Cool Bear Service Manua

PREFACE
　　TheThe COOL
COOL BEAR
BEAR is
is equipped
equipped with
with a
a GW4G13
GW4G13 or or GW4G15
GW4G15 gasoline
gasoline engine. The
engine. The GW4G13
GW4G13 and and
GW4G15 engine incorporates the newest VVT technology which meets the Euro IV emission standards.
COOL BEAR features McPherson technology on its front suspension system and the vehicle body is an
ultra-light body made from structural steel. With the high-intensity front and rear fender impact beams as
well as a collision impact absorption system, it is able to maintain the cab's integrity and safety to a greater
extent. We created this maintenance manual in order to meet the demands of the Great Wall after-sales
service technicians. This manual mainly introduces the areas of importance in regard to maintenance and
care and removal and installation of each system's assembly and maintenance technical parameters, but
not include all the items for vehicle repair and maintenance.
This manual is provided by the Great Wall Motor Co., Ltd. and is written for a technician's use. If non-pro-
fessional or unqualified personnel repair or maintain the vehicle, it may injure the operator and other per-
sons in and around the vehicle and damage the vehicle if the operator only refers to this manual or doesn't
have the appropriate equipment.
To prevent dangerous operational situations and avoid damaging the vehicle, read and follow the instruc-
tions carefully:
Read this manual carefully. Have a full understanding of all the contents in the sections entitled "Areas of
Importance" in the "Preface."
Any maintenance method introduced in this manual is effective for the maintenance and repair of the vehicle.
While following the procedures in this manual to complete repairs, please use specified or recommended
tools. If the user doesn't use specified or recommended tools, please guarantee the safety of the mainte-
nance personnel before operating and make sure that it won't cause bodily damage or vehicle damage.
If any vehicle part change is necessary, please use a part with the same part number or same quality and
same specification.Never use unqualified parts.
To effectively avoid bodily and vehicle damage or an unsafe environment due to misoperation during main-
tenance or repair, please follow the sections entitled "Caution" and "Warnings" in this manual. In addition,
the contents of the "Caution" and "Warnings" sections in this manual are not exaggerated, and actions con-
trary to these notes may cause dangerous results.
Please read carefully the section "Areas of Importance" before carrying out any maintenance or repair on
the airbag system's components or its surrounding electrical components. Actions contrary to any of the
"Areas of Importance" may lead to unexpected deployment the airbag, which may cause serious accidents.
If the airbag system and other systems require maintenance, it is recommended to repair the airbag sys-
tem first and then repair other systems to avoid unexpected deployment of the airbag and causing serious
accidents.
All of the information in this manual is based on the latest product information when the manual is pub-
lished. The maintenance specifications and procedures are subject to change without prior notice.
Although we have tried our best to write this manual well, we do not guarantee that the entire contents of
this manual is absolutely correct. Users may not make any legal claim against the Great Wall Motor Co.,
Ltd. in regards to this manual. Any loss caused by failure in following this manual is not our responsibility.
Because of the writer's limited experience, we welcome any user comments, suggestions, and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.
Editor
August
2009
CHASSIS AND BODY
MAINTENANCE MANUAL
General GL
Maintenance and care MA
Engine accessory system EG
Transmission MT
Drive system DT
Suspension SP
Brakes BR
Steering SR
Audio/video system AV
AC system AC
Safety supplemental restraint system RS
Vehicle interior IR
Vehicle exterior ET
Vehicle body BO
Circuitry EWD
GL-1
General
INTRODUCTION
How To Use This Manual................................................ GL-3
Identification Information............................................... GL-6
Repair Instructions......................................................... GL-7
How To Troubleshoot ECU Controlled Systems.......... GL-22
Terms............................................................................... GL-33 GL
SPECIAL TOOLS
Recommended Tools for Complete Vehicles............... GL-34
Tools for the ZM-007Q Transmission Case.................. GL-35
Tools for the CC001 Transmission Case...................... GL-37
SERVICE SPECIFICATIONS
Engine Mechanical.......................................................... GL-40
Transmission/Transaxle................................................. GL-42
Fuel................................................................................... GL-43
Ignition............................................................................. GL-43
Starting and Charging ................................................... GL-43
Discharge Control........................................................... GL-44
Exhaust System.............................................................. GL-44
Cooling System............................................................... GL-45
Drive Shaft/Axle.............................................................. GL-46
Clutch............................................................................... GL-47
Front Suspension System.............................................. GL-48
Rear Suspension System............................................... GL-50
Tire and Wheel................................................................ GL-50
Brake System.................................................................. GL-51
Parking Brake System.................................................... GL-52
Steering System.............................................................. GL-53
Power Steering System.................................................. GL-53
Air Conditioning System................................................ GL-55
Supplemental Restraint System.................................... GL-56
Seat Belt........................................................................... GL-56
Combination Meter......................................................... GL-56
GL-2
Seat.................................................................................. GL-57
Wiper and Washer System............................................. GL-57
Windshield/Window Glass/Rear view Mirror................ GL-57
Horn System.................................................................... GL-58
Engine Hood/Door.......................................................... GL-58
GENERAL GL-3
INTRODUCTION
How To Use This Manual
General Information
1. General
(a) Maintenance operations can be separated into 3 main processes:
(1) Diagnosis
(2) Removing/installing, replacing, disassembling/reassembling, checking and adjusting
(3) Final inspection
(b) This manual explains the “Diagnosis” and “Removing and Installing, Replacing, Disassembling, In-
stalling and Checking, and Adjusting.” The “Final Inspection” is omitted.
(c) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning a removed part when necessary
(3) Visual check
2. Preparation
(a) The use of special service tools (SST) may be required, depending on the repair situation.
Be sure to use the SST when they are required and follow the working procedures properly. A list of
SST is in the PREPARATION section of this manual.
3. Repair procedures
(a) The component drawing is placed under the title where necessary.
(b) Non-reusable parts, grease application areas, pre-coated parts, and tightening torque are specified in
the component drawings.
GL-4 COOL BEAR MAINTENANCE MANUAL
Example:
Bleeder Screw
Bleeder Screw Cap

Piston Spring
l Piston
��
Dust Cover
Piston l Cup
��
l Piston
��
Dust Cover
Pin
Pin Plug Piston
Hole Plug Rear Brake Cylinder

Parking Brake Shoe
l Cup
�� Lever
Parking Brake Cable l C-washer
��
Pin Assembly LH
Brake Shoe
Parking Brake Shoe Hold-Down Brake Shoe
Push Rod Kit LH Spring Hold-down
Spring Cup
Backing Plate
Brake Leading
Rear Brake Shoe Assembly
Brake Shoe
Automatic Ad-
Return Spring
just Lever
Rear Brake Auto- Tension Spring

matic
Adjust Lever Ten-
sion Spring Brake Trailing
Shoe Assembly
Brake Shoe Hold-
Down Spring Brake Shoe Hold-
down Spring Cup
: Specified torque
Rear Brake Drum
l Non-reusable
��
part
Grease
High temperature grease
ALA001G
GENERAL GL-5
(c) The tightening torque, grease application areas, and non-reusable parts are described as important
points in the procedures.
Caution:
There are cases where such information can only be explained by using an illustration. In
these cases, all the information such as torque, oil, etc. are described in the illustration.
(d) The installation procedures are the removal procedures in the reverse order. However, only the instal-
lation procedures requiring additional information are included.
(e) Only items with key points are described in the text. What to do and other details are placed in the illus-
trations next to the text. Both the text and illustrations are accompanied by standard values and notices.
(f) Illustrations of similar models are sometimes used. In those cases, specific details may be different
from the actual vehicle.
(g) Procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanatory text tells how to perform the task. It also tells information, such as the specifica-
tions and warnings.
Example:
Task heading: what you will be doing
Illustration
what to do and where
7. Inspect and adjust the vacuum
booster push rod
(d) If the clearance is outside of the
specified range, fix the push rod by
using SST and adjust the length of
the protruding adjusting bolt. Detailed text:
how to perform
task
ALA002G
Hint:
This format provides an experienced technician with a FAST TRACK to the necessary information.
The task headings are easy to read and the text below the task heading provides detailed information.
Important specifications and warnings always are written in bold type.
4. Service specifications
(a) SPECIFICATIONS are presented in bold-faced text throughout the text where needed. The specifica-
tions are also found in the SERVICE SPECIFICATIONS section for quick reference.
5. Terms Definition
Caution Indicates the possibility of injury to you or other people.
Note Indicates the possibility of damage to the components being repaired.
Hint Provides additional information to help you perform repairs.
6. SI UNIT
(a) The UNITS used in this manual comply with the SI UNIT (International System of Units) standard.
Example: Torque: 30 N·m
Identification Information
Vehicle Identification and Serial Numbers
1. Vehicle identification number

(a) The vehicle identification number is stamped on the ve-
hicle identification number plate and certification label,
as shown in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
ALA003G
ALA004G
2. Engine model and transmission model

(a) The engine model is stamped on the exhaust side of
the engine block (see figure); the transmission model is
stamped on the housing.
ENGINE��
: GW4G13/GW4G15
TRANSMISSION��
: ZM007Q/CC0011A
ALA005G
GENERAL GL-7
Maintenance Instructions
Precautions
1. Basic Maintenance hints
(a) Hints for operation
ALA006G
• Always wear a clean uniform.

1 Attire
• Hat and safety shoes must be worn.
• Place a grill cover, fender cover, seat cover, and floor mat before
2 Vehicle protection
starting the operation.
• In case of working with 2 or more persons, be sure to check each
other's safety procedures.
• When working with the engine running, take care to ventilate the
workshop.
3 Safe operation • In case of operating on high temperature parts, rotating, moving, and
vibrating parts, take care not to burn or injure yourself.
• When jacking up the vehicle, be sure to support the specified location
with a safety stand.
• When lifting up the vehicle, use safety equipment.
Preparation of tools • Before starting operation, prepare a tool stand, SST, gauge, oil, shop
4
and measuring gauge rag, and parts for replacement.
• Diagnose with a thorough understanding of the problem and perform

the necessary repairs.
• Before removing the parts, check the assembly for its general condi-
Removal and installa-
tion, deformation, and damage.
5 tion, disassembly, and
• When a structure is complex, make notes or put tags on the compo-
assembly operations
nents to avoid mistakes during reassembly.
• Clean and wash the removed parts if necessary and assemble them
after a thorough check.
• Place the removed parts in the correct order to avoid mixing up or
getting them dirty.
• As for non-reusable parts such as a gasket, an O-ring, and a self-locking
6 Removed parts
nut, change them with new ones following the instruction of this manual.
• Organize the replaced parts in a box and keep them for customer in-
spection, if necessary.
(b) Jacking up and supporting the vehicle

(1) Care must be taken when jacking up and support-
ing the vehicle. Be sure to lift and support the ve-
hicle at the proper locations (see page GL-20).
(c) Precoated parts
(1) Precoated parts are bolts, nuts, etc. that are coat-
ed with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened, or
moved in any way, it must be recoated with the
specified adhesive.
Seal Lock Adhesive (3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
ALA007G Then apply new seal lock adhesive appropriate to
the bolt, nut, etc.
Note:
Perform the torque with the lower limit value of the
torque tolerance.
(4) Depending on the seal lock adhesive to apply,
there may be a cases where it is necessary to
leave it for a specified time until it hardens.
(d) Gaskets
(1) When necessary, use a seal lock adhesive on the
gaskets to prevent leakage.
(e) Bolts, nuts, and screws
(1) Carefully observe all the specifications for tighten-
ing torques. Always use a torque wrench.
GENERAL GL-9
Medium Current Fuse and High Current Fuse (f) Fuses

(1) When replacing fuses, be sure that a new fuse has
Equal Amperage Rating
the correct amperage rating. Do not exceed the
rating or use one with a lower rating.
ALA008G
Illustration Symbol Part name Abbreviation
Fuse
Medium Current Fuse
High Current Fuse
ALA009G
(g) Clips
(1) The removal and installation methods of typical clips
used in vehicle body parts are shown in the table below.
Hint:
If the clip is damaged during the operation proce-
dure, always replace it with a new clip.
Shape (Example) Removal/Installation
Clip
Plier
Clip Remover
Protective Tape
Screwdriver
Protective Tape
Scraper
ALA010G
GENERAL GL-11
Shape (Example) Removal/Installation
Removal Installation
ALA011G
(h) Removal and installation of vacuum hoses

(1) To disconnect vacuum hoses, pull off the end of
the hose, not the middle.
Incorrect Correct
ALA012G
(2) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected.
(3) After completing the job, double check that the vac-
uum hoses are properly connected. The label under
the engine hood shows the proper connecting part.
(4) When using a vacuum gauge, never force the
hose onto a connector that is too large. Use a
step-down adapter for adjustment.
ALA013G Once the hose has been stretched, it may leak air.
(i) Torque when using a torque wrench with an extension

tool
(1) When the SST or extension tool is combined with
the torque wrench to extend its entire length, if
you tighten until the reading of the torque wrench
reaches the specified torque value, the actual
torque becomes excessive.
(2) In this manual, only the specified torque is de-
ALA014G scribed. In case of using the SST or extension
tool, calculate the reading of the torque wrench by
the following formula.
(3) Formula T’ = T × L2/(L1 + L2)

T’ Reading of torque wrench (N·m)
T Torque (N·m)
L1 Length of the SST or extension tool (cm)
L2 Length of the torque wrench (cm)
ALA015G
GENERAL GL-13
2. For vehicles equipped with SRS airbags and a seat

belt pretensioner
Hint:
The vehicle is equipped with a supplemental restraint
system (SRS) and a seat belt pretensioner.
Failure to carry out service operations in the correct
sequence could cause the SRS to unexpectedly deploy
during servicing, possibly leading to a serious accident.
Furthermore, if a mistake is made when servicing the SRS,
it is possible that the SRS may fail to operate properly.
Before servicing (including the removal or installation of
parts, inspection, or replacement), be sure to read the
following items carefully. Then follow the correct proce-
dures described in this manual.
(a) General notes
(1) Malfunction symptoms of the SRS are difficult to confirm, so the diagnostic trouble codes (DTCs)
become the most important source of information when troubleshooting. When troubleshooting
the SRS, always inspect the DTCs before disconnecting the battery (see page RS-11).
(2) To avoid serious injury, servicing the SRS must be started 90 seconds after meeting the following
conditions:
• The ignition switch is turned to the LOCK position.
• The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. So, if work is started within 90 seconds after
disconnecting the negative (-) terminal cable from the battery, the SRS may deploy). Disconnect-
ing the negative (-) terminal cable will erase clock memory and audio system presets.
Write down data as necessary before disconnecting the cable. To avoid erasing the memory set-
tings, never use a back-up power supply.
(3) In minor collisions where the SRS does not deploy, the driver airbag assembly, passenger airbag
assembly, and seat belt pretensioner should be inspected before further use of the vehicle (see
pages RS-11, RS-23).
(4) Never use the SRS parts from another vehicle. When replacing the parts, replace them with new
ones.
(5) Before repairing, removing the airbag ECU assembly if impacts are likely to occur to the assem-
bly during repairs.
(6) Never disassemble and repair the airbag ECU assembly, driver airbag assembly, passenger air-
bag assembly, or seat belt pretensioner.
(7) Replace the airbag ECU assembly, driver airbag assembly or front passenger airbag assembly if:
1) damage has occurred from being dropped; 2) if there are cracks, dents, or other defects in the
case, bracket or connector.
(8) Do not directly expose the airbag ECU assembly, driver airbag assembly, front passenger airbag
assembly or the seat belt pretensioner to hot air or flames.
(9) Never use a multimeter to measure the driver airbag assembly and front passenger airbag as-
sembly or the airbag will deploy and injury may result.
(10) Information labels are attached to the SRS components. Follow the instructions on the notices.
(11) After work on the SRS is completed, check the SRS warning light.
Mark (b) Clock spring (in the combination switch)

(1) The steering wheel must be attached correctly to
the steering column with the clock spring in the
neutral position, otherwise a cable disconnec-
tion and other problems may occur. Refer to page
SR-9 concerning the correct installation of the
steering wheel.
ALA016G
(c) Driver airbag assembly (w/airbag)

(1) When removing the driver airbag assembly or handling a new electric horn button, it should be
placed with the pad top surface facing up. See illustration below.
Placing it with the pad surface facing downward may lead to a serious accident if the airbag ac-
cidentally inflates. Also, do not place anything on top of the electric horn buttons.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could result in serious injury.
(3) Grease or detergents of any kind should not be applied to the steering wheel pad.
(4) Store the driver airbag assembly where the ambient temperature remains below 93°C, has a low
humidity, and is away from electrical noises.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors.
These connectors contain shorting springs. This feature reduces the possibility of the airbag or
seat belt pretensioner deploying due to currents entering the squib wiring.
(6) When disposing of the vehicle or driver airbag assembly, the airbag should be inflated by SST
before disposal (see page RS-27). Perform the operation in a safe place away from electrical
noise.
GENERAL GL-15
Example:
Correct Incorrect
ALA017G
Example:
ALA018G
(d) Front passenger airbag assembly

(1) Always place a removed or new front passenger airbag assembly with the airbag deployment
direction facing upward. Placing the airbag assembly with the airbag deployment direction facing
downward could cause a serious accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib or it may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kinds should not be applied to front passenger airbag assembly.
(4) Store the airbag assembly where the ambient temperature remains below 93°C, has a low hu-
midity, and is away from electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4
yellow pins).
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed
by SST before disposal (see page RS-27). Activate in a safe place away from electrical noise.
Example:
ALA019G
(e) Seat belt pretensioner

(1) Never measure the resistance of the seat belt pretensioner. This may activate the seat belt pre-
tensioner, which could cause serious injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner where the ambient temperature remains below 80°C , has a low
humidity, and is away from electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors.
(6) As a safety measure, always activate the seat belt pretensioner before disposal (see page RS-49).
Activate in a safe place away from electrical noise. (The seat belt pretensioner becomes hot after
activation. Allow it to cool before disposing. Never use water to cool seat belt pretensioner.)
(7) Oil or water should not be put on the front seat outer belt, and the front seat outer belt should not
be cleaned with any type of detergent.
Example:
ALA020G
(f) Airbag ECU assembly

(1) Never reuse an airbag ECU assembly which has been involved in a collision where its SRS has deployed.
(2) The connectors to the airbag ECU assembly should be connected or disconnected with the ECU
mounted on the floor. If the connectors are connected or disconnected while the airbag ECU as-
sembly is not mounted to the floor, it could cause accidental deployment of the SRS.
(3) To avoid serious injury, servicing the SRS must be started 90 seconds after meeting the following
conditions:
• The ignition switch is turned to the LOCK position.
• The negative (-) terminal cable is disconnected from the battery.
(g) Wire harness and connector
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connec-
tors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or
the connector becomes broken, repair or replace it.
GENERAL GL-17
3. Electronic control
Negative (-) Terminal (a) Removal and installation of battery terminal
(1) Before performing electronic work, disconnect the
battery negative (-) terminal cable before hand in
order to prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF and loosen the terminal nut completely. Per-
ALA021G form these operations without twisting or prying
the terminal.
(3) When the battery terminal cable is removed, all
the data stored (clock, CD player, DTCs, etc.) are
erased. Before removing the cable, make a record
of the settings of each memory system.
(4) When the battery negative (-) terminal cable is
disconnected, memories of various systems are
erased. Refer to the PRE-CHECK for each system
to make sure whether or not the system needs to
be initialized after the battery negative (-) terminal
cable is disconnected. If necessary, be sure to ini-
tialize the system.
(b) Handling of electronic parts
(1) Do not open the cover or case of the ECU unless
absolutely necessary.
(If the IC terminals are touched, the IC may be
rendered inoperative by static electricity��
.��)
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
Incorrect
ALA022G as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the
electronic components, air filter, and emission-
related components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connec-
tor, insert the tester probe carefully to prevent the
terminals from bending.
4. Removal and installation of fuel control parts

(a) Location for removing and installing fuel system parts
(1) Work in a place with good air ventilation without
any ignition sources, such as a welder, grinder,
drill, electric motor, or stove.
(2) Never work in a place such as a pit or near a pit
because vaporized fuel will collect in those places.
(b) Removal and installation of fuel system parts
(1) Prepare a fire extinguisher before starting opera-
tions.
(2) To prevent static electricity, install a ground cable
on the fuel changer, vehicle, and fuel tank, and do
not spray the area with water. The work surface
will become slippery. Do not clean up spills with
water as this will spread the gasoline and create a
fire hazard.
(3) Never use any electric equipment like an elec-
tric motor or a working light, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create
sparks.
(5) Dispose of shop rags containing fuel deposits sep-
arately in a fire-resistant container.
5. Removal and installation of engine intake parts

(a) Any metal particle enters the inlet pass may damage
the engine.
(b) When removing and installing the inlet system parts,
cover the openings of the removed parts and engine
openings. Use clean shop rags, gummed tape, or other
suitable materials.
(c) When installing the inlet system parts, check that no
ALA023G metal particles have entered the engine or the installed
part.
GENERAL GL-19
6. Handling of hose clamps

Spring Type Clamp
(a) Before removing the hose, check the clamp position so
you can restore it in the same way.
(b) Replace a deformed or dented clamp with a new one.
(c) When reusing a hose, attach the clamp on the clamp
track portion of the hose.
(d) For a spring type clamp, you can adjust and secure it
Clamp Track after installation by slightly pushing spring plate in the
ALA024G direction of the arrow marks as shown in the illustration.
7. For vehicles equipped with mobile communication

systems
(a) Install the antenna as far away from the ECU and sen-
sors of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm away from the
ECU and sensors of the vehicle electronic systems. For
details of the ECU and sensors locations, refer to the
section on applicable components.
ALA025G (c) Keep the antenna feeder separate from other wirings
as much as possible. This will prevent signals from the
communication equipment from affecting vehicle equip-
ment and vice versa.
(d) Check that the antenna and feeder are correctly ad-
justed.
(e) Do not install any high-powered mobile communication
system.
8. For vehicles equipped with a catalytic converter

Note:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause
overheating and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling of the engine.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never run the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
Vehicle Lift and Support Locations

1. Notice about vehicle condition when jacking up the vehicle
(a) The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily-loaded ve-
hicle.
(b) When removing heavy equipment such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or
shift or use a transmission jack to hold the jacking support.
2. Notice for using a 4-post lift
(a) Follow the safety procedures outlined in this instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Using a wheel stopper, fix the vehicle.
3. Notice for using a jack and safety stand
(a) Always use the wheel stopper when working on a flat surface.
Rubber Attachment (b) Use a safety stand with a rubber attachment, as shown
in the illustration.
(c) Apply the jack and rigid rack to the specified location on
the vehicle.
(d) When jacking up the front wheels, release the parking
brake and place the wheel chocks only behind the rear
wheels. When jacking up the rear wheels, place wheel
chocks only in front of the front wheels.
ALA026G (e) The jack should not be used without the rigid rack.
(f) When jacking up only the front wheels or only the rear wheels, place wheel chocks on both sides of
the wheels touching the ground.
(g) When jacking down the vehicle with its front wheels jacked up, release the parking brake and place
the wheel chocks only in front of the rear wheels. When jacking down a vehicle with its rear wheels
jacked up, place wheel chocks only behind the front wheels.
: Jack Position
: Support Position, Pantograph Jack Po-

sition
: Center of Vehicle Gravity

(unloaded condition)
ALA027G
GENERAL GL-21
4. Notice for using swing arm type lift

(a) Follow the safety procedures outlined in its instruction manual.
(b) Use a cradle with a rubber attachment, as shown in the illustration.
(c) When using the lift, its center should be as close to the vehicle’s center of gravity as possible.
(d) Set the vehicle on the cradle as level as possible. Then match the groove of the cradle to the rigid
rack support location. Do not raise the vehicle too high because the vehicle may become unstable.
(e) Be sure to lock the swing arm during the operation.
(f) Lift the vehicle up off the ground and shake it to make sure that it is stable.
5. Notice for using plate type lift
(a) Follow the safety procedures outlined in its instruction manual.
(b) Use plate lift attachments.
(c) Refer to the table below to determine how to properly set the vehicle.
Right and left set position • Place the vehicle over the center of the lift.
• Align the cushion gum ends of the plate with the attachment lower ends
Front and rear set position (A and C).
• Align the attachment upper end (B) with the rocker flange front side notch.
(d) Lift the vehicle up off the ground and shake it to make sure that it is stable.
Center of Lift
Swing Arm Type Lift
Center of Vehicle Gravity

(unloaded condition) Rubber
Attachment
Plate Type Lift
Attachment Dimensions
Attachment
ALA028G
How To Troubleshoot ECU Controlled Systems

General Information
A large number of ECU controlled systems are used in the vehicle. ECU controlled systems are considered
to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem
checking procedures only involve inspecting the ECU controlled system’s circuits one by one.
An adequate understanding of the system and a basic knowledge of electricity is enough to perform effec-
tive troubleshooting, accurate diagnoses, and necessary repairs. Detailed information and troubleshooting
procedures on major ECU controlled systems in this vehicle are outlined below:
System See page
1. ABS with EBD BR-33
2. Supplemental restraint system RS-1
3. Combination meter IR-20
4. Power door lock control system IR-51
5. Wireless door lock control system IR-55
For using the tester:

• Before using the diagnosis tool or tester, the diagnosis tool’s instruction book or tester’s operator manual
should be read thoroughly.
• If the diagnosis tool or tester cannot communicate with the ECU controlled systems, there is a problem
on the vehicle side or tester side.
(1) If the communication is normal when the tester is connected to another vehicle, inspect the diag-
nosis data link line (Bus ⊕ line) or the ECU power circuit of the vehicle.
(2) If communication is still impossible when the tester is connected to another vehicle, the problem is prob-
ably in the tester itself, so perform the self test procedures outlined in the Tester Operator’s Manual.
How To Proceed With Troubleshooting

Hint:
Carry out troubleshooting in accordance with the procedures below. Only the basic procedure is shown.
Details in the DIAGNOSTICS section show the most effective methods for each circuit. Confirm the trou-
bleshooting procedures for the relevant circuit before beginning troubleshooting.
1 Vehicle brought to workshop
2 Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem occurred.
3 Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage.

Voltage: 11 - 14 V (Engine stops)
(b) Visually check the wire harness, connectors, and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions and check for DTCs according to the related chart.
OK Go to step 5
GENERAL GL-23
NG
4 DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system and part
using the DTC chart.
Go to step 6
5 Problem symptoms table
(a) Check the results obtained in step 3. Confirm the inspection procedures for the system and part using
the problem symptoms table.
6 Circuit inspection or parts inspection
(a) Confirm the circuit in the system or the part that should be checked using the problem symptoms table
or the results obtained in step 4.
7 Repair
(a) Repair the affected system or part according to the instructions in step 6.
8 Confirmation test
(a) After completing repairs, confirm that the problem has been solved (If the problem does not reoccur,
perform a confirmation test under the same conditions and in the same environment as when it oc-
curred for the first time).
End
Customer Problem Analysis

Hint:
In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be dis-
carded in order to give an accurate judgement. To ascertain what the problem symptoms are, it is extreme-
ly important to ask the customer about the problem and the conditions at the time it occurred.
As much information as possible should be gathered for reference, even the past problems that seem un-
related may help in some cases. In the DIAGNOSTIC section, a customer problem analysis table is pro-
vided for each system.
The following 5 items are important points in the problem analysis:
Important points with customer problem analysis
• What ––––– Vehicle model, system name
• When ––––– Date, time, occurrence frequency
• Where ––––– Road conditions
• Under what conditions? ––––– Running conditions, driving conditions, weather conditions
• How did it happen? ––––– Problem symptoms
(Sample) supplemental restraint system check sheet
Customer problem analysis check

Supplemental restraint system check sheet Inspector’s name
VIN
Customer’s name Production date / /

License no.
Date vehicle km
brought in / / Odometer reading miles
Date problem first

occurred
Weather ¨Fine ¨Cloudy�� ¨Rainy �� ¨Snowy �� Öther
Temperature Approx.
¨Starting Ïdling
Vehicle operation
¨Driving [ ¨Constant speed Äcceleration�� ¨Deceleration
condition
Öther ]
GENERAL GL-25
Symptom Confirmation and Diagnostic Trouble Code

Hint:
The diagnostic system in the vehicle fulfills various functions.
The first function is the Diagnostic Trouble Code (DTC) Check. In a DTC Check, a previous malfunction’s
DTC can be checked by a technician during troubleshooting (A DTC is a code stored in the ECU memory
whenever a malfunction in the signal circuits to the ECU occurs)��.�
Another function is the Input Signal Check, which checks if the signals from various switches are sent to
the ECU correctly.
By using these check functions, the problem areas can be narrowed down and troubleshooting is more ef-
fective.
Diagnostic functions are incorporated in the following systems in the vehicle.
Diagnostic Input signal Diagnostic test
System trouble code check mode
check (sensor check) (active test)
ABS with EBD
Supplemental Restraint System
Combination meter
In the DTC Check, it is very important to determine whether the problem indicated by the DTC is: 1) still
occurring; 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to
the problem symptom to see if they are related. For this reason, DTCs should be checked before and after
confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current conditions, as
shown in the table below.
Never skip the DTC Check. Failure to check DTCs may, depending on the case, result in unnecessary
troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow the
procedures listed above in the correct order.
A flow chart showing how to proceed with troubleshooting using the DTC Check is shown below. Directions
from the flow chart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of
the problem symptoms table.
1 DTC check
2 Make a note of DTCs displayed and then clear the memory
3 Symptom confirmation
A Symptoms exist
B No symptoms exist
A Go to step 5
4 Simulation test using the symptom simulation methods
5 DTC check
A DTC displayed
B No DTC displayed
If a DTC was displayed in the initial DTC check, it indicates

that the trouble may have occurred in a wire harness or con-
nector in that circuit in the past.
Therefore, check the wire harness and connectors (see
page GL-24).
A System normal
Troubleshooting of each problem symptom

The problem is still occurring in a place other than the diagnostic circuit (The DTC displayed first is either
for a past problem or a secondary problem).
GENERAL GL-27
Symptom Simulation
Hint:
The most difficult case in troubleshooting is that no problem symptoms occur. In such cases, a thorough
customer problem analysis must be carried out. A simulation of the same or similar conditions and environ-
ment in which the problem occurred in the customer’s vehicle should be carried out. No matter how much
skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to
important repairs being overlooked and lead to mistakes or delays.
Example:
With a problem that only occurs when the engine is cold or occurs as result of vibration caused by the road
during driving, the problem can never be determined as long as the symptoms are being checked on a sta-
tionary vehicle or a vehicle with a warmed-up engine. Vibration, heat, or water penetration (moisture) is dif-
ficult to reproduce. The symptom simulation tests below are effected substitutes for the conditions and can
be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must be con-
firmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tes-
ter and carry out the symptom simulation test, judging whether the circuit being tested is defective or nor-
mal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each
system to narrow down the possible causes.
Vibrate Slightly 1. Vibration method: When vibration seems to be the
major cause.
(a) Part and sensor
(1) Apply a slight vibration with a finger to the part of
the sensor considered to be the cause of the prob-
lem and check whether or not the malfunction oc-
Shake Slightly
curs.
HINT:
Vibrate Slightly ALA029G Applying a strong vibration to relays may result in
open relays.
(b) Connectors
(1) Slightly shake the connector vertically and hori-
zontally.
(c) Wire harness
(1) Slightly shake the wire harness vertically and hori-
zontally.
The connector joint and fulcrum of the vibration
are the major areas that should be checked thor-
oughly.
2. Heat method: If the problem seems to occur when

the area in question is heated.
Malfunction
(a) Heat the component that is the possible cause of the
malfunction with a hair dryer or similar device. Check
whether or not the malfunction occurs.
Note:
• Do not heat to more than 60°C (Exceeding this tem-
perature may damage components).
ALA030G • Do not apply heat directly to the parts in the ECU.
3. Water sprinkling method: When the malfunction

seems to occur on a rainy day or in high humidity.
(a) Spray water onto the vehicle and check whether or not
the malfunction occurs.
Note:
• Never spray water directly into the engine compart-
ment. Indirectly change the temperature and humid-
ity by applying a spray of water onto the front of the
ALA031G radiator.
• Never apply water directly onto the electronic com-
ponents.
Hint:
If the vehicle has or had a water leakage problem, the
leakage may have damaged the ECU or connections.
Look for evidence of corrosion or shorts. Proceed with
caution during water tests.
4. Other: When a malfunction seems to occur when
the electrical load is excessive.
(a) Turn on all the electrical loads including the heater
blower, front combination light, rear window defogger,
etc., and check if the malfunction occurs.
ALA032G
Electronic Circuit Inspection Procedure

1. Basic inspection
(a) Resistance measuring condition of electronic parts
(1) Unless stated, all resistance is measured at an ambient temperature of 20°C. Resistances mea-
sured may not be as specified if measured at high temperatures, i.e. immediately after the ve-
hicle has been running. Measurements should be made when the engine has cooled down.
(b) Handling of the connector
(1) When disconnecting a connector, first squeeze the
mating halves tightly together to release the lock,
then press the lock claw and separate the connec-
tor.
Incorrect
(2) When disconnecting a connector, do not pull on
the harnesses. Grasp the connector directly and
separate it.
Correct
ALA033G (3) Before connecting the connector, check that there
are no deformed, damaged, loose, or missing ter-
minals.
(4) When connecting a connector, press firmly until
you hear the lock close with a “clicking” sound.
(5) If checking the connector with an electrical tester,
check it from the backside (harness side) of the
connector using a mini test lead.
GENERAL GL-29
Note:
• As a waterproof connector cannot be checked
from the backside, check by connecting a sub
harness.
• Do not damage the terminals by moving the
inserted tester needle.
Looseness of Crimping (c) Connector checking points
(1) Checking when the connector is connected:
Squeeze the connector together to confirm that it
Core Wire is fully inserted and locked.
(2) Checking when the connector is disconnected:
Terminal
Deformation Check by pulling the wire harness lightly from the
backside of the connector. Look for unlatched ter-
Pull Gently minals, missing terminals, loose crimps, or broken
ALA034G conductor wires.
Note:
When testing a gold-plated female terminal, al-
ways use a gold-plated male terminal.
(3) Checking the contact pressure of the terminal:
Prepare a spare male terminal. Insert it into a fe-
male terminal and check for good tension when
inserting and after full engagement.
Same Terminal as
a Male Terminal
ALA035G
(d) Repair method of the connector terminal

(1) If there is any dirt on the terminal, clean the con-
tact point by an air gun or shop rag. Never polish
the contact point with sandpaper as the painting
may come off.
(2) If there is abnormal contact pressure, replace the
female terminal.
Correct Incorrect If the male terminal is gold-plated (gold color), use
ALA036G a gold-plated female terminal; if it is silver-plated
(silver color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should
be replaced. If the terminal will not lock into the
housing, the housing may have to be replaced.
(e) Handling of the wire harness

Incorrect (1) If removing a wire harness, check the wiring and
clamping before proceeding so that it can be re-
stored in the same way.
(2) Never twist, pull, or loosen the wire harness more
than necessary.
(3) Never allow the wire harness come into contact
with a high temperature part, rotating, moving, vi-
ALA037G brating, or sharp-edged parts. Avoid panel edges,
screw tips, and similar sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness.
If it is cut or broken, replace it or securely repair it
with vinyl tape.
2. Check the open circuit
Fig. 1 (a) For an open circuit in the wire harness in Fig. 1, per-
OPEN form a resistance check (Step b) or a voltage check
Sensor (Step c).
ALA038G
(b) Check the resistance.

Fig. 2
(1) Disconnect connectors A and C and measure the
resistance between them.
Resistance: 1 Ω or less
Sensor Hint:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally.
Fig. 2:
ALA039G Between terminal 1 of connector A and terminal 1
of connector C → 10 kW or higher
Between terminal 2 of connector A and terminal 2
of connector C → Below 1 W
In this case, an open circuit exists between termi-
nal 1 of connector A and terminal 1 of connector C.
(2) Disconnect connector B and measure the
Fig. 3
resistance between the connectors.
Fig. 3:
Sensor Between terminal 1 of connector B1 and terminal
1 of connector A → Below 1 W
Between terminal 1 of connector B2 and terminal
1 of connector C → 10 kW or higher
In this case, an open circuit exists between terminal
ALA040G 1 of connector B2 and terminal 1 of connector C.
GENERAL GL-31
(c) Check the voltage.

Fig. 4
(1) In a circuit in which voltage is applied to the ECU
connector terminal, an open circuit can be checked
by conducting a voltage check.
Sensor Fig. 4:
With each connector still connected, measure the
voltage between the body ground and terminal 1
of connector A at the ECU 5 V output terminal, ter-
ALA041G minal 1 of connector B and terminal 1 of connector
C, in that order.
(2) Example results:
5 V: Between terminal 1 of connector A and body
ground
5 V: Between terminal 1 of connector B and body
ground
0 V: Between terminal 1 of connector C and body
ground
If your results match the examples above, an open
circuit exists in the wire harness between terminal
1 of B and terminal 1 of C.
3. Check for a short circuit
Fig. 5
(a) If the wire harness is ground shorted (Fig. 5), locate the
Short
section by conducting a resistance check with the body
ground (below).
ALA042G
(b) Check the resistance with the body ground.

Fig. 6
(1) Disconnect connectors A and C and measure the
resistance between terminals 1 and 2 of connector
A and the body ground.
Sensor Resistance: 10 Ω or higher
Hint:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally.
ALA043G Fig. 6:
Between terminal 1 of connector A and body
ground → Below 1 W
ground → 10 kW or higher
In this case, a short circuit exists between terminal
1 of connector A and terminal 1 of connector C.
Fig. 7 (2) Disconnect connector B and measure the resis-

tance between terminal 1 of connector A and the
body ground, and terminal 1 of connector B2 and
the body ground.
Sensor Fig. 7:
ground → 10 kW or higher
Between terminal 1 of connector B2 and body
ALA044G ground → Below 1 W
In this case, a short circuit exists between terminal
1 of connector B2 and terminal 1 of connector C.
4. Check and replace the ECU
Note:
• Start an inspection of the connector from the back-
side of the connector at the wire harness side with
the connector connected to the ECU.
• When no measuring condition is specified, perform
the inspection with the engine stopped and the igni-
tion switch ON.
• Check that the connectors are fully seated. Check
for loose, corroded, or broken wires.
(a) First check the ECU ground circuit. If it is faulty, repair
it.
If it is normal, the ECU could be faulty. Replace the
ECU with a normal functioning one and check if the
symptoms occur.
(1) Measure the resistance between the ECU ground
Example
terminal and body ground.
Resistance: 1 Ω or less
Ground
ALA045G
ECU Side (2) Disconnect the ECU connector. Check the ground
terminals (on the ECU side and wire harness side)
for evidence of bending, corrosion, or foreign ma-
Ground terials. Lastly, check the contact pressure of the
W/H Side
female terminals.
Ground
ALA046G
GENERAL GL-33
Terms
Abbreviations Used In This Manual
Abbreviations Meaning
ABS Anti-lock brake system
A/C Air conditioner
CD Compact disc
CPU Central processing unit
DTC Diagnostic trouble code
EBD Electronic brake force distribution
ECU Electronic control unit
GAS Gasoline
GND Ground
HI High
LH Left-hand
LO Low
MAX. Maximum value
MIN. Minimum value
N Neutral
RH Right-hand
SRS Supplemental restraint system
SSM Special service materials
SST Special service tools
T/M Transmission
VIN Vehicle identification number
VVT-i Variable valve timing-intelligent
W/H Wire harness
1st First gear
2nd Second ��
gear
2WD Two-wheel drive vehicle (4 × 2)
3rd Third ��
gear
4th Fourth ��
gear
5th Fifth ��
gear
SPECIAL TOOLS
Recommended Tools for Complete Vehicles
Part No. Description Sketch Purpose Remarks
Used for mounting

Rear wheel hub bear-
CC8011101 the rear wheel hub
ing mounting tool
bearing
Used for disassem-

Rear wheel hub bear-
CC8011102 bling the rear wheel
ing disassembling tool
hub bearing
Used for holding

CC8011103 Holding frame
tools
Used for disassem-

Front steering knuckle
bling and mounting
CC8011218 disassembling /mount-
the steering knuckle
ing tool
hub and bearing
Swing arm ball mount- Used for mounting Combining with

CC8011101
ing tool the swing arm ball CC8031108
Used for disassem-

Swing arm ball disas- Combining with
CC8011108 bling the swing arm
sembling tool CC8031108
ball
Used for holding the

Swing arm ball holding
CC8031108 ball during mounting
frame
and disassembling
Used for disassem-

Big swing arm bushing One end for moun-
bling and mounting
CC8021104 disassembling /mounting, the other end
the big swing arm
ing tool for disassembling
bushing

Big swing arm bushing
big bushing disas-
CC8021105 disassembling /mount-
sembling/mounting
ing tool holding frame
tool
GENERAL GL-35
Part No. Description Sketch Purpose Remarks

Small swing arm bush-
small bushing disas-
CC8021106 ing disassembling
sembling /mounting
/mounting tool holding
tool
Used for disassem-

Small swing arm bush-
bling and mounting
CC8021107 ing disassembling
the small swing arm
/mounting tool
bushing

Rear axle bushing dis-
rear axle bushing
CC8033216 assembling /mounting
during disassem-
holding frame
bling and mounting
Rear axle bushing dis- Used for disassem-

CC8033217 assembling /mounting bling and mounting
tool the rear axle bushing
Tools for the ZM-007Q Transmission Case
No. Part No. Description Sketch Purpose Remarks
Used for mount-

Differential bearing For both left and
1 CC8047301 ing the differential
mounting tool right sides
bearing
Used for disas-

Differential bearing dis- Combining with
2 CC8047302 sembling the differ-
assembling tool chuck
ential bearing
Used for mounting

Output shaft bearing
3 CC8047206 the output shaft
mounting tool (left)
bearing (left)
Used for disas-

Input/output shaft bear- Combining with
4 CC8047207 sembling the out-
ing disassembling tool chuck
put shaft bearing
Used for mounting

Differential oil seal Combining with
5 CC8047303 the differential oil
mounting tool (right) CC8027225
seal
Used for mounting

Input shaft oil seal Combining with
6 CC8047209 the input shaft oil
mounting tool CC8027225
seal
Used for mounting

the output shaft Combining with
7 CC8047210 outer ring mounting tool
bearing outer ring CC8027225
(left)
(left)
Used for mounting

the output shaft
8 CC8047211 outer ring mounting tool
bearing outer ring
(right)
(right)
Used for mount-

Differential bearing outer For both left and
9 CC8047304 ing the differential
ring mounting tool right sides
bearing outer ring
Used for disas-

Differential axle pin disas-
sembling the differ- G e n e r a l - p u r -
10 CC8027331 sembling tool (punch) 4
ential axle pin and pose
mm
selector lever axle
GENERAL GL-37
Tools for the CC��

��
001 Transmission Case
No. Part No. Description Sketch Purpose Remarks
Used for mounting

Differential bearing mount- For both left
1 CC8057326 the differential bear-
ing tool and right sides
ing
Used for disassem-

Differential bearing disas- Combining with
2 CC8047302 bling the differential
sembling tool chuck
bearing
Used for mount-

Output shaft bearing For both left
3 CC8057232 ing the output shaft
mounting tool and right sides
bearing
Used for disassem-

Input/output shaft bearing
4 CC8047207 bling the output shaft
disassembling tool
bearing
Used for mounting

Input shaft bearing mount-
5 CC8057233 the input shaft bear-
ing tool (left)
ing (left)
Used for mounting

Input shaft bearing mount- Combining with
6 CC8057234 the input shaft bearing
ing tool (right) CC8027225
(right)
Used for mounting

Differential oil seal mount- Combining with
ing tool (left) CC8027225
seal
Used for mounting

Differential oil seal mount- Combining with
ing tool (right) CC8027225
seal
Used for mounting

Differential bearing outer
ring mounting tool (right)
ing outer ring
Used for mounting

Differential bearing outer
ring mounting tool (left)
ing outer ring
Used for mounting the

Output shaft gear mounting 1st and 2nd speed
11 CC8057235
tool gears of the output
shaft
Used for mounting

Output shaft gear mounting
12 CC8057236 the 3rd speed gear of
tool
the output shaft
Used for mounting

Output shaft gear mounting
13 CC8057237 the 5th speed gear of
tool
the output shaft
Used for mounting

Output shaft gear mounting the 3rd speed syn-
14 CC8057238
tool chronizer gear hub of
the input shaft
Used for mounting

The 5th speed
Output shaft gear mounting the 5th speed syn-
15 CC8057237 gear of the out-
tool chronizer hub gear of
put shaft
the input shaft
GENERAL GL-39
Selector lever oil seal

16 CC8057239
mounting tool
Selector lever oil seal

17 CC8057240
mounting tool
18 CC8057242 Input shaft holding tool
Selector lever axle pin disas- Used for disassem-

19 CC8027331
sembling tool (punch) 4 mm bling the axle pin
Differential axle pin disas- Used for disassem-

20 CC8027330
sembling tool (punch) 5 mm bling the axle pin
SERVICE SPECIFICATIONS
Engine Mechanical
Maintenance Data
New drive belt deflection Fan and generator 7.0 to 8.5 mm
Pressure: 98 N Power steering oil pump 6.0 to 8.0 mm
Old drive belt deflection Fan and generator 11.0 to 13.0 mm
Pressure: 98 N Power steering oil pump 11.0 to 13.0 mm
New driving belt tension Fan and generator 490 to 690 N
Power steering oil pump 445 to 667 N
Old driving belt tension Fan and generator 340 to 440 N
Power steering oil pump 267 to 445 N
Ignition timing 8 to 12 BTDC
Idling speed M/T 800 ± 25 r/min
Piston diameter 74.940 to 74.955 mm
Piston pin temperature at 20°C 18.012 to 18.016 mm
Piston pin aperture 18.001 to 18.004 mm
Oil clearance Standard value 0.008 to 0.015 mm
Maximum value 0.050 mm
Standard value 0.045 to 0.070 mm
Piston clearance
Connecting bar linearity Maximum value 0.06 mm /100 mm
Connecting bar camber Maximum value 0.10 mm/100 mm
Piston ring groove clearance No.1 0.03 to 0.07 mm
No.2 0.02 to 0.06 mm
Piston ring end clearance Standard value No.1 0.20 to 0.35 mm
No.2 0.35 to 0.50 mm
Oil ring 0.20 to 0.70 mm
Connecting rod bolt diameter Standard value 6.6 to 6.7 mm
Main journal diameter 45.985 to 46.000 mm

Crank pin diameter 39.985 to 40.000 mm
Crank timing sprocket diam- Standard value 51.72 mm
eter (With chain) Minimum value 50.5 mm
Crankshaft bearing cap set bolt Standard value 7.3 to 7.5 mm
diameter Minimum value 7.2 mm
Main journal clearance Standard value 0.014 to 0.037 mm
Tight plug depth 0.2 to 1.2 mm
Cylinder head setting straight pin protrusion part 8.5 to 9.5 mm
Straight pin protrusion part Pin A 3.5 to 4.5 mm
Pin B 18.5 to 19.5 mm
Pin C 8.9 to 9.5 mm
Pin D 11.5 to 12.5 mm
GENERAL GL-41
Torque Specifications
Part tightened N·m
Generator × Engine Bolt A 24
Bolt B 60
Power steering oil pump × Engine 35
Engine under cover LH × Body 5.0
Engine under cover RH × Body 5.0
Exhaust manifold front heat insulator × Exhaust manifold 9-11
Manifold bracket × Cylinder block sub-assembly 28-32
Engine mounting insulator LH × Engine mounting bracket LH 78
Engine rear mounting insulator × Engine rear mounting

78
bracket
Engine mounting insulator RH × Body Bolt 78
Nut 78
Auxiliary frame sub-assembly × Body Bolt A 120
Bolt B 145
Front suspension lower control arm LH × Steering knuckle 98
Front axle hub nut × Front drive shaft 225
Tie rod end assembly LH × Steering knuckle 50
Front speed sensor LH × Steering knuckle 8.0
Oil pan drain plug × No.2 oil pan 16-20
Front exhaust pipe assembly × Exhaust manifold 60
Spark plug × Cylinder head 25-29
Auxiliary frame strut rod × Body 46
Water filler × Radiator 7.5
Transmission/Transaxle
Part tightened N·m
Transmission control cable assembly × Body 5.0
Floor shift lever assembly × Floor 12
Wire harness clamp × Transaxle 5.0
Ground wire × Engine mounting bracket LH 26
Air filter bracket × Transaxle 19
Clutch release cylinder × Brake hose 16
No.1 engine hanger × Engine 40
Auxiliary frame strut rod set bolt 46
Auxiliary frame sub-assembly × Body Bolt A 120
Bolt B 145
Engine mounting bracket LH × Transaxle 78
Engine Rear mounting bracket × Transaxle Bolt A 68
Bolt B 68
Engine mounting insulator LH × Engine mounting bracket LH 78
Engine rear mounting insulator × Engine rear mounting bracket 78
Starter assembly × Transaxle 37
Starter assembly × Starter wire harness 9.8
Transaxle × Engine 33
Filler plug × Transaxle 33
Drain plug × Transaxle 39
Clutch release cylinder assembly × Transaxle 12
Transmission filler plug × Transaxle 39
GENERAL GL-43
Fuel
Maintenance Data
Fuel pump
At ��
20°C 0.2 to 3.0 Ω
Resistance
Torque Specification
Part tightened N·m
Rear row seat cushion bracket sub-assembly RH × Floor 5.0
Fuel tank assembly × Body 26
Parking brake cable assembly LH × Body 5.4
Parking brake cable assembly RH × Body 5.4
Exhaust manifold × Exhaust pipe assembly (front) 60
Exhaust pipe assembly × Exhaust pipe assembly (tail) 60
Ignition
Maintenance Data
Spark plug Made by FEDERALMOGUL RC8YC
Electrode gap K16R-U, BKR5EYA 0.7 to 0.8 mm
Part tightened N·m
Spark plug × Cylinder head 25-29
Ignition coil (with igniter) × Cylinder head cover 6-8
Starting and Charging

Maintenance Data
Starter assembly
Specified current 65 A or lower when voltage is 11.5 V
Battery ��
voltage
Except maintenance-free battery Standard specific gravity When��20°C 1.27 to 1.29
At ��
20°C 12.5 to 12.9 V
Part tightened N·m
Engine under cover LH × Body 5.0
Discharge Control
Maintenance Data
Heated oxygen sensor HT (1) - +B (2) Continuity
Resistance HT (1) - E2 (4) No continuity
Rear heated oxygen sensor HT (1) - +B (2) Continuity
Resistance HT (1) - E2 (4) No continuity
Exhaust System
Part tightened N·m
Heated oxygen sensor × Rear catalytic converter assembly 60
Sub muffler assembly × Rear catalytic converter��
assembly 60
Main muffler assembly × Sub muffler assembly 60
Exhaust pipe rear shield bracket × Body 20
GENERAL GL-45
Cooling System
Maintenance Data
Thermostat
Valve opening temperature 82 ± 2°C
Valve lift At ��
95°C 8 mm or more
Radiator filler cap sub-assembly
Standard opening pressure 93 to 123 kPa
Minimum opening pressure 78 kPa
Cooling fan
Standard amperage 11.7 to 14.7 A
Continuity
Cooling fan relay Between terminals 1 and 2 No continuity
Specified condition Between terminals 3 and 5 Continuity (when battery voltage is applied to
terminal 1 and 2)
No.2 cooling fan relay Between terminals 1 and 2 Continuity

Specified condition Between terminals 3 and 4 Continuity
Between terminals 3 and 5 No continuity
Continuity (when battery voltage is applied to
terminal 1 and 2)
Cooling fan resistor

Resistance At ��
20°C 0.03 W
Part tightened N·m
Water pump × Oil pump assembly 10-12
Water pump pulley × Water pump 10-14
Water inlet × Cylinder body sub-assembly 10-12
Radiator assembly × Fan shroud 7.5
Radiator upper cross beam × Body 5.0
Radiator upper cross beam × Reservoir condenser 9.8
Engine hood lock support × Body 5.0
Engine hood lock assembly × Engine hood lock support 8.0
Water filler × Radiator 7.5
Drive Shaft/Axle
Maintenance Data
Front axle hub bearing: bearing play Maximum: 0.05 mm
Front axle hub sub-assembly: deviation Maximum: 0.07 mm
Rear axle hub & bearing assembly: bearing play Maximum: 0.05 mm
Rear axle hub & bearing assembly: deviation Maximum: 0.07 mm
Part tightened N·m
Front wheel set nut 110
Rear wheel set nut 110
Transaxle drain plug 39
Tie rod end assembly × Steering knuckle 50
Suspension lower control arm × Steering knuckle 98
Front stabilizer bar × Suspension lower control arm 37
Brake hose & front speed sensor × Front shock absorber assembly 29
Front speed sensor × Steering knuckle 8.0
Front axle hub nut 225
Front brake disc housing × Steering knuckle 8.3
Front axle assembly × Front shock absorber assembly 132
Front brake caliper assembly × Steering knuckle 88
Rear axle hub & bearing assembly × Rear twist beam 50
GENERAL GL-47
Clutch
Maintenance Data
Pedal height to the dash panel 134.3-144.3 mm
Clutch pedal free play 14 mm
Clutch pedal push rod play on the top end of the pedal 5.0-8.0 mm
Slotted spring pin protrusion part 1.5-3.5 mm
Distance between clutch release point and the full stroke end position 25 mm or more
Clutch disc rivet head depth��
Maximum
�� 0.3 mm
Clutch disc assembly runout��
��
Minimum 0.8 mm
Diaphragm spring finger Maximum depth 0.5 mm
wear Maximum width 6.0 mm
Flywheel sub-assembly
runout
Diaphragm spring tip
Maximum depth 0.5 mm
alignment
Part tightened N·m
Clutch pedal sub-assembly × Clutch pedal bracket 30
Clutch master cylinder push rod clevis lock nut 12
Clutch master cylinder × Clutch hose 15
Clutch pedal × Clutch master cylinder 23
Clutch release cylinder bleeder screw 8.4
Clutch release cylinder × Transaxle housing 12
Clutch release cylinder × Clutch hose 16
Clutch release cylinder × Clutch release end 25
Clutch cover assembly × Flywheel sub-assembly 19
Release fork support × Transaxle assembly 37
Front Suspension System

Maintenance Data
Vehicle height A-B: 82 mm
D-C: 12 mm
Front wheel toe-in (total) -0°04’ ± 10’
Rack end length difference 1.5 mm or less
Front Wheel turning angle Inner turning angle 32° - 37°

wheel Outer turning angle 28° - 33°
align- Front wheel camber -0°29’ ± 30’
ment RH-LH error 30’(0.5°) or less
Front wheel kingpin 2°08’ ± 45’
caster RH-LH error 36’��
(0.56°)��
or less
Front wheel kingpin 9°49’ ± 30’
inclination RH-LH error 30’��
(0.5°)��
or less
Front
Lower control arm ball
suspen- 5.0 N·m or less
pin turning torque
sion
A: Ground clearance of front wheel center

B: Ground clearance of front suspension lower control arm front bolt center
C: Ground clearance of rear twist beam set bolt center
D: Ground clearance of rear wheel center
GENERAL GL-49
Part tightened N·m
Tie rod end lock nut 37
Steering knuckle × Shock absorber 132
Front wheel hub nut 110
Front shock absorber pillar upper mounting seat × Piston rod 33
Front shock absorber pillar upper mounting pressure plate × Body 40
Speed sensor wire bracket set bolt 29
Cowl top outer panel × Body 5.0
Auxiliary frame sub-assembly × Body Bolt A: 120
Bolt B: 145
Auxiliary frame sub-assembly × Transverse engine mounting
78
insulator
Auxiliary frame sub-assembly × Steering combination tube 7.8
Power steering gear × Auxiliary frame sub-assembly 107
Stabilizer bar bolt set nut 37
Steering knuckle × Lower control arm ball pin 98
Suspension lower control arm × Bolt A: 180
Auxiliary frame sub-assembly Bolt B: 107
Stabilizer bar mounting bracket × Auxiliary frame sub-assembly 37
Rear Suspension System

Maintenance Data
Toe-in (total) 0°10’ ��
±��
15’(4 mm±5 mm)
Rear wheel
alignment Camber -0°43’ ��
±��
30’
RH-LH error 30’(0.5°) or less
Part tightened N·m
Piston rod set nut 25
Shock absorber × Rear twist beam 120
Rear axle hub set bolt 85
Parking brake cable bracket set bolt 5.4
Speed sensor wire harness bracket set bolt 8.0
Rear twist beam × Body 120
Hub nut 110
Tire and Wheel

Maintenance Data
185/65R 15 88H Front: 200 ��
± 10 ��
kPa
Cold tire infla-
Rear: 200 ± 10��
kPa
tion pressure
T125/70R16 96M Spare tire: 420 ��
± 10 ��
kPa
Tire runout 1.4 mm or less
Imbalance after adjustment 5.0 g or less
GENERAL GL-51
Brake System
Maintenance Data
Brake pedal height (to the cushion) 120-130 mm
Brake pedal free play 6-9 mm
Brake lamp switch clearance 0.5-2.4 mm
Pedal reverse distance from the dash panel at 490 N Longer than 55 mm
Front wheel brake pad thickness Standard value 11.0 mm
Minimum value 1.0 mm
Front wheel brake disc thickness Standard value 22.0 mm
Front wheel brake disc runout Maximum value 0.05 mm
Rear brake drum inside diameter Standard value 200.0 mm
Rear wheel brake drum brake shoe Standard value 4.0 mm
lining thickness Minimum value 1.0 mm
Rear wheel brake pad thickness Standard value 10.0 mm
Part tightened N·m
Bleeder screw 8.3
Vacuum booster clevis lock nut 26
Brake pedal bracket sub-assembly × Brake pedal sub-assembly 30
Brake pedal assembly × Vacuum booster 23
Brake master cylinder × Vacuum booster 23
Brake line union nut 16
Wheel nuts 110
Front brake cylinder set bracket × Steering knuckle 88
Front brake cylinder × Front brake cylinder set bracket 34
Front brake caliper × Brake hose 29
Rear drum brake wheel cylinder × Deck board 9.8
ABS controller assembly × ABS controller bracket 5.4
ABS controller bracket × Body 19
Front speed sensor × Steering knuckle 8.0
Front speed sensor wire harness clamp × Shock absorber 29
Front speed sensor wire harness clamp × Body 8.0
Yaw rate sensor × Body 14
Parking Brake System

Maintenance Data
When parking brake lever travel is at 196 N Clicking sound for 5-8 times
Part tightened N·m
Wheel nuts 110
Parking brake set nut 5.4
Parking brake handle × Body 13
Front floor middle heat insulator × Body 5.5
Parking brake cable assembly LH × Body 5.4
Parking Brake Cable Assembly LH × Deck board 7.8
GENERAL GL-53
Steering System
Maintenance Data
Steering wheel free play Maximum value 30 mm
Part tightened N·m
Cross rod × Rack end 88
Steering propeller shaft joint × Steering connecting shaft 28
Steering column set bolt 25
Propeller shaft × Main shaft 28
Steering wheel lock nut 50
Steering wheel pad set bolt 8.8
Power Steering System

Maintenance Data
Power steering system
Fluid level increment Maximum value 5 mm
Fluid pressure when idle and valve close 5,900 kPa
Steering torque when idling (Reference value) 6 N·m
Power steering gear
Steering tie rod ball stud assembly torque 0.8-3.4 N·m
Part tightened N·m
Power steering oil pump
Power steering oil pressure sensor 21
Pressure feed tube × Power steering oil pump 30
Power steering gear
Steering tie rod ball stud assembly lock nut 74
Power steering gear set bolt 107
Steering connecting shaft set bolt 28
Steering gear shield set bolt (a): 18
(b): 35
Auxiliary frame sub-assembly set A: 120
bolt B: 145
Engine rear mounting × Auxiliary frame sub-assembly 78
Auxiliary frame strut rod set bolt RH, LH 46
Pressure feed tube × Power steering gear 27 (25)
Steering combination tube clamp set bolt 7.8
Steering propeller shaft joint × Steering connecting shaft 28
GENERAL GL-55
Air Conditioning System

Maintenance Data
Refrigerant charge amount Standard value 490 ± 10 g
Part tightened N·m
A/C blower assembly
Evaporator expansion valve × Evaporator sub-assembly 10
A/C pipe assembly × Evaporator expansion valve 10
Suction hose sub-assembly × Body 9.8
Compressor assembly
Compressor assembly × Engine 32
Suction hose sub-assembly × Compressor assembly 10
Compressor discharge pipe assembly × Compressor assembly 10
Condenser with reservoir assembly
Cover × Condenser with reservoir assembly 2.9
Condenser upper mount assembly × Condenser with reservoir
3.9
assembly
Condenser with reservoir assembly × Body 9.8
Condenser outlet pipe × Condenser with reservoir assembly 10
Compressor discharge pipe assembly × Condenser with reser-
10
voir assembly
Engine hood lock support sub-assembly × Body 5.0
Supplemental Restraint System

Part tightened N·m
Driver airbag assembly × Steering wheel assembly 8.8
Steering wheel assembly × Steering column assembly 50
Front passenger airbag assembly × Instrument panel reinforce-
20
ment member
Front p��
assenger airbag assembly × Upper instrument panel 5
Seat Belt
Part tightened N·m
Front seat belt
Front p��
assenger seat outer belt assembly (Upper bolt) × Body 45
Front p��
assenger seat outer belt assembly (Lower bolt) × Body 45
Front p��
assenger seat buckle assembly × Front seat 45
Seat belt adjuster × Body 45
Front outer seat belt (End plate) × Body 45
Front outer seat belt (Guide ring) × Body 45
Rear seat belt
Rear seat 3-point type outer belt assembly × Body 45
Rear seat 3-point type outer belt assembly (End plate) × Body 45
Rear seat 3-point type outer belt assembly (Guide ring) × Body 45
Rear seat buckle w/center belt assembly RH × Body 45
Rear seat buckle w/center belt assembly LH × Body 45
Rear seat fixed cross member assembly × Body 23
Seatback hinge × Body 42
Combination Meter
Part tightened N·m
Instrument panel reinforcement member × Passenger airbag 20
GENERAL GL-57
Seat
Part tightened N·m
Front seat assembly
Front seat × Body 45
Front seat buckle assembly × Front seat adjuster 41
Front seatback assembly × Front seat adjuster 43
Rear seat assembly
Rear seatback assembly × Rear seatback hinge 37
Rear seat fixed cross member assembly × Body 23
Rear seatback hinge × Body 42
Rear seatback knuckle × Body 21
Rear seat belt assembly × Rear seatback frame 42
Wiper and Washer System

Part tightened N·m
Windshield wiper link assembly × Windshield wiper motor
9
assembly
Windshield wiper motor & link assembly × Body 9
Front wiper arm and blade assembly LH × Windshield
20
wiper link assembly
Front wiper arm and blade assembly RH × Windshield
20
wiper link assembly
Rear wiper motor assembly × Body 9
Rear wiper arm and blade × Rear wiper motor assembly 9
Windshield/Window Glass/Rear view Mirror

Part tightened N·m
Outside rear view mirror assembly LH
Outside rear view mirror assembly × Front door 8.0
Horn System
Part tightened N·m
Low tone horn assembly
Low tone horn assembly × Body 19.5
High tone horn assembly
High tone horn assembly × Body 19.5
Engine Hood/Door
Part tightened N·m
Engine hood
Engine hood × Engine hinge 23
Engine hood × Engine hood lock 7.0
Front door
Door ��
retainer� × Body 30
Door ��
retainer� × Door panel 5.5
Rear lower frame sub-assembly × Door panel 6.2
Door glass × Front door regulator sub-assembly 8.0
Door hinge × Body 23
Door hinge × Door panel 23
Door lock × Door panel 5.0
Door lock striker × Body 23
Door outside handle × Door panel 5.5
Outside rear view mirror × Door panel 8.0
Power glass regulator motor × Glass regulator 5.4
Glass regulator × Door panel 8.0
Rear door
Door ��
retainer� × Body 30
Door retainer × Door panel 5.5
Door window division bar sub-assembly × Door panel 5.0
MA-1
Maintenance and care
MAINTENANCE, CARE, AND CHECKS

Outside Vehicle General Maintenance.......................... MA-2
Inside Vehicle General Maintenance............................. MA-2
General Maintenance Under Engine Hood .................. MA-3
Engine On-vehicle Inspection........................................ MA-4
Chassis On-vehicle Inspection......................................
Brake On-vehicle Inspection..........................................
MA-5
MA-5
MA
Body On-vehicle Inspection........................................... MA-6
Power Source System Inspection................................. MA-6
PARAMETERS OF WHOLE VEHICLES

Basic Parameters of Complete Whole Vehicles........... MA-7
Technical Parameters of Engines.................................. MA-8
Technical Parameters of the Transmission and Clutch.... MA-8
Technical Parameters of Front/Rear Brakes................ MA-8
Main Technical Parameters of the Steering System.... MA-8
Technical Parameters of Front/Rear Suspensions...... MA-9
Structural Parameters of the Chassis........................... MA-9
Structure and Parameters of the Vehicle Body............ MA-10
Structure and Parameters of the
Air Conditioning System................................................ MA-10
Structure and Parameters of the Electrical System.... MA-11
Filling of Liquid/Fluid Agents......................................... MA-12
Tightening Torque of Important Fasteners................... MA-12
VEHICLE BODY BASIC CALIBRATION MEASUREMENTS

Engine Compartment...................................................... MA-15
Chassis............................................................................ MA-16
Chassis (Continued)....................................................... MA-17
Sub-frame........................................................................ MA-18
Rear Twist Beam............................................................. MA-18
Windshield....................................................................... MA-19
Trunk Door Frame........................................................... MA-19
Left side-panel................................................................. MA-20
Right side-panel.............................................................. MA-20
MA-2 COOL BEAR MAINTENANCE MANUAL
MAINTENANCE, CARE, AND CHECKS

Outside Vehicle General Maintenance
Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform
the maintenance himself or take the vehicle to a service center.
Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required.
The procedures for general maintenance are as follows:
1. General notes
• Maintenance requirements vary depending on the country.
• Check the maintenance schedule in the owner’s manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle using either miles driven or time (month)
elapsed, whichever reaches the specification first.
• Maintain similar intervals between periodic maintenance unless noted.
• Failing to check each vehicle part could lead to poor engine performance and increase exhaust
emissions.
2. Tire
(a) Check the tire pressure with a gauge. Make adjustments if necessary.
(b) Check the surfaces of tires for cuts, damage, or excessive wear.
3. Wheel nuts
(a) Check for nuts that are loose or missing. Tighten them if necessary.
4. Tire rotation
(a) Check the maintenance schedule in the owner’s manual supplement.
5. Windshield wiper blades
(a) Check the blades for wear or cracks when they are unable to wipe the windshield clean. Replace
them if necessary.
6. Fluid leakage
(a) Check under the vehicle for leaking fuel, oil, water, and other fluids.
(b) If you smell gasoline fumes or notice any leaks, find out the causes and correct them.
7. Doors and engine hood
(a) All of the doors and back door operate smoothly and that all the latches lock securely.
(b) When the primary latch is released, check if the engine hood secondary latch prevents the engine
hood from opening.
Inside Vehicle General Maintenance

Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform
the maintenance himself or take the vehicle to a service center.
Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required.
The procedures for general maintenance are as follows:
1. General notes
• Maintenance requirements vary depending on the country.
• Check the maintenance schedule in the owner’s manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle using either miles driven or time (month)
elapsed, whichever reaches the specification first.
• Maintain similar intervals between periodic maintenance unless noted.
• Failing to check each vehicle part could lead to poor engine performance and increase exhaust
emissions.
2. Lamp
(a) Check that if the front combination lamp, brake lamp, the rear combination lamp, turn signal lamps,
and other lamps illuminate or blink. Also, check if they have enough brightness.
(b) Check if the headlights are aimed properly.
3. Warning lights and buzzers
(a) Check that all the warning lights and buzzers will work.
MAINTENANCE AND CARE MA-3
4. Horn
(a) Check that the horn will work.
5. Windshield
(a) Check for scratches, pits, or abrasions.
6. Windshield wiper and washer
(a) Check if the wind shield washers are aimed properly. Also, check if the washer fluid hits the center of
the operating range of each wiper on the windshield.
(b) Check if there are any streaks left after the wipers operate.
7. Windshield defroster
(a) When the heater or air conditioner is on the defrost setting, check if air comes out of the defrost outlet.
8. Rear view mirror
(a) Check that the rear view mirror is securely mounted.
9. Sun visor
(a) Check that the sun visors move freely and are securely mounted.
10. Steering wheel
(a) Check that the steering wheel has the proper free play. Also check for steering difficulty and unusual noises.
11. Seats
(a) Check if the seat adjusters, seatback recliner and other front seat controllers operate smoothly.
(b) Check that the locks hold securely in all latched positions.
(c) Check that the headrest moves up and down smoothly and that the locks hold securely in all latched
positions.
(d) When the rear seatbacks are folded down, check if the latches lock securely.
12. Seat belts
(a) Check that the seat belt system such as the buckles, retractors, and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn, or damaged.
13. Accelerator pedal
(a) Check the pedal for smooth operation, uneven pedal effort, and catching.
14. Clutch pedal (see page DT-25)
(a) Check the pedal for smooth operation.
(b) Check that the steering wheel has the proper free play.
15. Break pedal (see page BR-9)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and free play.
(c) Start the engine and check the vacuum booster function.
16. Brakes
(a) In a safe place, check that the vehicle remains straight when applying the brakes.
17. Parking brake (see page BR-43)
(a) Check that the lever has the proper range of motion.
(b) On a slight slope, check if the parking brake can stabilize the vehicle alone.
General Maintenance Under Engine Hood

1. General notes
• Maintenance items vary depending on the country. Check the maintenance schedule as shown in
the owner’s manual supplement.
• Every service item in the periodic maintenance schedule must be performed.
• Periodic maintenance service must be performed according to whichever interval in the periodic
maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
• Maintenance service after the last period should be performed at the same interval as before un-
less noted.
• Failure to do even one of the items could lead to poor engine performance and increase exhaust
emissions.
2. Windshield washer fluid
(a) Check that there is sufficient fluid in the tank.
3. Engine coolant level

(a) Check that the coolant level is between the “F” and “L” lines on the see-through reservoir.
4. Radiator and hoses
(a) Check that the front part of the radiator is clean and not blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, twist, rot or loose connections.
5. Brake fluid level
(a) Check that the brake fluid level is near the upper level line on the see-through reservoirs.
Hint:
The brake fluid and the clutch fluid are from one reservoir.
6. Engine drive belt
(a) Check the drive belt for fraying, cracks, wear, or oiliness.
7. Engine oil level
(a) Check the level on the dipstick when the engine stops.
8. Power steering fluid level
(a) Check the level on the dipstick.
(b) The level should be in the “HOT” or “COLD” range depending on the fluid temperature.
9. Manual transmission fluid level
(a) Park the vehicle on a level surface.
(b) With the engine idling, shift the lever in N position and pull tightly the parking break lever.
(c) Release the transmission refill plug with wrench.
(d) Check that the lever is beneath the filler 10-15 mm. If the level is lower, refill transmission fluid. If not,
discharge the fluid.
10. Exhaust system
(a) If any change in the sound of the exhaust or the smell of the exhaust fumes is noticed, determine and
correct the causes.
Engine On-vehicle Inspection

Hint:
Inspect these items on a cooled down engine.
1. Inspect drive belt (see page MA-4)
2. Replace spark plugs
3. Inspect air filter
(a) Remove the air filter.
(b) Visually check that the air filter is not excessively dam-
Outside aged, dirty or oily. Replace the air filter if necessary.
(c) Clean the filter with compressed air.
First blow from the inside of the filter thoroughly then
blow from the outside.
Inside (d) Reinstall the air filter.
4. Replace air filter core
ALB001G
(a) Replace the air filter core with a new one.
5. Replace engine oil and oil filter
6. Replace engine coolant (see page EG-9)
7. Inspect gasket in fuel tank cap
8. Inspect fuel lines and connections, fuel tank vapor
vent system hoses and fuel tank
(a) Visually check the fuel lines for cracks, leakage, loose
connections, deformation, and tank bolt looseness.
9. Inspect exhaust pipes and fittings
(a) Visually check the pipes, hangers, and connections for
severe corrosion, leaks, and damage.
Brake On-vehicle Inspection

1. Inspect air filter
lens Hint:
Operate in a well-lighted area. Turn the front wheels
fully to the right or left before beginning.
(a) Check all the brake lines and hoses for:
• Damage
• Wear
• Deformation
• Cracks
ALB002G
• Corrosion
• Leakage
• Bending
• Twisting
(b) Check all the clamps for tightness and the connections
for leakage.
(c) Check that the hoses and lines are not near sharp edg-
es, moving parts or the exhaust system.
(d) Check that the lines are installed from the center of the
grommets.
2. Inspect the front brake pads and discs
3. Inspect the rear brake linings and drums
4. Inspect or change the brake fluid (see page BR-5)
Brake Fluid: DOT4 synthetic brake fluid
Chassis On-vehicle Inspection
1. Inspect the steering linkage
(a) Check the steering wheel free play (see page SR-3).
(b) Check the steering linkage for looseness or damage.
(1) Check that the tie rod ends do not have excessive play.
(2) Check that the dust seals and dust cover are not damaged.
(3) Check that the ��
dust cover��
clamps are not loose.
2. Inspect the steering gear housing oil
(a) Check the steering gear housing leakage.
If leaks, find the cause and repair it.
3. Inspect the ball joints and dust covers
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm under
the front tires.
(2) Lower the vehicle until the front coil spring reaches about half of its ordinary load. Place stands
under the vehicle for safety.
(3) Check that the front wheels are pointing straight ahead. Use chocks.
(4) Using a lever, pry up the end of the lower arm. Check the amount of play.
Maximum ball joint vertical play: 0 mm
If there is any play, replace the ball joint.
(b) Check ��
for ��
the dust cover damage.
4. Inspect the drive shaft boots
(a) Check the drive shaft boots for loose clamps, grease leakage, twist or damage.
5. Check the transaxle oil (fluid)
(a) Visually check the transaxle for oil (fluid) leakage.
If leaks, find the cause and repair it.
6. Tire rotation (see page SP-38)
Body On-vehicle Inspection

1. Tighten bolts and nuts on chassis and body
(a) Tighten the bolts and nuts on the chassis parts listed below, if necessary.
• Front axle and suspension
• Drive train
• Rear axle and suspension
• Brake system
• Engine mounting
• Other chassis parts
(b) Tighten the bolts and nuts on the body parts listed below, if necessary.
• Seat belt system
• Seat
• Doors and engine hood
• Body mountings
• Fuel tank
• Exhaust pipe system
• Other body parts
2. Check and replace the air conditioning filter
(a) Remove the glove box.
(b) Remove the filter case from the filter outlet.
(c) Remove the filter from the filter case.
(d) Check the air filter for excessive damage, dirty or oily. Replace the air filter if necessary.
(e) The installation sequence is the reverse of the removal sequence.
Power Source System Inspection

1. Generator
(a) Inspect ��
for ��
the generator radiation.
(b) Inspect the generator belt tension and pulley installation.
(c) Inspect the brush pressure and the segment surface.
(d) Inspect the connection of the battery line.
(e) Inspect to see if the connector is damaged.
(f) Inspect to see if the rectifier is dirty.
(g) Inspect the wear of the bearing.
2. Battery
(a) Inspect the battery housing for cracks, fractures, or damage.
(b) Inspect the battery ground wire.
(c) Inspect the battery according to the working condition of the headlamp.
3. Charge indicator
(a) Inspect the wire line of the charge indicator.
(b) Inspect to see if the filament has blown.
(c) Inspect to see if the generator works.
PARAMETERS OF WHOLE VEHICLES

Basic Parameters of Complete Whole Vehicles
CC7150AM01 CC7130AM01 CC7130AM02
Item
GW4G15 GW4G13
Length (mm) 3968
Width (mm) 1695
Dimension Height (mm) 1634
parameters Wheel base (mm) 2499
(No load) Tread: front/rear (mm) 1455/1430
Front suspension (mm) 790
Rear suspension (mm) 679
Laden mass (kg) 5×(68+7)
Kerb mass (kg) 1185 1182
Gross vehicle weight (kg) 1560 1557
Distribution of axle load under no load: 718/467 689/493
Quality front/rear (kg)
parameters Location of mass center under no load 1042/3.4/359.5 1042/3.4/359.5
(x, y, z) (mm)
Distribution of axle load under full load: 821/739 793/764
front/rear (kg)
Location of mass center under full load 1227/-1.8/412.6 1227/-1.8/412.6
(x, y, z) (mm)
Minimum turning diameter (m) 11.5
Passability Minimum ground clearance (mm) 133
parameters Approach angle (°) 18 (Full load)
Departure angle (°) 19 (Full load) ;
Minimum stable speed of the direct gear ≤25
(km/h)
Acceleration time(s) from 30km/h to 100 ≤32
Power per- km/h of the direct gear
formance Acceleration time(s) from vehicle ≤13.7 ≤15
starting in the 1st gear to 100 km/h
Maximum speed (km/h) 158 158
Maximum climbing capacity (%) 31.8 36
Coasting distance(m) at the initial speed ≥500
of 50 km/h
Fuel consumption at the constant speed 6.4
of 90 km/h (L/100 km)
Economy
Fuel consumption at the constant speed 8.5
of 120 km/h (L/100km)
Fuel consumption under simulated urban ≤8.1
and suburb conditions (L/100 km)
Braking distance(m) at the initial braking ≤19 (No load), ≤20 (Full load)
speed of 50 km/h
Braking per- Emergency braking distance(m) at the
formance initial braking speed of 50 km/h ≤38
Grade parking brake (%) ≥20
Maximum stable roll angle under no ≥35
Stability load and static state (°)
Operation stability (score ) Nan≥60, NZ≥60
RMS (root mean square) of weighted ≤0.6833
Smooth- acceleration σw (m/s2)
ness Equivalent mean value Leq (dB) ≤116.5
Reduced comfort boundary TCD (h) ≥1.2
Sealing per- Dust sealing M (%) ≥95
formance Rain proof performance (points) ≥93
External vehicle noise dB (A) when ≤74
accelerating
Noise Internal vehicle noise dB (A) when ≤65
driving at the constant speed of 60km/h
Noise level dB (A) at the driver’s ear ≤90
CO emission (g/km) ≤1.00
HC emission (g/km) ≤0.10
NOx emission (g/km) ≤0.08
Emission
Particulate emission (g/km) /
HC+NOx (g/km) /
Smoke -- /
Technical Parameters of Engines

Items Unit Specifications and Parameters
Model ---- GW4G15 GW4G13
Type ---- In-line 4-cylinder, 4-stroke, water-cooled, DOHC (double overhead
camshaft), gasoline engine
Fuel supply mode ---- VVT (variable valve timing) electronic control, sequential multi point fuel
injection
Cylinder bore × mm×mm 75×84.7 75×73.5
Stroke
Total displacement L 1.497 1.298
Compression ratio ---- 10.5 10.5
Number of valves/ ---- 16/4
cylinders
Minimum fuel g/kW•h ≤265 ≤265
consumption rate
Maximum power/ kW/(r/m) 77±3/6000 68±3/6000
speed
Maximum torque/ N.m/(r/m) 138/4000-5500 118/4000-5500
speed
Idle speed r/min 800±25 low-speed/2000±25 high-speed
Fuel type and RON/MON Unleaded gasoline, 93#
designation
Cooling mode Forced-circulation water cooled, the opening temperature of thermostat is
and performance ---- 80℃ - 84℃ and the normal working water temperature is 80℃-90℃, the
parameters opening pressure of 108±15 kpa
Starting mode and ---- Motor starting, the starting performance meets the requirements specified in
performance 8.1.2 and 8.1.3 of GB 18297
Lubrication mode ---- Combined force-feed and splash lubrication
Technical Parameters of the Transmission and Clutch

Items Index
Clutch type Single disc, dry-type, diaphragm spring,
driven disc dia.: 213 mm
Clutch
Clutch hydraulic control Total clutch pedal stroke: 119.2 mm, free
stroke: 14 mm, pedal force: 98.1N, drive ----
system ratio: 13.7
Model CC0011A ZM007Q VT2-11D
Transmission type Mechanical 5-speed manual transmission CVT
case
Final reduction ratio 4.313 4.267 5.760
I 3.545 3.364
II 1.905 1.895
Transmission III 1.310 1.286 0.443-2.416
Transmission ratio of each IV 0.970 0.969
gear V 0.816 0.800
Reverse 3.25 3.214 2.680
gear
Maximum bearable 160 153 170
torque (N•m)
Maximum input rotating 6000 ----
speed (r/min)
Technical Parameters of Front/Rear Brakes

Front wheel Rear wheel
Disc brake with floating caliper Leading trailing shoe drum brake
Performance item Performance parameter Performance item Performance parameter
Slave cylinder dia. Φ54 mm Slave cylinder dia. Φ19.05 mm
Brake disc dia. Φ255 mm Brake drum dia. Φ200 mm
Main Technical Parameters of the Steering System

Item Parameter Item Parameter
Inner wheel steering 32°-37° Number of turns of the 3.08
angle (°) steering wheel (n)
Outer wheel steering 28°-33° Steering system angle 19.03
angle (°) ratio (i0ω)
Technical Parameters of Front/Rear Suspensions

Front suspension type MacPherson independent suspension
Front suspension type
and components Front suspsension com- Lower arm assembly, front shock absorber with he-
ponents lical spring assembly, front transverse stabilizer bar
Item Range Lateral deviation
Front wheel camber -0°29′±30′ ±30′
Front angle
suspen- Front wheel kingpin incli-
sion 9°49′±30′ ±30′
Front wheel alignment nation angle
parameters (No load) Front wheel kingpin cast-
er angle 2°08′±45′ ±36′
Front wheel toe-in angle -0°04′±10′(1 mm± /

4 mm)
Rear suspension type Trailing arm and twist beam compound suspension
Rear suspension type
and components Rear suspension compo- Rear twist beam assembly, rear helical spring,
Rear sus- nents rear shock absorber assembly
pension Item Range Lateral deviation
Rear wheel alignment Rear wheel camber angle -0°43′±30′ ±30′
parameters (��
No load�)
Rear wheel toe-in 0°10′±15′ ----
Structural Parameters of the Chassis

Item Structure and Parameters
Air intake system Dry-type air filter, non-woven filter element
When equipped with GW4G15 or GW4G13 engine: two-stage muffler with a two-stage
three-way catalytic converter, front/rear oxygen sensors.
Exhaust system
When equipped with YC4W75-31 engine: two-stage muffler with a one-stage three-
way catalytic converter, oxygen sensor.
When equipped with a GW4G15 or GW4G13 engine: adopt a metal fuel tank (45L)
with a built-in electronic fuel pump and canister, The fuel supply is under the control of
the electronic accelerator pedal, The fuel evaporation control system takes the form
that the charcoal canister is controlled by an electromagnetic valve.
Fuel supply system
When equipped with YC4W75-31 engine: electronically-controlled high pressure com-
mon-rail fuel injection, dual fuel pipe. Adopt a metal fuel tank (45L) with a built-in fuel
strainer, electronic accelerator pedal, the fuel supply line is provided with an oil-water
separator and diesel filter.
Adopts a closed forced-circulation water cooled system, two-stage electronic speed
Cooling system regulated fan is integrated with the overflow tank, aluminum ribbon and tube type ra-
diator with upper/lower water chambers.
The service braking system adopts vacuum assisted hydraulic brake system. The front
Service brak- and rear brakes are respectively the disc brake and drum brake. The front disc brake is
hollow vented disc and the brake pedal is ��
a ��
pendant type pedal with a vacuum booster.
ing type The dual-circuit brake piping is in a diagonal arrangement. The ��
brake��
system adopts
ABS + EBD and brake force distribution system.
Service brak- Single-stage ø9 inch vacuum booster: vacuum bootster force transmission ratio 5.5,
ing booster tandem master cylinder: cylinder bore ø20.64 mm, master cylinder ��
total ��
stroke 38
Brake and master (19+19) mm, pedal force: 230 N.
system cylinder
Brake fluid Brake fluid reservoir and clutch master cylinder fluid reservoir are the same one and
reservoir equipped with an alarm device for brake fluid level.
Brake pedal Free stroke: 6-9 mm, working stroke: 37-40 mm, pedal force <367.9 N, transmission
stroke ratio: 3.
The parking brake system utilizes a mechanical remote ratchet cable control mecha-
Parking brake nism to control the rear wheel drum brake. The working stroke of the brake handle is
5-8 teeth.
Steering gear Rack-pinion hydraulic power steering gear: transmission ratio: 19.03, power steering
fuel pump flow: 5.15-6.55 L/min, fuel pump pressure ≤8 MPa.
Steering Steering col- Safe, energy-absorbing and variable-angle steering column: up-down adjusting angle:
system umn 3.6°
Steering wheel 3-spoke soft steering wheel with air bag: diameter: 370 mm, maximum one-way turns:
3.08 rounds.
The input end of driving shaft adopts a widely used approximately constant velocity
Propeller shaft slip spherical roller universal joint and the output end adopts a constant velocity rzeppa
universal joint.
Wheel specifi- Standard wheel: 15×6J wheel rim, offset: +40mm.
cations
Wheels Tire specifica- Standard tire: 185/65 R15 88H, tire pressure: 200±10 KPa.
and tires tions
Spare tire
specifications Spare tire: T125/70R16 96M, wheel rim: J16×4T, tire pressure: 420±10 KPa.
Structure and Parameters of the Vehicle Body

Items Structural Parameters and Performance Description
Body type All-metal enclosed hardtop unitary construction body
Body in white Stamped, welded, all-metal enclosed structure
Vehicle door Framed doors, side impact beams of 4 doors, clockwise opening of doors, hinged
assembly doors, upward opening of the back door, front and rear doors with electric regulators
Engine com- Upward and backward opening, single-arm hinged cover
Body partment cover
Parameters Opening angle of the Working opening angle
of open-close front door 35°/63° of the engine compart- 58°
parts ment cover
Opening angle of the 35°/65° Maximum opening angle 93°
rear door of the trunk door
Interior trim Satisfies ergonomic and comfort requirements. Fire resistance complies to regulatory
requirements.
Uses an injected molding structure with brace reinforcement, built in multifunctional
Instrument combination meter, knob plus button-press air conditioning controller, CD player (DVD
panel and GPS LCD are optional), and auxiliary facia console which adopts a gear shift con-
trol mechanism.
A, B, C, D pil- Uses injected molding and front door guard plates equipped with package tray, four-
lars and indoor door guard plates are all installed with window regulator switches. Four-door guard
plates, A pillar(luxury model), C pillar (luxury model) are all designed with
trims loudspeaker port.
Vehicle glass Windshield is laminated glass, front and rear door glass is tempered glass, trunk door
Interior glass is heating & defrosting tempered glass with resistance wire.
trim, Exterior rear-view mirror: electric exterior rear-view mirror with electric defroster, fold-
exterior Rear-view mir- ing, 4-direction adjustable mirror face.
trim and ror Interior rear-view mirror: manual multi-direction adjustment, anti, ball joint mounting.
acces-
sories Driver & front passenger seats, independent seats. For front and rear seats, backrest
angle and seat headrest are both manually adjustable. Second row seats use a three-
Seats seat arrangement. The seats' front and back positions and backrest angles are nonad-
justable. Seat headrests are both manually adjustable, back of the seat can be folded
forward, and the middle seat includes a child seat belt.
Seat belts The front and rear rows respectively use a 3-point fixed & electronically pre-tensioned
seat belts and 3-point fixed seat belts.
Sun visor Both left/right sun visors have vanity mirrors and can be moved up and down or later-
ally. You can stop them at any position when moving them up and down.
Sunroof The sunroof is equipped with an electric sunroof.
Front/rear bum- Injection mold bodies meet the regulatory requirements for crashes at a speed of 8 km/h.
pers
Structure and Parameters of the Air Conditioning System

Items Structure and Parameters
Structure Vapor compression refrigeration, water-heated heating
Air-conditioner cooling capacity: 4.5 kW
Performance Blower airflow: 420 m3/h
parameters
Air-conditioner heating capacity: 4 kW
Manually AC: Knobs, buttons and levers on the control panel are controlled by hand, while the
position door, Manually AC temperature door and fresh air door are driven by cable. Air outlet
position mode, heating/cooling mode, and internal/external air circulation mode can be selected
Control and airflow rate and temperature can be adjusted.
Automatic AC: the position door, temperature door and fresh air door are driven by electrical
servo. Air outlet position mode, heating/cooling mode, and internal/external air circulation mode
can be selected and airflow rate and temperature can be adjusted.
Refrigerant R134a, 490 ± 10 g
Compressor JSS-12T402002; SEBX13
Condenser Advective and subcooling structure with flat tube thickness of 16 mm and dry reservoir
Φ34 mm.
Interior air-conditioner (HVAC): with 3-box structure, it is composed of laminated evaporator,
Interior air-condi- horizontal flow heater, H-type expansion valve, centrifugal blower and air output distribution
tioner box, and has such functions as refrigeration, heating, defrosting and fresh air circulation. The
action of air valve is driven by the link mechanism.
Cooling tube and A compound structure using a rubber cooling pipe and an aluminum pipe. Hot water tube:
hot water tube molded rubber tube;
Sensor Evaporator temperature sensor
Pressure switch 3-position pressure switch
Structure and Parameters of the Electrical System

Items Structure and Parameters
Power Circuit Single wire system, 12V DC voltage, minus ground
supply, Battery 12V/60Ah, maintenance-free battery
starting,
and charg- Starter 1.2 kW
ing system Generator 14V/90A
Headlight White (high-beam: 55W, low-beam: 55W) H1, electric height adjustment
(luxury configuration with sunroof)
Position lamp Front positon lamp: white, 5W, two lone on the left and one on the right, rear
position lamp: LED (light-emitting diode)
Turn signal lamp Amber, front: 21W, 2 pcs, rear: 21W, 2 pcs, turn ��
lamp��
s are bulbs (mounted
on the exterior rear-view mirror)
Fog ��
lamp Front fog ��
lamp��
: 2 pcs, 55 W, Rear fog ��
lamp��
: 1 pc, 21W
Lighting
and signal Brake ��
lamp LED (light-emitting diode)
system License plate ��
lamp White, 5 W, 2 pcs
Reverse ��
lamp White, 21W, 1 pc
Alarm ��
lamp All the turn signal ��
lamps��
, switch control
Rear retro-reflector Red, non-triangle, in the rear combination lamp
Front reading lamp and Front reading lamp: white, 8W, one. Interior dome lamp: white, 10W, one
interior dome lamp
Cigarette lighter lamp Blue, 3W, 1 pc
Speedometer, tachometer, fuel gauge, electronic clock, automatic gear, and
Combination meter mileage LCD digital display. The addition or removal of other indicators de-
pends on the configuration. The backlight brightness is adjustable.
Front fog light indicator lamp, rear fog light indicator lamp, high beam indi-
cator lamp, left turn signal indicator lamp, right turn signal indicator lamp,
rear defrost/defog indicator lamp, master switch indicator lamp, 120 Km/h
warning indicator lamp, door open indicator lamp, battery charging indicator
Dash- lamp, engine cooling water high temperature indicator lamp, transmission
boardpanel malfunction indicator lamp, WINTER mode indicator lamp, engine cooling
Indicator lamps water low temperature indicator lamp, parking brake indicator lamp, airbag
malfunction indicator lamp, seat belt indicator lamp, brake system malfunc-
tion (low brake fluid) indicator lamp, ABS malfunction indicator lamp, low
oil pressure indicator lamp, fuel warning indicator lamp, engine malfunction
indicator lamp, OD switch indicator lamp (optional), engine maintenance in-
dicator lamp, EBD indicator lamp, engine warm-up indicator lamp (reserved
for diesel engines), oil-water separation indicator lamp (reserved for diesel
engines), etc.
Front wiper: inching, high-speed, low-speed, and interval position with inter-
Wiper system val adjustment, with a reset system
Rear wiper: normal positon with a reset system
Defroster/defogger Use heating wire (200 W) to heat and set the control switch on the instru-
ment panel
All the regulators are under the master control on the driver’s side, while
Electric glass regulator the others are under independent control, left/right front doors are set with
a central control door-lock control switch, an anti-clip system with automatic
window closing, the window lock switch is set on the driver’s side.
Remote control door lock (driver side door is controllable), rear doors are
Auxiliary Central door lock provided with child locks and an electronic immobilizer system, the opening
electrical of the rear doors are electronically controlled.
system Backup power supply 12V, 120W, 1pc
Single-disc CD, AM/FM, MP3, Kara OK, DVD (optional), steering wheel
Stereo equipment sound control switch, 12 speakers (refer to the specific configuration de-
scription for details)
Cigarette lighter 12V, with illumination, 1 pc
Horn Electric treble-bass disc type horn
Airbag Standard configuration: ordinary seat belt and double air bags. High con-
figuraton: electronically pre-tensioned seat belt and double air bags
Hands-free communica- Vehicle-based bluetooth system (refer to the specific configuration descrip-
tion equipment tion for details)
Filling of Liquid/Fluid Agents

Working Position Quantity Specifications
Engine fuel 45 L #93 and above high quality unleaded gasoline (GW4G15, GW4G13
engines, GB17930)
3.5 L (with oil filter) Above ��
SJ 15W-40
Engine lubricant oil GW4G15/ (summer),10W-30 (winter) China domestic model
GW4G13
3.3 L (without oil filter) Above ��
SJ 5W-30 Alpine region model
Ethylene-Glycol -35℃ antifreeze fluid China domestic model
Coolant 5.0±0.5 L
Ethylene��
-Glycol��
-45℃ antifreeze fluid Exported alpine region model
Clutch fluid and brake 0.49±0.02 L DOT4 synthetic brake fluid
fluid
GL-4 80W-90 For China domestic model
MT 1.9±
Transmission lubri- 0.15L GL-4 75W-90 For ��
exported alpine region model
cant oil GL-5 140 For exported high temperature region model
CVT 4.35± ESSO EZL 799A
0.05L
Power steering fluid 0.75±0.05 L ATF DEXRONIII hydraulic transmission fluid
Battery electrode 1.0±0.03 g Industrial vaseline
Windshield washer 2.2±0.01 L Normal temperature: clean water with hardness less than 205g/1000kg
fluid Low temperature (-18℃±3℃): 50% methanol aqueous solution
Air-conditioner refrig- 490g±10g R134a
erant
Other kinematic fric- ----- #��
2 general purpose lithium base grease
tion pairs
Tightening Torque of Important Fasteners

Tightening
Fastener Name and Model Fastener Position Torque Qty. Surface
Coating
(N•m)
Chassis
Hexagon flange bolt Left suspension and its bracket 78±5 2 Redglue
Hexagon flange bolt Left suspenstion bracket and transmission 46±5 3 Redglue
Hexagon flange bolt Right suspension and engine 78±5 1 Redglue
Hexagon flange bolt Right suspension and engine 78±5 1 Redglue
Hexagon flange nut Right suspension and engine 78±5 1 Redglue
Hexagon flange bolt Right suspension and body 78±5 2 Redglue
Hexagon flange bolt Right suspension and body 78±5 1 Redglue
Hexagon flange bolt Rear suspension and transmission case 46±5 1 Redglue
Hexagon flange bolt Rear suspension and transmission case 46±5 2 Redglue
Hexagon flange bolt Rear suspension and its mounting bracket 78±5 1 Redglue
Hexagon flange bolt Rear suspension and sub-frame 78±5 1 Redglue
(M10×1.25×70)
Hexagon flange nut (M10×1.25) Rear suspension and sub-frame 78±5 2 Redglue
Nut (M10×1.25) Rear suspension and its mounting bracket / 1
Hexagon bolt and flat washer Fuel tank and beam 26±3 4 Redglue
subassembly
Hexagon flange nut Accelerator pedal and body 10±1 3
Hexagon flange bolt Three-way catalytic converter assembly 60±6 2
and front muffler assembly
Three-way catalytic converter assembly
Bolt (M10×1.25) and engine exhaust manifold, front muffler 60±6 4 Redglue
assembly and rear muffler assembly
Oxygen sensor interface Oxygen sensor and three-way catalytic 50±5 1
converter assembly
Nut (M8) Clutch pedal and clutch master cylinder 23±3 2
Hexagon flange bolt Clutch pedal and tubular beam 23±3 1
Hexagon bolt and ��
flat��
washer Gearbox operating mechanism assembly 20±2 4 Redglue
subassembly and floor
Transmission filler cap nut 33±3 1
Front propeller shaft nut (M22×1.5) Propeller ��
shaft assembly 225±20 2
Hexagon flange bolt and flat washer Sub-frame and body (front) 120±10 2 Redglue
subassembly
Hexagon flange bolt and flat washer Sub-frame and body (rear) 145±15 2 Redglue
subassembly
Hexagon bolt and flat washer subas- Sub-frame strut bar and body 49±5 4 Redglue
sembly
Swing arm ball nut (M12×1.25) Swing arm and sub-frame 80±10 2
Tightening
Fastener Name and Model Fastener Position Torque Qty. Surface
Coating
(N•m)
Hexagon flange nut (M12×1.25) Swing arm and sub-frame / 2
Hexagon bolt and flat washer subas- Swing arm and sub-frame 180±10 2 Redglue
sembly
Hexagon bolt and flat washer assembly Swing arm and sub-frame 120±10 2 Redglue
Hexagon flange nut (M8) Front shock absorber and body 40±5 6
Hexagon flange bolt (M14×1.5) Front shock absorber and steering knuckle 132±10 4 Redglue
Hexagon flange nut Front shock absorber and steering knuckle 132±10 4
Hexagon bolt and flat washer assembly Front stabilizer bar arm and frame 37±4 4 Redglue
Type II non-metal insert hexagon locknut Hanger rod and swing arm/stabilizer bar 16±2 2
Hexagon bolt and flat washer assembly Trailing arm shaft sleeve assembly 120±10 2 Redglue
Hexagon flange nut Rear shock absorber support shaft 120±10 2 Redglue
After finishing assembling the mounting nuts
Type 1 hexagon nut (lower) of the rear shock absorber, the dis- 2
tance between their top end and the push
rod should be 14-16 mm
Type 1 hexagon nut Mounting nuts (upper) of the rear shock 35±3 2
absorber
Wheel taper faced nut (M12×1.25) Wheel hub 110±10 16
Hexagon flange nut Steering wheel and steering column 50±4 1
mounting nut
Hexagon flange bolt Steering column and tubular beam mount- 25±3 1 Redglue
ing bolt
Hexagon flange bolt Steering column and tubular beam mount- 25±3 2
ing bolt
Hexagon flange bolt Tension force adjusting support and engine 40±4 1
mounting bolt
Hexagon bolt and flat washer assembly Tension force adjusting support and power 40±4 1
steering pump assembly
Hexagon flange bolt Power steering pump and bracket mount- 30±3 1
ing bolt
Hexagon bolt and flat washer assembly Steering gear and sub-frame mounting bolt 107±7 2 Redglue
(M12×1.25×80)
Hexagon bolt and flat washer assembly Steering gear and sub-frame mounting bolt 107±7 2 Redglue
(M12×1.25×100)
Hexagon thin slotted nut Steering gear and steering knuckle mount- 49±5 2
ing nut
Steering tie rod locknut Steering gear assembly 74±7 2
Steering hose connection 16±2 1
Steering pump hollow bolt Steering pump 30±4 1
Hexagon bolt and spring washer as- Steering transmission shaft 25±3 3 Redglue
sembly (M8×30)
Front brake hose connection 40±4 2
Brake mounting bolt Rear brake and rear axle 85±5 8
Nut Brake pedal and booster 23±3 4
All the brake hose connections M10 16±2
All the brake hose connections M12 16±2
Vehicle Body
Front seat belt upper mounting bolt For connecting the seat belt 45±5 2
(7/16")
Seat belt lower mounting bolt (7/16") For connecting the seat belt 45±5 4
Front seat belt retractor lower bolt For connecting the seat belt retractor 45±5 2
(7/16")
Rear seat belt upper mounting bolt For connecting the seat belt 45±5 2
(7/16")
Rear seat belt retractor bolt (7/16") For connecting the seat belt retractor 45±5 2
Middle seat belt mounting bolt (7/16") For connecting the seat belt 45±5 1
Front seat belt buckle bolt (7/16") For connecting the front-row seat belt 45±5 2
buckle
Vertical adjuster bolt Vertical adjuster 45±5 2
Rear seat belt lock bolt (7/16") For connecting the rear seat belt lock 45±5 2
Door hinge/body mounting bolt (M8) Door hinge 23±3 16
Door hinge mounting bolt (M8) Door hinge 23±3 16
Door retainer mounting bolt (M8) Door retainer 23±3 4
Engine compartment cover hinge Engine compartment cover/trunk door 23±3 12
mounting bolt (M8×20) hinge
Hexagon flange nut Trunk door 28±3 2
Tightening Surface
Fastener Name and Model Fastener Position Torque Qty Coating
(N•m)
Interior/exterior trim
Hexagon bolt, spring washer and For mounting the driver trunk seat 45±5 4
flat washer assembly
Hexagon bolt, spring washer and For mounting the front passenger's seat 45±5 4
flat washer assembly
Hexagon flange bolt For mounting the rear fixed cross member 23±3 4
assembly of rear seats
Hexagon flange bolt For mounting the rear seat back bracket 45±5 2
Hexagon flange bolt For mounting the ��
rear-fixed cross member 45±5 2
assembly��
of rear seats and seat backrest
Hexagon flange bolt For connecting the left end of the brace re- 20±2 3
inforcement assembly and the side panel
Hexagon flange bolt For connecting the middle of ��
the ��
brace rein- 20±2 1
forcement assembly and the front wall
Hexagon flange bolt For connecting the right end of ��
the ��
brace rein- 20±2 2
forcement assembly and the side wall
Hexagon flange bolt For connecting the lower end of ��

the ��
brace rein- 20±2 2
forcement assembly and the floor
VEHICLE BODY BASIC CALIBRATION MEASUREMENTS

This part indicates the basic size of the complete vehicle, please refer to it for overhaul.
• All the sizes indicated by figures are actual sizes.
• The measuring point should be chosen from the center of the mounting hole.
• When using the gauge, adjust its two styli to equal length, and then check the styli and gauge to ensure that there
is no space to use.
• In the use of tape measure, make sure that there is no tension, torsion, and bending.
• The asterisk (*) following the value of the measuring points indicates that the measuring points in the symmetrical
position on the other side have the same value.
• The coordinates of a measuring point mean the measured distance between the point and the “X”/“Y”/“Z” reference line.
• The symmetrical points of the coordinates of the measurement points indicate the coordinates of the left points, and
the right and the left are symmetrical.
Vehicle Center Line
Imaginary Center Line

Front Wheel Center Line
“Z” Represents the Imaginary Reference

Line [below reference line ("OZ" line of the
design diagram) 400mm]
ALB003G
Engine Compartment
Unit: mm ALB004G
Mark Coordinates (X, Y, Z) Hole Dia. (mm) Mark Coordinates (X, Y, Z) Hole Dia.
(mm)
A 121.1, 0, 704.0 Φ11 F 47.2, -650.5, 724.6 Φ�
7
B -400.9, -469.4, 736.7 Square hole 9×9 G -606.8, -464.3, 290.6 Φ��
8.5
C 56.5, -520.2, 698.8 Φ��
11 H -538.1, -404, 442.0 Φ�
9
D -264, -255, 752.1 Φ�7
E -549, 36.4, 725.3 Φ�7
Chassis
Up Down
Front Front
Unit: mm ALB005G
Chassis (Continued)
Coordinates Coordinates
Dia. 20M
Dia. 18M
Dia. 18J
Dia. 18H
Dia. 18G
Dia. 18F
Dia. 17E
Dia. 15D
Dia. 11C
Dia. 18B
Dia. 18A
Front
Unit: mm ALB006G
Sub-frame
Unit: mm ALB007G
Rear Twist Beam
Distance Between the Center Points of both Shafts End Surfaces

Distance Between points P and Q
Unit: mm ALB008G
Windshield
Unit: mm ALB009G
Mark Designation Hole Dia. (mm) Mark Designation Hole Dia. (mm)
Central defroster airs Central ��
defroster airs �
A Oblong hole 7×12 C Oblong hole 7×12
duct mounting hole duct mounting hole
Windshield limiting Windshield limiting
B Oblong hole 11.5×9 D Oblong hole 11.5×9
stopper mounting hole stopper��
mounting hole
Trunk Door Frame
Unit: mm ALB010G
Trunk door left hinge Trunk��
door left hinge
A Φ��
15 C Φ��
15
mounting via hole mounting ��
via hole �
Rear bumper mounting Rear bumper mounting
B Φ�
7 D Φ�
7
hole hole
Left side-panel
Unit: mm ALB011G
A Front door lower hinge Φ11 F Process ��
cut
mounting via hole
B Rear door upper hinge ��
Φ��
15 G Process ��
cut
mounting ��
via hole
C Front door upper hinge ��
Φ��
11 H Process ��
cut
mounting ��
via hole
D Front door contact switch ��
Φ��
19 I Rear door lower hinge ��
Φ��
15
via hole mounting ��
via hole
E Process cut J Rear door contact switch ��
Φ��
19
via hole
Right side-panel
Unit: mm ALB012G
A Front door lower hinge ��
Φ��
11 F Process incision
mounting via hole
B Rear door lower hinge ��
Φ��
15 G Rear door lower hinge Φ��
15
mounting ��
via hole mounting ��
via hole
C Front door upper hinge ��
Φ��
11 H Rear door contact switch Φ��
19
mounting ��
via hole via hole
D Rear door upper hinge ��
Φ��
15 I Process cut
mounting ��
via hole
E Process ��
cut J Process ��
cut
EG-1
Engine accessory system
EXHAUST SYSTEM
Exhaust Pipe Assembly.................................................. EG-2
COOLING SYSTEM
On-vehicle Inspection..................................................... EG-5
Cooling Fan System....................................................... EG-6
Engine Coolant................................................................ EG-8
Radiator Assembly.......................................................... EG-9
EG
MOUNTING SYSTEM
Engine Mount.................................................................. EG-12
FUEL SUPPLY SYSTEM

Fuel Supply System Assembly...................................... EG-15
EG-2 COOL BEAR MAINTENANCE MANUAL
EXHAUST SYSTEM
Exhaust Pipe Assembly
Components
Front Heat Shield
Exhaust Manifold
Compression
Spring
Bolt Oxygen
Sensor
Sealing Ring Ⅱ
Spherical Three-way Catalytic Converter
Sealing Ring Spherical
Assembly
Sealing Ring
com-
Middle Heat pression
Shield spring Bolt
Compression
Spring
Exhaust Pipe Rear

Front Exhaust Protection Support
Hanger Front Muffler
Rear Heat Shield
Rear Exhaust
Rear Muffler Hanger
: Specified torque
ALC001G
ENGINE ACCESSORY SYSTEM EG-3
Replacement
Hint:
The installation procedures are the removal procedures in
the reverse order. However, only the installation sequences
requiring addition information are included.
Caution:
The removal of all components in the exhaust system should
be carried out after 30 minutes when the engine stops, so as
to avoid causing harm due to high temperature components.
1. Remove the rear muffler
(a) Using a torx wrench, remove the 2 bolts and 2 com-
pression springs in the connection between the rear
muffler front flange and the front muffler rear flange.
(b) Remove the 3 rear exhaust hangers, rear muffler, and
spherical sealing ring on the rear muffler.
Caution:
Hold the exhaust pipe assembly when perform-
ing this operation to prevent them from falling and
ALC002G
causing injury to the operator.
2. Remove the front muffler
(a) Using torx wrench, remove the 2 bolts in the connection
between the front muffler assembly front flange and
three-way catalytic converter assembly rear flange.
(b) Remove the 2 bolts and the exhaust pipe rear protection
support.
(c) Remove the 2 front exhaust hangers from the front muf-
fler assembly, and remove the ��
front��
muffler assembly.
Caution�:
ALC003G
Hold the front exhaust pipe assembly when per-
forming this operation to prevent them from falling
and causing injury to the operator.
3. Remove the three-way catalytic converter assembly
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts, 2 compression springs in the con-
nection between the exhaust manifold rear flange sur-
face, and the three-way catalytic converter assembly
front flange, and remove the spherical sealing ring.
(c) Remove the three-way catalytic converter assembly.
Caution�:
Hold the front exhaust pipe assembly when per-
ALC004G
forming this operation to prevent them from falling
and causing injury to the operator.
4. Install the rear catalytic converter assembly
(a) Using vernier calipers, measure the free length of the
compression spring.
If the minimum length is not as specified, replace the
compression spring.
ALC005G
(b) Using a plastic hammer and a wooden block, tap in a

new spherical sealing ring until its surface is flush with
the exhaust manifold.
Hint:
The main role of the spherical ��
sealing ring��
is sealing,
a large deformity may occur after the first installation,
which influences the sealing effect, it is suggested that
you do not reuse it. If necessary, reuse it only once.
ALC006G
(c) Connect the oxygen sensor connector.

(d) Install the 2 bolts and 2 compression springs in the
connection between the exhaust manifold rear flange
surface and the three-way catalytic converter assembly
front flange.
Torque: 60 N·m
(e) Install the ��
three-way��
catalytic converter assembly.
Hint:
ALC004G The distance between the exhaust pipe assembly and
parts on the both sides cannot be less than 15 mm.
5. Install front muffler
(a) Using a torx wrench, install the 2 bolts in the connec-
tion between the front muffler assembly front flange
and three-way catalytic converter assembly rear flange.
Torque: 60 N·m
(b) Install the exhaust pipe rear protection support with 2
bolts.
Torque: 43 N·m
ALC003G (c) Install the 2 front exhaust hangers on the front muffler
assembly, and install the front muffler assembly.
Hint:
To help the installation, apply the appropriate silicon
oil to the installation hole of the rubber hangers before
installation, the rubber hangers should receive strength
evenly after installation.
6. Install the rear muffler
(a) Using a torx wrench, install the 2 bolts and 2 compres-
sion springs in the connection between the rear muffler
front flange and front muffler rear flange.
Torque: 60 N·m
(b) Install the 3 rear exhaust hangers, rear muffler, and
spherical sealing ring.
Hint:
ALC002G To help the installation, apply a small amount of silicon
oil to the installation hole of the rubber hangers before
installation, the rubber hangers should receive force
evenly after installation.
7. Check for exhaust gas leakage
COOLING SYSTEM
On-vehicle Inspection
1. Check ��
for the
��
cooling system leakage
Caution:
To avoid being burned, do not remove the radiator
filler cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant
and steam to spill from the radiator.
(a) Fill the radiator with coolant and attach the radiator filler
cap tester.
ALC007G (b) Warm up the engine.
(c) Pump it to 137 kPa and check that the pressure does
not drop.
If the pressure drops, check ��
for ��
the hoses, radiator, and
water pump leakage. If there are no signs or traces of
external coolant leakage, check the heater core, cylin-
der block, and head.
2. Check the engine coolant level in the reservoir
(a) The engine coolant should be between the “L” and “F”
lines when the engine is cold.
If low, check for leakage and add ethylene glycol coolant
(-35°C) up to the “F” line.
3. Check engine coolant quality
(a) Remove the radiator filler cap.
Caution:
To avoid being burned, do not remove the radiator
filler cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant
and steam to spill from the radiator.
(b) Check the radiator filler cap and radiator filler for rust
and dirt. The coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator filler cap.
4. Check fins blockage
(a) If fins are clogged, wash them with water or a steam
cleaner and dry them with compressed air.
Note:
If the distance between the steam cleaner and core
is too close, there is a possibility of damaging the
fins, so keep the following injection distance:
Injection pressure Injection distance
ALC008G
(kPa) (mm)
2,942 to 4,903 300
4,903 to 7,845 500
• If the fins are bent, straighten them with a
screwdriver or pliers.
• Do not immerse the electronic into the water.
Inspection
1. Inspect the radiator filler cap sub-assembly
Note:
• If the radiator filler cap is contaminated, clean it
with water.
• Moisten the relief valve and vacuum valve with
engine coolant or water before the usage of a
radiator filler cap scanner.
• When performing the steps (a) and (b), keep the
scanner above 30° of the horizontal axle.
Radiator Filler (a) Use the radiator filler cap scanner and pump the scan-
Cap Scanner ner slowly. Confirm that the air has been released
through the vacuum valve.
Pump speed: pull out once every 3 seconds or longer
Note:
30° or above Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the
Radiator Filler radiator filler cap.
Cap (b) Pump the tester and measure the relief valve opening
ALC009G
pressure.
Pump speed: pull out once within 1 second
Note:
The above pump speed is for the first pump only
(in order to close the vacuum valve). After the first
pump, the pump speed can be reduced.
Standard opening pressure: 93 to 123 kPa
Minimum opening pressure: 78 kPa
If the opening pressure is less than the minimum, re-
place the radiator filler cap.
Hint:
Set the scanner maximum reading as the opening pres-
sure.
Cooling Fan System

1. Check the cooling fan operation at a low temperature (Below 83°C)
(a) Turn the ignition switch to the ON position.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor. Check for a disconnection
or circuit open between them.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM, and cooling fan. Check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. Check the cooling fan operation at a high temperature (Above 93°C )
(a) Start the engine, and raise coolant temperature to above 93°C .
Hint:
The coolant temperature is detected by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
Note: Cooling fan operation

Direction of rotation Low speed High speed
(View from the radiator) (r/min) (r/min)
Counterclockwise 1850 ± 150 2500 ± 150
3. Check the the cooling fan
(a) Disconnect the cooling fan connector.
(b) Connect a battery and an ammeter to the cooling fan.
(c) Check that the cooling fan rotates smoothly. Also, check the reading on the ammeter.
Standard amperage: 11.7 to 14.7 A
(d) Reconnect the cooling fan connector.
Inspection
1. Check the No.1 cooling fan relay
(a) Continuity check
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No. Specified condition
1-2 Continuity
No continuity
ALC010G 3-5 Continuity
(Apply battery voltage to terminals 1 and 2)
2. Check the No.2 cooling fan relay

(a) Continuity check
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No. Specified condition
1-2 Continuity
No continuity
ALC011G 3-5 Continuity
(Apply battery voltage to terminals 1 and 2)
3. Check the cooling fan resistor
(a) Using an ohmmeter, measure the resistance between
the terminals.
Resistance: 1.17 to 1.43 Ω at 20°C
Engine Coolant
Replacement
1. Drain engine coolant
Caution:
Do not remove the radiator filler cap when the en-
gine and radiator are still very hot to prevent burns
from occuring. Heat expansion may lead to spillage
of hot engine coolant and vapor out of the radiator.
(a) Remove the radiator filler cap.
(b) Loosen the radiator drain cock and drain engine coolant.
Water Drain Cock Sub-assembly
Radiator Filler Cap

Sub-assembly
Radiator Drain Cock Sub-assembly

ALC012G
2. Add engine coolant

(a) Tighten the radiator drain cock and fill coolant into the
radiator until it overflows.
Capacity: 5.0 L
Hint:
• Press the radiator inlet and outlet hoses several
times by hand.
• If the coolant level gets lower, add coolant.
(b) Tighten the radiator filler cap.
(c) Fill engine coolant into the reservoir until it reaches the
full level line.
(d) Warm up the engine until the thermostat valve begins
to open.
Hint:
Press the radiator inlet and outlet hoses several times
by hand during warm up.
(e) Stop the engine and wait until the coolant temperature
becomes cold.
(f) Then remove the radiator filler cap and check the
coolant level.
(g) If the level gets lower, perform the procedures from (a)
to (f) again.
(h) If the level does not get lower, add engine coolant to
adjust the reservoir coolant level.
3. Check for engine coolant leakage
(a) Fill the radiator with engine coolant and attach a radia-
tor filler cap tester.
(b) Pump it to 137 kPa and check for leakage.
Radiator Assembly
Components
Radiator Filler Radiator Filler Assembly
Radiator Upper Set Bracket
Mounting
Radiator Inlet
Pipe
Radiator
Assembly
B Type
Worm
Drive
Hose
Radiator Hoop
Lower
Mounting Radiator Outlet Pipe
Overflow
Electronic��
Fan With Steel Type Elastic Hoop Tube
Overflow��
Tank Assembly
For Models
with CVT Only
ALC013G
Replacement
1. Disconnect the negative battery terminal
2. Drain the engine coolant (see page EG-8)
3. Disconnect the radiator inlet pipe
4. Disconnect the radiator outlet pipe
5. Remove the front bumper upper grille (see page
BO-37)
6. Remove the front bumper (see page BO-37)
7. Remove the engine hood lock assembly

(a) Remove the 3 bolts, clip, and engine hood lock.
ALC014G
8. Remove the engine hood lock support

(a) Remove the 5 bolts and the engine hood lock support.
ALC015G
9. Remove the radiator upper member

(a) Remove the 2 bolts and disconnect the condenser from
the radiator upper member.
(b) Remove the 4 bolts and radiator upper member.
ALC016G
10. Remove the radiator assembly

(a) Disconnect the connector from the cooling fan motor,
and then remove the radiator assembly from the engine
compartment.
(b) Remove the 2 radiator upper mountings and the 2 ra-
diator lower mountings.
ALC017G
(c) Remove the 4 bolts and detach the electronic fan with
the overflow tank assembly.
(d) Remove the 2 bolts and water filler.
ALC018G
11. Install the radiator assembly

(a) Install the water filler with 2 bolts.
(b) Install the ��
electronic��
fan ��
overflow tube��
assembly with 4
bolts.
Torque: 7.5 N·m
ALC018G
(c) Install the 2 radiator upper mountings and lower mount-

ings on the radiator.
Torque: 7.5 N·m
(d) Install the radiator assembly and connect the connector
to the cooling fan motor.
ALC017G
12. Install the radiator upper member

(a) Install the radiator upper member with 4 bolts.
Torque: 5.0 N·m
(b) Install the condenser on the radiator upper member
with 2 bolts.
Torque: 9.8 N·m
ALC016G
13. Install the engine hood lock support

(a) Install the engine hood lock support with 5 bolts.
Torque: 5.0 N·m
ALC015G
14. Install the engine hood lock assembly

(a) Temporarily install the engine hood lock assembly with
3 bolts.
Torque: 8.0 N·m
15. Adjust the engine hood (see page BO-2)
16. Install the front bumper
17. Install the front bumper upper grille
18. Add engine coolant (see page EG-8)
ALC014G 19. Check for engine coolant leakage (see page EG-9)
20. Connect the negative battery terminal
MOUNTING SYSTEM
Engine Mount
Components
Engine Left Mounting

Engine Right Mounting
Engine Mounting Bracket LH

Engine Rear Mounting Bracket
Engine Rear Mounting
: Specified torque
ALC019G
Removal
Hint:
the reverse order.
1. Detach the the engine from the automobile
(a) Hang the engine with a crane.
(b) Using a socket wrench, remove the 2 bolts and 1 nut
from the engine right mounting.
ALC020G
(c) Using a socket wrench, remove the 1 bolt from the en-
gine rear mounting.
ALC021G
(d) Using a socket wrench, remove the 1 bolt from the en-
gine left mounting.
ALC022G
2. Remove the engine right mounting

(a) Using a socket wrench, remove the 3 bolts and the en-
gine right mounting from the body.
ALC023G
3. Remove the ��

engine rear
��
mounting
(a) Using a socket wrench, remove the 2 nuts, 1 bolt, and
the engine ��
rear ��
mounting from the subframe.
ALC024G
4. Remove the engine left mounting

gine left mounting from the left mounting bracket.
ALC025G
5. Remove the left mounting bracket

gine left mounting bracket from the transmission.
ALC026G
6. Remove the rear mounting bracket

gine ��
rear ��
mounting bracket from the transmission.
ALC027G
FUEL SUPPLY SYSTEM

Fuel Supply System Assembly
Components
Double-hole Hose Clamp Desorption Hose Ⅲ

Fuel Inlet Hose Ⅲ
Canister Solenoid Valve
Canister Solenoid Valve

Installation Sheath
Desorption Hose Ⅱ
Desorption��
Fuel Pipe
Fuel Pipe Sheath

Fuel Inlet Pipe
Double-hole
Hose Clamp
Fuel Filler Cap Mounting Plate Of
Hose Ⅰ Fuel Inlet Hose Ⅱ
Desorption�� Electronic Fuel Pump
Double-hole
Hose Clamp
Fuel Filter
Charcoal Canister
Fuel Filler
Pipe Sheath Single-hole Q1400835FD(Q402)
Fuel Filler Pipe Hose Clamp
Fuel Inlet Electronic Fuel Pump
Assembly Desorption��
Hose
Hose Ⅰ
Air Return Fuel Tank

Canister
Hose Assembly
Fuel Filler Air Pipe
Connecting Hose��
Fuel Tank Heat

Shield Assembly
ALC028G
Replacement
Hint:
The assembly procedure is in the reverse order of disas-
sembly. ��
However, only the installation sequences requiring
addition information are included.
Note:
If it is necessary to disassemble the oil circuit for repair-
ing the fuel system, be sure to release the pressure of
the fuel system to prevent high-pressure fuel from injec-
tion.
Fuel Tank Assy

Fuel Tank Removal
1. Pull out the electrical connector of the fuel tank at
the top of the fuel tank.
S t i ff e n i n g 2. Pull out the quick connectors connecting the fuel
Washer inlet hose Ⅱ and fuel inlet pipe, desorption hose
(1) and desorption��
��
pipe, and then block up the joint
with a cotton cloth to prevent high-pressure fuel
Fuel Tank Heat from injection
Q1400835FD(Q402)
Shield Assy ALC029G
3. Remove the hoops and clamps of the fuel filler con-

Fuel Filler
Pipe Assy Fuel Filler necting hose, air pipe and air return hose at the
Q67638 Connecting Hose rear of fuel tank
Q673B20 4. Remove the 4 fixing bolts of the fuel tank with the
specified torque (35-40 N·m) and the 2 strenghten-
Air
ing cushions.
Q1461025 Return
Q673B13 Hose
Air Hose
ALC030G
Fuel Pump and Charcoal Canister Removal

1. Assembly removal
(a) Thoroughly remove the dirt deposit around the flange
of the fuel pump.
(b) Diagonally unscrew the small bolts of the fuel pump
mounting plate in turn with a wrench.
(c) Be careful not to damage the fuel level sensor when
taking out the assembly from the fuel tank.
ALC031G
(d) Remove and dispose use of the seal ring.
(e) Remove the pipeline connected to the fuel pump.
Desorption Hose Ⅱ Q1400508 2. Connection installation

Fuel Inlet Hose Ⅱ (a) Be careful to mount the fuel pump and charcoal canis-
ter assembly and fuel level sensor while avoiding dam-
age.
(b) Make sure that the pipelines to the fuel pump and char-
Charcoal
Fuel Inlet Canister coal canister are connected to the correct joints.
Hose Ⅰ (c) Mount the sealing strip and mounting plate and then
Fuel Pump and Fuel tighten the bolts.
Level Sensor Assembly ALC032G Specified torque: 3-4 N·m
Gasoline Filter Removal

Fuel Inlet Hose Ⅰ
1. Pull out the 2 quick connectors connected to the
Fuel Inlet Hose Ⅱ
gasoline filter
2. Loosen the bolts of the gasoline filter bracket, take
out the filter, and replace it as a whole
Fuel Filter
Fuel Filter Mounting Bracket Assembly
ALC033G
Fuel Filler Pipe Assy Removal

Fuel Filler Cap
1. Remove the fuel filler cap and fuel filler pipe sheath.
2. Unscrew the fixing bolts of the fuel filler pipe as-
Fuel Filler Pipe Sheath sembly bracket and vehicle body.
Fuel Filler Pipe

Assembly
ALC034G
3. Disassemble the hoops and clamps of the fuel filler

Fuel Filler Pipe
Assembly Fuel Filler connecting hose, air return
��
hose,
��
and air pipe.
Q67638 Connecting Hose
Q673B20
Air
Q1461025 Return
Q673B13 Hose
Air Hose
ALC030G
MEMO
MT-1
Transmission
007Q Transmission
007Q Transmission’s Overall External Schematics..... MT-3
007Q Transmission Components.................................. MT-4
Areas of Importance....................................................... MT-5
Troubleshooting.............................................................. MT-5
Areas of importance before Disassembly.................... MT-6
Transmission removal.................................................... MT-6
Cleaning Instructions..................................................... MT-8
Inspecting Instructions.................................................. MT-8
Preparations for Assembly............................................ MT-8
Transmission installation............................................... MT-8
Bearing gaskets selection.............................................. MT-10
Disassembly & Assembly of the
Differential Subassembly............................................... MT-11 MT
Input Shaft Subassembly............................................... MT-13
Output Shaft Subassembly............................................ MT-21
Maintenance of the Clutch Housing.............................. MT-27
Maintenance of the Transmission Housing.................. MT-28
Repair of Other Parts...................................................... MT-30
Maintenance of the back-up lamp switch:.................... MT-33
Threaded Part Tightening Torque Table....................... MT-33
0011A Transmission
0011A Transmission’s Overall External Schematics... MT-34
Technical Parameters..................................................... MT-34
0011A Transmission Components................................. MT-36
Troubleshooting.............................................................. MT-37
Areas of Importance....................................................... MT-38
Transmission Assembly Removal................................. MT-39
Cleaning Instructions..................................................... MT-41
Transmission Assembly Installation............................. MT-42
Bearing gaskets selection.............................................. MT-45
Differential Components................................................ MT-46
Differential Assembly Removal..................................... MT-46
Differential Assembly Installation................................. MT-47
MT-2
Output Shaft Assembly Components........................... MT-50

Input Shaft Assembly Removal..................................... MT-50
3rd/4th gear radial clearance measurement................. MT-51
Areas of importance before installing.......................... MT-52
Input Shaft Assembly Installation................................. MT-52
Input Shaft Assembly Components.............................. MT-55
Output Shaft Assembly Removal.................................. MT-56
1st/2nd gear radial clearance measurement................ MT-57
Output Shaft Assembly Installation.............................. MT-58
Areas of importance before installing.......................... MT-58
Clutch housing assembly removal................................ MT-61
Clutch housing assembly installation.......................... MT-62
Transmission case assembly removal.......................... MT-64
Transmission case assembly installation.................... MT-65
Maintenance of Other Common
Easily-Damaged Parts.................................................... MT-67
Manipulation lid assembly removal and installation... MT-68
Synchronizer of each gear............................................. MT-69
Back-up lamp switch...................................................... MT-70
CVT Transmission
Overview.......................................................................... MT-71
Comparison Between Conventional Automatic
Transmission and Stepless Transmission................... MT-71
Transmission profile....................................................... MT-72
The Basic Principle of Stepless Transmission............ MT-73
Driving Mode................................................................... MT-80
Vehicle towing................................................................. MT-82
Periodic maintenance..................................................... MT-82
Lubricant specification................................................... MT-82
TCU wire connection diagram....................................... MT-82
Adaptive update.............................................................. MT-84
Service instructions........................................................ MT-86
SST and service parts replacement.............................. MT-97
Electronics Inspection.................................................... MT-112
Leakage............................................................................ MT-113
Gear Shift Mechanism System...................................... MT-123
Cooling System............................................................... MT-125
Transmission MT-3
007Q Transmission’s Overall External Schematics

This transmission is a step mechanical transmission with a differential, two-shaft front wheel drive appli-
cation. Its housing is made of aluminum alloy; its gear is a fine module gear with slender teeth; its forward
gears are all with an inertia lock-ring type synchronizer; it may shift gears in a smooth and fast way, great-
ly reducing the noise from the transmission assembly and prolonging the gear life, therefore it is highly
economical. This 5-speed transmission improves both the driving adaptability and reliability while relying
on its flexible and accurate gear a shifting, clearer feel for the driver as well as the interlocking mecha-
nism provided for preventing the reverse gear from being engaged by mistake.
ALD001G
007Q Basic parameters of the transmission

Input torque (N·m) 153
Input speed (rad/min) 6000
Net weight (kg) 31
Gear transmission ratio 1st gear 2st gear 3st gear 4st gear 5st gear Rev
3.364 1.895 1.286 0.969 0.800 3.214
Main deceleration ratio 4.267
Odometer speed ratio 31/35 (without driven wheel)
Lubricant number Lubricant 75W/90 (GL-4)
Lubricant capacity (L) 2.0
Match engine GW4G15
Control type Remote flexbile-shaft cable type
MT-4 COOL BEAR MAINTENANCE MANUAL
007Q Transmission Components
Clutch housing
Reverse gear idler
Reverse Gear Idler Shaft

Case 3rd Speed Gear Of
Input Shaft
3rd & 4th Speed

Synchronizer
4rd Speed Gear Input Shaft

for the Input Shaft
5rd Speed Gear

for the Input Shaft
5th Speed
Synchronizer
Output Shaft
5th Speed Gear for
the Output Shaft Planetary
Gear Shaft
4th Speed Gear for
the Output Shaft Planetary
Gear
Spacer
3th Speed Gear for

the Output Shaft
2th Speed Gear for
the Output Shaft
1st-2nd Speed
Synchronizer
1st Speed Gear for

the Output Shaft
Axle Shaft Gear
Transmission Case
ALD002G
Transmission MT-5
Areas of Importance
1. Disassembly
(a) In the process of disassembly, handle all the components with care and be careful not to knock them
together, especially joint faces; place all the components in order to avoid missing and misplacement.
2. Assembly
(a) Clean all parts before installation (except rubber pieces and gaskets).
(b) Do not reuse any oil seal, shaft retaining ring, or the elastic cylindrical pin.
(c) All rubbing surfaces should be coated with lubricant and the lips of all oil seals should be coated with
grease.
(d) During installation of the bearings, do not use any kind of rolling element to transmit pressure and
make sure not to tilt it.
(e) During the installation of the synchronizer components, the two sides of the spring piston's openings
should alternate.
(f) When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Troubleshooting
Symptom Possible Cause Troubleshooting
Noise is too loud Lubricant level is too low or insufficient lubrication Fill oil to the specified level
or abnormal Unqualified inferior lubricating oil Replace with the specified lubricant
Untimely oil changes Replace oil and damaged parts
The axial position or clearance of the gear is improper or the inter- Check, repair, and adjust
nal components knock against each other
Burrs, bruises,or spot corrosion of the gear tooth surface Repair or replace the gear
Damaged bearing Replace the bearing
Damaged clutch components Check, repair, and adjust
Difficult gear Improper clutch adjustment or incomplete release Adjustment
engagement Improper adjustment or motion interference of the gearshift trans- Check and adjust
mission mechanism
Positioning spring is too hard Replace components
Serious abrasion of the synchronizer ring Replace components
Leakage Excessive wear or damage of the oil seal Replace the oil seal
Too much oil is added, oil level too high Adjust to the specified level
Uneven sealant Recoat the sealant evenly
Bolt loose or missing Mount and tighten the bolt with the
specified torque
Joint surface damaged and not repaired in time Check and/or repair
Breather plug blocked Clean, clear, or replace
Gear disengage- Excessive wear of the synchronizer gear sleeve or gear dog tooth Replace relevant components
ment cone
The control mechanism is installed improperly or damaged Check, adjust, or replace
Failure or neglected installation of the positioning mechanism Replace or install
assembly
The fork is seriously deformed or worn out Replace
Too much gear axial clearance Check and adjust
Improper adjustment of gearshift transmission mechanism Check and adjust
Wrong gear The interlocking pin is lost or seriously damaged Replace
Synchronizer is Excessive gear shifting force Replace
damaged Not applying clutch Use the proper driving method
Synchronizer's spring expansion ring is damaged Replace
Difficulty shifting Synchronizer spring malfunction Replace
gears The internal groove of the synchronizer ring is worn out Replace
The synchronizer ring is seized into the conical surface Replace
Deformed shifting fork or shifting fork shaft Replace
Shifting fork is worn out Replace
Abnormal failure of Insufficient lubircation or low lubricating oil level Fill oil to the specified level
the bearing Lubricant is too dirty Clean, change lubricating oil, and
replace the relevant components
Unclean parts in the box Clean, change lubricating oil, and
replace the relevant components
Unqualified bearing Replace components
Mixed use of different oils or the use of additives Change lubricating oil and the replace
relevant components
Areas of Importance Before Disassembly

1. Open the oil drain plug before disassembly to drain the oil.
2. Before disassembly, thoroughly clean the exterior of the transmission with a steam cleaner or
cleaning solvent to prevent impurities from intruding into the transmission in the process of
disassembly and thus ensure the interior cleanliness and service life of the transmission.
3. Be sure to clean all the disassembled transmission components (except for sealed bearing)
and single parts with cleaning solvent. As for the sealed parts, just clean their surface and
then dry with compressed air.
4. Clean all the holes and pipes with compressed air and make sure that they are not clogged.
5. Use a clean container to hold the removed components to avoid losing any part or mixing with
other parts. Also, check whether any part has not been installed during the installation.
Reverse gear Transmission Removal

switch assembly
Hexagon 1. Disassembly of the accessories
Gasket head bolt (a) Place the transmission that has had the oil drained on
the work bench.
(b) Unscrew the hexagon head screw plug, hexagon head
magnetic screw plug, and gasket.
(c) Disassemble the positioning mechanism assembly, re-
verse gear switch assembly, hexagon bolt, and cable
bracket.
Gasket
Gasket Hexagon Head
Hexagon head Magnetic Screw
Position mecha- plug Plug
nism assembly ALD003G
Flange Bolt (Long) 2. Remove the manipulation lid subassembly

Set the tranmission in a neutral position, unscrew the
4 flange bolts of the shift lever cover, and then take out
Flange Bolt
(Short) the shift lever cover subassembly and compression
spring in turn.
Manipulation lid
subassembly Pressure spring
ALD004G
3. Disassembly of the transmission case

Flange bolt of (a) Unscrew the 14 flange bolts connecting the housings
the reverse of the transmission and clutch and the flange bolts of
idler shaft
the reverse idler shaft.
Bolt for the

flange face ALD005G
Transmission MT-7
(b) Remove the transmission housing assembly.

Transmission Housing Note: Do not scratch the joint face to avoid an oil
Assembly leak.
ALD006G
(c) Take out the magnet, reverse idler shaft, and the re-
Hexagon head bolt Reverse rocker arm verse idler assembly.
bracket subassembly (d) Unscrew the hexagon bolts connecting the reverse
rocker arm bracket subassembly and housing and
Reverse gear then remove the reverse rocker arm bracket subas-
idler shaft sembly.
Reverse
gear idler
Magnet
ALD007G
Input shaft subassembly 4. At first, remove the moving parts, namely the in-
Shift fork subassem-
Output shaft subas- put and output shaft subassemblies together.

sembly 5. Then, take out the operating parts, namely the
bly of each gear
Differential subassembly
shift fork subassemly of each gear.
6. Finally, remove the differential subassembly.
Clutch housing
ALD008G
Cleaning Instructions
After disassembling the transmission, clean the input shaft subassembly, output shaft subassembly, shift
lever cover subassembly, reverse idler assembly, clutch housing assembly, transmission housing assem-
bly, differential subassembly, shift fork of each gear, fork shaft, and magnet with a cleaning solvent. Then
dry all of these parts (except for bearings) with compressed air. Allow the bearings to dry naturally or wipe
them with a dry towel.
Inspecting Instructions
1. Check whether any gear has cracks, abnormal wear, or damage. Replace the gear if it has any of
the above problems.
2. Check whether the front and rear bearings and inner ring of the input and output shafts are dam-
aged, whether the self-sealing of the bearing is damaged, and whether there are abnormal sounds
when rotating the bearing. Replace the bearing if it has any of the above problems.
3. Check the shift fork of each gear for excessive wear. If any, replace the shift fork.
4. Check the rolling element of the front/rear bearings of the output shaft for excessive wear. If any,
replace the bearing.
5. Check the reverse arm for normal swinging and the spring for failure. If any, replace the relevant parts.
6. Check whether the ring on each fork shaft has abnormal wear, cracks, or deformation. Replace the
part if it has any of the above problems.
7. Check the relevant components and parts for damage as required by this manual. If any, replace them.
Preparations for Assembly
1. Before assembly, check and make sure that all the components and parts have been cleaned.
2. Before applying the sealant, be sure to remove the residual sealant on the joint face to avoid oil
leaks; and install the parts within 5 min. after applying the sealant.
3. Be sure to replace all the disassembled retaining rings with new ones.
4. When mounting the oil seal, apply lubricating grease onto the lip and then press into the oil seal
vertically without inclination.
5. All the bolts must be tightened with the proper torque as specified in the appendix.
6. In the process of installation, be careful not to scratch the oil seal in order to avoid oil leaks; you
may protect the oil seal with a special sheath.
Long Lockpin 3rd/4th, 5th reverse gear shift Transmission installation

fork subassembly
1. Buckle the 1st-2nd speed shift fork subasssembly
and 3rd-4th/5th reverse shift fork subassembly to
their synchronizer gear sleeves respectively.
2. After inserting the long lockpin into the 5th speed
Input shaft subassembly
shift fork hole, the resulting structure is as shown

in the left figure.
Output shaft
subassembly
1st/2nd shift fork

subassembly
ALD009G
Input shaft subassembly 1st/2nd shift fork 3. Mount each assembly as shown in the figure.
subassembly
Output shaft sub- (a) First, mount the differential subassembly.
assembly 3rd, 4th & 5th
reverse gear
(b) Then, mount the input shaft subassembly, output shaft
Differential Shift fork sub- subassembly, 1st-2nd speed shift fork subasssembly,
subassembly asssembly and the 3rd-4th/5th reverse shift fork subassembly.
Clutch housing
ALD010G
Transmission MT-9
4. Mount the reverse rocker arm bracket assembly

Reverse gear bracket Reverse gear and then tighten the bolt with washer of the reverse
idler shaft
assembly Bolts with
washer
bracket assembly.
5. Mount the reverse gear idler assembly and the re-
Reverse gear
idler subassembly verse gear idler shaft.
Reverse gear Caution:
rocker arm
bracket assembly
1. Be sure to apply a thread-locking sealant onto
the bolt with a washer of the reverse bracket as-
sembly before installation.
2. Be sure to align the position of the bolt hole of
the reverse idler shaft.
ALD011G
6. Coat sealant on the surface of the transmission

Face with sealant case assembly as shown in the figure.
Caution:
1. The joint surface should be free of oil, dirt, and
other contaminants.
2. The application position should be in the center
of the sealing face and inside the bolt hole.
3. Be sure to tighten the bolt before the sealant be-
comes dry, namely, within about 10 min. after ap-
plying the sealant.
ALD012G
7. Tighten the flange bolts of the reverse idler shaft

Reverse gear and transmission.
idler shaft Bolt
for flange face
Bolt for flange face

ALD013G
8. Apply sealant onto the joint face of the shift lever

Manipulation lid cover, mount the compression spring and shift le-
subassembly ver cover subassembly, and then tighten the flange
bolts of the shift lever cover.
Pressure spring
ALD014G
Reverse gear 9. Mount the reverse gear switch assembly, position-

switch assembly
ing mechanism assembly, and the cable bracket.
Gasket Hexagon head bolt
10. Tighten the hexagon head screw plug and hexagon
head magnetic screw plug.
Gasket
Gasket Hexagon head
Hexagon head plug magnetic screw
Position mechanism assembly plug
ALD015G
Bearing Gaskets Selection

Select and install the adjusting shim of the input shaft
bearings: maximum axial clearance: 0.1mm.
Select and install the adjusting shim of the output shaft
bearing: axial interference: 0.1mm; starting torque:
(0.6~1.4) N•m.
Select and install the adjusting shim of the differential
bearing: axial interference: 0.15mm; starting torque:
(0.6~1.4) N•m.
Transmission MT-11
Disassembly & Assembly of the Differential Subassembly
Small spherical washer

Differential hexagon bolt
Elastic cylindrical pin Odometer drive
Axle shaft gear gear retainer
Planetary
gear shaft
Tapered roller Flat Sleeve

Axle shaft gear Tapered roller bearings
bearings
Differential case Odometer drive gear
Differential ring gear Planetary gear
ALD016G
Differential Subassembly Removal

1. Unscrew the 8 differential hexagon bolts.
2. Remove the tapered roller bearing, differential gear
ring, odometer driving gear retaining ring, and
odometer driving gear in turn.
3. Remove the elastic cylindrical pin.
4. Take out the planetary gear shaft, planetary gear,
small spherical washer, axle shaft gear, and flat
sleeve in turn.
Areas of Importance Before Installing

1. Be sure to replace the disassembled odometer driv-
ing gear with a new one.
2. Be sure to replace the disassembled elastic cylin-
drical pin with a new one.
3. Be sure to replace the disassembled front/rear ta-
pered roller bearings of the differential with new
ones.
4. Before assembly, be sure to clean all the parts ex-
cept for the bearings and check all the parts for ab-
normal wear and damage.
5. It is necessary to apply a thread-locking sealant
onto the flange bolt of the differential gear ring just
before installation.
6. Be sure to prevent all of the parts (especially the
gears) from knocking in the process of disassem-
bly.
Planetary gear Differential Subassembly Installation

1. Mount the flat sleeve into the differential housing
2. Mount the 2 axle shaft gears
3. Mount the planetary gear with a small spherical
washer between the 2 axle shaft gears
4. Simultaneously turn the two planetary gears
to make their holes align with the two holes for
mounting the planetary gear shaft on the differen-
tial housing
ALD017G
5. Pass the planetary gear shaft through the two plan-

etary gears and then mount the 2 elastic cylindrical
pins into the differential housing
Planetary
gear shaft
ALD018G
6. Position and buckle the differential gear ring to the

Differential differential housing and then tighten the 8 flange
Bolt for
ring gear bolts
flange face
Note: The deeper side of the differential gear ring
faces toward the differential housing.
Differential case
ALD019G
Tapered roller bearings 7. Mount the odometer drive gear and odometer drive
Odometer drive gear
gear retainer
retainer 8. Mount the 2 tapered roller bearings of the differen-
Odometer drive tial by pressing
gear
Tapered roller
bearings ALD020G
Transmission MT-13
Disassembly & Assembly of the Input Shaft Subassembly
7
10
9
8
7
6
5
4
3
2
1
7
23
22
21
7
20
19
18
17
16
15
14
4
12 13
11
1. Deep groove ball bearing 2. Steel ball 3. Input shaft

4. Needle bearing 5. 3rd Speed gear assembly of the input shaft 6. 3rd gear synchronizer ring
7. Spring expansion ring 8. 3rd & 4th gear synchronizer gear sleeve 9. 3rd & 4th gear synchronizer gear hub
10. 3rd/4th gear synchronizer slider 11. 4th gear synchronizer ring gear 12. Shaft retainer
13. Washer 14. 4th speed gear assembly of the input shaft 15. Thrust Washer
16. Shaft retainer 17. Washer 18. Needle bearing
19. 5th gear gear assembly of the input shaft 20. 5th gear synchronizer ring 21. 5th gear synchronizer gear sleeve
22. 5th gear synchronizer gear hub 23. 5th gear synchronizer slider
ALD021G
Deep groove 1. Press out the deep groove ball bearing, 5th speed
ball bearing synchronizer assembly, and the 5th speed gear as-
5th speed synchro-
nizer assembly sembly of the input shaft
5th speed gear

assembly of the Input shaft
input shaft
ALD022G
2. Remove the needle bearing and washer and then

Needle bearing remove the shaft retaining ring with circlip pliers
Washer
Shaft retainer
ALD023G
3. Remove the thrust washer and steel ball

Input shaft
Steel ball
Thrust
washer
ALD024G
4th speed 4. Remove the 4th speed gear assembly of the input
gear assem- shaft, 4th speed synchronizer ring gear, and needle
bly of the bearing
input shaft
4th gear synchro- Input shaft

nizer ring gear
Needle
bearing
ALD025G
Transmission MT-15
5. Remove the washer and then remove the shaft re-

taining ring with circlip pliers
Washer
Input shaft
Shaft retainer
ALD026G
6. Press out the 3rd-4th speed synchronizer assembly

3rd & 4th speed and the 3rd speed gear assembly
synchronizer
assembly
Input shaft
3rd gear gear
subassembly
ALD027G
7. Remove the needle bearing

Needle bearing
Input shaft
ALD028G
8. Remove the deep groove ball bearing
Input shaft
Deep groove
ball bearing
ALD029G
Axial Clearance Control of Gears

Axial clearance of the 5th speed gear: 0.175~0.375 mm
Axial clearance of the 4th speed gear: 0.15~0.43 mm
Axial clearance of the 3rd speed gear: 0.1~0.25 mm
ALD030G
Allowance measurement for the 3rd, 4th, and 5th

speed synchronizer gear
Allowance δ (the axial clearance between the synchro-
nizer ring gear and dog teeth):
0.82~1.58
ALD031G
Areas of Importance Before Installing

1. In the process of disassembly, put the gear and
needle bearing of one speed together and separate
them from another speed.
For example, put the 3rd speed gear assembly and 3rd
speed needle bearing together. Likewise, please do so
for the 4th and 5th speed. Do not mix them at the time
of assembly.
2. After washing, check whether the conical surface
of any gear is damaged or has cracks. Replace the
gear if it has them.
3. After washing, check the wear of the synchronizer
gear sleeves and lock angles of the gears. Replace
the synchronizer assembly and the corresponding
gear assembly if they are seriously worn.
4. If the synchronizer disperses during removal (the
slider and spring expansion ring come out or the
gear sleeve detaches), please refer to the section
entitled "Assembly of Synchronizers of Different
Gears."
5. When installing, replace all used retainers and in-
stall the retainers of an appropriate thickness.
6. When installing the synchronizer, be sure to note
the installation direction of the synchronizer as-
sembly, and do not crush the synchronizer ring.
For the ring gears of the 3rd, 4th, and 5th speed
synchronizers are different from each other, do not
mix them at the time of assembly.
7. The removed parts (except for the bearings) must
be washed before installing.
Transmission MT-17
Input Shaft Subassembly Installation

Input shaft 1. Needle bearing
Needle bearing
ALD032G
2. Mount the 3rd Speed Gear Assembly of the Input

3rd speed gear
Shaft
assembly of the
Input shaft input shaft Caution: Coat oil on the conical surface of the 3rd
speed gear and needle bearing before installing.
Oiling position
ALD033G
3. Mount the 3rd gear synchronizer ring gears

Caution:
Input shaft 3rd gear syn- 1) Apply oil on the conical surface of the 3rd speed
chronizer ring gear before assembly.
2) T he 3rd speed synchronizer ring gear is marked
with “7W3.” Do not make a mistake at the time of
Oiling
position
assembly.
ALD034G
4. Mount the 3rd/4th gear synchronizer assembly by

pressing.
Caution:
1) At the time of assembly, align the groove of the
synchronizer ring gears with the synchronizer
slider;
2) K eep the big bevel face of the 3rd-4th speed syn-
3rd & 4th speed chronizer gear sleeve facing up.
synchronizer
assembly
ALD035G
5. Mount the shaft retainer and washer

Input shaft At the time of assembly, replace all the used retain-
Washer
ers with new ones of the proper thickness (clearance:
0~0.1mm).
Shaft retainer
ALD036G
4th gear synchro- 6. Mount the needle bearing and 4th speed synchro-
Input shaft nizer ring gear nizer ring gear
Caution: The 4th speed synchronizer ring gear is
marked with “7W4.” Do not make a mistake at the
time of assembly.
Needle bearing
ALD037G
Input shaft 7. Mount the 4th Speed Gear Assembly of the Input
Shaft
Caution: Coat oil on the conical surface of the 4th
speed gear and needle bearing before installing.
Oiling
position 4th Speed Gear
assembly of the
input shaft
ALD038G
Washer 8. Mount the steel ball, thrust washer, shaft retainer,

Shaft retainer and washer
Caution: At the time of assembly, replace all the
Input shaft used retainers with new ones with proper thickness
Thrust washer (clearance: 0~0.1mm).
Steel ball
ALD039G
Transmission MT-19
9. Mount the Needle bearing

Caution: Coat oil on the needle bearing before in-
Input shaft
stalling.
Needle bearing
Oiling position
ALD040G
10. Mount the 5th speed gear assembly of the input

Input shaft 5th gear sub- shaft
assembly
ALD041G
5th gear synchro- 11. Mount the 5th gear synchronizer ring gears
Input shaft nizer ring
Caution:
1) Apply oil on the conical surface of the 5th speed
Oiling
Position gear before assembly.
2) T he 5th speed synchronizer ring gear is marked
with “7W5.” Do not make a mistake at the time of
assembly.
ALD042G
5th speed synchronizer 12. Mount the 5th gear synchronizer assembly by
assembly
pressing.
Caution:
1) At the time of assembly, align the groove of syn-
chronizer ring gears with the synchronizer slider;
2) K eep the convex side of 5th speed synchronizer
gear sleeve facing up.
ALD043G
13. Mount the front/rear deep groove ball bearings of

Deep groove the input shaft by pressing.
ball bearing
Deep groove
ball bearing
ALD044G
14. Now, the assembly of input shaft subassembly is

over.
Caution: After installing the input shaft subassem-
bly, place the synchronizer gear sleeve of different
gears in the neutral position. Then, use your hands
to check whether the 3rd, 4th and 5th speed gear
assemblies work normally. Check and reinstall if
the gear will not rotate.
ALD045G
Transmission MT-21
Disassembly & Assembly of the Output Shaft Subassembly
6
9
8
7
6
5
4
3
20
19
18
17
16
15
14
13
12
11
10
1. Tapered roller bearing 2. Output shaft 3. Needle bearing

4. 1st gear gear assembly of the output shaft 5. 1st gear synchronizer ring gear 6. Spring expansion ring
7. 1st & 2nd gear synchronizer gear sleeve 8. 1st/2nd gear synchronizer slider 9. 1st & 2nd gear synchronizer gear hub
10. 2nd gear synchronizer ring gear 11. Shaft retainer 12. Washer
13. Needle bearing 14. 2nd gear gear assembly of output shaft 15. 3th speed gear of output shaft
16. Spacer 17. 4th speed gear of the output shaft 18. 5th speed gear Of the output shaft
19. Shaft retainer 20. Tapered roller bearings
ALD046G
Output Shaft Subassembly Removal

1. Press down the tapered roller bearing.
Tapered roller
Output shaft
bearings
ALD047G
2. Remove the shaft retainer with circlip pliers

Shaft retainer
ALD048G
5th speed gear of 3. Press out the 5th & 4th speed gears of the output
the output shaft
shaft and then take out the spacer.
4th speed gear of

the output shaft
Spacer
ALD049G
4. Engage the 1st gear and then press out the 3rd
speed gear and 2nd speed gear assembly of the
3th speed gear
of the output output shaft.
shaft
2nd speed gear

assembly of the
output shaft
ALD050G
Transmission MT-23
5. Take out the needle bearing, 2nd speed synchro-

Needle nizer ring gear, and washer
bearing
2nd gear syn-
chronizer ring
Washer
ALD051G
6. Remove the shaft retainer.
Shaft retainer
ALD052G
7. Press out the 1st-2nd speed synchronizer assem-

bly and the 1st speed gear assembly of the output
1st and 2nd speed syn- shaft, and then take out the needle bearing.
chronizer assembly
Needle bearing
ALD053G
8. Press out the tapered roller bearing.
Tapered roller
bearings
ALD054G
Measurement
Axial clearance of the 1nd speed gear: 0.1～0.25 mm
Axial clearance of the 2nd speed gear: 0.15～0.43 mm
ALD055G
Allowance of the 1st-2nd speed synchronizer ring

gears: 0.82~1.58 mm
Allowance
Synchronizer ring
ring gears
ALD056G
Areas of importance before installing

1. When installing, it is recommended to replace all re-
tainers and install retainers of an appropriate thick-
ness.
2. When installing the synchronizer ring gears, do not
crush the convex plate, claws, or sliders of the syn-
chronizer ring gears.
3. The 1st and 2nd speed synchronizer ring gears are dif-
ferent. Do not make a mistake at the time of assembly.
4. When mounting the 3rd, 4th, and 5th speed gears of
the output shaft by pressing, be sure to use correct
assembly methods and press into the gears in the
correct direction.
5. As for the assembly of 1st-2nd gear synchronizer, re-
fer to the section “Repair of the Synchronizer for Each
Gear.”
Output Shaft Subassembly Installation

1. Mount the Needle bearing
Caution: Coat oil on the needle bearing before in-
stalling.
Oiling Position Needle bearing
ALD057G
Transmission MT-25
2. Mount the 1st speed gear assembly of the output

shaft
1st speed gear

assembly of the
output shaft
ALD058G
3. Install 1st speed synchronizer ring gear

Caution: There is a groove as a mark (as shown in
the figure on the left) on the outer surface of the
1st gear synchronizer convex plate of the 1st speed synchronizer ring
ring gear gear, while there is no such mark on the 2nd speed
synchronizer ring gear. Do not make a mistake at
the time of assembly.
ALD059G
4. Mount the 1st-2nd synchronizer assembly, shaft re-

tainer, washer, and the 2nd speed synchronizer ring
gear in turn
2nd gear syn- Caution: When mounting the 1st-2nd speed syn-
chronizer ring Shaft retainer chronizer assembly by pressing, be sure to align
the groove and the convex plate. The synchronizer
Gear hub/gear
assembly should be installed in the direction as
sleeve
shown in the figure.
ALD060G
2nd gear gear as- 5. Mount the needle bearing and 2nd speed gear as-
sembly of the output sembly of the output shaft
shaft Caution: Apply lubricating oil onto the surface of
the needle bearing and the conical surface of the
2nd speed gear assembly of the output shaft.
Needle
Oiling bearing
Position
ALD061G
6. Mount the 3rd speed gear of the output shaft by

pressing
4th speed gear of
the output shaft 7. Mount the spacer
8. Mount the 4th speed gear of the output shaft by
pressing
3th speed gear of

Spacer
the output shaft
ALD062G
9. Mount the 5th speed gear of the output shaft by

5th speed gear of pressing and then mount the shaft retainer
Shaft retainer
the output shaft
ALD063G
10. Mount the tapered roller bearing by pressing.

Tapered roller Now, the assembly of the output shaft assembly is
bearings complete.
Tapered roller
bearings
ALD064G
Transmission MT-27
Maintenance of the Clutch Housing
C-type oil seal Outer ring of tapered roller bearing
Outer ring of tapered

roller bearing
Oil nozzle
Cylindrical pin
Oil seal of right

axle shaft
Clutch housing
ALD065G
Clutch housing removal

1. Remove the C-type oil seal and right axle shaft oil
seal
2. Remove the outer ring and oil nozzle of tapered
roller bearing of the output shaft
3. Remove the outer ring of tapered roller bearing of
the differential
4. Remove 4 cylindrical pins
Clutch housing assembly
1. Mount the 4 cylindrical pins
2. Press into the C-type oil seal vertically and then
mount the oil nozzle
3. Press into the outer ring of the tapered roller bear-
ing of the output shaft and differential in turn
4. Finally, press into the oil seal of the right axle shaft
Maintenance of the Transmission Housing

Oil drain slot
Transmission housing removal
1. Disassemble the oil groove
ALD066G
2. Remove the C-type oil seal
C-type oil seal
ALD067G
Outer ring of tapered 3. Take out the (input shaft) adjusting shim, outer ring
Adjusting shim roller bearing of tapered roller bearing, and the (output shaft) ad-
justing shim
ALD068G
Outer ring of tapered 4. Take out the outer ring of the tapered roller bearing
roller bearing and (differential) adjusting shim
Adjusting shim
ALD069G
Transmission MT-29
Transmission housing installation

Outer ring of tapered
roller bearing 1. When installing the transmission housing, select
the proper (differential) adjusting shim and place it
into the bearing hole, and then press into the outer
Adjusting shim
ring of the tapered roller bearing
ALD070G
Outer ring of tapered 2. Select the proper (output shaft) adjusting shim and
Adjusting shim roller bearing place it into the bearing hole, and then press into
the outer ring of the tapered roller bearing
3. Select the proper (input shaft) adjusting shim and
place it into the bearing hole
ALD071G
4. Mount the C-type oil seal vertically by pressing
C-type oil seal
ALD072G
5. Mount the oil groove

Oil drain slot
ALD073G
Gear shifting rocker

Repair of Other Parts
arm subassembly
1. Disassembly of the manipulation lid subassembly
(a) Disassemble the nylon washer, shaft retainer (small),
and the elastic cylindrical pin;
Shaft retainer (large)
(b) Then remove the gear shifting block, interlocking frame,
return spring, and spring seat in turn;
(c) Disassemble the positioning bolt of gear shifting block
Shaft retainer (small)
Dust cover and then take out the gear selecting block and gear se-
Normally closed
lecting rocker arm subassembly;
type air plug (d) Finally disassemble the shaft retaining ring (large), gear
S-type oil seal shifting rocker arm subassembly and dust cap.
Caution: At the time of repair, the following parts
Manipulation
lid assy
Gear selecting rocker
arm subassembly
may not be disassembled: T-type oil seal, gearshift
shaft oil seal, normally closed type air plug, and re-
verse stop block.
Small hollow C-type oil seal

positioning pin
Spring seat
Return spring Gear select-

ing block
Gear shifting block
Positioning bolt of
gear shifting block
Interlocking frame
Elastic cylindrical pin Nylon washer

ALD074G
Elastic cylindrical pin Set bolt
Grip retainer
Set bolt
Elastic cylin-
drical pin 1st/2nd speed gear
shift fork shaft
1st/2nd speed gear
5th speed gear shift guide block
shift fork Short lockpin
3rd-4th speed gear

shift fork shaft
1st/2nd speed gear

Long lockpin 5th reverse gear shift fork
shift guide block
Reverse gear Grip retainer
3rd-4th speed shifting block 5th speed gear
gear shift fork shift fork shaft ALD075G
2. Disassembly of the operating parts

(a) 1st-2nd speed: Disassemble the positioning bolt, elastic cylindrical pin and grip ring; disassemble the 1st-
2nd speed gear shift fork, 1st-2nd speed gear shift guide block, and 1st-2nd speed gear shift fork shaft.
(b) 3rd-4th/5th reverse: Disassemble the remaining 4 grip rings and then remove the 5th speed gear shift fork,
long lockpin, and compression spring; disassemble the positioning bolt and elastic cylindrical pin, remove
the 3rd-4th speed gear shift fork and 5th reverse gear shift guide block, and then take out the 5th reverse
gear shift fork shaft, reverse gear shifting block, short lockpin, and the 3rd-4th speed gear shift fork shaft.
Caution:
1. Do not reuse the disassembled elastic cylindrical pins and shaft retaining rings but replace them
with new ones;
2. In the process of disassembly, be careful not to damage the working face of shift forks and guide
blocks;
3. Apply thread-locking sealant onto the positioning bolt before mounting it;
4. After finishing assembly, check carefully and be sure that lockpins have been mounted.
Transmission MT-31
3. Assembly of the reverse stop block

Reverse stop block (a) Mount the torsion spring into the stop block as shown in
Pressure tor- the figure. Buckle the torsion spring to the convex plate
sion spring and then turn the reverse stop block counterclockwise
to the correct position.
ALD076G
(b) Mount the straight pin.

Caution: The position of both ends of the torsion
spring is as shown in the left figure.
Straight pin
ALD077G
(c) Knock in the steel ball.

Caution: The steel ball should be level with the face
to prevent it from getting out.
Steel ball
ALD078G
4. Maintenance of the synchronizer of each gear

The transmission has three synchronizer assemblies: 1st/2nd gear synchronizer assembly, 3rd/4th
gear synchronizer assembly, and the 5th gear synchronizer assembly. Each synchronizer assembly
consists of a gear sleeve, gear hub, slider, and spring expansion ring.
(a) 1st and 2nd Speed Synchronizer Assembly:
At the time of assembly, note the relative mounting direction between the gear sleeve and gear
hub; stagger the opening of the two spring expansion rings.
Spring expansion ring Slider

1st-2nd speed syn-
1st-2nd speed synchronizer gear hub
chronizer gear sleeve
ALD079G
(b) 3rd & 4th Speed Synchronizer Assembly:

At the time of assembly, note the relative mounting direction between the gear sleeve and gear
hub; stagger the opening of two spring expansion rings.
Spring expansion
ring Slider
3rd-4th speed syn-
3rd/4th speed synchronizer
chronizer gear hub
gear sleeve
ALD080G
Transmission MT-33
(c) 5th speed synchronizer assembly:

At the time of assembly, note the relative mounting direction between the gear sleeve, gear
hub, and slider; stagger the opening of the two spring expansion rings.
Slider
Spring expansion ring

5th speed synchronizer gear hub
5th speed synchronizer gear sleeve ALD081G
Maintenance of the back-up lamp switch:

The back-up lamp switch is in its entirety. If the switch fails to work normally, just unscrew it with a
wrench, replace it, and then tighten the new one with the torque of 50N•m.
Threaded Part Tightening Torque Table

Fastener No. Tightening torque
Fastening piece name Quantity Remarks
(Specification) (N•m)
Connecting bolt of manipulation lid ZMQ1840830-a Coat with
2 14～24
sealant
ZMQ1840835-a Coat with
2 14～24
sealant
Fixing bolt of differential ring gear ZM009A-2303309 Coat with
8 85～105
sealant
Reverse gear arm bracket bolt with ZMQ150B0816 Coat with
2 14～24
washer sealant
Gear shift block set bolt ZM001B-1702059 Coat with
1 28～40
sealant
Fixing bolt of reverse idler shaft ZMQ150B0835-c Coat with
1 25～38
sealant
Reverse gear switch assembly ZM001A-1701040-10 1 34～62
Position mechanism assembly ZM007W-1702080 1 30～50
Positioning screw of gear shift fork ZM007W-1702125 Coat with
2 15～25
sealant
Connecting bolt of housing and ZMQ1840835-a
14 25～38
clutch housing
Hexagon head magnetic screw plug ZM001A-1701050 1 34～62
Hexagon head plug ZM001A-1701051 1 34～62
0011A Transmission’s Overall External Schematics

The 0011A transmission is a step mechanical transmission with differential, two-shaft front wheel drive ap-
plication. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers
smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - im-
portant in achieving the overall economical efficiency. Regarding its control mechanism, the set steel ball
and spring allow for gear shifting to be quick and accurate with solid handling. The 5th gear transmission
is equipped with an interlocking mechanism to prevent accidental switching to reverse, to improve driving
comfort and reliability.
ALD082G
Technical Parameters
Basic technical parameters
Max. input torque 160 N·m/4,200 rpm
Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio for each gear
3.545 1.905 1.310 0.970 0.816 3.250
Main deceleration ratio 4.313
Odometer speed ratio 31/35
Center distance (mm) 70
Lubricant capacity (L) 1.9±0.15
Lubricant type SAE75W-90 GL-4
Net weight (kg) 36
Match engine EG01-1.5L EG02-1.3L
Transmission MT-35
ALD083G
Axial play (δ) between the synchronizer ring and the gear
Shift position Ⅰ(δ1) Ⅱ(δ2) Ⅲ(δ3) Ⅳ(δ4) Ⅴ(δ5)
Standard clearance (mm) 0.8-1.6 0.8-1.6 0.8-1.6 0.8-1.6 0.8-1.6
Axial play (δ) between each gear

Shift position Ⅰ(δ1) Ⅱ(δ2) Ⅲ(δ3) Ⅳ(δ4) Ⅴ(δ5)
Axial play (mm) 0.1-0.3 0.205-0.455 0.125-0.275 0.175-0.425 0.175-0.445
Tightening torque table

Quan- Tightening Specifica-
Parts Used Bolt code
tity torque N·m tion
Clutch housing × Cable bracket 1706124-001 3 11.3±3.4 M8×1.25
Clutch housing × Release fork support nail 1601013-001 1 36.8±7.4 M10×1.25
Clutch housing × Guide plate 1701027-001 1 11.3±3.4 M8×1.25
Clutch housing × Output shaft's roller bearing plate Q1420812 1 11.3±3.4 M8×1.25
Transmission case × Lock plug 1702583-001 2 24.5±3.4 M12×1.25
Shift fork shaft × Shift fork 1702115-001 4 15.7±3.1 M6×0.75
Clutch housing × Lock plug 1702583-001 1 24.5±3.4 M12×1.25
Clutch housing × Reverse gear arm bracket sub-
1702435-001 2 17.2±3.4 M8×1.25
assembly
Transmission case × Neutral position locating seat 1702550-001 1 29.4±5.9 M18×1.5
Transmission case × Reverse gear lock plug 1702574-001 1 12.7±3.4 M10×1.25
Transmission case × Input (output) shaft guide plate 1701021-001 2 17.2±3.4 M8×1.25
Transmission case × Reverse gear locating seat
1702560-001 1 39.2±11.7 M14×1.5
subassembly
Transmission case × Back-up lamp switch 1701014-001 1 40.2±12 M18×1.5
Transmission case × Oil filling/drain plug 1701013-001 2 39.2±11.7 M18×1.5
Transmission case × Clutch housing 1701022-001 13 29.4±5.9 M8×1.25
Transmission case × Clutch housing Q1840845 3 29.4±5.9 M8×1.25
Transmission case × Rear housing Q1420820 9 18.1±3.4 M8×1.25
Transmission case × Gear shifting arm bracket Q1841025TF2 2 24.5±3.4 M10×1.25
Transmission case × Manipulation lid subassembly Q1421025-1.25 2 19.6±3.4 M10×1.25
Transmission case × Manipulation lid subassembly Q1421030-1.25 2 19.6±3.4 M10×1.25
Transmission case × Bearing plate 1701030-001 5 27.4±5.9 M8×1.25
Transmission case × Reverse gear idler shaft 1701493-001 1 29.4±8.8 M8×1.25
Output shaft × Output shaft lock nut 1701253-001 1 118 ±7.4 M18×1.5
Gear shifting arm bracket × Gear shifting arm
1703113-001 1 11.8±2.4 M8×1.25
subassembly
Differential case × Differential gear ring 2303110-001 8 77.4±7.4 M11×1
Clutch housing × Release cylinder assembly 1609021-001 2 11.8±2.4 M8×1.25
0011A Transmission Components
ALD084G
1 1701812-001 Guide plate subassembly 2 1708305-001 5th gear hub shaft retainer
3 1708302-001 5th gear hub 4 1708303-001 5th gear synchronizer slider
5 1708304-001 5th gear synchronizer spring 6 1701154-001 5th gear needle bearing
expansion ring
7 1708301-001 5th gear sleeve 8 1701155-001 5th gear synchronizer ring
9 1701150-001 5th gear subassembly 10 1701153-001 5th gear needle bearing spacer
11 1701147-001 Rear ball bearing shaft re- 12 1701030-001 Plate bolt and flat washer subas-
tainer of input shaft sembly
13 Q1420820 Rear cover bolt and spring 14 1701811-001 Rear housing
washer subassembly
Transmission MT-37
15 1701029-001 Bearing plate 16 1701146-001 Input shaft rear ball bearing stopper
ring
17 1701145-001 Rear ball bearing of input 18 1701144-001 4th gear needle bearing
shaft
19 1701140-001 4th gear subassembly 20 1701134-001 3rd/4th gear synchronizer ring
21 1701143-001 4th gear needle bearing 22 1708205-001 3rd/4th gear hub shaft retainer
spacer
23 1708204-001 3rd/4th gear synchronizer 24 1708203-001 3rd/4th gear synchronizer slider
spring expansion ring
25 1708201-001 3rd/4th gear sleeve 26 1708202-001 3rd/4th gear hub
27 1701133-001 3rd gear needle bearing 28 1701130-001 3rd gear gear subassembly
29 1701011-001 Transmission case 30 1601014-001 Dust cover
31 1609010-001 Clutch slave cylinder subas- 32 1601011-001 Clutch housing
sembly
33 1601013-001 Release fork support nail 34 1701191-001 Input shaft
35 1701025-001 Cylindrical roller bearing of 36 1701024-001 Input shaft oil seal
input shaft
37 1701291-001 Output shaft 38 1701032-001 Output shaft guide nozzle
39 1701031-001 Cylindrical roller bearing of 40 2303131-001 Differential front oil seal
output shaft
41 2303109-001 Differential front gasket 42 2303112-001 Front tapered roller bearing
43 2303111-001 Odometer drive gear 44 2303102-001 Differential case
45 Q5220635 Cylindrical pin 46 2303105-001 Planetary gear shaft
47 2303103-001 Planetary gear 48 2303104-001 Planetary gear spherical gasket
49 2303110-001 Bolt for flange face 50 2303107-001 Axle shaft gear
51 2303106-001 Axle shaft gear adjusting 52 1701022-001 Hexagon bolt for flange face
gasket
53 2303101-001 Differential ring gear 54 2303115-001 Rear tapered roller bearing
55 2303108-001 Rear adjusting gasket of dif- 56 1701215-001 1st gear thrust washer
ferential
57 2303132-001 Rear oil seal of differential 58 GB/T308- Steel ball Sφ4.7625
59 1701210-001 1st gear gear subassembly 60 1701214-001 1st gear synchronizer ring gear
61 1701213-001 1st gear needle bearing 62 1708102-001 1st/2nd gear hub
63 1708104-001 1st/2nd gear synchronizer 64 1708101-001 1st/2nd gear sleeve
spring expansion ring
65 1701223-001 2nd gear synchronizer ring 66 1708105-001 1st/2nd gear hub shaft retainer
67 1701224-001 2nd gear needle bearing 68 1701220-001 2nd gear gear subassembly
spacer
69 1701225-001 2nd gear needle bearing 70 1708103-001 1st/2nd gear synchronizer slider
71 1701231-001 3rd gear driven gear 72 1701233-001 3rd/4th gear spacer
73 1701241-001 4th gear driven gear 74 1701243-001 Rear ball bearing of output shaft
75 1701244-001 Output shaft rear ball bearing 76 1701251-001 5th driven gear
stopper ring
77 1701253-001 Output shaft lock nut
Troubleshooting
Common problems Possible causes Troubleshooting
Not applying clutch Use proper driving method
Insufficient clutch separation Check and adjust
Difficult gear engagement Serious abrasion of the synchronizer Replace components
ring
Self-locking spring is too hard Replace components
Oil level is too low Fill oil to specified level
Lubricant is of poor quality Replace specified oil
Untimely oil changes Replace oil and damaged parts
Noise is too loud or abnormal Improper gear axial position and clear- Check and adjust
ance
Damaged bearing Replace components
Gear has a burr or has been knocked Repair or replace the gear
Too much oil is added, oil level too high Make the oil level to specified level
Bolt loose or missing Reinstall, tighten according to require-
Oil leakage ment
Breather plug fails Replacement
Damaged seal Replacement
Excessive gear shifting force Replacement
Synchronizer is damaged Not applying clutch Use proper driving method
Synchronizer's spring expansion ring is Replacement
damaged
Control mechanism malfunction Check and adjust
Spring or steel ball missing Install
Gear disengagement Self-locking spring malfunction Replacement
Fork groove of the gear sleeve is worn Replacement
out
Shifting fork is worn out Replacement
Oil level is too low Replace parts and fill oil
Lubricant is of poor quality Replace parts and lubricant
Bearing and gear are burned Untimely oil replacement causes the oil Replace parts and lubricant
to be too dirty
Mixed use of different oils or use of ad- Replace parts and lubricant
ditives
Synchronizer spring malfunction Replacement
The internal groove of the synchronizer Replacement
ring is worn out
Difficulty shifting gears The synchronizer ring is seized into the Replacement
conical surface
Deformed shifting fork or shifting fork Replacement
shaft
Shifting fork is worn out Replacement
Areas of Importance
Removal:
1. Open the oil drain plug before removal to drain the oil.
2. Use cleaning solvents to clean the exterior of the transmission before removal. Avoid mixing
impurities on the transmission or into the transmission during removing.
3. Use a clean container to hold the removed components to avoid losing any part or mixing with
other parts. Also check whether any part has not been installed during the installation.
4. Check whether every component works normally during removal and whether it is damaged,
deformed, or has any other problem.
Installation:
1. Clean all parts before installation (except rubber pieces and bearings).Use proper methods to
clean the components carefully and thoroughly.
2. When using compressed air to dry parts, the air may raise dust and other particles and cause
eyes to become irritated.
3. All oil seals, shaft retainers, elastic pins, and clasps should not be reused.
4. Tighten all bolts to the specified torque.
5. All rubbing surfaces should be coated with lubricant, and the openings of all oil seals should
be coated with grease. Use SST to press the oil seal into the transmission case and maintain
the proper installation.Be careful while installing to avoid scratching the oil seal and causing
oil leakage.
6. During installation of the bearings, do not use any kind of rolling element to transmit pressure,
and make sure not to tilt it.
7. During the installation of synchronizer components, the two sides of the spring piston's open-
ings should alternate.
8. Pay special attention to the parts that have requirement a regarding installation direction.
9. Coat with the specified sealant at the specified position. Clear the sealant on the contact sur-
face before coating and install parts within 10 minutes after coating.
Transmission MT-39
2 Transmission Assembly Removal

3 4
1. Place the transmission that has had the oil drained
1 5
on the work bench.
(a) Remove all the peripheral components with proper
6 tools, and then screw out the back-up lam switch and
neutral position locating seat.
1. Gear shifting arm assembly

2. Neutral position locating seat
3. Back-up lamp switch
4. Air filter bracket assembly
5. Clutch pipe bracket
6. Wire harness bracket 6
7. Cable bracket assembly ALD085G
1 2. Remove the manipulation lid bolt and manipulation

lid assembly.
1. Manipulation lid assembly

2. Manipulation lid bolt and spring
washer subassembly ALD086G
3. Use tools to remove the rear cover and corre-

1
sponding inner parts.
3
4
5
6
1. Rear cover bolt and spring washer

subassembly
2. Rear body subassembly
3. 5th gear hub shaft retainer
4. 5th gear synchronizer assembly
5. 5th gear shaft fork
6. Shift fork mounting bolt
ALD087G
3 4. Use tools to remove the parts as shown in the

2 4 figure.
1 5
6
1. Shift fork shaft limiting clasp

2. 5th driven gear
3. Output shaft lock nut
4. 5th gear subassembly
5. 5th gear needle bearing
6. 5th gear needle bearing spacer ALD088G
5. Remove the lock ball plug, lock ball spring seat,

lock ball spring, lock ball, reverse gear locating
1
seat, shift fork shaft limiting clasp, plate bolt and
flat washer subassembly, bearing plate, input shaft,
output shaft rear ball bearing stopper ring and 13
hexagon bolts for the flange face.
2
3
4 8
5
6
1. Reverse gear idler shaft mounting bolt and

flat washer
2. Plate bolt and flat washer subassembly
3. Bearing plate
4. Output shaft rear ball bearing stopper ring
5. Lock ball plug, lock ball spring seat, lock ball
spring, lock ball
6. Hexagon bolt for flange face
7. Reverse gear locating seat
8. Input shaft rear ball bearing stopper ring
ALD089G
1 6. Turn the transmission by 90° and then unscrew the

3 bolts on the side of the clutch housing.
1. Hexagon bolt for flange face ALD090G

Transmission MT-41
7. Remove the transmission case assembly.

1
1. Transmission case assembly ALD091G
8. Use tools to remove the reverse gear arm bracket

mounting bolt, reverse gear idler shaft, reverse
1 gear idler subassembly, and reverse gear arm
2 bracket subassembly.
3
4
1. Reverse gear idler shaft

2. Reverse gear idler subassembly
3. Reverse gear arm bracket mounting bolt
4. Reverse gear arm bracket subassembly
ALD092G
4 9. Vertically pull out the input shaft assembly, output

3 shaft assembly, 1st/2nd gear fork shaft assembly,
3rd/4th, 5th gear fork shaft assembly, and finally re-
2
5 move the differential assembly.
1. Clutch housing assembly

2. Differential assembly
3. Output assembly
4. Input shaft assembly
5. Shift fork shaft assembly of each gear
ALD093G
Cleaning Instructions
After disassembling the transmission, use solvent to clean the input shaft assembly, output shaft assembly, manipula-
tion lid assembly, reverse gear idler assembly, clutch housing assembly, transmission case assembly, shift fork as-
semblies, and the magnet.Dry with compressed air after cleaning.
Inspecting Instructions
1. Check whether any gear has cracks, abnormal wear, or damage. Replace the gear if it has any of the
above problems.
2. Check whether the front and rear bearings and inner ring of the input and output shafts are damaged,
whether the self-sealing of the bearing is damaged, and whether there is abnormal sound when rotating
the bearing. Replace the bearing if it has any of the above problems.
3. Check whether the 1st/2nd gear shift fork, 3rd/4th gear shift fork, and 5th reverse gear shift fork have ab-
normal wear. Replace the fork if any show abnormalities.
4. Check whether the ring on each fork has abnormal wear, cracks, or deformation. Replace the part if it
has any of the above problems.
Transmission Assembly Installation

1. After installing the 1st/2nd gear shift fork shaft as-
1
2 sembly and 3rd/4th, 5th reverse gear shift fork shaft
assembly, put them on corresponding synchronizer
gear sleeve respectively.
4
Caution: Do not miss the two interlocking steel
balls.
1. Output assembly
2. 1st/2nd shift fork shaft assembly
3. Input assembly
4. 3rd/4th, 5th reverse gear shift fork shaft
assembly
ALD094G
4 2. Keep the release bearing surface of the clutch

3 housing assembly downwards, put in the differen-
tial assembly, and then put in the input shaft as-
2
5 sembly, output shaft assembly, 1st/2nd gear fork
shaft assembly, 3rd/4th, and 5th reverse gear fork
1 shaft assembly.
1. Clutch housing assembly

2. Differential assembly
3. Output assembly
4. Input shaft assembly
5. Shift fork shaft assembly of each gear
ALD093G
3. Put in the reverse gear arm bracket assembly. Use

17.2 N·m to tighten the mounting bolt of the reverse
gear arm bracket. Put in the reverse gear idler sub-
1
2 assembly, reverse gear idler thrust washer, and re-
3
verse gear idler shaft.
4
5
1. Reverse gear idler shaft

2. Reverse gear idler thrust washer
3. Reverse gear idler subassembly
4. Reverse gear arm bracket mounting bolt
5. Reverse gear arm bracket subassembly
ALD092G
Transmission MT-43
Caution: The mark line on the reverse gear idler

shaft aligns with the bolt hole A in clutch.
The system is
normal
ALD095G
4. Coat sealant on the surface of the transmission

case assembly as shown in the figure.
Coating
position
ALD096G
5. Put the transmission case assembly and clutch

1
housing assembly closing box.
1. Transmission case assembly

ALD091G
6. Install the 13 reverse gear idler shaft mounting

4 bolts and flat washers, lock ball plug, lock ball
5 3 spring seat, lock ball spring, lock ball, reverse
gear locating seat, shift fork shaft limiting clasp,
6
7
input shaft, output shaft rear ball bearing stopper
2
ring,Tighten in specified torque.
1. Reverse gear idler shaft mounting bolt

and flat washer (coat)
2. Hexagon bolt for flange face
3. Input shaft, output shaft and rear ball
bearing stopper ring
4. Plate bolt, flat washer subassembly and
bearing plate
6. Lock ball plug, lock ball spring seat, lock
ball spring, lock ball
7. Reverse gear locating seat ALD097G
2 7. Install the 5th gear and other components.

1 4
3
5
6

2. 5th driven gear
3. Output shaft lock nut
4. 5th gear subassembly
6. 5th gear needle bearing spacer ALD088G
8. Install the rear cover, 5th gear synchronizer, and

1
other components.
3
4
5
6
1. Rear cover bolt and spring washer subassembly

2. Rear body subassembly
3. 5th gear hub shaft retainer
4. 5th gear synchronizer assembly
5. 5th gear shaft fork
6. Shift fork mounting bolt ALD087G
Transmission MT-45
1 9. Rotate the transmission 90°, screw in 3 bolts in

clutch housing, and tighten in the specified torque.
1. Hexagon bolt for flange face ALD090G
1 10. Install the manipulation lid assembly.

Caution: Coat glue on the two manipulation lid
mounting bolts at the bottom.
1. Manipulation lid assembly

2. Manipulation lid bolt and spring
washer subassembly ALD086G
11. Install the release bearing subassembly, release

shift fork subassembly, air filter bracket assembly,
engine mount, neutral position locating seat, back-
up lamp switch, gear shifting arm assembly, steer-
ing bracket and other gear shift mechanism subas-
sembly and manipulation lid bolt, and tighten them
with their specified torque.Complete the installa-
tion.
ALD085G
Bearing gaskets selection

If the input shaft, output shaft or gear, hub, or bearing
on the shaft is replaced during maintenance, measure
the axial play during installation, and select the proper
gasket and shaft retainer to satisfy the requirement of
axial play.If the transmission case, clutch housing, dif-
ferential case, or front/rear bearing of differential is re-
placed, measure the differential rotation starting torque
when installing.
Standard start torque:
New bearing: 0.78-1.57 N·m
Worn in bearing: 0.49-0.98 N·m
Differential Components
2
1
5
3
12
11
10 8
9
1. Front tapered roller bearing 5. Differential case 9. Planetary gear

2. Odometer drive gear 6. Differential ring gear 10. Planetary gear spherical gasket
3. Axle shaft gear 7. Rear tapered roller bearing 11. Planetary gear shaft
4. Cylindrical pin Q5220635 8. Bolt for flange face (8) 12. Axle shaft gear adjusting gasket
ALD098G
Differential Assembly Removal

1 1. Use the SST to remove the front/rear tapered roller
2 bearing of the differential and remove the odometer
drive gear.
3
1. Front tapered roller bearing
2. Odometer drive gear
3. Rear tapered roller bearing ALD099G
1. Bolt for flange face 1 2. ��

Remove 8 bolts on the flange face and remove the
2. Differential ring gear differential ring gear.
2
ALD100G
Transmission MT-47
3. Use the SST to remove the cylindrical pin that at-

taches the planetary gear shaft.
SST
Differential
assembly
Cylindrical pin
ALD101G
4. Remove the planetary gear shaft.
ALD102G
5. Remove the planetary gear and axle shaft gear.

3 5
2
4
1
1. Planetary gear 5. Differential case

spherical gasket
2. Axle shaft gear
3. Axle shaft gear
adjusting gasket
4. Planetary gear ALD103G
Differential Assembly Installation
Areas of Importance
1. Replace with a new component after removing the
front/rear bearing of the differential.
2. Clean all parts except the bearing before installing
and check whether any component has abnormal
wear and tear or is damaged.
3. Make sure no component (especially) is bumped
during removing.
1 Differential Assembly Installation
2 1. Install the axle shaft gear.
(a) Install two axle shaft gear adjusting gaskets on the axle
shaft gear and then put then into the differential case.
3
1. Axle shaft gear adjusting gasket

2. Axle shaft gear
3. Differential case
ALD104G
2
2. Install the planetary gear.
(a) Put the spherical gasket on the planetary gear and in-
sert between two axle shaft gears, and then rotate the
1 two planetary gears simultaneously to align the holes
to the two holes installing planetary gear shaft in the
differential case.
1. Planetary gear spherical gasket

2. Planetary gear
ALD105G
3. Install the planetary gear shaft.

(a) Put the planetary gear shaft through the two planetary
gears and align the pin hole in the shaft to the pin hole
in the differential case.
ALD102G
4. Pound into the cylindrical pin with SST.

(a) Install the rear-riveted differential case to avoid the cy-
Cylindrical pin lindrical pin falling off.
ALD106G
1 5. Install the differential ring gear and 8 bolts for the

flange face.
2 (a) Put the differential ring gear on the differential case,
align the holes and install.Then use a 77.4 N·m tighten-
ing torque to tighten the bolts for the flange face.
1. Bolt for flange face

2. Differential ring gear ALD100G
Transmission MT-49
6. Use the SST to press fit the front/rear tapered roller

1 bearing. Put in the odometer drive gear before
press fitting the front tapered roller bearing.
2
3
1. Front tapered roller bearing
2. Odometer drive gear
3. Rear tapered roller bearing ALD099G
7. Finish the installation of the differential.
ALD107G
Output Shaft Assembly Components
9
8
7
6
5
1. Input shaft 6. 4th gear needle bearing

2. 3rd gear gear subassembly 7. 4th gear subassembly
3. 3rd gear needle bearing 8. Rear ball bearing of input shaft
4. 3rd/4th gear synchronizer assembly 9. Rear ball bearing shaft retainer of input shaft
5. 3rd/4th gear hub shaft retainer
ALD108G
1 Input Shaft Assembly Removal

2
1. Remove the rear ball bearing shaft retainer of the
3
input shaft. Use the SST to press down the 4th gear
gear subassembly and rear ball bearing of the input
shaft simultaneously and remove 4th gear needle
4 bearing.
1. Rear ball bearing shaft retainer of input shaft

2. Rear ball bearing of input shaft
3. 4th gear components
4. 4th gear needle bearing ALD109G
Transmission MT-51
2. Remove the 3rd/4th hub shaft retainer and take

1
2 out the 4th gear synchronizer ring. Use the SST
3
to press out the 3rd gear gear subassembly and
4
3rd/4th gear synchronizer assembly and take out
the 3rd gear needle bearing.
1. 3rd/4th gear hub shaft

retainer
2. 4th gear synchronizer ring
3. 3rd/4th gear synchronizer
assembly
4. 3rd gear gear subassem-
bly
5. 3rd gear needle bearing
ALD110G
3rd/4th gear radial clearance measurement

1. Axial clearance control of gears
Items Data (mm)
Synchronizer ring gear al-
0.8-1.6
lowance
Axial clearance of 3rd gear 0.125-0.275
Axial clearance of 4th gear 0.175-0.425
Caution: Measure the gears and shafts only after
washing and drying to ensure the accuracy and va-
lidity of the dimensions.
ALD111G
2. Radial clearance control of gears.
Measure the radial clearance of gears after washing and
drying the parts.Compare the results with the table below
and replace new input shaft gear and needle bearings if the
results exceed the specified range.
Items Data (mm)
Radial clearance of 3rd gear 0.015-0.058
Radial clearance of 4th gear 0.015-0.058
3. Examine 3rd/4th gear synchronizer ring allowance.

Use your hands to press the synchronizer rings on the gears
Synchro- flatly and use a feeler gauge to measure the allowance be-
nizer ring
tween the gear and synchronizer ring.
Allowance
If the allowance is smaller than 0.8 mm or bigger than 1.6
mm, replace the synchronizer ring and measure again. If the
allowance of the new synchronizer ring is still smaller than
0.8 mm or bigger than 1.6 mm, replace with a new gear.
Gear subassembly
ALD112G

1. During removal, place the gears, needle bearings, and synchronizer rings separately, e.g. put the
3rd gear main gear, 3rd gear synchronizer ring and 3rd gear needle bearing together, same for 4th
gear and 5th gear. Do not mix when installing.
2. After washing, check whether the conical surface of any gear is damaged or has cracks. Replace
the gear if it has them.
3. After washing, check the wear of the synchronizer gear sleeves and lock angles of the gears. Re-
place the synchronizer and gear if they are seriously worn.
4. If the synchronizer disperses during removal (slider and spring come out or gear sleeve detaches),
please refer to the section entitled "Maintenance of Synchronizers of Different Gears" in Chapter
VII.
5. When installing, we suggest the replacement of all used clasps and install claps of an appropriate
thickness.
6. When installing the synchronizer, do not crush the convex plate of the synchronizer ring.Also, pay
attention to the installation directions of the gear hub and gear sleeve.
7. The synchronizer ring gear of the 3rd gear is different from the one for the 4th gear (has number
mark) and they can't be interchanged.
8. The removed parts must be washed before installing.
Input Shaft Assembly Installation

1. Install the 3rd gear needle bearing.
1
1. Input shaft
2. 3rd gear needle bearing
ALD113G
2. Install the 3rd gear drive gear subassembly.

Caution: Coat oil on the 3rd gear needle bearing
1
before installing.
Oil coating position
1. Input shaft
2. 3rd gear drive gear
subassembly
ALD114G
3. Install the 3rd gear synchronizer ring (marked with

number "3").
1 Caution: Coat oil on the conical surface of the 3rd
gear subassembly before installing.
2
1. Input shaft
2. 3rd gear synchronizer ring
ALD115G
Transmission MT-53
4. Install the 3rd/4th gear synchronizer assembly.

(a) Press to press in the synchronizer with tools and press.
1 Caution: Align the synchronizer ring groove to the
2 slider of the synchronizer when installing.Keep the
surface of the gear sleeve outer ring marked with a
notch downwards (3rd gear direction).
3
Notch mark
1. 3rd/4th gear synchronizer assembly

2. 3rd/4th gear synchronizer press fitting tool
3. Input shaft seat tool ALD116G
5. Use a clasp caliper to install the 3rd/4th gear hub

shaft retainer and put in the 4th gear needle bearing
spacer.Install 4th gear synchronizer ring (marked
1
with a number "4") and the 4th gear needle bearing.
3
2 (a) The thickness of the shaft retainer has six specifica-
4 tions and the installation clearance should be smaller
than 0.1 mm.

2. 4th gear needle bearing spacer
3. 3rd/4th gear hub shaft retainer
4. 4th gear synchronizer ring
ALD117G
6. Install the 4th gear gear subassembly.

Caution: Coat oil on the conical surface of the 4th
4th gear sub- gear subassembly and needle bearing before in-
assembly
stalling.
Oil coating
position
ALD118G
7. Install the rear ball bearing shaft retainer of the in-

put shaft and rear ball shaft of the input shaft.
(a) Use the SST to press fit the rear ball bearing of the in-
1 put shaft and install rear ball bearing shaft retainer of
2 the input shaft. The thickness of the shaft retainer has
six specifications and the installation clearance should
be smaller than 0.1 mm.
1. Rear ball bearing shaft retainer of

input shaft
2. Rear ball bearing of input shaft ALD119G
8. Finish the installation of the input shaft.

Caution: After installing input shaft assembly, place
the synchronizer gear sleeve of different gears in
the neutral position. Then, use your hands to check
whether the 3rd gear drive gear and 4th gear driven
gear work normally.Check and reinstall if the gear
can't rotate.
ALD120G
Transmission MT-55
Input Shaft Assembly Components
2
3
4
5
6
7
9
10
11
12
13
14
15
16
1. Output shaft 9. 1st/2nd gear hub shaft retainer

2. Rear ball bearing of output shaft 10. 2nd gear synchronizer ring
3. 4th gear driven gear 11. 1st/2nd gear synchronizer assembly
4. 3rd/4th gear spacer 12. 1st gear synchronizer ring gear
5. 3rd gear driven gear 13. 1st gear needle bearing
6. 2nd gear gear subassembly 14. 1st gear gear subassembly
7. 2nd gear needle bearing 15. 1st gear thrust washer
8. 2nd gear needle bearing spacer 16. Steel ball Sφ4.7625
ALD121G
Rear ball bearing

Output Shaft Assembly Removal
of output shaft 1. Use SST and press to press out the 4th gear driv-
4th gear driven en gear and rear ball bearing of the output shaft.
gear
Remark: Press out the two parts together.
ALD122G
2. Take out the 3rd/4th gear spacer and use the SST
1
and press to press out the 2nd gear subassembly
2 and 3rd gear driven gear.
Remark: Press out the two parts together.
3
1. 3rd/4th gear spacer

2. 3rd driven gear
3. 2nd gear gear subassembly
ALD123G
3. Take out the 2nd needle bearing, 2nd gear needle

bearing spacer, 2nd gear synchronizer ring gear,
and use a clasp caliper to remove the 1st/2nd gear
1 hub shaft retainer.
2
3
4
1. 2nd gear needle bearing

2. 2nd gear needle bearing spacer
3. 2nd gear synchronizer ring
4. 1st/2nd gear hub shaft retainer
ALD124G
Transmission MT-57
4. Use the SST and press to press out the 1st gear
subassembly, 1st synchronizer ring gear, and 1st/
2nd synchronizer assembly.
Remark: Press out the three parts together.
1
1. 1st/2nd synchronizer assembly

2. 1st gear synchronizer ring
3. 1st gear gear components ALD125G
5. Take out the 1st gear needle bearing, 1st gear

thrust washer, and steel ball Sφ4.7625.
2
3
1. 1st gear needle bearing

2. 1st gear thrust washer
3. Steel ball Sφ4.7625 ALD126G
1st/2nd gear radial clearance measure-

ment
1. Axial clearance control of gears
Unit: mm
Shift position Ⅰ Ⅱ
Synchronizer ring 0.8-1.6 0.8-1.6
gear allowance
Axial play of gears 0.1-0.3 0.205-0.455
2. Radial clearance control of 1st/2nd gears Unit: mm
Measure the radial clearance of gears after washing
ALD127G and drying the parts.Compare the results with the table
below and replace new input shaft gear and needle
bearings if the results exceed the specified range.
Unit: mm
Items Radial clearance of 1st Radial clearance of 2nd
gear gear
Data 0.015-0.056 0.015-0.056
3. Examine the 1st/2nd gear synchronizer allowance.

Use your hands to press the synchronizer rings on the
Synchro- gears flatly and use a feeler gauge to measure the al-
nizer ring
lowance between the gear and synchronizer ring.
Allowance
If the allowance is smaller than 0.8 mm or bigger than
Gear sub-
1.6 mm, replace the synchronizer ring and measure
assembly
again. If the allowance of the new synchronizer ring is
still smaller than 0.8 mm or bigger than 1.6 mm, replace
ALD128G
with a new gear.

1. During removal, place the gears, needle bearings, and synchronizer rings separately, e.g. put
the 1st gear subassembly, 1st gear synchronizer ring, and 1st gear needle bearing together -
same for 2nd gear. Do not mix when installing.
2. After washing, check whether the conical surface of any gear is damaged or has cracks. Re-
place the gear if it has them.
3. After washing, check the wear of the synchronizer gear sleeves and lock angles of the gears.
Replace the synchronizer and gear if they are seriously worn.
4. If the synchronizer disperses during removal, please refer to the section entitled "Maintenance
of Synchronizers" in Chapter VII.
5. When installing, we suggest the replacement of all used clasps and install claps of an appro-
priate thickness.
6. When installing the synchronizer, do not crush the convex plate of the synchronizer ring.Also,
pay attention to the installation directions of the gear hub and gear sleeve.
7. The synchronizer ring gear of the 1st gear is different from that of 2nd gear (has number
marked) and they can't be interchanged.
8. The removed parts must be washed before installing.
Output Shaft Assembly Installation

1
1. Install the steel ball Sφ4.7625 and the 1st gear
thrust washer.
2
1. Steel ball Sφ4.7625

2. 1st gear thrust
washer
ALD129G
2. Install the 1st gear needle bearing and 1st gear

subassembly.
Caution: Coat oil on the 1st gear needle bearing be-
fore installing the 1st gear subassembly.
2
1. 1st gear gear components
2. 1st gear needle bearing
ALD130G
Transmission MT-59
3. Install the 1st gear synchronizer ring and use a

1. 1st/2nd gear synchronizer press and the SST to press in the 1st/2nd synchro-
assembly
2. 1st gear synchronizer ring nizer assembly.
Caution: Coat oil on the conical surface and spline
before installing. Pay attention to the direction of
1
the synchronizer and align the slider to the syn-
chronizer ring groove during press fitting.
2
ALD131G
4. Use a clasp caliper to install the 1st/2nd gear hub

shaft retainer and install the 2nd gear needle bear-
ing spacer.The thickness of the shaft retainer has
six specifications and the installation clearance
1 should be smaller than 0.1 mm.
1. 2nd gear needle bear-

ing gasket
2. 1st/2nd gear hub shaft
retainer ALD132G
5. Install the 2nd gear synchronizer ring and 2nd gear

needle bearing.
2
1. 2nd gear needle bear-
ing
2. 2nd gear synchronizer
ring
ALD133G
6. Install 2nd gear subassembly.The slider should be

blocked in the slot of the synchronizer ring.
Caution: Coat oil on the conical surface of gear and
needle bearing before installing
1
1. 2nd gear subassembly

ALD134G
7. Use the SST to press fit the 3rd gear-driven gear.

Caution: Coat oil on the spline before installing.
1. 3rd driven gear
ALD135G
8. Install the 3rd/4th gear spacer and use the SST to

1 press fit the 4th gear-driven gear.
Caution: Coat oil on the spline before installing.
1. 4th driven gear

2. 3rd/4th gear spacer
ALD136G
9. Finish the installation of output shaft assembly.

Caution: After installing the output shaft assembly,
place the 1st/2nd gear synchronizer assembly in
the neutral position. Then, use your hands to check
whether the 1st gear subassembly and 2nd gear
subassembly work normally.Check and reinstall if
the gear can't rotate.
ALD137G
Transmission MT-61
2 1 Clutch housing assembly removal

1. Remove the clutch slave cylinder subassembly,
release bearing assembly and release fork subas-
sembly.
1. Release fork subassembly

2. Release bearing subassembly
3. Clutch slave cylinder subassembly ALD138G
2. Use the SST to remove the cylindrical roller bearing

1 of the input shaft and input shaft oil seal.
2
Caution: Replace the new bearing and oil seal.
1. Cylindrical roller bearing of input shaft

2. Input shaft oil seal ALD139G
3. Use the SST to remove the bearing plate, plate bolt

1 and flat washer subassembly, cylindrical roller
3 bearing of output shaft, and remove the guide noz-
2 zle of the output shaft.
1. Bearing plate, plate bolt and flat washer

subassembly
2. Cylindrical roller bearing of output shaft
3. Output shaft guide nozzle ALD140G
4. Use the SST to remove the front oil seal of the dif-
ferential
1
Caution: Replace with the new oil seal.
1. Front oil seal of differential ALD141G

5. Remove the outer ring of the front-tapered roller

1 bearing of the differential and front gasket of the
2
differential.
1. Outer ring of front tapered roller bearing

2. Differential front gasket ALD142G
6. Take out and clean the magnet, remove the guide

1
plate, bolt, and spring washer subassembly.
2
1. Guide plate, bolt and spring washer

subassembly
2. Magnet ALD143G
Clutch housing assembly installation

1 1. Use the SST to press fit the input shaft oil seal and
2
tapered roller bearing of the input shaft into posi-
tion.
Caution: Do not tilt during press fitting.
1. Cylindrical roller bearing of input shaft

2. Input shaft oil seal ALD139G
1 2. Install the guide nozzle. Use the SST to press fit the
2 tapered roller bearing of the output shaft into posi-
3
tion, install bearing plate, plate bolt, and flat washer
4
subassembly, and then install the guide plate, bolt,
and spring washer subassembly.
1. Bearing plate, plate bolt and flat washer

subassembly
2. Cylindrical roller bearing of output shaft
3. Guide plate, bolt and spring washer subas-
sembly
4. Guide nozzle ALD144G
Transmission MT-63
3. Install the front gasket of the differential and use

1 the SST to press fit the outer ring of front tapered
2 roller bearing of the differential into position.
1. Outer ring of front tapered roller bearing

2. Differential front gasket ALD142G
4. Use the SST to press fit the differential front oil seal
1
into position.
1. Front oil seal of differential

ALD141G
2 1 5. Tap in the four locating pins and install the clutch

slave cylinder subassembly, release bearing as-
sembly and release fork subassembly.Complete the
installation.
1. Release fork subassembly

2. Release bearing subassembly
3. Clutch slave cylinder subassembly ALD138G
Transmission case assembly removal

1. Remove the oil filling plug, oil drain plug, and flat
washer.
1 2
1. Oil filling plug 2. Oil drain plug
ALD145G
2. Use the SST to remove the rear oil seal of the dif-
ferential.
1. Rear oil seal of differential

ALD146G
3. Remove the outer ring of the rear tapered roller

1 bearing of the differential and rear adjusting gasket
2 of the differential.
1. Outer ring of rear tapered roller bearing

2. Rear adjusting gasket of differential
ALD147G
4. Use the SST to remove the rear straight bearing.

1
1. Rear straight bearing

ALD148G
Transmission MT-65
5. Remove the reverse gear lock mechanism subas-

1 sembly.
1. Reverse gear lock mechanism

subassembly ALD149G
Transmission case assembly installation

1
1. Install the reverse gear lock mechanism subassem-
2 bly, tap in the elastic pin, and tighten the reverse
gear lock plug with the specified torque.
3
1. Reverse gear lock mechanism
subassembly
2. Elastic pin
3. Reverse gear plug ALD150G
2. Use the SST to press in the rear straight bearing.
1. Rear straight bearing ALD148G
3. Install the rear-adjusting gasket of the differential

1
and use the SST to press in the outer ring of the
2 rear tapered roller bearing of the differential.
Caution: Select the correct adjusting gasket first.
1. Outer ring of rear tapered roller bearing

2. Rear adjusting gasket of differential
ALD147G
4. Use the SST to press in the rear oil seal of the dif-
ferential.
1
1. Rear oil seal of differential
ALD146G
5. Tighten the oil filling plug, oil drain plug, and flat
washer with the specified torque.
1 2
1. Oil filling plug 2. Oil drain plug ALD145G
Transmission MT-67
Maintenance of Other Common Easily-Damaged Parts

Shift fork and shift fork shaft of each gear
ALD151G
1. Shift fork and shift fork shaft of each gear removal.

(a) The maintenance of the shift fork and shift fork shaft of each gear is simple: remove the shift fork shaft
limiting clasp with a clasp caliper, remove the mounting bolt, and then remove the shift fork.
Caution: The removed clasps can't be reused. Protect the working surfaces of the shift fork
and keep the shift fork shaft from damage during removal.
2. Shift fork and shift fork shaft of each gear installation.
(a) The maintenance installation of the shift fork and shift fork shaft of each gear is simple: Place every
part in the correct position, tighten the shift fork mounting bolt, and install the shift fork shaft limiting
clasp. Do not miss the two interlocking steel balls during the installation of reverse gear shift lever.
Caution:
1. Protect the working surfaces of the shift fork and shift fork shaft from damage during instal-
lation.
2. Coat thread-fastening glue on the shift fork mounting bolt before installing.
3. Check if any interlocking steel ball and other parts miss after installing.
Manipulation lid assembly removal and

installation
1 1. Remove the gear shift arm mounting bolt and take
out the gear shift mechanism subassembly.
1. Gear shift mechanism subassembly

2. Gear shift arm mounting bolt
ALD152G
2. Use the SST to remove the three elastic pins. Re-

1 2 3 move the shaft spring retainer, 5th reverse gear re-
turn spring seat, and 5th reverse gear return spring.
4
1. Shaft spring retaine
2. 5th reverse gear return spring seat
3. 5th reverse gear return spring
4. Elastic pin ALD153G
3. Remove the interlocking shift block, gear shift

1 block and gear shift interlocking block, reverse
2
gear sensing block, 1st/2nd gear return spring seat,
3 1st/2nd gear return spring, and the 1st/2nd gear re-
4 turn spring seat clasp.
5
1. Interlocking shift block

2. Gear shift block and gear shift interlocking
block
3. Reverse gear sensing block
4. 1st/2nd gear return spring seat, 1st/2nd
gear return spring
5. 1st/2nd gear return spring seat clasp
ALD154G
Transmission MT-69
4. Take out the gear shift shaft and dust cover.

3
1. Gear shift assembly

2. Geasr shift shaft dust cover
3. Manipulation lid subassembly
ALD155G
1
5. Remove the front straight bearing and manipulation
2 lid oil seal from the manipulation lid subassembly
with tool.
1. Front dtraight bearing
2. Manipulation lid oil seal
ALD156G
6. Install the manipulation lid assembly: Install the

gear shift assembly, gear shift interlocking plate,
and other components in the reverse sequence of
removal.
Caution: Protect the openings of the oil seals dur-
ing installation and clean the shaft.
Synchronizer of each gear

The transmission has three synchronizer assemblies: 1st/2nd gear synchronizer assembly, 3rd/4th gear
synchronizer assembly, and 5th gear synchronizer assembly.Each synchronizer consists of a gear sleeve,
gear hub, slider, and spring expansion ring.
Caution:
• The openings of the spring expansion rings should alternate.
• When installing the 1st/2nd gear synchronizer, keep the gear hub with the conical surface
upwards (2nd gear direction) and keep the gear sleeve with gear upwards (2nd gear direc-
tion).
• When installing 3rd/4th gear synchronizer, keep the gear sleeve with the notch mark down-
wards (3rd gear direction).
• When installing the 5th gear synchronizer, keep the bigger end of the gear hub inner ring
downwards (5th gear direction) and keep the gear sleeve with the notch mark downwards
(5th gear direction).Keep the bevel surface of the slider upwards.
Installation explanation
1 The installation processes for the three synchronizers are
similar. This manual only provides the installation process of
the 5th gear synchronizer.
1. Installation process of the synchronizer.
(a) As shown in the figure: put the slider in the slider slot
of the gear hub. Put on the gear sleeve and then install
2
the spring expansion ring.
3
Caution:
Align the notch position of the gear sleeve to the
4 three slots of the gear hub.
The openings of spring expansion rings should al-
ternate for 120°.
1. Gear sleeve 2. Slider
3. Gear hub 4. Spring expansion ring
ALD157G
2. Installation characteristics of the 5th gear synchro-

nizer.
Caution: When installing, keep the bigger end of
the gear hub inner ring downwards (5th gear direc-
tion) and keep the gear sleeve with the notch mark
downwards (5th gear direction).Keep the bevel sur-
face of the slider upwards.
ALD158G
3. Installation characteristics of the 3rd/4th gear syn-

chronizer.
Caution: When installing the 3rd/4th gear synchro-
nizer, keep the gear sleeve with the notch mark
downwards (3rd gear direction).
ALD159G
4. Installation characteristics of the 1st/2nd gear syn-

chronizer.
When installing the 1st/2nd gear synchronizer, keep
the gear hub with the conical surface upwards (2nd
gear direction) and keep the gear sleeve with gear
upwards (2nd gear direction).
ALD160G
Back-up lamp switch

The back-up lamp switch is in its entirety. The maintenance
is just to remove the back-up lamp switch with a wrench and
replace it with a new one. The new back-up lamp switch
only needs to be tightened to the specified torque.
Transmission MT-71
CVT transmission
Overview
The continuous change of the transmission drive ratio can be implemented by a transmission device,
which includes inverted conical wheels on which a V-shaped steel drive belt goes around. The drive
ratio of the transmission device is transmitted to the differential in the transmission through an inter-
mediate shaft.
This manual introduces design and functions of the transmission and its components, plus the power
drive and control devices respectively. In addition, this manual provides a general overview of the oil
cooling system and external gearshift mechanism of the transmission. The stepless shift mode of the
transmission brings you more comfortable driving experience and higher vehicle performance.
The advantages of using this type of automatic transmission are as follows:
• Lower engine speed at a stable vehicle speed;
• Improved emission control/lower fuel consumption;
• Low NVH (noise, vibration, and harshness);
• Smooth acceleration;
• Flexible driving in mountain areas;
Comparison Between Conventional Automatic Transmission and Step-
less Transmission
In the following figure, a comparison of drive ratio change between manual or conventional automat-
ic transmission and stepless transmission is illustrated. Conventional automatic transmission (drive
device) has a drive ratio of a series of fixed values.
When the transmission is at high gears, the drive ratio changes according to the opening of the throt-
tle along the thick solid or the dotted line as illustrated in the first figure. When using a stepless trans-
mission, the drive ratio change is as shown in the second figure that the shift point of both transmis-
sions is related to the opening of the throttle controlled by the driver.
When the opening of the throttle is enlarged, the engine speeds up and the transmission shifts into
higher gears; in the case of conventional transmission, the engine speed is apparently lowered, but
in the case of stepless transmission, the engine speed is maintained. The stepless transmission may
shift into higher gears by moving the cone pully when the engine speed remains unchanged (see the
following explanations). In addition, we can choose other gearing strategies, which is helpful for new
users to accept stepless transmission more quickly.
Maximum acceleration
Secondary speed (Nsec)
Secondary speed (Nsec)
Maximum
acceleration
Primary speed (Nprim) Primary speed (Nprim)
4-gear automatic transmission (L) and stepless transmission (R) drive ra-
tio change
Transmission profile
3 5
10
1. Torsional shock absorber/flywheel 2. Oil pump 3. Backward clutch 4. Planetary structure

5. Drive clutch 6. Steel belt 7. Drive cone pully 8. Driven conical wheel
9. Intermediate shaft 10. Differential
Transmission MT-73
The Basic Principle of Stepless Transmission

VT2 consists of a number of components, which are divided into three groups according to corre-
sponding functions.
Group 1-mechanical drive devices
This component is designed to provide mechanical drive and transmit torque.
Group 2-control system
Components related to the control system. According to the load and drive requirement, the control
system ensures the power the transmission transmits and changes the drive ratio when applicable.
Group 3-external connections
Components connected to the exterior of the transmission. Some of the components are inside the
transmission or connected to the transmission and some are components of the entire system but
arranged in other parts of the vehicle.
Mechanical Torque Transmission
1. Planetary structure
Planetary Structure
The planetary mechanism enables the transmis-
sion to provide the drive torque in both the forward
and backward direction. The torque provided by the
engine is usually transmitted to the transmission by
the input shaft of the planet carrier. By joining the
multi-plate clutch in the forward direction, the planet
1
carrier can be directly connected to the sun gear; at
this time, the planet carrier and the sun gear form a
rotating entity by engagement, and the engine torque
2 is directly transmitted to the drive gear. Because the
planet gears do not transmit any torque, there is not
3
mechanical loss in the planetary mechanism, and the
direction of rotation of the drive gear will be in keeping
4 with that of the engine. This is the forward mode.
1. Planetary gear 2. Input shaft 3 In reverse mode, the joint of reverse multi-plate clutch
3. Sun gear 4. Gear ring will keep the gear ring of the planetary structure sta-
tionary and the planetary pinion carrier drives the
three pairs of planetary gears to rotate sun gear in a
reversed direction; now the drive ratio is 1:1.1, which
enables a slight torque multiplification by deceleration
to compensate the friction loss of planetary structure.
Clutch in the Planetary Structure 2. Multi-plate clutch

There are two wet multi-plate clutches in total, one
forward and one backward. For each clutch there are
three friction plates that are 6 friction faces. The clutch
is controlled through a hydraulic system to ensure a
stable forward movement at any throttle opening, and
when the drive gear is completely engaged, control of
the amount of the clutch engagement also helps stop
the vehicle. The coolant oil cools down the friction
plate to prevent friction face overheat.
1 2
1. Drive clutch group
2. Reverse clutch group
3. Conical wheel and steel belt

Drive belt The major design characteristic of CVT is that a pair of “V”-
shaped conical wheels is connected by a steel drive belt.
The center distance between the drive wheel and the driven
wheel is 155mm. Each conical wheel is divided into two
halves: one is fixed, the other slides along the axial direc-
tion, both of which have the inclination of 11°. 24 mm-wide
“Van Doorne” pushing-type drive belt is used to transmit the
torque between pulleys (If you want a larger torque value,
2 30 mm-wide transmission belt can be used). The transmis-
sion belt is lubricated and cooled by oil jet from the nozzle.
In order to reduce the angular error of the drive belt when
the gear is shifted, put the two moveable pulley halves in
the position of the diagonal of both, and then connect each
moveable pulley halves to the hydraulic cylinder/piston. The
1 hydraulic pressure is controlled by the control system; see
“hydraulic system” section. The spherical spline prevents
1. Steel strip 2. Steel plate the moveable pulley hallves from turning relatively to their
fixed pulley halves.
Since the sun gear is connected to the drive conical wheel

through a spline, the torque is transmitted directly from the
planetary gear structure to the drive conical wheel. The
steel drive belt transmits the power from the drive conical
wheel to the driven cone pully, and the power is then trans-
mitted from the driven conical wheel to the middle gear
shaft.
The torque and speed of the driven conical wheel is deter-

mined by the position of the drive belt. The sizes of the two
pulleys are designed to provide drive ratios of 2.416:1－
0.443:1, where the maximum is 5.45 times of the minimum.
Fuel consumption is the lowest at speeding drive ratio.
The steel drive belt includes 450 steel plates and 24 steel
strips that are 12 on each side fixed together.
Gear ring and planets 4. Intermediate shaft

The intermediate shaft (the small gear shaft) decelerates
2 the gear structure of two engaged helical gears between
the driven conical wheel and the differential between the
two helical gears so that the correct rotation direction of the
3 propeller shaft is ensured. The speed reduction between
4 the driven conical wheel and the drive shaft improves the
vehicle performance to a great extent. The intermediate
shaft is fixed by the two tapered bearings in the clutch case
1 and the independent bearing seat.
5
1. Drive conical wheel shaft drive gear

2. Differential crown gear
3. Small drive gear
4. Intermediate transmission gear
5. Driven conical wheel shaft gear
Transmission MT-75
5. Differential
Differential assembly
Just as the same as a manual transmission, the torque is
transmitted to the wheels through a differential from the
1 crown gear, which is fixed inside the differential by 8 bolts
and the propeller shaft is fixed into the differential through a
2 conventional cage-type universal joint and the gasket. The
tapered bearing is used to fix the differential.
3
4
1. Differential bearing 2. Differential case

3. Differential spider 4. D ifferential plan-
etary gear
5. Differential crown gear
6. Mechanical manipulation
(a) Drive ratio change.
Running gear position at low gears The automatic transmission of a conventional planetary
mechanism has a limited number of grades of drive ratio,
which is generally four, five, or six grades, but the stepless
transmission is different from it-as its name suggests, the
transmission ratio of the stepless transmission is continu-
ously variable. The low gear (low drive ratio) makes it easi-
er for a stationary vehicle to start; the diameter of the drive
conical wheel is relatively small, while that of the driven
conical wheel is relatively large. The drive belt is used to
transmit the power and the torque, and the acceleration will
be generated if high speed ratio is selected by increasing
the diameter of the drive conical wheel and decreasing the
diameter of the driven conical wheel. The optimal drive ratio
is ensured by controlling the extent of change.
1 Engine input
2 Output to the wheels The stepless transmission has two rotating pulleys, i.e. the
3 Minimum diameter drive gear (low speed) drive conical wheel and the driven conical wheel, and each
4 Maximum diameter driven gear (low speed) of which is composed of two halves, one half is fixed, and
the other half can be moved by a hydraulic pressure con-
trol. The drive ratio can be determined by the position of the
drive belt on the rotating pulleys. If the moveable pulley half
approaches its corresponding fixed pulley half, the drive
Pulley position at high gears (speeding)
belt will move towards its periphery. When the two pulley
halves separate, the circumference will become small, and
the moveable pulley half of the drive conical wheel and the
driven conical wheel are in the position of their respective
diagonal, and at this time the radius of the transmission belt
on the drive conical wheel decreases, while the radius of
the drive belt on the driven conical wheel increases.
The start of the vehicle needs low drive ratio, and therefore
the drive conical wheel separates to make the drive belt ad-
here to it and makes the transmission belt move around the
periphery of the closed driven bevel gear. High drive ratio is
needed when the speed increases, so moveable pulley half
of the drive conical wheel gradually approaches the cor-
responding fixed pulley half and the wheel circumference
1 Engine input of the conical wheel increases, and simultaneously, the
2 Output to the wheels driven conical wheel is forced to separate that the radius
3 Minimum diameter drive gear (speeding) decreases and thus producing high drive ratio. The drive ra-
4 Maximum diameter driven gear (speeding) tio of speeding is generated when the drive conical wheel is
fully closed and driven conical wheel is fully separated. The
drive conical wheel and the driven conical wheel turn at a
drive ratio of about 1:2.5.
(b) The lever is at the neutral or the parking gear

Transmission Torque Drive Mechanism
In this status, reverse clutch (2) and drive clutch (4)
separate and the wheels are not able to be driven.
• Transmission input shaft (1) speed is identical to the
engine speed.
• Backward clutch (2) separates.
• Drive clutch (4) separates.
• Planets (3) rotate around the sun gear in idle.
• If the sun gear remains stationary, the drive gear (5),
driven gear (7), and the vehicle are also stationary.
For any automatic transmission, the engine can only
be started at the neutral or the parking gear, and at
the parking gear, the mechanical prevents any move-
ment of the vehicle. In order to avoid any damage to
the transmission, parking gear can only be shifted
when the vehicle is stationary.
1. Input shaft 2. Backward clutch

3. Planetary gear 4. Drive clutch
5. Drive conical wheel 6. Steel drive belt
7. Driven cone pully
(c) The lever is at drive gear

In this status, the joint of drive clutch (4) send the ve-
hicle into movement.
engine speed.
• Reverse clutch (2) separates.
• Drive clutch (4) joins.
• The planet gears (3), the sun gear, and the gear ring
rotate together.
• Drive gear (5) keeps the same speed with the en-
gine at drive direction.
• The driven gear (7) is at drive direction, and the
speed is determined by the drive ratio at running.
1. Input shaft 2. Reverse clutch

7. Driven conical wheel 8. Driven conical wheel
9. Input shaft
Transmission MT-77
(d) The lever is at the reverse gear

In this status, the reverse clutch (2) joins and the gear
ring (9) is locked in the transmission case. The planet
gears (3) reverse the direction of the sun gear (10),
the drive gear (5), and the driven gear (7) as against
the direction of the transmission input shaft (1).
Now reverse gear is shifted
engine speed.
• Reverse clutch (2) joins.
• Drive clutch (4) separates.
• The gear ring (9) is connected to the transmission
case through the reverse clutch (2)
• The planet gears (3) directly driven by the transmis-
sion input gear (1) enable it rotate around the gear
ring, and then drive the sun gear (10), pulley (5), and
the driven conical wheel (7) in a reversed direction.
1. Input shaft 2. Backward clutch

7. Driven conical wheel 8. Driven conical wheel
9. Gear ring 10. Sun gear
Control System
Functions of the control system are as follows:
(a) The clamping force of the tension of the steel drive
belt is made adapted to the torque of the engine to
prevent slipping.
(b) Control the drive and reverse clutch while driving.
(c) Optimal drive ratio is provided for driving.
(d) Provide necessary lubricant and coolant oil for the
transmission.
1. Oil pump
The pump within the transmission is an external en-
gagement gear pump, the shaft of which is driven by
the engine oil pump shaft and reaches the inside of
1. Oil pump drive shaft 2. Oil pump assembly the pump through the hollow shaft of the drive conical
wheel. The pump shaft is connected to the planetary
gear rack through a spline, and the pump runs at en-
gine speed at an efficiency of 10cm³/rotation. System
pressure depends on the input torque, which is up to
40-50 bar.
Remark: the oil pressure is used for both hydraulic
transmission control and lubrication
1. Oil pump inlet 2. Oil pump seal

2. Transmission control unit

The transmission control unit ensures the drive belt and the pulleys free of slipping at the least ten-
sion, and provides drive ratio in accordance with the target set by the driving strategy (calculated by
the input (drive) and output (driven) speed). Within the service life, the decline of the control unit will
be maintained in a certain range that it does not affect driving comfort and drive belt tension.
3. Tension control unit
(a) The tension control unit can acquire the least tension that ensures the drive belt free of slipping,
which brings little affect onto the drive efficiency of the transmission and thus saves fuel consump-
tion.
(b) In addition to normal driving, special circumstances of maximum input and output torque of the trans-
mission are also considered for the tension control device to have the transmission protected to the
maximum. The brake of Anti-lock Braking System (ABS), tire locking (without ABS), and other pro-
pulsion control systems (such as ESP, and anti-skid control device, etc.) are taken into consideration
for the control device. Moreover, special road surfaces and circumstance are also considered for the
device, for example, passing the potholed road, road shoulders, transition between high and low ad-
hesion coefficients, and tire slips (e.g. on a low adhesion coefficient road).
(c) The software is able to compare the transmission torque drive performance and estimated input
torque of the transmission. When the tension control unit detects insufficient tension, ECU will re-
ceive a torque reduction signal and thus adjust the engine torque to an applicable range. This func-
tion is also a protection to the transmission.
(d) If the vehicle is not equipped with an electronic drive circuit system, the ECU passes torque signals
through CAN bus; if there is no CAN bus, the transmission control unit (TCU) will generate a default
torque signal.
4. Speed ratio control unit
(a) The transmission balances the pressure of the drive conical wheel and the driven conical wheel by
controlling the input and output pressure, thus controlling the drive ratio. The drive ratio can be cal-
culated according to the speed sensor signal of the drive conical wheel and the driven conical wheel,
and the drive ratio needed can be got by changing the output pressure. The minimum pressure can
be determined by the tension method. Physical model of the transmission contributes to the rapid
adjustment of pressure liquid level to the variable working point. The interference from other com-
ponents of the transmission is also considered in the control software, so the purpose of developing
the software is to reduce delay errors and target speed ratio errors as much as possible (in order to
improve the economical efficiency of the fuel).
(b) In order to guarantee that the mechanical requirements and requirements of durability limit state of
the transmission, we've made some strategies of driving under the limit state. In addition to the ve-
hicle speed limit, it controls the change rate of the drive ratio (set point) within the allowed range as
well. Moreover, the software also avoids the engine speed exceeding certain limit because of the
change of the vehicle speed and of the position of shift (POS). In order to realize the limiting condi-
tion, the software will require the reduction of the engine torque or make the moving vehicle gear up.
5. Transmission control unit
The transmission controlling software is integrated in the TCU (transmission control unit). TCU is in-
stalled in the engine compartment.
Remark: for the ports, interfaces, circuit, and interface schematic, please see Circuit and Interface.
Transmission MT-79
External connector
1. Oil cooler port
Two oil cooler ports are located on the front of the transmission case. An oil cooler inlet is arranged
beside the engine radiator to keep the temperature of lubricating oil at below 120°C.
The oil in the transmission flows out of the port on the right, which is connected to the lower port of
the oil cooler. The oil in the cooler flows into the transmission through the port on the left of the trans-
mission, so it is connected to the upper port of the oil cooler.
The oil flows into the

transmission
Outlet
Oil cooler
Inlet
The oil flows out of the transmission
2. Gearing lever
(a) The gears of VT2 may include Parking (P), Reverse
(R), Neutral (N), Drive (D), and Sport (S) or Low (L).
These gears are neatly arranged on the transmission
shift device.
(b) The vehicle is equipped with electronic gearing lock
controlled by TCU (transmission control unit).
(c) The new application may also be related to prompt
function, that is, to acquire the prompt signals, TCU
needs to be equipped with other ports. In addition, the
calibration of maximum rate of engine must be within
certain limits.
3. Main connector
The main connector is on the case of the transmission
with 16 pins. Lines are connected through a round
connector.
4. Torsion damper
Most of conventional automatic transmissions are
connected to the engine and input shaft through a hy-
draulic torque convertor, but this transmission adopts
torsion damper, which is not an integral part of the
transmission. Bunge strongly recommends torsion
damper, also known as dual-mass flywheel.
1. Main connector
Driving Mode
Status under special condition
The context below will explain the status under spe-
cial condition for vehicles with stepless transmission.
1. Parking and neutral gear funtion feature
The engine can only be started when the shift lever
is in parking or neutral position regardless of the
transmission type. The mechanical lock in the parking
position will prevent the vehicle from moving. Engage
the parking gear when the vehicle is stationary, as to
prevent damaging to the transmission. If the parking
gear is engaged carelessly when the vehicle is driving
in high speed, the parking device will not work untill
the speed is decelerated to 5 km/h.
TCU will control the starter lock relay when the vehi-
1. Parking lock claw 2. Driven conical wheel cle starts. This relay can start the engine. The vehicle
gear is controlled by internal driving mode sensor
which is connected to shift lever directly.
It is necessary to depress the brake pedal when move
the shift lever from parking (p) or neutral (N) posi-
tion to driving (D) or reverse (R) position. If the brake
pedal is not depressed, the shift lever will be locked in
the starting position.
2. Functions of D and R gear

• Routine operation
The operation of the transmission is totally different from that of the traditional automatic transmis-
sion when driving the vehicle, so you should adapt yourself to it. For example: If you step on the ac-
celerator pedal too hard, the engine speed will increase obviously, while the vehicle speed will not
change much. This function is normal for stepless transmission; however, it is possible that a driver
erroneously thinks there is a transmission failure if he does not understand this transmission. There
also might be other circumstances similar to the conventional automatic transmission.
Adaptive update
Either for drive or reverse, the corresponding clutches are to be re-calibrated to achieve best results
in the period of its use. In the following text self-adaptive update will be discussed.
• Crawling
From the performance of the automatic transmission, it can be known that when the shift lever is
in Drive (D) or Reverse (R), if the driver releases the brake pedal, the vehicle will begin to crawl
(level road). If the road gradient does not exceed 8°, the vehicle can also crawl; if the road gradient
is greater than 8°, the vehicle will back up slightly, as in the case with the vehicle equipped with the
hydraulic torque converting transmission, the vehicle will not back up if the gradient is not heavy.
Whether the road gradient is heavy or not, the maximum vehicle speed will be less than a limit (e.g.
8kph) when the vehicle crawls. Especially when the vehicle goes down a slope, the control system
will make the clutch change from separation to “joint” mode, and in this way the engine can be used
to brake during sliding.
• Idle stop (drive status only)
VT2 transmission can realize idle stop.Idle stop can occur when both the vehicle (battery status, air
conditioner on/off) and the transmission side (without prejudice to the durability of the transmission)
meet certain conditions. If all conditions are met, the internal combustion engine is turned off under
the stationary state. Only if the brake pedal is released, the engine is restarted, and the transmission
works rapidly, can the vehicle move back and forth.
Idle stop function applies in particular to a hybrid drive unit, but for a standard power drive device
without any special starter or starting motor, transmission idle stop is of no use.
• Acceleration and Deceleration
In a speed-up process, acceleration is mainly provided based on a driver's requirement and driving
conditions, so at this time, the trends of engine speed changes correspond to the initial speed and
thus the best driving comfort is achieved.
Transmission MT-81
Clutch controller also provides some methods to compensate for clutch differences (differences
among different vehicles) caused by wear and tear so as to ensure driving comfort.
• Acceleration support
To achieve the best driving comfort, most suitable engine speed is to be determined, which is be-
tween the minimum traction engine speed and constant cruising speed (economic speed).
The transmission control system provides the functionality satisfying these requirements by using the
combination control mode between the speed change device (speed ratio control) and the starting
clutch. Therefore, when the vehicle starts, the control target is focusing on controlling the driving perfor-
mance of higher engine speed related to the vehicle acceleration, whereas when the vehicle cruises or
slides, the control target transfers to the economical efficiency of the fuel of the drive system.
• Deceleration
If the driver steps on the accelerator pedal while stepping on the brake pedal, the engine speed will
be limited to a certain range (similar to hydraulic torque converting transmission). To this end, the
transmission needs to join the engine control system to block torque, so the transmission will be able
to respond quickly to control the clutch when the driver suddenly releases the brake pedal.
After long-term use, the clutch high-temperature loss will be caused, and transmission will have the
risk of damage, so we use monitoring functions to detect these dangerous situations. Activating in-
ternal diagnostic system of transmission can separate the clutch. At this time if the driver has the ac-
celerator pedal being stepped, the engine will accelerate to maximum speed.
But in other cases, the clutch controller can also follow the maximum control objectives to ensure the
original degree of safety and improve the driving degree of comfort.
• Driving and braking
When the vehicle decelerates to be stationary, the clutch separates again to prevent the engine from
stopping, and as the clutch is gradually separated with a steady decline of pressure under control,
torque fluctuations will not be caused.Therefore, the controller provides different patterns according
to the speed changes to separate the clutch. The clutch pressure control device also controls the
hydraulic control system power in accordance with transmission oil temperature. After the clutch is
separated, the vehicle can be quickly prepared to start.
In order to bring optimal driving comfort of the vehicle in braking and starting, the synergism of the
transmission software and other drive control devices makes the torque transmission temporarily in-
terrupted, and idling increased.
• The joint/separation of the clutch when driving
If the clutch is not used when driving, transmission controller will impact little on driving comfort be-
cause it has nothing to do with the characteristics of the hydraulic system. In this case (low load,
parking, low engine speed), in comparison with using the clutch in a static state, using the clutch
once again may decline driving comfort.
The default mode of failure
When the software detects a system error, the default rule will be applied; and this will be transferred
to the driver through the malfunction display of the instrument cluster. The driver will take a different
default-driven state in accordance with the severity of the error. In some cases, main relay will be
switched on. All the failure codes will appear on the OBD.
Vehicle towing
The vehicle equipped with VT2 transmission cannot be towed directly. Fluid pressure can only be
generated in the conical wheel and drives the belt when the engine rotates. Therefore, be sure to
raise the front wheels before towing (Hung in the air).
Periodic maintenance
Change the transmission fluid and replace the oil filter every 60,000 km. Therefore, the drain plug
and refill plug are fitted on the case.
Lubricant specification
Please use ESSO EZL799(A).
The application of non-specified lubricants maybe damage the transmission, and that may not be
covered under warranty.
TCU wire connection diagram
Connected
back-up lamp
Connected
diagnostic
port
Snow mode indicator
solenoid valve
Ignition switch
error lamp
Transmission case
Gear shift solenoid valve relay
Starter relay Ⅱ
Connected engine ECU
Connected brake lamp switch
Back-up lamp relay

Gear shift solenoid valve
Connected meter
brightness switch
Gear shift
control
mechanism
Gear shift control Transmission Actuator mechanism
mechanism
Transmission MT-83
TCU main connector pin
TCU pin configuration

VT2 – signal Pin
NC power supply Kl.30 1; 2
Ignition power supply Kl.15 6
Ground Kl.31 3; 4
VHSD1 (actuator power supply) 5
Speed and position sensor power supply (8,4 V) 30; 77; 78
Pressure sensor power supply (5 V) 32; 74
GND Driving mode sensor 33
GND: Sensor grounded 41; 64; 86;
Transmission case oil temperature 38
N_Prim (drive conical wheel speed) 61
N_ab (driven conical wheel speed) 63
N_MOT (engine speed signal) 87
DMS_A (driving mode sensor signal) 57
DMS_B (driving mode sensor signal) 58
DMS_C (driving mode sensor signal) 79
DMS_D (driving mode sensor signal) 35
Brake signal 34
Manual mode signal 59
Shift up signal 81
Shift down signal 80
P_S2 (driven conical wheel pressure) 75
Snow mode 76
Gear shifting lock 48
K-Line 85
CAN-high speed 9
CAN-low speed 8
Starter lock 92
EDS1 (driven bevel gear pressure regulator) 91
EDS1 (drive bevel gear pressure regulator) 90
EDS3 (Clutch pressure regulator) 89
Back-up lamp relay 71
Malfunction indicator 49
Transmission case main connector pin
Adaptive update
When the TCU refreshes software or replace transmission case or TCU, the clutch need to finish
adaptive update to compensate the tolerance generated in factory.
The process of adaptive update could be completed via Gear shifting operation with the engine
idling. If this process isn't over, the transmission case control system warning lamp will blink 1 time at
2 seconds intervals.
You'd better shift gears more times to finish adaptive update process.
Rigid shock will not happen when the adaptive value is 4 or more. So the transmission case control
system warning lamp will be off when the adaptive value raises to 4, and the adaptive process keeps
updating continously during driving operation.
Read the value of adaptive update using Punch INCA and MLT software, or other testers.The pro-
cess of adaptive update could be completed successfully though there is no tester to read the value.
If the adaptive value cannot be detected for testers lacking, the TCU will make the warning lamp
stopped blinking when the adaptive value is 4 or more in D or R position.
For the transmission case at critical (the tolerance generated in factory above the average), an ad-
ditional function is available in the adaptive update program.That is called swift adaptive update ap-
plication.Each transmission case has a special value of adaptive update under specified oil tempera-
ture, such as -20℃, 0℃, 10℃, 20℃, 40℃, 60℃, 80℃, 100℃, and 120℃. But it's not mean that the
process of adaptive update should be done at above temperatures.
When the process of adaptive update is applied under specified oil temperature, the current value
will be replicated and changed in accordance with a special temperature automatically. For the differ-
ence of clutch tolerances, some clutches of transmission cases may replicate relative data but some
may not do. this process is completed automatically when the transmission case warning lamp no
longer blinks.
1. Condition:
The main conditions to apply adaptive update is described below.
The vehicle is stationary.
Accelerator pedal isn't be depressed.
steady engine idling
steady engine torque
The brake pedal is depressed.
2. Procedure
Transmission MT-85
Perform the adaptive update of clutch under a special temperature according to the following proce-
dures.
1 Start the engine
2 Depress the brake pedal firmly (Remember to Keep this operation through the pro-
cess of adaptive update)
3 Engage in the N position
4 Wait for 5 seconds
5 Engage in the D position
9 Engage in the R position
13 Engage in the Forward position
17 Engage in the R position
19 Back to the 3rd step and repeat the above operations untill the warning lamp stops
blinking
When the shift lever is in the forward position or reverse position, the warning lamp should be off if
the respective adaptive value is over 4. If the warning lamp still remains illuminating, which means
that the adaptive value is not up to 4. To solve this problem, you need to operate shift lever to the
forward position and drive the vehicle at 50 km/h, then stop the vehicle. Make sure that the gear shift
control mechanism would have been raised to high gear position, and the pressure in the drive coni-
cal wheel returns to 0 bar.
Trouble code P0810 will be deactivated after self-learning. TCU will clear the trouble code automati-
cally after 3 driving cycles.
**Note that the engine idling update will influence the transmission case adaptive update directly.
The engine idling update will be cleared out automatically after power off.
***The adaptive update process will be performed during the whole transmission case temperature
range. However, the fast update only need the transmission case temperature at +20 ℃ to +60 ℃.
***Note that the TCU warning lamp will not flash if only replace the transmission case. The reason is
the transmission case clutch self-learning value is stored in the controller unit. Then, it is necessary
to perform the self-learn according to the study process mentioned above. However, the malfunc-
tion indicator cannot warn the learning process completion, please repeat the proecess above for
10 times.
Service instructions
Oil level inspection
Since the transmission is empty as a service part, it is necessary to add about 4L ESSO EZL799(A)
after installing to the vehicle.
Fill oil according to this procedure whenever drain the transmission oil or replace the transmission
case. Check the oil level after filling according to the following method:
• Start the engine and idle for at least 10 seconds (Caution: It is normal for hearing the cycling
sound of the airflow when starting the engine).
• Shift to different position (Parking-Reverse-Neutral-Drive). Wait for 5 seconds before shifting
to the next position.
• Shift to "D" (Drive).
• Release the brake pedal.
• Accelerate over 60 km/h (engine speed is less than 2,500 rpm).
• Release the accelerator gently and stop the vehicle (the noise created by airflow will disap-
pear).
• Drive for 5 minutes carefully or wait untill the transmission reaches 60��
ºc��
, as to raise the oil
temperature.
• Part the vehicle on a flat surface.
• Depress the brake pedal.
• Wait for 2 seconds.
• Shift to "R" (Reverse).
• Wait for 10 seconds.
• Shift to "P" (Parking).
• The engine is idling.
• Loosen the oil level plug.
• Make sure there will be at least 0.2 L oil discharged from the pipe after loosening the oil lev-
el plug (If not, it means that the original oil amount is insufficient). If the result is less than
0.2 L, add 0.5 L and repeat above steps again.
• Add untill there is oil dripping from the oil level plug.
• Re-tighten the oil level plug.
• Stop the engine.
Drain plug (1)
Oil level plug (2)
Oil filling plug (3)

Transmission MT-87
Components
Component list and torque requirement

482871 Differential oil seal
No.4
481274 Input shaft oil seal

No.2
482584 Shift lever nut gasket

No.48
481329 Shift lever nut

No.46 14.5±1.5 N·m
482099 Oil seal (gear shifting)

No.49
482751 Shift lever

No.47
Transmission MT-89
481173 Drive conical wheel shaft end

No.22 cover

No.23 cover buckle

No.50 cover O-ring
177.47×2.62

No.24 cover bolt M6×16
9.5±2.5 N·m
481259 Oil pump O-ring

No.18
481284 Oil pump bolt

No.20 10±1 N·m
481293 Drive conical wheel shaft nut

No.15 197.5±17.5 N·m
481826 Oil pump sealing ring

No.17
481856 Conical spring gasket

No.16
482773 Fuel pump

No.19
482294 Drive conical wheel shaft

No.14 ball bearing
481247 Oil filling plug gasket M14

No.5
Transmission MT-91
481248 Oil filling plug M14

No.6 21±3 N·m
481249 Oil level plug gasket M10

No.41
481250 Oil level plug M10

No.42 15±2.25 N·m
482982 Driven conical wheel shaft

No.12 end cover

No.9 end cover O-ring
17.12×2.62

No.11 end cover O-ring
72.63×3.53

No.10 end cover sealing ring

No.13 end cover countersunk screw
9.5±0.95 N·m
482456 Oil filter assembly

No.33
481283 Oil pan bolt M6×16

No.24 9±1 N·m
482504 Oil pan gasket

No.29
481870 Oil pan magnet

No.34
Transmission MT-93
482442 Oil drain plug

No.2 11±1 N•m
482489 Oil pan assembly

No.35
482945 TCU (Daisy)

483036 TCU (Dahlia)
482589 Valve body assembly

No.30
481311 Valve bolt

No.31 11±1 N·m
482493 Driving mode sensor

No.38
481090 Driving mode sensor

No.37 mounting screw
9.5±0.95 N·m
482468 Differential speed sensor

No.27 bracket
481289 Differential speed sensor

No.26 bracket mounting screw
9.5±0.95 N·m
482410 Speed sensor

No.25
481283 Speed sensor mounting bolt

No.24 8.5±2 N·m
481258 Oil cooler plug O-ring

No.39
Transmission MT-95
482121 Oil cooler plug

No.40
482235 Input shaft rubber sheath

No.1
481296 Differential oil seal cover

No.3
482105 Main connector buckle

No.44
482475 Main connector and internal wire

No.45
482031 Case breather valve

No.8
482032 Breather valve cover

No.7
482104 Main connector sealing cover

No.43
482642 Oil filter O-ring

No.32
Transmission MT-97
SST and service parts replacement

SST
Drive conical wheel bearing plug (Figure T00222) Gear shifting oil seal punch (Figure 480125)
Drive conical wheel bearing punch Drive conical wheel bearing remover
(Figure 480137 + 480126) (Figure 480136)
Input shaft oil seal punch (Figure 480130) Input shaft oil seal lock bushing (Figure 480129)
Hydraulic pressure control unit lock pin

Gear shifting oil seal remover (Figure 480127)
(Figure 23K002-099-84312)
Differential oil seal punch SST for oil pump removal

(Figure 23K002-099-84336) (Figure 23K002-099-84295)
Caution: The figure maybe different from the actual tool or drawings!
Transmission MT-99
Service parts replacement instructions

1. Replace the differential oil seal.
Malfunction: perform when the oil seal damage or
leakage occurs, or the axle shaft damage or leakage
occurs.
Maintenance method:
(a) Drain the transmission oil (see the oil filter re-
placement procedure).
(b) Remove the axle shaft.
(c) Pry out the oil seal with a big slotted screwdriver.
Do not put the slotted screwdriver deeply in order
to prevent the case.
Remove the oil seal.
(d) Discard the removed oil seal.

(e) Put a new oil seal on the case.
(f) Put SST (23K002-099-84336) on the oil seal and
tap it into the case with a rubber hammer. Make
sure to install into the correct position.
(g) Install the axle shaft.
(h) Refill the transmission case according to the in-
structions.
Install a new oil seal with SST.
2. Replace the input shaft oil seal.

Malfunction: perform when the input shaft oil seal
damage or leakage occurs.
Maintenance method:
(b) Take it off from the vehicle.
(c) Pry out the oil seal from the case with a big slot-
ted screwdriver along its hollow part. Make sure to
be extremely careful. Otherwise, the transmission
case input shaft may be damaged.
(d) Take out and discard the removed oil seal.
Remove the input shaft oil seal

(e) Put the oil seal lock bushing (480129) on the input
shaft.
Mount the SST on the input shaft (480129).
(f) Put a new oil seal on the lock bushing.
Press down the oil seal.
(g) Mount the SST (48013) on the input shaft.

(h) Tap the SST with a rubber hammer and pay atten-
tion to install into the correct position.
(i) Remove the SST and install the transmission case
back.
(j) Refill the transmission case according to the in-
structions.
Install the oil seal with SST (480130).
3. Replace the gear shifting oil seal.

Malfunction: perform when the gear shifting oil seal
leakage occurs.
Maintenance method:
(b) Take it off from the vehicle.
(c) Remove the shift lever.
(d) Mount the SST (480127) on the gear shifting.
Mount the SST (480127) on the gear shifting.

Transmission MT-101
(e) Screw SST into the oil seal with wrench. Press the
end of the wrench for the convenience of screwing
in the oil seal.
Press and rotate the SST.
(f) Turn the bolt on the SST with a tool and pull out
the gear shifting oil seal from the case.
Rotate the small bolt and pull out the oil seal.
(g) Discard the oil seal.
Take out the oil seal.
(h) Put a new oil seal on the gear shifting.

(i) Put the special punch (480125) on the shaft and
tap it with a rubber hammer. Pay attention to in-
stall into the correct position.
(j) Install the shift lever and mount the transmission
case back.
(k) Refill the transmission case according to the in-
structions.
Install the oil seal with SST (480125).

4. Replace the drive conical wheel shaft end cover.

Malfunction: perform when the drive conical wheel
shaft end cover leakage occurs.
Maintenance method:
(a) Discharge about 1L transmission oil (see the oil
filter replacement).
(b) The transmission case doesn't have to be re-
moved from the vehicle. The replacement will be-
come easy to lower the engine together with the
transmission case.
(c) Remove 3 bolts and take off the buckle. Remove
the end cover with a big slotted screwdriver. Put a
piece of cloth under the cover to prevent transmis-
Remove the drive conical wheel shaft end cover. sion case damage.
(d) Remove the end cover with a big slotted screw-
driver. Put a piece of cloth under the cover to pre-
vent transmission case damage.
(e) Remove the bigger O-ring and discard it together
with the end cover.
(f) Install a new O-ring.
(g) Replace a new end cover and tighten the bolt and
buckle.
Torque: 9.5±2.5 N•m
(h) Refill 1L transmission oil.
5. Replace the oil pump.
Malfunction: If the transmission case pressure is too
low or shocking, abnormal condition occurs during
driving, there are two key parts — soil pump and hy-
draulic pressure control unit， which may cause the
above mentioned problems. Then, we need to find
the damaged part by trouble codes. In most cases, it
is difficult to judge the damaged part, please change
one by one to troubleshoot.
Maintenance method:
(a) Remove the end cover following the replacement
procedure of the drive conical wheel shaft end cover.
(b) Remove the 6 bolts on the oil pump and put the
SST on the oil pump shaft.
Remove the 6 bolts and install the SST.
(c) Pull out the oil pump with SST (23K002-099-84295).
Pull out the oil pump.

Transmission MT-103
(d) Replace a new oil pump and make sure to put 2

new O-ring on the new oil pump. Pay attetion not
to take out the conical return spring. Confirm the
end with longer diameter faces the oil pump.
(e) Reinstall the 6 bolts and tighten with 10+1 N•m
torque.
(f) Install the end cover according to the procedures.
It is unnecessary to replace the O-ring and end
cover.
Conical spring gasket
6. Replace the drive conical wheel shaft ball bearing.

Malfunction: Replace the drive conical wheel shaft
bearing if it is worn. A worn drive conical wheel shaft
bearing will sound large noise, which will change ac-
cording to the engine speed. Then, this bearing may
be damaged when there is more and louder noise
suddenly under the condition to switch from D gear to
manual mode under the constant vehicle speed. For
the engine rotation will increase but not the vehicle
speed when change to manual mode.
Maintenance method:
(a) Remove the oil pump according to the procedures.
Mark on the shaft and bolt. (b) Take out the conical return spring.
(c) Mark on the shaft and nut.
(d) Remove the nut with pneumatic wrench using the

torque about 300 N•m.
Take out the dust cover on the drive conical

wheel shaft bearing.
(e) Remove the dust cover from the bearing with a

small slotted screwdriver.
Put the SST on the shaft (Drive conical

wheel plug T00222).
(f) Put the special plug on the shaft.

(g) Assemble the bearing remover (480136) and hook
the bearing outer ring with it.
Assemble the bearing remover (480136).
(h) Tighten the bolt in the centre to pull out the bear-
ing.
Tighten the central bolt to pull out the bearing.
(i) Discard the used bearing, clean the sealant on the

drive conical wheel shaft and oil pump drive shaft
and clean the oil pump champer.
Remove the drive conical wheel shaft bearing.
(j) Put the new bearing in the correct location and in-
stall it with special punch (480137+480126). Tap
the punch with a rubber hammer and pay attention
to install into the correct location.
(k) Tighten the bolt with pneumatic tool untill the
marks on the shaft and bolt overlapped ±5°.
(l) Install the conical return spring and make sure the
end with longer diameter faces the oil pump.
(m) Install the oil pump into the transmission case ac-
cording to the procedures.
Install a new bearing.

Transmission MT-105
7. Replace the driven conical wheel shaft end cover.

Malfunction: perform when the driven conical wheel
shaft end cover damage or leakage occurs.
Maintenance method:
(a) The transmission case doesn't have to be re-
moved from the vehicle. The replacement will be-
come easy to lower the engine together with the
transmission case.
(b) Remove 4 countersunk screws.
(c) Remove the 2 O-rings and one gasket on the end
cover.
(d) If the end cover is damaged, replace with a new
one I.
(e) Reinstall the 2 O-rings and a gasket on the end
cover.
(f) Remove the thread adhesive in the 4 screw holes
on the case.
(g) Tighten the 4 screws.
Torque: 9.5±0.95N•m
8. Replace the oil pan.
Malfunction: perform when the oil pan damage or
leakage occurs.
Maintenance method:
(a) Remove the drain plug and drain the oil.
(b) Discard the drain plug when there is no oil drip-
ping.
Remove the drain plug
(c) Remove all of the 13 bolts on the oil pan.

(d) Discard the used oil pan and gasket.
Remove the oil pan
(e) Take a new oil pan and gasket.

(f) Install the oil pan with new gasket.
Torque: (9.5±1) N•m
(g) Refill the transmission case according to the in-
structions.
Bolt sequence
9. Replace the oil filter

Malfunction: replace the oil filter every 60,000 km, it
depends specific conditions.
Maintenance method:
(a) Open the drain plug and drain the oil.
(b) Discard the drain plug when there is no oil drip-
ping.
(c) Tighten a new drain plug.
Torque: (11±1) N•m
Remove the drain plug
(d) Remove all of the 13 bolts on the oil pan.

(e) Discard the oil pan gasket.
(f) Take out the oil filter gently and discard it.
Remove the oil pan
(g) Take a oil filter with O-ring and lubricate it with

ESSO EZL799(A).
Lubricate the O-ring.
(h) Gently press the oil filter into position (match the
oil filter central hole with the hydraulic pressure
control unit central bolt).
(i) Clean the magnet and oil pan.
(j) Install the new gasket and oil pan and tighten the
13 bolts.
Torque: (9.5±1) N•m
(k) Refill the transmission case according to the in-
structions.
Install the oil filter into position.

Transmission MT-107
10. Change the driving mode sensor.

Malfunction: perform when the driving mode sensor is
at fault. Please change the driving mode sensor, if the
trouble code indicates that the driving mode sensor
occurs malfunction.
Maintenance method:
(a) Remove the oil filter according to the procedures.
(b) Remove the 2 screws on the driving mode sensor.
Remove the driving mode sensor bolt.
(c) Since the sensor is fixed with the hydraulic pres-

sure control unit metal slide via a small pin at the
back of the sensor, please be careful to remove
the driving mode sensor from hydraulic pressure
control unit. Press down the sensor to separate
the pin from the slide.
Press down the sensor and take it out.
(d) Open the lock on sensor connector with a small

slotted screwdriver, press the white buckle and
separate the connector.
(e) Connect the new sensor with the connector and
press in the white buckle and lock it.
Remove the driving mode sensor.
(f) Put the pin which is on the back of the sensor on

the metal slide, install in the correct location.
(g) Move the sensor to show up the bolt hole.
(h) Tighten the 2 screws with the torque of
(9.5 ± 0.95) N•m.
(i) Install the oil filter according to the procedures.
Install the pin on the correct location of the

metal slide.
11. Replace the hydraulic pressure control unit

Malfunction: If the transmission case pressure is too
low or shocking, abnormal conditions occur during
driving, there are two key parts — soil pump and hy-
draulic pressure control unit， which may cause the
above mentioned problems.Then, we need to find
the damaged part by trouble codes. In most cases, it
is difficult to judge the damaged part, please change
one by one to troubleshoot.
Maintenance method:
(a) Remove the driving mode sensor according to the
procedures.
Bolt sequence (b) Remove the bolts following the sequence of 20-
19-18-17-16-15-14-13-12-11-10-9-8-7-6-5-4-3-2-1
as shown in the figure.
(c) Take out the hydraulic pressure control unit and

separate the 4 connectors carefully with a small
slotted screwdriver.
Remove the 4 connectors with a small slotted

screwdriver.
Remove the 4 connectors with a small slotted

screwdriver.
(d) Take a new hydraulic pressure control unit and 4

connectors. Install the 4 connectors on the basis
of wire length.
(e) Install the hydraulic pressure control unit into the
correct location. There is a pin on the back of hy-
draulic pressure control unit and be sure to put it
to the correct location.
Restrict pin on the back of hydraulic pressure

control unit
Transmission MT-109
(f) Make sure to align the metal slide with the shifting
camshaft pin.
(g) Install and tighten the central bolt.
Fix the clutch control valve rod with the

shifting camshaft restrict pin.
(h) Install the SST (23K002-099-84312) on the upper

left bolt hole.
(i) Press down the wire of drive conical wheel speed
sensor on the hydraulic pressure control unit up-
per left corner.
Secure the hydraulic pressure control unit

with SST (23K002-099-84312).
(j) Install all of the hydraulic pressure control unit

bolts.Tighten the bolts with the torque of 11 N•m
and following the sequence of 1-2-3-4-5-6-7-8-9-
10-11-12-13-14-15-16-17-18-19-20 as shown in
the figure.
(k) Install the driving mode sensor according to the
procedures.
Bolt sequence
12. Replace the driven conical wheel speed sensor

and bracket.
Malfunction: Determine the damaged part via trouble
code.
Maintenance method:
(a) Remove the hydraulic pressure control unit ac-
(b) Loosen and discard the sensor bracket bolt.
Remove the bolt on the speed sensor bracket

(c) Extract the bracket from the gear shift shaft.
Speed sensor bracket
(d) Remove the sensor and connector with needle

nose pliers.
(e) Loosen the bolt on the bracket and remove the
sensor.
(f) Discard the sensor and bracket.
(g) Secure the new sensor and bracket with bolts.
Torque: (8.5±2)N•m
(h) Connect the wire and seize the bracket on the
gear shift shaft, pay attention to install into posi-
tion.
(i) Fix the bracket with a new bolt.
Torque(9.5±0.95)N•m
Separate the connector with needle nose pli- (j) Install the hydraulic pressure control unit accord-
ers. ing to the procedures.
13. Replace the drive conical wheel speed sensor.

code.
Maintenance method:
(a) Remove the drive conical wheel end cover ac-
(b) Loosen the bolt and remove the sensor.
(c) Separate the wires and discard the sensor.
(d) Secure the new sensor with bolt.
Torque: (8.5±2)N•m
(e) Connect wire with the sensor.
(f) Install the drive conical wheel end cover according
Drive conical wheel speed sensor to the procedures.
14. Replace the main connector and internal wire

code.
Maintenance method:
(a) Remove the hydraulic pressure control unit ac-
(b) Separate the 2 speed sensor connectors.
(c) Remove the cable connected the main connector
with the vehicle.
(d) Remove the main connector buckle and press the
main connector into transmission case.
Remove buckle from the main connector

Transmission MT-111
Press the main connector into the transmis-

sion case.
(e) Since the driving mode sensor connector is

clamped in the case, please remove it at first.
(f) Take out and discard the whole main connector.
(g) Put a new main connector into the transmission
case.
Remove the driving mode sensor connector

from the transmission case.
(h) Connect the main connector to the case with a

spline.
Restrict pin
Restrict pin
(i) It is easier to overdraught with the needle nose

pliers at the angle of 45 degree.
(j) Install the buckle back.
(k) Press and fit the driving mode sensor connector
into the case.
(l) Connect the speed sensor with connector.
(m) Install the hydraulic pressure control unit into the
transmission case according to the procedures.
Press and fit the driving mode sensor connec-

tor into the case.
Electronics Inspection
Transmission case electroics check list:
1. Driving mode sensor
Check the resistances among different pins and determine if the driving mode sensor is normal.
DMS_GND = 6 pins DMS_A = 13 pins DMS_B = 14 pins
DMS_C = 15 pins DMS_D = 16 pins DMS_Supply = 9 pins
DMS_Supply DMS_A DMS_B DMS_C DMS_D

DMS_Supply X 17.2 MΩ 17.2 MΩ 17.2 MΩ 17.2 MΩ
DMS_A 17.2 MΩ X 9 KΩ 9 KΩ 9 KΩ
DMS_B 17.2 MΩ 9 KΩ X 9 KΩ 9 KΩ
DMS_C 17.2 MΩ 9 KΩ 9 KΩ X 9 KΩ
DMS_D 17.2 MΩ 9 KΩ 9 KΩ 9 KΩ X
DMS_GND 4.5 KΩ 4.5 KΩ 4.5 KΩ 4.5 KΩ
2. Oil temerature sensor

Measure the internal resistance of oil temerature sensor.
Measure the resistance between the pin 5 and pin 7.
The resistance should be 942 KΩ to 1121 KΩ at 20℃ to 40℃.
3. Speed sensor
This is a complicated two-wire component, so there is no simple method to measure its operating
condition.
The resistance between pin 9 and pin 11 is about 24.3 MΩ.
The resistance between pin 9 and pin 12 is about 24.3 MΩ.
Caution: It cannot guarantee the speed sensor in good condition via this method.
4. Oil pressure sensor
The resistance between pin 7 and pin 10 is about 44.3 KΩ.
5. Clutch pressure regulator
The resistance between pin 1 and pin 4 is about 5.2 Ω.
6. Drive conical wheel pressure regulator
7. Driven conical wheel pressure regulator
8. TCU cannot be detected
Note: The measured resistance range will be different depending on the instrument accuracy.
Transmission MT-113
Leakage
Malfunction Troubleshooting
Check that the oil pan bolt is tightened.
Replace the oil pan washer.
Transmission oil pan washer leakage
Replace the drain hole.
Replace the oil pan assembly.
Check that the plug is tightened.
Transmission drain plug leakage Replace the drain plug.
Replace the oil pan assembly.
Check that the sealing cover is tightened firmly.
Drive conical wheel shaft end cover
Replace the O-ring.
leakage
Replace the drive conical wheel shaft end cover.
Check that the sealing cover is tightened firmly.
Driven conical wheel shaft end cover
Replace the sealing cover O-ring.
leakage
Replace the driven conical wheel shaft end cover assembly.
Shift lever leakage Replace the shift lever grommet.
Input shaft leakage Replace the input shaft grommet.
Differential oil seal leakage Replace the oil seal
Check that the pipe is secured.
Cooling pipe connector leakage Replace the cooling pipe connector sealing ring.
Replace the pipeline.
Trouble Codes and Troubleshooting

General instructions:
When the transmission case control system is detected at fault, the malfunction indicator
on the dashboard will light or flash. Please check if the trouble code is a history malfunction
whenever detected with scanner. Make sure that the malfunction did not occur during the
latest driving (it means history malfunction when "H" displayed on the scanner). If that hap-
pens, delete the trouble code and check if it will occur again. If it is a current malfunction (the
current malfunction occurs when "C" is displayed on the scanner), troubleshoot according to
the following trouble codes:
P0710 Oil Temperature Sensor Malfunction
TCU Troubleshooting: Malfunction indicator illuminates and the system sets the transmission oil tem-
perature automatically.
Maintenance Guide:
1. Measure the transmission oil temperature by scanner. If the signal data is appropriate, clear
the trouble code and check if it will occur again.
2. Check the wire (open, short or ground).
3. Measure the resistance between the two pins of transmission case main connector (it should
be 980Ω to 1,000Ω at 20ºC) to check if the oil temperature sensor is damaged. If it is damaged,
go to the next step and replace the main connector.
4. Replace a normal TCU.
5. Replace the transmission case.
P2765 Drive Conical Wheel Speed Sensor Malfunction
TCU Troubleshooting: The 3 pressure regulators are all powered down and the malfunction indicator
illuminates.
Maintenance Guide:
4. Replace the speed sensor.
P0720 Driven Conical Wheel Speed Sensor Malfunction

TCU Troubleshooting: Malfunction indicator illuminates and the system sets the driven conical wheel
speed automatically.
Maintenance Guide:
4. Replace the speed sensor.
P0840 Driven Conical Wheel Pressure Sensor TCU Troubleshooting:
The 3 pressure regulators are all powered down and the malfunction indicator illuminates.
Maintenance Guide:
1. Measure the driven conical wheel actual oil pressure by scanner and compare it with the
target value. If the signal data is appropriate, clear the trouble code and check if it will occur
again.
2. Check the circuit according to the value measured in the first step (ground: 0 bar (actual
pressure), short: 60 bar, open: 60 bar).
4. Replace the valve.
P0641 Pressure Sensor Power Supply Malfunction
illuminates.
Maintenance Guide:
1. Measure the input voltage by the scanner to see if the value is 8.4 V. If the signal data is ap-
propriate, clear the trouble code and check if it will occur again.
2. Measure the voltage between pressure sensor power cord and ground cable according to the
results in the first step.
P0651 Driving Mode Sensor and Speed Sensor Power Supply Malfunction
illuminates.
Maintenance Guide:
1. Measure the input voltage by the scanner to see if the value is 5 V. If the signal data is appro-
priate, clear the trouble code and check if it will occur again.
2. Measure the voltage between pressure sensor power cord and ground cable according to the
results in the first step.
P0659 Pressure Regulator Short
illuminates.
Maintenance Guide:
Measure the HS voltage: Compare with the battery voltage. If the result is the same, check the cir-
cuit (if there is short between the battery positive and VHS & transmission case connection)
and repair the wire. If not, replace the TCU.
P0658 Pressure Regulator Open or Grounded
illuminates.
Maintenance Guide:
Measure the HS voltage: Compare with the battery voltage. If the result is normal, the high-end
voltage is lower than 3.4 V. That means the wire is grounded. If the result is normal, the high-
end voltage is higher than 3.4 V. That means there is open. Check the pin wires under those
conditions mentioned above. After the inspection, if the wire is normal, please replace the
TCU. If the battery voltage is abnormal, check the battery.
P0702 TCU Internal Detection System Malfunction (During the Ignition)
illuminates.
Maintenance Guide:
Replace the TCU.
Transmission MT-115
P0962 EDS1 Drive Conical Wheel Pressure Regulator Grounded

TCU Troubleshooting:
The 3 pressure regulators are all powered down and the malfunction indicator illuminates.
Maintenance Guide:
1. Measure the drive conical wheel pressure regulator resistance, which should be 5.05±6% Ω.
2. Check the wire (ground).
3. Replace the hydraulic pressure control unit.
P0963 EDS1 Drive Conical Wheel Pressure Regulator Short
illuminates.
Maintenance Guide:
1. Measure the drive conical wheel pressure regulator resistance.
P0960 EDS1 Drive Conical Wheel Pressure Regulator Open
illuminates.
Maintenance Guide:
1. Measure the drive conical wheel pressure regulator resistance.
2. Check the wire (open).
P0966 EDS2 Driven Conical Wheel Pressure Regulator Grounded
illuminates.
Maintenance Guide:
1. Measure the driven conical wheel pressure regulator resistance.
P0967 EDS2 Driven Conical Wheel Pressure Regulator Short
illuminates.
Maintenance Guide:
2. Check the wire (short).
P0964 EDS2 Driven Conical Wheel Pressure Regulator Open
illuminates.
Maintenance Guide:
P0902 EDS3 Clutch Pressure Regulator Grounded
illuminates.
Maintenance Guide:
1. Measure the clutch pressure regulator resistance.
P0903 EDS3 Clutch Pressure Regulator Short

illuminates.
Maintenance Guide:
2. Check the wire (short).
P0900 EDS3 Clutch Pressure Regulator Open
illuminates.
Maintenance Guide:
P1763 Actuator Short or Grounded
illuminates.
Maintenance Guide: Check the wire.
P1764 Actuator Grounded
illuminates.
P0930 Gear Shifting Lock Grounded
illuminates.
P0931 Gear Shifting Lock Short or Open
illuminates.
P1768 Back-up Lamp Grounded
illuminates.
P1769 Back-up Lamp Short or Open
illuminates.
PXXXX Malfunction Indicator Grounded
illuminates.
PXXXX Malfunction Indicator Short or Open
illuminates.
P0868 Pressure Preload Adjustment Malfunction
illuminates.
Maintenance Guide:
1. Check the oil level and quality.
Transmission MT-117
P0811 Clutch Slip (Ahead or Backward)

TCU Troubleshooting: Malfunction indicator illuminates and the clutch released
Maintenance Guide:
1. Measure the clutch pressure and engine & drive conical wheel speed by scanner. If the result
is appropriate, clear the trouble code and check if it will occur again.
2. If the data is abnormal (for example, the drive conical wheel speed and engine speed is differ-
ent when the clutch pressure is 10 bar), go to the next step.
3. Check the oil level and type.
P0730 Drive Ratio Control Malfunction
TCU Troubleshooting: The 3 pressure regulators are all powered down and the malfunction indicator illuminates.
Maintenance Guide:
1. Check the speed sensor signals and the input and feedback current of drive conical wheel
pressure regulator by scanner.
2. Take measurements according to the malfunctions. For example, check the speed sensor or
the pressure sensor based on relative malfunction symptoms.
3. Check the oil level and type as well.
4. Replace the speed sensor or hydraulic pressure control unit.
P1765 Driven Conical Wheel Low Pressure
illuminates.
Maintenance Guide:
1. Measure the actual pressure during driving (eg. manual shift mode) and compare it with the
target value.
P1766 Driven Conical Wheel High Pressure
TCU Troubleshooting: Malfunction indicator illuminates.
Maintenance Guide:
1. Measure the actual pressure during driving (eg. manual shift mode) and compare it with the
target value.
P0701 Two Malfunctions Occur Which Needs to Power down the Pressure Regulator
illuminates.
Maintenance Guide: Check the other trouble codes.
P0218 Transmission Case Oil High Temperature
TCU Troubleshooting: Malfunction indicator illuminates
Maintenance Guide:
1. Check the oil cooler
2. Try to have the malfunction to occur again under normal driving conditions. If not happens,
consult customer to make sure the malfunction happen condition.
3. Measure the transmission case oil temperature by scanner under the driving condition in sec-
ond step. If the value is higher than 120 C (it is abnormal if the trouble code time is shorter
O
than filter), take measurement to prevent the transmission case temperature is overheated.
P1767 Transmission Case Oil Temperature out of Range
illuminates.
Maintenance Guide:
1. Try to have the malfunction to occur again under normal driving conditions. If not happens,
consult customer to make sure the malfunction happen condition (driving uphill or high
speed).
2. Check the oil cooler.
3. Check the oil level.
4. Transmission case oil temperature is higher than 140 C: pressure regulator is powered down
O
and the clutch is released.

5. Please be sure to check out the malfunction causes. For the clutch will be released when the
malfunctions occur!
P0219 Power System Speed out of Range
illuminates.
Maintenance Guide:
1. It will not happen in principle.
2. Check if the engine speed is limited within 6,000 rpm.
P2766 Indicated Drive Conical Wheel Speed Abnormal with Actual Speed Value
illuminates.
Maintenance Guide:
1. Detect if the other speed information (engine speed, output shaft speed or vehicle speed) is
lost by scanner. If so, troubleshoot these troubles and check if this malfunction occurs again.
2. Detect the drive conical wheel speed signal by scanner. Compare it with the engine speed
when the clutch is applied and the difference should be within 200 rpm. The comparison
should be taken from the low speed to high speed of the engine(up to 6,000 rpm).
3. Check the circuit and replace a normal TCU.
4. Check the sensor position, angle and trigger wheels. Check if there are objects (steel band
fragments) on the front of sensor.
Note: This is a mechanical fault. There is other trouble codes for the electrical failure
5. Replace the drive conical wheel speed sensor.
6. Replace a new TCU to determine if TCU is at fault.
P0721 Indicated Driven Conical Wheel Speed Abnormal with Actual Speed Value
TCU Troubleshooting: Malfunction indicator illuminates, enhance the clamp force to 0, the system
sets the driven conical wheel speed automatically.
Maintenance Guide:
1. Detect if the other speed information (engine speed, output shaft speed or vehicle speed) is
lost by scanner. If so, troubleshoot these troubles and check if this malfunction occurs again.
2. Check the wire.
3. Replace a normal TCU, and then there will be another electrical trouble code (other trouble
codes).
4. Check the sensor position, angle and trigger wheels. Check if there are objects (steel band
fragments) on the front of sensor.
Note: This is a mechanical fault. There is other trouble codes for the electrical failure.
5. Replace the driven conical wheel speed sensor.
6. Replace a new TCU to determine if TCU is at fault.
P0944 Insufficient Clamp Force (VSM)
TCU Troubleshooting: Malfunction indicator illuminates and the clutch released.
Maintenance Guide: If that happens for several times, then the driven conical wheel pressure is
too low (longer than 6 seconds). Check the oil level firstly. If it is still malfunctioning, please
replace the transmission case because this malfunction maybe caused by other components
(oil pump, hydraulic pressure control unit ect.)
Transmission MT-119
P0810 Linear Adaptive Update not Completed

TCU Troubleshooting: Malfunction indicator flashes.
Maintenance Guide:
1. Install a new TCU on the vehicle or renew the softwares in the TCU.
2. Make the adaptive update again according to the descriptions in the section 2.5. If the opera-
tion is correct, malfunction indicator will go out and the trouble code will be cleared automati-
cally after three driving cycles (ignition for 3 times).
P1762 Current Value is frozen, not Changed
illuminates.
Maintenance Guide:
1. After checking and repairing the trouble codes P0962 P0963 P0960 P0966 P0967 P0964 P0902
P0903 P0900 P1763 P1764, it is possible that there will be no trouble code any more.
P0882 Battery or High-end Low Voltage
illuminates.
Maintenance Guide:
1. There will be a battery voltage record when the malfunction happens (then you can determine
whether it is caused by battery or high-end voltage). If it is not a historic record, go to the
next step directly.
2. Measure the high-en or battery voltage by scanner - temperature is more influential to the value.
3. If the problem lies in battery: Check the circuit between battery and TCU (fuses and main re-
lay), or replace/check the battery.
4. If the problem lies in pressure regulator: Check the circuit between transmission case and TCU.
5. Replace the TCU.
P0883 Battery or High-end High Voltage
illuminates.
Maintenance Guide:
1. There will be a battery voltage record when the malfunction happens (then you can determine
whether it is caused by battery or high-end voltage). If it is not a historic record, go to the
next step directly.
2. Measure the high-en or battery voltage by scanner - temperature is more influential to the value.
3. Confirm with the customer if he/she uses other battery if the problem lies in battery (at this
time the power supply is 24 V). If it is, check the circuit between battery and TCU (fuses and
main relay).
4. Check and replace the battery.
5. If the problem lies in high-end voltage: Check the circuit between transmission case and TCU.
6. If the problem lies in high-end voltage but not for the circuit, replace the TCU or check/re-
place alternator.
P2787 Clutch High Temperature
TCU Troubleshooting: Malfunction indicator illuminates and the clutch released.
Maintenance Guide:
1. Check how many times the malfunction happened. If there is only once or a few times, check
the TCU internal data and negotiate with the customer for the special driving conditions (for
example uphill driving) at that time. Then delete the trouble code.
2. It happens only when depress the accelerator pedal and brake pedal at the same time. Delete
the trouble code to see if it occurs again.
3. Replace the TCU.
4. It maybe that the throttle is clogged. Replace the throttle.
P0727 Indicated Engine Speed Singal Transmission from ECU to TCU Wire Abnormal
with Actual Speed Value
TCU Troubleshooting: Malfunction indicator illuminates.
Maintenance Guide:
1. Check the engine test report to see if the engine is at fault. If it is, repair the engine.
2. Check the TCU input signal. It is a frequency signal (the signal will be 30 Hz at the engine
speed of 900 rpm, 100 Hz at 3,000 rpm).
3. Replace a normal transmission case.
P1761 Pressure Regulator Current Malfunction
illuminates.
Maintenance Guide:
1. Measure the pressure regulator internal voltage drop by scanner and compare the value with
specified current.
2. Measure the pressure regulator internal current by scanner and compare the value with
specified current. If it is different with the specified current, check the pressure regulator wire
(check the transmission case interior as well).
3. Replace a normal transmission case.
U0301 Vehicle Configuration Incorrect (eg. Inappropriate ECU is equipped)
illuminates.
Maintenance Guide:
1. Check if the configuration of TCU hardware and sofeware is correct or available.
2. If the software is updated by EMS or TCU: The software in the new controller is incorrect (the
transmission case controller is incompatible with the engine controller).
P0706 Driving Mode Sensor Single Wire Malfunction
TCU Troubleshooting: Malfunction indicator illuminates and the system sets the sensor position auto-
matically.
Maintenance Guide:
1. Check which wire is at fault and the type of fault by scanner. For example, the B wire is short
(this malfunction means there is one wire failed) ect.
2. Check the wire connected transmission case with TCU.
P0705 Driving Mode Sensor Multiple Wires Malfunction
illuminates.
Maintenance Guide:
1. Check which wire is at fault and the type of fault by scanner. For example, the B wire is short
(this malfunction means there is one wire failed). Check the wire connected transmission
case with TCU.
P0571 Brake Signal Malfunction
TCU Troubleshooting: Malfunction indicator illuminates and the brake signal is high level.
Maintenance Guide:
1. Check the brake signal.
2. Check the brake signal wire.
3. Replace the TCU.
PO955 Manual Shift Up and Down Signal Malfunction
TCU Troubleshooting: Malfunction indicator illuminates and there is no manual mode.
Maintenance Guide:
1. Check the circuit between gear shift mechanism and TCU.
3. Replace the gear shift mechanism.
Transmission MT-121
U0415 ABS Function Malfunction

TCU Troubleshooting: Enhance the clamp force to 0, the system sets anti-brake and rotation auto-
matically.
Maintenance Guide: Check the ABS system.
U0001 CAN Bus Malfunction
TCU Troubleshooting: Malfunction indicator illuminates, emergency mode is activated and there is
no manual mode.
Enhance the clamp force to 1 (maximum), the system will set anti-brake and rotation automatically.
The internal driving mode will be activated, then the system will set the engine speed, torque, cool-
ant temperature, brake signal connecting, accelerator pedal stable data, left front & right front & left
rear & right rear wheel speed automatically.
Maintenance Guide:
1. If the malfunction occurs in the other controllers, the wire is at fault (CAN high speed line and
low speed line short). Check the vehicle wires.
2. If the malfunction lies in TCU itself, replace a normal TCU.
U0121 ABS CAN Communication Malfunction
TCU Troubleshooting: Enhance the clamp force to 0, the system sets anti-brake and rotation auto-
matically. Then the system will set the left front & right front & left rear & right rear wheel speed auto-
matically.
Maintenance Guide: Check the ABS controller and the communication interface in it (The malfunc-
tion maybe occur on other controllers).
U0100 ECU CAN Communication Malfunction
TCU Troubleshooting: Malfunction indicator illuminates, emergency mode is activated and there is
no manual mode.
Enhance the clamp force to 0. The internal driving mode will be activated, then the system will set
the engine torque, cooling water temperature, accelerator pedal stable data, and stop the CAN data
communication.
Maintenance Guide: Check the engine controller and the communication interface in it (The mal-
function maybe occur on other controllers).
U1012 Engine Speed Signal on CAN Bus Malfunction
TCU Troubleshooting: Malfunction indicator and warning lamp illuminate.
Maintenance Guide: Check the MCU controller (engine speed sensor and its wires).
U1013 Accelerator Pedal Signal on CAN Bus Malfunction
TCU Troubleshooting: Malfunction indicator illuminates and the accelerator pedal data is frozen.
Maintenance Guide: Check the EMS controller (accelerator pedal sensor and its wires).
U1014 Engine Torque Signal on CAN Bus Incorrect
TCU Troubleshooting: Malfunction indicator illuminates, emergency mode is activated and there is no
manual mode. The internal driving mode will be activated, then the system will set the engine torque
automatically.
Maintenance Guide: Check the EMS controller.
U1016 Left Front Wheel Speed Signal on CAN Bus Incorrect
TCU Troubleshooting: Enhance the clamp force to 0, the system sets anti-brake, rotation and left
rear wheel speed automatically.
Maintenance Guide: Check the ABS controller (wheel speed sensor and its wires).
U1017 Right Front Wheel Speed Signal on CAN Bus Incorrect
front wheel speed automatically.
U1018 Left Rear Wheel Speed Signal on CAN Bus Incorrect
U1019 Right Rear Wheel Speed Signal on CAN Bus Incorrect
Remarks:
The 3 pressure regulators are all powered down:
When there is trouble code and the pressure regulator is powered down, the clutch is released and
the vehicle cannot move whatever the gear is engaged or not. In that case, you have to stop the
engine,make the ignition key return to its original position and restart the engine, then you could
drive the vehicle continously.
Enhance the clamp force to 0: The driven conical wheel pressure is maitained to stable value,
which is higher than the normal condition and lower than the highest level.
Enhance the clamp force to 1: The driven conical wheel pressure is kept at the highest level.
EDS1: Drive conical wheel pressure regulator.
EDS2: Driven conical wheel pressure regulator.
EDS3: Clutch pressure regulator.
Emergency mode* : which is called "limp home mode", and it will be activated under the condi-
tions below:
• CAN bus disconnected
• CAN ECU communication malfunction
• CAN engine torque signal incorrect
All of the signals related to engine and ABS will be substituted (troubleshooting):
• Throttle opening angle is fixed.
• The engine torque is substituted by engine map drawing.
• Engine coolant temperature is fixed.
• Wheel speed is substituted by transmission case output shaft speed.
• The speed signal from wire is used for engine speed.
• The clutch is released or engaged solidly. It seems not be calibrated according to specified data.
• The highest engine speed is limited within 3,200 rpm.
• The highest vehicle speed is limited within 98 km/h.
• The transmission case gear shift will be done only in a driving mode.
CVT will activate under the most elementary condition and provide enough power for driving to
the nearest vehicle service station:
2 seconds later,the manual gear and sport gear will be deactivated and the malfunction indicator will
illuminate.
Transmission MT-123
Gear Shift Mechanism System

Components
Lever knob
Ash tray
Brake lever panel

Auxiliary facia con-
sole assembly Sponge
carpet
Tr a n s m i s s i o n Screw
shift cable
Buckle
Parking brake
Shift lever Bolt lever
1. Shift lever removal

(a) Remove the parking brake lever panel.
(b) Remove the lever knob.
(c) Remove the auxiliary facia console sponge carpet.
Buckle
(d) Unscrew the auxiliary facia console mounting bolt with

screwdriver.
(e) Remove the auxiliary facia console.
(f) Remove the shift lever connector and separate shift

lever cable from the shift lever.
(g) Unscrew the shift lever mounting bolt with ratchet and
No.13 socket wrench. Remove the shift lever.
2. Shift lever cable removal

Caution: Remove the shift lever cable after the ex-
haust system is cooled down, as to avoid person-
nel injury due to hot components.
(a) Remove the front heat shield standard components,
then remove the front heat shield.
(b) Loosen the nut connecting shift lever cable and trans-
mission gear shift swing arm.
Transmission
Clip Gear shift bracket (c) Remove the transmission bracket with ratchet and
swing arm
No.10 socket wrench.
(d) Remove the buckle from the transmission bracket.
Separate the transmission bracket from shift lever
cable.
(e) Remove Q1400620F3 (Q402) and Q32006F3 four

standard components for shift lever cable and vehicle
body.
(f) Remove the shift lever cable.
Transmission MT-125
Cooling System
Components
Oil-pass bolt
Gasket Outlet pipe

assembly
Oil-pass bolt
Inlet pipe assembly

Gasket
Gasket
Q1400625
Double-hole clamp
Inlet and outlet pipe assemblies removal and instal-

lation
1. Removal and installation of inlet & outlet pipe as-
semblies and CVT
Caution: There are two gaskets on each side of
Oil-pass bolt the oil pipe, and keep the removed parts clean.
(a) Remove the oil-pass bolt with ratchet and socket.
(b) Take out the oil pipe from the double-hole tube clamp.
(c) Install the oil-pass bolt, oil pipe and gasket.
(d) Install the oil-pass bolt onto CVT.
Gasket
Double-hole
clamp
Outlet 2. Removal and installation for inlet & outlet pipe as-
pipe assemblies and cooler assembly
sembly
Oil-pass bolt Caution: There are two gaskets on each side of
Oil-pass bolt Gasket the oil pipe, and keep the removed parts clean.
(a) Remove the oil-pass bolt with ratchet and socket.
Inlet pipe assembly
(b) Remove the inlet & oulet pipe from the cooler assem-
bly.
(c) Install the oil-pass bolt, oil pipe and gasket.
(d) Install the oil-pass bolt on cooler assembly.
DT-�

Drive system
Propeller Shaft/Axle
Malfunction Indicator Table........................................... DT-2
Vehicle check.................................................................. DT-2
Front axle propeller shaft . ............................................ DT-4
Front axle hub subassembly LH.................................... DT-17
Front axle hub bolt LH.................................................... DT-21
Rear axle hub and bearing subassembly LH............... DT-22
Rear axle hub bolt LH..................................................... DT-23
Clutch
Malfunction Indicator Table........................................... DT-24
Clutch pedal subassembly............................................. DT-25
Clutch Master Cylinder Assembly................................. DT-30
Clutch Release Cylinder Assembly............................... DT-34 DT
Clutch assembly............................................................. DT-37
Clutch start switch assembly........................................ DT-41
Clutch Hydraulic Pressure System Bleeding............... DT-42
DT-�
COOL BEAR MAINTENANCE MANUAL
Propeller Shaft/Axle
Malfunction Indicator Table
In the following table, the suspected areas are listed according to the order of the number, in order to de-
termine the cause of the problem.If necessary, check, repair, or replace the parts according to procedures
listed in the following pages.
Problem Location in Question Reference Page (s)
1. Wheel SP-35
2. Front wheel alignment SP-7
3. Rear wheel alignment SP-24
4. Front hub bearing (worn) DT-2
5. Rear hub bearing (worn) DT-3
Deviation in driving
6. Front shock absorber with coil spring SP-10
assembly
7. S teering propeller mechanism (loose or -
worn)
8. Stabilizer bar SP-20
1. Wheel balance SP-40
2. Hub bearing (worn) DT-2
Front wheel shimmy
3. Front shock absorber with coil spring SP-10
assembly
1. Outer joint (worn) DT-10
Noise (Propeller shaft)
2. Inner joint (worn) DT-8
Vehicle check
1. Check whether front axle swings and has clearance
(a) Remove the front wheel.
(b) Remove the front brake caliper assembly
(see page DT-17).
(c) Remove the front brake disc.
(d) Check the bearing clearance.
(1) Use a dial indicator to check whether the center of
ALE001G axle hub has clearance.
Maximum value: 0.05 mm
If the clearance exceeds the maximum value,
replace the front axle hub bearing.
(e) Chech the axle hub swing.

(1) Use a dial indicator to check whether the axle hub
surface outside the hub bolt has runout.
If the swing exceeds the maximum value, re-
place the front axle hub subassembly.
(f) Install the front brake disc.
(g) Install the front brake caliper.
ALE002G (see page DT-19).
(h) Install the front wheel.
Torque: 110 N·m
Drive System DT-�

2. Check whether rear axle swings and has clearance

(a) Remove the rear wheel.
(b) Remove the rear brake drum.
(c) Check the bearing clearance.
(1) Use a dial indicator to check whether the center of
axle hub has clearance.
If the clearance exceeds the maximum value, re-
ALE003G place the rear axle hub and bearing assembly.
(d) Chech the axle hub swing.

(1) Use a dial indicator to check whether the axle hub
surface inside the hub bolt has runout.
If the swing exceeds the maximum value, replace
the rear axle hub and bearing assembly.
(e) Install the rear brake drum.
(f) Install the rear wheel.
ALE004G Torque: 110 N·m
DT-�
Front axle propeller shaft

Components
Front axle right propeller

shaft assembly
● Front axle right propeller

shaft clasp
● Front axle right propeller
shaft clasp
Front speed sensor LH Front axle left propeller

shaft assembly
Brake hose
● Cotter pin
Washer
Bush
Front stabilizer bar

Left steering tie rod
ball assembly
●
Bush
Front axle hub nut LH
Washer
● Lock pin
Front Suspension Lower Swing Arm LH
: Specified torque
● Disposable parts
ALE005G
Drive System DT-�

Outer joint shaft assembly of

front axle left propeller shaft ● Front axle left propeller shaft outside Joint
dust cover No.2 clip
Supplied
parts: ● Front axle left propeller
● Outer joint shaft outside
Dust cover Joint dust cover clip
Supplied
parts:
RH: ● Propeller shaft shock

absorber fixing clamp
One touch clamp

Claw engagement type
or
Claw engagement type

Front axle right propeller
shaft shock absorber One touch clamp
One touch ● Dust cover No.2 clip for inner joint of the front axle LH
clamp
or Claw engagement type
● Front axle left propeller shaft

or Inner clasp of propeller shaft
● Dust cover for inner joint

● Front axle left propeller shaft
inside Joint dust cover clip ● Oil seal of front axle
left propeller shaft
Three-ball stud joint assembly
One touch clamp
Inner joint assembly of front

axle left propeller shaft
ALE006G
DT-�
Overhaul
Hint:
Repair the right side in the maintenance procedure as the left.
1. Drain the propeller axle oil.
Torque: 39 N·m
2. Remove the front wheel.
3. Remove the left bottom cover of the engine.
4. Remove the front axle hub nut LH.
(a) Pry off the protruding parts of the front axle hub nut LH
with the SST and a hammer.
Note:
Loosen the locked parts of the nut completely or
the thread of the propeller shaft will be damaged.
(b) When using brake, remove the front axle hub nut LH.
ALE007G
5. Seperate the front speed sensor LH

LH: (a) Remove the bolt and the clip, and separate the front
speed sensor LH and thebrake hosefrom the front
shock absorber assembly LH.
Hint:
The positions of the bolt and clip on the right side differ
RH:
from those on the left side.
ALE008G
(b) Remove the bolt and separate the speed sensor of the
front wheel LH from the steering knuckle.
Note:
• Do not damage the wheel speed sensor.
• Avoid any contamination to the wheel speed
sensor.
ALE009G
Drive System DT-�

6. Remove the front stabilizer bar.

(a) Use a wrench (10 mm) to fasten the bolt and remove
the nut.
(b) Remove 2 washersand 2 bushes, seperate thefront
stabilizer bar.
ALE010G
7. Remove the front suspension lower swing arm LH.

(a) Remove the lock pin and the nut.
(b) Use the SST to separate thefront suspension lower
swing armfrom the steering knuckle.
ALE011G
8. Remove the steering tie rod ball assembly LH.

(a) Remove the cotter pin and nut.
(b) Use the SST to remove the steering tie rod ball assem-
bly LH from the steering knuckle.
9. Seperate the front axle hub assembly LH.
(a) Use a plastic hammer to remove thefront axle drive
shaft assembly LHfrom the front axle hub assembly LH.
Note:
ALE012G • Do not damage the dust cover.
• Do not damage the rotor of the wheel speed
sensor.
10. Remove thefront axle left propeller shaft assembly.

(a) Use the SST to remove thefront axle left propeller shaft
assembly.
Note:
• Do not damage the oil seal and dust cover.
• Do not drop the propeller shaft assembly.
ALE013G
11. Remove the front axle right propeller shaft assem-

bly (Right propeller shaft).
(a) Remove the front axle right propeller shaft assembly
with brass rod and hammer.
Note:
• Do not damage the oil seal and dust cover.
• Do not drop the propeller shaft assembly.
ALE014G
DT-�
12. Secure the front axle hub assembly LH.

Note:
• The hub bearing could be damaged if it is sub-
jected to the vehicle’s weight, such as when
SST moving the vehicle with the drive shaft re-
moved.
• Therefore, if it is necessary to place the vehicle’
s weight on the hub bearing, support it with SST
ALE015G firstly.
13. Check thefront axle left propeller shaft assembly.

Note:
Place the propeller shaft assembly in horizontal
during checking.
(a) Check that the outer joint has obvious clearance in a
radial direction.
(b) Check that the inner joint slides smoothly in the axial
direction.
ALE016G (c) Check that the inner joint has an obvious clearance in
the radial direction.
(d) Check whether the dust cover is damaged.
One touch clamp: 14. Remove the No.2 clip of the dust cover for the inner
joint of the front axle LH.
(a) One touch clamp:
As shown in the figure, use a screwdriver to remove the
No.2 clip of the dust cover for the front axle inner joint LH.
(b) Claw engagement type:
As shown in the figure, use needle nose pliers to re-
move the No.2 clip of dust cover for inner joint of front
ALE017G axle LH.
One touch clamp: 15. Remove the small clip of the dust cover for the in-
ner joint of the front axle LH.
As shown in the figure, use a screwdriver to remove the
clip of the dust cover for the front axle inner joint LH.
Claw engage-
ment type: (b) Claw engagement type:
As shown in the figure, use needle nose pliers to re-
move the small clip of the dust cover for the inner joint
ALE018G of the front axle LH.
16. Separate the dust cover for the inner joint of the
front axle.
(a) Separate the dust cover for the inner joint from the front
axle inner joint assembly LH.
Drive System DT-�

17. Remove the front axle inner joint assembly LH.

Installation mark (a) Remove the grease from the front axle inner joint as-
sembly LH.
(b) Make an installation mark on the front axle inner joint
assembly LH and outer joint shaft assembly.
Note:
Do not use a punch to mark the component.
(c) Remove the front axle inner joint assembly LH from the
ALE019G outer joint shaft assembly.
(d) Use a clasp expander to remove the inner clasp of left

propeller shaft.
ALE020G
Brass rod (e) Make installation mark on the outer joint shaft assembly
Installation mark and three-ball stud joint assembly.
Note:
Do not use a punch to mark the component.
(f) Use a brass rod and hammer to remove thethree-ball
stud joint assemblyfrom the outer joint shaft assembly.
Note:
Do not strike the roller.
(g) Separate the No.2 clip of the dust cover for the inner
joint of the front axle LH, dust cover for the inner joint,
ALE021G
the clip of dust cover for inner joint of front axle LH.
One touch clamp 18. Remove the propeller shaft shock absorber fixing
clamp (Right propeller shaft).
Hint:
The following procedure is only for right side disassembly.
Claw engagement (a) One touch clamp:
type: Use a screwdriver to remove the shock absorber fixing
clamp as shown in the figure.
ALE022G Use needle nose pliers to remove the shock absorber
fixing clamp as shown in the figure.
19. Remove the propeller shaft shock absorber (Right
propeller shaft).
Hint:
The following procedure is only for right side disassembly.
(a) Remove the right propeller shaft shock absorber.
DT-��
10 COOL BEAR MAINTENANCE MANUAL
20. Remove the No.2 clip of the dust cover for the outer
(a) Use a screwdriver to remove the No.2 clip of the dust
cover for left outer joint.
ALE023G
21. Remove th clip of the dust cover for the outer joint
of the front axle LH.
(a) Use a screwdriver to remove the clip of the dust cover
for the front axle inner joint LH.
22. Remove the dust cover for the outer joint of front
axle.
(a) Remove the dust cover for the outer joint from the outer
joint shaft assembly.
ALE024G (b) Remove the grease from the outer joint.
23. Remove the clasp of the front axle left propeller

shaft.
(a) Use a screwdriver to remove the clasp of the left pro-
peller shaft.
ALE025G
24. Remove the oil seal of the front axle left propeller
shaft.
SST
(a) Use the SST and press to remove the oil seal of the left
propeller shaft.
Note:
Do not drop the inner joint assembly.
ALE026G
Drive System DT-��
11
SST 25. Install the oil seal of the front axle left propeller
shaft.
(a) Use the SST and press to install the oil seal of the left
propeller shaft.
Note:
• Do not damage the oil seal.
• The oil seal must be mounted in position.
26. Install the clasp of the front axle left propeller shaft.
ALE027G (a) Install a new clasp for the front axle left propeller shaft.
27. Install the dust cover for the outer joint of the front
axle.
(a) Use PVC insulating tape to wrap the spline of outer
joint shaft to avoid damaging the dust cover.
(b) Install the new part on the inner joint shaft assembly in
the following sequence:
(1) No.2 clip of the dust cover for the outer joint of the
front axle LH
(2) Dust cover for the outer joint
(3) Clip of the dust cover for the outer joint of the front
axle LH
(c) Use grease to seal the outer joint assembly of front
axle LH.
Grease capacity: 155 to 170 g
(d) Install the dust cover of the outer joint onto the outer
28. Install the No.2 clip of the dust cover for the outer
Fix
SST Rotate (a) Install the No.2 clip of the dust cover for the outer joint of
the front axle LH onto the dust cover of the outer joint.
(b) Tighten SST to secure the No.2 clip of the dust cover
for the outer joint of the front axle LH.
(c) Tighten SST to secure the No.2 clip of the dust cover
for the outer joint of the front axle LH.
ALE028G
Note:
Do not over tighten the SST.
(d) Use SST to measure the No.2 clip clearance of the

SST
dust cover for the outer joint of the front axle LH.
Clearance: 0.8 mm or less
Note:
If the measured value exceeds the specified value,
retighten the clip.
ALE029G
DT-��
29. Install the clip of the dust cover for the outer joint
Fix
SST (a) Clip the propeller shaft in the vice.
(b) Install the dust cover for the outer joint of the front axle
LH onto the dust cover of the outer joint.
(c) Put SST on the clip of the dust cover for the outer joint
(d) Tighten SST to secure the clip of the dust cover for the
ALE030G outer joint of the front axle LH.
Note:
Do not over tighten the SST.
(e) Use SST to measure the clip clearance of the dust cov-
er for the outer joint of the front axle LH.
Clearance: 0.8 mm or less
Note:
If the measured value exceeds the specified value,
SST retighten the clip.
ALE031G
30. Instal the propeller shaft shock absorber (Right

propeller shaft).
Hint:
The following procedure is only for right side installation.
(a) Install the propeller shaft shock absorber onto the outer
31. Install the propeller shaft shock absorber fixing
clamp (Right propeller shaft).
Hint:
The following procedure is only for right side installation.
(a) Install the shock absorber fixing clamp onto the shaft.
Note:
Make sure the clamp is mounted in right position.
One touch clamp: (b) One touch clamp:

Use a screwdriver to install the shock absorber fixing
clamp as shown in the figure.
(c) Claw engagement type:
Use needle nose pliers to instal the shock absorber fix-
Claw engage-
ment type: ing clamp as shown in the figure.
ALE032G
13
32. Install the inner joint assembly of the front axle left
propeller shaft.
Hint:
Before installing the dust cover, use PVC insulating
tape to wrap the spline of the propeller shaft to avoid
damaging the dust cover.
(a) Install the new part on the outer joint shaft assembly in
the following sequence:
(1) Clip of the inner joint of the front axle LH
(2) Dust cover for the inner joint
(3) No.2 clip of the inner joint of the front axle LH
(b) Align the installation marks and install thethree-ball
stud joint assemblyonto the outer joint assembly.
(c) Use a brass rod and hammer to install thethree-ball
stud joint assembly.
Note:
• Do not strike the roller.
• Make sure that the three-ball stud joint is
Installation mark mounted in the correct direction.
ALE033G
(d) Use a clasp expander to install a new inner clasp of the

left propeller shaft.
(e) Coat the grease on the front axle inner joint assembly LH.
Grease capacity: 125 to 135 g
ALE020G
(f) Align the installation marks and install the front axle inner
Installation mark joint assembly LH onto the outer joint shaft assembly.
ALE019G
33. Install the dust cover for the inner joint of the front
axle.
(a) Install the dust cover of the inner joint onto the inner
joint assembly and outer joint shaft assembly.
DT-��
One touch 34. Install the No.2 clip of the dust cover for the inner
clamp type: joint of the front axle LH.
As shown in the figure, use a screwdriver to install the
No.2 clip of the dust cover for the front axle inner joint LH.
Claw engagement
type:
As shown in the figure, use needle nose pliers to install
the No.2 clip of the dust cover for the inner joint of the
front axle LH.
ALE034G
One touch
35. Install the clip of the dust cover for the inner joint
clamp type: of the front axle LH.
As shown in the figure, use a screwdriver to install the
clip of the dust cover for the front axle inner joint LH.
Claw engagement As shown in the figure, use needle nose pliers to install
type: the clip of the dust cover for the inner joint of the front
axle LH.
ALE035G
36. Check the front axle propeller shaft.

Note:
Place the propeller shaft assembly in horizontal
during checking.
(a) Check whether the outer joint has an obvious clearance.
(b) Check that the inner joint slides smoothly in an axial di-
rection.
(c) Check that the inner joint has an obvious clearance in
the radial direction.
ALE016G
(d) Check whether the dust cover is damaged.
37. Install the front axle left propeller shaft assembly.

(a) Apply the gear oil on the spline of the inner joint shaft
assembly.
(b) Align the spline of the shaft and install thefront axle pro-
peller shaft assembly LHwith a brass rod and hammer.
Note:
• Install the clasp with the engaging part down-
wards.
• Do not damage the dust cover and oil seal.
ALE036G
Hint:
Judge whether the inner joint shaft comes into contact
with the small gear shaft through the sound and feeling
when pulling it inside.
38. Install the front axle right propeller shaft assembly
(Right propeller shaft).
Hint:
The procedure is the same as the right side.
Note:
• Install the clasp with the engaging part down-
wards.
• Do not damage the dust cover and oil seal.
15
39. Install the front axle hub assembly LH.

(a) Install the left propeller shaft assembly onto the front
axle hub assembly LH.
Note:
• Do not damage the dust cover of the outer joint.
• Do not damage the rotor of the wheel speed
sensor.
• Do not excessively push the front axle assem-
bly LH.
40. Install the steering tie rod ball assembly LH.
(a) Use a nut to install the steering tie rod ball assembly
LH onto the steering knuckle.
Torque: 50 N·m
(b) Install a new cotter pin.
Note:
If the hole for mounting the cotter pin isn't aligned,
rotate the nut for 60°.
41. Install the front suspension lower swing arm LH.
(a) Use a nut to install thefront suspension lower swing
arm LHonto the steering knuckle.
Torque: 80 N·m
(b) Install a new lock pin.
Note:
If the hole for mounting lock pin isn't aligned, rotate
the nut for 60°.
42. Install the front stabilizer bar.

(a) As shown in the figure, install thefront stabilizer barwith
2washers, 2bushesand nut.
Note:
Make sure thebushes and washers are mounted in
right direction.
(b) Turn the nut with wrench (10 mm).
Torque: 37 N·m
ALE037G
LH: 43. Install the front speed sensor LH

(a) Install the front speed sensor LH and thebrake hoseon
the front shock absorber assembly LH with bolt and clip.
Torque: 29 N·m
Hint:
RH:
The positions of the bolt and clip on the right side differ
from those on the left side.
ALE008G
DT-��
(b) Install the wheel speed sensor of the front wheel LH on

the steering knuckle with bolts.
Torque: 8.0 N·m
Caution:
• Keep the wheel speed sensor clean.
• When installing the sensor, do not twist the sen-
sor wire harness.
ALE009G
44. Install the front axle hub nut LH.

(a) Install a new left hub nut.
Torque: 225 N·m
(b) Use a punch and hammer to lock the left hub nut.
45. Install the left bottom cover of the engine.
46. Install the front wheel.
Torque: 110 N·m
47. Add the propeller axle oil.
ALE038G 48. Check and adjust the propeller axle oil.
49. Check and adjust the front wheel alignment (see
page SP-7).
50. Check the signal of the ABS speed sensor.
17
Front axle hub subassembly LH

Components
Brake hose
Front speed sensor LH
Cotter
pin
Front axle left propel-

ler shaft assembly
Left front axle hub assembly
Washer
Left steering tie rod ball assembly
Front brake
Front wheel brake disc
caliper assembly LH
Bush
Lock pin
Washer
Front axle hub nut LH

Front Suspension Lower
Swing Arm LH
Front axle
hub clasp LH
Front axle
Hub bearing
Front axle hub bolt LH

Left steering knuckle
Front axle hub
subassembly LH
Front brake disc cover LH
: Specified torque
ALE039G
DT-��
Replacement
1. Remove front wheel LH (see page SP-42).
2. Remove front axle hub nut LH (see page DT-6).
3. Separate front wheel rotation speed sensor LH (see
page DT-6).
4. Remove the front wheel brake caliper assembly LH.

(a) Remove 2 bolts and remove the front brake caliper as-
sembly LH from the steering knuckle.
Caution:
Use a cord or other tools to avoid the brake caliper
suspending.
5. Remove the front disc brake.
6. Release the front stabilizer bar (see page DT-7).
7. Release the front suspension lower swing arm LH
8. Release the steering tie rod ball assembly LH (see
page DT-7).
9. Remove front axle hub assembly LH (see page
DT-7).
10. Release the front shock absorber assembly LH.

(a) Remove 2 bolts and 2 nuts and release the front shock
absorber assembly LH from the steering knuckle as-
sembly.
ALE041G
11. Remove the front axle hub hole clasp LH.

(a) Use the clasp pliers to remove the front axle hub hole
clasp LH.
ALE042G
12. Remove the front axle hub subassembly LH.

(a) Remove the front axle hub subassembly LH with SST.
ALE043G
19
(b) Remove the left hub bearing seat inner ring from front
axle hub subassembly LH with SST.
13. Remove the front brake disc cover.
(a) Remove the 3 bolts and front dust cover LH.
ALE044G
14. Remove the front axle hub bearing LH.

(a) Place the left hub bearing seat inner ring on its outer ring.
(b) Remove the left hub bearing seat outer ring from the
steering knuckle with SST and press.
Note:
Do not place the steering knuckle horizontally.
ALE045G
15. Install the front axle hub bearing LH.

(a) Install a new front axle hub bearing LH on the steering
knuckle with SST and press.
16. Install the front disc brake cover LH.
(a) Install the front disc brake cover LH with 3 bolts.
Torque: 8.3 N·m
ALE046G
17. Install the front axle hub subassembly LH.

(a) Install the front axle hub subassembly LH with SST and
press.
ALE047G
DT-��
18. Install the front axle hub hole clasp LH.

(a) Use the clasp pliers to install a new front axle hub hole
clasp LH.
ALE042G
19. Install the front shock absorber assembly LH.

(a) Install the 2 bolts, nuts and front shock absorber as-
sembly on the left steering knuckle assembly.
Torque: 132 N·m
Note:
When reusing the bolts and nuts, apply a small
amount of engine oil to the nut thread.
20. Install the front axle hub LH (see page DT-14).
ALE041G 21. Install the steering tie rod ball assembly LH (see
page DT-14).
22. Install the front suspension lower swing arm LH (see
page DT-14).
23. Install the front stabilizer bar (see page DT-15).
24. Install the front brake disc.
25. Install the front wheel brake caliper assembly LH.
(a) Use 2 bolts to install the brake caliper assembly on the
steering knuckle.
Torque: 88 N·m
26. Install the front axle hub nut LH.
(a) Install a new left hub nut.
Torque: 225 N·m
ALE040G Note:
Use a cord or other tools to avoid the brake caliper
suspending.
29. Check whether front axle swings and has clearance
(see page DT-2).
31. Install the front wheel brake caliper assembly LH.
32. Install the front wheel rotation speed sensor LH (see
page DT-15).
21
33. Tighten the front axle hub nut LH.

(a) Use a punch and hammer to lock the left hub nut.
Torque: 110 N·m
page SP-7).
ALE038G
Front axle hub bolt LH

Replacement
Hint:
Components: see page DT-16
2. Remove the front brake caliper assembly LH (see
page DT-17).
4. Remove the front axle hub bolt LH.
(a) Use the SST and screwdriver or similar tools to attach
the front axle hub subassembly LH and remove the
front axle hub bolt LH.
ALE048G
5. Install the front axle hub bolt LH.

(a) As shown in the figure, install the washer and nut on
Washer the new left hub bolt.
Nut (b) Use a screwdriver or similar tools to attach the front
axle hub subassembly LH and tighten the nuts to install
the left hub bolt.
7. Install the front brake caliper assembly LH (see
ALE049G page DT-19).
Torque: 110 N·m
DT-��
Rear axle hub and bearing subassembly LH

Components
Rear wheel speed sensor LH wire harness
Rear axle hub bolt LH
Rear axle hub and bearing

subassembly LH
Rear brake drum

: Specified torque
ALE050G
23
Replacement
1. Remove the rear wheel.
2. Remove the rear wheel brake drum.
3. Release the wheel speed sensor wire harness.
(a) Seperate the wheel speed sensor connector.
4. Remove the rear axle hub LH and bearing assembly.
(a) Remove the 4 bolts, rear axle hub LH and bearing as-
sembly.
ALE051G
5. Install the rear axle hub LH and bearing assembly.

(a) Install the rear axle hub LH and bearing assembly with
4 bolts.
Torque: 85 N·m
6. Connect the wheel speed sensor wire harness.
(a) Connect the wheel speed sensor connector.
Note:
Do not twist the sensor wire harness during the
connection.
ALE051G
7. Check whether the rear axle swings and has clear-
ance (see page DT-3).
8. Install the rear brake drum subassembly.
9. Install the rear wheel.
Torque: 110 N·m
Rear axle hub bolt LH

Replacement
Hint:
Components: see page DT-21
2. Remove the rear wheel brake drum.
3. Remove the rear axle hub bolt LH.
(a) Use the SST and screwdriver or similar tools to remove
the left hub bolt.
ALE052G
4. Install the rear axle hub bolt LH.

(a) As shown in the figure, install the washer and nut on
Washer the new rear hub bolt LH.
Nut
(b) Use a screwdriver or similar tools to attach the hub and
bearing assembly and tighten the nuts to install the rear
hub bolt LH.
5. Install the rear brake drum.
DT-��
Clutch
Clutch system installation precautions:
1. Coat grease on the clutch pedal and clutch master cylinder push rod clevis.
2. Tighten only as specified torque for tube connection.
(a) Master cylinder and rigid pipe: M10 16 ± 2 N·m
(b) Clutch rigid pipe and hose: M10 16 ± 2 N·m
3. While the clutch system is undergoing the exhausting process, make sure that all the air bub-
bles in the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should
be between MIN and MAX.
termine the cause of the problem. If necessary, check, repair, or replace the parts according to procedures

1. Engine mount (loose) -
2. Clutch driven disc assembly (excessive runout) DT-37
3. Clutch driven disc assembly (oil build-up) -
Clutch vibration 4. Clutch driven disc assembly (worn) DT-37
5. Clutch driven plate torsion damper (damaged) -
6. Clutch driven disc assembly (polished) DT-37
7. Diaphragm spring (the top end is not aligned) DT-39
1. Clutch pipeline (air entering) DT-41
Clutch pedal is spongy 2. Clutch master cylinder cup (damaged) -
3. Clutch slave cylinder cup (damaged) -
1. Clutch release bearing subassembly (worn and -
Clutch makes abnormal
torn, dirty, or damaged)
noises
2. Clutch driven plate torsion damper (damaged) -
1. Clutch pedal (free play out of alignment) DT-25
3. Clutch driven disc assembly (worn) DT-37
Clutch slips
4. Diaphragm spring (damaged) DT-39
5. Pressure plate (deformed) -
6. Flywheel subassembly (deformed) DT-38
1. Clutch pedal (free play out of alignment) DT-25
2. Clutch pipeline (air entering) DT-41
3. Clutch master cylinder cup (damaged) -
4. Clutch slave cylinder cup (damaged) -
5. Clutch driven disc assembly (installed incor- DT-38
rectly)
Insufficient clutch separation
6. Clutch driven disc assembly (excessive runout) DT-37
7. Clutch driven disc assembly (ruptured) -
8. Clutch driven disc assembly (dirty or burnt) -
10. Clutch driven disc assembly (lack of grease -
on the spline)
25
Clutch pedal subassembly

Components
Clutch master cylin-

der push rod
Clevis hole pin
Lock pin Clutch pedal bracket subassembly
Clutch pedal shaft
● Clutch pedal bush
Clutch switch
Clutch pedal spring
● Clutch pedal bush
● Clutch master cylinder push
rod clevis bush
Clutch pedal subassembly
: Specified torque Clutch pedal pad

MP grease
ALE054G
DT-��
Clutch switch Adjustment

1. Check and adjust the clutch pedal subassembly.
(a) Rotate the carpet.
Push rod play (b) Check that the pedal height is correct.
Pedal height above cowl panel:
127 to 134 mm
(c) Adjust the pedal height.
(1) Release nuts of clutch switch until correct height of
Push rod play and free Clutch
clutch pedal is obtained. Tighten the lock nut.
play adjusting point Pedal height
(d) Check that the clutch pedal free play and the push rod
play are correct.
(1) Depress the pedal until clutch resistance begins to
be felt.
Clutch pedal free play: 14 mm
(2) Gently depress the pedal until the resistance be-
gins to increase gradually.
Push rod play at pedal top:
1.0 to 5.0 mm
(e) Adjust the clutch pedal free play and the push rod play.
(1) Loosen the lock nut and turn the push rod until the
free play and the push rod play become correct.
(2) Tighten the lock nuts.
Torque: 12 N·m
(3) After adjusting the clutch pedal free play, check
the clutch pedal height.
Clutch pedal free play

ALE056G
(f) Check the clutch separation point.

(1) Pull the parking brake lever and install the wheel
stopper.
25 mm or more (2) Start up and run the engine at an idle speed.
Separation point (3) Without depressing the clutch pedal, slowly adjust
the shift lever into the reverse position until the
gears engage.
(4) Gradually depress the clutch pedal and measure
Pedal stroke the stroke distance from the point that the gear
end position ALE057G
noise stops (separation point) up to the full stroke
end position.
Standard distance: 25 mm or more
(From pedal stroke end position to separation
point)
If the distance is not as specified, perform the fol-
lowing operations:
• Check the clutch pedal height.
• Check the push rod play and the clutch pedal
free play.
• Bleed the clutch pipeline.
• Check the clutch cover assembly and the disc
assembly.
• Check the pedal stroke.
Clutch pedal stroke: 119.2 mm
27
Replacement
1. Remove the clutch pedal spring.
2. Remove the clutch master cylinder push rod clevis
hole pin.
(a) Remove the lock pin and hole pin.
ALE058G
3. Remove the clutch pedal bracket subassembly.

(a) Remove 2 nuts, bolts and the clutch pedal bracket sub-
assembly.
ALE059G
4. Remove the clutch pedal subassembly.

(a) Remove the clutch pedal shaft and nut.
(b) Remove the clutch spring.
(c) Remove the clutch pedal from the clutch pedal bracket.
ALE060G
5. Remove the clutch switch bolt.

(a) Loosen the lock nut and remove the clutch switch.
(b) Remove the lock nut from the clutch switch.
6. Remove the clutch pedal pad.
ALE061G
DT-��
7. Remove the clutch pedal bush.

(a) Remove 2 bushes from the clutch pedal.
MP grease
ALE062G

bush.
(a) Remove the clevis bush from the clutch pedal with 8
mm hexagon wrench and hammer.
ALE063G
9. Install the clutch master cylinder push rod clevis

bush.
(a) Coat MP grease in the exterior of the new clevis bush.
(b) Install the clevis bush on the clutch pedal.
Hint:
Install the clevis bush from the vehicle left side.
MP grease ALE064G
10. Install the clutch pedal bush.

(a) Coat MP grease on both sides of the 2 new bushes.
(b) Install 2 bushes onto the clutch pedal.
11. Install the clutch pedal pad.
MP grease
ALE062G
12. Install the clutch pedal subassembly.

(a) Install the clutch pedal spring.
(b) Install the clutch pedal on the clutch pedal bracket with
clutch pedal shaft and nut.
Torque: 30 N·m
Hint:
Install the clutch pedal shaft from the left side of the ve-
hicle.
ALE060G
29
13. Install the clutch switch.

(a) Install the lock nut on the clutch switch but do not tighten.
(b) Install the clutch switch bolt such that its end touches
the clutch pedal bush.
Hint:
Temporarily tighten the lock nuts.
ALE061G
14. Install the clutch pedal bracket subassembly.

(a) Install the clutch pedal bracket on the vehicle with 2
nuts and bolts.
Torque: 23 N·m
ALE059G

hole pin.
(a) Apply MP grease to the contact surface of the hole pin
and the clevis bush.
(b) Install the clevis bush on the clutch pedal with hole pin.
Hint:
Install the hole pin from the left side of the vehicle.
16. Check and adjust the clutch pedal subassembly
MP grease
17. Connect battery's negative cable.
DT-��
Clutch Master Cylinder Assembly

Components
Clutch reservoir tube

Clutch master cylin- Clutch pedal spring
der inlet union
● Clutch reservoir grommet Lock pin
Clutch master cylin-
der dust cover
Thrust plate
Slotted spring pin
Clamp
Push rod
Spring Piston Clutch master cylinder push rod
clevis hole pin
Master cylinder
: Specified torque
Grease
MP grease ALE066G
31
Overhaul
1. Remove the brake master cylinder subassembly
(see page BR-12).
2. Remove the ABS controller assembly (see page
BR-37).
3. Remove the vacuum booster assembly (see page
BR-17).
4. Remove the clutch pedal spring.
hole pin.
(a) Remove the lock pin and hole pin.
6. Drain the brake fluid.
ALE058G
7. Remove the clutch reservoir tube.

(a) Loosen the clamp and remove the clutch reservoir tube
from the clutch master cylinder assembly.
ALE067G
8. Disconnect the clutch hose connected with the

clutch master cylinder.
(a) Disconnect the clutch hose with SST.
Hint:
Catch the fluid with a container.
9. Remove the clutch master cylinder assembly.
(a) Remove 2 nuts and the clutch master cylinder assembly.
ALE068G
10. Remove the clutch master cylinder components.

(a) Use a pin punch and a hammer to tap out the slotted
spring pin.
(b) Remove the inlet union and grommet.
(c) Loosen the lock nut and remove the push rod clevis.
(d) Remove the lock nut from the push rod.
(e) Remove the dust cover from the cylinder body.
ALE069G
DT-��
(f) While pushing the push rod, remove the clamp with
clasp pliers.
(g) Remove the push rod from the cylinder.
Note:
The piston may pop out of the cylinder. Therefore,
slowly remove the push rod from the cylinder body.
(h) Remove the thrust plate from the push rod.
(i) Remove the piston with spring from the cylinder body.
ALE070G Note:
Be careful not to damage the inside of the cylinder
body.
11. Install the clutch master cylinder components.

(a) Coat the parts with grease as shown in the figure.
(b) Install the piston with spring into the master cylinder.
Note:
body.
(c) Install the thrust plate on the push rod.
(d) Install the push rod on the cylinder body.
ALE071G
(e) While pushing the push rod, install the clamp with clasp
pliers.
(f) Install the dust cover on the cylinder body.
(g) Install the lock nut on the push rod.
(h) Temporarily install the push rod clevis on the push rod
with lock nut.
(i) Install the inlet union and a new grommet.
ALE070G
(j) Use a pin punch and a hammer to drive in the slotted

Protruding part
1.5 to 3.5 mm spring pin.
12. Install the clutch master cylinder assembly.
(a) Install the clutch master cylinder assembly with 2 nuts.
Torque: 23 N·m
ALE072G
33
13. Connect the clutch hose with the clutch master cyl-
inder.
(a) Connect the clutch hose with SST.
Torque: 16 N·m
ALE068G
14. Install the clutch reservoir tube.

White mark (a) Install the clutch reservoir tube on the clutch master
cylinder assembly with clamp.
Caution:
• When connecting the clutch reservoir tube, take
care not to twist it.
• Face the white mark upward.
ALE073G

hole pin.
(a) Apply MP grease to the contact surface of the hole pin
and the clevis bush.
(b) Install the clevis on the clutch pedal with hole pin.
Hint:
Install the hole pin from the right side of the vehicle.
(c) Install the lock pin to the hole pin.
MP grease
ALE065G 16. Install the clutch pedal spring.
17. Install the vacuum booster assembly (see page
BR-18).
18. Install the ABS controller assembly (see page
BR-37).
19. Install the brake master cylinder subassembly (see
page BR-14).
20. Bleed the clutch pipeline.
(a) Fill the brake reservoir with brake fluid and bleed the
clutch system.
Torque: 8.4 N·m
21. Check for clutch fluid leakage.
22. Check the fluid level in the reservoir.
23. Check and adjust the clutch pedal subassembly
(see page DT-25).
DT-��
Clutch Release Cylinder Assembly

Components
Joint bolt
Clutch release union

● Gasket
● Gasket
Bleed screw cap
Release cylinder
bleed screw
● Spring Piston
Push rod
Slave cylinder body
: Specified torque
Dust cover
Grease
ALE074G
35
Overhaul
1. Disconnect the clutch hose from the clutch release
cylinder.
(a) Disconnect the clutch hose with SST.
Hint:
Catch the fluid with a container.
ALE075G
2. Remove the clutch release cylinder assembly.

(a) Remove 2 bolts and the clutch release cylinder assem-
bly.
3. Remove the clutch release union.
(a) Remove the union bolt.
(b) Remove the clutch release union and 2 gaskets.
4. Remove the clutch release cylinder components.
(a) Remove the dust cover from the cylinder body.
ALE076G (b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
Note:
body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleed screw cap from the bleed screw.
5. Remove the clutch release cylinder bleed screw.
6. Install the clutch release cylinder bleed screw.
7. Install the clutch release cylinder components.
(a) Install the bleed screw cap on the bleed screw.
(b) Install a new spring on the cylinder body.
(c) Coat the new piston with grease as shown in the figure.
(d) Install the piston on the cylinder body.
Note:
body.
(e) Install the push rod on the cylinder body.
(f) Install the dust cover on the cylinder body.
ALE077G
8. Install the clutch release union.

(a) Install the clutch release union with the union bolt and 2
new gaskets as shown in the figure.
Torque: 25 N·m
Note:
Installation angle of the clutch release union should
be 0°± 3° against the body.
ALE078G
DT-��
9. Install the clutch release cylinder assembly.

(a) Install the clutch release cylinder assembly with 2 blots.
Torque: 12 N·m
ALE076G
10. Connect the clutch hose with the clutch release cyl-
inder.
(a) Connect the clutch hose with SST.
Torque: 15 N·m
11. Bleed the clutch pipeline.
(a) Fill the brake reservoir with brake fluid and bleed the
clutch system.
Torque: 8.4 N·m
ALE075G 12. Check for clutch fluid leakage.
37
Clutch assembly
Components
Flywheel subassembly
Clutch driven disc assembly

Clutch cover assembly
Clutch release bearing

assembly
Release bearing
hub clamp spring
Clutch release fork

subassembly
Release fork
bracket
: Specified torque
Clutch spline grease

Clutch release fork dust cover
Release hub grease
ALE079G
DT-��
Overhaul
1. Remove the propeller axle assembly.
2. Remove the clutch release fork subassembly.
(a) Remove the clutch release fork from the propeller axle
assembly.
3. Remove the clutch release fork dust cover.
4. Remove the clutch release bearing assembly.
(a) Remove the clutch release bearing assembly from the
clutch release fork.
5. Release the release bearing hub clamp spring.
ALE080G 6. Remove the release fork bracket.
(a) Remove bracket and release the fork from the propeller
axle.
7. Remove the clutch cover assembly.
(a) Align the installation mark on the clutch cover assembly
to the corresponding installation mark on the flywheel
subassembly.
(b) Release every fixing bolt one circle every time until the
spring tension is released totally.
(c) Remove the fixing bolt and clutch cover assembly.
Note:
Installation mark ALE081G Do not let the clutch-driven disc fall off.
8. Remove the clutch-driven disc assembly.
9. Check the clutch-driven disc assembly.

(a) Use a vernier caliper to measure the depth of the rivet
head.
Maximum rivet depth: 0.3 mm
Replace the clutch-driven disc assembly if neces-
sary.
(b) Install the clutch-driven disc assembly onto the propel-
ler axle assembly.
ALE082G Note:
Do not install the clutch-driven disc assembly in
the wrong direction.
(c) Use a dial indicator to examine the runout of the clutch-

driven disc assembly.
Minimum runout: 0.8 mm
Replace the clutch-driven disc assembly if necessary.
Propeller
axle side
ALE083G
39
10. Check the clutch cover assembly.

(a) Use a vernier caliper to measure the wearing depth and
width of diaphragm spring.
Maximum value:
A (depth): 0.5 mm
B (width): 6.0 mm
Replace the clutch cover assembly if necessary.
ALE084G
11. Check the flywheel subassembly.

(a) Use a dial indicator to check whether the flywheel sub-
assembly has runout.
Maximum runout: 0.1 mm
Replace the flywheel subassembly if necessary.
ALE085G
12. Check the clutch release bearing assembly.

(a) When applying forces in an axial direction, rotate the
release bearing with hands.
Hint:
• This bearing is permanently lubricating. No cleaning
or lubricating is needed.
• Replace the release bearing assembly if necessary.
ALE086G
13. Install the clutch-driven disc assembly.

(a) Insert the SST into the clutch-driven disc assembly and
then insert them into the flywheel subassembly.
Caution:
Flywheel Caution: Do not install the clutch-driven disc as-
side sembly in the wrong direction.
ALE087G
DT-��
14. Install the clutch cover assembly.

Tem-
porary (a) Align the installation mark on the clutch cover assembly
to the corresponding installation mark on the flywheel
subassembly.
(b) As shown in the figure, tighten the six bolts from the
one near the top restrict pin.
Torque: 19 N·m
Hint:
Installation mark
ALE088G • Tighten the bolts gradually in the sequence shown
in the figure.
• After examining and confirming that the driven disc
is in the center, move the SST lightly to tighten the
bolts.
15. Check and adjust the clutch cover assembly.

(a) Use a dial indicator with a roller to measure the top
height gap of diaphragm spring.
Maximum gap: 0.5 mm
ALE089G
(b) If the gap is not in the specified range, adjust with the
SST.
16. Install the release fork bracket.
(a) Install the release fork bracket onto the propeller axle
assembly.
Torque: 37 N·m
17. Install the clutch release fork dust cover.
18. Install the release bearing hub clamp spring.
ALE090G
19. Install the clutch release fork subassembly.

(a) Coat release hub grease onto the contact surface of
the release fork and release the bearing assembly, con-
tact surface of release fork and push rod, and release
fork point.
(b) Install the release fork onto the release bearing assembly.
20. Install the clutch release bearing assembly.
(a) Coat clutch spline grease onto the input shaft slpine.
Release hub grease
ALE091G (b) Install the bearing on the release fork and then install
them onto the propeller axle assembly.
Note:
After the installation, move the release fork back
and forth to examine and confirm whether the
clutch release bearing slides smoothly.
21. Install the propeller axle assembly.
41
Clutch start switch assembly

Vehicle check
1. Check the clutch start system.
(a) Check that the engine does not start when the clutch
pedal is released.
(b) Check that the engine starts when the clutch pedal is
fully depressed.
If necessary, replace the clutch start switch assembly.
Inspection
1. Check the clutch start switch assembly.
(a) Check the continuity between the terminals when the
switch is ON and OFF.
Switch position Condition
ON (Pressed) Conducting
OFF (Free) Not conducting
ALE092G
Replacement
1. Remove the clutch start switch assembly.
(a) Disconnect the clutch start switch assembly connector.
(b) Loosen the lock nut and remove the clutch start switch.
(c) Remove the lock nut from the clutch start switch.
2. Install the clutch start switch assembly.
(a) Install the clutch start switch assembly with the nut.
Torque: 6.2 N·m
ALE093G (b) Connect the clutch start switch assembly connector.
3. Check the clutch start switch assembly (see page
DT-40).
DT-��
Clutch Hydraulic Pressure System Bleeding

Hint:
After repairing the clutch hydraulic pressure operation sys-
tem, air may enter into the pipelines and also the hydraulic
pressure system while adding brake fluid.After completion,
due to the shortening of the master cylinder push rod stroke
that is the pedal operation stroke make sure that the clutch
does not disengage.
1. Fill the reservoir with brake fluid.
Brake fluid: DOT4 synthetic brake fluid
Hint:
The brake fluid level in the reservoir needs to be be-
tween the MIN and MAX levels.
ALE094G
2. Hoist the vehicle.

(a) Raise the vehicle up to the appropriate level with a lift.
ALE095G
3. Bleed the clutch hydraulic pressure system.

(a) Connect the plastic pipe to the bleed screw.
(b) Press the clutch pedal several times and then loosen
the bleed screw in the process.
(c) When the brake fluid stops flowing, tighten the bleed
screw and then loosen the clutch pedal.
(d) Repeat steps (b) and (c) until all the air in the brake
fluid is released.
ALE096G Hint:
When performing air bleeding, it will need to be carried
out by two people.
4. After bleeding the air completely, check and adjust
the pedal free play again and add brake fluid.
SP-�

Suspension

Malfunction Indicator Table........................................... SP-2
Components.................................................................... SP-3
Front Wheel Alignment................................................... SP-7
Front Shock Absorber with Coil Spring Assembly...... SP-10
Steering Knuckle ........................................................... SP-14
Front Suspension Lower Swing Arm LH ..................... SP-17
Front Stabilizer Bar......................................................... SP-20

Malfunction Indicator Table........................................... SP-24
Rear Wheel Alignment.................................................... SP-24
Components.................................................................... SP-25
Rear Shock Absorber Assembly LH.............................. SP-26
Rear Coil Spring LH........................................................ SP-28
Rear Twist Beam Assembly........................................... SP-31 SP
Tires and Wheels
Tires................................................................................. SP-35
Wheels............................................................................. SP-40
SP-�

1. Tires (worn or improper inflation) SP-35
2. Wheel alignment (incorrect) SP-7
3. Steering propeller mechanism (loose or -
Deviation worn)
5. Steering (out of alignment or damaged) SR-12
6. Suspension parts (worn) -
1. Vehicle (overload) -
Drooping 2. Spring (fatigue) SP-10
3. Shock absorber (worn) SP-10
2. Stabilizer bar (bent or broken) SP-20
Tilting
3. Spring (fatigue) SP-10
2. Wheel (out of balance) SP-35
Front wheel shimmy 5. Ball stud (worn) SP-17
7. Steering propeller mechanism (loose or -
worn)
8. Steering (out of alignment or damaged) SR-12
Tire's abnormal wear
Suspension SP-�

Components
Front wiper arm bolt cover
Front wiper arm

assembly RH Expansion button
Front wiper arm assembly LH

Expansion button
Right vent panel body
Left vent panel body
Vent panel weatherstripping
Wiper rod motor assembly

Hose
Cowl top outer panel
W/H
(Wiper)
: Specified torque
ALF001G
SP-�
Dust cover on the

front shock absorber
Press plate on the front

shock absorber pillar
Mounting seat on the front
shock absorber pillar
Gasket
Mounting seat on the

front coil spring
Dust cover
Front Shock Absorber with Front bumper

Coil Spring Assembly
Front coil spring LH
Wheel speed sensor Brake hose

wire harness Front shock absorber
assembly LH
: Specified torque
Disposable parts ALF002G
Suspension SP-�

LH: Front stabilizer bar
Washer
Bush
Front Suspension Lower

Washer Swing Arm LH
Bush
Washer Washer
Bush
Lock pin
Washer
Bush
Washer
: Specified torque
SP-�
Engine Hood
Washer
Bush
Front stabilizer bar mounting bracket RH
Front stabilizer
bar bushing
Front stabilizer bar mounting bracket LH
Front stabilizer Front stabilizer bar bushing
Steering combination pipe bar
Washer
Bush
Bush
Washer
Front stabilizer
hanger rod Bush
Washer Power steering Washer
Bush gear
hanger rod
Washer
Bush
Lock pin
Lock pin
Subframe strut bar RH
Washer
Bush
Washer
Bush
Washer
Subframe strut bar LH
: Specified torque
Suspension SP-�

Front Wheel Alignment

Adjustment
1. Check the tires (see page SP-35).
2. Measure the vehicle height.
Vehicle height
A - B mm D - C mm
82 12
Measuring point:
A: Front wheel central ground clearance
B: Front suspension lower swing arm front bolt central
ground clearance
ALF005G C: Rear twist beam mounting bolt central ground clear-
ance
D: Rear wheel central ground clearance
Note:
Adjust the vehicle height to specified value before
inspecting vehicle location.
Hint:
Bounce the corners of the vehicle up and down to steady
suspension and inspect the height of the vehicle.
3. Inspect toe-in.
Toe-in:
Front A + B: -0o04' ± 10' (1mm±4mm)
Toe-in (total)
C - D: 0 ± 2 mm
If the toe-in is not in the specified range, adjust it at the
joint of the gear racks.
4. Adjust toe-in.
Note:
ALF006G
Adjust the camber before inspecting the toe-in.
(a) Remove the dust cover of the gear rack to fasten the
clamp.
(b) Loosen the lock nut at the joint of the tie rod.
(c) Turn the joint of the left and right gear racks in equal
amounts to adjust the toe-in.
Hint:
Adjust the toe-in to intermediate value within the speci-
fied range.
ALF007G
(d) Make sure the length of the joints of the left and right
gear racks is the same.
Length difference of the joint of the gear rack: 1.5 mm
or less
(e) Fasten the lock nut at the joint of the tie rod.
Torque: 74 N·m
(f) Place the dust cover on the base and install the clamp.
Hint:
ALF008G Make sure the dust cover is not twisted.
SP-�
5. Inspect the wheel angle.

(a) Turn the steering wheel to the end and measure the
angle.
Front Wheel angle
Inner side of the wheel Outer side of the wheel:
o o
32 - 37 28o - 33o
A: Inner side If the angle of the inner sides of the left and right
B: Outer side
wheels is not in conformity with the specified value,
inspect the length of the joints of the left and right gear
ALF009G
racks.
6. Inspect the front wheel camber, front wheel kingpin

caster, and front wheel kingpin angle.
Front wheel camber, front wheel kingpin caster, and
Meter
front wheel kingpin angle:
Front wheel camber -0o29' ± 30'
Location scanner Left - right error 30' (0.5o) or less
Front wheel king- 2o08' ± 45'
pin caster Left - right error 36' (0.56o) or less
ALF010G Front wheel king- 9o49' ± 30'
pin angle Left - right error 30' (0.5o) or less
If the front wheel kingpin caster and the front wheel
kingpin angle are not in the scope of the specified value,
adjust the camber first and then inspect again whether
the suspension parts are damaged and/or worn.
7. Adjust the camber.
(a) Remove the front wheel.
(b) Remove the 2 nuts under the stock absorber.
(c) Clean the mounting surface and steering knuckle of the
shock absorber.
ALF011G
(d) Temporarily install 2 nuts.

(e) Push/pull the underside of the shock absorber to adjust
the camber along the direction it requires.
(f) Tighten the nuts.
Torque: 132 N·m
(g) Install the front wheel.
Torque: 110 N·m
(h) Inspect the camber.
Hint:
: using adjusting bolts ● ��
Adjust the camber to the middle of the specified
ALF012G
value.
● The range to adjust the mounting bolt is form 6' to
30' (0.1° to 0.5°). If the camber is not in the scope of
the specified value, evaluate the value needs to be
adjusted, and select the camber adjusting bolts using
the following table.
Note:
Fasten the adjusting bolts using washers and new
nuts.
Suspension SP-�

Mounting bolt Adjusting bolt

Bolt 90105-14140 90105-14146 90105-14147
1 points 2 points
Ad-
just-
ment ALF013G ALF014G ALF015G
value 1 2 1 2 1 2
15' ● ●
30' ● ●
45' ● ●
o
1 00' ● ●
(i) Repeat the above steps. In step (b), replace 1 or 2 se-
lected bolts.
Hint:
When replacing 2 bolts, replace one by one.
SP-��
Front Shock Absorber with Coil Spring

Assembly
Overhaul
Hint:
Components: see page SP-3 and SP-4 .
1. Remove the front wiper arm bolt cover.
2. Remove the front wiper arm assembly LH.
3. Remove the front wiper arm assembly RH.
4. Remove the vent panel weatherstripping (see page
ET-5).
5. Remove the left vent panel body (see page ET-6).
6. Remove the right vent panel body (see page ET-6).
7. Remove the wiper rod motor assembly (see page
ET-6).
8. Remove the cowl top outer panel.
(a) Disconnect the hose and wire harness (wiper).
(b) Remove the cowl top outer panel with 8 bolts.
10. Disconnect the brake hose.
(a) Remove the bolt and disconnect the brake hose and
the speed sensor wire harness clamp from the shock
absorber bracket.
ALF016G
11. Remove the front shock absorber with coil spring

assembly.
(a) Remove 2 nuts and the bolts and disconnect the shock
absorber from the steering knuckle.
ALF011G
(b) Remove 3 nuts and the shock absorber with coil spring.
(c) Remove the press plate on the front shock absorber
pillar.
ALF017G
Suspension SP-��
11
12. Secure the front shock absorber with coil spring

assembly.
(a) Install 2 nuts and bolts on the bracket at the lower side
of the shock absorber and secure it in a vice.
(b) Compress the coil spring with SST.
Note:
Do not use an impact wrench. It will damage the
SST.
ALF018G 13. Remove the dust cover of the front shock absorber.
(a) Remove the dust cover from the front shock absorber
pillar upper mounting seat.
14. Remove the center nut.

(a) Use the 2 nuts and a screwdriver or similar tools to se-
cure the front shock absorber and remove the center
nut.
Note:
Be careful not to damage the front shock absorber
pillar upper mounting seat stud bolts.
15. Remove the mounting seat on the front shock ab-
ALF019G
sorber pillar.
16. Remove the grommet.
17. Remove the mounting seat on the front coil spring.
18. Remove the dust cover.
19. Remove the front coil spring LH.
20. Remove the front bumper.
21. Remove the front shock absorber assembly LH.
22. Inspect the front shock absorber assembly LH.
(a) Contract and expand the shock absorber bar. Inspect
and make sure there are no abnormal resistance or
noise during the operation.
If anything is abnormal, use a new shock absorber in-
stead.
ALF020G Note:
When discarding the shock absorber, see the "Dis-
posal" section onpage SP-13.
23. Install the front shock absorber assembly LH.
24. Install the front bumper.
25. Install the front coil spring LH.
(a) Compress the coil spring with SST.
Note:
Do not use an impact wrench. It will damage the
SST.
ALF021G
SP-��
(b) Install the coil spring on the shock absorber.

Hint:
Install the lower end of the coil spring to the clearance
of the lower seat of the spring.
Outside
ALF022G
26. Install the dust cover.

(a) Install the dust cover with the “△” mark facing the out-
side of the vehicle.
27. Install the mounting seat on the front coil spring.
(a) Install the coil spring upper mounting seat with the
“OUT” mark facing the outside of the vehicle.
28. Install the grommet.
29. Install the mounting seat on the front shock ab-
sorber pillar.
30. Install the center nut.
(a) Use the 2 nuts and a screwdriver or similar tools to se-
cure the front shock absorber and install the center nut.
Torque: 33 N·m
Note:
Be careful not to damage the front shock absorber
pillar upper mounting seat stud bolts.
(b) Remove the SST.
ALF023G
(c) Apply grease on the front shock absorber pillar upper

MP grease
mounting seat.
ALF024G 31. Install the dust cover of the front shock absorber.
32. Install the front shock absorber with coil spring as-
sembly.
(a) Install the press plate on the front shock absorber pillar.
(b) Use 3 nuts to install the shock absorber with coil spring.
Torque: 40 N·m
(c) Connect the shock absorber with the steering knuckle.
(d) Install 2 bolts and nuts.
Note:
When installing the bolt, keep it from rotating and
tighten the nut.
Torque: 132 N·m
13
33. Install the brake hose.

(a) Attach the brake hose and the speed sensor wire har-
ness clamp on the shock absorber bracket with the
bolt.
Torque: 29 N·m
Torque: 110 N·m
35. Install the cowl top outer panel.
(a) Install the cowl top outer panel with 8 bolts.
Torque: 5.0 N·m
(b) Connect the hose and wire harness (wiper).
36. Install the wiper rod motor assembly (see page
ET-5).
37. Install the right vent panel body.
38. Install the left vent panel body.
39. Install the vent panel weatherstripping.
40. Install the front left wiper arm and blade assembly.
41. Install the front right wiper arm and blade assem-
bly.
42. Install the windshield wiper arm bolt cover.
page SP-7).
Disposal
Hint:
Disposal on the right side is the same as it is on the left side.
1. Discard the front shock absorber assembly LH.
(a) Fully expand the shock absorber bar.
(b) As shown in the figure, drill a hole between A and B on
the cylinder with the drill to drain the gas in the cylinder.
Note:
• Be careful when drilling for the metal fragments
may spray, so make sure to use proper safety
equipment.
ALF025G • The gas is free of color, odor, or toxicity.
SP-��
Steering Knuckle
Removal
Hint:
The procedures for removing at the right side are the same
with the left side.
1. Remove front wheel LH (see page SP-41).
2. Remove the front axle hub nut LH.
(a) Pry off the protruding parts of the front axle hub nut LH
with the SST and a hammer.
Note:
Loosen the locked parts of the nut completely or
the thread of the propeller shaft will be damaged.
(b) When using brake, remove the front axle hub nut LH.
ALF026G
3. Separate the front wheel rotation speed sensor LH

and the brake hose.
(a) Remove the bolt and separate the wheel speed sensor
of the front wheel LH from the steering knuckle.
Note:
• Avoid any contamination to the wheel speed sensor.
ALF027G
(b) Remove the brake hose.

Note:
When removing the brake hose, the brake fluid will
flow out and will need to be stored in a container.
Be aware of personal protection, because the brake
fluid is corrosive.
Brake hose
Wheel speed sensor
ALF028G

(a) Remove 2 bolts and remove the front brake caliper as-
sembly LH from the steering knuckle.
ALF029G
15
5. Release the front stabilizer bar.

(a) Use a wrench (10 mm) to fasten the bolt and remove
the nut.
(b) Remove 2 washers, 2 bushings, and release the front
stabilizer bar.
ALF030G
6. Release the front suspension lower swing arm LH.

(b) Use the SST to separate the front suspension lower
swing arm from the steering knuckle.
ALF031G
7. Release the steering tie rod ball assembly LH.

(b) Use the SST to remove the steering tie rod ball assem-
bly LH from the steering knuckle.
ALF032G
8. Release the front shock absorber assembly LH.

(a) Remove 2 bolts and 2 nuts and release the front shock
absorber assembly LH from the steering knuckle as-
sembly.
9. Remove the front axle left propeller shaft assembly.
(a) Use a plastic hammer to remove the front axle drive
shaft assembly LH from the front axle hub assembly LH.
Note:
ALF033G • Do not damage the dust cover.
• Do not damage the rotor of the wheel speed sensor.
10. Remove the front axle hub hole clasp LH (see page
DT-17).
(a) Use the clasp pliers to remove the front axle hub hole
clasp LH.
11. Remove the front axle hub subassembly LH (see
page DT-17).
SP-��
12. Remove the left steering knuckle.

(a) Remove 3 bolts and the left steering knuckle.
Left steering knuckle
ALF034G
Installation
Hint:
The installation sequence is the reverse of the removal se-
quence.
17
Front Suspension Lower Swing Arm LH

Replacement
Hint:
• Components: see page SP-5
• Remove the front suspension lower swing arm RH in the
same steps as removing the LH.
1. Remove front wheel (see page SP-41).
(see page SP-15)
3. Release the front stabilizer bar (see page DT-15)
4. Remove the front suspension lower swing arm LH.

(a) Remove 2 bolts, the nuts, and the front suspension
lower swing arm.
Note:
Do not rotate the nut.
ALF035G
5. Check the front suspension lower swing arm LH.

(a) As shown in the figure, move the ball stud back and
forth 5 times in front of the mounting nut.
(b) Use a torque wrench to continuously rotate the nut at a
speed of 2 to 4 seconds per round and read the torque
reading during the fifth round.
Torque:
5.0 N·m or less
ALF036G (c) Check to see if the ball stud is damaged.
(d) Check to see if the ball stud dust cover is damaged and
replace it if necessary.
Note:
Do not take apart the lower swing arm weld assem-
bly and the lower swing arm ball stud. If the rota-
tion is not flexible and the ball stud is damaged,
you must replace the entire lower swing arm with
ball stud assembly.
6. Replace the ball stud dust cover.
(a) Rotate it with the SST and remove the clasp of the dust
cover of the ball stud.
(b) Replace the dust cover of the ball stud and the same
SST can be used to install the clasp.
ALF037G
SP-��
7. Inspect the lower swing arm's large and small shaft

sleeve.
(a) Clean the large and small shaft sleeve of the lower
swing arm with water and inspect for damage, wear,
cracks, and similar flaws and replace it if necessary.
ALF038G
8. Replace the lower swing arm's large shaft sleeve.

(a) Before removing, mark two lines on the lower swing
arm according to the shaft sleeve location, so as to re-
fer to the proper location during installation.
ALF039G
(b) On the press, press out the lower swing arm's large
shaft sleeve with SST, and replace it with a new one.
(c) Check that the lower swing arm's large shaft sleeve's
mounting hole dimensions are Ф55-0.2
-0.3 . If the result of
the measurement is not in conformity with the recom-

mended value, replace the lower swing arm's weld
assembly.
ALF040G
(d) Align to the marks before installing

Mark the same position on the new lower swing arm's
large shaft sleeve, so as to correspond to the mark on
the lower swing arm, and thus ensure proper angle
alignment.
ALF041G
(e) On the press, use SST to press the new lower swing
arm's large shaft sleeve into the correct position.
ALF042G
19
9. Replace the lower swing arm's small shaft sleeve.

(a) Use a sander to smooth level the rubber flange on the
Sanding spots
lower swing arm's small shaft sleeve.
Note:
When using the sander, be very careful not to dam-
age the lower swing arm.
Sanding spots
ALF043G
(b) On the press, press out the lower swing arm's small
shaft sleeve with SST, and replace it with a new one.
(c) Check that the lower swing arm's small shaft sleeve's
mounting hole dimensions are Ф31+0.05 0 . If the result of
the measurement is not in conformity with the recom-
mended value, replace the lower swing arm's weld as-
sembly.
ALF044G
(d) On the press, use SST to press the new lower swing
arm's small shaft sleeve into the correct position.
ALF045G
10. Temporarily fasten the front suspension lower

swing arm LH.
(a) Use 2 bolts and nuts to temporarily fasten the front sus-
pension lower swing arm LH.
11. Connect the front suspension lower swing arm LH
(see page DT-14).
12. Connect the front stabilizer bar (see page DT-23)
ALF035G Torque: 110 N·m
14. Fully fasten the front suspension lower swing arm

LH.
(a) Use 2 bolts to install the suspension lower arm.
Torque:
Bolt A: 180 N·m
Bolt B: 120 N·m
Note:
ALF046G 15. Check and adjust the front wheel alignment (see
page SP-7)
SP-��

Replacement
Hint:
Components: see page SP-6
2. Remove the engine hood.
3. Suspend the engine assembly (see page EG-14).
(see page SP-15).
5. Release the front suspension lower swing arm RH.
Hint:
The procedures to release on the right side are the
same as the left side.
6. Release the front stabilizer bar.
(a) While holding the front stabilizer bar hanger rod with
the spanner, remove the nut.
(b) Remove the 2 washers and bushes, and then remove
the front stabilizer bar hanger rod.
(c) Perform the procedure above on the other side.
ALF047G
7. Separate the power steering gear.

(a) Remove 4 bolts and 4 nuts, separate the power steer-
ing gear.
Hint:
Suspend the power steering gear.
ALF048G
8. Separate the steering combination tube.

(a) Remove the bolt and separate the steering combination
tube.
9. Remove the subframe strut bar LH.
(a) Remove the 2 bolts and the subframe strut bar LH.
10. Remove the subframe strut bar RH.
(a) Remove the 2 bolts and the subframe strut bar RH.
ALF049G
21
11. Seperate the subframe subassembly.

(a) Remove the bolt and 2 nuts.
ALF050G
(b) Support the subframe subassembly with the jack.

(c) Remove 4 bolts and separate the subframe subassembly.
ALF051G
12. Remove the front stabilizer bar.

(a) Remove 4 bolts, the mounting brackets at the right and
left side of the front stabilizer bar, and 2 bushings.
(b) Remove the front stabilizer bar.
ALF052G
13. Install the front stabilizer bar.

(a) Install the stabilizer bar, the 2 bushings, and the mount-
ing brackets with 4 bolts.
Torque: 37 N·m
Note:
Install the bushings with the slit facing the rear side
Paint line of the vehicle.
Hint:
ALF053G Install the bushings on the outside of each paint line.
SP-��
14. Connect the subframe subassembly.

(a) Align the holes of the subframe and vehicle body.
(b) Perform the procedure above on the other side.
ALF054G
(c) Install the subframe subassembly with 4 bolts.

Torque:
Bolt A: 120 N·m
Bolt B: 145 N·m
ALF055G
(d) Install the bolt and 2 nuts.

Torque: 78 N·m
ALF050G
15. Install the subframe strut bar LH.

(a) Install the subframe strut bar LH with 2 bolts.
Torque: 49 N·m
16. Install the subframe strut bar RH.
(a) Install the subframe strut bar RH with 2 bolts.
Torque: 49 N·m
17. Connect the steering combination tube.
(a) Connect the steering combination tube with bolts.
Torque: 7.8 N·m
ALF049G
23
18. Connect the power steering gear.

(a) Install the power steering gear with 4 bolts and 4 nuts.
Torque: 107 N·m
Note:
ALF048G
19. Connect the front stabilizer bar.

(a) Install 2 washers and bushings.
(b) While holding the front stabilizer bar hanger rod with
the spanner, install the nut.
Torque: 16 N·m
Hint:
Support the lower swing arm with the jack.
(c) Perform the procedure above on the other side.
ALF047G 20. Connect the front suspension lower swing arm LH
(see page DT-14).
21. Connect the front suspension lower swing arm RH.
Hint:
The procedures to connect on the right side are the
Torque: 110 N·m
23. Install the engine hood.
24. Check the engine hood (see page BO-2).
25. Adjust the engine hood (see page BO-2).
page SP-7).
SP-��

Deviation
1. Vehicle (overload) -
Drooping 2. Spring (fatigue) SP-28
Tilting
2. Wheel (out of balance) SP-40
Rear wheel shimmy
Rear Wheel Alignment

Inspection
1. Check the tires (see page SP-35).
2. Measure the vehicle height (see page SP-7).
Note:
Adjust the vehicle height to specified value before
inspecting vehicle location.
3. Inspect the rear wheel toe-in.
Rear wheel toe-in:
Front A + B: 0°10' ± 15' (4 mm ± 5 mm)
Toe-in (total)
C - D: 3.2 ± 3.0 mm
If the toe-in is not in the scope of the recommended
value, inspect it and replace the suspension parts when
necessary.
4. Inspect the camber.
(a) Install the front wheel alignment scanner or place the
ALF006G
vehicle on the wheel alignment scanner.
(b) Inspect the camber.
Camber:
Camber -0°43' ± 30'
Left/right error 30' or less
If the result of the measurement is not in the specified
range, inspect whether the suspension parts are dam-
aged and/or worn. As the camber is not adjustable, re-
place the part if necessary.
25
Components
Washer
Rear shock absorber upper mounting bushing No.1
Rear shock absorber upper mounting bushing No.2
Upper mounting rubber cush- Bush bracket

ion for the rear coil spring Rear bumper
Rear coil spring RH Rear shock ab-
sorber assembly Rear shock ab- Upper mounting rubber cushion
RH for the rear coil spring
sorber Dust cover
Lower mounting rubber cush-
ion for the rear coil spring
Rear shock
absorber as-
Rear brake drum subassembly sembly LH
Rear Coil Spring LH
Brake Lower mounting rubber cush-

Hose ion for the rear coil spring
Clip
Rear axle hub and bear-

Brake hose
ing subassembly RH
Washer
Rear brake assembly
Rear brake drum

Rear axle brackets
Washer subassembly
and bushings RH
Rear axle brackets and bushings LH
Rear twist beam
Wheel speed sensor wire

harness Clip
Rear axle hub and bearing subassembly LH
: Specified torque
SP-��
Rear shock absorber assembly LH

Replacement
Hint:
1. Remove the rear shock absorber cap.
3. Remove the rear shock absorber assembly LH.
(a) Support the rear twist beam with a jack.
ALF057G
(b) While holding the piston rod, remove the 2 nuts.

(c) Remove the washer and the rear shock absorber upper
mounting bushing No.1 and No.2.
ALF058G
(d) Remove the nut, washer and the rear shock absorber
assembly LH.
(e) Remove the rear bumper and the rear shock absorber
dust cover.
ALF059G
4. Inspect the rear shock absorber assembly LH.

(a) Contract and expand the shock absorber bar. Inspect
and make sure there are no abnormal resistance or
noise during the operation.
If anything is abnormal, use a new shock absorber in-
stead.
Note:
When discarding the shock absorber, see the "Dis-
ALF060G posal" section onpage SP-27.
27
5. Install the rear shock absorber assembly LH.

(a) Install the rear bumper and the rear shock absorber
dust cover.
(b) Install the shock absorber, the rear shock absorber up-
per mounting bushing No.1 and No.2, and the washer
on the body.
(c) While holding the piston rod, install the lower nut so
that the piston rod protrudes 15 to 18 mm from the low-
er nut.
(d) Install the upper nut and tighten it against the lower
one.
Torque: 35 N·m
ALF061G
(e) While lifting the rear twist beam with the jack, install the
shock absorber on the rear twist beam with the washer
and the nut.
Torque: 120 N·m
ALF059G

Torque: 110 N·m
7. Check the rear wheel alignment (see page SP-24).
Disposal
1. Discard the rear shock absorber assembly LH.
(a) Fully expand the shock absorber bar.
(b) Drill a hole on the cylinder with a drill to drain the gas in
the cylinder as shown in the figure.
Note:
• Be careful when drilling for the metal fragments
may spray, so make sure to use proper safety
equipment.
ALF062G • The gas is free of color, odor, or toxicity.
SP-��
Rear Coil Spring LH

Replacement
Hint:
2. Release the wheel speed sensor wire harness.
(a) Disconnect the wheel speed sensor's connector.
(b) Remove the bolt and release the wheel speed sensor
wire harness from the rear twist beam.
Hint:
The procedures to release on the right side are the
ALF063G
3. Separate the rear brake tube No.4.

(a) Separate the rear brake tube No.4 with SST.
(b) Remove the clip.
Note:
The clip cannot be reused.
Hint:
The disconnection of the rear brake tube No.3 is the
ALF064G same as that of the rear brake tube No.4.
5. Release the left parking brake cable assembly.

(a) Remove the nut and disconnect the parking brake ca-
ble assembly LH from the rear twist beam.
6. Release the right parking brake cable assembly.
Hint:
The procedures for releasing the right parking brake
cable assembly are the same with the left.
ALF065G
7. Loosen the rear twist beam assembly.

(a) Loosen the 2 bolts.
ALF066G
29
8. Release the rear shock absorber assembly LH.

(a) Raise the left and right sides of the rear twist beam with
a jack.
(b) Remove the nut and washer and release the rear shock
absorber assembly LH.
9. Release the rear shock absorber assembly RH.
Hint:
The procedures for removing at the right side are the
ALF059G same with the left side.
10. Remove the rear coil spring LH.
(a) Remove the coil spring LH, the upper insulator, and the
lower insulator by slowly lowering the jack.
11. Install the rear coil spring LH.

(a) Install the rear coil spring upper insulator so that its gap
fits onto the end of the rear coil spring LH.
ALF067G
(b) Install the rear coil spring lower insulator and the rear
coil spring LH on the rear twist beam.
Note:
Be sure to install the coil spring so that the paint
mark comes to just under the vehicle.
Paint mark
ALF068G
12. Temporarily tighten the rear shock absorber as-

sembly LH.
(a) While lifting the jack, install the rear shock absorber as-
sembly LH on the rear twist beam.
(b) Temporarily tighten the nut and washer.
sembly RH.
Hint:
ALF059G The procedures to connect on the right side are the
SP-��
14. Connect the left parking brake cable assembly.

(a) Install the parking brake cable assembly LH with the
nut.
Torque: 5.4 N·m
15. Connect the right parking brake cable assembly.
Hint:
ALF065G
16. Connect the rear brake tube No.4.

(a) Connect the brake pipeline to the brake hose with SST.
Torque: 16 N·m
(b) Install the clip.
Hint:
The connection of the rear brake tube No.3 is the same
as that of the rear brake tube No.4.
ALF064G
18. Connect the wheel speed sensor wire harness.

(a) Install the wheel speed sensor wire harness with bolt.
Torque: 8.0 N·m
(b) Connect the wheel speed sensor wire harness.
Hint:
ALF063G
19. Fully tighten the rear twist beam assembly.

(a) Stabilize the shock absorber assembly.
If the bolt cannot be tightened at this position, support
the rear twist beam with the jack and load the rear com-
partment with a mass of approximately 90 kg.
Length of the shock absorber: 250 mm
(b) Fully tighten the bolt.
Torque: 80 N·m
ALF069G 20. Fully tighten the rear shock absorber assembly LH.
(a) Fully tighten the nut.
Torque: 120 N·m
21. Fully tighten the rear shock absorber assembly RH.
Hint:
The procedures for installing at the right side are the
same with the left side.
22. Bleed the brake pipeline (see page BR-5).
Torque: 110 N·m
24. Check the rear wheel alignment (see page SP-24)
25. Check the signal of ABS speed sensor.
31
Rear twist beam assembly

Replacement
Hint:
Components:see page SP-25
2. Release the wheel speed sensor wire harness (see
page SP-28)
3. Separate the rear brake tube No.4 (see page SP-28)
Hint:
The disconnection of the rear brake tube No.3 is the
same as that of the rear brake tube No.4.
5. Separate parking brake cable assembly LH (see
page SP-29)
6. Release the right parking brake cable assembly.
Hint:
7. Remove the rear brake drum subassembly.
8. Remove the rear axle hub LH and bearing assem-
bly.
(a) Remove the nut and disconnect the parking brake ca-
ble assembly LH from the rear twist beam.
ALF065G
(b) Remove the 4 bolts, rear axle hub LH and bearing as-
sembly.
(c) Disconnect the rear brake assembly from the rear twist
beam.
9. Remove the rear axle hub RH and bearing assem-

bly.
ALF070G Hint:
10. Loosen the rear twist beam assembly.
11. Release the rear shock absorber assembly LH (see
page SP-29)
12. Release the rear shock absorber assembly RH.
Hint:
13. Remove the rear coil spring LH (see page SP-29)
SP-��
14. Remove the rear coil spring RH.

Hint:
15. Remove the rear twist beam assembly.
(b) Remove 2 bolts and the rear twist beam.
ALF066G
16. Remove the rear axle brackets and bushings LH

(a) Bend the 2 portions of the bushing rib with chisel and
hammer.
Hint:
Bend the bushing rib until the claw of SST can be hung.
(b) Remove the bushing from the rear twist beam with
Bend SST.
Portions
Note:
ALF071G If the rear twist beam has been scratched, apply the
paint.
17. Remove the rear axle brackets and bushings RH.
Hint:
18. Install the rear axle brackets and bushings LH.
(a) Position the rear axle bracket bushing LH with the rear
twist beam as shown in the figure.
Front
ALF072G
(b) Install the bushing on the rear twist beam with SST.
Rubber Note:
Portions • Hang the claw of SST to the bushing deeply and
firmly.
• Do not scratch the rubber portion of the bush-
ing.
• Do not deform the bushing rib.
ALF073G
33
19. Install the rear axle brackets and bushings RH.

Hint:
20. Temporarily tighten the rear twist beam assembly.
(b) Install the rear twist beam, and temporarily tighten the
2 bolts.
21. Install the rear coil spring LH (see page SP-29)
22. Install the rear coil spring RH.
Hint:
ALF066G same with the left side.
sembly LH.
sembly RH.
Hint:
25. Install the rear axle hub LH and bearing assembly.
(a) Install the rear brake assembly, rear axle hub LH and
bearing assembly with 4 bolts.
Torque: 50 N·m
26. Install the rear axle hub RH and bearing assembly.
Hint:
ALF070G 27. Install the rear brake drum subassembly.
28. Adjust rear drum brake shoe clearance (see page
BR-32).
29. Connect the left parking brake cable assembly (see
page BR-48).
30. Connect the right parking brake cable assembly.
Hint:
The procedures for connecting the right parking brake
cable assembly are the same with the left.
31. Connect the rear brake tube No.4 (see page SP-30)
Hint:
The connection of the rear brake tube No.3 is the same
as that of the rear brake tube No.4.
33. Connect the wheel speed sensor wire harness (see
page SP-30)
34. Fully tighten the rear twist beam assembly.
Torque: 80 N·m
35. Fully tighten the rear shock absorber assembly LH
(see page SP-30)
SP-��
36. Fully tighten the rear shock absorber assembly RH.

Hint:
The procedures to tighten on the right side are the
37. Bleed the brake pipeline (see page BR-5).
Torque: 110 N·m
39. Check the rear wheel alignment (see page SP-24)
40. Check the signal of ABS speed sensor.
35
Tires and Wheels

Tires
Explanation
This vehicle uses tubeless tires. The optimal design condition is met when the inflation pressure is at the
recommended value, and the tires are under full load. Maintaining suitable tire pressure and proper driving
habits greatly influence the tire's life. It not only achieves the vehicle riding comfort, stability, and handling,
but also reduces tread wear, damage to the tire and extends tire life. Overloading, speeding, and unneces-
sary emergency braking will all add to the tire's wear.
The tire pressure is too high The tire pressure is normal The tire pressure is too low
and the tire surface is worn and and the tire shoulder is worn
torn in the middle ALF074G
Tire pressure measurements should be taken under normal temperature conditions. If the tire pressure
rises due to motion-generated heat when driving, cooling it will return it to the normal temperature. There-
fore, do not deflate the tire when the air pressure has risen to this point. The tire's air pressure will naturally
and slowly decrease when used under normal conditions. Hence, please inspect the air pressure regularly
(suggested once a month). The spare tire should be kept in a useable condition at all times. The suggested
inflation pressure of this vehicle is evaluated through careful calculation. The tire pressure should be in-
spected when the tire is cool. Adjust the tire pressure to the recommended level. It is suggested to inspect
the tire pressure monthly or before a long drive, including the spare tire.
Tire inflation
During a new tire's initial stage of use, warming due to mo-
tion will cause the tire to swell, and thus reduce the cor-
responding air pressure. Therefore, after 24 hours or a
2,000-3,000 km drive, change the air pressure.
(a) Inspect whether the tire inflation pressure is normal.
Inflation pressure of a cool tire:
Tire size Front, rear KPa
185/65R15 88H 220 ± 10
(b) Use the dial indicator to inspect the tire's radial hop.
Tire's radial hop: 1.4 mm or less
ALF075G
SP-��
Areas of importance for tire inflation:

1. Inflate safely. Watch the pressure meter until reach-
ing the recommended value to avoid over-inflating
and causing a ruptured tire.
2. After driving, inflate the tire only when it becomes
cool, for the temperature will rise during driving
and influence the air pressure.
3. Inspect the inflation nozzle and the nozzle core.
If the inflation nozzle and the nozzle core are un-
smooth and have other flaws, it will be difficult to
inflate or to measure the air pressure.
4. Keep clean when inflating. The inflated air should
not mix with water or oil to avoid damaging the rub-
ber sealing.
5. Do not wait until the specified air pressure is ex-
ceeded to bleed the air. Neither should one inflate
air excessively after no inflation due to a long ab-
sence. If the specifiedvalue is greatly exceeded,
the tire cord will over-expanded, causing the decre-
ment of strength and life time.
6. Clean away the dust on the inflation nozzle before
inflating and do not loosen the nozzle core. After
inflating, apply some soapy water on the nozzle to
check whether it is leaking (small air bubbles will
be generated if leaking), and then match all the
valve caps and install them tightly to avoid dust
from entering into the valve.
7. Regularly calibrate the pressure meter equipped on
the vehicle and used in the workshop to make sure
the air pressure will be accurately gauged.
Possible problems caused by tire pressure:

Exceeding the recom- Below the recommended air Same vehicle axle,
mended air pressure pressure different air pressure
Possible problems 1. Bumpy ride 1. Noisy turns 1. Uneven braking
it can create 2. The tear or rupturing of 2. Uneasy turns 2. Over-steering
the tire 3. Tread edge wear is accel- 3. Steering failure
3.Rapid wear of the tire erated and��
��
uneven 4. Deviation while accel-
tread's center 4. The tire's rim is damaged erating
or ruptured
5. The steel belt ruptures
6. High tire temperature
7. Steering failure
37
Tire and wheel (steel wheel) installation instruc-

tions
When installing the tire and wheel, the tire's radial hardware
components, also called high spot, should be at the same
level of the wheel's minimum radius or so called low spot.
The high spot of the tire is initially marked by the paint spot
on the side of the tire's surface. This paint will eventually be
washed away. The low spot of the wheel is initially marked
by a paint spot on the wheel flange. If no paint spot is found
on the tire, draw a line on the tire and the wheel before they
are removed, in order to make sure that the tire and the
wheel will be re-assembled at the same place. Whenever
the tire is installed, the tire and wheel need re-balancing to
make sure the vehicle runs smoothly. Generally when in-
stalling a tire, pay attention to the items below:
1. The specification of the tire should match the spec-
ification of the rim, which should have no deforma-
tion, rust, cracks, or break, otherwise it may cause
damage to the tire.
2. Keep it clean when installing the rim on the tire.
Grit, scraps, or other grainy hard items, if mixed in
the tire, will cause partial heating of the tire.
3. Tires with different specifications or patterns
should not be installed on the same vehicle, other-
wise it can cause uneven wear.
4. Protect the inflation nozzle and keep the nozzle
core complete and clean when removing the tire.
5. Timely clean away the chips, hard items, or other
sharp items on the surface of the tire to reduce
damage to the tire.
6. Cracks and breaks on the tire head, shoulder, and
side should be renovated and repaired. If not re-
paired in time, the damage will get worse.
Using tires that are different in dimension or type
will influence the vehicle's riding comfort, handling,
speedometer and odometer calibration, vehicle
ground clearance, and the clearance between the
tire or the tire's skidproof chain, and the vehicle
body and the chassis. It is suggested to use a new
pair of tires on the same axle. If only one tire needs
to be replaced, make sure to use a tire with a tread
most similar to the original, so as to keep the brake
power and traction balanced.
Note:
Do not mix radial tires, bias belted tires, etc., which
are of different structures on the same vehicle unless
it is an emergency. Mixing different tires would seri-
ously influence the vehicle's handling and stability,
and even possibly lead to losing control of the vehicle.
SP-��

The tire's abnormal wear and tear includes uneven and ex-
cessive wear of the tire. There are many causes for this. For
example, improper tire pressure, tire rotation has not been
timely maintained, bad driving habits, abnormal front wheel
location, etc.
Change the tires in the following situations
1. When the extents of wear and tear of the front and
rear tires are different.
2. When any of the tire's tread has uneven wear and
tear.
3. When the extents of the wear and tear of the left
and right front tires are different.
4. When the extents of wear and tear of the left and
right rear wheels are different.
5. When the tire tread wear appears abnormal and the
tire's contact area starts to flatten.
Inspect the front wheel alignment when the fol-
lowing situations occur:
1. When the extents of the wear and tear of the left
and right front tires are different.
ALF076G
2. When any of the tire's tread has uneven wear and
tear.
3. When the tread pattern strip or pattern block of a
front tire's single side is badly worn.
A: Steering problems, air pressure not sufficient, or
tire rotation has not been maintained in a timely
manner.
B: Abnormal front wheel alignment. Tire or wheel
structure is not the same.
Wear marks
There are several tread wear marks (refer to A in the figure
shown on the left) on the inside of the tire's pattern groove.
These marks indicate that the tire has been worn to the
point of replacing. The tire's usage limit refers to when the
remaining pattern's depth reaches 1.6 mm (and its main pat-
tern groove bottom protrudes to the same level). For your
safety, please replace the tire before this happens. When
serious wear leads to the partial protrusion of the steel belt,
ALF077G or outside objects damage the tire to a depth that reaches
the cord fabric level or steel band level, stop using the tire.
Radial tire sway

Here, the sway means the vehicle's front or rear part
shakes from side to side, together or individually. Tire sway
is caused by the tire bead not being straight. It is the most
obvious when the vehicle runs at the speed of 8 - 48 km/h.
Road tests can help finding malfunctioning tires. If the mal-
function is with the rear tires, then left and right shaking or
swaying would take place at the back of the vehicle. Here
the driver of the vehicle would feel as if someone were
ALF078G pushing from one side of the vehicle to the other. If the mal-
function is with the front tires, swaying would be even more
obvious.
39
Vehicle road test methods

1. Drive the vehicle and find out if the swaying is
coming from the front tires or the back tires. Then,
replace theidentified problem tire with a standard
tire (one that has been tested on the same model of
vehicle).
2. If unable to determine the problem tire, replace
the rear wheels. Continue the road test and if the
driving condition obviously changes, replace the
original tires, and only switch one at a time until the
problem tire is identified.
3. If no obvious improvement, replace all four tires
with standard tires, and then replace the original
tires one by one following the steps mentioned
above.
Front Tire rotation

To ensure the even wear and tear of the tires, the tires
should be regularly switched as stipulated. The swapping
principle is shown on the left. Radial tires should be regu-
larly switched. Add pressure according to the regulations.
Note:
Due to structural reasons, radial tires usually quickly receive
most of its wear on the shoulders, especially the front tires.
ALF079G Do a tire rotation every 8,000-12,000 km, and the tire life
can increase by 20%. This makes regular tire rotation espe-
cially useful.
SP-��
Adjust the tire pressure to the

recommended level
Test by driving back and forth on a

straight and level road
After swapping the right and left front

tires, perform the above test again
Tends to lean in the After solving, if working, switch the Tends to lean in the
same direction tires again other direction
Return the tires to their ini- Replace one of the front

tial positions and inspect side tires with a "good��
��
tire"
the front wheel alignment
If the problem is not yet solved,�

After solving, switch replace one of the front side
the tires again tires with a "good tire"
After solving, switch the If the problem is not yet

tires again solved, it means the "good
tire" is in fact not good
ALF080G
Deviation causes
• Incorrect tire and front wheel alignment.
• Braking force is not even.
• Tire structure problems.
Tire production and manufacturing methods can also lead
to vehicle deviation. For example, the arrangement of the�
tires' inner steel belt. A steel belt, which is inside the radial
tire, deviating from the tires centerline can create lateral
force when the tires are rolling in a straight line. If one of
the tire's diameter��
��
is larger than the other, the tire will tend
to roll to that side, this also creates��
��
lateral force (a tapering
effect) leading to vehicle deviation. When the front wheel
alignment is found��
��
to be correct and in proper order, the
above process is also applicable in judging tire deviation.�
Rear tires cannot cause deviation.
Tire installation and removal
• Install or remove tires with a tire changer. When operating
machinery, make sure to��
��
comply to the machine manu-
facturer's operation manual. Please do not change tires
merely with manual hand tools or��
��
tire installation crowbars.
This will damage the tire chafer or the vehicle wheel's rim.
41
• Use a wire brush or coarse steel wool to clean off grease

and old rubber, as well as light rust or corrosion from the
rim tire bead's tire chafer seat. Before tire installation or
removal, first use the indicated tire lubricant to thoroughly
lube the tire chafer portions one time.
• After installing the tire, inflate it to the specified pressure
and make sure the tire bead is properly seated.
Note:
Do not over-inflate the tire. If the tire bead severally
expands and exceeds the safety limit, it may burst and
cause serious personal injury. Do not exceed the speci-
fied pressure��
��
when inflating. If the specified pressure
does not allow the tire bead to sit properly, deflate the
tire, re-lubricate, and then re-inflate.
Spare tire usage

• Spare tire standard inflation pressure is 420 ± 10 kPa.
• Spare tire pressure measurements should be taken under
normal temperature conditions.
• After inflating, check if the air nozzle core is leaking air with
soapy water, then lock on the cap.
• The spare tire should be kept in a useable condition at all
times. Check the air pressure at least once a month.
ALF081G • The spare tire's usage limit refers to when the remain-
ing pattern's depth reaches 1.6 mm (and its main��
��
pattern
groove bottom protrudes to the same level). For your safe-
ty, please stop using��
��
the spare tire.
Note:
• The "∆" symbol on the tire bead of the spare tire indi-
cates the set position of the wear index (as shown in
the figure).
• The spare tire's maximum driven speed is 80 km/h, and
maximum distance is��
200
��
km per trip.
• Each vehicle is allowed to use only one spare tire.
• The spare tire is only used as a temporary backup.
ALF082G Please go to a professional service station immediate-
ly to get the initial tire repaired or replaced.
SP-��
Wheel
General balancing procedures
Clean out the accumulated dirt and debris from the inside of
the rim.
Note:
The gravel on the tread must be eliminated to avoid flying
out and injuring the operator when undergoing rotational
balancing. This is also a good way to acquire better bal-
ance. First thoroughly inspect the tire's damaged condi-
tion, then according to the balancing device manufacture's
recommendations, carry out the balancing operation.
Off-vehicle balancing
Most off-vehicle balancers are more accurate and conve-
nient than on-vehicle rotational balancers. They are also
able to perform dynamic (two-sided) balancing. Although it
does not correct drum brake and disc brake imbalance like
on-vehicle balancing, it achieves the same effect based on
its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on the equipment
and tool manufacturer. Therefore, when performing balanc-
ing operations, be sure to comply with each manufacturer's
operating instructions.
Note:
Control the wheel rotation speed to make sure the
speedometer stays within 55 km/h. This restriction is
necessary because when a driven wheel slides while the
other one stays still, the speedometer will display only
half of the actual wheel speed. When a wheel is sliding,
be extremely careful, because sliding wheels can reach
very high speeds. This may lead to the tire rubber peel-
ing or differential damage, which may cause serious
personal injury, or damage to the vehicle.
Dynamic balance and static balance

There are two types of wheel balance: static and dynamic.
Diagram 1 shows static balance, and diagram 2 shows
dynamic balance. Static balance means that the weight
distribution around the wheel is equal. If the wheel is static
and unbalanced, violent vibrations may be created, called
jump vibration. This kind of situation can ultimately lead to
Diagram 1 the uneven wear and tear of the tires, as shown in diagram 1.
ALF083G
1. Wheel runout point [A]: C ounterweight not yet
added
2. Locations to add [B]: Counterweight added
counterweight
3. Axis
43
Dynamic balance means that the weight distribution on the

two sides of the medium plane of the wheel is equal, so
during the rotation process, the tire assembly cannot create a
tendency for the medium plane of the wheel to shift from one
side to the other. If the wheel is dynamic and unbalanced, it
can create a shimmying effect, as shown in diagram 2.
1. Wheel shimmy important [A]: C ounterweight not yet
points added
Diagram 2
ALF084G 2. Counterweight added [B]: Counterweight added
3. Axis
The methods to test the wheel's dynamic balance

are as follows:
1. Clean the wheel to be tested and remove dirt, sand-
stone, and the old counterweight.
2. Inflate the tire to the specified value.
3. Install the wheel on the dynamic balancer and lock
it up.
4. Switch on the power and check whether the indica-
ALF085G
tor works properly.
5. Enter the diameter and width of the rim, measure
the distance between the rim and the cabinet, and
enter it.
6. Release the protective cover and press the Start
button to start measuring.
7. When the wheel stops rotating, read the quality and
position of the inner and outer imbalance of the
wheel from the indicator.
8. Rotate the wheel slowly by hand and stop when the
indicator signals.
9. Place the quality of the dynamic imbalance dis-
played by the dynamic balancer on the edge of the
rim and lock it up.
10. Restart the dynamic balancer and make dynamic
balance test, until the dynamic imbalance is less
than 5 g and the balancer shows pass.
11. Remove the wheel and switch off the power and the
test is finished. Operations are different for dynamic
balancers of different models and brands, so make
sure to carefully read the user's manual before using.
SP-��
Wheel maintenance
Do not use welding, heating, or hammering to repair the
wheels. All damaged wheels must be replaced. If the vehi-
cle's wheel is twisted or deformed, sunken or depressed,
having too much horizontal or radial hop, leaking air from
the welded parts, stretched out at the bolt holes, having a
flimsy nut bolt lock, or severely rusty, the wheel must be re-
placed. When the wheel is hopping too much, it will lead to
undesirable vibrations. When replacing the tire, be sure that
the load capacity, diameter, rim width, offset distance, and
the installation structure of it are equal to the settings of the
original wheel. If the wheel dimensions are not appropriate,
this will influence the wheel and bearing's life, brake cool-
ing effect, speedometer and odometer calibration, vehicle
ground clearance, as well as the clearance between the tire
and the vehicle body, and the chassis.
Wheel (steel wheel) removal
1. Remove the wheelhouse and loosen the nuts, 1-2
turns is enough.
2. Hoist the vehicle.
3. Screw off the nuts and remove the wheel.
Nut tightening torque: 110 N·m
Note:
Heating methods absolutely must not be used to
ALF086G loosen tightened wheels. Otherwise the heat will re-
duce its service life and damage the hub bearing.
Wheel (steel wheel) installation

Installation according to the reversed instructions used for
removal and pay attention to the following requirements:
Wheel nuts must be tightened in the proper order and ac-
cording to the specified torque, so as to avoid wheel or
brake disc deformity. When installing the wheel house, be
sure to line up the wheel housing notch locations with the
inflation nozzle. Tightening sequence: A-C-B-D
ALF087G Note:
Note: Before installing the wheel, first clean off the cor-
rosion on the wheel's mounting surface and drum brake
or brake disc's installation surface with a wire brush in
order to make the wheel installation easier by making
the space between its metal, otherwise it may lead to
the wheel nuts loosening to the extent that the vehicle's
wheel may come off while driving some day.
BR-1
1
Brakes
Brake System
Position of components................................................. BR-2
Areas of importance....................................................... BR-3
Malfunction indicator table............................................ BR-3
Brake fluid....................................................................... BR-5
Brake pedal subassembly.............................................. BR-8
Brake master cylinder subassembly............................. BR-12
Vacuum booster assembly............................................. BR-15
Front wheel brakes......................................................... BR-20
Rear wheel brakes.......................................................... BR-26
ABS brake system.......................................................... BR-33
ABS controller assembly............................................... BR-36
Front wheel rotation speed sensor LH......................... BR-38
Rear wheel rotation speed sensor LH........................... BR-40
Parking brake system

Position of components................................................. BR-42
Malfunction indicator table............................................ BR-42 BR
Adjustments.................................................................... BR-43
Parking brake lever panel.............................................. BR-44
Left parking brake cable assembly............................... BR-46
BR-2
Brake System
Position of components
Front wheel brake assembly LH Front wheel brake assembly RH
ABS controller assembly
Front wheel speed sensor Front wheel speed sensor assembly RH

assembly LH
Vacuum booster
assembly
Brake pedal subassembly
Brake line assembly
Parking brake handle
Right parking brake cable

assembly
Left parking brake cable assembly
Rear wheel speed

Rear wheel speed
sensor assembly RH
sensor assembly LH
Rear brake assembly RH

Rear brake Rear brake assembly LH
drum
ALG001G
Brakes BR-3
3
Areas of Importance
• Pay careful attention to replace each part correctly as using incorrect parts will influence the perfor-
mance of the brake system and become dangerous to drive the vehicle. Replace with parts having the
same part number or the equivalent product.
• While maintaining the brake system, it is very important to keep the parts and maintenance area clean.
• If the vehicle is equipped with a mobile communication system, please refer to the "Areas of Impor-
tance" section in the "Overview" part.
Hint:
Refer to following tables to find the cause of the malfunction. The numbers indicate the possibility of the
cause of the malfunction. Check each part in order. Replace these parts if necessary.
Reference
Problem Location in Question
Page (s)
1. Brake fluid in brake system leaks -
2. Air exists in the brake system BR-5
3. Piston seals (worn or damaged) BR-22
4. Brake reservoir does not have enough fluid -
Pedal is positioned too low or feels spongy
5. Brake shoe clearance (out of alignment) BR-32
6. Brake master cylinder (failure) BR-12
7. Booster's push rod (out of alignment) BR-13
8. Brake pedal has too much free play BR-9
1. Free play of brake pedal (too little) BR-9
2. Parking brake lever's stroke (out of BR-43
alignment)
3. Parking brake cable (broken) -
4. Brake shoe clearance (out of alignment) BR-32
5. Brake linings (broken or deformed) -
Brakes drag
7. Disc brake piston (clamping) BR-22
9. Brake drum (out-of-round) -
10. Tension or return spring (damaged) BR-27
12. Vacuum in booster system leaks -
13. Brake master cylinder (failure) BR-12
2. Disc brake piston (clamping) -
3. Brake linings (oil build-up) -
Brakes deviate
5. Front wheel alignment is loss of position SP-7
6. Brake disc (scratched) -
BR-4
1. Brake fluid in brake system leaks -

2. Air exists in the brake system BR-5
3. Brake linings (worn) -
4. Brake shoe (worn) -
Poor braking efficiency 6. Brake shoe clearance (out of alignment) BR-32
8. Brake linings (polished) -
11. Vacuum in booster system leaks -
2. Mounting bolt (loose) -
4. Brake linings' clip reed (loose) BR-21
5. Brake guide pin (worn) -
Brake noises 6. Brake linings (dirty) -
7. Brake linings (polished) -
8. Brake guide pin, return spring or reten- BR-31
sion spring (damaged)
9. Muffler gasket (damaged) BR-24
10. Brake shoe hold-down spring (damaged) BR-28
Brakes BR-5
5
Brake fluid
Bleeding
Hint:
If the brake system is maintained or air in the brake lines is
suspected, then perform air bleeding on the brake system.
Caution:
Immediately clean if the brake fluid is splashed on any paint-
ed surface.
1. Fill the reservoir with brake fluid.
Hint:
The brake fluid level in the reservoir needs to be between
the MIN and MAX levels.
ALG002G
2. Bleed the master cylinder

Hint:
If the master cylinder has been disassembled or if the
reservoir becomes empty, bleed the air out of the mas-
ter cylinder.
When performing air bleeding on the master cylinder, it
will need to be carried out by two people.
(a) Disconnect the brake line from the master cylinder.
ALG003G (b) Slowly press the brake pedal.
(c) Plug the hole with your fingers and loosen the brake
pedal.
(d) Repeat steps (b) and (c) for 3 or 4 times.
(e) Connect the brake line to the master cylinder.
Torque: 16 N·m
ALG004G
3. Perform air bleeding on the brake line.

(a) Connect the plastic pipe to the bleed screw.
(b) Press the brake pedal several times and then loosen
the bleed screw in the process.
(c) When the brake fluid stops flowing, tighten the bleed
screw and then loosen the brake pedal.
Torque: 8.3 N·m
(d) Repeat steps (b) and (c) until all the air in the brake
ALG005G fluid is released.
(e) Repeat the above procedures to release the air in the
brake line of each wheel.
BR-6
4. Bleed the ABS controller

Caution:
After performing air bleeding on the brake system, if
the correct height or contact feel of the brake pedal
is not acquired, then use a hand-held detector to per-
form air bleeding on the ABS controller assembly.
(a) With the engine off, press the brake pedal more than 20 times.
(b) Connect the hand-held detector to the DLC3 and then
switch the ignition switch to the ON position.
Caution:
Do not start the engine.
Hand-held detector (c) Select "AIR BLEEDING" on the hand-held detector.

Hint:
For detailed information, please refer to the Operation
Manual of the Hand-held Detector.
(d) When "Step 1: Increase" is displayed on the hand-held
detector, exhaust the air from the brake line.
Caution:
• Exhaust the air according to the procedures dis-
played on the hand-held detector.
• Be sure not to empty the brake fluid in the master
cylinder reservoir.
ALG006G
(1) Connect the plastic pipe to the bleed screw.
(2) Press the brake pedal several times and then loosen
the bleed screw at the same time.
(3) When the brake fluid stops flowing, tighten the bleed
Torque: 8.3 N·m
(4) Repeat steps (2) and (3) until all the air in the brake
fluid is released.
(5) Repeat the above procedures to release the air in
the brake line of each wheel.
(e) When "Step 2: Increase" is displayed on the hand-held
detector, release the air from the suction line.
ALG005G
Caution:
cylinder reservoir.
(1) Connect the plastic pipe to the bleed screw of the
front right wheel or rear right wheel, and then loosen
the bleed screw.
(2) Operate the ABS controller assembly with a hand-
held detector to release the air.
Caution:
• The operation will automatically stop within 4
seconds.
• Make sure to loosen the brake pedal at that
time.
(3) Check and confirm if the image operation performed
by hand-held detector stops.
fluid is released.
Torque: 8.3 N·m
(5) Perform air bleeding according to the same proce-
dure for the other wheels.
(f) When "Step 3: Increase" is displayed on the hand-held de-
tector, exhaust the air from the pressure reduction line.
Caution:
• Be sure not to empty the brake fluid in the master cyl-
inder reservoir.
Brakes BR-7
7
(1) Connect the plastic pipe to any bleed screw.

(2) Loosen the bleed screw.
(3) Operate the ABS controller assembly with a hand-held
detector and keep pressing on the brake pedal fully.
Caution:
• The operation will automatically stop within 4
seconds. At least a 20 second time interval is
needed when performing the procedure continu-
ously.
• After performing the operation, the brake
pedal will drop slightly, and it is normal if the
solenoid valve is on at that time.
• While performing the procedure, the pedal
will be heavy, but it will still need to be
pressed fully to drain the brake fluid from the
bleed screw.
• Make sure to press the brake pedal. Please
do not press and release the pedal repeat-
edly.
(4) Tighten the bleed screw and then loosen the brake
pedal.
Torque: 8.3 N·m
(5) Repeat steps (2) to (4) until all the air in the brake
fluid is released.
(g) When "Step 4: Increase" is displayed on the hand-held
detector, exhaust the air from the brake line again.
Caution:
cylinder reservoir.
(1) Connect the plastic pipe to any bleed screw.
(2) Press the brake pedal several times and then loosen
the bleed screw of any wheel while pressing the
brake pedal.
(3) When no brake fluid is flowing out, tighten the bleed
Torque: 8.3 N·m
fluid is released.
ALG005G
5. Check the fluid level in the reservoir.

(a) Check the fluid level and add to it if necessary.
ALG002G
BR-8

Components
Brake lamp switch assembly

Brake pedal bracket subassembly
Brake lamp switch
lock nut
Brake pedal
return spring
● Brake pedal bushing
Brake pedal
shaft
Center pin
Brake lamp switch pad
Lock pin
Brake pedal pad
: Specified torque
Disposable parts
Grease
ALG007G
Brakes BR-9
9
Adjustment
Brake lamp switch assembly 1. Check and adjust the brake pedal height
(a) Check the brake pedal height.
Pedal height above the cowl panel:
120 to 130 mm
(b) Adjust the brake pedal height.
Push (1) Remove the instrument panel lower shield.
rod
(2) Disconnect the connector from the brake lamp
switch assembly.
Pedal height
ALG008G (3) Loosen the brake lamp switch lock nut, and re-
move the brake lamp switch assembly.
(4) Loosen the brake master cylinder push rod clevis
lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 18 N·m
(7) Install the brake lamp switch assembly.
(8) Connect the connector to the brake lamp switch
assembly.
(9) Push the brake pedal in 6 to 9 mm, and turn the
brake lamp switch assembly to lock the nut in the
position where the brake lamp goes off.
(10) After the installation, push the brake pedal in 6 to
9 mm, and check that the brake lamp comes on.
2. Inspect the pedal free play
(a) Stop the engine and depress the brake pedal several times
until there is no more vacuum left in the vacuum booster.
(b) Depress the brake pedal until the resistance begins to
be felt, and then measure the distance as shown in the
illustration.
Pedal free play: 6 to 9 mm
Pedal free play If the clearance is not as specified, check the brake
ALG009G lamp switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Brake lamp switch clearance:
0.5 to 2.4 mm
3. Inspect the pedal reserve distance
(a) Release the parking brake lever panel.
With the engine running, depress the pedal and mea-
sure the pedal reserve distance as shown in the illus-
tration.
Pedal reserve distance from dash panel at 490 N: more
than 55 mm.
Pedal reserve If the reserve distance is not as specified, troubleshoot
distance ALG010G the brake system.
BR-10
Replacement
1. Disconnect the battery negative terminal.
2. Remove the dashboard body (see page IR-28)
3. Separate master cylinder push rod clevis
(a) Disconnect the brake lamp switch connector.
Brake (b) Remove the brake pedal return spring.
pedal
(c) Remove the lock pin and the pin clevis and separate
return
spring the master cylinder push rod clevis from the brake ped-
al subassemby.
Lock pin
Center pin
ALG011G
4. Remove the brake pedal bracket assembly

Brake pedal bracket
(a) Remove the bolt from the brake pedal bracket assembly.
Dashboard
brace
reinforce-
ment
ALG012G
(b) Remove the 4 nuts and the brake pedal bracket assembly.
5. Remove the brake pedal subassembly
(a) Remove the brake pedal shaft and the nut from the
brake pedal bracket subassembly.
(b) Remove the brake pedal subassembly and the 2 bushings.
6. Remove the brake lamp switch assembly
(a) Loosen the brake lamp switch lock nut.
(b) Remove the brake lamp switch assembly from the
ALG013G brake pedal bracket subassembly.
7. Remove the brake pedal pad
(a) Remove the brake pedal pad from the brake pedal
bracket subassembly.
8. Install the brake pedal pad
(a) Install the brake pedal pad to the brake pedal bracket
subassembly.
9. Install the brake lamp switch assembly
(a) Install the nuts on the brake lamp switch assembly.
Torque: 26 N·m
10. Install the brake pedal subassembly
(a) Apply grease to the ends and sides of the 2 new brake
pedal bushings.
(b) Install the brake pedal subassembly and the 2 brake
pedal bushings on the brake pedal bracket with the
brake pedal shaft and the nut.
Torque: 30 N·m
Grease ALG014G
Brakes BR-11
11
11. Install the brake pedal subassembly

(a) Install the brake pedal bracket assembly with the 4
nuts.
Torque: 23 N·m
ALG013G
(b) Install the bolt to the brake pedal bracket assembly.

Brake pedal bracket
Torque: 23 N·m
Dashboard
brace rein-
forcement
ALG012G
12. Connect the master cylinder push rod clevis

(a) Apply grease to the pin clevis.
Brake (b) Install the pin clevis and the lock pin.
pedal
Caution:
return
spring The direction for the lock pin installation is as
shown in the illustration.
(c) Install the brake pedal return spring.
Lock pin
Center pin (d) Connect the brake lamp switch connector to the brake
ALG011G lamp switch assembly.
13. Install the dashboard body
14. Check and adjust brake pedal height (see Page
BR-9)
15. Check the pedal free play (see Page BR-9)
16. Check the pedal reserve distance (see Page BR-9)
17. Check the SRS warning lamp (with the SRS airbag)
BR-12
Brake master cylinder subassembly

Replacement
Hint:
Components: see Page BR-15
1. Drain the brake fluid
Caution:
Immediately clean if the brake fluid is splashed on
any painted surface.
2. Remove the air filter cap subassembly
3. Disconnect the clutch reservoir
(a) Slide the retaining clip and disconnect the clutch reservoir.
4. Remove the brake master cylinder

(a) Disconnect the switch connector of the fluid level warn-
ing switch.
(b) Using SST, connect the 2 brake lines to the brake mas-
ter cylinder.
ALG015G
(c) Remove the 2 nuts and pull out the brake master cylinder.
ALG016G
5. Remove the brake master cylinder subassembly

without a reservoir
(a) Pull out the brake reservoir pin clevis.
ALG017G
Brakes BR-13
13
(b) Remove the brake reservoir and the 2 sealing rings.

Cap
(c) Remove the cap from the brake reservoir.
Brake reservoir
Sealing ring
ALG018G
6. Install brake master cylinder subassembly without

Sealing ring a reservoir
(a) Apply grease to the 2 sealing rings and install them to
the brake master cylinder without a reservoir.
(b) Install the cap to the brake reservoir.
Brake master cylinder

Rectangular
Grease sealing ring ALG019G
(c) Install the brake reservoir assembly with the brake res-
ervoir pin clevis.
Caution:
Install the pin clevis securely to the groove of the
reservoir and master cylinder.
7. Check and adjust the vacuum booster's push rod
Caution:
Make an adjustment with the vacuum booster as-
sembly having no vacuum (depress the brake pedal
ALG020G
several times with the engine stopped).
Hint:
Adjustment of the vacuum booster push rod is per-
formed when the brake master cylinder subassembly is
replaced with a new one. The adjustment is not neces-
sary when the brake master cylinder subassembly is
reinstalled and the vacuum booster is replaced with a
new one.
(a) Apply the chalk to the tip of an accessory tool.
Hint:
The accessory tool is enclosed with the new brake
master cylinder subassembly.
Accessory tool (b) Place the accessory tool in the vacuum booster assembly.
(c) Measure the clearance between the vacuum booster
push rod and the accessory tool.
Clearance: 0 mm
Hint:
Adjust the clearance in the following cases:
• If there is a clearance between the accessory tool
and the shell of the vacuum booster (floating acces-
sory tool), and the clearance is too small.
ALG021G
• If the chalk does not stick on the tip of the vacuum
booster push rod, and the clearance is too large.
BR-14
(d) If the clearance is outside of the specified range, attach

the push rod by using a SST and adjust the length of
the protruding adjusting bolt.
Hint:
When adjusting the push rod, depress the brake pedal
sufficiently so that the push rod sticks out.
ALG022G
8. Install the brake master cylinder

(a) Install the brake master cylinder to the booster with 2
nuts.
Torque: 23 N·m
ALG016G
(b) Connect the 2 brake lines to the master cylinder with

SST.
Torque: 16 N·m
(c) Connect the switch connector of the fluid level warning
switch.
9. Connect the clutch reservoir
(a) Slide the retaining clip and connect the clutch reservoir.
10. Install the air filter cap subassembly
ALG015G 11. Fill the reservoir with brake fluid (see page BR-5)
12. Bleed the master cylinder (see page BR-5)
13. Bleed the clutch pipeline (see page DT-41)
14. Check the liquid level in the reservoir (see page
BR-7)
15. Check for leaking brake fluid
Brakes BR-15
15
Vacuum booster assembly

Components
Battery hook
Air filter assembly
Battery
plate Battery
plate
bracket
Cap
Battery assembly
Vacuum check valve assembly

Battery carrier
Brake reservoir
Adjusting fork
Brake master cylinder
Vacuum booster assembly
ABS mounting Connector

bracket assembly
ALG023G
BR-16
Vehicle check
Good Poorly 1. Check the vacuum booster

(a) Airtightness check
(1) Start the engine and stop it after 1 or 2 minutes.
Slowly press the pedal several times.
Hint:
If you press the brake pedal towards the floor for
Third time
Second time the first, releasing gradually the second or third
First time time, it indicates the booster has a good vacuum
ALG024G seal.
(2) Press the brake pedal when the engine is running and
then stop the engine while keeping the pedal pressed.
Hint:
After pressing the pedal for 30 seconds without
any change on the pedal stroke allowance, it indi-
cates the booster has a good vacuum seal.
(b) Operation check

(1) When the ignition switch is off, press the brake
pedal several times, and then check and confirm if
the pedal stroke allowance has changed.
(2) Press the brake pedal and start the engine.
Hint:
If the pedal has moved down slightly, it means that
the system is operating normally.
ALG025G 2. Check the vacuum check valve
(a) Check the vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check and confirm if ventilation from the booster

Ventilation No ventilation
to the engine is available or whether from the en-
gine to the booster is not available.
(4) If a problem is found, replace the vacuum check
valve.
ALG026G
Brakes BR-17
17
Replacement
Caution:
Immediately clean if the brake fluid is splashed on any paint-
ed surface.
2. Remove the air filter subassembly
3. Disconnect the clutch reservoir
(a) Slide the retaining clip and disconnect the clutch reservoir.
4. Remove the brake master cylinder (see page BR-12)
5. Remove the battery
6. Remove the ABS controller with bracket (see page
BR-37)
Vacuum 7. Remove the vacuum booster assembly

hose Clip (a) Disconnect the vacuum hose from the vacuum booster
assembly by sliding the clip.
Vacuum booster
ALG027G
(b) Remove the brake pedal return spring, the lock pin, and
Push rod clevis the pin clevis.
Lock nut Brake
pedal
(c) Loosen the push rod clevis lock nut.
return
spring
Lock pin
Center pin
ALG028G
(d) Remove the 4 nuts and the push rod clevis.

(e) Pull out the vacuum booster assembly and gasket.
ALG013G
BR-18
8. Install the vacuum booster assembly

(a) Install the vacuum booster assembly and a new gasket.
(b) Install the vacuum booster assembly with the 4 nuts
and the push rod clevis.
Torque: 23 N·m
ALG013G
(c) Apply grease to the pin clevis.

(d) Install the lock pin and the pin clevis.
Brake Caution:
pedal The direction for the lock pin installation is as
return
Front
spring
(e) Install the brake pedal return spring.
Lock pin
Center pin
Grease ALG029G
Vacuum (f) Connect the vacuum hose to the vacuum booster as-
Hose Clip sembly and slide the clip.
9. Check and adjust the vacuum booster's push rod
Caution:
Vacuum Make an adjustment with the vacuum booster as-
booster
sembly has no vacuum (depress the brake pedal
several times with the engine stopped).
Hint:
ALG027G Adjustment of the vacuum booster push rod is per-
formed when the brake master cylinder subassembly is
replaced with a new one. The adjustment is not neces-
sary when the brake master cylinder subassembly is
reinstalled and the vacuum booster is replaced with a
new one.
(a) Apply the chalk to the tip of an accessory tool.
Hint:
The accessory tool is enclosed with the new brake
master cylinder subassembly.
Accessory tool (b) Place the accessory tool in the vacuum booster assembly.
(c) Measure the clearance between the vacuum booster
push rod and the accessory tool.
Clearance: 0 mm
Hint:
Adjust the clearance in the following cases:
• If there is a clearance between the accessory tool
and the shell of the vacuum booster (floating acces-
ALG021G sory tool), and the clearance is too small.
• If the chalk does not stick on the tip of the vacuum
booster push rod, and the clearance is too large.
Brakes BR-19
19
(d) If the clearance is outside of the specified range, attach

the push rod by using an SST and adjust the length of
the protruding adjusting bolt.
Hint:
When adjusting the push rod, depress the brake pedal
sufficiently so that the push rod sticks out.
10. Install the ABS controller with bracket (see page
BR-38)
ALG022G 11. Install the brake master cylinder (see page BR-14)
12. Connect the clutch reservoir
(a) Slide the retaining clip and connect the clutch reservoir.
13. Install the air filter subassembly
14. Install the battery
15. Fill the reservoir with brake fluid (see page BR-5)
17. Bleed the brake lines (see page BR-5)
18. Bleed the clutch pipeline(see page DT-41)
19. Check and adjust brake pedal height (see page
BR-9)
20. Check the brake pedal free play (see page BR-9)
21. Check the brake pedal reserve distance (see page
BR-9)
BR-7)
24. Check the ABS controller with a hand-held detector
BR-20
Front wheel brakes

Components
Front disc brake

Guide pin
● Guide pin dust cover

Front disc brake LH
Brake cylinder fixed mount
● Guide pin dust cover

No.2 muffler gasket Brake linings
No.1 muffler gasket
Front disc brake Brake hose No.2 muffler gasket

Guide pin
Front disc brake
Air bleed screw cap
Joint bolt
No.1 muffler gasket
Front disc brake LH

Brake cylinder subassembly
● Piston seal
● Copper washer
● Piston dust cover
Brake linings' clip reed
Bleed screw cap
: Specified torque ● Location ring

Disposable parts
Front disc brake piston
Grease
Disk brake grease
ALG030G
Brakes BR-21
21
Overhauling
Hint:
The overhauling sequence on the right side is the same as
the left one.
1. Remove the front wheel
Caution:
Immediately clean if the brake fluid is splashed on
any painted surface.
3. Remove the brake cylinder subassembly of the

front disc brake
(a) Remove the joint bolt and copper washer from the
brake cylinder subassembly of front disc brake and
then disconnect the brake hose.
ALG031G
(b) Secure the front disc brake guide pin and remove the 2
bolts.
4. Remove the front brake lining subassembly (only
linings)
(a) Remove the brake linings with a muffler gasket.
5. Remove the front muffler gasket subassembly
(a) Remove the No.1 and No.2 muffler gasket from each
lining.
ALG032G 6. Remove the front brake lining clip reed
(a) Remove the 2 front brake lining clip reeds from the
fixed mount of the brake cylinder of the front disc brake.
Front disc brake guide pin 7. Remove the front disc brake guide pin
(a) Remove the 2 front disc brake guide pins from the fixed
mount of the brake cylinder of the front disc brake.
ALG033G
Fixed mount of the brake cylinder 8. Remove the guide pin dust cover
of the front disc brake (a) Remove the 2 guide pin dust covers from the fixed
mount of the brake cylinder of the front disc brake.
Guide pin dust cover

ALG034G
BR-22
9. Remove the fixed mount of the brake cylinder of

the front disc brake
(a) Remove the 2 bolts and the fixed mount of the brake
cylinder of the front disc brake.
ALG035G
10. Remove the piston dust cover

(a) Using a screwdriver, remove the set ring and the piston
dust cover.
ALG036G
11. Remove the front disc brake piston

(a) Place cotton rags between the front disc brake piston
and the brake cylinder of the front disc brake.
(b) Remove the front disc brake piston from the brake cylinder
subassembly of the front disc brake with compressed air.
Caution:
When using compressed air, be sure not to place
your fingers in front of the piston.
Cotton rags Caution:
ALG037G
Be sure not to spill the brake fluid.
12. Remove the piston seals

(a) Remove the piston seals from the brake cylinder of
front disc brake with a screwdriver.
Caution:
Be sure not to damage the inside cylinder and the
brake cylinder groove.
13. Remove the front disc brake bleed screw
(a) Remove the bleed screw cap and the front disc brake
bleed screw from the brake cylinder subassembly of
ALG038G
the front disc brake.
14. Check the brake cylinder and piston
(a) Check the brake cylinder bore and front disc brake pis-
ton for rust and scratches.
15. Check the lining thickness
(a) Measure the lining thickness with a ruler.
Standard thickness: 11.0 mm
Minimum thickness: 8.5 mm
16. Check the front brake lining clip reed
(a) Check the 2 front brake lining clip reeds. Make sure
they have sufficient rebound and are free of deforma-
tion, breakage or are worn out, and all rust, dirt, and
ALG039G contaminates are cleaned out.
Brakes BR-23
23
17. Inspect the disc brake thickness

(a) Use a micrometer caliper to measure the disc brake
thickness.
ALG040G
18. Remove the front disc brake

Installation mark
(a) Make an installation mark on the disc brake and axle hub.
(b) Remove the disc brake.
19. Install the front disc brake
(a) Install the front disc brake by aligning the installation
mark.
Hint:
When replacing with a new disc brake, select the minimum
ALG041G axial runout position of the front disc brake for installation.
20. Check the axial runout of the disc brake
(a) Temporarily tighten the disc brake with hub nuts.
Torque: 110 N·m
(b) Use a dial indicator to measure the disc brake axial run-
out at 10 mm away from the outer edge of the brake.
Maximum axial runout of the disc brake: 0.11 mm
(c) If the axial runout of the disc brake is larger or equal to
the maximum value, check the bearing axial clearance
ALG042G and the radial runout of the axle hub.
If the bearing clearance and the radial runout of the
axle hub is normal, then adjust the axial runout of the
brake disc or grind it on the brake turning machine.
21. Temporarily tighten the front disc brake bleed
screw
(a) Install the front disc brake bleed screw onto the brake
cylinder of the front disc brake.
(b) Install the bleed screw cap on the bleed screw.
22. Install the piston seal
(a) Coat grease to the new piston seal.
(b) Install the piston seal onto the brake cylinder of the
front disc brake.
23. Install the front disc brake piston
Piston dust cover
(a) Coat grease onto the front disc brake piston and the
new piston dust cover.
(b) Install the piston dust cover on the front disc brake piston.
(c) Install the piston on the brake cylinder inside the front
disc brake.
Piston Caution:
Grease Make sure not to use force to install the piston on
ALG043G the brake cylinder inside the disc brake.
BR-24
24. Install the piston dust cover

Piston dust cover Front disc brake
piston (a) Install the new piston dust cover on the brake cylinder
subassembly of front disc brake.
Caution:
Install the dust cover onto the groove of the brake
cylinder and piston.
Location ring (b) Install the location ring with a screwdriver.
Caution:
ALG044G Do not damage the piston dust cover.
25. Install the fixed mount of the brake cylinder of front

disc brake
(a) Install the fixed mount of the brake cylinder of the front
disc brake with 2 bolts.
Torque: 100 N·m
ALG035G
Fixed mount of the brake 26. Install the guide pin dust cover
cylinder of the front disc brake (a) Coat grease onto the surface of the 2 new dust cover
seals.
(b) Install the 2 guide pin dust covers on the fixed mount of
the brake cylinder of front disc brake.
Guide pin dust cover

Grease
ALG045G
Front disc brake guide pin 27. Install the front disc brake guide pin
(a) Coat grease to the sliding part and sealing surface of
the 2 disc brake guide pins.
(b) Install the 2 front disc guide pins on the fixed mount of
the brake cylinder of the front disc brake.
28. Install the front brake lining clip reeds
(a) Install the front brake lining clip reeds on the fixed
Grease mount of the brake cylinder of the front disc brake.
ALG046G
29. Install the front muffler gasket subassembly

No.1 muffler gasket (a) Coat the disc brake grease on both sides of the No.1
and No. 2 muffler gasket.
(b) Install the muffler gasket on each lining.
No.2 muffler gasket

Disk brake grease
ALG047G
Brakes BR-25
25
30. Install the front brake lining subassembly (only lin-

ings)
When replacing the brake linings, replace the muffler
gasket subassembly if necessary.
(a) Install the brake lining subassembly on the fixed mount
of the brake cylinder of front disc brake.
Caution:
Before installing the brake pad, make sure to press
the piston into the correct position. During instal-
lation, observe whether there is an interference
between the brake pad and the piston dust cover in
order to prevent breakage and failure of the piston
dust cover due to the existence of interference.
The rubbing surfaces of the linings and brake discs
should be free of oil build-up and grease.
31. Install the brake cylinder subassembly of the front
disc brake
(a) Install the brake cylinder subassembly of the front disc
brake with 2 bolts.
Torque: 34 N·m
ALG048G
(b) Install the new copper washer and brake hose with a
joint bolt.
Torque: 30 N·m
Hint:
Install the brake hose lock onto the brake cylinder sub-
assembly lock hole of the brake disc.
ALG031G 34. Bleed the brake lines (see page BR-5)
BR-7)
37. Install the front wheel
Torque: 110 N·m
BR-26
Rear wheel brakes

Components
Air bleed screw cap

Bleed screw cap
Piston spring ● Piston dust cover
Piston ●Ring cup
● Piston dust cover
Pin
Pin plug Piston
Hole plug Brake cylinder of the rear wheel brake
●Ring cup Parking brake shoe lever

Left parking brake cable ●C-washer
Pin assembly
Parking brake shoe LH Brake shoe
Brake shoe
Push rod kit hold-down
hold-down
spring
spring seat
Backing plate
Brake leading
Rear wheel brake Brake shoe shoe assembly
automatic return spring
adjustment lever
Rear wheel brake automatic Retainer spring

adjustment lever tension spring
Brake trailing shoe assembly
Brake shoe hold-down spring

Brake shoe hold-down spring seat
: Specified torque
Rear wheel brake drum
Disposable parts
Grease
ALG049G
Brakes BR-27
27
Overhauling
Hint:
The overhauling sequence on the right side is the same as
the left one.
1. Check rear drum brake shoe lining thickness
(a) Remove the hole plug and check the brake shoe lining
thickness through the hole.
If the thickness is less than the minimum, replace the
brake shoe.
2. Remove the rear wheel
ALG050G Caution:
Immediately clean if the brake fluid is splashed
onto any painted surface.
4. Remove the rear brake drum

Rear wheel brake
automatic adjust lever
(a) Release the parking brake handle and remove the
brake drum.
Hint:
If the brake drum cannot be removed easily, perform
the following procedures.
Contraction (b) Remove the hole plug and insert a screwdriver into the
hole on the backing plate, and hold the rear brake auto-
ALG051G matic adjustment lever away from the adjuster.
(c) Using another screwdriver, adjust the brake shoe ad-
juster by turning the adjusting wheel.
5. Check the internal diameter of the brake drum

(a) Use a brake drum gauge or equivalent product to mea-
sure the internal diameter of the brake drum.
Standard internal diameter: 200.0 mm
Maximum internal diameter: 201.0 mm
ALG052G
6. Separate parking brake shoe push rod kit LH

(a) Using SST, disconnect the brake shoe return spring
from the brake trailing shoe assembly and the brake
leading shoe assembly.
Caution:
Be careful not to damage the wheel cylinder dust
cover.
ALG053G
BR-28
7. Remove the brake trailing shoe assembly

(a) Using an SST, remove the brake shoe hold-down spring
cup, the brake shoe hold-down spring,, and the pin.
and the pin.
(b) Remove the brake trailing shoe assembly and tension
spring.
8. Remove the parking brake shoe push rod kit LH
(a) Remove the parking brake shoe push rod kit LH from
the brake leading shoe assembly.
ALG054G
9. Remove the rear brake automatic adjustment lever LH

(a) Remove the rear brake automatic adjustment lever ten-
sion spring and the rear brake automatic adjustment
lever.
ALG055G
10. Remove the brake leading shoe assembly

(a) Using an SST, remove the brake shoe hold-down spring
cup, the brake shoe hold-down spring,, and the pin.
and the pin.
ALG056G
(b) Using needle-nose pliers, disconnect the parking brake

cable LH from the parking brake shoe lever.
ALG057G
11. Remove the rear brake parking brake shoe lever

subassembly
(a) Using a screwdriver, remove the C-washer and the
C-washer parking C-washer brake shoe lever.
ALG058G
Brakes BR-29
29
12. Check the rear drum brake shoe lining thickness

(a) Using a ruler, measure the thickness of the brake shoe
lining.
If the lining thickness is equal to the minimum thickness
or less, or there is severe or uneven wear, replace the
brake shoe.
ALG059G
13. Inspect the brake drum and rear drum brake shoe
lining for proper contact
(a) Apply chalk to the inside surface of the brake drum, then
grind the brake drum on the brake shoe lining to fit.
If the contact between the brake drum and the brake
shoe lining is improper, repair it by using a brake shoe
grinder or replace the brake shoe assembly.
ALG060G
14. Remove the rear wheel brake cylinder assembly

(a) Using an SST, disconnect the brake line.
Hint:
Use a container to catch the brake fluid.
(b) Remove the bolt and the rear wheel brake cylinder as-
sembly.
15. Remove the rear wheel cylinder cup kit
(a) Remove the 2 piston dust covers from the rear wheel
ALG061G brake cylinder.
(b) Remove the 2 pistons and the piston spring.
(c) Remove the 2 cups from each piston.
16. Inspect the brake wheel cylinder
(a) Check the cylinder bore and the piston for rust or scoring.
17. Remove the rear drum brake bleeder screw
(a) Remove the rear drum brake bleeder screw from the
rear wheel cylinder assembly.
18. Install the rear wheel cylinder cup kit

(a) Apply grease to the 2 cups and the 2 pistons.
(b) Install the cups to each piston.
(c) Install the piston spring and the 2 pistons to the rear
wheel brake cylinder.
(d) Install the 2 new piston dust covers to the rear wheel
brake cylinder.
Grease 19. Temporarily tighten the rear drum brake bleeder
ALG062G screw
(a) Install the rear drum brake bleeder screw to the rear
wheel cylinder assembly.
BR-30
20. Install the rear wheel brake cylinder assembly

(a) Install the rear wheel brake cylinder assembly with the
bolt.
Torque: 8 N·m
(b) Using an SST, connect the brake line.
Torque: 16 N·m
ALG061G
21. Apply a high-temperature grease

(a) Apply a high-temperature grease to the brake shoe at-
tached to the surface of the backing plate.

ALG063G
22. Install the rear brake parking brake shoe lever sub-
assembly
(a) Using needle-nose pliers, install a new C-washer and
the parking brake lever.
ALG064G
23. Install the brake leading shoe assembly

(a) Using needle-nose pliers, connect the parking brake
cable LH to the parking brake shoe lever.
ALG057G
(b) Using an SST, install the brake leading shoe assembly,

the brake guide pin, the brake shoe hold down spring,
and the brake SST shoe hold down spring cup.
ALG056G
Brakes BR-31
31
24. Install the rear brake automatic adjustment lever LH

(a) Install the rear brake automatic adjustment lever LH
and the rear brake automatic adjust lever tension spring
to the brake trailing shoe assembly.
ALG055G
25. Install the parking brake shoe push rod kit LH

(a) Apply high temperature grease to the adjusting bolt and
assemble.
(b) Install the brake shoe return spring to the push rod kit.

ALG065G
(c) Install the parking brake shoe push rod kit LH as shown
Backing plate
Parking brake shoe push rod kit
ALG066G
26. Install the brake trailing shoe assembly

(a) Connect the tension spring to the brake trailing shoe
assembly and brake leading shoe assembly.
(b) Using an SST, install the brake trailing shoe assembly,
the brake guide pin, the brake shoe hold down spring
and the brake shoe hold down spring cup.
ALG054G
(c) Using needle-nose pliers, connect the tension spring

to the brake trailing shoe assembly and brake leading
shoe assembly.
ALG067G
BR-32
27. Connect the parking brake shoe push rod kit LH

(a) Using an SST, connect the brake shoe return spring
to the brake trailing shoe assembly and brake leading
shoe assembly.
Caution:
Be careful not to damage the wheel cylinder dust
cover.
28. Check the rear drum brake installation
ALG068G (a) Check that each part is installed properly.
LH: RH:
Front Front
ALG069G
(b) Measure the internal diameter of the brake drum and

the diameter of the brake shoe.
The difference between the calculated two diameters is
the brake shoe clearance.
Brake shoe clearance: 0.25 mm
Caution:
There should be no oil or grease adhering to the
friction surfaces of the brake shoe lining and the
ALG070G brake drum.
29. Install the rear brake drum
30. Adjust the rear drum brake shoe clearance

Rear wheel brake auto-
matic adjustment lever (a) Temporarily install the 2 hub nuts.
(b) Remove the hole plug and turn the adjuster to expand
the brake shoe until the drum locks.
(c) Rotate the adjuster by 8 notches.
(d) Install the hole plug.
Expansion 31. Fill the reservoir with brake fluid (see page BR-5)
ALG071G
Brakes BR-33
33

BR-7)
36. Install the rear wheel
Torque: 110 N·m
37. Check the parking brake lever travel (see page
BR-43)
38. Adjust the parking brake lever travel (see page
BR-43)
ABS Brake System

1. ABS Brake System Description (with EBD)
The ABS brake system detects wheel speed by a speed sensor and sends the treated speed signal to
the ECU which controls solenoid operation based on the speed signal and the pressure of the brake
cylinder to avoid wheel lock.　　
　　
Electronic brake force distribution (EBD), when the ABS does not work during braking, adjusts the
rear wheel brake pressure by parts of ABS to balance the brake pressure of the front and rear wheels,
which reaches optimum efficiency for braking.
2. System diagram
ABS control unit (ECU)
Vacuum Booster and

brake master cylinder
Wheel speed signal Work instruction
Speed sensor
Hydraulic adjuster
Brake cylinder of the rear wheel brake
ALG072G
BR-34
3. Areas of Importance
(a) In order to judge whether the fault is in the brake system or in the ABS system, sometimes, the ABS
system needs to quit working, namely, disconnect the connector of the ABS ECU or fuse, at this time,
the ABS and EBD do not work, emergency braking should be avoided as much as possible as it is
easy to drift and sideslip on the muddy, icy, and snowy roads.
(b) There is a low fault rate in the ABS system when a fault occurs in the brake system the warning light does
not illuminate); the fault in the brake system should be solved first and then the fault in the ABS system.
(c) The time that the ABS begins to work on a rainy or sandstone road is longer than that on a good road, as the
unstable attachment coefficient on those roads makes the measurement and calculation of the sliding ratio
different, so the driver should be reminded to take great care to drive on those roads described above.
(d) ABS ECU precautions:
(1) The ABS ECU can become easily damaged when being collided or knocked, therefore, pay close
attention so that the ECU should not be collided with or knocked.
(2) The ECU is also easily damaged when being placed under a high-temperature environment.
Therefore, the ECU should be removed from the vehicle that is to be painted.
(3) Do not remove the electric elements and the wire harness plug in the system with the power switch
ON, so as not to damage the ECU. The ignition switch should be turned OFF if removal is required. If
removal or installation must be carried out, be sure first to disconnect the ignition switch. The connec-
tor should also be disconnected from the ECU when the elements or circuit in the system are welded.
(4) The ECU should not be smeared with oil, especially for the terminal of the ECU; otherwise the
terminal of the ECU will have a poor contact.
4. Common faults and troubleshooting
(a) The ABS hydraulic pressure regulator makes a loud noise when braking
(1) The motor in the hydraulic pressure regulator is ceaselessly turning when the ABS is operating;
at this time, the resilience on the brake pedal can be felt by the driver, and the resilience varies
according to the different vehicle speed and road conditions.
(2) The noise from where the motor operates can also be heard when performing the motion test.
The noise from where the motor operates can be heard occasionally without braking when the
vehicle is driving-the reason of which is that the ABS is detecting the element, but not a fault.
(3) The motion test can be performed if the noise from the ABS hydraulic pressure regulator is ab-
normal, which is compared with the normal vehicle to determine whether the noise from the ABS
hydraulic pressure regulator is normal or not.
(b) Inlet and outlet solenoid valve malfunction
Each time the ignition switch on, the ABS control unit will perform a self-test automatically; if the inlet or outlet
solenoid valve are found to be short or open, the ABS control unit will record this fault, turn a malfunction indi-
cator on and quit operating. If the corresponding DTC is read by the tester and the fault in the solenoid valve
is determined by the motion test, replace the hydraulic pressure regulator assembly immediately.
X431 data flow: inlet or outlet solenoid valve will change operating conditions quickly when the ABS is operating.
EVFL - front inlet valve LH close/open
AVFL - front outlet valve LH close/open
EVFR - front inlet valve RH close/open
AVFR - front outlet valve RH close/open
EVRL - rear inlet valve LH close/open
AVRL - rear outlet valve LH close/open
EVRR - rear inlet valve RH close/open
AVRR - rear outlet valve RH close/open
(c) Wheel speed sensor malfunction
With the engine running, measure the voltage between the sensor's signal line and the ground with an
oscilloscope.
Output signal when the wheel is stationary:
or
ALG073G
Brakes BR-35
35
Output signal when turning the wheel: the signal form is the rectangular wave signal with the voltage
of 0.44 V and 1.26 V, the duty ratio: 50:50.
ALG074G
The X431 tester has the function to display the data flow in the form of a waveform. As for intermittent
faults, such as wheel speed signal error (wheel speed sensor fault), that happens only when driv-
ing at a high speed or wheel speed signal error that happens occasionally when driving, etc, and the
wheel speed sensor can be determined whether there is a fault or not by continuously observing its
waveform. Keep the vehicle driving on a level road in a straight line; at this time, the waveform of the
4 speed sensors is quite close, and the signal wave of the 2 front wheels or the 2 rear wheels can be
compared at the same time.
Mechanical reason: the deformation of the signal gear ring, the looseness of the hub bearing, and the
dirty surface of the sensor, etc, might lead to the interruption or deviation of the wheel speed signal.
Example of a malfunction:
Signal interruption
ALG075G
As shown in the illustrations above, the ABS control unit will record the sensor fault and turn on the
malfunction indicator as soon as the intermittent fault of the speed sensor is detected.
(d) Speed sensor rate malfunction
If the ECU measured that the difference between one of speed sensors and the others is too big, the
possible reason may be that the clearance of gear ring speed sensor is out of tolerance or the speed
sensor signal is interfered. The sensor whose signal is deviated should be firstly determined, then
troubleshooting is performed according to the DTC list.
BR-36
ABS Trouble Code List:

Trouble code Malfunction description
C0035 Front wheel speed sensor LH circuit failure, velocity failure
C0040 Front wheel speed sensor RH circuit failure, velocity failure
C0045 Rear wheel speed sensor LH circuit failure, velocity failure
C0050 Rear wheel speed sensor RH circuit failure, velocity failure
C0060 Front ABS outlet solenoid valve LH failure
C0065 Front ABS inlet solenoid valve LH failure
C0070 Front ABS outlet solenoid valve RH failure
C0075 Front ABS inlet solenoid valve RH failure
C0080 Rear ABS outlet solenoid valve LH failure
C0085 Rear ABS inlet solenoid valve LH failure
C0090 Rear ABS outlet solenoid valve RH failure
C0095 Rear ABS inlet solenoid valve RH failure
C0110 Pump motor circuit failure, operational error
C0121 Solenoid valve relay circuit failure
C0161 Brake switch circuit failure
C0245 Wheel speed sensor frequency error, wheel speed sensor signal failure
C0287 Acceleration sensor failure
C0550 ECU failure
C0800 Voltage fault, voltage too high or too low
C0232 Warning lamp positive short circuit, warning lamp ground short circuit

Vehicle check
Hand-held detector 1. Connect the hand-held detector:
(a) Connect the hand-held detector to the DLC3.
(b) Start up and run the engine at an idle speed.
(c) Select the ACTIVE TEST mode on the hand-held detector.
Hint:
For detailed information, please refer to the Operation
Manual of the Hand-held Detector.
2. Check the operation conditions of the actuator motor
ALG006G (a) Check the operation sound of the actuator motor when
the motor relay is connected.
(b) Disconnect the motor relay.
3. Check the operation conditions of the front right
wheel
(a) Press the brake pedal and hold it for 15 seconds. Confirm
that further pressing of the brake pedal is not possible.
(b) Confirm the pedal vibration when the motor relay is
connected.
Caution:
The continuous connection time of the motor relay
must not exceed 5 seconds. When it is in continuous
operation, an interval of over 20 seconds should be set.
(c) Disconnect the motor relay and loosen the brake pedal.
Caution:
The following procedures to be obeyed when con-
necting the solenoid valve:
Brakes BR-37
37
(d) When pressing the brake pedal, perform the following

operation.
(e) Connect the EVFR and AVFR solenoid valve simultaneously
and confirm that further pressing of the pedal is not possible.
Caution:
The connection time of the solenoid valve must not
exceed 5 seconds. When it is in continuous opera-
tion, an interval of over 20 seconds should be set.
(f) Disconnect the EVFR and AVFR solenoid valve simul-
taneously and confirm that further pressing of the pedal
is not possible.
(g) With the motor relay on, check that the pedal returns.
Caution:
Do not keep the motor relay on for more than 5 sec-
onds. When it is in continuous operation, an inter-
val of over 20 seconds should be set.
(h) Disconnect the motor relay and loosen the brake pedal.
4. Check the operation conditions of the other wheels
(a) Check the solenoid valve of the other wheels with the
same procedure.
Caution:
Do not press the brake pedal if only the pressure
reducing solenoid valve is connected.
Hint:
• Left Front wheel: EVFL, AVFL
• Right rear wheel: EVRR, AVRR
• Left rear wheel: EVRR, AVRR
Replacement
Caution:
Immediately clean if the brake fluid is splashed
onto any painted surface.
3. Remove the ABS controller with a bracket
ABS controller (a) Release the latch of the connector of the ABS controller
assembly
to disconnect the connector.
Shock pad
ABS mounting
bracket assembly
ALG076G
(b) Remove the 3 bolts and ABS controller with a bracket.

4. Remove the ABS controller assembly
ABS controller (a) Remove the nut, 2 bolts and ABS controller assembly
assembly from the ABS controller bracket.
5. Install the ABS controller assembly
shock pad
ABS mounting
(a) Install the ABS controller with the 2 nuts to the ABS
bracket assembly controller.
Torque: 5.4 N·m
ALG077G
BR-38
6. Install the ABS controller with bracket

(a) Install the ABS controller with bracket with the 3 bolts.
ABS controller Torque: 19 N·m
assembly (b) Using an SST, connect the 6 brake tubes to the correct
Shock pad positions of the ABS controller, according to the tags or
ABS mounting by making a memo.
bracket assembly Torque: 16 N·m
(c) Connect the connector of the ABS controller.
ALG077G 7. Install the battery
BR-7)
13. Check the ABS controller with a hand-held detector
Front speed sensor LH

Replacement
Hint:
The procedures for replacing on the right side are the same
as the left side.
3. Remove the front wheel speed sensor

ALG078G
(b) Remove the 2 clamp bolts holding the speed sensor

wire harness from the body and the shock absorber.
(c) Disconnect the resin clip and the speed sensor wire
harness from the shock absorber.
ALG079G
Brakes BR-39
39
(d) Remove the bolt and front wheel speed sensor LH.
Caution:
Foreign material on the sensor ends should be
avoided.
ALG080G
4. Install the front wheel speed sensor

(a) Install the front wheel speed sensor LH with the bolt.
Torque: 8.0 N·m
Caution:
avoided.
ALG080G
(b) Remove the bolt and the front speed sensor LH.
Torque:
A
Screw bolt A：8.0
8.0 N·m
：8.0 N·m
Screw bolt B：2929 N·m
：29 N·m
Caution:
When installing the sensor, do not twist the sensor
wire harness.
B
(c) Connect the resin clip and the speed sensor wire har-
ALG081G ness to the shock absorber.
(d) Connect the speed sensor connector.

Torque: 110 N·m
6. Install the battery
7. Check the ABS speed sensor signal
ALG078G
BR-40
Rear wheel rotation speed sensor LH

Replacement
Hint:
The procedures for replacing on the right side are the same
as the left side.
1. Set the ignition switch to the OFF position
2. Remove the rear wheel LH
3. Disconnect the rear wheel speed sensor connector
LH
(b) Remove the rubber bushing of the rear wheel speed
sensor LH with bracket assembly.
ALG082G
4. Remove the rear speed sensor set bracket LH

(a) Remove the No.1 set bracket.
(b) Remove the No.2 set bracket.
ALG083G
5. Remove the rear wheel speed sensor assembly LH

(a) Remove the set clip of rear speed sensor LH.
(b) Install the rear speed sensor LH with the bolt.
Caution:
avoided.
ALG084G
6. Install the rear wheel speed sensor

(a) Install the rear wheel speed sensor LH with the bolt.
Torque: 8.0 N·m
Caution:
avoided.
ALG084G
Brakes BR-41
41
7. Install the rear speed sensor set bracket LH

(a) Install the No.1 set bracket.
(b) Install the No.2 set bracket.
ALG083G
8. Connect the rear wheel speed sensor connector LH

(a) Install the rubber bushing of the rear wheel speed sen-
sor LH with bracket assembly.
(b) Connect the speed sensor connector.
9. Install the rear wheel LH
Torque: 110 N·m
10. Check the ABS speed sensor signal
ALG082G
BR-42
Parking Brake System

Position of components
Parking brake handle
Right parking brake cable assembly
ALG085G

Reference
Page (s)
1. Parking brake lever's stroke (out of alignment) BR-43
2. Parking brake cable (broken) BR-46
3. Parking brake shoe's clearance (out of alignment) BR-32
4. Parking brake shoe lining (cracked or distorted) BR-27
Parking brake functions poorly
5. Tension or return spring (damaged) BR-27
6. Parking brake drum (worn or out of round) BR-27
7. The contact area between parking brake shoe -
lining and brake drum is too small.
Brakes BR-43
43
Adjustment
2. Adjust the rear drum brake shoe clearance (see
page BR-32)
Torque: 110 N·m
4. Check the parking brake lever travel
(a) Pull the parking brake handle all the way up and count
the number of clicks.
Parking brake lever travel: 6 to 7 clicks at 196 N
5. Adjust the parking brake lever travel
(a) Remove the parking brake lever panel.
(b) Remove the auxiliary facia console decorative carpet.
(c) Remove the auxiliary facia console assembly.
(d) Turn No.1 adjusting nut until the lever travel becomes
correct.
(e) Tighten the lock nut.
No.1 Adjusting Nut Torque: 5.4 N·m
ALG086G
BR-44
Parking Brake Handle

Components
Front ash tray assembly
Parking brake lever panel

Auxiliary facia console
decorative carpet
Screw
Buckle
Auxiliary facia console

assembly
Parking brake switch assembly
Parking brake
handle No.2 Adjusting nut
No.1 Adjusting nut

Parking brake equalizer
Parking brake
pull rod
: Required Torque
ALG087G
Brakes BR-45
45
Replacement
1. Remove the shift lever knob sub-assembly
2. Remove the parking brake handle cover plate
3. Remove the auxiliary facia console decorative car-
pet
4. Remove the auxiliary facia console assembly
(a) Remove the screw.
(b) Using a clip remover, disengage the 2 clips and remove
the floor console assembly.
5. Remove the No.1 adjusting nut
(a) Remove the lock nut and No.1 adjusting nut.
Buckle
ALG088G
6. Remove the parking brake handle

(a) Disconnect the parking brake switch connector.
(b) Remove the 2 bolts and the parking brake handle.
7. Remove the parking brake switch assembly
(a) Remove the screw and the parking brake switch.
8. Install the parking brake switch assembly
(a) Install the parking brake switch with the screw.
9. Install the parking brake handle
ALG089G (a) Connect the parking brake pull rod to the handle and
install the lock nut and No.1 adjusting nut.
(b) Install the parking brake handle with the 2 bolts.
Torque: 13 N·m
(c) Connect the parking brake switch connector.
10. Check the parking brake the lever travel (see page
BR-43)
11. Adjust parking brake lever travel (see page BR-43)
BR-46

Components
Parking brake equalizer
: Specified torque
Grease
ALG090G
Replacement
Hint:
For the removal and installation of the parking brake cable
assembly RH, follow the same procedures as for the LH.
1. Remove the shift lever knob sub-assembly
2. Remove the parking brake handle cover plate
3. Remove the auxiliary facia console decorative car-
pet
4. Remove the floor console assembly (see page
BR-45)
5. Remove the No.1 adjusting nut
(a) Remove the No.1 adjusting nut.
6. Remove the exhaust pipe rear protective support
(a) Remove the 2 bolts and the exhaust pipe rear shield
support.
7. Remove the sub muffler (see page EG-3)
Brakes BR-47
47
8. Remove front floor middle heat insulator

(a) Remove the 3 bolts and the front floor middle heat in-
sulator.
9. Separate the parking brake cable assembly LH
(a) Remove the 4 bolts and disconnect the parking brake
cable LH from the body.
(b) Disconnect the parking brake cable assembly LH from
the parking brake equalizer and remove the parking
ALG091G brake cable LH.
11. Remove the rear brake drum (see page BR-27)
12. Remove the brake trailing shoe assembly (see
page BR-28)
13. Remove the rear brake automatic adjust lever LH
(see page BR-28)
14. Remove the brake leading shoe assembly (see
page BR-28)
15. Remove the parking brake cable assembly LH
(a) Remove the bolt and disconnect the parking brake
cable assembly LH from the backing plate.
16. Install the parking brake cable assembly LH
(a) Connect the parking brake cable assembly LH to the
parking brake equalizer.
(b) Install the parking brake cable assembly LH with the 4
bolts.
ALG092G Torque: 5.4 N·m
ALG093G
BR-48
17. Connect the parking brake cable assembly LH

(a) Install the parking brake cable assembly LH with the
bolt to the backing plate.
Torque: 7.8 N·m
18. Apply high temperature grease (see page BR-30)
19. Install the brake leading shoe assembly (see page
BR-31)
20. Install the brake leading shoe assembly return
ALG092G
spring
21. Install rear brake automatic adjust lever LH (see
page BR-31)
22. Install the brake trailing shoe assembly (see page
BR-31)
23. Check the rear drum brake installation (see page
BR-32)
24. Install the rear brake drum
25. Adjust the rear drum brake shoe clearance (see
page BR-32)
Torque: 110 N·m
27. Temporarily tighten the No.1 adjusting nut
28. Install the front floor middle heat insulator
(a) Install the front floor middle heat insulator with the 3 bolts.
Torque: 5.5 N·m
29. Install the sub-muffler (see page EG-5)
30. Install the exhaust pipe rear protective support
(a) Install the exhaust pipe rear protective support with the
bolts.
31. Check the parking brake lever travel (see page
ALG091G BR-43)
32. Adjust the parking brake lever travel (see page
BR-43)
33. Check for exhaust gas leakage�.
SR-�

Steering
Steering System
Areas of Importance....................................................... SR-2
Malfunction Indicator Table........................................... SR-2
On-vehicle Inspection..................................................... SR-3
Maintenance.................................................................... SR-3
Steering column assembly............................................ SR-5
Overhaul.......................................................................... SR-6
Power steering system

Areas of Importance....................................................... SR-11
Malfunction Indicator Table........................................... SR-11
On-vehicle Inspection..................................................... SR-12
Power steering pump..................................................... SR-15
Power steering gear........................................................ SR-17
SR
SR-�
Steering System
Areas of Importance
1. Operational notice of steering system
(a) Be careful when replacing components. Incorrect replacement may influence the steering system's
performance and cause danger during drivng.
2. Handling precautions for the SRS airbag system
(a) The vehicle is equipped with a SRS (Supplemental Restraint System) such as the driver airbag and
front passenger airbag. Incorrect maintenance procedures may result in accidental SRS airbag de-
ployment and may cause serious accidents. Before servicing (including the removal or installation of
parts, inspection, or replacement), be sure to read the precautionary notice for the supplemental re-
straint system (see page RS-2).

Problem Cause(s) Troubleshooting
1. The clearance of the steering gear, 1. The clearance is to be adjusted by a pro-
rack is excessive. fessional. If it cannot be adjusted, replace
the steering gear.
2. The steering link inner/outer ball joint 2. Replace the ball joint stud as necessary
stud is worn. after check and confirming.
3. Steering joint is worn. 3. Replace the lower steering column.
Steering wheel 4. The connection of the steering shaft 4. Tighten the service bolt to the specified
free play is excessive/ and the steering gear is loose. torque.
Abnormal noise 5. The connection of the steering wheel 5. Tighten the steering wheel lock nut; if the
and the steering column is loose. spline is worn, replace the steering wheel
or steering column.
6. The steering gear mounting bolt is 6. Tighten the steering gear mounting bolt.
loose.
7. Drive shaft slide spline is worn and 7. Replace the lower steering column.
loose.
1. Tire pressure is insufficient. 1. Inflate according to the specified pres-
sure.
2. Front wheel alignment is not correct. 2. Check and adjust the front wheel align-
ment.
3. Clearance of the steering gear adjust- 3. Replace the steering or adjust the gear
ing block is small. adjusting block clearance by professional.
4. Steering column joint spider bearing 4. Replace the lower section of steering col-
is damaged. umn.
5. Steering link ball joint stud is lack of 5. R e p l a c e t h e s t e e r i n g t i e r o d b a l l .
oil or damaged.
6. Front shock absorber upper seat 6. Replace the front shock absorber upper
bearing is worn. seat connecting kit (refer to the Front
Suspension repair section).
Difficulty steering 7. Lower control arm ball joint is dam- 7. Replace the lower control arm (refer to
aged. front suspension repair part).
8. Steering oil pump is damaged, result- 8. Replace the power steering pump.
ing in the lack of output flow and input
pressure.
9. Power steering oil pump belt slips. 9. Adjust the belt's tension.
10. The fluid from the power steering 10. Replace the power steering gear.
gear leaks severely.
11. Power steering contains air bubbles 11. Turn the steering wheel repeatedly in the
and produces irregular noises. original place, bleeding out bubbles.
12. Power steering is insufficient. 12. After leaving it untouched for1 hours,
fill the power steering fluid of specified
type. Fill the power steering fluid of the
specified type until the fluid goes up to the
specified line in the reservoir.
Steering SR-�

Problem Causes Troubleshooting

1. Tire pressure is insufficient. 1. Inflate the tire to the specified air pressure.
2. The poor wheel dynamic balance is 2. Correct the wheel dynamic balancing.
caused by factors such as the wheel
balance weight dropped.
3. The lower control arm bush rubber is 3. Replace the lower control arm.
deteriorated. The difference between
the LH and RH rigidity is great.
4. The lubrication of the front shock 4. Charge the grease as specified.
absorber upper seat bearing, lower
Poor return/Stability control arm ball joint is insufficient.
is poor when driving 5. Four wheel alignment parameters are 5. Measure and adjust the four wheel align-
straight not correct. ment parameters.
6. The condition of the steering gear 6. Replace the steering gear.
rack engaging is bad. The counter
resistance increases.
7. The steering column bearing and joint 7. Replace the steering column assembly.
spider bearing are damaged.
8. The oil volume of the power steering 8. Replace the power steering oil pump.
oil pum p is insufficient.
9. The performance of the steering gear 9. Replace the power steering gear.
inner control valve decreases.
Max.
free play 1. Check the steering wheel free play.
(a) Stop the vehicle with the wheels pointed straight ahead.
(b) Check the steering wheel free play by turning the steel
wheel in the clockwise and counterclockwise directions
until the resistance increases.
Maximum free play: 30 mm
ALH001G
Steering Maintenance
wheel
Adhesive tape 1. Steering eccentricity maintenance procedures
Combination (a) Check the mannerisms of the steering wheel.
switch upper (1) Apply adhesive tape to the center of the upper part
cover
of the steering wheel and the combination switch's
upper protective cover.
(2) Drive straight ahead for 100 meters at a constant
speed of 56 km/h and grip the steering wheel to
ALH002G
stay on the road.
Combination switch's (3) As shown in the figure, draw a line on the adhe-
upper protective cover sive tape.
Mark line
Steering wheel
Adhesive tape
ALH003G
SR-�
Combination switch's (4) Turn the steering wheel to the middle position.
upper protective cover Hint:
Mark line
Steering wheel
Refer to the upper surface of the steering wheel,
steering spoke, and the SRS airbag line for the
straight position.
(5) As shown in the figure, draw a new line on the ad-
hesive tape on the steering wheel.
(6) Measure the distance between the two lines on
ALH004G the adhesive tape on the steering wheel.
(7) Convert the measured distance into the steering
angle.
Measured distance of 1 mm = Steering angle of
about 1 degree.
Hint:
Make a note of the steering angle.
(b) Adjust the steering angle.
(c) Perform the following steps respectively on the left and
Tie rod Rack end right sides.
(1) Mark the tie rod and rack end in prominent posi-
tions.
(2) Use a gauge to measure the distance between the
tie rod and the rack end thread.
Mark line
ALH005G
(3) Remove the left and right dust cover clips from the
rack dust cover.
(4) Loosen the left and right lock nuts.
(5) Rotate the left and right rack ends in the same an-
gle (different directions). Turn the RH and LH rack
end by the same amount (but in different direc-
tions) according to the steering angle. Turn 360°
from the rack end (1.5 mm horizontal movement) -
ALH006G 12° of the steering angle.
(6) Tighten the RH and LH lock nuts.
Torque: 74 N·m
Notice:
Make sure that the difference in length be-
tween the RH and LH tie rod ends and rack end
threads are within 1.5 mm.
(7) Install the left and right dust cover clips.
Steering SR-�

Steering Column Assembly

Components
Driver side airbag

Combination switch's upper protective cover
Steering wheel
Clock spring
Combination switch assembly
assembly RH
Combination switch lower

protective cover
Combination switch assembly LH

Steering column
Steering propeller shaft
Steering dust cover
: ��
Specified torque
ALH007G
SR-�
Overhauling
1. Precautions (see page RS-2)
2. Disconnect the battery negative terminal (see page
RS-2)
3. Place the front wheels facing straight ahead
4. Remove the driver airbag (see page RS-26)
(a) Remove the 2 bolts and the driver's side airbag.
Bolt ALH008G
Lock nut 5. Remove the steering wheel

(a) Using an M18 socket wrench, turn the steering wheel
lock nut counterclockwise and remove it.
(b) Grip the entire steering wheel, shake it several times,
and then to pull out the steering wheel upwards.
ALH009G
Combination switch's upper protective cover 6. Remove the combination switch cover
(a) Remove the 3 screws.
(b) Remove the combination switch upper cover.
(c) Remove the combination switch lower cover.
7. Remove clock spring sub-assembly (see page
RS-33)
Combination
switch lower
protective cover
ALH010G
8. Remove the combination switch RH and LH and ig-

nition switch
(a) Disconnect the wire harness from the combination
Right Left
combination switch and ignition switch.
combination
switch switch (b) Remove the combination switch LH.
Ignition switch (c) Remove the combination switch RH.
ALH011G
Steering SR-�

(d) Remove the ignition switch.
ALH012G
9. Separate the steering column and steering shaft

(a) Put matchmarks on the steering shaft and steering col-
umn.
(b) Using an M13 socket wrench, remove the bolt and then
separate the steering shaft.
Bolt
ALH013G
Bolt (d=22) 10. Remove the steering column

(a) Using an M13 socket wrench, remove the 3 bolts con-
nected to the instrument panel reinforcement member.
(b) Pull out the steering column along the upper tip axis
line of the column.
Bolt
ALH014G
11. Remove the steering column dust cover

(a) Turn the plastic clip counterclockwise by hand.
(b) Remove the steering column dust cover from the steer-
ing shaft.
Buckle
ALH015G
12. Separate the steering shaft and steering connect-

ing shaft
(a) Put matchmarks on the steering shaft and steering con-
Bolt necting shaft.
(b) Using an M13 socket wrench, remove the bolt which
connects the steering shaft and steering connecting
shaft.
(c) Remove the steering shaft.
ALH016G
SR-�
13. Remove the steering connecting shaft

Connecting shaft (a) Remove the steering connecting shaft protector assem-
protector assembly bly.
(b) Using an M13 socket wrench, remove the bolt.
Bolt (c) Remove the steering connecting shaft.
ALH017G
14. Install the steering connecting shaft

Connecting shaft
(a) Connect the steering connecting shaft.
protector assembly
(b) Install the bolt.
(c) Install the steering connecting shaft protector assembly.
Bolt
ALH017G
15. Connect the steering shaft and steering connecting

shaft
(a) Install the steering shaft.
Bolt (b) Connect the steering shaft to the steering connecting
shaft.
ALH016G
16. Install the steering column dust cover

(a) Install the steering column dust cover to the steering
shaft.
(b) Turn the plastic clip clockwise by hand.
Buckle
ALH015G
Bolt (d=22) 17. Install the steering column

(a) Insert the steering column assembly along the upper tip
axis line of the column.
(b) Install the 3 bolts connected to the instrument panel re-
inforcement member.
Bolt
ALH014G
Steering SR-�

18. Connect the steering column and steering shaft

(a) Connect the steering shaft to the steering column.
Bolt
ALH013G
19. Install the combination switch RH and LH and igni-

tion switch
(a) Install the ignition switch.
ALH012G
(b) Install the combination switch RH.

(c) Install the combination switch LH.
(d) Connect the wire harness to the combination switch
Right combina- Left combination and ignition switch.
tion switch switch
20. Install clock spring sub-assembly (see page RS-34)
Ignition switch
ALH011G
Combination switch's upper protective cover 21. Install the combination switch cover
(a) Install the combination switch lower cover.
(b) Install the combination switch upper cover.
(c) Install the 3 screws.
Combination
switch lower
protective
cover ALH010G
Lock nut 22. Install the steering wheel

(a) Insert the steering wheel downward.
(b) Using an M18 socket wrench, turn the steering wheel
lock nut clockwise to install it.
ALH009G
SR-��
23. Install the driver airbag

(a) Install the 2 bolts and driver airbag.
24. Connect the battery negative terminal
Bolt ALH008G
Steering SR-��
11
Power Steering System

Areas of Importance
1. Operation notice of the steering system
(a) Be careful when replacing components. Incorrect replacement may influence the steering system's
performance and cause danger during drivng.
2. Handling precautions on the SRS airbag system
(a) The vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and
front passenger airbag. Incorrect maintenance procedures may result in SRS airbag accidental de-
ployment and can cause serious accidents. Before servicing (including the removal or installation of
parts, inspection, or replacement), be sure to read the precautionary notice for the supplemental re-
straint system (see page RS-2).
Hint:
In the following table, the suspected areas are listed according to the order of the number in order to de-
Reference
Page(s)
1. Tires (Improperly inflated) SP-35
2. Power steering fluid level (Low) SR-12
3. Front wheel alignment (Incorrect) SP-7
4. Steering system joints (Worn) -
Hard steering 5. Suspension lower rocker arm ball SP-17
joint (Worn)
6. Steering column (Binding) -
7. Power steering oil pump SR-15
8. Power steering gear SR-18
1. Tires (Improperly inflated) SP-35
2. Front wheel alignment (Incorrect) SP-7
3. Steering column (Binding) -
Poor return 1 4. Power steering gear SR-18
6. Suspension lower rocker arm ball SP-17
joint (Worn)
2. Suspension lower rocker arm ball SP-17
joint (Worn)
3. Steering connecting shaft sub-as- -
Excessive free play
sembly (Worn)
4. Steering shaft joints (Worn) -
5. Front wheel bearing (Worn) DT-2
1. Power steering fluid level (Low) SR-12
Abnormal noise
3. Power steering oil pump SR-15
SR-��
1. Check the steering pump belt.
(a) Visually check the belt for excessive wear, frayed
cords, etc. If any defect is found, replace the steering
oil pump belt.
Hint:
Cracks on the rib side of a belt are considered accept-
able. Replace the belt if there are any missing ribs.
ALH018G
2. Bleed the power steering system
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with
stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly
from lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Lower the vehicle.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to the left or
right full lock position and keep it there for 2 to 3
seconds, then turn the wheel to the opposite full
lock position and keep it there for 2 to 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for foaming or emulsification.
Yes NG If the system has to be bled twice because of foaming
or emulsification, be sure to check whether the fluid
leaks or is not in the system.
(i) Check the fluid level.
ALH019G
3. Check the fluid level

(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON III
Hint:
Check that the fluid level is between the MAX and MIN
ALH020G marks.
(c) Start the engine and run at idle.
(d) Turn the steering wheel from lock to lock several times
to raise the fluid temperature.
Fluid temperature: 80°C
Steering SR-��
13
(e) Check for foaming or emulsification.

Yes NG If foaming or emulsification is identified, bleed the pow-
er steering system.
ALH019G
(f) With the engine idling, measure the fluid level in the oil
5 mm or less
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and measure the fluid level in the
oil reservoir again.
Maximum fluid level rise: 5 mm
If a problem is found, bleed the power steering system.
Engine Idling Engine Stopped (i) Check the fluid level.
ALH021G 4. Check the steering fluid pressure
(a) Disconnect the pressure feed tube from the power
steering oil pump (see page SR-15).
(b) Connect the SST as shown in the following illustration.
Notice:
Check that the valve of the SST is in the open posi-
tion.
(c) Bleed the power steering system.
(d) Start the engine and run at idle.
(e) Turn the steering wheel from lock to lock several times
to raise the fluid temperature.
Fluid temperature: 75°C to 80°C
Attachment Pressure feed tube
Power steering pump
In Out
Attachment
ALH022G
SR-��
(f) With the engine idling, close the valve of the SST and
PS fluid observe the reading on the SST.
reservoir Minimum fluid pressure:
Power 5,900 kPa
steering Close Notice:
gear
• Do not keep the valve closed for more than 10
Power
steering seconds.
pump • Do not let the fluid temperature become too
ALH023G high.
(g) With the engine idling, open the valve fully.

PS fluid (h) Measure the fluid pressure at engine speeds of 1,000
reservoir rpm and 3,000rpm.
Power Fluid pressure difference:
steering
Open
490 kPa or less
gear
Notice:
Power
steering Do not turn the steering wheel.
pump
ALH024G
(i) With the engine idling and the valve fully opened, turn
the steering wheel to the full lock position.
PS fluid
Turn the steering reservoir Minimum fluid pressure:
Power wheel fully 5,900 kPa
Steering
Open
Notice:
gear • Do not maintain the lock position for more than
Power
steering
10 seconds.
pump • Do not let the fluid temperature become too
ALH025G high.
(j) Disconnect the SST.
(k) Connect the pressure feed tube to power steering oil
pump (see page SR-16).
(l) Bleed the power steering system.
5. Check the steering effort
(a) Center the steering wheel assembly.
(b) Remove the driver airbag (see page RS-26)
(c) Start the engine and run at idle.
(d) Measure the steering effort in both directions.
Steering effort (Reference):
6 N·m or less
Hint:
ALH026G Take the tire type, the pressure, and the contact sur-
face into consideration before making a diagnosis.
(e) Tighten the steering wheel assembly set nut.
Torque: 50 N·m
(f) Install the driver airbag (see page RS-26)
Steering SR-��
15
Power Steering Pump

Replacement
1. Remove the steering oil reservoir cover
2. Drain the power steering fluid
(a) Disconnect the inlet hose of the power steering oil
pump and store the power steering fluid in a container.
3. Remove the front wheel RH
4. Remove the engine under cover RH
5. Separate the pressure feed tube from the oil pres-
sure sensor
(a) Using an SST, disconnect the pressure feed tube from
the power steering oil pump.
(b) Disconnect the oil pressure sensor connector.
ALH027G
6. Remove the power steering oil pump

(a) Remove bolt A and power steering oil pump belt.
(b) Remove bolt B and power steering oil pump.
ALH028G
7. Install the power steering oil pump

(a) Install the power steering oil pump to the bracket with
bolt B.
(b) Install the oil pump belt and install the power steering
oil pump to the adjusting bracket with bolt A.
ALH028G
SR-��
8. Connect the pressure feed tube and oil pressure

sensor
(a) Using an SST, connect the pressure feed tube.
Torque: 30 N·m
Hint:
• Use a torque wrench with a fulcrum length of
Fulcrum 345 mm.
length • This torque value is effective when the SST is par-
allel to a torque wrench.
ALH029G
(b) Connect the oil pressure sensor connector.
9. Connect the fuel inlet house to the power steering
oil pump
10. Adjust the power steering oil pump belt
11. Inspect the power steering oil pump belt deviation
and tension (Reference)
12. Add power steering fluid (see page SR-12)
13. Bleed the power steering system (see page SR-12)
14. Check for fluid leakage
15. Install the engine under cover RH
16. Install the front wheel RH
Torque: 110 N·m
17. Check fluid level in the reservoir (see page SR-12)
18. Install the steering oil reservoir cover
Steering SR-��
17
Power Steering Gear

Components
Steering combination pipe Steering connecting shaft

protector assembly
Steering gear shield
Cotter pin
Steering
connecting
shaft
Steering gear mounting bracket
Auxiliary frame strut rod RH
Steering gear mounting bush
Engine rear mounting

Power steering gear
Lock pin
Auxiliary frame sub-assembly

Auxiliary frame
strut rod LH
Lock pin
: specified torque
non-reusable components
ALH030G
SR-��
Replacement
2. Remove the steering column dust cover (see page
SR-7)
3. Separate the steering shaft joint

(a) Attach the steering wheel with the seat belt in order to
prevent rotation.
Hint:
This operation is also useful to prevent damaging the
clock spring.
ALH031G
(b) Put matchmarks on steering shaft joint and steering

connecting shaft.
(c) Loosen the bolt, then separate steering shaft joint from
Installation
the steering connecting shaft.
mark
ALH032G
4. Separate the steering connecting shaft protector

assembly
(a) Separate clip A and the connecting shaft protector as-
sembly.
Notice:
Be careful not to damage clip B.
ALH033G
5. Open the engine hood

6. Drain the power steering fluid
8. Separate the tie rod end assembly LH (see page
SP-15)
9. Separate the tie rod end assembly RH
Hint:
Perform the same procedure on the other side.
10. Remove the engine under cover LH
11. Remove the engine under cover RH
Steering SR-��
19
Return 12. Separate the steering combination tube

Clamp hose (a) Remove the clamp and disconnect the return hose.
(b) Using an SST, disconnect the pressure feed tube.
SST
Pressure
feed tube
ALH034G
(c) Remove the bolt and separate the pipe clamp.
ALH035G 13. Separate the front suspension lower control arm

LH (see page SP-16)
14. Separate the front suspension lower control arm RH
Hint:
N o.1 Engine Hanger 15. Suspend the engine assembly
(a) Install 2 No.1 engine hangers with the bolts in the cor-
rect direction.
Torque: 40 N·m
(b) Attach the engine chain hoist to the engine hangers.
Caution:
Do not hang the engine by hooking the chain to any
other parts.
ALH036G
16. Remove the auxiliary frame sub-assembly

(a) Remove the 4 bolts and 2 strut rods.
ALH037G
SR-��
(b) Remove the bolt and the 2 nuts, and separate the en-
gine rear mounting.
(c) Using a jack, support the auxiliary frame sub-assembly.
ALH038G
(d) Remove the 4 bolts and the auxiliary frame sub-assem-

bly.
ALH039G
17. Remove the steering gear shield

(a) Remove the 2 bolts and the shield.
18. Remove the steering connecting shaft protector as-
sembly
19. Remove the steering connecting shaft
Installation mark (a) Put matchmarks on the power steering gear and the
connecting shaft.
(b) Remove the bolt and the connecting shaft.
ALH040G
20. Remove the power steering gear

Installation mark (a) Put matchmarks on the power steering gear and
mounting bracket.
Front
ALH041G
Steering SR-��
21
(b) Remove the 4 bolts, the nuts, the mounting bracket, the
bush, and the power steering gear.
Notice:
• Hold the nut to turn the bolt as the nut has its
own stopper.
• Do not turn the nut.
ALH042G
21. Attach the power steering gear

(a) Using an SST, hold the power steering gear.
Hint:
Wrap the SST with vinyl tape before use.
ALH043G
22. Remove tie rod end assembly LH

(a) Put matchmarks on the tie rod end assembly LH and
the rack end sub-assembly.
(b) Loosen the lock nut and remove the tie rod end assem-
bly LH and the lock nut.
Installation mark
ALH044G
23. Remove tie rod end assembly RH

Hint:
24. Inspect the tie rod end assembly LH
(a) Secure the tie rod end assembly LH in a vise.
(b) Install the nut to the ball joint.
(c) Flip the ball joint back and forth 5 times.
(d) Use a Torx wrench to turn the nut continuously at a rate
of 2 to 4 seconds per turn, and read the torque value at
the 5th turn.
Torque:
ALH045G 0.8 to 3.4N·m
25. Remove the tie rod end assembly RH
Hint:
SR-��
26. Install the tie rod end assembly LH

(a) Install the lock nut and tie rod end assembly LH to rack
end sub-assembly until the matchmarks are aligned.
Torque: 74 N·m
Hint:
After adjusting the toe-in, tighten the lock nut (see page
SP-7).
Installation mark
ALH044G
27. Install the tie rod end assembly RH

Hint:
28. Install the power steering gear
Installation mark (a) Install the mounting bushing to the power steering gear.
(b) Align the matchmarks and install the mounting bracket
to the power steering gear.
Notice:
Install the bracket with the inscribed mark facing to
the front of the vehicle.
Front
ALH041G
(c) Install the power steering gear with the 4 bolts and the
nuts.
Torque: 107 N·m
Notice:
• Hold the nut to tighten the bolt as the nut has
its own stopper.
• Do not turn the nut.
ALH042G
29. Install steering connecting shaft

Installation mark (a) Align the matchmarks on the power steering gear and
the connecting shaft.
(b) Install the bolt.
Torque: 25 N·m
ALH040G
Steering SR-��
23
30. Install the steering connecting shaft protector as-

sembly
31. Install the steering gear shield
(a) Install the shield with bolt A as shown in the illustration.
Torque: 18 N·m
(b) Install bolt B to the shield.
Torque: 21 N·m
ALH046G
32. Install the auxiliary frame sub-assembly

(a) Using a jack, support the auxiliary frame sub-assembly.
(b) Align the holes of the auxiliary frame and body.
Hint:
ALH047G
(c) Install the auxiliary frame sub-assembly with the 4

B B bolts.
Torque:
Bolt A: 145 N·m
Bolt B: 120 N·m
A A
ALH048G
(d) Connect the engine rear mounting with the bolt and the
2 nuts.
Torque: 78 N·m
ALH038G
SR-��
(e) Install the 2 strut rods with the 4 bolts.

Torque: 49 N·m
ALH037G 33. Install the front suspension lower control arm LH

(see page DT-14)
34. Install the front suspension lower control arm RH
Hint:
35. Connect the steering combination tube
(a) Using an SST, connect the pressure feed tube.
Torque: 27 N·m
Hint:
Use a torque wrench with a fulcrum length of 345 mm.
This torque value is effective when the SST is parallel
Fulcrum length to a torque wrench.
ALH049G
(b) Connect the return hose with the clamp.

(c) Install the pipe clamp to auxiliary frame sub-assembly
with the bolts.
Torque: 7.8 N·m
ALH035G
36. Install tie rod end assembly LH (see page SR-23)

37. Install the tie rod end assembly RH
Hint:
Torque: 110 N·m
39. Install the steering shaft joint
(a) Align the matchmarks on the steering shaft joint and
steering connecting shaft.
(b) Tighten the bolt.
Installation
mark Torque: 25 N·m
ALH032G
Steering SR-��
25

41. Install the steering connecting shaft protector as-
sembly
42. Fill the power steering fluid
43. Bleed power steering system (see page SR-12)
44. ��
Check fluid level in reservoir� (see page SR-12)
45. Check for fluid leakage
46. Inspect and adjust the front wheel alignment (see
page SP-7)
47. Install the engine under cover LH
48. Install the engine under cover RH
MEMO
AV-1
1
Audio/video system
Audio and Video System

Parts location.................................................................. AV-2
Malfunction Indicator Table........................................... AV-3
Inspection........................................................................ AV-4
CD Player Assembly....................................................... AV-4
Front door speaker assembly LH.................................. AV-5
Front tweeter assembly LH............................................ AV-6
D pillar mid-low tone speaker assembly LH................. AV-6
Antenna Wire Harness Assembly.................................. AV-7
Cigarette Lighter Assembly........................................... AV-8
Window Glass (Antenna Wire)....................................... AV-9
Power Socket.................................................................. AV-10
AV
AV-2
Audio and Video System

Parts location
CD player bracket LH
CD player assembly
CD player bracket RH
A/C control knob
Glove box body

CD player with
bracket assembly
Backup power socket
Cigarette lighter
assembly Small glove box body
Cigarette lighter socket assembly
Cigarette lighter light Cigarette lighter plug

ring assembly assembly
ALI001G
Audio/Video System AV-3
3
A pillar tweeter assembly LH D pillar tweeter assembly LH
Front tweeter assembly LH

W/ Holder Antenna Assembly
Front door speaker

assembly LH
Rear door low tone LH

apeaker assembly LH
D pillar mid-low tone
speaker assembly LH
Note:
The right speaker is not displayed
ALI002G

Hint:
The causes and the suspected areas of the other speakers are the same with the following table.
No sound can be heard only from the 1. Front door speaker assembly LH BO-10
front door speaker LH. 2. Wire harness -
No sound can be heard only from the 1. Front tweeter assembly LH AV-6
front tweeter LH. 2. Wire harness -
No sound can be heard only from the 1. D pillar mid-low tone speaker assembly LH AV-4
D pillar mid-low tone speaker LH. 2. Wire harness -
AV-4
Inspection
Hint:
The inspection method of the other speakers is the same as the
front door speaker LH or the D pillar mid-low tone speaker LH.
1. Front door speaker assembly LH
(a) Inspect whether the front door speaker LH is conducting.
(1) Inspect and confirm the terminals are conducting
with each other.
ALI003G
Standard:
Testing instrument
Condition Specification
connection
1 - 2 Always 4 W
2. D pillar mid-low tone speaker assembly LH

(a) Inspect the D pillar mid-low tone speaker assembly LH
continuity.
(1) Inspect the and confirm the terminals are conduct-
ing with each other.
Standard:
Testing instrument
Condition Specification
connection
ALI004G
1 - 2 Always 4 W
CD Player Assembly
Replacement
Hint:
Location: see page AV-2
1. Disconnect the battery negative terminal
2. Remove center console panel body (see page
IR-29)
3. Remove the CD player w/bracket assembly
(a) Remove 4 bolts.
(b) Disconnect the connector.
(c) Remove the CD player with bracket assembly.
ALI005G
5
4. Remove the CD player bracket RH

(a) Remove the 4 bolts and the CD player's right bracket.
ALI006G
5. Remove the CD player bracket LH

(a) Remove 4 the bolts and the CD player's left bracket.
6. Replace the CD player assembly
7. Install the CD player assembly by reversing the re-
moval steps
Front door speaker assembly LH

ALI007G
Replacement
Hint:
The replacement of the front door speaker LH is the same
as with the front door speaker RH.
1. Remove the front door triangular trim LH (see page
BO-8)
2. Remove the front window main switch assembly LH
(see page BO-9)
3. Remove the front door trim panel LH (see page
BO-9)
4. Remove the front door speaker assembly LH
(a) Remove the 3 screws and the 3 plastic clips.
(b) Remove the speaker.
(c) Disconnect the speaker connector.
ALI008G
5. Install the front door speaker assembly LH

(a) Connect the speaker connector.
(b) Install the speaker.
(c) Install the 3 screws and the 3 plastic clips.
ALI008G
AV-6
Front tweeter assembly LH

Replacement
Hint:
• The replacement of front tweeter assembly LH is the
same as front tweeter assembly RH.
• Location: see page AV-3
1. Remove the instrument panel speaker shield LH
2. Remove the front tweeter assembly LH
(a) Remove the 2 screws and the front tweeter assembly
LH.
3. Replace the front tweeter assembly LH
4. Install the front tweeter assembly LH
(a) Attach the connector
(b) Install the front tweeter assembly LH with the 2 screws.
ALI009G Hint:
The installation sequence is the reverse of the removal
sequence.
D pillar mid-low tone speaker assembly LH

Replacement
Hint:
• The removal procedure of D pillar mid-low tone speaker
RH is the same as D pillar mid-low tone speaker LH.
• Location: see page AV-3
1. Remove the rear rocker trim LH (see page IR-62)
2. Remove the rear door sealing strip LH (see page
BO-25)
3. Remove the back door sealing strip
4. Remove the spare-tire cover assembly
5. Remove the rear seat belt assembly
6. Remove back door rocker shield (see page IR-63)
7. Remove the C pillar lower trim panel assembly (see
page IR-63)
8. Remove the D pillar mid-low tone speaker assem-
bly LH
(a) Remove the 3 screws and the D pillar mid-low tone
speaker assembly LH.
9. Install the D pillar mid-low tone speaker assembly
LH
(a) Attach the connector
ALI010G
(b) Install the 3 screws and the D pillar mid-low tone
speaker assembly LH.
Hint:
sequence.
7
Antenna Wire Harness Assembly

Replacement
Hint:
1. Remove the roof headlining assembly (see page IR-64)
2. Remove the instrument panel body (see page IR-28)
3. Remove w/holder antenna wire harness assembly
(a) Disconnect the connector.
(b) Remove the relevant clips and bolts.
(c) Remove w/holder antenna wire harness assembly.
: Clip
ALI011G
4. Install roof headlining assembly

AV-8
Cigarette Lighter Assembly

Replacement
Hint:
2. Remove center console panel body (see page
IR-29)
3. Remove small glove box body (see page IR-34)
4. Remove the cigarette lighter cover
(a) Separate the 2 claws and remove the cigarette lighter
cover.
: Claw ALI012G
5. Remove the cigarette lighter assembly

(a) Remove the cigarette lighter assembly.
(b) Separate the claws between the cigarette lighter seat
assembly and the cigarette lighter clear aperture as-
sembly. Then rotate the cigarette lighter seat assembly
in the direction as shown in the figure and pull it out.
ALI013G
(c) Align the cigarette lighter seat assembly with the slot
on the cigaretter lighter clear aperture assembly and
remove the cigarette lighter assembly.
ALI014G
6. Install the cigarette lighter assembly

(a) Align the cigarette lighter seat assembly with the slot on
the cigarette lighter clear aperture assembly and push
the cigarette lighter assembly in as far as possible.
(b) Install the cigarette lighter head assembly.
9
Window Glass (Antenna Wire)

Maintenance
1. Check the window glass (antenna wire)
Caution:
When cleaning the glass, use a soft, dry cloth and wipe
Tester probe
the glass in the direction of the wire. Be careful not to
Lead wire
damage the wire. Do not use detergents or glass clean-
Tin foil ers with abrasive compounds. When measuring the
voltage, wind a piece of aluminum foil around the top of
the negative probe and press the aluminum foil against
ALI015G the wire with your finger, as shown in the illustration.
(a) Inspect the continuity, at the center of each antenna

wire, as shown in the illustration.
ALI016G
2. Repair the window glass (antenna wire)

Repair point
(a) Clean the broken wire tips with grease, wax, and, sili-
cone remover.
(b) Place masking tape along both sides of the wire to be
repaired.
Adhesive (c) Thoroughly mix the repair agent.
tape Broken wire
ALI017G
(d) Using a fine tip brush, apply a small amount repair

Fine tip brush agent to the wire.
(e) After a few minutes, remove the masking tape.
(f) Do not repair the antenna wire for at least 24 hours.
Repair point
Window
ALI018G
AV-10
Power Socket
Replacement
Hint:
• The following procedures do not apply to the left-hand
drive models.
• Location: see page AV-2.
2. Remove the center console panel body (see page
IR-29)
3. Remove the small glove box body (see page IR-34)
4. Remove the power socket assembly
(a) Rotate the socket to separate the slot.
ALI019G
(b) Pull out part of the socket and rotate it until the protrud-
ing component is aligned with the slot on the cover.
Then, remove the power socket.
ALI020G
5. Remove the power socket cover

(a) Separate the 2 claws and remove the cover.
ALI021G
11
Installation
Hint:
The following procedures do not apply to the left-hand drive
models.
1. Install the power socket cover
(a) Engage the 2 claws and install the socket cover.
ALI021G
2. Install the power socket assembly

(a) Align the protruding mechanism on the back of the
socket with the slot on the cover. Then, push the socket
into the cover.
3. Install small glove box body
4. Install the CD player with the bracket assembly
ALI022G
MEMO
AC-1
1
AC system

AC System....................................................................... AC-2
Areas of Importance....................................................... AC-2
Vehicle Check.................................................................. AC-4
Routine Inspections........................................................ AC-7
Refrigerant....................................................................... AC-9
Refrigerant Pipeline........................................................ AC-15
A/C Controller Assembly No.1....................................... AC-16
A/C Controller Assembly No.2....................................... AC-19
AC Assembly................................................................... AC-21
Compressor Assembly................................................... AC-27
Subcooling Condenser Assembly................................. AC-29
AC
AC-2
AC System
Areas of Importance
1. Do not handle the refrigerant in an enclosed area or
close to an exposed flame.
2. Make sure to wear goggles.
ALJ001G
3. Pay close attention not to get liquid refrigerant in the

eyes or on the skin.
(a) If the liquid refrigerant is splashed into the eyes or on
the skin, rinse the eyes or skin immediately with large
amounts of cool water.
Caution:
Do not rub the eyes or skin.
(b) Apply petroleum jelly to the skin.
(c) Go to the hospital to receive professional treatment imme-
diately.
4. Never heat the refrigerant tank or keep close to an
open flame.
ALJ002G 5. The refrigerant tank must not be dropped and must be
handled with care.
6. Do not operate the compressor in the event that there

Incorrect Correct is not enough refrigerant in the refrigeration system.
If there is not enough refrigerant in the refrigeration sys-
tem, the engine oil may lack sufficient lubrication and the
compressor may burn out. Please pay special attention so
that this does not occur.
7. Never open the high pressure manifold valve during
the operation of the compressor.
If the high pressure valve is opened, the refrigerant will
flow in the opposite direction and might break the charging
cylinder. Therefore, only the low pressure valve is allowed
ALJ003G
to be opened and closed.
8. Make sure not to put too much refrigerant into the
system.
If filling with too much refrigerant, then insufficient cooling,
poor fuel economy, and overheating of the engine might
occur.

listed on the following pages.
Reference
Page (s)
1. Blower fuse -
2. Instrument fuse -
AC system does not work
3. AC controller assembly 2 AC-8
4. Wire harness or connector -
1. Heater fuse -
3. Blower speed adjustive resistance AC-8
Blower does not work or works poorly 4. Blower relay AC-9
5. Blower assembly AC-9
AC System AC-3
3
Reference
Page (s)
1. Blower assembly AC-9
2. Blower speed adjustive resistance AC-8
Insufficient air vent function.
1. Refrigerant amount AC-9
2. Tension of drive belt -
3. Refrigerant pressure AC-10
4. Compressor assembly AC-6
Temperature control: no cold air is emitted.
5. Pressure switch AC-6
6. Condenser fan -
1. Engine coolant amount EG-5
Temperature control: no warm air is emitted.
3. AC assembly AC-21
Temperature control: air vent temperature
is higher or lower than the setting or has a
2. Temperature threshold cable -
slow response.
Temperature control: no temperature control.
2. Temperature threshold cable -
1. AC control knob assembly -
No air intake control.
No air outake control.
2. Position damper cable -
1. A/C Switch AC-8
Engine cannot run at an idle speed or runs 2. Compressor assembly AC-6
continuously at an idle speed. 3. AC controller assembly 1 AC-16
AC-4
Vehicle Check
1. AC function inspection
(a) Install high pressure gauge.
(b) Set the vehicle to the conditions below [*1].
Items Condition
Vehicle Stop the vehicle in the shade
Door Fully open
Air conditioner switch Open
Engine speed 2,000 rpm
Air inlet mode selector damper position Outer circle
Air outlet damper position Face
Set temperature MAX COOL
Blower speed Ground
A/C inlet temperature *2 25 to 30 °C
Condenser pressure (high pressure side gauge) *3 1.5 MPa
Hint:
• *2 Since the correct judgment can be made only when the inlet air temperature stays between
25 °C and 35 °C, postpone the test if the temperature is lower than 25 °C.
• *3 When the condenser pressure (high pressure side gauge) is higher than 1.5 MPa, water the
condenser to decrease the pressure. When the condenser pressure is too low, cover the front side
of the condenser to increase the pressure.
(c) Place a dry and wet bulb thermometer at the air inlet and insert the bulb of a dry bulb thermometer at
the center of the air outlet.
(d) Operate the air conditioner by following [*1] and stabilize the air outlet temperature (approx. 5 to 6
minutes).
(e) Measure the wet bulb temperature at the air inlet and the dry bulb temperature at the air outlet.
(f) Using the hygrometric chart below, determine the relative humidity value, based on the measured val-
ues of the wet and dry bulb thermometers in the inlet.
Relative Humidity
Wet Bulb Temperature
Relative Humidity
Dry Bulb Temperature (°C)

ALJ004G
AC System AC-5
5
Example (1) For example, when the dry bulb temperature is

Wet Bulb 25 °C and the wet bulb temperature is 19.5 °C, the
Temperature relative humidity value is 60%, which is shown in
the hygrometric chart as the point where the 2 dot-
ted lines intersect.
Dry Bulb Temperature (°C) ALJ005G
(g) Using the standard performance chart below, find the point where the difference between the temper-
atures measured in the inlet and outlet, and the relative humidity intersect.
Standard:
The intersecting point is within the diagonal range shown in the chart.
Temperature difference
between the inlet port
and outlet port
(°C)
Relative Humidity %
ALJ006G
Temperature difference between

Intersecting point (1) For example, when the difference between tem-
the inlet port and outlet port peratures measured in the inlet and outlet is 17 °C
(°C)
and the relative humidity is 60%, the intersecting
point is within the diagonal range. Therefore, this
air conditioner is normal.
Relative Humidity % ALJ007G

AC-6
2. Inspect the pressure switch

(a) Magnetic clutch control:
Inspect the pressure switch operation.
(1) Set the manifold gauge.
(2) Connect the two leads from the ohmmeter to ter-
High pressure
minal 4 and terminal 1.
Low pressure side side
(3) Check the continuity between the terminals when
refrigerant pressure is changed, as shown in the
illustration.
If operation is not as specified, replace the con-
OFF (No conducting) denser outlet tube (see page AC-15).
OFF (No conducting) ALJ008G
(b) Cooling fan control:

Inspect the pressure switch operation.
(1) Connect the two leads from the ohmmeter to ter-
minal 2 and terminal 3.
(2) Check the continuity between the terminals when
the refrigerant pressure is changed, as shown in
the illustration.
OFF (Non-conducting) If the operation is not as specified, replace the
ON (Conducting) condenser outlet tube (see page AC-15).
ALJ009G
3. Inspect the compressor assembly

(a) Check the working condition.
(1) Start the engine.
(2) Inspect the compressor pulley.
Standard:
The compressor can connect and disconnect
normally.
8103200-S16 8103100-S16
Two models of the compressor

are equal optional products. ALJ010G
AC System AC-7
7
(b) Inspect the compressor assembly

(1) Disconnect the connector.
(2) Measure the resistance according to the value in
the following table:
Standard:
Testing instrument Specified condition
connection
Terminal - Compressor case 4.5 ± 0.5 W
Hint:
When the refrigerant amount of the A/C cycle can-
not be checked by the condition of the sight glass,
connect the pressure gauge to check if the system
pressure is normal or not while the compressor
working. A jump connection with the compressor
relay or pressure switch can allow you to check if
there is cool air coming out from the A/C air outlet.
Routine Inspections
1. Evaporator thermistor
(a) Check whether the evaporator thermistor is conducting.
(1) As shown in the figure, measure the resistance
between Terminal 1 and Terminal 2 when the
evaporator thermistor is at varying temperatures.
ALJ011G
Standard:
Temperature (°C) Lower limit value (�
kW) Lower limit value (�
kW)
-20 13.555 14.270 14.985
-15 10.275 10.817 11.359
-10 7.808 8.220 8.632
-5 6.004 6.321 6.638
0 4.609 4.852 5.095
2 4.227 4.377 4.527
2.5 4.170 4.270 4.370
3 4.080 4.163 4.246
4.3 3.850 3.910 3.970
5 3.686 3.786 3.886
10 2.925 2.985 3.045
15 2.200 2.341 2.482
20 1.823 1.869 1.906
25 1.470 1.500 1.530
30 1.180 1.204 1.228
35 0.9625 0.9821 1.0017
40 0.784 0.800 0.816
45 0.6449 0.6587 0.6713
50 0.5332 0.5441 0.555
55 0.4451 0.4542 0.4633
60 0.3701 0.3777 0.3853
AC-8
Temperature (°C) Lower limit value (�

kW)
65 0.3124 0.3188 0.3252
70 0.2638 0.2692 0.2746
75 0.2241 0.2287 0.2333
80 0.1907 0.1946 0.1985
If the measured resistance value is not up to regulation,
replace the evaporator thermistor.
2. AC controller assembly 2
(a) Check the continuity of the blower switch.
Testing instrument Specified
Condition/circuit
connection condition
OFF 4 - 5 - 6 - 9 - 10 10 kW or higher
Left hand side 4 - 5 Below 1 W
LO - M1 4 - 5 - 9 Below 1 W
M1 4 - 5 - 9 Below 1 W
ALJ012G
M1 - M2 4 - 5 - 9 - 10 Below 1 W
M2 4 - 5 - 10 Below 1 W
M2 - HI 4 - 5 - 10 - 6 Below 1 W
HI 4 - 5 - 6 Below 1 W
If the value is not as specified, replace the A/C
controller assembly No.2.
(b) Check operation of the light.
Connect the positive (+) lead from the battery to ter-
minal 2, the negative (-) lead to terminal 5, and then
check that the lamp illuminates.
If any of the lamp does not illuminate, replace the A/C
controller assembly No.2.
(c) Check the continuity of the A/C switch.
Measure the resistance according to the value in the
following table:
Standard:
Switch operation
ON f - d and c Below 1 W
OFF f - d and c 10 kW or higher
If the continuity is not as specified, replace the A/C
switch.
ALJ013G (d) Check the operation of the indicator.
(1) Connect positive (+) lead from battery to terminal f,
negative (-) lead to terminal d.
(2) Press the A/C switch and check that indicator goes on.
If the operation is not as specified, replace the A/C
switch.
3. Blower speed adjustive resistance.
(a) Check whether the speed adjustive resistance of the
blower is conducting.
Standard:
Testing instrument connection Specified condition
1 - 2 1.09 ± 10% W
1 - 3 0.39 ± 10% W
1 - 4 1.27 ± 10% W
ALJ014G
If the measured value is not up to regulations, re-
place the speed adjustive resistance of the blower.
AC System AC-9
9
4. Blower assembly
(a) Inspect the blower assembly
(1) Connect the positive (+) lead from the battery to
terminal 2, the negative (-) lead to terminal 1, and
then check that the motor works smoothly.
If the operation is not as specified, replace the
blower motor.
ALJ015G
5. Blower relay
(a) Check the continuity of the relay.
Standard:
Testing instru- Specified
Condition
ment connection condition
Constant 87 - 30 10 kW or higher
Apply B+ between
87 - 30 Below 1 W
ALJ016G
terminal 85 and 86
If the value is not as specified, replace relay.
Refrigerant
Observation
port
Vehicle check
1. Inspect the refrigerant volume
(a) Check the observation port on the condenser discharge
pipe.
Test conditions:
• Engine is running at 1,500 rpm.
• Blower speed control switch is on “HI”.
• A/C switch is ON.
• Temperature adjusting knob is in the “MAX COOL”
ALJ017G position.
• Doors are fully open.
Amount of
Items Problem Corrective measures
refrigerant
1. C heck for gas leakage and repair
1 Bubbles are present Insufficient* if necessary
2. Add refrigerant until bubbles dis-
appear
2 No bubbles Empty, insufficient, Refer to 3 and 4

or too much
1. C heck for gas leakage with gas
There is no temperature difference leak detector and repair if neces-
3 between the inlet port and outlet Empty or not enough sary
port of the compressor 2. Add refrigerant until bubbles dis-
appear
The temperature difference is too Appropriate
4 much between the inlet and outlet amount or too Refer to 5 and 6
port of the compressor much
The refrigerant is clear immedi- Too much 1. R ecycle the refrigerant

5 ately after switching off the AC 2. E vaporate the air and supply a
proper amount of new refrigerant
After switching off the AC, the re-
6 frigerant bubbles immediately and Appropriate amount -
becomes clear later
*: If cooling is enough and the environmental temperature is higher than normal, then the bubbles inside
the observation port will be considered normal.
AC-10
2. Check the refrigerant pressure with a manifold

pressure gauge subassembly.
(a) This is a method in which the trouble is located by us-
ing a manifold gauge set.
Read the pressure on the manifold pressure gauge af-
ter these conditions are met.
Test conditions:
• When the switch is set at the inner circulation posi-
tion, the temperature at the inlet port is 30 to 35 °C.
• Engine is running at 1,500 rpm.
• Blower speed control switch is at “HI”.
• Temperature adjusting knob is in the “COOL” posi-
tion.
• The A/C switch is ON.
• Doors are fully open.
(1) Refrigeration system under normal operation.
Instrument Reading:
Low pressure side:
0.15 to 0.25 MPa
High pressure side:
1.37 to 1.57 MPa
ALJ018G
(2) Humidity appears in the refrigeration system.
Condition: cyclic cooling and finally fails to produce cold air.
ALJ019G
Problem Possible cause Diagnosis Corrective measures

• The dryer is in a su-
The humidity in the re- persaturation state. 1. Replace the dryer.
During operation, the frigeration system is fro- • The humidity in the 2. R emove moisture in
p r e s s u r e o n t h e l o w zen at the throttle hole refrigeration system is the cycleby repeatedly
pressure side is switch- of the expansion valve, frozen at the throttle evacuating the air.
ing between normal and which suspends the cir- hole of the expansion 3. Charge the appropri-
vacuum status. culation while returning valve, which stops ate amount of new
to normal during melting. the circulation of the refrigerant.
refrigerant.
AC System AC-11
11
(3) There is insufficient refrigeration.
Condition: refrigeration system does not work effectively.
ALJ020G

1. C heck for gas leak-
age and repair if nec-
• High and low pres- essary.
sure side's pressure 2. Charge the appropri-
is low. ate amount of new
refrigerant.
• Bubbles can be con- Air leakage occurs in the • Insufficient refrigerant. 3. W h e n c o n n e c t i n g
stantly seen from the refrigeration system. • The refrigerant leaks. with the instrument,
the indicating pres-
observation ports. sure values are close
• Refrigeration perfor- to zero. The vacuum
mance is insufficient. i s a v a i l a b l e a f t e r
checking and repair-
ing the leaked area.
(4) Poor circulation of refrigerant.
Condition: refrigeration system does not work effectively.
ALJ021G

• High and low pres-
sure side's pressure
is low. The refrigerant flow is
blocked by dust inside The reservoir is blocked. Replace the reservoir.
• The pipeline from con- the reservoir.
denser to the refrigerat-
ing device frosts over.
AC-12
(5) Refrigerant does not circulate.
Condition: refrigeration system does not work. (only works some of the time).
ALJ021G

1. Check the expansion valve.
• Low pressure side
2. R
emove the dust inside the
indicates a vacuum, • The refrigerant flow is
expansion valve by air-blow-
t h e h i g h p r e s s u r e blocked by the humd-
ing.
side indicates that it ity or dust in the re-
3. Replace condenser.
is too low. frigeration system. Refrigerant
4. E
vaporate the air and supply
• Frosting or conden- • The leakage of the cannot circulate.
a proper amount of new re-
sation appears on the e x p a n s i o n v a l v e
frigerant.
pipeline at both sides blocks the refrigerant
5. G
as leakage. occurs inside
of the reservoir/dryer flow.
the expansion valve; replace
or expansion valve.
expansion valve.
(6) Too much refrigerant charged or the condenser cools poorly.
Condition: refrigeration system does not work.
ALJ022G

1. R e p l a c e t h e c o n -
• Too much refriger-
denser.
• Low and high pres- ant in circulating →
• Over-use of the re- 2. C heck the cooling
sure side's pressure Too much refrigerant
frigeration system fan when the cooling
is too high. charged
prohibits full perfor- fan motor operates.
• The engine speed • The condenser cools
mance. 3. If 1 and 2 are normal,
drops and no bubbles poorly → The
The con-
• The condenser cools check the refrigerant
can be seen from the denser cooling fin
poorly. amount and provide
observation ports. of the cooling fan is
the appropriate re-
blocked
frigerant.
AC System AC-13
13
(7) Air exists in the refrigeration system.
Condition: refrigeration system does not work.
Note: These gauge indications

when the refrigeration system
is operating and
and the
the refriger-
ant is charged without
without vacuum
without vacuum
purging.
ALJ023G

• Low and high pres-
sure side's pressure 1. C heck whether the
is too high • Air exists in the refrig- c o m p r e s s o r o i l i s
There is air in the sys-
• The low pressure pip- eration system dirty or insufficient.
tem.
ing is too hot to touch • Insufficient purging 2. Vacuum and charge
• Bubbles can be seen new refrigerant.
through sight glass
(8) Expansion valve failure.
Condition: insufficient cooling
ALJ023G

• Low and high pres-
sure side's pressure • There is too much
is too high. refrigerant in the low
Check the expansion
• There is frost or a Expansion valve failure. pressure pipeline.
valve.
buildup of condensa- • E x p a n s i o n v a l v e
tion in the low pres- opening is too big.
sure side's pipeline.
AC-14
(9) Compressor functions poorly.
Condition: insufficient cooling
ALJ024G

• Low and high pres- • Compressor failure.
sure side's pressure • Leakage has occured
Internal leakage of the Maintain or repair the
is too high. in the damaged valve
compressor. compressor.
• High pressure side's o r b r o k e n s l i d i n g
pressure is too low. parts.
Gauge readings (Reference)
Pressure on Low Pressure Side
Blower HI Zone
Blower LO Zone
Pressure on High Pressure Side
ALJ025G
AC System AC-15
15
Replacement
1. Recycle the refrigerant in the refrigeration system.
(a) Turn the A/C switch on.
(b) Operating the compressor at the engine speed of approx. 1,000 rpm for 5 to 6 minutes, circulate the
refrigerant,, and collect compressor oil remaining in each component into the compressor as much as
and collect compressor oil remaining in each component into the compressor as much as
possible.
(c) Stop the engine.
(d) Recycle refrigerant with special tool.
2. Add refrigerant.
(a) Purify the refrigerant system with a vacuum pump.
(b) Add refrigerant, HFC-134a (R134a).
Standard: 490 ± 10 g
3. Warm up the engine.
4. Check for leaking refrigerant.
Refrigerant Pipeline
Components
Compressor suction hose assembly
Condenser discharge pipe
Compressor exhaust pipe assembly
ALJ026G
AC-16
A/C Controller Assembly No.1

Replacement
1. Remove the A/C control knob.
(a) Remove the 3 A/C control knobs.
ALJ027G
2. Remove the center console panel body.

(a) Remove the two screws.
(b) Using a molding remover, disengage the 6 claws and 6
clips and then remove the center console panel body.
(c) Disconnect the 3 connectors.
: 6 clips : 6 claws ALJ028G
3. Remove the A/C controller assembly No.1.

(a) Disengage the 3 claws and disconnect the A/C control-
ler assembly No.1.
: 3 claws ALJ029G
(b) Using a screwdriver, open the claw of the cable clamp

and disconnect the temperature damper cable.
Notice:
• Be careful not to bend the cable wire.
• If the cable wire bends, the temperature damper
cable operation may be affected.
Hint:
Tape the screwdriver tip before use.
ALJ030G
AC System AC-17
17
(c) Using a screwdriver, open the claw of the cable clamp

and disconnect the position damper cable.
Notice:
• Using a screwdriver, open the claw of the cable
clamp and disconnect the position damper ca-
ble.
ALJ031G
(d) Using a screwdriver, open the claw of the cable clamp

and disconnect the air intake damper cable.
Notice:
• If the cable wire bends, the air intake damper
(e) Remove A/C controller assembly No.1.
Hint:
ALJ032G
4. Remove the air inlet damper control lever.

(a) Disengage the claw, and remove the air inlet damper
control lever.
5. Install the air inlet damper control lever.
: Claw ALJ033G
6. Install the A/C controller assembly No.1.

(a) Install the inner cable end of the position damper cable
on the lever.
(b) Install the outer cable of the position damper cable on
the cable clamp.
Notice:
• Using a screwdriver, open the claw of the cable
clamp and disconnect the position damper ca-
ble.
Hint:
ALJ034G
• Operating the air flow position control knob, check
that it properly stops at both ends of the FACE and
DEF.
• Check that the outer cable is not disengaged
(moved) from the A/C controller assembly when the
cable is pulled.
AC-18
(c) Install the inner cable end of the temperature damper

cable on the temperature control lever.
(d) Install the outer cable of the temperature damper cable
on the cable clamp.
Notice:
• If the cable wire bends, the temperature damper
Hint:
• Operating the temperature control knob, check that
ALJ035G it properly stops at both ends of MAX COOL and
MAX HOT.
(moved) from the A/C controller assembly No.1
when the cable is pulled.
(e) Install the inner cable end of the air intake damper ca-
ble to the air intake damper control lever.
(f) Install the outer cable of the air intake damper cable on
the cable clamp.
Notice:
• If the cable wire bends, the air intake damper
Hint:
• Operating the circulation control knob, check that it
ALJ036G properly stops at both ends of the inner circulation
and outer circulation.
(moved) from the A/C controller assembly No.1
when the cable is pulled.
(g) Connect connector and install A/C controller assembly
No.1.
AC System AC-19
19

Overhauling
Hint:
quence.
1. Remove the A/C control knob.
ALJ027G
2. Remove the center console panel body.

(b) Using a molding remover, disengage the 6 claws and 6
clips, then remove center console panel body.
(c) Disconnect the 3 connectors.
6 clips 6 claws ALJ028G
3. Remove the A/C controller assembly No.1.

(b) Release the 3 claws and remove the A/C controller as-
sembly No.2.
: 3 claws ALJ037G
4. Remove the A/C switch.

(a) Disengage 3 claws and remove A/C switch.
: 3 claws ALJ038G
5. Remove the hazard warning light switch.

(a) Disengage the 3 claws and remove the hazard warning
light switch.
: 3 claws ALJ039G
AC-20
6. Remove the rear defogger switch.

(a) Disengage the 3 claws and remove the rear defogger
switch.
: 3 claws ALJ040G
7. Remove the light guide strip.

(a) Disengage the 2 claws and remove the light guide strip.
: 2 claws ALJ041G
AC System AC-21
21
AC Assembly
Components
Air intake
Air intake sponge
Inner-outer cycle
ventilator louver
Inner-outer cycle
damper
Ventilation baffle
Upper case
Expansion balve sponge

Heating core body
Heater water inlet
pipe protector A/C Air filter assembly
Defrost damper
Blower assembly
Blower resistance regulator

Main outlet damper Evaporator core body
Lower air vent Cool/Hot damper Drain pipe
Lower case
ALJ042G
AC-22
Overhauling
Hint:
quence. However, it only includes the installation sequence
with additional information.
1. Recycle refrigerant from refrigeration system (see
page AC-15)
2. Remove the compressor suction pipe assembly
and condenser outlet pipe
(a) Remove 1 bolt and disconnect the compressor suction
pipe assembly and condenser outlet pipe from the ex-
pansion valve.
ALJ043G
3. Disconnect the heater inlet water hose and outlet

water hose
(a) Joint the clip dog with pliers, slide the clip, and discon-
nect the heater's water inlet and outlet hose.
4. Remove the A/C controller knob (see page AC-16)
5. Remove the center console panel (see page AC-19)
6. Remove the upper instrument panel body
Hint:
For the removal of the upper instrument panel body, re-
fer to the relative description.
7. Remove lower instrument panel body w/the instru-
ment panel reinforcement member (see page IR-35)
ALJ044G Hint:
For the removal of the lower instrument panel body
w/the instrument panel reinforcement member, refer to
the relative description.
8. Remove the A/C assembly
(b) Remove the position damper cable.
(1) Disconnect the outer cable.
(2) Disconnect the inner cable and remove the posi-
tion damper cable.
ALJ045G
AC System AC-23
23
(c) Remove the temperature damper cable.

(2) Disconnect the inner cable and remove the tem-
perature damper cable.
(d) Remove the air intake damper cable.
(2) Disconnect the inner cable and remove the tem-
perature damper cable.
ALJ046G
(e) Remove the central defroster duct assembly.

(1) Remove the clasp.
(2) Disengage the 2 claws and remove the central de-
froster duct assembly.
: 2 claws ALJ047G
(f) Disconnect the rear lower air duct LH and the rear low-
er air duct RH.
Rear lower air duct LH Rear lower air duct RH
ALJ048G
(g) Remove the 7 bolts and A/C assembly.
ALJ049G
9. Remove the A/C air filter assembly

(a) Release the 2 claws joint surface and remove the A/C
air filter assembly.
: 2 claws ALJ050G
AC-24
10. Remove the blower speed regulating resistor

(b) Remove the 2 screws and blower speed regulating re-
sistor.
ALJ051G
11. Remove the blower assembly

(b) Remove the 3 screws and blower assembly.
ALJ052G
12. Remove the expansion valve

(a) Remove the 2 bolts and expansion valve.
ALJ053G
13. Remove the heater core

: Claws (a) Remove the screw and bracket.
(b) Remove the clip and disconnect the connector.
(c) Remove the heater core.
ALJ054G
14. Remove the A/C upper case

(a) Remove the screws and A/C upper case.
ALJ055G
AC System AC-25
25
15. Remove the evaporator thermistor

(a) Disengage the 2 claws and remove the evaporator
thermistor.
2 Claws ALJ056G
16. Remove the evaporator sub-assembly

(a) Remove the evaporator sub-assembly.
(b) Remove the 2 O-rings from the evaporator sub-assembly.
ALJ057G
17. Install the position damper cable

(a) Set the arm to the FACE position.
(b) Install the inner cable end to the control lever when the
arm in the FACE position.
(c) Install the outer cable to the cable clamp while slightly
pressing it in the direction of the arrow.
Notice:
Face • Be careful not to bend the cable wire.
Defroster • If the cable wire bends, the A/C controller as-
sembly No.1 operation may be affected.
ALJ058G Hint:
When operating the mode control lever, check that it
properly stops at both ends of the FACE and DEF.
18. Install the temperature damper cable

MAX HOT
(a) Set the arm in the MAX COOL position.
(b) Install the inner cable end to the control lever with the
arm in the MAX COOL position.
(c) Install the outer cable to the cable clamp while slightly
MAX pressing it in the direction of the arrow.
COOL Notice:
• If the cable wire bends, the A/C controller as-
sembly No.1 operation may be affected.
ALJ059G Hint:
Operating the mode control lever, check that it properly
stops at both ends of the MAX HOT and MAX COOL.
19. Install the air intake damper cable
20. Install the lower instrument panel body w/the in-
strument panel reinforcement member
21. Install the upper instrument panel body
22. Install the center console panel body
23. Install the A/C control knob
AC-26
24. Install the compressor suction pipe assembly and

condenser outlet pipe
(a) Install the compressor suction pipe assembly and con-
denser outlet pipe to the expansion valve with 1 bolt.
Torque: 10 N·m
ALJ043G
25. Install the heater inlet water hose and outlet water
hose
26. Add engine coolant (see page EG-10)
27. Charge refrigerant (see page AC-15)
Specified quantity: 490 ± 10 g
28. Warm up the engine
29. Check for engine coolant leaks (see page EG-10)
30. Check for leaking refrigerant
ALJ044G
AC System AC-27
27
Compressor Assembly
Replacement
1. Recycle refrigerant from the refrigeration system
(see page AC-15)
2. Remove the deflector panel assembly of engine LH
and RH
3. Remove the fan and the drive belt of the generator
4. Disconnect the compressor exhaust pipe assembly

(a) Remove the bolt and disconnect the exhaust pipe as-
sembly from the compressor assembly.
(b) Remove the o-ring from the compressor exhaust pipe
assembly.
Notice:
Disconnect the part's opening with PVC empire
tape seal to prevent humdity and foreign materials
from entering the equipment.
ALJ060G
5. Disconnect the compressor suction pipe assembly

(a) Remove the bolt and disconnect the suction hose as-
sembly from the compressor assembly.
(b) Remove the o-ring from the compressor suction hose
assembly.
Notice:
tape seal to prevent humdity and foreign matters
ALJ061G
6. Remove compressor assembly

(b) Remove the 4 bolts and the compressor assembly.
7. Inspect the compressor oil
(a) When replacing with a new compressor, first release
the gaseous refrigerant from the maintenance valve
gradually and then drain the following oil amount from
the new compresson assembly before installing.
Standard:
(Oil capacity inside new compressor: JSS-
12T402002: 200 ml;
ALJ062G SEBX13: 130 ml) - (Remaining oil amount in the
removed compressor ) = (Oil amount to be dis-
charged when replacing)
Notice:
• When checking the oil level of the compressor,
comply with the Areas of Importance during the
removal/installation of compressor.
• Because the compressor oil remains in the pipes
of the vehicle, if a new compressor is installed
without discharging some of the remaining oil, the
oil amount becomes too much, preventing heat
exchange in the refrigerant cycle and causing re-
frigerant failure.
• Check whether oil leakage exists if there is not
enough residual compressor oil in the removed
compressor.
• Be sure to use the right compressor oil (the lubri-
cant indicated in the label of the compressor).
AC-28
8. Install the compressor assembly

(a) Install the compressor assembly with 4 bolts.
Torque: 32 N·m
Notice:
Tighten the bolts as shown in the figure to install
the compressor assembly.
(b) Attach the connector.
ALJ062G
9. Install the compressor suction hose assembly

(a) Remove the PVC empire tape that is wound around the
hose.
(b) Fully apply the compressor oil on the new o-ring and
assembly surface of the compressor assembly.
Compressor oil: the lubricant indicated in the label
of the compressor.
(c) Install a new o-ring on the compressor suction hose as-
sembly.
(d) Install the compressor suction hose assembly to the
ALJ061G compressor assembly with bolts.
Torque: 10 N·m
10. Install the compressor discharge pipe assembly

hose.
(b) Fully apply the compressor oil to the new o-ring and as-
sembly surface of the compressor assembly.
of the compressor
(c) Install the o-ring on the compressor exhaust pipe as-
sembly and then install them on the compressor as-
sembly with bolts.
ALJ060G Torque: 10 N·m
11. Install the generator and connecting belt of the
steering oil pump
12. Adjust the belt tension by adjusting the generator
position
AC System AC-29
29
Subcooling Condenser Assembly

Vehicle check
1. Inspect the super-cooling type condenser assembly
(a) If the cooling fin of the subcooling condenser assem-
bly is dirty, it should be cleaned and dried using com-
pressed air.
Notice:
Be sure not to damage the cooling fin of the sub-
cooling condenser assembly.
(b) If the cooling fin of the subcooling condenser assembly
is bent, it will need to be straightened with a screw-
driver or pliers.
2. Check whether refrigerant leakage exists in the
condenser
(a) Using a halogen leak detector, check the pipe joints for
gas leakage.
(b) If air leakage is detected at the pipe connector, check
the torque of the connector.
Components
Condenser upper mount assembly
Dryer
●O-ring
●O-ring
Compressor exhaust pipe assembly
●O-ring Subcooling condenser assembly
Condenser discharge pipe
Specified torque
Non-reusable Part
Compressor oil: the lubricant indicated in the label of the compressor
ALJ063G
AC-30
Overhauling
Hint:
Components: see page AC-29
1. Recycle refrigerant from the refrigeration system
(see page AC-15)
2. Remove the front bumper upper grille body (see
page BO-37)
3. Remove the front bumper body (see page BO-37)
4. Disconnect the compressor exhaust pipe assembly
(a) Remove the bolts and disconnect the compressor ex-
haust pipe assembly from the subcooling condenser
assembly.
(b) Remove the o-ring from the compressor exhaust pipe
assembly.
Notice:
ALJ064G
5. Disconnect the condenser outlet pipe

(a) Remove the condenser discharge pipe from the sub-
cooling condenser assembly.
(b) Remove the o-ring from the condenser discharge pipe.
Notice:
(c) Disconnect the discharge pipe from the condenser dis-
charge pipe bracket.
ALJ065G
6. Remove the super-cooling type condenser assembly

(a) Remove the 2 bolts and the subcooling condenser as-
sembly.
ALJ066G
7. Remove the condenser upper mount assembly

(a) Remove the 2 bolts and 2 condenser upper mount as-
sembly.
ALJ067G
AC System AC-31
31
8. Remove the dryer

(a) Remove the cap from the adjuster with a 10mm socket
hexagon wrench.
ALJ068G
(b) Remove the O-rings from the cap.
ALJ069G
(c) Remove the dryer with pliers.
ALJ070G
9. Install the dryer

(a) Install the dryer with pliers.
ALJ070G
(b) Install the new O-rings to the cap.

(c) Apply a sufficient amount of compressor oil to the new
O-rings and fit the surface of the cap.
of the compressor
ALJ071G
AC-32
(d) Install the cap on the adjuster with a 10mm socket

hexagon wrench.
Torque: 2.9 N·m
ALJ068G
10. Install the condenser upper mount assembly

(a) Install the 2 bolts and 2 condenser upper mount as-
semblies.
Torque: 3.9 N·m
ALJ067G
11. Install the super-cooling type condenser assembly

(a) Install the subcooling condenser assembly with 2 bolts.
Torque: 9.8 N·m
12. Install the condenser outlet pipe
condenser discharge pipe and the subcooling condens-
er assembly.
(b) Fully apply the compressor oil to the new o-ring and
hose connector.
of the compressor
(c) Install the o-ring on the condenser discharge pipe.
ALJ066G (d) Attach the condenser discharge pipe onto the bracket.
(e) Install the condenser discharge pipe on the subcooling

condenser assembly with bolts.
Torque: 10 N·m
ALJ065G
RS-1
1
Safety supplemental restraint system
SRS
Precautions..................................................................... RS-2
SRS Airbag System Diagnosis...................................... RS-9
On-vehicle Inspection..................................................... RS-22
Driver Airbag Assembly................................................. RS-25
Clock Spring Sub-assembly.......................................... RS-33
Passenger Airbag Assembly.......................................... RS-35
Airbag ECU Assembly.................................................... RS-41
Seat Belts
Seat Belt Warning System.............................................. RS-43
Front Seat Belt................................................................ RS-45
Rear Seat Belt.................................................................. RS-53
RS
RS-2
SRS
Precautions
Caution:
• This vehicle is equipped with an SRS, which consists of the driver airbag, passenger airbag, and
seat belt. Failure to carry out service operations in the correct sequence could cause the SRS
to unexpectedly deploy during servicing, possibly leading to serious accidents. Further more,
if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before performing servicing (including the removal or installation of parts, inspection,
or replacement), be sure to read the following items carefully, then follow the correct procedures
indicated in the maintenance manul.
• Wait at least 90 seconds after the ignition switch is turned to the “LOCK” position and the nega-
tive (-) terminal cable is disconnected from the battery (the SRS is equipped with a back-up
power source, so that if work is started within 90 seconds after disconnecting the negative (-)
terminal cable of the battery, the SRS may be deployed).
• Do not expose the driver airbag assembly, passenger airbag assembly, or airbag ECU assembly
directly to hot air or flames.
Notice:
• Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important
source of information when troubleshooting. When clearing the SRS malfunction, the DTC must
be inspected before disconnecting the battery.
• Even in the case of a minor collision when the SRS does not deploy, the driver airbag assembly,
passenger airbag assembly, and airbag ECU assembly must be inspected (see page RS-22).
• Before repair work, remove the airbag ECU assembly if any kind of shock is likely to occur to the
assembly during operation.
• Never use the SRS parts from another vehicle. When replacing the parts, replace them with new
ones.
• Never disassemble nor repair the driver airbag assembly, passenger airbag assembly, airbag
ECU assembly in order to reuse it.
• If the driver airbag assembly, passenger airbag assembly, airbag ECU assembly have been
dropped, or if there are any cracks, dents, or other defects in this case, the bracket or connector,
replace it with a new one.
• Use an X-431 tester for troubleshooting the electrical circuits.
• Information labels can be found on the outside of the SRS components. Follow the instructions
in the notice.
• After completing the work on the SRS, inspect the SRS warning lamp.
• When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When the work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back-up power supply from outside the vehicle.
• If the vehicle is equipped with a mobile communication system, please refer to the "Areas of Im-
portance" section in the "Overview" part.
Supplemental Safety Restraint System RS-3
3
1. SRS connectors
Passenger Side Seat

Belt Assembly (Squib)
Passenger Airbag
Assembly (Squib)
Airbag ECU
Driver Airbag
C l o c k S p r i n g Assembly
Sub-assembly (Squib)
Driver Side Seat

Belt Assembly
(Squib)
ALK001G
No. Items Application

(1) Terminal dual-lock mechanism Connectors 2, 3, 5
(2) Explosion-proof mechanism Connectors 4, 6, 8, 10
(3) Connector lock up mechanism Connectors 1, 7, 9
RS-4
Gasket (a) All connectors in the SRS are colored in yellow to dis-
tinguish them from other connectors.
The connectors having special functions and specifi-
Shell
cally designed for the SRS are used in the locations
shown on the previous page to ensure high reliability.
These connectors use durable gold-plated terminals.
(1) Terminal twin-lock mechanism:
Each connector has a two-piece component con-
Negative sisting of a housing and a spacer. This design
Positive enables the terminal to be locked securely by two
ALK002G
locking devices (the retainer and the lance) to pre-
vent the terminals from coming out.
(2) Activation prevention mechanism:
Each connector contains a short spring plate.
When the connector is disconnected, the short
spring plate automatically connects positive (+)
terminal and negative (-) terminal of the squib.
When the connector is connected When the connector is disconnected
Short-connected
spring
Short-connected spring
Shell Contact positive
terminal
Shell
Short-connected spring conducting
Terminal
Short-connected
Connector spring Squib Closed circuit
Squib
ALK003G
Hint:
The type of connector is shown in the diagram on
the previous page.
5
(3) Half connection prevention mechanism:

If the connector is not completely connected, the connector is disconnected due to the spring op-
eration to the extent that no continuity exists.
Slider Stopper
Lock arm Spring
Lock up piece Rebound via slider
Stopper (spring)
ALK004G
(4) Connector lock mechanism:

Locking the connector lock button connects the connector securely.
Lock-up button
Claw
Slot
ALK005G
(5) Connector position assurance mechanism:

Only when the housing lock (white part) is completely engaged, the CPA (yellow part) slides,
which completes the connector engagement.
Case lock
(white part)
Case lock
(white part)
CPA (yellow part) CPA (yellow part)

ALK006G
Figure 1 (b) When the vehicle is involved in a frontal collision in the

hatched area (Fig.1) and the shock is larger than the
predetermined level, the SRS is activated automatical-
ly. The safing sensor is designed to go on at a smaller
Figure 2 Power supply deceleration rate than the airbag sensor. As illustrated
in the Fig.2, ignition is caused when current flows to
the squib, which happens when the safing sensor and
Security sensor Squib the deceleration sensor go on simultaneously. When a
deceleration force acts on the sensors, the 2 squibs in
the driver airbag and front passenger airbag ignite and
Deceleration sensor ALK007G
generate gas. The bags are deployed. Then the bags
deflate as the gas is discharged through discharge
holes at the bag’s rear or side.
RS-6
2. Disconnection of connectors for the driver airbag assembly

Hint:
(a) Loosen the lock-up button (yellow part) of the connector with a screwdriver.
(b) Insert a screwdriver tip between the connector and the base and then raise the connector.
Lock up button Lock up button (yellow)

(yellow)
Marks
ALK008G
3. Connection of connectors for the driver airbag assembly

(a) Connect the connectors.
(b) Push down securely on the lock button (yellow part) of the connector.
Lock up button (yellow)
ALK009G
7
4. Disconnection of the connector for the airbag ECU assembly

(a) Push down the housing lock (white part) and slide the CPA (yellow part). At this time, the connector
cannot be disconnected yet.
(b) Push down the housing lock (white part) again and disconnect the connector.
Hint:
Do not push down the A part, shown in the illustration, when disconnecting.
Housing lock (white part)
Connector lock
is released
CPA (yellow part)
ALK010G
(c) After disconnecting the connector, check that the position of the housing lock (the white part) is as
ALK011G
RS-8
5. Connection of the connector for the airbag ECU assembly

(a) Before connecting the connectors, check that the position of the housing lock (the white part) is as
ALK012G
(b) Be sure to engage the connectors until they are locked. (when locking, make sure that a clicking
sound can be heard)
Hint:
When connecting them, the housing lock (white part) slides. Be sure not to hold the housing lock (white
part) and the A part, as it may result in an insecure fit.
Housing lock (white part)
CPA (yellow part)
Connection is
completed
ALK013G
9
SRS Airbag System Diagnosis

1. Airbag ECU
Passenger airbag
assembly
Driver side Airbag ECU assembly

airbag
Malfunction
diagnosis
connector
Dotted line in the figure is the wire harness schematic drawing.
Driver side seat belt pretensioner

Passenger side seat belt pretensioner ALK014G
For safe operation, read the precautions for maintenance below before operation.
(a) When performing airbag maintenance, it should be operated as the order and cautions are indi-
cated in this chapter.
(b) Always operate with experimental instruments and special tools indicated in this chapter.
(c) When repairing the parts below, if the parts have a malfunction, always replace with a new one.
(1) Airbag ECU
(2) Clock spring sub-assembly
(3) Driver airbag assembly
(4) Driver airbag assembly
(5) Driver side seat belt pretensioner
(6) Driver side seat belt pretensioner
(7) Airbag wire harness
(d) Wait 90 seconds after the disconnection of the negative terminal to prevent the airbag from deploying.
2. Airbag ECU terminal
ALK015G
RS-10
Terminal number Diagram Description

1 DRV A/B+ Driver airbag, Positive
2 DRV A/B- Driver airbag, Negative
3 PSG A/B+ Passenger airbag, Positive
4 PSG A/B- Passenger airbag, Negative
7 PSG PRETENSIONER- Passenger side seat belt pretensioner, Nega-
tive
8 DRV PRETENSIONER+ Driver side seat belt pretensioner, Positive
9 DRV PRETENSIONER- Driver side seat belt pretensioner, Negative
10 WARNING LAMP Warning lamp
11 GND Ground cable
25 BPT Hi Battery voltage
30 PSG PRETENSIONER- Passenger side seat belt pretensioner, positive
46 K-LINE Serial data I/O (K wire) diagnosis
3. Airbag troubleshooting
(a) Using an X-431 tester diagnosis malfunction
Malfunction type of airbag ECU is divided into two kinds by time: the current malfunction and history
malfunction; and by nature: the outer malfunction and inner malfunction.
The current malfunction code and history malfunction code may exist at the same time; the outer
malfunction code can be eliminated by using a diagnosis tester; the inner malfunction code cannot be
eliminated, but replace the airbag ECU.
Caution:
After installing a new airbag system electrical control unit, the airbag system warning light
turns off after lighting 6~7 seconds when the ignition switch is ON, which means that the air-
bag system operates normally. At this time, it is not necessary to service, but for the others
except this, a system diagnosis and service should be performed.
Using the diagnosis tester
Warning lamp ab-
and K line, connect the Detected problem Troubleshooting Clear the trouble code
normal
ECU scan tool
SRS airbag warning lamp inspection

(1) When turning the ignition switch to the “ON” position, check that the warning light remains
on for 6 ~ 7 seconds.
(2) If the warning light turns off after 6 ~ 7 seconds, it is normal.
(3) Except for the items listed above, a diagnostic inspection is still needed.
System diagnosis
The airbag ECU will initiate a series of diagnostic test cycles to check if the airbag system func-
tions are ready for use. This test will prevent the restraint system from deploying unexpectedly
and be sure to make the necessary deployment in a collision. If a malfunction is found, the airbag
ECU will store a proper trouble code and turn on warning light to indicate a malfunction condition
for maintenance.
(b) Malfunction judgment
(1) Malfunction record (trouble code storage)
After the ECU determines a malfunction by a cycle
Diagnostic port
diagnosis test the, airbag ECU will store the cor-
responding code, the first judgment time, the last
judgment time, and the times in the EEPROM.
Only 16 trouble codes can be stored in the airbag
ECU.
ALK016G
11
Certified trouble code for airbag ECU:

Type Trouble
No. Malfunction introduction Troubleshooting
code code
1 (Passenger side seat belt pretensioner), connected 03H 01H Removable
to power source
2 (Driver side seat belt pretensioner), connect to pow- 03H 02H Removable
er source
3 (Driver front airbag), connect to power source 03H 03H Removable
4 (Passenger airbag), connect to power source 03H 04H Removable
5 (Passenger side seat belt pretensioner), ground 02H 01H Removable
6 (Driver side seat belt pretensioner), ground 02H 02H Removable
7 (Driver front airbag), ground 02H 03H Removable
8 (Passenger airbag), ground 02H 04H Removable
9 (Passenger side seat belt pretensioner), the resis- 01H 01H Removable
tance is too high or circuit is open
10 (Driver side seat belt pretensioner), the resistance is 01H 02H Removable
too high or circuit is open
11 (Driver front airbag), the resistance is too high or cir- 01H 03H Removable
cuit is open
12 (Passenger airbag), the resistance is too high or cir- 01H 04H Removable
cuit is open
13 (Passenger side seat belt pretensioner), the resis- 0CH 01H Removable
tance is too low or circuit is short
14 (Driver side seat belt pretensioner), the resistance is 0CH 02H Removable
too low or circuit is short
15 (Driver front airbag), the resistance is too low or cir- 0CH 03H Removable
cuit is short
16 (Passenger airbag), the resistance is too low or cir- 0CH 04H Removable
cuit is short
17 Voltage of power source is out of range (high volt- 12H 42H Removable
age or low voltage)
18 Power cord contact dysfunctional 11H 42H Removable
19 Warning light malfunction - connect to power source 03H 40H Removable
or bulb has a short
20 Warning light malfunction - ground or filament is 02H 41H Removable
open
21 Configuration error 06H 44H Removable
22 Internal malfunction 0DH >80H Cannot troubleshoot
(Replace airbag ECU)
Transmission of the trouble code is completed by the airbag ECU through the maintenance pro-
cedure serial data interface transmitting to a specified diagnosis tester (X-431 diagnosis tester).
(c) Clear the trouble code
Description:
Trouble code in the ECU is cleared when the ECU receives the order of a “clear trouble code” by the
serial interface from the X-431 diagnosis tester. However, it does not perform the order if a inner trou-
ble code or collision is recorded.
RS-12
4. Warning light troubleshooting

(a) Warning light does not come on or remains on.
Symptom Possible cause

Airbag system warning light does Airbag system warning circuit has a malfunction.
not come on.
Airbag system warning lamp is al- Airbag system warns of a circuit malfunction or external malfunction.
ways on.
(b) Airbag system warning light does not come on.
Airbag system warning light does Airbag system warning circuit has a malfunction.
not come on. • Voltage disappeared (fuse open)
• Combination meter malfunction
• Wire harness malfunction between the instrument cluster and
ECU unit
Diagnostic procedures
Hint:
When performing the first malfunction detection, it is recommended that you shake the wire and con-
nector to check for trouble in the contact in a timely fashion; if the problem exists, check if the connec-
tor, terminal,, and wire connect correctly and are undamaged. If not, go on to the following procedures.
and wire connect correctly and are undamaged. If not, go on to the following procedures.
Step Inspection Operation

1 Locate the other wire harness and instrument cluster Yes Turn the ignition switch to the “LOCK”
indicator lamps position; go to the next step for op-
• Turn the ignition switch to the “ON” position eration.
• Other warning light and lamp are on or not No Detect the instrument power supply
system and ground system (fuse),
then go to the step 5.
2 Inspect the bulbs Yes Go to the next step for operation.
Caution:
Failure to carry out the airbag system element in the
correct way could cause the airbag and belt preten-
sioner to unexpectedly deploy, possibly leading to
No Replace the warning light bulb.
serious accidents. Read the airbag system service
warnings before carrying out the airbag element.
• Turn the ignition switch to the “LOCK” position
• Disconnect the battery negative terminal and
keep for at least 90 seconds
• Remove the combination meter
• Check the airbag warning light corresponding to
the two terminals for continuity
3 Detect the wire harness connection between the Yes Go to the next step for operation.
ECU unit and the instrument cluster
• Disconnect the battery negative terminal No Replace the wire, then go to the step
• Disconnect the instrument connector 5.
• Check whether the warning lamp's corresponding
circuits are conducting
13
(c) Airbag system warning light remains on.

Airbag system warning light re- • Battery is low
mains on. • ECU internal malfunction
• Combination meter airbag warning lamp malfunction
• ECU connector connects incorrectly
• Combination meter connector connects incorrectly
• ECU power supply fuse is open or connects incorrectly
• ECU connector terminals connect incorrectly
• The wires between the ECU connector terminals and the ground
connect incorrectly
• Driver side airbag or passenger side airbag malfunction
• Driver side and passenger side seat belt pretensioner malfunc-
tion
Diagnostic procedures
Hint:
Using the special diagnostic equipment (X-431 diagnostic tester), communicate with the ECU before
inspection to identify the reasons for failure; if there is no communication, perform the following further
checks.
1 Check the battery Yes Go to the next step for operation.
• Measure the battery voltage No Battery voltage is low.
• Check that the battery voltage is higher than 9 V
Check charge/discharge system, then
go to the step 5.
2 Inspect the bulbs Yes Go to the next step for operation.
• Disconnect the battery negative
• Open the instrument panel lower socket
• Disconnect the instrument connector
• Connect the battery negative No Check the circuit and then go to step
• Turn the ignition switch to the “ON” position 5 after being repaired.
• Check that the voltage between the instrument
corresponding connector terminals is 12 V (power
supply and instrument wire)
3 • Turn the ignition switch to the “LOCK” position Yes Go to the next step for operation.
• Check the continuity between the instrument cor-
responding terminals and the diagnosis interface No Replace the wire, then go to the
(at both ends of the K Line) step 5.
4 Make sure to disconnect the battery negative termi- Yes Go to the next step for operation.
nal and keep for at least 90 seconds
• Disconnect the ECU connector
No Replace the wire, then go to the
• Disconnect the instrument connector
• Check the continuity between the ECU connector step 5.
terminals 25, 10, 46 and the instrument connector
5 Remove the ECU and check if the terminal is good, Yes Replace the ECU.
short spring plate is broken No Reconnect the ECU connector, then
go to the next step for operation.
next page
RS-14

6 Check the problem symptom does not exist after be- Yes Explain the repair procedure to the
ing repaired customer after troubleshooting.
• Disconnect the battery negative terminal and
keep for at least 90 seconds
• Connect all ECU connectors
• Connect the driver side airbag assembly connec- No Check the problem symptom again; if
tor the trouble occurs again, repeat the
• Connect the passenger side airbag assembly
connector procedure from step 1.
• Connect the driver and passenger side seat belt
pretensioner connector
• Connect the clock spring connector
• Connect the battery negative terminal
• Turn the ignition switch to the “ON” position
• Check the airbag warning indicator is operating
normally
5. Internal malfunction
Type code 0D Airbag system unit inner malfunction
Trouble code
>80
Detecting Caution:
conditions • The detection condition of this malfunction is that the trouble code may not occur be-
fore checking; perform DTC checking, which may cause injury or damage the system
due to the operating error during the inspection. Thus, before checking, perform prepa-
ration before work.
• Airbag system electronic control unit inner circuit malfunction.
Possible Airbag system unit inner malfunction
cause
Operation
Replace the airbag system unit, refer to the airbag system, and the removal/installation of the airbag sys-
tem unit.
15
6. Power supply
Trouble code 12 The power voltage of the airbag system electronic control unit exceeds the standard
Trouble code 42 voltage range
Detecting condi- Caution:
tions • The detection condition of this malfunction is that the trouble code may not occur
before checking; perform DTC checking, which may cause injury or damage the
system due to the operating error during the inspection. Thus, before checking, per-
form preparation before work.
• The voltage between terminal 5 and 6 of the airbag system unit connector is lower
than 9 V.
Possible cause • Battery voltage is too low
• The wires between the battery and airbag system electronic control unit have mal-
functions

1 • Inspect the battery Yes Go to the next step for operation.
• Measure the battery voltage
• Check the battery voltage is higher than 9 V NoThe battery voltage is too low,
check the charge/discharge sys-
tem
2 • Inspect the wire harness between the battery and the Yes Go to the next step for operation
fuse box
• Remove the fuse block and turn the ignition switch to
No Check the wire harness
the “ON” position with the connector connected
• Measure the voltage between the two fuse block ter-
minals and the voltage is higher than 9 V
3 Check the wire harness between the fuse block and air- Yes Go to the next step for operation
bag system unit
Caution:
• If the handling is incorrect, the airbag modules and
seat belt pretensioner may be deployed and tight-
ened, resulting in serious personal injury. Therefore,
read the repair warnings carefully before operating.
Refer to the airbag system repair warnings.
• Disconnect battery negative cable and wait more
than 90 seconds No Replace the wire harness
• Remove the combination switch cover
• Disconnect the clock spring connector
• Remove the glove box body (with the passanger air-
bag assembly)
• Disconnect the passenger airbag module connector
• Remove the instrument panel lower socket
• Disconnect all airbag system unit connectors
• Connect the battery negative cable, turn the ignition
switch to the “ON” position, and measure the voltage
between terminals 25 and 11 (ground) of the airbag
system unit connector, the voltage is higher than 9 V
4 • Turn the ignition switch to the “LOCK” position Yes [Current trouble code]
• Disconnect the battery negative cable and wait more Replace the airbag system unit
than 90 seconds See also the SRS airbag system
• Remove the inner trim panel LH removal/installation of the airbag
• Disconnect the airbag system unit adaptor connector system unit
• Connect the battery negative cable, turn the ignition [History trouble code]
switch to the “ON” position, and measure the voltage Fault diagnosis complete
between the adaptor connector and ground, the volt- No Replace the wire harness
age is higher than 9 V
RS-16
7. Driver side malfunction

Trouble code Driver airbag malfunction (Resistance is too large or too small, short, etc.)
02
Trouble code
01, 02, 03
Detecting Caution:
conditions • If the handling is incorrect, the airbag modules and seat belt pretensioner may be de-
ployed and tightened, resulting in serious personal injury; therefore, read the repair
warning carefully before operating. Refer to the airbag system repair warnings
• The resistance value between terminals of the airbag system unit connector is not as
specified
• A short-or open-circuit occurs in the wiring harness related to the driver airbag of the
airbag system
Possible • Driver airbag module malfunction
cause • Clock spring internal malfunction
• Connectors malfunction in the circuit between the clock spring and airbag system elec-
tronic control unit
• A short-or open-circuit occurs in the wiring harness between the clock spring and air-
bag system electronic control unit
• The connectors of the driver airbag in the airbag system do not insert well

1 Check the clock spring Yes Go to the next step for operation
Caution:
• If the handling is incorrect, the airbag modules
and seat belt pretensioner may be deployed and
tightened, resulting in serious personal injury.
Therefore, read the repair warnings carefully be- NG Replace the clock spring
fore operating. Refer to the airbag system repair Refer to the airbag system, removal/
warnings. installation of the clock spring
• Check the clock spring and its related parts are
normal (The connections between the terminals
are normal, no short, open circuit phenomenon,
etc.). If necessary, replace the clock spring with a
new one.
2 • Make sure there are malfunctions in driver airbag Yes Replace the driver airbag module
module or in other parts. Refer to the airbag system, removal/
• Replace with a good DAB module installation of the driver airbag module
• Connect the battery's negative cable.
• Turn the ignition switch to the “ON” position No Go to the next step for operation
• Whether the trouble code is display, or cleared
3 • Check the clock spring wire harness connector Yes Go to the next step for operation
than 90 seconds
• Remove the combination switch cover NG Replace the wire harness
• Whether the clock spring connector is normal
4 • Turn the ignition switch to the “LOCK” position Yes [Current trouble code]
• Disconnect battery negative cable and wait more Replace the airbag system unit
than 90 seconds See also the SRS airbag system
• Remove the inner trim panel LH removal/installation of the airbag sys-
• Disconnect the airbag system unit adaptor con- tem unit
nector [History trouble code]
• Connect the battery negative cable, turn the igni- Fault diagnosis complete
tion switch to “ON” position, and measure the volt- No Replace the wire harness
age between the adaptor connector and ground,
the voltage is higher than 9 V
next page
17

5 • Check the wire harness between the clock spring Yes Replace the airbag system unit
and airbag system electronic control unit See also the SRS airbag system
• Turn the ignition switch to the “LOCK” position removal/installation of airbag system
• Disconnect battery negative cable and wait more unit
than 90 seconds
• Remove the glove box body (with the passenger
airbag assembly)
• Disconnect the passenger airbag module connec-
tor
• Remove the instrument panel lower socket
• Disconnect all airbag system unit connectors NG Replace the wire harness
• Check the wire harness between the airbag sys-
tem unit connector terminals and the clock spring
connector terminals, and the terminals of the air-
bag system unit connector and the clock spring
connector:
(1) Ground
(2) Short to +B
(3) Open
Whether the wire harness is normal
6 • Check the clock spring connector Yes Go to the next step for operation
• Whether the clock spring connector is normal NG Replace the wire harness or connec-
tor
7 • Check the clock spring Yes Go to the next step for operation
• Remove the clock spring.
• Refer to airbag system, removal/installation of the
clock spring
• Check the clock spring NG Replace the clock spring
• Refer to airbag system, check the clock spring Refer to the airbag system, removal/
• Whether the clock spring connector is normal installation of the clock spring
8 • Check the wire harness between the clock spring Yes Replace the driver airbag module
and airbag system electronic control unit See also the SRS airbag system
• Turn the ignition switch to the “LOCK” position removal/installation of the driver air-
• Disconnect battery negative cable and wait more bag module
than 90 seconds
• Remove the glove box body (with the passenger
airbag assembly)
tor
• Remove the instrument panel lower socket NG Replace the wire harness
• Check the wire harness between the airbag sys-
tem unit connector terminals and the clock spring
connector terminals, and the terminals of the air-
bag system unit connector and the clock spring
connector:
(1) Ground
(2) Short to +B
(3) Open
RS-18
8. Front passenger side malfunction

Type code 02 Passenger side airbag module (Resistance is too large or too small, short, etc.)
Trouble code
01, 02, 03
Detecting Caution:
conditions • If the handling is incorrect, the airbag modules and seat belt pretensioner may be de-
ployed and tightened, resulting in serious personal injury; therefore, read the repair
warning carefully before operating. Refer to airbag system repair warnings
• The resistance value between terminals 3 and 4 of airbag system unit connector is not
as specified
• Wire harness between the airbag system unit terminals 3 and 4 has a short circuit
Possible • Passenger airbag module malfunction
cause • The connector malfunction between the passenger airbag module and the airbag sys-
tem electronic control unit
• The connector malfunction between the airbag system electronic control unit and the
ground
• The circuit between the passenger airbag module and the airbag system electronic
control unit is open or short
• The circuit between the airbag system electronic control unit and the ground is open or
short
• Airbag system unit malfunction

1 Whether the vehicle is equipped with passenger air- Yes Go to the next step for operation.
bag module No -
2 Disconnect the passenger airbag module connector Yes [Current trouble code]
• If the handling is incorrect, the airbag modules Go to the next step for operation.
and seat belt pretensioner may be deployed and [History trouble code]
tightened, resulting in serious personal injury; Go to the next step for operation.
therefore, read the repair warning carefully before
operating. Refer to the airbag system repair warn- NG Replace the wire harness
ings.
• Turn the ignition switch to “LOCK” position
than 90 seconds
• Remove the glove compartment body
tor
• Whether the passenger airbag connector is nor-
mal
3 • Make sure there is malfunction in the passenger Yes Go to the next step for operation.
airbag module or in other parts.
• Connect a good module to the passenger airbag
module connector terminal A and B
• Connect the battery's negative cable No Replace the passenger airbag mod-
• Turn the ignition switch to the “ON” position
ule
• Whether the trouble code is displayed
Refer to airbag system, removal/in-
stallation of the passenger airbag
module
next page
19

4 Check the wire harness between the passenger air- Yes [Current trouble code]
bag module and airbag system electronic control unit Replace the airbag system unit
• Turn the ignition switch to the “LOCK” position See also the SRS airbag system
• Disconnect battery negative cable and wait more removal/installation of the airbag sys-
than 90 seconds tem unit
• Remove the combination switch cover
• Disconnect the clock spring connector [History trouble code]
• Disconnect the driver and passenger airbag mod- Fault diagnosis complete
ule connector
• Remove the instrument panel lower socket NG Replace the related wire harness
• Check the circuit between the airbag system unit
connector terminals and the passenger airbag
module connector terminals, and the terminals of
the airbag system unit connector and the passen-
ger airbag module connector:
(1) Ground
(2) Short to +B
(3) Open
Whether the wire harness is normal
RS-20
9. Vehicle Collision Diagnostics

Whether the airbag is deployed or not, check and main-
tenance procedures for the vehicle involved in collision
are as follows::
(a) Check the ECU diagnosis signal
(1) Connect the (X-431) diagnosis connector.
(2) Read the diagnosis result with (X-431) diagnosis
tester.
Caution:
Because of the impact and the battery power
shortage, the instrument cannot communicate
with the airbag ECU; thus, use an external
power supply during the check and mainte-
nance of the instrument panel.
(b) Repair order
(1) When the airbag is deployed.
　　 Replace the following parts with new ones:
• Driver airbag module
• Passenger airbag module
• Airbag ECU
• Driver side and passenger side seat belt pre-
tensioner
Check the following parts, replace it with a new
one if it is abnormal:
• Clock spring
• Steering wheel, steering column, and steering
axis The installation conditions of the driver
airbag module for the steering wheel
The installation conditions of the driver airbag
module for the steering wheel.
• Check for abnormal noiss from the steering
wheel, and that the movement and clearance
is normal.
• Check for the damage of the wire harness and
the distortion of the terminals.
(c) Airbag ECU
(1) Check if the airbag ECU is dented, cracked, de-
formed, etc.
(2) Check for damage to the connector and the distor-
tion of terminals.
(3) Check the installation condition of the airbag ECU
bracket.
• Check if the cover is dented, cracked, de-
formed, etc.
• Check for the damage of the connector, the
distortion of terminals, and the pinch of the
ALK017G wire harness.
• Check if the airbag assembly is dented,
cracked deformed, etc.
• Check that the direction of the arrow is the
same with the vehicle.
(4) Check the installation condition of the airbag module.
(d) Check the driver airbag module.
(e) Clock spring
(1) Check for the damage of the connector, protect
the tube, and the distortion of the terminals.
(2) Check the distortion of the case.
(f) Steering wheel, steering column, and axis
(1) Check the installation condition of the driver airbag
module.
(2) Check for abnormal noises from the steering
wheel, and that the clearance is normal.
(g) Check the wire harness connector (instrument panel
wire harness).
(h) Check that the wire harness is firmly installed, the con-
nector for damage, and the terminal for deformation.
21
10. Test method for the airbag without a tester
Airbag indicator lamp warning
Check for airbag ECU connector looseness

and continuous alarms after installation
No
Disconnect the driver airbag wire harness, Yes Inspect whether the clock spring is
substitute the airbag alarm indicator with a 2 conducting
ohmmeter resistance, and check if it comes
on continually
No
No
Yes
Disconnect the passenger airbag wire harness,
substitute the airbag alarm indicator with a 2 Check whether the alarm continues
ohmmeter resistance, and check if it comes on after replacing the clock spring
continually
No
Disconnect the driver airbag harness, substi-

tute the airbag alarm indicator with a 2 ohm-
meter resistance, and check if it comes on
continually
No
Disconnect the passenger airbag harness,

substitute the airbag alarm indicator with a 2
ohmmeter resistance, and check if it comes on
continually
No
Go to a professional maintenance station to

perform an inspection
RS-22
1. Passenger airbag assembly (vehicles not involved
in a collision)
(a) Perform a diagnostic system check.
(b) Perform a visual check, which includes the following
items with the driver airbag assembly installed in the
vehicle:
Cuts, minute cracks, or marked discoloration on the
driver airbag assembly top surface and in the grooved
ALK018G portion.
2. Passenger airbag assembly (vehicle involved in a

collision and airbag is not deployed)
items with the driver airbag assembly removed from the
vehicle:
• Cuts, minute cracks, or marked discoloration on
the driver airbag assembly top surface and in the
grooved portion.
• Cracks or other damage in the connectors.
ALK019G
• Deformation of the horn button contact plate of the
steering wheel assembly.
Hint:
• There should be no interference between the driver
airbag assembly and steering wheel assembly, and
the clearance should be uniform all the way around
when the new driver airbag assembly is installed on
the steering wheel assembly.
ALK020G
Caution:
For the removal and installation procedures for the
driver airbag assembly, refer to page RS-26 on “RE-
PLACEMENT”, and be sure to follow the correct
procedures.
ALK021G
23
3. Passenger airbag assembly (vehicles not involved

in a collision)
items with the passenger airbag assembly installed in
the vehicle:
Cuts, minute cracks, or marked discoloration on the in-
strument panel around the passenger airbag assembly.
ALK022G
4. Passenger airbag assembly (vehicle involved in a

collision and the airbag is not deployed)
items with the passenger airbag assembly removed
from the vehicle:
• Cuts, minute cracks, or marked discoloration
around the passenger airbag assembly.
• Cuts and cracks in the wire harness, and chips in
the connector.
ALK023G
• Deformation or cracks on the instrument panel and
instrument panel reinforcement.
Hint:
• If the instrument panel or instrument panel rein-
forcement is deformed or cracked, never repair it.
Always replace it with a new one.
• There should be no interference between the instru-
ment panel upper body and the passenger airbag
assembly.
ALK024G
Caution:
For the removal and installation procedures for the
driver airbag assembly, refer to page RS-35 on “RE-
PLACEMENT”, and be sure to follow the correct
procedures.
ALK025G
RS-24
5. Airbag ECU assembly (vehicles not involved in a

collision)
6. Airbag ECU assembly (vehicle involved in a colli-
sion and the airbag is not deployed)
7. Airbag ECU assembly (vehicle involved in a colli-
sion and the airbag is deployed)
(a) Replace the airbag ECU assembly (see page RS-42).
8. Wire harness and connector (vehicle not involved
in a collision)
9. Wire harness and connector (vehicle involved in a
collision)
(b) Check for breaks in all wires of the SRS wire harness
and an exposed conductor.
(c) Check if the SRS wire harness connectors are cracked
or chipped.
Hint:
The SRS wire harness is integrated with the engine
room main wire, instrument panel wire, floor wire, har-
ness assembly.
25
Driver Airbag Assembly

Components
Torx screw
Torx screw
Combination
switch's upper
protective cover
Steering wheel assembly
Clock spring
sub-assembly
Combination switch lower protective cover
: Specified torque Driver airbag assembly

ALK026G
RS-26
Replacement
RS-2)
3. Remove the driver airbag assembly
(a) Place the front wheels facing straight ahead.
(b) Using a Torx socket wrench (T30), loosen the 2 Torx
screws until the groove along the screw circumference
catches on the screw case. The harness assembly is
integrated.
ALK027G
(c) Pull out the driver airbag assembly from the steering
wheel assembly and support the airbag assembly with
one hand as shown in the illustration.
Notice:
When removing the driver airbag assembly, do not
pull the airbag wire harness.
(d) Using a screwdriver, disconnect the driver airbag as-
sembly connectors.
(e) Disconnect the airbag connector.
ALK028G (f) Remove the driver airbag assembly.
4. Install the driver airbag assembly

(a) Support the driver airbag assembly with one hand as
(b) Connect the driver airbag assembly connectors.
(c) Connect the airbag connector.
(d) Confirm that the circumference groove of the Torx
screw fits in the screw case, and place the driver airbag
assembly onto the steering wheel assembly.
(e) Using a Torx socket wrench (T30), install the 2 screws.
Torque: 8.8 N·m
ALK029G
5. Inspect the driver airbag assembly

(a) Perform a visual check, which includes the following
items with the driver airbag assembly installed in the
vehicle:
Cuts, minute cracks, or marked discoloration on the
driver airbag assembly top surface or in the grooved
portion.
6. Inspect the SRS warning light
ALK018G
27
Disposal
Hint:
When scrapping a vehicle equipped with the SRS or dispos-
ing of the driver airbag assembly, be sure to deploy the air-
bag first in accordance with the procedures described below.
Caution:
• Never dispose of the driver airbag assembly that has
an undeployed airbag.
• The airbag produces an exploding sound when it is
deployed, so perform the operation outdoors where it
will not create a nuisance to nearby residents.
• When deploying the airbag, always use the specified
SST (airbag deployment tool). Perform the operation
ALK030G
in a place away from electrical noise.
• When deploying the airbag, perform the operation at
least 10 m away from the driver airbag assembly.
• The driver airbag assembly is extremely hot when the
airbag is deployed, so do not touch it within at least
30 minutes after deployment.
• Use gloves and safety glasses when handling the
driver airbag assembly with the deployed airbag.
• Do not apply water or other liquids to the driver air-
bag assembly with the deployed airbag.
• Always wash your hands with water after completing
the operation.
1. Dispose of the driver airbag assembly (when scrap-
ping the vehicle deployment method)
Hint:
Prepare a battery as the power source to deploy the
airbag.
(a) Check the function of the SST.
Caution:
When deploying the airbag, always use the speci-
fied SST: Airbag Deployment Tool.
ALK030G
(1) Connect the SST to the battery.

Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip of the SST to
the battery negative (-) terminal.
Hint:
Battery Do not connect the yellow connector of the SST,,
which is to be connected with the SRS.
ALK031G
RS-28
(2) Check the function of the SST.

Press the SST activation switch, and check that
the LED of the SST activation switch comes on.
Caution:
If the LED comes on when the activation
switch is not being pressed, SST malfunction
is possible, so be sure not to use the SST.
(3) Disconnect the SST from the battery.
ALK032G
Airbag (b) Install the SST.

Connector Caution:
Check that there is no looseness in the steering
wheel assembly and driver airbag assembly.
(1) While turning the steering wheel assembly to the
right and left, remove the 3 screws and combina-
tion switch cover.
(2) Disconnect the airbag connector of the clock
spring sub-assembly.
ALK033G
(3) Connect the connector of the SST to the airbag

connector of the clock spring sub-assembly.
Notice:
To avoid damaging the SST connector and wire
harness, do not lock the secondary lock of the
twin lock.
ALK034G
(4) Move the SST at least 10m away from the front of
the vehicle.
(5) Close the vehicle doors and windows.
Notice:
Battery
Take care not to damage the SST wire harness.
(6) Connect the red clip of the SST to the battery posi-
10 m or more
ALK035G
29
(c) Deploy the airbag.

(1) Check that no one is inside the vehicle or within a
10m radius of the vehicle.
(2) Press the activation switch of the SST and deploy
the airbag.
Hint:
The airbag is deployed as the LED of the SST ac-
tivation switch comes on.
(d) Dispose of the driver airbag assembly.
Caution:
• The driver airbag assembly is extremely hot
when the airbag is deployed, so do not touch it
within at least 30 minutes after deployment.
• Use gloves and safety glasses when handling
the driver airbag assembly with the deployed
airbag.
• Always wash your hands with water after com-
pleting the operation.
• Do not apply water or other liquids to the driver
airbag assembly with the deployed airbag.
2. Dispose of driver airbag assembly (when disposing
of airbag assembly deployment method)
Battery Notice:
• When disposing of the driver airbag assembly
only, never use the customer’s vehicle to deploy
the airbag.
• Be sure to follow the procedures detailed below
when deploying the airbag.
Hint:
ALK031G Prepare a battery as the power source to deploy the
airbag.
(a) Check the function of the SST (see step 1-(a)).
(b) Remove the driver airbag assembly (see page RS-26).
Caution:
• When removing the driver airbag assembly,
work must be started 90 seconds after the igni-
tion switch is turned to the “LOCK” position and
the negative (-) terminal cable is disconnected
from the battery.
• When storing the driver airbag assembly, keep
the upper surface of the airbag deployment side
facing upward.
(c) Using a service-purpose wire harness for the vehicle,
tie down the driver airbag assembly to the disc wheel.
Wire harness diameter Wire harness: Stripped wire harness section 1.25 mm2
or more.
Caution:
If a wire harness which is too thin or an alterna-
tive object is used to tie down the driver airbag as-
sembly, it may be snapped by the shock when the
Square of the Stripped Wire Harness Section airbag is deployed. This is highly dangerous. Al-
ways use a wire harness with a diameter of at least
ALK036G 1.25 mm2 for vehicle maintenance.
Hint:
To calculate the square of the stripped wire harness
section: Square = 3.14 × (Diameter)2/4
RS-30
(1) Install the 2 bolts with washers in the 2 bolt holes

of the driver airbag assembly.
Bolt:
L: 35.0 mm, M: 6.0 mm
Pitch: 1.0 mm
Notice:
• Tighten the bolts by hand until the bolts be-
come difficult to turn.
• Do not tighten the bolts too much.
ALK037G
(2) After connecting the SST below to each other,

connect them to the driver airbag assembly.
ALK038G
(3) Using 3 wire harnesses, wind each wire harness

at least 2 times each around the bolts installed on
the left and right sides of the driver airbag assem-
bly.
2 times or more Caution:
• Tightly wind the wire harness around the
bolts so that there is no slack.
• If there is slack in the wire harness, the
driver airbag assembly may become loose
due to the shock when the airbag is de-
ALK039G
ployed. This is highly dangerous.
(4) Face the upper surface of the driver airbag assem-

bly upward.
Separately tie the left and right sides of the driver
airbag assembly to the disc wheel through the hub
nut holes. Position the SST connector so that it
hangs downward through a hub hole in the disc
wheel.
Caution:
• Make sure that the wire harness is tight. It
is highly dangerous when looseness in the
ALK040G wire harness results in the driver airbag
assembly coming free due to the shock re-
sulted from the airbag deployment.
• Always tie down the driver airbag assembly
with the pad side facing upward. It is highly
dangerous if the driver airbag assembly is
tied down with the metal surface facing up-
ward as the wire harness will be cut by the
shock caused by the airbag deployment and
the driver airbag assembly will be thrown
into the air.
Notice:
The disc wheel will be marked by the airbag
deployment, so use a redundant disc wheel.
31
(d) Install the SST.

Caution:
Place the disc wheel on level ground.
(1) Connect the connector of the SST.
Notice:
twin lock. Also, secure some slack for the SST
wire harness inside the disc wheel.
ALK041G
(2) Move the SST to at least 10 m away from the driv-

er airbag assembly tied down to the disc wheel.
Battery
10m or more
ALK042G
(e) Cover the driver airbag assembly with a cardboard box

or tires.
(1) Covering method using a cardboard box:
Cover the driver airbag assembly with a cardboard
box and place the weights on the cardboard box in
4 places with at least 190 N.
Size of cardboard box:
Must exceed the following dimensions:
X = 460 mm
Weight Y = 650 mm
ALK043G
Notice:
• When the dimension Y of the cardboard
box exceeds the diameter of the disc wheel
with tire to whic��
h the driver airbag assem-
bly is tied, X should be the following size:
X = 460 mm + width of tire.
• If��
a cardboard box which is smaller than the
specified size is used, the cardboard box
will be broken by the shock from the airbag
deployment.
Inner diameter (2) Covering method using tires:
Place at least 3 tires with no disc wheels on top of
Width the tire with the disc wheel to which the driver air-
Tires bag assembly is tied.
(3 or
more) Tire size: Must exceed the following dimensions
Width: 185 mm
Inner diameter: 360 mm
Caution:
Do not use tires with disc wheels.
Notice:
ALK044G • The tires may be marked by the airbag de-
ployment, so use redundant tires.
• Do not place the SST connector under the
tire because the SST connector could be
damaged.
RS-32
(f) Deploy the airbag.

Battery tive (+) terminal and the black clip of the SST to
(2) Check that no one is within a 10m radius of the
disc wheel to which the driver airbag assembly is
tied.
the airbag.
10m or more Hint:
ALK042G
(g) Dispose of the driver airbag assembly.

Caution:
• The driver airbag assembly is extremely hot
the driver airbag assembly with the deployed
airbag.
ALK045G
• Do not apply water or other liquids to the driver
(1) Remove the driver airbag assembly from the disc
wheel.
(2) Place the driver airbag assembly in a plastic bag,
tie it tightly, and dispose of it as if it is another gen-
eral parts disposal.
33
Clock Spring Sub-assembly

Replacement
Hint:
Components: see page RS-25
RS-2)
4. Remove the driver airbag assembly (see page
RS-26)
5. Remove the steering wheel assembly (see page
SR-6)
6. Remove the combination switch cover

(a) Remove the 3 screws and the combination switch cover.
ALK046G
7. Remove the clock spring sub-assembly

(a) Disconnect the airbag connector and the clock spring
sub-assembly connector.
(b) Disengage the 3 claws and remove the clock spring
sub-assembly.
8. Check the clock spring sub-assembly
Airbag connector (a) If the following condition is identified, replace the
clock spring sub-assembly with a new one.
Conditions:
: Claw ALK047G
• Scratches or cracks on the connector.
• Cracks, dents, or chips in the clock spring sub-
assembly.
(a) Check that the front wheels are facing straight ahead.
RS-34
10. Install the clock spring sub-assembly

(a) Set the turn signal switch to the neutral position.
Notice:
Make sure that the turn signal switch is in the neu-
tral position since the pin of the turn signal switch
may be snapped.
(b) Engage the 3 claws and install the clock spring sub-
assembly.
Notice:
When replacing the clock spring sub-assembly with
a new one, remove the lock pin before installing the
steering wheel assembly.
(c) Connect the airbag connector and the clock spring sub-
assembly connector.
(d) Install the combination switch cover with the 3 screws.
11. Adjust the clock spring sub-assembly
(a) Check that the ignition switch is OFF.
(b) Check that the battery negative terminal is disconnect-
ed.
Notice:
Do not start the operation for 90 seconds after re-
moving the terminal.
(c) Turn the clock spring sub-assembly counterclockwise
slowly by hand until it feels firm.
ALK048G
(d) Then rotate the spiral cable sub-assembly clockwise

Marks
about 3.5 turns to align the marks.
Hint:
The clock spring will rotate about 3.5 turns to both the
left and right of the center.
12. Install the steering wheel assembly (see page SR-9)
13. Inspect the steering wheel center point
RS-26)
ALK049G
RS-26)
35
Passenger Airbag Assembly

Components
Passenger airbag assembly
Front tweeter shield RH
Front tweeter shield LH
Upper instrument panel body
ALK050G
Replacement
RS-2)
3. Remove the front tweeter assembly RH (see page
AV-6)
4. Remove the front tweeter assembly RH (see page
AV-6)
5. Disconnect the passenger airbag assembly con-
nector
(a) Remove the passenger airbag connector clip.
(b) Disconnect the passenger airbag connector.
Notice:
When handling the airbag connector, take care not
to damage the airbag wire harness.
6. Remove the upper instrument panel body w/pas-
senger airbag assembly (see page IR-30)
ALK051G
RS-36
7. Remove the passenger airbag assembly

(a) Remove the 2 nuts.
ALK052G
(b) Disengage the 12 claws of the passenger airbag as-

sembly, and then remove the passenger airbag assem-
bly from the upper instrument panel body.
8. Install the passenger airbag assembly
(a) Install the passenger airbag with 2 nuts.
Torque: 5.0 N·m
RS-23)
10. Install the upper instrument panel body w/passen-
: Claw ALK053G
ger airbag assembly
11. Connect the driver airbag assembly connectors
Disposal
Hint:
• When scrapping a vehicle equipped with the SRS or
disposing of the passenger airbag assembly, be sure to
deploy the airbag first in accordance with the procedures
described below.
• If any abnormality occurs with the airbag deployment,
contact the after-sales service department of the Great
Wall Motor Company.
Caution:
• Never dispose of the passenger airbag assembly that
has an undeployed airbag.
• The airbag produces an large exploding sound when
it is deployed, so perform the operation outdoors
where it will not create a nuisance to nearby resi-
dents.
• When deploying the airbag, always use the specified
SST (Airbag Deployment Tool). Perform the operation
ALK030G in a place away from electrical noise.
• When deploying the airbag, perform the operation at
least 10 m away from the driver airbag assembly.
• The passenger airbag assembly is extremely hot
when the airbag is deployed, so do not touch it within
at least 30 minutes after deployment.
• Use gloves and safety glasses when handling the
passenger airbag assembly with the deployed airbag.
• Do not apply water or other liquids to the passenger
the operation.
37
1. Dispose of the driver airbag assembly (when scrap-

ping the vehicle deployment method)
Hint:
airbag.
(a) Check the function of the SST (see page RS-27, Step
1-A).
Battery
ALK031G
(b) Disconnect the passenger airbag connector.

(1) Remove the glove box body (see page IR-34).
Notice:
When handling the airbag connector, take care
not to damage the airbag wire harness.
(2) Disconnect the passenger airbag assembly con-
nector.
ALK051G
(c) Install the SST.

(1) Connect the connector of the SST to the passen-
ger airbag assembly connector.
Notice:
twin lock.
SST
ALK054G
(2) Move the SST at least 10 m away from the front of

the vehicle.
(3) Close all vehicle doors and windows.
Battery
Notice:
10m or more
(d) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a
ALK035G
10m radius of the vehicle.
the airbag.
Hint:
RS-38
(e) Dispose of the passenger airbag assembly.

Caution:
the passenger airbag assembly with the de-
ployed airbag.
• Do not apply water or other liquids to the pas-
senger airbag assembly with the deployed air-
bag.
2. Dispose of the passenger airbag assembly (when
scrapping airbag assembly deployment method)
Notice:
• When disposing of the passenger airbag as-
sembly only, never use the customer’s vehicle
to deploy the airbag.
• Be sure to follow the procedures detailed below
when deploying the airbag.
Hint:
Battery airbag.
(a) Check the function of the SST (see page RS-27, step
1-a).
ALK031G
(b) Remove the passenger airbag assembly (see page

RS-36).
Caution:
• When removing the passenger airbag assembly,
work must be started 90 seconds after the igni-
tion switch is turned to the “LOCK” position and
the negative (-) terminal cable is disconnected
from the battery.
• When storing the passenger airbag assembly,
ALK023G
keep the upper surface of the airbag deploy-
ment side facing upward.
(c) Using a service-purpose wire harness for the vehicle,

tie down the passenger airbag assembly to the disc
Wire harness diameter wheel.
Wire harness: square of the stripped wire harness sec-
1.25 mm2 or more
tion 1.25
1.25 mm
Caution:
• If a wire harness which is too thin or an alterna-
Square of the stripped wire harness section tive object is used to tie down the passenger
airbag assembly, it may be snapped from the
ALK036G
shock as the airbag is deployed.
• This is highly dangerous. Always use a wire
harness with a diameter of at least 1.25 mm2 for
vehicle maintenance.
39
Hint:
To calculate the square of the stripped wire harness
section:
Square = 3.14 × (Diameter)2/4
Position the passenger airbag assembly inside the tire
with the airbag deployment side facing inside.
Tire size: must exceed the following dimensions
Width: 185 mm
Inner diameter: 360 mm
Caution:
• Make sure that the wire harness is tight. It is
highly dangerous when looseness in the wire
harness results in the passenger airbag assem-
bly coming free due to shock from the airbag
deployment.
• Always tie down the passenger airbag assembly
with the airbag deployment side facing inside
the tire.
Notice:
The tires may be marked by the airbag deployment,
so use redundant tires.
Inner diameter
Width Tires
ALK055G
(d) Install the SST.

Connect the connector of the SST to the passenger air-
bag assembly.
ALK056G
RS-40
(e) Place tires.

(1) Place at least 2 tires under the tire to which the
passenger airbag assembly is tied.
(2) Place at least 2 tires upper the tire to which the
Tires passenger airbag assembly is tied. The top tire
(5 or More) should have the disc wheel installed.
Notice:
Do not place the SST connector under the tire
because the SST connector could be damaged.
ALK057G
(3) Tie the tires together with 2 wire harnesses.

Caution:
Make sure that the wire harness is tight. It is
highly dangerous when looseness in the wire
harness results in the tires coming free due to
shock from the airbag deployment.
Hint:
Place the SST connector and the wire harness in-
side tires. Secure at least 1m of slack for the wire
harness.
ALK058G
(f) Install the SST.

Passenger airbag assembly
Connect the connector of the SST.
Notice:
Battery
harness, do not lock the secondary lock of the twin
lock. Also, secure some slack for the SST wire har-
ness inside the tire.
(g) Deploy the airbag.
10m or more tive (+) terminal and the black clip of the SST to
ALK059G
(2) Check that no one is within a 10m radius of the
disc wheel to which the driver airbag assembly is
tied.
the airbag.
Hint:
(h) Dispose of the passenger airbag assembly.
Caution:
the passenger airbag assembly with the de-
ployed airbag.
• Do not apply water or other liquids to the passen-
ger airbag assembly with the deployed airbag.
ALK060G • Always wash your hands with water after com-
(1) Remove the passenger airbag assembly from the tire.
(2) Place the driver airbag assembly in a plastic bag,
tie it tightly, and dispose of it as if it were another
general parts disposal.
41
Airbag ECU Assembly

Components
Airbag ECU assembly
Instrument panel lower shield
: specified torque
ALK061G
RS-42
Replacement
RS-2)
3. Remove the instrument panel lower shield (see
page IR-34)
4. Remove the airbag ECU assembly
(a) Disconnect the connectors from the airbag ECU as-
sembly.
(b) Using a socket wrench, remove the 3 screws and the
airbag ECU assembly.
5. Install the airbag ECU assembly
(a) Check that the ignition switch is OFF.
(b) Check that the battery negative (-) terminal is discon-
nected.
Notice:
ALK062G
After removing the terminal wait for at least 90 sec-
onds before starting the operation.
(c) Using a socket wrench, install the airbag ECU assem-
bly with the 3 screws.
Notice:
• If the airbag ECU assembly has been dropped,
or there are any cracks, dents, or other defects
in the case, bracket or connector, replace the
airbag ECU assembly with a new one.
• When installing the airbag ECU assembly, take
care that the SRS wiring does not interfere with
other parts and is not pinched between other
parts.
(d) Tighten the 3 screws to the specified torque.
Torque: 8 N·m
(e) Connect the connectors to the airbag ECU assembly.
(f) Check that there is no looseness in the installation
parts of the airbag ECU assembly.
(g) Check that the water-proof sheet is properly set.
43
Seat belts
Seat Belt Warning System
Components
Combination meter
(driver seat belt warning
indicator)
Passenger seat belt warning

indicator
Driver seat belt buckle assembly
Front passenger seat mortise lock assembly
ALK063G
RS-44
Reference Page
Symptom Location in Question
(s)
Driver seat belt warning indicator does not 2. Combination meter IR-40
come on 3. Driver seat belt buckle assembly RS-45
4. Wire harness -
1. Combination meter IR-40
Driver seat belt warning indicator does not
2. Driver seat belt buckle assembly RS-45
go off
3. Wire harness -
1. Center console panel body IR-29

Passenger seat belt warning indicator
2. Passenger seat belt buckle assembly RS-44
does not come on
3. Wire harness -
1. Center console panel body IR-29

Passenger seat belt warning indicator
2. Passenger seat belt buckle assembly RS-44
does not go off
3. Wire harness -
Inspection
1. Inspect passenger seat belt buckle assembly
(a) Check the buckle switch.
Connector A
(1) Fasten the seat belt (buckle switch is ON).
(2) Check the resistance between the terminals.
Standard:
Testing instrument connection Specified condi-
tion
ALK064G
A-1 - A-2 Below 1 W
(3) Release the seat belt (buckle switch is OFF).
Standard:
Testing instrument connection Specified condi-
tion
A-1 - A-2 10 kW or more
If the result is not as specified, replace the seat belt
buckle assembly.
45
2. Inspect driver seat belt buckle assembly

(a) Check the buckle switch.
(1) Fasten the seat belt (buckle switch is ON).
Connector A (2) Check the resistance between the terminals.
Standard:
Testing instrument connection Specified
condition
A-1 - A-2 Below 1 W
(3) Release the seat belt (buckle switch is OFF).
ALK064G
Standard:
Testing instrument connection Specified
condition
A-1 - A-2 10 kW or more
If the result is not as specified, replace the seat belt
buckle assembly.
Front Seat Belts

Precautions
Caution:
Replace the faulty parts of the seat belt systems (outer
belt, seat belt buckle assembly, bolts, nuts, seat belt ad-
juster assembly, tether anchor hardware, sill-bar, etc.)
Seat belt systems not in use at the time of a collision
should also be inspected and replaced if found to be
damaged or working improperly.
1. Test Drive
(a) Fasten the front seat belts.
(b) Drive the vehicle at 16 km/h and slam on the brakes.
Check that the belt locks and cannot be extended at
this time.
Hint:
Conduct this test in a safe area. If the belt does not
lock, remove the belt assembly and perform the inspec-
tions. Also, whenever installing a new belt assembly,
verify their proper operation before installation.
ALK065G
RS-46
Components
Right B-pillar upper guard plate
Seat belt adjuster

assembly
Front door weatherstripping RH
Rear door weatherstrip-

ping RH
Rear rocker
trim RH
Guide ring trim

cover RH
Front passenger seat

outer belt assembly
Cowl side trim
board RH Front rocker trim RH
Right B-pillar lower

guard plate
Driver seat rear

mounting bolt cover LH
End plate
cover
Passenger
seat assembly
Driver seat rear

mounting bolt cover LH
Front passenger seat

mortise lock assembly
: Specified torque
ALK066G
47
Replacement
Hint:
• The installation procedures are the removal procedures in
the reverse order. However, only installation procedures
requiring additional information are included.
• Use the same procedures for the RH side and LH side.
2. Remove the passenger seat assembly RH (see page
IR-66)
3. Remove the passenger seat belt buckle assembly
4. Remove the front rocker trim RH (see page IR-61)
5. Remove the rear rocker trim RH (see page IR-62)
6. Remove the front door sealing strip RH
7. Remove the rear door sealing strip RH
8. Remove the B pillar lower trim RH (see page IR-62)
9. Remove the passenger seat outer belt assembly
Notice:
• The removal operation concerning the seat belt
with the pretensioner must be started when 90
seconds or more has passed after the ignition
switch is turned OFF and the battery negative
terminal is disconnected.
• Carefully read the notices for the “pretensioner”
in the SRS airbag system section and the front
seat outer belt section.
(a) Remove the end plate cover.
(b) Remove the bolt on the plate side and the outer belt.
(c) Remove the guide ring trim cover RH.
(d) Remove the bolt on the guide ring side and the outer
belt.
(e) Disconnect the pretensioner connector as shown in the
illustration.
(f) Remove the 2 bolts on the retractor side and remove
the outer belt completely.
10. Remove the seat belt adjuster assembly
(a) Remove the bolt and the seat belt adjuster assembly.
ALK067G
11. Install the seat belt adjuster assembly
(a) Install the seat belt adjuster assembly with the bolt.
Torque: 45 N·m
Unlocking 12. Install the passenger seat outer belt assembly
Notice:
Do not disassemble the retractor.
(a) Check the degree of tilt when beginning to lock the re-
Locking tractor.
(1) Check that the belt does not lock within 15° of tilt
in all directions but locks with over 45° of tilt when
gently moving the retractor.
If operation is not as specified, replace the outer
Retractor belt assembly.
ALK068G
(b) Install the outer belt with the 2 bolts on the retractor
side.
Torque:
5.5 N·m for upper bolt
45 N·m for lower bolt
RS-48
(c) Connect the pretensioner connector as shown in the il-

lustration.
(d) Install the seat outer belt with the bolt on the guide ring
side.
Torque:
45 N·m
(e) Install the guide ring trim cover.
(f) Install the seat outer belt with the bolt on the end plate
side.
ALK067G
Torque: 45 N·m
(g) Install the end plate cover.
(h) Check the retractor lock.
Notice:
The check should be performed with the assembly
installed.
(1) Check that the belt locks by pulling it out quickly
after installation.
If operation is not as specified, replace the outer
belt assembly.
(i) Check the fastening function of the child restraint sys-
tem.
Notice:
installed.
(1) Check that the belt cannot be pulled out any more
but rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound
after it has been fully rewound.
If the operation is not as specified, replace the belt
assembly.
13. Install the passenger seat belt buckle assembly
(a) Install the buckle with the bolt.
Torque: 45 N·m
14. Install the passenger seat assembly
49
Disposal
Hint:
When scrapping vehicles equipped with a seat belt preten-
sioner or a front seat outer belt (w/seat belt pretensioner),
always first activate the seat belt pretensioner in accordance
with the procedures described below. When disposing of
a front seat outer belt assembly (w/seat belt pretensioner)
that was activated in a collision, follow the same procedures
listed in step 1-(e) in “DISPOSAL.”
Caution:
• Never dispose of a front seat outer belt assembly
with an inactivated pretensioner.
• The seat belt pretensioner produces a sizeable ex-
ploding sound when it activates, so perform the oper-
ation outdoors so as not to disturb nearby residents.
• When activating a front seat outer belt (w/seat belt
pretensioner), control operation at least 10m away
ALK069G from the front seat outer belt.
• Use gloves and safety glasses when handling a front
seat belt with an activated pretensioner.
activation.
• Do not apply water or other liquids onto a front seat
outer belt with an activated pretensioner.
• When activating the seat belt pretensioner, always
use the specified SST (SRS airbag deployment tool).
Perform operation in a place away from electrical in-
terference.
ALK070G 1. Dispose of the passenger seat outer belt assembly

(When installed in the vehicle)
Hint:
Check that the battery positive voltage is above 12 V.
(a) Check the function of the SST.
Caution:
When activating the seat belt pretensioner, always
use the specified SST.
ALK069G
RS-50
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(-) terminal.
Battery Hint:
Do not connect the yellow connector which will be
connected to the seat belt pretensioner.
ALK031G
(2) Press the SST activation switch and check that the
LED of the SST activation switch comes on.
Caution:
If the LED comes on when the activation switch
is not pressed, the SST may have a malfunc-
tion. In such case, the SST should not be used.
(b) Disconnect the SST from the battery.
(c) Disconnect the pretensioner connector.
(d) Disconnect the battery negative (-) terminal.
(e) Check the SRS airbag system (see page RS-22).
ALK071G
(f) Remove the front rocker trim RH (see page IR-61).
(g) Remove the rear rocker trim RH (see page IR-62).
(h) Remove the front door sealing strip RH.
(i) Remove the rear door sealing strip RH.
(j) Remove B pillar lower trim RH (see page IR-62).
(1) Disconnect the pretensioner connector as shown
(k) Connect SST.
(1) Install the end plate of the seat belt.
ALK067G
(2) Connect the SST, then connect them to the seat

belt pretensioner.
Notice:
twin lock.
ALK072G
51
(3) Move the SST at least 10m or more away from the
front of the vehicle.
(4) Close all the doors and windows of the vehicle.
Notice:
(-) terminal.
10 m or more (l) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within
ALK073G
10 m of the vehicle.
(2) Press the SST activation switch and activate the
seat belt pretensioner.
Hint:
The seat belt pretensioner operates simultaneous-
ly with the LED light for the SST activation switch.
(m) Dispose of the outer belt (w/the seat belt pretensioner).
Caution:
• The outer belt is very hot when the seat belt pre-
tensioner is activated, so leave it untouched for
at least 30 minutes after it has been activated.
an outer belt with a pretensioner that has been
activated.
pleting activation.
• Do not apply water or other liquids to the outer
belt assembly with a pretensioner that has been
activated.
Hint:
When scrapping a vehicle, activate the seat belt pre-
tensioner, and then scrap the vehicle with the activated
outer belt installed.
2. Dispose of the passenger seat outer belt assembly
(when not installed in vehicle)
Notice:
• When disposing of the front seat outer belt (w/
the seat belt pretensioner) only, never use the
customer’s vehicle to activate the seat belt pre-
Battery
tensioner.
• Be sure to follow the procedures listed below
when activating the seat belt pretensioner.
(a) Remove the outer belt (see page RS-47).
Hint:
Cut the belt near the seat belt retractor.
ALK031G (b) Check the function of SST (see step 1-(a)).
RS-52
(c) Connect the SST.

(1) Connect the SST, then connect them to the seat
belt pretensioner.
Notice:
twin lock.
ALK072G
(2) Place the outer belt on the ground and cover it

with a tire and wheel.
Notice:
Set the front seat outer belt assembly as
ALK074G
(3) Move the SST at least 10m or more away from the
front of the vehicle.
Notice:
(d) Activate the seat belt pretensioner.
10m or more (-) terminal.
(2) Check that no one is within 10m of the wheel.
(3) Press the SST activation switch and activate the
ALK075G
seat belt pretensioner.
Hint:
The seat belt pretensioner operates simultaneous-
ly with the LED light for the SST activation switch.
(e) Dispose of the outer belt (w/the seat belt pretensioner).
Caution:
• The outer belt assembly is very hot when the
seat belt pretensioner is activated, so leave it
untouched for at least 30 minutes after it has
been activated.
an outer belt assembly with a pretensioner that
ALK076G
has been activated.
pleting activation.
• Do not apply water or other liquids to the outer
belt assembly with a pretensioner that has been
activated.
(1) Remove the wheel and SST.
(2) Place the outer belt in a plastic bag, tie the end
tightly, or other liquids and dispose of it in the
same way as other general parts.
53
Rear Seat Belts

Components
Rear door weatherstripping RH

C Pillar upper trim panel assembly RH
Trunk door weatherstripping
C pillar lower
trim panel as-
sembly RH
Rear seat 3-
point type
outer belt as-
sembly
Back door rocker

shield
Center Rear Seat
outer belt assembly
Deck board No.2
R e a r r o c k e r Rear seat
trim RH shoulder belt cover Deck board No.1
Deck floor box RH
Spare tire bracket assembly
Rear seat
assembly
Center Rear seat setting cross member

rear seat assembly
buckle w/
center belt
assembly RH Rear seat buckle w/
center belt assembly LH
: Specified torque
ALK077G
RS-54
Replacement
Hint:
• The installation procedures are the removal procedures in
the reverse order. However, only installation procedures
3. Remove the deck board No.1
4. Remove the deck board No.2
5. Remove the spare tire bracket assembly
6. Remove the deck floor box RH
7. Remove the rear seat assembly (see page IR-71)
9. Remove the back door rocker trim
10. Remove the C pillar lower trim panel assembly RH
(see page IR-63)
11. Remove the roof inner trim panel RH
12. Remove the rear seat 3-point type outer belt assem-
bly
(a) Remove the bolt on the guide ring side and the belt.
(b) Remove the bolt on the retractor side, and remove the
seat belt completely.
13. Remove the center rear seat outer belt assembly
(a) Remove the seatback board (see page IR-71).
(b) Remove the shoulder belt cover (see page IR-72).
(c) Remove the bolt and the seat belt at the end plate side.
(d) Remove the bolt and nut on the retractor side, and re-
move the belt completely.
14. Remove the rear seat buckle w/center belt assem-
bly RH
(a) Remove the bolt and buckle.
15. Remove the rear seat buckle w/center belt assem-
bly LH
(a) Remove the bolt and buckle.
16. Remove the rear seat setting cross member assem-
bly
(a) Remove the 4 bolts and the setting cross member
bracket.
17. Install the rear seat setting cross member assembly
(a) Install the setting cross member bracket with the 4
bolts.
Torque: 23 N·m
18. Install rear seat buckle w/center belt assembly LH
(a) Install the end plate and the belt with the bolt as shown
Torque: 45 N·m
Notice:
Make sure that the end plate part does not run onto
the protrusion part of the floor panel.
ALK078G
55
19. Install the rear seat buckle w/center belt assembly

RH
(a) Install the end plate and the belt with the bolt as shown
Torque: 45 N·m
Notice:
ALK079G
Unlocking 20. Install the center rear seat outer belt assembly
(a) Install the belt on the retractor side with the nut.
Torque: 45 N·m
Locking
(b) Install the shoulder belt cover.
(c) Install the center seatback board.
(d) Check the degree of tilt when the belt begins to lock the
retractor.
in all directions,, but locks with over 45°
but locks with over 45 of tilt when
ALK080G
assembly.
(e) Install the belt with the bolt.
Torque: 45 N·m
(f) Check the retractor lock.
Notice:
installed.
after installation.
Hint:
The seat belt does not lock when it is pulled out to
a length of 955 mm or less.
assembly.
(g) Check the fastening function of the child restraint sys-
tem.
Notice:
installed.
assembly.
21. Install rear seat 3 point type outer belt assembly
(a) Install the belt with the bolt on the retractor side.
Torque: 45 N·m
RS-56
Unlocking (b) Check the degree of tilt when the belt begins to lock the
retractor.
in all directions, but locks with over 45° of tilt when
Locking If the operation is not as specified, replace the belt
assembly.
(c) Install the seat belt with the bolt on the end plate side.
Torque: 45 N·m
Notice:
ALK081G
after installation.
assembly.
(d) Check the retractor lock.
Notice:
installed.
after installation.
assembly.
(e) Check the fastening function of the child restraint sys-
tem.
Notice:
installed.
assembly.
22. Install the rear seat assembly
IR-�

Vehicle interior
Lighting System
Areas of Importance....................................................... IR-3
Malfunction indicator table............................................ IR-3
Vehicle check.................................................................. IR-5
Inspection........................................................................ IR-7
Front combination lamp assembly LH.......................... IR-10
Rear combination lamp assembly LH........................... IR-13
High-mounted brake lamp assembly............................ IR-14
License plate lamp assembly........................................ IR-15
Left combination switch assembly............................... IR-15
Front fog lamp assembly LH.......................................... IR-16
Back-up lamp assembly................................................. IR-17
Ignition switch
Replacement.................................................................... IR-18
Inspection........................................................................ IR-18
Combination Switch
Replacement.................................................................... IR-18
Combination meter
Malfunction indicator table............................................ IR-19
Pin definition................................................................... IR-21
Vehicle check.................................................................. IR-22
Dashboard/Meter............................................................. IR-24
Upper dashboard body................................................... IR-28
Lower dashboard body.................................................. IR-35
Combination meter assembly........................................ IR-40 IR
Reverse Sensor
System description......................................................... IR-41
Functional description................................................... IR-42
Circuitry........................................................................... IR-43
Technical parameters..................................................... IR-44
Connector terminal definitions...................................... IR-44
IR-�

Components.................................................................... IR-46
Back-up radar buzzer..................................................... IR-46
Parking distance control ECU....................................... IR-47
Immobilizer System
System description......................................................... IR-48
Functional description................................................... IR-48
Components.................................................................... IR-49
Theft deterrent ECU terminal definition........................ IR-49
Fault analysis.................................................................. IR-50
After-sales diagnostic matching process..................... IR-51
On-board Phone System

On-board phone ECU terminal definition..................... IR-52
Door Locks
Electric door lock control system................................. IR-53
Wireless door lock control system............................... IR-57
Transmitter battery......................................................... IR-58
Door control transmitter................................................. IR-58
Top Interior Cover

Components.................................................................... IR-60
Replacement.................................................................... IR-61
Seats
Front seat assembly....................................................... IR-65
Rear seat assembly........................................................ IR-70
VEHICLE INTERIOR IR-�

Lighting System
Areas of Importance
1. Areas of importance in replacing a headlight bulb
(a) If the halogen bulb (headlight) is coated with oil, its life will be shortened due to the heat produced
during usage.
(b) The internal pressure of the halogen bulb (headlight) is very high, so please handle carefully. Drop-
ping the bulb may lead to personal injury.
(c) When replacing the bulb, do not try to touch the lens with your fingers, as this may lead to lens con-
tamination or wetting. Before installation, be sure to prepare a new bulb.
(d) The new bulb should have the same wattage as the old one.
(e) Avoid wetting the lens with moisture or water.
(f) In order to avoid the lens wet or leakage, firmly reinstall the socket after bulb replacement.

Hint:
1. Headlights and rear parking lamps.
Reference Page
(s)
1.Bulb -
“LO-Beam” does not come on (One side).
2. Wire harness -
1. Low Beam fuse -
2. Low beam relay -
“LO-Beam” does not come on (All). 3. Left combination switch assembly SR-6
4. Bulb -
5. Wire harness -
“High-Beam” does not come on (One 1. Bulb -

side). 2. Wire harness -
1. High Beam fuse -
2. High beam relay -
“High-Beam” does not come on (All). 3. Left combination switch assembly SR-6
4. Bulb -
5. Wire harness -
1. Fuse -
“Flash” does not come on (All). 2. Left combination switch assembly SR-6
3. Wire harness -
1. Bulb -
Headlamp is dark.
2. Wire harness -
1. LED lamp -
Only one rear position lamp comes on.
2. Wire harness -
Both rear position lamps do not come on 1. LED lamp -
(Front position lamps are normal). 2. Wire harness -
1. Position lamp fuse -
2. Position lamp relay -
Both rear position lamps do not come on
3. Left combination switch assembly SR-6
(Front position lamps do not come on). -
4. LED lamp
5. Wire harness -
IR-�
2. Fog lamp
Problem Location in Question Reference Page(s)
1. Fog lamp fuse -
2. Fog lamp relay -
All fog lamps do not come on. 3. Fog lamp switch assembly -
4. Bulb -
5. Wire harness -
1. Fog lamp switch assembly -

Fog lamp always remains on.
2. Wire harness -
1. Bulb -
Fog lamp does not come on (One side).
2. Wire harness -
3. Turn signal light and hazard warning system

1. Hazard warning fuse -
“Hazard warning lamp” and “turn signal 2. Turn signal lamp fuse -
light” do not come on. 3. Flasher relay -
4. Wire harness -
Hazard warning lamp does not come on 1. Hazard warning fuse -
(Turn signal lamp is normal). 2. Wire harness -
Turn signal lamp does not come on (Haz- 1. Turn signal lamp switch IR-6
ard warning lamp is normal). 2. Wire harness -
1. Turn signal lamp switch IR-6
Turn signal lamp does not come on in one 2. Flasher relay -
direction. 3. Bulb -
4. Wire harness -
1. Bulb -
Only one bulb comes on.
2. Wire harness -
4. Brake Lamp System

1. Brake lamp fuse -
Both brake lamps do not come on. 2. Brake lamp switch assembly IR-7
3. Wire harness -
1. Brake lamp switch assembly IR-7
Brake lamp always remains on.
2. Wire harness -
1. LED lamp -
Brake lamp does not come on (One side).
2. Wire harness -
5. Back-up lamp system

1. Bulb -
2. Fuse -
Back-up lamp does not come on.
3. Back-up lamp switch assembly IR-7
4. Wire harness -
1. Back-up lamp switch assembly IR-7
Back-up lamp always remains on.
2. Wire harness -

6. Ceiling lamp system

1. Bulb -
Ceiling lamp does not come on. 2. Fuse -
3. Wire harness -
1. Bulb -
Reading lamp does not come on. 2. Fuse -
3. Wire harness -
Ceiling lamp and reading lamp do not
1. Fuse -
come on (All).
Wire Harness View:

Vehicle check
1. Inspect the turn signal flasher assembly
(a) Disconnect the connector from the turn signal flasher
assembly and inspect the connector on the wire har-
ness side as shown in the table below.
Standard:
Testing Condition Specified
instrument condition
connection
ALL001G
1 (IG) - Ground Ignition switch ON Battery voltage
1 (IG) - Ground Ignition switch LOCK No voltage
30 (IG) - Ground Always Battery voltage
7 (31) - Ground Always Conducting
(b) Connect the connector to the turn signal flasher assem-
bly and inspect the connector on the wire harness side
from the back as shown in the table below.
Standard:
Flash relay Testing
Specified
instrument Condition
condition
connection
0 V → 09 V (60 to
Hazard warning
2 (R) - Ground 120 times per min-
switch OFF → ON
ALL002G ute)
Turn signal lamp 0 V → 09 V (60 to
6 (15R) - Ground switch (Right turn) 120 times per min-
Turn signal flasher assembly OFF → ON ute)
The front view of connector:
0 V → 09 V (60 to
Hazard warning
3 (L) - Ground 120 times per min-
switch OFF → ON
ute)
Turn signal lamp 0 V → 09 V (60 to
5 (15L) - Ground switch (Right turn) 120 times per min-
OFF → ON ute)
Turn signal lamp
ALL003G 5 (15L) - Ground switch (Right turn) Above 9 V→ 0 V
ON → OFF
Turn signal lamp
6 (15R) - Ground switch (Right turn) Above 9 V→ 0 V
ON → OFF
Hazard warning
8 (HWS) - Ground Above 9 V→ 0 V
switch ON → OFF
IR-�
2. Delay function of the ceiling lamp (When the interior light switch is in the DOOR position)
(a) Open any door and then close, the ceiling lamp will be on for 10 seconds. If the ceiling lamp detects
that the vehicle key is inserted into the ignition switch again or any door is closed within 10 seconds, it
will change from bright to dark and fade out gradually.
(b) When removing the vehicle key from the ignition switch, the ceiling lamp comes on. If the key is insert-
ed into the ignition switch again or any door is closed, the ceiling lamp will go off. When there is not
any operation, the ceiling lamp will change from bright to dark and fade out gradually after 1 minute.
(c) When the vehicle key is in the ignition switch, the ceiling lamp will not come on whether the door is
open or closed.
Inspection
1. Inspect the light control switch continuity.
(a) Measure the resistance according to the value in the
following table.
Standard:
Left combination switch
assembly Testing instrument Specified
Switch operation
Close 4 - 5 - 6 - 7- 8 - 9 10 kW or higher
ALL004G Lamplet 4-7 Below 1 W
Headlight (low 4 - 5 - 6 - 7- 9 Below 1 W
beam)
Headlight (high 4 - 5 - 6 - 7- 8 Below 1 W
beam or overtake)
Replace if necessary.
2. Inspect front and rear fog lamps.
following table.
Standard:

Switch operation
Close 1-2-3 10 kW or higher

Front fog lamp 1-2 Below 1 W
Front and rear fog
1-2-3 Below 1 W
lamps
Replace if necessary.
Right turn 3. Inspect turn signal lamp switch.

following table.
Standard:
Testing
Left turn Specified
Switch operation instrument
Left condition
combination
connection
switch Close 10 - 11 - 12 10 kW or higher
assembly
Left turn 10 - 12 Below 1 W
ALL005G
Right turn 10 - 11 Below 1 W
Replace the switch as necessary.

2. Back-up lamp switch assembly

(a) Inspect the back-up lamp switch assembly continuity.
Standard:
Switch operation
ON 1-2 Below 1 W
OFF 1-2 10 kW or higher
ALL006G
3. Brake lamp switch assembly

Free Pushed in (a) Inspect the brake lamp switch assembly continuity.
2 1 (1) Measure the resistance according to the value in
Standard:
Switch operation
Switch pin pushed in
1-2 10 kW or higher
(Pedal released)
ALL007G Switch pin free
1-2 Below 1 W
(Pedal depressed)
4. A/C controller assembly No.2

Connector Front View: (a) Inspect the hazard warning signal switch continuity.
Standard:
Switch operation
ON 1-2 Below 1 W
ALL008G
If the value is not as specified, replace the integra-
tion control & panel assembly.
5. Front door courtesy lamp switch assembly
Front door courtesy (a) Inspect the front door courtesy lamp switch assembly
lamp switch assembly continuity.
Standard:
Switch operation
ON 1 - Body ground Below 1 W
ALL009G OFF 1 - Body ground 10 kW or higher
6. Rear door courtesy lamp switch assembly
(a) Inspect the rear door courtesy lamp switch assembly
continuity.
(1) Check the rear door courtesy lamp switch assem-
bly using the same procedures as for the front
door courtesy lamp switch assembly.
Standard: Same as the front door.
IR-�
Back door lock assembly 7. Back door courtesy lamp switch assembly
The front view of connector: (a) Inspect the back door courtesy lamp switch assembly
continuity.
Standard:
Switch operation
ON (Unlock) 1-2 Below 1 W
ALL010G OFF (Lock) 1-2 10 kW or higher
8. Reading lamp assembly

(a) Inspect the reading lamp assembly continuity.
(b) Measure the resistance according to the value in the
following table.
Standard:
Switch operation
ON 1-2 Below 1 W
DOOR 1-2 Below 1 W
ALL011G
Replace the lamp if necessary.
9. High beam light relay

(a) Inspect the high-beam headlamp relay continuity.
(b) Measure the resistance according to the value in the
following table.
Standard:
Testing instrument Specified condition
connection
3-5 10 kW or higher
Below 1 W
ALL012G
3-5 (When battery voltage is ap-
plied to terminals 1 and 2)
Replace the relay as necessary.
10. Low beam headlight relay
(a) Inspect the low-beam headlamp relay continuity.
(1) Check the low-beam headlamp relay using the
same procedures as for the high-beam headlamp
relay.
Standard: Same as the high-beam headlamp
relay.
Replace the relay as necessary.

Combination Headlamp Assembly LH

component
Combination headlamp assembly LH
Front position lamp bulb
High-beam lamp bulb
Low-beam lamp bulb

Turn signal lamp bulb LH
Combination headlamp assembly LH
ALL013G
IR-��
Replacement
Hint:
The removal sequence of the combination headlamp LH is
the same as the right side.
Component: see page IR-9
page BO-37)
2. Remove the front fender lining LH (see page BO-37)
3. Remove the front fender lining RH (see page BO-37)
4. Remove the front bumper connecting bracket LH
(see page BO-37)
5. Remove the front bumper connecting bracket RH
(see page BO-37)
6. Remove the front bumper body (see page BO-37)
page BO-38)
8. Remove the headlamp assembly LH

(b) Disconnect the connectors and remove the headlamp
assembly LH.
ALL014G
9. Remove the high-beam headlamp socket cover

(a) Turn the high-beam headlamp socket cover counter-
clockwise to remove it as shown in the illustration.
ALL015G
10. Remove the high-beam headlamp bulb

(a) Remove the high-beam headlamp bulb as shown in the
illustration.
(b) Remove the front position lamp bulb.
ALL016G
VEHICLE INTERIOR IR-��
11
11. Remove the low-beam headlamp socket cover

(a) Turn the low-beam headlamp socket cover counter-
clockwise as shown in the illustration.
12. Remove the low-beam headlamp bulb
(a) Remove the low-beam headlamp socket cover and the
low-beam headlamp bulb.
13. Remove the turn signal lamp socket LH and turn
signal lamp bulb LH
14. Install the headlight assembly
Hint:
ALL017G sequence.
15. Only for the focusing of headlight high beams
Adjustment
1. Only for the focusing of headlight high beams
Hint:
• Perform an aiming adjustment with a high-beam
headlamp.
• Use the same method to adjust the low-beam lamp.
(a) Prepare the vehicle according to the following condi-
tions:
• Check to make sure that the vehicle body around
the headlight is not damaged or deformed.
• The fuel tank is full.
• The tire pressure is within the specified range (see
page SP-35).
• The vehicle is parked on a flat road surface.
• A person of moderate weight (68 kg) is sitting in the
driver's seat.
• Bounce the vehicle up and down to stabilize the
suspension to the normal position.
(b) Prepare a thick piece of white paper (draw a base line).

Hint:
Left V-line V-line Right V-line • Stand the paper vertically against the wall.
• The base lines differ for “Low-beam inspection” and
“High-beam inspection.”
H-line (1) V-line (vehicle center position)
Draw a vertical line down the center of the paper
in order to align it with the center of the vehicle.
(2) H-line (headlight height)
Draw a horizontal line across the paper at the
Ground
same height from the ground as the center mark
ALL018G for the high-beam lamps.
(3) V LH line, V RH line (center mark position of right
and left headlamps)
Draw left and right vertical lines in the same posi-
tions as the high beam's center marks.
Hint:
Follow the same procedures when adjusting the
low-beam lamps.
(c) Check the high-beam headlamp aiming.
(1) Align the paper with the vehicle.
Right V-line
• Keep a distance of 3m between the headlight
and the paper. Place the paper on a wall with the
H-line at the same height as the center mark.
V-line • Align the vehicle's center with the V-line center
of the paper, ensuring that the paper is at an
angle of 90 degrees to the V-line.
Left V-line (2) Start the engine.
ALL019G
IR-��
(3) Turn on the headlamps and check that the aim is

Low beam: Left V-line
Right V-line
within the specified values as shown in the illustration.
Notice:
The headlight lens is fragile because it is made
of a synthetic resin.
H-line
Hint:
When checking the aiming of the high-beam, shut
off the low-beam or disconnect the low-beam
headlamp connector.
ALL020G
High beam: Left V-line

Right V-line
H-line
ALL021G
(d) Adjust the aiming in the vertical direction:

Using a screwdriver, adjust the aim of the high-beam
headlamp to within the specified range by turning aim-
ing screw A.
Notice:
• Adjust the high-beam headlamp aim by turning
the screw in the tightening direction.
• When the screw is tightened excessively, loosen
it once and re-tighten it to adjust the high-beam
headlamp aim.
ALL022G
Hint:
The optical axis aim moves downward when turning the
screwdriver clockwise, and it moves upward when turn-
ing the screwdriver counterclockwise.
13
Rear Combination Lamp Assembly LH

Replacement
1. Remove the C pillar lower trim panel assembly LH

(a) Remove the 2 bolts and the hook.
Claw (b) Remove the bolts and the seatback hinge.
(c) Remove the bolts on the end plate cover side and the
belt.
Buckle (d) Separate the 3 claws and 5 clips with a screwdriver and
remove the left C column lower guard plate.
ALL023G
2. Remove the rear combination lamp assembly LH

(b) Remove the 2 nuts and the rear combination lamp as-
sembly LH.
ALL024G
3. Remove the rear turn signal lamp bulb

(a) Remove the turn signal lamp bulb, turn signal lamp
socket, and the wire sub-assembly as shown in the il-
lustration.
ALL025G
4. Remove the rear brake lamp assembly

(a) As shown in the figure, remove the 4 screws.
(b) Remove the LED lamp cover.
(c) Remove the 6 screws and the LED lamp.
5. Install the rear combination lamp assembly LH
Hint:
sequence.
ALL026G
IR-��
High-mounted brake lamp assembly

Replacement
1. Remove the high-mounted brake lamp screw cover

(a) Remove the high-mounted brake lamp screw cover by
hand as shown in the illustration.
: 2 Screw Covers ALL027G
2. Remove the high-mounted brake lamp assembly

(b) Disconnect the connector and remove the high-mount-
ed brake lamp assembly.
ALL028G
(c) Remove the 3 screws and the LED lamp lens as shown
ALL029G
(d) Remove the 3 screws and replace the LED lamp as-
sembly as shown in the illustration.
ALL030G
15
License plate lamp assembly

Replacement
1. Remove the back door shield (see page BO-33)
2. Remove the license plate lamp trim panel assembly
(see page BO-44)
3. Remove the license plate lamp assembly
(a) Remove the 4 screws and the license plate lamp
assembly.
ALL031G
4. Remove the license plate lamp bulb

(a) Remove the license plate lamp bulb and socket as
(b) Remove the license plate lamp bulb from the socket.
5. Remove license plate lamp body
6. Install the license plate lamp assembly
Hint:
sequence.
ALL032G
Combination switch assembly LH

Replacement
1. Remove the combination switch cover (see page
SR-6)
2. Combination switch assembly LH
(b) Using a screwdriver, disengage the claw and pull out
the combination switch assembly LH.
Hint:
Before using a screwdriver, please wrap its tip with ad-
hesive tape.
3. Install the combination switch assembly LH
4. Install the combination switch cover (see page
: Claw SR-10)
ALL033G
IR-��
Front fog lamp assembly LH

Replacement
Hint:
The removal sequence of the front fog lamp assembly LH is
the same as the right side.
1. Remove front bumper upper grille body (see page
BO-37)
2. Remove the front fender lining LH (see page BO-37)
3. Remove the front fender lining RH (see page BO-37)
(see page BO-37)
(see page BO-37)
page BO-38)
ALL034G
7. Remove the front bumper body

(a) Remove the clip and the 2 bolts from the upper side of
the bumper body.
(b) Using a screwdriver, disengage the 2 claws and re-
move the 2 bolts and the 6 screws.
ALL035G
8. Remove the front fog lamp assembly LH

(b) Disconnect the connector and remove the front fog
lamp assembly LH from the front bumper body.
9. Remove the front fog lamp socket and bulb LH
10. Replace the front fog lamp bulb LH
11. Install the front fog lamp bulb LH
12. Install the front fog lamp assembly LH
(a) Install the front fog lamp assembly LH to the front bum-
per body with the 3 screws.
ALL036G
Hint:
sequence.
17
Back-up lamp assembly

Replacement
Hint:
Remove the back-up lamp assembly by following the same
order for the rear fog lamp assembly.
1. Remove the rear bumper mud guard LH
(a) Using a screwdriver, disengage the claw and remove
the screw and the 2 clips.
2. Remove the rear bumper mud guard RH
3. Remove the rear bumper body
(a) Using a screwdriver, disengage the 2 claws and re-
move the 7 bolts and the bumper body.
(b) Disconnect the wire harness, the connector, and the
clamp.
ALL037G
4. Back-up lamp assembly

(b) Remove the back-up lamp assembly from the rear
bumper body.
5. Remove the back-up lamp socket and bulb
6. Install the back-up lamp bulb
7. Install the back-up lamp assembly
(a) Install the back-up lamp assembly to the rear bumper
body with the 3 screws.
8. Install the rear bumper
ALL038G
Hint:
The installation sequence for the rear bumper is the re-
verse of the removal sequence.
IR-��
Ignition switch
Replacement
Hint:
quence.
2. Remove the steering wheel (see page SR-6)
3. Remove the combination switch lower cover and
upper cover (see page SR-6)
4. Remove the ignition switch assembly
(a) Disconnect the ignition switch connector and the unlock
the warning switch connector.
(b) Remove the clamp.
(c) Remove the 2 screws and ignition switch.
ALL039G
Inspection
LOCK 1. Inspect the ignition switch assembly
(a) Check the resistance of the switch.
Standard:
Testing instrument State of switch Specified condition
connection
START
1-3 ACC
1-2
1-3 ON
5-6 Below 1 W
ALL040G
1-2
4-5 START
5-6
If the result is not as specified, replace the switch as-
sembly.
Combination Switch
Replacement
Hint:
quence.
3. Remove the combination switch lower cover and
upper cover (see page SR-6)
4. Combination switch assembly LH
(a) Disconnect the connector and remove the combination
switch assembly LH.
5. Remove the combination switch assembly RH
(a) Disconnect the connector and remove the combination
switch assembly RH.
ALL041G
19
Combination meter
Indicator lamps:
Reference Page
(s)
Front fog lamp indicator doesn't illuminate. 2. Front fog lamp switch -
3. Combination meter assembly IR-40
Rear fog lamp indicator doesn't illuminate. 2. Rear fog lamp switch -
High beam indicator doesn't illuminate. 2. Left combination switch assembly IR-15
Turn signal lamps don't illuminate. 2. Turn signal and hazard warning system -
Door open warning lamp doesn't illumi-
2. Courtesy lamp switch IR-7
nate. IR-40
3. Combination meter assembly
Charging indicator doesn't illuminate. 2. Generator MA-7
Parking brake lamp doesn't illuminate. 2. Parking brake switch BR-45
Airbag warning lamp doesn't illuminate. 2. Airbag ECU assembly RS-42
Seat belt reminder indicator lamp doesn't
2. Buckle switch RS-44
illuminate. IR-40
Brake system failure indicator doesn't illu- 2. Parking brake switch BR-45
minate. 3. Brake fluid level warning switch IR-23
ABS failure indicator doesn't illuminate.
Oil pressure warning lamp doesn't illumi-
2. Oil pressure switch -
nate. IR-40
Fuel warning lamp doesn't illuminate. 2. Fuel gauge sensor -
IR-��
Problem Location in Question Reference Page

(s)
Engine system failure indicator doesn't il-
2. ECM -
luminate. IR-40
2. O/D main switch line -
O/D switch indicator doesn't come on.
3. ECM -
Engine service indicator lamp doesn't
2. ECM -
come on. IR-40
EBD indicator doesn't illuminate. 2. ABS module -
Engine water temperature warning indica-
2. Water temperature sensor -
tor does not come on. IR-40
Engine pre-heating indicator doesn't come
2. Pre-heeting sensor -
on. IR-40
Light main switch indicator doesn't illumi-
2. Master lighting switch -
nate. IR-40
Rear defogger/defroster indicator does not
2. Rear defroster/defogger switch -
come on. IR-40
Oil water separator warning indicator does
2. Water level sensor -
not come on. IR-40
2. Vehicle speed sensor (front right wheel -
120 km warning lamp doesn't illuminate. in case of CVT transmission)��
��
Speed
sensor the

Transmission failure indicator doesn't illu-
minate. -
3. TCU model
1. Snow mode button -
Snow mode indicator doesn't come on.
4. TCU model -
1. gearshift operating mechanism -
LCD level indication is not shown.
4. TCU model -
* For the Middle East and G.C.C. Countries.
21
Pin Definition
20 1
40 21
ALL049G
40-pin plug connector is AMP: 1318384-1 of TYCO electronics
Pin Definition Pin Definition

Engine maintenance indicator
Pin 1 Right turn indicator signal Pin 2
signal
Pin 3 High beam lamp indicator signal Pin 4 Rear defroster indicator
Pin 5 Left turn indicator signal Pin 6 Front fog lamp indicator signal
ABS warning light indicator sig-
Pin 7 Pin 8 Brake system failure indicator
nal
Battery charging/discharging in- Engine malfunction indicator
Pin 9 Pin 10
dicator signal lamp signal
Airbag malfuction indicator sig-
Pin 11 Pin 12 Seat belt indicator lamp signal
nal
Pin 13 Open door indicator lamp signal Pin 14 Parking brake indicator signal
Oil-water separation indicator
Pin 15 EBD indicator signal Pin 16 lamp (reserved for diesel en-
gines)
Engine pre-heating indicator
Oil pressure warning lamp
Pin 17 Pin 18 lamp signal(reserved for diesel
doesn't illuminate.
engines)
Pin 19 O/D switch indicator signal Pin 20 Rear fog lamp indicator signal
Pin 21 PGND digital ground Pin 22 Ignition voltage (13.5V)
Pin 23 Battery voltage (12V) Pin 24 AGND analog ground
Pin 25 CAN-L (for CVT models only) Pin 26 CAN-H (for CVT models only)
Instruction input for snow mode
Transmission malfunction indica-
Pin 27 Pin 28 (hard-line reservation only for
tor signal (for CVT models only)
the CVT Model)
Pin 29 Reserve Pin 30 Reserve
Pin 31 Reserve Pin 32 Central door lock signal output
Pin 33 Meter interior communication Pin 34 Vehicle speed signal output
Vehicle speed sensor signal (front
Pin 35 right wheel speed sensor in the Pin 36 Wheel speed sensor signal
case of CVT transmission )
Pin 37 Fuel sensor signal Pin 38 Temperature sensor signal
Pin 39 Lighting signal (PWM signal) Pin 40 Light main switch indicator signal
IR-��
Vehicle Check
1. Check the speedometer
(a) Check the operation.
(1) Using a speed meter tester, inspect the speed meter for allowable indication error, and check the
operation of the odometer.
Standard indication (km/h) Allowable range (km/h)
20 (17 to 23)
40 (36 to 40)
60 (55 to 60)
80 (75 to 80)
100 (95 to 100)
120 (114 to 120)
140 (133 to 140)
160 (152 to 160)
180 (171 to 180)
Note 1: The basic error of the speedometer at a higher speed should be determined by the customer
and producer.
Note 2: No assessment on the limit speed error.
Note 3: When users have special requirements, the basic error can be checked in accordance with
corporate standards approved through established procedures and user’s requirements.
Notice:
Tire wear and tire over-or under-inflation will increase the indication error.
2. Inspect the tachometer
(1) Connect a tune-up test tachometer and start the engine.
Notice:
• Reversing the connection of the tachometer will damage the transistors and the diodes
inside.
• When removing or installing the tachometer, be careful not to drop it or give it heavy
shock.
(2) Compare the test result with the tachometer indications.
25°C 13.5 V
Allowable range
Standard indication
(Percentage of speed at checked point, %)
Low engine speed ± 10
Middle, high engine speed ±5
Note 1: The low speed is less than or equal to 30% of the limit of the dial scale.
Note 2: The middle and high speed is more than 30% of the limit of the dial scale.
Note 3: When users have special requirements, the basic error can be checked in accordance with
corporate standards approved through established procedures and user’s requirements.
Fuel gauge sensor:

3. Inspect the fuel gauge sensor
(a) Check the circuit.
(1) Disconnect the fuel gauge sensor connector.
(2) Turn the ignition switch to the ON position, then
check the position of the fuel gauge needle.
Needle position: EMPTY
(3) Connect the positive (+) lead from the three 1.5 V
dry batteries to terminal 2 and its negative (-) lead
to terminal 3.
ALL042G
23
(4) Disconnect the negative (-) terminal from the battery and wait at least 60 seconds.
(5) Connect the negative (-) terminal to the battery and turn the ignition switch to the ON position,
then check the position of the fuel gauge needle.
Needle position: FULL
4. Inspect the fuel warning indicator
(1) Disconnect the fuel gauge sensor connector.
(2) Turn the ignition switch to the ON position, and check that the fuel level needle indicates EMPTY
and the fuel warning indicator comes on.
5. Inspect the seat belt reminder indicator (Driver's seat)
(1) Set the ignition switch to the "ON" position, check, and confirm that the indicator illuminates.
(2) Fasten the safety belt to the socket, check and confirm that the indicator goes out.
(3) Disconnect the connector of the buckle switch while the terminal of the connector on the side of
wire harness is grounded.
(4) Set the ignition switch to the "ON" position, check, and confirm that the indicator illuminates.
6. Check the oil pressure warning lamp
(1) Disconnect the low oil pressure switch connector.
(2) Set the ignition switch to the ON position.
(3) Connect the connector's terminal on the side of the wire harness and have it grounded. Then
check and confirm that the low oil pressure warning lamp illuminates.
7. Check the parking brake lamp
(a) Check the parking brake lamp.
(1) Disconnect the connector of the parking brake switch while having the terminal of the connector
on the side of wire harness grounded.
(2) Set the ignition switch to the "ON" position, check and confirm that the indicator illuminates.
8. Inspect the brake fluid level warning switch
(a) Inspect the continuity
(1) Remove the reservoir cap and the strainer.
(2) Disconnect the connector.
(3) Measure the resistance according to the value(s) below.
Float up (switch OFF): 10 kΩ or more
(4) Use a syphon, etc., to take fluid out of the reservoir.
(5) Measure the resistance according to the value(s) below.
Float down (switch ON): Below 1 Ω
(6) Refill the reservoir with brake fluid.
9. Inspect the key reminder warning buzzer
(a) Inspect the warning buzzer function.
(1) Turn the ignition switch off, and check that the key reminder warning buzzer sounds when the ig-
nition key is inserted into the key cylinder and the driver side door is opened.
IR-��
Dashboard/Meter
Component
Wind Tunnel Assembly LH Wind tunnel assembly RH
A pillar upper trim

panel assembly RH
A/C air vent ball assembly RH
A/C air vent ball assembly LH
passenger air bag

assembly
Left A-pillar upper guard plate assembly
Instrument end
trim panel
Front tweeter RH
Instrument panel front damp-
ing sealing sponge bar
Upper instrument
panel body
Front tweeter LH
Instrument panel
hole cover No.3 Front tweeter
shield LH
Front tweeter
shield RH CD player with Combination
A/C control knob
bracket assembly meter assembly
Combination meter hood
: Specified torque
ALL043G
25
A/C controller assembly No.1
Steering dust cover
Glove box body A Pillar Lower

CD player with bracket assembly Trim Panel
Assembly RH
Steering propeller shaft
Front threshold
Steering column pressure plate RH
A Pillar Lower combination switch

Trim Panel assembly RH
Assembly LH
Glove box body
Clock spring assembly

Instrument panel
combination switch lower shield
assembly LH
Front threshold
Steering wheel Shift lever knob
pressure plate LH
assembly sub-assembly
Combination
switch's up-
per cover
Driver side airbag
: Specified torque
ALL044G
IR-��
On the dashboard brace reinforcement
Reinforced supporting frame

for the instrument panel
Instrument panel brace

sub-assembly No.1
Bracket of left lower supporting

panel of the instrument panel
Central wind tunnel
Glove box striker
Coin box
Fuse box
: Specified torque
ALL045G
27
Combination meter
Combination
meter assembly
Combination
meter glass
ALL046G
Areas of Importance
1. Precautions for a vehicle with an SRS airbag and seat belt pretensioner
(a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding
operations, read the SRS airbag PRECAUTIONS (see page RS-2)
IR-��
Upper Instrument Panel Body

Replacement
1. Disconnect battery negative terminal (see page
RS-2)
2. Remove the combination meter trim cover
(a) Remove the clasp.
(b) Disengage the 7 claws and the 3 clips, and remove the
combination meter trim cover.
: 7 Claws
: 3 Clips ALL047G
3. Remove the combination meter assembly

(b) Disconnect the connector and then remove the combi-
nation meter assembly.
ALL048G
4. Remove the front tweeter shield LH

(a) Using a moulding remover, disengage the 5 claws and
remove the tweeter shield.
: 5 Claws ALL049G
5. Remove the front tweeter shield RH

6. Remove the front tweeter assembly LH and RH (see
page AV-6)
7. Remove the A/C control knob
ALL050G
29
8. CD player with bracket assembly

ALL051G
(b) Disengage the 8 clips and the 6 claws, and remove the
center console panel body.
: 6 Claws
: 8 Clips ALL052G
9. Remove CD player w/bracket assembly (see page

AV-4)
ALL053G
10. A Pillar upper trim panel assembly LH

(a) Disengage the 2 clips, and remove the A pillar upper
trim assembly LH.
11. Remove the A pillar upper trim assembly RH
: 2 Clips ALL054G
12. Remove the instrument panel hole cover No.3

(a) Disengage the 4 claws, and remove the instrument
panel hole cover No.3.
13. Disconnect the passenger airbag connector (see
page RS-35)
: 4 Claws
ALL055G
IR-��
14. Remove the upper instrument panel body w/pas-

senger airbag assembly
(a) Remove the bolt.
(b) Remove the 6 screws.
(c) Disengage the 7 clips and the 3 claws.
(d) Disconnect the connector.
(e) Pull the upper instrument panel body w/passenger air-
bag assembly and remove it.
ALL056G
: 3 Claws
: 7 Clips ALL057G
15. Remove the wind tunnel assembly LH

(a) Using snippers or another similiar tool cut off the ul-
trasonic welding portion as shown in the illustration to
remove the wind tunnel assembly LH from the upper
instrument panel body.
ALL058G
31
Ultrasonic welding portion

cut line
Wind tunnel
assembly LH
ALL059G
16. Remove the wind tunnel assembly RH

(a) Using snippers or other similar tool cut off the ultrasonic
welding portion as shown in the illustration to remove
the wind tunnel assembly RH from the upper instru-
ment panel body.
ALL060G

Cut line
Wind tunnel
assembly RH
ALL059G
17. Remove the A/C air vent ball assembly

(a) Using snippers or other similar tool cut off the ultrasonic
welding portion as shown in the illustration to remove
the A/C air vent ball assembly from the upper instru-
ment panel body.
ALL061G

Cut line
Air-conditioner
air outlet wind-
ball assembly
ALL059G
IR-��
18. Remove the instrument end trim panel

(b) Disengage the 2 claws and remove the instrument end
trim panel.
19. Remove the passenger airbag assembly (see page
RS-36)
20. Remove the instrument panel front damping seal-
ing sponge bar
(a) Remove the instrument panel front damping sealing
: 2 Claws sponge bar from the upper instrument panel body.
ALL062G
21. Remove the upper instrument panel body
22. Install the wind tunnel assembly LH

Cut line
Boss (a) When replacing the upper instrument panel body with a
new one, cut the boss off with snippers or other similar
tool, as shown in the illustration.
Notice:
When reusing the upper instrument panel body,
start from step B.
Snippers Wind tunnel
assembly LH
ALL063G
Wind tunnel assembly LH (b) Using a screw, install the wind tunnel assembly LH to
the upper instrument panel body.

ALL064G
23. Wind tunnel assembly LH

Cut line
Boss (a) When replacing the upper instrument panel body with a
new one, cut off the boss by using snippers or another
similar tool, as shown in the illustration.
Notice:
When reusing the upper instrument panel body,
start from step B.
Snippers Wind tunnel assembly RH
ALL063G
Wind tunnel assembly RH (b) Using a screw, install the wind tunnel assembly RH to
the upper instrument panel body.
24. Install the upper instrument panel body w/passen-
ger airbag assembly
(a) Install the upper instrument panel body w/passenger
airbag assembly with the 6 screws.

ALL064G
33
: 3 Claws
: 7 Clips
ALL065G
(b) Using a torque wrench, install the bolt.

Torque: 18 N·m
ALL056G
IR-��
Lower Instrument Panel Body

Replacement
1. Disconnect the battery negative terminal (see page RS-2)

2. Remove the upper instrument panel body w/passenger airbag assembly (see page IR-30)
5. Remove the combination switch cover (see page SR-6)
6. Remove the combination switch assembly LH (see page SR-6)
7. Remove the combination switch assembly LH (see page SR-6)
8. Remove the front rocker trim LH (see page IR-61)
10. Remove the A pillar lower trim panel assembly LH (see page IR-62)
11. Remove the A pillar lower trim panel assembly RH (see page IR-62)
12. Remove the A/C controller assembly No.1 (see page AC-16)
13. Remove the small glove box body

(a) Disengage the 2 claws and the 2 clips.
(b) Disconnect the connectors and then remove the small
glove box body.
: 2 Claws
: 2 Clips
ALL066G
14. Remove the instrument panel lower shield

(a) Using a clip remover, remove the clip.
(b) Disengage the 3 claws and remove the instrument pan-
el lower shield.
: 3 Claws
ALL067G
15. Remove the glove box body

(a) Push the right side wall and then push the left side wall
to release the stoppers.
: 2 Stoppers
ALL068G
35
(b) Pull the glove box rearward to remove it.
: 2 Claws
ALL069G 16. Remove the shift lever knob sub-assembly
17. Separate the steering column and steering shaft
(see page SR-7)
18. Remove the steering column (see page SR-7)
19. Remove the steering column dust cover (see page
SR-7)
20. Separate the steering shaft and steering connect-
ing shaft (see page SR-7)
21. Remove the antenna cord sub-assembly
22. Remove the lower instrument panel w/instrument
panel reinforcement member
(a) Remove the 2 bolts.
ALL070G
(b) Remove the 3 bolts.
ALL071G
(c) Using a clip remover, remove the clip.
ALL072G
IR-��
(d) Remove the 3 bolts.
ALL073G
(e) Remove the bolt and the instrument panel mounting

bracket No.1.
ALL074G
(f) Remove the bolt.

(g) Disconnect the connector and remove the door control
receiver.
ALL075G
(h) Remove the bolt.

(i) Disconnect the engine hood lock control cable.
(j) Remove the 2 bolts, 2 nuts, and the 2 screws.
(k) Remove the 2 screws and the 3 nuts, and separate the
instrument panel J/B assembly.
(l) Disconnect the connectors, and then remove the lower
instrument panel w/instrument panel reinforcement
member.
ALL076G
37
ALL077G
23. Remove the instrument panel reinforcement member

(a) Using a clip remover, remove the 2 clips.
ALL078G
(b) Remove the bolt.
ALL079G
IR-��
(c) Remove the 3 bolts and the lower instrument panel in-
sert LH.
ALL080G
(d) Remove the nut and the instrument panel brace sub-
assembly No.1.
24. Remove the fuse block opening cover
ALL081G
25. Remove the central wind tunnel

(a) Using snippers or another similar tool, cut off the ultra-
sonic welding portion as shown in the illustration to re-
move the central wind tunnel from the upper instrument
panel body.
ALL082G

Cut line
Central wind
tunnel
ALL059G
26. Remove the glove box striker

(a) Remove the screw and the glove box striker.
27. Remove the coin box
28. Remove the lower instrument panel body
ALL083G
39
29. Install the central wind tunnel

Cut line
Boss (a) When replacing the lower instrument panel body with a
new one, cut the boss off with snippers or another simi-
lar tool, as shown in the illustration.
Notice:
When reusing the lower instrument panel body,
start from step B.
Snippers Central wind tunnel
ALL063G
Central wind tunnel (b) Using a screw, install the central wind tunnel.
Lower instrument panel body

ALL064G
30. Connect the steering shaft and steering connecting

shaft (see page SR-8)
31. Install the steering column (see page SR-8)
32. Connect the steering column and steering shaft (see
page SR-9)
33. Install the upper instrument panel w/passenger air-
bag assembly (see page IR-32)
34. Adjust the clock spring sub-assembly
35. Install steering heel (see page SR-9)
36. Install the driver airbag assembly (see page RS-26)
37. Inspect the driver airbag assembly (see page
RS-26)
IR-��
Combination meter assembly

Overhauling
Notice:
When disassembling the combination meter assembly,
measures should be taken to prevent static electricity
from damaging the system.
1. Remove the combination meter trim cover
(a) Remove the clasp.
(b) Disengage the 7 claws and the 3 clips, and remove the
combination meter trim cover.
: 7 Claws
: ��
3 Clips ALL047G
2. Remove the combination meter assembly

(b) Disconnect the connector, and then remove the combi-
nation meter assembly.
ALL048G
3. Remove the combination meter glass

(a) Disengage the 3 claws and remove the combination
meter glass.
4. Remove the combination meter cover
(a) Disengage the 5 claws and remove the combination
meter cover.
: 3 Claws
ALL084G
41
Reverse Sensor
System Description
ALL085G
The back-up radar system components contains 1 ECU, 4 sensors, and 1 warning buzzer.
The ECU calculates the distance between the vehicle and the detected object base on the time difference
when the signal is sent and received.
*: For models equipped with a back-up radar system
IR-��
Functional Description
1. Self-check function
The system will delay 0.3s and begin to self-check when turning the power switch to ACC and switching
the shift lever to R. If all sensors operate normally, the buzzer will sound twice; if a malfunction occurs in
any of the sensors, the buzzer will sound three times, and the normal sensors will go on operating. For
specific malfunction warning specifications see the table below:
All the sensors Buzzer

are normal
Sensor malfunc- Buzzer

tion occurs
Malfunction Warning Specifications Description

ALL086G
2. Normal use function

(a) The system operates when the shift lever is switched to R; the system stops operating when the shift
lever is switched to other positions.
(b) When normal operation
(1) The warning signal is sent by the system, when the ultrasonic sensor receives the reflected wave
in the detection range.
(2) See the table below for the sensor detected distance and buzzer warning time.
(3) When the object is detected by more than one sensors, the system will be activated by the sen-
sor which detects the nearest object.
Distance from the object Response method of buzzer
Corner sensor Center sensor Within 150 to 90cm
——— 150 cm - 90cm ON��
: ��
75 ± 7.5ms/OFF: 225 ± 22.5ms
60 cm - 40cm 90 cm - 40cm ON��
: ��
75 ± 7.5 ms/OFF: 75 ± 7.5 ms
Within 40cm Within 40cm ON: Continuous/OFF: 0 ms
(4) Three different warning sounds will be performed according to the distance between the sensor
on the bumper and the object. The warning buzzer will not sound if the objects is beyond the de-
tecting scope.
Three different warning sound:
Sound Corner sensor Center sensor Mark on the table blow
Slow, and intermittent
Within 150 to 90cm
beep
Quick, and intermittent
Within 60 to 40cm Within 90 to 40cm
beep
Continuous beep Within 40cm Within 40cm
43
Corner sensor Corner sensor

Center sensor Center sensor
The data above is to distinguish the sensor detecting range; it is not the accurate detection data.
ALL087G
Circuitry
Corner sen-
sor LH
Corner sen-
sor RH
Buzzer
Center sen-
sor LH
Center sen-
sor RH
Back-up light
Power supply
ALL088G
IR-��
Technical Parameters
1. ECM
Standard voltage DC 13.5 V
Working voltage DC 9 ~ 16 V
0 mA (Operate only when turning to ON and
Static current
START)
Working temperature -40 ~ +80 °C
Storage temperature -40 ~ +85 °C
2. Sensors
Connecting types with ECU 2 solid wires
Standard voltage DC 8 V
Working voltage DC 7 ~ 9 V
Working frequency 58 ± 1.5 KHZ
150 cm ± 5 cm (Center sensor)
Maximum detection distance (Use plywood with a width of 30cm × Height 1m for
test)
3. Alarm buzzer
Warning frequency 2.8 KHZ ± 0.5 KHZ
Alarm sound pressure 75 dB (min)/30 cm
Operating mode Built-in driver buzzer
Connector terminal definitions

1. ECU connector terminals definition
ALL089G
45
Ter- Ter-
Terminal Terminal
minal State 4 Sensors minal State 4 Sensors
names names
number number
Back-up
Output ter-
1 NC NC 13 Light Power To apply
minal
Supply
2 NC NC 14 NC NC
3 NC To apply 15 NC NC
4 NC NC 16 NC NC
5 NC NC 17 NC NC
6 NC NC 18 NC NC
7 NC NC 19 NC NC
Corner sensor Input/Output
8 To apply 20 NC NC
R terminal
9 To apply 21 NC NC
R terminal
Corner sensor Input/Output Output ter-
10 To apply 22 Sensor GND To apply
L terminal minal
11 To apply 23 NC NC
L terminal
Input/Output Output ter-
12 BUZ To apply 24 GND To apply
terminal minal
2. Sensor connector terminals definition

Terminal number Terminal names State
Sensor power sup- Input/Output termi-
1
ply and signal nal
2 GND Input terminal
ALL090G
3. Buzzer connector terminals definition

Terminal number Wire position definition
1 Buzzer negative
2 Buzzer positive
ALL091G
IR-��
Components
Parking distance
control ECU
Sensor
Back-up radar buzzer
ALL092G
Back-up radar buzzer

Hint:
quence.
2. Remove upper instrument panel body w/passenger
airbag assembly (see page IR-30)
3. Remove back-up radar buzzer
(a) Disconnect back-up radar buzzer connector.
(b) Remove the bolt from the instrument panel reinforce-
ment member and remove the back-up radar buzzer.
ALL093G
47
Parking distance control ECU

Hint:
quence.
2. Remove the C pillar lower trim panel assembly RH
(see page IR-63)
3. Remove the back-up radar ECU
(a) Disconnect the back-up radar ECU connector.
(b) Remove the 2 bolts form D pillar RH and remove the
back-up radar ECU.
ALL094G
Reverse sensor probe

Hint:
quence.
2. Disassemble the rear bumper (see page BO-39)
3. Disassemble the probe
(a) Remove the probe clips.
(b) Disconnect the probe connector.
ALL149G
IR-��
Immobilizer System
System Description
The theft deterrent system components contains the following: theft deterrent ECU assembly, theft deter-
rent coil assembly, and converter assembly.
The main reason that the vehicle is equipped with a theft deterrent system are: 1. Prevent the vehicle from
missing; 2. Prevent strangers from breaking in illegally; 3. Prevent the vehicle from driving illegally; 4. Help
to monitor and search for the missing vehicle and so on.
Functional description
The following illustration is the theft deterrent system components as well as the standard mounting parts.
Theft deterrent
ECU assembly
Bolt, spring washer,

& plate washer kit
Theft deterrent converter
assembly
Theft deterrent
Theft deterrent indicator
coil assembly
ALL095G
Theft deterrent converter assembly is embedded in each key, when inserting a key into the lock cylinder
and turning it to “ON,” the communication between the theft deterrent ECU assembly and theft deterrent
converter assembly in the key is progressing by radio waves. If the key is confirmed to be correct, the
theft deterrent ECU assembly and engine ECU assembly will perform a code verification; if the verification
passes, the electronic theft deterrent system will allow engine to start. If any of the two kinds of code verifi-
cations fails, the engine will not be allowed to start.
49
Components
Other components of the theft deterrent system are assembled on the complete vehicle, except the theft
deterrent converter assembly contained in the key. They communicate via the wire harness connection.
The following illustration described each component’s location in the complete vehicle.
Theft deterrent converter assembly (in the key)
Theft deterrent
coil assembly
Hollow beam
Theft deterrent ECU assembly
Ignition switch
ALL096G
Theft Deterrent ECU Terminal Definition

The theft deterrent control ECU contains two connectors: connector A is the 8 - Pin connector and connec-
tor B is the 4 - Pin connector. Front view for the connectors is as below:
Front view for the theft deterrent

Front view for the theft deterrent control ECU connector A control ECU connector B
ALL107G
Each terminal definition is in the table below:

Port Signal name Signal definition Port Signal name Signal definition
A1 Battery/KL.30 Battery positive B1 GND/KL.31 Ground
A2 GND/KL.31 Ground B2 Coil Positive Coil positive
A3 Status LED State lamp B3 Coil Negative Coil negative
A4 Ignition/KL.15 Ignition switch B4 GND/KL.31 Ground
A5 R - Line R Line
A6 Reserve
Communication di-
A7 K - Line
agnosis interface
Engine certification
A8 W - Line
interface
IR-��
Fault Analysis
DTC code list
DTC Meaning Measures
B1500 Theft deterrent coil malfunction Replace the coil
B1501 No key is detected Check if the key is inserted
No key message is stored in the theft
B1502 See step 1.1 and 1.2 for matching the key
deterrent controller
B1503 PIN code is not input See step 2 for rematching the IMMO
B1504 SK is not created See step 2 for rematching the IMMO
After-sales Diagnostic Matching Process

The PIN used for after-sales authorization will be created and printed by offline equipment when offline
matching is carried out. Give the PIN and key to the owner after the sale to prove his/her legal identity.
If the PIN is lost, apply for a new one to the main engine plant after identifying the owner identity in an
after-sales service station.
The after-sales dealer will enter the PIN into the IMMO via a diagnostic device. The IMMO will determine
the identity after decoding. If it is valid, the matching process below will be allowed to proceed.
1. Add/delete the key
1.1 Add the new key
(a) Connect the scanner with the vehicle.
(b) Start the immobilizer system matching procedures (press the "Add the New Key" button).
(c) Insert a new key and turn it from the "OFF" to "ON" position.
(d) Manually input the PIN via the scanner.
(e) Turn the key to the "OFF" position after the matching is completed.
(f) If another new key needs to be added, remove the matched key and insert a new key; then repeat
the step C.
(g) Disconnect the scanner after all of the key matching is completed.
(h) Insert the matched keys into the cylinder hole one by one, and turn it from "OFF" to "Start" to
check if the engine can start��
��
normally. When the engine is started and stopped by the first key, re-
move it and wait for 20 seconds, then insert the other key to detect.
1.2 Add the matched key
(b) Start the immobilizer system matching procedures (press the "Add the Matched Key" button).
(c) Insert a key and turn it from the "OFF" to "ON" position.
(e) Turn the key to the "OFF" position.
(f) If another key needs to be added, remove the matched key and insert another matched key; then
repeat the step C.
(g) Disconnect the scanner after all of the key matching is completed.
(h) Insert the matched keys into the cylinder hole one by one, and turn it from "OFF" to "Start" to check
if the engine can start normally. When the engine is started and stopped by the first key, remove it
and wait for 20 seconds, then insert the other key to detect.
1.3 Delete all of the keys
(b) Start the immobilizer system matching procedures (press the "Delete All of the Keys" button).
(c) Insert a valid key and turn it from the "OFF" to "ON" position.
(f) Disconnect the scanner.
(g) Insert the valid keys into the cylinder hole one by one, and turn it from "OFF" to "Start" to check if
the engine can start normally. When the engine is started and stopped by the first key, remove it
51
2. Replace the theft deterrent control module

(b) Start the immobilizer system matching procedures (press the "Replace IMMO" button).
(d) Enter the VIN into a new theft deterrent control module.
(e) Manually input the PIN via the scanner.
(f) Turn the key to the "OFF" position after the matching is completed.
(g) Disconnect the scanner.
(h) Add all of the original keys again according to paragraph 1.2.
(i) Insert the valid keys into the cylinder hole one by one, and turn it from "OFF" to "Start" to check if
3. Replace the engine control module
(b) Start the immobilizer system matching procedures (press the "Replace ECM" button).
(f) Disconnect the scanner.
(g) Insert the valid keys into the cylinder hole one by one, and turn it from "OFF" to "Start" to check if
IR-��
On-board Phone System

On-board phone ECU terminal definition
On-board telephone ECU
ALL150G
JAM: JS092-14M (male)

PIN Func- Func- PIN
Function Function
ON tion tion ON
A1 A7
Micro-
A1 MIC+ A8 NC NC
phone+
A2 MIC- MIC- A9 NC NC
A3 NC NC A10 Signal light Signal lamp
A14 A8 A4 NC NC A11 NC NC
A5 NC NC A12 NC NC
ALL151G
SW IN Signal switch
A6 NC NC A13
input
A7 NC NC A14 GND Signal ground
JAM: JS092-12M (male)
PIN Func- PIN Func-
Function Function
ON tion ON tion
B1 B6
Audio front Audio front
B1 FR+IN horn RH B7 FLO+ horn LH out-
input + put +
Audio front Audio front
B2 FR-IN horn RH B8 FLO- horn LH out-
B12 B7 input + put -
Audio front
ALL152G Vehicle audio
B3 FR+OUT horn RH B9 Mute
mute
input +
Audio front
Vehicle bat-
B4 FR-OUT horn RH B10 B+
tery
input -
Audio front
B5 FRI+ horn LH out- B11 ACC ACC
put +
Audio front
Power supply
B6 FRI- horn LH out- B12 GND
ground
put -
53
Door Locks
Electric door lock control system
Vehicle check
1. Check the operation of the electric door lock
(a) Lock the front door with key
(1) Turn the key counterclockwise when locking the front door. Turn it clockwise to unlock.
(2) When locking or opening the left front door, the other doors will not be able to be locked or
opened simultaneously.
(b) Lock the door without the use of the key
(1) Left front door
The left front door cannot be locked if there is not a key outside the vehicle. This is to prevent
from locking the door accidentally when the key is put in the vehicle.
Caution:
With the left front door and right front door locked, pull up the handle when closing the
door, then the door will be locked.
(2) Other doors
If not locking the door with a key, press the interior push-type button to the lock position, then
close the door.
(c) Automatic Locking
(1) After unlocking with the remote function, the automatic door locking system can lock all of the
doors again automatically if any of the doors are not opened within the specified time.
(d) Rear door "Child Protection" lock
The "Child Protection" lock can prevent unintentional door unlocking, especially when there is a child
in any of the the rear seats. There is also a lock rod on each rear door.
(1) If the lock rod is set to the "Lock" position, the doors cannot be unlocked with the internal door
handles. If it is necessary to get the door unlocked when the "Child Protection" lock is in use,
please use the external door handle.
(2) If the lock rod is placed in the "unlocked" position, the "Child Protection" mechanism will not
work.
(e) Back door
(1) Open the back door
Take out the key from the ignition switch, press the back door unlock button on the remote con-
troller within 60 seconds, and pull the back door handle upward.
(2) Close the back door
Pull the back door handle downward and release the back door handle before it is completely
shut. Push the back door lightly from the outside to get it completely shut.
2. Inspect the lighting

(a) Check the door unlocking lighting system.
Hint:
"All vehicle doors" refers to the left and right front doors, the left and right rear doors, as well as the
back door.
(1) After closing the door, press the LOCK button once on the remote controller, the car lamp flashes
once, and all five doors will be locked.
(2) When locked, press the UNLOCK button once on the remote controller, the car lamp will flash
twice, and all four front doors will be unlocked.
(b) Check the onboard lighting system.
Hint:
"All vehicle doors" refers to the left and right front doors, the left and right rear doors, as well as the
back door. "Any vehicle door" refers to any of the vehicle doors mentioned above.
(1) Set the ceiling lamp switch to the DOOR position.
(2) Open any door and then close, the ceiling lamp will be on for 10 seconds. If the ceiling lamp
detects that the vehicle key is inserted into the ignition switch again within 10 seconds, it will
change from bright to dark and fade out gradually.
(3) When removing the vehicle key from the ignition switch, the ceiling lamp comes on. If the key
is inserted into the ignition switch again or any door is closed, the ceiling lamp will go off. When
there is not any operation, the ceiling lamp will change from bright to dark and fade out gradually
after 1 minute.
IR-��
(4) When the vehicle key is in the ignition switch, the ceiling lamp will not come on whether the door
is open or closed.
3. Back door independent open function
(a) After pressing the back door lock button on the remote controller and turning the back door switch on,
the back door actuator will activate (the 14th pin will output positive voltage), and then the back door
can be opened.
(b) The back door does not open after pressing the back door lock button on the remote controller for 60
seconds and then turning the back door on, then the trunk door actuator is unable to activate (the 14th
pin is not outputting positive voltage).
Inspection
Locking Unlocking
1. Inspect the front door lock actuator assembly LH
(a) Apply the battery voltage onto the fastener terminal and
check the working condition of the lock motor.
Standard:
Measuring condition Specified condition
Battery positive (+) →
Terminal A
Locking
Battery positive (-) →
ALL098G
Terminal B
Battery positive (+) →
Terminal B
Unlocking
Battery positive (-) →
Terminal A
If the result is not as specified, have the door lock as-
sembly replaced.
(b) Check the resistances among the respective actuators.
Standard:
Testing instru- State of switch Specified
1-4 Off Below 1 W
Hint:
The test methods for the respective actuators are the
same.
(c) Check the resistance of the control switch.
Standard:
Tester State of switch Specified
condition
Open 10 kW or higher
8-7
Off 1W
10 - 7
Off 1W
9-7
Off 1W
sembly replaced.
55
2. Inspect front door lock actuator assembly RH

Unlocking Locking (a) Apply the battery voltage onto the fastener terminal and
Standard:
Battery positive (+) → Terminal A
Locking
Battery positive (-) → Terminal B
Battery positive (+) → Terminal B
Unlocking
Battery positive (-) → Terminal A
ALL099G
sembly replaced.
(b) Check the resistances among the respective actuators.
Standard:
Testing instru- State of switch Specified
1-4 Off Below 1 W
Hint:
The test methods for the respective actuators are the
same.
(c) Check the resistance of the control switch.
Standard:
Tester State of switch Specified condition
8-7
Off 1W
10 - 7
Off 1W
9-7
Off 1W
sembly replaced.
3. Inspect the rear door lock actuator assembly LH
Standard:
Unlocking Measuring condition Specified condition
Locking
Locking Battery positive (+) → Terminal B
Unlocking
ALL100G
sembly replaced.
4. Inspect the rear door lock actuator assembly LH
Standard:
Unlocking
Locking
Locking Battery positive (+) → Terminal B
Unlocking
ALL101G
sembly replaced.
IR-��
5. Inspect the back door lock assembly

(a) Check the operation of the door lock.
(1) Using a screwdriver, move the latch to the full-
latch position.
(2) Apply battery voltage to the door lock terminals
Position
and check the operation of the latch.
Standard:
Full-latch
Unlock Battery positive (+) → Terminal 1 Latch turns to the open-
ALL102G Battery positive (-) → Terminal 2 latch position
sembly replaced.
(b) Check the back door control switch resistance.
Standard:
Testing instru- Door lock latch Specified condi-
ment connection condition tion
Unlock Below 1 W
1-2
Full-latch 10 kW or higher
sembly replaced.
Locking 6. Inspect the ignition switch assembly
(a) Check the resistance of the control switch.
Standard:
Unlocking Testing instru- Specified condi-
State of switch
ment connection tion
2-1 Locking
Below 1 W
3-1 Unlocking
If the result is not as specified, replace the switch as-
sembly.
ALL103G
7. Inspect the back door opener switch assembly

(a) Check the resistance of the switch.
Standard:
Testing instru- Specified condi-
State of switch
ment connection tion
Not pushed 10 kW or higher
1-2
Pushed Below 1 W
Pushed If the result is not as specified, replace the switch as-
Not pushed sembly.
ALL104G
57
Wireless Door Lock Control System

Areas of Importance
Precautions when checking
(a) Electric door locking/unlocking function
Unless the following three conditions are satisfied, the remote control function will not work:
(1) No key is inserted into the ignition key cylinder.
(2) All the doors are closed.
(3) The power door lock system operates normally.
Hint:
• The UNLOCK function operates even when a door is open.
(b) Remote function:
The wireless remote control function operates only when the key is not in the ignition switch cylinder.
(c) The wireless door lock remote control operation area differs depending on the situation.
(1) The operation area differs depending on the operators and the holding method of the transmitter.
(2) In certain areas, the remote control function will only operate partially as the operation area will
be reduced due to the vehicle body shape and the influence of the surrounding environment.
(3) Since the transmitter uses faint electric waves, strong electric waves or noises in the frequency
used may reduce the operation area or the remote control may not function.
(4) When the battery weakens, the operation area is reduced or the remote control may not function.
Hint:
If the door control transmitter is left in a place where it is exposed to the direct sunlight, such as
on the instrument panel, it may cause the battery to weaken or other related problems.
Vehicle Check
Check the wireless door lock control functions
(a) Lock function
(b) Unlock function
(c) Vehicle pager function
Press the LOCK button on the remote control once in the door LOCK condition and the lamp will flash
quickly 10 times. Press the UNLOCK button to withdraw the seeking function.
(d) Auto-defense function
Press the UNLOCK button on the remote control in the door LOCK condition; if the door is not
opened, then the door will automatically lock after 30 seconds.
(e) Automatic window close function
(1) After pressing the LOCK button on the remote control, the quarter window close negative output
will last 10 seconds (for the jam protection glass regulator).
(2) After pulling out the key, roof window close negative output will last 60s (For the vehicle equipped
with roof window).
(f) Remote controller function suspension
When inserting the key into the ignition switch cylinder, the remote control will not work; however, the
host machine will work normally.
(g) Deleting or registering the remote learning functions of the remote controller
(1) Under normal conditions, open the front door LH (do not close), insert the key into the ignition
switch cylinder, and press the key switch (ON-LOCK) 5 times within 5 seconds, stop at ON after
the fifth time; the warning buzzer sounds once and the lamp flashes once, then the remote con-
trol enters into the study status.
(2) Press any of the buttons on the remote control within 10 seconds, the warning buzzer sounds
twice and the lamp flashes twice, then the first remote control learning is complete. After that,
press any of the buttons on the second remote control, the warning buzzer sounds twice and the
lamp flashes twice, then the second remote control learning is complete (four remote controls
should be learned).
(3) After finishing the learning mode, close the key button and withdraw the learning status. If any of
the buttons is not pressed within 10 seconds, the system will withdraw the learning status after
10 seconds and the remote control will remain as it was.
IR-��
Transmitter Battery
Replacement
1. Remove the transmitter battery
Notice:
Special caution should be taken for handling each
component as they are precision electronic compo-
nents.
(a) Remove the bolt and take the case from the key.
ALL105G
(b) Remove the battery (lithium battery).

Notice:
• Do not push the terminals with your finger.
• Prying up the battery (lithium battery) forcibly to
re-move it will cause deformation of the termi-
nals.
• Do not touch the battery with wet hands. Water
may cause unexpected rust.
• Do not touch or move any components inside
the transmitter as it may interfere with proper
ALL106G
operation.
2. Install the transmitter battery

(a) Install a new battery (lithium battery) with the positive (+)
side facing upward, as shown in the illustration (Model:
CR2016).
Notice:
• Be sure that the positive side and the negative
side of the transmitter battery are matched-up
correctly.
• Be careful not to bend the electrode of the
transmit-ter battery insertion.
ALL107G
• Be careful that dust or oil does not adhere to
the transmitter case.
(b) Install the case securely.
Door control transmitter

Inspection
1. Inspect the door control transmitter
(a) Inspect the operation of the transmitter.
(1) Remove the battery (lithium battery) from the
transmitter.
(2) Install a new or normal battery (lithium battery).
59
(3) In a location where it is approx. 1m away from the

driver side outside door handle in the right direc-
tion, point the key plate of the transmitter at the
vehicle and check the operation of the transmitter
by pressing the transmission switch on the trans-
mitter body.
Standard:
The door lock can be operated via the remote
control.
Hint:
• The minimum operation distance differs de-
pending on the operator, the holding method of
the transmitter, and the location.
• Since the transmitter uses faint electric waves,
the operation distance might be shortened
if noise or strong electric wave occurs in the
area where the frequency is used.
(4) Install the battery (lithium battery).
(b) Inspect the battery capacity.
Hint:
• The capacity of the battery can be determined only
when the battery is installed in the transmitter. For
a lithium battery used in the transmitter, a voltage
of more than 2.5 V is shown on the tester until the
energy is completely consumed, or no battery is in-
stalled in the transmitter. Therefore, it is necessary
to measure the voltage while the battery is installed
in the transmitter (a resistance of 1.2 kW is applied
to the battery), when checking the amount of en-
ergy left in the battery.
• If the transmitter is faulty, the amount of energy left
in the battery might not be checked correctly.
(1) Remove the battery (lithium battery) from the
transmitter.
(2) Connect the lead to the negative (-) terminal of the
Lead wire transmitter and install the battery.
(3) Connect the tester positive (+) probe to the posi-
tive (+) battery (lithium battery) and the tester
negative (-) probe to the lead respectively.
(4) Press one of the transmission switches on the
transmitter for approx. 1 second.
(5) Press the transmission switch on the transmitter
again to check the voltage.
ALL108G
Standard:
2.2 V or higher
Hint:
• When the temperature of the battery is low, the
inspection cannot be performed correctly.
• When the outcome of the test is less than 2.2 V,
conduct the test again after leaving the battery
in a place with a temperature of 18 oC for more
than 30 minutes.
• The automatic power-off function causes the
voltage of the battery to be 2.5 V or more
(voltage with no resistance applied to the bat-
tery) when 0.8 seconds have passed after
the switch is pressed. Therefore, make sure
to read the voltage just after the switch is
pressed.
• Because high voltage might be shown once or
twice after the battery returns to the specified
temperature, the inspection should be made
with the voltage shown after the switch is
pressed at least 3 times.
(6) Disconnect the lead.
(7) Install the battery (lithium battery).
IR-��
Top Interior Cover

Component
Rear door sealing

strip RH Guild ring
cover
Right C-pillar upper
Right B-pillar upper guard plate assembly Back door
guard plate assembly sealing strip
Front door seal-

ing strip RH Right C-pillar lower
guard plate as-
Right A-pillar upper sembly
guard plate
assembly
Seatback hinge
Rear threshold
pressure plate
Deck board No.2
RH
Right B-pillar lower Back door threshold
guard plate guard plate
Front threshold pressure plate RH Deck board No.1

Right A-pillar lower guard plate assembly
Spare tire bracket assembly
Deck floor box RH
Left B-pillar upper guard plate assembly Rear door sealing

strip LH
Front guild ring cover LH
Front door sealing strip LH Left C-pillar upper

guard plate as-
sembly
Left A-pillar upper

guard plate assembly
Left C-pillar lower

guard plate assembly
Left B-pillar
Left A-pillar lower lower guard Rear threshold pressure plate LH
guard plate assembly plate
Front threshold
pressure plate LH
: Specified torque Seatback hinge
ALL109G
61
Roof rear handle assembly
Roof front handle Top interior cover

assembly
Passenger sun visor body

assembly
Holder Roof rear han-

cover Dome lamp dle assembly
assembly
Lens cover of dome light

Inner rear view
S u n v i s o r mirror assembly
bracket
Driver sun visor body assembly

Sun visor bracket
ALL110G
Replacement
Hint:
quence.
1. Remove the front rocker trim RH
(a) Using a screwdriver, disengage the 2 claws and the 3
clips and remove the front rocker trim RH.
Hint:
Claw
Clip Before using a screwdriver, please wrap its tip with ad-
ALL111G hesive tape.
2. Remove the front rocker trim LH
Hint:
Follow the same procedures described for the RH side.
IR-��
3. Remove the rear rocker trim RH

(a) Using a screwdriver, disengage the 2 claws and the 2
clips and remove the rear rocker trim RH.
Clip
Hint:
hesive tape.
4. Remove the rear rocker trim LH
Hint:
: Claw Follow the same procedures described for the RH side.
ALL112G
5. Remove the A pillar lower trim assembly RH

(a) Using a screwdriver, disengage the 2 clips and remove
the A pillar lower trim assembly RH.
Hint:
hesive tape.
6. Remove the A pillar lower trim assembly LH
Hint:
Clip 7. Remove the front door sealing strip RH
ALL113G
8. Remove the front door sealing strip LH
10. Remove the rear door sealing strip LH
11. Remove the B pillar lower trim RH

(a) Remove the end plate cover.
(b) Remove the bolt and the front outer seat belt at the end
plate side.
(c) Remove the B pillar lower trim RH.
12. Remove the B pillar lower trim LH
Hint:
ALL114G
13. Remove the B pillar upper trim assembly RH

(a) Remove the guild ring cover.
Clip (b) Remove the bolt and the front seat belt at the guild ring
cover side.
(c) Disengage the clip and remove the B pillar upper trim
panel assembly RH by pulling it up.
14. Remove the B pillar upper trim panel assembly LH
Hint:
: Claw 15. Remove deck board No.1
ALL115G
16. Remove deck board No.2
17. Remove the spare tire bracket assembly
18. Remove deck floor box RH
19. Remove the rear seat assembly (see page IR-71)
63
21. Remove the back door rocker shield

(a) Using a remover tool, disengage the 2 clips.
(b) Using a screwdriver, disengage the 4 clips and remove
the back door rocker shield.
Hint:
hesive tape.
ALL116G
22. Remove the C pillar lower trim assembly RH

(a) Remove the 2 bolts and the hook.
Claw (b) Remove the bolts and the seatback hinge.
(c) Remove the bolt and the seat belt at the end plate side.
(d) Using a screwdriver, disengage the 3 claws and 5 clips
and remove the C pillar lower trim assembly RH.
Buckle Hint:
hesive tape.
23. Remove the C pillar lower trim panel assembly LH
ALL117G
Hint:
Claw 24. Remove the C pillar upper trim panel assembly RH

(a) Remove the guild ring cover.
(b) Remove the bolt and the seat belt at the guild ring cov-
Buckle er side.
(c) Using a screwdriver, disengage the claws and 5 clips
and remove the C pillar upper trim assembly RH.
Hint:
hesive tape.
25. Remove the C pillar upper trim assembly LH
ALL118G
Hint:
26. Remove the A pillar upper trim assembly RH

(a) Using a screwdriver, disengage the 2 claws and 2 clips
and remove the A pillar upper trim assembly RH.
Hint:
Buckle Before using a screwdriver, please wrap its tip with ad-
hesive tape.
27. A Pillar upper trim panel assembly LH
Hint:
Claw Follow the same procedures described for the RH side.
ALL119G
IR-��
Claw 28. Remove the inner rear view mirror assembly

(a) Using a screwdriver, disengage the 2 clips and remove
the holder cover.
Hint:
hesive tape.
(b) Remove the 2 screws and rear view mirror.
29. Remove the passenger sun visor body assembly
(a) Remove the 2 screws and the sun visor.
30. Remove the driver sun visor body assembly
ALL120G
(a) Remove the 2 screws and the sun visor.
31. Remove the ceiling lamp assembly

move the lens cover.
Hint:
Claw Before using a screwdriver, please wrap its tip with ad-
Claw
hesive tape.
(b) Remove the 2 screws.
(c) Disconnect the connector and remove the lamp.
ALL121G
32. Remove the passenger sun visor bracket

(b) Using a molding remover, disengage the 3 clips and re-
move the bracket.
33. Remove the driver sun visor bracket
Hint:
ALL122G
34. Remove the roof handle assembly

Claw
move the roof handle cover.
Hint:
hesive tape.
(b) Remove the 2 bolts and the roof handle.
ALL123G
Clip
35. Remove the roof headlining assembly
(a) Using a clip remover, disengage the 4 clips and remove
the roof headlining.
ALL124G
65
Seats
Front Seat Assembly
Components
Front seat headrest assembly
Front seat headrest assembly

Front seatback cover
● Hog ring
Front seat cushion cover
Front seatback
spring assembly
● Hog ring
Front seat cushion pad Front weatback pad

Front seat buckle as-
sembly
Passenger seatback reclining
adjuster inner cover
Driver seatback re-

clining
Adjuster inner cover
Driver seat
cushion inner
shield
Driver seat
installation bolt guard
Driver seat rear mounting bolt

cover RH
Driver seatback reclining
: specified torque adjuster release handle
Driver seat cushion
nonr-eusable components shield
ALL125G
IR-��
Replacement
Hint:
• The installation sequence is the reverse of the removal
sequence. However, only the installation procedures re-
quiring additional information are included.
• Use the same procedure for the driver seat and passen-
ger seat.
Caution:
• Wear safety gloves because the cutting surface of
the seatback frame and seat adjuster may injure your
hand.
• The operation must be started more than 90 seconds
after the ignition switch is turned to the LOCK posi-
tion and the negative (-) terminal cable is disconnect-
ed from the battery (the SRS is equipped with a back-
up power source. If the operation is started within 90
seconds from disconnecting the negative (-) terminal
cable of the battery, the SRS may deploy).
1. Remove the driver seat assembly
(a) Remove the driver seat rear mounting bolt cover and 5
bolts.
(c) Remove the seat.
2. Remove the driver seat headrest assembly
3. Remove the driver seat buckle assembly
(a) Disconnect the wire harness of the buckle from the
seat adjuster.
(b) Remove the bolt and buckle.
ALL126G
4. Remove the driver seat cushion inner shield

(a) Remove the clip and the screw.
(b) Disengage the claw and remove the seat cushion in-
ner shield.
Screw
ALL127G
5. Remove the driver seatback reclining adjuster re-

Adhesive Tape lease handle
(a) Using a screwdriver, remove the seatback reclining
adjuster release handle.
Hint:
hesive tape.
ALL128G
67
6. Remove the driver seat cushion shield

(b) Disengage the 2 claws and remove the seat cushion
shield.
ALL129G
7. Remove the driver seatback assembly

(a) Remove the hog rings.
ALL131G
(b) Lift up the seatback cover and remove the hog rings.
ALL132G
(c) Disconnect the clips.

(d) Remove the 4 bolts and the seatback.
ALL133G
8. Remove the driver seat headrest support

(a) Lift up the seatback cover to the top, then disengage
the 4 claws and remove the 2 headrest supports.
ALL134G
IR-��
9. Remove the driver seatback spring assembly

(a) Remove the driver seatback spring assembly.
10. Remove the driver seatback cover
(a) Remove the hog rings and the seatback cover.
ALL135G
11. Remove the driver seat cushion cover

(a) Remove the hog rings.
(b) Disengage the claw of the front part of the seat adjust-
er.
(c) Disengage the hook and remove the seat cushion cov-
er (w/pad).
(d) Remove the hog rings and seat cushion cover.
ALL136G
12. Remove the driver seatback reclining adjuster inner

Slip cover
(a) Remove the screws and the adjuster inner cover.
13. Remove the passenger seatback reclining adjuster
inner cover
(a) Remove the screws and the adjuster inner cover.
ALL137G
14. Install the driver seat cushion cover

Hog ring pliers (a) Install the seat cushion cover to the seat cushion pad
with new hog rings.
(b) Install the seat cushion cover (w/pad) to the seat ad-
juster.
Notice:
Install the seat cushion cover (w/pad) to the seat
adjuster.
Hint:
ALL138G When installing the hog rings, take care to prevent
wrinkles as much as possible.
15. Install the passenger seatback cover
(a) Install the seat cushion cover to the seat cushion pad
with new hog rings.
(b) Install the seatback cover (w/pad) to the front seatback
frame.
Hog ring pliers
Notice:
Install the seat cushion cover (w/pad) to the seat
adjuster.
Hint:
When installing the hog rings, take care to prevent
wrinkles as much as possible.
(c) Install the 2 headrest supports.
ALL138G
69
16. Install the driver seatback assembly

(a) Install the seatback with the 4 bolts.
Torque: 45 N·m
(b) Install the new hog rings to the backside of the seat-
back.
(c) Install the headrest.
17. Install the driver seat buckle assembly
Torque: 41 N·m
ALL133G
18. Install the driver seat assembly

(a) Put the seat in the cabin.
(c) Install the 5 bolts.
Torque: 45 N·m
(d) Install the driver seat rear mounting bolt cover.
ALL126G
IR-��
Rear Seat Assembly

Components
Rear seat shoulder belt cover Center rear seat outer belt assembly
Rear seat headrest assembly
Rear seatback lock release button

Rear seatback lock button gasket
Rear seatback RH
lock assembly
Tether anchor cover

Rear seatback
buckle RH
Rear seat headrest support
Rear seatback lock

release button
Rear seatback lock

button gasket
Rear seat LH
Rear seatback seatback lock
hinge RH assembly
Rear seatback RH
Rear seatback LH
Rear seatback buckle LH

Rear seat setting
cross member as-
sembly
Rear seatback hinge LH
Rear seat cushion w/cover

pad sub-assembly
: Specified torque
ALL139G
71
Replacement
Hint:
quence. However, only installation procedures requiring ad-
ditional information are included.
Caution:
Wear gloves because the cutting surface of the seat
cushion frame and seat adjuster may injure your hand.
1. Remove the rear seat cushion w/the cover pad sub-

assembly
(a) Pull up the 2 seat brackets of the seat cushion, then re-
move them.
Notice:
In this case, hold the base of the clip up to prevent
the cushion frame from being distorted.
A: 100 mm or less.
ALL140G
2. Remove the rear seatback assembly LH

(a) Tilt down the seatback toward the front of the vehicle.
(b) Turn up the seatback cover as shown in the illustration.
(c) Remove the 2 bolts and seatback.
ALL141G
3. Remove the rear seatback assembly RH

Hint:
Follow the same procedures as for the LH side.
4. Follow the same procedures as for the LH side
(a) Remove the 2 bolts and rear seatback buckle LH.
5. Remove the rear seatback buckle RH
(a) Remove the nut, 2 bolts, and rear seatback buckle RH.
6. Remove the rear seatback hinge sub-assembly LH
(a) Remove the bolts and seatback hinge.
7. Remove the rear seatback hinge sub-assembly RH
ALL142G
(a) Remove the bolts and seatback hinge.
8. Remove the bolts and seatback hinge
(a) Remove the bolts and setting cross member assembly.
9. Remove the rear seat headrest assembly
(a) Remove the headrest.
10. Remove the rear seatback lock release button
IR-��
11. Only the right side:

Remove the rear seat shoulder belt cover
(a) Using a screwdriver, remove the shoulder belt cover.
ALL143G
Tether anchor cover 12. Remove the tether anchor cover

(a) Using a screwdriver, remove the 3 tether anchor covers.
: 4 Claws
ALL144G
Zipper Zipper 13. Remove the rear seat headrest support

(b) Remove the hog rings.
Clip
ALL145G
(c) Disengage the claws and remove the seat headrest

support.
Hint:
When performing this step, position yourself between
the seatback frame and the seatback cover (w/pad).
ALL146G
14. Remove the rear seatback lock button gasket

(a) Disengage the claws and remove the seatback lock
button gasket.
Hint:
When performing this step, position yourself between
the seatback frame and the seatback cover (w/pad).
ALL147G
73
15. Remove the rear seatback cover w/pad LH

(a) Remove the rear seatback cover w/pad LH.
16. Remove the rear seatback cover w/pad RH
(a) Remove the rear seatback cover w/pad LH.
17. Remove the rear seatback lock assembly LH

(a) Remove the 2 bolts and seatback lock.
18. Remove the rear seatback lock RH assembly
(a) Remove the 2 bolts and seatback lock.
19. Remove the center rear seat outer belt assembly
(a) Remove the nut and seat belt.
20. Install the center rear seat outer belt assembly
(a) Install the seat belt with nuts.
Torque: 45 N·m
21. Install the rear seatback cover w/pad LH
ALL148G
(a) Install the seatback cover (w/pad) to the front seatback
frame.
Notice:
Do not damage or contaminate the seatback cover
(w/pad).
22. Install the rear seatback cover w/pad RH
Hint:
Follow the same procedures for the LH side.
23. Install the rear seat setting cross member assembly
(a) Install the setting cross member assembly with bolts.
24. Install the rear seatback hinge sub-assembly LH
(a) Install the seatback hinge with the bolts.
25. Install the rear seatback hinge sub-assembly RH
(a) Install the seatback hinge with the bolts.
26. Install the rear seatback buckle LH
(a) Install the seatback buckle with the 2 bolts.
Torque: 21 N·m
27. Install the rear seatback buckle RH
(a) Install the seatback buckle RH with the 2 bolts and 1
nut.
Torque: 21 N·m
28. Install the rear seatback LH
Torque: 45 N·m
29. Install the rear seatback RH
Torque: 45 N·m
MEMO
ET-1
Vehicle exterior
Wipers and Washer System

Problem Symptoms Table 1........................................... ET-2
On-vehicle Inspection..................................................... ET-3
Inspection........................................................................ ET-3
Windshield Wiper Motor Assembly............................... ET-5
Rear Wiper Motor Assembly.......................................... ET-9
Left Wiper Rubber Strip.................................................. ET-10
Rear Wiper Rubber Strip................................................ ET-11
Combination Switch Assembly RH............................... ET-12
Washer Nozzle................................................................. ET-13
Windshield/Door Window Glass/Rearview Mirror

Power Window Control System..................................... ET-15
Windshield....................................................................... ET-20
Quarter Window Assembly RH...................................... ET-25
Trunk Door Glass............................................................ ET-30
Window Defogger System.............................................. ET-34
Power Mirror Control System........................................ ET-37
HORN SYSTEM
Parts Location................................................................. ET-41
Inspection........................................................................ ET-42
High Tone Electric Horn Assembly............................... ET-43
Low Tone Electric Horn Assembly (Condition 1)......... ET-43
Low Tone Electric Horn Assembly (Condition 2)......... ET-43
SLIDING SUNROOF
Functions......................................................................... ET-44
Routine Maintenance Procedures................................. ET-44 ET-
Components.................................................................... ET-45
Disassembly.................................................................... ET-47
Reassembly..................................................................... ET-48
Installation....................................................................... ET-49
Circuit Diagram of Sunroof Motor................................. ET-51
ET-2 COOL BEAR MAINTENANCE MANUAL
Wipers and Washer System

Problem Symptoms Table 1
Hint:
Use the table below, with the suspected areas listed in numerical order, to determine the cause of the prob-
lem.Inspect and repair or replace parts as necessary according to the steps on the following pages.
1. Wipers and Washer System
Symptom Suspected area See page
1. Wiper fuse -
2. Combination switch assembly RH IR-19
Front wipers do not operate.
3. Windshield wiper motor assembly ET-4
4. Wire harness -
Front wipers do not operate in the LO or HI
position.
3. Wire harness -
Front wipers do not operate in the INT position. 2. Windshield wiper motor assembly ET-4
3. Wire harness -
1. Washer fuse -
Front washer motor does not operate.
3. Washer motor ET-3
4. Wire harness -
Front wipers do not operate when the washer
switch is in the ON position.
3. Wire harness -
1. Wiper fuse -
2. Rear wiper switch -
Rear wiper and washers do not operate.
3. Wire harness ET-3
4. Rear wiper relay -
1. Washer fuse -
2. Rear washer switch -
Rear wipers do not operate in the INT position.
3. Washer motor ET-3
4. Wire harness -
1. Rear wiper switch ET-3
Rear wipers do not operate when the washer
2. Rear wiper motor ET-5
switch is in the ON position.
3. Wire harness -
Washer fluid does not flow. 1. Washer hose and nozzle -
• When the wiper switch is OFF, the wiper 1. Windshield wiper motor assembly ET-4
blade does not retract or retracts to the (Wiper arm and blade set position)
wrong position.
• The wiper blade is in contact with the body.
VEHICLE EXTERIOR ET-3
1. Washer motor
(a) Operation inspection
(1) Pour water into the washer container.
(2) Connect the battery positive cable to terminal 2 of
the front windshield washer motor and pump as-
sembly and the battery negative cable to terminal
Front side 1 of the front wind-shield washer motor and pump
assembly. Check that the water comes out from
the washer container.
ALM001G

the rear windshield washer motor and pump as-
sembly, the battery negative cable to terminal 1 of
Rear side
the rear wind-shield washer motor and pump as-
sembly. Check that the water comes out from the
washer jar.
ALM002G
Inspection
1. Combination switch assembly RH
Combination Switch Assembly RH Connector (a) Inspect the conducting conditions
Front View : (1) Measure the resistance according to the value in
Front wiper switch
Switch position Tester connection Specified conditions
MIST 3 - 4 Below 1 Ω
OFF 3 - 2 - 4 10 kΩ or higher
ALM003G
INT 3 - 4 Below 1 Ω
LO 3 - 4 Below 1 Ω
HI 3 - 2 Below 1 Ω
Front washer switch

OFF 7 - 6 10 kΩ or higher
ON 7 - 6 Below 1 Ω
Rear wiper switch

WASH 8 - 6 Below 1 Ω
OFF - 10 kΩ or higher
ON 9 - 6 Below 1 Ω
ON + WASH 9 - 8 - 6 Below 1 Ω
(b) Intermittent operation check

(1) Connect the voltmeter positive terminal to terminal
3 of the connector and the voltmeter negative ter-
minal to terminal 4.
the connector and the battery negative cable to
terminal 4.
(3) Turn the wiper switch to the INT position.
the connector for 5 seconds.
(5) Connect the battery negative cable to terminal 4 of
the connector. Operate the intermittent wiper relay
and check voltage between terminals 3 and 4.
Fast: Connect the battery negative Slow: Connect the battery negative cable to
to
to
cable to terminal 4 terminal 4
10 to 14 V
Voltage between the terminals
1.6 ± 1 sec. 10.7 ± 5 sec.
ALM004G
(c) Operation check (front washer)

(1) Turn the wiper switch off.
Washer
Switch
terminal 4.
10 to 14 V (3) Connect the voltmeter positive terminal to terminal
3 of the connector and the voltmeter negative ter-
Voltage between Approx. Approx. minal to terminal 4.
the terminals 0.3 sec. 2.2 sec. Turn the washer switch on and off and check volt-
ALM005G
age between terminals 3 and 4.
2. Windshield Wiper Motor Assembly

Windshield Wiper Motor Assembly Connector (a) LO (low speed) operation inspection
Front View:
(1) Connect the battery positive cable to terminal 5 of the
connector and the battery negative cable to terminal 4,
and check that the motor operates at high speed (HI).
(b) HI (high speed) operation inspection
the connector, connect the battery negative cable
to terminal 4, and then check to make sure that
ALM006G
the motor operates at low speed (LO).
(c) Autostop operation inspection
(1) Connect the battery positive cable to terminal 5 of the
connector and the battery negative cable to terminal
4. With the motor operating at low speed (LO), discon-
nect terminal 5 to stop the wiper motor operation at
any position other than the automatic stop position.
(2) Connect terminal 1 to positive electrode cable of
battery, connect terminal 5 to terminal 2, so that
the motor restarts and operates at low-speed.
3. Rear Wiper Motor Assembly

Rear Wiper Motor Assembly Connector Front (a) Operation inspection
View:
motor case, and check that the rear wiper motor
operates.
Notice:
The ground should be connected.
ALM007G
(b) Autostop position operation inspection

Blade position mark (1) Connect the battery positive cable to terminal 3 of
the motor case.
Notice:
The body earth should be connected.
(2) With the motor rotating, disconnect terminal 3 to
stop the motor operation at any position other than
ALM008G the automatic stop position.
(3) Connect the battery positive cable to terminal 2 or
3. Check that the motor is restarted and automati-
cally stops.
Windshield Wiper Motor Assembly

Replacement
1. Remove the windshield wiper arm bolt cover
2. Remove the front wiper arm & blade assembly RH
3. Remove the front wiper arm & blade assembly LH
ALM009G
4. Remove the vent panel front weatherstripping

(a) Using a clip remover, disconnect the 9 clips and re-
move the cowl ventilation cover plate sealing strip.
9 Clips
：9 Clips ALM010G
5. Remove the cowl top ventilation cover plate RH

(b) Disengage the 5 claws and remove the cowl top venti-
lation cover plate RH.
5 Claws
：5 Claws ALM011G
6. Remove the cowl top ventilation cover plate LH

(b) Disengage the 5 claws and remove the cowl top venti-
lation cover plate LH.
5 Claws
：5 Claws
ALM012G
7. Remove the windshield wiper motor & link assembly

(b) Remove the 3 bolts and the windshield wiper motor &
link assembly.
ALM013G
8. Remove the windshield wiper motor assembly

(a) Using a screwdriver, disconnect the 2 rods at the crank
arm pivot of the windshield wiper motor assembly.
Hint:
ALM014G
ALM015G
(b) Remove the 3 bolts and the windshield wiper motor as-
sembly.
ALM016G
9. Install the windshield wiper motor assembly

(a) Install the windshield wiper motor assembly with the 3
bolts.
(b) Apply MP grease to the crank arm pivot of the wind-
shield wiper motor assembly.
(c) Install the 2 rods to the windshield wiper motor assem-
bly.
ALM016G
10. Install the windshield wiper motor & link assembly

(a) Install the windshield wiper motor & link assembly with
the 3 bolts.
Torque: 9 N·m
(b) Connect the connectors.
ALM013G
11. Install the cowl top ventilation cover plate LH

(a) Engage the 5 claws and install the cowl top ventilation
cover plate LH.
(b) Install the 4 clips.
5 Claws
：5 Claws
ALM012G
12. Install the cowl top ventilation cover plate RH

(a) Engage the 5 claws and install the cowl top ventilation
cover plate RH.
(b) Install the 4 clips.
5 Claws
：5 Claws ALM011G
13. Install the cowl ventilation cover plate sealing strip

(a) Install the cowl ventilation cover plate sealing strip with
the 9 clips.
9 Clips
：9 Clips ALM010G
Triangular spline 14. Install front wiper arm & blade assembly LH
(a) Operate the wiper and stop the windshield wiper motor
assembly in the autostop position.
(b) Remove the impurities in the triangular spline with a
Wiper pivot tooth face three-square needle file or steel saw blade.
Wire brush
(c) Clean the wiper pivot tooth face with a wire brush.
ALM017G
(d) Install the front left wiper arm and blade assembly with
a nut in the position as shown in the figure.
Torque: 20 N·m
Installation position mark:
Installation position mark
25 to 40 mm
25 to 40mm Hint:
Hold the wiper arm to tighten the nut.
(e) Operate the wiper while spraying water or wiper fluid over
ALM018G the door window. Check the wiping effect and make sure
that the wiper does not touch the body of the vehicle.
Triangular spline 15. Install front wiper arm & blade assembly RH
(a) Remove the impurities in the triangular spline with a
three-square needle file or steel saw blade.
(b) Clean the wiper pivot tooth face with a wire brush.
Wiper pivot tooth face
Wire brush
ALM017G
(c) Install the front right wiper arm and blade assembly
with a nut in the position shown in the figure.
Torque: 20 N·m
Installation position mark Installation position mark:
29 to 44 mm
29 to 44 mm Hint:
Hold the arm hinge with hand to tighten the nut.
16. Install the windshield wiper arm bolt cap
ALM019G
Rear Wiper Motor Assembly

Replacement
2. Remove the rear wiper arm cover
3. Remove the rear wiper arm & blade assembly
4. Remove the rear wiper motor grommet
5. Remove the rear wiper motor assembly
(b) Remove the 3 bolts and rear wiper motor assembly.
ALM020G
6. Install the rear wiper motor assembly

Installation position mark (a) Install the rear wiper motor grommet in the position as
ALM020G
7. Install the rear wiper motor assembly

(a) Install the rear wiper motor assembly with the 3 bolts.
Torque: 9 N·m
8. Install the rear wiper arm & blade assembly
(a) Operate the wiper and stop the windshield wiper motor
assembly in the autostop position.
ALM021G
(b) Remove the impurities in the triangular spline with a

three-square needle file or steel saw blade.
Triangular spline (c) Clean the wiper pivot tooth face with a wire brush.
Wiper pivot tooth face

Wire brush
ALM022G
(d) Install the rear wiper arm & blade assembly with nuts in
Blade position mark the position shown in the illustration.
Torque: 9 N·m
Hint:
Hold the wiper arm to tighten the nut.
(e) Operate the wiper while spraying water or wiper fluid
over the door window. Check the wiping effect and
make sure that the wiper does not touch the body of
ALM030G the vehicle.
Left Wiper Rubber Strip

Replacement
1. Remove the front wiper blade LH
(a) Remove the front wiper blade LH from the front wiper
arm LH.
Notice:
Do not bend the front wiper arm when removing the
front wiper blade from it.
2. Remove the wiper rubber LH
(a) Remove the wiper rubber from the front wiper blade
Bend
LH.
(b) Remove the 2 wiper rubber backing plates from the
wiper rubber LH.
ALM023G
3. Install the wiper rubber LH

Bend (a) Install the 2 wiper rubber backing plates to the wiper
rubber LH.
Notice:
Make sure to install the wiper rubber strip back
boards in the correct direction.
ALM023G
(b) Install the left wiper rubber strip such that the head (the
longer side) of the wiper rubber strip is directed towards
the arm's spindle side.
Notice:
• Push the front wiper blade into the grooves of
the wiper rubber to engage them completely.
• Put back the wiper arm of the passenger side
before putting back that of the driver’s side.
ALM024G
Rear Wiper Rubber Strip

Replacement
1. Remove the rear wiper rubber
(a) Pull the end of the rubber protruding from the blade
stopper as shown in the illustration.
Push Notice:
Do not pull out the wiper rubber strip forcibly. Oth-
erwise, the backing plates will be deformed or the
blade claw will be damaged.
Pull
Hint:
Press the position near the middle of the blade to raise
Stop block
ALM025G the rubber strip. In this way, it will be easier to pull out
the rubber strip.
2. Install the rear wiper rubber
Bend (a) Install the 2 wiper rubber strip back boards on the rear
wiper rubber strip.
Notice:
Make sure to install the wiper rubber strip back
boards in the correct direction.
ALM023G
(b) Insert the rear wiper rubber from the claw side in the
middle of the rear wiper blade end position.
ALM026G
(c) After passing the rear wiper rubber through the rear
end side claw, extend it from the rear end stopper and
pass it through the front end side claw.
ALM027G
Combination switch assembly RH

Replacement
1. Remove the combination switch cover (see page
SR-6)
2. Remove the combination switch assembly RH
(b) Using a screwdriver, disengage the claw and pull out
the combination switch assembly RH.
Hint:
: Claw
Claw 3. Install the combination switch assembly RH
ALM028G
4. Install the combination switch cover (see page SR-9)

Washer Nozzle
Adjustment
1. Inspect washer nozzle
(a) With the engine running, turn on the washer nozzle switch, check that the area where the washer fuid
sprays on the windshield and the rear window is within the range as shown in the illustration.
Front:
Spray range of washer nozzle

ALM029G
Rear:
Spray range of washer nozzle
ALM030G
2. Adjust the washer nozzle

(a) Adjust the direction of the washer nozzle with a pin.
Notice:
Adjust the direction of the washer nozzle with a
smooth-ended pin.
ALM031G
Windshield/Door Window Glass/Rearview Mirror

Power Window Control System
Parts Location
Front glass regulator motor

Front window assembly RH
Instrument Panel Junction Main switch
assembly Front window switch assembly RH
Block Assembly
● Power source relay
● Instrument fuse Front door glass regulator
sub-assembly RH
Rear window switch assembly RH
Front glass regulator LH
motor assembly
Front door window

regulator LH
sub-assembly
Left rear window

Switch assembly
Rear door window regulator LH Rear glass regulator RH

Sub-assembly motor assembly
Rear door window regulator RH
sub-assembly
Rear glass regulator LH

Motor Assembly
ALM032G
1. Check the window lock switch
(a) Check that the operation of the power windows except
the driver side power window is disabled when the win-
dow lock switch of the power window main switch is
pressed.
(b) Check that the power windows can operate when the
window lock switch is pressed again.
ALM033G
2. Check the manual UP/DOWN function

(a) Check that each power window switch can operate each power window as follows:
Standard:
Condition Switch Switch Operation Power Window
Pulled up Rise
FL
Pushed down Descend
Pulled up Rise
• The ignition switch is set to FR
Pushed down Descend
the ON position
Pulled up Rise
• Window lock switch OFF RL
Pushed down Descend
Pulled up Rise
RR
Pushed down Descend
3. Check the UP/DOWN function of the main switch

(a) Check that the front window main switch LH can operate all other power windows besides the FL side
power window as follows:
Standard:
Condition Main Switch Switch Operation Power Window
Pulled up Rise
FR
Pushed down Descend
• The ignition switch is set to
Pulled up Rise
the ON position RL
Pushed down Descend
• Window lock switch OFF
Pulled up Rise
RR
Pushed down Descend

Symptom Suspected Area See Page
2. Power source relay -
No power window operates
3. Ignition switch IR-18
4. Wire harness -
1. Front window main switch assembly LH ET-17
2. Window switch assembly ET-17
Only one power window does not operate
3. Glass regulator motor assembly ET-17
4. Wire harness -
Window lock system does not operate 1. Front window main switch assembly LH ET-17
Inspection
1. Glass regulator system circuit
Window
Iock
switch
Driver
side Front Rear Rear
Rise Rise window Rise window Rise window
window
Off switch Off switch Off switch Off switch
LH RH LH LH
Descend Descend Descend Descend
Front Rise Rear Rise Rear Rise

window window Off window
Off Off
switch switch switch
RH Descend LH Descend LH Descend
Front window jam protection Front window jam protection Rear window jam protection Rear window jam protection
motor LH motor RH motor LH motor RH
ALL034G
Window lock switch 2. Check the front window main switch LH

(a) Check the resistance between each terminal of the
Front window
switch RH connector when the switch is operated.
Rear window
switch RH
Front window
switch LH
Rear window
switch LH
ALM035G
Standard:
Rear door electric switch FL
Window lock switch Window switch
Tester connection Specified conditions
condition condition
1 - 4
UP
B+ - 1
Constant 1 - 4
OFF Below 1 W
(OFF/ON) 4 - 6
4 - 6
DOWN
B+ - 6
Front door electric switch RH
condition condition
1 - 4
UP
B+ - 1
1 - 4
OFF OFF
4 - 6
4 - 6
DOWN
B+ - 6
Below 1 W
1 - 4
UP
B+ - 1
1 - 4
ON OFF
4 - 6
4 - 6
DOWN
B+ - 6
Rear door electric switch LH
condition condition
1 - 4
UP
B+ - 1
1 - 4
OFF OFF
4 - 6
4 - 6
DOWN
B+ - 6 Below 1 W
1 - 4
UP
B+ - 1
ON 1 - 4
OFF
4 - 6
DOWN 4 - 6
Rear window switch RH

Window lock switch Window switch condi-
Tester connection Specified condition
condition tion
1 - 4
UP
B+ - 1
1 - 4
OFF OFF
4 - 6
4 - 6
DOWN
B+ - 6
Below 1 W
1 - 4
UP
B+ - 1
1 - 4
ON OFF
4 - 6
4 - 6
DOWN
B+ - 6
If the results do not comply with the regulations, change the main switch assembly.
3. Inspect the front glass regulator motor assembly LH

(a) Check the operation of the regulator motor.
(1) Apply battery voltage to the motor terminals.
(2) Check that the motor rotates smoothly.
Standard:
Measurement condition Specified condition
Battery positive (+) → 1
Motor gear rotates clockwise
Battery negative (-) → 2
ALM036G Battery positive (+) → 2 Motor gear rotates counter-
Battery negative (-) → 1 clockwise
If the results do not comply with the regulations, replace
the motor assembly.
Windshield
Components
Roof board handle
Dome lamp assembly
Front passenger side sun visor body
Front door weatherstripping RH Dome lamp

Holder cover lens cover
Passenger sun visor
bracket Driver's side sun visor body
A Pillar Inside rear view mirror assembly

upper trim
panel ● Windshield outer protective strip
assembly ● Window glass adhesive dam
RH
Driver's side sun visor bracket
● Front windshield glass stopper
Ventilation cover
plate body RH Windshield
A Pillar upper trim

panel assembly LH
Front right wiper Vent panel body

arm
Front ventilation cover
plate sealing strip
Wiper arm
bolt cover RH
Left wiper arm bolt cover Front left wiper arm
Front door weatherstripping RH

: Specified torque
●non-reusable component
ALM037G
Replacement
Hint:
The installation sequence is the reverse of the removal sequence. However, it only includes the installation
sequence with additional information.
1. Remove the roof inner facing
(a) Remove the front door weatherstripping LH and front door weatherstripping RH.
(b) Remove the left and right A-pillar protective panel assemblies.
(c) Remove the driver's side sun visor body and front passenger side sun visor body.
(d) Remove the roof board handle assembly.
(e) Remove the driver's side sun visor bracket and front passenger side sun visor bracket.
(f) Remove the dome lamp lens cover.
(g) Remove the dome lamp.
(h) Remove a part of the roof inner facing to facilitate the removal of the windshield.
2. Remove the inner rear view mirror assembly (see page IR-64)
3. Remove ventilation cover plate body LH and RH
(a) Remove the wiper arm bolt cover LH and RH.
(b) Remove the left and right front wiper arms.
(c) Remove the vent panel front weatherstripping.
(d) Remove the ventilation cover plate body LH and RH.
4. Remove the windshield glass

(a) From the interior, insert piano wire between the vehicle
body and glass, as shown in the illustration.
(b) Tie objects that can serve as handles (for example,
Locating block
wooden blocks) to all wire ends.
Piano wire
ALM038G
Plastic plate Hint:

To prevent the external surface of the vehicle body from
being scratched, apply protective adhesive tape to its ex-
ternal surface.
Notice:
• When detaching the glass from the vehicle, take
care not to damage the body paint or the inte-
Protective tape rior and exterior trimmings.
ALM039G • When removing the glass, to prevent the dash-
board from being scratched, place a plastic
plate between the steel wire and the dashboard.
(c) Pull the steel wire around the glass to cut the glass.
(d) Detach the locating block.
(e) Remove the glass with a suction disc.
5. Clean the windshield glass

(a) Using a scraper, remove the damaged stoppers, dam,
and adhesive that is sticking to the glass.
(b) Clean the outer circumference of the glass with white gasoline.
Notice:
• After cleaning, do not touch the glass surface.
• Be careful not to damage the glass.
• Even if using new glass, clean the glass with
white gasoline.
ALM040G
6. Install 2 stoppers
Backside: 7. Install the window glass adhesive dam

(a) Coat the installation part of the adhesive dam with
primer.
Notice:
• Allow the primer coating to dry for 3 minutes or
more.
• Throw away any leftover primer.
• Do not apply too much primer.
(b) Install a new dam, apply double-sided tape all the way
ALM041G
around the glass except where the dam is installed, as
Specification:
Area Measurement
a 7.0 mm
b 23.5 mm
8. Install the windshield glass

Adhesive (a) Clean and shape the contact surface of the vehicle
body.
Adhesive
(1) Using a knife, cut away any excess or unneeded
adhesive on the contact surface.
(2) Clean the contact surface of the vehicle body with
a piece of shop rag saturated with cleaner.
Hint:
Even if all the adhesive is removed, you should
ALM042G
still clean the vehicle body.
(b) Position the glass.

(1) Using a suction cup, place the glass in the correct
position.
Mark (2) Check that the entire contact surface of the glass
rim is perfectly even.
(3) Place reference marks between the glass and ve-
hicle body.
Notice:
Check that the stoppers are attached to the ve-
ALM043G
hicle body correctly.
Hint:
When reusing the glass, check and correct the ref-
erence mark positions.
(4) Remove the glass.
Correct
(c) Apply the primer to the contact surface at the side of
Primer M the vehicle body with a brush.
Notice:
Incorrect • Allow the primer coating to dry for 3 minutes or
Primer M
more.
Adhesive
• Do not coat the adhesive with Primer M.
• Throw away any leftover Primer M.
Primer M ALM044G
Backside: (d) Using a brush or sponge, coat the edge of the glass
and the contact surface with primer, as shown in the il-
lustration.
Specification:
Area Specified conditions
a 7.0 mm
b 23.5 mm
Primer ALM045G
Hint:
If the primer is accidentally applied to another part of
the vehicle, wipe off the primer with a clean shop rag
before it dries.
Notice:
more.
• Do not coat the adhesive with primer.
Backside: (e) Apply adhesive.

(1) Cut off the tip of the cartridge nozzle, as shown in
the illustration.
Hint:
After cutting off the tip, use all adhesive within the
time described in the table below.
Service life
Temperature Service life
ALM046G 35 ºC 15 minutes
20 ºC 1 hour 40 minutes
5 ºC 8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the il-
lustration.
Specifications:
Area Measurement
a 8.0 mm
b 12.0 mm
(f) Install the glass.

(1) Using a suction cup, position the glass so that the
reference marks are aligned. Press it gently along
the rim.
Notice:
more.
• Check that the stoppers are attached to the
ALM047G vehicle body correctly.
• Check the clearance between the vehicle body
and glass.
(2) Lightly press the front surface of the glass to en-
sure a close fit.
(3) Using a scraper, remove any excess or protruding
adhesive.
Adhesive
ALM048G
Hint:
Windshield Apply adhesive onto the glass rim.
Weatherstripping Notice:
Take care not to drive the vehicle for the time
described in the table below.
Minimum time:
Temperature Minimum time before driving
Adhesive 35 ºC 1 hour 30 minutes
ALM049G 20 ºC 5 hours
5 ºC 24 hours
9. Check for leaks and repair
(a) Conduct a leak test after the adhesive has hardened
completely.
(b) Seal any leaks with auto glass sealer.
Quarter Window Assembly RH

Components
●Quarter window spacer
C Pillar upper trim panel assembly RH
Quarter window
assembly RH
●Quarter window guide pin No.1
C Pillar upper trim panel

assembly RH
Rear door
weatherstripping RH
Back door rocker shield
Rear rocker trim RH
Deck board No.2
Deck board No.1
Deck floor box RH
Spare tire bracket

assembly
: Specified torque
●non-reusable component
ALM050G
Replacement
Hint:
• The installation procedures are the removal procedures in the reverse order. However, only installation
procedures requiring additional information are included.
1. Remove the rear seatback RH (see page IR-71)
2. Remove the rear seatback LH (see page IR-71)
3. Remove the rear seat cushion with cover pad sub-assembly (see page IR-71)
4. Remove the rear seat setting cross member assembly (see page IR-54)
5. Remove the rear seatback hinge sub-assembly RH (see page IR-71)
6. Remove the C pillar upper trim panel assembly RH
(a) Remove the rear rocker trim RH.
(b) Remove the the rear door sealing strip RH.
(c) Remove the deck board No.2.
(d) Remove the deck board No.1.
(e) Remove the back door rocker shield.
(f) Remove the deck floor box RH and the spare tire bracket assembly.
(g) Remove the deck board trim panel RH.
(h) Remove the C pillar upper trim panel assembly RH.
7. Remove the quarter window RH

Moulding
(a) Using a knife, cut off the moulding, as shown in the il-
Cut
lustration.
Notice:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
Cut Quarter window Hint:
Make a partial cut in the moulding. Then, pull and re-
ALM051G move it by hand.
Piano wire
(c) From the interior, insert piano wire between the vehicle
(d) Tie objects that can serve as handles (for example,
Gasket
Pin
ALM052G
Hint:
Protective tape
Apply protective tape to the outer surface of the vehicle
to prevent its surface from being scratched.
Notice:
When separating the glass from the vehicle, take
care not to damage the vehicle paint, the interior,
and exterior decoration.
(e) Cut the glass by pulling the piano wires around the
glass.
ALM053G
(f) Remove the glass.
8. Clean the quarter window RH

(a) Clean the outer circumference of the glass with white
gasoline.
Notice:
ALM054G
9. Install the quarter window guild pin No.1

Backside:
(a) Using a brush or sponge, coat the edge of the glass
Pin and the contact surface with primer.
(b) Install new pins.
Notice:
more.
ALM055G
Specifications:
Area Measurement
a 40.0 mm
b 40.0 mm
c 37.0 mm
d 42.0 mm
e 11º
f 46.4º
10. Install the quarter window spacer

Backside: (a) Using a brush or sponge, coat the edge of the glass
Gasket
and the contact surface with primer.
(b) Install new spacers.
Notice:
more.
ALM056G
Specifications:
Area Measurement
a 41.0 mm
b 19.0 mm
c 20.0 mm
d 45.0 mm
e 28.0 mm
f 23.0 mm
g 63.0 mm
h 21.0 mm
i 4º
j 31º
11. Install the quarter window moulding RH

Notice:
more.
• Do not coat the adhesive with primer.
(b) Install the moulding.
12. Install the quarter window assembly RH
Adhesive (a) Clean and shape the contact surface of the vehicle body.
(1) Using a knife, cut away any excess or unneeded
Adhesive adhesive on the contact surface.
Hint:
Even if all the adhesive is removed, you should
ALM042G still clean the vehicle body.
(b) Using a brush, coat the contact surface of the vehicle

body with Primer M.
Primer M Correct Notice:
Incorrect more.
Primer M • Do not coat the adhesive with Primer M.
Adhesive • Throw away any leftover Primer M.
Primer ALM057G
(c) Using a brush or sponge, coat the edge of the glass

Backside:
Specifications:
Items Measurement
a 14.0 mm
A - A
Primer b 8.6 mm
a 14.0 mm
B - B
b 5.0 mm
ALM058G a 14.0 mm
C - C, D - D
b 6.0 mm
a 22.0 mm
E - E
b 8.6 mm
Hint:
before it dries.
Notice:
more.
Backside:
(d) Apply adhesive.
the illustration.
Hint:
Service life:
ALM059G
35 ºC 15 minutes
20 ºC 100 minutes
5 ºC 8 hours
(3) Coat the glass with adhesive, as shown in the illustration.
Specifications:
Area Measurement
a 8.0 mm
b 12.0 mm
c 13.0 mm
d 12.0 mm
e 13.0 mm
f 15.5 mm
(e) Install the glass to the body.
(1) Hold the quarter window glass assembly in place
securely with protective tape or the equivalent until
the adhesive hardens.
Notice:
• Allow the primer coating to dry for 3 minutes or more.
• Check that the clips are installed to the vehicle
body correctly.
and glass.
sure a close fit.

adhesive.
Hint:
Apply adhesive onto the glass rim.
Notice:
Adhesive Minimum time:
ALM048G Temperature Minimum time before driv-
ing
20 ºC 5 hours
5 ºC 24 hours
13. Water-leak check and repair
completely.
Trunk Door Glass

Replacement
Hint:
the reverse order. However, only installation procedures re-
quiring additional information are included.
1. Remove trunk door glass
Piano wire (a) From the interior, insert piano wire between the vehicle
(b) Tie objects that can serve as handles (for example,
Clip
ALM060G
Protective Tape Hint:

Apply protective tape to the outer surface of the vehicle
to prevent its surface from being scratched.
Caution: When detaching the glass from the ve-
hicle, take care not to damage the body paint or the
interior and exterior trimmings.
(c) Cut the glass by pulling the piano wires around the glass.
Notice:
ALM061G To reuse the trunk door glass, be careful not to dam-
age the clip installed on the glass when removing the
binding agent.
(d) Remove the glass with a suction disc.
2. Clean trunk door glass
(a) Clean the outer circumference of the glass with white
gasoline.
Notice:
ALM054G
Backside: 3. Install the back window glass clip

(b) Install the new clips.
Notice:
more.
ALM062G • Do not apply too much primer.
Specifications:
Area Measurement
a 528.8 mm
b 35.8 mm
Backside: 4. Install the back door glass spacer

(b) Install new spacers.
Notice:
more.
ALM063G
Specifications:
Area Measurement
a 15.0 mm
b 220 mm
c 220 mm
d 18.0 mm
Backside:
5. Install the back door outside moulding
(a) Coat the installation part of the window glass adhesive
dam with primer.
Notice:
more.
ALM064G (b) Install a new dam, apply double-sided tape all the way
around the glass except where the dam is installed, as
Specifications:
Area Measurement
a 3.0 mm
6. Install the trunk door glass

Adhesive (a) Clean and shape the contact surface of the vehicle
body.
Adhesive (1) Cut off the uneven binding agent on the vehicle
body contact surface with a knife to ensure a good
surface shape.
ALM042G Hint:
Continue to clean the vehicle body even if the
binding agent has been removed completely.
Primer M Correct (b) Apply the primer M to the exposed part of the vehicle
body with a brush.
Notice:
Incorrect
Primer M • Allow the primer coating to dry for 3 minutes or
Adhesive more.
• Do not apply the primer M on the binding agent.
• Throw away any leftover primer M.
Primer M ALM065G
Backside: (c) Using a brush or sponge, coat the edge of the glass
Hint:
before it dries.
Notice:
ALM066G more.
Specifications:
Area Measurement
a 14.0 mm
b 10.0 mm
c 12.8 mm
d 30.0 mm
e 22.0 mm
f 38.0 mm
Backside:
(d) Apply adhesive.
the illustration.
Hint:
Service life:
ALM067G 35 ºC 15 minutes
5 ºC 8 hours

(3) Coat the glass with adhesive, as shown in the il-
lustration.
Specifications:
Area Measurement
a 8.0 mm
b 12.5 mm
c 10.0 mm
d 12.8 mm
e 30.0 mm
f 30.0 mm
(e) Install the glass to the body.
(1) Fix the trunk door window glass to the vehicle body
securely with protective adhesive tape or similar
products until the binding agent has hardened.
Notice:
more.
• Check that the clips are installed to the vehicle
body correctly.
and glass.
sure a close fit.

adhesive.
Hint:
Apply adhesive onto the glass rim.
Notice:
Adhesive
Minimum time:
ALM048G Temperature Minimum time before driv-
ing
20 ºC 5 hours
5 ºC 24 hours
7. Check for leaks and repair

completely.
Window Defogger System

Parts Location
Instrument panel junction block assembly

● Defogger high current fuse
● Instrument fuse
Defogger wire
A/C controller assembly No.2
● Rear window defogger
switch
Defogger relay
ALM068G

2. Defogger high current fuse -
Rear window defogger does not operate
3. Defogger relay ET-36
(Indicator ON)
4. Rear window defogger wire ET-35
5. Wire harness -
2. Defogger high current fuse -
Rear window defogger does not operate 3. Defogger relay ET-36
(Indicator OFF) 4. AC controller assembly 2 -
5. Rear window defogger wire ET-35
6. Wire harness -
1.4 W test bulb Inspection

1. Inspect AC controller assembly No.2
(a) Check operation of the defogger timer.
terminal 3 and the negative (-) lead to terminal 4.
terminal 2 through a 1.4 W test bulb.
(3) Turn on the rear window defogger switch, check
ALM069G that the switch and the test bulb illuminates for 12
to 18 seconds, and then go off.
If the result is not as specified, replace the module
switch.
2. Inspect back door glass (defogger wire)
Notice:
Defogger wire
• When cleaning the glass, wipe the glass along the
Tester probe wire by a soft and dry cloth. Take care not to damage
the wires.
• Do not use detergents or glass cleaners includ-
ing abrasive ingredients.
Aluminum foil
• When measuring voltage, wrap a piece of alu-
ALM070G minum foilaround the tip of the negative tester
probe and press the foil against the wire with
your finger, as shown in the illustration.
At center (a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Check the voltage at the center of each defogger wire,
Standard:
Voltage Standard
Approx. 5 V Wire is not broken
Approx. 10 or 0 V Wire is broken
ALM071G
Hint:
If there is approximately 10 V, the wire may be faulty be-
tween the center of the wire and the wire end on the battery
side. If there is no voltage, the wire may be faulty between
the center of the wire and the wire end on the ground side.
Foil strip (d) Connect the voltmeter positive (+) lead to the defogger
wire on the battery side.
0 V Below 10V
(e) Connect the voltmeter negative (-) lead with the foil
Broken strip to the wire on the ground side.
wire
(f) Slide the positive (+) lead from the battery side to the
ground side.
Ground side Battery
side (g) The point where the voltage jumps from approximately
10 V to 0 V is the position where the defogger wire is
ALM072G broken.
Hint:
If the defogger wire is not broken, the voltmeter will
indicate 0V at the positive (+) end of the defogger wire
and gradually increase to approximately 12 V as the
meter probe moves to the other end.
(h) If necessary, repair the defogger wire.

Repair point (1) Clean the broken wire tips with grease, wax, or
silicone remover.
(2) Place the masking tape along both sides of the
wire.
(3) Thoroughly mix the repair agent (Dupont paste
Broken No. 4817).
wire
Masking tape
ALM073G
(4) Using a fine tip brush, apply a small amount of the

agent to the wire.
(5) After a few minutes, remove the masking tape.
Notice:
Do not repair the defogger wire again for at
least 24 hours.
3. Inspect the defogger relay
(a) Check the resistance.
Standard:
ALM074G
Terminal number Specified conditions
10 kW or higher
Below 1 W
85 - 86
(When battery voltage is applied to
terminals 30 and 87)
If the results are not as specified, replace the relay.

Power Mirror Control System

Parts Location
Outside rear view mirror assembly RH
Outside rear view mirror assembly LH
Outside rear view mirror adjustment switch
ALM075G

1. Outside rear view mirror adjustment switch ET-38
Mirror does not operate 2. Outside rear view mirror assembly ET-39
3. Wire harness -
1. Outside rear view mirror adjustment switch ET-38

Mirror operates abnormally 2. Outside rear view mirror assembly ET-39
3. Wire harness -
Inspection
Left/Right Mirror fold switch
select switch (Elite\Roof model) 1. Check the outside rear view mirror adjustment
switch
Rear view mirror
switch (a) The L side of the left/right select switch: Check the mir-
ror switch resistance.
Standard (left side):
Terminal Specified
Switch condition
Connect with Rear View Mirror Adjustment Switch connection conditions
ALM076G
4 - 8
UP
6 - 7
4 - 7
DOWN
6 - 8
Below 1 W
5 - 8
LEFT
6 - 7
5 - 7
RIGHT
6 - 8
If the resuls are not as specified, replace the switch as-

sembly.
(b) The R side of the left/right select switch: Check the mir-
ror switch resistance.
Standard (Right side):
Terminal Specified
Switch condition
connection conditions
3 - 8
UP
6 - 7
3 - 7
DOWN
6 - 8
Below 1 W
2 - 8
LEFT
6 - 7
2 - 7
RIGHT
6 - 8
If the resuls are not as specified, replace the switch as-

sembly.
2. Inspect the outer rear view mirror assembly LH

(a) Disconnect the mirror connector.
(b) Apply battery voltage to the mirror terminals and check
the operation of the mirror face, as shown in the table
and illustration.
Standard:
Measurement conditions Mirror operation
UP (A)
Outside power mirror LH ALM077G Battery negative (-) → �
8
DOWN (B)
Battery negative (-) → �
9
LEFT (C)
8
RIGHT (D)
7
If the resuls are not as specified, replace the mirror assembly.

3. Inspect the outer rear view mirror assembly RH
(a) Disconnect the mirror connector.
(b) Apply battery voltage to the mirror terminals and check
the operation of the mirror face, as shown in the table
and illustration.
Standard:
Measurement conditions Mirror operation
UP (A)
Outside power mirror RH ALM078G
Battery negative (-) → �8
DOWN (B)
LEFT (C)
RIGHT (D)
If the resuls are not as specified, replace the mirror assembly.
Outside Rear View Mirror Assembly LH

Replacement
Hint:
• The installation procedures are the removal procedures
in the reverse order. However, only the installation proce-
dures requiring additional information are included.
1. Remove the front door waterproof membrane LH
(a) Remove the front door triangular trim.
(b) Remove the front door inside pull handle.
(c) Remove the glass regulator main switch.
(d) Remove the front door trim panel.
(e) Remove the front door inside handle
(f) Remove the front door trim panel bracket.
(g) Remove the front door waterproof membrane.
2. Remove the outside rear view mirror assembly LH

(b) Remove the 3 nuts and mirror.
ALM079G
3. Install the outside rear view mirror assembly LH

(a) Install the mirror with the 3 nuts.
Torque: 8.0 N·m
ALM079G
Inside Rear View Mirror Assembly

Replacement
Hint:
the reverse order.
1. Remove the inner rear view mirror assembly

(a) Using a screwdriver, disengage the claws and mirror
cover.
Hint:
(b) Remove the 2 screws and rear view mirror. ALM080G
ALM080G
HORN SYSTEM
Parts Location
Horn button switch
Condition 1
Low tone electric horn assembly
Front engine room fuse block

Condition 2 Horn button switch
Low tone horn assembly
Front engine room fuse block

ALM081G

1. Horn button switch -
2. High tone horn assembly ET-42
3. Low tone horn assembly ET-42
Horn does not sound
4. Horn fuse -
5. Horn relay assembly ET-42
6. Wire harness -
Inspection
1. Inspect the low tone horn assembly
(a) Apply battery voltage to the horn and check the opera-
tion of the horn.
Standard:
Measurement condition Specified condition
Battery positive (+) → Terminal 1
Horn sounds
Battery negative (-)→ Horn body
ALM082G
If the results are not as specified, replace the horn as-
sembly.
2. Inspect the high tone horn assembly

(a) Apply battery voltage to the horn and check the opera-
tion of the horn.
Standard:
Specified condi-
Measurement condition
tion
Battery positive (+) → Terminal 1
Horn sounds
Battery negative (-) → Horn body
ALM083G
If the results are not as specified, replace the horn as-
sembly.
3. Inspect the horn relay assembly

(a) Remove the horn relay from the engine room fuse
block.
(b) Inspect the horn relay resistance.
Standard:
Tester connection Specified condi-
tion
10 W or higher
ALM084G Below 1 W
3 - 5 (when the battery
voltage is applied to
Terminals 3 and 5)
If the results are not as specified, replace the relay as-

sembly.
High Tone Horn Assembly

Replacement
Hint:
the reverse order. However, only the installation procedures
1. Remove high tone electric horn assembly

(a) Remove the front bumper upper grille.
(c) Remove the bolts and the horn.
2. Install the high tone horn assembly
(a) Attach the horn stay to the body panel with located pad
and then install the horn with the bolts.
Torque: 19.5 N·m
ALM085G
Low Tone Horn Assembly (Condition 1)

Replacement
Hint:
1. Remove the low tone horn assembly

(b) Remove the front bumper and the deflector.
(c) Disconnect the connector.
(d) Remove the bolts, the located pad, and the horn.
2. Install the low tone horn assembly
(a) Attach the horn stay to the body panel and then install
the horn with the bolts.
ALM086G Torque: 19.5 N·m
Low Tone Horn Assembly (Condition 2)

Replacement
Hint:
1. Remove the low tone horn assembly
ALM106G
(c) Remove the bolts and the electric horn.
2. Install the low tone horn assembly
(a) Attach the horn stay to the body panel with the located
pad and then install the horn with the bolts.
Torque: 19.5 N·m
SLIDING SUNROOF
Functions
When the ignition switch is on, the switch can be pressed to open and close the sunroof.
1. Horizontal opening of the sunroof
Press the sunroof push button switch SLIDE OPEN, the sunroof window completely opens backward;
at the same time, the sun visor automatically opens with the sunroof window.
2. Closing of the sunroof
Press the sunroof push button switch TILT UP, the sunroof completely closes forward; the sun visor
should be closed manually.
3. Tilted opening of the sunroof
Press the sunroof push button switch TILT UP, the sunroof window will tilt up to the largest angle;
4. Anti-clip function
If the sunroof encounters movement difficulty or stops due to resistance during closing, the sunroof
window will re-open immediately.
5. While open (close) window with the manual mode, continuously hold down the push button
switch, when the push button switch is released, the sunroof will stop.
6. While open (close) window with automatic mode, touch the push button switch of the sunroof,
the sunroof will automatically move to the open (close) position; in the automatic mode, when
toucing the push button switch again, the sunroof will automatically stop.
Routine Maintenance Procedures
1. When the sunroof is in the closed state, push the sunroof window glass with both hands inside
the vehicle to check whether the glass assembly bolts are loose. If so, the window glass may
move up and downand the bolts should be tightened and a torque within 4.5 ~ 6 N•m should be
ensured;
2. Open the sunroof window glass completely; check whether there is any foreign debris and
dust in the drainage channels of the left and right guide rails. If so, wipe off the slide with the
foreign debris and dust slightly with a soft clean dry cloth;
3. Open and close the sunroof; check whether there is any jamming during the movement of the
window glass. If so, the guide rails should be cleaned and applied with an appropriate amount
of No.00 grease or non-dust-absorption lubricant, and the window glass should be moved
again to get full lubrication;
4. When the sunroof is closed, push the sun visor inside the vehicle to check whether is any
jamming. If so, the sun visor should be pushed to the maximum opening position, the guide
rails should be cleaned and applied with an appropriate amount of No.00 grease or non-dust-
absorption lubricant, and the sun visor should be moved again to get full lubrication;
5. If you use too much grease, then wipe off excess grease with a soft cloth to avoid polluting the
interior components of the vehicle;
6. Re-open and close the sunroof to check the operational status;
7. Open the sunroof to the half-open position, then remove dust, sand, and other foreign debris
on the seal of the front end of the sunroof window glass with a clean wet sponge;
8. Open the sunroof to a full-open position, then remove dust, sand, and other foreign debris
on the seal of the rear end and left and right sides of sunroof window glass with a clean wet
sponge.
Components
ALM087G
1. Motor bolt (to lock motor) 17. Waterproof sponge

2. Motor 18. Screw
3. Copper tube assembly 19. Mechanism shield
4. Weatherboard assembly 20. Guide mechanism assembly L
5. Hinge screw 21. Guide mechanism assembly R
6. Copper bushing LH 22. Linkage assembly L
7. Copper bushing RH 23. Linkage assembly R
8. Frame assembly 24. Rear drain pipe assembly L
9. Connecting rod 25. Rear drain pipe assembly R
10. Sun visor front block LH 26. Sun visor assembly
11. Sun visor front block RH 27. Rear drainage channel
12. Screws (front pillar + aluminum slide rail +
28. Sunroof window glass assembly
mechanism locating block)
13. Mechanism locating block L 29. Glass screw
14. Mechanism locating block R 30. Trim cover L
15. Rocker locating block L 31. Trim cover R
16. Rocker locating block R 　

Symptom Possible cause Troubleshooting
Foreign debris in Remove the
the roof track blocked material
Misplaced parts in Install the parts
Roof cannot the track correctly
operate The locations of
(Motor operates) Correct the inter-
the roof parts are
fered parts
interfered
Wrong installation
Install them cor-
of the cable rectly
Fuse damage in Roof switch mal-
the system function
Check the line ac-
Motor malfunction cording to the roof
Roof cannot oper- switch description
ate
(Motor does not Check the line ac-
operate) Motor malfunction cording to the roof
motor description
Check the line ac-
Controller error cording to the roof
controller description
1. Remove the roof headlining

(a) Remove the roof headlining.
2. Remove the rear roof air duct
(a) Detach the 2 clips and remove the air duct.
ALM088G
3. Remove the sliding roof side decoration LH

(a) Detach the 5 claws and remove the side decoration.
4. Remove sliding roof side decoration RH
Hint:
Use the same procedures described for the LH side.
ALM089G
5. Remove the sliding roof glass

(a) Using a screwdriver, remove the 4 screws and glass.
6. Remove the sliding roof weatherstripping
7. Remove the sliding roof housing sub-assembly
(a) Disconnect the sliding roof drain pipes.
(b) Remove the bolts, nuts, and housing.
ALM090G
Disassembly
1. Remove the sliding roof lock catch plate LH
2. Remove the sliding roof motor
(a) Detach the bracket claw and remove the bracket.
(b) Remove the 3 bolts and sliding roof motor.
ALM091G
3. Remove the sunshade trim sub-assembly

Rearward
(b) Detach the 4 claws and remove the sliding roof piece
LH and RH.
(c) Slide and remove the trim.
ALM092G
4. Remove the sliding roof sunshade stopper LH

(a) Remove the stopper.
5. Remove the sliding roof sunshade stopper RH
Hint:
ALM093G
6. Remove the sliding roof drive cable sub-assembly

Notice:
Do not disassemble the sliding roof drive cable
sub-assembly except when replacing it.
(a) Remove the 2 screws and 2 stoppers.
(b) Using a screwdriver, detach the 2 claws and slide the
rear roof drip channel rearward to remove it.
Hint:
ALM094G Tape the screwdriver tip before use.
(c) Hold down the window deflector.
ALM095G
Matchmark A (d) Place matchmarks on the sliding roof drive cable sub-as-
Matchmark B
sembly at locations A and B as shown in the illustration.
ALM096G
Protective tape (e) Using a screwdriver, align the matchmarks by sliding

the drive cable in the directions indicated by the arrow
Hint:
ALM097G
Reassembly
1. Install the sliding roof drive cable sub-assembly
(a) Hold down the window deflector.
Notice:
Make sure that the spring indicated by the arrow in
the illustration is securely installed.
ALM098G
(b) Using a screwdriver, slide the drive cable in the direc-

Protective tape tion indicated by the arrow in the illustration to install it.
Hint:
ALM099G
(c) Slide the rear roof drip channel forward and attach the
2 claws to install it.
Forward
ALM100G
(d) Install the 2 stoppers with the 2 screws.
ALM101G
Matchmark A 2. Adjust the sliding roof drive cable sub-assembly

Matchmark B
(a) Using a screwdriver, align the matchmarks by sliding
the drive cable in the directions indicated by the arrow
Protective in the illustration.
tape
Hint:
ALM102G
3. Install the sliding roof sunshade stopper LH

(a) Install the stopper.
4. Install the sliding roof sunshade stopper RH
Hint:
ALM093G
5. Install the sunshade trim sub-assembly

Forward (a) Insert the sunshade trim into the sliding roof housing.
(b) Attach the 4 claws to install the sliding roof piece LH
and RH.
(c) Install the 2 screws.
6. Install the sliding roof motor
(a) Install the sliding roof motor with the bolts.
(b) Attach the bracket claw to install the bracket.
ALM103G 7. Install the sliding roof lock catch plate LH
Installation
1. Install the sliding roof housing sub-assembly
(a) Temporarily install the housing with the bolts (vehicle
body side) and nuts.
(b) Fasten 8 nuts.
(c) Fasten the 8 nuts.
(d) Connect the 4 sliding roof drain pipes.
ALM104G
2. Install the sliding roof weatherstripping

(a) Install the sliding roof weatherstripping as follows:
(1) Attach each corner of the weatherstripping so that
each weatherstrip mark is aligned with the sliding
roof glass center mark. After attaching the entire
weatherstripping, check that all weatherstrip marks
are within the sliding roof glass end marks.
(2) Make sure the weatherstripping cutout is toward
the rear side of the vehicle and centered.
(3) Make sure the weatherstripping is securely in-
stalled as shown in the illustration.
ALM105G
3. Install the sliding roof glass sub-assembly

(a) Using a screwdriver, temporarily install the glass with
the 4 screws.
(b) Perform a level check.
(1) Check the difference in the level between the roof
panel and the upper surface of the weatherstrip-
ping when the sliding roof glass is fully closed.
(2) Perform a gap check. Check the gap between the
ALM090G roof panel and roof glass.
Notice:
The gap must be even all around.
4. Check for water leaks
(a) After adjusting the sliding roof glass sub-assembly,
check for water leaks. If there are any leaks, readjust
the sliding roof glass sub-assembly.
5. Install the sliding roof side garnish LH
(a) Attach the 5 claws to install the sliding roof side decora-
tion.
6. Install the sliding roof side decoration RH
Hint:
ALM089G
7. Install the rear roof air duct

8. Install the roof headlining
(a) Install the roof headlining
ALM088G
Circuit Diagram of the Sunroof Motor
ALM089G
MEMO
BO-�

Vehicle body
Engine Hood
Engine Hood.................................................................... BO-2
Engine Hood Lock Release Cable................................. BO-4
Door
Front Door....................................................................... BO-5
Rear Door......................................................................... BO-18
Lower Back Door............................................................ BO-31
Bumper
Front Bumper.................................................................. BO-36
Rear Bumper................................................................... BO-39
DOOR OUTER WEATHERSTRIPPING

Front door external weatherstripping LH..................... BO-41
Rear door external weatherstripping LH...................... BO-41
Trim strip
Roof Panel Trim Strip LH................................................ BO-42
Rocker Trim Panel LH..................................................... BO-42
License Plate Lamp Trim Panel..................................... BO-43
FUEL TANK DOOR

Fuel Tank Door Cable..................................................... BO-44
BO
BO-�
Engine Hood
Engine Hood
Adjustment
Hint:
Centering bolts are used to mount the engine hood hinge
and engine hood lock. The engine hood and engine hood
Centering bolt Standard bolt
lock cannot be adjusted with the centering bolts on. During
ALN001G
the adjustment, replace the centering bolt with a standard
bolt (with a washer).
1. Check the engine hood subassembly

(a) Check and confirm if the clearance is within the standard range.
ALN002G
Standard:
Position Measured value
A 4.0 mm
B 0 mm
2. Adjust the engine hood sub-assembly

(a) Adjust the engine hood horizontally and vertically.
(1) Loosen the 4 hinge bolts on the engine hood side.
ALN003G
Vehicle Body BO-�

(2) Adjust the clearance by moving the engine hood

to set it within the standard range.
Standard range (A): 4.0 mm
(3) After adjustment, tighten the hinge bolt at the side
of the engine hood.
Torque: 23 N·m
ALN004G
(b) Adjust the front height of the engine hood with the ad-
justing block.
(1) Rotate the adjusting block to align the engine hood
with the fender.
Hint:
Move the adjusting block up and down by rotating.
(c) Adjust the engine hood lock.
(1) Remove the clip and grille.
ALN005G
(2) Adjust the position of the engine hood lock to let

the lock catch into it smoothly.
(3) After adjustment, tighten the engine hood lock
bolt.
Torque: 7.0 N·m
ALN006G
BO-�
Engine Hood Lock Release Cable

Replacement
1. Remove engine hood lock release cable
(a) Open the engine hood.
(b) Remove the engine hood lock release handle from the
instrument panel.
(c) Remove the cable from the engine hood lock release
handle.
(d) Remove the bolts and engine hood lock bolt release
mechanism assembly.
ALN007G (e) Remove the cable from engine hood lock bolt release
mechanism assembly.
2. Install the engine hood lock release cable
Hint:
Different metals making direct contact will accelerate
corrosion. Make sure to use the correct fastening piece
to avoid premature corrosion.
(a) Install the cable onto the engine hood lock latch release
mechanism assembly.
(b) Install the engine hood lock latch release mechanism
assembly with the bolts.
(c) Install the cable onto the engine hood lock latch release
lever.
(d) Install the engine hood release lever onto the dash-
board.
(e) Close the engine hood.
Vehicle Body BO-�

Door
Front Door
Components
Front door glass sealing strip LH
Front door window LH
Front door waterproof front door

Front door rear lower frame sub-assembly LH
waterproof membrane LH
Front door triangular trim LH
Front door glass regulator sub-assembly LH
Front door internal weatherstripping LH
Front glass regulator motor

assembly LH
Front door interior
Front window main switch pull handle LH
panel LH
Front door trim
panel LH Plastic clip
Front window main

switch assembly LH
Front door trim panel bracket LH
Plastic clip
: Specified torque Front door speaker assembly LH
● non-reusable component
ALN008G
BO-�
Front door outside handle and frame LH
Front door outside rear view mirror LH
Front door weatherstripping RH Turn Signal

Light
Front door external

weatherstripping LH
Front door upper hinge LH
Front door retainer LH

Buffer pad
Front door lower hinge LH
Front door lock control knob
Front door lock control

knob clip
Front door lock cable mounting clip
Front door inside handle assembly LH
Front door speaker assembly LH
Front door unlock cable

Front door lock assembly LH
Front door lock actuator assembly LH
: Specified torque
○ pre-removed part
ALN009G
Vehicle Body BO-�

Adjustment
Hint:
• The operation sequence on the right side is the same as
the left one.
• Centering bolts are used to mount the door hinge to the
vehicle body and door. The door cannot be adjusted with
the centering bolts on. Substitute the centering bolts with
Centering bolt Standard bolt standard bolts (w/washers) when making adjustments.
ALN001G
1. Inspect front door panel sub-assembly LH

*: 160 mm from the end of the window frame; check the clearances A and B as illustrated in the cross-section.
ALN010G
Standard:
A 5.0 mm
B 6.5 mm
C 3.8 mm
D 3.8 mm
E 6 mm
F 6 mm
2. Adjust the front door panel sub-assembly LH

(a) Using SST, adjust the door horizontally and vertically by
loosening the door side hinge bolts.
(b) Tighten the door side hinge bolts after the adjustment.
Torque: 23 N·m
ALN011G
BO-�
(c) As shown in the illustration, horizontally and vertically

adjust the door by loosening the body side hinge bolts.
(d) Tighten the body side hinge bolts after the adjustment.
Torque: 23 N·m
ALN012G
(e) Adjust the striker position by slightly loosening the strik-

er mounting screws and hitting the striker with a plastic-
head hammer.
(f) Tighten the striker mounting screws after the adjust-
ment.
Torque: 23 N·m
Overhauling
ALN013G
Hint:
sequence. However, it only includes the installation se-
quence with additional information.
the left one.
Buckle 1. Remove the front door triangular trim LH

(a) Using a screwdriver, disengage the clip and claw and
remove the triangular trim.
Hint:
Claw
ALN014G
2. Remove front door inside pull handle LH

(a) Remove the screw and remove the inside pull handle.
ALN015G
Vehicle Body BO-�

3. Remove the front window main switch assembly LH

(a) Using a screwdriver, disengage the clip and claw, and
Clip
remove the front window main switch panel LH together
with the main switch.
Hint:
(b) Disconnect the switch connector.
Claw
(c) Remove the 3 screws and the switch from the front win-
ALN016G dow main switch panel LH.
Protective adhesive tape Clipp A 4. Remove the front door trim panel LH
(a) Remove the screw and clip A as shown in the illustration.
(b) Using a screwdriver, disengage the 7 clips.
Hint:
Screw
(c) Remove the trim panel upward.
Hint:
In order to prevent the door panel from being damaged,
: Buckle ALN017G use protective tape to cover the areas indicated by the
arrow marks in the illustration.
(d) Using a screwdriver, disengage the clips, and remove
the inner weatherstripping.
Hint:
5. Remove the front door inside handle assembly LH

Claw A
(a) Using a screwdriver, disengage the claw A as shown in
the illustration.
Hint:
(b) Move the inside handle in the direction indicated by the
arrow mark in the illustration.
(c) Disconnect the cable from the inside handle.
: Claw
ALN018G
6. Remove front door waterproof membrane LH

(a) Remove the 2 screws and bracket.
ALN019G
BO-��
(b) Remove the waterproof membrane.

Notice:
Remove the remaining tape on the door side.
Butyl Tape
ALN020G
7. Remove the front door outside rear view mirror LH

(a) Disconnect the rearview mirror connector.
(b) Remove the 3 nuts and mirror.
Notice:
Be careful when removing the nuts as the mirror
may fall and become damaged.
ALN021G
8. Remove the front door outer weatherstripping

LH (see page BO-41)
9. Remove the front door speaker assembly LH
ALN022G
10. Remove the front door glass LH

Hint:
Insert a shop rag inside the door panel to prevent the
glass from being scratched.
(a) Move the door glass until the bolts appear in the ser-
vice holes.
(b) Move the door glass until the bolts appear in the ser-
vice holes.
ALN023G Notice:
Be careful when removing the bolts as the glass
may fall and become damaged.
Vehicle Body BO-��
11
(c) Remove the door glass in the direction indicated by the

white arrow marks in the illustration.
Notice:
Be careful not to damage the glass.
(d) Remove the glass sealing strip.
ALN024G
11. Remove the front door glass regulator sub-assembly

LH
(a) Disconnect the glass regulator connector.
(b) Remove the 6 bolts and glass regulator.
Notice:
regulator may fall and become damaged.
Hint:
ALN025G Remove the glass regulator through the service hole.
12. Remove the glass regulator through the service

hole.
(a) Using a Torx Driver, remove the 3 screws and motor.
ALN026G
13. Remove the front door rear lower frame sub-assem-

bly LH
(a) Remove the bolt and frame.
Hint:
Remove the frame through the service hole.
ALN027G
14. Remove front door lock body assembly LH

(a) Disconnect the clip and outside locking link from the
outside handle.
(b) Disconnect the clip and lock open rod from the outside
handle.
BO-��
(c) Turn the control knob and remove it, as shown in the il-
Control Knob
lustration.
(d) Using a screwdriver, disengage the 2 claws and re-
move the clip.
Hint:
Buckle
Claw
ALN028G
(e) Remove the bolt.

(f) Using a Torx socket wrench, remove the 3 screws and
door lock.
Notice:
Be careful not to drop the door lock as it may be-
come damaged.
Hint:
Remove the door lock through the service hole.
Bolt
ALN029G (g) Remove the cable from the lock.
(h) Remove the 2 screws and actuator.
ALN030G
15. Remove the front door outside handle LH

(a) Remove the 2 bolts, handle, and the cylinder.
Notice:
Be careful when removing the bolts as the outside
handle may fall and become damaged.
(b) Unlock the cylinder by turning it.
(c) Remove the cylinder.
ALN031G
16. Remove the front door check LH

(a) Remove the 3 screws and door check.
Hint:
Remove the retainer via the inspection hole.
ALN032G
13
17. Remove front door sealing strip LH

(a) Using a clip remover, disengage the clips and remove
the sealing strip.
Hint:
Using a clip remover, disengage the clips and remove
the sealing strip.
18. Install the front door check LH

(a) Apply general grease to the sliding region of the retainer.
(b) Install the retainer onto the vehicle's door sheet with 2
bolts.
Torque: 5.5 N·m
(c) Apply adhesive to the thread of the bolt.
Binding agent (d) Install the retainer onto the vehicle's door sheet with
bolts.
ALN033G Torque: 23 N·m
19. Install the front door outside handle LH

(a) Install the cylinder to the handle.
(b) Lock the cylinder by turning it.
(c) Install the handle and the cylinder with the 2 bolts.
Torque: 5.5 N·m
ALN031G
20. Install the front door lock body assembly LH

(a) Install the actuator with the 2 screws.
ALN030G
(b) Apply MP grease to the sliding and rotating areas of the

door lock.
ALN034G
BO-��
(c) Install the bolt.

Torque: 5.0 N·m
Binding agent
(d) Apply adhesive to the threads of the 3 screws.
(e) Using a Torx socket wrench, install the door lock with
the 3 screws.
Torque: 5.0 N·m
(f) Connect the door lock connector.
Binding agent
ALN035G
(g) Install the lock open rod and outside locking link.
Control knob
(h) Install the clip.
(i) Attach the control knob in the direction indicated by the
white arrow mark in the illustration.
Buckle Hint:
After attaching the control knob, rotate it 90 degrees in
the direction indicated by the arrow marks in the illus-
tration.
ALN036G
21. Install the front door rear lower frame sub-assem-

bly LH
(a) Install the frame with the bolt.
Torque: 5.5 N·m
ALN027G
22. Install the front glass regulator motor assembly LH

(a) Using a Torx Driver, install the 3 screws and motor.
Torque: 5.5 N·m
ALN026G
15
23. Install the front door glass regulator sub-assembly

LH
(a) Apply MP grease to the sliding and rotating areas of the
glass regulator.
Notice:
Do not apply grease to the spring of the glass regu-
lator.
ALN037G
(b) Install the glass regulator with the 6 bolts.

Torque: 8.0 N·m
Notice:
Be careful not to drop the glass regulator as it may
become damaged.
(c) Connect the glass regulator connector.
ALN025G
24. Install the front door glass LH

(a) Install the glass sealing strip.
Notice:
(b) Insert the door glass into the door panel along the glass
sealing strips as indicated in the illustration.
ALN038G
(c) Install the door glass to the glass regulator with the 2
bolts.
Torque: 5.0 N·m
(d) Check the operation of the power window.
(1) Connect the power window switch to the wire har-
ness and turn the ignition switch ON.
(2) Use the UP and DOWN function several times.
ALN023G
BO-��
25. Install the front door speaker assembly LH

ALN022G
26. Install the front door outside rear view mirror LH

(a) Install the mirror with the 3 nuts.
Torque: 8 N·m
(b) Connect the mirror connector.
ALN021G
27. Install the front door waterproof membrane LH

(a) Apply butyl tape to the door as shown in the illustration.
(b) Install a new waterproof membrane.
Hint:
Butyl Tape • When installing the waterproof membrane, pull out
the links and connectors through the waterproof
membrane.
• There should be no wrinkles or folds after attaching
the waterproof membrane.
ALN039G
• After attaching the waterproof membrane, check the
sealing quality.
(c) Install the bracket with the 2 bolts.
ALN019G
28. Install the front door inside handle assembly LH

Claw A
(a) Install the cable to the inside handle.
(c) Attach the claw A.
: Claw
ALN018G
17
Protective adhesive tape Clip A 29. Install the front door trim panel LH
(a) Install the inner weatherstripping and attach the clips.
(b) Install the trim panel.
(c) Attach the 7 clips.
(d) Install the screw and clip A as shown in the illustration.
Screw
: Buckle ALN017G
30. Install the rear door inside pull handle

(a) Install the rear door inside pull handle and attach it with
Clip
a screw.
(b) Connect the switch connector.
(c) Attach the clip and claw to install the window main
switch.
Claw
ALN016G
31. Install the front door inside pull handle LH

(a) Install the front door inside pull handle and attach it with
a screw.
ALN015G
Buckle 32. Install the front door triangular trim LH

(a) Attach the clip and claw to install the triangular trim.
: Claw
ALN014G
BO-��
Rear Door
Components
Rear door quarter window glass LH
Rear door window LH
Rear quarter window glass

sealing strip LH
Rear door
window LH
weatherstripping
Rear door window division Rear door glass regulator

bar sub-assembly LH motor assembly LH
Rear door glass regulator sub-assembly LH
Rear door internal weatherstrip LH
Rear door inside pull Rear door waterproof
handle LH membrane LH
Rear door trim panel bracket

Rear door window
switch panel LH
Rear window switch assembly LH
Rear door trim panel LH
Plastic clip
: Specified torque
ALN040G
19
Rear door outside handle and frame LH
Rear door weatherstripping LH
Rear door external weatherstripping LH
Rear door upper hinge LH
Rear door check
Rear door open cable LH
Rear door inside handle assembly LH
Rear door lock

assembly LH Rear door lower hinge LH
Rear door actuator assembly LH
Rear door lock cable installation

buckle Rear door lock Rear door woofer
control knob assembly LH
Rear door control link assembly No.2 LH
Rear door lock
control knob clip
Rear door rod assembly LH

Door link control bellcrank
: Specified torque
○ pre-removed part
ALN041G
BO-��
Adjustment
Hint:
the left one.
standard bolts (w/washers) when making adjustments.
Centering bolt Standard bolt

ALN001G
1. Inspect the front door panel sub-assembly LH

*: 160 mm from the end of the window frame; check the clearances A and B as illustrated in the cross-section.
ALN096G
Standard:
A 5.0 mm
B 6.5 mm
C 3.8 mm
D 3.8 mm
E 6 mm
F 6 mm
2. Adjust the front door panel sub-assembly LH

(a) Remove the lower decoration.
(b) As shown in the illustration, horizontally and vertically
adjust the door by loosening the body side hinge nuts.
(c) Tighten the body side hinge nuts after the adjustment.
Torque: 23 N·m
ALN042G
21
(d) Horizontally and vertically adjust the door by loosening

the door side hinge bolts.
(e) Tighten the door side hinge bolts after the adjustment.
Torque: 23 N·m
ALN043G
(f) Adjust the striker position by slightly loosening the strik-

head hammer.
(g) Tighten the striker mounting screws after the adjust-
ment.
Torque: 23 N·m
ALN044G
Overhauling
Hint:
the left one.
1. Remove the rear door inside pull handle LH

(a) Remove the screw and remove the inside pull handle.
ALN015G
2. Remove the rear window switch assembly LH

(a) Using a screwdriver, disengage the 2 claws labeled A in
the illustration. Remove the rear window switch panel
and the switch.
(b) Disengage the 2 claws labeled B in the illustration. Re-
move the switch.
ALN045G
BO-��
Protective 3. Remove the rear door trim panel LH

adhesive
tape (a) Remove the screw as shown in the illustration.
(b) Using a clip remover, disengage the 7 clips.
(c) Remove the trim panel upward.
Screw Hint:
In order to prevent the door panel from being damaged,
use protective tape to cover the areas indicated by the
arrow marks in the illustration.
: Buckle (d) Using a screwdriver, disengage the clips and remove
ALN046G
the inner weatherstripping.

Hint:
4. Remove rear door inside handle assembly LH

Claw A
(a) Using a screwdriver, disengage the claw A as shown in
the illustration.
Hint:
(c) Disconnect the cable from the inside handle.
: Claw
ALN018G
5. Remove the rear door waterproof membrane LH

(a) Remove the 2 screws and bracket.
ALN019G
(b) Remove the waterproof membrane.

Notice:
Remove the remaining tape on the door side.
Butyl Tape
ALN047G
6. Remove the front door outer weatherstripping LH

(see page BO-41)
23
7. Remove the rear door woofer assembly LH

ALN022G
8. Remove rear door window division bar sub-assem-

bly LH
Hint:
glass from being scratched.
Notice:
(a) Lower the glass as far as it can go.
ALN048G (b) Remove the glass sealing strip.
(c) Remove the 2 bolts and screw.
(d) Rotate the division bar and remove it, as shown in the
illustration.
ALN049G
9. Remove the rear door quarter window glass LH

(a) Remove the window glass in the direction indicated by
the white arrow mark in the illustration.
Notice:
(b) Remove the quarter window glass sealing strip.
ALN050G
10. Remove the front door glass LH

(a) Carefully pull up the door glass out of the door panel.
Hint:
door glass from being scratched.
BO-��
11. Remove the front door glass regulator sub-assembly

LH
(a) Disconnect the glass regulator connector.
(b) Remove the 4 bolts and glass regulator.
Notice:
regulator may fall and become damaged.
Hint:
ALN051G Remove the glass regulator through the service hole.
12. Remove the glass regulator through the service

hole
(a) Using a Torx Driver, remove the 3 screws and motor.
ALN052G
13. Remove the rear door lock body assembly LH

Rear Door Connecting
(a) Disconnect the clip and connecting rod in the direction
Clip Rod LH indicated by the white arrow marks in the illustration.
ALN053G
(b) Turn the control knob and remove it, as shown in the il-
Control knob
lustration.
(c) Using a screwdriver, disengage the 2 claws and re-
move the buckle.
Hint:
Buckle
Claw
ALN028G
(d) Using a screwdriver, disengage the 4 claws and re-

Connecting Rod move the bellcrank, the pull rod, and the connecting
rod.
Hint:
Claw
(e) Remove the pull rod and the connecting rod.
Pull rod Bellcrank

ALN054G
25
(f) Using a Torx socket wrench, remove the 3 screws and

door lock.
Notice:
Be careful when removing the bolts as the door
lock may fall and become damaged.
Hint:
ALN055G
(g) Remove the 2 screws and actuator.
ALN056G
14. Remove the rear door outside handle LH

(a) Remove the bolt, nut, and outside handle frame.
Nut (b) Remove the bolt and handle.
Bolt
Notice:
Be careful when removing the bolts as the outside
handle may fall and become damaged.
ALN057G
15. Remove the rear door check LH

(a) Remove the 3 screws and door check.
Hint:
Remove the retainer via inspection hole.
ALN058G
16. Remove the rear door sealing strip LH

(a) Using a clip remover, disengage the clips and remove
the sealing strip.
Hint:
Using a clip remover, disengage the clips and remove
the sealing strip.
BO-��
17. Install the rear door check LH

(a) Apply general grease to the sliding area of the retainer.
(b) Install the retainer onto the vehicle's door sheet with 2
bolts.
Torque: 5.5 N·m
(c) Apply adhesive to the thread of the bolt.
Binding agent
(d) Install the retainer onto the vehicle's door sheet with
bolts.
ALN059G Torque: 23 N·m
18. Install the rear door outside handle LH

(a) Install the handle with the bolt.
Torque: 5.0 N·m
(b) Install the outside handle with the bolt and nut.
Torque: 5.0 N·m
Bolt Nut
ALN057G
19. Install the rear door lock body assembly LH

(a) Install the actuator with the 2 screws.
ALN056G
(b) Apply MP grease to the sliding and rotating areas of the

door lock.
ALN060G
27
(c) Apply adhesive to the threads of the 3 screws.

(d) Using a Torx socket wrench, install the door lock with
the 3 screws.
Torque: 5.0 N·m
(e) Connect the door lock connector.
ALN055G
(f) Install the Bellcrank,, the

the pull rod and the connecting rod.
pull rod and the connecting rod.
Connecting Rod
Rear Door Connecting Rod LH Bellcrank

ALN061G
(g) Install the clip.

Control knob
(h) Attach the control knob in the direction indicated by the
white arrow mark in the illustration.
Buckle Hint:
After attaching the control knob, rotate it 90 degrees in
the direction indicated by the arrow marks in the illus-
tration.
ALN036G
(i) Connect the connecting rod in the direction indicated by

the arrow marks in the illustration.
Clip Connecting Rod
ALN053G
20. Install the rear glass regulator motor assembly LH

(a) Using a Torx Driver, install the 3 screws and motor.
Torque: 5.5 N·m
ALN052G
BO-��
21. Install the rear door glass regulator sub-assembly

LH
(a) Apply MP grease to the sliding and rotating areas of the
glass regulator.
Notice:
Do not apply grease to the spring of the glass regu-
lator.
ALN062G
(b) Install the glass regulator with the 4 bolts.

Torque: 8.0 N·m
(c) Connect the glass regulator connector.
Notice:
Be careful not to drop the glass regulator as it may
become damaged.
ALN051G
22. Install the rear door glass LH

Notice:
(a) Install the door glass into the door panel.
Hint:
door glass from being scratched.
23. Install the rear door quarter window glass LH

(a) Install the quarter window glass sealing strip to the
glass.
Notice:
(b) Install the quarter window glass in the direction indi-
cated by the white arrow mark in the illustration.
(c) Mount the door glass to the window regulator along the
ALN063G glass weatherstripping.
24. Install the rear door window division bar sub-as-

sembly LH
(a) Insert the division bar into the door panel and then ro-
tate it 90°, as shown in the illustration.
Torque: 8.0 N·m
ALN064G
29
(b) Install the division bar with the 2 bolts and screw.
Torque: 5.0 N·m
(c) Install the glass sealing strip.
(d) Check the operation of the power window.
(1) Connect the power window switch to the wire har-
ness and turn the ignition switch ON.
(2) Use the UP and DOWN function several times.
ALN048G
25. Install the rear door woofer assembly LH

ALN022G
26. Install rear door waterproof membrane LH

(a) Apply butyl tape to the door as shown in the illustration.
(b) Install a new waterproof membrane.
Butyl Tape
Hint:
• When installing the waterproof membrane, pull out
the links and connectors through the waterproof
membrane.
• There should be no wrinkles or folds after attaching
ALN065G the waterproof membrane.
• After attaching the waterproof membrane, check the
sealing quality.
(c) Install the bracket with the 2 bolts.
ALN019G
27. Install the rear door inside handle assembly LH

Claw A
(a) Install the cable to the inside handle.
(c) Attach the claw A as shown in the illustration.
: Claw
ALN018G
BO-��
Protective 28. Install the rear door trim panel LH

adhesive
tape (a) Install the inner weatherstripping and attach the clips.
(b) Install the trim panel downward.
(c) Attach the 7 clips.
Screw (d) Install the screw as shown in the illustration.
: Buckle
ALN046G
29. Install the rear window switch assembly LH

(a) Attach the 2 claws labeled B in the illustration to install
the switch to the switch panel.
(b) Attach the 2 claws labeled A in the illustration to install
the window switch assembly.
ALN045G
30. Install the rear door inside pull handle

(a) Install the rear door inside pull handle and attach it with
a screw.
ALN015G
31
Lower Back Door

Components
High-mounted brake lamp assembly
Back door hinge assembly RH

Back door hinge
assembly LH
Back door window

glass groove RH
Back door window

glass groove LH
Back door air spring RH
Back door air spring LH Back door

lower stop-
per RH Door pull handle
Back door lower stopper LH
License plate lamp trim

panel assembly
Rear wiper assembly
Back door outside handle switch

assembly
Rear wiper motor

assembly
Back door striker assembly

Back door lock assembly
Back door shield
: Specified torque
ALN066G
BO-��
Adjustment
Hint:
the left one.
Centering bolt Standard bolt standard bolts (w/washers) when making adjustments.
ALN001G
1. Inspect the back door panel sub-assembly

ALN067G
Standard:
A 7 mm
B 0 mm
C 5 mm
D 3 mm
E 5 mm
F 10 mm
2. Adjust the back door panel sub-assembly

(a) Remove the roof headliner (see page IR-64).
(b) As shown in the illustration, horizontally and vertically
adjust the door by loosening the body side hinge nuts.
(c) Tighten the body side hinge nuts after the adjustment.
Torque: 23 N·m
ALN068G
33
(d) Horizontally and vertically adjust the back door by loos-

ening the back door side hinge bolts.
(e) Tighten the back door side hinge bolts after the adjust-
ment.
Torque: 23 N·m
ALN069G
(f) Remove the back door rocker shield (see page IR-63).
(g) Adjust the striker position by slightly loosening the strik-
head hammer.
(h) Tighten the striker mounting screws after the adjust-
ment.
Torque: 11.5 N·m
ALN070G
Overhauling
Hint:
quence. However, it only includes the installation sequence
with additional information.
1. Remove the back door shield
(a) Using a clip remover, remove the 13 clips and cover.
(see page BO-43)
3. Remove the high-mounted brake lamp assembly
(see page IR-14)
4. Remove the rear wiper motor assembly (see page
ET-9)
5. Remove the back door lock assembly
(a) Disconnect the lock connector.
(b) Remove the 3 bolts and lock.
Hint:
ALN071G 6. Remove the back door window glass groove LH

(b) Using a heat light, heat the glass groove.
Heating temperature: 20 to 30 °C
Notice:
Do not heat the body and groove excessively.
(c) Using a screwdriver, remove the groove.
Hint:
7. Remove the back door window glass groove RH
(a) Use the same procedures for the RH side and LH side.
BO-��
8. Remove the door pull handle

move the pull handle.
Hint:
: Claw ALN072G
9. Remove the back door air spring assembly LH (see

page BO-35)
10. Remove the back door air spring assembly RH (see
page BO-35)
11. Remove the back door stopper lower
(a) Remove the bolts, left side, and right side stoppers.
12. Install the back door stopper low
(a) Install the left side and right side stoppers with the bolts.
Torque: 12.5 N·m
13. Install the back door window glass groove LH
(a) Clean the contact surface of the door with a shop rag
saturated with white gasoline.
(b) Using a heat light, heat the door and groove.
Heating temperature:
Items Temperature
Door 40 to 60 °C
Glass Groove 20 to 30 °C
Notice:
Do not heat the door and groove excessively.
(c) Remove peeling paper from the glass groove face.
(d) Install the glass groove and 2 clips.
14. Install back door window glass groove RH
(a) Use the same procedures for the RH side and LH side.
15. Install back door lock assembly

(a) Install the door lock with three bolts.
Torque: 12.5 N·m
(b) Connect the door lock connector.
ALN071G
Back Door Air Spring

Replacement
Hint:
the left one.
35
1. Remove back door air spring assembly LH

(a) Remove bolt A from the trunk door.
Hint:
Support the back door with your hands when removing
the back door spring.
(b) Remove the 2 bolts B and the air spring from the ve-
hicle body panels.
ALN073G
2. Install the back door air spring assembly LH

(a) Install the air spring with bolts.
Torque:
Bolt A: 22.0N·m
Bolt B: 8.0N·m
Disposal
Hint:
The operation sequence at the right side is the same as the
left one.
1. Dispose of back door air spring assembly LH
(a) Extract the piston rod and attach the air spring onto the
bench clamp horizontally.
(b) Wear the safety glasses, cut the part between A and B
(as shown in the figure) with a metalworking saw, and
release the gas gradually.
Specifications:
ALN074G
a 80 mm
b 20 mm
Notice:
Be careful to cover the area that is being cut as
there is a possibility that metal debris could be
blown out by the gas. (The gas is colourless,
odourless, and innocuous.)
BO-��
Bumper
Front Bumper
Components
Front bumper body
Front bumper upper grille body

Front bumper body
Connecting bracket RH Connecting bracket LH
Hook cover plate
Front bumper lower grating
ALN075G
37
Replacement
Hint:
quence.
1. Remove the front bumper upper grille body

(a) Remove the 1 clip and 2 screws and remove the front
bumper upper grille body.
ALN076G
2. Remove the front fender lining LH

(b) Partially remove the fender lining.
Hint:
Partially remove the fender lining and then remove the
front bumper
body.
3. Remove the front fender lining RH
ALN077G Hint:
The sequence of the right side is the same as the left
side.
(a) Remove the connecting bracket LH with a screwdriver.
Hint:
The procedures for removing the right side are the
ALN078G
6. Remove the front bumper body

(a) Disconnect the fog lamp connector.
(b) Remove the clip and the 2 bolts from the upper side of
the bumper body.
(c) Using a screwdriver, disengage the 2 claws and re-
move the 2 bolts, 6 screws, and bumper body.
Hint:
Apply protective tape to the front fender.
ALN079G
BO-��
7. Remove the front bumper lower grille

the lower grille of the bumper.
Hint:
ALN080G
8. Remove the front fog lamp assembly LH

(a) Remove the 3 screws and then remove the front fog
lamp assembly LH.
9. Remove the front fog lamp assembly RH
(a) Remove the 3 screws and then remove the front fog
lamp assembly RH.
ALN081G
10. Remove the front bumper cross member assembly

(a) Remove the 2 nuts from the front bumper bracket LH.
(b) Remove the 2 nuts from the front bumper bracket RH.
(c) Remove the front cross member from the front bumper
bracket LH and the front bumper bracket RH.
ALN082G
39
Rear Bumper
Components
Rear bumper body
Rear bumper buffer block Rear mounting bracket
Hook cover
plate
Rear exhaust shield trim

panel
Front mounting bracket
Rear exhaust upper shield
Rear bumper body
Rear exhaust lower shield

Rear exhaust lower bracket
ALN083G
BO-��
Replacement
Hint:
the reverse order.
1. Remove rear bumper mud guard LH
Hint:
2. Remove the rear bumper mud guard RH
Hint:
Follow the same procedures as the LH side.
: Claw
ALN084G
3. Remove the rear bumper body

Protective adhesive tape
move the 6 bolts and the bumper body.
Hint:
(b) Disconnect the harness of the rear lamp and back-up
Claw lamp, connector, and clip.
: Claw
ALN085G
4. Remove the back-up lamp assembly (see page

IR-17)
5. Remove the rear fog lamp assembly
(a) Remove the screws and the rear fog lamp.
ALN086G
6. Remove the rear bumper cross member assembly

(a) Remove the 3 nuts from the rear bumper bracket LH.
(b) Remove the 3 nuts from the rear bumper bracket RH.
(c) Remove the rear cross member from the rear bumper
bracket LH and the rear bumper bracket RH.
ALN087G
41
DOOR OUTER WEATHERSTRIPPING

Front door external weatherstripping LH
Replacement
Hint:
sequence.
• The sequence on the right side is the same as the left side.
1. Remove the rear door outer weatherstripping LH

(a) Apply protective tape under the outer weatherstripping.
(b) Using a moulding remover, pry out the weatherstripping
Hint:
Moulding Protective adhesive tape
Tape the remover tip before use.
Removal
Adhesive Tape ALN088G
Rear door external weatherstripping LH

Replacement
Hint:
sequence.
1. Remove rear door outer weatherstrip LH

(a) Apply protective tape under the outer weatherstripping.
(b) Using a moulding remover, pry out the weatherstripping
Protective Hint:
adhesive tape
Moulding Removal
Tape the remover tip before use.
Adhesive Tape ALN089G

BO-��
Trim strip
Roof Panel Trim Strip LH
Replacement
Hint:
The sequence on the right side is the same as the left side.
Mount 1. Remove the roof panel trim strip LH

(a) Apply the protective tape to the circumference of the
trim strip.
(b) Using a moulding remover, disengage the supporting
seat both in the front and rear ends of the trim strip,
and then remove the trim strip.
Adhesive Tape 2. Install the roof panel trim strip LH
(a) Install the roof panel trim strip LH.
ALN090G (b) Using a heat light, heat the supporting seat installation
surfaces of the body and the trim strip.
Heating temperature:
Items Temperature
Vehicle Body 40 to 60 °C
Trim strip 20 to 30 °C
Notice:
Do not heat the trim strip and body excessively.
Front side (c) Set the supplied clips in the positions as shown in the il-
lustration and press-fit those clips by hand to install them.
Notice:
The installation of the trim strip should be carried
out when 30 minutes or more have passed after
Rear side
press-fitting the clips.
Hint:
• Initial hardening time: 30 minutes
ALN091G • Ideal hardening time: 24 hours
Rocker Trim Panel LH

Replacement
Hint:
sequence.
1. Remove the rocker trim panel body LH
(b) Remove the front cover and rear cover of the rocker
trim panel LH and the 2 bolts.
(c) Disengage the 6 clips and remove the moulding.
ALN092G
43
License Plate Lamp Trim Panel

Replacement
Hint:
quence.
(a) Remove the 2 nuts, 2 clips, and 1 connecting bolt.
ALN093G
(b) Remove the 4 screws, back door opener switch, and

the 2 license lamps.
ALN094G
BO-��
FUEL TANK DOOR

Fuel Tank Door Cable
Removal:
1. Open the luggage room.
2. Remove the luggage room trim panel.
3. Remove the luggage room trim panel.
4. Remove the B pillar lower seat belt bolt and the fix-
ture.
5. Remove the clip of the fuel tank door cable.
6. Remove the bolt of the fuel tank door cable handle.
ALN095G 7. Disconnect the cable from the handle.
8. Remove the driver's seat.
9. Remove the front and rear door trim panel LH and
the B pillar lower decoration LH.
10. Move the carpet LH away.
11. Remove the cable.
Installation:
1. Pull the cable through the luggage room to the pas-
senger room.
2. Put the carpet LH back.
3. Install the front and rear door trim panel LH and the
B pillar lower decoration LH.
4. Install the driver's seat.
5. Connect the cable to the handle. Special Note: Dif-
ferent metals making direct contact will accelerate
corrosion. Make sure to use the correct fastening
piece to avoid premature corrosion.
6. Install the bolt of the fuel tank door cable handle.
7. Install the clip of the fuel tank door cable.
8. Install the B pillar lower seat belt fixture with the
bolt.
Tighten the bolt of the lower B pillar seat belt fixture.
Torque: 38 N·m
9. Connect the cable to the filler cap.
10. Install the luggage room trim panel.
11. Close the luggage room.
EWD-�

Circuitry
Basic Information About the Electrical System

Terminology and Symbol Table.................................... EWD-3
Electrical System Schematics Instructions................. EWD-6
Areas of Importance in Circuit Maintenance............... EWD-8
Circuit inspection steps................................................ EWD-8
Ground Point
Ground Point Definition and
Position Diagram........................................................... EWD-9
Key Electrical Components Module
Key Electrical Components Module Schematics........ EWD-11
Cab fuse box (No.1 fuse box)....................................... EWD-13
Engine Compartment Fuse Box
(No.2 fuse box)............................................................... EWD-14
Wiring Diagram
Engine compartment wire harness.............................. EWD-15
Dashboard wire harness............................................... EWD-16
Trunk Door Wire Harness.............................................. EWD-17
Front Door Wire Harness LH......................................... EWD-18
Rear Door Wire Harness LH.......................................... EWD-18
Floor Wire Harness........................................................ EWD-19
Vehicle Body Wire Harness........................................... EWD-20
Connector
Wire harness connector & Connector
numbered diagram......................................................... EWD-21
Wire Connector Terminal Function Diagram............... EWD-23
Connectors List.............................................................. EWD-29
General Circuit Diagram
Power & Starter Circuit.................................................. EWD-38
Airbag Circuit................................................................. EWD-39
ABS Circuit..................................................................... EWD-40
Combination Meter Circuit............................................ EWD-41
EWD
EWD-�

Air Conditioning and

Defrosting System Circuit............................................. EWD-42
Wiper and Washer Motor System Circuit..................... EWD-43
Electronic Rearview Mirror Circuit............................... EWD-44
CD System Circuit.......................................................... EWD-45
Sound & Entertainment System................................... EWD-46
Bluetooth System.......................................................... EWD-47
Electric AC...................................................................... EWD-48
Normal Glass Regulator................................................ EWD-49
Seat Heating................................................................... EWD-50
Sunroof, Headlight Height Adjustment........................ EWD-51
TCU Transmission Control System.............................. EWD-52
Electric Injection ECU Control System Circuit............ EWD-53
Light, signal alarm system circuit................................ EWD-54
Central Door Locking and Window
Regulator System Circuit.............................................. EWD-55
Circuitry EWD-�

Basic Information About the Electrical System

Terminology and Symbol Table
Symbols used in the Great Wall vehicle's circuitry diagram are as follows:
Battery Ground
Stores chemical en- This indicates the point
ergy and converts it into connecting the power
electric energy. Provides supply negative pole and
DC for each circuit of the vehicle body, and thus a
vehicle. loop is provided for the
circuit. If the ground is not
available, then the current
can not form a loop.
Capacitor Engine speed sensor
This is a small-size stor- Inspects the speed of the
age device for temporary crankshaft and provides
electricity. it to the ECU to serve
as a reference signal
confirming ignition timing
and working sequences.
Cigarette lighter Knocking sensor
This is an electrical This is installed on the
resistance heating ele- engine block for detect-
ment. ing when an engine be-
gins knocking and then
provides it to the ECU
for the adjustment of the
ignition advance angle
based on this signal.
Circuit breaker Horn
The circuit breaker is a This is an electronic com-
switch which can be used ponent emitting an HF
repeatedly. If too much audio frequency signal.
current flows through
it, the circuit breaker
will heat up and discon-
nect. After cooling, some
breakers will automati-
cally reset and conduct
electricity, while others
must be reset manually.
Diode Ignition coil
This is a semiconductor This converts low-volt-
allowing current to flow age DC to high-voltage
unidirectionally only. ignition current that
ignites the spark plug.
EWD-�
Zener diode Lamp

With a specified voltage, The current flowing
the diode only allows through the filament will
the current to flow unidi- heat up and light the fila-
rectionally and blocks it ment.
from flowing in reverse.
If the specified voltage
is exceeded, it will divert
the residual voltage. It
can simply serve as a
voltage regulator.
Photosensitive diode LED ( Light Emitting Di-
A photosensitive diode is ode)
a semiconductor which These diodes are differ-
controls the current on ent from common lamp.
the basis of light intensity. They are based on the
current and glow without
heat generation.
Pump Analogue meter
This is a device that The current will start a
vacuums or discharges solenoid coil in order to
gas or liquids. move the probe. Then
a corresponding display
relative to the backgroud
scale will be provided.
Fuse Digital meter
This is a thin metal sheet. The current starts one
If an over-rated current or several LED, LCD,
flows through it, it will or fluorescent displays.
melt and the circuit will be Then a relative or digital
protected from damage display will be provided.
( Medium current fuse) by breaking the current.
Safety fuse Motor
This is a heavy gauge This is a power device
wire for the strong current converting electrical
circuitry. If an over-rated energy to mechanical
current flows through it, it energy, especially for the
will melt and the circuit will rotation movement.
(For high current fuse be protected. The num-
safety fuse) ber indicates the cross-
section area of the wire.
Relay Speaker
Basically, #1 is normally This is an electrical de-
1. Normally closed or the electromag- vice generating sound-
netic operation switch of wave on the basis of
closed #2 is normally opened. current.
The current flowing Manual switch
2. Normally through the small coil Opens or closes the
will produce an electro- circuit to stop or circulate
open 1. Normally
magnetic field to open or the current in #1 or #2.
close the affiliated switch. open
Double-throw relay 2. Normally
This is a relay in which closed
the current flows through
one group contact or that
of another group.
Circuitry EWD-�

Resistor Double-throw switch

This is an electronic ele- This is a switch in which
ment having fixed resis- the current constantly
tance, which is installed flows through one group
on the circuit to drop the contact or that of another
voltage to a specified group.
value.
Tapped resistor Ignition switch
This is a resistor having This is a key switch,
two or many different which have many posi-
non-adjustable resis- tions to make each cir-
tance values. cuit operable, especially
Sliding resistor or vari- for the primary ignition
circuit.
able resistor
This is a control resistor
whose resistance ratio is
adjustable.
Sometimes it is also
called a potentiometer or
rheostat.
Sensor (Thermistor) Wiper stop switch
This resistor can change When the wiper switch is
its resistance according off, this switch will return
to variable temperatures. to the stopped position
via the wiper.
Speed sensor Transistor
The flux of induction This is a typical solid-
coils will change along state circuit device being
with the concave and used as an electronic re-
convex configuration of lay. It breaks or conducts
the tooth profile accord- the current according to
ingly and will induce the the voltage provided by
AC signal on the induc- the "base".
tion coils.
Short circuit pin Wiring
This is used to provide In the circuit diagram,
an uninterrupted connec- 1. not inter- the wiring is usually
tion in the junction box. connected shown in a straight line.
If there is no black round
point at the intersection
Solenoid valve as shown in (1), the wir-
This is a solenoid coil, 2. inter- ing is not inter-connected.
and one magnetic field connected If there is a black round
will form when the cur- point or octagonal mark
renct flows through it. at the intersection
as shown in (2), the wir-
ing is inter-connected.
EWD-�
Electrical System Schematics Instructions

1. Configuration introduction
There are three configurations for the Great Wall COOL BEAR vehicle: Luxury, Elite, and Roof model.
The wire harness is divided into 2 types. One is called a non-jam protection comfortable model for com-
fort and Elite model, and the other is called a roof type for the roof style. These two configurations are
commonly used in most of the contents of the manual. The part contents that are only for the non-jam
protection Luxury model have been marked in the manual; please note the difference when repairing.
2. Fuse box and power supply introduction
Theft
deterrent
Relay
ECU6
Connect-
ed ABS
ECU#1
Terminal
Ignition switch
Shift
position
Motor 40A
ALO001G
The fuse box located inside the left side of the dashboard is the cab fuse box. The other one inside
the left side of the engine compartment is the engine compartment fuse box.
• 30a represents a power cord for normal power, which is from the battery positive fuse box-60 A.
• 30b represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 30c represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 15a represents a power cord for small-capacity electronics. When the ignition switch is in the ON
position, power is supplied by IG relay.
• 15b represents a power cord for small-capacity electronics. When the ignition switch is in the ON
position, power is supplied directly by ignition switch IG2.
• X represents a power cord for small-capacity electronics. When the ignition switch is in the ACC
position, power is supplied by the ACC relay.
3. Connector Terminal
(a) Negative connector pin number
Arranged from upper left to lower right.
(b) Positive connector pin number
Arranged from upper right to lower left.
ALO002G
Circuitry EWD-�

(c) Differences between the positive and negative connec-

tors.
The differences lie mainly in the different types of inte-
rior pins.
(1) Every connector is indicated by its engaging part
and locked on the top.
(2) Please pull out the connector, instead of its wires.
Caution:
Before removing the connector, please check its
ALO003G type first.
4. Disconnection of the connector

To disconnect the connector, remove the connector instead of the wire harness.
Hint:
Before disconnection, please check its type first.
ALO004G
5. Wire's color and sectional area (mm2)

B— Black W— White R— Red Bl— Blue Br— Brown Y— Yellow
G— Green P— Pink Or— Orange V— Violet Lg— Light green Gr— Gray
In addition: the Double-Color wire is indicated by adding a back slash (/) between the letters which
stand for two colors. The letter before the "/" indicates a main color, and the one behind the "/" indi-
cates an assistant color.
For example: 0.5 Bl/R indicates that the main color of the lead is blue and the assistant color is red.
Sectional area is 0.5 mm2.
EWD-�
Areas of Importance in Circuit Maintenance

1. Before operating any electronic devices and when tools or maintenance devices could eas-
ily make contact with an uncovered electronic terminal, please make sure to turn the ignition
switch to the LOCK position and then disconnect the battery's negative cable to avoid injury or
vehicle damage. When the ignition switch is in the ON position, please do not disconnect the
battery's connecting wire or take out the power's fuse, regardless if the engine is running or
not. Otherwise, it would seriously damage the ECU and related micro-electronic devices such
as sensors.
2. When changing the fuse, please make sure that the new fuse possesses the proper current rat-
ing and is not above or below this rating.
3. When repairing the wire harnesses of the airbag and pretensioner, only specified contact
points, plugs, and wires are allowed to be used.
4. Before repairing the wire harness, make sure to eliminate any factor that might cause damage,
for example, the edge of a vehicle body part is too sharp or the used electronics are damaged
or corroded.
5. Shielded wires should not be repaired, it must be renewed entirely once it is damaged.
6. Unless it is specified during the test, please do not use an analog multimeter to test the ECU
and sensor, instead use a high-impedance digital multimeter (internal resistance should be ≥
10 kΩ) or a vehicle multimeter for inspection.
7. When inspecting the connector with a digital multimeter, take the waterproof rubber cover
off the connector and insert the test pen snugly along the connecting terminal. Don't use too
much force, as to avoid cracking the connector.
Circuit inspection steps

The principle of troubleshooting is to confirm the "Location in Question. "Once the possible cause is con-
firmed, the components that need to be inspected are limited to the components that are related to the
possible cause. The confirmed possible cause should be based on theory and be supported by facts, but
not just by intuition. If one tries to solve the problem but does not adopt the proper troubleshooting steps, it
may make the problem worse. At that point, the possible cause not only can't be confirmed, but also main-
tenance can't be performed properly. Troubleshooting should adhere to the four steps below:
1. Observe the symptoms carefully, inspect if there is anything else abnormal, and record it.
2. While confirming the location in question, study the circuitry diagram carefully, and regard it
as a whole system in order to understand the circuitry. Thorough knowledge of switches, re-
lays, and other electronic components is obligatory for proper analysis.
3. Inspect and eliminate the problems one by one until the cause is found.
4. After the malfunction is fixed, make sure to check if the inspected system is working properly
and also check if maintenance may have caused any new problems.
Circuitry EWD-�

Ground Point
Ground Point Definition and Position Diagram
The body ground point is a place connecting the ground cable and the vehicle body. The ground cable is
attached to the vehicle body's steel plate by putting the bolt through the hole at ground cable terminal and
the nut on the body's steel plate.
The ground point positions are shown below:
ALO005G
EWD-��
ALO006G
Number Ground position Remarks

G01, G02 Inside the engine compartment's left side fender Engine compartment's wire harness
G03 Inside the engine compartment's right side fender Engine compartment's wire harness
G04, G05 Wire harness fixture under the right A-pillar Engine & dashboard wire harness
G06 Wire harness fixture under the left A-pillar Meter wire harness
G06 On the dashboard brace reinforcement Meter wire harness
G07 Rear fender trim LH Vehicle body wire harness
G08 Rear fender trim RH Vehicle body wire harness
G09 Near rear wiper motor Trunk door wire harness assembly
Circuitry EWD-��
11
Key Electrical Components Module

Key Electrical Components Module Schematics
The main electrical element module contains a cab fuse block, engine compartment fuse block, engine
ECU, airbag ECU, theft deterrent ECU, central lock controller, and back-up radar ECU. The position of key
electrical components module is as shown in the figure:
Positive fuse box

Engine
compart-
ment
fuse box
ALO007G
EWD-��
Central on-board telephone

Central lock controller
Theft deterrent ECU
Engine ECU
No. 1 fuse box
Airbag ECU
ALO008G
Reverse sensor ECU
ALO009G
13
Cab fuse box (No.1 fuse box)

Fuse box: There are more and more various relays and fuses as the electrical equipment increases gradu-
ally. Various relays and fuses are installed on one or a few switchboards, which has plugs on its face and
has a connection socket on its backside. Such a switchboard and its cover are called fuse box.
ALO010G
Number Name Number Name

Reserve (MT)
J01 J08 Front fog lamp relay
Horn relay (CVT)
J02 Lamplet relay J09 Rear fog lamp relay
J03 Flasher relay J10 Compressor relay
J04 Blower high speed relay J11 ACC relay
J05 Reserve J12 IG relay
J06 Door window relay J13 Rear wiper relay
J07 Blower relay J14 Defroster relay
Number Name Ampere (a) Number Name Ampere (A)

F01 Reserve (MT) — F17 CD player 15
Horn (CVT) 10 F18 Reserve —
F02 Sunroof 25 F19 Reserve —
F03 Lamplet 10 F20 Reserve —
F04 AM1 15 F21 Cigarette lighter 25
F05 Reserve — F22 Rearview mirrors 15
F06 Warning lamp 15 F23 Front wiper 15
F07 Turn signal lamp 10 F24 Charge 10
F08 Front fog lamp 15 F25 ABS 10
F09 Rear fog lamp 10 F26 Airbag 15
F10 Compressor 10 F27 Reserve —
F11 Rear wiper 10 F28 Back-up lamp 10
F12 Defroster 25 S/B1 Reserve —
F13 Combination 10 S/B2 Door and window 30
meter
F14 Interior lighting 10 S/B3 Reserve —
F15 Central door locks 20 S/B4 Blower 40
F16 Brake lamp 10 S/B5 Reserve —
EWD-��
Engine Compartment Fuse Box (No.2 fuse box)
ALO011G
Number Name Number Name Ampere (a)

J01 Main relay F29 Starter 30
J02 Fuel pump relay F30 Main relay 25
Horn relay (MT) F31 Fuel pump 15
J03 Gear shift solenoid valve relay F32 Low-speed fan relay 30
(CVT) Reserve (MT) —
F33
J04 Low speed fan relay TCU（CVT） 15
Reserve (MT) F34 High speed fan relay 40
J05
Starter relay2 (CVT) Horn (MT)
F35 15
J06 Relay ON Gear shift solenoid valve (CVT)
J07 High beam relay F36 High beam 15
J08 Low beam relay F37 Low beam 15
Reserve (MT) F38 Engine ECU 10
J09
Back-up lump relay (CVT) F39 ABS 25
J10 High-speed fan relay F40 Reserve —
F41 AM2 15
F42 Reserve —
F43 Backup 10
F44 Backup 15
F45 Backup 25
15
Wiring Diagram
The wiring diagram refers to the circuit diagram drafted on the basis of the wire harness arranged on the
vehicle and includes a detailed connection of each branch wire terminal. The wiring diagram is mainly used
to indicate the connection position between the wire harness and each of the electronics as well as the
shape and position of the connectors.
Engine compartment wire harness
Connected
Brake fluid Brake lamp Front wiper Meter wire Meter wire vehicle body
level switch switch motor harness A harness B wire harness
To Battery
Positive Lead
Clutch
switch
Right ground point Front
combination
lamp LH
Front wheel speed sensor RH
Front combination Front turn
lamp RH signal lamp
Front turn signal LH
lamp RH
ABS ECU
Right headlight height
adjustment motor
Left headlight height
Low-pitch
horn
adjustment motor
Rear washer
motor
Front washer
motor
Front fog
lamp RH
High-pitch horn Radiator fan Front fog lamp LH
ALO012G
ALO013G
Reading Theft deterrent CD Combination
Ignition
Lamp indicator player Antenna meter HAVC1 Passenger airbag Front tweeter
switch
No.1 fuse box
assembly B18
Ground
point
Outside power rear-
view mirror switch
Engine compartment
wire harness 1
A pillar tweeter
Interior illumina- Engine compartment

Dashboard wire harness
tion switch wire harness 2

No.1 fuse box
assembly E8
Outside power
rearview mirror switch
HAVC2
No.1 fuse box
assembly H
No.1 fuse box
assembly D16
No.1 fuse box Front door wire
assembly A20 harness
Theft deter-
rent ECU
Ground
Left combina- point
tion switch Electronic
accelerator
Right combi-
nation switch
Diagnostic
port Airbag ECU
Clock
spring
Backup power
supply
Left front door Ground point Ignition switch Air conditioner Air conditioner Air conditioner Cigarette lighter Cigarette lighter
16
EWD-��
illumination controller 1 controller 2 controller 3 Illumination

17
Trunk Door Wire Harness

Vehicle body wire Connected vehicle body To defroster Connected high-mounted
harness A wire harness B brake lamp To defroster negative pole
positive pole
To rear wiper To back door lock To license plate lamp and back Ground To back door Ground point
door open switch point open switch
ALO014G
EWD-��
Front Door Wire Harness LH

To left outer electric
To front door window rearview mirror
switch LH
To front door To front door window To front door Connected meter Connected meter
lock LH regulator LH speaker LH wire harness B wire harness A ALO015G
Rear Door Wire Harness LH
To rear door
window switch
To rear window
regulator LH
To rear door
lock motor LH
Connected
vehicle body
wire harness
ALO016G
19
EWD-��
ALO017G
Connected rear left Dome To seat belt Vehicle body wire
To front door light Connected dash-
door wire harness lamp switch harness assembly
To driver seat belt switch LH board wire harness
pretensioner
Connected engine
compartment wire
harness
To rear door light
switch LH
Connected back-up
radar controller
Ground
Floor Wire Harness
point
To rear wheel speed
To seat heater
Circuitry
sensor LH
switch LH or RH
To rear combi-
nation lamp LH
To seat belt
switch
Connected park-
ing brake switch
To rear door lamp
switch RH
To back door wire
harness LH
Connected rear
right door wire
harness
To rear vehicle
body wire harness
To seat belt pre-
Fuel To rear combina- D Pillar middle & tensioner
Ground To rear wheel To rear door light
pump tion lamp RH low tone speaker point speed sensor RH switch LH or RH
ALO018G
Rear door wire har- Trunk door wire
ness assembly RH harness assembly
Defroster positive
pole wire harness
assembly
Dashboard's
Rear vehicle
wire harness
body wire har-
assembly
ness assembly
Front door wire
Vehicle Body Wire Harness
Defroster ground
harness as- wire harness as-
sembly LH sembly
Engine wire
harness as-
sembly
20
EWD-��
Battery's ground Engine compart- Front door wire Vehicle body Rear door wire
wire harness as- ment wire har- harness as- wire harness harness as-
sembly ness assembly sembly LH assembly sembly LH
Connected high
pitched horn
Connected front combi- Rediator fan motor Engine Connected elec- Connected low-
nation lamp LH ground tronic throttle pitch horn
Connected Connected front
compressor combination lamp RH
connected starter Connected starter
Connected front fog Connected VVT valve
lamp LH Battery negative field coil
transmission
Oil pressure switch Connected front
Body ground Connected
fog lamp RH
Battery knocking sensor
connected phase
Battery positive sensor Connected No.1
Connected No.3 nozzle Connected rear
Connected Ground nozzle (1st cylinder)
(4th cylinder) Connected No.2 washer motor
back-up Connected No.4 nozzle
Connected inlet tempera- nozzle (3rd cylinder)
switch (2nd cylinder)
ba
ture pressure sensor Connected front
washer motor
Ge ttery
connected coolant
Sta
ne po
c
Connected front wheel
batt
o
temperature sensor
rat sit
Connected A/C
ery
nn
speed sensor LH
r co
or ive
ec
pressure switch Connected front wheel speed
rte posit
iv
Speed sensor
ted
nne e
cte
Connected 2nd sensor RH
to
Connected 4th Connected 3rd Connected 1st
d to

cylinder ignition cylinder ignition cylinder ignition cylinder ignition Connected power
coil coil coil coil steering
Left ground Front oxygen
Connected ABS ECU
sensor Right ground
Connect-
ed speed
sensor
Connected brake fluid

Rear oxygen sensor
warning switch
Connected
Connected combina- ground P1#
tion meter A
Connected front wiper motor Connected
Connected
theft deterrent ground P2#
indicator Connected CD Back-up radar buzzer
Connected brake switch player
Connected Connected engine ECU
Connected TCU antenna
Theft deterrent ECU 1
Connected Connected central door lock
Connected lock accelerator controller (white) Connected speed
Connected AC Passenger airbag Ground
cylinder light pedal adjustive resis-
Ground Connected AC switch temperature sensor plate 3
plate 1 tance, blower
Connected ignition switch (white)
The key is inserted into the detected switch Ground plate 2 Diagnostic
Connected lamp
brightness switch Connected rearview mir- port connected
rorregulate switch (white)
gearshift
Ground plate 4 mechanism Connected AC governor & passenger seat belt
Right combination switch (wiper)
Left combination unfastened indicator lamp
switch (light) Connected airbag
Connected main ECU (yellow)
airbag, horn Connected cigarette lighter (lighting)
switch
Connected
glove box
lamp Connected cigarette
lighter
Left front door glass Right outer electric
regulator mirror
Left outer electric Front window regulator RH
mirror
Front medium
woofer LH
Connected parking Front medium
Window regulator mainly brake switch
control switch, central door woofer RH
Front window regulator
lock mainly control switch switch RH
Passenger side central

Driver seat belt switch Passenger seat belt switch
door lock switch
Front door lamp

switch RH
motor LH
Front door lamp Front door lock motor
switch LH
Front door lock

RH
Driver seat belt preten- Passenger seat belt
sioner pretensioner
Circuitry
Connector
Rear window
regulator RH
Rear window
regulator LH Rear medium woofer RH
Rear medium
woofer LH
Rear window
regulator switch
RH
Rear window regulator
switch LH
Wire harness connector & Connector numbered diagram
Rear wheel speed sen-

sor RH
Fuel pump, fuel
Rear wheel speed sensor
sensor LH
Rear door lamp

Rear door lock switch RH
Rear door lamp
motor LH switch LH
Rear door lock
motor RH
Ground point A
Capacitor
Connected back-up
Vehicle power supply radar controller
Rear interior dome lamp
Ground
point B
Rear combination Rear fog lamp

lamp LH Right license RH
Reverse sensor
Rear combination
Rear fog probe Reverse sensor Left license plate lamp plate lamp
Reverse sensor Reverse sensor lamp RH
lamp LH probe probe probe
High-mounted brake lamp
Rear windshield
Rear wiper motor defroster “-”
Rear windshield
Back door open switch Ground point
defroster “+”
Back door lock motor
Back door lamp switch

EWD-��
21
EWD-��
23
Wire Connector Terminal Function Diagram
Terminal Function Diagram 1
Connected engine compartment wire harness Connected engine compartment wire harness
Connected cab fuse box Connected engine compartment wire harness
Connected cab fuse box A-20 Connected dashboard wire harness
Connected cab fuse box B-18 Connected dashboard wire harness

EWD-��
Connected cab fuse box C-14 Connected dashboard wire harness
Connected cab fuse box D-16 Connected dashboard wire harness
Connected cab fuse box E-8 Connected dashboard wire harness
Connected cab fuse box H-1 Connected dashboard wire harness

25
Connected dashboard's wire harness A Connected engine compartment wire harness A
Connected dashboard's wire harness B Connected engine compartment wire harness B
Connected dashboard's wire harness A Connected dashboard's wire harness A (white)
Connected dashboard's wire harness B Connected engine wire harness B

EWD-��
Connected meter wire harness A Connected front left door wire harness A (white)
Connected meter wire harness B Connected front left door wire harness B
Connected dashboard's wire harness A Connected vehicle body wire harness A

27
Connected vehicle body wire harness A

Connected dashboard's wire harness B Connected vehicle body wire harness B
Connected vehicle body wire harness Connected engine compartment wire harness
Connected meter wire harness A Connected front right door wire harness A
Connected meter wire harness B Connected front right door wire harness B
EWD-��
Connected vehicle body wire harness Connected rear left door wire harness
Connected vehicle body wire harness Connected rear right door wire harness
Connected vehicle body wire harness A Connected trunk wire harness A
Connected vehicle body wire harness B Connected trunk wire harness B

29
Connectors' List
Power & Starter System
Ignition switch Engine regulator
Airbag & ABS
Airbag ECU (Yellow)
Front wheel speed Front wheel speed

sensor LH sensor RH
Rear wheel speed Rear wheel speed

sensor LH sensor RH
Main airbag
Diagnostic port
Driver seat belt Passenger seat belt
pretensioner pretensioner
EWD-��
Combination meter
Connected combination meter A
Driver seat belt switch Brake fluid level warning switch
Air conditioning and defrosting system
Rear defroster & alarm switch AC switch
Connected AC governor & passenger

seat belt unfastened indicator lamp
Passenger seat belt switch Connected speed adjustive

resistance, blower
Electric Injection ECU Control System
Engine ECU
31
1st cylinder 2st cylinder 3rd cylinder 4th cylinder

injection nozzle injection nozzle injection nozzle injection nozzle VVT valve
Phase sensor Inlet temperature Knocking sensor Canister control valve

pressure sensor
To 1st cylinder ignition coil To 2nd cylinder ignition coil To 3rd cylinder ignition coil To 4th cylinder ignition coil
Electronic throttle Engine speed sensor AC pressure switch AC temperature sensor
Coolant temperature sensor Front oxygen sensor Rear oxygen sensor Radiator fan motor
Fuel pump, fuel sensor Theft deterrent ECU Diagnostic port
Connected accelerator pedal

EWD-��
Wiper, washer motor system
Right combination switch (wiper)
Front wiper motor
Connected front Connected rear Rear wiper motor

washer motor washer motor
Electronic rearview mirror & CD system
Right outer electric mirror Left outer electric mirror
Connected electric mirror regulate

switch (white)
Front tweeter LH Front tweeter LH

CD player
Front medium woofer LH Front medium woofer RH Rear medium woofer LH Rear medium woofer RH
33
Central Door Locking and Window Regulator System
Connected central door lock controller (white) Window regulator main control switch,
Central door lock main control switch
Connected meter wire harness A Connected meter wire harness A
Left front door glass regulator Front window regulator switch RH Front window regulator RH
Front door lock motor LH Front door lock motor RH Back door lamp switch Back door open switch
Rear door lock motor LH Rear door lock motor RH The key is inserted Back door lock
into the detected motor LH
switch
Front door lamp Front door lamp Rear door lamp Rear door lamp
switch LH switch RH switch LH switch RH
EWD-��
Light and Signal Alarm System
Front fog lamp RH Front fog lamp LH Front combination lamp RH Front combination lamp LH
Rear combination lamp LH Rear combination lamp RH Rear defroster & alarm switch
Left outer electric mirror Right outer electric mirror Left combination switch (light)
(left turn signal lamp) (right turn signal lamp)
Horn switch High pitched horn Low pitched horn
Headlight Height Adjustment
Connected headlight vertical switch Right headlight height adjustment motor Left headlight height
adjustment motor
35
Sound & Entertainment System
Connect to left front A Front tweeter LH Connect to left front right Front tweeter RH
pillar tweeter pillar tweeter
Right D pillar tweeter Right D pillar middle & Left D pillar middle & low Right D pillar tweeter
low tone speaker tone speaker
Clock Spring Assembly III Clock Spring Assembly II

(On-board telephone) (Sound control-by-wire)
Amplifier Amplifier 2 Connected CD player
Connected CD player 2
Bluetooth System
Twistered-pair
On-board telephone A On-board telephone B Front tweeter RH Connected to right

front A pillar tweeter
Left front loudspeaker Right front loudspeaker Rear door loudspeaker Right front loudspeaker
EWD-��
Normal glass regulator

Connected front right Connected left front door
door wire harness A wire harness A
Dashboard wire Dashboard

harness fixture wire harness
fixture
Connected front right door Connected front left door

wire harness B wire harness B
Connected vehicle body Connected vehicle Rear door wire harness LH Rear door wire
wire harness body wire harness harness RH
Connected dashboard's wire harness A Connected dashboard's Connected dashboard's

wire harness B wire harness A
Connected dashboard's
wire harness B
Left front door glass regulator main Connected right front door Left front door glass
control switch glass regulator switch regulator
Right front door glass Left rear door glass Right rear door glass Left rear door
regulator regulator regulator switch
Right rear door window switch Auxiliary switch of the central door lock
37
Seat Heating
Driver’s Seat Heating Switch Front passenger’s Driver's Seat Heating Front passenger's
Seat Heating Switch Seat Heating
Sunroof
Sunroof ECU Sunroof switch
TCU Transmission Control System
Transmission connected gearshift mechanism Ignition lock
TCU
EWD-��
General Circuit Diagram

Power & Starter Circuit
Theft deterrent
ECU6
Connected
ABS #1
Main relay
Terminal
Shift
position
Ignition switch
Motor40A
Starter relay
Engine ECU
Pin 74
Clutch switch
Battery
Starter
Generator
39
Airbag Circuit
Connected engine ECU #58

Indicator lamp
Airbag electric control module
Scanner
Clock spring
Driver seat Passenger

belt pre- seat belt
tensioner pretensioner
Driver side Passenger
airbag side airbag
EWD-��
ABS Circuit
Central Control ECU#17
Brake lamp switch

Theft deterrent controller A7
Connected engine
ECU
72
pin
High-mounted brake Lamp

Left brake lamp
Right brake lamp

ABS electric control module
Front Front Rear Rear

wheel wheel wheel wheel
speed speed speed speed
sensor LH sensor RH sensor LH sensor RH
Connected central
Connected central
41
EWD-��
control ECU #11
control ECU #18
Odometer
Tachometer
LCD display
(Front wheel speed

sensor RH for CVT
Speed sensor transmission)
IC module
Fuel sensor
Combination Meter Circuit
Low water Tempera-

ture alarm
High water
Temperature alarm
Fuel gauge
Low fuel alarm
Circuitry
Seat belt unfastened Driver seat belt switch

indicator lamp
Low oil pressure indicator Oil pressure switch
Brake warning lamp Brake fluid level switch
Parking brake lamp Parking brake switch
Instrument Lighting
temperature sensor
Connected coolant
Connected lamplet relay

EWD-��
Air Conditioning and Defrosting System Circuit
Connected position
lamp relay
Connected AC
pressure switch
Passenger seat belt switch

Blower relay
Defroster relay
AC panel lighting
AC wind speed switch
Front passenger seat belt unfastened indicator lamp

AC switch
Terminal
Defroster switch
Terminal Terminal
Position Position Position
Open Off
Off Open
Right outer mirror defroster
Rear windshield defroster
Left outer mirror defroster
Capacitor
Blower
Speed adjustive
resistance
43
Wiper and Washer Motor System Circuit
Rear wiper relay

Front wiper switch
Front
washer
INT
Regulate
time
Rear
Rear wiper switch
washer
Rear washer
with wiper
Terminal
Rear washer motor
Front wiper motor
Rear wiper motor

Front washer motor
EWD-��
Electronic Rearview Mirror Circuit
Outer electric mirror regulator switch
Terminal Terminal Terminal

Shift switch
Fold switch
Mirror adjustment switch
Position Position Position

Reset Upper Left
Fold Left Off

Off Right
Right
Lower
Foldable motor
Right mirror adjustment motor
Left mirror adjustment motor

45
CD System Circuit
Connected position
lamp relay
Antenna
Antenna
amplifier
Integrated CD Player
Front tweeter LH Front tweeter RH
Front medium Rear medium Rear medium Front medium

sub-woofer LH sub-woofer LH sub-woofer RH sub-woofer RH
Permanent Electricity for Cab
Sound & Entertainment System
Mute sound
Antenna
Antenna
amplifier
Spiral coil
Linear control mode

Steering switch
Sound amplifier Right D pillar tweeter Integrated CD/DVD player
Left A pillar tweeter
Front tweeter LH Right A pillar tweeter
Front tweeter RH
Left front door Left D pillar Right D pillar Right front door
46
EWD-��
Left rear door Right rear door Right D pillar tweeter speaker middle & low middle & low speaker
speaker speaker tone speaker tone speaker
47
Bluetooth System
Mute sound
Microphone
Left front door

speaker
Left front door
speaker
Right front door
speaker
Right front door
speaker
Left A pillar tweeter Right A pillar
Clock spring
tweeter
Front tweeter LH
Front tweeter RH
Steering switch
Left front door speaker

Right front door
speaker
EWD-��
Electric AC
Blower relay
Blower high-speed module
Blower high-speed relay

AC controller
Rear defroster indicator
Mode damper actuator Temperature Cycle damper

regulation actuator
damper
actuator
49
Normal Glass Regulator

Window relay
Lock signal
Unlock signal Electric door main control switch

Front door motor LH
Front left door switch

Window lock switch
Desce
Off
Rise
Front door motor RH
Desce
Rise
Off
Left front door glass regulator mainly control switch
Rear door switch LH Front door electric

switch RH
Desce
Rise
Off
Desce
Rise
Off
Rear door motor LH
Rear door switch RH Rear door electric

switch LH
Desce
Rise
Off
Rise
Desce
Front door motor RH
Off
Rear door electric

switch RH
Front Passenger's Seat Heating Switch
Heater
Seat Heating
Driver’s Seat Heating Switch

Heater
50
EWD-��
51
Sunroof Headlight Height Adjustment
Permanent Electricity of Cab
Sunroof Switch
Headlight vertical switch

Sunroof Motor Module
Right headlight adjustment motor

Red and
Red and white white
Left headlight adjustment motor

EWD-��
TCU Transmission Control System
Connected to
Back-up Lamp
Connected
to Diagnosis
Interface
Snow Mode Indicator Lamp
Valve
Ignition Switch Solenoid
Lamp
Transmission Malfunction
Gearshift Solenoid Valve Relay
Connected to Engine ECU

Connected to Brake Light Switch
Starter Relay 2
Back-up Lamp Relay

Gearshift Solenoid Valve
Connected to Dash-
board Brightness
Adjusting Switch
Gearshift Operating Transmission Actuating Mechanism

Mechanism
53
Electric Injection ECU Control System Circuit
Theft Deterrent Control System
Engine service indicator lamp

Connected combination meter
Engine malfunction indicator lamp

Relay
Scanner
Ignition System
Fan relay low
Fan relay high

Compressor clutch
Theft deterrent indicator

Ignition switch
VVT valve
Radiator fan
Electric Control Module Theft deterrent controller
Central pressure switch
Power steering load
brake lamp
AC pressure
Connected
nation meter
Connected combi-
switch
switch
Connected AC switch
Connected ABS ECU Theft deterrent coil
Connected power steering

Rear Front Inlet pressure & Coolant Accelerator Phase sensor Electronic throttle AC temperature Knocking Engine speed sensor
oxygen oxygen temp. sensor temperature pedal module sensor sensor
sensor sensor sensor
EWD-��
Light, signal alarm system circuit
connected central
control ECU #1

Terminal
Turn signal lamp switch

Left turn
Low beam relay
Position lamp relay

Front fog lamp relay
Rear fog lamp relay

Off
High beam relay

Right turn
Horn relay
Flasher relay
Front turn signal

lamp LH
Rear turn signal

lamp LH
Low beam
Front position
Lamp
lamp LH
Horn switch
ON High beam Left turn signal lamp
Overtaking
Terminal
Fog lamp switch
Off High beam Front position Left turn signal lamp

Lamp lamp RH
Front fog Off
lamp Low beam
Rear fog
lamp Overtaking Rear position Front turn signal
lamp LH
Low pitched horn
High pitched horn
lamp RH
Rear position Rear turn signal

lamp RH lamp RH
Rear fog indicator lamp
Front fog lamp indicator
Alarm switch
Terminal
High beam indicator
Left license
Front fog lamp LH
Right turn signal lamp

Rear fog lamp LH
plate lamp Position
Right headlight
Front fog lamp RH
Left headlight
Open
Right license Off

Right turn signal lamp
plate lamp
55
Central Door Locking and Window Regulator System Circuit
Connected
combination meter
Connected
combination meter
Connected
combination meter
Connected high
beam relay
Connected airbag
ECU
Connected combination
Left front door glass regulator main
Open door indicator lamp
meter
control switch
Right turn signal
Door & Window lock switch

Driver side electric switch
Rear door electric switch RH

Left turn signal
Vehicle speed signal
Central control switch
Front door electric switch RH

Lighting detection
Rear door electric switch LH

Airbag signal
Terminal
Position
Door lock Rise Rise Rise Rise
is locked
Stationary state Off Off Off Off
Door lock De- Descend Descend Descend

is on scend
Central control module
Front right door switch
Rear door switch RH

Rear door switch LH
Rise Rise Rise
Connected interior dome
signal
Delay
Off Off Off

lamp Descend
Descend Descend
Connected reading lamp
control switch
Passenger side central
The key is inserted into the detected switch
Back door lock motor

Back door open switch
Terminal
Position
Front door lock LH Lock

Front door jam protection Front door jam protection Rear door jam protection Rear door jam protection
Unlock
motor LH motor RH motor LH motor RH
Front door lock motor RH
Back door lamp switch
Rear door lamp switch LH
Rear door lamp switch RH
Front door lamp switch RH
Front door lamp switch LH
Rear door lock motor LH
Rear door lock motor RH

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PREFACE

Bleeder Screw Cap

Hole Plug Rear Brake Cylinder

Rear Brake Auto- Tension Spring

1. Vehicle identification number

2. Engine model and transmission model

• Always wear a clean uniform.

• Diagnose with a thorough understanding of the problem and perform

(b) Jacking up and supporting the vehicle

Medium Current Fuse and High Current Fuse (f) Fuses

Illustration Symbol Part name Abbreviation

Medium Current Fuse

High Current Fuse

Shape (Example) Removal/Installation

Shape (Example) Removal/Installation

(h) Removal and installation of vacuum hoses

(2) When disconnecting vacuum hoses, use tags to

(i) Torque when using a torque wrench with an extension

(3) Formula T’ = T × L2/(L1 + L2)

2. For vehicles equipped with SRS airbags and a seat

Mark (b) Clock spring (in the combination switch)

(c) Driver airbag assembly (w/airbag)

(d) Front passenger airbag assembly

(e) Seat belt pretensioner

(f) Airbag ECU assembly

4. Removal and installation of fuel control parts

5. Removal and installation of engine intake parts

6. Handling of hose clamps

7. For vehicles equipped with mobile communication

8. For vehicles equipped with a catalytic converter

Vehicle Lift and Support Locations

: Support Position, Pantograph Jack Po-

: Center of Vehicle Gravity

4. Notice for using swing arm type lift

Center of Vehicle Gravity

How To Troubleshoot ECU Controlled Systems

For using the tester:

How To Proceed With Troubleshooting

2 Customer problem analysis

3 Symptom confirmation and DTC (and freeze frame data) check

(a) Check the battery positive voltage.

5 Problem symptoms table

6 Circuit inspection or parts inspection

Customer Problem Analysis

(Sample) supplemental restraint system check sheet

Customer problem analysis check

Customer’s name Production date / /

Date problem first

Weather ¨Fine ¨Cloudy��������� ¨Rainy �������� ¨Snowy �������� ¨Other

Symptom Confirmation and Diagnostic Trouble Code

2 Make a note of DTCs displayed and then clear the memory

4 Simulation test using the symptom simulation methods

If a DTC was displayed in the initial DTC check, it indicates

Troubleshooting of each problem symptom

2. Heat method: If the problem seems to occur when

3. Water sprinkling method: When the malfunction

Electronic Circuit Inspection Procedure

(d) Repair method of the connector terminal

(e) Handling of the wire harness

(b) Check the resistance.

(c) Check the voltage.

(b) Check the resistance with the body ground.

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

Used for mounting

Weather ¨Fine ¨Cloudy�� ¨Rainy �� ¨Snowy �� ¨Other

Tools for the CC��