake system. Refer to Brake
System Exhaust for details.
22-20
Brake System
Installation Replacement of ABS/ESP Regulator

1 Install the brake master cylinder and brake fluid Removal
reservoir assembly onto the vacuum booster 1 Place the ignition switch in OFF position and
with new nuts. Refer to Replacement of Brake disconnect the negative battery cable.
Master Cylinder and Brake Fluid Reservoir
2 Place a piece of cloth under the ABS/ESP
regulator to absorb the spilled oil.
2 Clean the junction surface between the vacuum
booster and body, and install the new vacuum Note：The brake fluid may damage the paint
booster pad onto the vacuum booster. surface. If it spills by accident, wipe it rapidly and
clean these areas.
3 Locate the vacuum booster and brake pedal onto
the engine compartment, and install 4 nuts. 3 Disconnect the ABS/ESP regulator harness.
Tighten the nuts to 20 ± 2N.m. 4 Depress the brake pedal and support it with a
4 Connect the vacuum booster push rod to the pedal bracket to avoid brake fluid from flowing
brake pedal with hinge pin, cotter pin and out after the brake pipeline is removed.
washer. Refer to Replacement of Brake Pedal 5 Mark the position of ABS/ESP regulator oil outlet
Assembly for details. for assembling. Then disconnect 6 brake tubes
5 Clean the brake tube joint. connected with the regulator.
6 Connect the brake tube and clutch tube onto the
brake master cylinder, and tighten them to 15 ±
2N.m.
7 Connect the level sensor connector.
8 Connect the vacuum tube to the vacuum
booster.
9 Fill the specified brake fluid to the specified scale
range.
10 Exhaust the brake system. Refer to Brake
System Exhaust for details.
ES110029

6 Remove the bolt fixing the regulator bracket to
the body, and remove the regulator bracket and
regulator.
22-21
Brake System
Installation
1 Install the ABS/ESP regulator onto the bracket
with nuts, and tighten the nuts to 8 ± 2N.m.
2 Clamp the shock pad into the bracket mounting
hole.
3 Clamp the regulator onto the shock pad.
4 Fix the regulator and bracket assembly to the
body with bolts, and tighten the bolts to 22 ±
2N.m.
5 Clean up the brake connector.
6 According to the marks made during removal,
ES110030 connect 6 tubes to correct pipe orifices
respectively. Tighten brake tube joints to 15 ±
7 Loosen the nut connecting the bracket to the 2N.m.
regulator, and remove ABS/ESP regulator from
7 Connect the regulator harness.
the bracket.
8 Loosen the pedal bracket. Refill brake fluid to
Max position.
9 Drain the ABS/ESP regulator. If the replaced
regulator has been filled with oil, generally there
is no need to drain the regulator. The drain
operation can be conducted through the scan
tool. Refer to Instructions for SAIC Commercial
Vehicle Scan Tool for details.
10 Drain the brake system. Refer to Brake System
Drain for details.
11 Connect the scan tool to clear the DTC.
ES110031
8 Remove the shock pad clamped on the regulator

bracket.
ES110032
22-22
Brake System
Replacement of Brake Pedal Assembly Installation

Removal 1 Fix the brake pedal to the vacuum booster with 4
1 Disconnect the negative battery. nuts. Fix the brake pedal to engine compartment
with 1 bolt. Then tighten to 20 ± 2N.m.
2 Unplug the brake pedal position sensor harness.
2 Fix the vacuum booster push rod onto the brake
3 Remove the hinge pin, washer and cotter pin
pedal with a hinge pin, a washer and a cotter pin,
fixing the vacuum booster push rod to the brake
and apply some lubricating grease (automobile
pedal.
universal MR2 lithium grease) onto the surfaces
4 Remove 4 nuts fixing the brake pedal to the of hinge pin, vacuum booster push rod U-fork
booster and 1 bolt fixing the brake pedal to the hole and pedal hole. Do not install the hinge pin
engine compartment. reversely.
For right-hand-drive model:
ES110033 ES110045
5 Remove the brake pedal assembly. 3 Install the brake pedal position sensor, and
connect the harness. Refer to Replacement of
Brake Pedal Position Sensor for details.
4 Connect the battery negative.
5 Start the vehicle and depress the brake pedal for
8-20mm. Then the brake lamp shall go on. If not,
conduct self-learning to the pedal stroke sensor
again.
22-23
Brake System
Replacement of Brake Pedal Position Sensor Removal & installation of Yaw Angle Sensor/
Removal G-sensor
The yaw angle sensor/G-sensor is in front of the auxiliary
1 Pull out the sensor connector, and remove
screws. Then the sensor can be removed. fascia console as illustrated below.
ES110035 ES110046
Installation The sensor can be seen when the trim panel illustrated is
1 Installation is the reverse of removal. removed. Tighten the sensor mounting nuts to 9 ± 1N.m.
2 After installation, conduct self-learning to the
clutch stroke sensor.
Note：Depress the brake pedal for 8-20mm. Then
the brake lamp shall go on. If not, conduct self-
learning to the pedal stroke sensor again.
22-24
Brake System
Replacement of Brake Pipeline Replacement of Parking Brake Cable

Removal
1 The tightening torque for the nuts/bolts fixing the
brake pipeline to brake master cylinder, fixing the 1 Place the vehicle on the lifting platform and lift it
brake pipeline to ABS/ESP regulator and to a certain height.
between brake pipelines is 15 ± 2N.m. Warning：The vehicle must be supported on a
2 The tightening torque for the nuts/bolts fixing the safe device.
brake hose to the front/rear brake caliper is
2 Remove the bolt connecting the cable to the
35 ± 3N.m; the tightening torque for the nuts/
body.
bolts fixing the front brake hose bracket is
16 ± 2N.m. 3 Remove the rear cover plate of auxiliary fascia
console, and disconnect the cable from the
balancer.
ES110049
The torque for the bolt - rear brake tube bracket (drum) is ES110036
9 ± 1N.m.
4 Remove the bolt connecting the cable to the
frame.
5 Remove the bolt connecting the cable to the rear
leaf spring.
6 Remove wheels, disconnect the cable from the
rear brake, and remove the cable.
ES110038
22-25
Brake System
Installation Replacement of Parking Brake Handle

1 Connect the cable to the rear brake. Removal
2 Connect the cable to the rear leaf spring with the 1 Remove the auxiliary fascia console assembly.
bolt, and tighten to 22 ± 2N.m. Refer to Removal of Auxiliary Fascia Console
3 Connect the cable to the frame beams and Assembly for details.
girders with bolts, and tighten to 10 ± 1N.m. 2 Remove the parking brake balancer.
4 Connect the cable to the body with the bolt, and 3 Remove the bolt fixing the parking brake handle
tighten to 20 ± 2N.m. to body, and remove the parking brake handle.
5 Connect the cable to the balancer. Install the rear 4 Remove the parking brake switch.
cover plate of auxiliary fascia console.
Installation
6 Adjust the parking brake handle, and install the
wheels. 1 Installation is the reverse of removal. Adjust the
parking brake handle after installation. Refer to
Adjustment of Parking Brake Handle Assembly
for details.
4 Tighten the bolt fixing the parking brake handle to body to
22 ± 2N.m.
3 3 2
ES110037
22-26
Brake System

Brake System
The brake system consists of the front/rear disc brakes which are controlled by the dual-circuit hydraulic brake system
with the vacuum booster in the diagonal way.
Brake System Diagram
2
6b 6a
3
5 4
5 4
ES110051
1 Brake Master Cylinder/Vacuum Booster 2 Brake Pedal

Assembly
3 ABS/ESP 4 Rear Brake
5 Front Brake 6 Hydraulic Circuit (A. Primary, B. Secondary)
Under normal operating conditions, the displacement of the brake pedal is boosted and delivered by the vacuum booster
assembly to the brake master cylinder assembly. The brake master cylinder assembly converts the movement of brake
pedal into hydraulic pressure. The primary and secondary hydraulic circuit pipes deliver the hydraulic pressure to the
brake through the ABS/ESP modulator. The primary circuit supplies pressure to the left front and right rear brakes, and
the secondary circuit supplies pressure to the right front and left rear brakes.
22-27
Brake System
Vacuum Booster Assembly

The vacuum booster assembly provides power assist during braking to reduce the pedal force required for braking. In
case the vacuum booster assembly fails, the hydraulic system still has the brake function, but greater pedal braking force
is required due to lack of vacuum booster.
Diaphragm return spring

Rear housing
Front housing
Vacuum port (opened)
Air source
Strut
Check valve
Valve stem
Air inlet (closed)
Vacuum source
ES110052
When the brake pedal is depressed, the input push rod and piston start to move forward in the valve body, then the input
push rod overcomes the resistance of return spring before moving together with the valve body and the output push rod,
by this way, the braking force is passed to the brake master cylinder assembly. At the beginning of the piston movement,
the control valve, with the help of the control valve spring, moves with the piston, closing the vacuum outlet; by this way,
the chamber behind the membrane is isolated from the vacuum source. Further movement of the input push rod allows
the piston to separate from the control valve, opening the air inlet; by this way, the filtered ambient air of limited flows
enters into the chamber behind the membrane via the air inlet and produces a booster pressure there. The force
produced by the pressure difference on both sides of the membrane is passed to the output push rod through the control
valve body, which magnifies the pressure applied on the brake pedal.
22-28
Brake System
Brake Master Cylinder Assembly
1 2 3 4 4 5 6
13 12 11 10 9 8 7
ES110053
1 Secondary Pressure Chamber 2 Secondary Piston
3 Secondary Oil Inlet 4 Brake Fluid Reservoir Port
5 Brake Master Cylinder 6 Primary Oil Inlet
7 Primary Center Valve 8 Primary Piston
9 Primary Spring 10 Primary Pressure Chamber
11 Secondary Center Valve 12 Valve Pin
13 Secondary Spring
When the brake pedal is depressed, the brake master cylinder assembly produces hydraulic pressure so that the brake
operates. The assembly is fitted in front of the vacuum booster assembly, which contains a pump body with a total of two
pistons in the front and rear sections. The rear piston produces brake pressure for the primary circuit, and the front piston
produces brake pressure for the secondary circuit. The brake fluid reservoir is fitted at the top of the master cylinder. The
fluid reservoir is partitioned inside to feed liquid for every brake circuit independently, thus avoiding the condition that
neither the primary brake circuit nor the secondary brake circuit can operate due to one brake fluid leak. If one brake
circuit is out of order, the remaining brake circuits can still effectively operate, but the brake pedal travel and the braking
distance of the vehicle will increase. If the brake fluid level in the fluid reservoir is too low, turn on the brake fluid level
switch to illuminate the brake warning lamp. The brake fluid level switch contains a reed switch located in the plastic
sheath at the downside of the fluid reservoir. A permanent magnet is provided on the float in the fluid reservoir, which
keeps the brake fluid level switch in the OFF state when the brake fluid level is at a suitable height. When the brake fluid
level is dropped to an inappropriate height, the float sinks, causing the reed switch to be turned on.
22-29
Brake System
Applying Brakes
When the brake pedal is depressed, the output push rod of the vacuum booster assembly pushes the primary piston
along the hole in the brake master cylinder, producing pressure in the primary pressure chamber. Then, together with the
primary spring, the pressure overcomes the secondary spring force and pushes the secondary piston to move
simultaneously along the hole in the master cylinder. The initial movement of the piston closes the primary and secondary
center valve. Further movement of the piston increases the pressure of liquid in the primary and secondary pressure
chambers, the pressure in the brake circuit is thus increased. The liquid behind the piston in the pressure chamber is not
affected by piston movement, therefore, it can flow freely between the pressure chamber and the brake fluid reservoir via
the oil supply hole.
Disabling Brakes
When the brake pedal is released, the primary and secondary springs push the pistons back along the hole in the master
cylinder. Partial vacuum is generated in the pressure chamber by the quick movement of piston, which opens the center
valves and allows the free flow of brake fluid between the two brake circuits and the brake fluid reservoir.
Front Brake
Each front brake consists of a piston sliding brake caliper assembly fitted to the hub, and a brake disc with a ventilation
device. The inside of the brake disc is protected by a guard plate. When the hydraulic pressure is transmitted to the brake
caliper, the piston stretches outward, forcing the inner brake pad to press against the brake disc. The brake caliper
housing under reaction slides along the guide pin to drive the outer brake pad to come into contact with the brake disc.
22-30
Brake System
Rear Brake
Each rear brake consists of a piston sliding brake caliper assembly fitted to the hub, and a brake disc with a ventilation
device. In the center of each brake disc is a brake drum for parking brake purpose. The inside of the brake disc is
protected by a guard plate combined with the parking brake backing plate. When the hydraulic pressure is transmitted to
the brake caliper, the piston stretches outward, forcing the inner brake pad to press against the brake disc. The brake
caliper housing under reaction slides along the guide pin to drive the outer brake pad to come into contact with the brake
disc.
ESP hydraulic transmission system diagram
MC2 MC1
P
U
HSV2 USV2 USV1 HSV1
sRP2 sRP1
M
FREV RLEV RREV FLEV

RVR2 RVR1
A2 A1
FRAV RLAV RRAV FLAV
FR RL RR FL
ES110054
MC1 Primary circuit of brake FLAV Front left wheel fluid outlet
master cylinder valve
MC2 Secondary circuit of brake FREV Front right wheel fluid inlet
master cylinder valve
M Motor FRAV Front right wheel fluid outlet

valve
RP1 Reflux pump 1 RLEV Rear left wheel fluid inlet

valve
RP2 Reflux pump 2 RLAV Rear left wheel fluid outlet

valve
A1 Energy accumulator 1 RREV Rear right wheel fluid inlet

valve
A2 Energy accumulator 2 RRAV Rear right wheel fluid outlet

valve
FL Front left wheel HSV1 High pressure valve 1
22-31
Brake System
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 fluid inlet P/U Pressure sensor

valve
ESP 9 hydraulic pressure regulator consists of a motor, a pressure sensor, two reflux pumps, two energy accumulators
and twelve solenoid valves.
22-32
Brake System
Braking process of ESP hydraulic transmission system (single wheel braking process (e.g. front right
wheel))
Boosting
MC2 MC1
HSV2 USV2
sRP2
M
FREV RLEV
RVR2
A2
FRAV RLAV
FR RL
ES110055
As soon as the state of pilot valve USV2 changes from Normally Open to Pressure Limited, the high pressure valve
HSV2 opens, the oil return pump sRP2 operates, the front right wheel fluid inlet valve FREV opens and the rear left wheel
fluid inlet valve RLEV closes. The brake fluid enters into the front right wheel cylinder through the HSV2, sRP2 and
FREV, and pushes the piston in the wheel cylinder to press tightly against the friction disc to brake.
22-33
Brake System
Pressure maintaining
MC2 MC1
HSV2 USV2
sRP2
M
FREV RLEV
RVR2
A2
FRAV RLAV
FR RL
ES110056
Both the fluid inlet (FREV) and outlet (FRAV) valves of the front right wheel close. The brake fluid is sealed in the wheel
cylinder, thus maintaining the brake pressure.
22-34
Brake System
Pressure reducing
MC2 MC1
HSV2 USV2
sRP2
M
FREV RLEV
RVR2
A2
FRAV RLAV
FR RL
ES110057
The front right wheel outlet valve FRAV opens. High pressure brake fluid in the front right wheel cylinder enters into the
energy accumulator A2 via the front right wheel fluid outlet valve FRAV, and the energy accumulator A2 becomes the oil
source of next boosting.
22-35
Brake System
ESP System Control Diagram
OBD ESP-OFF EMS TCM

KL15(ignition)
GND_ECU
GND_MR
UB_MR
UB_VR
ILL
13 38 25 1 CAN1P
26
CAN1M
14
DIAGK
6
ESP_OFF
12
IP
NEBD_SLAMP
3
NABS_SLAMP
33
VSO
10
BLS
30 KL15(ignition)
19 8 16 4 18 31 17 29 BLS
WSP_RR
WSS_RR
WSP_FR
WSS_FR
WSS_RL
WSP_RL
WSP_FL
WSS_FL
SAS
FL FR RL RR
ES110058
22-36
Brake System
ABS System
3 2
ES110047
Note：The management layout illustrated is not the SK81 form.
1 ABS module and its bracket

2 Wheel speed sensor
3 G Sensor (4WD ABS)
Composition description: ABS is composed of the ABS control module and its mounting bracket, and front & rear
wheel speed sensors; for 4WD ABS, a G Sensor shall be equipped for speed computation.
22-37
Brake System
ESP System
2
2
3
2
4
4
1
ES110048
Note：The management layout illustrated is not the SK81 form.
1 ESP module and its bracket

2 Wheel speed sensor
3 Steering angle sensor
4 Yaw speed sensor
Composition description: ESP system is composed of the ESP control module and its mounting bracket, front &
rear wheel speed sensors, steering angle sensor and yaw speed sensor.
22-38
Brake System
Wheel Speed Sensor TCS System

A Hall sensor is used as the wheel speed sensor and It automatically controls the driving force during takeoff
installed on the brake corner. and acceleration to prevent wheel slip and keep the
driving stability.
G Sensor
It is installed under the center instrument desk. 4WD ABS VDC System
model shall be equipped with G sensor for speed It is an advanced computer system, which can help you
computation. The reference speed of 2WD vehicle is to control the vehicle driving direction in bad driving
mainly obtained from the driven wheel speed sensor. All conditions. When the computer detects the deviation
wheels of a 4WD vehicle are driving wheels. On the road between the expected driving route and the actual driving
with a small friction coefficient, if the four wheels skid, the direction, VDC system will apply braking pressure onto
reference speed computed by ABS according to the one or several brakes of the vehicle selectively to keep
wheel speed sensor will be higher than the actual value, the vehicle driving in the direction commanded.
thus ABS will make a deviated judgment on wheel
EBA
locking, causing insufficient braking force and poor
braking effect. ABS and ECU of a 4WD vehicle will In case of an emergency, the force applied by a driver on
compare G sensor signal and wheel speed signal. When the brake pedal is usually insufficient. EBA (hydraulic
four wheels skid, the vehicle will compute vehicle speed auxiliary brake) can recognize this rapid action with
according to G sensor signals. When certain wheel skids, insufficient force on the brake pedal and automatically
the ABS module will compare signals of 4 wheel speed establishes a brake pressure close to the locking level to
sensors to judge which wheel skids and do not compute shorten the braking distance greatly.
the reference speed using the wheel speed sensor of this RMI
wheel.
It can recognize the vehicle rollover trend as soon as
Stroke Position Sensor possible by monitoring the turning angle and lateral
It transmits signals to ABS module and ECM during acceleration of steering wheel, and apply braking to a
braking; it is installed on the brake pedal. single wheel or multiple wheels to furthest prevent
rollover.
Yaw Speed Sensor
HHC
It is used for measuring the lateral acceleration sensor of
the vehicle and the vehicle's rotating motion around its When a vehicle drives uphill, HHC can prevent the
mass center axis. It is installed on the floor in front of the vehicle from sliding backwards after the driver releases
central armrest. the brake pedal. The driver has 1.5s at most to move his
foot from the brake pedal to the accelerator pedal for hill
Steering Angle Sensor takeoff.
It mainly feeds back the driver's steering information to
ESP control module. It is located over the combination
switch below the steering wheel.
ESP has the functions of ABS, EBD, TCS, VDC, EBA,

RMI, HHC and HDC.
EBD System
It automatically detects the gripping force between
wheels and ground, distributes the optimum brake force
to 4 wheels, so as to improve brake efficiency and driving
stability.
22-39
Brake System
HDC
When driving on a long downhill road with a relatively
greatgradient (4?-26?), if the vehicle speed is between 8
and 35km/h,there is no need for the driver to depress the
brake pedal and accelerator pedal, and the vehicle will
run at a low speed automatically, so as to ensure the
vehicle goes downhill steadily.In this case, the driver can
also adjust the vehicle speed automatically controlled by
the system through the brake pedal and accelerator
pedal.
When the vehicle speed is lower than 8km/h or between

35 and 60km/h, HDC is not functioning but in standby
state.
When the vehicle speed is greater than 60km/h, HDC

function will exit automatically. To restart the system,
press HDC switch again.
When the ignition switch is placed in "ON" position, HDC

is in off state by default, and other functions of ESP are all
in standby state.
HDC function introduction

Target speed range: 8-35km/h HDC only involves brake intervention,
without engine intervention
Adjust the target speed with
accelerator/brake pedal or During the operation of HDC, if the
speed control button wheel slip rate is great, ABS system
may activate
Normal Mode: Always maintain If any wheel loses contact with the
the preset speed ground, the brake torque will be
Fade out Mode: Maintain the
distributed to the wheel with higher
current speed only
road attachment coefficient
8km/h 35km/h 60km/h
Normal Mode Fade·Out Mode

Function OFF
Function activation (automatically exit HDC)
(turn on/off this function with HDC switch)
ES110043
22-40
Transfer Case
Transfer Case
Specification
Torque
Nut - front flange (62) 203~241
Nut - rear flange (62) 305~332
Oil filler plug, drain plug (5) 19~30
Motor bracket bolt (66) 8~11
Motor subassembly screw (71) 8~11
Clutch coil nut (64) 8~11
Housing bolt (59) 27~40
Air nozzle (43) 4~7
Bolt - transitional housing to transfer case 27~35
Bolt - transfer case to 6AT 65 ± 5

Bolt - transfer case to MT 22 ± 2
Nut - transfer case to 5MT 65 ± 5
Bolt - propeller shaft to transfer case 100 ± 10
Nut - transfer case controller to body 9±1
Bolt - transfer case to rear engine mount 60 ± 5
23-1
Transfer Case
Layout
Transfer Case Layout
1
2
ES080000
1 Transmission 3 Propeller shaft

2 Transfer case
23-2
Transfer Case
Transfer Case Exploded View
66 56
78
54
79 62 53
61
60 76
77 44 43
75 1
7 4
65
2
3
8
45 9
46 5
49 6 11
42 12
47 38
41 13
48 40
37 10
39
36 14
8 15
35
34 16
51
17
52
33
50 18
32
73 19
57 20
72 73 31
66 64 58 30
74 59
70 68 55 24
67 29 23 21
69 71 7
28
63
61 25
60 27 22
62
26
ES080001
1 Transfer case assembly 7 Transfer case front output shaft oil seal
2 Front transfer case housing 8 Transfer case front output shaft bearing
3 Locating pin - transfer case housing 9 Clamp - transfer case input shaft
4 Transfer case input shaft oil seal 10 Transfer case input shaft
5 Transfer case input shaft gear ring 11 Clamp - transfer case input shaft bearing
6 Clip - transfer case washer 12 Transfer case input shaft bearing
13 Gasket - transfer case sun gear thrust
23-3
Transfer Case
14 Transfer case input shaft bearing 45 Front transfer case housing magnet
15 Clip - transfer case sun gear 46 Transfer case front output shaft
16 Transfer case sun gear thrust plate 47 Transfer case front output shaft driven sprocket
17 Thrust plate sun gear at transfer case input end 48 Transfer case front output shaft spacer bush
18 Planet carrier component at transfer case input 49 Transfer case sprocket chain
end 50 Rear transfer case housing
19 Clip - transfer case sun gear 51 Clip - rear transfer case housing
20 Deceleration shift gear sleeve of transfer case 52 Rear transfer case housing bearing
planet mechanism
53 Front transfer case housing transitional housing
21 Transfer case rear output shaft
54 Screw - transfer case transitional housing
22 Transfer case rear output shaft oil pump
55 Rear transfer case housing bush
component
56 Clip - transfer case transitional housing
23 Clamp - Transfer case rear output shaft (elastic)
57 Rear transfer case housing oil seal
24 Transfer case rear output shaft oil pipe
58 Clip - rear transfer case housing
25 Transfer case rear output shaft oil filter
component 59 Bolt - rear transfer case housing
26 Rear transfer case housing solenoid coil 60 Transfer case rear output shaft oil seal
component 61 Gasket - transfer case input end
27 Clutch coil housing assembly of transfer case 62 Nut - transfer case front output shaft
rear output shaft
63 Transfer case rear output shaft plate
28 Clip - transfer case shift gear sleeve
64 Nut - rear transfer case housing
29 Transfer case shift gear sleeve armature
65 Bolt - transfer
30 Transfer case shift gear sleeve return spring
66 Bolt - transfer
31 Transfer case shift gear sleeve/hub
67 Clip - rear transfer case housing
32 Transfer case shift gear sleeve return spring
68 Clip - transfer case motor
33 Transfer case shift gear hub/sleeve
69 Clip - transfer case motor connector
34 Transfer case rear output shaft drive sprocket
70 Clip - transfer case solenoid connector
35 Transfer case shift shaft return spring
71 Bolt - transfer motor
36 Front transfer case housing shift shaft
72 Rear transfer case housing shift motor
37 Transfer case shift shaft 4WD shift fork subassembly
38 Transfer case shift shaft deceleration shift fork 73 Rear transfer case housing oil plug
subassembly
74 Transfer case motor bracket
39 Transfer case shift shaft/cam
75 Transfer case rear dust shield
40 Transfer case shift shaft torsional spring
76 Transfer case assembly
41 Transfer case shift shaft bush
77 Transfer case control module
42 Transfer case shift shaft
78 Transfer case breather pipe
43 Front transfer case housing air nozzle
79 Nut - transfer case controller
44 Transfer case front output shaft plate
23-4
Transfer Case
Troubleshooting
General Inspection Process Specific Inspection Process
Carry out visual inspection for all parts (excluding parts to Follow the instructions specified in table 4-1 to check the
be renewed, such as oil pump pipe, O-ring and oil seal, parts listed in the table. The part number shown in table
etc) to see if the parts are damaged or excessively and 4-1 is identical with the part indicated in the Transfer
unevenly worn, and discard the damaged or worn parts Case Assembly Exploded View of section 8.
that will affect the performance. Items to be inspected are
as follows:
Gear/Sprocket Tooth Check
Burr: raised sharp edge on some part of the material.
When specified by table 4-1, check the gear or sprocket
Debris: broken or grated piece or particle. tooth according to the following methods:
Crack: surface crack line that represents the material will Note：Do not mix the tool mark resulted from
partially or completely separate. machining with the extrusion mark. Figure 4-1
shows the typical machining mark.
Excessive wear: severe or obvious wear that goes
beyond the range of application. 1 Check the form of the engagement/contact area
of the gear or sprocket tooth. Figure 4-2 provides
Shrinkage: material slip due to local stress. the common engagement/contact area. Parts
with the contact area shown by the ACCEPT
Adhesion: loose and soft metal material adheres to the
column are acceptable, if other requirements are
hard metal surface.
met, continue to use the part. Parts with the
Furrow: local crack or groove, normally refers to the contact area shown by the REJECT column are
unacceptable, discard the part and do not repair
transfer of the material instead of loss of the material.
it.
Pitting: break of the metal surface due to contact
pressure. Change of color due to heat from metal friction
is visible.
Step type wear: a visible or perceptible step between the

Typical machining mark on
adjacent contact surface and non-contact surface, which the gear face is acceptable,
Typical gear shaving mark while the rough surface or
is caused by excessive wear. irregular mark will be
rejected
Uneven wear: locally and unevenly distributed wear,

including hole, bright spot, non-uniform polish and other
visible signs
Typical gear grinding mark
Figure 4-1: Typical Gear Face Machining Mark

ES080002
23-5
Transfer Case
Description Accept Reject Repair Reject
Ideal engagement Two sides of contact Middle part of

contact area face tooth top spalling contact area spalling
Contact area locating

at one side Two sides of tooth
Middle part of contact
top spalling
face tooth top spallin
Contact area locating
at the other side
One side of non-contact
face tooth top spalling
Contact area close to
the tooth top
Contact area close to Middle part of one

the tooth root side of contact
face tooth spalling
Figure 4-2: Gear Face Contact Area Figure 4-3: Gear Face Defect
ES080003 ES080004
2 Check the gear/sprocket tooth for peeling. Tooth 1 Service the patch peeling with a suitable manual
peeling or groove form is shown in figure 4-3. As high-speed grinding tool.
shown by the REPAIR column, parts with patch
2 When grinding the base metal, try not to remove
peeling can be repaired and reused (see section
more metal.
4-3). As shown by the REJECT column, parts
with severe peeling or broken tooth cannot be 3 All sharp corners or flashes shall be the smooth
repaired, the part shall be discarded and no outline. The sharp corner or flash may peel off
repair is allowed. again or become cracks. Remove the burr with a
suitable grinding stone, and remove the raised
material carefully without damaging the base.
Replace the unrepairable parts (for example,
Spline Tooth Check
bearing, etc), If there is any doubt whether the
Check for broken or peeling spline tooth. Patch peeling part can be reused, replace it.
and gear tooth peeling can be repaired in the same way,
and such parts can be reused (see figure 4-2 and 4-3). If
any broken spline tooth is found, the part shall be
discarded and no repair is allowed. The contact form of
the spline tooth is different form that of the gear, however,
splines showing step slip shall be discarded and no
repair is allowed.
4-3 Service/Replacement
Replace the parts rejected by the inspection, unless the
parts are serviced according to the procedures specified
in the figure below or other parts needing minor service
can be further used.
Gear/Sprocket Tooth Service

The service shall be limited to the patch peeling shown in
figure 4-3.
23-6
Transfer Case
Table 4-1 Inspection
Part (item) Inspection Accept/reject
All parts (including all springs) Inspect for crack Reject all parts with cracks
Inspect for twist Reject parts with curve, twist and
Inspect for corrosion unsatisfactory runout
Reject all parts with pitting or corrosion
All threaded parts Inspect for thread damage or other Reject parts not suitable for tapping or
damages clamping
Flange (44), (63) Inspect splines according to section 4- 2 Handle as per section 4-2
Motor assembly (72), electric clutch Perform a function inspection on the Replace the parts as required
parts vehicle with reference to the Service
Manual of the vehicle
Ball bearing (8, 12, 52, 53) Perform a visual inspection for the Reject damaged bearing
bearing ball and raceway to see if there
is any peeling, adhesion, pitting or other Reject damaged and loose bearing or
damages inspect if the axial clearance exceeds
Confirm that the bearing is lubricated, 0.23mm.
hold the inner ring of the bearing and
turn the outer ring of the bearing slowly.
Determine if it can work freely or if it is
corroded. The bearing shall turn
smoothly and shall be no any play and
wandering
Needle bearing (14) Perform a visual inspection for the Reject damaged bearing
bearing needle and raceway to see if
there is any peeling, adhesion, pitting or
other damages
Transfer case front housing (2)/rear Inspect the mating face for burrs or other Remove the burr according to section
housing (50) damages that may affect fit and seal 4-3, or replace the damaged parts
Transfer case front housing (2) Inspect the bore of the bearing (8) If any pitting or damage is observed,
reject the part
Transfer case rear housing (50) Inspect the bore of the bearing (52 and If any pitting or damage is observed,
53) reject the part
Clutch coil housing (27) and shift gear Inspect splines according to section 4- 2 Handle as per section 4-2
hub (31)
Shift gear sleeve (33) Inspect the shift fork groove for damage If any step slip or damage is observed,
or wear reject the part
Inspect splines according to section 4- 2 Handle as per section 4-2.
Shift shaft (36) Inspect for deformation If any curve is found, reject the part
Inspect the outer circle for any burr or Handle in accordance with section 4-3,
other damages or reject the damaged shaft
Inspect the outer circle for wear If any step slip or damage is observed,
reject the part
Shift fork (37) Inspect the location where the shift fork, If any step slip or damage is observed,
shift cam and gear sleeve fit for wear or reject the part
damage
23-7
Transfer Case
Shift fork subassembly (38) Inspect the shift fork veneer fitting with If step wear or damage occurs, reject
the gear sleeve for wear or damage the veneer
Inspect if the roller can rotate freely or if If the roller cannot rotate freely or if it is
it is damaged. damaged, use a new pin - roller
subassembly
Drive sprocket (34) and driven Inspect the sprocket tooth according to Sprocket Tooth Check in section 4-2
sprocket （47） section 4-2 Spline Check in section 4-2
Inspect the sprocket spline according to
section 4-2
Drive sprocket (34) Inspect the inner diameter fitting with the If any pitting or damage is observed,
output shaft reject the part
Drive chain (49) Inspect for step slip, loose part or Reject worn or damaged drive chain
damaged pin/connector
Strainer (25) Inspect the strainer for cleanness, small Clean it when necessary, and reject if it
hole or damage is damaged
Oil pump component (22) Check the inner diameter of the pump If the pump housing is damaged or
housing for pitting or step slip severely worn, reject it
Output shaft (21) Inspect splines according to section 4- 2 Spline Check in section 4-2
Inspect the surface fitting with the If any pitting or damage is observed,
bearing reject the part
Inspect for twist If any curve occurs or the runout is
unsatisfactory, reject the part
Deceleration shift gear sleeve (20) Inspect the sprocket spline according to Spline Check in section 4-2
section 4-2 If any step slip or damage is observed,
Inspect the location fitting with the shift reject the part.
fork for wear or damage.
Front output shaft (46) Inspect the surface fitting with the If any pitting or damage is observed,
bearing reject the part
Inspect splines according to section 4- 2 Spline Check in section 4-2
Input shaft (10) Inspect splines according to section 4-2 Spline Check in section 4-2
Inspect for twist If any curve occurs or the runout is
unsatisfactory, reject the part
Thrust gasket (13) and thrust plate Check for pitting If any pitting or damage is observed,
(16) reject the part
Sun gear (17) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2 Spline Check in section 4-2
Inspect splines according to section 4-2
Planet carrier component (18) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2 If any step slip or pitting is observed,
Inspect if the shaft pin of the planet gear reject the part
is damaged or loose and if the thrust
gasket is worn
Shift cam (39) Inspect for pitting or step slip If any step slip or pitting is observed,
reject the part
Shift shaft (42) Inspect for pitting or step slip If any step slip or pitting is observed,
Inspect for twist reject the part
If the part is curved, reject it
23-8
Transfer Case
Big gear ring (5) Inspect the gear tooth according to Gear Tooth Check in section 4-2
section 4-2
23-9
Transfer Case
Repair Guidance
Replacement of Transfer Case Assembly 11 Remove the bolt between the transfer case and
the transmission, and remove the transfer case.
Removal
12 Simply move the transfer case backward until
1 Position the vehicle on a suitable lifting machine.
the transfer case input shaft is completely
Note：The transfer case bracket or jack shall disconnected from the transmission spline.
support the transfer case independently, and 13 Carefully lower the lifting machine of the transfer
shall be able to go up/down and move the case and remove the transfer case.
transfer case horizontally.
2 Transmission shift to parking or neutral
space,part-time case shift to 2H mode and go
out engine.
3 Disconnect the negative battery after the ignition
switch is off for 1min.
4 Lift the vehicle.
5 Remove all electrical harnesses related to the
transfer case.
6 Remove the hose from the vent valve of the
transfer case.
7 Disconnect the front/rear propeller shaft from the
flange of the transfer case.
8 Disconnect the rear propeller shaft from the rear
flange of the transfer case.
9 Support the transfer case with the jack.
Warning：Ensure the transfer case is completely
under the support of the lifting machine before
removing the bolt connecting the transfer case
and transmission. Do not hang the transfer case
directly on the transmission through the spline
shaft, this may cause damage to the parts of the
transfer case.
10 Remove the bolt connecting the transfer case
and rear mount.
ES080005
23-10
Transfer Case
Installation ·Transfer case connected with 5MT: the torque of 5 nuts

1 Apply appropriate specified grease to the spline is 65 ± 5N.m.
of the transmission input shaft with a thin sleeve
·Transfer case connected with rear mount: the torque of
containing grease.
2 bolts is 60 ± 5N.m.
2 Raise the lifting bracket of the transfer case, and
ensure the transfer case and transmission are 5 Connect the front/rear propeller shaft and front/
aligned with one axis. rear output flange of the transfer case, and
Warning：Before connecting the spline, ensure tighten the bolt to 100 ± 10N.m.
the transfer case is aligned with the transmission. 6 Connect the air nozzle and breather hose.
Do not force the spline of the transfer case into 7 Connect all electrical harnesses related to the
the transmission, otherwise, the transfer case transfer case.
may damage. When necessary, turn the rear 8 Lower the vehicle and connect the negative
output flange of the transfer case to align it with battery.
the spline.
3 Move the transfer case forward slowly, assemble
the spline of the transmission output shaft,
locating pin and stud of the rear transmission
housing until the front transfer case housing and
rear transmission housing fit closely.
4 Ensure the front transfer case housing is aligned
with the mounting hole of the rear transmission
housing, then align the lower mounting hole of
the transfer case with the mounting hole of the
rear mount. Install the bolt/nut, and tighten the
bolt/nut in the diagonal sequence, the torque is
as follows:
·Transfer case connected with DYMOS 6MT: bolt 1:
M8X1.25X30, bolt 2-11: M8X1.25X35, the torque is 22
± 2N.m.
1 2
3
4
5
6
7 8
11
9 10
ES080006
·Transfer case connected with SAGW 6MT: torque of 11

bolts is 22 ± 2N.m.
·Transfer case connected with Punch 6AT: the torque of

6 bolts is 65 ± 5N.m.
23-11
Transfer Case
TCCU Replacement Transfer Case Removal

Removal Note：If the service is only for the damaged part
Note：The TCCU is on the right rear side of the left on the transfer case, as long as the damaged part
front seat, the carpet is provided with the service/ is taken out, stop removing the transfer case.
diagnosis slot, by this slot, you can directly Remove the part from the transfer case as a
access the connector of the TCCU. But when the subassembly or assembly, no need to
TCCU shall be replaced, lift the carpet under the disassemble it, unless it contains any damaged
left front seat. part.
1 Disconnect the negative battery after the ignition 1 Position the transfer case on the workbench,
switch is off for 1min. with the rear housing up.
2 Remove the left front seat (refer to Removal/
Installation of Left Front Seat).
3 Remove the A-pillar upper trim panel, A-pillar
handle, footrest, A-pillar lower trim panel, rear
step, seat belt anchor point, B-pillar lower trim
panel and front step, please refer to Removal of
Relevant Interiors for details.
A-pillar upper trim panel

A-pillar handle
End cover plate

5D 5L
ES080008
Footrest
A-pillar lower
Front pedal trim panel
B-pillar lower
trim panel Seat belt
anchor point
Rear pedal
ES080007
4 Lift the carpet under the left front seat.

5 Remove the nut fixing the transfer case to the
body (nut torque:9 ± 1N.m).
6 Disconnect the connector of the TCCU to
remove the TCCU.
ES080009
2 Prepare a clean container for oil collection,

Installation release the drain plug 5D (73) from the rear
1 Installation is the reverse of removal. housing (50), invert the transfer case and drain
the lubricant in the transfer case.
3 Then turn over the transfer case, place a block
under the front housing to keep the transfer case
level, and release the oil filler plug 5L (73).
4 Secure the flange (63) with an anti-torsion bar,
release the nut (62), remove the gasket (61), and
remove the flange (63) and oil seal (60).
23-12
Transfer Case
Removal of Transfer Case Electric Shift

Component
71
67
68 69 70
72 66
ES080010
1 Remove the flange bolt (66), 3 bolts (71) and 2 J-

clips (67).
2 Remove the shift motor subassembly (72).
3 The harness clip (68), connector harness clip
(69) and connector (70) are removed for
replacement only.
23-13
Transfer Case
Rear Housing Removal
83
50
52 82
51 59
58 59
26
56
55
64 83
57
35 53
36 83
21
45
2
ES080011
1 Remove 17 bolts (59), nameplate (82) and 2 6 Remove the oil seal (56) from the rear transfer
harness clips (58). The nameplate contains case housing (50).
information for replacement, so please keep it 7 Remove the magnet (45) from the front transfer
properly. Keep the harness clip properly, case housing (2).
remember the location of the harness clip (58)
8 Remove the return spring (35) from the shift
for subsequent installation.
shaft (36).
2 Slightly pry the housing, and release the sealant
9 Remove the sealant on the mating face of the
on the mating face, then directly lift the transfer
front (2)/rear (50) housing of the transfer case,
case housing subassembly (83).
take care not to damage the mating face of the
3 Remove the oil seal (57), 3 flange nuts (64) and two housings or drop the material removed into
clutch solenoid (26). the transfer case.
4 Remove the snap ring (51), and remove the
bearing (52) and shaft bush (55) from the rear
housing (50).
5 Remove the bearing (53) from the rear transfer
case housing (50).
23-14
Transfer Case
4WD Shift Component Removal Chain Drive System Removal

Remove the following parts from the remaining transfer Remove the following parts from the remaining transfer
case housing subassembly. case housing subassembly.
34
21
27 21
48
28
47
29
30
84 46
31 36
32
37
33 49
ES080012 ES080013
1 Remove the clutch coil housing (27) from the 1 Remove the spacer bush (48) from the front
rear output shaft (21). output shaft (46).
2 Remove the 4WD shift gear sleeve subassembly 2 Remove the drive sprocket (34), driven sprocket
(84) and 4WD shift fork (37) from the rear output (47) and chain (49) from the two output shafts
shaft (21) and shift shaft (36), disconnect each (21 and 46).
subassembly and remove the shift shaft (36).
3 Disassemble the 4WD shift gear sleeve
subassembly (84), remove the snap ring (28)
first, then remove the armature (29), return
spring (30), shift gear hub (31), conical return
spring (32) and shift gear sleeve (33).
23-15
Transfer Case
Rear Output Shaft/Pump Subassembly Deceleration Shift Component Removal

Removal Remove the following parts from the remaining transfer
Remove the following parts from the remaining transfer case housing subassembly.
case housing subassembly.
20
22
85
23 83
24
21 25
38
ES080015
ES080014
1 Remove the deceleration shift gear sleeve (20)

1 Remove the rear output shaft and pump and deceleration shift fork subassembly (38)
subassembly (85). from the housing.
2 Remove the oil pump component (22) and rear
output shaft (21) from the rear output shaft and
pump subassembly (85).
3 Remove the elastic clamp (23), oil pipe (24) and
oil filter component (25) from the oil pump
component (22).
23-16
Transfer Case
Front Output Shaft Subassembly Removal Shift Cam Mechanism Removal

Remove the following parts from the remaining transfer Remove the following parts from the remaining transfer
case housing subassembly. case housing assembly.
42 41 40 39
62 61 60 44 2 46
ES080016 ES080017
1 Secure the front output flange (44) with the 1 Remove the electric shift cam mechanism (39-
antitorsion bar, release the nut (62), and remove 42) from the front transfer case housing as an
the gasket (61), front output flange and O-ring assembly.
(60). 2 Use a vise with soft mouth to clamp the end of
2 Remove the front output shaft (46). the shift shaft (42), knock it with a screwdriver to
disconnect and remove the shift cam (39),
torsional spring (40) and bush (41).
23-17
Transfer Case
Removal of Front Housing/Output Shaft/Planet Mechanism Subassembly
86
6
5
9
2
43
8
3 19
7 18
17
16
86 15
14
10 88
13
12
11
87 89
ES080018
Remove the following parts from the remaining transfer 5 Remove the planet mechanism subassembly
case housing subassembly. (89) of the input shaft, stretch the snap ring (19)
with a plier, and remove the planet gear
1 The air nozzle (43) is removed from the front subassembly (88) from the input shaft
housing subassembly (86) for replacement only. subassembly (87).
2 Remove the snap ring (6) and take out the big 6 The input shaft subassembly (87) is removed for
gear ring (5). replacement only. Remove the snap ring (11)
3 Hold one end of the input shaft (10) on the from the input shaft (10), press and remove the
workbench, stretch the long end of the snap ring bearing (12), and remove the thrust washer (13)
(9), and slightly press the front end of the input and needle bearing (14).
shaft (10) to remove the planet mechanism 7 Remove the snap ring (15) from the planet
subassembly (89) of the input shaft as an carrier gear subassembly (88), remove the thrust
assembly, then remove the split ring (9) from the plate (16) and sun gear (17), and disconnect the
front transfer case housing (2). planet carrier component (18).
4 Remove the oil seal (4), (7) from the front 8 Do not attempt to remove the planet carrier
transfer case housing (2), and pull out the 9 component (18).
bearing (8). The 2 locating pins (3) are removed
for replacement only.
23-18
Transfer Case
Transfer Case Installation Installation of Front Transfer Case Housing

Precautions before Installation Subassembly
Cleaning Installation of the front transfer case housing
subassembly is as follows:
Note：Check the magnet for metal debris prior to
cleaning. Occurrence of big, granular or irregular
particle indicates fracture or similar damage;
occurrence of small and powder debris indicates 6
5
non-uniform or excessive wear. In case of metal 9
2
debris, carefully check the rotating part and the
corresponding part for damage and wear.
86
General Cleaning Process
Clean the part in cleaner, remove lubricant residue and

precipitate. Remove the precipitate on the oil hole with a 4 8
brush. For parts that cannot be cleaned with a brush,
3
take care not to scratch the metal mating face etc during 7
cleaning. ES080019
Blow the parts cleaned dry.

1 Position the front transfer case housing (2) on a
Dry the parts with low-pressure compressed air (max. 20 suitable press machine, the mating face is up
psi), do not wipe with a cloth, for this may leave lint on the and parallel with the working face of the press
machine.
parts. When drying the bearing, hold it with hands to
prevent it from rotating. 2 Press the bearing (8) into the front transfer case
housing (2) with tool C00089925.
Lubrication during Installation 3 Turn over the housing, position the new oil seal
All internal parts without grease shall be lubricated with using the specification shown and press it into
the specified lubricant (grease) before installation, this the housing. Install the oil seal (4) with tool
can facilitate installation and helps to provide initial C00089920 and oil seal (7) with tool C00089921.
lubrication for the operation. 4 If the 2 locating pins (3) are removed, install new
locating pin (3) of the specification shown into
1 Prior to installation, damage to the O-ring or oil the housing.
seal without grease may occur.
2 Ensure the bearing or bush is sufficiently
lubricated before installation, operation of the
non-lubricated bearing or bush even for a short 6 9 5 8 10.0 3
period of time will cause damage.
3 Before installation, lubricate the lip of the oil seal
and the corresponding parts.
2.0
4
1.0
ES080020
5 Install the snap ring (9) into the snap ring slot on
the housing (2).
23-19
Transfer Case
6 Place the big gear ring (5) into the groove on the
housing (2), and install the snap ring (6).
Note：Execute this process after installing the
planet mechanism subassembly (89) of the input
shaft into the front housing, input shaft
subassembly and planet mechanism assembly.
23-20
Transfer Case
Installation of Front Housing/Input Shaft Subassembly/Planet Mechanism
86
19
9 18
2 17
16
15
14
10 88
13
12
11
87 89
43
ES080021
Install the following parts on the workbench. install the snap ring (11) into the slot of the input
shaft, then complete installation of the input shaft
1 If the input shaft subassembly (87) is removed, subassembly (87).
position the needle bearing (14) as illustrated
3 Place the planet carrier component (18) on the
and press the input shaft using the specification
workbench, the end with the snap ring slot shall
shown.
be up.
4 Install the sun gear (17), the section with the
protruding end shall be up. Turn the planet
12
carrier component until the planet gear
completely engages with the sun gear.
11 5 Align the protruding tooth, and install the thrust
plate (16) into the planet carrier component (18).
14 6 Install the snap ring (15) to complete installation
of the whole planet gear subassembly (88).
7 Lift the planet gear subassembly (88), install the
input shaft subassembly (87), stretch the snap
ring (19) with a plier and install it into the snap
10
13 ring slot of the input shaft to complete installation
ES080022
of the planet mechanism subassembly (89) of
the input shaft.
2 Install the thrust washer (13) into the input shaft,
install the bearing (12) with tool C00089927, and
23-21
Transfer Case
8 With the mating face of the front housing Front Output Shaft Installation
subassembly (86) up, position the front mating
Install the front output shaft component.
face of the transfer case housing (2) on two
blocks so that a gap can be maintained between
the input shaft (10) installed on the front housing
and the workbench. Stretch the long end of the
snap ring (9) on the front transfer case housing
(2), lift the planet mechanism subassembly (89)
of the input shaft to have the spline end of the
input shaft (10) down, until the snap ring (9)
enters into the snap ring slot on the outer ring of
the bearing (12).
9 Install the air nozzle (43) with a torque of 4~
7N.m.
62 61 60 44 2 46
ES080023
1 Place the front output shaft (46) into the front

transfer case housing (2), and install the flange
(44), seal ring (60), gasket (61) and nut (62).
2 Insert the anti-torsion bar into the mounting hole
of the front flange to secure the flange, and
tighten the nut (62) to a torque of 203~ 241N.m.
23-22
Transfer Case
Electric Shift Cam Installation

Installation of the electric shift cam subassembly is as
follows:
39
40
41 40
41 42
ES080026
42
4 Try to push the torsional spring (40) and bush
(41) back.
ES080024
40
1 Insert the bush (41) into the inner diameter of the
torsional spring (40), and pass it through the free
end of the shift shaft (42).
2 Slide the torsional spring (40) and bush (41) on 41
the shift shaft (42) to the drive tongue, and place
the first finger of the torsional spring on the left of
the drive tongue (viewed from the free end of the
shift shaft).
42
ES080027
40 5 Install the electric shift cam (39) into the shift

shaft (42), the cam end with drive tongue enters
first. Place the cam drive tongue under the drive
41
tongue of the shift shaft (between the two fingers
42 of the torsional spring), and keep it inward as
much as possible.
6 Install the shift fork to the housing, and then
install the shift cam subassembly (39-42) into the
front housing subassembly of the transfer case
ES080025
(refer to Shift Lock Component Installation).
3 Turn the second finger of the torsional spring on

the shift shaft (42) to the right of the drive tongue.
23-23
Transfer Case
Deceleration Shift Component Installation Output Shaft/Pump Subassembly Installation

The installation process is as follows. Note：Immerse the strainer of the oil pump into
the lubricant, rotate the output shaft
counterclockwise (viewed from the rear of the
output shaft), observe if the oil pump delivers oil
and determine if the oil pump can work properly.
20
The parts installed can be installed into the
88
transfer case housing as a subassembly.
18
Ensure the oil pump, etc to be installed is sufficiently
lubricated and the lubricant can come out of the taper
hole on the front cover of the oil pump. Installation of the
oil pump is as follows.
38
ES080028
22
85
1 The deceleration shift fork subassembly (38) and
deceleration gear sleeve (20) are in the housing, 21
and the deceleration shift gear sleeve is in the
planet gear subassembly installed (88). 20 23
24
25
85
ES080029
1 Install the oil filter into the oil pipe (24), place the
elastic clamp (23) on the end of the oil pipe (24),
install the oil pipe to the oil nozzle of the oil pump
component (22) and tighten the elastic clamp
(23).
2 Locate the fitting part of the rear output shaft (21)
and oil pump component (22), and slide it to the
rear output shaft (21) through the shaft hole of
the oil pump component (22).
3 Vertically position the output shaft into the
deceleration shift gear sleeve (20).
23-24
Transfer Case
Chain Drive System Installation Installation of 4WD Shift Component/Shift

The installation process is as follows: Lock Mechanism
The installation process is as follows:
34
21
48 21
47 27
28
46
29
30
84
31 36
49 32
37
ES080030 33
ES080031
1 After the front housing subassembly of the
transfer case is installed on the workbench,
1 Install the conical return spring (32) and shift
position the drive sprocket (34) on the rear of the
rear output shaft (21) and the driven sprocket gear hub (31) into the shift gear sleeve (33), then
(47) on the rear of the front output shaft (46). install the return spring (30) and armature (29),
and secure with a snap ring (28) to complete
2 Position the sprocket (34 and 47) horizontally, installation of the 4WD shift gear sleeve
install the chain (49), and the blue link of the subassembly (84).
chain is up.
2 Pass the shift shaft (36) through the deceleration
3 Grasp the two sprockets and attach the chain shift fork subassembly installed, and install it into
closely to the sprocket, parallel it with the the blind hole of the front housing of the transfer
transfer case, and install the chain and sprocket case.
(34 and 47) through the two output shafts (21
3 Install the 4WD shift fork (37) on the 4WD shift
and 46), and slightly turn the driven sprocket (47)
to ensure it engages with the spline of the front gear sleeve subassembly (84), and slide the
output shaft (46). whole subassembly through the shift shaft (36)
and rear output shaft (21).
4 Install the spacer bush (48) on the front output
shaft (46). 4 Install the electric shift cam component and
clutch coil housing assembly (27) installed in
section 5-5, the process is as follows:
23-25
Transfer Case
1） Position the shift cam component according to the Installation of Rear Transfer Case Housing
figure. Subassembly
Installation of rear transfer case housing subassembly is
as follows:
38
42
40
39
83 55 56
57
64
50
52
51
26
36 37
ES080032
2） Hold the shift shaft (36) down, and gently lift the shift 51 83
fork (37 and 38). Turn the shift cam component to ES080033
locate it, so that the roller of the deceleration shift fork
subassembly (38) can enter into the groove of the
1 Position the rear transfer case housing (50) on a
shift cam and the protrusion of the 4WD shift fork (37) suitable press machine, the mating face is up
can locate at the end of the shift cam. Then, lower and parallel with the working face of the press
the component, allow it to come into the front housing machine.
of the transfer case, and allow the shift shaft (42) to 2 Press the ball bearing (52, 53) into the rear
engage with the pin hole in the transfer case housing. transfer case housing (50), and install the snap
ring (51). Install two bearings with tool
3） Install the clutch coil housing assembly (27) on the C00089926.
rear output shaft (21), and ensure its spline engages
3 Turn over the housing, install the shaft bush (55)
with the spline of the rear output shaft (21). into the rear transfer case housing (50).
4 Position the new oil seal (56, 57) using the
specification shown and press it into the housing.
Install the oil seal (56) with tool C00089921 and
oil seal (57) with tool C00089924.
56
55
57 54
54
50
53 52 51
ES080034
23-26
Transfer Case
5 Installation of the transfer case solenoid Installation of Transfer Case Housing

component is as follows: Subassembly
Confirm that the 4 O-rings are on the specified location of Install the rear housing subassembly installed above on
the front housing subassembly, the process is as follows:
the solenoid component (26) (on one coil harness, three
studs). Install the solenoid component (26) into the rear
housing (50), the harness and stud extend from the rear
59
housing, and take care not to damage the electrical 82
59
harness. Install 3 nuts (64) and tighten to the torque of 8 58
88
~ 11N.m.
2
35
36
50
45
83
ES080035
1 Install the return spring (35) on the shift shaft

(36) of the transfer case.
2 Install the magnet (45) on the corresponding slot
of the front transfer case housing (2).
3 Apply Loctite adhesive 598 with a diameter of
1.6mm to the mating face of the front transfer
case housing, the adhesive shall go round the
thread hole and be continuous.
Warning：During the following procedures, do not
clamp the rear housing into the front transfer
case housing with excessive force. When all
requirements for alignment are met, it takes no
efforts to install the rear housing into the front
housing. If installation is impossible, remove the
rear housing subassembly and check for
alignment.
23-27
Transfer Case
4 Install the rear housing subassembly (83) on the Shift Motor Subassembly Installation
front transfer case housing (2), the following Installation of the electric shift transfer case is as follows:
conditions for alignment shall be met:
50 68 69
35 70
42 21 71
40 36
60
3
72 61
ES080038
ES080036
1） Align the locating pin (3) on the housing with the pin 1 Apply Loctite adhesive 598 with a diameter of
hole on the rear transfer case housing (50). 1.6mm to the mating face of the motor
subassembly (72) and rear transfer case
2） The rear output shaft (21), front output shaft (46) and housing (50), the adhesive shall go round the
the bearing in the hole of the rear transfer case thread hole and be continuous.
housing (50) shall be aligned. 2 Position the shift motor subassembly (72), and
align the triangular groove of the motor with the
3） The blind hole of the rear housing and shift shaft (36) shift shaft (42). Move the shift motor
shall be aligned, ensure the return spring (35) will not subassembly, assemble it into the shift shaft and
tilt. allow it to fit tightly with the rear transfer case
housing (50). Then, rotate the motor until it
4） Align the shift shaft (42) with the shift shaft mounting locates properly and is aligned with the mounting
hole on the rear transfer case housing. hole.
5 Position the nameplate, and tighten 17 bolts (59)

to 27 ~40N.m.
42
72
ES080039
23-28
Transfer Case
3 Install 2 J-clips (67) properly, and install 3 bolts Rear Flange Component Installation &
(71) to the torque of 8~11N.m. Lubricant Refill
The installation process is as follows:
72
50
62
60 61
63
73
73
67 67 67 82
ES080037
ES080040
4 Tighten the flange bolt (66) on the motor harness
clip to the torque of 8 ~11N.m.
1 Position the transfer case horizontally, refill
Dexron III 1.5 ± 0.05L as per the location of the
oil filler plug shown.
5D 5L
ES080008
2 Install 2 oil filler plugs (73) on the rear housing

(50),Oil filler plug, drain plug Torque Value 19~30N.m.
3 Install the flange (63), oil seal (60) and gasket
(61). Tighten the nut (62) to 305~332N.m.
23-29
Transfer Case
Installation of Transfer Case Transitional

Housing (with AT)
When installing the transitional housing (77), keep the
edge clean. The outer elongation of the locating pin is
10.0 ± 0.4mm, the torque of the screw is 27~35Nm,
please tighten the screw symmetrically and uniformly.
77
ES080041
23-30
Transfer Case
Special Tool Tool Number and Illustration

Description

Description C00089927
Bearing (input shaft)
press tool
C00089920 C00089927
Oil seal input shaft
press tool
C00089920
C00089921
Oil seal (front/rear
output shaft) press tool
C00089921
C00089924
Oil seal (motor) press
tool
C00089924
C00089925
Bearing (front output
shaft) press tool
C00089925
C00089926
Bearing (rear output
shaft) press tool
C00089926
23-31
Transfer Case

Internal Structure of Transfer Case
ES080042
1 Planet gear set 6 Shift motor

2 Oil pump 7 Output shaft - front propeller shaft
3 Electromagnetic clutch 8 4H-4L shift fork (deceleration shift fork)
4 Output shaft - rear propeller shaft 9 Input shaft
5 2H-4H shift fork (lock shift fork)
23-32
Transfer Case
Description of Transfer Case Function

The transfer case is an electric dual range part-time 4WD one. Deceleration is achieved by a planet gear mechanism,
and power transmission to the front drive wheel is realized by a silent chain of high precision. Lubrication of the planet
gear pair and rear output component of the transfer case is performed by oil bath and oil pump. The transfer case is
provided with 3 ranges, when 2WD HIGH is selected, only the two rear wheels are driven; when 4WD HIGH is selected,
4 wheels are driven, the transmission connects the transfer case directly; and when 4WD LOW is selected, the speed
ratio will be 2.48. The shift action of the transfer case is achieved by a shift cam driven by a shift servo motor. In addition,
shift to 2H/4H can be easily realized by the switch on the instrument panel, and parking is required for shifting to 4L.
When the speed control system of the transfer case fails, the warning lamp will alert the driver.
Transfer Case Power Flow
Rear Shaft
Input Shaft
2H
Front Shaft
ES080043
23-33
Transfer Case
2H Power Flow Chart
Transmission
Front output shaft

of transfer case Transfer case
Rear output shaft

Front axle of transfer case
Rear axle
ES080044
23-34
Transfer Case
Input Rear Shaft

Shaft
4H
Front Shaft
ES080045
23-35
Transfer Case
4H Power Flow Chart
TCCU
Half shaft clutch
Electromagnetic
Shift motor
clutch
Transmission
2H-4H fork
Front output shaft

Rear output shaft

Rear axle
ES080046
23-36
Transfer Case
Rear Shaft
Input Shaft
4L
Front Shaft
ES080047
23-37
Transfer Case
4L Power Flow Chart
TCCU
Half shaft clutch
Electromagnetic
Shift motor
clutch
Transmission
2H-4H fork
4H-4L fork
Front output shaft

Rear output shaft

Rear axle
ES080048
23-38
Propeller Shaft
Propeller Shaft
Specification
Torque
Nut- front hub 350 ± 15

Nut - front stabilizer bar link rod to lower swing arm 65 ± 5
Nut - front stabilizer bar to stabilizer bar link rod 50 ± 5
Nut/bolt - propeller shaft to transmission 75 ± 5
Nut/bolt - propeller shaft to rear axle 75 ± 5
Bolt - intermediate support of propeller shaft to frame 55 ± 5
Bolt/nut - propeller shaft to front axle 75 ± 5
Bolt - propeller shaft to transfer case 100 ± 10
Bolt - intermediate support to propeller shaft 35~50
24-1
Propeller Shaft
Layout
Layout of Propeller Shaft System (4WD)
4
2
3
ES100000
1 Front drive shaft 4 Transfer case

2 Front axle 5 Rear axle
3 Propeller shaft
24-2
Propeller Shaft
Layout of Propeller Shaft System (2WD)
ES100001
1 Transmission 3 Rear axle

2 Propeller shaft
24-3
Propeller Shaft
Exploded View of Front Drive Shaft Assembly
1
3
5
4
ES100002
1 Constant-velocity joint assembly 7 Clamp (small)

2 Snap ring 8 Dust shield of tripod universal joint
3 Clamp (large) 9 Clamp (large)
4 Dust shield of constant-velocity universal joint 10 Circlip
5 Clamp (small) 11 Tripod universal joint assembly
6 Intermediate solid shaft 12 Connecting ring
24-4
Propeller Shaft
Exploded View of Propeller Shaft Assembly
ES100003
1 Cross shaft assembly 3 Propeller shaft

2 Intermediate support assembly
24-5
Propeller Shaft
Repair Guidance
Replacement of Front Drive Shaft Assembly
(4WD)
Removal
2
6 8
5 ES100005
9 After removing the front drive shaft, block the

front axle connecting port with a plug to prevent
3 dust.
1 4
ES100004
1 Lift the vehicle from the lifting platform. Installation

Note：During shipping and installation/removal of
2 Remove the upper swing arm assembly. Refer to
Removal of Upper Swing Arm Assembly for the propeller shaft, ensure the swing angle of
details. movable joint (the end close to the front axle)
does not exceed 26°and the swing angle of fixed
3 Unscrew the nut fastening the stabilizer bar to
joint (the end close to the wheel) does not exceed
the lower swing arm.
50°.
4 Unscrew the nut fastening the steering gear tie
rod to the steering angle. If necessary, use the 1 Replace the drive shaft with a new one, and
ball head puller C00017036 and support the clean its mounting position inside the front wheel
steering angle with a jack. hub and its junction with the front axle.
Note：Do not damage the dust shield. 2 Locate the drive shaft on the front axle housing
and push it into place.
5 Remove and discard the locking nut and washer
of drive shaft hub. Note：When installing the front drive shaft
6 Rotate the steering angle outward to a certain assembly, pay attention to not damaging the
angle to remove the outside constant-velocity sealing parts inside front axle housing.
universal joint from the knuckle. 3 Install the drive shaft into the knuckle with new
Note：Do not damage the dust shield. washer and nut.
7 Place a proper drain pan under the front axle When installing the hub nut, follow the instructions below:
housing.
· The mating surface with a "JPS" mark of the locking
8 To avoid damage to the front axle oil seal,
washer shall face the mounting surface of nut.
horizontally pull out the inside tripod universal
joint connecting the drive shaft to the front ·Pre-tightening torque: 100 ± 10N.m.
axle.During removal, pry it up as shown in the
figure. If it is difficult to remove, rotate the shaft ·Rotate the hub for 10 circles back and force. Install the
for 1/3 circle (1/3 circle more if necessary). hub bearing in place and tighten to: 350 ± 15N.m.
Note：Do not damage the front axle oil seal.
·Vertically knock down the locking nut of front hub into
the groove of drive shaft or spindle to prevent the nut
from loosening.
24-6
Propeller Shaft
Replacement of Constant-velocity Universal

Joint and its Dust Shield
Removal
1 Remove the drive shaft assembly. Refer to
Replacement of Drive Shaft for details.
2 Install the drive shaft clip to the vise.
3 Loosen and discard both clamps of the dust
shield.
4 Align the constant-velocity universal joint with the
intermediate solid shaft. Then slightly knock the
constant-velocity universal joint with a copper
ES100006 hammer to separate it. Remove the constant-
velocity universal joint and its dust shield.
4 Install the lower nut of stabilizer bar link rod and
the nut fastening the steering gear tie rod to the
knuckle, and tighten them to 65 ± 5N.m and
90 ± 5N.m respectively.
5 Install the upper swing arm assembly. Refer to
Installation of Upper Swing Arm Assembly for
details.
ES100007
5 Remove the snap ring from the drive shaft and

discard.
ES100008
24-7
Propeller Shaft
Installation Replacement of Tripod Universal Joint and

its Dust Shield
1 Fix the dust shield to the intermediate solid shaft
with a clamp (small), and install its ends to the Removal
outside of two grooves. 1 Remove the drive shaft. Refer to Replacement of
Drive Shaft for details.
2 Install the drive shaft clip to the vise.
3 Loosen and discard both clamps of the dust
shield.
4 Remove the intermediate solid shaft of drive
shaft.
5 Remove the snap spring at the end of
intermediate solid shaft with a nipper plier and
discard it.
ES100009
2 Install a new snap ring to the intermediate solid

shaft.
3 Fill the constant-velocity universal joint with the
lubricating grease provided, and apply the
residual grease on the inner side of dust shield of
constant-velocity universal joint.
4 Press the intermediate solid shaft into the
constant-velocity universal joint completely.
ES100010
5 Clean the juncture between the dust shield and
constant-velocity universal joint, and fix the dust
6 Remove the tripod joint and dust shield from the
shield clamp (large).
intermediate shaft.
6 Ensure the constant-velocity universal joint will
not interfere the dust shield when rotating freely
from each direction.
7 Install the drive shaft. Refer to Installation of
24-8
Propeller Shaft
Installation Replacement of Propeller Shaft

1 Clean the intermediate solid shaft, tripod shaft Removal
and sleeve. 1 Place the vehicle on the lifting platform and lift it
2 Install the dust shield to the intermediate solid to a certain height.
shaft with a new clamp (small) and install its 2 Remove the bolt connecting the propeller shaft
ends to the outside of two grooves. to the rear axle flange.
3 Locate the tripod joint onto the intermediate solid 3 Remove the bolt fastening the intermediate
shaft. support to the body.
4 Install new snap spring onto the end of 4 Remove the bolt connecting the propeller shaft
intermediate solid shaft. to the transmission. (2WD model)
5 Fill the tripod universal joint with the lubricating 5 Remove the bolt connecting the propeller shaft
grease provided, and apply the residual grease to the transfer case. (4WD model)
on the inner side of dust shield of constant-
6 Remove the bolt connecting the propeller shaft
velocity universal joint.
to the front axle flange. (4WD model)
6 Press the intermediate solid shaft into the tripod
7 Remove the drive shaft.
universal joint completely.
7 Clean the juncture between the dust shield and
tripod universal joint, and fix the dust shield
clamp (large). Installation
8 Ensure the tripod universal joint will not interfere 1 Installation is the reverse of removal.
the dust shield when rotating freely from each Key torques for installation are shown as follows. Please
direction. tighten torques symmetrically and evenly during
9 Install the drive shaft. Refer to Installation of installation:
—For the nut/bolt fastening the propeller shaft to the
transmission, tighten to 75 ± 5N.m. (2WD)
—For the nut/bolt fastening the propeller shaft to the rear

axle, tighten to 75 ± 5N.m. (2WD/4WD)
—For the bolt fastening the intermediate support of

propeller shaft to the frame, tighten to 55 ± 5N.m. (2WD/
4WD)
—For the nut/bolt fastening the propeller shaft to the front

axle, tighten to 75 ± 5N.m. (4WD)
—For the bolt fastening the propeller shaft to the transfer

case, tighten to 100 ± 10N.m. (4WD)
24-9
Propeller Shaft
Replacement of Cross Shaft 4 Knock the universal joint fork with the punch.
Removal Push out the bearing bowl through the opposite
Note：Do not fix the propeller shaft with a bench force of the universal joint.
vice directly, as indentation or local cracks may
lead to propeller shaft failure during vehicle
usage.
1 Mark the matching position line at the position on

the universal joint for replacing the cross shaft.
ES100013
5 Remove the bearing bowl. Repeat step 4 to

remove the other 3 bearing bowls, and then
remove the cross shaft.
ES100011
Installation
2 Knock the circlip with a hammer and a punch to
1 Prepare the cross shaft repair package. Check
loosen it.
whether the roller pins in the bearing bowl are
3 Remove 4 circlips with a nipper plier. arranged neatly without any shortage. Check
and ensure the inner wall of universal joint fork
earhole is smooth and clean.
2 Place the bearing bowl outside one end of the
universal joint fork earhole. Then place the cross
shaft near the earhole and insert its one end into
the bearing bowl.
ES100012
ES100014
24-10
Propeller Shaft
3 Knock the bearing bowl from outside of earhole Replacement of Intermediate Support of
to the depth where the retainer groove is just Propeller Shaft
exposed with a hammer and a punch, and install Removal
the circlip with a nipper plier. Note：Do not fix the propeller shaft with a bench
Note： vice directly, as indentation or local cracks may
lead to propeller shaft failure during vehicle
1）After installation, check and confirm the circlip is in the
usage.
retainer groove and has rebounded in place.
2）In case of a great resistance during push-in of bearing

bowl, stop pushing immediately, and check the
matching between the cross shaft and bearing bowl 1
and the interference between the cross shaft and the
1
universal joint fork. 2
3
4
ES100016
1 Mark the mounting positions of the propeller

shaft and steering yoke.
2 Pry up the locking gasket with a flat-blade
screwdriver.
ES100015 3 Lock the propeller shaft with a long thrust rod,
and loosen the bolt of intermediate support with
a wrench.
4 Overturn the universal joint fork for 180°, and
repeat the aforesaid steps to install the bearing
bowl and circilp on the other side. The cross
shaft must be swung during push-in, so as to
prevent the clamping stagnation between the
cross shaft and bearing bowl.
5 Place the cross shaft journals at the rest two
ends near the universal joint fork earhole on the
other end. Repeat the aforesaid steps to install
the bearing bowls and circlips at two other sides.
Pay attention to the marked position on the
universal joint fork during installation to ensure
the alignment.
6 After installation, swing the universal joint
ES100018
towards four directions to check whether it
swings flexibly. If the swing torque is excessively
great or it is stuck, hammer the outside of the 4 Remove the U-shape gasket and pull out the
universal joint fork earhole clamping the bearing steering yoke and intermediate support.
bowl with a rubber hammer.
24-11
Propeller Shaft
Installation 6 Flatten the turnup of locking gasket with a

flatblade awl.
1 After installing the intermediate support, install
the locking gasket and bolt into the spline sleeve,
and then install the spline sleeve into the
steering yoke shaft hole.
Note：The right angle of the sheet shall face the
intermediate support.
ES100021
ES100019
2 Align with the mark of the mounting position of

steering yoke and propeller shaft.
3 Pry up the locking gasket with a flat-blade
screwdriver, meanwhile insert a new U-shape
gasket.
ES100020
4 Lock the propeller shaft with a long thrust rod, fix

the bolt of intermediate support with a wrench
and tighten to 35-50N.m.
5 Turn the locking gasket outwards with a nipper
awl.
24-12
Propeller Shaft

The front drive shaft connects the front axle to the wheel
and transmits the torque. The inner tripod universal joint
(movable joint 2) can move along the shaft direction to
realize both steering and driving; the outer joint adopts
the rzeppa constant-velocity universal joint (fixed joint 1)
structure.
1 2
ES100022
The intermediate propeller shaft is composed of one or

two integrated tubes. Cross universal joints are used
between propeller shaft as well as propeller shaft and
male flange for connection. Fix the long propeller shaft
with an intermediate shaft onto the frame. Male flanges
are used for connecting the propeller shaft to the front
axle as well as the rear axle to the transmission. propeller
shaft is connected to 5MT transmission through a spline
pair and connected to other types of transmission
through a male flange. The propeller shaft with an
intermediate spline pair can automatically extend and
retract to meet the dynamic requirements of a complete
vehicle.
24-13
Propeller Shaft
24-14
Front Axle and Rear Axle
Specification
Torque
Front axle bolt - the third beam to frame 70 ± 5

Bolt/nut - front axle to frame assembly 180 ± 10
Bolt/nut - front axle to the third beam 180 ± 10
Bolt/nut - front axle flange to propeller shaft 75 ± 5
Front axle oil filler plug/drain plug 30~40
Bolt - front axle half-shaft clutch to axle housing 44~50
Bolt - front axle driven gear to differential 110~130
Bolt - front axle differential bearing cap to front axle housing 56~70
Bolt - bracket cover to front axle housing 25~35
Bolt - front axle bracket to front axle housing 125~135
Front axle drive gear lock nut 200~800
Nut - rear axle U-bolt 120 ± 10

Bolt/nut - shock absorber to leaf spring lower bracket 110 ± 10
Bolt/nut - rear axle flange to propeller shaft 75 ± 5
Rear axle oil filler plug/drain plug 55~85
The filler plug 30~40
Nut - half-shaft assembly to axle housing 110~130
Bolt - rear axle driven gear to differential 145~161
Bolt - rear axle differential bearing cap to rear axle housing 90~115
Bolt - final drive assembly to rear axle housing 64~80
Rear axle drive gear lock nut 186~370
Rear axle air plug 18~22
25-1
Layout
Exploded View of Front Axle
6
7
8
11
17 19
20
12 9 12
6 10 15
16
24
7
23
2 3 18
14
1
13
5
4 7 33
22 21
25
20
19
10
26
31
32
30 27
28
10
9
29
11
ES150084
1 Drive gear lock nut 7 Gasket - drive axle to frame assembly

2 Flange assembly 8 Front axle bracket
3 Drive gear oil seal 9 Front axle output oil seal
4 Drive gear outer bearing 10 Front axle output bearing
5 Bearing spacer bush 11 Bolt - front axle bracket
6 Bolt - drive axle to frame assembly 12 Front axle oil filler/drain plug
25-2
13 Washer - bracket cover 24 Bracket cover bolt

14 Drive gear inner bearing 25 Front axle clutch motor
15 Drive gear adjusting gasket 26 Front axle output shaft assembly
16 Breather pipe joint 27 Washer - front axle clutch
17 Air plug 28 Front axle clutch component
18 Drive/driven gear set 29 Front axle bracket
19 Differential bearing adjusting gasket 30 Front axle output shaft assembly
20 Differential bearing 31 Clip - transfer case washer
21 Differential assembly 32 Front axle
22 Driven gear mounting bolt 33 Nut - drive axle to frame assembly
23 Rear axle bracket cover
25-3
Exploded View of Rear Axle
30
10
11
22
33 1 3 5 7 9 12
14 19 26
1617 18
13 25
2 4 6 8 24
21 15 19 23
20
35
29 27
28
31
34
32
ES150085
1 Drive gear lock nut 9 Drive/driven gear set

2 Drive gear lock gasket 10 Nut - differential bearing
3 Flange assembly 11 Differential bearing
4 Drive gear oil seal 12 Driven gear mounting bolt
5 Drive gear outer bearing 13 Differential assembly
6 Bearing spacer bush 14 Nut - final drive assembly to axle housing
7 Drive gear inner bearing 15 Bolt - final drive assembly to axle housing
8 Drive gear adjusting gasket 16 Differential bearing nut locking plate
25-4
17 Washer - differential bearing nut locking plate 27 Nut - rear brake to rear axle
18 Bolt - differential bearing nut locking plate 28 Half-shaft oil seal
19 Washer - final drive assembly to axle housing 29 Half shaft
20 Reducer housing assembly 30 Wheel bolt
21 Final drive assembly 31 Bolt/screw - rear brake disc
22 Axle housing assembly accessory 32 Rear axle with brake assembly
23 Washer - oil filler plug 33 Rear axle with brake assembly
24 Oil filler plug assembly 34 Rear brake disc
25 Washer - oil drain plug 35 Air plug
26 Drain plug
25-5
Repair Guidance
Replacement of Front Axle Assembly
Removal Installation
1 Place the vehicle on the lifting platform and lift it 1 Lift the front axle and ensure the mounting holes
to a certain height. on both ends of the front axle are aligned with
2 Remove the front drive shaft assembly. Refer to the frame mounting holes on the same axis.
Replacement of Front Drive Shaft Assembly for 2 Install the gasket and bolt, and tighten the bolt to
details. 180 ± 10N.m.
3 Loosen the bolt fixing the propeller shaft to the 3 Install the third beam bracket. Do not tighten the
front axle flange. bolt temporarily.
4 Remove the third beam bracket. 4 Install the front axle intermediate bolt and
gasket, and tighten the bolt to 180 ± 10N.m.
5 Tighten the bolt mentioned in Step 3 to 70 ±
5N.m.
6 Connect the propeller shaft to the front axle
flange, and tighten the bolt to 75 ± 5N.m.
7 Install the drive shaft. Refer to Installation of
6 6
4
ES150001
5 Jack up the front axle.

Warning：Ensure the front axle is completely
jacked up.
6 Remove the bolt fixing the front axle to the
frame.
7 Lower the jack and take down the front axle.
25-6
Replacement of Rear Axle Assembly Installation

1 Move the front axle to a proper position below
the leaf spring, and lift the rear axle.
2 (For a low-chassis model) Install the rear leaf
spring assembly. Refer to Removal/Installation of
Rear Leaf Spring Assembly for details.
3 (For a low-chassis model) Install the U-bolt and
nut, and do not tighten them temporarily. (The
tightening torque for the nut is 120 ± 10N.m.
Refer to the Removal/Installation of Leaf Spring
for details).
4 Connect the shock absorber lower retaining
points to the leaf spring lower bracket with nuts
ES150002 and tighten to 110 ± 10N.m, then tighten the nut
of U-bolt.
Removal 5 Install the bolt connecting the rear axle flange to
1 Place the vehicle on the lifting platform and lift it the propeller shaft, and tighten it to 75 ± 5N.m.
to a certain height. 6 Install the parking brake cable. Refer to the
2 Remove the rear wheels. Removal/Installation of Parking Brake Cable for
details.
3 Jack up the rear axle.
7 Fix relevant brake pipeline onto the rear axle.
Warning：Ensure the front axle is completely
jacked up. 8 Install the rear wheels. Refer to Installation of
Wheels for details.
4 Disconnect the brake tube from the rear axle
housing.
5 Remove the parking brake cable. Refer to the
Removal/Installation of Parking Brake Cable for
details.
6 Disconnect the rear axle flange from the
propeller shaft.
7 (For a high-chassis model) Remove the shock
absorber lower retaining points and U-bolt and
nut. Refer to Removal/Installation of Leaf Spring
for details.
8 (For a low-chassis model) Remove the rear leaf
spring assembly. Refer to Removal/Installation of
Rear Leaf Spring Assembly for details.
9 Lower the jack and take down the rear axle.
25-7
Refill & Drain of Front Axle Lubricant Replacement of Front Axle Drive Gear Flange
Drain and Drive Gear Oil Seal
The drain plug is at the bottom of final drive housing. Removal
Tightening torque for the drain plug: 30-40N.m. 1 Place the vehicle on the lifting platform and lift it
Refill
2 Disconnect the propeller shaft from the front axle
The filler plug is in the middle of rear oil filler cover. Fill the
flange, and place the propeller shaft aside.
specified lubricant GL-5 80W-90 until the lubricant level is
3 Drain the oil.
flush with the filler port basically. Tightening torque for the
filler plug: 30-40N.m. 4 Remove the lock nut and washer of drive gear
shaft flange with the special tool C00045927,
and discard them.
2 C00045930
ES150008
ES150009
5 Remove the drive gear shaft flange with a

dualfoot puller.
ES150010
6 Pry out the oil seal with a flat-blade screwdriver

and discard it.
25-8
Installation
1 Check and clean the burrs and contamination of
drive gear seal cavity, and clean the sealant on
the spline.
2 Press-fit the drive gear oil seal with the special
tool C00089941, but pay attention to not
contaminating the oil seal lip.
ES150013
5 Install the new drive gear gasket and nut. During

assembly, rotate the drive gear flange forwards
and backwards while tightening the nut to
200N.m.
6 Check the starting torque of drive gear with the
torque wrench.
ES150011
The starting torque shall be between 1.7 and 3.4N.m
3 Apply Loctite 565 pipe thread sealant from the (remove the front drive shaft. Refer to the Removal/
center of flange inner spline towards 360 ° Installation of Drive Shaft). It shall be measured for
circular direction. multiple times to obtain an accurate value.
If the starting torque is less than the target range value,

the drive gear nut must be tightened with the torque
increased by 5N.m until the starting torque reaches the
target value, but the tightening torque for the nut shall not
exceed 800N.m.
If the starting torque is more than the target range value,

replace the elastic spacer bush with a new one.
7 Connect the propeller shaft to the front axle

flange, and tighten the bolts to 75 ± 5N.m.
8 Fill the oil.
ES150012 9 Lower the vehicle to the ground.
4 Install the flange onto the drive gear and press it

to the bottom.
25-9
Replacement of Front Axle Rim Oil Seal and Installation

Needle Bearing
1 Check and clean the mounting surface, and
Removal press-fit the half shaft bearing with the special
1 Lift the vehicle to a certain height, and remove tool C00089945 (apply some 40012020
the rear wheels. Refer to Removal/Installation of multifunction lithium grease onto the front axle
Wheels for details. needle bearing for installation).
2 Drain the oil.

3 Remove the drive shaft assembly. Refer to
Replacement of Drive Shaft for details.
and discard it.
5 Remove the half shaft bearing.
ES150014
2 Check and clean the oil seal hole. Then press-fit

the drive gear oil seal with the special tool
C00089937 (the lip is pre-applied with lithium
grease), but do not contaminate the oil seal lip.
ES150015
3 Fill the oil.

4 Install rear wheels and lower the vehicle.
25-10
Replacement of Front Axle Half-shaft Clutch Installation

Assembly
1 Install the clutch.
Removal
1 Remove the front axle assembly.
2 Drain the oil.
3 Remove the front axle half-shaft clutch screws,
and take down shift fork, spring, gear ring, gear
and gasket.
ES150018
Note：Apply 2.5g of Loctite 565 pipe thread

sealant from the thread center towards 360 °
circular direction.
2 Install the gear, gear ring, shift fork, spring and
half shaft clutch housing in turn.
ES150016
4 Remove the clutch motor (the motor is

connected to housing by thread).
ES150019
ES150017
ES150091
25-11
Replacement of Front Axle Output Shaft

For a model equipped with a half shaft clutch, remove the
half shaft clutch assembly and then take down the front
axle output shaft assembly.
For a model not equipped with a half shaft clutch, remove

the left and right drive shaft assemblies first (refer to
Removal/Installation of Drive Shaft Assembly for details).
There are elastic snap rings on both ends of a half shaft.
Push the front axle output shaft with the special tool
C00089928.
ES150092
C00089928
ES150021
ES150093
3 Install the clutch bolt, and tighten it to 44-50N.m.
ES150020
4 Install the front axle assembly.
25-12
Replacement of Front Axle Bracket Replacement of Front Axle Final Drive

Remove the front axle assembly first. For the bolts fixing Assembly
the left and right bracket assemblies to the front axle Removal
housing, the tightening torque is 125-135N.m. 1 Remove the front axle assembly. Refer to
Replacement of Front Axle Assembly.
2 Remove the drive gear flange and oil seal. Refer
to Replacement of Drive Gear Flange and Oil
Seal for details.
3 Remove the front axle output half shaft. Refer to
Replacement of Front Axle Output Half Shaft for
details.
4 Remove the rear oil filler cap and washer.
ES150022
ES150023
5 Check the overall final drive assembly to provide

reference for subsequent gasket assembly and
facilitate the subsequent troubleshooting
analysis.
Apply red lead powder onto 4~5 gears in three positions
120° apart on the driven gear.
Rotate the driven gear for 2~3 circles forwards and

backwards to mesh the drive gear with the driven gear
and form spots. Then make a record.
25-13
ES150024 ES150026
6 Remove the differential bearing cap. Pay Note：If you plan to reuse the driven and drive
attention to the pairing mark on the bearing cap. gears, take them out carefully to protect the
If there is no mark or the mark is unclear, make a driven gear from damage.
mark again.。 12 Knock the drive gear out of the final drive
7 Remove the differential bearing adjusting housing with a rubber hammer, and take out the
gaskets, and mark the left and right gaskets. elastic spacer bush.
8 Remove the differential assembly. 13 Move the drive gear inner bearing cone out with
9 Remove bearings from both ends of differential a puller.
with a puller.
ES150027
ES150025
Note：If you plan to reuse the driven and drive
gears, take them out carefully to protect the drive
Disassembly of Drive/Driven Gears
gear from damage.
10 Clamp the differential assembly into the caliper, 14 Remove the drive gear adjusting gasket. Then
and cover the driven gear on the caliper with a measure and record the thickness of adjusting
cloth. gasket.
11 Release the driven gear bolts in turn, and knock 15 Remove the inner bearing outer ring and outer
the driven gear edge slightly with a copper rod or bearing outer ring of the drive gear.
wooden hammer to separate the driven gear
from the differential housing.
25-14
Installation
1 Install the outer bearing outer ring of drive gear
with the special tool C00089940.
＞ 50% tooth depth

1~2
3~5
>50% tooth length
ES150030
In Step 4 of differential assembly removal, select the

thickness of new gasket according to this engaging mark
ES150028 when checking the overall final drive assembly. In Step
14 of differential assembly disassembly, the thickness of
2 Install the inner bearing outer ring of drive gear
original adjusting gasket has been measured.
ES150029
3 Select the drive gear adjusting gasket.

The thicknesses of gaskets include:
0.79mm/0.84mm/0.86mm/0.91mm/0.94mm/0.99mm
Standard even engaging mark
25-15
4 Press-fit the drive gear inner bearing cone to the

drive gear with the special tool C00089935. Do
Gear face contacting Causes Adjustment method: not leave out the drive gear adjusting gasket.
condition A - gear face contact
area adjustment
B - backlash
adjustment
Lean to tooth top The The drive gear

drive
adjusting gasket is
gear is
too far thicker than the drive
from the gear gasket
driven
removed
gear
ES150031
ES150035
Lean to tooth root The The drive gear
drive Note：The drive and driven gears must be
adjusting gasket is
gear is replaced in pair.
too close thinner than the
to the drive gear gasket 5 Pass the elastic spacer bush into the drive gear
driven shaft.
removed
gear
6 Install the drive gear into the reducer housing.
7 Press the drive gear outer bearing cone into the
ES150032 drive gear shaft to the bottom.
Note：Press it carefully to protect the drive gear
Lean to small end The The drive gear from damage.
driven
adjusting gasket is
gear is 8 Press the drive gear oil seal with the special tool
C00089934 to the bottom.
to the drive gear gasket
drive
removed
gear
ES150033
Lean to big end The The drive gear

driven
adjusting gasket is
gear is
too far thicker than the drive
from the gear gasket
drive
removed
gear
ES150036
ES150034
9 Install the drive gear flange and oil seal. Refer to
Replacement of Drive Gear Flange and Oil Seal
The specific adjustment amount of gasket thickness shall for details.
be judged according to spots and experience.
25-16
Assembly of Drive/Driven Gears 12 Install the differential assembly and left and right
adjusting gaskets into the final drive housing
10 Clear burrs and sundries on the mating face (The thickness of left and right gaskets removed
between the driven gear and differential housing. is okay by default. Adjust the thickness later).
Align the screw holes of driven gear with those of
differential housing. Then tighten bolts diagonally
in turn to 110-130N.m.
ES150039
ES150037 13 Install the bearing cap. Pay attention to pairing

the bearing cap with the bearing. Then tighten
Note：The drive and driven gears must be the bolt of bearing cap to 56-70N.m.
replaced in pair. The thicknesses of gaskets include:
11 Press the differential bearing cone with special
6.25mm/6.35mm/6.40mm/6.45mm/6.55mm
tools C00089938 and C00089939.
ES150038 ES150040
25-17
14 Measure the backlash with a dial indicator. 15 Apply red lead powder onto 4~5 gears in three
Measure 4 points above uniformly. The required positions 120 ° apart on the driven gear. Rotate
value range shall be 0.127-0.203mm. the driven gear for 2~3 circles forwards and
backwards to mesh the drive gear with the driven
gear and form spots.
＞ 50% tooth depth

1~2
3~5
>50% tooth length
ES150041
Adjustment Method for Backlash ES150043
Increase or reduce the thickness specification of Correct meshing spots

differential adjusting gasket to obtain the correct
backlash. The adjustment method is as illustrated below.
Later when the backlash shall be adjusted due to spot
adjustment, in order to keep the pre-tightening degree of
originally adjusted differential bearing, the thickness
increased on one end shall be equal to the thickness
decreased on the other end.
When the clearance is large
Increase the gasket Decrease the gasket
Increase the gasket Decrease the gasket
When the clearance is small

ES150042
25-18
Adjustment Method for Driven Gear Spots Gear face contacting Causes Adjustment method:
area adjustment
B - backlash
Gear face contacting Causes Adjustment method: adjustment
area adjustment Lean to small end The 1. The driven gear
B - backlash driven
leaves the drive gear
adjustment gear is
too to obtain correct
Lean to tooth top The 1.The drive gear gets close to backlash (increase
drive the drive
close to the driven or decrease
gear is gear
too far gear (increase the differential bearing
from the drive gear bearing gasket)
driven
gasket)
gear ES150033
2. The drive gear
2.The driven gear gets close to the
leaves the drive gear driven gear
ES150031
to obtain correct (decrease the drive
backlash (increase gear bearing gasket)
or decrease
differential bearing
gasket)
ES150046
Lean to big end The 1. The driven gear

driven
leaves the drive gear
ES150044 gear is
too far to obtain correct
Lean to tooth root The 1.The drive gear gets from the backlash (increase
drive drive
close to the driven or decrease
gear is gear
too gear (decrease the differential bearing
close to drive gear bearing gasket)
the
gasket)
driven ES150034
2. The drive gear
gear
2.The driven gear gets close to the
leaves the drive gear driven gear (increase
ES150032
to obtain correct the drive gear
backlash (increase bearing gasket)
or decrease
differential bearing
gasket)
ES150047
16 Adjust the backlash. Refer to the above

ES150045 Backlash Adjustment for details.
25-19
17 Adjust the driven gear spots. Refer to the above Refill & Drain of Rear Axle Lubricant
Adjustment of Driven Gear Spots for details. Drain
18 Adjust the backlash and spots until they are The drain plug is at the bottom of axle housing.
conforming. Tightening torque for the filler plug: 55-85N.m.
19 Check the starting torque (which shall be no
more than 3.7N.m) of final drive with the torque Refill
wrench. The filler plug is in the middle of axle housing. Fill the
The starting torque shall be measured for multiple times specified lubricant GL-5 80W-90(Shanghai Tempo/Total)
to obtain an accurate value. until the lubricant level is flush with the filler port basically.
Tightening torque for the filler plug: 55~85N.m.
Firstly, ensure the drive gear starting torque is within the
specified range.
If the final drive starting torque is high, it is proven that the

differential bearing pre-tightening force is great. Reduce
the gaskets on both sides by the same thickness
meanwhile and reduce the differential bearing
pretightening force. Then check whether the backlash is
conforming. If so, it is proven that the adjustment
succeeded; if not, adjust the backlash to the specified
range. Then measure the final drive starting torque. If it is
conforming, the adjustment succeeded; if it is
nonconforming, continue adjusting according to the
ES150049
torque. Keep this cycle until the starting torque and
backlash are conforming.
20 Install the front axle output half shaft. Refer to

Replacement of Front Axle Output Half Shaft for
details.
21 After aligning the seal washer and rear oil filler
cap with the screw hole correspondingly, tighten
the bolt to 25-35N.m.
ES150048
22 Fill the oil.
25-20
Replacement of Rear Axle Drive Gear Flange Installation

and Drive Gear Oil Seal
1 Check and clean the burrs and contamination of
Removal drive gear seal cavity, and clean the sealant on
1 Place the vehicle on the lifting platform and lift it the spline.
to a certain height. 2 Press-fit the drive gear oil seal with the special
2 Disconnect the propeller shaft from the rear axle tool C00089934. The drive gear oil seal is
flange, and place the propeller shaft aside. preapplied with lithium grease.
3 Measure and record the starting torque of rear

axle assembly. (This step only applies to the
replacement of drive gear oil seal and drive gear
flange)
Note：Two side breaks has no drag torque on half
axle.
4 Remove the lock nut and washer of drive gear
shaft flange with the special tool C00045930,
and discard them.
ES150052
3 Apply Loctite 565 pipe thread sealant onto the

drive gear spline.
C00045930
4 Install the flange onto the drive gear and press it
to the bottom.
ES150050
5 Remove the drive gear shaft flange with a

dualfoot puller.
ES150053
5 Install the new drive gear gasket and nut, tighten

the nut to 186N.m.
6 Check the starting torque of drive gear with the
torque wrench.
When only the drive gear oil seal and drive gear flange
ES150051 are replaced, the starting torque shall reach the value
measured in Step 3.
and discard it.
25-21
The starting torque shall be between 1.0 and 1.5N.m Replacement of Rear Axle Half Shaft
(only with the drive gear, driven gear and differential Assembly
assembly are not installed). It shall be measured for Removal
multiple times to obtain an accurate value. 1 Lift the vehicle to a certain height, and remove
the rear wheels. Refer to Removal/Installation of
If the starting torque is less than the target range value,
Wheels for details.
the drive gear nut must be tightened with the torque
2 Drain the oil.
increased by 5N.m until the starting torque reaches the
target value, but the tightening torque for the nut shall not 3 For a disc brake, remove the caliper and
disconnect the parking brake cable. For a drum
exceed 370N.m.
brake, disconnect the brake pipeline and collect
If the starting torque is more than the target range value, the brake fluid.
replace the elastic spacer bush with a new one. 4 Loosen 4 nuts fixing the half shaft assembly to
the axle housing.
7 Connect the drive shaft to the rear axle flange,
and tighten the bolt to 75 ± 5N.m.
ES150054
5 Pull out the half shaft assembly. If it is difficult to

remove the half shaft assembly manually, use
the slide hammer. Fix the slide hammer onto the
wheel-end flange with wheel-end nuts.
ES150055
25-22
Installation 3 Apply 1587 silicone rubber onto both ends of the

axle housing tube (gluing shall be continuous).
1 Distinguish the left and right half shafts
according to the steel seal ("L" or "R") on the
back of brake.
ES150058
4 Confirm whether the mounting positions of brake

bracket and cable relative to the axle housing
ES150056 are correct. Then push the half shaft assembly
into the rear axle housing until the half shaft
2 Before installing a half shaft assembly, check the mounting surface is flush with the axle housing
aperture area of shaft tube flange, and clear any tube flange face.
debris with a clean cloth if necessary. Pry out the
Note：When pushing the half shaft, avoid the half
oil seal with a flat-blade screwdriver if it is
damaged. Apply ZL-2 automobile universal shaft from contacting and damaging the oil seal.
lithium grease onto the outer lip and lip of the 5 Install 4 nuts fixing the half shaft assembly to the
new half shaft oil seal, and press the oil seal into axle housing, and tighten nuts to 110~130N.m.
the axle housing tube with the special tool
C00089929.
ES150059
ES150057
6 Install the brake and parking cable.
7 Fill the rear axle lubricant.
9 Lower the wheels to ground.
25-23
Replacement of Rear Axle Final Drive Installation

Assembly
1 Clean the sealant and contaminant on the
Removal bracket cover flange face, and wash oil residues
1 Remove the half shaft assembly. Refer to with mineral ethyl alcohol. Until the flange is
Replacement of Half Shaft Assembly for details. completely dry, apply 1587 silicone rubber onto
the inner bolt hole (gluing shall be continuous).
2 Remove the bolts fixing the final drive assembly
to the axle housing and remove the final drive
assembly.
ES150061
2 Install the main differential assembly onto the

ES150060
axle housing, and tighten bolts/nuts diagonally in
Note：If you plan to reuse the driven and drive turn to 64-80N.m.
gears, take them out carefully to protect the 3 Install the half shaft assembly. Refer to
driven gear from damage. Replacement of Half Shaft Assembly for details.
25-24
Rear Axle Final Drive Assembly

Disassembly
1 Remove the final drive assembly. Refer to
Replacement of Final Drive.
2 Remove the drive gear flange and oil seal. Refer
to Replacement of Drive Gear Flange and Oil
Seal for details.
3 Check the overall final drive assembly to provide
reference for subsequent gasket assembly and
facilitate the subsequent troubleshooting
analysis.
Measure the clearance between drive gear and driven ES150063
gear with a dial indicator. Measure 4 points above
uniformly, and record the measurement data. (Clearance 5 Remove the differential bearing cap. Pay
attention to the pairing mark on the bearing cap.
requirement: 0.15-0.2mm). If the clearance
If there is no mark or the mark is unclear, make a
measurement value is non-conforming, adjust the
mark again.
differential bearing nut as per the specific method below:
Screw in the nut Screw out the nut
Screw out the nut Screw in the nut
When the clearance is small ES150064

ES150062
6 Remove the left and right adjusting nuts from the
Apply red lead powder onto 4~5 gears in three positions differential.
120° apart on the driven gear. 7 Remove the differential assembly.
Rotate the driven gear for 2~3 circles forwards and 8 Remove bearings from both ends of differential
backwards to mesh the drive gear with the driven gear with a puller.
and form spots. Then make a record.
4 Remove the differential bearing nut locking plate.
ES150065
25-25
13 Remove the drive gear adjusting gasket. Then

Disassembly of Drive/Driven Gears
measure and record the thickness of adjusting
9 Clamp the differential assembly into the caliper, gasket.
and cover the driven gear on the caliper with a 14 Remove the inner bearing outer ring and outer
cloth. bearing outer ring of the drive gear.
10 Release the driven gear bolts in turn, and knock
the driven gear edge slightly with a copper rod or
wooden hammer to separate the driven gear
from the differential housing.
ES150066

gears, take them out carefully to protect the
driven gear from damage.
11 Knock the drive gear out of the final drive
housing with a rubber hammer, and take out the
elastic spacer bush.
12 Move the drive gear inner bearing cone out with
a puller.
ES150067

gears, take them out carefully to protect the drive
gear from damage.
25-26
Assembly Standard even engaging mark

1 Install the outer bearing outer ring of drive gear
＞ 50% tooth depth

1~2
3~5
>50% tooth length
ES150070
ES150068
In Step 4 of differential assembly disassembly, select the
thickness of new gasket according to this engaging mark
2 Install the inner bearing outer ring of drive gear
with the special tool C00089936. when checking the overall final drive assembly. In Step
13 of differential assembly disassembly, the thickness of
original adjusting gasket has been measured.
Gear face contacting Causes Adjustment method:

area adjustment
B - backlash
adjustment
Lean to tooth top The The drive gear

drive
adjusting gasket is
gear is
too far thicker than the
ES150069 from the drive gear gasket
driven
removed
gear
3 Select the drive gear adjusting gasket. Drive
gear adjusting height range: 1.4-1.95mm. Use
two gaskets if the adjusting height is more than
1.65mm. ES150031
Generally the thickness of drive gear adjusting gasket is Lean to tooth root The The drive gear
1.5-1.6mm. The specifications of gaskets include: drive
adjusting gasket is
gear is
0.30mm/1.44mm/1.47mm/1.50mm/1.53mm/1.56mm/ too close thinner than the
1.59mm/1.62mm/1.65mm to the drive gear gasket
driven removed
gear
ES150032
25-27
Gear face contacting Causes Adjustment method: 7 Press the drive gear outer bearing cone into the
condition A - gear face contact drive gear shaft to the bottom.
area adjustment
B - backlash
adjustment
Lean to small end The The drive gear

driven
adjusting gasket is
gear is
to the drive gear gasket
drive
removed
gear
ES150033
Lean to big end The The drive gear ES150072

driven
adjusting gasket is
gear is Note：Press it carefully to protect the drive gear
too far thicker than the
from damage.
from the drive gear gasket
drive 8 Install the drive gear flange and oil seal. Refer to
removed
gear Replacement of Drive Gear Flange and Oil Seal
for details.
Installation of Final Drive Assembly
ES150034
9 Clear burrs and sundries on the mating face
The specific adjustment amount of gasket thickness shall between the driven gear and differential housing.
be judged according to spots and experience. Align the screw hole of driven gear with that of
differential housing. Then tighten bolts diagonally
4 Press-fit the drive gear inner bearing cone to the in turn to 145~161N.m.
drive gear with the special tool C00089935. Do
not leave out the drive gear adjusting gasket.
ES150073
ES150071 Note：The drive and driven gears must be

replaced in pair.
Note：The drive and driven gears must be
replaced in pair.
5 Pass the elastic spacer bush into the drive gear
shaft.
6 Install the drive gear into the reducer housing.
25-28
10 Press the differential bearing cone with special 12 Measure the backlash with a dial indicator.
tools C00089938 and C00089939. Measure 4 points above uniformly. The required
value shall be 0.15~0.20 mm.
ES150074 ES150076
11 Install the differential assembly into the reducer

housing and install the bearing cover. During Adjustment Method for Backlash
installation, pay attention to pairing the bearing
Adjust the differential bearing nut to make it close to or
cover with the bearing. The threads of adjusting
away from the drive gear, so as to obtain accurate
ring shall be matched with the bearing cover and
base threads. It is prohibited to press-fit the clearance. The adjustment method is as illustrated
bearing cover with bolts forcibly. Tighten the below. Then tighten left and right nuts relatively to ensure
bearing cover bolts to 90-115N.m. a proper pre-tightening force for the bearing (reference
value: respectively screw both nuts in for 1-3 adjusting
nut small hole positions). Later when the backlash shall
be adjusted due to spot adjustment, in order to keep the
pre-tightening degree of originally adjusted differential
bearing, the screw-in circles of the adjusting nut on one
end shall be equal to the screw-out circles of the nut on
the other end.
ES150075 Screw in the nut Screw out the nut
Screw out the nut Screw in the nut
When the clearance is small

ES150077
25-29
09521-43001 Gear face contacting Causes Adjustment method:

area adjustment
B - backlash
adjustment
Lean to tooth top The 1. The drive gear

drive
gets close to the
gear is
too far driven gear
from the (increase the drive
driven gear bearing
gear
ES150078 gasket)
13 Apply red lead powder onto 4~5 gears in three 2. The driven gear
ES150031
positions 120 ° apart on the driven gear. Rotate leaves the drive
the driven gear for 2~3 circles forwards and gear to obtain
backwards to mesh the drive gear with the driven correct backlash
gear and form spots. (adjust the
differential adjusting
ring)
＞ 50% tooth depth
1~2
ES150044
3~5
Lean to tooth root The 1. The drive gear
>50% tooth length drive
leaves the driven
gear is
too close gear (decrease the
ES150079 to the drive gear bearing
driven
Correct meshing spots gasket)
gear
Adjustment method for driven gear spots. In this step, 2. The driven gear
adjust the differential adjusting nut and drive gear bearing gets close to the
ES150032
gasket synchronously to obtain correct spots. drive gear to obtain
correct backlash
(adjust the
differential adjusting
ring)
ES150045
25-30
15 Adjust the driven gear spots. Refer to the above

Gear face contacting Causes Adjustment method:
condition Adjustment of Driven Gear Spots for details.
A - gear face contact
area adjustment 16 Adjust the backlash and spots until they are
B - backlash conforming.
adjustment
17 Check the starting torque of final drive with the
Lean to small end The 1. The driven gear torque wrench.
driven
gets close to the The starting torque shall be between 2.5 and 3N.m. It
gear is
too close drive gear (adjust shall be measured for multiple times to obtain an
to the the differential accurate value.
drive
adjusting ring)
gear
Firstly, ensure the drive gear starting torque is within the
2. The drive gear specified range.
leaves the driven
ES150033 If the final drive starting torque is high, it is proven that the
gear to obtain
correct backlash differential bearing pre-tightening force is great. Roll back
(decrease the drive the adjusting nuts on both sides anticlockwise by the
gear bearing same angle meanwhile and reduce the differential
gasket) bearing pre-tightening force. Then check whether the
backlash is conforming. If so, it is proven that the
adjustment succeeded; if not, adjust the backlash to the
specified range. Then measure the final drive starting
torque. If it is conforming, the adjustment succeeded; if it
is nonconforming, continue adjusting according to the
ES150046
Lean to big end The 1. The driven gear
driven
leaves the drive
gear is
too far gear (adjust the
from the differential adjusting
drive
ring)
gear
2. The drive gear
gets close to the
ES150034
driven gear to
obtain correct
backlash (increase
the drive gear
bearing gasket) ES150080
If the final drive starting torque is low, it is proven that the

differential bearing pre-tightening force is small. Screw in
the adjusting nuts on both sides anticlockwise by the
same angle meanwhile and increase the differential
ES150047 bearing pre-tightening force. Then check whether the
backlash is conforming. If so, it is proven that the
14 Adjust the backlash. Refer to the above adjustment succeeded; if not, adjust the backlash to the
Backlash Adjustment for details. specified range. Then measure the final drive starting
torque. If it is conforming, the adjustment succeeded; if it
25-31
is nonconforming, continue adjusting according to the

ES150081
Starting torque Return the

is large adjusting nut
Normal Backlash check
differential and adjustment
Starting torque Screw in
is small adjusting nut
ES150082
18 Install the differential adjusting nut locking plate,

and tighten the bolt to 15-22N.m.
ES150083
25-32
Special Tool Tool Number and Illustration

Description

Description C00089935
Installer for the inner
bearing inner ring of
rear axle drive gear
C00089929 C00089935
Rear axle differential
bearing installer
C00089929 C00089936
bearing outer ring of
C00089930 C00089936
Rear axle half shaft oil
seal installer
C00089930
C00089937
Front axle half shaft oil
seal installer
C00089931 C00089937
Rear axle differential
bearing mounting block
C00089931
C00089938
Front axle differential
bearing installer
C00089933
C00089938
Installer for the outer
C00089933
C00089939
Front axle differential
bearing mounting block
C00089934 C00089939
Rear axle drive gear oil
seal installer
C00089934 C00089940
Installer for the outer
front axle drive gear
C00089940
25-33

Description
C00089941
Front axle drive gear oil
seal installer
C00089941
C00089942
bearing inner ring of
C00089942
C00089943
C00089943
C00089945
Front axle half shaft
bearing installer
C00089945
C00089928
Front axle output shaft
remover
C00089928
25-34

The front axle is composed of the reducer assembly, differential assembly, front axle housing assembly, etc.
The rear axle is composed of the final drive assembly, differential assembly, differential lock assembly (optional), rear
axle housing assembly, left & right half shaft assemblies, brake drum (disc), etc.
The drive axle distributes the power input by the universal drive device of which torque is increased and power transfer
direction is changed by the reducer to the left and right driving wheels, so as to propel the vehicle to drive. It allows the left
and right driving wheels to rotate at different speeds.
The final drive increases the torque input, lowers the speed and transfers the power to the differential after changing its
transfer direction.
The differential transfers the power from the final drive to the left and right half shafts and allows the two half shafts to
rotate at different speeds when necessary to satisfy the differential need of both driving wheels.
Front Axle Half Shaft Clutch (optional)

The half shaft clutch is on the front axle (refer to Front Axle for detailed structure). It is mainly used for connecting/
disconnecting the power transmission between the front wheels and the transfer case. When it is placed in 2H position,
the actuator will impel the shift fork to move and separate the front axle output shaft from the drive shaft. At this time, the
transfer case disconnects the power transmission to the transfer case front output shaft. If there is no half shaft clutch,
front wheels will drag the chain wheels in the differential and transfer case to rotate, which not only increases the
dragging torque, oil consumption and parts wear but also lowers the driving stability and NVH. When it is placed in 4H/4L
position, the actuator will impel the shift fork to move and separate the front axle output shaft from the drive shaft.
Front and rear axle speed ratio
Speed ratio Gear ratio Engine type Gearbox type
3.818 42/11 FGT/VGT/D20 6MT
3.636 40/11 FGT/VGT/D20 5MT AISIN/6AT PUNCH
4.556 41/9 4G69 5MT SAGW
4.1 41/10 2.0T 6MT SAGW/6AT PUNCH
25-35
Eaton Differential Lock

1 The differential lock of pickup car is installed on the rear axle differential.
Eaton MLocker
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Transmission
਎䙕㇧
Engine
ਇࣞᵰ Rear Differential
੄ᐤ䙕ಞ
Transfer Case(T-Case)
࠼ࣞ㇧ѣཤᐤ䙕ಞ
ES150086
25-36
2 Comparison between Eaton mechanical-lock differential and common differential
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ES150087
3 Characteristics of Eaton differential lock

· Full-mechanical structure, automatic slipping induction and automatic locking/unlocking
· When the speed difference between left and right wheels reaches 100rpm/min, it will lock the rear axle completely
· It is made of durable Eaton patented material
· It does not add the complete vehicle weight, improving performance but not increasing fuel consumption
· Locking cannot be realized above 30km/h; completely compatible with ABS/ESP
· Give the driver more confidence to enjoy driving
25-37
4 Eaton differential lock mechanism
1 2 18
19
4 14
5 6 20
7 12
13 11
10
8
3
17
16
15 9
ES150088
1 Gasket 11 Friction lining

2 Friction lining component on the flange end 12 Spherical gasket
3 Spring snap ring 13 Planet gear
4 Fuse disc plate 14 Planet gear shaft
5 Wave-shape ring 15 Gasket
6 Cam plate 16 Lock bracket
7 Cam half shaft gear 17 Locking mechanism
8 Reaction block 18 Differential housing
9 Half shaft gear 19 Planet shaft retaining bolt
10 Limiting lug 20 Sleeve
25-38
21 Operating principle of Eaton differential lock

If there is speed difference between both wheels, the cam plate will rotate at the same speed with the speed difference
(relative to the rotating angle of differential housing), meanwhile the gear on the cam plate will drive the locking
mechanism to rotate 1. When the speed difference between both sides reaches 100-150RPM above, the flywheel on the
locking mechanism will be opened under the centrifugal force and mesh with the locking bracket, so as to stop the locking
mechanism from rotating 2, and accordingly the cam plate will stop rotating 3. At this time, the originally meshed slant on
the cam half shaft gear back and the slant on the cam plate will slide out mutually and push the cam plate and cam gear
to move towards the opposite directions. The cam plate will press the friction lining housing to 4. Then the reactive force
on the cam gear transfers to the half shaft gear on the other side through the reaction block and presses the friction lining
behind it. The friction lining connects the half shaft gear to the housing to form a rigid body 5. Finally the half shafts on
both sides are integrated.
1
2
3
ES150089
25-39
The mechanical differential lock also has the safety function to automatically adjust according to vehicle speed. When the
vehicle speed reaches 30km/h, the locking bracket connected to the housing will be opened a little under the centrifugal
force. At this time, the flywheel of locking mechanism cannot mesh with the locking bracket even though it is open.
Therefore the mechanical differential lock cannot be locked during high-speed driving.
ES150090
The differential lock is prohibited to operate under overload. It is recommended to use the rear axle lubricating oil
recommended by the manufacturer. The differential lock can be unlocked manually after it is locked. Rotate the steering
wheel towards the wheel slipping side for a half circle. Then the differential lock will be unlocked after the tires rotate for a
circle.
25-40
Exteriors
Exteriors
Torque
Bolt - fasten the side fixed courtesy assembly to the side 22 ± 2

sliding door courtesy bracket
Bolt - fasten the cargo compartment guardrail to the cargo 20 ± 2

compartment sideboard
Bolt - fasten the roll cage to cargo compartment trim 22 ± 2

Bolt - fasten the internal cord hook bracket to cargo 22 ± 2
compartment trim
Bolt - fasten the rear bumper assembly to the rear bumper 40 ± 5

mounting bracket
26-1
Exteriors
Layout
10
9
10
10
10 9
10
10
1
20
14 2
8
21 6 3
7 4 6 8
22
7
5
5
5
11
23
16 13 18
12
17
19
15
ES180016
1 Front Door B Pillar Film 9 Roof Rack

2 Rear Door B Pillar Film 10 Nut - Roof Rack
3 C Pillar Trim Panel 11 Cargo Compartment Tim
4 Cargo Guard Rail 12 Cargo Door Trim
5 Bolt - Cargo Guard Rail 13 Strapping Ring
6 Strapping Ring - Cargo Guard Rail 14 Bolt - Internal Rope Hook Bracket
7 Bolt - Cargo Guard Rail Strapping Ring 15 Bolt - Cargo Door Trim
8 Nut - Cargo Guard Rail Strapping Ring 16 Reflecting Marking
26-2
Exteriors
17 Reflecting Marking 21 Cargo Guard Rail
18 C Pillar Relief Valve 22 Cargo Guard Rail
19 Relief Valve Acoustic Wool 23 Beltline Decal
20 Cargo Compartment Protection Box Mounting

Accessories
26-3
Exteriors
Repair Guidance
Replacement of Front Grille
Replacement of Windshield Plate
Removal
Removal
1 Remove the snap fastener connecting the front
1 Remove the front wipers.
grille plate to the upper beam plate of radiator.
Remove the front grille plate. 2 Remove the snap fastener (1) and bolt (2)
connecting the windshield plate to the windshield
gutter channel.
ES180002 2
ES180004
2 Unscrew the bolt fastening the front grille to the
headlamp assembly.
3 Remove the windshield plate.
Installation
ES180003
3 Separate the front grill from the front bumper

mounting point.
Installation
26-4
Exteriors
Replacement of Front Wheelhouse Liner Replacement of Rear Wheelhouse Liner

Removal Removal
1 Respectively remove the snap fastener (1) 1 Respectively remove the snap fastener (1) and
connecting the front wheelhouse liner to the front bolt (2) connecting the rear wheelhouse liner to
bumper, wheelhouse test piece and front the cargo compartment.
structure; snap fastener (2) to the front bumper;
bolt (3) to the front bumper and front bracket and
snap fastener (4) to the front structure and
fender.
1
4 1
1
3
2
ES180006
2
2 Remove the rear wheelhouse liner.
ES180005
Installation
2 Remove the front wheelhouse liner.
Installation
26-5
Exteriors
Replacement of Front Mudguard Replacement of Rear Mudguard

Removal Removal
1 Respectively unscrew the bolts connecting the 1 Unscrew the bolts connecting the rear mudguard
front mudguard to the front wheelhouse liner and to the rear wheelhouse liner and cargo
the fender. compartment.
ES180007 ES180008
2 Remove the front mudguard. 2 Remove the rear mudguard.
1 Installation is the reverse of removal. 1 Installation is the reverse of removal.
26-6
Exteriors
Replacement of Side Fixed Courtesy Replacement of Cargo Compartment

Removal Removal
1 Unscrew the bolt fastening the side fixed 1 Unscrew the bolt fastening the cargo
courtesy assembly to the side sliding door compartment guardrail to the cargo compartment
courtesy bracket. sideboard.
ES180009 ES180010
2 Remove the side fixed courtesy assembly. 2 Unscrew the bolt fastening the cargo
compartment guardrail to the cargo compartment
front board.
Installation
—For the bolt fastening the side fixed courtesy assembly
to the side sliding door courtesy bracket, the tightening
torque: 22 ± 2N.m.
ES180011
3 Remove the cargo compartment guardrail.
Installation
—For the bolt fastening the cargo compartment guardrail
to the cargo compartment sideboard, the tightening
torque: 20 ± 2N.m.
26-7
Exteriors
Replacement of Roof Rack Replacement of Cargo Compartment Trim

Removal Removal
1 Unscrew the nut fastening the roof rack 1 Unscrew the bolt fastening the roll cage to the
mounting bolt to the body bracket. cargo compartment trim.
ES180012 ES180013
2 Remove the roof rack. 2 Unscrew the bolt fastening the internal cord hook
bracket to the cargo compartment trim.
Installation
ES180014
26-8
Exteriors
3 Remove the screw trim cover and self-tapping

screw of the cargo compartment door trim.
ES180015
4 Remove the cargo compartment trim.
Installation
—For the bolt fastening the roll cage to the cargo
compartment trim, the tightening torque: 22 ± 2N.m.
—For the bolt fastening the internal cord hook bracket to

the cargo compartment trim, the tightening torque: 22 ±
2N.m.
26-9
Exteriors
26-10
Driver Compartment Interiors and Switches
Specification
Torque
Bolt - instrument panel beam to body 20 ± 2

Bolt - instrument panel beam connecting plate 22 ± 2
Bolt - instrument panel beam to beam bracket 20 ± 2
Bolt - instrument panel beam bracket to body 20 ± 2
27-1
Layout
Layout
1 3 9 3
1 12 2
8
7
2
10 11 13 4 5 10 6 5 10 6
ES130000
1 A-pillar upper trim panel assembly 8 B-pillar handle assembly

2 B-pillar upper trim panel assembly 9 Rear guard plate assembly
3 C-pillar upper trim panel assembly 10 Courtesy trim panel
4 A-pillar lower trim panel assembly 11 Floor cover
5 B-pillar lower trim panel assembly 12 Driver compartment roof interior assembly
6 C-pillar lower trim panel assembly 13 Footrest
7 A-pillar handle assembly
27-2
Layout
7 6 5 4 13 12 3
9 10 11 1
ES130001
1 Left cover plate assembly 8 Right end cover assembly

2 Left air outlet panel assembly 9 Glove box side trim panel assembly
3 Left loudspeaker grille assembly 10 Glove box assembly
4 Central control panel assembly 11 Driver side lower guard plate assembly
5 Front passenger airbag cover plate 12 Instrument cluster shroud assembly
6 Right loudspeaker grille assembly 13 Instrument panel body assembly
7 Right air outlet panel assembly
27-3
Layout
1
2
4
5
6
3
8
7
ES130002
1 Forward extending plate of the auxiliary fascia 5 Auxiliary fascia console molding
console
6 Shift lever guard plate assembly
2 Auxiliary fascia console assembly
7 Rear panel assembly of the auxiliary fascia
3 Front handbrake cover plate console
4 Ashtray assembly 8 Plug
27-4
Layout
7 6 4 3 2 1
9
5
10
8
ES130003
1 Driver window regulator switch assembly 6 Hazard warning lamp switch assembly
2 Rearview mirror regulating switch 7 Entertainment control switch assembly
3 Dimmer switch assembly 8 Drive conversion switch assembly
4 Combination switch assembly 9 Central control switch block assembly
5 Start-stop switch 10 Fuel tank cap switch
27-5
Layout
ES250000
1 Instrument cluster
27-6
Repair Guidance Replacement of Rear Door Interior Trim

Panel
Replacement of Front Door Interior Trim
Panel Removal
Removal 1 Disconnect the battery (negative first).

2 Remove the interior cover plate assembly of rear
door quarter window and the rear door inclined
2 Remove the interior cover plate assembly of handle cover plate.
front door quarter window and the front door
inclined handle cover plate. 3 Remove 5 screws as shown in the figure. Then
remove the rear door interior trim panel.
3 Remove 5 screws as shown in the figure.
ES130005
ES130004
4 Disconnect the electrical connector.
5 Remove the rear door interior trim panel.
5 Remove the front door interior trim panel.
Installation
Installation
Replacement of Courtesy Trim Panel

Removal
1 Pry up the courtesy trim panel along the panel
edge with a flat-blade screwdriver or another
tool.
Installation
27-7
Replacement of Driver Compartment Roof Replacement of A-pillar Upper Trim Panel

Interior Assembly Removal
Removal
1 Remove the A-pillar handle (refer to
1 Remove A, B and C-pillar upper trim panels Replacement of Pillar Handle).
(refer to Replacement of A, B and C-pillar Upper 2 Pry the curtain airbag plug, and remove screws.
Trim Panels).
2 Remove the sun visor retaining bracket and sun
visor assembly.
3 Remove the front passenger and driver roof

handles.
4 Remove the front and rear dome lamp

assemblies.
5 Remove the driver compartment roof interior

assembly along the edge.
ES130007
3 Remove the A-pillar upper trim panel (clip

positions are as illustrated).
ES130006
Installation
ES130008
Installation
27-8
Replacement of A-pillar Lower Trim Panel Replacement of B-pillar Trim Panels

Removal Removal
1 Pry the footrest assembly. 1 Remove seat belt retaining bolts (refer to
2 Remove the front door. Removal of Seat Belt).
3 Remove retaining nuts of A-pillar trim panel.
ES130010
ES130056 2 Remove the courtesy panel.
3 Remove the B-pillar lower trim panel (clip

4 Remove the A-pillar lower trim panel (clip
ES130011
ES130009
Installation
27-9
4 Remove the B-pillar upper trim panel plug and

Replacement of C-pillar Trim Panels
bolts.
Removal
1 Remove the courtesy panel.
2 Remove the rear trim panel (refer to
Replacement of Rear Trim Panel).
3 Remove seat belt anchor points of C-pillar lower

trim panel (refer to Replacement of Seat Belt).
ES130012
5 Remove seat belt anchor points (refer to

Replacement of Seat Belt).
6 Remove the B-pillar upper trim panel (clip

ES130014
4 Remove the C-pillar lower trim panel.
5 Remove the C-pillar plug and the seat belt

anchor points of C-pillar upper trim panel (refer
to Replacement of Seat Belt).
ES130013
Installation
ES130015
6 Remove the C-pillar upper trim panel.
Installation
27-10
Replacement of Front Passenger and Driver Replacement of Rear Trim Panel and Upper &
Roof Handles Lower Guard Plates of Rear Seat Belts
Removal Removal
1 Remove the handles. 1 Overturn the rear seats.
2 Unscrew retaining screws. 2 Remove the rear trim panel and upper & lower
guard plates of rear seat belts (clip positions are
3 Remove the handle assembly.
as illustrated).
Installation
Replacement of Pillar Handle

Removal
1 Pry the handle plug.
ES130017
3 Remove the upper guard plate of rear seat belts.
4 Remove the lower guard plate of rear seat belts.
Installation
ES130016 1 Installation is the reverse of removal.
2 Remove handle retaining screws.

Replacement of Footrest Assembly
3 Remove the pillar handle.
Removal
1 Pry the footrest assembly along the edge.
27-11
Replacement of Glove Box Assembly Replacement of Instrument Panel Side End

Removal Cover Assembly
Removal
1 Disconnect the damping instrument panel.
1 Pry the clips of removal points with a crowbar.
2 Pry clamping points towards both sides in turn.
3 Remove the instrument panel side end cover

assembly.
ES130054
2 Remove the glove box from the glove box

rotating shaft.
ES130020
Installation
ES130018
Installation
27-12
Replacement of Driver Side Lower Guard Replacement of Central Control Panel

Plate Assembly Assembly of Instrument Panel
Removal Removal
1 Remove the instrument panel side air outlet 1 Pry 4 upper clips.
panel assembly (refer to Replacement of 2 Pry other clamping points in turn from top to
Instrument Panel Side Air Outlet Panel bottom.
Assembly).
3 Disconnect the harness connector.
2 Remove the 2 screws connecting the driver side
lower guard plate assembly to body. 4 Remove the central control panel assembly of
the instrument panel.
ES130021
ES130022
3 Remove the engine hood cable handle.
4 Remove the connecting bolts (bottom) from data

link connector.
5 Remove the driver side lower guard plate

assembly.
Installation
ES130023
Installation
27-13
Replacement of Instrument Cluster Shroud Replacement of Instrument Panel Side Air

Assembly Outlet Panel Assembly
Removal Removal
1 Remove two retaining screws from the 1 Remove the instrument panel end cover.
instrument cluster shroud. 2 Remove the screws connecting the instrument
2 Pull out the instrument cluster shroud assembly panel side air outlet panel assembly to the
upwards. instrument panel.
3 Pull out the instrument panel side air outlet

assembly.
ES130024
ES130025
Installation
Installation
27-14
Replacement of Instrument Panel Replacement of Radio Lower Storage Bo

Loudspeaker Grille Removal
Removal
1 Remove the central control panel assembly.
1 Slightly pry the grille with a crowbar or flat-blade 2 Remove the radio (refer to Replacement of
screwdriver upwards. Radio)
2 Remove the instrument panel loudspeaker grille.
3 Unscrew the screws connecting the radio lower
storage box to the instrument panel body
assembly.
4 Remove the radio lower storage box.
ES130026
Installation ES130027
Installation
27-15
Replacement of Glove Box Side Trim Panel Replacement of Front Passenger Airbag
Assembly Cover Plate
Removal Removal
1 Remove the instrument panel end cover. 1 Slightly pry the cover plate from its lower left
2 Unscrew two retaining screws from one side of corner with a crowbar or flat-blade screwdriver.
glove box side trim panel. 2 Pry clips along the edge in turn (be careful to
prevent damaging clips).
3 Pull out the glove box side trim panel assembly.
3 Remove the front passenger airbag cover plate.
ES130028
ES130029
Installation
Installation
27-16
Replacement of Upper and Lower Steering Replacement of Instrument Cluster

Column Shrouds Removal
Removal
1 Pry the upper steering column shroud with a 2 Remove the instrument cluster shroud assembly
flatblade screwdriver. (refer to Removal of Shroud).
2 Rotate the steering wheel to a proper position,
remove the screws connecting the lower steering
column shroud to the combination switch base.
3 Remove the screws from the bottom of lower

steering column shroud.
ES250002
3 Remove 4 bolts fixing the instrument cluster to

the instrument panel body.
ES130030
4 Remove the lower steering column shroud.
Installation
ES250003

5 Remove the instrument cluster assembly.
Installation
27-17
Installation
Replacement of Instrument Panel Body
Removal
Note：Connect the instrument panel body to the
dash panel with one pin in the middle and each
2 Remove the auxiliary fascia console assembly insert slice on both sides, and fasten it to the side
(refer to Replacement of Auxiliary Fascia wall inner plate by each bolt on both ends
Console Assembly).
respectively.
3 Remove left and right end cover assemblies
(refer to Replacement of Left and Right End
Cover Assemblies).
4 Remove the driver side lower guard plate

assembly (refer to Replacement of Driver Side
Lower Guard Plate Assembly).
5 Remove the steering wheel (refer to

Replacement of Steering Wheel).
6 Remove the instrument cluster and shroud

assembly (refer to Replacement of Instrument
Cluster and Shroud Assembly).
7 Remove the glove box assembly (refer to ES130032

Replacement of Glove Box Assembly).
8 Remove the central control panel assembly and

entertainment system (refer to Replacement of
Entertainment System Display and Host).
10 Unscrew the screws as shown in the figure.
ES130031
11 Remove the instrument panel body assembly.
27-18
4 Unscrew two bolts connecting the instrument

Replacement of Instrument Panel Beam
panel beam to both ends of body.
Removal
1 Remove the instrument panel body assembly
(refer to Replacement of Instrument Panel Body
Assembly).
2 Remove the steering column (refer to Removal
of Steering Column).
ES130035
5 Remove three retaining nuts of fuse box.
6 Loosen brake pedal bolts.
7 Remove the instrument panel beam assembly.
ES130033
3 Unscrew two bolts connecting the instrument Installation

panel beam to the beam bracket. 1 Installation is the reverse of removal.
ES130034
27-19
4 Remove the A/C control panel, and unscrew two

Replacement of Auxiliary Fascia Console
screws.
Removal
1 Remove the rear panel assembly of the auxiliary
fascia console (refer to Removal of Rear Panel
Assembly of the Auxiliary Fascia Console).
2 Remove the auxiliary fascia console plug, and
unscrew two bolts.
ES130038
5 Pull out 6 metal clips from the instrument panel

forcibly, and remove the body assembly by
avoiding the shift lever and handbrake.
ES130036
3 Remove left and right forward extending plates

of the auxiliary fascia console, and remove 2
snap fasteners connected with the floor bracket.
ES130039
Installation
ES130037
27-20
Replacement of Auxiliary Fascia Console Replacement of Auxiliary Fascia Console

Cup Holder Molding
Removal Removal
1 Remove the auxiliary fascia console body 1 Pry up the auxiliary fascia console molding along
assembly (refer to Auxiliary Fascia Console the edge with a flat-blade screwdriver from
Body). bottom to top.
2 Remove A/C outlet pipes (for the model
equipped with rear air outlets).
3 Remove the screws connecting the cup holder to

the auxiliary fascia console.
ES130041
Installation
4 Remove the auxiliary fascia console cup holder.
Installation
27-21
Replacement of Ashtray Assembly Replacement of Shift Lever Guard Plate

Removal Assembly
Removal
1 Open the ashtray assembly cover plate, and take
out the ashtray. 1 Remove the auxiliary fascia console molding.
2 Unscrew retaining screws. 2 Unscrew four screws.
ES130042 ES130044
3 Pull out the ashtray assembly hard. 3 Pull out 7 metal clips from the auxiliary fascia
console body assembly hard.
ES130043
ES130045
Installation Note：For the vehicle equipped with start-stop

button, carry out the aforesaid operations after
1 Installation is the reverse of removal. disconnecting the battery, and disconnect IMMO
station connector after pulling out 7 clips from
the auxiliary fascia console body.
Installation
27-22
Replacement of Rear Panel Assembly of the Replacement of Front Handbrake Cover Plate
Auxiliary Fascia Console Removal
1 Pull out the metal clips from the auxiliary fascia 1 Move the auxiliary fascia console armrest
console body assembly hard. backwards.
2 Pull out the handbrake cover plate from the
auxiliary fascia console body assembly upwards
hard.
ES130046
2 Unplug the connector.
3 Then remove the rear panel along the air outlet ES130047
direction.
Installation
Installation
Replacement of Left & Right Forward

Extending Plate Assembly of the Auxiliary
Fascia Console
Removal
1 Pull it out towards both sides hard.
Installation
27-23
Replacement of Combination Switch Replacement of Dimmer Switch Assembly

Assembly Removal
Removal
1 Remove the steering wheel assembly (Refer to 2 Remove the driver side lower guard plate
Replacement of Steering Wheel). assembly (refer to Removal of Driver Side Lower
2 Remove the upper and lower steering column Guard Plate Assembly).
shrouds (refer to Replacement of Upper and
3 Disconnect the dimmer switch connector.
Lower Steering Column Shrouds).
4 Remove the dimmer switch assembly.
3 Remove the clock spring and clock spring
returning ring (refer to Replacement of Clock
Spring and Clock Spring Returning Ring).
4 Unscrew 3 bolts connecting the combination

switch to the steering column.
ES130049
Installation
5 Remove the combination switch base and

combination switch assembly.
Installation
27-24
Replacement of Start-stop Switch Replacement of Entertainment Control

Removal Switch
Removal
2 Remove the driver side lower guard plate 1 Disconnect the battery (negative first).
assembly (refer to Removal of Driver Side Lower 2 Remove the central control panel (refer to
Guard Plate Assembly). Replacement of Central Control Panel).
3 Disconnect the start-stop switch connector. 3 Disconnect the entertainment switch connector.
4 Remove the start-stop switch. 4 Remove the entertainment control switch.
ES130055 ES130050
1 Installation is the reverse of removal. 1 Install the control panel first.
2 Connect the entertainment control switch
connector.
3 Install the entertainment control switch.
27-25
Replacement of Hazard Warning Lamp Replacement of Drive Conversion Switch

Switch Assembly Assembly
Removal Removal
1 Disconnect the battery (negative first). 1 Disconnect the battery (negative first).
2 Remove the central control panel (refer to 2 Remove the auxiliary fascia console molding and
Replacement of Central Control Panel). shift lever guard plate (refer to Removal of
Auxiliary Fascia Console Molding and Shift Lever
3 Disconnect the hazard warning lamp switch
Guard Plate).
connector.
3 Disconnect the drive switch connector.
4 Remove the hazard warning lamp switch.
4 Remove the drive conversion switch.
ES130051
ES130052
Installation
Installation
Replacement of Driver Side Window

Regulator Switch Assembly
Removal
2 Remove the driver side front door interior trim
panel assembly (refer to Replacement of Driver
Side Front Door Interior Trim Panel Assembly).
3 Disconnect the driver side window regulator

switch connector.
4 Remove the driver side window regulator switch.
Installation
27-26
Replacement of Central Control Switch Block Replacement of Rearview Mirror Regulating

Assembly Switch
Removal Removal
1 Disconnect the battery (negative first). 1 Disconnect the battery (negative first).
2 Remove the auxiliary fascia console molding 2 Remove the driver side front door interior trim
(refer to Replacement of Auxiliary Fascia panel assembly (refer to Replacement of Driver
Console Molding). Side Front Door Interior Trim Panel Assembly).
3 Disconnect the central control switch block 3 Disconnect the rearview mirror regulating switch
connector. connector.
4 Remove the central control switch block. 4 Remove the rearview mirror regulating switch.
Installation
ES130053
Installation
27-27
Electric
Name Left Right Front High Rear Headlamp Position power AFS
steering steering fog beam fog leveling lamp steering adjustment
lamp lamp
Symbol
Feature
Signal
input mode CAN CAN CAN CAN CAN CAN CAN CAN
No lighting
Color
Lighting Green Green Green Blue Yellow Yellow Green Yellow
ES250009
27-28
Brake Injection Tire

Name HDC Coolant
system Pre-heat Engine malfunction Engine ESP pressure
temperature
malfunction/ indication malfunction indicator immobilizer monitoring
warning
parking
Symbol
Feature
Signal CAN CAN Hard wire CAN CAN CAN CAN CAN CAN
input mode
No
lighting
Color
Lighting Yellow Red Red Yellow Yellow Yellow Yellow Yellow Yellow
ES250011
27-29
Main Auxiliary Water

Name ABS Cruise Airbag EBD EPS Oil
seat seat in
indication OFF pressure
belt belt fuel
Symbol
Feature
Signal input mode Hard

CAN CAN CAN CAN CAN CAN CAN CAN
wire
No lighting
Color
Green
Lighting Yellow Red Red Yellow Red Red Red Yellow
/white
ES250012
27-30
Name Charge/ 4WD Body

Fuel Towing
discharge malfunction LDW anti-theft
warning indication
indication indicator indication
Symbol
Feature
Signal input mode CAN Hard wire CAN CAN CAN CAN CAN CAN CAN
No
lighting
Color
Yellow Green
Lighting Yellow Red Red /green (reserved) Red
ES250013
27-31
27-32
Seats
Seats
Torque
Bolt - seat to body 58 ± 5

Bolt - front seat belt buckle to seat 50 ± 3
Bolt - rear seat belt buckle to body 50 ± 3
Bolt - seat cushion assembly to seat back assembly 45 ± 3
28-1
Seats
Layout
Layout
1 2 1 2
ES160001
Model Single-row model with 2 seats Double-row model with 5 seats
Driver seat 6-way manual/power adjustment 6-way manual/power adjustment
Front passenger seat 4-way manual adjustment/6-way 4-way manual adjustment/6-way

power adjustment power adjustment
Rear seats None Seat cushion can be turned backward

and the seat back forward
28-2
Seats
Repair Guidance
Replacement of Driver Seat and Front Installation
Passenger Seat 1 Firstly insert the seat locator into the locating
Removal hole in the underbody.
1 Disconnect the battery negative and wait for 1 2 Then pre-tighten 4 bolts on the leg brackets to
minute. (For power seat). pre-install the seat on the floor.
2 Remove 4 leg caps. 3 Adjust the slide rail to the rearmost position,
tighten 2 bolts at the front, then adjust the slide
rail to the frontmost position, and tighten the bolt
at the rear end. The tightening torque of the bolts
is 58 ± 5N.m.
4 Connect the seat harness connector.
5
5 Install 4 plastic seat leg caps into each clamp
one by one and clamp the caps into the sheet
metal slot.
2
2
ES160002
3 Remove 4 fastening bolts on the seat leg

bracket.
4 Disconnect the harness connector of seat belt
switch. For vehicles with power seats,
disconnect the seat harness connector.
5 Remove the seat. Pay attention to the locator at
the front mounting point of the seat.
Note：The seat with an airbag is marked with
"AIRBAG" on the lower side of the seat shoulder,
where shall be protected from overpressure
during installation.
28-3
Seats
Replacement of Rear Seats

Removal
1 Turn upward the seat cushion and remove the
seat leg caps.
2 Remove 4 fastening bolts.
3 Remove the seat. Pay attention to the locator at
the front mounting point of the seat.
ES160003
Installation
1 The seat back shall be pre-folded. Insert the seat
locator into the locating hole in the underbody.
2 Then pre-tighten 2 bolts on the back of the seat
leg bracket to pre-install the seat on the floor.
3 Turn upward the seat cushion and pre-tighten
the front mounting point of the seat leg bracket.
4 Finally tighten 2 bolts at the front, then fold down
the seat back and tighten the bolts at the rear
end to 58 ± 5N.m.
5 Turn upward the seat cushion and install the seat
leg cap.
28-4
Seat Belt
Seat Belt
Torque
Bolt - front seat belt upper anchor point 50 ± 5

Bolt - front seat belt lower anchor point 50 ± 5
Bolt - front seat belt retractor upper anchor point 9±1
Bolt - front seat belt retractor lower anchor point 50 ± 5
Bolt - lap belt pretensioner 50 ± 5
Bolt - rear seat belt upper anchor point 50 ± 5
Bolt - rear seat belt lower anchor point 50 ± 5
Bolt - rear seat belt retractor 50 ± 5
Bolt - seat belt buckle 50 ± 5
29-1
Seat Belt
Repair Guidance Replacement of Driver/Front Passenger Seat

Belt (Without Lap Belt Pretensioner)
Precautions for handling expanded
pretightening seat belt or lap belt Removal
pretensioner Warning：For seat belt retractors with
pretensioner, do not start work until the battery
The expanded pretightening seat belt or lap belt
(or any possible auxiliary power supply of the
pretensioner may carry some sodium hydroxide which is
vehicle) is disconnected and the capacitor of the
the by-product of the expansion action, in case of skin or SRS control module is discharged for at least
eye contact, irritation may occur. 10min.
When handling the expanded pretightening seat belt or 1 Disconnect the battery. Note: Disconnect the
lap belt pretensioner, please wear protective gloves and negative first.
glasses. Please wash your hands with soap after the
operation.
Precautions for handling unexpanded 4/5

pretightening seat belt or lap belt
pretensioner
When handling the unexpanded pretightening seat belt 3
or lap belt pretensioner, ensure the back of the gas
generator faces the body.
When handling the pretightening seat belt or lap belt 2

pretensioner, never hold its connector or harness with ES170002
your hands,
2 Remove the bolt of the seat belt lower anchor
and never place any article on the unexpanded point.
pretightening seat belt. 3 Remove the B-pillar lower trim panel.
4 Remove the cap of the height regulator.
5 Remove the seat belt upper anchor point.
6 Disconnect the pretensioner harness (if
equipped).
7 Unscrew the retractor bolt, and remove the seat
belt.
29-2
Seat Belt
Installation
Replacement of Driver/Front Passenger Seat
1 Installation is the reverse of removal. Pay Belt (With Lap Belt Pretensioner)
Removal
—Ensure the assembly is properly located in the Warning：For seat belt retractors with
mounting slot provided. pretensioner, do not start work until the battery
(or any possible auxiliary power supply of the
—Before re-installing the trim panel, ensure the seat belt
vehicle) is disconnected and the capacitor of the
is properly positioned on the trim panel.
SRS control module is discharged for at least
—Reconnect the battery, the positive (+) first. 10min.
—Check the operation of the SRS warning lamp.
—The torque of the seat belt upper/lower anchor point is

50 ± 5N.m.
3/4
—The torque of the retractor upper anchor point is 9 ±
1N.m, and that of the lower anchor point is 50 ± 5N.m.
2 6
ES170005
1 Disconnect the battery.

Note：Disconnect the negative first.
2 Remove the B-pillar lower trim panel.
3 Remove the cap of the height regulator.
ES170003 4 Remove the seat belt upper anchor point.
5 Disconnect the pretensioner harness (if
equipped).
29-3
Seat Belt
6 Disconnect the locking tab from the lap belt Installation

pretensioner. Use the following methods:
1）Insert tool C00089919 into the 2 lap belt pretensioner attention to the following precautions:
holes shown in the figure below.
—Ensure the assembly is properly located in the
mounting slot provided.
—Before re-installing the trim panel, ensure the seat belt

is properly positioned on the trim panel.
—Reconnect the battery, the positive (+) first.
—Check the operation of the SRS warning lamp.
—The torque of the seat belt upper anchor point is 50 ±

5N.m.
—The torque of the retractor upper anchor point is 9 ±

1N.m, and that of the lower anchor point is 50 ± 5N.m.
ES170010
2）Insert a sharp object into the hole on the opposite side

of the lap belt pretensioner to remove the locking tab.
ES170011
29-4
Seat Belt
Replacement of Height Regulator Replacement of Lap Belt Pretensioner (If

Removal Any)
Removal
2 Remove the B-pillar upper trim panel. 1 Disconnect the locking tab from the lap belt
pretensioner. For specific procedures, please
3 Remove the bolt of the height regulator.
refer to Replacement of Driver/Front Passenger
4 Remove the height regulator. Seat Belt (With Lap Belt Pretensioner).
2 Remove the anchor point of the lap belt
pretensioner.
Installation
1 Installation is the reverse of removal. The torque
of the height regulator is 50 ± 5N.m.
ES170006
Installation
of the lap belt pretensioner bolt is 50 ± 5N.m.
29-5
Seat Belt
Installation
Replacement of Rear Seat Belt
Removal
of the seat belt upper/lower anchor point and
retractor bolt retaining point is 50 ± 5N.m.
3/4 2 After the rear seat is installed, to prevent the belt
7
buckle from dropping under the seat, please
6 pass it through the bungee provided for the seat.
ES170008
1 Remove the seat belt lower anchor point.

2 Remove the C-pillar lower trim panel.
3 Remove the trim cover of the seat belt guide ES170009
ring.
5 Remove the anchor point of the side seat belt
retractor, and remove the side seat belt
assembly.
6 Remove the C-pillar upper trim panel.
7 Remove the rear trim panel.
8 Remove the anchor point of the middle seat belt
retractor, and remove the middle seat belt
assembly.
29-6
Seat Belt
Replacement of Front/Rear Seat Belt Buckle Special Tool

Removal
1 Disconnect the harness of the seat belt buckle (if
any). Tool Number and Illustration
Description
2 Remove the seat belt buckle bolt.
3 Remove the seat belt buckle.
C00089919
Unlocking device for
Installation dual pretightening
1 Installation is the reverse of removal. The torque seat belt
of the seat belt buckle bolt is 50 ± 5N.m. C00089919
29-7
Seat Belt

Seat Belt Check/Test
In case of impact, perform the following checks/tests for
the seat belt unused in the impact, if any damage is
found, install new seat belt parts.
1 Check the appearance for obvious mechanical

damage, if any, replace the parts. Check if all
bolts and screws of the seat belt are secure. The
buckle shall be easily locked and unlocked.
Insert the locking plate into the buckle, and push
the belt hard. The buckle shall not be loose. Pull
out all shoulder straps, and ensure the strap is
not twisted or torn.
2 The seat belt pretensioner is controlled as a part
of the SRS. When turning the ignition switch to
START position, the SRS warning lamp will
illuminate for 4s. If the self-test of the system is
OK, the SRS warning lamp will be off. If any
failure occurs (airbag or seat belt pretensioner),
the SRS warning lamp will illuminate the SRS
warning lamp on the instrument panel.
3 Test seat belt retaining performance: keep the
vehicle stationary, park the vehicle on the level
road, and tightly hold the seat belt and pull it out
swiftly, the retractor shall retract within appr.
0.05m, and the damaged belt will be pulled
beyond this range, then renew the seat belt
assembly. CAUTION: All seat belts (including the
retractor, buckle and other hardwares) used in
the impact shall be replaced with a new seat belt
assembly. Never attempt to service or lubricate
the retractor/buckle mechanism or modify the
seat belt. After replacement, if the seat belt
cannot properly retract to the retractor, check if
the trim panel is properly installed or if it rubs the
seat belt. If any friction appears, release the bolts
and correct the retractor to keep the seat belt in
the center and then tighten the bolts.
29-8
Rear Body
Rear Body
Torque
Bolt/screw - rear panel hinge (mounting) 22 ± 2

Bolt/screw - rear panel hinge (mounting) 45 ± 5
Bolt/screw - rear panel cover plate/cargo box cover 9±1
(mounting)
Bolt/screw - rear panel stopper mounting bracket 22 ± 2

Bolt - fasten the rear bumper assembly to the rear bumper 40 ± 5
mounting bracket
30-1
Rear Body
Layout
Rear Panel Layout
5 4
7
3
2
ES200000
1 Tailgate Sheet Metal Assembly 5 Tailgate Panel Mounting Screw

2 Tailgate Max. Opening Limiter 6 Tailgate Hinge Mounting Screw
3 Tailgate Hinge Assembly 7 Tailgate Limiter Mounting Screw
4 Tailgate Inner Panel Cover
30-2
Rear Body
Rear Bumper Layout
6
8 9 10
7
2
5
1
11
4
12
11
ES200005
1 Rear Bumper Middle Section Assembly 7 Nut - Rear Bumper Middle Section Assembly
2 Bolt/Screw - Rear Bumper Bracket to Vehicle 8 Nut - Rear Bumper Middle Section Assembly
Frame
9 Bolt/Screw - Rear Bumper Assembly
3 Rear Bumper Interior Side Panel
10 Bolt - Rear Bumper Middle Section Assembly
4 Rear Bumper License Plate Lamp Trim Panel
11 Mounting Bracket - Rear Bumper Assembly
5 Rear Bumper Trim Panel
12 Bolt/Screw - Rear Bumper Bracket to Rear
6 Plug Cap - Rear Bumper Bumper
30-3
Rear Body
4 Remove the rear panel hinge assembly.

Repair Guidance
Rear Panel Replacement
Removal
1 Open the rear panel.
2 Remove the cover of the rear panel inner panel.
ES200003
5 Remove the rear panel from the vehicle.
Installation
ES200001
3 Remove the rear panel stopper for maximum
opening. —Tighten the hinge bolts of the rear panel to the torque
of 22 ± 2N.m and 45 ± 5N.m.
ES200002
30-4
Rear Body
Rear Bumper Assembly Replacement

Removal
1 Remove the bolt retaining rear bumper assembly
to rear bumper mounting bracket.
ES200004
2 Remove the rear bumper assembly.
Installation
—Tighten the bolt retaining rear bumper assembly to rear
bumper mounting bracket to the torque of 40 ± 5N.m.
30-5
Rear Body
30-6
Entertainment System
Layout
Layout
ES230000
1 Radio+MP3 3 MP5 display

2 Radio+MP5+Mirrorlink
31-1
Repair Guidance
Replacement of Radio+MP3
Replacement of MP5 display
Removal
Removal
2 Remove the central control panel of the
2 Remove the central control panel of the
instrument panel.
instrument panel.
3 Remove 4 bolts fixing the radio+MP3 to the
3 Remove 6 bolts(4) fixing the MP5 display to the
instrument panel body.
instrument panel body.
1
2
4 3
ES230001
ES230003
4 Disconnect the electrical connector. 4 Disconnect the electrical connector.

5 Remove the Radio+MP3 assembly.
5 Remove the MP5 display assembly (3).
ES230002
ES230004
31-2
Replacement of Radio+MP5+Mirrorlink Replacement of Printed Antenna Amplifier

Removal Removal
2 Remove the MP5 display. 2 Remove the right A-pillar lower trim panel
3 Remove 4 bolts (2) fixing the assembly.
radio+MP5+Mirrorlink to the instrument panel 3 Disconnect the electrical connector.
body. 4 Remove the bolt fixing the amplifier to the right
A-pillar connecting plate.
1
2
4 3
ES230005
ES230007
5 Remove the radio+MP5+Mirrorlink assembly (1). 5 Remove the instrument panel body.
7 Unloose the stripe fixing the antenna harness to

the instrument panel harness.
ES230006
8 Remove the printed antenna amplifier assembly.
Installation
31-3
Replacement of Front Loudspeaker Replacement of Rear Loudspeaker

Removal Removal
2 Remove the front door interior trim panel 2 Remove the front door interior trim panel
assembly. assembly.
3 Remove 4 bolts fixing the front loudspeaker to 3 Remove 4 bolts fixing the rear loudspeaker to the
the front door. front door.
ES230009 ES230009
4 Disconnect the electrical connector. 4 Disconnect the electrical connector.
5 Remove the front loudspeaker assembly. 5 Remove the front loudspeaker assembly.
31-4
Replacement of Front Loudspeaker (Treble)

Removal
2 Remove the A-pillar upper trim panel.
3 Remove the front loudspeaker grille.
4 Remove 2 bolts fixing the front loudspeaker to
the instrument panel.
ES230010
6 Remove the front loudspeaker assembly.
Installation
31-5
31-6
Front Body
Front Body
Torque
Bolt - engine hood hinge 22 ± 2

Bolt - fender 9±1
32-1
Front Body
Layout
Engine Hood and Fender Layout
3
11
10
14
1
13
2
4
8 12
7 6
ES190000
1 Hood Assembly 8 Spring Mounting Bracket Bolt

2 Hood Hinge Assembly 9 Hood Gas Spring Upper Ball Head
3 Hood Hinge Assembly 10 Hood Bumper Block
4 Hood Hinge Mounting Bolt 11 Hood Bumper Block
5 Hood Rear Weatherstrip 12 Hood Strut
6 Hood Gas Strut 13 Engine Compartment Lock Front Weatherstrip
7 Hood Gas Spring Mounting Bracket 14 Engine Compartment Lock Front Weatherstrip
32-2
Front Body
Fender Layout
5
6
1
2 3
ES190007
1 Fender 4 Fender Thermal Baffle

2 Fender Support Part 5 Snap Fastener
3 Fender Mounting Bolt 6 Fender Acoustic Baffle
32-3
Front Body
Front Bumper Assembly Layout
6
6
10
7 11
5 9
4
4
8
7
2
3
ES190006
1 Front Bumper Fascia 7 Bolt/Screw - Front Bumper

2 Front Bumper Lower Grille 8 Screw - Front Bumper to Fender
3 Front Bumper Lower Trim Panel 9 Nut - Front Bumper Fascia and Fender
4 Fog Lamp Frame 10 Screw - Front Bumper Mounting Bracket to
Fender
5 Spring Nut - Front Bumper Assembly
11 Nut - Front Bumper Mounting Bracket
6 Front Bumper Bracket
32-4
Front Body
Repair Guidance Replacement of Fender
Replacement of Engine Hood Removal
Removal 1 Open the engine hood and support it properly.

2 Disconnect the negative battery.
3 Remove the headlamp assembly.
2 Pull the release handle of the engine hood.
4 Remove the front bumper.
3 Lift and support the engine hood.
5 Remove the front wheelhouse liner.
4 Install the protective cover on the fender to avoid
paint damage during engine hood installation/ 6 Remove all bolts fixing the fender to the body.
removal.
5 Mark the position of the engine hood hinge
relative to the engine hood to re-install the
engine hood.
6 Remove the bolt of the engine hood hinge.
ES190002
7 Remove the fender.
ES190001 Installation
7 Remove the engine hood. attention to the following precautions:
—Tighten the bolt of the fender to 9 ± 1N.m.
Installation
—Tighten the hinge bolt of the engine hood to 22±2N.m.
Note：Discard the engine hood handle removed,

and replace the engine hood.
32-5
Front Body
Replacement of Front Bumper Assembly 4 Remove the snap fastener (1), self-tapping
screw and big washer component (2) fixing the
Removal
front bumper assembly to the front wheelhouse
1 Disconnect the harness of the front fog lamp. liner.
2 Remove the bolt (1) fixing the front bumper
assembly to the front beam; the bolt (2) fixing the
front bumper assembly to the fender and the bolt 1
(3) fixing it to front small bracket respectively.
1
2
ES190005
2 2
5 Remove the front bumper assembly.

3
ES190003
Installation
3 Remove the snap fastener fixing the front 1 Installation is the reverse of removal.
bumper assembly to the lower baffle of front
bumper.
ES190004
32-6
Frame
Frame
Torque
1
3 8
8
2 7
6
12 5 10
11
ES150007
No. Part Name Tightening torque (N.m)
Bolt/nut - body to frame 70 ± 5

1 Integral frame longitudinal thrust beam
2 Integral frame 3rd beam (middle section)
3 4th beam bracket assembly (middle section)
4 Integral frame 4th beam reinforcing beam
6 Bolt - 4th beam reinforcing beam 110 ± 10

7 Bolt - connect the 4th beam 70 ± 10
8 Nut - the 3rd beam 70 ± 10
9 Bolt - the 3rd beam 70 ± 10
10 Nut - longitudinal thrust beam to 2nd beam 70 ± 10
11 Bolt - longitudinal thrust beam to 2nd beam 70 ± 10
12 Bolt - longitudinal thrust beam 70 ± 10
33-1
Frame
Layout
BIW Layout
ES150012
33-2
Frame
Body Frame Layout
3
2
2
1 3
ES150013
1 Bodyside Inner Panel Assembly 3 Rear End Panel Assembly

2 Bodyside Outer Panel Assembly
33-3
Frame
Roof Frame Layout
1 5
7 3 4
ES150014
1 Roof Outer Panel 6 Rear Roof Beam Assembly

2 Front Frame Assembly 7 Roof Outer Panel
3 No.1 Roof Beam 8 Front Sunroof Beam Frame Assembly
4 No.2 Roof Beam 9 Front Frame Assembly
5 No.3 Roof Beam
33-4
Frame
Front Floor Layout
1 3
ES150015
1 Front Floor Central Channel Reinforcement 4 Door Sill Inner Panel Assembly
Assembly
5 Door Sill Inner Panel Assembly
2 Front Floor
6 Front Floor Beam Assembly
3 Front Floor Reinforcement
7 Floor Beam
33-5
Frame
Rear Floor Layout
ES150016
1 Rear Floor 2 No.4 Suspension Beam Reinforcement

Assembly
33-6
Frame
Front Compartment Frame Structure
1
5
2
4
3
ES150017
1 Dash Panel Assembly 4 Upper Radiator Beam Welding Assembly

2 Front Wheelhouse Side Beam Assembly 5 Headlamp Upper Beam Assembly
3 Headlamp Upper Beam Assembly 6 Front Wheelhouse Side Beam Assembly
33-7
Frame
Cargo Compartment Assembly
1
2
ES150018
1 Side Cargo Guard Outer Panel Assembly 4 Cargo Compartment Beam

2 Side Cargo Guard Inner Panel Assembly 5 Cargo Bed
3 Front Cargo Guard Panel Assembly
33-8
Frame
Body Mount Layout
5
4
1 3
2
ES150000
1 Body mount 1 4 Body mount 4

2 Body mount 2 5 Cargo box soft gasket
3 Body mount 3
33-9
Frame
Body Suspension Point Layout
ES150001
Double row seat (4 rows of body mounts)
33-10
Frame
ES150009
One and a half row seat (3 rows of body mounts); based on double row seat cabin, with body shortened and cargo box
lengthened.
33-11
Frame
ES150010
Single row seat (3 rows of body mounts); based on one and a half row seat cabin, with body shortened and cargo box
lengthened.
33-12
Frame
ES150011
Large space double row seat (4 rows of body mounts); based on double row seat cabin, with body unchanged and cargo
box lengthened.
33-13
Frame
Repair Guidance Upper Soft Gasket Identification
Mount Installation 1 The mount of the 1st row is the lowest.

2 Mounts of the 2nd/3rd row.
1 Install upper gasket 1 on the frame.
2 Install the body, and align the frame with the
body mounting hole.
3 Install the left mount of the second row first.
·Pass bolt 2 through the body hole from top to bottom.
·Install limit sleeve 3 and lower soft gasket 4.
·Install nut 5. The sleeve controls the initial compression

of the upper/lower soft gasket, tighten the nut to allow
the frame of the upper/ lower soft gasket and the two
ends of the sleeve to touch the limit device. The nut
torque is 70 ± 5N.m.
ES150004
3 Mounts of the 4th row.
1
3
5
ES150003
4 Install the left mount of the 4th row (if any), then
ES150005
install the remaining mounts (the 1st row, 2nd
row (right), 3rd row, 4th row (right)). For specific
installation procedures, follow the procedures of
the left mount of the second row.
33-14
Frame
Lower Soft Gasket Identification
1 The soft gasket of the 1st and 4th rows has a

smaller hole, and the soft gasket of the front 1st
row is higher than that of the 4th row.
ES150006
2 The soft gasket of the 2nd and 3rd rows has a

larger hole.
ES150008
Limit Sleeve Identification

The limit sleeve of the 1st row is the shortest, and that of
the last three rows is long; the limit sleeves of the 2nd row
and 3rd row are identical and thicker than that of the 4th
row.
33-15
Frame
33-16
Stationary Windows
Stationary Windows
Layout
Layout
ES210000
1 Rear window
34-1
Stationary Windows
Fixed Window Layout
2
ES210006
1 Windshield Assembly 3 Rear Door Window Glass

2 Front Door Window Glass 4 Rear Window Assembly
34-2
Stationary Windows
Repair Guidance Replacement of Rear Door Glass
Replacement of Front Door Glass Removal
Removal 1 Remove the interior trim panel and waterproof

membrane of the door.
1 Remove the interior trim panel and waterproof
2 Descend the door window till the gripper
membrane of the door.
securing the rear door glass is exposed, loosen
2 Lift the window regulator to the top till the nut
the gripper.。
securing the front door glass is exposed, loosen
the nut (without removal) and then descend the
window regulator to some extent (for the
convenience of glass removal).
ES210002
3 Pull the door glass upward and outward from the

door.
ES210001
3 Pull the glass upward and outward from the door.

Installation
Installation
34-3
Stationary Windows
2 Fully shake the glass primer and paint primer.

Replacement of Windshield
Dip a small amount of mixture with a clean brush
Removal or gauze and evenly wipe the surface of the
glass and top fixing frame which have been
1 Remove the interior mirror, refer to the
cleaned by cleaner. One-time instead of
Replacement of Interior Mirror.
repeated painting is required with drying time of
2 Disconnect the rain sensor harness connector (if approximately 5-15 minutes.
equipped).
3 Remove the wiper arm. Refer to Replacement of

Wiper Arm.
4 Remove the windshield cover plate assembly

and windshield cover plate trim cover. Refer to
Replacement of Windshield Cover Plate
Assembly.
5 Cut the adhesive around the windshield with tool.
ES210004
3
ES210003
Installation
1 Wipe the inner surface of glass with clean cloth ES210005
or bleached fiber (roll paper) immersed with a
proper amount of specified glass cleaner, and Note：The surface coated with primer must be dry
clean the body paint with organic solvent inactive and free from dust, grease and other
to the surface (such as acetone), then dry it for at
contaminants that may affect adhesion. Shake up
least 5 minutes.
the primer to prevent it from precipitation each
Note：The used cloth or bleached fiber (roll paper) time it is not in use for a long period.
must be replaced. Use the cleaner directly and
Warning：Do not apply primer onto the body and
never dilute it with water.
glass with any remaining polyurethane adhesive,
Warning：To avoid any adverse reaction between otherwise it may result in poor adhesion of the
cleaner and primer or polyurethane adhesive, newly coated polyurethane adhesive.
prevent the cleaner from contacting with newly
3 Apply a layer of 8mm wide polyurethane
painted primer or polyurethane adhesive. Do not
adhesive evenly, continuously and vertically
use the cleaner to remove excess primer or
around the windshield with standard pneumatic
polyurethane adhesive; the surface to be cleaned or manual glue gun by reference to the glue
must be complete dry before applying primer or track.
polyurethane adhesive.
34-4
Stationary Windows
4 Align the upper locating pin of the windshield

Replacement of Rear Window
with the body hole.
The replacement procedures of the rear window are
5 Press the windshield in place.
similar to that of the windshield. But note: Please
6 Stick tape around the windshield to keep it in the disconnect/connect the harness connector during
correct installation position until the polyurethane removal and installation of the rear window with heating
adhesive is solidified.
wire.
Note：For moisture-curable polyurethane
adhesive, solidify it at 21 °C (70 °F) or higher
temperature and the relative humidity no less
than 30% for at least 6 hours. It takes at least 24
hours for the polyurethane adhesive to be fully
solidified. For chemical-curable polyurethane
adhesive, solidify it for at least 1 hour. DO NOT
touch the repaired area until the minimum
solidification time has elapsed.
7 Conduct a rain test, that is, shower the
windshield softly with warm water to check the
windshield for any sign of leakage.
8 If any leakage is found, apply more polyurethane

adhesive around the leakage point. If it still
leaks, remove the windshield and repeat the
whole procedure.
9 Install the windshield cover plate assembly and

windshield cover plate trim cover.
10 Install the wiper arm.
11 Connect the rain sensor harness connector (if

equipped).
12 Install the interior mirror.
34-5
Stationary Windows
34-6
Door
Door
Torque
Bolt - front door hinge 26 ± 3

Bolt - front door check 9±1
Bolt - rear door hinge 26 ± 3
Bolt - rear door check 9±1
Bolt - fix front door lock catch assembly to sheet metal 22 ± 2
Bolt - fix rear door lock catch assembly to sheet metal 22 ± 2
Bolt - fix rear panel lock assembly to rear panel 22 ± 2
Bolt - fix rear panel lock assembly to cargo box side wall 22 ± 2
35-1
Door
Layout
Front Door Layout
3 1
2
4
5
6
7
8
9
10
11 7
ES300000 12
1 Front Door Welding Assembly 7 Front Door Hinge Bolt

2 Front Door Weatherstrip 8 Front Door Hinge Bolt
3 Front Door Frame Weatherstrip 9 Front Door Check Assembly
4 Front Door Outer Weatherstrip 10 Front Door Check Bolt
5 Front Door Outer Weatherstrip Mounting Screw 11 Front Door Lower Hinge Assembly
6 Front Door Upper Hinge Assembly 12 Front Door Bumper Block
35-2
Door
Rear Door Layout
2 1
3
6 5
7
8
10
11 7
1 Rear Door Welding Assembly 7 Rear Door Hinge Bolt

2 Rear Door Weatherstrip 8 Rear Door Hinge Bolt
3 Rear Door Frame Weatherstrip 9 Rear Door Check Assembly
4 Rear Door Outer Weatherstrip 10 Rear Door Check Bolt
5 Rear Door Outer Weatherstrip Mounting Screw 11 Rear Door Lower Hinge Assembly
6 Rear Door Upper Hinge Assembly
35-3
Door
Door Lock Layout
3
1
7
5 16
9
10
12 8
14 15
13
18
17
20
13
19 22
11
26
24
25
21
23 25
ES300033
1 Front Door Outer Handle Cover (driver side) 9 Front Door Lock Cylinder Deflector Rod
2 Front Door Outer Handle Cover (front passenger 10 Front Door Inner Handle Cable Assembly
side)
11 Front Door Lock Catch Assembly
3 Front Door Outer Handle Outer Tie Rod
12 Screw/Bolt - Front Door Lock Assembly
Assembly
13 Screw/Bolt - Front Door Lock Catch
4 Front Door Outer Handle Bracket Assembly
14 Plug Cap - Front Door Lock Emergency
5 Seal Washer - Front Door Outer Handle
Lockhole
Assembly
15 Rear Door Outer Handle Cover
6 Plug Cap - Front Door Outer Handle
16 Rear Door Outer Handle Outer Tie Rod
7 Front Door Outer Handle Tie Rod
Assembly
8 Front Door Lock Assembly
17 Rear Door Outer Handle Bracket Assembly
35-4
Door
18 Seal Washer - Rear Door Outer Handle 21 Rear Door Lock Assembly
Assembly
22 Rear Door Inner Handle Cable Assembly
19 Plug Cap - Rear Door Outer Handle
23 Rear Door Lock Catch Assembly
20 Rear Door Outer Handle Tie Rod
24 Bolt/Screw - Rear Door Lock
35-5
Door
Window Regulator Layout
9
4 7
5
4 9
1
2
10
3
8
ES300034
1 Front Door Window Regulator Assembly 6 Rear Door Window Regulator Assembly
2 Front Door Rear Guide Rail Assembly 7 Rear Door Rear Guide Rail Assembly
3 Front Door Window Weatherstrip 8 Rear Door Window Weatherstrip
4 Nut - Front Door Window Regulator 9 Nut - Rear Door Window Regulator
5 Screw - Front Door Window Guide Rail 10 Bolt/Screw- Rear Door Window Guide Rail
35-6
Door
Repair Guidance
Replacement of Front Door/Hinge 13 Remove the front door.
Removal
1 Open the front door and support it.
Installation
2 Remove the front door interior trim panel.
3 Remove the front door waterproof membrane. attention to the following precautions:
4 Remove the front door glass and regulator. —Tighten the hinge bolt of the front door to the torque of
5 Remove the front door lock and link. 26 ± 3N.m
6 Remove the loudspeaker assembly. —Tighten the hinge bolt of the front door check to the
7 Remove the exterior mirror.
8 Remove the front door inner/outer handle.
10 Disconnect the front door harness from the front

door.
11 Remove the front door check.
ES300029
12 Remove the front door upper/lower hinge.
ES300030
35-7
Door
12 Remove the rear door.

Replacement of Rear Door/Hinge
Removal
1 Open the rear door and support it. Installation
2 Remove the rear door interior trim panel. 1 Installation is the reverse of removal. Pay
3 Remove the rear door waterproof membrane.
—Tighten the hinge bolt of the rear door to the torque of
4 Remove the rear door glass and regulator.
26 ± 3N.m
5 Remove the rear door lock and link.
—Tighten the hinge bolt of the rear door check to the
6 Remove the loudspeaker assembly.
7 Remove the rear door inner/outer handle.
9 Disconnect the rear door harness from the rear

door.
10 Remove the rear door check.
ES300031
11 Remove the rear door upper/lower hinge.
ES300032
35-8
Door
4 Disconnect the front door lock assembly from the

Replacement of Front Door Lock Assembly
front door lock cylinder lever.
Removal
1 Remove the front door trim panel.
2 Remove the bolt fixing the front door lock
assembly to the sheet metal.
ES300003

front door outer handle link.
ES300001

front door inner handle cable assembly.
ES300004
6 Remove the door harness connector of the front

door lock assembly, and remove the front door
lock assembly.
ES300002
Installation
35-9
Door
Replacement of Front Door Lock Catch Replacement of Rear Door Lock Assembly
Removal Removal
1 Remove the bolt fixing the front door lock catch 1 Remove the rear door trim panel.
2 Remove the bolt fixing the rear door lock
ES300005
ES300006
2 Remove the front door lock catch assembly.
3 Disconnect the rear door lock assembly from the

rear door inner handle cable assembly.
Installation
—Tighten the bolt fixing the front door lock catch
assembly to the sheet metal to the torque of 22 ± 2N.m.
ES300007
35-10
Door
4 Disconnect the rear door lock assembly from the

Replacement of Rear Door Lock Catch
rear door outer handle link.
Assembly
Removal
1 Remove the bolt fixing the rear door lock catch
ES300008
5 Remove the door harness connector of the rear

door lock assembly, and remove the rear door
lock assembly. ES300009
2 Remove the rear door lock catch assembly.

Installation
Installation
—Tighten the bolt fixing the rear door lock catch
assembly to the sheet metal to the torque of 22 ± 2N.m.
35-11
Door
Replacement of Rear Panel Lock Assembly Replacement of Rear Panel Lock Catch
Removal Assembly
Removal
1 Remove the bolt fixing the rear panel lock
assembly to rear panel. 1 Remove the bolt fixing the rear panel lock
assembly to rear panel.
ES300010
ES300012
2 Disconnect the rear panel lock assembly from
the rear panel outer link. 2 Remove the rear panel lock catch assembly.
Installation
—Tighten the bolt fixing the rear panel lock catch
assembly to the cargo box side wall to the torque of
22 ± 2N.m.
ES300011
3 Remove the rear panel lock assembly.
Installation
—Tighten the bolt fixing the rear panel lock assembly to
the rear panel to the torque of 22 ± 2N.m..
35-12
Door
Replacement of Engine Hood Lock Assembly Replacement of Front/Rear Door Outer

Removal Handle
Removal
1 Remove the bolt of the engine hood lock
assembly. 1 Remove the bolt of the engine hood lock
assembly.
2 Remove the front/rear door waterproof
membrane.
3 Remove the link of the front door lock cylinder
and that of the front/rear door outer handle.
4 Remove the front door lock cylinder from the
bracket screw of the front door outer handle.
5 Remove the front/rear door outer handle from
the bracket screw of the front/rear door outer
handle.
6 Remove the cover of the front/rear door outer
handle.
ES300013
2 Disconnect the engine hood lock assembly from

the engine hood unlock cable and harness
connector.
ES300015
7 Remove the front/rear door outer handle.
ES300014
Installation
3 Remove the engine hood lock assembly. 1 Installation is the reverse of removal.
Installation
35-13
Door
Replacement of Front/Rear Door Inner Replacement of Rear Panel Outer Handle

Handle Assembly
Removal Removal
1 Remove the front/rear door interior trim panel. 1 Remove the bolt fixing the rear panel outer
2 Remove the base of the front/rear door inner handle assembly to rear panel.
handle.
ES300018
ES300016
2 Disconnect the rear panel outer handle assembly
3 Remove the front/rear door inner handle from its from the rear panel lock link.
base.
ES300019
ES300017
Installation
35-14
Door
3 Remove the bolt fixing the reverse camera to the

Replacement of Exterior Mirror
rear panel outer handle assembly.
Removal
1 Remove the bolt fixing the exterior mirror to the
body sheet metal.
ES300020
4 Remove the rear panel outer handle assembly.

ES300021
Installation 2 Disconnect the exterior mirror harness from the

1 Installation is the reverse of removal. door harness.
3 Remove the exterior mirror.
Installation
35-15
Door
4 Remove the harness connector of the front door

Replacement of Front Door Glass Regulator
glass regulator assembly motor.
Assembly
Removal
membrane of the front door.
2 Remove the nut fixing the front door glass
regulator assembly to front door welding
assembly.
ES300024
5 Remove the front door glass regulator assembly.
Installation
ES300022
3 Remove the front door glass.
ES300023
35-16
Door
4 Remove the harness connector of the rear door

Replacement of Rear Door Glass Regulator
glass regulator assembly motor.
Assembly
Removal
membrane of the rear door.
2 Remove the nut fixing the rear door glass
regulator assembly to rear door welding
assembly.
ES300027
5 Remove the rear door glass regulator assembly.
Installation
ES300025
3 Remove the rear door glass.
ES300026
35-17
Door
Replacement of Fuel Filler Flap Assembly

Removal
1 When it is powered on, push the button of the
fuel filler flap to open it.
2 Fully open the fuel filler flap with hands.
3 Remove 4 rivets from the fuel filler flap.
ES300028
4 Remove the fuel filler flap.
Installation
Install 4 rivets according to the corresponding hole, and
keep them aligned.
35-18
Supplemental Inflatable Restraint (SIR)
Specification
Torque
Bolt - curtain airbag 9±1

Screw/bolt - instrument panel (front passenger) airbag 9±1
assembly
Bolt/screw - airbag side impact sensor 10 ± 1.5
36-1
Layout
Layout
2 1
ES120001
1 Driver airbag assembly 3 Curtain airbag assembly

2 Instrument panel (front passenger) airbag
assembly
36-2
Layout
ES120004
1 Airbag control module
36-3
Layout
1
ES120005
1 Airbag front impact sensor 2 Airbag side impact sensor
36-4
Repair Guidance
Replacement of Airbag Control Module
Replacement of Airbag Front Impact Sensor
Removal
Removal
2 Remove the air conditioning host.
4 Remove 3 nuts securing airbag ECU to the
4 Remove 2 bolts securing the airbag front impact
reinforcing plate of front floor central channel.
sensor to the lower radiator beam.
ES270002
ES270003
5 Remove the airbag control module assembly.

5 Remove the airbag front impact sensor
assembly.
Installation
ES270004
Installation
36-5
Replacement of Airbag Side Impact Sensor Replacement of Driver Airbag Assembly

Removal Removal
1 Disconnect the negative battery cable. Warning：DO NOT remove the airbag until the
battery (or any possible auxiliary power supply of
2 Disconnect the electrical connector
the vehicle) is disconnected and the capacitor of
3 Remove 2 bolts securing the airbag side impact SRS control module is discharged for at least
sensor to the lower interior trim panel of B-pillar. 10min.

2 Make sure that the wheels are in a position of
straight driving and loosen the lower screws of
steering wheel on both sides.
ES270005
4 Remove the airbag side impact sensor

assembly.
ES120002
3 Lift the airbag module from the steering wheel

carefully and disconnect the airbag electrical
connector.
Note：The airbag electrical connector has a safety

buckle to secure it in place. Loosen the safety
buckle before removing the connector.
4 Store the airbag in place according to storage
requirements.
ES270006
Installation
Installation
—Re-tighten the safety buckle when installing the
electrical connector.
—Ensure correct wiring.
—Check the operation of SRS warning lamp after

installation.
36-6
Replacement of Instrument Panel (front Replacement of Curtain Airbag Assembly

passenger) Airbag Assembly Removal
Removal Warning：DO NOT remove the airbag until the
Warning：DO NOT remove the airbag until the battery (or any possible auxiliary power supply of
battery (or any possible auxiliary power supply of the vehicle) is disconnected and the capacitor of
the vehicle) is disconnected and the capacitor of SRS control module is discharged for at least
SRS control module is discharged for at least 10min.
10min.
1 Disconnect the battery (negative first). 2 Remove the A-pillar upper trim panel and driver
2 Remove the glove box (Refer to Replacement of compartment roof trims (Refer to Replacement of
Glove Box). Pillar Trim Panel and Driver Compartment Roof
Trims).
3 Remove the instrument panel assembly (Refer to
Replacement of Instrument Panel Assembly). 3 Disconnect the curtain airbag electrical
connector carefully.
4 Disconnect the lighting switch and electrical
connector. 4 Unscrew the bolt securing the curtain airbag to
body.
5 Unscrew 2 bolts securing the airbag to the
instrument panel cross member assembly.
6 Lift the airbag from instrument panel carefully,

loosen electrical connector safety buckle and
disconnect the harness connector.
7 Store the airbag in place according to storage

requirements.
Installation
ES120003
—Tighten the airbag bolt to the torque of 8-10N.m.
—Reconnect the battery, the positive (+) first. 5 Store the left (right) curtain airbag in place
according to storage requirements.

Installation
installation.
—Tighten the airbag bolt to the torque of 8-10N.m.

installation.
36-7
36-8
Body Control System
Body Control System
Layout
Layout
ES280000
1 Body control module
37-1
Body Control System
Layout
1 2
ES280001
1 Gateway 2 Towing module
37-2
Body Control System
Layout
1
2
ES280002
1 Rain/solar sensor 2 LDW control module
37-3
Body Control System
Repair Guidance
Replacement of Body Control Module
Replacement of Trailer Module
Removal
Removal
2 Remove the glove box assembly.
2 Lift the cushion of the rear seats.
3 Remove the right A-pillar lower trim panel.
5 Remove 4 nuts fixing the BCM to the bracket.
ES280005

ES280003
6 Remove the BCM assembly.

7 Remove 3 bolts fixing the BCM bracket to the
front panel.
ES280006
4 Remove 2 bolts fixing the trailer module to the

floor.
ES280004
8 Remove the BCM bracket.
Installation
37-4
Body Control System
5 Remove the trailer module assembly.

Replacement of Gateway
Removal
2 Lift up the front carpet.
4 Remove 3 nuts securing the gateway to the floor.
ES280007
Installation
ES280008
5 Remove the gateway assembly.
Installation
37-5
Body Control System
5 Remove the LDWS control module assembly.

Replacement of LDWS Control Module
Removal
2 Remove the cover of the rain/solar sensor.
ES250006
Installation
ES250004
ES250010
37-6
Body Control System
4 Remove the rain/solar sensor assembly.

Replacement of Rain/Solar Sensor
Removal
2 Remove the cover of the rain/solar sensor.
ES280010
Installation
ES280009
ES250005
37-7
Body Control System

When the driver has no intention of departing from the original lane (does not enable the direction indicator lamp), the
lane departure warning system (LDWS) can send an alarm by sound and light before the departure to alert the driver to
correct the direction. It prevents entrance into other lanes and even the collision with other vehicles, thus dramatically
reducing collisions due to departure.
Function Description
1 When the power mode is switched to KL15, the LDWS activates the alarm function automatically. The user
can disable the alarm function manually, then the yellow warning lamp on the instrument will alert the user
that the function is disabled.
2 When the vehicle speed reaches 60km/h, the LDWS enables the alarm function, then if the vehicle departs
from the lane and goes across the lane line, the system gives an alarm by sound and light; when it speeds
down to 50km/h, the LDWS stops the alarm function.
3 The LDWS can accurately detect and identify the following lane lines:
a.Solid line and dash line;
b.Single solid line and double solid line;
c.White and yellow lines.
4 The LDWS can accurately detect and identify lane line on roads with a turning radius greater than 250m and
straight roads.
Instrument Warning Lamp
Standby 1 If the LDWS is enabled, when driving at a speed of 60km/h or above

and the system detects left/right lane line, the indicator of the LDWS
will be illuminated in green.
2 If the conditions for activating the alarm are met, and it changes the
lane without applying the direction indicator lamp, the warning lamp
flashes and the buzzer sends an alarm.
Not in Standby 1 When the LDWS is disabled, the yellow warning lamp is normally on;
2 If the lane line cannot be identified due to weather or other reasons,
the yellow warning lamp is normally on;
3 If the LDWS does not connect with the power supply and network,
the yellow warning lamp flashes.
37-8
PEPS and Immobilizer System
PEPS-ECU Parameters
Items Parameters Remarks
Normal operating voltage 9V~16V
Normal operating voltage (start-related 9V~16V

functions)
Static current <3mA
Operating temperature -40 ℃ ~+85 ℃

Storage temperature -40 ℃ ~+85 ℃
Frequency of controller receiving 433.87MHz
center
Modulation ASK
Receiving sensitivity <-80dBm
RKE Parameters

Normal operating voltage range 2.35V~3.5V
Static current <6uA
Frequency of low-frequency receiving 125kHz

center
Frequency of radio frequency 433.87MHz

transmission center
Pressure 11 ± 2N
Stroke 0.4~0.8mm
Waterproof/dustproof grade IP5K7
38-1
Parameters of Door Handle Antenna

Operating voltage 0~46V
Operating current 0~1020mAp
Resonant frequency 125KHZ ± 5%

Impedance <30 Ω
Parameters of Low-Frequency Antenna inside the Vehicle

Operating voltage 9v~16v
Operating frequency 125KHZ
Modulation ASK
Inductance 491uH
Capacitance 3.3nF
38-2
Layout
Layout
3
5
2
1 3
ES140001
1 Low-frequency antenna inside the vehicle 4 Door handle antenna

2 PEPS Controller ECU 5 Electronic steering lock
3 Remote control receiving module
38-3
Repair Guidance Replacement of Low-Frequency Antenna

(Auxiliary Fascia Console) inside the Vehicle
Replacement of Low-Frequency Antenna
(Instrument Panel) inside the Vehicle Removal
Removal 1 Disconnect the battery (negative first).

fascia console.
2 Remove the entertainment system display and
mainframe (Refer to Removal/Installation of 3 Disconnect the connector.
Entertainment System Display and Mainframe). 4 Screw out the two fastening screws, and remove
3 Disconnect the connector. the low-frequency antenna (auxiliary fascia
console) inside the vehicle.
4 Screw out the two fastening screws, and remove
the low-frequency antenna (instrument panel)
inside the vehicle.
ES140003
ES140002
Installation
Installation
38-4
Replacement of PEPS Controller ECU Replacement of Clock Spring Assembly and

Removal Clock Spring Returning Ring
Removal
2 Remove the A-pillar lower trim panel assembly 1 Remove the steering wheel assembly (Refer to
(Refer to Replacement of A-Pillar Lower Trim Steering Wheel Removal)
Panel Assembly). 2 Remove the upper and lower steering column
shroud (Refer to Removal of Upper and Lower
3 Disconnect the connector of PEPS controller.
Steering Column Shroud).
4 Screw out the fastening screw, and remove the
PEPS controller ECU.
ES140005
ES140004 3 Remove the clock spring assembly and the clock

spring returning ring.
Installation
ES140006
38-5
Installation
Replacement of Immobilizer Base Station
Removal
Note：Installation Requirements of the Clock
1 Remove the shift lever shroud assembly.
Spring:
2 Remove 3 screws fixing the immobilizer base
1 The clock spring is retained with a pin, which station on the shift lever shroud.
shall not be pulled out before installing the
steering wheel, otherwise the clock spring will
rotate freely and deviate from the center position.
2 When installing the steering wheel, pull out the
pin to confirm whether the clock spring is at the
center position (If a yellow mark is visible on the
clock spring surface window, it means the spring
is centered). If yes, fix the steering wheel.
3 If not, adjust the spring to the center position,

and then install the steering wheel.
4 Removal and installation of the clock spring may

cause the position change to the steering angle
sensor, please carry out zero calibration for the ES140007
steering angle sensor with an aftermarket scan
tool after the installation (If not calibrated, ESP
warning indicator may keep ON).
Installation
38-6
Replacement of Remote Control Receiving

Module
Removal
1 Disconnect the battery.
2 Remove the dome lamp in the driver
compartment, and disconnect the cable of
remote control receiving module.
3 Remove the remote control receiving module (on

the right of driver compartment dome lamp).
ES140008
Installation
Note：Before installation, glue it first.
38-7
38-8
Layout
Layout
ES250007
1 Cigar lighter
39-1
Layout
ES290000
1 Power outlet 2 On-board inverter
39-2
Repair Guidance
Replacement of Cigar Lighter
Replacement of Power Outlet
Removal
Removal
2 Remove the ashtray assembly.
2 Pry off the power outlet.
ES250008
ES290001
4 Remove the cigar lighter assembly.
4 Remove the power outlet assembly.
Installation
ES290002
5 Remove the body control module bracket.
Installation
39-3
5 Remove 3 nuts securing the on-board inverter to

Replacement of On-board Inverter
the front floor.
Removal
fascia console.
ES290005
7 Remove the on-board inverter assembly.

ES290003
3 Pry off the on-board inverter outlet.
ES290006
ES290004
Installation
4 Lift up the front carpet. 1 Installation is the reverse of removal.
39-4
Parking Assist System
Layout
Layout
ES320000
1 Radar buzzer 2 Blind spot monitoring control module
40-1
Layout
ES320001
1 Front camera 3 Front bumper radar sensor bracket

2 Front bumper radar sensor 4 Lateral camera
40-2
Layout
1
1
2 2
ES320002
1 Rear bumper radar sensor 3 Rear camera

2 Rear bumper radar sensor bracket
40-3
Repair Guidance
Replacement of Blind Spot Monitoring
Replacement of Front Bumper Radar Sensor
Control Module
and its Bracket
Removal
Removal
2 Lift the front carpet on the right side.
4 Remove 2 nuts fastening the blind spot
monitoring control module to the front floor.
ES320004
ES320003 4 Loosen the clip fixing the sensor to the sensor

bracket.
5 Remove the blind spot monitoring control
5 Remove the front bumper radar sensor and its
module assembly.
bracket.
Installation
ES320005
Installation
40-4
6 Remove the license plate lamp trim panel

Replacement of Rear Bumper Radar Sensor
(including the license plate lamp), and
and its Bracket disconnect the harness connector.
Removal
2 Disconnect the wire harness for the reversing
radar and the chassis harness connector.
3 Remove the rear bumper assembly.

4 Unscrew the bolts circled in the figure.
ES320016
7 Disconnect the radar harness connector.
ES320006
5 Remove the screw fixing rear bumper frame to

rear bumper beam assembly.
ES320017
8 Disconnect the junctions of rear bumper side

panel, rear bumper fascia and rear bumper
frame respectively with a screwdriver.
ES320015
ES320018
40-5
9 After loosening the above junctions, pull the 11 Remove the rear bumper radar sensor and its
fascia open by hands, and disconnect the lower bracket.
junctions of radar and radar bracket respectively
with a screwdriver through the space below the
fascia.
ES320007
ES320019
Installation
10 disconnect the upper junctions of radar and 1 Installation is the reverse of removal.
radar bracket respectively with a screwdriver.。
ES320020
40-6
Replacement of Radar Buzzer Replacement of Front Camera

Removal Removal
2 Remove the instrument panel body.
4 Remove 2 screws fastening the radar buzzer to
the instrument panel beam.
ES320010
2 Remove the front camera.

ES320008 4 Remove the front camera assembly.
5 Remove the radar buzzer assembly.
ES320011
ES320009
Installation
Installation
40-7
5 Remove the rear camera assembly.

Replacement of Rear Camera
Removal
2 Remove the rear panel outer handle assembly.
ES320014
Installation
ES320012

4 Remove 2 screws fastening the rear camera to
the rear panel outer handle.
ES320013
40-8

360-degree All Around View Calibration
Re-calibration is necessary for the following conditions
·Any one of the cameras of the 360-degree all around view system is replaced, damaged or moved
·The entertainment mainframe is replaced (excluding any update)
Calibration Site Layout
3000mm
Front
520mm
Direction
1520mm
900mm
5360mm
6400mm
550mm
550mm
700mm
520mm
1000mm
Short axle
ES320024
40-9
3000mm
Front
Direction
360
1520mm
900mm
5680mm
6400mm
550mm
550mm
700mm
360mm
1000mm
Long axle
ES320025
40-10
Calibration Method
Drive the vehicle into the calibration site work station：
1 Tap the "HOME" button on the control panel, and then the "Vehicle Body Figure 360" icon on the right side of
the screen, as shown below.
Now Playing : FM87.5 MHz
Vehicle Status : -
setup Picture Carplay
2 Turn on the panoramic calibration program.
Rear Left
Front Right
40-11
3 Long press the center area of the "Rear" and "Left" icons (as shown by the red zone below) in the lower left
of the 360 switching area for 3s and then release to skip to the calibration program, and log in.
Rear Left
Front Right
Please log in
The default password
is number "1"
Touch OK after the
input to enter the
calibration interface
Panoramic Exit
Calibration
40-12
4 Enter the interface as shown below.
On/Off Calibration
Exit
360°
Result: The video is turned
on successfully
40-13
5 Touch to commence the calibration work.
！ Parameters are in calibration...

Calibration is ongoing, it takes approximately
10 seconds, please wait with patience
5% 5/100 On/Off Calibration
Exit
360°
Result: The video is turned
on successfully
6 Calibration successfully completed interface.
Video Switching
Exit
40-14
7 Touch to compare with the original image.
Video Switching
Exit
8 Exit the panoramic calibration, enter the panoramic parking for normal use.
Note：The operation methods at the calibration work station of panoramic parking assist system are as：
1） Park the vehicle at the designated position ；
2）Touch the Panoramic Parking button on the navigation interface to enter the system, and touch the button to enter the
automatic calibration state ；
3）After the automatic calibration is successfully completed, the screen will show "Calibration Successfully Completed" ；
4） When the automatic calibration prompts a failure, please check the camera lens for foreign materials, if the ambient
illumination conditions are met, if there are contaminants on the surface of square floor tiles, if the vehicle is driven into
the designated position. After confirming that all are ok, perform the automatic calibration again.
40-15
40-16
Tire Pressure Monitoring
Layout
Layout
ES240000
1 Tire pressure monitoring control module
41-1
Repair Guidance Operating instructions for hand-held

TPMS match tool
Tire Pressure Monitoring Control Module
Brief introduction to hand-held TPMS match
Replacement tool
Removal General
1 Disconnect the negative battery cable. The hand-held TPMS match tool is used for delivery
2 Remove the rear roof interior trim panel. matching and fault diagnosis of the TPMS tire pressure
3 Remove 2 bolts and 2 washers fixing the tire sensor and monitor to ensure normal working of the
pressure monitoring control module to the rear TPMS system.
top beam.
Packaging
5 Remove the control module assembly. 1 One hand-held TPMS match tool.
2 One SD card.
3 One OBDII patch cord.
4 One battery charger.
Appearance
ES240001
Installation
DS380004
Schematic
3. Patch cord interface

4. Charging
8. Power switch
power interface
1. LCD
OK
2. Keyboard
1 2 3
4 5 6
7 8 9
ESC 0 DEL
5. SD card interface 6. USB interface

DS380005
41-2
Keyboard
1 Keyboard diagram
读左前轮信息读右前轮信息中　　文

Read LF Tire Read RF Tire English
读左后轮信息读右后轮信息匹　　配

Read LR Tire Read RR Tire Match
OK
1 2 3
4 5 6
7 8 9
ESC 0 DEL
DS380006
2 Keyboard functions
Buttons Functions
Read the F/L In the match mode, it can quickly start
wheel to read the F/L wheel information
information
Read the R/L In the match mode, it can quickly start
wheel to read the R/L wheel information
information
Read the F/R In the match mode, it can quickly start
wheel to read the F/R wheel information
information
Read the R/R In the match mode, it can quickly start
wheel to read the R/R wheel information
information
Chinese/English Switch the display language。
Match In the match mode, it can quickly start
the match function
Direction keys Move to select the cursor/ page down
or up
OK OK
Numeric keys Shortcut keys: used to start the
corresponding function of the current
menu. Used as a digital keyboard
when a password is set or a service
instruction is input.
ESC Exit/Quit
DEL In the match mode, quickly start the
function of match delete / delete the
contents in the current input box when
a password is set or a service
instruction is input
41-3
Hand-held TPMS match tool battery and charging method

Items Parameters Remark
Rated capacity Nominal capacity 1600mAh 0.2A standard discharge after standard
Minimum capacity 1560mAh charging
Normal voltage 7.5V Working voltage

Charging voltage DC12 ± 0.06V
Standard charging Persistent current: 0.5A Charging time: about 4 hours
Continuous voltage: 8.4V
Cutoff current: 0.01A
Working temperature range Charging: 0~45°C
Discharging: -20~60°C
RF operating parameters, hand-held TPMS match tool
1 Parameters for low frequency communications
Low frequency 125kHz ± 5kHz

transmitting frequency
Baud rate 3.9kbps ± 0.05kbps
Field strength According to the actual effect of communications, the sensor installed in the tire can achieve the
communication distance of 0.2m-0.5 m
Modulation system ASK
Coding system Manchester encoding
2 Parameters for high frequency communications
High frequency 433.92MHz ± 200kHz

transmitting frequency
Baud rate 9.6kbps
Field strength According to the actual effect of communications, the high-frequency communication distance is
greater than 5 m
Modulation system ASK
Coding system Manchester encoding
Hand-held TPMS match tool configuration

files
By updating the configuration files in the SD card, the
equipment configuration information can be quickly and
easily changed.
41-4
Hand-held TPMS match tool: match mode 7 According to the interface prompts, read the tire
pressure parameters in turn.
1 The ignition switch must be turned to "ON
position". 8 After reading is completed, use a data cable to
connect the patch cord interfaces of the OBD
2 Turn on the power switch of the TPMS match
and the TPMS match tool as shown in figure:
tool.
3 When the saved model configuration displays,
press the "OK" button.
4 When the saved model configuration displays,
press the "OK" button.
1/2 Select model
>SK81-215/70R15
>SK81-245/65R17
>SK81-245/70R16
>SV61-CAN DS380009
9 Press the "OK" button to start data match with
>SV61-RF the control module.
>SV71-LTR LUXURY-CAN 10 If successful, it will prompt "Match completed".
ES240002 11 Press the "ESC" button, remove the data cable

and turn off the power of the TPMS match tool.
SK81-215/70R15：15 inch tire Note：If it prompts match failures, switch off the
TPMS match tool and match again according to
SK81-245/65R17：17 inch tire
the above steps.
SK81-245/70R16：16 inch tire
5 Select the model option accordingly based on

the current model configurations.
6 Select [Read the F/L wheel sensor information],
align the TPMS match tool to the F/L tire valve
as shown in the figure and press the "OK" button
to start data reading.
DS380008
41-5
41-6
Air-conditioning
Air-conditioning
Specification
Parameters
Compressor type BX13
Compressor displacement 140ml/r
Speed
·Minimum speed 600rpm
·Maximum speed 9000rpm
Lubricating oil SP10
Refill amount 150ml
Evaporator temperature sensor
·Compressor ON 5℃
·Compressor OFF 2℃
Pressure protection
·High pressure protection ON 3.14MPa
·Low pressure protection ON 0.196MPa
Rated voltage 12V
Power consumed 48W
Refrigerant R134a
Refill amount of refrigerant 580g
Torque
Bolt - fasten the compressor intake pipe to the compressor 23 ± 2

Bolt - fasten the compressor exhaust pipe to the 23 ± 2
compressor
Bolt - fasten the intercooler assembly to body 22 ± 2

Bolt - fasten the transmission oil cooling pipe assembly to 23 ± 1
the transmission
42-1
Air-conditioning
Layout
A/C System Layout
2
4 5
ES310068
1 Condenser 4 Heater pipeline

2 A/C compressor 5 Front A/C assembly
3 A/C pipeline 6 Front A/C control panel
42-2
Air-conditioning
Cooling Pipeline Layout
3
4
8
9
ES310069
1 Expansion tank assembly 6 Intercooler intake pipe assembly

2 Engine exhaust pipe assembly 7 Intercooler exhaust pipe assembly
3 Hose between engine and expansion tank 8 Intercooler
4 Radiator water inlet pipe 9 Cooling module assembly
5 Radiator water outlet pipe
42-3
Air-conditioning
Troubleshooting Information and Procedure
System Failure
Poor refrigeration effect Lack of refrigerant Exclude leakage points, and refill the
refrigerant
Excessive refrigerant Release a proper amount of refrigerant
Check the evaporator core for dirts Clean/clear dirts
Condenser contaminated or blocked Clear dirts
There is frost on the compressor air return Re-fix the thermal bulb
connecting pipe joint
Compressor starts and Check high pressure Release a proper amount of refrigerant
stops frequently
There is frost on the Receiver-drier blocked Replace

dryer connecting outlet
There is frost on the Expansion valve blocked Replace

expansion valve inlet
side
Electric Appliance Failure
A/C does not work A/C fuse failure Replace
Compressor does not A/C switch failure Replace

work
Compressor power line failure Repair
Pressure switch failure Re-plug or replace
Electromagnetic clutch failure Replace the compressor
The blower does not Fuse failure Replace

work
Control panel air volume switch failure Replace
Blower wiring failure Repair
Blower failure Replace
Evaporator freezes Defroster switch is on Replace the defroster switch
Poor contact of defroster switch Repair
Fuse failure Replace
The condenser fan Pressure switch failure Re-plug or replace

does not work
Condenser fan power line failure Repair
Condenser fan failure Replace
Control panel failure Replace
Failing to switch Water valve actuator failure Replace

between cooling and
heating modes
42-4
Air-conditioning
Mechanical Failure
Belt slackness Belt vibrates severely Adjust the belt tension
Clutch slip The clutch slips due to friction surface Clean the clutch surface
contamination Replace the compressor
The clutch makes friction noise after
engagement
The compressor makes The compressor makes metal friction sound Replace the compressor
abnormal sound inside
The compressor gets The compressor does not work Replace the compressor
stuck
Poor Heating Effect
No warm air or poor Low water temperature Notify the engine manufacturer or vehicle
heating effect manufacturer
Lack of coolant Refill coolant
Coolant circulates inadequately Clean or replace
Heater valve failure Replace
42-5
Air-conditioning
Refill
Repair Guidance
1 Confirm the system is vacuum without leakage,
Coolant Drain and Refill connect the intermediate pipe connecting the
Emission manifold gauge to the vacuum pump to the joint
of refrigerant tank.
1 Connect 3 pipes onto the manifold gauge as
required. 2 Place the refrigerant tank on an electronic scale,
open the refrigerant tank valve, and loosen the
2 Respectively connect the red high-pressure pipe intermediate pipe on the manifold gauge to
and blue low-pressure pipe onto the flush valve release air in the pipe. Do not tighten the joint
of A/C system. until refrigerant flows out from the joint.
3 Prepare a measuring cup, place a yellow 3 Check and record the weight reading on the
intermediate connecting pipe in it, and cover it electronic scale, and turn on the high-pressure
with a clean cloth to prevent the refrigerant oil switch on the manifold gauge. Then refrigerant
from spraying out. flows into HVAC system. Observe the weight
4 Slowly turn the blue and red knobs on the reading on the electronic scale at any time.
manifold gauge, and then coolant and refrigerant 4 When the refilling amount reaches the specified
oil will flow out slowly. weight, turn off the manifold gauge switch and
5 After the coolant in the system is drained subsequently close the refrigerant tank valve.
completely, tighten the high-low pressure knob 5 Remove the manifold gauge, and refilling is
on the gauge, and remove the pipe. finished.
6 Suck the refrigerant oil drained out into the Note: High pressure: 31.4MPa
system in virtue of the vacuum in the system and
manifold gauge after vacuuming the system. Low pressure: 0.196MPa
Medium pressure: 1.57MPa
Low pressure High pressure

gauge gauge LOW pressure
pipe (blue) Placement
Vacuum pumping starts
Vacuum pumping stops
20 for 5 Pressure gauge

Air tightness check
Refrigerant charge
minutes minutes indicating normal
Connecting pipe
(yellow) End
High pressure -750

pipe (red) mmhg
Gauge seat
Check the Pressure

connection rises back
ES310001
ES310002
42-6
Air-conditioning
Replacement of Receiver-drier to Front 3 Respectively separate the receiver-drier to front

Expansion Valve Pipeline Assembly expansion valve pipeline assembly from the
Removal compressor intake pipe and the condenser to
receiver-drier pipeline assembly.
1 Unscrew the bolts connecting the receiver-drier
to front expansion valve pipeline assembly to the
front expansion valve.
ES310005
4 Remove the receiver-drier to front expansion

ES310003 valve pipeline assembly.
2 Unscrew the nuts connecting the receiver-drier

to front expansion valve pipeline assembly to the
body.
ES310006
ES310004 Installation
42-7
Air-conditioning
Replacement of Compressor Intake Pipe Replacement of Compressor Exhaust Pipe

Removal Removal
1 Separate the compressor intake pipe from the 1 Separate the compressor intake pipe from the
receiver-drier to front expansion valve pipeline receiver-drier to front expansion valve pipeline
assembly. assembly.
2 Unscrew the bolts fastening the compressor
intake pipe to the compressor.
ES310009
2 Unscrew the bolts fastening the compressor

ES310007
exhaust pipe to the condenser.
3 Remove the compressor intake pipe.
ES310010
ES310008
Installation
—Tighten the bolts fastening the compressor intake pipe
to the compressor to the torque of 23 ± 2N.m
42-8
Air-conditioning
3 Remove the compressor exhaust pipe.

Replacement of Condenser Outlet Pipe
Assembly
Removal
1 Unscrew the bolts fastening the condenser outlet
pipe assembly to the condenser.
ES310011
Installation
ES310012
—Tighten the bolt fastening the compressor exhaust pipe
to the compressor to the torque of 23 ± 2N.m 2 Unscrew the nuts fastening the condenser outlet
pipe assembly to the body.
ES310013
3 Separate the condenser outlet pipe from the

receiver-drier to front expansion valve pipeline
42-9
Air-conditioning
assembly. Remove the condenser outlet pipe

Replacement of Front Heater Water Inlet Pipe
assembly.
Assembly
Removal
1 Remove the clamps fixing the front heater water
inlet pipe assembly to the front heater.
ES310014
Installation
ES310015
2 Unscrew the bolts fixing the front heater water

inlet pipe assembly to the engine.
ES310016
42-10
Air-conditioning

Replacement of Front Heater Water Outlet
inlet pipe assembly to the engine.
Pipe Assembly
Removal
outlet pipe assembly to the front heater.
ES310017
4 Remove the front heater water inlet pipe

assembly.
ES310019
2 Unscrew the nuts fixing the front heater water

outlet pipe assembly to the body.
ES310018
Installation
ES310020
42-11
Air-conditioning

Replacement of Front A/C Assembly
outlet pipe assembly to the engine.
Removal
1 Remove the instrument panel (refer to
Replacement of Instrument Panel).
2 Respectively separate the front A/C assembly
from A/C pipeline and heater pipeline.
3 Respectively separate the front A/C assembly

from driver & front passenger feet air ducts and
front floor air duct.
4 Unscrew the bolts fixing the front A/C assembly

to IP beam.
ES310021
4 Remove the front heater water outlet pipe

assembly.
ES310023
5 Unscrew the nuts and washers fixing the front A/

C assembly to the body.
ES310022
Installation
ES310024
6 Remove the front A/C assembly.
Installation
42-12
Air-conditioning
Replacement of Mode Motor, Cooler & Heater Replacement of A/C Filter Element Cover
Motor and Fresh Air Damper Motor Plate
Removal Removal
1 Remove the instrument panel (refer to 1 Remove the glove box. Then the A/C filter
Replacement of Instrument Panel). element cover plate can be seen.
2 Unscrew bolts of mode motor, cooler & heater
motor and fresh air damper motor in turn.
ES310026
2 Slightly pull out the cover plate clamping position

ES310025
with fingers to remove the A/C filter element
cover plate.
3 Unplug harnesses of mode motor, cooler &
heater motor and fresh air damper motor in turn,
and remove these three motors.
Installation
ES310027
Installation
42-13
Air-conditioning
Replacement of A/C Filter Replacement of Front Expansion Valve

Removal Removal
1 Remove the glove box and A/C filter element 1 Remove the instrument panel (refer to
cover plate in turn. Replacement of Instrument Panel).
2 Pull out the A/C filter element. 2 Remove the front A/C assembly (refer to
Replacement of Front A/C Assembly).
3 Remove the high-low pressure pipe from the

front expansion valve (refer to Replacement of
High-low Pressure Pipe).
4 Unscrew bolts from the front expansion valve.
ES310028
Installation
ES310029
5 Unscrew the front expansion valve.
ES310030
Installation
42-14
Air-conditioning
Replacement of Evaporator Core Replacement of Heater Core and

Components Accessories
Removal Removal
1 Remove the instrument panel (refer to 1 Remove the instrument panel (refer to
Replacement of Instrument Panel). Replacement of Instrument Panel).
2 Remove the front A/C assembly (refer to 2 Remove the front A/C assembly (refer to
Replacement of Front A/C Assembly). Replacement of Front A/C Assembly).
3 Remove the front expansion valve (refer to 3 Remove the heater pipe (refer to Replacement of
Replacement of Front Expansion Valve). Heater Pipe).
4 Remove the front A/C assembly housing. 4 Remove the front A/C assembly housing.
5 Remove evaporator core components. 5 Remove the heater core and accessories.
ES310031 ES310032
42-15
Air-conditioning
5 Remove the blower assembly.

Replacement of Blower Assembly
Removal
1 Unscrew the bolts fixing the instrument panel to
front A/C assembly.
ES310035
Installation
ES310033
2 Unscrew the bolts fixing the blower assembly to
the housing.
ES310034
3 Remove the front A/C assembly housing.
4 Disconnect the harness from the blower

assembly.
42-16
Air-conditioning
Replacement of Speed Regulating Module Replacement of Evaporator Temperature

Removal Sensor
Removal
1 Unscrew bolts from the speed regulating
module. 1 Remove the instrument panel (refer to
Replacement of Instrument Panel).
2 Remove the front A/C assembly (refer to
Replacement of Front A/C Assembly).
3 Remove the front A/C assembly housing and

evaporator temperature sensor.
ES310037
2 Unplug the harness from the speed regulating

module.
3 Remove the speed regulating module.
ES310039
Installation
ES310038
Installation
42-17
Air-conditioning
Replacement of Automatic A/C Suction Pipe Replacement of Front Floor Air Duct
Removal Removal
1 Remove the instrument panel (refer to 1 Remove the front carpet (refer to Replacement
Replacement of Instrument Panel). of Front Carpet).
2 Remove the automatic A/C suction pipe from the 2 Separate the front floor air duct from the front A/
front A/C assembly. C assembly.
ES310040 ES310041
3 Unscrew the nuts fixing the front floor air duct to

the body.
Installation
ES310042
4 Remove the front floor air duct.
Installation
42-18
Air-conditioning
Replacement of Front A/C Control Panel Replacement of Condenser

Removal Removal
1 Remove the molding from the instrument panel. 1 Respectively separate the condenser from the
compressor exhaust pipe and condenser outlet
2 Unscrew the bolts fixing the front A/C control
pipe assembly.
panel to the instrument panel.
2 Unscrew the bolt (1) fixing the extending bracket
on the condenser top to the radiator upper water
chamber; pull out the extending bracket (2) at
the condenser bottom from the radiator lower
water chamber slot.
ES310043
3 Unscrew the front A/C control panel.
2
1 Installation is the reverse of removal. 3 Remove the condenser.
Installation
42-19
Air-conditioning
3 Pull out the lower rubber mat of intercooler

Replacement of Intercooler Assembly
assembly from the body mounting hole.
Removal
1 Respectively separate the intercooler assembly
from the intercooler intake hose (1) and
intercooler exhaust pipe assembly (2).
ES310053
1 4 Remove the intercooler assembly.
ES310051
Installation
2 Unscrew the bolt fastening the intercooler
assembly to body.
—Tighten the bolt fastening the intercooler assembly to
body to the torque of 22 ± 2N.m
ES310052
42-20
Air-conditioning
3 Separate the expansion tank assembly from the

Replacement of Expansion Tank Assembly
hose between engine and expansion tank.
Removal
1 Unscrew the bolts fastening the expansion tank
assembly to body.
ES310056
4 Remove the expansion tank assembly.

ES310054
2 Separate the expansion tank assembly from the Installation

engine exhaust pipe assembly.
ES310055
42-21
Air-conditioning
Replacement of Engine Exhaust Pipe Replacement of Hose between Engine and

Assembly Expansion Tank
Removal Removal
1 Remove the clamp fixing the engine exhaust 1 Remove the clamp fixing the engine to the
pipe assembly to expansion tank assembly, and expansion tank hose to expansion tank
pull out the engine exhaust pipe assembly. assembly, and pull out the hose between engine
and expansion tank.
ES310057
ES310059
2 Remove the clamp fixing the engine exhaust
pipe assembly to the condenser assembly, and 2 Unscrew the bolts fixing the hose bracket
pull out the engine exhaust pipe assembly. between engine and expansion tank to the body.
ES310058 ES310060
3 Separate the engine exhaust pipe assembly from 3 Separate the hose between engine and
the engine. Remove the engine exhaust pipe expansion tank from the engine. Remove the
assembly. hose between engine and expansion tank.
42-22
Air-conditioning
3 Unscrew the bolt fixing the intercooler exhaust

Replacement of Intercooler Intake and
hose to the engine.
Exhaust Hoses
Removal
1 Respectively separate the intercooler intake
hose (1) and intercooler exhaust pipe assembly
(2) from the intercooler assembly.
2
ES310063
4 Respectively separate the intercooler intake

1 hose and intercooler exhaust pipe assembly
from the engine. Remove the intercooler intake
ES310061 hose and intercooler exhaust pipe assembly.
2 Unscrew the bolt fixing the intercooler intake

hose to the subframe. Installation
ES310062
42-23
Air-conditioning
Replacement of Radiator Water Inlet and Replacement of Transmission Oil Cooling

Outlet Pipes Pipe Assembly
Removal Removal
1 Respectively separate the radiator water inlet 1 Unscrew the bolt fixing the transmission oil
pipe (1) and radiator water outlet pipe (2) from cooling pipe assembly to the transmission.
the radiator.
2 ES310065
ES310064
2 Unscrew the bolt fixing the transmission oil
2 Respectively separate the radiator water inlet cooling pipe assembly to the body.
pipe and outlet pipe from the engine. Remove
the radiator water inlet and outlet pipes.
Installation
ES310066
42-24
Air-conditioning
3 Respectively separate the transmission oil

cooling pipe assembly from the mounting points
on the radiator.
ES310067
4 Remove the transmission oil cooling pipe.
Installation
—Tighten the bolt fixing the transmission oil cooling pipe
to the transmission to the torque of 23 ± 1N.m.
42-25
Air-conditioning

Overview
The heating, ventilation and air-conditioning (HVAC) system can create a comfortable environment with fresh air and
moderate temperature for driver and passengers in the vehicle. The automobile HVAC system shall have greater
refrigerating capacity, warm air capacity and ventilation volume to adapt to the great temperature disparity in different
areas. The HVAC system equipped for this vehicle can realize rapid refrigeration to satisfy the user's demand.
HVAC system is mainly composed of a compressor, a condenser, an expansion valve, an evaporator, a pipeline
assembly, etc.
Operating Principle
The HVAC system absorbs heat from air through refrigerant circulation to lower the air temperature and eliminate water
vapor in the air, so as to maintain the cooling and moisture. Meanwhile, the HVAC system also can clear the frost and fog
on the windshields and side windows by introducing cool and hot air.
HVAC Schematic Diagram
Gas
High temperature and
high pressure Low temperature and
low pressure
High-temperature Compre
high-pressure gas ssor Expansion Gas
valve
Compre
Liquid ssing Evapora
Condenser Conden tion
sation To absorb
heat
Release of heat
Expan Expansion
sion valve
Liquids(high pressure)
ES310070
1 After starting the vehicle, driven by the engine, the compressor starts operating to impel refrigerant to
circulate in the sealed HVAC system. Then the compressor compresses the gaseous refrigerant into
hightemperature and high-pressure refrigerant gas and exhausts the gas.
2 After flowing into the condenser via pipeline, the high-temperature and high-pressure refrigerant gas will
radiate and cool down in the condenser, and then become medium-temperature and high-pressure liquid
refrigerant and flow out. (Condensation refers to the process of cooling steam to a temperature no more than
its saturation temperature to convert the steam to liquid. It is an exothermic process because the conversion
from gas to liquid must be realized through heat release).
3 Then the medium-temperature high-pressure liquid refrigerant flows into the receiver-drier via pipeline. After
drying and filtration, it flows into the expansion valve.
42-26
Air-conditioning
4 The medium-temperature high-pressure liquid refrigerant will rapidly change into the low-temperature/
pressure fog-state refrigerant after it is throttled by the expansion valve.
5 Then the low-temperature/pressure fog-state refrigerant immediately enters the evaporator and absorbs
heat from the air flowing through the evaporator, so as to lower the air temperature and generate cool air,
realizing cooling effect. Then the refrigerant will evaporate to the low-temperature/pressure gaseous
refrigerant due to heat absorption. (In refrigeration technology, evaporation refers to the process where a
liquid converts from liquid to gas in the boiling state. It is an endothermic process because the conversion
from liquid to gas must be realized by absorbing heat from the external).
6 Then the low-temperature/pressure gaseous refrigerant is sucked by the compressor again via pipeline for
compression and enters the next circulation. As long as the compressor keeps operating, the refrigerant will
circulate in the HVAC system to realize refrigeration; if the compressor stops operating, the refrigerant will
stop circulating accordingly and not produce refrigeration effect.
Introduction of Parts Function

Compressor: It compresses the low-temperature and low-pressure gas from the evaporator to the high-temperature and
high-pressure gas. It is located between the evaporator and condenser and driven by the engine.
Condenser: It converts the gaseous refrigerant to liquid refrigerant. It is located between the compressor and
receiverdrier.
Expansion valve: It is the throttling device which isolates the system high-pressure side and low-pressure side. After the
high-pressure liquid refrigerant is throttled, the refrigerant will convert into the low-pressure and low-temperature fog
mixture of gas and liquid, which has the capacity to absorb heat. It measures the volume of liquid refrigerant entering the
evaporator by detecting the temperature of evaporator outlet and adjusts the inlet clearance to adapt to condition change.
It automatically adjusts the refrigerant flow according to the size of thermal load, so as to ensure the evaporator operates
safely and efficiently.
Evaporator: It absorbs heat from exterior air to heat and evaporate the refrigerant from the expansion valve to the
lowtemperature and low-pressure gas. At this time, the air around the evaporator exterior cools down, and then the
blower blows out the cool air. Then the gas is sent to the compressor again to carry on refrigerating through circulation.
Front HVAC assembly:
1 It adopts the cooler-heater integrated design: the cooler and heater share one set of blower equipment;
2 Fix the HVAC assembly and instrument desk beam to the dash panel after split assembly;
3 The shall be a temperature sensor for preventing frosting on the evaporator surface;
4 The assembly does not require any harnesses, but it shall be easy to plug the complete vehicle harness to
connectors of electric appliances including the actuator, fan, speed regulating module, etc;
5 The HVAC assembly shall be provided with drain pipe to drain condensate water out of the vehicle; the joints
between the HVAC assembly and body shall be well sealed;
6 Air ducts shall be embedded; joints shall be firm and well sealed;
7 Connect the expansion valve and heater water inlet & outlet pipes to the pipeline inside the engine
compartment through the opening on the firewall, and the area around the opening shall be sealed well;
8 The assembly interior shall be equipped with a dust filter which is easy to remove and replace;
9 The HVAC assembly shall have a good thermal insulation performance, and its exterior surface shall be free
of condensation water.
42-27
Air-conditioning
Condenser assembly
The condenser is parallel-flow type and integrated with the receiver-drier. The condenser assembly is arranged in the
front of cooling module and fixed with the condenser bracket, rubber shock pad and bolts;
Pipeline assembly
1 The pipeline assembly shall be provided with lubricating oil to facilitate assembly and removal;
2 The heater pipeline assembly shall be provided with retaining clamps;
3 The pipeline shall be provided with a pipeline bracket, clips, O-rings, etc.;
4 The pipeline assembly shall be packed well with dust plugs on both ends.
42-28
Air-conditioning
Refrigeration performance targets:
Refrigeration performance requirements for complete vehicle
Reference test method: 43 ℃ Maximum temperature drop test specification

Single front evaporator Dual-evaporator
Front Rear
Air outlet 10min@ 50kph 16 18 21

average
temperature 30min@ 100kph 9 10 11
℃ 10min idle 15 17 21
　　Single front evaporator Dual-evaporator
Average The first row @ 15min 50kph 27 29

temperature
℃ of The second row @ 15min 50kph 28 29
passenger
The third row @ 15min 50kph N/A 31
breathing
plane
The first row @ 30min 50kph 23 24
The second row @ 30min 50kph 24 24
The first row @ 30min 100kph 22 21
The second row @ 30min 100kph 21 22
The first row @ 10min idle 23 25
The second row @ 10min idle 24 25
The third row @ 10min idle N/A 26
End cover Mechanical fan @ 30min idle 2700 2700

pressure kPa
Electronic fan @ 30min idle 2350 2350
Heating performance targets
Heating performance requirements for complete vehicle (bus)
Reference test method: GB/T12782-2007 Motor Vehicle - Heating Performance Requirement - Test Method
Ambient temperature 40min@40kph Footwell temperature for driver and front passenger ≥ 15 ℃
-25 ± 3 ℃
Temperature difference between head space and footwell ≤5℃
for driver and front passenger
Footwell temperature for passengers ≥ 15 ℃
42-29
Air-conditioning
Defrosting and defogging performance targets
Defrosting performance requirements for complete vehicle
Standard Test time/min Evaluation parameter Target value
GB11555-2009 20 A area ≥ 80%

25 A' area ≥ 80%
40 B area ≥ 95%
Defogging performance requirements for complete vehicle
Standard Test time/min Evaluation parameter Target value
GB11555-2009 10 A area ≥ 90%

B area ≥ 80%
Front side window ≥ 80%
Immersion amount of exterior water

The water entering the interior compartment through the exterior air duct (that is, the amount of water absorbed by the A/
C filter screen) shall not exceed 5g.
Air distribution of front HVAC mode
Mode Temperature damper Air flow distribution [%]

position
Front HVAC
Face mode Defrost mode Feet mode
Face mode Minimum mode 100 0 0
Face/Feet mode Minimum mode 60 ± 10% 0 40 ± 10%

Feet mode Maximum mode 0 0 100
Feet/Defrost mode Maximum mode 0 40 ± 10% 60 ± 10%

Defrost mode Maximum mode 0 100 0
42-30
Air-conditioning
Noise requirements for HVAC assembly
Basic condition Measuring position Performance

requirements
Interior noise Engine non-operating, front and rear Front wind noise - the inner ear ≤ 68dB
during blowers at the high-speed position; position of driver;
ventilation
HVAC system mode: Rear wind noise -- the passenger ear
Exterior circulation, minimum + face position closest to the rear HVAC;
mode
Interior noise Engine idling; front blower at the The inner ear position of driver ≤ 70dB
when the highspeed position
front system
is started HVAC system mode:
(1) Exterior circulation, minimum +
face mode;
(2) Exterior circulation, maximum +

feet mode;
(3) Exterior circulation, maximum +

defrost mode;
Interior noise Engine idling; front and rear blowers at Front wind noise - the inner ear ≤ 70dB
when the the high-speed position position of driver;
dual-system
is started HVAC system mode:
Front HVAC: Exterior circulation, Rear wind noise -- the passenger ear
minimum + face mode position closest to the rear HVAC;
Rear HVAC: Cool air mode
System power consumption requirements
Under the rated voltage of 12V, the current load on the front HVAC in the stable operating mode shall be ≤ 25A; the
current load on the rear HVAC in the stable operating mode shall be ≤ 18A.
42-31
Air-conditioning
42-32
Lighting System
Lighting System
Layout
Layout
4 3
ES220000
1 Rear roof reading lamp 4 Front fog lamp

2 Rear combination lamp 5 Front roof reading lamp
3 Headlamp assembly
43-1
Lighting System
Repair Guidance
Replacement of Front Roof Reading Lamp
Replacement of Rear Roof Reading Lamp
Removal
Removal
2 Remove 2 bolts fixing the reading lamp to the
2 Pry off the lampshade of rear roof reading lamp.
front roof.
3 Remove 2 bolts fixing the reading lamp to the
rear roof.
ES220001
3 Disconnect the electrical connector. ES220003

4 Remove the front reading lamp assembly.
5 Remove the inoperative bulb.
6 Remove the inoperative microphone. 5 Remove the rear roof reading lamp.
6 Remove the inoperative bulb.
ES220002
ES220004
Installation
Installation
43-2
Lighting System
Replacement of Headlamp Assembly Replacement of Front Fog Lamp

Removal Removal
2 Remove the bumper assembly. 2 Remove 3 fastening screws of the front fog lamp.
3 Remove 4 fastening screws of headlamp

assembly.
ES220006
3 Disconnect the electrical connector of front fog

ES220005
lamp.
4 Disconnect the electrical connector. 4 Remove the front fog lamp assembly.
5 Remove the headlamp assembly. 5 Remove the inoperative bulb.
6 Remove the inoperative bulb of direction

indicator lamp (1).
7 Remove the inoperative bulb of low beam lamp

(2).
8 Remove the inoperative bulb of position lamp

(3).
3 2
ES220014
1
Installation
ES220013
Installation
43-3
Lighting System
Replacement of Headlamp Leveling ECU Replacement of Front Height Sensor and

Removal Bracket
Removal
2 Remove the glove box assembly. 1 Disconnect the negative battery cable.
3 Remove the bolt fixing the front height sensor
4 Remove 2 nuts fixing the headlamp ECU bracket
and bracket to the right side member welding
to the cross member of instrument panel.
assembly.
ES220015
ES220017
5 Remove the headlamp leveling ECU.
4 Remove 2 nuts fixing the front height sensor and
6 Remove the headlamp leveling ECU bracket. bracket to right upper swing arm of front
suspension.
ES220016
ES220018
Installation
43-4
Lighting System
5 Remove the front height sensor and bracket

Replacement of Rear Height Sensor and
assembly.
Bracket
Removal
3 Remove 2 bolts fixing the rear height sensor and

bracket to the right side member welding
assembly.
ES220019
Installation
ES220020
ES220022
43-5
Lighting System
4 Remove 2 nuts fixing the rear height sensor and

Replacement of Rear Combination Lamp
bracket to the rear axle assembly.
Removal
2 Remove 2 bolts fixing the rear combination lamp
to the rear panel mounting plate.
ES220021
5 Remove the rear height sensor and bracket

assembly.
ES220007
4 Remove the rear combination lamp assembly.
5 Remove the inoperative bulbs of position lamp

and brake lamp (1), bulb of direction indicator
lamp (2), bulb of reverse lamp (3) and bulb of
rear fog lamp (4).
1
ES220023
2
Installation 3
ES220024
Installation
43-6
Lighting System
5 Remove the inoperative bulb of license lamp.

Replacement of License Lamp
Removal
ES220025
ES220008
Installation
ES220009
2 Pry off the license lamp through the access hole.
4 Remove the license lamp assembly.
43-7
Lighting System
Replacement of Reflex Reflector Replacement of High Mounted Stop Lamp

Removal Removal
2 Remove 2 fastening nuts and 2 washers of the 2 Remove the interior trim panel assembly.
reflex reflector.
3 Press the buckle of high mounted stop lamp with
a flat blade screwdriver through the access hole,
and eject out the high mounted stop lamp.
ES220010
3 Remove the reflex reflector assembly.

ES220011

Installation
5 Remove the high mounted stop lamp assembly.
ES220012
Installation
43-8
Wiper/Washer System
Wiper/Washer System
Torque
Nut - wiper arm assembly 22 ± 2

Bolt - wiper motor assembly 9±1
Bolt - front washer reservoir assembly 9±1
44-1
Wiper/Washer System
Layout
Layout
ES350001
1 Wiper linkage mechanism 3 Wiper arm

2 Wiper motor 4 Wiper blade
44-2
Wiper/Washer System
Front Washer Reservoir Assembly
ES350002
44-3
Wiper/Washer System
Repair Guidance
Replacement of Wiper Blade Replacement of Wiper Arm Assembly
Removal Removal
1 Rotate the wiper blade on the wiper arm. 1 Take off the wiper arm cover.
2 Slide the wiper blade downward along the wiper 2 Remove the nuts securing the wiper arm onto
arm while pressing the retaining clip to remove it. the linkage mechanism mandrel.
3 Remove the wiper arm assembly from the
linkage mechanism mandrel.
4 Remove the windshield wiper blade assembly
(refer to Replacement of Wiper Blade").
ES350003
Installation
1 Slide the wiper blade into the arm till the
retaining clip is engaged to install the wiper ES350004
blade.
2 Locate the wiper blade to the windshield. Installation
1 Install the windshield wiper blade assembly
(refer to Replacement of Wiper Blade").
2 Put the wiper arm onto the wiper linkage
mechanism mandrel and tighten with nuts.
Tightening torque: 22 ± 2.0N.m.
3 Install the wiper arm cover.
44-4
Wiper/Washer System
Replacement of Wiper Linkage Mechanism Installation

Assembly (with Motor)
1 Place the wiper motor assembly into the
Removal windshield gutter channel.
1 Place the wiper control switch on "PARK" 2 Tighten the screw connecting the linkage
position. mechanism assembly and the front wall to
9 ± 1N.m.
2 Disconnect the battery. Note: Disconnect the
negative first. 3 Adjust the linkage position to allow three joints of
the drive rod on the same line.
3 Remove the wipe arm (refer to Replacement of
Wiper Arm) 4 Tighten the wiper arm assembly nut to
22 ± 2N.m.
4 Remove the windshield cover plate assembly
(refer to Replacement of Windshield Cover Plate 5 Connect the harness connector of the wiper
Assembly). motor.
5 Disconnect the harness connector of the wiper 6 Connect the battery. Note: Connect the positive
motor. first.
6 Remove the linkage mechanism assembly 7 Operate the wiper switch shortly, check whether
screw. (Indicated by arrow) the wiper mechanism is on "PARK" position.
8 Install the wiper arm (refer to Replacement of
Wiper Arm Assembly).
9 Pour water on the windshield to check the
operability of the wiper. Connect the battery.
ES350005
7 Remove the wiper motor assembly.
44-5
Wiper/Washer System
Replacement of Wiper Motor Replacement of Washer Reservoir Cover

Removal Assembly
Removal
1 Remove the windshield wiper linkage
mechanism assembly witch motor (refer to 1 Remove the screws and washers, and carefully
Replacement of Wiper Linkage Mechanism pull out the washer reservoir cover assembly.
Assembly (with Motor)).
2 Take off the screws and nuts connecting the
motor and the linkage mechanism and remove
the wiper motor.
ES350007
Installation
ES350006
Installation
1 Installation is the reverse of removal. Observe
the following precaution:
44-6
Wiper/Washer System
Replacement of Washer Reservoir Assembly Replacement of Washer Pump

Removal Removal
1 Disconnect the battery. 1 Disconnect the battery. Note: Disconnect the

negative first.
Note：Disconnect the negative first.
windshield washer pump.
windshield washer pump.
3 Disconnect the hose from the windshield washer
3 Disconnect the hose from the windshield washer
pump.
pump.
4 Remove the wheelhouse liner.
ES350009
ES350008 4 Remove the washer pump from the washer

reservoir assembly.
5 Remove the nuts and bolts from the vehicle and
take off the washer reservoir assembly.
Installation
Installation 1 Installation is the reverse of removal. Observe

the following precaution:
1 Installation is the reverse of removal. Observe
the following precaution: —Reconnect the battery, the positive (+) first.
44-7
Wiper/Washer System

Wiper system is a functional system designed to keep a
clear view for the driver and passengers, which shall
work normally when the vehicle is parking or driving or at
the highest speed. The front wipers are required to wipe
in a clockwise manner. And the wiper system shall
possess the function of pedestrian protection.
Wiper motor assembly includes (but is not limited to): 1

wiper motor, 1 pair of drive linkage, left and right wiper
shaft lock ring (1 for each) and structures related to body
installation. IP54 wiper motor and above is equipped with
thermal protection device to prevent the performance
reduction in case of motor stalling.
The wiper shaft lock ring can not only reduce the
vibration, but also introduce the water flow at the end of
wiper arm to the windshield gutter channel, thereby
discharging out of the vehicle.
Wiper Arm Assembly
The wipe arm shall be serviceable during all wiping

processes. It is connected on the propeller shaft with the
nuts (each with a cap). The wiper arm shall be in an error
proofing design to ensure correct installation. And it must
be able to endure an excess of torque of the nut.
Wiper Blade
After-sales repair shall be achievable for the wiper blade

without using special tool. Under no circumstance can
the blade vibrate. And it should be with the function of
rotation prevention, so that the end of the blade will not
knock the glass during repair. Traditional wiper blades
are recommended for SV71 front wipers.
The wiper blade at the driver side shall be in the length of

600mm, at the front passenger side shall be 500mm and
355mm for the rear wiper blades.
44-8
Wiper/Washer System
Requirements for Wiping Mode
a Requirement for the minimum clearance between wiper blade top and intake grille/A-pillar (see Table 1)
Table 1
Intake grille/windshield weatherstrip (original position) Windshield weatherstrip (wiping position)
Driver side 2 degrees 2 degrees
Passenger side 2 degrees 2 degrees
b When the wiper blade at the passenger side is adopting the wiping mode at the driver side, the clearance between it
and the eye ellipse shall be no less than 100mm;
c The tolerance (as follows) of the wiper mechanism in the output shaft direction should be regards as the critical
dimension:
F/A C/C
Driver side: + 1° + 1°
Passenger side: + 1° + 1°
d The tolerance (critical dimension) within 1mm is allowed for the mounting point of front wiper mechanism;
e The positional tolerance (critical dimension) at the front wiper mechanism shaft spline shall be no more than 2mm;
f The torsion angle of front wiper is the critical dimension, with the tolerance within 2°; while the pressure at the wiper
arm top shall also be the critical dimension, with the tolerance within 8%.
Wipe blade quality
In the whole life span, the wipe blade can provide smooth wiping and the wiping quality shall be at least grade 5 (see
Table 2);
Table 2: Wiping Quality
Volts 13.5 10.5
Glass dry wet dry wet

Condition
Arm Force Blade Condition Motor Speed low high Low high low high low high
Nominal New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 >7 >7
End of Useful Life >5 >5 >5 >5 >5 >5 >5 >5
Min New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 >7 >7
Max New > 10 > 10 > 10 > 10 > 10 > 10 > 10 > 10
Perm. set >7 >7 >7 >7 >7 >7 7 >7
44-9
Wiper/Washer System
10 A very thin and discontinuous stripe
09 A very thin and discontinuous stripe
08 A very thin and continuous stripe
3 very thin and continuous stripes, but cannot be shown in the

07
center of the area being wiped
4 continuous stripes (with the width not more than 1mm), and
06 only 1 thin and discontinuous stripe can be shown in the
center of the area being wiped
6 thin and continuous stripes (with the width not more than
05 1mm), and only 1 very thin and continuous stripe can be
shown in the center of the area being wiped
04 A number of continuous stripes
03 A layer of thin film that cannot be wiped
02 Some areas cannot be wiped
01 Shake during the wiping
In any cases, wiper blade cannot be contacted with surrounding parts to avoid damage.
44-10
Horn
Horn
Layout
Layout
ES340000
1 Woofer 2 Tweeter
45-1
Horn
Repair Guidance
Horn Replacement
Removal
2 Remove the radiator grille assembly.
2
ES340001
3 Remove 1 bolt secure the woofer (1).

4 Remove 1 bolt secure the tweeter (2).
6 Remove the woofer (1) and tweeter (2).
Installation
45-2
SK81 controller instruction of GRADE-X
EMS （Engine Management System） VM FGT/VGT

Configuration
46-1
46-2
Special Function
46-3
1 EGR replacement
After changing component, turn on ignition switch.
Open GRADE-X, go to Configuration → EMS （Engine Management System） VM FGT/VGT → 【Trigger EGR offset
learning】to Trigger EGR valve (Close position)/ (Open position) offset Learning respectively.
In the following interface, press the Close to Trigger EGR valve (Close position) offset Learning.
Waiting for 30 seconds for EGR valve learning .
46-4
Press the Open to Trigger EGR valve (Open position) offset Learning.
Press the Cancel to exit.
Close the GRADE-X and ignition switch, waiting for 2 minutes, the EMS will save the new value.
46-5
2 TVA replacement
After changing component, open GRADE-X, go to Configuration → EMS（Engine Management System）VM FGT/VGT
→ 【Trigger TVA offset learning】to Trigger TVA offset Learning.
In the following interface, press the Close to Trigger TVA (Close position) offset Learning.
After finishing, close the GRADE-X and ignition switch, waiting for 2 minutes, the EMS will save the new value.
46-6
3 HFM replacement
→ HFM System 【HFM Drift compensation reset】 , FMO System 【FMO reset(Change HFM)】 .
After finishing one function, close the Grade-X and ignition switch, waiting for 2 minutes, the EMS will save the new value.
Then open the Grade-X and ignition switch again, go to the next function.
4 LSU replacement(Only available for Euro 5 EMS)
After changing component, open Grade-X, go to Configuration → EMS（Engine Management System）VM FGT/VGT
→ LSU System【LSU dew detection heater release reset】,【LSU adaptation reset】, FMO System【FMO reset(Change
LSU)】 .
46-7
After finishing one function, close the GRADE-X and ignition switch, waiting for 2 minutes, the EMS will save the new
value. Then open the GRADE-X and ignition switch again, go to the next function.
5 RPS(rail) replacement
→ FMO System 【FMO reset(Change RDS)】 .
46-8
6 Injector replacement
→ 【Write IQA】 , FMO System 【FMO reset(Change Injector)】 .
7 BPS replacement
→ HFM System 【HFM Drift compensation reset】 .
46-9
8 Clutch Pedal clutch pedal position sensor replacement（This function only use for the vehicles with 6MT and
clutch pedal position sensor.）
After changing component, open GRADE-X, go to Special Function → EMS（Engine Management System）VM FGT/
VGT → 【Clutch Pedal self learning】 .
In the following interface, step on the clutch pedal to keep 10 seconds, then press the OK button.
46-10
In the following interface, release the clutch pedal, waiting 10 seconds, and Routine status is Routine finished, then press
the OK button.
After finishing learning, press the OK button to exit.
46-11
9 DPF Catalyst Replacement(Only available for Euro 5 EMS)
VGT → DPF System 【DPF value reset】 .
10 DPF Soot mass VS DPF Special Functions in GRADE-X(Only available for Euro 5 EMS)
46-12
T4：Exhaust Gas Temperature upstream of oxidation catalyst
T5：The adapted value of temperature at TPFltUs
Soot mass in the State Strategy Result/Remark

particulate filter
0<Soot normal no no
mass<36.6g
36.6g ≤颗粒量 slight Check intake/exhaust system leakage.

<40g overload Check if T4 and T5 sensor mount opposite to
each other. Check DTC, and repair if any.
Then follow steps below
1. If vehicle and road condition can be
satisfied, use tester to trigger 【Cancel
regeneration locking】function(pay attention
to T4 and T5). Power off for 2min. Drive the
vehicle and keep vehicle speed at 60-80km/
h for 30min continuously. Power off for 2min
1.1 If Soot mass ≤ 20g, RGN successfully Symptom fixed, use tester to clean error
code
1.2 If 20g<Soot mass ≤ 36.6g, then RGN After RGN cycle, if Soot mass ≤ 20g,
again(pay attention to T4 and T5). use tester RGN successfully. Symptom fixed, use
to trigger 【Reset the regeneration lock and tester to clean error code. If Soot
increase the soot mass】function. Power off mass>20g, check DTC again (focus on
for 2min. Drive the vehicle and keep vehicle DTCs which can disable RGN, repair if
speed at 60-80km/h for 30min continuously. any). And check T5 temperature whetheer
Power off for 2min in 550-680degree during RGN
1.3 If 36.6g <Soot mass ≤ 40g, service RGN After RGN cycle, if Soot mass ≤ 20g,
efficiency is low and need RGN again(pay RGN successfully. Symptom fixed, use
attention to T5). use tester to trigger tester to clean error code. If 20g <Soot
【Cancel regeneration locking】function. mass ≤ 36.6g, check DTC again (focus
Power off for 2min. Drive the vehicle and on DTCs which can disable RGN, repair if
keep vehicle speed at 60-80km/h for 30min any). And check T5 temperature whetheer
continuously. Power off for 2min in 550-680degree during RGN
2.if vehicle cannot drive or road condition is
not satisfied, use service RGN. Use tester to
trigger 【Activate service regeneration by
tester】 function and wait for service RGN
stop. Service RGN stop condition: Soot
mass ≤ 20g or time of RGN ≥ 2400s. After
service RGN, power off for 2min
2.1 If Soot mass ≤ 20g, service RGN Symptom fixed, use tester to clean error
successfully code
2.2 If 20g<Soot mass ≤ 40g, then RGN After RGN cycle, if Soot mass ≤ 20g,
again(pay attention to T5). use tester to RGN successfully. Symptom fixed, use
trigger 【Activate service regeneration by tester to clean error code. If Soot
tester】 function and wait for service RGN mass>20g, check DFC again (focus on
stop. Power off for 2min DFCs which can disable RGN, repair if
any). And check T5 temperature whetheer
in 550-680degree during RGN
46-13
Soot mass in the State Strategy Result/Remark

particulate filter
40g ≤ Soot severe Check intake/exhaust system leakage. no

mass<49.95g overload Check if T4 and T5 sensor mount opposite to
each other. Check DFC, and repair if any.
3.use tester to trigger 【Activate service

regeneration by tester】function and wait for
service RGN stop. Service RGN stop
condition: Soot mass<20g or time of RGN ≥
2400s . After service RGN, power off for
2min:
3.1 If Soot mass ≤ 20g, service RGN Symptom fixed, use tester to clean error
successfully code, MIL off
3.2 If 20g<Soot mass ≤ 36.6g, then RGN After RGN cycle, if Soot mass ≤ 20g,
again(pay attention to T5). use tester to RGN successfully. Symptom fixed, use
trigger 【Reset the regeneration lock and tester to clean error code. If Soot
increase the soot mass】function. Power off mass>20g, check DFC again (focus on
for 2min. Drive the vehicle and keep vehicle DFCs which can disable RGN, repari if
speed at 60-80km/h for 30min continuously. any). And check T5 temperature
Power off for 2min whetheer in 550-680degree during RGN
3.3 If 36.6g<Soot mass ≤ 40g, service RGN After RGN cycle, if Soot mass ≤ 20g,
efficiency is low and need RGN again(pay RGN successfully. Symptom fixed, use
attention to T5). use tester to trigger tester to clean error code. If Soot
【Cancel regeneration locking】function. mass>20g, check DFC again (focus on
Power off for 2min. Drive the vehicle and DFCs which can disable RGN, repari if
keep vehicle speed at 60-80km/h for 30min any). And check T5 temperature
continuously. Power off for 2min whetheer in 550-680degree during RGN
3.4 If Soot mass>40g, Change a new DPF, if Symptom fixed, use tester to clean error
not change EMS, use tester to trigger code, MIL off
【DPF value reset】function. If change EMS,
first use 【Engine Running time】function to
copy the old EMS's Running time, then
replace the new EMS and go to 【Engine
Running time】function to set engine
running time to new EMS, then trigger
【DPF value reset】function
Soot mass ≥ blocking Check intake/exhaust system leakage.
49.95g Check if T4 and T5 sensor mount opposite to
each other. Check DTC, and repair if any.
4. Change a new DPF, if not change EMS, Symptom fixed, use tester to clean error
use tester to trigger 【DPF value reset】 code, MIL off
function. If change EMS, first use 【Engine
Running time 】 function to copy the old
EMS's Running time, then replace the new
EMS and go to 【Engine Running time】
function to set engine running time to new
EMS, then trigger 【DPF value reset】
function
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DTC list of forbid regeneration
DTC English name Block or Block

interrupt 【Activate
regeneration service
rengeration by
tester】
P0100-F4 Correction factor of the drift compensation function exceed the Y Y
maximum drift limit
P0100-F5 Correction factor of the drift compensation function exceed the Y Y
maximum drift limit
P0100-11 Battery voltage error of HFM sensor SCG of hardware signal of HFM N Y
sensor
P0100-F3 Sensitivity drift high error for HFM sensor Y Y
P0100-F1 Sensitivity drift error low for HFM sensor Y Y
P0103-29 Hardware error detection for HFM sensor Y Y
P0103-12 SRC high error for raw value in HFM sensor Y Y
P0102-11 SRC low error for raw value in HFM sensor Y Y
P0402-9C Air control system governor deviation above limit Y Y
P0401-9B Air control system governor deviation below limit N Y
P2299-64 Plausibility Check between APP and Brake N Y
P0563-85 SRC high for battery voltage sensor N Y
P0562-84 SRC low for battery voltage sensor N Y
P0116-27 Defect fault check for Coolant temperature dynamic plausibility test N Y
P0118-12 SRC High for Engine coolant temperature(down stream) N Y
P0117-11 SRC low for Engine coolant temperature(down stream) N Y
P1707-64 Plausibility check for Clutch N Y
U0431-F0 Message checksum error DFC for the receive frame BCM1 N Y
U0431-81 Message-Length-Error of CAN-Receive-Frame BCM1 N Y
U0141-87 Timeout DFC for the receive frame BCM1 N Y
U118C-81 DFC report if brake pedal switch message is invalid from CAN N Y
P0402-9B EGR Valve Permanent negative governor deviation Y Y
P042E-72 Jammed EGR valve in open state Y Y
P0073-12 SRC High for EnviroN.ment Temperature N Y
P0072-11 SRC Low for EnviroN.ment Temperature N Y
P0251-F1 Open load of metering unit output Y Y
P0252-92 Over teperature of device driver of metering unit Y Y
P0251-12 Short circuit to battery of metering unit output Y Y
P2263-F1 Error case for permanent MAX governor deviation for partial load Y Y
P2263-F3 Error case for permanent MIN governor deviation for partial load Y Y
P244B-00 Diagnostic fault check for maximum pressure differential Y Y
charecterstics of DPF
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DTC English name Block or Block

interrupt 【Activate
regeneration service
rengeration by
tester】
P0242-12 Diagnostic fault check for SRC high in air pressure upstream of Y Y
intake valve sensor
P0241-11 Diagnostic fault check for SRC low in air pressure upstream of intake Y Y
valve sensor
P0087-F2 Maximum positive deviation of rail pressure exceeded Y Y
P0087-F4 Maximum negative rail pressure deviation with metering unit on Y Y
lower limit is exceeded
P0088-F0 Maximum rail pressure exceeded Y Y
P0123-12 Signal Range Check High for APP1 Y Y
P0223-12 Signal Range Check High for APP2 Y Y
P0122-11 Signal Range Check Low for APP1 Y Y
P0222-11 Signal Range Check Low for APP2 Y Y
P0643-12 Error Sensor supplies 1 Y Y
P2135-64 Plausibility Check between APP1 and APP2 Y Y
P2112-73 Jammed valve closed of throttle valve Y Y
P2111-72 Jammed valve open of throttle valve Y Y
P2622-12 SRC high for throttle valve position sensor value Y Y
P2621-11 SRC low for throttle valve position sensor value Y Y
P0428-12 Diagnostic fault check for SRC high in Oxidation Catalyst upstream Y Y
temperature
P0427-11 Diagnostic fault check for SRC low in Oxidation Catalyst upstream Y Y
temperature
P200C-85 Physical Range Check high for particulate filter upstream Y Y
temperature sensor
P200C-11 Diagnostic fault check for SRC low in Particle filter upstream Y Y
temperature
P0045-13 No load error for turbo charger powerstage Y Y
P0045-4B Over temperature error for turbo charger powerstage Y Y
P0048-12 Short circuit to battery error of turbo charger powerstage Y Y
P0047-11 Short circuit to ground error of turbo charger powerstage Y Y
P215A-08 Signal error for vehicle speed over CAN Y Y
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11 EMS replacement (GRADE-X can communication with old EMS available)
11.1 Before changing the EMS, use GRADE-X to connect to the old EMS on vehicle, read the data lists as follow and
save them.
· VIN
· IQA injector quantity adjustment value
· ZFC correction value
· Engine running time
· Vehicle running distance
· Maximum Vehicle Speed Limitation
· Engine number
· Configuration （Include: Vehicle Speed Selection, Dual Flywheel configuration, Fan configuration, ABS/ESP
configuration, IMMO configuration, Cruise control device type configuration, Cruise control configuration, Start
configuration, AC Coolant Pressure sensor configuration, AC configuration）
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· HFM drift compensation value
· FMO value
· DPF value(Only available for Euro 5 EMS)
11.2 Change the new EMS.
11.3 Reflash the HEX.
11.4 IMMO match.
For AT vehicles with PEPS, after EMS replacement, go to Special Function → 【IMMO】→ 【PEPS(Passive Entry
Passive Start)】→ 【AT】→ 【New MC/EMS Learn】 to enable engine matching.
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For vehicles with PEPS, IMMO function is offered by PEPS and IMMO not used in BCM, so IMMO in BCM is Not-Exist
and PEPS is Exist. And IMMO in EMS configuration is Immobillizer.
Go to Configuration → 【BCM(Body Control Module)】→ 【Write BCM Configuration Information】
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Go to Configuration → EMS （Engine Management System） VM FGT/VGT → 【Configuration】
For vehicles without PEPS, after EMS replacement, go to Special Function → 【IMMO】→ 【BCM(Body Control
Module)】→ 【Change MC/EMS】to enable engine matching.
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For vehicles without PEPS, IMMO function is offered and used in BCM, so IMMO in BCM is Exist and PEPS is Not-
Exist.And IMMO in EMS configuration is Immobillizer.
Go to Configuration → EMS （Engine Management System） VM FGT/VGT → 【Configuration】
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11.5 Write the data lists of old EMS to the new EMS.
→ 【Write VIN】 , 【Write IQA】 , 【Write ZFC correction values】 , 【Write Engine running time】 , 【Vehicle running
distance】, 【Write Maximum Vehicle Speed Limitation】, 【Write Engine number】, 【Configuration】（Include: Vehicle
Speed Selection, Dual Flywheel configuration, Fan configuration, ABS/ESP configuration, IMMO configuration, Cruise
control device type configuration, Cruise control configuration, Start configuration, AC Coolant Pressure sensor
configuration, AC configuration） , HFM System 【HFM drift compensation write】 , FMO System 【FMO write】 .
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Go to Special Function → EMS （Engine Management System） VM FGT/VGT → DPF System 【DPF value write】
(Only available for Euro 5 EMS)
11.6 Go to reset.
Go to Configuration → EMS（Engine Management System）VM FGT/VGT →【Trigger EGR offset learning】,【Trigger

TVA offset learning】, LSU System 【LSU dew detection heater release reset】(Only available for Euro 5 EMS),【LSU
adaptation reset】 (Only available for Euro 5 EMS).
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11.7 Clutch Pedal clutch pedal position sensor replacement（This function only use for the vehicles with 6MT and clutch
pedal position sensor.）
VGT → 【Clutch Pedal self learning】
12 EMS replacement (Communication with old EMS not available)
12.1 Change the new EMS.
12.2 Reflash the HEX.
12.3 IMMO match. See 11.4.
12.4 Write the data lists to the new EMS.
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→【Write VIN】,【Write IQA】,【Maximum Vehicle Speed Limitation】, 【Engine number write】, 【Configuration】
（Include: Vehicle Speed Selection, Dual Flywheel configuration, Fan configuration, ABS/ESP configuration, IMMO
configuration, Cruise control device type configuration, Cruise control configuration, Start configuration, AC Coolant
Pressure sensor configuration, AC configuration） .
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12.5 Go to reset.
VGT → DPF System 【DPF value reset】 (Only available for Euro 5 EMS).
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12.6 Clutch Pedal clutch pedal position sensor replacement（This function only use for the vehicles with 6MT and clutch
pedal position sensor.）
VGT → 【Clutch Pedal self learning】 .
13 Special Functions for Auxiliary Engine Diagnosis
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13.1 Special Function → EMS（Engine Management System）VM FGT/VGT【Cylinder Specific Engine Speed】(Only
available for Euro 5 EMS)
Cylinder Specific Engine Speed test is a function integrated in the electronic control unit (ECU) to evaluate the
comprehensive performance of the combusting condition of each cylinder. During the test, the engine shall be kept
running at a steady speed. The ECU will measure the instantaneous engine speed at the power stroke of each cylinder.
By comparing the rotational speed of each cylinder, the integrated conditions of combusting and power for each cylinder
can be evaluated comprehensively.
Prerequisites for Starting the Test: 1. Normal engine running; 2. Hand brake is applied e; 3. In the Neutral position, with
the vehicle speed at 0; 4. No synchronization signal or sensor-related electrical fault in the system; 5. Battery is fully
charged.
By the test, the instantaneous speed of each cylinder at the idle/stable speed shall be evaluated. When the speed of one
or more cylinders differs greatly from that of other cylinder, the engine cylinder air-tightness and/or fuel injector
performance shall be checked further through the 【Compression Test】and 【Run-Up Test】 .
13.2 Special Function → EMS（Engine Management System）VM FGT/VGT【Shut-off Test】(Only available for Euro
5 EMS)
Shut-off Test is a software function integrated in the ECU to control injection of the fuel injectors through the diagnostic
equipment. During the test, you can individually control a single injection or multiple injections (such as shut-off pre-
injection or main injection + pre-injection) of the fuel injector(s) of a certain cylinder (or multiple cylinders). This can be
used to detect the fuel injector performances through comprehensive evaluation of the engine performance before and
after the injection shut-off.
Prerequisites for Starting the Test: 1. Normal engine running; 2. Hand brake is applied; 3. In the Neutral position, with the
vehicle speed at 0; 4. No synchronization signal or sensor-related electrical fault in the system; 5. Battery is fully charged.
By the test, you are allowed to control (turn on/off) the injection of the fuel injector of each cylinder flexibly, so as to
perform different operations for variant fault symptoms. For example:
Engine smoke: You can shut off all the injections (pre-injection, main injection and post-injection 【if any】 ) of the fuel
injectors of the cylinders one by one, and then check whether the smoke phenomenon is removed. If so, it is likely that
there is a trouble in the cylinder air tightness, or the injection quantity is too large. Furthermore, this can be judged
comprehensively from the results of the compression test and the run-up test.
Engine knock: You can shut off the pre-injection of the fuel injectors of the cylinders one by one, and then check whether
the engine noise becomes large after turning off the injection of each cylinder. If there is a significant change in the engine
noise before and after turning off the pre-injection, this indicates that the pre-injection of the injector of the cylinder can be
performed basically and properly as expected. Otherwise, this indicates that the pre-injection of the fuel injector of the
cylinder fails.
13.3 Special Function → EMS（Engine Management System）VM FGT/VGT【Information For Trouble In Starting Of
Engine】 (Only available for Euro 5 EMS)
This function is used to give the maintenance personnel the engine start trouble information, including the rail pressure is
not established, no engine speed signal is detected (no crankshaft / camshaft sensor signal), synchronization failure, start
failure due to serious system / sensor failure, etc. Reading the start trouble information can help the maintenance
personnel to quickly locate the cause leading to the start failure, thus indicating the direction for further troubleshooting.
Prerequisites for Starting the Test: 1. Engine stopped, with the ignition switch in the ON position; 2. Hand brake is applied;
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3. Gear in the Neutral position; 4. Battery is fully charged; 5. Air-conditioning equipment and other power utilization
equipment are turned off.
By the test, the fault reasons for failure to start can be read through the diagnostic tester and a preliminary assessment
can be made.
13.4 Special Function → EMS（Engine Management System）VM FGT/VGT【Compression Test】 (Only available
for Euro 5 EMS)
Compression test is an engine test function integrated in the ECU and used primarily for the detection of the air tightness
of each cylinder. This function can work only after the diagnostic tester is triggered. After the compression test is run
through the diagnostic tester, the ignition switch needs to be turned and allows the starter to drive the engine to run. The
ECU will automatically measure the running time of a certain angle section after top dead center of each cylinder to
calculate the instantaneous speed. In this process, the ECU stops fuel injection so that the engine will not start.
Prerequisites for Starting the Test: 1. Engine stopped, with the ignition switch in the ON position; 2. Hand brake is applied;
3. Gear in the Neutral position; 4. No crankshaft/camshaft-related electrical faults; 5. Battery is fully charged (otherwise,
the test may fail, or the test results cannot be trusted)
Procedures: 1. Turn the ignition switch to ON, and let the engine be shut down; 2. Connect the diagnostic tester and
activate the compression test through diagnostic tester; 3. After receiving the prompt from the diagnostic tester, turn the
ignition switch to operate the starter; 4. After receiving the prompt that the test by the diagnostic tester finishes, release
the ignition switch; 5. Check the test results.
By the test, the diagnostic tester will display the speed of each cylinder after the test finishes. The air tightness for each
cylinder can be assessed by calculating the deviation between the speed of each cylinder and the average speed of the
other cylinders. When the deviation is too large, it is recommended to check the air tightness of the cylinder, including
valve clearance and piston rings and other mechanical parts.
13.5 Special Function → EMS（Engine Management System）VM FGT/VGT【High Pressure Test】(Only available
for Euro 5 EMS)
High pressure test is a test function for the engine fuel system integrated in the ECU and used for the performance
evaluation of the engine oil lines and the fuel system components. This function is triggered by the diagnostic tester. High
pressure test is divided into two phases: efficiency detection of system pressure building and leak detection of high
pressure fuel lines.
The detection of the pressure-building efficiency of low pressure system is achieved by measuring the time required for
the fuel system to reach a certain set rail pressure at different engine speeds. In this process, the ECU will control the
engine to run at four different speeds, and respectively measure the time required from the lower rail pressure setpoint to
the higher one t1, t2, t3, t4.
The high-pressure fuel line leak detection is used to determine whether there is a leak phenomenon in the high pressure
fuel line by measuring the time required from the maximum of the system rail pressure to the rail pressure value of certain
two measuring points. In this test phase, the ECU will allow the system rail pressure to be maintained at the allowable
maximum rail pressure, and then stop fuel injection to allow the fuel in the rail to leak naturally. The ECU will measure the
time required from the highest rail pressure to a desired set point t5 and the time required from the set point to another
lower rail pressure value t6.
Prerequisites for Starting the Test: 1. Engine is idling; 2. Hand brake is applied; 3. Gear in the Neutral position, with the
vehicle speed at 0; 4. Battery is fully charged; 5. No water temperature sensor/fuel system actuator/sensor-related
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electrical fault; 6. During the test, the brake pedal is released; 7. During the test, the accelerator pedal is released; 8.
During the test, the clutch pedal is released; 9. Coolant temperature must be greater than 70 ° C.
By the test, for the two stages of the high-pressure test, evaluation of the test results shall be also divided into two parts.
System pressure-building efficiency detection: When one or more values in t1, t2, t3 and t4 is greater than the prescribed
limit, this may be caused by one or more of the following reasons: a. blockage or leakage of low-pressure fuel line or
fittings; b. fuel filter clogging; c. high-pressure pump inlet blockage; d. high-pressure pump's gear pump failure; e. high-
pressure fuel line leakage.
High-pressure fuel line leak detection: When t5 and/or t6 are smaller than the prescribed limit, this may be caused by one
or more of the following reasons: a. leakage of high-pressure fuel line components /pipeline; b. excessive fuel return
caused by fuel injector valve seat wear.
13.6 Special Function → EMS（Engine Management System）VM FGT/VGT【Run-Up Test】(Only available for Euro
5 EMS)
Run-up test is a function integrated in the ECU to evaluate the performance of fuel injectors of each cylinder. During the
test, the test is triggered by the diagnostic tester and the injection of each cylinder injector is disabled individually. The
ECU will control the other cylinder injectors to perform a limited number of injections under a certain rail pressure in
accordance with the programmed injection quantity, and automatically record the maximum speed of the engine after the
injection finishes. The performance of each cylinder injector can be evaluated through the assessment of the maximum
speed measured after each cylinder injector disabled. NOTE: Before the run-up test, the 【Compression Test】 must be
carried out to ensure that the airtightness of each cylinder is normal.
Prerequisites for Starting the Test: 1. 【Compression Test】has been completed, and the air tightness of each cylinder is
normal; 2. Engine is idle; 3. Hand brake is applied; 4. Gear in the Neutral position, with the vehicle speed at 0; 5. Battery
is fully charged; 6. No water temperature sensor/fuel system actuator/sensor-related electrical fault; 7. Air conditioning
equipment and other power utilization equipment are turned off; 8. For vehicle models with air brakes, make sure the air
pump is not operating in the whole testing process. Otherwise, the test results may be severely affected, and the test
needs to be re-triggered. It is proposed to start this test at a full pressure of the air reservoir; 9. During the test, the brake
pedal is released; 10. During the test, the accelerator pedal is released; 11. During the test, the clutch pedal is released;
12. Coolant temperature must be greater than 70 ° C.
By the test, the results of the compression test must be judged before evaluating the run-up test results to ensure the
airtightness of each cylinder is normal. Otherwise, the difference of the air tightness of each cylinder of the engine will
seriously affect the credibility of the results of the run-up test, so that the assessment of the injectors cannot be trusted. If
a cylinder injector is disabled, when there is a great deviation between its measured speed and the average of the
measured speeds of the other cylinder injectors disabled, this indicates that there may be a larger injection deviation in
the injector corresponding to the cylinder. When the speed deviation is greater than the predetermined positive deviation
limit, this indicates that there may be a trouble of smaller fuel injection quantity in the injector corresponding to the
cylinder. When the speed deviation is greater than the predetermined negative deviation limit, this indicates that there
may be a trouble of larger fuel injection quantity in the injector corresponding to the cylinder.
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BCM
1 After replacement, complete controller configuration with diagnostic software based on vehicle actual
configuration.
46-31
2 For vehicles without PEPS, after BCM replacement, go to Special Function → 【IMMO】→ 【BCM(Body
Control Module)】→ 【Change BCM IMMO】 to enable BCM matching, then add current vehicle keys to
newly replaced BCM with 【Add Key】 .
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For vehicles without PEPS, IMMO function is offered and used in BCM, so IMMO in BCM is Exist and PEPS is Not-Exist.
3 If your vehicle have Car Network function, after matching BCM, go to Special Function → 【TBOX Car
Network Match】→ 【Change BCM 】 to enable BCM matching.
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4 After matching BCM, go to Special Function →【BCM（Body Control Module）】→【Brake pedal learning】
to brake pedal learning.
46-34
5 If your vehicle have Rain Light Sensor, after matching BCM, go to Special Function →【BCM（Body Control
Module）】→ 【Initialize RLS(Rain Light Sensor)】 to Initialize Rain Light Sensor.
46-35
PEPS
1 After replacement, complete controller configuration with diagnostic software based on vehicle actual
configuration.
46-36
【ECU Config】function as follows：
46-37
2 For AT vehicles with PEPS, after PEPS replacement, go to Special Function →【IMMO】→【PEPS(Passive
Entry Passive Start)】→【AT】→【New Peps Learn(AT)】 to enable PEPS matching. Press the unlock button
to active the new fob after the new fob added.
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3 For MT vehicles with PEPS, after PEPS replacement, go to Special Function→【IMMO】→【PEPS(Passive

Entry Passive Start)】→ 【MT】→ 【New Peps Learn(MT)】 to enable PEPS matching. Press the unlock
button to active the new fob after the new fob added.
46-39
Note：For vehicles with PEPS, IMMO function is offered by PEPS and IMMO not used in BCM, so IMMO in BCM is Not-
Exist and PEPS is Exist.
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4 For MT vehicles with PEPS, after replace ESCL(Electrical Steering Colum Lock), go to Special Function →
【IMMO】→ 【PEPS(Passive Entry Passive Start)】→ 【MT】→ 【New ESCL Learn】 to enable
ESCL(Electrical Steering Colum Lock) matching.
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IMMO matching method of replacing PEPS and EMS at the same time
1 For vehicles with PEPS, after simultaneous PEPS and EMS replacement, use GRADE-X to finish EMS
reflash with corresponding vehicles of data, complete controller PEPS and EMS basic configuration with
diagnostic software. Then go to Special Function →【IMMO】→【PEPS(Passive Entry Passive Start)】→
【AT】/ 【MT】→【All New System Learn (AT)】/【All New System Learn (MT)】 to operate PEPS and EMS
matching learning. At this time, the original vehicle fob will be out of service as well and a new fob required to
be learned again (no BCM IMMO matching operation required as PEPS IMMO enabled). Press the unlock
button to active the new fob after the new fob added.
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IMMO matching method of replacing BCM and EMS at the same time
1 For vehicles without PEPS, after simultaneous BCM and EMS replacement, use GRADE-X to finish EMS
reflash with corresponding vehicles of data, complete controller BCM and EMS basic configuration with
diagnostic software. Then go to Special Function →【IMMO】→【BCM(Body Control Module)】→【Replace
the Whole System】 to operate BCM matching, generate SK and teach EMS learn SK in BCM. At that, the
original vehicle key will be out of service as well and a new key required to be learned by going to 【Add
Key】 process.
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2 For vehicles with PEPS, after simultaneous BCM and EMS replacement, use GRADE-X to finish EMS
reflash with corresponding vehicles of data, complete controller BCM and EMS basic configuration with
diagnostic software. Then go to Special Function →【IMMO】→【PEPS(Passive Entry Passive Start)】→
【AT】 / 【MT】→ 【New MC/EMS Learn】 to enable engine matching.
For vehicles with PEPS, IMMO function is offered by PEPS and IMMO not used in BCM, so IMMO in BCM is Not-Exist
and PEPS is Exist. And IMMO in EMS configuration is Immobillizer (PEPS)
46-44
3 If your vehicle have Car Network function, after matching BCM, go to Special Function → 【TBOX Car
Network Match】→ 【Change BCM 】 to enable BCM matching.
46-45
TBOX
1 After replacement, go to Configuration to write vehicle VIN in with diagnostic software.
2 Go to Special Function → 【TBOX Car Network Match】→ 【Change TBOX】 to enable TBOX matching,
then go to 【Get New Authentication Key】 to get new authentication key.
46-46
Caution:If you replace the BCM and TBOX at the same time, please see "BCM", after replacement, complete controller
configuration with diagnostic software based on vehicle actual configuration. For vehicles without PEPS, after BCM
replacement, go to Special Function →【IMMO】→【BCM(Body Control Module)】→【Change BCM IMMO】to enable
BCM matching, then add current vehicle keys to newly replaced BCM with 【Add Key】 . For vehicles without PEPS,
IMMO function is offered and used in BCM, so IMMO in BCM is Exist and PEPS is Not-Exist, go to Configuration →
【BCM(Body Control Module)】→ 【Write BCM Configuration Information】 . Then go to Special Function → 【TBOX
Car Network Match】→ 【Change BCM and TBOX】 to enable TBOX matching, then go to 【Get New Authentication
Key】 to get new authentication key.
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TCU
1 After replacement, go to Configuration to complete controller configuration with diagnostic software based
on vehicle actual configuration.
46-48
ABS/ESP
2 Go to Special Function to complete special function with diagnostic software based on vehicle actual
configuration.
46-49
SAS
1 After SAS replacement, go to Special Function to complete calibration operation in special function with
diagnostic software.
46-50
SRS
46-51
TPMS
46-52
IPK
Note：After 【Write VIN】 through GRADE-X,IPK will copy the vehicle mileage from BCM automatic, then re-start the
engine, mileage copy success.
46-53
2 With next vehicle maintenance indicator lighting on, maintenance mileage can be reset with go to Special
Function to 【Perform SIA Reset】 . This function is suggested for vehicle maintenance every time.
46-54
AFS
46-55
configuration.
46-56
GAW
46-57
LDW
46-58
configuration.
46-59
HVAC
46-60
TCCU
46-61
LSM
46-62
BSD
46-63
FICM-Color Radio
46-64
FICM
46-65
46-66
Electrical System
Electrical System
Fuse
Auxiliary Fuse Box (Engine Compartment)
R1
R2
R3
R4
R5
R6
R7
R8
FS17
FS18
FS19
FS20
FS21
FS22
FS23
FS24
FS25
FS26
FS27
FS28
FS29
FS30
FS31
FS32
PR1
FS34
FS33
R14
R15
R16
R17
JF11
PR2
R10
R12
R13
R11
R9
JF12
FS10
FS12
FS13
FS14
FS15
FS16
MID1
FS11
FS1
FS2
FS3
FS4
FS5
FS6
FS7
FS8
FS9
JF10
JF9
JF8
JF7
JF6
JF5
JF4
JF3
JF2
JF1
ES290001
Fuses Specification Function
JF1 30A Main relay
JF2 40A/60A DC stabilizer 2/cooling fan (480W)
JF3 30A Starter
JF4 30A Passenger compartment fuse box power supply 1
JF8 40A ABS power supply (motor)
JF9 40A Front blower
JF10 60A Pre-heating relay/fuel pump
JF11 60A Window regulator motor
FS1 30A Transfer case control module
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Electrical System
FS2 25A Rearview mirror/heated rear window
FS3 30A Passenger compartment fuse box power supply 6
FS4 25A/10A Fuel heater/engine control module
FS5 25A ABS power supply - valve
FS6 30A Towing module
FS7 20A Front wiper
FS8 10A/15A Ignition switch/(passive entry & passive start and electronic steering column lock)
FS9 15A A/C compressor
FS11 15A Front fog lamp
FS13 25A Low beam headlamp/regulating motor
FS14 20A High beam headlamp
FS15 10A Daytime running lamp/position lamp
FS17 15A Main relay power supply 1
FS20 - -
FS21 15A Water pump
FS22 10A Starter
FS23 - -
FS24 - -
FS25 - -
FS26 - -
FS27 - -
FS28 15A Left high beam
FS29 15A Right high beam
FS30 15A Left low beam
FS31 15A Right low beam
FS32 10A Headlamp leveling
FS33 - -
FS34 - -
MIDI 80A Cooling fan (600W)
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Electrical System
Relays Function
PR1 Cooling fan high speed
PR2 Cooling fan medium speed
R1 Water pump
R2 -
R3 Cooling fan low speed
R4 Starter relay
R5 Fuel heater/fuel pump relay
R6 Wiper power supply relay
R7 Wiper speed control relay
R8 Main relay
R9 A/C compressor relay
R10 Rear fog lamp relay
R11 Position lamp relay
R12 Left front fog lamp relay
R13 Right front fog lamp relay
R14 Low beam relay
R15 High beam relay
R16 Left daytime running lamp relay
R17 Right daytime running lamp relay
47-3
Electrical System
Master Fuse Box (Passenger Compartment)
FS34 JF1 FS21 FS13 FS1 FS35

FS33 R6 R7 FS22 FS14 FS2 R9 R8 FS36
FS31 FS24 FS16 FS4 FS38
FS29 FS26 FS18 FS6 FS40
FS28 R4 R5 FS19 FS7 R11 R10 FS41
FS27 R3 FS20 FS8 FS42
FS9
FS10
R1 R2 FS11
FS12
ES290002
JF1 - -
JF2 25A Driver's seat adjustment
JF3 25A Front passenger's seat adjustment
FS1 7.5A Engine control module
FS2 10A Instrument/body control module
FS3 10A Airbag control module
FS4 7.5A ABS/electronic stability program
FS5 10A Tire pressure monitoring/gateway
FS6 10A Automatic transmission/shift lever
FS7 7.5A Mirror fold
FS8 25A Central lock
FS9 7.5A Interior lamp
FS10 10A Fuel tank cap actuator
FS11 10A Windshield washer
47-4
Electrical System
FS12 25A Exterior lamp
FS13 10A Internet of vehicles/10-inch screen
FS14 25A Inverter
FS15 10A Driver's seat heater
FS16 10A Front passenger's seat heater
FS17 15A 12V socket/A/C blower
FS18 10A Inverter/rearview mirror regulation/towing
FS19 15A Cigar lighter
FS20 10A Gateway/tuner
FS21 10A Data link connector/tire pressure monitoring
FS22 10A Automatic transmission
FS23 25A Entertainment system/tuner
FS24 10A Instrument/IMMO base station
FS25 20A Horn
FS26 10A Headlamp self-adaptive adjustment/A/C panel/rain & solar sensor
FS27 10A Transfer case controller/front axle clutch
FS28 10A Front blower feedback signal
FS29 25A Driver's window regulator motor
FS30 25A Front passenger's window regulator motor
FS31 25A Rear left window regulator motor
FS32 25A Rear right window regulator motor
FS33 15A Gateway
FS34 7.5A Mirror heater
FS35 - -
FS36 - -
FS37 25A Towing power supply 1
FS38 25A Towing power supply 2
FS39 25A DC stabilizer 1
47-5
Electrical System
Relays Function
R1 Front blower relay
R2 ACC relay
R3 IG relay
R4 -
R5 Horn relay
R6 Left window regulator motor relay
R7 Left window regulator motor relay

R8 Driver's power seat regulator relay
R9 Front passenger's power seat regulator relay
R10 Rearview mirrors & heated rear window relay

R11 -
47-6
Electrical System
Layout of Complete Vehicle Harness
4 5
2 5
3
7 8
10
9
13 11 14
12
16
17
15
47-7
Electrical System
1 Engine compartment harness 10 Transmission harness

2 Engine harness 11 Floor harness
3 Battery harness 12 Chassis harness
4 Negative battery harness 13 Rear left door harness
5 Engine grounding harness 14 Rear right door harness
6 Instrument panel harness 15 Reverse sensor harness
7 Driver's door harness 16 Camera harness
8 Front passenger's door harness 17 Towing harness
9 Roof harness
47-8
Electrical System
Layout of Grounding Points
G_EN1N G_EN2
G_EN2N G_EN1
G_EBR1_1
G_EBL1 G_EBR1_2
G_EBR1_3
G_EBL2_1
G_EBR1_4
G_EBL2_2 G_EN03 G_EBR2_1
G_EBL2_3 G_BT1 G_EBR2_2
G_EBL3_1
G_EBL3_2
G_IPL_5
G_IPL_3
G_IPL_1
G_EBR3
G_IPR_2
G_IPL_2
G_IPL_4
G_IPR_3 G_IPR_1
G_IP5_1
G_IP5_2 G_IP3
G_IP6 G_IP4_1
G_IP4_2
G_IP4_3
G_FLBL_2 G_FLBR_1
G_FLBL_1 G_FLBR_2
G_FLBR_3
G_FLL2_4
G_FLL2_3 G_FLL2_1
G_FLL2_2 G_FLR1 G_FLR2_1
G_FLR2_3
G_FLR2_2
G_FLL1_4
G_FLL1_3
G_FLL1_1
G_FLL1_2
G_FLCL_1
G_FLCL_2
G_FLCL_3
ES290004
47-9
Electrical System
47-10
Connector
Connector
This section lists the details of each connector based on the connector number and describes each connector in details in
a standard format. The connector number is located at the top of each page. The information of each connector includes
the followings:
·Connector number - the number distributed by the system, with a prefix representing the harness name code, e.g.
"RA12","BT01", etc. (refer to Harness Name Code).
·Connector description - generally derives from the component it connected.
·Connector position - defines the specific position of the connector on the vehicle, combining with the illustration.
·Connector color - indicates the color of the connector housing.
·Connector nature - male/female connector, generally including convex pin or concave pin.
·Connector end view - displays the connector profile and the pin layout (with pin no.).
·Pin description - describes in a two-column table as below, showing the color of each wire in the connector.
Pin No. Wire Color
1 BLK
2 WHT
3 RED
Pin No.: represents the serial number of each connector pin.

Wire Color: represents the wire color of the connector pin (refer to Harness Color Code)
Note：Some jacks may have no wire connected.
48-1
Connector
IP2DRD_1 17 GY 295A
17 L-GN 295H
18 GY 6798C
22 2120 19 D-BU 1166

19 18 16 15
17 20 PU 218
14 13 11 10
12 21 BN 219
9 8 6 5
7
4 3 2 1 22 BK 850PA
IP2DRD_1
Connector Connect to the driver door harness

Description
Connector Lower part of left A-pillar

Position
Connector Natural
Color
Connector Female
Nature
Pin Wire Color Wire Code
1 L-BU 14B
2 RD/WH 4040C
3 YE 166A
4 TN 167A
5 YE/BK 6859A
6 PK 5853A
7 WH 249E
8 TN 201A
8 TN 201R
9 GY 118A
9 GY 118R
10 RD/WH 1640A
11 BARE SHIELD6798C
12 TN 294A
13 BN/OG 6202C
14 PK/BK 780A
15 GY/BK 745A
16 OG 6201C
48-2
Connector
IP2DRD_2 G_IPL_1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
IP2DRD_2 G_IPL_1
Connector Connect to the driver door harness Connector Instrument harness ground
Description Description
Connector Lower part of left A-pillar Connector Lower part of left A-pillar
Position Position
Connector Natural Connector Silver

Color Color
Connector Female Connector Connector with hole

Nature Nature
Pin Wire Color Wire Code Pin Wire Color Wire Code
1 D-BU/YE 7176A 1 BK 850
2 D-BU/BK 7177A
3 GY 1963A
4 PU/WH 1382P
5 PK/WH 1447A
6 D-GN 168A
7 PU 169A
8 L-GN 170A
9 GY 171A
10 BN/WH 1498A
11 OG 889A
12 GY 90A
13 BK 850Z
14 YE 190A
15 PK 191A
16 RD/BK 1142
48-3
Connector
IP2FL_1 B11 WH 199B
B11 WH 199R
B12 YE 116B
B12 YE 116R
A2
A7
A3
A8
A4
A6
A5
A1
C1 WH/BK 2132
B12 C12
B11 C11
B10 C10
B9
B6
B5
B4
B3
B2
B8
B7
B1
C3
C2 PU/WH 6628
C2
C8
C7
C5
C9
C6
C4
C1
C3 D-GN 2134
D3
D4
D6
D5
D2
D8
D1
D7
C4 WH/BK 6629
IP2FL_1 C5 BN/OG 2118B
C6 OG/BK 2119B
Connector Connect to the driver door harness
C7 BN/OG 2118
Description
C7 BN/OG 2118J
Position C8 OG/BK 2119
Connector Natural
C8 OG/BK 2119J
Color
C9 RD/WH 4740B
Connector Female
Nature C10 RD/WH 840A
C11 D-GN 1562
A1 L-BU 1320A C12 D-GN/WH 1559
A2 RD/WH 1140 D1 YE/BK 7482A
A3 RD/WH 4640 D2 D-GN 7481A
A4 RD 242EE D3 YE 234
A5 L-BU 1296A D4 RD/WH 4440B
A6 D-BU 5985 D5 BN 1865A
A7 BN 998 D6 YE 288A
A8 RD/WH 840C D7 PK 2077A
B1 RD/WH 4040D D8 D-BU 2479A
B2 D-GN 168A
B3 PU 169A
B4 YE/BK 6859C
B5 PU/WH 1382F
B6 D-BU 4042D
B7 L-GN 170A
B8 GY 171A
B9 YE/BK 6859D
B10 PU/WH 1382E
48-4
Connector
G_IPL_2 G_IPL_3
G_IPL_2 G_IPL_3
Connector Instrument harness ground Connector Instrument harness ground

Position Position
Connector Natural Connector Natural

Color Color
Connector Male Connector Male

Nature Nature
1 BK 850S 1 BK 850PA
48-5
Connector
G_IPL_4 G_IPL_5
G_IPL_4 G_IPL_5

Position Position

Color Color

Nature Nature
1 BK 850PB 1 BK 850Z
48-6
Connector
IP09_C IP09_B
12 11 10 9 8 7 16 15 14 13 12 11 10 9
6 5 4 3 2 1 8 7 6 5 4 3 2 1
IP09_C IP09_B
Connector PEPS control module Connector PEPS control module

Connector Rear of PEPS control module Connector Rear of PEPS control module
Position Position
Connector White Connector White

Color Color
Connector Female Connector Female

Nature Nature
1 PU 218 1 BN/BK 5720
2 OG 5708 2 - -
3 L-GN 5707 3 - -
4 PK 5709 4 BN 4A
5 - - 5 D-BU 3A
6 - - 6 - -
7 BN 219 7 BN 6433G
8 OG/BK 5712 8 WH 5741
9 L-GN/BK 5711 9 - -
10 PK/WH 5713 10 D-BU/BK 5719
11 - - 11 D-GN/BK 3558
12 - - 12 - -
13 BK/GY 3559
14 - -
15 L-GN/BK 6432G
16 - -
48-7
Connector
IP09_A 19 GY 344A
20 - -
21 RD/YE 5240C
22 - -
23 PU 1604
1 13
24 D-BU 229
14 26
25 L-GN 483
26 - -
IP09_A
Connector PEPS control module

Description
Connector Rear of PEPS control module

Position
Connector White
Color
Connector Female
Nature
1 RD/BK 42C
2 RD/BK 42B
3 OG/BK 233
4 D-BU 1166
5 - -
6 - -
7 - -
8 - -
9 RD/WH 1140P
10 L-GN 11
11 OG 1603
12 D-GN 220
13 - -
14 BK 850PE
15 BK 850PS
16 YE/BK 1827A
17 GY 1167
18 - -
48-8
Connector
IP66 IP28
A B
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
IP66 IP28
Connector Terminal Resistance Connector Data link connector

Connector Left side of the instrument panel Connector Left side of the instrument panel
Position beam Position beam
Connector Black Connector Black

Color Color

Nature Nature
A PK/WH 6434C 1 OG/BK 6444
B GY/BK 6435C 2 YE/BK 6445
3 - -
4 BK 750DB
5 BK 750DA
6 PK/WH 6434E
6 BN/WH 6437L
7 PU 326
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 GY/BK 6435E
14 WH 6436L
15 - -
16 RD/WH 4740C
48-9
Connector
IP2EB_1 15 RD/WH 842N
16 RD/WH 640E
17 RD/WH 2940A
44 45 46 47 48 49 50 51 52 53 54 55 56 57
18 RD/WH 1540C
36 37 38 39 40 41 42 43
34 35 19 PU 6NAD
32 33
27 28 29 30 31
25 26 20 D-GN 1329
23 24
16 17 18 19 20 21
21 L-BU 7483A
15 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
22 L-GN 6257A
IP2EB_1 23 RD/BK 42A
24 D-BU 1809A
Connector Connect to the engine compartment
25 TN 407NC
Description harness
26 L-GN/BK 6258A
Position 27 YE/BK 6120NA
Connector Natural
28 RD/BK 642A
Color
29 RD 3040A
Connector Male
Nature 30 RD/WH 340A
31 BN/WH 2086C
1 D-BU 6105K 32 BN/WH 5974
2 L-BU 6106K 33 OG/BK 5219F
3 D-BU 6105L 34 GY 2165B
3 BN/WH 6437J 35 BN 2184B
4 WH 6106L 36 PU 2185B
4 WH 6436J 37 RD/YE 242E
5 BN/WH 2500C 38 RD/BK 242F
5 BN/WH 6437F 39 RD/BK 302E
6 BN 2501C 40 RD/BN 302F
6 WH 6436F 41 RD 1262B
7 GY/WH 7524A 42 RD/WH 1263A
8 BN/WH 7525A 43 PU 209
9 PU/WH 7526A 44 YE 6793B
10 D-GN 189E 45 BARE SHIELD6793B
11 OG/BK 5272B 45 BARE SHIELD6798N
12 BN 25A 46 OG/BK 5219B
13 RD/WH 40A 46 OG 6201A
14 YE/BK 1827A 47 BN/OG 6202A
48-10
Connector
48 GY 6798A IP2EB_PWR_LINK1
49 BARE SHIELD6798A
50 GY 597N
51 OG/BK 380N
52 YE/BK 7482A
53 D-GN 7481A
4 3 2 1
54 D-GN/WH 6727A
55 L-GN 6844A
56 D-BU 6727 IP2EB_PWR_LINK1

57 D-BU/WH 6844
Description harness
Connector Lower left of the instrument panel

Position beam
Connector Natural
Color
Connector Male
Nature
1 RD/YE 202E
2 RD/BK 202F
3 RD 240E
4 RD/WH 240F
48-11
Connector
IP12 IP21
8 7 6 5
4 3 2 1 1 2
IP12 IP21
Connector Headlamp leveling switch Connector Left front loudspeaker

Connector Rear of the headlamp leveling switch Connector Rear of the left front loudspeaker
Position Position
Connector Natural Connector Brown

Color Color

Nature Nature
1 RD/YE 202E 1 TN 1856
2 RD/BK 202F 1 TN 1856R
3 RD 240E 2 GY 1956
4 RD/WH 240F 2 GY 1956R
5 - -
6 - -
7 - -
8 - -
48-12
Connector
IP2RF_1 17 WH 6106M
18 RD/BK 840F
19 - -
20 - -
21 - -
1 12 22 - -
13 24
23 BK 850PB
24 BK 850S
IP2RF_1
Connector Connect to the roof harness

Description
Connector Left A-pillar

Position
Connector Natural
Color
Connector Male
Nature
1 RD/WH 4740A
2 RD/WH 840B
3 OG/BK 5219E
4 TN 481A
5 BN 7133D
6 GY/BK 1598
7 PK/BK 1597
8 YE 7043A
9 BARE SHIELD7043A
10 YE 7044A
10 YE 7044C
11 BARE SHIELD7044A
11 BARE SHIELD7044C
12 GY 344A
13 BN 7133C
14 BN 8011
15 D-GN 8012
16 D-BU 6105M
48-13
Connector
IP2RF_2 IP03
12 11 10 9 8 7
1 2 3 4 6 5 4 3 2 1
IP2RF_2 IP03
Connector Connect to the roof harness Connector Combination switch (lights)

Connector Left A-pillar Connector Rear of the steering column switch

Position Position
Connector Yellow Connector Black

Color Color
Connector Male Connector Female

Nature Nature
1 PU/WH 5019 1 BN/OG 6009D
2 PK 5020 2 TN 664
3 YE/BK 5021 3 - -
4 WH/BK 5022 4 - -
5 YE 307
6 BK 850LS
7 WH 103
8 L-BU 187
9 OG 192
10 PU/WH 5981
11 GY 663
12 D-GN 534
48-14
Connector
IP54_A IP54_B
6 5 4 3 2 1
1 2
IP54_A IP54_B
Connector Ignition switch Connector Ignition switch

Connector Rear of the ignition switch Connector Rear of the ignition switch
Position Position

Color Color

Nature Nature
1 D-BU 3 1 PK 1020
2 RD/WH 40A 2 L-GN 80
3 BN 4
4 L-GN 80
5 PK 1020B
6 WH 1073
48-15
Connector
IP26 IP16
4 3 2 1
4 1
5 2
6 3
IP26 IP16
Connector ESCL Connector Immobilizer base station (BCM)

Connector Connector Lower part of the steering wheel

Position Position
Connector Brown Connector Natural

Color Color

Nature Nature
1 OG 1603 1 RD/WH 5040A
2 WH 5741 2 BK 750MM
3 RD/BK 42D 3 D-GN 7560
4 L-GN 11 4 L-BU 7561
5 PU 1604
6 BK 850ES
48-16
Connector
IP14 IP50_C
1 2 3 4
1 4
IP14 IP50_C
Connector Steering angle sensor Connector Clock spring

Connector On the steering angle sensor Connector On the clock spring

Position Position
Connector Yellow Connector Natural

Color Color

Nature Nature
1 BK 2088B 1 BK 850SW
2 BN/WH 2086B 2 PU/WH 1382W
3 D-BU 6105G 3 - -
3 BN/WH 6437M 4 WH 1765A
4 WH 6106G
4 WH 6436M
48-17
Connector
IP50_A IP50_B
1 2 3 4 1 2 3 4
IP50_A IP50_B
Connector Clock spring Connector Clock spring

Connector On the clock spring Connector On the clock spring

Position Position
Connector White Connector Black

Color Color

Nature Nature
1 BK 850HS 1 L-GN 1763A
2 TN 28A 2 L-BU 1764A
3 BN 3020K 3 TN 6310B
3 TN 3021 4 PK 6309B
3 TN 3021J
4 BN 3020
4 BN 3020J
4 TN 3021K
48-18
Connector
IP04 IP31
10 9 8 7 6
5 4 3 2 1
1 2
IP04 IP31
Connector Combination switch (wiper) Connector Air conditioning temperature sensor

Connector Rear of the steering column switch Connector Middle of the instrument panel beam
Position Position
Connector Black Connector Natural

Color Color

Nature Nature
1 BK 850LL 1 D-GN 734
2 PK/BK 5982 2 TN 6102
3 - -
4 - -
5 BN/OG 6009B
6 PK 94
7 L-GN 1715
8 BN/OG 6009A
9 L-BU 1714
10 D-BU/YE 6985
48-19
Connector
IP02 17 BK 850KB
18 - -
19 - -
20 - -
21 - -
17 32
22 - -
1 16
23 - -
24 - -
IP02 25 - -
26 BN 25A
Connector Instrument cluster
27 YE 234
Description
28 - -
Connector Rear of the instrument cluster
Position 29 GY 728
Connector Natural
30 - -
Color
31 - -
Connector Female
Nature 32 BK 850KC
1 RD/YE 5240A
2 RD/WH 5040B
3 - -
4 - -
5 PU/WH 5981
6 PK/BK 5982
7 - -
8 PU 209
9 YE/BK 1131A
10 - -
11 - -
12 - -
13 - -
14 BN/WH 5169B
14 BN/WH 6437
15 BN 5170B
15 WH 6436
16 BK 850KA
48-20
Connector
IP65 IP35
5 4 3 2 1
2 1
IP65 IP35
Connector Reverse radar buzzer Connector Mode actuator

Connector On the reverse radar buzzer Connector On the mode actuator

Position Position

Color Color

Nature Nature
1 PK 5974 1 YE 1791A
2 OG/BK 5219G 2 L-GN 2275
3 GY 597A
4 WH 119
5 TN 2273
48-21
Connector
IP34 IP37
5 4 3 2 1
1 2
IP34 IP37
Connector A/C motor Connector Evaporator temperature sensor

Connector On the A/C Motor Connector On the evaporator temperature

Position Position sensor

Color Color

Nature Nature
1 YE 1791B 1 TN 6138
2 L-BU 733 2 GY 6137
3 GY 597B
4 D-BU 1199
5 L-GN 2210
48-22
Connector
IP20 IP05
5 4 3 2 1
10 9 8 7 6 6 5 4 3 2 1
12 11 10 9 8 7
IP20 IP05
Connector Start-stop switch Connector Central control switch (left)

Connector Rear of the start-stop switch Connector Rear of the central control switch
Position Position

Color Color

Nature Nature
1 D-BU/BN 6817 1 D-GN 8012
2 D-BU/BK 5719 2 - -
3 BN/BK 5720 3 - -
4 D-GN/BK 3558 4 BN 8011
5 BK/GY 3559 5 - -
6 YE 5723 6 PU/WH 1382S
7 BK 850BT 7 D-BU/YE 6745
8 BK 850BN 8 YE/GY 6744
9 - - 9 - -
10 - - 10 BK 750CL
11 - -
12 BK 750CM
48-23
Connector
IP38_B IP38_A
11 20
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 1 10
IP38_B IP38_A
Connector Front A/C control panel Connector Front A/C control panel
Connector Rear of the front A/C control panel Connector Rear of the front A/C control panel
Position Position
Connector Natural Connector Black

Color Color

Nature Nature
1 BK 650HC 1 BN 6433H
2 BN/OG 2274 2 L-GN 2275
3 D-GN 1614 3 L-BU 733
4 WH 119 4 - -
5 TN 2273 5 RD/WH 3340
6 D-BU 1199 6 YE/BK 6120NA
7 L-GN 2210 7 D-GN 734
8 WH 193 8 OG/BK 380N
9 - - 9 GY 6137
10 PU/WH 760 10 BN 7133B
11 D-BU 762 11 L-GN/BK 6432H
12 OG 761C 12 PU/WH 1382C
13 YE 182 13 TN 407
14 GY 5961 14 BK 650HA
15 - - 15 BK 650HB
16 BK 650HD 16 YE 1791
17 GY 597
18 - -
48-24
Connector
19 - - IP53
20 - -
4 5 6
1 2 3
IP53
Connector MP5 control switch

Description
Connector Rear of the MP5 control switch

Position
Connector White
Color
Connector Female
Nature
1 - -
2 PU/WH 1382MS
3 WH 7066
4 WH/BK 6775
5 D-BU 6791
6 BK 750MS
48-25
Connector
IP10 IP06
12 11 10 9 8 7
6 5 4 3 2 1
1 2
IP10 IP06
Connector Door receiving antenna (front) Connector Central control switch (right)
Connector Center of the I/P Connector Rear of the central control switch
Position Position

Color Color

Nature Nature
1 OG 5708 1 PU/WH 1382N
2 OG/BK 5712 2 BK 750CT
3 - -
4 TN 7135
5 BN 7129
6 BK 750CS
7 D-GN/WH 6727A
8 L-GN 6844A
9 - -
10 D-BU 6727
11 D-BU/WH 6844
12 BN/WH 2086D
48-26
Connector
IP57 IP15
6 5 4 3 2 1 3 2 1
12 11 10 9 8 7
IP57 IP15
Connector Touch screen Connector Acceleration sensor

Connector Rear of the touch screen Connector On the acceleration sensor

Position Position
Connector Brown Connector White

Color Color

Nature Nature
1 - - 1 L-GN 6257A
2 BN 2355 2 D-BU 1809A
3 D-GN 1755 3 L-GN/BK 6258A
4 - -
5 RD/WH 4540A
6 BK 1450S
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
48-27
Connector
G_IP4_1 G_IP4_2
G_IP4_1 G_IP4_2

Connector Left side of the dash panel Connector Middle of the instrument panel beam
Position Position
Connector Silver Connector Silver

Color Color
Connector Connector with hole Connector Connector with hole

Nature Nature
1 BK 1450R 1 BK 1450M、 1450S
48-28
Connector
G_IP4_3 G_IP5_1
G_IP4_2 G_IP5_1

Connector Middle of the instrument panel beam Connector Middle of the instrument panel beam
Position Position

Color Color

Nature Nature
1 BK 1450B、 1450T 1 BK 750
48-29
Connector
G_IP5_2 IP13
3 1
4 2
G_IP5_2 IP13
Connector Instrument harness ground Connector Yaw sensor

Connector Middle of the instrument panel beam Connector On the yaw sensor
Position Position
Connector Silver Connector Black

Color Color
Connector Connector with hole Connector Female

Nature Nature
1 BK 750LT 1 BK 2088A
2 D-BU 6105K
3 L-BU 6106K
4 BN/WH 2086A
48-30
Connector
IP08_C 18 - -
19 - -
20 - -
21 - -
17 32
22 - -
23 - -
1 16 24 D-GN 1409J
25 GY 5600J
IP08_C 26 YE 354J
27 PK/BK 5045J
Connector Airbag control module
28 - -
Description
29 - -
Connector On the airbag control module
Position 30 PK/WH 5163J
Connector Natural
31 BN/WH 2500H
Color
31 BN/WH 6437N
Connector Female
Nature 32 BN 2501H
32 WH 6436N
1 - -
2 TN 3021J
3 TN 3021K
3 BN 3020K
4 OG 3024J
5 L-GN 3025J
6 BN/OG 2118J
7 OG/BK 2119J
8 OG 2117J
9 L-GN 2116J
10 YE 5161J
11 OG 1000B
12 PU 5162J
13 - -
14 OG 1362J
15 - -
16 RD/WH 140A
17 BK 1350L
48-31
Connector
IP08_B 19 BN 2137
20 YE/BK 2138
21 WH/BK 5022
22 YE/BK 5021
23 PU/WH 5019
24 13
24 PK 5020
12 1
IP08_B

Description

Position
Connector Gray
Color
Connector Female
Nature
1 - -
2 - -
3 PK/WH 5163
4 PU 5162
5 OG 2117B
6 L-GN 2116B
7 BN/OG 2118B
8 OG/BK 2119B
9 WH/BK 2132
10 PU/WH 6628
11 WH/BK 6629
12 D-GN 2134
13 - -
14 - -
15 - -
16 - -
17 L-GN 2136
18 BN/OG 2135
48-32
Connector
IP08_A 19 BN/OG 2118
20 OG/BK 2119
21 OG 3024
22 L-GN 3025
23 TN 3021
24 13
24 BN 3020
12 1
IP08_A

Description

Position
Connector Black
Color
Connector Female
Nature
1 RD/WH 140
2 OG 1000A
3 OG 1362
4 - -
5 YE 5161
6 L-BU 1361
7 YE 354
8 PK/BK 5045
9 D-GN 1409
10 GY 5600
11 BN 2501G
12 BN/WH 2500G
13 - -
14 - -
15 BK 1350H
16 - -
17 OG 2117
18 L-GN 2116
48-33
Connector
G_IP6 G_IP3
G_IP6 G_IP3

Connector Middle of the instrument panel beam Connector Middle of the instrument panel beam
Position Position

Color Color

Nature Nature
1 BK 650 1 BK 1350H
1 BK 650CG 1 BK 1350L
1 BK 650HR
48-34
Connector
IP74 IP73
1 2 1 2
IP74 IP73
Connector 12 power outlet Connector Door receiving antenna (center)

Connector Rear of the 12 power outlet Connector On the rear panel of auxiliary fascia
Position Position console

Color Color

Nature Nature
1 BK 750LT 1 PK 5709
2 RD/BK 1042 2 PK/WH 5713
48-35
Connector
IP2FL_3 IP59
4 3 2 1 7 6 5 4 3 2 1
8 9 10 11
IP2FL_3 IP59
Connector Connect to the floor harness Connector Shift lever

Connector Rear of the front floor Connector Lower part of the shift lever
Position Position

Color Color

Nature Nature
1 BN 2137 1 TN 7553
2 YE/BK 2138 2 BN/OG 6009C
3 BN/OG 2135 3 OG/BK 233
4 L-GN 2136 4 BK 750TC
5 - -
6 RD/WH 842B
7 L-BU 553
8 YE 772
9 GY 773
10 PU/WH 1382M
11 BK 750TD
48-36
Connector
IP71 IP72
5 4 3 2 1 3 2 1
10 9 8 7 6
IP71 IP72
Connector 4WD switch Connector Immobilizer base station (PEPS)

Connector On the 4WD switch Connector On the PEPS immobilizer base

Position Position station
Connector Black Connector Blue

Color Color

Nature Nature
1 PU/WH 1382B 1 D-BU 229
2 - - 2 D-GN 220
3 BK 750TA 3 L-GN 483
4 D-GN 1562
5 D-GN/WH 1559
6 BK 750TB
7 - -
8 - -
9 - -
10 - -
48-37
Connector
IP29 IP61
1 4
2 2 3
IP29 IP61
Connector Entertainment system Connector Cigar lighter illumination

Connector Rear of the entertainment system Connector Upper rear of the cigar lighter
Position Position

Color Color

Nature Nature
1 D-GN 1001 1
2 BK 650CG 2
48-38
Connector
IP60 19 PK/WH 6434D
20 RD/WH 4540B
21 - -
22 - -
23 - -
40 21
20 1 24 - -
25 YE 7043C
26 BARE SHIELD7043A
IP60 27 - -
28 OG/BK 2061
Connector T-BOX
29 - -
Description
30 - -
Connector Rear of the T-BOX
Position 31 - -
Connector Natural
32 - -
Color
33 - -
Connector Female
Nature 34 - -
35 YE/BK 6445
1 - - 36 - -
2 - - 37 - -
3 BK 1450B 38 - -
4 - - 39 GY/BK 6435D
5 BARE SHIELD7043C 40 BK 1450T
6 YE 7043A
7 - -
8 PK/BK 2062
9 - -
10 - -
11 OG 1000D
12 - -
13 - -
14 - -
15 OG/BK 6444
16 - -
17 - -
18 - -
48-39
Connector
IP33 IP32
1 2 3 4 5
G S
IP33 IP32
Connector Internal/external circulation motor Connector Internal/external circulation motor

Connector On the internal/external circulation Connector On the internal/external circulation

Position motor Position motor

Color Color

Nature Nature
1 - - D OG 761
2 - - S BK 650HR
3 - - G PU/WH 760
4 BN/OG 2274
5 D-GN 1614
48-40
Connector
IP40 IP63
1 2 4 3 2 1
12 11 10 9 8 7 6 5
IP40 IP63
Connector Front blower Connector Radio/MP5 camera

Connector On the front blower Connector Rear of the entertainment mainframe

Position Position

Color Color

Nature Nature
1 RD/WH 7572 1 OG 6201
2 OG 761B 2 BN/OG 6202
3 - -
4 - -
5 GY 6798A
6 BARE SHIELD6798A
7 GY 6798C
8 BARE SHIELD6798C
9 GY 6798D
10 BARE SHIELD6798D
11 - -
12 - -
48-41
Connector
IP55_B IP55_E
5 1
13 9
16 12 12 11 10 9 8 7
B 8 4
6 5 4 3 2 1
6 1 6 1
12 7 12 7
E D
IP55_B IP55_E
Connector Radio/MP5 Connector Radio/MP5

Connector Rear of the entertainment mainframe Connector Rear of the entertainment mainframe
Position Position

Color Color

Nature Nature
9 - - 1 D-BU 6791
10 - - 2 YE 7044A
11 WH/BK 6775 3 - -
12 - - 4 WH 7066
13 - - 5 YE 6793B
14 - - 6 YE 6798N
15 RD/WH 4940 7 D-GN 1755
16 BK 1450M 8 BARE SHIELD7044A
9 - -
10 BN 2355
11 BARE SHIELD6793B
11 BARE SHIELD6798N
12 OG/BK 2061
48-42
Connector
IP55_D IP55_A
7 8 9 10 11 12 8 7 6 5
1 2 3 4 5 6 4 3 2 1
IP55_D IP55_A
Connector Radio/MP5 Connector Radio/MP5

Connector Rear of the entertainment mainframe Connector Rear of the entertainment mainframe
Position Position

Color Color

Nature Nature
1 - 1 D-BU 46B
2 - 2 L-GN 200C
3 WH 1765A 3 TN 201C
4 L-GN 1763A 4 WH 1998
5 BAKE SHIELD7043C 5 WH 115B
6 BN/WH 5169C 6 PU 117C
7 - - 7 GY 118C
8 - - 8 YE 116B
9 - -
10 L-BU 1764C
11 YE 7043C
12 RD 100
48-43
Connector
IP27 IP56_A
4 5 6 2 4 6 8
1 2 3 1 3 5 7
IP27 IP56_A
Connector Hazard warning lamp switch Connector Radio

Connector Rear of the hazard warning lamp Connector Rear of the entertainment mainframe
Position switch Position
Connector White Connector Gray

Color Color

Nature Nature
1 BK 750HA 1 BARE SHIELD7044C
2 - - 2 OG/BK 5219D
3 PU/WH 1382J 3 YE 7044C
4 BK 750HB 4 GY 1375
5 BN 27 5 - -
6 - - 6 PU/WH 1382H
7 RD/WH 1364
8 BK 1450R
48-44
Connector
IP56_B IP58
2 4 6 8
1
1 3 5 7
IP56_B IP58
Connector Radio Connector Antenna amplifier

Connector Rear of the entertainment mainframe Connector On the antenna amplifier

Position Position
Connector Brown Connector White

Color Color

Nature Nature
1 D-BU 46R 1 GY 6001
2 WH 115R
3 L-GN 200B
4 PU 117B
5 TN 201B
6 GY 118B
7 WH 199R
8 YE 116R
48-45
Connector
IP24 IP22
1 2
2 1
IP24 IP22
Connector Passenger airbag Connector Right front speaker

Connector Rear of the passenger airbag module Connector On the right front speaker
Position Position
Connector Light green Connector Brown

Color Color

Nature Nature
1 L-GN 3025 1 L-GN 1852
1 L-GN 3025J 1 L-GN 1852R
2 OG 3024 2 PU 1952
2 OG 3024J 2 PU 1952R
48-46
Connector
IP11 19 PU/WH 7525A
20 - -
21 - -
22 - -
23 TN 7135
1 13
24 BN 2184B
14 26
25 - -
26 GY 7132
IP11
Connector Adaptive headlamp control module

Description
Connector On the adaptive headlamp control

Position module
Connector White
Color
Connector Female
Nature
1 BN 7129
2 - -
3 WH 6106F
4 BN/WH 7525A
5 YE 5356A
6 PU 2185B
7 BK 1550AF
8 - -
9 RD/WH 842C
10 - -
11 - -
12 GY 2165B
13 - -
14 BN 7133
15 GY/WH 7524A
16 D-BU 6105F
17 PU 5357A
18 - -
48-47
Connector
IP01_D 19 - -
20 - -
21 - -
22 - -
23 - -
24 13
12 1 24 - -
IP01_D
Connector Body control module

Description
Connector On the body control module

Position
Connector Natural
Color
Connector Female
Nature
1 - -
2 GY 6039A
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 GY 1963A
17 - -
18 YE/BK 6038A
48-48
Connector
IP01_A 19 - -
20 - -
21 - -
22 D-BU/BK 7177A
52 40
23 WH 103
39 27
24 PK 94
26 14
25 GY/WH 7389A
13 1
26 WH 193
IP01_A 27 PK/BK 1597
28 D-GN 1317D
29 BN/OG 6009
Description
30 - -
Position 31 - -
Connector Black
32 YE 307
Color
33 L-GN 1715
Connector Female
Nature 34 TN 664
35 OG/BK 5219C
1 - - 36 - -
2 PK 1020A 37 L-BU 187
3 YE 5066A 38 - -
4 BK 1550BF 39 - -
5 L-BU 553 40 - -
6 GY/BK 7388 41 L-GN/BK 6432J
7 BN 4 41 WH 6436P
8 BN 4A 42 BN 6433J
9 BN 27 42 BN/WH 6437P
10 - - 43 - -
11 GY 728 44 - -
12 - - 45 D-BU/YE 6985
13 - - 46 WH 1073
14 - - 47 D-BU/YE 7176A
15 D-BU 45A 48 - -
16 L-BU 1714 49 - -
17 - - 50 YE 772
18 - - 51 D-BU/BN 6817
48-49
Connector
51 L-BU 7561
52 - -
48-50
Connector
IP01_B 18 BN 1969A
19 D-GN 534
20 - -
21 YE 196A
12 1 22 - -
24 13
23 PU/BK 5222C
36 25
48 37 24 L-BU 14
25 L-BU 1350A
IP01_B 26 - -
27 BN/OG 746A
28 - -
Description
29 D-BU 545A
Position 30 - -
Connector Black
31 TN 860A
Color
32 GY 773
Connector Female
Nature 33 - -
34 D-GN 7560
1 L-BU/BK 747B 35 D-BU 15
2 L-GN/BK 748B 36 OG/BK 5219
3 PK/BK 780A 37 OG 1000C
4 L-BU 244A 38 YE 5723
5 YE 5530A 39 GY/BK 745A
6 WH 249 40 PK/WH 1447A
7 GY 663 41 PK/WH 1970A
8 BK 1550BG 42 TN 28B
9 - - 43 RD/WH 2940C
10 - - 44 OG 192
11 - - 45 L-GN 5007
12 GY/BK 1598 46 TN 481A
13 D-BU 3 47 YE 43
13 D-BU 3A 48 YE 5199
14 YE 1977
15 D-GN/WH 1317C
16 PU 544A
17 GY 91A
48-51
Connector
IP01_C 19 BK 1550BC
20 GY 295
21 BK 1550BD
22 BK 1550BE
21 19 17 15 13 11 9 7 5 3 1
22 20 18 16 14 12 10 8 6 4 2
IP01_C

Description

Position
Connector Black
Color
Connector Female
Nature
1 RD/WH 1242
2 - -
3 RD/WH 1440
4 - -
5 PU/WH 1382
6 - -
7 BK 1550BA
8 - -
9 BK 1550BB
10 - -
11 WH 93
12 L-GN 295H
13 OG 228A
14 RD/WH 1240
15 RD/WH 1340
16 TN 7553
17 RD/BK 1342
18 TN 294
48-52
Connector
IP01_E IP67
17 15 13 11 9 7 5 3 1 A B
18 16 14 12 10 8 6 4 2
IP01_E IP67
Connector Body control module Connector Terminal resistance

Connector On the body control module Connector Right side of the instrument panel
Position Position beam
Color Color

Nature Nature
1 - - A BN 6433E
2 - - B L-GN/BK 6432E
3 - -
4 BK 1550BM
5 - -
6 PK 191
7 - -
8 RD/WH 1202
9 - -
10 YE 190
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
48-53
Connector
IP2EB_2 17 - -
18 - -
19 - -
44 45 46 47 48 49 50 51 52 53 54 55 56 57
20 - -
36 37 38 39 40 41 42 43
34 35 21 - -
32 33
27 28 29 30 31
25 26 22 YE 354
23 24
16 17 18 19 20 21
22 YE 354J
15 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
23 D-GN 1409
IP2EB_2 23 D-GN 1409J
24 GY 5600
24 GY 5600J
Description harness
25 D-BU 15A
Connector Right A-pillar
Position 26 PU/BK 5222C
Connector Natural 27 YE 1977
Color
28 - -
Connector Male
Nature 29 - -
Pin Wire Color Wire Code 30 - -
1 GY 7132 31 WH 5857A
2 RD/WH 1040 32 GY 5969A
3 YE 5859A 33 PK 5861A
4 PU 5854A 34 L-GN/WH 5860A
5 PK/BK 5855A 35 OG 5863A
6 GY 6039A 36 - -
6 GY 6039B 37 YE 5356A
7 YE/BK 6038A 38 PU 5357A
7 YE/BK 6038B 39 PU 326
8 YE 5066A 40 - -
9 GY 91A 41 - -
10 TN 860A 42 - -
11 D-BU 45A 43 TN 6310B
12 D-GN 1317D 44 PK 6309B
13 D-GN/WH 1317C 45 PK/BK 5045
14 D-BU 545A 45 PK/BK 5045J
15 PU 544A 46 YE 43
16 - - 47 YE/GY 6744
48-54
Connector
48 D-BU/YE 6745 G_IPR_1

49 BN 1969A
50 PK/WH 1970A
51 L-BU 14A
52 YE 196A
53 D-BU 762
54 YE 5530A
55 OG 228A
56 WH 93 G_IPL_1
57 OG/BK 5219C
Connector Instrument harness ground
Description
Connector Lower part of right A-pillar

Position
Connector Silver
Color
Connector Connector with hole

Nature
1 BK 1550B
48-55
Connector
G_IPR_2 G_IPR_3
G_IPR_2 G_IPR_3

Connector Lower part of right A-pillar Connector Lower part of right A-pillar
Position Position

Color Color

Nature Nature
1 BK 1150PB 1 BK 1550BA
1 BK 1550 1 BK 1550BB
1 BK 1550BE
1 BK 1550PA
48-56
Connector
IP2PAD_1 17 BN/OG 6202D
18 GY 6798D
19 GY 1167
20 L-GN 5707
21 L-GN/BK 5711
1 2 7 3 4
5 6 8 9 22 BK 1550PA
12
10 11 13 14
17
15 16 18 19
20 21 22
IP2PAD_1
Connector Connect to the front passenger door

Description harness

Position
Connector Natural
Color
Connector Female
Nature
1 D-BU 15B
2 L-GN 4042C
3 YE 166A
4 TN 167A
5 BK 1150PB
6 PU/WH 1382G
7 WH 249C
8 L-GN 200A
8 L-GN 200R
9 PU 117A
9 PU 117R
10 RD/WH 1640B
11 BARE SHIELD6798D
12 TN 294B
13 GY 295B
14 L-BU 244A
15 BN/OG 746A
16 OG 6201D
48-57
Connector
IP2PAD_2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
IP2PAD_2
Connector Connect to the front passenger door

Description harness

Position
Connector Natural
Color
Connector Female
Nature
1 GY 90A
2 OG 889A
3 BN/WH 1498A
4 YE 190B
5 PK 191B
6 BK 1550
7 BN 5856A
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
48-58
Connector
IP2FL_2 16 RD/BK 242ED
17 TN 294C
18 TN 294D
44 45 46 47 48 49 50 51 52 53 54 55 56 57
19 GY 295D
36 37 38 39 40 41 42 43
34 35 20 RD 640C
32 33
27 28 29 30 31
25 26 21 PK 640D
23 24
16 17 18 19 20 21
22 L-BU 1361
15 22
1 2 3 4 5 6 7 8 9 10 11 12 13 14
23 PU 5162
IP2FL_2 23 PU 5162J
24 PK/WH 5163
24 PK/WH 5163J
Description harness
25 YE 5161
Position 26 L-GN 2116B
Connector Natural
27 OG 2117B
Color
28 RD 1540A
Connector Male
Nature 29 RD 1542A
30 - -
1 L-GN 5007 31 YE/BK 1131A
2 RD/OG 4840 32 L-BU/BK 747B
3 WH 6106A 33 BN 2501B
4 RD/WH 842A 33 WH 6436Q
5 RD/WH 840E 34 L-GN/BK 748B
6 BN/WH 2500B 35 PU 6NAD
6 BN/WH 6437Q 36 TN 5858
7 PK 5853A 37 RD 1263CA
8 BN 5856A 38 RD 1263CB
9 BN/WH 5169A 39 RD/YE 1262CA
10 BN 5170A 40 RD/YE 1262CB
11 BN 6433B 41 GY 295C
11 BN/WH 6437T 42 RD/BK 242FD
12 L-GN/BK 6432B 43 OG 1362
12 WH 6436T 43 OG 1362J
13 PK/WH 6434A 44 L-GN 2116
14 GY/B5 6435A 44 L-GN 2116J
15 D-BU 6105A 45 OG 2117
48-59
Connector
45 OG 2117J RF2IP_2
46 D-BU 46B
46 D-BU 46R
47 WH 115B
47 WH 115R
48 WH 249J 4 3 2 1
49 WH 249K
50 YE 5859A
51 PU 5854A RF2IP_2
52 PK/BK 5855A
Connector Connect to the instrument panel
53 WH 5857A
Description harness
54 GY 5969A
55 PK 5861A Position
Connector Yellow
56 L-GN/WH 5860A
Color
57 OG 5863A
Connector Female
Nature
1 YE 5019A
2 BK 5020A
3 D-BU 5021A
4 BK 5022A
48-60
Connector
RF2IP_1 19 D-BU 2307
20 GY 2280
21 - -
22 - -
23 BK 850RP
13 24 24 BK 850RS
1 12
RF2IP_1

Description harness

Position
Connector Natural
Color
Connector Female
Nature
1 RD/WH 4740AA
2 RD/WH 840BA
3 OG/BK 5219EA
4 TN 481
5 L-GN 482
6 GY/BK 1598A
7 PK/BK 1597A
8 YE 7043
9 BARE SHIELD7043
10 GY 7044
11 BARE SHIELD7044
12 GY 344
13 BN 7133AA
14 BN 8011A
15 D-GN 8012A
16 D-BU 6105N
17 L-BU 6106N
18 RD/BK 840FA
48-61
Connector
RF05 RF04
2 1
1 2 3
RF05 RF04
Connector Side curtain airbag (left) Connector Rear roof reading lamp
Connector On the left side curtain airbag Connector On the rear roof reading lamp
Position Position

Color Color

Nature Nature
1 YE 5019A 1 GY/BK 1598R
2 BK 5020A 2 BK 850RL
3 PK/BK 1597R
48-62
Connector
RF08 RF10
12 11 10 9 8 7
6 5 4 3 2 1
3 2 1
RF08 RF10
Connector Rain sensor Connector Lane departure control module

Connector On the rain sensor Connector On the lane departure control module
Position Position

Color Color

Nature Nature
1 L-GN 482 1 D-BU 6105N
2 BK 850RR 2 - -
3 TN 481 3 BK 850RW
4 - -
5 BN 8011A
6 RD/BK 840FA
7 L-BU 6106N
8 - -
9 D-GN 8012A
10 - -
11 - -
12 BN 7133AA
48-63
Connector
RF07 RF11
5 4 3 2 1 3 2 1
RF07 RF11
Connector Interior rearview mirror Connector Remote key receiving module

Connector On the interior rearview mirror Connector On the remote key receiving module
Position Position
Connector Natural Connector Blue

Color Color

Nature Nature
1 RD/WH 840BA 1 RD/WH 4740AA
2 BK 850RM 2 GY 344
3 OG/BK 5219EA 3 BK 850RF
4 - -
5 - -
48-64
Connector
RF03 RF09
3 2 1 4 3 2 1
8 7 6 5 4
RF03 RF09
Connector Front roof reading lamp Connector Microphone

Connector Rear of the front roof reading lamp Connector Rear of the front roof reading lamp
Position Position

Color Color

Nature Nature
1 PK/BK 1597F 1 BARE SHIELD7044
2 GY/BK 1598F 2 YE 7044
3 - - 3 BARE SHIELD7043
4 BK 850RQ 4 YE 7043
5 BK 850RN
6 - -
7 - -
8 - -
48-65
Connector
RF06 BT02
1 2
RF06 BT02
Connector Side curtain airbag (right) Connector Starter

Connector On the right side curtain airbag Connector On the starter

Position Position
Connector Yellow Connector Silver

Color Color

Nature Nature
1 D-BU 5021A 1 RD 2
2 BK 5022A
48-66
Connector
BT11 BT01_A
BT11 BT01_A
Connector A/C compressor Connector Battery positive

Connector On the A/C compressor Connector On the battery positive terminal

Position Position
Connector Black Connector Silver

Color Color

Nature Nature
1 D-GN 59A 1 RD 1
1 RD 2
48-67
Connector
BT01_A BT01_C
BT01_A BT01_C
Connector Battery positive Connector Battery positive

Connector On the battery positive terminal Connector On the battery positive terminal
Position Position

Color Color

Nature Nature
1 RD 1 1 RD 1A
1 RD 2
48-68
Connector
BT2EB BT04
C B A
BT2EB BT04
Connector Battery positive Connector Engine compartment fuse box

Connector On the battery positive terminal Connector In the engine compartment fuse box
Position Position

Color Color

Nature Nature
A PU 6K 1 RD 1
B D-GN 59A
C - -
48-69
Connector
BT05 G_EN2
BT05 G_EN2
Connector Engine compartment fuse box Connector Engine harness ground

Connector In the engine compartment fuse box Connector Right side of the engine compartment
Position Position

Color Color

Nature Nature
1 RD 1A 1 NAT 2450
48-70
Connector
G_EN1 BTN01
G_EN1 BTN01
Connector Engine harness ground Connector Battery positive

Connector Right side of the engine compartment Connector On the battery positive terminal
Position Position

Color Color

Nature Nature
1 NAT 2450 1 BK 150
48-71
Connector
G_EBL1 CH14
3 2 1
G_EBL1 CH14
Connector Battery negative harness ground Connector Fuel filter water level alarm
Connector Left side of the engine compartment Connector On the fuel filter
Position Position

Color Color

Nature Nature
1 BK 150 1 BK 1050WFA
2 D-BU/YE 6861A
3 PK/BK 5293NA
48-72
Connector
CH2EB 19 D-BU/WH 619A
20 PU/BK 5222A
21 OG 122
22 BK 1050WFA
36 35 30 29 23 OG/BK 5219CB
28 23
22 21 16 15 24 WH 93B
14 9
8 1 25 YE 7361CB
7 2
26 OG/BK 1175
CH2EB 27 D-BU/YE 6861A
28 BK 550PR
29 RD/WH 7071GA
Description harness
30 BK 550L
Connector Left side of the dash panel
Position 31 BK 550S
Connector Black
32 GY 6798MA
Color
33 D-BU 6798MAB
Connector Female
Nature 34 BN/OG 6202GA
35 OG 6201GA
1 PU 30 36 BK 550PL
2 BN/WH 6281
3 L-GN 5962E
4 OG 5973E
5 GY 5969C
6 PK 5861C
7 L-GN/WH 5860C
8 OG 5863C
9 L-GN 866A
10 GY/BK 7127A
11 PU 865A
12 GY/BK 7128A
13 GY 2165
14 BN 2184
15 PK/BK 5293NA
16 PU 2185
17 BN 6846C
18 L-BU/WH 618A
48-73
Connector
CH2FL CH08
D C B A
3 2 1
H G F E
6 5 4
CH2FL CH08
Connector Fuel filter water level alarm Connector Fuel filter water level alarm
Connector On the fuel filter Connector On the fuel filter

Position Position

Color Color

Nature Nature
A BN 8001A 1 RD/WH 7071GA
B - 8002A 2 RD/WH 550G
C D-BU 8003A 3 OG/BK 1175
D D-GN 8004A 4 YE 7361CB
E GY 8005A 5 - -
F L-BU 8006A 6 - -
G PK 8007A
H OG 8008A
48-74
Connector
CH07 CH13
3 2 1
1 2
4 5
CH07 CH13
Connector Fuel level sensor Connector Fuel tank cap actuator

Connector On the fuel tank Connector Rear of the fuel tank cap actuator
Position Position
Connector Dark gray Connector Black

Color Color

Nature Nature
1 BN/WH 6281 1 BK 550F
2 PU 30 2 WH 93B
3 - -
4 - -
5 - -
48-75
Connector
CH01 CH2PR
5 6 7 8 F E D C B A
1 2 3 4 M L K J H G
CH01 CH2PR
Connector Left rear combination lamp Connector Fuel filter water level alarm
Connector On the left rear combination lamp Connector On the fuel filter
Position Position

Color Color

Nature Nature
1 GY/BK 5221 A BN 6846J
2 BN 2509A B - -
3 L-BU/WH 618A C BK 550LN
4 BK 550LC D BK 550LM
5 OG 122A E L-GN 5962E
6 OG/BK 5219CC F OG 5973E
7 BK 550LT G BK 550RL
8 - - H BK 550RL
J BK 550RR
K L-GN/WH 5860C
L OG 5863C
M GY 5969C
48-76
Connector
CH10 CH09
1 2 1 2
CH10 CH09
Connector Right rear license plate lamp Connector Left rear license plate lamp
Connector On the license plate lamp Connector On the license plate lamp
Position Position

Color Color

Nature Nature
1 BN 6846A 1 BN 6846
2 BK 550LB 2 BK 550LA
48-77
Connector
CH12 CH04
1 2 3
2 1
4 5 6
CH12 CH04
Connector Rear height sensor Connector Right rear wheel speed sensor
Connector On the rear height sensor Connector On the right rear wheel speed sensor
Position Position

Color Color

Nature Nature
1 - - 1 PU 865A
2 GY 2165 2 GY/BK 7128A
3 BN 2184
4 - -
5 - -
6 PU 2185
48-78
Connector
CH03 CH2TRAILER
A B C D
1 2
E F G H
CH03 CH2TRAILER
Connector Left rear wheel speed sensor Connector Connect to the trailer harness
Connector On the left rear wheel speed sensor Connector Tail of vehicle
Position Position

Color Color
Connector Female Connector Male

Nature Nature
1 L-GN 866A A BN 8001A
2 GY/BK 7127A B - 8002A
C D-BU 8003A
D D-GN 8004A
E GY 8005A
F L-BU 8006A
G PK 8007A
H OG 8008A
48-79
Connector
CH2RC CH02
D C B A 5 6 7 8
H G F E 1 2 3 4
CH2RC CH01
Connector Connect to the camera harness Connector Right rear combination lamp
Connector Rear of the Camera Connector On the right rear combination lamp
Position Position

Color Color

Nature Nature
A GY 6798MA 1 PU/BK 5222
B D-BU 6798MAA 2 BN 2609
C BN/OG 6202GA 3 D-BU/WH 619A
D OG 6201GA 4 BK 550LD
E - - 5 OG 122B
F - - 6 OG/BK 5219CD
G - - 7 BK 550LG
H - - 8 - -
48-80
Connector
EB90 EB55
C A
B
E D
1 2 3
EB90 EB55
Connector Clutch Connector Differential pressure sensor

Connector On the clutch Connector Right front of the engine compartment

Position Position

Color Color

Nature Nature
A D-GN 7481 1 D-BU 736
B YE/BK 7482 2 GY 2704
C L-BU 7483 3 L-GN 432
D - -
E BK 1050FC
48-81
Connector
EB23 EB14
1 2 3
1 2 3 4
4 5 6
EB23 EB14
Connector Front height sensor Connector Mass air flow sensor

Connector On the front height sensor Connector On the mass air flow sensor
Position Position

Color Color

Nature Nature
1 - - 1 YE 492
2 GY/WH 7524 2 BN 4387
3 BN/WH 7525 3 GY/BK 2931
4 - - 4 YE/BK 7337
5 - -
6 PU/WH 7526
48-82
Connector
G_EBR2_1 G_EBR2_2
G_EBR2_1 G_EBR2_2
Connector Engine compartment harness ground Connector Engine compartment harness ground
Connector Right front of the engine compartment Connector Right front of the engine compartment
Position Position

Color Color

Nature Nature
1 BK 350 1 BK 550C
1 BK 350WA
1 BK 550B
1 BK 1050BL
1 BK 1050UW
1 BK 1050WF
48-83
Connector
EB2IP_2 15 PU 544
16 - -
17 - -
18 - -
1 2 3 4 5 6 7 8 9 10 11 12 13 14
19 - -
15 22
23 16 17 18 19 20 21 24
25
27
26
31
20 - -
32 28 29 30 33
34
36
35
43
21 - -
37 38 39 40 41 42
44 45 46 47 48 49 50 51 52 53 54 55 56 57
22 YE 354A
EB2IP_2 23 D-GN 1409A
24 GY 5600A
25 D-BU/WH 1315A
Description harness
26 PU/BK 5222B
Position 27 YE 1977B
Connector Natural
28 - -
Color
29 - -
Connector Female
Nature 30 - -
31 WH 5857B
1 GY 7132A 32 GY 5969B
2 RD/WH 1040A 33 PK 5861B
2 RD/WH 1040B 34 L-GN/WH 5860B
3 YE 5859B 35 OG 5863B
4 PU 5854B 36 - -
5 PK/BK 5855B 37 YE 5356
6 GY 6039 38 PU 5357
6 GY 6039G 39 PU 326A
7 YE/BK 6038 40 - -
7 YE/BK 6038G 41 - -
8 YE 5066 42 - -
8 YE 5066G 43 TN 6310
9 GY 91 43 TN 6310G
10 TN 860 44 YE 7361AD
11 D-BU 45 45 PK/BK 5045A
12 D-GN/WH 1317B 46 YE 43C
13 D-GN/WH 1317A 47 YE/GY 6744A
14 D-BU 545 48 D-BU/YE 6745A
48-84
Connector
49 BN 1969 EB2FL
50 PK/WH 1970
51 L-BU/WH 1314A
52 YE 196
53 L-BU 203A
53 D-GN 603 10 9 8 7 6 5
4 3 2 1
53 D-GN 603G
54 YE 5530
55 OG 228 EB2FL
56 WH 93A
Connector Connect to the floor harness
57 OG/BK 5219CA
Description

Position
Connector Natural
Color
Connector Male
Nature
1 L-GN 275A
2 TN 1664BA
3 YE 43A
3 D-BU 7583
4 BN 1667A
4 L-GN 5378
5 - -
6 - -
7 - -
8 L-GN 432A
8 PK/BK 5294E
9 GY 2704A
10 D-BU 736A
48-85
Connector
G_EBR3 EB53
1 2
3 4
5 6
G_EBR3 EB53
Connector Engine compartment harness ground Connector Oxygen sensor

Connector Right rear of the engine compartment Connector On the oxygen sensor
Position Position

Color Color

Nature Nature
1 BK 450 1 WH 5279
1 BK 450G 2 OG 6426
3 D-BU 6424
4 PK/BK 5293M
5 GY 6425
6 PU 6427
48-86
Connector
EB2EN 18 - -
19 - -
20 - -
21 - -
30 31 32 33 34 35
29 36 22 BK/WH 506A
23 24 25 26 27 28
15 16 17 18 19 20 21 22
9 10 11 12 13 14 22 PU/WH 1582
1 2 3 4 5 6 7 8
23 TN 6109
24 YE 447
EB2EN 25 PU/WH 1035
26 - -
Connector Connect to the engine harness
27 - -
Description
28 BN 331
Connector Right rear of the engine compartment
Position 29 BK/WH 506C
Connector Black
30 BK 350EN
Color
31 WH 6110
Connector Male
Nature 32 YE 6111
33 - -
1 - - 34 PK/BK 5293P
2 - - 35 PK/BK 5293Q
3 - - 36 BK/WH 506D
4 - - 36 YE/BK 1584
5 - -
6 - -
7 - -
8 BN 25
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 BK/WH 506A
15 PU 1581
16 YE/BK 6120
17 GY 6119
48-87
Connector
EB57 EB28
2 1 B
A
EB57 EB28
Connector Front temperature sensor Connector Brake fluid level sensor

Connector Right rear of the engine compartment Connector On the brake fluid level sensor
Position Position

Color Color

Nature Nature
1 PU/WH 7584 A PU 209A
2 L-BU 5377 B BK 1050BL
48-88
Connector
EB02_K 19 - -
20 YE 492
21 - -
22 TN 1274
28
23 BN 4387
7
1 2
29 50 24 - -
3 4
51 72
25 - -
5 6 73 94
26 GY 2700
EB02_K 27 D-BU 736
27 D-BU 736A
Connector Engine control module
28 WH/BK 1162
Description
29 - -
Connector On the engine control module
Position 30 PK 6309
Connector Black
31 - -
Color
32 OG/BK 380
Connector Female
Nature 33 L-GN 5378
34 PU/WH 7584
1 PK/BK 5291 35 YE/BK 7337
2 BK 450A 36 - -
3 PK/BK 5292A 37 L-BU 203
4 BK 450B 37 L-BU 203A
5 PK/BK 5292B 38 - -
6 BK 450C 39 BN/WH 6281A
7 D-BU 6424 40 - -
8 TN 6310 41 - -
9 PU 30A 42 YE 505
10 - - 43 - -
11 YE/GY 6744A 44 - -
12 - - 45 YE 505A
13 D-BU 7583 46 RD/WH 1040A
14 YE 1578 47 YE 5991
15 - - 48 WH 1579
16 - - 49 - -
17 D-BU 214 50 - -
18 L-BU 5377 51 - -
48-89
Connector
52 - - 85 - -
53 - - 86 - -
54 - - 87 BN 2501D
55 BN 331 87 WH 6436G
56 - - 88 - -
57 BN 5614 89 L-GN 275A
58 YE 1172 90 - -
59 L-GN 432 91 - -
60 L-GN 432A 92 WH 2368
61 TN 1171 93 PU 5128
62 WH 5279 94 D-BU 5530B
63 GY/BK 2931
64 - -
65 - -
66 BN/WH 2500D
66 BN/WH 6437G
67 L-BU 1162
68 WH/BK 5267
69 D-BU 7071A
70 - -
71 - -
72 D-GN/WH 459
73 D-BU/YE 6745A
74 YE 43B
75 D-BU 204
76 - -
77 D-BU/YE 6861
78 - -
79 - -
80 GY 2704
80 GY 2704A
81 D-BU 1161
82 - -
83 OG 6426
84 GY 6425
48-90
Connector
EB08 EB27
5 4
3 2 1 3 2 1
EB08 EB27
Connector Front wiper motor Connector Clutch switch

Connector On the front wiper motor Connector On the clutch switch

Position Position
Connector Gray Connector Black

Color Color

Nature Nature
1 - - 1 WH 6110
2 YE 196 1 YE 7361AB
3 PU 92 2 YE 6111
4 BK 350WA 2 D-BU/YE 7344A
5 D-GN 95 3 TN 6109
3 TN 7360AB
48-91
Connector
EB2IP_1 11 OG/BK 5272A
12 BN 25
12 BN 25G
13 RD/WH 40
1 2 3 4 5 6 7 8 9 10 11 12 13 14
14 YE/BK 1827
15 22
23 16 17 18 19 20 21 24
25
27
26
31
15 - -
32 28 29 30 33
34
36
35
43
16 RD/WH 640
37 38 39 40 41 42
44 45 46 47 48 49 50 51 52 53 54 55 56 57
17 RD/WH 2940
EB2IP_1 18 RD/YE 1540
19 - -
20 D-GN 1329C
Description harness
21 L-BU 7483
Position 22 L-GN 6257
Connector Natural
23 RD/BK 42
Color
24 D-BU 1809
Connector Female
Nature 25 - -
26 L-GN/BK 6258
1 D-BU 6105J 27 - -
2 L-BU 6106J 28 RD/BK 642
3 D-BU 6105D 29 RD 3040
3 BN/WH 6437K 30 RD/WH 340
4 WH 6106D 31 GY/BK 1687
4 WH 6436K 32 L-GN 5962A
5 BN/WH 2500D 33 OG 5973B
5 BN/WH 2500DA 34 GY 2165A
5 BN/WH 6437G 35 BN 2184A
5 BN/WH 6437GA 36 PU 2185A
6 BN 2501D 37 RD/YE 242A
6 BN 2501DA 38 RD/BK 242B
6 WH 6436G 39 RD/BK 302A
6 WH 6436GA 40 RD/BK 302B
7 GY/WH 7524 41 - -
8 BN/WH 7525 42 - -
9 PU/WH 7526 43 PU 209A
10 D-GN 189A 44 YE 6793A
48-92
Connector
44 YE 6798M EB26
45 L-BU 6793AB
45 L-BU 6798MB
46 OG/BK 5219M
46 OG 6201E
47 BN/OG 6202E 6 5 4 3 2 1
48 YE 6798F
49 L-BU 6798FB
50 - - EB26
51 - -
Connector Brake switch sensor
52 YE/BK 7482
Description
53 D-GN 7481
Connector On the brake switch sensor
54 D-GN 6272C Position
Connector Black
55 L-GN 6844C
Color
56 D-BU 6272B
Connector Female
57 L-BU 6844B Nature
1 TN 7360AC
2 YE 7361AC
3 L-BU 1934A
4 YE 5066G
5 GY 6039G
6 YE/BK 6038G
48-93
Connector
EB24 EB2IP_PWR LINK1
3 2 1 4 3 2 1
EB24 EB2IP_PWR LINK1
Connector Brake sensor Connector Connect to the instrument panel

Description Description harness
Connector On the brake sensor Connector Left A-pillar

Position Position

Color Color

Nature Nature
1 YE/BK 6038 1 RD/YE 202A
2 YE 5066 2 RD/BK 202B
3 GY 6039 3 RD/YE 240A
4 RD/WH 240B
48-94
Connector
EB25 EB52
6 5 4 3 2 1 7 2 8
3 5
6 1 9
EB25 EB52
Connector Brake sensor Connector Glow plug controller (EU4)

Connector On the brake sensor Connector Left rear of the engine compartment
Position Position

Color Color

Nature Nature
1 TN 1274 1 PK/BK 5293H
1 TN 1274G 2 YE 505A
2 TN 1171 3 BN 5540B
2 L-GN 1171G 9 - -
3 YE 1172 5 L-BU 506
3 YE 1172G 6 - -
4 D-BU 1161G 7 - -
4 L-BU 1162 8 - -
5 D-BU 1161
5 OG 1162G
6 WH/BK 1164
6 WH/BK 1164G
48-95
Connector
EB54 EB65
10 11 9
8 7 6 5
4 3 2 1 B A
EB54 EB65
Connector Glow plug controller (EU5) Connector Terminal resistance

Connector Left rear of the engine compartment Connector Left rear of the engine compartment
Position Position

Color Color

Nature Nature
1 YE/BK 1584 A D-BU 6105E
2 BK/WH 1583 B WH 6106E
3 PU/WH 1582
9 PU 1581
5 - -
6 BK 1050GC
7 PK/BK 5293R
8 - -
9 YE 505
10 BN 5614
11 BN 5540A
48-96
Connector
EB04 18 L-GN 866
19 GY/WH 7064
20 D-BU 6105J
21 - -
22 - -
25 38
1 14 24 23 D-GN 6272C
2 12 13
24 D-BU 1809
25 PU 856
EB04 26 BN/WH 6437K
27 - -
Connector ABS/ESP control module
28 GY/BK 1687
Description
29 PU 865
Connector On the ABS/ESP control module
Position 30 - -
Connector Black
31 GY/BK 7127
Color
32 L-GN/BK 6258
Connector Female
Nature 33 L-BU 6106J
34 L-GN 6844C
1 PK 173 35 - -
2 - - 36 - -
3 - - 37 - -
4 D-GN 872 38 BK 250B
5 L-GN 6257
6 - -
7 - -
8 L-BU 830
9 L-BU 6844B
10 YE/BK 1827
11 - -
12 D-BU 6272B
13 BK 250A
14 WH 6106H
14 WH 6436K
15 - -
16 GY/WH 7065
17 GY/BK 7128
48-97
Connector
G_EBL3_1 G_EBL3_2
G_EBL3_1 G_EBL3_2
Connector Left rear of the engine compartment Connector Left rear of the engine compartment
Position Position

Color Color

Nature Nature
1 BK 250A 1 BK 250B
48-98
Connector
G_EBL2_1 G_EBL2_2
G_EBL2_1 G_EBL2_2
Connector Left front of the engine compartment Connector Left front of the engine compartment
Position Position

Color Color

Nature Nature
1 BK 1250 1 BK 1050GC
1 BK 1250A
48-99
Connector
G_EBL2_3 EB2BT
C B A
G_EBL2_3 EB2BT
Connector Engine compartment harness ground Connector Connect to the battery harness
Connector Left front of the engine compartment Connector Left side of the engine compartment
Position Position

Color Color

Nature Nature
1 BK 550A A PU 6
1 BK 550GM B D-GN 59
1 BK 1050 C - -
1 BK 1050UD
48-100
Connector
EB2CH 19 D-BU/WH 1315B
20 PU/BK 5222B
21 YE 1977A
22 BK 1050WF
30 31 32 33 34 35
29 36 23 OG/BK 5219CA
23 24 25 26 27 28
15 16 17 18 19 20 21 22
9 10 11 12 13 14 24 WH 93A
1 2 3 4 5 6 7 8
25 YE 7361CA
26 OG/BK 1175A
EB2EN 27 D-BU/YE 6861
28 BK 1150A
Connector Connect to the chassis harness
29 RD/WH 7071G
Description
30 BK 550A
Connector Left side of the dash panel
Position 31 BK 550B
Connector Black
32 YE 6793A
Color
32 YE 6798M
Connector Male
Nature 33 L-BU 6793AA
33 L-BU 6798MA
1 PU 30A 34 BK 550C
2 BN/WH 6281A 34 BN/OG 6202G
3 L-GN 5962A 35 OG/BK 5219M
4 OG 5973B 35 OG 6201G
5 GY 5969B 36 BK 550GM
6 PK 5861B
7 L-GN/WH 5860B
8 OG 5863B
9 L-GN 866
10 GY/BK 7127
11 PU 865
12 GY/BK 7128
13 GY 2165A
14 BN 2184A
15 PK/BK 5293N
16 PU 2185A
17 BN 5846B
18 L-BU/WH 1314B
48-101
Connector
EB60 EB62
A B
1 2
EB60 EB62
Connector Fuel-fired heater Connector Fuel temperature sensor

Connector On the fuel filter Connector On the fuel filter

Position Position

Color Color

Nature Nature
A BK 1050FH 1 YE 1578
B D-BU 7071 2 WH 1579
48-102
Connector
EB07 EB39
10 11 12 13 14
1 2 9
5 6 7 8
3
1 2 3 4
EB07 EB39
Connector Windshield washer pump Connector Front combination lamp (left)

Connector On the windshield washer pump Connector Rear of the left front combination
Position Position lamp

Color Color

Nature Nature
1 OG 228 1 BK 1050LA
2 BK 350WB 2 L-GN/BK 311
3 - - 3 BK 1050LB
4 TN/WH 312
5 BK 1050LC
6 L-BU/WH 1314
7 - -
8 BK 1050LE
9 D-GN 189C
9 L-BU 7130
10 OG/BK 5272
10 GY 7132C
11 BK 1050LD
12 L-BU 7538B
13 BN 1254
14 YE 5356
48-103
Connector
EB33 EB67
1 2 3 2 1
EB33 EB67
Connector Front fog lamp (left) Connector Radar sensor (left front)
Connector Rear of the left front fog lamp Connector Left side of the front bumper
Position Position

Color Color

Nature Nature
1 GY 5061 1 YE 5859C
2 BK 1050LF 2 PU 5854B
3 PK/BK 5855C
48-104
Connector
EB17 EB71
2 1
2 1 4 3
EB17 EB71
Connector Impact sensor (left front) Connector Front camera

Connector Left side of the lower radiator beam Connector Rear of the front camera
Position Position

Color Color

Nature Nature
1 PK/BK 5045A 1 YE 6798F
2 YE 354A 2 L-BU 6798FA
3 BN/OG 6202F
4 OG 6201F
48-105
Connector
EB59 EB15
1 2
1 2
EB59 EB15
Connector Ambient temperature sensor Connector Wheel speed sensor (left front)
Connector Middle of the radiator beam Connector Left rear of the engine compartment
Position Position

Color Color

Nature Nature
1 YE/BK 6120 1 L-BU 830
1 YE/BK 6120G 2 GY/WH 7064
2 GY 6119
2 GY 6119G
48-106
Connector
EB22 EB13
1 2 3 2 1
EB22 EB13
Connector Cooling fan (600W) Connector A/C pressure sensor

Connector Left front of the engine compartment Connector Left front of the engine compartment
Position Position

Color Color

Nature Nature
1 RD 342W 1 D-BU 214
2 BK 1250A 2 OG/BK 380
4 D-BU 2364 3 GY 2700
48-107
Connector
EB12 EB31
1 1
2 3
4 2
EB12 EB31
Connector A/C pressure switch Connector Horn (left)

Connector Left front of the engine compartment Connector On the horn

Position Position

Color Color

Nature Nature
1 D-GN 603 1 D-GN 1329A
1 D-GN 603G 2 BK 1050HL
2 BK 1150HS
3 D-BU 204
3 D-BU 204G
4 L-BU 203
4 L-BU 203G
48-108
Connector
EB21 EB70
3
1 4
2 A B C
EB21 EB70
Connector A/C pressure switch Connector Headlamp leveling switch

Connector Left front of the engine compartment Connector On the headlamp leveling switch
Position Position

Color Color

Nature Nature
1 D-GN 603 A YE 5530
1 D-GN 603G B D-BU 5530B
2 BK 1150HS C BK 1050HA
3 D-BU 204
3 D-BU 204G
4 L-BU 203
4 L-BU 203G
48-109
Connector
EB32 EB16
1 1 2
2
EB32 EB16
Connector Horn (right) Connector Wheel speed sensor (right front)

Connector On the horn Connector Right rear of the engine compartment

Position Position

Color Color

Nature Nature
1 D-GN 1329B 1 D-GN 872
2 BK 1050HR 2 GY/WH 7065
48-110
Connector
G_EBR1_3 G_EBR1_1
G_EBR1_3 G_EBR1_1
Connector Right front of the engine compartment Connector Right front of the engine compartment
Position Position

Color Color

Nature Nature
1 BK 1150HS 1 BK 1150
1 BK 1150A
48-111
Connector
G_EBR1_2 EB40
10 11 12 13 14
5 6 7 8 9
1 2 3 4
G_EBR1_2 EB40
Connector Engine compartment harness ground Connector Front combination lamp (right)
Connector Right front of the engine compartment Connector Rear of the right front combination
Position Position lamp

Color Color

Nature Nature
1 BK 1150HA 1 BK 1150LA
2 D-GN/WH 711
3 BK 1150LB
4 YE 712
5 BK 1150LC
6 D-BU/WH 1315
7 - -
8 BK 1150LE
9 D-GN 189B
9 D-GN 7131
10 D-GN 5273
10 GY 7132B
11 BK 1150LD
12 D-BU 7539B
13 BN 1253
14 PU 5357
48-112
Connector
EB18 EB68
3 2 1
2 1
EB18 EB68
Connector Impact sensor (right front) Connector Radar sensor (right front)
Connector Right side of the lower radiator beam Connector Right side of the front bumper
Position Position

Color Color

Nature Nature
1 D-GN 1409A 1 YE 5859D
2 GY 5600A 2 WH 5857B
3 PK/BK 5855D
48-113
Connector
EB34 FL62_A
1 2 1
EB34 FL62_A
Connector Front fog lamp (right) Connector Heated rear window

Connector Rear of the right front fog lamp Connector On the rear window
Position Position

Color Color

Nature Nature
1 BN 5062 1 RD/WH 4440BA
2 BK 1150LF
48-114
Connector
FL30 18 BK 2250TB
19 - -
20 - -
21 - -
22 RD 840AA
24 13
12 1 22 RD 840AB
23 - -
24 - -
FL30
Connector Tire pressure monitoring control

Description module
Connector On the rear beam

Position
Connector Natural
Color
Connector Female
Nature
1 BN 6433F
2 L-GN/BK 6432F
3 - -
4 - -
5 - -
6 BK 2250TA
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 RD/WH 4740BA
17 RD/BK 4740BB
48-115
Connector
FL61 FL62_B
1 2
1
FL61 FL62_B
Connector High-mounted brake lamp Connector Heated rear window

Connector Rear of the high-mounted brake lamp Connector On the rear window
Position Position

Color Color

Nature Nature
1 L-BU 1320 1 BK 2250H
2 BK 2250LC
48-116
Connector
G_FLCL_1 G_FLCL_2
G_FLCL_1 G_FLCL_2
Connector Floor harness ground Connector Floor harness ground

Connector Lower part of left C-pillar Connector Lower part of left C-pillar
Position Position

Color Color

Nature Nature
1 BK 2250H 1 BK 2250LC
48-117
Connector
G_FLCL_3 G_FLBL_1
G_FLCL_3 G_FLBL_1

Connector Lower part of left C-pillar Connector Lower part of left B-pillar
Position Position

Color Color

Nature Nature
1 BK 2250TA 1 BK 2150A
1 BK 2250TB 1 BK 2150B
48-118
Connector
G_FLBL_2 FL2RLD_1
10 9 8 7 6 5
4 3 2 1
G_FLBL_2 FL2RLD_1
Connector Floor harness ground Connector Connect to the left rear door harness
Connector Lower part of left B-pillar Connector Inside left rear door trim panel
Position Position
Connector Silver Connector Natural

Color Color

Nature Nature
1 BK 2150TA 1 BK 2150B
1 BK 2150TB 2 L-GN 4042CA
3 D-GN 168B
4 PU 169B
5 YE/BK 6859CA
6 PU/WH 1382FA
7 WH 249JA
8 OG 1091A
9 PK 1092A
10 L-BU/BK 747A
48-119
Connector
FL2RLD_2 FL09
1 2
3 2 1
8 7 6 5 4
FL2RLD_2 FL09
Connector Connect to the left rear door harness Connector Seat belt pretensioner (driver side)
Connector Inside left rear door trim panel Connector Left B-pillar
Position Position

Color Color

Nature Nature
1 BK 2150A 1 OG 2118K
2 WH 199A 2 L-GN 2119K
3 YE 116A
4 - -
5 - -
6 - -
7 - -
8 - -
48-120
Connector
FL21 G_FLL1_1
1 2
FL21 G_FLL1_1
Connector Side impact sensor (left) Connector Floor harness ground

Connector Lower part of left B-pillar Connector Left side of the rear floor
Position Position
Connector Natural Connector Silver

Color Color

Nature Nature
1 D-GN 2134A 1 BK 1650BK
2 WH/BK 6629A
48-121
Connector
FL2IP_1 B11 WH 199A
B12 YE 116A
C1 WH/BK 2132A
C2 PU/WH 6628A
B9 A6
B6 A4
B3 A2
B2 A1
B4 A3
B7 A5
B10 A7
B11 A8
C3 D-GN 2134A
B12
B8
B1
B5
C4 WH/BK 6629A
C12
C10
D8 C11
C3
C1
D3 C4
D5 C7
C8
D6 C9
C2
C5
D4 C6
C5 - -
D2
D1
D7
C6 - -
FL2IP_1 C7 OG 2118K
C8 L-GN 2119K
C9 RD/WH 4740BA
Description harness
C10 RD 840AA
Position C11 D-GN 1562A
Connector Black
C12 D-GN/WH 1559A
Color
D1 YE/BK 7482B
Connector Female
Nature D2 D-GN 7481B
D3 YE 234A
A1 L-BU 1320 D4 RD/WH 4440BA
A2 RD/WH 1140A D5 BN 1865
A3 RD/WH 4640A D6 YE 288
A4 RD 242EG D7 PK 2077D
A5 L-BU 1296 D8 D-BU 2479D
A6 D-BU 5985A
A7 BN 998C
A8 PK 139
B1 L-GN 4042CA
B2 D-GN 168B
B3 PU 169B
B4 YE/BK 6859CA
B5 PU/WH 1382FA
B6 D-BU 4042DA
B7 L-GN 170B
B8 GY 171B
B9 YE/BK 6859DA
B10 PU/WH 1382EA
48-122
Connector
G_FLL1_3 G_FLL2_1
G_FLL1_3 G_FLL2_1

Connector Left side of the rear floor Connector Left side of the rear floor
Position Position

Color Color

Nature Nature
1 BK 1650GA 1 BK 1750
1 BK 1650GB
48-123
Connector
G_FLL2_2 FL02_B
7 8 9 10 11 12
1 2 3 4 5 6
G_FLL2_2 FL02_B
Connector Floor harness ground Connector Gateway

Connector Left side of the rear floor Connector Lower part of the driver seat
Position Position

Color Color

Nature Nature
1 BK 1750H 1 -
2 -
3 -
4 -
5 -
6 BK 1650GB
7 - -
8 - -
9 - -
10 - -
11 D-BU 5985A
12 BN 998A
48-124
Connector
FL02_A 19 BN 998B
20 BK 1650GA
11 20
1 10
FL02_A
Connector Gateway
Description
Connector Lower part of the driver seat

Position
Connector Black
Color
Connector Female
Nature
1 PK/WH 6434
2 D-BU 6105
3 BN 6433
4 BN/WH 2500
5 BN/WH 5169
6 - -
7 - -
8 - -
9 - -
10 - -
11 GY/BK 6435
12 L-BU 6106
13 L-GN/BK 6432
14 BN 2501
15 BN 5170
16 - -
17 - -
18 PK 139
48-125
Connector
FL07 FL05
1 2
1
FL07 FL05
Connector Seat belt buckle (driver side) Connector Seat heater (driver side)
Connector At the driver seat Connector At the driver seat

Position Position

Color Color

Nature Nature
1 YE 234A 1 PK 2077D
2 BK 1650BK 2 BK 1750H
48-126
Connector
FL23 FL03
1 2
2 1
3 4 5 6
FL23 FL03
Connector Side airbag (driver side) Connector Power seat adjustment(driver side)
Connector At the driver seat Connector At the driver seat

Position Position

Color Color

Nature Nature
1 BN 2137A 1 BN 1865
2 YE/BK 2138A 2 BK 1750
3 - -
4 - -
5 - -
6 - -
48-127
Connector
FL71_2
FL71_2
Connector Brake lamp switch

Description
Connector Lower part of the auxiliary fascia

Position console
Connector Natural
Color
Connector Female
Nature
1 YE/BK 1131
48-128
Connector
FL01 17 BN/WH 1555C
18 D-BU/WH 1557C
19 OG/WH 1556C
20 YE/BK 7478C
21 - -
1 13
22 - -
14 26
23 L-BU 1296
24 - -
FL01 25 BK 2150TA
26 PK 640B
Connector Transfer case ECU
Description
Connector Rear of the transmission

Position
Connector Black
Color
Connector Female
Nature
1 OG 1553D
2 TN 1552D
3 D-GN 7481B
4 D-GN 1562A
5 YE/BK 1558C
6 YE/BK 7482B
7 - -
8 BN/WH 2500F
8 BN/WH 6437S
9 BN 2501F
9 WH 6436S
10 - -
11 PK/BK 5501C
12 BK 2150TB
13 RD 640A
14 OG 1553E
15 TN 1552E
16 D-GN/WH 1559A
48-129
Connector
FL2IP_3 FL60
4 3 2 1 3 2 1
FL2IP_3 FL60
Connector Connect to the instrument panel Connector 220V power supply

Description harness Description
Connector Lower part of the auxiliary fascia Connector Lower part of the auxiliary fascia
Position console Position console

Color Color

Nature Nature
1 BN 2137A 1 BK 2050V
2 YE/BK 2138A 2 RD/WH 4640A
3 BN/OG 2135A 3 RD/WH 1140AA
4 L-GN 2136A
48-130
Connector
FL04 FL24
1 2
6 5 4 3
1 2
FL04 FL24
Connector Power seat adjustment (front Connector Side airbag (front passenger side)
Description passenger side) Description
Connector At the driver seat Connector At the front passenger seat

Position Position
Connector Natural Connector Yellow

Color Color

Nature Nature
1 YE 288 1 BN/OG 2135A
2 BK 2050 2 L-GN 2136A
3 - -
4 - -
5 - -
6 - -
48-131
Connector
FL08 FL06
1 2
1
FL07 FL06
Connector Seat belt buckle (front passenger Connector Seat heater (front passenger side)
Description side) Description
Connector At the front passenger seat Connector At the front passenger seat
Position Position

Color Color

Nature Nature
1 OG 1362A 1 D-BU 2479D
2 D-BU 1363 2 BK 2050H
48-132
Connector
FL12 FL55
2 1
1 2 3
FL12 FL55
Connector Seat track position sensor Connector Differential pressure sensor

Connector At the front passenger seat Connector Right side of the front floor
Position Position

Color Color

Nature Nature
1 D-BU 1363 1 D-BU 736B
2 L-BU 1361E 2 GY 2740B
3 L-GN 432B
48-133
Connector
FL2GB 17 PK/BK 5501C
18 PK/BK 5294NE
18 D-BU 7583B
19 L-GN 5378B
20 15 19 WH/BK 5666A
20 PK/BK 5294EA
6 1
FL2GB
Connector Connect to the transmission harness

Description
Connector Right side of the front floor

Position
Connector Black
Color
Connector Male
Nature
1 BK 350TE
2 BN 2501L
2 BN 2503R
3 BN/WH 2500L
3 BN/WH 2502R
4 L-GN 5007A
5 L-GN 275B
6 YE 43AB
7 OG 1553C
8 TN 1552C
9 YE/BK 7478C
10 BN/WH 1555C
11 OG/WH 1556C
12 YE/BK 1558C
13 D-BU/WH 1557C
14 RD/OG 4840AB
15 RD/BK 842AB
16 BK 350TA
48-134
Connector
G_FLR2_3 G_FLR2_2
G_FLR2_3 G_FLR2_2

Connector Right B-pillar Connector Right B-pillar

Position Position

Color Color

Nature Nature
1 BK 2050H 1 BK 2050
48-135
Connector
G_FLR2_1 G_FLR1
G_FLR2_1 G_FLR1


Position Position

Color Color

Nature Nature
1 BK 2050V 1 BK 1850
48-136
Connector
FL2IP_2 14 GY/BK 6435
15 D-BU 6105P
16 RD/BK 242EF
17 OG 1091A
1 2 3 4 5 6 7 8 9 10 11 12 13 14
18 PU/WH 1094A
15 22
23 16 17 18 19 20 21 24
25
27
26
31
19 TN/BK 1095A
32 28 29 30 33
34
36
35
43
20 RD 640D
37 38 39 40 41 42
44 45 46 47 48 49 50 51 52 53 54 55 56 57
21 PK 640B
FL2IP_2 22 L-BU 1361A
23 - -
24 - -
Description harness
25 - -
Position 26 - -
Connector Natural
27 - -
Color
28 - -
Connector Female
Nature 29 - -
30 - -
1 L-GN 5007A 31 YE/BK 1131
2 RD/OG 4840AB 32 L-BU/BK 747A
3 WH 6106P 33 BN 2501E
4 RD/BK 842AB 34 L-GN/BK 748A
5 - - 35 PU 6NAE
6 BN/WH 2500E 36 TN 5858A
6 BN/WH 6437R 37 RD 1263DA
7 PK 5853 38 RD 1263DB
8 BN 5856 39 RD/YE 1262DA
9 BN/WH 5169 40 RD/YE 1262DB
9 BN/WH 5169H 41 PK 1092A
10 BN 5170 42 RD/PK 242FE
10 BN 5170L 43 OG 1362A
11 BN/WH 2502R 44 OG 2116K
11 BN 6433A 45 L-GN 2117K
12 BN 2503R 46 D-BU 46A
12 BN 6432A 47 WH 115A
13 PK/WH 6434 48 WH 249JA
48-137
Connector
49 WH 249KA FL2EB
50 YE 5859
51 PU 5854
52 PK/BK 5855
53 WH 5857
4 3 2 1
54 GY 5969
10 9 8 7 6 5
55 PK 5861
56 L-GN/WH 5860
57 OG 5863 FL2EB

Description harness

Position
Connector Natural
Color
Connector Female
Nature
1 L-GN 275B
2 YE 43AB
3 D-BU 7583B
4 L-GN 5378B
5 TN 3121B
6 PU 3120B
7 GY/WH 3122B
8 L-GN 432B
8 PK/BK 5294EA
8 PK/BK 5294NC
9 GY 2740B
9 WH/BK 5666A
10 D-BU 736B
48-138
Connector
FL22 G_FLBR_3
1 2
FL21 G_FLBR_3
Connector Side impact sensor (right) Connector Floor harness ground

Connector Lower part of right B-pillar Connector Right B-pillar

Position Position
Connector Black Connector Silver

Color Color

Nature Nature
1 WH/BK 2132A 1 BK 350TE
2 PU/WH 6628A
48-139
Connector
G_FLBR_2 G_FLBR_1
G_FLBR_2 G_FLBR_1


Position Position

Color Color

Nature Nature
1 BK 350TA 1 BK 2350
1 BK 2350P
48-140
Connector
FL10 FL2RRD_1
1 2
1 2 3 4
5 6 7 8 9 10
FL10 FL2RRD_1
Connector Seat belt pretensioner (front Connector Connect to the right rear door
Description passenger side) Description harness
Connector Right B-pillar Connector Inside right rear door trim panel
Position Position

Color Color

Nature Nature
1 OG 2116K 1 BK 2350
2 L-GN 2117K 2 D-BU 4042DA
3 L-GN 170B
4 GY 171B
5 YE/BK 6859DA
6 PU/WH 1382EA
7 WH 249KA
8 PU/WH 1094A
9 TN/BK 1095A
10 L-GN/BK 748A
48-141
Connector
FL2RRD_2 GB08 （AT）
3 2 1 1 2
8 7 6 5 4
FL2RRD_2 GB08
Connector Connect to the right rear door Connector Rear temperature sensor
Connector Inside right rear door trim panel Connector Beside the transmission
Position Position

Color Color

Nature Nature
1 BK 2350P 1 D-BU 7583A
2 D-BU 46A 2 L-GN 5378A
3 WH 115A
4 - -
5 - -
6 - -
7 - -
8 - -
48-142
Connector
GB06 （AT） GB01 （AT）
G B
F A C
A
E D
GB06 GB01
Connector Front axle halfshaft clutch motor Connector Transfer case control motor
Connector On the front axle Connector On the transfer case

Position Position

Color Color

Nature Nature
A PK/BK 5501 A BN/WH 1555
B TN 1552
C OG/WH 1556
D YE/BK 1558
E D-BU/WH 1557
F YE/BK 7478
G OG 1553
48-143
Connector
GB2FL （AT） 19 L-GN 5378A
20 - -
15 16 17 18 19 20
11 12 13 14
7 8 9 10
1 2 3 4 5 6
GB2FL
Connector Connect to the floor harness

Description
Connector Right side of the 4th beam

Position
Connector Black
Color
Connector Female
Nature
1 - -
2 BN 2501K
3 BN/WH 2500K
4 - -
5 L-GN 275
6 YE 43AA
7 OG 1553
8 TN 1552
9 YE/BK 7478
10 BN/WH 1555
11 OG/WH 1556
12 YE/BK 1558
13 D-BU/WH 1557
14 RD/WH 4840AA
15 BK 842AC
16 BK 350TK
17 PK/BK 5501
18 D-BU 7583A
48-144
Connector
GB02 （AT） GB2FL （MT）E
10
15 11
3
15 16 17 18 19 20
8 4
12 1 11 12 13 14
16 5
13 9
6
7 8 9 10
2
14
7 1 2 3 4 5 6
GB02 GB2FL
Connector Transfer case Connector Connect to the floor harness

Connector Rear of the transmission Connector Right side of the 4th beam
Position Position

Color Color

Nature Nature
1 - - 1 BK 750TW
2 - - 1 BK 750TX
3 L-GN 275 1 BK 750TY
4 RD/WH 4840AA 1 BK 750TZ
5 BK 350TK 2 - -
6 - - 3 - -
7 - - 4 L-GN 5007AA
8 - - 4 L-GN 5007AB
9 YE 43AA 4 L-GN 5007AC
10 BN/WH 2500K 4 L-GN 5007AD
11 BN 2501K 5 OG/BK 1664BC
12 RD/BK 842AC 6 - -
13 - - 7 OG 1553
14 - - 8 PK 1552
15 - - 9 YE/BK 7478
16 - - 10 BN/WH 1555
11 OG/WH 1556
12 YE/BK 1558
48-145
Connector
13 D-BU/WH 1557 GB09 （MT）

14 - -
15 - -
16 - -
17 PK/BK 5501
18 RD/WH 1666C
18 D-BU 7583A A B C D
19 BN 1667C
19 L-GN 5378A GB09

20 YE 5294EB
Connector Transfer case control motor
Description
Connector On the transfer case

Position
Connector Black
Color
Connector Female
Nature
A BN/WH 1555
B TN 1552
C OG/WH 1556
D YE/BK 1558
E D-BU/WH 1557
F YE/BK 7478
G OG 1553
48-146
Connector
GB08 （MT） GB03_D （MT）
1 2
2 1
GB08 GB03_D
Connector Rear temperature sensor Connector Reverse gear switch (5MT SAGW）
Connector Beside the transmission Connector Rear of the transmission

Position Position
Connector Black Connector Gray

Color Color

Nature Nature
1 D-BU 7583A 1 BK 750TW
2 L-GN 5378A 2 L-GN 5007AD
48-147
Connector
GB03_C （MT） GB03_B （MT）
2 1
1 2
GB03_C GB03_B
Connector Reverse gear switch (6MT DMS Connector Reverse gear switch (6MT SAIC
Description 4WD） Description 4WD）
Connector Rear of the transmission Connector Rear of the transmission
Position Position

Color Color

Nature Nature
1 BK 750TX 1 BK 750TY
2 L-GN 5007AA 2 L-GN 5007AC
48-148
Connector
GB03_A （MT） GB01 （MT）
G B
F A C
E D
1 1
GB03_A GB01
Connector Reverse gear switch (5MT AX） Connector Transfer case control motor
Connector Rear of the transmission Connector On the transfer case

Position Position

Color Color

Nature Nature
1 BK 750TZ A BN/WH 1555
2 L-GN 5007AB B PK 1552
C OG/WH 1556
D YE/BK 1558
E D-BU/WH 1557
F YE/BK 7478
G OG 1553
48-149
Connector
GB06 （MT） PR2CH
M L K J H G
A
F E D C B A
GB06 PR2CH
Connector Front axle halfshaft clutch motor Connector Transfer case control motor
Connector On the front axle Connector On the transfer case

Position Position

Color Color

Nature Nature
A PK/BK 5501 A BN 6846K
B - -
C BK 550LJ
D BK 550LK
E L-GN 5962
F OG 5973A
G BK 550RX
H BK 550RZ
J PK 5861D
K L-GN/WH 5860D
L OG 5863D
M GY 5969D
48-150
Connector
PR05 PR01
2 1
3 2 1
PR05 PR01
Connector Blind spot monitoring sensor (left Connector Rear license plate lamp (left)
Description rear) Description
Connector Outside of the rear bumper Connector Back of the rear license plate lamp
Position Position

Color Color

Nature Nature
1 GY 5969E 1 BN 6846M
2 PK 5861D 2 BK 550LJ
3 L-GN/WH 5860E
48-151
Connector
PR03 PR06
4 2
3 2 1
3 1
PR03 PR06
Connector Reverse radar sensor (left) Connector Blind spot monitoring sensor (right
Description Description rear)
Connector Middle of the rear bumper Connector Outside of the rear bumper
Position Position

Color Color

Nature Nature
1 L-GN 5962 1 GY 5969F
2 BK 550RX 2 OG 5863D
3 OG 5973 3 L-GN/WH 5860F
4 D-BU 5977
48-152
Connector
PR04 PR02
4 2
2 1
3 1
PR03 PR02
Connector Reverse radar sensor (right) Connector Rear license plate lamp (right)
Connector Middle of the rear bumper Connector Back of the rear license plate lamp
Position Position

Color Color

Nature Nature
1 BK 550RW 1 BN 6846N
2 BK 550RY 2 BK 550LK
3 OG 5973D
4 D-BU 5977
48-153
Connector
RC2CH RC02
H G F E
D C B A 2 1
4 3
RC2CH RC02
Connector Connect to the chassis harness Connector 360° rear camera

Connector Middle of the rear bumper Connector Back of 360° rear camera
Position Position

Color Color

Nature Nature
A YE 6793 1 YE 6798B
A YE 6798B 2 D-BU 6798BA
B D-BU 6793AB 3 BN/OG 6202B
B D-BU 6798BB 4 OG 6201B
C BK 550CA
C BN/OG 6202B
D OG/BK 5219N
D OG 6201B
E - -
F - -
G - -
H - -
48-154
Connector
RC01 DRD2IP_2
9 10 11 12 13 14 15 16
2 1 1 2 3 4 5 6 7 8
4 3
RC01 DRD2IP_2
Connector Rear vision camera Connector Connect to the instrument panel

Description Description harness
Connector Back of the rear vision camera Connector Inside driver door trim panel
Position Position

Color Color

Nature Nature
1 YE 6793 1 D-BU/YE 7176
2 D-BU 6793AA 2 D-BU/BK 7177
3 BK 550CA 3 GY 1963
4 OG/BK 5219N 4 PU/WH 1382Q
5 PK/WH 1447
6 D-GN 168
7 PU 169
8 L-GN 170
9 GY 171
10 BN/WH 1498B
10 BN/WH 1498B_RHD
11 OG 889B
11 OG 889B_RHD
12 YE 88B
13 BK 850DZ
14 YE 6802
15 PK 6803
16 RD/BK 1142A
48-155
Connector
DD03
5 4 3 2 1
12 11 10 9 8 7 6
DD03
Connector Exterior mirror (left)

Description
Connector Inside driver door trim panel

Position
Connector White
Color
Connector Female
Nature
1 PU 82
1 PU 82_RHD
2 D-BU 88
3 L-GN 89
4 WH 606
5 BK 8500N
6 L-BU 14C
7 YE 6802
8 PK 6803
9 PK 5853B
10 BK 850BS
11 - -
12 - -
48-156
Connector
DRD2IP_1 15 GY/BK 745
15 GY/BK 745_RHD
16 OG 6201L
19 14 9 4 17 GY 195
18 13 8 3
22 17 L-GN 195C
21 17 12 7 17 L-GN 195C_RHD
20
16 11 6 2 17 GY 195_RHD
15 10 5 1 18 GY 6798L
DRD2IP_1 19 D-BU 1166A
20 PU 218A
21 BN 219A
Description harness
22 BK 850DY
Position
Connector Natural
Color
Connector Male
Nature
1 L-BU 14C
2 RD/WH 4040CA
2 RD/WH 4040CB
3 YE 166
4 TN 167
5 YE/BK 6859
6 PK 5853B
7 WH 294EA
7 WH 294EB
8 TN 201
9 GY 118
10 WH 606
11 BK SHIELD6798L
12 TN 194
12 TN 194_RHD
13 BN/OG 6202L
14 PK/BK 780
14 PK/BK 780_RHD
48-157
Connector
DD13 DD11
2 1 5 4 3 2 1
4 3 10 9 8 7 6
DD13 DD11
Connector Exterior mirror camera (left) Connector Exterior mirror adjustment switch (left)
Connector Inside driver door trim panel Connector Inside driver door trim panel
Position Position

Color Color

Nature Nature
1 GY 6798L 1 GY 1963
2 BK SHIELD6798L 2 YE 88A
3 BN/OG 6202L 3 BK 850DM
4 OG 6201L 4 PU/WH 1382R
5 RD/BK 1142A
6 L-GN 89_RHD
6 OG 889B
7 PU 82
7 BN/WH 1498B_RHD
8 - -
9 PU 82_RHD
9 BN/WH 1498B
10 L-GN 89
10 OG 889B_RHD
48-158
Connector
DD10 DD02
4 3 2 1
2
DD10 DD02
Connector Fuel tank cap switch Connector Loudspeaker (left front)

Position Position

Color Color

Nature Nature
1 BK 850DE 1 TN 201
2 PU/WH 1382L 2 GY 118
3 BK 850DF
4 PK/WH 1447
48-159
Connector
DD07 DD05
4 5 6
1 2
1 2 3
DD07 DD05
Connector Window regulator motor (one-touch Connector Window regulator motor (one-touch
Description button) Description down)
Position Position

Color Color

Nature Nature
1 BK 850WD 1 D-BU 164
2 BN 165A 2 BN 165
3 D-GN/PU 7628
4 RD/WH 4040CB
5 D-BU 164A
6 - -
48-160
Connector
DD06 DD04_A
1 2
3 4
D C B A
DD06 DD04_A
Connector Window regulator switch (one-touch Connector Door lock motor (left)
Description down) Description
Position Position

Color Color

Nature Nature
1 BN 165 A GY/BK 745
2 D-BU 164 B BK 850DA
3 RD/WH 4040CA C GY 195
4 BK 850WC C GY 195C
D TN 194
48-161
Connector
DD08 19 BK 850WB
20 - -
21 TN 167
22 WH 294EB
23 YE 166
24 D-BU/YE 7176
13 24
1 12
DD08
Connector Window regulator switch (one-touch

Description button)

Position
Connector White
Color
Connector Female
Nature
1 PU 169
2 - -
3 D-GN 168
4 YE/BK 6859
5 - -
6 PU/WH 1382DA
7 BK 850WA
8 WH 294EA
9 - -
10 L-GN 170
11 - -
12 GY 171
13 D-BU/BK 7177
14 D-BU 164A
15 D-GN/PU 7628
16 - -
17 BN 165A
18 - -
48-162
Connector
DD04_B DD01
D C B A 1 2 3 4
DD04_B
DD01
Connector Door lock motor (left) Connector PEPS antenna

Position Position

Color Color

Nature Nature
A PK/BK 780 1 BN 219A
B BK 850DB 1 D-BU 1166A
C - - 2 PU 218A
D - - 3 BK 850DT
4 - -
48-163
Connector
PAD2IP_2 PD03
5 4 3 2 1
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 12 11 10 9 8 7 6
PAD2IP_2 PD03
Connector Connect to the instrument panel Connector Exterior mirror (right)

Connector Inside front passenger door trim panel Connector Inside front passenger door trim panel
Position Position
Connector Natural Connector White

Color Color

Nature Nature
1 GY 90 1 BN/WH 1498
2 OG 889 2 GY 90
3 BN/WH 1498 3 OG 889
4 YE 6804 4 PU 607
5 PK 6805 5 BK 1550DM
6 BK 1550DZ 6 D-BU 15C
7 BN 5856B 7 YE 6804
8 - - 8 PK 6805
9 - - 9 BN 5856B
10 - - 10 BN 1550BS
11 - - 11 - -
12 - - 12 - -
13 - -
14 - -
15 - -
16 - -
48-164
Connector
PAD2IP_1 15 BN/OG 746_RHD
16 OG 6201R
17 BN/OG 6202R
19 14 9 4 18 GY 6798R
18 13 8 3
22 19 GY 1167A
21 17 12 7 20 L-GN 5707A
20
16 11 6 2 21 L-GN/BK 5711A
15 10 5 1 22 BK 1550WA
PAD2IP_1

Description harness
Connector Inside front passenger door trim panel

Position
Connector Natural
Color
Connector Male
Nature
1 D-BU 15C
2 RD/WH 4040DA
3 YE 166B
4 TN 167B
5 YE/BK 6859BA
6 PU/WH 1382GA
7 WH 249GA
8 L-GN 200
9 PU 117
10 PU 607
11 BK SHIELD6798R
12 WH 194B
12 WH 194B_RHD
13 L-BU 195B
13 L-BU 195B_RHD
14 BN 244
14 BN 244_RHD
15 BN/OG 746
48-165
Connector
PD07 PD02
2
2 1
4 3
1
PD07 PD02
Connector Exterior mirror camera (right) Connector Loudspeaker (right front)

Position Position

Color Color

Nature Nature
1 GY 6798R 1 L-GN 200
2 BK SHIELD6798R 2 PU 117
3 BN/OG 6202R
4 OG 6201R
48-166
Connector
PD05 PD06
5 4 3 2 1
1 2
12 11 10 9 8 7 6
PD05 PD06
Connector Window regulator motor Connector Window regulator switch

Position Position

Color Color

Nature Nature
1 D-BU 666 1 BK 1550WA
2 BN 667 2 BN 667
3 YE/BK 6859BA
4 D-BU 666
5 RD/WH 4040DA
6 - -
7 TN 167B
8 BK 1550WB
9 PU/WH 1382GA
10 WH 249GA
11 YE 166B
12 - -
48-167
Connector
PD04_A PD04_B
D C B A D C B A
PD04_A PD04_B
Connector Door lock motor (right) Connector Door lock motor (right)
Position Position

Color Color

Nature Nature
A WH 194B A - -
B L-BU 195B B - -
C BK 1550DA C BK 1550DB
D BN/OG 746 D BN 244
48-168
Connector
PD01 RLD2FL_1
5 6 7 8 9 10
1 2 3 4
1 2 3 4
PD01 RLD2FL_1
Connector PEPS antenna Connector Connect to the floor harness

Connector Inside front passenger door trim panel Connector Inside left rear door trim panel
Position Position

Color Color

Nature Nature
1 GY 1167A 1 BK 2150DZ
2 BK 1550DT 2 L-GN 4042CB
3 L-GN 5707A 3 D-GN 168C
4 L-GN/BK 5711A 4 PU 169C
5 YE/BK 6859CB
6 PU/WH 1382FB
7 WH 249JB
8 OG 1091
9 PK 1092
10 L-BU/BK 747
48-169
Connector
RLD2FL_2 RL01
8 7 6 5 4
2
3 2 1
1
RLD2FL_2 RL01
Connector Connect to the floor harness Connector Loudspeaker (left rear)

Connector Inside left rear door trim panel Connector Inside left rear door trim panel
Position Position

Color Color

Nature Nature
1 BK 2150WA 1 WH 199
2 WH 199 2 YE 116
3 YE 116
4 - -
5 - -
6 - -
7 - -
8 - -
48-170
Connector
RL04 RL03
5 4 3 2 1
2 1
12 11 10 9 8 7 6
RL04 RL03
Connector Window regulator switch Connector Window regulator motor

Connector Inside left rear door trim panel Connector Inside left rear door trim panel
Position Position
Connector Natural Connector Gray

Color Color

Nature Nature
1 BK 2150WA 1 BN 669
2 BN 669 2 D-BU 668
3 YE/BK 6859CB
4 D-BU 668
5 L-GN 4042CB
6 - -
7 PU 169C
8 BK 2150WB
9 PU/WH 1382FB
10 WH 249JB
11 D-GN 168C
12 - -
48-171
Connector
RL02 RRD2FL_1
5 6 7 8 9 10
D C B A 1 2 3 4
RL02 RRD2FL_1
Connector Door lock motor Connector Connect to the floor harness

Connector Inside left rear door trim panel Connector Inside right rear door trim panel
Position Position

Color Color
Connector Female Connector Male

Nature Nature
A L-BU/BK 747 1 BK 2350DZ
B BK 2150DA 2 D-BU 4042DB
C PK 1092 3 L-GN 170C
D OG 1091 4 GY 171C
5 YE/BK 6859DB
6 PU/WH 1382EB
7 WH 249KB
8 OG 1091
8 PU/WH 1094
9 PK 1092
9 TN/BK 1095
10 L-BU/BK 747
10 L-GN/BK 748
48-172
Connector
RRD2FL_2 RR01
8 7 6 5 4
2
3 2 1
1
RRD2FL_2 RR01
Connector Connect to the floor harness Connector Loudspeaker (right rear)

Connector Inside right rear door trim panel Connector Inside right rear door trim panel
Position Position

Color Color

Nature Nature
1 BK 2350WA 1 D-BU 46
2 D-BU 46 2 WH 115
3 WH 115
4 - -
5 - -
6 - -
7 - -
8 - -
48-173
Connector
RR04 RR03
5 4 3 2 1
2 1
12 11 10 9 8 7 6
RR04 RR03
Connector Window regulator switch Connector Window regulator motor

Connector Inside right rear door trim panel Connector Inside right rear door trim panel
Position Position
Connector Natural Connector Gray

Color Color

Nature Nature
1 BK 2350WA 1 BN 671
2 BN 671 2 D-BU 670
3 YE/BK 6859DB
4 D-BU 670
5 D-BU 4042DB
6 - -
7 GY 171C
8 BK 2350WB
9 PU/WH 1382EB
10 WH 249KB
11 L-GN 170C
12 - -
48-174
Connector
RR02
D C B A
RR02
Connector Door lock motor

Description
Connector Inside right rear door trim panel

Position
Connector Black
Color
Connector Female
Nature
A PU/WH 1094
B TN/BK 1095
C BK 2350DA
D L-GN/BK 748
48-175
Connector
48-176
Circuit Diagram
Circuit Diagram
Abbreviations
ABS Anti-lock Brake System or Anti-Block Steering 防抱死制动系统

AFS Adaptable front lighting system 自适应前照灯系统
ADJ Adjust 调节
BCM Body control moudle 车身控制器
CONT Control 控制
DRL Day time running lamp 日间行车灯
ECU Electronic Control Unit 发动机控制器
ESP Electronic Stability Process 电子稳定系统
FFOG Front fog lamp 前雾灯
HVAC Heat ventilation and air condition 空调蒸发器
IEC IP electrical center 仪表板电器盒
IMMO Immoblizer 发动机防盗
IPK Instrument cluster 组合仪表
MAP Manifold absolute pressure 歧管空气压力温度传感器
PEPS Passive entry&Passive start 无钥匙进入与无钥匙起动
PRED Pretrnsion seat belt driver side 驾驶员侧预张紧安全带
PREP Pretrnsion seat belt passenger side 乘客侧预张紧安全带
PWR Power 电源
SAS Steer angle sensor 角度传感器
SRS Air bag system 安全气囊
ST Start 起动
TPMS Tyre pressure monitor system 胎压监测系统
UEC Under bonnet electrical center 前舱电器盒
YAW Yaw rate sensor 横摆加速度传感器
RLS Rain and Light Sensor 雨量阳光传感器
49-1
Circuit Diagram
Wire Color Codes
BK Black 黑色
BN Brown 棕色
BU Blue 蓝色
GY Gray 灰色
GN Green 绿色
NAT Nature 本色
OG Orange 橙色
PK Pink 粉红色
PU Purple 紫色
RD Red 红色
TN Tan 褐色
WH White 白色
YE Yellow 黄色
D-GN Dark Green 深绿色
L-GN Little Green 浅绿色
YE/BK Yellow/Black 黄黑
BARE Bare 屏蔽裸线
Note：The combination of 2 color codes is a mixed color code, among which the preceding letters
indicate the essential color, while the later letters indicates the complementary color. (For example: YW/
WH indicates the mixed color wire with yellow as the essential color, and white as the complementary
color.)
49-2
Circuit Diagram
Harness Codes
EB Engine bay harness 发动机舱线束

BT Battery harness 蓄电池线束
BTN Battery negetive harness 蓄电池负极线束
GB Transmission harness 变速箱线束
IP Instrument pannel harness 仪表板线束
RF Roof harness 顶棚线束
FL Floor harness 地板线束
CH Classic harness 底盘线束
DD Driver door harness 驾驶员门线束
PD Passenger door harness 副驾驶门线束
RL Left rear door 左后门线束
RR Right rear door 右后门线束
RC Camera harness 摄像头线束
PR Parking radar harness 倒车雷达线束
G_EN Engine ground harness 发动机接地线束
49-3
Circuit Diagram
Configuration Codes
LHD Left hand drive 左舵

RHD Right hand drive 右舵
LWB Long wheelbase 长轴
SWB Short wheelbase 短轴
HGC High chassis 高底盘
LGC Low chassis 低底盘
4WD 4-wheel drive 4驱
SCB Single row seats 单排
EXCB One and half row seats 排半
DCB Double row seats 双排
EDCB Extra double row seats 大双排
ALL All 标配
2.8FGT VM 2.8FGT engine VM 2.8FGT 发动机
2.8VGT VM 2.8VGT engine VM 2.8VGT 发动机
4G69 4G69 engine 4G69 发动机
NLE2.0T NLE2.0T engine NLE2.0T 发动机
MT Manual transmission 手动变速箱
5MT Aisin/5MT SAGW 5MT Aisin/5MT SAGW 5MT 爱信 5MT Aisin/5MT 上汽齿
5MT SAGW 5MT SAGW 5MT 上汽齿
6MT 6MT SAGW 6MT 上汽齿 6MT SAGW
6MT 6MT Dymos 6MT 戴莫斯 6MT Dymos
AT 6AT Punch 6AT 邦奇 6AT Punch
RCSW Cruise control system 定速巡航
EFAC Electronically controlled front axle half 电控前桥半轴离合器
shaft clutch
ELC Electronic lock control + one-touch start + 电子锁控 + 一键启动 +MT
MT
ABS Anti-lock brake system + Electronic brake 制动防抱死系统 + 电子制动分配
force distribution
ESP Electronic stability program + electronic 电子稳定程序 + 电子制动辅助（HAS、 RMI、
brake assist (HAS, RMI, HDC) HDC)
TPMS Tire pressure monitoring system 胎压监测系统
SPHM Side power heated mirror 电动带加热外后视镜
SPHCM Side power folding & heated mirror 电动电折叠带加热外后视镜
PGAM Automatic anti-dazzle interior mirror 自动防炫目内后视镜
CIGAR Cigarette lighter 点烟器
PST Front seats 6-direction power + 2-direction 主副驾驶电动 6 向 + 手动 2 向（腰托），鞭
manual (lumbar support), protection 打保护
against whip
FSHF Front seats heating (cushion) 主副座椅加热（坐垫）
SRSH Supplemental restraint system ECU high 安全气囊 ECU 高配
configuration
SRSL Supplemental restraint system ECU low 安全气囊 ECU 低配
configuration
DAB Driver airbag 驾驶员安全气囊
PAB Front passenger airbag 副驾驶安全气囊
49-4
Circuit Diagram
LDW Lane departure warning system 车道偏离预警系统

BSD Blind spot detection system 盲区监测系统
FRSAB Front seats side airbag 主副驾侧气囊
CAB Equipped with through-type air curtain 带前后贯穿气帘
D2PSB Driver adjustable 2-stage pretensioner seat 主驾驶可调双极预紧限力式安全带
belt
D1PSB Driver adjustable 1-stage pretensioner seat 主驾驶可调预紧限力式安全带
belt
DSBR Seat belt reminder for driver seat only 仅驾驶员安全带未系提醒
FSBR Seat belt reminder for front seats only 仅前排安全带未系提醒
SBR Seat belt reminder for all seats 全车安全带未系提醒
P2PSB Passenger adjustable 2-stage pretensioner 副驾驶可调双极预紧限力式安全带
seat belt
P1PSB Passenger adjustable 1-stage pretensioner 副驾驶可调预紧限力式安全带
seat belt
BL Backlight adjustment 背光调节
HALP Halogen headlamp 卤素前大灯
XELP LED headlamp + lens LED 前大灯 + 透镜
AFS Adaptive forward lighting system + ESP 自适应前大灯系统 +ESP
RFOG Rear fog lamp 后雾灯
DRLP With daytime running lamp 带日间行车灯
FRLP Front reading lamp (With glasses box) 前阅读灯（带眼镜盒）
CHMSL Center high mounted stop lamp 高位制动灯
ALLP Auto headlamp on + rain & light sensor 大灯自动点亮 + 雨量阳光传感器
RLP Tail lamp (without light guide) 后尾灯 ( 不带光导 )
TULP Turning signal lamp 转向辅助灯
RRDEFROST Rear window defrost 后窗电加热除霜
PZLP Passenger compartment lighting 乘客区照明灯
RCAM Rear camera 后摄像头
BSV BSV (360° panorama image) BSV （360°全景影像）
PEPS Passive entry & passive start system 无钥匙进入及启动系统
-PEPS Non-passive entry & passive start system 非无钥匙进入及启动系统
IMMO With engine immobilizer system 带发动机电子芯片防盗系统
PDC Reverse radar (parking distance control) 倒车雷达 ( 驻车距离控制 )
RLS Rain & light sensor 雨量阳光传感器
ANTIPIN One-touch lifting (with anti-pinch) 一键升降（带防夹）
1 SHOT One-touch down 一键下降
RREGL Rear power window glass lifting 后排电动玻璃升降
INV 220V power supply 220V 便利电源
12V DC 12V power supply 12V 电源
MSAC Manual front air conditioning 手动前空调
AT A/C Automatic front air conditioning 自动前空调
RADIO Radio RADIO
BLTH Bluetooth 蓝牙
10-SCREEN 10-inch touch screen (Radio MP5 10 寸触摸屏（Radio MP5 手机互联自动空调
MirrorLink Auto A/C display Bluetooth) 显示蓝牙 +AUX+USB）
49-5
Circuit Diagram
7-SCREEN 7-inch touch screen (Radio MP5 MirrorLink 7 寸触摸屏 (Radio MP5 手机互联蓝牙 USB)
Auto A/C display Bluetooth)
AR Voice recognition 语音识别
T-BOX Connected vehicles 车联网
0 SPEAKER 0 speaker 无扬声器
2 SPEAKER 2 speakers 2 扬声器
PTANT Built-in print antenna 内置印刷天线
TRAILER Trailer 拖车
GTWY Gateway 网关
-GTWY Non-gateway 非网关
PABSW Front passenger airbag switch 副驾驶安全气囊开关
HeatingOnly Heating only (only available on standard 单暖（单暖仅南非标准版才有）
version for South Africa)
-HeatingOnly Non-heating only 非单暖
MFSW Multifunctional steering wheel 多功能方向盘
-MFSW Non-multifunctional steering wheel 非都功能方向盘
GCC Saudi Arabia 沙特
-GCC Non-Saudi Arabia 非沙特
600W 600W fan 600 瓦风扇
480W 400W fan 480 瓦风扇
EPS Electrical power steering 电动助力转向
ESSS Start/Stop function 启停功能
NLE2.0T 2.0T engine 2.0T 发动机
49-6
Circuit Diagram
How to Use Circuit Diagram
Power Mode Description
B+ 蓄电池正极 positive battery
ACC 点火开关解锁 lgnition switch unlocks
IG1 点火开关1 lgnition switch 1
IG2 点火开关2 lgnition switch 2
ST 点火开关起动 lgnition switch starts
Wire Properties
121_GRA_2.5_ALL
The description of wire properties is located on top of wires in the circuit diagram.
"121" represents the wire code.
"GRA" represents the wire color, please refer to "Wire Color Codes" for relevant information.
"2.5" represents the cross sectional area of wire in square millimeters.
"All" represents the model configuration, herein it represents applicable to all models.
49-7
Circuit Diagram
Connectors
1339_YEL/BLK_0.5_MT
1C_RED_25_ALL
RA03
1
⭫Ⓠ A7 FB2IPR
BATT IP2FBR
ਇ⭫ᵰ
Alternator
For example: RA03 represents Connector RA03, Pin 1.
represents female connector

represents male connector
Grounding Point
G106_1
The grounding point is usually represented by a double circle symbol, with a grounding point number marked on the top,
as shown in Figure G106-1.
Twisted Pairs
2501A_YE/BRN_0.35_ESP
2500A_YEL/BK_0.35_ESP
The twisted pairs are illustrated on the circuit diagram as above.
49-8
Circuit Diagram
Shielded Wires
The shielded wires are illustrated on the circuit diagram as above.
49-9
Circuit Diagram
Harness Configuration Codes
Refer to the following table for the meaning of harness configuration codes.
Harness Configuration Codes Harness Configuration Description 线束配置描述

ALL All models 所有车型
CBW Rear A/C 后空调
CBW&HBW Rear heating and rear A/C 后暖风和后空调
CRUS Cruise control 巡航控制
CAME Camera 摄像头
DEF Rear window heating 后风窗加热
DRL Daytime running lamp 日间行车灯
HBW Rear heating 后暖风
INV Rear heating 车载逆变器
LSLD Left sliding door 左侧移门
MP5 MP5 multimedia player 第五代多媒体播放机
OSM Exterior mirror heating and power 外后视镜加热及电调
adjustment
PAB Front passenger airbag 前排乘客安全气囊

PDC Reverse radar 倒车雷达
SPKS Rear speakers 后扬声器
TPMS Tire pressure monitoring 胎压监测
EU4 Euro IV 欧四
EU5 Euro V 欧五
AMT Automatic transmission 自动变速箱
MT Manual transmission 手动变速箱
TCU Transmission control module 变速箱控制模块
GSL Gear shift lever 换挡机构
HHC Hill hold control 坡道辅助系统
-HHC Without hill hold control 无坡道辅助系统
IMMO Immobilizer 发动机防盗锁止系统
EDSO Power outward swing door 电动外摆门
-EDSO Without power outward swing door 无电动外摆门
49-10
Circuit Diagram
Circuit Diagram
Starting&Charging System
BT02 BT01
1 1
RT BATT-
150_BK_25_ESSS
150N_BK_25
㫺⭫⊖Ֆ᝕ಞ 㫺⭫⊖Ֆ
IBS BATTERY
B+2 LIN 1
2 1
EB06
㫺⭫⊖人ؓ䲟ѓⴈ
PRE-FUSE BOX
G_EBL1 P-MGE P-MGD

DCOC1 EPS ALTERATOR
3140B_RD/WH_0.75_ESSS
40A 100A 175A
1 1 1 1
TB01_E BT01_D EN08_C BT01_C
1262_RD_3.0_ESSS
1NF_RD_10_EPS
1AG_RD_25_4G69
1_RD_25_2.8FGTI/2.8VGT
1_RD_25_NLE2.0T
SP14602
3140A_RD/WH_0.75_HTOL
3140_RD/WH_0.75_HTOL/ESSS
6 BT2EB_N
EB2BT_N
1262A_RD_3.0_ESSS
BT07_A
2 EN04 BT05 BT14
V BATT
1 1 1
⭫࣑ࣞࣟ䖢ੇ 2 B+ 1 B+ 3 B+
᧝࡬ঋ‫ݹ‬
EPS ECU
Ӛ⍷ਇ⭫ᵰ
ALTERATOR
EB2IP
1 IP2EB L B1 FR B2 LIN 1N
IP07_B 1 2
1262B_RD_3.0_ESSS
B5 B6 EN01
25GA_BN_0.5_4G69
U-FS9
U-R9
A/C
A/C
CONPRESSOR EN2EB EN2EB
CONPRESSOR 8 EB2EN 11 EB2EN
15A
ਇࣞᵰ㡧ؓ䲟ѓⴈ
25_BN_0.5_2.8FGT/2.8VGT
SP14702
UEC EN02_A
1262BA_RD_3.0_ESSS
1262BB_RD_3.0_ESSS
EN2EB_G 43
4 EB2EN_G SP2510
I_T_ALT
25G_BN_0.5_4G69
ਇࣞᵰ᧝࡬ঋ‫ݹ‬
2450_BK_2.5_2.8FGTI/2.8CGTI/4G69
EMS
2450N_BK_2.5_NLE2.0T
IP07_B EB02_K1
B5 B6 65
B_D_LIN
EB2IP_1
12 IP2EB_1 ਇࣞᵰ᧝࡬ঋ‫ݹ‬
25A_BN_0.5_ALL
I-FS39 I-FS40 (NLE2.0T)

DCDC-1 DCDC-2 EMS(NLE2.0T)
25A 25A
Ԡ㺞ᶵؓ䲟ѓⴈ
IEC
G_EN1 G_EN2 G_EN1N G_EN2N IP02
26
CHARGING SIG
Ԡ㺞
CLUSTER
17SK8101A01
49-11
IP01_B
17SK8101A02
IGNITION SW
KL15
13
IP01_A
䖜䓡᧝࡬⁗ඍ
(PEPS&ESCL)
KLP
SW
7
BCM
SP14603
IGNITION
10A/15A
1020A_PK_0.35_PEPS
BT01_A
IGN SW
SIG
U-FS8
2
EB01
BT04
1_RD_25_2.8FGTI/2.VGTI/NLE2.0T 41_RD/BK_0.75_ALL
20
P-MGA UEC
46
1
5V
IP54_A
EN08_A
40_RD/BK_0.35_ALL
EN09
175A
OFF ACC RUN START 1073_WH/BK_0.35_PEPS

EB2IP_1
13 IP2EB_1
6
1G_RD_25_4G69
IP54_A
SP411
1
REGULATED PWR
STARTER
40A_RD/BK_0.35_PEPS 1020B_PK_0.35_PEPS
5
U-FS22
2
OFF/RUN/CRANK
4_BN_0.35_PEPS
10A
3
6NA_PU_3.0_NLE2.0T/ESSS ACC ESSORY
3_D-BU_0.35_PEPS
34
EN02_A
1
RUN/CRANK
4
D_S_STRTH
TO KEY-INSW
IP54_B
UEC
135
STARTER
㫺⭫⊖人ؓ䲟ѓⴈ
PRE-FUSE BOX
80_L-GN_0.35_PEPS
䎭ࣞᵰ
2
EMS
U-R4
BATT FROM KEY-INSW
1020_PK_0.35_PEPS
1
KEY-IN TO PMM
D_S_STRTL
134
SP14699
5
6N_PU_3.0_NLE2.0T/ESSS 6NB_PU_3.0_NLE2.0T
137
6GB_PU_2.5_4G69
6_PU_3.0_2.8FGT/2.8VGT
START
䎭ࣞᵰ
EN08_B
BT2EB
EB2BT
EN05
BT06
STATER(4G69) 2G_RD/BK_25_4G69 1(4G69)EATT ST2 6K_PU_3.0_2.8FGT/2.8 VGT
15 EB2EN_G A
1
EN2EB_G
BT01_B
EN06
BT02
Starting&Charging System
START 2_RD/BK_25_2.8FGTI/2.8VGT 1EATT ST(4G69) 6GA_PU_2.5_4G69

B+
1
Circuit Diagram
(NLE2.0T)
START
䎭ࣞᵰ
20 BT2EB_N
EB2BT_N
BT13
BT12
2N_RD/BK_25_NLE2.0T BATT ST 6NBA_PU_3.0_NLE2.0T
49-12
Circuit Diagram
Power Distribution System
ECU
17SK8102A01
49-13
Circuit Diagram
ICE_B
ICE
ICE_A
17SK8102A02
49-14
Circuit Diagram
+
P-MGC
㫺⭫⊖ P-MGD P-MGE
P-MGA UEC ਇ⭫ᵰ
Battery ⭫ࣞ䱱࣑䖢ੇ DCDC1
175A ALTERNATOR
- 100A 40A
175A
1RD_25.0_4G69
1RD_25.0_2.8L/2.0T
2_RD/BK_25.0
1A_ED_25.0
1NE_RD_10.0
1262_RD_3.0
1 1 2 6
BATT BATT BATT BATT
䎭ࣞᵰ ਇ⭫ᵰ ⭫ࣞ䱱࣑䖢ੇ Ԡ㺞ᶵсؓ䲟ѓⴈ

STARTER ALTERNATOR EPS IEC
ਇࣞᵰ㡧сؓ䲟ѓⴈ
RT1 UEC
A
U-FS8 U-FJ2
U-MD1 U-FJ8 U-FJ5 U-FJ10 U-FJ9 U-FJ1 U-FJ6
IGN SW/ RRDEFROST&
COOLING FAN ABS_MOT ABS_VALVE GCU/FUEL PUMP FRT BLOWER TCCU TRAILER PWR
(PEPS&ESCL) MIRROR
80A 40A 25A 60A/30A 40A 30A 30A
10A/15A 25A
20 RT2 8 17 10 9 13 18 14
EB01 EB01_A EB01
41_RD/BK_0.75
342W_RD_8.0_4G69
173_PK_4.0_ESP
856_PU_1.5_ESP
3240GA_RD/WH_2.5_2.0T
3240G_RD/WH_2.5_4G69/2.0T
5540A_BW_6.0_2.8VGT
5540B_BW_6.0_2.8FGT
642_RD/BK_4.0_ALL
640_RD/WH_2.5_4WD
1540_RD/YW_2.5_TRAILER
2940_RD/WH_1.5_RRDEFROST
342N_RD_10.0_2.0T
EB2IP_1
13 IP2EB_1
40A_RD/BK_0.35_PEPS
IP54_A EB22 IP54_A

2 1 1 25
BATT BATT BATT PWR_VALVE
ᆆ㌱㔕⽰ᝅഴ
⛯⚡ᔶީ ߭প伄᡽ ࡬ࣞ䱨ᣧ↱᧝࡬㌱㔕 SUBSYSTEM SCHERMATICS
IGNITION SW COOLIONG FAN ABS/ESP
17SK8102A03
49-15
Circuit Diagram
UEC
B+BUS
A
U-FS16 U-FS10 U-FS3 U-FS12 U-JF7 U-JF6 U-JF5 U-JF4 U-JF12 U-JF11
IEC PWR8 IEC PWR7 IEC PWR6 IEC PWR5 IEC PWR4 IEC PWR3 IEC PWR2 IEC PWR1 IEC PWR9 PWR WINDOW
20A 30A 30A 30A 30A 30A 30A 30A 30A 30A
28 22 15 24 7 6 5 4 12 11
U-JF1 U-JF2 U-JF3 U-FS9

MAIN RELAY DCDC2/COOLING FAN(48W) START A/C COMPRESSOR
30A 40A 30A 15A
1 2 3 21
155 153 128 112 116 133 65
U-R8 U-R3 U-PR2 U-PR1 U-R4 U-R9 A

ѱ㔝⭫ಞ ք䙕߭প伄᡽ ք䙕߭প伄᡽ 儎䙕߭প伄᡽ 䎭ࣞᵰ㔝⭫ಞ グ䈹ু㕟ᵰ㔝⭫ಞ
MAIN RLY FAN LOW FAN MID FAN HI STARTER RLY A/C COMPRESSOR
137
34
U-FS22
START FB
10A
17SK8102A04
49-16
Circuit Diagram
UEC
B+BUS
A
U-FS4 U-FS13
U-FS11 U-FS14
FUEL FILTER HEATER/ECU LOW BEAM&
FRT FOG HI BEAM
(4G69/2.0T) ADJ MOTOR
15A 20A
25A/10A 25A
16 23 25 26
138 82 80 87 85 92 90 97 95
U-R5
U-R13 U-R12 U-R15 U-R14
⟹⋯ࣖ✣⟹⋯⌫㔝⭫ಞ
਩ࢃ䴴⚥ ᐜࢃ䴴⚥ 䘇‫⚥ݿ‬㔝⭫ಞ 䘒‫⚥ݿ‬㔝⭫ಞ
FUEL FILTER HEATER/
FUEL FOG_R FUEL FOG_L LOW BEAM HI BEAM
FUEL PUMP
U-FS15 U-FS7
DAYTIME LP/POSITION LP/AFS MOT/REAR FOG FRT WIPER
10A 25A
27 19
102 100 107 105 75 77 70 72 149 144 147
U-R16 U-R10 U-R7 U-R6 A

U-R17 U-R11
ᐜ‫ם‬ᰛ䰪㺂䖜⚥ ੄䴴⚥㔝⭫ಞ 䴞ࡤ䈹䙕䴞ࡤ⭫Ⓠ
਩‫ם‬ᰛ䰪㺂䖜⚥ փ㖤⚥㔝⭫ಞ
DAYTIME LP_L REAR FOG 㔝⭫ಞ 㔝⭫ಞ
DAYTIME LP_R POITION LP
RELAY WIPER SPEED WIPER POWER
17SK8102A05
49-17
Circuit Diagram
UEC
B+BUS
A A
U-FS13 U-FS14 U-JF10
LOW BEAM&ADJ MOTOR HI BEAM GCU/FIEL PUMP
25A 20A 60A/30A
25 26 10
92 90 97 95 33
U-R15 U-R14 U-FS21

䘇‫⚥ݿ‬㔝⭫ಞ 䘒‫⚥ݿ‬㔝⭫ಞ WATER PUMP
LOW BEAM HI BEAM 15A
96 91 56
44 43 42 41 40 118
U-FS32 U-FS31 U-FS30 U-FS29 U-FS28 U-R1

ADJ MOTOR LO BEAM_RH LO BEAM_LH HI BEAM_RH HI BEAM_LH ≪⌫㔝⭫ಞ(2.0T)
10A 15A 15A 15A 15A WATER PUMP(2.0T)
17SK8102A06
49-18
Circuit Diagram
UEC
B+BUS
A
U-JF1
MAIN RELAY
30A
155 153
U-R8
ѱ㔝⭫ಞ
MAIN RLY
157
31 30 29 32
U-FS19 U-FS18 U-FS17 U-FS20

MAIN RLY PWR3 MAIN RLY PWR2 MAIN RLY PWR1 ESS SW
15A 15A 15A 10A
17SK8102A07
49-19
Circuit Diagram
B+ 人ؓ䲟ѓⴈ B+ ਇࣞᵰ㡧сؓ䲟ѓⴈ
Pre-Fuse Box UEC
U-JF2
P-MCE DCDC1 U-FS6 U-JF7
DCDC2/COOLIG
40A TRAILER PWR IEC PWR4
FAN(480W)
30A 30A
40A
2 18 7
Ԡ㺞ᶵсؓ䲟ѓⴈ
B6 B5 B8 B7 B4 B3 28 27 64 IEC
I-FS40 I-FS39 I-FS42 I-FS41 I-FS38 I-FS37 I-FS16 I-FS15 I-JF3

DCDC1-2 DCDC1-1 DCDC2-2 DCDC2-1 TRAILER PWR2 TRAILER PWR1 HEAT_PAS SEAT HEAT_DRV SEAT ADJ_PASS
25A 25A 25A 25A 25A 25A 10A 10A 25A
B14 B13 B16 B15 B12 B11 36 35

1262CB_RD/YE_2.0_ESSS
1262CA_RD/YE_2.0_ESSS
1263CB_RD_2.0_ESSS
1263CA_RD_2.0_ESSS
1542A_RD_2.0_TRAILER
B22 B26 B19 B24
I-R9 I-R9
ࢥ傴ᓝἻࣖ✣ ѱ傴ᓝἻࣖ✣
SEAT HEAT_PASS SEAT HEAT_DRV
40 39 38 37 29 28 IP2FL_2 B25 B23 67

FL2IP_2
1262DB_RD/YE_2.0_ESSS
1262DA_RD/YE_2.0_ESSS
1263DB_RD_2.0_ESSS
1263DA_RD_2.0_ESSS
1542D_RD_2.0_TRAILER
FL31_B FL70
6 5 2 1 13 1 1 1 1
DCDC1-2 DCDC1-1 DCDC2-2 DCDC1-1 BATT BATT BATT BATT BATT
どু⴪⍷⁗ඍ ᤌ䖜᧝࡬ঋ‫ݹ‬ ࢥ傴ᓝἻࣖ✣ ѱ傴ᓝἻࣖ✣ ࢥ傴ᓝἻ䈹㢸⭫ᵰ

DCDC TRAILER SEAT HEAT_PASS SEAT HEAT_DRV SEAT ADJ_PASS
17SK8102A08
49-20
Circuit Diagram
B+ ਇࣞᵰ㡧сؓ䲟ѓⴈ
UEC
U-JF9 U-JF5 U-JF6

FRT BLOWER IEC PWR2(ACC) IEC PWR3
40A 30A 30A
9 5 6
70 43 41 IEC
I-R1 I-R2 I-FS36 I-FS35

I-JF1
啉伄ᵰ㔝⭫ಞ 䱺Ԭ⭫Ⓠ㔝⭫ಞ RESERVED RESERVED
SPARED
BLOWER ACC RELAY 30A 30A
72 42
32 31 30 29 25 63
I-FS20 I-FS19 I-FS18 I-FS17 I-FS13

I-JF2
GATEWAY/ CIGAR INVERTER/ 12V OUTLET&BLOWER T-BOX/
SEAT ADJ_DRV
RADIO LIGHTER MIR_AD/TRAILER RELAY COIL 10 SCREEN
25A
7.5A 7.5A 7.5A 15A 10A
40 39 38 37 33 66
4540_RD/WH_0.5_10-SCREEN/TBOX
7572_RD_4.0_ALL
1375A_GY_0.5_RADIO/GTWY/PTANT
1001_D-GN_0.75_CIGAR
1140C_RD/WH_0.5_ALL
1042A_RD/BK_0.756_ALL
1865_BN_1.5_PST
4540B_RD/WH_0.5_TBOX
4540A_RD/WH_0.5_10-SCREEN
IP60 IP57
1 20 5 1
MOTOR+ BATT BATT BATT
ᆆ㌱㔕⽰ᝅഴ
ࢃ啉伄ᵰ SUBSYSTEM SCHEMATICS 䖜㚊㖇᧝࡬ঋ‫ݹ‬ 10ሮኅ ѱ傴ᓝἻ䈹㢸⭫ᵰ
FRT BLOWER MOT TBOX 10 SCREEN SEAT ADJ_DRV
17SK8102A09
49-21
Circuit Diagram
UEC
U-FS2
U-FS3
RR DEFROST&
IEC PWR6(HORN/ACPANEL/AFS/IPK/IMMO)
MIRROR
30A
25A
15 24
51 49 50 IEC
I-FS26 I-FS24 I-FS25

AC PANLEL/AFS/LDW/RLS IPK/IMMO HORN
10A 10A 20A
57 55 56
7133A_BN_0.5_ALL
5040_RD/WH_0.5_ALL
96 100 48 47 46
I-R5 I-FS23 I-FS22 I-FS21

஽ਣ㔝⭫ಞ MP5/RADIO TCU OBD/TPMS RF/ESSS
HORN 25A 10A 7.5A
99 54 53 52
482_L-GN_0.5_RL5
7133B_BN_0.5_ALL
7133_BN_0.5_XELP
7133AA_BN_0.5_LDW
5040A_RD/WH_0.5_-PEPS
5040B_RD/WH_0.5_ALL
1329_D-GN_1.0_ALL
1364_RD/WH_2.5_RADIO
4840AA_RD/OR_0.5_AT&2.8L&4G69
4740BB_RD/WH_0.5_TPMS
4740_RD/WH_0.5_ALL
4740AA_RD/WH_0.5_PEPS
IP38_A RF10 IP02 IP56_A GB02 IP28

10 12 2 7 17 16
BATT BATT BATT BATT BATT BATT
ࢃグ䈹᧝࡬䶘ᶵ 䖜䚉‫⿱څ‬䖻ࣟ᧝࡬ Ԡ㺞 ᭬丩ᵰ 㠠ࣞ਎䙕ಞ᧝࡬ঋ‫ݹ‬ 䈀ᯣ᧛ਙ

FRT A/C CONT PNL LDW CLUSTER RADIO TCU OBD
RF08 IP11 IP16 IP55_B FL30 RF11

1 14 1 1 15 4 1
PWR BATT PWR BATT BATT BATT BATT
䴞䠅䱩‫ݿ‬Ֆ᝕ಞ 㠠䘸ᓊࢃཝ⚥ 䱨ⴍ᧝࡬⁗ඍ ᐜ਩‫ם‬஽ਣ ၧ҆㌱㔕ѱᵰ 㜄ুⴇ⎁ ᧛᭬ಞ

RAIN LIGHT SEN AFS ECU IMMO HORN-R&L MPS TPMS FR
17SK8102A10
49-22
Circuit Diagram
UEC
U-FS2
U-JF4
RR DEFROST&
UEC PWR1(IG/200V)
MIRROR
30A
25A
4 14
26 69 B29 B34 IEC
I-R10
I-FS14 I-R3
੄㿼䮒ૂ੄ネ
INVERTER ⛯⚡㔝⭫ಞ
ࣖ✣㔝⭫ಞ
25A IG RELAY
HRW&MIRROR
34 68 B33
4640_RD/WH_1.5_INV
1 6 5 4 3 2 75 82
I-FS5 I-FS2 I-FS27

I-FS1 I-FS6 I-FS4 I-FS3 I-FS34
TPMS/ISRVM/ IPK&BCM& TCCU/FRT
ECU TCU/SHIFT ABS/ESP SRS MIRROR
GATEWAY/ESSS PEPS&BSD CLUTCH
7.5A 10A 7.5A 10A 7.5A
10A 10A 10A
IP2FL_1
A3 FL2IP_1 13 18 17 16 15 14 83 90
1640_RD/WH_0.35_SPHCM/SPHM
4640A_RD/WH_1.5_INV
1040_RD/WH_0.5_ALL
842_RD/WH_0.5_ALL
840_RD/WH_0.5_ALL
2086_BN/WH_0.5_ESP
140_RD_0.5_ALL
5240_RD/YW_0.5_ALL
1296B_L-BU_1.0_4WD/EFAC
4440BA_RD/WH_1.5_RRDEFROST
1640A_RD/WH_0.35_SPHCM/SPHM
1640B_RD/WH_0.35_SPHCM/SPHM
FL60 FL62_A DD03 PD03

2 1 4 4
PWR BATT BATT BATT
ᆆ㌱㔕⽰ᝅഴ
220V䘼਎ಞ SUBSYSTEM SCHEMATICS ੄䲚䵒傴催઎‫੄ם‬㿼䮒 ࢥ傴‫੄ם‬㿼䮒
220V INVERTER REAR WIN HEATER MIRROR_DD MIRROR_PD
17SK8102A11
49-23
Circuit Diagram
UEC
U-JF5
U-JF11 U-JF12
ICE PWR2
ᐜ‫ࣞ⭫ם‬䖜ネ㔝⭫ಞ IEC PWR9(BCM_KL30_2/GATEWAY)
(ACC)
PWR_WIN_L 30A
30A
5 11 12
103 110 103 108 12 81 IEC
I-R7 I-R6
਩‫ࣞ⭫ם‬䖜ネ㔝⭫ಞ ᐜ‫ࣞ⭫ם‬䖜ネ㔝⭫ಞ
PWR_WIN_R PWR_WIN_L
104 109 101
80 78 79 77
I-FS32 I-FS30 I-FS31 I-FS29 I-FS12 I-FS33

PWR WIN_RR PWR WIN_PD PWR WIN_RL PWR WIN_DD BCM_EXT LP GATEWAY
25A 25A 25A 25A 25A 15A
88 86 87 85 24 89
249_WH_0.5_ALL
4042DB_D-BU_1.5_RREGL
4042DA_RD/WH_1.5_ALL
4042CB_L-GN_1.5_RREGL
4040C_RD/WH_1.5
1440_RD/WH_1.5_ALL
998_BN_0.75
4040CA_RD/WH_1.5_1SHOT
4040CB_RD/WH_1.5_ANTIPIN
998A_BN_0.75_GTWY
998B_BN_0.75_GTWY
RR04 RL04 DD08 FL02_B FL02_B

5 5 4 12 19
BATT BATT BATT BATT BATT
ѱ傴ж䭤ॽ䲃⭫ᵰ
਩੄䰞⧱⪹ॽ䲃ᔶީ ᐜ੄䰞⧱⪹ॽ䲃ᔶީ 㖇ީ
SMART WIN
STD WINS SW_RR STD WINS SW_RL GATEWAY
MOT_DD
IP01_B PD06 DD06 IP01_C

1 5 4 3
RELAY BATT BATT BATT
䖜䓡᧝࡬ঋ‫ݹ‬ ࢥ傴⧱⪹ॽ䲃ᔶީ ѱ傴⧱⪹ॽ䲃ᔶީ 䖜䓡᧝࡬ঋ‫ݹ‬

BCM STD WINS SW_PD STD WINS SW_DD BCM
17SK8102A12
49-24
Circuit Diagram
UEC
I-FS16 I-FS10
IEC PWR8(BCM_FUEL FLAP/ IEC PWR7(BCM FOLD/
FRT WASH) CDL/INT LP)
20A 30A
28 22
11 10 9 8 7 IEC
I-FS11 I-FS10 I-FS9 I-FS8 I-FS7 I-FS28

BCM_FRT WASH BCM_FUEL FLAP BCM_INT LP BCM_CDL BCM_REAR FOLD FRT BLWOER FB
10A 10A 7.5A 25A 7.5A 10A
23 22 21 20 19 84 76
1342_RD/BK_0.5_ALL
1340_RD/WH_0.5_ALL
1242_RD/BU_0.35_ALL
1240_RD/WH_1.5_ALL
1202_RD/WH_0.35_SPHCM
761C_OG_0.5_ALL
761_OG_4.0_ALL
IP01_C IP01_E IP01_B IP32

17 15 1 14 8 12 D
PWR PWR PWR PWR PWR BATT BATT
䖜䓡᧝࡬ঋ‫ݹ‬ ࢃグ䈹᧝࡬䶘ᶵ 䈹䙕⁗ඍ

BCM FRT A/C CONT PNL A/C RESISTANCE
17SK8102A13
49-25
Circuit Diagram
Engine Management System
UEC
U-R5 FUEL FILTER U-R9 A/C
85 30
U-JF1 U-FS/7 U-FS/8 U-R3 FAN LOW U-PR2 FAN MID U-PR1 FAN H1 HEATER/FUEL PUMP COMPRESSOR
U-R8
MAIN RELAY PWR1 PWR2 ք䙕伄᡽㔝⭫ಞ ѣ䙕伄᡽㔝⭫ಞ ઀䇿䙕伄᡽㔝⭫ಞ ⟹⋯䗽┚ࣖ✣෡ૂ⋯⌫㔝⭫ಞ グ䈹ু㕟ᵰ㔝⭫ಞ
MAIN RLY
ѱ㔝⭫ಞ ѱ㔝⭫ ѱ㔝⭫ 86 86 86 86 87 86
ѱ㔝⭫ಞ
30A 86 87
ಞ⭫Ⓠ1 ಞ⭫Ⓠ2
154 157 60 59 129 111 115 139 142 69

I-R3 IG RELAY EB01
⛯⚡㔝⭫ಞ
87
5991_YE_0.5
5290_PK/BK_0.5
5291_PK/BK_2.5
5292_PK/BK_2.5
5267_WH/BK_0.75_2.8FGT/VGT
5128_PD_0.75_2.8FGT/VGT
2368_WH_0.75_2.8FGT/VGT
7071A_D-BU_0.75_2.8FGT/VGT
7071_D-BU_0.75_2.8FGT/VGT
459_D-GN/WH_0.5
I-FS1 EB60
ECU B
ؓ䲟ѓ ⟹⋯┚␻
7.5A ࣖ✣ಞ
FUEL
13 FILTER
IP07
HEATER
1040_RD/WH_0.5
A
SP016 EB60
5292A_PK/BK_2.5
5292B_PK/BK_2.5
1050FH_BK_2.5
2 IP2EB
EB2IP
1040A_RD/WH_0.5
G_EBL2_3
EB02_K
46 47 1 3 5 68 93 92 69 72
O_ST_MRLY VBAT_A VBAT_B VBAT_C O_S_FAN3 O_S_FAN2 O_S_FAN1 O_S_FHRLY O_S_ACRLY
ਇࣞᵰ᧝࡬⁗ඍ
ECM
G_BAT_1 G_BAT_2 G_BAT_3
2 4 6
EB02_K
450A_BK_2.5
450B_BK_2.5
450C_BK_2.5
EB_450_BK_2.5
G_EBR3
17SK8103A01
49-26
Circuit Diagram
B+
U-R8
MAIN RLY
ѱ㔝⭫ಞ
87
U-JF/0 U-FS/9
GCU/FUEL PUMP MAIN RLY PWR3
ࣖ✣᧝࡬⟹⋯⌫ ѱ㔝⭫ಞ⭫Ⓠ3
60A 15A
10 58
EB01
SP015
5540B_BN_6.0_2.8FGT
5293H_PK/BK_0.75_2.8FGT
5540A_BN_6.0_2.8FGT
5293_PK/BK_0.75_2.8FGT
5293M_PK/BK_0.75_2.8FGT
5293N_PK/BK_0.75
15 EB2CH
CH2EB
EB52 EB54
CH5293NA_PK/BK_0.75
3 1 11 7
PWR MAIN RLY PWR MAIN RLY
人✣ດ
人✣ດ᧝࡬ঋ‫⅝ݹ‬ӊ
᧝࡬ঋ‫⅝ݹ‬഑
GCU_EU5
GCU_EU4
CONTROL
SIG GP GP4 GP3 GP2 GP1 SIG D_SIG GND
2 5 1 2 3 4 9 10 6
EB52 SP101 EB54
505A_YEL_0.75_2.8FGT
506_BK/RD_6.0_2.8FGT
CH14
3
506DL_BU_2.5
1584_YE/BK_2.5
506C_BK/RD_2.5
1583_BK/RD_2.5
506B_BK/RD_2.5
1582_PU/WH_2.5
506A_BK/RD_2.5
1581_PU_2.5
505_OG_0.75_2.8VGT
5614_BN_0.75_2.8VGT
1050GC_BK_2.5_2.8VGT
12V
⟹⋯੡≪Ֆ᝕ಞ
WIF SEN
SIG GND
2 1
36 29 22 15 CH14
CH6861A_D-BU/YE_0.75
CH1050WFA_BK_0.75
G_EBL2_2
人✣ດ4 人✣ດ3 人✣ດ2 人✣ດ1
GLOW PLOG4 GLOW PLOG3 GLOW PLOG2 GLOW PLOG1
EB53
4 CH2EB
HEATER+ 27 22 EB2CH
EB6861_D-BU/YE_0.75
EB1050WF_BK_0.75
≝Ֆ᝕ಞ
LAMBDA SEN
RE+ IPN R APE HEATER-
6 2 5 1 3
EB52
6427_PU_0.5_2.8VGT
6426_OG_0.5_2.8VGT
6425_GY_0.5_2.8VGT
5279_WH_0.5_2.8VGT
6424D_BU_0.5_2.8VGT
G_EBR2_1
EB02_K
45 42 57 61 83 84 62 7 77
O_S_GLW O_T_GLW I_S_GLW LSVN LSVG LSCA LSCP LSH I_S_WFLS
BCM
17SK8103A02
49-27
Circuit Diagram
ECM
I_A_CTS G_R_CTS I_S_ACC SW I_S_ACC MED O_V_HFM I_T_AMS I_A_IATS I_S_T500 I_S_PN I_S_OPS G_R_FTS I_A_FTS
37 50 11 73 37 75 23 20 63 35 74 89 55 48 14
EN02_A EB02_K
6744A_YE/GY_0.5
6745A_D-BU/YE_0.5
331_BN_0.5_2.8FGT/VGT
203_L-BU_0.75_MT&HTOL
204_D-BU_0.75_MT&HTOL
1
4387_BN_0.5_2.8FGT/VGT
492_OG_0.5_2.8FGT/VGT
2931_GY/BK_0.5_2.8FGT/VGT
7337_YE/BK_0.5_2.8FGT/VGT
43B_YE_0.5_2.8FGT&VGT
275A_L-GN_0.5_2.8VGT&AT
ਇࣞᵰ߭প⏨
⑟ᓜՖ᝕ಞ
COOLANT
1579_WH_0.5_2.8FGT/VGT
1578_YE_0.5_2.8FGT/VGT.5_ALL
TEMP
2 EB2IP_2
47 48 IP2EB_2
6744_YE/GY_0.5_ALL
6745_D-BU/YE_0.5_ALL
EB12 28 EB2EN
EN2EB
4 3
331_BN_0.5_2.8FGT/VGT
LO
MID
1 EB2FL
EB14 FL2EB
2 1 3 4
275B_L-GN_0.5
EB2IP_2
46
IP2EB_2
IP05 1 2
43_YE_0.5_ALL
8 7 EB12
グ䈹ু࣑ᔶީ 5 FL2GB EB62
A/C PRESSURE SW GB2FL 8 7
㔅⎄⁗ᕅ
275_L-GN_0.5
SP
1
603G_D-GN_0.75
࣑ࣞ⁗ᕅ
IP01_B GB02
47 3
ACC WAKE UP PIN_SIG
IP38_B
11 䖜䓡᧝࡬⁗ඍ ਎䙕ಞ᧝࡬⁗ඍ
ѣཤ᧝࡬㓺ᔶީ AC
CONSOLE SW_L BCM TCU
ࢃグ䈹᧝࡬䶘ᶵ ⟹⋯⑟ᓜՖ᝕ಞ
FRT A/C CONT PNL FUEL TEM SEN
ᵰ⋯ু࣑ᔶީ
OIL PRESSURE
17SK8103A03
49-28
Circuit Diagram
49-29
EB02_K
17SK8103A04
EB62
FUEL TEMP SEN

⟹⋯⑟ᓜՖ᝕ಞ
1578_YE_0.5_2.8FGT/VGT
14
to
1
1579_WH_0.5_2.8FGT/VGT
48
2
EB25
1164_WH/BK_0.5_2.8FGT/VGT
58 60 22 67 81 28
ACC ELERATOR PEDAL

6
1161_D-BU_0.5_2.8FGT/VGT
5
1162_L-BU_0.75_2.8FGT/VGT
ࣖ䙕䑅ᶵ
4
1274_TN_0.5_2.8FGT/VGT
1
1171_TN_0.5_2.8FGT/VGT
2
1172_YE_0.5_2.8FGT/VGT
3
FB55
ু࣑Ֆ᝕ಞ-HGC
736_D-BU_0.5_2.8VGT/&HGC
仍㋈⢟ᦋ᥿
80 59 27
PF PSEN
P
432_L-GN_0.5_2.8VGT&HGC
U
2704_GY_0.5_2.8VGT&HGC
2
10 EB2FL
FL2EB
FL55
ু࣑Ֆ᝕ಞ-LGC
736A_D-BU_0.5_2.8VGT/&LGC 736B_D-BU_0.5_2.8VGT/&LGC
仍㋈⢟ᦋ᥿
DPF PSEN
1
P
432A_L-GN_0.5_2.8VGT&LGC 432B_L-GN_0.5_2.8VGT&LGC
8
U
270A_GY_0.5_2.8VGT&LGC 270B_GY_0.5_2.8VGT&LGC
2
EB57
EXHAUST
ᓕ≊⑟ᓜ
Ֆ᝕ಞ1
T-SEN1
34
to
1
ECM
U
18
2
18 FL2GB
GB2FL
3 EB2FL
FL2EB
CB08
EXHAUST
7583_D-BU_0.5 7583B_D-BU_0.5_2.8VGT/4G69 7583A_D-BU_0.5_2.8VGT
ᓕ≊⑟ᓜ
Ֆ᝕ಞ2
T-SEN2
13
to
1
U
5378_L-GN_0.5 5378B_L-GN_0.5_2.8VGT/4G69 5378A_L-GN_0.5_2.8VGT
33
19
4
2
EB2IP_2
43 IP2EB_2
SW01
6310_TN_0.5 6310B_TN_0.5 6310A_TN_0.5_RCSW
8
CROISE SW
SPRING
CLOCK
ᐗ㡠ᔶީ
ᕯ㉝㓵
1.2K
1.3K
5.1K
11K
1K
ਇࣞᵰ㡧ⴌᔶީ
HOOD ADJSW
EB70
6309_PK_0.5 6309B_PK_0.5 6309A_PK_0.5_RCSW
30
44
4
5530B_D-BU_0.5_PEPS&2.8FGT/VGT
2
36 94
グ䈹ু࣑ EGR߭প⏨с⑮
EGR COOLER
⑟ᓜՖ᝕ಞ
DS T-SEN
1
to
U
2
85
EB13
2700_GY_0.5_2.8FGT/VGT&8AT-HTO
PRESSURE
17 32 26
Ֆ᝕ಞ
380_OG/BK_0.5_2.8FGT/VGT&8AT-HTO
A/C
2
U
214_D-BU_0.5_2.8FGT/VGT&8AT-HTO
1
1 EB2CH
CH2EB
CH07
FUEL LEVEL
30A_PU_0.5_2.8FGT/VGT 30_PU_0.5_2.8FGT/VGT
⟹⋯⏨փ
Ֆ᝕ಞ
9
2
6281A_BN/WH_0.5_2.8FGT/VGT 6281_BN/WH_0.5_2.8FGT/VGT
39
1
Circuit Diagram
ਇࣞᵰ㖟сؓ䲟ѓⴈ
UEC
ѱ㔝⭫ಞ
U_R8 MAIN RLY
87
ѱ㔝⭫ಞ⭫Ⓠ3
U_FS19
MAIN PWR3 䎭ࣞѱ㔝⭫ಞ
15A U_R4 STARTER
58 134 135
EB01
5293_PK/BK_0.75
350_BK_1.5
5293P_PK/BK_0.75
SP104
5293Y_PK/BK_0.75
SP105
350_BK_1.5
5293P_PK/BK_0.75
G_EBR2_1
35 30 34 24 25 EB2EN
EN2EB
໔ুু࣑ᢝ㺂ಞ EGR߭প
௭⋯ಞ2㕮 ௭⋯ಞ3㕮 ௭⋯ಞ4㕮 ௭⋯ಞ1㕮儎ু⋯⌫ ⅝഑ BOOST ᯷䙐䰶 EGRփ㖤Ֆ᝕ಞ਀ᢝ㺂ಞ
CYL2 CYL3 CYL4 CYL1 HP PUMP EGR P_ACTU EGR-BY PASS EGR
O_T PWR GND
2 1 2 1 2 1 2 1 2 1 2 1 4 1 2 2 1 5 4 3 2 1
EN02_A
31 2 46 1 33 17 47 16 60 29 59 19 4 41 39 10 5 3
IGJECTOR2 IGJECTOR3 IGJECTOR4 IGJECTOR1 O_T_MEU O_T_BPA O_T_EGRCBP - + - SIG + L H
ECM
17SK8103A05
49-30
Circuit Diagram
ECM
- + - + - SIG 5V GND SIG PWR - + - SIG 5V T - P 5V 5V SIG -
27 51 49 34 26 38 12 55 36 9 50 37 40 52 6 53 28 54 7 8 57 35 13 14
EN02_A
EN2EB EN2EB
16 17 EB2EN 31 32 33 EB2EN
6120_YE/BK_0.5
6119_GY_0.5
6110_WH_0.5_MT&2.8
6111_YE_0.5_MT&2.8
6109_TN_0.5_MT&2.8
EB59 EB13
1 2 5 4 3 2 1 1 2 3 2 1 1 2 3 2 1 4 3 3 2 1 2 1
U U U U U
P P P&to N N
⧥ູ⑟ᓜՖ᝕ಞ 㢸≊䰞 ⿱ਾಞᔶީ ߭প⏨⑟ᓜ 䖪⋯䖞ু࣑Ֆ᝕ಞ ໔ুু࣑Ֆ᝕ಞ ࠮䖤䖪Ֆ᝕ಞ ᴨ䖪փ㖤Ֆ᝕ಞ

AMBIENT TEMP THROTTLE BODY CLUSTCH SW COOLANT TEP RAIL BOOST SEGMENT INCREMENT
PRESSURE PRESSURE-SEN SOEED SEN SPEED SEN
17SK8103A06
49-31
17SK8104A01
EB01_A
EB2EN_G
EN2EB_G
58
EB03
MAIN POWER RELAY

5991G_YE/WH_0.5_4G69 5991G_YE/WH_0.5_4G69
EMS
MAIN RLY PWR
31
44
U-FS19
20 EB2EN_G
EN2EB_G
15A
EB03
5290C_PK/BK_2.5_ALL
31
SPEED FAN
2368G_HW_0.75_4G69&480W 2368GA_HW_0.75_4G69&480W
MAIN RLY
HISH
17
ѱ㔝⭫ಞ
U-R8
SPEED FAN
5128G_PU_0.75_4G69&480W 5128GA_PU_0.75_4G69&480W
MIDDLE
EMS
ਇࣞᵰ㡧с
21
16
5290_PK/BK_2.5_ALL
ؓ䲟ѓⴈ
157
EB02_K
LOW SPEED FAN/

UEC
PWM FAN
5267G_WH/BK_0.75_4G69&480W 5267GA_WH/BK_0.75_4G69
K47 O_S_MRLY
22
65
5991_YE_0.5_2.8FGT/2.8VGT
EMS
154
47
儎䙕伄᡽
5148B_WH_2.5_ALL
155
FAN HI
U-PR1
㔝⭫ಞ
EB02_K
EB01
EB01
O_S_FAN1
5293A_PK/BK_0.75_480W 2368_HW_0.75_2.8FGTI/2.8VGT
SP032
117
115
5148A_WH_2.5_ALL
UEC
92
K92
153
O_S_FAN2
342C_RD/BK_6.0_480W 5128_PU_0.75_2.8FGTI/2.8VGT
EMS
112
114
93
K93
MAIN RELAY
O_S_FAN3
FAN MID
ѣ䙕伄᡽
5267_WH/BK_0.75_2.8FGTI/2.8VGT
68
K68
U-JF1
U-PR2
㔝⭫ಞ
30A
SP014
5148_WH_2.5_ALL
1
5293B_PK/BK_0.75_480W
113
111
SP006
G_EBL_2-1
342A_RD/BK_6.0_480W 342B_RD/BK_6.0_480W
116
110
FAN LOW
ք䙕伄᡽
1250_BK_6.0_480W
U-PR3
㔝⭫ಞ
COOLING FAN(480W)
DCDC2/COOLING
1
Cooling Fan System
Circuit Diagram
409_L-BN_6.0_480W
߭প伄᡽
FAN(480W)
4
5293C_PK/BK_0.75_480W
130
129
532_BRNN_0.5_480W
U-JF2
SP005
3
40A
342_RD/BK_6.0_480W 342D_RD/BK_6.0_480W 5538_OG_5.0_480W
128
132
B+
2
2
49-32
Circuit Diagram
Cooling Fan System
B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ
UEC
ਇࣞᵰ㡧᧝࡬ঋ‫ݹ‬ ਇࣞᵰ᧝࡬ঋ‫ݹ‬
U-MD1 EMS(4G69) EMS(NLE2.0T)
COOLING FAN 600W LOW SPEED K26
80A(LE:65A) FAN/PWM FAN O_T_FAN
65 26
1 EN03 EB02_K1
EB01_A
2364GA_D-BU_0.75_4G69
2364N_D-BU_0.5_NLE2.0T&600W
342W_RD_8.0_4G69&600W
342N_RD_10.0_NLE2.0T&600W
EN2EB_G
1250A_BK_8.0_4G69&600W
1250N_BK_10.0_NLE2.0T&600W
22 EB2EN_G
2364_D-BU_0.5_4G69&600W
1 4 2
߭প伄᡽
COOLING FAN(600W)
G_EBL2_1
17SK8104A02
49-33
CH2FL_N
5 FL2CH_N
FL2EB_N
B11 EB2FL_N
17SK8105A01
7128NB_GY/BK_0.5_ESP&NLE 2.0T 7128NA_GY/BK_0.5_ESP&NLE 2.0T 7128N_GY/BK_0.5_ESP&NLE 2.0T
865NB_L-GN_0.5_ESP&NLE 2.0T 865NA_L-GN_0.5_ESP&NLE 2.0T 865N_L-GN_0.5_ESP&NLE 2.0T
A11
4
CH04
EB04
WSP_RR
7128A_GY/BK_0.5_ESP&(2.8FGT/2.8VGT/4G69) 7128_GY/BK_0.5_ESP&(2.8FGT/2.8VGT/4G69)
਩੄䖤䙕Ֆ᝕ಞ
17
12
2
WSS_RR
WSS_RR
865A_PU_0.5_ESP&(2.8FGT/2.8VGT/4G69) 865_PU_0.5_ESP&(2.8FGT/2.8VGT/4G69)
29
10 EB2CH 11
1
CH2EB
CH03
WSP_RL
7127A_GY/BK_0.5_ESP&(2.8FGT/2.8VGT/4G69) 7127_GY/BK_0.5_ESP&(2.8FGT/2.8VGT/4G69)
ᐜ੄䖤䙕Ֆ᝕ಞ
31
2
WSS_RL
WSS_RL
866A_L-GN_0.5_ESP&(2.8FGT/2.8VGT/4G69) 866_L-GN_0.5_ESP&(2.8FGT/2.8VGT/4G69)
18
1
9
7127NB_GY/BK_0.5_ESP&NLE 2.0T 7127NA_GY/BK_0.5_ESP&NLE 2.0T 7127N_GY/BK_0.5_ESP&NLE 2.0T
A10
3
࡬ࣞ䱨ᣧ↱㌱㔕䖜䓡⭫ᆆどᇐ㌱㔕᧝࡬ঋ‫ݹ‬
866NB_L-GN_0.5_ESP&NLE 2.0T 866NA_L-GN_0.5_ESP&NLE 2.0T 866N_L-GN_0.5_ESP&NLE 2.0T
EB2FL_N A9
FL2CH_N 2
CH2FL_N
FL2EB_N
EB16
WSP_FR
7065_GY/WH_0.5_ESP&(2.8FGT/2.8VGT/4G69)
16
2
ABS/ESP
PWR
WSS_FR
SIG
872_D-GN_0.5_ESP&(2.8FGT/2.8VGT/4G69)
਩ࢃ䖤䙕Ֆ᝕ಞ
4
17 BT2EB_N
EB2BT_N
WSS_FR
BT08
7065NA_GY/WH_0.5_ESP&NLE 2.0T 7065N_GY/WH_0.5_ESP&NLE 2.0T
2
PWR
SIG
872NA_D-GN_0.5_ESP&NLE 2.0T 872N_D-GN_0.5_ESP&NLE 2.0T
16
EB15
WSP_FL
7064_GY/WH_0.5_ESP
ᐜࢃ䖤䙕Ֆ᝕ಞ
19
2
WSS_FL
PWR
Brake Control System
SIG
WSS_FL
830_D-BU/WH_0.5_ESP
Circuit Diagram
8
IP15
FUNCTION
6258A_L-GN/BK_0.5_ESP 6258_L-GN/BK_0.5_ESP
GND
26
32
3
ࣖ䙕ᓜՖ᝕ಞ
G SEN
1809A_D-BU_0.5_ESP 1809_D-BU_0.5_ESP
VOUT
VOUT
24
24
2
ᰖ䫛ॏ㌱㔕᧝࡬ঋ‫ݹ‬
IP09_A
6257A_L-GN_0.5_ESP 6257_L-GN_0.5_ESP
VCC
VCC
22
1
5
PEPS ECU
V-SPEED
1827A_YE/BK_0.5_ESP&PEPS 1827_YE/BK_0.5_ESP&PEPS
VSO
16
IP2EB_1 14
10
49-34
EB2IP_1
Circuit Diagram
49-35
17SK8105A02
57 IP2EB_1
EB2IP_1
EB04
IP06
HDC_OFF_SW 6844_D-BU/WH_0.5_ESP 6844B_D-BU/WH_0.5_ESP
HID_
11
SW
9
ESPOFF_SW 6727_D-BU_0.5_ESP 6727B_D-BU_0.5_ESP
ESP_
OFF
10
56
12
AFS OFF_SW
IP01_C
ѣཤ᧝࡬㓺ਾᔶީ਩
䖜䓡᧝࡬ঋ‫ݹ‬
CONSOLE_SW-R
750CS_BK_0.5_XELP/ESP
SP914
DIMMER ILL
6
BCM
G_IP5_1
5
750CT_BK_0.5_XELP/ESP 750_BK_0.5_ALL
LED-
55 IP2EB_1
EB2IP_1
2
LED+ 1382N_PU/WH_0.5_ALL
ABS/ESP Ԡ㺞ᶵؓ䲟ѓⴈ
HDC LED
6844A_L-GN_0.5_ESP 6844C_L-GN_0.5_ESP
HID_
34
LP
8
ESP LED
6727A_D-GN/WH_0.5_ESP 6727C_D-GN/WH_0.5_ESP
PALA
54
23
7
IEC
AFS LED
IG
2086D_BN/WH_0.5_ESP
12
SP029
IP07
IP07
I-FS4
7.5A
࡬ࣞ䱨ᣧ↱㌱㔕䖜䓡⭫ᆆどᇐ㌱㔕᧝࡬ঋ‫ݹ‬
2086_BN/WH_0.5_ESP 2086C_BN/WH_0.5_ESP 1687_GY/BK_0.5_ESP
PWR_
31
28
IGN
4
4
IG RELAY
ᯯੇⴎ䖢䀈Ֆ᝕ಞ
I-R3
SP902
SP901
SP008
ANGLE SEN
IP14
IP14
STEERING
G_IP1_1
ABS/ESP
202J_RD/YE_2.5_ALL 2086B_BN/WH_0.5_ESP 2088B_BK_0.5_ESP 850A_BK_0.75_ALL 850_BK_1.5_ALL
KL15
GND
2
1
68
69
SP091
G_EBL3_1 G_EBL3_2
850BC_BK_0.5_ALL
58
60
250B_BK_1.5_ESP
GND_
ECU
38
G_IP1_1
IP01_B
850_BK_1.5_ALL
KL15 RELAY IG1
5199_YW_0.5_ALL
BCM
48
250A_BK_4.0_ESP
MOTOR
GND_
13
IEC PWR1
U-JF4
EB01
ᚈ᩼䀈䙕ᓜՖ᝕ಞ
30A
YAW RATE SEN
SP913
SP914
IP13
IP13
202A_RD/YE_2.5_ALL 202E_RD/YE_2.5_ALL
G_IP5_1
4
1
UEC
2086A_BN/WH_0.5_ESP 2088A_BK_0.5_ESP 750A_BK_1.0_ALL 750_BK_1.5_ALL
UBAT
GND
4
1
ABS-VALVE
Brake Control System
U-FS5
15A
856_PU_1.5_ESP
VALVE
PWR_
17
25
ABS MOT
U-JF8
40A
173_PK_4.0_ESP
MOTOR
PWR_
B+
1
Circuit Diagram
Exterior Lighting System(LHD)
IP12
1
PWR
䈹‫ݿ‬ᔶީ
DIMMEP SW
OUT GND
2 3
IP12
189E_D-GN_0.5_HALP
5272B_OG/BK_0.5_HALP
850LM_BK_0.5_HALP
B+ EB01
UEC 40 41 42 43 44
U-FS14 U-FS13 U-FS28 U-FS29 U-FS30 U-FS31 U-FS32

HI BEAM LD BEAM HI BEAM_LH HI BEAM_RH LO BEAM_LH LO BEAM_RH ADJ MOTOR
20A &ADJ MOTOR 15A(LE:5.3A) 15A(LE:5.3A) 15A(LE:4.5A) 15A(LE:4.5A) 10A
26 25 49 48 47 46 45
EB01 ਇࣞᵰ㡧 EB01
SP902
10 11 IP2EB_1
311_L-GN/BK_0.75_ALL
711-D-GN/WH_0.75_ALL
312_TN/WH_0.75_ALL
712_YE_0.75_ALL
189_D-GN_0.75_HALP
EB01 ؓ䲟ѓⴈ EB2IP_1
UEC
189A_D-GN_0.5_HALP
5272A_OG/BK_0.5_HALP
850A_BK_0.5_HALP
95 97 92 90
30 85 85 30
U-R15 U-R14
HI BEAM LOBEAM
87 86 86 87
96 99 94 88
EB01 SP301
1969_BN_0.35_ALL
1970_PK/WH_0.35_ALL
SP901
SP302
850_BK_1.5
189C_D-GN_0.75_HALP
5272_OG/BK_0.5_HALD
189B_D-GN_0.5_HALP
527E_D-GN_0.5_HALD
EB2IP_2
49 50 IP2EB_2 G_IPL_1
1969A_BN_0.35_ALL
1970A_PK/WH_0.35_ALL
ᐜ㓺ਾᔶީ EB39 EB40

COMBINE_LP 2 4 9 10 2 4 9 10
LD BEAM
LD BEAM
HI BEAM
HI BEAM
ᐜࢃ㓺ਾཝ⚥
HEADLP_LH
ཝ⚥䈹㢸 ཝ⚥䈹㢸
਩ࢃ㓺ਾཝ⚥
HEADLP_RH
6 12 5 7 1
IP03 1 3 8 1 3 8
EB39 EB40
850LS_BK_0.5_ALL
534_D-GN_0.5_ALL
307_YE_0.5_ALL
103_WH_0.5_ALL
6009D_BN/OG_0.5_ALL
1050LA_BK_0.75_ALL
1050LB_BK_0.75_ALL
1050LE_BK_0.5_ALL
1150LA_BK_0.75_ALL
1150LB_BK_0.75_ALL
1150LE_BK_0.5_ALL
SP910 SP909
SP902 SP513
1050A_BK_1.0_ALL
1150A_BK_1.0_ALL
850_BK_1.5_ALL
850A_BK_0.75_ALL
6009A_GY/WH_0.5_ALL
SP911 G_EBR1_1
1050_BK_3.0_ALL
G_IP1_1
IP01_B IP01_A
18 41 19 32 23 25
MAIN BEAM DIPPED BEAM MAIN MAIN MAIN SW GND_
RELAY RELAY BEAM BEAM OF LIGHT DIMMES
SW FLASH SW
SW
䖜䓡᧝࡬⁗ඍ
BCM
G_EBL2_3
17SK8106L01
49-36
Circuit Diagram
B+
U-FS15 ਇࣞᵰ㡧
DAY TIME LP ؓ䲟ѓⴈ
10A(LE:3AX2)
UEC
27
EB01
EB01
100 102 107 105
30 85 85 30
U-R16 U-R17 ਇࣞᵰ㡧
DAY TIME DAY TIME ؓ䲟ѓⴈ
LP_L LP_R
87 86 86 87
UEC
101 104 109 106

EB01
7538B_L-BU_0.5_DPLP
544_PU_0.35_DRLP
545_D-BU_0.35_DRLP
7539B_D-BU_0.5_DRLP
EB2IP_2
15 14 IP2EB_2
544A_PU_0.35_DRLP
545A_D-BU_0.35_DRLP
EB39 IP01_A EB40

12 16 29 12
PWR_DRL DAY TIME LP_L DAY TIME LP_R PWR_DRL
ᐜࢃ㓺ਾཝ⚥ 䖜䓡᧝࡬ঋ‫ݹ‬ ਩ࢃ㓺ਾཝ⚥

HEAD LP_LH BCM HEAD LP_RH
17SK8106L02
49-37
17SK8106L03
਩੄⢂➝⚥
LICENSE
LR_RR
PR2CH
D CH2PR
6846N_BN_0.75 550LK_BK_0.5 550LM_BK_0.5
1
2
ᐜ੄⢂➝⚥
LICENSE
LR_RL
A CH2PR
PR2CH
6846M_BN_0.75 550LJ_BK_0.5 550LN_BK_0.5
C
1
2
COMBINE_
਩੄㓺ਾ⚥
RR
2609_BN_0.75 550LD_BK_0.5
4
6846J_BN_0.75_PDC
COMBINE_
ᐜ੄㓺ਾ⚥
17 EB2CH 7 FL2CH_N
CH2FL_N
A4 EB2FL_N
FL2EB_N
SP910
SP911
RL
S309
G_EBL2_3
6846BN_BN_0.75_NLE2.0T 6846CN_BN_0.75_NLE2.0T 2509A_BN_0.75 550LC_BK_0.5 1050A_BK_1.0 1050A_BK_3.0_ALL
4
CH2EB
LICENSE
঍䶔਩੄
LP_RR
⢂➝⚥
(ZAF)
6846B_BN_0.75_2.8FGT/2.8VGT/4G69 6846C_BN_0.75_2.8FGT/2.8VGT/4G69
CH2EB
28 EB2CH
SP921
G_EBR1_1
5864BNB_BN_0.75_NLE2.0T
LP_LH
ᐜࢃ㓺
ਾཝ⚥
6846A_BN_0.75_PDC 550LB_BK_0.5_PDC 550PR_BK_0.75_ 1150B_BK_0.75
HEAD
2
SP909
EB39
EB39
1253_BN_0.5 1150LD_BK_0.5 1150LD_BK_1.0_ALL
13
11
LICENSE
঍䶔ᐜ੄
POS/DRL
LP_RL
⢂➝⚥
(ZAF)
CH2EB
36 EB2CH
SP915
6846_BN_0.75_PDC 550LA_BK_0.5_PDC 550PL_BK_0.75_2.8FGT/2.8VGT
2
LP_LH
ᐜࢃ㓺
ਾཝ⚥
HEAD
SP910
550A_BK_0.75
SP911
SP308
EB39
EB39
G_EBL2_3
550GM_BK_2.5_4G69
1254_BN_0.5 1050LD_BK_0.5 1050A_BK_1.0 1050_BK_3.0_ALL
13
11
POS/DRL
ਇࣞᵰ㡧
ؓ䲟ѓⴈ
ਇࣞᵰ㡧
ؓ䲟ѓⴈ
UEC
UEC
Circuit Diagram
IP01_C
SP913
SP914
IP27
DIMMER ILL
POSITION LP
POSITION
G_IP5_1
750HB_BK_0.5 750A_BK_1.0 750_BK_1.5
5
ধ䲟ᣛ䆜⚥ᔶީ
U-R11
4
HAZARD SW
U-FS15
SP425
750HA_BK_0.5
EB01
SP004
EB01
LP
EB01
IP01_A
10A
BCM
1382J_PU/WH_0.5 1382_PU/WH_0.5
EB2IPR_2
11 IP2EBR_2
9_BN_0.5
30
87
3
B+
75
76
27
POSITIONHAZARD
27_BN_0.5_ALL
SW
5
9
45-D-BU_0.35 45A_D-BU_0.35
85
86
49-38
79
15
77
LP
Circuit Diagram
UEC
U-FS11 U-FS8
FRT FOG IEC PWR6
15A(LE:4.5AX2) 30A
23 27
EB01
EB01
80 82 87 85 72 70
30 85 85 30 85 30
U-R10 ਇࣞᵰ㡧
U-R12 U-R13
REAR FOG ؓ䲟ѓⴈ
FRT FOG_L FRT FOG_R
RELAY
87 86 86 87 86 87 UEC
81 84 89 86 74 71 SP304
EB01
122_OG_0.75_ALL
122A_OG_0.75_ALL
122B_OG_0.75_ALL
5061_GY_0.75_FFOG
1317A_D-GN/WH_0.5_FFOG
1317B_D-GN/WH_0.5_FFOG
5062_BN_0.75_FFOG
1977B_YE_0.75_ALL
1977NA_YE_0.75_NEL2.0T
CH2FL_N CH01 CH02

FL2CH_N 11 5 5
EB33 EB34 EB2IP_2
1977NB)OG)0.75_NLE2.0T
1 1 IP2EB_2 27 ᐜ੄㓺ਾ⚥ ਩੄㓺ਾ⚥
COMBINE COMBINE
ᐜࢃ䴴⚥ ਩ࢃ䴴⚥ LP_RL LP_RR
1977_YE_0.5_ALL
FOGLP_ FOGLP_
FL FR
4 4
EB2IP_1 CH01 CH02
IP2EB_1 13 12 A7 EB2FL_N
550LC_BK_0.5_ALL
550LD_BK_0.5_ALL
2 2
EB33 EB34 FL2EB_N
1050LF_BK_0.5_FFOG
1150LF_BK_0.5_FFOG
1317C_D-GN/WH_0.5_FFOG
1317D_D-GN/WH_0.5_FFOG
ᐜ㓺ਾᔶީ
COMBINE SW_LP
REAR FRT
SP915
550GL_BK_2.5_4G69
550PL_BK_0.5_2.8FGT/2.8VGT
SP921
550PR_BK_0.75_ALL
SP910 SP909 8 9
IP03
187_L-BU_0.5_ALL
192_OG_0.5_FFOG
1050A_BK_1.0_ALL
1150A_BK_1.0_ALL
CH2EB
28 EB2CH
CH2EB
1150A_BK_0.75_ALL
36 EB2CH
550GM_BK_0.75_4G69
550A_BK_0.75_ALL
SP911
1050_BK_3.0_ALL
G_EBL2_3 G_EBR1_1 G_EBL2_3 G_EBR1_1

IP01_B IP01_A IP01_B IP01_A IP01_B
15 15 14 37 44
FRT FOG FRT FOG REAR FOG REAR FOG FRT FOG
RELAY_L RELAY_R LP LP SW SW
䈀ᯣ᧛ਙ
OBD CONNECTOR
17SK8106L04
49-39
Circuit Diagram
BCM
LEFT TURN LP RIGHT TURN LP LEFT TURN SW RIGHT TURN SW
24 35 7 34
IP01_B IP01_B IP01_A
14_L-BU_0.5
15_D-BU_0.5
663_D-GN_0.5
664_TN_0.5
SP415 SP416
14A_L-BU_0.5
15A_D-BU_0.5
IP03
14B_L-BU_0.5
15B_D-BU_0.5
11 2
ᐜ㓺ਾᔶީ
COMBINE
SW_LP
51 IP2EB_2 IP2PRD_1 25 IP2EB_2 IP2PAD_1
EB2IP_2 1 PRD2IP_1 EB2IP_2 1 PAD2IP_1
1314A_L-BU/WH_0.5
6
1315A_D-BU/WH_0.5
14C_L-BU
15C_D-BU
IP03
850LS_BK_0.5
6 6
1314B_L-BU/WH_0.5 1315B_L-BU/WH_0.5
SP307 SP306 SP902
傴催‫ם‬ ࢥ傴催‫ם‬
1314N_L-BU/WH_0.5_NLE2.0T
1315N_D-BU/WH_0.5_NLE2.0T
8 FL2CH_N 18 EB2CH ཌ੄㿼䮒 9 FL2CH_N 19 EB2CH
850A_BK_0.75
ཌ੄㿼䮒
CH2FL_N CH2EB MIRROR_DD CH2FL_N CH2EB MIRROR_DD
1314_L-BU/WH_0.5
1314NA_L-BU_0.5_NLE2.0T
618A_L-BU/WH_0.5
1315_D-BU/WH_0.5
1315NA_L-BU_0.5_NLE2.0T
619A_L-BU/WH_0.5
5 5
1550DM_BK_0.35
850DN_BK_0.35
SP901
850_BK_1.5_ALL
EB2FL_N SP907 EB2FL_N
A5 A6 SP905
FL2EB_N FL2EB_N
1550DZ_BK_0.5
850DZ_BK_0.5
6 3 6 3
ᐜࢃ㓺 ᐜ੄㓺 ਩ࢃ㓺 ਩੄㓺
ਾཝ⚥ ਾཝ⚥ ਾཝ⚥ ਾཝ⚥ G_IPL_1
HEAD COMBINE HEAD COMBINE
LP_LH LP_RL LP_RH LP_RL
5 4 6 PAD2IP_2 5 4 13 DRD2IP_2
IP2PAD_2 IP2DRD_2
1050LC_BK_0.5
550LC_BK_0.5
1150LC_BK_0.5
550LD_BK_0.75_ALL
1550_BK_0.5
850Z_BK_0.5
SP915
SP910 SP909
550PL_BK_0.75_2.8FGT/2.8VGT
550GL_BK_2.5_4G69
G_IPL_2
1050A_BK_1.0
G_IPR_2
1150A_BK_1.0
SP921
550PR_BK_0.75
SP910
1050_BK_3.0
CH2EB
28 EB2CH
1150A_BK_0.75
CH2EB
36 EB2CH
550A_BK_0.75
550GM_BK_2.5_4G69
G_EBL2_3
G_EBR1_3
G_EBL2_3
17SK8106L05
49-40
Circuit Diagram
49-41
17SK8106L06
儎փ࡬ࣞ⚥
CHMSL
IP2FL_1
FL2IP_1
IP01_B
G_FLCL_2
LP+
LP-
1320A_L-BU_0.5_CHMSL 1320_L-BU_0.5_CHMSL 2250LC_BK_0.5_CHMSL

CHMSL
A1
25
CH2EB
28 EB2CH
G_EBR1_1
1150A_BK_0.75
SP921
550PR_BK_0.75 550LD_BK_0.75
4
2 IP2FL_2N
FL2IP_2N
9 FL2CH_2
CH2FL_2
SP15500
5219FN_OG/BK_0.5_NLE2.0T 5973BN_OG_0.5_NLE2.0T 5973_OG_0.5_NLE2.0T
COMBINE LP_RR
5219NN_OG/BK_0.5_NLE2.0T
਩੄㓺ਾ⚥
57 IP2EB_2
EB2IP_2
23 EB2CH
CH2EB
SP305
SP418
REVERSE LP
BACK UP
BCM
5219_OG/BK_0.5 5219_OG/BK_0.5_2.8FGT/2.8VGT 5219CA_OG/BK_0.5 5219CB_OG/BK_0.5 5219CD_OG/BK_0.5

36
6
STOP
5222_PU/BK_0.5
1
BACK UP
5219CC_OG/BK_0.5
6
SP303
COMBINE LP_RL
STOP
BRAKE LP
5222C_PU/BK_0.5_2.8FGT/2.8VGT/4G69 5222B_PU/BK_0.5 5222A_PU/BK_0.5 5221_GY/BK_0.5

23
26
20
ᐜ੄㓺ਾ⚥
IP2FL_2N
FL2IP_2N
5222NC_PU/BK_0.5_NLE2.0T 5222NB_PU/BK_0.5_NLE2.0T 5222NA_PU/BK_0.5_NLE2.0T
10
6
EB2CH
CH2EB
550GL_BK_2.5_4G69 550LC_BK_0.5
4
550PL_BK_0.75_2.8FGT/2.8VGT
36
550GM_BK_2.5_4G69
G_EBL2_3
550A_BK_0.75_ALL
Circuit Diagram
UEC
U-FS8 U-FS15
IEC PWR6 AFS MOT
30A 30A
57 18
EB01 SP004
SP310
IP07 Ԡ㺞ᶵؓ䲟ѓⴈ ੄儎ᓜՖ᝕ಞ
7130_L-BU_0.5_XELP
7132C_GY_0.5_XELP
7132B_GY_0.5_XELP
7131_D-GN_0.5_XELP
51 IEC REAR HIGHT SEN
I-FS26 I-FS6 ࢃ儎ᓜՖ᝕ಞ

AC PANEL/AFS/ TCU/SHIFT/ (NLE2.0T)
LDW/RLS AC PANEL/AFS FRT HIGHT SEN
10A 10A (NLE2.0T)
PWR
GND
SIG
PWR SIG GND

15 27 2 3 6 2 3 6
IP07
7524_GY/WH_0.5_XELP
7525_BN/WH_0.5_XELP
7526_PU/WH_0.5_XELP
2165_GY_0.5_XELP
2184_BN_0.5_XELP
2185_PU_0.5_XELP
7133A_BN_0.5
842_RD/WH_0.5
9 10 10 9
PWR SIG SIG PWR
ཝ⚥䈹㢸 ᐜࢃ㓺ਾཝ⚥ ཝ⚥䈹㢸 ਩ࢃ㓺ਾཝ⚥

HEAD LO_LH HEAD LO_RH
SP026 SP031 14 14
7312A_GY_0.5_XELP
CH2EB
7133_BN_0.5_XELP
842C_RD/WH_0.5_XELP
5356_YE_0.5_XELP
5357_YE_0.5_XELP
1550B_BK_1.5
13 14 16 EB2CH
2165A_GY_0.5_XELP
2184A_BN_0.5_XELP
2185A_PU_0.5_XELP
ѣཤ᧝࡬㓺ᔶީ਩
CONSOLE SW_R
AFS AFS G_IPR_1
OFF_SW LED
5 4
IP06
EB2IP_2 EB2IP_2 EB2IP_2
7129_BN_0.5_XELP
7135_TN_0.5_XELP
37 1 IP2EB_2 38 SP922
IP2EB_2 IP2EB_2
EB2IP_1
5356A_YE_0.5_XELP
7312_GY_0.5_XELP
5357A_YE_0.5_XELP
1550AF_BK_0.5_XELP
7 8 9 34 35 36 IP2EB_1
7524A_GY/WH_0.5_XELP
7525A_BN/WH_0.5_XELP
7526A_PU/WH_0.5_XELP
2165B_GY_0.5_XELP
2184B_BN_0.5_XELP
2185B_PU_0.5_XELP
IP11
14 9 1 23 15 4 19 24 21 12 5 26 17 7
PWR AFS OFF SW AFS OFF LED IGN V_V_FSP V_V_FSS V_V_FSG V_V_RSP V_V_RSS V_V_RSG B_D-LIN G_G_GND
㠠䘸ᓊࢃཝ⚥᧝࡬ঋ‫ݹ‬
AFS ECU
17SK8106L07
49-42
Circuit Diagram
49-43
17SK8106L08
FL2IP_2N
5 IP2FL_2N
CH2FL_2
16 FL2CH_2
IP11
V_V_RSG
2185_PU_0.5_NLE2.0T 2185A_PU_0.5_NLE2.0T 2185NB_PU_0.5_NLE2.0T
REAR HIGHT SEN
GND
6
6
੄儎ᓜՖ᝕ಞ
V_V_RSS
SIG 2184_BN_0.5_NLE2.0T 2184A_BN_0.5_NLE2.0T 2184NB_BN_0.5_NLE2.0T
15
24
3
V_V_RSP
PWR 2165_GY_0.5_NLE2.0T 2165A_GY_0.5_NLE2.0T 2165NB_GY_0.5_NLE2.0T
14
12
2
AFS ECU
5 BT2EB_N
EB2BT_N
9 EB2IP_1
IP2EB_1
V_V_FSG
7526N_PU/WH_0.5_XELP&NLE2.0T 7526NA_PU/WH_0.5_XELP&NLE2.0T 7526A_PU/WH_0.5_XELP
GND
19
6
FRT HIGHT SEN
ࢃ儎ᓜՖ᝕ಞ
(NLE2.0T)
(NLE2.0T)
V_V_FSS
7525N_BN/WH_0.5_XELP&NLE2.0T 7525NA_BN/WH_0.5_XELP&NLE2.0T 7525A_BN/WH_0.5_XELP
SIG
4
V_V_FSP
7524N_GY/WH_0.5_XELP&NLE2.0T 7524NA_GY/WH_0.5_XELP&NLE2.0T 7524A_GY/WH_0.5_XELP
PWR
15
2
7
Circuit Diagram
Exterior Lighting System(RHD)
IP12
1
PWR
䈹‫ݿ‬ᔶީ
DIMMEP SW
OUT
2
IP12
189E_D-GN_0.5_HALP
5272B_OG/BK_0.5_HALP
B+ EB01
UEC 40 41 42 43 44
U-MD1
U-FS14 U-FS13 U-FS28 U-FS29 U-FS30 U-FS31 U-FS32
COOLING
HI BEAM LD BEAM HI BEAM_LH HI BEAM_RH LO BEAM_LH LO BEAM_RH ADJ MOTOR
FAN 600W
20A &ADJ MOTOR 15A(LE:5.3A) 15A(LE:5.3A) 15A(LE:4.5A) 15A(LE:4.5A) 10A
80A(LE:65A)
26 25 49 48 47 46 45
EB01 ਇࣞᵰ㡧 EB01
10 11 IP2EB_1
311_L-GN/BK_0.75_ALL
711-D-GN/WH_0.75_ALL
312_TN/WH_0.75_ALL
712_YE_0.75_ALL
189_D-GN_0.75_HALP
EB01 ؓ䲟ѓⴈ EB2IP_1
UEC
189A_D-GN_0.5_HALP
5272A_OG/BK_0.5_HALP
95 97 92 90
30 85 85 30
U-R15 U-R14
HI BEAM LOBEAM
87 86 86 87
96 99 94 91
EB01 SP301
1969_BN_0.35_ALL
1970_PK/WH_0.35_ALL
SP302
189C_D-GN_0.75_HALP
5272_OG/BK_0.5_HALD
189B_D-GN_0.5_HALP
527E_D-GN_0.5_HALD
FB2IP_2
49 50 IP2EB_2
1969A_BN_0.35_ALL
1970A_PK/WH_0.35_ALL
ᐜ㓺ਾᔶީ EB39 EB40

COMBINE_LP 2 4 9 10 2 4 9 10
LD BEAM
LD BEAM
HI BEAM
HI BEAM
ᐜࢃ㓺ਾཝ⚥
HEADLP_LH
ཝ⚥䈹㢸 ཝ⚥䈹㢸
਩ࢃ㓺ਾཝ⚥
HEADLP_RH
6 12 5 7 1
IP03 1 3 8 1 3 8
EB39 EB40
850LS_BK_0.5_ALL
534_D-GN_0.5_ALL
307_YE_0.5_ALL
103_WH_0.5_ALL
6009D_BN/OG_0.5_ALL
1050LA_BK_0.75_ALL
1050LB_BK_0.75_ALL
1050LE_BK_0.5_ALL
1150LA_BK_0.75_ALL
1150LB_BK_0.75_ALL
1150LE_BK_0.5_ALL
SP910 SP909
SP902 SP513
1050A_BK_1.0_ALL
1150A_BK_1.0_ALL
850_BK_1.5_ALL
850A_BK_0.75_ALL
6009A_GY/WH_0.5_ALL
SP911 G_EBR1_1
1050_BK_3.0_ALL
G_IP1_1
IP01_B IP01_A
18 41 19 32 23 25
MAIN BEAM DIPPED BEAM MAIN MAIN MAIN SW GND_
RELAY RELAY BEAM BEAM OF LIGHT DIMMES
SW FLASH SW
SW
䖜䓡᧝࡬⁗ඍ
BCM
G_EBL2_3
17SK8106R01
49-44
Circuit Diagram
B+
U-MD1
COOLING U-FS15 ਇࣞᵰ㡧
FAN 600W DAY TIME LP ؓ䲟ѓⴈ
80A(LE:65A) 10A(LE:3AX2) UEC
27
EB01
EB01
100 102 107 105
30 85 85 30
U-R16 U-R17 ਇࣞᵰ㡧
DAY TIME DAY TIME ؓ䲟ѓⴈ
LP_L LP_R
87 86 86 87
UEC
101 104 109 106

EB01
7538B_L-BU_0.5_DPLP
544_PU_0.35_DRLP
545_D-BU_0.35_DRLP
7539B_D-BU_0.5_DRLP
EB2IP_2
15 14 IP2EB_2
544A_PU_0.35_DRLP
545A_D-BU_0.35_DRLP
EB39 IP01_A EB40

12 16 29 12
PWR_DRL DAY TIME LP_L DAY TIME LP_R PWR_DRL
ᐜࢃ㓺ਾཝ⚥ 䖜䓡᧝࡬ঋ‫ݹ‬ ਩ࢃ㓺ਾཝ⚥

HEAD LP_LH BCM HEAD LP_RH
17SK8106R02
49-45
Circuit Diagram
B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ SP308 5864BNB_BN_0.75_NLE2.0T

UEC
6846B_BN_0.75_2.8FGT/2.8VGT/4G69
A4 EB2FL_N
U-MD1 FL2EB_N
COOLING U-FS15
FAN 600W
6846BN_BN_0.75_NLE2.0T
POSITION LP
80A(LE:65A) 10A
27
EB01
SP004
EB01
1254_BN_0.5
77 75 1253_BN_0.5
85 30
U-R11
POSITION 17 EB2CH 7 FL2CH_N
CH2EB CH2FL_N
LP
6846C_BN_0.75_2.8FGT/2.8VGT/4G69
6846CN_BN_0.75_NLE2.0T
6846J_BN_0.75_PDC
86 87
EB39 EB39
79 76 ਇࣞᵰ㡧 3 3
EB01 ᐜࢃ㓺 ᐜࢃ㓺 A CH2PR
ؓ䲟ѓⴈ
45-D-BU_0.35
9_BN_0.5
ਾཝ⚥ ਾཝ⚥ PR2CH

UEC
POS/DRL
POS/DRL
HEAD HEAD
LP_LH LP_LH
11 11
EB39 EB39
1050LD_BK_0.5
1150LD_BK_0.5
EB2IPR_2
11 IP2EBR_2
ধ䲟ᣛ䆜⚥ᔶީ
HAZARD SW
S309
SP910 SP909
6846_BN_0.75_PDC
6846A_BN_0.75_PDC
2509A_BN_0.75
2609_BN_0.75
6846M_BN_0.75
6846N_BN_0.75
1050A_BK_1.0
1150LD_BK_1.0_ALL
5 3 1 4
IP27
45A_D-BU_0.5
27_BN_0.5_ALL
1382J_PU/WH_0.5
750HA_BK_0.5
750HB_BK_0.5
SP911
1050_BK_3.0_ALL
13 13 2 2 1 1
SP913 ঍䶔ᐜ੄ ঍䶔਩੄
⢂➝⚥ ⢂➝⚥ ᐜ੄㓺ਾ⚥ ਩੄㓺ਾ⚥ ᐜ੄⢂➝⚥ ਩੄⢂➝⚥
750A_BK_1.0
SP425
LICENSE LICENSE COMBINE_ COMBINE_ LICENSE LICENSE
1382_PU/WH_0.5
LP_RL LP_RR RL RR LR_RL LR_RR

(ZAF) (ZAF)
2 2 4 4 2 2
550LA_BK_0.5_PDC
550LB_BK_0.5_PDC
550LC_BK_0.5
550LD_BK_0.5
550LJ_BK_0.5
550LK_BK_0.5
SP914
750_BK_1.5
SP910 PR2CH
C D CH2PR
1050A_BK_1.0
G_IP5_1
550LN_BK_0.5
550LM_BK_0.5
SP915 SP921
IP01_A IP01_C
550PL_BK_0.75_2.8FGT/2.8VGT
550PR_BK_0.75_
15 9 5
POSITIONHAZARD DIMMER ILL
LP SW
䖜䓡᧝࡬ঋ‫ݹ‬ SP911
BCM
1050A_BK_3.0_ALL
550GM_BK_2.5_4G69
550A_BK_0.75
CH2EB
28 EB2CH
1150B_BK_0.75
CH2EB
36 EB2CH
G_EBL2_3
G_EBL2_3 G_EBR1_1
17SK8106R03
49-46
Circuit Diagram
UEC
U-M01
COOLING U-FS11 U-FS11
FAN 600W FRT FOG FRT FOG
80A(LE:65A) 15A(LE:4.5AX2) 15A(LE:4.5AX2)
23 27
EB01
EB01
80 82 87 85 72 70
30 85 85 30 85 30
U-R10 ਇࣞᵰ㡧
U-R12 U-R13
REAR FOG ؓ䲟ѓⴈ
FRT FOG_L FRT FOG_R
RELAY
87 86 86 87 86 87 UEC
81 84 89 86 74 71 SP304
EB01
122_OG_0.75_ALL
122A_OG_0.75_ALL
122B_OG_0.75_ALL
5061_GY_0.75_FFOG
1317A_D-GN/WH_0.5_FFOG
1317B_D-GN/WH_0.5_FFOG
5062_BN_0.75_FFOG
1977B_YE_0.75_ALL
1977A_YE_0.75_2.8FGT/2.8VGT/4G69
CH01 CH02
5 5
EB33 EB34 EB2IP_2
1 1 IP2EB_2 27 ᐜ੄㓺ਾ⚥ ਩੄㓺ਾ⚥
COMBINE COMBINE
ᐜࢃ䴴⚥ ਩ࢃ䴴⚥ LP_RL LP_RR
1977_YE_0.5_ALL
FOGLP_ FOGLP_
FL FR
4 4
EB2IP_1 CH01 CH02
IP2EB_1 13 12 21 EB2CH
550LC_BK_0.5_ALL
550LD_BK_0.5_ALL
2 2
EB33 EB34 CH2EB
1050LF_BK_0.5_FFOG
1150LF_BK_0.5_FFOG
1317C_D-GN/WH_0.5_FFOG
1317D_D-GN/WH_0.5_FFOG
ᐜ㓺ਾᔶީ
COMBINE SW_LP
REAR FRT
SP915
550GL_BK_2.5_4G69
550PL_BK_0.5_2.8FGT/2.8VGT
SP921
550PR_BK_0.75_ALL
SP910 SP909 8 9
IP03
187_L-BU_0.5_ALL
192_OG_0.5_FFOG
1050A_BK_1.0_ALL
1150A_BK_1.0_ALL
CH2EB
28 EB2CH
CH2EB
1150A_BK_0.75_ALL
36 EB2CH
550GM_BK_0.75_4G69
550A_BK_0.75_ALL
SP911
1050_BK_3.0_ALL
G_EBL2_3 G_EBR1_1 G_EBL2_3 G_EBR1_1

IP01_A IP01_B IP01_A
15 28 14 37 44
FRT FOG FRT FOG REAR FOG REAR FOG FRT FOG
RELAY_L RELAY_R LP LP SW SW
䈀ᯣ᧛ਙ
OBD CONNECTOR
17SK8106R04
49-47
Circuit Diagram
BCM
LEFT TURN LP RIGHT TURN LP LEFT TURN SW RIGHT TURN SW
24 35 7 34
IP01_B IP01_B IP01_A
14_L-BU_0.5
15_D-BU_0.5
663_D-GN_0.5
664_TN_0.5
SP415 SP416
14A_L-BU_0.5
15A_D-BU_0.5
IP03
14B_L-BU_0.5
15B_D-BU_0.5
11 2
ᐜ㓺ਾᔶީ
COMBINE
SW_LP
51 IP2EB_2 IP2PRD_1 25 IP2EB_2 IP2PAD_1
EB2IP_2 1 PRD2IP_1 EB2IP_2 1 PAD2IP_1
1314A_L-BU/WH_0.5
6
1315A_D-BU/WH_0.5
15C_D-BU_0.5
14C_L-BU_0.5
IP03
850LS_BK_0.5
6 6
1314B_L-BU/WH_0.5 1315B_L-BU/WH_0.5
SP307 SP306 SP902
ࢥ傴催‫ם‬ ࢥ傴催‫ם‬
18 EB2CH ཌ੄㿼䮒 19 EB2CH
850A_BK_0.75
ཌ੄㿼䮒
CH2EB MIRROR_DD CH2EB MIRROR_DD
1314_L-BU/WH_0.5
618A_L-BU/WH_0.5
1315_D-BU/WH_0.5
619A_L-BU/WH_0.5
5 5
1550DM_BK_0.35
850DN_BK_0.35
SP901
850_BK_1.5_ALL
SP907 SP905
1550DZ_BK_0.5
850DZ_BK_0.5
6 3 6 3
ᐜࢃ㓺 ᐜ੄㓺 ਩ࢃ㓺 ਩੄㓺
ਾཝ⚥ ਾཝ⚥ ਾཝ⚥ ਾཝ⚥ G_IPL_1
HEAD COMBINE HEAD COMBINE
LP_LH LP_RL LP_RH LP_RL
5 4 6 PAD2IP_2 5 4 13 DRD2IP_2
IP2PAD_2 IP2DRD_2
1050LC_BK_0.5
550LC_BK_0.5
1150LC_BK_0.5
550LD_BK_0.75_ALL
1550_BK_0.5
850Z_BK_0.5
SP915
SP910 SP909
550PL_BK_0.75_2.8FGT/2.8VGT
550GL_BK_2.5_4G69
G_IPL_2
1050A_BK_1.0
G_IPR_2
1150A_BK_1.0
SP921
550PR_BK_0.75
SP910
1050_BK_3.0
CH2EB
28 EB2CH
1150A_BK_0.75
CH2EB
36 EB2CH
550A_BK_0.75
550GM_BK_2.5_4G69
G_EBL2_3
G_EBR1_3
G_EBL2_3
17SK8106R05
49-48
Circuit Diagram
49-49
17SK8106R06
儎փ࡬ࣞ⚥
CHMSL
IP2FL_1
FL2IP_1
IP01_B
G_FLCL_2
LP+
LP-
1320A_L-BU_0.5_CHMSL 1320_L-BU_0.5_CHMSL 2250LC_BK_0.5_CHMSL
CHMSL
A1
25
CH2EB
28 EB2CH
G_EBR1_1
1150A_BK_0.75
SP921
550PR_BK_0.75 550LD_BK_0.75
28 IP2EB_2
EB2IP_2
23 EB2CH
CH2EB
COMBINE LP_RR
SP305
SP418
਩੄㓺ਾ⚥
REVERSE LP
BACK UP
BCM
5219_OG/BK_0.5 5219_OG/BK_0.5_2.8FGT/2.8VGT 5219CA_OG/BK_0.5 5219CB_OG/BK_0.5 5219CD_OG/BK_0.5

36
6
STOP
5222_PU/BK_0.5
1
BACK UP
5219CC_OG/BK_0.5
COMBINE LP_RL
SP303
ᐜ੄㓺ਾ⚥
STOP
BRAKE LP
5222C_PU/BK_0.5_2.8FGT/2.8VGT/4G69 5222B_PU/BK_0.5 5222A_PU/BK_0.5 5221_GY/BK_0.5

23
26
20
1
EB2CH
CH2EB
550GL_BK_2.5_4G69 550LC_BK_0.5
4
550PL_BK_0.75_2.8FGT/2.8VGT
36
550GM_BK_2.5_4G69
G_EBL2_3
550A_BK_0.75_ALL
Circuit Diagram
UEC
U-MD1
COOLING U-FS3 U-FS15
FAN 600W IEC PWR6 IEC PWR6
80A(LE:65A) 30A 30A
15 27
EB01 SP004
SP310
IP07 Ԡ㺞ᶵؓ䲟ѓⴈ ੄儎ᓜՖ᝕ಞ
7130_L-BU_0.5_XELP
7132C_GY_0.5_XELP
7132B_GY_0.5_XELP
7131_D-GN_0.5_XELP
51 IEC REAR HIGHT SEN
I-FS26 I-FS6 ࢃ儎ᓜՖ᝕ಞ

AC PANEL/AFS/ TCU/SHIFT/ (NLE2.0T)
LDW/RLS AC PANEL/AFS FRT HIGHT SEN
10A 10A (NLE2.0T)
PWR
GND
SIG
PWR SIG GND

57 18 2 3 6 2 3 6
IP07
7524_GY/WH_0.5_XELP
7525_BN/WH_0.5_XELP
7526_PU/WH_0.5_XELP
2165_GY_0.5_XELP
2184_BN_0.5_XELP
2185_PU_0.5_XELP
7133A_BN_0.5
842_RD/WH_0.5
9 10 10 9
PWR SIG SIG PWR
ཝ⚥䈹㢸 ᐜࢃ㓺ਾཝ⚥ ཝ⚥䈹㢸 ਩ࢃ㓺ਾཝ⚥

HEAD LO_LH HEAD LO_RH
SP026 SP031 14 14
7312A_GY_0.5_XELP
CH2EN
7133_BN_0.5_XELP
842C_RD/WH_0.5_XELP
5356_YE_0.5_XELP
5357_YE_0.5_XELP
1550B_BK_1.5
13 14 16 EB2CH
2165A_GY_0.5_XELP
2184A_BN_0.5_XELP
2185A_PU_0.5_XELP
ѣཤ᧝࡬㓺ᔶީ਩
CONSOLE SW_R
AFS AFS G_IPR_1
OFF_SW LED
5 4
IP06
EB2IP_2 IP2EB_2 EB2IP_2
7129_BN_0.5_XELP
7135_TN_0.5_XELP
37 1 EB2IP_2 38 SP922
IP2EB_2 IP2EB_2
EB2IP_1
5356A_YE_0.5_XELP
7312_GY_0.5_XELP
5357A_YE_0.5_XELP
1550AF_BK_0.5_XELP
7 8 9 34 35 36 IP2EB_1
7524A_GY/WH_0.5_XELP
7525A_BN/WH_0.5_XELP
7526A_PU/WH_0.5_XELP
2165B_GY_0.5_XELP
2184B_BN_0.5_XELP
2185B_PU_0.5_XELP
IP11
14 9 1 23 15 4 19 12 24 6 5 26 17 7
PWR AFS OFF SW AFS OFF LED IGN V_V_FSP V_V_FSS V_V_FSG V_V_RSP V_V_RSS V_V_RSG B_D-LIN G_G_GND
AFS ECU
17SK8106R07
49-50
Circuit Diagram
Transmission Control System
UEC
U-JF4 IEC1
U-FS1 TCCU IEC⭫Ⓠ1
30A 30A
13 4
EB01
640_RD/WH_2.5_4WD
202J_RD/YE_2.5
640E_RD/WH_2.5_4WD
EB2IP_1
16 IP2EB_1 IP07 Ԡ㺞ᶵсؓ䲟ѓⴈ
69 IEC
30
I-R3 I-FS27
⛯⚡㔝⭫ಞ TCCU/FRT
IG Relay CLUTCH
SP041
87 10A
2 1 IP07_B 68 75 83
IP07
Ԡ㺞ᶵс 1296B_L-BU_1.0
I-FS36 I-FS35
ؓ䲟ѓⴈ
TCCU 2 TCCU 1
IEC
10 9 IP07_B
21 20 IP2FL_2
FL2IP_2 IP2FL_1
A5
640B_RD/WH_2.0
640A_RD/WH_2.0
FL2IP_1
1296_L-BU_1.0
7483A_L-BO_1.0_EFAC
FL01
26 13 23
12V BAT 12V BAT 12V IG
࠼ࣞಞ⭫᧝ঋ‫ݹ‬
TCCU
MOTOR MOTOR MOTOR MOTOR FAD FEED

GND GND H/L MODE 2WD/4WD CLUTCH COIL L-H L-H H-L H-L BALCK CONTROL
12 25 16 4 11 18 5 19 17 20 15 2 14 1 3 6
FL01
2150TB_BK_2.0
2150TA_BK_2.0
1559A_WH/D-GN
1562A_D-GN_0.5
5501C_PK/BK_1.0_4WD
1557C_D-BU/WH_0.5
1558C_YE/BK_0.5
1556C_OG/WH_0.5
1555C_BN/WH_0.5
7478C__YE/BK_0.5
1552E_TN_1.0
1552D_TN_1.0
1553E_OG_1.0
1553D_OG_1.0
7481A_D-GN
7482A_YE/BK
53 52 51 IP2EB_1
FL2IP_1 EB2IP_1
7481_D-GN
7482_YE/BK
7483_L-BU
C12 C11 IP2FL_1

1559_WH/D-GN
1562_D-GN_0.5
17 13 12 11 10 9 8 7 FL2GB
5501WB_PK/BK_1.0
5501NA_PK/BK_1.0
GB2FL
5501_PK/BK_1.0_4WD
1557_D-BU/WH_0.5_4WD
1558_YE/BK_0.5_4WD
1556_OG/WH_0.5_4WD
1555_BN/WH_0.5_4WD
7478__YE/BK_0.5_4WD
1552_TN_1.0_4WD
1553_OG_1.0_4WD
EB90
A B C
IP71
5 4 FORNT ACTUATOR
傧ࣞ䖢 ࢃẛ⿱ਾಞ
ᦘᔶީ FRT CLUTCH
DRV 1 2
E
MODE
1050FC_BK_1.0
SW ࠼ࣞಞ⭫⻷⿱ਾಞ GB01
6 3 1 E D C A D B G
IP71 㓵ാ傧ࣞ(2.0T)
750TB_BK_0.5
750TA_BK_0.5
1382A_PU/WH_0.5
POSITION ENCODER SHIFT MOTOR

IP01_C GB06
5 A ࠼ࣞಞᦘᥗ⭫ᵰ
DRIVE CONTROL MOT
࠼ࣞಞ⭫⻷⿱ਾಞ
䖜䓡᧝࡬⁗ඍ 㓵ാ傧ࣞ G_EBL2_3
BCM CLUTCH COIL
DRIVER
G_FLBL_2 G_IP5_1
17SK8107A01
49-51
Circuit Diagram
B+ B+
人ؓ䲟ѓⴈ P-MGO
U-F12 U-JF4 Pre-Fuse Box EPS
IEC PWR5 IEC PWR1 100A
30A 30A
A
24 4
EB01
842N_RD/WH_0.5_EPS
IP07 Ԡ㺞ᶵсؓ䲟ѓⴈ
47 69 IEC
30
⛯⚡㔝⭫ಞ
I-R3
U-FS22
IG RELAY
TCU 87
10A ᰖ䫛ॏ㌱㔕⁗ඍ
PEPSIP09_A
ECU
I-FS6 15 IP2EB_1
1NE_RD_10.0_EPS
TCU/SHIFT/AC/AFS AT_P EB2IP_1
842NA_RD/WH_0.5
10A 3
233_OG/BK_0.5_AT&PEPS
53 18 G_FLBR_3
IP07
750TD_BK_0.5_AT
750TC_BK_0.5_AT
4840_RD/OR_0.5_AT
842_RD/WH_0.5_ALL
EB2BT_N
1 BT2EB_N
842NB_RD/WH_0.5_EPS
SP031
IP59
842A_RD/WH_0.5_AT
842B_RD/WH_0.5_AT
6 11 4 3
P
R ਎䙕ಞ
A
᧝࡬⁗ඍ N ᦘᥗᵼ
D
M
FEAR
BT07_A BT07_B
+
2 5
350TA_BK_0.5_AT
-
G_FLBR_2 V_BATT COMM ENABLE
9 8 7 2 1 10
53 18 FL2IP_2 IP59
IP2FL_2 ⭫࣑ࣞࣟ䖢ੇ᧝࡬ঋ‫ݹ‬
43A_YE_0.5_AT
773_GY_0.5_AT
772_YE_0.5_AT
553_L-BU_0.5_AT
6009_BN/OG_0.5_ALL
7553_TN_0.5_AT
1382_PU/WH_0.5_ALL
EPS ECU
4840AB
842AB
275A_L-GN_0.5_AT&2.8VGT
275N_L-GN_0.5 AT&NLE2.0T
2 1 FL2GB
GND
EB2FL
275B_L-GN_0.5_AT
43AB_YE_0.35_AT
1
16 14 15 FL2GB BT07_A
GB2FL
1050N_BK_10.0_EPS
350TK
4840AA
842AC
GB02 IP01_B IP01_A IP01_C

5 4 12 47 32 50 5 29 16 5
GND V_BATT IGN ACC WINTER SPORT GEAR WIPER P PINMER
5 6 FL2GB SW SW SHIFT SW UNLOCK ILL
GB2FL
275_L-GN_0.5_AT&2.8VGT
43AA_YE_0.5_AT
਎䙕ಞ᧝࡬⁗ඍ 䖜䓡᧝࡬⁗ඍ
TCU BCM
G_BT1
ACC P/N_SIG
9 3 EB02_K1
GB02
22
I_S_PN
ECM
EB02_K
89
I_S_PN
ECM
17SK8107A02
49-52
Circuit Diagram
49-53
17SK8107A03
IP2EB_2
EB2IP_2
IP01_A
EB24
PEDALSW
OUT POT
5066A_YE_0.5_ALL 5066_YE_0.5_GCC&ESSS
BRAKE
2
IP01_D
6038B_YE/BK_0.5_PEPS
GND
18
BRAKE SEN
࡯䖜Ֆ᝕ಞ
6038A_YE/BK_0.5_PEPS 6038_YE/BK_GCC&ESSS
GND
GND
2
1
IP01_B
䖜䓡᧝࡬⁗ඍ
BCM
6039A_GY_0.5_PEPS 6039_GY_0.5_GCC&ESSS
VCC
5V
5
3
6039B_GY_0.5_PEPS
HOOD
AJAR
45
‫و‬ᥗ
ᔶީ
5007AD_L-GN_0.5_5MT-SAGW 750TW_BK_0.5
1
1 IP2FL_2
FL2IP_2
4 FL2GB
GB2FL
GB2FL
FL2GB
IP01_B
‫و‬ᥗ
ᔶީ
G_FLBR_3
REVERSE
GEAR SW
5007_L-GN_0.5_MT 5007A_L-GN_0.5_MT 5007AC_L-GN_0.5_6MT-SAGW 750TY_BK_0.5 350_BK_0.5

45
1
‫و‬ᥗ
ᔶީ
5007AB_L-GN_0.5_5MT-AISN 750TZ_BK_0.5
1
‫و‬ᥗ
ᔶީ
5007AA_L-GN_0.5_6MT-DYMOS 750TX_BK_0.5
1
Circuit Diagram
Wiper & Wash System
UEC
U-F27
U-FS13 U-FS16
ࢃ䴞ࡤ
IEC PWR6 IEC PWR8
FRT WIPER
30A 20A
25A
U-R6 U-R7
䴞ࡤ⭫Ⓠ 䴞ࡤ䙕ᓜ
WIPER POWER WIPER SPEED
146 145 150 152 151 15 28

EB01
1050_BK_3.0_ALL
91_GY_0.5_ALL
860_TN_0.5_ALL
92_PU_1.5_ALL
95_D-GN_1.5_ALL
242B_RD/BK_2.5
302B_RD/BK_1.0
EB2IP_2 EB2IP_1
17 31 IP2EB_2 51 11 IP2EB_1
91A_GY_0.5_ALL
860A_TN_0.5_ALL
242FC_RD/BK
302F_RD/BN
G_EBL2_3
ཐࣕ㜳ᔶީ䴞ࡤ
CIMBINE SW
IP07
51 11
IP01_B
17 31
CONT_ I-FS26 I-FS11 Ԡ㺞ᶵ WASH SIG2 SIG1 GND INT INT
RELAY
AC PANEL BCM ؓ䲟ѓⴈ 6 9 7 8 5 10
䖜䓡᧝࡬⁗ඍ 10A 10A
BCM IEC
94_PK_0.5_ALL
1714_L-BU_0.5_ALL
1715_L-GN_0.5_ALL
6009A_BN/OG_0.5_ALL
6009E_BN/OG_0.5
57 23
IP07
7133A_BN_0.5_ALL
1342_RD/BK_0.5_ALL
䖜䓡᧝࡬⁗ඍ
BCM
FRT SP412
WIPER WIPER
6009_BN/OG_0.5_ALL
PARK SW RLS PARK SW
21 46 17 SP901
850_BK_1.5_ALL
IP01_B
55 IP2EB_2
EB2IP_2
481_TN_0.5_RLS
228_OG_0.5_ALL
G_IPL_1
EB08 IP01_B IP01_A

3 5 2 3 1 1 13 24 16 33 29 45
HIGH LOW WASH PUMP WASH SW SIG2 LOW SIG1 HIGH GND INT SIG
ࢃ⍍⏚⌫
ࢃ䴞ࡤ⭫ᵰ 䴞䠅Ֆ᝕ಞ FRT 䖜䓡᧝࡬⁗ඍ
FRT WIOER MOT RAIN LIGHT WASH BCM
POMP
GND
1 2 2
EB08
850RR_BK_0.5
350WB_BK_0.5
350WA_BK_1.5_ALL
SP904 SP908
850S_BK_0.75
350_BK_0.5
G_EBR2_1 G_IPL_2 G_EBR2_1
17SK8108A01
49-54
Circuit Diagram
Body Control System
UEC
U-FS10 U-FS16 U-FS12 U-FS4

IEC PWR7 IEC PWR8 IEC PWR9 IEC PWR10
30A 20A 30A 30A
22 28 12 4
EB01
302A_PD/BK_2.5_ALL
302B_PD/BN_1.0_ALL
340_RD/WH_2.5_ALL
202A_RD/YE_2.5_ALL
EB2IP_1 EB2IP_PWR
39 40 30 IP2EB_1 1 IP2EB_PWR
302E_PD/BK_2.5
302F_PD/BN_1.0_ALL
340A_RD/WH_2.5_ALL
440_RD/WH_2.5_ALL
202E_RD/YE_2.5_ALL
850_BK_1.5_ALL
G_IPL_1
SP039 SP040
SP034 SP024 SP008 SP901
302EA_PD/BK_2.5
302EB_PD/BK_2.5
302EC_PD/BK_2.5
302FA_PD/BN_1.0_ALL
302FB_PD/BN_1.0_ALL
340B_RD/WH_2.5_ALL
440C_RD/WH_2.5_ALL
202J_RD/YE_2.5_ALL
850BC_BK_0.5_ALL
G_IPR_2
IEC
I-R7 PWE WIN_R I-R2 ACC RELAY
G_IPR_1
⭫ࣞ䖜ネ਩ 䱺Ԭ⭫Ⓠ㔝⭫ಞ
87 87
SP922
7 8 9 10 11 12 2 68 69 60
30 86
I-R6 PWE WIN_l
I-FS8 I-FS9 I-FS10 I-FS11 I-FS12 I-R3
I-FS7 I-FS2 ⭫ࣞ䖜ネᐜ
BCM_ BCM_ BCM_ BCM_ BCM_ ⛯⚡㔝⭫ಞ
BCM IPK&BCM 87
CLD INT LF FVEL FLAF FRT WASH EXT_LF IG RELAY
10A 10A G_
10A 10A 10A 10A 25A 87 85
IPR_3
19 20 21 22 23 24 14 58 104 101 45
1202_PD/WH_0.35_SPHCM
1240_PD/WH_1.5_ALL
1242_PD/WH_1.5_ALL
1340_PD/WH_0.5_ALL
1342_PD/WH_0.5_ALL
1340_PD/WH_1.5_ALL
5240E_PD/YE_0.5
5199_YE_0.5_ALL
549C
549B
549A
1550BE_BK_2.5_ALL
1550BD_BK_0.5_ALL
1550BC_BK_0.5_ALL
1550BB_BK_2.5_ALL
1550BA_BK_2.5_ALL
1550BF_BK_0.5_ALL
1550BG_BK_0.5_ALL
1550BM_BK_0.5_SPHCM
549_WH_0.5
IP01_E IP01_C IP01_A IP01_B IP01_C IP01_A IP01_B

3 14 1 15 17 3 8 48 6 22 21 19 9 7 4 8 4
V_BATT V_BATT V_BATT V_BATT V_BATT V_BATT IGN_SW IGN_RELAY PAP/ACC_RELAY GND GND GND GND GND GND GND GND
䖜䓡᧝࡬⁗ඍ
BCM
17SK8109A01
49-55
Circuit Diagram
Body Control System
䖜䓡᧝࡬⁗ඍ
BCM
ACC WAKE UP REVERSE LP
47 36
IP01_B
43_YE_0.5_ALL
5219_OG/BK_0.5_PGAM IP2FL_2N
33 2
FL2IP_2N
5219FN_OG/BK_0.5_NLE2.0T
5219F_OG/BK_0.5_2.8FGT/VGT
5973E_OG_0.35
5973BW_OG_0.35
46 IP2EB_2
EB2IP_2
43C_YE_0.5_ALL
EB2CH FL2CH_2
4 9
CH2EB CH2FL_2
5973E_OG_0.35
5973EN_OG_0.35
SP414 SP414
43N_YE_0.5_NLE2.0T
43G_YE_0.5_4G69
43E_YE_0.5_2.8FGT/VGT
43A_YE_0.5_AT
5219E_OG/BK_0.5_PGAM
5219B_OG/BK_0.5_RCAM
5219D_OG/BK_0.5_PADLO
5219C_OG/BK_0.5_2.8FGT/VGT
CH2RP
F
RO2CH
5973A_OG_0.35_PDC
2 FL2GB
GB2FL
43AB_YE_0.5_AT
3 RF2IP_1
IP2RF_1 SP305 SP701
6 GB2FL
FL2GB
43AA_YE_0.5_AT
5219EA_OG/BK_0.5_PGAM
5219CC_OG/BK_0.5
5219CD_OG/BK_0.5
5973D_OG_0.35_PDC
5973_OG_0.35_PDC
EB02_K1 EB02_K RF07 IP56_A CH02 PR04

85 74 3 2 6 85
ACC ACC REVERSE REVERSE REVERSE R-SGIFT
ਇࣞᵰ᧝࡬
ਇࣞᵰ᧝࡬⁗ඍ 䖜޻੄㿼䮒 ᭬丩ᵰ 㓺ਾཝ⚥-ᐜ੄ ‫و‬䖜䖻ࣟ-਩
⁗ඍ-2.0T
ECM ISRVM RADIO COMBINE_LP_RL RAPAR_R
ECM(2.0T)
EN03 GB02 R01 CH01 PR03

59 9 4 6 3
ACC ACC PWR1 REVERSE R-SGIFT
ਇࣞᵰ᧝࡬
਎䙕ಞ᧝࡬⁗ඍ 傱䖜᩺‫܅‬ཪ 㓺ਾཝ⚥-਩੄ ‫و‬䖜䖻ࣟ-ᐜ
⁗ඍ-4G69
TCU PARKING CAM COMBINE_LP_RR RAPAR_L
ECM(4G69)
17SK8109A02
49-56
Circuit Diagram
49-57
17SK8109A03
1382MS_PU/WH_0.5_10-WCREEN
1382B_PU/WH_0.5_4WD
REFER TO THE SUBSYSTEM SCHEMATICS:INTERIOR LIGHT-DIMMER INDICTOR

1382F_PU/WH_0.5_RREGL
1382E_PU/WH_0.5_RREGL
1382G_PU/WH_0.5_ALL
৸㘹ᆆ㌱㔕⽰ᝅഴφ޻䜞➝᱄㜂Ქ⚥⽰ᝅഴ
1382H_PU/WH_0.5_RADIO
1382A_PU/WH_0.5_ALL 1382C_PU/WH_0.5_ALL
1382W_PU/WH_0.5_ALL
1382J_PU/WH_0.5_ALL
1382K_PU/WH_0.5_ALL
1382M_PU/WH_0.5_ALL
1382N_PU/WH_0.5_ALL
1382S_PU/WH_0.5_ALL
1382L_PU/WH_0.5_ALL
IP2DRD_2
4 DRD2IP_2
1382R_PU/WH_0.5_ALL
IP01_C
SP427
SP425
DIMMER ILL
1382_PU/WH_0.5_ALL 1382F_PU/WH_0.5_ALL 1382Q_PU/WH_0.5_ALL 1382DA_PU/WH_0.5_ALL

5
GEAR SHIFTER
IP59
ᦘẙᵼ
GND_BC,
6009C_BN/OG_0.5_AT
2
IP01_A
ཐࣕ㜳ᔶީ䴞ࡤ
COMBINE SW_
SP412
IP04
BCM
Body Control System
WIPER SW GND
WIPER
GND_INT
6009_BN/OG_0.5_ALL 6009E_BN/OG_0.5_ALL
29
5
IP54_B
1020_PK_0.35_PEPS
KEY_IN
1
⛯⚡ᔶީ
IGW SW
SP411
OFF/ROW
1020A_PK_0.35_PEPS 1020E_PK_0.35_PEPS
IGN SIG
/CRANK
2
5
Circuit Diagram
Entry & Security System(LHD)
B+
UEC
U-FS3 U-FS10 U-FS16 ਇࣞᵰ㡧с
IEC PWR6 IEC PWR7 IEC PWR8 ؓ䲟ѓⴈ
30A 30A 20A
15 22 28
EB01
IP07
50 56 100 96 8 10
FUEL FLAP SW
I-FS10 IEC
I-FS25 I-R5 I-FS8 I-FS24 ⋯㇧ⴌᔶީ
BCM_FUEL
HORN ஽ਣ HORN BCM_CDL IPK/IMMO Ԡ㺞ᶵс
FLAP ؓ䲟ѓⴈ
20A ஽ਣ㔝⭫ಞ 25A 10A
10A
99 94 20 22 55
IP07
28_TN_0.5_ALL
1329_D-GN_1.0_ALL
5040_RD/WH_0.5_ALL
750A_BK_1.0
3 4 2 1
SP914
850DF_BK_0.35_ALL
1447_PK/WH_0.35_ALL
1382L_PU/WH_0.35_ALL
850DE_BK_0.35_ALL
SP049
750_BK_1.5_ALL
850HS_BK_0.5_ALL
28B_TN_0.5_ALL
1240_RD/WH_1.5_ALL
1340_RD/WH_0.5_ALL
20 IP2EB-1
EB2IP-1 SP045 SP9B
1329_D-GN_1.0_ALL
IP50_A
1 2
5040A_RD/WH_0.5_PEPS
750MM_BK_0.5
G_IP5_1
850DZ_BK_3.5
SP902 DRD2IP_2
CLOCKSPRING 5 4
IP2DRD_2
850A_BK_0.75_ALL
ᕯ㉝㓵ഴ
1447A_PK/WH_0.5_ALL
1382P_PU/WH_0.5_ALL
SP451
1329B_D-GN_1.0
1329A_D-GN_1.0
IP16
DRD2IP_1
1 2 IP2DRD_1 13
PWR GND
HORN SW
஽ਣᔶީ SP901 IMMO_BCM
MCU
䱨ⴍ᧝࡬⁗ඍ
EB32 EB31 LIN LED
1 1
3 4
IP16
HORN_R HORN_L
850Z_BK_1.5_ALL
7560_D-GN_0.5_PEPS
7561_:-BU_0.5_PEPS
஽ਣB਩ ஽ਣBᐜ
2 2
850A_BK_1.5_ALL
EB32 EB31
1050HR_BK_1.0_ALL
1050HL_BK_1.0_ALL
G_IPL_5
G_IPL_1
IP01_B IP01_C IP01_B IP01_A IP01_B IP01_C
42 14 15 34 51 40 5
HORN RELAY VBATT VBATT IMMO IGN ILLUM FUEL FLAP DZMMER
1050_BK_3.0_ALL
BCM
䖜䓡᧝࡬⁗ඍ
G_EBL2_3
17SK8110L01
49-58
Circuit Diagram
Entry & Security System(LHD)
BCM
䖜䓡᧝࡬⁗ඍ
CDL_UNLOCK
HOOD ADJ SW FUEL FLAP ACTUATOR DOOR AJAR RRSW DOOR AJAR RlSW PAS_SW DRV_SW CDL_LOCK
5 11 2 1 4 27 3 39 12 20 18
IP01-B IP01_C
IP2FL_2 34 P01_B P01_C
5530A_YE_0.5_PEPS
32 IP2FL_2
FP2IP_2 FP2IP_2
93_WH_0.5_ALL
4 EB2IP_2 56 IP2EB_2
IP2EB_2 EB2IP_2
93A_WH_0.5_ALL
748_L-GN_0.35_RREGL
1095_TN/BK_1.0_RREGL
1094_PU/WH_1.0
747_L-GU/BK_0.35
1092_PK_1.0_RREGL
1091_DG_1.0_RREGL
244_BN_0.5_PEPS
246_BN/OG_0.5_ALL
195B_L-BU_1.0_ALL
194B_WH_1.0_ALL
780_PK/BK_0.5
745_GY/BK_0.5
195C_L-GN_1.0
195C_GY_1.0
194_TN_1.0
ECM
/ਇࣞᵰ
MOID ADJ
SW
94 24 EB2CH
EB02_K CH2EB
5530_YE_0.5_PEPS
5530B_D-BU_0.5
93B_NH_0.5_ALL
10 9 8 FL2RLD_1 14 15 17 17 12 IP2DRD_1
RLD2FL_1 DRD2IP_1
10 9 8 FL2RRD_1 14 15 13 12 IP2PAD_1
RRD2FL_1 PAD2IP_1
EB70 RRD2 PD04_B PD04_A

1 2 D B A D D B A
SIG2 SIG1
LOCK_
MOT_PD
HOOD ADJ SW ࢥ催઎䬷䰞
ਇࣞᵰ㡧ⴌᔶީ
2 C C C
LOCK_MOT_RR
RR02 RL02 PD04_B PD04_A DD04_B DD04_A
GND
਩੄䬷䰞
2350DA_BK_0.5_RREGL
1550DB_BK_0.5_PEPS
1550DA_BK_0.5_ALL
A C D A A C D
3 FUEL FLAP
EB70 ACTCATOR
1050HA_BK_0.5_PEPS/ESSS
ࣖ⋯ਙⴌ
ᢝ㺂ಞ
1 B LOCK_MOT_RL LOCK_MOT_DD B B
RL02 ᐜ੄䬷䰞傴催઎䬷䰞 DD04_B DD04_A
550F_BK_0.35_ALL
2150DA_BK_0.5_RREGL
850DB_BK_0.5_PEPS
850DA_BK_0.5_ALL
2150DZ_BK_0.5
850DZ_BK_0.5
SP907
SP918
2350DZ_BK_0.5
1550DZ_BK_0.5
SP905
SP916 1 RLD2FL_1 SP917 1 RLD2FL_2 6 PAD2IP_2 13 DRD2IP_1
FL2RLD_1 FL2RLD_2 IP2PAD_2 IP2DRD_1
2150DA_BK_0.5_RREGL
1550_BK_0.5_ALL
850_BK_0.5_ALL
550_BK_0.35_ALL
2350DZ_BK_0.5_RREGL
G_EBR1_2 G_EBR2_1 G_FLBR_1 G_FLBL_1 G_IPR_2 G_IPL_5
17SK8110L02
49-59
Circuit Diagram
Entry & Security System(RHD)
B+
UEC
U-FS3 U-FS10 U-FS16 ਇࣞᵰ㡧с
IEC PWR6 IEC PWR7 IEC PWR8 ؓ䲟ѓⴈ
30A 30A 20A
15 22 28
EB01
IP07
50 56 100 96 8 10
FUEL FLAP SW
I-FS10 IEC
I-FS25 I-R5 I-FS8 I-FS24 ⋯㇧ⴌᔶީ
BCM_FUEL
HORN ஽ਣ HORN BCM_CDL IPK/IMMO Ԡ㺞ᶵс
FLAP ؓ䲟ѓⴈ
20A ஽ਣ㔝⭫ಞ 25A 10A
10A
99 94 20 22 55
IP07
28_TN_0.5_ALL
1329_D-GN_1.0_ALL
5040_RD/WH_0.5_ALL
750A_BK_1.0
3 4 2 1
SP914
850DF_BK_0.35_ALL
1447_PK/WH_0.35_ALL
1382L_PU/WH_0.35_ALL
850DE_BK_0.35_ALL
SP049
750_BK_1.5_ALL
850HS_BK_0.5_ALL
28B_TN_0.5_ALL
1240_RD/WH_1.5_ALL
1340_RD/WH_0.5_ALL
20 IP2EB-1
EB2IP-1 SP045 SP9B
1329_D-GN_1.0_ALL
IP50_A
1 2
750MM_BK_0.5
G_IP5_1
850DZ_BK_3.5
SP902 DRD2IP_2
CLOCKSPRING 5 4
IP2DRD_2
850A_BK_0.75_ALL
ᕯ㉝㓵ഴ
1447A_PK/WH_0.5_ALL
1382P_PU/WH_0.5_ALL
SP451
1329B_D-GN_1.0
1329A_D-GN_1.0
IP16
DRD2IP_1
1 2 IP2DRD_1 13
PWR GND
HORN SW
஽ਣᔶީ SP901 IMMO_BCM
MCU
䱨ⴍ᧝࡬⁗ඍ
EB32 EB31 LIN LED
1 1
3 4
IP16
HORN_R HORN_L
850Z_BK_1.5_ALL
7560_D-GN_0.5_PEPS
7561_:-BU_0.5_PEPS
஽ਣB਩ ஽ਣBᐜ
2 2
850A_BK_1.5_ALL
EB32 EB31
1050HR_BK_1.0_ALL
1050HL_BK_1.0_ALL
G_IPL_5
G_IPL_1
IP01_B IP01_C IP01_B IP01_A IP01_B IP01_C
42 14 15 34 51 40 5
HORN RELAY VBATT VBATT IMMO IGN ILLUM FUEL FLAP DZMMER
1050_BK_3.0_ALL
BCM
䖜䓡᧝࡬⁗ඍ
G_EBL2_3
17SK8110R01
49-60
Circuit Diagram
Entry & Security System(RHD)
BCM
䖜䓡᧝࡬⁗ඍ
HOOD AJAR
HOOD ADJ SW SW FUEL FLAP ACTUATOR DOOR AJAR RRSW DOOR AJAR RlSW PAS_SW DRV_SW CDL_UNLOCK CDL_LOCK
5 11 2 1 4 27 3 39 12 20 18
IP01-B IP01_C
5530C_L-GN_0.5
IP2FL_2 34 P01_B P01_C

5530A_YE_0.5_PEPS
32 IP2FL_2
FP2IP_2 FP2IP_2
93N_WH_0.5_ALL
93_WH_0.5_ALL
54 EB2IP_2 IP2EB_2 56 7 IP2FL_2

IP2EB_2 EB2IP_2 FP2IP_2
93A_WH_0.5_ALL
93NA_WH_0.5_ALL
748_L-GN_0.35_RREGL
1095_TN/BK_1.0_RREGL
1094_PU/WH_1.0
747_L-GU/BK_0.35
1092_PK_1.0_RREGL
1091_DG_1.0_RREGL
244_BN_0.5_PEPS
246_BN/OG_0.5_ALL
195B_L-BU_1.0_ALL
194B_WH_1.0_ALL
780_PK/BK_0.5
745_GY/BK_0.5
195C_L-GN_1.0
195C_GY_1.0
194_TN_1.0
ECM
/ਇࣞᵰ
MOID ADJ
SW
94 24 EB2CH 3 FL2CH_2
EB02_K CH2EB CH2FL_2
5530_YE_0.5_PEPS
5530B_D-BU_0.5
93B_NH_0.5_ALL
93NB_WH_0.5
10 9 8 FL2RLD_1 14 15 17 17 12 IP2DRD_1
RLD2FL_1 DRD2IP_1
10 9 8 FL2RRD_1 14 15 13 12 IP2PAD_1
RRD2FL_1 PAD2IP_1
EB70 CH13 RRD2 PD04_B PD04_A

1 2 2 D B A A A C D
SIG2 SIG1
FUEL FLAP
HOOD ADJ SW ACTCATOR
ਇࣞᵰ㡧ⴌᔶީ ࣖ⋯ਙⴌ
ᢝ㺂ಞ C B B LOCK_MOT_PD
LOCK_MOT_RR
RR02 ਩੄䬷䰞 PD04_B PD04_A ࢥ傴催઎䬷䰞 DD04_B DD04_A
GND
RL02
2350DA_BK_0.5_RREGL
1550DB_BK_0.5_PEPS
1550DA_BK_0.5_ALL
A C D D D B A
3 1
EB70 CH13
550F_BK_0.35_ALL
B LOCK_MOT_RL C C LOCK_MOT_DD
RL02 ᐜ੄䬷䰞 DD04_B DD04_A 傴催઎䬷䰞
2150DA_BK_0.5_RREGL
850DB_BK_0.5_PEPS
850DA_BK_0.5_ALL
2150DZ_BK_0.5
850DZ_BK_0.5
SP907
SP916 SP918
550_BK_0.35_ALL
2350DZ_BK_0.5
1550DZ_BK_0.5
SP905
1 RLD2FL_1 SP917 1 RLD2FL_2 6 PAD2IP_2 13 DRD2IP_1
FL2RLD_1 FL2RLD_2 IP2PAD_2 IP2DRD_1
2150DA_BK_0.5_RREGL
1550_BK_0.5_ALL
850_BK_0.5_ALL
2350DZ_BK_0.5_RREGL
G_EBR1_2 G_EBR2_1 G_FLBR_1 G_FLBL_1 G_IPR_2 G_IPL_5
17SK8110R02
49-61
Circuit Diagram
Passive Entry & Passive Start System
B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ Ԡ㺞ᶵؓ䲟ѓⴈ
UEC 46 41 69 IEC
I-FS18
U-FD8 I-FS21 I-R2 I-R3 I-FS2
U-FD12 U-JF5 U-JF4 INVERTER/
IGN/SW OBD/TPMS ACC IG IPK&BCM&
IEC POWER5 IEC POWER2 IEC POWER MIP_ADJ/
(PEPS&ESCL) /FR RELAY RELAY PEPS&BSD
30A 30A 30A TRAILER
10A/15A
20 24 5 4 52 42 30 38 68 2 14
EB01 IP07
41_RD/BK_0.75
4740_RD/WH_0.5
1140C_RD/WH_0.5_ALL
5240_RD/WH_0.5_ALL
RF2IP_1
24 IP2RF_1
850RS_BK_0.75_ADAS/PGAM/RLS/PEPS
850S_BK_0.75_ADAS/PGAM/RLS/PEPS
SP14603
IP26 SP025
42_RD/BK_0.75
3
KL30
⭫ᆆ䖢ੇ䬷䖜䓡᧝࡬ঋ‫ݹ‬ SP044 SP028

ESCL BCM
MOTOR_ LOCK_ UNLOCK_ KLIS
1140P_RD/WH_0.5_PEPS
5240C_RD/WH_0.5_PEPS
EN EN FB LIN GND IGNITION SW KLIS SW
EB2IP_1 1 5 4 2 6 13 7
23 IP2EB_1
IP26 IP01_B IP01_A
42A_RD/BK_0.75_PEPS
42D_RD/BK_0.75_PEPS
1063_OG_0.5_PEPS
1064_PU_0.5_PEPS
11_L-GN_0.5_PEPS
5741_WH_0.5_PEPS
850ES_BK_0.5_PEPS
3A_D-BU_0.5_PEPS
4A_BN_0.5_PEPS
1 IP2RF_1
RD2IP_1
4740AA_RD/WH_0.5_PEPS
SP904
850RF_BK_0.5_PEPS
G_IPL_4
SP902
850A_BK_0.75
SP501
42C_RD/BK_0.75_PEPS
42B_RD/BK_0.75_PEPS
12 IP2RF_1
RF2IP_1
SP901 1 3
344_GY_0.5_PEPS
344A_GY_0.5_PEPS
850_BK_1.5
PWR GND
RF᧛᭬ಞ
RF CONTROLLER
RF COM
2
G_IPL_1
IP09_A IP09_B IP09_A

1 2 11 23 10 8 5 4 19 9 21
KL30_1 KL30_2 ESCL_ ESCL_ ESCL_ ESCL_LIN CRANK_RUN_CTL ACC_IGN_CTL RF_COM ACC_FB IGN_FB
MOTOR_ LOCK_ UNLOCK_
POWER EN FB
PEPS ECU
17SK8111A01
49-62
Circuit Diagram
ж䭤੥ࣞᔶީ
START/STOP SW
䱨ⴍะㄏ_PEPS
IMMO_PEPS
࡬ࣞ䱨ᣧ↱㌱㔕
䖜䓡⭫ᆆどᇐ㌱㔕 ਎䙕ಞᬃ㓫ᵼ
᧝࡬ঋ‫ݹ‬ GEAR SHIFTER
ABS/ESP
SSB_GND2
SSB_GND1
MMO_PWR
MMO_GND
SSB_LED1
SSB_LED2
SSB_SW2
SSB_SW1
MMO_LIN
SSB_LED
GND
VSO P_SE_INPUT(PEPS)
7 8 1 2 3 6 5 4 10 1 2 3 3
IP20 FB04 IP72 IP59
850BT_BK_0.5_PEPS
850BT_BN_0.5_PEPS
6817_D-BU/BK_0.5_PEPS
5719_D-BU/BK_0.5_PEPS
5720_BN/BK_0.5_PEPS
5723_YE_0.5_PEPS
3559_BK/GY_0.5_PEPS
3358-D-GN/BK_0.5_PEPS
1827_YE/BK_0.5_ESP&PEPS
229_D-BU_0.5_PEPS
220_D-DG_0.5_PEPS
483_L-GN_0.5_PEPS
233_OG/BK_0.5_AT&PEPS
850_BK_1.5_ALL
SP902
SP901
850A_BK_0.75
EB2IP_1 G_IPL_1
14 IP2EB_1
1827A_YE/BK_0.5_ESP&PEPS
850PE_BK_0.75_PEPS
850PS_BK_0.75_PEPS
SP901
850_BK_1.5
G_IPL_1
IP01_A IP01_B IP09_B IP09_A

51 38 10 1 13 11 16 24 12 25 3 14 15
IGNITION SSW SSB_ SSB_ SSB_ SSB_ V_SPEED IMMO_ IMMO_ IMMO_ AT_P KL31_1 KL31_2
RING ILLUM (PEPS SW) LED1 LED2 GND1 SW1 PWR LIN GND (GND) (GND)
䖜䓡᧝࡬ঋ‫ݹ‬ ᰖ䫛ॏ㌱㔕᧝࡬ঋ‫ݹ‬
BCM PEPS ECU
17SK8111A02
49-63
Circuit Diagram
PEPS ANT_DO PEPS ANT_PD PEPS ANT_FRT PEPS ANT_MID
PKE PKE
SIG ANT+ ANT- GND SIG ANT+ ANT- GND ANT+ ANT- ANT+ ANT-
1 3 4 2 1 3 4 2 1 2 1 2
1166A_D-BU_0.35_PEPS
218A_PU_0.35_PEPS
219A_BN_0.35_PEPS
850DT_BK_0.35_PEPS
1167A_GY_0.35_PEPS
5707A_L-GN_0.35_PEPS
5711A_L-GN/BK_0.35_PEPS
1550DT_BK_0.35_PEPS
5708_OG_0.35_PEPS
5712_OG/BK_0.35_PEPS
5709_PK_0.35_PEPS
5713_PK/WH_0.35_PEPS
SP905 SP907
850DZ_BK_0.35
1550DZ_BK_0.35
19 20 21 13 DRD2IP_1 19 20 21 6 PAD2IP_1
IP2DRD_1 IP2PAD_1
1166_D-BU_0.35_PEPS
218_PU_0.35_PEPS
219_BN_0.35_PEPS
850T_BK_0.35_PEPS
1167_GY_0.35_PEPS
5707_L-GN_0.35_PEPS
5711_L-GN/BK_0.35_PEPS
1550_BK_0.35_PEPS
G_IPR_2 G_IPL_2
IP09_A IP09_C IP09_A IP09_C

4 1 7 17 3 9 2 8 4 10
DRIVER_ DRIVER_ DRIVER_ PASSENGER_ PASSENGER_ PASSENGER_ IN1_ IN1_ IN2_ IN2_
DOOR_SW ANT_POS ANT_NEG DOOR_SW ANT_POS ANT_NEG ANT_POS ANT_NEG ANT_POS ANT_NEG
PEPS ECU
17SK8111A03
49-64
Circuit Diagram
Interior Lighting System
ਇࣞᵰ㡧
B+ ؓ䲟ѓⴈ
UEC
U-FS10
IEC PWR7
BCM INT LP IP01_C
30A 1
VBATT
22
EB01 䖜䓡᧝࡬⁗ඍ
Ԡ㺞ᶵс
BCM
IP07 ؓ䲟ѓⴈ DIMMER DIMMER ROOF LP ROOF LP
9 IEC ILL SW GND HSD LSD
5 6 25 27 12
IP01_C IP01_A IP01_B
I-FS9
1597_PK/BK_0.5
1598_GY/BK_0.5
BCM INT LP
7.5A
21
IP07
1382_PU/WH_0.5_ALL
7389A_GY/WH_0.5_ALL
IP2RF_1
1242_PD/WH_0.35_ALL
7 6
RF2IP_1
1597R_PK/BK_0.5_PZLF
1598R_GY/BK_0.5_PZLF
1598F_GY/BK_0.5_FRLF
1597F_PK/BK_0.5_FRLF
RF04 RF03
SPL901 SPL SPL543 3 1 2 1
425
੄京⚥
REAR ࢃ京⚥
ROOM LP REAR
ROOM LP
2 AUTO ON
850_BK_1.5_ALL
850SA_BK_0.5_ALL
1382K_PU/WH_0.5_ALL
7388_GY/BK_0.5_BL
7389_GY/WH_0.5_ALL
RF04 OFF GND

850RL_BK_0.5
4 5
RF03
850_RO_0.5
850RN_BK_0.5
SP903
850RP_BK_0.5
RF2IP_1
IP12 23 IP2RD_1
5 4 5 8
850PA_BK_0.5
G_IPL_1 LED- LED+ DIM

MER+
DIMMER-
䈹‫ݿ‬ᔶީ
DIMMER SW G_IPL_4
17SK8112A01
49-65
Circuit Diagram
Mirror System(LHD)
UEC
U-FD4
U-FS2 U-JF5
IEC PWR1
MIRROR IEC PWR2
30A
25A 30A
4 14 5 Ԡ㺞ᶵсؓ䲟ѓⴈ
EB01 IEC
IP07
5 62 69 34 33 82 41 42 30
I-R10 I-R10
I-FS5 I-R3 䖜ཌ੄㿼䮒 I-FS3 䱺Ԭ⭫Ⓠ
TPMS ѱ㔝⭫ಞ 㔝⭫ಞ MIRROR 㔝⭫ಞ
10A IG RELAY HRW 1.5A ACC
MIRROR MIRROR
58 60 27 90 45 38
IP07
2940C
1640_RD/WH
549A_WH_0.5
1140C_RD/WH_0.5
5199_YE_0.5
850_BK_0.5
IP01_B IP01_B IP01_B

48 43 6
IGN RELAY MIRROR RELAY ACC RELAY
䖜䓡᧝࡬⁗ඍ 䖜䓡᧝࡬⁗ඍ 䖜䓡᧝࡬⁗ඍ

BCM BCM BCM
G_IPL_1
ࢥ傴催‫ם‬ཌ੄㿼䮒傴催‫ם‬ཌ੄㿼䮒䖜ཌ੄㿼䮒䈹㢸ᔶީ

2 1 MIRROR_PD 5 4 MIRROR_DD 5 4 MIRROR ADJ SW 3 5
850RS_BK_0.5
1550DZ_BK_0.5_ALL
850DZ_BK_0.5_ALL
PAD2IP_2
6 13 DDR2IP_2
IP2PAD_2 IP2DDR_2
3 6 8 7 2 3 1 6 8 7 2 3 1 9 6 2 10 7 1 4
24 RF2IP_1 RF07 PD03 DD03 DD11
5219EA_OG/BK_0.5
6805_PK_0.35_SPHCM
6804_YE_0.35_SPHCM
90_GY_0.5_SPHCM
889_OG_0.5_SPHCM
1498_BN/WH_0.5_SPHCM
1550_BK_0.5_ALL
6803_PK_0.35_SPHCM
6802_YE_0.35_SPHCM
88_D-BU_0.5_SPHCM/SPHM
89_L-GN_0.5_SPHCM/SPHM
82_PU_0.5_SPHCM/SPHM
850Z_BK_0.5_ALL
88A_YE_0.5
889B_OG_0.5
1498E_BW/WH_0.5
1963_GY_0.5
1382Q_PU/WH_0.5
IP2RF_1
850S_BK_0.75_LDW/PGAM/RLS/PEPS
3 RF2IP_1 12 11 10 3 4 DRD2IP_2
IP2RF_1 IP2DRD_2
G_IPL_2 G_IPL_5
5219_OG/BK_0.5_ALL
1963A_GY_0.5_SPHCM
1382_PU/WH_0.5_ALL
5 4 1 2 3 PAD2IP_2
IP2PAD_2
15 14 DDR2IP_2
191E_PK_0.35_SPHCM
190B_YE_0.35_SPHCM
90A_GY_0.5
889A_OG_0.5
1498B_BN/WH
IP2DDR_2
G_IPL_2
191_PK_0.35_SPHCM
190_YE_0.35_SPHCM
IP01_B IP01_E IP01_D IP01_E

36 35 24 6 10 16 5
RECERSE LF TURN_R TURN_L REAR FOLD REAR FOLD REAR MIR ILL
MOTOR- MOTOR+ FOLD SW
䖜䓡᧝࡬⁗ඍ
BCM
17SK8113L01
49-66
Circuit Diagram
Mirror System(RHD)
UEC
U-FD4
U-FS2 U-JF5
IEC PWR1
MIRROR IEC PWR2
30A
25A 30A
4 14 5 Ԡ㺞ᶵсؓ䲟ѓⴈ
EB01 IEC
IP07
5 62 69 34 33 82 41 42 30
I-R10 I-R10
I-FS5 I-R3 䖜ཌ੄㿼䮒 I-FS3 䱺Ԭ⭫Ⓠ
TPMS ѱ㔝⭫ಞ 㔝⭫ಞ MIRROR 㔝⭫ಞ
10A IG RELAY HRW 1.5A ACC
MIRROR MIRROR
58 60 27 90 45 38
IP07
2940C
1640_RD/WH
549A_WH_0.5
1140C_RD/WH_0.5
5199_YE_0.5
850_BK_0.5
IP01_B IP01_B IP01_B

48 43 6
IGN RELAY MIRROR RELAY ACC RELAY
䖜䓡᧝࡬⁗ඍ 䖜䓡᧝࡬⁗ඍ 䖜䓡᧝࡬⁗ඍ

BCM BCM BCM
G_IPL_1
ࢥ傴催‫ם‬ཌ੄㿼䮒傴催‫ם‬ཌ੄㿼䮒䖜ཌ੄㿼䮒䈹㢸ᔶީ

2 1 MIRROR_PD 5 4 MIRROR_DD 5 4 MIRROR ADJ SW 3 5
850RS_BK_0.5
1550DZ_BK_0.5_ALL
850DZ_BK_0.5_ALL
PAD2IP_2
6 13 DDR2IP_2
IP2PAD_2 IP2DDR_2
3 6 8 7 2 3 1 6 8 7 2 3 1 9 6 2 10 7 1 4
24 RF2IP_1 RF07 PD03 DD03 DD11
5219EA_OG/BK_0.5
6805_PK_0.35_SPHCM
6804_YE_0.35_SPHCM
90_GY_0.5_SPHCM
889_OG_0.5_SPHCM
1498_BN/WH_0.5_SPHCM
1550_BK_0.5_ALL
6803_PK_0.35_SPHCM
6802_YE_0.35_SPHCM
88_D-BU_0.5_SPHCM/SPHM
89_L-GN_0.5_SPHCM/SPHM
82_PU_0.5_SPHCM/SPHM
850Z_BK_0.5_ALL
88A_YE_0.5
889B_OG_0.5
1498E_BW/WH_0.5
1963_GY_0.5
1382Q_PU/WH_0.5
IP2RF_1
3 RF2IP_1 12 11 10 3 4 DRD2IP_2
IP2RF_1 IP2DRD_2
G_IPL_2 G_IPL_5
5219_OG/BK_0.5_ALL
1963A_GY_0.5_SPHCM
1382_PU/WH_0.5_ALL
5 4 1 2 3 PAD2IP_2
IP2PAD_2
15 14 DDR2IP_2
191E_PK_0.35_SPHCM
190B_YE_0.35_SPHCM
90A_GY_0.5
889A_OG_0.5
1498B_BN/WH
IP2DDR_2
G_IPL_2
191_PK_0.35_SPHCM
190_YE_0.35_SPHCM
IP01_B IP01_E IP01_D IP01_E

36 24 35 6 10 16 5
RECERSE LF TURN_L TURN_R REAR FOLD REAR FOLD REAR MIR ILL
MOTOR- MOTOR+ FOLD SW
䖜䓡᧝࡬⁗ඍ
BCM
17SK8113R01
49-67
Circuit Diagram
Infotainment System
B+
MICROPHONE
UEC 哜‫ށ‬伄
U-FS12 U-JF5 ਇࣞᵰ㡧
IEC PWR5 IEC PWR2 ؓ䲟ѓⴈ
30A 30A
24 5
EB01 MIC+ MIC-
4 3
SHIELD
BCM
48 41 䖜䓡᧝࡬ঋ‫ݹ‬
30
I-FS23 I-R2 I-FS20 IEC

MP5/RADIO ACC RELAY GATEWAY/RADIO Ԡ㺞ᶵс
25A 10A ؓ䲟ѓⴈ
7044_YE_0.5_BLTH
87
DEVERSE LP DIMMER ILL
54 42 32 40 36 5
IP07 IP01_B IP01_C
1364_RD/WH_2.5_RADIO
5219_OG/BK_0.5
1382_PU/WA_0.5
SHIELD
SP48 SP425
5219D_OG/BK_0.5_RADIO
1382A_PU/WA_0.5
RF2IP_1
10 11 IP2RF_1
SHIELD
SP048 SP423
1382A_PU/WA_0.5_RADIO
1375A_GY_0.5_RADIO
6001_GY_0.5_PTANT
7044C_0.5_RADIO & BLTH
1
1450R_BK_2.5_RADIO
G_IP4_1
I
SHIELD
ANTENNA
ཟ㓵᭴ཝಞ
IP56-A
7 4 2 6 3 1 8
VBATT ACC REVERSE ILL MIC+ MIC- GND
RADIO
᭬丩ᵰ
17SK8114A01
49-68
Circuit Diagram
49-69
17SK8114A02
FL2RRD-2
RRD2FL-2
47 IP2FL-2
FL2IP-2
IP56_B
NEG
RR SPK-
SPEAKER_RR
115A_WH_0.5_RADIO & 6SPEAKER 115A_WH_0.5_ 6SPEAKER 115_WH_0.5_ 6SPEAKER
਩੄ᢢ༦ಞ
3
2
2
RR SPK+
POS
46R_D-BU_0.5_RADIO & 6SPEAKER 46A_D-BU_0.5_6SPEAKER 46_D-BU_0.5_6SPEAKER
46
1
1
FL2RLD-2
RLD2FL-2
B12 IP2FL-1
FL2IP-1
NEG
SPEAKER_RL
116R_YE_0.5_RADIO & 6SPEAKER 116A_YE_0.5_ 6SPEAKER 116_YE_0.5_ 6SPEAKER
RL SPK-
ᐜ੄ᢢ༦ಞ
3
2
8
POS
B11
RL SPK+
119R_WH_0.5_RADIO & 6SPEAKER 119A_WH_0.5_6SPEAKER 119_WH_0.5_6SPEAKER
1
7
HI SPEAKER_RH
NEG
1952R_PU_0.5_RADIO & 4SPEAKER
਩儎丩ᢢ༦ಞ
2
POS
1852R_L-GN_0.5_RADIO & 4SPEAKER
RADIO
᭬丩ᵰ
1
IP2PAD-1
9 PAD2IP-1
SP611
NEG
ࢥ傴催䰞ᢢ༦ಞ
117B_PU_0.5_RADIO 117R_PU_0.5_RADIO 117_PU_0.5_2SPEAKER
FR SPK-
SPEAKER PD
2
4
SP610
POS
FR SPK+
200B_L-GN_0.5_RADIO 200R_L-GN_0.5_RADIO 200_L-GN_0.5_2SPEAKER
1
3
NEG
HI SPEAKER_LH
195R_GY_0.5_RADIO & 4SPEAKER
ᐜ儎丩ᢢ༦ಞ
2
POS
Infotainment System
1856R_TN_0.5_RADIO & 4SPEAKER
1
IP2DRD-1
9 DRD2IP-1
SP609
NEG
傴催઎䰞ᢢ༦ಞ
118B_GY_0.5_RADIO 118R_GY_0.5_RADIO 118_GY_0.5_2SPEAKER
FL SPK-
SPEAKER DD
2
6
SP608
POS
201B_TN_0.5_RADIO 201R_TN_0.5_RADIO 201_TN_0.5_2SPEAKER
FL SPK+
1
5
Circuit Diagram
Infotainment System
B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ IP57 哜‫ށ‬伄

UEC 5 MICROPHONE
BATT
10ሮᱴ⽰ኅ
Ω Ω
U-FS12 U-JF6 䈀ᯣ᧛ਙ ᆿ‫≊ޞ‬ഀ᧝࡬ঋ‫ݹ‬
IEC PWR5 IEC PWR3 10 SCREEN OBD SRS_ECU
MIC2+
MIC2-
MIC1+
MIC1-
30A 30A DATA FOR DATA FOR DRAIN FOR CRASH CRASH
FCD- FCD+ FCD ENABLE LIN GND OUT PUT OUT PUT
24 6 4 5 6 3 2 6 1 2 2 1 2 1 4 3
EB01 EB01 IP57 IP08_A IP08_C RF09
6444_OG/BK_0.5_TBOX
6445_YE/BK_0.5_TBOX
1000A_OG_0.5_SRSH
1000B_OG_0.5_SRSL
SHIELD
SHIELD
SHIELD
IP07
48 25
U-FS23 G_IP4_3
7043_YE_0.5_TBOX
7044_YE_0.5_BLTH
U-JF13
4540B_RD/WH_0.5_10-SCREEN
4540A_RD/WH_0.5_10-SCREEN
5175_GY_0.5_10-SCREEN
5174_GN_0.5_10-SCREEN
1755_D-GN_0.5_10-SCREEN
2355_BN_0.5_10-SCREEN
1450T_BK_0.5_TBOX
1450B_BK_0.5_TBOX
T-BOX/10-
1450S_BK_0.5_10-SREEN
MP5/RAD10
SCREEN
25A
10A
54 33 Ԡ㺞ᶵ
IP07 SP652
ؓ䲟ѓⴈ
1000D_OG_0.5_TBOX
IEC
4940_RD/WH_2.5_10-SCREEN
4540_RD/WH_2.5_10-SCREEN/TBOX
SHIELD
SHIELD
RF2IP_1
IP2RF_1 8 9 10 11
SHIELD
SHIELD
G_IP4_2
SHIELD
1450M_BK_0.5_10-SCREEN
7043A_YE_0.5_TBOX
7044A_PK/BK_0.5_10-SCREEN&BLTH
SP027
SHIELD
IP60
40 3 20 15 35 11 26 6
KL31 GND KL30 DEBUG_RX DEBUG_TX SRS MIC IN- MIC IN+
ӈ㚊㖇᧝࡬ঋ‫ݹ‬
T-BOX
USB PWR USB PATA+ USB PATA- USB GND MIC OUT+ MIC OUT- AUDIO OUT+ AUDIO OUT-
1 2 4 3 25 5 8 28
IP68 IP60
SHIELD
4601_D-GN_0.5_T-BOX
4602_L-BU_0.5_T-BOX
4603_PK_0.5_T-BOX
4604_UT_0.5_T-BOX
7043C_YE_0.5_T-BOX
2062_PK/BK_0.5_T-BOX
2061_OG/BK_0.5_T-BOX
SHIELD
SHIELD
IP55_B IP62 IP55_B IP61 IP55_D

15 4 5 6 7 10 IP55_E 16 1 2 4 3 11 5 6 12 8 2
VBATT+_PMPC LUDS_4 LUDS_5 LUDS_6 CNTR STACK LIN GND VBOS DATA+ DATA- GND MIC+ MIC- T BOX OUT+ T BOX OUT- MIC2- MIC2+
DATA DATA DRAIN ENABLE
FOR FCD- FOR FCD+ FOR FCD
ၧ҆㌱㔕ѱᵰ
MP5
17SK8114A03
49-70
Circuit Diagram
49-71
17SK8114A04
FL2RLD-2
RLD2FL-2
47 IP2FL-2
FL2IP-2
IP55_A
NEG
AUDIO_RR-
SPEAKER_RR
115B_WH_0.5_10-SCREEN & 6SPEAKER 115A_WH_0.5_ 6SPEAKER 115_WH_0.5_ 6SPEAKER
਩੄ᢢ༦ಞ
3
2
5
AUDIO_RR+
POS
46B_D-BU_0.5_10-SCREEN & 6SPEAKER 46A_D-BU_0.5_6SPEAKER 46_D-BU_0.5_6SPEAKER
46
1
1
FL2RLD-2
RLD2FL-2
B12 IP2FL-1
FL2IP-1
NEG
AUDIO_LR-
SPEAKER_RL
116B_YE_0.5_10-SCREEN & 6SPEAKER 116A_YE_0.5_ 6SPEAKER 116_YE_0.5_ 6SPEAKER
ᐜ੄ᢢ༦ಞ
3
2
8
POS
AUDIO_LR+
B11
119B_WH_0.5_10-SCREEN & 6SPEAKER 119A_WH_0.5_6SPEAKER 119_WH_0.5_6SPEAKER
1
4
HI SPEAKER_RH
NEG
1952_PU_0.5_10-SCREEN & 4SPEAKER
਩儎丩ᢢ༦ಞ
2
ၧ҆㌱㔕ѱᵰ
POS
1852_L-GN_0.5_10-SCREEN & 4SPEAKER
1
MP5
PAD2IP-1
9 IP2PAD-1
SP6115
NEG
AUDIO_RF-
ࢥ傴催䰞ᢢ༦ಞ
117C_PU_0.5_10-SCREEN 117A_PU_0.5_10-SCREEN 117_PU_0.5_2SPEAKER
SPEAKER PD
2
6
SP614
AUDIO_RF+
POS
200C_L-GN_0.5_10-SCREEN 200A_L-GN_0.5_10-SCREEN 200_L-GN_0.5_2SPEAKER
1
2
NEG
HI SPEAKER_LH
1956_GY_0.5_10-SCREEN & 4SPEAKER
ᐜ儎丩ᢢ༦ಞ
2
POS
Infotainment System
1856_TN_0.5_10-SCREEN & 4SPEAKER
1
IP2DRD-1
9 DRD2IP-1
SP613
NEG
AUDIO_LF-
傴催઎䰞ᢢ༦ಞ
118C_GY_0.5_10-SCREEN 118A_GY_0.5_10-SCREEN 118_GY_0.5_2SPEAKER
SPEAKER DD
2
7
SP612
POS
AUDIO_LF+
201C_TN_0.5_10-SCREEN 201A_TN_0.5_10-SCREEN 201_TN_0.5_2SPEAKER
1
3
17SK8114A05
IP55_B
NEXT PAGE
6202G_BN/OG_0.5_BSV&(2.8FGT/2.8VGT/4G69)
MP5 CONTROL SW
сж享
ၧ҆᧝࡬ᔶީ
6775_WH/BK_0.5_10-SCREEN 6201G_OG_0.5_BSV&(2.8FGT/2.8VGT/4G69)
11
D CH2RC
RC2CH
35 EB2CH
CH2EB
LNOUJOR
7066_WH_0.5_10-SCREEN
RC02
4
GND
6791_D-BU_0.5_10-SCREEN
1
LNO 6201GA_OG_0.5_RCAM/BSV&(2.8FGT/2.8VGT/4G69) 6201B_OG_0.5_RCAM/BSV
PWR
4
੄㿼‫ޞ‬Ქ᩺‫܅‬ཪ
IP2EB_1
45 EB2IP_1
BSV CAM_RR
IP55_E
6202GA_BN/OG_0.5_RCAM/BSV&(2.8FGT/2.8VGT/4G69) 6202B_BN/OG_0.5_RCAM/BSV
GND
34
3
SHIELD
SHIELD SHIELD SHIELD SHIELD SHIELD SHIELD SHIELD
33
2
6798M_YE_0.5_BSV 6798MA_YE_0.5_RCAM/BSV 6798B_YE_0.5_RCAM/BSV
SIG+
44
32
1
(2.8FGT/2.8VGT/4G69)
6798N_YE_0.5_BSV&
SHIELD
19 FL2CH_N
CH2FL_N
46 IP2FL_1
FL2IP_1
D CH2RC
RC2CH
6201GN_OG_0.5_BSU&NLE2.0T
5219MN_OG/BK_0.5_RCAM&NLE2.0T 6201GNA_OG_0.5_(RCAM/BSV)&NLE2.0T 6201GNB_OG_0.5_(RCAM/BSV)&NLE2.0T
IP55_E
B2
REAR_CAMERA
6202G_BK/OG_0.5_RCAM&NLE2.0T 6202GNA_BN/OG_0.5_(RCAM/BSV)&NLE2.0T 6202GNB_BN/OG_0.5_(RCAM/BSV)&NLE2.0T

GND(SHIELD)
ၧ҆㌱㔕ѱᵰ
B1
18
C
550CNB_BK_0.5_RCAM&NLE2.0T
11
MP5
G_EBR2_2
(ᐜ㡫)
SHIELD SHIELD SHIELD SHIELD SHIELD
17
B
9
REAR_CAMERA
6793BN_YE_0.5_(RCAM/BSV)&NLE2.0T 6793AN_YE_0.5_RCAM/BSV 6798MAN_YE_0.5_RCAM/BSV
12
A
5
IP2FL_2N 8
FL2IP_2N
6793B_YE_0.5_RCAM&
(2.8FGT/2.8VGT/4G69)
IP2EB_1
EB2IP_1
B CH2RC
RC2CH
33 EB2CH
CH2EB
SHIELD
RC01
SHIELD
SHIELD SHIELD SHIELD SHIELD SHIELD SHIELD SHIELD
45
‫و‬䖜੄㿼᩺‫܅‬ཪ
PARKING CAM
6793A_YE_0.5_RCAM 6798MA_YE_0.5_RCAM&BSV 6793_YE_0.5_RCAM/BSV
CIDO3
44
32
1
5219M_OG/BK_0.5_RCAM 6201GA_OG_0.5_RCAM/BSV 5219N_OG/BK_0.5_RCAM/BSV
PWR
46
35
4
550C_BK_0.5_RCAM&(2.8FGT/2.8VGT/4G69) 6202GA_BN/OG_0.5_RCAM/BSV 550CA_BK_0.5_RCAM/BSV
GND
34
3
G_EBR2_2
SP418
Infotainment System
Circuit Diagram
REVERSE LP
5219B_OG/BK_0.5_RCAM 5219_OG/BK_0.5_ALL
BCM
36
49-72
Circuit Diagram
49-73
17SK8114A06
IP55_D
SW04
IP50_B IP50_C
SWC COMMON
1765A_WH_0.5_10-SCREEN LOMMON 1765_WH_0.5_10-SCREEN

3
SEEK+
SEEK-
VOL+
MVIE
VOL-
VOLUME SW
1763A_L-GN_0.5_10-SCREEN 1763C_L-GN_0.5_10-SCREEN
ᯯੇⴎᔶީ
SWC1+
SW1
4
3
1764C_L-BU_0.5_10-SCREEN SIN2
5
CLOCK SPRING
VOICE
ᰬ䫕ᕯ㉝
6
SW2_COMMON
5343OG_0.5_10-SCREEN
ᇐ䙕ᐗ㡠ᔶީ
SW2_COMMON
CRVISE SW
6
VOICE
SP605
1764A_L-BU_0.5_10-SCREEN 1764_L-BU_0.5_10-SCREEN 1764B_L-BU_0.5_10-SCREEN
SWC2+
SW2
10
5
SIN2
IP2PRD_1
PRD2IP_1
IP63
GND(SHIELD)
RIGHT CAM
SHIELD
10
SHIELD
SHIELD SHIELD SHIELD
ࢥ傴‫ޞם‬Ქ᩺‫܅‬ཪ
11
BSV CAM_PO
ၧ҆㌱㔕ѱᵰ
RIGHT CAM
6798D_GY_0.5_BSV 6798R_GY_0.5_BSV
CVES
18
sig+
9
1
MP5
6202D_BN/OG_0.35_BSU 6202R_BN/OG_0.5_BSU
17
gnd
3
6201D_OG_0.35_BSU 6201R_OG_0.5_BSU
PWR
16
4
IP2DRD_1
DRD2IP_1
GND(SHIELD)
LEFT CAM
SHIELD
8
SHIELD
ѱ傴‫ޞם‬Ქ᩺‫܅‬ཪ
11
BSV CAM_DO
LEFT CAM
6798C_GY_0.5_BSV 6798L_GY_0.5_BSV
CVES
18
sig+
7
1
6202C_BN/OG_0.35_BSU 6202L_BN/OG_0.5_BSU
13
gnd
3
6201C_OG_0.35_BSU 6201L_OG_0.5_BSU
PWR
16
4
49 IP2EB
EB2IP
GND(SHIELD)
FRT CAM
SHIELD
SHIELD
ࢃ㿼‫ޞ‬Ქ᩺‫܅‬ཪ
BSV CAM_FRT
Infotainment System
CAM FRT CAM

6798F_YE_0.5_BSV
SP602
CUBS
48
sig+
5
1
6202_BN/OG_0.35_BSU 6202A_BN/OG_0.35_BSU 6202E_BN/OG_0.35_BSU 6202F_BN/OG_0.5_BSU
SP601
GND
47
gnd
2
3
SP604
6201_OG_0.35_BSU 6201A_OG_0.35_BSU 6201E_OG_0.5_BSU 6201F_OG_0.5_BSU
PWR
PWR
CAM
46
1
4
PRECIOUS PAGE
SP603
6201G_BN/OG_0.35_BSU(2.8FGT/2.8VGT/4G69)
рж享
6202G_BK/OG_0.5_BSU&(2.8FGT/2.8VGT/4G69)
Circuit Diagram
Protection System
B+
ਇࣞᵰ㡧
U-FS1
ؓ䲟ѓⴈ
IEC PWR5
30A UEC
24
EB01
IP07 Ԡ㺞ᶵсؓ䲟ѓⴈ
46 IEC
U-R3 FAN LOW
ք䙕伄᡽㔝⭫ಞ
87
I-FS21
OBD/
TPMS/RF I-FS5
10A I-FS3
TPMS/SRVIM/ ࢥ傴↙⻦Ֆ᝕ಞ ѱ傴↙⻦Ֆ᝕ಞ ࢥ傴‫⻦ם‬Ֆ᝕ಞ ѱ傴‫⻦ם‬Ֆ᝕ಞ
SRS
ESSS UFS_PASS UFS_DRV PAS_PASS PAS_DRV
10A
10A
SIG GND GND SIG GND SIG GND SIG
52 17 15 1 2 2 1 2 1 2 1
IP07 EB18 EB17 EB18 EB17
4740_RD/WH_0.5_ALL
840_RD/WH_0.5_TPMS/ESSS
140A_RD/WH_0.5_SPSL
140_RD/WH_0.5_SPSH
1409A_D-GN_0.5_SPSH/SPSL
5600A_GY_0.5_SPSH/SPSL
354A_YE_0.5_SPSH/SPSL
5045A_PK/BK_0.5_SPSH/SPSL
6628A_PU/WH_0.5_SRSH
2132A_WH/BK_0.5_SRSH
6629A_WH/BK_0.5_SRSH
2134A_D-GN_0.5_SRSH
SPL025 SPL030
4740E_RD/WH_0.5_TPMS
840A_RD/WH_0.5_TPMS
EB2IP_2 FL2IP_1
23 24 22 45 IP2EB_2 C2 C1 C4 C3 IP2FL_1
IP2FL_1
C9 C10 FL2IP_1
G_IP_3
4740BB_RD/WH_0.5
840AB_RD_0.35
840AC_RD_0.35_ESSS
4740BS_RD/WH_0.5_ESSS
5600J_GY_0.5_SPSL
1409J_D-GN_0.5_SPSL
5600_GY_0.5_SPSH
1409_D-GN_0.5_SPSH
354J_YE_0.5_SPSL
354_YE_0.5_SPSH
5045J_PK/BK_0.5_SPSL
5045_PK/BK_0.5_SPSH
6628_PU/WH_0.5_SRSH
2132_WH/BK_0.5_SRSH
6629_WH/BK_0.5_SRSH
2134_D-GN_0.5_SRSH
1350H_BK_0.5_SRSH
1350L_BK_0.5_SRSL
FL30
22 17
VBATT IGN
㜄ুⴇ⎁⁗ඍ
TPMS ECL
GND GND
18 6 FL31_B FL31_A
FL30 10 29
2250TE_BK_0.5_TPMS
2250TA_BK_0.5_TPMS
IGN VBATT
⴪⍷䖢ᦘ⁗ඍ
DC/DC
FL31_B FL31_A IP08_C IP08_A IP08_C IP08_A IP08_C IP08_A IP08_B IP08_A IP08_C
10 29 25 24 10 9 26 7 27 8 10 9 11 12 15 17
IGN IGN UFSP- UFSP+ UFSP- UFSP+ UFSD- UFSD- UFSD+ UFSD+ PASFP- PASFP+ PASFD- PASFD+ GND GND
ᆿ‫≊ޞ‬ഀ᧝࡬⁗ඍ
SRS ECU
G_FLCL_3
17SK8115A01
49-74
Circuit Diagram
49-75
17SK8115A02
IP2FL_3
FL2IP_3
IP08_B
FL23
SABFD+
2137_BN_0.5_SRSH&CAE 2137A_BN_0.5_SRSH&CAE
19
1
1
ѱ傴‫≊ם‬ഀ
SAB_DRV
2138_YE/BK_0.5_SRSH&CAE 2138A_YE/BK_0.5_SRSH&CAE
SABFD-
20
2
2
FL24
SABFP+
5135_BN/OG_0.5_SRSH&CAE 5135A_BN/OG_0.5_SRSH&CAE
18
1
3
SAB_PASS
ࢥ傴‫≊ם‬ഀ
2136_L-GN_0.5_SRSH&CAE 2136A_L-GN_0.5_SRSH&CAE
SABFP-
17
2
4
RF05
5019_PU/WH_0.5_SRSH&CAE 5019A_PU/WH_0.5_SRSH&CAE
CAFD+
23
2 IP2RF_2 1
ѱ傴‫≊ם‬ᑎ
CAB_DRV
RF2IP_2
5020_PK_0.5_SRSH&CAE 5020A_PK_0.5_SRSH&CAE
CAFD-
24
2
RF06
5021_YE/BK_0.5_SRSH&CAE 5021A_YE/BK_0.5_SRSH&CAE
CAFP+
22
1
3
CAB_PASS
ࢥ傴‫≊ם‬ᑎ
5022_WH/BK_0.5_SRSH&CAE 5022A_WH/BK_0.5_SRSH&CAE
CAFP-
21
2
4
FL08
BLFP+PDM
1362_OG_0.5_SRSL&FSBR 1362A_OG_0.5_FSBR
BUCKLE_PAS
ᆿ‫≊ޞ‬ഀ᧝࡬⁗ඍ
14
FL2IP_2 43
ࢥ傴ᆿ‫ޞ‬ᑜ
IP2FL_2
SRS ECU
BLFP+PDM
1362_OG_0.5_SRSH&FSBR
1363_D-BU_0.5_FSBR
3
2
FL12
1
SBR_PAS
ࢥ傴SBR
1361E_L-BU_0.5_SBR
IP08_B IP08_C IP08_B IP08_C IP08_A IP08_C IP08_A
2
SP651
G_FLR1
1361_L-BU_0.5_SRSH 1850BK_0.5_SRSL&FSBR/SBR
GND
22
6
FL51
1361D_L-BU_0.5_SBR
੄ᧈᐜ‫ם‬ᆿ‫ޞ‬ᑜ
5161_YE_0.5_SRSL
BUCKLE_RL
2
BLRP
10
5161_YE_0.5_SRSH 5161A_YE_0.5_SBR
BLRP
25
5
FL53
1361C_L-BU_0.5_SBR
੄ѣ䰪‫ם‬ᆿ‫ޞ‬ᑜ
BUCKLE_RM
5163_PK/WH_0.5_SRSL
2
Protection System
BLRM
30
5163_PK/WH_0.5_SRSH 5163A_PK/WH_0.5_SBR
BLRM
24
3
1
FL52
1361B_L-BU_0.5_SBR
੄ᧈ਩‫ם‬ᆿ‫ޞ‬ᑜ
BUCKLE_RR
5162_PU_0.5_SRSL
2
BLRF
12
5162_PL_0.5_SRSH 5162A_PL_0.5_SBR
BLRP
23
4
1
17SK8115A03
IP60
1000D_OG_FLRB_0.5_TBOX
11 SRS
䖜㚊㖇᧝࡬ঋ‫ݹ‬
11
T-BOX
IP08_C IP08_A IP08_C IP08_A
IP01_B
SP652
CRASH SIG
1000A_OG_FLRB_0.5_SRSH 1000C_OG_FLRB_0.5_SRSH
OUTPUT
CRASH
B37
37
2
BCM
1000B_OG_FLRB_0.5_SRSL
OUTPUT
CRASH
1
ABFP+
FL50_A
22
MC1511 MC1511
ABFP+
3
IP4_4
PAB+
PAB+
MC1512 MC1512
IP08_C IP08_A
MC1535 IP4_4
DAB-
PAB-
ABFP-
21
4
MC1511 MC1511
ᰬ䫕ᕯ㉝ ѱ傴≊ഀ
ABFP-
CLOCK SPRING PAB

4
MC1512 MC1512
MC1535
IP08_B IP08_C IP08_A IP08_C IP08_A
FL13
3025_YE FLRB_0.5_SRSL&PAB
ABFD+
23
1
PAB+
MC1513 MC1513
3025J_YE FLRB_0.5_SRSL&PAB
ABFD+
MC1514 MC1514
PAB-
3024_OG FLRB_0.5_SRSH&PAB
ABFD-
24
2
ᆿ‫≊ޞ‬ഀ᧝࡬ঋ‫ݹ‬
MC1513 MC1513
ࢥ傴≊ഀ
SRS ECU
3024J_OG FLRB_0.5_SRSL&PAB
ABFD-
PAB
3
MC1514 MC1514
FL15
2118C_BN/OG FLRB_0.5_D1PSB&SRSH
BT2FD- BT2FD+
C6 C5
7
1
2118C_OG/BK FLRB_0.5_D1PSB&SRSH
8
2
MC1523 MC1534 MC1534
IP08_A
ѱ傴ᆿ‫ޞ‬ᑜ人㍝2δਂ㓝ε
FL13
2118A_BN/OG FLRB_0.5_D2PSB&SRSH SEAT BELT 2 PRETESIONER_DRV2
FD+A
FL2IP_1 C8 C7
19
BT1
1
FD-A
2118A_OG/BK FLRB_0.5_D2PSB&SRSH
20
BT1
2
MC1525 MC1526 MC1526
IP08_C
IP2FL_1
ѱ傴ᆿ‫ޞ‬ᑜ人㍝2δਂ㓝ε
FL09
2118K_BN/OG FLRB_0.5_D1PSB&(SRSL/SRSH) SEAT BELT 2 PRETESIONER_DRV1
B2FD- B2FD+
1
2118K_OG/BK FLRB_0.5_D1PSB&(SRSL/SRSH)
2
MC1527 MC1528
IP08_B
FL16
ѱ傴ᆿ‫ޞ‬ᑜ人㍝δঋ㓝ε
2116C_L-GN FLRB_0.5_P2PSB&SRSH SEAT BELT 1 PRETESIONER_DRV
BT2FP- BT2FP+
26
6
1
2117C_OG FLRB_0.5_P2PSB&SRSH
Circuit Diagram
27
5
2
MC1529 MC1530 MC1530
Protection System
IP08_A
ࢥ傴ᆿ‫ޞ‬ᑜ人㍝2δਂ㓝ε
FL14
2116A_L-GN FLRB_0.5_P2PSB&SRSH SEAT BELT 2 PRETESIONER_PAS2
FP+A
18
44
BT1
1
2117A_OG FLRB_0.5_P2PSB&SRSH
FP-A
17
FL2IP_2 45
BT1
2
MC1531 MC1532 MC1532
IP08_C
IP2FL_2
ࢥ傴ᆿ‫ޞ‬ᑜ人㍝δਂ㓝ε
FL10
2116K_L-GN FLRB_0.5_P1PSB&(SRSL/SRSH) SEAT BELT 2 PRETESIONER_PAS1
BTFP- BTFP+
1
2117K_OG FLRB_0.5_P1PSB&(SRSL/SRSH)
49-76
8
2
MC1533 MC1534
ࢥ傴ᆿ‫ޞ‬ᑜ人㍝δঋ㓝ε
SEAT BELT 1 PRETESIONER_PAS
Circuit Diagram
49-77
17SK8116A01
IP01_A
IP65
WAKE UP ENABLE
5219G_OG/BK_0.5_PDC
35
㴸呙ಞ
BEEP
1
PR04
PR2CH
CH2PR
550RW_BK_0.35_PDC
DATA
1
SP703
PR04
‫و‬䖜䴭䗴਩
RADAR-R
5973D_OG_0.35_PDC 550RY_BK_0.35 550RZ_BK_0.35 550RR_BK_0.35

R-SHIFT
GND
H
3
2
ID
4
PR03
DATA
4
SP701
PR03
‫و‬䖜䴭䗴ᐜ
G_EBR2_1
RADAR-L
550RX_BK_0.35 550RL_BK_0.35 550B_BK_0.5
R-SHIFT
5973_OG_0.35_PDC
GND
G
3
2
䖜䓡᧝࡬⁗ඍ
5962_L-GN_0.35_PDC
ID
1
BCM
32 IP2EB_1
EB2IP_1
CH2PR
PR2CH
EB2CH
CH2EB
5974_PK_0.5_PDDC&2.8L/4G69 5962A_L-GN_0.35 5962E_L-GN_0.35
3
Parking Distance Control System
5219F_OG/BK_0.5_PDDC&2.8L/4G69 5973_OG_0.35 5973E_OG_0.35
33
COMBINE LP-RL
CH01
ᐜ੄‫و‬䖜⚥
㓺ਾཝ⚥
BACK UP
5219CP_OG/BK_0.5
6
IP2FL_2N
FL2IP_2N
FL2CH_2
CH2FL_2
5974N_PK_0.5_PDC&2.0T 5962AN_L-GN_0.35 5962E_OG_0.35
8
IP01_B
COMBINE LP-RR
SP418
SP418
CH02
਩੄‫و‬䖜⚥
㓺ਾཝ⚥
REVERSE LP
BACK UP
5219_OG/BK_0.5_ALL 5219FN_OG/BK_0.5_2.0T 5219BN_OG_0.35 5219NN_OG/BK_0.5 5219CP_OG/BK_0.5
36
6
Circuit Diagram
Information System
B+ ਇࣞᵰ㡧с䲟ѓⴈ
UEC
U-JF4 U-JF3
IEC PWR1 IEC PWR6
30A 30A
4 15
EB01
IP07
69 49
Ԡ㺞ᶵс
I-R3
ؓ䲟ѓⴈ
⛯⚡㔝⭫ಞ IEC
I-FS24
IG RELAY IPK/IMMO
10A ࡬ࣞ⏨փ
I-FS2 䖜䓡᧝࡬⁗ඍ ཐࣕ㜳ᔶީᐜ‫ם‬
BRAKE
IPK&BCM&PEPS BCM COMBINE SW_LF
LEVEL SEN
10A
SECURITY SET SIG GND
14 55 11 10 2 1
IP07 IP01_A IP03 EB28
5240_RD/YE_0.5_ALL
5040_RD/WH_0.5_ALL
ᆿ‫ޞ‬ᑜᔶީ傴催઎
ᢁ࡯ BUCKLE-DRV ཐࣕ㜳ᔶީ䴞ࡤ
ਇ⭫ᵰ
PARKING COMBINE
ALTERNATOR
BRAKE SW SW_MPER
CHARCHING POWER SET2 GND
1 1 1 2 2 1
EN01 FL71 FL02 IP04
728_GY_0.5_ALL
1131_YE/BK_0.5_ALL
5981_PU/WH_0.5_ALL
234A_YE_0.5_ALL
1550BK_BK_0.5_ALL
209A_PU_0.5_ALL
1050BL_BK_0.5_ALL
5982_PK/BK_0.5_ALL
850LL_BK_0.5_ALL
EN2EB
SP028 SP045 8 EB2EN
5240A_RD/YE_0.5_ALL
5040E_RD/WH_0.5_ALL
25_BN_0.5_2.8L
SP910 SPL902
1050A_BK_1.0_ALL
850A_BK_0.75_ALL
EB2IP_1 FL2IP_2 FL2IP_1 EB2IP_1

12 IP2EB_1 31 IP2FL_2 D3 IP2FL_1 43 IP2EB_1 850KC_BK_0.5_ALL
850KA_BK_0.5_ALL
850KE_BK_0.5_ALL
209_PU_0.5_ALL
25A_BN_0.5_ALL
234_YE_0.5_ALL
SP911 SPL901
1050_BK_3.0_ALL
850_BK_1.5_ALL
G_FLLI_1 G_EBL2_3 G_IPL_1
1 2 26 29 19 5 27 6 8 16 17 32
IGN VBAT CHARGING SIG IMMO LP+ PARKING BRAKE SET- BELT BRAKE LEVEL SET2-WIPER GND GND GND
LIGHT WARNING WARNING
㓺ਾԠ㺞
CLUSTER
17SK8117A01
49-78
Circuit Diagram
CAN Bus System
B+ ਇࣞᵰ㡧䲟ѓⴈ
UEC
U-JF12 U-JF4 U-JF5

IEC PWR9 IEC PWR1 IEC PWR2
30A 30A 30A
12 4 5
EB01
IP07 Ԡ㺞ؓ䲟ѓⴈ
81 69 41 IEC
ၧ҆㌱㔕ѱᵰ Ԡ㺞
I-FS33 I-F20 I-FS5 MP5 CLUSTER
I-R3 I-R2
GATEWAY GATEWAY/ TPMS/ISEVM/
IG RELAY ACC RELAY CAN-H CAN-L CAN-H CAN-L
15A RADIO GATEWAY/ESSS
6 12 14 15
10A 10A
IP55_D IP02
89 68 42 32 5 17 40
IP07
5169C_BN/WH_0.35_10-SCREEN
5170C_BN_0.35_10-SCREEN
5169B_BN/WH_0.35_GTWY
5170B_BN_0.35_GTWY
998_BN_0.75_GTWY
840_RD/WH_0.5_TRAILER/TPMS/PGAM/GTWY/LDW/PABSW/ESSS
SP30
SP777
840C_RD/WH_0.5_GTWY
SP048
5985_D-BU_0.5_GTWY SP778
5169A_BN/WH_0.35_GTWY
5170A_BN_0.35_GTWY
A7 A8 A6 IP2FL_1
FL2IP_1
998C_BN_0.75_GTWY
139_PK_0.5_GTWY
5985A_D_BU_0.5_GTWY
9 10 IP2FL_2
FL2IP_2
G_FLLI_3
5169_BN/WH_0.35_GTWY
5170_BN_0.35_GTWY
1650GA_BK_0.75_GTWY
1650GB_BK_0.75_GTWY
SP751
998A_BN_0.75_GTWY
998B_BN_0.75_GTWY
FL02_B FL02_A FL02_B FL02_A FL02_B

12 19 18 11 5 15 20 6
KL30 KL30 HD11_KL15 HD12_KLR INFO_CAN_H INFO_CAN_L KL31 KL31
㖇ީ
GATEWAY
17SK8118A01
49-79
IP66
IP60
17SK8118A02
6435C_GY/BK_0.35_GTWY 6435D_GY/BK_0.35_TBOX
CAN-L
CAN-L
39
B
䖜㚊㖇᧝࡬ঋ‫ݹ‬
㓾ㄥ⭫䱱-BD
TR-BD
T-BOX
6434C_PK/WH_0.35_GTWY 6434D_PK/WH_0.35_TBOX
CAN-H
CAN-H
19
A
14 IP2FL_2
FL2IP_2
FL02_A
SP764
SP762
IP28
DIAG_CAN_L
6435E_GY/BK_0.35_GTWY 6435B_GY/BK_0.35_GTWY 6435A_GY/BK_0.35_GTWY 6435_GY/BK_0.35_GTWY
CAN-L
14
11
䈀ᯣ᧛ਙ
OBD
SP763
SP761
DIAG_CAN_H
6434E_PK/WH_0.35_GTWY 6434B_PK/WH_0.35_GTWY 6434A_PK/WH_0.35_GTWY 6434_PK/WH_0.35_GTWY
CAN-H
13
6
1
FL30
FL70
6432F_L-GN/BK_0.35_GTWY&TPMS 6432M_L-GN/BK_0.35_GTWY&TRAILER
CAN-L
CAN-L
㜄ুⴇ⎁᧝࡬ঋ‫ݹ‬
GATEWAY
2
TRAILER ECU
ᤌ䖜᧝࡬ঋ‫ݹ‬
TPMS ECU
㖇ީ
6433F_BN_0.35_GTWY&TPMS 6433M_BN_0.35_GTWY&TRAILER
CAN-H
CAN-H
1
4
SP754
SP794
BD_CAN_L
6432L_L-GN/BK_0.35_GTWY 6432_L-GN/BK_0.35_GTWY
13
SP753
SP793
BD_CAN_H
6433L_BN_0.35_GTWY 6433_BN_0.35_GTWY
3
FL2IP_2
11 IP2FL_2
6433A_BN_0.35_GTWY 6433B_BN_0.35_GTWY
6432A_L-GN/BK_0.35_GTWY 6432B_L-GN/BK_0.35_GTWY
12
IP38_A
IP09_B
IP67
FRT A/C CONT PNL
CAN-L
6432E_L-GN_0.35_GTWY 6432H_L-GN/BK_0.35_AT A/C 6432G_L-GN_0.35_PEPS
CAN-L
CAN-L
15
11
B
ࢃグ䈹᧝࡬䶘ᶵ
㓾ㄥ⭫䱱-BD
PEPS ECU
TR-BD
Circuit Diagram
6433E_BN_0.35_GTWY 6433H_BN_0.35_AT A/C 6433G_BN_0.35_PEPS

CAN Bus System
CAN-H
CAN-H
CAN-H
A
7
IP01_A
SP760
SP758
SP755
6432J_L-GN/BK_0.35_GTWY 6432D_L-GN/BK_0.35_GTWY 6432C_L-GN/BK_0.35_GTWY
CAN-L
41
BCM
SP759
SP757
SP756
49-80
6433J_BN_0.35_GTWY 6433D_BN_0.35_GTWY 6433C_BN_0.35_GTWY
CAN-H
42
Circuit Diagram
49-81
17SK8118A03
15 IP2FL_2
FL2IP_2
FL02_A
6105A_D-BU_0.35_GTWY&(ESP/XELP/LDW/EPS) 6105P_D-BU_0.35_GTWY 6105_D-BU_0.35_GTWY
CAN_H
CH_
2
SP797
GATEWAY
㖇ީ
SP798
6106A_WH_0.35_GTWY&(ESP/XELP/LDW/EPS) 6106P_WH_0.35_GTWY 6106_WH_0.35_GTWY
CAN_L
CH_
12
3
IP11
FL59
6105F_D-BU_0.35_ELP&GTWY
CAN_H
16
SP765
㠠䘸ᓊࢃཝ⚥
6105Q_D-BU_0.35_GTWY&BSD
CAN_H
⴨॰ⴇ⎁᧝࡬ঋ‫ݹ‬
AFS ECU
9
᧝࡬ঋ‫ݹ‬
BSD ECU
SP766
6106F_WH_0.35_ELP&GTWY
CAN_L
3
6106Q_WH_0.35_GTWY&BSD
CAN_L
25
GTWY&(ESP/LDW/EPS)
GTWY&(ESP/LDW/EPS)
6105B_D-BU_0.35_
6106B_WH_0.35_
RF2IP_1
17 IP2RF_1
RF10
6106M_WH_0.35_GTWY&LDW 6106N_WH_0.35_GTWY&LDW
CAN_L
B_D_
7
䖻ࣟ᧝࡬ঋ‫ݹ‬
IP14
䖜䚉‫⿱څ‬
LDW
6105G_D-BU_0.35_GTWY&ESP
CAN_H
3
SP767
ANGLE SEN
STEERING
6105M_D-BU_0.35_GTWY&LDW 6105N_D-BU_0.35_GTWY&LDW
CAN_H
B_D_
16
1
IP2EB_1
EB2IP_1
SP768
6106G_WH_0.35_GTWY&ESP
CAN_L
4
6106C_WH_0.35_GTWY&(ESP/EPS) 6106L_WH_0.35_GTWY&(ESP/EPS) 6106D_WH_0.35_GTWY&(ESP/EPS)
4
SP796
SP795
6105C_D-BU_0.35_GTWY&(ESP/EPS) 6105L_D-BU_0.35_GTWY&(ESP/EPS) 6105D_D-BU_0.35_GTWY&(ESP/EPS)
3
8 BT2EB_N
EB2BT_N
BT07_B
SP15202
EB65
6106E_WH_0.35_GTWY 6106RA_WH_0.35_GTWY&EPS 6106R_WH_0.35_GTWY&EPS
CAN-L
CAN-L
B
4
⭫࣑ࣞࣟ䖢ੇ
㓾ㄥ⭫䱱-EB
EPS ECU
᧝࡬ঋ‫ݹ‬
TR-EB
SP15201
6105E_D-BU_0.35_GTWY 6105RA_D-BU_0.35_GTWY&EPS 6105R_D-BU_0.35_GTWY&EPS
CAN-H
CAN-H
A
7
SP770
EB04
6106H_WH_0.35_GTWY 6106U_WH_0.35_GTWY&(ESP/EPS)
14
EB2IP_1 SP769
䖜䓡⭫ᆆどᇐ㌱㔕᧝࡬ঋ‫ݹ‬
6105H_D-BU_0.35_GTWY 6105U_D-BU_0.35_GTWY&(ESP/EPS)
26
CAN Bus System
2 IP2EB_1
ABS/ESP
IP13
6106J_L-BU_0.35_ESP 6106K_L-BU_0.35_ESP
CAN_H
CAM-L
⁠᩼䀈䙕ᓜՖ᝕ಞ
33
YAW RATE SEN

3
6105J_D-BU_0.35_ESP 6105K_D-BU_0.35_ESP
CAM-H
CAN_L
20
2
17SK8118A04
FL31_A
2501AA_BN_0.35_GTWY 2501M_BN_0.35_GTWY
CAN_H
14
PT_
SP15200
GATEWAY
㖇ީ
2500AA_BN/WH_0.35_GTWY 2500M_BN/WH_0.35_GTWY
CAN_L
PT_
4
FL31_A
EL01
SP772
2501F_BN_0.35_GTWY&4WD 2500M_BN/WH_0.35_GTWY&ESSS
CAN_H
CAN_L
࠼ࣞಞ⭫᧝࡬ঋ‫ݹ‬
23
9
どু⴪⍷⭫Ⓠ
DCDC
TCCU
SP771
2500F_BN/WH_0.35_GTWY&4WD 2501M_BN_0.35_GTWY&ESSS
CAN_H
CAN_L
22
8
FL2IP_2
IP2FL_2
SP775
2500A_BN/WH_0.35_GTWY 2500E_BN/WH_0.35_GTWY 2500B_BN/WH_0.35_GTWY
6
SP776
2501A_BN_0.35_GTWY 2501E_BN_0.35_GTWY 2501B_BN_0.35_GTWY
33
GB2FL
3 FL2GB
IP08_A
GB02
㠠ࣞ਎䙕㇧᧝࡬ঋ‫ݹ‬
2500K_BN/WH_0.35_AT 2500L_BN/WH_0.35_AT
CAN-H
2500G_BN/WH_0.35_SRSH
10
CAN-L
11
TCU
2501K_BN_0.35_AT 2501L_BN_0.35_AT
CAN-L
2501G_BN_0.35_SRSH
11
CAN-H
2
12
EB02_K1
SRS ECU
IP08_C
2501N_BN_0.35_GTWY&NLE 2.0T
CAN-L
SP773
B_D_
44
2500H_BN/WH_0.35_SRSL&GTWY
CAN-L
EMS(NLE 2.0T)
32
(NLE 2.0T) 2500N_BN/WH_0.35_GTWY&NLE 2.0T
CAN-H
SP774
B_D_
2501H_BN_0.35_SRSL&GTWY
45
CAN-H
31
EN2EB_G
25 EB2EN_G
EB2IP_1
6 IP2EB_1
BT07_B
2501DB_BN_0.35_4G69 2501DA_BN_0.35_GTWY&4G69 2500DC_BN/WH_0.35_GTWY
CAN-L
38
⭫࣑ࣞࣟ䖢ੇ
EPS ECU
᧝࡬ঋ‫ݹ‬
Circuit Diagram
CAN Bus System
2500DB_BN/WH_0.35_4G69 2500DA_BN/WH_0.35_GTWY&4G69 2501DC_BN_0.35_GTWY
CAN-H
39
24
5
EB02_K
2501D_BN_0.35_GTWY&(2.8FGT/2.8VGT)
CAN-L
B_D_
87
EMS
49-82
2500D_BN/WH_0.35_GTWY&(2.8FGT/2.8VGT)
CAN-H
B_D_
66
Circuit Diagram
49-83
IP02
17SK8118A05
6436B_WH_0.35_-GTWY 6436A_WH_0.35_-GTWY 6436_WH_0.35_-GTWY
CAN_L
15
SP781
SP779
CLUSTER
Ԡ㺞
SP782
SP780
6437B_BN/WH_0.35_-GTWY 6437A_BN/WH_0.35_-GTWY 6437_BN/WH_0.35_-GTWY
CAN_H
14
4 IP2EB_1
EB2IP_1
EB04
IP28
CAN_1M
6436L_WH_0.35_-GTWY 6436J_WH_0.35_-GTWY 6436K_WH_0.35_-GTWY
CAN_L
14
14
⭫ᆆどᇐ㌱㔕
ABS/ESP
䈀ᯣ᧛ਙ
᧝࡬ঋ‫ݹ‬
OBD
6437L_BN/WH_0.35_-GTWY 6437J_BN/WH_0.35_-GTWY 6437K_BN/WH_0.35_- GTWY
CAN_1P
CAN_H
26
6
IP08_C
IP14
6436M_WH_0.35_-GTWY&ESP 6437N_BN/WH_0.35_SRSL-GTWY
CAN_H
CAN_L
31
4
ANGLE SEN
STEERING
SRS ECU
6437M_BN/WH_0.35_-GTWY&ESP 6436N_BN/WH_0.35_SRSL-GTWY
CAN_H
CAN_L
IP01_A
32
3
6436C_WH_0.35_-GTWY 6436D_WH_0.35_-GTWY 6436P_BN/WH_0.35_-GTWY
CAN_L
41
SP787
SP783
SP785
BCM
SP788
SP784
SP786
6437C_BN/WH_0.35_-GTWY 6437D_BN/WH_0.35_-GTWY 6437P_BN/WH_0.35_-GTWY
CAN_H
42
6437TE_BN/WH_
6436TE_WH_
0.35_-GTWY
0.35_-GTWY
FL2IP_2
12 IP2FL_2
GB2FL
2 FL2GB
GB02
2503R_WH_0.35_-GTWY 6436T_WH_0.35_-GTWY
CAN-L
11
SP15204
TCU
SP15203
2502R_BN/WH_0.35_-GTWY 6437T_BN/WH_0.35_-GTWY
CAN-H
10
11
3
6437H_BN/WH_
0.35_-GTWY
0.35_-GTWY
6436H_WH_
EN2EB_G
25 EB2EN_G
EB2IP_1
6 IP2EB_1
EB2IP_1
33 IP2EB_1
EN03
2501DB_BN_0.35_4G69 6436GA_WH_0.35_-GTWY&4G69 6436F_WH_0.35_GTWY 6436Q_WH_0.35_GTWY&(TRAILER/4WD)

CAN-L
38
SP789
EMS(4G69)
GTWY&(TRAILER/4WD)
(4G69)
6436R_WH_0.35_
SP790
GTWY&(TRAILER/4WD)
2500DB_BN/WH_0.35_4G69 6437GA_BN/WH_0.35_-GTWY&4G69 6437F_BN/WH_0.35_GTWY 6437Q_BN/WH_0.35_GTWY&(TRAILER/4WD)
CAN-H
6437R_BN/WH_0.35_
39
24
6
EB02_K
6436G_WH_0.35_-GTWY&(2.8FGT/2.8VGT)
CAN-L1
B_D_
87
EMS
FL70
CAN Bus System
CAN-H
6437G_BN/WH_0.35_-GTWY&(2.8FGT/2.8VGT)
CAN-H1
4
B_D_
66
ᤌ䖜᧝࡬ঋ‫ݹ‬
SP792
EB02_K1
TCCU
SP791
2501NA_BN_0.35_-GTWY&NLE 2.0T
CAN-L
B_D_
44
CAN-L
EMS(NLE 2.0T)
5
(NLE 2.0T)
TL01
6437S_BN/WH_0.35_-GTWY&(TRAILER/4WD)
CAN-H
8
࠼ࣞಞ᧝࡬ঋ‫ݹ‬
2500NA_BN/WH_0.35_-GTWY&NLE 2.0T
CAN-H
B_D_
45
TCCU
6436S_WH_0.35_-GTWY&(TRAILER/4WD)
CAN-L
9
Circuit Diagram
Auxiliary Device
B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ B+ 人ؓ䲟ѓⴈ B+ ਇࣞᵰ㡧ؓ䲟ѓⴈ

UEC PRE-FUSE BOX UEC
U-R4 STARTER
䎭ࣞ㔝⭫ಞ
U-JF2 P-MCE U-FS6
87 U-JF4 U-FS21
DCDC2/ DCDC1 TRAILER
IEC PWR1 IEC PWR5
COOLING FAN 40A PWR
U-FS22 30A 30A
40A 30A
STARTER
10A
55 2 5 18 24
EB01 EB01 EB01
IP07
B7 B8 B6 B5 69 B4 B3 46
6NAC_PL_0.5
U-R2 ACC RELAY

I-R3 䱺Ԭ⭫Ⓠ㔝⭫ಞ
I-FS42 I-FS41 I-FS40 I-FS39 ⛯⚡㔝⭫ಞ I-FS33 I-FS37 87 I-FS21
IG Relay TRAILER TRAILER
DCDC2-2 DCDC2-1 DCDC-2 DCDC-1 OBD/TPMS/RF
PWR1 PWR2
25A 25A 25A 25A I-FS5 I-FS18 10A
25A 25A
TMPS/ISRM/ESSS INCERTER/TRAILER
10A 10A
19 16 15 14 13 17 B12 B11 38 52
IP07_E IP07
6NAC_PL_0.5_ESSS
1263CB_RD_2.0_ESSS
1263CA_RD_2.0_ESSS
1263CB_RD/YE_2.0_ESSS
1262CA_RD/YE_2.0_ESSS
840_RD/WH_0.5
1542A_RD_2.0
1540A_RD_2.0
1140C_RD/WH_0.5_ALL
4740_RD/WH_0.5
A
IP28
5 29 28 IP2FL_2 A3 IP2FL_1 16
35 38 37 40 39 IP2FL_2 FL2IP_2 FL2IP_1 PWR
840EA
1542E
1540E
1140A
FL2IP_2
6NAE_PL_0.5_ESSS
1263DE_RD_2.0_ESSS
1263DA_RD_2.0_ESSS
1263PB_RD/YE_2.0_ESSS
1262PA_RD/YE_2.0_ESSS
4740BC_RD/WH_0.5_ESSS
1840AC_RD_0.5_ESSS
䈀ᯣ᧛ਙ A
FL70 OBD
3 13 1 16
IGN VBAT VBAT ACC SIG_GND GND
5 4
IP28
ᤸ䖜⁗ඍ
750DA_BK_0.5_ALL
750DE_BK_0.5_ALL
TRAILER ECU
TRAILER BRAKE R_POSI L_POSI R_ BACK L_ R_
GND GND SW SIG _SLG _SLG FOG UP TURN TURN
FL31_B FL31_A 24 21 14 23 33 21 11 12 9 8
FL70
26 2 1 6 5 26 5
1650TE_BK_2.5_TRAILER
1650TA_BK_2.5_TRAILER
8008_OG_0.5_TRAILER
8807_PK_0.5_TRAILER
8806_L-BL_0.5_TRAILER
8805_GY_0.5_TRAILER
8804_D-GN_0.5_TRAILER
8803_D-BL_0.5_TRAILER
8802_BN/BL_0.5_TRAILER
8801_BN_0.5_TRAILER
START DCB2-2 DCB2-1 DCB1-2 DCB1-1 VBAT IGN
⴪⍷਎ᦘ⁗ඍ
DCDC
OUT2-2 OUT2-1 OUT1-2 OUT1-1 GND GND GND
6 5 2 1 21 4 3
FL31_A FL31_B
242EGE_RD_2.0
242EGA_RD_2.0
242FD_RD/BK_2.0_ESS
242ED_RD/BK_2.0 AT&ESS
1150NC_BK_0.5_ESSS
1150NE_BK_2.0
1150NA_BK_2.0
H G F E D C B A FL2CH
CH2FL
8008A_OG_0.5
8807A_PK_0.5
8806A_L-BL_0.5
8805A_GY_0.5
8804A_D-GN_0.5
8803A_D-BL_0.5
8802A_BN/BL_0.5
8801A_BN_0.5
242EG_RD_2.0_ESSS
1150N_BK_2.5_ESSS
G_FLL1_2 G_IP5_1
H G F E D C B A FL2CH
CH2FL
PIN8 PIN7 PIN6 PIN5 PIN4 PIN3 PIN2 PIN1
᣿䖜᧛ਙ
TRAILER
IP07
48 49 47
I-FS23 I-FS24 I-FS25 G_FFL2_4 G_FFL1_4
IEC
17SK8119A01
49-84
Circuit Diagram
、
Auxiliary Device
B+
U-JF4
IEC PWR1 ਇࣞᵰ㡧䲟ѓⴈ
30A UEC
5 4
EB01
IP07
69 41 49
85 30
I-R3
⛯⚡㔝⭫ಞ
IG RELAY I-FS14
86 87
INVERTER Ԡ㺞ᶵؓ䲟ѓⴈ
I-FS19 I-FS17
I-FS18 25A IEC
INVERTER/
CIGAR LIGHTER IZV OUTLET
TRAILER
15A 15A
10A
45 39 37 38 34
1140C_PD/WH_0.5 IP07
4640_PD/WH_1.5
1042A_RD/BK_0.75
249A_WH_0.5_ALL
1001_D-GN_0.75_CI GAR
SP403 A2 A3 IP2FL_1
FL2IP_1
1042_RD/BK_0.75
1140A_PD/WH_0.5
4640A_PD/WH_0.5
SP413 FL60
IP29 IP74 3 2
1 2
12V DC
⛯✕ಞ 220V䘼਎ಞ
12V䗉࠰ਙ
CIGAR 220V INVERTER
12V OUTLET
LIGHTER 220V AC
2 1 1
IP29 IP74 FL60
249_WH_0.5_ALL
650CG_BK_0.75_C/GAR
750LT_BK_0.75_12V DC
2050V_BK_1.5_INV
G_IP6 G_IP5_2 G_FLR2_1

IP01_B
6
PAR/ACC RELAY
䖜䓡᧝࡬⁗ඍ
BCM
17SK8119A02
49-85
Circuit Diagram
Power Window System
850WC_BK_0.5_ALL
3
DD06
G_IPL_5
850Z_BK_0.5_ALL 850PZ_BK_0.5_ALL 850WB_BK_0.5_ALL
13 DRD2IP_2
19 7 22 8
850WA_BK_0.5_ALL
IP2DRD_2
249EE_WH_0.5_SHOT
249EA_WH_0.5_ANTIPN
7 DDR2IP_1
IP2DDR_1
249E_WH_0.5_ALL
UNLOCK
MASTER
7177A_BU/BK_0.5_ALL 7177_BU/BK
22
13
SW
2
IP01_B
䖜䓡᧝࡬⁗ඍ
7176A_BU/YE_0.5_ALL 7176_BU/YE
BCM
MACER
LOCK
47
24
SW
1
IP01_A
1382_PU/WH_0.5_ALL 1382_PU/WH
DIM
5
6
IP01_C
G_FLBR_1
2350WB_BK_0.5 1382E_PU/WH_0.5
B10B9 B8 B7 B6
8 1 2 4 10
9 3 7 11 5
6 5 4 3 2 FL2RRD_1
2350WA_BK_0.5 6859D_YE/BK_0.5 6859_YE/BK
5 9 8
4 12 10
671_BN_1.5 171A_GY_0.5 171_GY_0.5
䲃⭫ᵰ
਩੄ॽ
1 2
670_D-BU_1.5 170A_L-GN_1.5 170_L-GN_1.5

249KE_WH_0.5 4042D_D-BL_1.5
7
249A_WH_0.5
RRD2FL_1
49
䲃ᔶީ
਩੄ॽ
ѱ傴催⧱⪹ॽ䲃ᔶީ
WIN’S SW_DD
G_FLBL_1
2150WB_BK_1.5 1382F_PU/WH_0.5
B5 B4 B3 B2 B1 IP2FL_1
8 1 2 4 10
9 3 7 11 5
6 5 4 3 2 FL2RLD_1
2150WA_BK_1.5 6859C_YE/BK_0.5
669_BN_1.5 169A_PL_0.5 169_PL_0.5
䲃⭫ᵰ
ᐜ੄ॽ
1 3
668_D-BU_1.5 168A_D-GN_0.5 168_D-GN_0.5
2
6 DDR2IP_2
2491E_WH_0.5 4040D_RD/WH
IP2DDR_2
7
2491A_WH_0.5
RLD2FL_1
FL2IP_1
49
䲃ᔶީ
ᐜ੄ॽ
G_IPL_2
G_FLBR_1
1550WB_BK_0.5 1382GA_PU/WH_0.5
8 1 2 4 10
9 3 7 11 15
6 5 4 3 2 IP2PAD_1
1550WA_BK_0.5 6859BA_YE/BK_0.5
с䲃⭫ᵰ
ࢥ傴ж䭤
667_BN_1.5 167E_TN_0.5 167_TN_0.5

21 23
1
4 3 DDR2IP_1
666_D-BU_1.5 166E_YE_0.5 166_YE_0.5

2
249GA_WH_0.5 4040PA_RD/WH_1.5
DD08
IP2DDR_1
7
249G_WH_0.5_ALL
PAD2IP_1
䲃ᔶީ
ࢥ傴ॽ
с䲃⭫ᵰ
ѱ傴ж䭤
165_BN_1.5_SHOT
1
2 1
164_D-BL_1.5_SHOT
2
G_IPL_3
DD06
22
1 3 2 5 4
ѱ傴ॽ䲃ᔶީ
7628_D-GN/PL_0.35
15 17 14
MICOM
165A_BN_0.35
164A_D-BL_0.35
4040CB_RD/WH_1.5_ANTPIN
DD08
4040CA_RD/WH_1.5
4
DD06
䖜䓡᧝࡬⁗ඍ
RAP/ACC RELAY
249_WH_0.5_ALL
BCM
6
IP01_6
104
B+
30A
IEC PWR2
U-JF5
109
88
25A
WIN_RR
PWR_
I-FS32
WIN-R
PWR
I-R7
86
25A
WIN_RD
PWR_
I-FS30
101
87
UEC
25A
WIN_RL
PWR_
I-FS31
107
60A
PWR WINDOW
U-JF11
4040C_RD/WH_1.5_ALL
WIN-L
PWR
I-R6
85
2 DRD2IP_1
25A
WIN_DD
PWR_
I-FS29
IP2DRD_1
IEC
I-R2 ACC RELAY
䱺Ԭ⭫Ⓠ
249D_WH_0.5_ALL 1140C_RD/WH_0.5_ALL
IEC
38
87
SP426
SP044
10A
INVERTER
I-FS18
17SK8120A01
49-86
Circuit Diagram
49-87
17SK8121A01
EB01 B+
65 21
30 85
U-FS9 U-MD1 U-JF6 U-JF7 U-JF4 U-FS3
U-R9
A/C COOLING IEC PWR3 IEC PWR4 IEC PWR1 IEC PWR6
A/C
COMPRESSCR FAN 600W 30A 30A 30A 30A
COMPRESSCR
87 86
15A 80A
66 6 7 4 15
EB01
59_D-GN_0.75_-HOT&(2.8FGT/2.8VGT)
IP07
59N_D-GN_0.75_-HOT&NLE 2.0T
63 64 27 28 6 68 69 51
59G_D-GN_0.75_-HOT&4G69
87
I-JF2 I-JF3 I-JF15 I-JF16 I-FS6 I-FS26
I-R10 I-R3
SEAT_ADJ_DRV SEAT_ADJ_PAS HEAT SEAT DRU HEAT SEAT PAS TCU/SHIFT/ AC PANEL/AFS/
HRW& IG
25A 10A 10A 10A AC PANEL/AFS LDW/RLS
MIRROR RELAY
10A 30
10A
33 27 66 67 35 36 18 40
IP07_B IP07_B IP07
4440_RD/WH_1.5_RRDEFROST/SPHCM/SPHM
842_RD/WH_0.5_ALL
IP07_B
7133A_BN_0.5_ALL
24 19 26 22
2940C_RD/WH_0.5_RRDEFROST/SPHCM/SPHM
30 85 30 85
EB2EN_N EB2EN_G EB2BT I-R8 I-R9
6 11 Ԡ㺞ؓ䲟ѓⴈ
EN2EB_N EN2EB_G 8 BT2EB SEAT SEAT
1865A_BN_1.5_PST
FL62_A
288A_YE_1.5_PST HEAT-DRU HEAT-PAS IEC
59A_D-GN_0.75_-HOT&(2.8FGT/2.8VGT)
1 87 86 87 86
59AN_D-GN_0.75_-HTOL&NLE 2.0T
PWR
23 17 25 20
59AG_D-GN_0.75_-HOT&4G69
IP07_B SP031 SP026

੄ネ䲚䵒
2479A_D-BU_0.5_FSHF
REAR WIN HEATER
5961_GY_0.5_FSHF
2077A_PK_0.5_FSHF
182_YE_0.5_FSHF
3340_RD/WH_0.5_ALL
7133B_BN_0.5_ALL
GND
1
FL62_B
2250H_BK_1.5_RRDEFROST
4440BA_RD/WH_1.5_RRDEFROST
SP023
4440B_RD/WH_1.5_RRDEFROST
IP38_B IP38_A
D5 D6 D7 D8 IP2FL_1 13 14 5 10
EN07_N EN07 BT11 FL2IP_1
2479D_D-BU_0.5_FSHF
LEFT_ RIGHR_ IGN VBAT
1 1 1 IP01_B
2077D_PK_0.5_FSHF
HEAT HEAT
1865_BN_1.5_PST
NLE 2.0T 4G69
43
288_YE_1.5_PST
MIRROR&HRW RELAY
グ䈹ু㕟ᵰ FRT A/C CONT PNL
A/C COMPRESSOR 䖜䓡᧝࡬ঋ‫ݹ‬
BCM
14 15 1 16
IP38_A IP38_B
G_FLC1_1
650HD_BK_0.5
650HB_BK_0.5
650HC_BK_0.5
650HA_BK_0.5
IP2FL_1 1 1 1 1
D4
HEATER BATT
HEATER BATT
FL2IP_1 SW SW
ѱ傴ᓝ ࢥ傴ᓝ
RATT ѱ傴ᓝἻ RATT ࢥ傴ᓝἻ
Ἳࣖ✣ Ἳࣖ✣
HEATER GND
HEATER GND
䈹㢸⭫ᵰ 䈹㢸⭫ᵰ
SEAT SEAT
SEAT ADJST SEAT ADJST
HEATER HEATER
SW _DRV SW _PSA SP912
GND GND _DRV _PSA
2 2 2 2
650_BK_1.0
2050H_BK_0.5_FSHE
1750H_BK_0.5_EFHF
1750_BK_1.5_PST
2050_BK_1.5_PST
HVAC System
G_IP6
G_FLL2_1 G_FLR2_2 G_FLL2_2 G_FLR2_3
17SK8121A02
27 IP2EB_1
EB2IP_1
IP38_A
OUT TOOR
6120NA_YE/BK_0.5_NLE2.0T 6120N_YE/BK_0.5_NLE2.0T
SENSOR
POS
20
⧥ູ⑟ᓜՖ᝕ಞ
AMBIENT SEN
407NA_TN_0.5_NLE2.0T
NEG
1
A/C PRESSURE
グ䈹ু࣑Ֆ᝕ಞ
EB02_K
SP16099
SEN
SP853
EB13
EB13
G_R_PAC
COMPRESS SENSOR
407_TN_0.5 407NC_TN_0.5_AT&HTOL&NLE2.0T 407N_0.5_TN 407NB_TN_0.5_AT&HTOL&NLE2.0T 214-D-BU_0.5_AT&HTOL&(2.8FGT/2.8VGT)

GND
GND
GND
13
25
17
1
1
FRT A/C CONT PNL
U
SENSOR
I_A_PAC
380N_OG/BK_0.5_AT&HTOL&NLE2.0T 380NA_OG/BK_0.5_AT&HTOL&NLE2.0T 380_OG_0.5_AT&HTOL&(2.8FGT/2.8VGT)
VOUT
VOUT
19
51
32
2
2
P
597N_GY_0.5_AT&HTOL&NLE2.0T 597NA_GA_0.5_AT&HTOL&NLE2.0T 2700_GY_0.5_AT&HTOL&(2.8FGT/2.8VGT)
SEN 5V
5V PAC
V_V_
18
50
26
+5V
+5V
3
203A_L-BU_0.5_AT&(2.8FGT/2.8VGT)
G_EBR1_3
EMS
A/C PRESSURE SW
ACC MED
1150HS_BK_0.75_MT-HTOL 204_D-BU_0.5_MT&HTOL&(2.8FGT/2.8VGT)
GND
I_S_
75
MID
2
3
グ䈹ু࣑ᔶީ
IP2EB_2
53 EB2IP_2
IP38_B
762_D-BL_0.5_HTOL 603_D-GN_0.75_MT&HTOL&(2.8FGT/2.8VGT) 203_L-BU_0.75_MT&HTOL&(2.8FGT/2.8VGT)
ACC SW
LOW
I_S_
37
11
AC
H1
1
26 EB2EM_G
EN2EB_G
760_PU/WH_0.5
FB_SIG LPM
10
EB03
BLOWER_
761C_OG_0.5
12
A/C PRESSURE SW
SWITCH+
REOEST
603G_D-GN_0.75_MT&HTOL&4G69 203G_L-BU_0.5_MT&HTOL&4G69 203GA_L-BU_0.5_MT&HTOL&4G69
LOW
79
A/C
H1
1
G_EBR1_3
グ䈹ু࣑ᔶީ
IP07
EMS(4G69)
(4G69)
84
FRT BLOWER FB
PRESSURE
SWITCH
1150HS_BK_0.75_MT-HTOL&4G69 204G_D-BU_0.5_MT&HTOL&4G69 204GA_D_BU_0.5_MT&HTOL&4G69
MIDOLE
GND
27
40
MID
2
3
I-FS28
Ԡ㺞ؓ䲟ѓⴈ
10A
Circuit Diagram
761A_RD/WH_3.0
A/C RES/
䈹䙕⁗ඍ
STANCE
76
IEC
UEC
BLOWER
FRT BLOWER
I-R1
HVAC System
WNTROL
FRT BLOWER
G
ࢃ啉伄ᵰ
85
86
G_IP6
650HR_BK_4.0
MOT
5
U-JF9
EB01
GND
IP07
40A
MOTOR+ MOTOR- BLOWER
7572_RD_4.0 761B_OG_4.0 761_OG_4.0
30
87
B+
FEED BACK
70
72
D
9
49-88
SP854
Circuit Diagram
HVAC System
FRT A/C CONT PNL

INLET_ INLET_ REAR_DEFOG_ INDOOR_ SENSOR_ EVAP_ ACTUATOR_ ACTUATOR_ ACTUATOR_ MODE_ MODE_ ACTUATOR_ TEMP_ TEMP_
MOTOR+ MOTOR- CONTROL ILL SENSOR GND SENSOR 5V MODE_FB GND MOTOR+ MOTOR- TEMP_FB MOTOR+ MOTOR-
2 3 8 12 7 13 9 17 2 16 4 5 3 6 7
IP38_B IP38_A IP38_B IP38_A IP38_B
1382C_PU/WH_0.5
734_D-GN_0.5_AT A/C
407_TN_0.5
6137_GY_0.5
597_GY_0.5
1791_YE_0.5
193_WH_0.5_RRDEFROST/SPHCM/SPHM
SP423
SP852
2274_BN/OG_0.5
1614_D-GN_0.5
1382A_PU/WH_0.5
SP851
SP853
6102_TN_0.5_AT A/C
6138_TN_0.5
597A_GY_0.5
2275_L-GN_0.5
1791A_YE_0.5
119_WH_0.5
2273_TN_0.5
597B_GY_0.5
733_L-BU_0.5
1791B_YE_0.5
1199_D-BU_0.5
2210_L-GN_0.5
SP425
1382_PU/WH_0.5
IP01_A IP01_C
4 5 26 5 1 2 1 2 3 2 1 4 5 3 2 1 4 5
SIG
MOTOR+
MOTOR-
REAR_DEMSIT SW
DEMSIT ILL
VCC
GND
GND
SIG
+5V
SIG
+5V
GND
GND
MOTOR-
MOTOR-
MOTOR+
MOTOR+
᯦伄䰞ᢝ㺂ಞ 䖜䓡᧝࡬ঋ‫ݹ‬ 䖜޻⑟ᓜՖ᝕ಞ ࢃ㫮ਇಞ ⁗ᕅ伄䰞ᢝ㺂ಞ どᇐ伄䰞ᢝ㺂ಞ

FRESH CYC ACTUATOR BCM INDOOR TEMP SEN ⑟ᓜՖ᝕ಞ MODE MOT AIR MIX TEMP MOT
EVAP TEMP SEN
17SK8121A03
49-89
Circuit Diagram
Advanced Driver Assistance System
B+ ᧝࡬ਦᔶީᐜ‫ם‬
CONSOLE SW_L
J-FS3
IEC PWR6 ਇࣞᵰ㡧ؓ䲟ѓⴈ
30A UEC 䖜䚉‫⿱څ‬ᔶީ
15 LED+ GND LED-

EB01 1 4 6 10 12
Ԡ㺞ؓ䲟ѓⴈ
8012_D-GN_0.5_LDW
8011_BN_0.5_LDW
1382S_PU/WH_0.5_ALL
750CL_BK_0.5_LDW
750CM_BK_0.5_ALL
IP07
51 IEC
I-R3 IG RELAY
⛯⚡㔝⭫ಞ
850PB_BK_0.5_ADAS/PGAM/RLS/PEPS
I-FS26 87
AC PANEL/AFS
10A
57 17
IP07 SP914
SP425
7133A_BN_0.5_ALL
840_RD/WH_0.5
1382_PU/WH_0.5_ALL
750_BK_1.5_ALL
SP026 SP030
RF2IP_1
24
7133C_BN_0.5_LDW
840F_RD/WH_0.5_LDW
IP2RF_1
IP01_C
850RS_BK_0.5_LDW
5
DIMMER ILL G_IP5_1 G_IPL_4
䖜䓡᧝࡬⁗ඍ
BCM
13 18 15 14 IP2FR_1
FR2IP_1
7133AA_BN_0.5_LDW
840FA_RD/WH_0.5_LDW
8012A_D-GN_0.5_LDW
8011A_BN_0.5_LDW
850RW_BK_0.5_LDW
12 6 9 5 3
VBAT IGN L_S_IM O_S_OUT1 GND
䖜䚉‫⿱څ‬䖻ࣟ᧝࡬ঋ‫ݹ‬
LDW
17SK8122A01
49-90
Circuit Diagram
49-91
12 FL2CH_2
CH2FL_2
17SK8122A02
K CH2PR
PR2CH
FL59
5860N_L-GN/WH_0.5 5860NA_L-GN/WH_0.5_BSD&2.0T
(2.0T)
GND
21
5861N_PK_0.5 5861NA_PK_0.5_BSD&2.0T
SIG RR POWER SIG RL
11
7
5969N_GY_0.5 5969NA_GY_0.5_BSD&2.0T
10
M
5
5863N_OG_0.5 5863NA_OG_0.5_BSD&2.0T
23
13
L
IP2EB_2
EB2IP_2
FL2IP_2
50 IP2FL_2
5859_YE_0.5 5859A_YE_0.5 5859B_YE_0.5_BSD 5859C_YE_0.5_BSD
⴨॰ⴇ⎁ᐜࢃ
BSD SEN_FL
PWR
PWR
1
1
5854_PU_0.5 5854A_PU_0.5 5854E_PL_0.5_BSD 5854E_PL_0.5_BSD
51
SIG
SIG
2
2
5855_PK/BK_0.5 5855A_PK/BK_0.5 5855B_PK/BK_0.5_BSD 5855C_PK/BK_0.5_BSD
GND
GND
17
52
3
5859D_YE_0.5_BSD
⴨॰ⴇ⎁਩ࢃ
BSD SEN_FR
PWR
1
⴨॰ⴇ⎁᧝࡬ঋ‫ݹ‬
5857_WH_0.5 5857A_WH_0.5 5857E_WH_0.5_BSD 5857E_WH_0.5_BSD

BSD ECU
18
53
31
SIG
SIG
2
5860D_PK/BK_0.5_BSD
CH2PR
PR2CH
EB2CH
CH2EB
GND
3
5969_GY_0.5 5969A_GY_0.5 5969E 5969C 5969D_GY_0.5 5969E_GY_0.5_BSD
⴨॰ⴇ⎁ᐜ੄
BSD SEN_RL
PWR
PWR
54
32
M
5
1
5861_PK_0.5 5861A_PK_0.5 5861E 5861C 5861D_PK_0.5_BSD
SIG
55
33
SIG
7
2
J
5860_L-GN/WH_0.5 5860A_L-GN/WH_0.5 5860B 5860C 5860D_L-GN/WH_0.5 5860E_L-GN/WH_0.5_BSD
GND
GND
21
56
34
K
7
3
5969F_GY_0.5_BSD
⴨॰ⴇ⎁਩੄
BSD SEN_RR
PWR
1
SWN SIG RR
5863_OG_0.5 5863A_OG_0.5 5863B 5863C_OG_0.5 5863D_OG_0.5_BSD

23
57
35
SIG
L
8
2
MIRPOR_
IP2DRD_1
6 DRD2IP_1
੄㿼䮒
5860F_L-GN/WH_0.5_BSD
傴催‫ם‬
GND
3
2IP_1
RD_1
SP905
13 IP2D
DRD
DD
Advanced Driver Assistance System
G_IPL_2 G_IPR_2
5853_PK_0.5_BSD 5853A_PK_0.5 5853B_PK_0.5 850BS_BK_0.5_BSD 850DZ_BK_0.5 850Z_BK_0.5_ALL
LED RR
12
10
7
SP907
FL59
5856_BN_0.5_BSD 5856A_BN_0.5 5856B_BN_0.5 1550BS_BK_0.5_BSD 1550DZ_BK_0.5 1550_BK_0.5_ALL

LED RR
16
13
10
IGN
PAD2IP_2 7
PAD2IP_2 6
8
IP2PAD_2
IP2PAD_2
੄㿼䮒
ࢥ傴‫ם‬
MIRPOR_
PD
EPK/BCM/PEPS
⛯⚡㔝⭫ಞ
IG RELAY
IEC PWR10
36 IP2FL_2
FL2IP_2
I-R3
SP028
U-JF4
I-FS2
30A
10A
5240_RD/YE_0.5_ALL 5858_TN_0.5_BSD 5858A_TN_0.5_BSD
B+
69
14
4
G_IPL_1
Ԡ㺞ؓ䲟ѓⴈ
850BC_BK_0.5_ALL
60
ਇࣞᵰ㡧
ؓ䲟ѓⴈ
UEC
IEC
䖜䓡᧝࡬⁗ඍ
IGN RELAY
5199_YE_0.5_ALL
BCM
58
48
Circuit Diagram
Grounding(LHD)
ᰬ䫕ᕯ㉝ ᐜ㓺ਾᔶީ ⭫ᆆ䖢ੇḧ䬷 ж䭤੥ࣞᔶީ 䈹‫ݿ‬ᔶީ Ԡ㺞 ਩㓺ਾᔶީ ᚈ᩼䀈䙕ᓜՖ᝕ಞ

CLOCK COMBINE ESCL START/STOP DIMMER SW CLUSTER COMBINE YAW RATE SEN
SORING SW_LP SW SW_WIPER
HORN- GND GND SSB_GND2 GND GND GND_PWR GND_PWR IMMO LP GND GND
1 6 6 7 8 3 16 17 32 1 1
IP50_A IP03 IP26 IP20 IP12 IP02 IP04 IP13
850HS_BK_0.5
850LS_BK_0.5
850ES_BK_PEPS
850BT_BK_PEPS
850BN_BK_0.5_PEPS
850LM_BK_0.5_HALP
850KA_BK_0.5
850KB_BK_0.5
850KC_BK_0.5
850LL_BK_0.5
20888_BK_0.5_EPS
SP902
850A_BK_0.75
Ԡ㺞ᶵؓ䲟ѓⴈ
IEC
ᰬ䫕ᕯ㉝ ᰖ䫛ॏ㌱㔕᧝࡬ঋ‫ݹ‬ 䈹‫ݿ‬ᔶީ I-R3 I-R1

CLOCK PEPS_FCV DIMMER SW IG RELAY BLOWFR
SORING
ILL_GND KL31_1(GND) KL31_2(GND) LED-
6 14 15 6 60 71
IP50_C IP09_A IP12 IP01
850PE_BK_PEPS
850PS_BK_0.5_PEPS
850BC_BK_0.5
850BE_BK_0.5
850SW_BK_0.5_RCSW//10-SCREEN
850SA_BK_0.5
SP901
850_BK_1.5
G_IPL_1
17SK8123L01
49-92
Circuit Diagram
Grounding(LHD)
ѱ傴 ѱ傴ж䭤ॽ䲃
⧱⪹ॽ䲃ᔶީ Ჰ㜳⭫ᵰ ੄京⚥ ࢃ京⚥ 䴞䠅䱩‫ݿ‬Ֆ᝕ಞ 䖜䚉‫⿱څ‬䖻ࣟ 㠠ࣞ䱨ⵟⴤ RF᧛᭬ಞ
WIN’S SMART WIN REAR FRT ROOM LP RAIN LIGHT ᧝࡬ঋ‫ݹ‬ ޻੄㿼䮒 RF
SW_DD MOT_DO ROOM LP SEN LDW ISRUM CONTROLLER
(STO)KL31 GND GND ON GND GND GND GND GND
3 1 2 4 5 2 3 2 3
DD06 DD07 RF04 RF03 RF08 RF10 RF07 RF11
850WC_BK_1.5_SHOT
850WD_BK_1.5_ANTIPION
850RL_BK_0.5_PZLP
850RQ_BK_0.5_FRLP
850RN_BK_0.5_FRLP
850RR_BK_0.5_RLS
850PW_BK_0.5_LDW
850RM_BK_0.5_PGAM
850RF_BK_0.5_PEPS
SP904
SP903
SP906
850DY_BK_1.5
850RP_BK_0.5_FRLP//PZLP
850RS_BK_0.75
22 DR2IP-1 RF2IP-1
IP2DRD 23 24 IP2RF-1
850PA_BK_1.5
850PB_BK_0.5_FRLP//PZLP
850OS_BK_0.75_LDW//PGAM//RLS//PEPS
G_IPL_3 G_IPL_4 G_IPL_2
17SK8123L02
49-93
Circuit Diagram
Grounding(LHD)
ѱ傴
⋯㇧ⴌᔶީ 傴催઎䰞䬷傴催઎䰞ᣀᢁཟ㓵 ⧱⪹ॽ䲃ᔶީ 傴催઎‫ם‬ཌ੄㿼䮒 ཌ੄㿼䮒䈹㢸ᔶީ
FUEL FLAP LOCK MOT_DO PEPS ANT_DO WIN’S MIRROR_DD MIRROR_ADJ SW
SW SW_DO
GND_TURN &
LED- GND STATUS- GND GND TAIL-KL31 GND LED- HEATER GND
1 3 B B 2 7 19 10 5 3
DD01 DD04_A DD04_B DD01 DD08 DD03 DD11
850DE_BK_0.35
850DF_BK_0.35
850DA_BK_0.5
850DB_BK_0.5
850DT_BK_0.35
850WA_BK_0.5
850WB_BK_0.5
850BS_BK_0.5_BSD
850DN_BK_0.35
850DM_BK_0.5
SP905
850DZ_BK_0.5
DRD2IP_2
13
IP2DRD_2
850Z_BK_0.5
G_IPL_5
17SK8123L03
49-94
Circuit Diagram
Grounding(LHD)
㠠䘸ᓊࢃཝ⚥᧝࡬ঋ‫ݹ‬ 䖜䓡᧝࡬ঋ‫ݹ‬
AFS FW BCM
KL30_REAR KL30_FRT KL30_FUEL GND GND
G_G_GND SGND4 SGND3 FOLD_GND WASH_GND FLAP_GND SIG_1 SIG_2
7 8 4 4 19 21 7 9
IP11 IP01_B IP01_A IP01_E IP01_C
1550AF_BK_0.5_XELP
1550BG_BK_0.5
1550BF_BK_0.5
1550BM_BK_0.5_SPHCM
1550BC_BK_0.5
1550BD_BK_0.5
1550BA_BK_2.5
1550BB_BK_0.5
SP922
155OB_BK_1.5
G_IPR_1 G_IPR_3
17SK8123L04
49-95
Circuit Diagram
Grounding(LHD)
਩੄䰞⧱⪹ॽ䲃ᔶީ ࢥ傴催䰞ᣀᢁᔶީ ࢥ傴催䰞䬷 ࢥ傴催‫ם‬ཌ੄㿼䮒

STD WIN’S PEPS ANT_PD LOCK MOT_PD MIRROR_PD
SW_RR
GND TURN &
KL31 TAIL- GND STATUS GND HEATER LED-
1 8 2 C C 5 10
RR04 PD01 PD04_A PD04_B PD03
1550WA_BK_1.5
1550WB_BK_0.5
1550DT_BK_0.35_PEPS
1550DA_BK_0.5
1550DB_BK_0.5_PEPS
1550DM_BK_0.35
1550BS_BN_0.5_BSD
SP907
䖜䓡᧝࡬ঋ‫ݹ‬ ࢥ傴催䰞⧱⪹ॽ䲃ᔶީ
BCM STD WIN’S
SW_PD
GND_PWR KEY_COM
22 3
IP01_C PD06
1150BE_BK_2.5
1550DZ_BK_0.5
6859BA_YE/BK_0.5
22 PAD2IP_1 6 PAD2IP_2 5 PAD2IP_1

IP2PAD_1 IP2PAD_2 IP2PAD_1
1550PA_BK_1.5
1550_BK_0.5
1150PB_BK_0.5
G_IPR_2
17SK8123L05
49-96
Circuit Diagram
49-97
17SK8123L06
EN03
PWR GND3
450GC_BK_2.5_4G69
3
EMS(4G69)
δ*ε
EN2EB_G
1 EB2EN_G
SP4340
PWR GND2
450GB_BK_2.5_4G69 450GA_BK_2.5_4G69 450G_BK_2.5_4G69

2
EB02_K
G.G.BAT_1 K06
450C_BK_2.5_2.8FGT//2.8VGT
6
SP102
G.G.BAT_1 K04
G_EBR3
EMS
450B_BK_2.5_2.8FGT//2.8VGT 450_BK_2.5_2.8FGT//2.8VGT
4
G.G.BAT_1 K02
450A_BK_2.5_2.8FGT//2.8VGT
2
EB02_K1
G.G.EL K04
ਇࣞᵰ᧝࡬ঋ‫ݹ‬δ1(/7ε
450NC_BK_2.5_NLE2.0T
4
EMS(NLE2.0T)
SP2502
G.G.EL K02
450NB_BK_2.5_NLE2.0T 450N_BK_2.5_NLE2.0T
2
G.G.EL K01
450NA_BK_2.5_NLE2.0T
1
CH2FL_N
14 FL2CH_N
FL2EB_N
A1 EB2FL_N
SP170
਩੄㓺ਾ⚥
CH02
COMBINE
LP_RR
TURN GND
550LG_BK_0.5 550R_BK_0.5_NLE2.0T 550NA_BK_0.5_NLE2.0T 550N_BK_0.5_NLE2.0T
7
Grounding(LHD)
CH2EB
30 EB2CH
ᐜ੄㓺ਾ⚥
CH01
COMBINE
G_EBR1-4
LP_RL
TURN GND
550LT_BK_0.5 550L_BK_0.5_2.8FGT//2.8VGT//4G69 550L_BK_0.5_2.8FGT//2.8VGT//4G69
7
Circuit Diagram
Grounding(LHD)
࡬ࣞ䱨ᣧ↱㌱㔕グ䈹ু࣑ᔶީ ߭প伄᡽ ߭প伄᡽

ࢃ㡧ⴌᔶީ ⅝ӊ人✣᧝
䖜䓡⭫ᆆどᇐ㌱㔕᧝࡬ঋ‫ݹ‬ A/C : :
HOOD ADJ ࡬ಞδ9*7ε
ABS/ESP PRESSURE COOLING COOLING
SW GCU_EUS
SW FAN(480W) FAN(600W)
GND_MOTOR GND_ECU GND GND GND BLACK GND
13 38 3 2 1 2 6
EB04 EB70 EB12 EB21 EB22 EB54
250A_BK_4.0_ESP
250B_BK_1.5_ESP
1050HA_BK_0.5_PEPS//ESSS
1150HS_BK_0.75_MT&-HTOL
1250_BK_6.0_480W
1250N_BK_10.0_NELE2.0T&600W
1250A_BK_8.0_4G69&600W
1050GC_BK_2.5_2.8VGT
G_EBL3-1 G_EBL3-2 G_EBR1-2 G_EBR1-3 G_EBL2-1 G_EBL2-2
17SK8123L07
49-98
Circuit Diagram
Grounding(LHD)
⟹⋯ࣖ✣
ᐜࢃ䴴⚥ ᐜࢃ㓺ਾཝ⚥ ᐜ஽ਣ ਩஽ਣ ࢃẛ⿱ਾಞ
FUEL FILTER
FOG LP_FL HEAD LP_LH HORN_L HORN_R FRT CLUTCH
HEATER
GND GND_H GND_L GND_T GND GND NEG NEG GND GND
2 1 3 5 11 8 2 2 E A
1050LF_BK_0.5
1050LA_BK_0.75
1050LB_BK_0.75
1050LC_BK_0.5
1050LD_BK_0.5
1050LE_BK_0.5
1050HL_BK_1.0
1050HR_BK_1.0
1050FC_BK_1.0
1050FH_BK_2.5_2.8FGT/2.8VGT
SP910
1050A_BK_1.0
SP911
ӂᶷ㇗
DIODE
1050_BK_3.0
SPD2
1050UD_BK_3.0
G_EBL2_3
17SK8123L08
49-99
17SK8123L09
CH2FL_N
18 FL2CH_N
FL2EB_N
B1 EB2FL_N
RC2CH
C CH2RC
6206GNB_BN/OG_0.5_(RACAM//BSV) & NLE2.0T 6202GNA_BN/OG_0.5_(RACAM//BSV) & NLE2.0T 550CNB_BK_0.5_RACAM & NLE2.0T

‫و‬䖜੄㿼䮒᩺‫܅‬ཪ
PARKING CAM
RC2CH
C CH2RC
CH2EB
34 EB2CH
RC01
G_EBR2-2
550CA_BK_0.5_RCAM//BSV 6202GA_BN/OG_0.5_(RACAM//BSV) & (2.8FGT//2.8VGT//4G69) 550C_BK_0.5_(RACAM//BSV) & (2.8FGT//2.8VGT//4G69)
GND
3
FUEL PUMP
CH08
⟹⋯⌫
550G_BK_2.5_4G69//NEL2.0T
GND
2
LICENSE LP_RL
PR2CH
C CH2PR
ᐜ੄⢂➝⚥
PR01
550LJ_BK_0.5
CH2FL_N
6 FL2CH_N
NEG
FL2EB_N
B5 EB2FL_N
2
550ANB_BK_2.5_NLE2.0T 550ANA_BK_2.5_NLE2.0T 550AN_BK_2.5_NEL2.0T
CH2EB
36 EB2CH
SP915
ᐜ੄㓺ਾ⚥
CH01
COMBINE
G_EBL2-3
LP_RL
550LC_BK_0.5 550PL_BK_0.75_2.8FGT//2.8VGT 550A_BK_0.75_2.8FGT//2.8VGT
GND
4
Circuit Diagram
Grounding(LHD)
550GL_BK_2.5_4G69 550GM_BK_2.5_4G69
঍䶔ᐜ੄⢂➝⚥
LICENSE LP_
CH09
RL(ZAF)
550LA_BK_0.5-PDC
NEG
49-100
Circuit Diagram
Grounding(LHD)
ࢃグ䈹᧝࡬䶘ᶵ 䈹䙕⁗ඍ ⛯✕ಞ

FRT A/C CONT PNL A/C RESISRANCE CIGAR LIGHT
GND GND GND GND PGND GND
14 15 1 16 5 2
IP38_A IP38_B IP32 IP29
650HA_BK_0.5
650HB_BK_0.5
650HC_BK_0.5
650HD_BK_0.5
650HR_BK_4.0
650CG_BK_0.75_CIGAR
SP912
650_BK_1.0
G_IP6
17SK8123L10
49-101
17SK8123L11
ACTUATOR
FUEL FLAP
CH13
ࣖ⋯ਙⴌ
ᢝ㺂ಞ
550F_BK_0.5
GND
1
PR04 PR04
RADAR_R
550RW_BK_0.35_PDC
GND
PR2CH
਩‫ם‬䴭䗴
H CH2PR
CH2EB
31 EB2CH
2
SP916
SP703
550RY_BK_0.35_PDC 550RZ_BK_0.35_PDC 550RR_BK_0.35_PDC 550S_BK_0.5_0.75_2.8FGT//2.8VGT//4G69 550B_BK_0.5_0.75_2.8FGT//2.8VGT//4G69

GND
PR03
RADAR_L
ᐜ‫ם‬䴭䗴
550RX_BK_0.35_PDC 550RL_BK_0.35_PDC
GND
CH2FL_N
16 FL2CH_N
FL2EB_N
B6 EB2FL_N
EN2EB_N
13 EB2EN_N
550BNB_BK_0.75_NLE2.0T 550BNA_BK_0.75_NLE2.0T 550BN_BK_0.75_NLE2.0T

UNKNOW
FUNCTION PIN1
650B_BK_0.5_NLE2.0T
WATER PUMP
SP923
≪⌫
650A_BK_1.0_NLE2.0T 650A_BK_0.75_NLE2.0T
GND
14
EB01
ਇࣞᵰ㡧
ؓ䲟ѓⴈ
G_EBR2_1
UEC
1050UW_BK_1.5
146
CH2EB
22 EB2CH
CH14
WIF SEN
⋯≪࠼⿱
Ֆ᝕ಞ 1050WFA_BK_0.75_2.8FGT//2.8VGT 1050WF_BK_0.75_2.8FGT//2.8VGT
GND
1
BRAKE LEVEL
࡬ࣞ⏨⏨փ
EB28
Ֆ᝕ಞ
SEN 1050BL_BK_0.5
GND
FRT WIPER
ࢃ䴞ࡤ⭫ᵰ
EB08
MOT
350WA_BK_1.5
GND
4
Circuit Diagram
BOOST PRESSURE
໔ুু࣑ᢝ㺂ಞ
EN2EB
30 EB2EN
Grounding(LHD)
ACTUATOR
SP908
CH01
350EN_BK_0.75_2.8FGT//2.8VGT 350_BK_1.0
GND
WASH PUMP
ࢃ伄ネ⍍⏚⌫
EB07
FRT WIN
49-102
350WB_BK_0.5
GND
2
Circuit Diagram
Grounding(LHD)
9⭫Ⓠᨈᓝ ᭬丩ᵰ ၧ҆㌱㔕ѱᵰ

12V OUTLET RADIO MP5
GND GND GND
1 8 8
IP14 IP56_A IP55_B
750LT_BK_0.75_12VDC
1450R_BK_2.5_RADIO
1450M_BK_2.5_10-SEREEN
⭫࣑ࣞࣟ䖢ੇ
᧝࡬ঋ‫ݹ‬ ᆿ‫≊ޞ‬ഀ᧝࡬ঋ‫ݹ‬ ሮᱴ⽰ኅ 䖜㚊㖇᧝࡬ঋ‫ݹ‬
EPS_ECU SRS ECU 10 SCREEN T-BOX
BATT GND GND GND KL31 GND
1 17 15 6 40 3
IP07_A IP08_C IP08_A IP57 IP60
1050N_BK_10.0_EPS
1350L_BK_0.5_SRSL
1350H_BK_0.5_SRSL
1450S_BK_0.5_10-SEREEN
1450T_BK_0.5_TBOX
1450B_BK_0.5_TBOX
G_BT1 G_IP5_2 G_IP3 G_IP4_1 G_IP4_2 G_IP4_3
17SK8123L12
49-103
Circuit Diagram
Grounding(LHD)
ᚈ᩼䀈
傧ࣞ䖢ᦘᔶީ ਎䙕ಞᬃ㓫ᵼ ধ䲟䆜ᣛ⚥ᔶީ ၧ҆᧝࡬ᔶީ 䱨ⴍ⁗ඍB%&0 䙕ᓜՖ᝕ಞ
DRV MODE SW GEAR SHIFT HAZZARD SW MP5 CONTEOL IMMO_BCM YAM RATE SEN
P_SW_ BACK LIGHT_
SW
ILL GND GND OUTPUT(GND) (GND) ILL- GND LED- LED- GND
3 6 4 11 1 4 6 2 1
IP71 IP59 IP27 IP53 IP16 IP13
750TA_BK_0.5_4WD
750TB_BK_0.5_4WD
750TC_BK_0.5_AT
750TD_BK_0.5_AT
750HA_BK_0.5
750HB_BK_0.5
750MS_BK_0.5_10_SCREEN
750MN_BK_0.5_PEPS
2088A_BK_0.5_ESP
SP913
䈀ᯣ᧛ਙ ѣཤ᧝࡬㓺ᔶީBᐜ ѣཤ᧝࡬㓺ᔶީB਩

OBD CONSOLE SW_L CONSOLE SW_R
SIG_GND GND GND LED- LED- GND
5 4 10 12 2 2
EN28 EN05 IP06
750DA_BK_0.5
750DB_BK_0.5
750CL_BK_0.5_LDW
750CM_BK_0.5
750A_BK_1.0
750CT_BK_0.5_XELP//ESP
750CS_BK_0.5_XELP//ESP
SP914
750A_BK_1.5
G_IP5_1
17SK8123L13
49-104
Circuit Diagram
Grounding(LHD)
ᐜ੄⧱⪹ॽ䲃ᔶީ ᐜ੄䰞䬷 ࠼ࣞಞ᧝࡬ঋ‫ݹ‬ ਩੄⧱⪹ॽ䲃ᔶީ ਩੄䰞䬷

STD WIN’S SW_RL LOCK MOT_RL TCCU STE WIN’S SW_RR LOCK MOT_RR
KL31 TAIL- STATUS- GND GND KL31 TAIL- SRARUS-
1 8 B 25 12 1 8 C
RL04 RL02 FL01 RR04 RR02
2150WA_BK_1.5_RREGL
2150WB_BK_0.5_RREGL
2150DA_BK_0.5_RREGL
2150TA_BK_2.0_4WD
2150TB_BK_2.0_4WD
2350WA_BK_1.5_RREGL
2350WB_BK_0.5_RREGL
2350DA_BK_0.5_RREGL
SP917 SP918
2150Z_BK_0.5_RREGL
2350DZ_BK_0.5_RREGL
1 RL2FL_2 1 RL2FL_1 1 RR2FL_2 1 RR2FL_1

FL2RL_2 FL2RL_1 FL2RR_2 FL2RR_1
2350P_BK_1.5_RREGL
2350_BK_0.5_RREGL
2150A_BK_1.5_RREGL
2150B_BK_0.5_RREGL
G_FLBL_1 G_FLBL_2 G_FLBR_1
17SK8123L14
49-105
Circuit Diagram
Grounding(LHD)
ѱ傴ᆿ‫ޞ‬ᑜ 㠠ࣞ਎䙕ಞ ‫و‬ᥗᔶީB07

δᵠ㌱ᨆ䟈ε 㖇ީ ᤌ䖜᧝࡬ঋ‫ݹ‬ どু⴪⍷⭫Ⓠ ᧝࡬ঋ‫ݹ‬ ᡪ㧡ᯥ
BUCKLE_DRV GATEWAY TRAILER ECU DC DC TCU REVESE SW_
6MT DYMOS
GND KL31 KL31 GND GND KL31 GND GND GND GND
2 20 6 12 24 21 5 1 1 2
FL07 FL02_A FL02_B FL70 FL31_A GB02 GB03_1 GB03_C GB03_2
1650_BK_0.5
1650GA_BK_0.75_GTWY
1650GB_BK_0.75_GTWY
1650TB_BK_2.5_TRAILER
1150N_BK_2.5_ESSS
350TK_BK_0.5_AT
750TXA_BK_0.5_6MT-DYMOS & NLE2.0T
750TX_BK_0.5_6MT-DYMOS & NL(2.8FGT//2.8VGT)
750TXB_BK_0.5_6MT-DYMOS & NLE2.0T

GB2FL
16
350TA_BK_0.5_AT 1 FL2GB
750TE_BK_0.5_MT
G_FLLI_1 G_FLLI_3 G_FLLI_2 G_FLLI_4 G_FLBR_2 G_FLBR_3
17SK8123L15
49-106
Circuit Diagram
Grounding(LHD)
‫و‬ᥗᔶީB07⡧‫ؗ‬ ‫و‬ᥗᔶީB07р⊳ ‫و‬ᥗᔶީB07р⊳

REBERSE SW_5MT AISIN REVERSE SW_6MT SAIC REBERSE SW_5MT SAIC
GND GND GND GND GND
1 1 1 2 1
GB03_A GB03_5 GB03_B GB03_4 GB03_D
750TZ_0.5_5MT_AISIN
750TYA_BK_0.5_6MT_SAIC & NLE2.0T
750TX_BK_0.5_6MT_SAIC & (2.8FGT//2.8VGT)
750TYB_BK_0.5_6MT_SAIC & NLE2.0T
750TW_BK_0.5_5MT_SAGM & (2.8FGT//2.8VGT//4G69)
GB2FL
1 FL2GB
350TE_BK_0.5_MT
G_FLBR_3
17SK8123L16
49-107
Circuit Diagram
Grounding(LHD)
ᆿ‫≊ޞ‬ഀ
᧝࡬ঋ‫ݹ‬ ੄ᧈ਩‫ם‬ᆿ‫ޞ‬ᑜ ੄ᧈѣ䰪ᆿ‫ޞ‬ᑜ ੄ᧈᐜ‫ם‬ᆿ‫ޞ‬ᑜ ੄䲚䵒ࣖ✣
SRS ECU BUCKLE_RR BUCKLE_RM BUCKLE_RL REAR WIN HEATER
ANALOG_GND GND GND GND GND
6 3 2 2 1
IP08_A FL52 FL53 FL51 FL62_B
1361_L_BU_0.5_SRSH
1361B_L_BU_0.5_(SRSH//SRSL) & SBR
1361C_L_BU_0.5_(SRSH//SRSL) & SBR
1361D_L_BU_0.5_(SRSH//SRSL) & SBR
2250H_BK_1.5_RRDERROST
22 IP2FL_2
FL2IP_2
1361A_L_BU_0.5_SRSH
SP651
1850_BK_0.5_SRSL & (FSBR//SBR)
G_FLRI G_FLCL_1
17SK8123L17
49-108
Circuit Diagram
Grounding(LHD)
ѱ傴催ᓝἻ ࢥ傴催ᓝἻ
ѱ傴催ᓝἻࣖ✣ ࢥ傴催ᓝἻࣖ✣
儎փ࡯䖜⚥ 㜄ুⴇ⎁᧝࡬ঋ‫ݹ‬ 䈹㢸⭫ᵰ SEAT 䈹㢸⭫ᵰ SEAT
CHMSL TPMS ECU SEAT HEATER_DVR SEAT HEATER_PAS
LP- GND GND
ADJUST_DVR
GND GND
ADJUST_PAS
GND GND
2 6 18 2 2 2 2
FL61 FL30 FL03 FL05 FL04 FL06
2250LC_BK_0.5_CHMSL
2250TA_BK_0.5_TPMS
2250TB_BK_0.5_TPMS
1750_BK_1.5_PST
1750H_BK_0.5_FSHF
2050_BK_1.5_PST
2050_BK_0.5_FSHF
G_FLCL_2 G_FLCL_3 G_FLL2_1 G_FLL2_2 G_FLR2_2 G_FLR2_3
17SK8123L18
49-109
Circuit Diagram
Grounding(LHD)
⴨॰ⴇ⎁᧝࡬ঋ‫ݹ‬ どু⴪⍷⭫Ⓠ 9䘼਎ಞ

BSD ECU DC DC 220V INVERTER
GND KL31 GND
32 21 1
FL59 FL31_B FL60
1750DB_BK_0.5BSD
1150NC_BK_0.5_ESSS
2050V_BK_1.5_INV
G_FLL2_3 G_FLL2_4 G_FLR2_2
17SK8123L19
49-110
Circuit Diagram
49-111
17SK8123L20
CH2FL_N
13 FL2CH_N
FL2EB_N
B4 EB2FL_N
PR2CH
D CH2PR
LICENSE LP_RR
PR02
਩੄⢂➝⚥
550LK_BK_0.5 550LM_BK_0.5_PDC 550PRN_BK_0.75_NLE2.0T 1150AN_BK_0.75_NLE2.0T 1150ANA_BK_0.75_NLE2.0T

NEG
CH2EB
B4 EB2CH
COMBINE LP_RR
SP921
CH02
G_EBR1_1
਩੄㓺ਾ⚥
550LD_BK_0.75 550PR_BK_0.75_2.8FGT/2.8VGT/4G69 1150A_BK_0.75_2.8FGT/2.8VGT/4G69

GND
4
LICENSE LP_RR
঍䶔਩੄⢂➝⚥
CH10
(EAF)
550LB_BK_0.5_PDC
GND
2
EB33
FOG LP_FR
਩ࢃ䴴⚥
1150LF_BK_0.5_FFOG
GND
2
EB40
SP909
1150LE_BK_0.5 1150_BK_1.0
GND
8
1150LD_BK_0.5
GND
11
HEAD LP_RH
਩ࢃ㓺ਾཝ⚥
1150LC_BK_0.5
GND_T
5
1150LB_BK_0.75
GND_L
Grounding(LHD)
3
1150LA_BK_0.75
GND_H
1
Circuit Diagram
Grounding(RHD)
਩㓺ਾᔶީ
ᰬ䫕ᕯ㉝ ᐜ㓺ਾᔶީ ⭫ᆆ䖢ੇḧ䬷 ж䭤੥ࣞᔶީ 䈹‫ݿ‬ᔶީ Ԡ㺞 ᚈ᩼䀈䙕ᓜՖ᝕ಞ
COMBINE
CLOCK SPRING COMBINE SW_LP ESCL START/STOP SW DIMMER CLUSTER YAW RATE SEN
SW_WPER
HORN GND GND SSB_GND2 GND GND GND_PWR GND_PWR IMMOLP GND GND
1 6 6 7 8 3 16 17 32 1 1
IP50_A IP03 IP26 IP20 IP12 IP02 IP04 IP13
850HS_BK_0.5
850LS_BK_0.5
850ES_BK_0.5_PEPS
850BT_BK_0.5_PEPS
850BN_BK_0.5_PEPS
850LM_BK_0.5_HALP
850KA_BK_0.5
850KB_BK_0.5
850KC_BK_0.5
850LL_BK_0.5
20888_BK_0.5_ESP
SP902
Ԡ㺞ᶵؓ䲟ѓⴈ
IEC
ᰬ䫕ᕯ㉝ ᰖ䫛ॏ㌱㔕᧝࡬ঋ‫ݹ‬ I-R3 I-R1 䈹‫ݿ‬ᔶީ

CLOCK SPRING PEPS_ECU IG RELAY BLOWER DIMMER SW
ILL_GND KL31_1(GND) KL31_2(GND) LED-
1 14 15 60 71 6
IP50_C IP09_A IP07 IP12
850SW_BK_0.5_RCSW/I.0-SCREEN
850PE_BK_0.5_PEPS
850PS_BK_0.75_PEPS
850A_BK_0.75
850BC_BK_0.5
850BE_BK_0.5
850SA_BK_0.5
SP901
850_BK_1.5
G_IPL_1
17SK8123R01
49-112
Circuit Diagram
Grounding(RHD)
䖜䓡᧝࡬⁗ඍ ਩੄䰞⧱⪹ॽ䲃ᔶީ ࢥ傴催䰞ᣀᢁᔶީ ࢥ傴催䰞䬷 ࢥ傴催‫ם‬ཌ੄㿼䮒

BCM STD WIN’S SW_RR PEPS ANT_PD LOCK MOT_PD MIRROR_PD
GND TVRN&
GND_PWR KL31 TAIL- GND STATUS- GND HEATER LED-
22 1 8 2 C C 5 10
IP01_C RR04 PD01 PD04_A PD04_B PD03
1150BE_BK_2.5
1550WA_BK_1.5
1550WB_BK_0.5
1550DT_BK_0.35_PEPS
1550DA_BK_0.5
1550DB_BK_0.5_PEPS
1550DM_BK_0.35
1550BS_BN_0.5_BSD
SP907
1550DZ_BK_0.5
22 PAD2IP_1 6 PAD2IP_2
IP2PAD_1 IP2PAD_2
1550PA_BK_1.5
1550_BK_0.5
G_IPL_2
17SK8123R02
49-113
Circuit Diagram
Grounding(RHD)
䖜䚉‫⿱څ‬䖻ࣟ
੄京⚥ ੄京⚥ 䴞䠅䱩‫ݿ‬Ֆ᝕ಞ 㠠ࣞ䱨⛡ⴤ੄㿼䮒
᧝࡬ঋ‫ݹ‬ RF CONTROLLER
REAR ROOM LP FRT ROOM LP RAIN LIGHT SEN ISRVM
LDW
GND ON GND GND GND GND GND
2 4 5 2 3 2 3
RF04 RF03 RF08 RF10 RT07 RF11
850RL_BK_0.5_PZLP
850RQ_BK_0.5_FRLP
850RN_BK_0.5_FRLP
850RR_BK_0.5_RLS
850RW_BK_0.5_LDW
850RM_BK_0.5_PGAM
850RF_BK_0.5_PEPS
SP903 SP904
850RP_BK_0.5_FRLP/PZLP
850RS_BK_0.75
RF2IP_1
23 24 IP2RF_1
850PB_BK_0.5_FRLP/PZLP
G_IPL_3 G_IPL_4
17SK8123R03
49-114
Circuit Diagram
Grounding(RHD)
㠠䘸ᓊࢃཝ⚥
䖜䓡᧝࡬⁗ඍ
᧝࡬ঋ‫ݹ‬
BCM
AFS ECU
KL30_REAR KL30_FRT KL30_FUEL
G_G_GND SGND4 SGND3 FOLD_GND WASH_GND FLAP_GND GND SIG_1 GND SIG_2
7 8 4 4 19 21 7 9
IP11 IP01_B IP01_A IP01_E IP01_C
1550AF_BK_0.5_XELP
1550BG_BK_0.5
1550BF_BK_0.5
1550BM_BK_0.5_SPHCM
1550BC_BK_0.5
1550BD_BK_0.5
1550BA_BK_2.5
1550BB_BK_2.5
SP922
1550B_BK_1.5
G_IPR_1 G_IPR_3
17SK8123R04
49-115
Circuit Diagram
Grounding(RHD)
⋯㇧ⴌᔶީ 傴催઎䰞䬷傴催઎䰞ᣀᢁཟ㓵 ѱ傴⧱⪹ॽ䲃ᔶީ 傴催઎‫ם‬ཌ੄㿼䮒 ཌ੄㿼䮒䈹㢸ᔶީ

FUEL FLAP SW LOCK MOT_DO PEPS ANT_DO WIN’S SW_DD MIRROR_DD MIRROR_ADJ SW
GND_TURN&
LED- GND STATUS- GND GND TAIL- LED- HEATER GND
1 3 B B 2 7 10 5 3
DD01 DD04_A DD04_B DD01 DD08 DD03 DD11
850DE_BK_0.35
850DF_BK_0.35
850DA_BK_0.5
850DB_BK_0.5
850DT_BK_0.35
850WA_BK_0.5
850BS_BK_0.5_BSD
850DN_BK_0.35
850DM_BK_0.5
SP905
ѱ傴ж䭤ॽ䲃
ѱ傴⧱⪹ॽ䲃ᔶީ Ჰ㜳⭫ᵰ 䖜䓡᧝࡬⁗ඍ
WIN’S SW_DD SMART WIN BCM
MOT_DD
KL31 KL31 GND GND_PWR
3 19 2 22
DD06 DD08 DD07 IP01_C
850WC_BK_1.5_1SHOT
850WB_BK_0.5
850WD_BK_1.5_ANTIPIN
850DZ_BK_0.5
1550BE_BK_2.5
SP906 13 DRD2IP_2
IP2DRD_2
850DY_BK_1.5
850Z_BK_0.5
22 DRD2IP_1
IP2DRD_1
850PA_BK_1.5
G_IPR_2
17SK8123R05
49-116
Circuit Diagram
Grounding(RHD)
ᐜ੄㓺ਾ⚥ ਩੄㓺ਾ⚥ ਇࣞᵰ᧝࡬ঋ‫ݹ‬ ਇࣞᵰ᧝࡬ঋ‫(ݹ‬4G69)

COMBINE LP_RL COMBINE LP_RR EMS EMS(4G69)
G_G_BAT_1 G_G_BAT_2 G_G_BAT_3 POWER POWER
TURN GND TURN GND K02 K04 K06 GROUND2 GROUND3
7 7 2 4 6 2 3
CH01 CH02 EB02_K EB03
550LT_BK_0.5
550LG_BK_0.5
450A_BK_2.5_2.8FGT/2.8VGT
450B_BK_2.5_2.8FGT/2.8VGT
450C_BK_2.5_2.8FGT/2.8VGT
450GB_BK_2.5_4G69
450GC_BK_2.5_4G69
SP170 SP102 SP4340
550L_BK_0.5_2.8FGT/2.8VGT/4G69
450_BK_2.5_2.8FGT/2.8VGT
450GA_BK_2.5_4G69
CH2EB EN2EB_G
30 EB2CH 1 EB2EN_G
550_BK_0.5_2.8FGT/2.8VGT/4G69
450G_BK_2.5_4G69
G_EBR4 G_EBR3
17SK8123R06
49-117
Circuit Diagram
Grounding(RHD)
࡬ࣞ䱨ᣧ↱㌱㔕 ߭প伄᡽(480W) ⅝ӊ人✣᧝࡬ಞ

ࢃ㡧ⴌᔶީ グ䈹ু࣑ᔶީ
䖜䓡⭫ᆆどᇐ㌱㔕᧝࡬ঋ‫ݹ‬ COOLING (VGT)
HOOD ADJ SW A/C PRESSURE SW
ABS/EPS FAN(480W) GCU_EUS
GND_MOTOR GND_ECU GND GND GND GND
13 38 3 2 1 6
EB04 EB70 EB12 EB21 EB54
250A_BK_4.0_ESP
250B_BK_1.5_ESP
1150HS_BK_0.75_MT&-HTOL
1250_BK_6.0_480W
1050GC_BK_2.5_2.8VGT
G_EBL3_1 G_EBL3_2 G_EBR1_2 G_EBR1_3 G_EBL2_1 G_EBL2_2
17SK8123R07
49-118
Circuit Diagram
Grounding(RHD)
⟹⋯ࣖ✣
ᐜࢃ䴴⚥ ᐜࢃ㓺ਾཝ⚥ ᐜ஽ਣ ਩஽ਣ ࢃẛ⿱ਾಞ
FUEL FILTER
FOG LP_FL HEAD LP_LH HORN_L HORN_R FRT CLUTCH
HEATER
GND GND_H GND_L GND_T GND GND NEG NEG GND GND
2 1 3 5 11 8 2 2 E A
1050LF_BK_0.5
1050LA_BK_0.75
1050LB_BK_0.75
1050LC_BK_0.5
1050LD_BK_0.5
1050LE_BK_0.5
1050HL_BK_1.0
1050HR_BK_1.0
1050FC_BK_1.0_EFAC
1050FH_BK_2.5_2.8FGT/2.8VGT
SP910
1050A_BK_1.0
SP911
ӂᶷ㇗
DIODE
1050_BK_3.0
SPD2
1050UD_BK_3.0
G_EBL2_3
17SK8123R08
49-119
17SK8123R09
RC2CH
C CH2RC
CH2EB
C EB2CH
‫و‬䖜੄㿼䮒᩺‫܅‬ཪ
PARKING CAM
RC01
G_EBR2_2
550CA_BK_0.5_RCAM/BSV 6202GA_BN/OG_0.5_(RCAM/BSV)&(2.8FGT/2.8VGT/4G69) 550C_BK_0.5_RCAM&(2.8FGT/2.8VGT/4G69)
GND
3
CH08
FUEL PUMP
⟹⋯⌫
550G_BK_2.5_4G69/NLE2.0T
GND
PR2CH
C CH2PR
LICENSE LP_RL
PR01
ᐜ੄⢂➝⚥
550LJ_BK_0.5 550LN_BK_0.5_PDC
NEG
CH2EB
36 EB2CH
COMBINE LP_RL
SP915
CH01
ᐜ੄㓺ਾ⚥
G_EBL2_3
550LC_BK_0.5 550PL_BK_0.75_2.8FGT/2.8VGT 550A_BK_0.75_2.8FGT/2.8VGT
GND
4
550GL_BK_2.5_4G69 550GM_BK_2.5_4G69
LICENSE LP_RL
঍䶔ᐜ੄⢂➝⚥
CH09
(EAF)
550LA_BK_0.5_PDC
NEG
2
Circuit Diagram
Grounding(RHD)
49-120
Circuit Diagram
Grounding(RHD)
ࢃグ䈹᧝࡬䶘ᶵ 䈹䙕⁗ඍ ⛯✕ಞ

FRT A/C CONT PNL A/C RESIS TANCE CIGAR LIGHT
GND GND GND GND GND GND
14 15 1 16 S 2
IP38_A IP38_B IP32 IP29
650HA_BK_0.5
650HB_BK_0.5
650HC_BK_0.5
650HD_BK_0.5
650HR_BK_4.0
650CG_BK_0.75_CIGAR
SP912
650_BK_1.0
G_IP6
17SK8123R10
49-121
Circuit Diagram
Grounding(RHD)
ࢃ伄ネ⍍⏚⌫ ࣖ⋯ਙⴌᢝ㺂ಞ
ࢃ䴞ࡤ⭫ᵰ ⋯≪࠼⿱Ֆ᝕ಞ ᐜ‫ם‬䴭䗴
FRT WIN FUEL FLAP
FRT WIPER MOT WIF SEN RADAR_L
WASH PUMP ACTUATOR
GND GND GND GND GND
2 4 1 2 1
EB07 EB08 CH14 PR03 CH13
໔ুু࣑ᢝ㺂ಞ
࡬ࣞ⏨փՖ᝕ಞ ਇࣞᵰ㡧ؓ䲟ѓⴈ ਩‫ם‬䴭䗴
BOOST PRESSURE
BRAKE LEVEL SEN UEC RADAR_R
ACTUATOR
GND GND GND GND GND
2 2 146 1 2
EB28 EB01 PR04
EN2EB
350WB_BK_0.5
350WA_BK_1.5
1050BL_BK_0.5
1050WFA_BK_0.75_2.8FGT/2.8VGT
1050UW_BK_1.5
550RX_BK_0.35_PDC
550RW_BK_0.35_PDC
550RY_BK_0.35_PDC
550F_BK_0.5
22 EB2EN
350EN_BK_0.75_2.8FGT/2.8VGT
SP703
550RZ_BK_0.35_PDC
SP908
CH2EB PR2CH
22 EB2CH G H CH2PR
350_BK_1.0
1050WF_BK_0.75_2.8FGT/2.8VGT
550RL_BK_0.35_PDC
550RR_BK_0.35_PDC
SP916
550B_BK_0.75_2.8FGT/2.8VGT/4G69
550S_BK_0.75_2.8FGT/2.8VGT/4G69
CH2EB
31 EB2CH
G_EBR2_1
17SK8123R11
49-122
Circuit Diagram
Grounding(RHD)
12V⭫Ⓠᨈᓝ ᆿ‫≊ޞ‬ഀ᧝࡬ঋ‫ݹ‬ ᭬丩ᵰ 10ሮᱴ⽰ኅ ၧ҆㌱㔕ѱᵰ 䖜㚊㖇᧝࡬ঋ‫ݹ‬

12V OUTLET SRS ECU RADIO 10 SCREEN MP5 T-BOX
GND GND GND GND GND GND KL31 GND
1 17 15 8 6 8 40 3
IP74 IP08_C IP08_A IP56_A IP57 IP55_B IP60
750LT_BK_0.75_12V DC
1350L_BK_0.5_SRSL
1350H_BK_0.5_SRSH
1450R_BK_2.5_RADIO
1450S_BK_0.5_10-SCREEN
1450M_BK_2.5_10-SCREEN
1450T_BK_0.5_TBOX
1450B_BK_0.5_TBOX
G_IP5_2 G_IP3 G_IP4_1 G_IP4_2 G_IP4_3
17SK8123R12
49-123
Circuit Diagram
Grounding(RHD)
傧ࣞ䖢ᦘᔶީ ਎䙕ಞᬃ㓫ᵼ ধ䲟ᣛ䆜⚥ᔶީ ၧ҆᧝࡬ᔶީ 䱨ⴍ⁗ඍ_BCM ᚈ᩼䀈䙕ᓜՖ᝕ಞ

DRV MODE SW GEAR SHIFT HAZZARD SW MP5 CONTROL SW IMMO_BCM YAW RATE SEN
P_SW_ BACK LIGHT_
ILL GND GND OUTPUT(GND) (GND) ILL- GND LED- GND GND
3 6 4 11 1 4 6 2 1
IP71 IP59 IP27 IP53 IP16 IP13
750TA_BK_0.5_4WD
750TB_BK_0.5_4WD
750TL_BK_0.5_AT
750TD_BK_0.5_AT
750HA_BK_0.5
750HB_BK_0.5
750MS_BK_0.5_10-SCREEN
750MN_BK_0.5_-PEPS
2088A_BK_0.5_-ESP
SP913
䈀ᯣ᧛ਙ ѣཤ᧝࡬㓺ᔶީBᐜ ѣཤ᧝࡬㓺ᔶީB਩

OBD CONSDLE SW_L CONSDLE SW_R
SIG_GND GND GND LED- LED- GND
5 4 10 12 2 6
IP28 IP05 IP06
750DA_BK_0.5
750DB_BK_0.5
750CL_BK_0.5_LDW
750CM_BK_0.5
750A_BK_1.0
750CT_BK_0.5_XELP/ESP
750CS_BK_0.5_XELP/ESP
SP914
750_BK_1.5
G_IP5_1
17SK8123R13
49-124
Circuit Diagram
Grounding(RHD)
ᐜ੄⧱⪹ॽ䲃ᔶީ ᐜ੄䰞䰞䬷 ࠼ࣞಞ᧝࡬ঋ‫ݹ‬ ਩੄⧱⪹ॽ䲃ᔶީ ਩੄䰞䰞䬷

STD WIN’S SW_RL LOCK MOT_RL TCCU STD WIN’S SW_RR LOCK MOT_RR
KL31 TAIL- STATUS- GROUND GROUND KL31 TAIL- LED-
1 8 B 25 12 1 8 C
RL04 RL02 FL01 RR04 RR02
2150WA_BK_1.5_RREGL
2150WB_BK_0.5_RREGL
2150DA_BK_0.5_RREGL
2150TA_BK_2.0_4WD
2150TB_BK_2.0_4WD
2350WA_BK_1.5_RREGL
2350WB_BK_0.5_RREGL
2350DA_BK_0.5_RREGL
SP917 SP918
1 RLD2FL_2 1 RRD2FL_2
FL2RLD_2 FL2RRD_2
2150A_BK_1.5_RREGL
2150DZ_BK_0.5_RREGL
2350P_BK_1.5_RREGL
2350DZ_BK_0.5_RREGL
1 RLD2FL_1 1 RRD2FL_1
FL2RLD_1 FL2RRD_1
2150B_BK_0.5_RREGL
2350_BK_0.5_RREGL
G_FLBL_1 G_FLBL_2 G_FLBR_1
17SK8123R14
49-125
Circuit Diagram
Grounding(RHD)
ѱ傴ᆿ‫ޞ‬ᑜ
㖇ީ ᤌ䖜᧝࡬ঋ‫ݹ‬ 㠠ࣞ਎䙕ಞ᧝࡬ঋ‫ݹ‬ ‫و‬ẙᔶީ_6MTᡪ㧡ᯥ
δᵠ㌱ᨆ䟈ε
GATEWAY TRAILER ECU TCU REVESE SW_6MT DYMOS
BUCKLE_DRV
GND KL31 KL31 GND GND STATUS- GND GND GND
2 20 6 12 24 5 1 1 2
FL07 FL02_A FL02_B FL70 GB02 GB03_1 GB03_C GB03_2
1650_BK_0.5
1650GA_BK_0.75_GTWY
1650GB_BK_0.75_GTWY
1650TB_BK_2.5_TRAILER
350TK_BK_0.5_AT
750TXA_BK_0.5_6MT-DYMOS&NLE2.0T
750TX_BK_0.5_6MT-DYMOS&(2.8FGT/2.8VGT)
750TXB_BK_0.5_6MT-DYMOS&NLE2.0T
GB2FL
16 1 FL2GB
350TA_BK_0.5_AT
350TE_BK_0.5_MT
G_FLL1_1 G_FLL1_3 G_FLL1_2 G_FLBR_2 G_FLBR_3
17SK8123R15
49-126
Circuit Diagram
Grounding(RHD)
‫و‬ẙᔶީ_5MT⡧‫ؗ‬ ‫و‬ẙᔶީ_5MTр⊳
‫و‬ẙᔶީ_6MTр⊳
REVERSE SW_5MT REVERSE SW_5MT
REVERSE SW_6MT SAIC
AISIN SAIC
GND GND GND GND GND
1 1 1 2 1
GB03_A GB03_5 GB03_B GB03_4 GB03_D
750TZ_0.5_5MT-AISIN
750TYA_BK_0.5_6MT-SAIC&NLE2.0T
750TX_BK_0.5_6MT-SAIC&(2.8FGT/2.8VGT)
750TYB_BK_0.5_6MT-SAIC&NLE2.0T
750TW_BK_0.5_5MT_SAGM&(2.8FGT/2.8VGT/4G69)
GB2FL
1 FL2GB
350TE_BK_0.5_MT
G_FLBR_3
17SK8123R16
49-127
Circuit Diagram
Grounding(RHD)
ᆿ‫≊ޞ‬ഀ᧝࡬ঋ‫ݹ‬ ੄ᧈ਩‫ם‬ᆿ‫ޞ‬ᑜ ੄ᧈѣ䰪ᆿ‫ޞ‬ᑜ ੄ᧈᐜ‫ם‬ᆿ‫ޞ‬ᑜ ੄䲚䴴ࣖ✣

SRS ECU BUCKLE_RR BUCKLE_RM BUCKLE_RL REAR WIN HEATER
ANALOG_GND GND GND GND GND
6 3 2 2 1
IP08_A FL52 FL53 FL51 FL62_B
1361_L-BU_0.5_SRSH
1361B_L-BU_0.5_(SRSH/SRSL)&SBR
1361C_L-BU_0.5_(SRSH/SRSL)&SBR
1361D_L-BU_0.5_(SRSH/SRSL)&SBR
2250H_BK_1.5_RRDEFROST
IP2FL_2
22
FL2IP_2
1361A_L-BU_0.5_SRSH
SP651
1850_BK_0.5_SRSL&(FSBR/SBR)
G_FLR1 G_FLCL_1
17SK8123R17
49-128
Circuit Diagram
Grounding(RHD)
儎փ࡯䖜⚥ 㜄ুⴇ⎁᧝࡬ঋ‫ݹ‬ ࢥ傴ᓝἻ䈹㢸⭫ᵰ ࢥ傴ᓝἻࣖ✣ ѱ傴ᓝἻ䈹㢸⭫ᵰ ѱ傴ᓝἻࣖ✣

CHMSL TPMS ECU SEAT ADJUST_PST SEAT HEATER_DRV SEAT ADJUST_DRV SEAT HEATER_DRV
LP- GND GND GND GND GND GND
2 6 18 2 2 2 2
FL61 FL30 FL04 FL06 FL04 FL06
2250LC_BK_0.5_CHMSL
2250TB_BK_0.5_TPMS
2250TA_BK_0.5_TPMS
2050H_BK_0.5_FSHF
1750H_BK_0.5_FSHF
2050_BK_1.5_PST
1750_BK_1.5_PST
G_FLCL_2 G_FLCL_3 G_FLL2_1 G_FLL2_2 G_FLR2_2 G_FLR2_3
17SK8123R18
49-129
Circuit Diagram
Grounding(RHD)
⴨॰ⴇ⎁᧝࡬ঋ‫ݹ‬ 220V䘼਎ಞ
BSD ECU 220V INVERTER
GND GND
32 1
FL59 FL60
1750B_BK_0.5_BSD
2050V_BK_1.5_INV
G_FLL2_3 G_FLR2_1
17SK8123R19
49-130
Circuit Diagram
Grounding(RHD)
঍䶔਩੄⢂➝⚥
਩ࢃ㓺ਾཝ⚥ ਩ࢃ䴴⚥ ਩੄㓺ਾ⚥ ਩੄⢂➝⚥
LICENSE LP_RR
HEADLAMP_RH FOG LP_FL COMBINE LP_RR LICENSE LP_RR
(EAF)
GND_H GND_L GND_T GND GND GND GND GND NEG
1 3 5 11 8 2 2 4 2
EB40 EB33 CH10 CH02 PR02
1150LA_BK_0.75
1150LB_BK_0.75
1150LC_BK_0.5
1150LD_BK_0.5
1150LE_BK_0.5
1150LF_BK_0.5_FFOG
550LB_BK_0.5_PDC
550LD_BK_0.75
550LK_BK_0.5
PR2CH
D CH2PR
550LM_BK_0.5_PDC
SP921
SP909
550PR_BK_0.75_2.8FGT/2.8VGT/4G69
550PRN_BK_0.75_NLE2.0T
CH2FL_N
13 FL2CH_N
1150AN_BK_0.75_NLE2.0T
1150_BK_1.0
CH2EB
28 EB2CH
1150A_BK_0.75_2.8FGT/2.8VGT/4G69
EB2FL_N
B4 FL2EB_N
1150ANA_BK_0.75_NLE2.0T
G_EBR1_1 G_EBR1_1
17SK8123R20
49-131
Circuit Diagram
Enging Management System(4G69)
UEC
U-JF1 U-FS19 U-FS4

U-R8 U-FS4
MAIN RELAY MAIN RELAY FUEL FILTER HEATER/
MAIN RELAY IEC PWR1
30A PWR3 ECU(4G69/NLE2.0T)
30A
15A 25A
1 153 155 154 157 31 58 16 4

EB01
5991G_YE/WH_0.5_4G69
142_RD/BK_0.75_4G69
IP07 Ԡ㺞ؓ䲟ѓⴈ
69 IEC
SP032 SP011
I-FS1
I-R3
ECU
IG Relay
7.5A
68 1 13
IP07
1040_RD/WH_0.5
31 EB2EN_G 28 EB2EN_G
EN2EB_G EN2EB_G
SP024 SP037
5991GA_YE/WH_0.5_4G69
5294C_PK_0.75_4G69
142A_RD/BK_0.75_4G69
2 IP2EB_2
EB2IP_2
1040B_RD/WH_0.5_4G69
EN2EB_G
1 EB2EN_G
450GC_BK_2.5_4G69
450G_BK_2.5_4G69
SP4340 29 EB2EN_G
EN2EB_G
450GB_BK_2.5_4G69
450GC_BK_2.5_4G69
1040BA_RD/WH_0.5_4G69
G_EBR3
EN03
44 5 67 2 3 68
MAIN POWER PROTECTED BATTERY POWER POWER IGNITION
RELAY BATTERY GROUND GROUND
ਇࣞᵰ᧝࡬ঋ‫(ݹ‬4G69)
EMS(4G69)
17SK8124A01
49-132
Circuit Diagram
EMS(4G69)
PRE-02 SENSOR POST-02 SENSOR ETC MOTOR THROTTLE POSITION INTAKE CAMSHAFT
SIGNAL HIGH SIGNAL HIGH LOW SENSOR1 POSITION SENSOR V5 RETURN1
RRE-02 02 SENSOR POST-02 ETC MOTOR THROTTLE POSITION REFERANCE VOLTAGE COOLANT TEMPERATURE ENVIRONMENT PEDAL POSITION
HEATER SIGNAL LOW HEATER HIGH SENSOR2 SOURCE SUPPLY1 SENSOR TEMPERATURE SENSOR1
24 47 73 48 23 20 21 52 27 77 70 74 49 72 41
EN03
1665_PU/WH_0.75_4G69
1653_TN_0.5_4G69
1664_TN_0.75_4G69
631_OG_0.5_4G69
632_PK/BK_0.5_4G69
UEC
1664B_TN_0.45_4G69
1666_PU_0.5_4G69
1667_BN_0.75_4G69
SP4324
SP4327
U-FS19
MAIN RLY SP4328
632D_PK/BK_0.5_4G69
6120GA_YE/BK_0.5_4G69
PWR3
411_D-BU_0.75_4G69
416_GY_0.75_4G69
417_D_BU_0.5_4G69
631B_OG_0.5_4G69
484_WH_0.5_4G69
632B_PK/BK_0.5_4G69
58
EB01
630_TN_0.5_4G69
631A_OG_0.5_4G69
632A_PK/BK_0.5_4G69
SP014
EB2EN_G EN2EB_G
EN2EB_G 16 EB2EN_G 2 34 3
1664BA_TN_0.45_4G69
1666A_PU_0.5_4G69
1667A_BN_0.75_4G69
5294E_PK/BK_0.75_4G69
SP4404
EN2EB_G
5294D_PU/WH_0.5_4G69
2 1 6 5 3 4 EB2EN_G 5 6
632DA_GY_0.5_4G69
631E_OG_0.5_4G69
1162GA_OG_0.45_4G69
632C_PK/BK_0.5_4G69
7421_BU/WH_0.5_4G69
C A B
㢸≊䰞ᢝ㺂ಞ(4G69)
EB2FL 1 3 4 8 THROTTLE VALVE
FL2EB
ACTUATOR(4G69)
2758_L-GN_0.5_AT&(2.8VGT/2.8FGT/4G69)
7538B_D-BU_0.5_2.8VGT/4G69
5378B_L-GN_0.75_2.8VGT/4G69
5294EA_PK/BK_0.75_4G69
D C B A EN2EB_G
࠮䖤䖪փ㖤
SP4343 10 12 EB2EN_G
Ֆ᝕ಞ(4G69)
CAM SEN(4G69)
6119G_GY_0.5_4G69
6120G_YE/BK_0.5_4G69
1164G_WH/BK_0.5_4G69
1162G_YE/BK_0.5_4G69
1161G_D-BU_0.45_4G69
B A
р⑮≝Ֆ᝕ಞ(4G69)
UP STREAM LAMBDA
SEN(4G69)
≪⑟Ֆ᝕ಞ(4G69)
WATER SEN(4G69)
EB25
2 1 6 5 4
VBAT-1
SIG-1
GND-1
FL2GB 5 18 19 20
GB2FL
1664BC_TN_0.5_4G69
1666C_PU_0.5_4G69
1667C_BN_0.75_4G69
5294EB_PK/BK_0.75_4G69
⧥ູ⑟ᓜՖ᝕ಞ ⭫ᆆࣖ䙕䑅ᶵ
AMBIENT SEN ACCELERA
A B C D
с⑮≝Ֆ᝕ಞ(4G69)
DOWN STREAM LAMBDA
SEN(4G69)
17SK8124A02
49-133
Circuit Diagram
CRANK REFERANE EMS(4G69) INTAKEMANIFOLD
PEDAL POSITION CLUTCH VOLTAG ABSLVTE INTAKE AIR
POSITION SENSOR TOP SOURCE V5 PRESSURE TEMPERA BRAKE CRUISE
SESOR2 HALL SWITCH SUPPLK2 RETURN2 SENSOR TURE SWITCH ANALOGINPUT
42 30 57 66 76 54 71 53 26
EN03
7360_TN_0.5_4G69
7361_YE_0.5_4G69
SP4332
SP4333
1934_L-BU_0.5_4G69&GCC
1171GA_GN_0.5_4G69
573_YE_0.5_4G69
7360B_TN_0.5_4G69
7361B_YE_0.5_4G69
7344_D-BU/YE_0.5_4G69
7360A_TN_0.5_4G69
7361A_YE_0.5_4G69
7361D_YE_0.5_4G69
7360D_TN_0.5_4G69
5638_BN_0.5_4G69
5639-D-BU_0.5_4G69
6310GA_TN_0.5_4G69
A C B 1 3 4 2
EN2EB_G
14 8 7 EB2EN_G
䖜䓡᧝࡬ঋ‫ݹ‬ HOOD
7360AA_TN_0.5_4G69
7361AA_YE_0.5_4G69
AJAR SW
GND_
GND
SENSOR_
BCM VCC
(HIGH)
BRRKE
DIMMER BRAKE BRAKE SENSOR PEDAL SEN
SW SEN PEDAL SW (BRAKE SEN) PWR(LOW)
ᴨ䖪փ㖤Ֆ᝕ಞ(4G69) ໔ুু࣑Ֆ᝕ಞ(4G69) 25 18 3 2 5
CRANK SHAFT SEN(4G69) BOOST AIR PRESSURE IP01_A IP01_D IP01_A IP01_D IP01_B
7389A_GY/WH_0.5
SEN(4G69)
EN2EB_G EN2EB_G EN2EB_G

13 EB2EN_G SP4338 32 EB2EN_G 9 EB2EN_G
SP4337
1172G_YE_0.5_4G69
1171G_GN_0.5_4G69
1172G_YE_0.5_4G69
7344A_D-BU/YE_0.5_4G69
7360AB_TN_0.5_4G69
7361AB_YE_0.5_4G69
7361AC_YE_0.5_4G69&GCC
1934AC_L-BU_0.5_4G69&GCC
7360AC_TN_0.5_4G69&GCC
7361AD_YE_0.5_4G69
6310G_TN_0.5_4G69
SP543
6038B_YE/BK_0.5_PEPS
6038A_YE/BK_0.5_PEPS
5066A_YE_0.5_PEPS
6039A_GY_0.5_PEPS
6039B_GY_0.5_PEPS
EB25 EB2IP_2
1 2 3 2 3 1 1 2 3 44 43 IP2EB-2
SIG
PWR
GND
GND2
SIG2
VIN2
7 8 6 IP2EB_2
EB2IP_2
IP50_B
6038G_YE/BK_0.5_GCC/ESSS
5066G_YE_0.5_GCC/ESSS
6039G_GY_0.5_GCC/ESSS
4 3
CRUISE- CRUISE+
⭫ᆆࣖ䙕䑅ᶵ ⭫ᆆࣖ䙕䑅ᶵ ਂ䐥࡯䖜Ֆ᝕ಞ ᰬ䫕ᕯ㉝

ACCELERATOR PEDAL ACCELERATOR PEDAL BRAKE SWITCH CLOCK SPRING
SENSOR
5 4 6
17SK8124A03
49-134
Circuit Diagram
UEC
U-FS4
U-FS19
FUELFILTER HEATER U-R5
MAIN RLY PWR3
/ECU(4G69/NLE2.0T) FUELF/LTER HEATER
15A
25A /FUEL PUMP
16 138 142 58
EB01
SP014
16 EB2EN_C
7071G_RD/WH_2.5_4G69
EN2EB_C
SP4404
5294B_PK_0.75_4G69
䖜䓡᧝࡬⁗ඍ
BCM
ACC WAKE UP
47
IP01_B
29 EB2CH
43_YE_0.5
CH2EB SP4339
7071GA_RD/WH_2.5_4G69
5421_PK_0.75_4G69
5423_PK_0.75_4G69
5426_PK_0.75_4G69
46 IP2EB_2
EB2IP_2
43C_YE_0.5
5422_PK_0.75_4G69
5425_PK_0.75_4G69
⟹⋯⌫ SP414
A A B ⻩㖆⭫⻷䰶
43G_YE_0.5_4G69
1 FUEL PUMP
CANISTER
PWR
௭⋯ಞ1 ௭⋯ಞ3
INJECTOR INJECTOR PURGE
CYL1 (4G69) CYL3 (4G69) SOLENOID
FUEL LEVEL SEN+
FUEL LEVEL SEN-
ACCP
INJA INJB (PWM) VALVE
B A B A A (4G69)
1744_BN_0.75_4G69
1746_PK/BK_0.75_4G69
845_TN/WH_0.75_4G69
GND
௭⋯ಞ2 ௭⋯ಞ4
2 3 4 36 EB2EN_G INJECTOR INJECTOR
EN2EB_G CYL2 (4G69) CYL4 (4G69)
550GM_BK_2.5_4G69
550G_BK_2.5_4G69/NLE2.0T
1175_OG/BK_0.5_4G69
7361CB_YE_0.5_4G69
43GA_YE_0.5_4G69
INJD INJC
B B
1745_L-GN/BK_0.75_4G69
844_L-BU/BK_0.75_4G69
G_EBL2_3
SP4333
1175B_OG/BK_0.5_4G69
CH2EB
26 25 EB2CH
1175A_OG/BK_0.5_4G69
7361GA_YE_0.5_4G69
SP915
EN03
550GL_BK_2.5_4G69
31 59 6 8 7 25 64
FUEL LEVEL ACC INJECTOR INJECTOR INJECTOR INJECTOR CANISTER
SENSOR CYL/NDERA CYL/NDERD CYL/NDERB CYL/NDERC SOLENOID VALVE
EB2CH 36
CH2EB ਇࣞᵰ᧝࡬ঋ‫(ݹ‬4G69)
EB2EN_G 33 35 EMS(4G69)
EN2EB_G
17SK8124A04
49-135
Circuit Diagram
UEC
U-FS4
IEC PWR1
30A EMS(4G69) FUEL
IGNITION IGNITION SENIAL KNOCK SENSOR KNOCK SENSOR PRESSURE
(OIL A)(#1) (OIL B)(#3) COMMUNICATION SIGNAL HIGH SIGNAL LOW SWITCH
59 4 1 75 36 37 33
EB01 EN03
5292G_PK_0.75_4G69
1730_BK_0.75_4G69
SHIELD
1847_BK_0.75_4G69
SHIELD
326B_PU_0.5_4G69
BLUNT BLUNT
EN2EB_G
1876_L-BU_0.5_4G69
1716_GY_0.5_4G69
331G_BN_0.5_4G69
23 EB2EN_G
17 EB2EN_G
326A_PU_0.5_4G69
EN2EB_G
5292GA_PK_0.75_4G69
SP4347
SHIELD
SHIELD
EB2IP_2
2401A_BK_0.75_4G69
39 IP2EB_2
326_PU_0.5_4G69
B A C
CY1 CY4 CY2 CY3

IP28
7 1 2 1
G_EN03 KW2000
䈀ᯣ᧛ਙ
OBD
⠼䴽Ֆ᝕ಞ ᵰ⋯ু࣑ᔶީ
KNOCK SEN(4G69) OIL PRESSURE_SW
17SK8124A05
49-136
Circuit Diagram
49-137
17SK8125A01
UEC
U-JF10 U-FS9 U-JF3 U-JF4
BCU/FUEL PUMP A/C COMPRESSOR STATER IEC PWR10
60A 15A 30A 30A
U-FS4 U-FC19
U-JF1 U-FC21
FUEL FELTER/ MAIN RELAY
MAIN RELAY MEAR PUMP
HEATER/ECU PWR3
30A 15A
25A 150A
U-R5
U-R8 U-R1 U-R9 U-R4
⟹⋯⌫ U-FS22
ѱ㔝⭫ಞ ≪⌫㔝⭫ಞ グ䈹ু㕟ᵰ
RLEL HOCK 䎭ࣞᵰ START FB
MAIN RELAY WATER PUMP A/C
RDATEK/ STARTER 10A
COMPRESSOR
FUEL PUMP
16 154 157 119 122 139 142 69 66 135 134 137 34 55 4
EB01
7071N_RD/WH_2.5
1035N_PU/WH_0.75
459N_D-GN/WH_0.5
142N_RD/BK_0.75
447N_YE_0.5
Ԡ㺞ᶵс
5290_PK/BK_0.75
6NA_PU_3.0
6NAB_PU_0.5
7423_BN/GN_0.75
1580N_PK_0.75
421N_BU/WH_1.0
6N_PU_3.0
59N_B-GN_0.75
ؓ䲟ѓⴈ
5991N_YE_0.5
IP07
IEC 69
I-R3
⛯⚡㔝⭫ಞ
IG RELAY
SP011 7 EB2EN_N B7 EB2FL_N 6 EB2EN_N 58 60 13
EN2EB_N FL2EB_N EN2EB_N IP07
7071NE_RD/WH_2.5
850_BK_0.5
1040N_RD/WH_0.5
5199_YW_0.5
7071NE_RD/WH_2.5
6NB_PU_3.0
5290D_PK/BK_0.75
BT12
Engine Management System(NLE2.0T)
1 1 1 1 48
PWR A/C ST IGN RELAY
≪⌫ ⟹⋯⌫
WAER FUEL
PUMP PUMP
GND
2 2 グ䈹ু㕟ᵰ 䎭ࣞᵰ 䖜䓡᧝࡬⁗ඍ
A/C STARTER BCM
COMPRESSOR
EN2EB_N
550AN_BK_2.5
5290DC_PK/BK_2.5 14 EB2EN_N
5290DE_PK/BK_2.5
5290DA_PK/BK_2.5
614N_BK_1.0
G_EBR2_1 G_EBL2_3 G_IPL_1
EB02_K1
30 69 6 5 3 42 28 72 3 5 48 87
VBATT O_S_MRLY V_V_ V_V_ O_S_WATER PUMP O_S_FUEL PUMP O_S_A/C O_S_STATER I_S_KL50 I_S_T50
MRLY MRLY
ਇࣞᵰ᧝࡬⁗ඍ(NLE2.0T)
ECM(NLE2.0T)
MAIN RELAY PWR2
17SK8125A02
2
⛯⚡㓵ാ1
A16 O_P_ICC1
U-FS18
IGNITION COIL CYL1

1.00
15A
1
59
2
⛯⚡㓵ാ2
A02 O_P_ICC4
IGNITION COIL CYL2
1.00
1
2
⛯⚡㓵ാ3
A17 O_P_ICC2
IGNITION COIL CYL3
1.00
1
2
⛯⚡㓵ാ4
A01 O_P_ICC3
IGNITION COIL CYL4
1.00
1
1+
⻩㖆᧝࡬䰶
VARIABLE CAMSHAFT
A35 O_T_TEV
TIMING(INTAKE)
0.50
2-
ਇࣞᵰ᧝࡬⁗ඍ(NLE2.0T)
ECM(NLE2.0T)
1
ᓕᔹ᧝࡬䰶
A18 O_T_WCCV
VARIABLE CAMSHAFT
TIMING(INTAKE)
0.75
MAIN RELAY PWR3
2
1+
䘑≊⋺⍷䰶
U-FS19
VARIABLE CAMSHAFT
A21 O_S_DV
TIMING(INTAKE)
0.75
15A
2-
58
1
⭫ᆆ⑟ᓜಞ᧝࡬
VARIABLE CAMSHAFT
A60 O_S_ET
TIMING(INTAKE) 0.75
2
TION1
FUNC
⿱ਾಞ≪⌫
A15 O_T_SMP
SWITCHABLE WATER
PUMP 0.75
TION2
FUNC
Circuit Diagram
1
STARTER
ਥ਎≊䰞↙ᰬ䰶
U-R8 MAIN RELAY

δ䘑≊ε
A50 O_T_CVVTE
U-FS22
VARIABLE CAMSHAFT
TIMING(INTAKE) 0.75
10A
2
ѱ㔝⭫ಞ
87
55
TION1
FUNC
ਥ਎≊䰞↙ᰬ䰶
δᧈ≊ε
A05 O_T_CVVTE
49-138
VARIABLE CAMSHAFT
TION2
FUNC
TIMING(EX HAUST)
Circuit Diagram
49-139
17SK8125A03
AD+ A38
C_R_SENSVE2 A13
18 EN2EB_N
EB2EN_N
0.75
47 EB2IP_2
IP2EB_2
V_V_SVE1 A27
3
䘑≊⴮ᓊՖ᝕ಞ
0.75
IP05
CAMSHAFT
C_R_SENSVE1 A08
1
POSITION
INTAKE SEN
I_T_CAMPOSI A53
0.75 18EB 6744NA_YE/GY FLRB_0.5_NLE2.0T
2
8
MC2 507 MC2 507
V_V_SVES(DC) A07
0.50
3
ᧈ≊⴮ᓊՖ᝕ಞ EB 6745NA_D-BU/YW FLRB_0.5_NLE2.0T

0.75
19
48
CAMSHAFT
7
C_R_SENSVES A22
1
POSITION 䎭ࣞ⁗ᕅᔶީ ࣑ࣞ⁗ᕅᔶީ

EXHAUST SEN
I_T_CAMPOSE A54
0.75
ѣཤ᧝࡬㓺ᔶީᐜ
2
CONSOLE SW_L
MC2 510 MC2 510
4
I_A_TVP1 A24
0.75
1
䖜䚉‫څ‬〱᤽⽰⚥
V_V_TVP A12
0.75
2
1
MC2 509 MC2 509
䖜䚉‫څ‬〱ᔶީ
0.75
I_A_TVP2 A41
4
⭫ᆆ㢸≊䰞
10
THROTTLE VALVE
C_R_TVP A44
0.75 ACTUATOR
6
MC2 511 MC2 511

LED+
0.75
6
O_T_TVP A19
3
O_T_TVN A20 0.75

5
LED-
13
MC2 512 MC2 512
ᵰ⋯ু࣑ᔶީ
I_S_OPS A55
0.50 OIL PRESSURE
1
SWITCH
0.50
TION1
FUNC
I_A_KS1A A25
⠼䴽Ֆ᝕ಞ
KNOCK SEN
I_A_KS1B A10
0.50
2
MC2 506 MC2 506
V_V_SVE2(DC) A07
0.50
1
I_F_ENGSPH A23
0.50 䖢䙕Ֆ᝕ಞ
2
HALL SEN
0.50
C_R_SENSVES A22
3
3
I_A_MPS A39
0.75 䘑≊ু࣑Ֆ᝕ಞ
4
MANIFOLD
PRESSURE SEN
1
0.75
2
V_V_SVE2 A29
3
⋯䖞ু࣑Ֆ᝕ಞ
I_A_FRP A40
0.50 FUEL RALL
2
PRESSURE SEN
C_R_SENSVE2 A13
0.75
1
O_P_MSCL A03
0.75
2
⟹⋯᧝࡬䰶
OUANLITY FLOW
O_S_MSVH A04
0.75 CONTROL VALVE
1
MC2 508 MC2 508
G_R_SEN3 VE A14
0.75
1
≪⑟Ֆ᝕ಞ
WATER TEMP
I_A_TMOT A57
0.75 SENSOR
2
O_P_HDEV1_L A33
0.50
2
௭⋯౪1
INIECTOR CYL1
O_P_BANK1_1 A31
0.50
1
MC2 502 MC2 502
O_P_HDEV4_L A49
1.50
2
௭⋯౪2
INIECTOR CYL2
1.50
O_P_BANK2_2 A47
1
MC2 503 MC2 503
O_P_HDEV2_L A34
1.00
2
௭⋯౪3
INIECTOR CYL3
1.00
O_P_BANK2_1 A46
1
MC2 504 MC2 504
O_P_HDEV3_L A48
1.00
EN2EB_N
9 EB2EN_N
௭⋯౪4
INIECTOR CYL4
1.00
EB70
O_P_BANK1_2 A32
1
MC2 505 MC2 505
EB 5530N_D-BU FLRB_0.5_NLE2.0T
EMS
ࢃ㡧ᔶީ
B
I_A_HS A37
HOOD ADJ SW
17SK8125A04
EB02
EB25
1272N_PU FLRB_0.5_NLE2.0T GND_2
11
3
G_R_APP2 K11
ACCELERATOR PEDAL
1172N_L-BU FLRB_0.5_NLE2.0T SIG_2
61
2
I_A_APP2 K61
⭫ᆆࣖ䙕䑅ᶵ
1174M_BN FLRB_0.5_NLE2.0T SBAT_2
81
1
V_V_APP2 K81
1162N_GY FLRB_0.5_NLE2.0T GND_2
35
4
G_R_APP1 K35
1161N_D-BU FLRB_0.5_NLE2.0T SIG_2
83
5
I_A_APP1 K83
1164N_WH/BK FLRB_0.5_NLE2.0T SBAT_2
82
6
V_V_APP1 K82
EB2IP_2
43 IP2EB_2
CLOCK SPRING
5391E_PU FLRB_0.5_NLE2.0T&RCNA
12
I_ACRUISE K12 IP5_4 CURISE-
ᰬ䫕ᕯ㉝
SP3506
7361ND_YE FLRB_0.5_NLE2.0T
15
44
G_R_SEN3VE K15 IP5_4 CURISE+
EB27
⿱ਾ㺂ぁՖ᝕ಞ
5391E_PU FLRB_0.5_NLE2.0T&MT
BRAKE CACUUM SEN CLUTCH SEN

PWR
3
7344N_D-BU/YE FLRB_0.5_NLE2.0T&MT SIG
60
2
I_A_CSA K60
5073B_BK/WH FLRB_0.5_NLE2.0T&MT
EMS(NLE2.0T)
GND
1
EB41
࡯䖜ⵕグᓜՖ᝕ಞ
5391D_OU FLRB_0.5_NLE2.0T&ESSS
3
3+
6030_OG FLRB_0.5_NLE2.0T&ESSS
13
1
I_A_BKV K13 1
5073D_BK/WH FLRB_0.5_NLE2.0T&ESSS
2
2
EB2IP_2
7 IP2EB_2
SP2503
EB26
EB26
BRAKE SWITCH
ਂ䐥࡯䖜Ֆ᝕ಞ
5073_BK/WH FLRB_0.5_NLE2.0T 5073A_BK/WH FLRB_0.5_NLE2.0T GND2 GND1
EB 6038C_YE/BK FLRB_0.5_GCC/ESSS
14
6
G_R_SEN 5VV1 K14
SENSOR
6041_L-CN FLRB_0.5_NLE2.0T&ESSS SIG2 SIG1 EB 5066C_YE FLRB_0.5_GCC/ESSS
64
8
I_A_BAP K64
5391_PU FLRB_0.5_NLE2.0T 5391A_PU FLRB_0.5_NLE2.0T VIN2 VIN1
EB 6039C_CY FLRB_0.5_GCC/ESSS
58
6
V_V_5VV1 K58
SP2504
EB11
BOOST AIR PRESSURE

໔ুু࣑⑟ᓜՖ᝕ಞ
5391_PU FLRB_0.5_NLE2.0T
SEN(NLE2.0T)
3 5V
1533_WH FLRB_0.5_NLE2.0T
63
D
I_A_BAP K63 4 OUTPUT SIG
Circuit Diagram
5073C_BK/WH FLRB_0.5_NLE2.0T
A
1 GND
5266_OG/BK FLRB_0.5_NLE2.0T
37
B
I_A_ITAS K37 2 NTC
SP2502
450NA_BK FLRB_2.5_NLE2.0T
1
G_G_EL K01
G_EBR3
450NB_BK FLRB_2.5_NLE2.0T 450N_BK FLRB_2.5_NLE2.0T
2
G_G_EL K02
450NC_BK FLRB_2.5_NLE2.0T
4
G_G_EL K04
49-140
Circuit Diagram
49-141
17SK8125A05
MAIN RLY
SP2507
U-FS19
PWR3
15A
EB02_K1
5294N_PK/BK FLRB_0.75_NLE2.0T 5294NA_PK/BK FLRB_0.75_MT&THCL&NLE2.0T

58
12
UPSTREAM LAMBDA
MAIN REALY
4
5297N_WH FLRB_0.75_NLE2.0T
76 77 79
1
2
UEC
р⑮≝Ֆ᝕ಞ
U-R8 MAIN RELAY
3110_PU/WH FLRB_0.75_NLE2.0T
U-FS17
SP2508
PWR1
8
3111_TN/WH FLRB_0.75_NLE2.0T
10A
ѱ㔝⭫ಞ
3
5291N_PK/BK FLRB_0.75_NLE2.0T 5291NB_PK/BK FLRB_0.75_MT&THCL&NLE2.0T MC2513 MC2513
87
60
3113_GY/WH FLRB_0.75_NLE2.0T
78 73
3
4
5231_PU/WH FLRB_0.75_NLE2.0T
EB2EN_N 5
EN2EB_N
5291NC_PK/BK FLRB_0.75_NLE2.0T&ESSS
GB2FL
18 19 FL2GB
EB12
EB12
CH07
5565_WH/BK FLRB_0.75_NLE2.0T&AT 5661A_WH/BK FLRB_0.75_NLE2.0T&AT H LC 203N_L-BU FLRB_0.5_MT&THCL&NLE2.0T
21 20
4
1
2
HRDALLC ACCLALL&TCR 1 4
COLNTRCL 5294NEA_PK/BK FLRB_0.75_NLE2.0T&AT 5294NE_PK/BK FLRB_0.75_NLE2.0T&AT GND MC 204N_D-BU FLRB_0.5_MT&THCL&NLE2.0T
3
1
2 3
FL2EB
9 EB2FL
CH2FL_2
1 FL2CH_2
A/C PPE SSLFE SW
G_EB
RL_3
1150WH_BK_0.75
SP2503
CH05
5666B_WH/BK FLRB_0.75_NLE2.0T
21
5231NDA_PU FLRB_0.75_NLE2.0T 5231ND_PU FLRB_0.75_NLE2.0T CH 5231NC_PU FLRB_0.75_NLE2.0T 5231NB_PU FLRB_0.75_NLE2.0T
3
8
3121_TN FLRB_0.5_NLE2.0T 3121B_TN FLRB_0.5_NLE2.0T 3121C_TN FLRB_0.5_NLE2.0T
29 62 33
4
5
3120_PU FLRB_0.5_NLE2.0T 3120B_PU FLRB_0.5_NLE2.0T 3120C_PU FLRB_0.5_NLE2.0T
2
ECM(NLE2.0T)
3122_GY/WH FLRB_0.75_NLE2.0T 3122B_GY/WH FLRB_0.75_NLE2.0T 3122C_GY/WH FLRB_0.75_NLE2.0T
16 IP2EB_2
EB2IP_2
7
IP05
IP05
5037A_PU FLRB_0.5_ESSS 5067_PU FLRB_0.5_NLE2.0T&ESSS
SIG 5 SIG 3
SVS SVS
OFF OFF
EB2IP_2 17 18
49 94
TF OR SG
3
5291NCA_PE/EE FLRB_0.75_ESSS ѣཤ᧝࡬ਦᔶީ
KL3
4
CON SIG SW_N 5035A_GY FLRB_0.5_ESSS 5085_GY FLRB_0.5_NLE2.0T&ESSS
IP2EB_2
FL2EB_N
A3 A2 EB2FL_N
CH2FL_2
2 FL2CH_2
CH08
FUEL LEVEL SENSOR+3 1175NC OG/BK FLRB_0.5_NLE2.0T 75NB_OG/BK FLRB_0.5_NLE2.0T NLE2.0T
15 36
3
7361NC_YE FLRB_0.5_NLE2.0T 7361MB_YE FLRB_0.5_NLE2.0T 7361N_YE FLRB_0.5_NLE2.0T
1
FUEL LEVEL SENSOR-4
GB22
COOLING FAI
⟹⋯⌫
߭প伄᡽
FUEL PUMP
2364N_D-BU FLRB_0.5_NLE2.0T&600W
EB14_N
PWN
26
4
5264N_PU/WH FLRB_0.5_NLE2.0T
4 PUT1
FRQ-
IAT OUT
59 57 40 18
1
492N_YE FLRB_0.5_NLE2.0T
4
グ≊⍷䠅䇗(NEL2.0T)
2931N_GY/BK FLRB_0.5_NLE2.0T
GND
HFM(NEL2.0T)
3
3
738N_GY FLRB_0.5_NLE2.0T
5V
2
2
GB2FL
5 FL2GB
FL2EB
1 EB2FL
GB02
P/N_SIG3
275_L-GN FLRB_0.5_AT&NLE2.0T 275B_L-GN FLRB_0.5_AT&(2.8VGT/NLE2.0T)/4G69 275N_L-GN FLRB_0.5_AT&NLE2.0T
22
3
TCU
5428_PU FLRB_0.5_NLE2.0T 5428A_PU FLRB_0.5_NLE2.0T
LIN 1N
Ӛ⍷ਇ⭫ᵰ
65
EB2EN_N 11
ALTERNATOR
EB06
SP2510
FN2EB_N
㫺⭫⊖
Ֆ᝕ಞ
5428B_PU FLRB_0.5_NLE2.0T&ESS
LIN
1
Circuit Diagram
EMS1

B+
BATTER
175A PFB
P-MGA
UEC
1 BT01_A
1 BTN01
1 RD 25.0
150 BK 25.0
1 BT04 UEC
30A
U-JF17
STARTER
30 85
U-R4
STARTER
87 86
ST
1 BT01_B 137 134 135 EB06_D
6F PU 3.0
447D YE 0.5
1035D PU/WH 0.75

BT 2D RD 25.0
SP14605
6D PU 2.5
EB2EN_D
EN2EB_D
1
6DB RD 2.5
447D YE 0.5
BT02_A 1 1 EN06 18 72 EB03_K

PWR O-S-STRTL O_S_STRTH
ST
G_EBL1
起动机 EMS
49-142
Circuit Diagram
EMS2
UEC
30 86
15A 20A 20A 10A
10A 60A U-FS17 U-R12
U-FS19 U-FS18 U-FS23
U-FS25 U-JF10 A MAIN MAIN
GCU/HCU MAIN RLY MAIN 87 85
ECU GCU EMS 4 RLY RLY
RLY
PWR1
52 EB01 10 58 59 54 60 154 EB01
142H RD/BK 0.75
EB 15 RD FLRB 6.0
5293 PK/BK 0.75
5292D PK/BK 1.0
5296D RD/BK 2.5
5295D PK/BK 2.5
5991D YE 0.5
5293WA PK/BK 0.75
a EMS 4
SP14607 5291DK PK 1.0
b EMS 9
5291DE RD/BK 1.0
c EMS 9
5293EA PK/BK 0.75
d EMS 4
5293RD PK/BK 0.75
5292DC PK/BK 1.0

SP14608 h EMS 5
11
2565D BU/WH 1.0
6 EB54
B+ KL87
GCU
ST DI GND GP1 GP2 GP3 GP4
10 9 7 1 2 3 4 EB54_D
1581DB PU 1.5
1582DB PU/WH 1.5
1583DB D-BU 1.5
1584DB YE/BK 1.5
1 EB15_D
505D RD/BK 1.0
5614D BN 1.0
523D RD/BK 1.0
VBAT SP2002
WCAC COOLANT SP2005

EB2EN_D PUMP
9 13 22 29
EN2EB_D GND PWM
1581D PU 1.5
1582D PU/WH 1.5
1583D BK/RD 1.5
1584D YE/BK 1.5
3 2 EB15_D
650D BK 1.0
2566DA YE 1.0
EN2GP
1 2 3 4
GP2EN
1581DA PU 1.5
1582DA PU/WH 1.5
1583DA BK/RD 1.5
1584DA YE/BK 1.5
EB2EN_D
12
EN2EB_D
5295DA YE/BK 2.5
5295DB YE/BK 2.5
31DA BK 2.5
31DB BK 2.5
31DC BK 2.5
31D BK 2.5
2566D YE 0.75
GP04
GP03
GP01
GP02
1 1 1 1 G_EBR3
EB03_K GLOW GLOW GLOW GLOW G_EBR2_1

PLUG 1 PLUG 2 PLUG 3 PLUG 4
91 57 53 27 72 EN30_A 3 5 1 2 4 6 69 EB03_K
PWR ST DI G_R_GLW O_T_WCAC BAT2 BAT3 BAT1 BAT1 BAT2 BAT3 O_S_MRLY
GND GND GND
EMS
49-143
Circuit Diagram
EMS3
UEC IEC
30A
30 85 7.5A
I-R3 I-F14
U-JF4 IG1
IG PWR ECU IG1
RLY 87 86
PWR
4 EB01 45 41 68 58 1 13 IP07_B
202A RD/YE 2.5
850BC BK 0.5
440H RD/WH 2.5
1040 RD/WH 0.5

440 RD/WH 2.5
5199 YE 0.5
202J RD/YE 2.5
SP901
EB2IP_PL 1
1 IP2EB_PL 1
202E RD/YE 2.5 SP008 440D RD/WH 2.5 IP2EB_2
2
EB2IP_2
850 BK 1.5 SP024 SP037
1934D L-BU 0.5
7361D YE 0.5
7360D TN 0.5
7360D TN 0.5
7361D YE 0.5
1040D RD/BK 0.5
G_IPL_1
1375D YE 0.5
62 36 31 75 35 EB10
GND SIG IG ACC
5V
PWR wakeup
EMS SP024
I_A_EXTS2 G_R_EXTS2
43C YE 0.5
SIG GND
59 81 75 74 EN30_A
7583E D-BU 0.5
5378D L-GN 0.5

36D WH 0.5
6745D GY 0.75
EB2IP_2
2
IP2EB_2
10 11 EN2EB_D
D20E D-BU0.75
D20F L-GN 0.75
EB2EN_D
43 YE 0.5
SP15
6745DB GY 0.5
EB2FL_D
A8 B6 16
FL2EB_D
D20EA D-BU 0.75
D20FA L-GN 0.75
EN2EB_D EN2EB_D
27 28 18 19
EB2EN_D EB2EN_D
36E WH 0.5
6745E GY 0.5
D20EB D-BU 0.75
D20FB L-GN 0.75
3 2 1 EB26
1 2 EB19_D 1 2 GB05_D 47 48 IP01_B
SIG2 GND2 5V
SIG GND2 SIG GND2 ACC KL15
RELAY
DUAL BRAKE IG1
SWITCH SENSOR
Coolant Exhaust gas

temperature BCM
temperature
sensor sensor2 T5
49-144
Circuit Diagram
EMS4
UEC
30A 25A 15A

U-R2 U-FS24 U-FS4 U-FS9
FUEL FUEL PUMP FUEL FILTER A/C
PUMP HEATER COMPRESSOR
85 30 30 85 30 85
U-R5 U-R9
FUEL FILTER A/C
86 87 87 86 HEATER/ 87 86 COMPRESSOR
FUEL PUMP
125 124 127 142 139 66 69 EB01
5293EA PK/BK 0.75
5293EB PK/BK 0.75
3240DA RD/WH 3.0
7071DB D-BU 2.5
7071D D-BU 0.75
59 D-GN 0.75
459D D-GN/WH 0.5

EB2CH
22 1
CH2EB
3240DB RD/WH 3.0
7071DA D-BU 2.5
EB2EN_D
5293WC PK/BK 0.75
12
5293WB EN2EB_D
EMS 2 d PK/BK FL2CH CH2FL
0.75 _D2 14 _D2 EB2CH
EMS 2 a B2
59D D-GN 0.75
CH2EB
EB2FL_D FL2EB_D 550GDA BK 3.0
29
1050FHA BK 2.5
36
1050FHB BK2.5
550GD BK 3.0
1 2 CH01_A 6 3 7 CH14_D 1 EN08

GND PWR HEAT + VCC HEAT -
FUEL PUMP FUEL FILTER

FUEL LEVEL FUEL LEVEL TEMP TEMP
SNR + SNR - OUT SNR+ SNR- GND
3 4 CH01_A 4 1 2 5 CH14_D A/C

COMPRESSOR
6861D D-BU/YE 0.75
1578DB YE 0.5
1579DB WH 0.5
1050DB BK 0.75
6281DC BN/WH 0.5
30DB PU 0.5
CH2FL_D2
23 22 33 18 19 FL2CH_D2
30DA PU 0.5
6281DB BN/WH 0.5
6861C D-BU/YE 0.75
1578DA YE 0.5
1579DA WH 0.5
1050DA BK 0.75
SP911
1050 BK 3.0
FL2EB_D
A7 A6 33 B10 B11 B3
EB2FL_D
6861C D-BU/YE 0.75
1578DA YE 0.5
1579D WH 0.5
1050D BK 0.75
30D PU 0.5
SP2006
6281D BN/WH 0.5
G_EBL2_3
G_EBR2_1 EB03_K
74 64 7 70 45 8 20 21
O_S_PSPL I_A_FLS G_R_FLS I_S_WFLS I_A_FTS G_R_FTS O_S_FHRLY O_S_ACRLY
EMS
49-145
Circuit Diagram
EMS5
EMS 4 85 30
B U-R1 15A 40A
SCR U-FS09 UEC P-MGE
RLY 86 87 SCR HCU
119 122 EB01 1 BT01_E

142GA RD/WH 0.75
EB 334 VT FLRA 0.75
1262D RD 3.0
EB2FL_D
A5 FL2EB_D
142GD RD/WH 0.75
FL2CH_D2
2 CH2FL_D2
SP1004
142GC RD/WH 0.75
142GB RD/WH 0.75
BT2EB
5292DC PK/BK 1.0 EB2FL_D FL2EB_D C EB2BT
5292DE PK/BK 1.0

EMS 2 g A4
CH 40E RD FLRA 2.0

7527D PK 2.0
1 CH19_D 3 5 CH20_D
BAT BAT HEAT+ FL2CH_D2
20 CH2FL_D2
MAGNETIC PUMP & REDUCTION AGENT UREA 5292DD PK/BK 1.0
REDUCTION AGENT ULTRASONIC LEVEL NOZZLE
1262E RD 3.0
PURGING PUMP
SIGNAL
SENSOR LEVER LEVER
SIGNAL MAGNETIC BAT SIGNAL GND HEAT- SENSOR- SENSOR+
SP1003
2 3 4 CH19_D 1 2 4 CH20_D 2 1 CH15_D CH2EB

1
7530DB BK 1.5
7529D RD/WH 2.0
EB2CH
7823DC GY 0.75
1536DC BN 0.75
1535DC OG 0.75
7525EB WH 0.5
7526EB PU 0.5
7528DB BK 1.5
5292EC PK/BK 1.0
1262F RD 3.0
CH2FL_D1 CH2FL_D1
CH2FL_D2
14 17 16 9 10 6 1
FL2CH_D2 FL2CH_D1
FL2CH_D1
7528DA BK 1.5
4 1 6 8 CH16_D
7823DB GY 0.75
1535DB OG 0.75
1536DB BN 0.75
7525EA WH 0.5
7526EA PU 0.5
7530DA BK 1.5
HEAT2 HEAT1 KL87 BAT
EB2FL .);
FL2EB_D
A3 A10 A9 A1 A2 5 FL2EB4
EB2FL_D GND ST CAN DI CAN
7823DA GY 0.75
7525E WH 0.5
7526E PU 0.5
1535DA OG0.75
1536DA BN 0.75
7528DA BK 1.5
7 10 9 CH16_D
7530D BK 1.5
7544DA BK 3.0
CH 1814A D-GN/WH FLRA 0.5
CH 1813A WH/BK FLRA 0.5
EB2EN_D
21 24 23 19 20 EN2EB_D
7823D GY 0.75
1536D BN 0.75
1535D OG 0.75
7525D WH 0.5
7526D PU 0.5
SP_CH5
CH2EB
15 EB2CH
7544D BK 3.0
EB10 22 5 92 89 50 48 EN30
O_S_ O_T_ O_T_ O_T_ G_R_ I_T_
SCRMRLY RAPP RAMCPY RAMCPH RAULS RAULS
G_EBL2 SEE EMS11

EMS
G_EBL3
49-146
Circuit Diagram
49-147
EB03_K
CH2FL_D2
FL2CH_D2
EB2EN_D
EN2EB_D
EB14
CH21_D
FL2EB
EB2FL
EN30
G_R_AMS
G_R_ETA
GND
2931D YE/BK 0.5
87
3
2752DC BN 0.75 2752DB BN 0.75 2752DA BN 0.75 2752D BN 0.75
GND
AIR FLOW SENSOR HFM

76
10
8
5
I_T_AMS
ACTUATOR/POSITION SNSR
I_T_AMS
492D GY/BK 0.5
I_A_ETA
86
1
417DC D-BU 0.75 417DB D-BU 0.75 417DA D-BU 0.75 417D D-BU 0.75
SIG
77
3
7
EXHAUST THROTTLE
I_A_IATS
I_A_IATS
7337D OG 0.5
V Bat 5V
5VETA
76
4
V_V_
416DC GY 0.75 416DB GY 0.75 416DA GY0.75 416D GY 0.75

39
1
ETVNEG
5VAMS
4387D BN 0.5
5V+
O_V_
41
2
O_T_
561DC GY 0.75 561DB GY 0.75 561DA GY 0.75 561D GY 0.75
NEG
25
2
EB2FL_D
FL2EB_D
GB04_D
ETVPOS
FL2GB
GB2FL
SP2602
O_T_
POS
560DC WH 0.75 560DB WH 0.75 560DA WH 0.75 560D WH 0.75
Exhaust gas
temperature
6
3
6
GND
1664DB D-BU 0.5 D20H D-BU 0.75 D20HA L-GN 0.75 D20H D-BU 0.75
GND
50
2
20
B8
EB03_K
SP2601
EMS
1653DB L-GN 0.5 D20G L-GN 0.75 D20GA D-BU 0.75 D20GB D-BU 0.75
B7
SIG
SIG
47
1
6
EB13
EB2EN_D
EN2EB_D
LP EGR UPSTREAM
EN43
A/C PRESSURE
5V I_A_PAC GND
GND
214D D-BU 0.5 AT 1653DA L-GN 0.5 1653D L-GN 0.5
44 24
TEMP SNSR
SIG
1
2
2
380D OG/BK 0.5 AT
SIG
GND
1664DA D-BU 0.5 1664D L-GN 0.5
2700D GY 0.5 AT
1
3
43
5V
SEN
EN2EB_D
EB2EN_D
EB42_D
EN30
AGENT DOSING
EB12
REDUCTION
RAMV
O_T_
A/C PRESSURE SW
7079D YE 0.75 707ADA YE 0.75
71
GND
26
2
G_EBR1
GND
1150HS BK 0.75
VALVE
2
RAMVH
BAT
I_S_ACCMED
O_T_
7077D D-BU 0.75 7077DA D-BU 0.75
94
25
1
204D D-BU 0.75 MT
MID
52
3
EMS6
Circuit Diagram
EMS7
LP EGR ACTUATOR/POSITION SNSR FUEL METERING UNIT TVA ACTUATOR/POSITION SNSR
Vbat 5V GND SIG NEG POS PIN1 PIN2 SIG Vbat5V GND NEG POS
1 5 3 2 6 EN49 1 2 EN61 1 2 6 3 5 EN51

2753 BN 0.75
2702D GY 0.75
5047 RD/BN 0.75
5764 OG 0.75
5746 L-GN 0.75
7299D PU 0.5
7301D YE 0.5
417E D-BU 0.75
632E L-GN/BK 0.75
631D OG 0.75
416E GY 0.75
411D D-BU 0.75

17 57 58 2 1 7 6 98 16 97 8 9 EN30_A
V_V_ G_R_ I_A_LPEGR O_T_ O_T_ O_V_MEU O_T_MEU I_A_TVA V_V_5VTVA G_R_TVA O_T_TVAPOS
5VLPEGR LPEGR LPEGRNEG LPEGRPOS O_T_TVANEGI
EMS
I_F_CRS G_R_CRS V_V_5VCRS G_R_CAS I_F_CAS V_V_5VCAS I_S_OPS1 I_A_LPEGRDP G_R_LPEGRDP V_V_5VLPEGRDP
11 28 19 51 52 37 30 54 53 14 EN30_A
573D L-GN 0.5
574D BN 0.5
2867D YE 0.5
632DB GY 0.5
633D WH 0.5
7376D YE 0.5
231D L-GN/BK 0.75
469D BN/WH 0.75
736D D-BU 0.75
2530D PU/WH 0.75
1 2 3 EN35 1 2 3 EN36 1 EN40 1 2 3 EN44

SIG GND 5V GND SIG 5V SIG SIG GND 5V
CRANKSHAFT SPEED SNSR CAMSHAFT SPEED SNSR OIL PRESSURE SW LP EGR DIFFERENTIAL
PRESSURE SNSR
49-148
Circuit Diagram
EMS8
INTAKE VALVE SNSR HP EGR ACTUATOR/POSITION SNSR RAIL PRESSURE SNSR
GND T22 Vbat 5V SIG GND SIG Vbat5V NEG POS GND SIG 5V
1 2 3 4 EN37 1 3 5 6 2 EN48 1 2 3 EN47

2760DB TN 0.5
473DB TN 0.5
5300D D-BU 0.5
473DA TN 0.5
2753D BN 0.75
5375D YE 0.75
5047D GY 0.75
5764D BN/WH 0.75
5746D L-GN/BK 0.75
2919D OG/BK 0.5
2918D YE 0.5
2917D TN 0.5
95 101 38 96 78 79 40 88 67 63 62 42 EN30_A
G_R_P22 I_A_T22 V_V_ I_A_P22 G_R_HP I_A_HP V_V_5V O_T_HP O_T_HP G_R_RAILPSI_A_RAILPS V_V_5V
5VP22 EGR EGR HPEGR EGRNEG EGRPOS RAILPS
EMS
I_A_HP G_R_HP I_A_LP G_R_LP

I_A_EXTS3 G_R_EXTS3 I_A_T21 O_V_PCV O_T_PCV EGRTD EGRTD EGRTD EGRTD
13 12 61 27 26 34 33 36 35 EN30_A
474D L-BU 0.5
2760D TN 0.5
472D L-GN 0.5
5424DA L-BU 0.75
5424DB PK 0.75
7584D PU/WH 0.5
6274D BN 0.5
7583D D-BU 0.5
6783D WH 0.5
SP03
2760DC TN 0.5
2760DA TN 0.5
1 2 EN45 2 1 EN38 1 2 EN58 1 2 EN41 1 2 EN42

SIG GND GND SIG PWR GND SIG GND 信号 GND
T3 TEMP SNSR T21 TEMP SNSR PRESSURE HP EGR COOLER LP EGR COOLER
CONTROL VALVE DOWNSTREAM DOWNSTREAM
TEMP SNSR TEMP SNSR
49-149
Circuit Diagram
EMS9
EMS 2 b
EMS 2 c OIL PUMP VALVE VSA LAMBDA SEN (DOC UPSTREAM) VGT
5290DE RD/BK 1.0
5291DK PK 1.0
Inner Air duct

Vbat 12V GND PWM IN Diagnosis GND Vbat Heater + Heater - Electrode electrode Vbat PWM IN GND
1 2 EN57 1 5 2 6 EN59 1 2 3 4 EN64 1 4 2 EN60

5291DF PK 0.75
6391H L-GN 0.5
7314D GY 0.5
7316D L-GN 0.5
7315 BK 0.5
5291DH PK 0.5
5293DD BN/WH 0.75
6424D D-BU 0.75
6426D OG 0.75
6425D GY 0.75
5291DG D-BU 0.75
7316DA D-GN 0.75
450DB BK 0.75
EB2EN_D
33 32
EN2EB_D
5292D RD/BK 1.0
5291DA PK 1.0
SP01
SP05
SP02
EN30_A
90 93 29 46 83 104 47
450DA BK 1.0
O_S_OILP O_T_VSA I_T_VSA O_T_ O_R_ I_A_ O_T_VGT
LSH1 LSVG1 LSCP 1
EMS
O_T_LPTBV O_T_HPCBV O_T_HPTBV O_S_HPEGRCBP
91 68 73 69 EN30_A
6391D D-GN 0.75
6391E GY 0.5
6391F L-BU/BK 0.5
6391G YE 0.75
EN2EB_D
16
EB2EN_D
31DF BK 1.0
2 EN52 2 EN53 2 EN54 2 EN55

GND GND GND GND
L-TURB H-CHARGER H-TURB HP EGR
BYPASS BYPASS BYPASS COOLER
VALVE VALVE VALVE BYPASS
BAT BAT BAT BAT VALVE
1 EN52 1 EN53 1 EN54 1 EN55
5291DD PK 0.75
5291DC PK 0.5
5291DB PK 0.5
5291DE PK 0.75
G_EBR2
17SK8102A05
49-150
Circuit Diagram
EMS10
ACCELERATOR PEDAL CRUISE SW TCU(AT)

CONSOLE SW_L
P/N SIG
Cruise- Cruise+
AD+ AD-
SIG_1 Vbat_1 GND_1 SIG_2 GND_2 Vbat_2 4 3 IP50_B 3 GB02_D
8 7 IP05
5 6 4 2 3 1 EB25
275D L-GN 0.5

6309A PK 0.5 RCSW
6310A TN 0.5 RCSW

6744 YE/GY 0.5
6745 D-BU/YE 0.5

1161D D-BU 0.5
1164D WH/BK 0.5
1162D L-BU 0.5
1171D OG 0.5
1172D YE 0.5
1274D TN 0.5
ABS/ESP
IP2EB_2 SW04 GB2FL
47 48 5
EB2IP_2 10 9 FL2GB
6744DA YE/GY 0.5
6744DC D-BU/YE 0.5

CLOCK VSO
SPRING 10 EB04
275B L-GN 0.5

Cruise- Cruise+
1827 YE/BK 0.5

4 3 IP50_B
6309B PK 0.5 RCSW
6310B TN 0.5 RCSW

EB2EN_D
14 15
EN2EB_D
6744D L-GN 0.75
6745DA GY 0.75
IP2EB_2 SP257
44 43 EB2IP_2 FL2EB
1
EB2FL
6309D PK 0.5
6310D TN 0.5
275DA L-GN 0.5
1827D YE/BK 0.5

6745D GY 0.75
48 32 65 49 33 66 EB03_K 80 81 EN30 10 63 68 17 EB03_K
V_V_5V I_A_APP1 G_R_ V_V_5V I_A_ G_R_APP2 I_A_ G_R_ Cruise- Cruise+ I_S_PN VSO
APP1 APP1 APP2 APP2 DRVSW DRVSW
EMS
G_R_CLTH I_A_CLTH V_V_5VCLTH I_A_CTS G_R_CTS
9 46 59 EB03_K 100 99 EN30_A

410D L-GN 0.5
2761D WH 0.5
6110D WH 0.5
6111D YE 0.5
6109D TE 0.5
1 2 3 EB27 1 2 EN39
GND SIG PWR SIG GND
CLUTCH SEN COOLANT TEMP SNSR
49-151
Circuit Diagram
EMS11
PM SNR DOWNSTREAM NOX SNR UEC
30 86
20A
U-FS18 U-R8
D4
MAIN MAIN RLY
87 85
RLY
CAN_H CAN_L GND UBAT GND CAN_L CAN_H 电源
3 4 2 1 CH18_D FL45_D 2 3 4 1 59 157 EB01

2500ZH D-BU 0.35
2501ZH D-GN 0.35
5296DJ BK 1.0
5292 PK/BK 1.0
5295F BK 1.0
2501ZL D-GN 0.35
2500ZL D-BU 0.35
5292DB PK/BK1.0
5292D PK/BK 1.0
5991D YE 0.5
CH2FL_D2 FL2EB_D FL2EB_D
2 20 B5 B4
FL2CH_D2 EB2FL_D EB2FL_D
5292DB PK/BK 1.0
SP14608
FL2EB_D EB2FL_D
5292DE PK/BK 1.0 5292DC PK/BK 1.0
A4
5293DG BK 1.0
5294DG BK 1.0
5292DA PK/BK 1.0
5296DH BK 1.0 5296DG BK 1.0
2
FL2EB_D
EMS CAN TR A11 B1 EB2FL_D
5295DG BK 1.0
EB35_D 1 2 5
CAN_L CAN_H UBAT GND GND2
B A CH22_D
UPSTREAM
2501ZA D-GN 0.35
2500ZA D-BU 0.35
NOX SNR
CAN_L CAN_H
G_EBR2 EB35_D 3 4
2501ZJ D-GN 0.35
2500ZJ D-BU 0.35

2501ZG D-GN 0.35
2500ZG D-BU 0.35
SP15216 G_EBR2
2501ZK D-GN 0.35 2501ZC D-GN 0.35
SP15217 2501ZD D-GN 0.35 SP15219
27
2500ZK D-BU 0.35 2500ZC D-BU 0.35 2500ZD D-BU 0.35 SP15218
2
SP15213
2501ZJ D-GN 0.35
2500ZJ D-BU 0.35
CH2EB EB2CH SP15214

2500ZB D-BU 0.35
2501ZB D-GN 0.35
SP15215 80 81 69 EB03_K
CAN_L CAN_H
主继电器
控制
SP15212
发动机控制模块 EMS
O_P_ O_P_ O_P_ O_P_ O_P_ O_P_ O_P_ O_P_
INJVH11 INJVL11 INJVH22 INJVL22 INJVH21 INJVL21 INJVH12 INJVL12
64 85 24 45 22 43 66 87 EN30
EN30
5421D PK 0.75
1744D BN 0.75
5423D YE 0.75
844D L-BU/BK 0.75
5422D OG 0.75
1746D BN 0.75
5424D TN 0.75
1745D L-GN/BK 0.75

2500ZF D-BU 0.35
2501ZF D-GN 0.35
0.75
0.75
1 2 EN31 1 2 EN32 1 2 EN33 1 2 EN34

SIG GND SIG GND SIG GND SIG GND
6 7 CH16_D
CAN_H CAN_L
HCU INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4
49-152
Circuit Diagram
EMS12
UEC
B+
80A
U-MD1
PWM FAN
1
EB01_A
342M RD 10.0
1 EB22
PWR
COOLING
FAN(600W)
GND PWM
1 4 EB22
1250D BK 10.0
2364D D-BU 0.5
G_EBL2
73 EB10
FAN
ECM EMS
49-153

Workshop Manual T60

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T60/T70 㔪‫ؤ‬ᢁ߂

General ........................................................................................................... 2-1

Service and Maintenance................................................................................................... 2-11

Engine Mechanical System ............................................................................. 3-1

Layout .................................................................................................................................. 3-7

Troubleshooting ................................................................................................................. 3-12

Special Tool ....................................................................................................................... 3-17

Repair Guidance ................................................................................................................ 3-20

Engine Cooling System................................................................................... 4-1

Layout ................................................................................................................................... 4-2

Troubleshooting .................................................................................................................... 4-7

Repair Guidance ................................................................................................................... 4-8

Engine Electrical System ................................................................................ 5-1

Troubleshooting ................................................................................................................... 5-4

Repair Guidance .................................................................................................................. 5-5

Description and Operation ................................................................................................... 5-8

Battery Usage and Maintenance .......................................................................................... 5-8

Engine Controls............................................................................................... 6-1

Layout .................................................................................................................................. 6-6

Repair Guidance .................................................................................................................. 6-8

Fuel System .................................................................................................... 7-1

Layout .................................................................................................................................. 7-2

Repair Guidance .................................................................................................................. 7-6

Engine Fuel System 20L4E............................................................................. 8-1

Layout ................................................................................................................................... 8-2

Diagnostic Information and Procedures................................................................................ 8-5

Service Guide ....................................................................................................................... 8-6

Intake and Exhaust System ............................................................................ 9-1

Layout ................................................................................................................................... 9-2

Engine Intake/Exhaust System 20L4E.......................................................... 10-1

Layout ................................................................................................................................. 10-2

Description and Operation ............................................................................................... 10-10

5MT ............................................................................................................... 11-1

Precautions ........................................................................................................................ 11-2

Troubleshooting ................................................................................................................. 11-2

Layout ................................................................................................................................ 11-4

Repair Guidance .............................................................................................................. 11-14

Tool .................................................................................................................................. 11-53

Layout ................................................................................................................................ 12-3

Service ............................................................................................................................... 12-9

Repair Guidance .............................................................................................................. 12-10

Special Tool ...................................................................................................................... 12-36

DYMOS 6MT................................................................................................. 13-1

Layout ................................................................................................................................. 13-6

Repair Guidance ................................................................................................................. 13-7

Special Tool ...................................................................................................................... 13-44

SAGW 6MT ................................................................................................... 14-1

Transmission Assembly Structure Detail .......................................................................... 14-10

Special Tool ..................................................................................................................... 14-50

SC25M(B)5 Transmission ............................................................................. 15-1

Repair Guides .................................................................................................................. 15-29

Special Tools.................................................................................................................... 15-49

Clutch ............................................................................................................ 16-1

Layout ................................................................................................................................ 16-2

Diagnostic Information and Procedures ............................................................................. 16-3

Repair Guidance ................................................................................................................ 16-5

Steering System ............................................................................................ 17-1

Layout ................................................................................................................................. 17-2

Repair Guidance ................................................................................................................. 17-4

Special Tool ...................................................................................................................... 17-11

Description and Operation ................................................................................................ 17-11

Steering Wheel.............................................................................................. 18-1

Layout ................................................................................................................................. 18-2

Front Suspension .......................................................................................... 19-1