Cowry Service Manual

Preface
With the larger and larger demand to automobiles, the automobile industry is
developing rapidly in China. Great Wall Automobile Co., Ltd. promotes the first high
grade multi-function vehicle timely – COWRY MPV, and Great Wall COWRY is equipped
with a 2.0L engine with intelligent variable valve system, a maximum power of 105 Kw, a
maximum torque of 185 N·m, and a 5-speed manual transmission. COWRY has a non-
frame integral vehicle body, and steel integral automobile shell structure, so COWRY is
economical and energy efficient with lighter body weight.
The service maintenance and repair information included in this manual is provided
for the specialized technical personnel with qualification to use. To perform the service
maintenance and repair without regular training or correct tools or equipments will cause
injury to the operator himself or others, and cause damage to the automobile or lead
to insecure state. Therefore, the correct service and maintenance is very important to
the customer security as well as the vehicle reliability. In order to help you to make the
wise decision, we have given the corresponding security information or other security
instructions throughout the manual. To adapt the demand of Great Wall after-sale service
technical personnel, we have compiled the maintenance manual. In the manual the
precautions of maintenance and repair, the disassembly and installation of each system
assembly and the maintenance technical parameters are mainly introduced.
Sincere gratitude is herein given to those specialized technical personnel who have
provided strong support and help during the preparation of this manual.
Though this manual is prepared with great effort and carefulness, it cannot be
ensured that all the contents in this manual are completely correct. The user is not
entitled to raise any claim on the Great Wall Motor by right of this manual. We are going
to take no responsibility for all the losses caused by the use of this manual. Because
of the limited capability of the compilers, it is unavoidable to make some mistakes in
preparing this manual, which are earnestly waiting for your generous criticism and
correction.
Great Wall Motor Co., Ltd. reserves the right of final interpretation of this manual.
Prepared by:
October 2007
Chassis and Car Body
Maintenance Manual
General Introduction
Complete Vehicle Parameters
Engine Mechanical System
Engine Electronic Fuel Injection System
Fuel System and Exhaust System
Clutch Control System
Transmission
Suspension and Axle
Braking System
Steering System
Electrical System of the Car Body
Electrical Accessories
Safety airbag
Air-Conditioning System
Car Body
General Introduction-
Use of this manual........................................................................... 2

Position of VIN................................................................................. 3
Instruction for comprehensive repair............................................ 4
Use of this manual

For the convenience of consulting, the chapter (section) titles and key headings are indicated on the top of each page
in this manual.
To facilitate the location of maintenance items, an index is given on the first page of each chapter.
Precautions concerning all the maintenance operations in the current chapter are also given at the beginning of each
chapter.
Please carefully read these precautions before any maintenance work.
The fault diagnosis list of each system can help you diagnose the system faults and find out the causes.
In the column of repair method, the specific repair methods against the possible causes are provided, so that you can
get the solution quickly.
Repair procedures
In most occasions, you can start your repair operation with the reference to the illustrations, which will
help you recognize the parts and understand the mutual relation between them.
For example:
Left front braking caliper assembly Axle center bolt

Copper washer
Q150B1235 100±10
◆Heavy spring washer
Q43082
Front hub bearing assembly
Left front braking disc cover casing
Left steering knuckle
9±2
Front hub flange disc
N•m : specified torque Front braking disc

◆ Non-reusable parts
The repair procedure will be explained step by step:

● The illustrations show you what to do and where to do
it.
● The title of repair work tells you what to do.
● The detailed description tells you how to complete the
repair work and explains other related matters, such as
the specifications and cautions, etc.
For example: Job title: what to do?
4. Check the thickness of the front brake disc.

Standard thickness: 22.0mm Specifications
Minimum thickness: 20.0mm
Illustration: What to do and where to do it In case of the thickness less than the minimum value,
please replace the brake disc.
Detailed description: How to do it

This form can help those experienced technicians quickly find out the causes of the failure. The
maintenance personnel can run through the titles only and read the detailed description below
whenever necessary. The important specifications and cautions are marked in black letters.
Specifications
Each repair step in the whole manual is provided with the corresponding specifications in black letters,
so there is no need to set aside the repair work to check the specification.
Caution、notice and remarks
● Caution is given in black letters, indicating the possibility of injury to yourself or others.
● Notice is given in black letters, indicating the possibility of damage to the parts being repaired.
● Remarks are given separately in the instruction, but not in black letters. They are mainly used to make
some additional instruction, so as to help you finish the work more efficiently.
Position of VIN
Identification symbol of vehicle
VIN is a unique 17-digit code that is used to identify the
vehicle. This code is marked in three different places:
on the nameplate, on the left upper instrument panel .
Nameplate of vehicle
All vehicles of various models have nameplates .
Engine No.
Engine number is imprinted on the left side of engine
cylinder.
Instruction for comprehensive repair

● Use clean cloth or polyethylene cover to cover all the
lacquer finish and seats, so as to prevent dust and
scratch.
● Pay attention to safety during the work and concentrate
on the work. After the front or rear wheel is lifted,
the rest wheels that aren't lifted should be blocked
reliably. If two or more persons are involved in the work
simultaneously, intercommunication should be made
as much as possible. The engine can be run only when
the plant and working area has favorable ventilation.
● Before removing or disconnecting the parts, careful
check must be performed, so as to block the parts that
need repair. Please abide by all the safety instructions
and precautions provided in this manual and perform
the operation according to the correct procedures.
● All the parts that are removed should be marked or

placed on the parts rack in order, so as to facilitate the
reassembly in original sequence.
● Use special tools in accordance with the requirement if

necessary.
● The components and parts must be assembled with

correct torque specified in the maintenance standard.
● When tightening a set of bolts or nuts, it should be
started from the center one or in a diagonal way. In
addition, cross-over manner should be applied to tight
the bolts or nuts in two or several steps.
● Unrecycled parts
(a) During the reassembly, new filler, washer,
O-sealing ring and cotter pin should be used.
(b) The unrecycled parts are indicated with the
symbol of “◆” in the component diagram.
● The old components and parts that need replacing
should not be recycled and must be replaced.
● Components and parts and lubricant that are produced

by the original manufacturer should be used. The
components and parts, if continued to be used, must
be checked carefully to ensure that no damage or
deterioration occurs and they are all in sound working
state.
● Components and parts should be applied with or filled

with specified grease. When disassembling, use solution
to clean all the parts removed.
● Precoated parts
Precoated parts include bolts and nuts, which are all
lock sealant
applied with lock sealant.
(a) The precoated parts, if tightened, unscrewed or
moved for some reasons, must be applied with
specified fluid sealant again.
(b) The precoated parts are applied with the fluid
sealant in the following steps:
1) Clean and remove the old fluid sealant from
the thread of the part.
2) Dry it with compressed air.
3) Apply specified lock sealant to the thread of
the part.
(c) Precoated parts are indicated with the symbol of
“” in the component diagram.
● Dismantling and installation of the vacuum hose
(a) To extract the vacuum hose, one should hold the
end of the hose, and then twist and pull it out. Don’
wrong correct t hold the middle of the hose and draw it stiffly, for
fear of damage to the hose.
(b) To facilitate the reinstallation, the hose after

disconnected should be labeled for convenience
of identification.
(c) After finishing these operations, one should
carefully check and ensure that all the vacuum
hoses are connected correctly.
(d) When applying vacuum meter, don’t connect the
hose to the excessively big fitting by force. The
size of the fitting must be adjusted gradually. Bear
in mind that there is a possibility of leakage if the
hose is too expanded.
● Dismantling of the hose clip
(a) Before disconnecting the hose, check the position of
the hose clip, so as to ensure the correct reposition.
(b) Replace those distorted clips or those with dent.
(c) When reusing the original hoses, place the clip to
the part with holding trace.
(d) As for the spring clip, one could gently pull the
spring in the direction of arrow to adjust the spring
clip tight after the installation.
● Brake fluid and hydraulic element

(a) Special care should be taken when adding fluid to
the system, so as to prevent the dust and pollutant
from entering the system.
(b) Don’t mix the fluid of different brands, for they are
might undissolvable.
(c) Don’t reuse the brake fluid discharged.
(d) For the brake fluid will damage the lacquer finish
or resin surfaces, pay attention not to let the
brake fluid spatter on the similar surfaces. If that
is the case, flush them with water or warm water
immediately. Plug opening after the brake hose or
brake pipe is disconnected, so as to ensure that
the brake fluid will not run down.
(e) All parts removed must be cleaned with clean brake fluid and all the holes and passages should
be purged with compressed air.
(f) Prevent the parts removed from contacting the dust and friction materials carried in the air.
(g) Before the assembly, please check and make sure all the parts are clean.
(h) Unless otherwise specified, don’t allow the oil or grease to be applied to the rubber parts or
pipes.
(i) During the assembly, one should check whether every part is correctly installed and whether
every part works normally.
Instructions for electric trouble shooting
● Before trouble shooting
(a) Check the fuses in the corresponding fuse/relay box.
(b) Check whether the battery is damaged, whether it is in good charging state and whether it is
clean, and tighten the connector.
Notice:
(a) If the earth wire of the battery isn't disconnected, quick charge of the battery is prohibited;
or else, the diode of alternator will be damaged.
(b) If the connection of the earth wire of the

battery is comparatively loose, attempt to start
the engine isn't allowed; or else, the wire will
be badly damaged.
(c) Check the belt tension of the alternator.
● Basic operation
1. Assembly/disassembly of the wire harness
connector
(a) When disconnecting the connector, first press
both ends of the connector with hand, release the
Wrong lock and then press the pawl to disengage the
connector.
Wrong (b) When disconnecting the connector, one should
not pull the wire harness and directly hold the
connector to disengage it.
(c) Before connecting the connector, one should
Correct check and make sure the connector isn't distorted
or damaged and the terminal port isn't lost.
(d) When connecting the connector, one should hear
the crack sound that indicates the successful
connection.
2. Check of the wire harness connector
Unfold the curl
(a) Check when connecting the connector
Press both ends of the connector to make sure it
Wire core
is completely inserted and locked.
(b) Check when disconnecting the connector
Terminal Gently pull the wire harness from the back of
deformation the connector to check. Find out whether there
Gently pull is unengaged terminal, dropped terminal, loose
clip or damaged wire.Perform visual inspection
to check whether there is metal scrap, foreign
matters and water, and whether corrosion, bent,
rustiness, overheating, pollution or terminal
deformation occurs.
(c) Check the contact pressure of terminals:
Prepare a plug adapter that matches the
connector terminal and plug it into the plug socket,
and then check whether the tension is favorable
both when they are inserted and after they are
Terminal with similar totally engaged.
plug adapter
3. Repair method of wire harness connector terminal

(a) If the terminals are polluted with dust, the contacts
Correct Wrong should be cleaned with air gun or wiping cloth.
Don’t use tissue paper to clean, for fear of
damage to the galvanized coating.
(b) If the contact pressure is abnormal, replace the
plug socket with an equivalent one.
(c) All the terminals damaged, deformed or corroded
should be replaced. In case the terminal isn't
locked into the hosing, replace the hosing too.
4. Disassembly and assembly of wire harness

Wrong Wrong
(a) Before dismantling the wire harness, first check
the connection and tightness of the wire harness,
so as to facilitate the correct reinstallation.
(b) Never distort, stretch or loosen the wire harness.
(c) Don’t let the wire harness contact the high
temperature, rotating, moving, vibrating parts,
or those with sharp corners. Prevent it from
Wrong
contacting the edge of the panel, screw tip or
other similar articles.
(d) When installing parts, don’t mix the wire harness
with them.
(e) Don’t use the conductor or wire harness whose
insulating coat cracks. If that is the case,
measures must be taken: replace it or use electric
tape to wrap the parts with crack.
(f) After the parts are installed, make sure there is no
conductor clipped under the parts.
(g) Insert the probe of the tester from the side of
conductor (except for the waterproof connector), if
possible. Use a probe with gimlet-point.
Notice: If the isolating coat of the conductor is
pierced, poor electric connection or intermittent
electric connection fault will be caused.
Five-step trouble shooting method
1. Check the fault
Switch on all the components in the fault circuit to check the fault described by the client and observe
the signs. Never start dismantling or testing till you find out the exact trouble location.
2. Make analysis on the principle
Consult the circuit diagram to confirm the fault circuit. Check each component from the power supply,
along the current path, and to the earth, so as to determine the working principle of this circuit. If
several circuits are suffering from failure simultaneously, the most possible cause may be the fault of
fuse or earthing. Recognize the cause or causes of fault based on the signs and the understanding of
circuit working principle.
3. Isolate the fault through a circuit test
Make a circuit test to check the diagnosis performed in step 2. Bear in mind that theoretical and simple
procedure is essential to efficient trouble shooting. It is advised to first test the most possible cause to
the fault and start with the most accessible points.
4. Treat the fault
Once the fault is recognized, make prompt maintenance. During the maintenance, proper tools should
be used and the safe operation procedures should be followed.
5. Confirm that the circuit is in normal state
Switch on all the components in the circuit that have been repaired under each working mode to
confirm that the trouble is completely removed. If the fault is caused due to the blowing out of the fuse,
all circuits connected to the fuse must be tested. Make sure there is no new fault happening and the
former fault doesn't occur again.
● Dismantling and installation of clips

The clips for body parts are dismantled and installed in the method as shown in the following table.
Remarks: Theses clips, in the event of damage during the operation, must be replaced with new ones.
Shape Dismantling/installation
Jaw vice
Clip detacher
Protective tape
Screwdriver
Protective tape
Screwdriver
General Introduction-10
Table continued:
Shape Dismantling/installation
Dismantling Installation
Screwdriver Press
Clip detacher
Push the master pin out, remove it

and pry off the master pin bush.
Screwdriver Press
Clip detacher
Screw out the master pin out, remove it

and pry off the master pin bush.
Press
Screwdriver
Clip detacher
Small clip detacher
Prize the master pin out, remove the rivet and

then pry off the master pin bush.
Complete Vehicle Parameter-
Complete Vehicle Parameter
Complete Vehicle Basic Parameter............................................... 2

Dimension and Weight Parameter.............................................. 2
Complete Vehicle Basic Performance Parameter........................ 3
Structure Form and Performance Parameter of the Main
Assemblies...................................................................................... 4
Structure Form and Technical Parameter of Power Assembly
and accessories........................................................................... 4
Structure Form and Parameter of the Main Assemblies
of Chassis.................................................................................... 5
Structure Form and Parameter of Vehicle Body.......................... 6
Structure and Parameter of Electrical System............................. 8
Complete Vehicle Basic Dimension............................................... 11
Complete Vehicle Basic Parameter

Model of
Vehicle model Cab Type Driving Method Remarks
Matched Engine
V08 4G63S4N Left Rudder Front Wheel Driving 5-speed Manual Transmission
V10 4G63S4N Right Rudder Front Wheel Driving 5-speed Manual Transmission
Dimension and Weight Parameter

Vehicle model V08
Length mm 4574
Outline dimen-
Width mm 1704
sion
Height mm 1845
Axle Distance mm 2825
Front Wheeltrack (half loaded) mm 1480
Wheeltrack
Rear Wheeltrack (half loaded) mm 1466
Front overhang mm 842
Rear overhang mm 907
Luggage Compartment Volume
L 1059/809
(the rear two rows of seats folded/ the rear row of seat folded)
Vehicle gross weight kg 1510
Front and Rear Axle Load When Unloaded kg 876/634
Percentage of Front and Rear Axle Load When Unloaded % 58.0/42.0
Loaded weight kg 600(68×8+7×8)
Mass Parameter Height of Mass Center When Unloaded mm 588
Weight when fully loaded kg 2110
Height of Mass Center When Fully Loaded mm 574
Front and Rear Axle Load When Fully Loaded kg 996/1114
Percentage of Front and Rear Axle Load When Fully Loaded % 47.2/52.8
Grade One Opening Degree （°） 34
Front Door
Grade Two Opening Degree （°） 62
Opening Degree
Grade One Opening Degree （°） 12
of Opening and Back Door
Grade Two Opening Degree （°） 79
Closing Parts
Sliding Door Maximum Sliding Volume mm 750.3
Engine Hood （°） 61
Complete Vehicle Basic Performance Parameter

Item Unit V08
Power Perform- Highest Speed km/h ≥175
ance Acceleration Time (0-100 km/h) s ≤20
(Fully Loaded) Maximum Climbing Degree % ＞30
50km/h Braking Service Braking Distance m ≤15 (Fully Loaded)
Braking Initial Speed Emergency Braking Distance m ≤38 (Fully Loaded)
Performance No move within 5 min-
Parking Braking (at slope degree of 20%)
utes (unloaded)
Meet the requirements
Collision Frontal collision
of GB11551-2003
Accord with the regula-
Driver’s front vision field
Vision tions of GB11562
Field Accord with the regula-
Driver’s Rear Vision Field
tions of GB15084
Maximum sta- Maximum stable roll angle to the left and right
(°) ≥35
ble roll angle under the unloaded and static condition
Turning Left 5≤an≤9.8
Security
an m/s2
Turning Right 5≤an≤9.8
Steady Turning Left (°)/(m/ 0.4≤U≤1
U
Revolution Turning Right s2) 0.4≤U≤1
Turning Left (°)/(m/ 0.7≤Kφ≤1.2
Operational Stability
Kφ
Turning Right s2) 0.7≤Kφ≤1.2
Turning Left 0≤Δγ≤2
Δγ (°)/s
Steering Turning Right 0≤Δγ≤2
wheel Return Turning Left 0.3≤ET≤0.6
ET s
Turning Right 0.3≤ET≤0.6
Turning Left
Fs N 15≤Fs≤50
Steering Turning Right
Portability Turning Left
Fm N 30≤Fm≤80
Turning Right
tection Performance
Accelerated run (outside the vehicle) dB(A) ≤74

Environmental Pro-
Noise 60 km/h run at uniform speed (inside the vehicle) dB(A) ≤70
Noise emitted by stationary road vehicle dB(A) ≤85
CO g/km ≤4.17
Emission
HC g/km ≤0.25
Index
NOx g/km ≤0.18
Approach angle (fully loaded) （°） 19
Traverse ability Departure angle (fully loaded) （°） 15.5
data Minimum ground clearance (fully loaded) mm 108
Minimum turning diameter m 11.5
Smoothness Equivalent mean value Leq dB ≤112
Economical Effi- Commercial vehicle fuel consumption limit value L/100km ≤10.3
ciency Fuel consumption per 100 km at 90 km/h L/100km ≤8.5
Structure Form and Performance Parameter of the Main Assemblies

Structure Form and Technical Parameter of Power Assembly and accessories
Vehicle Model V08
Engine Model 4G63 S4N
In-line 4-cylinder, water-cooling 4-stroke, 16-valve, SOHC,

Engine form Mitsubishi intelligent variable valve, electronic multi-point
injection gasoline engine
Engine configuration form Front lateral positioning engine, front wheel drive
Engine Displacement L 1.997
Cylinder Diameter × Stroke mm×mm 85×88
Compression Ratio 9.5:1
Maximum Power kW/r/min 105/6000
Maximum Toque N•m / r/min 185/4000
Fuel Supply Method Multi-point electrically controlling fuel ejection
Cold Start Performance With good low-temperature cold start performance (at -18℃)
Model JC523TM9
Form 5-speed manual transmission
Gear I 3.583
Transmission Ratio
Gear II 1.947
of Each Gear
Transmission
Gear III 1.379
Gear IV 1.030
Gear V 0.820
Reverse Gear 3.363
Main Reducer Main Reduction Ratio 3.722
Intake System Dry air cleaner, intake air resonator installed in the intake tube
Emission control reaches the Stage III standard of China,
Emission System
and meet the requirements of noise laws and regulations
Plastic fuel tank, with the capacity of 60 L, and internal
Fuel Tank
installation type electric fuel pump
Fuel Sup-
Fuel Supply Control Mechanical pedal fuel supply control
ply System
Fuel supply evaporation and External installation type filter, activated carbon tank, and
control VSV valve electric control
Strip-tube radiator, electric fan, 2-stage speed adjustment,
Cooling System
forced circulating water cooling
Structure Form and Parameter of the Main Assemblies of Chassis

Vehicle Model V08
Clutch Form Single disc dry diaphragm spring
Fixed ball basket constant velocity universal joint on one end, extensible
Transmis-
Form spherical roller constant velocity universal joint on the other end, transmis-
sion Shaft
sion shaft on the right side has the intermediate support.
Overhang Front overhang system Spring column Overhang (McPherson type)

system Rear overhang system Trailing arm twist beam semi-independent Overhang
Front Wheel Camber (°) 0°00′±45′
Front Wheel Toe-in (°) 0°11′±21′
Wheel Align- Kingpin Inclination (°) 10°05′±45′
ment
(Unloaded) Kingpin Reverse Caster (°) 3°20′±45′
Rear Wheel Camber (°) -1°15′±30′
Rear Wheel Toe-in (°) 0°22′±32′
Wheel Type Tubeless radial ply tyre.
Two specifications of 195/65 R15 91H and 91V standards (Optional
Wheel Specification
installation: two specifications of 205/55 R16 91H and 91V wide tyres).
Wheel and Standard configuration: steel 15×6J with plastic decorative
Tyre Wheel Rim Specification cover, (Optional installation: 16×6.5J) ET=+49; advanced
configuration: aluminum wheel rim.
Tyre Pressure Front tyre 230 kPa, rear tyre 230 kPa, spare tyre 420 kPa.
Spare Tyre T125/90R16 98M, placed under the floor of the driving seat.
Steering gear type Gear-rack type, hydraulic power steering.
Steering Steering wheel outer diameter Φ380 mm (with volume
System Steering linkage device switch, vehicle bluetooth button in advanced configuration);
energy absorbing steering column, 3.6°adjustable angle.
Hydraulic dual tube line, with vacuum booster, installed with
Structure form
ABS+EBD.
Braking Sys- Ventilation disc brake on the front wheel, drum brake on the rear
tem Service Brake
wheel.
Parking manual braking, mechanical cable type, rear wheel
Parking Brake
braking.
Structure Form and Parameter of Vehicle Body

Ve Stru
ctur hi
e mo cl
Para e
mete de V08
r l
Assem
bly
Ve h i c l e B o d y Integrated vehicle body, steel integral body shell structure, 5 doors and a bon-
Structure Type net, plane back.
Vehicle Body Shell
Metal frame vehicle door, with side guiding bar on the side vehicle door; hinge
type front door, with template door lock, with door check; left/right passenger
Vehicle Door sliding door, with door check, central door lock, rear door child security door
Assembly lock; 4-door electric glass lifter, anti-clip function to be chosen; the opening
degree of the rear left door is limited when fuel filler cover; the rear back door
with hinges is opened upward, and the glass can’t be lifted.
Engine Hood With single arm hinge and rigid strut bar is opened backward.
The front row safety belt adopts 3-point electric pretensioner safety belt, which
can be adjusted vertically, and the middle row and rear row safety belts adopt
Safety Belt
3-point emergency locking safety belt on both sides, and 2-point emergency
locking safety belt in the middle.
Vehicle Body Accessories
With the front and rear windscreen washing function, a cleaning fluid tank, two
Windscreen
motors, two sets of tube lines in the front and rear, and two cleaning fluid noz-
Washer
zle in the front and one in the rear.
Exterior rear vision mirror: the mirror surface can be electrically adjusted in four
directions (with defrosting function in advanced configuration), and can be folded
Rear Vision manually
Mirror Interior rear vision mirror: can be adjusted in multiple directions, with the dimming
function; with reversing radar display screen in advanced configuration, electronic
Anti-glare function
The sun visors at the driver’s and co-driver’s seats are installed with cosmetic
Sun Visor
mirror, are symmetric and can be turned vertically
Front and Rear

Injection molded main body.
Interior and exterior decorations, instrument cluster
Bumpers
Tail Fin Blowing molded.
Glove Box Glove boxes are set inside the front and rear doors.
Front row
Glasses box is set between the front sun visors
glasses Box
Ashtray With front, middle and rear ashtrays
Drink holders are set on the auxiliary instrument panel, the rear vehicle door
Drink Holder
protective plate and the side wall protective plate.
Injection molded body is equipped with supporting beam, and the combined
Instrument
instrument is positioned in the middle; the big glove box entity is molded
Panel
through injection with friction welding; with auxiliary instrument panel.
Pillars A, B and
C and Protective Injection molded, the glove boxes are set on the front and rear protective
Plate inside the plates and partially covered with softened fabric.
Door
StruVe
ctur hi
e cl
Para e
mo V08
mete d
Assem r el
bly
Interior Handle The main body is molded through plastic injection

Ceiling internal protective plate material (PUR+GF) +(PET); the ceiling can be
Ceiling cleaned with soap water or vacuum cleaner (the sunroof opening should be
reserved when chosen to install dual sunroof)
The front windscreen adopts hyperboloid, laminated bonded glass; the rear
Windscreen,
windscreen adopts hyperboloid, toughened glass with defrosting function; the
Vehicle Door
vehicle door and side winders adopt toughened glass, and the rear right side
Glass
glass is installed with printed antenna.
The driver’s seat is separate, and the position, cushion height, backrest angle and the
seat headrest can be manually adjusted, the seat is equipped with central hand rest,
Driver’s
and the back of the seat is equipped with a sundries bag and sundries hook. In the
Interior and exterior decorations, instrument cluster
Seat
standard configuration the seat adopts knitting fabric, and in the advanced configura-
tion the seat adopts leather as the fabric. (Seat heating can be chosen to install)
The co-driver’s seat is separate, and the seat position, cushion height, backrest
angle and the seat headrest can be manually adjusted, the seat is equipped
Co-driver’
with central hand rest, and the back of the seat is equipped with a sundries bag
s Seat
and sundries hook. In the standard configuration the seat adopts knitting fabric,
and in the advanced configuration the seat adopts leather as the fabric.
Configuration One: 60%+40% collocation, the seat is separate, and the position
and the seat headrest can be adjusted; the backrest can be folded flat forward and
backward; after the seat is folded, it can be overturned from the front part and fixed
Seats onto the handle of Pillar B with hanging belt, and the middle row seat is equipped
The
with child fixing device. In the standard configuration the seat adopts knitting fabric,
Second
Row
Configuration Two: 40%+20%+40% collocation, the seat is separate, and the posi-
Seat
tion and the seat headrest can be adjusted; the seat can be rotated to 180°, and the
middle row seat is equipped with child fixing device. In the standard configuration
the seat adopts knitting fabric, and in the advanced configuration the seat adopts
leather as the fabric.
The two seats are separate, can be seated by three persons; it can be adjusted
The to the two most front and most rear positions, and the backrest can be over-
Third turned flat foreword and backward; when the seat backrest is overturned flat
Row foreword, it can be wholly overturned and hanged onto the side walls to the left
Seat and right separately. In the standard configuration the seat adopts knitting fabric,
Door Handle Door outer handle.

Structure and Parameter of Electrical System

Stru Ve
ctu hic
Parare mo le
mete de V08
r l
Assemb
ly
Single wire system, the negative pole is grounded, with 12 V

Electrical System
Circuit
direct current voltage.
Alternator 90 A
Starter 1.4 kW
Battery 60 Ah
High Beam White 60 W 2 pieces
Front Com-
bined Light
Low Beam White 55 W 2 pieces

Position Lamp White 5W 2 pieces
Steering Light Amber 21 W 2 pieces
raking Lamp Red 21 W 2 pieces
Rear combined lamp
Reversing Lamp White 21 W 2 pieces

Position Lamp White 5W 2 pieces
Steering Lamp Amber 21 W 2 pieces
Lighting and Signaling System
Rear fog Lamp Red 21 W 2 pieces

Side Steering Lamp Amber 5W 2 pieces
Front Fog Lamp White/yellow 55 W 2 pieces
Instrument Lighting Lamp LED
High Mounted Braking Lamp Red 16 W
License Plate Lamp White 5W 2 pieces
Front Residential Lamp White 8W×2 with separate switch
Middle Residential Lamp White 8W with separate switch and door control function
Rear Residential Lamp White 8W with separate switch and door control function
Rear Luggage Compartment White 5W with separate switch and not controlled by the
Lamp rear back door
Cigarette Lighter Lighting White 5W
Ashtray Lighting White 5W
Ignition Switch Lamp Blue LED
Stru Ve
ctur hic
e l
Para mo e V08
m de
Assem eter l
bly
Instruments include: automotive speedometer, tachometer, driving odometer

Combined (including driving general odometer and two phases odometer), driving odometer
Instrument conversion and reset button, fuel meter, meter backlight brightness adjustable
function etc.
Fuel sensor, vehicle speed sensor, water temperature sensor, parking brake
Instrumental System
Sensors and switch, door contact switch, safety belt contact, brake fluid level sensor, brake-
Switches light switch, interior lighting regulator tap assembly, door contact signal switch,
door/window switch etc.
Diesel engine preheating indicator(reserved), parking brake indicator, ABS fault
indicator, master lighting switch indicator(reserved), front fog light indicator, steer-
ing signal indicator, high beam indicator lamp, fog tail light indicator, rear fog/frost
removal indicator(reserved), seat belt fastened alarm indicator, safety bag fault indi-
Indicating cator lamp, brake system fault indicator lamp, engine maintenance service indicator
lamps lamp, oil/water separator clog warning indicator lamp (reserved), 4WD indicator
lamp (reserved), low fuel alarm indicator lamp, engine fault indicator lamp, EBD sys-
tem fault indicator light, 120Km/h alarm indicator light (reserved), AT indicator lamp
(reserved), O\D switch indicator lamp (reserved), door open alarm indicator light,
battery charging system indicator lamp, engine oil pressure alarm indicator light etc.
Front wiper: four-combined lever dual arm type; rear wiper: single arm type; DC
Wiper System
motor of front and rear wipers: two-gear speed adjustment and intermittent control.
Equipped with four speakers (equipped with 6 speakers for Elite model), single-
Audio Equipment disc CD+MP3 interface (equipped with DVD player for Elite model), adopt printed
glass antenna.
Cigarette
Dual 12 V with lighting 120 W.
Lighter
Auxiliary Electrical System
Vehicle Power 12 V vehicle power, under the instrument panel.

Rear Window Glass filming resistance heating type, the control switch is set on the instrument
Defrosting panel, and the power is 200 W.
Electronic Anti-
Create anti-theft function by shutting off the ignition system.
theft System
Equipped with blue tooth hands-free function for Elite model (the car owner
Vehicle Telephone
should have blue tooth handset)
All the five vehicle doors are equipped with central locks. The lock has remote
Door Lock
control function. The rear sliding door is equipped with child lock.
The driver’s door controls the rising and lowering of the glass of all the four
Electric Glass
doors, each door can be controlled separately, and Anti-squeeze; the glass lock-
Lifter
ing switch is equipped on the driver’s side.
Horn Dual sound and electric.
Electric sunroof The electric switch is placed onto the inner roof light assembly.
Electric radar
3-probe reversing radar, and the distance will be electrically displayed on the
distance meas-
internal rear view mirror.
urement
Safety Airbag Electric dual safety airbag (driver and co-driver).
Complete Vehicle Parameter-10
Ve Stru
ctur hic
e le
Para m
mete od V08
Assem r el
bly
Front and rear dual evaporator; steam compression refrigeration, water-heat-

Structure Type ing; front and rear evaporators connected in parallel; the rear air-conditioner
has no heating function.
Controlled manually and electrically (Automatic temperature controlling air-
conditioner with pollen filter in advanced configuration), with control panel
buttons + knobs (manually and electrically). The air outlet is driven by micro
Control
motor, the air outlet position mode, heating/refrigerating mode, air internal/
external circulation mode and air speed and temperature can be chosen and
adjusted, and the temperature in/outside the vehicle can be displayed.
Air-conditioner refrigerating capacity: >7KW.
Air-conditioning
Front blower air output: 500 m3/h; air-conditioner heat capacity: >5KW.
Performance
Rear blower air output: 400m3/h.
Cooling Agent R134a, app. 1Kg.
Compressor type SE10B17 Double-way sloping-cam plate model rated displacement.
Air Cleaning System Dust filter.

1. Front vehicle air-conditioner (front HVAC): dual box-typed structure, com-
posed of laminated evaporator, horizontal flow heater, H-shaped expan-
Air-conditioning System
sion valve, centrifugal blower and air outlet distribution box, having refrig-
Vehicle Air-condi- erating, heating, defogging, and fresh air function, and the air valve is
tioner driven by macro motor.
2. Rear vehicle air-conditioner: composed of laminated evaporator, H-shaped
expansion valve, centrifugal blower and air outlet distribution box, having
refrigerating function, without heating and fresh air function.
Horizontal flow super-cooled structure, the thickness of flat tube is 16 mm,
Condenser
dry fluid storage tank φ34mm×L358mm.
Air tubes of central defogging, left and right defogging, central face blowing,
left and right face blowing, rear foot blowing, rear air-conditioner air blowing,
Air Channel
etc. are all molded through blowing; air tubes of central defogging, fresh air,
and left and right foot blowing are molded through injection.
The two air outlets on the instrument panel are overturning vane-typed, with-
out thumb wheel, and the vane can be used to close the air outlet; the air
outlets on both sides are also overturning vane-typed with thumb wheel to
Air Outlet
control the opening and closing of the air outlet; the four rear air-conditioner
air outlets placed on the roof are long strip-shaped overturning plate-typed
structure, and the vane can be used to close the air outlet.
The refrigerating tube adopts the combined structure of rubber refrigerating
Refrigerating
hose and aluminum tube, and the rear air-conditioner refrigerating tubes are
Tube
aluminum hard tubes.
Warm Water Tube Rubber formed tube.
Sensor Front evaporator temperature sensor, interior and exterior temperature sensors.
Pressure Switch High, middle and low 3-position combined type.
Complete Vehicle Basic Dimension
Auxiliary Vehicle Frame
912.5
359±0.2
20
22
250
903.5
Rear Overhang
1.5 22
72.5
40
50
77.2
Bottom Ring Circle center of Pallet Big Hole

36±0.5
0.5°
1215±0.5
630.5
10
φ65
52
169±0.8
220.5±0.5
143
310.5±0.8
440±0.2
13. 538.3±0.3
478±0.5
5°
122 477.5±0.3
699±0.2
1109
1398±0.4
Unit：mm
Complete Vehicle Basic Dimension (continued)

Side Wall
J
1395.1
101
7.2
C
A 7 .6 E
1009. 1028
877.4
B D G 109
2.4
H
F
Unit: mm
Mark Name Hole Diameter Mark Name Hole Diameter
Positioning and harness Lower hinge installing
A Φ40 B Φ13
via hole via hole
Positioning hole. Door lamp
C Φ19 D Technical cut
switch via hole
Positioning and door control Buffer block installing
E Φ19 F Φ10
switch via hole hole
Sliding door lower positioning
G Φ10 H Technical cut
block installing via hole
I Triangle window buckle hole Φ8 J Technical cut
Engine Room
D E
72
8.
0 8
6.
76
A B
Unit: mm

A Bracket installing hole Φ7 B Bracket installing hole Φ7
E Bolt installing via hole Ф9 D Spare hole Ф11
Complete Vehicle Basic Dimension (continued)
Front Windscreen
C D
157
9.6
9.6
157
A B
Unit: mm

A Positioning hole Φ9 B Positioning hole Φ9
C Decorative strip buckle hole Ф4.2 D Decorative strip buckle hole Ф4.2
Headlight Seat Board
B
A
8 930.
889. 9
C D
Unit: mm

A Condenser installing hole Φ7 B Anti-collision beam installing hole Φ11
C Condenser installing hole Ф11 D Anti-collision beam installing hole Ф11
Engine Mechanical System-
Engine Mechanical System
General of Engine
Operation Instruction...................................................................... 2
General ............................................................................................ 3
Maintenance Specification............................................................. 4
Specification of Tightening Torque............................................... 6
Special Tools.................................................................................... 8
Engine Inspection and Repair
Maintenance on Vehicle.................................................................. 11
Camshaft and Valve Stem Oil Seal................................................ 14
Timing Belt....................................................................................... 19
Engine Overhaul
Alternator and Ignition System...................................................... 29
Exhaust Manifold............................................................................. 31
Timing Belt....................................................................................... 33
Fuel and Exhaust Emission Parts.................................................. 43
Intake Manifold and Water Pump................................................... 45
Swing arm and Camshaft............................................................... 48
Cylinder Cover and Valve............................................................... 51
Oil Pan and Oil Pump...................................................................... 56
Piston and Connecting Rod........................................................... 65
Crankshaft and Cylinder Body....................................................... 71
Operating Instruction
Maintenance Procedure
1 The sectional drawing is placed in front of the parts, for the convenience of mastering the installation
status of each of the components and parts.
2 The serial numbers of the components shall be used to indicate the operating procedure, and the
parts which can’t be reused (marked with ◆) and the tightening torque shall be marked clearly.
Delimitation of Maintenance Directions
Maintenance directions and the operating methods of standard values and special tools shall be
explained in detail together as the maintenance directions, if applicable.
Marks of filling lubricating oil, sealing adhesive and bonding agent
Mark the place of filling lubricating oil, applying or adding sealing adhesive and bonding agent in the
parts and elements drawings.
Disassembly Procedure: the parts should correspond to the serial numbers in the parts and elements
drawings, indicating the Disassembly Procedure.
Installation procedure: if installation in the reverse disassembly procedure is not permitted, the
installation procedure shall be marked. If installation in reverse disassembly procedure is permitted,
the installation procedure can be omitted.
Diagram
<<A>>:Indicating that there are disassembling or dismantling directions.
>>A<<:Indicating that there are installing or assembling directions.
……Lubricating grease (multi-purpose lubricating grease shall be adopted when there is no

special designation)
……Sealing adhesive and bonding agent
……Engine oil or gear oil

General
Vehicle and Engine Type
Vehicle Name Vehicle Model Engine Model Engine Displacement (mL) Specification
Great Wall Single overhead
CC6460VM00 4G63S4N 1,997
COWRY camshaft, 16-valve
General Specification
Item Specification
Form In line water-cooling, single overhead camshaft
Cylinder Number 4
Combustion Chamber Pentroof-type
Total Displacement (mL) 1,997
Cylinder Hole Diameter ( mm) 85
Piston Stroke ( mm) 88
Compression Ratio 9.5
Opened 6°<low speed cam>
Intake (BTDC) 20°<high speed cam>
Valve 38°<low speed cam>
Closed (ABDC)
Valve Timing 72°<high speed cam>
Opened 60°
Exhaust
(BBDC)
Valve
Closed (ATDC) 16°
Lubricating System Pressure supply, all-flow filtering
Oil pump type Involute gear
Processing Size
Item Standard Value
The secondary processing size 0.3 oversize 35.30-35.33
Intake
of the enlarging of the intake and 0.6 oversize 35.60-35.63
exhaust valve seat ring hole (mm)
0.3 oversize 33.30-33.33
Exhaust
0.6 oversize 33.60-33.63
The secondary processing size of the enlarging 0.05 oversize 11.05-11.07
of the valve guide installing hole (intake valve and 0.25 oversize 11.25-11.27
exhaust valve) ( mm)
0.50 oversize 11.50-11.52
Maintenance Specification
Item Standard Value Operating Limit Value
Timing belt
Automatic tensioner stem length ( mm) 3.5-4.5 -
Automatic tensioner arm protrusion amount ( mm) 12 -
Automatic tensioner stem pushing amount [pushing in at (98-196) N] ( mm) Below 1.0 -
Intake ( mm) 0.11 0.11±0.03
Valve clearance (in cold state)
Exhaust ( mm) 0.20 0.20±0.03
Swing arm and Camshaft
Low speed cam A 37.471 Minimum 36.971
Intake Low speed cam B 37.471 Minimum 36.971
Cam height of camshaft ( mm)
High speed cam 37.209 Minimum 36.709
Exhaust 37.857 Minimum 37.357
Outer diameter of camshaft journal ( mm) 45 -
Cylinder Cover and Valve
Planeness of lower surface of cylinder cover ( mm) Less than 0.03 0.2
Surface grinding limit * total of grinding amount of cylinder and
- *0.2
cylinder cover ( mm)
Total height of cylinder cover ( mm) 120 -
Bolt grip length of cylinder cover ( mm) - 99.4
Intake 1.0 Minimum 0.5
Valve thickness (edge) ( mm)
Total valve height ( mm)
Outer diameter of valve stem ( mm) 6.0 -
Radial clearance of valve stem and Intake 0.02-0.04 0.10
guide tube( mm) Exhaust 0.04-0.06 0.15
Tilting angle ( mm) 45° -
Free length of valve spring ( mm)
Valve spring load/installation length (N/ Intake 235/44.2 -
mm) Exhaust 226/44.2 -
Verticality of valve spring Below 2° -
Valve contact width of valve seat ( mm) 0.9-1.3 -
Internal diameter of valve guide ( mm) 6.0 -
Protrusion height of valve guide ( mm) 14.0 -
Intake 48.33 48.83
Protrusion part of valve stem ( mm)
Exhaust 48.34 48.84
Oil Pan and Oil Pump
Driving gear 0.08-0.14 -
Side clearance of oil pump ( mm)
Driven gear 0.06-0.12 -
The oil temperature is (75-90) ° when the oil pressure is lowest and
More than 78 -
the idling speed is limited.
Maintenance speciation (continued)

Item Standard Value Operating Limit Value
Piston and Connecting Rod
Piston outer diameter Φ ( mm) 87 -
No. 1 0.03-0.07 0.1
Side clearance of piston ring ( mm)
No. 2 0.02-0.06 0.1
No. 1 0.15-0.30 0.8
End clearance of piston ring ( mm) No. 2 0.28-0.43 0.8
Oil ring edge track 0.10-0.40 1.0
Outer diameter of piston pin Φ ( mm) 22.0 -
Piston pin pressing load (N) (room temperature) 7,350 - 17,200 -
Oil film clearance of crankshaft pin ( mm) 0.02-0.05 0.1
Side clearance of rod big end ( mm) 0.10-0.25 0.4
Crankshaft and Cylinder Body
Axial clearance of crankshaft ( mm) 0.05-0.175 0.40
Outer diameter of crankshaft journal Φ ( mm) 57.0 -
Outer diameter of crankshaft pin Φ ( mm) 45.0 -
Oil film clearance of crankshaft journal ( mm) 0.02-0.04 0.1
Bearing cover bolt length ( mm) - 71.1
Clearance between piston and cylinder ( mm) 0.02-0.04 -
Planeness of cylinder surface ( mm) 0.05 0.1
Upper surface grinding limit * total of grinding amount of
- 0.2
cylinder and cylinder cover ( mm)
Total cylinder height ( mm) 284 -
Inner diameter of cylinder Φ ( mm) 87.0 -
Cylinder hole cylindricity ( mm) 0.01 -
Tightening Torque
Tightening Tightening
Item Item
Torque (N•m) Torque (N•m)
Alternator and Ignition System
Automatic tensioner bracket bolt M10 44±10 Alternator bolt 49±9
Automatic tensioner bracket bolt M8 19-28 Alternator pivot nut 44±10
Camshaft position signal sleeve bolt 22±4 Idle wheel belt tray bolt 79±5
Camshaft position sensor bolt 10±2 Ignition coil bolt 10±2
Camshaft position sensor bracket bolt 14±1 Oil dipstick guide bolt 13±1
Connector bracket bolt 10±1 Spark plug 25±5
Camshaft belt tray bolt 25±5 Water pump belt tray bolt 8-10
Exhaust Manifold
Exhaust manifold bracket bolt(bolt and
Oxygen sensor 44±5 44±5
washer assembly)
Engine hanger bolt 24±3 Exhaust manifold washer-head bolt 10×30 49-69
Exhaust manifold cover bolt 14±1 Exhaust manifold bracket bolt (flange bolt) 36±5
Timing Belt
Automatic tensioner bolt 23±2 Engine right bracket bolt 49±5
Camshaft sprocket bolt 88±10 Alternator bracket bolt 49±9
Reversing balancing axis sprocket bolt 45±3 Idle wheel belt tray bolt 35±6
Camshaft bolt 167 Oil pump sprocket nut 54±4
Camshaft position sensor bolt 8.5±0.5
Timing Belt
Tensioner “B” bolt 19±3 Tensioner arm bolt 20-26
Tensioner belt tray bolt 48±5 Timing belt cover bolt M8 14±1
Timing belt cover bolt M6(bolt and Timing belt cover bolt M6
9.0±1.0 11±1
washer assembly) (Flange bolt and nut)
Fuel and Exhaust Emission Parts
Solenoid valve bracket bolt 11±1 Solenoid valve nut 9.0±1.0
Fuel pressure regulator bolt 9.0±1.0 Throttle valve body bolt 15-22
Fuel distributing pipe bolt 11±1 Vacuum tube and hose bolt 11±1
Intake Manifold and Water Pump
Engine coolant temperature sensor 30±9 Knock sensor 23±2
Manifold absolute pressure sensor bolt 5.0±1.0 Oil pressure switch 19±3
Engine hanger bolt 24±3 Thermostat housing bolt 24±4
Wiring hardness bracket bolt 10±1 Water inlet fitting bolt 13±2
Intake manifold bolt 24±3 Water inlet pipe bolt 13±2
Intake manifold nut 20±2 Water outlet fitting bolt 13±2
Intake manifold bracket bolt 31±3 Water pump bolt 14±1
Tightening Torque (continued)

Tightening Tightening
Item Item
Torque(N•m) Torque(N•m)
Swing arm and Camshaft
Swing arm and swing arm shaft bolt
Accumulator body bolt 44±5 12-16.8
<exhaust side>
Swing arm and swing arm shaft bolt
Oil control valve bolt 11±1 28-40.8
<intake side>
Nut 9.0±1.0 Swing arm cover bolt 3.5±0.5
Conical plug 47±7
Cylinder cover bolt (78±2) N•m →0N•m →(20±2)N•m→+90°→+90°
Oil Pan and Oil Pump
Partition board bolt 9.0±2.0 Oil pan bolt 9.0±3.0
Drain plug 39±5 Oil pump cover bolt 17±1
Flange bolt 36±3 Oil pump cover screw 10±2
Front housing bolt 23±3 Oil filter bolt 19±3
Oil filter bracket bolt 19±3 Plug 23±3
Oil filter(except MITSUBISHI
17±3 Drain plug 44±5
factory filter p/n MD356000)
Oil filter (MD356000) 14±2 Transmission column bolt 22±4
Piston and Connecting Rod
Connecting rod cover nut (20±2) N•m →+90°to 94°
(25±2）N•
Bearing cover bolt Flywheel bolt (M/T) 50-60
m→+90°
Bell casing cover bolt 9.0±1.0 Oil seal housing body bolt 11±1
Driving board bolt(A/T) 132±5 Back panel bolt 11±1
Special Tools
Tool Part No. Name Usage
MD998781 Flywheel stopper To fix flywheel and driving tray
To disassemble and assemble spark

MB991398 Spark plug spanner
plug
Oxygen sensor To disassemble and assemble oxygen

MD998770
spanner sensor
Crankshaft toothed To disassemble Crankshaft toothed belt

MD998778
belt pulley puller pulley
Timing toothed belt To retain balancing axis toothed belt

MD998785
pulley stopper pulley
Camshaft belt pulley

MB990767
spanner
To fix camshaft sprocket wheel when
loosening or screwing bolts
MD998719 Belt pulley fixing pin
·To fix automatic tensioner

MD998738 Adjusting screw
·To adjust timing belt tension
Tension belt tray

MD998767 To adjust timing belt tension
spanner
Oil pressure switch To disassemble and assemble engine

MD998054
spanner oil pressure switch
Camshaft oil seal

MD998713 To assemble camshaft oil seal
erector
Special Tools (continued)

Cylinder cover bolt disassemble and assemble cylinder

MB991654
spanner (12) cover bolt
Valve spring
MD998735 To compress valve spring
compressor
MD998774 Valve oil seal erector To assemble valve oil seal
MD998727 Oil pan detacher To disassemble oil pan
MD998162 Screw plug spanner
To disassemble and assemble front

casing cover plug
Screw plug spanner
MD998783
holding fixture
Balancing axis bearing To disassemble reverse balancing axis

MD998371
puller front bearing
Balancing axis bearing To disassemble reverse balancing axis

MD998372
puller rear bearing
To disassemble reverse balancing axis

Balancing axis bearing
MB991603 rear bearing and install guide limit,
puller limiter
using with MD998372
Balancing axis bearing To assemble reverse balancing axis

MD998705
erector front and rear bearing
Engine Mechanical System-10
Special Tools (continued)

Crankshaft front oil

MD998285
seal guiding pipe
To assemble crankshaft front oil seal
with MD998375
Crankshaft front oil
MD998375
seal erector
Piston disassembling To disassemble and assemble piston

MD998375
and installing device pin
MB990938 Handle
To assemble crankshaft rear oil seal

with MB990938
Crankshaft rear oil seal
MD998776
erector
Intake valve side

Maintenance on Vehicle
Inspection and Adjustment of Valve Clearance
1. Before the inspection, check and confirm that
the engine oil, the starter and the battery are all
in normal condition, and simultaneously set the
vehicle into the following status:
• Engine coolant temperature: (80-95) °C
Exhaust valve side
• Lights and all the auxiliary facilities: OFF
2. Disassemble all the ignition coils.
3. Disassemble the swing arm chamber cover.
4. Turn the crankshaft clockwise, until the notch on the
belt tray aims at the sign T on the timing indicator.
5. Move the No.1 and No.4 cylinder swing arms upward
and downward manually to determine whether
the cylinder piston is at the top dead center of the
compression stroke. If both the intake and exhaust
valve swing arms have valve clearance, the piston
in the cylinder corresponding to this swing arm is at
the top dead center of the compression stroke.
6. When the No.1 cylinder piston is at the top dead
center of the compression stroke, inspect and adjust
the valve clearance of the swing arm indicated with
the white arrowhead; when the No.4 cylinder piston
is at the top dead center of the compression stroke,
inspect and adjust the valve clearance of the swing
arm indicated with the black arrowhead.
7. Measure the valve clearance
If the valve clearance doesn’t accord with the specification,
loosen the swing arm locking nut and turn and adjust the
screw adjusting clearance with a feeler gauge.
Standard value (hot engine):
Intake valve: 0.20 mm
Exhaust valve: 0.30 mm
8. Fix the adjusting screw with a screwdriver to avoid
being turned, and lock the fixing nut to regulated
torque.
Tightening torque: (9±1) N•m
9. Turn the crankshaft to 360°, to make the notch line
up with T mark on timing indicator.
10. Repeat the steps of (7) and (8) for the clearance
adjustment of other valves.
11. Install the swing arm cover.
12. Install the ignition coils.
Inspection of Swing arm Piston Function

Oil pressure inspection hole
1. Disassemble all the ignition coils.
Engine oil control valve 2. Disassemble the swing arm cover.
3. Disassemble the engine oil control valve.
4. Disassemble the oil pressure inspection hole on
the engine cylinder cover.
Ignition coil 5. Turn the crankshaft clockwise, until the notch on the
belt tray aims at the sign T on the timing belt lower
Swing arm cover AK302683AB cover.
6. Move the No.1 and No.4 cylinder swing arms
upward and downward manually to determine the
Intake valve side top dead center position of the compression stroke.
Remarks: when the No.1 cylinder piston is at the top
dead center of the compression stroke, inspect the
valve clearance of the swing arm indicated with the
white arrowhead; when the No.4 cylinder piston is at
the top dead center of the compression stroke, inspect
the valve clearance of the swing arm indicated with the
Exhaust valve side black arrowhead.
7. Close the bottom of the installing hole of the
engine oil control valve with fingers to prevent
air leakage, and blow compressed air into the
installing hole of the engine oil pressure switch
with an air gun. At this time, confirm whether the
swing arm can actuate.
Remarks: in order to confirm the inspection, avoid
Swing arm compressed air leaking from the installing O-shaped
ring at the end of the air gun as much as possible.
Swing arm
piston 8. Turn the crankshaft clockwise, until the notch on
the belt tray aims at the sign T on the timing belt
lower cover.
9. At Step 7, confirm other swing arm pistons.
Oil passage 10. If the rocker piston has no effect, replace the swing
arm piston assembly.
11. Apply sealing adhesive onto the bolt thread, with
Blow in compressed air
LOCTITE203MP or equivalent products.
Remarks: within one hour after the installation of the oil
pressure switch, never start the engine.
12. Install the engine oil pressure switch and tighten it
to the regulated torque.
Standard value: (15-22) N•m
13. Install engine oil control valve.
14. Install all the ignition coils.
15. I n s t a l l t h e s w i n g a r m c o v e r o f o i l p r e s s u r e
inspection hole .
Compression pressure inspection

1. Before inspection, check that the engine oil, the starter and the battery are all in normal
condition, and set the vehicle into the following status:
• Engine coolant temperature: (80-95) °C
• Lights and all the auxiliary facilities: OFF
• Automatic transmission: Gear P
2. Disassemble all the ignition coils and spark plugs.
3. Disconnect the connector of the crankshaft position sensor.
Remarks: this operation can avoid the engine control module to perform ignition and fuel ejection.
Warning: When turning the engine, keep away from the spark plug holes, because the oil, fuel,
etc. may be ejected from the spark plug holes and cause serious injury.
4. When turning the engine, use a towel or something
Crankshaft position
else to cover the spark plug holes. After turning
sensor connector the engine, inspect whether foreign matter is stuck
onto the towel.
5. Install the compression pressure gauge onto the
spark plug holes.
6. When the throttle valve is opened completely, turn
the engine and measure the compression pressure.
Standard value (engine speed 200 r/min): 1,560 kPa
Alternator Minimum limit value (engine speed 200 r/min): 1,130 kPa
AK303339AB
7. Measure the compression pressure of all the
cylinders, and inspect whether the cylinder pressure
Compression pressure gauge is lower than the limit value.
8. If the compression pressure of one cylinder is
lower than the limit value or the difference value of
the compression pressure is beyond the limit value,
drip a small amount of engine oil via the spark plug
hole, and then repeat Steps 6 to 8.
(a) After the oil addition, if the compression pressure
increases, the cause of the fault would be the
piston ring, and/or there is abrasion or damage on
AK204360AC the cylinder inner surface.
(b) After the oil addition, if the compression pressure
doesn’t increase, the cause of the fault would be the
Intake manifold Vacuum gauge
valve seat burnt and damaged or in poor condition,
and/or the pressure is leaked from the gasket.
9. Connect the connector of the crankshaft position
sensor.
10. Install the ignition coils.
11. Remove the diagnosis malfunction code with the
scanning device.
Remarks: once the connector of the crankshaft position
Fuel pressure adjuster sensor is disconnected, the diagnosis malfunction code
will be cancelled.
Manifold Vacuum Inspection
1. Start the engine and warm the vehicle until the engine coolant temperature reaches (80-95) °C.
2. Turn the ignition switch to the LOCK (OFF) position, and connect the MUT-III detector.
3. Disconnect the vacuum tube of vacuum booster, and connect the vacuum gauge.
4. Start the engine, and check whether the idling speed is within the standard value.
Standard value: (700±50) r/min
5. Inspect the vacuum of the intake manifold.
Minimum limit value: 60 kPa
6. Shut off the ignition switch, and disconnect the vacuum gauge and the detector.
Camshaft and Valve Stem Oil Seal

Disassembly and Assembling
Disassemble and assemble the marked parts of each cylinder unit.
3.0±0.5
4
1 3.5±0.5
3
9
13±2
◆10
6
2 (Enging oil)
◆8
5±1 11±1
◆11 3.5±0.5
5
7
12
45±5
N·m : Regulated torque

◆ Parts which can’t be reused
Camshaft Disassembling Procedure

>>K<< 1. Engine hood 6. Engine hanger
2. Engine hood bracket >>J<< 7. Oil control valve
3. PCV hose connection >>J<< 8. O-ring
of rocker arm cover >>J<< 9. Swing arm cover assembly
4. Air hose connection of 10. S
wing arm cover sealing ringring
rocker arm cover 11. S
ealing ring of spark plug guiding pip
5. Engine wire harness 12. Accumulator assembly
31±3 11±1
Apply engine oil onto 13
all the moving parts 13±1
before installation. 20
14
21
47±7 23
24
18 14±1
25±4 22±4
15
25
26* 19
27* 22
28*
◆30*
31* 26*
27*
29*
◆30*
89±9 31*
◆17
16

* Disassemble and assemble the marked parts of each cylinder.
Camshaft Disassembling Procedure Valve stem oil seal disassembling procedure

13. Connector bracket 1. Engine hood
>>I<< 14. C amshaft position sensor 2. Engine hoodbracket
bracket seat 3. P CV hose connection of rocker
15. C a m s h a f t p o s i t i o n s i g n a l arm cover
sleeve 4. A ir hose connection of rocker
<<A>> >>H<< 16. Camshaft sprocket arm cover
>>G<< 17. Camshaft oil seal 5. Control harness connection
>>F<< 18. Exhaust swing arm shaft cover 6. Engine hanger
<> >>F<< 19. Exhaust swing arm and shaft 9. Swing arm cover assembly
assembly 10. Swing arm cover gasket
>>E<< 20. Intake swing arm shaft cover 11. Spark plug guiding track oil seal
<> >>E<< 21. Intake swing arm shaft assembly >>F<< 18. Exhaust swing arm shaft cover
>>D<< 22. Camshaft <> >>F<< 19. E xhaust swing arm and shaft
23. Cylinder cover plug assembly
24. Oil control valve filter >>E<< 20. Intake swing arm shaft cover
<> >>E<< 21. Intake swing arm shaft assembly
25. Spark plug
<<C>> >>C<< 26. Fixer lock of valve spring
Required Special Tools 27. Valve spring fixer
MD998713: Camshaft oil seal erector >>B<< 28. Intake valve spring
MD998719: Pin >>B<< 29. Exhaust valve spring
MD998772: Valve spring compressor >>A<< 30. Valve stem oil seal
MD998774: Valve stem oil seal erector 31. Valve spring seat
Disassembly Maintenance Key Points

<<A>> Disassembly of camshaft sprocket
MB990767 1. Fix the camshaft sprocket with the special tools
MB990767 and MD998719.
2. Loosen the camshaft sprocket fixing bolts and
MD998719 disassemble the camshaft sprocket.
<> Disassemble the exhaust swing arm and
shaft assembly/intake swing arm and shaft
assembly
Notice: Never disassemble the exhaust swing arm
and shaft assembly and intake swing arm and shaft
assembly when inspecting.
MD998772 <<C>> Disassemble the Fixer lock of valve spring
When disassembling the valve spring fixer, place each
cylinder piston at the TDC(top dead center)position. If
the piston is not at the appropriate TDC position, the
valve will drop into the cylinder.
Compress the valve spring with the special tool
MD998772 and then disassemble the valve spring fixer.
Installation Maintenance Key Points

MD998774 >>A<< Valve stem oil seal installation
Valve 1. Apply a small amount of engine oil onto the valve
stem oil seal.
Valve stem oil seal • Never reuse the valve stem oil seal.
• The special tool MD998774 must be used when
Valve guide the valve stem oil seal is installed. Inappropriate
installation may cause oil leakage at the valve guide.
2. Press in the new valve stem oil seal into the valve
guide with the special tool MD998774 together with
the guiding pipe in the stem oil area.
Swing arm side
>>B<< Exhaust valve spring /intake valve spring
installation
Identifying color Install the valve spring upward according to the
Intake side: light blue identifying color printed on the bottom.
Exhaust side: orange
>>C<< Valve spring fixer installation

Compress the valve spring with the special tool of
MD998772 MD998772, and then install the valve spring fixer
according to the same disassembling method.
Positioning pin
>>D<< Camshaft installation
Set the camshaft positioning pin at the position
marked in the figure.
Engine front >>E<< Intake swing arm and shaft assembly/

Ф5.5 mm intake swing arm shaft cover installation
1. Place the intake swing arm shaft at the position
with the hole Ф5.5 mm toward the cylinder cover.
2. Install the intake swing arm shaft cover.
3. Lock the intake swing arm shaft fixing bolt to the
regulated torque.
Tightening torque: (28-40.8) N•m
>>F<< Exhaust swing arm and shaft assembly/

Engine front exhaust swing arm shaft cover installation
1. Install the exhaust swing arm shaft, and place the
groove at the position marked in the figure.
2. Install the exhaust swing arm shaft cover.
3. Lock the exhaust swing arm shaft fixing bolt to the
regulated torque.
Groove
Tightening torque: (12-16.8) N•m
>>G<< Camshaft oil seal installation

Camshaft oil seal
1. Apply engine oil to all the inner diameter of the oil
seal.
2. Press in the oil seal with the special tool of MD998713
as shown in the figure.
Engine oil
MD998713
>>H<< Camshaft sprocket installation

1. Fix the camshaft sprocket with the special tools of
MB990767 MB990767 and MD998719 in the same disassembling
method.
2. Lock the camshaft sprocket fixing bolt to the regulated
torque.
MD998719
>>I<< Camshaft position sensor bracket seat

installation
1. Remove the sealing adhesive from the surface of
Ф3 mm
camshaft position sensor bracket seat and the
cylinder cover.
2. Apply sealing adhesive onto the camshaft position
sensor bracket seat flange in a continuous pearl
shape, as shown in the figure.
Sealing adhesive specification: MD970389 or
equivalent products
Remarks: within 15 minutes after applying sealing
adhesive, install the camshaft position sensor bracket
seat.
Adhesive bandage
3. Install camshaft position sensor bracket seat onto
the cylinder cover.
Notice: after waiting for at least one hour, never
start the engine or let engine oil and coolant contact
the applied surface.
4. Lock the camshaft position sensor bracket seat to
the regulated torque.
>>J<< O-ring/engine oil control valve installation
Notice: Never reuse O-ring.
Before installing the O-ring, entwine around the closing
oil pipe of the engine oil control valve with soft sticky
adhesive bandage to avoid damage. If the O-ring is
damaged, it may cause oil leakage.
1. Apply a small amount of engine oil onto the O-ring
and then install the O-ring onto the engine oil
control valve.
2. Assemble the engine oil control valve onto the
cylinder cover.
3. Lock the engine oil control valve fixing bolts to the
regulated torque.
>>K<< Engine bonnet installation
1. Insert the clips of the engine bonnet into the
bonnet bracket.
2. Assemble the installing bolts onto the position
shown in the figure according to the sequence.
3. Lock the bolts to the regulated torque.
Tightening torque: (3.0±0.5) N•m
Timing Belt
Disassembling and Assembling
14±3
11±1
3
5
4 1
14±1 12
11
48±5
14±1
6
9
8.8±1.0 11±1
8 21±4
13
44±10
23±3
10
22±4
7
79±5
11±1
9.0±1.0
Disassembling Procedure
1. Control harness connector
2. Battery harness connector
3. Connector bracket
4. Harness bracket
5. Timing belt upper cover
6. Water pump belt tray
7. Idle pulley belt tray
8. Automatic tensioner
9. Timing belt upper cover
>>G<< Valve timing belt tension adjustment
(only for installation)
<> >>F<< 10. Valve timing belt
>>E<< 11. Timing belt tensioner belt tray
12. Timing belt tensioner arm
>>D<< 13. Timing belt tensioner adjustment
14
35±6
22
21
19±3
18
Engine oil
20 16
15
19
167 17
8.5±0.5
Disassembly Procedure Required Special Tools

14.Timing belt idle pulley belt tray MB991367: Special spanner
15.Timing belt lower cover bracket MB991385: Pin
16.Crankshaft position sensor MD998738: Adjusting bolt
<<C>> >>C<< 17.Crankshaft pulley central bolt MD998767: Tensioner spanner
<<C>> >>C<< 18.Crankshaft pulley gasket
<<C>> >>C<< 19.Crankshaft driving sprocket
>>C<< 20.Crankshaft position signal plate
>>B<< Balancing timing belt tension adjustment (only for installation)
>>A<< 21.Balancing timing belt tensioner
<<D>> >>A<< 22.Balancing timing belt
Timing mark
Disassembling Maintenance Key Points
<<A>> Valve timing belt disassembly
Notice: Never turn the crankshaft counterclockwise.
1. Turn the crankshaft clockwise, and align the timing
mark and the TDC of the first cylinder compression
stroke.
Camshaft sprocket
Timing mark
Timing mark
Engine oil pump sprocket
Crankshaft camshaft driving sprocket
2. Disassemble the rubber plug of the timing belt

lower cover and set the special tool of MD998738.
MD998738
Ti m i n g b e l t
lower cover
3. Turn the special tool of MD998738 manually until it

contacts the timing belt tensioner arm.
Timing belt Turn the special tool of MD998738 with 30° per second
tensioner arm
to install gradually. If the tool is turned in one time, the
MD998738 adjusting stem of the timing belt tensioner may not be
retracted easily, and the special tool of MD998738 may
be bent.
4. Turn the special tool of MD998738 gradually and

then align the setting hole A of the timing belt
tensioner adjusting stem and the setting hole B of
the timing belt tensioner adjusting stem.
Timing belt tensioner

5. Insert the line or pin into the aligned setting hole.
pulley fixing bolt Notice: When reusing the driving belt, draw an
Line or pin
arrowhead indicating the rotating direction (clockwise)
on the belt back with a piece of chalk, etc.
6. After disassembling the special tool of MD998738,
loosen the timing belt tensioner, and the pulley
fixing bolts and disassemble the valve timing belt.
<> Crankshaft pulley central bolt/crankshaft

pulley gasket/crankshaft driving sprocket
disassembly
1. Fix the flywheel with a special tool.
2. Disassemble the crankshaft bolts.
Support the flywheel with a special tool.
MD998781
<> Crankshaft gear belt disassembly

If the gear belt is stuck and not easy to be disassembled,
the special tool should be used.
MD998778 <<C>> Balancing axis timing belt disassembly
Use the balancing axis timing belt again, draw an ar-
rowhead indicating the rotating direction on the belt
back with a piece of chalk.

Timing >>A<< Timing gear belt B installation
mark 1. Align the marks of the crankshaft gear belt pulley
(front Timing
cover) mark B and the balancing axis gear belt pulley and the
mark on the front cover.
2. Install the timing gear belt B onto the crankshaft
gear belt pulley B and the balancing axis gear belt
pulley. The tensioned side shall not be loosened.
3. Confirm that the positions of the tensioiner pulley

Tensioner B center and the bolt center are as shown in the
figure.
Tensioner
wheel center
Bolt center
4. When exerting force on one side of the timing gear

belt tensioner with fingers, move the tensioner
B toward the arrowhead direction. At this time,
tighten the bolts and fix the tensioner B.
Notice: When tightening the bolts, never let the
axis turn with the gear belt pulley together to avoid
overtighten of the gear belt.
5. Conform that the gear belt pulley is aligned to the

mark on the front cover.
Gear belt
Timing pressing amount 6. Press the central part of one side of the tensioner
mark of the timing gear belt B with the forefinger, and the
pressing amount of the gear belt is (5-7) mm.
Timing
mark
○ Clean >>B<< Crankshaft position signal plate/crankshaft

* Apply engine oil driving sprocket/crankshaft belt tray gasket/
● Clean and remove oil stain
crankshaft belt tray central bolt installation
Crankshaft belt Crankshaft position 1. Clean the crankshaft, crankshaft position signal
tray central bolt signal plate
plate, crankshaft driving sprocket and crankshaft
Crankshaft belt
tray gasket belt tray gasket and or remove oil stain as shown
in the figure.
Remarks: clean oil stained surface.
2. Install the crankshaft position signal plate,
crankshaft driving sprocket in the direction as
shown in the figure.
3. Place the crankshaft belt tray gasket into the bigger
Crankshaft groove side in the direction as shown in the figure,
Crankshaft driving sprocket
and assemble the crankshaft belt tray central bolts.
4. Apply a small amount of engine oil onto the surface
Engine front
of the crankshaft belt tray central bolt bearing and
bolt thread.
5. Fix the crankshaft driving sprocket with the special

Crankshaft camshaft tools of MB991367 and MB991385 in the same
MB991385
driving sprocket disassembling method.
6. Lock the crankshaft belt tray central bolt to the
regulated torque.
Tightening torque: 167 N•m
MB991367
>>C<< Timing belt tensioner adjustor installation

1. When the timing belt tensioner adjustor stem is
outstretched completely, set according to the
following procedure.
If the compression process is too rapid, the stem will
be damaged, so pay attention to press in slowly and
completely.
(a) Press in the timing belt tensioner adjusting stem
with a press machine or jaw vice slowly, and align
the stem setting hole A and the setting hole B of
the timing belt tensioner adjuster.
(b) Insert a line of pin into the aligned setting hole.
Line or pin Remarks: When replacing with a new timing belt
tension adjuster, the belt tensioner adjuster has already
been fixed with a pin.
2. Install the timing belt tensioner adjuster onto
the engine, and then lock the fixing bolts to the
regulated torque. The line or pin shall not be
disassembled until the tension of the valve timing
belt is adjusted.
>>D<< Timing belt tensioner belt tray installation.

Lock the timing belt tensioner belt tray temporarily as
Timing belt tensioner

belt tray hole
>>E<< Valve timing belt installation

1. Align the timing marks on the camshaft sprocket,
the crankshaft driving sprocket and Engine oil
Timing mark pump sprocket.
Camshaft sprocket
Timing mark
Timing mark
Crankshaft Engine oil pump sprocket

driving sprocket
2. Adjust the timing mark of the engine oil pump

Bolt
Balancing axis sprocket.
Pull off the cylinder plug, and insert a bolt (M6 with
section width of 10 mm and nominal length of 45 mm)
into the plug hole. If the bolt contacts the balancing
axis, turn the engine oil pump sprocket for a round.
Readjust the timing mark, and then check the matching
Plug of the bolts. The bolts can’t be disassembled until the
Cylinder body
composition of the valve timing belt is accomplished.
3. If using the following methods, the belt tension will

not be loosened.
(a) Place the valve timing belt onto the timing belt
tensioner belt tray and the crankshaft driving
Camshaft sprocket
sprocket, and then hold it with the left hand not to
make it slide.
(b) When pulling the belt with the right hand, place
the valve timing belt onto the engine oil pump
Timing belt
tensioner
Belt tension side sprocket.
belt tray (c) Place the valve timing belt onto the timing belt idle
pulley belt tray.
(d) Place the valve timing belt onto the camshaft
Timing belt idle sprocket.
pulley belt tray

Crankshaft
driving sprocket
4. Turn the timing belt tensioner belt tray in the

direction as shown in the figure with the special
tool of MD998767 and exert a tension onto the
valve timing belt. Then lock and fix the timing belt
tensioner belt tray fixing bolts temporarily.
5. Check whether the timing mark is aligned.
Timing mark
Camshaft sprocket
Timing mark
Timing mark

Crankshaft camshaft
driving sprocket
6. Disassemble the bolts inserted in the step 2 above.

Bolt Then install the cylinder body plug.
Balancing axis
7. Lock the cylinder body plug to the regulated torque.
8. Adjust the valve timing belt tension.
Plug
Cylinder body
>>F<< Valve timing belt tension adjustment

1. When disassembling the valve timing belt, set the
MD998738 special tool of MD998738.
Notice: Turn the special tool of MD998738 with
hand, if a screw spanner or other tools are used,
they will damage the line or pin inserted into the
timing belt tensioner adjuster.
Timing belt
lower cover
2. Turn the special tool of MD998738 gradually
until the line or pin inserted into the timing belt
tensioner adjuster can be moved slightly.
3. Turn the crankshaft counterclockwise to 1/4 round.
4. Turn the crankshaft clockwise, and align all the
Timing mark timing marks.
5. Loosen the timing belt tensioner belt tray fixing
bolts.
Camshaft sprocket
Timing mark
Timing mark
Crankshaft driving sprocket
When locking the fixing bolts, confirm that the timing

belt tensioner belt tray and the bolts will not be turned
MD998767
simultaneously. Being turned simultaneously will cause
poor belt tension.
6. Use the special tool of MD998767 and the torque
spanner, tighten to 3.5 N•m with the torque spanner,
and when holding the tensioner belt tray with the
special tool and the torque spanner, tighten the
central bolt to the standard torque.
7. Disassemble the line or pin inserted into the belt

tensioner adjuster.
Line or pin
8. Disassemble the special tool of MD998738 and

install the rubber plug onto the timing belt cover.
MD998738
9. Turn the crankshaft clockwise for two rounds, and
stop for 15 minutes.
Timing belt
lower cover
10. Insert in the line or pin disassembled in step 7, and

confirm that it can be pulled out with a slight force.
Line or pin If the line of the pin can be easily disassembled, it
means that the appropriate tension has been exerted on
the belt. The line or pin can be disassembled in this way.
The protrusion amount of the timing belt tensioner

adjuster stem (A).
A Standard value (A): (3.8-4.5) mm
11. If the line of pin can’t be pulled out easily, repeat the
steps 1 to 9 to make it reach the appropriate valve
Stem
timing belt tension.
Notice: When turning the crankshaft belt tray
central bolts counterclockwise, the tightening
Timing mark
torque of the crankshaft belt tray central bolts must
be inspected. If the bolts are loosened, relock them.
12. Re-inspect whether the timing mark on the sprocket
is aligned.
Camshaft sprocket
Timing mark
Timing mark Engine oil

Crankshaft driving sprocket pump sprocket
98-196 N Timing Belt Tensioner Adjuster Inspection

1. Inspect whether the oil seal leaks, and if it leaks,
M replace the oil seal.
A B
Rod 2. Inspect whether the upper end of the stem is
R abraded or damaged, and replace if necessary.
3. Fix the timing belt tensioner adjuster with hands,
and measure the displacement value of the stem
at the upper end of the pressing stem on metal (for
example: cylinder body) with the pressure of less
than (98-196) N.
Standard value: within 1 mm
A: Free length (not pressed)
B: Length when pressed
A-B: Displacement
4. If the measured value is beyond the standard,
replace the timing belt tensioner adjuster.
Alternator and Ignition System

10±2 10±2
25±5 10±1
1 10 13
11 ◆14
15
16
10±1
13±1
12
2 14±1
22±4
◆3
8
44±10
6
8.8±1.0
25±4 22±4
7
79±5 9
5
49±9
44±10

Disassembling Procedure Required Special Tools

1. Oil dipstick MB991398: Spark plug spanner
2. Oil dipsti-ck guiding pipe MD998781: Flywheel stopper
3. O-ring
4. Automatic tensioner
5. Crankshaft belt tray
6. Water pump belt tray
7. Idle pulley belt tray
9. Alternator
10. Ignition coil
<<A>> >>C<< 11. Spark plug
13.Camshaft position sensor
14. O-ring
>>B<< 15.Camshaft position sensor bracket
<> >>A<< 16.Camshaft position signal sleeve

<<A>> Spark Plug Disassembly
Disassemble the spark plug with the special tool of
MB991398 MB991398.
<> Camshaft position signal sleeve disassembly

1. Fix the flywheel with the special tool of MD998781.
2. Disassemble the camshaft position sleeve
MD998781

>>A<< Camshaft position signal sleeve installation
1. Fix the spark plug with the special tool of MD998781.
2. Lock the camshaft position sleeve to the regulated
torque.
MD998781
>>B<< Camshaft position sensor bracket installation

Ф3 mm
(0.12 in) 1. Remove the sealing adhesive on the surface of the
camshaft position sensor bracket and the cylinder
cover.
2. Apply (3±1) mm pearl-shaped sealing adhesive
inside the groove, as shown in the figure.
(MITSUBISHI genuine parts number MD970389).
>>C<< Spark plug installation

Lock the spark plug with the special tool of MB991398
MB991398 Tightening torque: (25±5) N•m
Exhaust Manifold
14±1
14±1
◆7
49±5
14±1
6
1
2
3
44±4
24±3 5
8 44±4
36±5
N·m : Regulated torque 44±5
Disassembly Procedure Disassembling Procedure (continued)

1. Engine hanger 6. Exhaust manifold
<<A>> >>B<< 2. Oxygen sensor 7. Exhaust manifold gasket
<<A>> >>B<< 3. Oxygen sensor 8. Exhaust manifold bracket
4. Exhaust manifold cover Required Special Tools
>>A<< 5.Exhaust manifold bracket MD998770: Oxygen sensor spanner

<<A>> Oxygen sensor disassembly
Disassemble the oxygen sensor with the special
tool of MD998770.
MD998770

>>A<< Installation of the exhaust manifold
bracket “B”
Before locking the fixing bolts to the regulated
torque, inspect and confirm that the exhaust
manifold bracket “B” contacts the manifold bracket
and the cylinder body closely.
Tightening torque:
Bolt and gasket assembly: (34±5) N•m
Flange bolt: (36±5) N•m
>>B<< Oxygen sensor installation
Install the oxygen sensor with the special tool of
MD998770.
MD998770
Timing Belt
6
14±1 48±5 5
1 2 23±3
11±1
7 21±4
14±1
14
13
12 22
167
11±1 23
3
19
4 18
14±1
9±1
26
89±9 49±9
25 24
21
10
20 9
49±9
8 49±5
16 8.5±0.5
35±6 15 17
19±3
54±4
11
Disassembly Procedure Disassembling Procedure (continued)

1. Connector bracket <<D>> >>G<< 14. C rankshaft sprocket
2. Timing belt front upper cover >>G<< 15. C rankshaft signal plate
3. Timing belt front lower cover 16. Tensioner “B”
<<A>> >>K<< 4. Timing belt <<E>> >>F<< 17. Timing belt “B”
>>J<< 5. Tensioner belt tray <<F>> >>E<< 18. L eft balancing axis sprocket
6. Tensioner arm >>D<< 19. Gasket
>>I<< 7. Automatic tensioner <<G>> >>C<< 20. Crankshaft sprocket “B”
8. Idle pulley belt tray 21. Crankshaft pin
9. Bracket 22. Alternator bracket
10. Crankshaft position sensor >>B<< 23. Engine
hanger bracket
<> >>H<< 11. Oil pump sprocket 24. Timing belt rear cover
<<C>> >>G<< 12. C rankshaft bolt <<H>> >>A<< 25. C amshaft sprocket bolt
>>G<< 13. Crankshaft belt tray 26. Camshaft sprocket
Required Special Tools
MB990767: End yoke fixer
MD998719: Pin
MD998767: Tensioner belt tray spanner
MD998778:Crankshaft sprocket puller
MD998781: Flywheel stopper
MD998785: Sprocket stopper

<<A>> Timing belt disassembly
Notice: Water or oil on the belt will shorten the belt
service life greatly, so when disassembling the timing
belt, the sprocket and the tensioner, they must be
cleaned or immersed into the wash solution. If they are
polluted, they must be replaced. If there is water or oil
on any parts, inspect whether the front casing oil seal,
the camshaft oil seal and the water pump leak.
1. Make a rotating direction mark of the belt for the
convenience of the re-installation.
2. Loosen the tensioner belt tray bolts, and disassemble
the timing belt.
<> Oil pump sprocket disassembly
1. Disassemble the left plug of the cylinder body.
2. Insert in a cross-head screwdriver with the diameter
of 8 mm via the plug hole to fix the left balancing
axis.
3. Loosen the nut and then disassemble the oil pump
sprocket.
<<C>> Crankshaft bolt loosening

1. Install the special tool of MD998781 to fix the
flywheel.
2. Loosen and disassemble the crankshaft bolt and
gasket.
MD998781
<<D>> Crankshaft sprocket disassembly

1. Install the special tool of MD998778 as shown in
the figure.
2. Screw in the special tool center bolt, and disassemble
crankshaft sprocket.
MD998778 <<E>> Disassembly of the timing belt “B”

Water or oil on the belt will shorten the belt service
life greatly, so when disassembling the timing belt, the
sprocket and the tensioner, they must be cleaned or
immersed into the wash solution. If they are polluted,
they must be replaced. If there is water or oil on any
parts, inspect whether the front casing oil seal, the
camshaft oil seal and the water pump leak.
1. Make a mark of the belt rotating direction for the
convenience of re-assembly.
2. Loosen the bolts of the tensioner “B”, and then
disassemble the timing belt “B”.
<<F>> Left balancing axis sprocket disassembly

MD998785 1. Install the special tool of MD998785 as shown in
the figure, to avoid the left balancing axis sprocket
to be turned together.
2. Loosen the bolts and disassemble the sprocket.
<<G>> Disassembly of the crankshaft sprocket “B”

1. Install the special tool of MD998778 as shown in
the figure.
2. Screw in the central bolt of the special tool, and
disassemble the crankshaft sprocket “B”.
<<H>> Camshaft sprocket disassembly

MB990767 1. When fixing the camshaft sprocket with the special
tools of MB990767 and MD998719, loosen the
camshaft sprocket bolts.
MD998719 2. Disassemble the camshaft sprocket.
MB990767
Assemble Maintenance Key Points
>>A<< Camshaft sprocket installation
1. Install the camshaft sprocket in front of the
camshaft.
2. When fixing the camshaft sprocket with the
special tools of MB990767 and MD998719, lock the
camshaft sprocket bolts tightly.
MD998719
>>B<< Engine hanger bracket installation

Apply 3MTMAAD with parts number of 8672 or
equivalent products onto the sealing bolt thread
before locking, as shown in the figure.
>>C<< Installation of crankshaft sprocket “B”

Sprocket “B” Clean, and then remove the oil stain on the front part
Crankshaft
of the front casing, the crankshaft sprocket “B” and the
installation surface of the crankshaft sprocket “B”.
Remarks: to avoid decreasing the abrasion force
between the contact surfaces, it is necessary to
remove oil stain.
Oil stain removal
Front casings
>>D<< Gasket installation

Oil seal Balancing axis 1. Apply a thin layer of engine oil onto the oil seal lip
Gasket area.
2. Install the gasket into the groove bottom with the
surface toward the oil seal.
Groove
>>E<< Balancing sprocket installation

1. Install the balancing axis sprocket and turn the
MD998785
bolts.
2. Install the special tool of MD998785 and lock the
balancing axis as explained in the figure.
3. Lock the bolts tightly, and then disassemble the
special tool.
>>F<< Installation of the timing belt “B”

1. Align the timing mark on the crankshaft sprocket
Timing “B” and the mark of the left balancing axis sprocket
mark
of the front casing.
2. Install the timing belt “B” onto the crankshaft
sprocket “B” and the balancing axis sprocket. At this
time, there shouldn’t be looseness on the tension
Timing side.
mark
3. Confirm that the position of the tensioner belt tray

center and the bolt center is as shown in the figure.
Tensioner B
Bolt center
Tensioner belt tray center

4. When pulling the timing belt with the fingers in

order to make the belt have adequate tension,
move the tensioner “B” in the arrowhead direction.
In this case, lock the bolts to fix the tensioner “B”.
When the bolts are locked tightly, note to avoid that
the tensioner belt tray axis shouldn’t be turned with the
bolts. If the axis is turned with the bolts, the belt will
exceed the tension.
5. Inspect whether the timing mark is aligned to the

timing mark on the front casing body.
6. Press on the center of the full length of the tension
side of the timing belt “B” with the forefinger, and
the bolt must incline to (5-7) mm.
>>G<< Crankshaft signal plate / crankshaft sprocket

/ crankshaft belt tray gasket / crankshaft bolt
installation
1. Clean and then remove the oil stain on the contact
surface of the crankshaft sprocket, the signal plate
and the crankshaft.
Signal plate
Crankshaft
Remarks: to avoid decreasing the abrasion force
Sprocket Crankshaft between the contact surfaces, it is necessary to
Cleaning remove oil stain.
2. Clean the contact surface of the crankshaft bolt
hole, the crankshaft and the crankshaft sprocket
and gasket.
Gasket 3. Install the signal plate and the crankshaft sprocket
Big groove side Oil stain removal
onto the crankshaft.
4. Apply a small amount of engine oil onto the bolt
thread and the sealing surface of the crankshaft
bolt.
5. Install the bigger groove side of the gasket onto
the crankshaft bolt with the groove side toward the
bolt head.
6. Fix the flywheel with the special tool of MD998781.
7. Lock the crankshaft bolts tightly to the regulated
torque.
MD998781
Tightening torque: (157-167) N•m
>>H<< Oil pump sprocket installation
1. Insert a cross-head screwdriver (diameter 8 mm)

into the left side of the cylinder via the plug hole,
and block the left balancing axis.
2. Install the oil pump sprocket.
3. Apply a thin layer of engine oil onto the bolt sealing
surface.
4. Lock the nut tightly to the regulated torque.
>>I<< Automatic Tensioner Installation

If the automatic tensioner stem is expanded completely,
reset it according to the following:
1. Clamp the automatic tensioner with the jaw vice
with a soft mouth.
2. Push the stem slowly with the jaw vice until the
setting hole A of the stem is aligned to the cylinder
inner hole B.
3. Insert a line (diameter 1.4 mm) into the setting hole.
This setting line of the automatic tensioner will be
used for timing belt alignment.
4. Loosen the automatic tensioner by the jaw vice.
Notice: Keep the line inside the installed automatic

tensioner.
5. Install the automatic tensioner onto the front
casing and lock it tightly to the regulated torque.
>>J<< Tensioner belt tray installation

Install the tensioner belt tray in order that the spanner
can be installed into the hole at the position marked in
the figure.
Tensioner belt
tray hole
>>K<< Timing belt installation

1. Align the timing mark on the camshaft sprocket to
Timing mark
the timing mark on the rocker cover.
2. Align the timing mark on the crankshaft sprocket

to the timing mark on the front casing.
Timing mark
3. Align the timing mark on the oil pump sprocket to

its matching mark.
Timing mark
4. Disassemble the plug on the cylinder body, and

insert a cross-head screwdriver (diameter 8 mm)
60mm above through the plug hole. If the screwdriver can be
inserted more than 60 mm, the timing mark has
been aligned correctly.
If the screwdriver can be inserted into only (20-25)
mm, turn the oil pump sprocket for a round and align
Balancing axis the timing mark again, and then inspect and confirm
that the screwdriver can be inserted more than 60
mm. Hold the inserted cross-head screwdriver until the
installation of the timing belt is accomplished.
5. As shown in the figure, install the special tool of
MD998738 and turn it until the line inserted in the
automatic tensioner will be moved slightly.
MD998738 6. Install the timing belt onto the crankshaft sprocket,
the oil pump sprocket, the idle pulley belt tray,
the camshaft sprocket and the tensioner belt tray
according to the sequence.
7. Pull up the tensioner belt tray according to the

Automatic tensioner arrowhead direction and lock the central bolt
tightly.
8. Inspect that all the timing mark has been aligned.
9. Disassemble the cross-head screwdriver inserted
in Step 5, and Install the plug.
10. Turn the crankshaft counterclockwise by 1/4 round.
Then turn it clockwise unitl the timing mark is
aligned again.
11. Install the special tool of MD998767, the sprocket

spanner and the torque spanner onto the tensioner belt
tray, and loosen the tensioner belt tray central bolt.
Remarks: Use the torque spanner which can be used
to measure the torque of (0-5) N•m.
12. Use torque spanner to the torque of 3.5N•m.
13. Fix the tensioner belt tray with the special tool
MD998767 MD998767 and the torque spanner, and lock the
central bolts to the regulated torque.
14. Pull out the line inserted in the automatic tensioner,

and disassemble the special tool of MD998738 with
hands.
15. Turn the crankshaft clockwise by two rounds, wait
15 minutes and perform the following inspection
procedure.
16. Inspect whether can the metal line (when the

automatic tensioner is installed) be disassembled
with no resistance.
If the metal line can be disassembled without
resistance, it means that the tension of the belt is
appropriate. Disassemble the metal line. In this case,
inspect whether the protrusion part of the automatic
tensioner stem is within the standard value.
Standard value: (3.8-4.5) mm
17. If there is resistance when the metal line is disassembled,
repeat Steps 10 to 15 until the protrusion part of the
automatic tensioner stem obtains the standard value.
Inspection of Timing Belt

If the following cases occur, replace the belt:
1. The rubber inner lining becomes stiffened. The
back side should be smooth without elasticity, and
no notch should be left when pressed with the nail.
2. There is crack on the rubber back.

Crack
Crack 3. The canvas has crack or skinning
4. The rib bottom has crack.
5. The belt side has crack.
Canvas skinning
Side crack
Tooth root crack

6. The belt side has abnormal abrasion.

Round edge
(a) The normal abrasion means that the side edge
has the cut shape.
(b) The abnormal abrasion means that the side edge
has the sawtooth shape.
Abnormal abrasion (rough and broken edge)
7. Abnormal tooth abrasion

The preliminary stage: canvas abrasion (flock canvas
Outer exposure of the rubber fabric, disappeared elastic structure, albefaction and
vague canvas structure).
Teeth missed and can-
vas fabric exposed The final stage: canvas abrasion, rubber exposure
(decreased tooth width).
8. Missing teeth.
Automatic Tensioner
12mm(0.5 in) 1. Oil leakage inspection.
If there is obvious oil leakage, replace the automatic
tensioner.
2. Inspect the abrasion or damage of the stem end,
and replace the automatic tensioner if necessary.
3. Measure the protrusion part of the stem.
If the protrusion is beyond the regulated value, replace
the automatic tensioner.
Standard value: 12 mm
98-196 N
4. Press the stem by exerting the force of (98-196) N,
and measure the movement value of the stem. If
the measured value is beyond the standard value,
replace the automatic tensioner.
Displacement
Standard value: less than 1.0 mm
Valve Clearance Adjustment

Notice: Turn the crankshaft clockwise.
Timing mark
1. Turn the crankshaft clockwise, and then align the
timing mark on the camshaft sprocket to the timing
mark on the swing arm cover (place it at the top
dead center of the compression stroke of the first
cylinder).
2. Disassemble the swing arm chamber cover.
3. Measure the valve clearance as indicated in by the

Intake valve side
arrowhead.
A: When the first cylinder is at the top dead center of
the compression stroke.
B: When the fourth cylinder is at the top dead center
of the compression stroke.
Exhaust valve side
4. Adjust the clearance between the end of the valve

axis and the adjusting screw with the thickness
gauge.
Standard value (when the engine is cold): intake
side: 0.11 mm
Exhaust side: 0.20 mm
Remarks: Install the engine, and after warming the
engine, inspect the valve clearance again, and adjust if
necessary.
5. Fix the adjusting screw with a screwdriver to make
it not to turn and lock the fixing nut.
6. Turn the crankshaft clockwise for a round, and then
align the timing mark on the crankshaft sprocket
(The fourth cylinder is at the top dead center of the
compression stroke).
7. Adjust the valve clearance for other valves.
8. Install the swing arm cover.
Fuel and Exhaust Emission Parts

Disassembly of Assembly
28±4
24±3
12 13
11±1
◆11
9
◆10
6
◆8
◆14 ◆2
1
7
11±1
3 9.0±1.0
11±1
5
4
Disassembly Procedure
1. Throttle valve body
2. Throttle valve body gasket
3. Vacuum tube and hose
4. Solenoid valve
5. Solenoid valve bracket
6. Fuel injection nozzle and fuel rail
7. Insulator
8. Insulator
>>B<< 9. Fuel injection nozzle
10. O-ring
11. Locking ring
>>B<< 12. Fuel rail
13. Exhaust recirculation valve
14. Exhaust recirculation valve gasket

>>B<< Fuel injection nozzle installation
Notice: Pay attention to avoid making engine oil
enter into the fuel rail.
1. Apply clean engine oil onto the O-ring.
2. Insert the fuel injection nozzle into the fuel rail.
3. Confirm that the fuel injection nozzle can be turned
Protrusion part
smoothly.
If the nozzle can’t be turned smoothly, disassemble the
fuel injection nozzle to inspect whether the O-ring is
damaged, and replace the O-ring if necessary. Install
the fuel injection nozzle again, and inspect whether the
fuel injection nozzle is turned smoothly.
Intake manifold
Fuel trail
Fuel injection nozzle

Intake Manifold and Water Pump

Disassembly of assembly
13±2 11±1
5.0±1.0
12 13 2
15
24±4
◆ 24±3
1 9
10
13±2 ◆7 11
20±9
24±3 19±3
18
◆14 17 13±2
◆5
20±2
6
16
23±2 19
◆4
8
31±3
14±1
Disassembly Procedure Disassembly Procedure (continued)

1. Water pipe >>D<< 11. Thermostat casing
2. Water pipe 12. Intake pressure temperature sensor
3. Water pump 13. Intake manifold
4. Water pump gasket 14. Intake manifold gasket
>>G<< 5. O-ring 15. Engine hanger
>>G<< 6. Water inlet pipe 16. Knock sensor
<<A>> >>C<< 17. Engine oil pressure switch
>>G<< 7. O-ring
>>B<< 18. Engine coolant temperature sensor
>>F<< 8. Intake manifold bracket
>>A<< 19. Water outlet fitting
9. Water inlet fitting
Required Special Tool
>>E<< 10. Thermostat
MD998054: oil pressure switch spanner

<<A>> Engine oil pressure switch disassembly
Disassemble the engine oil pressure switch with the
special tool of MD998054.
MD998054
Installation Maintenance Key Point

Ф3mm >>A<< Water outlet fitting installation
1. Apply 3 mm pear-shaped sealing adhesive (MITSUBISHI
genuine product with part number MD970389) in the
groove, as shown in the figure.
2. Install the casing rapidly (within 15 minutes), and
when the sealing adhesive is not dry, lock the bolts
to the regulated torque tightly.
Remarks: After installation, keep the sealing adhesive
away from the coolant for about one hour.
>>B<< Sealing of the engine coolant temperature
sensor
1. Remove all the sealing adhesive left on the engine
coolant temperature sensor and bolt thread hole.
2. Apply sealing adhesive onto the bolt thread of the
engine coolant temperature sensor as shown in the
figure.
>>C<< Sealing of the engine oil pressure switch

The sealing adhesive shouldn’t block the oil passage.
1. Apply 3MTM or equivalent products onto the bolt
thread of the engine oil pressure switch.
1mm 5mm
2. Lock the engine oil pressure switch tightly to the

MD998054 regulated torque with the special tool of MD998054.
>>D<< Thermostat casing body installation

1. A p p l y 3 m m p e a r l - s h a p e d s e a l i n g a d h e s i v e
(MITSUBISHI genuine product with part number
MD970389) in the groove, as shown in the figure.
Ф3mm
2. Apply 3MTM or equivalent products onto the bolt

thread of the sealing bolt before locking.
3. Install the casing rapidly (within 15 minutes), and
when the sealing adhesive is not dry, lock the bolts
to the regulated torque tightly.
Remarks: Keep the sealing adhesive away from the
coolant for about one hour after installation.
>>E<< Thermostat installation

1. Inspect whether the runner ring is damaged and
Oscillating valve
whether the thermostat flange seat is installed
correctly.
2. Install the thermostat as shown in the figure,
and the oscillating valve should be on the upper
position.
Thermostat casing
>>F<< Intake manifold bracket seat installation

1. Install the intake manifold bracket seat and lock the
bolts with hands tightly.
Intake manifold 2. Inspect to confirm that the fixed seat has been
contacted with the intake manifold and the
protrusion object of the cylinder.
3. Lock the intake manifold bolts and the cylinder
side bolts tightly to the regulated torque.
Cylinder Tightening torque: (31±3) N•m
>>G<< Water inlet pipe/O-ring installation

O-ring
Notice: the O-ring should be kept away from engine
oil or grease.
1. Install an O-ring into the end of each water pipe.
2. Wet the O-ring with water.
3. Insert the rear end of the pipe into the thermostat
casing.
Water inlet pipe

Rocker Arm and Camshaft

Apply engine oil onto

all the moving parts
before installation.
◆
13±1
◆ 3.5±0.5
◆
13±1
9±1
11±1
47±7
44±5
◆


1. Air hose 15. Swing arm “C”
2. Positive crankcase ventilation pipe 16. T-stem
3. P ositive crankcase ventilation 17. Swing arm “D”
valve 18. Swing arm shaft (exhaust side)
4. PCV valve bracket >>A<< 19. Engine oil control valve
5. Oil filter cover 20. O-ring
6. Swing arm cover 21. Gripping ring
7. Swing arm cover gasket 22. Accumulator spring seat
8. Oil seal 23. Plunger spring
>>D<< 9. Oil seal 24. Accumulator plunger
<<A>> >>C<< 10. Swing arm and Swing arm shaft 25. Accumulator body
(intake side) 26. Conical plug
<<A>> >>C<< 11. Swing arm and Swing arm shaft 27. Oil control valve filter
(exhaust side) 28. Camshaft
12. Nut Required Special Tool
>>B<< 13. Adjusting screw MD998713: Camshaft oil seal erector
14. Rocker axis (intake side)
Note: The installation of the swing arm needs higher accuracy (intake side). So the incorrect
swing arm installation procedure may cause malfunction. When performing vehicle overhaul,
mark the different groups of the swing arm “A”, the T-stem and the swing arm “B” clearly, and
then disassemble each group. When assembling, install the swing arm “A”, the T-stem and the
swing arm “B” according to the marks made when disassembling.
<<A>> Swing arm and swing arm shaft disassembly
When the swing arm is disassembled from the swing arm shaft, make the installation position
mark, to the re-installation of the swing arm, the T-stem, the piston arm assembly and other
parts.

>>A<< Engine oil control valve/O-ring installation
Adhesive bandage Notice:
• Never reuse O-ring.
• After clean off the adhesive substance of the
adhesive bandage around the oil passage groove
of the engine oil control valve, install the O-ring
to avoid damage. The damaged O-ring will cause
oil leakage.
1. Apply a small amount of engine oil onto the O-ring
of the engine oil control valve.
2. Install the engine oil control valve onto the cylinder
cover.
3. Lock the engine oil control valve onto the regulated
torque tightly.
3mm >>B<< Adjusting screw installation
(0.12in）
Install the screw onto the swing arm temporarily,
and protrude it 3 mm from the swing arm end to the
level surface.
>>C<< Rocker axis spring/swing arm and rocker

Timing belt side bolt hole axis installation
Swing arm axis, exhaust 1. Install the swing arm and other part onto the rocker
arm shaft according to the marks made during the
disassembly.
Oil hole
2. Install the swing arm shaft with larger groove onto
Large groove
the timing belt.
3. Install the swing arm shaft with oil hole onto the
Bolt hole Rocker axis, intake lower side (of the cylinder cover).
4. Install the swing arm and the swing arm shaft

assembly temporarily (intake).
Timing belt side 5. Install the swing arm and the swing arm shaft
assembly temporarily (exhaust).
6. Confirm that each swing arm and rocker axis
assembly is at the correct position, and lock tightly
Tightening torque:
M6:(13±1) N•m
M8:(31±3) N•m
>>D<< Camshaft oil seal installation

1. Apply engine oil onto the oil seal lip area and the
outer diameter of the camshaft front end.
2. Install the camshaft oil seal with the special tool of
MD998713.
MD998713
Camshaft Inspection
Measure the cam height. If the measured value is
lower than the limit value, replace the camshaft.
Standard Minimum Limit

value (mm) Value (mm)
A: Intake low speed cam A 37.47 36.97
B: Intake low speed cam B 37.47 36.97
C: Intake high speed cam 37.21 36.71
D: Exhaust cam 37.86 37.36

78±2 0 20±2 +90° +90°

8
1 9
10
20
4 ◆14
5
15
6
17◆
12◆
13
◆16 19
11
◆18 2
7
3◆


Disassemby Procedure Disassembly Procedure (continued)

<<A>> >>D<< 1. Cylinder cover bolt 13. Valve spring seat
2. Cylinder cover assembly >>A<< 14. Valve stem oil seal
3. Cylinder cover gasket 15. Valve spring seat
<> >>C<< 4. Fixer buckle 16. Intake valve guiding pipe
5. Valve spring fixer 17. Exhaust valve guiding pipe
>>B<< 6. Valve spring 18. Intake valve seat
7. Intake valve 19. Exhaust valve seat
<> >>C<< 8. Fixer buckle 20. Cylinder cover
9. Valve spring fixer Required Special Tools
>>B<< 10. Valve spring MB991654: Cylinder cover bolt spanner (12)
11. Exhaust valve MD998735: Valve spring compressor
>>A<< 12. Valve stem oil seal MD998774: Valve stem oil seal erector

<<A>> Cylinder cover bolt disassembly
Loosen the cylinder cover bolts with the special tool of
MB991654
MB991654. Loosen each bolt evenly bit by bit for two
or three times.
<> Fixing buckle disassembly

MD998735 1. Press down the valve spring with the special tool
of MD998735 and disassemble the fixer buckle, as
2. Release the spring tension, and disassemble the
valve, fixer, spring, etc. Mark the disassembled
valve, spring and other parts, to indicate the cylinder
number and position for the convenience of
reassembly.

>>A<< Valve stem oil seal installation
MD998774 When installing the valve stem oil seal, the special tool
must be used. The incorrect installation may cause the
oil leakage from the valve guiding pipe.
1. Install the valve spring seat.
2. Install a new valve stem oil seal with the special
tool of MD998774.
>>B<< Valve spring installation

Install the valve spring upward (toward the valve spring
fixer) according to the identifying color printed on the
Printed bottom spring bottom (bigger clearance side).
Identification:
Intake: light blue
Exhaust: orange
>>C<< Fixer buckle installation

MD998735
Never compress the valve spring excessively, or
the valve stem oil seal will be damaged.
1. Press down the valve spring with the special tool
of MD998735 and install the fixer buckle, as shown
in the figure.
2. Release the spring tension, and inspect whether
the fixer buckle is positioned correctly.
>>D<< Cylinder cover bolt installation

1. When the disassembled cylinder bolts are reused,
inspect whether the length of each bolt grip
accords with the standard value. If the length is
beyond the limit value, replace the bolt.
Handle length Limit value: 99.4 mm
2. Apply engine oil onto the bolt thread and the gasket.
3. Lock the bolts tightly to the regulated torque with

the special tool of MB991654 according to the
MB991654
sequence.
4. Loosen all the bolts completely in the reverse
locking sequence.
5. Lock the loosened bolts again, to the regulated
torque according to the shown sequence.
6. Print a mark crossing each bolt head and the cylinder

cover.
Timing belt side
7. Lock the cylinder cover bolts to 90 degrees according
to the specified sequence.
Notice:
• If the bolt is turned less than 90 degrees, the
appropriate tension may not be obtained, so turn
each bolt to 90 degrees carefully.
• If the bolt is excessively locked, loosen the bolt
completely, and then lock the bolt again from
Step 1 of the locking procedure.
8. In addition, lock the bolt to 90 degrees in the
sequence identical to step 7, and inspect whether
the printed mark on the cylinder cover bolt is
aligned to the mark printed on the cylinder cover.
Printed mark
Inspection
Cylinder Cover
1. Inspect the planeness of the cylinder cover gasket
with a line tool and a feeler gauge.
Standard value: 0.03 mm
Limit value: 0.2 mm
2. If the value is beyond the limit value, correct it to
accord with the specification value.
Grinding limit value: 0.2 mm
Grinding combine with cylinder.
Cylinder cover height (new parts specification):120 mm
Valve
1. Valve seat contact inspection
The valve seat contact shall be same to the valve
surface center. If it is incorrect, refurbish again with the
Contact
(at the valve valve surface refurbishing machine.
surface center) 2. If the valve edge is lower than the limit value,
Edge replace the valve.
Standard Value (mm) Minimum Limit Value (mm)
Intake 1 0.5
Exhaust 1.2 0.7
3. Measure the total length of the valve. If the measured

value is lower than the limit value, replace the valve.
Intake 111.33 110.83
Exhaust 113.54 113.04
Total length
Valve Spring
1. Measure the spring free length.
Alteration angle from the vertical direction If lower than the limit value, replace the valve spring.
Intake 54.8 53.8
Exhaust 56.1 55.1
Free height
2. Measure the spring squareness, if the measured value
is beyond the limit value, replace the valve spring.
Standard value: less than 2°
Limit value: 4°
Valve Guiding Pipe

Measure the clearance between the valve guiding
pipe and the valve stem. If the measured value is
beyond the limit value, replace the guiding pipe or
Valve Guiding
the valve, or both of them.
Intake 0.02-0.04 0.1
Diameter of the
Inner diameter of guiding pipe Exhaust 0.04-0.06 0.15
the guiding pipe
Valve stem end

Valve Seat
Assemble the valve, and then measure the valve stem
protrusion part between the valve stem end and the
Valve stem
protrusion part spring seat surface. If the measured value is beyond
the specification limit value, replace the valve seat.
Spring seat surface Standard Value (mm) Minimum Limit Value (mm)
Intake 48.33 48.83
Exhaust 48.34 48.84
Intake side
Valve Seat Refurbishing Procedure
Exhaust side
(0.9-1.3)mm (0.9-1.3)mm 1. Before refurbishing the valve seat, inspect the
65° 65° clearance between the valve guiding pipe and the
valve. If necessary, replace the valve guiding pipe.
2. Refurbish the valve seat with the grinding machine
to reach the regulated valve width and angle.
20° 10°
3. After refurbishing the valve seat, overlap the valve
43.5°-44°
and the valve seat with the over-grinding machine.
Then inspect the valve stem protrusion part.
Valve Seat Replacement Procedure

(0.5-1)mm 1. Cut the valve seat from the inside to make the wall
thickness thin. Then, disassemble the valve seat.
Cutting
(0.5-1)mm
2. Rebore the valve seat hole on the cylinder cover to

the well-chosen larger valve seat diameter.
Intake valve seat ring hole diameter.
0.3 enlarged size: (35.30-35.33) mm
Valve seat height 0.6 enlarged size: (35.60-35.63) mm
Exhaust valve seat ring hole diameter.
0.3 oversize: (33.30-33.33) mm
Large-sized hole 0.6 oversize: (33.60-33.63) mm
diameter 3. Before assembling the valve seat, heat the cylinder
cover to about 250℃, or freeze the valve seat in
liquid nitrogen to avoid scratch.
4. Correct the valve seat to the specified width and
angle with the valve seat grinder.
Refer to Valve Seat Refurbishing Procedure in the
previous page.
Valve Guiding Pipe Replacement Procedure
1. Disassemble the valve guiding pipe toward the
cylinder body with a press machine.
Notice: The guiding pipe with the same size can’t
be installed.
2. Rebore the valve guiding hole on the cylinder
cover to accord with the pressure matching of
the collocation installation, and enlarge the valve
guiding pipe size.
valve guiding pipe hole diameter
0.05 oversize: (11.05-11.07) mm
0.25 oversize: (11.25-11.27) mm
0.50 oversize: (11.50-11.52) mm
14.0mm 3. Press in the installing valve guiding size until it
protrudes 14.0 mm above the upper surface of the
cylinder cover as shown in the figure.
Remarks: When pressing in the installing valve guiding
valve, move out from the upper surface of the cylinder
cover. Note the length of the different valve guiding
pipe.
Intake side: 45.5 mm
Exhaust side: 50.5 mm
Remarks: After the installation of the valve guiding
pipe, insert the new valve into the valve guiding pipe,
to inspect whether it can slide smoothly.
Oil pan and Oil Pump

◆28
Apply engine oil onto 26

all the moving parts ◆29
◆19
◆30
18
10±2
23±3 27
◆24 20
17±1 ◆8 6
7
13
19±3 21 9±2
23
◆14 22 19±3 22±4
◆25
17
12 15◆16
36±3 23±3
11
◆10 23±3
9 1 9±3
◆2
44±5
39±5 5
3
4
22±4

1. Releasing plug 19. Front casing gasket
>>M<< 2. Releasing plug gasket 20. Oil pump protective cover
<<A>> >>L<< 3. Oil filter >>G<< 21. Oil pump driving gear
4. Transmission partition board >>G<< 22 Oil pump driving gear
<> >>K<< 5. Oil pan >>F<< 23. Crankshaft front oil seal
7. Oil filter >>E<< 24. Oil pump oil seal
8. Oil filter gasket >>D<< 25. Balancing axis oil seal
9. Releasing plug 26. Balancing axis, left
10. Gasket 27. Balancing axis, right
11. Releasing spring <<E>> >>C<< 28. L
eft balancing axis, front bearing
12. Releasing plunger <<F>> >>B<< 29. L
eft balancing axis, rear bearing
13. Oil filter bracket <<F>> >>A<< 30. B
alancing axis, rear bearing, right
14. Oil filter bracket gasket Required Special Tools
<<C>> >>J<< 15. Oil pan MB991603: Bearing erector stopper
16. O-ring MD998162: Plug spanner
<<D>> >>I<< 17. Flange bolt MD998285: Crankshaft front oil seal guiding pipe
>>H<< 18. Front casing MD998371: Silent axis bearing puller
MD998372: Silent axis bearing puller
MD998375: Crankshaft front oil seal erector
MD998705: Silent axis bearing erector
MD998727: Oil pan scraper
MD998783: Plug spanner fixer

<<A>> Oil filter disassembly
MD998727 <> Oil pan disassembly
1. Disassemble all the oil pan bolts.
2. Press in the special tool of MD998727 between the
cylinder body and the oil pan.
Notice: never disassemble the oil pan with a
screwdriver or chisel, which will cause flange distortion
and oil leakage of the oil pan.
3. Knock the special tool into the bottom corner
(shoulder part) of the oil pan, and then disassemble
it by sliding it along the oil pan.
MD998162 <<C>> Plug disassembly
1. Install the special tool of MD998162 onto the plug,
and fix it on the position with the special tool of
MD998783.
2. Loosen the plug.
3. Disassemble the special tools of MD998783 and
MD998783 MD998162, and then disassemble the plug.
<<D>> Flange bolt disassembly

1. Disassemble the plug on the cylinder body side.
via the plug hole to fix the balancing axis.
3. Loosen the flange bolts.
<<E>> Balancing front bearing disassembly

Confirm the disassembled front bearing, if it is not
disassembled, the special tool of MD998372 can’t be
used to disassemble the balancing axis bearing.
Disassemble the balancing front bearing from the
cylinder body with the special tool of MD998371.
MD998372
<<F>> Balancing rear bearing disassembly

1. When disassembling the left balancing axis, install
the special tools of MB991603 and MD998372 in
front of the cylinder body.
MD998372
2. Disassemble the right balancing axis rear bearing

MB991603 with the special tool of MD998372.
MD998372

MB991603
>>A<< Left balancing axis rear bearing installation
1. Install the special tool of MB991603 onto the
cylinder body.
2. Apply engine oil onto the outer surface of the
rear bearing and onto the bearing hole inside the
cylinder body.
MD998705
(stopper)
3. Install the rear bearing with the special tool of

MD998705.
MB991603 MD998705 Remarks: The left rear bearing has no oil hole.
(stopper)
Rear bearing
>>B<< Right balancing axis rear bearing

installation
1. Install the guiding pin of the special tool of
MD998705 into the thread hole of the cylinder body,
MD998705
(guiding pin)
2. Align the ratchet wheel steel ball of the special tool

Right rear bearing of MD998705 to the rear bearing oil hole to install
the bearing of the special tool of MD998705.
Ratchet wheel steel ball
Oil hole 3. Apply engine oil onto the outer surface of the
cylinder body.

MD998705
(stopper) MD998705.
Confirm that the bearing oil hole is aligned to the
cylinder body oil hole.
MD998705 (guiding pin)
>>C<< Assembly of front shaft of balancing

MD998705 (stopper)
shaft
1. Disassemble the bearing subassembly of the rear
MD998705 (stopper)
Installing parts of the rear bearing
2. Install the guiding pin of the special tool of

MD998705 into the cylinder body thread hole, as

3. Align the ratchet wheel steel ball of the special tool

Right front bearing of MD998705 to the rear bearing oil hole to install
Ratchet wheel steel ball Oil hole the bearing of the special tool of MD998705.
4. Apply engine oil onto the outer surface of the
cylinder body.

MD998705 MD998705. Confirm that the bearing oil hole is
(stopper)
aligned to the cylinder body oil hole.
>>D<< Balancing axis oil seal installation

Socket spanner Install the balancing axis oil seal into the front casing
with an appropriate socket spanner.
Front casing
Oil seal
>>E<< Oil pump oil seal installation

Install the oil pump oil seal into the front casing with an
Socket spanner
appropriate socket spanner.
Oil seal
Front casing
>>F<< Crankshaft front oil seal installation

MD998375 Install the crankshaft oil seal into the front casing with
the special tool of MD998375.
Oil seal
Front casing
>>G<< Oil pump driving gear installation

Install the oil pump gear into the front casing, and align
the locating mark.
Locating mark
>>H<< Oil pump casing body installation

1. Install the special tool of MD998285 on the front
end of the crankshaft, and apply a thin layer of
engine oil onto the surface of the special tool of
MD998285.
2. Apply engine oil onto the lip part of the crankshaft
front oil seal.
MD998285
3. Install the front casing carefully to avoid the

damage to the oil seal.
MD998285
4. Lock all the flange bolts tightly to the regulated

22mm 40mm
torque.
20mm
25mm
Remarks: Install the locked bolts carefully, and note the
32mm
length of each of them.
>>I<< Flange bolt installation

into the left hole of the cylinder to fix the balancing
axis.
2. Lock the flange bolts tightly to the regulated

torque, to fix the oil pump driving gear onto the left
balancing axis.
3. Pull out the screwdriver and then screw the plug
on.
>>J<< Plug installation

MD998162 1. Install the new O-ring into the front casing groove.
2. Install the plug onto the front casing.
3. Install the special tool of MD998162 onto the plug,
and then fix it at the position with the special tool
of MD998783.
MD998783 4. Lock the plug tightly to the specified torque.
5. Disassemble the special tools of MD998783 and
MD998162.
Timing belt side

>>K<< Oil pan installation
1. Clean the used sealing adhesive on the oil pan and
the cylinder body surfaces.
Bolt hole
2. Apply a continuous pearl-shaped layer of sealing
adhesive of Ф(3-5) mm. (MITSUBISHI genuine
product with part number MD970389 or equivalent
products) onto the oil pan flange.
Groove
3. Install the 8 mm bolts into the two holes marked

with the letter “S”, and install 10 mm bolts into the
17 bolts. Lock all the bolts to the regulated torque.
Remarks: After installation, keep the sealing adhesive
away from oil for about one hour.
>>L<< Oil filter installation

1. Clean the surface of the oil filter bracket.
2. Apply engine oil onto the O-ring of the oil filter.
3. Install the oil filter onto the bracket with common

maintenance tools and lock it tightly to the
regulated torque.
Tightening torque: parts number MD356000 filter: (4
±2) N•m
Other Mitsubishi genuine filters: (17±3) N•m
4. If the torque spanner is unavailable, perform
according to the following procedure:
(a) Turn the oil filter until the O-ring contacts the oil
filter bracket.
(b) Lock the oil filter tightly according to the following:
Filter with the parts number of MD356000: turn one
Common maintenance tool round.
Other Mitsubishi genuine filters: turn 3/4 round
>>M<< Releasing plug gasket installation

Notice: the installation of gasket in wrong direction
Releasing plug
would cause oil leakage.
Install the releasing plug gasket in the direction as
Oil pan
Gasket
Oil pan side
Inspection
Front Casing
1. Inspect whether the oil passage is blocked, and
clean it if necessary.
2. Inspect whether the left balancing axis front
bearing is abraded, damaged or clinched. If the
bearing is damaged, replace the front casing.
3. Inspect whether the front casing has crack or other
damages. Replace the cracked or damaged front
casing.
Oil Seal
1. Inspect whether the oil sea lip is abraded or
damaged, and replace the oil seal if necessary.
2. Inspect whether the oil seal lip is deteriorated, and
replace the oil seal if necessary.
Balancing Axis
1. Inspect whether the oil hole is blocked, and clean it
if necessary.
2. Inspect whether the axis journal is clinched,
damaged, or contacts the bearing.
If there is any problem about the axis journal,
replace the balancing axis, the bearing or the front
casing assembly if necessary.
Oil Pump
1. Assemble the oil pump gear onto the front casing
and turn it, to confirm that it can be turned
smoothly without relaxation.
2. Confirm that there is no carinate abrasion on the
contact surface of the front casing and the oil
pump cover gear surface.
3. Inspect the side clearance.
Standard value:
Driving gear: (0.08-0.14) mm
Driven gear: (0.06-0.12) mm
Poston and Connecting Rod

Disassembly and Assembly

all the moving parts 6
7
8
10 4
12
11
3
2
1 (20±2)N·m (90-94)°

>>G<< 1. Nut >>C<< 7. Piston ring No.1
<<A>> >> F<< 2. Connecting rod cover >>B<< 8. Oil ring
>>D<< 3. Connecting rod bearing <> >>A<< 9. Piston pin
>>E<< 4. Piston and connecting rod assembly 10. Piston
>>D<< 5. Connecting rod bearing 11. Connecting rod
>>C<< 6. Piston ring No. 1 12. Bolt
Required Special Tool
MD998780: piston pin setting tool

<<A>> Connecting rod cover disassembly
1. Make cylinder mark on the big end side of the
Cylinder number connecting rod for the convenience of reassembly.
2. Keep the disassembled connecting rod, the connecting
rod cover and the bearing in turn according to the
cylinder number.
<> Piston pin disassembly

A:17.9 mm
Guiding pipe Use the special tool of MD998780 as shown in the
Pressing pin Guiding pipe B figure.
A:18.9 mm
Guiding pipe
Guiding pipe C
A:20.9 mm
Guiding pipe
Engine base
A:21.9 mm
Guiding pipe
1. After inserting in the special tool of the pressing

pin from the side of the piston top marked with an
arrowhead, and install the guiding pipe C onto the
Pressing pin pressing pin end part.
2. Keep the front mark of the piston upward, and
Install the piston rod assembly onto the base
Piston pin
(special tool) of the piston pin erector.
Front mark
Front mark 3. Press out the piston pin with pressure.
Remarks: Place the disassembled piston, piston pin
and connecting rod according to the cylinder number.
Guiding pipe
Engine base

>>A<< Piston pin installation
Timing belt side
1. When replacing the piston, read the instructions
Crankshaft hole
size mark established for the the cyinder hole size of the
cylinder body, and choose a cylinder according to
the following table.
Cylinder Hole Size Mark Piston Size Mark
I A
II No mark
III C
Remarks: The piston size mark is on the piston top.
2. Measure size:
A. Inserted length of the piston pin in the hole
B. Width between the pin seats
C. Piston pin length
D C D. Width of the connecting rod small end
3. The length L can be obtained through the following
formula: L=[(A-C)-(B-D)]/2
4. After inserting the special tool of the pressing pin
Connecting rod
into the piston pin, install the guiding pipe A onto
Piston pin the pressing pin end part.
Piston
5. Keep the front mark of the connecting rod and the
piston toward the same direction.
6. Apply engine oil onto the surface of the piston pin.
7. Assemble the piston pin, the pressing pin and the
B A guiding pipe assembly according to Item 4, and
insert into the piston hole from the mark side made
in front of the guiding pipe A end.
8. Screw the guiding pipe B into the guiding pipe A,
to make the clearance value between the guiding
pipe B and the guiding pipe A to be the value L that
made from the three items plus 3 mm.
9. Keep the front mark of the piston upward, and
install the piston connecting rod assembly onto the
base of the position pin erector.
10. Press in the piston pin with pressure. When the
pressure is less than the standard value, replace the
piston and piston pin assembly or the connecting
rod.
Standard value: (7350-17200) N
11. Inspect whether the piston can be turned freely.
Scraper end >>B<< Oil ring installation

1. Install the oil main ring into the piston ring groove.
Notice: the piston ring expander can’t be used
when installing the scraper.
2. Install the upper scraper
In order to install the scraper, install one end of the scraper
into the piston groove, and then press the rest part into the
piston groove with hands, as shown in the figure.
Remarks: the main ring and the scraper may be
installed in any direction. The size of the new main ring
and the scraper should be identified from the color.
Upper scraper
Size Identifying Color
Standard No color
0.5 mm (oversize) Red
3. Install the lower scraper in the same method described
Main ring
in Step 2.
4. Confirm that the scraper should be moved smoothly
in the directions of the both sides.
Lower scraper
>>C<< Piston ring No. 2/piston ring No. 1 installation

Piston ring expander 1. Install piston ring No. 2 into the second groove of
the piston with the piston ring expander.
Remarks: install the identifying mark of the piston ring
upward, toward the piston top.
2. Install piston ring No.1 in the same method as Step
1.
Identifying mark: Ring No. 1: 1R Ring No. 2: 2R
Remarks: confirm the piston rings No. 1 and 2 carefully.
Pay attention to the correction installation direction of
the piston ring top and bottom parts.
Remarks: the identifying size and the size mark are on
the upper plane of the piston ring (piston top side).
3. In order to avoid incorrect installation, inspect the
identifying mark of each piston ring.
The identifying mark is on the part near the ring joint.
Size Identifying mark
Standard No identifying mark
0.5 mm (over size) 50
Identifying mark of the crankshaft pin diameter

>>D<< Connecting rod bearing installation
1. Measure the crankshaft diameter and confirm
the classification from the following table. One
crankshaft is supplied with one maintenance part,
and the identifying mark of the crankshaft pin is at
the position as shown in the figure.
Outer diameter of Connecting
the crankshaft pin rod bearing
Identifying mark Size (mm) Identifying mark
I 44.995 - 45.000 1
II 44.985 - 44.995 2
III 44.980 - 44.985 3
2. For example, if the identifying mark of the crankshaft
pin outer diameter is “1”, the bearing with the
identifying mark of “1” will be chosen.
If there is no identifying color mark on the crankshaft,
measure the pin outer diameter and select and
measure the appropriate bearing.
3. Install the chosen bearing onto the big end and the
Identifying mark position
connecting rod cover.
>>E<< Piston and connecting rod installation

Upper scraper The first 1. Apply engine oil onto the piston, the piston ring
and the oil ring.
2. Arrange the joint of the piston ring and the oil ring
Piston pin ring (scraper and oil ring)
3. Turn the crankshaft to make the crankshaft pin
position at the cylinder hole center.
Lower scraper
The second ring joint and the oil ring joint
4. Before inserting the piston and connecting rod

assembly into the cylinder body, use appropriate
bolts of the buckle protector connecting rod.
Remarks: be careful not to touch the crankshaft pin.
5. Install the piston and connecting rod assembly into
the cylinder with the forward mark on the piston
top toward the timing belt side.
6. Install the piston and connecting rod assembly
into the cylinder with the appropriate piston ring
compression tool.
>>F<< Connecting rod cover installation
1. Confirm the mark made during the disassembly,
Cylinder number and Install the bearing cover onto the connecting
rod.
If the connecting rod is a new one without mark,
confirm that the bearing fixing groove is at the same
side as shown in the figure.
Groove
2. Confirm that the side clearance of the connecting

rod big end accords with the specified value.
Limit value: 0.4 mm
>>G<< Connecting rod cover nut locking

1. Inspect the bolts before the connecting rod is
reused.
If the bolt thread is damaged, replace the bolt. Turn the
nut through the total length of the thread part with hands.
If the nut can be turned smoothly, replace the bolt.
90°－94° Printed mark 2. Before installing each nut, apply engine oil onto
Printed mark the thread part and the surface of the nut bearing.
3. Fix the nut onto the bolt loosely.
4. Then lock to the regulated torque in turn to install
the connecting rod cover appropriately.
Bolt
Nut 5. Make a printed mark on each nut head.
6. Make a printed mark at (90-94)° of the bolt end from
the printed mark on the nut to the locking direction.
Notice:
• If the bolt is turned less than 90°, the appropriate
tension can’t be obtained. Turn each bolt to the
correct 90° carefully.
• If the bolt is turned and locked more than 94°,
loosen the bolt completely, then perform step 3
of the locking procedure, and lock the bolt again.
7. Turn the nut (90-94)°, and confirm the printed marks
on the nuts and the bolts are aligned.
Inspection
Piston
If there is obvious scratch or clinching phenomena on the piston surface (especially the thrust
surface), replace the piston. If there is crack, replace the piston.
Piston Pin
1. Insert the piston pin into the piston pin hole with the thumb. There should be a slight resistance. If
the piston pin can be inserted in easily or have excessive clearance, replace the piston pin.
2. The piston and the piston pin must be replaced as a whole assembly.
Piston Ring
1. Inspect whether the piston ring is abraded, excessively
worn and damaged.
If there is obviously poor condition, replace the piston.
If the piston has been replaced, the piston ring must be
replaced too.
2. Inspect the clearance between the piston ring and
the ring groove.
If the clearance is more than the limit value, replace
the ring or the piston, or both of them.
Standard value:
The first ring: (0.03-0.07) mm
With the piston pusher The second ring: (0.02-0.06) mm
Limit value: 0.1mm
3. Insert the piston ring into the cylinder hole, and
push down the piston ring. The piston top contacts
the ring, to correct the angle of the ring and the
cylinder wall side. Measure the end clearance with
Piston ring Piston ring joint a feeler gauge. If the end clearance is beyond the
limit value, replace the piston ring.
Standard Value(mm) Limit Value(mm)
The first ring 0.15-0.30 0.8
Plastic gauge material
The second ring 0.28-0.43 0.8
Oil ring 0.10-0.40 1
Crankshaft Pin Oil Film Clearance

<plastic gauge material method>
1. Clean the oil film on the crankshaft pin and the
connecting rod bearing.
2. Cut off the plastic gauge material with the same
length as the bearing width, and place it on the pin,
parallel with the pin.
3. Install the connecting rod cover carefully, and lock
the nuts to the regulated torque.
4. Disassemble the connecting cover carefully.
5. Measure the width of the plastic gauge at the
widest part with the scale printed on the plastic
gauge wrappage.
Plastic gauge material Standard value: (0.02-0.05) mm
Limit value: 0.1 mm

11±1
◆12 5
11
6
20 8 132±5
7
9
132±5
10
1
11±1
9.0±1.0
19
18
2
17
A 3
4
16
15
13 25±2 +90° Apply engine oil onto

25±2 +90° before installation.
14
◆ Parts which can’t be reused.

1. Flywheel Bolt (M/T) >>E<< 11. Oil seal casing
2. Switchover plate (M/T) >>D<< 12. Oil seal
3. Flywheel (M/T) >>C<< 13. Bearing cover bolt (bolt head 14)
4. Crankshaft liner (M/T) >>C<< 14. Bearing cover bolt (bolt head 17)
5. Driving disk bolt (A/T) >>C<< 15. Bearing cover
6. Switchover plate (A/T) >>B<< 16. Crankshaft bearing (lower)
7. Driving disk (A/T) 17. Crankshaft
8. Crankshaft liner (A/T) >>B<< 18. Crankshaft bearing (upper)
9. Rear plate >>A<< 19. Crankshaft thrust bearing
10. Bell casing cover 20. Cylinder body
Required Special Tools
MB990938: Handle
MD998776: Crankshaft rear oil seal erector

>>A<< Crankshaft thrust bearing installation
1. Install two thrust bearings inside the bearing hole
of Cylinder No. 3.
In order to facilitate the installation, apply engine oil
onto the bearing to help to fix it at the position.
Groove 2. Install the thrust bearings with the surface with
groove toward the crankshaft webpiston.
The position recorded for the crankshaft journal >>B<< Crankshaft bearing installation
diameter
When replacing the bearing, choose the bearing from
the following procedure and install correctly.
1. Measure the diameter of the crankshaft journal,
and confirm the grade from the following table.
When the crankshaft is supplied with maintenance
parts, the identifying mark of the crankshaft journal
is at the position as shown in the figure.
Timing belt side 2. The identifying mark of the cylinder bearing hole
diameter is from the left of the right, beginning
from No. 1, as shown in the following figure.
Identifying mark of
the cylinder hole
Outer Diameter of Bearing Hole of Crankshaft Crankshaft

Crankshaft Journal Cylinder Body Bearing Bearing No. 3
Identifying Mark Size mm (in) Identifying Mark Identifying Mark Identifying Mark
0 1 0
0 56.994-57.000 1 2 1
2 3 2
0 2 1
1 56.988-56.994 1 3 2
2 4 3
0 3 2
2 56.982-56.988 1 4 3
2 6 4
For example, if the identifying mark of the crankshaft

journal outer diameter is “0”, and the identifying mark of
the cylinder body bearing hole is “1”, the corresponding
identifying mark of the choosing bearings No. 1, 2, 4
and 5 would be “2”, and the mark of bearing No. 3 is
“1”. If there is no identifying mark on the crankshaft,
measure the outer diameter of the crankshaft journal
Identifying mark position and choose a bearing accordant to the measured
value.
3. Install the bearing with oil groove onto the cylinder

body.
Groove 4. Install the bearing without oil groove onto the
bearing cover.
Upper part
Lower part
>>C<< Bearing cover/bearing cover bolt

installation
1. Install the bearing cover with the arrowhead toward
the timing belt side.
2. Before installing the bearing cover bolts, inspect
whether the length of each bolt grip accords with
Handle length the standard value.
If the length is beyond the limit value, replace the bolts.
Limit value: 71.1 mm
3. Apply engine oil onto the thread and the bolt
bearing surface.
4. Lock the bolts to the regulated torque according to
the sequence as shown in the figure.
Arrowhead
5. Make a printed mark on each bolt head.

Notice:
Printed mark Printed mark
• If the bolt is locked excessively, loosen the
bolt completely, and then lock the bolt again
according to Step 4.
• If the bolt is turned less than 90°, the appropriate
tension may not be obtained, so turn each bolt to
90° carefully.
6. Make a printed mark on the 90° of the bearing
cover from the printed mark made on the bolt.
7. Turn each bolt to 90° in turn according to Step 4,
and confirm whether the marks on the bolt and the
bolt cover are aligned.
8. Confirm that the crankshaft is turned smoothly and
the clearance of the tail end is correct.
If the clearance of the tail end is beyond the limit value,
replace the thrust bearing of Crankshaft No. 3.
Limit value: 0.40 mm
>>D<< Oil seal installation

MB990938 Press the oil seal into the casing with the special tools
of MD998776 and MB990938.
MD998776
>>E<< Applying sealing adhesive onto the casing

oil seal
1. Apply sealing adhesive of MITSUBISHI genuine
product with part number MD970389 or equivalent
products onto the oil seal casing surface at the
position shown in the figure.
Remarks: within 15 minutes after applying sealing
adhesive, install rapidly.
2. Apply engine oil onto the oil seal lip, and then
install the casing oil seal onto the cylinder body.
Bolt tightening torque: (11±1) N•m
Remarks: keep the sealing adhesive away from oil for
about one hour.
Inspection
Plastic gauge material
Oil Film Clearance of Crankshaft Journal
<plastic gauge material method>
1. Clean the oil film on the crankshaft journal and the
crankshaft bearing.
2. Install the crankshaft.
3. Cut off the plastic gauge material with the same
length as the bearing width, and place it on the
crankshaft journal, parallel with the journal.
4. Install the crankshaft bearing cover carefully, and
lock the locking nuts tightly to the regulated torque.
Plastic gauge material 5. Disassemble the crankshaft bearing cover carefully.
6. Measure the width of the plastic gauge at the
widest part with the scale printed on the plastic
gauge wrappage.
Limit value: 0.1 mm
Cylinder Body
1. Inspect scratch, rust and corrosion visually. The
checking agent can be also used in the inspection.
If there is obvious fault, correct or replace.
2. Inspect the planeness of the cylinder body upper
surface with a line tool and a feeler gauge.
Confirm that there are no gasket bits and foreign matter
on the surface.
Standard value: 0.05 mm
Limit value: 0.1 mm
3. If the bending is beyond the standard value, correct

within the limit value or replace.
Grinding limit value: 0.2 mm
Including/combining with the cylinder cover grinding
Cylinder body height (new parts): 284 mm
4. Inspect the scratch and clinching on the cylinder
wall. If there is obvious fault, replace the piston and
the piston ring or before the cylinder to an oversize
and replace the piston and the piston ring.
5. Measure the planeness of the cylinder hole and

the cylinder diameter with a cylinder gauge. If
the abrasion is serious, correct the cylinder to an
oversize and replace piston and the piston ring.
Measure the points indicated in the figure.
12mm
Standard value:
Cylinder inner diameter: 87.0 mm
Central Cylinder diameter planeness: less than 0.01 mm
bottom
Cylinder Reboring
1. The use of oversized piston depends on the cylinder
size with bigger hole diameter.
Piston size identifying
Remarks: the size mark is on the piston top.
Size Identifying mark
Outer diameter
of the cylinder 0.50 mm (oversize) 50
2. Measure the outer diameter of the using piston.
Measure the thrust direction, as shown in the figure.
3. Calculate the final size of the reboring hole, on the
base of measured outer diameter of the piston.
Final size of the reboring = piston outer diameter +
(clearance between the piston outer diameter and the
cylinder) - 0.02 mm (reboring edge)
Notice: in order to avoid the distortion caused by the
increasing of the temperature during the reboring
process, the reboring operation should be from the
second to the fourth, then to the first and the third.
4. Rebore all the cylinders to the final calculated hole
reboring size.
5. Final reboring size = piston outer diameter + (clearance
between the piston outer diameter and the cylinder).
6. Inspect the clearance between the piston and the
cylinder
Clearance between the piston and the cylinder:
(0.02-0.04) mm
Remarks: When reboring the cylinders, all the four
cylinders should reach the same size. Never rebore
only one cylinder to a larger size.
Engine Electronic Fuel Injection System-
Engine Electronic Fuel Injection System
Engine Electronic Control Module (ECM)..................................... 2

Mechanical Throttle valve Body Assembly................................... 5
Digital Camshaft Position Sensor.................................................. 7
Engine Coolant Temperature Sensor............................................ 9
Canister Cleaning Control Solenoid Switch................................. 11
Fuel Rail and Fuel Injector Assembly . ......................................... 13
Knock Sensor.................................................................................. 15
Oxygen Sensor................................................................................ 17
Intake Manifold Absolute Pressure and Temperature Sensor.... 19
Engine Anti-theft System................................................................ 22
Engine Electronic Control Module (ECM)

● The engine electronic control module (for short, ECM) is the core control element of modern
engine management system, with functions of continuous monitoring and controlling normal
work and operation of the engine. The ECM calculates the desired air-fuel ratio and ignition
advance angle of the engine and other parameters according to the input signal of various
sensors installed on the engine and complete vehicle, and directly controls the fuel feed, fuel
injection timing, high tension ignition timing, ignition dwell angle, engine idling speed, and the
operation modes of other accessory systems of the vehicle in various working condition of the
engine.
● According to the different application of engine management systems, the quantity of
practically complemented components are different too. Through the signal input and output
of these sensors, and through actuator, ECM performs and controls the normal work of the
engine. The sensor will provide various measured and inducted data for ECM, the output
control actuator execute various instructions according to the control data stored in ECM
after calibration and debugging in advance. The main output control functions include: fuel
injection, fuel injection timing, ignition coil input dwell angle, engine ignition advance angle,
engine idling speed control, detonation control, complete vehicle combustion and emission
control, fuel supply system control, vehicle cooling fan control, vehicle air-conditioning
system control, on-board diagnostics (OBD) system function and so on.
Operation Principle
● The ECM generally gets various information on the actual operation conditions of the engine
or the complete vehicle through a number of sensors equipped on the engine management
system, and ECM performs the task of optimizing and controlling the engine working condition
according to the actuator equipped on the rating data driving system calibrated and stored in
advance.
● Generally, sensors of main input signal of the system include: integrated intake pressure
and temperature sensor (MAPMAT), coolant temperature sensor (CTS), oxygen sensor (O2),
crankshaft position sensor (CPS), camshaft position sensor (CAM), knock sensor (KNOCK),
acceleration position sensor (“G” Sensor), fuel level sensor (FLVL), etc..
● The engine control by ECM is realized through the actuator equipped on the system. Generally,
actuators equipped on the system mainly include elements such as fuel injector (INJ), ignition
coil (IGN), canister solenoid valve (ECP), electric fuel pump and idle air control valve (IACV),
etc.
The ECM communicates with other on-board control systems (such as ABS, automatic transmission)
through related hard wares and related communication protocols of the CAN bus equipped on the
system.
Technical Characteristics
1. Main Technical Performance
The main output control functions of ECM include: fuel injection, fuel injection timing, ignition coil input
dwell angle, engine ignition advance angle, engine idling speed control in various conditions, complete
vehicle combustion and emission control, fuel supply system control, vehicle cooling fan control,
vehicle air-conditioning system control, on-board diagnostics (OBD) system function and so on.
2. Main Technical Parameter
(a) Characteristic Parameter of Electric Appliance
Voltage range: ( 12-24) V
Normal working voltage range: (9.0-16) V
The ECM system contains the functions of 24V-resistant over voltage protection and 14V-resistant
antipole voltage protection.
(b) Temperature Characteristic Parameter
Storage temperature: (-40-125) ℃ Operation temperature: (-40-105) ℃
Connection Terminal Definition

Pin No. PIN Definition. Detail Descriptions
J1-1 IGN IGNITION SWITCH
J1-2 LOSPAREDI01 LOW ACTIVE DI 01
J1-3 VSS VEHICLE SPEED SENSOR
J1-4 V5B2 5V SUPPLY #2
J1-5 V5BRTN1 5V GROUND #1
J1-6 O2LO O2 SENSOR LOW
J1-7 IMMOCODE IMMOBILIZER CODE (Not used)
J1-8 LOACREQ AC REQUEST (LOW ACTIVE) (Not used)
J1-9 LOELOAD2 ELECTRICAL LOAD2 (LOW ACTIVE)
J1-10 CAM CAM SENSOR (HALL )
J1-11 SDATA SERIAL DATA
J1-12 58XVRHI 58X SIGNAL HIGH
J1-13 LEGRFB LINEAR-EGR FEEDBACK (Not used)
J1-14 CAN LO CAN LOW (Not used)
J1-15 CAN HI CAN HIGH (Not used)
J1-16 ESTD ELECTRICAL SPARK TIMING D
J1-17 PS-VBAT1 BATTERY 1
J1-18 PS-VBAT2 BATTERY 2
J1-19 SPAREAN03 ANALOG INPUT 03 (Not used)
J1-20 V5B1 5V SUPPLY #1
J1-21 V5BRTN2 5V GROUND #2
J1-22 SPAREAN02 ANALOG INPUT 02 (Not used)
J1-23 FLVL Fuel Level (Not used)
J1-24 TPS THROTTLE VALVE POSITION SENSOR
J1-25 PWM03 PULSE-WIDTH MODULATION (Not used)
J1-26 F_EVAP FRONT EVAP. TEMP. SENSOR (Not used)
J1-27 MAT MANIFOLD AIR TEMP. SENSOR
J1-28 58XVRLO 58X SIGNAL LOW
J1-29 SVS SERVICE VEHICLE SOON
J1-30 MIDACLO MID. AC LOW ACTIVE (Not used)
J1-31 CEL CHECK ENGINE LIGHT
J1-32 COILA COIL DRIVER A
J1-33 IACBHI IACB HIGH
J1-34 IACBLO IACB HIGH
J1-35 RROAD ROUGH ROAD (Not used)
J1-36 SPAREDI01(PSPS) POWERPOWER STEERING (Not used)
J1-37 SPAREAN01 ANALOG INPUT01 (Not used)
J1-38 O2BHI O2B SENSOR HIGH
J1-39 HIACREQ AC REQUEST (HIGH ACTIVE)
J1-40 -------
Pin No. PIN Definition. Detail Descriptions

J1-41 PNSW P/N SWITCH (Not used)
J1-42 MAP MANIFOLD AIR PRESSURE SENSOR
J1-43 CLT COOLANT TEMP.SENSOR
J1-44 R_EVAP REAR EVAP. TEMP. SENSOR (Not used for COWRY models)
J1-45 TACH TACHOMETER
J1-46 ACRLY AC CLUTCH RELAY
J1-47 FPR FUEL PUMP RELAY
J1-48 ESTC ELECTRICAL SPARK TIMING C
J1-49 PWM02 PULSE-WIDTH MODULATION (Not used for COWRY models)
J1-50 FAN2 RADIATOR HIGH SPEED FAN
J1-51 FAN3Rec Fan3 Recirculation (Not used for COWRY models)
J1-52 COILB COIL DRIVER B
J1-53 IACALO IAC A LOW
J1-54 IACAHI IAC A HIGH
J1-55 INJA INJECTOR CYL#1
J1-56 INJB INJECTOR CYL#3
J1-57 HIELOAD1 ELECTRICAL LOAD 1 (HIGH ACTIVE) (Not used for COWRY models)
J1-58 MPR MAIN POWER RELAY
J1-59 LOELOAD1 ELECTRICAL LOAD 1 (LOW ACTIVE) (Not used for COWRY models)
J1-60 IMMOREQ IMMOBILIZER REQUEST (Not used for COWRY models)
J1-61 O2AHTR O2A HEATER CONTROL
J1-62 O2AHI O2A SENSOR HIGH
J1-63 ECP CANISTOR PERGE VALVE
J1-64 O2BHTR O2B HEATER CONTROL
J1-65 PWM Variable valve controlled by solenoid valve
Recirc for LEGR/Spared PWM output 01,02 (Not used for COWRY
J1-66 RECIRC1
models)
J1-67 FAN1 RADIATOR LOW SPEED FAN
J1-68 FAN3/RLCUT AC FAN/REAR LOOP CUT OFF (Not used for COWRY models)
J1-69 ESC KNOCK SENSOR SIGNAL
J1-70 INJD INJECTOR CYL#2
J1-71 INJC INJECTOR CYL#4
J1-72 SPAREPWM01 PULSE-WIDTH MODULATION 01 ( Not used for COWRY models)
J1-73 PWRGND POWER GROUND
Notices for Use

1. Pay attention to static during assembling to avoid spark produced by static leading to the
damage to the ECM.
2. When ECM is assembled to the wiring harness connector, make sure that the system power
supply is off, i.e., the ignition switch of the engine or the vehicle is shut.
3. When the ignition switch of the system is turned on for the first time, in order to ensure
that ECM gets correct position information of the engine idle control valve, please proceed
according to the operation mode in the following steps:
4. After a short time after turning on the ignition switch (at least 2 seconds), turn off the ignition
switch and keep it off for at least 5 seconds.

5. Turn on the vehicle ignition switch again, and the process can make the module acquire
position information of the idle valve.
6. ECM must not be subjected to instant over voltage of the system over 16V.
7. If the voltage on the positive terminal of the accumulator is all applied to the ECM housing, large current
will flow through ECM, which leads to the damage of the connecting wiring of the internal system earth
wire. As a result, ECM will be thoroughly defective. For example, a metal wrench causes short circuit
of the positive terminal of the ECM housing and accumulator by accident (i.e. the wrench provides the
passage of current), this will cause the defectiveness of ECM. This kind of defectiveness also happens
on the housing on which jumper wire accidentally contacts with the module during jump starting.
Mechanical Throttle valve Body Assembly

Throttle valve body assembly, also called air flow (metering) valve, is one of the main
components of the air fuel subsystem of the engine management system. It is a mechanical
adjustment device, used for controlling the intake volume of the engine intake pipe, and
consequently controlling the rotate speed and the output power of the engine.
Throttle valve body assembly is equipped with throttle valve position sensor (TPS), and does
rotating works driven by throttle valve body shaft. It is used for measuring the position of the
throttle valve opening degree, and making feedback to the engine electronic control module
(ECM), to check the engine running state and load condition (high or low) so as to control fuel
feed.
Throttle valve body assembly is equipped with idle air control valve (IACV) for adjusting idle
bypass air volume and controlling engine idling more accurately.
A coolant flow pipeline is usually designed on the throttle valve body assembly. When coolant
is flowing through the pipe, the bottom of the throttle valve body can be heated, thus avoiding
icing at the valve plate of the throttle valve body or at the space between the shaft and the
bearing during driving in very cold weather at an even speed, which may cause accidents.
Some throttle valve body assembly is equipped with a vacuum tube interface, which can be
used to provide vacuum source and its passage for the system or vacuum source for system
components needing vacuum signal.
Generally, the temperature range under normal work of the throttle valve body is between ( 40-125)℃.
Operation Principle
Throttle valve body assembly is in fact an air flow (metering) control device. Throttle valve
body assembly is designed to be equipped with throttle valve position sensor (TPS) and
engine idle airflow control valve (IACV). Throttle valve position sensor can be used for
monitoring the real opening degree position condition of the throttle valve, converting the
monitoring result into electric signal, and transmitting the signal to the engine electronic
control module (ECM); engie idle airflow control valve can be driven and controlled directly by
the engine electronic control module, through the feedback signal of the engine speed signal,
realize intake flow adjustment closed loop control of the engine idle working condition, and
increase intake air moderately in the condition of sudden increase of load, ensure the stability
of engine idling; while in the engine dynamic working condition , steadier running in engine
transient conditions can be realized through the adjusting function of the idle airflow control
valve, which is favorable for the improvement and optimization of driving performance in
transient conditions.
Performance Parameter of Throttle valve

Position Sensor
• Measuring range: (7-93) % opening degree (from
idling to fully open)
• Reference voltage of throttle valve position sensor: (5
±0.1) V
• When the throttle valve is fully closed, normal
output is (12±5) % of the reference voltage
• When the throttle valve is fully open, normal output
is (83-93) % of the reference voltage
• Impedance between terminal T1 and T2 is (3-12) kΩ
• Adaptive temperature of working condition:
(-40-125) ℃
• A ssembled tightening torque of throttle valve
position sensor: (1.8-3) N•m
Signal
ground
Idle Air Control

The engine idle airflow control of the throttle valve body assembly researched and developed by
Delphi Company controls with idle speed control stepper motor - called idle control valve, ECM can be
used directly to adjust the engine, and during idle running, suitable air flow is provided for the engine.
Air flow
Idle air flow
Notice for Use

1. Never adjust the position of the idle control valve central spindle with hands. Pushing and
pulling the idle control valve central spindle will cause too high stress and damage internal
elements. The position of the idle control valve central spindle can only be adjusted by
electronic pulse console.
2. During the first assembling, if the idle control valve central spindle is screwed out too long,
when tightening the fitting screw, it is possible to oppress the central spindle, damage the
elements and coils. Suitable adjustment on the length of unscrewed part of the idle control
valve should be made on the electronic pulse console for correct assembling.
3. Idle control valve (IACV) must be reset after being installed on the valve body.
4. Raffle or sludge and fouling heap on the valve air opening cause clogging, which influences
air flow in the throttle valve body, especially idle air flow. Measure: cleaning should be done
periodically.
Digital Camshaft Position Sensor

● The camshaft position sensor is one of the main components of modern engine management
system. Its function is to induce and detect timely and correctly the relative rotation angle
position of the engine camshaft during engine running process (usually also called phase
sensor), and to provide it for the engine electronic control module (ECM) in the form of electric
signal, so that with the crankshaft position signal that is input by crankshaft position sensor,
the engine electronic control module judges the working phase of each cylinder of the engine
at this moment, and makes the system control fuel injection and ignition order according to
specified engine working order Therefore, combustion process of the engine can be more
accurately controlled and harmful combustion emissions can be reduced. Camshaft position
sensor is an essential configuration element of the system components through which the two
control functions of sequential fuel injection of each cylinder and sequential individual ignition
of each cylinder can be realized simultaneously. The use of camshaft position sensor is helpful
for optimal control of the ignition and injection timing of each engine cylinder.
● The camshaft position sensor is made of circuit elements based on Hall principle, whose
output signal is switch signal in square waveform. The output signal voltage has no positive
connection with the target rotation speed but just sends out the frequency change of the
voltage signal, so this kind of signal is called digital sensor.
● Usually single target tooth is designed on the camshaft for corresponding target cam of camshaft
position sensor. The target tooth is made up of ferrous metal material, such as cast iron or mild
steel plate material. 4G63 engine camshaft position sensor matching with Cowry, Great Wall
is designed to be installed on the end of the camshaft. When the target tooth rotates through
the sensor, a level signal will be produced at the output end of the sensor elements, indicating
corresponding specified working state of related cylinders located system of the system engine.
● The placement design of the camshaft position sensor has a close relation with the
algorithmic language of the engine management system and system logic control. In other
words, the specified relative phase logical relation between the camshaft position sensor
and the crankshaft position sensor is decided by the logical relation specified by the engine
management system software. This kind of phase relation can not be changed freely.
Performance Parameter of Camshaft

Position Sensor
System input voltage: 5.0 V, working voltage range:
(4.75-5.25) V
Peak value voltage: (23-24) V (an hour)
Output signal: digital level (switch signal)
Operating temperature range: (-40-140) ℃
Low level output: (0-400) mV (when the system
signal voltage is 5V)
High level output: (4.75-5.25) V (when the system
signal voltage is 5V)
Installation Requirements
The assembling design of the camshaft position sensor and the logical relation specified by the
engine management system must match each other. The relative phase logical relation between the
camshaft position sensor and the crankshaft position sensor specified by Delphi engine management
system determines that the camshaft position sensor of this system should be operated according to
the following principles.
1. First confirm the installation position of the crankshaft position sensor on the engine or
transmission housing.
2. Place the engine to the piston top dead center position of cylinders 1 and 4, and cylinder 4 is
at the compression stroke top dead center.

3. 60 teeth should be designed uniformly distributed 360 degree above the clutch flywheel, that
is, one tooth per (6±0.1) degree. Reasonable and feasible relative position degree should be
guaranteed between teeth. The clearance between the crankshaft position sensor and flywheel
target cam is (0.3-1.5) mm.
4. It is required that when the conditions in 1 and 2 are met, crankshaft position sensor centre
line is at the lower edge of the 20th tooth along crankshaft rotating direction (i.e. when piston
of cylinder 1 and 4 are at the top dead center, the first tooth of the crankshaft target cam has
passed 20 teeth of the sensor,and 120 degree crank angle).
5. At this time, the camshaft position sensor is at the 51°target cam signal tooth center after the
signal tooth center line of the camshaft target cam.
6. The recommended clearance between the detecting terminal of the camshaft position sensor
and the camshaft target cam is (0.10-1.5) mm.
7. Recommended range of the included angle between the assembly hole center line of the
camshaft position sensor and water level is (15-90) °, (the detecting head of the sensor is
required to be downward).
Engine Coolant Temperature Sensor

● The engine coolant temperature sensor is an important element characterizing actual engine operation
mode in engine management system. It is one of the important components of the air-fuel supply
control subsystem of the engine management system. The negative temperature coefficient (NTC)
thermisters with quick response characteristic are adopted on the engine coolant temperature sensor
as its core temperature sensing elements. And the resistance characteristics of these temperature
sensing elements possess fine product consistency; no matter where they are applied, the sensors
with the same components number have the same resistance output signal.
● The BDW-CS-XXX series engine coolant temperature sensor products integrate the
temperature parameters for the vehicle instrument panel temperature display instrument and
for the engine management system. The engine coolant temperature sensors of this series
possess two functions: one is to provide engine coolant temperature parameter for the engine
management system; the other one is to provide engine coolant temperature parameter for the
vehicle instrument panel.
Operation Principle
● The core temperature sensing elements of the engine coolant temperature sensor are
composed of semiconductor thermister with negative temperature coefficient characteristic.
The temperature characteristic is the negative temperature coefficient (NTC) thermister
characteristic. This kind of temperature sensor usually needs resistance characteristic testing
with special measuring circuit.
● The output characteristic of semiconductor thermister with negative temperature coefficient
characteristic is that the resistance of thermister has an inverse relation with temperature
change: when the temperature rises, the output resistance of the thermister decreases; when
the temperature reduces, the output resistance of the thermister increase.
● The engine electronic control module (ECM) provides 5V D.C signal for the engine coolant
temperature sensor and measures its voltage drop through the internal circuit of ECM itself,
and the engine management system will judge the actual engine operation mode according
to this voltage signal. For negative temperature coefficient temperature sensors, when the
engine temperature is low, magnitude of voltage detected by the system is high, while when
the engine temperature is high, magnitude of voltage detected by the system is low.
Coolant temperature sensor Actual applied circuit of sensor
Reference voltage signal
Tempera-
ture sensor Sensing electricity
Input circuit
Signal output
Performance Parameter
Refer to the following table for zero load resistance - temperature characteristics and
temperature accuracy of the sensors
Engine Electronic Fuel Injection System-10
Output Resistance Characteristics

(between the Two Terminals of A–C) Temperature
Test Temperature (℃)
Accuracy (+/-℃)
Resistance(Ω) Resistance Error(+/-%)
-40 100865 4.9 0.7
-35 72437 4.6 0.7
-30 52594 4.4 0.7
-25 38583 4.2 0.7
-20 28582 4 0.7
-15 21371 3.8 0.7
-10 16120 3.6 0.7
-5 12261 3.4 0.6
0 9399 3.2 0.6
5 7263 3.1 0.6
10 5658 2.9 0.6
15 4441 2.8 0.6
20 3511 2.6 0.6
25 2795 2.5 0.6
30 2240 2.5 0.6
35 1806 2.4 0.6
40 1465 2.4 0.6
45 1195 2.3 0.6
50 980.3 2.3 0.6
55 808.8 2.2 0.6
60 670.9 2.2 0.6
65 559.4 2.2 0.6
70 469.7 2.1 0.6
75 394.6 2.1 0.6
80 333.8 2 0.6
85 283.5 2 0.6
90 241.8 2.1 0.7
95 207.1 2.2 0.7
100 178 2.3 0.8
105 153.5 2.4 0.8
110 133.1 2.5 0.9
115 115.7 2.6 0.9
120 100.9 2.7 1
125 88.3 2.8 1
130 77.5 2.8 1.1
135 68.3 2.8 1.1
140 60.3 2.9 1.2
145 53.4 2.9 1.2
150 47.5 2.9 1.2
Canister Cleaning Control Solenoid

Switch
● The canister cleaning control solenoid switch is
an important control element in fuel evaporation
and emission control subsystem of the engine
management system. Its main purpose is to control
cleaning speed of fuel vapor stored in charcoal
evaporation and recovery tank, and deliver the fuel
vapor in charcoal evaporation and recovery tank into the engine cylinder for combustion.
● The canister cleaning control solenoid switch is installed between the charcoal evaporation
and recovery tank and the intake manifold air inlet or the rear end of the throttle valve body
assembly. The optimal scheme is to install it on the engine intake manifold assembly.
● The canister cleaning control solenoid switch is controlled by the engine electronic control
module (ECM) in input pulse width modulation method. That is, the engine electronic control
module (ECM) regulates the fuel vapour (cleaning stream) flow delivered from the charcoal
canister to the intake manifold through modulating the electrical pulse width delivered to the
canister cleaning control solenoid switch at a proper moment, to get the purpose of purging
the charcoal canister fuel vapour and controlling the fuel evaporation pollution.
● Through regulating the cleaning and desorption air flow with the canister cleaning control
solenoid switch, the engine electronic control module (ECM) can indirectly control gasoline
vapour flow entering the engine intake manifold from the charcoal evaporation and recovery
tank and mixing with fresh air, so as to avoid great effect caused by the air flow on the air fuel
ratio of the working engine.
● The effective cleaning control on the fuel vapour absorbed in the charcoal evaporation
and recovery tank can effectively prevent it from being released into the atmosphere, and
consequently the target of controlling air pollution by fuel evaporant is realized.
● The solenoid switches of 25351449 developed by Delphi Company are function reinforced
canister cleaning control solenoid switches, which are designed to meet the requirements of
continuously developed and consolidated and more strict evaporation emission regulation,
with an aim of improving the system fuel vapour emission control level.
Operation Principle
● As the name implies, canister cleaning control solenoid switch is still a solenoid switch
element utilizing solenoid switch operation principle in a regulation mode of solenoid switch
motion controlled by electrical pulse width modulation.
● The function reinforced canister cleaning control solenoid switches developed by Delphi
Company can regulate the air flow flowing through the solenoid switch in a certain differential
pressure (duty ratio) condition through controlling the solenoid switch motion frequency.
When inlet and outlet gas differential pressure of the solenoid switch are definite, the air flow
flowing through the canister cleaning control solenoid switch is in linear direct proportion to
the electrical pulse input duty ratio (%).
● The flow passage between the fuel vapour absorbed and stored in the charcoal canister and the
engine intake manifold is controlled by the canister cleaning control solenoid switch. The canister
cleaning control solenoid switch is directly controlled by the engine electronic control module
(ECM) through the pulse width modulation parameter (PWM) signal specially calibrated, debugged
and prescribed by the calibration engineer according to different types of engine and vehicle
application.
● In suitable engine working condition (generally the part-loaded condition of the engine), when
the internal vacuum degree of the intake manifold assembly is high at this time, and the air
differential pressure in the upstream and downstream of the canister cleaning control solenoid
switch is high, the time for canister cleaning is best.. At this time, the engine electronic control
module (ECM) sends control electronical pulse signal to the solenoid switch, and starts the
solenoid switch to work. With the help of the vacuum degree of the intake manifold, the fuel
vapour stored in the charcoal canister flows through the charcoal canister and is absorbed
into each cylinder for combustion. Fuel vapour emission into the atmosphere is effectively
reduced, and the aim of controlling fuel vapour emission is realized.
● When the engine electronic control module (ECM) exports low duty ratio, the solenoid switch
can control the fuel vapour flow accurately to guarantee accurate air fuel ratio control during
running at a low speed; if high flow cleaning is necessary, the engine electronic control
module (ECM) will send high duty ratio output order, and the solenoid switch will control the
fuel vapour flow delivered into the intake manifold in a higher flow.
After the fuel vapour entering the engine intake manifold flows and mixes with the air in
the intake pipe, it enters the combustion chamber in each cylinder for combustion. When
leading the cleaning control air flow into the intake manifold is designed, requirement on the
distribution uniformity into each cylinder of the air flow must be considered, so as to avoid the
influence on the overall uniformity of air fuel distribution in each cylinder.
Charcoal canister connector Normal working voltage: (8-16) V
Intake manifold interface
Operation temperature range: (-40-120) ℃
Maximum operation frequency: 16Hz
Mass: 120g
Magnetic coil resistance: (19-22) Ω
Magnetic coil inductance: (12-15) mH
Minimum trigger voltage: (in 50 kPa differential
Electric appliance connector pressure condition): 8V
Solenoid switches are normally closed Operation noise (when the duty ratio is 50%):
52dB (measure in 0.5m distance)
Fuel Rail and Fuel Injector Assembly

● The fuel rail and fuel injector assembly is the most important assembly element in the fuel
supply subsystem components of the engine management system. The assembly plays a very
important role in allocating optimum air fuel ratio for the engine management system.
● The fuel rail and fuel injector assembly element can distribute fuel uniformly and rationally and
provide ideal air fuel ratio and well atomized fuel for the engine. The main function of the fuel
rail and fuel injector assembly is to distribute the fuel pumped out by the electric fuel pump
into the inlet channel led from the intake manifold to each cylinder under uniform fuel pressure
and make the fuel injected out by the fuel injector completely absorb into the cylinder for
combustion during engine intake process.
● The main function of the fuel rail is to fix and hold the fuel injector on the engine cylinder
cover or the intake manifold assembly, and to keep a certain amount of fuel under certain
pressure then transmit the fuel to each fuel injector; while getting well atomized fuel injection
is controlled by the fuel injection performance of each fuel injector itself.
● The steady pressure of the fuel supply system of modern engine management system is
realized through the fuel pressure regulator equipped on the system. The fuel pressure
regulator of the no fuel return and limited fuel return fuel supply system is generally designed
to be integrated on the fuel return pipe system mounted on the electric fuel pump in the fuel
tank and on the bracket assembly.
Operation Principle
● Fuel Rail
1. The fuel rail assembly equipped on conventional multi-point fuel injection engine management
system is generally made of stainless steel, aluminium casting alloy or carbon steel material.
The main components include fuel delivery line, pipe connecting joint, fuel injector installing
seat and other main parts.
2. The fuel rail is designed to have space for the flow of the pressure fuel (the main pipe of the
fuel rail), branch line distributed to each fuel injector (fuel injector installing seat), fuel in-and-
out line and joints. The fuel injector usually adopts top fuel feeding which is used to fix the
fuel injector. The fuel injector installing seat directly mounted on the fuel rail plays a function
of fixing the top of the fuel injector.
● Fuel Injector
The fuel injector is actually an electromagnetic hydraulic switch control element. The magnetic
coil with circle iron core is designed in the internal of the fuel injector, and the two electrodes
led out from the magnetic coil is the electrical input control interface. The fuel injector directly
connects with the output control circuit of the engine electronic control module (ECM) and
the system power supply through the engine wire harness. After the magnetic coil conncets
to power, strong electromagnetic field is produced immediately, the magnetism produced by
the electromagnetic field gets over the tension of

the injector return spring, the pressure of system
fuel and the vacuum suction force of the manifold,
then draws the iron core, and liquid fuel flows
through the ball valve sealing surface of the fuel
injector, and gets to the guiding spray orifice.
After the fuel runs through the spray orifice, it
changes into atomized fuel taper. After the engine
electronic control module (ECM) releases the
order to cut off the power supply, the fuel injector
is shut off under the effect of the return spring,
and cuts the fuel supply, resulting in the stopping
of fuel injection. The performance of the fuel rail and fuel injector assembly directly reflects
the fuel pressure characteristic of the engine fuel management subsystem, and influences
the control accuracy on the engine air fuel ratio. Finally it will directly relate with such as
the power, fuel economical efficiency, emission performance, driving performance, starting
performance, idle work stability and other comprehensive performances.
Technical Parameter
Fuel rail assembly (metal parts)
Operation temperature condition: (–30-125) ℃
System burst pressure: 900kPa (maximum)
Maximum leakage (assembly): 3 SCCM in the condition of air being used under 420kPa
Fuel injector
Operation temperature range: (–30-125) ℃
Lowest working voltage: 6V
System fuel pressure: 350kPa
Set pulse width: 2.5ms
Static coil resistance: (12.0±0.6) Ω
Knock Sensor
● The knock sensor is a kind of vibration sensor
with piezoelectric crystal structure principle,
which is generally installed on the side of the
e n g i n e c y l i n d e r b o d y, u s e d f o r t e s ting the
conditions during the engine running process and
providing for the system whether fierce knock and
combustion happen on the engine combustion in
the form of outputing voltage signal.
● The knock sensor is an optimized optional component of the engine combustion management
subsystem in the engine management system.
● The knock sensor, utilizing piezoelectric crystal technology principle, senses and detects
knock happening during engine combustion which causes strong vibration signal when the
engine is at certain frequency. The engine electronic control module regulates moderately
the engine ignition timing control according to the rating data set by the system engineer in
advance, so that the knock intensity can be regulated rationally, the combustion state of the
engine gets optimum control, and at the same time, obvious knock phenomenon in normal
running condition of the engine is eliminated, and damage on the engine caused by the strong
knock during combustion is avoided.
● The function of the knock sensor in the engine management system is to sense and detect
timely and accurately whether knock happens during the engine combustion process and
the intensity of the knock, and to provide corresponding knock intensity information for the
engine electronic control module. Therefore, knock sensor is one of the important elements
through which optimized control of the engine combustion management control subsystem
can be realized.
Operating Principle
● The knock sensor, adopting piezoelectric crystal principle, transforms certain mechanical
vibration signal produced when the engine is knocked into corresponding voltage signal
through piezoelectric crystal circuit treatment and amplification.
● Knock sensor developed by Delphi Company is of flat characteristic and frequency response
type. It is necessary to design signal filtering circuit in the system electronic control circuit
to conduct filtering treatment on the signals in different frequency, so as to filter various
background frequency noises, and retrieve the natural frequency produced when the engine is
knocked.
● The development of modern automobile industry makes electronic control circuit equip on
its core – the engine electronic control module, and makes the filtering treatment process
is directly completed by the engine electronic control module (ECM). The technology makes
the flat characteristic frequency response type knock sensors are extensively used: a kind of
sensor can be used for different types of engines with different displacement, and different
material structure.
● Because of the relative weak output signal of the flat characteristic frequency response type
knock sensor, it is necessary to adopt shielded wire as its signal leading out wire to provide
signal output for the engine electronic control module.
The basic performance parameter of knock sensor of Delphi Company is as follows:
Frequency response range: (3-18) KHz
Frequency output signal: not lower than 17mV/g (in any case)
Sensor resistance: >1MΩ (25±5℃)
Sensor capacitance: ((900-1,300) pF (tested in the condition of 1,000 Hz frequency, 25±5℃
ambient temperature)
Technical requirements on output signal voltage:
Minimum value: 17mV/g when the frequency range is 5-18KHz
Maximum value: 37mV/g when the frequency is 5 KHz
42.5mV/g when the frequency is 8 KHz
48.1mV/g when the frequency is 13 KHz
74mV/g when the frequency is 13 KHz
Oxygen Sensor
● The oxygen Sensor is an essential component in modern engine management system. It is an
electrical element developed utilizing electrochemistry operation principle.
● The oxygen sensor is used for detecting the oxygen content in combustion gas emitted from
the vehicle engine in the configuration mechanism of modern engine management system
through which to judge the actual condition of air fuel ratio of the real time fuel supply of
the engine, and feed it back to the engine electronic control module (ECM) through the
electrical reactive signal produced by itself, as an important reference of the closed loop
fuel revision compensation control of the system fuel management system. Thus the fuel
management subsystem can control and regulate the air fuel ratio more accurately in any
engine operation mode, and the system can keep an ideal air fuel ratio operation mode in most
working conditions to gain better vehicle emission control characteristic and fuel economical
efficiency.
● The OSP+ type heated oxygen sensor developed by Delphi Company with a small size can
effectively control the rapid heating of the sensor, and combustion starts very rapidly, which
can early realize the closed loop fuel management control of the system on the engine
management system.
Operation Principle
● The OSP+ type oxygen sensor of Delphi Company adopts flat plate construction multilayer
ceramic element as the basic element of the sensor. The zirconia element is a kind of ceramic
basic element with numerous micropores throughout the full body and with zirconia coating,
whose exterior side exposes in the engine combustion gas; and the inside stores reference
oxygen in a tiny cavity. The difference between the oxygen content concentrating on the inside
electrode and the oxygen content concentrating on the outside electrode of the zirconia forms
the differential voltage signal.
● When the zirconia element is activated through current heating or heating of the engine
combustion gas flowing through the sensor, oxygen stored in the cavity connects with the
inner electrode of the zirconia element, while the combustion gas flows through the outer
electrode of the zirconia. Oxyanion will move from the inner electrode of the zirconia to the
outer electrode, a simple primary battery is formed between the inner and the outer electrode
of the sensor, and different oxygen content in the engine combustion gas creates different
output voltage signals between the two electrodes. The oxygen sensor will change the level
of the output signal according to the changes of the oxyanion concentration in the engine
combustion gas.
● The output signal of an oxygen sensor is an alternating voltage signal at 0-1V. In specified
operation temperature range, the oxygen sensor can automatically sense and detect a
continuously changing voltage signal and output it to the engine electronic control module.
● The working status of an oxygen sensor is presented as when the air fuel ratio during engine
running becomes low, the concentration of the oxygen content in the exhaust air will increase,
and at this time, the output voltage signal of the oxygen sensor will be close to 0V; when the
air fuel ratio becomes high, the concentration of the oxygen content in the exhaust air will
decrease, and the output voltage signal of the sensor will be close to 1V.
● The engine electronic control module (ECM) can adjust the system output control order
according to the input voltage signal in combination with the system control logic and control
strategy through responsive sensor and actuator, so that the engine works in and keeps ideal
air fuel ratio fuel supply state.
● The permissible lowest operation temperature of the core element of the oxygen sensor is
300℃, and the highest temperature generally does not exceed 850℃.
● Refer to the actual values specified in the actual product drawing for specific details.
Performance Parameter and Technical Specifications
Measured values on the engine dynamometer at the temperature of 450℃
Voltage signal when the air fuel ratio is high: >750mv
Voltage signal when the air fuel ratio is low: <120mv
Response time of the air fuel ratio from thick to thin at 450℃: <80ms
Response time of the air fuel ratio from low to high at 450℃: <65ms
Heating element resistance (21℃): (9.6±1.5) Ω
Heating element current: (0.52±0.10) A
Intake Manifold Absolute Pressure and Temperature Sensor

● The intake manifold absolute pressure and temperature sensor is one of the main elements in
the engine management system elements which indicates the actual engine intake condition
during the engine running, and subsequently indicates the working condition and the load
condition of the engine. Therefore, an intake manifold absolute pressure and temperature
sensor is a particularly important component in the air fuel supply control subsystem of the
engine management system.
● The intake manifold absolute pressure and temperature sensor developed by Delphi Company
has integrated the functions of both an intake manifold absolute pressure sensor and an intake
manifold absolute temperature sensor to make them one sensor. At the same time, it achieves
the goal of detecting the engine intake manifold absolute pressure and the air temperature in
the intake manifold. The sensor applies to naturally aspirated engines.
● In the mechanism configuration of the engine management system adopting speed density
principle, the intake air temperature sensing element is used for providing the intake air
temperature test data in the engine intake manifold for the system, to make the engine
electronic control module calculates the actual air density after it entering the engine
according to the system software, and the system subsequently reckons the actual air supply
(actual charge) entering the engine for combustion, according to other related parameter
states of the engine.
● The engine management system, basing on the fluid mechanics principle, reckons the actual
charge state of the engine according to the actual test data of the air temperature and pressure
in the intake manifold, and considering comprehensively the influencing factors of other
related parameters, provides fuel injection supply at an ideal ratio for the engine. Therefore,
an intake manifold absolute pressure and temperature sensor is one of the important elements
constituting the air flow metering mode of the speed density engine management system.
Operation Principle
● The intake manifold absolute pressure and temperature sensor integrates the functions of both
an intake manifold absolute pressure sensor and an intake manifold absolute temperature
sensor into a whole.
● The intake manifold absolute pressure sensor is designed based on the piezoelectric
technology principle. The sensor is mainly composed of a well-sealed elastic diaphragm and
an iron magnetic core. The diaphragm and the magnetic core are accurately placed into the
micro coil, and when pressure is sensed, an output signal proportional to the input signal and
in proportion to the reference voltage is created.
The functional relation between the pressure signal voltage output of the intake manifold absolute
pressure and temperature sensor is:
Vout = Vref （ 0.01059 * P - 0.10941 ）
P refers to the actual test value of the intake pressure, unit: kPa.
Vref refers to the system signal reference voltage, which is 5V.
Air pressure and voltage transformation curve characteristic curve (when V ref = 5.0 V)
Output voltage
Pressure (unit: kPa)

● The pressure level in intake manifold directly indicates the current load and the operation
status of the engine. It has a decisive influence on the control behavior of the engine
management system output. In principle, the engine fuel supply state is in direct proportion
to the intake manifold pressure; the ignition timing (ignition advance angle) of the engine is in
inverse proportion to the intake manifold pressure.
● The core temperature sensing element of the engine intake temperature sensor is composed of
negative temperature coefficient semiconductor thermistor. The temperature characteristic is
negative temperature coefficient (NTC) thermistor characteristic. For this kind of temperature
sensor, a special measuring circuit is necessary for testing the resistance characteristics.
● The output characteristic of the semiconductor thermistor with negative temperature
coefficient characteristic is that the resistance of the thermistor is inversely proportional to the
temperature changes: i.e. when the temperature rises, the output resistance of the thermistor
decreases; when the temperature falls, the output resistance of the thermistor increases.
● The electronic control module (ECM) of the engine provides 5V D.C signal for the engine intake
temperature sensor and measures its voltage drop, and then the engine management system
judges the actual operation mode of the engine according to this voltage signal. For temperature
sensors with negative temperature coefficient characteristic, when the temperature of the air
sucked by the engine is low, the voltage signal value detected by the system will be high, and
when the temperature of the air sucked by the engine is high, the voltage value detected by the
system will be low.
● The intake air temperature directly influences the output control state of the engine
management system. High intake air temperature will cause the increase of the engine knock
tendency, so it is possible that the fuel supply of the system and the ignition timing time
(ignition advance angle) of the engine need correction and compensation because of different
intake air temperature.
● Mechanical and electrical characteristic parameter
Operating pressure range: (20-102) kPa
Maximum operating pressure: 300 kPa
Storage temperature range: (-40-150) ℃
System supply voltage: (5+0.1) VDC
Consumption supply current: <10mA DC
Maximum operation current: =12mA DC
Pressure accuracy range: 1.8% (total mileage)
Temperature accuracy range: ±1℃ at 25℃
System output voltage: (0.512-4.584) V @ 5 V signal voltage
● Sensor temperature character parameter
Refer to the following table for details of off-load thermistor character parameter of the intake manifold
absolute pressure and temperature sensor:
Temperature Resistance Reference
Temperature (℃) Output Resistance (Ω)
Reference Error (℃) Error (Ω)
-40 42,820.00 2.3 21.41
-35 32,240.00 2.2 16.12
-30 24,500.00 2.1 12.25
-25 18,800.00 2 9.4
-20 14,540.00 1.9 7.27
-15 11,342.00 1.8 5.67
-10 8,914.00 1.7 4.46
-5 7,058.00 1.6 3.53
Temperature Resistance Reference

Temperature (℃) Output Resistance (Ω)
Reference Error (℃) Error (Ω)
0 5,626.00 1.5 2.81
5 4,514.00 1.4 2.26
10 3,648.00 1.3 1.82
15 2,968.00 1.2 1.48
20 2,428.00 1.1 1.21
25 2,000.00 1 1
30 1,656.40 1.1 0.83
35 1,379.40 1.3 0.69
40 1,154.60 1.4 0.58
45 971.4 1.6 0.49
50 821 1.7 0.41
55 697 1.9 0.35
60 594.4 2 0.3
65 509.2 2.1 0.25
70 437.8 2.3 0.22
75 378 2.5 0.19
80 327.6 2.6 0.16
85 285 2.8 0.14
90 248.8 2.9 0.12
95 217.8 3 0.11
100 191.4 3.2 0.1
105 168.3 3.4 0.08
110 148.6 3.6 0.07
115 131.5 3.8 0.07
120 116.8 4 0.06
125 104.1 4.2 0.05
130 93 4.4 0.05
135 83.3 4.6 0.04
140 74.9 4.8 0.04
145 67.4 5 0.03
150 60.9 5.2 0.03
Description：
1. The data listed in the above table are off-load thermistor characteristic data.
2. The data specified in the table do not reflect the influence of system application error and
component aging.
3. Because of the influence of the thermistor self-heating, the resistance value is related to
specific applications.
Engine Anti-theft System

The engine adopts Delphi anti-theft system, and contains three parts including anti-theft controller, anti-theft
coil, and anti-theft transponder. After the anti-theft controller is aroused, the anti-theft controller and the
transponder, the anti-theft controller and the engine control module establish communication separately,
and authenticate each other’s cipher; if cipher authentication succeeds, the engine will be permitted to
start, or else the engine will enter fuel cut-off mode .
Anti-theft system schematic diagram
Only after #1 and #2 cipher authen- Anti-theft transponder The protocol + encryption function between the
tications are successfully passed, the anti-theft transponder and the anti-theft controller
engine is permitted to start.. compose front end encryption.
#1 cipher authentication Front end encryption
＃2 cipher Cipher authentication

authentication
Engine
control Anti-theft Diagnosis
module controller equipment
Terminal encryption Maintenance end encryption

The specified communication protocol + ECM between The communication protocol between the anti-theft controller
the engine ECM and the anti-theft ECU and the encryp- and the diagnosis equipment usually conform to some open
tion function in ECU compose the terminal encryption. complete vehicle protocol, so special strategies are adopted to
effectively prevent malicious attacks by professional thieves.
Anti-theft system schematic circuit

Ignition switch
Ignition signal
Accumulator anode
＋ - Grounding
Accum-
ulator
Diagnosis Anti-theft Controller

equipment
Engine con- Serial communication port

trol module K line
Warning lamp driver
Coil＋
Coil-
Cipher responser Coil
1. Anti-theft controller
2. Cipher responser
Cipher responser is a very small passive monolithic processor, and every cipher responser has the
only identification code for indicating its identity.
3. Anti-theft coil
Because specified magnetic field is necessary between the anti-theft transponder and the anti-theft
responser for communication, the anti-theft coil must be fixed on the ignition switch in axial direction,
and then the anti-theft coil connects with the anti-theft controller through cables.
Anti-theft system installing position
Anti-theft controller
Anti-theft coil
Anti-theft transponder
Anti-theft controller terminal definition
B1 Warning Lamp Warning lamp A1 Coil positive Positive electrode coil

B2 GND Bonding A2 N/U Empty pin
B3 IGN Ignition switch A3 Coil negative Negative electrode coil
B4 Battery Positive electrode of accumulator battery
B5 N/U Empty pin
B6 N/U Empty pin
B7 K-Line(Diagnose) Interface of diagnosis communication
B8 N/U Empty pin
Maintenance Instructions
1. Interface to the engine control module: the terminal B7 of the anti-theft controller connects
with the engine control module through K line, and input/output the interface to the engine
control module.
2. Ignition switch state input: when the ignition switch is turned to “ON” position, the anti-theft
controller starts to perform the procedure and initializes. One thing to do is to detect and
confirm the ignition switch state: on one hand, ensure to detect correctly the state changes,
and on the other hand, avoid wrong judgment on the state changes. The anti-theft controller
detects the ignition switch state once every 2ms.
3. Warning lamp driver output
(a) When the ignition switch is turned on “ON” position, the warning lamp will lighten for 2s±50ms.
(b) When in sleep mode, the warning lamp will blink at the following frequency: keeps lightening for
50ms every 2s±10ms.
(c) If cipher authentication fails, the warning lamp will blink at the following frequency: 1Hz, 50% duty
cycle.
(d) If cipher authentication succeeds, the warning lamp will be turned off.
(e) If in diagnosis mode, the warning lamp will be turned off.

4. A maximum of 6 identification codes can be stored in the controller, if the key is lost or the
transponder fails, the diagnosis equipment can be used for matching.
Anti-theft System Matching
● Replace key programming
The key table indicates the list of password response unit’s identification code, and diagnostic
apparatus can be used to establish key save programming, and such programming should complete
the following tasks:
1. Write anti-theft controller key to password response unit.
2. Write password response unit’s identifier to anti-theft controller.
Programming procedures:
1. Connect the diagnosis equipment to the vehicle diagnosis interface.
2. Insert the key which needs learning into the keyhole.
3. Turn the ignition switch to “ON” position.
4. Establish communication between the anti-theft controller and the diagnosis equipment.
5. Input user authorization code.
6. Confirm the position of the key which needs learning in the key list after learning through
diagnosis order, and then get the number of the keys already learned in the key list of the anti-
theft controller.
7. If the sum of number of the keys stored in the key list and the number of the keys which need
learning is larger than 6, proceed the following steps to clear those stored in the anti-theft
controller.
8. If the sum of number of the keys stored in the key list and the number of the keys which need
learning is less than or equal to 6, proceed the following steps.
9. Operate key learning through diagnosis order, with anti-theft controller operation as follows:
(a) Red the key’s password response unit identifier.
(b) Compare identifier with list of identifiers saved in anti-theft controller.
(c) Write anti-theft controller key to password response unit (12bytes).
(d) Verify if the key is correct.
(e) Save the identifier to the corresponding position of identifier list saved in anti-theft controller.
10. Read the key learning result through diagnosis order. Verify whether the key learning is correct
through reading the learning state of the cipher responser identification code.
11. If the key study is incorrect, stop the communication between anti-theft controller and
diagnostic apparatus, and the programming fails.
12. If the key is learning correctly, operate as follows.
13. Stop the communication between the anti-theft controller and the diagnosis equipment.
14. Turn the ignition switch to “OFF” position and pull out the key that has learned successfully.
15. If there are other keys that need learning, repeat the above procedures in 2-14.
16. If the key learning has been finished, operate as follows.
17. Insert the key that has successfully learned into the keyhole.
20. Read the anti-theft controller malfunction code through the diagnosis order.
21. In the event that there are trouble codes corresponding with password response unit (including
9003, 9008, 9009, 9010), the communication between anti-theft controller and diagnostic
apparatus should be terminated, and the programming fails.
22. If no malfunction code related to the cipher responser appears, operate as follows.
24. Finish and turn the ignition switch to “OFF” position.
● Replace anti-theft controller programming
After replacing anti-theft controller, the programming should complete the following tasks:
1. Write the key saved in Engine Control Module to new anti-theft controller.
2. Write the password response unit identifier to new anti-theft controller.

3. Write the user authorization code to new anti-theft controller.
Programming steps:
1. Install a new anti-theft controller.
3. Insert the key into the keyhole.
5. Establish communication between the engine control module and the diagnosis equipment.
Note: take advantage of Tester present service to keep the communication normal.
6. Input user authorization code and pass the certification of the engine control module.
7. Read the cryptographic key stored in the engine control module through the diagnosis order
and store it into the diagnosis equipment temporarily (12 byte).
8. Stop the communication between the engine control module and the diagnosis equipment.
10. Write the cryptographic key into the anti-theft controller.
11. Take advantage of diagnosis command to read key, verify if the key is correct, in the event that
the key is correct, please continue the following operations; or repeat step 10-11 two times;
in the event that the key is incorrect after two times of repeating, the communication between
anti-theft controller and diagnostic apparatus should be terminated, and the programming
fails.
12. By diagnosis command, anti-theft controller will study the key, and anti-theft controller will:
(a) Read Key1’s password response unit identifier.
(b) Compare identifier with list of identifiers saved in anti-theft controller.
(c) Write the key to password response unit (12 bytes).
(d) Verify if the key is correct.
(e) Save the identifier to Position 1 of identifier list saved in anti-theft controller.
13. Read the key learning result through diagnosis order. Verify whether the key learning is correct
through reading the learning state of the key.
14. In the event that the key study is incorrect (response unit code is not $00), communication
between anti-theft controller and diagnostic apparatus should be terminated, and programming
fails.
15. If the key learning is correct, operate as follows:
16. If there are still keys that need learning, then:
(a) Stop the communication between the anti-theft controller and the diagnosis equipment.
(b) Turn the ignition switch to “OFF” and pull out the key that has learned successfully from the
keyhole.
(c) Repeat the above steps of 3-4.
(d) Establish communication between the anti-theft controller and the diagnosis equipment.
(e) Repeat the above steps of 11-15.
17. If the key learning has been finished, operate as follows:
18. Write the vehicle identification code into the anti-theft controller through diagnosis order.
19. Take advantage of diagnosis command to read vehicle identifier, verify if the vehicle identifier
is correct: if correct, please continue the following operations; or repeat 18-19 for two times; in
the event that the vehicle identifier is incorrect after two times of repeating, the communication
between anti-theft controller and diagnostic apparatus should be terminated, and programming
fails.
20. Write the user authorization code on CAR PASS into the anti-theft controller.
21. Take advantage of diagnosis command to read user authorization code, verify if user
authorization code is correct; if correct, please continue the following operations; or repeat
20-21for two times; in the event that user authorization code is incorrect after two times of
repeating, the communication between anti-theft controller and diagnostic apparatus should
be terminated, and programming fails.
22. Take advantage of diagnosis command to remove trouble code in anti-theft controller.
24. Turn the ignition switch to “OFF” position and pull out the key that has learned successfully
from the keyhole.
25. Insert the key that has learned successfully into the keyhole.
29. In the event that there is any trouble code, the communication between anti-theft controller
and diagnostic apparatus should be terminated, and programming fails.
30. If no malfunction code appears, operate as follows:
● Replace Engine Control Module programming
After replacing Engine Control Module, the programming should complete the following missions:
Write the key saved in anti-theft controller to new Engine Control Module.
Programming steps:
1. Install a new engine control module.
3. Insert the key that has successfully learned into the keyhole.
6. Input user authorization code to pass the certification of the engine control module.
7. Read the cryptographic key stored in the anti-theft controller and store it into the diagnosis
equipment temporarily (12 byte).
9. Establish communication between the engine control module and the diagnosis equipment.
Note: Tester present service is needed to maintain the communication normal
10. Take advantage of diagnosis command to have safety access to Engine Control Module
($FFFF).
11. Take advantage of diagnosis command to write key to Engine Control Module (12bytes).
12. Take advantage of diagnosis command to read key, verify if the key is correct; if correct, please
continue the following operations; or repeat 11-12 for two times, if the key is incorrect after
two times of repeating, the communication between Engine Control Module and diagnostic
apparatus should be terminated, and programming fails.
13. Take advantage of diagnosis command to write vehicle identifier to Engine Control Module.
14. Take advantage of diagnosis command to read vehicle identifier, verify if the vehicle identifier
is correct; if correct, please continue the following operations; or repeat 12-13 for two times; in
the event that the vehicle identifier is incorrect after two times of repeating, the communication
between Engine Control Module and diagnostic apparatus should be terminated, and
programming fails.
15. Take advantage of diagnosis command to write user authorization code to Engine Control
Module.
16. Take advantage of diagnosis command to read user authorization code, verify if user
authorization code is correct; if correct, please continue the following operations; or repeat
14-15 for two times; in the event that user authorization code is incorrect after two times of
repeating, the communication between Engine Control Module and diagnostic apparatus
should be terminated, and programming fails.
17. If other programming should be conducted, please go on.
18. If there is no need of other programming, please go on with the following operations.
19. Stop the communication between the engine control module and the diagnosis equipment.
20. Turn the ignition switch to “OFF” position and then turn it to “ON” position.
23. In the event that there is Engine Control Module-related trouble codes (including 9005, 9006,
9007), communication between anti-theft controller and diagnostic apparatus should be
terminated, and programming fails.
24. If malfunction code related to the engine control module does not appear, operate as follows:
Anti-theft system malfunction code list

Malfunction Code
Serial
(Hexadecimal Fault Description
Number
Notation)
The anti-theft controller fails
1 9001
RAM／ROM error or EEPROM error
The user authorization code has not been programmed
2 9002
The user authorization codes in EEPROM are all OOH or FFH
There is no cipher responser modulation signal
The cipher responser identification code is not received, when the ignition
switch is turned on, there is no key or there is only mechanical key, there
3 9003 is no cipher responser in the key or the cipher responser is damaged;
when the ignition switch is turned on, cipher responser information
reading fails (the cipher responser cipher authentication lasts over 1s);
the cipher responser fails; circuit reading hardware fails.
The cryptographic key has not been programmed
4 9004
The cryptographic key is all “0” or all “1”
K line short circuit to earth
5 9005
K line short circuit to earth is longer than 450ms
The cipher authentication of the engine control module fails
6 9006
The cipher authentication result of the engine control module is NG
The request or confirmation information of the engine control
module is not received
K line open circuit or the engine control module is damaged; the request
7 9007 information of the engine control module is not received within 2s; in a
cipher authentication period, the confirmation information of the engine
control module is not received within 3.5s after the first request from the
engine control module has been received.
The cipher authentication of the cipher responser fails
8 9008 The identification code of the cipher responser does not match the
identification code in EEPROM, or cryptographic key error.
The cipher responser identification code list is empty
9 9009
No cipher responser identification code is stored in EEPROM.
Format error of received cipher responser data
10 9010 Format error of received cipher responser data (format of received cipher
responser data is not in agreement with preliminarily defined format)
Defective warning lamp output
11 9017
Short circuit to battery or warning lamp driver failure
Fuel Supply System and Exhaust System-
Fuel Supply System and Exhaust

System
Fuel System:
Fuel System..................................................................................... 2
Dismantling of Fuel Tank................................................................ 3
Disassembly and Installation of Fuel Pump................................. 3
Fuel Filter Disassembly.................................................................. 3
Disassembly and Installation of Charcoal Canister .................... 3
Dismantling of Oil Filler ................................................................. 4
Exhaust System:
Exhaust System . ............................................................................ 5
Dismantling of Exhaust System..................................................... 5
Dismantling of Main Muffler Assembly ........................................ 5
Dismantling of Auxiliary Muffler Assem-bly ................................ 6
Dismantling of Post Catalytic Converter Assembly . .................. 6
Dismantling of Front Exhaust Pipe Assembly.............................. 6
Fuel System
Component Diagram
Adsorption Hose 1
Ventilating Pipe Adsorption Hose
Charcoal Canister Q1460612

Assembly
Adsorption Hose Fixing Bracket
Q673B11
Q673B11
Oil Inlet Nylon Pipe Assembly 1
Q673B16 Oil Inlet Pipe Clip 1

Q673B09
Q1460612
Oil Inlet Pipe Clip 2 Adsorption Hard Pipe Assembly

Charcoal Canister
Installation Bracket
Oil Filler Protecting Sleeve Clip Spring 1 Return Oil Nylon Pipe Assembly
Oil Inlet Hard Pipe Assembly

Oil Filler Cover
Oil Filler Q673B11
Protecting Sleeve Oil Inlet Nylon
Pipe Assembly 1
Oil Filler Freeing
Cover Plate of
Oil Filler Protecting Hose 2
Fuel Pump
Sleeve Clip Spring 2 Fuel Filter Assembly Seal Ring
Q673B205
Oil Filler Hard Pipe Assembly Oil Filler Freeing Hose
Q673B21
Q1460612 Fuel Pump Assembly
Fuel Tank Body Assembly

Q1410816 FD
Oil Filler Hose
Oil Filler Freeing Hard Pipe
Q1410816 Q67650
Installation Bandage 1
Q2213519
Q1841035 63
Warning: When the fuel line needs to be disassembled during the fuel system repair, the
pressure of the fuel system must be released so as to avoid ejection of the high pressure fuel.
Dismantling of Fuel Tank

1. Disassemble the connection of the fuel tank and
oil filler hard pipe assembly, and then disconnect
the connection at the point of vaporizing pipe of
Q673B11.
2. Support the bottom of the fuel tank with the
hydraulic trailer, and then disassemble 4 fixing
bolts of the fastening belt of the fuel tank.
3. Lower the hydraulic trailer slightly, till the
connection of the fuel pump terminal and the
circuit can be disconnected with hands.
4. Put down the fuel tank slowly.
Disassembly and Installation of Fuel Pump

1. Fuel Pump Disassembly
(a) Clean any soil accumulated around the connecting
flange of the fuel pump.
(b) Counterclockwise rotate the cover plate of the fuel
pump, till it is disassembled.
(c) Disassemble the fuel pump bracket assembly
upward along the vertical direction of the fuel tank
body. Remember not to damage the liquid level
sensor and the float rod.
2. Fuel Pump Installation
(a) Clean the installation flange of the fuel pump, and the assembly surface and the sealing ring of
the fuel tank.
(b) Assemble the assembly of the fuel pump with bracket, and ensure that the fuel sensor shouldn’t
be damaged.
(c) Always keep the fuel pump at the appropriate position, and the arrowhead on the fuel pump
should be aligned to the arrowhead on the fuel tank.
(d) Tighten the cover plate of the fuel pump with the special tool.
Fuel Filter Disassembly

1. Disconnect the quick plugs on both ends.
2. Loosen the bolts on the fuel filter fixing bracket,
and then take out the fuel filter.
Disassembly and Installation of Charcoal

Canister
1. Clamp out the elastic ring clamp with pinchers, and
then disconnect two connecting rubber pipes of
the charcoal canister.
2. Pull out the charcoal canister upward along the
direction of the charcoal canister.
Dismantling of Oil Filler

1. Disassemble the fuel tank cover, and remove the
bolts at the oil filler lock.
2. Disassemble the oil filler protective sleeve clip
springs (two) and the protecting sleeve.
3. Disassemble the three fixing bolts on the oil filler
and the vehicle body and one bolt at the oil filler
hard pipe.
4. Disassemble the clip connected to the fuel tank,
and disconnect the rubber pipe
Exhaust System
Component Diagram
Q33012(M10×1.25)
Assembly of Middle Exhaust Pipe

Sealing Gasket with Three-way Catalytic Converter
Sealing Ring Thermal Separator of Three-

Front Exhaust Pipe way Catalytic Converter
Bolt Q1460616 FD
Spring
Rubber Hanger
Main Muffler Thermal Separator

Sealing Ring
Q32006 Rubber Hanger

Q1841035(M10×1.25)
Middle Exhaust Pipe and

Auxiliary Muffler Assembly
Q1841035(M10×1.25)
Sealing Ring
Rear Exhaust Pipe and
Main Muffler Assembly
Q1460620 FD
Dismantling of Exhaust System

Warning: The disassembly of all the parts of the
exhaust system should be performed 30 minutes
after the engine’s flameout so as to avoid human
injury due to the high temperature parts.
Dismantling of Main Muffler Assembly
1. Disassemble the connecting bolts of the front flange
of the main muffler assembly and the rear flange
of the auxiliary muffler assembly with M13 ring
spanner (open-ended) or the ratchet spanner, and
then take out the sealing ring between the flanges.
2. Disassemble the three rubber hangers of the main
muffler.
3. Disassemble the main muffler assembly.
Notice: The sealing ring between the front flange
of the main muffler assembly and the rear flange
of the auxiliary muffler assembly has the main
function of sealing, may cause the distortion of
sealing ring after installation, and also may cause
the degrading of sealing effect, and thus it is
suggested that the sealing ring not be reused, only
once if necessary.
Warning: Have a fulltime person hold the main muffler
when performing the operation, so as to prevent the
operator from injury caused by its dropping.
Dismantling of Auxiliary Muffler Assem-bly

1. Disassemble the connecting bolts of the front
flange of the auxiliary muffler assembly and the
rear flange of the medial exhaust pipe and three-
way catalytic converter assembly with M13 ring
spanner (open-ended) or the socket ratchet wrench,
and take out the sealing ring between the flanges.
2. Disassemble the auxiliary muffler assembly.
Notice: The sealing ring between the front flange of
the auxiliary muffler assembly and the rear flange
of rear catalytic converter assembly has the main
function of sealing, may cause the distortion of
sealing ring after installation, and also may cause
the degrading of sealing effect, and thus it is
suggested that the sealing ring not be reused, only
once if necessary.
Warning: Have a fulltime person hold the main muffler
when performing the operation, so as to prevent the
operator from injury caused by its dropping.
Dismantling of Post Catalytic Converter
Assembly
1. Pull down the wire harness plug of the oxygen
sensor, and take down the plug from the oxygen
sensor bracket.
2. Disassemble the connecting spring bolts of the
front flange of rear catalytic converter assembly
and the rear flange of the front exhaust pipe
assembly with M14 ring spanner (open-ended) or
the socket ratchet wrench and disassemble the
sealing ring between the flanges.
3. Disassemble the two rubber suspensions with two
holes connected between the rear catalytic converter and the vehicle frame.
4. Disassemble the rear catalytic converter assembly.
Warning: Have a fulltime person hold the main muffler when performing the operation, so as to
prevent the operator from injury caused by its dropping.
Dismantling of Front Exhaust Pipe Assembly
1. Disassemble the connecting nuts of the front flange of the front exhaust pipe assembly and
the flange of exhaust manifold with M19 ring spanner (open-ended) or the socket ratchet
spanner, and disassemble the sealing gasket between the flanges.
2. Take off the front exhaust pipe from the auxiliary vehicle frame carefully.
Notice: The sealing gasket between the front flange of the front exhaust pipe assembly and the
flange of exhaust manifold mainly has the main function of sealing, may cause the distortion
of sealing ring after installation, and also may cause the degrading of sealing effect, and thus
it is suggested that the sealing ring not be reused, only once if necessary.
Installation of Exhaust System
1. The clearance of the exhaust pipe assembly from the parts of the both sides shouldn’t be less
than15mm.
2. Apply a proper amount of silicone oil into the mounting hole of the rubber hanger before the rubber
hanger is installed, and the received force should be even after the rubber hanger is installed.
3. The oxygen sensor plug should be ensured to be connected after installing the middle exhaust
pipe and the three-way catalytic converter assembly.
Clutch Control System-
Clutch Control System
Precautions......................................................................................... 2
Troubleshooting................................................................................. 2
Layout Diagram of Clutch Control System Elements..................... 3
Inspection and Adjustment of Clutch Pedal.................................... 3
Disassembling and Installation of Clutch Pedal.............................. 4
Precautions
1. Installation of Clutch Hard Pipe.
Inspect whether the contact surface of the rigid tube bell mouth is in good condition before installation.
The pipe should be cleaned inside, free of foreign matter.
2. Installation of Clutch Hose.
Inspect the hose surface to ensure no damage and the pipe should be clean inside.
3. Apply lubricating grease around the U-shaped connector between the pedal and the master
pump.
4. Tighten the pipeline connector according to the regulated torque.
Torque of the hard pipe and the master pump: M12 (15±2) N•m
Torque of the clutch hard pipe and the hose: M10 (15±2) N•m
5. During the process of discharging the clutch system, ensure that the bubble in the pipeline is
discharged completely. At this time, inspect the liquid level of the braking fluid in the braking
fluid storage tank, which should range from MIN to MAX.
Troubleshooting
The numbers in the table represent the possible sequence of trouble causes, and you should inspect
all the parts in turns and replace them if necessary.
Fault Causes
Clutch Vibration 1. Engine fixing bracket (loosened)
2. Clutch disc (wiggled too much)
3. Clutch disc (stained)
4. Clutch disc (polished)
5. Clutch disc (hardened)
6. Diaphragm spring (top end)
Loosened Clutch Pedal 1. Clutch pipeline (air entered)
2. Clutch master pump cup (damaged)
3. Clutch slave pump cup (damaged)
Abnormal Sound of 1. Clutch release bearing (worn, dirty or damaged)
Clutch 2. Torsion reducer of driven disc (damaged)
Clutch Skid 1. Clutch pedal (pedal free travel goes out of adjustment)
3. Clutch disc (polished)
4. Diaphragm spring (damaged)
5. Compressing disc (distorted)
6. Flywheel (distorted)
Clutch non-separation 1 Clutch pedal (pedal free travel goes out of adjustment)
2 Clutch pipeline (air entered)
3. Clutch master pump cup (damaged)
4. Clutch slave pump cup (damaged)
5. Clutch disc(wiggled too much)
6. Clutch disc (broken upon friction)
7. Clutch disc (dirty or burned)
9. Clutch disc (the spline part runs short of lubricating grease )
Layout Diagram of Clutch Control System Elements
Braking fluid storage tank assembly
Pipe clip
Steel belt spring ring
Clutch oil inlet pipe assembly
Clutch master pump assembly
Locking nut
Pin shaft Clutch pedal mechanism assembly

Clutch hard pipe assembly 1
Cotter pin
Clutch hard pipe

assembly 2
Spring clamp
Clutch pedal limit adjusting bolt

Split retaining ring
Clutch slave pump assembly Clutch hose assembly
Inspection and Adjustment of Clutch

Pedal
1. Inspect whether the pedal height is correct or not.
Height above the carpet: 135 mm
2. Adjust the pedal height.
Loosen the locking nut and adjust the clutch pedal limit
adjusting bolt to the correct height, and then clamp the
locking nut.
Tightening torque: 16 N• m
3. Inspect whether pedal free travel is correct or not.
Carpet
Step on the pedal till resistance is felt.
Pedal free travel: (5-15) mm
4. Adjust the pedal free travel.
6. Loosen the locking nut on the clutch master pump

and turn the push-rod till the pedal free travel is
controlled under (5-15) mm.
7. Tightening torque of the locking nut: 12N•m.
8. Inspect the clutch pedal height again.
Disassembling and Installation of Clutch

Pedal
Disassembly
1. Disassemble the battery negative cable (ensure the
Return spring safety of electrical system).
2. Disassemble storage box on the left side of the
instrument panel.
Clutch pedal 3. Disassemble the cotter pin of the clutch master
arm fixing nut
pump U-connector, and pull out the pin shaft to
separate the master pump from the pedal.
Clutch pedal
arm fixing bolt 4. Disassemble the clutch pedal bracket from the
front wall.
5. Disassemble the clutch pedal.
(a) Keep the clutch pedal return spring in its free
state so as to prevent personnel from injury as a
result of bounced spring when disassembling.
(b) Disassemble the bolt and the nut.
(c) Disassemble the clutch pedal arm from the pedal
bracket.
(d) Take off the return spring.
Installation
1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal arm.
(c) Install the bolt and the nut.
Tightening torque: (25-35) N• m
Notice: Install the bolt from the left side of the
vehicle.
(d) Keep the clutch pedal at the maximum travel
position, connect the spring and the clutch pedal
arm, and keep the clutch pedal at the initial
position.
2. Install the clutch pedal onto the four project-
welding studs on the front wall.
3. Tighten the four Q32008 nuts to fix the clutch pedal bracket with the M13 spanner.
Tightening torque: (23±2) N• m
4. Install the pushing rod of the clutch master pump (master cylinder) with U-connector.
(a) Connect U-connector (pedal connector) onto the clutch pedal arm in series with the cotter pin.
Remark: Pass the pin shaft into the pedal arm from the left side of the vehicle (refer to the figure).
(b) Connect U-connector (pedal connector) onto the clutch pedal arm in series with the cotter pin.
Notice: Pass the pin shaft into the pedal arm from the left side of the vehicle
(c) Install the cotter pin on the pin shaft.
5. Inspect and adjust the clutch pedal.
6. Connect the battery negative cable.
Transmission-
Transmission
Precautions...................................................................................... 2
Sealant and Adhesive..................................................................... 2
Lubricating Grease.......................................................................... 2
Troubleshooting.............................................................................. 3
Sectional Drawing and Technical Parameter................................ 4
Adjusting Snap ring and Adjusting Gasket.................................. 5
Maintenance Specification............................................................. 6
Tightening Torque........................................................................... 6
Transmission................................................................................... 7
Input axis.......................................................................................... 15
Output axis....................................................................................... 21
Reverse Idler Gear . ........................................................................ 29
Speedometer Gear.......................................................................... 30
Gear Selecting Lever....................................................................... 31
Controller Casing............................................................................ 32
Clutch Casing.................................................................................. 35
Transmission Casing...................................................................... 38
Differential........................................................................................ 40
Transmission-
Form-in-place gasket (FIPG) Precautions

The form-in-place gasket (FIPG) is used in many parts of the transmission. When using this sealant,
particular attention should be paid to the applying amount, the applying position and the state of the
adhesive applying surface so as to achieve the purpose of full sealing. Inadequate applying amount
will cause leakage, while excessive applying amount will cause the overflow of the sealant, the
blocking of the passage of water or oil or the narrowing of the passage. Therefore, in order to prevent
the junction surface from leakage, it is absolutely necessary to ensure correct applying amount and
continuous application. RTV (room temperature vulcanizing) sealant is hardened after reacting with
the moisture in the atmosphere, and thus is often used on metal flanged parts.
Tips for Application
The precautions to be noticed when assembling parts with FIPG.
Apply the sealing adhesive evenly on the regulated diameter, and surround the installing hole completely.
The sealing adhesive not hardened could be erased. When the sealing adhesive is in wet condition (within
15 minutes), install the parts at the fixed position. When it is installed, remember not to stick the sealing
adhesive to the unnecessary places. After installing the parts, wait till the sealing adhesive is fully hardened
(about one hour). In the process, don’t apply oil onto the applying parts or wet the part, or start the engine.
The apply procedure of the FIPG is different because of the parts’ shape.
Disassembly
The parts assembled with sealing adhesive will be easily disassembled without special method. But
in some cases, it is necessary to use a wooden mallet or similar tools to knock the parts gently to
destroy the sealing adhesive on the connecting surface, or punch a smooth and thin sealing adhesive
scraper into the connecting surface, and pay special attention not to damage the connecting surface.
Cleaning of the Sealing Surface
Remove the sundries on the sealing surface with a sealing adhesive scarper or steel brush. Confirm
the sealing surface is smooth without oil stain and foreign matter. Don’t forget to remove the used
sealing adhesive in the installing hole and the threaded hole.
Legend
…… Lubricating grease (multi-purpose lubricating grease when there is no special designation)
…… Sealing adhesive and adhesive agent
…… Engine oil or gear lubricating oil
Sealant and Adhesive Agent

Item Regulated Sealant and Adhesive Agent
Clutch Casing -- Matching Surface of
Transmission Casing
Control Device Casing -- Matching Mitsubishi Genuine Sealant with Part Number of MD997740
Surface of Transmission Casing or Equivalent Products
Bottom Cover -- Matching Surface of
Transmission Casing
Air Outlet 3M SUPER WEATHERSTRIP NO.8001 or Equivalent Products
Differential Driving Gear Bolt 3M STUD LOCKING NO.4170 or Equivalent Products
Lubricating Grease
Item Regulated Lubricating Grease
Hypoid gear oil SAE above GL-4 in accordance with API
Driving Axis Oil Seal Lip
classification
Input Axis Oil Seal Lip Mitsubishi Genuine Lubricating Grease with Part Number of
Selecting Rod Support Block 0101011 or Equivalent Products
Transmission-
Troubleshooting
Fault Cause Judgment and solution
Bound back to the neutral gear 1. The clutch fork axis arch groove 1. C h e c k w h e t h e r t h e c o n t r o l
during the running is excessively worn, and the system pushes the shift rocker to
elasticity of the lock ball spring the position, or disassemble the
resilience is distorted. transmission and put the clutch
fork into the gear manually to
check the meshing condition.
2. The clutch fork working surface 2. I f the meshing is incomplete,
is excessively worn. check whether the clutch fork is
distorted or the working surface
is excessively worn.
3.T he toothed ring or the gear 3. I f the gear sleeve has entered
sleeve connecting surface is the meshing, check the abrasion
excessively worn. of the upcoming part of the gear
sleeve and the connecting gear.
4.T h e g e a r a x i s i s l o o s e n e d 4. If excessive clearance is touched
axially. when moving, check whether
the fork axis groove and the
alignment spring are worn or
ineffective.
nder the condition that the clutch The synchronizer ring is seriously Replace the synchronizer ring
U
has no fault, the gear shifting is worn.
difficult and has serious impulsive
sound or is difficult in one gear.
The transmission utters 1. Caused by some broken gear 1. C heck the parts causing fault,
1.regular impact sound tooth. and remove.
2. even noise 2. The tooth space increases or 2.Inspect, clean, and replace the
the gear is damaged. damaged gear or bearing.
3. The bearing is worn. 3. Replace or add new oil.
4. T he lubricating oil amount is
insufficient.
Oil impregnate 1. T he oil is added excessively, 1. Disassemble the oil filling plug,
and the oil level is too high. and check the oil level.
2. The oil seal is excessively worn 2. Replace the oil seal.
or damaged. 3.D isassemble each connecting
3. The sealing adhesive is unevenly surface part, check the knocking
applied or the sealing paper points, flatten them, and apply
gasket is damaged. adhesive evenly.
4. The breather plug is ineffective. 4. Replace the breather plug.
5.T h e c o n n e c t i n g s u r f a c e i s
knocked and not flattened in
time.
The bearing is damaged 1. The lubricating oil is too dirty. 1. Replace the lubricating oil.
abnormally. 2. T he lubrication is insufficient 2. C heck the lubricating oil level,
or the lubricating oil doesn’t add or replace the lubricating oil.
accord with the requirements,
or the quality is too poor.
3. Use the unqualified bearing. 3. Replace the bearing.
Transmission-
Sectional Drawing and Technical Parameter

Sectional Drawing
The product is a synchronizer manual gear shifting mechanical transmission, and the gear shifting is
flexible with good hand feeling, low noise, compact structure, great bearing capacity, and good sealing
performance. There are five forward gears and one reverse gear, which are all helical gear constant
meshing transmission. Gear 1 and Gear 2 are adopted with the 3-taper synchronizer, other gears are
adopted with single taper synchronizer, and the gear shifting mechanism is adopted with cable type remote
control. The following figure is the sectional drawing of the transmission.
1 2 3 4 5
16 15 14 13 12 11
10
1. Reverse idler gear 2. 4-speed gear 3. 3- and 4-speed synchronizer 4. 3-speed gear
5. Transmission casing 6. Clutch casing 7. Release thrust bearing retainer 8. Input axis
9. Output axis 10. Differential 11. 1-speed gear 12. 1- and 2-speed synchronizer
13. 2-speed gear 14. 5-speed gear 15. 5-speeds — reverse speed synchronizer 16. Reverse speed gear
Technical Parameter
Main Reduction 3.722 Speedometer gear transmission ratio 29/36
Ratio
Torque Capacity 230N.m Clutch Control Hydraulic
Form Manual Weight (kg) 45 (not including oil)
Front-wheel drive Transmission casing lubricating oil
Driving Type 75W/95.GL-4 80W/95.GL-4
specification
Fill in necessary amount from
Transmission casing lubricating oil filling the side plug hole
Gear Number 5 method Lubrication oil level: lower
level of the plug hole
See the Transmission casing lubricating oil filling
Transmission Ratio specification (2.0-2.1) L
table amount
JC523TM9 transmission casing transmission ratio:
1ST: 3.583; 2ND: 1.947; 3RD: 1.379; 4TH: 1.030; 5TH: 0.82
Transmission-
Adjusting Snap ring and Adjusting Gasket

Parts' Name Thickness（mm） Identifying mark Parts' Code
2.24 None SMD706537
Snap ring
(for the adjustment of the 2.31 Blue SMD706538
input axis front bearing
axial clearance) 2.38 Brown SMD706539
2.31 Black(2) SMD747149

2.35 None SMD746561
Snap ring 2.39 Blue SMD746562
(for the adjustment of the 2.43 Brown SMD746563
input axis rear bearing 2.47 Green SMD746564
axial clearance) 2.51 White SMD746565
(for the adjustment of the 2.55 Yellow SMD746566
output axis rear bearing 2.59 Black SMD746567
axial clearance) 2.63 Orange SMD746568
2.67 Blue SMD746569
2.71 Brown SMD746570
2.82 － SMD748015
2.86 － SMD748016
Thrust plate 2.90 － SMD748017
(for the adjustment of the 2.94 － SMD748018
input axis 5-speed gear 2.98 － SMD748019
axial clearance) 3.02 － SMD748020
3.06 － SMD748021
3.10 SMD748022
Snap ring 1.43 Green (2) SMD746708
(for the adjustment of 1.51 White (2) SMD746709
the output axis front axis
1.59 Yellow (2) SMD746710
bearing axial clearance)
2.81 Green SMD745799
2.85 White SMD745800
Snap ring 2.89 Yellow SMD745801
(for the adjustment of the 2.93 Black SMD745802
output axis 3-speed axial 2.97 Orange SMD745803
clearance) 3.01 Red SMD745804
3.05 Pink SMD745805
3.09 Blue SMD745806
0.80 80 SMD727661
0.83 83 SMD720937
0.86 86 SMD720938
Gasket
0.89 89 SMD720939
(for the adjustment of
0.92 92 SMD720940
the differential casing
0.95 95 SMD720941
prestressing amount)
0.98 98 SMD720942
1.01 01 SMD720943
1.04 04 SMD720944
Transmission-
Parts' Name Thickness(mm) Identifying mark Parts' Code

1.07 07 SMD720945
1.10 J SMD710454
Gasket
1.13 D SMD700270
(for the adjustment of
1.16 K SMD710455
the differential casing
1.19 L SMD710456
prestressing amount)
1.22 G SMD700271
1.25 M SMD710457
0.75～0.82 - SMA180862
Gasket
0.83～0.92 - SMA180861
(for the adjustment of the
0.93～1.00 - SMA180860
differential casing tooth
1.01～1.08 - SMA180875
space)
1.09～1.16 - SMA180876
Maintenance Specification
Item Permissive Range Limit Value
Input axis front bearing axial clearance (mm) －0.01～0.21 －
Input axis rear bearing axial clearance (mm) －0.01～0.12 －
Input axis 5-speed gear shaft axial clearance (mm) －0.01～0.09 －
Input axis front bearing axial clearance (mm) －0.01～0.12 －
Output axis rear bearing axial clearance (mm) －0.01～0.09 －
Output axis 3-speed gear axis axial clearance (mm) －0.01～0.09 －
Differential casing pinion gear back clearance (mm) 0.025～0.150 －
Differential casing prestressing degree (mm) 0.05～0.11 －
Synchronizer ring back surface and gear clearance (mm) － 0.05
Remarks: standard clearance ＝ 0 mm
Tightening Torque
Item TorqueN·m
Lower cover installing bolt 6.9
Interlocked plate bolt 30
Clutch casing -- transmission casing installing bolt 44
Clutch release thrust bearing retainer installing bolt 9.8
Controller casing installing bolt 18
Gear shifting wire bracket installing bolt 18
Speedometer gear installing bolt 3.9
Position limiter bracket installing bolt 22
Gear selecting lever installing bolt 18
Gear selecting lever installing nut 11
Differential driving gear installing bolt 132
Reversing lamp switch 32
Front bearing seat installing bolt 18
Spring lifting assembly 32
Reverse idler gear axis installing bolt 48
Transverse rolling limiter bracket installing bolt 69
Transmission-
Transmission Case
Apply gear oil to lubricate all the 18

inner parts when assembling.
32
3
2
1 7
5
◆8
◆6
3.9
69
N·m : regulated torque

◆ Parts which can’t be reused. 69
Disassembly Procedures
1. Transverse rolling position limiter bracket
2. Gear shifting cable bracket
3. Gear selecting lever
4. Speedometer gear
5. Reversing lamp switch
6. Sealing gasket
7. Spring lifting assembly
8. Sealing gasket
Transmission-
11
Apply gear oil to lubricate all the
30
12
9
44 ◆10 ◆17
18
20
19
14
◆15
16
48
21
22
13
6.9

◆Parts which can’t be reused.
9. Interlocked plate bolt
10. Sealing gasket
11. Controller casing
12. Neutral gear return spring
13. Lower cover
14. Reverse idler gear axis bolt
15. Sealing gasket
16. Reverse idler gear
17. Sealing cover
18. Transmission casing
19. Outside race
20. Gasket
21. Magnetic plug seat
22. Magnetic plug
Transmission-

inner parts when assembling. ◆26
24
◆27
◆23
25
35 29
31
28 30
36
32 18
34
33

23. Spring pin
24. 1-speed -- 2-speed gear shifting sliding rail assembly
25. 1-speed -- 2-speed gear shifting fork
26. Spring pin
27. Spring pin
28. 3-speed and 4-speed gear shifting sliding rail assembly
29. 3-speed -- 4-speed clutch fork
30. 5-speed -- reverse gear shifting sliding rail assembly
31. 5-speed -- reverse shift clutch fork
32. Input axis front bearing seat
33. Input axis
34. Output axis
35. Differential assembly
36. Clutch casing
Transmission-10
Disassembly Directions
Sealing cover 1. Disassembly of sealing cover
2. Disassembly of transmission casing

Expand the spring snap ring, and disassemble this
snap ring from inside the groove of the ball bearing.
Remark: once the spring snap ring is expanded, the
spring snap ring could bounce out because of the
output axis’ own weight.
Disassemble the controller housing.
Spring snap ring
Disassemble the transmission lower cover and the
reverse idler wheel axis positioning bolt, and take out
the reverse idler wheel and the idler wheel axis.
Disassemble the self-locking mechanism.
Separate the transmission casing from the clutch
3-speed -- casing.
4-speed gear 3. Disassembly of the input axis / output axis, and the
shifting fork
gear shifting fork.
(a) Move the 3-speed -- 4-speed fork and 5-speed
5-speed -- reverse -- reverse gear shifting fork toward the direction
gear shifting fork shown in the figure.
(b) Slide the input axis, the output axis, 3-speed --

5-speed -- 4-speed gear shifting fork and the 5-speed --
reverse gear reverse gear shifting fork toward the direction
3-speed -- 4-speed shifting fork
shown in the figure, and disassemble them
gear shifting fork
together.
4. Disassembly of the input axis/ output axis

Output axis Input axis Disassemble the input axis and the output axis
simultaneously.
Transmission-11
Adjustment before Assembly

Gasket
Select the gasket thickness to adjust the differential
prestressing amount.
1. Place the soldering tin sheet at the part of transmission
casing as shown in the figure (length of 10 mm and
the diameter of about 1.6 mm), and then install the
bearing outside race and the differential.
2. Install the clutch casing, and tighten the bolt to the
regulated torque.
3. If the soldering tin is not pressed flat, replace into
thicker soldering tin sheet, and then repeat Steps (1)
and (2).
4. Measure the soldering tin sheet thickness with a
micrometer caliper, and select the thickness of the
gasket to be installed according to the following
equation.
Thickness of the gasket:(T+0.05)mm-(T+0.11)mm
Assembly Directions
Input axis 1. Installation of the input axis/ output axis
Output axis
Install the input axis and the output axis simultaneously.
2. Installation of the 5-speed gear shifting synchronizer

3-speed -- / 5-speed -- reverse gear shifting sliding rail / 3-speed
4-speed
gear shifting -- 4-speed gear shifting synchronizer / 3-speed --
synchronizer 4-speed gear shifting sliding rail
(a) Move the 3-speed -- 4-speed synchronizer and
5-speed -- reverse
gear shifting 5-speed -- reverse synchronizer toward the
synchronizer direction shown in the figure.
(b) Install the 3-speed -- 4-speed gear shifting sliding

3-speed -- 4-speed gear shifting sliding rail
rail and fork and 5-speed -- reverse gear shifting
3-speed -- 4-speed
gear shifting fork sliding rail and fork.
5-speed -- reverse
gear shifting fork 5-speed – re-
verse gear shift-
ing sliding rail
Transmission-12
(c) Install each gear shifting fork into the sleeve, while
5-speed -- moving the gear shifting sliding rail toward the di-
3-speed -- reverse gear rection shown in the figure.
4-speed gear shifting sliding rail
shifting sliding rail
3. Installation of the spring pin

4. Installation of the gasket
Installation of the gasket selected in the section of “Ad-
justment before assembly”.
5. Installation of the outer race
6. Installation of the transmission casing

(a) Extrude the sealing adhesive with the diameter of
1.5mm on the position of transmission casing as
Regulated sealing adhesive: Mitsubishi genuinesealing
adhesive with the part number of MD997740 or
equivalent products (Letai 5699).
Notice: the extruded sealing adhesive line should
be continuously even, which can’t have the place
of breaking or excessive applying.
(b) Install the transmission casing, and then expand
the spring snap ring.
(c) Tighten the transmission casing bolt to the
regulated torque.
Remark: turn over the transmission, and make the
spring snap ring embed into the groove result with
Spring gripping ring the output axis’ own weight.
Transmission-13
7. Installation of the sealing cover

Sealing cover Press the sealing cover to the bottom as shown in the
figure.
MB990938
MB990927
8 Installation of lower cover

Extrude sealing adhesive with the diameter of 1.5 mm
on the position of the transmission casing as shown in
the figure.
Regulated sealing adhesive: Mitsubishi genuine
sealing adhesive with the part number of MD997740
or equivalent products (Letai 5699).
9. Installation of the controller casing

Extrude sealing adhesive with the diameter of 1.5mm
on the position of transmission casing as shown in the
figure.
Regulated sealing adhesive: Mitsubishi genuine
sealing adhesive with the part number of MD997740
or equivalent products (Letai 5699).
10. Installation of the speedometer gear
Apply transmission oil onto the sealing O-ring of the
O-shaped sealing ring
speedometer gear.
The transmission oil should be the hypoid gear oil
of SAE 75W/85W above GL-4 in accordance with
the API classification.
Transmission-14
11. Installation of the selection lever

Control axis Apply lubricating grease onto the control axis sliding
surface of the selection lever supporting block.
Regulated lubricating grease: Mitsubishi genuine
Selection
lever gasket sealing adhesive with the part number of 0101011
or equivalent products.
Inspection
Inspect whether open circuit occurs between the
terminals of the reversing lamp switch.
Switch Status Circuit
When pressed down Disconnected
When released Connected
Transmission-15
Input Axis
9
11
12
13
14
15
16
2
18 ◆ 19
4
20 6
7
◆ 1
8
3
◆ 17 16
1. Spring snap ring 11. Synchronizer sleeve
2. Ball bearing 12. 3-speed -- 4-speed Synchronizer hub
3. Thrust plate position limiter 13. Synchronizer spring
4. Thrust plate 14. Synchronizer ring
5. 5-speed gear 15. 3-speed gear
6. 4-speed gear 16. Needle roller bearing
7. Needle roller bearing 17. Spring snap ring
8. 4-speed gear sleeve 18. Ball bearing
9. Synchronizer ring 19. Oil seal
10. Synchronizer spring 20. Input axis
MD998801
1. Disassemble the input axis rear bearing clip spring
Disassemble the ball bearing with the special tool.
Transmission-16
2. Disassemble the input axis rear bearing clip spring

MD998801 Disassemble the thrust plate position limiter and thrust
plate with the special tool.
Disassemble the 5-speed gear with the special tool.
3. Disassembly of the 3-speed--4-speed synchronizer

assembly
Disassemble the 4-speed gear, the needle roller
MD998801
bearing and the bearing sleeve.
Assemble the special tool on the 3-speed gear, to
disassemble the 3-speed--4-speed synchronizer
assembly.
4 Disassemble the input axis front bearing clip

spring
MD998801
Disassemble the ball bearing with the special tool.
Assembly Directions
Oil seal 1 Installation of the oil seal
3.5mm
Press in the oil seal until the size shown in the figure is
obtained.
2. Installation of the input axis front bearing

MD998812
MD998813
MD998816
MD998801
Transmission-17
3. Installation of the spring snap ring

Select the spring snap ring thickness, to make the input
axis front bearing axial clearance accordant with the
standard.
Standard value: (-0.01-0.12) mm
Spring gripping ring
4. Installation of the synchronizer spring

Install the synchronizer spring at the position of the
synchronizer ring as shown in the figure.
Synchronizer spring
5. Installation of the 3-speed -- 4-speed synchronizer

hub
Install the 3-speed -- 4-speed synchronizer hub at the
direction shown in the figure.
Transmission
rear part
Identifying mark
Notice: when installing the synchronizer hub,

MD998812 confirm that the synchronizer ring isn’t stuck.
MD998813
MD998801 MD998825

sleeve
Engine front end
(a) Install the synchronizer sleeve at the direction
Identifying mark
Transmission-18
(b) When installing the synchronizer sleeve, confirm

Synchronizer sleeve that the two deep tooth grooves of synchronizer
hub accord with the two high toothed bars of the
sleeve correctly.
Synchronizer hub
7. Installation of the 4-speed gear sleeve

MD998812
MD998813
MD998824
MD998801
8. Installation of the 5-speed gear

MD998812
MD998813
MD998824
MD998801
9. Installation of the transmission casing

Select the thrust plate thickness, to make the input axis
5-speed axis axial clearance accord with the standard.
Thrust plate
10. Installation of the thrust plate position limiter

Thrust plate position limiter When installing the thrust plate, confirm that the thrust
plate doesn’t incline.
Install the thrust plate position limiter.
Thrust plate
Transmission-19
11. Installation of the input axis rear axis bearing

MD998812
MD998801 MD998818

Select the spring snap ring thickness, to make the input
axis rear axial clearance accord with the standard.
Installation of the spring snap ring.
Spring gripping
ring
Inspection
1. Input axis
(a) Inspect whether there is damage, abnormal
abrasion or jamming on the outer surface of the
installation part of the needle roller bearing.
(b) Inspect whether there is damage or abrasion on
the spline part.
2. Needle roller bearing
Inspect whether the input axis and the gear are
assembled correctly, whether they can be turned
smoothly, and whether they have looseness or noise
and so on.
3. Synchronizer ring
(a) Inspect whether there is damage on gear surface
of the clutch gear.
(b) Inspect whether there is damage or abrasion
on the conical surface and whether there is
compression of the bolt thread.
(c) Place the synchronizer ring toward the pressing of

the gear, and inspect the clearance “A”. If the “A”
is less than the limit value, replace it.
Limit value: 0.5 mm
Synchronizer ring Gear

Transmission-20
4. Synchronizer Sleeve and nave

(a) Assemble the synchronizer sleeve and the nave
together, and inspect whether they can slide
smoothly, and whether they are stuck.
(b) Inspect whether there is damage on the front and
rear ends of the sleeve inner surface.
Notice: if the synchronizer or nave needs to be
replaced, replace them in set.
5. Synchronizer spring
Inspect whether the spring is loosened, distorted or
damaged.
6. Speed gear
(a) Inspect whether there is damage or abrasion
on the gear surface of the helical gear and the
synchronizing ring clutch gear.
(b) Inspect whether there is roughness, damage
or abrasion on the conical surface of the
synchronizer.
(c) Inspect whether there is damage or abrasion on
the gear internal diameter and the front and rear
ends.
Transmission-21
Output Axis

18
19
20
21
22
23
24
4
25
26 ◆1
28
27 5
29
30
31
34
3 2
33
◆32 17 6
7 4
8
9
14 10 11
◆16 15 13
1. Spring snap ring 18. 2-speed gear
2. Ball bearing 19. Needle roller bearing
3. Reverse gear bearing sleeve 20. 2-speed gear sleeve
4. Needle roller bearing 21. Inside synchronizer ring
5. Reverse gear 22. Synchronizer frication conical wheel
6. Synchronizer ring 23. Outside synchronizer ring
7. Synchronizer spring 24. Synchronizer spring
8. Synchronizer sleeve 25. Synchronizer sleeve
9. 5-speed -- reverse synchronizer gear nave 26. 1-speed -- 2-speed synchronizer hub
10. Synchronizer ring 27. Synchronizer ring group
11. Synchronizer spring 28. Synchronizer spring
12. 5-speed gear 29. 1-speed gear
13. Needle roller bearing 30. Needle roller bearing
14. 5-speed gear sleeve 31. 1-speed gear sleeve
15. 4-speed gear 32. Spring snap ring
16. Spring snap ring 33. Ball bearing inner race
17. 3-speed gear 34. Output axis
Transmission-22
MD998917 Ball bearing 1. Disassembly of the output axis rear bearing
2. Disassembly of the reverse gear bearing sleeve

Install the special tool onto the reverse gear, and then
Bearing sleeve
MD998801 disassemble the reverse gear bearing sleeve.
3. Disassembly of the 5-speed -- reverse speed

Synchronizer hub synchronizer hub
MD998801
Install the special tool between the gears of the 3-speed
and the 4-speed, and then disassemble the 4-speed
gear, the 5-speed – reverse gear sleeve, the 5-speed --
reverse speed synchronizer hub.
4. Disassemble of the 3-speed gear

Disassemble the 3-speed snap ring, install special tool
on the 2-speed gear, and then disassemble the 3-speed
MD998917 3-speed gear
gear.
5. Disassembly of the 2-speed gear

Assemble the special tool onto the 1-speed gear, to
disassemble the 1-speed -- 2-speed synchronizer hub.
MD998917 Gear sleeve
Transmission-23
6. Disassembly of the 1-speed gear sleeve
Gear sleeve
MD998801
7. Disassembly of the ball bearing inner race

Inner race
MD998917
Assembly Directions
MD998812
1. Installation of the ball bearing inner race
MD998801 MD998818
Inner race
2. Installation of the spring gripping

Select and install the spring snap ring, to make the
MD998801 output axis front bearing axial accord with the standard
value.
Spring griping ring

MD998812
MD998814
Gear sleeve
MD998825
Transmission-24

Install the synchronizer spring at the position correctly
Synchronizer spring

hub
Install the 1-speed -- 2-speed synchronizer hub at the
position as shown in the figure.
Transmission
rear part
Identifying mark
Notice: when installing the synchronizer hub,

MD998812
confirm that the synchronizer ring is not struck.
MD998814
Synchronizer hub
MD998825
6. Installation of the synchronizer sleeve

(a) Install the synchronizer sleeve at the position as
Identifying groove
Transmission
rear part
(b) When installing the synchronizer sleeve, confirm

Synchronizer sleeve that the two deep tooth grooves of synchronizer
hub accord with the two high toothed bars of the
sleeve correctly.
Synchronizer hub
Transmission-25
Synchronizer spring

MD998812
MD998814
Sleeve thrust plate MD998822

MD998812
MD998814
3-speed gear
MD998822

axial clearance of the output axis gear accord with the
standard value.
Spring gripping ring

MD998812
MD998813
MD998819
4-speed gear
Transmission-26

MD998812
MD998813
MD998819
Sleeve
13. Installation of the 5-speed -- reverse speed

synchronizer hub
Install the 5-speed -- reverse synchronizer hub at the
position shown in the figure.
Transmission
rear part
Identifying mark
Notice: when installing 5-speed -- reverse

MD998812 synchronizer hub, confirm that the synchronizer
MD998813 ring is not stuck.
Synchronizer hub
MD998819
14. Installation of the reverse gear/ needle roller

MD998812 bearing / reverse gear bearing sleeve
MD998818
Reverse gear Ball bearing
15. Installation of the ball bearing

MD998812
MD998818
ball bearing
Transmission-27

axial clearance of the output axis rear bearing accord
with the standard value.
Spring snap ring
Inspection
1. Output axis
Inspect whether there is damage or abrasion on the
spline part.
(a) Combine the bearing sleeve and the gear, and
inspect whether they can be turned smoothly, and
whether they have looseness or noise, etc.
(b) Synchronizer ring.
3. Speed gear
(a) Inspect whether there is damage on the tooth of
the clutch gear.
(b) Inspect whether there is damage or abrasion
on the conical surface, and whether there is
compressed damage on the bolt thread.
(c) Place the synchronizer ring toward the pressing of

the gear, and inspect the clearance “A”. If the “A”
is less than the limit value, replace it.
Limit value: 0.5 mm
Synchronizer ring Gear shifting fork
4. Outside synchronizer ring / inside synchronizer

ring / synchronizer conical surface ring
(a) Inspect whether there is damage or abrasion on
the gear surface of the clutch gear and the conical
surface.
Transmission-28
(b) Install the outside ring and the inside surface, and
Gear then press them toward the pressing of the gear,
A
and inspect the clearance “A”. If the “A” is less
External ring than the limit value, replace it.
Limit value:0.5 mm
Conical ring
Notice: if the outside ring, the inside ring or the
conical ring should be replaced, replace the outside
ring, the inside ring and the conical ring in set.
Internal ring
5. Synchronizer sleeve and nave

(a) Assemble the synchronizer sleeve and the nave
together, and inspect whether they can slide
smoothly.
(b) Inspect whether the front and back ends of the
sleeve inner surface is damaged.
Notice: if the synchronizer sleeve or nave needs
to be replaced, the synchronizer sleeve and nave
should be replaced in set.
6. Synchronizer spring
Inspect whether the spring is loosened, distorted or
damaged.
7. Transmission
(a) Inspect whether there is damage or abrasion on
the tooth surface of the helical gear and the clutch.
(b) Inspect whether there is roughness, damage
or abrasion on the conical ring surface of the
synchronizer.
(c) Inspect whether there is damage or abrasion on
the gear inner surface and the front and rear end
surfaces.
Transmission-29
Reverse Idler

◆1
5
1. Spring snap ring
2. Thrust washer
3. Reverse idler gear
5. Reverse idler gear axis
Inspection
Needle roller bearing
(a) Combine the axis and the gear together, and
inspect whether they can be turned smoothly, and
whether they have looseness or noise, etc.
(b) Inspect whether the bearing retaining frame is
distorted.
Transmission-30
Speedometer Gear

◆3
1. E-shaped clip
2. Speed gear
3. O-shaped sealing ring
4. Speed sensor
Transmission-31
Gear Selecting Lever

Disassemble and Assembly
7
1
8 11
9
3
10
1. Dust shield 6. Selecting lever sliding block
2. Nut 7. Selecting lever
3. Spring gasket 8. Selecting lever sleeve
4. Gasket 9. Dust shield
5. Gear selecting lever sleeve 10. Selecting lever axis
Assembly Directions
Dust-proof
Installation of the dust shield.
Transmission-32
Controller Casing
10
9
5 8
4 7
17 3
16
18
15
14
13
2
1
12 11
1. Bolt (two) 10. Position limiter entity
2. Spring gasket (two) 11. Neutral return spring
3. Pin 12. Neutral gear return spring seat
4. Return spring 13. Controller casing
5. Limiting plate 14. Needle roller bearing
6. Position limiter bracket 15. Oil seal
7. Interlock plate 16. Control axis cover
8. Lock pin 17. Control axis
9. Control claw 18. Ventilating pipe
Disassembly of the lock pin
Lock pin Punch out the lock pin toward the direction shown in
the figure.
Control finger
Transmission-33
Assembly Directions
Controller casing 1. Installation of the needle roller bearing
Press in the needle roller bearing to the size shown in
the figure. At this time, the Type mintmark side should
Needle roller at the side of the controller casing.
bearing
Type mint-
mark plane
2. Installation of the oil seal

Apply transmission oil at the oil seal lip.
Transmission oil: hypoid gear oil SAE 75W/85W
above GL-4 in accordance with the API classification.
3. Installation of the air outlet

(a) Apply the sealant on the surface of inserted part.
Regulated sealant: 3M SUPER WEATHERSTRIP
No.8001 or equivalent products (Letai 480)
(b) Confirm that the protrusion part toward the

direction indicated by the arrowhead.
4. Installation of the Spring Pin

Control axis Positioning device
Installation direction
Gaping
Spring pin
Transmission-34
Spring pin

Punch out the lock pin toward the direction shown in
Lock pin the figure.
Control finger
Transmission-35
Clutch Casing
7
4
8
◆3 6
◆2
9.8

1. Clutch release thrust bearing retainer 5. Output axis front bearing
2. Input axis oil seal 6. Sealing gasket
3. Differential oil seal 7. Sleeve
4. Differential bearing outer race 8. Clutch casing
1. Disassemble of the outer race
MD999566
Outside ring
Transmission-36
2. Disassembly of the output axis front bearing outer

MD998772 MD998348 race
Assembly Directions
1. Installation of the sleeve
Press in the sleeve to the position as shown in the
Outcut end
figure, to make the sleeve outcut end inconsistent with
the air groove.
Air groove
1mm
2. Installation of the output front axis outer race

Install the outside race, to set the Type mintmark mark
at the position as shown in the figure.
Type mintmark side
MB990938
MB990934
Transmission-37
3. Installation of the outer race
MB990938
MB990935
4. Installation of the differential oil seal

Apply transmission oil on the lip part of the oil seal.
Regulated oil: hypoid gear oil SAE 75/85W above
GL-4 in accordance with API classification.
MB998325
5. Installation of the input axis oil seal

Fill lubricating grease on the lip part of the oil seal.
Regulated lubricating grease: Mitsubishi brand
lubricating grease with the part number of 0101011
or equivalent products (OMEGA 85).
MB990938
MB990926
Transmission-38
Transmission Casing
Assembly and Disassembly
◆1
2
4 3 6
1. Oil seal 4. Spring snap ring
2. Needle roller bearing 5. Sleeve
3. Oil guide 6. Transmission casing
Outcut end Assembly Directions

1. Installation of the sleeve
Press in the sleeve to the position shown in the figure,
to make the sleeve outcut end inconsistent with the air
groove.
Air groove
Transmission-39
2. Installation of the needle roller bearing

Type mintmark Press in the needle roller bearing till it can align with
the casing surface, and confirm the type mintmark
plane at the position shown in the figure.
3. Installation of the oil sea

Apply transmission oil on the lip part of the oil seal.
Regulated oil: hypoid gear oil of SAE 75/85W above
GL-4 in accordance with API classification.
MD998325
Transmission-40
Differential

3 6
2
5
4
7
132
8
6
9
2

1. Differential driving gear
2. Conical roller bearing
3. Lock pin
4. Pinion axis
5. Pinion
6. Gasket
7. Side gear
8. Spacer
9. Differential casing
MD998801 Disassembly of the conical roller bearing
Transmission-41
Assembly Directions
1. Installation of the spacer/ inverse gear / pinion axis
(a) Install the spacer on the back surface of the
side gear, and then install the side gear into the
differential.
Remark: when installing the new side gear, assemble the
spacer of medium thickness of (0.93~1.00) mm.
(b) Mesh the two pinions with the side gear, after the
gasket is placed on each pinion back surface,
rotate the gear, and install them at the correct
position.
(c) Install the pinion axis.
(d) Measure the clearance between the side gear and

the pinion.
Standard value: (0.025~0.150) mm
(e) If the pinion to be measured doesn’t conform to
the standard, select and install the gasket, and
then measure the clearance again.
Notice: adjust the gear back clearance till the gear
clearance of the two sides is equal.
2. Installation of the lock pin

Differential casing
Install the lock pin at the position shown in the figure.
Lock pin Pinion axis
3. Install the conical roller bearing
MD998812
Conical roller bearing
MD998819
Transmission-42
4. Installation of the differential driving gear

(a) Apply sealant on the thread of all the bolts.
Regulated sealant: 3MSTUDLOCKINGNO.4170 or
equivalent products.
(b) Tighten the bolts to the regulated torque in accor-

6 1
dance with the sequence shown in the figure.
3
4
8
7
5 2
Suspension and Axle-
Suspension and Axle
Suspension system Technical Parameter.................................... 2

Tightening Torque........................................................................... 3
Front Suspension............................................................................ 4
Sub-frame......................................................................................... 7
Disassembly and Installation of Front
Shock Absorber............................................................................... 9
Front Transverse Stabilization Bar
Assembly......................................................................................... 11
Rear Suspension............................................................................. 13
Wheel and Tyre.......................................................16
Suspension system Technical Parameter

Main Parameter of Front Suspension
Type and Composition of Front Suspension
Front Suspension Form Spring column suspension (McPherson type)
Spiral spring, hydraulic telescopic shock absorber, transverse
Front Suspension Composition
stabilization bar, etc.
Front Wheel Alignment Parameter (unloaded)
Item Scope
Front Wheel Camber Angle -0°00′±45′
Front Wheel Kingpin Inclination Angle 10°05′±45′
Front Wheel Kingpin Caster Angle 3°20′±45′
Front Wheel Toe-in (1±2)mm or 0°11′±21′
Main Parameter of Rear Suspension

Form and Composition of Rear Suspension
Rear Suspension Type Trailing arm twist beam semi-independent suspension.
Spiral spring, hydraulic telescopic shock absorber, bridge
Rear Suspension Composition
girder welding parts
Rear Wheel Alignment Parameter (unloaded)
Item Scope
Rear Wheel Camber Angle -1°15′±30′
Rear Wheel Toe-in (2±3)mm or 0°22′±32′
Tightening Torque
System Surface
Installation Position of Tightening Quantity
Serial Code Torque
Used on Rubber
Standard Parts Suspension
Number Coating
Q1841490+Q40114(d2=32)(M1 Sub-frame and Vehicle Red

133±12 2
4×1.5) FD Body (rear) Rubber
Sub-frame and Vehicle Red
Q32014(M14×1.5) FD 133±12 2
Body (front) Rubber
Bracket and Vehicle Red
Q1421230(Q403)(M12×1.25)FD 80±8 6
Body Rubber
Swing arm and Steering Red
2904011-V08 123±12 2
Knuckle Rubber
Swing arm and Sub- Red
Q1401495(Q401)(M14×1.5) FD 137±12 4
Front Suspension
frame Rubber
Swing arm and Sub- Red
Q32014(M14×1.5)FD \ 2
frame Rubber
Front Shock Absorber
2905102-V08 80±8 6
and Wheel Cowl
Front Shock Absorber Red
2905103-V08 220±20 4
and Steering Knuckle Rubber
Front Shock Absorber
2905104-V08 \ 4
and Steering Knuckle
Stabilization Bar Bracket Red
Q1400825 FD 21±2 4
and sub-frame Rubber
Pension Link and Shock Red
Q32012( M12×1.25) FD 74±6 4
Absorber Rubber
Twist Beam and Vehicle Red
Q18414140 (M14×1.5) FD 135±12 2
Body Rubber
Twist Beam and Vehicle
Q32014 (M14×1.5) FD \ 2
Body
Rear Suspension
Supporting Plate and Red

Q1401025(Q400)(M10×.25)FD 63±6 2
Cross Beam Rubber
Rear Shock Absorber Red
Q1841430+Q40214(M14×1.5)FD 160±15 2
and Twist Beam Rubber
Rear Shock Absorber Red
31±3 2
and Vehicle Body Rubber
3101014-K00 Wheel Nut (M12×1.25) 103±10 20
Spare Tyre Bracket and
Q1840820 23±2 2
Wheel Vehicle Body
Spare Tyre Bracket and
Q1840820 23±2 1
Vehicle Body
Front Suspension
Component Diagram
Assembly of Front Left Shock Absorber with Helical Spring
Bolt M16×1.5
Hexagon Flange Nut Bolt M8×1.25×25

M12×1.25
Front Transverse
Nut M16×1.5 Stabilization Bar Bracket
Front Transverse
Stabilization Bar Liner
Pension Link Assembly
Bolt M14×1.5×95
Big Washer Q50116 FD

Lock Pin Q50116 Nut M14×1.5 Nut M14×1.5
Form 1 Hexagon Slotted Nut M14×1.5

Bolt M14×1.5×95
Lower Left Sway Arm Assembly
Bolt M14×1.5×90
Bolt M12×1.25×30
Disassembly and Installation of Lower

Swing Arm Assembly
1. Lower Swing arm Ball Pin Inspection
(a) Inspect whether the bulb can swing freely within
the angle of 50°.
(b) Nspect whether the cotter pin is damaged.
(c) Inspect whether the ball pin dust shield is dam-
aged, and replace it if damaged.
Notice: don’t disassemble the lower swing arm
welding assembly and the lower swing arm ball
pin, and if they can’t be turned freely, or the ball pin
is damaged, the whole assembly of the lower swing
arm with ball pin must be replaced.
2. Replacement of Ball Pin Dust Shield

Turn and disassemble the snap ring fixing the ball pin
dust shield with the special tool, replace the ball pin
dust shield and install the snap ring with the same
special tool.
Special Tool
3. Inspection of Abrasion of Big and Small Linings of

swing arm
Clean the surface of the big and small linings of the
swing arm with water, observe whether there are
damage, abrasion, crack, etc. and replace them if
necessary.
4. Disassembly, Replacement and Installation of

Lower Swing Arm Big Lining
(a) Before assembling, make two marks on the swing
arm according to the lining position with marking
chalk, for the convenience of the positioning con-
ference when installing.
(b) Press out the lower swing arm big lining with the
special tool on the pressing machine, and replace
the lower swing arm big lining.
(c) Inspect the installing hole size of the lower swing
arm big lining of Φ59.5 --0.15
0 . 2 5 , and if the measured
size is beyond the tolerance, replace the lower

swing arm welding assembly.
(d) Align the marks before installation.

Make marks on the new lower swing arm big lining
according to the same position, for the conven-
ience of the aligning the marks on the lower swing
arm when installing, to ensure the relative angle.
(e) Press and install the new lower swing arm big lin-
ing with the special tool on the pressing machine.
Special Tool
5. Disassembly, Replacement and Installation of

Lower Swing Arm Small Lining
Grinding Machine (a) Cut off the rubber flange on the lower swing arm
small lining with the grinding machine and grind it
flat.
Notice: when using the grinding machine, do not
damage the lower swing arm.
Grinding Machine
(b) Press out the lower swing arm small lining with the
special tool on the pressing machine, and replace
the lower swing arm small lining.
Special Tool Notice: the pressing force of the lower swing arm
small lining assembly shouldn’t be less than 5 KN,
and the pulling force shouldn’t be less than 6 KN.
(c) Press and install the new lower swing arm

small lining with the special tool on the pressing
machine.
Special Tool
Sub-frame
Component Diagram
Bolt M8×1.25×25
Hexagon Flange Nut

M12×1.25 Front Transverse
Stabilization Bar Bracket
Front Transverse
Stabilization Bar Liner
Bolt M14×1.5×95
Big Washer Q50116 FD

Lock Pin Q50116 Sub-frame Assembly
Nut M14×1.5
Nut M14×1.5
Form 1 Hexagon Slotted Nut M14×1.5

Bolt M14×1.5×95
Lower Left Swing Arm Assembly
Bolt M14×1.5×90
Bolt M12×1.25×30
Disassembly and Installation of Sub-frame

1. Lift the vehicle with the lifting machine, and
disassemble the wheels on both sides.
2. Disassemble the fixing bolts of the engine susp–
ension (the suspension is connected with the sub-
frame).
3. Disassemble the steering high and low pressure
pipe.
4. Disassemble the steering knuckle and the wheel
rim brake assembly.
5. Disassemble the sub-frame
Disassemble the sub-frame from the vehicle body, and
hold the sub-frame when disassembling the sub-frame
assembly.
Tightening torque of the sub-frame and the vehicle
body (rear): (133±12) N•m
Tightening torque of the sub-frame and the vehicle
body (front): (133±12) N•m
Tightening torque of the bracket and the vehicle body: (80
±8) N•m
6. Disassemble the steering gear and the steering

pipe from the sub-frame, refer to the disassembly
and installation of the steering gear and the steer-
ing pipe.
7. Disassemble the pension link assemble from the
sub-frame.
Tightening torque of the fixing bolts of the pension
link and the shock absorber: (74±6) N•m
Tightening torque of the fixing bolts of the pension
link and the stabilization bar: (74±6) N•m
8. Disassemble the lower swing arm from the sub-

frame.
Tightening torque of the swing arm and the sub-
frame: (137±12) N•m
Notice: when disassembling, notice that this place
is the connection of the bolt and nut, hold the
nut with an open wrench to prevent it from being
turned with the axis, and then screw the other end.
9. Disassemble the transverse stabilization bar from

the sub-frame.
Tightening torque of the stabilization bar and the
sub-frame: (21±2) N•m
10. Confirm the status of the sub-frame.

Inspect whether there is break or damage.
Disassembly and Installation of Front Shock Absorber

Component Diagram
Upper Support Assembly

Rubber Pad of Spring Lower Pallet Spiral Spring Spring Upper Pallet
Nut 3-M10
Nut Q33814 M14×15

Buffer Block Assembly Dust Shield
Front Shock Absorber Assembly (left, right) Support Seat Bearing

Shock Absorber with Spiral Spring
1. Lift the vehicle to let the front suspension in a free
suspension state.
2. Disassemble the wheels, and disassemble the front
transverse stabilization bar from the front shock
absorber bracket.
Connecting torque of the front shock absorber
bracket and the front transverse stabilization bar
pension link: (74±5) N•m
3. Disassemble the braking hose from the shock
absorber bracket. Then disconnect the wheel
speed sensor harness from the steering knuckle (as
shown in the left figure).
4. Disassemble the bolts on the front shock absorber

and the steering knuckle and brake wheel rim
assembly.
Bolt tightening torque of the front shock absorber
support seat and the steering knuckle: (220±20) N•m
Suspension and Axle-10
5. Disassemble the assembly of front shock absorber

with spiral spring (as shown in the left figure).
Installation fixing torque of the front shock
absorber: (80±8) N•m
Installation: install according to the reverse
sequence of the disassembly.
Precautions:
• A fter inserting the bolts, make the installing posi-
tion of the steering knuckle on the shock absorber
lower end toward the outside, for the convenience
of the installation of the steering knuckle.
• All the fixing parts should be screwed to the reg-
ulated torque.
Disassembly and Installation of
Assembly of Front Shock Absorber
with Spiral Spring
Disassemble the Assembly of Front
Shock Absorber with Spiral Spring
1. As shown in the figure, clinch the spring with the spe-
cial tool, separate off at the contact place with adhesive
bandage, and turn the bolts on the special tool alter-
nately, until the spring seat can’t bear the spring ten-
sion. Judge whether the spring is compressed when
the front spiral spring can be turned.
2. Disassemble the upper top bolts (M14×1.5) with the
ratchet spanner and the M18 sleeve, and disassem-
ble the upper support seat assembly of the shock
absorber, the support seat bearing, the upper sup-
port seat of the front spiral spring, the front spiral
spring (with spiral spring), the dust shield and the
buffer block, etc. in turn.
3. Turn the bolts on the special tool alternately, until
the spring tension is completely released to loosen
the spring, and disassemble the spring compres-
sor.
4. Replace the necessary parts.
Install the Assembly of the Front Shock
Absorber with Spiral Spring
Install according to the sequence reverse to the
disassembly, and notice the followings:
1. Compress the spring with the special tool.
2. Install the all the parts of the assembly of the front shock absorber with spiral spring accord-
ing to the disassembly drawing of the assembly of the front shock absorber with spiral spring.
3. Pull up the column piston rod as much as possible and notice not to let it retract back into the
column tube.
4. Put the compressed spring onto the lower pallet of the shock absorber, align the “ ” mark
on the spring pallet, the positioning hole of the spring lower pallet, and the installation surface
central line of the absorber and the steering knuckle in a straight line by inspecting visually,
and apply red rubber onto the tightened nuts and make painted marks to confirm the torque.
Front Transverse Stabilization Bar Assembly

Component Diagram
Assembly of Front Shock

Absorber with Helical Spring
Front Transverse
Stabilization Bar Bracket
Front Transverse Stabilization
Bar Connection Rod Assembly
Nut M10×1.25
Nut M10×1.25 Front Transverse Stabilization Bar Assembly
Front Transverse
Sub-Frame Assembly Stabilization Bar Liner

Transverse Stabilization Bar Assembly
1. Disassemble the front transverse stabilization bar
connection rod assembly.
Connecting torque of front transverse stabilization
bar assembly and the stabilization bar connection
rod assembly: (74±6) N•m
2. Disassemble the sub-frame from the vehicle body,
and refer to the disassembly process of the sub-
frame.
3. Disassemble the front transverse stabilization bar
support seat bolts.
Connecting torque: (21±2) N•m
4. Disassemble the steering column support seat
bolts, refer to the disassembly process of the
steering pipe.
5. Disassemble the transverse stabilization bar sup-
port seat and the front transverse stabilization bar
rubber liner.
Inspection of Front Transverse Stabilization

Bar Assembly, Front Transverse Stabiliza-
tion Bar Rubber Liner, and Front Transverse
Stabilization Bar Connecting Rod Assembly
1024.7 1. Front Transverse Stabilization Bar Assembly
Inspect whether there are faults such as damage,
568.8 distortion, etc. Replace it if there is any fault.
259
2. Front Transverse Stabilization Bar Rubber Liner
Ins0pect whether there are faults such as damage, abrasion
or degradation, etc., and replace it if there is any fault.
3. Front Transverse Stabilization Bar Connecting Rod
Assembly
Stabilization Bar Connector Inspection
1. Inspect whether the connector can be turned freely.
2. Inspect whether the bulb is damaged.
3. Inspect where the rubber is damaged.
Notice: don’t disassemble the connecting rod
assembly. No matter which part of the rod assem-
bly is damaged, the whole front transverse sta-
bilization bar connecting rod assembly must be
replaced.
Rear Suspension
Component Diagram
Rear Helical Spring Rear Spiral Spring Seat Protective Sleeve
Nut M14×1.5
Left Supporting Board
Assembly – Rear
Supporting Bridge
Rear Shock Bolt M14×1.5×140

Absorber Assembly
Right Supporting Board
Assembly – Rear
Supporting Bridge
Bolt M14×1.5×30
Nut M14×1.5
Rear Twist Beam
Assembly
Disassembly and Installation of Rear

Suspension
1. Lift the vehicle with the lifting machine, and disas-
semble the wheels on both sides.
2. Fix the spiral spring.
When disassembling the rear twist beam, clamp the
spiral spring with the special tool to avoid the spring to
be bounced out to cause personal injury when disas-
sembling the rear twist beam.
3. Fix the rear twist beam assmembly.

Lift the rear twist beam upward with the lifting machine.
Fix
4. Disassemble the rear shock absorber

When disassembling the rear shock absorber, lower
Rear Right Shock the rear twist beam, and screw off the rear shock
Absorber Assembly
absorber fixing bolts Q1841430+Q40214FD (M14×1.5).
Tightening torque of the rear shock absorber and
the twist beam: (160±15) N•m
Q1841430+Q40214FD
(M14×1.5) Notice: when disassembling the rear twist beam,
it is not necessary to disassemble the connect-
ing bolts between the rear shock absorber and the
vehicle body.
5. Disassembly the spiral spring

Helical Spring Sleeve Hold the spiral springs on the both sides with hands,
lower down the rear twist beam slowly, take out the
rear spiral spring, and then take off the rear spiral
spring sleeve.
Spiral Spring
6. Disassemble the rear twist beam assembly

Q32014 FD(M14×1.5) Hold the rear twist beam assembly with the lifting
machine, disassemble the hexagon flange bolt
Q18414140FD (M14×1.5) and the hexagon flange
nut Q32014 FD (M14×1.5), and notice the both sides
should be performed simultaneously to prevent that
they are turned with the axis.
Tightening torque of the twist beam and the vehicle
Q18414140FD(M14×1.5)
body: (135±12) N•m
7. Disassemble the supporting board assembly

Left Supporting Board Assembly –
Rear Supporting Bridge Disassemble the hexagon bolts connecting the
supporting board and the cross beam and the small
washer assembly parts Q1401025 (Q400) FD (M10×
1.25), and take off the supporting board.
Tightening torque of the supporting board and the
Q1401025(Q400)FD(M10×1.25) cross beam: (63±6) N•m
8. Rear twist beam status

Inspect whether there is break or damage.
Disassembling of the trailing arm axle

sleeve assembly
1. Inspect the trailing arm axle sleeve
(a) Inspect whether the trailing arm axle sleeve has
distortion, displacement, eccentricity and serious
fissuration, and whether the sealing is loosened.
(b) If it is not easy to make clear whether there is

damage on the trailing arm axle sleeve, the follow-
ing measures should be adopted: clean the rub-
ber place of the trailing arm axle sleeve with clean
water, wipe up with cotton when cleaning, and
inspect whether there are above faults mentioned
on the rubber surface.
If there is any above fault mentioned, replace with
a new trailing arm axle sleeve assembly.
2. Disassemble the trailing arm axle sleeve

(a) Make marks with a white paint pen, and remem-
ber the direction of the trailing arm axle sleeve
assembly.
(b) The trailing arm axle sleeve is one-time parts, and
if it is damaged, firstly pry up the outer pipe edge
of the trailing arm axle sleeve with a steel pry for
the convenience of the installation of the special
tool.
(c) Clamp the axle sleeve installing pipe with the

Special Tool special tool, screw the two bolts tightly, screw the
bolts with a spanner, and push out the sleeve.
3. Install the new trailing arm axle sleeve assembly

Special Tool Before pressing and installing the new trailing arm axle
sleeve assembly, identify the installation direction of
the assembly of the trailing arm axle sleeve with nylon
lining.
Wheel and Tyre

This tyre is tubeless tyre. When the tyre is charged to the recommended charging pressure, the tyre
load reaches the fully loaded state, which is the optimum design status, and the appropriate tyre
pressure and the correct driving habit has important influence on the tyre service life. The appropriate
tyre pressure and the correct driving habit will cause appropriate seating comfort, stability and
controllability for the complete vehicle and will decrease the tyre surface abrasion, lengthen the tyre
service life and avoid tyre damage. Overload, over-speed and unnecessary emergent braking will
aggravate the tyre abrasion.
Inspect the tyre pressure in the cold tyre state monthly or before the long distance driving. Adjust the
pressure to the regulated value. Generally, the tyre will become hotter during the driving process, and
the pressure will increase a bit during the driving process. So, don’t discharge or decrease the tyre
pressure after driving, which will cause “cold tyre pressure” decrease.
Higher Than the Lower Than the Recommended Different Pressure of
Recommended Pressure Pressure the Same Axle
Possible 1.Bumpy running; 1.The tyre utters noise when steering; 1.Unbalanced braking;
Faults 2.Scuffed tyre or broken tyre 2.Inflexible steering; 2.Advanced steering;
body; 3.Rapid and uneven edge abrasion of 3.Steering out of control;
3.Rapid abrasion on the the tyre; 4.Deviation during
central tyre tread. 4.Bruise and crack on the wheel rim; acceleration.
5.Broken tyre cord;
6.High temperature of the tyre;
7.Steering out of control;
8.High fuel consumption.
Installation of Tyre and Wheel (Steel Wheel)

When installing the tyre and wheel, the hard radial part of the tyre or so-called “high point” should be
aligned to the wheel’s minimum radius or so-called “low point”.
The “high point” of the tyre is marked through the paint point on the outer side surface of the tyre
originally. The paint point will be rinsed off.
The “low point” of the tyre is marked through the paint point on the tyre rim originally. Whenever the
tyre is disassembled from the wheel, the tyre and the wheel need to be performed with dynamic
balancing again, to ensure the stationarity of the vehicle running. If the position of the paint point can’
t be found on the tyre, a line should be drawn on the tyre and the wheel before disassembly, to ensure
that the tyre and the wheel will be re-installed at the same position.
Replace the tyre
When replacing, the tyre with the original specification must be adopted. The tyre to be replaced must
be the same tyre as the original vehicle tyre in size, loading scope, and structure. If the tyre with other
size or form is adopted, the tyre will influence the seating comfort, the steer-ability, the calibration of
the speedometer, the vehicle ground clearance, etc.
It is better to install a pair of new tyres on the same vehicle axle. If only one tyre needs to be replaced,
the tyre with the most similar to the original tyre tread must be installed to ensure the balanced braking
force and traction.
Warning:
The tyres of different structures such as radial tyre, biasply tyre, biasply harness tyre, etc. can’t be
used on the same vehicle, except for emergent cases. If the tyres of different forms are used,
this will influence the vehicle’s steer-ability and stability, or cause to get out of control.
Wheel Maintenance
It is not permitted to repair the wheel by welding, heating or hammering. All the damaged wheels must
be replaced.
If the wheel is twisted and distorted, sagged, or has excessive transversal or radial jerking, the wheel leaks
from the welding place, the bolt hole is lengthened, the cap nuts can’t be locked tightly, or the rust becomes
serious, the wheel must be replaced. When the wheel jerks excessively, it will cause poor vibration.
The wheel to be replaced should be the same as the original wheel in loading capacity, diameter,
wheel rim width, offset distance, installation structure, etc. If the size and form of the tyre are
inappropriate, the service lift of the wheel and the bearing, the braking cooling effect, the calibration of
speedometer, the vehicle ground clearance, and the clearance between the tyre and the vehicle body
and the chassis will be influenced.
If there are the following conditions, the tyre must be replaced:
1. The front and rear tyres are abraded to different degrees.
2. Any tyre tread is abraded unevenly.
3. The left and right front tyres are abraded to different degrees.
4. The left and right rear tyres are abraded to different degrees.
5. The tread groove is abraded abnormally, and the tyre ground touching point becomes flat.
If there are the following conditions, front

wheel alignment must be inspected:
1. The left and right front tyres are abraded to differ-
ent degrees.
2. Any tyre tread is abraded unevenly.
3. The tread pattern strip or the pattern block of the
wheel on one side is abraded seriously.
Abrasion Mark
The abrasion marks are distributed in the tyre pattern
groove evenly (the place indicated in Figure 1). Such
marks indicate that the tyre is so abraded that the tyre
must be replaced.
The service limit of the tyre is that the residual pattern
1
depth reaches 1.6mm (that is, the pastern becomes as
flat as the protrusion of the main groove bottom), and
replace the tyre for your security.
The tyre with exposed partial cord caused by serious
deflected abrasion can’t be used.
The tyre with the damage into the cord layer or steel
tape layer by foreign matter shouldn’t be used further.
Swing of Radial Tyre
Such swing indicates the swinging to both sides of the
vehicle front part, the rear part of both parts. The tyre
swing is caused by the uneven steel belt inside the
tyre, and when the vehicle runs at the speed of (8-48)
km/h, the swing is most obvious.
The faulted tyre can be found through road test. If the
faulted tyre is on the rear part, the vehicle rear part will
slosh to the left and right, which can be called “swing”.
At this time the driver on the seat will feel that somebody is pushing the vehicle on one side.
If the faulted tyre is on the front part, the swing will be more obvious. The front metal plate seems
moving forward and backward, and the driver feels as if the vehicle is at the circulation central point
Vehicle’s Road Test Method
1. Drive the vehicle and make clear whether the swing is on the front wheel of on the rear wheel;
2. Install the tyre and wheel determined to be in good condition (on the vehicle with the same form) onto
the place where the vehicle swing occurs. If the swing place can’t be identified, replace the rear wheel
tyre;
3. Go on with the road test, and if the status is improved obviously, re-install the original wheel and
tyre, one is replaced once, till the tyre causing swing is found. If the status is not improved obvi-
ously, replace four tyres in good condition, and then replace with original tyres one by one to per-
form the inspection in the above related method.
Adjust the tyre pressure to the recommended pressure
Perform the road test on the flat and straight road
Perform the above related road test after replace the left and right tyres mutually
Deviate to the same direction Corrected, and if there is any effect, replace the tyre Deviate to the other direction
Install the tyre onto the original position and

inspect the front wheel alignment Replace with a “good tyre” on one side in the front part
Not corrected, and replace with a “good tyre”

Corrected, and replace the tyre on the other side in the front part
Corrected, and replace the tyre Not corrected, and the “good tyre” is not so good
Deviation of Radial Tyre

“Deviation” means that the vehicle doesn’t run along a straight line on the flat road without the
control on the steering wheel.
The deviation usually is caused by the following causes
• Incorrect tyre and front wheel alignment;
• Uneven braking force;
• Problems about the tyre structure.
The production method of the tyre will cause the vehicle’s derivation, such as the layout of the steel
cord inside the tyre. The steel cord off the tyre central line of the radial tyre will cause lateral force
when the tyre rolls along a straight line. If one side of the tyre diameter is larger than the other side,
the tyre will roll to one side, causing the lateral force leading to the vehicle’s derivation. If the front
wheel alignment is correct, the above related procedure also applies to the judgment of the wheel’s
derivation, and the rear tyre will not cause derivation.
（A）（B）
General Balancing Procedure
Clean the soil and so on accumulated in the inner side
2
of the wheel rim.
Warning: the stone on the tread must be removed,
lest it will fly away to hurt the operators when per-
forming rotating balancing, and doing so will help to
obtain good balance. The damaged case of the tyre
3 must be inspected carefully, and the balancing opera-
1
tion should be performed according to the operating
instructions of the balancing device.
(C) (D) 1. Jerking point of the vehicle [A]: Balancing block not added
2. Place to add balancing block [B]: Balancing block added
2
3. Axle center
1. Jerking point of the vehicle [C]: Balancing block not added

2. Place to add balancing block [D]: Balancing block added
3
1 3. Axle center
Wheel Balancing
There are two methods for the wheel and tyre balancing: static and dynamic.
Static balancing means that the weight distribution around the wheel is equal. If the wheel is
unbalanced in the static state, this will cause violent jerking upward and downward, or so-called
“bounce”, and the phenomenon will finally cause uneven tyre abrasion.
Dynamic balancing means weight distribution on both sides of the tyre central line is equal, which will cause the
tyre to move to one side from the other in rotation. The tyre’s dynamic unbalancing will cause “bounce”.
Tyre Transposition
In order to make the abrasion equal, perform the tyre transposition according to the figure. Perform
the tyre transposition regularly for the radial tyre, and charge the pressure according to the regulation.
Notice: because of the structure, the shoulder part of the radial tyre will be abraded rapidly,
especially the front tyre. Perform the tyre transpo-
sition once per 8,000 km or 12,000 km, to increase
20% of the tyre service life. This makes the regular
tyre transposition more important.
Disassembly and Installation of
Wheel
Disassembly
1. Disassemble the wheel cover, and loosen the nuts.
2. Lift the vehicle
3. Disassemble the wheel.
Warning: never loosen the fixed wheel by heating,
or the wheel’s service life will be reduced because
of heat and the wheel bearing will be also dam-
aged.
Installation
Install the wheel according the reverse disassembly
procedure and perform according to the following
requirements.
The wheel nuts must be loosened in 2-3 times in turn
to the regulated torque so as to avoid the distortion of
the wheel or the braking disc.
(C)
Notice: before installing the wheel, scrape clean
the corrosive from the installation surface of the
(A) wheel and the installation surface of the braking
(E) drum and the braking disc with a steel bush. If the
contact between metals of the installation surfaces
is poor when installing the wheel, it will cause the
loosened wheel nuts; as a result, the wheel may
drop out during the running in the future.
(D) (B) Tightening sequence: (A)--(B)--(C)--(D)--(E)
Assembly and Disassembly of Wheel

1. The tyre will be installed or disassembled with the tyre changer. The operation of the tyre
changer must be performed according to the operating instructions of the manufacturer. Don’t replace
the tyre with a manual tool or pry bar, or the tyre edge or the wheel rim will be damaged.
2. Remove the lubricating oil or used rubber from the wheel rim seat with a steel brush or rough
steel wool, and clean the slight rust. Before installing of disassembling, lubricate the edge part
of the wheel rim well with appointed tyre lubricating agent.
3. After installing the tyre, charge the tyre to the regulated pressure and inspect whether the tyre
bead reaches the seat completely.
Warning:
• Don’t charge the tyre excessively. When the tyre bead expands to exceed the security limit of
the wheel rim, the tyre bead may be broken to cause serious human injury.
• The tyre charging can’t exceed the regulated pressure. If the regulated pressure can’t make
the tyre bead return the seat, discharge the tyre, and lubricate and charge again.
• Excessive charging will cause tyre bead broken, and may cause serious human injury.
Use of Spare Tyre
The charging pressure of spare tyre is 420kPa.
The measurement of the spare tyre pressure should be performed at the normal temperature.
After charging the tyre, test with soapy water to confirm whether the tyre valve leaks, and lock the tyre
valve cover tightly.
Keep the spare tyre in the available state, and inspect the inner pressure at least once per month.
The service limit of the spare tyre is that the residual pattern depth reaches 1.6 mm (that is, the
pastern becomes as flat as the protrusion of the main groove bottom), and don’t continue to use the
spare tyre for your security.
Precautions:
• The mark “△” on the tire bead of the spare tyre is
used to indicate the setting position of the abra-
sion index (as shown in the left figure).
•T he maximum running speed for the spare tyre
is 80km/h and the longest distance is 200km for
driving once.
• Only one spare tyre is used on each vehicle, and
the spare tyre can’t be used on the steering wheel
(front wheel).
Braking System-
Braking System
Braking system................................................................................ 2
Braking system maintenance......................................................... 3
Brake pedal...................................................................................... 6
Parking braking operating mechanism......................................... 9
Assembly of vacuum booster with braking pump....................... 10
Anti-lock braking system................................................................ 12
Front braking caliper....................................................................... 17
Assembly of steering knuckle and hub brake.............................. 22
Rear brake........................................................................................ 28
Rear support axle............................................................................ 35
Braking System-
Braking system
Component diagram
ABS controller assembly

Left front wheel speed
sensor assembly
Right front wheel speed
sensor assembly
Left steering knuckle and Right steering knuckle and

hub brake assembly hub brake assembly
Vacuum booster with
braking pump assembly
Brake pedal assembly
Parking braking operating

mechanism assembly
Left parking braking Right parking braking

cable assembly cable assembly
Left rear wheel speed Right rear wheel speed

sensor assembly sensor assembly
Left rear brake Right rear brake

assembly assembly
Rear braking drum Rear braking drum
Braking System-
Braking system maintenance

Inspection and adjustment of brake pedal
1. Inspect whether the height of the pedal is correct
In free condition, the vertical distance between the lower limb of the pedal gasket and the
carpet should be 130 mm.
2. If necessary, adjust the height of the pedal
(a) Unscrew the locking nut of the operating rod, adjust the brake pedal height to the standard value
by turning the operating rod with combination pliers, and after the height reaches the standard
value, lock the locking nut, at the same time ensure that the idle travel of the pedal pushrod is 1
mm.
(b) When the brake pedal is released, the braking lamp should not be on.
3. Inspect the free travel of the brake pedal
In the halting state of the engine, step on the brake pedal 2 to 3 times, after clearing the influence
from the brake booster, push down the brake pedal until it meets with the resistance force, measure
its amount of movement (free travel). It should meet the requirements of the standard value.
Pedal free travel: (4-6) mm
4. Adjust the travel of the pedal if necessary
(a) If the travel value is incorrect, turn the pedal pushrod to adjust the free travel.
(b) Start the engine to confirm the pedal free travel.
(c) After adjusting the pedal free pedal, inspect the pedal height.
(d) The relative height difference between the brake pedal and the clutch pedal should be (0-10) mm.
(e) The relative height difference between the brake pedal and the throttle pedal should be (35±5) mm.
5. When the clearance between the brake pedal and the bush is too large, disassemble the pedal
and replace it.
Inspection and replacement of the braking fluid
The braking fluid will directly affect the brake performance and the working state and the service life
of the system elements. The braking fluid has a very strong hygroscopicity, absorbs water easily,
and causes crossion of metal elements and degeneration of rubber elements; the braking fluid
disintegration or mixing will cause ebullition and aerification, and decline the performance. So pay
special attention when filling or replacing the braking fluid:
1. The container which holds braking fluid must be covered tightly and sealed;
2. The braking fluid is poisonous, and will damage the lacquer finish, so if it is sprayed onto the
vehicle body or finish, rub away immediately;
3. If the braking fluid is found containing water or other pollutants, and the Braking master pump
piston seal ring has already been damaged, the braking fluid and all rubber parts including the
brake hose must be replaced.
4. The correct level of the braking fluid in the fluid storage tank must be maintained between the
upper limit line (MAX) and lower limit line (MIN). After the vehicle travels 1,000 KM, the level
of the braking fluid in the fluid storage tank should be inspected. If the level doesn’t meet the
requirements, add braking fluid to the tank until it reaches the upper limit line.
Hydraulic element maintenance and system rinsing
1. If oil base solvent enters the hydraulic system, the entire system should be rinsed, and all the
rubber parts must be replaced;
2. Before installing new rubber parts or other elements, wash hands clearly;
3. When maintaining or cleaning the hydraulic elements, do not use normal solvent (such as,
kerosene or gasoline, etc), but use degreasing alcohol or braking fluid;
4. After elements maintenance, drain the braking fluid inside the system as quick as possible;
after rinsing the system with new braking fluid, add new braking fluid and discharge the
hydraulic system;
5. Rinse finishing sign: until the braking fluid flowing from the dump valve is clear without soil.
Braking System-
Hydraulic system emptying

If the braking fluid inside the hydraulic system should be emptied, all the discharging screws should
be opened. Each screw is inserted with a hose to let the braking fluid be drained into the container,
step slowly on the pedal until all the air is discharged, and during this process, all the valves should be
ensure to be in the opening state.
Hydraulic system discharging
The hydraulic braking system must work without air. When air enters the hydraulic system, it will
cause spongy brake pedal or braking failure. If carrying out any operation to the braking system or
doubting that the braking system contains air, it is very necessary to discharge the system.
1. Discharging sequence
(a) If the inner braking pump assembly is doubted to contain air, discharge the master braking pump
first;
(b) If various valves are installed, discharge them;
(c) Other sequence principles: discharge in turn from the wheel brake nearest to the master pump,
the discharging sequence of the LHD vehicles should be: right rear wheel -- left rear wheel --
right front wheel -- left front wheel; the discharging sequence of the RHD vehicles should be: right
rear wheel -- left rear wheel -- left front wheel -- right front wheel.
2. Discharging method
(1) Manual discharging
When the discharging screw is loosened, drain out the braking fluid which contains air bubble, using
the brake pedal and master pump as the discharging power source. Usually this will be performed by
two people together, one steps on the brake pedal, the other operates the discharging screw. Some
points should be paid attention to:
(a) When the ignition switch is in the shutoff position, step on the pedal for several times repeatedly,
to remove the vacuum or hydraulic pressure;
(b) Before or after discharging, add clean braking fluid to the master pump until it reaches the correct
(regulated) liquid level;
(c) During the discharging process, inspect the liquid level frequently, to keep more than half amount
of fluid in the tank;
(d) The discharging screw can be only loosened when the pedal is pressed down, and it should be
closed before the pedal is released, at the same time, observe whether the drained braking fluid
contains air bubble;
(e) The valves in the system must not block the discharging;
(f) When the braking fluid flowing from the hose or connector has no air bubble, it indicates the air
inside the system has been removed; when the hose inserted in the braking fluid bubbles when
the pedal is pressed down, it indicates that the system still contains air.
(g) Keep the free end of the hose immerged in the fluid, to prevent air from entering unexpectedly
when the screw is loosened;
(h) During the discharging process, knock on the cast part of the vibration brake device with a rubble
hammer, which will help to remove the air bubbles deep in the braking fluid;
(i) If the master pump is doubted to contain air, discharge the master barking cylinder before
discharging the wheel cylinder or the braking caliper;
(j) When discharging, discharge all the wheels;
(k) Discharging hose with one-way valve, to prevent air from being absorbed into the system from
the reverse direction.
(2) Pressure discharging
Discharge braking system with pressure discharging device if conditions allow.
3. Discharging steps
(1) Master pump discharging
If the master cylinder has no discharging screw, operate according to the following steps:
(a) Inspect the braking fluid level of the master cylinder fluid storage tank, and add fluid if necessary;
Braking System-
(b) Slowly disassemble the front brake hose connector of the master pump, until the braking fluid
flows out from the outlet;
(c) Connect the brake hose again without tightening;
(d) Step on the pedal slowly and hold it, and observe whether the braking fluid overflowing from the
connector contains air bubble;
(e) Tightening the hose connector;
(f) Let an assistant release the pedal, and wait for 15 s;
(g) Repeat the above steps, until all the air is discharged out;
(h) Disassembly the rear end brake hose connector of the master pump, and repeat the above
steps.
(2) Wheel braking discharging
(a) Inspect the level of braking fluid in the fluid storage tank of the master cylinder, add fluid if
necessary, and during the discharging progress, inspect again and replenish the braking fluid in
time;
(b) Connect one end of the discharging hose to the discharging screw, insert the other end under the
fluid level of the container with part braking fluid;
(c) Let the assistant slowly step on the pedal for several times, make the pedal lift up gradually until
it can’t be moved, and press the pedal with force;
(d) Loosen the discharging screw, observe whether the braking fluid contains air bubble, and at the
same time the pedal should decline slowly;
(e) When the brake pedal approaches the travel end or the discharging fluid contains no air bubbly,
loosen the discharging screw;
(f) Let the assistant release the pedal and wait for 15 s;
(g) Repeat the above steps, until the flowing fluid contains no air bubble when the screw is loosened;
(h) Discharge all the wheels in turn in the same method;
(i) After discharging the entire system, the ignition switch should be turned to the power-on position;
(j) Inspect the brake pedal travel and the counteracting force of the pedal;
(k) Inspect the display of the brake warning lamp, clear the faults if necessary or repeat the
discharging operation;
(l) Add braking fluid to the regulated liquid level of the fluid storage tank, and the discharging
progress is finished.
Braking System-
Brake pedal
Component diagram
Return spring
Pushrod assembly
Upper bracket welding
Connection plate assembly of brake pedal
Braking
lamp switch Bracket welding
Assembling bolt assembly of brake pedal
Plastic liner
Position limiter
Pedal sleeve
Assembling nut
Inner liner
Precautions
1. During the process of disassembling the brake pedal, please note to deal with the parts gently,
avoiding to be knocked and damaged; all the parts should be put in good order, to avoid being
lost or taken by mistake.
2. All the parts should be ensured to be clean, without dust, cutting pieces, rust, oil stain or other
foreign matters.
3. Apply oil on all the friction surfaces in relative motion.
4. When assembling, tighten the assembling nuts strictly according to the standard torque.
5. When installing the return spring, note that the spring back may bounce back to cause human
injury.
Troubleshooting
Fault Cause Remedy
The return spring is broken Replace the spring
The brake pedal cannot return The fixing end of the return spring is
Inspect, and fix in position
broken offis broken off
The pedal gasket is damaged Replace
Slippery pedal
Pedal gasket is broken off Reinstall
Plastic liner is seriously worn Replace
Abnormal sound when stepping
The spring is broken Replace
on the pedal
Spring fixed end is broken off Inspect, and refix
Braking System-
Disassembly of the brake pedal assembly

1. Disassemble the braking lamp switch, the return
spring, the assembling bolts and the assembling
nuts.
2. Continue to disassemble into the plastic liner, the

inner liner, the pushrod assembly, the connection
plate, the pedal arm welding assembly, the pedal
upper bracket welding assembly and the pedal
lower welding assembly.
3. Disassemble the position limiter, the pedal sleeve

from the pedal welding assembly.
Assembling of the brake pedal assembly

1. Install the position limiter, the pedal onto the pedal
welding assembly.
2. Apply oil evenly onto the friction surface in relative

motion of the parts of the plastic liner, the inner
liner, the pushrod assembly, the connection plate
and the pedal welding assembly.
Braking System-
3. Assemble the liner, the inner liner, the pushrod

assembly, the connection plate and the pedal
welding assembly together.
4. Install the above subassembly, the pedal upper

bracket assembly and the pedal lower welding
assembly together with assembling bolts and nuts,
and tighten with the standard torque.
Standard torque: 23N•m
5. Install the return spring and the braking lamp

switch.
Braking System-
Parking braking operating mechanism

Device structure diagram
Parking braking
controlling unit assembly
Hexagon head bolt
Parking braking cable assembly
Disassembly and installation of the

Parking braking
parking braking handle
controlling unit assembly 1. Disassembly
(a) Disassemble the auxiliary instrument panel, and
lower the parking braking handle to the bottom.
(b) Disassemble the four hexagon head bolts which
fix the parking braking control onto the vehicle
body.
(c) Loosen the parking braking cable adjusting bolts
with a spanner, and take out the pulling cable from
the adjustment clamp.
2. Assembly
The reversed sequence of disassembling the parking
braking controlling unit will be used to assemble the
parking braking control assembly, but please pay
attention to the following three points:
(a) The pulling cable clamp of the parking braking
handle which has the opening should be placed
toward the ground.
(b) When assembling the parking barking handle, the
assembly should be adjusted in position, usually
(6-8) teeth.
(c) When tightening the parking braking cable, the
torque should be no more than 400 N•m.
Braking System-10
Assembly of vacuum booster with braking pump

Component diagram
Fuel inlet connector
Screw
Braking master pump assembly
Locking nut
Connection gasket
One-way valve
Hexagon thin nut
Adjusting fork
Vacuum booster assembly

Valve rod
Pin axis
Lock pin
Precautions
1. The vacuum booster with braking pump assembly is connected with the brake pedal assembly
at the front wall plate with four nuts, and connected with the brake pedal handle with the
pin axis and the lock pin; so before disassembling the assembly, screw open the hard pipe
connector with a open end spanner, disconnect the lock pin and pin axis with a pair of pliers,
loosen the four nuts, and perform operation to the booster assembly.
2. Tighten the braking master pump and the locking nut on the vacuum booster to the regulated
torque, and apply the marking paint.
3. The dimension of the rear casing end face to the middle hole of the adjusting fork has been
adjusted qualified before delivery, and it is not permitted to be adjusted at all.
4. The vacuum booster valve rod must be in free state on vehicle.
5. The working medium of the braking master pump is DOT4 braking fluid, and it is not permitted
to be mixed with other braking fluid.
Disassembly of the assembly of the vacuum
Vacuum booster
assembly
booster with braking pump
1. Disassembly of the vacuum booster assembly and
the braking master pump assembly.
Locking nut Remove the two locking nuts with a spanner, take off
the master pump (braking master pump assembly)
from the vacuum booster, and put them on a piece of
clear soft cloth.
Braking master Tightening torque: (25±4) N•m
pump assembly
Braking System-11
2. Disassembly of the fuel inlet connector braking

Fuel inlet connector
master pump assembly.
Screw
Screw off the cross recessed screw with a screwdriver,
and take off the fuel inlet connector directly from the
master pump with hands.
Braking master
pump assembly
3. Disassembly of the one-way valve and the vacuum

Vacuum booster booster.
assembly
Take off the one-way valve directly from the vacuum
booster.
One-way
valve parts
4. Disassembly of the connection gasket.

Vacuum booster The connection gasket is put directly on the vacuum
assembly
booster, so take it gently with hands.
Connection gasket
5. Disassembly of the lock pin and the pin axis

Vacuum booster
assembly
Open the end part of the lock pin with a pair of pliers,
take out the lock pin, and take off the pin axis from the
adjusting fork.
Pin axis
Lock pin
6. Disassembly of the adjusting fork

Vacuum booster
assembly Note to measure the distance between the adjusting
fork centre and the thick casing end face, when
assembling, the distance must be accordant with it.
Insert an axis thinner than the adjusting fork into the
Hexagon thin nut hole first, hold it and loosen the nuts of the adjusting
Adjusting fork fork with a spanner, and screw off the adjusting fork
from the valve rod.
Valve rod
Braking System-12
Anti-lock braking system

Brief introduction of ABS/EBD
1. Operating principle
The Vehicle Anti-lock Braking System (ABS for short), is a kind of safety device which becomes more
and more popular on vehicles. It detects the wheel speed through the wheel speed sensor, transfer
the wheel speed performed after signal processing in computer,
And the computer controls the working condition of the solenoid valve according to the wheel speed
in certain algorithm and controlling methods, controlling the pressure in the braking wheel pump to
prevent wheel locking. The ABS will prevent sideslip, deviation, tail swing and control ability loss
during the vehicle braking process, improve the vehicle steerability and stability, and shorten the
braking distance as well as prevent part abrasion of the wheel tyre, and increase the service life.
The Electronic brake distribution (EBD for short), is used to adjust the braking pressure of the rear
wheels with the ABS parts to balance the braking pressure of the front and wheels and obtain
optimum efficiency of the vehicle braking, when the vehicle is braked but the ABS doesn’t function.
The EBD uses the ABS’s parts, but its control logic is independent from the ABS, when ABS takes
effect, EBD will fail to work.
2. Basic Structure
ABS controlling unit
Vacuum booster and master pump

Valve body working order
Wheel speed signal

Wheel speed sensor
Hydraulic adjuster
Wheel cylinder
3. ABS working process

(a) Pressure raising stage: when the vehicle is braked, the oil pressure output from the master pump
will enter the braking pump through solenoid valve, the brake produces braking force, and the
wheel speed decreases rapidly, until the ABS controlling unit detects the wheel’s locking trend
through the wheel speed sensor.
(b) Pressure maintaining stage: the ABS controlling unit identifies the wheel’s locking trend through
the wheel speed sensor signal, then switch off the oil inlet solenoid valve, and the oil outlet
solenoid valve is still closed constantly, the pressure maintaining stage begins.
(c) Pressure reduction stage: during the pressure maintaining stage, the wheel shows a tendency to
lock further, and the ABS goes into pressure reduction stage. The oil inlet valve is closed, and the
outlet valve is opened, the hydraulic pump begin to work, the braking fluid is back from the low
pressure accumulator to the Braking master pump, the braking pressure is decreased, and the
brake pedal rebounds.
(d) Pressure maintaining stage: the locking level of the wheel decreases, the wheel speed begins to
increase, and now the pressure maintaining stage begins.
(e) Pressure raising stage of the next circulation: when the wheel reaches specific speed, the ABS
will enter the pressure raising stage again, and begin the next circulation.
Braking System-13
1 2 3 4 5
Vehicle speed
Wheel slip amount
Wheel speed
Master pump pressure
4. EBD working process

The EBD will take effect when the wheels are slightly braked, the wheel speed sensor detects the speed
information of the four wheels, and the ECU calculates the rotating speed of the wheels; if the slip rate of
the rear wheels increase, the ECU will adjust the braking pressure, to maintain or decrease the rear wheel
braking force. The EBD guarantees higher lateral force of the rear wheels and appropriate distribution
of the braking force. When the ABS does not work, the EBD can still adjust the braking force of the rear
wheels, ensuring that the rear wheels will not be locked before the front ones, and ensuring the vehicle’s
security.
The pressure raising and pressure maintaining of the EBD are exactly like the ABS working process,
but the pressure reduction control is somewhat different. When the rear wheels show a tendency
to lock, the normally opening valve is closed, and the normally closing valve is opened, the wheel
pressure decrease, and the difference from the ABS is: now the hydraulic pump does not work, the
braking fluid from the pressure reduction is temporarily stored in the low pressure accumulator. After
the braking is finished, the pedal is loosened, the pressure inside the master pump is zero, and the
normally closing valve is opened, the braking fluid returns back to the master pump through the
normally closing/opening valves, and the low pressure accumulator is emptied, for the preparation for
the next braking.
ABS system assembly

ABS controller 1. Assembling of the ABS controller assembly
assembly (a) F i x t h e A B S b r a c k e t a s s e m b l y o n t o t h e
ABS hydraulic pump vehicle body with three hexagon flange nuts
shock absorber gasket
(Q1840816FD).
Hexagon flange bolt (b) Fix the ABS hydraulic pump shock absorber
gasket onto the installation hole of the ABS
ABS bracket assembly bracket assembly.
(c) Insert the installation pin of the ABS controller
assembly into the hole of the shock absorber
gasket, and insert the two fixed pins onto the
bracket.
Braking System-14
2. Assembling of the assembly of ABS front wheel

Assembly of wheel speed speed sensor with bracket
sensor with bracket (a) Connect the sensor and the steering knuckle with
hexagonal head bolts, spring washer and plain
washer subassembly.
Steering knuckle
(b) Connect the sensor bracket and shock absorber
with the hexagonal head bolt and plain washer
subassembly (M8).
(c) Connect the sensor bracket and vehicle body
Transmission shaft
with the hexagonal head bolt and plain washer
subassembly (M6).
Assembly of rear wheel 3. Installation of the assembly of the ABS rear wheel
speed sensor with bracket speed sensor with bracket.
Connect the sensor, the rear hub unit, the rear pin
Rear hub unit axis beam and the vehicle body with three hexagonal
assembly head bolts, spring washer and plain washer assembly
subassemblies.
Hexagon head bolt,

spring washer and plain
washer subassembly
ABS system common fault and maintenance

1. When braking, the ABS hydraulic unit is producing loud noise.
When the ABS is working, the motor inside the hydraulic unit keeps on running, at this time the driver
will feel the pedal bouncing, and in different speed and road condition, this bouncing feeling is not
always the same. In addition, when the operation test is performed, the motor’s running noise can be
also heard. When the vehicle is running and the driver does not brake the vehicle, the motor running
noise can be heard by accident, which is because the ABS is performing the parts inspection and is
not a fault.
If the noise of the ABS hydraulic unit is considered to be abnormal, perform the operation test, and
compare with normal vehicles, to determine whether the noise of the ABS hydraulic unit is normal.
2. Solenoid valve fault of the oil inlet and outlet
Every time after powering on the ignition switch, the ABS controlling unit will perform self inspection,
and if it finds short circuit or open circuit of the inlet and outlet solenoid valve, it will record the fault,
light the fault lamp, and exit working. If the corresponding fault code is invoked with the diagnosis
gauge, and the solenoid valve is ensure to fail, replace the hydraulic unit assembly directly.
X431 data stream: the oil inlet and outlet solenoid valve will switch the working conditions rapidly
when the ABS works.
EVFL -- left front inlet valve ON/OFF
AVFL -- left front outlet valve ON/OFF
EVFR -- right front inlet valve ON/OFF
AVFR -- right front outlet valve ON/OFF
EVRR -- left rear inlet valve ON/OFF
AVRR -- left rear outlet valve ON/OFF
EVRR -- right rear inlet valve ON/OFF
AVRR -- right rear outlet valve ON/OFF
Braking System-15
3. Wheel speed sensor fault

In the engine ignition state, detect the electric voltage between the signal wire of the sensor and the
grounding with an oscillometer.
Output signal when the vehicle is in standstill state:
v v
or
0
t
0
t
Output signal when turning the wheels: the signal form is 0.44V and 1.26V square signal,
duty cycle: 50:50.
v
0
t
The X431 diagnose gauge data stream has the wave form function, for the internal faults such as the
wheel speed signal error (wheel speed sensor fault) when the speed is too high, the occasional wheel
speed error during using process, observe the wave form to confirm whether it is abnormal. If the
vehicle is driven on plane road in a straight line, the wave form of the sensor of the four wheels should
be very similar to each other, and compare the two front wheel signal wave or the rear ones.
Mechanical cause:
The signal rim is distorted, or the hub axis bearing is loosened, the sensor surface is stained, which
will cause the disruption and variation of the wheel speed signal. Fault example:
V(Km/h)
60
30
Signal disruption
As shown in the above figure, once the internal fault of the wheel speed sensor signal is detected, the
ABS controlling unit will record the sensor fault and light the warning lamp.
4. Wheel speed sensor speed fault (the difference between the speed sensor signal of some
wheel detected by the ECU and the speed sensor of other wheels is too great.)
The possible cause is that the rim wheel speed sensor clearance exceeds the tolerance
t or the signal
of the wheel speed sensor is disturbed, for this problem, judge the sensor which has signal variation
first, and clear the fault according to the troubleshooting method in fault III.
Braking System-16
Precautions
1. Sometimes in order to determine whether it is the normal braking system problem or the ABS
system problem, the ABS needs to exit from working, that is, to disconnect the ABSECU plug
or the fuse, then the ABS/EBD are both out of work; the vehicle may drift or sideslip, so the
driver should avoid emergent braking as much as possible.
2. The fault rate of the ABS system is very low, so when the braking system has problems (the
warning lamp is not on), first clear the normal braking system problems, and then consider the
ABS system faults.
3. On rainy or sandy road, this adjustment process will take longer time than on normal road,
because the attachment coefficient of this kind of road will cause different measurement and
calculation of the slip rate, so all the driver should be careful when running on such roads.
4. ABS/ECU Precautions:
(a) The ABS/ECU will be easily damaged when it is crashed or knocked, so note to protect the ECU
from being crashed and knocked.
(b) The high temperature environment will also damage the ECU easily, so when the vehicle is under
finish baking operation, please remove the ECU from the vehicle.
(c) When the power switch is at the ON position, do not disassemble or assemble the electric
elements and wire hardness plugs to avoid damage to the ECU. If it needs to be disassembled
and assembled, shut off the ignition switch first. When the elements or the circuit is welded,
disconnect the harness plugs from the ECU.
(d) Do not stain the ECU with oil, especially the ECU terminals; or else, it will cause poor contact of
the harness terminals.
Notice: the BOSCH ABS8.0 hydraulic unit can’t be repaired (which is integrated with the ECU),
so the entire unit will be replaced when it was damaged.
ABS fault code list
Fault Code Fault Description
C0035 Left front wheel speed sensor circuit fault, speed fault
C0040 Right front wheel speed sensor circuit fault, speed fault
C0045 Left rear wheel speed sensor circuit fault, speed fault
C0050 Right rear wheel speed sensor circuit fault, speed fault
C0060 Left front ABS outlet solenoid valve fault
C0065 Left front ABS inlet solenoid valve fault
C0070 Right front ABS outlet solenoid valve fault
C0075 Right front ABS inlet solenoid valve fault
C0080 Left rear ABS outlet solenoid valve fault
C0085 Left rear ABS outlet solenoid valve fault
C0090 Right rear ABS outlet solenoid valve fault
C0095 Right rear ABS inlet solenoid valve fault
C0110 Pump motor circuit fault, running error
C0121 Solenoid valve relaying circuit fault
C0161 Brake switch circuit fault
C0245 Wheel speed sensor ratio fault, wheel speed sensor signal fault
C0287 Acceleration sensor fault
C0550 ECU fault
C0800 Voltage fault, too high or too low
Warning lamp and the positive electrode has short circuit, warning lamp and the earth
C0232
has short circuit
Braking System-17
Front braking caliper

Component diagram
Air discharging cap

Piston ◆Oil seal ring Cylinder body 7-9
Air discharging screw
22-32
Connecting bolt
◆Piston dust shield
Outer braking block

Outer shim B Inner braking block
Fixing bracket
Warner
Inner shim B
◆Piston Yoke springs

Pin
dust shield
Inner shim A
Outer shim A
Lubricating grease of lithium base
N•m : Regulated torque

Replacement of inner and outer braking

block assembly
Remarks: during the running process, if the front
wheels produce a continuous squeal, the wearing
limit warning piece should be inspected. If the warning
piece has abrasion marks rubbed by the braking disc,
the inner and outer braking block assembly should be
replaced.
1. Disassemble the front wheels
2. Disassemble the caliper body assembly

(a) Disassemble a hexagon flange bolts connecting
the caliper body and the lower end of the caliper
bracket.
Braking System-18
(b) Raise up the clamp assembly, and hang it with a

cording in order to protect the brake oil pipe.
Remarks: do not loosen the brake oil pipe and the air
discharging screw.
3. Disassemble the following parts

Inner braking block
Outer braking block
(a) A group of inner and outer shim B;
Warner (b) A group of inner and outer shim A;
Outer shim B
(c) A group of inner and outer braking block;
(d) A pair of yoke springs.
Yoke springs Inner shim B

Outer shim A
Inner shim A
4. Install the yoke springs

Install the braking block yoke spring leafs onto the
caliper bracket.
5. Install the new inner and outer braking block

Outer braking block
subassembly.
Inner braking block Warner
Outer shim B (a) Install the outer shims A, and B onto the outer
braking block.
(b) Install the outer shims A, and B onto the outer
braking block.
Inner shim A
Outer shim A Inner shim B
(c) Install the inner and outer braking block assembly

with muffling piece subassembly onto the caliper
bracket, and make the inner braking block
assembly with muffling piece subassembly with
warning piece closer to the inside of the braking
caliper.
Notice: the inner and outer braking block assembly
and the braking disc working surface should not
be stained by grease or paint.
Braking System-19
(d) Suck out a small amount of braking fluid from the

fluid storage tank (to prevent the braking fluid
overflowing from the fluid storage tank).
Special tool
(e) Pressing in the piston with the special tool.
6. Install the caliper body assembly

Loosen the cording, put down the caliper body
assembly and then screw tight the hexagon flange
bolts.
Remarks: the braking block of only one wheel can be
replaced in one time, lest the piston on another wheel
will bounce out.
7. Install the front wheel
Tightening torque of the front wheel fixing nut:
(103±10) N•m
Disassembly of front braking caliper piston
1. Disassemble the brake pipeline.
Disassemble the brake pipeline, and use a clean
container to collect the braking fluid
2. Disassemble the caliper body assembly

(a) Disassemble the two hexagon flange bolts
connecting the caliper body and caliper bracket.
(b) Disassemble the caliper body assembly from the
caliper bracket.
3. Remove the following parts

(a) A group of inner and outer shim B;
(b) A group inner and outer shim A;
(c) A group of inner and outer braking block;
(d) A pair of yoke springs.
Braking System-20
4. Disassemble the piston and the dust proof cover

Wood block from the caliper body
(a) Put the wood block into the caliper body.
(b) Use air gun or air pipe to aim at the brake oil pipe
hole, disassemble the piston from the caliper
body, and at the same time, disassemble the dust
proof cover.
(c) Take out the piston with clean wiping cloth or other
soft cloth.
Warning: do not put the fingers in front of the
piston when using compressed air.
5. Disassemble the square seal ring from the caliper
body
Disassemble the square seal ring with a clip.
Notice: do not tools which are too sharp to prevent
them from scratching the dust proof cover.
Inspection of steering knuckle and hub

brake assembly
See inspection and disassembly of the steering knuckle
and hub brake assembly
Measure the thickness of the inner and outer braking
block assembly
Standard thickness: 8.5 mm
Minimum thickness: 2.0 mm
If the thickness is less than the minimum thickness or
the block is with uneven abrasion, the braking block
should be replaced.
Assembly of the front braking caliper

assembly
1. Preparation
Keep all the parts clean and without foreign matters
before assembly. When assembling, apply an
appropriate amount of rubble grease on the working
surface of the guide pin and the piston, and also apply
an appropriate amount of rubble grease on the working
surface of the square seal ring and the piston shield.
2. Install the square seal ring into the caliper body

(a) Screw the air discharging screw into the air
discharging hole of the caliper body.
(b) After applying an appropriate amount of rubber
grease on the working surface of the square seal
ring, install it into the caliper body seal groove.
Braking System-21
3. Install the piston with the dust proof cover into the
caliper body
(a) Cover the dust proof cover onto the piston.
(b) Lengthen the piston dust proof cover, and make
the clip edge ring of the dust proof cover exposed
out of the piston bottom; insert clip ring into the
cylinder hole groove with the help of tools (for
example, iron wire of about Ф2 mm).
Notice: do not tools which are too sharp to prevent
them from scratching the dust proof cover.
(c) Then press the piston to the bottom of the cylinder
hole with fingers.
4. Install the guide pin and the dust proof cover onto
the caliper bracket
(a) Install the dust proof cover onto the guide pin.
(b) Screw the guide pin into the caliper bracket.
Notice: do not damage the dust proof cover of the
guide pin.
5. Install the inner and outer braking block assembly
and the inner and outer silencing piece subassembly
6. Install the braking block clip spring piece and inner

and outer braking block assembly and the inner
and outer silencing piece subassembly onto the
caliper bracket.
7. Install the caliper body assembly

(a) Install the caliper body assembly
(b) Install the hexagon flange bolts and tighten them.
8. Connect the brake pipeline

Connect the brake oil pipe and the caliper body.
9. Fill the liquid storage tank with braking fluid, and
discharge all the air from the system
10. Inspect whether there is braking fluid leakage
Remarks: the replacement is finished, and the air is
discharged. (See the steps of air discharging)
Braking System-22
Assembly of steering knuckle and hub brake

Component diagram
Left front braking caliper assembly
Axle center bolt
Copper washer
100±10
Q150B1235
◆Heavy spring washer
Q40512
Q43082
Front hub bearing assembly
Left steering knuckle
Left front braking

disc cover casing
9±2
Q1420612
Front hub flange disc
Front braking disc

Inspection and disassembly of steering

knuckle and hub brake assembly
1. Lift the vehicle and disassemble the wheels
2. Loosen the riveting points of the front transmission
shaft nuts, and disassemble them
3. Inspect the front braking disc surface jumping
amount of the after being assembled.
Before measurement, tighten the three wheel nuts first,
the jumping amount of the both side of the braking
surface of the front braking disc measured according to
the figure shouldn’t be more than 0.11 mm, and if the
measured value exceeds the tolerance, it should be
repaired or replaced.
Braking System-23
4. Disassemble the front braking caliper

Disassemble the bolts locking the front braking caliper,
and remove the braking caliper.
Notice: remove the front braking caliper then hang
the braking caliper tightly with steel wire and other
materials (to avoid the brake oil pipe excessively
distorted, bent or pulled down).
5. Take off the locking nut

Pry up the rivet tightened part of the locking nut with
a piercer and then screw off the locking nut with a
spanner.
6. Disassemble the front braking disc

The braking disc shouldn’t be easily disassembled
after the vehicle travels for a while, and the braking
disc can be ejected out by screwing the two M8 bolts
alternatively with a spanner into the disassembling bolt
thread hole of the braking disc (the position as shown
in the figure).
7. Inspection on the front braking disc
The jumping amount of the single disc should not
exceed 0.03 mm, and the jumping amount of the front
braking disc end surface should not exceed 0.11 mm
after the assembly is installed.The two values should
be distinguished.
8. Take off the front driving axis
Knock the driving axis end surface with a hammer, to
pull out the driving axis from the spline of the steering
knuckle flange disc.
Notice: do not knock any part when the driving axis
is pulled out.
9. Disassemble the shock absorber bolt

Disassemble the two bolts fixing the shock absorber
with a spanner.
Braking System-24
10. Disassemble the sway arm ball pin

Special tool (a) Take off the cotter pin of the sway arm first, loosen
the ball pin tank nut, and then press out the sway
arm ball pin with the special tool.
(b) Disassemble the ball pin of the steering gear in
the same way.
(c) Disassemble the steering knuckle.
(d) Turn the front hub flange disc to detect whether

the axis turns freely.
(e) Measure the jumping amount of the front hub
flange disc, and the jumping amount should not
exceed 0.04 mm.
11. Disassembly of the steering knuckle front hub

bearing and front hub flange assembly
(a) Take off the clip spring with the clip spring plier.
(b) Hold the hammer and knock the front hub flange
Bearing inner race disc repeatedly with the special tool, disassemble
the assembly from the steering knuckle and front
hub bearing. The front hub flange disc contains
bearing inner race.
Special tool
(c) Disassemble the hub flange upper bearing inner

race.
Special tool Disassemble the bearing inner race with the special
tool.
Braking System-25
(d) Inspect the front hub flange disc with dye

penetrant and confirm whether it is cracked, and if
there are cracks, it should be replaced.
(e) If the front hub flange disc assembly is to be used
further, the bearing installing position should be
inspected to confirm whether there is damage,
and if there is damage, it must be replaced.
12. Remove the four bolts fixing the cover casing, and
take off the cover casing.
13. Put the disassembled bearing inner race back to

the original position.
14. Press out the front hub bearing inside the steering
knuckle
Special tool On the pressing machine, control the bearing inner
race with the special tool to press out the whole front
wheel hub bearing.
The disassembly of the steering knuckle and the hub
Special tool brake assembly is finished.
Notice: the front hub bearing assembly is a part
that can not be reused, so the used bearing should
be replaced with a new one.
15. If the steering knuckle has no crack and to be

used further, the bearing installing position in the
steering knuckle must be inspected, and if it is
damaged or the size exceeds the torlerance, the
Size range steering knuckle must be replaced.
-0.078
Size range: Φ82-0.113 mm
Braking System-26
Assembly of the steering knuckle and

hub brake assembly
Special tool 1. Press the front hub bearing assembly into the inner
hole bearing installation position of the steering
knuckle.
On the pressing machine, press in the front hub bearing
assembly into the bearing installationinstallation
position of the steering knuckle with the special tool.
2. Press in the front hub flange disc assembly

On the pressing machine, press in the front hub flange
disc into the bearing installation position of the front
hub with the special tool.
3. Install the cover casing

Install the braking disc cover casing onto the steering
Special tool knuckle and tighten it to the regulated torque.
Special tool
4. Inspect the starting torque of the front hub bearing

assembly
Inspecting method is the same as the disassembling
method, cover the special tool onto the two wheel
bolts at the symmetrical positions, and turn the flange
assembly slowly (45°/4S) on the special tool with the
panel type torque spanner
Required starting torque range: (0.1-0.3) N•m
5. The elastic retaining ring 82 is used in the installing

hole
Install the elastic retaining ring 82 for holes onto the
installation position of steering knuckle retaining ring
with crooked beak elastic collar calipers.
Braking System-27
6. Install the steering knuckle assembly onto the

suspension
Install the steering knuckle onto the suspension in the
reverse process of the above disassembly.
Tightening torque of the shock absorber bolt: 220N•m
7. Inspect the jumping amount of the front braking

disc surface
Screw the two wheel nuts at the symmetrical positions
and measure, and the jumping amount of the braking
surface on both sides of the front braking disc should
be no more than 0.11 mm.
8. Install the braking caliper assembly

Install the braking caliper onto the steering knuckles,
and screw up the bolt with the required torque.
Hold Addition: if the wheel bolt thread part is

damaged, the bolt should be replaced
according to the following procedure:
1. Disassemble the damaged bolts
Seize the steering knuckle with an iron bar with the left
hand with the special tool, and eject out the wheel bolts
Special tool
by turning the spanner with the right hand.
Running
2. Assemble new wheel bolts

Put a washer with the thickness of more than 5 mm
Hold
onto the bolt, tighten with a M14×1.25 nut, keep it
unmoved with the left hand, and turn the spanner with
the right hand, and take the bolt into the flange disc.
Running
Braking System-28
Rear brake
Component diagram
9.5
Air discharging screw cap Piston spring

8.5 Wheel
cylinder ◆Dust shield
Air discharging screw
Hexagon head bolt Piston assembly
Clearance adjusting
Spring washer axle head
Rear left brake bottom
plate assembly Return spring
Spring pressing handle Left parking braking

pulling arm assembly Braking trailing Clearance
Inspection hole shoe assembly adjusting wheel
rubber plug
Clearance adjusting
screw rod
◆Retaining ring
Braking drum
Brake shoe assembly
Parking
Left shoe clearance
pushing plate
self-adjusting plate
Selt-adjsuting plate
tightening spring Parking pushing plate
tightening spring Lower tightening
spring
Rear braking drum

rubber block
Compressing spring seat

Compressing spring
Lithium lubricating grease

Disassembly of the rear brake

1. Inspect the thickness of the brake pads
Disassemble the clearance inspection hole rubber
block, and observe the thickness of the friction disc
from the inspection hole. If it is less than the minimum
value, the braking collar and the trailing shoe assembly
should be replaced.
2. Disassemble the rear wheel
3. Drain the braking fluid
Notice: never make the braking fluid spray onto the
paint surface.
Braking System-29
4. Disassemble the rear braking drum

Remarks: if the rear braking drum is not easy to be
disassembled, please take the following steps:
Method I:
(a) Disassemble the rubber block of the adjusting
gear inspection hole, insert a flathead screwdriver
into the hole of the brake bottom plate, and drag
the adjusting piece out of the clearance adjusting
wheel.
(b) Use another flathead screwdriver to loosen the
braking collar and trailing shoe by toggling the
adjustment wheel, and form a tension force to the
rear braking drum.
Method II:
M6×40 (a) Screw two M6X40 (with screw thread length
greater than 25 mm) cross recessed screws, to
the two screw holes on the rear braking drum.
(b) Eject out the rear braking drum by screwing the
cross recessed screw with a cross recessed
screwdriver.
Remarks: screw the two screws tightly alternatively.
5. Disassemble the braking collar, the trailing shoe
assembly and the adjusting piece
Special tool (a) Disassemble the spring pressing cap of the
braking collar and the trailing shoe assembly, and
disassemble the pressing spring and the spring
pressing handle.
(b) Disassemble the braking collar and trailing

assembly from the brake bottom plate assembly,
disassemble the holding spring, and disassemble
the pulling cable connector.
Remarks: when disassembling the braking collar
and trailing assembly from the brake bottom plate
assembly, turn the entire adjustment wheel thread in to
the adjustment screw bolt, to decrease the pressure of
the braking collar and trailing shoe assembly from the
return spring.
(c) Disassemble the brake shoe adjustment tension

spring with a nipper plier, and take off the self
adjusting board.
Braking System-30
(d) Disassemble the two retaining ring with nipper

pliers, and take off the braking pulling arm.
(e) Disassemble the return spring from the braking

collar and trailing shoe assembly with pliers, and
separate the braking collar and the trailing shoe.
6. Disassemble the return spring and the ratchet

adjusting gear assembly
(a) Disassemble the clearance adjusting axis head.
(b) Disassemble the clearance adjusting wheel.
(c) Disassemble the return spring
7. Disassemble wheel braking sub pump

(a) Disassemble the brake pipeline with the 10 mm
open end spanner, and block the tube with clean
block plug.
(b) Disassemble the two bolts with the 8 mm open
end spanner, and remove the cylinder assemble.
8. Disassemble the following parts from the cylinder

assembly
(a) Two dust proof covers.
(b) Two piston assembly.
(c) One piston spring
(d) Air discharging screw.
(e) Air discharging screw cap
Braking System-31
Inspection and maintenance of brake

parts
1. Inspect the disassembled parts
Inspect whether the disassembled parts are abraded,
rusted or damaged.
2. Measure the inner diameter of the rear braking
drum
Standard inner diameter: Ф228.6 mm
Limit inner diameter: Ф230.6 mm
3. Measure the thickness of the friction disc

Standard thickness: 6.0 mm
If the thickness of the friction disc is less than the
minimum value or unevenly abraded, the braking collar
and trailing shoe assembly must be replaced.
Remarks: If the trailing shoes assembly is to be
replaced, all the rear braking collar and trailing shoe
assembly should also be replaced in order to keep
consistent brake performance.
Braking System-32
Assembly of rear brake
Notice: assemble the parts according with the direction shown in the figure
Front Front
Left wheel Right wheel
1. Assemble wheel cylinder pump

(a) Applying a small amount of lithium base lubricating
grease onto the two pistons.
(b) Assemble the wheel cylinder assembly
• Install two dust proof covers onto the two pistons.
• Install the piston spring and two piston parts onto
the wheel cylinder body.
Remarks: assemble correctly according to the direction
2. Assemble the vehicle wheel cylinder assembly

(a) Assemble the wheel cylinder assembling to the
brake bottom plate assembly with two bolts.
Tightening torque: 9.5N•m
(b) Connect the brake oil pipe to the wheel cylinder
assembly.
Tightening torque: 15N•m
3. Apply an appropriate amount of lubricating grease

onto the following parts
(a) Apply a small amount of grease onto the dummy
club which contacts the brake bottom plate
assembly and brake shoe.
Braking System-33
(b) Apply a small amount of lithium base lubricating

grease onto the braking collar and braking trailing
shoe assembly (see the arrowhead area indicated
in the figure).
Remarks: do not pollute the friction disc.
(c) Put the return spring into the adjustment screw,

and apply an appropriate amount of lithium base
lubricating grease onto the axle head of the thread
and screw, and the axle head of the adjustment
screw and the axle head of the clearance
adjusting axis.
4. Install the braking pulling arm to the braking

trailing shoe assembly
(a) Install the braking pulling arm, turn the tumbler,
and thread into the pin.
(b) Assemble a new split washer to the pin with a pair
of pliers.
5. Install the return spring and the ratchet wheel

adjustment unit assembly onto the braking collar
assembly and braking trailing shoe with the
braking pulling arm and the tumbler assembly
Hang one end of the return spring on the braking collar
shoe assembly, and hang the other end to the braking
trailing shoe with braking pulling arm assembly with a
pair of pliers.
6. Install the self adjusting plate onto the braking

collar shoe assembly
(a) Install the self adjusting plate onto the braking
collar shoe assembly.
(b) Install the brake shoe adjustment spring onto the
self adjusting piece and braking collar assembly
with sharp nose pliers.
Braking System-34
7. Install the brake pulling cable onto the braking

trailing shoe with braking pulling arm assembly
(a) Install the brake pulling cable onto the braking
trailing shoe with the braking pulling arm
assembly.
(b) Insert the shoe end of the braking trailing shoe
with braking pulling arm assembly and braking
collar shoe assembly into the wheel cylinder
assembly.
Remarks: do not stain the brake shoe liner with oil or
grease.
8. Install the holding spring
9. Install the braking collar, trailing shoe assembly to

the brake bottom plate assembly
(a) Thread the compressing spring through the brake
bottom plate assembly and the braking collar and
trailing shoe assembly.
Special tool (b) Press the compressing spring into the handle,
and put the cap in to lock the compressing spring
handle of the cap with the special tool.
10. Inspect the operation process of the automatic
adjustment unit
(a) In the direction shown in the figure, step on the
brake pedal up and down, inspect whether the
self adjusting screw can be turned. If not, please
inspect and find out which part of the rear brake
has problems.
(b) Adjust the length of the clearance adjusting unit,
and make it as short as possible.
(c) Install the rear braking drum.
(d) Step on the brake pedal to the bottom, until no
sound such as click can be heard.
11. Inspect the clearance between the brake friction
disc and the rear braking drum.
(a) Disassemble the rear braking drum.
(b) Measure the outer diameter of the braking drum and
the brake shoe friction disc, and inspect whether the
diameter difference is in the standard clearance range.
Single side clearance: 0.6 mm
If it is not correct, please inspect the parking braking
system.
12. Install the rear wheel
Tightening torque: 103N•m
13. Fill the liquid tank with braking fluid and drain all
the air from the braking system
14. Inspect whether the braking fluid leaks
Braking System-35
Rear support axle

Component diagram
◆ Rear braking
drum rubber block
Q32010
Left parking braking ◆Trailing arm axis assembly
pulling cable assembly
◆Trailing arm axis assembly

Rear twist beam assembly
Rear braking drum
Rear hub assembly

Right parking brake
pulling cable assembly
Left rear brake assembly
Bolt assembly
Rear hub assembly
Right rear brake assembly
Q32010
Rear braking drum
◆Rear braking drum rubber block
Inspection and disassembly of the rear

hub assembly
1. By turning the wheel by hands according to the
direction shown in the figure, inspect the axis
of the rear hub assembly to confirm whether it
has abnormal sound or whether the turning is
flexible. If the fault is found, please replace the hub
assembly
2. Disassemble the wheel
3. Screw the three wheel nuts diagonally onto the

wheel bolt with hands in order to fix the rear hub
drum
Remarks: screw the three nuts alternately, and screw
to the maximum value with hands.
Braking System-36
4. Measure the jumping amount of the outer end face

of the rear braking drum
Suck the dial indicator magnet on the rear hub bracket,
and put the cursor to the φ136 mm circle of the outer
end face of the rear braking drum; turning the rear
braking drum, measure the jumping amount, and the
maximum jumping amount allowed should be 0.11 mm.
Notice: when the jumping amount exceeds the
maximum allowed value 0.11 mm, the rear hub
assembly should be replaced.
5. Disassemble the rear braking drum

6. Measure the starting torque of the rear hub
assembly
(a) Turn the rear hub assembly to confirm whether it
has abnormal sound or looseness. If the above
problems are found, the rear hub assembly should
be replaced.
(b) Use a spring tension meter to inspect the pre-
loading.
Notice: pre-loading (when start): 1N•m. If the
preloading is greater than 1N•m, the rear hub need
to be replaced.
7. Measure the inner diameter of the rear braking
drum with caliber rule, if the result exceeds 230.6
mm, replace the braking drum
Disassemble the trailing arm axis sleeve

assembly
1. Inspect the trailing arm axis sleeve
(a) Inspect the vertical arm axis sleeve to confirm
whether it has distortion, moving, offcenter or
serious craze, and whether the seal is loosened.
(b) If it is not easy to determine whether the vertical

arm axis sleeve is damaged, take the following
measures: clean the rubble part position of the
vertical arm axis sleeve with clean water, wipe
up with cotton silk, and inspect the surface of the
rubble to confirm whether it has the above faults.
If the above fault is found, the vertical arm axis
sleeve should be replaced with a new one.
Braking System-37
2. Disassemble the trailing arm axis sleeve

(a) Mark a sign with white paint pen, and remember
the direction of the vertical arm axis sleeve.
(b) The vertical arm axis sleeve is a part which can
not be reused, if it is damaged, use a steel pries
to pry up the outer tube fringe of the vertical arm
axis sleeve first, in order to install the special tool.
(c) Use the special tool to block the installation tube

of the axis sleeve, screw up the two bolts, and
Special tool
screw the bolt with a spanner to push out the axis
sleeve.
3. Install the new vertical arm axis sleeve assembly

Special tool
Before pressing in the new vertical arm axis sleeve,
identify the assembling direction of the vertical arm axis
sleeve with nylon bush assembly first.
Steering System-
Steering System
Troubleshooting.............................................................................. 2
Inspection and maintenance of steering system......................... 4
Filling up of power steering fluid................................................... 9
Technical requirements.................................................................. 9
Steering System-
Troubleshooting
Fault Symptom Cause Remedy
Excessive 1.The clearance between the steering 1. A djust the clearance by professional
steering wheel gear and the gear rack is too large. staff, and when the clearance cannot be
free travel / adjusted, replace the steering gear.
abnormal sound 2.The steering linkage inner and outer 2.After the inspection and confirmation,
bulb pins are worn. replace the bulb pin according to the
request.
3. The steering universal joint is worn. 3. Replace the lower part of the steering column.
4.The connection between the steering 4.Retighten the connecting bolt according to
transmission shaft and the steering the regulated torque.
gear becomes loosened.
5. T he connection between the steering 5.Tighten the steering wheel locking nut;
wheel and the steering column becomes when the spline is damaged, replace the
loosened. steering wheel or steering column.
6.The steering gear installing bolt 6.Tighten the steering gear installing bolt.
becomes loosened.
7.The lower transmission shaft sliding 7. Replace the lower part of the steering column.
spline becomes worn and loosened.
Heavy steering 1.The tire pressure is insufficient. 1. Charge the tyre according to the regulated
air pressure.
2.The front wheel alignment angle is not 2. C orrectly inspect and adjust the front
correct. wheel alignment angle.
3.The clearance between the steering 3.Replace the steering gear or adjust the
gear pressed block is small. pressed block clearance by professional
4.The steering column cross bearing is staff.
damaged. 4. Replace the lower part of the steering column.
5.The steering linkage bulb pin lacks oil 5. Replace the steering linkage bulb.
or is damaged.
6.The supporting bearing of the front 6.Replace the front shock absorber upper
shock absorber is damaged. sub-connection subassembly (see the front
suspension maintenance part).
7.The lower swing arm bulb is damaged. 7.Replace the lower swing arm (see the front
suspension maintenance part).
8.The steering oil pump is damaged, 8. Replace the power steering oil pump.
causing insufficient output flow and
output pressure.
9.The power steering oil pump belt skids. 9. Adjust the belt tension.
10.The leakage inside the power steering 10. Replace the power steering gear.
gear is too much.
11.The power steering fluid contains air 11.Turn the steering wheel repeatedly at the
bubble and utters abnormal sound. fixed place to drain out the air bubble, and
after waiting for one hour, complement the
power steering fluid of regulated type.
12.The power steering fluid is insufficient. 12. C omplement the power steering fluid
of regulated type to the regulated scale
mark of the oil reservoir.
Steering System-
Fault Symptom Cause Remedy

Poor steering 1. The tire pressure is insufficient. 1.Charge the tyre according to the regulated
wheel return and 2.The wheel dynamic balancing caused air pressure.
poor stability by the factors, such as the wheel 2. Recalibrate the wheel dynamic balancing.
of straight- balancing block dropout, exceeds the
line running tolerance.
3.The lower swing arm rubber liner 3. Replace the lower swing arm.
becomes aged and the difference of
the stiffness on the left and right sides
is great.
4.The upper supporting bearing of 4. Fill lubricating grease of the regulated type.
the front shock absorber and the
lower swing arm bulb are lubricated
insufficiently.
5.The four-wheel alignment parameter is 5.Re-measure and adjust the four-wheel
not exact. alignment parameter.
6.The matching condition for the gear 6. Replace the steering gear.
and the rack of the steering gear is
deteriorated and the converse
resistance force increases.
7.The steering column bearing and the 7. Replace the steering column assembly.
cross bearing is damaged.
8.The oil supply of the power steering oil 8. Replace the power steering oil pump.
pump is insufficient.
9. The performance of the interior control 9. Replace the power steering gear.
valve of the steering gear degrades.
Steering System-
Inspection and maintenance of steering system

Structure introduction
The steering wheel has the safety airbag module, and the inspection and maintenance of the safety
airbag module should be operated by specialized staff. The upper part of the steering column adopts
steel sheet distortion energy absorption retractor mechanism, to protect the driver from colliding, the
lower section of the steering column adopts high precision sliding spline to efficiently eliminate the
mechanism interference caused by the vehicle body distortion, and the steering column angle can be
adjusted, to increase the driver’s adaptability and at the same time, the steering column has rational
reverse efficiency, to ensure that the driver has better road feel. The steering system is shown in the
following figure:
Steering oil reservoir

Steering column
Power steering oil pump Steering high

pressure oil pipe
Dust shield Steering wheel
Steering transmission shaft
Belt
Steering oil return pipe

Power steering gear
Disassembling and assembling of steering

column assembly
1. Operate the steering wheel to make the front
wheels keep running in a straight line, and during
the process of disassembling and assembling the
steering column assembly, the front wheels should
Inner hexagon be kept running in a straight line.
spline screw
2. Disassemble the two inner hexagon spline screws
to take off the safety airbag module.
Q32012(M12×1.25) 3. Disassemble the steering wheel.

(a) Screw out the steering wheel locking nuts Q32012
(M12×1.25) counterclockwise with the M18 socket
spanner.
(b) Hold the steering wheel and shake it around, and
pull out the steering wheel upward.
Steering System-
4. Disassemble the upper and lower decorative

covers of the combined switch.
Combined switch
upper decorative cover
Combined switch lower

decorative cover
5. Pull out the wiring harness of the left and

right combined switches and the ignition lock,
disassemble the left and right combined switches
and the ignition lock, and the condition after
finishing the disassembly is shown in the left
figure.
6. Screw out the bolts 3404201-V08 connecting the

steering column and the steering transmission
shaft counterclockwise with the M13 socket
spanner.
3404201-V08
7. Screw out the two flange bolts Q1840825FD and

one flange bolt Q1840850FD connecting the steer-
ing column and the instrument enforced beam
Q1840825FD counterclockwise with the M10 socket spanner,
and pull out the steering column assembly upward
along the column upper end axis.
Q1840850FD
Steering System-
8. Disassemble the three hexagon bolt and plain

washer subassemblies Q1400620FD installing the
reverse dust boot in the counterclockwise direction
with the M10 socket spanner.
9. Disassemble the hexagon bolt and plain washer
Q1400620FD subassemblies Q1400830FD connecting the
steering transmission shaft and the steering gear
with the M13 socket spanner, and pull out the
steering transmission shaft.
Notice: the upper and lower parts of the steering
transmission shaft cannot be disassembled
because of the two accurate cross shaft phase
relationship between the upper and lower parts of
Q1400830FD
the transmission shaft, so do pay attention when
disassembling.
The installation process of the steering column
assembly is inverse to the disassembly process, and
the steering column assembly should be installed
according to installing sequence of Step 2 through Step
9. The following points should be paid attention:
(a) W h e n i n s t a l l i n g t h e s t e e r i n g c o l u m n a n d
the steering transmission shaft, the steering
transmission shaft and the power steering gear,
the screw should align the arch groove when
inserted into the threaded hole, as shown in the
left figure.
(b) When installing the steering wheel, ensure that the
front wheels should be kept running in a straight
line, and keep the vehicle logo on the steering
wheel forward to ensure that the steering wheel
Arc groove
inner spline should align the steering shaft spline.
(c) Tighten all bolts and nuts according to the
regulated torque.
Disassembling and assembling of steering
pipeline
1. Disassemble the hollow bolt connecting the high-
pressure oil pipe and the power steering oil pump
Hollow bolt with the M22 socket spanner. When installing,
notice that the two sealing gaskets should be at
the both sides of the high-pressure oil ring, and the
tightening torque of the hollow bolts should be
(50±5) N•m
2. Disassemble the hexagon flange bolt Q32006
connecting the vehicle body and the low pressure
oil pipe with the M10 socket spanner.
Q32006
Steering System-
3. After disassembling the power steering gear and the

steering pipeline together with the auxiliary vehicle
frame from the complete vehicle, and disconnect the
nuts connecting the steering pipeline and the steering
gear high/low pressure oil outlets with the M18 socket
spanner, to finish the steering pipeline disassembly.
When installing, ensure that the O-shaped rings on the
two places should be in good condition, and that the
tightening torque of the bolts connecting the high /low
pressure pipelines and the steering gear low pressure
oil outlet should be (50±5) N•m and 44 N•m separately.
4. Loosen the clip Q673B21 with fish-lip pincers,
then disassemble the plastic clip BL1475B, and
disassemble the steering oil return pipe.
Notice: oil fluid sprinkle and leakage!
BL1475B
Q673B21
Disassembling and assembling of power

steering gear
3411101-V08 1. Screw out the flange bolts connecting the lower
Cotter pin part of the steering column and the power steering
gear pinion shaft the with M13 socket spanner, and
pull out the lower part of the steering column.
2. Disassemble the steering linkage bulb assembly.
Disassemble the cotter pin, and unscrew the hexagon
slotted type I nuts of 3411101-V08 (pitch distance 1.25)
with the M18 socket spanner.
3. Knock around the knuckle arm with a hammer
along the conical hole direction, until the matching
3411110-V08 between the linkage bulb and the knuckle arm is
loosened, and pull out the linkage bulb upward.
4. With the M14 socket spanner, unscrew the three
hexagon bolt gasket subassemblies of 3411110-V08
and a hexagon bolt gasket subassembly of
3411020-V08 3411020-V08 installing the steering gear onto the
auxiliary vehicle frame.
5. Disassemble and replace the steering linkage bulb

assembly.
Unscrew the tightening hexagon nut of Q32010 on
Q32010 the steering transversal linkage with two M18 open
spanner, and then disassemble the steering linkage
bulb assembly from the steering gear with the M12 and
M18 open spanners.
Steering System-
6. When the bulb of the steering linkage bulb

assembly becomes loosened, and the Dust boot
is damaged, replace the steering linkage bulb
Left steering bulb
assembly, and notice the differences of the left and
right parts, the left marked with “L” and the right
marked with “R”.
Right steering bulb
7. When installing the steering linkage bulb assembly,

tighten the hexagon nuts of Q32010 with the M18
open spanner slightly, and after finishing installing
Q32010
onto the complete vehicle and adjusting the toe-in,
tighten the nuts.
Disassembling and assembling of power

steering pump on the engine
Only after disassemble the high pressure connector
between the power steering pipeline and the steering
Adjusting bolt oil pump and the oil inlet hose, disassemble the power
steering oil pump.
1. Unscrew the flange hexagon bolts on the tensioning
wheel with the M14 open spanner, keep the oil
pump belt in loosened state, and then disassemble
the steering oil pump belt.
2. Unscrew the three hexagon fixed flange bolts of

Q1840840FD with the M13 socket, and after pulling
out the hexagon fixed flange bolts of Q1840840FD,
finish the assembly of the steering oil pump.
Q1840840FD
3. After installing the power steering oil pump and the

belt, adjust the steering oil pump belt tension.
Belt tension: (450±50) N•m
98N When exerting the force of 98N on the middle belt,
and the belt deflection is (4-6) mm.
Steering System-
Filling up of power steering fluid

Replace the power steering fluid in the following conditions:
1. After the new vehicle has run for 6000Km.
2. After replacing any assembly of the power steering gear, the power steering oil pump and the
steering pipeline.
3. When the vehicle runs for 6000Km after the power steering gear or the power steering oil
pump is replaced.
Notice:
1. The power steering fluid drained when replacing the power steering parts can’t be reused.
2. Only use the power steering fluid of ATF DEXRON III.
3. No matter when the level decline of the oil reservoir of the steering gear is found, inspect the
steering oil reservoir, the steering oil pump, the power steering gear and the steering pipeline,
together the sealing reliability of all the connecting parts. The filling the steering fluid needs
two persons to operate. Under the condition of closing the engine, one person fills the steering
oil fluid into the steering oil reservoir, the other turns the steering wheel (to the limit positions)
for more than 10 times, until the level of the steering oil fluid is between the marks MAX and
MIN, then start the engine, turn the steering wheel left and right to the limit positions (the stay
time at the limit position shouldn’t exceed five seconds), at this time, the steering fluid level
height may descend, and complement the steering fluid until the level is between the marks of
MAX and MIN.
Technical requirements
1. Apply thread sealant adhesive onto the installing bolts of the power steering gear assembly,
and the tightening torque should be (49±5) N•m.
The tightening torque of the nuts at the joint between the steering linkage and the linkage bulb
should be (74±7) N•m.
The tightening torque of the nuts at the joint of the linkage bulb pin and the steering knuckle
should be (49±5) N•m.
2. The tightening torque of the bolts at the joint of the steering column and the steering gear
assembly should be (36±4) N•m.
The tightening torque of the bolts at the joint of the steering column and the instrument panel
enforced beam should be (21±2) N•m.
The tightening torque of the nuts fixing the steering wheel on the upper end of the steering
column should be (50±5) N•m.
3. Centralized fixing of the steering wheel.
After taking off the steering wheel when the front
wheels is turned straightly forward without any change
to the steering rod, centralize and install the steering
wheel. The auxiliary plate of the steering wheel should
be centralized left/right, and the Great Wall logo on the
steering wheel should be at the front position of the
driver’s view, tightening the nuts.
4. Inspect the free clearance of the steering wheel.
Turn the vehicle to the centralized direction, stop the
engine, exert the force of 5N to turn the steering wheel
to the left along the circular direction, and stop when
the resistance is felt to increase; measure the angle
value of the steering wheel turned along the outer edge
as the free clearance, the standard value should be
less than 20 degree, and the turning angle to the left
and the right from the middle position should not be
more than 10 degree.
Vehicle Body Electrical System-
Vehicle Body Electrical System
Figure Reading Instruction............................................................. 2

Fuse Box.......................................................................................... 3
Complete Vehicle Groundinging Point Position........................... 5
Module Installation Position Figure............................................... 6
Low Configuration
Function figure of the wire harness intermediate connection
number leading foot (low configuration)....................................... 7
number lead foot.......................................................................... 8
Complete vehicle electrical circuit breakdown drawing................ 15
Advanced disposition
number leading foot (advanced configuration)............................. 25
Function figure of the wire harness intermediate
connection number lead foot........................................................ 26
Complete vehicle electrical circuit breakdown drawing................ 33
Figure Reading Instruction

1. 30a represents the power wire, which comes from the battery positive pole fuse box -- 60A.
2. 30a represents the power wire, which comes from the battery positive pole fuse box -- 80A.
3. 15a represents the power wire for connecting the electrical apparatus of small capacity, which
comes from the IG relay.
4. 15b represents the power wire for connecting the electrical apparatus of small capacity, and
when the ignition switch is located at “ON” position, the power will be directly supplied from
the ignition switch IG1 terminal.
5. X represents the power wire for connecting the electrical apparatus of small capacity, which
comes from the ACC relay.
6. Pluggable unit lead foot number takes the pluggable unit front end as the view direction, the
plug parts are numbered from the left to the right, and the socket parts are numbered from the
right to the left.
Boot view direction

Boot view direction
Pin number direction at Pin number direction at

anode end of plug cathode end of plug
7. Conducting wire color and sectional area (mm2)

B---Black Br---Brown G---Green Gr---Grey Bl---Blue Lg---Light green
Or---Orange P---Pink R---Red V---Violet W---White Y---Yellow
The color notation of the monocolor wire uses directly the letter in the above table, the first color
notation of the double color wire is main color, and the second is the auxiliary color. For example:
Monocolor wire: red, with the notation of R.
Double color wire: the main color is red, the auxiliary color is blue, and the notation is RBl.
0.5BrGr indicates the brown power wire with grey thin wire, and the sectional area is 0.5 mm2.
8. Illustration figure and definition of the complete vehicle Groundinging point position.
9. Position illustration figure of the complete vehicle electrical elements (the main controller).
10. This vehicle models are divided into three configurations such as the comfortable type, the
luxury type, and the elite type, and divided into two sets of different wire harness installation
(low configuration and advanced configuration).
Great Wall COWRY luxury type is added with the functions of the car reversing radar, the anti-pinch
glass lifter, the GPS, the headlight adjustment comparative with the comfort type. The elite type is
added with the reversing image, the vehicle Bluetooth telephone system, without the reversing radar
system comparative with the luxury type. But there are only two configurations on the wire harness,
the low configuration is without any of the above functions, the advanced configuration wire harness
has all the functions of the luxury type and the elite type, and the function of the skylight and the
revering image can be optionally installed.
Fuse Box
Driving Cab (No. 1) Fuse Box
Fusing
No. Name
Horn Relay Small Lamp Relay

Current
J1 Horn Relay
Horn
J2 Small Lamp Relay
Reserved J3 Flash Lamp Relay
J4 Blower High-speed Relay
Front Fog Lamp Relay Rear Fog Lamp Relay

J5 Rear Air-conditioner Relay
Reserved
Small Lamp
J6 Door Window Relay
J7 Blower Relay
J8 Front Fog Lamp Relay
Reserved J9 Rear Fog Lamp Relay
Flash Lamp Relay
Combined Instrument J10 Compressor Relay
J11 ACC Relay
Inner Lighting J12 IG Relay
Danger J13 Rear Wiper Relay
Central Control Lock Warning
J14 Defogging Relay
F01 Horn 15A
Braking Lamp F02 Reserved
Blower High-speed Relay
Steering F03 Small Lamp 10A

CD Player Lamp
F04 AM1 15A
Compressor Relay ACC Relay
F05 Reserved
Front Skylight
F06 Danger Warning 15A
F07 Steering Lamp 10A
Rear Skylight
F08 Front Fog Lamp 15A
Rear Air-conditioner Relay Door Window Relay
Reserved F09 Rear Fog Lamp 10A

Rear Air-conditioner
F10 Compressor 10A

Cigarette Lighter F11 Rear Rain Wiper 10A
F12 Defogging 20A
Rear View Mirror F13 Combined Instrument 10A
IG Relay
F14 Inner Lighting 10A

Front Rain Wiper F15 Central Control Lock 20A
F16 Braking Lamp 10A
Door Window Reserved
Charging F17 CD Player 15A

Rear Wiper Relay
F18 Front Skylight 15A

F19 Rear Skylight 15A
F20 Reserved
Safety Airbag F21 Cigarette Lighter 25A
F22 Rear View Mirror 15A
Seat Heating
F23 Front Rain Wiper 15A
Blower Relay
Defogging Relay
F24 Charging 10A

Blower
Reversing Lamp F25 ABS 10A

F26 Safety Airbag 15A
F27 Seat Heating 20A
F28 Reversing Lamp 10A
S/B1 Rear Air-conditioner 30A
A/B2 Door Window 30A
S/B3 Reserved
S/B4 Blower 40A
S/B5 Reserved
Front Engine Room (No. 2)
Fan Relay 1 Fan Relay 2 Fan Relay 3
Deteching tool
Reserved Reserved Reserved
Fuel Pump Reserved Reserved
Starting Relay
High Beam Relay Dim Light Relay Fuel Pump Relay

Main Relay High Beam Dim Light
Reserved
Main Relay
Reserved
Engine Wire harness
No. Name Fusing Current(A) No. Name Fusing Current(A)

J1 Fan Relay 1 F33 Reserved
J2 Fan Relay 2 F34 Fan 3 30
J3 Fan Relay 3 F35 Reserved
J4 Starting Relay F36 High Beam 15
J5 Main Relay F37 Dim Light 15
J6 Reserved F38 EFI 10
J7 High Beam Relay F39 ABS 25
J8 Dim Light Relay F40 Reserved
J9 Fuel Pump Relay F41 AM2 7.5
F29 Starter 30 F42 Reserved 25
F30 Main Relay 15 F43 Reserved 15
F31 Fuel Pump 15 F44 Reserved 10
F32 Fan 1 30
Complete Vehicle Groundinging Point Position
No. Groundinging Position Remarks

G01 Inside the Right Side Wing Panel ABS Grounding
G02 Inside the Right Side Wing Panel Engine Room Wire Harness
G03 Transmission Casing Engine Wire Harness
G04 Front Cross Beam Left Front Headlight Bracket Battery Grounding
G05 Lower Side of Right Column A Wire Harness Fixer Instrument Panel Wire Harness
G06 On Instrument Panel Reinforced Instrument Panel Wire Harness
G07 Right Sliding Door Right Sliding Door
G08 Right Side Wall Right Side Vehicle Body Wire Harness
G09 Near Rear Wiper Motor Back Door Wire Harness Assembly 2
G10 Left Side Wall Left Side Vehicle Body Wire Harness
G11 Left Sliding Door Left Back Door Wire Harness
G12 Lower Side of Left Column A Wire Harness Fixer Instrument Panel Wire Harness
G13 Transmission Casing Battery Grounding
G14 G15 At Radiator Left Side Longitudinal Beam Engine Room Wire Harness
Module Installation Position Figure

M05 M06
M04
M07
M03 M09
M02
M01
M08
M10
M01 Engine Room Fuse Box M02 Anti-theft ECU

M03 Central Control Box M04 Safety Airbag ECU
M05 Car telephone ECU M06 Engine ECU
M07 Cab Fuse Box M08 Reversing Radar ECU (advanced configuration )
M09 GPS Controller (advanced configuration ) M10 Reversing Image ECU (advanced configuration )
Vehicle Body Electrical System(low configuration)-
Function Figure of The Wire Harness Intermediate Connection

Number Leading Foot (Low Configuration)
分两页布置
Function figure of the wire harness intermediate connection number lead foot
Connecor 1
C01
Connected to engine compartment Connected to instrument

wiring harness No.1 panel wiring harness No.1
C02

C03
Connected to instrument Connected to roof

panel wiring harness wiring harness
C04
Connected to engine compartment Connected to cab fuse block

wiring harness
Connecor 2
C05
Connected to cab fuse block A-20 Connected to instrument

panel wiring harness
C06
Connected to cab fuse block B-18 Connected to instrument

C07
Connected to cab fuse block C-14 Connected to instrument

C08
Connected to cab fuse block D-16 Connected to instrument

Vehicle Body Electrical System(low configuration)-10
Connecor 3
C09
Cab fuse block E-8 Connected to instrument

C10 C11
Connected to cab Connected to instrument Connected to cab Connected to instrument

fuse block F-2 panel wiring harness fuse block H-1 panel wiring harness
C12
Connected to instrument Connected to engine wiring harness

C13
Connected to engine wiring harness 3 Connected to instrument

panel wiring harness 3
Connecor 4
C14
Connected to instrument Connected to (front door

panel wiring harness 1 wiring harness No.1, LH)
C15

panel wiring harness 2 wiring harness No.2, LH)
C16
Connected to instrument Connected to Harness,

panel wiring harness 1 body wiring, No.1LH
C17
Instrument panel wiring harness 2 Harness, body wiring, No.2 LH

Connecor 5
C19
Connected to instrument Connected to air condi-

panel wiring harness 2 tioner wiring harness No.2
C20
Connected to air condi- Connected to instrument

tioner wiring harness No.1 panel wiring harness 1
C21

panel wiring harness 1 body wiring, No.1 RH
C22

panel wiring harness 2 body wiring, No.2 RH
Connecor 6
C23

panel wiring harness wiring harness, RH)
C24
Connected to Harness, body wiring, LH Connected to (rear sliding

door wiring harness, LH)
C25
Connected to Harness, body wiring, RH Connected to (rear sliding

door wiring harness, RH)
C27
Connected to Harness, body wiring, LH Connected to tail door wiring harness

Connecor 7
C28
Connected to tail door wir- Harness assembly,

ing harness assembly No.1 tail door wiring, No.2
C29
Connected to No.2 fuse block Connected to engine wiring harness

Complete vehicle e lectrical circuit breakdown drawing

Power Supply
Anode, battery QZ22

Switch, ignition, Switch, ignition, Regulator, generator CT19
No.1 YZ16 No.2 YZ27
Washer & Sunroof circuit
Motor,front Motor, rear wiper MZ7 Motor, front Motor, rear Switch, combination, Spring assembly, clock, No.1 Horn, high tone
wiper QZ4 washer QZ10 washer QZ11 RH (for wiper) YZ17 (driver air bag horn) YZ22 electric QZ12
Horn, low tone
electric QZ13
ABS & Airbag
ABS ECU Tensioner, seat Bag, front passenger

belt, LH CZ32 Tensioner, seat air YZ26
belt, RH CZ30
Switch, driver
seat belt CZ28
Sensor, front wheel Sensor, front wheel Sensor, rear wheel Sensor, rear wheel Spring assembly, clock, No.1
speed, RH QZ18 speed, LH QZ17 speed, LH CT35 speed, RH CT9 (driver air bag horn) YZ22
ECU, air bag YZ11

Combined Instrument
Instrument A, combination, LH YZ23 Pump, fuel CY34
Instrument B, Sensor, coolant Sensor, vehicle Switch, instrument

combination, RH YZ8 temperature CT12 speed CT17 brightness adjusting YZ4
Switch, combination, Switch, brake Switch, driver Switch, oil Switch, brake
LH (for headlamp) YZ20 fluid level Q23 seat belt CZ28 pressure CT18 lamp YZ20
Switch, parking
brake CZ53
Air Conditioner circuit
Sensor, evaporator
temperature KZ6 Control,air conditioner B YZ14 Control,air conditioner A YZ15
Motor, inner-outer circulation KZ4 Motor, temperature damper KZ1 Motor, mode damper KZ7
Switch, air conditioner pressure QZ26 Blower,

front KZ2
Sensor, indoor Module, governor KZ3 Sensor, outdoor
temperature YZ6 temperature QZ9
Acoustics & Power Rear-view Mirror
CD/DVD & on- Speaker, front Speaker, front Speaker,rear Speaker,rear Speaker, front
board phone door,LH MZ4 door,RH MZ4 LH CZ37 RH CZ13 high tone, RH
Speaker, front Mirror, power Mirror, power Switch, power exterior Antenna, radio &
high tone, LH rear view, LH rear view, RH rear view mirror cassette player YT32
Glass Regulator circuit
Motor, front door

glass regulator, LH
Motor, front door

glass regulator, RH
Motor, rear door

UP UP UP glass regulator, LH
UP DOWN DOWN DOWN
DOWN
Switch, front door Switch, front door Switch, rear sliding door Switch, rear sliding door Motor, rear door
glass regulator, LH glass regulator, RH glass regulator, LH glass regulator, RH glass regulator, RH
Central Door Locking Controllor
Lock, front Lock, front ECU, central door

door,LH MZ6 door,RH MZ6 locking YZ1
Motor, rear door Motor, rear sliding Switch, ignition,No.2

lock,RH MZ4 door lock,LH MZ4 YZ27
Illumination & Signal System

分两页布置
分两页布置
Engine Electronic Control System
Vehicle Body Electrical System(Advanced Configuration)－25

number leading foot (Advanced Configuration)
分两页布置
Function figure of the wire harness intermediate connection number lead foot
Connecor 1
C01

C02

C03
Connected to instrument Connected to roof wiring harness

C04
Connected to engine Connected to

compartment wiring harness cab fuse block
Connecor 2
C05
Connected to cab fuse block A-20 Connected to instrument

C06
Connected to cab fuse block B-18 Connected to instrument

C07
Connected to cab fuse block C-14 Connected to instrument

C08
Connected to cab fuse block D-16 Connected to instrument

Connecor 3
C09
Connected to cab fuse block E-8 Connected to instrument

C10 C11
Connected to cab Connected to Connected to cab Connected to

fuse block F-2 instrument fuse block H-1 instrument
panel wiring panel wiring
harness harness
C12
Connected to engine Connected to instrument

wiring harness panel wiring harness
C13
Connected to instrument Connected to engine compartment

panel wiring harness No.3 wiring harness No.3
Connecor 4
C14

panel wiring harness, No.1 wiring harness No.1, LH)
C15

C16
Connected to instrument Connected to (body

C17
Instrument panel wiring Harness, body wiring, No.2 LH

harness No.2
Connecor 5
C18
123 123
Line,web Line,web
124 124
wire, core wire, core
Connected to (body Connected to instrument

wiring harness, LH) panel wiring harness
C19
Connected to instrument Connected to air conditioner

panel wiring harness , No.2 wiring harness No.2
C20
Connected to air conditioner Connected to instrument

wiring harness No.1 panel wiring harness , No.1
C21
Connected to instrument Connected to (body

panel wiring harness , No.1 wiring harness No.1, RH)
Connecor 6
C22
Connected to instrument Connected to (door wiring

panel wiring harness , No.2 harness No.2, RH)
C23

panel wiring harness wiring harness, RH)
C24
Connected to (rear sliding Connected to (body

door wiring harness, LH) wiring harness, LH)
C25
Connected to (body Connected to (rear sliding

wiring harness, RH) door wiring harness, RH)
Connecor 7
C26
121
Line,web
122
wire, core
Connected to (body Connected to tail door

wiring harness, LH) wiring harness
C27
Connected to (body Connected to tail door

wiring harness, LH) wiring harness
C28
Connected to tail door wiring Harness assembly, tail

harness assembly No.1 door wiring, No.2
C29
Connected to No.2 fuse block Connected to engine wiring harness

Complete vehicle electrical circuit breakdown drawing

Power Supply
Anode, battery QZ22

Switch, ignition, Switch, ignition, Regulator, generator CT19
No.1 YZ16 No.2 YZ27
AM1 IG1 ACC
Washer & Sunroof Circuit
Horn, high tone

electric QZ12
Horn, low tone

electric QZ13
Motor, rear wiper MZ7
ECU, rear sunroof

ECU,front sunroof
Motor,front Switch, combination, Switch, rear sunroof Spring assembly, clock, No.1 Switch, front sunroof
wiper QZ4 RH (for wiper) YZ17 (driver air bag horn) YZ22
Motor, front Motor, rear

washer QZ10 washer QZ11
Abs & Air Bag
ABS ECU Tensioner, seat Tensioner, seat Bag, front

belt, LH CZ32 belt, RH CZ30 passenger air YZ26
Switch, driver
seat belt CZ38
Sensor, front wheel Sensor, front wheel Sensor, rear wheel Sensor, rear wheel Spring assembly, clock, No.1
speed, RH QZ18 speed, LH QZ17 speed, LH CT35 speed, RH CT9 (driver air bag horn) YZ22
ECU, air bag YZ11

Combined Instrument
Instrument A, combination, LH YZ23 Pump, fuel CY34
Instrument B, Sensor, coolant Sensor, vehicle Switch, instrument

combination, RH YZ8 temperature CT12 speed CT17 brightness adjusting YZ4
Switch, combination, Switch, brake Switch, driver Switch, oil Switch, brake
LH (for headlamp) YZ20 fluid level Q23 seat belt CZ28 pressure CT18 lamp YZ20
Switch, parking
brake CZ53
Air Conditioner Circuit
Sensor, evaporator
temperature KZ6 Control,air conditioner B YZ14 Control,air conditioner A YZ15
Motor, inner-outer circulation KZ4 Motor, temperature damper KZ1 Motor, mode damper KZ7
Switch, air conditioner pressure QZ26 Blower,

front KZ2
Sensor, indoor Module, governor KZ3 Sensor, outdoor
temperature YZ6 temperature QZ9
Back-up Radar Mirror, Power Rear View
Lamp, rear Lamp, rear Mirror, power rear Mirror, power

combination,RH CZ15 combination,LH CZ38 view, LH MT3 rear view,RH MZ7
Screen, back-up radar display CZ5 Switch, power exterior rear view mirror YZ3 Switch, reversing CT16
Detector,LH CT1 Detector, middle CT2 Detector,RH CT3 ECU, back-up radar CZ47
Acoustics Gps Back-up Video
B09 B11 B10 A10 A07 A06
B06 B05 B08 B07 B02 B01 B04 B03 A14 A08 A13 B12
Connected to GPS ECU Speaker, front Speaker, front Speaker,rear Speaker,rear Speaker, front Speaker, front Microphone Antenna, radio &
door,LH MZ4 door,RH MZ4 LH CZ37 RH CZ13 high tone, LH high tone, RH CZ6 cassette player YT32
CD/DVD & on-board phone
Spring assembly, clock, Phone A,on-board YZ24 Phone B,on-board YZ25 Connected to Connected to back-up video ECU
No.3 (on-board phone) CMOS assembly
Central Door Locking & Door Glass Regulator Circuit
分两页布置
Illumination & Signal System
分两页布置
分两页布置
System, Engine Electronic Control
Electrical Accessories-
Electrical Accessories
On-board Telephone........................................................................ 2
Electric Window............................................................................... 6
Reversing Radar.............................................................................. 9
Vehicle Reversing Radar Imaging System.................................... 12
Central Lock..................................................................................... 14
CD Player......................................................................................... 17
DVD Player....................................................................................... 19
On-board Navigation GPS.............................................................. 21
On-board Telephone
Structural Drawing
Vehicle Power Power Main chip

Conversion Control Button
power and Bluetooth Bluetooth
Module Circuit Decoding
Upgrading Interface Controller
Circuit
Resetting
circuit
Main Control
Chip MCU
Bluetooth
Mute Bluetooth Mobile
DVD Control Module Phone
Memory
Circuit
Voice DSP Acoustic

Audio Output
Feedback Echo Processing
Control Circuit
Circuit Module
Left and Preposition

Right Power Audio Output Microphone
amplifier Biasing Microphone
Loudspeaker Amplification Switch Circuit Circuit Circuit
Precautions
1. Please ensure that the on-board telephone system installation position should be dry and kept
away from the objects containing erosive substance such as rain, humidity and all kinds of
fluid or moisture.
2. Please don’t disassemble the on-board telephone system, and disassembly by non-
professional staff may damage the on-board telephone system.
3. If the problem can’t be solved, send to professional staff for maintenance service.
Troubleshooting
Serial Fault Symptoms Troubleshooting Method
Number
Start the vehicle and the on-board Confirm whether the wiring is installed correctly or
1
telephone has no starting sound. whether the connector is damaged
The on-board telephone can be started After shutting off the mobile phone, and restart
2 normally, but after entering the pairing the pairing of the mobile phone and the on-board
mode, the mobile phone can’t match. telephone.
After accomplishing the pairing, the Confirm whether the microphone is fixed correctly
3
receiver can’t hear when calling. with the on-board telephone.
Using the on-board telephone system
not in accordance with the standard Please hold the on-board telephone button to reset
4
operating method results in abnormal the system.
system.
Steering Wheel Button

Hang Up key
1. In the event of calling, press the button for one
time, indicating call rejection.
2. During the call, press the button for one time,
indicating the call termination.
Hang On key
1. In the event of calling, press the button for one
time, indicating call answer.
2. During the call, press the button, the voice can
switch between blue tooth handset and hands free.
3. During the call, continue pressing the button for
3sec, microphone turns into silent mode, and press
the button for another 3sec, silent mode cancelled.
Volume Up key
1. During the call, press the button to increase the
horn output volume (Grade 1-5)
Volume Down key
1. During the call, press the button to decrease the
horn output volume (Grade 1-5)
Bluetooth key
1. Hold the Bluetooth button for 3s to enter the
pairing mode.
2. In the pairing mode, press the Bluetooth button
singly once to exit the pairing mode.
3. If the phone has performed the pairing but is off
line, press the Bluetooth button once to search the
paired mobile phone.
4. During the connection of the Bluetooth with the
mobile phone, hold for 3s to get off line.
5. Hold for 5s to reset the on-board telephone system.
Relative Function Descriptions
1. Car telephone’s basic functions:
All-round wireless transmission, enables you to say
freely.
2. Steering wheel rapid button function
It is safe and convenient to operate the Bluetooth
hand-free system through the rapid button to exert the
Bluetooth hand-free system thoroughly.
3. Pairing number of the hand-free mobile phones
The car telephone blue tooth system can record four
handsets, with working mode First In, First Out.
4. Automatic connection function
When vehicle is started, the Bluetooth hand-free will
attentively and automatically connect the Bluetooth
mobile phone with Bluetooth system on the vehicle in
series.
5. Sound MUTE
When dialing number, or there is a coming call or voice
reminder, the sound will automatically enter mute to
let the driver know what statement it enters, and the
communication cannot be overlapped with music.

6. Voice quality treatment
Use the up to date audio DSP IC to suppress the noise
and echo in calling, in order to assure your calling
quality.
7. Speech volume adjustment
Use the fast-dial key to adjust the volume to your
favorite
Vehicle Telephone Controller Connector Parts Definition
JS091-12M JS091-14M
1 6 1 7
7 12 8 14
JS091-12M JS091-14M
JSO92—12M
Item Pin Number Pin Name Pin Function Description
1 FRI+ Right front loudspeaker audio input is positive
2 FRI- Right front loudspeaker audio input is negative
3 FRO+ Right front loudspeaker audio output is positive
4 FRO- Right front loudspeaker audio output is negative
Vehicle 5 FLI+ Left front loudspeaker audio input is positive
Sound
6 FLI- Left front loudspeaker audio input is negative
7 FLO+ Left front loudspeaker audio output is positive
8 FLO- Left front loudspeaker audio output is negative
9 MUTE Vehicle acoustics is mute
10 B+ Power positive pole
Vehicle 11 ACC Accessories switch
Power
12 GND Power grounding
JSO92—14M
Item Pin Number Pin Name Pin Function Description
1 MIC+ Microphone input is positive
Microphone
2 MIC- Microphone input is negative
8 VCC 5V power
Steering 10 RED Red Light Signal Cable
Wheel
Switch 13 SW IN Steering wheel switch signal input
14 GND Power grounding
Electric Window
Electric window lifter of Jiayu is composed of motor and module which has such functions as
anti-clip, centralized control rise, soft stop and has features of convenient control and long
service life.
Electric Window Lifter Function
1. Anti-clip Function
When performing the manual and automatic lifting after the electric window lifter is initialized, the anti-
clip function will work, and the anti-clip times are not limited. The anti-clip function will work within the
range of (200~370) mm ,4 mm under the lower sealing strip of the vehicle door window.
4mm
Max.370mm
Min.200mm
The anti-clip force of lifting the glass is less than 100 N under the circumstance of room temperature
of (25+5)- ℃, 150mΩ line-to-line resistance and 14.5V operating voltage. When the glass is lifted
manually or automatically, once meeting the counteract effect more than the anti-clip force, the glass
lifting would stop at once, and the motor will reverse with the reversing distance of about 125mm.
2. Centralized control lifting
The central lock controller provides a low level signal to the four door regulators, and the electric
windows will be closed until they reach the completely closed position. The central lock controller will
make the two window lifting motors start in separate time to avoid the peak current of simultaneous
startup. As long as the centralized control lifting pin obtains the low level signal, the motor will make
the widow closed until the window is completely closed (or until the pin signal changes into high level
position).
3. Soft Stop Function
In order to prevent the motor from impacting on decreasing the service life of window lifting machine,
the soft stop function is needed, and when lifting or descending manually and automatically, the soft
stop function would work.
(a) Soft Close Function
When the glass rises closely to the top, that is, the rising soft stop point, the motor power will be
cut off to make the motor stop working, and at the same time, make the glass rise to the top by
inertia. The rising soft stop point is located about 2 mm under the limit superior position.
(b) When the glass descends closely to the bottom, that is, the descending soft stop point, the motor
power will be cut off to make the motor stop working, and at the same time, make glass descend
to the bottom by inertia. The descending soft stop point is located about 12mm above the limit
inferior position.
(c) Zero position adjustment: the system adopts the upper limit position as the zero position. In
order to ensure the system more reliable and secure work, the zero position should be calibrated
continuously.
Manual calibration: when the glass stops at the rising soft stop position after the glass rises,
press the rise button to make the glass rise to the upper limit position again, and the zero
calibration operation is finished.

Automatic calibration: when the motor runs in the positive and reverse directions for more
than 20 times, the zero position will be calibrated once. That is to say, when completely
performing the starting or shutting operation, the motor will lock once. The soft closing and
shutting function fails at this time. When the glass is completely closed to the upper limit
position, the zero calibration operation is automatically performed.
4. Motor locking protection
When the motor is locked in 250ms, the Controlling Module will cut off the motor power to make motor
stop operating.
5. Motor temperature protection
After the Controlling Module is connected with the power, the motor initially set temperature is 40
degrees.
Motor heat protection function has two temperature limited values. When motor wire temperature is
more than the first temperature limited value (170 degree), the motor has no reaction for all new input
operation, but still accomplish present action. When temperature is more than the first temperature
limited value in motor operation, the motor will operate continuously until motor wire temperature up
to the second temperature limited value (190 degree). The motor operating reversely is not limited by
the second temperature limited value to ensure user’s safety. Once motor temperature reduced below
temperature limited value, the motor operates normally.
6. Self-Diagnosis Protection Function
In order to ensure the system reliability and improve the system mean time between failures, some
self-diagnosis protection measures are adopted: if the power voltage is more than (16V±0.5)V, the
Controlling Module will close the automatic rise function.
(a) Switch contact conglutination:
After inspecting that there has ten seconds’ conglutination, the switch contact doesn’t receive the
input instruction; if inspecting that the switch contact is disconnected again, return back to the
normal function.
(b) Relay contact conglutination:
The window lifting motor is controlled by two-contact relays.
After sending the cutting order, if the system inspects that the relay is still powered on, the
system judges that the relay contact is conglutinated. So, the system sends order to connect
another relay that ensures to cut off the motor power. When sending any new input order, the
software firstly inspects whether conglutinating relay contact releases. If released, all including
sleep mode operation can be operated again. If the contact is still conglutinated, only operation
in one direction is possible (depending on the corresponding relay contact direction where the
conglutination occurs). Later, activate the relay contact conglutination management function
again.
(c) Motor Protection for Hall Component Failure or Magnetic Ring Damage:
If the Hall components or magnetic ring fail, the Controlling Module can not receive the Hall
component signal. The Controlling Module will return back to the state before the basic
initialization, i.e. when lifted, it would rise about 45 mm. At the same time, it doesn’t have anti-clip
function. Never operate the reinitialization in centralized control rising process. Once any switch
is activated, the window will stop operating.
Maintenance Precautions
1. Initialization
Consider the closed connection between the system operating stability, reliability and the specific
vehicle’s door board and the sealing strip state, so that it is required to perform the initialization
process on specific vehicle assembly line. Later, after releasing the switch, press the rising button
continuously. The glass rising is not more than 45 mm.; Then wait for releasing the power switch and
holding the ascending button sustained, the most rose by only 45 mm, the process accomplishes
initialization basically until the glass is locked. After that, the system has all functions except
descending the soft stop function. The anti-clip function in basic initialization process doesn’t work.
Before accomplishing the basic initialization process, the automatic descending function still works.
2. Reinitialization implementation process as following
(a) Only when accomplishing the following events, the function could be carried out.
• Manually adjust the zero position function automatically.
• The vehicle window stays at the mechanical dead point: zero position.
(b) Loosen the button in two seconds when adjusting the zero position (after the motor is locked),
and then press the button again and keep for at least 20 seconds.
(c) After more than 20 seconds, the window automatically descends about 46mm to show the
characteristic curve and that the zero position is deleted.
(d) After deleted, the electric window only has manual function.
(e) Restart the initialization.
Reversing Radar
Reversing Radar Operating Principle (Ultrasonic Distance Measurement
Principle)
Sound is a kind of wave. Generally, the sound frequency range that people can hear is 20 HZ-20 KHZ.
The sound frequency range more than 20 KHZ is called ultrasonic. Now that ultrasonic is also a kind
of sound, the spreading speed in the air also equals the velocity of sound (340 m/s). When ultrasonic
meets an obstacle, a part of it will be reflected back. So the obstacle distance can be calculated by
calculating the time difference of transmitting the sound wave and receiving the sound wave.
System Composition and Wiring Diagram
1. System Composition
The system is composed of the reversing radar mainframe (ECU, including buzzer), three sensors
and a rear view mirror display.
2. System Connection Schematic Diagram
CLK
GN
DATA
MIRROR
ECU
SEN-M
SEN-L
SEN-R
GND
GND
GND
SENSOR SENSOR SENSOR

Electrical Accessories-10
Pin definition
Reversing mainframe Sensor
foot
1 2
position
Function GND SEN
HV16HW
Function Description and Display Scheme

1. Shift into the reversing gear to enter the self-check state.
(a) The system is self-checked normal and the buzzer doesn’t warn.
(b) If a group of sensors or many sensors are damaged, the buzzer utters twice.
2. After the self-check, enter the normal detection mode. The relationship between the obstacle
distance and the alarm sound frequency is as the following.
Area A (Long alert) B (8Hz tact sound) C (4Hz tact sound)
40±5 100±5 150±5

Unit：cm
(a) District A: the alarm sound frequency is long, the display shows (STOP), the three corresponding
LED lamps (red, yellow and green) are on and flickering continuously.
(b) District B: the alarm sound with the frequency of 8 Hz is the intermittent sound, the display shows
the distance (100, 95… 45, 40), and the two LED lamps of each corresponding direction (yellow
and green) are on.
(c) District C: the alarm sound frequency is 4 Hz intermittent sound, the display shows the distance
(150, 145… 105, 100), and the one LED lamp of the corresponding direction (green) is on.
Display Displaying Scheme

Direction Notice: the rear view mirror display has LED
displaying area composed of green, yellow and red fragments
(Amber) which indicate whether the SENSOR detects
display Distance obstacles. The LED composed of three fragments
displaying area separately indicates the detected distance range
Red for right, middle, right SENSOR of reversing radar.
Yellow The amber color displays the reversing state. The
Green digital tube displays the latest distance of the
obstacle that the sensor detects.
Precautions
1. Because of the physical properties, the position, the angle, the size, the material or the
background complex sites of the object will result in narrow detection range and produce no
action or misunderstanding action, but this is not the abnormal condition for the system.
2. Especially when reversing on upgrade or downgrade, the wrong alarm may be uttered.
3. It’s easy to cause no detection or bad detection state in the following sites or obstacles.
(a) Small objects such as wire netting, thin rope, etc.

(b) Driving in grass or on bumpy road.
(c) Snow, cotton materials or material easy to absorb sound wave.
(d) The sensor surface is stuck with foreign matter.
(e) Interference from ultrasonic cacophony, metallic sound and high pressure gas ventilation sound,
etc. of the same frequency.
(f) The obstacle is the reflector with acute angle and conical objects.
Technical Parameter
1. Rated Operating Voltage DC 12V
2. Operating Voltage Range DC (9.6～16)V
3. Operating Temperature Range (-30～80)℃
4. Storage Temperature Range (-40～85)℃
5. Consumption Power <2W
6. Detection Segment Number Three segments; (150-100-40) cm
7. Maximum Detection Distance (150±5) cm
8. Effective Distance (15±5)～(150±5)cm
9. Detection Method Ultrasonic wave
Vehicle Reversing Radar Imaging System

Product Principle
The vehicle reversing radar imaging system completely displays the camera video installed at the rear
of the vehicle through on-board display, and overlaps the radiation pattern on the video OSD.
Structure Sketch
Image
Camera
Controlling
Module DVD Display
Gear R
Pin Definition
OSD controller
Display
OSD video OSD video

Gear R
OSD video masking
OSD Video
Shield
Camera
Power
Camera
Video
Power Camera power
Camera
Grounding Shield Camera video
Camera masking
Camera power
ground
Camera interface
Function Description
1. Rear View Image Display
When using the reversing gear, the camera installed on rear bumper begins to work to send rear view
to display screen. The driver can observe obstacle after vehicle through DVD display. As shown in the
following figure:
The distance apart from The distance apart from The distance apart from
the obstacle is 3 m. the obstacle is 2 m. the obstacle is 1 m.
Notice: the two cambers on the screen represents that in the two sides of the vehicle body’s
area extending backwards, i.e., the objects outside the two lines are safe.
2. The view will be displayed first when the vehicle is reversed.

When the DVD player is playing other programs, if reversing the vehicle, the active play will be
automatically intermitted and shifted to the reversing rear view image display.
Precautions during the Use
1. When the camera surface is stained with dust or other foreign matter, which will influence the
video effect, and the user should clean in time.
2. Don’t spray the camera directly with high pressure squirt gun.
3. When reversing at night, if there has no lamp and it is dark, the reversing video may have
snow dot because of the insufficient illumination.
4. Camera view angle limit: the area close to the two sides of the rear spoiler is the camera’s
blind zone in which the image cannot be observed.
Technical Specification
Operating Voltage (9～16)V
Current Consumption ≤90mA
Operating Temperature Range (-30～80)℃
Mainframe Storage Temperature Range (-40～85)℃
Signal Amplitude (1.0±20%)Vpp
TV System NTSC
Rated Voltage 12V
Operating Voltage (9～16)V DC
Current Consumption 100mA/MAX
Operating Temperature Range (-30～80)℃
Storage Temperature Range (-40～85)℃
Image Pixel 300,000 pixels (color image)
Signal Amplitude (1.0±20%)Vpp
Camera TV System NTSC

Video Output Amplitude 1.0Vpp/75Ω
Video Range V：(88±5)°

H: (115±5)°
Minimum Illumination under 1.51ux
Color Carrier Frequency 3.579545MHz±200Hz
Image Time Stability 2Sec/MAX
Image Analysis Degree ≥300
Central Lock
Central Lock Function Description
1. Lock
In unlock status, press Lock Key on the remote controller for one time, the vehicle lamp will flash one
time, central lock will be locked.
2. Unlock
Press the LOCK button of the remote controller once on the locked state and the vehicle lamp flickers
twice, and the central lock is unlocked.
3. Vehicle Seeking Function
When all vehicle doors are closed,and the locks are in locking status,press the LOCK button of the
remote controller once and the vehicle lamp flickers for ten times. Press the UNLOCK button to exit
the vehicle seeking function;When the vehicle door is open, and the lock is in locking status, press the
Lock key on the remote controller for one time, the vehicle light does not flash.
4. Automatic Return Function
Press the UNLOCK button of the remote controller to unlock the lock. If the vehicle door is not
opened, it will lock automatically after 30 seconds.
5. Automatic Window Closing Function
(a) Take out the vehicle key, and all vehicle doors closed, after pressing the LOCK button of the
remote controller, there is ten seconds’ time of electric window negative output.
(b) After pulling out the key, there is 60 seconds’ time to close the positive output. (Reserved)
6. Remote Control Function Pause
When the vehicle key is inserted in the ignition lock, the remote controller will not be operated but the
mainframe operation is normal.
7. Manual Upper and Lower Locking
Control the upper and lower locking with the manual switch.
8. Eliminate and Register the Remote Controller
Remote Controller Learning Function
Step1: in normal condition, open left front door (do not close), insert the original vehicle key into
ignition lock, and turn on/off the vehicle key for five times in five seconds, and the vehicle key should
be in On status at the fifth time, and the buzzer will sound one time, and the vehicle light will flash one
time, and the study status is on.
Step 2: press any button of the remote controller in ten seconds, the buzzer utters twice and the
vehicle lamp flickers twice. The first remote controller learning succeeds. Press any button of the
second remote controller that the buzzer utters twice and the vehicle lamp flickers twice. The second
remote controller learning succeeds (finally, there are four remote controllers learning).
Step 3: after the learning succeeds, turn off the vehicle key (ON-OFF) to quit learning. If not pressing
any remote control button in ten seconds, the system will exit learning state after ten seconds, and
initial remote control state is not changed.
9. Top Lamp Time Delay Function
(a) Open the vehicle door and then close, at this time the lamp is on in ten seconds. If detect that
vehicle key plugs in ignition lock again or door locks in ten seconds, the top lamp gradually fades
out from strong to weak.
(b) When pulling out the vehicle key from the ignition lock, the top lamp is on. If the vehicle key is
inserted in the ignition lock again or the door is locked, the top lamp gradually fade out from
strong to weak after one minute without any touch.
10. Buzzing Function
(a) Plug in the key (low), not at the ON (high) position, and when opening the left front door (low),
the buzzer buzzes discontinuously.
(b) When the key is not at the position (high), and the small light is on (high) and the left front door
(low) is opened, the buzzer buzzes continuously.
11. Air Bag Detection
After detecting the air bag signal, output five seconds’ unlocking signal.
12. When detecting that any door is opened, the door lamp indictor is on.
(VA－882) Type Remote Control Central Lock Connection Line Definition
10 1
1 10
11 22
22 11
Controller Pin Face

Controller Socket Face
The door lamp signal and side window

are the triode emitter open output.
Power Positive Pole

High Beam switch
Small light (＋) Detection
Right Turning lamp Output (12V) Power 12V
Negative
Skylight Positive Output (12V) (Reserved) Positive Left Front Window Switch
Electric window Negative (1 00 mA) Output Electric window Relay

Connection Side Window
Central Lock Lock Positive (12V) Output Controller Negative Trigger
Central Lock Unlock Positive (12V) Output Actuator
Vehicle Key Inserting Detection(-)

When actuator is in unlocking
Left Turing Light Output (12V) Front Reading state, inner switch turns on.
Lamp
Reading Lamp Negative (3.3A) Output Power Positive Pole
Lockout On-off Lock Detection
Not connected (NC)

ON Power Detection (12V)
Connection Vehicle Key Power Door ON Wire
Power Negative Pole
Rear Back Door Motor
Ground
Not connected (NC)
Power Positive Pole (12V)
Air Bag Signal Detection Pulse Connection Air
Door Lamp Indication ＋12V
Bag Output Line Resistance 10KΩ
Door Lamp Signal
Manual Locking Signal

Manual On-off Lock See-saw Switch
Manual Unlocking Signal
Left Front Door Switch
Left Front Door Detection
Right Front Door Detection
Right Front Door Switch
1. Small light
The small light connects to the positive pole wire of the vehicle small light (vehicle head lamp). When
the small light is on, the voltage of the wire is 12V.
2. Right Turning Lamp
Connect tight turning lamp to the positive pole wire of vehicle right turning lamp. The positive pole wire
has a 12V voltage output when operating.
3. Skylight Positive Output (Reserved)
The skylight is connected to one end of the window lifter relay wire packet. When the vehicle key is
turned to the ON position, the wire has a 12V voltage output. When pulling out the key, there are 60
seconds of a 12 V voltage of the wire delays time.
4. Side Window Negative Output
The side window is connected to the controller negative trigger wire. The trigger wire has ten seconds
negative signal output after the system remote controller locks the door.
5. Central Lock Unlock Output
The central lock is connected to unlock the wire of the central lock actuator. The wire has a 12 V
voltage output when carrying out the unlock action.
6. Central Lock Locking Output
The central lock is connected to unlock the wire of the central lock actuator. The wire has a 12 V
voltage output when carrying out the lock action.
7. Key Inserting Detection
The key is connected to the vehicle lock detection wire. When detecting that the key is inserted in, the
wire electric level is descended.
8. Left Turning lamp
The left turning lamp is connected to the positive wire of left turning lamp. The wire has 12V voltage
output when operating.
9. Reading Lamp Output
The reading lamp is connected to the trigger wire of the reading lamp. The wire has low electric level
output and controls the reading lamp.
10. Lockout On-off Lock Detection
The on-off lock is connected to the inner switch of the left front door lockout. When the lockout
unlocks the door, its inner switch turns on. The wire electric level is also descended.
12. ON Power Detection
ON connects to the vehicle power door 0N wire. When the vehicle key is turned to ON, the wire has
12V voltage.
13. Power Negative Pole
The wire is grounded (too long wire will produce interference source).
14. Rear Back Door Motor
The wire connects to the rear back door motor. When pressing UNLOCK key on the remote controll,
the wire has a 12V power output.
16. Power Positive Pole
The wire connects to the vehicle battery positive pole (red fire wire).
17. Air Bag Signal
The wire connects to the vehicle air bag protection signal.
18. Door Lamp Signal
The wire connects to the combined meter door lamp indicating lamp. The wire has a 100 mA negative
output (when detecting that any vehicle door is opened, the door lamp dictator is on) when operating.
19. Manual Lock Signal
The wire connects to control wire of vehicle left front door manual on-off lock see-saw switch. The
wire is connected onto power negative pole (grounding) when operating.
20. Manual Unlock Signal
The wire connects to control wire of vehicle left front door manual on-off lock see-saw switch. The
wire is connected onto power negative pole (grounding) when operating.
21. Left Front Vehicle Door Switch
The wire connects to the control wire of the vehicle left front door. The wire is connected onto the
power negative pole (grounding) when operating.
22. Right Front Vehicle Door Switch
The wire connects to the control wire of the vehicle right front door. The wire is connected onto power
negative pole (grounding) when operating.
CD Player
Brief Introduction of CD player Function
The product has the PLL electronic tuning reception system which can receive amplitude modulation,
frequency modulation stereo broadcasting, play CD and MP3 disc, is a sound with AUDIO IN interface
(play music by MP3, MP4 player), and display contents of reception, the working state of CD or MP3
play in display screen.
Wiring Description
1. The connection of the mainframe and the loudspeaker: the system mainframe amplifier is four-
channel BTL output and every loudspeaker must trace wire independently. The loudspeaker
phase and position must be connected exactly. Before connecting loudspeaker, please first cut
off the radio power and prevent connection short-circuit.
2. The connection of the mainframe and the antenna: insert the vehicle antenna coaxial cable
plug in the mainframe antenna socket.
Notice: Wrong connection will damage machine!
Terminal Diagram
Connecting parts
Terminal Terminal Definition Terminal Terminal Definition

A1 B1 Right Back Loudspeaker
A2 TEL/MUTE Phone / Mute B2 RR+ Right Back Loudspeaker
A3 LI/CORT Wire Control Terminal B3 RR- Right Back Loudspeaker
A4 ACC+ ACC Power B4 FR+ Right Back Loudspeaker
A5 ANT+ Automatic Antenna Power B5 FR- Left Front Loudspeaker
A6 ILL+ Background Light B6 FL+ Left Front Loudspeaker
A7 BATT+ BATT Power B7 RL+ Left Front Loudspeaker
A8 GND Grounding B8 RL- Left Front Loudspeaker
A B

1 11 AGND Analogue-ground
2 12
3 13 AUX-L AUX Left Channel
4 KAOK-IN KAOK Right Channel 14
5 KAOK-L KAOK Left Channel 15
6 16
7 GND Ground 17
8 AUX-CORT AUX Detection Signal 18
9 KAOK-9V KAOK power 9V 19
10 AUX-R AUX Right Channel 20
C
DVD Player
Brief introduction of DVD Player Function
The product has PLL electronic tuning reception system which can receive amplitude modulation,
frequency modulation stereo broadcast, play VCD, DVD, CD and MP3 disc, preserve on-board
telephone and on-board navigation interface in advance, is a sound with AUDIO IN interface (play
music by MP3, MP4 player) and with function of Karaoke sound and display contents of reception, the
working state of VCD, DVD, CD or MP3 play in display screen.
Wiring Description
1. The connection of mainframe and loudspeaker: the system mainframe amplifier is four-channel
BTL output and every loudspeaker must trace wire independently. Loudspeaker phase and
position must connect exactly. Before connects loudspeaker, please first cut off radio power
and prevent from connection short-circuit.
2. The connection of mainframe and antenna: insert vehicle antenna coaxial cable plug in the
mainframe antenna socket.
Notice: the incorrect connection will damage the machine!

A1 B1 Right Back Loudspeaker
A2 TEL/MUTE Phone / Mute B2 RR+ Right Back Loudspeaker
A3 LI/CORT Wire Control Terminal B3 RR- Right Back Loudspeaker
A4 ACC+ ACC Power B4 FR+ Right Back Loudspeaker
A5 ANT+ Automatic Antenna Power B5 FR- Left Front Loudspeaker
A6 ILL+ Background Light B6 FL+ Left Front Loudspeaker
A7 BATT+ BATT Power B7 RL+ Left Front Loudspeaker
A8 GND Grounding B8 RL- Left Front Loudspeaker
A B

1 11 AGND Analogue-ground
2 12
3 13 AUX-L AUX Left Channel
4 KAOK-IN KAOK Right Channel 14
5 KAOK-L KAOK Left Channel 15
6 16
7 GND Ground 17
8 AUX-CORT AUX Detection Signal 18
9 KAOK-9V KAOK power 9V 19
10 AUX-R AUX Right Channel 20
C
NO. Name
Navigation ON Signal
Name NO. Sound ON Signal

Right Channel (+)
Ground
power ACC
Color Batch R
Ground
Color Batch G
power B+
Disc Case Color Batch B
Communications Line
CD ON Signal Synchronizing Signal
Right Channel (+) Analogue-ground

Signal Ground
Sound Output +
Sound Output -
Remote Control Signal
No Connection
Detection Signal
On-board Navigation GPS

Brief Introduction of On-board Navigation
The navigation system is composed of three parts, that is, the mainframe (navigation controller), the
remote controller, the DVD and antenna. The navigation system depends on the relative information
that the DVD display screen shows.
The GPS module in the navigation controller depends on the antenna to receive the satellite
positioning signal and other modified signals to calculate self position (longitude, latitude and altitude),
time and movement state (speed and course), and then send to singlechip and store. Then combine
the inner electric map to provide positioning information at any moment by the DVD display screen.
Satellite Signal
The navigation system needs to depend on the global positioning system (GPS) to confirm the vehicle
position. Basically, GPS needs to know the longitude and the latitude. The GPS yet needs to know
altitude to position exactly in some special state. If there are three groups of data, the exactness
of GPS positioning will reach (2-3) m. Because the GPS needs the on-board navigation system to
work in the direct sight of the synchronous satellite, tunnel, bridge or high building will block off the
direct sight so that the navigation system cannot work. Besides, the navigation system calculates the
vehicle position with trigonometry and geometry theorems. Generally, as long as the system receives
four satellites’ signal, the exact position of the vehicle will be calculated exactly (GPS navigation
system needs at least four satellite signals. Three signals confirm longitude, latitude and altitude of
GPS receptor. The fourth signal provides synchronous adjusting time). There are more synchronous
satellites in the direct sight range of navigation system, positioning is more exact. The system can
display the satellite number in signal state.
Signal Reception
The working principle of the GPS system analyzes the signal received from the synchronous satellite.
The signals project on the upright surface which can show as some reverse funnels visually. When the
half low part of these “funnels” has definite superposition, analysis the procedure of GPS will calculate
the coordinate of the vehicle position. The device similar to the gyroscope used on plane or steamship
navigation can continuously provide the vehicle position. When the satellite signal is interrupted, the
blank is filled up with the data provided by the calculator and is used to record traveling time with the
data.
Map Database
When the coordinate information provided by GPS is superposed on the electric map, the driver can
see the present position and the coming position. The final link is called the finished drawing and also
the most important link in on-board navigation system. Without the finished drawing, the navigation
system will have no direction.
Mainframe Diagram
Fragile Label
Function
Number Label
Qualification
Certificate
Client Name Great Wall

Parts Name GPS Control Unit
Parts Serial Number
Production Date
Production Batch
Number
Pin Definition
Number Function Number Function
1 GPS Antenna Socket 1 RGB Red Signal Line
2 RGB Green Signal Line
3 RGB Blue Signal Line
Number Function 4 Navigation Synchronous Line
1 12V Battery 5 Navigation Signal Ground
2 Grounding 6 Voice Indication Giving sign line
3 12V ACC 7 Infrared Input Ray
4 Stop Line 8 Navigation Display On (Infrared Input Signal) Line
5 Speed Line 9 Grounding
6 Reversing Line 10 Output 12V
11 Lighting
12 Navigation Voice Output (L Channel)
13 Navigation Voice Output Ground
14 RGB Red Signal Line
Airbag-
Airbag
SRS airbag......................................................................................... 2
Maintenance precautions................................................................. 3
Test instrument.................................................................................. 4
Fault handling.................................................................................... 5
Vehicle Impact Diagnosis................................................................. 18
Disassembly Method of Each Part................................................... 19
Airbag Module Abolish Outline........................................................ 22
Airbag-
SRS airbag
Airbag module in driver side Airbag module in co-driver side
Safety airbag ECU
The structure of the main parts and the operational principle of the SRS system
1. Airbag ECU
The SRS ECU, installed under the shifting handle, is the electric control maincenter of the SRS
system and is made up with CPU central processing unit, electronic acceleration sensor, diagnostic
data storage, impact record storage and energy storage. SRS ECU has many functions such as
selfcheck, monitoring the working conditions of each sensor and the conductor, fault storage, the
blasting airbag or tensioner and impact record storage. When impact happens, SRS ECU can not only
determine the impact intensity and angel, send firing command to the airbag or safety belt tensioner
and let them work, but also send a impact signal to the centre door lock controller, the centre door lock
controller computer will send out the unlock command, and let people escape quickly after accident
happens.
2. Airbag warning lamp
The airbag is on the inner odometer disc of the gauge board, when the working voltage is provided to
SRS-ECU by battery, SRS-ECU will turn on the warning lamp to check. In initializing stage the light
will flash for 6 seconds with 1Hz frequency then turns off. The warning lamp will keep on lighting after
the w orking voltage is provided in order to inform the driver that some fault is existed.
3. Airbag assembly
The airbag assembly is made up with ignitor, fuel blasting pipe, airbag, inert gas generator, lead wire
plug and casing. The main airbag is installed inside the steering wheel, and the sub-airbag is installed
inside the gauge desk of the co-driver side.
When impact happens, the airbag computer will send out blast signal according to the preset data,
the airbag will spread out immediately after it has been detonated and form a air cushion between
the passenger and the component inside the automobile, and press the passenger’s head and breast
or lumbar on the airbag which is filled up with air, use the buffer action of airbag itself and the buffer
action of the air discharge choke of the discharging hole in the back of the airbag to absorb the kinetic
energy created by the body inertial force, and then achieve the purpose of protecting the human body.
4. Lock preloader
The mechanism is shown in the figure. This preloader uses gun powder as power. The top of the lock
catch is connected with the mesh belt, and the underside is connected with the piston of the preloader
by steel wire cable. When impact happens, firing the gun powder installed in the preloader by ignition
equipment, and the gas produced by the guy powder fills into the air chamber. The piston moves to
Airbag-
Lock catch Gun powder right by the pressure of the gas, then pulls back the
lock catch for about 80 mm by steel wire cable, and
Steel wire cable
eliminates the gap between safety belt and passenger.
Air-chamber Self-locking Cage The piston is assembled with steel ball, which makes
steel ball
Piston the piston can only move to right and prevents the
piston moving to left under the pull of the safety belt.
Besides normal emergency locking safety belt function,
it also has intellectualized blasting controlling functions.
It mainly made up with ignitor, blasting pipe, inflator
and tension device. When impact happens, SRS computer sends the firing command to ignitor of the
tightener, and drives the safety belt pretension device, then the safety belt is crimple immediately in
the maximum tension force range which the passenger can bear, and decreases the forward lead and side lead of the
human body, then protects the driver and passenger from injury.
5. Clock spring
The clock spring is the wire harness interface unit between the steering wheel airbag and steering
column, it is made of plastic casing and inner screw conductor. The screw conductor will make
telescopic movement in the cage when the automobile is steering, and protect the connecting line
between the steering wheel airbag and SRS ECU from being pulled apart.
6. SRS system connecting harness
The connecting harness of SRS system is yellow harness, being different from other system harness,
which can prevent being wrongly measured when repairing other system, and is also easy to inspect,
repair and replace. Each part of SRS system is connected by airbag wire harness and forms a
system, its joint plug piece is also yellow, and assembles with short circuit sheet, to prevent wrong
blasting after disassembly; and it is assembled with double locking device to prevent falling off.
Maintenance precautions
Read the following maintenance precautions before operation for safety operation.
1. When doing the maintenance of SRS airbag, the operation should comply with the sequence
and proceeding specified in this chapter.
2. The operation should use the experimental apparatus and special tools regulated in this
chapter.
3. When maintaining the following component parts, if one of the component parts has problem,
it must be replaced by new one.
• SRS airbag control elements (SRS-ECU)
• Clock spring module
• Driver side front airbag module
• Passenger side front airbag module
• Driver side front row preloaded safety belt
• Passenger side front row preloaded safety belt
• Airbag harness
4. Disassemble the negative pole connection of the accumulator battery when maintaining
the system, after waiting for 60S then begins to maintain. In addition, the negative pole
disassembled should be tangled with insulated rubber tape in order to insulate.
The capacitor inside the SRS-ECU should keep a mount of electric power in order to make the airbag spread
in specific time after the accumulator battery is switched off. So if the operation is taken without waiting for a
moment, serious injury accident will be caused because the airbag spreads has been delayed.
5. The SRS-ECU, airbag module and clock spring should be take off when doing paint spraying,
because too high temperature will affect the operation (93℃ above).
When SRS airbag has been maintained, don’t forget to use diagnosis scanner to clear the fault code,
in order to make the warning lamp work normally.
6. The electric schematic diagram of the airbag and socket connector definition is shown in the
figure, the SRS-ECU pin definition is shown in the table, the position and shape of the airbag
fault indicator light in the cluster gauge is shown in the figure.
Airbag-
No Name Description No Name Description

5 IGN Battery voltage 14 BPT Lo Driver side safety belt pre-tension, low end
6 GND Earth cable 15 DUAGREQ Diagnosis request
7 WL Airbag warning light 16 BPT Lo Passenger side safety belt pre-tension, low end
9 K Diagnose serial data I/O (K line) 17 BPT Hi passenger side safety belt pre-tension, high end
10 DAB Hi Driver side front airbag, high end 18 PAB Hi Passenger side front airbag, high end
11 DAB Lo Front airbag in driver side, low end 19 PAB Lo Passenger side front airbag , low end
driver side safety belt pre-
13 BPT Hi 34 Crash out Impact output
tension, high end
1Grelay
Instrument indicator light
Diagnosis 2#
Safety airbag indicator light
Diagnosis 7# plug
Centre control ECU 17#
YW R BlW
BW
Br
Airbag fault indicator
Airbag ECU
BlR BlY WR RW G GY Y YB
Clock pellet
Driver airbag Co-driver airbag Driver safety belt Co-driver safety

B pre-tension belt pretension
Test instrument
Instrument Name Usage
X-431 diagnosis detector Check the system fault of SRS
safety airbag, and clear the ECU
Airbag-
Fault handling
Basic process of fault diagnosis
The fault code DTC of the existing fault and the fault code DTC of the former fault may exist at the
same time.
● After new electronic control unit of SRS airbag system is assembled, the airbag warning lamp
will be off permanently after lighting for 6 seconds when the ignition switch is in ON state, this
means the SRS airbag system works normally. In this case there is no need to maintain the
system, otherwise system diagnosis and maintainance is needed.
● If the warning lamp of the airbag system does not light when the ignition switch is in ON state,
maintain the relative circuit of the warning lamp, then operate again to make it in working state.
The warning light Use diagnosis equipment
Find out where Handling Clear the
state is constant- and K line connection to
is the fault the fault fault code
ly lighting scan ECU
Inspection of the SRS safety airbag warning light

1. Turn the ignition switch to ON position, and check whether the warning lamp is on.
2. After ON-OFF for six times, check whether the warning lamp is off permanently
3. Make other diagnosis inspection besides the above contents.
SDATA
System diagnosis
F26
10A DUAG REQ S R S - E C U w i l l p e r f o r m a s e r i e s o f c i rcu l a ti n g
449
YW 65a 391 diagnosis test to inspect whether the function of the
0.5 GB BW airbag system is ready. This inspection will prevent
0.5 0.5 constrained system blasting incorrect and at the same
time ensure the necessary blasting during cashing. If
fault is found, SRS-ECU will store a suitable fault code
and turn on the warning lamp indicating a fault state in
913 order to maintain. Earth the No. 2 pin of the diagnose
B Diagnosis interface interface for 2 seconds, the safety bag warning lamp
0.5 will flash and show the code.
Fault determination
1. Fault record (fault code storage)
When the ECU fault is determined by circulating diagnosis test, SRS-ECU will store corresponding
code in the EEPROM, first discretion time, last discretion time and happening times.
SRS-ECU can store 5 faults at most, voltage extremely low fault and two impact faults (front side and
lateral)
Serial
Fault Instruction Removing
number
1 Ignition loop 1(driver side front airbag), resistor too high or short circuit Possible
2 Ignition loop 1(driver side front airbag), resistor too low or short circuit Possible
3 Ignition loop 1(driver side front airbag), ground Possible
4 Ignition loop 1(driver side front airbag),join to the power Possible
5 Ignition loop 2(passenger side front airbag), resistor too high or short circuit Possible
6 Ignition loop 2(passenger side front airbag), resistor too low or short circuit Possible
7 Ignition loop 2(passenger side front airbag), ground Possible
8 Ignition loop 2(passenger side front airbag), join to the power Possible
9 Driver side preloader, resistor too high Possible
Airbag-
Serial
Fault Instruction Removing
number
10 Driver side preloader, resistor too low Possible
11 Driver side preloader, GND short circuit Possible
12 Driver side preloader, VBATT short circuit Possible
13 Passenger side preloader safety belt, resistor too high Possible
14 Passenger side preloader safety belt, resistor too low Possible
15 Passenger side preloader safety belt, GND short circuit Possible
16 Passenger side preloader safety belt, VBATT short circuit Possible
17 Power voltage too high Possible
18 Power voltage too low Possible
19 Warning light fault- join to the power bulb short circuit Possible
20 Warning light fault-ground or filament short circuit Possible
Impossible (re-
21 Algorithm parameter lack/ error
place SRS-ECU)
Impossible (re-
22 Forward collision recorded
place SRS-ECU)
23 Communication fault Possible

Impossible (re-
24 Internal fault
place SRS-ECU)
The fault code transmission is outputted by the SRS-EUC through the serial port of the maintenance
procedure to the appointed diagnosis detector(X-431 diagnosis detector) to accomplish.
2. Fault code diagnosis
Description of the flashing code.
Serial
Fault Fault code Flashing code
number
1 No storage error $12
2 Front airbag driver, resistor too high $9,021 $21
3 Front airbag driver, resistor too low $9,022 $22
4 Front airbag driver, GND short circuit $9,024 $24
5 Front airbag driver, WBATT short circuit $9,025 $25
6 Driver side preloader, resistor too high $9,015 $15
7 Driver side preloader, resistor too low $9,016 $16
8 Driver side preloader, GND short circuit $9,018 $18
9 Driver side preloader, VBATT short circuit $9,019 $19
10 Front airbag driver, resistor too high $9,041 $41
11 Front airbag driver, resistor too low $9,042 $42
12 Front airbag driver, GND short circuit $9,043 $43
13 Front airbag driver, VBATT short circuit $9,044 $44
Airbag-
Serial
Fault Fault code Flashing code
number
14 Passenger side preloader safety belt, resistor too high $9,045 $45
15 Passenger side preloader safety belt, resistor too low $9,046 $46
16 Passenger side preloader safety belt, GND short circuit $9,047 $47
17 Passenger side preloader safety belt, VBATT short circuit $9,048 $48
18 Battery voltage too high $9,031 $31
19 Battery voltage too low $9,032 $32
20 Warning light failure $9,061 $61
21 Internal fault(replace SDM) $9,071 $71
22 Forward collision record $9,051 $51
23 Side collision driver record $9,056 $56
24 Side collision passenger record $9,057 $57
25 Preloader safety belt collision $9,058 $58
26 Exceed permitted reuse number $9,054 $54
3. Internal fault
Micro-controller can inspect the items of the follow not only in the start inspection but also in the
circulation diagnosis inspection.
(a) The ignition circuit trigger transistor: the high-end transistor is not inspected in the start inspection
but also in the circulation diagnosis inspection. But because of low-end transistor opening in the
condition of short circuit fault, the low-end transistor is only to be inspected in the start inspection
to avoid detonation.
(b) The ignition voltage is supplied by the supercharging converter.
(c) The acceleration sensor performs selfcheck when starting inspection.
(d) The permitted deflection range of the acceleration sensor in circulation diagnosis.
(e) The micro-controller includes the AD converter, ROM, and RAM, etc.
(f) The safety sensor condition.
Notice: The connector of the squib circuit, the concealed short bar, the connector is not
connected, squib circuit (+) end and (-) end short circuit, prevent error development caused
by electrostatic and other cause. When the connector disorder short bar is connected, the
malfunction is impossible to be eliminated.
A piece of outer watchdog will inspect the running state of the Microcontroller. If the failure of the
Microcontroller can trigger the watchdog, the watchdog will reset the Microcontroller and turn on the
warning lamp.
Airbag-
Confirmation of internal fault by SRS-EUC

Serial
Fault list Fault description
number
• AD converter or EEPROM mistake(in case of RAM
1 Microcontroller and ROM making a mistake, micro-controller will
reset)and warning light will be on at the same time.
• Activation fault
2 Driver front airbag ignition loop
• Measure circuit fault
Passenger front airbag ignition loop(if • Activation fault
3
realized) • Measure circuit fault
Driver side safety belt preloader ignition • Activation fault
4
loop(if realized) • Measure circuit fault
Passenger side safety belt preloader igni- • Activation fault
5
tion loop(if realized) • Measure circuit fault
• Activation fault
6 Driver side airbag ignition loop(if realized)
• Measure circuit fault
Passenger side airbag ignition loop(if real- • Activation fault
7
ized) • Measure circuit fault
8 Ignition voltage • Too low
9 Watch/reset • Fault
Detonation maximum number of safety
10 • Reach maximum number 6
belt preloader
11 ECU energy storage time (self-feeding time) • Too short
• Deflection range
12 Accelerometer • Sensor is not in steady mode
• sensor selfcheck fault
Ignition loop measurement is abandoned • implement circulation diagnoses
13
continuously inspection(repeat algorithm calculates)
• Close for 2 seconds or more then 2 seconds
14 Safety sensor • When fault develops by algorithm calculating,
safety sensor short circuit
15 Ignition current • When airbag develops, all ignition flow condition is nor mal
•Though 5 times of ignition information is received by
16 Side airbag ignition not confirmed SRS-EUC during circulation ignition, side safety func-
tion side airbag ignition can not be proved by HAE2
4. Remove fault code
Method 1: when the “remove fault code” is received by the X-431 diagnoses detector through the
serial interface, the fault code in the ECU is removed. But if an internal fault code is recorded or
impact recorded once, it will not implement the removing order.
Method 2: Perform 5 times of grounding of the No.2 pin of the diagnoses interface, the fault code will
be removed.
(a) Display of fault condition (warning lamp will keep on lighting)
Bulk inspection
When the working voltage supplied to SRS-EUC by the battery, SRS-EUC illumines the warning lamp
to inspect the bulk. During the initialization stage the light will twinkle for 6 seconds by 1Hz and then
be off. In order to inform the driver system the existing of some faults, the warning lamp will be always
on after supplying of the working voltage. If the historical fault is less than 5 times, the warning lamp
Airbag-
will be off after ignition on for 6 seconds. During the initialization stage, SRS-EUC will not inspect
impact and prevent developing until the SRS-EUC lines are steady.
So, after ignition on, the display usage is one of following options shown in the initialization stage.
Option 1: When the impact record exists or the
historical records of the faults exceed or equal to
5 times, the warning lamp will always be on. At
the same time, if there are detonation faults, the
ON
warning lamp will always be on.
lgnition ON
Option 2: The historical records exceed or equal to

1 time and is less than 5 times (“battery voltage too
low” is removed to the summation of the happened
6sec
ON
faults)
OFF
lgnition ON
Option 3: Work normally (namely there are no

impact fault and no historical fault).
6sec
ON
OFF
lgnition ON 1sec(=1HZ)
Warning lamp behavior after ignition
(b) Fault indication

If there are faults, the warning lamp will indicate. If the external fault is historical, the indication will
be canceled. When the frequency of the historical faults exceed or equal to 5 times, namely there is
no fault found, and the indicator light will always be on. “Battery too low” is not to be calculated to the
summation of the faults happing.
A display or historical fault is only to reset by the service personnel. An internal fault or “impact record”
of SRS-ECU can not be reset, SRS-ECU must be replaced in this case.
(c) Micro-controller-unique warning lamp illumining.
The microprocessor with specific fault condition can not implement responsibility, so it can not control
the warning lamp working. In this case, the warning lamp will directly illumine through proper circuit
without regarding micro-processing unit. As listed bellow:
• The battery supplied to SRS-ECU loses effectiveness: The warning lamp turns on continuously
through the self-autograph light driving function.
• Lose of internal working voltage: Alarming light is on.
• Reset ting caused by watchdog trigger failure : Warning lamp twinkles.
• Non-working of micro- processing unit: Alarming light is on.
• Incomplete inserting of SRS-ECU connector : warning lamp is on by short circuiting bar.
Airbag-10
Fault diagnoses and removal

If found the airbag is on, though finally put out, please inspect as the steps bellow. The first step is to inspect the
location of fault with the diagnosis equipment, and then adopt the same inspecting method to perform.
Remarks: if the scan result is internal faulty or the airbag has been blasted, replace the SRS-EUC directly.
Indicating faulty
1. The warning lamp of the airbag system does not indicate
Inspecting condition Air airbag system alarm circuit faulty
• Voltage disappears (safety fuse short circuit)
Impossible reason • Combination instrument faulty
• Harness faulty of instrument group and ECU module
Diagnoses procedure
When perform the faulty inspection, suggest shaking the harness and plug to inspect whether there is
discontinuity bad contact. If there is, check whether the plugs, the terminals and the harness are right
and not damaged, if not, perform as the steps bellow.
Steps Inspection Operation
Inspect the other harness and the combination gauge Place the ignition switch to
indicator light Yes the LOCK position, and then
• Place the ignition switch to the “ON” position perform the next operation
1 • Whether other alarm and indictor illumined Inspect the combination
gauge power supply sys-
No
tem and grounding system
(safety fuse)
Inspect bulk Perform the next step
Warning:
Incorrect handling the airbag system elements will cause
Yes
unexpected opening airbag and pretension safety belt, it
will cause a nasty accident. Please read the airbag system
service warning before handling the airbag system ele-
2 ments. Replace combination instru-
• Place the ignition switch to the LOCK position ment
•Disconnect the battery negative pole lines and retain
at least 60 seconds No
• Disassemble the combination gauge
• Inspect the airbag warning lamp(LED) whether there
are faulty
Inspect the harness connecting of ECU module and the Perform the next step
combination gauge Yes
• Place the ignition switch to the LOCK position
3 • Disconnect the battery negative pole lin es
• Disconnect the plugs of the ECU module and the combi- Replace harness
nation gauge No
• Inspect the alarm circuit relevant line whether con ductivity
Airbag-11
2. Airbag system warning lamp is on

Inspection condition Airbag system alarm is on
• Battery supply not enough
• Internal fault of ECU
• Combination gauge airbag warning lamp fault
• Bad connecting of ECU plug
• Bad contact of combination gauge
Possible cause
• ECU power supply safety fuse circuit break or bad contact
• Bad connecting of ECU plug terminal
• Bad connecting of ECU plug terminal and harness of ground surface
• Airbag driver side or passenger side circuit fault
• Driver side and passenger side preloader safety belt fault
Diagnoses procedure
When beginning inspecting, find out the cause of faulty by diagnoses communicating with the
diagnoses gauge (X-431 diagnoses detector) and ECU, if the diagnoses is not performed by
diagnoses communicating, perform the inspection as bellow.

Inspecting the battery Yes Perform the next step
•Inspecting the battery voltage Battery supply not enough
1 •Whether the voltage higher than 9V? Inspect the charging/discharg-
No
ing system, and then perform
the step 6
Inspect the harness connecting of ECU module and the Perform the next step
combination gauge Yes
•Place the ignition switch to the LOCK position
•Disconnect the battery negative pole
•Disassemble the combination gauge Inspect the circuit part, and
2 •Disassemble the gauge group PIU then perform the step 6
•Connect the battery negative pole
•Place the ignition switch to the ON position No
•Inspect the gauge group relevant connecting plug-in ter-
minal voltage whether 12V (the connecting line of power
and gauge)
•Place the ignition switch to the LOCK position Yes Perform the next step
•I nspect the gauge group relevant connecting plug-in Mend or replace the harness,
3
terminal and the diagnosis interface relevant terminal No and then perform the step 6
whether connect.( diagnosis the two ends of the K line)
Make sure disconnecting battery negative pole line and Yes Perform the next step
retain at least 1 minute Replace the harness, and
•Disconnect ECU PIU then perform the step 6
4
•Disconnect the combination gauge plug No
•whether to connect between the ECU plug terminal5, 7 , 9
and the gauge group plug?
Disassemble ECU to inspect the terminal Whether in good Yes Replace ECU
condition and the short circuit bar whether fractured Reconnect the ECU connect-
5
No ing plug-in, and then perform
the next step
Airbag-12

Make sure fault symptom not be relapsed after repairing Remove the fault, and then
• Place the ignition switch to the LOCK position explain the repairing proce-
Yes dure to the consumers
• Disconnect battery negative pole and retain at least 1
minute
• Connect all the EUC plugs
Inspect the fault symptom
• Connect the driver airbag component plugs
again, and then if the fault
6 • Connect the passenger airbag component plugs
happens again, repeat from
• Connect the driver and passenger pretension safety belt
the step 1.
plugs No
• Connect the clock spring plugs
• Connect the battery negative pole line
• Place the ignition switch to the ON position
• Whether the airbag warning lamp work normally?
Internal fault
Fault code$9071 SRS safety airbag system module internal fault
Warning:
• The inspection condition of the fault maybe the fault code that not happened before
Inspection inspecting, DTC performs inspection work, the performance of the inspection work
condition may cause personal injury or system damage because of misoperation. So, before
inspection, the preparation wore should be done.
• The internal circuit fault of the SRS airbag system electronic control unit
possible cause The internal fault of the SRS airbag system unit
Replace the SRS airbag system unit (found in the airbag system, the SRS airbag sys-
operation
tem unit assembling /dissembling )
Power
Fault code$9032 The power voltage of the SRS airbag system electronic control module is too low
• The performance of the inspection work may cause personal injury or system dam-
age because of misoperation. So, before inspection, the preparation work should be
Inspection
done.
condition
• The electric potential of pins No.5, 6 of the PIU pin of the SRS airbag system mod-
ule should low than 9V.
• the battery voltage too low
Possible rea-
•There is a fault between the harness of the battery and the SRS airbag system elec-
son
tronic control module
Airbag-13
Diagnosis procedure
Inspect the battery Yes Perform the next step
• Measure the battery voltage
1 The battery voltage is too low,
• Whether the voltage higher than 9V?
No inspect the charging/discharg-
ing system
IInspect the harness between the battery and the fuse box Yes Perform the next step
• Place to ON position
2 Maintenance harness
• Measure whether the electric potential of the two posts
No
connected to the fuse box more than 9V?
Inspect the harness between the safety fuse box and the Perform the next step
SRS airbag system unit PIU
Warning:
If not handling correct, the airbag module may be triggered Yes
develop, and cause personal injury, so read the mainte-
nance warning carefully before handling.
• Place the ignition switch to the “LOCK” position
• Disconnect battery negative pole cable and retain about 1
Replace harness
minute
• Dissemble the steering wheel, combination switch cover
3
• Disconnect the clock spring PIU
• Dissemble the glove box (with passenger side airbag
module)
• Disconnect the passenger side airbag unit PIU No
• Dissemble the gauge cluster base
• Disconnect all the SRS airbag system unit PIU
• Assemble to the battery negative pole cable and to place
the switch to the ON position to measure the electric
potential of the PIU pins 5 and 6 (ground) of the SRS
airbag system module whether more than 9V?
• Place the ignition switch to the “LOCK” position Replace the SRS safety air-
• Disconnect battery negative pole cable and retain about 1 bag system module
minute Replace the SRS airbag
• Dissemble the gauge cluster base system unit
• Disconnect the SRS airbag system unit PIU Yes To be seen in the airbag
4 • Assemble to the battery negative cable and to place the system
switch to the ON position Measure the transferred PIU The dissembling/assembling
related pin electric potential whether more than 9V? of the SRS airbag system
Fault diagnosis is over
No Replace the harness
Airbag-14
Driver side fault

Fault code $9021 Driver side airbag fault(resistance too high or too low, short circuit, and ground-
$9022 $9024 $9025 ing)
Warning:
• If
not handling correct, the airbag module may be triggered and stretched out,
which may cause serious personal injury, so read the maintenance warning
carefully before handling.
To be seen in the airbag system maintenance notice.
Inspection condition
If having the driver side airbag
•The resistance between the SRS airbag system module PIU post is not in the
regulated range
The harness circuit break or short circuit related with the SRS airbag system
driver airbag
• Driver side airbag module fault
• Clock spring internal fault
• The fault of the circuit PIU fault between the clock spring and SRS airbag sys-
Possible reason tem electronic module
• The wire harness circuit break or short circuit related with the SRS airbag sys-
tem driver side
• The SRS airbag system driver airbag generator PIU is not be inserted well
Diagnosis procedure
Inspect the clock spring Perform the next step
Normal
Warning:
If not handling correct, the airbag module may be triggered
and stretched out, which may cause personal injury, so read
the maintenance warning carefully before handling. Replace the clock spring
1 See the airbag system maintenance notices See the airbag system, the
Abnormal
•Is related parts of the clock spring normal?(Whether the installation/disassembly

relation between the stitch is normal, and whether have clock spring
the phenomenon of the short circuit, short circuit and so
on) if it is not normal, the existing clock spring can be re-
placed by the good.
Confirm the fault on the driver side airbag module, or on Replace the driver side air-
the other parts bag module
Can
• Replace a good DAB module See the airbag system, the

• Assemble back the battery negative pole cable installation/disassembly of the
2 • Open the ignition switch at the “ON” position driver side airbag module
• Is the fault code still displayed? Or whether it can be re- Perform the next step
Without
moved?
Inspect the clock spring harness PIU Perform the next step
Normal
• Place the ignition switch to the “LOCK” position

• Disconnect battery negative pole cable and retain for
more than 1 minute Replace the harness
3
Abnormal
• Disassemble out the steering wheel, and combine the switch

cover
• Loose the clock spring PIU
• Is the clock spring PIU normal?
Airbag-15
Diagnosis procedure (adding)

Confirm the fault on the clock spring or on the other parts Perform the next step
With
• Set the special-purpose detector at the two ohm position
• Install the battery negative cable
Replace the clock spring
• Place the ignition switch to the “ON” position
Without
• Is the fault mode displayed? See the airbag, the disas-
4 sembly/installation of the
clock spring
Replace the wire harness
Abnormal
Inspect the harness between the clock spring and the SRS Replace the SRS airbag
airbag system electronic control unit system module
Normal
• Open the switch ignition at the “LOCK” position See the airbag system
• After loose the battery negative pole to wait exceed one The disassembly/installation
minute of the SRS airbag
• Disassemble out the glove box (with )
• Disconnect the passenger side safety side airbag plug – in Replace the harness
• disassemble the gauge panel base
5
• Disconnect all SRS airbag system module PIU
• Inspect whether the harness of the between the SRS
airbag system module PIU post and the clock spring PIU Abnormal
post have the following conditions
a. Ground
b. Short circuit with the power
c. Circuit break
• Is the above wire harness normal?
Inspect the clock spring PIU Perform the next step
Normal
• disassemble the steering wheel, combined switch cover

• Disconnect the spring PIU
6 • Is the clock spring PIU normal? Replace the harness or PIU
Normal Abnormal
Inspect the clock spring Perform the next step

• Disassemble the clock spring
• See the airbag system, the disassemble / installation of
7 the clock spring Replace the clock spring
Abnormal
• Inspect the clock spring See the airbag system, dis-

• See the airbag system, the inspection of the clock spring assemble / installation of the
• Inspect the clock spring is normal? clock spring
Airbag-16
Inspect the harness between the clock spring and the SRS Replace the driver side
airbag system electronic control unit safety module
• Place the ignition switch to “LOCK” position See the airbag system
Normal
• After disconnect battery negative pole cable to retain for The disassembly / installa-
more than 1 minute tion of the driver side safety
• Disassemble the glove box (with the passenger airbag ) side airbag
• Disconnect the passenger side airbag module PIU
• Disassemble the gauge panel base Replace the harness
• Disconnect all SRS airbag system module PIU
8
• Inspect whether the harness between of the SRS airbag
system module PIU bar, and the clock spring PIU post,
and whether the harness between of the SRS airbag sys-
Abnormal
tem module PIU post and the clock spring plug PIU post
have the following conditions
a. Ground
c. Circuit break
• Is the above harness normal?
Passenger side fault

Fault code $9045 Passenger side airbag module (resistor is too high or too low, short circuit ground
$9046 $9047 $9048 and so on )
Warning:
• If not handling correct, the airbag module may be triggered and stretched out,
which may cause personal injury, so read the maintenance warning carefully
before handling.
See the airbag system maintenance notices
Inspection condi-
• The resistance of the SRS airbag system module PIU stitch eighteen and nine-
tion
teen is not in the regulated range
• The harness between the SRS airbag system module PIU stitch eighteen and nineteen
is short circuit
• The between the SRS airbag system unit PIU stitch eighteen and nineteen is
circuit break, if without the passenger airbag
• passenger side airbag module fault
• The PIU fault between the passenger side airbag module and the SRS airbag
system electronic control unit
• The PIU fault between the SRS airbag system module and the ground location
Possible cause • The circuit between the passenger side airbag module and the SRS airbag sys-
tem electronic control unit is circuit break or short circuit
• The circuit between the SRS airbag system unit and the ground location is cir-
cuit break or short circuit
• SRS airbag system unit fault
Airbag-17
Diagnosis procedure
Is the vehicle installed passenger side airbag module? Perform the next step
With
1
Install the passenger side
Without
airbag module
Inspect the passenger side airbag module plug – in [the fault code of the exist-
Warning: ing fault]
Normal
If not handling correct, the airbag module may be triggered Perform the next step
and stretched out, which may cause personal injury, so [the fault code of the past
read the maintenance warning carefully before handling. fault]
See the airbag system maintenance notices Perform the next step
2 • Place the ignition switch to “LOCK” position
Replace the wire harness
• Disconnect battery negative pole cable and retain about
Abnormal
1 minute
• Disassemble the glove box
• Disconnect the passenger side airbag module plug – in
• Is the passenger side airbag module plug – in normal?
Perform the next step
With
Confirm the fault reason on the passenger side airbag
module, or on the other parts
• Use a good module connect to the passenger side airbag Replace the passenger side
3 module plug – in airbag module
Without
• Connect the battery negative pole See the airbag system, the
• Place the ignition switch to “ON” position disassembly / installation of
• Is the fault mode displayed? the passenger side module
Inspect the harness between the passenger side airbag [existing fault code]
module and the SRS airbag system electronic module Replace the SRS airbag
• Place the ignition switch to “LOCK” position system module
• After disconnect battery negative pole cable to retain for See the airbag system
Normal
more than 1 minute The disassembly / installa-

• Disassemble the steering wheel, combined switch cover tion of the SRS airbag sys-
• Disconnect the clock spring plug – in tem
• Disconnect the driver side and the passenger side airbag [recoded fault code]
module plug – in Finish the fault diagnosis
• Disassemble the gauge base
Replace the related wire
4 • Disconnect all SRS airbag system module plug – in
harness
• Inspect whether the circuit between the SRS airbag sys-
tem electronic control unit module PIU (Plug-in-unit) post
and passenger side airbag module PIUpost, and whether
Abnormal
the circuit between of the SRS airbag system module

PIUpost and passenger side airbag module PIU post
have the following conditions
a. Ground
c. Circuit break
• Is the above wire harness normal?
Airbag-18
Vehicle Impact Diagnosis

Whether the airbag is unfolded or not, the vehicle impact inspection and maintenance should be
operated by the following sequence.
1. Inspect SRS-ECU Diagnosis Signal
(a) Connect (X-431 diagnosis detector) diagnosis connector.
(b) Numerate the diagnosis outcome with X-431 diagnosis detector.
Notice: When accumulator power fails because of dash, diagnosis detector cannot
communicate with SRS-ECU. Inspect and maintain the gauge panel wiring harness or use the
outer power.
2. Reparation Sequence
(a) When the airbag is unfolded, the following components should be replaced.
• Passenger side air bag module
• SRS-ECU
• Driver airbag module
• Driver and passenger side front row pretension seat belt
(b) Inspect the following components. If they have unusual state, please change them into the new
components.
• Clock Spring
• Steering wheel, steering column, steering low shaft assembly
(c) Driver side airbag module for the steering wheel installation state
• Inspect whether the steering wheel has abnormal knocking or not, whether the action is better
or not and whether the clearance is normal or not.
• Inspect whether the harness connector is damaged or not and whether the terminal is distorted or not.
3. Warning Signs
The side airbag of the driver, the clock spring, SRS-ECU and passenger has the warning sign.When
using and maintaining the SRS airbag, operate according to the instruction of the marks. If the marks
damage or dirt, replace new ones.
4. SRS-ECU
(a) Inspect whether the SRS-ECU housing and the
bracket have sinking, crack and distortion or not.
(b) Inspect whether the connector is damaged or not
and whether the terminal is distorted or not.
Driver Side
Inflator 5. Driver and Passenger Side Air Bag Module+
(a) Inspect whether the air bag cover surface has
sinking, crack or not.
(b) Inspect whether the plug is damaged or not and
whether the terminal is distorted or not.
(c) Inspect whether the inflator housing has sinking,
Bracket crack and distortion or not.
Airbag-19
6. Clock Spring
Connected to Horn
(a) Inspect whether the connector and the protective
Connected to Driver pipe is damaged or not and whether the terminal
Module is distorted or not.
(b) Inspect whether the housing is distorted or not.
7. Inspect whether the harness is installed firmly or
not, whether the connector is damaged or not and
whether the terminal is distorted or not.
Disassembly Method of Each Part

SRS Airbag Control Element (SRS-ECU)
1. Precautions
(a) After disassembling the accumulator (-) negative pole, operate after 60s. The disassembled (-)
negative pole is tangled with the rubber tape to insulate.
(b) Never disassemble or repair SRS-ECU. If fault is found, please change new SRS-ECU.
(c) Don’t impact and vibrate the SRS-ECU. If you find the states as sinking, crack and distortion,
please change new SRS-ECU.
(d) After unfolding the airbag, change new SRS-ECU.
(e) When disassembling or maintaining parts around the SRS-ECU , don’t impact the SRS-ECU.
2. Operation before Disassembly
(a) Place the ignition switch on the OFF position.
(b) Disassemble the accumulator (-) negative pole and install it on valid position or tangle it with the
rubber tape.
3. Disassembly Sequence
(a) Disassemble the auxiliary gauge panel.
(b) Disassemble the PIU connected to the ECU airbag.
(c) Disassemble the SRS-ECU.
4. Assembly Sequence
(a) SRS-ECU.
(b) Install the socket connector connected to the ECU airbag.
(c) Disassemble the auxiliary gauge panel.
(d) Connect the accumulator (-) negative pole.
5. Installation Operation Outline
(a) Install SRS-ECU.
Notice: If the SRS-ECU cannot be installed exactly, the SRS airbag will not operate normally.
(b) Inspection after Installation
• Place the ignition switch on the ON position.
• SRS warning lamp is on in 6s and keep being off.
• If the lamp don’t be off, fault inspection and troubleshooting is needed.
6. Inspection
(a) Whether the SRS-ECU housing has sinking, crack and distortion or not.
(b) Whether the connector is damaged or distorted or not.
Notice: If the state of sinking, crack and distortion is found, change new SRS-ECU.
Consult the relative content of troubleshooting for the other SRS-ECU inspection.
Airbag-20
Driver and Passenger Side Airbag Module (DAB, PAB), Block Spring
Precautions
1. After disassembling the accumulator (-) negative pole, operate after 60s. The disassembled (-)
negative pole is tangled with the rubber tape to insulate.
2. The airbag module and the block spring cannot be disassembled or repaired. If fauld is found,
change a new one.
3. When using the airbag module and the block spring , be careful and don’t drop them on the
ground or dip into the water or the oil. If the state of sinking, crack and distortion is found,
change a new one.
4. When unfolding the airbag, please place the unfolding side upwards and keep it on the flat
place. Don’t lay other things on it.
5. Don’t put the airbag module in the place that the temperature exceeds 93℃.
6. After unfolding the airbag module, change a new one. Meanwhile, inspect the clock spring
(contact resistance is not more than 0.8 ohm among the corresponding terminals) and change
a new one if it is abnormal.
7. When operating the unfolding airbag, use gloves and protective glass.
8. When abolishing the unfolding airbag , please first unfold it and then abolish it.
9. When disassembling, first disassemble the harness PIU of DAB and PAB module to prevent
from causing the wrongly explosion because of the electrostatic disturbancen and then
disassemble the other harness PIU. Installing process is reverse to that of disassembly.
Disassembly and Installation
1. Operation before Disassembly
(a) After the steering wheel and the front wheel are in straight forward direction, pull out the ignition switch key.
(b) Disassemble the connection of accumulator (-) negative poles.
2. Driver Side Airbag Module Disassembly Sequence
(a) Screw the two sides screws loosened.
(b) Disconnect the harness PIU.
(c) Disassemble the safety module air bag assembly.
(d) Disassemble the steering wheel.
3. Block Spring Disassembly Sequence
(a) Disassemble DAB module (disconnect joint PIU).
(b) Disassemble the steering wheel lightly (see Precautions).
(c) Open the combined switch cover, find out and disconnect the harness PIU.
(d) Disassemble block spring.
4 Driver Side Airbag Module and Installation Sequence
(a) Inspection before Installation
• Install the Steering wheel.
• Connect the airbag harness.
• Install the driver side airbag module.
• Tighten the two sides installation screws.
(b) Accumulator (-) terminal connection.
(c) Inspection after Installation (the same as inspection before installation)
5. Clock Spring Installation Sequence
(a) Inspection before Installation
• The upper wire of block spring rip into through the steering wheel body.
• Fix the connection of block spring and the steering column
• Install the combined switch cover.
• Install the steering wheel.
• Steering Wheel and Airbag Module Assembly
(b) Connect the accumulator (-)terminal.
(c) Inspection after Installation (the same as inspection before installation)
Airbag-21
6. Steering Wheel Disassembly

Disassemble the installation screw from the central position to disassemble the steering wheel
(disconnect the horn connector).
Installation Operation Outline
1. Precautions
(a) Diagnose the airbag module circuit with the testing gauge, but do not analyze it.
(b) Disassemble the driver side airbag module and keep bottom upwards in the clean and dry place.
(c) Keep the disassembled clock spring in clean and dry place.
2. Inspection before Installation
(a) Before installing the new airbag or the clock spring, inspect them.
(b) Connect the accumulator (-) negative pole.
3. Installation Steps
(a) Place the ignition switch at ON position.
(b) Read the diagnosis circuit to confirm whether the outside of the airbag except the position that
occurs failures keep a normal state or not.
(c) Place the ignition switch at OFF position.
(d) Disassemble the accumulator (-) negative pole and tangle it with the rubber tape to insulate.
Notice: Cut off the accumulator (-) negative pole, operate after 60s.
After combining the clock spring face to face, install it on the steering wheel.
4. Clock Spring Centre Face-to-face Combination

Turn the clock spring in clockwise direction (till doesn’t
turn) and then turn it three circle in reverse direction to
combine with the signal face to face (see left figure).
Notice: If the block spring centre cannot be
combined face to face, the steering wheel will not
turn or the block spring circuit will work abnormally,
which prevents the SRS airbag from operating
normally.
5. Installation of Steering Wheel and Airbag Module Assembly

(a) After the clock spring centre combined face to face, install the steering wheel and the airbag
module assembly.
Notice: When installing the steering wheel and the airbag module assembly, don’t block the
clock spring wire harness.
(b) Turn the steering wheel at right position as much as possible after the installation and confirm
whether it is normal or not.
6. Inspection after Installation
(a) Turn the steering wheel right and left lightly to confirm whether there is abnormity or noise (driver
side airbag module, clock spring).
(b) Place the ignition switch on the ON position.
(c) SRS warning lamp is on in 6s and then is off.
(d) If the lamp is often on (or all along is on) after the lamp off in 6s, troubleshooting is needed.
Inspection
1. Inspection of Driver Side Air Bag Module
Inspect the following items. If fault is found, change the corresponding new airbag module components. Unfold
the old components by the specified sequence and abolish it.
Notice: The circuit resistance of the airbag module (squib) cannot be mensurated even with
the specified testing gauge. If mensurating the resistance with the testing gauge, electrical
current runs through the squib. Sometimes the wrongly unfolding may cause by electrostatic.
which may result in the serious accident.
Airbag-22
(a) Whether the covering lid has sinking, crack and distortion or not.
(b) Whether the harness is damaged or not and whether the terminal is distorted or not.
(c) Whether the inflator housing has sinking, crack and distortion or not.
(d) The state of the airbag module installation.
Notice: If there is sinking, crack and distortion, please change new airbag module. The old
components must be abolished after unfolded.
2. Clock Spring Inspection
When inspect the following item, even though a small fault, change new clock spring.
(a) Whether the connector and protective tube are damaged or not and whether the terminal is
distorted or not.
(b) Whether the housing is damaged or not.
(c) Inspect whether the upper connector terminal of the clock spring and the lower corresponding
connector terminal are fully connected or not. The contact resistance is not more than 0.8 ohm.
Airbag Module Abolish Outline
Precautions
1. Before abolishing the SRS airbag, first unfold the airbag.
2. When chaning the airbag module, unfold the airbag outside the car.
3. When unfolding the airbag, smoke will be occurred, so the operation should be done round the
smoke detector.
4. When unfolding the airbag, as the sound is loud, the people around should plug ears. So avoid
unfolding it in living areas.
Unfold in Car
1. Stop the car at flat place.
2. Disassemble the accumulator positive pole and
negative pole and disassemble the accumulator
Housing from the car.
Warning: Disassemble the accumulator positive
pole and negative pole , operate after 60s.
1
3. Unfold the airbag by the following sequence.
2
Driver Side Airbag Module
Protection Pipe
(a) Disassemble the locking rod
(b) Disassemble the clock spring connector and the
Short-circuit Failure gauge panel harness connector (see the left figure).
Unfolding Wire Harness Warning: Disassemble the clock spring connector
from the gauge panel wire harness and the clock
SRS Switch Harness spring connector will short-circuit automatically to
More Than 6m prevent driver side airbag module from unfolding
by electrostatic to result n serious accident.
(c) Connect the SRS airbag switch harness to two
unfolding wire harness more than 6m (as show in
left figure). The connection part is tangled with the
rubber tape to insulate.
Warning: connect the other end of the unfolding
Block Spring
wire harness to avoid wrongly unfolding caused by
Block Spring PIU electrostatic.
SRS Switch Harness (d) The number 2 connector of the clock spring will
connect SRS airbag switch harness. Lead the
Unfolding Harness harness to outside the car with unfolding harness.
(see the left figure)
Airbag-23
(e) Close all the car windows and doors to prevent

Body Covering from noise and install car cover.
(f) Cut off the connector of the driver side airbag
module unfolding harness in the place far away
from the car. Connect the connector with two ends
Unfolding Harness of the accumulator disassembled from the car and
unfold it (as shown in the left figure).
Notice: First confirm whether there are people in the
car or around the car or not. Operate after confirming
that there are no persons. When unfolding the driver
side airbag, the inflator is on high temperature. Leave
it alone for more than 30 min and operate it after
cooling. If the driver side airbag cannot be unfolded,
discuss with the local special service station of Great
Wall Motor Company, Ltd.
4. The unfolding driver side airbag module should be
abolished according to the Abolish Outline.
Unfold Outside Car
Notice: The unfolding of airbag should be done
apart from the obstacle or persons more than 6m
in wide and flat place. When unfolding the airbag
module outdoors, avoid the strong wind and set
fire facing the breezing wind.
1. Disassemble the accumulator positive pole
and negative pole and then disassemble the
accumulator from the car.
Wa r n i n g : O p e r a t e a f t e r d i s a s s e m b l e d t h e
accumulator in 60s.
2. Unfold the airbag module by the following sequence.
Driver Side Airbag Module
(a) Disassemble the driver side airbag module from the car.
Warning: when the connector of the driver
side airbag module is not in connection state,
Unfolding Harness the two ends of the terminal will short-circuit
automatically, which can prevent wrongly unfolding
Short-circuit Location
by electrostatic. If unfolding by mistake, lay the
unfolding side upwards in the flat place and don’t
place other things on it.
(b) Prepare two folding harness more than 6m. Connect
More Than 6m (short-circuit) another end to prevent from accident
by electrostatic to unfold it (see the left figure).
Passenger Side Unfolding (c) Touch the car body by hands to eliminate all
Air Bag Module Harness electrostatic.
Remark: Above sequence can prevent from
wrongly unfolding by electrostatic. Carry it out
strictly.
(d) After cutting off the wire harness of the driver side
airbag module, connect with two unfolding harness.
The connection part should be tangled with the
Short-circuit rubber tape to insulate (see the left figure).
Insulated Rubber Tape Location
Airbag-24
(e) Install the unused bolt on the inner side bolt of

Driver Side Airbag Module the driver side airbag module. Connect thicker
metallic filament used by fixed rim on the rim.
(f) Switch the unfolding harness connecting with
the driver side airbag module with the bottom of
the old tyre that fixes the rim. Fix the driver side
Unfolding Harness
airbag module upwards with the metallic filament
connected on the bolt (see the left figure).
(g) Place three non-hub old tyres on the fixed driver

side airbag module.
Non-Hub Old Tyre
Unfolding Harness
(h) Cut off the connector of the driver side airbag

module unfolding harness in the place far away
from car. Connect the connector with two ends of
the accumulator disassembled from the car and
unfold it (see the left figure).
Notice: First confirm whether there are people
in the car or around the car or not. Operate after
confirming that there are no persons. When
Unfolding Harness unfolding the driver side airbag, the inflator is on
high temperature. Leave it alone for more than
30 min and operate it after cooling. If the driver
side airbag cannot be unfolded, discuss with the
local special service station of Great Wall Motor
Company, Ltd.
(i) The driver side airbag module unfolded should be
abolished by the Abolish Outline.
Air-conditioning system-
Air-conditioning system
Air-conditioning system structure and principle......................... 2

Air-conditioning system function’s brief introduction ............... 3
Air-conditioning self-test process................................................. 4
Air-conditioner compressor........................................................... 7
Air-conditioner ECU wiring electric schematic diagram ............ 8
Rear blower wiring electric schematic diagram........................... 8
Each terminal definition of air-conditioning system.................... 9
Air-conditioning system's daily maintenance ............................. 11
Refrigerate oil filling volume and notice....................................... 11
Air-conditioning system structure and principle

Indoor temperature sensor
Front air-conditioner
Condenser
Fluid reservoir
Compressor
Outdoor temperature
High pressure pipeline sensor
Low pressure pipelines
Rear air-conditioner
Air-conditioning system's basic composition

The air-conditioning system is an automatically controlled air-conditioning system, through which the
integration of ventilation, warming and refrigeration is realized. The cool air and warm air are sepa-
rated, and it is equipped with an air cleaning device.
Basic composition: the front warm air heater assembly, the compressor assembly, the front and the
rear air blower assembly, the condenser assembly, the front and the rear evaporator assembly, the
pipeline, the air conditioner control panel assembly, the defrost system, and the heating and ventilat-
ing system.
Air-conditioning system’s brief introduction
● The Great Wall COWRY air-conditioning system is a dual-evaporator system, that is, there are
two air conditioners in the front and in the rear; the front air conditioner integrates heating and
refrigerating, while the rear air conditioner only has the refrigerating function. The system is
divided into the automatic and the manual air-conditioning system. Automatic control program
is eliminated on the manual air-conditioning system based on the automatic air-conditioning
system, and the hardware parts of it are the same as that of the automatic air conditioner. The
internal and external circulation, the blowing mode, and the high and low temperature regula-
tion of the air-conditioning system are all controlled by the air-conditioning controller. The
steam compression refrigeration system being used, the compressor is driven by the engine
directly, the high-temperature and high-pressure refrigerant steam emitted from the compres-
sor enters the condenser through the high pressure pipe. The temperature difference is uti-
lized for heat releasing, the steam forms into high pressure liquid, enter into the expansion
valve through the condenser liquid discharge pipe pressure switch assembly, and after throt-
tling, it becomes low-temperature and low-pressure liquid. Through the heat exchange by the
evaporator, the room air is changed into cool air. The refrigerant in the system is low-temper-
ature and low-pressure steam, which is sucked into the compressor, and is compressed into
high-temperature and high-pressure gas, then forms a refrigeration circulation. The circulation
proceeds repeatedly, maintaining the temperature inside the vehicle at a comfortable state.
● The air-conditioning system adopts the SE10B17 two way sloping plate type positive displace-
ment compressor, the front and the rear air conditioner all adopt H expansion valve, and the
front blower has non-woven air purifier .
● The electrical device of the air-conditioning system mainly includes: the air-conditioning con-
troller, the mixture choke actuator motor, the mode choke actuator motor, the inner and outer
choke actuator motor, the indoor temperature sensor, the outdoor temperature sensor, the
evaporator temperature sensor, the front blower motor, the front blower motor speed regula-
tion module, the rear blower motor, the rear blower motor speed regulation resistor, the air
conditioning pressure switch, etc.
Air-conditioning system function’s brief introduction
1. Temperature setting
The range of the temperature regulation is (18-32) ℃, and the regulation unit is 0.5℃.
2. Air volume setting
Gear 1-4 air volume, to ensure the safety operation of the air-conditioning system compressor, the air-
conditioning controller forbids starting the air-conditioner compressor when the air volume is in Gear
o. In the mode of forced refrigerating or forced heating, the air volume automatically rises to Gear 4.
Air Volume Indication Air Volume Voltage The driving of the air-conditioner fan is accom-
plished by the fan speed regulation module.
Grade 1 About 4V
The signal-driven motor speed regulation mod-
Grade 2 About 7V ule of the air-conditioning controller regulates
Grade 3 About 10V the voltage of the fan to adjust the fan rotation
About 12V (vehicle mains speed and the air volume of the air conditioner,
Grade 4
voltage) and the speed regulation module feedback the
operation voltage message of the motor at the same time. The controller controls the running of the
fan at the corresponding set point. The operation point of the fan is set in Gear 4, and the gear posi-
tion and the voltage of each fan is shown in the table.
3. Rear air conditioning control
The users can start or stop the rear air conditioner by operating the rear air conditioner button. The
state of the rear conditioner request signal is displayed correspondingly through the indicator embed-
ded in the button.
4. Rear defrosting control
The users can start or stop the rear defrosting by operating the rear defrosting button. It is stopped
after starting with a 10 minutes automatic delay, and can also be stopped through manual control at
any moment. The state of the rear defrosting request signal is displayed correspondingly through the
indicator embedded in the button.
5. Front defrosting control
Users can start or stop the front defrosting by operating the front defrosting button. The state of the
front defrosting is displayed correspondingly through the indicator embedded in the button. Air is
delivered to the front wind shield and the front side window through the air outlets of the instrument
panel to realize the defrosting function after the mode is started. The mode choke is switched to the
defrosting position after the button is pressed. The circulation choke is switched to the outer circula-
tion position, the air volume rises to the maximum, and then the compressor starts. After pressing
the defrosting button again, the system returns to the working state before defrosting. Press the AC
button, the AC works according to the consumer operation, and working states of other parts do not
change. Press the AC button again, AC does not return to the working state before defrosting, other
parts return to the working state before defrosting. Press the mode button, the mode returns to the
working state before defrosting, while other parts working state do not change. Press the AUTO but-
ton, each part of the system comes into the automatic working state and the defrosting state is can-
celed. Press the circulation button, the circulation choke works according to the users’ operation, while
the working state of other parts does not change. Press the defrosting button again, the circulation
air does not return to the working state before defrosting, while other parts return to the working state
before defrosting.
6. Compressor control
The controller stops the air-conditioner compressor when the evaporator temperature is lower than the
set value, according to the temperature massage of the evaporator temperature sensor, to avoid the
evaporator frosting. The set point is (1-3) ℃. In the AUTO state, the compressor stops automatically
when the outdoor temperature is lower than 14℃, and starts automatically when the outdoor is higher
than 16℃. Operating the compressor button can start or stop the compressor no matter in the AUTO
state or the non-AUTO state. The air-conditioning controller has the memory function, to maintain the
state when it is stopped last time. The high air conditioner request signal is highly effective (12V), the
request signal emitted by the air-conditioning controller arrives to the engine ECU9 foot through the
three-stage pressure switch, After the air conditioner request signal is received by the engine ECU,
the air conditioner starts and the engine speed increases if conforming to the condition, and the elec-
tric fan rotates in low speed gear. The control electric fan rotates in high speed gear after the three-
stage pressure switch medium pressure signal (slightly effective) is received by the engine ECU39
foot.
7. Time adjustment
When the users operate H button, the hour part of the time will add 1, when the number in hour part
is 12, operate the button H, and the response in the hour part is 1. The users operate M button, the
minute part of the time will add 1, when the minute part number is 59, operate M button, and the
response in the minute part is 00. The users operate 00 button, the number response in the minute
part is 00.
8. Air-conditioning system diagnosis
The controller has the diagnostic function of the air-conditioning system, so as to assist to locate and
analyze the system malfunction in the case of air-conditioning system failure. The diagnostic system
diagnoses the executive mechanism such as the sensor, choke motor, and blower motor, etc. through
the system harness. When switching from the regular control to the self-diagnostic system, start the
engine first (turn the ignition switch from “OFF” to “ON”), push the button “OFF” and keep holding for
at least 3 seconds. The button must be pressed in 10 seconds after starting the engine (the ignition
switch is turned to “ON”). When relieving the system, both pressing the switch AUTO and turning off
the ignition switch (OFF) are ok. The temperature knobs are corresponding to the test procedure.
Air-conditioning self-test process

All the indicating lamps lighten after entering the test mode, and the display screen, according to the
temperature knot, shows the relevant test data as shown in the following table:
The V08 display screen is divided into three parts as shown in the following table:
The separate display and the meanings of the test procedure is shown in the following table
Temperature
Part Ⅰ Part Ⅱ Part Ⅲ
Knob
Lo Software Version No. Test Mode Test Mode
Gear I Sensor Trouble Code Displaying AUTO Test Procedure
AMB INC EVAP Trouble Code
OK OK OK 0
Short OK OK 1
Broken OK OK 2
OK Short OK 4
OK Broken OK 8
OK OK Short 16
OK OK Broken 32
When several sensors fail, the trouble
codes are the sum of the sensor faults. It
is as follows:
AMB INC EVAP Trouble Code
Short Short OK 5
Broken Short OK 6
Short Broken OK 9
Broken Broken OK 10
Short OK Short 17
Broken OK Short 18
Short OK Broken 33
Broken OK Broken 34
OK Short Short 20
OK Broken Short 24
OK Short Broken 36
OK Broken Broken 40
Short Short Short 21
Short Short Broken 37
Short Broken Short 25
Short Broken Broken 41
Short Broken Broken 41
Broken Broken Broken 42
Broken Broken Short 26
Broken Short Broken 38
Broken Short Short 22
Temperature
Part Ⅰ Part Ⅱ Part Ⅲ
Knob
Lo Software Version No. Test Mode Test Mode
Gear 2 Outdoor Temperature Value Out Test Procedure
Gear 3 Indoor Temperature Value Inc Test Procedure
Gear 4 Evaporator Temperature Value Evap Test Procedure
COLD (driven to
Gear 5 Temperature Choke Position Test Procedure
the cold end )
HOT (driven to
Gear 6 Temperature Choke Position Test Procedure
the hot end)
FACE (driven to
Gear 7 Mode Choke Position Test Procedure
the face blowing)
DEF(driven to
Gear 8 Mode Choke Position Test Procedure
the defrosting)
Gear 9 Outer Circulation Out Test Procedure
Gear 10 Inner Circulation In Test Procedure
FAN4 (air volume
Gear 11 Air Volume Value Test Procedure
largest)
Gear 12 Air Volume Value FANO (Air volume off) Test Procedure
Gear 13 Compressor On AC On Test Procedure
Gear 14 Compressor Off AC OF Test Procedure
Gear 15 Rear Air Conditioner On RE On Test Procedure
Gear 16 Rear Air Conditioner Off RE OF Test Procedure
Gear 17 Rear Defrosting On RE On Test Procedure
Gear 18 Rear Defrosting Off RE OF Test Procedure
Gear 19 Inspection Finished OFF Test Procedure
Air-conditioner compressor
structural diagram
Front cover Slipper Piston

Clutch
Front cylinder body Rear cylinder body Slanting plate Rear cover
Character of the SE10B17 bidirectional slanting plate type compressor:the piston with teflon coated
surface has a low friction coefficient and high seal efficiency.The slanting plate slipper mechanism
with a long life cycle and good lubrication operates smoothly.The cylinder block with high strength
Al-alloy tends to make the compressor lighter and smaller.The slanting plate with special antifriction
coat has a low friction coefficient and long durability.
SE10B17 bidirectional slanting plate compressor parameter
Theoretic Displacement (ml/r) 178

Cylinder Number 10
Maximum Continued Speed (r/min) 7000
Maximum Authorized Angle(°) ±35
Gyration Direction Clockwise
Used Cooling Agent R134a
Lubricating Oil Brand sp-10
Oil Volume (ml) 200±10
Rated Voltage (V) 12
Power Consumption (W/max) 40
Breakaway Torque (N. m) 39.2
Air-conditioner ECU wiring electric schematic diagram
Air blower relay

Mode actuator Inner/outer Temperature
circulation actuator actuator
Air blower high Blower
speed relay
Speed
regulation
module
V08 air conditioner ECU
Evaporator Out-car In-car

temperature temperature temperature
sensor sensor sensor
Temperature regulation knob
Note: the buttons in the dashed box is in the front of the control panel
Rear blower wiring electric schematic diagram
Rear air-conditioner relay
Rear blower
Rear vaporizing air machine
speed regulation resistor
Rated
current
air volume switch
Rear vaporizing
Each terminal definition of air-conditioning system
Lead foot definition of Rear Lead foot definition of internal and Front blower motor
vaporizing air volume switch external circulation servo motor Lead foot definition
Blower speed regulation Mode servo motor Rear blower motor

module terminal definition lead foot definition lead foot definition
definition of rear evaporator speed Definition of temperature Definition of outdoor

adjusting resistance terminal servo motor lead foot temperature sensor
In-door temperature sensor Evaporator temperature

lead foot definition sensor lead foot definition
Air-conditioning system-10
Interface Lead Interface

Pin Description Remarks Description Remarks
signal foot signal
Temperature choke
2A01 GND Ground 2B01 VDD_T
feedback power
Temperature choke
2A02 IG2 Power 2B02 TEMP+
motor driving+
Temperature choke
2A03 BATT Battery power 2B03 TEMP F/B
motor feedback
Air-conditioner Circulation choke
2A04 A/C High level 2B04 INTAKE+
request signal motor driving+
Mode choke
2A05 2B05 VDD_M
feedback power
Back light Mode choke
2A06 LIGHT+ 2B06 MODE+
anode motor driving+
Back light Mode choke
2A07 LIGHT- 2B07 MODE F/B
cathode motor feedback
Emergency
2A08 EME lamp switch Low level 2B08 EVAP GND Evaporator sensor-
output
2A09 GND Ground 2B09 AMB GND Outdoor sensor-
INCAR
2A10 IG2 Power 2B10 Indoor sensor-
GND
Rear defrosting Temperature
2A11 RR_SW Low level 2B11 GND_T
control choke-
Blower delay Temperature choke
2A12 FAN Low level 2B12 TEMP-
control motor driving-
Rear air- Internal and
2A13 REAR conditioner Low level 2B13 IG2_INT external circulation
relay control choke motor power
Blower high Circulation choke
2A14 HS Low level 2B14 INTAKE-
speed motor driving-
Air volume
2A15 FAN_GATE 2B15 GND_M Mode choke
control
Air volume Mode choke
2A16 FAN_F/B 2B16 MODE-
feedback motor driving-
2B17
Evaporator
2B18 EVAP temperature
sensor
Outdoor
2B19 AMB temperature
sensor
Indoor temperature
2B20 INCAR
sensor
Air-conditioning system's daily maintenance

In order to ensure the normal operation of the air-conditioning system, the air-conditioning system
should usually be maintained, and the daily maintenance of the air-conditioning system is as follows:
1. Inspect and clean the condenser of the air-conditioning system, and the cooling fin is required
to be clean and there is no stemming between the fins. After driving in the rain or on the
muddy road, the condenser fan should be inspected to find whether there are silt and stones
in it, and clear them if there are, or the refrigeration effect will be affected.
2. Inspect the refrigeration system refrigerant; observe the moisture liquid indicator when the air
conditioning unit works normally. Normally there is no air bubble in the moisture liquid indica-
tor.
3. Inspect whether the compressor clamp bolt is tight and reliable.
4. Inspect whether the air-conditioning system has abnormal noise and smell.
5. Inspect whether the temperature difference at the compressor intake and exhaust port is nor-
mal.
6. Inspect whether the appearance of the refrigeration system hose is normal, and the connec-
tion of each connector is tight.
7. Inspect whether the pipeline of the refrigeration system contacts other parts, and whether
each connector has smear leaked.
8. Inspect whether the connecting of the refrigeration system circuit is reliable and whether there
is a short circuit.
Refrigerate oil filling volume and notice

The air-conditioning system adopts Sanden Behr
SE10B17 type compressor, the specified refrigerate
oil type is sp-10, and the parts of the compressor will
be damaged if other types of refrigerate oil are used.
When repairing the air-conditioning system and chang-
ing the parts, the amount of the refrigerate oil need
increasing: the evaporator, and the condenser: 50ml,
the pipeline: 20ml.
Notice:
1. When the used compressor is replaced with a
new compressor, a slight mount of oil must be
discharged to make the oil volume keep consist-
ent with that in the used compressor, and to avoid
affecting the refrigeration effect due to the over oil
volume.
2. When using the used compressor or the repaired
compressor, make sure that the oil volume in the
compressor is the same as that in the replaced
compressor.
Low pressure
High pressure
Vacuum pumping and filling refrigerant
Manifold Notice: when using the R134a in the special device
Low pressure Blue
Red recovery system, avoid emitting it to the atmos-
pipe
phere to pollute the environment.
High pressure
pipe Connect the air-conditioner (compressor) pipeline
Quick loading
connector and the multipurpose connector of the vacuum pump
Quick loading with the pressure manifold to perform vacuum pump-
Vacuum pump connector ing. Before vacuum pumping, open the high and low
pressure valve of the pressure manifold, and open the
end valve of the vacuum pump (if there is), and then
press the “ON” button to start the vacuum pump,
and the duration should exceed 20 minutes. When
the pressure manifold indicates -760mmHg or even
lower, close the high and low pressure valve and the
end valve of the vacuum pump (if any),and press the
switch to close the vacuum pump.
Manifold Inspect gas tightness

After closing the vacuum pump, continue to inspect
Low pressure gauge High pressure gauge
the pressure reading of the pressure manifold
If the pressure reading remains the same for 20
minutes after the vacuum pump stops running, it is
proved that there is not a leakage in the system,and
Yellow the next step can be continued. If the reading
changes, it is proved that there is a leakage in the
Blue Yellow Red system. Inspect and repair the leak part, and perform
vacuum pumping again.
Filling refrigerant
1. After confirming the gas tightness of the system,
Air purge connect the refrigerant canister (or gas cylinder)
Off
with one end of the yellow inflatable hose. Con-
Red
nect the other end of the yellow inflatable hose
Yellow with the injecting liquid port of in the middle of
Blue the pressure manifold. After confirming the con-
necting of the nut of the refrigerant canister and
Cooling agent canister
the inflatable hose, open the valve of the refriger-
ant canister. The high and low pressure valve is
closed now, keep pressing the valve plug beside
the port for 1-2 seconds with the acrocephalia
screwdriver or similar instruments to emit the air
in the inflatable hose and the manifold.
2. Open the high valve of the pressure manifold to
Low pressure
Off High pressure charge with refrigerant from the high pressure
On pipeline to the system. Here notice the reading
Blue
Red of the high pressure gauge and the low pres-
sure gauge, and ensure both of them rise. If the
Yellow refrigerant is been charged, but the pressure
does not rise, it will be considered that the pipe-
line is loose at the connector or the sealing point
Cooling agent canister is damaged, and after finding out the cause and
repairing, recharge with refrigerant again. After
the pressure rising stops, close the high pressure
valve of the pressure manifold, and then start the
engine.
Low pressure Operate the switch in the following methods

High pressure
1. Turn on the air conditioner, and start the com-
Blue On On
pressor.
2. Turn the temperature controlling knob to the
Red
coldest position.
Yellow 3. Turn the fan knob to the highest position.
4. Choose the inner/outer air circulation to outer air
circulation.
Cooling agent canister 5. The vehicle door and the vehicle window is open
during the process.
6. Regulate the motor speed to (850-950) r/min.
High pressure 7. Stick up the refrigerant canister or the gas cylin-
side pressure der (make the refrigerant inject to the refrigera-
(MPa)
tion system as gaseous), open the low pressure
Appropriate valve of the pressure manifold.
pressure
8. When filling refrigerant, observe the value of the
(Proper charging) (over charging) pressure manifold carefully, the refrigerant flow
state (clear, bubble, cloudy) can be seen through
the inspection window, to judge when it is appro-
Cooling agent charging volume(g)
priate to stop filling refrigerant (by closing the
low pressure valve).
When the compressor is running, do not open the
high pressure valve.
When inspecting the refrigeration level, confirm the
filling volume of the refrigerant specified by the air-
conditioning system.
Notice: Please charge with R134a according to
the requirement, and after filling, observe whether
the high and low pressure of the system is nor-
mal, and whether the refrigeration is normal.
Vehicle body-
Vehicle body
Font door.......................................................................................... 2
Front door lock ............................................................................... 5
Sliding door...................................................................................... 6
Sliding door lock............................................................................. 9
Rear back door ............................................................................... 10
Front bumper................................................................................... 12
Rear bumper.................................................................................... 14
Instrument panel.............................................................................. 16
Electric sunroof............................................................................... 21
Seats ................................................................................................ 33
Safety belt........................................................................................ 36
Vehicle body-
Font door
component diagram
Right front door triangle

protective plate Right front door glass
Right front door

Right outer rear glass sealing strip
view mirror body
Right front door
front guide slot
Right front door glass
external water cut
Right front door outer

Right door inner handle assembly
handle assembly
Right front door Right door arrester

internal water cut
Right front door glass
frame riser assembly
Right front door

sealing strip
Front door Right door window switch assembly

protective surface
Right front door rear guide slot
Front door disassembly

1. Disassemble the front door interior decorative plate
(a) Disassemble the triangle protective plate.
(b) Disassemble the inner handle screw and the
buckle.
(c) Disassemble the inner door handle screw.
(d) Disassemble the electric switch and pull off the
Front door interior
handrest
wire harness.
(e) Insert the screwdriver between the fixed buckle
and the door interior decorative plate to loosen it.
Left front door interior Notice: the head of the screwdriver must be muf-
decorative plate
fled with adhesive tape before using it.
(f) Take off the door interior decorative plate.
Vehicle body-
Right front door glass 2. Disassemble the front door external water cut
Adjust the glass downwards to the proper position;
grasp the external water cut tightly with hands and pull
up forcibly to disassemble it.
Right front door glass 3. Disassemble the front door glass assembly
external water cut
(a) Adjust the glass to make the glass bracket fixing
bolt align with the inner plate installing hole, and
disassemble the two glass bracket fixing bolt.
(b) Pull upward the glass and then disassemble it
slantways.
Right front door 4. Disassemble the front glass sealing strip

glass sealing strip 5. Disassemble the front door glass guide slot assem-
bly
Front door glass

guide slot
6. Disassemble the glass riser

(a) Disassemble the four fixing bolts and the two nuts
of the riser bracket.
(b) Disassemble the riser through the auxiliary hole.
7. Disassemble the vehicle inner lock raising handle
8. Disassemble the door lock and the door outer han-
dle with lock core
Right front door glass Front door glass assembly replacement

1. Adjust the glass to make the glass bracket fixing
bolt align with the door inner plate installing hole
2. Disassemble the glass bracket fixing bolt and take
out the glass.
Front door assembly

1. Before installing the parts, MP grease should be
applied first
(a) Apply MP greas e onto the sliding face and the
gear of the glass riser.
Notice: never apply MP grease onto the spring of
the glass riser.
(b) Apply MP grease onto the sliding face of the door
lock.
2. Install the door outer handle with lock core and
door lock
3. Install door inner lock raising handle.
Install the door inner lock raising handle, and connect
the control rod.
Vehicle body-
4. Install the glass riser

(a) Install the riser through the auxiliary hole.
(b) Install the four riser fixing bolts.
(c) Install the two riser bracket fixing nuts.
Left front door 5. Install the front door glass guide slot assembly
glass sealing strip Install the guide rail and the bolt.
6. Install the front door glass sealing strip
Front door glass

guide slot
7. Install the front door glass assembly

Left front door glass
Install the glass into the door cavity, and then fix the
glass on the glass riser with two bolts.
8. Install the front external water cut
Adjust the glass downward to the proper position, and
Left front door make the external water cut get stuck on the outside
glass external
water cut
door plate rabbet.
Left front door triangle

9. Install the front door interior decorative plate
protective plate 10. Install the front door inner handle
(a) Push the door handle into the vehicle door panel,
and make it slide backward.
Left inner (b) Tighten the screw.
handrest bracket
Front inner handrest
Left front door interior

decorative plate
Vehicle body-
Front door lock

component diagram
Front door outer handle
Front door lock core Front door inner
decorative cover Front door outer handle handle assembly
sealing gasket II
Front door outer handle
Front door locking
sealing gasket I Front door outer pulling cable
handle frame
Front door tension
rod assembly Outer handle
Front door lock installing screw
core assembly Front door lock
opening pulling cable Inner handle
installing screw
Lock core
installing screw Front door lock pulling
Front door locks cable installing buckle
body assembly
Lock body fixing bolt

Q2580820+Q414F32
Front door lock
Front door lock installation

1. Install the front door outer handle sealing gasket I
and the front door outer handle sealing gasket II.
2. Install the front door outer handle frame, and
tighten the outer handle installing screw.
3. Install the front door outer handle.
4. Install the front door tension rod assembly.
5. Install the front door lock body assembly, the front
door lock locking pulling cable, the front door lock
opening pulling cable, and the side door inner han-
dle assembly separately.
6. Install the assemblies that have been assembled,
and tighten the lock body set screw (pay attention
to insert the lower end of the front door tension rod
assembly into the outer rocker arm protector).
7. Install the side door inner handle assembly.
8. Install the front door lock pulling cable installing
buckle.
9. Install the front door lock core, the lock core deco-
rative cover, and tighten the lock core fixing screw.
10. Tighten the inner handle installing screw after fin-
ishing installing the door core plate.
Front door lock Disassembly
Disassemble in the reverse order of that in the
installation.
Vehicle body-
Sliding door
component diagrams
Sliding door glass assembly
Sliding door upper hinge
Sliding door glass

sealing strip
Sliding door frame
upper sealing strip
Sliding door lock assembly Sliding door glass

external water cut
Sliding
door lock
Sliding door lock
assembly accessories Sliding door middle
Sliding door lock guide rail stopper
Sliding door Sliding door rear

lower hinge lower glass guide slot
Sliding door lower buckle
Sliding door internal water cut
Sliding door window Sliding door sheeting

switch assembly upper plate assembly
Sliding door sheeting

lower plate assembly
Sliding door Disassembly

1. Disassemble the sliding door interior decorative plate
(a) Disassemble the inner handle cover plate screw
and the inner handle.
(b) Insert the screwdriver between the fixing buckle
and the door interior decorative plate to loosen it,
and disassemble the door interior decorative plate.
Notice: there are wire harnesses connecting with
Sliding door window the vehicle door on the door decorative board,
switch assembly
which can not be taken down completely.
(c) Disassemble the glass riser wire harness and the switch.
Notice: before using the screwdriver, its head must
Sliding door interior be coated with adhesive bandage.
decorative plate assembly
(d) Take down the vehicle door interior decorative plate.
Vehicle body-
2. Disassemble the sliding door external water cut

Adjust the glass to move it downward to the proper
Left sliding
door glass position, hold tightly the external water cut with hands,
and pull upward forcibly to disassemble it.
3. Disassemble the sliding door glass assembly
Left sliding door (a) Adjust the glass to make the glass bracket fixing
external water cut bolt align with the door inner plate installing hole,
and disassemble the two glass bracket fixing bolts.
(b) Pull the glass upward and then disassemble it
slantways.
4. Disassemble the sliding door glass sealing strip
Glass sealing strip
5. Disassemble the sliding door glass guide slot

assembly
Sliding door
glass guide slot
6. Disassemble the glass riser

(a) Disassemble the four fixing bolts and the two
retaining nuts of the riser bracket.
(b) Disassemble the riser through the auxiliary hole.
7. Disassemble the sliding door lock assembly
Sliding door glass assembly replacement

Sliding door glass 1. Adjust the glass to make the glass bracket fixing
bolt align with the door inner plate installing hole
2. Disassemble the glass bracket fixing bolt and take
out the glass
Vehicle body-
Sliding door assembly

1. Before installing the parts, MP grease should be
applied onto them
(a) Apply MP grease onto the sliding surface and the
gear of the glass riser.
Notice: never apply MP grease onto the spring of
the glass riser.
(b) Apply MP grease onto the sliding surface of the
door lock.
2. Install the sliding door lock assembly and the outer
handle
3. Install the glass riser
(a) Install the riser through auxiliary hole.
(b) Install four riser fixing bolts.
(c) Install two riser bracket retaining nuts.
4. Install the sliding door glass guide slot assembly

Install the guide rail and the bolt.
5. Install the sliding door glass sealing strip

6. Install the sliding door glass assembly
Install the glass into the door cavity, and then fix the
two bolts on the glass riser.
7. Install the sliding door external water cut
Adjust the glass to move downward into the proper
position, and make the external water cut get stuck on
the door outer plate rabbet.
8. Install the sliding door interior decorative plate

9. Install the sliding door inner handle
Push the door handle into the vehicle door panel, and
make it slide backward. Then tighten the screw.
Door inner handle
Vehicle body-
Sliding door lock

Component diagram
Sliding door inner handle body
Sliding door inner handle Inner handle body construction bolt
body decorative cover Front lock pulling cable
Inner handle body decorative Lower lock pulling cable
cover installing screw
Sliding lock pulling cable
Sliding door outer handle frame Sliding door rear buckle
Lock core Sliding door rear
Outer handle
installing screw installing screw buckle installing bolt
Sliding door outer Rear door outer handle
handle sealing gasket I sealing gasket I
Sliding door lock Outward
opening Pulling cable buckle
decorative cover Sliding door pulling Sliding door rear
Sliding door inner handle locker outer handle cable lock installing bolt
Sliding door tension Sliding door rear
rod assembly lock assembly
Sliding door locking
pulling cable
Sliding door lock
Sliding door lock body assembly
Sliding door lock body
Sliding door lock construction bolt
construction bolt Lower buckle installing bolt
Lower lock installing bolt
Sliding door lower buckle

Sliding door lower lock assembly
Sliding door lock installation

1. Installing the sealing gasket I and II.
2. Install the outer handle frame, and tighten the frame fixing screw.
3. Install the front door outer handle onto the outer handle frame.
4. Install the sliding door lock decorative cover, and tighten the decorative cover installing screw.
5. Install the front lock pulling cable, front lock body after installing them separately, and tighten
the lock body fixing screw.
6. Install the rear lock pulling cable, rear lock body after i nstalling them separately, and tighten
the lock body fixing screw.
7. Install the lower lock body, lower pulling cable, rear door glass anti-clip pulling cable after
installing them separately, and tighten the lock body fixing screw.
8. Install the sliding door tension rod assembly.
9. Connect the other end of the front lock pulling cable, the rear lock pulling cable, the lower lock
pulling cable, the outward opening pulling cable to the inner handle body (the rear door lock-
ing pulling cable is connected with the glass riser).
10. Install the inner handle body, and tighten the fixing screw.
11. Install the six pulling cable buckles.
12. Install the inner handle body decorative cover after finishing installing the door core plate, and
tighten the fixing screw.
Note: when the sliding door is closed, both the sliding door rear lock body assembly and the
sliding door rear lock work. The rear lower door lock has the function of two gears locking, when
the sliding door glass is at the bottom, and when pull the sliding door backward about 2/3, the
rear lower door lock locks, if all the sliding doors are expected to be open, the sliding door glass
needed to be lifted to the top. When all the sliding doors are open, the rear lower door lock plays
the locking function, preventing the slide of the sliding door caused by outer forces.
Disassembly of sliding door lock
Please disassemble in the reverse order of that in installation.
Vehicle body-10
Rear back door

Component diagram
Spoiler body Rear back door glass assembly
Rear back glass sealing strip
High mounted braking lamp cover

Rear back glass sealing strip
High mounted braking

lamp assembly
Rear back door
Rear back door right gas spring
right shock pad
Rear wiper assembly
Rear back door
Rear back door left shock pad
left gas spring Rear back door outer handle
Rear back door lock

Camera head assembly
License plate lamp

License plate
decorative strip
lamp assembly
Rear back door outer plate

Rear back door interior
Rear back door frame sealing strip decorative plate
Rear back door interior

Rear back door disassembly
decorative plate 1. Disassemble the rear back door interior decorative
plate
(a) Insert the buckle driver between the fixing buckle
and the rear back door interior decorative plate to
loosen it.
Notice: before using the buckle driver, its head
must be coated with adhesive bandage.
(b) Disassemble the rear back door interior decorative
plate.
Vehicle body-11
Rear back door lock Rear back door lock 2. Disassemble the rear back door lock assembly
core assembly core reinforcing plate (a) Disassemble the rear back door tension rod.
Rear back door (b) Disassemble the rear back door lock core, and the
outer handle
assembly lock core reinforcing plate.
(c) Disassemble the rear back door outer handle.
Rear back door
Rear back door
tension rod
locker assembly (d) Disassemble the rear back door lock body.
Rear back door
lock body assembly Q1400616FD
Q2580820+Q414F32
Rear back door lock
3. Take down the license plate lamp decorative, and

disassemble the license plate lamp assembly
License lamp
decorative strip
License lamp assembly
4. Disassemble the rear wiper arm assembly

(a) Disassemble the one rear wiper arm retaining nut
and the rear wiper arm.
(b) Disassemble the three rear wiper motor fixing
Rear wiper arm
bolts and the rear wiper motor.
(c) Disassemble the rear wiper waterproofing glue.
Rear wiper motor
High mounted 5. Disassemble the high mounted braking lamp

braking lamp cover assembly
(a) Disassemble the rear back door glass sealing
High mounted braking strip.
lamp assembly (b) Disassemble the high mounted braking lamp
cover.
Rear back door (c) Disassemble the high mounted braking lamp
glass sealing strip assembly.
Vehicle body-12
Front bumper
Component diagram
Expansion buckle Front bumper left supporting plate

Front bumper middle
construction bolt
Front bumper left bracket
Wing panel
plug hole nut
Big washer
Screw seat
Hexagon flange
tapping screw
Big washer
Cross recessed hexagon
tapping screw
Hexagon flange
tapping screw Front bumper installing
subassembly
Expansion buckle
1. Screw out the hexagon flange tapping of the front

bumper connecting with the splash-proof cushion,
and take down the big washer
Big washer
Screw seat
Hexagon flange face
self-tapping screw
2. Disassemble the expansion buckle for connecting

the front bumper and the splash—proof cushion
Expansion buckle
Vehicle body-13
3. Disassemble the front bumper installing sub-

assembly for connecting the front bumper side and
the splash-proof cushion
Front bumper installing

subassembly
4. Screw out the hexagon flange tapping screw a

Front bumper left bracket of the front bumper upper corners on the two
sides connecting with the front bumper left / right
bracket, and take down the big washer
Big washer
Hexagon flange tapping screw
5. Screw out the front bumper middle construction

Front bumper middle bolt, which connects the grid, the bumper and the
construction bolt
vehicle body in the bumper middle part
6. Disassemble the expansion buckle for connect-

Expansion buckle
ing the upper middle front bumper and the vehicle
Front bumper left bracket body
7. Pull out the front bumper from the front bumper left
/ right bracket and the bumper fixing slot under the
front head light
Wing panel plug hole nut

8. Disconnect the plug connection of the front fog
lamp
Front bumper 9. Screw out the cross recessed hexagon tapping
left bracket screw, take down the big washer, and take down
the front bumper left / right bracket
Big washer
Cross recessed hexagon

tapping screw
Vehicle body-14
Rear bumper
Component diagram
Rear bumper right

bracket subassembly
Hexagon flange tapping screw Q2704816FDH
Hexagon flange tapping Rear bumper plug hole nut

screw of Q2706319FDH
Big washer
Hexagon flange tapping nut Big washer
Rear bumper hatch Rear bumper Big washer

hook rubber washer plug hole nut
Rear bumper hatch
hook bolt (M6) Hexagon flange tapping
Big washer
Expansion buckle
1. Disassemble the expansion buckle connecting

with the vehicle body and the dash board under the
bumper lower
Expansion buckle
Hexagon flange 2. Screw down the rear storage box, tighten the hexa-
Rear bumper hatch tapping nut gon flange nut of the rear bumper hatch hook bolt,
hook rubber washer
and take down the rear bumper hatch hook rubber
washer
Rear bumper hatch hook bolt (M6)

Vehicle body-15
3. Screw down the hexagon flange tapping screw of

Big washer Q2706319FDH connecting the rear bumper and the
Rear bumper plug hole nut
vehicle body on the two sides of the rear bumper,
and take down the big washer
Hexagon flange face tapping

Rear bumper plug hole nut 4. Screw down the hexagon flange tapping screw of
Q2706319FDH connecting the rear bumper and the
Big washer vehicle body in the middle of the rear bumper, and
Rear bumper plug hole nut take down the big washer
Big washer
Hexagon flange face tapping

5. Pull out the rear bumper from the rear bumper

Rear bumper right left and right bracket, and the middle part of the
bracket subassembly
bumper breaks off along the bumper hatch hook
Rear bumper hatch
hook bolt (M6)
6. Disassemble the rear bumper plug hole nuts on the

two sides and the middle of the rear bumper
Rear bumper
plug hole nut
Rear bumper right 7. Screw down the hexagon flange tapping screw of
bracket subassembly
Hexagon flange tapping
Q2704816FDH connecting the rear bumper left /
screw of Q2704816FDH right bracket with the vehicle body, and disassem-
ble the rear bumper left / right bracket assembly
Big washer
Vehicle body-16
Instrument panel
Component diagram
Instrument panel upper the right triangle window

frame assembly demister air outlet assembly
Left triangle window

demister air outlet assembl
Combined instrument cover

Central air outlet panel assembly
Right upper sundries
box cover assembly
Left upper sundries

box cover assembly Front air-conditioner right side
air outlet panel assembly
Front air-conditioner left side
air outlet panel assembly
Right lower sundries

box assembly
Instrument panel lower frame assembly
Right lower glove case
Steering column protective upper baffle
Steering wheel lower protecting plate Shift handle assembly
Left lower small

Instrument panel Auxiliary instrument
sundries box assembly
base assembly panel assembly
Combined switch cover assembly
Rear ashtray assembly
1. Disassemble the auxiliary instrument panel assem-

bly
Screw
(a) Open the rear sundries box cover.
(b) Disassemble the two screws.
(c) Disassemble the rear cover assembly.
(d) Take down the felt of the cup carrier bottom.
(e) Disassemble a screw.
(f) Disassemble the auxiliary instrument panel body.
Vehicle body-17
2. Disassemble the instrument panel base assembly

(a) Take down the two felts.
(b) Disassemble the three screws.
(c) Disassemble the four buckles.
(d) Disassemble the instrument panel base protective
Screw plate.
(e) Disassemble the instrument panel base body.
Buckle
3. Disassemble the left upper sundries box cover

assembly
Disassemble the two screws.
Screw
4. Disassemble the right upper sundries box cover

assembly
5. Disassemble the air-conditioner control panel
Screw
6. Disassemble the central air-outlet panel assembly
7. Disassemble the steering panel

8. Disassemble the steering lower protective plate
Screw
Vehicle body-18
9. Combined switch cover assembly

Disassemble the three screws.
Screw
10. Disassemble the combination instrument cover

(a) Disassemble the two screws.
Buckle (b) Disassemble the three buckles.
11. Disassemble the CD player
Screw
12. Disassemble the right lower sundries box assem-
13. Disassemble the left lower small sundries box

assembly
14. Disassemble the shift handle cover assembly

Vehicle body-19
15. Disassemble the front air-conditioner left side air

outlet panel assembly
16. Disassemble the front air–conditioner right side air

outlet panel assembly
17. Disassemble the left column A upper protective

plate and the left triangle window demister air out-
let assembly
18. Disassemble the right column A upper protective

plate and the right triangle window demister air
outlet assembly
19. Disassemble the anti – theft indicating lamp wire
harness
20. Disassemble the instrument panel upper frame

assembly
Screw
Vehicle body-20
21. Disassemble the right lower glove case

22. Disassemble the steering protective cover upper
baffle
Screw
Four nuts
Seven screws
Four nuts
23. D isassemble the instrument panel lower instru-

ment frame assembly
(a) Disassemble the seven screws.
(b) Disassemble the four bolts.
(c) Disassemble the four nuts.
Instrument panel installation

Install the instrument panel parts in the reverse
procedure of that in disassembly.
Vehicle body-21
Electric sunroof
Double sunroof and roof cover combined figure
Electric sunroof system subassembly view

4
1
5
6
7
2
1. Sunroof upper frame assembly 2. Sunroof inner fixing frame 3. Sunroof sun visor and
fixing frame assembly
4. Sunroof motor and control 5. Sunroof control module 6. Sunroof motor
module connector
7. Sunroof switch connector 8. Sunroof switch base 9. Sunroof switch
Vehicle body-22
Sunroof upper frame assembly
3
11
10
9
4
7 6 5
1. Sunroof glass plate 2. Sunroof glass guide rail ×2 3. Sunroof upper frame 4. Sunroof deflector
5. Glass lift rod ×2 6. Rail slider ×2 7. Glass connector ×2 8. Glass support ×2
9. Gear 10. Chain clamping plate 11. Soft driving shaft ×2
2, 5, 6, and 7 are called mechanical group assembly among them.
Windscreen switch
Reading light and Sunroof combination Roof light and Sunroof

combination switch
Vehicle body-23
Electric Sunroof system inspection
Steps Operations Normal Results Abnormal Results

1. Make sure that the
1.The Sunroof glass plate slants, and slides
Sunroof is closed
backward automatically to the fully open position. See “electric Sunroof
2. Press the start button
1 During the running process, if the following fault causes it unable
(on the rear part of the
condition appears, the Sunroof will stop moving: to work”
switch) for shorter than
• The Sunroof switch is pressed
0.3s
The Sunroof glass plate slide for closing (forward)
and slide backward automatically to the fully closed
1. Make sure that the position. During the running process, if the following
Sunroof is in the fully condition appears, the Sunroof will stop moving:
open position • The Sunroof switch is pressed See “electric Sunroof
2 2. Press the close button If the Sunroof glass plate encounters an obstacle, fault causes it unable
(on the front of the the Sunroof will move automatically in the reverse to work”
switch) for shorter than direction at this moment till it gets to the fully open
0.3 s position and it embeds and closes automatically.
(If the obstacle still remains there, the Sunroof will
move reciprocally, till the obstacle disappears.)
The glass plate rear part is lifted and opened.
Sunroof is in the fully
during the running process, if one of the following
close position See “electric Sunroof
conditions appears, the Sunroof will stop moving:
3 2. Press continually the fault causes it unable
• The Sunroof switch is released
start switch (on the to work”
• The glass plate is opened to completely inclined
rear part of the switch)
ventilating position
for longer than 0.3 s
Sunroof is in the The glass plate slides backward. During the running
completely inclined process, if one of the following conditions appears,
See “electric Sunroof
ventilating position the Sunroof will stop moving:
4 fault causes it unable
2. Press continually the • The Sunroof switch is released
to work”
start button (on the • The Sunroof glass plate gets to the fully open
rear part of the switch position
) for longer than 0.3 s
Sunroof is in the fully The Sunroof glass slid forward. During the running,
open position if appear one of the following conditions, the See “electric Sunroof
5 2. Press the close button Sunroof will stop moving: fault causes it unable
(on the front part of the • The Sunroof switch is released to work”
switch) for longer than • The glass plate gets to inclined ventilating position
0.3 s
Sunroof is in inclined The Sunroof rear part drops, and is divided into
ventilating position five opening angles till the Sunroof is closed See “electric Sunroof
6 2. Press continually the completely,(see inclined ventilation for details) till fault causes it unable
close button (on the one of the following conditions appears: to work ”
front part of the switch) • The Sunroof switch is released
for longer than 0.3 s
The Sunroof glass shuts off (forward) automatically
after about 4 seconds. During the running process,
if one of the following conditions appears, the See “the ignition
1. Open the Sunroof
Sunroof will stop moving: switch is shut off,
glass plate to any
• The Sunroof switch is pressed (in any direction) and the electric
7 position
• The Sunroof glass plate encounters obstacles Sunroof fault causes
2. Shut off the ignition
Continue to press the close button, and the Sunroof it unable to close
switch
will be shut off completely. During the whole automatically”
process, the Sunroof can not make the opening
motion
Vehicle body-24
Steps Operations Normal Results Abnormal Results

ignition switch of the
vehicle is in off position,
and the Sunroof glass
plate stays still in the
opened position
2. Press the close button
See the “the ignition
(on the front part of
switch is shut off, and
the switch) for shorter The Sunroof glass plate moves forward to the
8 the electric Sunroof
than 0.3 s, or press fully closed position
fault causes it unable to
continuously the close
close automatically”
button to make the
glass slides to the
inclined ventilation
position, release the
button, and press
the close button
continuously
Vehicle body-25
Electric Sunroof fault diagnosis
Fault Phenomena Fault Reasons Troubleshooting

The Sunroof can not be shut off The locking slide is damaged Replace the locking slide
and it is difficult to open it
When the Sunroof is opened or The gear and the soft driving shaft Re-place the gear and the soft
closed, the Sunroof left and right have wrong relative positions driving shaft at the correct positions
positions are asymmetric
The Sunroof glass plate slides The mechanical device is Clean the mechanical device or
slowly contaminated or needs lubricating lubricate it with oil
Under voltage, which can not Inspect the vehicle body power
support the normal working of the supply and the electric circuit
Sunroof motor
Motor driving shaft be damaged Replace the motor
It is an electric Sunroof but the The distance between the motor Reinstall the motor, and adjust
Sunroof glass plate can not move driving shaft and the gear is the soft driving shaft to the correct
improper position
The Sunroof does not work, without The distance between the motor Reinstall the motor, and adjust the
any reaction driving shaft and the gear is improper driving shaft to the correct position
Error memory or damage of the Disconnect the regular power
computer box supply of the computer box to
eliminate the error memory or make
a replacement
The motor or the switch is damaged Replace it
Water leakage(general) The Sealing strip is contaminated Clean or replace the sealing strip,
or damaged and inform the customers the
reason
Dust particles deposit under the Clean the under part of the glass
Sunroof glass plate plate, and inform the customers the
reason
The Sunroof is opened when there Remove water, and inform the
is still water on the roof customers the reason
The Sunroof is not shut off well in Remove water, and inform the
rainy or snowy days customers the reason
There is water leakage at the rear The locking slide is damaged Replace the locking slide
corner of the Sunroof glass plate The arrester is damaged Replace it
The riser is damaged Replace it
Vehicle body-26
Maintain procedure
Replacement of the electric sunroof
switch and the switch base
● Disassembly procedure
1. Grasp the switch base on the front and the rear
side.
2. Pull the switch base downward to make the switch
disconnect with the switch bracket on the motor.
3. Disconnect the electrical connector on the switch.
4. Disassemble the switch and the switch base from
the vehicle.
5. Push out the switch from the switch base to make
the two separate from each other.
● Installation procedure
1. Push the switch into the switch base to make the
two get stuck with each other.
2. Connect the electrical connector onto the switch.
Important precautions: put the streaked part of the
switch toward the vehicle front part.
3. Press the switch forcibly into the switch bracket on
the motor to fix the assembly.
Replacement of the sunroof motor
ECU control module
1. Disassemble the sunroof switch and the switch
base.
Sunroof 2. Disassemble the roof cover inner decoration.
motor Draw downward
3. Disconnect the motor with the white connector of
the control module to separate the two.
Left side 4. Disassemble the two sunroof motors to the sun-
roof upper frame screw.
5. Draw the motor downward to disassemble the sun-
roof motor from the sunroof.
● Installation procedure
ECU control module 1. Insert the output shaft of the motor into the gear of
the sunroof upper frame.
2. Install the two sunroof motors to the sunroof upper
frame screw.
Sunroof Tightening torque: 3.5N•m
motor Upward 3. Connect the white motor with the control module
connector.
Left side
4. Make the sunroof switch connector run through
the switch bracket square hole on the motor.
5. Connect the sunroof switch with the switch con-
nector, and start the vehicle to check whether the
sunroof can work normally.
Replacement of the sunroof control module
1. Disassemble the sunroof switch and the switch base.
2. Disassemble the roof cover inner decoration.
3. Disconnect the control module from the vehicle body
wire harness.
Left side 4. Disconnect the white motor and the control module
connector.
5. Draw the control module downward forcibly to degum
it and disconnect it with the vehicle roof cover.
Vehicle body-27
● Installing procedure
1. Connect the white motor with the control module
connector.
Left side
2. Tear off the adhesive protective paper on the con-

Sunroof control module trol module.
Left side
3. Stick the control module onto the vehicle roof
inner surface on the left side of the vehicle running
direction, and align it with the reinforcing rib on the
roof front beam as shown in the figure.
4. Connect the sunroof switch with the switch con-
nector, and start the vehicle to check whether the
sunroof can work normally.
Replacement of the sunroof sun visor

and the fixing frame assembly
1. Disassemble the sunroof motor.
2. Disassemble the four sunroof sun visor fixing
frames to the sunroof upper frame screw.
3. Through the vehicle opening, disassemble the sun-
roof sun visor and the fixing frame assembly from
the vehicle.
1. Put the sunroof sun visor and the fixing frame into
the vehicle, and push them upward.
2. Install the four sunroof sun visor fixing frames to
the sunroof upper frame screw.
Replacement of the sunroof inner fixed

frame
1. Disassemble the sunroof sun visor and the fixing
frame assembly.
2. Disassemble the twelve sunroof inner fixing frames
to the sunroof upper frame screw.
3. Through the vehicle opening, disassemble the sun-
roof inner fixing frame from the vehicle.
Vehicle body-28
1. Adjust the sunroof upper frame assembly to make
it at the middle position of the vehicle roof cover
opening hole.
2. Press down the sunroof upper frame assembly to
make the vehicle roof cover distorted, and make
the two fit each other on the contacting surface.
3. Put the sunroof sun visor fixing frame into the
vehicle, and push upward.
4. Install the twelve sunroof inner fixing frames to the

upper frame screw in the order as shown in the fig-
8 4 2 7 ure.
5 6
9 10 1 3 11 12
Replacement of the upper frame assembly

1. Disassemble the sunroof inner fixing frame.
2. Take out the sunroof upper frame assembly from
the vehicle roof cover opening hole.
Replacement of the sunroof sun visor

1. Disassemble the sunroof sun visor and the fixing
frame assembly.
2. Toggle the four iron wires which are located on the
left and right side of the back of the sunroof sun
visor with flat head screw driver to make them drop
off from the stopper.
3. Take out the two sunroof sun visor fastening sheet

from the sunroof sun visor.
4. Disassemble the sunroof sun visor.
Vehicle body-29
1. Place the sunroof sun visor at the guide rail of the
sunroof sun visor.
2. Chuck two sunroof sun visor fastening disc at the
two sides of the sunroof sun visor, and make the
guide rail of the fastening disc cross the sunroof
into the guide rail of the sunroof sun visor.
3. Draw out the four iron wire of the sunroof sun visor
with clout screw driver, and chuck them at the baf-
fle plate upper.
4. Slide the sunroof plate forward and backward to
detect whether the installation is correct.
Replace of the sunroof glass plate assembly

● disassembly producer
1. Open the sunroof glass, and stop at the position
from the glass open completely about 10mm.
2. Disassemble the sunroof upper frame assembly.
3. Hook off the slider locate at the baffle plate front
part from the sunroof upper frame, and draw out
the installation block of the baffle plate from the
glass guide rail, to disassemble the sunroof baffle
plate.
4. Convert the sunroof upper frame assembly on the

glass cloth, which can’t be scraped, and the front
toward the disassembly personnel.
5. Disassemble two sunroof chain pressure plates to

the upper frame screw, to disassemble the chain
pressure plate and gear.
6. Take out the driving shaft from the sunroof upper
frame, and take down the black guide pipe.
Vehicle body-30
7. Mark out the corresponding relation between the

glass guide rail and the sunroof upper frame.
8. Disassemble four red sunroof glass guide rail that
locate at the turning corner, to the sunroof upper
frame screw.
9. Pull the glass guide rail about 10mm forward, and
raise the end of the glass guide rail to separate it
from the sunroof upper frame.
Notice: during disassembling process, the sunroof
upper frame must be supported.
10. Make the sunroof upper frame rotate toward front
lower direction, slide it forward, and disassemble
the sunroof upper frame.
11. Pull forward the glass guide rail to separate it from
the rotation connecting rod on the supporting seat.
Notice: during the pulling process, do not bend
downward the glass guide rail.
12. Take out the soft driving shaft from the slider, and
then disassemble the rail slider from the glass lift-
ing rod and the glass connector.
13. Turn forward the glass lifting rod, and pull forward
the glass lifting rod and the locking slide seat to
the end.
14. Insert the flathead screw driver between the lock-
ing slide and the glass support carefully to force
the outward distortion of the locking slide front
end, and to separate the pin on the glass lifting rod
from the hole of the locking seat. Disassemble the
left and right glass lifting rods.
15. Keep the state of outward distortion of the locking

slide front end in the above step, and pull upward
the front end of the locking slide, make it slide for-
ward, and take off the left and right locking slides.
16. Take away the glass plate assembly (only contain-
ing the glass plate and left and right glass sup-
ports).
Vehicle body-31
1. Lubricate the glass guide rail, the soft driving
shaft, the glass lifting rod, the locking slide and the
glass support with Teflon grease.
2. Place the front of the locking slide outside on the
glass support, and slide it back to make it get
stuck on the glass support.
3. Slide the locking slide forward to the end, and then

carefully insert the pin of the glass lifting arm into
the space in the locking slide through the sliding
groove of the glass support.
4. Slide back both the glass lifting arm and the lock-
ing slide to the end, and rotate the glass lifting arm
backward.
5. Nest the rail slider with the pin on the glass lifting
arm, and at the same time, put the pin of the glass
connector on the end of the sliding groove on the
rail slider.
6. Put the glass connector in alignment with the rail

slider.
7. Slide the glass guide rail carefully to make the
glass connector and the rail slider cased in the
guide rail until the rail slider keeps 4.5mm outside
the glass guide rail.
Notice: do not make too great force during install-
ing to avoid the damage on the parts.
8. Insert the soft driving shaft into the glass guide
rail, embed the end with the metal rod into the rail
slider, and make the other end run through the hole
at the long narrow gap near the front end of the
glass guide rail.
9. Side back the glass guide rail until the rail slider is
at about 1mm in the glass guide rail.
10. Case the two glass guide rails into the rear part of
the sunroof upper frame, and lead them between
the glass guide rail and the glass support. Pull for-
ward the sunroof upper frame, and install the sun-
roof upper frame on the glass assembly.
11. Cover the black guiding pipe onto the soft driving
shaft, and push it into the groove of the sunroof
upper frame together with the oft driving shaft.
12. Slide the glass guide rail according to the mark left
during disassembly to make it match the position
where it is disassembled.
13. Install the 4 red sunroof glasses onto the sunroof
upper frame screws.
Fastening torque: 3.5N•m
Notice: always take care to check whether the
position of the soft driving shaft is correct during
installation process.
Vehicle body-32
14. Install the sunroof deflector.

Embed the installing block of the deflector into the
glass guide rail, and then hook the slider in the front
part of the deflector onto the sunroof upper frame.
15. Push the sunroof glass plate to make it open as
wide as possible.
16. Place the gear on the bearing in the sunroof upper

frame, and make it mesh with the soft driving
shafts in opposite directions.
17. Install the chain clamping plate.
Place 2 sunroof chain clamping plates to the sunroof
upper frame screw, and install the chain clamping plates.
18. Connect the sunroof upper frame assembly to the
motor, the sunroof control module and the switch,
and connect the sunroof control module with the
vehicle body wire harness. Start the vehicle to
check whether the sunroof can work normally.
19. Disassemble the motor, the control module and the
switch.
Sunroof sealing strip replacement

● Disassembling procedure
1. Disassemble the sunroof upper frame.
See the steps 1 to 10 of the disassembling procedure
of “sunroof glass assembly replacement” in “external
decorate”.
2. First, pull up part of the sunroof sealing strip from
the sunroof upper frame, and then disassemble the
whole cycle of the sealing strip from the sunroof
upper frame.
3. Infuse the sealing strip installing groove of the
sunroof upper frame in amyl acetate for (4-5) min,
then drain away amyl acetate, and clear the seal
gum remained by the old sealing strip with a flat-
head screw driver.
4. Wipe up the sealing strip installing groove of the
Sili sunroof upper frame.
c
the a ge
inn l in ● Installing procedure
er c
ircl 1. Apply a circle of acidic silica gel with a diameter
e
Silica gel in the

of about (2-3) mm on the periphery of the sealing
outer circle strip installing groove bottom of the sunroof upper
frame.
2. Apply continuously acidic silica gel with a diameter
of about (2-3) mm on the whole inner circle, and the
front 1/3 of the inner circle on the two sides of the
installing groove bottom.
3. Press the sealing strip in the installing groove of
the sunroof upper frame, and make sure to fill all
parts of the sealing strip in the installing groove to
guarantee uniform compression of the glass and
the sealing strip.
Notice: when installing the sealing strip, overflow
of the silica gel must not happen. Install the glass
plate, etc. 8 hours after the sunroof upper frame
that has been installed with the sealing strip is
placed in room temperature.
Vehicle body-33
Seats
Component diagram
Rear seats
Middle row seats
Front row seats handrest
Co-driver’s seat
Backrest angle adjusting handle

Seat pan rear height control hand wheel
Driver’s Seat Seat pan front height control hand wheel
The driver’s seat can be adjusted manually in eight directions, and the head rest can be manually
adjusted in two directions,
Precautions
1. Mind your safety when disassembling, carrying, and installing the seats to avoid being
scratched and crushed by them.
2. Take care to protect the interior decorative parts during installing and carrying process to
avoid the scratch of the side plate.
3. After installation is finished, the tightening torque of the construction bolt should be verified.
Seats disassembly
1. Front row seat disassembly
(a) Slide the seat to the rearmost position.
(b) Open the floor cover plate, and screw out the seat
front fixing bolt.
(c) Slide the seat to the foremost position.
(d) Open the floor cover plate, and screw out the seat
rear fixing bolt.
(e) Take out the seat from the vehicle.
Vehicle body-34
1. Middle row seat disassembly

(a) Ensure that the floor lock is in lock mode.
(b) Remove the seat floor front buckle and the foot
rear cover.
(c) Make the seat floor lock in lock mode, and the
sliding way in rearmost position.
(d) Screw out the two seat front fixing bolts.
Floor
Floor front
buckle
Floor rear cover
(e) Unlock the seat floor lock.

(f) Screw out the two seat rear fixing bolts.
The rear floor lock has
been unlocked and folded
(g) After finishing the middle row seat disassembly,

take out the seat from the vehicle.
3. Rear row seat disassembly

(a) Make sure that the sliding way is in rearmost
position.
Vehicle body-35
(b) Fold and unlock the seat, and hang it on the

vehicle body handrest.
(c) Open the plastic decorative cover, and screw out
a seat front retaining nut.
(d) Slide the seat sliding way to the foremost position.
(e) Open the plastic decorative cover, and screw out
a seat rear retaining nut.
(f) Take down the seat hatch hook from the vehicle
body handrest, and take out the seat.
Seat installation
1. Front seat installation
(a) Determine the position of the locating hole and the
positioning pin, and place the seat well.
(b) Slide the seat to the rearmost position.
(c) Screw down the two seat front fixing bolts.
(d) Slide the seat to the foremost position.
(e) Screw the two bolts at the rear fixed point.
(f) Verify the seat fixing bolt torque.
(g) Close the floor cover plate.
2. Middle seat installation
(a) Make the seat in folding mode.
The rear floor lock has (b) Determine the position of the locating hole and the
been unlocked and folded
positioning pin, and place the seat well.
(c) Install the four seat fixing bolts, and screw up No.
2 and 4 bolts.
(d) Lock the seat onto the floor.
(e) Screw up No.1 and 3 bolts, verify the torque, and
Bolts 2 and 4 close the floor cover plate.
(f) Unlock the seat, verify the torques of No. 2 and 4
bolts, and close the floor cover plate.
3. Rear row seat installation
(a) Make the seat in folding mode, and slide the
sliding way to the rearmost position.
(b) Hang the seat onto the vehicle body handrest.
(c) Screw a seat front retaining nut, and close the
plastic decorative plate.
(d) Slide the seat sliding way to the foremost position.
(e) Screw a seat rear retaining nut, and close the
plastic decorative plate.
Vehicle body-36
Safety belt
Component diagram
Guiding ring
Front row retractor 42±5
38±5
42±5
Rear-row safety-belt
anchor end piece
Front row retractor Middle row retractor
Rear row
38±5 retracto
Front-row safety-belt
anchor end piece Middle-row safety-
belt anchor end piece
38±5
38±5
Vehicle body B Guiding ring fixing bolt 42±5

column sheet metal
Fix bolt of height adjuster

Guiding ring
Upper fix point of
height adjuster Webbing
Height adjuster
Retractor
Lower fix point of

height adjuster Safety-belt anchor
end piece guard
Safety-belt anchor
end piece
N·m :Regulated torque
Safety belt
The front row safety belt is the pretensioning safety belt, which has an electronic initiation device
compared to an ordinary safety belt. During the installation process of such kind of safety belts, do not
forget to insert the safety belt initiator socket connector. Do not disassemble the safety belt of this type
to avoid injury to human body caused by misexplosion. The safety belts in middle and rear rows are
ordinary safety belts.
Safety belts disassembly and precautions for installation
1. Only personnel who have received training are permitted to check, disassemble, and assemble
the safety belts.
2. It is forbidden to disassemble and repair the elements of the safety belt; only the change of new
safety belt assembly is permitted.
3. It is not permitted to install the safety belts onto the vehicle that have been subject to severe col-
lision.
4. The safety belts that have mechanical damage (dent or bulge, crack) must be replaced.
5. Every time after an accident happens, check the safety belt system systematically. If it is assured
that the items have been damaged according to the inspection, the safety belt must be replaced.

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Preface

Use of this manual........................................................................... 2

Use of this manual

Left front braking caliper assembly Axle center bolt

Front hub flange disc

N•m : specified torque Front braking disc

The repair procedure will be explained step by step:

4. Check the thickness of the front brake disc.

Detailed description: How to do it

Instruction for comprehensive repair

● All the parts that are removed should be marked or

● Use special tools in accordance with the requirement if

● The components and parts must be assembled with

● Components and parts and lubricant that are produced

● Components and parts should be applied with or filled

(b) To facilitate the reinstallation, the hose after

● Brake fluid and hydraulic element

(b) If the connection of the earth wire of the

3. Repair method of wire harness connector terminal

4. Disassembly and assembly of wire harness

● Dismantling and installation of clips

Push the master pin out, remove it

Screw out the master pin out, remove it

Small clip detacher

Prize the master pin out, remove the rivet and

Complete Vehicle Parameter

Complete Vehicle Basic Parameter............................................... 2

Complete Vehicle Basic Parameter

Dimension and Weight Parameter

Complete Vehicle Basic Performance Parameter

Accelerated run (outside the vehicle) dB(A) ≤74

Structure Form and Performance Parameter of the Main Assemblies

In-line 4-cylinder, water-cooling 4-stroke, 16-valve, SOHC,

Structure Form and Parameter of the Main Assemblies of Chassis

Overhang Front overhang system Spring column Overhang (McPherson type)

Structure Form and Parameter of Vehicle Body

Front and Rear

Interior Handle The main body is molded through plastic injection

Door Handle Door outer handle.

Structure and Parameter of Electrical System

Single wire system, the negative pole is grounded, with 12 V

Low Beam White 55 W 2 pieces

Reversing Lamp White 21 W 2 pieces

Rear fog Lamp Red 21 W 2 pieces

Instruments include: automotive speedometer, tachometer, driving odometer

Vehicle Power 12 V vehicle power, under the instrument panel.

Front and rear dual evaporator; steam compression refrigeration, water-heat-

Compressor type SE10B17 Double-way sloping-cam plate model rated displacement.

Air Cleaning System Dust filter.

Complete Vehicle Basic Dimension

Auxiliary Vehicle Frame

Bottom Ring Circle center of Pallet Big Hole

Complete Vehicle Basic Dimension (continued)

Mark Name Hole Diameter Mark Name Hole Diameter

Complete Vehicle Basic Dimension (continued)

Mark Name Hole Diameter Mark Name Hole Diameter

Headlight Seat Board

Mark Name Hole Diameter Mark Name Hole Diameter

Engine Mechanical System

……Lubricating grease (multi-purpose lubricating grease shall be adopted when there is no

……Engine oil or gear oil

Maintenance speciation (continued)

Tightening Torque (continued)

MD998781 Flywheel stopper To fix flywheel and driving tray